Lincoln Electric Welder 11458 User Manual
RETURN TO MAIN MENU  
IM971-A  
June, 2010  
®
Ranger 305D (CE)  
For use with machines having Code Numbers:  
11458, 11459, 11587  
Safety Depends on You  
Lincoln arc welding and cutting  
equipment is designed and built  
with safety in mind. However,  
your overall safety can be  
increased by proper installation  
... and thoughtful operation on  
your part. DO NOT INSTALL,  
OPERATE OR REPAIR THIS  
EQUIPMENT WITHOUT READ-  
ING THIS MANUAL AND THE  
SAFETY PRECAUTIONS CON-  
TAINED THROUGHOUT. And,  
most importantly, think before  
you act and be careful.  
EN 60974-1  
OPERATORʼSꢀMANUAL  
Copyright © Lincoln Global Inc.  
• World's Leader in Welding and Cutting Products •  
• Sales and Service through Subsidiaries and Distributors Worldwide •  
Cleveland, Ohio 44117-1199 U.S.A. TEL: 216.481.8100 FAX: 216.486.1751 WEBꢀSITE: www.lincolnelectric.com  
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ii  
SAFETY  
ARC RAYS can burn.  
ELECTRIC SHOCK can  
4.a. Use a shield with the proper filter and cover  
plates to protect your eyes from sparks and  
the rays of the arc when welding or observing  
open arc welding. Headshield and filter lens  
should conform to ANSI Z87. I standards.  
kill.  
3.a. The electrode and work (or ground) circuits  
are electrically “hot” when the welder is on.  
Do not touch these “hot” parts with your bare  
skin or wet clothing. Wear dry, hole-free  
gloves to insulate hands.  
4.b. Use suitable clothing made from durable flame-resistant  
material to protect your skin and that of your helpers from  
the arc rays.  
3.b. Insulate yourself from work and ground using dry insulation.  
Make certain the insulation is large enough to cover your full  
area of physical contact with work and ground.  
4.c. Protect other nearby personnel with suitable, non-flammable  
screening and/or warn them not to watch the arc nor expose  
themselves to the arc rays or to hot spatter or metal.  
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:  
FUMES AND GASES  
can be dangerous.  
5.a. Welding may produce fumes and gases  
hazardous to health. Avoid breathing these  
• Semiautomatic DC Constant Voltage (Wire) Welder.  
• DC Manual (Stick) Welder.  
fumes and gases. When welding, keep  
your head out of the fume. Use enough  
ventilation and/or exhaust at the arc to keep  
• AC Welder with Reduced Voltage Control.  
fumes and gases away from the breathing zone. When  
welding with electrodes which require special  
ventilation such as stainless or hard facing (see  
instructions on container or MSDS) or on lead or  
cadmium plated steel and other metals or coatings  
which produce highly toxic fumes, keep exposure as  
low as possible and within applicable OSHA PEL and  
ACGIH TLV limits using local exhaust or mechanical  
ventilation. In confined spaces or in some circum-  
stances, outdoors, a respirator may be required.  
Additional precautions are also required when welding  
on galvanized steel.  
3.c. In semiautomatic or automatic wire welding, the electrode,  
electrode reel, welding head, nozzle or semiautomatic  
welding gun are also electrically “hot”.  
3.d. Always be sure the work cable makes a good electrical  
connection with the metal being welded. The connection  
should be as close as possible to the area being welded.  
3.e. Ground the work or metal to be welded to a good electrical  
(earth) ground.  
3.f. Maintain the electrode holder, work clamp, welding cable and  
welding machine in good, safe operating condition. Replace  
damaged insulation.  
5. b. The operation of welding fume control equipment is affected  
by various factors including proper use and positioning of  
the equipment, maintenance of the equipment and the spe-  
cific welding procedure and application involved. Worker  
exposure level should be checked upon installation and  
periodically thereafter to be certain it is within applicable  
OSHA PEL and ACGIH TLV limits.  
3.g. Never dip the electrode in water for cooling.  
3.h. Never simultaneously touch electrically “hot” parts of  
electrode holders connected to two welders because voltage  
between the two can be the total of the open circuit voltage  
of both welders.  
5.c. Do not weld in locations near chlorinated hydrocarbon vapors  
coming from degreasing, cleaning or spraying operations.  
The heat and rays of the arc can react with solvent vapors to  
form phosgene, a highly toxic gas, and other irritating prod-  
ucts.  
3.i. When working above floor level, use a safety belt to protect  
yourself from a fall should you get a shock.  
3.j. Also see Items 6.c. and 8.  
5.d. Shielding gases used for arc welding can displace air and  
cause injury or death. Always use enough ventilation,  
especially in confined areas, to insure breathing air is safe.  
5.e. Read and understand the manufacturerʼs instructions for this  
equipment and the consumables to be used, including the  
material safety data sheet (MSDS) and follow your  
employerʼs safety practices. MSDS forms are available from  
your welding distributor or from the manufacturer.  
5.f. Also see item 1.b.  
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SAFETY  
WELDING and CUTTING  
CYLINDER may explode  
if damaged.  
SPARKS can  
cause fire or explosion.  
6.a. Remove fire hazards from the welding area.  
7.a. Use only compressed gas cylinders  
containing the correct shielding gas for the  
If this is not possible, cover them to prevent  
process used and properly operating  
the welding sparks from starting a fire.  
regulators designed for the gas and  
Remember that welding sparks and hot  
materials from welding can easily go through small cracks  
and openings to adjacent areas. Avoid welding near  
hydraulic lines. Have a fire extinguisher readily available.  
pressure used. All hoses, fittings, etc. should be suitable for  
the application and maintained in good condition.  
7.b. Always keep cylinders in an upright position securely  
chained to an undercarriage or fixed support.  
6.b. Where compressed gases are to be used at the job site,  
special precautions should be used to prevent hazardous  
situations. Refer to “Safety in Welding and Cutting” (ANSI  
Standard Z49.1) and the operating information for the  
equipment being used.  
7.c. Cylinders should be located:  
•Away from areas where they may be struck or subjected to  
physical damage.  
•A safe distance from arc welding or cutting operations and  
any other source of heat, sparks, or flame.  
6.c. When not welding, make certain no part of the electrode  
circuit is touching the work or ground. Accidental contact  
can cause overheating and create a fire hazard.  
7.d. Never allow the electrode, electrode holder or any other  
electrically “hot” parts to touch a cylinder.  
6.d. Do not heat, cut or weld tanks, drums or containers until the  
proper steps have been taken to insure that such procedures  
will not cause flammable or toxic vapors from substances  
inside. They can cause an explosion even though they have  
been “cleaned”. For information, purchase “Recommended  
Safe Practices for the Preparation for Welding and Cutting of  
Containers and Piping That Have Held Hazardous  
Substances”, AWS F4.1 from the American Welding Society  
(see address above).  
7.e. Keep your head and face away from the cylinder valve outlet  
when opening the cylinder valve.  
7.f. Valve protection caps should always be in place and hand  
tight except when the cylinder is in use or connected for  
use.  
7.g. Read and follow the instructions on compressed gas  
cylinders, associated equipment, and CGA publication P-l,  
“Precautions for Safe Handling of Compressed Gases in  
Cylinders,” available from the Compressed Gas Association  
1235 Jefferson Davis Highway, Arlington, VA 22202.  
6.e. Vent hollow castings or containers before heating, cutting or  
welding. They may explode.  
6.f. Sparks and spatter are thrown from the welding arc. Wear oil  
free protective garments such as leather gloves, heavy shirt,  
cuffless trousers, high shoes and a cap over your hair. Wear  
ear plugs when welding out of position or in confined places.  
Always wear safety glasses with side shields when in a  
welding area.  
FOR ELECTRICALLY  
powered equipment.  
8.a. Turn off input power using the disconnect  
switch at the fuse box before working on  
the equipment.  
6.g. Connect the work cable to the work as close to the welding  
area as practical. Work cables connected to the building  
framework or other locations away from the welding area  
increase the possibility of the welding current passing  
through lifting chains, crane cables or other alternate cir-  
cuits. This can create fire hazards or overheat lifting chains  
or cables until they fail.  
8.b. Install equipment in accordance with the U.S. National  
Electrical Code, all local codes and the manufacturerʼs  
recommendations.  
8.c. Ground the equipment in accordance with the U.S. National  
Electrical Code and the manufacturerʼs recommendations.  
6.h. Also see item 1.c.  
6.I. Read and follow NFPA 51B “ Standard for Fire Prevention  
During Welding, Cutting and Other Hot Work”, available  
from NFPA, 1 Batterymarch Park, PO box 9101, Quincy, Ma  
022690-9101.  
6.j. Do not use a welding power source for pipe thawing.  
Refer to http://www.lincolnelectric.com/safety for additional safety information.  
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SAFETY  
5. Toujours porter des lunettes de sécurité dans la zone de  
soudage. Utiliser des lunettes avec écrans lateraux dans les  
zones où lʼon pique le laitier.  
PRÉCAUTIONS DE SÛRETÉ  
Pour votre propre protection lire et observer toutes les instruc-  
tions et les précautions de sûreté specifiques qui parraissent  
dans ce manuel aussi bien que les précautions de sûreté  
générales suivantes:  
6. Eloigner les matériaux inflammables ou les recouvrir afin de  
prévenir tout risque dʼincendie dû aux étincelles.  
7. Quand on ne soude pas, poser la pince à une endroit isolé de  
la masse. Un court-circuit accidental peut provoquer un  
échauffement et un risque dʼincendie.  
Sûreté Pour Soudage A LʼArc  
1. Protegez-vous contre la secousse électrique:  
a. Les circuits à lʼélectrode et à la piéce sont sous tension  
quand la machine à souder est en marche. Eviter toujours  
tout contact entre les parties sous tension et la peau nue  
ou les vétements mouillés. Porter des gants secs et sans  
trous pour isoler les mains.  
b. Faire trés attention de bien sʼisoler de la masse quand on  
soude dans des endroits humides, ou sur un plancher  
metallique ou des grilles metalliques, principalement dans  
les positions assis ou couché pour lesquelles une  
grande partie du corps peut être en contact avec la  
masse.  
c. Maintenir le porte-électrode, la pince de masse, le câble  
de soudage et la machine à souder en bon et sûr état  
defonctionnement.  
d.Ne jamais plonger le porte-électrode dans lʼeau pour le  
refroidir.  
e. Ne jamais toucher simultanément les parties sous tension  
des porte-électrodes connectés à deux machines à soud-  
er parce que la tension entre les deux pinces peut être le  
total de la tension à vide des deux machines.  
f. Si on utilise la machine à souder comme une source de  
courant pour soudage semi-automatique, ces precautions  
pour le porte-électrode sʼapplicuent aussi au pistolet de  
soudage.  
8. Sʼassurer que la masse est connectée le plus prés possible  
de la zone de travail quʼil est pratique de le faire. Si on place  
la masse sur la charpente de la construction ou dʼautres  
endroits éloignés de la zone de travail, on augmente le risque  
de voir passer le courant de soudage par les chaines de lev-  
age, câbles de grue, ou autres circuits. Cela peut provoquer  
des risques dʼincendie ou dʼechauffement des chaines et des  
câbles jusquʼà ce quʼils se rompent.  
9. Assurer une ventilation suffisante dans la zone de soudage.  
Ceci est particuliérement important pour le soudage de tôles  
galvanisées plombées, ou cadmiées ou tout autre métal qui  
produit des fumeés toxiques.  
10. Ne pas souder en présence de vapeurs de chlore provenant  
dʼopérations de dégraissage, nettoyage ou pistolage. La  
chaleur ou les rayons de lʼarc peuvent réagir avec les  
vapeurs du solvant pour produire du phosgéne (gas forte-  
ment toxique) ou autres produits irritants.  
11. Pour obtenir de plus amples renseignements sur la sûreté,  
voir le code “Code for safety in welding and cutting” CSA  
Standard W 117.2-1974.  
2. Dans le cas de travail au dessus du niveau du sol, se pro-  
téger contre les chutes dans le cas ou on recoit un choc. Ne  
jamais enrouler le câble-électrode autour de nʼimporte quelle  
partie du corps.  
PRÉCAUTIONS DE SÛRETÉ POUR  
LES MACHINES À SOUDER À  
TRANSFORMATEUR ET À  
REDRESSEUR  
3. Un coup dʼarc peut être plus sévère quʼun coup de soliel,  
donc:  
a. Utiliser un bon masque avec un verre filtrant approprié  
ainsi quʼun verre blanc afin de se protéger les yeux du  
rayonnement de lʼarc et des projections quand on soude  
ou quand on regarde lʼarc.  
b. Porter des vêtements convenables afin de protéger la  
peau de soudeur et des aides contre le rayonnement de  
lʻarc.  
1. Relier à la terre le chassis du poste conformement au code  
de lʼélectricité et aux recommendations du fabricant. Le dis-  
positif de montage ou la piece à souder doit être branché à  
une bonne mise à la terre.  
c. Protéger lʼautre personnel travaillant à proximité au  
soudage à lʼaide dʼécrans appropriés et non-inflamma-  
bles.  
2. Autant que possible, Iʼinstallation et lʼentretien du poste  
seront effectués par un électricien qualifié.  
3. Avant de faires des travaux à lʼinterieur de poste, la  
debrancher à lʼinterrupteur à la boite de fusibles.  
4. Des gouttes de laitier en fusion sont émises de lʼarc de  
soudage. Se protéger avec des vêtements de protection  
libres de lʼhuile, tels que les gants en cuir, chemise épaisse,  
pantalons sans revers, et chaussures montantes.  
