Lincoln Electric IM10158 User Manual

Operator’s Manual

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RANGER ® 305G EFI

For use with machines having Code Numbers:

12157, 12206

Save for future reference

Date Purchased

Code: (ex: 10859)

Serial: (ex: U1060512345)

IM10158-A | Issue D ate Aug-13

© Lincoln Global, Inc. All Rights Reserved.

Register your machine:

www.lincolnelectric.com/register

Authorized Service and Distributor Locator:

www.lincolnelectric.com/locator

Need Help? Call 1.888.935.3877

to talk to a Service Representative

Hours of Operation:

8:00 AM to 6:00 PM (ET) Mon. thru Fri.

After hours?

Use “Ask the Experts” at lincolnelectric.com
A Lincoln Service Representative will contact you
no later than the following business day.

For Service outside the USA:

Email: [e-mail]

THANK YOU FOR SELECTING

AT ALL

TIMES.

SPECIAL SITUATIONS

Additional precautionary measures

A QUALITY PRODUCT BY
LINCOLN ELEC TRIC.

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.

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 READING THIS MANUAL AND THE SAFETY PRECAUTIONS
CONTAINED THROUGHOUT. And, most importantly, think before you

act and be careful.

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.

KEEP YOUR HEAD OUT OF THE FUMES.

DON’T get too close to the arc. Use

corrective lenses if necessary to
stay a reasonable distance away
from the arc.

READ and obey the Material Safety

Data Sheet (MSDS) and the warning
label that appears on all containers
of welding materials.

USE ENOUGH VENTILATION or

exhaust at the arc, or both, to keep
the fumes and gases from your breathing zone and the general area.

IN A LARGE ROOM OR OUTDOORS, natural ventilation may be

adequate if you keep your head out of the fumes (See below).

USE NATURAL DRAFTS or fans to keep the fumes away from your

face.

If you de velop unusual symptoms, see your supervisor. Perhaps the
welding atmosphere and ventilation system should be checked.

WEAR CORRECT EYE, EAR & BODY PROTECTION

PROTECT your eyes and face with welding helmet

properly fitted and with proper grade of filter plate
(See ANSI Z49.1).

PROTECT your body from welding spatter and arc

flash with protective clothing including woolen
clothing, flame-proof apron and gloves, leather
leggings, and high boots.

PROTECT others from splatter, flash, and glare with

protective screens or barriers.

IN SOME AREAS, protection from noise may be

appropriate.

BE SURE protective equipment is in good condition.

Also, wear safety glasses in work area

DO NOT WELD OR CUT containers or materials which previously had

been in contact with hazardous substances unless they are properly
cleaned. This is extremely dangerous.

DO NOT WELD OR CUT painted or plated parts unless special

precautions with ventilation have been taken. They can release highly
toxic fumes or gases.

PROTECT compressed gas cylinders from excessive heat, mechanical

shocks, and arcs; fasten cylinders so they cannot fall.

BE SURE cylinders are never grounded or part of an electrical circuit.
REMOVE all potential fire hazards from welding area.
ALWAYS HAVE FIRE FIGHTING EQUIPMENT READY FOR

IMMEDIATE USE AND KNOW HOW TO USE IT.

SECTION A:

Diesel Engines

Gasoline Engines

WARNINGS

CALIFORNIA PROPOSITION 65 WARNINGS

Diesel engine exhaust and some of its constituents are known
to the State of California to cause cancer, birth defects, and other
reproductive harm.

The engine exhaust from this product contains chemicals known
to the State of California to cause cancer, birth defects, or other
reproductive harm.

ARC WELDING CAN BE HAZARDOUS. PROTECT
YOURSELF AND OTHERS FROM POSSIBLE SERIOUS
INJURY OR DEATH. KEEP CHILDREN AWAY. PACE­MAKER WEARERS SHOULD CONSULT WITH THEIR
DOCTOR BEFORE OPERATING.

Read and understand the following safety highlights. For additional
safety information, it is strongly recommended that you purchase a
copy of “Safety in Welding & Cutting - ANSI Standard Z49.1” from the
American Welding Society, P.O. Box 351040, Miami, Florida 33135 or
CSA Standard W117.2-1974. A Free copy of “Arc Welding Safety”
booklet E205 is available from the Lincoln Electric Company, 22801
St. Clair Avenue, Cleveland, Ohio 44117-1199.

BE SURE THAT ALL INSTALLATION, OPERATION,
MAINTENANCE AND REPAIR PROCEDURES ARE
PERFORMED ONLY BY QUALIFIED INDIVIDUALS.

SAFETY

1.d. Keep all equipment safety guards, covers and
devices in position and in good repair.Keep
hands, hair, clothing and tools away from
V-belts, gears, fans and all other moving parts
when starting, operating or repairing
equipment.

1.e. In some cases it may be necessary to remove safety guards to
perform required maintenance. Remove guards only when
necessary and replace them when the maintenance requiring
their removal is complete. Always use the greatest care when
working near moving parts.

1.f. Do not put your hands near the engine fan. Do not attempt to
override the governor or idler by pushing on the throttle control
rods while the engine is running.

1.g. To prevent accidentally starting gasoline engines while turning
the engine or welding generator during maintenance work,
disconnect the spark plug wires, distributor cap or magneto wire
as appropriate.

1.h. To avoid scalding, do not remove the radiator
pressure cap when the engine is

hot.

ELECTRIC AND
MAGNETIC FIELDS MAY
BE DANGEROUS

2.a. Electric current flowing through any conductor
causes localized Electric and Magnetic Fields (EMF). Welding
current creates EMF fields around welding cables and welding
machines

FOR ENGINE POWERED
EQUIPMENT.

1.a. Turn the engine off before troubleshooting
and maintenance work unless the
maintenance work requires it to be running.

1.b. Operate engines in open, well-ventilated
areas or vent the engine exhaust fumes outdoors.

1.c. Do not add the fuel near an open flame
welding arc or when the engine is running.
Stop the engine and allow it to cool before
refueling to prevent spilled fuel from
vaporizing on contact with hot engine parts
and igniting. Do not spill fuel when filling
tank. If fuel is spilled, wipe it up and do not start engine until
fumes have been eliminated.

2.b. EMF fields may interfere with some pacemakers, and welders
having a pacemaker should consult their physician before
welding.

2.c. Exposure to EMF fields in welding may have other health effects
which are now not known.

2.d. All welders should use the following procedures in order to
minimize exposure to EMF fields from the welding circuit:

2.d.1. Route the electrode and work cables together - Secure
them with tape when possible.

2.d.2. Never coil the electrode lead around your body.

2.d.3. Do not place your body between the electrode and work
cables. If the electrode cable is on your right side, the
work cable should also be on your right side.

2.d.4. Connect the work cable to the workpiece as close as pos­sible to the area being welded.

2.d.5. Do not work next to welding power source.

3

SAFETY

ELECTRIC SHOCK
CAN 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.

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.

In addition to the normal safety precautions, if
welding must be performed under electrically
hazardous conditions (in damp locations or while
wearing wet clothing; on metal structures such as
floors, gratings or scaffolds; when in cramped
positions such as sitting, kneeling or lying, if there
is a high risk of unavoidable or accidental contact
with the workpiece or ground) use the following
equipment:

• Semiautomatic DC Constant Voltage (Wire) Welder.

• DC Manual (Stick) Welder.

• AC Welder with Reduced Voltage Control.

3.c. In semiautomatic or automatic wire welding, the electrode,
electrode reel, welding head, nozzle or semiautomatic 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.

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

two can be the total of the open circuit voltage of both
welders.

3.i. When working above floor level, use a safety belt to protect
yourself from a fall should you get a shock.

between the

ARC RAYS CAN BURN.

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.

4.b. Use suitable clothing made from durable flame-resistant material
to protect your skin and that of your helpers from the arc rays.

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.

FUMES AND GASES
CAN BE DANGEROUS.

5.a. Welding may produce fumes and gases
hazardous to health. Avoid breathing these
fumes and gases. When welding, keep your head out of the fume.
Use enough ventilation and/or exhaust at the arc to keep 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 circumstances, outdoors, a respirator may
be required. Additional precautions are also
required when welding on galvanized steel.

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 specific
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.

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 products.

3.j. Also see It ems 6.c. and 8.

5.d. Shielding gases used for arc welding can displace air and

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.

4

cause

SAFETY

WELDING AND CUTTING
SPARKS CAN CAUSE
FIRE OR EXPLOSION.

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. 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.

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.

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.

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).

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.

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 circuits. This can create fire
hazards or overheat lifting chains or cables until they fail.

6.h. Also see item 1.c.

CYLINDER MAY EXPLODE IF
DAMAGED.

7.a. Use only compressed gas cylinders containing
the correct shielding gas for the process used
and properly operating regulators designed for
the gas and 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.

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.

7.d. Never allow the electrode, electrode holder or any other
electrically “hot” parts to touch a cylinder.

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.

FOR ELECTRICALLY
POWERED EQUIPMENT.

8.a. Turn off input power using the disconnect
switch at the fuse box before working on the
equipment.

8.b. Install equipment in accordance with the U.S. National Electrical
Code, all local codes and the manufacturer’s recommendations.

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.

8.c. Ground the equipment in accordance with the U.S. National
Electrical Code and the manufacturer’s recommendations.

Refer to

http://www.lincolnelectric.com/safety

for additional safety information.

Welding Safety
Interactive Web Guide
for mobile devices

5

vi

TABLE OF CONTENTS

Page

Installation.......................................................................................................................Section A

Technical Specifications.......................................................................................................A-1

Machine Specifications ........................................................................................................A-2

Safety Precautions........................................................................................................A-3

Location and Ventilation................................................................................................A-3

Stacking ........................................................................................................................A-3

Angle of Operation ........................................................................................................A-3

Lifting.............................................................................................................................A-3

Additional Safety Precautions .......................................................................................A-3

High Altitude Operation.................................................................................................A-3

High Temperature Operation ........................................................................................A-3

Towing...........................................................................................................................A-3

Vehicle Mounting...........................................................................................................A-4

Pre-Operation Engine Service..............................................................................................A-4

Oil..................................................................................................................................A-4

Fuel ...............................................................................................................................A-4

Engine Coolant..............................................................................................................A-4

Battery Connections......................................................................................................A-4

Muffler Outlet Pipe ........................................................................................................A-5

Spark Arrester...............................................................................................................A-5

High Frequency Generators for Tig Applications ..........................................................A-5

Remote Control.............................................................................................................A-5

Electrical Connections..........................................................................................................A-5

Machine Grounding.......................................................................................................A-5

Welding Terminals ........................................................................................................A-5

Welding Output Cables .................................................................................................A-6

Cable Installation...........................................................................................................A-6

Auxiliary Power Receptacles and Plugs...............................................................................A-6

Standby Power Connections................................................................................................A-6

Electrical Device Used with the RANGER

Premises Wiring...................................................................................................................A-8

Connection of Lincoln Electric Wire Feeders...............................................................A-9,A-10

________________________________________________________________________________

®

305G EFI.........................................................A-7

vi

Operation.........................................................................................................................Section B

Safety Precautions ..............................................................................................................B-1

General Description..............................................................................................................B-1

Design Features...................................................................................................................B-1

Engine Operation..................................................................................................................B-1

Fuel ......................................................................................................................................B-1

