RETURN TO MAIN INDEX
IM674
Ranger 305 G August, 2001
10708
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 thought-
ful 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.
Date of Purchase:
Serial Number:
Code Number:
Model:
Where Purchased:
OPERATOR’S MANUAL
Copyright © 2001 Lincoln Global Inc.
� World's Leader in Welding and Cutting Products �
� Sales and Service through Subsidiaries and Distributors Worldwide �
Cleveland, Ohio 44117-1199 U.S.A. TEL: 216.481.8100 FAX: 216.486.1751 WEB SITE: www.lincolnelectric.com
i i
SAFETY
WARNING
CALIFORNIA PROPOSITION 65 WARNINGS
The engine exhaust from this product contains
Diesel engine exhaust and some of its constituents
chemicals known to the State of California to cause
are known to the State of California to cause can-
cancer, birth defects, or other reproductive harm.
cer, birth defects, and other reproductive harm.
The Above For Gasoline Engines
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.
FOR ENGINE 1.h. To avoid scalding, do not remove the
radiator pressure cap when the engine is
powered equipment. hot.
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.
ELECTRIC AND
MAGNETIC FIELDS
____________________________________________________
may be dangerous
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 2.a. Electric current flowing through any conductor causes
refueling to prevent spilled fuel from vaporiz- localized Electric and Magnetic Fields (EMF). Welding
ing on contact with hot engine parts and current creates EMF fields around welding cables and
igniting. Do not spill fuel when filling tank. If welding machines
fuel is spilled, wipe it up and do not start
engine until fumes have been eliminated. 2.b. EMF fields may interfere with some pacemakers, and
____________________________________________________ welders having a pacemaker should consult their physician
1.d. Keep all equipment safety guards, covers and devices in before welding.
position and in good repair.Keep hands, hair, clothing and
tools away from V-belts, gears, fans and all other moving 2.c. Exposure to EMF fields in welding may have other health
parts when starting, operating or repairing equipment. effects which are now not known.
____________________________________________________
2.d. All welders should use the following procedures in order to
1.e. In some cases it may be necessary to remove safety
minimize exposure to EMF fields from the welding circuit:
guards to perform required maintenance. Remove
guards only when necessary and replace them when the
2.d.1. Route the electrode and work cables together - Secure
maintenance requiring their removal is complete.
them with tape when possible.
Always use the greatest care when working near moving
parts.
2.d.2. Never coil the electrode lead around your body.
___________________________________________________
1.f. Do not put your hands near the engine fan.
Do not attempt to override the governor or 2.d.3. Do not place your body between the electrode and
idler by pushing on the throttle control rods work cables. If the electrode cable is on your right
while the engine is running. side, the work cable should also be on your right side.
2.d.4. Connect the work cable to the workpiece as close as
possible to the area being welded.
___________________________________________________
1.g. To prevent accidentally starting gasoline engines while 2.d.5. Do not work next to welding power source.
turning the engine or welding generator during maintenance
work, disconnect the spark plug wires, distributor cap or
magneto wire as appropriate. Mar �95
ii ii
SAFETY
ARC RAYS can burn.
ELECTRIC SHOCK can
4.a. Use a shield with the proper filter and cover
kill. plates to protect your eyes from sparks and
3.a. The electrode and work (or ground) circuits
the rays of the arc when welding or observing
are electrically “hot� when the welder is on. open arc welding. Headshield and filter lens
Do not touch these “hot� parts with your bare should conform to ANSI Z87. I standards.
skin or wet clothing. Wear dry, hole-free
gloves to insulate hands. 4.b. Use suitable clothing made from durable flame-resistant
material to protect your skin and that of your helpers from
3.b. Insulate yourself from work and ground using dry insulation. the arc rays.
Make certain the insulation is large enough to cover your full
area of physical contact with work and ground. 4.c. Protect other nearby personnel with suitable, non-flammable
screening and/or warn them not to watch the arc nor expose
In addition to the normal safety precautions, if welding themselves to the arc rays or to hot spatter or metal.
must be performed under electrically hazardous
conditions (in damp locations or while wearing wet
FUMES AND GASES
clothing; on metal structures such as floors, gratings or
scaffolds; when in cramped positions such as sitting,
can be dangerous.
kneeling or lying, if there is a high risk of unavoidable or
accidental contact with the workpiece or ground) use 5.a. Welding may produce fumes and gases
the following equipment: hazardous to health. Avoid breathing these
� Semiautomatic DC Constant Voltage (Wire) Welder. fumes and gases.When welding, keep
� DC Manual (Stick) Welder. your head out of the fume. Use enough
� AC Welder with Reduced Voltage Control. ventilation and/or exhaust at the arc to keep
fumes and gases away from the breathing zone. When
3.c. In semiautomatic or automatic wire welding, the electrode, welding with electrodes which require special
electrode reel, welding head, nozzle or semiautomatic ventilation such as stainless or hard facing (see
welding gun are also electrically “hot�. instructions on container or MSDS) or on lead or
cadmium plated steel and other metals or coatings
3.d. Always be sure the work cable makes a good electrical which produce highly toxic fumes, keep exposure as
connection with the metal being welded. The connection low as possible and below Threshold Limit Values (TLV)
should be as close as possible to the area being welded. using local exhaust or mechanical ventilation. In
confined spaces or in some circumstances, outdoors, a
3.e. Ground the work or metal to be welded to a good electrical respirator may be required. Additional precautions are
(earth) ground. also required when welding on galvanized steel.
5.b. Do not weld in locations near chlorinated hydrocarbon vapors
3.f. Maintain the electrode holder, work clamp, welding cable and
coming from degreasing, cleaning or spraying operations.
welding machine in good, safe operating condition. Replace
The heat and rays of the arc can react with solvent vapors to
damaged insulation.
form phosgene, a highly toxic gas, and outher irritating pro-
ducts.
3.g. Never dip the electrode in water for cooling.
5.c. Shielding gases used for arc welding can displace air and
3.h. Never simultaneously touch electrically “hot� parts of
cause injury or death. Always use enough ventilation,
electrode holders connected to two welders because voltage
especially in confined areas, to insure breathing air is safe.
between the two can be the total of the open circuit voltage
of both welders.
5.d. Read and understand the manufacturer’s instructions for this
equipment and the consumables to be used, including the
3.i. When working above floor level, use a safety belt to protect
material safety data sheet (MSDS) and follow your
yourself from a fall should you get a shock.
employer’s safety practices. MSDS forms are available from
your welding distributor or from the manufacturer.
3.j. Also see Items 6.c. and 8.
5.e. Also see item 1.b.
Mar �95
iii iii
SAFETY
WELDING SPARKS can CYLINDER may explode
cause fire or explosion. if damaged.
6.a. Remove fire hazards from the welding area.
7.a. Use only compressed gas cylinders
If this is not possible, cover them to prevent
containing the correct shielding gas for the
the welding sparks from starting a fire.
process used and properly operating
Remember that welding sparks and hot
regulators designed for the gas and
materials from welding can easily go through small cracks
pressure used. All hoses, fittings, etc. should be suitable for
and openings to adjacent areas. Avoid welding near
the application and maintained in good condition.
hydraulic lines. Have a fire extinguisher readily available.
7.b. Always keep cylinders in an upright position securely
6.b. Where compressed gases are to be used at the job site,
chained to an undercarriage or fixed support.
special precautions should be used to prevent hazardous
situations. Refer to “Safety in Welding and Cutting� (ANSI
7.c. Cylinders should be located:
Standard Z49.1) and the operating information for the
� Away from areas where they may be struck or subjected to
equipment being used.
physical damage.
6.c. When not welding, make certain no part of the electrode
� A safe distance from arc welding or cutting operations and
circuit is touching the work or ground. Accidental contact
any other source of heat, sparks, or flame.
can cause overheating and create a fire hazard.
7.d. Never allow the electrode, electrode holder or any other
6.d. Do not heat, cut or weld tanks, drums or containers until the
electrically “hot� parts to touch a cylinder.
proper steps have been taken to insure that such procedures
will not cause flammable or toxic vapors from substances
7.e. Keep your head and face away from the cylinder valve outlet
inside. They can cause an explosion even though they have
when opening the cylinder valve.
been “cleaned�. For information, purchase “Recommended
Safe Practices for the Preparation for Welding and Cutting of
7.f. Valve protection caps should always be in place and hand
Containers and Piping That Have Held Hazardous
tight except when the cylinder is in use or connected for
Substances�, AWS F4.1 from the American Welding Society
use.
(see address above).
7.g. Read and follow the instructions on compressed gas
6.e. Vent hollow castings or containers before heating, cutting or
cylinders, associated equipment, and CGA publication P-l,
welding. They may explode.
“Precautions for Safe Handling of Compressed Gases in
Cylinders,� available from the Compressed Gas Association
6.f. Sparks and spatter are thrown from the welding arc. Wear oil
1235 Jefferson Davis Highway, Arlington, VA 22202.
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.
FOR ELECTRICALLY
Always wear safety glasses with side shields when in a
powered equipment.
welding area.
6.g. Connect the work cable to the work as close to the welding
8.a. Turn off input power using the disconnect
area as practical. Work cables connected to the building
switch at the fuse box before working on
framework or other locations away from the welding area
the equipment.
increase the possibility of the welding current passing
through lifting chains, crane cables or other alternate cir-
8.b. Install equipment in accordance with the U.S. National
cuits. This can create fire hazards or overheat lifting chains
Electrical Code, all local codes and the manufacturer’s
or cables until they fail.
recommendations.
6.h. Also see item 1.c.
8.c. Ground the equipment in accordance with the U.S. National
Electrical Code and the manufacturer’s recommendations.
Mar �95
iv iv
SAFETY
zones où l’on pique le laitier.
PRÉCAUTIONS DE SÛRETÉ
6. Eloigner les matériaux inflammables ou les recouvrir afin de
Pour votre propre protection lire et observer toutes les instructions
prévenir tout risque d’incendie dû aux étincelles.
et les précautions de sûreté specifiques qui parraissent dans ce
manuel aussi bien que les précautions de sûreté générales suiv-
7. Quand on ne soude pas, poser la pince à une endroit isolé de
antes:
la masse. Un court-circuit accidental peut provoquer un
échauffement et un risque d’incendie.
