Lincoln Electric SVM175-A User Manual

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Ranger 305D

For use with machines having Code Numbers: 10926, 11121, 11188, 11275 (Domestic)

11027, 11122, 11189, 11314 (UK) 11039, 11123, 11190, 11315 (EUROPE)

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.

SVM175-A

July, 2007

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Cleveland, Ohio 44117-1199 U.S.A. TEL: 1-888-935-3877 FAX: 216.486.1751 WEB SITE: www.lincolnelectric.com

SERVICE MANUAL

• World's Leader in Welding and Cutting Products •

• Sales and Service through Subsidiaries and Distributors Worldwide •

SAFETY

WARNING

CALIFORNIA PROPOSITION 65 WARNINGS

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

The Above For Diesel Engines

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

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

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

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

The Above For Gasoline Engines

FOR ENGINE powered equipment.

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

____________________________________________________

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

____________________________________________________

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.

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___________________________________________________

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

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

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

Mar ʻ95

SAFETY

ELECTRIC SHOCK can kill.

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

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

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

• Semiautomatic DC Constant Voltage (Wire) Welder.

• DC Manual (Stick) Welder.

• AC Welder with Reduced Voltage Control.

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

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

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

3.f.

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

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

3.h. Never simultaneously touch electrically “hot” parts of electrode holders connected to two welders because voltage 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 below Threshold Limit Values (TLV) using local exhaust or mechanical ventilation. In confined spaces or in some circumstances, outdoors, a respirator may be required. Additional precautions are also required when welding on galvanized steel.

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

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5.e. Read and understand the manufacturerʼs instructions for this

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

5.f. Also see item 1.b.

AUG ʻ06

iii

SAFETY

iii

WELDING SPARKS can cause fire or explosion.

6.a.

Remove fire hazards from the welding area.

If this is not possible, cover them to prevent

the welding sparks from starting a fire.

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

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

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

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

(see address above).

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

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

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

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

6.h. Also see item 1.c.

Remember that welding sparks and hot

though

they have

Preparation

for Welding and Cutting of

CYLINDER may explode if damaged.

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

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

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

7.c. Cylinders should be located:

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

physical damage.

• A safe distance from arc welding or cutting operations and

any other source of heat, sparks, or flame.

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

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

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

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

FOR ELECTRICALLY powered equipment.

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

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

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

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Mar ʻ95

SAFETY

PRÉCAUTIONS DE SÛRETÉ

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

Sûreté Pour Soudage A 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.

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.

5. Toujours porter des lunettes de sécurité dans la zone de soudage. Utiliser des lunettes avec écrans lateraux dans les

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.

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Mar. ʻ93

v v

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MASTER TABLE OF CONTENTS FOR ALL SECTIONS

Page

Safety.................................................................................................................................................i-iv

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

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

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

Maintenance..........................................................................................................................Section D

Theory of Operation .............................................................................................................Section E

Troubleshooting and Repair ................................................................................................Section F

Electrical Diagrams ..............................................................................................................Section G

Parts Manuals.......................................................................................................(Code 10926) P-417

..........................................................................................(Code 11027, 11039) P-479

...............................................................................(Code 11121, 11188, 11275) P-492

............................................(Code 11122, 11123, 11189, 11190, 11314, 11315) P-494

RANGER 305D

Section A-1 Section A-1

TABLE OF CONTENTS

- INSTALLATION SECTION -

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

Technical Specifications.......................................................................................................A-2, A-3

Safety Precautions ......................................................................................................................A-4

Location and Ventilation..............................................................................................................A-4

Storing ..................................................................................................................................A-4

Stacking ................................................................................................................................A-4

Angle of Operation................................................................................................................A-4

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

High Altitude Operation.........................................................................................................A-5

High Temperature Operation ................................................................................................A-5

Cold Weather Starting and Operation ..................................................................................A-5

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

Pre-Operation Engine Service ....................................................................................................A-6

Oil .........................................................................................................................................A-6

Fuel.......................................................................................................................................A-6

Engine Cooling System ........................................................................................................A-6

Battery Connections .............................................................................................................A-6

Muffler Outlet Pipe................................................................................................................A-6

Spark Arrester.......................................................................................................................A-6

High Frequency Generators for TIG Applications.................................................................A-6

Remote Control.....................................................................................................................A-7

Electrical Output Connections.....................................................................................................A-7

Machine Grounding ..............................................................................................................A-7

Welding Output Cables.........................................................................................................A-8

Cable Installation ............................................................................................................A-8

Auxiliary Power Receptacles ................................................................................................A-8

Standby Power Connections .......................................................................................A-8 - A-9

Connection of Ranger 305D to Premises Wiring......................................................................A-10

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RANGER 305D

A-2 A-2

INSTALLATION

TECHNICAL SPECIFICATIONS - Ranger 305D (K1727-2) Code 10926, 11121, 11188, 11275

INPUT - DIESEL ENGINE

Make/Model Description Speed (RPM) Displacement Starting Capacities

cu. in. (cu. cm.) System

3 cylinder 43.88(789)

12VDC Battery &

Fuel: 12 gal.(45L)

4 stroke starter

18.8 HP High Idle 3650

Bore x Stroke inch (mm)

Oil: 3.4Qts. (3.2L)

Kubota** (14 KW)

D722 Net intermittent Full Load 3500

3600 RPM

2.64 x 2.68

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

(Group 58; 550 Radiator Coolant:

naturally aspirated Low Idle 2450 Battery Charger water cooled engine

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

Welding Process

DC Constant Current

DC Pipe Current

Touch-Start™TIG

DC Constant Voltage

Welding Output

Current/Voltage/Duty Cycle

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

Output Range

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

Max. Weld OCV

@Rated Load RPM

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

Auxiliary Power

10,000 Watts Peak, / 9,500 Watts Continuous, 60 Hz 120/240 Volts

Sound Levels

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

PHYSICAL DIMENSIONS

HEIGHT WIDTH DEPTH WEIGHT

30.00* in. 21.50 in 52.25 in.

762.0 mm 546.0 mm 1327.0 mm

698 lbs. (317kg.)

