Lincoln Electric Ranger 305LPG Operator's Manual
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Lincoln Electric Ranger 305LPG Operator's Manual

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Operator's Manual
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Date Purchased
Code: (ex: 10859)
Serial: (ex: U1060512345)
IM10381
| Issue D ate Apr-21
© Lincoln Global, Inc. All Rights Reserved.
305LPG
®
For use with machines having Code Numbers:
12669, 13173
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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  • Page 1 Operator’s Manual Ranger 305LPG ® For use with machines having Code Numbers: 12669, 13173 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. LINCOLN ELEC TRIC. Use corrective lenses if necessary to stay a reasonable distance away from the arc. READ and obey the Safety Data PLEASE EXAMINE CARTON AND EQUIPMENT FOR Sheet (SDS) and the warning label DAMAGE IMMEDIATELY...
  • Page 3 W117.2-1974. A Free copy of “Arc Welding Safety” booklet E205 is available from the Lincoln Electric Company, 2.d. All welders should use the following procedures in order to 22801 St. Clair Avenue, Cleveland, Ohio 44117-1199.
  • Page 4 SAFETY 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 SAFETY 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.

  • Page 6: Table Of Contents

    Electrical Connections ......................A-5 Machine Grounding.......................A-5 Welding Terminals ......................A-6 Welding Output Cables ....................A-6 Cable Installation......................A-6 Electrical Device Used with the Ranger 305LPG ..............A-7 Auxiliary Power Receptacles and Plugs................A-8 Standby Power Connections ....................A-8 Premises Wiring ........................A-9 Connection of Lincoln Electric Wire Feeders.............A-10,A-11 ________________________________________________________________________________ Operation.........................Section B...
  • 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 Engine Adjustment ..................D-4...

  • Page 8: Installation

    INSTALLATION TECHNICAL SPECIFICATIONS - RANGER® 305LPG (K2937-10) INPUT - LPG ENGINE Make/Model Description Horsepower Operating Displacement cu.in.(cu.cm) Starting Capacities @ 3600 RPM Speed Bore x Stroke in.(mm) System 12VDC Battery High and Starter Fuel: LPG Kohler 2 Cylinder 3700RPM Cylinder CH730S 4 Cycle 25 HP...

  • Page 9: Machine Specifications

    INSTALLATION MACHINE SPECIFICATIONS - RANGER® 305LPG (K2937-10) RECEPTACLES AND CIRCUIT BREAKERS RECEPTACLES AUXILIARY POWER CIRCUIT BREAKER OTHER CIRCUIT BREAKERS (2) 120VAC Duplex GFCI(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) RANGER®...

  • Page 10: Safety Precautions

    INSTALLATION SAFETY PRECAUTIONS ADDITIONAL SAFETY PRECAUTIONS WARNING WARNING Do not attempt to use this equipment until you • Lift only with equipment of have thoroughly read the engine manufacturer’s adequate lifting capacity. manual supplied with your welder. It includes important safety precautions, detailed engine •...

  • Page 11: Vehicle Mounting

    INSTALLATION VEHICLE MOUNTING CAUTION WARNING Be certain that the cylinder valve is CLOSED before Improperly mounted concentrated loads may attempting to attach the fuel supply hose coupler to cause unstable vehicle handling and tires or other the cylinder. Connect the coupler to the fuel cylinder components to fail.

  • Page 12: Oil

    INSTALLATION CAUTION The RANGER® 305LPG is shipped with the engine crankcase filled with high quality SAE 10W-30 oil. tained. An incorrect spark arrestor may lead to damage to Check the oil level before starting the engine. If it is the engine or adversely affect performance. not up to the full mark on the dip stick, add oil as required.

  • Page 13: Welding Terminals

    INSTALLATION ------------------------------------------------------------------------ TABLE A-1 When this welder is mounted on a truck or trailer, its TOTAL COMBINED LENGTH OF frame must be electrically connected to the metal ELECTRODE AND WORK CABLES frame of the vehicle, use a #8 or larger copper wire connected between the machine grounding stud and frame of the vehicle.
  • Page 14 Do NoT USE THESE DEVICES WITH THIS pRoDUCT The Lincoln Electric Company is not responsible for any damage to electrical components improperly connected RANGER® 305LPG...