Sûreté Pour Soudage A L’Arc
1. Protegez-vous contre la secousse électrique:
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
a. Les circuits à l’électrode et à la piéce sont sous tension
la masse sur la charpente de la construction ou d’autres
quand la machine à souder est en marche. Eviter toujours
endroits éloignés de la zone de travail, on augmente le risque
tout contact entre les parties sous tension et la peau nue
de voir passer le courant de soudage par les chaines de lev-
ou les vétements mouillés. Porter des gants secs et sans
age, câbles de grue, ou autres circuits. Cela peut provoquer
trous pour isoler les mains.
des risques d’incendie ou d’echauffement des chaines et des
b. Faire trés attention de bien s’isoler de la masse quand on
câbles jusqu’� ce qu’ils se rompent.
soude dans des endroits humides, ou sur un plancher
metallique ou des grilles metalliques, principalement dans
9. Assurer une ventilation suffisante dans la zone de soudage.
les positions assis ou couché pour lesquelles une grande
Ceci est particuliérement important pour le soudage de tôles
partie du corps peut être en contact avec la masse.
galvanisées plombées, ou cadmiées ou tout autre métal qui
c. Maintenir le porte-électrode, la pince de masse, le câble
produit des fumeés toxiques.
de soudage et la machine à souder en bon et sûr état
defonctionnement.
10. Ne pas souder en présence de vapeurs de chlore provenant
d.Ne jamais plonger le porte-électrode dans l’eau pour le
d’opérations de dégraissage, nettoyage ou pistolage. La
refroidir.
chaleur ou les rayons de l’arc peuvent réagir avec les vapeurs
e. Ne jamais toucher simultanément les parties sous tension
du solvant pour produire du phosgéne (gas fortement toxique)
des porte-électrodes connectés à deux machines à souder
ou autres produits irritants.
parce que la tension entre les deux pinces peut être le
total de la tension à vide des deux machines.
11. Pour obtenir de plus amples renseignements sur la sûreté,
f. Si on utilise la machine à souder comme une source de
voir le code “Code for safety in welding and cutting� CSA
courant pour soudage semi-automatique, ces precautions
Standard W 117.2-1974.
pour le porte-électrode s’applicuent aussi au pistolet de
soudage.
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
PRÉCAUTIONS DE SÛRETÉ POUR
enrouler le câble-électrode autour de n’importe quelle partie
LES MACHINES À SOUDER À
du corps.
TRANSFORMATEUR ET À
3. Un coup d’arc peut être plus sévère qu’un coup de soliel,
REDRESSEUR
donc:
a. Utiliser un bon masque avec un verre filtrant approprié
ainsi qu’un verre blanc afin de se protéger les yeux du ray- 1. Relier à la terre le chassis du poste conformement au code de
onnement de l’arc et des projections quand on soude ou l’électricité et aux recommendations du fabricant. Le dispositif
quand on regarde l’arc. de montage ou la piece à souder doit être branché à une
b. Porter des vêtements convenables afin de protéger la bonne mise à la terre.
peau de soudeur et des aides contre le rayonnement de
l‘arc. 2. Autant que possible, I’installation et l’entretien du poste seront
c. Protéger l’autre personnel travaillant à proximité au effectués par un électricien qualifié.
soudage à l’aide d’écrans appropriés et non-inflammables.
3. Avant de faires des travaux à l’interieur de poste, la debranch-
4. Des gouttes de laitier en fusion sont émises de l’arc de er à l’interrupteur à la boite de fusibles.
soudage. Se protéger avec des vêtements de protection libres
de l’huile, tels que les gants en cuir, chemise épaisse, pan- 4. Garder tous les couvercles et dispositifs de sûreté à leur
talons sans revers, et chaussures montantes. place.
5. Toujours porter des lunettes de sécurité dans la zone de
soudage. Utiliser des lunettes avec écrans lateraux dans les Mar. �93
v v
for selecting a QUALITY product by Lincoln Electric. We want you
Thank You to take pride in operating this Lincoln Electric Company product
•â?¢â?? 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.
vi
TABLE OF CONTENTS
Page
Installation.......................................................................................................................Section A
Technical Specifications .......................................................................................................A-1
Machine Specifications ........................................................................................................A-2
Safety Precautions ........................................................................................................A-3
Location and Ventilation ................................................................................................A-3
Stacking ........................................................................................................................A-3
Angle of Operation ........................................................................................................A-3
Lifting.............................................................................................................................A-3
Additional Safety Precautions .......................................................................................A-3
High Altitude Operation .................................................................................................A-3
High Temperature Operation ........................................................................................A-3
Towing...........................................................................................................................A-3
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
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
A-1 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
2 cylinder High Idle 3700 41(674) 12VDC Battery & Fuel: 12 gal.
Kohler CH22 Starter 45.4 L
(K1726-1) 22 HP @ Bore x Stroke inch (mm) (Group 58; 435 Oil: 2.0 Qts
3600 RPM Full Load 3500 cold crank amps) 1.9 L
Battery Charger
3.03 x 2.85 (77 x 72)
RATED OUTPUT - 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 -------
CC PIPE DC Output 29 Volts @ 300 Amps 100%
CC 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 -------
OUTPUT - GENERATOR
Auxiliary Power 1
9,000 Watts, 60 Hz
120/240 Volts
100 % Duty Cycle
PHYSICAL DIMENSIONS
HEIGHT WIDTH DEPTH WEIGHT
30.00** in. 21.50 in .42.25 in.
510 lbs. (231kg.)
762.0 mm 546.0 mm 1073.0 mm
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
A-2 A-2
INSTALLATION
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 15AMP for 42V Wire Feeder Power
Full KVA (14-50R)
RANGER 305G
A-3 A-3
INSTALLATION
LIFTING
SAFETY PRECAUTIONS
The RANGER 305G weighs approximately 530 lbs.
with a full tank of gasoline. A lift bail is mounted to the
WARNING
machine and should always be used when lifting the
Do not attempt to use this equipment until you machine.
have thoroughly read the engine manufacturer’s
manual supplied with your welder. It includes ADDITIONAL SAFETY PRECAUTIONS
important safety precautions, detailed engine
starting, operating and maintenance instructions,
WARNING
and parts lists.
------------------------------------------------------------------------
ELECTRIC SHOCK can kill. FALLING EQUIPMENT can cause injury.
� Do not touch electrically live parts or � Do not lift this machine using lift
electrode with skin or wet clothing. bale if it is equipped with a heavy
� Insulate yourself from work and accessory such as trailer or gas
ground cylinder.
� Always wear dry insulating gloves.
� Lift only with equipment of ade-
------------------------------------------------------------------------
quate lifting capacity.
ENGINE EXHAUST can kill.
� Use in open, well ventilated areas or � Be sure machine is stable when lifting.
vent exhaust outside. ------------------------------------------------------------------------
HIGH ALTITUDE OPERATION
At higher altitudes, output de-rating may be neces-
------------------------------------------------------------------------
sary. For maximum rating, de-rate the welder output
MOVING PARTS can injure.
� Do not operate with doors open or 3.5% for every 1000 ft. (305m). Contact an autho-
guards off. rized engine service shop for modifications to operate
� Stop engine before servicing. above 5,000 ft. (1525m).
� Keep away from moving parts.
------------------------------------------------------------------------
HIGH TEMPERATURE OPERATION
At temperatures above 40°C, output de-rating is nec-
See additional warning information at essary. For maximum output ratings, de-rate the
front of this operator’s manual. welder output 2 volts for every 10°C above 40°C.
-----------------------------------------------------------
TOWING
Only qualified personnel should install,
The recommended trailer for use with this equipment
use, or service 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
LOCATION AND VENTILATION
of attachment and usage does not result in a safety
The welder should be located to provide an unrestrict-
hazard nor damage the welding equipment. Some of
ed flow of clean, cool air to the cooling air inlets and to
the factors to be considered are as follows:
avoid restricting the cooling air outlets. Also, locate
the welder so that the engine exhaust fumes are prop-
1. Design capacity of trailer vs. weight of Lincoln
erly vented to an outside area.
equipment and likely additional attachments.
STACKING
2. Proper support of, and attachment to, the base of
RANGER 305G machines cannot be stacked.
the welding equipment so there will be no undue
stress to the framework.
ANGLE OF OPERATION
Engines are designed to run in the level condition
3. Proper placement of the equipment on the trailer to
which is where the optimum performance is achieved.
insure stability side to side and front to back when
The maximum angle of continuous operation is 15
being moved and when standing by itself while
degrees in any direction. If the engine is to be operat-
being operated or serviced.
ed at an angle, provisions must be made for checking
and maintaining the oil level at the normal (FULL) oil
4. Typical conditions of use, i.e., travel speed; rough-
capacity in the crankcase.
ness of surface on which the trailer will be operat-
ed; environmental conditions; like maintenance.
When operating the welder at an angle, the effective
fuel capacity will be slightly less than the specified 12
gallons.
RANGER 305G
A-4 A-4
INSTALLATION
5. Conformance with federal, state and local laws.(1) The RANGER 305G is shipped with the negative bat-
tery cable disconnected. Make certain that the RUN-
STOP switch is in the STOP position. Remove the two
Consult applicable federal, state and local laws
(1)
screws from the rear battery tray using a screwdriver
regarding specific requirements for use on public
or a 3/8" socket. Attach the negative battery cable to
highways.
the negative battery terminal and tighten using a 1/2"
PRE-OPERATION ENGINE SERVICE socket or wrench.
READ the engine operating and maintenance instruc-
tions supplied with this machine. NOTE: This machine is furnished with a wet charged
battery; if unused for several months, the battery may
WARNING require a booster charge. Be careful to charge the bat-
tery with the correct polarity.
