Lincoln Electric IM730 User Manual

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Ranger 305 D

For use with machines having Code Numbers:

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.

August, 2004

10926

Cleveland, Ohio 44117-1199 U.S.A. TEL: 216.481.8100 FAX: 216.486.1751 WEB SITE: www.lincolnelectric.com

OPERATOR’S MANUAL

• World's Leader in Welding and Cutting Products •

• Sales and Service through Subsidiaries and Distributors Worldwide •

Page 2

SAFETY

WARNING

CALIFORNIA PROPOSITION 65 WARNINGS

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

The Above For Diesel Engines

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.

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

The Above For Gasoline Engines

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.

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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.

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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.

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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.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

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.

___________________________________________________

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

2.d.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.

Mar ‘95

Page 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.

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 below Threshold Limit Values (TLV) using local exhaust or mechanical ventilation. In confined spaces or in some circumstances, outdoors, a respirator may be required. Additional precautions are also required when welding on galvanized steel.

3.f.

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

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

3.h. Never simultaneously touch electrically “hot” parts of electrode holders connected to two welders because voltage between the two can be the total of the open circuit voltage of both welders.

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

3.j. Also see Items 6.c. and 8.

5.b.

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

5.c. Shielding gases used for arc welding can displace air and cause injury or death. Always use enough ventilation, especially in confined areas, to insure breathing air is safe.

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

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

5.e. Also see item 1.b.

vapors

Mar ‘95

Page 4

iii

SAFETY

iii

WELDING SPARKS can cause fire or explosion.

6.a.

Remove fire hazards from the welding area.

If this is not possible, cover them to prevent

the welding sparks from starting a fire.

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 been “cleaned”. For information, purchase “Recommended Safe Practices for the 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.

Sparks and spatter are thrown from the welding arc. Wear oil

6.f. 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.

Remember that welding sparks and hot

though

they have

Preparation

for Welding and Cutting of

CYLINDER may explode if damaged.

7.a. Use only compressed gas cylinders containing the correct shielding gas for the process used and properly operating regulators designed for the gas and

pressure used. All hoses, fittings, etc. should be suitable for the application and maintained in good condition.

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

7.c. Cylinders should be located:

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

physical damage.

• A safe distance from arc welding or cutting operations and

any other source of heat, sparks, or flame.

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

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

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

7.g. Read and follow the instructions on compressed gas cylinders, associated equipment, and CGA publication P-l, “Precautions for Safe Handling of Compressed Gases in Cylinders,” available from the Compressed Gas Association 1235 Jefferson Davis Highway, Arlington, VA 22202.

FOR ELECTRICALLY powered equipment.

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

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

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

Mar ‘95

Page 5

SAFETY

PRÉCAUTIONS DE SÛRETÉ

Pour votre propre protection lire et observer toutes les instructions et les précautions de sûreté specifiques qui parraissent dans ce manuel aussi bien que les précautions de sûreté générales suivantes:

Sûreté Pour Soudage A L’Arc

1. Protegez-vous contre la secousse électrique:

a. Les circuits à l’électrode et à la piéce sont sous tension

quand la machine à souder est en marche. Eviter toujours tout contact entre les parties sous tension et la peau nue ou les vétements mouillés. Porter des gants secs et sans trous pour isoler les mains.

b. Faire trés attention de bien s’isoler de la masse quand on

soude dans des endroits humides, ou sur un plancher metallique ou des grilles metalliques, principalement dans les positions assis ou couché pour lesquelles une grande partie du corps peut être en contact avec la masse.

c. Maintenir le porte-électrode, la pince de masse, le câble

de soudage et la machine à souder en bon et sûr état defonctionnement.

d.Ne jamais plonger le porte-électrode dans l’eau pour le

refroidir.

e. Ne jamais toucher simultanément les parties sous tension

des porte-électrodes connectés à deux machines à souder parce que la tension entre les deux pinces peut être le total de la tension à vide des deux machines.

f. Si on utilise la machine à souder comme une source de

courant pour soudage semi-automatique, ces precautions pour le porte-électrode s’applicuent aussi au pistolet de soudage.

6. Eloigner les matériaux inflammables ou les recouvrir afin de prévenir tout risque d’incendie dû aux étincelles.

7. Quand on ne soude pas, poser la pince à une endroit isolé de la masse. Un court-circuit accidental peut provoquer un échauffement et un risque d’incendie.

8. S’assurer que la masse est connectée le plus prés possible de la zone de travail qu’il est pratique de le faire. Si on place la masse sur la charpente de la construction ou d’autres endroits éloignés de la zone de travail, on augmente le risque de voir passer le courant de soudage par les chaines de levage, câbles de grue, ou autres circuits. Cela peut provoquer des risques d’incendie ou d’echauffement des chaines et des câbles jusqu’à ce qu’ils se rompent.

9. Assurer une ventilation suffisante dans la zone de soudage. Ceci est particuliérement important pour le soudage de tôles galvanisées plombées, ou cadmiées ou tout autre métal qui produit des fumeés toxiques.

10. Ne pas souder en présence de vapeurs de chlore provenant d’opérations de dégraissage, nettoyage ou pistolage. La chaleur ou les rayons de l’arc peuvent réagir avec les vapeurs du solvant pour produire du phosgéne (gas fortement toxique) ou autres produits irritants.

11. Pour obtenir de plus amples renseignements sur la sûreté, voir le code “Code for safety in welding and cutting” CSA Standard W 117.2-1974.

2. Dans le cas de travail au dessus du niveau du sol, se protéger contre les chutes dans le cas ou on recoit un choc. Ne jamais enrouler le câble-électrode autour de n’importe quelle partie du corps.

3. Un coup d’arc peut être plus sévère qu’un coup de soliel, donc:

a. Utiliser un bon masque avec un verre filtrant approprié

ainsi qu’un verre blanc afin de se protéger les yeux du rayonnement de l’arc et des projections quand on soude ou quand on regarde l’arc.

b. Porter des vêtements convenables afin de protéger la

peau de soudeur et des aides contre le rayonnement de l‘arc.

c. Protéger l’autre personnel travaillant à proximité au

soudage à l’aide d’écrans appropriés et non-inflammables.

4. Des gouttes de laitier en fusion sont émises de l’arc de soudage. Se protéger avec des vêtements de protection libres de l’huile, tels que les gants en cuir, chemise épaisse, pantalons sans revers, et chaussures montantes.

5. Toujours porter des lunettes de sécurité dans la zone de soudage. Utiliser des lunettes avec écrans lateraux dans les zones où l’on pique le laitier.

