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Lincoln Electric RANGER IM742-A User's Manual

Contents

1. GAMBIA NMOHS S1N3NOdWOO 1NOM3 3SVO NOLL3SNI MBA SHOLOBNNOD 15 MOTISA M 15613 88451080445 WOHLIN 24 AH311V8r83d 9 6 g i AVHO HO yOV18 8 EREEEREE m 9309891099991 sopa 22200229 o o o o o P ages SININOdWOS 3NISN3 os V9 L Rol 002 D x 9 fuf z eroe 5100 rano E men e 55554 6555 ha p 21 8012 d 340553804 9290999 ooo sax mm w 2 L NONI kamas 3012 em M LS 35 us nes mE PR SHE m lt 1894 3207 are 1 wamni 4 20 ISd T 8r 3 az o E sg We 65 BOIOvINOO Le 622 892 8 howiNoo VOS 24 ONINOO
2. Weal AMI d ous uil el jay oa Y O Ales ay gl uit slt All usu JS daas ule Y Jio moe e Keep flammable materials away e Mantenga el material combustible fuera del rea de trabajo Gardez l cart de tout mat riel inflammable Entfernen Sie brennbarres Material e Mantenha inflam veis bem guarda dos e naedoe6 0o08 CIE REA 9 MR B T fF35 FF o eis Jo ALD al gll pis Ac AI Wear eye ear and body protection Prot jase los ojos los o dos y el cuerpo Prot gez vos yeux vos oreilles et votre corps Tragen Sie Augen Ohren und K r perschutz Use prote o para a vista ouvido corpo e R HAUSHERMRELTTF HEBS SOSRSHR ez 119 59 s ESSAI dise vues al ad ne 4 aun y 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 LISEZ ET COMPRENEZ LES INSTRUCTIONS DU FABRICANT EN CE QUI REGARDE CET EQUIPMENT ET LES PRODUITS A ETRE EMPLOYES ET SUIVEZ LES PROCEDURES DE SECURITE DE VOTRE EMPLOYEUR LESEN SIE UND BEFOLGEN SIE DIE
3. jenueui siy Aq eq jou 1 juo 10 SI SIUL 3 LON uva NOM A GAMBIA NMOHS SLNANOdWOD LNOHA 3SVO TIV an NOLLSSNI WOY4 SHOLIINNOD 1 MOTIAWM N339 5 16513 Hd STOBNAS TVOI8193 B ALIHMEM g X 89 PESE EEG E b oo o o o o o wqof Cama p m 3NION3 3009 ava Dar 120006 SI og 92020 77 imm DNS ve asme xo NOSNE 0 mS 2 2 palais 9 z AMOUS 05559 2 sm n tons 70 rao 214 sawas M i suus es ion E SHI SN OS Isr
4. ANVL 1905 3NISN3 NI TIO ALIAVHO 40 H31N39 F 14 990 H39NVH 1 NOISN3WIG RANGER 305G LINCOLN E NOTES RANGER 305G LINCOLN Now Available 12th Edition The Procedure Handbook of Arc Welding With over 500 000 copies of previous editions published since 1933 the Procedure Handbook is considered by many to be the Bible of the arc welding industry This printing will go fast so don t delay Place your order now using the coupon below The hardbound book contains over 750 pages of welding information techniques and procedures Much of this material has never been included in any other book A must for all welders supervisors engineers and designers Many welding instructors will want to use the book as a reference for all students by taking advantage of the low quantity discount prices which include shipping by 4th class parcel post 15 00 postage paid U S A Mainland How To Read Shop Drawings The book contains the latest information and application data on the American Welding Society Standard Welding Symbols Detailed discussion tells how engineers and draftsmen use the short cut language of symbols to pass on assembly and welding information to shop personnel Practical exercises and examples develop the reader s ability to visualize mechanically d
5. dO 38 LSNN S3 18 VO 9NIQTJM WANVA ONILLVe3dO 83Q713M NI Q31ST1 SNOLLVOIJIO3dS 3AO8V LSn av LON OG AHOLOVJ LV 13S 34d SI ONILLAS HONS3AOO9 3NISN3 TOS LNOO 39VINVO NVO HOIHM 39 VL 10A 83033 SIM OV JHL NI 3SV3SONI NV ASNVO TIM 39 VMNTT3TLLOSH 9NIQIHSSAO ONILLAS HONSH3AO9 JHL 9NISNVHO 3NION3 3 Il H9IH JHL dO 3SV38ONI LINN 8383 OL RIOT 3180 390419573 HHOM OL ON3HdlAV 1031409 SLOWSY Nid 9 158 IVNOILdO J18vO 1OHLNOO 853 Md 318V9 ON3HdlAV 21 OL 1 jueuudinbe 14 2 5 10 sued Ajeoujoeje jou esn jeisui pjnous jauuosied e Buas e10jeq sued deeye peaj Moyeg 3ALLVO3N 12euuoo sigq e eoe d ui sjaued jou og e ONINHVM W WVYSVId NOLLO3NNOO 2 7 SH3Q13M 3NION3 RANGER 305G LINCOLN E 5 8 705 5 0002 22 01 8341530 SV NOILISOd HOIH NI HOLIMS 414101 39VId JN NOILISOd 4 1041 02 ATALOWSY OL HOLIMS SIVNINYSL Y3013M 39V1ld ON NOLLISOd 3H L NI HOLIMS SGOW 318V9 3904419315 SHL dO ALINV10d JHL HOLVIN OL HOLIMS H3L3IALLTOA 830332 SHL 0 ALII V TOd 341540 803 SONLS LAdLNO OL S318V9 ONIGTAM LO3NNOO 9NILVeI3dO 33 5 39119 ANY 31VIQ3NWNI dO 41949
6. e peal Ajegeg 3ALLVO3N 12euuoosid e eoejd ui desye uedo sjaued jou oq ONINHVM 7 WVUOVIC NOILOANNOD 10085 2877 8893 01 1699 SH3TT3M 3NISN3 RANGER 305G LINCOLN E 6 8 705 9 0002 22 01 0341530 SV NOILISOd NI HOLIMS 4141013914 TN NOLLISOd 10H1LNO9 SLOWS NI HOLIMS TOH INOO LAdLNO NOILISOd 911 SHL NI HOLIMS SGOW 39Vld ON 0341530 58715 LNdLNO OL SATEVO ONIGTAM LO3NNOO WANVIA ONILVasAdO 335 SNOILVOrTaav SYNLNA ANY ALVIGSNWI dO 319A9 ALNG LN33309 JHL ALIOVdVO dO 38 LSNW S3 18V9 9NIQTJM 9 83Q13M 3NION3 NI 091511 SNOILVOISIOSdS 3AO8V LSNPAV LON OG AHOLOV SHL LV 13S 3Md SI ONILLAS NONS3AO9 TOMLNOO JHL NYO HOIHM 39VLTOA 830333 38IM OV JHL NI 3SV3HONI NV 2SNV9 TIM JTLLOSH L JHL ONIGIHS3AO ONILLAS HONSH3AO9 SHL 9NIDNVHO 3NION3 dO ASVAYONI NOLLOVO AYOM OL HOLIMS LYVLS 98V t 18M HO D o T1O LdAV QNVH L 96H 3040419717 lt TOsLdlA V 1003 0287 18 9 TOSLNOO L 9 6 2 ONILLIA E SV9 OL SV9 NO9NV FINGOW OIL JON3HdNV 8313AMO 13 DEA x 01 1 N jueuudinbe 14 eores JO sued Ajeouiosje u
7. 03 LVHL S3NIHOVIN 3SOH L OL A lddV SALON ONIMOTI01 JHL 1 ANY 0 31 YOM QV319NISN3S dVHM 0 av3la3l93NNOOSId 30 Q3SOdX3 3dV1 dIYLS TWNINYSL OL QV319NISN3S 193NNOO ANY 4131 TWNINYSL AHL WO 3 18V 14 0 dO QV31 193NNOOSIG 4 18 02 H31dvQv 401 23038 NIVALS HONOYHL QV319NISN3S 31008 AIM X314 Q383A00 434414 4194 V1 ONISN OL ATLO3SIG HAIWOLSNO A8 Q3ON3 LLX3 38 OL QY319NISN3S ALOWSY H31dVQV NI 911 TWNINYAL 330333 OL 193NNOO 351 SI d CN13NO 31 S3ZIS YAdOYd 401 WNNVW ONILVYAdO d CN133S SNOLLVONMdd ANY 31VIQ3WINI dO 31949 SHL ANY 1N323130O JHL ALIO Vd VO 934034 40 38 LSNW S3 18V9 SNOILONYLSNI ONILVHIdO LIM 431dV0V 105 3 1811 VdWOO SSH3Q 13M 3NI9N3 INVSHO VIO NOLL23NNOO 12414 8 830333 38IM 330333 390319513 8 430334 430334 S31dVQV aval SNISN3S 39VI 10A x ONY A i Losey LOANNOOSIC E 318vO ON jueuudinbe 14 eorues 10 esn e1sui pjnous jauuosied peyienb e sued Aeme e eoe d ui spien e ONINHVM Y JON3HdMY
8. WANVA 9NILVS3dO 83G713M ANIONS NI 9151 SNOILVOISIOSdS Wd 3AO8V LSNPAV LON OG AHOLOVA 13S 3Md SI S9NILL3S HONS3AOO9 JHL LINDYID TOHLNOO SHL NVO HOIHM 39V L10A Y30334 38IM OV JHL NI 3SV3SONI NV 2SNV9 TIM 39 VMNTTI 31LLOSH 3H1 ONIGISS3AO ONILLAS HONS3AO9 JHL 3NI9N3 4101 HOIH SHL dO 3SV339NI 0333 OL 31872 300812313 OL 114V9 9697 Orid 318v9 8 N1 OL jueuudinbe 14 eorAJes 10 Sued jou asn je sul pinoys jeuuosied e Buas eJoJeq syed e JALLVO3N 1 euuoo sig e eoejd ui uedo sjeued jou ONINHVM 7 NOLLO3NNOO 8 N T SH3Q 13M 3NION3 NOILNVS RANGER 3056 LINCOLN E 1182705 0002 22 01 F 7 439333 LN38809 INDINIXVIN NOLLONYLSNI 39808 83MOd OL 43134 4 1130 339 v 2 58741 35012 OL 13 NOILVIOSI SSN 114100 9NIQT3M 303 TVN IS V NHn L38 1 SH30333 303 SN ATIVRGIAIONI 951 GASNNN H2V3 31V10SNI NOILISOd 38IM7AO JHL NI HOLIMS SGOW 8185 300810313 AHL dO ALIYV10d JHL HOLVIN OL HOLIMS YALAWLIOA 3033 38IM NOILISOd ALII V 10d 044
9. a le vel 9 8 los ae vu PNY 1 L ONSHdAV rs NOLLVNINYT 3HL OL Ne eg vez S3tNGN AS OL p indu SO Tan Q319 NNOO HSNUE 3ALLISOd g e Wd 5552 if E 309 osou 8 4 Folovinoo et 5015 vou aseo josuag of 092 as wet e lt 4 a 7 0012 uz O3N lt H ME o 4 TEI wo ate 18 15 lo virte um 2012 T alely ven puua Tira Hs v ONO ua Np eKr GION31OS 24 vs Le b oz omo LV lii LA NOILISOd OLNV 8 gt S FRE NINMOHS 1 ez 1N0833510 40 30ISNI s vaL 31 m vaz 60 NO EROS OND 401 kranassvl vsz y le 92104 ay a Jb 6 1NOMd3S VO QNO WOLLOS 30N5 rano ssvaia e d MONS 3144V8 HALN3O ered SF zz 212 4 NO MIHIS QNS may 16 ve Vas pH diit t NI e nuog 7 9 mano 7 SANS 94 DOTYNY 2824 ine se Od AN 1 2 gliQuisos ws _ P Rage a 5 NI NVOHS pz ow 007 6 ym PVA er 74 ES EN Lo OVA Zi HOLIMS sr sa sz FEMA t Lo okinviod an 6 2 z z li i 9MONIM HOLVLS abe
10. sued e pee JALLVO3N 12euuoosiq e ui doeye sjeued ejejedo jou oq e u WVYSVId NOLLO3NNOO 2ILVINVH8OO 128613 SH3Q0 13M 3NION3 RANGER 305G LINCOLN E DIAGRAMS F 11 F 11 d c 4 VN 0002 22 01 ANIONS EV 43398 3HL OLNO ATHW3SSV H3 LdvOv AHL N31SV4 OL WSHL 3SN ANY NMOHS 339 SSYHL JHL 31OH V SVH LVHL L3 V88 Haldvav JHL ATHW3SSV S3 LavQV NO L3X0VS8 ONILSIXS 30V 1884 L A TINO 006 00 AHL SNOILONYLSNI NOILVTIVLSNI 119345 NOLLV8I3dO SNIHOVW HLIM 3434431NI OL LON SV NOLLV2O I LN3IN3ANOO V NI 43d VOV LNNOW IN SMNV1 TAN HO S38IM S1N3NOdWOO 1VOI8 193 T3 OL LON 1n8 Sv HONS S1N3NOdIAOO OL LON SV 38 OL SI 7710346 H3QT3M OL 93149 ONILNNON NOLLO VO SNOILONALSNI NOLLV TIV LSNI LIM 8 14 0 ATALOWSY OL HOLIMS STVNINYAL ONIQTAM 195 OL HOLIMS 3L0N34 1V901 JHL 13S ISN SI LAdLNO 31ON32 JI O N WONIGTAM FAIMA OL HOLIMS 80193138 IHL 13S TN OL HOLMS YALSWLIOA Y30334 SHIM LAS TN NMOHS NVHL 14333358 ATLHONS 38 S3NIHOVIN dNOS NO ADOTONINYSL daialo3ds 330 933 sv TOL Leivd JHL
11. Garder tous les couvercles et dispositifs de s ret leur place V for selecting a QUALITY product by Lincoln Electric We want you Thank You to take pride in operating this Lincoln Electric Company product eee 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 Consequently Claims for material damaged in shipment must be made by the purchaser against the transportation company at the time the shipment is received Please record your equipment identification information below for future reference This information can be found on your machine nameplate Model Name amp Number Code amp Serial Number Date of Purchase Whenever you request replacement parts for or information on this equipment always supply the information you have recorded above Read this Operators Manual completely before attempting to use this equipment Save this manual and keep it handy for quick reference Pay particular attention to the safety instructions we have provided for your protection The level of seriousness to be applied to each is explained below A WARNING This statement appears where the information must be followed exactly to avoid serious personal injury or loss of life CAUTION This statement appears where the information must be followed to
12. els SN ds Weird ii gt S 94 EY lo m 02 4 lt 9802 0 802 on OV ZH m gt Ww re Logoz O 8907 m 104 1802 vr vsa tioj En jac roz aXe oi i EEE EM 31000W H zm uM E v 00 9 porum wae m EE f Vo o o td SLIOA Y QL caves 4 NI 3083195 ms amnaon Dy 3001020 Pm Lj d F p swe pa nz ww cusa PON ho or OLW 3r ON 1 IM 1 wee SESEESES Y 4 5 lt EM b 8 amis MNISIV3H BEEN sonas a sm zzz ZN 4 390149 3SVHd iu iN iN oz SEA tO ot Va Os 12 On ME PIT 40193 HS 200N ss 10v123238 10 3015 0 31 NOUA 32430085 ONUAGNNN ALIAVO 319v 143938 13 4 66801 3002 401 ONIAIM 9506 439NVH RANGER 305G LINCOLN E F 13 ENHANCED DIAGRAM DIAGRAMS F 13 Jequunu epoo eu 104 ejqiDejr si eui sjeued y Jo euo uo eui paysed si Jenoryed e 0 urejBeip
13. mm 9 ONIGNIM HOLVLS us CEA as s4 9L 4 6 2 d 0802 O 802 4 G a90z lt m 104 1NOO INdINO LH IOH1NOO ZH 71 EN 9 za e 3 Tu m TONT ou moat 53 vao BRE T E se L L Re T 5 amp 9 890 eE Ww RS L id uil sawv oov Awos a s o 8s98 IF YOR SNUML OML VUM 1NnHs vo wA Sf a eL WW ew 3 ri 9 T aii L 5902 5902 1 Lg 2 gt eM coc ELI z we is1van w oy ins Vis gto SLIOA vous m a n n 3SVHd 2EHL 19 TH oM aed pasim 49601 3002 NY49VIQ 9 9506 F 14 OLV6LIN S310H ONILNNON SOVINYVONSONN ONL 0c Ww 6 9 8 NOISN3WIG 05 55 V NOISN3WIG DIAGRAMS
14. LINCOLN E DIAGRAMS F 8 F 8 8 8 705 0002 22 01 NOILISOd 4101 HOIH NI HOLIMS 41101 39V1d NOILISOd Q3TIOSH LNOO AT310W38M OL HOLIMS 5 1 9NIQT3M 39V Id NOILISOd 38IM AO NI H9LIMS SGOW ALldv lod 4341 30 404 58715 LAdLNO OL S318V9 LO3NNOO NOILVOllaav dO 41949 LNAYYND 9371 38 LSNW S318V9 ONIGTAM WANVA 9NILV83dO 3Q13M 3NI9N3 NI GALS SNOILVOISIOAdS 3AO8V 15 LON OG AHOLOV3 SHL 135 344 SI ONILL3S HONS3AO9 JHL LINDYID TOHLNOO NYO HOIHM 39V L10A 30334 SHIM NI 3SV389NI NV 3Sn v9 39 VMNTT31LLOSHI AHL YO ONILLAS HONSH3AO9 JHL Ad Wd ANIONS H9IH 30 3SV38ONI 194N0S 42MOd FINGOW OL NI L 10838 1002 NOILISOd HOLIMS LO38809NI TOHLNOI 11V41d0 OL ONILdWALLV 3404338 NOILISOd 3408019 12 1 02 NIOONIT IHL NI SI HOLIMS IQON 1OM1NOO LVHL 340 38 NOILNYO 31ndONW 1 OL 318V9 3008193 l3 MYOM OL 318V9 LNANI 119V1d3934 01 1691 ALOWSY 9 NN9 10085 SC 18V JINON 10HLNO9 319914393 OS 887 Y30334 Nid 7 m jueuudinbe 14 BdIAJES JO sued YONO jou oq e esn jeisui pjnous jeuuosied e fulaues sued
