Lincoln Electric RANGER 305D Operator's Manual
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Lincoln Electric RANGER 305D Operator's Manual

Welding machine
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Operator's Manual
RANGER
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Date Purchased
Code: (ex: 10859)
Serial: (ex: U1060512345)
IM970-A
| Issue D ate Sept- 13
© Lincoln Global, Inc. All Rights Reserved.
®
305D
For use with machines having Code Numbers:
11457, 11909
Need Help? Call 1.888.935.3877
to talk to a Service Representative
Hours of Operation:
8:00 AM to 6:00 PM (ET) Mon. thru Fri.
After hours?
Use "Ask the Experts" at lincolnelectric.com
A Lincoln Service Representative will contact you
no later than the following business day.
For Service outside the USA:
Email: globalservice@lincolnelectric.com

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  • Page 1 Operator’s Manual ® RANGER 305D For use with machines having Code Numbers: 11457, 11909 Need Help? Call 1.888.935.3877 Register your machine: to talk to a Service Representative www.lincolnelectric.com/register Authorized Service and Distributor Locator: Hours of Operation: www.lincolnelectric.com/locator 8:00 AM to 6:00 PM (ET) Mon. thru Fri. Save for future reference After hours? Use “Ask the Experts”...
  • Page 2 THANK YOU FOR SELECTING A QUALITY PRODUCT BY KEEP YOUR HEAD OUT OF THE FUMES. LINCOLN ELEC TRIC. DON’T get too close to the arc. Use corrective lenses if necessary to stay a reasonable distance away from the arc. READ and obey the Material Safety PLEASE EXAMINE CARTON AND EQUIPMENT FOR Data Sheet (MSDS) and the warning DAMAGE IMMEDIATELY...

  • Page 3: California Proposition 65 Warnings

    SAFETY SECTION A: 1.d. Keep all equipment safety guards, covers and devices in position and in good repair.Keep hands, hair, clothing and tools away from WARNINGS V-belts, gears, fans and all other moving parts when starting, operating or repairing equipment. CALIFORNIA PROPOSITION 65 WARNINGS 1.e.

  • Page 4: Electric Shock Can Kill

    SAFETY ELECTRIC SHOCK ARC RAYS CAN BURN. CAN KILL. 3.a. The electrode and work (or ground) circuits are 4.a. Use a shield with the proper filter and cover plates to protect your electrically “hot” when the welder is on. Do eyes from sparks and the rays of the arc when welding or not touch these “hot”...
  • Page 5 SAFETY WELDING AND CUTTING CYLINDER MAY EXPLODE IF SPARKS CAN CAUSE DAMAGED. FIRE OR EXPLOSION. 7.a. Use only compressed gas cylinders containing the correct shielding gas for the process used 6.a. Remove fire hazards from the welding area. If and properly operating regulators designed for this is not possible, cover them to prevent the the gas and pressure used.

  • Page 6: Table Of Contents

    Electrical Connections ......................A-4 Machine Grounding .......................A-4 Welding Terminals ......................A-5 Welding Output Cables ....................A-5 Cable Installation......................A-5 Electrical Device Used with the Ranger 305D..............A-6 Auxiliary Power Receptacles and Plugs ................A-7 Standby Power Connections ....................A-7 Premises Wiring ........................A-8 Connection of Lincoln Electric Wire Feeders...............A-9,A-10 ________________________________________________________________________________ Operation.........................Section B...
  • Page 7 TABLE OF CONTENTS Maintenance......................Section D Safety Precautions ....................D-1 Routine Maintenance ....................D-1 Engine Maintenance Components ................D-1 Kubota Diesel Engine ....................D-1 Engine Oil Change..................D-2 Engine Oil Refill Capacities................D-2 Engine Oil Filter Change.................D-2 Air Cleaner Service ..................D-2 Service Instructions And Installation Tips for Engine Air Filter .......D-3 Cooling System .....................D-4 Fan Belt......................D-4 Fuel .........................D-4...

  • Page 8: Installation

    INSTALLATION TECHNICAL SPECIFICATIONS - Ranger® 305D (K1727-3, K1727-4) 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. 4 stroke starter (45 Liters) 18.8 HP High Idle 3650 Bore x Stroke inch (mm) Oil: 3.4Qts.

  • Page 9: Safety Precautions

    INSTALLATION SAFETY PRECAUTIONS LIFTING The RANGER® 305D weighs approximately WARNING 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. Do not attempt to use this equipment until you have thoroughly read the engine manufacturerʼs WARNING manual supplied with your welder.

  • Page 10: Towing

    INSTALLATION PRE-OPERATION ENGINE SERVICE TOWING READ the engine operating and maintenance instruc- The recommended trailer for use with this equipment for road, tions supplied with this machine. in-plant and yard towing by a vehicle(1) is Lincolnʼs K957-1. If the user adapts a non-Lincoln trailer, he must assume responsi- WARNING bility that the method of attachment and usage does not result in a safety hazard nor damage the welding equipment.

