Embed Size (px)
Citation preview
Operator’s Manual
RANGER ® 305D (CE)
Register your machine: www.lincolnelectric.com/register
Authorized Service and Distributor Locator: www.lincolnelectric.com/locator
IM971-C | Issue D ate Mar-17
© Lincoln Global, Inc. All Rights Reserved.
For use with machines having Code Numbers:
11458, 11459, 11587, 12486,12681
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.comA Lincoln Service Representative will contact you no later than the following business day.
For Service outside the USA: Email: [email protected]
Save for future reference
Date Purchased
Code: (ex: 10859)
Serial: (ex: U1060512345)
THANK YOU FOR SELECTING A QUALITY PRODUCT BY LINCOLN ELEC TRIC.
PLEASE EXAMINE CARTON AND EQUIPMENT FORDAMAGE IMMEDIATELY
When this equipment is shipped, title passes to the purchaserupon receipt by the carrier. Consequently, claims for materialdamaged in shipment must be made by the purchaser against thetransportation company at the time the shipment is received.
SAFETY DEPENDS ON YOU
Lincoln arc welding and cutting equipment is designed and builtwith safety in mind. However, your overall safety can be increasedby proper installation ... and thoughtful operation on your part. DO NOT INSTALL, OPERATE OR REPAIR THIS EQUIPMENT WITHOUT READING THIS MANUAL AND THE SAFETYPRECAUTIONS CONTAINED THROUGHOUT. And, most importantly,think before you act and be careful.
This statement appears where the information must be followedexactly to avoid serious personal injury or loss of life.
This statement appears where the information must be followedto avoid minor personal injury or damage to this equipment.
KEEP YOUR HEAD OUT OF THE FUMES.
DON’T get too close to the arc.Use corrective lenses if necessaryto stay a reasonable distanceaway from the arc.
READ and obey the Safety DataSheet (SDS) and the warning labelthat appears on all containers ofwelding materials.
USE ENOUGH VENTILATION orexhaust at the arc, or both, tokeep the fumes and gases from your breathing zone and the general area.
IN A LARGE ROOM OR OUTDOORS, natural ventilation may beadequate if you keep your head out of the fumes (See below).
USE NATURAL DRAFTS or fans to keep the fumes away from your face.
If you de velop unusual symptoms, see your supervisor. Perhaps the welding atmosphere and ventilation system should be checked.
WEAR CORRECT EYE, EAR & BODY PROTECTION
PROTECT your eyes and face with welding helmetproperly fitted and with proper grade of filter plate(See ANSI Z49.1).
PROTECT your body from welding spatter and arcflash with protective clothing including woolenclothing, flame-proof apron and gloves, leatherleggings, and high boots.
PROTECT others from splatter, flash, and glarewith protective screens or barriers.
IN SOME AREAS, protection from noise may be appropriate.
BE SURE protective equipment is in good condition.
Also, wear safety glasses in work areaAT ALL TIMES.
SPECIAL SITUATIONS
DO NOT WELD OR CUT containers or materials which previouslyhad been in contact with hazardous substances unless they areproperly cleaned. This is extremely dangerous.
DO NOT WELD OR CUT painted or plated parts unless specialprecautions with ventilation have been taken. They can releasehighly toxic fumes or gases.
Additional precautionary measures
PROTECT compressed gas cylinders from excessive heat,mechanical shocks, and arcs; fasten cylinders so they cannot fall.
BE SURE cylinders are never grounded or part of an electrical circuit.
REMOVE all potential fire hazards from welding area.
ALWAYS HAVE FIRE FIGHTING EQUIPMENT READY FORIMMEDIATE USE AND KNOW HOW TO USE IT.
WARNING
CAUTION
Safety 01 of 04 - 5/16/2018
SECTION A:WARNINGS
CALIFORNIA PROPOSITION 65 WARNINGS
WARNING: Breathing diesel engine exhaustexposes you to chemicals known to the Stateof California to cause cancer and birth defects,
or other reproductive harm.• Always start and operate the engine in a
well-ventilated area.• If in an exposed area, vent the exhaust to the outside.• Do not modify or tamper with the exhaust system. • Do not idle the engine except as necessary.For more information go to www.P65 warnings.ca.gov/diesel
WARNING: This product, when used for welding or
cutting, produces fumes or gases which contain
chemicals known to the State of California to cause
birth defects and, in some cases, cancer. (California
Health & Safety Code § 25249.5 et seq.)
WARNING: Cancer and Reproductive Harm
www.P65warnings.ca.gov
ARC WELDING CAN BE HAZARDOUS. PROTECTYOURSELF AND OTHERS FROM POSSIBLE SERIOUSINJURY OR DEATH. KEEP CHILDREN AWAY. PACEMAKER WEARERS SHOULD CONSULT WITHTHEIR DOCTOR BEFORE OPERATING.
Read and understand the following safety highlights. Foradditional 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 AREPERFORMED ONLY BY QUALIFIED INDIVIDUALS.
FOR ENGINE POWEREDEQUIPMENT.
1.a. Turn the engine off before troubleshootingand maintenance work unless themaintenance work requires it to be running.
1.b. Operate engines in open, well-ventilated areas or vent the engineexhaust fumes outdoors.
1.c. Do not add the fuel near an open flame weldingarc or when the engine is running. Stop theengine and allow it to cool before refueling toprevent spilled fuel from vaporizing on contact
with hot engine parts and igniting. Do not spill fuel when fillingtank. If fuel is spilled, wipe it up and do not start engine untilfumes 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 orrepairing equipment.
1.e. In some cases it may be necessary to remove safety guards toperform required maintenance. Remove guards only whennecessary and replace them when the maintenance requiringtheir removal is complete. Always use the greatest care whenworking near moving parts.
1.f. Do not put your hands near the engine fan. Do not attempt tooverride the governor or idler by pushing on the throttle controlrods while the engine is running.
1.g. To prevent accidentally starting gasoline engines while turningthe engine or welding generator during maintenance work,disconnect the spark plug wires, distributor cap or magneto wireas appropriate.
1.h. To avoid scalding, do not remove the radiatorpressure cap when the engine is hot.
ELECTRIC ANDMAGNETIC FIELDS MAYBE DANGEROUS
2.a. Electric current flowing through any conductorcauses 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 physicianbefore welding.
2.c. Exposure to EMF fields in welding may have other health effectswhich are now not known.
2.d. All welders should use the following procedures in order tominimize exposure to EMF fields from the welding circuit:
2.d.1. Route the electrode and work cables together - Securethem 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 workcables. If the electrode cable is on your right side, thework cable should also be on your right side.
2.d.4. Connect the work cable to the workpiece as close as pos-sible to the area being welded.
2.d.5. Do not work next to welding power source.
SAFETY
Safety 02 of 04 - 5/16/2018
ELECTRIC SHOCK CAN KILL.
3.a. The electrode and work (or ground) circuits areelectrically “hot” when the welder is on. Donot 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 areaof 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 weldinggun are also electrically “hot”.
3.d. Always be sure the work cable makes a good electricalconnection with the metal being welded. The connection shouldbe 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 andwelding machine in good, safe operating condition. Replacedamaged insulation.
3.g. Never dip the electrode in water for cooling.
3.h. Never simultaneously touch electrically “hot” parts of electrodeholders connected to two welders because voltage between thetwo can be the total of the open circuit voltage of bothwelders.
3.i. When working above floor level, use a safety belt to protectyourself from a fall should you get a shock.
3.j. Also see It ems 6.c. and 8.
ARC RAYS CAN BURN.
4.a. Use a shield with the proper filter and cover plates to protect youreyes from sparks and the rays of the arc when welding orobserving open arc welding. Headshield and filter lens shouldconform to ANSI Z87. I standards.
4.b. Use suitable clothing made from durable flame-resistant materialto protect your skin and that of your helpers from the arc rays.
4.c. Protect other nearby personnel with suitable, non-flammablescreening and/or warn them not to watch the arc nor exposethemselves to the arc rays or to hot spatter or metal.
FUMES AND GASESCAN BE DANGEROUS.
5.a. Welding may produce fumes and gaseshazardous to health. Avoid breathing thesefumes and gases. When welding, keep your head out of the fume.Use enough ventilation and/or exhaust at the arc to keep fumesand gases away from the breathing zone. When welding
hardfacing (see instructions on container or SDS)
or on lead or cadmium plated steel and other
metals or coatings which produce highly toxic
fumes, keep exposure as low as possible and
within applicable OSHA PEL and ACGIH TLV limits
using local exhaust or mechanical ventilation
unless exposure assessments indicate otherwise.
In confined spaces or in some circumstances,
outdoors, a respirator may also be required.
Additional precautions are also required when
welding
on galvanized steel.
5. b. The operation of welding fume control equipment is affected byvarious factors including proper use and positioning of theequipment, maintenance of the equipment and the specificwelding procedure and application involved. Worker exposurelevel should be checked upon installation and periodicallythereafter to be certain it is within applicable OSHA PEL andACGIH TLV limits.
5.c. Do not weld in locations near chlorinated hydrocarbon vaporscoming from degreasing, cleaning or spraying operations. Theheat and rays of the arc can react with solvent vapors to formphosgene, a highly toxic gas, and other irritating products.
5.d. Shielding gases used for arc welding can displace air and causeinjury or death. Always use enough ventilation, especially inconfined areas, to insure breathing air is safe.
5.e. Read and understand the manufacturer’s instructions for thisequipment and the consumables to be used, including theSafety Data Sheet (SDS) and follow your employer’s safetypractices. SDS forms are available from your weldingdistributor or from the manufacturer.
5.f. Also see item 1.b.
SAFETY
Safety 03 of 04 - 5/16/2018
WELDING AND CUTTINGSPARKS CAN CAUSEFIRE OR EXPLOSION.
6.a. Remove fire hazards from the welding area. Ifthis is not possible, cover them to prevent the welding sparksfrom starting a fire. Remember that welding sparks and hotmaterials from welding can easily go through small cracks andopenings 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, specialprecautions 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 istouching the work or ground. Accidental contact can causeoverheating and create a fire hazard.
6.d. Do not heat, cut or weld tanks, drums or containers until theproper 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 though they have been“cleaned”. For information, purchase “Recommended SafePractices for the Preparation for Welding and Cutting ofContainers 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 orwelding. They may explode.
6.f. Sparks and spatter are thrown from the welding arc. Wear oil freeprotective garments such as leather gloves, heavy shirt, cufflesstrousers, high shoes and a cap over your hair. Wear ear plugswhen welding out of position or in confined places. Always wearsafety glasses with side shields when in a welding area.
6.g. Connect the work cable to the work as close to the welding areaas practical. Work cables connected to the building framework orother locations away from the welding area increase thepossibility of the welding current passing through lifting chains,crane cables or other alternate circuits. This can create firehazards or overheat lifting chains or cables until they fail.
6.h. Also see item 1.c.
6.I. Read and follow NFPA 51B “Standard for Fire Prevention DuringWelding, Cutting and Other Hot Work”, available from NFPA, 1Batterymarch Park, PO box 9101, Quincy, MA 022690-9101.
6.j. Do not use a welding power source for pipe thawing.
CYLINDER MAY EXPLODE IFDAMAGED.
7.a. Use only compressed gas cylinders containingthe correct shielding gas for the process usedand properly operating regulators designed forthe gas and pressure used. All hoses, fittings,etc. should be suitable for the application andmaintained in good condition.
7.b. Always keep cylinders in an upright position securely chained toan undercarriage or fixed support.
7.c. Cylinders should be located:
• Away from areas where they may be struck or subjectedto physical damage.
• A safe distance from arc welding or cutting operationsand any other source of heat, sparks, or flame.
7.d. Never allow the electrode, electrode holder or any otherelectrically “hot” parts to touch a cylinder.
7.e. Keep your head and face away from the cylinder valve outletwhen opening the cylinder valve.
7.f. Valve protection caps should always be in place and hand tightexcept 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 forSafe Handling of Compressed Gases in Cylinders,” available fromthe Compressed Gas Association, 14501 George Carter WayChantilly, VA 20151.
FOR ELECTRICALLYPOWERED EQUIPMENT.
8.a. Turn off input power using the disconnectswitch at the fuse box before working on the equipment.
8.b. Install equipment in accordance with the U.S. National ElectricalCode, all local codes and the manufacturer’s recommendations.
8.c. Ground the equipment in accordance with the U.S. NationalElectrical Code and the manufacturer’s recommendations.
Refer to
http://www.lincolnelectric.com/safety
for additional safety information.
SAFETY
Safety 04 of 04 - 5/16/2018
vsafetyv!
!
!
!!! """###$$$%%%###&&&'''((()))***!!!"""+++&&&)))(((%%%(((""",,,)))+++!!!!!! "-./01023/!4-!25615.70/8!9!:5615.70/;/<=-<2>-060?@6?!"#$%&#'%&()*!%+!'&#,,)*!-.!/01!&2345!6477489:7!;!<=>.<!'5/??4@!A4B4C!'DE1!F!G>!HG!I.!>G!GG!;!+/C!F!G>!HG!I.!>-!HJ!
K9LM45!!!!!!!!!!!!!F!"#$%&'!(!"#$$)&! !"""#$%&'"$$%(!&$)
N/79O/PQ1!F!*+,&-.+/0!(!1)&20)33)&!
*+,-.*,)/*/-01+-)-.234,5)--=G>!*/:7Q!AE/:5!#04R!A")S)"#KT!%U:2!JJ><<;>>..!V*#) K2Q:O:4B!M2BW!!!!!F!
4&5+/-2$)!/'0-6-%!!7#220)33)/8)!9&:620)33)!
,6)""7$))
#??E:P/7Q!!F!;)$+/8)#&!(!7/0&+520)33)&!
