Page 1
RANGER 305D CE
OPERATOR’S MANUAL
IM2024
10/2017
REV01
22801 St. Clair Ave., Cleveland Ohio 44117-1199 USA
English English
THE LINCOLN ELECTRIC COMPANY
www.lincolnelectric.eu
I
Page 2
THE LINCOLN ELECTRIC COMPANY
EC DECLARATION OF CONFORMITY
Manufacturerandtechnical
documentationholder:
ECCompany:
Herebydeclarethatweldingequipment:
Productnumber:
IsinconformitywithCouncil
Directivesandamendments:
EN60974‐1:2012,Safetyrequirementsforarcweldingequipment,
Notifiedbody(for2000/14/EC
Conformity):
Guaranteedsoundpowerlevel:
Measuredsoundpowerlevel: LWA96dB(netpowerPel=
CEmarkingaffixedin‘15
SamirFarah,Manufacturer
ComplianceEngineeringManager
7September2017
MCD40e
TheLincolnElectricCompany
22801St.ClairAve.
ClevelandOhio44117‐1199USA
LincolnElectricEuropeS.L.
c/oBalmes,89‐802a
08008BarcelonaSPAIN
Ranger305DwithCEmarking
K2279(maycontainprefixes
andsuffixes)
MachineryDirective2006/42/EC;
LowVoltageDirective2014/35/EU
ElectromagneticCompatibility(EMC)Directive2014/30/EU
Noiseemissionintheenvironmentbyequipmentforuseoutdoors
2000/14/EC.
powersources;
EN60974‐10:2014,ArcWelding
Equipment‐Part10:Electromagnetic
compatibility(EMC)requirements;
ENISO3744:2010,Acoustics–Determinationofsoundpowerlevelsof
noisesourcesusingsoundpressure…reflectingplane;
EN60204‐1:2006,Safetyofmachinery–Electricalequipmentof
machines,Part1:Generalrequirements;
EN12100:2010,Safetyofmachinery–Generalprinciplesfordesign
assessmentandriskreduction.
LNE– Number:0071
ZAdeTrappes‐Élancourt
29,avenueRogerHennequin
78197TRAPPESCedex
LWA97dB(netpowerPel=7.5kW)
7.5 kW)
JacekStefaniak,EuropeanCommunityRepresentative
EuropeanProductManagerEquipment
8September2017
risk
English English
II
Page 3
THANKS! For having chosen the QUALITY of the Lincoln Electric products.
Please Examine Package and Equipment for Damage. Claims for material damaged in shipment must be notified
immediately to the dealer.
For future reference record in the table below your equipment identification information. Model Name, Code &
Serial Number can be found on the machine rating plate.
Model Name:
………………...…………………………….…………………………………………………………………………………………..
Code & Serial number:
………………….……………………………………………….. …………………………………………………….……………..
Date & Where Purchased:
…………………………………………………………………... ……………………….…………………………………………..
ENGLISH INDEX
Technical Specifications ...................................................................................................................................................... 1
Electromagnetic Compatibility (EMC) ................................................................................................................................. 2
Safety .................................................................................................................................................................................. 3
Installation and Operator Instructions ................................................................................................................................. 4
Diagrams ........................................................................................................................................................................... 17
WEEE ................................................................................................................................................................................ 22
Spare Parts ....................................................................................................................................................................... 22
Authorized Service Shops Location .................................................................................................................................. 22
Electrical Schematic .......................................................................................................................................................... 22
12/05
English English
III
Page 4
Technical Specifications
RANGER
®
305D (CE) (K2279-1, K2279-2, K2279-3)
INPUT – DIESEL ENGINE
Model Description Speed (RPM)
Displacement
(cu. cm)
Starting System Capacities
789
Bore x Stroke
(mm)
67x 68
12VDC Battery &
Starter
(Group 58: 550
cold crank amps)
Battery Charger
(3.6L)
Fuel: 45L
Oil: 3.2L
Radiator Coolant:
Kubota
D722
3 cylinder, 4 stroke
15.9 HP (12KW)
(3)
Net intermittent
3000 RPM
naturally aspirated
water cooled
High Idle 3100
Full Load 3000
Low Idle 2200
Diesel engine
RATED OUTPUT @ 40°C - 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%
RATED OUTPUT @ 40°C - GENERATOR
Auxiliary Power
Output Range
20 to 305A
40 to 300A
20 to 250A
14 to 29V
(1)
8500 Watts Peak / 8000Watts Continuous, 50 Hz , 230V/400V, 3Phase
Sound Level
Sound Power: 97dB Lwa
Max. Weld OCV @
Rated Load RPM
60V
PHYSICAL DIMENSIONS
Height
909 mm
(2)
Width
546 mm
Length
1524 mm
Weight
341kg
ENGINE
Lubrication Emission Fuel System Governor
Full pressure with
full flow filter
Air Cleaner Engine Idler Muffler Engine Protection
Single element Automatic idler
ENGINE WARRANTY: 2 year complete (parts and labor) 3rd. year major components (parts and labor)
Certified to
EPA Tier 4
Compliant
Mechanical fuel pomp, Auto air bleed system
Electric shutoff solenoid indirect fuel injector.