4. Garder tous les couvercles et dispositifs de sûreté à leur  
place.  
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SAFETY  
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ꢑꢛ'ꢇ5ꢇꢕ2ꢞꢇ3!ꢇ  
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"ꢉꢝꢝꢆꢅꢎꢀꢖꢇꢀꢑꢉꢊꢆꢅꢉꢎꢆꢋꢅꢇꢀ ꢀ  
ꢗꢅꢘꢔꢊꢇꢅꢋꢌ#ꢎꢀ  
-ꢒꢍꢞꢗꢓꢒ!ꢀꢞꢐꢗꢕ!ꢀꢝꢐ8ꢒꢓꢀ$ꢒꢎꢒ$ꢀ%ꢀꢀ  
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 ꢇꢃꢇꢐꢐꢇꢍꢇꢅꢀꢐꢌ#ꢉꢑꢑꢇꢋꢐꢎꢂꢍꢓꢐꢝꢇꢓꢇꢑꢀ  
ꢈꢉꢊꢋꢌꢈꢊ6ꢇ  
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ꢄꢇ7*$8*)ꢝꢇꢀꢁꢁ ꢇ  
" ꢇꢘ#.ꢒ0ꢇ  
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ꢙꢋꢇꢐꢇꢀ )ꢇꢐꢌ#ꢇꢋꢍꢋꢓꢂꢍꢓꢀ ꢞꢋꢅꢖꢀ ꢂꢍꢎꢇꢅꢀ ꢔꢆꢑꢓꢇꢍꢖꢇꢍꢀ )ꢇꢖꢋꢍꢓꢂꢍꢓꢇꢍꢀ  
ꢉꢂꢐꢓꢇꢐꢎꢇꢑꢑꢎ-ꢀ  
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/4ꢍꢕꢑꢒꢀ ꢘꢕꢀ 04ꢒꢀ ꢍ,ꢐꢎꢒꢀ ꢓꢒ.ꢒꢓꢒꢕ/ꢒ!ꢀ 0ꢒ/4ꢕꢘ/ꢍ$ꢀ .ꢘ$ꢒ1ꢀ  
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.+ꢀ/ꢑꢀ ꢍꢇꢀ ꢐ(ꢉꢝꢝꢑꢋ$ꢂꢇꢀ $ꢂ(ꢉꢂꢀ ꢎ0ꢝꢇꢀ ꢃꢇꢍꢎꢋꢆꢍꢍꢄ1ꢀ ꢐꢉꢍꢐꢀ  
ꢌ#ꢉꢍꢓꢇꢃꢇꢍꢎꢀ ꢖꢉꢍꢐꢀ ꢑꢇꢀ ꢖꢆꢐꢐꢋꢇꢅꢀ ꢎꢇꢌ#ꢍꢋ$ꢂꢇꢀ ꢐꢆꢂꢃꢋꢐꢀ ꢉꢂꢀ  
2ꢁꢜꢀꢇꢎꢀꢅꢄꢔꢄꢅꢇꢍꢌꢄꢀꢌꢋ!ꢖꢇꢐꢐꢂꢐ+ꢀ  
.+ꢀ6ꢋꢇꢀ ꢓꢋꢑꢎꢀ ꢔꢘꢅꢀ ꢖꢉꢐꢀ ꢓꢇꢝꢅꢘꢔꢎꢇꢀ )ꢉꢂꢃꢂꢐꢎꢇꢅ1ꢀ ꢆ#ꢍꢇꢀ :ꢍꢖꢇꢅꢂꢍꢓꢀ ꢖꢇꢅꢀ  
ꢎꢇꢌ#ꢍꢋꢐꢌ#ꢇꢍꢀꢙꢆ;ꢂꢃꢇꢍꢎꢉꢎꢋꢆꢍꢀꢖꢋꢇꢀꢖꢇꢃꢀ2ꢁꢜꢀꢘꢊꢇꢅꢃꢋꢎꢎꢇꢑꢎꢀꢞꢂꢅꢖꢇ+ꢀ  
ꢋꢏꢀ 0ꢀ ꢘ+ꢝ$ꢘꢒꢞꢀ 04ꢍ0ꢀ ꢍꢀ .ꢐ$$ꢐ8ꢙꢗꢝꢀ ꢐ.ꢀ 04ꢒꢀ +ꢍꢕꢗ.ꢍ/0ꢗꢓꢘꢕꢑꢀ ꢘꢞꢀ  
ꢝꢒꢓ.ꢐꢓ+ꢒ!ꢀ8ꢘ04ꢀꢍꢀꢁ*ꢇꢀ/ꢐꢕ0ꢓꢐ$1ꢀ/ꢍꢓꢓꢘꢒ!ꢀꢐꢗ0ꢀꢍ0ꢀ$ꢒꢍꢞ0ꢀꢐꢕ/ꢒꢀ  
ꢒꢎꢒꢓ6ꢀ 04ꢓꢒꢒꢀ 6ꢒꢍꢓꢞꢏꢀ =ꢘ04ꢐꢗ0ꢀ 04ꢘꢞꢀ /ꢐꢕ0ꢓꢐ$ꢀ ꢐꢓꢀ ꢘꢕꢀ /ꢍꢞꢒꢀ ꢐ.ꢀ  
ꢕꢐꢕ/ꢐꢕ.ꢐꢓ+ꢘ061ꢀ04ꢒꢀꢁ*ꢇꢀꢘꢞꢀ,ꢐꢗꢕ!ꢀ0ꢐꢀꢀꢘꢕ.ꢐꢓ+ꢀ04ꢒꢀꢉꢓꢒꢕ/4ꢀ  
-ꢘꢕꢘꢞ0ꢓ6ꢀꢘꢕꢀ/4ꢍꢓꢑꢒꢀꢐ.ꢀꢒꢕꢎꢘꢓꢐꢕ+ꢒꢕ0ꢏꢀ  
3+ꢀ/ꢑꢀꢋꢃꢝꢑꢋ$ꢂꢇꢀ$ꢂ%ꢂꢍꢇꢀꢐꢂꢅꢚꢇꢋꢑꢑꢉꢍꢌꢇꢀꢖꢇꢀꢝꢅꢆꢖꢂꢌꢎꢋꢆꢍꢀꢇꢐꢎꢀꢃꢋꢐꢇꢀ  
ꢇꢍꢀꢝꢑꢉꢌꢇꢀꢉꢚꢇꢌꢀꢂꢍꢀꢌꢆꢍꢎꢅ4ꢑꢇꢀꢝꢉꢅꢀꢑꢇꢀ2ꢁꢜꢀꢉꢂꢀꢃꢆꢋꢍꢐꢀꢎꢆꢂꢐꢀ  
ꢑꢇꢐꢀ 5ꢀ ꢉꢍꢐ+ꢀ 6ꢉꢍꢐꢀ ꢌꢇꢀ ꢌꢆꢍꢎꢅ4ꢑꢇꢀ ꢆꢂꢀ ꢇꢍꢀ ꢌꢉꢐꢀ ꢖꢇꢀ ꢍꢆꢍꢀ  
ꢌꢆꢍꢔꢆꢅꢃꢋꢎꢄ1ꢀ ꢑꢇꢀ 2ꢁꢜꢀ ꢇꢐꢎꢀ ꢇꢍꢓꢉꢓꢄꢀ 7ꢀ ꢇꢍꢀ ꢋꢍꢔꢆꢅꢃꢇꢅꢀ ꢑꢇꢀ  
,ꢋꢍꢋꢐꢎ8ꢅꢇꢀꢈꢅꢉꢍ9ꢉꢋꢐꢀꢌ#ꢉꢅꢓꢄꢀꢖꢇꢀꢑ(ꢜꢍꢚꢋꢅꢆꢍꢍꢇꢃꢇꢍꢎ+ꢀ  
3+ꢀꢜꢋꢍꢀ <ꢊꢇꢅꢞꢉꢌ#ꢂꢍꢓꢐꢚꢇꢅꢔꢉ#ꢅꢇꢍꢀ ꢖꢇꢅꢀ ꢏꢇꢅꢐꢎꢇꢑꢑꢂꢍꢓꢀ ꢞꢂꢅꢖꢇꢀ  
ꢖꢂꢅꢌ#ꢓꢇꢔꢘ#ꢅꢎꢀꢃꢋꢎꢀꢇꢋꢍꢇꢅꢀ<ꢊꢇꢅꢝꢅꢘꢔꢂꢍꢓꢀꢚꢆꢍꢀ2ꢁꢜꢀꢀꢃꢋꢍꢖꢇꢐꢎꢇꢍꢐꢀꢉꢑꢑꢇꢀ  
5ꢀ =ꢉ#ꢅꢇ+ꢀ ꢒ#ꢍꢇꢀ ꢖꢋꢇꢐꢇꢀ <ꢊꢇꢅꢝꢅꢘꢔꢂꢍꢓꢀ ꢆꢖꢇꢅꢀ ꢋꢃꢀ ꢈꢉꢑꢑꢇꢀ ꢇꢋꢍꢇꢅꢀ  
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ꢎ)*::ꢛ4;ꢇꢀꢞꢇꢐ*)<=ꢇꢀꢁꢁ"ꢇ  
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vi  
vi  
SAFETY  
THE LINCOLN ELECTRIC COMPANY  
EC DECLARATION OF CONFORMITY  
Manufacturer and technical documentation  
holder:  
The Lincoln Electric Company  
Address:  
22801 St. Clair Ave.  
Cleveland Ohio 44117-1199 USA  
EC Company:  
Address:  
Lincoln Electric Europe S.L.  
c/o Balmes, 89 - 80 2a  
08008 Barcelona  
SPAIN  
Hereby declare that machine:  
Sales code:  
Welding Equipment - Ranger 305D  
K2279 (with prefixes and suffixes)  
Is in conformity with Council Directives and  
amendments:  
EMC Directive 89/336/EEC  
Low Voltage Directive 73/23/EEC  
Noise emission in the environment by equipment for use outdoors  
2000/14/EC; Annex VI, procedure 1  
Standards:  
EN 50199 Electromagnetic compatibility (EMC) product standard  
for arc welding equipment, 1995 + A1  
EN 60974-1, Safety requirements for arc welding equipment, power  
sources, 1998 + A1  
EN ISO 3744, Acoustic ñ Determination of sound power levels of  
noise sources using sound pressure Ö 1995  
Notified body (for 2000/14/EC Conformity): LNE ñ Number: 0071  
Address:  
ZA de Trappes-…lancourt  
29, avenue Roger Hennequin  
78197 TRAPPES Cedex  
Guaranteed sound power level:  
Measured sound power level:  
LWA 97 dB (net power Pel = 7.5kW)  
LWA 96 dB (net power Pel = 7.5kW)  
Frank Stupczy, Manufacturer  
Compliance Engineering Manager  
25 January 2006  
Dario Gatti, European Community Representative  
European Engineering Director Machines  
26 January 2006  
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vii  
vii  
SAFETY  
Electromagnetic Compatibility (EMC)  
Conformance  
Products displaying the CE mark are in conformity with European Community Council Directive of 15 Dec  
2004 on the approximation of the laws of the Member States relating to electromagnetic compatibility,  
2004/108/EC. It was manufactured in conformity with a national standard that implements a harmonized  
standard: EN 60974-10 Electromagnetic Compatibility (EMC) Product Standard for Arc Welding Equipment.  
It is for use with other Lincoln Electric equipment. It is designed for industrial and professional use.  
Introduction  
All electrical equipment generates small amounts of electromagnetic emission. Electrical emission may be  
transmitted through power lines or radiated through space, similar to a radio transmitter. When emissions  
are received by other equipment, electrical interference may result. Electrical emissions may affect many  
kinds of electrical equipment; other nearby welding equipment, radio and TV reception, numerical controlled  
machines, telephone systems, computers, etc. Be aware that interference may result and extra precautions  
may be required when a welding power source is used in a domestic establishment.  
Installation and Use  
The user is responsible for installing and using the welding equipment according to the manufacturer’s  
instructions. If electromagnetic disturbances are detected then it shall be the responsibility of the user of the  
welding equipment to resolve the situation with the technical assistance of the manufacturer. In some cases  
this remedial action may be as simple as earthing (grounding) the welding circuit, see Note. In other cases it  
could involve construction of an electromagnetic screen enclosing the power source and the work complete  
with associated input filters. In all cases electromagnetic disturbances must be reduced to the point where  
they are no longer troublesome.  
Note: The welding circuit may or may not be earthed for safety reasons according to national codes.  
Changing the earthing arrangements should only be authorized by a person who is compe-  
tent to access whether the changes will increase the risk of injury, e.g., by allowing parallel  
welding current return paths which may damage the earth circuits of other equipment.  
Assessment of Area  
Before installing welding equipment the user shall make an assessment of potential electromagnetic 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 the  
welding equipment;  
b) radio and television transmitters and receivers;  
c) computer and other control equipment;  
d) safety critical equipment, e.g., guarding of industrial equipment;  
e) the health of the people around, e.g., the use of pacemakers and hearing aids;  
f) equipment used for calibration or measurement  
g) the immunity of other equipment in the environment. The user shall ensure that other equipment being  
used in the environment is compatible. This may require additional protection measures;  
h) the time of day that welding or other activities are to be carried out.  
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viii  
viii  
SAFETY  
Electromagnetic Compatibility (EMC)  
The size of the surrounding area to be considered will depend on the structure of the building and other  
activities that are taking place. The surrounding area may extend beyond the boundaries of the premises.  
