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IM742-A
August, 2002
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:
OPERATOR’S MANUAL
Copyright © 2002 Lincoln Global Inc.
• 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
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SAFETY
ARC RAYS can burn.
ELECTRIC SHOCK can
4.a. Use a shield with the proper filter and cover
plates to protect your eyes from sparks and
the rays of the arc when welding or observing
open arc welding. Headshield and filter lens
should conform to ANSI Z87. I standards.
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.
4.b. Use suitable clothing made from durable flame-resistant
material to protect your skin and that of your helpers from
the arc rays.
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.
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.
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 lying, if there is a high risk of unavoidable or
accidental contact with the workpiece or ground) use
the following equipment:
FUMES AND GASES
can be dangerous.
5.a. Welding may produce fumes and gases
hazardous to health. Avoid breathing these
• Semiautomatic DC Constant Voltage (Wire) Welder.
• DC Manual (Stick) Welder.
fumes and gases.When welding, keep
your head out of the fume. Use enough
• AC Welder with Reduced Voltage Control.
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.
3.c. In semiautomatic or automatic wire welding, the electrode,
electrode reel, welding head, nozzle or semiautomatic
welding gun are also electrically “hot”.
3.d. 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.
3.e. Ground the work or metal to be welded to a good electrical
(earth) ground.
5.b. 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.
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.
5.c. Shielding gases used for arc welding can displace air and
cause injury or death. Always use enough ventilation,
especially in confined areas, to insure breathing air is safe.
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.
5.d. 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.
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.
5.e. Also see item 1.b.
Mar ‘95
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SAFETY
WELDING SPARKS can
cause fire or explosion.
CYLINDER may explode
if damaged.
6.a. Remove fire hazards from the welding area.
If this is not possible, cover them to prevent
7.a. Use only compressed gas cylinders
containing the correct shielding gas for the
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.
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.
7.b. Always keep cylinders in an upright position securely
chained to an undercarriage or fixed support.
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.
7.c. Cylinders should be located:
•Away from areas where they may be struck or subjected to
physical damage.
6.c. 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.
•A safe distance from arc welding or cutting operations and
any other source of heat, sparks, or flame.
7.d. Never allow the electrode, electrode holder or any other
electrically “hot” parts to touch a cylinder.
6.d. 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
been “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).
7.e. Keep your head and face away from the cylinder valve outlet
when opening the cylinder valve.
7.f. Valve protection caps should always be in place and hand
tight except when the cylinder is in use or connected for
use.
7.g. Read and follow the instructions on compressed gas
cylinders, associated equipment, and CGA publication P-l,
“Precautions for Safe Handling of Compressed Gases in
Cylinders,” available from the Compressed Gas Association
1235 Jefferson Davis Highway, Arlington, VA 22202.
6.e. Vent hollow castings or containers before heating, cutting or
welding. They may explode.
6.f. 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.
FOR ELECTRICALLY
powered equipment.
6.g. 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.
8.a. Turn off input power using the disconnect
switch at the fuse box before working on
the equipment.
8.b. Install equipment in accordance with the U.S. National
Electrical Code, all local codes and the manufacturer’s
recommendations.
6.h. Also see item 1.c.
8.c. Ground the equipment in accordance with the U.S. National
Electrical Code and the manufacturer’s recommendations.
Mar ‘95
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SAFETY
zones où l’on pique le laitier.
PRÉCAUTIONS DE SÛRETÉ
6. Eloigner les matériaux inflammables ou les recouvrir afin de
prévenir tout risque d’incendie dû aux étincelles.
Pour votre propre protection lire et observer toutes les instructions
et les précautions de sûreté specifiques qui parraissent dans ce
manuel aussi bien que les précautions de sûreté générales suiv-
antes:
7. Quand on ne soude pas, poser la pince à une endroit isolé de
la masse. Un court-circuit accidental peut provoquer un
échauffement et un risque d’incendie.
Sûreté Pour Soudage A L’Arc
1. Protegez-vous contre la secousse électrique:
8. S’assurer que la masse est connectée le plus prés 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 éloignés de la zone de travail, on augmente le risque
de voir passer le courant de soudage par les chaines de lev-
age, câbles de grue, ou autres circuits. Cela peut provoquer
des risques d’incendie ou d’echauffement des chaines et des
câbles jusqu’à ce qu’ils se rompent.
a. Les circuits à l’électrode et à la piéce sont sous tension
quand la machine à souder est en marche. Eviter toujours
tout contact entre les parties sous tension et la peau nue
ou les vétements mouillés. Porter des gants secs et sans
trous pour isoler les mains.
b. Faire trés 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 couché pour lesquelles une grande
partie du corps peut être en contact avec la masse.
c. Maintenir le porte-électrode, la pince de masse, le câble
de soudage et la machine à souder en bon et sûr état
defonctionnement.
9. Assurer une ventilation suffisante dans la zone de soudage.
Ceci est particuliérement important pour le soudage de tôles
galvanisées plombées, ou cadmiées ou tout autre métal qui
produit des fumeés toxiques.
10. Ne pas souder en présence de vapeurs de chlore provenant
d’opérations de dégraissage, nettoyage ou pistolage. La
chaleur ou les rayons de l’arc peuvent réagir avec les vapeurs
du solvant pour produire du phosgéne (gas fortement toxique)
ou autres produits irritants.
d.Ne jamais plonger le porte-électrode dans l’eau pour le
refroidir.
e. Ne jamais toucher simultanément les parties sous tension
des porte-électrodes connectés à deux machines à souder
parce que la tension entre les deux pinces peut être le
total de la tension à vide des deux machines.
11. Pour obtenir de plus amples renseignements sur la sûreté,
voir le code “Code for safety in welding and cutting” CSA
Standard W 117.2-1974.
f. Si on utilise la machine à souder comme une source de
courant pour soudage semi-automatique, ces precautions
pour le porte-électrode s’applicuent aussi au pistolet de
soudage.
