Lincoln Electric RANGER 305G EFI 12157 Operator'S Manual Download Page 31

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E-2

TROUBLESHOOTING

E-2

RANGER

305G EFI

Observe all Safety Guidelines detailed throughout this manual

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.

CAUTION

PROBLEMS

(SYMPTOMS)

POSSIBLE

CAUSE

RECOMMENDED

COURSE OF ACTION

Major Physical or Electrical Damage

is Evident.

Engine will not "crank".

Engine will "crank" but not start.

Engine shuts down shortly after

starting.

Battery does not stay charged.

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.

2. Faulty EFI component(s) or faulty

PC board or ignition system.

3. Fuel lift pump not working.

1. Low oil level. Change oil and oil filter

And fill to proper level. Start engine

And look for leaks.

2. Faulty oil pressure switch or other

engine component.

3. Low fuel level.

4. Fuel pump not working.

1. Faulty battery, replace.

2. Loose connections at battery or

alternator. Clean and tighten connec-

tions.

3. Faulty engine alternator or charg-

er module.

If all recommended possible areas

of misadjustment have been

checked and the problem persists,

Contact your local Lincoln

Authorized Field Service Facility.

Summary of Contents for RANGER 305G EFI 12157

Page 1: ...es having Code Numbers 12157 12206 12653 Need Help Call 1 888 935 3877 to talk to a Service Representative Hours of Operation 8 00 AM to 6 00 PM ET Mon thru Fri After hours Use Ask the Experts at lincolnelectric com A Lincoln Service Representative will contact you no later than the following business day For Service outside the USA Email globalservice lincolnelectric com Save for future reference...

Page 2: ...the general area IN A LARGE ROOM OR OUTDOORS natural ventilation may be adequate if you keep your head out of the fumes See below USE NATURAL DRAFTS or fans to keep the fumes away from your face If you develop unusual symptoms see your supervisor Perhaps the welding atmosphere and ventilation system should be checked wear CorreCt eye ear body ProteCtion PROTECT your eyes and face with welding helm...

Page 3: ...ty 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 1 e In some cases it may be necessary to remove safety guards to perform required maintenance Remove guards only when necessary and replace them when the maintenance requiring their removal is complete ...

Page 4: ...o ANSI Z87 I standards 4 b Use suitable clothing made from durable flame resistant material to protect your skin and that of your helpers from the arc rays 4 c 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 FUMES AND GASES CAN BE DANGEROUS 5 a Welding may produce fumes and g...

Page 5: ... lifting chains crane cables or other alternate circuits This can create fire hazards or overheat lifting chains or cables until they fail 6 h Also see item 1 c 6 I Read and follow NFPA 51B Standard for Fire Prevention During Welding Cutting and Other Hot Work available from NFPA 1 Batterymarch Park PO box 9101 Quincy Ma 022690 9101 6 j Do not use a welding power source for pipe thawing CYLINDER M...

Page 6: ...ER 305G EFI A 7 Premises Wiring A 8 Connection of Lincoln Electric Wire Feeders A 9 A 10 ________________________________________________________________________________ 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 D...

Page 7: ...ter 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 8: ...VALVE LIFTERS FUEL SYSTEM GOVERNOR Full Pressure Hydraulic Mechanical Fuel Pump with Mechanical Governor With Full Flow Filter additional electric fuel lift pump 5 Regulation AIR CLEANER ENGINE IDLER MUFFLER ENGINE PROTECTION Low noise Muffler Top outlet Shutdown on low oil Dual Element Automatic Idler can be rotated Made from pressure Long life aluminized steel ENGINE WARRANTY 2 year unlimited ho...

Page 9: ...CLES AUXILIARY POWER CIRCUIT BREAKER OTHER CIRCUIT BREAKERS 2 120VAC Duplex 5 20R Two 20AMP for Two Duplex Receptacle 20AMP for Battery Charging Circuit 1 120 240VAC Dual Voltage One 50AMP for Dual Voltage 2 pole 15AMP for 42V Wire Feeder Power Full KVA 14 50R RECEPTACLES AND CIRCUIT BREAKERS ...

