Lincoln Electric RANGER 11676 Operator's Manual
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Lincoln Electric RANGER 11676 Operator's Manual

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Operator's Manual
RANGER
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Date Purchased
Code: (ex: 10859)
Serial: (ex: U1060512345)
IM10042-D
| Issue D ate Aug- 13
© Lincoln Global, Inc. All Rights Reserved.
®
305G
For use with machines having Code Numbers:
11676, 11738, 11794, 11801,
12097, 12203
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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Summary of Contents for Lincoln Electric RANGER 11676

  • Page 1 Operator’s Manual ® RANGER 305G For use with machines having Code Numbers: 11676, 11738, 11794, 11801, 12097, 12203 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.
  • Page 2 THANK YOU FOR SELECTING A QUALITY PRODUCT BY KEEP YOUR HEAD OUT OF THE FUMES. LINCOLN ELEC TRIC. DON’T get too close to the arc. Use 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...
  • Page 3 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, 2.a.
  • 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 the gas and pressure used.

  • Page 6: Table Of Contents

    Welding Output Cables ....................A-6 Cable Installation......................A-6 Auxiliary Power Receptacles and Plugs ................A-6 Standby Power Connections ....................A-6 Electrical Device Used with the Ranger® 305G..............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...
  • 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...

  • Page 8: Installation

    INSTALLATION TECHNICAL SPECIFICATIONS - RANGER® 305G (K1726-5) INPUT - GASOLINE ENGINE Make/Model Speed (RPM) Displacement Bore x Stroke Starting Description Capacities cu. In.(cu. Cm.) inch (mm) System High Idle 3700 41(674) 3.15 x 2.64 12VDC Battery & Kohler 2 cylinder Fuel: 12 gal.

  • Page 9: Machine Specifications

    INSTALLATION MACHINE SPECIFICATIONS - RANGER® 305G (K1726-5) 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) RANGER®...

  • Page 10: Safety Precautions

    INSTALLATION SAFETY PRECAUTIONS LIFTING The RANGER® 305G weighs approximately 539lbs. WARNING (244.5kg) with a full tank of gasoline. A lift bail is mounted to the machine and should always be used when lifting the machine. Do not attempt to use this equipment until you have thoroughly read the engine manufacturerʼs manual supplied with your welder.

  • Page 11: Vehicle Mounting

    INSTALLATION 1. Design capacity of trailer vs. Weight of Lincoln equipment and likely additional attachments. The RANGER® 305G is shipped with the engine crankcase 2. Proper support of, and attachment to, the base of the welding filled with high quality SAE 10W-30 oil. Check the oil level equipment so there will be no undue stress to the framework.

  • Page 12: Muffler Outlet Pipe

    INSTALLATION NOTE: This machine is furnished with a wet charged bat- NOTE: When a wire feeder with a built in welding volt- tery; if unused for several months, the battery may require a age control is connected to the 14-pin connector, do booster charge.

  • Page 13: Welding Output Cables

    INSTALLATION WELDING OUTPUT CABLES The auxiliary power capacity is 10,500 watts Peak, 9500 Watts Continuous of 60 Hz, single phase power. The auxil- With the engine off connect the electrode and work cables to the output studs. The welding process dic- iary power capacity rating in watts is equivalent to volt- tates the polarity of the electrode cable.

  • Page 14: Electrical Device Used With The Ranger® 305G

    DO NOT USE THESE DEVICES WITH A RANGER® 305G The Lincoln Electric Company is not responsible for any damage to electrical components improperly connected to the RANGER® 305G. RANGER® 305G...

  • Page 15: Premises Wiring

    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 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 WIRE FEEDERS • Set the "WIRE FEEDER VOLTMETER" switch to 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 1.
  • Page 17 A-10 A-10 INSTALLATION 7. Set the "IDLE" switch to the "AUTO" position. When not welding, the RANGER® 305G engine will be at the low idle speed. If you are using an LN-25 with an internal contactor, the electrode is not energized until the gun trigger is closed. 8.

  • Page 18: Operation

    OPERATION SAFETY PRECAUTIONS DESIGN FEATURES Read and understand this entire section before FOR AUXILIARY POWER: operating your RANGER® 305G Start the engine and set the IDLER control switch to Do not attempt to use this equipment until you the desired operating mode. Full power is available have thoroughly read all operating and mainte- regardless of the welding control settings providing no nance manuals supplied with your machine.
  • Page 19 OPERATION WELDING CONTROLS 4. ARC CONTROL The ARC CONTROL WIRE/STICK dial is active in the WIRE, 1. OUTPUT CONTROL: 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 13. START PUSH BUTTON CV-WIRE mode: In this mode, turning the ARC CONTROL 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 can be used with a broad range Operating the starter motor for more than 5 sec- 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: before operation the starter again.

  • Page 22: Tig Welding

    • Set the MODE Switch to the TOUCH START TIG setting. • Set the "IDLER" Switch to the "AUTO" position. Contact your local authorized Lincoln Electric Distributor or the • Set the "WELDING TERMINALS" switch to the "REMOTE- Lincoln Electric Company for specific wires used on certain LY CONTROLLED"...

