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Operator's Manual
RANGER
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Date Purchased
Code: (ex: 10859)
Serial: (ex: U1060512345)
IM10158-B
| Issue D ate Sep-16
© Lincoln Global, Inc. All Rights Reserved.
®
305G EFI
For use with machines having Code Numbers:
12157, 12206, 12653
Need Help? Call 1.888.935.3877
to talk to a Service Representative
Hours of Operation:
8:00 AM to 6:00 PM (ET) Mon. thru Fri.
After hours?
Use "Ask the Experts" at lincolnelectric.com
A Lincoln Service Representative will contact you
no later than the following business day.
For Service outside the USA:
Email: globalservice@lincolnelectric.com
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Table of Contents
Related Manuals for Lincoln Electric RANGER 305G EFI 12157
Summary of Contents for Lincoln Electric RANGER 305G EFI 12157
- Page 1 Operator’s Manual RANGER ® 305G EFI For use with machines having Code Numbers: 12157, 12206, 12653 Need Help? Call 1.888.935.3877 Register your machine: to talk to a Service Representative www.lincolnelectric.com/register Authorized Service and Distributor Locator: Hours of Operation: www.lincolnelectric.com/locator 8:00 AM to 6:00 PM (ET) Mon. thru Fri. Save for future reference After hours? Use “Ask the Experts”...
- Page 2 THANK YOU FOR SELECTING A QUALITY PRODUCT BY KeeP your head out oF the Fumes. DON’T get too close to the arc. Use LINCOLN ELEC TRIC. corrective lenses if necessary to stay a reasonable distance away from the arc. READ and obey the Material Safety Please examine Carton and equiPment For Data Sheet (MSDS) and the warning damage immediately...
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Page 3: California Proposition 65 Warnings
American Welding Society, P.O. Box 351040, Miami, Florida 33135 or ELECTRIC AND CSA Standard W117.2-1974. A Free copy of “Arc Welding Safety” MAGNETIC FIELDS MAY booklet E205 is available from the Lincoln Electric Company, 22801 St. Clair Avenue, Cleveland, Ohio 44117-1199. BE DANGEROUS BE SURE THAT ALL INSTALLATION, OPERATION, MAINTENANCE AND REPAIR PROCEDURES ARE 2.a. -
Page 4: Electric Shock Can Kill
S FETY ELECTRIC SHOCK ARC RAYS CAN BURN. CAN KILL. 3.a. The electrode and work (or ground) circuits are 4.a. Use a shield with the proper filter and cover plates to protect your electrically “hot” when the welder is on. Do eyes from sparks and the rays of the arc when welding or not touch these “hot”... - Page 5 S FETY WELDING AND CUTTING CYLINDER MAY EXPLODE IF SPARKS CAN CAUSE DAMAGED. FIRE OR EXPLOSION. 7.a. Use only compressed gas cylinders containing the correct shielding gas for the process used 6.a. Remove fire hazards from the welding area. If and properly operating regulators designed for this is not possible, cover them to prevent the welding sparks the gas and pressure used.
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Page 6: Table Of Contents
Auxiliary Power Receptacles and Plugs................A-6 Standby Power Connections ....................A-6 ® Electrical Device Used with the RANGER 305G EFI ............A-7 Premises Wiring ........................A-8 Connection of Lincoln Electric Wire Feeders...............A-9,A-10 ________________________________________________________________________________ Operation.........................Section B Safety Precautions ......................B-1 General Description......................B-1 Design Features ........................B-1 Engine Operation........................B-1 Fuel ............................B-1... - Page 7 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 Oil Filter Change .....................D-2 Air Cleaner Service ..................D-2 Air Pre-Cleaner Service ..................D-2 Air Filter Paper Element ..................D-3 Spark Plug ......................D-3 Spark Plug Service ..................D-3 Fuel Filter ......................D-4...
