Lincoln-electric IM10053 RANGER 305 D (AU) User Manual

Operator’s ManualRANGER®305D (AU)Register your machine: www.lincolnelectric.com/registerAuthorized Service and Distributor Locator: www.lincolnelect

PRE-OPERATION ENGINE SERVICEREAD the engine operating and maintenance instruc-tions supplied with this machine.• Stop engine and allow to cool before

A-4INSTALLATION RANGER® 305D (AU)A-4REMOTE CONTROLThe Ranger® 305D (AU) is equipped with a 6-pin anda 14-pin connector. The 6-pin connector is for c

TABLE A.1CABLE INSTALLATIONInstall the welding cables to your Ranger® 305D (AU)as follows. 1. The engine must be OFF to install welding cables.2. Rem

A-6INSTALLATION RANGER® 305D (AU)A-6TABLE lllELECTRICAL DEVICE USE WITH THE RANGER® 305D (AU).Type Common Electrical Devices Possible ConcernsResist

AUXILIARY POWER RECEPTACLESThe auxiliary power capacity of the Ranger® 305D(AU) is 7.2KW of 60Hz single phase power protectedby an RCD (Residual Curre

1. Shut the welder off.2. For electrode Positive, connect the electrodecable from the LN-25 to the "+" terminal of thewelder and work cable

B-1OPERATIONRANGER® 305D (AU)B-1SAFETY PRECAUTIONSDo not attempt to use this equipment until youhave thoroughly read the engine manufacturerʼsmanual s

FIGURE B.1B-2OPERATIONB-2WELDING CONTROLS (Figure B.1)1. OUTPUT CONTROL- The OUTPUT dial isused to preset the output voltage or current as dis-played

B-3OPERATIONB-34. ARC CONTROL- The ARC CONTROL dial is active inthe CV-WIRE, CC-STICK and DOWNHILL PIPE modes,and has different functions in these mod

B-4OPERATIONB-415. ELECTRIC FUEL GAUGE- The electric fuelgauge gives accurate and reliable indication as tohow much fuel is in the fuel tank.16. ENGIN

THANK YOU FOR SELECTING A QUALITY PRODUCT BY LINCOLN ELEC TRIC. PLEASE EXAMINE CARTON AND EQUIPMENT FORDAMAGE IMMEDIATELYWhen this equipment is shipp

B-5OPERATIONB-5STARTING THE ENGINE1. Remove all plugs connected to the AC powerreceptacles.2. Set IDLER switch to AUTO.3. Set the RUN/STOP switch to

B-6OPERATIONB-6The Ranger® 305D (AU) can be used with a broad rangeof DC stick electrodes. The MODE switch provides twostick welding settings as follo

RANGER® 305D (AU)B-7OPERATIONB-7Ranger® 305D (AU) settings when using the K930-2TIG Module with an Amptrol or Arc Start Switch:• Set the MODE Switch

B-8OPERATIONB-8AUXILIARY POWER OPERATION:Start the engine and set the IDLER control switch tothe desired operating mode. Full power is availableregard

C-1ACCESSORIESC-1FIELD INSTALLED OPTIONS /ACCESSORIES K957-1 HEAVY DUTY, TWO WHEEL TRAILER FORSMALL WELDERSFor road, off-road and in-plant and yard to

D-1MAINTENANCED-1RANGER® 305D (AU)SAFETY PRECAUTIONS• Have qualified personnel do all maintenanceand troubleshooting work.• Turn the engine off before

D-2MAINTENANCED-2Engine Oil ChangeDrain the engine oil while the engine is warm toassure rapid and complete draining. It is recommend-ed that each tim

D-3MAINTENANCED-3RANGER® 305D (AU)Unfasten or unlatch theservice cover. Becausethe filter fits tightly over theoutlet tube to create the critical seal

D-4MAINTENANCED-4COOLING SYSTEMHOT COOLANTcan burn skin.• Do not remove cap if radiator ishot.-------------------------------------------------------

D-5MAINTENANCED-5FUEL FILTER1. Check the fuel filter and fuel pre-filter for wateraccumulation or sediment.2. Replace the fuel filter if it is found w

SECTION A:WARNINGS CALIFORNIA PROPOSITION 65 WARNINGSDiesel EnginesDiesel engine exhaust and some of its constituents are known to the State of Calif

D-6MAINTENANCED-6RANGER® 305D (AU)WELDER / GENERATORMAINTENANCESTORAGE: Store the Ranger® 305D (AU) in clean,dry protected areas.CLEANING: Blow out th

E-1TROUBLESHOOTINGE-1RANGER® 305D (AU)If for any reason you do not understand the test procedures or are unable to perform the tests/repairs safely, c

E-2TROUBLESHOOTINGE-2RANGER® 305D (AU)Observe all Safety Guidelines detailed throughout this manualIf for any reason you do not understand the test pr

E-3TROUBLESHOOTINGE-3RANGER® 305D (AU)Observe all Safety Guidelines detailed throughout this manualIf for any reason you do not understand the test pr