*+,-.*,)/*/-01+-)-.234,5)--=G>!*/:7Q!AE/:5!#04R!A")S)"#KT!%U:2!JJ><<;>>..!V*#)
)A!T:54PQ:04!/??E:P/ME4!F!;-&).0-<)!=>!+??3-.+,3)!(!7/@)/8,+&)!>ABC-.D03-/)!
!"""&$%&/-)89:;<;=:)>?)!""@&AA&/-)
X9/5/7Q44B!@297B!?2Y45!E404E!F!*B4)C7):D!"-<)+#!8)!?#-22+/.)!+.'#20-E#)!5+&+/0-!(!A+&+/0-)&0)&!2.D+33)-20#/52?)5)3! !"#$%#&''()%*#"+#,(-."/0&1!
A27O25L:QW!/@@4@@L47Q!?52P4B954!F!!9&'.%8#&)!8F%<+3#+0-'/!8)!3+!.'/6'&$-0%!(!G'/6'&$-0H02,)@)&0#/52<)&6+D&)/!
4EE=F)G+)
T4@P5:?Q:27!2O!489:?L47Q!!;)2.&-?0-'/!8)!3I%E#-?)$)/0!(!J)2.D&)-,#/5!8)2!5)&H02!,K@L!8)&!M+2.D-/)!N!
;! 'W?4!2O!489:?L47Q!!!!F! B=H:;EI)I=E=JKL9J) T:54PQ:04!B4O:7:Q:27!:Q4L!F! @7)
;! N/Z4!;!'5/B4!7/L4!F! *+,-.*,) 'W?4!;!N2B4E!F!
- Drive engine Moteur / Motoren :!
14,'/1)M"@N)
OP)!!7C#$)9J)#!)9J)#MQ)
Make :! PRD.04) N2B4E!;!'W?4!F! N7!!)
Net installed power : ! $$SC)TB) Rated speed :! M""")r.p.m) )7453W!F! N;=U=H)
;! %QU45!5489:54B!Q4PU7:P/E!PU/5/PQ45:@Q:P@!F! 3=H)V)7S@)TB)
&4O4547P4!B2P9L47Q/Q:27!;'.#$)/02!8)!&%6%&)/.)!(!9&:65&#/83+5)/!F)
;! "/M25/Q25W!54?25Q!F!C+??'&0!8)!3+,'&+0'-&)!(!9&:6,)&-.D0!
*+,-.*,W)
R$"@"C"AA@(&7&A)
%)XKEYKJ?)!""()
N4/@954B!@297B!?2Y45!E404E!F!!"-<)+#!8)!?#-22+/.)!+.'#20-E#)!$)2#&%!(!A)$)22)/)&!2.D+33)-20#/52?)5)3!
C():DO4Q)[T4O:7:Q:27!F!#5Q1!H14!\!
;! %QU45!Q4PU7:P/E!B2P9L47Q/Q:27!F! *+,-.*,)W)"!)Z=>JYKJ?)!""C))))*,/)W)P"M"$CA!
'U:@!P45Q:O:P/Q4!:@!:@@94B!97B45!QU4!O2EE2Y:73!P27B:Q:27@!F!
>1!(Q! /??E:4@! 27EW! Q2! QU4! 54P25B4B! QW?4R! Y:QU29Q! /7W!PU/734! :7! QU4! /M204! 54O4547P4B! Q4PU7:P/E! O:E4R!@9M]4PQ4B!Q2!QU4!"K)!4C/L:7/Q:271!
-1!(Q! :L?E:4@! QU/Q! /! O2EE2Y;9?! 2O! QU4! L/79O/PQ95:73! :@!?45O25L4B!Y:QU!/!"K)!P27Q52ER!P/55:4B!29Q!/Q!E4/@Q!27P4!4045W! QU544! W4/5@1! ^:QU29Q! QU:@! P27Q52E! 25! :7! P/@4! 2O!727P27O25L:QWR!QU4!"K)!:@!M297B!Q2!!:7O25L!QU4!+547PU!N:7:@Q5W!:7!PU/534!2O!470:527L47Q1!
=)!.)&0-6-.+0!)20!8%3-<&%!8+/2!3)2!.'/8-0-'/2!2#-<+/0)2!N!
OL!P3! /)! 2I+??3-E#)! E#I+#! 0Q?)! $)/0-'//%R! 2+/2!.D+/5)$)/0! 8+/2! 3)! 8'22-)&! 0).D/-E#)! 2'#$-2! +#!S">!)0!&%6%&)/.%!.-B8)22#2L!
TL!P3!-$?3-E#)!E#F#/)!2#&<)-33+/.)!8)!?&'8#.0-'/!)20!$-2)!)/!?3+.)!+<).!#/!.'/0&U3)!?+&! 3)!S">!+#!$'-/2!0'#2!3)2! V! +/2L! W+/2! .)! .'/0&U3)! '#! )/! .+2! 8)! /'/!.'/6'&$-0%R! 3)! S">! )20! )/5+5%! X! )/! -/6'&$)&! 3)!M-/-20Y&)!*&+/Z+-2!.D+&5%!8)!3I>/<-&'//)$)/0L!
;-)2)! J)2.D)-/-5#/5! @-&8! #/0)&! 6'35)/8)/! J)8-/5#/5)/!+#25)20)330N!
OL!W-)! 5-30! 6:&! 8+2! 5)?&:60)! J+#$#20)&R! 'D/)! [/8)&#/5! 8)&!0).D/-2.D)/!;'\#$)/0+0-'/!8-)!8)$!S">!:,)&$-00)30!@#&8)L!
TL!>-/! ],)&@+.D#/52<)&6+D&)/! 8)&! 1)&20)33#/5! @#&8)!8#&.D5)6:D&0!$-0!)-/)&!],)&?&:6#/5!<'/!S">!!$-/8)20)/2!+33)!V! ^+D&)L! 4D/)! 8-)2)! ],)&?&:6#/5! '8)&! -$! *+33)! )-/)&!_/\'/6'&$-0H0!D+0!2-.D!S">!<)&?63-.D0)0!8-)2)/!`#20+/8!8)$!6&+/Ka2-2.D)/!M-/-20)&-#$!6:&!_$@)30!K#!$)38)/L!
0JK[[=U\)!@)2KJ]^)!""C)
) _=K:):=H=IKL=)<9J)K]9YUL;])
) K]L;`;L?)9<)Z-!4):=[KJL8=EL) 0=]^E;]KH)1=U[9EU;>H=).<<;]=J)
) )
) )
) )
) )
) X=KE#,9aH)NR1.-_/1) 3KLJ;]T)-/**41N!
+25L!F!A45Q:O-G>J#I,BO_&40>>)
,9ME:P/Q:27!25!54?52B9PQ:27!2O!QU:@!B2P9L47Q!:@!/EE2Y4B!27EW!:7!QU4!O25L!2O!/7!:7Q435/E!?U2Q2P2?W!!;!!+:E4!`GHG>.=!;!T2P9L47Q!TN*(_>!;!,/34!>_>!
viisafetyvii
Electromagnetic Compatibility (EMC)
ConformanceProducts displaying the CE mark are in conformity with European Community Council Directive of 15 Dec2004 on the approximation of the laws of the Member States relating to electromagnetic compatibility,2004/108/EC. It was manufactured in conformity with a national standard that implements a harmonizedstandard: EN 60974-10 Electromagnetic Compatibility (EMC) Product Standard for Arc Welding Equipment.It is for use with other Lincoln Electric equipment. It is designed for industrial and professional use.
IntroductionAll electrical equipment generates small amounts of electromagnetic emission. Electrical emission may betransmitted through power lines or radiated through space, similar to a radio transmitter. When emissionsare received by other equipment, electrical interference may result. Electrical emissions may affect manykinds of electrical equipment; other nearby welding equipment, radio and TV reception, numerical controlledmachines, telephone systems, computers, etc. Be aware that interference may result and extra precautionsmay be required when a welding power source is used in a domestic establishment.
Installation and UseThe user is responsible for installing and using the welding equipment according to the manufacturer’sinstructions. If electromagnetic disturbances are detected then it shall be the responsibility of the user of thewelding equipment to resolve the situation with the technical assistance of the manufacturer. In some casesthis remedial action may be as simple as earthing (grounding) the welding circuit, see Note. In other cases itcould involve construction of an electromagnetic screen enclosing the power source and the work completewith associated input filters. In all cases electromagnetic disturbances must be reduced to the point wherethey are no longer troublesome.
Note: The welding circuit may or may not be earthed for safety reasons according to nationalcodes. Changing the earthing arrangements should only be authorized by a person who iscompetent to access whether the changes will increase the risk of injury, e.g., by allowingparallel welding current return paths which may damage the earth circuits of other equipment.
Assessment of AreaBefore installing welding equipment the user shall make an assessment of potential electromagnetic prob-lems in the surrounding area. The following shall be taken into account:
a) other supply cables, control cables, signaling and telephone cables; above, below and adjacent to thewelding equipment;
b) radio and television transmitters and receivers;
c) computer and other control equipment;
d) safety critical equipment, e.g., guarding of industrial equipment;
e) the health of the people around, e.g., the use of pacemakers and hearing aids;
f) equipment used for calibration or measurement
g) the immunity of other equipment in the environment. The user shall ensure that other equipment beingused in the environment is compatible. This may require additional protection measures;
h) the time of day that welding or other activities are to be carried out.
viiisafetyviii
Electromagnetic Compatibility (EMC)
The size of the surrounding area to be considered will depend on the structure of the building and otheractivities that are taking place. The surrounding area may extend beyond the boundaries of the premises.
Methods of Reducing Emissions
Mains SupplyWelding equipment should be connected to the mains supply according to the manufacturer’s recommenda-tions. If interference occurs, it may be necessary to take additional precautions such as filtering of the mainssupply. Consideration should be given to shielding the supply cable of permanently installed welding equip-ment, in metallic conduit or equivalent. Shielding should be electrically continuous throughout its length. Theshielding should be connected to the welding power source so that good electrical contact is maintainedbetween the conduit and the welding power source enclosure.
Maintenance of the Welding EquipmentThe welding equipment should be routinely maintained according to the manufacturer’s recommendations.All access and service doors and covers should be closed and properly fastened when the welding equip-ment is in operation. The welding equipment should not be modified in any way except for those changesand adjustments covered in the manufacturers instructions. In particular, the spark gaps of arc striking andstabilizing devices should be adjusted and maintained according to the manufacturer’s recommendations.
Welding CablesThe welding cables should be kept as short as possible and should be positioned close together, running ator close to floor level.
Equipotential BondingBonding of all metallic components in the welding installation and adjacent to it should be considered.However, metallic components bonded to the work piece will increase the risk that the operator couldreceive a shock by touching these metallic components and the electrode at the same time. The operatorshould be insulated from all such bonded metallic components.
Earthing of the WorkpieceWhere the workpiece is not bonded to earth for electrical safety, not connected to earth because of its sizeand position, e.g., ships hull or building steelwork, a connection bonding the workpiece to earth may reduceemissions in some, but not all instances. Care should be taken to prevent the earthing of the workpieceincreasing the risk of injury to users, or damage to other electrical equipment. Where necessary, the connec-tion of the workpiece to earth should be made by a direct connection to the workpiece, but in some countrieswhere direct connection is not permitted, the bonding should be achieved by suitable capacitance, selectedaccording to national regulations.
Screening and ShieldingSelective screening and shielding of other cables and equipment in the surrounding area may alleviate prob-lems of interference. Screening of the entire welding installation may be considered for special applications1.
_________________________
1 Portions of the preceding text are contained in EN 60974-10: “Electromagnetic Compatibility (EMC) prod-uct standard for arc welding equipment.”
xx taBLe Of CONteNts Page
Installation.......................................................................................................................section a Technical Specifications.......................................................................................................A-1
Safety Precautions........................................................................................................ A-2 Location and Ventilation................................................................................................A-2 Stacking........................................................................................................................ A-2 Angle of Operation........................................................................................................ A-2
Lifting.............................................................................................................................A-2 High Altitude Operation................................................................................................. A-2 High Temperature Operation........................................................................................ A-2
Cold Weather Operation............................................................................................... A-2 Towing...........................................................................................................................A-3 Vehicle Mounting...........................................................................................................A-3 Pre-Operation Engine Service..............................................................................................A-3 Oil..................................................................................................................................A-3 Fuel............................................................................................................................... A-3 Engine Coolant..............................................................................................................A-4 Battery Connections......................................................................................................A-4 Muffler Outlet Pipe........................................................................................................ A-4 Spark Arrester............................................................................................................... A-4
Remote Control............................................................................................................. A-4 Electrical Connections..........................................................................................................A-4 Machine Grounding.......................................................................................................A-4 Welding Terminals........................................................................................................ A-5
Welding Output Cables................................................................................................. A-5Cable Installation...........................................................................................................A-5
Auxiliary Power ....................................................................................................................A-5 Standby Power Connections................................................................................................ A-5
Connection of Lincoln Electric Wire Feeders................................................................A-6,A-7________________________________________________________________________________
Operation.........................................................................................................................section B Safety Precautions .............................................................................................................. B-1
General Description..............................................................................................................B-1 For Auxiliary Power.............................................................................................................. B-1 Engine Operation..................................................................................................................B-1 Break in Period.....................................................................................................................B-1 Add Fuel............................................................................................................................... B-1 Fuel ......................................................................................................................................B-1 Welder Controls............................................................................................................ B-2 Engine Controls.............................................................................................................B-3 Starting and Stopping the Engine........................................................................... B-3, B4 Stopping ....................................................................................................................... B-4 Welder Operation................................................................................................................. B-5 Duty Cycle.....................................................................................................................B-5 Constant Current (Stick) Welding..................................................................................B-5 Downhill Pipe (Stick) Welding....................................................................................... B-5 Tig Welding................................................................................................................... B-5 Typical Current Ranges for Tungsten Electrodes......................................................... B-5 Wire Welding-CV...........................................................................................................B-6 Arc Gouging.................................................................................................................. B-6 Auxiliary Power............................................................................................................. B-6________________________________________________________________________________
accessories.....................................................................................................section C Field Installed Options / Accessories ...............................................................................C-1________________________________________________________________________________
xi xitaBLe Of CONteNtsMaintenance......................................................................................................section D
Safety Precautions................................................................................................ D-1Routine Maintenance............................................................................................ D-1
Engine Maintenance Components........................................................................ D-1 Kubota Diesel Engine............................................................................................D-1 Engine Oil Change..........................................................................................D-2 Engine Oil Refill Capacities.............................................................................D-2 Engine Oil Filter Change.................................................................................D-2 Air Cleaner Service.........................................................................................D-2 Service Instructions And Installation Tips for Engine Air Filter....................... D-3 Cooling System..................................................................................................... D-4 Fan Belt...........................................................................................................D-4 Fuel................................................................................................................. D-4 Bleeding the Fuel System............................................................................... D-4 Fuel Filter........................................................................................................ D-5
Engine Adjustment.......................................................................................... D-5Battery Maintenance....................................................................................... D-5
Servicing Optional Spark Arrestor................................................................... D-5 Welder / Generator Maintenance........................................................................ D-6 Storage........................................................................................................... D-6 Cleaning..........................................................................................................D-6 Brush Removal and Replacement.................................................................. D-6________________________________________________________________________ troubleshooting.............................................................................................. section e How to Use Troubleshooting Guide.......................................................................E-1 Troubleshooting Guide............................................................................ E-2 thru E-6________________________________________________________________________ Diagrams and Dimension Print...................................................................... section f________________________________________________________________________ Parts List.................................................................................................................P-494________________________________________________________________________
RaNGeR® 305D (Ce)
(1) Output rating in watts is equivalent to volt-amperes at unity power factor. Output voltage is within ± 10% at all loads up to rated capacity. When welding,available auxiliary power will be reduced.