Welder Controls....................................................................................................................B-2

Engine Controls....................................................................................................................B-3

Starting and Stopping the Engine .................................................................................B-3

Stopping .......................................................................................................................B-4

Welding Operation................................................................................................................B-4

Duty Cycle.....................................................................................................................B-4

DC Stick Welding ..........................................................................................................B-4

Constant Current (Stick) Welding..................................................................................B-4

Downhill Pipe Welding ..................................................................................................B-4

Fuel Consumption.........................................................................................................B-4

Tig Welding ...................................................................................................................B-5

Typical Current Ranges for Tungsten Electrodes .........................................................B-5

Wire Welding-CV...........................................................................................................B-5

Arc Gouging ..................................................................................................................B-6

Auxiliary Power .............................................................................................................B-6

Simultaneous Welding and Auxiliary Power Loads.......................................................B-6

Extension Cord Recommendations...............................................................................B-6

________________________________________________________________________________

Accessories.....................................................................................................Section C

Options / Accessories and Compatible Lincoln Equipment.................................................C-1

________________________________________________________________________________
_

vii vii

Maintenance......................................................................................................Section D

Safety Precautions ................................................................................................D-1

Routine Maintenance............................................................................................D-1

Kohler Engine........................................................................................................D-1

Engine Maintenance Components ........................................................................D-1

Engine Oil Change..........................................................................................D-2

Engine Oil Refill Capacities.............................................................................D-2

Oil Filter Change.............................................................................................D-2

Air Cleaner Service.........................................................................................D-2

Air Pre-Cleaner Service..................................................................................D-2

Air Filter Paper Element ........................................................................................D-3

Spark Plug ......................................................................................................D-3

Spark Plug Service .........................................................................................D-3

Fuel Filter........................................................................................................D-4

Engine Adjustment..........................................................................................D-4

Battery Maintenance.......................................................................................D-4

Servicing Optional Spark Arrestor...................................................................D-4

Welder / Generator Maintenance ........................................................................D-5

Storage ...........................................................................................................D-5

Cleaning..........................................................................................................D-5

Brush Removal and Replacement..................................................................D-5

________________________________________________________________________

Troubleshooting..............................................................................................Section E

How to Use Troubleshooting Guide.......................................................................E-1

Troubleshooting Guide ..........................................................................................E-2

Troubleshooting Guide..........................................................................................E-3

Troubleshooting Guide..........................................................................................E-4

Troubleshooting Guide ..........................................................................................E-5

Diagrams and Dimension Prints....................................................................Section F

Parts List.................................................................................................................P-742

________________________________________________________________________

TABLE OF CONTENTS

A-1

INSTALLATION

TECHNICAL SPECIFICATIONS - RANGER®305G EFI (K3928-1)

INPUT - GASOLINE ENGINE

A-1

Make/Model

(K3928-1)

Kohler

ECH740

Description

2 cylinder

25 HP @

3600 RPM

Gasoline

Engine

Speed (RPM)

High Idle 3700

Full Load 3500

Low Idle 2400

Displacement

cu. In.(cu. Cm.)

45.6(747))

Bore x Stroke

inch (mm)

3.27 x 2.72
(83 x 69)

Starting
System

12VDC Battery &

Starter

(Group 58; 435

Cold crank amps)

Battery Charger

RATED OUTPUT @ 104° F (40° C) - WELDER

Welding Output Volts at Rated Amps Duty Cycle Max. OCV @ 3700 RPM

CC STICK DC Output 29 Volts @ 305 Amps 100%
CC STICK Output Range 20 to 305 Amps -------

PIPE DC Output 29 Volts @ 300 Amps 100%
PIPE Output Range 40 to 300 Amps ------- 60 Volts

CC TIG DC Output 30 Volts @ 250 Amps 100%

TIG Output Range 20 to 250 Amps -------

CV WIRE DC Output 29 Volts @ 300 Amps 100%
CV WIRE Output Range 14 to 29 volts -------

RATED OUTPUT @ 104° F (40° C).- GENERATOR

Auxiliary Power

12,000 Watts Peak, 9500 Watts Continuous, 60 Hz

120/240 Volts

1

Capacities

Fuel: 12 gal.

45.4 L

Oil: 2.0 qt.

1.9 ltr.

PHYSICAL DIMENSIONS

HEIGHT WIDTH DEPTH WEIGHT

30.00** in. 21.50 in 42.25 in.

762.0 mm 546.0 mm 1073.0 mm

510 lbs. (231kg.)

ENGINE COMPONENTS

LUBRICATION VALVE LIFTERS FUEL SYSTEM GOVERNOR

Full Pressure Hydraulic Mechanical Fuel Pump with Mechanical Governor

With Full Flow Filter additional electric fuel lift pump.

5% Regulation

AIR CLEANER ENGINE IDLER MUFFLER ENGINE PROTECTION

Low noise Muffler: Top outlet Shutdown on low oil

Dual Element Automatic Idler can be rotated. Made from pressure.

Long life, aluminized steel.

ENGINE WARRANTY: 2 year unlimited hours (See engine manufacturer warranty for details.) Kohler

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.

RANGER®305G EFI

A-2

INSTALLATION

MACHINE SPECIFICATIONS - RANGER®305G EFI (K3928-1)

RECEPTACLES AND CIRCUIT BREAKERS

RECEPTACLES AUXILIARY POWER CIRCUIT BREAKER OTHER CIRCUIT BREAKERS

A-2

(2) 120VAC Duplex (5-20R) Two 20AMP for Two Duplex Receptacle
(1) 120/240VAC Dual Voltage One 50AMP for Dual Voltage (2-pole)

Full KVA (14-50R)

20AMP for Battery Charging Circuit

15AMP for 42V Wire Feeder Power

RANGER®305G EFI

A-3

INSTALLATION

SAFETY PRECAUTIONS

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.

------------------------------------------------------------------------

ELECTRIC SHOCK can kill.

• Do not touch electrically live parts or
electrode with skin or wet clothing.

• Insulate yourself from work and
ground

• Always wear dry insulating gloves.

-------------------------------------------------------

ENGINEȊEXHAUSTȊcan kill.

• Use in open, well ventilated areas or
vent exhaust outside.

--------------------------------------------------------

MOVING PARTSȊcan injure.

• Do not operate with doors open or
guards off.

• Stop engine before servicing.

• Keep away from moving parts.

------------------------------------------------------------------------

See additional warning information at

front of this operators manual.

A-3

LIFTING

®

The RANGER
539lbs. (244.5kg) with a full tank of gasoline. A lift bail
is mounted to the machine and should always be used
when lifting the machine.

305G EFI weighs approximately

ADDITIONAL SAFETY PRECAUTIONS

WARNING

• Lift only with equipment of
adequate lifting capacity.

• Be sure machine is stable
when lifting.

• Do not lift this machine using
lift bail if it is equipped with a
heavy accessory such as trail­er or gas cylinder.

FALLING • Do not lift machine if lift bail is

EQUIPMENT can damaged.

Cause injury. • Do not operate machine while

Suspended from lift bail.

------------------------------------------------------------------------

HIGH ALTITUDE OPERATION

At higher altitudes, Welder output de-rating may be
necessary. For maximum rating, de-rate the welder
output 3.5% for every 1000 ft. (im) above 3000 ft. (im).

Only qualified personnel should install,
Use, or service this equipment.

LOCA TION AND VENTILA TION

The welder should be located to provide an unrestrict­ed 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.

STACKING

®

RANGER

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 15
degrees in any direction. 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.

When operating the welder at an angle, the effective
fuel capacity will be slightly less than the specified 12
gallons.

305G EFI machines cannot be stacked.

RANGER®305G EFI

HIGH TEMPERATURE OPERATION

At temperatures above 40°C(104°F), Welder output
de-rating is necessary. For maximum output ratings,
de-rate the welder output 2 volts for every 10°C(50°F)
above 40°C(104°F).

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 responsibility 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:

1. Design capacity of trailer vs. Weight of Lincoln
equipment and likely additional attachments.

2. Proper support of, and attachment to, the base of
the welding equipment so there will be no undue
stress to the framework.

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 serviced.

A-4

4. Typical conditions of use, i.e., travel speed; rough­ness of surface on which the trailer will be operat­ed; environmental conditions; like maintenance.

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

INSTALLATION

(1)

WARNING

Improperly mounted concentrated loads may
cause unstable vehicle handling and tires or other
components to fail.

• 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.

• Do not exceed maximum rated loads for compo­nents such as suspension, axles and tires.

• Mount equipment base to metal bed or frame of
vehicle.

• Follow vehicle manufactures instructions.

------------------------------------------------------------------------

PRE-OPERATION ENGINE SERVICE

READ the engine operating and maintenance instruc­tions supplied with this machine.

WARNING

• Stop engine while fueling.

• Do not smoke when fueling.

• Keep sparks and flame away
from tank.

• Do not leave unattended while
fueling.

• Wipe up spilled fuel and allow

GASOLINE

Can cause fire
Or explosion.

fumes to clear before starting
engine.

• Do not overfill tank, fuel expan­sion may cause overflow.

GASOLINE FUEL ONLY

------------------------------------------------------------------------

OIL

The RANGER®305G EFI is shipped with the engine
crankcase filled with high quality SAE 10W-30 oil. Check
the oil level before starting the engine. If it is not up to the
full mark on the dip stick, add oil as required. Check the oil
level every four hours of running time during the first 25 run­ning hours. Refer to the engine Operators Manual for spe­cific oil recommendations and break-in information. The oil
change interval is dependent on the quality of the oil and the
operating environment. Refer to the Engine Operators
Manual for the proper service and maintenance intervals.

A-4

FUEL

USE GASOLINE FUEL ONLY

WARNING

• Fill the fuel tank with clean, fresh fuel. Observe the
fuel gauge while filling to prevent overfilling. Stop
fueling once the gauge reads full. Do not top off tank.
Be sure to leave filler neck empty to allow room for
expansion. The capacity of the fuel tank is 12 gallons
(45.4 liters). When the fuel gauge reads empty the
tank contains approximately 2 gallons(7.6 liters) of
reserve fuel.

FULL

NOTE: The fuel tank is mounted below the engine so a

fuel shutoff valve is not required.

--------------------------------------------------------------------------------

ENGINE COOLING SYSTEM

WARNING

Air to cool the engine is drawn in lower set of louvers on the
case back. It is important that the intake air is not restricted.
Allow a minimum clearance of 2 feet (Im) from the case
back to a vertical surface.

BATTERY CONNECTION

CAUTION

Use caution as the electrolyte is a strong acid that can
burn skin and damage eyes.

--------------------------------------------------------------------------------

The RANGER®305G EFI 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 battery cable to the negative battery ter­minal and tighten using a 1/2" socket or wrench.

• Do not allow battery cables to touch opposing
terminals. When connecting battery cables
attach positive (+) cable to positive (+) battery
terminal first, followed by negative (-) cable to
negative (-) battery terminal.

• Never start engine when cables are loose or
poorly connected to battery terminals.

• Never diconnect battery while engine is running.

NOTE: This machine is furnished with a wet charged bat-

tery; if unused for several months, the battery may require a
booster charge. Be careful to charge the battery with the
correct polarity.

RANGER®305G EFI

A-5

INSTALLATION

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.

SP ARK 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 main­tained.