� Stop engine and allow to cool before fueling
� Do not smoke when fueling MUFFLER OUTLET PIPE
� Fill fuel tank at a moderate rate and do not over- Using the clamp provided secure the outlet pipe to the
fill. outlet tube with the pipe positioned such that it will
� Wipe up spilled fuel and allow fumes to clear direct the exhaust in the desired direction. Tighten
before starting engine using a 9/16" socket or wrench.
� Keep sparks and flame away from tank.
------------------------------------------------------------------------ SPARK ARRESTER
OIL Some federal, state or local laws may require that
gasoline or diesel engines be equipped with exhaust
The RANGER 305G is shipped with the engine spark arresters when they are operated in certain
crankcase filled with high quality SAE 10W-30 oil. locations where unarrested sparks may present a fire
Check the oil level before starting the engine. If it is
hazard. The standard muffler included with this welder
not up to the full mark on the dip stick, add oil as
does not qualify as a spark arrester. When required by
required. Check the oil level every four hours of run-
local regulations, a suitable spark arrester, such as
ning time during the first 25 running hours. Refer to
the S24647 must be installed and properly main-
the engine Operator’s Manual for specific oil recom-
tained.
mendations and break-in information. The oil change
interval is dependent on the quality of the oil and the
CAUTION
operating environment. Refer to the Engine Operator’s
Manual for the proper service and maintenance inter-
vals. An incorrect spark arrestor may lead to damage to
the engine or adversely affect performance.
FUEL ------------------------------------------------------------------------
USE GASOLINE FUEL ONLY
HIGH FREQUENCY GENERATORS FOR
WARNING TIG APPLICATIONS
The K930-2 TIG Module is suitable for use with the
� Fill the fuel tank with clean, fresh fuel. The
RANGER 305G. The RANGER 305G and any high
capacity of the fuel tank is 12 gallons (45.4
frequency generating equipment must be properly
liters).
grounded. See the K930-2 Operating Manual for com-
NOTE: The fuel tank is mounted below the engine
pleted instructions on installation, operation, and
so a fuel shutoff valve is not required.
maintenance.
------------------------------------------------------------------------
ENGINE COOLING SYSTEM
REMOTE CONTROL
Air to cool the engine is drawn in lower set of louvers
The RANGER 305G is equipped with a 6 pin and a 14
on the case back. It is important that the intake air is
pin Amphenol connector. The 6 pin connector is for
not restricted. Allow a minimum clearance of 2 feet
connecting the K857 or K857-1 Remote Control
(0.6m) from the case back to a vertical surface.
(optional) or for TIG welding, the K870 foot Amptrol or
the K812 hand Amptrol.
CAUTION
When in the CC-STICK, PIPE, and CV-WIRE modes
BATTERY CONNECTION and when a remote control is connected to the
Amphenol, the auto-sensing circuit in the RANGER
Use caution as the electrolyte is a strong acid that
305G automatically switches the OUTPUT control
can burn skin and damage eyes.
from control at the welder to remote control .
------------------------------------------------------------------------
RANGER 305G
A-5 A-5
INSTALLATION
WELDING TERMINALS
The 14 pin connector is used to directly connect a
wire feeder or TIG Module (K930-2) control cable. In The RANGER 305G is equipped with a toggle switch
the CV-WIRE mode, the RANGER 305G auto-sensing for selecting "hot" welding terminal when in the
circuit automatically makes the RANGER 305G "WELD TERMINALS ON" position or "cold" welding
Output Control inactive and the wire feeder voltage terminal when in the "REMOTELY CONTROLLED"
control active when the control cable is connected to position.
the 14 pin connector.
WELDING OUTPUT CABLES
NOTE: When a wire feeder with a built in welding volt- With the engine off connect the electrode and work
age control is connected to the 14 pin connector, do cables to the output studs. The welding process dic-
not connect anything to the 6 pin connector. tates the polarity of the electrode cable. These con-
nections should be checked periodically and tightened
ELECTRICAL CONNECTIONS with a 3/4" wrench.
Table A.1 lists recommended cable sizes and lengths
MACHINE GROUNDING
for rated current and duty cycle. Length refers to the
distance from the welder to the work and back to the
Because this portable engine driven welder creates its
welder. Cable diameters are increased for long cable
own power, it is not necessary to connect its frame to
lengths to reduce voltage drops.
an earth ground, unless the machine is connected to
TABLE A-1
premises wiring (home, shop, etc.)
CABLE INSTALLATION
Install the welding cables to your RANGER 305G as
To prevent dangerous electric shock, other equipment
follows.
to which this engine driven welder supplies power
must:
1. The gasoline engine must be OFF to install welding
cables.
WARNING TOTAL COMBINED LENGTH OF
ELECTRODE AND WORK CABLES
� Be grounded to the frame of the welder using a
grounded type plug. Cable Size for
Cable Length 305 Amps
� Be double insulated. 100% Duty Cycle
Do not ground the machine to a pipe that carries 1 / 0 AWG
0-100Ft. (0-30meters)
explosive or combustible material.
------------------------------------------------------------------------ 2 / 0 AWG
100-150 Ft. (30-46m meters)
When this welder is mounted on a truck or trailer, its
frame must be securely connected to the metal frame 3 / 0 AWG
150-200 Ft. (46-61 meters)
of the vehicle. When this engine driven welder is con-
nected to premises wiring such as that in a home or
shop, its frame must be connected to the system earth
2. Remove the flanged nuts from the output terminals.
ground. See further connection instructions in the sec-
tion entitled "Standby Power Connections" as well as
3. Connect the electrode holder and work cables to
the article on grounding in the latest U.S. National
the weld output terminals. The terminals are identi-
Electrical Code and the local code.
fied on the case front.
In general, if the machine is to be grounded, it should
4. Tighten the flanged nuts securely.
be connected with a #8 or larger copper wire to a solid
earth ground such as a metal water pipe going into
5. Be certain that the metal piece you are welding (the
the ground for at least ten feet and having no insulat-
“work�) is properly connected to the work clamp and
ed joints, or to the metal framework of a building
cable.
which has been effectively grounded.
6. Check and tighten the connections periodically.
The U.S. National Electrical Code lists a number of
alternate means of grounding electrical equipment. A
CAUTION
machine grounding stud marked with the symbol is
provided on the front of the welder.
� Loose connections will cause the output termi-
nals to overheat. The terminals may eventually
melt.
RANGER 305G
A-6 A-6
INSTALLATION
� Do not cross the welding cables at the output
� Take necessary steps to assure load is limited to
terminal connection. Keep the cables isolated
the capacity of the RANGER 305G by installing a 40
and separate from one another.
amp, 240 VAC double pole circuit breaker.
------------------------------------------------------------------------
Maximum rated load for each leg of the 240 VAC
AUXILIARY POWER RECEPTACLES auxiliary is 38 amperes. Loading above the rated
The auxiliary power of the RANGER 305G consists of output will reduce output voltage below the allow-
two 20 Amp-120 VAC (5-20R) duplex receptacles and able - 10% of rated voltage which may damage
one 50 Amp 120/240 VAC (14-50R) receptacle. The appliances or other motor-driven equipment and
240 VAC receptacle can be split for single phase 120 may result in overheating of the RANGER 305G
VAC operation. engine and/or alternator windings.
The auxiliary power capacity is 9,000 watts of 60 Hz, � Install a 50 amp, 120/240 VAC plug (NEMA Type
single phase power. The auxiliary power capacity rat- 14-50) to the double-pole circuit breaker using No.
ing in watts is equivalent to volt-amperes at unity 6, 4 conductor cable of the desired length. (The 50
power factor. The max permissible current of the 240 amp, 120/240 VAC plug is available in the optional
VAC output is 38 Amps. The 240 VAC output can be K802R plug kit or as part number T12153-9.)
split to provide two separate 120 VAC outputs with a
max permissible current of 38 Amps per output to two � Plug this cable into the 50 Amp, 120/240 Volt recep-
separate 120 VAC branch circuits (these circuits can- tacle on the RANGER 305G case front.
not 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.
NOTE: The 240 V receptacle has two 120 V circuits,
but are of opposite polarities and cannot be paralleled.
STANDBY POWER CONNECTIONS
The RANGER 305G 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, 38 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 premis-
es disconnect. Switch rating must be the same or
greater than the customer’s premises disconnect
and service over current protection.
RANGER 305G
A-7 A-7
INSTALLATION
CONNECTION OF RANGER 305G TO PREMISES WIRING
240 VOLT
GROUNDED CONDUCTOR
POWER
240 Volt 120 VOLT
60 Hz.
COMPANY
3-Wire
120 VOLT
Service
METER
NEUTRAL
BUS
N
LOAD
DOUBLE POLE DOUBLE THROW
SWITCH RATING TO BE THE SAME
AS OR GREATER THAN PREMISES
SERVICE OVERCURRENT
PROTECTION.
PREMISES
DISCONNECT AND
SERVICE
GROUND OVERCURRENT
40AMP
PROTECTION
240 VOLT
DOUBLE
POLE
50 AMP, 120/240 CIRCUIT
VOLT PLUG 240 VOLT BREAKER
NEMA TYPE 14-50
GND
N
50 AMP, 120/240 VOLT
NOTE: No. 6 COPPER CONDUCTOR CABLE SEE
RECEPTACLE
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
A-8 A-8
INSTALLATION
CONNECTION OF LINCOLN ELECTRIC CAUTION
WIRE FEEDERS
If you are using an LN-25 without an internal con-
tactor, the electrode will be energized when the
Connection of the LN-25 to the RANGER 305G Ranger 305G is started.
------------------------------------------------------------------------
Connection of LN-7 or LN-8 to the RANGER 305G
WARNING
1. Shut the welder off.
Shut off welder before making any electrical con- 2. Connect the LN-7 or LN-8 per instructions on the
nections. appropriate connection diagram in Section F
------------------------------------------------------------------------ 3. Set the "WIRE FEEDER VOLTMETER" switch to
The LN-25 with or without an external contactor may either "+" or "-" as required by the electrode being
be used with the RANGER 305G. See the appropriate used.
connection diagram in Section F. 4. Set the "MODE" switch to the "CV WIRE " posi-
tion.
