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Lincoln Electric IM834-B - page 1
RA NG ER 3 0 5 G OPERA TOR’S MANUAL IM834-B August, 2005 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 ...
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Lincoln Electric IM834-B - page 2
FOR ENGINE powered equipment. 1.a. Turn the engine off before troubleshooting and maintenance work unless the maintenance work requires it to be running. ____________________________________________________ 1.b. Operate engines in open, well-ventilated areas or vent the engine exhaust fumes outdoors. ________________________________________________ ...
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Lincoln Electric IM834-B - page 3
ii SAFETY ii ARC RA YS can burn. 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. 4.b. Use suitable clothing made from durable flame-resistant material to protect your skin ...
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Lincoln Electric IM834-B - page 4
FOR ELECTRICALL Y powered equipment. 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. 8.c. Ground the equipment in accordance with the U.S. National Electrical C ...
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Lincoln Electric IM834-B - page 5
iv SAFETY iv PRÉCAUTIONS DE SÛRETÉ 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: Sûreté Pour Soudage A L’Arc 1. Protegez-vous contre la secousse électrique: a. Les circuits ? ...
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Lincoln Electric IM834-B - page 6
v v Thank You 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! Read this Operators Manual completely before attempting to use this equipment. Save this manual and keep it handy for quick reference. Pay ...
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Lincoln Electric IM834-B - page 7
vi vi T ABLE OF CONTENTS Page Installation ................................................................................................................... ....Section A Technical Specifications .......................................................................................................A-1 Machine Specifications ...................... ...
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Lincoln Electric IM834-B - page 8
vii vii T ABLE OF CONTENTS Maintenance ......................................................................................................Section D Safety Precautions ................................................................................................D-1 Routine Maintenance ............................................................ ...
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Lincoln Electric IM834-B - page 9
RANGER 305G 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. A-1 INST ALLA TION A-1 TECHNICAL SPECIFICA TIONS - RANGER 305G (K1726-2, K1726-3) Make/Model Description Speed (RPM) Displacement Start ...
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Lincoln Electric IM834-B - page 10
A-2 INST ALLA TION RANGER 305G A-2 MACHINE SPECIFICA TIONS - RANGER 305G (K1726-2, K1726-3) RECEPTACLES AUXILIARY POWER CIRCUIT BREAKER OTHER CIRCUIT BREAKERS (2) 120VAC Duplex (5-20R) Two 20AMP for Two Duplex Receptacle 20AMP for Battery Charging Circuit (1) 120/240VAC Dual Voltage One 50AMP for Dual Voltage (2-pole) 15AMP for 42V Wire Feeder Powe ...
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Lincoln Electric IM834-B - page 11
A-3 INST ALLA TION RANGER 305G A-3 LIFTING The RANGER 305G weighs approximately 530 lbs. with a full tank of gasoline. A lift bail is mounted to the machine and should always be used when lifting the machine. ADDITIONAL SAFETY PRECAUTIONS HIGH ALTITUDE OPERATION At higher altitudes, Welder output de-rating may be necessary. For maximum rating, de-r ...
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Lincoln Electric IM834-B - page 12
A-4 INST ALLA TION RANGER 305G A-4 VEHICLE MOUNTING Improperly mounted concentrated loads may cause unstable vehicle handling and tires or other components to fail. • Only transport this Equipment on serviceable vehicles which are rated and designed for such loads. • Distribute, balance and secure loads so vehicle is stable under conditions of ...
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Lincoln Electric IM834-B - page 13
A-5 INST ALLA TION RANGER 305G A-5 SP ARK 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. ...
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Lincoln Electric IM834-B - page 14
A-6 INST ALLA TION RANGER 305G A-6 WELDING OUTPUT CABLES With the engine off connect the electrode and work cables to the output studs. The welding process dic- tates the polarity of the electrode cable. These con- nections should be checked periodically and tightened with a 3/4" wrench. Table A.1 lists recommended cable sizes and lengths for ...
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Lincoln Electric IM834-B - page 15
A-7 INST ALLA TION RANGER 305G A-7 240 Volt 60 Hz. 3-Wire Service POWER COMPANY METER 240 VOLT 120 VOLT 120 VOLT LOAD N NEUTRAL BUS GROUND PREMISES DISCONNECT AND SERVICE OVERCURRENT PROTECTION GND N NOTE: No. 6 COPPER CONDUCTOR CABLE SEE NATIONAL ELECTRICAL CODE FOR ALTERNATE WIRE SIZE RECOMMENDATIONS. 240 VOLT GROUNDED CONDUCTOR 40AMP 240 VOLT DO ...
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Lincoln Electric IM834-B - page 16
A-8 INST ALLA TION RANGER 305G A-8 CONNECTION OF LINCOLN ELECTRIC WIRE FEEDERS Connection of LN-7 or LN-8 to the RANGER 305G 1. Shut the welder off. 2. Connect the LN-7 or LN-8 per instructions on the appropriate connection diagram in Section F 3. Set the "WIRE FEEDER VOLTMETER" switch to either "+" or "-" as required ...
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Lincoln Electric IM834-B - page 17
A-9 INST ALLA TION RANGER 305G A-9 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- in ...
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Lincoln Electric IM834-B - page 18
B-1 OPERA TION RANGER 305G B-1 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 u ...
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Lincoln Electric IM834-B - page 19
B-2 OPERA TION B-2 WELDING CONTROLS 1. OUTPUT CONTROL: The CONTROL dial provides continuous control of the welding current or welding voltage depending on the selected welding mode. This control is not active in the CC-STICK, DOWN HILL PIPE, and CV-WIRE modes when a remote control or wire feeder with remote control is connected to either the 6 pin ...