Methods of Reducing Emissions  
Mains Supply  
Welding equipment should be connected to the mains supply according to the manufacturer’s recommenda-  
tions. If interference occurs, it may be necessary to take additional precautions such as filtering of the mains  
supply. Consideration should be given to shielding the supply cable of permanently installed welding equip-  
ment, in metallic conduit or equivalent. Shielding should be electrically continuous throughout its length. The  
shielding should be connected to the welding power source so that good electrical contact is maintained  
between the conduit and the welding power source enclosure.  
Maintenance of the Welding Equipment  
The welding equipment should be routinely maintained according to the manufacturer’s recommendations.  
All access and service doors and covers should be closed and properly fastened when the welding equip-  
ment is in operation. The welding equipment should not be modified in any way except for those changes  
and adjustments covered in the manufacturers instructions. In particular, the spark gaps of arc striking and  
stabilizing devices should be adjusted and maintained according to the manufacturer’s recommendations.  
Welding Cables  
The welding cables should be kept as short as possible and should be positioned close together, running at  
or close to floor level.  
Equipotential Bonding  
Bonding of all metallic components in the welding installation and adjacent to it should be considered.  
However, metallic components bonded to the work piece will increase the risk that the operator could  
receive a shock by touching these metallic components and the electrode at the same time. The operator  
should be insulated from all such bonded metallic components.  
Earthing of the Workpiece  
Where the workpiece is not bonded to earth for electrical safety, not connected to earth because of its size  
and position, e.g., ships hull or building steelwork, a connection bonding the workpiece to earth may reduce  
emissions in some, but not all instances. Care should be taken to prevent the earthing of the workpiece  
increasing the risk of injury to users, or damage to other electrical equipment. Where necessary, the connec-  
tion of the workpiece to earth should be made by a direct connection to the workpiece, but in some countries  
where direct connection is not permitted, the bonding should be achieved by suitable capacitance, selected  
according to national regulations.  
Screening and Shielding  
Selective screening and shielding of other cables and equipment in the surrounding area may alleviate prob-  
lems of interference. Screening of the entire welding installation may be considered for special  
1.  
applications  
_________________________  
1
Portions of the preceding text are contained in EN 60974-10: “Electromagnetic Compatibility (EMC) prod-  
uct standard for arc welding equipment.”  
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ix  
ix  
for selecting a QUALITY product by Lincoln Electric. We want you  
to take pride in operating this Lincoln Electric Company product  
••• as much pride as we have in bringing this product to you!  
Thank You  
CUSTOMER ASSISTANCE POLICY  
The business of The Lincoln Electric Company is manufacturing and selling high quality welding equipment, consumables, and cutting equip-  
ment. Our challenge is to meet the needs of our customers and to exceed their expectations. On occasion, purchasers may ask Lincoln  
Electric for advice or information about their use of our products. We respond to our customers based on the best information in our posses-  
sion at that time. Lincoln Electric is not in a position to warrant or guarantee such advice, and assumes no liability, with respect to such infor-  
mation or advice. We expressly disclaim any warranty of any kind, including any warranty of fitness for any customerʼs particular purpose,  
with respect to such information or advice. As a matter of practical consideration, we also cannot assume any responsibility for updating or  
correcting any such information or advice once it has been given, nor does the provision of information or advice create, expand or alter any  
warranty with respect to the sale of our products.  
Lincoln Electric is a responsive manufacturer, but the selection and use of specific products sold by Lincoln Electric is solely within the control  
of, and remains the sole responsibility of the customer. Many variables beyond the control of Lincoln Electric affect the results obtained in  
applying these types of fabrication methods and service requirements.  
Subject to Change – This information is accurate to the best of our knowledge at the time of printing. Please refer to www.lincolnelectric.com  
for any updated information.  
Please Examine Carton and Equipment For Damage Immediately  
When this equipment is shipped, title passes to the purchaser upon receipt by the carrier. Consequently, Claims  
for material damaged in shipment must be made by the purchaser against the transportation company at the  
time the shipment is received.  
Please record your equipment identification information below for future reference. This information can be  
found on your machine nameplate.  
Product _________________________________________________________________________________  
Model Number ___________________________________________________________________________  
Code Number or Date Code_________________________________________________________________  
Serial Number____________________________________________________________________________  
Date Purchased___________________________________________________________________________  
Where Purchased_________________________________________________________________________  
Whenever you request replacement parts or information on this equipment, always supply the information you  
have recorded above. The code number is especially important when identifying the correct replacement parts.  
On-Line Product Registration  
- Register your machine with Lincoln Electric either via fax or over the Internet.  
• For faxing: Complete the form on the back of the warranty statement included in the literature packet  
accompanying this machine and fax the form per the instructions printed on it.  
• For On-Line Registration: Go to our WEBꢀSITE at www.lincolnelectric.com. Choose “Quick Links” and then  
“Product Registration”. Please complete the form and submit your registration.  
Read this Operators Manual completely before attempting to use this equipment. Save this manual and keep it  
handy for quick reference. Pay particular attention to the safety instructions we have provided for your protection.  
The level of seriousness to be applied to each is explained below:  
WARNING  
This statement appears where the information must be followed exactly to avoid serious personal injury or loss of life.  
CAUTION  
This statement appears where the information must be followed to avoid minor personal injury or damage to this equipment.  
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x
x
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-5  
Cable 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  
Welding Operation................................................................................................................B-5  
Duty Cycle.....................................................................................................................B-5  
Constant Current (Stick) Welding..................................................................................B-5  
Downhill Pipe (Stick) Welding .......................................................................................B-5  
Tig Welding ...................................................................................................................B-5  
Typical Current Ranges for Tungsten Electrodes .........................................................B-5  
Wire Welding-CV...........................................................................................................B-6  
Arc Gouging ..................................................................................................................B-6  
Auxiliary Power .............................................................................................................B-6  
________________________________________________________________________________  
Accessories.....................................................................................................Section C  
Field Installed Options / Accessories ...............................................................................C-1  
________________________________________________________________________________  
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xi  
xi  
TABLE OF CONTENTS  
Maintenance......................................................................................................Section D  
Safety Precautions ................................................................................................D-1  
Routine Maintenance ............................................................................................D-1  
Engine Maintenance Components ........................................................................D-1  
Kubota Diesel Engine............................................................................................D-1  
Engine Oil Change..........................................................................................D-2  
Engine Oil Refill Capacities.............................................................................D-2  
Engine Oil Filter Change.................................................................................D-2  
Air Cleaner Service.........................................................................................D-2  
Service Instructions And Installation Tips for Engine Air Filter .......................D-3  
Cooling System .....................................................................................................D-4  
Fan Belt...........................................................................................................D-4  
Fuel.................................................................................................................D-4  
Bleeding the Fuel System...............................................................................D-4  
Fuel Filter........................................................................................................D-5  
Engine Adjustment..........................................................................................D-5  
Battery Maintenance .......................................................................................D-5  
Servicing Optional Spark Arrestor ...................................................................D-5  
Welder / Generator Maintenance ........................................................................D-6  
Storage ...........................................................................................................D-6  
Cleaning..........................................................................................................D-6  
Brush Removal and Replacement ..................................................................D-6  
________________________________________________________________________  
Troubleshooting..............................................................................................Section E  
How to Use Troubleshooting Guide.......................................................................E-1  
Troubleshooting Guide.............................................................................E-2 thru E-6  
________________________________________________________________________  
Diagrams and Dimension Print ......................................................................Section F  
________________________________________________________________________  
Parts List.................................................................................................................P-494  
________________________________________________________________________  
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A-1  
A-1  
INSTALLATION  
TECHNICAL SPECIFICATIONS - RANGER® 305D (CE)(  
INPUT - DIESEL ENGINE  
K2279-1, K2279-2, K2279-3)  
Make/Model  
Description  
Speed (RPM)  
Displacement  
Starting  
System  
Capacities  
cu. in. (cu. cm.)  
3 cylinder, 4 stroke  
15.9 HP  
43.88(789)  
12VDC Battery & Fuel:  
starter  
45L (12 US.gal.)  
(12 KW)  
High Idle 3100  
Full Load 3000  
Low Idle 2200  
Bore x Stroke inch (mm)  
Oil:  
(3)  
Kubota  
Net intermittent  
3000 RPM  
3.2L(3.4 US. Qts.)  
D722  
2.64 x 2.68  
(Group 58; 550 Radiator Coolant:  
cold crank amps) 3.6L(3.85 U Qts)  
Battery Charger  
naturally aspirated  
water cooled  
Diesel engine  
(67 x 68 mm)  
(3.6L)  
RATED OUTPUT @ 40° C (104° F) - WELDER  
Welding Process  
Welding Output  
Current/Voltage/Duty Cycle  
250A / 30V / 100%  
Output Range  
Max. Weld OCV  
@Rated Load RPM  
DC Constant Current  
DC Pipe Current  
20 TO 305 AMPS  
40 TO 300 AMPS  
20 TO 250 AMPS  
14 TO 29 VOLTS  
250A / 30V / 100%  
®
250A / 20V / 100%  
60 Volts  
Touch-Start TIG  
250A / 27V / 100%  
DC Constant Voltage  
RATED OUTPUT @ 40° C (104° F) - GENERATOR  
(1)  
Auxiliary Power  
8,500 Watts Peak, / 8,000 Watts Continuous, 50 Hz 230/400 Volts - 3 Phase  
Sound Levels  
Sound Power: 97 dB Lwa  
PHYSICAL DIMENSIONS  
HEIGHT  
WIDTH  
546mm  
21.50 in  
DEPTH  
1524mm  
60.0 in.  
WEIGHT  
909mm  
341kg.ꢀ(752lbs.)  
(2)  
30.0 in.  
ENGINE  
LUBRICATION  
EMISSIONS  
FUEL SYSTEM  
GOVERNOR  
Full Pressure  
Certified to  
Mechanical Fuel Pump, Auto air bleed  
with Full Flow Filter EPA Tier 4  
Compliant  
system Electric shutoff solenoid Indirect fuel injector. Mechanical Governor  
AIR CLEANER  
ENGINE IDLER  
MUFFLER  
Low noise Muffler:  
ENGINE PROTECTION  
Shutdown on low oil  
pressure & engine  
Single Element  
Automatic Idler  
Made from long life, aluminized steel.  
temperature  
(3)  
ENGINE WARRANTY: 2 year complete (parts and labor) 3rd. year major components (parts and labor)  
MODEL NUMBER  
K2279-1, K2279-3 (UK)  
400V (3 Ph) x 1  
K2279-2 (EUROPE)  
400V (3 Ph) x 1  
230V (1 Ph) x 2  
14 Pin Connector  
6 Pin Connector  
Receptacles  
230V (1 Ph) x 1  
(4)  
115V x 1  
14 Pin Connector  
6 Pin Connector  
Residual Current Device (RCD)  
4-pole, 25 Amp  
4-pole, 25 Amp  
(30mA trip current)  
3 Phase, 20 Amp x 1  
1 Phase, 15 Amp x 4  
(30mA trip current)  
3 Phase, 20 Amp x 1  
1 Phase, 15 Amp x 5  
Circuit Breakers (Thermal/Magnetic)  
(1) Output rating in watts is equivalent to volt-amperes at unity power factor. Output voltage is within 10% at all loads up to rated capacity. When welding,  
available auxiliary power will be reduced.  
(2) To top of enclosure, add 152mm (6ꢀ“) to top of exhaust elbow.  
(3) Engine warranty may vary outside of the USA. (See Engine warranty for details)  
(4) Center-Tapped to ground.  
RANGER® 305D (CE)  
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A-2  
A-2  
INSTALLATION  
SAFETY PRECAUTIONS  
LIFTING  
The machine weighs approximately 374 kg. (824 lbs)  
with a full tank of fuel. A lift bail is mounted to the  
machine and should always be used when lifting the  
machine.  
WARNING  
Do not attempt to use this equipment until you  
have thoroughly read the engine manufacturerʼs  
manual supplied with your welder. It includes  
important safety precautions, detailed engine  
starting, operating and maintenance instructions,  
and parts lists.  
WARNING  
• Lift only with equipment of ade-  
quate lifting capacity.  
------------------------------------------------------------------------  
ELECTRIC SHOCK can kill.  
• Be sure machine is stable when lift-  
ing.  
• Do not touch electrically live parts or  
electrode with skin or wet clothing.  
• Do not lift this machine using lift  
bail if it is equipped with a heavy  
accessory such as trailer or gas  
cylinder.  
• Insulate yourself from work and  
ground  
• Always wear dry insulating gloves.  
------------------------------------------------------------------------  
FALLING  
• Do not lift machine if lift bail is  
damaged.  
• Do not operate machine while  
suspended from lift bail.  
EQUIPMENT can  
cause injury.  
ENGINEꢀEXHAUSTꢀcan kill.  
• Use in open, well ventilated areas or  
vent exhaust outside.  
--------------------------------------------------------------------------------  
------------------------------------------------------------------------  
HIGH ALTITUDE OPERATION  
MOVING PARTSꢀcan injure.  
• Do not operate with doors open or  
guards off.  
At 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 restricted  
within the United States and some European Countries. Use  
above 1828m (6000 ft.) may be limited due to poor engine per-  
formance or excessive exhaust smoke. An authorized Kubota  
engine field service shop should be contacted to determine if  
any adjustments can be made for operation in higher elevations  
locally.  
• Stop engine before servicing.  
• Keep away from moving parts.  
------------------------------------------------------------------------  
See additional warning information at  
front of this operatorʼs manual.  
Only qualified personnel should install,  
use, or service this equipment.  