CAUTION

An incorrect spark arrestor may lead to damage to
the engine or adversely affect performance.

------------------------------------------------------------------------

HIGH FREQUENCY GENERATORS FOR
TIG APPLICA TIONS

The K930-2 TIG Module is suitable for use with the
RANGER

any high frequency generating equipment must be
properly grounded. See the K930-2 Operating Manual
for completed instructions on installation, operation,
and maintenance.

REMOTE CONTROL

The RANGER®305G EFI is equipped with a 6-pin
and a 14-pin connector. The 6-pin connector is for
connecting the K857 or K857-1 Remote Control
(optional) or for TIG welding, the K870 foot Amptrol or
the K963-3 hand Amptrol.

When in the CC-STICK, PIPE, and CV-WIRE modes
and when a remote control is connected to the

Amphenol, the auto-sensing circuit in the RANGER
305G EFI automatically switches the OUTPUT control
from control at the welder to remote control.

The 14-pin connector is used to directly connect a
wire feeder or TIG Module (K930-2) control cable. In

the CV-WIRE mode, the RANGER
sensing circuit automatically makes the RANGER

305G EFI Output Control inactive and the wire feeder
voltage control active when the control cable is con­nected to the 14-pin connector.
NOTE: When a wire feeder with a built in welding volt­age control is connected to the 14-pin connector, do
not connect anything to the 6-pin connector.

®

305G EFI. The RANGER®305G EFI and

®

305G EFI auto-

ELECTRICAL CONNECTIONS

MACHINE GROUNDING

Because this portable engine driven welder creates its
own power, it is not necessary to connect its frame to
an earth ground, unless the machine is connected to
premises wiring (home, shop, etc.)

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. Do not ground the machine
to a pipe that carries explosive or combustible
material.

------------------------------------------------------------------------

When this welder is mounted on a truck or trailer, its
frame must be electrically connected to the metal
frame of the vehicle, use a #8 or larger copper wire
connected between the machine grounding stud and
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
system earth ground. See further connection instruc­tions in the section entitled "Standby Power
Connections" as well as the article on grounding in the
latest U.S. National Electrical Code and the local
code.

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.

The U.S. National Electrical Code lists a number of

®

alternate means of grounding electrical equipment. A
machine grounding stud marked with the symbol is
provided on the front of the welder.

WELDING TERMINALS

The RANGER®305G EFI 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.

A-5

RANGER®305G EFI

A-6

INSTALLATION

WELDING OUTPUT CABLES

With the engine off connect the electrode and work
cables to the output studs. The welding process dic­tates the polarity of the electrode cable. These con­nections 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.

TABLE A-1

TOTAL COMBINED LENGTH OF

ELECTRODE AND WORK CABLES

Cable Length

0-100Ft. (0-30 meters)

100-150 Ft. (Im meters)
150-200 Ft. (46-61 meters)

Cable Size for

305 Amps

100% Duty Cycle

1 / 0 AWG

2 / 0 AWG

3 / 0 AWG

A-6

The auxiliary power capacity is 12,000 watts Peak, 9500
Watts Continuous of 60 Hz, single phase power. The auxil­iary power capacity rating in watts is equivalent to volt­amperes 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
permissible 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.

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 paralleled.

STANDBY POWER CONNECTIONS

The RANGER®305G EFI is suitable for temporary, standby
or emergency power using the engine manufacturers rec­ommended maintenance schedule.

CABLE INSTALLATION

®

Install the welding cables to your RANGER
EFI 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.

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.

6. Check and tighten the connections periodically.

305G

CAUTION

• Loose connections will cause the output termi-

nals to overheat. The terminals may eventually
melt.

• Do not cross the welding cables at the output

terminal connection. Keep the cables isolated
and separate from one another.

------------------------------------------------------------------------

AUXILIARY POWER RECEPTACLES

The auxiliary power of the RANGER®305G EFI con­sists of two 20 Amp-120 VAC (5-20R) duplex recepta­cles and one 50 Amp 120/240 VAC (14-50R) recepta­cle. The 240 VAC receptacle can be split for single
phase 120 VAC operation.

The RANGER
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.

• Install the double-pole, double-throw switch between the
power company meter and the premises disconnect.
Switch rating must be the same or greater than the cus­tomers premises disconnect and service over current pro­tection.

• Take necessary steps to assure load is limited to the
capacity of the RANGER

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 allowable - 10% of rated voltage
which may damage appliances or other motor-driven
equipment and may result in overheating of the

RANGER

• 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 receptacle
on the RANGER

®

305G EFI can be permanently installed as a

®

305G EFI by installing a 40

®

305G EFI engine and/or alternator windings.

®

305G EFI case front.

RANGER®305G EFI

A-7

ELECTRICAL DEVICE USE WITH THE RANGER

Type Common Electrical Devices Possible Concerns

Resistive Heaters, toasters, incandescent NONE

light bulbs, electric range, hot
pan, skillet, coffee maker.

Capacitive TV sets, radios, microwaves, Voltage spikes or high voltage

appliances with electrical control. regulation can cause the capaci-

Inductive Single-phase induction motors, These devices require large

drills, well pumps, grinders, small current inrush for starting.
refrigerators, weed and hedge Some synchronous motors may
trimmers be frequency sensitive to attain

INSTALLATION

TABLE lll

®

305G EFI.

tative elements to fail. Surge
protection, transient protection,
and additional loading is recom­mended for 100% fail-safe oper-

ation. DO NOT RUN THESE

DEVICES WITHOUT ADDI­TIONAL RESISTIVE TYPE
LOADS.

maximum output torque, but
they SHOULD BE SAFE from
any frequency induced failures.

A-7

Capacitive/Inductive Computers, high resolution TV sets, An inductive type line condition-

complicated electrical equipment. er along with transient and

surge protection is required, and
liabilities still exist. DO NOT

USE THESE DEVICES WITH A

®

RANGER

The Lincoln Electric Company is not responsible for any damage to electrical components improperly connected
to the RANGER

®

305G EFI.

305G EFI

RANGER®305G EFI

A-8

240 Volt

60 Hz.

3-Wire

Service

INSTALLATION

CONNECTION OF RANGER®305G EFI TO PREMISES WIRING

240 VOLT

POWER

COMPANY

METER

DOUBLE POLE DOUBLE THROW
SWITCH RATING TO BE THE SAME
AS OR GREATER THAN PREMISES
SERVICE OVERCURRENT
PROTECTION.

120 VOLT

120 VOLT

40AMP

240 VOLT

GROUNDED CONDUCTOR

NEUTRAL
BUS

GROUND

PREMISES

DISCONNECT AND

OVERCURRENT

PROTECTION

N

SERVICE

A-8

LOAD

DOUBLE

50 AMP, 120/240

VOLT PLUG

NEMA TYPE 14-50

240 VOLT

50 AMP, 120/240 VOLT

RECEPTACLE

POLE

CIRCUIT

BREAKER

GND

N

NOTE: No. 6 COPPER CONDUCTOR CABLE SEE

NATIONAL ELECTRICAL CODE FOR ALTERNATE WIRE

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®305G EFI

A-9

INSTALLATION

A-9

CONNECTION OF LINCOLN ELECTRIC
WIRE FEEDERS

Connection of LN-7 or LN-8 to the RANGER®305G
EFI

1. Shut the welder off.

2. Connect the LN-7 or LN-8 per instructions on the
appropriate connection diagram in Section F

3. Set the "WIRE FEEDER VOLTMETER" switch to
either "+" or "-" as required by the electrode being
used.

4. Set the "MODE" switch to the "CV WIRE " posi­tion.

5. Set the "ARC CONTROL" knob to "0" initially and
adjust to suit.

6 Set the "WELD TERMINALS" switch to the

"REMOTELY CONTROLLED" position.

7. Set the "IDLE" switch to the "HIGH" position.

®

Connection of LN-15 to the RANGER

These connections instructions apply to both the LN­15 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.

• 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.

• Across The-Arc Model:

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.

Set the "WELD TERMINALS" switch to "WELD TER­MINALS ON"

• Control Cable Model:

305G EFI

• Set the "WIRE FEEDER VOLTMETER" switch to

either "+" or "-" as required by the electrode polarity
being used.

• Set the "ARC CONTROL" knob to "0" initially and
adjust to suit.

• Set the "IDLE" switch to the "AUTO" position.

WARNING

®

Connection of the LN-25 to the RANGER
EFI

• Shut off welder before making any electrical con­nections.

------------------------------------------------------------------------

The LN-25 with or without an internal contactor may
be used with the RANGER

appropriate connection diagram in Section F.
NOTE: The LN-25 (K431) Remote Control Module

and (K432) Remote Cable are not recommended for
use with the RANGER

1. Shut the welder off.

2. For electrode Positive, connect the electrode
cable from the LN-25 to the "+" terminal of the
welder and work cable to the "-" terminal of the
welder. For electrode Negative, connect the elec­trode cable from the LN-25 to the "-" 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.

4. Set the MODE switch to the "CV-WIRE " position.

5. Set the "WELD TERMINALS" switch to "WELD
TERMINALS ON"

6. Set the "ARC CONTROL" knob to "0" initially and
adjust to suit.

®

®

305G EFI.

305G EFI. See the

305G

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.

RANGER 305G

A-10

7. Set the "IDLE" switch to the "AUTO" position.
When not welding, the RANGER

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.

8. When the gun trigger is closed, the current sens-

ng circuit will cause the RANGER

i
engine to go to the high idle speed, the wire will
begin to feed and the welding process started.
When welding is stopped, the engine will revert to
low idle speed after approximately 12 seconds
unless welding is resumed.

INSTALLATION

®

305G EFI

®

305G EFI

CAUTION

If you are using an LN-25 without an internal con­tactor, the electrode will be energized when the

®

RANGER

------------------------------------------------------------------------

Connection of LN-742,K487-25 Spool Gun, and
Cobramatic to RANGER

305G EFI is started.

®

305G EFI

A-10

1. Shut the welder off.

2. Connect per instructions on the appropriate con­nection diagram in Section F.

RANGER®305G EFI

B-1

OPERATION

B-1

SAFETY PRECAUTIONS

Read and understand this entire section before
operating your RANGER

Do not attempt to use this equipment until you
have thoroughly read all operating and mainte­nance manuals supplied with your machine. They
include important safety precautions, detailed
engine starting, operating and maintenance
instructions and parts lists.

ELECTRIC SHOCK can kill.

•Do not touch electrically live parts
such as output terminals or internal
wiring.

•Insulate yourself from the work and
ground.

•Always wear dry insulating gloves.

------------------------------------------------------------------------

ENGINE EXHAUST can kill.

•Use in open, well ventilated areas or
vent exhaust outside

•Do not stack anything near the
engine.

------------------------------------------------------------------------

MOVING PARTS can injure.

•Do not operate with doors open or
guards off.

®

305G EFI

DESIGN FEATURES

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.

®

The auxiliary power of the RANGER
sists of two 20 Amp-120 VAC (5-20R) duplex recepta­cles and one 50 Amp 120/240 VAC (14-50R) recepta­cle. The 240 VAC receptacle can be split for single
phase 120 VAC operation.

ENGINE OPERATION

Before Starting the Engine:

• Be sure the machine is on a level surface.

• Open top engine door and remove the engine oil
dipstick and wipe it with a clean cloth. Reinsert the
dipstick and check the level on the dipstick.

