Lincoln Electric RANGER IM742-A, RANGER 305 G Operator's Manual

Page 1

RANGER 305

IM742-A

For use with machines having Code Numbers:

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.

10855,10955

August, 2002

Date of Purchase: Serial Number: Code Number: Model: Where Purchased:

OPERATOR’S MANUAL

• World's Leader in Welding and Cutting Products •

• Sales and Service through Subsidiaries and Distributors Worldwide •

Cleveland, Ohio 44117-1199 U.S.A. TEL: 216.481.8100 FAX: 216.486.1751 WEB SITE: www.lincolnelectric.com

Page 2

SAFETY

WARNING

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 Above For Diesel Engines

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.

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

The Above For Gasoline Engines

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.

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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.

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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.

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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.

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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.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

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.

___________________________________________________

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.

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.

Mar ‘95

Page 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.

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 below Threshold Limit Values (TLV) 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.

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 between the 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.

3.j. Also see Items 6.c. and 8.

5.b.

Do not weld in locations near chlorinated hydrocarbon 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 outher irritating products.

5.c. Shielding gases used for arc welding can displace air and cause injury or death. Always use enough ventilation, especially in confined areas, to insure breathing air is safe.

5.d. 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.e. Also see item 1.b.

vapors

Mar ‘95

Page 4

iii

SAFETY

iii

WELDING 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.

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 been “cleaned”. For information, purchase “Recommended Safe Practices for the 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.

Sparks and spatter are thrown from the welding arc. Wear oil

6.f. 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.

Remember that welding sparks and hot

though

they have

Preparation

for Welding and Cutting of

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.

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

Mar ‘95

Page 5

SAFETY

PRÉCAUTIONS DE SÛRETÉ

Pour votre propre protection lire et observer toutes les instructions et les précautions de sûreté specifiques qui parraissent dans ce manuel aussi bien que les précautions de sûreté générales suivantes:

Sûreté Pour Soudage A L’Arc

1. Protegez-vous contre la secousse électrique:

a. Les circuits à l’électrode et à la piéce sont sous tension

quand la machine à souder est en marche. Eviter toujours tout contact entre les parties sous tension et la peau nue ou les vétements mouillés. Porter des gants secs et sans trous pour isoler les mains.

b. Faire trés attention de bien s’isoler de la masse quand on

soude dans des endroits humides, ou sur un plancher metallique ou des grilles metalliques, principalement dans les positions assis ou couché pour lesquelles une grande partie du corps peut être en contact avec la masse.

c. Maintenir le porte-électrode, la pince de masse, le câble

de soudage et la machine à souder en bon et sûr état defonctionnement.

d.Ne jamais plonger le porte-électrode dans l’eau pour le

refroidir.

e. Ne jamais toucher simultanément les parties sous tension

des porte-électrodes connectés à deux machines à souder parce que la tension entre les deux pinces peut être le total de la tension à vide des deux machines.

f. Si on utilise la machine à souder comme une source de

courant pour soudage semi-automatique, ces precautions pour le porte-électrode s’applicuent aussi au pistolet de soudage.

zones où l’on pique le laitier.

6. Eloigner les matériaux inflammables ou les recouvrir afin de prévenir tout risque d’incendie dû aux étincelles.

7. Quand on ne soude pas, poser la pince à une endroit isolé de la masse. Un court-circuit accidental peut provoquer un échauffement et un risque d’incendie.

8. S’assurer que la masse est connectée le plus prés possible de la zone de travail qu’il est pratique de le faire. Si on place la masse sur la charpente de la construction ou d’autres endroits éloignés de la zone de travail, on augmente le risque de voir passer le courant de soudage par les chaines de levage, câbles de grue, ou autres circuits. Cela peut provoquer des risques d’incendie ou d’echauffement des chaines et des câbles jusqu’à ce qu’ils se rompent.

9. Assurer une ventilation suffisante dans la zone de soudage. Ceci est particuliérement important pour le soudage de tôles galvanisées plombées, ou cadmiées ou tout autre métal qui produit des fumeés toxiques.

10. Ne pas souder en présence de vapeurs de chlore provenant d’opérations de dégraissage, nettoyage ou pistolage. La chaleur ou les rayons de l’arc peuvent réagir avec les vapeurs du solvant pour produire du phosgéne (gas fortement toxique) ou autres produits irritants.

11. Pour obtenir de plus amples renseignements sur la sûreté, voir le code “Code for safety in welding and cutting” CSA Standard W 117.2-1974.

2. Dans le cas de travail au dessus du niveau du sol, se protéger contre les chutes dans le cas ou on recoit un choc. Ne jamais enrouler le câble-électrode autour de n’importe quelle partie du corps.

3. Un coup d’arc peut être plus sévère qu’un coup de soliel, donc:

a. Utiliser un bon masque avec un verre filtrant approprié

ainsi qu’un verre blanc afin de se protéger les yeux du rayonnement de l’arc et des projections quand on soude ou quand on regarde l’arc.

b. Porter des vêtements convenables afin de protéger la

peau de soudeur et des aides contre le rayonnement de l‘arc.

c. Protéger l’autre personnel travaillant à proximité au

soudage à l’aide d’écrans appropriés et non-inflammables.

4. Des gouttes de laitier en fusion sont émises de l’arc de soudage. Se protéger avec des vêtements de protection libres de l’huile, tels que les gants en cuir, chemise épaisse, pantalons sans revers, et chaussures montantes.

5. Toujours porter des lunettes de sécurité dans la zone de soudage. Utiliser des lunettes avec écrans lateraux dans les

PRÉCAUTIONS DE SÛRETÉ POUR LES MACHINES À SOUDER À TRANSFORMATEUR ET À REDRESSEUR

1. Relier à la terre le chassis du poste conformement au code de l’électricité et aux recommendations du fabricant. Le dispositif de montage ou la piece à souder doit être branché à une bonne mise à la terre.

