Lincoln Electric Welder 305D User Manual
RETURN TO MAIN MENU  
IM970  
December, 2010  
®
Ranger 305D  
For use with machines having Code Numbers:  
11457  
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.  
OPERATOR’SꢀMANUAL  
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  
Download from Www.Somanuals.com. All Manuals Search And Download.  
ii  
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 manufacturer’s instructions for this  
equipment and the consumables to be used, including the  
material safety data sheet (MSDS) and follow your  
employer’s safety practices. MSDS forms are available from  
your welding distributor or from the manufacturer.  
5.f. Also see item 1.b.  
Download from Www.Somanuals.com. All Manuals Search And Download.  
iii  
iii  
SAFETY  
WELDING and CUTTING  
CYLINDER may explode  
if damaged.  
SPARKS can  
cause fire or explosion.  
7.a. Use only compressed gas cylinders  
containing the correct shielding gas for the  
6.a. Remove fire hazards from the welding area.  
If this is not possible, cover them to prevent  
the welding sparks from starting a fire.  
process used and properly operating  
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 manufacturer’s  
recommendations.  
8.c. Ground the equipment in accordance with the U.S. National  
Electrical Code and the manufacturer’s 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.  
Download from Www.Somanuals.com. All Manuals Search And Download.  
iv  
iv  
SAFETY  
5. Toujours porter des lunettes de sécurité dans la zone de  
PRÉCAUTIONS DE SÛRETÉ  
soudage. Utiliser des lunettes avec écrans lateraux dans les  
zones où l’on pique le laitier.  
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 d’incendie 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 d’incendie.  
Sûreté Pour Soudage A L’Arc  
1. Protegez-vous contre la secousse électrique:  
a. Les circuits à l’électrode 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.  
8. S’assurer que la masse est connectée le plus prés possible  
de la zone de travail qu’il est pratique de le faire. Si on place  
la masse sur la charpente de la construction ou d’autres  
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 d’incendie ou d’echauffement des chaines et des  
câbles jusqu’à ce qu’ils se rompent.  
b. Faire trés attention de bien s’isoler 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.  
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.  
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 l’eau pour le  
refroidir.  
10. Ne pas souder en présence de vapeurs de chlore provenant  
d’opérations de dégraissage, nettoyage ou pistolage. La  
chaleur ou les rayons de l’arc peuvent réagir avec les  
vapeurs du solvant pour produire du phosgéne (gas forte-  
ment toxique) ou autres produits irritants.  
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 s’applicuent aussi au pistolet de  
soudage.  
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 n’importe quelle  
partie du corps.  
PRÉCAUTIONS DE SÛRETÉ POUR  
LES MACHINES À SOUDER À  
TRANSFORMATEUR ET À  
REDRESSEUR  
3. Un coup d’arc peut être plus sévère qu’un coup de soliel,  
donc:  
a. Utiliser un bon masque avec un verre filtrant approprié  
ainsi qu’un verre blanc afin de se protéger les yeux du  
rayonnement de l’arc et des projections quand on soude  
ou quand on regarde l’arc.  
1. Relier à la terre le chassis du poste conformement au code  
de l’électricité 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.  
b. Porter des vêtements convenables afin de protéger la  
peau de soudeur et des aides contre le rayonnement de  
l‘arc.  
c. Protéger l’autre personnel travaillant à proximité au  
soudage à l’aide d’écrans appropriés et non-inflamma-  
bles.  
2. Autant que possible, I’installation et l’entretien du poste  
seront effectués par un électricien qualifié.  
3. Avant de faires des travaux à l’interieur de poste, la  
debrancher à l’interrupteur à la boite de fusibles.  
4. Des gouttes de laitier en fusion sont émises de l’arc de  
soudage. Se protéger avec des vêtements de protection  
libres de l’huile, 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.  
Download from Www.Somanuals.com. All Manuals Search And Download.  
v
v
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 customer’s 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.  
Download from Www.Somanuals.com. All Manuals Search And Download.  
vi  
vi  
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  
Electrical Device Used with the Ranger 305D......................................................................A-6  
Auxiliary Power Receptacles and Plugs...............................................................................A-7  
Standby Power Connections................................................................................................A-7  
Premises Wiring...................................................................................................................A-8  
Connection of Lincoln Electric Wire Feeders...............................................................A-9,A-10  
________________________________________________________________________________  
Operation.........................................................................................................................Section b  
Safety Precautions ..............................................................................................................B-1  
General Description..............................................................................................................B-1  
For Auxiliary Power ..............................................................................................................B-1  
Engine Operation..................................................................................................................B-1  
Add Fuel...............................................................................................................................B-1  
Break in Period.....................................................................................................................B-1  
Welder Controls.............................................................................................................B-2,B-3  
Engine Controls....................................................................................................................B-3  
Starting and Stopping the Engine .................................................................................B-4  
Welding Operation................................................................................................................B-4  
Duty Cycle ..............................................................................................................B-4,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-7  
Simultaneous Welding and Auxiliary Power Loads.......................................................B-7  
Extension Cord Recommendations...............................................................................B-7  
________________________________________________________________________________  
Accessories.....................................................................................................Section C  
Field Installed Options / Accessories ...............................................................................C-1  
________________________________________________________________________________  
Download from Www.Somanuals.com. All Manuals Search And Download.  
vii  
vii  
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  
GFCI Testing and Resetting Procedure..........................................................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-492  
________________________________________________________________________  
Download from Www.Somanuals.com. All Manuals Search And Download.  
A-1  
A-1  
INSTALLATION  
TECHNICAL SPECIFICATIONS - Ranger® 305D (K1727-3)  
INPUT - DIESEL ENGINE  
Make/Model  
Description  
Speed (RPM)  
Displacement  
cu. in. (cu. cm.)  
Starting  
System  
Capacities  
3 cylinder  
4 stroke  
18.8 HP  
(14 KW)  
43.88(789)  
12VDC Battery &  
starter  
Fuel: 12 gal.  
(45 Liters)  
Oil: 3.4Qts. (3.2L)  
High Idle 3650  
Full Load 3500  
Bore x Stroke inch (mm)  
Kubota**  
D722  
Net intermittent  
3600 RPM  
naturally aspirated Low Idle 2450  
water cooled  
Diesel Engine  
2.64 x 2.68  
(67 x 68 mm)  
(Group 58; 550 Radiator Coolant:  
cold crank amps) 3.85Qts. (3.6L)  
Battery Charger  
(3.6L)  
RATED OUTPUT @ 104° F (40° C) - WELDER  
Welding Process  
Welding Output  
Current/Voltage/Duty Cycle  
305A / 29V / 100%  
Output Range  
Max. Weld OCV  
@Rated Load RPM  
DC Constant Current  
DC Pipe Current  
Touch-Start™TIG  
DC Constant Voltage  
20 TO 305 AMPS  
40 TO 300 AMPS  
20 TO 250 AMPS  
14 TO 29 VOLTS  
300A / 29V / 100%  
250A / 30V / 100%  
300A / 29V / 100%  
60 Volts  
.
RATED OUTPUT @ 104° F (40° C) - GENERATOR  
Auxiliary Power 1  
10,000 Watts Peak, / 9,500 Watts Continuous, 60 Hz 120/240 Volts  
Sound Levels  
Sound Power: 104.2 dB Lwa, Sound Level: 80.6 dBA @ 23 ft ( 7m )  
PHYSICAL DIMENSIONS  
DEPTH  
HEIGHT  
30.00* in.  
762.0 mm  
WIDTH  
WEIGHT  
21.50 in  
546.0 mm  
52.25 in.  
698 lbs. (317kg.)  
1327.0 mm  
ENGINE  
FUEL SYSTEM  
Mechanical Fuel Pump, Auto air bleed  
LUbRICATION  
Full Pressure  
with Full Flow Filter  
EMISSIONS  
Certified to EPA Tier 4  
Compliant  
GOVERNOR  
Mechanical  
Governor  
system Electric shutoff solenoid Indirect fuel injector  
AIR CLEANER  
ENGINE IDLER  
MUFFLER  
Low noise Muffler:  
Top outlet can be rotated.  
Made from long life, aluminized steel.  