60 Volts

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ENGINE

LUBRICATION EMISSIONS FUEL SYSTEM GOVERNOR

Full Pressure

Electric Fuel Pump (Code 10926, 11121) or Mechanical Mechanical

with Full Flow Filter Certified to EPA Tier I Fuel Pump (Code 11188, 11275), Auto air bleed Governor

system Electric shutoff solenoid Indirect fuel injector

AIR CLEANER ENGINE IDLER MUFFLER ENGINE PROTECTION

Low noise Muffler: Shutdown on low oil

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

Made from long life, aluminized steel. temperature

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

RECEPTACLES AND CIRCUIT BREAKERS

RECEPTACLES AUXILIARY POWER CIRCUIT BREAKER OTHER CIRCUIT BREAKERS

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

Full KVA (14-50R)

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

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

details)

RANGER 305D

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

A-3 A-3

INSTALLATION

TECHNICAL SPECIFICATIONS - RANGER 305D (CE) K2279-1 (UK) Code 11027, 11122, 11189, 11314

& K2279-2 (EUROPE) Code 11039, 11123, 11190, 11315

INPUT - DIESEL ENGINE

Make/Model Description Speed (RPM) Displacement Starting Capacities

cu. in. (cu. cm.) System

3 cylinder 43.88(789)

12VDC Battery &

4 stroke starter 45L (12 US.gal.)

15.9 HP High Idle 3100

Kubota

(3)

(12 KW)

D722 Net intermittent Full Load 3000

Bore x Stroke inch (mm)

2.64 x 2.68

(Group 58; 550

3000 RPM (67 x 68 mm) cold crank amps) 3.6L(3.85 U Qts)

naturally aspirated Low Idle 2200 Battery Charge

water cooled engine

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 115 & 230 Volts - 1 Phase

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

(1)

Sound Power: 98 dB Lwa

PHYSICAL DIMENSIONS

HEIGHT WIDTH DEPTH WEIGHT

762mm 546mm 1524mm

30.0 in.

(2)

21.50 in. 60.0 in.

Fuel:

Oil:

3.2L(3.4 US. Qts.)

Radiator Coolant:

Max. Weld OCV

@Rated Load RPM

60 Volts

Sound Levels

341kg. (752lbs.)

LUBRICATION EMISSIONS FUEL SYSTEM GOVERNOR

Full Pressure with Full Flow Filter Certified to EPA Tier I

AIR CLEANER ENGINE IDLER MUFFLER ENGINE PROTECTION

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

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

RECEPTACLES AND CIRCUIT BREAKERS

MODEL NUMBER

Receptacles

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.

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ENGINE

Electric Fuel Pump (Code 11027, 11039, 11122, 11123) or Mechanical

Fuel Pump (Code 11189, 11190, 11314, 11315), Auto air bleed system Electric shutoff solenoid Indirect fuel injector

Low noise Muffler: Shutdown on low oil

Made from long life, aluminized steel. temperature

K2279-1 (UK)

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

115V x 1

(4)

14 Pin Connector

6 Pin Connector

4-pole, 25 Amp

(30mA trip current) 3 Phase, 20 Amp x 1 1 Phase, 15 Amp x 5

(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.

RANGER 305D

K2279-2 (EUROPE)

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

Mechanical

Governor

(3)

A-4 A-4

INSTALLATION

Read this entire installation section before you start installation.

STORING

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.

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-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.

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ENGINE EXHAUST can kill.

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

• Do not set anything near the engine.

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MOVING PARTS can injure.

• Do not operate with doors open or guards off.

• Stop engine before servicing.

• Keep away from moving parts.

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

See additional safety information in the front of this manual.

1. Store the machine in a cool, dry place when it is not in use. Protect it from dust and dirt. Keep it where it canʼt be accidentally damaged from construction activities, moving vehicles, and other hazards.

2. If you will be storing the machine for over 30 days, you should drain the coolant from the radiator. Open the cock at the bottom of the radiator and remove the pressure cap so that the coolant drains completely. Attach a note that says “NO WATER” on the radiator.

3. While the engine is still warm, drain the oil and refill with fresh 10W30 oil. Change the oil filter. Run the engine for about five minutes to circulate oil to all the parts. See the Maintenance section for details on changing oil.

4. Remove the battery, recharge it, and adjust the

electrolyte level. Store the battery in a dry, dark place.

5. If the engine is not used for a long period of time, every two or three months fill the radiator and run the engine for about five minutes to keep it free from rust.

Also see your engine Operatorʼs manual.

Fuel should also be drained when stored for long periods or a fuel additive should be used.

STACKING

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

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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. Allow a minimum clearance of 2 feet (0.6m) from the case back and 16in. (406mm) from either side of the base to a vertical surface. Also, locate the welder so that the engine exhaust fumes are properly vented to an outside area.

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Ranger 305D machines CANNOT be stacked.

ANGLE OF OPERATION

Engines are designed to run in the level of condition which is where the optimum performance is achieved. The maximum angle of continuous operation is 20 degrees in all directions. 30 degrees Intermittent (less than 10 minutes continuous) in all directions. If the engine is to be operated at an angle, provisions must be made for checking and maintaining the oil level at the normal (FULL) oil capacity in the crankcase.

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

RANGER 305D

A-5 A-5

INSTALLATION

LIFTING

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

WARNING

• Lift only with equipment of adequate lifting capacity.

• Be sure machine is stable when lifting.

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

FALLING • Do not lift machine if lift bail is

EQUIPMENT can damaged.

cause injury. • Do not operate machine while

suspended from lift bail.

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HIGH ALTITUDE OPERATION

WARNING

DO NOT USE ETHER OR STARTING FLUID FOR STARTING. SEVERE DAMAGE TO THE ENGINE WILL RESULT.

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TOWING

The recommended trailer for use with this equipment for road, inplant and yard towing by a vehicle1is Lincolnʼs K957-1. (See Accessories Section of this manual for trailer and trailer options). 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.

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

HIGH TEMPERATURE OPERATION

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

Cold Weather Starting & Operation:

The Kubota engine used in the Ranger 305D can be started in temperatures as low as 5°F (-15°C). At temperatures below 23°F (-5°C) it is recommended that No. 1D diesel fuel is used in place of No. 2D. Allow engine to warm up before applying a load or switching to high idle. Lincoln Electric supplies a Cold Weather Kit if the unit is to be used in Cold Weather Extremes for long periods. See Field Installed options in the Accessories section of this manual.

