Lincoln Electric IM893 User Manual [en, de, es, fr]

IM893

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Ranger 305 D (CE)

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.

December, 2010

11314, 11315

Cleveland, Ohio 44117-1199 U.S.A. TEL: [phone] FAX: [phone] WEB SITE: www.lincolnelectric.com

EN 60974-1

OPERATORʼS MANUAL

Copyright © Lincoln Global Inc.

• World's Leader in Welding and Cutting Products •

• Sales and Service through Subsidiaries and Distributors Worldwide •

i

SAFETY

i

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.

____________________________________________________

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.

____________________________________________________

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

____________________________________________________

1.e. In some cases it may be necessary to remove safety

guards to perform required maintenance. Remove
guards only when necessary and replace them when the
maintenance requiring their removal is complete.
Always use the greatest care when working near moving
parts.

___________________________________________________

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

1.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.

ii

SAFETY

ii

ELECTRIC SHOCK can
kill.

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

gloves to insulate hands.

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

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

• Semiautomatic DC Constant Voltage (Wire) Welder.

• DC Manual (Stick) Welder.

• AC Welder with Reduced Voltage Control.

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

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

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

3.f.

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

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

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

ARC RAYS can burn.

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

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

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

FUMES AND GASES
can be dangerous.

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

fumes and gases away from the breathing zone. When

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

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

5.c.

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

5.d. 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.

vapors

to

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

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

5.f. Also see item 1.b.

iii

SAFETY

iii

WELDING and CUTTING
SPARKS can
cause fire or explosion.

6.a.

Remove fire hazards from the welding area.

If this is not possible, cover them to prevent

Remember that welding sparks and hot
materials from welding can easily go through small cracks
and openings to adjacent areas. Avoid welding near
hydraulic lines. Have a fire extinguisher readily available.

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

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

6.d. Do not heat, cut or weld tanks, drums or containers until the
proper steps have been taken to insure that such procedures
will not cause flammable or toxic vapors from substances
inside. They can cause an explosion even
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.

the welding sparks from starting a fire.

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.

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

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

Refer to http://www.lincolnelectric.com/safety for additional safety information.

iv

SAFETY

iv

PRÉCAUTIONS DE SÛRETÉ

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

Sûreté Pour Soudage A LʼArc

1. Protegez-vous contre la secousse électrique:

a. Les circuits à lʼélectrode 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 sʼisoler 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 lʼeau 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 sʼapplicuent aussi au pistolet de
soudage.

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

6. Eloigner les matériaux inflammables ou les recouvrir afin de
prévenir tout risque dʼincendie 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 dʼincendie.

8. Sʼassurer que la masse est connectée le plus prés possible
de la zone de travail quʼil est pratique de le faire. Si on place
la masse sur la charpente de la construction ou dʼautres
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 dʼincendie ou dʼechauffement des chaines et des
câbles jusquʼà ce quʼils 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
dʼopérations de dégraissage, nettoyage ou pistolage. La
chaleur ou les rayons de lʼarc 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 nʼimporte quelle
partie du corps.

3. Un coup dʼarc peut être plus sévère quʼun coup de soliel,
donc:

a. Utiliser un bon masque avec un verre filtrant approprié

ainsi quʼun verre blanc afin de se protéger les yeux du
rayonnement de lʼarc et des projections quand on soude
ou quand on regarde lʼarc.

b. Porter des vêtements convenables afin de protéger la

peau de soudeur et des aides contre le rayonnement de
lʻarc.

c. Protéger lʼautre personnel travaillant à proximité au

soudage à lʼaide dʼécrans appropriés et non-inflamma­bles.

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

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 lʼélectricité 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, Iʼinstallation et lʼentretien du poste
seront effectués par un électricien qualifié.

3. Avant de faires des travaux à lʼinterieur de poste, la
debrancher à lʼinterrupteur à la boite de fusibles.

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

v

SAFETY

v

vi

SAFETY

THE LINCOLN ELECTRIC COMPANY

EC DECLARATION OF CONFORMITY

Manufacturer and technical documentation
holder: The Lincoln Electric Company

Address: 22801 St. Clair Ave.

Cleveland Ohio 44117-1199 USA

EC Company: Lincoln Electric Europe S.L.