Page 10: ...ool 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 EFI 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 d...

Page 11: ... gauge reads full Do not top off tank Be sure to leave filler neck empty to allow room for expansion The capacity of the fuel tank is 12 gallons 45 4 liters When the fuel gauge reads empty the tank contains approximately 2 gallons 7 6 liters of reserve fuel NOTE The fuel tank is mounted below the engine so a fuel shutoff valve is not required ENGINE COOLING SYSTEM Air to cool the engine is drawn i...

Page 12: ... when the control cable is con nected 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 c...

Page 13: ...ithin 10 at all loads up to rated capacity All auxiliary power is protected by circuit breakers 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 cur rent capacity of the associated receptacle NOTE The 240 V receptacle ...

Page 14: ...without addi tional resistiVe tyPe loads Inductive Single phase induction motors These devices require large drills well pumps grinders small current inrush for starting refrigerators weed and hedge Some synchronous motors may trimmers be frequency sensitive to attain maximum output torque but they SHOULD BE SAFE from any frequency induced failures Capacitive Inductive Computers high resolution TV...

Page 15: ...0 50 AMP 120 240 VOLT RECEPTACLE CONNECTION OF RANGER 305G EFI 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 occ...

Page 16: ... to the wire feeder motor it does not carry welding current Set the WELD TERMINALS switch to WELD TER MINALS ON Control Cable Model Connect Control Cable between Engine Welder and Feeder Set the WELD TERMINALS switch to REMOTELY CONTROLLED Set the MODE switch to the CV WIRE position Set the WIRE FEEDER VOLTMETER switch to either or as required by the electrode polarity being used Set the ARC CONTR...

Page 17: ... the RANGER 305G EFI engine to go to the high idle speed the wire will begin to feed and the welding process started When welding is stopped the engine will revert to low idle speed after approximately 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 EFI is started Connection of LN 742 K487 25 Spool G...

Page 18: ...specific oil recom mendations ADD FUEL 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 tank until the fuel gauge reads full DO NOT TOP OFF TANK Be sure to leave filler neck empty for expansion Replace the fuel cap and tighten ...

Page 19: ... START TIG 4 ARC CONTROL The ARC CONTROL WIRE STICK dial is active in the WIRE STICK and DOWN HILL PIPE modes and has different func tions in these modes This control is not active in the TIG mode CC STICK mode In this mode the ARC CONTROL dial sets the short circuit current arc force during stick weld ing to adjust for a soft or crisp arc Increasing the number from 10 soft to 10 crisp increases t...

Page 20: ... 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 oper ating 12 START PUSH BUTTON Energizes the starter motor to crank the engine 13 IDLER SWITCH Has two positions as follows 1 In the HIGH position the engine runs at the high idle speed controlled by the engine govern...

Page 21: ...al 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 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 re...

Page 22: ...s for MIG welding gas metal arc welding Welding can be finely tuned using the ARC CONTROL 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 inductance con trol The proper setting depends on the procedure and oper ator preference Start with the dial set at 0 Listed below are some wires suitable for use on this machin...

Page 23: ...ted by circuit breakers 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 opposi...

Page 24: ...lec trode cable and 30 ft Im of work cable headshield work clamp electrode holder Cables are rated at 400 amps 100 duty cycle K857 25 ft Im or K857 1 100 ft Im REMOTE CON TROL Portable control provides same dial range as the output control on the welder Has a convenient 6 pin plug for easy connection to the welder K1690 1 GFCI RECEPTACLE KIT Includes one UL approved 120V ground fault circuit inter...