3. Proper placement of the equipment on the trailer to insure

stability side to side and front to back when being moved and when standing by itself while being operated or serviced.

4. Typical conditions of use, i.e., travel speed; roughness of surface on which the trailer will be operated; environmental conditions; like maintenance.

5. Conformance with federal, state and local laws.

Consult applicable federal, state and local laws regarding specific requirements for use on public highways.

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.

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RANGER 305D

A-6 A-6

INSTALLATION

PRE-OPERATION ENGINE SERVICE

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

WARNING

• Keep hands away from the engine muffler or HOT engine parts.

• Stop the engine and allow it to cool before fueling.

• Do not smoke when fueling.

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

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

• Keep sparks and flame away from the fuel tank.

• Remove the fuel cap slowly to release pressure.

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OIL

The RANGER 305D is shipped with the engine crankcase filled with high quality SAE 10W-30 Oil that

meets classification CG-4 or CF-4 for diesel engines. CHECK THE OIL LEVEL BEFORE YOU START THE ENGINE. If it

is not up to the full mark on the dip stick, add oil as required. Check the oil level every four hours of running time during the first 50 running hours. Refer to the engine Operatorʼs Manual for specific oil recommendations and break-in information. The oil change interval is dependent on the quality of the oil and the operating environment. Refer to the Engine Operatorʼs Manual for more details on the proper service and

maintenance intervals.

FUEL

USE DIESEL FUEL ONLY

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

NOTE: Close the fuel shutoff valve located on the pre-

filter if not running the welder for extended periods.

ENGINE COOLING SYSTEM

WARNING

HOT COOLANT can burn skin.

•Do not remove cap if radiator is hot.

•The engine and radiator or this machine are filled with a 50% mixture of ethylene-glycol based permanent type antifreeze. See the Maintenance section and the engine Operationʼs Manual for more information.

BATTERY CONNECTION

WARNING

BATTERY ACID CAN BURN EYES AND SKIN.

•Wear gloves and eye protection and be careful when working near a battery. Follow the instructions printed on the battery.

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

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The RANGER 305D is shipped with the negative battery cable disconnected. Make certain that the RUNSTOP switch is in the STOP position. Access the negative post of the battery by opening the left side engine cover. Attach the negative battery cable to the negative battery terminal and tighten using a socket or wrench.

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

MUFFLER OUTLET PIPE

Using the clamp provided secure the outlet pipe to the outlet tube with the pipe positioned to direct the exhaust in the desired direction. Tighten using a socket or wrench.

SPARK ARRESTER

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

CAUTION

An incorrect spark arrestor may lead to damage to the

engine or adversely affect performance.

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HIGH FREQUENCY GENERATORS FOR TIG APPLICATIONS.

The K930-2 TIG Module is suitable for use with the Ranger 305D. The Ranger 305D and any high frequency generating equipment must be properly grounded. See the K930-2 operating manual for complete instructions on installation, operation, and maintenance.

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RANGER 305D

A-7 A-7

Note: Output stud covers not shown. Code 11275 and above

INSTALLATION

REMOTE CONTROL

The RANGER 305D is equipped with both a 6-pin and a 14-pin Amphenol connector. The 6-pin connector is primarily used to connect a remote control device, such as a K857, or a TIG Amptrol, such as the K870 or K812. The 14-pin Amphenol connector is primarily used to directly connect a wire feeder, TIG module, or Spool Gun module control cable. See Accessories section for more information.

NOTE: Both the 6-pin and 14-pin Amphenols share the same output control auto-sensing and contactor circuitry; for this reason, there can only be one device plugged into the Ranger 305D at any time.

Switch operation is covered in “Operation” section.

ELECTRICAL OUTPUT CONNECTIONS

See Figure A.1 for the location of the 120 and 240 volt receptacles, weld output terminals, and ground stud. Output stud covers are provided on code 11275 and above.

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:

• Be grounded to the frame of the welder using a grounded type plug or be double insulated.

WARNING

Do not ground this 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" as well as the article on grounding in the latest National Electrical Code and the local code.

Figure A.1 - RANGER 305D OUTPUT CONNECTIONS

Note: Different models appearance may vary slightly.

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RANGER 305D

A-8 A-8

INSTALLATION

In general, if the machine is to be grounded, it should be connected with a #8 or larger copper wire to a solid earth ground such as a metal water pipe going into the ground for at least ten feet and having no insulated joints, or to the metal framework of a building which has been effectively grounded. The National Electrical Code lists a number of alternate means of grounding electrical equipment. A machine grounding stud marked with the ground symbol is provided on the front of the welder.

WELDING OUTPUT CABLES

With the engine off connect the electrode and work cables to the output terminals. The welding process dictates the polarity of the electrode cable. These connections should be checked periodically and tightened with a 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. Long lengths of cable should not be left coiled when welding.

CABLE INSTALLATION TABLE A.1

TOTAL COMBINED LENGTH OF

ELECTRODE AND WORK CABLES

Cable Length

0-100Ft. (0-30 meters)

100-150 Ft. (30-46 meters)

Cable Size for

305 Amps

100% Duty Cycle

1 / 0 AWG

2 / 0 AWG

NOTE: Long lengths of welding cable should not

remain coiled or wrapped while welding.

CAUTION

• 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.

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AUXILIARY POWER RECEPTACLES

The auxiliary power of the RANGER 305D consists of two 20 Amp-120 VAC (5-20R) duplex receptacles with GFCI protection and one 50 Amp 120/240 VAC (1450R) receptacle. The 240 VAC receptacle can be split for single phase 120 VAC operation.

The auxiliary power capacity is 10,000 watts Peak, 9,500 Watts Continuous of 60 Hz, single phase power. The auxiliary power capacity rating in watts is equivalent to volt-amperes at unity power factor. The max permissible current of the 240 VAC output is 42 amps. The 240 VAC output can be split to provide two separate 120 VAC outputs with a max permissible current of 42 Amps per output to two separate 120 VAC branch circuits (these circuits cannot be paralleled). Output voltage is within ± 10% at all loads up to rated capacity. Auxiliary power is protected by circuit breakers.