(2) To top of enclosure, add 152mm (6 “) to top of exhaust elbow.(3) Engine warranty may vary outside of the USA. (See Engine warranty for details)(4) Center-Tapped to ground.
a-1INstaLLatION a-1teCHNICaL sPeCIfICatIONs - RaNGeR® 305D (Ce)(K2279-1, K2279-2, K2279-3)
Make/Model Description speed (RPM) Displacement starting Capacities cu. in. (cu. cm.) system
3 cylinder, 4 stroke 43.88(789) 12VDC Battery & Fuel: 15.9 HP starter 45L (12 US.gal.)
(12 KW) High Idle 3100 Bore x Stroke inch (mm) Oil:Kubota(3) Net intermittent 3.2L(3.4 US. Qts.)D722 3000 RPM Full Load 3000 2.64 x 2.68 (Group 58; 550 Radiator Coolant:
naturally aspirated (67 x 68 mm) cold crank amps) 3.6L(3.85 U Qts)water cooled Low Idle 2200 Battery Charger Diesel engine (3.6L)
INPUt - DIeseL eNGINe
RateD OUtPUt @ 40° C (104° f) - WeLDeR
HeIGHt WIDtH DePtH WeIGHt909mm 546mm 1524mm 30.0 in.(2) 21.50 in 60.0 in.
LUBRICatION eMIssIONs fUeL systeM GOVeRNORFull Pressure Certified to Mechanical Fuel Pump, Auto air bleedwith Full Flow Filter EPA Tier 4 system Electric shutoff solenoid Indirect fuel injector. Mechanical Governor
Compliant aIR CLeaNeR eNGINe IDLeR MUffLeR eNGINe PROteCtION
Low noise Muffler: Shutdown on low oilSingle Element Automatic Idler Made from long life, aluminized steel. pressure & engine
temperatureeNGINe WaRRaNty: 2 year complete (parts and labor) 3rd. year major components (parts and labor)(3)
Welding Process
DC Constant CurrentDC Pipe CurrentTouch-Start®TIG
DC Constant Voltage
Output Range
20 TO 305 AMPS40 TO 300 AMPS20 TO 250 AMPS14 TO 29 VOLTS
Max. Weld OCV@Rated Load RPM
60 Volts
Welding OutputCurrent/Voltage/Duty Cycle
250A / 30V / 100%250A / 30V / 100%250A / 20V / 100%250A / 27V / 100%
auxiliary Power (1)
8,500 Watts Peak, / 8,000 Watts Continuous, 50 Hz 230/400 Volts - 3 Phasesound Levels
Sound Power: 97 dB LwaPHysICaL DIMeNsIONs
eNGINe
MODeL NUMBeRReceptacles
Residual Current Device (RCD)
Circuit Breakers (Thermal/Magnetic)
K2279-1, K2279-3 (UK)400V (3 Ph) x 1230V (1 Ph) x 1
115V x 1(4)
14 Pin Connector6 Pin Connector4-pole, 25 Amp
(30mA trip current)3 Phase, 16 Amp x 11 Phase, 15 Amp x 5
K2279-2 (eUROPe)400V (3 Ph) x 1230V (1 Ph) x 214 Pin Connector6 Pin Connector
4-pole, 25 Amp(30mA trip current)
3 Phase, 20 Amp x 11 Phase, 15 Amp x 4
RateD OUtPUt @ 40° C (104° f) - GeNeRatOR
341kg. (752lbs.)
liters (12 gallons).LIftINGThe machine weighs approximately 374 kg. (824 lbs)with a full tank of fuel. A lift bail is mounted to themachine and should always be used when lifting the
machine.HIGH aLtItUDe OPeRatIONAt higher altitudes, output derating may be necessary. For max-imum rating, derate the machine 2.5% to 3.5% for every 305m(1000ft.). Due to new EPA and other local emissions regula-tions, modifications to the engine for high altitude are restrictedwithin the United States and some European Countries. Useabove 1828m (6000 ft.) may be limited due to poor engine per-formance or excessive exhaust smoke. An authorized Kubotaengine field service shop should be contacted to determine ifany adjustments can be made for operation in higher elevationslocally.
HIGH teMPeRatURe OPeRatIONAt temperatures above 40°C,welder output derating is neces-sary. For maximum output ratings, derate the welder output 2volts for every 10°C above 40°C.
Cold weather starting:With a fully charged battery and the proper oil, theengine should start satisfactorily down to about -15°C(5°F). If the engine must be frequently started at orbelow -5°C (23°F), it may be desirable to install cold-starting aides. The use of No. 1D diesel fuel is recom-mended in place of No. 2D at temperatures below-5°C (23°F). Allow the engine to warm up before
applying a load or switching to high idle.Note: Extreme cold weather starting may requirelonger glow plug operation.Under no conditions should ether or other startingfluids be used!------------------------------------------------------------------------
WaRNING
a-2INstaLLatION
RaNGeR® 305D (Ce)
a-2safety PReCaUtIONs
Only qualified personnel should install, use, or service this equipment.
LOCatION aND VeNtILatION
The welder should be located to provide an unrestrict-ed flow of clean, cool air to the cooling air inlets and toavoid restricting the cooling air outlets. Also, locate thewelder so that the engine exhaust fumes are properlyvented to an outside area.
staCKINGRANGER® 305D (CE) machines cannot be stacked.
aNGLe Of OPeRatIONEngines are designed to run in the level conditionwhich is where the optimum performance is achieved.The maximum angle of continuous operation is 20degrees in all directions, 35 degrees Intermittent (lessthan 10 minutes continuous) in all directions. If theengine is to be operated at an angle, provisions mustbe made for checking and maintaining the oil level atthe normal (FULL) oil capacity in the crankcase.
When operating the welder at an angle, the effectivefuel capacity will be slightly less than the specified 45
Do not attempt to use this equipment until youhave thoroughly read the engine manufacturer’smanual supplied with your welder. It includesimportant safety precautions, detailed enginestarting, operating and maintenance instructions,and parts lists.------------------------------------------------------------------------
eLeCtRIC sHOCK can kill.• Do not touch electrically live parts or
electrode with skin or wet clothing.• Insulate yourself from work and
ground• always wear dry insulating gloves.------------------------------------------------------------------------eNGINe eXHaUst can kill.• Use in open, well ventilated areas or
vent exhaust outside.------------------------------------------------------------------------
MOVING PaRts can injure.• Do not operate with doors open or
guards off.• stop engine before servicing.• Keep away from moving parts.
------------------------------------------------------------------------see additional warning information atfront of this operator’s manual.
WaRNING
• Lift only with equipment of ade-quate lifting capacity.
• Be sure machine is stable when lift-ing.
• Do not lift this machine using liftbail if it is equipped with a heavyaccessory such as trailer or gascylinder.
faLLING • Do not lift machine if lift bail is eQUIPMeNt can damaged.
cause injury. • Do not operate machine while suspended from lift bail.--------------------------------------------------------------------------------
WaRNING
a-3INstaLLatION
RaNGeR® 305D (Ce)
a-3
tOWINGCheck with distributor for the recommended trailer for use withthis equipment for road, in-plant and yard towing by a vehicle. Ifthe user adapts a non-Lincoln trailer, he must assume responsi-bility that the method of attachment and usage does not resultin a safety hazard nor damage the welding equipment. Some ofthe factors to be considered are as follows:
1. Design capacity of trailer vs. weight of Lincoln equipment andlikely 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 frame-work.
3. Proper placement of the equipment on the trailer to insurestability side to side and front to back when being movedand when standing by itself while being operated or ser-viced.
4. Typical conditions of use, i.e., travel speed; roughness of sur-face on which the trailer will be operated; environmental con-ditions; like maintenance.
5. Conformance with laws in nation / region to be used.
PRe-OPeRatION eNGINe seRVICeREAD the engine operating and maintenance instruc-tions supplied with this machine.
• stop engine and allow to cool before fueling.• Do not smoke when fueling.• fill fuel tank at a moderate rate and do not over-
fill.• Wipe up spilled fuel and allow fumes to clear
before starting engine.• Keep sparks and flame away from tank.------------------------------------------------------------------------
OIL The machine is shipped with theengine crankcase filled with high quality SAE 10W-30Oil that meets classification CG-4 or CH-4 for dieselengines. Check the oil level before starting theengine. If it is not up to the full mark on the dip stick,add oil as required. Check the oil level every fourhours of running time during the first 50 running hours.Refer to the engine Operator’s Manual for specific oilrecommendations and break-in information. The oilchange interval is dependent on the quality of the oiland the operating environment. Refer to the EngineOperator’s Manual for more details on the proper ser-vice and maintenance intervals.
fUeLUSE DIESEL FUEL ONLY
• fill the fuel tank with clean, fresh fuel. thecapacity of the tank is, about 45 ltr.’s (12 Gal.’s).
NOte: a fuel shut off valve is located on the pre-filter/sediment filter. Which should be inthe closed position when the welder is notoperated for extended periods of time.
------------------------------------------------------------------------
WaRNING
WaRNING
WaRNING
VeHICLe MOUNtING
Improperly mounted concentrated loads maycause unstable vehicle handling and tires or othercomponents to fail.
• Only transport this equipment on serviceablevehicles which are rated and designed for suchloads.
• Distribute, balance and secure loads so vehicleis stable under conditions of use.
• Do not exceed maximum rated loads for compo-nents such as suspension, axles and tires.
• Mount equipment base to metal bed or frame ofvehicle.
• follow vehicle manufacturer’s instructions.------------------------------------------------------------------------
WaRNING
a-4INstaLLatION
RaNGeR® 305D (Ce)
a-4eNGINe COOLING systeM
air to cool the engine is drawn in the base sidesand exhaust through radiator & case back. It isimportant that the intake and exhaust air is notrestricted. allow a minimum clearance of 0.6m (2feet) from the case back and 40cm (16”) fromeither side of the base to a vertical surface.------------------------------------------------------------------------BatteRy CONNeCtION
Use caution as the electrolyte is a strong acid thatcan burn skin and damage eyes.------------------------------------------------------------------------The machine is shipped with the negative batterycable disconnected. Make certain that the RUN-STOPswitch is in the STOP position. Attach the negativebattery cable to the negative battery terminal andtighten using a 13mm socket or wrench. It may behelpful to remove the coolant over-fill bottle. Pull up onbottle to remove from bracket.
NOte: This machine is furnished with a wet chargedbattery; if unused for several months, the battery mayrequire a booster charge. Be careful to charge the bat-tery with the correct polarity.
MUffLeR OUtLet / sPaRK aRRestORIn addition to operating as a Spark Arrestor the SparkArrestor serves as an outlet cover for the muffler aswell as providing additional sound reduction. Removefrom the box and install using the clamp and instruc-tions provided.
an incorrect spark arrestor may lead to damage tothe engine or adversely affect performance.------------------------------------------------------------------------
ReMOte CONtROLThe machine is equipped with a 6-pin and a 14-pinconnector. The 6-pin connector is for connecting theK857 or K857-1 Remote Control or for TIG welding,the K870 foot Amptrol or the K963-3 hand Amptrol.When in the CC-STICK, DOWNHILL PIPE, or CV-WIRE modes and when a remote control is connectedto the 6-pin Connector, the auto-sensing circuit auto-matically switches the OUTPUT control from control atthe welder to remote control.
When in TOUCH START TIG mode and when aAmptrol is connected to the 6-Pin Connector, theOUTPUT dial is used to set the maximum currentrange of the CURRENT CONTROL of the Amptrol.
The 14-pin connector is used to directly connect a wirefeeder control cable. In the CV-WIRE mode, when thecontrol cable is connected to the 14-pin connector, theauto-sensing circuit automatically makes the OutputControl inactive and the wire feeder voltage controlactive.
NOte: When a wire feeder with a built in weldingvoltage control is connected to the 14-pin connec-tor, do not connect anything to the 6-pin connec-tor.------------------------------------------------------------------------eLeCtRICaL CONNeCtIONs
MaCHINe GROUNDINGBecause this portable engine driven welder creates itsown power, it is not necessary to connect its frame toan earth ground, unless the machine is connected topremises wiring (home, shop, etc.)
