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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 G
10855,10955
THIS
OPERATOR'S MANUAL
• World's Leader in Welding and Cutting Products •
Copyright © 2002 Lincoln Global Inc.
IM742-A
August, 2002
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Summary of Contents for Lincoln Electric RANGER IM742-A
- Page 1 RANGER 305 G 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. 3.b. - 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 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...
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Page 9: Installation
TECHNICAL SPECIFICATIONS - Ranger 305G (K1726-1) Make/Model Description 2 cylinder Kohler CH22 (K1726-1) 22 HP @ 3600 RPM RATED OUTPUT @ 104° F (40° C) - WELDER Welding Output CC STICK DC Output CC STICK Output Range PIPE DC Output PIPE Output Range TIG Output Range CV WIRE DC Output... -
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
SAFETY PRECAUTIONS WARNING Do not attempt to use this equipment until you have thoroughly read the engine manufacturer’s manual supplied with your welder. It includes important safety precautions, detailed engine starting, operating and maintenance instructions, and parts lists. ------------------------------------------------------------------------ ELECTRIC SHOCK can kill. •... -
Page 12: Pre-Operation Engine Service
PRE-OPERATION ENGINE SERVICE WARNING READ the engine operating and maintenance instruc- tions supplied with this machine. • Stop engine and allow to cool before fueling • Do not smoke when fueling • Fill fuel tank at a moderate rate and do not over- fill. -
Page 13: Electrical Connections
The 14 pin connector is used to directly connect a wire feeder or TIG Module (K930-2) control cable. In the CV-WIRE mode, the RANGER 305G auto-sensing circuit automatically makes the RANGER 305G Output Control inactive and the wire feeder voltage control active when the control cable is connected to the 14 pin connector. -
Page 14: Standby Power Connections
CAUTION • Loose connections will cause the output termi- nals to overheat. The terminals may eventually melt. • 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
CONNECTION OF LINCOLN ELECTRIC WIRE FEEDERS Connection of the LN-25 to the RANGER 305G WARNING Shut off welder before making any electrical con- nections. ------------------------------------------------------------------------ The LN-25 with or without an external contactor may be used with the RANGER 305G. See the appropriate connection diagram in Section F. -
Page 17: Operation
SAFETY PRECAUTIONS WARNING Do not attempt to use this equipment until you have thoroughly read the engine manufacturer’s manual supplied with your welder. It includes important safety precautions, detailed engine starting, operating and maintenance instructions, and parts lists. ------------------------------------------------------------------------ ELECTRIC SHOCK can kill. •... - Page 18 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.
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Page 19: Engine Controls
5. WELD OUTPUT TERMINALS WITH FLANGE NUT: Provides a connection point for the electrode and work cables. 6. GROUND STUD: (graphic) Provides a connection point for connecting the machine case to earth ground for the safest grounding procedure. 7. 14 PIN AMPHENOL: For attaching wire feeder control cables to the RANGER 305G. -
Page 20: Stopping
• The engine will run at high idle speed for approxi- mately 12 seconds and then go to low idle speed. Allow the engine to warm up at low idle for several minutes before applying a load and/or switching to high idle. -
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 cur- rent 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 con- tamination. -
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
OPTIONS/ACCESSORIES AND COM- PATIBLE LINCOLN EQUIPMENT K957-1 HEAVY DUTY, TWO WHEEL TRAILER FOR SMALL WELDERS For road, off-road and in-plant and yard towing. (For highway use, consult applicable federal, state and local laws regarding requirements for brakes, lights, fenders, etc.).Order: K957-1 Trailer K958-1 Ball Hitch K958-2 Lunette Eye Hitch... -
Page 24: Maintenance
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
FUEL FILTER • Check the fuel filter for water accumulation or sedi- ment. • Replace the fuel filter if it is found with excessive water accumulation or sediment. ENGINE ADJUSTMENT OVERSPEED IS HAZARDOUS The maximum allowable high idle speed for this machine is 3750 RPM, no load. -
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 Observe all Safety Guidelines detailed throughout this manual PROBLEMS (SYMPTOMS) Engine will not idle down to low speed. Engine will not go to high idle when attempting to weld. Engine will not go to high idle when using auxiliary power. Engine does not develop full power.
- Page 32 Observe all Safety Guidelines detailed throughout this manual PROBLEMS (SYMPTOMS) No welding power output. Welder has output but no control. Wire feeder does not work when control cable is connected to 14 pin Amphenol. No auxiliary power. 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 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 WHITE GREEN RANGER 305G ENHANCED DIAGRAM GREEN BLACK BLACK WHITE GREEN F-12...
- Page 46 F-13 DIAGRAMS 1 1 1 1 BLACK WHITE RANGER 305G ENHANCED DIAGRAM BLACK WHITE F-13...
- Page 47 F-14 F-14 DIAGRAMS RANGER 305G...
- Page 48 NOTES RANGER 305G...
- Page 49 _______________________________________________ _______________________________________________ Telephone: _______________________________________________ |_|_| |_|_| Exp Date Month Year BOOK DIVISION, The Lincoln Electric Company, 22801 St. Clair Avenue, Cleveland, Ohio 44117-1199 for fastest service, FAX this completed form to: 216-361-5901 Telephone: 216-383-2211 or, Price Code $5.00 $15.00 $4.50 $5.00...
- Page 50 ● WARNING ● Spanish ● AVISO DE PRECAUCION ● French ● ATTENTION ● German ● WARNUNG ● Portuguese ● ATENÇÃO ● Japanese Chinese Korean Arabic ● ● ● ● ● ● ● ● ● ●...
- Page 51 ● ● ● ● ● ● ● ● ● ● ● ● ● ● ● ● ● ● Spanish ● PRECAUCION French ● ATTENTION German ● WARNUNG Portuguese ● ● Japanese Chinese Korean Arabic WARNING AVISO DE ATENÇÃO...
- Page 52 • 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...