PRÉCAUTIONS DE SÛRETÉ POUR LES MACHINES À SOUDER À TRANSFORMATEUR ET À REDRESSEUR

1. Relier à la terre le chassis du poste conformement au code de l’électricité et aux recommendations du fabricant. Le dispositif de montage ou la piece à souder doit être branché à une bonne mise à la terre.

2. Autant que possible, I’installation et l’entretien du poste seront effectués par un électricien qualifié.

3. Avant de faires des travaux à l’interieur de poste, la debrancher à l’interrupteur à la boite de fusibles.

4. Garder tous les couvercles et dispositifs de sûreté à leur place.

Mar. ‘93

Page 6

for selecting a QUALITY product by Lincoln Electric. We want you

Thank You

to take pride in operating this Lincoln Electric Company product

••• as much pride as we have in bringing this product to you!

Please Examine Carton and Equipment For Damage Immediately

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

Please record your equipment identification information below for future reference. This information can be found on your machine nameplate.

Product _________________________________________________________________________________

Model Number ___________________________________________________________________________

Code Number or Date Code_________________________________________________________________

Serial Number____________________________________________________________________________

Date Purchased___________________________________________________________________________

Where Purchased_________________________________________________________________________

Whenever you request replacement parts or information on this equipment, always supply the information you have recorded above. The code number is especially important when identifying the correct replacement parts.

On-Line Product Registration

- Register your machine with Lincoln Electric either via fax or over the Internet.

• For faxing: Complete the form on the back of the warranty statement included in the literature packet accompanying this machine and fax the form per the instructions printed on it.

• For On-Line Registration: Go to our

“Product Registration”. Please complete the form and submit your registration.

Read this Operators Manual completely before attempting to use this equipment. Save this manual and keep it handy for quick reference. Pay particular attention to the safety instructions we have provided for your protection. The level of seriousness to be applied to each is explained below:

WEB SITE at www.lincolnelectric.com. Choose “Quick Links” and then

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.

Page 7

TABLE OF CONTENTS

Page

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

Engine Coolant..............................................................................................................A-3

Battery Connections......................................................................................................A-3

Muffler Outlet Pipe ........................................................................................................A-3

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

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

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

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

Welding Terminals ........................................................................................................A-4

Welding Output Cables .................................................................................................A-4

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

Auxiliary Power Receptacles and Plugs...............................................................................A-5

Standby Power Connections ................................................................................................A-5

Premises Wiring ...................................................................................................................A-6

Connection of Lincoln Electric Wire Feeders .......................................................................A-7

________________________________________________________________________________

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

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

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

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

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

Engine Break in ...................................................................................................................B-1

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

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

Welder Controls ............................................................................................................B-2

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

Starting and Stopping the Engine ...........................................................................B-3, B4

Stopping .......................................................................................................................B-4

Welding Operation................................................................................................................B-5

Duty Cycle.....................................................................................................................B-5

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

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

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

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

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

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

Auxiliary Power .............................................................................................................B-7

Simultaneous Welding and Auxiliary Power Loads.......................................................B-7

Extension Cord Recommendations...............................................................................B-7

________________________________________________________________________________

Accessories.....................................................................................................Section C

Field Installed Options / Accessories ...............................................................................C-1

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Page 8

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

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

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

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

________________________________________________________________________

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

________________________________________________________________________

Parts List..................................................................................................................P417

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Page 9

A-1

INSTALLATION

TECHNICAL SPECIFICATIONS - Ranger 305D (K1727-2)

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

18.8 HP High Idle 3650

Kubota** (14 KW)

D722 Net intermittent Full Load 3500

3600 RPM (67 x 68 mm) cold crank amps) 3.85Qts. (3.6L)

naturally aspirated Low Idle 2450 Battery Charger

water cooled engine (3.6L)

Bore x Stroke inch (mm)

2.64 x 2.68

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 Electric Fuel Pump, Auto air bleed system with Full Flow Filter Certified to EPA Tier I Electric shutoff solenoid Mechanical Governor

Indirect fuel injector

AIR CLEANER ENGINE IDLER MUFFLER ENGINE PROTECTION

Low noise Muffler: Shutdown on low oil

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

Made from long life, aluminized steel. temperature

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

RECEPTACLES AUXILIARY POWER CIRCUIT BREAKER OTHER CIRCUIT BREAKERS

(2) 120VAC Duplex (5-20R) Two 20AMP for Two Duplex Receptacle (1) 120/240VAC Dual Voltage Two 50AMP for Dual Voltage

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

25AMP for Battery Charging Circuit 15AMP for 42V Wire Feeder Power

Page 10

A-2

INSTALLATION

SAFETY PRECAUTIONS

WARNING

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

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

ELECTRIC SHOCK can kill.

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

• Insulate yourself from work and ground

• Always wear dry insulating gloves.

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

ENGINE EXHAUST can kill.

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

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

MOVING PARTS can injure.

• Do not operate with doors open or guards off.

• Stop engine before servicing.

• Keep away from moving parts.

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

See additional warning information at

front of this operator’s manual.

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

LOCATION AND VENTILATION

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

STACKING

RANGER 305D machines cannot be stacked.

ANGLE OF OPERATION

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

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

A-2

LIFTING

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

WARNING

• Lift only with equipment of adequate lifting capacity.

• Be sure machine is stable when lifting.

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

FALLING • 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.

HIGH TEMPERATURE OPERATION

At temperatures above104°F (40°C), output derating is necessary. For maximum output ratings, derate the welder output 2 volts for every 50°F(10°C) above 104°F (40°C).

Cold weather starting:

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

WARNING

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

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

RANGER 305D

Page 11

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 Lincoln’s K957-1. If the user adapts a non-Lincoln trailer, he must assume responsibility that the method of attachment and usage does not result in a safety hazard nor damage the welding equipment. Some of the factors to be considered are as follows:

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

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

ways.

(1)

VEHICLE MOUNTING

WARNING

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

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

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

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

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

• Follow vehicle manufacturer’s instructions.

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

PRE-OPERATION ENGINE SERVICE

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

The oil change interval is dependent on the quality of the oil and the operating environment. Refer to the Engine Operator’s Manual for more details on the

proper service and maintenance intervals.

FUEL

USE DIESEL FUEL ONLY

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

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

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

ENGINE COOLING SYSTEM

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

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

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

The RANGER 305D is shipped with the negative battery cable disconnected. Make certain that the RUNSTOP switch is in the STOP position. Remove the two screws from the rear battery tray using a screwdriver or a 3/8" socket. Attach the negative battery cable to the negative battery terminal and tighten using a 1/2" socket or wrench.