ENGINE PROTECTION  
Shutdown on low oil  
pressure & engine  
temperature  
Single Element  
Automatic Idler  
ENGINE WARRANTY: 2 year complete (parts and labor) 3rd. year major components (parts and labor)  
RECEPTACLES AND CIRCUIT bREAKERS  
RECEPTACLES  
AUXILIARY POWER CIRCUIT bREAKER OTHER CIRCUIT bREAKERS  
(2) 120VAC GFCI Duplex (5-20R)  
(1) 120/240VAC Dual Voltage  
Full KVA (14-50R)  
Two 20AMP for Two Duplex Receptacle  
One 50AMP for Dual Voltage(2-pole)  
15AMP for Battery Charging Circuit  
15AMP for 42V Wire Feeder Power  
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.  
* Top of enclosure add 6in. (152mm) for exhaust pipe.  
** Engine warranty may vary outside of the USA. (See Engine warranty for details)  
RANGER® 305D  
Download from Www.Somanuals.com. All Manuals Search And Download.  
A-2  
A-2  
INSTALLATION  
LIFTING  
SAFETY PRECAUTIONS  
The RANGER® 305D weighs approximately  
775lbs.(352kg.) with a full tank of fuel (698 lbs. less  
fuel). A lift bail is mounted to the machine and should  
always be used when lifting the machine.  
WARNING  
Do not attempt to use this equipment until you  
have thoroughly read the engine manufacturer’s  
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.  
• Insulate yourself from work and  
ground  
• Do not lift this machine using lift  
bail if it is equipped with a heavy  
accessory such as trailer or gas  
cylinder.  
• Always wear dry insulating gloves.  
------------------------------------------------------------------------  
ENGINEꢀEXHAUSTꢀcan kill.  
FALLING  
• Do not lift machine if lift bail is  
damaged.  
EQUIPMENT can  
cause injury.  
• Use in open, well ventilated areas or  
vent exhaust outside.  
• Do not operate machine while  
suspended from lift bail.  
------------------------------------------------------------------------  
MOVING PARTSꢀcan injure.  
--------------------------------------------------------------------------------  
• Do not operate with doors open or  
guards off.  
• Stop engine before servicing.  
HIGH ALTITUDE OPERATION  
At higher altitudes, output derating may be necessary. For max-  
imum rating, derate the machine 2.5% to 3.5% for every 1000 ft.  
(305m). Due to new EPA and other local emissions regulations,  
modifications to the engine for high altitude are restricted within  
the United States and some other European Countries. Use  
above 6000 ft.(1828 m) 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.  
• Keep away from moving parts.  
------------------------------------------------------------------------  
See additional warning information at  
front of this operator’s manual.  
Only qualified personnel should install,  
use, or service this equipment.  
LOCATION AND VENTILATION  
HIGH TEMPERATURE OPERATION  
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.  
At temperatures above 104°F(40°C), Welder output derating is  
necessary. For maximum output ratings, derate the welder out-  
put 2 volts for every 50°F(10°C) above 104°F(40°C).  
STACKING  
Cold weather starting:  
With a fully charged battery and the proper weight oil,  
the engine should start satisfactorily even down to  
about 5°F (-15°C). If the engine must be frequently  
started at or below 23°F (-5°C), it may be desirable to  
install cold-starting aides. The use of No. 1D diesel  
fuel is recommended in place of No. 2D at tempera-  
tures below 23°F (-5°C). Allow the engine to warm up  
before applying a load or switching to high idle.  
Note: Extreme cold weather starting may require  
longer glow plug operation.  
RANGER® 305D 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  
When operating the welder at an angle, the effective  
fuel capacity will be slightly less than the specified 12  
gallons (45ltrs.).  
Under no conditions should ether or other starting  
fluids be used with this engine!  
--------------------------------------------------------------------------------  
RANGER® 305D  
Download from Www.Somanuals.com. All Manuals Search And Download.  
A-3  
A-3  
INSTALLATION  
PRE-OPERATION ENGINE SERVICE  
READ the engine operating and maintenance instruc-  
tions supplied with this machine.  
TOWING  
The recommended trailer for use with this equipment for road,  
in-plant and yard towing by a vehicle(1) is Lincoln’s K957-1. 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.  
• Keep sparks and flame away from tank.  
--------------------------------------------------------------------------------  
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.  
OIL  
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.  
The RANGER® 305D 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 run-  
ning time during the first 50 running hours. Refer to  
the engine Operator’s Manual for specific oil recom-  
mendations and break-in information. The oil change  
interval is dependent on the quality of the oil and the  
operating environment. Refer to the Engine Operator’s  
Manual for more details on the proper service and  
maintenance intervals.  
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.  
(1)  
5. Conformance with federal, state and local laws.  
(1)  
Consult applicable federal, state and local laws regarding specific  
requirements for use on public highways.  
VEHICLE MOUNTING  
WARNING  
FUEL  
DIESEL FUEL ONLY-Low sulphur fuel or ultra low  
sulphur fuel in U.S.A. and Canada.  
Improperly mounted concentrated loads may  
cause unstable vehicle handling and tires or other  
components to fail.  
WARNING  
• Only transport this Equipment on serviceable  
vehicles which are rated and designed for such  
loads.  
• Distribute, balance and secure loads so vehicle  
is stable under conditions of use.  
• Fill the fuel tank with clean, fresh fuel. The  
capacity of the tank is 12 gals. (45.4ltrs). When  
the fuel gauge reads empty the tank contains  
approximately 2 gals. (7.6ltrs.) of reserve fuel.  
• 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.  
• Follow vehicle manufacturer’s instructions.  
--------------------------------------------------------------------------------  
WARNING  
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  
ran for extended periods of time.  
--------------------------------------------------------------------------------  
RANGER® 305D  
Download from Www.Somanuals.com. All Manuals Search And Download.  
A-4  
A-4  
INSTALLATION  
REMOTE CONTROL  
ENGINE COOLING SYSTEM  
The RANGER® 305D is equipped with a 6-pin and a  
14-pin connector. The 6-pin connector is for connect-  
ing the K857 or K857-1 Remote Control or for TIG  
welding, the K870 foot Amptrol or the K936-3 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 automatically 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 2 feet  
(0.6m) from the case back and 16in.(406mm) from  
either side of the base to a vertical surface.  
--------------------------------------------------------------------------------  
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.  
bATTERY CONNECTION  
CAUTION  
Use caution as the electrolyte is a strong acid that  
can burn skin and damage eyes.  
--------------------------------------------------------------------------------  
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 con-  
nector, the auto-sensing circuit automatically makes  
the Output Control inactive and the wire feeder volt-  
age control active  
The RANGER® 305D is shipped with the negative  
battery cable disconnected. Make certain that the  
RUN-STOP switch is in the STOP position. Remove  
the two screws from the rear battery tray using a  
screwdriver or a 3/8" socket. Attach the negative bat-  
tery cable to the negative battery terminal and tighten  
using a 1/2" socket or wrench.  
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.  
--------------------------------------------------------------------------------  
ELECTRICAL CONNECTIONS  
MUFFLER OUTLET PIPE  
Using the clamp provided secure the outlet pipe to the  
outlet tube with the pipe positioned such that it will  
direct the exhaust in the desired direction. Tighten  
using a 9/16" socket or wrench.  
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.)  
SPARK ARRESTER  
Some federal, state or local laws may require that  
gasoline or diesel engines be equipped with exhaust  
spark arresters when they are operated in certain  
locations where unarrested sparks may present a fire  
hazard. The standard muffler included with this welder  
does not qualify as a spark arrester. When required by  
local regulations, a suitable spark arrester, such as  
the K1898-1 must be installed and properly main-  
tained.  
To prevent dangerous electric shock, other equipment  
to which this engine driven welder supplies power  
must:  
WARNING  
• be grounded to the frame of the welder using a  
grounded type plug.  
• be double insulated.  
WARNING  
• Do not ground the machine to a pipe that carries  
explosive or combustible material.  
--------------------------------------------------------------------------------  
An incorrect spark arrestor may lead to damage to  
the engine or adversely affect performance.  
--------------------------------------------------------------------------------  
RANGER® 305D  
Download from Www.Somanuals.com. All Manuals Search And Download.  
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 connect-  
ed between the machine grounding stud and the  
frame of the vehicle. When this engine driven welder  
is connected to premises wiring such as that in a  
home or shop, its frame must be connected to the sys-  
tem earth ground. See further connection instructions  
in the section entitled "Standby Power Connections"  
as well as the article on grounding in the latest  
National Electrical Code and the local code.  
CAbLE INSTALLATION  
Install the welding cables to your RANGER® 305D as  
follows.  