E-4TROUBLESHOOTINGE-4RANGER® 305D (AU)Observe all Safety Guidelines detailed throughout this manualIf for any reason you do not understand the test pr

E-5TROUBLESHOOTINGE-5RANGER® 305D (AU)Observe all Safety Guidelines detailed throughout this manualIf for any reason you do not understand the test pr

E-6TROUBLESHOOTINGE-6RANGER® 305D (AU)Observe all Safety Guidelines detailed throughout this manualIf for any reason you do not understand the test pr

F-1DIAGRAMSF-1RANGER® 305D (AU)

F-2DIAGRAMSF-2RANGER® 305D (AU)

F-3DIAGRAMSF-3RANGER® 305D (AU)

ELECTRIC SHOCK CAN KILL.3.a. The electrode and work (or ground) circuits areelectrically “hot” when the welder is on. Donot touch these “hot” parts wi

F-4DIAGRAMSF-4RANGER® 305D (AU)

F-5DIAGRAMSF-5RANGER® 305D (AU)or service this equipment.Only qualified personnel should install,useKeep away from moving parts.Keep guards in place.M

F-6DIAGRAMSF-6RANGER® 305D (AU)

F-7DIAGRAMSF-7RANGER® 305D (AU)

F-8DIAGRAMSF-8RANGER® 305D (AU) 29/03

F-9DIAGRAMSF-9RANGER® 305D (AU)

F-10DIAGRAMSF-10RANGER® 305D (AU)NOTE: This diagram is for reference only. It may not be accurate for all machines covered by this manual. The spec

F-11DIMENSION PRINTF-11RANGER® 305D (AU)M20334 B21.06534.951.201300.517 .5 044 4. 519.50495.335.77908 .429.83757.634. 24869 .8CIRCUITBREA KERS1326 .45

NOTES RANGER® 305D (AU)

RANGER®305D (AU)P-646P-646PARTS LIST FORRANGER®305D (AU)This parts list is provided as an informative guide only.It was accurate at the time of printi

WELDING AND CUTTINGSPARKS CAN CAUSEFIRE OR EXPLOSION.6.a. Remove fire hazards from the welding area. Ifthis is not possible, cover them to prevent the

RANGER®305D (AU)08-17-2012P-646-AP-646-AILLUSTRATION OF SUB-ASSEMBLIES87364521

RANGER®305D (AU)Oct-13Do Not use this Parts List for a machine if its code number is not listed. Contact the Service Department for anycode numbers no

RANGER®305D (AU)08-17-2012P-646-CP-646-CCase Front Assembly (Upper)1A1A46A46A3A3A38A38A5A5A4A4A52C52C52E52E51D51D51E51E51E51E52B52B28A28A28A28A31A31A8

1 Case Front Assembly (G3666-53), Includes: NSS 1X1A Case Front G3860-13 1 X3A Top Bezel G3593 1 X3B Self Tapping Screw (Not Shown) S24738-1 7 X4A Rig

RANGER®305D (AU)08-17-2012P-646-DP-646-DCase Front Assembly (Lower)17B17B222221216A6A15A15A50B50B50C50C13A13A13A13A14A14A18A18A17A17A55A55A565655B55B5

6A Output Terminal Kit, Includes: T14166-9 2 X X6B Output Stud Nut T3960 2 X X6C Self Tapping Screw S8025-91 4 X X6D 1/2-13 x .875 HHCS CF000344 2 X X

RANGER®305D (AU)08-17-2012P-646-EP-646-EStator Rotor Assembly1616171718184D4D4E4E4G4G4F4F4A4A4C4C4B4B952A2A2B2B1A1A2C2C76811C11C11B11B11F11F11D11D11A1

1A Stator Frame Assembly G3930-2 1 X1B 3/8-16 x 1.25 HHCS CF000105 8 X1C Lock Washer E106A-16 8 X2A Plain Washer S9262-120 2 X2B Lock Washer E106A-16

RANGER®305D (AU)08-17-2012P-646-FP-646-FBlower Baffle Assembly2202074A4A8C8C13A13A5B5B8A8A15A5A9A9A9G9G9H9H9B9B9H9H9K9K9J9J9F9F9E9E9D9D14A14A212115A 1

Blower Baffle Assembly, Includes: G4097-13 1 X1 Baffle G3862-2 1 X2 Warning Decal T13086-163 1 X3A Chopper Board Assembly L11845-[ ] 1 X3B Baffle S246

vi vi TABLE OF CONTENTSPageInstallation...

viiviiTABLE OF CONTENTSMaintenance...Section DSafet

RANGER® 305D (AU)1. Output rating in watts is equivalent to volt-amperes at unity power factor. Output voltage is within ± 10% at all loads up torated

LIFTINGThe Ranger® 305D (AU) weighs approximately775lbs.(352kg.) with a full tank of fuel (698 lbs. lessfuel). A lift bail is mounted to the machine a