WARNING

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

CAUTION

OIL

The RANGER 305D is shipped with the engine crankcase filled with high quality SAE 10W-30 Oil that meets classification CG-4 or CH-4 for diesel engines. Check the oil level before starting the engine. If it is not up to the full mark on the dip stick, add oil as required. Check the oil level every four hours of running time during the first 50 running hours. Refer to the engine Operator’s Manual for specific oil recommendations and break-in information.

RANGER 305D

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.

Page 12

A-4

INSTALLATION

SPARK ARRESTER

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

CAUTION

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

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

REMOTE CONTROL

The RANGER 305D is equipped with a 6-pin and a 14-pin connector. The 6-pin connector is for connecting the K857 or K857-1 Remote Control or for TIG welding, the K870 foot Amptrol or the K936-2 hand Amptrol. When in the CC-STICK, DOWNHILL PIPE, or CV-WIRE modes and when a remote control is connected to the 6-pin Connector, the auto-sensing circuit automatically switches the OUTPUT control from control at the welder to remote control.

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

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

WARNING

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

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

ELECTRICAL CONNECTIONS

A-4

To prevent dangerous electric shock, other equipment to which this engine driven welder supplies power must be grounded to the frame of the welder using a grounded type plug or be double insulated.

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

In general, if the machine is to be grounded, it should be connected with a #8 or larger copper wire to a solid earth ground such as a metal water pipe going into the ground for at least ten feet and having no insulated joints, or to the metal framework of a building which has been effectively grounded. Do not ground the machine to a pipe that carries explosive or combustible material.

The National Electrical Code lists a number of alternate means of grounding electrical equipment. A machine grounding stud marked with the symbol is provided on the front of the welder.

WELDING TERMINALS

The RANGER 305D is equipped with a toggle switch for selecting "hot" welding terminal when in the "WELD TERMINALS ON" position or "cold" welding terminal when in the "REMOTELY CONTROLLED" position.

WELDING OUTPUT CABLES

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

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

MACHINE GROUNDING

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

RANGER 305D

Page 13

A-5

TABLE A-1

INSTALLATION

TOTAL COMBINED LENGTH OF

ELECTRODE AND WORK CABLES

Cable Length

0-100Ft. (0-30meters)

100-150 Ft. (30-46m meters)

150-200 Ft. (46-61 meters)

CABLE INSTALLATION

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

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

2. Remove the flanged nuts from the output terminals

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

4. Tighten the flanged nuts securely.

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

6. Check and tighten the connections periodically.

Cable Size for

305 Amps

100% Duty Cycle

1 / 0 AWG

2 / 0 AWG

3 / 0 AWG

CAUTION

A-5

The 240 VAC output can be split to provide two separate 120 VAC outputs with a max permissible current of 44 Amps per output to two separate 120 VAC branch circuits (these circuits cannot be paralleled). Output voltage is within ± 10% at all loads up to rated capacity.

The 120 V auxiliary power receptacles should only be used with three wire grounded type plugs or approved double insulated tools with two wire plugs. The current rating of any plug used with the system must be at least equal to the current capacity of the associated receptacle.

NOTE: The 240 V receptacle has two 120 V circuits, but are of opposite polarities and cannot be paralleled.

STANDBY POWER CONNECTIONS

The RANGER 305D is suitable for temporary, standby or emergency power using the engine manufacturer’s recommended maintenance schedule.

The RANGER 305D can be permanently installed as a standby power unit for 240 VAC, 3 wire, single phase, 44 amp service. Connections must be made by a licensed electrician who can determine how the 120/240 VAC power can be adapted to the particular installation and comply with all applicable electrical codes.

• Install the double-pole, double-throw switch between the power company meter and the premises disconnect. Switch rating must be the same or greater than the customer’s premises disconnect and service over current protection.

• Loose connections will cause the output terminals to overheat. The terminals may eventually melt.

• Do not cross the welding cables at the output terminal connection. Keep the cables isolated and separate from one another.

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

AUXILIARY POWER RECEPTACLES

The auxiliary power capacity is 10,500 watts Peak, 10000 Watts Continuous of 60 Hz, single phase power. The auxiliary power capacity rating in watts is equivalent to volt-amperes at unity power factor. The max permissible current of the 240 VAC output is 44 amps.

RANGER 305D

• Take necessary steps to assure load is limited to the capacity of the RANGER 305D by installing a 50 amp, 240 VAC double pole circuit breaker. Maximum rated load for each leg of the 240 VAC auxiliary is 44 amperes. Loading above the rated output will reduce output voltage below the allowable - 10% of rated voltage which may damage appliances or other motor-driven equipment and may result in overheating of the RANGER 305D engine and/or alternator windings.

• Install a 50 amp, 120/240 VAC plug (NEMA Type 14-50) to the double-pole circuit breaker using No. 6, 4 conductor cable of the desired length. (The 50 amp, 120/240 VAC plug is available in the optional K802R plug kit or as part number T12153-9.)

• Plug this cable into the 50 Amp, 120/240 Volt receptacle on the RANGER 305D case front.

Page 14

A-6

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

A-6

PREMISES

DISCONNECT AND

SERVICE

OVERCURRENT

PROTECTION

LOAD

DOUBLE

50 AMP, 120/240

VOLT PLUG

NEMA TYPE 14-50

240 VOLT

50 AMP, 120/240 VOLT

RECEPTACLE

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

Page 15

A-7

INSTALLATION

CONNECTION OF LINCOLN ELECTRIC WIRE FEEDERS

A-7

• Control Cable Model: Connect Control Cable between Engine Welder and Feeder.

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.

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

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

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

• Set the "IDLE" switch to the "HIGH" position.

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

• Shut the welder off.

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

Connection of LN-15 to the Ranger 305D

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.

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

• Across-The-Arc Model: Set the "WELD TERMINALS" switch to "WELD TERMINALS ON"

Control Cable Model: Set the "WELD TERMINALS" switch to "REMOTELY CONTROLLED"

• Set the "WIRE FEEDER VOLTMETER" switch to

either "+" or "-" as required by the electrode polarity being used.

• Set the "ARC CONTROL" knob to "0" initially and

adjust to suit.

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

Connection of an LN-23P Wire Feeder to the RANGER 305D

• Shut the welder off.

• Connect the LN-23P as per instructions on the

appropriate connection diagram in Section F. (NOTE): When connecting an LN-23P to the RANGER 305D, a K350-1 adapter kit must be used.