15. enrouler le c ble lectrode autour de n importe quelle partie en LES MACHINES SOUDER Un coup d arc peut tre plus s v re qu un coup de soliel donc REDRESSEUR a Utiliser un bon masque avec un verre filtrant appropri ainsi qu un verre blanc afin de se prot ger les yeux du ray 1 onnement de l arc et des projections quand on soude ou quand on regarde l arc b Porter des v tements convenables afin de prot ger la peau de soudeur et des aides contre le rayonnement de l arc c Prot ger l autre personnel travaillant proximit au soudage l aide d crans appropri s et non inflammables Des gouttes de laitier en fusion sont mises de l arc de soudage Se prot ger avec des v tements de protection libres de l huile tels que les gants en cuir chemise paisse pan talons sans revers et chaussures montantes Toujours porter des lunettes de s curit dans la zone de soudage Utiliser des lunettes avec crans lateraux dans les LINCOLN TRANSFORMATEUR ET Relier la terre le chassis du poste conformement au code de l lectricit et aux recommendations du fabricant Le dispositif de montage ou la piece souder doit tre branch une bonne mise la terre Autant que possible l installation et l entretien du poste seront effectu s par un lectricien qualifi Avant de faires des travaux l interieur de poste la debranch er l interrupteur la boite de fusibles
16. 2 DIGITAL OUTPUT METERS The digital meters allow the output voltage CV WIRE mode or current CC STICK PIPE and TIG modes to be set prior to welding using the OUTPUT control dial During welding the meter display the actual output volt age VOLTS and current AMPS A memory feature holds the display of both meters on for seven seconds after welding is stopped This allows the operator to read the actual current and voltage just prior to when welding was ceased While the display is being held the left most decimal point in each display will be flashing The accuracy of the meters is 3 3 WELD MODE SELECTOR SWITCH Provides four selectable welding modes CV WIRE PIPE CC STICK TOUCH START TIG 4 ARC CONTROL The ARC CONTROL WIRE STICK dial is active in the WIRE STICK and PIPE modes and has different functions in these modes This control is not active in the TIG mode CC STICK PIPE modes In these modes the ARC CONTROL knob sets the short circuit current during stick welding arc force Increasing the number from 10 to 10 increases the short circuit current and prevents sticking of the electrode to the plate while welding This can also increase spatter It is recom mended that the ARC CONTROL be set to the minimum num ber without electrode sticking Start with a setting at O CV WIRE mode In this mode turning the ARC CONTROL clock wise from 10 soft to 10 crisp changes the arc from soft and was
17. OVA SLL 43d 13M 3NISN3 sued Ajeoujogje jou og e peel 3ALLVO3N 1 euuoosid e uedo sjeued jou od e RANGER 305G LINCOLN E F 12 ENHANCED DIAGRAM DIAGRAMS F 12 Jequunu epoo ou BAIN 104 29S ejqiDejr si sjeued einsoj oue y euo uo eui episui pejsed si epoo e Jenueui siy Aq 40 eq jou SI SIUL 310 v 9
18. 1 0 AWG Cable Length 0 100Ft 0 30meters 100 150 Ft 30 46m meters 2 0 AWG 150 200 Ft 46 61 meters 3 0 AWG CABLE INSTALLATION Install the welding cables to your RANGER 305G as follows 1 The gasoline engine must be OFF to install welding cables 2 Remove the flanged nuts from the output terminals 3 Connect the electrode holder and work cables to the weld output terminals The terminals are identi fied on the case front 4 Tighten the flanged nuts securely 5 Be certain that the metal piece you are welding the work is properly connected to the work clamp and cable 6 Check and tighten the connections periodically RANGER 305G LINCOLN A 6 INSTALLATION A 6 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 The 240 VAC receptacle can be split for single phase 120 VAC operation The auxiliary power capacity is 10 000 watts Peak 9500 Watts Continuous of 60 Hz single phase power The auxiliary power capacity rating in watts is equiva lent to volt amperes at unity power factor The max permissible current of the 240 VAC out
19. 250 305 Amps AUXILIARY POWER Start the engine and set the IDLER control switch to the desired operating mode Full power is available regardless of the welding control settings providing no welding current is being drawn 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 The 240 VAC receptacle can be split for single phase 120 VAC operation OPERATION B 6 The auxiliary power capacity is 10 000 watts Peak 9500 Watts continuous of 60 Hz single phase power The auxiliary power capacity rating in watts is equiva lent to volt amperes at unity power factor The max permissible current of the 240 VAC output is 40 Amps The 240 VAC output can be split to provide two sepa rate 120 VAC outputs with a max permissible current of 40 Amps per output to two separate 120 VAC branch circuits these circuits cannot be paralleled Output voltage is within 10 at all loads up to rated capacity The 120 V auxiliary power receptacles should only be used with three wire grounded type plugs or approved double insulated tools with two wire plugs The current rating of any plug used with the system must be at least equal to the current capacity of the associated receptacle NOTE The 240 V receptacle has two circuits each of which measure 120 V to neutral but are of opposite polarities and cannot be paralleled Simultaneous Welding and Auxilia
20. 3QOW 39 Vd WANVW 0 YSCTAM JHL 91511 SNOILVOISIOSdS 3AO8V LSP Qv LON Od AHOLOVA SHL LV 13S 3Md SI SNIL13S HONS3AO9 3NION3 IHL LINOYIO TOHLNOO 1 NYO HOIHM 39 VL 10A 830334 OV FHL NI 3SV3SONI NV 9 39 VXNIT3TLLOSHL JHL 9NIGIHSSAO YO 9NILE3S HONS3AO9 SHL 9NISNVHO Ad 3NION3 3 GI HOIH dO 3SV3HONI OL NOILOVO 0393 38IM OL 1872 330412313 AT8IN3SSV 318VO LNANI 9293 DIAGRAMS 41875 B JON3HdNV INdNI Nid vl ueuudinbe 141 2 10 sped Ajeoujoeje jou og e esn e1sur pjnous jeuuosjed e Buioiues eJojeq syed pee JALLVO3N 12euuoosiq e eoejd ui deey e uedo sjeued jou ONINHVM WV NOLLO3NNOO TINGON 1ON LNOO 1Nd1NO 310W38 LIOA 27 1 9 HLIM S N 1 SH3Q 13M ANISNA F 3 RANGER 305G LINCOLN E V L8LvCS F 4 0002 22 01 DIAGRAMS F 4 NOLLISOd NI HOLIMS 41101 SOVId NOLLISOd 34IM A9 3H L NI HOLIMS SGOW 818 5 300419314 JHL dO ALIYV10d JHL HO1VIN OL HOLIMS YSLANLION 420331 38IM NOLLISOd ALINV10d 9341534 401 SONLS LNdLNO OL S318V9 9NIQTJ3M LO3NNOO TN 9NILVe3dO 335 SNOILVO 1ddV 340413 ANY ALVIGAWWI dO 31949 ALNG ANY LNSYYNSD JHL 303 ALIOVdVO
21. ANY JHL ALIO VdVO dO 38 15 S3 18V9 ONIOTIM 9NILVS3dO 83013M 3NISN3 JHL NI Q31ST1SNOILVOI3lI034dS 3AO8V LSNPAV LON OG 7 AHOLOVA JHL LV 13S 3Md SI 9NILL3S HONS3AO9 3NION3 JHL TOHLNOO JHL NYO HOIHM 83033 SIM NI 3SV3HONI NV 3Sn vo TIM 39VMNIT31LLOSH JHL 9NIQIHS3AO HO ONILLAS HONS3AO9 JHL 9NIDNVHO Ad 3NISN3 31d 3HL 30 ASVAYONI 1333 38IM OL NOLLOVO 918 300419313 OL DIAGRAMS 318V9 1OWLNOO 691 31875 LAdNI CYZ NTOL jueuudinbe 14 2 JO sued jou asn jeysul pjnous jeuuosied e sued deey e peg JALLVO3N 12euuoosiq e ui e uedo sjeued 9jejedo jou oq e ONINHVM 7 F 5 NOLL23NNOO CtZ N 1 SH3Q 13M RANGER 305G LINCOLN E DIAGRAMS F 6 F 6 9 282725 0002 71 NOILISOd NI HOLIMS 41141 39Vld 11872 300819313 3H1 dO ALIS V 10d JHL HOLVIA OL HOLIMS YALAWLIOA 830334 38IM NOLLISOd ALIYV10d Q38I830 303 0015 LAdLNO OL S318V9 LO3NNOO TN WANVI 9NILV33dO 33 SNOILVOlldav AYALA ANY ALVIGSAWWI 41949 ANY LN388809 JHL ALIO VdVO 40 38 LSNW S318V9 ONIGISM
22. Amps 29 Volts 300 Amps 14 to 29 volts 80 Volts RATED OUTPUT 104 F 40 C GENERATOR Auxiliary Power 10 000 Watts Peak 9500 Watts Continuous 60 Hz 120 240 Volts PHYSICAL DIMENSIONS WIDTH DEPTH 42 25 in 1073 0 mm 21 50 in 546 0 mm ENGINE COMPONENTS FUEL SYSTEM Low noise Muffler Top outlet can be rotated Made from long life aluminized steel WEIGHT 510 Ibs 231kg GOVERNOR Mechanical Governor 5 Regulation Shutdown on low oil pressure ENGINE WARRANTY 2 year unlimited hours See engine manufacturer warranty for details Kohler 1 Output rating in watts is equivalent to volt amperes at unity power factor Output voltage is within 10 at all loads up to rated capacity When welding available auxiliary power will be reduced RANGER 305G LINCOLN A 2 INSTALLATION A 2 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 LINCOLN A 3 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 operati
23. Book Rate for U S A Mainland Only Please allow up to 4 weeks for delivery IUPS Shipping for North America Only All prepaid orders that request UPS shipment please add 55 00 For order value up to 49 99 10 00 For order value between 50 00 amp 99 99 15 00 For order value between 100 00 amp 149 00 North America invoiced orders over 50 00 amp credit card orders if UPS is requested it will be invoiced or charged to you at cost Outside U S A Mainland order must be prepaid in U S Funds Please add 2 00 per book for surface mail or 15 00 per book for air parcel post shipment METHOD OF PAYMENT Sorry No C O D Orders y CHECKONE Address Please Invoice only if order is over 50 00 Check or Money Order Enclosed U S Funds only Credit Card SERE Exp Date IN Signature as it appears on Charge Card I Mon Year lyse THIS FORM TO ORDER Order from BOOK DIVISION The Lincoln Electric Company 22801 St Clair Avenue Cleveland Ohio 44117 1199 sooks OR FREE INFORMATIVE CATALOGS Telephone 216 383 2211 or for fastest service FAX this completed form to 216 361 5901 lL incon Welding School _ KU ENIM Cost ED 80 New bum in Arc Welding 5 00 5 Procedure Handbook Twelfth Edition 515 00 mn H Ho
24. Field Service Facility for technical troubleshooting assistance before you proceed RANGER 305G LINCOLN E 2 TROUBLESHOOTING E 2 Observe all Safety Guidelines detailed throughout this manual Authorized Field Service Facility Engine will not crank Battery is low Charge Battery Loose battery cable connections Inspect clean and tighten Faulty engine starter motor Battery Circuit circuit breaker is tripped Engine will crank but not start Out of fuel Fill tank and bleed fuel System Faulty fuel solenoid or faulty PC board or ignition system If all recommended possible areas of misadjustment have been checked and the problem persists Engine shuts down shortly after Low oil level Change oil and oil fiter Contact your local Lincoln starting and fill to proper level Start engine Authorized Field Service Facility and look for leaks Faulty oil pressure switch or other engine component Open rotor circuit Battery does not stay charged Faulty battery replace Engine alternator trouble light is on Loose connections at battery or while machine is running alternator Clean and tighten connec tions Faulty engine alternator or charg er modual CAUTION 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 yo
25. NO OLAV NI HOLIMS 3 1d 39V Id NOILISOd IVNIINS3 L NI HOLIMS S IVNIINS3 L ADV Id NOILISOd 34IM A9 NI HOLIMS SGOW 39V ld 31870 300819313 SHL dO ALI V 10d JHL HOLVW OL HOLIMS S3 L3IAL TOA 934333 38IM JHL NOILISOd ALIYV10d 153 401 50715 1NdINO OL 531979 9NIQT3M LOANNOO WANVW 0 33 SNOILVOrlaav 3801603 ANY 31VIQ3WIAI dO 41949 ALNG ANY 3HL ALIOVdVO dO 38 LSNN 31899 319 300819313 OL OL 07 1 830333 38IM SCNI SLOWSY 1889 TVNOILdO la jueuudinbe 14 2 5 JO sued Ajeoujoeje uonoj jou oqe esn jejsui pjnous jauuosied AIUO e BUIDIAIaS sued e pee J3ALLVON 12euuoosiq e ui desye sjoued jou dy ONINHVM 7 TOULNOOD 3 L0IN38 2689 TVNOILdO WV49VIQ NOLL23NNOO AHL SSOUIVY SC N I SH3Q13M ANISNA RANGER 305G LINCOLN E DIAGRAMS F 2 F 2 C18LvcS 0002 22 01 Q38I S3Q SV NOILISOd 7101 OLAV NI HOLIMS 47101 39V Id 3 N NOILISOd 51 NI HOLIMS S IVNIINS3 L ONIQT3M 39V1d NOILISOd 38IM AO NI HOLIMS 39 1 ON 318V9 300819313 3H1 dO ALINY 10d AHL OL HOLIMS S3 L3I