Address: c/o Balmes, 89 - 80 2a

08008 Barcelona
SPAIN

Hereby declare that machine: Welding Equipment - Ranger 305D

vi

Sales code: K2279 (with prefixes and suffixes)

Is in conformity with Council Directives and
amendments: EMC Directive 89/336/EEC

Low Voltage Directive 73/23/EEC
Noise emission in the environment by equipment for use outdoors
2000/14/EC; Annex VI, procedure 1

Standards: EN 50199 Electromagnetic compatibility (EMC) product standard

for arc welding equipment, 1995 + A1
EN 60974-1, Safety requirements for arc welding equipment, power
sources, 1998 + A1
EN ISO 3744, Acoustic ñ Determination of sound power levels of
noise sources using sound pressure Ö 1995

Notified body (for 2000/14/EC Conformity): LNE ñ Number: 0071

Address: ZA de Trappes-…lancourt

29, avenue Roger Hennequin
78197 TRAPPES Cedex

Guaranteed sound power level: LWA 97 dB (net power Pel = 7.5kW)
Measured sound power level: LWA 96 dB (net power Pel = 7.5kW)

Frank Stupczy, Manufacturer Dario Gatti, European Community Representative
Compliance Engineering Manager European Engineering Director Machines
25 January 2006 26 January 2006

vii

SAFETY

Electromagnetic Compatibility (EMC)

Conformance

Products displaying the CE mark are in conformity with European Community Council Directive of 15 Dec
2004 on the approximation of the laws of the Member States relating to electromagnetic compatibility,
2004/108/EC. It was manufactured in conformity with a national standard that implements a harmonized
standard: EN 60974-10 Electromagnetic Compatibility (EMC) Product Standard for Arc Welding Equipment.
It is for use with other Lincoln Electric equipment. It is designed for industrial and professional use.

Introduction

All electrical equipment generates small amounts of electromagnetic emission. Electrical emission may be
transmitted through power lines or radiated through space, similar to a radio transmitter. When emissions
are received by other equipment, electrical interference may result. Electrical emissions may affect many
kinds of electrical equipment; other nearby welding equipment, radio and TV reception, numerical controlled
machines, telephone systems, computers, etc. Be aware that interference may result and extra precautions
may be required when a welding power source is used in a domestic establishment.

Installation and Use

The user is responsible for installing and using the welding equipment according to the manufacturer’s
instructions. If electromagnetic disturbances are detected then it shall be the responsibility of the user of the
welding equipment to resolve the situation with the technical assistance of the manufacturer. In some cases
this remedial action may be as simple as earthing (grounding) the welding circuit, see Note. In other cases it
could involve construction of an electromagnetic screen enclosing the power source and the work complete
with associated input filters. In all cases electromagnetic disturbances must be reduced to the point where
they are no longer troublesome.

vii

Note: The welding circuit may or may not be earthed for safety reasons according to national codes.

Changing the earthing arrangements should only be authorized by a person who is compe­tent to access whether the changes will increase the risk of injury, e.g., by allowing parallel
welding current return paths which may damage the earth circuits of other equipment.

Assessment of Area

Before installing welding equipment the user shall make an assessment of potential electromagnetic prob­lems in the surrounding area. The following shall be taken into account:

a) other supply cables, control cables, signaling and telephone cables; above, below and adjacent to the

welding equipment;

b) radio and television transmitters and receivers;

c) computer and other control equipment;

d) safety critical equipment, e.g., guarding of industrial equipment;

e) the health of the people around, e.g., the use of pacemakers and hearing aids;

f) equipment used for calibration or measurement

g) the immunity of other equipment in the environment. The user shall ensure that other equipment being

used in the environment is compatible. This may require additional protection measures;

h) the time of day that welding or other activities are to be carried out.

RANGER 305D (CE)

viii

SAFETY

Electromagnetic Compatibility (EMC)

The size of the surrounding area to be considered will depend on the structure of the building and other
activities that are taking place. The surrounding area may extend beyond the boundaries of the premises.

Methods of Reducing Emissions

Mains Supply

Welding equipment should be connected to the mains supply according to the manufacturer’s recommenda­tions. If interference occurs, it may be necessary to take additional precautions such as filtering of the mains
supply. Consideration should be given to shielding the supply cable of permanently installed welding equip­ment, in metallic conduit or equivalent. Shielding should be electrically continuous throughout its length. The
shielding should be connected to the welding power source so that good electrical contact is maintained
between the conduit and the welding power source enclosure.

Maintenance of the Welding Equipment

The welding equipment should be routinely maintained according to the manufacturer’s recommendations.
All access and service doors and covers should be closed and properly fastened when the welding equip­ment is in operation. The welding equipment should not be modified in any way except for those changes
and adjustments covered in the manufacturers instructions. In particular, the spark gaps of arc striking and
stabilizing devices should be adjusted and maintained according to the manufacturer’s recommendations.

viii

Welding Cables

The welding cables should be kept as short as possible and should be positioned close together, running at
or close to floor level.