• Set the "VOLTMETER" switch to "-".

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

• Set the "WELD TERMINALS" switch to "REMOTELY

CONTROLLED".

• Set the "ARC CONTROL" knob to "0" initially and

adjust to suit.

• 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.

RANGER 305D

• Set the "IDLE" switch to the "AUTO" position. When not welding, the RANGER 305D engine will be at the low idle speed. If you are using an LN-23P with the K350-1 adapter kit, the electrode is not energized until the gun trigger is closed. When the gun trigger is closed, the current sensing circuit will cause the RANGER 305D engine to go to the high idle speed, the wire will begin to feed and the welding process can be started. When welding is stopped, the engine will revert to low idle speed after approximately 12 seconds unless welding is resumed.

Page 16

A-8

INSTALLATION

A-8

WARNING

Connection of the LN-25 to the RANGER 305D Shut off welder before making any electrical connections.

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

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

NOTE: The LN-25 (K431) Remote Control Module

and (K432) Remote Cable are not recommended for use with the RANGER 305D.

1. Shut the welder off.

2. For electrode Positive, connect the electrode cable from the LN-25 to the "+" terminal of the welder and work cable to the "-" terminal of the welder. For electrode Negative, connect the electrode cable from the LN-25 to the "-" terminal of the welder and work cable to the "+" terminal of the welder.

3. Attach the single lead from the front of the LN-25 to work using the spring clip at the end of the lead. This is a control lead to supply current to the wire feeder motor; it does not carry welding current.

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

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.

• 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.

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

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

7. Set the "IDLE" switch to the "AUTO" position. When not welding, the RANGER 305D engine will be at the low idle speed. If you are using an LN-25 with an internal contactor, the electrode is not energized until the gun trigger is closed.

8. When the gun trigger is closed, the current sensing circuit will cause the RANGER 305D engine to go to the high idle speed, the wire will begin to feed and the welding process started. When welding is stopped, the engine will revert to low idle speed after approximately 12 seconds unless welding is resumed.

CAUTION

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

-----------------------------------------------------------------------RANGER 305D

Page 17

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 FUEL

• Remove the fuel tank cap.

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

• Replace the fuel cap and tighten securely.

• See Engine Owner’s Manual for specific fuel recommendations.

WARNING

• Stop engine while fueling.

• Do not smoke when fueling.

• Keep sparks and flame away from tank.

• Do not leave unattended while fueling.

• Wipe up spilled fuel and allow

DIESEL FUEL

can cause fire.

fumes to clear before starting engine.

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

DIESEL FUEL ONLY

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

The RANGER 305D is a diesel engine powered DC multiprocess welding power source and 120 / 240 volt AC power generator. The engine drives a generator that supplies three phase power for the DC welding circuit and single phase power for the AC auxiliary outlets. The DC welding control system uses state of the art Chopper Technology (CT tm) for superior welding performance.

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.

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

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

• See Engine Owner’s Manual for specific oil and coolant recommendations.

BREAK-IN PERIOD

Lincoln Electric selects high quality, heavy-duty industrial engines for the portable welding machines we offer. While it is normal to see a small amount of crankcase oil consumption during initial operation, excessive oil use, wetstacking (oil or tar like substance at the exhaust port), or excessive smoke is not normal.

Larger machines with a capacity of 350 amperes and higher, which are operated at low or no-load conditions for extended periods of time are especially susceptible to the conditions described above. To accomplish successful engine break-in, most diesel-powered equipment needs only to be run at a reasonably heavy load within the rating of the welder for some period of time during the engine’s early life. However, if the welder is subjected to extensive light loading, occasional moderate to heavy loading of the engine may sometimes be necessary. Caution must be observed in correctly loading a diesel/generator unit.

1. Connect the welder output studs to a suitable resistive load bank. Note that any attempt to short the output studs by connecting the welding leads together, direct shorting of the output studs, or connecting the output leads to a length of steel will result in catastrophic damage to the generator and voids the warranty.

2. Set the welder controls for an output current and voltage within the welder rating and duty cycle. Note that any attempt to exceed the welder rating or duty cycle for any period of time will result in catastrophic damage to the generator and voids the warranty.

3. Periodically shut off the engine and check the crankcase oil

level.

RANGER 305D

Page 18

B-2

OPERATION

B-2

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 autosensing circuit automatically switches the OUTPUT CONTROL from control at the welder to the remote control.

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

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

The OUTPUT dial is

2. DIGITAL OUTPUT METERS

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

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

3. WELD MODE SELECTOR SWITCH:

(Provides four selectable welding modes)

CV-WIRE

DOWNHILL PIPE CC-STICK TOUCH START TIG

RANGER 305D

Page 19

B-3

OPERATION

B-3

4. ARC CONTROL:

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

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

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

DOWNHILL PIPE mode: In this mode, the ARC CONTROL

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

The ARC CONTROL dial is

10. WIRE FEEDER VOLTMETER SWITCH:

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

ENGINE CONTROLS: (Figure B.2)

FIGURE B.2

11. RUN/STOP SWITCH - RUN position ener-

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

12. GLOW PLUG PUSH BUTTON -

When pushed activates the glow plugs as well as the electric fuel pump for quick starting. Glow plug should not be activated for more then 20 seconds continuously.

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 inductance/pinch control. The proper setting depends on the procedure and operator preference. Start with a setting of 0.

. It acts as an

5. WELD OUTPUT TERMINALS WITH FLANGE NUT: Provides a connection point for the

electrode and work cables.

6. GROUND STUD: (graphic)

Provides a connection point for connecting the machine case to earth ground.

7. 14-PIN CONNECTOR: For attaching wire

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

8. 6-PIN CONNECTOR: For attaching optional

remote control equipment. Includes auto-sensing remote control circuit.

9. WELD TERMINALS CONTROL SWITCH:

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

remote switch is depressed.

AUTO BLEED FUNCTION – Air will automatically

bleed from the fuel system by simply pushing the GLOW PLUG BUTTON. It is generally not required to crack open fittings in the fuel system to bleed air from the fuel system.

13. START PUSH BUTTON -

Energizes the starter motor to crank the engine.

14. IDLER SWITCH- Has two positions as follows:

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

idle speed controlled by the engine governor.

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

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

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

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

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

RANGER 305D

Page 20

B-4

OPERATION

15. ENGINE ALTERNATOR TROUBLE LIGHT-The engine alternator light is off when battery

charging system is functioning normally. If light turns on, the alternator or the voltage regulator may not be operating correctly. The light may also come on due to the battery not holding a charge. It is normal for the light to be on while initially starting the engine.