26. Standby Power Connections as well as the article on grounding in the latest U S National Electrical Code and the local code In general if the machine is to be grounded it should be connected with a 8 or larger copper wire to a solid earth ground such as a metal water pipe going into the ground for at least ten feet and having no insulat ed joints or to the metal framework of a building which has been effectively grounded The U S National Electrical Code lists a number of alternate means of grounding electrical equipment A machine grounding stud marked with the symbol Di provided on the front of the welder WELDING TERMINALS The RANGER 3056 is equipped with a toggle switch for selecting hot welding terminal when in the WELD TERMINALS position or cold welding terminal when in the REMOTELY CONTROLLED position WELDING OUTPUT CABLES With the engine off connect the electrode and work cables to the output studs The welding process dic tates the polarity of the electrode cable These con nections should be checked periodically and tightened with a 3 4 wrench Table A 1 lists recommended cable sizes and lengths for rated current and duty cycle Length refers to the distance from the welder to the work and back to the welder Cable diameters are increased for long cable lengths to reduce voltage drops TABLE A 1 TOTAL COMBINED LENGTH OF ELECTRODE AND WORK CABLES Cable Size for 305 Amps 100 Duty Cycle
27. avoid minor personal injury or damage to this equipment TABLE OF CONTENTS Page LE Section A Technical Specifications rs A 1 DE A 2 Safety Precautions 2252 uu p A 3 Location and Ventilation ire A 3 STACKING En ses ed u ee Angle of Operation Additional Safety Precautions u u aw nennen tenens A 3 High Altitude Operation sise A 3 High Temperature Operation sise A 3 TOWING s u au A 3 Pre Operation Engine Service ss 4 Oll Am EUMD MIEL A 4 4 Engine Coolant u a A 4 Battery ERR 4 Muter Outlet PIDE EE 4 shrusgicl mI nr 4 High Frequency Generators for Tig Applications a 4 R mote PEE A 4 Electrical Connections ie A 5 Machi eGre ndi g RETE 5 Welding uyu uuu O A 5 Welding Output Cables iii A 5 Cable installati 5 Auxiliary Power Receptacles and A 6 Standby Power Conn
28. dans ce manuel aussi bien que les pr cautions de s ret g n rales suiv antes S ret Pour Soudage A L Arc 1 Protegez vous contre la secousse lectrique a Les circuits l lectrode et la pi ce sont sous tension quand la machine souder est en marche Eviter toujours tout contact entre les parties sous tension et la peau nue ou les v tements mouill s Porter des gants secs et sans trous pour isoler les mains Faire tr s attention de bien s isoler de la masse quand on soude dans des endroits humides ou sur un plancher metallique ou des grilles metalliques principalement dans les positions assis ou couch pour lesquelles une grande partie du corps peut tre en contact avec la masse Maintenir le porte lectrode la pince de masse le c ble de soudage et la machine souder en bon et s r tat defonctionnement d Ne jamais plonger le porte lectrode dans l eau pour le refroidir Ne jamais toucher simultan ment les parties sous tension des porte lectrodes connect s deux machines souder parce que la tension entre les deux pinces peut tre le total de la tension vide des deux machines Si on utilise la machine souder comme une source de courant pour soudage semi automatique ces precautions pour le porte lectrode s applicuent aussi au pistolet de soudage 2 Dans le cas de travail au dessus du niveau du sol se prot ger zones o l on pique le laitier 6 Eloigner les mat riaux
29. from control at the welder to remote control RANGER 305G LINCOLN A 5 INSTALLATION A 5 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 volt age control is connected to the 14 pin connector do not connect anything to the 6 pin connector ELECTRICAL CONNECTIONS MACHINE GROUNDING Because this portable engine driven welder creates its own power it is not necessary to connect its frame to an earth ground unless the machine is connected to premises wiring home shop etc 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 When this welder is mounted on a truck or trailer its frame must be securely connected to the metal frame of the vehicle When this engine driven welder is con nected to premises wiring such as that in a home or shop its frame must be connected to the system earth ground See further connection instructions in the sec tion entitled
30. inflammables ou les recouvrir afin de pr venir tout risque d incendie d aux tincelles Quand on ne soude pas poser la pince une endroit isol de la masse Un court circuit accidental peut provoquer un chauffement et un risque d incendie S assurer que la masse est connect e le plus pr s possible de la zone de travail qu il est pratique de le faire Si on place la masse sur la charpente de la construction ou d autres endroits loign s de la zone de travail on augmente le risque de voir passer le courant de soudage par les chaines de lev age c bles de grue ou autres circuits Cela peut provoquer des risques d incendie ou d echauffement des chaines et des c bles jusqu ce qu ils se rompent Assurer une ventilation suffisante dans la zone de soudage Ceci est particuli rement important pour le soudage de t les galvanis es plomb es ou cadmi es ou tout autre m tal qui produit des fume s toxiques Ne pas souder en pr sence de vapeurs de chlore provenant d op rations de d graissage nettoyage ou pistolage La chaleur ou les rayons de l arc peuvent r agir avec les vapeurs du solvant pour produire du phosg ne gas fortement toxique ou autres produits irritants Pour obtenir de plus amples renseignements sur la s ret voir le code Code for safety in welding and cutting CSA Standard W 117 2 1974 contre les chutes dans le cas ou on recoit un choc Ne jamais PR CAUTIONS DE S RET POUR
31. of the weld ing equipment so there will be no undue stress to the frame Work 3 Proper placement of the equipment on the trailer to insure stability side to side and front to back when being moved and when standing by itself while being operated or ser viced 4 Typical conditions of use i e travel speed roughness of sur face on which the trailer will be operated environmental con ditions like maintenance 5 Conformance with federal state and local laws Consult applicable federal state and local laws regarding specific requirements for use on public highways RANGER 305G LINCOLN A 4 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 Wipe up spilled fuel and allow fumes to clear before starting engine Keep sparks and flame away from tank OIL qn The RANGER 305G is shipped with the engine crankcase filled with high quality SAE 10W 30 oil Check the oil level before starting the engine If it is not up to the full mark on the dip stick add oil as required Check the oil level every four hours of run ning time during the first 25 running hours Refer to the engine Operator s Manual for specific oil recom mendations and break in information The oil change interval is depend
32. reproductive harm cancer birth defects or other reproductive harm The Above For Diesel Engines The Above For Gasoline Engines ARC WELDING CAN BE HAZARDOUS PROTECT YOURSELF AND OTHERS FROM POSSIBLE SERIOUS INJURY OR DEATH KEEP CHILDREN AWAY PACEMAKER WEARERS SHOULD CONSULT WITH THEIR DOCTOR BEFORE OPERATING Read and understand the following safety highlights For additional safety information it is strongly recommended that you purchase a copy of Safety in Welding amp Cutting ANSI Standard Z49 1 from the American Welding Society P O Box 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 powered equipment 1 Turn the engine off before troubleshooting and maintenance work unless the maintenance work requires it to be running 3 SX 1 h To avoid scalding do not remove the radiator pressure cap when the engine is hot 1 b Operate engines in open well ventilated areas or vent the engine exhaust fumes outdoors ELECTRIC AND 3 m MAGNETIC FIELDS be dangerous 1 c Do not add the fuel near an open flame welding arc or when the engine is running Stop the engi
33. secure the outlet pipe to the outlet tube with the pipe positioned such that it will direct the exhaust in the desired direction Tighten using a 9 16 socket or wrench SPARK ARRESTER Some federal state or local laws may require that gasoline or diesel engines be equipped with exhaust spark arresters when they are operated in certain locations where unarrested sparks may present a fire hazard The standard muffler included with this welder does not qualify as a spark arrester When required by local regulations a suitable spark arrester such as the S24647 must be installed and properly main tained CAUTION An incorrect spark arrestor may lead to damage to the engine or adversely affect performance HIGH FREQUENCY GENERATORS FOR TIG APPLICATIONS The K930 2 TIG Module is suitable for use with the RANGER 305G The RANGER 305G and any high frequency generating equipment must be properly grounded See the K930 2 Operating Manual for com pleted instructions on installation operation and maintenance REMOTE CONTROL The RANGER 3056 is equipped with a 6 pin and 14 pin Amphenol connector The 6 pin connector is for connecting the K857 or K857 1 Remote Control optional or for TIG welding the K870 foot Amptrol or the K812 hand Amptrol 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
34. suitable clothing made from durable flame resistant material to protect your skin and that of your helpers from the arc rays Protect other nearby personnel with suitable non flammable screening and or warn them not to watch the arc nor expose themselves to the arc rays or to hot spatter or metal 23 FUMES AND GASES can be dangerous 5 a Welding may produce fumes and gases hazardous to health Avoid breathing these fumes and gases When welding keep your head out of the fume Use enough ventilation and or exhaust at the arc to keep fumes and gases away from the breathing zone When welding with electrodes which require special ventilation such as stainless or hard facing see instructions on container or MSDS or on lead or cadmium plated steel and other metals or coatings which produce highly toxic fumes keep exposure as low as possible and below Threshold Limit Values TLV using local exhaust or mechanical ventilation In confined spaces or in some circumstances outdoors a respirator may be required Additional precautions are also required when welding on galvanized steel Do not weld in locations near chlorinated hydrocarbon vapors coming from degreasing cleaning or spraying operations The heat and rays of the arc can react with solvent vapors to form phosgene a highly toxic gas and outher irritating pro ducts Shielding gases used for arc welding can displace air and cause injury or death Always use enou