HIGH TEMPERATURE OPERATION  
LOCATION AND VENTILATION  
At temperatures above 40°C,welder output derating is neces-  
sary. For maximum output ratings, derate the welder output 2  
volts for every 10°C above 40°C.  
The welder should be located to provide an unrestrict-  
ed flow of clean, cool air to the cooling air inlets and to  
avoid restricting the cooling air outlets. Also, locate the  
welder so that the engine exhaust fumes are properly  
vented to an outside area.  
Cold weather starting:  
With a fully charged battery and the proper oil, the  
engine should start satisfactorily down to about -15°C  
(5°F). If the engine must be frequently started at or  
below -5°C (23°F), it may be desirable to install 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.  
STACKING  
RANGER® 305D (CE) machines cannot be stacked.  
ANGLE OF OPERATION  
Engines are designed to run in the level condition  
which is where the optimum performance is achieved.  
The maximum angle of continuous operation is 20  
degrees in all directions, 35 degrees Intermittent (less  
than 10 minutes continuous) in all directions. If the  
engine is to be operated at an angle, provisions must  
be made for checking and maintaining the oil level at  
the normal (FULL) oil capacity in the crankcase.  
WARNING  
Note: Extreme cold weather starting may require  
longer glow plug operation.  
Under no conditions should ether or other starting  
fluids be used!  
When operating the welder at an angle, the effective  
fuel capacity will be slightly less than the specified 45  
liters (12 gallons).  
------------------------------------------------------------------------  
RANGER® 305D (CE)  
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A-3  
A-3  
INSTALLATION  
PRE-OPERATION ENGINE SERVICE  
TOWING  
READ the engine operating and maintenance instruc-  
tions supplied with this machine.  
Check with distributor for the recommended trailer for use with  
this equipment for road, in-plant and yard towing by a vehicle. If  
the user adapts a non-Lincoln trailer, he must assume responsi-  
bility that the method of attachment and usage does not result  
in a safety hazard nor damage the welding equipment. Some of  
the factors to be considered are as follows:  
WARNING  
• 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.  
1. Design capacity of trailer vs. weight of Lincoln equipment and  
likely additional attachments.  
• Wipe up spilled fuel and allow fumes to clear  
before starting engine.  
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.  
• Keep sparks and flame away from tank.  
------------------------------------------------------------------------  
3. Proper placement of the equipment on the trailer to insure  
stability side to side and front to back when being moved  
and when standing by itself while being operated or ser-  
viced.  
OIL  
The machine is shipped with the engine crankcase  
filled with high quality SAE 10W-30 Oil that meets  
classification CG-4 or CH-4 for diesel engines. Check  
the oil level before starting the engine. If it is not up to  
the full mark on the dip stick, add oil as required.  
Check the oil level every four hours of running time  
during the first 50 running hours. Refer to the engine  
Operatorʼs Manual for specific oil recommendations  
and break-in information. The oil change interval is  
dependent on the quality of the oil and the operating  
environment. Refer to the Engine Operatorʼs Manual  
for more details on the proper service and mainte-  
nance intervals.  
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.  
VEHICLE MOUNTING  
WARNING  
Improperly mounted concentrated loads may  
cause unstable vehicle handling and tires or other  
components to fail.  
FUEL  
USE DIESEL FUEL ONLY  
WARNING  
• Only transport this Equipment on serviceable  
vehicles which are rated and designed for such  
loads.  
• Fill the fuel tank with clean, fresh fuel. The  
capacity of the tank is, about 45 ltr.ʼs (12 Gal.ʼs).  
• Distribute, balance and secure loads so vehicle  
is stable under conditions of use.  
WARNING  
• Do not exceed maximum rated loads for compo-  
nents such as suspension, axles and tires.  
• Mount equipment base to metal bed or frame of  
vehicle.  
NOTE: A fuel shut off valve is located on the pre-  
filter/sediment filter. Which should be in  
the closed position when the welder is not  
operated for extended periods of time.  
• Follow vehicle manufacturerʼs instructions.  
------------------------------------------------------------------------  
------------------------------------------------------------------------  
RANGER® 305D (CE)  
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A-4  
A-4  
INSTALLATION  
ENGINE COOLING SYSTEM  
REMOTE CONTROL  
The machine is equipped with a 6-pin and a 14-pin  
connector. The 6-pin connector is for connecting the  
K857 or K857-1 Remote Control or for TIG welding,  
the K870 foot Amptrol or the K963-3 hand Amptrol.  
When in the CC-STICK, DOWNHILL PIPE, or CV-  
WIRE modes and when a remote control is connected  
to the 6-pin Connector, the auto-sensing circuit auto-  
matically switches the OUTPUT control from control at  
the welder to remote control.  
WARNING  
Air to cool the engine is drawn in the base sides  
and exhaust through radiator & case back. It is  
important that the intake and exhaust air is not  
restricted. Allow a minimum clearance of 0.6m (2  
feet) from the case back and 40cm (16”) from  
either side of the base to a vertical surface.  
------------------------------------------------------------------------  
BATTERY CONNECTION  
When in TOUCH START TIG mode and when a  
Amptrol is connected to the 6-Pin Connector, the  
OUTPUT dial is used to set the maximum current  
range of the CURRENT CONTROL of the Amptrol.  
CAUTION  
Use caution as the electrolyte is a strong acid that  
can burn skin and damage eyes.  
------------------------------------------------------------------------  
The machine is shipped with the negative battery  
cable disconnected. Make certain that the RUN-STOP  
switch is in the STOP position. Attach the negative  
battery cable to the negative battery terminal and  
tighten using a 13mm socket or wrench. It may be  
helpful to remove the coolant over-fill bottle. Pull up on  
bottle to remove from bracket.  
The 14-pin connector is used to directly connect a wire  
feeder control cable. In the CV-WIRE mode, when the  
control cable is connected to the 14-pin connector, the  
auto-sensing circuit automatically makes the Output  
Control inactive and the wire feeder voltage control  
active.  
WARNING  
NOTE: When a wire feeder with a built in welding  
voltage control is connected to the 14-pin connec-  
tor, do not connect anything to the 6-pin connec-  
tor.  
NOTE: This machine is furnished with a wet charged  
battery; if unused for several months, the battery may  
require a booster charge. Be careful to charge the bat-  
tery with the correct polarity.  
------------------------------------------------------------------------  
MUFFLER OUTLET / SPARK ARRESTOR  
In addition to operating as a Spark Arrestor the Spark  
Arrestor serves as an outlet cover for the muffler as  
well as providing additional sound reduction. Remove  
from the box and install using the clamp and instruc-  
tions provided.  
ELECTRICAL CONNECTIONS  
MACHINE GROUNDING  
Because this portable engine driven welder creates its  
own power, it is not necessary to connect its frame to  
an earth ground, unless the machine is connected to  
premises wiring (home, shop, etc.)  
WARNING  
To prevent dangerous electric shock, other equipment  
to which this engine driven welder supplies power  
must:  
An incorrect spark arrestor may lead to damage to  
the engine or adversely affect performance.  
------------------------------------------------------------------------  
WARNING  
• Be grounded to the frame of the welder using a  
grounded type plug.  
• Be double insulated.  
• Do not ground the machine to a pipe that carries  
explosive or combustible material.  
------------------------------------------------------------------------  
RANGER® 305D (CE)  
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A-5  
A-5  
INSTALLATION  
When this welder is mounted on a truck or trailer, its  
frame must be electrically bonded to the metal frame of  
the vehicle. Use a #8 or larger copper wire connected  
between the machine grounding stud and the frame of  
the vehicle. When this engine driven welder is connect-  
ed to premises wiring such as that in a home or shop,  
its frame must be connected to the system earth  
ground. See further connection instructions in the sec-  
tion entitled "Standby Power Connections" .  
CABLE INSTALLATION  
Install the welding cables to your machine as follows:  
1. The diesel engine must be OFF to install welding  
cables.  
2. Remove the flanged nuts from the output 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 work  
clamp and cable.  
In general, if the machine is to be grounded, it should  
be connected with a #8 or larger copper wire to a solid  
earth ground such as a metal water pipe going into the  
ground for at least ten feet and having no insulated  
joints, or to the metal framework of a building which  
has been effectively grounded.  
6. Check and tighten the connections periodically.  
CAUTION  
A machine grounding stud marked with the symbol  
is provided on the front of the welder.  
• Loose connections will cause the output termi-  
nals to overheat. The terminals may eventually  
melt.  
• Do not cross the welding cables at the output  
terminal connection. Keep the cables isolated  
and separate from one another.  
WELDING TERMINALS  
The machine is equipped with a toggle switch for  
selecting "hot" welding terminal when in the "WELD  
TERMINALS ON" position or "cold" welding terminal  
when in the "REMOTE" position.  
-----------------------------------------------------------------------  
AUXILIARY POWER  
The auxiliary power capacity is 8500 watts Peak,  
8,000 Watts Continuous of 50 Hz, three phase  
power. The auxiliary power capacity rating in watts is  
equivalent to volt-amperes at unity power factor. The  
max permissible current of the 400 VAC output is 12  
amps. Output voltage is within 10% at all loads up  
to the rated capacity.  
WELDING OUTPUT CABLES  
With the engine off connect the electrode and work  
cables to the output studs. The welding process dic-  
tates the polarity of the electrode cable. These connec-  
tions should be checked periodically and tightened with  
a 19mm wrench.  
Table A.1 lists recommended cable sizes and lengths  
for rated current and duty cycle. Length refers to the  
distance from the welder to the work and back to the  
welder. Cable diameters are increased for long cable  
lengths to reduce voltage drops.  
STANDBY POWER CONNECTIONS  
The machine is suitable for temporary, standby or  
emergency power using the engine manufacturerʼs  
recommended maintenance schedule.  
TABLE A-1  
TOTAL COMBINED LENGTH OF  
The machine can be permanently installed as a  
standby power unit for 400 VAC, three phase, 12  
amp service.  
ELECTRODE AND WORK CABLES  
Cable Size for  
Cable Length  
305 Amps  
100% Duty Cycle  
1 / 0 AWG  
Connections must be made by a licensed electrician  
who can determine how the power can be adapted to  
the particular installation and comply with all applica-  
ble electrical codes.  
0-30 meters (0-100Ft.)  
2 / 0 AWG  
3 / 0 AWG  
30-46 meters (100-150 Ft.)  
46-61 meters (150-200 Ft.)  
• Take necessary steps to assure load is limited to  
the capacity of the RANGER® 305D (CE).  
WARNING  
• Only a licensed, certified, trained electrician  
should install the machine to a premises or resi-  
dential electrical system. Be certain that:  
RANGER® 305D (CE)  
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A-6  
A-6  
INSTALLATION  
• The installation complies with the National  
Electrical Code and all other applicable electri-  
cal codes.  
WARNING  
Connection of the LN-25 to the RANGER® 305D  
(CE).  
• The premises is isolated and no feedback into  
the utility system can occur. Certain laws require  
the premises to be isolated before the generator  
is linked to the premises. Check your local  
requirements.  
Shut off welder before making any electrical con-  
nections.  
------------------------------------------------------------------------  
The LN-25 with or without an internal contactor may  
be used with the RANGER® 305D (CE). See the  
appropriate connection diagram in Section F.  
NOTE: The LN-25 (K431) Remote Control Module  
and (K432) Remote Cable are not recommended for  
use with the RANGER® 305D (CE).  
-----------------------------------------------------------------------  
CONNECTION OF LINCOLN ELECTRIC  
WIRE FEEDERS  
Connection of LN-15 to the RANGER® 305D (CE)  
These connections instructions apply to both the LN-  
15 Across The-Arc and Control Cable models. The  
LN-15 has an internal contactor and the electrode is  
not energized until the gun trigger is closed. When the  
gun trigger is closed the wire will begin to feed and the  
welding process is started.  
1. Shut the welder off.  
2. For electrode Positive, connect the electrode  
cable from the LN-25 to the "+" terminal of the  
welder and work cable to the "-" terminal of the  
welder. For electrode Negative, connect the elec-  
trode cable from the LN-25 to the "-" terminal of  
the welder and work cable to the "+" terminal of  
the welder.  
• Shut the welder off.  
• For electrode Positive, connect the electrode cable  
to the "+" terminal of the welder and work cable to  
the "-" terminal of the welder. For electrode  
Negative, connect the electrode cable "-" terminal  
of the welder and work cable to the "+" terminal of  
the welder.  
3. Attach the single lead from the front of the LN-25  
to work using the spring clip at the end of the lead.  
This is a control lead to supply current to the wire  
feeder motor; it does not carry welding current.  
• Across The-Arc Model:  
4. Set the MODE switch to the "CV-WIRE " position.  
Attach the single lead from the front of the LN-15 to  
work using the spring clip at the end of the lead. This  
is a control lead to supply current to the wire feeder  
motor; it does not carry welding current.  
5. Set the "WELD TERMINALS" switch to "WELD  
TERMINALS ON".  
6. Set the "ARC CONTROL" knob to "0" initially and  
adjust to suit.  
Set the "WELD TERMINALS" switch to "WELD TER-  
MINALS ON".  
7. Set the "IDLE" switch to the "AUTO" position.  
When not welding, the RANGER® 305D (CE)  
engine will be at the low idle speed. If you are  
using an LN-25 with an internal contactor, the  
electrode is not energized until the gun trigger is  
closed.  
• Control Cable Model:  
Connect Control Cable between Engine Welder and  
Feeder.  
Set the MODE switch to the "CV-WIRE " position.  
8. When the gun trigger is closed, the current sensing  
circuit will cause the RANGER® 305D (CE) engine  
to go to the high idle speed, the wire will begin to  
feed and the welding process started. When weld-  
ing is stopped, the engine will revert to low idle  
speed after approximately 12 seconds unless  
welding is resumed.  