NOTE: The LN-25 (K431) Remote Control Module 5. Set the "ARC CONTROL" knob to "0" initially and
and (K432) Remote Cable are not recommended for adjust to suit.
use with the RANGER 305G. 6 Set the "WELD TERMINALS" switch to the
"REMOTELY CONTROLLED" position.
1. Shut the welder off. 7. Set the "IDLE" switch to the "HIGH" position.
2. For electrode Positive, connect the electrode Connection of an LN-23P Wire Feeder to the
cable from the LN-25 to the "+" terminal of the RANGER 305G
welder and work cable to the "-" terminal of the
welder. For electrode Negative, connect the elec- 1. Shut the welder off.
trode cable from the LN-25 to the "-" terminal of 2. Connect the LN-23P as per instructions on the
the welder and work cable to the "+" terminal of appropriate connection diagram in Section F.
the welder. (NOTE): When connecting an LN-23P to the
RANGER 305G, a K350-1 adapter kit must be
3. Attach the single lead from the front of the LN-25 used.
to work using the spring clip at the end of the lead. 3. Set the "VOLTMETER" switch to "-".
This is a control lead to supply current to the wire 4. Set the "MODE" switch to "CV WIRE " position.
feeder motor; it does not carry welding current. 5. Set the "WELD TERMINALS" switch to
"REMOTELY CONTROLLED".
4. Set the MODE switch to the "CV-WIRE " position. 6. Set the "ARC CONTROL" knob to "0" initially and
adjust to suit.
5. Set the "WELD TERMINALS" switch to "WELD 7. Set the "IDLE" switch to the "AUTO" position.
TERMINALS ON" When not welding, the RANGER 305G engine will
be at the low idle speed. If you are using an LN-
6. Set the "ARC CONTROL" knob to "0" initially and 23P with the K350-1 adapter kit, the electrode is
adjust to suit. not energized until the gun trigger is closed.
When the gun trigger is closed, the current sens-
7. Set the "IDLE" switch to the "AUTO" position. ing circuit will cause the RANGER 305G engine to
When not welding, the RANGER 305G engine will go to the high idle speed, the wire will begin to
be at the low idle speed. If you are using an LN-25 feed and the welding process can be started.
with an internal contactor, the electrode is not When welding is stopped, the engine will revert to
energized until the gun trigger is closed. low idle speed after approximately 12 seconds
unless welding is resumed.
8. When the gun trigger is closed, the current sens-
ing circuit will cause the RANGER 305G engine to Connection of LN-742, Spool Gun, and Cobramatic
go to the high idle speed, the wire will begin to to RANGER 305G
feed and the welding process started. When weld-
ing is stopped, the engine will revert to low idle 1. Shut the welder off.
speed after approximately 12 seconds unless
welding is resumed. 2. Connect per instructions on the appropriate con-
nection diagram in Section F.
RANGER 305G
B-1 B-1
OPERATION
SAFETY PRECAUTIONS ENGINE OPERATION
Before Starting the Engine:
WARNING � Be sure the machine is on a level surface.
Do not attempt to use this equipment until you � Open top engine door and remove the engine oil
have thoroughly read the engine manufacturer’s dipstick and wipe it with a clean cloth. Reinsert the
manual supplied with your welder. It includes dipstick and check the level on the dipstick.
important safety precautions, detailed engine
starting, operating and maintenance instructions,
� Add oil (if necessary) to bring the level up to the full
and parts lists.
mark. Do not overfill. Close engine door.
------------------------------------------------------------------------
ELECTRIC SHOCK can kill.
� Do not touch electrically live parts or � See Engine Owner’s Manual for specific oil recom-
electrode with skin or wet clothing. mendations.
� Insulate yourself from work and
ground
ADD FUEL
� Always wear dry insulating gloves.
� Always operate the welder with the hinged door
WARNING
closed and the side panels in place.
GASOLINE can cause fire or
� Read carefully the Safety Precautions page
explosion.
before operating this machine. Always follow
� Stop engine when fueling.
these and any other safety procedures included
� Do not smoke when fueling.
in this manual and in the Engine Instruction
� Do not overfill tank.
Manual.
� Avoid contact with skin or breathing of vapor.
� Keep sparks and flame away from tank.
GENERAL DESCRIPTION
------------------------------------------------------------------------
� Remove the fuel tank cap.
The RANGER 305G is a gasoline engine powered DC
multi-process welding power source and 120 / 240
� Fill the tank approximately 4 inches (100mm) from
volt AC power generator. The engine drives a genera-
the top of the filler neck to allow for fuel expansion
tor that supplies three phase power for the DC weld-
(observe the fuel gauge while filling). DO NOT FILL
ing circuit and single phase power for the AC auxiliary
THE TANK TO THE POINT OF OVERFLOW.
outlets. The DC welding control system uses state of
the art Chopper Technology (CT tm) for superior weld-
� Replace the fuel cap and tighten securely.
ing performance.
� See Engine Owner’s Manual for specific fuel recom-
DESIGN FEATURES mendations.
FOR AUXILIARY POWER:
Start the engine and set the IDLER control switch to
the desired operating mode. Full power is available
regardless of the welding control settings providing no
welding current is being drawn.
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.
RANGER 305G
B-2 B-2
OPERATION
16
1
15
14
2
13
3 12
11
4
10
9
8
7
5
6
WELDING CONTROLS CV-WIRE
1. OUTPUT CONTROL: The CONTROL dial PIPE
CC-STICK
provides continuous control of the welding current or
TOUCH START TIG
welding voltage depending on the selected welding
mode. This control is not active in the CC-STICK,
4. ARC CONTROL :
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. The ARC CONTROL WIRE/STICK dial is active in the
WIRE and STICK modes, and has different functions
2. DIGITAL OUTPUT METERS in these modes. This control is not active in the TIG
and PIPE modes.
The digital meters allow the output voltage (CV-WIRE
mode) or current (CC-STICK, PIPE and TIG modes)
CC-STICK mode: In this mode, the ARC CONTROL
to be set prior to welding using the OUTPUT control
knob sets the short circuit current during stick welding
dial. During welding, the meter display the actual out-
(arc-force). Increasing the number from -10 to +10
put voltage (VOLTS) and current (AMPS). A memory
increases the short circuit current and prevents stick-
feature holds the display of both meters on for seven
ing of the electrode to the plate while welding. This
seconds after welding is stopped. This allows the
can also increase spatter. It is recommended that the
operator to read the actual current and voltage just
ARC CONTROL be set to the minimum number with-
prior to when welding was ceased. While the display
out electrode sticking. Start with a setting at 0.
is being held the left-most decimal point in each dis-
play will be flashing. The accuracy of the meters is
CV-WIRE mode: In this mode, turning the ARC CON-
+/- 3%.
TROL clockwise from �10 (soft) to +10 (crisp) changes
3. WELD MODE SELECTOR SWITCH:
the arc from soft and washed-in to crisp and narrow.
(Provides four selectable welding modes)
RANGER 305G
B-3 B-3
OPERATION
It acts as an inductance control. The proper setting 13. START PUSH BUTTON - Energizes the
depends on the procedure and operator preference. starter motor to crank the engine.
Start with a setting at 0.
5. WELD OUTPUT TERMINALS WITH 14. IDLER SWITCH- Has two positions as follows:
FLANGE NUT:
Provides a connection point for the electrode and 1) In the HIGH position, the engine runs at the high
idle speed controlled by the engine governor.
work cables.
2) In the AUTO position, the idler operates as follows:
6. GROUND STUD: (graphic)
Provides a connection point for connecting the � When switched from HIGH to AUTO or after start-
machine case to earth ground for the safest grounding ing the engine, the engine will operate at full
procedure. speed for approximately 12 seconds and then go
to low idle speed.
7. 14 PIN AMPHENOL: � When the electrode touches the work or power is
For attaching wire feeder control cables to the drawn for lights or tools (approximately 100
RANGER 305G. Includes contactor closure circuit , Watts minimum), the engine accelerates and
auto-sensing remote control circuit, and 120V and operates at full speed.
42V power. The remote control circuit operates the � When welding ceases or the AC power load is
same as the 6 Pin Amphenol. turned off, a fixed time delay of approximately 12
seconds starts. If the welding or AC power l o a d
8. 6 PIN AMPHENOL: is not restarted before the end of the time delay,
For attaching optional remote control equipment. the idler reduces the engine speed to low idle
When in the CC-STICK, PIPE, and CV-WIRE modes speed.
and when a remote control is connected to the � The engine will automatically return to high idle
Amphenol, the auto-sensing circuit in the RANGER speed when there is welding load or AC power
305G automatically switches the OUTPUT control load reapplied.
from control at the welder to remote control .
When using the TOUCH START TIG mode with a TIG 15. ENGINE ALTERNATOR TROUBLE
Module connected to the RANGER 305G, the OUT- LIGHT-The engine alternator light is off when battery
PUT control on the front of the RANGER 305G is charging system is functioning normally. If light turns
used to set the maximum current range of the CUR- on, the alternator or the voltage regulator may not be
RENT CONTROL on the TIG Module. operating correctly. The light may also come on due to
the battery not holding a charge. It is normal for the
9. WELD TERMINALS CONTROL SWITCH: light to come on while starting the engine.
In the WELD TERMINALS ON position, the output is
electrically hot all the time. In the REMOTELY CON- 16. ENGINE HOUR METER � Displays the total
TROLLED position, the output is controlled by a wire time that the engine has been running. This meter is
feeder or amptrol device, and is electrically off until a useful for scheduling prescribed maintenance.
remote switch is depressed.
STARTING AND STOPPING
10. WIRE FEEDER VOLTMETER SWITCH: THE ENGINE
Matches the polarity of the wire feeder voltmeter to � Remove all plugs connected to the AC power
the polarity of the electrode. receptacles.
ENGINE CONTROLS: � Set IDLER switch to AUTO.
� Set the RUN/STOP switch to RUN.
11. RUN/STOP SWITCH - RUN position ener-
� Pull the choke to the full out position.
gizes the engine prior to starting. STOP position stops
� Press and hold the engine START button until the
the engine. The oil pressure interlock switch prevents
engine starts.
battery drain if the switch is left in the RUN position
and the engine is not operating.