• Add oil (if necessary) to bring the level up to the full
mark. Do not overfill. Close engine door.

• See Engine Owners Manual for specific oil recom­mendations.

ADD FUEL

305G EFI con-

•Stop engine before servicing.

•Keep away from moving parts

------------------------------------------------------------------------

• Only qualified personnel should operate this
equipment.

ADDITIONAL SAFETY PRECAUTIONS

Always operate the welder with the hinged door
closed and the side panels in place as these pro­vide maximum protection from moving parts and
insure proper cooling air flow.

GENERAL DESCRIPTION

The RANGER®305G EFI is a gasoline engine pow­ered DC multi-process welding power source and 120
/ 240 volt AC power generator. The engine drives a
generator that supplies three phase power for the DC
welding circuit and single phase power for the AC
auxiliary outlets. The DC welding control system uses
state of the art Chopper Technology for superior
welding performance.

Code 12157 and above meet EPA evaporative emis­sion requirements.

WARNING

GASOLINE can cause fire
or explosion.

• Stop engine when fueling.

• Do not smoke when fueling.

• Do not overfill tank.

• Avoid contact with skin or

breathing of vapor.

• Keep sparks and flame away from tank.

------------------------------------------------------------------------

• Remove the fuel tank cap.

• Fill tank until the fuel gauge
reads full. DO NOT TOP OFF
TANK. Be sure to leave filler
neck empty for expansion.

• Replace the fuel cap and tighten securely.

• See Engine Owners Manual for specific fuel recom­mendations.

FULL

RANGER®305G EFI

B-2

OPERATION

B-2

1

14
13

2

12

3

11

4

10

9

5

WELDING CONTROLS

1. OUTPUT CONTROL:

The CONTROL dial provides continuous control of the
welding current or welding voltage depending on the
selected welding mode. This control is not active in the
CC-STICK, DOWN HILL PIPE, and CV-WIRE modes
when a remote control or wire feeder with remote control
is connected to either the 6 pin or 14 pin Amphenol.

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 OUTPUT con­trol dial. During welding, the meter display the actual out­put voltage (VOLTS) and current (AMPS). A memory fea­ture holds the display of both meters on for seven sec­onds after welding is stopped. This allows the operator to
read the actual current and voltage just prior to when
welding was ceased. While the display is being held the
left-most decimal point in each display will be flashing.
The accuracy of the meters is +/- 3%.

3. WELD MODE SELECTOR SWITCH:

(Provides four selectable welding modes)

CV-WIRE
DOWN HILL PIPE
CC-STICK
TOUCH START TIG

RANGER®305G EFI

8
7
6

4. ARC CONTROL:

The ARC CONTROL WIRE/STICK dial is active in the WIRE,
STICK and DOWN HILL PIPE modes, and has different func­tions in these modes. This control is not active in the TIG mode.

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 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 CONTROL be set to the minimum
number without electrode sticking. Start with a setting at

0.

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 preferred for root and hot passes. A softer arc is
preferred for fill and cap passes where weld puddle con­trol and deposition (“stacking” of iron) are key to fast trav­el speeds. It is recommended that the ARC CONTROL
be set initially at 0.

B-3

CV-WIRE mode: In this mode, 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 control. The proper setting depends on the procedure
and operator preference. Start with a setting at 0.

5. WELD OUTPUT TERMINALS WITH FLANGE
NUT:

Provides a connection point for the electrode and work
cables.

OPERATION

12. START PUSH BUTTON

- Energizes the starter motor to crank the engine

13. IDLER SWITCH

- Has two positions as follows:

1) In the HIGH position, the engine runs at the high

2) In the AUTO position, the idler operates as follows:

6. GROUND STUD:

Provides a connection point for connecting the machine case
to earth ground for the safest grounding procedure.

7. 14 PIN CONNECTOR:

For attaching wire feeder control cables to the RANGER
305G EFI. Includes contactor closure 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. When in
the CC-STICK, PIPE, and CV-WIRE modes and when a
remote control is connected to the Amphenol, the auto-sens-

ing circuit in the RANGER
the OUTPUT control from control at the welder to remote
control.

When using the TOUCH START TIG
Module connected to the RANGER
control on the front of the RANGER

the maximum current range of the CURRENT CONTROL on
the TIG Module.

®

305G EFI automatically switches

®

mode with a TIG

®

305G EFI, the OUTPUT

®

305G EFI is used to set

14. ELECTRIC FUEL GAUGE / HOUR METER

The electric fuel gauge gives accurate and reliable
indication as to how much fuel is in the fuel tank. The
hour meter displays the total time that the engine has
been running. This meter is useful for scheduling pre­scribed maintenance.

STARTING AND STOPPING THE ENGINE

B-3

idle speed controlled by the engine governor.

• 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.

• 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.

9. WELD TERMINALS CONTROL SWITCH:

In the WELD TERMINALS ON position, the output is electri­cally hot all the time. In the REMOTELY CONTROLLED
position, the output is controlled by a wire feeder or amptrol
device, and is electrically off until a remote switch is

depressed.

10. WIRE FEEDER VOLTMETER SWITCH:

Matches the polarity of the wire feeder voltmeter to the polar­ity of the electrode.

ENGINE CONTROLS:

11. RUN/STOP SWITCH

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.

- RUN position energizes the

RANGER®305G EFI

• Remove all plugs connected to the AC power
receptacles.

• Set IDLER switch to AUTO.

• Set the RUN/STOP switch to RUN.

• Press and hold the engine START button until the

engine starts.

• Release the engine START button when the engine

starts.

• The engine will run at high idle speed for approxi-

mately 12 seconds and then go 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.

B-4

OPERATION

CAUTION

Operating the starter motor for more than 5 sec­onds can damage the motor. If the engine fails to
start, release the switch and wait 10 seconds
before operation the starter again. Do NOT push
the START button while the engine is running
because this can damage the ring gear and/or the
starter motor.

------------------------------------------------------------------------

NOTE: When starting a RANGER®305G EFI for the
first time, or after and extended period of time of not
operating, it can take longer than normal because the
fuel pump has to fill the fuel line.

STOPPING

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.

Stop the engine by placing the RUN-STOP in the
STOP position.

B-4

DC STICK WELDING

The RANGER®305G EFI can be used with a broad
range of DC stick electrodes.
The MODE switch provides two stick welding settings
as follows:

CONSTANT CURRENT (CC-STICK)
WELDING

The CC-STICK position of the MODE switch is
designed for horizontal and vertical-up welding with all
types of electrodes, especially low hydrogen. The out­put CONTROL dial adjusts the full output range for
stick welding.

The ARC CONTROL knob sets the short circuit current
during stick welding (arc-force). Increasing the number
from -10 to +10 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 the
dial set at 0.

NOTE: A fuel shut off valve is not required on the
RANGER

below the engine.

®

305G EFI because the fuel tank is mounted

WELDER OPERATION

DUTY CYCLE

Duty Cycle is the percentage of time the load is being
applied in a 10 minute period. For Example, a 60%
duty cycle represents 6 minutes of load and 4 minutes
of no load in a 10 minute period.

TYPICAL RANGER®305G EFI FUEL CONSUMPTION

Kohler ECH740

Gal./hrs (liters/hr)

Low Idle - No Load

2400 R.P.M

High Idle - No Load

3700 R.P.M

.39 (1.46)

.68 (2.54)

DOWN HILL PIPE WELDING

This slope controlled setting is intended for "out-of­position" 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 knob sets the short circuit current
during stick welding (arc-force). Increasing the number
from -10 to +10 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 the
dial set at 0.

Running Time for

12 gallons -(hrs.)

31.13

17.54

DC Weld Output

250 Amps @ 29 Volts

DC Weld Output

300 Amps @ 29 Volts

Auxiliary Power

9,500 Watts

1.37 (5.18)

1.54 (5.84)

1.50 (5.64)

RANGER®305G EFI

8.77

7.78

7.98

B-5
TIG 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 tung-

OPERATION

When using the TIG Module, the OUTPUT control on the
RANGER

the CURRENTCONTROLon the TIG module or an Amptrol

if connected to the TIG Module.
sten is touched to the work. During the time the tungsten is
touching the work there is very little voltage or current and in
general, no tungsten contamination. Then, the tungsten is
gently lifted off the work in a rocking motion, which establish­es the arc.

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, re touch the tungsten to the work
and lift. Alternatively, the weld can be stopped by releasing
the Amptrol or arc start switch.

®

The RANGER

305G EFI 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

WIRE WELDING-CV

Connect a wire feeder to the RANGER®305G EFI according
to the instructions in INSTALLATION INSTRUCTIONS
Section.

The RANGER
to be used with a broad range of flux cored wire (Innershield
and outreached) 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 con­trol. The proper setting depends on the procedure and oper­ator preference. Start with the dial set at 0.

Listed below are some wires suitable for use on this
machine:

Hi-frequency unit. If desired, the K930-2 TIG Module can be
used with the Ranger 305D. The settings are for reference.

®

RANGER

305G EFI settings when using the K930-2 TIG

Module with an Amptrol or Arc Start Switch:

• Innershield - NR-311, NS-3M, NR-207, NR-203 Ni 1%,

• outreached - 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

• Set the MODE Switch to the TOUCH START TIG setting.

.045 (1.1 mm) Blue Max MIG 308 lw.

• Set the "IDLER" Switch to the "AUTO" position.

• Set the "WELDING TERMINALS" switch to the "REMOTE­LY CONTROLLED" position. This will keep the "Solid
State" contactor open and provide a “cold” electrode until
the Amptrol or Arc Start Switch is pressed.

Contact your local authorized Lincoln Electric Distributor or the
Lincoln Electric Company for specific wires used on certain
applications with this machine.

NR-212.

B-5

®

305G EFI is used to set the maximum range of

®

305G EFI in the CV-WIRE mode, permits it

TYPICAL CURRENT RANGES

Tungsten Electrode DDENE (-) DAZE (+) Approximate Argon Gas Flow TIG TORCH

Diameter in. (mm) Flow Rate C.F.H. ( l /min.) Nozzle Size (4), (5)

1%, 2% Thoriated 1%, 2% Thoriated Aluminum Stainless Steel
Tungsten Tungsten

.010 (.25) 2-15 (3) 3-8 (2-4) 3-8 (2-4) #4, #5, #6

0.020 (.50) 5-20 (3) 5-10 (3-5) 5-10 (3-5)

0.040 (1.0) 15-80 (3) 5-10 (3-5) 5-10 (3-5)
1/16 (1.6) 70-150 10-20 5-10 (3-5) 9-13 (4-6) #5, #6
3/32 (2.4) 150-250 15-30 13-17 (6-8) 11-15 (5-7) #6, #7, #8

1/8 (3.2) 250-400 25-40 15-23 (7-11) 11-15 (5-7)
5/32 (4.0) 400-500 40-55 21-25 (10-12) 13-17 (6-8) #8, #10

3/16 (4.8) 500-750 55-80 23-27 (11-13) 18-22 (8-10)
1/4 (6.4) 750-1000 80-125 28-32 (13-15) 23-27 (11-13)

(1) When used with argon gas. The current ranges shown must be reduced when using argon/helium or pure helium shielding gases.
(2) Tungsten electrodes are classified as follows by the American Welding Society (AWS):

Pure EWP

1% Thoriated Esther

2% Thoriated Esther

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) DAZE is not commonly used in these sizes.
(4) TIG torch nozzle "sizes" are in multiples of thus of an inch:

(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

# 4 = 1/4 in. (6 mm)
# 5 = 5/16 in. (8 mm)
# 6 = 3/8 in. (10 mm)
# 7 = 7/16 in. (11 mm)
# 8 = _ in. (12.5 mm)
#10 = 5/8 in. (16 mm)

and high duty cycles.