Set the "WELD TERMINALS" switch to "REMOTELY  
CONTROLLED".  
Set the "WIRE FEEDER VOLTMETER" switch to  
either "+" or "-" as required by the electrode polarity  
being used.  
CAUTION  
Set the "ARC CONTROL" knob to "0" initially and  
adjust to suit.  
If you are using an LN-25 without an internal con-  
tactor, the electrode will be energized when the  
RANGER® 305D (CE) is started.  
Set the "IDLE" switch to the "AUTO" position. 0  
------------------------------------------------------------------------  
RANGER 305D (CE)  
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A-7  
A-7  
INSTALLATION  
Connection of LN-742 and Cobramatic to  
RANGER® 305D (CE).  
• Shut the welder off.  
• Connect per instructions on the appropriate connec-  
tion diagram in Section F.  
RANGER® 305D (CE)  
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B-1  
B-1  
OPERATION  
• Check radiator for proper coolant level. (Fill if nec-  
SAFETY PRECAUTIONS  
essary).  
• See Engine Ownerʼs Manual for specific oil and  
coolant recommendations.  
WARNING  
Do not attempt to use this equipment until you  
have thoroughly read the engine manufacturerʼs  
manual supplied with your welder. It includes  
important safety precautions, detailed engine  
starting, operating and maintenance instructions,  
and parts lists.  
ADD FUEL  
WARNING  
• Stop engine while fueling.  
• Do not smoke when fueling.  
• Keep sparks and flame away  
from tank.  
------------------------------------------------------------------------  
ELECTRIC SHOCK can kill.  
• Do not touch electrically live parts or  
electrode with skin or wet clothing.  
• Do not leave unattended while  
fueling.  
• Insulate yourself from work and  
ground.  
• Always wear dry insulating gloves.  
• Wipe up spilled fuel and allow  
DIESEL FUEL  
fumes to clear before starting  
engine.  
can cause fire.  
• Always operate the welder with the hinged door  
closed and the side panels in place.  
• Do not overfill tank, fuel expan-  
DsIEionSmEaLy FcaUusEeLovOerNfloLwY.  
• Read carefully the Safety Precautions page  
before operating this machine. Always follow  
these and any other safety procedures included  
in this manual and in the Engine Instruction  
Manual.  
------------------------------------------------------------------------  
• Remove the fuel tank cap.  
• Fill the tank approximately 4 inches (100mm) from  
the top of the filler neck to allow for fuel expansion  
(observe the fuel gauge while filling). DO NOT FILL  
THE TANK TO THE POINT OF OVERFLOW.  
GENERAL DESCRIPTION  
The RANGER® 305D (CE) is a diesel engine pow-  
ered DC multi-process welding power source and AC  
power generator. The engine drives a generator that  
supplies three phase power for the DC welding circuit  
and three phase and single phase power for the AC  
auxiliary outlets. The DC welding control system uses  
• Replace the fuel cap and tighten securely.  
• See Engine Ownerʼs Manual for specific fuel recom-  
mendations.  
TM  
state of the art Chopper Technology (CT ) for supe-  
BREAK-IN PERIOD  
rior welding performance.  
Any engine will use a small amount of oil during its  
“break-in” period. For the diesel engine on the  
RANGER® 305D (CE), break-in is about 50 running  
hours.  
FOR AUXILIARY POWER:  
Start the engine and set the IDLER control switch to  
the desired operating mode. Full power is available  
regardless of the welding control settings providing no  
welding current is being drawn.  
Check the oil every four hours during break-in.  
Change the oil after the first 50 hours of operation,  
every 100 hours thereafter. Change the oil filter at the  
second oil change.  
ENGINE OPERATION  
During break-in, subject the RANGER® 305D (CE)  
Before Starting the Engine:  
CAUTION  
• 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.  
to moderate loads. Avoid long periods running at  
idle. Before stopping the engine, remove all loads  
and allow the engine to cool several minutes.  
------------------------------------------------------------------------  
• Add oil (if necessary) to bring the level up to the full  
mark. Do not overfill. Close engine door.  
RANGER® 305D (CE)  
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B-2  
B-2  
OPERATION  
16  
15  
14  
1
2
17  
3
13  
12  
11  
4
10  
9
8
7
6
5
FIGURE B.1  
WELDING CONTROLS (Figure B.1)  
When in the TOUCH START TIG mode and when a  
Amptrol is connected to the 6-Pin Connector, the OUT-  
PUT control is used to set the maximum current range of  
the CURRENT CONTROL of the Amptrol.  
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 control  
is connected to the 6-Pin or 14-Pin Connector, the auto-  
sensing circuit automatically switches the OUTPUT  
CONTROL from control at the welder to the remote con-  
trol.  
2. DIGITAL OUTPUT METERS  
The digital meters allow the output voltage (CV-WIRE  
mode) or current (CC-STICK, PIPE and TIG modes) to  
be 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 feature  
holds the display of both meters on for seven seconds  
after welding is stopped. This allows the operator to read  
the actual current and voltage just prior to when welding  
was ceased.  
When in the DOWNHILL PIPE mode and when a REMOTE  
CONTROL is connected to the 6-Pin or 14-Pin Connector,  
the OUTPUT CONTROL is used to set the maximum cur-  
rent range of the OUTPUT CONTROL of the REMOTE.  
Example:  
While the display is being held the left-most decimal  
point in each display will be flashing. The accuracy of the  
meters is +/- 3%.  
When the OUTPUT CONTROL on the welder is set to 200  
amps the current range on the REMOTE CONTROL will be  
40-200 amps rather than the full 40-300 amps. Any current  
range that is less than the full range provides finer current  
resolution for more fine tuning of the output.  
In the CV-WIRE mode, if the wire feeder has voltage con-  
trol capability, when the control cable is connected to the  
14-Pin Connector, the auto-sensing circuit automatically  
makes OUTPUT CONTROL inactive and the wire feeder  
voltage control active.  
3. WELD MODE SELECTOR SWITCH:  
(Provides four selectable welding modes)  
CV-WIRE  
DOWNHILL PIPE  
CC-STICK  
TOUCH START TIG  
RANGER® 305D (CE)  
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B-3  
B-3  
OPERATION  
10. WIRE FEEDER VOLTMETER SWITCH:  
4. ARC CONTROL: The ARC CONTROL dial is active in  
the CV-WIRE, CC-STICK and DOWNHILL PIPE modes,  
and has different functions in these modes. This control is  
not active in the TIG mode.  
Matches the polarity of the wire feeder voltmeter to the  
polarity of the electrode.  
ENGINE CONTROLS: (Figure B.2)  
CC-STICK mode: In this mode, the ARC CONTROL dial  
sets the short circuit current (arc-force) during stick welding  
to adjust for a soft or crisp arc. Increasing the dial from –10  
(soft) to +10 (crisp) increases the short circuit current and  
prevents sticking of the electrode to the plate while welding.  
This can also increase spatter. It is recommended that the  
ARC CONTROL be set to the minimum number without  
electrode sticking. Start with a setting at 0.  
11. RUN/STOP SWITCH - RUN position energizes the  
engine prior to starting. STOP position stops the engine.  
The oil pressure interlock switch prevents battery drain if  
the switch is left in the RUN position and the engine is not  
operating.  
DOWNHILL PIPE mode: In this mode, the ARC CONTROL  
dial sets the short circuit current (arc-force) during stick  
welding to adjust for a soft or a more forceful digging arc  
(crisp). Increasing the number from –10 (soft) to +10 (crisp)  
increases the short circuit current which results in a more  
forceful digging arc. Typically a forceful digging arc is pre-  
ferred for root and hot passes. A softer arc is preferred for  
fill and cap passes where weld puddle control and deposi-  
tion ("stacking" of iron) are key to fast travel speeds. It is  
recommended that the ARC CONTROL be set initially at 0.  
12. GLOW PLUG PUSH BUTTON -  
• When pushed activates the glow plugs. Glow plug  
should not be activated for more than 20 seconds  
continuously.  
13. START PUSH BUTTON  
-
Energizes the starter motor to crank engine.  
CV-WIRE mode: In this mode, turning the ARC CONTROL  
clock wise from –10 (soft) to +10 (crisp) changes the arc  
from soft and washed-in to crisp and narrow. It acts as an  
inductance/pinch control. The proper setting depends on  
the procedure and operator preference. Start with a setting  
of 0.  
14. IDLER SWITCH- Has two positions as follows:  
1) In the HIGH position, the engine runs at the high idle  
speed controlled by the engine governor.  
2) In the AUTO position, the idler operates as follows:  
• When switched from HIGH to AUTO or after starting the  
engine, the engine will operate at full speed for approxi-  
mately 12 seconds and then go to low idle speed.  
• When the electrode touches the work or power is drawn  
for lights or tools (approximately 100 Watts minimum), the  
engine accelerates and operates at full speed.  
5. WELD OUTPUT TERMINALS WITH FLANGE  
NUT: Provides a connection point for the electrode and  
work cables.  
6. GROUND STUD:  
• When welding ceases or the AC power load is turned off,  
a fixed time delay of approximately 12 seconds starts. If  
the welding or AC power load is not restarted before the  
end of the time delay, the idler reduces the engine speed  
to low idle speed.  
Provides a connection point for connecting the machine  
case to earth ground.  
7. 14-PIN CONNECTOR: For attaching wire feeder con-  
trol cables to the RANGER® 305D (CE). Includes contactor  
closure circuit, auto-sensing remote control circuit, and 42V  
power. The remote control circuit operates the same as the  
6 Pin connector.  
• The engine will automatically return to high idle speed  
when there is welding load or AC power load reapplied.  
Note: The 14-pin connector does not include 120V.  
8. 6-PIN CONNECTOR: For attaching optional remote  
control equipment. Includes auto-sensing remote control  
circuit.  
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 is  
controlled by a wire feeder or amptrol device, and is electri-  
cally off until a remote switch is depressed.  
RANGER® 305D (CE)  
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B-4  
B-4  
OPERATION  
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 several  
minutes before applying a load and/or switching to  
high idle. Allow a longer warm up time in cold  
weather.  
15. ELECTRIC FUEL GAUGE- Provides accu-  
rate, reliable indication of how much fuel is in the  
tank.  
.
16. ENGINE HOUR METER – Displays the total  
time that the engine has been running. This meter  
is useful for scheduling prescribed maintenance.  
NOTE: If the unit fails to start repeat step 4 through  
step 7 after waiting 30 seconds.  
17. ENGINEꢀPROTECTION LIGHT-A warning  
indicator light for Low Oil Pressure and/or Coolant  
Over Temperature. The light is off when the sys-  
tems are functioning properly. The light turns on  
when the RUN-STOP switch is in the “ON” posi-  
tion prior to starting the engine. If the Engine  
Protection or Battery Charging Lights do “not”  
turn off shortly after starting the engine shut off  
the engine immediately and determine the cause.  
CAUTION  
• Do not allow the starter motor to run continuously  
for more than 20 seconds.  
• Do not push the START button while the engine  
is running because this can damage the ring  
gear and/or the starter motor.  
• IF the Engine Protection or Battery Charging  
Lights do “not” turn off shortly after starting the  
engine shut off the engine immediately and deter  
mine the cause.  
STARTING THE ENGINE  
1. Remove all plugs connected to the AC power  
receptacles.  
-----------------------------------------------------------------------  
NOTE: When starting a RANGER® 305D (CE) for the  
first time, or after and extended period of time of not  
operating, it will take longer than normal because the  
fuel pump has to fill the fuel system.  
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.  
STOPPING THE ENGINE  
Remove all welding and auxiliary power loads and  
allow the engine to run at low idle speed for a few  
minutes to cool the engine.  
5. Press and hold both the “Glow Plug” Button and  
START button together until the engine starts or for  
up to 10 seconds.  
STOP the engine by placing the RUN-STOP switch in  
the STOP position.  
6. Release the engine START button immediately  
when the engine starts.  
NOTE: A fuel shut off valve is located on the fuel pre-  
filter. Turn on Fuel shut-off valve on the fuel pre-filter.  
7. Release the glow plug button after the Engine  
Protection Light turns off or after an additional 5  
seconds maximum.  
TABLE B.1  
TYPICAL RANGER® 305D (CE) FUEL CONSUMPTION  
Kubota D722  
Running time for  
45 Liters/hours  
Liters/Hr (Gal./Hr)  
Low Idle - No Load  
2200 R.P.M.  
.92 (.24)  
1.62 (.43)  
49.38  
28.07  
13.30  
15.55  
13.54  
17.12  
20.78  
High Idle - No Load  
3100 R.P.M.  
DC Weld Output  
250 Amps @ 30 Volts  
DC Weld Output  
225 Amps @ 25 Volts  
3.42 (.90)  
2.92 (.77)  
8,000 Watts, 3 PHASE  
5,000 Watts, 3 PHASE  
3,000 Watts, 3 PHASE  
3.35 (.89)  
2.65 (.70)  
2.19 (.58)  
RANGER® 305D (CE)  
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B-5  
B-5  
OPERATION  
The OUTPUT CONTROL dial adjusts the full output range  
for stick welding. The ARC CONTROL dial sets the short  
circuit current (arc-force) during stick welding to adjust for  
a soft or a more forceful digging arc(crisp). Increasing the  
number from –10 (soft) to +10 (crisp) increases the short  
circuit current which results in a more forceful digging arc.  