Low noise muffler: made from long life, aluminized
steel.
Mechanical governor
Shutdown on low oil pressure &
engine temperature
(3)
DESCRIPTION
MODEL NUMBER K2279-1, K2279-3 (UK) K2279-2 (Europe)
400V (3 Ph) x 1
Receptacles
230V (1 Ph) x 1
115V x 1
(4)
14 Pin Connector
6 Pin Connector
Residual Current Device (RCD)
Circuit Breakers (Thermal/Magnetic)
(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 5
400V (3 Ph) x 1
230V (1 Ph) x 2
14 Pin Connector
6 Pin Connector
4-pole, 25 Amp
(30mA trip current)
3 Phase, 20 Amp x 1
1 Phase, 15 Amp x 4
3.6L
English English
1
Page 5
Electromagnetic Compatibility (EMC)
This machine has been designed in accordance with all relevant directives and standards. However, it may still generate
electromagnetic disturbances that can affect other systems like telecommunications (telephone, radio, and television) or
other safety systems. These disturbances can cause safety problems in the affected systems. Read and understand
this section to eliminate or reduce the amount of electromagnetic disturbance generated by this machine.
system, it is responsibility of the installer or user of the equipment to ensure, by consultation with the distribution network
operator if necessary, that the equipment may be connected.
Before installing the machine, the operator must check the work area for any devices that may malfunction because of
electromagnetic disturbances. Consider the following.
Input and output cables, control cables, and telephone cables that are in or adjacent to the work area and the
Radio and/or television transmitters and receivers. Computers or computer controlled equipment.
Safety and control equipment for industrial processes. Equipment for calibration and measurement.
Personal medical devices like pacemakers and hearing aids.
Check the electromagnetic immunity for equipment operating in or near the work area. The operator must be sure
The dimensions of the work area to consider will depend on the construction of the area and other activities that are
Consider the following guidelines to reduce electromagnetic emissions from the machine.
Connect the machine to the input supply according to this manual. If disturbances occur if may be necessary to take
The output cables should be kept as short as possible and should be positioned together. If possible connect the
Shielding of cables in the work area can reduce electromagnetic emissions. This may be necessary for special
The Class A equipment is not intended for use in residential locations where the electrical power is provided by the public
low-voltage supply system. There can be potential difficulties in ensuring electromagnetic compatibility in those locations,
due to conducted as well as radio-frequency disturbances.
This machine has been designed to operate in an industrial area. The operator must install and operate this
equipment as described in this manual. If any electromagnetic disturbances are detected the operator must
put in place corrective actions to eliminate these disturbances with, if necessary, assistance from Lincoln
Electric. This equipment does not comply with IEC 61000-3-12. If it is connected to a public low-voltage
machine.
that all equipment in the area is compatible. This may require additional protection measures.
taking place.
additional precautions such as filtering the input supply.
work piece to ground in order to reduce the electromagnetic emissions. The operator must check that connecting
the work piece to ground does not cause problems or unsafe operating conditions for personnel and equipment.
applications.
WARNING
English English
2
Page 6
Safety
03/09
WARNING
This equipment must be used by qualified personnel. Be sure that all installation, operation, maintenance and repair
procedures are performed only by qualified person. Read and understand this manual before operating this equipment.
Failure to follow the instructions in this manual could cause serious personal injury, loss of life, or damage to this
equipment. Read and understand the following explanations of the warning symbols. Lincoln Electric is not responsible
for damages caused by improper installation, improper care or abnormal operation.
WARNING: This symbol indicates that instructions must be followed to avoid serious personal injury,
loss of life, or damage to this equipment. Protect yourself and others from possible serious injury or
death.
READ AND UNDERSTAND INSTRUCTIONS: Read and understand this manual before operating
this equipment. Arc welding can be hazardous. Failure to follow the instructions in this manual could
cause serious personal injury, loss of life, or damage to this equipment.
ELECTRIC SHOCK CAN KILL: Welding equipment generates high voltages. Do not touch the
electrode, work clamp, or connected work pieces when this equipment is on. Insulate yourself from
the electrode, work clamp, and connected work pieces.
ELECTRICALLY POWERED EQUIPMENT: Turn off input power using the disconnect switch at the
fuse box before working on this equipment. Ground this equipment in accordance with local electrical
regulations.
ELECTRICALLY POWERED EQUIPMENT: Regularly inspect the input, electrode, and work clamp
cables. If any insulation damage exists replace the cable immediately. Do not place the electrode
holder directly on the welding table or any other surface in contact with the work clamp to avoid the
risk of accidental arc ignition.
ELECTRIC AND MAGNETIC FIELDS MAY BE DANGEROUS: Electric current flowing through any
conductor creates electric and magnetic fields (EMF). EMF fields may interfere with some
pacemakers, and welders having a pacemaker shall consult their physician before operating this
equipment.
CE COMPLIANCE: This equipment complies with the European Community Directives.
FUMES AND GASES CAN BE DANGEROUS: Welding may produce fumes and gases hazardous to
health. Avoid breathing these fumes and gases. To avoid these dangers the operator must use
enough ventilation or exhaust to keep fumes and gases away from the breathing zone.
