RETURN TO MAIN MENU IM742-A RANGER 305 G For use with machines having Code Numbers: August, 2002 10855,10955 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 thoughtful operation on your part. DO NOT INSTALL, OPERATE OR REPAIR THIS EQUIPMENT WITHOUT READING THIS MANUAL AND THE SAFETY PRECAUTIONS CONTAINED THROUGHOUT.
i i SAFETY WARNING CALIFORNIA PROPOSITION 65 WARNINGS Diesel engine exhaust and some of its constituents are known to the State of California to cause cancer, birth defects, and other reproductive harm. The Above For Diesel Engines The engine exhaust from this product contains chemicals known to the State of California to cause cancer, birth defects, or other reproductive harm. The Above For Gasoline Engines ARC WELDING CAN BE HAZARDOUS.
ii ii SAFETY ARC RAYS can burn. 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. Insulate yourself from work and ground using dry insulation. Make certain the insulation is large enough to cover your full area of physical contact with work and ground.
iii iii SAFETY 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. Avoid welding near hydraulic lines. Have a fire extinguisher readily available. 6.b.
iv SAFETY 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 suivantes: Sûreté Pour Soudage A L’Arc 1. Protegez-vous contre la secousse électrique: a. Les circuits à l’électrode et à la piéce sont sous tension quand la machine à souder est en marche.
v v Thank You for selecting a QUALITY product by Lincoln Electric. We want you to take pride in operating this Lincoln Electric Company product ••• as much pride as we have in bringing this product to you! Please Examine Carton and Equipment For Damage Immediately When this equipment is shipped, title passes to the purchaser upon receipt by the carrier.
vi TABLE OF CONTENTS Page Installation.......................................................................................................................Section A Technical Specifications .......................................................................................................A-1 Machine Specifications ........................................................................................................A-2 Safety Precautions ..............................................................
vii TABLE OF CONTENTS Maintenance......................................................................................................Section D Safety Precautions ................................................................................................D-1 Routine Maintenance ............................................................................................D-1 Kohler Engine........................................................................................................
A-1 A-1 INSTALLATION TECHNICAL SPECIFICATIONS - Ranger 305G (K1726-1) INPUT - GASOLINE ENGINE Make/Model Kohler CH22 (K1726-1) Description Speed (RPM) Displacement cu. in. (cu. cm.) 2 cylinder High Idle 3700 22 HP @ 3600 RPM Full Load 3500 Starting System 41(674) Capacities 12VDC Battery & Starter Bore x Stroke inch (mm) (Group 58; 435 cold crank amps) 3.03 x 2.85 (77 x 72) Battery Charger Fuel: 12 gal. 45.4 L Oil: 2.0 Qts 1.
A-2 INSTALLATION A-2 MACHINE SPECIFICATIONS - Ranger 305G (K1726-1) RECEPTACLES (2) 120VAC Duplex (5-20R) (1) 120/240VAC Dual Voltage Full KVA (14-50R) AUXILIARY POWER CIRCUIT BREAKER Two 20AMP for Two Duplex Recptacle Two 50AMP for Dual Voltage RANGER 305G OTHER CIRCUIT BREAKERS 25AMP for Battery Charging Circuit 15AMP for 42V Wire Feeder Power
A-3 A-3 INSTALLATION 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. • Do not touch electrically live parts or electrode with skin or wet clothing.
A-4 A-4 INSTALLATION PRE-OPERATION ENGINE SERVICE WARNING READ the engine operating and maintenance instructions 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 overfill. • Wipe up spilled fuel and allow fumes to clear before starting engine • Keep sparks and flame away from tank.
A-5 A-5 INSTALLATION 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. NOTE: When a wire feeder with a built in welding voltage control is connected to the 14 pin connector, do not connect anything to the 6 pin connector.
A-6 INSTALLATION A-6 STANDBY POWER CONNECTIONS CAUTION • Loose connections will cause the output terminals 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.
A-7 A-7 INSTALLATION CONNECTION OF RANGER 305G TO PREMISES WIRING 240 VOLT GROUNDED CONDUCTOR POWER 240 Volt 60 Hz. 3-Wire Service 120 VOLT COMPANY 120 VOLT METER NEUTRAL BUS N LOAD DOUBLE POLE DOUBLE THROW SWITCH RATING TO BE THE SAME AS OR GREATER THAN PREMISES SERVICE OVERCURRENT PROTECTION.
A-8 A-8 INSTALLATION CONNECTION OF LINCOLN ELECTRIC WIRE FEEDERS Connection of the LN-25 to the RANGER 305G WARNING Shut off welder before making any electrical connections. -----------------------------------------------------------------------The LN-25 with or without an external contactor may be used with the RANGER 305G. See the appropriate connection diagram in Section F. NOTE: The LN-25 (K431) Remote Control Module and (K432) Remote Cable are not recommended for use with the RANGER 305G. 1.