2. Autant que possible, I’installation et l’entretien du poste seront effectués par un électricien qualifié.

3. Avant de faires des travaux à l’interieur de poste, la debrancher à l’interrupteur à la boite de fusibles.

4. Garder tous les couvercles et dispositifs de sûreté à leur place.

Mar. ‘93

Page 6

for selecting a QUALITY product by Lincoln Electric. We want you

Thank You

to take pride in operating this Lincoln Electric Company product

••• as much pride as we have in bringing this product to you!

Please Examine Carton and Equipment For Damage Immediately

When this equipment is shipped, title passes to the purchaser upon receipt by the carrier. Consequently, Claims for material damaged in shipment must be made by the purchaser against the transportation company at the time the shipment is received.

Please record your equipment identification information below for future reference. This information can be found on your machine nameplate.

Model Name & Number _____________________________________

Code & Serial Number _____________________________________

Date of Purchase _____________________________________

Whenever you request replacement parts for or information on this equipment always supply the information you have recorded above.

Read this Operators Manual completely before attempting to use this equipment. Save this manual and keep it

handy for quick reference. Pay particular attention to the safety instructions we have provided for your protection. The level of seriousness to be applied to each is explained below:

WARNING

This statement appears where the information must be followed exactly to avoid serious personal injury or loss of life.

CAUTION

This statement appears where the information must be followed to avoid minor personal injury or damage to this equipment.

Page 7

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

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

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

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

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

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

Muffler Outlet Pipe ........................................................................................................A-4

Spark Arrester ...............................................................................................................A-4

High Frequency Generators for Tig Applications ..........................................................A-4

Remote Control .............................................................................................................A-4

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

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

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

Welding Output Cables .................................................................................................A-5

Cable Installation...........................................................................................................A-5

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

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

Premises Wiring ...................................................................................................................A-7

Connection of Lincoln Electric Wire Feeders .......................................................................A-8

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

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

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

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 PowerLoads........................................................B-6

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

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

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

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

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

Page 8

vii

TABLE OF CONTENTS

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

Engine 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 Print ......................................................................Section F

Parts List..................................................................................................................P384

Page 9

A-1

INSTALLATION

TECHNICAL SPECIFICATIONS - Ranger 305G (K1726-1)

INPUT - GASOLINE ENGINE

Make/Model Description Speed (RPM) Displacement Starting Capacities

cu. in. (cu. cm.) System

A-1

Kohler CH22 Starter 45.4 L

(K1726-1) 22 HP @

2 cylinder High Idle 3700 41(674)

Bore x Stroke inch (mm)

3600 RPM Full Load 3500 cold crank amps) 1.9 L

3.03 x 2.85 (77 x 72) Battery Charger

12VDC Battery &

(Group 58; 435 Oil: 2.0 Qts

Fuel: 12 gal.

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 ------- 80 Volts 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

10,000 Watts Peak, 9500 Watts Continuous, 60 Hz

120/240 Volts

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 Mechanical Governor with Full Flow Filter 5% Regulation

AIR CLEANER ENGINE IDLER MUFFLER ENGINE PROTECTION

Low noise Muffler: Top outlet Shutdown on low oil

Duel 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

Page 10

A-2

INSTALLATION

MACHINE SPECIFICATIONS - Ranger 305G (K1726-1)

RECEPTACLES AUXILIARY POWER CIRCUIT BREAKER OTHER CIRCUIT BREAKERS

A-2

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

Full KVA (14-50R)

25AMP for Battery Charging Circuit 15AMP for 42V Wire Feeder Power

RANGER 305G

Page 11

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.

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

ENGINE EXHAUST can kill.

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

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

MOVING PARTS can injure.

• Do not operate with doors open or guards off.

• Stop engine before servicing.

• Keep away from moving parts.

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

See additional warning information at

front of this operator’s manual.

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

LOCATION AND VENTILATION

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 305G machines cannot be stacked.

ANGLE OF OPERATION

Engines are designed to run in the level condition which is where the optimum performance is achieved. The maximum angle of continuous operation is 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.

A-3

LIFTING

The RANGER 305G weighs approximately 530 lbs. with a full tank of gasoline. A lift bail is mounted to the machine and should always be used when lifting the machine.

ADDITIONAL SAFETY PRECAUTIONS

WARNING

FALLING EQUIPMENT can cause injury.

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

• Lift only with equipment of adequate lifting capacity.

• Be sure machine is stable when lifting.

-----------------------------------------------------------------------HIGH ALTITUDE OPERATION

At higher altitudes, output de-rating may be necessary. For maximum rating, de-rate the welder output 3.5% for every 1000 ft. (305m). Contact an authorized engine service shop for modifications to operate above 5,000 ft. (1525m).

HIGH TEMPERATURE OPERATION

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

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 weld-

ing 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.

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.

(1)

RANGER 305G

Page 12

A-4

INSTALLATION

A-4

PRE-OPERATION ENGINE SERVICE

WARNING

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

• Stop engine and allow to cool before fueling

• Do not smoke when fueling

• Fill fuel tank at a moderate rate and do not overfill.

• Wipe up spilled fuel and allow fumes to clear before starting engine

• Keep sparks and flame away from tank.

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

OIL

The RANGER 305G 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.

FUEL

USE GASOLINE FUEL ONLY

WARNING

• Fill the fuel tank with clean, fresh fuel. The capacity of the fuel tank is 12 gallons (45.4 liters). When the fuel gauge reads empty the tank contains approximately 2 gallons of reserve fuel.

NOTE: The fuel tank is mounted below the engine

so a fuel shutoff valve is not required.

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

ENGINE COOLING SYSTEM

WARNING

The RANGER 305G is shipped with the negative battery cable disconnected. Make certain that the RUNSTOP 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.

NOTE: This machine is furnished with a wet charged battery; if unused for several months, the battery may require a booster charge. Be careful to charge the battery with the correct polarity.

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.