  • Page 15: Standby Power Connections

    INSTALLATION AUXILIARY POWER RECEPTACLES STANDBY POWER CONNECTIONS Start the engine and set the “IDLER” control switch to the “High Idle” mode. Voltage is now correct at the receptacles for auxiliary power. This must be done The RANGER® 305LPG is suitable for temporary, standby before a tripped GFCI can be reset properly.
  • Page 16 INSTALLATION CONNECTION OF RANGER® 305LPG TO PREMISES 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 17: Connection Of Lincoln Electric Wire Feeders

    INSTALLATION A-10 A-10 CONNECTION OF LINCOLN ELECTRIC • Set the "WIRE FEEDER VOLTMETER" switch to WIRE FEEDERS either "+" or "-" as required by the electrode polarity being used. • Set the "ARC CONTROL" knob to "0" initially and Connection of LN-7 or LN-8 to the RANGER®...
  • Page 18 INSTALLATION A-11 A-11 CAUTION If you are using an LN-25 without an internal con- tactor, the electrode will be energized when the RANGER® 305LPG is started. ------------------------------------------------------------------------ Connection of LN-742,K487-25 Spool Gun, and Cobramatic to RANGER® 305LPG 1. Shut the welder off. 2.

  • Page 19: Operation

    DC welding circuit and single phase power for the AC auxiliary outlets. The DC welding control system uses state of the art Chopper Technology for superior welding performance. The RANGER 305LPG is NOT RECOMMENED for pipe thawing. RANGER® 305LPG...
  • Page 20 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 welding current or welding voltage depending on the mode.

  • Page 21: Engine Controls

    OPERATION 12. CHOKE CV-WIRE mode: In this mode, turning the ARC CONTROL - When pulled out, it closes the choke valve clockwise from –10 (soft) to +10 (crisp) changes the arc on the engine carburetor for quick starting. from soft and washed-in to crisp and narrow. It acts as an 13.

  • Page 22: Stopping

    OPERATION DC STICK WELDING CAUTION The RANGER® 305LPG can be used with a broad range of DC stick electrodes. The MODE switch provides two stick welding settings Operating the starter motor for more than 5 sec- as follows: onds can damage the motor. If the engine fails to start, release the switch and wait 10 seconds CONSTANT CURRENT...

  • Page 23: 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 24: Arc Gouging

    OPERATION ARC GOUGING The auxiliary power capacity is 10,000 watts Peak, 9,000 Watts continuous of 60 Hz, single phase power. The RANGER® 305LPG can be used for limited arc The auxiliary power capacity rating in watts is equiva- gouging. For optimal performance, set the MODE lent to volt-amperes at unity power factor.

  • Page 25: Accessories

    ACCESSORIES OPTIONS/ACCESSORIES AND COM- PATIBLE LINCOLN EQUIPMENT K802N POWER PLUG KIT Provides four 120 volt plugs rated at 20 amps each K957-1 HEAVY DUTY, TWO WHEEL TRAILER FOR and one dual voltage, full KVA plug rated at 120/240 SMALL WELDERS volts, 50 amps.

  • Page 26: Maintenance

    MAINTENANCE SAFETY PRECAUTIONS KOHLER ENGINE FREQUENCY MAINTENANCE REQUIRED WARNING Daily or Before • Check oil level. • Have qualified personnel do all maintenance Starting Engine • Check air cleaner for dirty, loose, and troubleshooting work. or damaged parts. • Turn the engine off before working inside the •...

  • Page 27: 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 28: 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 29: Engine Adjustment

    MAINTENANCE CLEANING THE BATTERY ENGINE ADJUSTMENT Keep the battery clean by wiping it with a damp cloth OVERSPEED IS HAZARDOUS when dirty. If the terminals appear corroded, discon- nect the battery cables and wash the terminals with an The maximum allowable high idle speed for this ammonia solution or a solution of 1/4 pound (0.11kg) machine is 3750 RPM, no load.