2. Dans le cas de travail au dessus du niveau du sol, se protéger
contre les chutes dans le cas ou on recoit un choc. Ne jamais
enrouler le câble-électrode autour de n’importe quelle partie
du corps.
PRÉCAUTIONS DE SÛRETÉ POUR
LES MACHINES À SOUDER À
TRANSFORMATEUR ET À
REDRESSEUR
3. Un coup d’arc peut être plus sévère qu’un coup de soliel,
donc:
a. Utiliser un bon masque avec un verre filtrant approprié
ainsi qu’un verre blanc afin de se protéger les yeux du ray-
onnement de l’arc et des projections quand on soude ou
quand on regarde l’arc.
b. Porter des vêtements convenables afin de protéger la
peau de soudeur et des aides contre le rayonnement de
l‘arc.
1. Relier à la terre le chassis du poste conformement au code de
l’électricité et aux recommendations du fabricant. Le dispositif
de montage ou la piece à souder doit être branché à une
bonne mise à la terre.
2. Autant que possible, I’installation et l’entretien du poste seront
effectués par un électricien qualifié.
c. Protéger l’autre personnel travaillant à proximité au
soudage à l’aide d’écrans appropriés et non-inflammables.
3. Avant de faires des travaux à l’interieur de poste, la debranch-
er à l’interrupteur à la boite de fusibles.
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.
4. Garder tous les couvercles et dispositifs de sûreté à leur
place.
5. Toujours porter des lunettes de sécurité dans la zone de
soudage. Utiliser des lunettes avec écrans lateraux dans les
Mar. ‘93
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for selecting a QUALITY product by Lincoln Electric. We want you
to take pride in operating this Lincoln Electric Company product
••• as much pride as we have in bringing this product to you!
Thank 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 & Number _____________________________________
Code & 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:
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 avoid minor personal injury or damage to
this equipment.
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vi
TABLE OF CONTENTS
Page
Installation.......................................................................................................................Section A
Technical Specifications.......................................................................................................A-1
Machine Specifications ........................................................................................................A-2
Safety Precautions........................................................................................................A-3
Location and Ventilation................................................................................................A-3
Stacking ........................................................................................................................A-3
Angle of Operation ........................................................................................................A-3
Lifting.............................................................................................................................A-3
Additional Safety Precautions .......................................................................................A-3
High Altitude Operation.................................................................................................A-3
High Temperature Operation ........................................................................................A-3
Towing...........................................................................................................................A-3
Pre-Operation Engine Service..............................................................................................A-4
Oil..................................................................................................................................A-4
Fuel ...............................................................................................................................A-4
Engine Coolant..............................................................................................................A-4
Battery Connections......................................................................................................A-4
Muffler Outlet Pipe ........................................................................................................A-4
Spark Arrester...............................................................................................................A-4
High Frequency Generators for Tig Applications ..........................................................A-4
Remote Control.............................................................................................................A-4
Electrical Connections..........................................................................................................A-5
Machine Grounding.......................................................................................................A-5
Welding Terminals ........................................................................................................A-5
Welding Output Cables .................................................................................................A-5
Cable Installation...........................................................................................................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
Constant Current (Stick) Welding..................................................................................B-4
Pipe Welding.................................................................................................................B-4
Fuel Consumption.........................................................................................................B-4
Tig Welding ...................................................................................................................B-5
Typical Current Ranges for Tungsten Electrodes .........................................................B-5
Wire Welding-CV...........................................................................................................B-5
Arc Gouging ..................................................................................................................B-6
Auxiliary Power .............................................................................................................B-6
Simultaneous Welding and Auxiliary PowerLoads........................................................B-6
Extension Cord Recommendations...............................................................................B-6
Auxiliary Power .............................................................................................................B-6
Simultaneous Welding and Auxiliary Power Loads.......................................................B-6
Accessories.....................................................................................................Section C
Options / Accessories and Compatible Lincoln Equipment.................................................C-1
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vii
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
Engine 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
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
Troubleshooting Guide ..........................................................................................E-5
Diagrams and Dimension Print ......................................................................Section F
Parts List..................................................................................................................P384
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A-1
A-1
INSTALLATION
TECHNICAL SPECIFICATIONS - Ranger 305G (K1726-1)
INPUT - GASOLINE ENGINE
Make/Model
Description
Speed (RPM)
High Idle 3700
Full Load 3500
Displacement
Starting
System
Capacities
cu. in. (cu. cm.)
2 cylinder
41(674)
12VDC Battery &
Starter
Fuel: 12 gal.
45.4 L
Oil: 2.0 Qts
1.9 L
Kohler CH22
(K1726-1)
22 HP @
3600 RPM
Bore x Stroke inch (mm) (Group 58; 435
cold crank amps)
3.03 x 2.85 (77 x 72)
Battery Charger
RATED OUTPUT @ 104° F (40° C) - WELDER
Welding Output
Volts at Rated Amps
Duty Cycle Max.
OCV @ 3700 RPM
CC STICK DC Output
CC STICK Output Range
29 Volts @ 305 Amps
20 to 305 Amps
100%
-------
PIPE DC Output
29 Volts @ 300 Amps
40 to 300 Amps
20 to 250 Amps
29 Volts @ 300 Amps
14 to 29 volts
100%
-------
-------
100%
-------
PIPE Output Range
TIG Output Range
CV WIRE DC Output
CV WIRE Output Range
80 Volts
.
RATED OUTPUT @ 104° F (40° C) - GENERATOR
1
Auxiliary Power
10,000 Watts Peak, 9500 Watts Continuous, 60 Hz
120/240 Volts
PHYSICAL DIMENSIONS
HEIGHT
WIDTH
DEPTH
WEIGHT
30.00** in.