  • Page 23: Arc Gouging

    OPERATION ARC GOUGING The auxiliary power capacity is 10,500 watts Peak, 9500 Watts continuous of 60 Hz, single phase power. The RANGER® 305G 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 24: Accessories

    ACCESSORIES OPTIONS/ACCESSORIES AND COM- K1690-1 GFCI RECEPTACLE KIT PATIBLE LINCOLN EQUIPMENT 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: Welder/Generator Maintenance

    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.

  • 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 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.
  • 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...
  • Page 36 DIAGRAMS RANGER® 305G...
  • Page 37 DIAGRAMS RANGER® 305G...
  • Page 38 DIAGRAMS RANGER® 305G...
  • Page 39 DIAGRAMS RANGER® 305G...
  • Page 40 DIAGRAMS RANGER® 305G...
  • Page 41 DIAGRAMS RANGER® 305G...
  • Page 42 DIAGRAMS RANGER® 305G...
  • Page 43 DIAGRAMS RANGER® 305G...
  • Page 44 F-10 F-10 DIAGRAMS RANGER® 305G...
  • Page 45 F-11 F-11 DIAGRAMS RANGER® 305G...
  • Page 46 F-12 F-12 DIMENSION PRINT Enhanced Diagram RANGER® 305G...
  • Page 47 F-13 F-13 DIMENSION PRINT RANGER® 305G...
  • Page 48 NOTES RANGER® 305G...
  • Page 49 This parts list is provided as an informative guide only. It was accurate at the time of printing. These pages are only updated on the Service Navigator DVD and in Lincoln Electricʼs official Parts Book (BK-34). When ordering parts, always refer to Lincoln Electricʼs official Parts Book (BK-34) for the latest pages.
  • Page 50 P-640-A P-640-A ILLUSTRATION OF SUB-ASSEMBLIES Jan-14 RANGER 305G ®...
  • Page 51 P-640-A.1 P-640-A.1 RANGER 305G ® For Codes: 11676, 11738, 11794, 11801, 12097 & 12203 Do Not use this Parts List for a machine if its code number is not listed. Contact the Service Department for any code numbers not listed. Use the Illustration of Sub-Assemblies page and the table below to determine which sub assembly page and column the desired part is located on for your particular code machine.
  • Page 52 P-640-C P-640-C Control Panel Assembly Jan-14 RANGER 305G ®...
  • Page 53 P-640-C.1 P-640-C.1 # Indicates a change this printing. Use only the parts marked “x” in the column under the heading number called for in the model index page. 1 2 3 4 5 6 7 8 9 ITEM DESCRIPTION PART NO. QTY.
  • Page 54 P-640-D P-640-D Case Front Assembly Jan-14 RANGER 305G ®...
  • Page 55 P-640-D.1 P-640-D.1 # Indicates a change this printing. Use only the parts marked “x” in the column under the heading number called for in the model index page. 1 2 3 4 5 6 7 8 9 ITEM DESCRIPTION PART NO. QTY.
  • Page 56 P-640-E P-640-E Base/Fuel Tank/Battery Assembly 4G 4H Jan-14 RANGER 305G ®...
  • Page 57 P-640-E.1 P-640-E.1 # Indicates a change this printing. Use only the parts marked “x” in the column under the heading number called for in the model index page. 1 2 3 4 5 6 7 8 9 ITEM DESCRIPTION PART NO. QTY.
  • Page 58 P-640-E.2 P-640-E.2 # Indicates a change this printing. Use only the parts marked “x” in the column under the heading number called for in the model index page. 1 2 3 4 5 6 7 8 9 ITEM DESCRIPTION PART NO. QTY.
  • Page 59 NOTES RANGER 305G ®...
  • Page 60 P-640-F P-640-F Engine Assembly Jan-14 RANGER 305G ®...
  • Page 61 P-640-F.1 P-640-F.1 # Indicates a change this printing. Use only the parts marked “x” in the column under the heading number called for in the model index page. 1 2 3 4 5 6 7 8 9 ITEM DESCRIPTION PART NO. QTY.
  • Page 62 P-640-G P-640-G Blower Baffle Assembly Jan-14 RANGER 305G ®...
  • Page 63 P-640-G.1 P-640-G.1 # Indicates a change this printing. Use only the parts marked “x” in the column under the heading number called for in the model index page. 1 2 3 4 5 6 7 8 9 ITEM DESCRIPTION PART NO. QTY.
  • Page 64 P-640-H P-640-H Stator/Rotor Assembly 11 11 10 Jan-14 RANGER 305G ®...
  • Page 65 P-640-H.1 P-640-H.1 # Indicates a change this printing. Use only the parts marked “x” in the column under the heading number called for in the model index page. 1 2 3 4 5 6 7 8 9 ITEM DESCRIPTION PART NO. QTY.
  • Page 66 P-640-J P-640-J Covers & Case Back Assembly Jan-14 RANGER 305G ®...
  • Page 67 P-640-J.1 P-640-J.1 # Indicates a change this printing. Use only the parts marked “x” in the column under the heading number called for in the model index page. 1 2 3 4 5 6 7 8 9 ITEM DESCRIPTION PART NO. QTY.
  • Page 68 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.

This manual is also suitable for:

Ranger 305gRanger 11738Ranger 11794Ranger 11801Ranger 12097Ranger 12203

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