ARC RAYS CAN BURN: 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. Use suitable clothing made from durable
flame-resistant material to protect you skin and that of your helpers. Protect other nearby personnel
with suitable, non-flammable screening and warn them not to watch the arc nor expose themselves to
the arc.
WELDING SPARKS CAN CAUSE FIRE OR EXPLOSION: Remove fire hazards from the welding
area and have a fire extinguisher readily available. Welding sparks and hot materials from the welding
process can easily go through small cracks and openings to adjacent areas. Do not weld on any
tanks, drums, containers, or material until the proper steps have been taken to insure that no
flammable or toxic vapors will be present. Never operate this equipment when flammable gases,
vapors or liquid combustibles are present.
WELDED MATERIALS CAN BURN: Welding generates a large amount of heat. Hot surfaces and
materials in work area can cause serious burns. Use gloves and pliers when touching or moving
materials in the work area.
SAFETY MARK: This equipment is suitable for supplying power for welding operations carried out in
an environment with increased hazard of electric shock.
English English
3
Page 7
CYLINDER MAY EXPLODE IF DAMAGED: 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. Always keep cylinders in an upright position securely chained to a fixed support. Do
not move or transport gas cylinders with the protection cap removed. Do not allow the electrode,
electrode holder, work clamp or any other electrically live part to touch a gas cylinder. Gas cylinders
must be located away from areas where they may be subjected to physical damage or the welding
process including sparks and heat sources.
MOVING PARTS can injure. Do not operate with doors open or guards off. Stop engine before
servicing. Keep away from moving parts. 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.
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.
To avoid scalding, do not remove the radiator pressure cap when the engine is hot.
Installation and Operator Instructions
Read this entire section before installation or operation
of the machine.
Do not attempt to use this equipment until you have
thoroughly read the engine manufacturer
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.
WARNING
ʼs manual
General Description
The RANGER 305D (CE) is a diesel engine powered DC
multi-process welding power source and AC power
generator. The engine drives a generator that supplies
three-phase power for the DC welding circuit and threephase 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.
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).
English English
4
Page 8
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
Falling equipment can cause injury.
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.
Do not lift machine if lift bail is damaged.
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 deter-mine if any adjustments can be made
for operation in higher elevations locally.
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. If
the engine must be frequently started at or below -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 -5°C. 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!
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:
Design capacity of trailer vs. weight of Lincoln
equipment and likely additional attachments.
Proper support of, and attachment to, the base of
the welding equipment so there will be no undue
stress to the framework.
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.
Typical conditions of use, i.e., travel speed;
roughness of surface on which the trailer will be
operated; environmental conditions; like
maintenance.
Conformance with laws in nation / region to be
used.
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.
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 Operator's
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 Operator's Manual for more details on the
proper service and maintenance intervals.
Fuel
Use Diesel fuel only.
WARNING
Fill the fuel tank with clean, fresh fuel. The capacity of
the tank is about 45 l.
WARNING
NOTE: A fuel shut off valve is located on the
prefilter/sediment filter. Which should be in the closed
position when the welder is not operated for extended
periods of time.
English English
5
Page 9
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 from the case back and
40cm from either side of the base to a vertical surface.
Battery Connection
WARNING
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.
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 / 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. An incorrect spark arrestor may lead to
damage to the engine or adversely affect performance.
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.
When in TOUCH START TIG mode and when an
Amptrol is connected to the 6-Pin Connector, the
OUTPUT dial is used to set the maximum current range
of the CURRENT CONTROL of the Amptrol.
The 14-pin connector is used to directly connect a wire
feeder control cable. In the CV-WIRE mode, when the
control cable is connected to the 14-pin connector, the
auto-sensing circuit automatically makes the Output
Control inactive and the wire feeder voltage control
active.
WARNING
NOTE: When a wire feeder with a built in welding
voltage control is connected to the 14-pin connector, do
not connect anything to the 6-pin connector.
Electrical Connections
Machine Grounding
Because this portable engine driven welder creates its
own power, it is not necessary to connect its frame to an
earth ground, unless the machine is connected to
premises wiring (home, shop, etc.).
To prevent dangerous electric shock, other equipment to
which this engine driven welder supplies power must:
WARNING
Be grounded to the frame of the welder using a
grounded type plug.
Be double insulated.
Do not ground the machine to a pipe that carries
explosive or combustible material.
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.
A machine grounding stud marked with the symbol
provided on the front of the welder.
is
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 below 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.
Total Combined Length of Electrode and Work
Cable Length Cable Size for 305 A @
0-30 meters 1/0 AWG
30-46 meters 2/0 AWG
46-61 meters 3/0 AWG
Cables
35%Duty Cycle
English English
6
Page 10
Cable Installation
Install the welding cables to your machine 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.
WARNING
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
The auxiliary power capacity is 8500W Peak, 8000W
continuous of 50Hz, three phase power. The auxiliary
power capacity rating in watts is equivalent to voltamperes at unity power factor. The max permissible
current of the 400 VAC output is 12A. Output voltage is
within ±10% at all loads up to the rated capacity.
Standby Power Connections
The machine is suitable for temporary, standby or
emergency power using the engine manufacturer's
recommended maintenance schedule.