1. The engine must be OFF to install welding cables.  
2. Remove the flanged nuts from the output terminals  
.
3. Connect the electrode holder and work cables to the  
weld output terminals. The terminals are identified  
on the case front.  
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.  
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.  
The National Electrical Code lists a number of alter-  
nate means of grounding electrical equipment. A  
machine grounding stud marked with the symbol  
is provided on the front of the welder.  
CAUTION  
6. Check and tighten the connections periodically.  
• Loose connections will cause the output termi-  
nals to overheat. The terminals may eventually  
melt.  
WELDING TERMINALS  
• Do not cross the welding cables at the output ter-  
minal connection. Keep the cables isolated and  
separate from one another.  
The RANGER® 305D 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 "REMOTELY CONTROLLED" position.  
--------------------------------------------------------------------------------  
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 con-  
nections should be checked periodically and tightened  
with a 3/4" 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.  
TOTAL COMbINED LENGTH OF  
ELECTRODE AND WORK CAbLES  
Cable Size for  
Cable Length  
305 Amps  
100% Duty Cycle  
1 / 0 AWG  
0-100Ft. (0-30 meters)  
2 / 0 AWG  
3 / 0 AWG  
100-150 Ft. (30-46 meters)  
150-200 Ft. (46-61 meters)  
TAbLE A.1  
RANGER® 305D  
Download from Www.Somanuals.com. All Manuals Search And Download.  
A-6  
A-6  
INSTALLATION  
TABLE lll  
ELECTRICAL DEVICE USE WITH THE RANGER® 305D  
Type  
Common Electrical Devices  
Possible Concerns  
Resistive  
Heaters, toasters, incandescent  
light bulbs, electric range, hot  
pan, skillet, coffee maker.  
NONE  
Capacitive  
TV sets, radios, microwaves,  
appliances with electrical control.  
Voltage spikes or high voltage  
regulation can cause the capaci-  
tative elements to fail. Surge  
protection, transient protection,  
and additional loading is recom-  
mended for 100% fail-safe oper-  
ation. DO NOT RUN THESE  
DEVICES WITHOUT ADDI-  
TIONAL RESISTIVE TYPE  
LOADS.  
Inductive  
Single-phase induction motors,  
drills, well pumps, grinders, small  
refrigerators, weed and hedge  
trimmers  
These devices require large  
current inrush for starting.  
Some synchronous motors may  
be frequency sensitive to attain  
maximum output torque, but  
they SHOULD BE SAFE from  
any frequency induced failures.  
Capacitive/Inductive  
Computers, high resolution TV sets,  
complicated electrical equipment.  
An inductive type line condition-  
er along with transient and  
surge protection is required, and  
liabilities still exist. DO NOT  
USE THESE DEVICES WITH A  
RANGER® 305D  
The Lincoln Electric Company is not responsible for any damage to electrical components improperly connected  
to the RANGER® 305D.  
RANGER 305D  
Download from Www.Somanuals.com. All Manuals Search And Download.  
A-7  
A-7  
INSTALLATION  
AUXILIARY POWER RECEPTACLES  
• Install the double-pole, double-throw switch  
between the power company meter and the premis-  
es disconnect. Switch rating must be the same or  
greater than the customer’s premises disconnect  
and service over current protection.  
Start the engine and set the “IDLER” control switch to  
the “High Idle” mode. Voltage is now correct at the  
receptacles for auxiliary power. This must be done  
before a tripped GFCI receptacle can be reset prop-  
erly. See the MAINTENANCE section for detailed  
information on testing and resetting the GFCI recep-  
tacle.  
• Take necessary steps to assure load is limited to  
the capacity of the RANGER® 305D by installing a  
50 amp, 240 VAC double pole circuit breaker.  
Maximum rated load for each leg of the 240 VAC  
auxiliary is 40 amperes. Loading above the rated  
output will reduce output voltage below the allow-  
able - 10% of rated voltage which may damage  
appliances or other motor-driven equipment and  
may result in overheating of the RANGER® 305D  
engine and/or alternator windings.  
The auxiliary power of the RANGER® 305D consists  
of two 20 Amp-120 VAC (5-20R) duplex receptacles  
with GFCI protection and one 50 Amp 120/240 VAC  
(14-50R) receptacle. The 240 VAC receptacle can be  
split for single phase 120 VAC operation.  
The auxiliary power capacity is 10,000 watts Peak,  
9,500 Watts Continuous of 60 Hz, single phase  
power. The auxiliary power capacity rating in watts is  
equivalent to volt-amperes at unity power factor. The  
max permissible current of the 240 VAC output is 40  
amps. The 240 VAC output can be split to provide  
two separate 120 VAC outputs with a max permissi-  
ble current of 40 Amps per output to two separate  
120 VAC branch circuits (these circuits cannot be  
paralleled). Output voltage is within ± 10% at all loads  
up to rated capacity. All auxiliary power is protected  
by circuit breakers.  
• Install a 50 amp, 120/240 VAC plug (NEMA Type  
14-50) to the double-pole circuit breaker using No.  
6, 4 conductor cable of the desired length. (The 50  
amp, 120/240 VAC plug is available in the optional  
K802R plug kit or as part number T12153-9.)  
• Plug this cable into the 50 Amp, 120/240 Volt recep-  
tacle on the RANGER® 305D case front.  
The 120 V auxiliary power receptacles should only be  
used with three wire grounded type plugs or  
approved double insulated tools with two wire plugs.  
The current rating of any plug used with the system  
must be at least equal to the current capacity of the  
associated receptacle.  
NOTE: The 240 V receptacle has two 120 V circuits,  
but are of opposite polarities and cannot be paral-  
leled.  
STANDbY POWER CONNECTIONS  
The RANGER® 305D is suitable for temporary,  
standby or emergency power using the engine manu-  
facturer’s recommended maintenance schedule.  
The RANGER® 305D can be permanently installed  
as a standby power unit for 240 VAC, 3 wire, single  
phase, 40 amp service. Connections must be made  
by a licensed electrician who can determine how the  
120/240 VAC power can be adapted to the particular  
installation and comply with all applicable electrical  
codes.  
RANGER® 305D  
Download from Www.Somanuals.com. All Manuals Search And Download.  
A-8  
A-8  
INSTALLATION  
CONNECTION OF RANGER® 305D TO PREMISES WIRING  
240 VOLT  
GROUNDED CONDUCTOR  
POWERꢀ  
ꢀ
COMPANYꢀ  
240 Voltꢀ  
60 Hz.ꢀ  
3-Wireꢀ  
Service  
120 VOLT  
120 VOLT  
ꢀ
METER  
NEUTRAL  
BUS  
N
LOAD  
DOUBLE POLE DOUBLE THROW  
SWITCH RATING TO BE THE SAME  
AS OR GREATER THAN PREMISES  
SERVICE OVERCURRENT  
PROTECTION.  
PREMISESꢀ  
DISCONNECT ANDꢀ  
SERVICEꢀ  
OVERCURRENTꢀ  
PROTECTION  
GROUND  
50AMPꢀ  
240 VOLT  
DOUBLEꢀ  
POLEꢀ  
CIRCUITꢀ  
BREAKER  
50 AMP, 120/240ꢀ  
VOLT PLUGꢀ  
NEMA TYPE 14-50  
240 VOLT  
GND  
N
50 AMP, 120/240 VOLTꢀ  
RECEPTACLE  
NOTE: No. 6 COPPER CONDUCTOR CABLE SEEꢀ  
NATIONAL ELECTRICAL CODE FOR ALTERNATE WIREꢀ  
SIZE RECOMMENDATIONS.  
WARNING  
• Only a licensed, certified, trained electrician should install the machine to a premises or residential  
electrical system. be certain that:  
• The installation complies with the National Electrical Code and all other applicable electrical codes.  
• The premises is isolated and no feedback into the utility system can occur. Certain state and local  
laws require the premises to be isolated before the generator is linked to the premises. Check your  
state and local requirements.  
• A double pole, double throw transfer switch in conjunction with the properly rated double throw  
circuit breaker is connected between the generator power and the utility meter.  
RANGER® 305D  
Download from Www.Somanuals.com. All Manuals Search And Download.  
A-9  
A-9  
INSTALLATION  
• Across The-Arc Model:  
CONNECTION OF LINCOLN ELECTRIC  
WIRE FEEDERS  
Attach the single lead from the front of the LN-15 to  
work using the spring clip at the end of the lead. This  
is a control lead to supply current to the wire feeder  
motor; it does not carry welding current.  