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Page 8: Installation
INSTALLATION TECHNICAL SPECIFICATIONS - RANGER 305G EFI (K3928-1, K3928-10) ® INPUT - GASOLINE ENGINE Make/Model Speed (RPM) Bore x Stroke Starting Description Capacities Displacement inch (mm) System cu. In.(cu. Cm.) High Idle 3700 2 cylinder 12VDC Battery & Fuel: 12 gal. Starter (K3928-1) 3.27 x 2.72... -
Page 9: Machine Specifications
INSTALLATION MACHINE SPECIFICATIONS - RANGER 305G EFI (K3928-1) ® RECEPTACLES AND CIRCUIT BREAKERS RECEPTACLES AUXILIARY POWER CIRCUIT BREAKER OTHER CIRCUIT BREAKERS (2) 120VAC Duplex (5-20R) Two 20AMP for Two Duplex Receptacle 20AMP for Battery Charging Circuit (1) 120/240VAC Dual Voltage One 50AMP for Dual Voltage (2-pole) 15AMP for 42V Wire Feeder Power Full KVA (14-50R) -
Page 10: Safety Precautions
INSTALLATION SAFETY PRECAUTIONS LIFTING The RANGER 305G EFI weighs approximately WARNING ® 539lbs. (244.5kg) with a full tank of gasoline. A lift bail is mounted to the machine and should always be used Do not attempt to use this equipment until you when lifting the machine. -
Page 11: Vehicle Mounting
INSTALLATION 4. Typical conditions of use, i.e., travel speed; rough- FUEL ness of surface on which the trailer will be operat- ed; environmental conditions; like maintenance. USE GASOLINE FUEL ONLY 5. Conformance with federal, state and local laws. WARNING Consult applicable federal, state and local laws regarding specific requirements for use on public highways. -
Page 12: Muffler Outlet Pipe
INSTALLATION MUFFLER OUTLET PIPE MACHINE GROUNDING Using the clamp provided secure the outlet pipe to the outlet tube with the pipe positioned such that it will direct the exhaust in the desired direction. Tighten Because this portable engine driven using a 9/16" socket or wrench. welder creates its own power, it is not necessary to connect its frame to an earth ground, SPARK ARRESTER... -
Page 13: Cable Installation
INSTALLATION With the engine off connect the electrode and work iary power capacity rating in watts is equivalent to volt- cables to the output studs. The welding process dic- amperes at unity power factor. The max permissible current tates the polarity of the electrode cable. These con- of the 240 VAC output is 40 Amps. -
Page 14: Electrical Device Used With The Ranger
® ranger 305g eFi The Lincoln Electric Company is not responsible for any damage to electrical components improperly connected to the RANGER 305G EFI. ® RANGER 305G EFI... -
Page 15: Premises Wiring
INSTALLATION CONNECTION OF RANGER 305G EFI TO PREMISES WIRING ® 240 VOLT GROUNDED CONDUCTOR POWER 240 Volt 120 VOLT 60 Hz. COMPANY 3-Wire 120 VOLT Service METER NEUTRAL LOAD DOUBLE POLE DOUBLE THROW SWITCH RATING TO BE THE SAME AS OR GREATER THAN PREMISES SERVICE OVERCURRENT PROTECTION. -
Page 16: Connection Of Lincoln Electric Wire Feeders
INSTALLATION CONNECTION OF LINCOLN ELECTRIC • Set the "WIRE FEEDER VOLTMETER" switch to WIRE FEEDERS either "+" or "-" as required by the electrode polarity being used. Connection of LN-7 or LN-8 to the RANGER 305G ® • Set the "ARC CONTROL" knob to "0" initially and adjust to suit. - Page 17 INSTALLATION A-10 A-10 7. Set the "IDLE" switch to the "AUTO" position. When not welding, the RANGER 305G EFI ® engine will be at the low idle speed. If you are using an LN-25 with an internal contactor, the electrode is not energized until the gun trigger is closed.