To prevent dangerous electric shock, other equipmentto which this engine driven welder supplies powermust:
• Be grounded to the frame of the welder using agrounded type plug.
• Be double insulated.• Do not ground the machine to a pipe that carries
explosive or combustible material.------------------------------------------------------------------------
WaRNING
WaRNING
WaRNING
CaUtION
WaRNING
CaBLe INstaLLatIONInstall the welding cables to your machine as follows: 1. The diesel engine must be OFF to install welding
cables.2. Remove the flanged nuts from the output termi-
nals.3. Connect the electrode holder and work cables to
the weld output terminals. The terminals are identi-fied 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 workclamp and cable.
6. Check and tighten the connections periodically.
• Loose connections will cause the output termi-nals to overheat. the terminals may eventuallymelt.
• Do not cross the welding cables at the outputterminal connection. Keep the cables isolatedand separate from one another.
-----------------------------------------------------------------------aUXILIaRy POWeR
The auxiliary power capacity is 8500 watts Peak,8,000 Watts Continuous of 50 Hz, three phasepower. The auxiliary power capacity rating in watts isequivalent to volt-amperes at unity power factor. Themax permissible current of the 400 VAC output is 12amps. Output voltage is within ± 10% at all loads upto the rated capacity.
staNDBy POWeR CONNeCtIONs
The machine is suitable for temporary, standby oremergency power using the engine manufacturer’srecommended maintenance schedule.
The machine can be permanently installed as astandby power unit for 400 VAC, three phase, 12amp service.
Connections must be made by a licensed electricianwho can determine how the power can be adapted tothe particular installation and comply with all applica-ble electrical codes.
• Take necessary steps to assure load is limited tothe capacity of the RANGER® 305D (CE).
• Only a licensed, certified, trained electricianshould install the machine to a premises or resi-dential electrical system. Be certain that:
a-5INstaLLatION
RaNGeR® 305D (Ce)
a-5When this welder is mounted on a truck or trailer, itsframe must be electrically bonded to the metal frame ofthe vehicle. Use a #8 or larger copper wire connectedbetween the machine grounding stud and the frame ofthe vehicle. When this engine driven welder is connect-ed to premises wiring such as that in a home or shop,its frame must be connected to the system earthground. See further connection instructions in the sec-tion entitled "Standby Power Connections" .
In general, if the machine is to be grounded, it shouldbe connected with a #8 or larger copper wire to a solidearth ground such as a metal water pipe going into theground for at least ten feet and having no insulatedjoints, or to the metal framework of a building whichhas been effectively grounded.
A machine grounding stud marked with the symbolis provided on the front of the welder.
WeLDING teRMINaLsThe machine is equipped with a toggle switch forselecting "hot" welding terminal when in the "WELDTERMINALS ON" position or "cold" welding terminalwhen in the "REMOTE" position.
WeLDING OUtPUt CaBLes With the engine off connect the electrode and workcables to the output studs. The welding process dic-tates the polarity of the electrode cable. These connec-tions should be checked periodically and tightened witha 19mm wrench.
table a.1 lists recommended cable sizes and lengthsfor rated current and duty cycle. Length refers to thedistance from the welder to the work and back to thewelder. Cable diameters are increased for long cablelengths to reduce voltage drops.
taBLe a-1
tOtaL COMBINeD LeNGtH OfeLeCtRODe aND WORK CaBLes
Cable Length
0-30 meters (0-100ft.)
30-46 meters (100-150 ft.)
46-61 meters (150-200 ft.)
Cable size for 305 amps
100% Duty Cycle1 / 0 aWG
2 / 0 aWG
3 / 0 aWG
CaUtION
WaRNING
a-6INstaLLatION
RaNGeR 305D (Ce)
a-6• the installation complies with the National
electrical Code and all other applicable electri-cal codes.
• the premises is isolated and no feedback intothe utility system can occur. Certain laws requirethe premises to be isolated before the generatoris linked to the premises. Check your localrequirements.
-----------------------------------------------------------------------
a-7INstaLLatION
RaNGeR® 305D (Ce)
a-7CONNECTION OF ACROSS THE ARC WIRE FEEDERSTO THE Ranger 305D CE
These connections instructions apply to both the LN-25 Pro andActiv8 models. The feeders have an internal contactor and theelectrode is not energized until the gun trigger is closed. When thegun trigger is closed the wire will begin to feed and the weldingprocess is started.
• Shut the welder off.
• For electrode Positive, connect the electrode cable to the "+"terminal of the welder and work cable to the "-" terminal of thewelder. For electrode Negative, connect the electrode cable "-"terminal of the welder and work cable to the "+" terminal of thewelder.
• Attach the single lead from the front of the feeder to work usingthe spring clip at the end of the lead. This is a control lead tosupply current to the wire feeder motor; it does not carry weld-ing current (See Figure A.8).
• Set the MODE switch to the "CV-WIRE" position (See Figure A.7).
• Set the "WELD TERMINALS" switch to "WELD TERMINALS ON"
• Set the "ARC CONTROL" knob to "0" initially and adjust to suit.
• Set the “REMOTE/LOCAL” switch to “LOCAL” control.
Set Mode to CV Wire
Set toLocal
Weld Terminals On
FIGURE A.7
FIGURE A.8
B-1OPeRatION
RaNGeR® 305D (Ce)
B-1safety PReCaUtIONs
Do not attempt to use this equipment until youhave thoroughly read the engine manufacturer’smanual supplied with your welder. It includesimportant safety precautions, detailed enginestarting, operating and maintenance instructions,and parts lists.------------------------------------------------------------------------
eLeCtRIC sHOCK can kill.• Do not touch electrically live parts or
electrode with skin or wet clothing.• Insulate yourself from work and
ground.• always wear dry insulating gloves.
• always operate the welder with the hinged doorclosed and the side panels in place.
• Read carefully the safety Precautions pagebefore operating this machine. always followthese and any other safety procedures includedin this manual and in the engine InstructionManual.
GeNeRaL DesCRIPtIONThe RANGER® 305D (CE) is a diesel engine pow-ered DC multi-process welding power source and ACpower generator. The engine drives a generator thatsupplies three phase power for the DC welding circuitand three phase and single phase power for the ACauxiliary outlets. The DC welding control system usesstate of the art Chopper Technology (CT TM) for supe-rior welding performance.
fOR aUXILIaRy POWeR:
Start the engine and set the IDLER control switch tothe desired operating mode. Full power is availableregardless of the welding control settings providing nowelding current is being drawn.
eNGINe OPeRatIONBefore Starting the Engine:
• Be sure the machine is on a level surface.• Open top & side engine doors and remove the
engine oil dipstick and wipe it with a clean cloth.Reinsert the dipstick and check the level on the dip-stick.
• Add oil (if necessary) to bring the level up to the fullmark. Do not overfill. Close engine door.
• Check radiator for proper coolant level. (Fill if nec-essary).
• See Engine Owner’s Manual for specific oil andcoolant recommendations.
aDD fUeL
• stop engine while fueling.• Do not smoke when fueling.• Keep sparks and flame away
from tank.• Do not leave unattended while
fueling.• Wipe up spilled fuel and allow
fumes to clear before startingengine.
• Do not overfill tank, fuel expan-sion may cause overflow.
DIeseL fUeL ONLy------------------------------------------------------------------------• Remove the fuel tank cap.
• Fill the tank approximately 4 inches (100mm) fromthe top of the filler neck to allow for fuel expansion(observe the fuel gauge while filling). DO NOT FILLTHE TANK TO THE POINT OF OVERFLOW.
• Replace the fuel cap and tighten securely.
• See Engine Owner’s Manual for specific fuel recom-mendations.
BReaK-IN PeRIOD
Any engine will use a small amount of oil during its“break-in” period. For the diesel engine on theRANGER® 305D (CE), break-in is about 50 runninghours.
Check the oil every four hours during break-in.Change the oil after the first 50 hours of operation,every 100 hours thereafter. Change the oil filter at thesecond oil change.
During break-in, subject the RaNGeR® 305D (Ce)to moderate loads. avoid long periods running atidle. Before stopping the engine, remove all loadsand allow the engine to cool several minutes.------------------------------------------------------------------------
WaRNING
WaRNING
CaUtION
DIeseL fUeLcan cause fire.
B-2OPeRatIONB-2
WeLDING CONtROLs (figure B.1)1. OUtPUt CONtROL: The OUTPUT dial is used to pre-
set the output voltage or current as displayed on the digi-tal meters for the four welding modes. When in the CC-STICK, or CV-WIRE modes and when a remote controlis connected to the 6-Pin or 14-Pin Connector, the auto-sensing circuit automatically switches the OUTPUTCONTROL from control at the welder to the remote con-trol.
When in the DOWNHILL PIPE mode and when a REMOTECONTROL is connected to the 6-Pin or 14-Pin Connector,the OUTPUT CONTROL is used to set the maximum cur-rent range of the OUTPUT CONTROL of the REMOTE.example:When the OUTPUT CONTROL on the welder is set to 200amps the current range on the REMOTE CONTROL will be40-200 amps rather than the full 40-300 amps. Any currentrange that is less than the full range provides finer currentresolution for more fine tuning of the output.
In the CV-WIRE mode, if the wire feeder has voltage con-trol capability, when the control cable is connected to the14-Pin Connector, the auto-sensing circuit automaticallymakes OUTPUT CONTROL inactive and the wire feedervoltage control active.
When in the TOUCH START TIG mode and when aAmptrol is connected to the 6-Pin Connector, the OUT-PUT control is used to set the maximum current range ofthe CURRENT CONTROL of the Amptrol.
2. DIGItaL OUtPUt MeteRsThe digital meters allow the output voltage (CV-WIREmode) or current (CC-STICK, PIPE and TIG modes) tobe set prior to welding using the OUTPUT control dial.During welding, the meter display the actual output volt-age (VOLTS) and current (AMPS). A memory featureholds the display of both meters on for seven secondsafter welding is stopped. This allows the operator to readthe actual current and voltage just prior to when weldingwas ceased.
While the display is being held the left-most decimalpoint in each display will be flashing. The accuracy of themeters is +/- 3%.
3. WeLD MODe seLeCtOR sWItCH:(Provides four selectable welding modes)CV-WIREDOWNHILL PIPECC-STICKTOUCH START TIG
RaNGeR® 305D (Ce)
1
10
7
4
9
5
8
11
12
13
6
15
1417
16
2
3
fIGURe B.1
B-3OPeRatIONB-3
4. aRC CONtROL: The ARC CONTROL dial is active inthe CV-WIRE, CC-STICK and DOWNHILL PIPE modes,and has different functions in these modes. This control isnot active in the TIG mode.
CC-stICK mode: In this mode, the ARC CONTROL dialsets the short circuit current (arc-force) during stick weldingto adjust for a soft or crisp arc. Increasing the dial from –10(soft) to +10 (crisp) increases the short circuit current andprevents sticking of the electrode to the plate while welding.This can also increase spatter. It is recommended that theARC CONTROL be set to the minimum number withoutelectrode sticking. Start with a setting at 0.
DOWNHILL PIPe mode: In this mode, the ARC CONTROLdial sets the short circuit current (arc-force) during stickwelding 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 moreforceful digging arc. Typically a forceful digging arc is pre-ferred for root and hot passes. A softer arc is preferred forfill and cap passes where weld puddle control and deposi-tion ("stacking" of iron) are key to fast travel speeds. It isrecommended that the ARC CONTROL be set initially at 0.
CV-WIRe mode: In this mode, turning the ARC CONTROLclock wise from –10 (soft) to +10 (crisp) changes the arcfrom soft and washed-in to crisp and narrow. It acts as aninductance/pinch control. The proper setting depends onthe procedure and operator preference. Start with a settingof 0.
5. WeLD OUtPUt teRMINaLs WItH fLaNGeNUt: Provides a connection point for the electrode andwork cables.
6. GROUND stUD: Provides a connection point for connecting the machinecase to earth ground.
7. 14-PIN CONNeCtOR: For attaching wire feeder con-trol cables to the RANGER® 305D (CE). Includes contactorclosure circuit, auto-sensing remote control circuit, and 42Vpower. The remote control circuit operates the same as the6 Pin connector.Note: The 14-pin connector does not include 120V.
8. 6-PIN CONNeCtOR: For attaching optional remotecontrol equipment. Includes auto-sensing remote controlcircuit.
9. WeLD teRMINaLs sWItCH: In the WELD TERMI-NALS ON position, the output is electrically hot all the time.In the REMOTELY CONTROLLED position, the output iscontrolled by a wire feeder or amptrol device, and is electri-cally off until a remote switch is depressed.
10. WIRe feeDeR VOLtMeteR sWItCH:Matches the polarity of the wire feeder voltmeter to thepolarity of the electrode.
eNGINe CONtROLs: (figure B.2)
11. RUN/stOP sWItCH - RUN position energizes theengine prior to starting. STOP position stops the engine.The oil pressure interlock switch prevents battery drain ifthe switch is left in the RUN position and the engine is notoperating.
12. GLOW PLUG PUsH BUttON -
• When pushed activates the glow plugs. Glow plugshould not be activated for more than 20 secondscontinuously.
13. staRt PUsH BUttON - Energizes the starter motor to crank engine.
14. IDLeR sWItCH- Has two positions as follows:1) In the HIGH position, the engine runs at the high idle
speed controlled by the engine governor.2) In the AUTO position, the idler operates as follows:
• When switched from HIGH to AUTO or after starting theengine, the engine will operate at full speed for approxi-mately 12 seconds and then go to low idle speed.
• When the electrode touches the work or power is drawnfor lights or tools (approximately 100 Watts minimum), theengine 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. Ifthe welding or AC power load is not restarted before theend of the time delay, the idler reduces the engine speedto low idle speed.