The machine can be permanently installed as a standby
power unit for 400 VAC, three phase, 12A service.
Connections must be made by a licensed electrician who
can determine how the power can be adapted to the
particular installation and comply with all applicable
electrical codes.
Take necessary steps to assure load is limited to
the capacity of the RANGER® 305D (CE).
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 laws require the
premises to be isolated before the generator is
linked to the premises. Check your local
requirements.
Connection of Lincoln Electric Wire
Feeders
Connection of the LN-15 to the RANGER® 305D
(CE)
These connections instructions apply to both the LN-15
across the Arc and Control Cable models. The LN-15
has an internal contactor and the electrode is not
energized until the gun trigger is closed. When the gun
trigger is closed the wire will begin to feed and the
welding process is started.
Shut the welder off.
For electrode Positive, connect the electrode cable
to the "+" terminal of the welder and work cable to
the "-" terminal of the welder. For electrode
Negative, connect the electrode cable "-" terminal of
the welder and work cable to the "+" terminal of the
welder.
Across The-Arc Model:
Attach the single lead from the front of the LN-15 to
work using the spring clip at the end of the lead.
This is a control lead to supply current to the wire
feeder motor; it does not carry welding current.
Set the "WELD TERMINALS" switch to "WELD
TERMINALS ON".
Control Cable Model:
Connect Control Cable between Engine Welder and
Feeder.
Set the MODE switch to the "CV-WIRE" position.
Set the "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 "AUTO" position. 0
Connection of the LN-25 to the RANGER® 305D
(CE)
WARNING
Shut off welder before making any electrical
connections.
The LN-25 with or without an internal contactor may be
used with the RANGER® 305D (CE). See the
appropriate connection diagram.
NOTE: The LN-25 (K431) Remote Control Module and
(K432) Remote Cable are not recommended for use with
the RANGER 305D (CE).
Shut the welder off.
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.
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.
Set the MODE switch to the "CV-WIRE " position.
Set the "WELD TERMINALS" switch to "WELD
TERMINALS ON"
English English
7
Page 11
Set the "ARC CONTROL" knob to "0" initially and
adjust to suit.
Set the "IDLE" switch to the "AUTO" position. When
not welding, the RANGER® 305D (CE) 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.
When the gun trigger is closed, the current sensing
circuit will cause the RANGER 305D (CE) 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.
WARNING
If you are using an LN-25 without an internal contactor,
the electrode will be energized when the RANGER®
305D (CE) is started.
Connection of the LN-742 and Cobramatic to
the RANGER® 305D (CE)
Shut the welder off.
Connect per instructions on the appropriate
connection diagram in Section below.
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.
Break-in Period
Any engine will use a small amount of oil during its
“break-in” period. For the diesel engine on the
RANGER® 305D (CE), break-in is about 50 running
hours.
Check the oil every four hours during break-in. Change
the oil after the first 50 hours of operation, every 100
hours thereafter. Change the oil filter at the second oil
change.
WARNING
During break-in, subject the RANGER® 305D (CE) to
moderate loads. Avoid long periods running at idle.
Before stopping the engine, remove all loads and allow
the engine to cool several minutes.
Controls and Operational Features
Welding Controls
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 Ownerʼs Manual for specific oil and
coolant recommendations.
Add Fuel
DIESEL FUEL can cause fire.
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 fumes to clear before
starting engine.
Do not overfill tank, fuel exapnsion may cause
overflow.
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
recommendations.
WARNING
DIESEL FUEL ONLY.
ʼs Manual for specific fuel
Figure 1
1. Output Control: The OUTPUT dial is used to preset
the output voltage or current as displayed on the
digital meters for the four welding modes. When in
the CC-STICK, or CV-WIRE modes and when a
remote control is connected to the 6-Pin or 14-Pin
Connector, the auto-sensing circuit automatically
switches the OUTPUT CONTROL from control at
the welder to the remote control.
When in the DOWNHILL PIPE mode and when a
REMOTE CONTROL is connected to the 6-Pin or
14-Pin Connector, the OUTPUT CONTROL is used
to set the maximum current range of the OUTPUT
CONTROL of the REMOTE.
Example:
When the OUTPUT CONTROL on the welder is set
to 200 amps the current range on the REMOTE
CONTROL will be 40-200 amps rather than the full
40-300 amps. Any current range that is less than
the full range provides finer current resolution for
more fine tuning of the output.
English English
8
Page 12
In the CV-WIRE mode, if the wire feeder has
voltage control capability, when the 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 control is used to set the maximum
current range of the CURRENT CONTROL of the
Amptrol.
2. Digital Output Meters: The digital meters allow the
output voltage (CVWIRE mode) or current (CCSTICK, PIPE and TIG modes) to be set prior to
welding using the OUTPUT control dial. During
welding, the meter display the actual output voltage
(V) and current (A). 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
4. Arc Control: The ARC CONTROL dial is active in
the CV-WIRE, CC-STICK and DOWNHILL PIPE
modes, and has different functions in these modes.
This control 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.