762.0 mm
21.50 in
.42.25 in.
510 lbs. (231kg.)
546.0 mm
1073.0 mm
ENGINE COMPONENTS
LUBRICATION
Full Pressure
with Full Flow Filter
VALVE LIFTERS
FUEL SYSTEM
GOVERNOR
Mechanical Governor
5% Regulation
Hydraulic
Mechanical Fuel Pump
AIR CLEANER
ENGINE IDLER
MUFFLER
ENGINE PROTECTION
Shutdown on low oil
pressure.
Low noise Muffler: Top outlet
can be rotated. Made from
long life, aluminized steel.
Duel Element
Automatic Idler
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
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A-2
MACHINE SPECIFICATIONS - Ranger 305G (K1726-1)
A-2
INSTALLATION
RECEPTACLES
AUXILIARY POWER CIRCUIT BREAKER OTHER CIRCUIT BREAKERS
(2) 120VAC Duplex (5-20R)
(1) 120/240VAC Dual Voltage
Full KVA (14-50R)
Two 20AMP for Two Duplex Recptacle
Two 50AMP for Dual Voltage
25AMP for Battery Charging Circuit
15AMP for 42V Wire Feeder Power
RANGER 305G
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A-3
A-3
INSTALLATION
LIFTING
SAFETY PRECAUTIONS
WARNING
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.
Do not attempt to use this equipment until you
have thoroughly read the engine manufacturer’s
manual supplied with your welder. It includes
important safety precautions, detailed engine
starting, operating and maintenance instructions,
and parts lists.
ADDITIONAL SAFETY PRECAUTIONS
WARNING
------------------------------------------------------------------------
ELECTRIC SHOCK can kill.
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.
• Do not touch electrically live parts or
electrode with skin or wet clothing.
• Insulate yourself from work and
ground
• Always wear dry insulating gloves.
-------------------------------------------------------
• Be sure machine is stable when lifting.
------------------------------------------------------------------------
HIGH ALTITUDE OPERATION
ENGINE EXHAUST can kill.
• Use in open, well ventilated areas or
vent exhaust outside.
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).
------------------------------------------------------
MOVING PARTS can injure.
• Do not operate with doors open or
guards off.
HIGH TEMPERATURE OPERATION
• Stop engine before servicing.
• Keep away from moving parts.
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.
------------------------------------------------------------------------
See additional warning information at
front of this operator’s manual.
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:
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.
1. Design capacity of trailer vs. weight of Lincoln equipment and
likely additional attachments.
2. Proper support of, and attachment to, the base of the weld-
ing equipment so there will be no undue stress to the frame-
work.
STACKING
RANGER 305G machines cannot be stacked.
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.
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.
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.
(1)
5. Conformance with federal, state and local laws.
(1)
Consult applicable federal, state and local laws regarding
When operating the welder at an angle, the effective
fuel capacity will be slightly less than the specified 12
gallons.
specific requirements for use on public highways.
RANGER 305G
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A-4
PRE-OPERATION ENGINE SERVICE
A-4
INSTALLATION
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.
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
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.
• Keep sparks and flame away from tank.
------------------------------------------------------------------
OIL
MUFFLER OUTLET PIPE
Using the clamp provided 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.
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 dependent on the quality of the oil and the
operating environment. Refer to the Engine Operator’s
Manual for the proper service and maintenance inter-
vals.
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.
FUEL
USE GASOLINE FUEL ONLY
CAUTION
An incorrect spark arrestor may lead to damage to
the engine or adversely affect performance.
------------------------------------------------------------------------
HIGH FREQUENCY GENERATORS FOR
TIG APPLICATIONS
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
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.
WARNING
REMOTE CONTROL
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.
The RANGER 305G is equipped with a 6 pin and a 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.
BATTERY CONNECTION
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.
CAUTION
Use caution as the electrolyte is a strong acid that
can burn skin and damage eyes.
------------------------------------------------------------------------
RANGER 305G
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A-5
A-5
INSTALLATION
WELDING TERMINALS
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.
The RANGER 305G is equipped with a toggle switch
for selecting "hot" welding terminal when in the
"WELD TERMINALS ON" 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.
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
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.
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.)
TABLE A-1
TOTAL COMBINED LENGTH OF
ELECTRODE AND WORK CABLES
To prevent dangerous electric shock, other equipment
to which this engine driven welder supplies power
must:
Cable Size for
Cable Length
305 Amps
100% Duty Cycle
WARNING
1 / 0 AWG
2 / 0 AWG
3 / 0 AWG
0-100Ft. (0-30meters)
• Be grounded to the frame of the welder using a
grounded type plug.
100-150 Ft. (30-46m meters)
150-200 Ft. (46-61 meters)
• Be double insulated.
Do not ground the machine to a pipe that carries
explosive or combustible material.
CABLE INSTALLATION
Install the welding cables to your RANGER 305G as
follows.
------------------------------------------------------------------------
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 "Standby Power Connections" as well as
the article on grounding in the latest U.S. National
Electrical Code and the local code.
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.
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.
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.
The U.S. National Electrical Code lists a number of
alternate means of grounding electrical equipment. A
6. Check and tighten the connections periodically.
machine grounding stud marked with the symbol
provided on the front of the welder.
is
RANGER 305G
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A-6
A-6
INSTALLATION
STANDBY POWER CONNECTIONS
CAUTION
The RANGER 305G is suitable for temporary, standby
or emergency power using the engine manufacturer’s
recommended maintenance schedule.
• Loose connections will cause the output termi-
nals to overheat. The terminals may eventually
melt.
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.
• 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.
• 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.
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.
• Take necessary steps to assure load is limited to
the capacity of the RANGER 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 - 10% 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.