SPARK ARRESTER

Some federal, state or local laws may require that gasoline or diesel engines be equipped with exhaust spark arresters when they are operated in certain locations where unarrested sparks may present a fire hazard. The standard muffler included with this welder does not qualify as a spark arrester. When required by local regulations, a suitable spark arrester, such as the S24647 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 APPLICATIONS

The K930-2 TIG Module is suitable for use with the RANGER 305G. The RANGER 305G and any high frequency generating equipment must be properly grounded. See the K930-2 Operating Manual for completed instructions on installation, operation, and maintenance.

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 (0.6m) 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.

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

REMOTE CONTROL

The RANGER 305G is equipped with a 6 pin and a 14 pin Amphenol 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 K812 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 automatically switches the OUTPUT control from control at the welder to remote control.

RANGER 305G

Page 13

A-5

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 305G auto-sensing circuit automatically makes the RANGER 305G 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.

INSTALLATION

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

A-5

WELDING TERMINALS

The RANGER 305G is equipped with a toggle switch for selecting "hot" welding terminal when in the "WELD TERMINALS ON" position or "cold" welding terminal when in the "REMOTELY CONTROLLED" position.

WELDING OUTPUT CABLES

With the engine off connect the electrode and work cables to the output studs. The welding process 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. (0-30meters)

Cable Size for

305 Amps

100% Duty Cycle

1 / 0 AWG

• 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 securely connected to the metal 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.

100-150 Ft. (30-46m meters)

150-200 Ft. (46-61 meters)

CABLE INSTALLATION

Install the welding cables to your RANGER 305G as follows.

1. The gasoline 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.

2 / 0 AWG

3 / 0 AWG

RANGER 305G

Page 14

A-6

INSTALLATION

CAUTION

• Loose connections will cause the output terminals 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 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 auxiliary power capacity is 10,000 watts Peak, 9500 Watts Continuous of 60 Hz, single phase power. The auxiliary power capacity rating in watts is equivalent to volt-amperes at unity power factor. The max permissible current of the 240 VAC output is 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.

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.

A-6

STANDBY POWER CONNECTIONS

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

The RANGER 305G can be permanently installed as a standby power unit for 240 VAC, 3 wire, single phase, 40 amp service. Connections must be made by a licensed electrician who can determine how the 120/240 VAC power can be adapted to the particular installation and comply with all applicable electrical codes.

• 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 305G by installing a 40 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 305G engine and/or alternator windings.

• 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.)

NOTE: The 240 V receptacle has two 120 V circuits, but are of opposite polarities and cannot be paralleled.

• Plug this cable into the 50 Amp, 120/240 Volt receptacle on the RANGER 305G case front.

RANGER 305G

Page 15

A-7

240 Volt

60 Hz.

3-Wire

Service

INSTALLATION

CONNECTION OF RANGER 305G 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

40AMP

240 VOLT

GROUNDED CONDUCTOR

NEUTRAL BUS

GROUND

A-7

PREMISES

DISCONNECT AND

SERVICE

OVERCURRENT

PROTECTION

LOAD

DOUBLE

50 AMP, 120/240

VOLT PLUG

NEMA TYPE 14-50

240 VOLT

50 AMP, 120/240 VOLT

RECEPTACLE

POLE

CIRCUIT

BREAKER

GND

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

Page 16

A-8

INSTALLATION

A-8

CONNECTION OF LINCOLN ELECTRIC WIRE FEEDERS

Connection of the LN-25 to the RANGER 305G

WARNING

Shut off welder before making any electrical connections.

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

The LN-25 with or without an external contactor may be used with the RANGER 305G. See the appropriate connection diagram in Section F.

NOTE: The LN-25 (K431) Remote Control Module

and (K432) Remote Cable are not recommended for use with the RANGER 305G.

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.

7. Set the "IDLE" switch to the "AUTO" position. When not welding, the RANGER 305G 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 sensing circuit will cause the RANGER 305G 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.

CAUTION

If you are using an LN-25 without an internal contactor, the electrode will be energized when the Ranger 305G is started.

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

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 an LN-23P Wire Feeder to the RANGER 305G

1. Shut the welder off.

2. Connect the LN-23P as per instructions on the appropriate connection diagram in Section F. (NOTE): When connecting an LN-23P to the RANGER 305G, a K350-1 adapter kit must be used.

3. Set the "VOLTMETER" switch to "-".

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

5. Set the "WELD TERMINALS" switch to "REMOTELY CONTROLLED".

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

7. Set the "IDLE" switch to the "AUTO" position. When not welding, the RANGER 305G engine will be at the low idle speed. If you are using an LN23P with the K350-1 adapter kit, the electrode is not energized until the gun trigger is closed. When the gun trigger is closed, the current sensing circuit will cause the RANGER 305G engine to go to the high idle speed, the wire will begin to feed and the welding process can be started. When welding is stopped, the engine will revert to low idle speed after approximately 12 seconds unless welding is resumed.

Connection of LN-742, Spool Gun, and Cobramatic to RANGER 305G

1. Shut the welder off.

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

RANGER 305G

Page 17

B-1 SAFETY PRECAUTIONS

OPERATION

ENGINE OPERATION

Before Starting the Engine:

B-1

WARNING

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

ELECTRIC SHOCK can kill.

• Do not touch electrically live parts or

electrode with skin or wet clothing.

• Insulate yourself from work and

ground

• Always wear dry insulating gloves.

• Always operate the welder with the hinged door

closed and the side panels in place.

• Read carefully the Safety Precautions page

before operating this machine. Always follow these and any other safety procedures included in this manual and in the Engine Instruction Manual.

GENERAL DESCRIPTION

The RANGER 305G 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 (CT tm) for superior welding performance.

• 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

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 the tank approximately 4 inches (100mm) from the top of the filler neck to allow for fuel expansion (observe the fuel gauge while filling). DO NOT FILL THE TANK TO THE POINT OF OVERFLOW.

• Replace the fuel cap and tighten securely.

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.

RANGER 305G

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

Page 18

B-2

OPERATION

B-2

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, 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, 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 PIPE CC-STICK TOUCH START TIG

4. ARC CONTROL:

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

CC-STICK, PIPE modes In these modes, the ARC CONTROL knob sets the short circuit current during stick welding (arcforce). 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 a setting at 0.