CV-WIRE mode: In this mode, turning the ARC
CONTROL clock wise from –10 (soft) to +10
(crisp) changes the arc from soft and washed-in
to crisp and narrow. It acts as an
inductance/pinch control. The proper setting
depends on the procedure and operator
5. Weld Output Terminals with Flange Nut: Provides a
6. Ground Stud
7. 14-pin Connector: For attaching wire feeder control
8. 6-pin Connector: For attaching optional remote
9. Weld Terminals Switch: In the WELD TERMINALS
10. Wire Feeder Voltmeter Switch: Matches the polarity
preference. Start with a setting of 0.
connection point for the electrode and work cables.
: Provides a connection point for
connecting the machine case to earth ground.
cables to the RANGER® 305D (CE). Includes
contactor closure circuit, auto-sensing remote
control circuit, and 42V power. The remote control
circuit operates the same as the 6 Pin connector.
Note: The 14-pin connector does not include 120V.
control equipment. Includes auto-sensing remote
control circuit.
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.
of the wire feeder voltmeter to the polarity of the
electrode.
Engine Controls
Figure 2
11. Run/Stop Switch: RUN position energizes the
engine prior to starting. STOP position stops the
engine. The oil pressure interlock switch prevents
battery drain if the switch is left in the RUN position
and the engine is not operating.
12. Glow Plug Push Button:
When pushed activates the glow plugs. Glow plug
should not be activated for more than 20 seconds
continuously.
13. Start Push Button:
Energizes the starter motor to crank engine.
English English
9
Page 13
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
drawn for lights or tools (approximately 100W
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.
15. Electric Fuel Gauge: Provides accurate, reliable
indication of how much fuel is in the tank.
16. Engine Hour Meter: Displays the total time that the
engine has been running. This meter is useful for
scheduling prescribed maintenance.
17. Engine Protection Light: A warning indicator light
for Low Oil Pressure and/or Coolant Over
Temperature. The light is off when the systems are
functioning properly. The light turns on when the
RUN-STOP switch is in the “ON” position prior to
starting the engine. If the Engine Protection or
Battery Charging Lights do “not” turn off shortly after
starting the engine shut off the engine immediately
and determine the cause.
Starting the Engine
1. Remove all plugs connected to the AC power
receptacles.
2. Set IDLER switch to AUTO.
3. Set the RUN/STOP switch to RUN.
4. Press Glow Plug Button and hold 5 to 10 seconds.
5. Press and hold both the “Glow Plug” Button and
START button together until the engine starts or for
up to 10 seconds.
6. Release the engine START button immediately
when the engine starts.
7. Release the glow plug button after the Engine
Protection Light turns off or after an additional 5
seconds maximum.
8. The engine will run at high idle speed for
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
WARNING
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 determine the
cause.
Note: When starting a RANGER® 305D (CE) for the
first time, or after and extended period of time of not
operating, it will take longer than normal because the
fuel pump has to fill the fuel system.
Stopping the Engine
Remove all welding and auxiliary power loads and allow
the engine to run at low idle speed for a few minutes to
cool the engine.
STOP the engine by placing the RUN-STOP switch in
the STOP position.
Note: A fuel shut off valve is located on the fuel prefilter. Turn on Fuel shut-off valve on the fuel pre-filter.
TYPICAL RANGER® 305D (CE) FUEL
Kubota D722
Low Idle - No Load
2200 R.P.M.
High Idle - No Load
3100 R.P.M.
DC Weld Output
250A @ 30V
DC Weld Output
225A @ 25V
8000 Watts,
3 Phase
5000 Watts,
3 Phase
3000 Watts,
3 Phase
CONSUMPTION
Liters/Hr
.92 49.38
1.62 28.07
3.42 13.30
2.92 15.55
3.35 13.54
2.65 17.12
2.19 20.78
Running time for
45 Liters/hours
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 (CE) can be used with a broad
range of DC stick electrodes. The MODE switch
provides two stick welding settings as follows:
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.
English English
10
Page 14
(1)
(2)
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 (STICK) Welding
The DOWNHILL PIPE position of the MODE switch is a
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.
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.
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.
TYPICAL CURRENT RANGES
Tungsten Electrode
Diameter (mm)
.25
.50
1.0
1.6
2.4
3.2
4.0
4.8
6.4
(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:
# 4 = 6 mm
# 5 = 8 mm
# 6 = 10 mm
# 7 = 11 mm
# 8 = 12.5 mm
#10 = 16 mm
(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 and high duty cycles.
DCEN (-) DCEP (+)
1%, 2% Thoriated
Tungsten
2-15
5-20
15-80
70-150
150-250
250-400
400-500
500-750
750-1000
1%, 2% Thoriated
Tungsten
(3)
(3)
(3)
10-20
15-30
25-40
40-55
55-80
80-125
FOR TUNGSTEN ELECTRODES
Approximate Argon Gas Flow
Flow Rate C.F.H. (l/min)
Aluminum Stainless Steel
3-8
5-10
5-10
5-10
13-17
15-23
21-25
23-27
28-32
(2-4)
(3-5)
(3-5)
(3-5)
(6-8)
(7-11)
(10-12)
(11-13)
(13-15)
3-8
5-10
5-10
9-13
11-15
11-15
13-17
18-22
23-27
(2-4)
(3-5)
(3-5)
(4-6)
(5-7)
(5-7)
(6-8)
(8-10)
(11-13)
TIG TORCH
Nozzle Size (4), (5)
#4, #5, #6
#5, #6
#6, #7, #8
#8, #10
English English
11
Page 15
When in the TOUCH START TIG mode and when an
Amptrol is connected to the 6-pin Connector the
OUTPUT dial is used to set the maximum current range
of the CURRENT CONTROL of the Amptrol.