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.
• 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.
NOTE: The 240 V receptacle has two 120 V circuits,
but are of opposite polarities and cannot be paralleled.
RANGER 305G
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A-7
A-7
INSTALLATION
CONNECTION OF RANGER 305G TO PREMISES WIRING
240 VOLT
GROUNDED CONDUCTOR
POWER
240 Volt
60 Hz.
3-Wire
Service
120 VOLT
COMPANY
120 VOLT
METER
NEUTRAL
BUS
N
LOAD
DOUBLE POLE DOUBLE THROW
SWITCH RATING TO BE THE SAME
AS OR GREATER THAN PREMISES
SERVICE OVERCURRENT
PROTECTION.
PREMISES
DISCONNECT AND
SERVICE
OVERCURRENT
PROTECTION
GROUND
40AMP
240 VOLT
DOUBLE
POLE
CIRCUIT
BREAKER
50 AMP, 120/240
VOLT PLUG
NEMA TYPE 14-50
240 VOLT
GND
N
50 AMP, 120/240 VOLT
RECEPTACLE
NOTE: No. 6 COPPER CONDUCTOR CABLE SEE
NATIONAL ELECTRICAL CODE FOR ALTERNATE WIRE
SIZE RECOMMENDATIONS.
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. 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
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A-8
A-8
INSTALLATION
CONNECTION OF LINCOLN ELECTRIC
WIRE FEEDERS
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 the LN-25 to the RANGER 305G
------------------------------------------------------------------------
Connection of LN-7 or LN-8 to the RANGER 305G
WARNING
1. Shut the welder off.
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.
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 "ARC CONTROL" knob to "0" initially and
adjust to suit.
6 Set the "WELD TERMINALS" switch to the
"REMOTELY CONTROLLED" position.
7. Set the "IDLE" switch to the "HIGH" position.
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.
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. Attach the single lead from the front of the LN-25
to work using 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.
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 "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-
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.
4. Set the MODE switch to the "CV-WIRE " position.
5. Set the "WELD TERMINALS" switch to "WELD
TERMINALS ON"
6. Set the "ARC 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.
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
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B-1
B-1
OPERATION
SAFETY PRECAUTIONS
ENGINE OPERATION
Before Starting the Engine:
WARNING
• Be sure the machine is on a level surface.
Do not attempt to use this equipment until you
have thoroughly read the engine manufacturer’s
manual supplied with your welder. It includes
important safety precautions, detailed engine
starting, operating and maintenance instructions,
and parts lists.
• 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.
• Add oil (if necessary) to bring the level up to the full
mark. Do not overfill. Close engine door.
------------------------------------------------------------------------
ELECTRIC SHOCK can kill.
• Do not touch electrically live parts or
• See Engine Owner’s Manual for specific oil recom-
mendations.
electrode with skin or wet clothing.
• Insulate yourself from work and
ground
ADD FUEL
• Always wear dry insulating gloves.
• Always operate the welder with the hinged door
closed and the side panels in place.
WARNING
GASOLINE can cause fire or
explosion.
• 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.
• 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.
GENERAL DESCRIPTION
The RANGER 305G 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.
• 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.
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 receptacle can be split for single phase 120
VAC operation.
RANGER 305G
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B-2
B-2
OPERATION
16
15
1
2
14
13
3
12
11
4
10
9
8
7
6
5
WELDING CONTROLS
1. OUTPUT CONTROL:
3. WELD MODE SELECTOR SWITCH:
(Provides four selectable welding modes)
CV-WIRE
PIPE
CC-STICK
TOUCH START TIG
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.
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.
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%.
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 0.
CV-WIRE mode: In this mode, turning the ARC CONTROL
clock wise 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 proce-
dure and operator preference. Start with a setting of 0.
RANGER 305G
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B-3
B-3
OPERATION
5. WELD OUTPUT TERMINALS WITH
FLANGE NUT:
Provides a connection point for the electrode and
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.
work cables.
2) In the AUTO position, the idler operates as follows:
6. GROUND STUD: (graphic)
Provides a connection point for connecting the
machine case to earth ground for the safest grounding
procedure.
• 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 l o a d
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 when there is welding load or AC power
load reapplied.
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.
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.
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 electrically off until a
remote switch is depressed.
16. ENGINE HOUR METER – Displays the total
time that the engine has been running. This meter is
useful for scheduling prescribed maintenance.
10. WIRE FEEDER VOLTMETER SWITCH:
Matches the polarity of the wire feeder voltmeter to
the polarity of the electrode.
STARTING AND STOPPING
THE ENGINE
• Remove all plugs connected to the AC power
receptacles.
ENGINE CONTROLS:
• Set IDLER switch to AUTO.
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.
• 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.
12. CHOKE - When pulled out, it closes the choke
valve on the engine carburetor for quick starting.
• Release the engine START button when the engine
starts.
13. START PUSH BUTTON - Energizes the
• Push the choke back in.
starter motor to crank the engine.
RANGER 305G
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B-4
B-4
OPERATION
WELDER OPERATION
• 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.
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
CAUTION
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.
Operating the starter motor for more than 5 sec-
onds can damage the motor. If the engine fails to
start, 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.
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 0.
------------------------------------------------------------------------
NOTE: When starting a RANGER 305G 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.
PIPE Welding
STOPPING
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.
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.
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 0.
NOTE: A fuel shut off valve is not required on the
RANGER 305G because the fuel tank is mounted
below the engine.
TYPICAL RANGER 305G FUEL CONSUMPTION
Kohler CH22
gal./hr (liters/hr)
Running Time for
12 gallons -(hrs.)