• The engine will automatically return to high idle speedwhen there is welding load or AC power load reapplied.
RaNGeR® 305D (Ce)
B-4OPeRatIONB-415. eLeCtRIC fUeL GaUGe- Provides accu-
rate, reliable indication of how much fuel is in thetank.
.16. eNGINe HOUR MeteR – Displays the total
time that the engine has been running. This meteris useful for scheduling prescribed maintenance.
17. eNGINe PROteCtION LIGHt-A warningindicator light for Low Oil Pressure and/or CoolantOver Temperature. The light is off when the sys-tems are functioning properly. The light turns onwhen the RUN-STOP switch is in the “ON” posi-tion prior to starting the engine. If the EngineProtection or Battery Charging Lights do “not”turn off shortly after starting the engine shut offthe engine immediately and determine the cause.
staRtING tHe eNGINe1. 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 andSTART button together until the engine starts or forup to 10 seconds.
6. Release the engine START button immediatelywhen the engine starts.
7. Release the glow plug button after the EngineProtection Light turns off or after an additional 5seconds maximum.
8. The engine will run at high idle speed for approxi-mately 12 seconds and then drop to low idle speed.Allow the engine to warm up at low idle for severalminutes before applying a load and/or switching tohigh idle. Allow a longer warm up time in coldweather.
NOte: If the unit fails to start repeat step 4 throughstep 7 after waiting 30 seconds.
• Do not allow the starter motor to run continuouslyfor more than 20 seconds.
• Do not push the staRt button while the engineis running because this can damage the ringgear and/or the starter motor.
• If the engine Protection or Battery ChargingLights do “not” turn off shortly after starting theengine shut off the engine immediately and determine the cause.
-----------------------------------------------------------------------NOte: When starting a RANGER® 305D (CE) for thefirst time, or after and extended period of time of notoperating, it will take longer than normal because thefuel pump has to fill the fuel system.
stOPPING tHe eNGINeRemove all welding and auxiliary power loads andallow the engine to run at low idle speed for a fewminutes to cool the engine.
stOP the engine by placing the RUN-STOP switch inthe STOP position.
NOte: A fuel shut off valve is located on the fuel pre-filter. Turn on Fuel shut-off valve on the fuel pre-filter.
RaNGeR® 305D (Ce)
CaUtION
tyPICaL RaNGeR® 305D (Ce) fUeL CONsUMPtIONKubota D722 Running time forLiters/Hr (Gal./Hr) 45 Liters/hours
Low Idle - No Load2200 R.P.M. .92 (.24) 49.38High Idle - No Load3100 R.P.M. 1.62 (.43) 28.07DC Weld Output250 Amps @ 30 Volts 3.42 (.90) 13.30DC Weld Output225 Amps @ 25 Volts 2.92 (.77) 15.55
8,000 Watts, 3 PHASE 3.35 (.89) 13.54
5,000 Watts, 3 PHASE 2.65 (.70) 17.12
3,000 Watts, 3 PHASE 2.19 (.58) 20.78
taBLe B.1
tyPICaL CURReNt RaNGes (1) fOR tUNGsteN eLeCtRODes(2)Tungsten Electrode DCEN (-) DCEP (+) Approximate Argon Gas Flow TIG TORCH Diameter in. (mm) Flow Rate C.F.H. ( l /min.) Nozzle Size (4), (5)
1%, 2% Thoriated 1%, 2% Thoriated Aluminum Stainless SteelTungsten Tungsten
.010 (.25) 2-15 (3) 3-8 (2-4) 3-8 (2-4) #4, #5, #60.020 (.50) 5-20 (3) 5-10 (3-5) 5-10 (3-5)0.040 (1.0) 15-80 (3) 5-10 (3-5) 5-10 (3-5)
1/16 (1.6) 70-150 10-20 5-10 (3-5) 9-13 (4-6) #5, #6
3/32 (2.4) 150-250 15-30 13-17 (6-8) 11-15 (5-7) #6, #7, #81/8 (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, #103/16 (4.8) 500-750 55-80 23-27 (11-13) 18-22 (8-10)1/4 (6.4) 750-1000 80-125 28-32 (13-15) 23-27 (11-13)
(1) When used with argon gas. The current ranges shown must be reduced when using argon/helium or pure helium shielding gases.(2) Tungsten electrodes are classified as follows by the American Welding Society (AWS):
Pure EWP1% Thoriated EWTh-12% Thoriated EWTh-2
Though not yet recognized by the AWS, Ceriated Tungsten is now widely accepted as a substitute for 2% Thoriated Tungsten in AC and DC applications.(3) DCEP is not commonly used in these sizes.(4) TIG torch nozzle "sizes" are in multiples of 1/16ths of an inch:
# 4 = 1/4 in. (6 mm)# 5 = 5/16 in. (8 mm)# 6 = 3/8 in. (10 mm)# 7 = 7/16 in. (11 mm)# 8 = _ in. (12.5 mm)#10 = 5/8 in. (16 mm)
(5) TIG torch nozzles are typically made from alumina ceramic. Special applications may require lava nozzles, which are less prone to breakage, but cannot withstand high temperaturesand high duty cycles.
B-5OPeRatIONB-5WeLDeR OPeRatIONDUty CyCLeDuty Cycle is the percentage of time the load is beingapplied in a 10 minute period. For example a 60% dutycycle, represents 6 minutes of load and 4 minutes of noload in a 10 minute period.
The RANGER® 305D (CE) can be used with a broad rangeof DC stick electrodes. The MODE switch provides twostick welding settings as follows:
CONstaNt CURReNt (CC-stICK) WeldingThe CC-STICK position of the MODE switch is designed forhorizontal and vertical-up welding with all types of elec-trodes, especially low hydrogen.
The OUTPUT CONTROL dial adjusts the full output rangefor 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 dial from –10 (soft) to +10 (crisp) increasesthe short circuit current and prevents sticking of the elec-trode to the plate while welding. This can also increasespatter. It is recommended that the ARC CONTROL be setto the minimum number without electrode sticking. Startwith a setting at 0.
DOWNHILL PIPe (stICK) WeldingThe DOWNHILL PIPE position of the MODE switch is aslope controlled setting intended for "out-of-position" and"down hill" pipe welding where the operator would like tocontrol the current level by changing the arc length.
The OUTPUT CONTROL dial adjusts the full output rangefor stick welding. The ARC CONTROL dial sets the shortcircuit current (arc-force) during stick welding to adjust fora soft or a more forceful digging arc(crisp). Increasing thenumber from –10 (soft) to +10 (crisp) increases the shortcircuit current which results in a more forceful digging arc.Typically a forceful digging arc is preferred for root and hotpasses. A softer arc is preferred for fill and cap passeswhere weld puddle control and deposition ("stacking" ofiron) are key to fast travel speeds. It is recommended thatthe ARC CONTROL be set initially at 0.
tIG WeLDING
The TOUCH START TIG setting of the MODE switch is forDC TIG (Tungsten Inert Gas) welding. To initiate a weld,the OUTPUT CONTROL dial is first set to the desired cur-rent and the tungsten is touched to the work. During thetime the tungsten is touching the work there is very littlevoltage or current and, in general, no tungsten contamina-tion. Then, the tungsten is gently lifted off the work in arocking motion, which establishes the arc.
To stop the arc, simply lift the TIG torch away from thework piece. When the arc voltage reaches approximately30 volts, the arc will go out and the machine will automati-cally reset to the touch start current level. The tungstenmay then be retouched to the work piece to restrike thearc. The arc may also be started and stopped with anAmptrol or Arc Start Switch. See the following para-graphs.
RaNGeR® 305D (Ce)
taBLe B.2
aUXILIaRy POWeR:
Start the engine and set the IDLER control switch tothe desired operating mode. Full power is availableregardless of the welding control settings providing nowelding current is being drawn.
simultaneous Welding and auxiliary Power Loads
While welding, the amount of 3-phase Auxiliary poweravailable is reduced. (See table A.4)
RaNGeR® 305D (Ce)
B-6OPeRatIONB-6When in the TOUCH START TIG mode and when aAmptrol is connected to the 6-pin Connector the OUT-PUT dial is used to set the maximum current range ofthe CURRENT CONTROL of the Amptrol.
The ARC CONTROL is not active in the TIG mode.
The RANGER® 305D (CE) can be used in a wide vari-ety of DC TIG welding applications. In general the‘Touch Start’ feature allows contamination free startingwithout the use of a Hi-frequency unit. If desired, theK930-2 TIG Module can be used with the RANGER®305D (CE). The settings are for reference.
RANGER® 305D (CE) settings when using the K930-2TIG Module with an Amptrol or Arc Start Switch:
• Set the MODE Switch to the TOUCH START TIGsetting.
• Set the "IDLER" Switch to the "AUTO" position.• Set the "WELDING TERMINALS" switch to the
"REMOTELY CONTROLLED" position. This will keepthe "Solid State" contactor open and provide a “cold”electrode until the Amptrol or Arc Start Switch ispressed.
When using the TIG Module, the OUTPUT control onthe RANGER® 305D (CE) is used to set the maximumrange of the CURRENT CONTROL on the TIG moduleor an Amptrol if connected to the TIG Module. (SeeTable B.2.)
WIRe WeLDING-CVConnect a wire feeder to the RANGER® 305D (CE)according to the instructions in INSTALLATIONINSTRUCTIONS Section.
The RANGER® 305D (CE) in the CV-WIRE mode, per-mits it to be used with a broad range of flux cored wire(Innershield and Outershield) electrodes and solid wiresfor MIG welding (gas metal arc welding). Welding canbe finely tuned using the ARC CONTROL. Turning theARC CONTROL clockwise from –10 (soft) to +10 (crisp)changes the arc from soft and washed-in to crisp andnarrow. It acts as an inductance/pinch control. Theproper setting depends on the procedure and operatorpreference. Start with the dial set at 0.
For any electrodes the procedures should be keptwithin the rating of the machine. For additional elec-trode information see WWW.Lincolnelectric.com orthe appropriate Lincoln publication.
aRC GOUGINGThe RANGER® 305D (CE) can be used for limited arcgouging. For optimal performance, set the MODEswitch to CC-STICK and the ARC CONTROL to +10.
Set the OUTPUT CONTROL knob to adjust outputcurrent to the desired level for the gouging electrodebeing used according to the ratings in the followingTable B.3.
Carbon Diameter Current Range (DC, electrode positive)
1/8" 60-90 Amps
5/32" 90-150 Amps
3/16" 200-250 Amps
taBLe B.3
WeLDING OUtPUt-aMPs
050
100150200250
PeRMIssIBLe POWeR-Watts(UNIty POWeR faCtOR)
80006500500035002000
0
PeRMIssIBLe aUXPOWeR @400V, 3PHase
12 amps9 amps7 amps5 amps3 amps0 amps
taBLe a.4
C-1aCCessORIesC-1
fIeLD INstaLLeD OPtIONs /aCCessORIes K704 aCCessORy set - Includes (10m) 35 ft. ofelectrode cable and (9.m) 30 ft. of work cable, head-shield, work clamp electrode holder. Cables are ratedat 400 amps, 100% duty cycle.
K857 (7.6m) 25 ft. or K857-1 (30.4m) 100 ft.ReMOte CONtROL - Portable control provides samedial range as the output control on the welder. Has aconvenient 6 pin plug for easy connection to thewelder.
RaNGeR® 305D (Ce)
D-1MaINteNaNCeD-1
RaNGeR® 305D (Ce)
safety PReCaUtIONs
• Have qualified personnel do all maintenanceand troubleshooting work.
• turn the engine off before working inside themachine or servicing the engine.
• Remove guards only when necessary toperform maintenance and replace them whenthe maintenance requiring their removal iscomplete. If guards are missing from themachine, obtain replacements from a LincolnDistributor. (see Operating Manual Parts List.)
• Read the safety Precautions in the front of thismanual and in the engine Owner’s Manualbefore working on this machine.
• Keep all equipment safety guards, covers, anddevices in position and in good repair. Keephands, hair, clothing, and tools away from thegears, fans, and all other moving parts whenstarting, operating, or repairing the equipment.
Routine Maintenance
At the end of each day’s use, refill the fuel tank tominimize moisture condensation in the tank. Runningout of fuel tends to draw dirt into the fuel system.Also, check the crankcase oil level and add oil ifindicated.
WaRNINGFREQUENCY
DAILY OR BEFORE STARTING ENGINE
MAINTENANCE REQUIRED • FILL FUEL TANK.• CHECK OIL LEVEL.• CHECK COOLANT LEVEL.• CHECK AIR CLEANER ELE-
MENT AND HOUSING FORDIRTY, LOOSE OR DAMAGEDPARTS.
• CHECK AIR INTAKE HOSEFOR CRACKS OR LOOSECONNECTIONS.
• CHECK AIR INTAKE/EXHAUSTAREAS & RADIATOR FORDIRT. CLEAN AS NECESSARY.
• CHECK ALTERNATOR BELTTENSION AND WEAR.
IteM MaKe aND PaRt NUMBeR
OIL FILTER KUBOTA 70000-15241
AIR FILTER ELEMENT DONALDSON P822686
FUEL FILTER ELEMENT KUBOTA 15231-43560
BATTERY KUBOTA GROUP 58, 550 CCA
BELT KUBOTA 15881-97011
GLOW PLUGS KUBOTA 16851-65512
INLINE FUEL FILTER KUBOTA 12581-43012
eNGINe MaINteNaNCe COMPONeNtsKUBOta D722 DIeseL eNGINe
KUBOta D722 DIeseL eNGINe
Service IntervalsObserve the following for service and maintenance. The lubricatingoil change intervals listed in the table below are for Classes CF,CEand CD lubricating oils of API classification with a low sulfur fuel inuse. If the CF-4 or CG-4 lubricating oil is used with a high-sulfurfuel, change the lubricating oil at shorter intervals than recommend-ed in the table below depending on the operating condition.