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

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150-200 Ft. (46-61 meters)

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

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

2. Remove the flanged nuts from the output terminals.

3. Connect the electrode 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.

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3 / 0 AWG

NOTE: The 240 V receptacle has two 120 V circuits,

but are of opposite polarities and cannot be paralleled.

STANDBY POWER CONNECTIONS

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

The RANGER 305D can be permanently installed as a standby power unit for 240 VAC, 3 wire, single phase, 50 amp service. Connections must be made by a licensed electrician who can determine how the 120/240 VAC power can be adapted to the particular installation and comply with all applicable electrical codes.The following information can be used as a guide by the electrician for most applications. Refer to the connection diagram in Figure A.2.

RANGER 305D

A-9 A-9

INSTALLATION

1. Install the double-pole, double-throw switch

between the power company meter and the premises disconnect. Switch rating must be the same or greater than the customerʼs premises disconnect and service over-current protection.

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

2. Take necessary steps to assure load is limited to the capacity of the Ranger 305D by installing a 50 amp, 240 VAC double-pole circuit breaker.

Maximum continuous rated load for each leg of the 240 VAC auxiliary is 40 amperes. Loading above the rated output will reduce output voltage below the allowable +/- 10% of rated voltage, which may damage appliances or other motor-driven equipment and may result in overheating of the Ranger 305D engine and/or alternator windings.

4. Plug this cable into th 50 amp, 120/240 VAC receptacle on the Ranger 305D case front.

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RANGER 305D

A-10 A-10

240 Volt

60 Hz. 3-Wire

Service

POWER

COMPANY

METER

240 VOLT

120 VOLT

LOAD

NEUTRAL

BUS

GROUND

PREMISES

DISCONNECT AND

SERVICE

OVERCURRENT

PROTECTION

GND

NOTE: No. 6 COPPER CONDUCTOR CABLE SEE

NATIONAL ELECTRICALCODE FOR ALTERNATE WIRE

SIZE RECOMMENDATIONS.

240 VOLT

GROUNDED CONDUCTOR

50AMP

240 VOLT

DOUBLE

POLE

CIRCUIT

BREAKER

DOUBLE POLEDOUBLE THROW SWITCH RATINGTO BE THE SAME AS ORGREATER THAN PREMISES SERVICE OVERCURRENT PROTECTION.

50 AMP,120/240

VOLT PLUG

NEMA TYPE14-50

50 AMP,120/240 VOLT

RECEPTACLE

INSTALLATION

FIGURE A.2 CONNECTION OF RANGER 305D TO PREMISES WIRING

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.

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• The premises is isolated and no feedback into the utility system can occur. Certain state and local laws require the premises to be isolated before the generator is linked to the premises. Check your state and local requirements.

• A double pole, double throw transfer switch in conjunction with the properly rated double-pole/ double throw circuit breaker is connected between the generator power and the utility meter.

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RANGER 305D

Section B-1 Section B-1

TABLE OF CONTENTS

- OPERATION SECTION -

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

Operating Instructions .................................................................................................................B-2

Safety Instructions.......................................................................................................................B-2

General Description ....................................................................................................................B-2

Design Features ..........................................................................................................................B-3

Controls and Settings..................................................................................................................B-3

Engine Controls ....................................................................................................................B-4

Welding Controls ..................................................................................................................B-5

Engine Operation ........................................................................................................................B-6

Before Starting the Engine ...................................................................................................B-6

Starting the Engine...............................................................................................................B-6

Stopping the Engine .............................................................................................................B-6

Stick Welding ..............................................................................................................................B-7

Constant Current (CC-Stick) Welding.............................................................................B-7

Pipe Welding...................................................................................................................B-7

TIG Welding..........................................................................................................................B-8

Wire Welding-CV ..................................................................................................................B-8

Arc Gouging..........................................................................................................................B-8

Auxiliary Power ...........................................................................................................................B-8

Simultaneous Welding and Auxiliary Power Loads ..............................................................B-9

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RANGER 305D

B-2 B-2

OPERATION

OPERATING INSTRUCTIONS

WARNING

Read and understand this entire section before operating your Ranger 305D.

SAFETY INSTRUCTIONS

WARNING

ENGINE EXHAUST can kill.

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

• Do not stack anything on or near the engine.

Do not attempt to use this equipment until you have thoroughly read all the operating and maintenance manuals supplied with your machine. They include important safety precautions; detailed engine starting, operating and maintenance instructions and parts lists.

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ELECTRIC SHOCK can kill.

• Do not touch electrically live parts such as output terminals or internal wiring.

• Insulate yourself from work and ground.

• Always wear dry insulating gloves.

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FUMES AND GASES can be dangerous.

• Keep your head out of fumes.

• Use ventilation or exhaust to remove fumes from breathing zone.

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WELDING SPARKS can cause fire or

explosion.

• Keep flammable material away.

• Do not weld on containers that have held combustibles.

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ARC RAYS can burn.

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MOVING PARTS can injure.

• Do not operate this equipment with any of its doors open or guards off.

• Stop the engine before servicing it.

• Keep away from moving parts.

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Only qualified personnel should install, use, or ser-

vice this equipment.

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ADDITIONAL SAFETY PRECAUTIONS

Always operate the welder with the hinged door closed and the side panels in place. These provide maximum protection from moving parts and insure proper cooling air flow.

GENERAL DESCRIPTION

The Ranger 305D is a diesel-engine-powered DC multi-process welding power source and 120 / 240 VAC power generator. The engine drives a generator that supplies three-phase power for the DC welding circuit and single-phase power for the AC auxiliary outlets. The DC welding control system uses state of the

art Chopper Technology (CT performance.

) for superior welding

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• Wear eye, ear, and body protection.

RANGER 305D

B-3 B-3

OPERATION

DESIGN FEATURES

• Single, full-range output control dial.

• 4 welding modes: CC-stick, downhill stick welding on pipe, CV wire welding and Touch-Start TIGTM(eliminates high frequency and tungsten contamination).

• Output at welding terminals controlled by electronic contactor. Can be switched to “On”, or to “Remotely Controlled”.

• Many wire feeder combinations: 14-pin connector for Lincoln wire feeders LN-25, LN-23P, LN-7, LN-8 operates when using a Lincoln wire feeder with the appropriate control cable.