Low Idle - No Load
2400 R.P.M.
.51 (1.9)
.83 (3.2)
1.39 (5.3)
1.53 (5.8)
1.64 (6.2)
23.5
14.5
8.6
High Idle - No Load
3700 R.P.M.
DC Weld Output
240 Amps @ 29 Volts
DC Weld Output
300 Amps @ 29 Volts
7.8
Auxiliary Power
9,500 Watts
7.3
RANGER 305G
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B-5
B-5
OPERATION
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.
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 general, 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.
WIRE WELDING-CV
Connect a wire feeder to the RANGER 305G accord-
ing to the instructions in INSTALLATION INSTRUC-
TIONS Section.
The RANGER 305G 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.
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.
Some recommended Innershield electrodes are:
NR-311, NS-3M, NR-207, NR-203 Ni 1%, NR-204-H.
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
Recommended Outershield electrodes are:
0S-70, 0S-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.
(1)
(2)
TYPICAL CURRENT RANGES
FOR TUNGSTEN ELECTRODES
Tungsten Electrode
Diameter in. (mm)
DCEN (-)
DCEP (+)
Approximate Argon Gas Flow
Flow Rate C.F.H. ( l /min.)
TIG TORCH
Nozzle Size (4), (5)
1%, 2% Thoriated
Tungsten
1%, 2% Thoriated Aluminum
Tungsten
Stainless Steel
.010
0.020
0.040
(.25)
(.50)
(1.0)
2-15
5-20
15-80
(3)
(3)
(3)
3-8
5-10
5-10
(2-4)
(3-5)
(3-5)
3-8
5-10
5-10
(2-4)
(3-5)
(3-5)
#4, #5, #6
1/16
(1.6)
70-150
10-20
1
1
5-10
(3-5)
9-13
(4-6)
#5, #6
3/32
1/8
(2.4)
(3.2)
150-250
250-400
15-30
25-40
13-17
15-23
(6-8)
(7-11)
11-15
11-15
(5-7)
(5-7)
#6, #7, #8
5/32
3/16
1/4
(4.0)
(4.8)
(6.4)
400-500
500-750
750-1000
40-55
55-80
80-125
21-25
23-27
28-32
(10-12)
(11-13)
(13-15)
13-17
18-22
23-27
(6-8)
(8-10)
(11-13)
#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
EWP
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.
# 5 = 5/16 in.
# 6 = 3/8 in.
# 7 = 7/16 in.
# 8 = _ in.
(6 mm)
(8 mm)
(10 mm)
(11 mm)
(12.5 mm)
(16 mm)
#10 = 5/8 in.
(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
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B-6
B-6
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 output is 40 Amps.
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.
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.
Electrode Diameter
Current Range (DC, electrode
positive)
1/8"
30-60 Amps
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.
5/32"
3/16"
1/4"
90-150 Amps
150-250 Amps
250-305 Amps
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.
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.
Simultaneous Welding and Auxiliary 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).
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.
RANGER 305G Simultaneous Welding and Power Loads
Permissible Power-Watts
(Unity Power Factor)
Welding
Output-Amps
Permissible Auxiliary
Current in -Amps
@120 VAC *
@ 240 VAC
9500
7100
5600
4200
2300
0
0
80**
60**
46**
36
20
0
40
30
23
18
10
0
100
150
200
250
300
* 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
12 AWG 10 AWG 8 AWG 6 AWG
Current Voltage Load
(Amps) Volts (Watts)
14 AWG
4 AWG
15
20
15
20
40
120
120
240
240
240
1800
2400
3600
4800
9500
30
(9)
40
(12)
(9)
75
(23)
(15)
(46)
(30)
(15)
125
(38)
(27)
(69)
(53)
(27)
175
(53)
(42)
(107)
(84)
(46)
300
(91)
(69)
30
75
60
50
150
100
50
88
225
175
90
138
350
275
150
225
600
450
225
60
(18)
(23)
(18)
(183)
(137)
(69)
Conductor size is based on manimum 2.0% voltage drop.
RANGER 305G
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C-1
C-1
ACCESSORIES
OPTIONS/ACCESSORIES AND COM-
PATIBLE LINCOLN EQUIPMENT
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 GFCI Duplex is limited to the 20 Amps.
Two kits are required.
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 & Light Kit
K965-1 Cable Storage Rack
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.
K1737-1 FOUR WHEEL ALL-TERRAIN UNDERCAR-
RIAGE For moving by hand at construction sites.
Heavy duty puncture resistant pneumatic tires.
T12153-9 50 AMP, 120/240 V POWER PLUG
K1770-1 UNDERCARRIAGE (FACTORY)
For moving by hand on a smooth surface.
Heavy duty puncture resistant pneumatic tires & 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).
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.)
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.
RANGER 305G
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D-1
D-1
MAINTENANCE
KOHLER ENGINE
FREQUENCY
Daily or Before
Starting Engine
MAINTENANCE REQUIRED
• Fill fuel tank.
• Check oil level.
• Check air cleaner for dirty, loose,
or damaged parts.
• Check air intake and cooling
areas, clean as necessary.
First Oil Change
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.)
5 Hours
Every 25 Hours
• Service air pre-cleaner..
(1)
Every 100 Hours
Every 100 Hours
Every 100 Hours
• Change engine oil.
• Replace fuel filter element.
Read the Safety Precautions in the front of this
manual and in the Engine Owner’s Manual before
working on this machine.
• Clean or replace air filter ele-
(1)
ment.
Every 100 Hours
Every 200 Hours
Every 200 Hours
Every 2 Years
• Spark Plug Arrester
(1)
• Replace oil filter.
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.
• Check spark plug and gap
• Check fuel lines and clamps.
(1) Service more frequently when used in dusty areas and/or at high ambient
temperatures.
Routine Maintenance
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.