35. 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 Do NOT tamper with governor components or setting or make any other adjustments to increase the maximum speed Severe personal injury and damage to the machine can result if operated at speeds above maximum Adjustments to the engine are to be made only by a Lincoln Service Center or an authorized Field Service Shop BATTERY MAINTENANCE To access the battery Remove the 2 screws from the rear battery tray using a screwdriver or a 3 8 socket Slide the battery tray out only far enough to access the battery terminals WARNING VMENGASES FROM BATTERY can explode e Keep sparks flame and cigarettes away from battery To prevent EXPLOSION when e INSTALLING A NEW BATTERY disconnect negative cable from old battery first and con nect to new battery last 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 e USING A BOOSTER connect positive lead to battery first then connect negative lead to neg ative battery lead at engine foot BATTERY ACID can burn eyes and gt skin e Wear gloves
36. the spring clip at the end of the lead This is a control lead to supply current to the wire feeder motor it does not carry welding current 4 Set the MODE switch to the CV WIRE position 5 Set the WELD TERMINALS switch to WELD TERMINALS ON 6 Set the CONTROL knob to 0 initially and adjust to suit 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 When the gun trigger is closed the current sens ing circuit will cause the RANGER 305G engine to go to the high idle speed the wire will begin to feed and the welding process started When weld ing is stopped the engine will revert to low idle speed after approximately 12 seconds unless welding is resumed CAUTION If you are using an LN 25 without an internal con tactor the electrode will be energized when the Ranger 305G is started Connection of LN 7 or LN 8 to the RANGER 305G 1 Shut the welder off 2 Connect the LN 7 or LN 8 per instructions on the appropriate connection diagram in Section F 3 Set the WIRE FEEDER VOLTMETER switch to either or as required by the electrode being used 4 Set the MODE switch to the CV WIRE posi tion 5 Set the CONTROL knob to 0 initially and adjust to suit 6 Set the WELD TERMINALS switch t
37. to air dry Saturate the pre cleaner with new engine oil Squeeze out all excess oil Reinstall the pre cleaner over the paper element Reinstall the air cleaner cover Secure cover with the cover retaining knob RANGER 305G LINCOLN D 3 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 Replace a dirty bent or damaged element with a new ele ment Handle new elements carefully do not use if the sealing surfaces are bent or damaged When servicing the air cleaner check the air clean er base Make sure it is secured and not bent or damaged Also check the element cover for dam aged or improper fit Replace all damaged air cleaner components NOTE Before air cleaner is reassembled make sure rubber seal is in position around stud Inspect mak ing sure it is not damaged and seals with the element cover Reinstall the paper element pre cleaner element cover element cover nut and air cleaner cover Secure cover with the cover retaining knob SPARK PLUG To ensure proper engine operation the spark plug must be properly gapped and free of deposits WARNING NOTE Before removing spark plug the muffler becomes very hot during operation and remains hot
38. vez 2 ON3HdWV ma t Wie NON 199 HONO 4 dieu 1 xao m ta v as lt a wz wi SL 99 91899 48 E RANTS m 1 8 t w ova OND GNVOB 24 TONLNOD T HMZ82d wz a T fs vos YON Me aunouo m HE 22 je en i MOLON Le 301971400 E AL OL hr o SN NUJE OL 1 21 co amp ie eis ui eus ad 8 vaNo Qi 3m izte lt H 12 2 SOND Sem i w H T 22 ovner LN a s alesy 906 Mao leor 5 lt NOLLSOd OL QV lo ion a NL MOHS L zsz o was 4 F e pass 4 m m ceo epo SL isz aa ONO INVES a Te vs oueydury Rel OUND UST TT 96 le mj um 090 55 siz Hs Ls J Mi 5 NS o 5 802 1NON335VO 2 5 9 NO MEHDS OND 801 vip var z en ml s lao arez ayez x Nc Ue Wz 20 P BALLISOd NI NMOHS zr 30N9 AGISNI 2 Er EM va veoz LR CALNIOd yamod 0333
39. 1530 804 8115 LAdLNO OL 31899 ONIGTAM LOANNOO dO 319A9 LNSYYND 303 Q3ZIS 38 LSNW 53185 ONIGTAM IV NV 9NILVH3dO 83Q013M 3NI9N3 JHL NI Q31ST1SNOLLV2I3I93dS 3AO8V LSNFAY LON Od 7 AHOLOV3 FHL 135 334 SI ONILLAS YONYSAOD 3NION3 JHL LINDYIO TOHLNOO 3H1 39VIAVO NYO HOIHM 830333 SHIM OV IHL NI 3SV3SONI NV 3575 39 VMNIT FTLLOYHL JHL SNIGIISH3AO HO ONILLAS ONIONVHI 3NISN3 SHL dO 35744 LINN 9333 OL 57890 30041933 NOILAWS 3240065 HAMOd dO IWNINYAL MYOM OL SLO3NNOO NOLLO3NNOO YALAWLIOA 830333 38IM OL NOLLO3NNOO 3IAV3 324005 H3MOd 9 QN9 CE Le DIAGRAMS OWA P OVA 4 je JN Zp JN DE LNdLNO t 4 Z ON s 303 33 13901 LOANNOO W 5904105 YACTAM ANIONS NO LON 19 28 TVSH3AINR 98 JON3HdINV 18 ueuudinbe 141 ones 10 pjnous sued Aeme deay e eoe d ui desye sued Ajeouioeje jou Burmas Aieneg 3ALLVO3N 12euuoosiq e uedo sjaued jou ONINHVM WV u NOILOANNOD 31d VOV 318V9 1O31NO9 298M OL SH3Q 13M 3NION3 RANGER 305G
40. 6 486 1751 WEB SITE www lincolnelectric com
41. ALL 10A 430333 dH1 NOILISOd ALISIV 10d 0341540 SONLS LAdLNO OL 31895 SNIQT3M LO3NNOO AN IV NV ONILVYSdO 33 SNOI1VO I 1ddV SYNLNA ANY JLVICAWNI dO 41949 ALNG ANY ALIOVdVO dO 38 LSNW 31899 300819313 OL OL MHOM 30333 38IM 1031405 3 L03H WNOILdO JON3HdlAV Nid 9 jueuudinbe 14 2 JO syed Ajeouoeje jou oqe esn ejsui pinous jeuuosied e sued e peaj 3ALLVO3N 12euuoosiq e goed ui e uedo sjoued ejejedo jou oq e ONINHVM YV 10 1 09 SLOWS L riv9 TWNOILdO NOLL23NNOO 3H1 5504 5 S N 1 SH3Q 13M 3NION3 RANGER 305G LINCOLN E 6 8 05 3 0002 22 01 8341530 SV NOILISOd H9IH OLAV NIHOLIMS 41101 39V1Id WANVW 9NILV83dO 395 SNOILVOl1daV 9340403 ANY ALVIGAWWI dO 41949 ALNG LNSYYND JHL ALIO VdVO HIdOHd dO 38 LSNW S318V9 ONIGTAM 318V9 300819313 AHL dO SHL HOLVIN OL HOLIMS YSLAWLIOA 830333 38IM JHL NOILISOd ALINV10d 6341530 803 58715 LNdLNO 015318 2 9NIQTJM LOANNOD NOILISOd 411041 09 AT310IN38 OL HOLIMS S IVNIIASH3LE 83QT3M SOV Id 5 38IM AO NI HOLIMS
42. BETRIEBSANLEITUNG DER ANLAGE UND DEN ELEKTRODENEINSATZ DES HER STELLERS DIE UNFALLVERHUTUNGSVORSCHRIFTEN DES ARBEITGEBERS SIND EBENFALLS ZU BEACHTEN Keep your head out of fumes Use ventilation or exhaust to remove fumes from breathing zone Los humos fuera de la zona de res piraci n e Mantenga la cabeza fuera de los humos Utilice ventilaci n o aspiraci n para gases e Gardez la t te l cart des fum es e Utilisez un ventilateur ou un aspira teur pour ter les fum es des zones de travail e Vermeiden Sie das Einatmen von Schweibrauch Sorgen Sie f r gute Be und Entl ftung des Arbeitsplatzes e Mantenha seu rosto da fumaca Use ventilac o exhaust o para remover fumo da zona respirat ria 9 fsUPBHEILTASESUCFEU CARE 24752 else e SUAS MAS sis PARAH 7 Turn power off before servicing Desconectar el cable de ali mentaci n de poder de la m quina antes de iniciar cualquier servicio e D branchez le courant avant l entre tien Strom vor Wartungsarbeiten abschalten Netzstrom v llig ff nen Maschine anhalten opere com as tampas removidas Desligue a corrente antes de fazer servico N o toque as partes el tricas nuas e XL7TTL2A 9 AVCWRUD RET BRAY FE e HE BIS AGS XA Do not operate with panel ope
43. CI Duplex is limited to the 20 Amps Two kits are required K802 N POWER PLUG KIT Provides four 120 volt plugs rated at 20 amps each and one dual voltage full KVA plug rated at 120 240 volts 50 amps K802 R POWER PLUG KIT Provides four 120 volt plugs rated at 15 amps each and one dual voltage full KVA plug rated at 120 240 volts 50 amps T12153 9 50 AMP 120 240 V POWER PLUG K1816 1 FULL KVA ADAPTER KIT Plugs into the 120 240V NEMA 14 50R receptacle on the casefront which accepts 4 prong plugs and converts it to a NEMA 6 50R receptacle which accepts 3 prong plugs RANGER 305G LINCOLN D 1 MAINTENANCE D 1 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 If guards are missing from the machine obtain replacements from a Lincoln Distributor See Operating Manual Parts List Read the Safety Precautions in the front of this manual and in the Engine Owner s Manual before working on this machine Keep all equipment safety guards covers and devices in position and in good repair Keep hands hair clothing and tools away from the gears fans and all other moving parts when starting operating or repairing the equipment Routine Maintenance At the end o
44. E 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 This Troubleshooting Guide is provided to help you locate and repair possible machine malfunctions Simply follow the three step procedure listed below Step 1 LOCATE PROBLEM SYMPTOM Look under the column labeled PROBLEM SYMP TOMS This column describes possible symptoms that the machine may exhibit Find the listing that best describes the symptom that the machine is exhibiting Step 2 POSSIBLE CAUSE The second column labeled POSSIBLE CAUSE lists the obvious external possibilities that may contribute to the machine symptom Step 3 RECOMMENDED COURSE OF ACTION This column provides a course of action for the Possible Cause generally it states to contact your local Lincoln Authorized Field Service Facility If you do not understand or are unable to perform the Recommended Course of Action safely contact your local Lincoln Authorized Field Service Facility CAUTION 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
45. H 1 min TIG TORCH Nozzle Size 4 5 Stainless Steel 4 5 6 5 6 6 7 8 8 10 1 When used with argon gas The current ranges shown must be reduced when using argon helium or pure helium shielding gases 2 Tungsten electrodes are classified as follows by the American Welding Society AWS Pure P 1 Thoriated 2 Thoriated EWTh 1 EWTh 2 Though not yet recognized by the AWS Ceriated Tungsten is now widely accepted as a substitute for 2 Thoriated Tungsten in AC and DC applications 3 DCEP is not commonly used in these sizes 4 TIG torch nozzle sizes are in multiples of 1 16ths of an inch 4 1 4 in 6 mm 5 5 16 in 6 3 8 in 10 7 7 16 in 11 8 in 12 5 mm 10 5 8 in 16 mm 5 TIG torch nozzles are typically made from alumina ceramic Special applications may require lava nozzles which are less prone to breakage but cannot withstand high temperatures and high duty cycles RANGER 305G LINCOLN B 6 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 Electrode Diameter Current Range DC electrode positive 1 8 30 60 Amps 5 32 90 150 Amps 3 16 150 250 Amps 1 4
46. IM742 A RANGER 305 G For use with machines having Code Numbers 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 thought ful operation on your part DO NOT INSTALL OPERATE OR REPAIR THIS EQUIPMENT WITHOUT READING THIS 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 SSS eee OPERATOR S MANUAL SSS o pr 1809001 ee mm Designed and Manufactured Under a Quality Program Certified by ABS Quality Evaluations Inc to ISO 9001 Requirements A CERTIFICATE NUMBER 30273 ht 2002 Lincoln Global Inc CERTIFICATE NUMBER 30273 LI N C L N Copyrig 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 WARNING CALIFORNIA PROPOSITION 65 WARNINGS A Diesel engine exhaust and some of its constituents The engine exhaust from this product contains are known to the State of California to cause can chemicals known to the State of California to cause cer birth defects and other
47. LLATION A 3 LIFTING The RANGER 305G weighs approximately 530 lbs with a full tank of gasoline A lift bail is mounted to the machine and should always be used when lifting the machine ADDITIONAL SAFETY PRECAUTIONS WARNING FALLING EQUIPMENT can cause injury Do not lift this machine using lift bale if it is equipped with a heavy accessory such as trailer or gas cylinder Lift only with equipment of ade quate lifting capacity Be sure machine is stable when lifting HIGH ALTITUDE OPERATION At higher altitudes output de rating may be necessary For maximum rating de rate the welder output 3 5 for every 1000 ft 305m Contact an authorized engine service shop for modi fications to operate above 5 000 ft 1525m HIGH TEMPERATURE OPERATION At temperatures above 40 C output de rating is necessary For maximum output ratings de rate the welder output 2 volts for every 10 C above 40 C TOWING The recommended trailer for use with this equipment for road in plant and yard towing by a vehicle 1 is Lincoln s K957 1 If the user adapts a non Lincoln trailer he must assume responsi bility that the method of attachment and usage does not result in a safety hazard nor damage the welding equipment Some of the factors to be considered are as follows 1 Design capacity of trailer vs weight of Lincoln equipment and likely additional attachments 2 Proper support of and attachment to the base