B-4

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

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

step 7 after waiting 30 seconds

16. ENGINE HOUR METER – Displays the total

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

17. ENGINE PROTECTION LIGHT-A warning

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

STARTING THE ENGINE

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

2. Set IDLER switch to AUTO.

3. Set the RUN/STOP switch to RUN.

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

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

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

6. Release the engine START button immediately

when the engine starts.

7. Release the glow plug button after the Engine

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

CAUTION

• Do not allow the starter motor to run continuously for more than 20 seconds.

• Do not push the START button while the engine

is running because this can damage the ring gear and/or the starter motor.

• IF the Engine Protection or Battery Charging

Lights do “not” turn off shortly after starting the engine shut off the engine immediately and deter mine the cause.

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

NOTE: When starting a RANGER 305D for the first

time, or after and extended period of time of not operating, it will take longer than normal because the fuel pump has to fill the fuel system.

STOPPING THE ENGINE

Remove all welding and auxiliary power loads and allow the engine to run at low idle speed for a few minutes to cool the engine.

STOP the engine by placing the RUN-STOP switch in

the STOP position.

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

filter.

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

10,000 Watts 1.16 (4.38) 10.37

7,000 Watts .96 (3.63) 12.50

3,000 Watts .70 (2.67) 17.03

RANGER 305D

Page 21

B-5

OPERATION

WELDER OPERATION

DUTY CYCLE

Duty Cycle is the percentage of time the load is being applied in a 10 minute period. For example a 60% duty cycle, represents 6 minutes of load and 4 minutes of no

load in a 10 minute period.

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

B-5

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

CONSTANT CURRENT (CC-STICK) Welding

The CC-STICK position of the MODE switch is designed for horizontal and vertical-up welding with all types of electrodes, especially low hydrogen.

The OUTPUT CONTROL dial adjusts the full output range for stick welding.

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

DOWNHILL PIPE (STICK) Welding

The DOWNHILL PIPE position of the MODE switch is a

TIG WELDING

The TOUCH START TIG setting of the MODE switch is for DC TIG (Tungsten Inert Gas) welding. To initiate a weld, the OUTPUT CONTROL dial is first set to the desired current and the tungsten is touched to the work. During the time the tungsten is touching the work there is very little voltage or current and, in general, no tungsten contamination. Then, the tungsten is gently lifted off the work in a rocking motion, which establishes the arc.

To stop the arc, simply lift the TIG torch away from the work piece. When the arc voltage reaches approximately 30 volts, the arc will go out and the machine will automatically reset to the touch start current level. The tungsten may then be retouched to the work piece to restrike the arc. The arc may also be started and stopped with an Amptrol or Arc Start Switch. See the following paragraphs.

slope controlled setting 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.

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)

TABLE B.2

(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

Page 22

B-6

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.

OPERATION

B-6

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.

The ARC CONTROL is not active in the TIG mode.

The Ranger 305D can be used in a wide variety of DC TIG welding applications. In general the ‘Touch Start’ feature allows contamination free starting without the use of a Hi-frequency unit. If desired, the K930-2 TIG Module can be used with the Ranger 305D. The settings are for reference.

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

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

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

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

When using the TIG Module, the OUTPUT control on the Ranger 305D is used to set the maximum range of the CURRENT CONTROL on the TIG module or an Amptrol if connected to the TIG Module. (See Table B.2.)

Set the OUTPUT CONTROL knob to adjust output current to the desired level for the gouging electrode being used according to the ratings in the following Table B.3.

Electrode Diameter

1/8" (3.2) 30-60 Amps

5/32"(4.0) 90-150 Amps

3/16"(4.8) 150-250 Amps

TABLE B.3

Current Range (DC, electrode

positive)

WIRE WELDING-CV

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

The Ranger 305D in the CV-WIRE mode, permits it to be used with a broad range of flux cored wire (Innershield and Outershield) electrodes and solid wires for MIG welding (gas metal arc welding). Welding can be finely tuned using the ARC CONTROL. Turning the ARC CONTROL clockwise from –10 (soft) to +10 (crisp) changes the arc from soft and washed-in to crisp and narrow. It acts as an inductance/pinch control. The proper setting depends on the procedure and operator preference. Start with the dial set at 0.

Contact your local authorized Lincoln Electric Distributor or the Lincoln Electric Company for specific wires used on certain applications with this machine. Also for additional information contact WWW.Lincolnelectric.com

RANGER 305D

Page 23

B-7

OPERATION

B-7

AUXILIARY POWER:

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

The auxiliary power of the RANGER 305D consists of two 20 Amp-120 VAC (5-20R) duplex receptacles and one 50 Amp 120/240 VAC (14-50R) receptacle. The 240 VAC receptacle can be split for single phase 120 VAC operation. The auxiliary power capacity is 10,000 watts Peak, 9500 Watts continuous of 60 Hz, single phase power. The auxiliary power capacity rating in watts is equivalent to volt-amperes at unity power factor. The max permissible current of the 240 VAC output is 44 Amps.

NOTE: The 240 V receptacle has two circuits, each of

which measure 120 V to neutral but are of opposite polarities and cannot be paralleled.

Simultaneous Welding and Auxiliary Power Loads

The above auxiliary power ratings are with no welding load. Simultaneous welding and power loads are specified in the following table. The permissible currents shown assume that current is being drawn from either the 120 VAC or 240 VAC supply (not both at the same time).

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

10000

7500 5800 4500 2800

700

44 31 24 19 12

* 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

Page 24

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 300 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.

K1690-1 GFCI RECEPTACLE KIT

Includes one UL approved 120V ground fault circuit interrupter duplex type receptacle with cover and installation instructions. Replaces the factory installed 120V duplex receptacle. Each receptacle of the GFCI Duplex is rated at 20 Amps, the maximum total current from the GFCI Duplex is limited to the 20 Amps. Two kits are required.

K802-N POWER PLUG KIT

Provides four 120 volt plugs rated at 20 amps each and one dual voltage, full KVA plug rated at 120/240 volts, 50 amps.

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 OPTIONS

K963-2 HAND AMPTROL K870 FOOT AMPTROL

K2174-1 COLD WEATHER OPERATIONS KIT-

Provides starting aid and enhancement in extreme cold weather. Includes radiator grill cover, oil pan heater, coolant Lester and all hardware required for installation.

RANGER 305D

Page 25

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 Owner’s Manual before working on this machine.

