Page 2 - SAFETY; WARNING; CALIFORNIA PROPOSITION 65 WARNINGS; The Above For Diesel Engines
FOR ENGINEpowered 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....
Page 3 - ii
ii SAFETY ii ARC RAYS can burn. 4.a. Use a shield with the proper filter and cover plates to protect your eyes from sparks andthe rays of the arc when welding or observingopen arc welding. Headshield and filter lensshould conform to ANSI Z87. I standards. 4.b. Use suitable clothing made from durable...
Page 4 - iii
FOR ELECTRICALLYpowered equipment. 8.a. Turn off input power using the disconnect switch at the fuse box before working onthe equipment. 8.b. Install equipment in accordance with the U.S. National Electrical Code, all local codes and the manufacturer’srecommendations. 8.c. Ground the equipment in ac...
Page 5 - iv; PRÉCAUTIONS DE SÛRETÉ
iv SAFETY iv 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 suiv- antes: Sûreté Pour Soudage A L’Arc 1. Protegez-vous contre la seco...
Page 6 - Thank You; Please Examine Carton and Equipment For Damage Immediately
Thank You for selecting a QUALITY product by Lincoln Electric. We want you to take pride in operating this Lincoln Electric Company product••• as much pride as we have in bringing this product to you! Read this Operators Manual completely before attempting to use this equipment. Save this manual and...
Page 7 - TABLE OF CONTENTS
vi TABLE OF CONTENTS Page Installation .......................................................................................................................Section A Technical Specifications .......................................................................................................A-1 ...
Page 8 - vii
vii TABLE OF CONTENTS Maintenance......................................................................................................Section D Safety Precautions ................................................................................................D-1 Routine Maintenance ...................
Page 9 - INSTALLATION; INPUT - GASOLINE ENGINE
RANGER 305G 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. A-1 INSTALLATION A-1 TECHNICAL SPECIFICATIONS - Ranger 305G (K1726-1) Make/Model Descr...
Page 10 - 5AMP for Battery Charging Circuit
A-2 INSTALLATION RANGER 305G A-2 MACHINE SPECIFICATIONS - Ranger 305G (K1726-1) RECEPTACLES AUXILIARY POWER CIRCUIT BREAKER OTHER CIRCUIT BREAKERS (2) 120VAC Duplex (5-20R) Two 20AMP for Two Duplex Recptacle 25AMP for Battery Charging Circuit (1) 120/240VAC Dual Voltage Two 50AMP for Dual Voltage 15...
Page 11 - ADDITIONAL SAFETY PRECAUTIONS; Design capacity of trailer vs. weight of Lincoln equipment and; SAFETY PRECAUTIONS; LOCATION AND VENTILATION; RANGER 305G machines cannot be stacked.; S e e a d d i t i o n a l w a r n i n g i n f o r m a t i o n a t
A-3 INSTALLATION RANGER 305G A-3 LIFTING The RANGER 305G weighs approximately 530 lbs.with a full tank of gasoline. A lift bail is mounted to themachine and should always be used when lifting themachine. ADDITIONAL SAFETY PRECAUTIONS FALLING EQUIPMENT can cause injury. • Do not lift this machine usi...
Page 12 - USE GASOLINE FUEL ONLY; CAUTION
A-4 INSTALLATION RANGER 305G A-4 PRE-OPERATION ENGINE SERVICE READ the engine operating and maintenance instruc-tions 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 over- fill. • Wipe up spilled fuel...
Page 13 - NOTE; ELECTRICAL CONNECTIONS; MACHINE GROUNDING; • Be grounded to the frame of the welder using a; WELDING TERMINALS; CABLE INSTALLATION; TOTAL COMBINED LENGTH OF; Cable Length
A-5 INSTALLATION RANGER 305G A-5 The 14 pin connector is used to directly connect awire feeder or TIG Module (K930-2) control cable. Inthe CV-WIRE mode, the RANGER 305G auto-sensingc i r c u i t a u t o m a t i c a l l y m a k e s t h e R A N G E R 3 0 5 GOutput Control inactive and the wire feeder ...
Page 14 - • Loose connections will cause the output termi-; AUXILIARY POWER RECEPTACLES; The 240 V receptacle has two 120 V circuits,; STANDBY POWER CONNECTIONS; • I n s t a l l t h e d o u b l e - p o l e , d o u b l e - t h r o w s w i t c h
A-6 INSTALLATION RANGER 305G A-6 • Loose connections will cause the output termi- nals to overheat. The terminals may eventuallymelt. • Do not cross the welding cables at the output terminal connection. Keep the cables isolatedand separate from one another. ------------------------------------------...