� Release the engine START button when the engine
starts.
12. CHOKE - When pulled out, it closes the choke
valve on the engine carburetor for quick starting.
� Push the choke back in.
RANGER 305G
B-4 B-4
OPERATION
� The engine will run at high idle speed for approxi-
WELDER OPERATION
mately 12 seconds and then go to low idle speed.
Stick Welding
Allow the engine to warm up at low idle for several
The RANGER 305G can be used with a broad range
minutes before applying a load and/or switching to
of DC stick electrodes.
high idle. Allow a longer warm up time in cold
The MODE switch provides two stick welding settings
weather.
as follows:
CAUTION Constant Current (CC-STICK) Welding
The CC-STICK position of the MODE switch is
Operating the starter motor for more than 5 sec-
designed for horizontal and vertical-up welding with all
onds can damage the motor. If the engine fails to
types of electrodes, especially low hydrogen. The out-
start, release the switch and wait 10 seconds
put CONTROL dial adjusts the full output range for
before operation the starter again. Do NOT push
stick welding.
the START button while the engine is running
because this can damage the ring gear and/or the
The ARC CONTROL knob sets the short circuit cur-
starter motor.
rent during stick welding (arc-force). Increasing the
------------------------------------------------------------------------
number from -10 to +10 increases the short circuit cur-
rent and prevents sticking of the electrode to the plate
NOTE: When starting a RANGER 305G for the first
while welding. This can also increase spatter. It is
time, or after and extended period of time of not oper-
recommended that the ARC CONTROL be set to the
ating, it will take longer than normal because the fuel
minimum number without electrode sticking. Start
pump has to fill the fuel line and carburetor.
with the dial set at 0.
STOPPING PIPE Welding
Remove all welding and auxiliary power loads and This slope controlled setting is intended for "out-of-
allow the engine to run at low idle speed for a few position" and "down hill" pipe welding where the oper-
minutes to cool the engine. ator would like to control the current level by changing
the arc length. The output CONTROL dial adjusts the
Stop the engine by placing the RUN-STOP in the full output range for pipe welding. The ARC CON-
STOP position. TROL is not active in the PIPE mode.
NOTE: A fuel shut off valve is not required on the
RANGER 305G because the fuel tank is mounted
below the engine.
TYPICAL RANGER 305G FUEL CONSUMPTION
Kohler CH22 Running Time for
gal./hr (liters/hr) 12 gallons-(hrs.)
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
9,000 Watts 1.47 (5.6) 8.2
RANGER 305G
B-5 B-5
OPERATION
TIG Welding When using the TIG Module, the OUTPUT control on
The TOUCH START TIG setting of the MODE switch the RANGER 305G is used to set the maximum range
is for DC TIG (Tungsten Inert Gas) welding. To initiate of the CURRENT CONTROL on the TIG Module or an
a weld, the CONTROL dial is first set to the desired Amptrol if connected to the TIG Module.
current and the tungsten is touched to the work.
During the time the tungsten is touching the work WIRE WELDING-CV
there is very little voltage or current and, in general, Connect a wire feeder to the RANGER 305G accord-
no tungsten contamination. Then, the tungsten is gen- ing to the instructions in INSTALLATION INSTRUC-
tly lifted off the work in a rocking motion, which estab- TIONS Section.
lishes the arc. The RANGER 305G in the CV-WIRE mode, permits it
to be used with a broad range of flux cored wire
The ARC CONTROL is not active in the TIG mode. (Innershield and Outershield) electrodes and solid
wires for MIG welding (gas metal arc welding).
The RANGER 305G can be used in a wide variety of Welding can be finely tuned using the ARC CON-
DC TIG welding applications. In general the ‘Touch TROL. Turning the ARC CONTROL clockwise from
Start� feature allows contamination free starting with- �10 (soft) to +10 (crisp) changes the arc from soft and
out the use of a Hi-frequency unit. If desired, the washed-in to crisp and narrow. It acts as an induc-
K930-2 TIG Module can be used with the RANGER tance control. The proper setting depends on the pro-
305G. The settings are for reference. cedure and operator preference. Start with the dial set
at 0.
RANGER 305G settings when using the K930-2 TIG Some recommended Innershield electrodes are:
Module with an Amptrol or Arc Start Switch: NR-311, NS-3M, NR-207, NR-203 Ni 1%, NR-204-H.
� Set the MODE Switch to the TOUCH START TIG Recommended Outershield electrodes are:
setting. 0S-70, 0S-71M.
� Set the "IDLER" Switch to the "AUTO" position. Some recommended solid wires for MIG welding are:
� Set the "WELDING TERMINALS" switch to the .035 (0.9 mm), and .045 (1.1 mm), L-50 and L-56,
"REMOTELY CONTROLLED" position. This will .035 (0.9 mm) and .045 (1.1 mm) Blue Max MIG 308
keep the "Solid State" contactor open and provide LS.
a "cold" electrode until the Amptrol or Arc Start For any electrodes, including the above recommenda-
Switch is pressed. tions, the procedures should be kept within the rating
of the machine.
TYPICAL CURRENT RANGES (1) FOR TUNGSTEN ELECTRODES(2)
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:
# 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)
(5) TIG torch nozzles are typically made from alumina ceramic. Special applications may require lava nozzles, which are less prone to breakage, but cannot withstand high temperatures
and high duty cycles.
RANGER 305G
B-6 B-6
OPERATION
ARC GOUGING The auxiliary power capacity is 9,000 watts of 60 Hz,
The RANGER 305G can be used for limited arc goug- single phase power. The auxiliary power capacity rat-
ing. For optimal performance, set the MODE switch to ing in watts is equivalent to volt-amperes at unity
CC-STICK and the ARC CONTROL to +10. power factor. The max permissible current of the 240
VAC output is 38 Amps.
Set the CONTROL knob to adjust output current to the
desired level for the gouging electrode being used The 240 VAC output can be split to provide two sepa-
according to the ratings in the following table. rate 120 VAC outputs with a max permissible current
of 38 Amps per output to two separate 120 VAC
Electrode Diameter Current Range (DC, electrode branch circuits (these circuits cannot be paralleled).
positive) Output voltage is within ± 10% at all loads up to rated
capacity.
1/8" 30-60 Amps
The 120 V auxiliary power receptacles should only be
5/32" 90-150 Amps used with three wire grounded type plugs or approved
double insulated tools with two wire plugs. The current
3/16" 150-250 Amps rating of any plug used with the system must be at
least equal to the current capacity of the associated
1/4" 250-305 Amps receptacle.
AUXILIARY POWER: NOTE: The 240 V receptacle has two circuits, each of
Start the engine and set the IDLER control switch to which measure 120 V to neutral but are of opposite
the desired operating mode. Full power is available polarities and cannot be paralleled.
regardless of the welding control settings providing no
welding current is being drawn. Simultaneous Welding and Auxiliary Power Loads
The above auxiliary power ratings are with no welding
The auxiliary power of the RANGER 305G consists of load. Simultaneous welding and power loads are
two 20 Amp-120 VAC (5-20R) duplex receptacles and specified in the following table. The permissible cur-
one 50 Amp 120/240 VAC (14-50R) receptacle. The rents shown assume that current is being drawn from
240 VAC receptacle can be split for single phase 120 either the 120 VAC or 240 VAC supply (not both at the
VAC operation. same time).
RANGER 305G Simultaneous Welding and Power Loads
Permissible Power-Watts
Welding Permissible Auxiliary
(Unity Power Factor)
Output-Amps Current in -Amps
@ 240 VAC
@120 VAC *
9000
0 33
40**
6000
100 21
40**
4500
150 12.5
37**
3000
200 6.3
12.5
0
300 0
0
* Each duplex receptacle is limited to 20 amps.
** Not to exceed 38 A 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.)
Maximum Allowable Cord Length in ft. (m) for Conductor Size
Current Voltage Load
(Amps) Volts (Watts) 14 AWG 12 AWG 10 AWG 8 AWG 6 AWG 4 AWG
120
15 1800 30 (9) 40 (12) 75 (23) 125 (38) 175 (53) 300 (91)
120
20 2400 30 (9) 50 (15) 88 (27) 138 (42) 225 (69)
240
15 3600 60 (18) 75 (23) 150 (46) 225 (69) 350 (107) 600 (183)
240
20 4800 60 (18) 100 (30) 175 (53) 275 (84) 450 (137)
240
38 9000 50 (15) 90 (27) 150 (46) 225 (69)
Conductor size is based on manimum 2.0% voltage drop.
RANGER 305G
C-1 C-1
ACCESSORIES
OPTIONS/ACCESSORIES AND COM- K802-N POWER PLUG KIT
Provides four 120 volt plugs rated at 20 amps each
PATIBLE LINCOLN EQUIPMENT and one dual voltage, full KVA plug rated at 120/240
K957-1 HEAVY DUTY, TWO WHEEL TRAILER FOR volts, 50 amps.
SMALL WELDERS
For road, off-road and in-plant and yard towing. K802-R POWER PLUG KIT
(For highway use, consult applicable federal, state and Provides four 120 volt plugs rated at 15 amps each
local laws regarding requirements for brakes, lights, and one dual voltage, full KVA plug rated at 120/240
fenders, etc.). volts, 50 amps.
T12153-9 50 AMP, 120/240 V POWER PLUG
K1737-1 FOUR WHEEL ALL-TERRAIN UNDERCAR-
RIAGE For moving by hand.
K1816-1 FULL KVA ADAPTER KIT
Plugs into the 120/240V NEMA 14-50R receptacle on
K1770-1 UNDERCARRIAGE (FACTORY)
the casefront (which accepts 4-prong plugs) and
For moving by hand on a smooth surface. One or two
converts it to a NEMA 6-50R receptacle, (which
gas cylinders can be mounted on the rear of the
accepts 3-prong plugs.)
undercarriage with the installation of K1745-1 Cylinder
Holder(s).
K1739-1 CABLE CARRIER KIT
For use on K1737-1 and K1770-1 Undercarriages.
K1745-1 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.