  • Page 30: Welder/Generator Maintenance

    • Push the "Test" button located on the GFCI. The Service and Repair should only be performed by night-light or other product should go "OFF". Lincoln Electric Factory Trained Personnel. • Push the "Reset" button, again. The light or other Unauthorized repairs performed on this equip- product should go "ON"...
  • Page 31 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 32: Troubleshooting

    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 33 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 34 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 35 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 36 DIAGRAMS RANGER® 305LPG...
  • Page 37 DIAGRAMS RANGER® 305LPG...
  • Page 38 DIAGRAMS RANGER® 305LPG...
  • Page 39 DIAGRAMS RANGER® 305LPG...
  • Page 40 DIAGRAMS RANGER® 305LPG...
  • Page 41 DIAGRAMS RANGER® 305LPG...
  • Page 42 DIAGRAMS RANGER® 305LPG...
  • Page 43 DIAGRAMS RANGER® 305LPG...
  • Page 44 DIMENSION PRINT RANGER® 305LPG...
  • Page 45 Ranger 305LPG - 12669...
  • Page 46 INDEX OF SUB ASSEMBLIES P-1110-C CASE FRONT ASSEMBLY - UPPER P-1110-D CASE FRONT ASSEMBLY - LOWER P-1110-E BASE ASSEMBLY & BATTERY P-1110-F ENGINE ASSEMBLY P-1110-G BLOWER BAFFLE ASSEMBLY P-1110-H STATOR/ROTOR ASSEMBLY P-1110-J COVERS & CASE BACK ASSEMBLY Ranger 305LPG - 12669...
  • Page 47 Index of Sub Assemblies - 12669 P-1110-A.jpg Ranger 305LPG - 12669...
  • Page 48 DOOR LATCH 9SS24659 CATCH BRACKET 9SS8025-98 SELF TAPPING SCREW 9SS17475-8 HOUR METER DIGITAL SNAP-IN 9SM19685-24 CONNECTOR & LEAD ASBLY 9ST10800-38 SWITCH-TOGGLE 9ST10800-39 SWITCH-TOGGLE 9SM19685-30 CONNECTOR & LEAD ASBLY 9SS16670-10 ROTARY SWITCH 9ST10812-119 POTENTIOMETER 9SS18280 POTENTIOMETER SPACER Ranger 305LPG - 12669...
  • Page 49 Case Front Assembly - Upper PART NUMBER DESCRIPTION 9SL11160 METER HOUSING ASBLY 9SS24630 METER HOUSING SEAL 9SM19368 METER BEZEL 9ST14807-9 FILTER LENS 9SCF000389 #4-40X.375SS-PPNHS-FULL-GR2-3147 9SCF000005 #6-32HN 9SS9262-3 PLAIN WASHER 9SS9225-68 THREAD FORMING SCREW (CUTTING) 9SM19452-4 OPERATION DECAL Ranger 305LPG - 12669...
  • Page 50 Case Front Assembly - Upper P-1110-C.jpg Ranger 305LPG - 12669...
  • Page 51 9SS24738-3 THERMOPLASTIC SCREW 9SS27176 RECEPTACLE SEAL 9ST9187-1 1/4-20HJLN 9SCF000017 1/4-20HN 9SL12790-11 RATING PLATE 9SS8025-96 SELF TAPPING SCREW 9SS17062-11 CABLE CONNECTOR CAP 9SS17062-10 CABLE CONNECTOR CAP 9SS24982 BYPASS FILTER ASBLY 9SS9262-27 PLAIN WASHER 9SE106A-1 LOCKWASHER 9SCF000010 #10-24HN Ranger 305LPG - 12669...
  • Page 52 DESCRIPTION 9SS12021-70 BOX RECEPTACLE SOLID SHELL 9SS12021-68 CONNECTOR 9SS24097-4 SHUNT & LEAD ASBLY 9SCF000344 HEX HD SCREW 9SS9262-1 PLAIN WASHER 9SE106A-15 LOCKWASHER 9SS25669 OUTPUT STUD COVER PLATE 9SS9225-68 THREAD FORMING SCREW (CUTTING) 9SM20007 OUTPUT STUD COVER Ranger 305LPG - 12669...
  • Page 53 Case Front Assembly - Lower P-1110-D.jpg Ranger 305LPG - 12669...