Page 25: ...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 KOHLER ECH740 ENGINE Oil Filter Kohler 12 050 01 Fram PH8172 Air Filter Element Kohler 47 083 03 Fram CA79 Air Filter Pre Cleaner Kohler 24 083 05 Fuel Filter Kohler 24 050 05 Spark ...

Page 26: ... 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 to 7 8 turn Refill the crankcase wit...

Page 27: ...mains 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 crack...

Page 28: ...TTERY 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 11kg of baking soda and 1 quart 0 1 L 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 ba...

Page 29: ...ly Inspect the brushes when a generator over haul is necessary Do not attempt to Polish slip rings while the engine is running WARNING WARNING MUFFLER MAY BE HOT ALLOW ENGINE TO COOL BEFORE INSTALLING THE SPARK ARRESTER DO NOT OPERATE ENGINE WHILE INSTALLING THE SPARK ARRESTER Service and Repair should only be performed by Lincoln Electric Factory Trained Personnel Unauthorized repairs performed o...

Page 30: ...IBLE 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 Autho...

Page 31: ...orized 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 2 Faulty EFI component s or faulty PC board or ignition system 3 Fuel lift pump not working 1 Low oil level Change oil and oil filter And fill to proper level Start engine And loo...

Page 32: ...ch 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 chap ter for proper use of this switch 3 Faulty PC board Low idle s...

Page 33: ...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 tripped 2 Faulty control cable Repair or replace cable 3 Faulty...

Page 34: ...s 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 cable c...

Page 35: ...F 1 DIAGRAMS F 1 RANGER 305G EFI ...

Page 36: ...F 2 DIAGRAMS F 2 RANGER 305G EFI ...

Page 37: ...F 3 DIAGRAMS F 3 RANGER 305G EFI ...

Page 38: ...F 4 DIAGRAMS F 4 RANGER 305G EFI ...

Page 39: ...F 5 DIAGRAMS F 5 RANGER 305G EFI ...

Page 40: ...NY 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 AN...

Page 41: ...F 7 DIAGRAMS F 7 RANGER 305G EFI ...

Page 42: ...F 8 DIAGRAMS F 8 RANGER 305G EFI ...

Page 43: ...F 9 DIAGRAMS F 9 RANGER 305G EFI 2 9 03 ...

Page 44: ...F 10 DIAGRAMS F 10 RANGER 305G EFI ...

Page 45: ... It may not be accurate for all machines covered by this manual The specific diagram for a particular code is pasted inside the machine on one of the enclosure panels If the diagram is illegible write to the Service Department for a replacement Give the equipment code number ...

Page 46: ... 16 75 425 4 TRUCK UNDERCARRIAGE MOUNTING HOLES 7 22 183 3 24 86 631 3 2 62 66 5 CENTER OF GRAVITY 29 80 756 9 INCH MM 42 10 1069 5 20 80 528 3 23 50 596 9 10 28 261 0 10 78 273 9 33 62 854 0 36 24 920 4 DIMENSION DIAGRAM F 12 DIMENSION PRINT F 12 RANGER 305G EFI ...

Page 47: ...NOTES RANGER 305G EFI ...

Page 48: ...ii THIS PAGE INTENTIONALLY LEFT BLANK ...

Page 49: ...ii THIS PAGE INTENTIONALLY LEFT BLANK ...

Page 50: ...parts or electrode with skin or wet clothing l Insulate yourself from work and ground l No toque las partes o los electrodos bajo carga con la piel o ropa moja da l Aislese del trabajo y de la tierra l Ne laissez ni la peau ni des vête ments mouillés entrer en contact avec des pièces sous tension l Isolez vous du travail et de la terre l Berühren Sie keine stromführenden Teile oder Elektroden mit ...

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

Page 52: ...stomer s particular purpose with respect to such information or advice As a matter of practical consideration we also cannot assume any responsibility for updating or correcting any such information or advice once it has been given nor does the provision of information or advice create expand or alter any warranty with respect to the sale of our products Lincoln Electric is a responsive manufactur...

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