Connection of LN-7 or LN-8 to the RANGER® 305D  
• Shut the welder off.  
Set the "WELD TERMINALS" switch to "WELD TER-  
MINALS ON"  
• Connect the LN-7 or LN-8 per instructions on the  
appropriate connection diagram in Section F.  
• Control Cable Model:  
• Set the "WIRE FEEDER VOLTMETER" switch to  
either "+" or "-" as required by the electrode being  
used.  
Connect Control Cable between Engine Welder and  
Feeder.  
Set the "WELD TERMINALS" switch to "REMOTELY  
CONTROLLED".  
• Set the "MODE" switch to the "CV WIRE " position.  
• Set the "ARC CONTROL" knob to "0" initially and  
adjust to suit.  
• Set the MODE switch to the "CV-WIRE " position.  
• Set the "WELD TERMINALS" switch to the  
"REMOTELY CONTROLLED" position.  
• Set the "WIRE FEEDER VOLTMETER" switch to  
either "+" or "-" as required by the electrode polarity  
being used.  
• Set the "IDLE" switch to the "HIGH" position.  
• Set the "ARC CONTROL" knob to "0" initially and  
adjust to suit.  
Connection of LN-15 to the Ranger® 305D  
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.  
• Set the "IDLE" switch to the "AUTO" position  
• 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.  
RANGER® 305D  
Download from Www.Somanuals.com. All Manuals Search And Download.  
A-10  
A-10  
INSTALLATION  
Connection of LN-742, Spool Gun (K487-25) and  
Cobramatic to RANGER® 305D  
WARNING  
Connection of the LN-25 to the RANGER® 305D  
Shut off welder before making any electrical con-  
nections.  
--------------------------------------------------------------------------------  
The LN-25 with or without an internal contactor may  
• Shut the welder off.  
• Connect per instructions on the appropriate connec-  
tion diagram in Section F.  
be used with the RANGER® 305D. See the appropri-  
ate connection diagram in Section F.  
Connection of PRINCE XL SPOOL GUN to the  
Ranger® 305D  
1. Shut the welder off.  
Connection of the Prince XL Spool Gun requires the  
use of the K1849-1 Adapter Module.  
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.  
• Connect the Control Cable of the Spool Gun to the  
Adapter Module and connect the Control Cable of  
the Adapter Module to the Welder.  
4. Set the MODE switch to the "CV-WIRE " position.  
5. Set the "WELD TERMINALS" switch to "WELD  
TERMINALS ON"  
• Connect the Gas Hose.  
• Set the MODE switch to the "CV-WIRE " position.  
6. Set the "ARC CONTROL" knob to "0" initially and  
adjust to suit.  
• Set the "WELD TERMINALS" switch to "WELD  
TERMINALS ON".  
7. Set the "IDLE" switch to the "AUTO" position.  
When not welding, the RANGER® 305D 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.  
• Set the "ARC CONTROL" knob to "0" initially and  
adjust to suit.  
• Set the “IDLE” switch to the “HIGH” position.  
8. When the gun trigger is closed, the current sens-  
ing circuit will cause the RANGER® 305D 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.  
CAUTION  
If you are using an LN-25 without an internal con-  
tactor, the electrode will be energized when the  
Ranger® 305D is started.  
--------------------------------------------------------------------------------  
RANGER® 305D  
Download from Www.Somanuals.com. All Manuals Search And Download.  
b-1  
b-1  
OPERATION  
• Add oil (if necessary) to bring the level up to the full  
mark. Do not overfill. Close engine door.  
• Check radiator for proper coolant level. (Fill if nec-  
essary).  
SAFETY PRECAUTIONS  
WARNING  
• See Engine Owner’s Manual for specific oil and  
coolant recommendations.  
Do not attempt to use this equipment until you  
have thoroughly read the engine manufacturer’s  
manual supplied with your welder. It includes  
important safety precautions, detailed engine  
starting, operating and maintenance instructions,  
and parts lists.  
ADD FUEL  
WARNING  
------------------------------------------------------------------------  
ELECTRIC SHOCK can kill.  
• Stop engine while fueling.  
• Do not smoke when fueling.  
• Keep sparks and flame away from  
tank.  
• Do not touch electrically live parts or  
electrode with skin or wet clothing.  
• Insulate yourself from work and  
ground  
• Always wear dry insulating gloves.  
• Do not leave unattended while fuel-  
ing.  
• Wipe up spilled fuel and allow  
• Always operate the welder with the hinged door  
closed and the side panels in place.  
DIESEL FUEL  
can cause fire.  
fumes to clear before starting  
engine.  
• 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.  
• Do not overfill tank, fuel expan-  
sion may cause overflow.  
DIESEL FUEL ONLY-Low sulphur fuel or ultra low  
sulphur fuel in U.S.A. and Canada.  
--------------------------------------------------------------------------------  
• Remove the fuel tank cap.  
GENERAL DESCRIPTION  
The RANGER® 305D is a diesel engine powered DC  
multi-process welding power source and 120 / 240  
volt AC power generator. The engine drives a genera-  
tor that supplies three phase power for the DC weld-  
ing circuit and single phase power for the AC auxiliary  
outlets. The DC welding control system uses state of  
the art Chopper Technology (CT tm) for superior weld-  
ing performance.  
• Fill the tank approximately 4 inches (100mm) from  
the top of the filler neck to allow for fuel expansion .  
DO NOT FILL THE TANK TO THE POINT OF  
OVERFLOW.  
• Replace the fuel cap and tighten securely.  
• See Engine Owner’s Manual for specific fuel recom-  
mendations.  
FOR AUXILIARY POWER:  
Start the engine and set the IDLER control switch to  
the desired operating mode. Full power is available  
regardless of the welding control settings providing no  
welding current is being drawn.  
bREAK-IN PERIOD  
Any engine will use a small amount of oil during its  
“break-in” period. For the diesel engine on the  
RANGER® 305D, break-in is about 50 running hours.  
The auxiliary power of the RANGER® 305D consists  
of two 20 Amp-120 VAC (5-20R) duplex receptacles  
with GFCI protection and one 50 Amp 120/240 VAC  
(14-50R) receptacle. The 240 VAC receptacle can be  
split for single phase 120 VAC operation. Also refer to  
the AUXILIARY POWER OPERATION section later in  
this chapter.  
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.  
CAUTION  
During break-in, subject the RANGER® 305D to  
moderate loads. Avoid long periods running at  
idle. before stopping the engine, remove all loads  
and allow the engine to cool several minutes.  
--------------------------------------------------------------------------------  
ENGINE OPERATION  
Before Starting the Engine:  
• Be sure the machine is on a level surface.  
• Open top & side engine doors and remove the  
engine oil dipstick and wipe it with a clean cloth.  
Reinsert the dipstick and check the level on the dip-  
stick.  
RANGER® 305D  
Download from Www.Somanuals.com. All Manuals Search And Download.  
b-2  
b-2  
OPERATION  
16  
15  
14  
1
2
17  
13  
12  
3
11  
4
10  
9
8
7
6
5
FIGURE b.1  
WELDING CONTROLS (Figure b.1)  
2. DIGITAL OUTPUT METERS-The digital  
meters allow the output voltage (CV-WIRE mode)  
or current (CC-STICK,DOWN HILL PIPE and TIG  
modes) to be set prior to welding using the OUT-  
PUT control dial. During welding, the meter dis-  
play the actual output voltage (VOLTS) and cur-  
rent (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 weld-  
ing was ceased.  
1. OUTPUT CONTROL- The OUTPUT dial is  
used to preset the output voltage or current as dis-  
played on the digital meters for the four welding  
modes. When in the CC-STICK, DOWNHILL PIPE  
or CV-WIRE modes and when a remote control is  
connected to the 6-Pin or 14-Pin Connector, the  
auto-sensing circuit automatically switches the  
OUTPUT CONTROL from control at the welder to  
the remote control.  
While the display is being held the left-most deci-  
mal point in each display will be flashing. The  
accuracy of the meters is +/- 3%.  
In the CV-WIRE mode, when the wire feeder con-  
trol 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  
When in the 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.  
RANGER® 305D  
Download from Www.Somanuals.com. All Manuals Search And Download.  
b-3  
b-3  
10. WIRE FEEDER VOLTMETER SWITCH:  
OPERATION  
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 deposition  
("stacking" of iron) are key to fast travel speeds. It is recom-  
mended 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 the  
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  
approximately 12 seconds and then go to low idle  
speed.  