  • Page 54 THREE PHASE BRIDGE RECTIFIER 9SE106A-14 LOCKWASHER 9SS24344-1 RUBBER MOUNT 9SCF000196 3/8-16X2.50HHB-FULL-GR5-1817/1 9SS9262-113 PLAIN WASHER 9SCF000067 3/8-16HN 9SS9225-68 THREAD FORMING SCREW (CUTTING) 9SM9399-13 BATTERY 9SS22018 BATTERY BRKT 9SS8070-20 BATTERY CABLE 9SS8070-11 BATTERY CABLE 9ST14654 CAP-PLASTIC 9SS20191-1 BATTERY TERMINAL COVER Ranger 305LPG - 12669...
  • Page 55 Base Assembly & Battery P-1110-E.jpg Ranger 305LPG - 12669...
  • Page 56 9SM21306 ENGINE 9SS24344-1 RUBBER MOUNT 9SCF000196 3/8-16X2.50HHB-FULL-GR5-1817/1 9SS9262-120 PLAIN WASHER 9SS9262-47 PLAIN WASHER 9SE106A-16 LOCKWASHER 9SCF000067 3/8-16HN 9SG3574-4 MUFFLER ASBLY 9SM16999-1 GASKET-EXHAUST MANIFOLD 9SM16980-1 OUTLET PIPE ELBOW 9SS20462 SPARK ARRESTOR CLAMP 9SM18995-1 LPG FUEL HOSE ASBLY Ranger 305LPG - 12669...
  • Page 57 Engine Assembly P-1110-F.jpg Ranger 305LPG - 12669...
  • Page 58 PLAIN WASHER 9SE106A-1 LOCKWASHER 9SCF000010 #10-24HN 9SS10404-138 RESISTOR-WW100W505% 9SS22168 HEAT SINK HOLDER 9SS9225-17 THREAD FORMING SCREW (ROLLING) 9SS9262-98 PLAIN WASHER 9SE106A-2 LOCKWASHER 9SCF000017 1/4-20HN 9SCF000191 #10-24X7.50RHS 9SS9262-27 PLAIN WASHER 9SE106A-1 LOCKWASHER 9SCF000010 #10-24HN 9ST13637-6 DIODE-BRIDGE35A400VF-W1-PH 9SCF000072 #10-24X.75RHS Ranger 305LPG - 12669...
  • Page 59 Blower Baffle Assembly PART NUMBER DESCRIPTION 9SS9262-27 PLAIN WASHER 9SE106A-1 LOCKWASHER 9SCF000010 #10-24HN 9SS9225-68 THREAD FORMING SCREW (CUTTING) 9SS18543-5 GROMMET Ranger 305LPG - 12669...
  • Page 60 Blower Baffle Assembly P-1110-G.jpg Ranger 305LPG - 12669...
  • Page 61 1/4-20HN 9SG3541-7 STATOR LAMINATION ASBLY 9ST8833-10 HEX HD CAP SCREW 9SE106A-16 LOCKWASHER 9SS9262-120 PLAIN WASHER 9SE106A-16 LOCKWASHER 9SCF000067 3/8-16HN 9SS20752 SOLENOID ASBLY 9SS8025-91 SELF TAPPING SCREW 9SS20848 PULL WIRE 9SS21177 BRACKET 9SS21015 BUSHINGLINKAGE RETAINING 9ST6778 SPRING Ranger 305LPG - 12669...
  • Page 62 Stator/Rotor Assembly PART NUMBER DESCRIPTION 9SS21020 PLUNGER 9SS9262-98 PLAIN WASHER 9ST9187-1 1/4-20HJLN 9ST10642-242 FLEX TUBE 9ST14882-1 DOOR BUMPER Ranger 305LPG - 12669...
  • Page 63 Stator/Rotor Assembly P-1110-H.jpg Ranger 305LPG - 12669...
  • Page 64 9SS17851 DECAL-CAUTION 9SM16197 DECAL-WARNING 9ST13086-109 DECAL-LPG WARNING 9SG6844 WIRING DIAGRAM 9SS30277-3 WARRANTY DECAL 9SS27368-5 DECAL - 14IN LINCOLN LOGO 9SS26886 ENGINE SERVICE DECAL 9SS24665 OIL DRAIN DECAL 9SM21436 CARBON MONOXIDE WARNING DECAL 9SS24727-1 DECALCOUNTRY OF ORIGIN Ranger 305LPG - 12669...
  • Page 65 Covers & Case Back Assembly PART NUMBER DESCRIPTION 9SS25896 DECAL-WARNING 9SM22185 BATTERY COVER 9SS9225-68 THREAD FORMING SCREW (CUTTING) 9SM22367 FOAM AIR BOX 9SM21952-1 DECAL - RANGER FAMILY NAME Ranger 305LPG - 12669...
  • Page 66 Covers & Case Back Assembly P-1110-J.jpg Ranger 305LPG - 12669...
  • Page 67 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 68 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 69 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.

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