ENGINE MAINTENANCE COMPONENTS
ITEM
MAKE AND PART NUMBER
KOHLER CH22 ENGINE
Oil Filter
Kohler 1205001, Fram PH3614
Kohler 4708303, Fram CA79
Kohler 2408302
Air Filter Element
Air Filter Pre-Cleaner
Fuel Filter
Kohler 2405002, Fram G1
Champion RC12YC (.030" Gap)
Spark Plug
Battery
BCI Group 58 (435 CCA)
RANGER 305G
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D-2
D-2
MAINTENANCE
• Refill the crankcase with the specified amount of the
recommended oil. Reinstall the oil filler cap.
Engine Oil Change
Drain the oil while the engine is warm to assure rapid
and complete draining.
• Start the engine and check for oil filter leaks.
• Remove the oil filler cap and dipstick. Remove the
yellow cap from the oil drain valve and attach the
flexible drain tube supplied with the machine. Push
in and twist the drain valve counterclockwise. Pull
the valve out and drain the oil into a suitable
container.
• 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.
• 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.
WARNING
Never use gasoline or low flash point solvents for
cleaning the air cleaner element. A fire or explo-
sion could result.
Engine Oil Refill Capacities
Without oil filter replacement:
• 1.7 US qt. (1.4 Imp qt., 1.6 liter)-Kohler
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.
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- Engine
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).
Air Pre-cleaner Service
• Loosen the cover retaining knob and remove the
cover.
See Engine Owner’s Manual for more specific infor-
mation on oil viscosity recommendations.
• Remove the pre-cleaner from the paper element.
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.
• 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 to air dry.
• Saturate the pre-cleaner with new engine oil.
Squeeze out all excess oil.
Oil Filter Change
• Drain the engine oil.
• Reinstall the pre-cleaner over the paper element.
• Reinstall the air cleaner cover. Secure cover with
the cover retaining knob.
• 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.
RANGER 305G
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D-3
D-3
MAINTENANCE
AIR FILTER PAPER ELEMENT
Spark Plug Service
• Loosen the cover retaining knob and remove the
cover.
To ensure proper engine operation, the spark plug
must be properly gapped and free of deposits.
• Remove the pre-cleaner from the paper element.
• Remove the spark plug cap.
• Remove the element cover nut, element cover, and
paper element.
• Clean any dirt from around the spark plug base.
• Use a plug wrench to remove the spark plug.
• 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.
• 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.
• 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.
• 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.
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.
• After the spark plug is seated, tighten with a spark
plug wrench to compress the washer.
• If installing a new spark plug, tighten 1/2 turn after
the spark plug seats to compress the washer.
• Reinstall the paper element, pre-cleaner, element
cover, element cover nut, and air cleaner cover.
Secure cover with the cover retaining knob.
• If reinstalling a used spark plug, tighten 1/8 - 1/4
turn after the spark plug seats to compress the
washer.
SPARK PLUG
To ensure proper engine operation, the spark plug
must be properly gapped and free of deposits.
Spark Plug Gap: .030 in. (0.76 mm)-Kohler
Spark Plug Torque: 20 ft. Lb. (27 N-m)-Kohler
WARNING
CAUTION
NOTE: Before removing spark plug, the muffler
becomes very hot during operation and remains
hot for a while after stopping the engine. Be care-
ful not to touch the muffler while it is hot.
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
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D-4
D-4
MAINTENANCE
CLEANING THE BATTERY
FUEL FILTER
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.
• Check the fuel filter for water accumulation or sedi-
ment.
• Replace the fuel filter if it is found with excessive
water accumulation or sediment.
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.
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.
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.
Adjustments to the engine are to be made only by a
Lincoln Service Center or an authorized Field Service
Shop.
BATTERY MAINTENANCE
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.
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
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 leads.
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.
GASES FROM BATTERY can explode.
● Keep sparks, flame and cigarettes
away from battery.
To prevent EXPLOSION when:
Follow the instructions of the battery charger manu-
facturer for proper charger settings and charging time.
● 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.
SERVICING OPTIONAL SPARK
ARRESTOR
WARNING
● 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
skin.
• MUFFLER MAY BE HOT
• ALLOW ENGINE TO COOL BEFORE INSTALLING
THE SPARK ARRESTER!
● Wear gloves and eye protection
and be careful when working near
battery.
• DO NOT OPERATE ENGINE WHILE INSTALLING
THE SPARK ARRESTER!
● Follow instructions printed on battery.
Clean every 100 hours.
RANGER 305G
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D-5
D-5
MAINTENANCE
Welder/Generator Maintenance
STORAGE: Store the RANGER 305G 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
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E-1
E-1
TROUBLESHOOTING
HOW TO USE TROUBLESHOOTING GUIDE
WARNING
Service and Repair should only be performed by Lincoln Electric Factory Trained Personnel.
Unauthorized repairs performed on this equipment may result in danger to the technician and
machine operator and will invalidate your factory warranty. For your safety and to avoid Electrical
Shock, please observe all safety notes and precautions detailed throughout this manual.
__________________________________________________________________________
This Troubleshooting Guide is provided to help you
locate and repair possible machine malfunctions.
Simply follow the three-step procedure listed below.
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.
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.
If you do not understand or are unable to perform the
Recommended Course of Action safely, contact your
local Lincoln Authorized Field Service Facility.
Step 2. POSSIBLE CAUSE.
The second column labeled “POSSIBLE CAUSE” lists
the obvious external possibilities that may contribute
to the machine symptom.
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
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E-2
E-2
TROUBLESHOOTING
Observe all Safety Guidelines detailed throughout this manual
PROBLEMS
(SYMPTOMS)
POSSIBLE AREAS OF
MISADJUSTMENT(S)
RECOMMENDED
COURSE OF ACTION
Major Physical or Electrical Damage 1. Contact your local Lincoln
is Evident.
Authorized Field Service
Facility.
Engine will not "crank".