Every 50 hoursEvery 75 hours
Every 100 hours
Every 150 hours
Every 200 hoursEvery 400 hoursEvery 500 hours
Every 1 or 2 monthsEvery 800 hoursEvery 1500 hours
Every 3000 hours
Every 2 years
Check of fuel lines and clamp bands.Change of engine oil
Inspect/Clean air cleaner elementand Vacuator™ valve.Cleaning of fuel filter.Check the battery electrolyte level.Check the fan belt tightness.Check the radiator and hose clamps.Replacement of oil filter cartridge Check the intake air lines.Replacement of Air Filter element. Replacement of fuel filter element.Cleaning of water jacket (radiatorinterior).Replacement of fan belt.
Recharging of Battery.Check of valve clearance.Check the fuel injection nozzle injec-tion pressure.Check of injection pump.Check of fuel injector timer.Replacement of batteryReplacement of radiator hoses andclamp band.Replacement of fuel pipes andclamps.Change the radiator coolant.(L.L.C.)Replacement of intake air line.
•
*1
•
*1,*2
*3*3
*3*3
*4
Intervals Items
IMPORtaNt• These jobs should be done after the first 50 hours of operation.*1 Air cleaner should be inspected/cleaned more often in dusty conditions than
the normal conditions.*2 Follow service Instructions and Installation tips for air cleaner in
Section D.*3 Consult your local KUBOTA Dealer for this service.*4 Replace only if necessary.
Please see Engine Owners Manual for Warranty Statement in detail.
D-2MaINteNaNCeD-2
eNGINe OIL CHaNGeDrain the engine oil while the engine is warm to assurerapid and complete draining. It is recommended thateach time the oil is changed the oil filter be changed aswell.
• Be sure the unit is off. Disconnect the negative bat-tery cable to ensure safety.
• Locate oil drain hose and valve in bottom of baseand pull through the hole in the battery access panelon the welder.
• Remove the cap from the drain valve. Push valve inand twist counterclockwise. Pull to open and drainthe oil into a suitable container for disposal.
• Close the drain valve by pushing in and twistingclockwise. Replace the cap.
• Re-fill the crankcase to the upper limit mark on thedipstick with the recommended oil (see engine oper-ation manual OR engine service items decal ORbelow). Replace and tighten the oil filler cap secure-ly.
• Push oil drain hose and valve back into unit, re-con-nect negative battery cable, and close doors andengine top cover before restarting unit.Wash yourhands with soap and water after handling usedmotor oil. Please dispose of used motor oil in amanner that is compatible with the environment. Wesuggest you take it in a sealed container to yourlocal service station or recycling center for reclama-tion. DO NOT throw it in the trash; pour it on theground or down a drain.
eNGINe OIL RefILL CaPaCItIesWithout oil filter replacement: • 3.2 liter (3.3 U.S. Quart)
With oil filter replacement:• 3.2 liter ( 3.4 U.S. Quart.)
Use motor oil designed for diesel engines that meetsrequirements for API service classif icationCC/CD/CE/CF/CF-4/CG-4 or CH-4.ACEA E1/E2/E3. Always check the API service labelon the oil container to be sure it includes the lettersindicated. (Note: An S-grade oil must not be used in adiesel engine or damage may result. It IS permissibleto use an oil that meets S and C grade service classifi-cations.)SAE 10W30 is recommended for general, all tempera-ture use, -15C to 40C (5F to 104F).See engine owner’s manual for more specific informa-tion on oil viscosity recommendations.
OIL fILteR CHaNGe• Drain the oil.
• Remove the oil filter with an oil filter wrench anddrain the oil into a suitable container. Discard theused filter. Note: Care should be taken during filterremoval to not disrupt or damage in any way the fuellines.
• Clean the filter mounting base and coat the gasketof the new filter with clean engine oil.
• Screw the new filter on by hand until the gasket con-tacts the mounting base. Using an oil filter wrench,tighten the filter an additional 1/2 to 7/8 of a turn.
• Refill the crankcase with the specified amount of therecommended engine oil. Reinstall the oil filler capand tighten securely.
• Start the engine and check for oil filter leaks.
• Stop the engine and check the oil level. If neces-sary, add oil to the upper limit mark on the dipstick.
• Never use gasoline or low flash point solventsfor cleaning the air cleaner element. a fire orexplosion could result.
• Never run the engine without the air cleaner.Rapid engine wear will result from contaminants,such as dust and dirt being drawn into theengine.
------------------------------------------------------------------------aIR CLeaNeR
The diesel engine is equipped with a dry type air filter.Never apply oil to it. Service the air cleaner as follows:
Replace the element at least every 200 hours ofoperation and sooner under dusty conditions.
RaNGeR® 305D (Ce)
CaUtION
WaRNING
D-3MaINteNaNCeD-3
RaNGeR® 305D (Ce)
D-4MaINteNaNCeD-4COOLING systeM
HOt COOLaNt can burn skin.
• Do not remove cap if radiator ishot.
------------------------------------------------------------------------Check the coolant level by observing the level in theradiator and recovery bottle. Add 50/50 antifreeze /water solution if the level is close to or below the"LOW" mark. do not fill above the "FULL" mark.Remove radiator cap and add coolant to radiator. Fillup to the top of the tube in the radiator filler neckwhich includes a connecting hose coming from thethermostat housing.
To drain the coolant, open the valve of the radiator.Open the radiator cap to allow complete drainage.(Tighten the valve and refi l l with a 50/50antifreeze/water solution.) Use an automotive grade(low silicate) ethylene glycol antifreeze. The coolingsystem capacity is 3.6L (3.85 quarts). Squeeze upperand lower radiator hoses while filling to bleed air fromsystem coolant. Replace and tighten the radiator cap.
always premix the antifreeze and clean tap waterbefore adding to the radiator. It is very importantthat a precise 50/50 solution be used with thisengine year round. this gives proper cooling dur-ing hot weather and freezing protection to -37° C(-34° f).
Cooling solution exceeding 50% ethylene glycolcan result in engine overheating and damage tothe engine. Coolant solution must be premixedbefore adding to radiator.------------------------------------------------------------------------
Periodically remove the dirt from the radiator fins.
Periodically check the fan belt and radiator hoses.Replace if signs of deterioration are found.
tIGHteNING tHe faN BeLt
If the fan belt is loose, the engine can overheat andthe battery lose its charge. Check tightness by press-ing on the belt midway between the pulleys. It shoulddeflect about 6mm (.25 in) under a load of 9 Kg (20lbs).
fUeL
At the end of each day’s use, refill the fuel tank to min-imize moisture condensation and dirt contamination inthe fuel line. Do not overfill; leave room for the fuel toexpand.
Use only fresh, No. 2 grade DIESEL fuel. Do not usekerosene.
See the Engine Operator's Manual for instructions onreplacing the fuel filter.
BLeeDING tHe fUeL systeM
You may need to bleed air from the fuel system if thefuel filter or fuel lines have been detached, the fueltank has been ran empty or after periods of long stor-age. It is recommended that the fuel shutoff valve beclosed during periods of non-use.
The Kubota D722 engine supplied with this welder isequipped with an automatic bleeding mechanism thathelps purge the air from the mechanical fuel pumpsystem. It is generally not necessary to open a ventscrew or fuel line fitting to bleed the fuel system.Operate the priming lever on the pump to assist start-ing after extended periods of non-use or out of fuelconditions.
to avoid personal injury, do not bleed a hotengine. this could cause fuel to spill onto a hotexhaust manifold, creating a danger of fire.------------------------------------------------------------------------Bleed the fuel system as follows:
1. Fill the fuel tank with fuel.2. Open the fuel shut off valve (vertical position of
handle) on the Fuel Filter.3. Crank the engine by pressing the start button for 45
seconds. 4. Check to see that fuel is flowing through both fuel
filters.5. Follow the normal STARTING procedures.
RaNGeR® 305D (Ce)
WaRNING
CaUtION WaRNING
D-5MaINteNaNCeD-5
fUeL fILteR1. Check the fuel filter and fuel pre-filter for water accu-
mulation or sediment.
2. Replace the fuel filter if it is found with excessivewater accumulation or sediment. Empty fuel pre-filter.
eNGINe aDJUstMeNtAdjustments to the engine are to be made only by aLincoln Service Center or an authorized Field ServiceShop.
BatteRy MaINteNaNCeTo access the battery, Disconnect the Negative andthen Positive battery cables. Remove the 4 screwsfrom the battery door using a screwdriver or a 10mmsocket. Remove the 2 nuts from the battery bracketusing a 11mm wrench or socket. Slide the battery outand remove from welder.
Gases fROM BatteRy can explode.l Keep sparks, flame and cigarettes
away from battery.
to prevent eXPLOsION when:l INstaLLING a NeW BatteRy — disconnect
negative cable from old battery first and con-nect to new battery last.
l CONNeCtING a BatteRy CHaRGeR —remove battery from welder by disconnectingnegative cable first, then positive cable and bat-tery clamp. When reinstalling, connect
negative cable last. Keep well ventilated.l UsING a BOOsteR — connect positive lead to
battery first then connect negative lead to nega-tive battery lead at engine foot.BatteRy aCID can burn eyes andskin.l Wear gloves and eye protection and
be careful when working near bat-tery.
l follow instructions printed on battery.
RaNGeR® 305D (Ce)
OVeRsPeeD Is HaZaRDOUsthe maximum allowable high idle speed for thismachine is 3150 RPM, no load. Do NOt tamperwith governor components or setting or make anyother adjustments to increase the maximumspeed. severe personal injury and damage to themachine can result if operated at speeds abovemaximum.
CLeaNING tHe BatteRyKeep the battery clean by wiping it with a damp clothwhen dirty. If the terminals appear corroded, discon-nect the battery cables and wash the terminals with anammonia solution or a solution of 113g (1/4 pound) ofbaking soda and 0.9461L (1 quart) of water. Be surethe battery vent plugs (if equipped) are tight so thatnone of the solution enters the cells.After cleaning, flush the outside of the battery, the bat-tery compartment, and surrounding areas with clearwater. Coat the battery terminals lightly with petroleumjelly or a non-conductive grease to retard corrosion.Keep the battery clean and dry. Moisture accumula-tion on the battery can lead to more rapid dischargeand early battery failure.
CHeCKING tHe eLeCtROLyte LeVeL
If battery cells are low, fill them to the neck of the fillerhole with distilled water and recharge. If one cell islow, check for leaks.
CHaRGING tHe BatteRyWhen you charge, jump, replace, or otherwise con-nect battery cables to the battery, be sure the polarityis correct. Improper polarity can damage the chargingcircuit. The RANGER® 305D (CE) positive (+) batteryterminal has a red terminal cover.
If you need to charge the battery with an externalcharger, disconnect the negative cable first, then thepositive cable before you attach the charger leads.After the battery is charged, reconnect the positivebattery cable first and the negative cable last. Failureto do so can result in damage to the internal chargercomponents.Follow the instructions of the battery charger manu-facturer for proper charger settings and charging time.
seRVICING sPaRK aRRestORClean every 100 hours or twice a year, whicheveroccurs frist.1. Stop engine and allow to cool.2. Loosen clamp and remove spark arrestor from machine.3. Remove locknut on top of spark arrestor housing and lift
off cap.4. Separate plates and clean with a wire brush if neces-
sary.5. Inspect plates and housing for holes or cracks. Replace
if damaged.6. Reassemble and reinstall on to muffler outlet pipe.
WaRNING
WaRNING
• MUffLeR May Be HOt------------------------------------------------------------
D-6MaINteNaNCeD-6
RaNGeR® 305D (Ce)
WeLDeR / GeNeRatORMaINteNaNCe
stORaGe: Store the RANGER® 305D (CE) in clean,dry protected areas.
CLeaNING: Blow out the generator and controls peri-odically with low pressure air. Do this at least once aweek in particularly dirty areas.
BRUsH ReMOVaL aND RePLaCeMeNt: It’s nor-mal for the brushes and slip rings to wear and darkenslightly. Inspect the brushes when a generator over-haul is necessary.
• Do not attempt to polish slip rings while theengine is running.
WaRNING• service and Repair should only be performed by
Lincoln electric factory trained Personnel.Unauthorized repairs performed on this equip-ment may result in danger to the technician andmachine operator and will invalidate your factorywarranty. for your safety and to avoid electricalshock, please observe all safety notes and pre-cautions.
CaUtION
e-1tROUBLesHOOtINGe-1
RaNGeR® 305D (Ce)
If for any reason you do not understand the test procedures or are unable to perform the tests/repairs safely, contact yourLocal Lincoln authorized field service facility for technical troubleshooting assistance before you proceed.
CaUtION
This Troubleshooting Guide is provided to help youlocate and repair possible machine malfunctions.Simply follow the three-step procedure listed below.
Step 1. LOCATE PROBLEM (SYMPTOM).Look under the column labeled “PROBLEM (SYMP-TOMS)”. This column describes possible symptomsthat the machine may exhibit. Find the listing thatbest describes the symptom that the machine isexhibiting.
Step 2. POSSIBLE CAUSE.The second column labeled “POSSIBLE CAUSE” liststhe obvious external possibilities that may contributeto the machine symptom.
Step 3. RECOMMENDED COURSE OF ACTIONThis column provides a course of action for thePossible Cause, generally it states to contact yourlocal Lincoln Authorized Field Service Facility.
If you do not understand or are unable to perform theRecommended Course of Action safely, contact yourlocal Lincoln Authorized Field Service Facility.
HOW tO Use tROUBLesHOOtING GUIDe
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 andmachine operator and will invalidate your factory warranty. For your safety and to avoid ElectricalShock, please observe all safety notes and precautions detailed throughout this manual.
__________________________________________________________________________
WaRNING
e-2tROUBLesHOOtINGe-2
RaNGeR® 305D (Ce)
Observe all Safety Guidelines detailed throughout this manual
If for any reason you do not understand the test procedures or are unable to perform the tests/repairs safely, contact yourLocal Lincoln authorized field service facility for technical troubleshooting assistance before you proceed.
