Lincoln Electric IM10053 User Manual

Operator’s Manual

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RANGER®305D (AU)

For use with machines having Code Numbers:

11692, 12193

Save for future reference

Date Purchased

Code: (ex: 10859)

Serial: (ex: U1060512345)

IM10053-A | Issue D ate Aug- 13

© Lincoln Global, Inc. All Rights Reserved.

Register your machine:

www.lincolnelectric.com/register

Authorized Service and Distributor Locator:

www.lincolnelectric.com/locator

Need Help? Call 1.888.935.3877

to talk to a Service Representative

Hours of Operation:

8:00 AM to 6:00 PM (ET) Mon. thru Fri.

After hours?

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: [e-mail]

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:

WARNINGS

CALIFORNIA PROPOSITION 65 WARNINGS

Diesel Engines

Diesel engine exhaust and some of its constituents are known
to the State of California to cause cancer, birth defects, and other
reproductive harm.

Gasoline Engines

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.

3

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.

4

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

5

vi

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 (AU) .............................................................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

________________________________________________________________________________

vi

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 Operation.............................................................................................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-646

________________________________________________________________________

vii

A-1

INSTALLATION

TECHNICAL SPECIFICATIONS - Ranger® 305D (AU) (K2922-1)

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

7200 Watts Continuous, 60 Hz 240 Volts

Sound Levels

Sound Power: 104.2 dB Lwa, Sound Level: 80.6 dBA @ 23 ft ( 7m )

1

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) 240VAC Receptacles Two 15AMP for Two Receptacles 15AMP for Battery Charging Circuit

15AMP for 42V Wire Feeder Power

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

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

RANGER® 305D (AU)

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 (AU) 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.

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

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 (AU) 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 (AU)

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 50°F(10°C) above 104°F(40°C).

Cold weather starting:

With a fully charged battery and the proper weight oil,
the engine should start satisfactorily even down to
about 5°F (-15°C). If the engine must be frequently
started at or below 23°F (-5°C), it may be desirable to
install cold-starting aides. The use of No. 1D diesel
fuel is recommended in place of No. 2D at tempera­tures below 23°F (-5°C). Allow the engine to warm up
before applying a load or switching to high idle.
Note: Extreme cold weather starting may require
longer glow plug operation.

WARNING

Under no conditions should ether or other starting
fluids be used with this engine!

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

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.

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

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 sur-

face 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

The Ranger® 305D (AU) 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

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 (AU)

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.

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

BATTERY CONNECTION

CAUTION

Use caution as the electrolyte is a strong acid that
can burn skin and damage eyes.

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

The Ranger® 305D (AU) 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.

REMOTE CONTROL

The Ranger® 305D (AU) 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

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.

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

RANGER® 305D (AU)

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.

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

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.

INSTALLATION

A-5

TABLE A.1

CABLE INSTALLATION

Install the welding cables to your Ranger® 305D (AU)
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.

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 (AU) is equipped with a toggle
switch for selecting "hot" welding terminal when in the
"WELD TERMINALS ON" position or "cold" welding
terminal when in the "REMOTELY CONTROLLED"
position.

WELDING OUTPUT CABLES

With the engine off connect the electrode and work
cables to the output studs. The welding process dic­tates the polarity of the electrode cable. These con­nections should be checked periodically and tightened
with a 3/4" wrench.

Table A.1 lists recommended cable sizes and lengths
for rated current and duty cycle. Length refers to the
distance from the welder to the work and back to the
welder. Cable diameters are increased for long cable
lengths to reduce voltage drops.

6. Check and tighten the connections periodically.

CAUTION

• 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.

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

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 (AU)

A-6

ELECTRICAL DEVICE USE WITH THE RANGER® 305D (AU).

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 (AU)

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

RANGER® 305D (AU)

A-7

INSTALLATION

AUXILIARY POWER RECEPTACLES

The auxiliary power capacity of the Ranger® 305D
(AU) is 7.2KW of 60Hz single phase power protected
by an RCD (Residual Current Device) and 2 single
phase 15 amp circuit breakers. The auxiliary power
capacity in watts equivalent to volt-amperes at unity
power factor.

This model has:

1 Residual Current Device (RCD) protection (30mA).
2 x 1 phase 15 amp Circuit Breakers.
2 x 1 phase 240 volt 15 amp per outlet.

Note: The single-phase outlets are from different

phases and cannot be paralleled.

The auxiliary power receptacles should only be used
with three grounded type plugs or approved double
insulated tools. The current rating of any plug used
with the system must be at least equal to the current
capacity of the associated receptacle.

A-7

STANDBY POWER CONNECTIONS

The Ranger® 305D (AU) is suitable for temporary,
standby or emergency power using the engine manu­facturerʼs recommended maintenance schedule.

The Ranger® 305D (AU) can be permanently
installed as a standby power unit for 240 volt (60Hz).
Connections must be made by a licensed electrician
who can determine how the 240 VAC power can be
adapted to the particular installation and comply with
all applicable electrical codes. The following informa­tion can be used as a guide by the electrician for
most applications.

1 Install an isolation switch between the power com-

pany meter and the premises disconnect. (The
Ranger® 305D (AU) and the power company sup­plies must not be connected together).