Typically a forceful digging arc is preferred for root and hot  
passes. A softer arc is preferred for fill and cap passes  
where weld puddle control and deposition ("stacking" of  
iron) are key to fast travel speeds. It is recommended that  
the ARC CONTROL be set initially at 0.  
WELDER OPERATION  
DUTY CYCLE  
Duty Cycle is the percentage of time the load is being  
applied in a 10 minute period. For example a 60% duty  
cycle, represents 6 minutes of load and 4 minutes of no  
load in a 10 minute period.  
The RANGER® 305D (CE) can be used with a broad range  
of DC stick electrodes. The MODE switch provides two  
stick welding settings as follows:  
TIG WELDING  
CONSTANT CURRENT (CC-STICK) Welding  
The CC-STICK position of the MODE switch is designed for  
horizontal and vertical-up welding with all types of elec-  
trodes, especially low hydrogen.  
The TOUCH START TIG setting of the MODE switch is for  
DC TIG (Tungsten Inert Gas) welding. To initiate a weld,  
the OUTPUT CONTROL dial is first set to the desired cur-  
rent and the tungsten is touched to the work. During the  
time the tungsten is touching the work there is very little  
voltage or current and, in general, no tungsten contamina-  
tion. Then, the tungsten is gently lifted off the work in a  
rocking motion, which establishes the arc.  
The OUTPUT CONTROL dial adjusts the full output range  
for stick welding.  
The ARC CONTROL dial sets the short circuit current (arc-  
force) during stick welding to adjust for a soft or crisp arc.  
Increasing the dial from –10 (soft) to +10 (crisp) increases  
the short circuit current and prevents sticking of the elec-  
trode to the plate while welding. This can also increase  
spatter. It is recommended that the ARC CONTROL be set  
to the minimum number without electrode sticking. Start  
with a setting at 0.  
To stop the arc, simply lift the TIG torch away from the  
work piece. When the arc voltage reaches approximately  
30 volts, the arc will go out and the machine will automati-  
cally reset to the touch start current level. The tungsten  
may then be retouched to the work piece to restrike the  
arc. The arc may also be started and stopped with an  
Amptrol or Arc Start Switch. See the following para-  
graphs.  
DOWNHILL PIPE (STICK) Welding  
The DOWNHILL PIPE position of the MODE switch is a  
slope controlled setting intended for "out-of-position" and  
"down hill" pipe welding where the operator would like to  
control the current level by changing the arc length.  
TABLE B.2  
(1)  
(2)  
TYPICAL CURRENT RANGES  
FOR TUNGSTEN ELECTRODES  
Tungsten Electrode  
Diameter in. (mm)  
DCEN (-)  
DCEP (+)  
Approximate Argon Gas Flow  
Flow Rate C.F.H. ( l /min.)  
TIG TORCH  
Nozzle Size (4), (5)  
1%, 2% Thoriated  
Tungsten  
1%, 2% Thoriated Aluminum  
Tungsten  
Stainless Steel  
.010  
(.25)  
2-15  
5-20  
(3)  
(3)  
(3)  
3-8  
(2-4)  
(3-5)  
(3-5)  
3-8  
(2-4)  
(3-5)  
(3-5)  
#4, #5, #6  
0.020  
0.040  
(.50)  
(1.0)  
5-10  
5-10  
5-10  
5-10  
15-80  
1/16  
(1.6)  
70-150  
10-20  
5-10  
(3-5)  
9-13  
(4-6)  
#5, #6  
3/32  
1/8  
(2.4)  
(3.2)  
150-250  
250-400  
15-30  
25-40  
13-17  
15-23  
(6-8)  
11-15  
11-15  
(5-7)  
(5-7)  
#6, #7, #8  
(7-11)  
5/32  
3/16  
1/4  
(4.0)  
(4.8)  
(6.4)  
400-500  
500-750  
750-1000  
40-55  
55-80  
80-125  
21-25  
23-27  
28-32  
(10-12)  
(11-13)  
(13-15)  
13-17  
18-22  
23-27  
(6-8)  
#8, #10  
(8-10)  
(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  
EWP  
1% Thoriated  
2% Thoriated  
EWTh-1  
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.  
# 5 = 5/16 in.  
# 6 = 3/8 in.  
# 7 = 7/16 in.  
# 8 = _ in.  
(6 mm)  
(8 mm)  
(10 mm)  
(11 mm)  
(12.5 mm)  
(16 mm)  
#10 = 5/8 in.  
(5) TIG torch nozzles are typically made from alumina ceramic. Special applications may require lava nozzles, which are less prone to breakage, but cannot withstand high temperatures  
and high duty cycles.  
RANGER® 305D (CE)  
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B-6  
B-6  
OPERATION  
When in the TOUCH START TIG mode and when a  
Amptrol is connected to the 6-pin Connector the OUT-  
PUT dial is used to set the maximum current range of  
the CURRENT CONTROL of the Amptrol.  
For any electrodes the procedures should be kept  
within the rating of the machine. For additional elec-  
trode information see WWW.Lincolnelectric.com or  
the appropriate Lincoln publication.  
The ARC CONTROL is not active in the TIG mode.  
ARC GOUGING  
The RANGER® 305D (CE) can be used for limited arc  
gouging. For optimal performance, set the MODE  
switch to CC-STICK and the ARC CONTROL to +10.  
The RANGER® 305D (CE) can be used in a wide vari-  
ety of DC TIG welding applications. In general the  
ʻTouch Startʼ feature allows contamination free starting  
without the use of a Hi-frequency unit. If desired, the  
K930-2 TIG Module can be used with the RANGER®  
305D (CE). The settings are for reference.  
Set the OUTPUT CONTROL knob to adjust output  
current to the desired level for the gouging electrode  
being used according to the ratings in the following  
Table B.3.  
RANGER® 305D (CE) settings when using the K930-2  
TIG Module with an Amptrol or Arc Start Switch:  
TABLE B.3  
Carbon Diameter  
Current Range (DC, electrode  
positive)  
• Set the MODE Switch to the TOUCH START TIG  
setting.  
• Set the "IDLER" Switch to the "AUTO" position.  
• Set the "WELDING TERMINALS" switch to the  
"REMOTELY CONTROLLED" position. This will keep  
the "Solid State" contactor open and provide a “cold”  
electrode until the Amptrol or Arc Start Switch is  
pressed.  
1/8"  
60-90 Amps  
5/32"  
3/16"  
90-150 Amps  
200-250 Amps  
When using the TIG Module, the OUTPUT control on  
the RANGER® 305D (CE) is used to set the maximum  
range of the CURRENTꢀCONTROLꢀon the TIG module  
or an Amptrol if connected to the TIG Module. (See  
Table B.2.)  
AUXILIARY POWER:  
Start the engine and set the IDLER control switch to  
the desired operating mode. Full power is available  
regardless of the welding control settings providing no  
welding current is being drawn.  
WIRE WELDING-CV  
Connect a wire feeder to the RANGER® 305D (CE)  
according to the instructions in INSTALLATION  
INSTRUCTIONS Section.  
Simultaneous Welding and Auxiliary Power Loads  
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 wires  
for MIG welding (gas metal arc welding). Welding can  
be finely tuned using the ARC CONTROL. Turning the  
ARC CONTROL clockwise from –10 (soft) to +10 (crisp)  
changes the arc from soft and washed-in to crisp and  
narrow. It acts as an inductance/pinch control. The  
proper setting depends on the procedure and operator  
preference. Start with the dial set at 0.  
While welding, the amount of 3-phase Auxiliary power  
available is reduced. (See table A.4)  
TABLE A.4  
PERMISSIBLE POWER-WATTS  
PERMISSIBLE AUX  
WELDING OUTPUT-  
AMPS  
(UNITY POWER FACTOR)  
POWER @400V, 3PHASE  
8000  
6500  
5000  
3500  
2000  
0
12 Amps  
9 Amps  
7 Amps  
5 Amps  
3ꢀAmps  
0 Amps  
0
50  
100  
150  
200  
250  
RANGER® 305D (CE)  
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C-1  
C-1  
ACCESSORIES  
FIELD INSTALLED OPTIONS /  
ACCESSORIES  
K704 ACCESSORY SET - Includes (10m) 35 ft. of  
electrode cable and (9.m) 30 ft. of work cable, head-  
shield, work clamp electrode holder. Cables are rated  
at 400 amps, 100% duty cycle.  
K857 (7.6m) 25 ft. or K857-1 (30.4m) 100 ft.  
REMOTE CONTROL - Portable control provides same  
dial range as the output control on the welder. Has a  
convenient 6 pin plug for easy connection to the  
welder.  
RANGER® 305D (CE)  
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D-1  
D-1  
MAINTENANCE  
KUBOTA D722 DIESEL ENGINE  
SAFETY PRECAUTIONS  
FREQUENCY  
MAINTENANCE REQUIRED  
• FILL FUEL TANK.  
WARNING  
• CHECK OIL LEVEL.  
• CHECK COOLANT LEVEL.  
• Have qualified personnel do all maintenance  
and troubleshooting work.  
• CHECK AIR CLEANER ELE-  
MENT AND HOUSING FOR  
DIRTY, LOOSE OR DAMAGED  
PARTS.  
• Turn the engine off before working inside the  
machine or servicing the engine.  
DAILY OR BEFORE  
STARTING ENGINE  
• CHECK AIR INTAKE HOSE  
FOR CRACKS OR LOOSE  
CONNECTIONS.  
• CHECK AIR INTAKE/EXHAUST  
• Remove guards only when necessary to  
perform maintenance and replace them when  
the maintenance requiring their removal is  
complete. If guards are missing from the  
machine, obtain replacements from a Lincoln  
Distributor. (See Operating Manual Parts List.)  
AREAS  
&
RADIATOR FOR  
DIRT. CLEAN AS NECESSARY.  
• CHECK ALTERNATOR BELT  
TENSION AND WEAR.  
Service Intervals  
Observe the following for service and maintenance. The lubricating  
oil change intervals listed in the table below are for Classes CF,CE  
and CD lubricating oils of API classification with a low sulfur fuel in  
use. If the CF-4 or CG-4 lubricating oil is used with a high-sulfur  
fuel, change the lubricating oil at shorter intervals than recommend-  
ed in the table below depending on the operating condition.  
• Read the Safety Precautions in the front of this  
manual and in the Engine Ownerʼs Manual before  
working on this machine.  
• Keep all equipment safety guards, covers, and  
devices in position and in good repair. Keep  
hands, hair, clothing, and tools away from the  
gears, fans, and all other moving parts when  
starting, operating, or repairing the equipment.  
Intervals  
Items  
Every 50 hours  
Every 75 hours  
Check of fuel lines and clamp bands.  
Change of engine oil  
•
Every 100 hours  
*1  
Inspect/Clean air cleaner element  
and Vacuator™ valve.  
Cleaning of fuel filter.  
Routine Maintenance  
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.  
At the end of each dayʼs use, refill the fuel tank to  
minimize moisture condensation in the tank. Running  
out of fuel tends to draw dirt into the fuel system.  
Also, check the crankcase oil level and add oil if  
indicated.  
Every 150 hours  
•
Every 200 hours  
Every 400 hours  
Every 500 hours  
*1,*2  
Replacement of Air Filter element.  
Replacement of fuel filter element.  
Cleaning of water jacket (radiator  
interior).  
ENGINE MAINTENANCE COMPONENTS  
Replacement of fan belt.  
KUBOTA D722 DIESEL ENGINE  
Every 1 or 2 months  
Every 800 hours  
Recharging of Battery.  
*3  
*3  
Check of valve clearance.  
Check the fuel injection nozzle injec-  
tion pressure.  
Every 1500 hours  
ITEM  
MAKE AND PART NUMBER  
Every 3000 hours  
Every 2 years  
*3  
*3  
Check of injection pump.  
Check of fuel injector timer.  
Replacement of battery  
OIL FILTER  
KUBOTA 70000-15241  
Replacement of radiator hoses and  
clamp band.  
AIR FILTER ELEMENT DONALDSON P822686  
FUEL FILTER ELEMENT KUBOTA 15231-43560  
Replacement of fuel pipes and  
clamps.  
*4  
Change the radiator coolant.(L.L.C.)  
Replacement of intake air line.  
BATTERY  
KUBOTA GROUP 58, 550 CCA  
KUBOTA 15881-97011  
KUBOTA 16851-65512  
KUBOTA 12581-43012  
IMPORTANT  
•
These jobs should be done after the first 50 hours of operation.  
BELT  
*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.  
GLOW PLUGS  
INLINE FUEL FILTER  
*3 Consult your local KUBOTA Dealer for this service.  
*4 Replace only if necessary.  
Please see Engine Owners Manual for Warranty Statement in detail.  
RANGER® 305D (CE)  
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D-2  
D-2  
MAINTENANCE  
OIL FILTER CHANGE  
• Drain the oil.  
ENGINE OIL CHANGE  
Drain the engine oil while the engine is warm to assure  
rapid and complete draining. It is recommended that  
each time the oil is changed the oil filter be changed as  
well.  
• Remove the oil filter with an oil filter wrench and  
drain the oil into a suitable container. Discard the  
used filter. Note: Care should be taken during filter  
removal to not disrupt or damage in any way the fuel  
lines.  
• Be sure the unit is off. Disconnect the negative bat-  
tery cable to ensure safety.  
• Clean the filter mounting base and coat the gasket  
of the new filter with clean engine oil.  
• Locate oil drain hose and valve in bottom of base  
and pull through the hole in the battery access panel  
on the welder.  
• 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 the  
recommended engine oil. Reinstall the oil filler cap  
and tighten securely.  