(1)

FOR TUNGSTEN ELECTRODES

(2)

RANGER®305G EFI

B-6

OPERATION

ARC GOUGING

The RANGER®305G EFI 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 CONTROL knob to adjust output current to the
desired level for the gouging electrode being used
according to the ratings in the following table.

Carbon Diameter

Current Range (DC, electrode

Positive)
1/8" 60-90 Amps
5/32" 90-150 Amps
3/16" 200-250 Amps

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.

The auxiliary power of the RANGER
sists of two 20 Amp-120 VAC (5-20R) duplex recepta­cles and one 50 Amp 120/240 VAC (14-50R) recepta­cle. The 240 VAC receptacle can be split for single
phase 120 VAC operation.

®

305G EFI con-

B-6

The auxiliary power capacity is 12,000 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 40 Amps.
The 240 VAC output can be split to provide two sepa­rate 120 VAC outputs with a max permissible 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.

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 circuits, each of
which measure 120 V to neutral but are of opposite
polarities and cannot be paralleled.

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 cur­rents shown assume that current is being drawn from
either the 120 VAC or 240 VAC supply (not both at the
same time).

Current

(Amps)

15
20
15
20
40

RANGER®305G EFI Simultaneous Welding and Power Loads

Welding

Output-Amps

Permissible Power-Watts

(Unity Power Factor)

Permissible

Current in

Auxiliary

-Amps

@120 VAC *

0
100
150

200
250
300

9500
7100
5600
4200
2300

0

80**
60**
46**

36
20

0

* Each duplex receptacle is limited to 20 amps.
** Not to exceed 40A per 120 VAC branch circuit when splitting the 240 VAC output.

RANGER®305G EFI Extension Cord Length Recommendations

(Use the shortest length extension cord possible sized per the following table.)

voltam-

meters

120
120
240
240
240

Load

(Watts)

1800
2400
3600
4800
9500

14 AWG 12 AWG 10 AWG 8 AWG 6 AWG 4 AWG

30
60

(9)

(18)

Conductor size is based on maximum 2.0% voltage drop.

Maximum Allowable Cord Length in ft. (m) for Conductor Size

40
30
75
60

(12)

(9)
(23)
(18)

75

50
150
100

50

(23)
(15)
(46)
(30)
(15)

125

88
225
175

90

(38)
(27)
(69)
(53)
(27)

175
138
350
275
150

@ 240 VAC

40
30

23
18
10

0

(53)

(42)

(107)

(84)

(46)

300
225
600
450
225

(91)

(69)
(183)
(137)

(69)

RANGER®305G EFI

C-1

ACCESSORIES

C-1

OPTIONS/ACCESSORIES AND COM­PATIBLE LINCOLN EQUIPMENT

K957-1 HEAVY DUTY, TWO WHEEL TRAILER FOR
SMALL WELDERS

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:

K957-1 Trailer
K958-1 Ball Hitch
K958-2 Lunette Eye Hitch
K959-2 Fender & Light Kit
K965-1 Cable Storage Rack

K1737-1 FOUR WHEEL ALL-TERRAIN UNDERCAR­RIAGE For moving by hand at construction sites.

Heavy duty puncture resistant pneumatic tires.

K1770-1 UNDERCARRIAGE (FACTORY)

For moving by hand on a smooth surface.
Heavy duty puncture resistant pneumatic tires & front
caster, One or two gas cylinders can be mounted on
the rear of the undercarriage with the installation of
K1745-1 Cylinder Holder(s).

K1739-1 CABLE CARRIER KIT

For use on K1737-1 and K1770-1 Undercarriages.

K1745-1 WELDING GAS CYLINDER LOX TANK
HOLDER

For use on K1770-1 Undercarriage. One or two may be
installed on an undercarriage.

K1788-1 ROLL CAGE - Gives added damage protection.
K886-2 CANVAS COVER - Protects machine when not in use.

K1690-1 GFCI RECEPTACLE KIT

Includes one UL approved 120V ground fault circuit
interrupter duplex type receptacle with cover and
installation instructions. Replaces the factory installed
120V duplex receptacle. Each receptacle of the GFCI
Duplex is rated at 20 Amps, the maximum total cur­rent from the GFCI Duplex is limited to the 20 Amps.
Two kits are required.

K802N 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.

K802R POWER PLUG KIT

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

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.)

TIG Welding
K1783-9 TIG Torch PTA-26V (25ft.)
K963-3 Hand Amptrol
K870 Foot Amptrol
KP509 Magnum Parts Kit

Spool Gun
K487-25 Magnum Spool Gun
K488 Magnum Control Module

K691-10 Input Cable)

K1898-1 SPARK ARRESTOR

Mounts inside exhaust pipe.
K704 ACCESSORY SET - Includes 35 ft. (im) of elec-

trode cable and 30 ft. (Im) of work cable, headshield,
work clamp electrode holder. Cables are rated at 400
amps, 100% duty cycle.

K857 25 ft (Im) or K857-1 100 ft. (Im) REMOTE CON-
TROL

Portable control provides same dial range as the output
control on the welder. Has a convenient 6 pin plug for
easy connection to the welder.

RANGER®305G EFI

D-1

MAINTENANCE

D-1

SAFETY PRECAUTIONS

WARNING

• Have qualified personnel do all maintenance
and troubleshooting work.

• Turn the engine off before working inside the
machine or servicing the engine.

• 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.)

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.

Routine Maintenance

KOHLER ENGINE

FREQUENCY

Daily or Before
Starting Engine

5 Hours
Every 25 Hours
Every 100 Hours

Every 100 Hours
Every 100 Hours

Every 100 Hours
Every 200 Hours
Every 200 Hours
Every 2 Years

(1) Service more frequently when used in dusty areas and/or at high ambient

temperatures.

MAINTENANCE REQUIRED

• Fill fuel tank.

• Check oil level.

• Check air cleaner for dirty, loose,
or damaged parts.

• Check air intake and cooling
areas, clean as necessary.

First Oil Change

• Service air pre-cleaner..

• Change engine oil.

• Replace fuel filter element.

• Clean or replace air filter ele-

(1)

ment.

• Spark Arrester

• Replace oil filter.

• Check spark plug and gap

• Check fuel lines and clamps.

(1)

(1)

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.

ENGINE MAINTENANCE COMPONENTS

ITEM

Oil Filter
Air Filter Element Kohler 47 083 03, Fram CA79
Air Filter Pre-Cleaner Kohler 24 083 05
Fuel Filter Kohler 24 050 05
Spark Plug Champion RC12YC (.030" Gap)

MAKE AND PART NUMBER

KOHLER

Kohler 12 050 01, Fram PH8172*

ECH740

ENGINE

Battery ci Group 58 (435 CCA)

* Oil capacity increases from 2.0 Qts. to 2.1 Qts. when using this filter.

RANGER®305G EFI

D-2

MAINTENANCE

D-2

Engine Oil Change

Drain the oil while the engine is warm to assure rapid
and complete draining.

• Remove the oil filler cap and dipstick. Remove the
yellow cap from the oil drain valve and attach the
flexible drain tube supplied with the machine. Push
in and twist the drain valve counterclockwise. Pull
the valve out and drain the oil into a suitable
container.

• Close the drain valve by pushing in and twisting
clockwise. Replace the yellow cap.

• Refill to the upper limit mark on the dipstick with the
recommended oil. Tighten the oil filler cap securely.

Engine Oil Refill Capacities

Without oil filter replacement:

• 1.7 US qt. (1.4 Imp qt., 1.6 liter)-Kohler

With oil filter replacement:

• 2.0 US qt. (1.7 Imp qt., 1.9 liter)-Kohler

Use 4-stroke motor oil that meets or exceeds the
requirements for APIO service classification SG or
SH. Always check the APIO SERVICE label on the oil
container to be sure it includes the letters SG or SH.

SAE 10W-30 is recommended for general, all-temper­ature use, -5ºF to 104ºF (-20ºC to 40ºC).

See Engine Owners Manual for more specific infor­mation on oil viscosity recommendations.
Wash your hands with soap and water after handling
used 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 reclamation. Do not throw
it in the trash, pour it on the ground or down a drain.

• Refill the crankcase with the specified amount of the
recommended oil. Reinstall the oil filler cap.

• Start the engine and check for oil filter leaks.

• Stop the engine, and check the oil level. If neces­sary, add oil to the upper limit mark on the dipstick.

Air Cleaner Service

A dirty air cleaner will restrict air flow to the carbure­tor. To prevent carburetor malfunction, service the air
cleaner regularly. Service more frequently when oper­ating the engine in extremely dusty areas.

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 Pre-cleaner Service

• Loosen the cover retaining knob and remove the
cover.

• Remove the pre-cleaner from the paper element.

• Wash the pre-cleaner in warm water with detergent.
Rinse the pre-cleaner thoroughly until all traces of
detergent are eliminated. Squeeze out excess water
(do not wring). Allow the pre-cleaner to air dry.

• Saturate the pre-cleaner with new engine oil.
Squeeze out all excess oil.

• Reinstall the pre-cleaner over the paper element.

Oil Filter Change

• Drain the engine oil.

• Remove the oil filter, and drain the oil into a suitable
container. Discard the used oil filter.

• Clean the filter mounting base, and coat the gasket
of the new oil filter with clean engine oil.

• Screw on the new oil filter by hand, until the gasket
contacts the filter mounting base, then use an oil fil­ter socket tool to tighten the filter an additional 1/2 to
7/8 turn.

RANGER®305G EFI

• Reinstall the air cleaner cover. Secure cover with
the cover retaining knob.

D-3

MAINTENANCE

D-3

AIR FILTER PAPER ELEMENT

• Loosen the cover retaining knob and remove the
cover.

• Remove the pre-cleaner from the paper element.

• Remove the element cover nut, element cover, and
paper element.

• Do not wash the paper element or use pressurized
air, as this will damage the element. Replace a
Dirty, bent, or damaged element with a new ele­ment. Handle new elements carefully; do not use if
the sealing surfaces are bent or damaged.

• When servicing the air cleaner, check the air clean­er base. Make sure it is secured and not bent or
damaged. Also check the element cover for dam­aged or improper fit. Replace all damaged air
cleaner components.

NOTE: Before air cleaner is reassembled make sure
rubber seal is in position around stud. Inspect, mak­ing sure it is not damaged and seals with the element
cover.

• Reinstall the paper element, pre-cleaner, element
cover, element cover nut, and air cleaner cover.
Secure cover with the cover retaining knob.

SPARK PLUG

To ensure proper engine operation, the spark plug
must be properly gapped and free of deposits.

Spark Plug Service

To ensure proper engine operation, the spark plug
must be properly gapped and free of deposits.

• Remove the spark plug cap.

• Clean any dirt from around the spark plug base.

• Use a plug wrench to remove the spark plug.