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

Routine Maintenance

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

ENGINE MAINTENANCE COMPONENTS

KUBOTA D722 DIESEL ENGINE

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

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.

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. Removal of of sediment in fuel tank. 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.

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.

Items

•

*1,*2

@ @

• 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 KAB-

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

Page 26

D-2

MAINTENANCE

D-2

Engine Oil Change

Drain the engine oil while the engine is warm to assure rapid and complete draining.

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

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

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

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

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

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 owner’s 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

Page 27

D-3

MAINTENANCE

Service Instructions & Installation Tips

For Engine Air Filter

D-3

Release the

1Seal Carefully

Unlatch and remove the service cover of the air cleaner. Make certain the latches are folded back against the cover so that they donít hinder filter removal/installation. Most latches are spring loaded to fold back when open. The filter fits tightly over the outlet tube, creating the critical seal on the inside diameter of the filter endcap. The filter should be removed gently to reduce the amount of dust dislodged. There will be some initial resistance, similar to breaking the seal on a jar. filter back and forth to break the seal.

Gently move the end of the

Avoid Dislodging

2Dust from the Filter

Gently pull the filter off the outlet tube and out of the housing. Avoid knocking the filter against the housing.

Clean Sealing Surface

3of the Outlet Tube

Use a clean cloth to wipe the sealing surface. Dust on the outside diameter of the

outlet tube could hinder

an effective seal

and cause leakage. Make sure that all contaminant is removed before the

new filter is inserted.

Check the Old

5Filter 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.

Inspect the New

6Filter 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.

Insert the New

7RadialSeal

by Hand

Insert carefully. Seat the new filter by hand, making certain it is completely into the air cleaner housing place. If the cover hits the filter before it is fully in place, remove the cover and push (by hand) the filter further into the air cleaner and try again. The cover should go on with no extra force.

Filter

before latching the cover in

Donaldson filters with RadialSeal Technology are self-aligning, self-centering, and self-sealing. A new filter has a dry lubricant to aid installation. The critical sealing area will stretch slightly, adjust itself and distribute the sealing pressure evenly. To complete a tight seal, apply pressure by hand at the outer rim of the filter, not the flexible center. (Avoid pushing on the center of the urethane end cap.) No cover pressure is required to hold the seal. Again, do NOT use the service cover to push the filter into place!

When the filter in is place, put the service cover back on, making sure the Vacuator Valve points down. Inspect the Vacuator Valve for cracks or dust hang-ups to insure that it is functioning properly. Re-fasten the latches.

™

Sealing

™

Check Connections

8for Tight Fit

Make sure that all clamps, bolts, and connections in the entire air intake system are tight. Check for holes in piping, and repair if needed.

Clean the Inside of

4the Outlet Tube

Carefully wipe the inside of the outlet tube with a clean cloth. Dirt accidently transferred to the inside of the outlet tube will reach the engine and cause wear. (Engine manufacturers says that it takes only a few grams of dirt to ëdustí an engine!) Be careful not to damage the sealing area on the tube.

Never use the latches on the cover to force the filter into the air cleaner! It is tempting to assume the cover will do the job of seating the filter ñ but it will not! Using the latches to push the filter in could cause damage to the housing and will void the warranty.

RANGER 305D

Page 28

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 day’s use, refill the fuel tank to minimize moisture condensation and dirt contamination in the fuel line. Do not overfill; leave room for the fuel to expand.

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

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

BLEEDING THE FUEL SYSTEM

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

The Kubota D722 engine supplied with this welder is equipped with an automatic bleeding mechanism that functions when the electric fuel pump is actuated. It is generally not necessary to open a vent screw or fuel line fitting to bleed the fuel system.

WARNING

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).

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

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

Bleed the fuel system as follows:

1. Fill the fuel tank with fuel.

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

3. Press and hold the glow plug button for 10 to 20

seconds

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

filters

5. Follow the normal STARTING procedures.

RANGER 305D

Page 29

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.

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

● USING A BOOSTER — connect positive lead to

battery first then connect negative lead to negative battery lead at engine foot.

BATTERY ACID can burn eyes and skin.

● Wear gloves and eye protection

and be careful when working near battery.

● Follow instructions printed on battery.

RANGER 305D

• MUFFLER MAY BE HOT

• ALLOW ENGINE TO COOL BEFORE INSTALLING

THE SPARK ARRESTER!

• DO NOT OPERATE ENGINE WHILE INSTALLING THE SPARK ARRESTER!

Page 30

D-6

MAINTENANCE

WELDER / GENERATOR MAINTENANCE

STORAGE: Store the RANGER 305D in clean, dry

protected areas.

CLEANING: Blow out the generator and controls periodically with low pressure air. Do this at least once a week in particularly dirty areas.

BRUSH REMOVAL AND REPLACEMENT: It’s nor- mal 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.

D-6

WARNING

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

RANGER 305D

Page 31

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

Page 32

E-2

Observe all Safety Guidelines detailed throughout this manual

PROBLEMS

(SYMPTOMS)

TROUBLESHOOTING

POSSIBLE AREAS OF

MISADJUSTMENT(S)

E-2

RECOMMENDED

COURSE OF ACTION

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 electric 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

Page 33

E-3

Observe all Safety Guidelines detailed throughout this manual

PROBLEMS

(SYMPTOMS)

TROUBLESHOOTING

POSSIBLE AREAS OF

MISADJUSTMENT(S)

E-3

RECOMMENDED

COURSE OF ACTION

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

Page 34

E-4

Observe all Safety Guidelines detailed throughout this manual

PROBLEMS

(SYMPTOMS)

TROUBLESHOOTING

POSSIBLE AREAS OF

MISADJUSTMENT(S)

E-4

RECOMMENDED

COURSE OF ACTION

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

Page 35

E-5

Observe all Safety Guidelines detailed throughout this manual

PROBLEMS

(SYMPTOMS)

TROUBLESHOOTING

POSSIBLE AREAS OF

MISADJUSTMENT (S)

E-5

RECOMMENDED

COURSE OF ACTION

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.

3. GFCI tripped (if installed). Clear any ground fault and reset GFCI circuit by pressing "Reset" button on the 120 V receptacle.