CV-WIRE mode: In this mode, turning the ARC CONTROL clock wise from –10 (soft) to +10 (crisp) changes the arc from soft and washed-in to crisp and narrow tance control. The proper setting depends on the procedure and operator preference. Start with a setting of 0.

. It acts as an induc-

RANGER 305G

Page 19

B-3

OPERATION

B-3

5. WELD OUTPUT TERMINALS WITH FLANGE NUT:

Provides a connection point for the electrode and work cables.

6. GROUND STUD: (graphic)

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

7. 14 PIN AMPHENOL:

For attaching wire feeder control cables to the RANGER 305G. 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 AMPHENOL:

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-sensing circuit in the RANGER 305G automatically switches the OUTPUT control from control at the welder to remote control . When using the TOUCH START TIG mode with a TIG Module connected to the RANGER 305G, the OUTPUT control on the front of the RANGER 305G is used to set the maximum current range of the CURRENT CONTROL on the TIG Module.

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:

14. IDLER SWITCH- Has two positions as follows:

1) In the HIGH position, the engine runs at the high idle speed controlled by the engine governor.

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

• When switched from HIGH to AUTO or after starting the engine, the engine will operate at full speed for approximately 12 seconds and then go to low idle speed.

• 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.

15. ENGINE ALTERNATOR TROUBLE LIGHT-The engine alternator light is off when battery

charging system is functioning normally. If light turns on, the alternator or the voltage regulator may not be operating correctly. The light may also come on due to the battery not holding a charge. It is normal for the light to come on during shutdown of the engine. The light will remain lit with the meters for a short period of time after the engine has shut down.

16. ENGINE 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

• Remove all plugs connected to the AC power receptacles.

11. RUN/STOP SWITCH

gizes the engine prior to starting. STOP position stops the engine. The oil pressure interlock switch prevents battery drain if the switch is left in the RUN position and the engine is not operating.

- RUN position ener-

12. CHOKE - When pulled out, it closes the choke

valve on the engine carburetor for quick starting.

13. START PUSH BUTTON - Energizes the

starter motor to crank the engine.

• Set IDLER switch to AUTO.

• Set the RUN/STOP switch to RUN.

• Pull the choke to the full out position.

• Press and hold the engine START button until the

engine starts.

• Release the engine START button when the engine

starts.

• Push the choke back in.

RANGER 305G

Page 20

B-4

• The engine will run at high idle speed for approximately 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.

OPERATION

B-4

WELDER OPERATION

Stick Welding

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

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 for the first

time, or after and extended period of time of not operating, it will take longer than normal because the fuel pump has to fill the fuel line and carburetor.

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.

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

RANGER 305G because the fuel tank is mounted below the engine.

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.

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.

Low Idle - No Load 2400 R.P.M. .51 (1.9) 23.5

High Idle - No Load 3700 R.P.M. .83 (3.2) 14.5

DC Weld Output 240 Amps @ 29 Volts 1.39 (5.3) 8.6

DC Weld Output 300 Amps @ 29 Volts 1.53 (5.8) 7.8

Auxiliary Power 9,500 Watts 1.64 (6.2) 7.3

TYPICAL RANGER 305G FUEL CONSUMPTION

Kohler CH22 Running Time for

gal./hr (liters/hr) 12 gallons -(hrs.)

RANGER 305G

Page 21

B-5

OPERATION

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 tungsten is touched to the work. During the time the tungsten is touching the work there is very little voltage or current and in general, no tungsten 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 can be used in a wide variety of DC TIG welding applications. In general the ‘Touch Start’ feature allows contamination free starting without the use of a Hi-frequency unit. If desired, the K930-2 TIG Module can be used with the Ranger 305D. The settings are for reference. Ranger 305G settings when using the K930-2 TIG Module with an Amptrol or Arc Start Switch:

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

• 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

B-5

When using the TIG Module, the OUTPUT control on the Ranger 305G is used to set the maximum range of the CURRENT CONTROL on the TIG module or an Amptrol if connected to the TIG Module.

WIRE WELDING-CV

Connect a wire feeder to the RANGER 305G according to the instructions in INSTALLATION INSTRUCTIONS Section. The RANGER 305G in the CV-WIRE mode, permits it to be used with a broad range of flux cored wire (Innershield and Outershield) electrodes and solid wires for MIG welding (gas metal arc welding). Welding can be finely tuned using the ARC CONTROL. Turning the ARC CONTROL clockwise from –10 (soft) to +10 (crisp) changes the arc from soft and washed-in to crisp and narrow. It acts as an inductance control. The proper setting depends on the procedure and operator preference. Start with the dial set at 0. Some recommended Innershield electrodes are: NR-311, NS-3M, NR-207, NR-203 Ni 1%, NR-204-H.

Recommended Outershield electrodes are:

0S-70, 0S-71M.

Some recommended solid wires for MIG welding are: .035 (0.9 mm), and .045 (1.1 mm), L-50 and L-56, .035 (0.9 mm) and .045 (1.1 mm) Blue Max MIG 308 LS. For any electrodes, including the above recommendations, the procedures should be kept within the rating of the machine.

TYPICAL CURRENT RANGES

Tungsten Electrode DCEN (-) DCEP (+) Approximate Argon Gas Flow TIG TORCH

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

1%, 2% Thoriated 1%, 2% Thoriated Aluminum Stainless 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 1 5-10 (3-5) 9-13 (4-6) #5, #6

3/32 (2.4) 150-250 15-30 1 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 EWTh-1

2% Thoriated EWTh-2

Though not yet recognized by the AWS, Ceriated Tungsten is now widely accepted as a substitute for 2% Thoriated Tungsten in AC and DC applications. (3) DCEP is not commonly used in these sizes. (4) TIG torch nozzle "sizes" are in multiples of 1/16ths of an inch:

(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

Page 22

B-6

OPERATION

ARC GOUGING

The RANGER 305G 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.

