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Lincoln Electric RANGER 305LPG, Operator'S Manual

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Lincoln Electric RANGER 305LPG Operator'S Manual Download Page 8

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TAbLE OF CONTENTS

Maintenance......................................................................................................Section D

Safety Precautions ................................................................................................D-1

Routine Maintenance ............................................................................................D-1
Kohler Engine........................................................................................................D-1

Engine Maintenance Components ........................................................................D-1

Engine Oil Change..........................................................................................D-2
Engine Oil Refill Capacities.............................................................................D-2
Oil Filter Change .............................................................................................D-2
Air Cleaner Service .........................................................................................D-2
Air Pre-Cleaner Service ..................................................................................D-2

Air Filter Paper Element ........................................................................................D-3

Spark Plug ......................................................................................................D-3
Spark Plug Service .........................................................................................D-3

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 thru E-5

________________________________________________________________________

Diagrams and Dimension Print ......................................................................Section F
Parts List ................................................................................................................P-649     

________________________________________________________________________

Summary of Contents for RANGER 305LPG

Page 1: ...OT INSTALL OPERATE OR REPAIR THIS EQUIPMENT WITHOUT READ ING THIS MANUAL AND THE SAFETY PRECAUTIONS CON TAINED THROUGHOUT And most importantly think before you act and be careful For use with machines having Code Numbers 11677 11739 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 Wo...

Page 2: ...AKER 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 ava...

Page 3: ...or 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 i When working above floor level use a safety belt to protect yourself from a fall should you get a shock 3 j Also see Items 6 c and 8 FUMES AND GASES can be dangerous 5 a Welding may produce fu...

Page 4: ...s 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 Welding and Cutting ANSI Standard Z49 1 and the operating information for the equipment being used 6 c When not welding make certain no part of the electrode ...

Page 5: ...riés 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 Elo...

Page 6: ... important when identifying the correct replacement parts On Line Product Registration Register your machine with Lincoln Electric either via fax or over the Internet For fazing Complete the form on the back of the warranty statement included in the literature packet Accompanying this machine and fax the form per the instructions printed on it For On Line Registration Go to our WEb SITE at www lin...

Page 7: ...r Connections A 8 Premises Wiring A 9 Connection of Lincoln Electric Wire Feeders A 10 A 11 ________________________________________________________________________________ Operation Section b Safety Precautions B 1 General Description B 1 For Auxiliary Power B 1 Engine Operation B 1 Welder Controls B 2 Engine Controls B 3 Starting and Stopping the Engine B 3 Stopping B 4 Welding Operation B 4 Dut...

Page 8: ...ervice D 3 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 thru E 5 ____________________________________________________________________...

Page 9: ... 546 0 mm 1073 0 mm 218Kg Top of enclosure add 6 0 152mm for exhaust LUbRICATION VALVE LIFTERS FUEL SYSTEM GOVERNOR Full Pressure Hydraulic LPG Regulator and Vaporizer Mechanical Governor With Full Flow Filter 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 alum...

Page 10: ...AUXILIARY POWER CIRCUIT bREAKER OTHER CIRCUIT bREAKERS 2 120VAC Duplex GFCI 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 11: ...ed 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 305LPG 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 m...

Page 12: ...ylinder is NOT in the welding circuit Do not allow either weld ing cable to come in contact with the supply cylin der Replace the fuel supply hose if there is exces sive abrasion cracks or wear or if the hose is cut WARNING CAUTION be certain that the cylinder valve is CLOSED before attempting to attach the fuel supply hose coupler to the cylinder Connect the coupler to the fuel cylinder and tight...

Page 13: ...ANGER 305LPG 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 ...

Page 14: ...in a home or shop its frame must be connected to the system earth ground See further connection instruc tions in the section entitled 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 wate...

Page 15: ...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 16: ...er T12153 9 Plug this cable into the 50 Amp 120 240 Volt receptacle on the RANGER 305LPG case front AUXILIARY POWER RECEPTACLES Start the engine and set the IDLER control switch to the High Idle mode Voltage is now correct at the receptacles for auxiliary power This must be done before a tripped GFCI receptacle can be reset proper ly See the MAINTENANCE section for detailed infor mation on testing...

Page 17: ... FOR ALTERNATE WIRE SIZE RECOMMENDATIONS 240 VOLT GROUNDED CONDUCTOR 40AMP 240 VOLT DOUBLE POLE CIRCUIT BREAKER DOUBLE POLE DOUBLE THROW SWITCH RATING TO BE THE SAME AS OR GREATER THAN PREMISES SERVICE OVERCURRENT PROTECTION 50 AMP 120 240 VOLT PLUG NEMA TYPE 14 50 50 AMP 120 240 VOLT RECEPTACLE CONNECTION OF RANGER 305LPG TO PREMISES WARNING Only a licensed certified trained electrician should in...

Page 18: ...CV WIRE position Set the WIRE FEEDER VOLTMETER switch to either or as required by the electrode polarity being used Set the ARC CONTROL knob to 0 initially and adjust to suit Set the IDLE switch to the AUTO position Connection of the LN 25 to the RANGER 305LPG Shut off welder before making any electrical con nections The LN 25 with or without an internal contactor may be used with the RANGER 305LP...