5. WELD OUTPUT TERMINALS WITH FLANGE  
NUT- Provides a connection point for the electrode and  
work cables.  
6. GROUND STUD-  
Provides a connection point for  
• When the electrode touches the work or power is  
drawn for lights or tools (approximately 100 Watts  
minimum), the engine accelerates and operates at  
full speed.  
• When welding ceases or the AC power load is  
turned off, a fixed time delay of approximately 12  
seconds starts. If the welding or AC power load is  
not restarted before the end of the time delay, the  
idler reduces the engine speed to low idle speed.  
• The engine will automatically return to high idle  
speed when there is welding load or AC power load  
reapplied.  
connecting the machine case to earth ground.  
7. 14-PIN CONNECTOR- For attaching wire feeder con-  
trol cables to the RANGER® 305D. Includes contactor clo-  
sure circuit, auto-sensing remote control circuit, and 120V  
and 42V power. The remote control circuit operates the  
same as the 6 Pin Amphenol.  
8. 6-PIN CONNECTOR- For attaching optional remote  
control equipment. Includes auto-sensing remote control  
circuit.  
9. WELD TERMINALS CONTROL SWITCH- In the  
WELD TERMINALS ON position, the output is electrically  
hot all the time. In the REMOTELY CONTROLLED posi-  
tion, the output is controlled by a wire feeder or amptrol  
device, and is electrically off until a remote switch is  
depressed.  
RANGER® 305D  
Download from Www.Somanuals.com. All Manuals Search And Download.  
b-4  
b-4  
OPERATION  
NOTE: If the unit fails to start repeat step 4 through  
step 7 after waiting 30 seconds  
15. ELECTRIC FUEL GAUGE- The electric fuel  
gauge gives accurate and reliable indication as to  
how much fuel is in the fuel tank.  
CAUTION  
16. ENGINE HOUR METER- Displays the total  
time that the engine has been running. This meter  
is useful for scheduling prescribed maintenance.  
• 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.  
--------------------------------------------------------------------------------  
NOTE: When starting a RANGER® 305D for the first  
time, or after and extended period of time of not oper-  
ating, it will take longer than normal because the fuel  
pump has to fill the fuel system.  
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.  
STARTING THE ENGINE  
1. Remove all plugs connected to the AC power  
STOPPING THE ENGINE  
receptacles.  
2. Set IDLER switch to AUTO.  
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.  
3. Set the RUN/STOP switch to RUN.  
4. Press Glow Plug Button and hold 5 to 10 seconds.  
5. Press and hold both the “Glow Plug” Button and  
START button together until the engine starts or for  
up to 10 seconds.  
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.  
7. Release the glow plug button after the Engine  
Protection Light turns off or after an additional 5  
seconds maximum.  
WELDER OPERATION  
DUTY CYCLE  
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.  
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.  
TAbLE b.1  
TYPICAL RANGER® 305D FUEL CONSUMPTION  
Kubota D722  
Running time for  
Gal./Hr (Liters/Hr)  
12 gallons-hours  
41.77  
Low Idle - No Load  
2450 R.P.M.  
High Idle - No Load  
3650 R.P.M.  
.29 (1.09)  
.54 (2.06)  
22.02  
DC Weld Output  
250 Amps @ 28 Volts  
DC Weld Output  
300 Amps @ 29 Volts  
1.03 (3.91)  
1.18 (4.47)  
1.16 (4.38)  
.96 (3.63)  
11.62  
10.16  
9,500 Watts  
7,000 Watts  
3,000 Watts  
10.37  
12.50  
.70 (2.67)  
17.03  
RANGER® 305D  
Download from Www.Somanuals.com. All Manuals Search And Download.  
b-5  
b-5  
OPERATION  
The Ranger® 305D can be used with a broad range of DC  
stick electrodes. The MODE switch provides two stick  
welding settings as follows:  
It is recommended that the ARC CONTROL be set to the  
minimum number without electrode sticking. Start with  
the dial set at 0.  
Constant Current (CC-STICK) Welding  
TIG 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 output CONTROL  
dial adjusts the full output range for stick welding.  
The TOUCH START TIG setting of the MODE switch is  
for DC TIG (Tungsten Inert Gas) welding. To initiate a  
weld, the CONTROL dial is first set to the desired current  
and the tungsten is touched to the work. During the time  
the tungsten is touching the work there is very little volt-  
age 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 ARC CONTROL dial sets the short circuit current  
(arc-force) during stick welding to adjust for a soft or crisp  
arc. Increasing the number from -10(soft) to +10(crisp)  
increases the short circuit current and prevents sticking of  
the electrode to the plate while welding. This can also  
increase spatter. It is recommended that the ARC CON-  
TROL be set to the minimum number without electrode  
sticking. Start with the dial set at 0.  
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.  
DOWNHILL PIPE Welding  
The ARC CONTROL is not active in the TIG mode. To  
STOP a weld, simply pull the TIG torch away from the  
work. When the arc voltage reaches approximately 30  
Volts the arc will go out and the machine will reset the  
current to the Touch Start level. To reinitiate the arc,  
retouch the tungsten to the work and lift. Alternatively,  
the weld can be stopped by releasing the Amptrol or arc  
start switch.  
This slope controlled setting is intended for "out-of-posi-  
tion" and "down hill" pipe welding where the operator  
would like to control the current level by changing the arc  
length. The output CONTROL dial adjusts the full output  
range for pipe welding. The ARC CONTROL dial sets the  
short circuit current (arc-force) during stick welding to  
adjust for a soft or more forceful digging arc (crisp).  
Increasing the number from -10(soft) to +10(crisp)  
increases the short circuit current which results in a more  
forceful digging arc.Typically a forceful digging arc is 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. This  
The RANGER® 305 D can be used in a wide variety of  
DC TIG welding applications. In general the ‘Touch Start’  
feature allows contamination free starting without the use  
of a Hi-frequency unit. If desired, the K930-2 TIG Module  
can be used with the RANGER® 305 D. The settings are  
for reference.  
can also increase spatter.  
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  
0.020  
0.040  
(.25)  
(.50)  
(1.0)  
2-15  
5-20  
15-80  
(3)  
(3)  
(3)  
3-8  
5-10  
5-10  
(2-4)  
(3-5)  
(3-5)  
3-8  
5-10  
5-10  
(2-4)  
(3-5)  
(3-5)  
#4, #5, #6  
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)  
(7-11)  
11-15  
11-15  
(5-7)  
(5-7)  
#6, #7, #8  
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)  
(11-13)  
#8, #10  
(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  
Download from Www.Somanuals.com. All Manuals Search And Download.  
b-6  
b-6  
OPERATION  
RANGER® 305 D settings when using the K930-2 TIG Module  
with an Amptrol or Arc Start Switch:  
• Set the MODE Switch to the TOUCH START TIG setting.  
ARC GOUGING  
The RANGER® 305D can be used for limited arc  
gouging. For optimal performance, set the MODE  
switch to CC-STICK and the ARC CONTROL to +10.  
• Set the "IDLER" Switch to the "AUTO" position.  
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.  
• Set the "WELDING TERMINALS" switch to the "REMOTELY  
CONTROLLED" position. This will keep the "Solid State" con-  
tactor open and provide a "cold" electrode until the Amptrol or  
Arc Start Switch is pressed.  
Carbon Diameter  
Current Range (DC, electrode  
positive)  
When using the TIG Module, the OUTPUT control on the  
RANGER® 305 D is used to set the maximum range of the CUR-  
RENT CONTROL on the TIG Module or an Amptrol if connected  
to the TIG Module.  
1/8"  
60-90 Amps  
5/32"  
3/16"  
90-150 Amps  
200-250 Amps  
WIRE WELDING-CV  
Connect a wire feeder to the RANGER® 305 D according to the  
instructions in INSTALLATION INSTRUCTIONS Section.  
The RANGER® 305 D in the CV-WIRE mode, permits it to be  
used with a broad range of flux cored wire (Innershield and  
Outershield) electrodes and solid wires for MIG welding (gas  
metal arc welding). Welding can be finely tuned using the ARC  
CONTROL. Turning the ARC CONTROL clockwise from –10  
(soft) to +10 (crisp) changes the arc from soft and washed-in to  
crisp and narrow. It acts as an inductance/pinch control. The  
proper setting depends on the procedure and operator prefer-  
ence. Start with the dial set at 0.  