• Smart machine! Remote operation and Magnum spool gun; 42VAC for LN-742 and Cobramatic®wire feeders.

• 12 gallon fuel capacity allows you to run an extended day.

• Easily check fuel level during operation and refuelling with highly visuable fuel gauge.

Some models have gauge located next to fuel cap on case top.

• Longer engine life, reduced noise emissions and great fuel economy with the automatic engine idler.

• Conveniently located engine maintenance label under top engine door.

• Engine hour meter for scheduled maintenance.

• Electric start.

• Oil drain valve (no tools required).

• See spec pages for watts of continuous duty AC generator power.

• See spec pages for Amp and voltages output specs. Circuit breaker protection.

• See spec pages for receptacle information.

CONTROL AND SETTINGS

The diesel engine stop/start and idler controls are located on the case front panel. The welder controls are also located here. See Figure B.1.

Some models have gauge located on front panel.

• Voltmeter and ammeter display actual volts and amps at output terminals when welding.

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RANGER 305D

B-4 B-4

NOTE: Layout and appearance vary between models.

OPERATION

FIGURE B.1

ENGINE CONTROLS (Figure B.1)

1. RUN.STOP SWITCH:

the engine prior to starting. STOP position stops the engine.

RUN position energizes

2. GLOW PLUG PUSH BUTTON: When

pressed, this button activates the engine glow plugs to preheat the engine for starting. This button also temporarily powers the fuel solenoid hold coil. On codes 10926 and 11121, the electric fuel pump is also temporarily activated.

3. START PUSH BUTTON: Energizes the

starter to crank the engine and activates the fuel solenoid pull coil.

A) In the HIGH position, the engine runs at the high idle

speed controlled by the engine governor.

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

a. When switched from HIGH to AUTO or after starting the

engine, the engine will operate at high speed for approximately 12 seconds and then go to low idle speed.

b. When the electrode touches the work or power is drawn

from the auxiliary power receptacles (approximately 100 watts minimum, the engine accelerates and operates at high speed.

c. 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 RPM to low idle speed.

d. The engine will automatically return to high idle speed

when the welding load or AC power load is reapplied.

ENGINE ALTERNATOR TROUBLE LIGHT:

The yellow engine alternator light is off when the battery charging system is functioning normally. If the light turns on, the alternator or the voltage regulator may not be operating correctly. The light may also come on if the battery is not holding a charge. It is normal for the light to come on while starting the engine. (Code 10926 and over)

5. ELECTRIC FUEL GAUGE: (Codes 11121

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

6. ENGINE HOUR METER: Displays the total

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

7. 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 then the RUN/STOP switch is in the “ON” position before starting the engine. If the Engine Protection or Battery Charging lights do NOT turn off shortly after starting the engine, stop the engine immediately and determine the cause.

8. 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.

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RANGER 305D

B-5 B-5

OPERATION

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

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

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

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

12. 14-PIN AMPHENOL: Primarily used for attaching

accessories, such as a wire feeder, spool gun module or TIG module. It provides connections to both 120VAC and 42VAC power, and to the weld circuit work voltage sensing lead. It also provides a connection to the same control circuits described in the 6-PIN AMPHENOL section below.

WELDING CONTROLS

9. OUTPUT CONTROL: The output control dial is used

to present the output voltage or current as displayed on the digital meters for each of the four welding modes. It can also be used to vary the output while welding. This control is disabled by an auto-sensing circuit if the machine is in CC-Stick, Downhill pipe, or CV-wire modes, and an accessory device with output control capability is plugged into either amphenol.

When in Touch-Start TIG mode, and when an accessory device with output control, such as an Amptrol, is plugged in to either Amphenol, the OUTPUT control dial is used to set the maximum current range of the accessory output control device.

10. WELD MODE SELECTOR SWITCH: This switch

provides four selectable welding modes:

- CV-WIRE

- DOWNHILL PIPE

- CC-STICK

- TOUCH STARTING

11. 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 TOUCH START 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.

13. 6-PIN AMPHENOL- Primarily used to connect a

remote control device, such as the K857, or a TIG Amptrol, such as the K870 or K812.

Both the 6 and 14-Pin amphenols are connected to a remote control auto-sensing circuit that transfers all or partial output control functions from the front panel output control dial to the remote output control device.

When in TOUCH START TIG mode, a remote output control device will vary the output from MIN up to the value set with the front panel output control dial. In all other modes, the front panel output control is completely disabled, and full MIN to MAX control is transferred to the remote output control device.

Both Amphenols also connect to an electronic output contactor circuit. When the “Weld Terminals” switch is in the “remotely controlled” position, the weld terminals are switched on an doff by the device connected to either amphenol.

NOTE: Both the 6 pin and 14 pin Amphenols share the same

output control auto-sensing and contactor circuitry; for this reason, there can only be one device plugged into the Ranger 305D at any time.

14. WELD TERMINALS CONTROL SWITCH- In the

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

15. WIRE FEEDER VOLTMETER SWITCH:

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

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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.

RANGER 305D

16. DIGITAL OUTPUT METERS:

The digital meters allow the output voltage (“CVWIRE” mode) or current (“CC-STICK”, “DOWNHILL PIPE” and “TOUCH START TIG” modes) to be preset prior to welding using the output control dial. When pre-setting voltage the AMPS display will be off and while pre-setting amps, the VOLTS display will be off. While welding, the machine display both the actual voltage (VOLTS) and current (AMPS).

B-6 B-6

OPERATION

ENGINE OPERATION

WARNING

DO NOT RUN THE ENGINE AT EXCESSIVE SPEEDS. The maximum allowable high idle speed for the Ranger 305D is 3650 RPM, no load. Do NOT adjust the governor screw on the engine. Severe personal injury and damage to the machine can result if it is operated at speeds above the maximum rated speed.

Read and understand all safety instructions included in the engine operatorʼs manual that is shipped with your Ranger 305D.

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BEFORE STARTING THE ENGINE

Check and fill the engine oil level:

1. Be sure the machine is on a level surface.

2. Open the right side (facing control panel) engine door and remove the engine oil dipstick and wipe it with a clean cloth. Reinsert the dipstick and check the level on the dipstick.