48. NTROL be set to the minimum number without electrode sticking Start with the dial set at O PIPE Welding This slope controlled setting is intended for out of position and down hill pipe welding where the oper ator would like to control the current level by changing the arc length The output CONTROL dial adjusts the full output range for pipe welding The ARC CONTROL knob sets the short circuit cur rent during stick welding arc force Increasing the number from 10 to 10 increases the short circuit cur rent and prevents sticking of the electrode to the plate while welding This can also increase spatter It is rec ommended that the ARC CONTROL be set to the minimum number without electrode sticking Start with the dial set at O TYPICAL RANGER 305G FUEL CONSUMPTION Kohler CH22 gal hr liters hr Low Idle No Load 2400 R P M High Idle No Load 3700 R P M Running Time for 12 gallons hrs DC Weld Output 240 Amps 29 Volts 1 39 5 3 Auxiliary Power 9 500 Watts 1 64 6 2 7 3 DC Weld Output 300 Amps 29 Volts 1 53 5 8 7 8 RANGER 305G LINCOLN B 5 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 gen
49. R 305G by installing a 40 amp 240 VAC double pole circuit breaker Maximum rated load for each leg of the 240 VAC auxiliary is 40 amperes Loading above the rated output will reduce output voltage below the allow able 1096 of rated voltage which may damage appliances or other motor driven equipment and may result in overheating of the RANGER 305G engine and or alternator windings Install a 50 amp 120 240 VAC plug NEMA Type 14 50 to the double pole circuit breaker using No 6 4 conductor cable of the desired length The 50 amp 120 240 VAC plug is available in the optional K802R plug kit or as part number T12153 9 Plug this cable into the 50 Amp 120 240 Volt recep tacle on the RANGER 305G case front RANGER 305G LINCOLN 7 INSTALLATION A 7 CONNECTION OF RANGER 305G TO PREMISES WIRING 240 VOLT 240 Volt POWER 60 Hz 3 Wire COMPANY Service METER NEUTRAL LOAD DOUBLE POLE DOUBLE THROW SWITCH RATING TO BE THE SAME AS OR GREATER THAN PREMISES SERVICE OVERCURRENT PROTECTION PREMISES DISCONNECT AND SERVICE GROUND OVERCURRENT 240 VOLT PROTECTION DOUBLE 50 AMP 120 240 CIRCUIT VOLT PLUG 240 VOLT BREAKER NEMA TYPE 14 50 1 s 50 AMP 120 240 VOLT s Ee O NOTE No 6 COPPER CONDUCTOR CABLE SEE RECEPTACLE NATIONAL ELECTRICAL CODE FOR ALTERNATE WIRE SIZE RECOMMENDATIONS WARNING e Only a licensed certified trained electrician should install the mac
50. ad around your body 1 f Do not put your hands near the engine fan Do not attempt to override the governor or idler by pushing on the throttle control rods while the engine is running 2 d 3 Do not place your body between the electrode and work cables If the electrode cable is on your right side the work cable should also be on your right side X Connect the work cable to the workpiece as close as possible to the area being welded 1 9 To prevent accidentally starting gasoline engines while turning the engine or welding generator during maintenance work disconnect the spark plug wires distributor cap or magneto wire as appropriate Do not work next to welding power source Mar 95 LINCOLN SAFETY 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 In addition to the normal safety precautions if welding must be performed under electrically hazardous conditions in damp locations or while wearing wet clothing on metal structures such as floors gratings or scaffolds when in cramped positions such as sitting kneeling or lyi
51. and eye protection and be careful when working near battery e Follow instructions printed on battery MAINTENANCE D 4 CLEANING THE BATTERY Keep the battery clean by wiping it with a damp cloth when dirty If the terminals appear corroded discon nect the battery cables and wash the terminals with an ammonia solution or a solution of 1 4 pound 0 1113 kg of baking soda and 1 quart 0 9461 of water Be sure the battery vent plugs if equipped are tight so that none of the solution enters the cells After cleaning flush the outside of the battery the bat tery compartment and surrounding areas with clear water Coat the battery terminals lightly with petroleum jelly or a non conductive grease to retard corrosion Keep the battery clean and dry Moisture accumula tion on the battery can lead to more rapid discharge and early battery failure CHECKING THE ELECTROLYTE LEVEL If battery cells are low fill them to the neck of the filler hole with distilled water and recharge If one cell is low check for leaks CHARGING THE BATTERY When you charge jump replace or otherwise con nect battery cables to the battery be sure the polarity is correct Improper polarity can damage the charging circuit The RANGER 305G positive battery termi nal has a red terminal cover If you need to charge the battery with an external charger disconnect the negative cable first then the positive cable before you attach the charger l
52. ceptacle can be split for single phase 120 VAC operation ENGINE OPERATION Before Starting the Engine e Be sure the machine is on a level surface e Open top engine door and remove the engine oil dipstick and wipe it with a clean cloth Reinsert the dipstick and check the level on the dipstick e Add oil if necessary to bring the level up to the full mark Do not overfill Close engine door e See Engine Owner s Manual for specific oil recom mendations ADD FUEL m WARNING GASOLINE can cause fire or explosion Stop engine when fueling Do not smoke when fueling Do not overfill tank Avoid contact with skin or breathing of vapor Keep sparks and flame away from tank Remove the fuel tank cap Fill the tank approximately 4 inches 100mm from the top of the filler neck to allow for fuel expansion observe the fuel gauge while filling DO NOT FILL THE TANK TO THE POINT OF OVERFLOW Replace the fuel cap and tighten securely See Engine Owner s Manual for specific fuel recom mendations RANGER 305G LINCOLN B 2 OPERATION 2 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
53. chained to an undercarriage or fixed support Oylinders should be located Away from areas where they may be struck or subjected to physical damage safe distance from arc welding or cutting operations and any other source of heat sparks or flame Never allow the electrode electrode holder or any other electrically hot parts to touch a cylinder Keep your head and face away from the cylinder valve outlet when opening the cylinder valve Valve protection caps should always be in place and hand tight except when the cylinder is in use or connected for use Read and follow the instructions on compressed gas cylinders associated equipment and publication Precautions for Safe Handling of Compressed Gases in Cylinders available from the Compressed Gas Association 1235 Jefferson Davis Highway Arlington VA 22202 FOR ELECTRICALLY powered equipment 8 a Turn off input power using the disconnect Switch at the fuse box before working on the equipment Install equipment in accordance with the U S National Electrical Code all local codes and the manufacturer s recommendations Ground the equipment in accordance with the U S National Electrical Code and the manufacturer s recommendations Mar 95 SAFETY PR CAUTIONS DE S RET Pour votre propre protection lire et observer toutes les instructions et les pr cautions de s ret specifiques qui parraissent
54. ctrically off until a remote switch is depressed 10 WIRE FEEDER VOLTMETER SWITCH Matches the polarity of the wire feeder voltmeter to the polarity of the electrode ENGINE CONTROLS 11 RUN STOP SWITCH RUN position ener gizes the engine prior to starting STOP position stops the engine The oil pressure interlock switch prevents battery drain if the switch is left in the RUN position and the engine is not operating 12 CHOKE When pulled out it closes the choke valve on the engine carburetor for quick starting 13 START PUSH BUTTON Energizes the starter motor to crank the engine 14 IDLER SWITCH Has two positions as follows 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 When switched from HIGH to AUTO or after start ing the engine the engine will operate at full speed for approximately 12 seconds and then go to low idle speed When the electrode touches the work or power is drawn for lights or tools approximately 100 Watts minimum the engine accelerates and operates at full speed When welding ceases or the AC power load is turned off a fixed time delay of approximately 12 seconds starts If the welding or AC power load is not restarted before the end of the time delay the idler reduces the engine speed to low idle Speed The engine will automatically return to high idle speed
55. der to the RANGER 305G accord ing to the instructions in INSTALLATION INSTRUC TIONS Section The RANGER 3059 in the CV WIRE mode permits it to be used with a broad range of flux cored wire Innershield and Outershield electrodes and solid wires for MIG welding gas metal arc welding Welding can be finely tuned using the ARC CON TROL Turning the ARC CONTROL clockwise from 10 soft to 10 crisp changes the arc from soft and washed in to crisp and narrow It acts as an induc tance control The proper setting depends on the pro cedure and operator preference Start with the dial set at 0 Some recommended Innershield electrodes are NR 311 NS 3M NR 207 NR 203 Ni 196 NR 204 H Recommended Outershield electrodes are 0S 70 OS 71M Some recommended solid wires for MIG welding are 035 0 9 mm and 045 1 1 mm L 50 and L 56 035 0 9 mm and 045 1 1 mm Blue Max MIG 308 LS For any electrodes including the above recommenda tions the procedures should be kept within the rating of the machine TYPICAL CURRENT RANGES 1 FOR TUNGSTEN ELECTRODES 2 Tungsten Electrode DCEN DCEP Diameter in mm 196 296 Thoriated Tungsten 196 296 Thoriated Aluminum Tungsten 2 15 3 8 2 4 5 20 5 10 3 5 15 80 8 5 70 150 5 10 3 5 150 250 250 400 13 17 6 8 15 23 7 11 400 500 500 750 750 1000 21 25 23 27 28 32 10 12 11 13 13 15 Approximate Argon Gas Flow Flow Rate C F
56. eads After the battery is charged reconnect the positive battery cable first and the negative cable last Failure to do so can result in damage to the internal charger components Follow the instructions of the battery charger manu facturer for proper charger settings and charging time SERVICING OPTIONAL SPARK ARRESTOR WARNING MUFFLER MAY BE ALLOW ENGINE TO COOL BEFORE INSTALLING THE SPARK ARRESTER DO NOT OPERATE ENGINE WHILE INSTALLING THE SPARK ARRESTER RANGER 305G LINCOLN D 5 MAINTENANCE Welder Generator Maintenance STORAGE Store the RANGER 3056 in clean dry protected areas CLEANING Blow out the generator and controls peri odically with low pressure air Do this at least once a week in particularly dirty areas BRUSH REMOVAL AND REPLACEMENT It s nor mal for the brushes and slip rings to wear and darken slightly Inspect the brushes when a generator over haul is necessary CAUTION 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 For your safety and to avoid Electrical Shock please observe all safety notes and pre cautions RANGER 305G LINCOLN D 5 1 TROUBLESHOOTING 1 HOW US