Listed below are some wires suitable for use on this machine:  
• Innershield - NR-311, NS-3M, NR-207, NR-203 Ni 1%,  
NR-212.  
• Outershield - 0S-70, 0S-71M, 0S-71 ELITE.  
• Solid wires for MIG welding - .035 (0.9 mm), and  
.045 (1.1 mm), Super Arc L-50 and L-56, .035 (0.9 mm) and  
.045 (1.1 mm) Blue Max MIG 308 LS.  
Contact your local authorized Lincoln Electric Distributor or the  
Lincoln Electric Company for specific wires used on certain appli-  
cations with this machine.  
RANGER® 305D  
Download from Www.Somanuals.com. All Manuals Search And Download.  
b-7  
b-7  
OPERATION  
AUXILIARY POWER:  
The 120 V auxiliary power receptacles should only be  
used with three wire grounded type plugs or approved  
double insulated tools with two wire plugs. The current  
rating of any plug used with the system must be at  
least equal to the current capacity of the associated  
receptacle.  
If a GFCI receptacle is tripped, See the MAINTE-  
NANCE section for detailed information on testing and  
resetting the GFCI receptacle.  
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.  
NOTE: The 240 V receptacle has two circuits, each of  
which measure 120 V to neutral but are of opposite  
polarities and cannot be paralleled.  
The auxiliary power of the RANGER® 305D consists  
of two 20 Amp-120 VAC GFCI (5-20R) duplex recep-  
tacles and one 50 Amp 120/240 VAC (14-50R) recep-  
tacle. The 240 VAC receptacle can be split for single  
phase 120 VAC operation. The auxiliary power capac-  
ity is 10,000 watts Peak, 9500 Watts continuous of 60  
Hz, single phase power. The auxiliary power capacity  
rating in watts is equivalent to volt-amperes at unity  
power factor. The max permissible current of the 240  
VAC output is 44 Amps. The 240 VAC output can be  
split to provide two separate 120 VAC outputs with a  
max permissible current of 44 Amps per output to two  
separate 120 VAC branch circuits (these circuits can-  
not be paralleled). Output voltage is within ± 10% at  
all loads up to rated capacity. All auxiliary power is  
protected by circuit breakers.  
Simultaneous Welding and Auxiliary Power Loads  
The above auxiliary power ratings are with no welding  
load. Simultaneous welding and power loads are  
specified in the following table. The permissible cur-  
rents shown assume that current is being drawn from  
either the 120 VAC or 240 VAC supply (not both at the  
same time).  
RANGER® 305D Simultaneous Welding and Power Loads  
Permissible Power-Watts  
(Unity Power Factor)  
Welding  
Output-Amps  
Permissible Auxiliary  
Current in -Amps  
@ 240 VAC  
9000  
7500  
5800  
4500  
2800  
700  
0
44  
31  
24  
19  
12  
3
100  
150  
200  
250  
300  
* Each duplex receptacle is limited to 20 amps.  
** Not to exceed 44A per 120 VAC branch circuit when splitting the 240 VAC output.  
RANGER® 305D Extension Cord Length Recommendations  
(Use the shortest length extension cord possible sized per the following table.)  
Maximum Allowable Cord Length in ft. (m) for Conductor Size  
12 AWG 10 AWG 8 AWG 6 AWG  
Current Voltage Load  
(Amps) Volts (Watts)  
14 AWG  
4 AWG  
15  
20  
15  
20  
44  
120  
120  
240  
240  
240  
1800  
2400  
3600  
4800  
9500  
30  
(9)  
40  
(12)  
(9)  
(23)  
(18)  
75  
(23)  
(15)  
(46)  
(30)  
(15)  
125  
(38)  
(27)  
(69)  
(53)  
(27)  
175  
(53)  
(42)  
(107)  
(84)  
(46)  
300  
(91)  
(69)  
(183)  
(137)  
(69)  
30  
75  
60  
50  
150  
100  
50  
88  
225  
175  
90  
138  
350  
275  
150  
225  
600  
450  
225  
60  
(18)  
Conductor size is based on maximum 2.0% voltage drop.  
RANGER® 305D  
Download from Www.Somanuals.com. All Manuals Search And Download.  
C-1  
C-1  
ACCESSORIES  
FIELD INSTALLED OPTIONS /  
ACCESSORIES  
K802-N POWER PLUG KIT  
Provides four 120 volt plugs rated at 20 amps each  
and one dual voltage, full KVA plug rated at 120/240  
volts, 50 amps.  
K957-1 HEAVY DUTY, TWO WHEEL TRAILER FOR  
SMALL WELDERS  
K802-R POWER PLUG KIT  
For road, off-road and in-plant and yard towing.  
(For highway use, consult applicable federal, state  
and local laws regarding requirements for brakes,  
lights, fenders, etc.).Order:  
Provides four 120 volt plugs rated at 15 amps each  
and one dual voltage, full KVA plug rated at 120/240  
volts, 50 amps.  
T12153-9 50 AMP, 120/240 V POWER PLUG  
K957-1 Trailer  
K958-1 ball Hitch  
K958-2 Lunette Eye Hitch  
K959-2 Fender & Light Kit  
K965-1 Cable Storage Rack  
K1816-1 FULL KVA ADAPTER KIT  
Plugs into the 120/240V NEMA 14-50R receptacle on  
the case front (which accepts 4-prong plugs) and  
converts it to a NEMA 6-50R receptacle, (which  
accepts 3-prong plugs.) For connection of Lincoln  
equipment with NEMA 6-50R plug.  
K1789-1 ROLL CAGE - Gives added damage protection.  
K1898-1 SPARK ARRESTOR  
TIG Welding  
K1783-9 TIG Torch PTA-26V (25ft.)  
K963-3 Hand Amptrol  
K870 Foot Amptrol  
K704 ACCESSORY SET - Includes 35 ft. (10m) of  
electrode cable and 30 ft. (9.1m) of work cable, head-  
shield, work clamp electrode holder. Cables are rated  
at 400 amps, 100% duty cycle.  
KP509 Magnum Parts Kit  
Spool Gun  
K1692-2 Prince XL Spool Gun (25ft.)  
K857 25 ft (7.6m) or K857-1 100 ft. (30.4m)  
REMOTE CONTROL  
Portable control provides same dial range as the out-  
put control on the welder. Has a convenient 6 pin plug  
for easy connection to the welder.  
K487-25 Magnum Spool Gun  
K488 Magnum Control Module  
K691-10 Input Cable)  
K2174-1 COLD WEATHER OPERATIONS KIT-  
Provides starting aid and enhancement in extreme  
cold weather. Includes radiator grill cover, oil pan  
heater, coolant Lester and all hardware required for  
installation.  
RANGER® 305D  
Download from Www.Somanuals.com. All Manuals Search And Download.  
D-1  
D-1  
MAINTENANCE  
KUbOTA D722 DIESEL ENGINE  
SAFETY PRECAUTIONS  
FREQUENCY  
MAINTENANCE REQUIRED  
• FILL FUEL TANK.  
WARNING  
• Have qualified personnel do all maintenance  
and troubleshooting work.  
• CHECK OIL LEVEL.  
• CHECK COOLANT LEVEL.  
• CHECK AIR CLEANER ELE-  
MENT AND HOUSING FOR  
DIRTY, LOOSE OR DAMAGED  
PARTS.  
• CHECK AIR INTAKE HOSE  
FOR CRACKS OR LOOSE  
CONNECTIONS.  
• Turn the engine off before working inside the  
machine or servicing the engine.  
DAILY OR BEFORE  
STARTING ENGINE  
• CHECK AIR INTAKE/EXHAUST  
RADIATOR FOR  
DIRT. CLEAN AS NECESSARY.  
• CHECK ALTERNATOR BELT  
TENSION AND WEAR.  
• 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  
&
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 Owner’s Manual before  
working on this machine.  
Keep all equipment safety guards, covers, and  
devices in position and in good repair. Keep  
hands, hair, clothing, and tools away from the  
gears, fans, and all other moving parts when  
starting, operating, or repairing the equipment.  
Intervals  
Items  
Every 50 hours  
Every 75 hours  
@
@
Check of fuel pipes and clamp bands.  
Change of engine oil  
•
Every 100 hours  
Every 150 hours  
*1  
Inspect/Clean air cleaner element  
and Vacuator™ valve.  
Cleaning of fuel filter.  
Check the battery electrolyte level.  
Check the fan belt tightness.  