Electrode Diameter

1/8" 30-60 Amps

5/32" 90-150 Amps

3/16" 150-250 Amps

1/4" 250-305 Amps

Current Range (DC, electrode

positive)

B-6

The auxiliary power capacity is 10,000 watts Peak, 9500 Watts continuous of 60 Hz, single phase power. The auxiliary power capacity rating in watts is equivalent to volt-amperes at unity power factor. The max permissible current of the 240 VAC output is 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.

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.

RANGER 305G Simultaneous Welding and Power Loads

Permissible Power-Watts

(Unity Power Factor)

9500 7100 5600 4200 2300

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

40 30 75 60

(12)

(9) (23) (18)

Current

(Amps)

15 20 15 20 40

Welding

Output-Amps

0 100 150

200 250 300

* 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 Extension Cord Length Recommendations

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

Voltage

Volts

120 120 240 240 240

Load

(Watts)

1800 2400 3600 4800 9500

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

(9)

(18)

Conductor size is based on manimum 2.0% voltage drop.

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).

Auxiliary

-Amps

@ 240 VAC

40 30

23 18 10

175 138 350 275 150

(53)

(42)

(107)

(84)

(46)

300 225 600 450 225

50 150 100

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

Permissible

Current in

@120 VAC *

80** 60** 46**

36 20

125

88 225 175

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

(91)

(69) (183) (137)

(69)

RANGER 305G

Page 23

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.

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.

K802-N POWER PLUG KIT

Provides four 120 volt plugs rated at 20 amps each and one dual voltage, full KVA plug rated at 120/240 volts, 50 amps.

K802-R 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 casefront (which accepts 4-prong plugs) and converts it to a NEMA 6-50R receptacle, (which accepts 3-prong plugs.)

K1745-1 SINGLE GAS CYLINDER 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.

K1898-1 SPARK ARRESTOR

Mounts inside exhaust pipe.

K702 ACCESSORY KIT

Accessory set includes 35 ft. (10.7 meters) 2 AWG electrode cable, 30 ft. (9.1 meters) 2 AWG work cable, headshield with No. 12 filter, GC300 work clamp and Cooltong 300 electrode holder. Cables are rated at 250 amps, 40% duty cycle.

K857 25 ft (7.5m) or K857-1 100 ft. (30.4m) REMOTE CONTROL

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

RANGER 305G

Page 24

D-1

MAINTENANCE

KOHLER ENGINE

D-1

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

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 Plug Arrester

• Replace oil filter.

• Check spark plug and gap

• Check fuel lines and clamps.

(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 Kohler 1205001, Fram PH3614

Air Filter Element Kohler 4708303, Fram CA79

Air Filter Pre-Cleaner Kohler 2408302

MAKE AND PART NUMBER

KOHLER CH22 ENGINE

Fuel Filter Kohler 2405002, Fram G1

Spark Plug Champion RC12YC (.030" Gap)

Battery BCI Group 58 (435 CCA)

RANGER 305G

Page 25

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 API service classification SG or SH. Always check the API 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, -5 F to 104 F (-20 C to 40 C). For the Onan engine, it is recommended that SAE 30 oil be used above 82 F (27 C). 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.

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.

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.

• Reinstall the pre-cleaner over the paper element.

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

RANGER 305G

Page 26

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

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.

Page 27

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

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.

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 (0.1113 kg) of baking soda and 1 quart (0.9461) of water. Be sure the battery vent plugs (if equipped) are tight so that none of the solution enters the cells. 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 305G positive (+) battery terminal has a red terminal cover.

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.

SERVICING OPTIONAL SPARK ARRESTOR

WARNING

● 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.

• MUFFLER MAY BE HOT

• ALLOW ENGINE TO COOL BEFORE INSTALLING

THE SPARK ARRESTER!

• DO NOT OPERATE ENGINE WHILE INSTALLING THE SPARK ARRESTER!

Clean every 100 hours.

RANGER 305G

Page 28

D-5

MAINTENANCE

Welder/Generator Maintenance

STORAGE: Store the RANGER 305G in clean, dry

protected areas.

CLEANING: Blow out the generator and controls peri-

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

BRUSH REMOVAL AND REPLACEMENT: It’s nor-

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

CAUTION

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

D-5

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.

RANGER 305G

Page 29

E-1

TROUBLESHOOTING

HOW TO USE TROUBLESHOOTING GUIDE

WARNING

__________________________________________________________________________

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.

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.

CAUTION

RANGER 305G

Page 30

E-2

Observe all Safety Guidelines detailed throughout this manual

PROBLEMS

(SYMPTOMS)

TROUBLESHOOTING

POSSIBLE AREAS OF

MISADJUSTMENT(S)

E-2

RECOMMENDED

COURSE OF ACTION

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,

system.

2. Faulty fuel solenoid or faulty PC board or ignition system.

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

Charge Battery

Fill tank and bleed fuel

Change oil and oil filter

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. Open rotor circuit.

Battery does not stay charged. Engine alternator trouble light is on while machine is running.

1. Faulty battery,

2. Loose connections at battery or

alternator. tions.

3. Faulty engine alternator or charg-

er modual.

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

Page 31

E-3

Observe all Safety Guidelines detailed throughout this manual

PROBLEMS

(SYMPTOMS)

TROUBLESHOOTING

POSSIBLE AREAS OF

MISADJUSTMENT(S)

E-3

RECOMMENDED

COURSE OF ACTION

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 auxiliary power. loads.

3. Faulty PC board or idler solenoid.

1. Poor work lead connection to work. Make sure work clamp is tightly metal.

2. "Contactor" switch is in wrong position. 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. with less than a 100 watt load. Set idler to "High".

2. Faulty PC board.

1. Fuel filter clogged,

2. Air filter clogged,

3. Fouled spark plugs, replace.

4. Valves out of adjustment.

Remove all external

connected to clean base

Set to "Welding On" when

Idler may not respond

Replace.

clean or replace.

clean or

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

Contact your local Lincoln Authorized Field Service Facility.