4. Faulty PC board or welder alternator.

CAUTION

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

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

RANGER 305D

Page 36

E-6

Observe all Safety Guidelines detailed throughout this manual

PROBLEMS

(SYMPTOMS)

TROUBLESHOOTING

POSSIBLE AREAS OF

MISADJUSTMENT(S)

E-6

RECOMMENDED

COURSE OF ACTION

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

Page 37

F-1

DIAGRAMS

F-1

RANGER 305D

Page 38

F-2

DIAGRAMS

F-2

RANGER 305D

Page 39

F-3

DIAGRAMS

F-3

RANGER 305D

Page 40

F-4

DIAGRAMS

F-4

RANGER 305D

Page 41

F-5

DIAGRAMS

F-5

RANGER 305D

Page 42

F-6

Keep away from moving parts.

Keep guards in place.

MOVING PARTS can injure

DIAGRAMS

F-6

4-14-2000

S24787-6

TO WORK

or service this equipment.

Only qualified personnel should install,use

ENGINE WELDERS /LN-8 CONNECTION DIAGRAM

WARNING

Do not operate with panels open.

Disconnect NEGATIVE (-) Battery lead

ELECTRIC SHOCK can kill

before servicing.

Do not touch electrically live parts.

CABLE PLUG

TO LN-8 INPUT

14 PIN

AMPHENOL

K595 CONTROL CABLE

ELECTRODE CABLE

TO WIRE FEED UNIT

CAUTION:

ANY INCREASE OF THE HIGH IDLE ENGINE RPM BY CHANGING THE GOVERNOR SETTING OR OVERRIDING THE THROTTLE LINKAGE WILL CAUSE

AN INCREASE IN THE AC WIRE FEEDER VOLTAGE, WHICH CAN DAMAGE THE CONTROL CIRCUIT. THE ENGINE GOVERNOR SETTING IS PRE-SET

AT THE FACTORY – DO NOT ADJUST ABOVE RPM SPECIFICATIONS LISTED IN THE ENGINE WELDER OPERATING MANUAL.

N.A. WELDING CABLES MUST BE OF PROPER CAPACITY FOR THE CURRENT AND DUTY CYCLE OF IMMEDIATE AND FUTURE

APPLICATIONS. SEE OPERATING MANUAL.

N.B. CONNECT WELDING CABLES TO OUTPUT STUDS FOR DESIRED POLARITY. POSITION THE WIRE FEEDER VOLTMETER SWITCH TO

MATCH THE POLARITY OF THE ELECTRODE CABLE.

N.C. PLACE IDLER SWITCH IN “HIGH” POSITION.

RANGER 305D

Page 43

F-7

DIAGRAMS

F-7

RANGER 305D

Page 44

F-8

DIAGRAMS

F-8

RANGER 305D

Page 45

F-9

DIAGRAMS

F-9

RANGER 305D

Page 46

F-10

DIAGRAMS

F-10

RANGER 305D

Page 47

F-11

DIAGRAMS

F-11

RANGER 305D

Page 48

F-12

ENHANCED DIAGRAM

DIAGRAMS

F-12

RANGER 305D- KUBOTA - WIRING DIAGRAM

P54 - J4

WELD

WINDINGS

Meter

P5 - J5

Meter

151

M10

M10 M9 M6 M5 M4

M3 M2

AMPS

S6 MODE SELECTOR SWITCH

151

M10

M10 M9 M6 M5 M4

CCW

OUTPUT CONT. POT

ARC CONTROL

(LOCATED BELOW

TERMINAL 2)

TIG

PIPE

220

222

214

218

P6-J6

Shunt

2 1

206S

204S

VOLTS

STATOR

D1 - THREE PHASE BRIDGE RECTIFIER

W10

Twisted

Pair

301

HEATSINK

W11

300 AMP

MODULE

PCB 1

C11

C10

302

WRAP TWO TURNS #3 &

#6 LEADS IN DIRECTION

SHOWN THROUGH

TOROID

TWISTED PAIR

261

260

W10

204S

SHUNT

206S

206B

50MV=400 AMPS

L1 CHOKE

206A

208B

Output &

Arc Cont.

Mode

Select

P7 - J7

218

220

222

279

277

278

10K

279

10K

278

CCW

277

42 VAC

FIELD WINDING

P2 - J2

214

Key

404

215

224B

224A

GND-R

GND-E

STATOR AUX. WINDING

GND-R

GND-E

GND-K

GND-N

BOTTOM GND INSIDE CASEFRONT

206A

206C

208C

206B

SWITCH

POLARITY

VOLTMETER

208

WIRE FEED POWER

WINDING

208A

42 VAC

SHOWN IN

P1 - J1

Amphenol,

Model

Select,

Engine &

Battery

Function

200N

224B

HOUR METER

Hot Start

305

Key

210H

76A

75A

77A

252

251

IDLER CONTROL

200N

800uf

150vdc

200B

TOP GND. SCREW ON

INSIDE OF CASE FRON T

FRAME GND.

POSITIVE (+)

POSITION

41A

CB8

15A

42A

208C

206C

BYPASS

FILTER

ASSEMBLY

Sense/

Idler/

PWM

P3-J3

P43-J43

261

260

251

252

208B

GND-R

210B

PCB2 WELD CONTROL PC BOARD

224

SHOWN IN

"AUTO" POSITION

CR1

210G

223A

225

210F

210B

Battery Charge

Light PL2

START

BUTTON

210A

228

210E

Engine Protection

Light PL1

229B

229A

210D

200

200A

201

201A

POSITIVE BRUSH CONNECTED

TO SLIP RING NEAREST

TO THE LAMINATION

BLACK

20A

CB1

BLACK

WHITE

J102

SILVER

GND-G

GND-D

GND-C

GND-D

GND-G

GND-A

GND-B

GND-N

FRAME GND.

GND. SCREW ON LEFT

INSIDE CASEFRONT

ROTOR

CB2

J101

210

210H

212A

210D

S1RUN-STOP

SWITCH

(SHOWN IN

RUN POS.)

212

CB7

15A

209B

GLOW

PLUG

BUTTON

BLACK

50A

CB5

CB6

WHITE

BLACK

WHITE

BLACK

115/230V

J100

SILVER

WHITE

GND-C

GND-B

TERM.

404

232

whtred

4 3

blk

210A

215

J72

P72

225B

wht

blk

red

J73

P73

red

FUEL

blk

J74

P74

GND-M

231

GND-L

BATTERY

12 VOLT

211

209

209A

210C

BAT

229A

H2O

TEMP

229

223A

OIL

PRES

223

GND-J

GND-K

GND SCREW ON

FAN BAFFLE.

CONTACTOR

CONTROL

SHOWN IN

"WELDING ON"

PCB3

PULL

COIL

HOLD

PULL

COIL

HOLD

PUMP

GND-H

ENGINE

GROUND

228

IGN

ENGINE COMPONENTS

GLOW

PLUGS

POSITION

LEAD COLOR CODE:

B=BLACK OR GRAY

PULL COIL BD.