3. Add oil (if necessary) to bring the level up to the fullmark. Do not overfill. Close the engine door.

4. Open the left side engine door and check the coolant level in the coolant recovery tank. Add coolant if necessary. See Maintenance section of this manual for details.

5. See the Maintenance section for specific oil and antifreeze recommendations.

Check and fill the engine fuel tank:

WARNING

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

CAUTION

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

• Do not push the START button while the engine is running because this can damage the ring gear and/or the starter motor.

• If the Engine Protection or Battery Charging Lights do “not” turn off shortly after starting the engine shut off the engine immediately and deter mine the cause.

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• Stop engine while fueling.

• Do not smoke when fueling.

• Keep sparks and flame away from tank.

• Do not leave unattended while

DIESEL FUEL can cause fire.

1. Remove the fuel tank cap.

2. 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.

3. Replace the fuel cap and tighten securely.

4. See the Maintenance section and engine manual for specific fuel recommendations.

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fueling.

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

• Do not overfill tank, fuel expansion may cause over-flow.

DIESEL FUEL ONLY

NOTE: When starting a RANGER 305D for the first

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

STOPPING THE ENGINE

1. 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

2. 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.

RANGER 305D

B-7 B-7

OPERATION

BREAK-IN PERIOD

Constant Current (CC-STICK) Welding

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

Check the oil every four hours during break-in, and change both oil and oil filter at 50 hours of operation. Change the oil every 75 hours thereafter and the oil filter every 150 hours. For more details, see the Maintenance section of this manual.

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

several minutes.

STICK WELDING

The Ranger 305D can be used with a broad range of DC stick electrodes.

The MODE switch provides two stick welding settings as follows:

The CC-STICK position of the MODE switch is designed for horizontal and vertical-up welding with all types of electrodes, especially low hydrogen. The OUTPUT control dial adjusts the full output range for stick welding. The ARC CONTROL dial sets the short circuit current (arc-force) during stick welding to adjust for a soft or crisp arc. Increasing the number 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 the dial set at 0.

DOWNHILL PIPE Welding

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

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TABLE B.2 - TYPICAL CURRENT RANGES1FOR TUNGSTEN ELECTRODES

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

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

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

0.010 (.25) 2-15

0.020 (.50) 5-20

0.040 (1.0) 15-80

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

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

5/32 (4.0) 400-500 40-55 21-25 (10-12) 13-17 (6-8) #8, #10 3/16 (4.8) 500-750 55-80 23-27 (11-13) 18-22 (8-10) 1/4 (6.4) 750-1000 180-125 28-32 (13-15) 23-27 (11-13)

When used with argon gas. The current ranges shown must be reduced when using argon/helium or pure helium shielding gases.

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.

DCEP is not commonly used in these sizes.

TIG torch nozzle "sizes" are in multiples of 1/16ths of an inch:

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.

# 4 = 1/4 in. (6 mm) # 5 = 5/16 in. (8 mm) # 6 = 3/8 in. (10 mm) # 7 = 7/16 in. (11 mm) # 8 = 1/2 in. (12.5 mm) #10 = 5/8 in. (16 mm)

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3-8 (2-4) 3-8 (2-4) #4, #5, #6 5-10 (3-5) 5-10 (3-5) 5-10 (3-5) 5-10 (3-5)

RANGER 305D

4, 5

B-8 B-8

OPERATION

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 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.

The ARC CONTROL is not active in the TIG mode.

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

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

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

b. Set the “IDLER” Switch to the “AUTO” position.

c. Set the “WELD 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

ARC GOUGING

The RANGER 305D can be used for limited arc gouging. For optimal performance, set the MODE switch to CC-STICK and the ARC CONTROL to +10.

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

TABLE B.3 - CURRENT RANGE

PER ELECTRODE DIAMETER

Carbon Diameter

1/8" 75-140 Amps

5/32" 90-150 Amps

3/16" 200-250 Amps

Current Range (DC, electrode

positive)

AUXILIARY POWER

WARNING

When using the TIG Module, the OUTPUT control on the Ranger 305D is used to set the maximum range of the CURRENT.

WIRE WELDING-CV

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

In the CV-WIRE mode, the Ranger 305D can 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 for -10 (soft) to +10 (crisp) changes the arc from soft and washed-in to crisp and narrow. It acts as an inductance control. The proper setting depends on the procedure and operator preference. Start with the dial set at 0.

Some recommended Innershield electrodes are: NR-311, NS3M, NR-203 Ni 1%, NR-204H. Recommended Outershield electrodes are :0S-70, OS-71M.

Some recommended solid wires for MIG welding are: .035 (0.9mm), and .045 (1.1mm), L-50 and L-56, .035 (0.9 mm) and .045 (1.1mm) Blue Max MIG 308 LS.

For any electrodes, including those above, the procedure should be kept within the rating of the machine.

Be sure that any electrical equipment plugged into the generator AC power receptacles can withstand +/- 10% voltage and a +/3% frequency variation.

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

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

The auxiliary power of the Ranger 305D consists of two 20 amp-120 VAC (5-20R) duplex receptacles and one 50 amps 120/240 VAC (14-50R) receptacle. The 240 VAC receptacle can be split for single-phase 120 VAC operation.

The auxiliary power capacity is 10,000 watts peak, 9,500 watts of continuous 60 Hz, singe-phase power. The auxiliary power capacity rating in watts is equivalent to volt-amperes at unity power factor. The maximum permissible, 40 amps continuous current of the 240 VAC output is 42 amps maximum.

NOTE: Machines with code numbers of 11121 and higher are equipped with GFCI duplex receptacles. If a GFCI receptacle is “tripped”, it will not reset unless it is receiving nearly full voltage from the generator; for this reason, the engine must be running at high RPM before resetting a GFCI.

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RANGER 305D

B-9 B-9

OPERATION

The 240 VAC receptacle can be split to provide two separate120 VAC outputs with a maximum permissible current of 42 amps pea, 40 amps continuous per outlet to two separate 20 amp branch circuits. (These circuits cannot be paralleled.) Output voltage is within +/10% at all loads up to rated capacity.