57. ections cuo hos eite redeunt ta te cepa e te Dara A 6 wid ds A 7 Connection of Lincoln Electric Wire Feeders sene A 8 Section B Safety Precautions E M B 1 General Descriptio M eR EE B 1 Ib CIPUE P B 1 Engine Operation B 1 lC ET sua aa dl B 1 Welder Controls sise B 2 Engine Controls 222 22 B 3 Starting and Stopping the Engine ss B 3 reset ayau a asal 4 Welding Operaatiot us u una 4 DC Stick Welding Em B 4 Constant Current Stick Weldirig 2 12 cicli B 4 Pipe W 8Idiiga c L M B 4 Fuel Consumption iii B 4 5 Typical Current Ranges for Tungsten Electrodes B 5 Wire Welding CV eec e M Simultaneous Welding and Auxiliary B 6 Extension Cord Recommendations B 6 Auxiliary POWT ae
58. ent on the quality of the oil and the operating environment Refer to the Engine Operator s Manual for the proper service and maintenance inter FUEL vals USE GASOLINE FUEL ONLY m WARNING Fill the fuel tank with clean fresh fuel The capacity of the fuel tank is 12 gallons 45 4 liters When the fuel gauge reads empty the tank contains approximately 2 gallons of reserve fuel NOTE The fuel tank is mounted below the engine so a fuel shutoff valve is not required ENGINE COOLING SYSTEM WARNING Air to cool the engine is drawn in lower set of louvers on the case back It is important that the intake air is not restricted Allow a minimum clearance of 2 feet 0 6m from the case back to a vertical surface BATTERY CONNECTION CAUTION Use caution as the electrolyte is a strong acid that can burn skin and damage eyes INSTALLATION A 4 The RANGER 305G is shipped with the negative bat tery cable disconnected Make certain that the RUN STOP switch is in the STOP position Remove the two screws from the rear battery tray using a screwdriver or a 3 8 socket Attach the negative battery cable to the negative battery terminal and tighten using a 1 2 socket or wrench NOTE This machine is furnished with a wet charged battery if unused for several months the battery may require a booster charge Be careful to charge the bat tery with the correct polarity MUFFLER OUTLET PIPE Using the clamp provided
59. eral no tungsten con tamination Then the tungsten is gently lifted off the work in a rocking motion which establishes the arc The ARC CONTROL is not active in the TIG mode To STOP a weld simply pull the TIG torch away from the work When the arc voltage reaches approximately 30 Volts the arc will go out and the machine will reset the current to the Touch Start level To reinitiate the arc re touch the tungsten to the work and lift Alternatively the weld can be stopped by releasing the Amptrol or arc start switch The Ranger 305G can be used in a wide variety of DC TIG welding applications In general the Touch Start feature allows contamination free starting without the use of a Hi frequency unit If desired the K930 2 TIG Module can be used with the Ranger 305D The set tings are for reference Ranger 305G settings when using the K930 2 TIG Module with an Amptrol or Arc Start Switch Set the MODE Switch to the TOUCH START TIG setting Set the IDLER Switch to the AUTO position Set the WELDING TERMINALS switch to the REMOTELY CONTROLLED position This will keep the Solid State contactor open and provide a cold electrode until the Amptrol or Arc Start Switch is pressed OPERATION B 5 When using the TIG Module the OUTPUT control on the Ranger 305G is used to set the maximum range of the CURRENT CONTROL on the TIG module or an Amptrol if connected to the TIG Module WIRE WELDING CV Connect a wire fee
60. f each day s use refill the fuel tank to minimize moisture condensation in the tank Running out of fuel tends to draw dirt into the fuel system Also check the crankcase oil level and add oil if indicated KOHLER ENGINE FREQUENCY Fill fuel tank Daily or Before Check oil level Starting Engine Check air cleaner for dirty loose or damaged parts Check air intake and cooling areas clean as necessary First Oil Change Every 25 Hours Service air pre cleaner Every 100 Hours Every 100 Hours Every 100 Hours e Change engine oil Replace fuel filter element Clean or replace air filter ele ment 7 Every 100 Hours Spark Plug Arrester Every 200 Hours Replace oil filter Every 200 Hours Check spark plug and gap Every 2 Years Check fuel lines and clamps 1 Service more frequently when used in dusty areas and or at high ambient temperatures ENGINE MAINTENANCE COMPONENTS KOHLER CH22 ENGINE Oil Filter Kohler 1205001 Fram PH3614 Air Filter Element Kohler 4708303 Fram CA79 Air Filter Pre Cleaner Kohler 2408302 Fuel Filter Kohler 2405002 Fram G1 Spark Plug Champion RC12YC 030 Gap BCI Group 58 435 CCA RANGER 305G LINCOLN 8 Battery D 2 Engine Oil Change SE 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 dra
61. for a while after stopping the engine Be care ful not to touch the muffler while it is hot MAINTENANCE D 3 Spark Plug Service To ensure proper engine operation the spark plug must be properly gapped and free of deposits Remove the spark plug cap Clean any dirt from around the spark plug base Use a plug wrench to remove the spark plug Visually inspect the spark plug Discard them if the insulator is cracked or chipped Clean the spark plug with a wire brush if it is to be reused Measure the plug gap with a feeler gauge Correct as necessary by bending the side electrode Check that the spark plug washer is in good condi tion and thread the spark plug in by hand to prevent cross threading After the spark plug is seated tighten with a spark plug wrench to compress the washer f installing a new spark plug tighten 1 2 turn after the spark plug seats to compress the washer f reinstalling a used spark plug tighten 1 8 1 4 turn after the spark plug seats to compress the washer Spark Plug Gap 030 in 0 76 mm Kohler Spark Plug Torque 20 ft Lb 27 N m Kohler CAUTION The spark plug must be securely tightened An improperly tightened spark plug can become very hot and may cause engine damage Use only the recommended spark plug or equiva lent A spark plug which has an improper heat range may cause engine damage RANGER 305G LINCOLN D 4 FUEL FILTER Check
62. gh ventilation especially in confined areas to insure breathing air is safe Read and understand the manufacturer s instructions for this equipment and the consumables to be used including the material safety data sheet MSDS and follow your employer s safety practices MSDS forms are available from your welding distributor or from the manufacturer Also see item 1 b SAFETY 7 WELDING SPARKS gt 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 Where compressed gases are to be used at the job site special precautions should be used to prevent hazardous situations Refer to Safety in Welding and Cutting ANSI Standard Z49 1 and the operating information for the equipment being used When not welding make certain no part of the electrode circuit is touching the work or ground Accidental contact can cause overheating and create a fire hazard Do not heat cut or weld tanks drums or containers until the proper steps have been taken to insure that such procedures will not cause flammable or toxic vapors from substances inside They can cause an explosion even though they have bee
63. he 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 e Insulate yourself from work and ground Always wear dry insulating gloves e 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 these and any other safety procedures included in this manual and in the Engine Instruction Manual GENERAL DESCRIPTION The RANGER 3056 is a gasoline engine powered DC multi process welding power source and 120 240 volt AC power generator The engine drives a genera tor that supplies three phase power for the DC weld ing circuit and single phase power for the AC auxiliary outlets The DC welding control system uses state of the art Chopper Technology CT tm for superior weld ing performance DESIGN FEATURES FOR AUXILIARY POWER Start the engine and set the IDLER control switch to the desired operating mode Full power is available regardless of the welding control settings providing no welding current is being drawn 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 The 240 VAC re
64. hed in to crisp and narrow It acts as an induc tance control The proper setting depends on the proce dure and operator preference Start with a setting of O RANGER 305G LINCOLN B3 OPERATION B 3 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 Includes contactor closure circuit auto sensing remote control circuit and 120V and 42V power The remote control circuit operates the same as the 6 Pin Amphenol 8 6 PIN AMPHENOL For attaching optional remote control equipment 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 When using the TOUCH START TIG mode with a TIG Module connected to the RANGER 305G the OUT PUT control on the front of the RANGER 305G is used to set the maximum current range of the CUR RENT CONTROL on the TIG Module 9 WELD TERMINALS CONTROL SWITCH In the WELD TERMINALS ON position the output is electrically hot all the time In the REMOTELY CON TROLLED position the output is controlled by a wire feeder or amptrol device and is ele
65. hine to a premises or residential electrical system Be certain that e The installation complies with the National Electrical Code and all other applicable electrical codes e The premises is isolated and no feedback into the utility system can occur Certain state and local laws require the premises to be isolated before the generator is linked to the premises Check your state and local requirements A double pole double throw transfer switch in conjunction with the properly rated double throw circuit breaker is connected between the generator power and the utility meter RANGER 305G LINCOLN A 8 INSTALLATION A 8 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 NOTE The LN 25 K431 Remote Control Module and K432 Remote Cable are not recommended for use with the RANGER 305G 1 Shut the welder off 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 terminal of the welder 3 Attach the single lead from the front of the LN 25 to work using
66. in 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 Refill to the upper limit mark on the dipstick with the recommended oil Tighten the oil filler cap securely Engine Oil Refill Capacities Without oil filter replacement 1 7 US qt 1 4 Imp qt 1 6 liter Kohler With oil filter replacement 2 0 US qt 1 7 Imp qt 1 9 liter Kohler Use 4 stroke motor oil that meets or exceeds the requirements for API service classification SG or SH Always check the API SERVICE label on the oil con tainer to be sure it includes the letters SG or SH SAE 10W 30 is recommended for general all temper ature use 5 F to 104 F 20 C to 40 C For the Onan engine it is recommended that SAE 30 oil be used above 82 F 27 C See Engine Owners Manual for more specific infor mation on oil viscosity recommendations Wash your hands with soap and water after handling used oil Please dispose of used motor oil in a manner that is compatible with the environment We suggest you take it in a sealed container to your local service sta tion or recycling center for reclamation Do not throw it in the trash pour it on the ground or down a drain Cil Filter Change Drain the engine oil Remove the oil filter and drain the oil into a suitable container Discard
