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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
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:
• 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
RETURN TO MAIN MENU
Ranger 305 G
10708
THIS
OPERATOR'S MANUAL
• World's Leader in Welding and Cutting Products •
Copyright © 2001 Lincoln Global Inc.
IM674
August, 2001
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Summary of Contents for Lincoln Electric RANGER 10708
- Page 1 Ranger 305 G 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.
-
Page 2: California Proposition 65 Warnings
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. -
Page 3: Electric Shock Can Kill
ELECTRIC SHOCK can kill. 3.a. The electrode and work (or ground) circuits are electrically “hot” when the welder is on. Do not touch these “hot” parts with your bare skin or wet clothing. Wear dry, hole-free gloves to insulate hands. - Page 4 WELDING SPARKS can cause fire or explosion. 6.a. Remove fire hazards from the welding area. If this is not possible, cover them to prevent the welding sparks from starting a fire. Remember that welding sparks and hot materials from welding can easily go through small cracks and openings to adjacent areas.
- Page 5 PRÉCAUTIONS DE SÛRETÉ Pour votre propre protection lire et observer toutes les instructions et les précautions de sûreté specifiques qui parraissent dans ce manuel aussi bien que les précautions de sûreté générales suiv- antes: Sûreté Pour Soudage A L’Arc 1. Protegez-vous contre la secousse électrique: a.
- Page 6 This statement appears where the information must be followed to avoid minor personal injury or damage to this equipment. for selecting a QUALITY product by Lincoln Electric. We want you to take pride in operating this Lincoln Electric Company product •••...
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Page 7: Table Of Contents
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... - Page 8 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...
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Page 9: Installation
High Idle 3700 41(674) Bore x Stroke inch (mm) (Group 58; 435 Full Load 3500 3.03 x 2.85 (77 x 72) RATED OUTPUT - WELDER Volts at Rated Amps Duty Cycle Max. 29 Volts @ 305 Amps 100% 20 to 305 Amps... -
Page 10: Machine Specifications
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... -
Page 11: Safety Precautions
The welder should be located to provide an unrestrict- ed flow of clean, cool air to the cooling air inlets and to avoid restricting the cooling air outlets. Also, locate the welder so that the engine exhaust fumes are prop- erly vented to an outside area. STACKING RANGER 305G machines cannot be stacked. -
Page 12: Pre-Operation Engine Service
When in the CC-STICK, PIPE, and CV-WIRE modes and when a remote control is connected to the Amphenol, the auto-sensing circuit in the RANGER 305G automatically switches the OUTPUT control from control at the welder to remote control . RANGER 305G CAUTION... -
Page 13: Electrical Connections
To prevent dangerous electric shock, other equipment to which this engine driven welder supplies power must: WARNING • Be grounded to the frame of the welder using a grounded type plug. • Be double insulated. Do not ground the machine to a pipe that carries explosive or combustible material. -
Page 14: Auxiliary Power Receptacles
• Do not cross the welding cables at the output terminal connection. Keep the cables isolated and separate from one another. ------------------------------------------------------------------------ AUXILIARY POWER RECEPTACLES 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. -
Page 15: Premises Wiring
CONNECTION OF RANGER 305G TO PREMISES WIRING 240 VOLT POWER 240 Volt 60 Hz. COMPANY 3-Wire Service METER DOUBLE POLE DOUBLE THROW SWITCH RATING TO BE THE SAME AS OR GREATER THAN PREMISES SERVICE OVERCURRENT PROTECTION. 50 AMP, 120/240 VOLT PLUG NEMA TYPE 14-50 50 AMP, 120/240 VOLT RECEPTACLE... -
Page 16: Connection Of Lincoln Electric Wire Feeders
2. For electrode Positive, connect the electrode cable from the LN-25 to the "+" terminal of the welder and work cable to the "-" terminal of the welder. For electrode Negative, connect the elec- trode cable from the LN-25 to the "-" terminal of the welder and work cable to the "+"... -
Page 17: Operation
• Insulate yourself from work and ground • Always wear dry insulating gloves. • Always operate the welder with the hinged door closed and the side panels in place. • Read carefully the Safety Precautions page before operating this machine. Always follow... -
Page 18: Arc Control