The 120 V auxiliary power receptacles should only be used with three-wire, grounded type plugs or approved double insulated tools with two-wire plugs. The current rating of any plug used with the system must be at least equal to the current capacity of the associated receptacle. For extension cord lengths, see Table B.5.

RANGER 305D Simultaneous Welding and Power Loads

NOTE: The 240 VAC receptacle has two circuits, each

of which measure 120 VAC to neutral. However, they are of opposite polarities and cannot be paralleled.

SIMULTANEOUS WELDING AND AUXILIARY POWER LOADS

The above auxiliary power ratings are with no welding load. Simultaneous welding and power loads are specified in Table B.4. The permissible currents shown assume that current is being drawn from either the 120 VAC or 240 VAC supply (not both at the same time).

Current

(Amps)

15 20 15 20 33

Welding

Output-Amps

at NEMA Arc-Volts

Permissible Auxiliary

Power-Watts

(Unity Power Factor)

Permissible Auxiliary Current in -Amps @

120 VAC* 240 VAC

0 100 150

200 250 300

9500 7100 5600 4500 2800

40*, (42* Peak) 40, (42 Peak)

40* 30 40* 23

32 16 16 8

0 0

* Each 120 VAC leg of the 120/240 VAC Full KVA receptacle can deliver a maximum

40 amps, up to a total of 80 amps at 9500 Watts, 60 amps at 7100 Watts, or 46 amps at 5600 Watts. These outputs cannot be paralleled, so the greatest single 120 VAC load is 40 amps.

Each 120 VAC Duplex receptacle is limited to 20 amps maximum.

TABLE B.5 - RANGER 305D Extension Cord Length Recommendations

(Use the shortest length extension cord possible sized per the following table.)

Voltage

(Volts)

120 120 240 240 240

Load

(Watts)

1800 2400 3600 4800 8000

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

(9)

(18)

Conductor size is based on maximum 2.0% voltage drop.

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

40 30 75 60

(12)

(9) (23) (18)

50 150 100

(23) (15) (46) (30) (18)

125

88 225 175 100

(38) (27) (69) (53) (30)

175 138 350 275 175

(53) (42)

(107)

(84) (53)

300 225 600 450 250

(91)

(69) (183) (137)

(76)

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RANGER 305D

B-10 B-10

NOTES

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RANGER 305D

Section C-1 Section C-1

TABLE OF CONTENTS

- ACCESSORIES -

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

Options/Accessories ...................................................................................................................C-2

Field Installed Options .........................................................................................................C-2

TIG Welding Accessories .....................................................................................................C-2

Semiautomatic FCAW and MIG Welding Accessories.........................................................C-2

Connection of Lincoln Electric Wire Feeders .......................................................................C-3

Connection of the K867 Universal Adapter....................................................................C-3

Connection of the LN-25 “Across the Arc” .....................................................................C-4

Connection of the LN-25 with 42V Remote Output Control Module ..............................C-5

Connection of the LN-25 with K857 Remote Control .....................................................C-6

Connection of the LN-7 Using the K584 Control Cable .................................................C-7

Connection of the LN-8 Using the K595 Control Cable .................................................C-8

Connection of the LN-742 ..............................................................................................C-9

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RANGER 305D

C-2 C-2

ACCESSORIES

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OPTIONS / ACCESSORIES

FIELD INSTALLED OPTIONS

The following options/accessories are available for your Ranger 305D from your Lincoln distributor.

K957-1 HEAVY DUTY, TWO WHEEL TRAILER FOR SMALL WELDERS - For road, off-road and in-plant

and yard towing. (For highway use, consult applicable federal, state and local laws regarding requirements for brakes, lights, fenders, etc.)

K1737-1 FOUR-WHEEL ALL-TERRAIN UNDERCARRIAGE - For moving by hand.

K1770-1 UNDERCARRIAGE (FACTORY) - For moving

by hand on a smooth surface. One or two gas cylinders can be mounted on the rear of the undercarriage with the installation of K1745-1 Cylinder Holder(s).

K1739-1 CABLE CARRIER KIT - For use on K1737-1 and K1770-1 Undercarriages.

K1745-1 SINGLE GAS CYLINDER HOLDER - For use on K1770-1 Undercarriage. One or tow may be installed on an undercarriage.

K1789-1 ROLL CAGE - Gives added damage protection. K886-2 CANVAS COVER - Protects machine when

not in use. K1898-1 SPARK ARRESTER - Attaches between

muffler or exhaust elbow. K704 ACCESSORY KIT - Accessory set includes 35 ft.

(10.7meters) 2 AWG electrode cable, 30 ft. (9.1 meters) 2 AWG work cable, headshield with No. 12 filter, G300 work clamp and Cooltong 300 electrode holder. Cables are rated at 300 amps, 40% duty cycle.

K857 28 ft (8.5m) or K857-1 100 ft. (30.4m) REMOTE CONTROL - Portable control provides same

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

K1690-1 GFCI RECEPTACLE KIT - Includes one UL approved 120 volt ground fault circuit interrupter duplex type receptacle with cover and installation instructions. Replaces the factory installed 120V duplex receptacle. Each receptacle of the GFCI Duplex is rated at 20 amps. The maximum total current from the GFCI Duplex is limited to 20 amps. Two kits are required.

K802-N POWER PLUG KIT - Provides four 120 volt plugs rated at 20 amps each and one dual voltage, full KVA plug rated at 120/240 volts, 50 amps.

K802-R POWER PLUG KIT - Provides four 120 volt plugs rated at 15 amps each and one dual voltage, full KVA plug rated at 120/240 volts, 50 amps.

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

Provides one dual voltage plug for full KVA power.

TIG WELDING ACCESSORIES

K1783-9 TIG TORCH - For TIG welding with shielding

gas. Includes 25 feet of cable.

K963-2 - Hand Amptrol. K870 - Foot Amptrol

NOTE: TIG welding requires a Magnum

appropriate Magnum Parts Kit and argon gas.

SEMIAUTOMATIC FCAW AND MIG WELDING ACCESSORIES

LN-25 WIRE FEEDER K449 - This portable unit pro-

vides CC/CV for flux-cored arc welding (FCAW) and metal inert gas welding (MIG). Includes a gas solenoid and an internal contactor that allows across-the-arc operation with no control cable. The LN-25 provides a “cold” electrode until the gun trigger is pressed. For voltage control at the feeder, a K444-1 Remote Voltage Control Kit or K857 Remote Control is required. Refer to connection instructions later in this section.