Equipotential Bonding

Bonding of all metallic components in the welding installation and adjacent to it should be considered.
However, metallic components bonded to the work piece will increase the risk that the operator could
receive a shock by touching these metallic components and the electrode at the same time. The operator
should be insulated from all such bonded metallic components.

Earthing of the Workpiece

Where the workpiece is not bonded to earth for electrical safety, not connected to earth because of its size
and position, e.g., ships hull or building steelwork, a connection bonding the workpiece to earth may reduce
emissions in some, but not all instances. Care should be taken to prevent the earthing of the workpiece
increasing the risk of injury to users, or damage to other electrical equipment. Where necessary, the connec­tion of the workpiece to earth should be made by a direct connection to the workpiece, but in some countries
where direct connection is not permitted, the bonding should be achieved by suitable capacitance, selected
according to national regulations.

Screening and Shielding

Selective screening and shielding of other cables and equipment in the surrounding area may alleviate prob­lems of interference. Screening of the entire welding installation may be considered for special

applications

1.

_________________________

1

Portions of the preceding text are contained in EN 60974-10: “Electromagnetic Compatibility (EMC) prod­uct standard for arc welding equipment.”

RANGER 305D (CE)

Thank You

ixix

for selecting a QUALITY product by Lincoln Electric. We want you
to take pride in operating this Lincoln Electric Company product

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

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

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

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

CUSTOMER ASSISTANCE POLICY

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.

x

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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 ....................................................................................................................A-5

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

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

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

________________________________________________________________________________

TABLE OF CONTENTS

Page

x

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

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

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

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

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

Break in Period.....................................................................................................................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-6

________________________________________________________________________________

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

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

________________________________________________________________________________

xi

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

________________________________________________________________________

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

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

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

________________________________________________________________________

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

________________________________________________________________________

Parts List.................................................................................................................P-494

________________________________________________________________________

xi

A-1

INSTALLATION

TECHNICAL SPECIFICATIONS - RANGER 305D (CE)

INPUT - DIESEL ENGINE

Make/Model Description Speed (RPM) Displacement Starting Capacities

cu. in. (cu. cm.) System

A-1

3 cylinder, 4 stroke 43.88(789)

12VDC Battery &

15.9 HP starter 45L (12 US.gal.)
(12 KW) High Idle 3100

Kubota

(3)

Net intermittent

D722 3000 RPM Full Load 3000

Bore x Stroke inch (mm)

2.64 x 2.68

(Group 58; 550 Radiator Coolant:

naturally aspirated (67 x 68 mm) cold crank amps) 3.6L(3.85 U Qts)

water cooled Low Idle 2200 Battery Charger

Diesel engine (3.6L)

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

Welding Process

DC Constant Current

DC Pipe Current
Touch-Start®TIG

DC Constant Voltage

Welding Output

Current/Voltage/Duty Cycle

250A / 30V / 100%
250A / 30V / 100%
250A / 20V / 100%
250A / 27V / 100%

Output Range

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

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

Auxiliary Power

8,500 Watts Peak, / 8,000 Watts Continuous, 50 Hz 230/400 Volts - 3 Phase

Sound Levels

Sound Power: 97 dB Lwa

(1)

PHYSICAL DIMENSIONS

HEIGHT WIDTH DEPTH WEIGHT

909mm 546mm 1524mm

30.0 in.

(2)

21.50 in 60.0 in.

341kg. (752lbs.)

Fuel:

Oil:

3.2L(3.4 US. Qts.)

Max. Weld OCV

@Rated Load RPM

60 Volts

ENGINE

LUBRICATION EMISSIONS FUEL SYSTEM GOVERNOR

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

AIR CLEANER ENGINE IDLER MUFFLER ENGINE PROTECTION

Low noise Muffler: Shutdown on low oil

Single Element Automatic Idler Made from long life, aluminized steel. pressure & engine

temperature

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

MODEL NUMBER

Receptacles

K2279-1 (UK)

400V (3 Ph) x 1
230V (1 Ph) x 1

115V x 1

(4)

14 Pin Connector

K2279-2 (EUROPE)

400V (3 Ph) x 1
230V (1 Ph) x 2

14 Pin Connector

6 Pin Connector

6 Pin Connector

Residual Current Device (RCD)

4-pole, 25 Amp

(30mA trip current)

Circuit Breakers (Thermal/Magnetic)

3 Phase, 20 Amp x 1
1 Phase, 15 Amp x 5

(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.
(2) To top of enclosure, add 152mm (6 “) to top of exhaust elbow.
(3) Engine warranty may vary outside of the USA. (See Engine warranty for details)
(4) Center-Tapped to ground.