S24647 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 28 ft (8.5m) 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.
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.
RANGER 305G
D-1 D-1
MAINTENANCE
KOHLER ENGINE
SAFETY PRECAUTIONS
FREQUENCY MAINTENANCE REQUIRED
WARNING Daily or Before � Fill fuel tank.
� Have qualified personnel do all maintenance Starting Engine � Check oil level.
and troubleshooting work. � Check air cleaner for dirty, loose,
� Turn the engine off before working inside the or damaged parts.
machine or servicing the engine. � Check air intake and cooling
� Remove guards only when necessary to areas, clean as necessary.
perform maintenance and replace them when 5 Hours First Oil Change
the maintenance requiring their removal is
complete. If guards are missing from the Every 25 Hours � Service air pre-cleaner..
machine, obtain replacements from a Lincoln
Distributor. (See Operating Manual Parts List.) Every 100 Hours � Change engine oil. (1)
Every 100 Hours � Replace fuel filter element.
Read the Safety Precautions in the front of this Every 100 Hours � Clean or replace air filter ele-
manual and in the Engine Owner’s Manual before ment. (1)
working on this machine. Every 100 Hours � Spark Plug Arrester
Every 200 Hours � Replace oil filter. (1)
Keep all equipment safety guards, covers, and Every 200 Hours � Check spark plug and gap
devices in position and in good repair. Keep hands, Every 2 Years � Check fuel lines and clamps.
hair, clothing, and tools away from the gears, fans,
and all other moving parts when starting, operating, or (1) Service more frequently when used in dusty areas and/or at high ambient
temperatures.
repairing the equipment.
Routine Maintenance
At the end of each day’s use, refill the fuel tank to
minimize moisture condensation in the tank. Running
out of fuel tends to draw dirt into the fuel system.
Also, check the crankcase oil level and add oil if
indicated.
ENGINE MAINTENANCE COMPONENTS
ITEM MAKE AND PART NUMBER
KOHLER CH22 ENGINE
Oil Filter Kohler 1205001, Fram PH3614
Air Filter Element Kohler 4708303, Fram CA79
Air Filter Pre-Cleaner Kohler 2408302
Fuel Filter Kohler 2405002, Fram G1
Spark Plug Champion RC12YC (.030" Gap)
Battery BCI Group 58 (435 CCA)
RANGER 305G
D-2 D-2
MAINTENANCE
� Refill the crankcase with the specified amount of the
Engine Oil Change
recommended oil. Reinstall the oil filler cap.
Drain the oil while the engine is warm to assure rapid
and complete draining.
� Start the engine and check for oil filter leaks.
� Remove the oil filler cap and dipstick. Remove the
� Stop the engine, and check the oil level. If neces-
yellow cap from the oil drain valve and attach the
sary, add oil to the upper limit mark on the dipstick.
flexible drain tube supplied with the machine. Push
in and twist the drain valve counterclockwise. Pull
Air Cleaner Service
the valve out and drain the oil into a suitable
A dirty air cleaner will restrict air flow to the carbure-
container.
tor. To prevent carburetor malfunction, service the air
cleaner regularly. Service more frequently when oper-
� Close the drain valve by pushing in and twisting
ating the engine in extremely dusty areas.
clockwise. Replace the yellow cap.
WARNING
� Refill to the upper limit mark on the dipstick with the
recommended oil. Tighten the oil filler cap securely.
Never use gasoline or low flash point solvents for
cleaning the air cleaner element. A fire or explo-
Engine Oil Refill Capacities
sion could result.
Without oil filter replacement:
� 1.7 US qt. (1.4 Imp qt., 1.6 liter)-Kohler
CAUTION
With oil filter replacement:
Never run the engine without the air cleaner.
� 2.0 US qt. (1.7 Imp qt., 1.9 liter)-Kohler
Rapid engine wear will result from contaminants,
such as dust and dirt being drawn into the engine.
Use 4-stroke motor oil that meets or exceeds the
requirements for API service classification SG or SH.
Engine
Always check the API SERVICE label on the oil con-
tainer to be sure it includes the letters SG or SH. Air Pre-cleaner Service
SAE 10W-30 is recommended for general, all-temper-
ature use, -5 F to 104 F (-20 C to 40 C). For the Onan � Loosen the cover retaining knob and remove the
engine, it is recommended that SAE 30 oil be used cover.
above 82 F (27 C).
See Engine Owner’s Manual for more specific infor- � Remove the pre-cleaner from the paper element.
mation on oil viscosity recommendations.
Wash your hands with soap and water after handling � Wash the pre-cleaner in warm water with detergent.
used oil. Rinse the pre-cleaner thoroughly until all traces of
Please dispose of used motor oil in a manner that is detergent are eliminated. Squeeze out excess water
compatible with the environment. We suggest you (do not wring). Allow the pre-cleaner to air dry.
take it in a sealed container to your local service sta-
tion or recycling center for reclamation. Do not throw � Saturate the pre-cleaner with new engine oil.
it in the trash, pour it on the ground or down a drain. Squeeze out all excess oil.
Oil Filter Change � Reinstall the pre-cleaner over the paper element.
� Drain the engine oil.
� Reinstall the air cleaner cover. Secure cover with
� Remove the oil filter, and drain the oil into a suitable the cover retaining knob.
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 fil-
ter socket tool to tighten the filter an additional 1/2 to
7/8 turn.
RANGER 305G
D-3 D-3
MAINTENANCE
AIR FILTER PAPER ELEMENT Spark Plug Service
� Loosen the cover retaining knob and remove the
cover. To ensure proper engine operation, the spark plug
must be properly gapped and free of deposits.
� Remove the pre-cleaner from the paper element.
� Remove the spark plug cap.
� Remove the element cover nut, element cover, and
paper element. � Clean any dirt from around the spark plug base.
� Do not wash the paper element or use pressurized � Use a plug wrench to remove the spark plug.
air, as this will damage the element. Replace a
dirty, bent, or damaged element with a new ele- � Visually inspect the spark plug. Discard them if the
ment. Handle new elements carefully; do not use if insulator is cracked or chipped. Clean the spark
the sealing surfaces are bent or damaged. plug with a wire brush if it is to be reused.
� When servicing the air cleaner, check the air clean- � Measure the plug gap with a feeler gauge. Correct
er base. Make sure it is secured and not bent or as necessary by bending the side electrode.
damaged. Also check the element cover for dam-
aged or improper fit. Replace all damaged air � Check that the spark plug washer is in good condi-
cleaner components. tion and thread the spark plug in by hand to prevent
cross-threading.
NOTE: Before air cleaner is reassembled make sure
rubber seal is in position around stud. Inspect, mak- � After the spark plug is seated, tighten with a spark
ing sure it is not damaged and seals with the element plug wrench to compress the washer.
cover.
� If installing a new spark plug, tighten 1/2 turn after
� Reinstall the paper element, pre-cleaner, element the spark plug seats to compress the washer.
cover, element cover nut, and air cleaner cover.
Secure cover with the cover retaining knob. � If reinstalling a used spark plug, tighten 1/8 - 1/4
turn after the spark plug seats to compress the
SPARK PLUG washer.
To ensure proper engine operation, the spark plug
Spark Plug Gap: .030 in. (0.76 mm)-Kohler
must be properly gapped and free of deposits.
Spark Plug Torque: 20 ft. Lb. (27 N-m)-Kohler
WARNING
CAUTION
NOTE: Before removing spark plug, the muffler
The spark plug must be securely tightened. An
becomes very hot during operation and remains
improperly tightened spark plug can become very
hot for a while after stopping the engine. Be care-
hot and may cause engine damage.
ful not to touch the muffler while it is hot.
Use only the recommended spark plug or equiva-
lent. A spark plug which has an improper heat
range may cause engine damage.
RANGER 305G
D-4 D-4
MAINTENANCE
CLEANING THE BATTERY
FUEL FILTER Keep the battery clean by wiping it with a damp cloth
� Check the fuel filter for water accumulation or sedi- when dirty. If the terminals appear corroded, discon-
ment. nect the battery cables and wash the terminals with an
ammonia solution or a solution of 1/4 pound (0.1113
� Replace the fuel filter if it is found with excessive kg) of baking soda and 1 quart (0.9461) of water. Be
water accumulation or sediment. 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 bat-
ENGINE ADJUSTMENT tery compartment, and surrounding areas with clear
OVERSPEED IS HAZARDOUS water. Coat the battery terminals lightly with petroleum
The maximum allowable high idle speed for this jelly or a non-conductive grease to retard corrosion.
machine is 3750 RPM, no load. Do NOT tamper Keep the battery clean and dry. Moisture accumula-
with governor components or setting or make any tion on the battery can lead to more rapid discharge
other adjustments to increase the maximum and early battery failure.
speed. Severe personal injury and damage to the
machine can result if operated at speeds above
CHECKING THE ELECTROLYTE LEVEL
maximum.
If battery cells are low, fill them to the neck of the filler
Adjustments to the engine are to be made only by a
hole with distilled water and recharge. If one cell is
Lincoln Service Center or an authorized Field Service
low, check for leaks.
Shop.
BATTERY MAINTENANCE CHARGING THE BATTERY
When you charge, jump, replace, or otherwise con-
To access the battery, Remove the 2 screws from the
nect battery cables to the battery, be sure the polarity
rear battery tray using a screwdriver or a 3/8" socket.
is correct. Improper polarity can damage the charging
Slide the battery tray out only far enough to access
circuit. The RANGER 305G positive (+) battery termi-
the battery terminals.
nal has a red terminal cover.
WARNING
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.
GASES FROM BATTERY can explode.
After the battery is charged, reconnect the positive
Keep sparks, flame and cigarettes
q
battery cable first and the negative cable last. Failure
away from battery.
to do so can result in damage to the internal charger
To prevent EXPLOSION when: components.
Follow the instructions of the battery charger manu-
q INSTALLING A NEW BATTERY � disconnect
facturer for proper charger settings and charging time.
negative cable from old battery first and con-
nect to new battery last.