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.

CAUTION

RANGER 305G

Page 32

E-4

Observe all Safety Guidelines detailed throughout this manual

PROBLEMS

(SYMPTOMS)

TROUBLESHOOTING

POSSIBLE AREAS OF

MISADJUSTMENT (S)

E-4

RECOMMENDED

COURSE OF ACTION

No welding power output.

Welder has output but no control.

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

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.

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. Faulty PC board or welder alternator.

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

Page 33

E-5

Observe all Safety Guidelines detailed throughout this manual

PROBLEMS

(SYMPTOMS)

TROUBLESHOOTING

POSSIBLE AREAS OF

MISADJUSTMENT(S)

E-5

RECOMMENDED

COURSE OF ACTION

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.

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.

CAUTION

RANGER 305G

Page 34

F-1

DIAGRAMS

F-1

RANGER 305G

Page 35

F-2

DIAGRAMS

F-2

RANGER 305G

Page 36

F-3

DIAGRAMS

F-3

RANGER 305G

Page 37

F-4

DIAGRAMS

F-4

RANGER 305G

Page 38

F-5

DIAGRAMS

F-5

RANGER 305G

Page 39

F-6

Keep away from moving parts.

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

ENGINE WELDERS /LN-8 CONNECTION DIAGRAM

WARNING

Do not operate with panels open.

Disconnect NEGATIVE (-) Battery lead

ELECTRIC SHOCK can kill

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

Page 40

F-7

DIAGRAMS

F-7

RANGER 305G

Page 41

F-8

DIAGRAMS

F-8

RANGER 305G

Page 42

F-9

DIAGRAMS

F-9

RANGER 305G

Page 43

F-10

DIAGRAMS

F-10

RANGER 305G

Page 44

F-11

DIAGRAMS

F-11

RANGER 305G

Page 45

F-12

DIAGRAMS

F-12

14 Pin

Ampenol

P10-J10

Thermal

Arc Force

P11-J11

76A

77A

75A

250

SHOWN IN

"AUTO" POSITION

215

250

208B

251

215

IDLE SOLENOID

210C

P13-J13

P12-J12

210D

POWER

Sense/

Idler/

PWM

261

101A

260

115A

105A

116A

118A

PCB3 WELD CONTROL PC BOARD

228

229

P34-J34

P43-J43

225

210B

229

224B

211

228

200

210D

PCB4 BATTERY PC BOARD

G3743

PCB7 Battery Display

P54 - J4

P2-J2

S6 MODE SELECTOR SWITCH

Programing

222

(LOCATED BELOW

TERMINAL 2)

TIG

PIPE

220

222

214

218

Machine

Mode

Selection

218

214

220

JUMPER

Meter

Selection

151

M10

PLUG

M10

10K

CCW

OUTPUT CONT. POT

10K

ARC CONTROL

CCW

Shunt

P5 - J5

P6-J6

Meter

151

279

278

277

2 1

206S

204S

279

278

277

251

IDLER CONTROL

CONTACTOR

CONTROL

SHOWN IN

"WELDING ON"

POSITION

Pinch/

P9-J9

Hot Start

Output

Control

P7-J7

M10

M1M2M3

789

123

456

P4 J54

M5M6M9

M1M2M3

M10

M10 M9 M6 M5 M4 M3 M2

AMPS

STATOR

WELD

WINDINGS

D1 - THREE PHASE BRIDGE RECTIFIER

RANGER 305G - WIRING DIAGRAM FOR CODE 10855

789

456

J50

321

HEATSINK

D2 DIODE

PC BOARD TO

HEAT SINK CONN.

POS

NEG

W11

L1 CHOKE

TWISTED PAIR

321

P50

9 PIN

456

789

204S

206S

123

J50

654

987

9 PIN

(VIEWED FROM LEAD SIDE OF RECEPTACL E)

PANEL RECEPTACLE CAVITY NUMBERING SEQUENCE

221E

123

211E

210E

225E

212E

224E

209E

200E

J52

789

456

211

P52

225

M10 M9 M6 M5 M4 M3 M2

VOLTS

W11

P50

987

654

123

300 AMP

MODULE

PC BOARD TO

HEAT SINK CONN.

P41-J41

PCB 1

NEG

221

209

200

224

210

212A

211A

P42-J42

118A

42 VAC

101A

116A

105A

115A

PCB2 ANALOG POWER PC BOARD

GND-E 5

200B

GND-J

GND. SCREW ON

CENTER BAFFLE

FIELD WINDING

STATOR AUX. WINDING

211A

212A

210C

START

BUTTON

CB7

25A

212

209

TOP GND. SCREW ON

BOTTOM GND INSIDE CASEFRONT

GND E

GND-L

224

INSIDE OF CASE FRONT

GND-K

221

210

800uf

150vdc

201A

WHITE

FRAME GND.

GND M

GND. SCREW ON LEFT

INSIDE CASEFRONT

200A

POS.BRUSH

201

WHITE

NEG. BRUSH

BLACK

20A

CB1

BLACK

WHITE

J102

SILVER

GND-G

GREEN

GND-D

GND-B

FRAME GND.

GND-A

HOUR METER

224B

224

210A

CND-C

S1RUN-STOP

ROTOR

CB2

J101

209E

SWITCH

(SHOWN IN

RUN POS.)

211E

221E

200E

210E

POSITIVE BRUSH CONNECTED

TO SLIP RING NEAREST

TO THE LAMINATION

BLACK

50A

CB5

CB6

WHITE

BLACK

WHITE

BLACK

115/230V

J100

SILVER

GREEN

210B

GND-B

WRAP TWO TURNS #3 &

#6 LEADS IN DIRECTION

SHOWN THROUGH

TOROID

W10

SHUNT

50MV=400 AMPS

206C

206A

260

208C

261

206B

206A

206B

208

208B

SHOWN IN

POSITIVE (+)

POSITION

SWITCH

POLARITY

VOLTMETER

208A

42 VAC

WIRE FEED POWER

WINDING

41A

CB8

15A

42A

206C

BYPASS

GND-K

FILTER

42A

41A

76B

77B

EFG

208C

ASSEMBLY

115VAC

42VAC

WORK

REMOTE

CONTROL

77A

76A

75A

75B

GND-A

77B

76B

75B

CHB

ABCDE

AMPHENOL 1

REMOTE

GROUND

CONTACTOR

CONTROL

BATTERY

12 VOLT

P51

225E

212E

WHITE

TERM.