67. n cleaned For information purchase Recommended Safe Practices for the Preparation for Welding and Cutting of Containers and Piping That Have Held Hazardous Substances AWS F4 1 from the American Welding Society see address above Vent hollow castings or containers before heating cutting or welding They may explode Sparks and spatter are thrown from the welding arc Wear oil free protective garments such as leather gloves heavy shirt cuffless trousers high shoes and a cap over your hair Wear ear plugs when welding out of position or in confined places Always wear safety glasses with side shields when in a welding area Connect the work cable to the work as close to the welding area as practical Work cables connected to the building framework or other locations away from the welding area increase the possibility of the welding current passing through lifting chains crane cables or other alternate cir cuits This can create fire hazards or overheat lifting chains or cables until they fail 6 h Also see item 1 c LINCOLN 8 CYLINDER may explode 22238 if damaged 7 Use only compressed gas cylinders containing the correct shielding gas for the process used and properly operating regulators designed for the gas and pressure used All hoses fittings etc should be suitable for the application and maintained in good condition Always keep cylinders in an upright position securely
68. n or guards off No operar con panel abierto 0 guardas quitadas N op rez pas avec les panneaux ouverts ou avec les dispositifs de protection enlev s e Anlage nie ohne Schutzgeh use oder Innenschutzverkleidung in Betrieb setzen e Mantenha se afastado das partes moventes opere com os paineis abertos ou guardas removidas e S J P p A RALE 3 E U uA C F uv e 20 Sel Sepe Asal HAS WARNING Spanish AVISO DE PRECAUCION French ATTENTION German WARNUNG ATEN O BIR Chinese Qai oe dul jua e os uui ARI ge cal sd ue Aie Ao pha J e Ads cuts 13 gall l Jai y e Cut Ll gt LEIA COMPREENDA AS INSTRUCOES DO FABRICANTE PARA ESTE EQUIPAMENTO E AS PARTES DE USO SIGA AS PR TICAS DE SEGURANCA DO EMPREGADOR SRM OBUOX HD OHBRBEE lt K RA ETISRIUCESU CL TRHORERMEI HS F ux ET REL BE SUCR Rr de EL AMENER 0 SAAD HA HHR ele BEHE ET gl illai aui J al gll Gail guet LINCOLN 5 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 21
69. n sites Heavy duty puncture resistant pneumatic tires K1770 1 UNDERCARRIAGE FACTORY For moving by hand on a smooth surface Heavy duty puncture resistant pneumatic tires amp front caster One or two gas cylinders can be mounted on the rear of the undercarriage with the installation of K1745 1 Cylinder Holder s K1739 1 CABLE CARRIER KIT For use on K1737 1 and K1770 1 Undercarriages K1745 1 SINGLE GAS CYLINDER HOLDER For use on K1770 1 Undercarriage One or two may be installed on an undercarriage K1788 1 ROLL CAGE Gives added damage protection K886 2 CANVAS COVER Protects machine when not in use K1898 1 SPARK ARRESTOR Mounts inside exhaust pipe K702 ACCESSORY KIT Accessory set includes 35 ft 10 7 meters 2 AWG electrode cable 30 ft 9 1 meters 2 AWG work cable headshield with No 12 filter GC300 work clamp and Cooltong 300 electrode holder Cables are rated at 250 amps 40 duty cycle K857 25 ft 7 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 ACCESSORIES K1690 1 GFCI RECEPTACLE KIT Includes one UL approved 120V ground fault circuit interrupter duplex type receptacle with cover and installation instructions Replaces the factory installed 120V duplex receptacle Each receptacle of the GFCI Duplex is rated at 20 Amps the maximum total cur rent from the GF
70. na Da Sus B 6 Simultaneous Welding and Auxiliary Power B 6 DIDCILIImM Section C Options Accessories and Compatible Lincoln C 1 vii TABLE OF CONTENTS L EU CIE Section D Safety Precautions iii D 1 Routine eet tcr cere EE D 1 Kohler a uu u E D 1 Engine Maintenance D 1 Engine Oil Change sise D 2 Engine Oil Refill Capacitles u u R ne ind D 2 Engine Filter Change ui D 2 Air Cleaner Services Aid eh eae D 2 Air Pre Cleaner Service iii D 2 Air Fiter Paper Element cient ite d rx Rt nc D 3 Spark PIU pL D 3 Plug ss Anan ea hese ee D 3 D 4 Engine Adjustment iir idein died bereit LE d R D 4 Battery D 4 Servicing Optional Spark Arresto P scierie aaa D 4 Welder Generator D 5 sire D 5 Cleaning T UEM D 5 Brush Removal and D 5 Troubleshooting 1 1 12er ISL aasawa wwqsaawaawa awawaqwaquawaawnawwaqana
71. ne and allow it to cool before refueling to prevent spilled fuel from vaporiz ing on contact with hot engine parts and igniting Do not spill fuel when filling tank If fuel is spilled wipe it up and do not start engine until fumes have been eliminated 2 a Electric current flowing through any conductor causes localized Electric and Magnetic Fields EMF Welding current creates EMF fields around welding cables and welding machines EMF fields may interfere with some pacemakers and welders having a pacemaker should consult their physician before welding 1 d Keep all equipment safety guards covers and devices in position and in good repair Keep hands hair clothing and tools away from V belts gears fans and all other moving parts when starting operating or repairing equipment Exposure to EMF fields in welding may have other health effects which are now not known All welders should use the following procedures in order to 1 e In some cases it may be necessary to remove safety nes minimize exposure to EMF fields from the welding circuit guards to perform required maintenance Remove guards only when necessary and replace them when the maintenance requiring their removal is complete Always use the greatest care when working near moving parts 2 d 1 Route the electrode and work cables together Secure them with tape when possible 2 d 2 Never coil the electrode le
72. ng if there is a high risk of unavoidable or accidental contact with the workpiece or ground use the following equipment Semiautomatic DC Constant Voltage Wire Welder DC Manual Stick Welder AC Welder with Reduced Voltage Control In semiautomatic or automatic wire welding the electrode electrode reel welding head nozzle or semiautomatic welding gun are also electrically hot Always be sure the work cable makes a good electrical connection with the metal being welded The connection should be as close as possible to the area being welded Ground the work or metal to be welded to a good electrical earth ground Maintain the electrode holder work clamp welding cable and welding machine in good safe operating condition Replace damaged insulation Never dip the electrode in water for cooling Never simultaneously touch electrically hot parts of electrode holders connected to two welders because voltage between the two can be the total of the open circuit voltage of both welders When working above floor level use a safety belt to protect yourself from a fall should you get a shock Also see Items 6 c and 8 LINCOLN 8 ARC RAYS can burn 4 a Use a shield with the proper filter and cover plates to protect your eyes from sparks the rays of the arc when welding or observing open arc welding Headshield and filter lens should conform to ANSI Z87 standards 4 b Use
73. ng and maintenance instructions and parts lists ELECTRIC SHOCK can kill Do not touch electrically live parts or mu electrode with skin or wet clothing e insulate yourself from work and ground Always wear dry insulating gloves ENGINE EXHAUST can kill Use in open well ventilated areas or vent exhaust outside 4 MOVING PARTS can injure Do not operate with doors open or guards off A Stop engine before servicing Keep away from moving parts See additional warning information at front of this operator s manual Only qualified personnel should install use or service this equipment LOCATION AND VENTILATION 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 properly vented to an outside area STACKING RANGER 305G machines cannot be stacked ANGLE OF OPERATION Engines are designed to run in the level condition which is where the optimum performance is achieved The maximum angle of continuous operation is 15 degrees in any direction If the engine is to be operat ed at an angle provisions must be made for checking and maintaining the oil level at the normal FULL oil capacity in the crankcase When operating the welder at an angle the effective fuel capacity will be slightly less than the specified 12 gallons INSTA
74. o the REMOTELY CONTROLLED position 7 Set the IDLE switch to the HIGH position Connection of an LN 23P Wire Feeder to the RANGER 305G 1 Shut the welder off 2 Connect the LN 23P as per instructions on the appropriate connection diagram in Section F NOTE When connecting an LN 23P to the RANGER 305G a K350 1 adapter kit must be used 3 Set the VOLTMETER switch to 4 Set the MODE switch to CV WIRE position 5 Set the WELD TERMINALS switch to REMOTELY CONTROLLED 6 Set the ARC CONTROL knob to O initially and adjust to suit 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 23P with the K350 1 adapter kit the electrode is not energized until the gun trigger is closed When the gun trigger is closed the current sens ing circuit will cause the RANGER 305G engine to go to the high idle speed the wire will begin to feed and the welding process can be started When welding is stopped the engine will revert to low idle speed after approximately 12 seconds unless welding is resumed Connection of LN 742 Spool Gun and Cobramatic to RANGER 305G 1 Shut the welder off 2 Connect per instructions on the appropriate con nection diagram in Section F RANGER 305G LINCOLN 8 B 1 OPERATION B 1 SAFETY PRECAUTIONS WARNING Do not attempt to use this equipment until you have thoroughly read t
75. onoj jou esn eisur pjnoys jeuuosJed AIUO e BUIDIAIES e1oJeq sued Aeme e peaj JALLVO3N 12euuoosiq e goed ui desye uedo sjeued 9jeJedo jou oq e i NY49VIQ NOLLO3NNOO 911 0 69 43913 ANIONS RANGER 305G LINCOLN E 01 28178 F 10 0002 22 01 OL HOLIMS AOW NOILISOd 318v9 300819313 JHL dO ALIS V 10d JHL HOLVW OL LAS SI HOLIMS SIHL SS3 Nn 31V33d0 LON TIM 3801V33 LYVLS VSOd JHL NOILISOd OL YSLAWLIOA 3349333 38IM 3HL 145 AN 0 33 SNOILVOl TddV ANY 31VIQ3NNI dO 37949 ANY LNAYYNSD 3HL ALIO VaVO YAdOUd dO 38 LSNW S3 18V9 SNIQGT3M 0 83Q 13M ANIONS JHL NI 31611 SNOILLV2I3I23dS 3AO8V 15 LON Od AHOLOVJ LY 13 4 SI ONILLAS 9 3NION3 SHL LINDYID TOHLNOO 3H1 39VIAVO HOIHM 39V L 10A 830334 38IM OV NI 3SV3SONI NV 3573 FILLOYHL 3H1 9NIGIHS3AO ONILLAS HONSH3AO9 1 9NISNVHO 3NISN3 J101 H9IH JHL dO 3SV38ONI NOLLOVO LANIGVO 0333 OL o 318 2 390419313 MYOM OL tc 2 JON3HdNV a 51899 I13NI8VO 9995 SHIM 9ILVNVH409 OL jueuudinbe 14 2 JO sued Ajeouioeje jou esn ejsui pjnous jeuuosjed AIUO e
76. put is 40 Amps The 240 VAC output can be split to provide two sepa rate 120 VAC outputs with a max permissible current of 40 Amps per output to two separate 120 VAC branch circuits these circuits cannot be paralleled Output voltage is within 10 at all loads up to rated capacity The 120 V auxiliary power receptacles should only be used with three wire grounded type plugs or approved double insulated tools with two wire plugs The current rating of any plug used with the system must be at least equal to the current capacity of the associated receptacle NOTE The 240 V receptacle has two 120 V circuits but are of opposite polarities and cannot be paralleled STANDBY POWER CONNECTIONS The RANGER 30560 is suitable for temporary standby or emergency power using the engine manufacturer s recommended maintenance schedule The RANGER 305G can be permanently installed as a standby power unit for 240 VAC 3 wire single phase 40 amp service Connections must be made by a licensed electrician who can determine how the 120 240 VAC power can be adapted to the particular installation and comply with all applicable electrical codes e Install the double pole double throw switch between the power company meter and the premis es disconnect Switch rating must be the same or greater than the customer s premises disconnect and service over current protection Take necessary steps to assure load is limited to the capacity of the RANGE