1. Battery is low, Charge Battery
2. Loose battery cable connections.
Inspect, clean and tighten.
3. Faulty engine starter motor.
4. “Battery Circuit” circuit breaker is
tripped.
Engine will "crank" but not start.
1. Out of fuel, Fill tank and bleed fuel
system.
2. Faulty fuel solenoid or faulty PC
board or ignition system.
I
f all recommended possible areas
of misadjustment have been
checked and the problem persists,
Contact your local Lincoln
Authorized Field Service Facility.
Engine shuts down shortly after
starting.
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. Open rotor circuit.
Battery does not stay charged.
1. Faulty battery, replace.
Engine alternator trouble light is on 2. Loose connections at battery or
while machine is running.
alternator. Clean and tighten connec-
tions.
3. 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 you proceed.
RANGER 305G
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E-3
E-3
TROUBLESHOOTING
Observe all Safety Guidelines detailed throughout this manual
PROBLEMS
(SYMPTOMS)
POSSIBLE AREAS OF
MISADJUSTMENT(S)
RECOMMENDED
COURSE OF ACTION
Engine will not idle down to low 1. Idler switch in High idle position.
speed.
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.
Engine will not go to high idle when 1. Poor work lead connection to
attempting to weld.
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. Low idle speed
set to low.
Engine will not go to high idle when 1. Auxiliary power load is less than
using auxiliary power. 100 watts. Idler may not respond
with less than a 100 watt load. Set If all recommended possible areas
idler to "High".
2. Faulty PC board.
of misadjustment have been
checked and the problem persists,
Contact your local Lincoln
Authorized Field Service Facility.
Engine does not develop full 1. Fuel filter clogged, Replace.
power.
2. Air filter clogged, clean or replace.
3. Fouled spark plugs, clean or
replace.
4. Valves out of adjustment.
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
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E-4
E-4
TROUBLESHOOTING
Observe all Safety Guidelines detailed throughout this manual
PROBLEMS
(SYMPTOMS)
POSSIBLE AREAS OF
MISADJUSTMENT (S)
RECOMMENDED
COURSE OF ACTION
No welding power output.
1. Poor work lead connection to
work. Make sure work clamp is
tightly connected to clean base
metal.
2. "Weld Terminals" switch in wrong
position. Place switch in "Weld
Terminals On" position when
welding without control cable.
3. Faulty PC board or welder alterna-
tor.
Welder has output but no control.
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.
I
f all recommended possible areas
Wire feeder does not work when 1. Wire Feeder Power circuit breaker of misadjustment have been
control cable is connected to 14 pin open. Check 42V and 120V checked and the problem persists,
Amphenol.
beakers and reset if tripped.
2. Faulty control cable. Repair or
replace cable.
Contact your local Lincoln
Authorized Field Service Facility.
3. Faulty wire feeder.
No auxiliary power.
1. Open circuit breakers. Reset
breakers. If breakers keep trip-
ping, reduce power draw.
2. Faulty connections to auxiliary
receptacles. Check connections.
3. GFCI tripped (if installed). Clear
any ground fault and reset GFCI
circuit by pressing "Reset" button
on the 120 V receptacle.
4. Faulty 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
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E-5
E-5
TROUBLESHOOTING
Observe all Safety Guidelines detailed throughout this manual
PROBLEMS
(SYMPTOMS)
POSSIBLE AREAS OF
MISADJUSTMENT(S)
RECOMMENDED
COURSE OF ACTION
The welding arc is “cold.” The weld- 1. Make sure the MODE selector
ing arc is not stable or is not satis- switch is in the correct position for
factory. the engine runs normally. the process being used. (For
The auxiliary power is normal.
example, CV-WIRE, PIPE, 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 connections.
If all recommended possible areas of
misadjustment have been checked
and the problem persists, Contact
your local Lincoln Authorized
Field Service Facility.
4. The welding cables may be too
long or coiled, causing an exces-
sive voltage drop.
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
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F-1
F-1
DIAGRAMS
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F-2
F-2
DIAGRAMS
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F-3
F-3
DIAGRAMS
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F-4
F-4
DIAGRAMS
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F-5
F-5
DIAGRAMS
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F-6
F-6
DIAGRAMS
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F-7
F-7
DIAGRAMS
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F-8
F-8
DIAGRAMS
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F-9
F-9
DIAGRAMS
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F-10
F-10
DIAGRAMS
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F-11
F-11
DIAGRAMS
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F-12
ENHANCED DIAGRAM
F-12
DIAGRAMS
8
4
1 6
1 6
9
1
5
1
4
1
1 0
6
9
1
1 0
1 6
9
1
8
4
6
3
6
1
4
2
4
4
2
6
3
4
1
5
6
1
3
3
4
1
3
2
1
3
8
1
1
2
1
8
5
5
1
8
6
3
4
1
4
3
2
1
0
M 1
M 9
0
M 1
M 9
M 6
M 5
M 4
M 3
M 2
M 6
M 5
M 4
M 3
M 2
M 1
M 1
6
1 0
5
4
2
3
1
1
N
E E G R
B L A C K
K
A C B L
E T I W H
E T I W H
N
E E G R
E N G R E
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ENHANCED DIAGRAM
F-13
F-13
DIAGRAMS
1 0
6
1
1 6
1 2
6
1 6
1 0
7
1
6
1
1 6
9
1
9
1
9
1
2
1
5
8
8
5
8
L 2
0
M 1
M 9
M 6
M 5
M 4
M 3
M 2
0
M 1
M 9
M 6
M 5
M 4
M 3
M 2
M 1
M 1
B L A C K
A L C B K
E T I W H
E T I W H
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F-14
F-14
DIAGRAMS
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NOTES
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Now Available...12th Edition
New Lessons in Arc Welding
The Procedure Handbook of 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.