• Visually inspect the spark plug. Discard them if the
insulator is cracked or chipped. Clean the spark
plug with a wire brush if it is to be reused.

• Measure the plug gap with a feeler gauge. Correct
as necessary by bending the side electrode.

• Check that the spark plug washer is in good condi­tion and thread the spark plug in by hand to prevent
cross-threading.

• After the spark plug is seated, tighten with a spark
plug wrench to compress the washer.

• If installing a new spark plug, tighten 1/2 turn after
the spark plug seats to compress the washer.

• If reinstalling a used spark plug, tighten 1/8 - 1/4
turn after the spark plug seats to compress the
washer.

Spark Plug Gap: .030 in. (0.76 mm)-Kohler

WARNING

NOTE: Before removing spark plug, the muffler
becomes very hot during operation and remains
hot for a while after stopping the engine. Be care­ful not to touch the muffler while it is hot.

RANGER®305G EFI

Spark Plug Torque: 20 ft. Lb. (27 N-m)-Kohler

CAUTION

The spark plug must be securely tightened. An
improperly tightened spark plug can become very
hot and may cause engine damage.
Use only the recommended spark plug or equiva­lent. A spark plug which has an improper heat
range may cause engine damage.

D-4

MAINTENANCE

D-4

FUEL FILTER

• Check the fuel filter for water accumulation or sedi­ment.

• Replace the fuel filter if it is found with excessive
water accumulation or sediment.

ENGINE ADJUSTMENT

OVERSPEED IS HAZARDOUS

The maximum allowable high idle speed for this
machine is 3750 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.

Adjustments to the engine are to be made only by a
Lincoln Service Center or an authorized Field Service
Shop.

BATTERY MAINTENANCE

To access the battery, Remove the 2 screws from the
rear battery tray using a screwdriver or a 3/8" socket.
Slide the battery tray out only far enough to access
the battery terminals.

WARNING

CLEANING THE BATTERY

Keep the battery clean by wiping it with a damp cloth
when dirty. If the terminals appear corroded, discon­nect the battery cables and wash the terminals with an
ammonia solution or a solution of 1/4 pound (0.11kg)
of baking soda and 1 quart (0.1 L) of water. Be sure
the battery vent plugs (if equipped) are tight so that
none of the solution enters the cells.

After cleaning, flush the outside of the battery, the bat­tery 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 accumula­tion on the battery can lead to more rapid discharge
and early battery failure.

CHECKING THE ELECTROLYTE LEVEL

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

When you charge, jump, replace, or otherwise con­nect battery cables to the battery, be sure the polarity
is correct. Improper polarity can damage the charging

circuit. The RANGER
terminal has a red terminal cover.

®

305G EFI positive (+) battery

GASES FROM BATTERY can explode.

• Keep sparks, flame and cigarettes
away from battery.

To prevent EXPLOSION when:

• INSTALLING A NEW BATTERY — disconnect
negative cable from old battery first and connect
to new battery last.

• 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.

• USING A BOOSTER — connect positive lead to
battery first then connect negative lead to nega­tive battery lead at engine foot.

BATTERY ACID can burn eyes and
skin.

• Wear gloves and eye protection
and be careful when working near
battery.

• Follow instructions printed on battery.

------------------------------------------------------------------------

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. Follow the instructions of the battery
charger manufacturer for proper charger settings and
charging time.

• Never use a quick battery charger to start
engine.

• Do not charge battery with RUN/STOP switch set
to “RUN”.

• Always diconnect negative (-) battery cable
before charging.

RANGER®305G EFI

D-5

MAINTENANCE

WARNING

• MUFFLER MAY BE HOT

• ALLOW ENGINE TO COOL BEFORE INSTALLING
THE SPARK ARRESTER!

• DO NOT OPERATE ENGINE WHILE INSTALLING
THE SPARK ARRESTER!

SERVICING OPTIONAL SPARK
ARRESTOR

Clean every 100 hours.

Welder/Generator Maintenance

STORAGE: Store the RANGER®305G EFI in clean,

dry protected areas.

D-5

CLEANING: Blow out the generator and controls peri-

odically with low pressure air. Do this at least once a
week in particularly dirty areas.

BRUSH REMOVAL AND REPLACEMENT: Its nor-

CAUTION

mal for the brushes and slip rings to wear and darken
slightly. Inspect the brushes when a generator over­haul is necessary.

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.

Do not attempt to Polish slip rings while the
engine is running.

RANGER®305G EFI

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.

__________________________________________________________________________

E-1

This Troubleshooting Guide is provided to help you
locate and repair possible machine malfunctions.
Simply follow the three-step procedure listed below.

Step 1. LOCATE PROBLEM(SYMPTOM).

Look under the column labeled “PROBLEM (SYMP­TOMS)”. This column describes possible symptoms
that the machine may exhibit. Find the listing that
best describes the symptom that the machine is
exhibiting.

Step 2. POSSIBLE CAUSE.

The second column labeled “POSSIBLE CAUSE” lists
the obvious external possibilities that may contribute
to the machine symptom.

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.

If you do not understand or are unable to perform the
Recommended Course of Action safely, 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®305G EFI

E-2

PROBLEMS

(SYMPTOMS)

TROUBLESHOOTING

Observe all Safety Guidelines detailed throughout this manual

POSSIBLE

CAUSE

RECOMMENDED

COURSE OF ACTION

E-2

Major Physical or Electrical Damage
is Evident.

Engine will not "crank".

Engine will "crank" but not start.

Engine shuts down shortly after
starting.

1. Contact your local Lincoln
Authorized Field Service
Facility.

1. Battery is low.

2. Loose battery cable connections.

Inspect, clean and tighten.

3. Faulty engine starter motor.

4. “Battery Circuit” circuit breaker is
tripped.

1. Out of fuel.

2. Faulty EFI component(s) or faulty
PC board or ignition system.

3. Fuel lift pump not working.

1. Low oil level.
And fill to proper level. Start engine
And look for leaks.

Charge Battery.

Fill tank.

Change oil and oil filter

I

f all recommended possible areas
of misadjustment have been
checked and the problem persists,

Contact your local Lincoln
Authorized Field Service Facility.

2. Faulty oil pressure switch or other
engine component.

3. Low fuel level.

4. Fuel pump not working.

Battery does not stay charged.

1. Faulty battery,

2. Loose connections at battery or
alternator.
tions.

3. Faulty engine alternator or charg­er module.

replace.

Clean and tighten connec-

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®305G EFI

E-3

PROBLEMS

(SYMPTOMS)

TROUBLESHOOTING

Observe all Safety Guidelines detailed throughout this manual

POSSIBLE

CAUSE

RECOMMENDED

COURSE OF ACTION

E-3

Engine will not idle down to low
speed.

Engine will not go to high idle when
attempting to weld.

Engine will not go to high idle when
using auxiliary power.

Engine does not develop full
power.

1. Idler switch in High idle position.
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.

1. Poor work lead connection to

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 proper use of this switch.

3. Faulty PC board. Low idle speed

set to low.

1. Auxiliary power load is less than

100 watts. Idler may not respond
with less than a 100 watt load.
Set idler to "High".

2. Faulty PC board.

1. Fuel filter clogged, Replace.

2. Air filter clogged, clean or

replace.

3. Fouled spark plugs, clean or

replace.

4. Valves out of adjustment.

I

f 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®305G EFI

E-4

PROBLEMS

(SYMPTOMS)

TROUBLESHOOTING

Observe all Safety Guidelines detailed throughout this manual

POSSIBLE

CAUSE

RECOMMENDED

COURSE OF ACTION

E-4

No welding power output.

Welder has output but no control.

Wire feeder does not work when
control cable is connected to 14 pin
Connector.

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 alterna­tor.

1. Poor remote/control cable connec­tion to 6 pin or 14 pin Amphenol
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.

1. Wire Feeder Power circuit breaker
open. Check 42V and 120V
beakers and reset if tripped.

2. Faulty control cable. Repair or
replace cable.

3. Faulty wire feeder.

I

f all recommended possible areas
of misadjustment have been
checked and the problem persists,

Contact your local Lincoln
Authorized Field Service Facility.

No auxiliary power.

1. Open circuit breakers. Reset
breakers. If breakers keep trip­ping, reduce power draw.

2. Faulty connections to auxiliary
receptacles. Check connections.

3. GFCI tripped (if installed). Clear
any ground fault and reset GFCI
circuit by pressing "Reset" button
on the 120 V receptacle.

4. Breakers worn out or not contact­ing slip rings.

5. Rotor field winding not receiving
flashing current from P.C. board.

6. Open field winding on rotor.

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®305G EFI

E-5

PROBLEMS

(SYMPTOMS)

TROUBLESHOOTING

Observe all Safety Guidelines detailed throughout this manual

POSSIBLE

CAUSE

RECOMMENDED

COURSE OF ACTION

E-5

The welding arc is “cold.” The weld­ing arc is not stable or is not satis­factory. The engine runs normally.
The auxiliary power is normal.

1. Make sure the MODE selector
switch is in the correct position for
the process being used. (For
example, CV-WIRE, PIPE, CC­STICK.)

2. Make sure the electrode (wire,
gas, voltage, current etc.) is cor­rect for the process being used.

3. Check for loose or faulty connec­tions 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®305G EFI

F-1

DIAGRAMS

F-1

RANGER®305G EFI

F-2

DIAGRAMS

F-2

RANGER®305G EFI

F-3

DIAGRAMS

F-3

RANGER®305G EFI

F-4

DIAGRAMS

F-4

RANGER®305G EFI

F-5

DIAGRAMS

F-5

RANGER®305G EFI

F-6

Keep guards in place.

MOVING PARTS can injure

DIAGRAMS

F-6

4-14-2000

S24787-6

TO WORK

or service this equipment.

Only qualified personnel should install,use

Keep away from moving parts.

ENGINE WELDERS /LN-8 CONNECTION DIAGRAM

WARNING

ELECTRIC SHOCK can kill

Do not operate with panels open.

Disconnect NEGATIVE (-) Battery lead

before servicing.

Do not touch electrically live parts.

CABLE PLUG

TO LN-8 INPUT

14 PIN

AMPHENOL

K595 CONTROL CABLE

_

+

ELECTRODE CABLE

TO WIRE FEED UNIT

CAUTION:

ANY INCREASE OF THE HIGH IDLE ENGINE RPM BY CHANGING THE GOVERNOR SETTING OR OVERRIDING THE THROTTLE LINKAGE WILL CAUSE

AN INCREASE IN THE AC WIRE FEEDER VOLTAGE, WHICH CAN DAMAGE THE CONTROL CIRCUIT. THE ENGINE GOVERNOR SETTING IS PRE-SET

AT THE FACTORY – DO NOT ADJUST ABOVE RPM SPECIFICATIONS LISTED IN THE ENGINE WELDER OPERATING MANUAL.

N.A. WELDING CABLES MUST BE OF PROPER CAPACITY FOR THE CURRENT AND DUTY CYCLE OF IMMEDIATE AND FUTURE

APPLICATIONS. SEE OPERATING MANUAL.

N.B. CONNECT WELDING CABLES TO OUTPUT STUDS FOR DESIRED POLARITY. POSITION THE WIRE FEEDER VOLTMETER SWITCH TO

MATCH THE POLARITY OF THE ELECTRODE CABLE.

