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Lincoln Electric Ranger 305 G, Operator'S Manual

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RANGER 305 G

G

OPERATOR’S MANUAL

IM742-A

August, 2002

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.

For use with machines having Code Numbers:

10855,10955

• 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

• World's Leader in Welding and Cutting Products •

Date of Purchase:
Serial Number:
Code Number:
Model:
Where Purchased:

Copyright © 2002 Lincoln Global Inc.

Summary of Contents for Ranger 305 G

Page 1: ...QUIPMENT WITHOUT READING THIS MANUAL AND THE SAFETY PRECAUTIONS CONTAINED THROUGHOUT And most importantly think before you act and be careful For use with machines having Code Numbers 10855 10955 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 World s Leader in Welding and Cutting P...

Page 2: ...R 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 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 availa...

Page 3: ...ical earth ground 3 f Maintain the electrode holder work clamp welding cable and welding machine in good safe operating condition Replace damaged insulation 3 g Never dip the electrode in water for cooling 3 h 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 3...

Page 4: ...event the welding sparks from starting a fire Remember that welding sparks and hot materials from welding can easily go through small cracks and openings to adjacent areas Avoid welding near hydraulic lines Have a fire extinguisher readily available 6 b Where compressed gases are to be used at the job site special precautions should be used to prevent hazardous situations Refer to Safety in Weldin...

Page 5: ...s et non inflammables 4 Des gouttes de laitier en fusion sont émises de l arc de soudage Se protéger avec des vêtements de protection libres de l huile tels que les gants en cuir chemise épaisse pan talons sans revers et chaussures montantes 5 Toujours porter des lunettes de sécurité dans la zone de soudage Utiliser des lunettes avec écrans lateraux dans les zones où l on pique le laitier 6 Eloign...

Page 6: ...he information must be followed to avoid minor personal injury or damage to this equipment CAUTION 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 receive...

Page 7: ...ion A 5 Auxiliary Power Receptacles and Plugs A 6 Standby Power Connections A 6 Premises Wiring A 7 Connection of Lincoln Electric Wire Feeders A 8 Operation Section B Safety Precautions B 1 General Description B 1 Design Features B 1 Engine Operation B 1 Fuel B 1 Welder Controls B 2 Engine Controls B 3 Starting and Stopping the Engine B 3 Stopping B 4 Welding Operation B 4 DC Stick Welding B 4 Co...

Page 8: ...r Filter Paper Element D 3 Spark Plug D 3 Spark Plug Service D 3 Fuel Filter D 4 Engine Adjustment D 4 Battery Maintenance D 4 Servicing Optional Spark Arrestor D 4 Welder Generator Maintenance D 5 Storage D 5 Cleaning D 5 Brush Removal and Replacement D 5 Troubleshooting Section E How to Use Troubleshooting Guide E 1 Troubleshooting Guide E 2 Troubleshooting Guide E 3 Troubleshooting Guide E 4 Tr...

Page 9: ... LUBRICATION VALVE LIFTERS FUEL SYSTEM GOVERNOR Full Pressure Hydraulic Mechanical Fuel Pump Mechanical Governor with Full Flow Filter 5 Regulation AIR CLEANER ENGINE IDLER MUFFLER ENGINE PROTECTION Low noise Muffler Top outlet Shutdown on low oil Duel Element Automatic Idler can be rotated Made from pressure long life aluminized steel ENGINE WARRANTY 2 year unlimited hours See engine manufacturer...

Page 10: ... 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 ...

Page 11: ... 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 1 1 Consult applicable federal state and local laws regarding specific requirements for use on public highways SAFETY PRECAUTIONS Only qualified personnel should install use or service this equipment LOCATION AND VENTILATION The we...

Page 12: ...on 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 P...

Page 13: ... 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 is provided on the front of the welder WELDING TERMINALS The RANGER 305...

Page 14: ...rcuits but are of opposite polarities and cannot be paralleled STANDBY POWER CONNECTIONS The RANGER 305G 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 de...

Page 15: ...0 50 AMP 120 240 VOLT RECEPTACLE CONNECTION OF RANGER 305G TO PREMISES WIRING WARNING Only a licensed certified trained electrician should install the machine to a premises or residential electrical system Be certain that The installation complies with the National Electrical Code and all other applicable electrical codes The premises is isolated and no feedback into the utility system can occur C...

Page 16: ...ly 12 seconds unless welding is resumed 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 elect...

Page 17: ...TURES 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 receptacle can be split for sin...

Page 18: ...ach 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 set...

Page 19: ...e 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 spee...

Page 20: ...s 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 T...

Page 21: ...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 ...

Page 22: ...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 a...

Page 23: ...aust 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 ...

Page 24: ...intenance At the end of 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 WARNING ITEM MAKE AND PART NUMBER KOHLER CH22 ENGINE Oil Filter Kohler 1205001 Fram PH3614 Air Filter Element Kohler 4708303 Fram CA79 Air Filter Pre Cleaner Kohler 2408302 F...

Page 25: ...n a drain Oil Filter Change Drain the engine oil Remove the oil filter and drain the oil into a suitable container Discard 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...

Page 26: ...remains hot for a while after stopping the engine Be care ful not to touch the muffler while it is hot 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 cra...

Page 27: ... 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...

Page 28: ...and slip rings to wear and darken slightly Inspect the brushes when a generator over haul is necessary 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 ...

Page 29: ...LE 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 Authori...

Page 30: ...e machine is running 1 Contact your local Lincoln Authorized Field Service Facility 1 Battery is low Charge Battery 2 Loose battery cable connections Inspect clean and tighten 3 Faulty engine starter motor 4 Battery Circuit circuit breaker is tripped 1 Out of fuel Fill tank and bleed fuel system 2 Faulty fuel solenoid or faulty PC board or ignition system 1 Low oil level Change oil and oil filter ...