CaUtION
PROBLeMs(syMPtOMs)
POssIBLe CaUse
ReCOMMeNDeDCOURse Of aCtION
Major Physical or Electrical Damageis Evident.
Engine will not "crank".
Engine will "crank" but not start.
Engine shuts down shortly afterstarting.
1. Contact your local Lincolnauthorized field servicefacility.
1. Battery is low, Charge Battery.2. Loose battery cable connections.
Inspect, clean and tighten terminals.3. Faulty engine starter motor.
Contact authorized local EngineService Shop.
1. Fuel shut off valve on Main FuelFilter in the OFF position. Openvalve (vertical) position of handle.
2. Fuel Filters dirty/clogged. Checkand replace main filter elementand/or Inline Fuel Filter.
3. Out of fuel. Fill tank and bleed fuelsystem.
4. High coolant temperature or lowoil pressure. (indictor lights lit)Check oil and coolant levels. Fill ifrequired. Check for loose or bro-ken fan belt.
5. Faulty fuel shutdown solenoid.Check that shutdown solenoid isfunctioning properly and not bind-ing/ contact authorized engineservice shop.
6. Faulty fuel pump. Check for fuelf low through fi l ters. Contactauthorized local Engine ServiceShop.
1. High coolant temperature or lowoil pressure. (indictor light lit)Change oil and oil filters and fill toproper level. Check and fill coolantlevel. Check for loose or brokenfan belt. Start engine and look forleaks.
2. Faulty oil pressure switch or otherengine component. Contactauthorized local Engine ServiceShop.
3. Faulty engine protection relay.
If all recommended possible areasof misadjustment have beenchecked and the problem persists,Contact your local Lincolnauthorized field service facility.
e-3tROUBLesHOOtINGe-3
RaNGeR® 305D (Ce)
Observe all Safety Guidelines detailed throughout this manual
If for any reason you do not understand the test procedures or are unable to perform the tests/repairs safely, contact yourLocal Lincoln authorized field service facility for technical troubleshooting assistance before you proceed.
CaUtION
PROBLeMs(syMPtOMs)
POssIBLe CaUse
ReCOMMeNDeDCOURse Of aCtION
Engine shuts down while under aload.
Engine runs rough.
Battery does not stay charged.
Engine will not idle down to lowspeed.
Engine will not go to high idle whenattempting to weld.
1. High radiator coolant tempera-ture. Reduce load if it is exceed-ing machine rating. Add coolantto system if low. Clean fins onradiator if dirty. Tighten fan belt ifloose. Remove objects blockingor close to intake openings onboth sides of base and exhaustend (case back).
1. Dirty fuel or air filters. Inspect andclean/replace filters as needed.Inspect and clean/replace filtersas needed.
2. Water in fuel. If water found intank. Empty fuel tank and refillthen purge fuel lines.
1. Faulty battery. Replace.2. Loose connections at battery or
alternator. Clean and tighten con-nections.
3. Faulty engine alternator or charg-er module. Consult authorizedEngine Service Shop.
1. Idler switch in High idle position.Set switch to Auto.
2. External load on welder or auxil-iary power. Remove all externalloads.
3. Faulty PC board or idler sole-noid.
1. Poor work lead connection towork. Make sure work clamp istightly connected to clean basemetal.
2. "Contactor" switch is in wrongposition. Set to "Welding On" whenwelding without a control cable.Refer to Operations chapter for prop-er use of this switch.
3. Faulty PC board. Low idle speedset to low.
If all recommended possible areas ofmisadjustment have been checkedand the problem persists, Contactyour local Lincoln authorizedfield service facility.
e-4tROUBLesHOOtINGe-4
RaNGeR® 305D (Ce)
Observe all Safety Guidelines detailed throughout this manual
If for any reason you do not understand the test procedures or are unable to perform the tests/repairs safely, contact yourLocal Lincoln authorized field service facility for technical troubleshooting assistance before you proceed.
CaUtION
PROBLeMs(syMPtOMs)
POssIBLe CaUse
ReCOMMeNDeDCOURse Of aCtION
Engine will not go to high idle whenusing auxiliary power.
Engine wil l not go to high idleunder weld or auxiliary loading.
Engine does not develop ful lpower. Engine runs rough.
Engine will not go to high idle whenattempting to weld or using auxil-iary power. Switching to manualhigh idle does not work.
Engine will not shut off.
Engine does not develop full power.Low weld and auxil iary output.Engine runs rough.
1. Auxiliary power load is less than100 watts. Idler may not respondwith less than a 100 watt load. Setidler to "High".
2. Faulty PC board.
1. Faulty idler solenoid. Check forbent linkage or broken spring.
1. Fuel filter clogged, Replace.2. Air filter clogged, clean or replace.3. High idle setting incorrect, check
and adjust if required.4. Valves out of adjustment.5. Fuel contaminated with water or
sediment. Check fuel pre-filterand empty of water, bleed fuelsystem. Replace fuel in tank ifneeded.
1. Broken spring on Idle Solenoid,solenoid linkage binding, FaultyPC board, low idle speed set toolow on idle solenoid.
1. Fuel Shutdown solenoid notfunctioning properly / linkagebinding. Stop engine by shuttingoff valve located on main fuel fil-ter. Contact authorized localEngine Service Shop.
1. Fuel filter dirty/clogged. Replace.2. Air filter dirty/clogged. Replace
Air Filter Element.3. Fouled fuel injector(s). Contact
authorized Engine Service Shop.4. Fuel contaminated with water.
Check Main Filter Bowl and InlineFuel filters for water. Clean andreplace as needed. Replace fuelin tank.
5. Cracked or loose fuel hose.Replace hose and tightenclamps.
6. Valves out of adjustment. Contactauthorized local Engine ServiceShop.
If all recommended possible areasof misadjustment have beenchecked and the problem persists,Contact your local Lincolnauthorized field service facility.
e-5tROUBLesHOOtINGe-5
RaNGeR® 305D (Ce)
Observe all Safety Guidelines detailed throughout this manual
If for any reason you do not understand the test procedures or are unable to perform the tests/repairs safely, contact yourLocal Lincoln authorized field service facility for technical troubleshooting assistance before you proceed.
CaUtION
PROBLeMs(syMPtOMs)
POssIBLe CaUse
ReCOMMeNDeDCOURse Of aCtION
No welding power output. Auxiliary Power OK.
Welder has output but no control.
Wire feeder does not work whencontrol cable is connected to 14 pinconnector.
No auxiliary power.
1. Poor work lead connection towork. Make sure work clamp istightly connected to clean basemetal.
2. "Weld Terminals" switch in wrongposition. Place switch in "WeldTerminals On" posit ion whenwelding without control cable.
3. Faulty PC board.
1. Poor remote/control cable connec-tion to 6-pin or 14-pin connector.Check connections.
2. Faulty remote cable or faulty wirefeeder or wire feeder cable.Replace if necessary.
3. Faulty control potentiometer or PCboard.
1. Wire Feeder Power circuit breakeropen. Check 42V beaker andreset if tripped.
2. Faulty control cable. Repair orreplace cable.
3. Faulty wire feeder. Replace wirefeeder.
1. Open circuit breakers. Resetbreakers. If breakers keep trip-ping, reduce power draw.
2. Faulty connections to auxiliaryreceptacles. Check connections.
3. RCD tripped. Clear any groundfault and reset RCD circuit bypressing "Reset" button.
4. Faulty PC board or welder alterna-tor.
If all recommended possible areasof misadjustment have beenchecked and the problem persists,Contact your local Lincolnauthorized field service facility.
e-6tROUBLesHOOtINGe-6
RaNGeR® 305D (Ce)
Observe all Safety Guidelines detailed throughout this manual
If for any reason you do not understand the test procedures or are unable to perform the tests/repairs safely, contact yourLocal Lincoln authorized field service facility for technical troubleshooting assistance before you proceed.
CaUtION
PROBLeMs(syMPtOMs)
POssIBLe CaUse
ReCOMMeNDeDCOURse Of aCtION
The welding arc is “cold.” The weld-ing arc is not stable or is not satis-factory. the engine runs normally.The auxiliary power is normal.
1. Make sure the MODE selectorswitch is in the correct position forthe process being used. (For exam-ple, CV-WIRE, PIPE, CC-STICK.)
2. Make sure the electrode (wire, gas,voltage, current etc.) is correct forthe process being used.
3. Check for loose or faulty connec-tions at the weld output terminalsand welding cable connections.
4. The welding cables may be too longor coiled, causing an excessivevoltage drop. If all recommended possible areas of
misadjustment have been checkedand the problem persists, Contactyour local Lincoln authorizedfield service facility.
f-1DIaGRaMsf-1
RaNGeR® 305D (Ce)
f-2DIaGRaMsf-2
RaNGeR® 305D (Ce)
f-3DIaGRaMsf-3
RaNGeR® 305D (Ce)
or service this equip
ment.
Only qualified pe
rsonnel should instal
l,use
Keep away from moving parts.
Keep guards
in place.
MOVING PARTS can injure
WARNING
Do not touch elect
rically live parts.
before se
rvicing.
Disconnect NEGATIVE (-) Battery lead
Do not operate
with panel
s open.
ELECTRIC SHOCK can kill
14 P
IN
AMPH
ENOL
TO W
ORK
+_
ENGI
NE W
ELDE
RS /L
N-74
2 CON
NECT
ION
DIAG
RAM
S247
87-13
A.01
TO LN
-742
INPU
TCA
BLE
PLUG
ELEC
TROD
E CA
BLE
TO W
IRE
FEED
UNI
TCA
UTIO
N:
ANY
INCR
EASE
OF
THE
HIGH
IDLE
ENG
INE
RPM
BY C
HANG
ING
THE
GOVE
RNOR
SET
TING
OR
OVER
RIDI
NG T
HE T
HROT
TLE
LINKA
GE W
ILL C
AUSE
AN IN
CREA
SE IN
THE
AC
WIR
E FE
EDER
VOL
TAGE
, WHI
CH C
AN D
AMAG
E TH
E CO
NTRO
L CIR
CUIT
. THE
ENG
INE
GOVE
RNOR
SET
TING
IS P
RE-S
ETAT
THE
FAC
TORY
Ð DO
NOT
ADJ
UST
ABOV
E RP
M SP
ECIF
ICAT
IONS
LIST
ED IN
THE
ENG
INE
WEL
DER
OPER
ATIN
G MA
NUAL
.
N.A.
WEL
DING
CAB
LES
MUST
BE
OF P
ROPE
R CA
PACI
TY F
OR T
HE C
URRE
NT A
ND D
UTY
CYCL
E OF
IMME
DIAT
E AN
D FU
TURE
APP
LICAT
IONS
. SEE
OPE
RATI
NG M
ANUA
L.N.
B. C
ONNE
CT W
ELDI
NG C
ABLE
S TO
OUT
PUT
STUD
S FO
R DE
SIRE
D PO
LARI
TY. P
OSIT
ION
THE
WIR
E FE
EDER
VOL
TMET
ER S
WIT
CH T
O
M
ATCH
THE
POL
ARIT
Y OF
THE
ELE
CTRO
DE C
ABLE
.N.
C. P
LACE
THE
MOD
E SW
ITCH
IN T
HE ÒC
V-W
IREÓ
POS
ITIO
N.N.
D. P
LACE
WEL
DER
TERM
INAL
S SW
ITCH
TO
ÒREM
OTEL
Y CO
NTRO
LLED
Ó POS
ITIO
N.N.
E. P
LACE
IDLE
R SW
ITCH
IN Ò
AUTO
Ó OR
ÒHIG
HÓ ID
LE P
OSIT
ION
AS D
ESIR
ED.
K181
9-10
CON
TROL
CAB
LE
f-4DIaGRaMsf-4
RaNGeR® 305D (Ce)
2
9/03
f-5DIaGRaMsf-5
RaNGeR® 305D (Ce)
f-6DIaGRaMsf-6
RaNGeR® 305D (Ce)
NOte
:Th
is dia
gram
is fo
r ref
eren
ce o
nly.
It m
ay n
ot b
e ac
cura
te fo
r all m
achin
es co
vere
d by
this
man
ual.
The
spec
ific d
iagra
m fo
r a p
artic
ular c
ode
is pa
sted
inside
the
mac
hine
on o
ne o
f the
enc
losur
e pa
nels.
If t
he d
iagra
m is
illeg
ible,
writ
e to
the
Serv
ice D
epar
tmen
t for
a re
place
men
t. G
ive th
e eq
uipm
ent c
ode
num
ber.
f-7DIaGRaMsf-7
RaNGeR® 305D (Ce)
NOte
:Th
is dia
gram
is fo
r ref
eren
ce o
nly.
It m
ay n
ot b
e ac
cura
te fo
r all m
achin
es co
vere
d by
this
man
ual.
The
spec
ific d
iagra
m fo
r a p
artic
ular c
ode
is pa
sted
inside
the
mac
hine
on o
ne o
f the
enc
losur
e pa
nels.
If t
he d
iagra
m is
illeg
ible,
writ
e to
the
Serv
ice D
epar
tmen
t for
a re
place
men
t. G
ive th
e eq
uipm
ent c
ode
num
ber.
CONT
ACTO
RCO
NTRO
L
SHO
WN
IN"W
ELDI
NG O
N"PO
SITI
ON
WIR
E F
EE
D P
OW
ER
WIN
DIN
G 42 V
AC
C11
C10
42 V
AC
STAT
OR
EXCI
TATI
ON
WIN
DING D3
AR
C C
ON
TR
OL
ALL
CA
SE
FR
ON
T C
OM
PO
NE
NT
S S
HO
WN
VIE
WE
D F
RO
M R
EA
R.