• Remove the cap from the drain valve. Push valve in  
and twist counterclockwise. Pull to open and drain  
the oil into a suitable container for disposal.  
• Close the drain valve by pushing in and twisting  
clockwise. Replace the cap.  
• Start the engine and check for oil filter leaks.  
• Re-fill the crankcase to the upper limit mark on the  
dipstick with the recommended oil (see engine oper-  
ation manual OR engine service items decal OR  
below). Replace and tighten the oil filler cap secure-  
ly.  
• Stop the engine and check the oil level. If neces-  
sary, add oil to the upper limit mark on the dipstick.  
WARNING  
• Push oil drain hose and valve back into unit, re-con-  
nect negative battery cable, and close doors and  
engine top cover before restarting unit.Wash your  
hands with soap and water after handling used  
motor oil. Please dispose of used motor oil in a  
manner that is compatible with the environment. We  
suggest you take it in a sealed container to your  
local service station or recycling center for reclama-  
tion. DO NOT throw it in the trash; pour it on the  
ground or down a drain.  
• Never use gasoline or low flash point solvents  
for cleaning the air cleaner element. A fire or  
explosion could result.  
CAUTION  
• Never run the engine without the air cleaner.  
Rapid engine wear will result from contaminants,  
such as dust and dirt being drawn into the  
engine.  
ENGINE OIL REFILL CAPACITIES  
Without oil filter replacement:  
• 3.2 liter (3.3 U.S. Quart)  
------------------------------------------------------------------------  
AIR CLEANER  
The diesel engine is equipped with a dry type air filter.  
Never apply oil to it. Service the air cleaner as follows:  
With oil filter replacement:  
• 3.2 liter ( 3.4 U.S. Quart.)  
Replace the element at least every 200 hours of  
operation and sooner under dusty conditions.  
Use motor oil designed for diesel engines that meets  
requirements for API service classification  
CC/CD/CE/CF/CF-4/CG-4 or CH-4.  
ACEA E1/E2/E3. Always check the API service label  
on the oil container to be sure it includes the letters  
indicated. (Note: An S-grade oil must not be used in a  
diesel engine or damage may result. It IS permissible  
to use an oil that meets S and C grade service classifi-  
cations.)  
SAE 10W30 is recommended for general, all tempera-  
ture use, -15C to 40C (5F to 104F).  
See engine ownerʼs manual for more specific informa-  
tion on oil viscosity recommendations.  
RANGER® 305D (CE)  
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D-3  
D-3  
MAINTENANCE  
RANGER® 305D (CE)  
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D-4  
D-4  
MAINTENANCE  
FUEL  
COOLING SYSTEM  
WARNING  
At the end of each dayʼs use, refill the fuel tank to min-  
imize moisture condensation and dirt contamination in  
the fuel line. Do not overfill; leave room for the fuel to  
expand.  
HOT COOLANT can burn skin.  
• Do not remove cap if radiator is  
hot.  
Use only fresh, No. 2 grade DIESEL fuel. Do not use  
kerosene.  
------------------------------------------------------------------------  
Check the coolant level by observing the level in the  
radiator and recovery bottle. Add 50/50 antifreeze /  
water solution if the level is close to or below the  
"LOW" mark. do not fill above the "FULL" mark.  
Remove radiator cap and add coolant to radiator. Fill  
up to the top of the tube in the radiator filler neck  
which includes a connecting hose coming from the  
thermostat housing.  
See the Engine Operator's Manual for instructions on  
replacing the fuel filter.  
BLEEDING THE FUEL SYSTEM  
You may need to bleed air from the fuel system if the  
fuel filter or fuel lines have been detached, the fuel  
tank has been ran empty or after periods of long stor-  
age. It is recommended that the fuel shutoff valve be  
closed during periods of non-use.  
To drain the coolant, open the valve of the radiator.  
Open the radiator cap to allow complete drainage.  
(Tighten the valve and refill with a 50/50  
antifreeze/water solution.) Use an automotive grade  
(low silicate) ethylene glycol antifreeze. The cooling  
system capacity is 3.6L (3.85 quarts). Squeeze upper  
and lower radiator hoses while filling to bleed air from  
system coolant. Replace and tighten the radiator cap.  
The Kubota D722 engine supplied with this welder is  
equipped with an automatic bleeding mechanism that  
helps purge the air from the mechanical fuel pump  
system. It is generally not necessary to open a vent  
screw or fuel line fitting to bleed the fuel system.  
Operate the priming lever on the pump to assist start-  
ing after extended periods of non-use or out of fuel  
conditions.  
CAUTION  
WARNING  
Always premix the antifreeze and clean tap water  
before adding to the radiator. It is very important  
that a precise 50/50 solution be used with this  
engine year round. This gives proper cooling dur-  
ing hot weather and freezing protection to -37° C  
(-34° F).  
To avoid personal injury, do not bleed a hot  
engine. This could cause fuel to spill onto a hot  
exhaust manifold, creating a danger of fire.  
------------------------------------------------------------------------  
Bleed the fuel system as follows:  
1. Fill the fuel tank with fuel.  
Cooling solution exceeding 50% ethylene glycol  
can result in engine overheating and damage to  
the engine. Coolant solution must be premixed  
before adding to radiator.  
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.  
Periodically remove the dirt from the radiator fins.  
5. Follow the normal STARTING procedures.  
Periodically check the fan belt and radiator hoses.  
Replace if signs of deterioration are found.  
TIGHTENING THE FAN BELT  
If the fan belt is loose, the engine can overheat and  
the battery lose its charge. Check tightness by press-  
ing on the belt midway between the pulleys. It should  
deflect about 6mm (.25 in) under a load of 9 Kg (20  
lbs).  
RANGER® 305D (CE)  
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D-5  
D-5  
MAINTENANCE  
CLEANING THE BATTERY  
FUEL FILTER  
Keep the battery clean by wiping it with a damp cloth  
when dirty. If the terminals appear corroded, discon-  
nect the battery cables and wash the terminals with an  
ammonia solution or a solution of 113g (1/4 pound) of  
baking soda and 0.9461L (1 quart) of water. Be sure  
the battery vent plugs (if equipped) are tight so that  
none of the solution enters the cells.  
1. Check the fuel filter and fuel pre-filter for water accu-  
mulation or sediment.  
2. Replace the fuel filter if it is found with excessive  
water accumulation or sediment. Empty fuel pre-  
filter.  
After cleaning, flush the outside of the battery, the bat-  
tery compartment, and surrounding areas with clear  
water. Coat the battery terminals lightly with petroleum  
jelly or a non-conductive grease to retard corrosion.  
Keep the battery clean and dry. Moisture accumula-  
tion on the battery can lead to more rapid discharge  
and early battery failure.  
OVERSPEED IS HAZARDOUS  
The maximum allowable high idle speed for this  
machine is 3150 RPM, no load. Do NOT tamper  
with governor components or setting or make any  
other adjustments to increase the maximum  
speed. Severe personal injury and damage to the  
machine can result if operated at speeds above  
maximum.  
CHECKING THE ELECTROLYTE LEVEL  
ENGINE ADJUSTMENT  
If battery cells are low, fill them to the neck of the filler  
hole with distilled water and recharge. If one cell is  
low, check for leaks.  
Adjustments to the engine are to be made only by a  
Lincoln Service Center or an authorized Field Service  
Shop.  
CHARGING THE BATTERY  
BATTERY MAINTENANCE  
When you charge, jump, replace, or otherwise con-  
nect battery cables to the battery, be sure the polarity  
is correct. Improper polarity can damage the charging  
circuit. The RANGER® 305D (CE) positive (+) battery  
terminal has a red terminal cover.  
To access the battery, Disconnect the Negative and  
then Positive battery cables. Remove the 4 screws  
from the battery door using a screwdriver or a 10mm  
socket. Remove the 2 nuts from the battery bracket  
using a 11mm wrench or socket. Slide the battery out  
and remove from welder.  
If you need to charge the battery with an external  
charger, disconnect the negative cable first, then the  
positive cable before you attach the charger leads.  
After the battery is charged, reconnect the positive  
battery cable first and the negative cable last. Failure  
to do so can result in damage to the internal charger  
components.  
WARNING  
GASES FROM BATTERY can explode.  
G Keep sparks, flame and cigarettes  
away from battery.  
Follow the instructions of the battery charger manu-  
facturer for proper charger settings and charging time.  
To prevent EXPLOSION when:  
G INSTALLING A NEW BATTERY — disconnect  
negative cable from old battery first and con-  
nect to new battery last.  
SERVICING SPARK ARRESTOR  
Clean every 100 hours or twice a year, whichever  
occurs frist.  
G CONNECTING A BATTERY CHARGER —  
remove battery from welder by disconnecting  
negative cable first, then positive cable and bat-  
tery clamp. When reinstalling, connect  
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.  
negative cable last. Keep well ventilated.  
4. Separate plates and clean with a wire brush if neces-  
sary.  
G 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 and  
skin.  
5. Inspect plates and housing for holes or cracks. Replace  
if damaged.  
6. Reassemble and reinstall on to muffler outlet pipe.  
WARNING  
G Wear gloves and eye protection and  
be careful when working near bat-  
tery.  
• MUFFLER MAY BE HOT  
G Follow instructions printed on battery.  
------------------------------------------------------------  
RANGER® 305D (CE)  
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D-6  
D-6  
MAINTENANCE  
WELDER / GENERATOR  
MAINTENANCE  
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 a  
week in particularly dirty areas.  
BRUSH REMOVAL AND REPLACEMENT: Itʼs nor-  
mal for the brushes and slip rings to wear and darken  
slightly. Inspect the brushes when a generator over-  
haul is necessary.  
CAUTION  
• Do not attempt to polish slip rings while the  
engine 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 and  
machine operator and will invalidate your factory  
warranty. For your safety and to avoid Electrical  
Shock, please observe all safety notes and pre-  
cautions.  
RANGER® 305D (CE)  
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E-1  
E-1  
TROUBLESHOOTING  
HOW TO USE TROUBLESHOOTING GUIDE  
WARNING  
Service and Repair should only be performed by Lincoln Electric Factory Trained Personnel.  
Unauthorized repairs performed on this equipment may result in danger to the technician and  
machine operator and will invalidate your factory warranty. For your safety and to avoid Electrical  
Shock, please observe all safety notes and precautions detailed throughout this manual.  
__________________________________________________________________________  
This Troubleshooting Guide is provided to help you  
locate and repair possible machine malfunctions.  
Simply follow the three-step procedure listed below.  
Step 3. RECOMMENDED COURSE OF ACTION  
This column provides a course of action for the  
Possible Cause, generally it states to contact your  
local Lincoln Authorized Field Service Facility.  
Step 1. LOCATE PROBLEMꢀ(SYMPTOM).  
Look under the column labeled “PROBLEM (SYMP-  
TOMS)”. This column describes possible symptoms  
that the machine may exhibit. Find the listing that  
best describes the symptom that the machine is  
exhibiting.  
If you do not understand or are unable to perform the  
Recommended Course of Action safely, contact your  
local Lincoln Authorized Field Service Facility.  
Step 2. POSSIBLE CAUSE.  
The second column labeled “POSSIBLE CAUSE” lists  
the obvious external possibilities that may contribute  
to the machine symptom.  
CAUTION  
If for any reason you do not understand the test procedures or are unable to perform the tests/repairs safely, contact your  
Local Lincoln Authorized Field Service Facility for technical troubleshooting assistance before you proceed.  
RANGER® 305D (CE)  
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E-2  
E-2  
TROUBLESHOOTING  
Observe all Safety Guidelines detailed throughout this manual  
PROBLEMS  
POSSIBLE  
RECOMMENDED  
(SYMPTOMS)  
CAUSE  
COURSE OF ACTION  
Major Physical or Electrical Damage 1. Contact your local Lincoln  
is Evident.  
Authorized Field Service  
Facility.  
Engine will not "crank".  
1. Battery is low, Charge Battery.  
2. Loose battery cable connections.  
Inspect, clean and tighten terminals.  
3. Faulty engine starter motor.  
Contact authorized local Engine  
Service Shop.  
Engine will "crank" but not start.  
1. Fuel shut off valve on Main Fuel  
Filter in the OFF position. Open  
valve (vertical) position of handle.  
2. Fuel Filters dirty/clogged. Check  
and replace main filter element  
and/or Inline Fuel Filter.  
3. Out of fuel. Fill tank and bleed fuel  
system.  
4. High coolant temperature or low  
oil pressure. (indictor lights lit)  
I
f all recommended possible areas  
Check oil and coolant levels. Fill if of misadjustment have been  
required. Check for loose or bro- checked and the problem persists,  
ken fan belt.  
Contact your local Lincoln  
5. Faulty fuel shutdown solenoid. Authorized Field Service Facility.  
Check that shutdown solenoid is  
functioning properly and not bind-  
ing/ contact authorized engine  
service shop.  
6. Faulty fuel pump. Check for fuel  
flow through filters. Contact  
authorized local Engine Service  
Shop.  
Engine shuts down shortly after  
starting.  
1. High coolant temperature or low  
oil pressure. (indictor light lit)  
Change oil and oil filters and fill to  
proper level. Check and fill coolant  
level. Check for loose or broken  
fan belt. Start engine and look for  
leaks.  
2. Faulty oil pressure switch or other  
engine component. Contact  
authorized local Engine Service  
Shop.  
3. Faulty engine protection relay.  
CAUTION  
If for any reason you do not understand the test procedures or are unable to perform the tests/repairs safely, contact your  
Local Lincoln Authorized Field Service Facility for technical troubleshooting assistance before you proceed.  