77. r technical troubleshooting assistance before you proceed RANGER 305G LINCOLN E 4 TROUBLESHOOTING E 4 Observe all Safety Guidelines detailed throughout this manual No welding power output Poor work lead connection to work Make sure work clamp is tightly connected to clean base metal Weld Terminals switch in wrong position Place switch in Weld Terminals On position when welding without control cable Faulty PC board or welder alterna tor Welder has output but no control Poor remote control cable connec tion to 6 pin or 14 pin Amphenol connector Check connections Faulty remote cable or faulty wire feeder or wire feeder cable Replace if necessary Faulty control potentiometer or PC board If all recommended possible areas Wire feeder does not work when 1 Wire Feeder Power circuit breakerlof misadjustment have been control cable is connected to 14 open Check 42V and 120V checked and the problem persists Amphenol beakers and reset if tripped Contact your local Lincoln Faulty control cable Repair or Authorized Field Service Facility replace cable Faulty wire feeder No auxiliary power Open circuit breakers Reset breakers If breakers keep trip ping reduce power draw Faulty connections to auxiliary receptacles Check connections GFCI tripped if installed Clear any ground fault and reset GFCI circuit by pressing Reset button on the 120 V receptacle Faul
78. rawn objects as they will appear in their assembled form 187 pages with more than 100 illustrations Size 8 1 2 x 11 Durable cloth covered board binding 4 50 postage paid U S A Mainland New Lessons in Arc Welding 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 528 pages well illustrated 6 x 9 size bound in simulated gold embossed leather 5 00 postage paid U S A Mainland Need Welding Training The Lincoln Electric Company operates the oldest and most respected Arc Welding School in the United States at its corporate headquarters in Cleveland Ohio Over 100 000 stu dents have graduated Tuition is low and the training is hands on For details write Lincoln Welding School 22801 St Clair Ave Cleveland Ohio 44117 1199 and ask for bulletin ED 80 or call 216 383 2259 and ask for the Welding School Registrar Lincoln Welding School BASIC COURSE 5 weeks of fundamentals 700 00 There is a 10 discount on all orders of 7550 00 or more e for shipment at or one time to one location lorders of 50 or less before discount or orders outside of North America must be prepaid with charge check or money order in U S Funds Only IPrices include shipment by 4th Class
79. ry Power Loads The above auxiliary power ratings are with no welding load Simultaneous welding and power loads are specified in the following table The permissible cur rents shown assume that current is being drawn from either the 120 VAC or 240 VAC supply not both at the same time RANGER 305G Simultaneous Welding and Power Loads Welding Output Amps Permissible Power Watts Unity Power Factor Permissible Auxiliary Current in Amps 120 240 VAC 6 4 36 20 Each duplex receptacle is limited to 20 amps Not to exceed 40A per 120 VAC branch circuit when splitting the 240 VAC output RANGER 305G Extension Cord Length Recommendations Use the shortest length extension cord possible sized per the following table Maximum Allowable Cord Length in ft m for Conductor Size 6 AWG 175 138 350 275 150 Conductor size is based on manimum 2 0 voltage drop RANGER 305G LINCOLN C 1 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 K959 2 Fender amp Light Kit K965 1 Cable Storage Rack K1737 1 FOUR WHEEL ALL TERRAIN UNDERCAR RIAGE For moving by hand at constructio
80. tart release the switch and wait 10 seconds before operation the starter again Do NOT push the START button while the engine is running because this can damage the ring gear and or the starter motor NOTE When starting RANGER 3050 for the first time or after and extended period of time of not oper ating it will take longer than normal because the fuel pump has to fill the fuel line and carburetor STOPPING Remove all welding and auxiliary power loads and allow the engine to run at low idle speed for a few minutes to cool the engine Stop the engine by placing the RUN STOP in the STOP position NOTE A fuel shut off valve is not required on the RANGER 305G because the fuel tank is mounted below the engine 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 Constant Current CC STICK Welding The CC STICK position of the MODE switch is designed for horizontal and vertical up welding with all types of electrodes especially low hydrogen The out put CONTROL dial adjusts the full output range for stick welding The ARC CONTROL knob sets the short circuit cur rent during stick welding arc force Increasing the number from 10 to 10 increases the short circuit cur rent and prevents sticking of the electrode to the plate while welding This can also increase spatter It is rec ommended that the ARC CO
81. the used oil filter Clean the filter mounting base and coat the gasket of the new oil filter with clean engine oil Screw on the new oil filter by hand until the gasket contacts the filter mounting base then use an oil fil ter socket tool to tighten the filter an additional 1 2 to 7 8 turn MAINTENANCE D 2 Refill the crankcase with the specified amount of the recommended oil Reinstall the oil filler cap Start the engine and check for oil filter leaks Stop the engine and check the oil level If neces sary add oil to the upper limit mark on the dipstick Air Cleaner Service A dirty air cleaner will restrict air flow to the carbure tor To prevent carburetor malfunction service the air cleaner regularly Service more frequently when oper ating the engine in extremely dusty areas WARNING Never use gasoline or low flash point solvents for cleaning the air cleaner element A fire or explo sion could result CAUTION Never run the engine without the air cleaner Rapid engine wear will result from contaminants such as dust and dirt being drawn into the engine Engine Air Pre cleaner Service Loosen the cover retaining knob and remove the cover Remove the pre cleaner from the paper element Wash the pre cleaner in warm water with detergent Rinse the pre cleaner thoroughly until all traces of detergent are eliminated Squeeze out excess water do not wring Allow the pre cleaner
82. ty PC board or welder alterna tor CAUTION 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 RANGER 305G LINCOLN E 5 TROUBLESHOOTING E 5 Observe all Safety Guidelines detailed throughout this manual 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 CC STICK Make sure the electrode wire gas voltage current etc is cor rect for the process being used Check for loose or faulty connec tions at the weld output terminals and welding cable connections If all recommended possible areas of misadjustment have been checked The welding cables may be tooland the problem persists Contact long or coiled causing an exces your local Lincoln Authorized sive voltage drop Field Service Facility CAUTION 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 RANGER 305G LINCOLN DIAGRAMS F 1 F 1 181905 0002 22 01 04415 04 SV NOILISOd 4101
83. u proceed RANGER 305G LINCOLN TROUBLESHOOTING Observe all Safety Guidelines detailed throughout this manual 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 1 Idler switch in High idle position Set switch to Auto 2 External load on welder or auxil iary power Remove all external loads Faulty PC board or idler sole noid Poor work lead connection to work Make sure work clamp is tightly connected to clean base metal Contactor switch is in wrong position Set to Welding On when welding without a control cable Refer to Operations chapter for prop er use of this switch Faulty PC board Low idle speed set to low Auxiliary power load is less than 100 watts Idler may not respond with less than a 100 watt load Set idler to High Faulty PC board Fuel filter clogged Replace Air filter clogged clean or replace Fouled spark plugs clean or replace Valves out of adjustment If all recommended possible areas of misadjustment have been checked and the problem persists Contact your local Lincoln Authorized Field Service Facility CAUTION 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 fo
84. w to Head Shop Drawings a Video Information Incentive Management 5 00 IM lames F Lincoln Arc Welding Foundation Book Information JFLF 515 A New Approach to Industrial Economics m 00 oo The American Century of John C Umen 9507 AC Waking Cale WCS Pipe Welding Chans 50 Ens TL SSSA ona Shipping Costs 777777 ae a a JJ J Lm WARNING Spanish AVISO DE PRECAUCION French ATTENTION German WARNUNG ATENCAO Japanese BIR Korean Do not touch electrically live parts or 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 moja a e Aislese del trabajo y de la tierra Ne laissez ni la peau ni des v te ments mouill s entrer en contact avec des pi ces sous tension Isolez vous du travail et de la terre e Ber hren Sie keine stromf hrenden Teile oder Elektroden mit Ihrem K rper oder feuchter Kleidung Isolieren Sie sich von den Elektroden und dem Erdboden e toque partes el tricas e elec trodos com a pele ou roupa molha da Isole se da e terra o REPOR 7 amp nf dchsn zucct e J T p gt ATUBHELTF EL E GUB see Oa CRM EER e Xe Bp
85. wawawas Section E How to Use Troubleshooting Guide E 1 Troubleshooting 2 Troubleshooting Guide ss E 3 Troubleshooting Gude 4 Troubleshooting Guide iii 5 Diagrams and Dimension Print J Section F Parts te teste P384 A 1 INSTALLATION TECHNICAL SPECIFICATIONS Ranger 305G K1726 1 Make Model Kohler CH22 K1726 1 Welding Output Volts at Rated Amps Duty Cycle Max OCV 3700 RPM Description 2 cylinder 22 HP 3600 RPM GASOLINE ENGINE Speed RPM Displacement CU in cu cm High Idle 3700 41 674 Bore x Stroke inch mm Full Load 3500 3 03 x 2 85 77 x 72 Starting System Capacities 12VDC Battery amp Starter Group 58 435 cold crank amps Battery Charger Fuel 12 gal 45 4 L Oil 2 0 Qts 191 RATED OUTPUT 104 F 40 C WELDER CC STICK DC Output CC STICK Output Range PIPE DC Output PIPE Output Range TIG Output Range CV WIRE DC Output CV WIRE Output Range HEIGHT 30 00 in 762 0 mm LUBRICATION VALVE LIFTERS Full Pressure Hydraulic Mechanical Fuel Pump with Full Flow Filter AIR CLEANER ENGINE IDLER MUFFLER ENGINE PROTECTION Duel Element Automatic Idler 29 Volts 305 Amps 20 to 305 Amps 29 Volts 300 Amps 40 to 300 Amps 20 to 250
86. when there is welding load or AC power load reapplied 15 ENGINE ALTERNATOR TROUBLE LIGHT The engine alternator light is off when battery charging system is functioning normally If light turns on the alternator or the voltage regulator may not be operating correctly The light may also come on due to the battery not holding a charge It is normal for the light to come on during shutdown of the engine The light will remain lit with the meters for a short period of time after the engine has shut down 16 ENGINE HOUR METER Displays the total time that the engine has been running This meter is useful for scheduling prescribed maintenance STARTING AND STOPPING THE ENGINE S PA lt gt e Remove all plugs connected to the AC power receptacles e Set IDLER switch to AUTO e Set the RUN STOP switch to RUN Pull the choke to the full out position Press and hold the engine START button until the engine starts Release the engine START button when the engine starts Push the choke back in RANGER 305G LINCOLN B 4 OPERATION B 4 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 Allow a longer warm up time in cold weath er CAUTION Operating the starter motor for more than 5 sec onds can damage the motor If the engine fails to s

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