B-1 B-1 OPERATION SAFETY PRECAUTIONS ENGINE OPERATION Before Starting the Engine: WARNING • Be sure the machine is on a level surface. 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.
B-2 B-2 OPERATION 16 1 15 14 2 13 3 12 11 4 10 9 8 7 5 6 WELDING CONTROLS 1. OUTPUT CONTROL: 3. WELD MODE SELECTOR SWITCH: 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.
B-3 OPERATION B-3 5. WELD OUTPUT TERMINALS WITH FLANGE NUT: 14. IDLER SWITCH- Has two positions as follows: Provides a connection point for the electrode and work cables. 1) In the HIGH position, the engine runs at the high idle speed controlled by the engine governor. 2) In the AUTO position, the idler operates as follows: 6. GROUND STUD: (graphic) Provides a connection point for connecting the machine case to earth ground for the safest grounding procedure. 7.
B-4 B-4 OPERATION • The engine will run at high idle speed for approximately 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. Allow a longer warm up time in cold weather. CAUTION Operating the starter motor for more than 5 seconds can damage the motor. If the engine fails to start, release the switch and wait 10 seconds before operation the starter again.
B-5 B-5 OPERATION 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. Then, the tungsten is gently lifted off the work in a rocking motion, which establishes the arc.
B-6 B-6 OPERATION ARC GOUGING The RANGER 305G can be used for limited arc gouging. 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. Electrode Diameter Current Range (DC, electrode positive) 1/8" The auxiliary power capacity is 10,000 watts Peak, 9500 Watts continuous of 60 Hz, single phase power.
C-1 ACCESSORIES OPTIONS/ACCESSORIES AND COMPATIBLE 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.).
D-1 D-1 MAINTENANCE KOHLER ENGINE FREQUENCY WARNING Daily or Before Starting Engine • 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. If guards are missing from the machine, obtain replacements from a Lincoln Distributor. (See Operating Manual Parts List.
D-2 D-2 MAINTENANCE 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. Pull the valve out and drain the oil into a suitable container. • Close the drain valve by pushing in and twisting clockwise. Replace the yellow cap.
D-3 D-3 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. • Remove the spark plug cap. • Remove the element cover nut, element cover, and paper element. • Clean any dirt from around the spark plug base. • Do not wash the paper element or use pressurized air, as this will damage the element.
D-4 D-4 MAINTENANCE CLEANING THE BATTERY FUEL FILTER • Check the fuel filter for water accumulation or sediment. • 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. Do NOT tamper with governor components or setting or make any other adjustments to increase the maximum speed.
D-5 MAINTENANCE Welder/Generator Maintenance STORAGE: Store the RANGER 305G in clean, dry protected areas. CLEANING: Blow out the generator and controls periodically with low pressure air. Do this at least once a week in particularly dirty areas. BRUSH REMOVAL AND REPLACEMENT: It’s normal for the brushes and slip rings to wear and darken slightly. Inspect the brushes when a generator overhaul is necessary. CAUTION Do not attempt to polish slip rings while the engine is running.
E-1 TROUBLESHOOTING E-1 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.
E-2 E-2 TROUBLESHOOTING Observe all Safety Guidelines detailed throughout this manual PROBLEMS (SYMPTOMS) POSSIBLE AREAS OF MISADJUSTMENT(S) RECOMMENDED 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. Loose battery cable connections. Inspect, clean and tighten. 3. Faulty engine starter motor. 4. “Battery Circuit” circuit breaker is tripped.
E-3 E-3 TROUBLESHOOTING Observe all Safety Guidelines detailed throughout this manual PROBLEMS (SYMPTOMS) POSSIBLE AREAS OF MISADJUSTMENT(S) Engine will not idle down to low speed. 1. Idler switch in High idle position. Set switch to Auto. 2. External load on welder or auxiliary power. Remove all external loads. 3. Faulty PC board or idler solenoid. Engine will not go to high idle when attempting to weld. 1. Poor work lead connection to work.
E-4 E-4 TROUBLESHOOTING Observe all Safety Guidelines detailed throughout this manual PROBLEMS (SYMPTOMS) POSSIBLE AREAS OF MISADJUSTMENT (S) 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. Place switch in "Weld Terminals On" position when welding without control cable. 3. Faulty PC board or welder alternator. Welder has output but no control. 1.