The ARC CONTROL is not active in the TIG mode.
The RANGER® 305D (CE) 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
(CE). The settings are for reference.
RANGER® 305D (CE) 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 (CE) 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
above).
Wire Welding-CV
Connect a wire feeder to the Ranger 305D (CE)
according to the instructions in INSTALLATION
INSTRUCTIONS Section.
The RANGER® 305D (CE) 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.
For any electrodes the procedures should be kept within
the rating of the machine. For additional electrode
information see www.Lincolnelectric.com or the
appropriate Lincoln publication.
Arc Gouging
The RANGER® 305D (CE) can be used for limited arc
gouging. For optimal performance, set the MODE switch
to CC-STICK and the ARC CONTROL to +10.
Set the OUTPUT CONTROL knob to adjust output
current to the desired level for the gouging electrode
being used according to the ratings in the following table:
Carbon Diameter
(mm)
3.2 60 - 90
4.0 90 - 150
4.75 200 - 250
Current Range
(DC, electrode positive) (A)
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.
Simultaneous Welding and Auxiliary Power
Loads
While welding, the amount of 3-phase Auxiliary power
available is reduced. (See Table below).
Welding
Output
(A)
50 6500 9
100 5000 7
150 3500 5
200 2000 3
250 0 0
Permissible Power(W)
(Unity Power Factor)
0 8000 12
Permissible Aux
Power @400V,
3 phase (A)
Accessories
Field Installed Options / Accessories
K704 Accessory Set - Includes (10m) 35 ft. of electrode
cable and (9m) 30 ft. of work cable, head shield, work
clamp electrode holder. Cables are rated at 400A, 100%
duty cycle.
K857 7.6m or K857-1 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.
Maintenance
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.
English English
12
Page 16
Engine Maintenance Components
Kubota D722 Diesel Engine
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
Frequency Maintenance Required
Daily or before
starting engine
Item Make and Part Number
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.
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 Items
Every 50 h Check of fuel lines and clamp bands.
Every 75 h Change of engine oil
Every 100 h Inspect/Clean air cleaner element and
Every 150 h Check the radiator and hose clamps.
Every 200 h Replacement of air filter element. *1
Every 400 h Replacement of fuel filter element.
Every 500 h Removal of sediment in fuel tank.
Every 1 or 2
months
Every 800 h Check of valve clearance. *3
Every 1500 h Check the fuel injection nozzle injection
Every 3000 h Check of injection pump. *3
Every 2 years Replacement of battery
Vacuator™ valve.
Cleaning of fuel filter.
Check the battery electrolyte level.
Check the fan belt tightness.
Replacement of oil filter cartridge.
Check the intake air lines.
Cleaning of water jacket (radiator
interior).
Replacement of fan belt.
Recharging of Battery.
pressure.
Check of fuel injector timer. *3
Replacement of radiator hoses and
clamp band.
Replacement of fuel pipes and clamps.
Change the radiator coolant.(L.L.C.) *4
Replacement of intake air line.
*1
*2
*3
Important
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.
Please see Engine Owners Manual for Warranty
Statement in detail.
Engine Oil Change
Drain the engine oil while the engine is warm to assure
rapid and complete draining. It is recommended that
each time the oil is changed the oil filter be changed as
well.
Be sure the unit is off. Disconnect the negative
battery cable to ensure safety.
Locate oil drain hose and valve in bottom of base
and pull through the hole in the battery access panel
on the welder.
Remove the cap from the drain valve. Push valve in
and twist counter clockwise. 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.
Push oil drain hose and valve back into unit,
reconnect 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: 3.2 liter
With oil filter replacement: 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, -15C to 40C (5F to 104F). See engine
owner's manual for more specific information on oil
viscosity recommendations.
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
contacts the mounting base. Using an oil filter
wrench, tighten the filter an additional 1/2 to 7/8 of a
turn.
English English
13
Page 17
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
necessary, add oil to the upper limit mark on the
dipstick.
WARNING
Never use gasoline or low flash point solvents for
cleaning the air cleaner element. A fire or explosion
could result.
WARNING
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.
Cooling System
WARNING
HOT COOLANT can burn skin.
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 valve of the radiator.
Open the radiator cap to allow complete drainage.
(Tighten the valve and refill with a 50/50 antifreeze/water
solution.) Use an automotive grade (low silicate)
ethylene glycol antifreeze. The cooling system capacity
is 3.6l. Squeeze upper and lower radiator hoses while
filling to bleed air from system coolant. Replace and
tighten the radiator cap.
WARNING
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 -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 6mm under a load of 9 Kg.
Fuel
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
helps purge the air from the mechanical fuel pump
system. It is generally not necessary to open a vent
screw or fuel line fitting to bleed the fuel system.