SERVICING OPTIONAL SPARK
q CONNECTING A BATTERY CHARGER �
remove battery from welder by disconnecting
ARRESTOR
negative cable first, then positive cable and
battery clamp. When reinstalling, connect
negative cable last. Keep well ventilated.
WARNING
USING A BOOSTER � connect positive lead to
q
battery first then connect negative lead to neg- � MUFFLER MAY BE HOT
ative battery lead at engine foot.
BATTERY ACID can burn eyes and
� ALLOW ENGINE TO COOL BEFORE INSTALLING
skin.
THE SPARK ARRESTER!
q Wear gloves and eye protection
and be careful when working near � DO NOT OPERATE ENGINE WHILE INSTALLING
battery. THE SPARK ARRESTER!
Follow instructions printed on battery.
q
Clean every 100 hours.
RANGER 305G
D-5 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 over-
haul is necessary.
CAUTION
Do not attempt to polish slip rings while the
engine is running.
WARNING
Service and Repair should only be performed by
Lincoln Electric Factory Trained Personnel.
Unauthorized repairs performed on this equip-
ment may result in danger to the technician and
machine operator and will invalidate your factory
warranty. For your safety and to avoid Electrical
Shock, please observe all safety notes and pre-
cautions.
RANGER 305G
E-1 E-1
TROUBLESHOOTING
HOW TO USE TROUBLESHOOTING GUIDE
WARNING
Service and Repair should only be performed by Lincoln Electric Factory Trained Personnel.
Unauthorized repairs performed on this equipment may result in danger to the technician and
machine operator and will invalidate your factory warranty. For your safety and to avoid Electrical
Shock, please observe all safety notes and precautions detailed throughout this manual.
__________________________________________________________________________
This Troubleshooting Guide is provided to help you Step 3. RECOMMENDED COURSE OF ACTION
locate and repair possible machine malfunctions. This column provides a course of action for the
Simply follow the three-step procedure listed below. Possible Cause, generally it states to contact your
local Lincoln Authorized Field Service Facility.
Step 1. LOCATE PROBLEM (SYMPTOM).
Look under the column labeled “PROBLEM (SYMP- If you do not understand or are unable to perform the
TOMS)�. This column describes possible symptoms Recommended Course of Action safely, contact your
that the machine may exhibit. Find the listing that local Lincoln Authorized Field Service Facility.
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.
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
E-2 E-2
TROUBLESHOOTING
Observe all Safety Guidelines detailed throughout this manual
PROBLEMS POSSIBLE AREAS OF RECOMMENDED
(SYMPTOMS) MISADJUSTMENT(S) COURSE OF ACTION
Major Physical or Electrical Damage 1. Contact your local Lincoln
is Evident. Authorized Field Service
Facility.
Engine will not "crank". 1. Battery is low, Charge Battery
2. Loose battery cable connections.
Inspect, clean and tighten.
3. Faulty engine starter motor.
4. “Battery Circuit� circuit breaker is
tripped.
Engine will "crank" but not start. 1. Out of fuel, Fill tank and bleed fuel
system.
2. Faulty fuel solenoid or faulty PC
board or ignition system.
If all recommended possible areas
of misadjustment have been
checked and the problem persists,
Engine shuts down shortly after 1. Low oil level, Change oil and oil filter Contact your local Lincoln
starting. and fill to proper level. Start engine Authorized Field Service Facility.
and look for leaks.
2. Faulty oil pressure switch or other
engine component.
3. Open rotor circuit.
Battery does not stay charged. 1. Faulty battery, replace.
Engine alternator trouble light is on 2. Loose connections at battery or
while machine is running. alternator. Clean and tighten connec-
tions.
3. Faulty engine alternator or charg-
er modual.
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
E-3 E-3
TROUBLESHOOTING
Observe all Safety Guidelines detailed throughout this manual
PROBLEMS POSSIBLE AREAS OF RECOMMENDED
(SYMPTOMS) MISADJUSTMENT(S) COURSE OF ACTION
Engine will not idle down to low 1. Idler switch in High idle position.
speed. Set switch to Auto.
2. External load on welder or auxil-
iary power. Remove all external
loads.
3. Faulty PC board or idler sole-
noid.
Engine will not go to high idle when 1. Poor work lead connection to
attempting to weld. work. Make sure work clamp is
tightly connected to clean base
metal.
2. "Contactor" switch is in wrong
position. Set to "Welding On" when
welding without a control cable.
Refer to Operations chapter for prop-
er use of this switch.
3. Faulty PC board. Low idle speed
set to low.
Engine will not go to high idle when 1. Auxiliary power load is less than
using auxiliary power. 100 watts. Idler may not respond
with less than a 100 watt load. Set If all recommended possible areas
idler to "High". of misadjustment have been
2. Faulty PC board. checked and the problem persists,
Contact your local Lincoln
Engine does not develop full 1. Fuel filter clogged, Replace. Authorized Field Service Facility.
power. 2. Air filter clogged, clean or replace.
3. Fouled spark plugs, clean or
replace.
4. Valves out of adjustment.
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
E-4 E-4
TROUBLESHOOTING
Observe all Safety Guidelines detailed throughout this manual
PROBLEMS POSSIBLE AREAS OF RECOMMENDED
(SYMPTOMS) MISADJUSTMENT (S) COURSE OF ACTION
No welding power output. 1. Poor work lead connection to
work. Make sure work clamp is
tightly connected to clean base
metal.
2. "Weld Terminals" switch in wrong
position. Place switch in "Weld
Terminals On" position when
welding without control cable.
3. Faulty PC board or welder alterna-
tor.
Welder has output but no control. 1. Poor remote/control cable connec-
tion to 6 pin or 14 pin 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.
If all recommended possible areas
Wire feeder does not work when 1. Wire Feeder Power circuit breaker of misadjustment have been
control cable is connected to 14 pin open. Check 42V and 120V checked and the problem persists,
Amphenol. beakers and reset if tripped. Contact your local Lincoln
2. Faulty control cable. Repair or Authorized Field Service Facility.
replace cable.
3. Faulty wire feeder.
No auxiliary power. 1. Open circuit breakers. Reset
breakers. If breakers keep trip-
ping, reduce power draw.
2. Faulty connections to auxiliary
receptacles. Check connections.
3. GFCI 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 alterna-
tor.
CAUTION
If for any reason you do not understand the test procedures or are unable to perform the tests/repairs safely, contact your
Local Lincoln Authorized Field Service Facility for technical troubleshooting assistance before you proceed.
RANGER 305G
E-5 E-5
TROUBLESHOOTING
Observe all Safety Guidelines detailed throughout this manual
PROBLEMS POSSIBLE AREAS OF RECOMMENDED
(SYMPTOMS) MISADJUSTMENT(S) COURSE OF ACTION
The welding arc is “cold.� The weld- 1. Make sure the MODE selector
ing arc is not stable or is not satis- switch is in the correct position for
factory. the engine runs normally. the process being used. (For
The auxiliary power is normal. example, CV-WIRE, PIPE, CC-
STICK.)
2. Make sure the electrode (wire,
gas, voltage, current etc.) is cor-
rect for the process being used.
3. Check for loose or faulty connec-
tions at the weld output terminals
and welding cable connections. If all recommended possible areas of
misadjustment have been checked
4. The welding cables may be too and the problem persists, Contact
long or coiled, causing an exces- your local Lincoln Authorized
sive voltage drop. Field Service Facility.
CAUTION
If for any reason you do not understand the test procedures or are unable to perform the tests/repairs safely, contact your
Local Lincoln Authorized Field Service Facility for technical troubleshooting assistance before you proceed.
RANGER 305G
F-1 F-1
DIAGRAMS
RANGER 305G
F-2 F-2
DIAGRAMS
RANGER 305G
F-3 F-3
DIAGRAMS
RANGER 305G
F-4 F-4
DIAGRAMS
RANGER 305G
F-5 F-5
DIAGRAMS
RANGER 305G
F-6
ENGINE WELDERS /LN-8 CONNECTION DIAGRAM
WARNING
MOVING PARTS can injure
ELECTRIC SHOCK can kill
Do not operate with panels open. Keep guards in place.
Keep away from moving parts.
Disconnect NEGATIVE (-) Battery lead
before servicing. Only qualified personnel should install,use
or service this equipment.
Do not touch electrically live parts.
14 PIN
TO LN-8 INPUT
AMPHENOL
CABLE PLUG
K595 CONTROL CABLE
_
+
TO WORK
RANGER 305G
ELECTRODE CABLE
DIAGRAMS
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.
4-14-2000
S24787-6
F-6
F-7 F-7
DIAGRAMS
RANGER 305G
F-8 F-8
DIAGRAMS
RANGER 305G
F-9 F-9
DIAGRAMS
RANGER 305G
F-10 F-10
DIAGRAMS
RANGER 305G
F-11 F-11
DIAGRAMS
RANGER 305G
F-12
RANGER 305G WIRING DIAGRAM
PANEL RECEPTACLE CAVITY NUMBERING SEQUENCE
(VIEWED FROM LEAD SIDE OF RECEPTACLE)
321
123
8
654
16
456 S6 MODE SELECTOR SWITCH
987
789 CV
1
214
PIPE
218 A
2
9 PIN 9 PIN (LOCATED BELOW
CC J1
3 TERMINAL 2)
J50 P50
Programing
4
220 TIG
M1 M1
1 222
W4 D1 - THREE PHASE BRIDGE RECTIFIER M2 M2
2
1
9
M3 3 M3
STATOR AMPS
J50 M4 M4
W5 4
HEATSINK M5
WELD M5
5
8
4
+ M6 M6
6
B1 321 WINDINGS 222
7
W3
POS
W9 B2 654
M2
M1
M3
M4
M5
M6
+
C1
M9
220
8
M10
987
B3 P2-J2
M9
M9 9 218
NEG B7 W1 M10 M10
10 Mode
PC BOARD TO
W11
TWISTED PAIR
214
HEAT SINK CONN.