CONTACTOR

FRAME

J51 4 3 2 1

ENGINE TERMINAL

BLOCK

224E

GND-B

GROUND

AMPHENOL 2

ENGINE

GROUND

GND J

GND-H

STARTER

CR1

STARTER

SOLENOID

FUEL

SHUTOFF

SOLENOID

R R

B-

REGULATOR

WHITE

FLYWHEEL ALTERNATOR

IGNITION

MODULE

SWITCH

STOPS THE ENGINE

OIL

PRESSURE

GROUNDING THIS CIRCUIT

KOHLER ENGINE COMPONENTS

210E

GREEN

LEAD COLOR CODE:

B=BLACK OR GRAY

R=RED OR PINK

W=WHITE

G=GREEN (W/YELLOW STRIPE)

L2, L3: RF CHOKES

CONNECTORS VIEWED FROM INSERTION END

ELECTRICAL SYMBOLS PER E1537

ALL CASE FRONT COMPONENTS SHOWN VIEWED FROM REAR.

RANGER 305G

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..

Page 46

F-13

DIAGRAMS

P5 - J5

P6-J6

Shunt

2 1

206S

204S

Voltmeter

P4 - J4

Ammeter

M10

151

M10

Output &

Arc Cont.

Mode

Select

P7 - J7

218

220

222

151

277

279

278

P2 - J2

214

Key

210C

215

228

225

P1 - J1

Amphenol,

Model

Select,

Engine &

Battery

Function

200N

229

211

224B

Hot Start

305

210B

76A

75A

77A

Sense/

Idler/

PWM

P3-J3

Key

261

260

251

252

208B

PCB2 WELD CONTROL PC BOARD

A.03

F-13

G4285

M10 M9 M6 M5 M4 M3 M2 M1

VOLTS

STATOR

WELD

WINDINGS

D1 - THREE PHASE BRIDGE RECTIFIER

RANGER 305G - WIRING DIAGRAM FOR CODE 10955

W10

Twisted

Pair

C11

301

C10

HEATSINK

302

TWISTED PAIR

261

260

W10

204S

206S

300 AMP

WRAP TWO TURNS #3 &

SHUNT

MODULE

AMPS

S6 MODE SELECTOR SWITCH

#6 LEADS IN DIRECTION

SHOWN THROUGH

50MV=400 AMPS

M10

10K

M6 M5

M4 M3 M2 M1

(LOCATED BELOW

TERMINAL 2)

PIPE

214

218

W11

TOROID

206A

206B

CCW

OUTPUT CONT. POT

279

10K

278

ARC CONTROL

CCW

277

TIG

220

222

42 VAC

FIELD WINDING

PCB 1

208B

STATOR AUX. WINDING

208A

206C

206A

L1 CHOKE

208C

206B

POLARITY

VOLTMETER

208

WIRE FEED POWER

WINDING

HOUR METER

224B

224

200N

GND-E

GND-N

BOTTOM GND INSIDE CASEFRONT

SHOWN IN

SWITCH

42 VAC

TOP GND. SCREW ON

INSIDE OF CASE FRONT

GND-K

POSITIVE (+)

POSITION

41A

CB8

15A

42A

252

251

SHOWN IN

"AUTO" POSITION

IDLER CONTROL

215 210C

212

IDLE

SOLENOID

200B

FRAME GND.

208C

206C

BYPASS

FILTER

ASSEMBLY

221

200

200A

800uf

150vdc

201

201A

20A

BLACK

WHITE

J102

GND-G

GND-C

GND-D

GND-G

GND-B

GND-N

GND. SCREW ON LEFT

INSIDE CASEFRONT

42A

41A

42VAC

115VAC

211A

229

209

211A

221

BLACK

CB6

BLACK

WHITE

115/230V

WHITE

TERM.

76A

75A

77B

76B

75B

ABCDE

REMOTE

CONTACTOR

CONTROL

228

Battery Charge

Light PL2

ENGINE

BLOCK

GND-H

BATTERY

12 VOLT

J51

P51

225

212A

WHITE

ENGINE TERMINAL

BLOCK

224

STOPS THE ENGINE

GROUNDING THIS CIRCUIT

GND-K

GND. SCREW ON

FAN BAFFLE.

CONTACTOR

CONTROL

GND-B

AMPHENOL 2

GROUND

STARTER

210

STARTER

CR1

SOLENOID

REGULATOR

OIL

GND-J

SHOWN IN

"WELDING ON"

B-

IGNITION

PRESSURE

GND-J

FRAME

GROUND

FUEL

SHUTOFF

SOLENOID

FLYWHEEL ALTERNATOR

MODULE

SWITCH

ENGINE COMPONENTS

POSITION

LEAD COLOR CODE:

B=BLACK OR GRAY

R=RED OR PINK

W=WHITE

L2, L3: RF CHOKES

G=GREEN (W/YELLOW STRIPE)

CONNECTORS VIEWED FROM INSERTION END

ELECTRICAL SYMBOLS PER E1537

ALL CASE FRONT COMPONENTS SHOWN VIEWED FROM REAR.

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..

211

210B

START

BUTTON

210A

210A210

S1RUN-STOP

SWITCH

(SHOWN IN

RUN POS.)

CB7

15A

ROTOR

POSITIVE BRUSH CONNECTED

TO SLIP RING NEAREST

TO THE LAMINATION

BLACK

CB1

GND-D

GND-A

FRAME GND.