Operate the priming lever on the pump to assist starting
after extended periods of non-use or out of fuel
conditions.
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:
Fill the fuel tank with fuel.
Open the fuel shut off valve (vertical position of
handle) on the Fuel Filter.
Crank the engine by pressing the start button for 45
seconds.
Check to see that fuel is flowing through both fuel
filters.
Follow the normal STARTING procedures.
Fuel Filter
Check the fuel filter and fuel pre-filter for water
accumulation or sediment.
Replace the fuel filter if it is found with excessive
water accumulation or sediment. Empty fuel prefilter.
OVERSPEED IS HAZARDOUS. The maximum
allowable high idle speed for this machine is 3150 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.
WARNING
WARNING
English English
14
Page 18
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 4 screws from the
battery door using a screwdriver or a 10mm socket.
Remove the 2 nuts from the battery bracket using a
11mm wrench or socket. Slide the battery out and
remove from welder
WARNING
GASES FROM BATTERY can explode.
Keep sparks, flame and cigarettes away
from battery.
To prevent EXPLOSION when:
INSTALLING A NEW BATTERY – disconnect
negative cable from old battery first and connect to
new battery last.
CONNECTING A BATTERY CHARGER - remove
battery from welder by disconnecting negative cable
first, then positive cable and battery clamp. When
reinstalling, connect negative cable last. Keep well
ventilated.
USING A BOOSTER — connect positive lead to
battery first then connect negative lead to 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.
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 113g of baking soda
and 0.9461L 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 (CE) 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 Spark Arrestor
Clean every 100 hours or twice a year, which ever
occurs first.
Stop engine and allow to cool.
Loosen clamp and remove spark arrestor from
machine.
Remove lock nut on top of spark arrestor housing
and lift off cap.
Separate plates and clean with a wire brush if
necessary.
Inspect plates and housing for holes or cracks.
Replace if damaged.
Reassemble and reinstall on to muffler outlet pipe.
WARNING
WARNING
MUFFLER MAY BE HOT
W
Welder / Generator Maintenance
Storage: Store the RANGER® 305D (CE) 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 normal for the
brushes and slip rings to wear and darken slightly.
Inspect the brushes when a generator overhaul is
necessary.
Do not attempt to polish slip rings while the engine is
running.
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.
WARNING
WARNING
English English
15
Page 19
Customer Assistance Policy
The business of The Lincoln Electric Company is
manufacturing and selling high quality welding
equipment, consumables, and cutting equipment. Our
challenge is to meet the needs of our customers and to
exceed their expectations. On occasion, purchasers may
ask Lincoln Electric for advice or information about their
use of our products. We respond to our customers
based on the best information in our possession at that
time. Lincoln Electric is not in a position to warrant or
guarantee such advice, and assumes no liability, with
respect to such information or advice. We expressly
disclaim any warranty of any kind, including any
warranty of fitness for any customer’s particular purpose,
with respect to such information or advice. As a matter of
practical consideration, we also cannot assume any
respon- sibility 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.
.
English English
16
Page 20
Diagrams
Engine Welders/LN-25 across the Arc Connection Diagram with Optional K857
Remote Control
WARNING
Do not operate with panels open.
Disconnect NEGATIVE (-) Battery lead before servicing.
Do not touch electrically live parts.
WARNING
Keep guards in place
Keep away from moving parts.
Only qualified personnel should install, use or service this equipment
OPTIONAL K857
REMOTE CONTROL
WORK CLIP LEAD
TO WORK
TO WORK
ELECTRODE CABLE
A. WELDING CABLES MUST BE OF PROPER CAPACITY FOR THE CURRENT AND DUTY CYCLE OF IMMEDIATE
AND FUTURE APPLICATIONS. SEE OPERATING MANUAL.
B. CONNECT WELDING CABLES TO OUTPUT STUDS FOR DESIRED POLARITY. POSITION THE WIRE FEEDER
VOLTMETER SWITCH TO MATCH THE POLARITY OF THE ELECTRODE CABLE.
C. PLACE THE MODE SWITCH IN THE “CV-WIRE” POSITION.
D. PLACE THE WELDING TERMINALS SWITCH IN THE “WELD TERMINALS ON” POSITION.
E. PLACE IDLER SWITCH IN “AUTO” OR “HIGH” IDLE POSITION AS DESIRED.
S24787-1
English English
17
Page 21
Engine Welders/LN-25 across the Arc Connection Diagram with Optional K444-1
Remote Control
WARNING
Do not operate with panels open.
Disconnect NEGATIVE (-) Battery lead before servicing.
Do not touch electrically live parts.
WARNING
Keep guards in place
Keep away from moving parts.
Only qualified personnel should install, use or service this equipment
OPTIONAL K444-1
REMOTE CONTROL
WORK CLIP LEAD
TO WORK
TO WORK
ELECTRODE CABLE
A. WELDING CABLES MUST BE OF PROPER CAPACITY FOR THE CURRENT AND DUTY CYCLE OF IMMEDIATE
AND FUTURE APPLICATIONS. SEE OPERATING MANUAL.
B. CONNECT WELDING CABLES TO OUTPUT STUDS FOR DESIRED POLARITY. POSITION THE WIRE FEEDER
VOLTMETER SWITCH TO MATCH THE POLARITY OF THE ELECTRODE CABLE.