N.C. PLACE IDLER SWITCH IN “HIGH” POSITION.

RANGER®305G EFI

F-7

DIAGRAMS

F-7

RANGER®305G EFI

F-8

DIAGRAMS

F-8

RANGER®305G EFI

F-9

DIAGRAMS

2

F-9

9/03

RANGER®305G EFI

F-10

DIAGRAMS

F-10

RANGER®305G EFI

F-11

DIAGRAMS

F-11

RANGER®305G EFI

NOTE: This diagram is for reference only. It may not be accurate for all machines covered by this manual. The specific diagram for a particular code is pasted inside the

machine on one of the enclosure panels. If the diagram is illegible, write to the Service Department for a replacement. Give the equipment code number.

F-12

DIMENSION PRINT

36.24

920.4

33.62

854.0

29.80

756.9

10.78

273.9

10.28

261.0

7.22

183.3

CIRCUIT

BREAKERS

MM

INCH

F-12

A

M22449

DIMENSION DIAGRAM

20.80

528.3

596.9

23.50

24.86

631.3

2.62

66.5

495.3

19.50

16.75

425.4

CENTER OF GRAVI TY

1069.5

42.10

444.5

17.50

1046.5

41.20

TRUCK/UNDERCARRIAGE MOUNTIN G HOLES

RANGER®305G EFI

PARTS LIST FOR

Ranger

P-742P-742

®

305G EFI

This parts list is provided as an informative guide only.

It was accurate at the time of printing. These pages are only updated on the
Service Navigator DVD and in Lincoln Electrics ofcial Parts Book (BK-34).

When ordering parts, always refer to Lincoln Electrics ofcial Parts Book
(BK-34) for the latest pages.

RANGER®305G EFI

ILLUSTRATION OF SUB-ASSEMBLIES

7

5

6

4

1

2

3

P-742-AP-742-A

RANGER®305G EFI

Oct-13

P-742-A.1P-742-A.1

RANGER®305G EFI

For Codes: 12157 & 12206

Do Not use this Parts List for a machine if its code number is not listed. Contact the Service Department for any
code numbers not listed.

Use the Illustration of Sub-Assemblies page and the table below to determine which sub assembly page and
column the desired part is located on for your particular code machine.

Sub Assembly Item

No.

SUB ASSEMBL Y

PAGE NAME

PA GE NO.

CODE NO.

12157 1111111

12206 1121111

1

Case Front Assembly

P-742-C

2

Control Panel Assembly

P-742-D

3

Base/Fuel Tank/Battery

P-742-E

Assembly

4

Engine Assembly

P-742-F

5

Blower Baffle Assembly

P-742-G P-742-J

6

Stator/Rotor Assembly

P-742-H

7

Covers & Case Back Assembly

RANGER®305G EFI

Jan-14

Case Front Assembly

1A

41A

3A

33

33

25

8A

34

35A

38A

37

5A

4A

52C

52E

52B

27B

50A

50B

9

52A

51A

51B

51B

51C

51C

27A

23

41A

52B

52C

5A

23

1A

27A

27B

P-742-CP-742-C

51B

51A

51C

52A

51B

34

52E

25

37

33

33

8A

38A

50B

50A

51C

RANGER®305G EFI

Oct-13

P-742-C.1

P-742-C.1

# Indicates a change this printing.

Use only the parts marked “x” in the column under the
heading number called for in the model index page.

ITEM DESCRIPTION PART NO. QTY. 123456789

1 Case Front Assembly (G3666-54), Includes: NSS 1X
1A Case Front G3860-8 1 X
3A Top Bezel G3593 1 X
3B Self Tapping Screw (Not Shown) S24738-1 7 X
4A Right Bezel G3594-1 1 X
4B Self Tapping Screw (Not Shown) S24738-1 2 X
5A Left Bezel G3594-2 1 X
5B Self Tapping Screw (Not Shown) S24738-1 2 X
8A Choke Control S7525-21 1 X
8B Choke Control Bushing (Not Shown) S25335 1 X
8C Plain Washer (Not Shown) S9262-4 1 X
9 Start Button S13146-1 1 X
23

Nameplate (Ranger 305G EFI) G7771

1X
25 Knob T10491-1 1 X
26 “O” Ring (Not Shown) T13483-7 2 X
27 Harness Assembly , Includes: G6828 1 X
27A Toggle Switch (DPDT) T10800-36 1 X
27B Toggle Switch (SPST) T10800-38 1 X
28 Sealing Boot (Not Shown) S22061-4 4 X
33 Knob T10491 2 X
34 Front Door Nameplate L13919 1 X
35A Door Welded Assembly L11185 1 X
35B Rivet (Not Shown) T12584-6 2 X
37 Latch S21033 1 X
38A Catch Bracket S24659 1 X
38B Self Tapping Screw (Not Shown) S8025-98 2 X
41A Fuel/Hour Meter M22209 1 X
50 Plug & Lead Assembly, Includes: M19685-24 1 X
50A Toggle Switch (SPST) T10800-38 1 X
50B Toggle Switch (DPDT) T10800-39 1 X
51 Plug & Lead Asbly, Includes: M19685-30 1 X
51A Rotary Switch (S5) S16670-10 1 X
51B Potentiometer (10K) (R1, R2) T10812-119 2 X
51C Potentiometer Spacer S18280 2 X
52 Digital Weld Meter Kit, Includes: K2467-1 1 X
52A Meter Housing Asbly (L11160) NSS 2X
52B Meter Seal S24630 2 X
52C Meter Bezel M19368 2 X
52D Lens (Not Shown) T14807-9 2 X
52E #4-40 x .375 SS-PPNHS CF000389 4 X
52F #6-32 HN (Not Shown) CF000005 4 X
52G Plain Washer (Not Shown) S9262-3 4 X
55 Thread Forming Screw (Not Shown) S9225-68 4 X
56 Operation Decal (On Front Door) (Not Shown) M19452-4 1 X
57 Lubrication Tag (Not Shown) T11590-151 1 X
58 Hang Tag (Not Shown) L16540 1 X

NSS - Not Sold Separately

RANGER

®

305G EFI

Oct-13

Control Panel Assembly

24

20A

50A

50B

49A

22

21

20C

11A

11B

13

13

14

15

15

45

40

39

7A

7B

7C

7E

7F

7D

19

18

20B

16

17A

72

71A

71B

13

P-742-DP-742-D

17A

20B

24

49A

7B

7A

50A

20A

7F

11B

11A

13

16

39

71B

71A

RANGER®305G EFI

21

Oct-13

P-742-D.1

P-742-D.1

# Indicates a change this printing.

Use only the parts marked “x” in the column under the
heading number called for in the model index page.

ITEM DESCRIPTION PART NO. QTY. 123456789

7A Output Terminal Assembly, Includes: (1/2 Per Asbly) T14166-9 2 X
7B Output Stud Nut T3960 2 X
7C Self Tapping Screw S8025-91 4 X
7D 1/2-13 x .875 HHCS CF000344 1 X
7E Plain Washer S9262-1 1 X
7F Lock Washer E106A-15 1 X
11A Circuit Breaker (50 Amp) 250VAC 50VDC M20585 1 X
11B Circuit Breaker Cover Seal S24911-2 1 X
11C Sems Screw (Not Shown) T10082-30 4 X
11D Lock Washer (Not Shown) T4294-A 4 X
13 Circuit Breaker (20 Amp) 250VAC, 50VDC T12287-38 3 X
14 Circuit Breaker (15 Amp) 250VAC, 50VDC T12287-37 1 X
15 Sealing Boot S22061-2 4 X
16 Receptacle Cover M18861 1 X
17A Receptacle, Single S18907-2 1 X
17B Lock Washer (Not Shown) T9695-3 4 X
17C #8-32 HN (Not Shown) CF000042 4 X
18 Receptacle, Gasket S21088 2 X
19 Receptacle Cover M16996 2 X
20A Receptacle, Duplex S20184 2 X
20B Thread Forming Screw S9225-63 4 X
20C Speed Nut, #10-24 T11525-1 4 X
21 1/4-20 HJLN T9187-1 1 X
22 1/4-20 HN CF000017 1 X
24 Rating Plate L12790-13 1 X
39 Self Tapping Screw S8025-96 4 X
40 Connector Cap S17062-11 1 X
45 Connector Cap S27062-10 1 X
49A RF Bypass Filter Assembly S24982 1 X
49B Plain Washer (Not Shown) S9262-27 1 X
49C Lock Washer (Not Shown) E106A-1 1 X
49D #10-24 HN (Not Shown) CF000010 1 X
50 Plug & Lead Asbly, Includes: M19685-24 1 X
50A Connector Receptacle (14 Socket) S12021-70 1 X
50B Connector Receptacle (6 Socket) S12021-68 1 X
70A Shunt & Lead Asbly (Not Shown) S24097-4 1 X
70B 1/2-13 x .875 HHCS (Not Shown) CF000344 1 X
70C Plain Washer (Not Shown) S9262-1 1 X
70D Lock Washer (Not Shown) E106A-15 1 X
71A Output Stud Cover Plate S25669 2 X
71B Thread Forming Screw S9225-66 4 X
72 Output Stud Cover M20007 2 X

RANGER

®

305G EFI

Oct-13

Base/Fuel Tank/Battery Assembly

4G

4C

4D

2B

8B

1

5L

5K

5B

5C

5D

5G

5A

{

5M

5L

5J

10

2A

17A

17G

17F

17F

17H

17H

17E

17C

17B

17D

8A

7

4E

4F

4A

4B

20

4C

P-742-EP-742-E

17E

5G

5J

4F

4G

17G

17F

17F

17H

17B

17A

17C

2A

17D

5C
5D

20

RANGER®305G EFI

8B

2B

Oct-13

P-742-E.1

P-742-E.1

# Indicates a change this printing.

Use only the parts marked “x” in the column under the
heading number called for in the model index page.