1
Selection
5
P4 J54
206S 204S L1 CHOKE
6 D2 DIODE
W10 W6 MODULE
3
6
6
6
3
11
WRAP TWO TURNS #3 &
SHUNT 14 J3
P3
PC BOARD TO
#6 LEADS IN DIRECTION
50MV=400 AMPS VOLTS
HEAT SINK CONN. JUMPER
P50 Machine
3 SHOWN THROUGH 123 W6
12
NEG
TOROID PLUG
456 Selection
206B
4
1
4
1
C2 789
6 W8 +
206A W11
300 AMP
3 W2
23
PCB 1
M2
M1
M3
M4
M5
M6
M9
MODULE
+
M10
W3 M10
5
25
208B
10
M5
13
261 M9 M4
260
P54 - J4
M3
R1 OUTPUT CONT. POT M2 Meter
CCW M1
206B
1
206C
6
6
10K
M6
R2 ARC CONTROL
W7
4
2
208 208C CCW 77
14 M10
76 75
5
10K
10
P41-J41 M5
13
S5 M9
221 221E
1
1
FIELD WINDING
208A M4
3
279
277
STATOR AUX. WINDING 6
VOLTMETER 212A 212E
2 P5 - J5
M3
WIRE FEED POW ER 206A 278
3
POLARITY 211A 211E
3 M2
WINDING 42 VAC
5
Meter
10
SWITCH 210E
210 M1
4
118A
7
1
6
9 115A 200
5 GND-E M6
200E
5
116A
42 VAC
5L 206S
5H 5E
6 P6-J6
204S
42 P42-J42
41
1
2
21 SHOW N IN 225E
225 L3
7
101A Shunt
POSITIVE (+) 224 224E
105A 8
4
2
12
POSITION 209 209E
9
11 76
1
6
4A
10 P7-J7
77
CONTACTOR
1
PCB2 ANALOG POWER PC BOARD 4
3
Output
CONTROL 75
P52 J52 Control
S3
6
4
2
CB8 3 3
SHOWN IN J8
15A 2
"WELDING ON"
1
3
Hot Start
POSITION
41A
42A 2A
4
2
5L
278
5K 279 P9-J9
IDLER CONTROL
5F 277
1
GND. SCREW ON
3
206C Pinch/
GND-J
CENTER BAFFLE 251
200B Arc Force
L2
BYPASS GND-L
3
GND E BOTTOM GND INSIDE CASEFRONT
6
9
GND-K S4
FILTER 75A
250
ASSEMBLY 212A
209
TOP GND. SCREW ON 76A P10-J10
5 2
224 SHOWN IN
208C INSIDE OF CASE FRONT 77A
GND-K 25A
D3 14 Pin
7 "AUTO" POSITION
4
C3
1
4
CB7 Ampenol
800uf
5H
GND M 210
3
6
5H
150vdc
GND. SCREW ON LEFT 201A
INSIDE CASEFRONT 5C
31 5A WHITE 212 IDLE SOLENOID P11-J11
211A
FRAME GND. 200A 221
31
RANGER 305G
J 5G
GND-A 5B Thermal
115VAC
1
32
A 210C 210C
32 208B
DIAGRAMS
8
6
16 4
201 S2
41A FRAME GND. WHITE S1
I GND-G 250
START
20A POS.BRUSH
42VAC
BUTTON
42A 251
K BLACK
J102
WHITE
215 215
GREEN
3A
3D 211
WORK 21 210D
H NEG. BRUSH
CB1
P12-J12
77B GND-B
E GND-D SILVER
REMOTE 20A
5A Sense/
5E 5J
76B
CONTROL 3A
F BLACK
BLACK
260
210B Idler/
23
CND-C 6B
6E 210A
75B 261
G ROTOR PWM
S1RUN-STOP
5C
CB2
CONTACTOR 25
J101
SWITCH
200E
4B
D 224B HOUR METER
(SHOWN IN
3
89
+
POSITIVE BRUSH CONNECTED
41
RUN POS.)
2B
C 116A
WHITE
224
TO SLIP RING NEAREST
SILVER
GREEN
5F
GROUND 5B
B 105A
5J
TO THE LAMINATION
GND-A 50A P13-J13
CB5 101A
3A POWER
BLACK 118A
AMPHENOL 1 GND-B 6B
3
3E 115A
5
1
77A J100 50A 5G
211E 209E
3E
BLACK
115/230V
77B
A 210E
CB6
REMOTE 221E
76A BLACK 6 PCB3 WELD CONTROL PC BOARD
6F
CONTROL 76B
B 229
4
6B
75A
2
WHITE
75B
C +
225E
WHITE 5C
2A
CONTACTOR 212E
2B 12 VOLT
D
1
TERM.
3
4A BATTERY
P51 228
4B
E - P34-J34
ENGINE TERMINAL 1 234
GROUND GND-B
F PCB7 Battery Display
BLOCK J51
224E
FRAME
GROUND
AMPHENOL 2 U
GROUNDING THIS CIRCUIT WHITE
8
16
STOPS THE ENGINE RR
V GND-H
STARTER
1 2 1 ENGINE
3 210E 224B
GREEN
REGULATOR CR1
OIL GROUND
STARTER
4
1 228
1 1 5 AC
AC B SOLENOID
B- 210B
PRESSURE +
IGNITION 210D
SWITCH 229
MODULE FUEL P43-J43
200
GND J
SHUTOFF
2 3 4 6
4 FLYWHEEL ALTERNATOR
5 10
8 6 SOLENOID
211
KOHLER ENGINE COMPONENTS 5K
1 1
6 8 225
1
9
LEAD COLOR CODE:
L2, L3: RF CHOKES
B=BLACK OR GRAY
R=RED OR PINK PCB4 BATTERY PC BOARD
12 16
7 9 W=WHITE
ELECTRICAL SYMBOLS PER E1537 G=GREEN (W/YELLOW STRIPE)
CONNECTORS VIEWED FROM INSERTION END
ALL CASE FRONT COMPONENTS SHOW N VIEWED FROM REAR. 11-3-2000C
G3743
NOTE: This diagram is for reference only. It may not be accurate for all machines covered by this manual. The specific diagram for a particular code is pasted inside
the machine on one of the enclosure panels. If the diagram is illegible, write to the Service Department for a replacement. Give the equipment code number..
F-12
DIMENSION PRINT RANGER 305G
F-13
10.28 10.78
2.6 24.86
7.22
"A"
20.80
36.24
33.62
CENTER OF GRAVITY WITH OIL IN
ENGINE AND EMPTY FUEL TANK
29.88
"B"
42.10
RANGER 305G
DIAGRAMS
17.50 19.50
DIMENSION “A� 23.50
DIMENSION “B� 16.75
41.20
TRUCK/UNDERCARRIAGE MOUNTING HOLES
3-2000
M19410
F-13
NOTES
RANGER 305G
q Do not touch electrically live parts or q Keep flammable materials away. q Wear eye, ear and body protection.
WARNING electrode with skin or wet clothing.
q Insulate yourself from work and
ground.
Spanish
q No toque las partes o los electrodos q Mantenga el material combustible q Protéjase los ojos, los oÃdos y el
AVISO DE bajo carga con la piel o ropa moja- fuera del área de trabajo. cuerpo.
da.
PRECAUCION q Aislese del trabajo y de la tierra.
French q Ne laissez ni la peau ni des vête- q Gardez à l’écart de tout matériel q Protégez vos yeux, vos oreilles et
ments mouillés entrer en contact inflammable. votre corps.
ATTENTION avec des pièces sous tension.
q Isolez-vous du travail et de la terre.
German q Berühren Sie keine stromführenden q Entfernen Sie brennbarres Material! q Tragen Sie Augen-, Ohren- und Kör-
Teile oder Elektroden mit Ihrem perschutz!
WARNUNG Körper oder feuchter Kleidung!
q Isolieren Sie sich von den
Elektroden und dem Erdboden!
Portuguese
q Não toque partes elétricas e elec- q Mantenha inflamáveis bem guarda- q Use proteção para a vista, ouvido e
trodos com a pele ou roupa molha- dos. corpo.
ATENÇÃO da.
q Isole-se da peça e terra.
Japanese
Chinese
Korean
Arabic
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 HER-
STELLERS. DIE UNFALLVERHÃœTUNGSVORSCHRIFTEN DES ARBEITGEBERS SIND EBENFALLS ZU BEACHTEN.
q Keep your head out of fumes. q Turn power off before servicing. q Do not operate with panel open or
WARNING
q Use ventilation or exhaust to guards off.
remove fumes from breathing zone.
Spanish
q Los humos fuera de la zona de res- q Desconectar el cable de ali- q No operar con panel abierto o
AVISO DE
piración. mentación de poder de la máquina guardas quitadas.
q Mantenga la cabeza fuera de los antes de iniciar cualquier servicio.
PRECAUCION
humos. Utilice ventilación o
aspiración para gases.
French
q Débranchez le courant avant l’entre- q N’opérez pas avec les panneaux
q Gardez la tête à l’écart des fumées.
tien. ouverts ou avec les dispositifs de
q Utilisez un ventilateur ou un aspira-
ATTENTION
protection enlevés.
teur pour ôter les fumées des zones
de travail.
German
q Strom vor Wartungsarbeiten q Anlage nie ohne Schutzgehäuse
q Vermeiden Sie das Einatmen von
abschalten! (Netzstrom völlig öff- oder Innenschutzverkleidung in
Schweibrauch!
WARNUNG
nen; Maschine anhalten!) Betrieb setzen!
q Sorgen Sie für gute Be- und
Entlüftung des Arbeitsplatzes!
Portuguese
q Não opere com as tampas removidas. q Mantenha-se afastado das partes
q Mantenha seu rosto da fumaça.
q Desligue a corrente antes de fazer moventes.
q Use ventilação e exhaustão para
ATENÇÃO
serviço. q Não opere com os paineis abertos
remover fumo da zona respiratória.
q Não toque as partes elétricas nuas. ou guardas removidas.
Japanese
Chinese
Korean
Arabic
LEIA E COMPREENDA AS INSTRUÇÕES DO FABRICANTE PARA ESTE EQUIPAMENTO E AS PARTES DE USO, E SIGA AS
PRÃTICAS DE SEGURANÇA DO EMPREGADOR.
� 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
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