IDLE SOLENOID

FUEL SOLENOID

FRAME

GROUND

GND-J

STARTER

ALTERNATOR

R=RED OR PINK

W=WHITE

G=GREEN (W/YELLOW STRIPE)

A.03

G4250

L2, L3: RF CHOKES

CONNECTORS VIEWED FROM INSERTION END

ELECTRICAL SYMBOLS PER E1537

ALL CASE FRONT COMPONENTS SHOWN VIEWED FROM REAR.

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..

115VAC

77A

76A

75A

42A

41A

75B

76B

GND-A

77B

EFG

42VAC

WORK

REMOTE

CONTROL

CHB

CONTACTOR

77B

76B

75B

ABCDE

AMPHENOL 1

REMOTE

GROUND

CONTACTOR

CONTROL

GND-B

AMPHENOL 2

GROUND

RANGER 305D

Page 49

F-13

A.05

F-13

M19772

DIAGRAMS

35.77

34.24

30.71

29.83

5.57

6.33

11.03

21.5

NTER OF GRAVITY *CE

*11.3

26.64

29.57

*29.0

DIMENSION PRINT RANGER 305D

52.2

21.06

17.50 19.50

52.00

51.20

RANGER 305D

Page 50

NOTES

RANGER 305D

Page 51

NOTES

RANGER 305D

Page 52

WARNING

Spanish

AVISO DE

PRECAUCION

● Do not touch electrically live parts or

electrode with skin or wet clothing.

● Insulate yourself from work and

ground.

● No toque las partes o los electrodos

bajo carga con la piel o ropa mojada.

● Aislese del trabajo y de la tierra.

● Keep flammable materials away.

● Mantenga el material combustible

fuera del área de trabajo.

● Wear eye, ear and body protection.

● Protéjase los ojos, los oídos y el

cuerpo.

French

ATTENTION

German

WARNUNG

Portuguese

ATENÇÃO

Japanese

Chinese

Korean

Arabic

● Ne laissez ni la peau ni des vête-

ments mouillés entrer en contact avec des pièces sous tension.

● Isolez-vous du travail et de la terre.

● Berühren Sie keine stromführenden

Teile oder Elektroden mit Ihrem Körper oder feuchter Kleidung!

● Isolieren Sie sich von den

Elektroden und dem Erdboden!

● Não toque partes elétricas e elec-

trodos com a pele ou roupa molhada.

● Isole-se da peça e terra.

● Gardez à l’écart de tout matériel

inflammable.

● Entfernen Sie brennbarres Material!

● Mantenha inflamáveis bem guarda-

dos.

● Protégez vos yeux, vos oreilles et

votre corps.

● Tragen Sie Augen-, Ohren- und Kör-

perschutz!

● Use proteção para a vista, ouvido e

corpo.

READ AND UNDERSTAND THE MANUFACTURER’S INSTRUCTION FOR THIS EQUIPMENT AND THE CONSUMABLES TO BE USED AND FOLLOW YOUR EMPLOYER’S SAFETY PRACTICES.

SE RECOMIENDA LEER Y ENTENDER LAS INSTRUCCIONES DEL FABRICANTE PARA EL USO DE ESTE EQUIPO Y LOS CONSUMIBLES QUE VA A UTILIZAR, SIGA LAS MEDIDAS DE SEGURIDAD DE SU SUPERVISOR.

LISEZ ET COMPRENEZ LES INSTRUCTIONS DU FABRICANT EN CE QUI REGARDE CET EQUIPMENT ET LES PRODUITS A ETRE EMPLOYES ET SUIVEZ LES PROCEDURES DE SECURITE DE VOTRE EMPLOYEUR.

LESEN SIE UND BEFOLGEN SIE DIE BETRIEBSANLEITUNG DER ANLAGE UND DEN ELEKTRODENEINSATZ DES HERSTELLERS. DIE UNFALLVERHÜTUNGSVORSCHRIFTEN DES ARBEITGEBERS SIND EBENFALLS ZU BEACHTEN.

Page 53

● Keep your head out of fumes.

● Use ventilation or exhaust to

remove fumes from breathing zone.

● Turn power off before servicing.

● Do not operate with panel open or

guards off.

WARNING

● Los humos fuera de la zona de res-

piración.

● Mantenga la cabeza fuera de los

humos. Utilice ventilación o aspiración para gases.

● Gardez la tête à l’écart des fumées.

● Utilisez un ventilateur ou un aspira-

teur pour ôter les fumées des zones de travail.

● Vermeiden Sie das Einatmen von

Schweibrauch!

● Sorgen Sie für gute Be- und

Entlüftung des Arbeitsplatzes!

● Mantenha seu rosto da fumaça.

● Use ventilação e exhaustão para

remover fumo da zona respiratória.

● Desconectar el cable de ali-

mentación de poder de la máquina

antes de iniciar cualquier servicio.

● Débranchez le courant avant l’entre-

tien.

● Strom vor Wartungsarbeiten

abschalten! (Netzstrom völlig öff-

nen; Maschine anhalten!)

● Não opere com as tampas removidas.

● Desligue a corrente antes de fazer

serviço.

● Não toque as partes elétricas nuas.

● No operar con panel abierto o

guardas quitadas.

● N’opérez pas avec les panneaux

ouverts ou avec les dispositifs de protection enlevés.

● Anlage nie ohne Schutzgehäuse

oder Innenschutzverkleidung in Betrieb setzen!

● Mantenha-se afastado das partes

moventes.

● Não opere com os paineis abertos

ou guardas removidas.

Spanish

AVISO DE

PRECAUCION

French

ATTENTION

German

WARNUNG

Portuguese

ATENÇÃO

Japanese

Chinese

Korean

Arabic

LEIA E COMPREENDA AS INSTRUÇÕES DO FABRICANTE PARA ESTE EQUIPAMENTO E AS PARTES DE USO, E SIGA AS PRÁTICAS DE SEGURANÇA DO EMPREGADOR.

Page 54

• World's Leader in Welding and Cutting Products •

• Sales and Service through Subsidiaries and Distributors Worldwide •

Cleveland, Ohio 44117-1199 U.S.A. TEL: 216.481.8100 FAX: 216.486.1751 WEB SITE: www.lincolnelectric.com

Lincoln Electric IM730 User Manual

Specifications and Main Features

Frequently Asked Questions

User Manual