ITEM DESCRIPTION PART NO. QTY. 123456789

1 Base G3870 1 X X
2A Engine Cross Support L11147-2 1 X X
2B Thread Forming Screw S9225-68 8 X X
4 Fuel Tank & Assembly, Includes: L12164-4 1 X •
4 Fuel Tank & Assembly, Includes: L12164-6 1 • X
4A Fuel Tank NSS 1XX
4B Fuel Sender M20302 1 X X
4C Fuel Fitting Assembly S19565-4 1 X X
4D Rubber Plug S19563 1 X X
4E Remote Vent Valve M22694 1 X X
4F Rubber Plug S28522 1 X X
4G Fuel Cap S28521 1 X X
5 Rectifier, Choke, Stator Support Assembly, Includes: L11135-3 1 X X
5A Stator Support Bracket L11010 1 X X
5B Choke Assembly M19416 1 X X
5C 5/16-18 x 2.50 HHCS CF000187 3 X X
5D Lock Washer E106A-14 3 X X
5E Plain Washer (Not Shown) S9262-121 1 X X
5F 5/16-18 HN (Not Shown) CF000029 3 X X
5G Three Phase Rectifier Assembly L11132-3 1 X X
5H Lock Washer (Not Shown) E106A-14 2 X X
5J Rubber Mounting S24344-1 2 X X
5K 3/8-16 x 2.50 HHB CF000196 2 X X
5L Plain Washer S9262-113 2 X X
5M 3/8-16 HN CF000067 2 X X
5N Thread Forming Screw (Not Shown) S9262-47 4 X X
7 12 Volt Storage Battery (M9399-14) NSS 1XX
8A Battery Bracket S22018 1 X X
8B Carriage Bolt T11827-68 2 X X
8C 1/4-20 HLN (Not Shown) T9187-16 2 X X
9A Battery Cable (Neg.) (Not Shown) S8070-20 1 X X
9B Battery Cable (Pos.) (Not Shown) S8070-11 1 X X
9C Plastic Cap (Not Shown) T14654 1 X X
9D Battery Terminal Cover (Red) (Not Shown) S20191-1 1 X X
10 Fuel Tank Brace G4003-2 1 X X
17A Electric Fuel Pump M20393 1 X X
17B Fuel Pump Bracket S25778 1 X X
17C Thread Forming Screw S9225-68 4 X X
17D Plain Washer S9262-98 2 X X
17E Flex Tube (Supplied w/Engine) * 1XX
17F Flex Tube T10642-275 2 X X
17G Fuel Filter (Supplied w/Engine) * 1XX
17H Hose Clamp T13777-7 4 X X
20 EPA Compliance Decal NSS 1XX

NSS - Not Sold Separately
* Contact Engine Manufacturer

RANGER

®

305G EFI

Jan-14

Engine Assembly

2A

1C

1A

1B

1E

1E

1F

2B

2A

P-742-FP-742-F

1A

2B

1E

1E

1C

1B

1F

RANGER®305G EFI

Oct-13

P-742-F.1

P-742-F.1

# Indicates a change this printing.

Use only the parts marked “x” in the column under the
heading number called for in the model index page.

ITEM DESCRIPTION PART NO. QTY. 123456789

1A Engine - Kohler (M24984) NSS 1X
1B Rubber Mounting S24344 2 X
1C 3/8-16 x 2.50 HHB CF000196 2 X
1D Plain Washer (Not Shown) S9262-120 2 X
1E Plain Washer S9262-47 4 X
1F Lock Washer E106A-16 2 X
1G 3/8-16 HN (Not Shown) CF000067 2 X
2A Muffler Assembly G3574-9 1 X
2B Exhaust Gasket (Supplied w/Engine) * 2X
3A Outlet Pipe Elbow (Not Shown) M16980-1 1 X
3B Spark Arrestor Clamp (Not Shown) S20462 1 X

NSS - Not Sold Separately
* Contact Engine Manufacturer

RANGER

®

305G EFI

Oct-13

Blower Baffle Assembly

7

2

15

4A

16

8A

8C

8D

8E

8F

1

5A

5B

9A

9B

9H

9K

9J

9F

9E

9D

3A

3C

3B

3H

3F

3G

13A

9B

9K

3C

P-742-GP-742-G

3B

3H

8E

8F

9E

9D

16

13A

RANGER®305G EFI

Oct-13

P-742-G.1P-742-G.1

# Indicates a change this printing.

Use only the parts marked “x” in the column under the
heading number called for in the model index page.

ITEM DESCRIPTION PART NO. QTY. 123456789

Blower Baffle Assembly, Includes: G4097-12 1 X
1 Baffle G3862-1 1 X
2 Warning Decal T13086-163 2 X
3A Chopper Board Assembly L11845-[ ] 1 X
3B Baffle S24624 1 X
3C Heat Sink Holder S22168 3 X
3D Thread Forming Screw (Not Shown) S9225-17 3 X
3E Thread Forming Screw (Not Shown) S9225-17 3 X
3F Plain Washer S9262-98 3 X
3G Lock Washer E106A-2 3 X
3H 1/4-20 HN CF000017 3 X
4A Weld Control PC Board Assembly G5507-[ ] 1 X
4B Self Tapping Screw (Not Shown) S8025-100 4 X
5A Capacitor S13490-114 1 X
5B Capacitor Bracket L9250 1 X
7 Bushing T14614-1 2 X
8A Resistor S10404-132 1 X
8B #10-24 x 3 RHS (Not Shown) CF000009 1 X
8C Insulating Washer T4479-A 2 X
8D Plain Washer S9262-27 1 X
8E Lock Washer E106A-1 1 X
8F #10-24 HN CF000010 1 X
9A Resistor S10404-138 1 X
9B Heat Sink Holder S22168 2 X
9C Thread Forming Screw (Not Shown) S9225-17 2 X
9D Plain Washer S9262-98 2 X
9E Lock Washer E106A-2 2 X
9F 1/4-20 HN CF000017 2 X
9G #10-24 x 7.50 RHS (Not Shown) CF000191 1 X
9H Plain Washer S9262-27 2 X
9J Lock Washer E106A-1 1 X
9K #10-24 HN CF000010 1 X
13A Diode Bridge T13637-6 1 X
13B #10-24 x .75 RHS (Not Shown) CF000072 1 X
13C Plain Washer (Not Shown) S9262-27 1 X
13D Lock Washer (Not Shown) E106A-1 1 X
13E #10-24 HN (Not Shown) CF000010 1 X
15 Thread Forming Screw S9225-68 1 X
16 Grommet S18543-5 1 X

Note: When ordering new printed circuit boards indicate the dash number [ ] of the “Old” board

that is to be replaced. This will aid Lincoln in supplying the correct and latest board along
with any necessary jumpers or adapters. The dash number brackets [ ] have purposely
been left blank so as to eliminate errors, confusion and updates.

®

RANGER

305G EFI

Oct-13

Stator/Rotor Assembly

1A

1G

1D

1F

8A

8B

11

10

12

13

9A

4A

7A

5D

5A

5B

5E

5F

1C

1B

1E

7F

4B

4C

5B

7A

4C

4A

P-742-HP-742-H

1A

5D

5A

1C

1B

1E

5F

7F

1F

1G

8A

1D

8B

11

10

9A

12

13

RANGER®305G EFI

Oct-13

P-742-H.1

P-742-H.1

# Indicates a change this printing.

Use only the parts marked “x” in the column under the
heading number called for in the model index page.

ITEM DESCRIPTION PART NO. QTY. 123456789

1A Rotor & Shaft Assembly L11086-2 1 X
1B Centering Washer S20110-3 1 X
1C Special Hex Head Bolt T14843-6 1 X
1D Tolerance Ring S18044-9 1 X
1E Blower L9033 1 X
1F Plain Washer S9262-149 1 X
1G Bearing M9300-85 1 X
4A Firewall G3849-1 1 X
4B Bushing T12380-1 1 X
4C Bushing T12380-6 1 X
5A Brush & Brush Holder Assembly, Includes: M16158 1 X

Brush Holder Cartridge G2114 1 X
Brush Assembly , Includes: S19480 2 X

Brush Clip S19475 2 X
Compression Spring T11862-44 2 X
Brush S19474 2 X

Brush Assembly Retainer M16157 1 X
5B Brush Holder Bracket M18336 1 X
5C Self Tapping Screw (Not Shown) S8025-91 2 X
5D 1/4-20 x 1.00 HHCS CF000015 2 X
5E Lock Washer E106A-2 2 X
5F 1/4-10 HN CF000017 2 X
7A Stator Frame Assembly G3541-7 1 X
7B 3/8-16 x 1.25 HHCS (Not Shown) T8833-10 4 X
7C Lock Washer (Not Shown) E106A-4 4 X
7D Plain Washer (Not Shown) S9262-120 2 X
7E Lock Washer (Not Shown) E106A-16 2 X
7F 3/8-16 HN CF000067 2 X
8A Solenoid Assembly S20752 1 X
8B Self Tapping Screw S8025-91 3 X
9A Pull Wire S20848 1 X
9B Bracket (Not Shown) S21177 1 X
9C Bushing, Linkage Retaining (Not Shown) S21015 2 X
10 Spring T6778 1 X
11 Plunger S21020 1 X
12 Plain Washer S9262-98 1 X
13 1/4-20 HLN T9187-1 1 X
15 Flex Tube (Not Shown) T10642-242 1 X
16 Door Bumper (Not Shown) T14882-1 4 X

RANGER

®

305G EFI

Oct-13

Covers & Case Back Assembly

9A

9B

18

20

14

16

8

7

4B

12

23

4A

24

6B

6A

13

15

6C

21

5A

15

2A

1A

3A

22A

10

19

6F

9B

9A

P-742-JP-742-J

4A

2A

18

15

20

12

19

22A

10

6B

6A

RANGER®305G EFI

Oct-13

P-742-J.1

P-742-J.1

# Indicates a change this printing.

Use only the parts marked “x” in the column under the
heading number called for in the model index page.

ITEM DESCRIPTION PART NO. QTY. 123456789

1A Case Side (Right) G3510 1 X
1B Thread Forming Screw (Not Shown) S9225-68 3 X
2A Case Side (Left) G3511 1 X
2B Thread Forming Screw (Not Shown) S9225-68 3 X
3A Case Back (Includes Item 23) G3865-4 1 X
3B Thread Forming Screw (Not Shown) S9225-68 4 X
3C Fastener Button (Not Shown) T14659-1 2 X
4A Roof G3882-6 1 X
4B Thread Forming Screw S9225-68 16 X
4C Door Bumper (Not Shown) T14882-1 6 X
5A Left Engine Cover L11529-1 1 X
5B Thread Forming Screw (Not Shown) S9225-68 1 X
5C Speed Nut (Not Shown) T11525-5 1 X
6A Right Engine Cover, Includes 6B, 6C & 6E L11528 1 X
6B Latch S24694 1 X
6C Hinge S24348 2 X
6E Rivet (Not Shown) T12584-12 6 X
6F Oil Drain Decal S24665 1 X
7 Fuel Trough L12084 1 X
8 Cover Seal S12934-1 1 X
9A Engine Top Cover Welded Assembly G3514-2 1 X
9B Latch S24694 1 X
9D Door Bumper (Not Shown) T14882 2 X
9E Rivet (Not Shown) T12584-6 2 X
9F Rivet (Not Shown) T12584-12 2 X
10 Battery Caution Decal S17851 1 X
11 Warning Label (Not Shown) M16197 1 X
12 Fuel Warning Decal T13086-108 1 X
13 Wiring Diagram G7774 1 X
14 Warranty Decal Part of L12790-13 1 X
15 Logo Decal S27368-5 2 X
16 Engine Decal S29949 1 X
18 CO Warning Decal M21436 1 X
19 Country of Origin Decal S24727-1 1 X
20 Warning Decal S25896 1 X
21A Hinge Assembly (Right Side) S24295-2 2 X
21B Rivet (Not Shown) T12584-12 4 X
22A Battery Cover M22185 1 X
22B Thread Forming Screw (Not Shown) S9225-68 3 X
23 Airbox M22367 1 X
24 Family Decal M21952-1 2 X
25 Fuel Filling Warning Decal (Not Shown) T13086-215 1 X

RANGER

®

305G EFI

Oct-13

CUSTOMER ASSISTANCE POLICY

The business of The Lincoln Electric Company is manufacturing and
selling high quality welding equipment, consumables, and cutting
equipment. Our challenge is to meet the needs of our customers and
to exceed their expectations. On occasion, purchasers may ask
Lincoln Electric for advice or information about their use of our
products. We respond to our customers based on the best information
in our possession at that time. Lincoln Electric is not in a position to
warrant or guarantee such advice, and assumes no liability, with
respect to such information 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.