E-5 E-5 TROUBLESHOOTING Observe all Safety Guidelines detailed throughout this manual PROBLEMS (SYMPTOMS) POSSIBLE AREAS OF MISADJUSTMENT(S) RECOMMENDED 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. the engine runs normally. the process being used. (For The auxiliary power is normal. example, CV-WIRE, PIPE, CCSTICK.) 2. Make sure the electrode (wire, gas, voltage, current etc.
F-1 DIAGRAMS RANGER 305G F-1
F-2 DIAGRAMS RANGER 305G F-2
F-3 DIAGRAMS RANGER 305G F-3
F-4 DIAGRAMS RANGER 305G F-4
F-5 DIAGRAMS RANGER 305G F-5
RANGER 305G + _ ELECTRODE CABLE TO WIRE FEED UNIT K595 CONTROL CABLE TO LN-8 INPUT CABLE PLUG TO WORK Keep guards in place. Keep away from moving parts. Only qualified personnel should install,use or service this equipment. Do not operate with panels open. Disconnect NEGATIVE (-) Battery lead before servicing. Do not touch electrically live parts. N.A. WELDING CABLES MUST BE OF PROPER CAPACITY FOR THE CURRENT AND DUTY CYCLE OF IMMEDIATE AND FUTURE APPLICATIONS. SEE OPERATING MANUAL. N.B.
F-7 DIAGRAMS RANGER 305G F-7
F-8 DIAGRAMS RANGER 305G F-8
F-9 DIAGRAMS RANGER 305G F-9
F-10 DIAGRAMS RANGER 305G F-10
F-11 DIAGRAMS RANGER 305G F-11
GND-K 208C 206C CB8 15A 42A 42 41A 41 208A 208C 206B 261 260 9 12 6 3 31 77A 76A 75A 2A 4A 5 1 GND-B 77B 76B 75B 2B 4B GND-A 4B 2B 75B 76B 77B 21 42A 41A 32 206A 206C 6 3 TOROID 8 16 8 4 6 1 L2, L3: RF CHOKES 10 5 + C2 W7 13 3 14 NEG NEG GND-B POS PCB 1 GND-B FRAME GND. GND-A GND. SCREW ON LEFT INSIDE CASEFRONT GND-L WHITE TERM.
CB8 15A 5N 42A 208C 206C 42 41A 41 A B C D E F 3 9 12 7 76A 75A 2A 4A 6 1 GND-B 77B 76B 75B 2B 4B 77A GND-A 4B 2B 75B 76B 77B 21 42A 41A 32 31 16 8 10 5 GND-K LEAD COLOR CODE: B=BLACK OR GRAY R=RED OR PINK W=WHITE G=GREEN (W/YELLOW STRIPE) GND-B FRAME GND. GND-G GND-D GND-C GND-E GND-B GND-A 31 GND-N GND-N C9 13 PCB 1 B5 C8 300 AMP MODULE 14 B2 B4 B1 B7 B8 WHITE TERM.
RANGER 305G 42.10 20.80 CENTER OF GRAVITY WITH OIL IN ENGINE AND EMPTY FUEL TANK "A" 24.86 41.20 TRUCK/UNDERCARRIAGE MOUNTING HOLES 2.6 17.50 19.50 "B" DIMENSION PRINT DIMENSION “A” DIMENSION “B” 23.50 16.75 10.28 7.22 RANGER 305G 10.78 29.88 33.62 3-2000 M19410 36.
NOTES RANGER 305G
Now Available...12th Edition The Procedure Handbook of Arc Welding New Lessons in Arc Welding This printing will go fast so don’t delay. Place your order now using the coupon below. Lessons, simply written, cover manipulatory techniques; machine and electrode characteristics; related subjects, such as distortion; and supplemental information on arc welding applications, speeds and costs. Practice materials, exercises, questions and answers are suggested for each lesson.
WARNING Spanish AVISO DE PRECAUCION French ATTENTION German WARNUNG Portuguese ATENÇÃO ● Do not touch electrically live parts or ● Keep flammable materials away. ● Wear eye, ear and body protection. ● Mantenga el material combustible ● Protéjase los ojos, los oídos y el electrode with skin or wet clothing. ● Insulate yourself from work and ground. ● No toque las partes o los electrodos bajo carga con la piel o ropa mojada. ● Aislese del trabajo y de la tierra.
● Keep your head out of fumes. ● Use ventilation or exhaust to ● Turn power off before servicing. ● Do not operate with panel open or guards off. remove fumes from breathing zone. ● Los humos fuera de la zona de res- piración. ● Mantenga la cabeza fuera de los humos. Utilice ventilación o aspiración para gases. ● Gardez la tête à l’écart des fumées. ● Utilisez un ventilateur ou un aspira- ● Desconectar el cable de ali- mentación de poder de la máquina antes de iniciar cualquier servicio.
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