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Page 18: Operation
OPERATION SAFETY PRECAUTIONS DESIGN FEATURES FOR AUXILIARY POWER: Read and understand this entire section before operating your RANGER 305G EFI ® Start the engine and set the IDLER control switch to Do not attempt to use this equipment until you the desired operating mode. -
Page 19: Welding Controls
OPERATION WELDING CONTROLS 4. ARC CONTROL 1. OUTPUT CONTROL: The ARC CONTROL WIRE/STICK dial is active in the WIRE, STICK and DOWN HILL PIPE modes, and has different func- The CONTROL dial provides continuous control of the tions in these modes. This control is not active in the TIG mode. welding current or welding voltage depending on the selected welding mode. -
Page 20: Engine Controls
OPERATION CV-WIRE mode: In this mode, turning the ARC CONTROL 12. START PUSH BUTTON clockwise from –10 (soft) to +10 (crisp) changes the arc from - Energizes the starter motor to crank the engine soft and washed-in to crisp and narrow. It acts as an induc- tance control. -
Page 21: Stopping
OPERATION DC STICK WELDING CAUTION The RANGER 305G EFI can be used with a broad ® Operating the starter motor for more than 5 sec- range of DC stick electrodes. onds can damage the motor. If the engine fails to The MODE switch provides two stick welding settings start, release the switch and wait 10 seconds as follows:... -
Page 22: Tig Welding
• Set the "IDLER" Switch to the "AUTO" position. • Set the "WELDING TERMINALS" switch to the "REMOTE- Contact your local authorized Lincoln Electric Distributor or the LY CONTROLLED" position. This will keep the "Solid Lincoln Electric Company for specific wires used on certain State"... -
Page 23: Arc Gouging
OPERATION ARC GOUGING The auxiliary power capacity is 12,000 watts Peak, 9500 Watts continuous of 60 Hz, single phase power. The RANGER 305G EFI can be used for limited arc ® The auxiliary power capacity rating in watts is equiva- gouging. -
Page 24: Accessories
ACCESSORIES OPTIONS/ACCESSORIES AND COM- PATIBLE LINCOLN EQUIPMENT K1690-1 GFCI RECEPTACLE KIT Includes one UL approved 120V ground fault circuit K957-1 HEAVY DUTY, TWO WHEEL TRAILER FOR interrupter duplex type receptacle with cover and SMALL WELDERS installation instructions. Replaces the factory installed For road, off-road and in-plant and yard towing. -
Page 25: Maintenance
MAINTENANCE SAFETY PRECAUTIONS KOHLER ENGINE 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. -
Page 26: Engine Oil Change
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. •... -
Page 27: Air Filter Paper Element
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. •... -
Page 28: Fuel Filter
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 (0.11kg) •... -
Page 29: Servicing Optional Spark Arrestor
Inspect the brushes when a generator over- haul is necessary. 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. -
Page 30: 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. - Page 31 TROUBLESHOOTING Observe all Safety Guidelines detailed throughout this manual PROBLEMS POSSIBLE RECOMMENDED (SYMPTOMS) CAUSE COURSE OF ACTION 1. Contact your local Lincoln Major Physical or Electrical Damage Authorized Field Service is Evident. Facility. Engine will not "crank". 1. Battery is low. Charge Battery. 2.
- Page 32 TROUBLESHOOTING Observe all Safety Guidelines detailed throughout this manual PROBLEMS POSSIBLE RECOMMENDED (SYMPTOMS) CAUSE 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.
- Page 33 TROUBLESHOOTING Observe all Safety Guidelines detailed throughout this manual PROBLEMS POSSIBLE RECOMMENDED (SYMPTOMS) CAUSE 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.
- Page 34 TROUBLESHOOTING Observe all Safety Guidelines detailed throughout this manual PROBLEMS POSSIBLE RECOMMENDED (SYMPTOMS) CAUSE 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.
- Page 35 DIAGRAMS RANGER 305G EFI ®...
- Page 36 DIAGRAMS RANGER 305G EFI ®...
- Page 37 DIAGRAMS RANGER 305G EFI ®...
- Page 38 DIAGRAMS RANGER 305G EFI ®...
- Page 39 DIAGRAMS RANGER 305G EFI ®...
- Page 40 DIAGRAMS RANGER 305G EFI ®...
- Page 41 DIAGRAMS RANGER 305G EFI ®...
- Page 42 DIAGRAMS RANGER 305G EFI ®...
- Page 43 DIAGRAMS RANGER 305G EFI ®...
- Page 44 DIAGRAMS F-10 F-10 RANGER 305G EFI ®...
- Page 45 DIAGRAMS F-11 F-11 RANGER 305G EFI ®...
- Page 46 DIMENSION PRINT F-12 F-12 RANGER 305G EFI ®...
- Page 47 NOTES RANGER 305G EFI ®...
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- Page 50 WARNING Do not touch electrically live parts or Keep flammable materials away. Wear eye, ear and body protection. electrode with skin or wet clothing. Insulate yourself from work and AVISO DE ground. Spanish PRECAuCION No toque las partes o los electrodos Mantenga el material combustible Protéjase los ojos, los oídos y el bajo carga con la piel o ropa moja-...
- Page 51 WARNING Keep your head out of fumes. Turn power off before servicing. Do not operate with panel open or Use ventilation or exhaust to guards off. remove fumes from breathing zone. AVISO DE Spanish PRECAuCION Los humos fuera de la zona de res- Desconectar el cable de ali- No operar con panel abierto o piración.
- Page 52 Lincoln Electric for advice or information about their use of our products. We respond to our customers based on the best information in our possession at that time. Lincoln Electric is not in a position to warrant or guarantee such advice, and assumes no liability, with respect to such information or advice.