C. PLACE THE MODE SWITCH IN THE “CV-WIRE” POSITION.
D. PLACE THE WELDING TERMINALS SWITCH IN THE “WELD TERMINALS ON” POSITION.
E. PLACE IDLER SWITCH IN “AUTO” OR “HIGH” IDLE POSITION AS DESIRED.
S24787-2
English English
18
Page 22
Engine Welders/LN-742 Connection Diagram
WARNING
Do not operate with panels open.
Disconnect NEGATIVE (-) Battery lead before servicing.
Do not touch electrically live parts.
WARNING
Keep guards in place
Keep away from moving parts.
Only qualified personnel should install, use or service this equipment
TO LN-742 INPUT CABLE
PLUG
K1819-10 CONTROL
CABLE
TO WORK
ELECTRODE CABLE
TO WIRE FEED UNIT
WARNING
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.
A. WELDING CABLES MUST BE OF PROPER CAPACITY FOR THE CURRENT AND DUTY CYCLE OF IMMEDIATE
AND FUTURE APPLICATIONS. SEE OPERATING MANUAL.
B. CONNECT WELDING CABLES TO OUTPUT STUDS FOR DESIRED POLARITY. POSITION THE WIRE FEEDER
VOLTMETER SWITCH TO MATCH THE POLARITY OF THE ELECTRODE CABLE.
C. PLACE THE MODE SWITCH IN THE “CV-WIRE” POSITION.
D. PLACE WELDER TERMINALS SWITCH TO “REMOTLY CONTROLLED” POSITION.
E. PLACE IDLER SWITCH IN “AUTO” OR “HIGH” IDLE POSITION AS DESIRED.
S24787-13
English English
19
Page 23
Engine Welders/K930 Tig Module Connection Diagram
WARNING
Do not operate with panels open.
Disconnect NEGATIVE (-) Battery lead before servicing.
Do not touch electrically live parts.
WARNING
Keep guards in place
Keep away from moving parts.
Only qualified personnel should install, use or service this equipment
REGULATOR
FLOWMETER
K870 FOOT AMPTROL
-ORK963-1 HAND AMPTROL
-ORK814 ARC START SWITCH
ARGON GAS
CYLINDER
TO GAS
INPUT
FITTING
K936-1
CONTROL CABLE
ELECTRODE
TO WORK
WARNING
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.
A. WELDING CABLES MUST BE OF PROPER CAPACITY FOR THE CURRENT AND DUTY CYCLE OF
IMMEDIATE AND FUTURE APPLICATIONS. SEE OPERATING MANUAL.
B. CONNECT WELDING CABLES TO OUTPUT STUDS FOR DESIRED POLARITY.
C. PLACE THE MODE SWITCH IN THE “TIG” POSITION.
D. PLACE OUTPUT CONTROL SWITCH TO “REMOTE CONTROL” POSITION.
E. PLACE IDLER SWITCH IN “AUTO” OR “HIGH” IDLE POSITION AS DESIRED.
S24787-9
English English
20
Page 24
Engine Welders/K1587-1 Cobramatic Connection Diagram
WARNING
Do not operate with panels open.
Disconnect NEGATIVE (-) Battery lead before servicing.
Do not touch electrically live parts.
WARNING
Keep guards in place
Keep away from moving parts.
Only qualified personnel should install, use or service this equipment
TO COBRAMATIC WIRE FEED CABINET
INPUT CABLE PLUG
TO WORK
ELECTRODE CABLE
TO WIRE FEED
CABINET
WARNING
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.
A. WELDING CABLES MUST BE OF PROPER CAPACITY FOR THE CURRENT AND DUTY CYCLE OF IMMEDIATE
AND FUTURE APPLICATIONS. SEE OPERATING MANUAL.
B. SET THE WIRE FEEDER VOLTMETER TO THE “+” POSITION. THE POSA-START FEATURE WILL NOT
OPERATE UNLESS THIS SWITCH IS SET TO MATCH THE POLARITY OF THE ELECTRODE CABLE.
C. POSIYION THE MODE SWITCH TO “CV-WIRE”.
S24787-10
English English
21
Page 25
WEEE
Do not dispose of electrical equipment together with normal waste!
In observance of European Directive 2012/19/EC on Waste Electrical and Electronic Equipment (WEEE)
and its implementation in accordance with national law, electrical equipment that has reached the end of its
life must be collected separately and returned to an environmentally compatible recycling facility. As the
English
owner of the equipment, you should get information on approved collection systems from our local
representative.
By applying this European Directive you will protect the environment and human health!
Spare Parts
For Spare Parts references visit the Web page: https://www.lincolnelectric.com/LEExtranet/EPC/
Authorized Service Shops Location
The purchaser must contact a Lincoln Authorized Service Facility (LASF) about any defect claimed under Lincoln's
warranty period.
Contact your local Lincoln Sales Representative for assistance in locating a LASF or go to
www.lincolnelectric.com/en-gb/Support/Locator.
Electrical Schematic
Refer to the "Electrical Schematics" section.
07/06
12/05
09/16
English English
22
Loading...