RANGER® 305D (CE)  
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E-3  
E-3  
TROUBLESHOOTING  
Observe all Safety Guidelines detailed throughout this manual  
PROBLEMS  
POSSIBLE  
RECOMMENDED  
(SYMPTOMS)  
CAUSE  
COURSE OF ACTION  
Engine shuts down while under a 1. High radiator coolant tempera-  
load.  
ture. Reduce load if it is exceed-  
ing machine rating. Add coolant  
to system if low. Clean fins on  
radiator if dirty. Tighten fan belt if  
loose. Remove objects blocking  
or close to intake openings on  
both sides of base and exhaust  
end (case back).  
Engine runs rough.  
1. Dirty fuel or air filters. Inspect and  
clean/replace filters as needed.  
Inspect and clean/replace filters  
as needed.  
2. Water in fuel. If water found in  
tank. Empty fuel tank and refill  
then purge fuel lines.  
Battery does not stay charged.  
1. Faulty battery. Replace.  
2. Loose connections at battery or  
alternator. Clean and tighten con-  
nections.  
If all recommended possible areas of  
misadjustment have been checked  
and the problem persists, Contact  
your local Lincoln Authorized  
Field Service Facility.  
3. Faulty engine alternator or charg-  
er module. Consult authorized  
Engine Service Shop.  
Engine will not idle down to low 1. Idler switch in High idle position.  
speed.  
Set switch to Auto.  
2. External load on welder or auxil-  
iary power. Remove all external  
loads.  
3. Faulty PC board or idler sole-  
noid.  
Engine will not go to high idle when 1. Poor work lead connection to  
attempting to weld.  
work. Make sure work clamp is  
tightly connected to clean base  
metal.  
2. "Contactor" switch is in wrong  
position. Set to "Welding On" when  
welding without a control cable.  
Refer to Operations chapter for prop-  
er use of this switch.  
3. Faulty PC board. Low idle speed  
set to low.  
CAUTION  
If for any reason you do not understand the test procedures or are unable to perform the tests/repairs safely, contact your  
Local Lincoln Authorized Field Service Facility for technical troubleshooting assistance before you proceed.  
RANGER® 305D (CE)  
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E-4  
E-4  
TROUBLESHOOTING  
Observe all Safety Guidelines detailed throughout this manual  
PROBLEMS  
POSSIBLE  
RECOMMENDED  
(SYMPTOMS)  
CAUSE  
COURSE OF ACTION  
Engine will not go to high idle when 1. Auxiliary power load is less than  
using auxiliary power.  
100 watts. Idler may not respond  
with less than a 100 watt load. Set  
idler to "High".  
2. Faulty PC board.  
Engine will not go to high idle 1. Faulty idler solenoid. Check for  
under weld or auxiliary loading. bent linkage or broken spring.  
Engine does not develop full 1. Fuel filter clogged, Replace.  
power. Engine runs rough.  
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-filter  
and empty of water, bleed fuel  
system. Replace fuel in tank if  
needed.  
Engine will not go to high idle when 1. Broken spring on Idle Solenoid,  
attempting to weld or using auxil-  
iary power. Switching to manual  
high idle does not work.  
solenoid linkage binding, Faulty  
PC board, low idle speed set too  
low on idle solenoid.  
I
f all recommended possible areas  
of misadjustment have been  
checked and the problem persists,  
Engine will not shut off.  
1. Fuel Shutdown solenoid not Contact your local Lincoln  
functioning properly / linkage Authorized Field Service Facility.  
binding. Stop engine by shutting  
off valve located on main fuel fil-  
ter. Contact authorized local  
Engine Service Shop.  
Engine does not develop full power. 1. Fuel filter dirty/clogged. Replace.  
Low weld and auxiliary output. 2. Air filter dirty/clogged. Replace  
Engine runs rough.  
Air Filter Element.  
3. Fouled fuel injector(s). Contact  
authorized Engine Service Shop.  
4. Fuel contaminated with water.  
Check Main Filter Bowl and Inline  
Fuel filters for water. Clean and  
replace as needed. Replace fuel  
in tank.  
5. Cracked or loose fuel hose.  
Replace hose and tighten  
clamps.  
6. Valves out of adjustment. Contact  
authorized local Engine Service  
Shop.  
CAUTION  
If for any reason you do not understand the test procedures or are unable to perform the tests/repairs safely, contact your  
Local Lincoln Authorized Field Service Facility for technical troubleshooting assistance before you proceed.  
RANGER® 305D (CE)  
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E-5  
E-5  
TROUBLESHOOTING  
Observe all Safety Guidelines detailed throughout this manual  
PROBLEMS  
POSSIBLE  
RECOMMENDED  
(SYMPTOMS)  
CAUSE  
COURSE OF ACTION  
No welding power output.  
Auxiliary Power OK.  
1. Poor work lead connection to  
work. Make sure work clamp is  
tightly connected to clean base  
metal.  
2. "Weld Terminals" switch in wrong  
position. Place switch in "Weld  
Terminals On" position when  
welding without control cable.  
3. Faulty PC board.  
Welder has output but no control.  
1. Poor remote/control cable connec-  
tion to 6-pin or 14-pin connector.  
Check connections.  
2. Faulty remote cable or faulty wire  
feeder or wire feeder cable.  
Replace if necessary.  
3. Faulty control potentiometer or PC  
board.  
I
f all recommended possible areas  
Wire feeder does not work when 1. Wire Feeder Power circuit breaker of misadjustment have been  
control cable is connected to 14 pin  
connector.  
open. Check 42V beaker and checked and the problem persists,  
reset if tripped.  
Contact your local Lincoln  
Authorized Field Service Facility.  
2. Faulty control cable. Repair or  
replace cable.  
3. Faulty wire feeder. Replace wire  
feeder.  
No auxiliary power.  
1. Open circuit breakers. Reset  
breakers. If breakers keep trip-  
ping, reduce power draw.  
2. Faulty connections to auxiliary  
receptacles. Check connections.  
3. RCD tripped. Clear any ground  
fault and reset RCD circuit by  
pressing "Reset" button.  
4. Faulty PC board or welder alterna-  
tor.  
CAUTION  
If for any reason you do not understand the test procedures or are unable to perform the tests/repairs safely, contact your  
Local Lincoln Authorized Field Service Facility for technical troubleshooting assistance before you proceed.  
RANGER® 305D (CE)  
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E-6  
E-6  
TROUBLESHOOTING  
Observe all Safety Guidelines detailed throughout this manual  
PROBLEMS  
POSSIBLE  
RECOMMENDED  
(SYMPTOMS)  
CAUSE  
COURSE OF ACTION  
The welding arc is “cold.” The weld- 1. Make sure the MODE selector  
ing arc is not stable or is not satis- switch is in the correct position for  
factory. the engine runs normally. the process being used. (For exam-  
The auxiliary power is normal.  
ple, CV-WIRE, PIPE, CC-STICK.)  
2. Make sure the electrode (wire, gas,  
voltage, current etc.) is correct for  
the process being used.  
3. Check for loose or faulty connec-  
tions at the weld output terminals  
and welding cable connections.  
4. The welding cables may be too long  
or coiled, causing an excessive  
voltage drop.  
If all recommended possible areas of  
misadjustment have been checked  
and the problem persists, Contact  
your local Lincoln Authorized  
Field Service Facility.  
CAUTION  
If for any reason you do not understand the test procedures or are unable to perform the tests/repairs safely, contact your  
Local Lincoln Authorized Field Service Facility for technical troubleshooting assistance before you proceed.  
RANGER® 305D (CE)  
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F-1  
F-1  
DIAGRAMS  
RANGER® 305D (CE)  
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F-2  
F-2  
DIAGRAMS  
RANGER® 305D (CE)  
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F-3  
F-3  
DIAGRAMS  
RANGER® 305D (CE)  
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F-4  
F-4  
DIAGRAMS  
RANGER® 305D (CE)  
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F-5  
F-5  
DIAGRAMS  
RANGER® 305D (CE)  
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F-6  
F-6  
DIAGRAMS  
RANGER® 305D (CE)  
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F-7  
F-7  
DIAGRAMS  
RANGER® 305D (CE)  
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F-8  
F-8  
DIMENSION PRINT  
RANGER® 305D (CE)  
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NOTES  
RANGER® 305D (CE)  
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NOTES  
RANGER® 305D (CE)  
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NOTES  
RANGER® 305D (CE)  
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•
•
Do not touch electrically live parts or  
electrode with skin or wet clothing.  
Insulate yourself from work and  
ground.  
•
•
Keep flammable materials away.  
•
•
Wear eye, ear and body protection.  
WARNING  
Spanish  
•
No toque las partes o los electrodos  
bajo carga con la piel o ropa moja-  
da.  
Mantenga el material combustible  
fuera del área de trabajo.  
Protéjase los ojos, los oídos y el  
cuerpo.  
AVISO DE  
PRECAUCION  
French  
•
•
Aislese del trabajo y de la tierra.  
Ne laissez ni la peau ni des vête-  
ments mouillés entrer en contact  
avec des pièces sous tension.  
Isolez-vous du travail et de la terre.  
•
•
Gardez à l’écart de tout matériel  
inflammable.  
•
•
Protégez vos yeux, vos oreilles et  
votre corps.  
ATTENTION  
•
•
German  
Berühren Sie keine stromführenden  
Teile oder Elektroden mit Ihrem  
Körper oder feuchter Kleidung!  
Isolieren Sie sich von den  
Entfernen Sie brennbarres Material!  
Tragen Sie Augen-, Ohren- und Kör-  
perschutz!  
WARNUNG  
•
Elektroden und dem Erdboden!  
Portuguese  
•
•
Não toque partes elétricas e electro-  
dos com a pele ou roupa molhada.  
Isole-se da peça e terra.  
•
Mantenha inflamáveis bem guarda-  
dos.  
•
Use proteção para a vista, ouvido e  
corpo.  
ATENÇÃO  
Japanese  
Chinese  
Korean  
Arabic  
READ AND UNDERSTAND THE MANUFACTURER’S INSTRUCTION FOR THIS EQUIPMENT AND THE  
CONSUMABLES TO BE USED AND FOLLOWYOUR EMPLOYER’S SAFETY PRACTICES.  
SE RECOMIENDA LEERY ENTENDER LAS INSTRUCCIONES DEL FABRICANTE PARA EL USO DE  
ESTE EQUIPOY LOS CONSUMIBLES QUE VA A UTILIZAR, SIGA LAS MEDIDAS DE SEGURIDAD DE SU  
SUPERVISOR.  
LISEZ ET COMPRENEZ LES INSTRUCTIONS DU FABRICANT EN CE QUI REGARDE CET EQUIPMENT  
ET LES PRODUITS A ETRE EMPLOYES ET SUIVEZ LES PROCEDURES DE SECURITE DE VOTRE  
EMPLOYEUR.  
LESEN SIE UND BEFOLGEN SIE DIE BETRIEBSANLEITUNG DER ANLAGE UND DEN ELEKTRO-  
DENEINSATZ DES HERSTELLERS. DIE UNFALLVERHÜTUNGSVORSCHRIFTEN DES ARBEITGEBERS  
SIND EBENFALLS ZU BEACHTEN.  
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•
•
Keep your head out of fumes.  
Use ventilation or exhaust to  
remove fumes from breathing zone.  
•
•
Turn power off before servicing.  
•
•
Do not operate with panel open or  
guards off.  
WARNING  
Spanish  
•
•
Los humos fuera de la zona de res-  
piración.  
Mantenga la cabeza fuera de los  
humos. Utilice ventilación o  
aspiración para gases.  
Desconectar el cable de ali-  
mentación de poder de la máquina  
antes de iniciar cualquier servicio.  
No operar con panel abierto o  
guardas quitadas.  
AVISO DE  
PRECAUCION  
French  
•
•
Débranchez le courant avant l’entre-  
tien.  
•
•
N’opérez pas avec les panneaux  
ouverts ou avec les dispositifs de  
protection enlevés.  
•
•
Gardez la tête à l’écart des fumées.  
Utilisez un ventilateur ou un aspira-  
teur pour ôter les fumées des zones  
de travail.  
ATTENTION  
German  
Strom vor Wartungsarbeiten  
abschalten! (Netzstrom völlig öffnen;  
Maschine anhalten!)  
Anlage nie ohne Schutzgehäuse  
oder Innenschutzverkleidung in  
Betrieb setzen!  
•
•
Vermeiden Sie das Einatmen von  
Schweibrauch!  
Sorgen Sie für gute Be- und  
Entlüftung des Arbeitsplatzes!  
WARNUNG  
Portuguese  
•
•
Não opere com as tampas removidas.  
Desligue a corrente antes de fazer  
serviço.  
•
•
Mantenha-se afastado das partes  
moventes.  
Não opere com os paineis abertos  
ou guardas removidas.  
•
•
Mantenha seu rosto da fumaça.  
Use ventilação e exhaustão para  
remover fumo da zona respiratória.  
ATENÇÃO  
•
Não toque as partes elétricas nuas.  
Japanese  
Chinese  
Korean  
Arabic  
LEIA E COMPREENDA AS INSTRUÇÕES DO FABRICANTE PARA ESTE EQUIPAMENTO E AS PARTES  
DE USO, E SIGA AS PRÁTICAS DE SEGURANÇA DO EMPREGADOR.  
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• World's Leader in Welding and Cutting Products •  
• Sales and Service through Subsidiaries and Distributors Worldwide •  
Cleveland, Ohio 44117-1199 U.S.A. TEL: 216.481.8100 FAX: 216.486.1751 WEBꢀSITE: www.lincolnelectric.com  
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