  • Page 11: Battery Connections

    INSTALLATION REMOTE CONTROL ENGINE COOLING SYSTEM The RANGER® 305D is equipped with a 6-pin and a 14-pin connector. The 6-pin connector is for connect- WARNING ing the K857 or K857-1 Remote Control or for TIG welding, the K870 foot Amptrol or the K936-3 hand Air to cool the engine is drawn in the base sides Amptrol.

  • Page 12: Welding Terminals

    INSTALLATION When this welder is mounted on a truck or trailer, its CABLE INSTALLATION frame must be electrically bonded to the metal frame Install the welding cables to your RANGER® 305D as of the vehicle. Use a #8 or larger copper wire connect- follows.

  • Page 13: Electrical Device Used With The Ranger 305D

    DO NOT USE THESE DEVICES WITH A RANGER® 305D The Lincoln Electric Company is not responsible for any damage to electrical components improperly connected to the RANGER® 305D. RANGER 305D...

  • Page 14: Standby Power Connections

    INSTALLATION AUXILIARY POWER RECEPTACLES • Install the double-pole, double-throw switch between the power company meter and the premis- es disconnect. Switch rating must be the same or Start the engine and set the “IDLER” control switch to greater than the customerʼs premises disconnect the “High Idle”...

  • Page 15: Premises Wiring

    INSTALLATION CONNECTION OF RANGER® 305D TO PREMISES WIRING 240 VOLT GROUNDED CONDUCTOR POWER 240 Volt 120 VOLT 60 Hz. COMPANY 3-Wire 120 VOLT Service METER NEUTRAL LOAD DOUBLE POLE DOUBLE THROW SWITCH RATING TO BE THE SAME AS OR GREATER THAN PREMISES SERVICE OVERCURRENT PROTECTION.

  • Page 16: Connection Of Lincoln Electric Wire Feeders

    INSTALLATION • Across The-Arc Model: CONNECTION OF LINCOLN ELECTRIC WIRE FEEDERS 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 Connection of LN-7 or LN-8 to the RANGER®...
  • Page 17 A-10 A-10 INSTALLATION Connection of LN-742, Spool Gun (K487-25) and WARNING Cobramatic to RANGER® 305D Connection of the LN-25 to the RANGER® 305D • Shut the welder off. Shut off welder before making any electrical con- nections. • Connect per instructions on the appropriate connec- -------------------------------------------------------------------------------- The LN-25 with or without an internal contactor may tion diagram in Section F.

  • Page 18: Operation

    OPERATION SAFETY PRECAUTIONS • 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 nec- WARNING essary). • See Engine Ownerʼs Manual for specific oil and Do not attempt to use this equipment until you coolant recommendations.

  • Page 19: Welding Controls

    OPERATION FIGURE B.1 WELDING CONTROLS (Figure B.1) 2. DIGITAL OUTPUT METERS- The digital meters allow the output voltage (CV-WIRE mode) 1. OUTPUT CONTROL- or current (CC-STICK,DOWN HILL PIPE and TIG The OUTPUT dial is modes) to be set prior to welding using the OUT- used to preset the output voltage or current as dis- PUT control dial.

  • Page 20: Engine Controls

    OPERATION 10. WIRE FEEDER VOLTMETER SWITCH: 4. ARC CONTROL - The ARC CONTROL dial is active in Matches the polarity of the wire feeder voltmeter to the CV-WIRE, CC-STICK and DOWNHILL PIPE modes, the polarity of the electrode. and has different functions in these modes. This control is not active in the TIG mode.

  • Page 21: Duty Cycle

    OPERATION 15. ELECTRIC FUEL GAUGE- NOTE: If the unit fails to start repeat step 4 through The electric fuel step 7 after waiting 30 seconds gauge gives accurate and reliable indication as to how much fuel is in the fuel tank. CAUTION 16.

  • Page 22: Tig Welding

    OPERATION The Ranger® 305D can be used with a broad range of DC It is recommended that the ARC CONTROL be set to the stick electrodes. The MODE switch provides two stick minimum number without electrode sticking. Start with welding settings as follows: the dial set at 0.

  • Page 23: Wire Welding-Cv

    OPERATION RANGER® 305 D settings when using the K930-2 TIG Module ARC GOUGING with an Amptrol or Arc Start Switch: The RANGER® 305D can be used for limited arc • Set the MODE Switch to the TOUCH START TIG setting. gouging.

  • Page 24: Auxiliary Power

    OPERATION AUXILIARY POWER: 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 If a GFCI receptacle is tripped, See the MAINTE- rating of any plug used with the system must be at NANCE section for detailed information on testing and least equal to the current capacity of the associated resetting the GFCI receptacle.