Page 31: ...Set switch to Auto 2 External load on welder or auxil iary power Remove all external loads 3 Faulty PC board or idler sole noid 1 Poor work lead connection to work Make sure work clamp is tightly connected to clean base metal 2 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 3 Faulty PC board Lo...

Page 32: ...nals On position when welding without control cable 3 Faulty PC board or welder alterna tor 1 Poor remote control cable connec tion to 6 pin or 14 pin Amphenol connector Check connections 2 Faulty remote cable or faulty wire feeder or wire feeder cable Replace if necessary 3 Faulty control potentiometer or PC board 1 Wire Feeder Power circuit breaker open Check 42V and 120V beakers and reset if tr...

Page 33: ...g arc is not stable or is not satis factory the engine runs normally The auxiliary power is normal 1 Make sure the MODE selector switch is in the correct position for the process being used For example CV WIRE PIPE CC STICK 2 Make sure the electrode wire gas voltage current etc is cor rect for the process being used 3 Check for loose or faulty connec tions at the weld output terminals and welding ...

Page 34: ...F 1 DIAGRAMS F 1 RANGER 305G ...

Page 35: ...F 2 DIAGRAMS F 2 RANGER 305G ...

Page 36: ...F 3 DIAGRAMS F 3 RANGER 305G ...

Page 37: ...F 4 DIAGRAMS F 4 RANGER 305G ...

Page 38: ...F 5 DIAGRAMS F 5 RANGER 305G ...

Page 39: ... INCREASE OF THE HIGH IDLE ENGINE RPM BY CHANGING THE GOVERNOR SETTING OR OVERRIDING THE THROTTLE LINKAGE WILL CAUSE AN INCREASE IN THE AC WIRE FEEDER VOLTAGE WHICH CAN DAMAGE THE CONTROL CIRCUIT THE ENGINE GOVERNOR SETTING IS PRE SET AT THE FACTORY DO NOT ADJUST ABOVE RPM SPECIFICATIONS LISTED IN THE ENGINE WELDER OPERATING MANUAL N A WELDING CABLES MUST BE OF PROPER CAPACITY FOR THE CURRENT AND ...

Page 40: ...F 7 DIAGRAMS F 7 RANGER 305G ...

Page 41: ...F 8 DIAGRAMS F 8 RANGER 305G ...

Page 42: ...F 9 DIAGRAMS F 9 RANGER 305G ...

Page 43: ...F 10 DIAGRAMS F 10 RANGER 305G ...

Page 44: ...F 11 DIAGRAMS F 11 RANGER 305G ...

Page 45: ... VIEWED FROM LEAD SIDE OF RECE PTACLE 9 PIN J50 1 2 3 6 5 4 9 8 7 3 2 1 4 5 6 7 8 9 9 PIN P50 9 8 7 6 5 4 1 2 3 11 12 23 25 L1 CHOKE W9 W8 3 6 261 260 WRAP TWO TURNS 3 6 LEADS IN DIRECTION SHOWN THROUGH TOROID 3 6 7 8 9 4 5 6 3 2 1 RANGER 305G WIRING DIAGRAM FOR CODE 10855 B IDLER CONTROL SHOWN IN AUTO POSITION S4 250 251 S2 START BUTTON C3 800uf 150vdc POSITIVE BRUSH CONNECTED TO SLIP RING NEARES...

Page 46: ...SWITCH SHOWN IN RUN POS 12 7 6 1 1 2 6 10 L2 L3 RF CHOKES 16 9 8 1 CB8 TOP GND SCREW ON INSIDE OF CASE FRONT LEAD COLOR CODE B BLACK OR GRAY R RED OR PINK W WHITE G GREEN W YELLOW STRIPE FRAME GND 5 1 41A 42A 15A 206A 21 S5 VOLTMETER POLARITY SWITCH 208A SHOWN IN POSITIVE POSITION G4285 31 32 GND B A B C D E F 77B 21 75B GND A 41A 42A 76B 115VAC CONTACTOR 77B 76B WORK 75B REMOTE CONTROL 42VAC GROU...

Page 47: ...0 80 A B CENTER OF GRAVITY WITH OIL IN ENGINE AND EMPTY FUEL TANK 29 88 33 62 36 24 10 28 10 78 TRUCK UNDERCARRIAGE MOUNTING HOLES 7 22 24 86 2 6 F 14 DIAGRAMS F 14 RANGER 305G DIMENSION PRINT RANGER 305G DIMENSION A DIMENSION B 23 50 16 75 ...

Page 48: ...NOTES RANGER 305G ...

Page 49: ...16 383 2259 and ask for the Welding School Registrar Lincoln Welding School BASIC COURSE 700 00 5 weeks of fundamentals There is a 10 discount on all orders of 50 00 or more for shipment at one time to one location Orders 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 Prices include shipment by 4thClass Book Rate ...

Page 50: ...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 da Aislese del trabajo y de la tierra Ne laissez ni la peau ni des vête ments mouillés entrer en contact avec des pièces sous tension Isolez vous du travail et de la terre Berühren Sie keine stromführenden Teile oder Elektrode...

Page 51: ...gute Be und Entlüftung des Arbeitsplatzes Mantenha seu rosto da fumaça Use ventilação e exhaustão para remover fumo da zona respiratória Turn power off before servicing Desconectar el cable de ali mentación de poder de la máquina antes de iniciar cualquier servicio Débranchez le courant avant l entre tien Strom vor Wartungsarbeiten abschalten Netzstrom völlig öff nen Maschine anhalten Não opere co...

Page 52: ...s 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 World s Leader in Welding and Cutting Products ...

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