4-pole, 25 Amp

(30mA trip current)
3 Phase, 20 Amp x 1
1 Phase, 15 Amp x 4

RANGER 305D (CE)

(3)

A-2

INSTALLATION

A-2

SAFETY PRECAUTIONS

WARNING

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

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

ELECTRIC SHOCK can kill.

• Do not touch electrically live parts or

electrode with skin or wet clothing.

• Insulate yourself from work and

ground

• Always wear dry insulating gloves.

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

ENGINE EXHAUST can kill.

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

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

MOVING PARTS can injure.

• Do not operate with doors open or
guards off.

• Stop engine before servicing.

• Keep away from moving parts.

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

See additional warning information at

front of this operatorʼs manual.

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

LIFTING

The machine weighs approximately 374 kg. (824 lbs)
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 305m
(1000ft.). Due to new EPA and other local emissions regula­tions, modifications to the engine for high altitude are restricted
within the United States and some European Countries. Use
above 1828m (6000 ft.) 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.

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 (CE) 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 45
liters (12 gallons).

RANGER 305D (CE)

HIGH TEMPERATURE OPERATION

At temperatures above 40°C,welder output derating is neces­sary. For maximum output ratings, derate the welder output 2
volts for every 10°C above 40°C.

Cold weather starting:

With a fully charged battery and the proper oil, the
engine should start satisfactorily down to about -15°C
(5°F). If the engine must be frequently started at or
below -5°C (23°F), it may be desirable to install cold­starting aides. The use of No. 1D diesel fuel is recom­mended in place of No. 2D at temperatures below

-5°C (23°F). Allow the engine to warm up before
applying a load or switching to high idle.

WARNING

Note: Extreme cold weather starting may require

longer glow plug operation.

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

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

A-3

INSTALLATION

A-3

TOWING

Check with distributor for the recommended trailer for use with
this equipment for road, in-plant and yard towing by a vehicle. 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 laws in nation / region to be used.

OIL

The machine is shipped with the engine crankcase
filled with high quality SAE 10W-30 Oil that meets
classification CG-4 or CH-4 for diesel engines. Check
the oil level before starting the engine. If it is not up to
the full mark on the dip stick, add oil as required.
Check the oil level every four hours of running time
during the first 50 running hours. Refer to the engine
Operatorʼs Manual for specific oil recommendations
and break-in information. The oil change interval is
dependent on the quality of the oil and the operating
environment. Refer to the Engine Operatorʼs Manual
for more details on the proper service and mainte-

nance intervals.

FUEL

USE DIESEL FUEL ONLY

• Fill the fuel tank with clean, fresh fuel. The
capacity of the tank is, about 45 ltr.ʼs (12 Gal.ʼs).

WARNING

WARNING

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 manufacturerʼs instructions.

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

PRE-OPERATION ENGINE SERVICE

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

WARNING

• Stop engine and allow to cool before fueling

• Do not smoke when fueling

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

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

• Keep sparks and flame away from tank.

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

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

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

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

ENGINE COOLING SYSTEM

WARNING

Air to cool the engine is drawn in the base sides
and exhaust through radiator & case back. It is
important that the intake and exhaust air is not
restricted. Allow a minimum clearance of 0.6m (2
feet) from the case back and 40cm (16”) from
either side of the base to a vertical surface.

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

BATTERY CONNECTION

CAUTION

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

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

The machine is shipped with the negative battery
cable disconnected. Make certain that the RUN-STOP
switch is in the STOP position. Attach the negative
battery cable to the negative battery terminal and
tighten using a 13mm socket or wrench. It may be
helpful to remove the coolant over-fill bottle. Pull up on
bottle to remove from bracket.

RANGER 305D (CE)

A-4

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.

INSTALLATION

MUFFLER OUTLET / SPARK ARRESTOR

In addition to operating as a Spark Arrestor the Spark
Arrestor serves as an outlet cover for the muffler as
well as providing additional sound reduction. Remove
from the box and install using the clamp and instruc­tions provided.

WARNING

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

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

REMOTE CONTROL

The machine 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 K963-3 hand Amptrol.
When in the CC-STICK, DOWNHILL PIPE, or CV­WIRE 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.

A-4

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

WARNING

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

• Be double insulated.

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

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

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" .

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.

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

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

WARNING

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

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

ELECTRICAL CONNECTIONS

MACHINE GROUNDING

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

A machine grounding stud marked with the symbol

is provided on the front of the welder.

WELDING TERMINALS

The machine 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 "REMOTE" 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 19mm 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.

RANGER 305D (CE)