LN-7 OR LN-8 WIRE FEEDER - Semiautomatic, constant speed wire feeders.

NOTE: Gas-shielding welding requires a Magnum Gun. Gasless welding requires an Innershield Gun.

LN-742 WIRE FEEDER - A semiautomatic wire feeder with “cold” electrode. Refer to connection instructions later in this section.

MAGNUM SPOOL GUN (K487-25) - A lightweight, semiautomatic wire feeder for aluminum welding with argon gas. Has built-in remote wire speed control in the handle. Requires the K488 SG Control Module. Refer to connection instructions later in this section.

SG CONTROL MODULE (K488) - Controls wire speed and gas flow. Provides the required control interface between the Ranger 305D and the K487-25 Magnum Spool Gun. Requires the K691-10 Input Cable.

K444-1 REMOTE VOLTAGE CONTROL - Provides voltage adjustment control at the feeder. Includes 25 feet of cable.

K126-2 INNERSHIELD GUN - For gasless welding. Includes 15 feet of cable.

K470-2 MAGNUM GUN CONNECTOR KIT - For gasshielding welding.

K466-1 MAGNUM GUN CONNECTOR KIT - For connecting the Magnum 300 MIG Gun to the feeder for gas-shielding welding.

RANGER 305D

TIG Gun,

C-3 C-3

81 82

SPARE

GND

POWER SOURCE FRAME CONNECTION WIRE FEEDER VOLTMETER CONNECTION CONNECTS TO (WORK TERMINAL) OF POWER SOURCE

10K

MIN.

REMOTE OUTPUT CONTROL

115 VAC

42 VAC

WELDING OUTPUT

CONNECT TOGETHER FOR

NOT USED ON RANGER POWER SOURCES

ELECTRODE CABLE TO WIRE FEED UNIT

TO WORK

K867 UNIVERSAL ADAPTER PLUG

14-PIN AMPHENOL

TO K867

TO WIRE FEEDER

ACCESSORIES

K18161 FULL KVA ADAPTER KIT

Plugs into the 120/240V NEMA 14-0R receptacle on the casefront (which accepts 4-prongs plugs) and converts it to a NEMA 6-50R receptacle, (which accepts 3prong plugs.)

CONNECTION OF LINCOLN ELECTRIC WIRE FEEDERS

WARNING

ELECTRIC SHOCK can kill.

. Do not operate with panels open. . Disconnect NEGATIVE (-) BATTERY

LEAD before servicing.

. Do not touch electrically live parts.

MOVING PARTS can injure.

. Keep guards in place. . Keep away from moving parts. . Only qualified personnel should

install, use or service this equipment.

2. Connect the electrode cable from the wire feeder to the “+” terminal of the welder. Connect the work cable to the “-” terminal of the welder.

NOTE: Welding cable must be sized for current and duty cycle of application.

3. Connect the K867 Universal Adapter to the 14-pin amphenol of the Ranger 305D as shown in Figure C.1. Make the proper connections for local or remote control according to Figure C.1. and the following NOTES, indicated on the figure:

A. These leads are not used for the Ranger

305D. Insulate each unused lead individually.

B. For wire feeders that return a signal for weld-

ing output, use an isolation relay to close leads 2 and 4.

C. Refer to the Operation section of this manual

for maximum wire feeder auxiliary current draw.

4. Set the “MODE” switch to the “CV-WIRE” position.

5. Place the “IDLER” switch in the “AUTO” position.

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

CONNECTION OF THE RANGER 305D TO WIRE FEEDERS USING K867 UNIVERSAL ADAPTER (SEE FIGURE C.1)

NOTE: When you use the Ranger 305D with non-

Lincoln Electric wire feeders or with certain earlier models of Lincoln wire feeders, you will require the K867 Universal Adapter. The following discussion and connection diagram explain in general how to make the proper connections.

1. Shut the welder off.

FIGURE C.1 - Ranger 305D/K867 UNIVERSAL ADAPTER CONNECTION DIAGRAM

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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 auxiliary voltage. If this voltage goes over 140 volts, wire feeder control circuit may be damaged. The engine governor setting is preset at the factory - do not adjust above RPM specifications listed in this manual.

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

6. Set the “VOLTMETER” switch to “+” or “-” depending on the polarity chosen.

7. Set the ARC control to “0” initially and adjust to suit.

8. Adjust wire feed speed at the wire feeder.

RANGER 305D

CAUTION

C-4 C-4

TO WORK

14-PIN AMPHENOL

6-PIN AMPHENOL

OPTIONAL K444-1 REMOTE CONTROL

ELECTRODE CABLE

LN-25

WIRE FEEDER

TO WORK

WORK CLIP LEAD

ACCESSORIES

CONNECTION OF THE LN-25 TO THE RANGER 305D “ACROSS THE ARC” (SEE FIGURE C.2.)

1. Shut the welder off.

2. Connect the electrode cable from the LN-25 to the “-” terminal of the welder. Connect the work cable to the “+” terminal of the welder.

NOTE: Figure C.2 shows the electrode connected for negative polarity. To change polarity, shut the welder off and reverse the electrode and work cables at the Ranger 305D output terminals.

NOTE: Welding cable must be sized for current and duty cycle of application.

3. Set the “VOLTMETER” switch to “+” or “-” depending on the polarity chosen.

4. Set the “MODE” switch to the “CV-WIRE” position.

5. Attach the single lead from the LN-25 control box to the work using the spring clip on the end of the lead. This is only a control lead - it carries no welding current.

6. Place the “IDLER” switch in the “AUTO” or “HIGH” position as desired.

CAUTION

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

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

7. Place the “WELD TERMINALS” switch in the “WELD TERMINALS ON” position.

8. Adjust wire feed speed at the LN-25 and adjust the welding voltage with the output “CONTROL” at the LN-25 if optional remote control kit is used.

9. Set the ARC control to “0” initially and adjust to suit.

FIGURE C.2 - Ranger 305D/LN-25 ACROSS THE ARC CONNECTION DIAGRAM

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RANGER 305D

+ 164 hidden pages