77B

EFG

WORK

CB2

20A

50A

CB5

BLACK

WHITE

BLACK

J101

J100

SILVER

GND-C

GND-B

77A

75B

76B

GND-A

CHB

AMPHENOL 1

REMOTE

GROUND

CONTACTOR

CONTROL

RANGER 305G

Page 47

3-2000

M19410

41.20

17.50 19.50

42.10

20.80

"A"

"B"

CENTER OF GRAVITY WITH OIL IN

ENGINE AND EMPTY FUEL TANK

29.88

33.62

36.24

10.28 10.78

TRUCK/UNDERCARRIAGE MOUNTING HOLES

7.22

24.862.6

F-14

DIAGRAMS

F-14

23.50

16.75

DIMENSION “A”

DIMENSION “B”

DIMENSION PRINT RANGER 305G

RANGER 305G

Page 48

NOTES

RANGER 305G

Page 49

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Page 50

WARNING

Spanish

AVISO DE

PRECAUCION

● Do not touch electrically live parts or

electrode with skin or wet clothing.

● Insulate yourself from work and

ground.

● No toque las partes o los electrodos

bajo carga con la piel o ropa mojada.

● Aislese del trabajo y de la tierra.

● Keep flammable materials away.

● Mantenga el material combustible

fuera del área de trabajo.

● Wear eye, ear and body protection.

● Protéjase los ojos, los oídos y el

cuerpo.

French

ATTENTION

German

WARNUNG

Portuguese

ATENÇÃO

Japanese

Chinese

Korean

Arabic

● Ne laissez ni la peau ni des vête-

ments mouillés entrer en contact avec des pièces sous tension.

● Isolez-vous du travail et de la terre.

● Berühren Sie keine stromführenden

Teile oder Elektroden mit Ihrem Körper oder feuchter Kleidung!

● Isolieren Sie sich von den

Elektroden und dem Erdboden!

● Não toque partes elétricas e elec-

trodos com a pele ou roupa molhada.

● Isole-se da peça e terra.

● Gardez à l’écart de tout matériel

inflammable.

● Entfernen Sie brennbarres Material!

● Mantenha inflamáveis bem guarda-

dos.

● Protégez vos yeux, vos oreilles et

votre corps.

● Tragen Sie Augen-, Ohren- und Kör-

perschutz!

● Use proteção para a vista, ouvido e

corpo.

READ AND UNDERSTAND THE MANUFACTURER’S INSTRUCTION FOR THIS EQUIPMENT AND THE CONSUMABLES TO BE USED AND FOLLOW YOUR EMPLOYER’S SAFETY PRACTICES.

SE RECOMIENDA LEER Y ENTENDER LAS INSTRUCCIONES DEL FABRICANTE PARA EL USO DE ESTE EQUIPO Y LOS CONSUMIBLES QUE VA A UTILIZAR, SIGA LAS MEDIDAS DE SEGURIDAD DE SU SUPERVISOR.

LISEZ ET COMPRENEZ LES INSTRUCTIONS DU FABRICANT EN CE QUI REGARDE CET EQUIPMENT ET LES PRODUITS A ETRE EMPLOYES ET SUIVEZ LES PROCEDURES DE SECURITE DE VOTRE EMPLOYEUR.

LESEN SIE UND BEFOLGEN SIE DIE BETRIEBSANLEITUNG DER ANLAGE UND DEN ELEKTRODENEINSATZ DES HERSTELLERS. DIE UNFALLVERHÜTUNGSVORSCHRIFTEN DES ARBEITGEBERS SIND EBENFALLS ZU BEACHTEN.

Page 51

● Keep your head out of fumes.

● Use ventilation or exhaust to

remove fumes from breathing zone.

● Turn power off before servicing.

● Do not operate with panel open or

guards off.

WARNING

● Los humos fuera de la zona de res-

piración.

● Mantenga la cabeza fuera de los

humos. Utilice ventilación o aspiración para gases.

● Gardez la tête à l’écart des fumées.

● Utilisez un ventilateur ou un aspira-

teur pour ôter les fumées des zones de travail.

● Vermeiden Sie das Einatmen von

Schweibrauch!

● Sorgen Sie für gute Be- und

Entlüftung des Arbeitsplatzes!

● Mantenha seu rosto da fumaça.

● Use ventilação e exhaustão para

remover fumo da zona respiratória.

● Desconectar el cable de ali-

mentación de poder de la máquina antes de iniciar cualquier servicio.

● Débranchez le courant avant l’entre-

tien.

● Strom vor Wartungsarbeiten

abschalten! (Netzstrom völlig öffnen; Maschine anhalten!)

● Não opere com as tampas removidas.

● Desligue a corrente antes de fazer

serviço.

● Não toque as partes elétricas nuas.

● No operar con panel abierto o

guardas quitadas.

● N’opérez pas avec les panneaux

ouverts ou avec les dispositifs de protection enlevés.

● Anlage nie ohne Schutzgehäuse

oder Innenschutzverkleidung in Betrieb setzen!

● Mantenha-se afastado das partes

moventes.

● Não opere com os paineis abertos

ou guardas removidas.

Spanish

AVISO DE

PRECAUCION

French

ATTENTION

German

WARNUNG

Portuguese

ATENÇÃO

Japanese

Chinese

Korean

Arabic

LEIA E COMPREENDA AS INSTRUÇÕES DO FABRICANTE PARA ESTE EQUIPAMENTO E AS PARTES DE USO, E SIGA AS PRÁTICAS DE SEGURANÇA DO EMPREGADOR.

Page 52

• World's Leader in Welding and Cutting Products •

• Sales and Service through Subsidiaries and Distributors Worldwide •

Cleveland, Ohio 44117-1199 U.S.A. TEL: 216.481.8100 FAX: 216.486.1751 WEB SITE: www.lincolnelectric.com

Lincoln Electric RANGER IM742-A, RANGER 305 G Operator's Manual

Specifications and Main Features

Frequently Asked Questions

User Manual