  • Page 25: Accessories

    ACCESSORIES FIELD INSTALLED OPTIONS / K802-N POWER PLUG KIT ACCESSORIES Provides four 120 volt plugs rated at 20 amps each and one dual voltage, full KVA plug rated at 120/240 volts, 50 amps. K957-1 HEAVY DUTY, TWO WHEEL TRAILER FOR SMALL WELDERS K802-R POWER PLUG KIT For road, off-road and in-plant and yard towing.

  • Page 26: Maintenance

    MAINTENANCE KUBOTA D722 DIESEL ENGINE SAFETY PRECAUTIONS FREQUENCY MAINTENANCE REQUIRED • FILL FUEL TANK. WARNING • CHECK OIL LEVEL. • CHECK COOLANT LEVEL. • Have qualified personnel do all maintenance • CHECK AIR CLEANER ELE- and troubleshooting work. MENT AND HOUSING FOR DIRTY, LOOSE OR DAMAGED PARTS.

  • Page 27: Engine Oil Change

    MAINTENANCE Oil Filter Change Engine Oil Change • Drain the oil. Drain the engine oil while the engine is warm to assure rapid and complete draining. It is recommend- • Remove the oil filter with an oil filter wrench and ed that each time the oil is changed the oil filter be drain the oil into a suitable container.
  • Page 28 MAINTENANCE Service Instructions Service Instructions Single- and Two-Stage Engine Air Cleaners Single- and Two-Stage Engine Air Cleaners Inspect the New Filter for Damage Inspect the New Filter for Damage Remove the Filter Remove the Filter Inspect the new filter carefully, paying attention to Unfasten or unlatch the the inside of the open end, which is the service cover.

  • Page 29: Cooling System

    MAINTENANCE FUEL COOLING SYSTEM WARNING At the end of each dayʼs use, refill the fuel tank to min- imize moisture condensation and dirt contamination in HOT COOLANT can burn skin. the fuel line. Do not overfill; leave room for the fuel to expand.

  • Page 30: Fuel Filter

    MAINTENANCE CLEANING THE BATTERY FUEL FILTER Keep the battery clean by wiping it with a damp cloth 1. Check the fuel filter and fuel pre-filter for water when dirty. If the terminals appear corroded, discon- accumulation or sediment. nect the battery cables and wash the terminals with an ammonia solution or a solution of 1/4 pound (0.1113 2.

  • Page 31: Welder / Generator Maintenance

    MAINTENANCE WELDER / GENERATOR GFCI RECEPTACLE TESTING AND RESET- TING PROCEDURE MAINTENANCE The GFCI receptacle should be properly tested at STORAGE: Store the RANGER® 305D in clean, dry least once every month or whenever it is tripped. To protected areas. properly test and reset the GFCI receptacle: CLEANING: Blow out the generator and controls peri- •...

  • Page 32: Troubleshooting

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

  • Page 33: Troubleshooting

    TROUBLESHOOTING Observe all Safety Guidelines detailed throughout this manual PROBLEMS POSSIBLE RECOMMENDED (SYMPTOMS) CAUSE COURSE OF ACTION Major Physical or Electrical Damage 1. Contact your local Lincoln is Evident. Authorized Field Service Facility. Engine will not "crank". 1. Battery is low, Charge Battery. 2.
  • Page 34 TROUBLESHOOTING Observe all Safety Guidelines detailed throughout this manual PROBLEMS POSSIBLE RECOMMENDED (SYMPTOMS) CAUSE COURSE OF ACTION Engine shuts down while under a 1. High radiator coolant tempera- load. ture. Reduce load if it is exceed- ing machine rating. Add coolant to system if low.
  • Page 35 TROUBLESHOOTING Observe all Safety Guidelines detailed throughout this manual PROBLEMS POSSIBLE RECOMMENDED (SYMPTOMS) CAUSE COURSE OF ACTION Engine will not go to high idle when 1. Auxiliary power load is less than using auxiliary power. 100 watts. Idler may not respond with less than a 100 watt load.
  • Page 36 TROUBLESHOOTING Observe all Safety Guidelines detailed throughout this manual PROBLEMS POSSIBLE RECOMMENDED (SYMPTOMS) CAUSE COURSE OF ACTION No welding power output. 1. Poor work lead connection to work. Make sure work clamp is tightly connected to clean base metal. 2. "Weld Terminals" switch in wrong position.
  • Page 37 TROUBLESHOOTING Observe all Safety Guidelines detailed throughout this manual PROBLEMS POSSIBLE RECOMMENDED (SYMPTOMS) CAUSE COURSE OF ACTION The welding arc is “cold.” The weld- 1. Make sure the MODE selector ing arc is not stable or is not satis- switch is in the correct position for factory.
  • Page 38 DIAGRAMS RANGER® 305D...
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  • Page 45 DIAGRAMS RANGER® 305D...
  • Page 46 DIAGRAMS RANGER® 305D...
  • Page 47 F-10 F-10 DIAGRAMS ENHANCED DIAGRAM RANGER® 305D...
  • Page 48 F-11 F-11 DIMENSION PRINT RANGER® 305D...
  • Page 49 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.

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