Page 19: ...t an internal con tactor the electrode will be energized when the RANGER 305LPG is started Connection of LN 742 K487 25 Spool Gun and Cobramatic to RANGER 305LPG 1 Shut the welder off 2 Connect per instructions on the appropriate con nection diagram in Section F CAUTION ...

Page 20: ...urce and 120 240 volt AC power generator The engine drives a generator that supplies three phase power for the DC welding circuit and single phase power for the AC auxiliary outlets The DC welding control system uses state of the art Chopper Technology for superior welding performance The RANGER 305LPG is NOT RECOMMENED for pipe thawing SAFETY PRECAUTIONS Read and understand this entire section be...

Page 21: ...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 th...

Page 22: ...ting 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 RANGER 305LPG 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 H...

Page 23: ...e 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 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 wh...

Page 24: ...ing 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 machine Innershield ...

Page 25: ...s 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 current capacity of the associated receptacle NOTE The 240 V receptacle has two circuits each...

Page 26: ... tank 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 K704 ACCESSORY SET Includes 35 ft 10 6m of electrode cable and 30 ft 9 1m of work cable head shield work clamp electrode holder Cables are rated at 400 amps 100 duty cycle K857 25 ft 7 6m or K857 1 100 ft 30 5m REMOTE CON TROL Portable control...

Page 27: ... all other moving parts when starting operating or repairing the equipment Routine Maintenance At the end of each day s use make certain that the valve on the LPG fuel supply cylinder is closed Also check the crankcase oil level and add oil if indicated WARNING ITEM MAKE AND PART NUMbER KOHLER CH23S ENGINE Oil Filter Kohler 12 050 01 Fram PH8172 Air Filter Element Kohler 47 083 03 Fram CA79 Air Fi...

Page 28: ...down 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 ...

Page 29: ...emains 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 crac...

Page 30: ...rroded 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 battery the bat tery compartment and surrounding areas with clear water Coat the battery terminals ...

Page 31: ...s providing at least 80 volts to the receptacle input terminals The circuit breaker for this receptacle must not be tripped Reset if necessary Push the Reset button located on the GFCI recep tacle This will assure normal GFCI operation Plug a night light with an ON OFF switch or other product such as a lamp into the GFCI receptacle and turn the product ON Push the Test button located on the GFCI r...

Page 32: ...BLE 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 Author...

Page 33: ...ct 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 LPG Fuel Cylinder Empty 2 Faulty fuel solenoid or faulty PC board or ignition system 1 Low oil level Change oil and oil filter And fill to proper level Start engine And look f...

Page 34: ...ition 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 chap ter for proper use of this switch 3 Faulty PC bo...

Page 35: ...ulty 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 F...

Page 36: ... 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 co...

Page 37: ...F 1 DIAGRAMS F 1 RANGER 305LPG ...

Page 38: ...F 2 DIAGRAMS F 2 RANGER 305LPG ...

Page 39: ...F 3 DIAGRAMS F 3 RANGER 305LPG ...

Page 40: ...F 4 DIAGRAMS F 4 RANGER 305LPG ...

Page 41: ...F 5 DIAGRAMS F 5 RANGER 305LPG ...

Page 42: ...E C U R R E N T A N D D U T Y C Y C L E O F I M M E D I A T E A N D F U T U R E A P P L I C A T I O N S S E E O P E R A T I N G M A N U A L N B C O N N E C T W E L D I N G C A B L E S T O O U T P U T S T U D S F O R D E S I R E D P O L A R I T Y P O S I T I O N T H E W I R E F E E D E R V O L T M E T E R S W I T C H T O M A T C H T H E P O L A R I T Y O F T H E E L E C T R O D E C A B L E N C P L ...

Page 43: ...F 7 DIAGRAMS F 7 RANGER 305LPG ...

Page 44: ...F 8 DIAGRAMS F 8 RANGER 305LPG ...

Page 45: ...F 9 DIAGRAMS F 9 RANGER 305LPG 2 9 0 3 2 9 03 ...

Page 46: ...F 10 DIAGRAMS F 10 RANGER 305LPG ...

Page 47: ...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 48: ...2 9 8 0 7 5 6 9 I N C H M M 4 2 1 0 1 0 6 9 5 2 0 8 0 5 2 8 3 2 3 5 0 5 9 6 9 1 0 2 8 2 6 1 0 1 0 7 8 2 7 3 9 3 3 6 2 8 5 4 0 3 6 2 4 9 2 0 4 M22449 A 01 CIRCUIT BREAKERS 41 20 1046 5 17 50 444 5 19 50 495 3 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 3...

Page 49: ...NOTES RANGER 305LPG ...

Page 50: ...NOTES RANGER 305LPG ...

Page 51: ... 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 Elektrod...

Page 52: ... 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 öffnen Maschine anhalten Não opere co...

Page 53: ...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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