42
W3
CB7
15A
S1
��W
1
ST
AT
OR
WE
LD
WIN
DIN
GS
W3
W2
75
R1
7677
278
CC
WO
UTPU
T CO
NT. P
OT
S3
2
�����
300
AM
PM
OD
ULE
SH
UN
T
50M
V=4
00 A
MP
S
RO
TO
R
ST
AT
OR
AU
X. W
IND
ING
CO
NN
ECTO
RS
VIEW
EDFR
OM
INSE
RTI
ON
EN
DEL
ECTR
ICAL
SYM
BOLS
PER
E15
37
41
206B
206A
�
��
����
+
���
����
������
�
�
HE
AT
SIN
K
208
4
279
BO
TTO
M G
ND
INS
IDE
LE
FT
CA
SE
FR
ON
T
�����
������
���
��
��������
����
�������
��
��
��
���
610
����
�
����
�
2
1
��
�
16
8 1
9
���
9
1
16
�� �
����
����
����
�����
���
����
����
�
����
�
6
15
10
����
�
����
� !"
#��
���
204S
206S
2A
13
IDLE
SO
LEN
OID
��
206S
204S
14
208B
8
CC
WR
2
B7
B8
L1 C
HOKE
�$ �%
WRA
P TW
O T
URNS
OF
LEAD
S A,
3, D
, B, &
C IN
DIRE
CTIO
NSH
OW
N TH
ROUG
H TO
ROID
CLEV
ELAN
D, O
HIO
U.S
.A.
���&
�����
����
���'
( ��
����
!�!�
&��!
�&��
���(
' 12
486
IDLE
R CO
NTRO
L
SHO
WN
IN"A
UTO
" PO
SITI
ON
S4
252
251
C3
800u
f15
0vdc
��������
����
� ����
����
����
�����
��������
���
���
�� �
�����
����
��
EN
GIN
E C
OM
PO
NE
NTS
���
����
��
���
S1R
UN
-STO
PS
WIT
CH
(SH
OW
N IN
RU
N P
OS
.)
���
��
� �
� ��
��
����� !���
�� �
"��
���
��
LEA
D C
OLO
R C
OD
E:
B=B
LAC
K O
R G
RA
YR
=RE
D O
R P
INK
W=
WH
ITE
G=G
RE
EN
(W
/YE
LLO
W S
TRIP
E)
FRAM
E G
ND
.
��
�
41A
42A
15A
208A
21
S5
VO
LTM
ET
ER
PO
LAR
ITY
SW
ITC
H
206A
SH
OW
N IN
PO
SIT
IVE
(+)
PO
SIT
ION
6
15
10
AM
PS
M1M2M3
M1
M2
M3
M4
M9
M5
M10
M10M9M6M5M4
M6
VO
LTS
M1M2M3
M10M9M6M5M4
15 15
M1
M2
M3
M4
M9
M5
M10 M6
15 15
M1
M2
M3
M4
M9
M5
M10
15 15
M1
M2
M3
M4
M5
M10
11
M1
M2
M3
M4
M5
M10
11
M1
M2
M3
M4
M5
M10
15 15
M1
M2
M3
M4
M9
M5
M10 M6
15 15
M1
M2
M3
M4
M9
M5
M10 M6
15 15
M1
M2
M3
M4
M9
M5
M10
15 15
M1
M2
M3
M4
M9
M5
M10
15 15
M1
M2
M3
M4
M9
M5
M10
15 15
M1
M2
M3
M4
M9
M5
M10
G45
72-4
PR
INT
�����
A B C D E F
77B
21 75B
GN
D-A
41A
42A
76B
CO
NT
AC
TO
R
���
���
WO
RK
���
RE
MO
TE
CO
NT
RO
L
42V
AC
GR
OU
ND
AM
PH
EN
OL
1
RE
MO
TE
CO
NT
AC
TO
R
GR
OU
ND
AM
PH
EN
OL
2
CO
NT
RO
L
J A D CH BK E F GI
���
���
BY
PA
SS
FIL
TE
RA
SS
EM
BLY
��
�� �� �� ��
208C
206C
206B
4A
��
��
��
� �
��)*
����
�+��,
�*+�
�*)�
������
�
���
�(��
���!
�� �-
��
���
S7
GLO
WP
LUG
BU
TT
ON
�
����
��
���
��� �
9
1
7
1
12
6
�.��
.��
�/��
�0��
,��+�
�-�+
"���
#�,�
����
���
)*��
�0 1
����2
3��,
�*+�
����
��4
/���
+#5
�+"�
#��
#�,�5
6+���
�1��
C8
C9
2523
Tw
iste
dP
air
� �
�
� �
�
��
����
�
8 514
12
34
P72
J72
��
���
��
200
777675
277
279
278
277
214
218
220
222
���
������
��
��
��
� �
���
��
���
� �� �
����
�
���
� �
���
��
����
����
��
��
��
�"
�"
��
��
���
�����
����"
�����
�����
�����
�"��
����� �������
���
����
�����
�����
����#
��
R3
��
"$%
"$%
����������
���
���
FU
EL
SO
LEN
OID
blk
wht
red
P73
J73
CO
ILP
UL
LC
OIL
HO
LD
blk
wht
red
CO
ILP
UL
LC
OIL
HO
LD
��
���
�
���
��
��
���
� �
S2
ST
AR
TB
UT
TO
ND4
���
��
���
���
���
���
���
��
��
���
����
���
��
�
��
���
�����
��
�
�
����"
������
��&���
����
����
'
A
�.
���
CB
2C
B3
CB
4
��
CB
116
A
���
��
����
(
��
��
��
���
��
��
��
��
�
�
�
���
����
��
NA E
�
15A
NA E
15A
�
15A
�
�
�
� �
��
� �
CB
5
�
����
!���
��� �
���
� �����
����
�'�
�����
�����
���
�����
���'
����
!���
������
�� ��
������
�'�
�����
�����
���
����
���'
�
��#�
#��
#��
230
FU
EL
SE
ND
ER
5L
P52
230
210J
5L
41 J5
2
FU
EL
GA
UG
E5M
��
��#
������
�'���
��&���
������
�����
���
����
���
GN
D. S
CR
EW
ON
RIG
HT
INS
IDE
CA
SE
FR
ON
T
��
��
��
��
���. �%
R
��
�� �� ��
(LO
CA
TE
D B
ELO
W T
ER
MIN
AL
2)
1
218
220
CV
PIP
E
CC T
IG
222
A
S6
MO
DE
SE
LE
CTO
R S
WIT
CH
2 43
�&����
����
��
12 V
OLT
BATT
ERY
-+
����
���
���
����
����#
������
����
�������
���
���
���
�� ��
��
��
����
���
�
��
���
���
8
16
�
Ran
ger
305
D C
E K
ub
ota
Wir
ing
Dia
gra
ms
- U
K 1
2486
, 126
81
f-8DIaGRaMsf-8
RaNGeR® 305D (Ce)
NOte
:Th
is dia
gram
is fo
r ref
eren
ce o
nly.
It m
ay n
ot b
e ac
cura
te fo
r all m
achin
es co
vere
d by
this
man
ual.
The
spec
ific d
iagra
m fo
r a p
artic
ular c
ode
is pa
sted
inside
the
mac
hine
on o
ne o
f the
enc
losur
e pa
nels.
If t
he d
iagra
m is
illeg
ible,
writ
e to
the
Serv
ice D
epar
tmen
t for
a re
place
men
t. G
ive th
e eq
uipm
ent c
ode
num
ber.
f-9DIMeNsION PRINtf-9
RaNGeR® 305D (Ce)
A
M21
086
60.21
1529
.329
.6775
3.6
60.00
1524
.0
59.20
1503
.7
17.50
444.5
19.50
495.3
21.06
534.9
21.50
546.1
29.83
757.6
34.24
869.8
11.03
280.2
29.63
752.6
17.00
431.8
CENT
ER O
F GR
AVIT
Y35
.0889
1.03
26.52
673.6
6.33
160.9
WARNING
AVISO DEPRECAUCION
ATTENTION
WARNUNG
ATENÇÃO
Spanish
French
German
Portuguese
Japanese
Chinese
Korean
Arabic
READ AND UNDERSTAND THE MANUFACTURER’S INSTRUCTION FOR THIS EQUIPMENT AND THECONSUMABLES TO BE USED AND FOLLOW YOUR EMPLOYER’S SAFETY PRACTICES.
SE RECOMIENDA LEER Y ENTENDER LAS INSTRUCCIONES DEL FABRICANTE PARA EL USO DEESTE EQUIPO Y LOS CONSUMIBLES QUE VA A UTILIZAR, SIGA LAS MEDIDAS DE SEGURIDAD DESU SUPERVISOR.
LISEZ ET COMPRENEZ LES INSTRUCTIONS DU FABRICANT EN CE QUI REGARDE CET EQUIPMENTET LES PRODUITS A ETRE EMPLOYES ET SUIVEZ LES PROCEDURES DE SECURITE DE VOTREEMPLOYEUR.
LESEN SIE UND BEFOLGEN SIE DIE BETRIEBSANLEITUNG DER ANLAGE UND DEN ELEKTRO-DENEINSATZ DES HERSTELLERS. DIE UNFALLVERHÜTUNGSVORSCHRIFTEN DES ARBEITGEBERSSIND EBENFALLS ZU BEACHTEN.
• Do not touch electrically live parts orelectrode with skin or wet clothing.
• Insulate yourself from work andground.
• No toque las partes o los electrodosbajo carga con la piel o ropa moja-da.
• Aislese del trabajo y de la tierra.
• Ne laissez ni la peau ni des vête-ments mouillés entrer en contactavec des pièces sous tension.
• Isolez-vous du travail et de la terre.
• Berühren Sie keine stromführendenTeile oder Elektroden mit IhremKörper oder feuchter Kleidung!
• Isolieren Sie sich von denElektroden und dem Erdboden!
• Não toque partes elétricas e electro-dos com a pele ou roupa molhada.
• Isole-se da peça e terra.
• Keep flammable materials away.
• Mantenga el material combustiblefuera del área de trabajo.
• Gardez à l’écart de tout matérielinflammable.
• Entfernen Sie brennbarres Material!
• Mantenha inflamáveis bem guarda-dos.
• Wear eye, ear and body protection.
• Protéjase los ojos, los oídos y elcuerpo.
• Protégez vos yeux, vos oreilles etvotre corps.
• Tragen Sie Augen-, Ohren- und Kör-perschutz!
• Use proteção para a vista, ouvido ecorpo.
WARNING
AVISO DEPRECAUCION
ATTENTION
WARNUNG
ATENÇÃO
Spanish
French
German
Portuguese
Japanese
Chinese
Korean
Arabic
LEIA E COMPREENDA AS INSTRUÇÕES DO FABRICANTE PARA ESTE EQUIPAMENTO E AS PARTESDE USO, E SIGA AS PRÁTICAS DE SEGURANÇA DO EMPREGADOR.
• Keep your head out of fumes.• Use ventilation or exhaust toremove fumes from breathing zone.
• Los humos fuera de la zona de res-piración.
• Mantenga la cabeza fuera de loshumos. Utilice ventilación oaspiración para gases.
• Gardez la tête à l’écart des fumées.• Utilisez un ventilateur ou un aspira-teur pour ôter les fumées des zonesde travail.
• Vermeiden Sie das Einatmen vonSchweibrauch!
• Sorgen Sie für gute Be- undEntlüftung des Arbeitsplatzes!
• Mantenha seu rosto da fumaça.• Use ventilação e exhaustão pararemover fumo da zona respiratória.
• Turn power off before servicing.
• Desconectar el cable de ali-mentación de poder de la máquinaantes de iniciar cualquier servicio.
• Débranchez le courant avant l’entre-tien.
• Strom vor Wartungsarbeitenabschalten! (Netzstrom völlig öffnen;Maschine anhalten!)
• Não opere com as tampas removidas.• Desligue a corrente antes de fazerserviço.
• Não toque as partes elétricas nuas.
• Do not operate with panel open orguards off.
• No operar con panel abierto oguardas quitadas.
• N’opérez pas avec les panneauxouverts ou avec les dispositifs deprotection enlevés.
• Anlage nie ohne Schutzgehäuseoder Innenschutzverkleidung inBetrieb setzen!
• Mantenha-se afastado das partesmoventes.
• Não opere com os paineis abertosou guardas removidas.
CUSTOMER ASSISTANCE POLICY
The business of The Lincoln Electric Company is manufacturing andselling high quality welding equipment, consumables, and cuttingequipment. Our challenge is to meet the needs of our customers andto exceed their expectations. On occasion, purchasers may askLincoln Electric for advice or information about their use of ourproducts. We respond to our customers based on the best informationin our possession at that time. Lincoln Electric is not in a position towarrant or guarantee such advice, and assumes no liability, withrespect to such information or advice. We expressly disclaim anywarranty of any kind, including any warranty of fitness for anycustomer’s particular purpose, with respect to such information oradvice. As a matter of practical consideration, we also cannot assumeany responsibility for updating or correcting any such information oradvice once it has been given, nor does the provision of informationor advice create, expand or alter any warranty with respect to the saleof our products.
Lincoln Electric is a responsive manufacturer, but the selection anduse of specific products sold by Lincoln Electric is solely within thecontrol of, and remains the sole responsibility of the customer. Manyvariables beyond the control of Lincoln Electric affect the resultsobtained in applying these types of fabrication methods and servicerequirements.
Subject to Change – This information is accurate to the best of ourknowledge at the time of printing. Please refer to www.lincolnelectric.com for any updated information.
![Journal of American Science 0203arc welding, atomic hydrogen welding, shielded metal arc welding, plasma arc welding, electroslag welding, etc. Arc welding has been described [3] to](https://img.dokumen.tips/doc/110x75/5ec0a6e76045b75960496969/journal-of-american-science-arc-welding-atomic-hydrogen-welding-shielded-metal.jpg)