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.
528 pages, well illustrated, 6” x 9” size, bound in simulated,
gold embossed leather.
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.
$5.00 postage paid U.S.A. Mainland
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
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”
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.
For details write:
Lincoln Welding School
22801 St. Clair Ave.
Cleveland, Ohio 44117-1199.
Practical exercises and examples develop the reader’s ability
to visualize mechanically drawn objects as they will appear
in their assembled form.
and ask for bulletin ED-80 or call 216-383-2259 and ask for the
Welding School Registrar.
187 pages with more than 100 illustrations. Size 8-1/2” x 11”
Durable, cloth-covered board binding.
Lincoln Welding School
BASIC COURSE
5 weeks of fundamentals
$700.00
$4.50 postage paid U.S.A. Mainland
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 for U.S.A. Mainland Only. Please allow up to 4 weeks for delivery.
UPS Shipping for North America Only. All prepaid orders that request UPS shipment please add:
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For order value up to $49.99
For order value between $50.00 & $99.99
For order value between $100.00 & $149.00
For North America invoiced orders over $50.00 & 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)
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USE THIS FORM TO ORDER:
BOOKS OR FREE INFORMATIVE CATALOGS
Order from: BOOK DIVISION, The Lincoln Electric Company, 22801 St. Clair Avenue, Cleveland, Ohio 44117-1199
Telephone: 216-383-2211 or, for fastest service, FAX this completed form to: 216-361-5901.
Lincoln Welding School
Titles:
Price
$5.00
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Code
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Quantity
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(ED-80)
New Lessons in Arc Welding
Procedure Handbook “Twelfth Edition”
How to Read Shop Drawings
Incentive Management
A New Approach to Industrial Economics $5.00
The American Century of John C. Lincoln $5.00
Seminar Information
(ED-45)
Educational Video Information
(ED-93)
NA
AC
James F. Lincoln Arc Welding
Foundation Book Information
Welding Preheat Calculator
Pipe Welding Charts
$3.00
$4.50
WC-8
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(JFLF-515)
SUB TOTAL
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● Do not touch electrically live parts or
electrode with skin or wet clothing.
● Insulate yourself from work and
ground.
● Keep flammable materials away.
● Wear eye, ear and body protection.
WARNING
SpanisAh VISO DE
PRECAUCION
French
● No toque las partes o los electrodos ● Mantenga el material combustible
● Protéjase los ojos, los oídos y el
bajo carga con la piel o ropa moja-
da.
● Aislese del trabajo y de la tierra.
fuera del área de trabajo.
cuerpo.
● Ne laissez ni la peau ni des vête-
ments mouillés entrer en contact
avec des pièces sous tension.
● Gardez à l’écart de tout matériel
inflammable.
● Protégez vos yeux, vos oreilles et
votre corps.
ATTENTION
● Isolez-vous du travail et de la terre.
German
● Berühren Sie keine stromführenden
Teile oder Elektroden mit Ihrem
Körper oder feuchter Kleidung!
● Isolieren Sie sich von den
● Entfernen Sie brennbarres Material! ● Tragen Sie Augen-, Ohren- und Kör-
perschutz!
WARNUNG
Elektroden und dem Erdboden!
Portuguese
● Não toque partes elétricas e elec-
trodos com a pele ou roupa molha-
da.
● Mantenha inflamáveis bem guarda- ● Use proteção para a vista, ouvido e
dos.
corpo.
ATENÇÃO
● Isole-se da peça e terra.
Japanese
Chinese
Korean
Arabic
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 BETRIEBSANLEITUNG DER ANLAGE UND DEN ELEKTRODENEINSATZ DES HER-
STELLERS. DIE UNFALLVERHÜTUNGSVORSCHRIFTEN DES ARBEITGEBERS SIND EBENFALLS ZU BEACHTEN.
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● Keep your head out of fumes.
● Use ventilation or exhaust to
remove fumes from breathing zone.
● Turn power off before servicing.
● Do not operate with panel open or
guards off.
WARNING
Spanish
● Los humos fuera de la zona de res-
piración.
● Mantenga la cabeza fuera de los
humos. Utilice ventilación o
aspiración para gases.
● Desconectar el cable de ali-
mentación de poder de la máquina
antes de iniciar cualquier servicio.
● No operar con panel abierto o
guardas quitadas.
AVISO DE
PRECAUCION
French
● Débranchez le courant avant l’entre- ● N’opérez pas avec les panneaux
tien.
● Gardez la tête à l’écart des fumées.
● Utilisez un ventilateur ou un aspira-
teur pour ôter les fumées des zones
de travail.
ouverts ou avec les dispositifs de
protection enlevés.
ATTENTION
German
● Strom vor Wartungsarbeiten
abschalten! (Netzstrom völlig öff-
nen; Maschine anhalten!)
● Anlage nie ohne Schutzgehäuse
oder Innenschutzverkleidung in
Betrieb setzen!
● Vermeiden Sie das Einatmen von
Schweibrauch!
● Sorgen Sie für gute Be- und
Entlüftung des Arbeitsplatzes!
WARNUNG
Portuguese
● Não opere com as tampas removidas.
● Desligue a corrente antes de fazer
serviço.
● Mantenha-se afastado das partes
moventes.
● Não opere com os paineis abertos
ou guardas removidas.
● Mantenha seu rosto da fumaça.
● Use ventilação e exhaustão para
remover fumo da zona respiratória.
ATENÇÃO
● Não toque as partes elétricas nuas.
Japanese
Chinese
Korean
Arabic
LEIA E COMPREENDA AS INSTRUÇÕES DO FABRICANTE PARA ESTE EQUIPAMENTO E AS PARTES DE USO, E SIGA AS
PRÁTICAS DE SEGURANÇA DO EMPREGADOR.
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• 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
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