Check the radiator and hose clamps.  
Replacement of oil filter cartridge  
Check the intake air lines.  
Replacement of Air Filter element.  
Replacement of fuel filter element.  
Cleaning of water jacket (radiator  
interior).  
Routine Maintenance  
At the end of each day’s use, refill the fuel tank to  
minimize moisture condensation in the tank. Running  
out of fuel tends to draw dirt into the fuel system.  
Also, check the crankcase oil level and add oil if  
indicated.  
•
@
@
@
Every 200 hours  
Every 400 hours  
Every 500 hours  
*1,*2  
ENGINE MAINTENANCE COMPONENTS  
KUbOTA D722 DIESEL ENGINE  
Replacement of fan belt.  
Recharging of Battery.  
Every 1 or 2 months  
Every 800 hours  
Every 1500 hours  
Check of valve clearance.  
Check the fuel injection nozzle injec-  
tion pressure.  
Check of injection pump.  
Check of fuel injector timer.  
Replacement of battery  
*3  
*3  
@
@
ITEM  
MAKE AND PART NUMbER  
Every 3000 hours  
Every 2 years  
*3  
*3  
@
@
OIL FILTER  
KUBOTA 70000-15241  
Replacement of radiator hoses and  
clamp band.  
Replacement of fuel pipes and  
clamps.  
Change the radiator coolant.(L.L.C.)  
Replacement of intake air line.  
AIR FILTER ELEMENT DONALDSON P822686  
FUEL FILTER ELEMENT KUBOTA 15231-43560  
*4  
@
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.  
*3 Consult your local KUBOTA Dealer for this service.  
*4 Replace only if necessary.  
@ All these markings are registered as emission related critical parts by KUB-  
OTA in the U.S. EPA nonroad emission regulation. As the engine owner,  
you are responsible for the performance of the required maintenance on  
the according to the above instruction.  
GLOW PLUGS  
INLINE FUEL FILTER  
Please see Engine Owners Manual for Warranty Statement in detail.  
RANGER® 305D  
Download from Www.Somanuals.com. All Manuals Search And Download.  
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 recommend-  
ed 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.  
• 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.  
WARNING  
• 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.  
--------------------------------------------------------------------------------  
AIR CLEANER  
Engine Oil Refill capacities  
Without oil filter replacement:  
• 3.3 U.S. Quart. (2.7 Imp Quart, 3.2 liter)  
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:  
• 3.4 U.S. Quart. (3.0 Imp Quart, 3.2 liter)  
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, 5F to 104F (-15C to 40C).  
See engine owner’s manual for more specific informa-  
tion on oil viscosity recommendations.  
RANGER® 305D  
Download from Www.Somanuals.com. All Manuals Search And Download.  
D-3  
D-3  
MAINTENANCE  
Service Instructions  
Single- and Two-Staage Engine Air Cleaners  
Inspect the New Filter for Damage  
Remove the Filter  
Inspect the new filter carefully, paying attention to  
the inside of the open end, which is the  
sealing area. NEVER install a damaged  
filter. A new Donaldson radial seal  
filter may have a dry lubricant on the  
seal to aid installation.  
Unfasten or unlatch the  
service cover. Because  
the filter fits tightly over the  
outlet tube to create the critical seal, there will  
be some initial resistance, similar to breaking  
the seal on a jar. Gently move the end of the filter  
back and forth to break the seal then rotate while  
pulling straight out. Avoid knocking the filter  
against the housing.  
Rotate the  
filter while  
pulling  
straight out.  
Insert the New Radial Seal Filter Properly  
If you're servicing the safety filter, this should be seated into  
position before installing the primary filter.  
If your air cleaner has a safety filter, replace it every third primary  
filter change. Remove the safety filter as you would the primary  
filter. Make sure you cover the air cleaner outlet tube to avoid any  
unfiltered contaminant dropping into the engine.  
Insert the new filter carefully. Seat  
the filter by hand, making certain it is  
completely into the air cleaner housing  
before securing the cover in place.  
Clean Booth Surfaces oof the Outllet Tube  
and Check the Vacuuator™™ Valve  
The critical sealing area will stretch  
Use a clean cloth to wipe the filter sealing surface and the inside of  
the outlet tube. Contaminant on the sealing surface could hinder an  
effective seal and cause leakage. Make sure that all contaminant is  
removed before the new filter is inserted. Dirt accidently transferred  
to the inside of the outlet tube will reach the engine and cause  
wear. Engine manufacturers say that it takes only a few grams of  
dirt to "dust" an engine! Be careful not to damage the sealing area  
on the tube.  
slightly, adjust itself and distribute the sealing pressure evenly. To  
complete a tight seal, apply pressure by hand at the outer rim of  
the filter, not the flexible center. (Avoid pushing on the center of the  
urethane end cap.) No cover pressure is required to hold the seal.  
NEVER use the service cover to push the filter into place! Using the  
cover to push the filter in could cause damage to the housing, cover  
fasteners and will void the warranty.  
If the service cover hits the filter before it is fully in place, remove  
the cover and push the filter (by hand) further into the air cleaner  
and try again. The cover should go on with no extra force.  
Wipe both sides  
of the outlet  
tube clean.  
Once the filter is in place, secure the service cover.  
Outer edge of the  
Inner edge of the  
outlet tube  
Caution  
outlet tube  
NEVER usee the serrvice ccoover to  
push the fillter intto placee! Using  
the cover too push the ffilter iin could  
cause damaage to thee housinngg, cover  
fastenerrs and will vvooid the waarranty.  
If your air cleaner is equipped with a Vacuator Valve  
Visually check and physically squeeze to make sure the  
valve is flexible and not inverted, damaged or plugged.  
Inspecct the Old  
Filter for Leak Clues  
Check Connectors foor Tight Fit  
Make sure that all mounting bands, clamps, bolts, and connections  
in the entire air cleaner system are tight. Check for holes in piping  
and repair if needed. Any leaks in your intake piping will send dust  
directly to the engine!  
Visually inspect the old filter for any signs  
of leaks. A streak of dust on the clean side  
of the filter is a telltale sign. Remove any  
cause of leaks before installing new filter.  
RANGER® 305D  
Download from Www.Somanuals.com. All Manuals Search And Download.  
D-4  
D-4  
MAINTENANCE  
FUEL  
COOLING SYSTEM  
WARNING  
At the end of each day’s 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 petcock at the bottom  
of the radiator. Open the radiator cap to allow com-  
plete drainage. (Tighten the petcock and refill with a  
50/50 antifreeze/water solution.) Use an automotive  
grade (low silicate) ethylene glycol antifreeze. The  
cooling system capacity is 3.85 quarts (3.6L.).  
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 -34° F (-  
37° C).  
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.  
2. Open the fuel shut off valve (vertical position of  
handle) on the Fuel Filter.  
3. Crank the engine by pressing the start button for 45  
seconds.  
4. Check to see that fuel is flowing through both fuel  
filters  
5. Follow the normal STARTING procedures.  
Cooling solution exceeding 50% ethylene glycol  
can result in engine overheating and damage to  
the engine. Coolant solution must be premixed  
before adding to radiator.  
--------------------------------------------------------------------------------  
Periodically remove the dirt from the radiator fins.  
Periodically check the fan belt and radiator hoses.  
Replace if signs of deterioration are found.  
TIGHTENING THE FAN bELT  
If the fan belt is loose, the engine can overheat and  
the battery lose its charge. Check tightness by press-  
ing on the belt midway between the pulleys. It should  
deflect about .25 in. under a load of 20 lbs. (9 Kg) (6  
mm).  
RANGER® 305D  
Download from Www.Somanuals.com. All Manuals Search And Download.  
D-5  
D-5  
MAINTENANCE  
CLEANING THE bATTERY  
FUEL FILTER  
1. Check the fuel filter and fuel pre-filter for water  
accumulation or sediment.  
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 1/4 pound (0.1113  
kg) of baking soda and 1 quart (0.9461) of water. Be  
sure the battery vent plugs (if equipped) are tight so  
that none of the solution enters the cells.  
2. Replace the fuel filter if it is found with excessive  
water accumulation or sediment. Empty fuel pre-fil-  
ter.  
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 3650 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  
Adjustments to the engine are to be made only by a  
Lincoln Service Center or an authorized Field Service  
Shop.  
If battery cells are low, fill them to the neck of the filler  
hole with distilled water and recharge. If one cell is  
low, check for leaks.  