Page 15 - CONNECTION OF RANGER 305G TO PREMISES WIRING
A-7 INSTALLATION RANGER 305G A-7 240 Volt 60 Hz. 3-Wire Service POWER COMPANY METER 240 VOLT 120 VOLT 120 VOLT LOAD N NEUTRALBUS GROUND PREMISES DISCONNECT AND SERVICE OVERCURRENT PROTECTION GND N NOTE: No. 6 COPPER CONDUCTOR CABLE SEE NATIONAL ELECTRICAL CODE FOR ALTERNATE WIRE SIZE RECOMMENDATIONS...
Page 16 - Connection of the LN-25 to the RANGER 305G
A-8 INSTALLATION RANGER 305G A-8 C O N N E C T I O N O F L I N C O L N E L E C T R I CWIRE FEEDERS Connection of the LN-25 to the RANGER 305G Shut off welder before making any electrical con-nections.------------------------------------------------------------------------ The LN-25 with or without a...
Page 17 - OPERATION; GENERAL DESCRIPTION; ENGINE OPERATION
B-1 OPERATION RANGER 305G B-1 SAFETY PRECAUTIONS Do not attempt to use this equipment until youhave thoroughly read the engine manufacturer ’ s manual supplied with your welder. It includesi m p o r t a n t s a f e t y p r e c a u t i o n s , d e t a i l e d e n g i n estarting, operating and mainte...
Page 18 - DIGITAL OUTPUT METERS
B-2 OPERATION B-2 WELDING CONTROLS1. OUTPUT CONTROL: The CONTROL dial provides continuous control of thewelding current or welding voltage depending on theselected welding mode. This control is not active in theCC-STICK, PIPE, and CV-WIRE modes when a remotecontrol or wire feeder with remote control...
Page 19 - START PUSH BUTTON
B-3 OPERATION B-3 5 . W E L D O U T P U T T E R M I N A L S W I T HFLANGE NUT: Provides a connection point for the electrode andwork cables. 6. GROUND STUD: (graphic) P r o v i d e s a c o n n e c t i o n p o i n t f o r c o n n e c t i n g t h emachine case to earth ground for the safest groundingp...
Page 20 - • The engine will run at high idle speed for approxi-; : When starting a RANGER 305G for the first; STOPPING; A fuel shut off valve is not required on the; WELDER OPERATION; Stick Welding; TYPICAL RANGER 305G FUEL CONSUMPTION; Running Time for
B-4 OPERATION B-4 • The engine will run at high idle speed for approxi- mately 12 seconds and then go to low idle speed.Allow the engine to warm up at low idle for severalminutes before applying a load and/or switching tohigh idle. Allow a longer warm up time in cold weath-er. Operating the starter ...
Page 21 - TIG Welding; • Set the MODE Switch to the TOUCH START TIG; TYPICAL CURRENT RANGES
B-5 OPERATION B-5 TIG Welding The TOUCH START TIG setting of the MODE switch isfor DC TIG (Tungsten Inert Gas) welding. To initiate aweld, the CONTROL dial is first set to the desired cur-rent and the tungsten is touched to the work. Duringthe time the tungsten is touching the work there is verylitt...
Page 22 - ARC GOUGING
Permissible Current in @120 VAC * 80**60**46** 3620 0 B-6 OPERATION B-6 ARC GOUGING The RANGER 305G can be used for limited arc goug-ing. For optimal performance, set the MODE switch toCC-STICK and the ARC CONTROL to +10. Set the CONTROL knob to adjust output current to thedesired level for the goug...
Page 23 - ACCESSORIES; For moving by hand at construction sites.; K1745-1 SINGLE GAS CYLINDER HOLDER; Mounts inside exhaust pipe.; REMOTE
C-1 ACCESSORIES C-1 OPTIONS/ACCESSORIES AND COM-PATIBLE LINCOLN EQUIPMENT K957-1 HEAVY DUTY, TWO WHEEL TRAILER FORSMALL WELDERS F o r r o a d , o f f - r o a d a n d i n - p l a n t a n d y a r d t o w i n g .(For highway use, consult applicable federal, state andlocal laws regarding requirements fo...
Page 24 - MAINTENANCE; KOHLER ENGINE; Have qualified personnel do all maintenance
D-1 MAINTENANCE D-1 RANGER 305G KOHLER ENGINE (1) Service more frequently when used in dusty areas and/or at high ambient temperatures. • Have qualified personnel do all maintenance and troubleshooting work. • Turn the engine off before working inside the machine or servicing the engine. • R e m o v...