WELDING CONTROLS 1. OUTPUT CONTROL: The CONTROL dial provides continuous control of the welding current or welding voltage depending on the selected welding mode. This control is not active in the CC-STICK, 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. -
Page 19: Engine Controls
Amphenol, the auto-sensing circuit in the RANGER 305G automatically switches the OUTPUT control from control at the welder to remote control . When using the TOUCH START TIG mode with a TIG Module connected to the RANGER 305G, the OUT-... -
Page 20: Stopping
DC Weld Output 300 Amps @ 29 Volts Auxiliary Power 9,000 Watts OPERATION WELDER OPERATION Stick Welding The RANGER 305G can be used with a broad range of DC stick electrodes. The MODE switch provides two stick welding settings as follows:... -
Page 21: Tig Welding
TIG Welding The TOUCH START TIG setting of the MODE switch is for DC TIG (Tungsten Inert Gas) welding. To initiate a weld, the CONTROL dial is first set to the desired current and the tungsten is touched to the work. During the time the tungsten is touching the work there is very little voltage or current and, in general, no tungsten contamination. -
Page 22: Arc Gouging
ARC GOUGING The RANGER 305G can be used for limited arc goug- ing. For optimal performance, set the MODE switch to CC-STICK and the ARC CONTROL to +10. Set the CONTROL knob to adjust output current to the desired level for the gouging electrode being used according to the ratings in the following table. -
Page 23: Accessories
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... -
Page 24: Maintenance
SAFETY PRECAUTIONS WARNING • Have qualified personnel do all maintenance and troubleshooting work. • Turn the engine off before working inside the machine or servicing the engine. • Remove guards only when necessary to perform maintenance and replace them when the maintenance requiring their removal is complete. -
Page 25: Engine Oil Change
Engine Oil Change Drain the oil while the engine is warm to assure rapid and complete draining. • Remove the oil filler cap and dipstick. Remove the yellow cap from the oil drain valve and attach the flexible drain tube supplied with the machine. Push in and twist the drain valve counterclockwise. -
Page 26: Air Filter Paper Element
AIR FILTER PAPER ELEMENT • Loosen the cover retaining knob and remove the cover. • Remove the pre-cleaner from the paper element. • Remove the element cover nut, element cover, and paper element. • Do not wash the paper element or use pressurized air, as this will damage the element. -
Page 27: Fuel Filter
● CONNECTING A BATTERY CHARGER — remove battery from welder by disconnecting negative cable first, then positive cable and battery clamp. When reinstalling, connect negative cable last. Keep well ventilated. -
Page 28: 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 29: Troubleshooting
HOW TO USE TROUBLESHOOTING GUIDE 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 30 Observe all Safety Guidelines detailed throughout this manual PROBLEMS (SYMPTOMS) Major Physical or Electrical Damage is Evident. Engine will not "crank". Engine will "crank" but not start. Engine shuts down shortly after starting. Battery does not stay charged. Engine alternator trouble light is on while machine is running.
- Page 31 TROUBLESHOOTING POSSIBLE AREAS OF MISADJUSTMENT(S) 1. Idler switch in High idle position. 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. 1. Poor work lead connection to work.
- Page 32 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. 1. Poor remote/control cable connec- tion to 6 pin or 14 pin Amphenol connector.
- Page 33 Observe all Safety Guidelines detailed throughout this manual PROBLEMS (SYMPTOMS) The welding arc is “cold.” The weld- ing arc is not stable or is not satis- factory. the engine runs normally. The auxiliary power is normal. 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.
- Page 34 DIAGRAMS RANGER 305G...
- 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 F-10 F-10 DIAGRAMS RANGER 305G...
- Page 44 F-11 F-11 DIAGRAMS RANGER 305G...
- Page 45 F-12 DIAGRAMS 1 1 1 1 BLACK WHITE GREEN RANGER 305G GREEN BLACK WHITE GREEN F-12...
- Page 46 F-13 F-13 DIAGRAMS RANGER 305G...
- Page 47 NOTES RANGER 305G...
- Page 48 ● WARNING ● Spanish ● AVISO DE PRECAUCION ● French ● ATTENTION ● ● German WARNUNG ● Portuguese ● ATENÇÃO ● 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.
- Page 49 ● ● Keep your head out of fumes. Turn power off before servicing. ● Use ventilation or exhaust to remove fumes from breathing zone. ● Los humos fuera de la zona de res- ● Desconectar el cable de ali- piración. mentación de poder de la máquina ●...
- Page 50 • 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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