CHARGING THE bATTERY  
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 positive (+) battery ter-  
minal has a red terminal cover.  
To access the battery, Disconnect the Negative and  
then Positive battery cables. Remove the 2 screws  
from the battery door using a screwdriver or a 3/8"  
socket. Remove the 2 nuts from the battery bracket  
using a 7/16” 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.  
l
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:  
l INSTALLING A NEW bATTERY — disconnect  
negative cable from old battery first and con-  
nect to new battery last.  
SERVICING OPTIONAL SPARK  
ARRESTOR  
Clean every 100 hours.  
l CONNECTING A bATTERY CHARGER —  
remove battery from welder by disconnecting  
negative cable first, then positive cable and  
battery clamp. When reinstalling, connect  
negative cable last. Keep well ventilated.  
WARNING  
• MUFFLER MAY bE HOT  
l USING A bOOSTER — connect positive lead to  
battery first then connect negative lead to neg-  
ative battery lead at engine foot.  
bATTERY ACID can burn eyes and  
skin.  
• ALLOW ENGINE TO COOL bEFORE INSTALLING  
THE SPARK ARRESTER!  
• DO NOT OPERATE ENGINE WHILE INSTALLING  
THE SPARK ARRESTER!  
l Wear gloves and eye protection  
and be careful when working near  
battery.  
l Follow instructions printed on battery.  
RANGER® 305D  
Download from Www.Somanuals.com. All Manuals Search And Download.  
D-6  
D-6  
MAINTENANCE  
GFCI RECEPTACLE TESTING AND RESET-  
TING PROCEDURE  
WELDER / GENERATOR  
MAINTENANCE  
The GFCI receptacle should be properly tested at  
least once every month or whenever it is tripped. To  
properly test and reset the GFCI receptacle:  
STORAGE: Store the RANGER® 305D in clean, dry  
protected areas.  
• If the receptacle has tripped, first carefully remove  
any load and check it for damage.  
• If the equipment has been shut down, it must be  
restarted.  
CLEANING: Blow out the generator and controls peri-  
odically with low pressure air. Do this at least once a  
week in particularly dirty areas.  
• The equipment needs to be operating at high idle  
speed and any necessary adjustments made on the  
control panel so that the equipment is providing at  
least 80 volts to the receptacle input terminals.  
• The circuit breaker for this receptacle must not be  
tripped. Reset if necessary.  
bRUSH REMOVAL AND REPLACEMENT: It’s nor-  
mal for the brushes and slip rings to wear and darken  
slightly. Inspect the brushes when a generator over-  
haul is necessary.  
• Push the "Reset" button located on the GFCI recep-  
tacle. This will assure normal GFCI operation.  
• Plug a night-light (with an "ON/OFF" switch) or other  
product (such as a lamp) into the GFCI receptacle  
and turn the product "ON".  
CAUTION  
• Do not attempt to polish slip rings while the  
engine is running.  
• Push the "Test" button located on the GFCI recepta-  
cle. The night-light or other product should go  
"OFF".  
• Push the "Reset" button, again. The light or other  
product should go "ON" again.  
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.  
If the light or other product remains "ON" when the  
"Test" button is pushed, the GFCI is not working prop-  
erly or has been incorrectly installed (miswired). If  
your GFCI is not working properly, contact a qualified,  
certified electrician who can assess the situation,  
rewire the GFCI if necessary or replace the device.  
RANGER® 305D  
Download from Www.Somanuals.com. All Manuals Search And Download.  
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  
Download from Www.Somanuals.com. All Manuals Search And Download.  
E-2  
E-2  
TROUbLESHOOTING  
Observe all Safety Guidelines detailed throughout this manual  
PRObLEMS  
(SYMPTOMS)  
POSSIbLE  
CAUSE  
RECOMMENDED  
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 autho-  
rized 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  
Download from Www.Somanuals.com. All Manuals Search And Download.  
E-3  
E-3  
TROUbLESHOOTING  
Observe all Safety Guidelines detailed throughout this manual  
PRObLEMS  
(SYMPTOMS)  
POSSIbLE  
CAUSE  
RECOMMENDED  
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.  
Engine alternator trouble light is on 2. Loose connections at battery or  
while machine is running.  
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  
Download from Www.Somanuals.com. All Manuals Search And Download.  
E-4  
E-4  
TROUbLESHOOTING  
Observe all Safety Guidelines detailed throughout this manual  
PRObLEMS  
(SYMPTOMS)  
POSSIbLE  
CAUSE  
RECOMMENDED  
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  
Download from Www.Somanuals.com. All Manuals Search And Download.  
E-5  
E-5  
TROUbLESHOOTING  
Observe all Safety Guidelines detailed throughout this manual  
PRObLEMS  
(SYMPTOMS)  
POSSIbLE  
CAUSE  
RECOMMENDED  
COURSE OF ACTION  
No welding power output.  
1. Poor work lead connection to  
work. Make sure work clamp is  
tightly connected to clean base  
metal.  
2. "Weld Terminals" switch in wrong  
position. Place switch in "Weld  
Terminals On" position when  
welding without control cable.  
3. Faulty PC board or welder alterna-  
tor.  
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 open. Check 42V and 120V checked and the problem persists,  
connector.  
beakers and reset if tripped.  
2. Faulty control cable. Repair or  
replace cable.  
Contact your local Lincoln  
Authorized Field Service Facility.  
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.  
GFCI Receptacle may have  
tripped. Follow “GFCI Receptacle  
Testing and Resetting Procedure”  
in the MAINTENANCE section of  
this manual.  
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  
Download from Www.Somanuals.com. All Manuals Search And Download.  
E-6  
E-6  
TROUbLESHOOTING  
Observe all Safety Guidelines detailed throughout this manual  
PRObLEMS  
(SYMPTOMS)  
POSSIbLE  
CAUSE  
RECOMMENDED  
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  
Download from Www.Somanuals.com. All Manuals Search And Download.  
F-1  
F-1  
DIAGRAMS  
RANGER® 305D  
Download from Www.Somanuals.com. All Manuals Search And Download.  
F-2  
F-2  
DIAGRAMS  
RANGER® 305D  
Download from Www.Somanuals.com. All Manuals Search And Download.  
F-3  
F-3  
DIAGRAMS  
RANGER® 305D  
Download from Www.Somanuals.com. All Manuals Search And Download.  
F-4  
F-4  
DIAGRAMS  
RANGER® 305D  
Download from Www.Somanuals.com. All Manuals Search And Download.  
F-5  
F-5  
DIAGRAMS  
RANGER® 305D  
Download from Www.Somanuals.com. All Manuals Search And Download.  
F-6  
F-6  
DIAGRAMS  
RANGER® 305D  
Download from Www.Somanuals.com. All Manuals Search And Download.  
F-7  
F-7  
DIAGRAMS  
RANGER® 305D  
Download from Www.Somanuals.com. All Manuals Search And Download.  
F-8  
F-8  
DIAGRAMS  
RANGER® 305D  
Download from Www.Somanuals.com. All Manuals Search And Download.  
F-9  
F-9  
DIAGRAMS  
RANGER® 305D  
Download from Www.Somanuals.com. All Manuals Search And Download.  
F-10  
F-10  
DIAGRAMS  
RANGER® 305D  
Download from Www.Somanuals.com. All Manuals Search And Download.  
F-11  
F-11  
DIMENSION PRINT  
RANGER® 305D  
Download from Www.Somanuals.com. All Manuals Search And Download.  
NOTES  
RANGER® 305D  
Download from Www.Somanuals.com. All Manuals Search And Download.  
NOTES  
RANGER® 305D  
Download from Www.Somanuals.com. All Manuals Search And Download.  
•
•
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.  
Download from Www.Somanuals.com. All Manuals Search And Download.  
•
•
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.  
Download from Www.Somanuals.com. All Manuals Search And Download.  
• 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  
Download from Www.Somanuals.com. All Manuals Search And Download.  

Kyocera Cell Phone KX160A User Manual
Kyocera Cell Phone VMS200 User Manual
La Crosse Technology Clock Radio WS 8007U User Manual
Learning Resources Baby Toy LER 2572 User Manual
LG Electronics Microwave Oven LMAB1240ST User Manual
Makita Brush Cutter EK7650H User Manual
Makita Impact Driver 6910 User Manual
Masterbuilt Smoker 20070910 User Manual
Maxim Marine Radio DS21Q55 User Manual
Melissa Microwave Oven WP700AL17 User Manual