Switch rating must be the same or greater than the
customerʼs premises disconnect and service over
current protection.

2. Take necessary steps to assure load is limited to
the capacity of the Ranger® 305D (AU). 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 (AU) engine.

RANGER® 305D (AU)

A-8

INSTALLATION

CONNECTION OF LINCOLN ELECTRIC
WIRE FEEDERS

Connection of LN-15 to the Ranger® 305D (AU)

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.

A-8

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.

• For electrode Positive, connect the electrode cable
to the "+" terminal of the welder and work cable to
the "-" terminal of the welder. For electrode
Negative, connect the electrode cable "-" terminal of
the welder and work cable to the "+" terminal of the
welder.

• Across The-Arc Model:

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

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

• Control Cable Model:

Connect Control Cable between Engine Welder and
Feeder.

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

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

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

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

7. Set the "IDLE" switch to the "AUTO" position.
When not welding, the Ranger® 305D (AU)
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 (AU)
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

• 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.

Connection of the LN-25 to the Ranger® 305D (AU)

WARNING

Shut off welder before making any electrical con­nections.

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

The LN-25 with or without an internal contactor may
be used with the Ranger® 305D (AU). See the appro­priate connection diagram in Section F.

RANGER® 305D (AU)

If you are using an LN-25 without an internal con­tactor, the electrode will be energized when the
Ranger® 305D (AU) is started.

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

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

• Shut the welder off.

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

B-1

OPERATION

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.

• 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

The Ranger® 305D (AU) is a diesel engine powered
DC multi-process welding power source and 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.

The auxiliary power of the Ranger® 305D (AU) con­sists of two 15 Amp-240 VAC receptacles. Also refer
to the AUXILIARY POWER OPERATION section later
in this chapter.

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.

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.

• 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 (AU), 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.

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

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

CAUTION

During break-in, subject the Ranger® 305D (AU) 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 (AU)

B-2

OPERATION

B-2

1

16

15

14

2

17

13

3

12

11

4

10

9

5

FIGURE B.1

FIGURE B.1

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

8

7

6

2. DIGITAL OUTPUT METERS-The digital

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%.

3. WELD MODE SELECTOR SWITCH-

(Provides four selectable welding modes)

CV-WIRE
DOWNHILL PIPE
CC-STICK
TOUCH START TIG

RANGER® 305D (AU)

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 (AU). 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 (AU)

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.

AUXILIARY POWER CONTROLS

(Items 18-21)

18. CIRCUIT BREAKERS

These circuit breakers provide separate overload
current protection for each 240V receptacles, the
42VAC in the 14-Pin connector and battery cir­cuit overload protection.

B-4

19. 240 VAC RECEPTACLES

These two 240VAC receptacles provide up to 15
amp total rating each and are IP66 rated. Refer
to the AUXILIARY POWER RECEPTACLES
section in the installation chapter for further infor­mation about these receptacles. Also refer to the
AUXILIARY POWER OPERATION section later
in this chapter.

20. RCD:

“Residual Current Device” provides protection

from active to ground contact.

RCD will not protect against electrical shock
resulting from contact with active and neutral
wires.

21. VRD INDICATOR LIGHTS:

(Part of Optional VRD Kit)

Indicates OCV voltage across the output termi­nals. Also indicates operation of VRD in CC
mode. A Green light indicates OCV below 30V
and a red light indicates OCV above 30V.

During welding both lights will flash, depending on
the type of Consumable being used.

RANGER® 305D (AU)

B-5

OPERATION

B-5

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.

NOTE: If the unit fails to start repeat step 4 through
step 7 after waiting 30 seconds

CAUTION

NOTE: When starting a Ranger® 305D (AU) 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.

• 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.

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

TABLE B.1

TYPICAL Ranger® 305D (AU) 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

7,000 Watts .96 (3.63) 12.50

3,000 Watts .70 (2.67) 17.03

RANGER® 305D (AU)

B-6

OPERATION

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

B-6

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

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.

+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 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 OUT­PUT 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® 305D (AU) 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® 305D (AU). 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 (AU)

B-7

OPERATION

B-7

Ranger® 305D (AU) settings when using the K930-2
TIG Module with an Amptrol or Arc Start Switch:

• Set the MODE Switch to the TOUCH START TIG
setting.

• Set the "IDLER" Switch to the "AUTO" position.

• Set the "WELDING TERMINALS" switch to the
"REMOTELY CONTROLLED" position. This will keep
the "Solid State" contactor open and provide a "cold"
electrode until the Amptrol or Arc Start Switch is
pressed.

When using the TIG Module, the OUTPUT control on
the Ranger® 305D (AU) is used to set the maximum
range of the CURRENT CONTROL on the TIG Module
or an Amptrol if connected to the TIG Module.

WIRE WELDING-CV

Connect a wire feeder to the Ranger® 305D (AU)
according to the instructions in INSTALLATION
INSTRUCTIONS Section.

The Ranger® 305D (AU) 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.

ARC GOUGING

The Ranger® 305D (AU) 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

1/8" 60-90 Amps

5/32" 90-150 Amps

3/16" 200-250 Amps

Current Range (DC, electrode
positive)

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 (AU)