Page 25 - Engine Oil Change; Engine; Air Pre-cleaner Service
D-2 MAINTENANCE D-2 Engine Oil Change Drain the oil while the engine is warm to assure rapidand complete draining. • Remove the oil filler cap and dipstick. Remove the yellow cap from the oil drain valve and attach theflexible drain tube supplied with the machine. Pushin and twist the drain valve co...
Page 26 - AIR FILTER PAPER ELEMENT; SPARK PLUG; Spark Plug Service
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 elem...
Page 27 - FUEL FILTER; • Check the fuel filter for water accumulation or sedi-; ENGINE ADJUSTMENT; OVERSPEED IS HAZARDOUS; Clean every 100 hours.; MUFFLER MAY BE HOT
D-4 MAINTENANCE D-4 FUEL FILTER • Check the fuel filter for water accumulation or sedi- ment. • Replace the fuel filter if it is found with excessive water accumulation or sediment. ENGINE ADJUSTMENT Adjustments to the engine are to be made only by aLincoln Service Center or an authorized Field Serv...
Page 28 - Welder/Generator Maintenance; Store the RANGER 305G in clean, dry; BRUSH REMOVAL AND REPLACEMENT:
D-5 MAINTENANCE D-5 RANGER 305G 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 aweek in particularly dirty areas. BRUSH REMOVAL AND REPLACEMENT: It’s ...
Page 29 - TROUBLESHOOTING; Local Lincoln Authorized Field Service Facility; for technical troubleshooting assistance before you proceed.; Step 3. RECOMMENDED COURSE OF ACTION; HOW TO USE TROUBLESHOOTING GUIDE
E-1 TROUBLESHOOTING E-1 RANGER 305G 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 This Troubleshooting Gu...
Page 30 - PROBLEMS; C o n t a c t y o u r l o c a l L i n c o l n
E-2 TROUBLESHOOTING E-2 RANGER 305G Observe all Safety Guidelines detailed throughout this manual 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 ...
Page 31 - Observe all Safety Guidelines detailed throughout this manual; P o o r w o r k l e a d c o n n e c t i o n t o
E-3 TROUBLESHOOTING E-3 RANGER 305G Observe all Safety Guidelines detailed throughout this manual 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 ...
Page 33 - M a k e s u r e t h e M O D E s e l e c t o r; Contact
E-5 TROUBLESHOOTING E-5 RANGER 305G Observe all Safety Guidelines detailed throughout this manual 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 ...
Page 34 - DIAGRAMS
Page 39 - ARN; INE
F-6 DIAGRAMS F-6 RANGER 305G o r s e rvice t his e q u ip m e n t. O n ly qualified pe rs onne l s hou ld ins tall, u s e Keep aw ay from m ovi ng pa rt s . Keep gua rd s in p lac e. MO VING PART S ca n injure W ARN ING Do not touch e lectricall y liv e pa rt s . be fo re s e rvici ng. Disconnect NE...
Page 45 - ram for a particular code is pasted inside; RANGER 3
F-12 DIAGRAMS F-12 RANGER 305G NOTE: This diagram is for reference only. It may not be accurate for all machines covered by this manual. The specific diag ram for a particular code is pasted inside the machine on one of the enclosure panels. If the diagram is illegible, write to the Service Departme...
Page 47 - DIMENSION
3-2000 M19410 41.20 17 .5 0 19 .5 0 42 .1 0 20.80 " A" " B" CENTER OF GRAVITY WITH OIL IN ENGINE AND EMPTY FUEL TANK 29 .8 8 33.6 2 36.24 10 .2 8 10.78 TRU CK/UNDER CARRIAGE MOUNTING HO LES 7.2 2 24.86 2.6 F-14 DIAGRAMS F-14 RANGER 305G DIMENSION PRINT RANGER 305G DIMENSION “ A ” DIM...
Page 48 - NOTES
Page 49 - Lincoln Welding School; BASIC COURSE; weeks of fundamentals
Now Available...12th Edition The Procedure Handbook of Arc Welding With over 500,000 copies of previous editions published since 1933, the Procedure Handbook is considered by many to be the “Bible” of the arc welding industry. T h i s p r i n t i n g w i l l g o f a s t s o d o n ’ t d e l a y . P l...
Page 50 - ÇÃ
WARNING AVISO DE PRECAUCION ATTENTION WARNUNG ATEN ÇÃ O Spanish French German Portuguese Japanese Chinese Korean Arabic READ AND UNDERSTAND THE MANUFACTURER’S INSTRUCTION FOR THIS EQUIPMENT AND THE CONSUMABLES TO BEUSED AND FOLLOW YOUR EMPLOYER’S SAFETY PRACTICES. SE RECOMIENDA LEER Y ENTENDER LAS I...
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