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Lincoln Electric IM834-B - page 20
B-3 OPERA TION B-3 CV-WIRE mode: In this mode, 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 procedure and operator preference. Start with a setting at 0. 5. WELD OUTPUT TERMINALS WITH FLANGE NUT : ...
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Lincoln Electric IM834-B - page 21
B-4 OPERA TION B-4 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. ----------------------------- ...
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Lincoln Electric IM834-B - page 22
B-5 OPERA TION B-5 TIG WELDING The TOUCH START TIG setting of the MODE switch is for DC TIG (Tungsten Inert Gas) welding. To initiate a weld, the CONTROL dial is first set to the desired cur- rent and the tungsten is touched to the work. During the time the tungsten is touching the work there is very little voltage or current and in general, no tun ...
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Lincoln Electric IM834-B - page 23
Permissible Current in @120 VAC * 80** 60** 46** 36 20 0 B-6 OPERA TION B-6 ARC GOUGING The RANGER 305G can be used for limited arc goug- ing. For optimal performance, set the MODE switch to CC-STICK and the ARC CONTROL to +10. Set the CONTROL knob to adjust output current to the desired level for the gouging electrode being used according to the r ...
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Lincoln Electric IM834-B - page 24
C-1 ACCESSORIES C-1 OPTIONS/ACCESSORIES AND COM- P A TIBLE LINCOLN EQUIPMENT K957-1 HEAVY DUTY, TWO WHEEL TRAILER FOR SMALL WELDERS For road, off-road and in-plant and yard towing. (For highway use, consult applicable federal, state and local laws regarding requirements for brakes, lights, fenders, etc.).Order: K957-1 Trailer K958-1 Ball Hitch K958 ...
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Lincoln Electric IM834-B - page 25
D-1 MAINTENANCE D-1 RANGER 305G KOHLER ENGINE (1) Service more frequently when used in dusty areas and/or at high ambient temperatures. SAFETY PRECAUTIONS • 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 ...
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Lincoln Electric IM834-B - page 26
D-2 MAINTENANCE D-2 Engine Oil Change Drain the oil while the engine is warm to assure rapid and complete draining. • Remove the oil filler cap and dipstick. Remove the yellow cap from the oil drain valve and attach the flexible drain tube supplied with the machine. Push in and twist the drain valve counterclockwise. Pull the valve out and drain ...
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Lincoln Electric IM834-B - page 27
D-3 MAINTENANCE D-3 AIR FIL TER P APER ELEMENT • Loosen the cover retaining knob and remove the cover. • Remove the pre-cleaner from the paper element. • Remove the element cover nut, element cover, and paper element. • Do not wash the paper element or use pressurized air, as this will damage the element. Replace a dirty, bent, or damaged e ...
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Lincoln Electric IM834-B - page 28
D-4 MAINTENANCE D-4 FUEL FIL TER • Check the fuel filter for water accumulation or sedi- ment. • Replace the fuel filter if it is found with excessive water accumulation or sediment. ENGINE ADJUSTMENT Adjustments to the engine are to be made only by a Lincoln Service Center or an authorized Field Service Shop. BA TTER Y MAINTENANCE To access th ...
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Lincoln Electric IM834-B - page 29
D-5 MAINTENANCE D-5 RANGER 305G W elder/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 wea ...
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Lincoln Electric IM834-B - page 30
E-1 TROUBLESHOOTING E-1 RANGER 305G If for any reason you do not understand the test procedures or are unable to perform the tests/repairs safely, contact your Local Lincoln Authorized Field Service Facility for technical troubleshooting assistance before you proceed. CAUTION This Troubleshooting Guide is provided to help you locate and repair poss ...
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Lincoln Electric IM834-B - page 31
E-2 TROUBLESHOOTING E-2 RANGER 305G Observe all Safety Guidelines detailed throughout this manual If for any reason you do not understand the test procedures or are unable to perform the tests/repairs safely, contact your Local Lincoln Authorized Field Service Facility for technical troubleshooting assistance before you proceed. CAUTION PROBLEMS (S ...
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Lincoln Electric IM834-B - page 32
E-3 TROUBLESHOOTING E-3 RANGER 305G Observe all Safety Guidelines detailed throughout this manual If for any reason you do not understand the test procedures or are unable to perform the tests/repairs safely, contact your Local Lincoln Authorized Field Service Facility for technical troubleshooting assistance before you proceed. CAUTION PROBLEMS (S ...
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Lincoln Electric IM834-B - page 33
E-4 TROUBLESHOOTING E-4 RANGER 305G Observe all Safety Guidelines detailed throughout this manual If for any reason you do not understand the test procedures or are unable to perform the tests/repairs safely, contact your Local Lincoln Authorized Field Service Facility for technical troubleshooting assistance before you proceed. CAUTION PROBLEMS (S ...
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Lincoln Electric IM834-B - page 34
E-5 TROUBLESHOOTING E-5 RANGER 305G Observe all Safety Guidelines detailed throughout this manual If for any reason you do not understand the test procedures or are unable to perform the tests/repairs safely, contact your Local Lincoln Authorized Field Service Facility for technical troubleshooting assistance before you proceed. CAUTION PROBLEMS (S ...
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Lincoln Electric IM834-B - page 35
F-1 DIAGRAMS F-1 RANGER 305G ...
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Lincoln Electric IM834-B - page 36
F-2 DIAGRAMS F-2 RANGER 305G ...
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Lincoln Electric IM834-B - page 37
F-3 DIAGRAMS F-3 RANGER 305G ...
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Lincoln Electric IM834-B - page 38
F-4 DIAGRAMS F-4 RANGER 305G ...
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Lincoln Electric IM834-B - page 39
F-5 DIAGRAMS F-5 RANGER 305G ...
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Lincoln Electric IM834-B - page 40
F-6 DIAGRAMS F-6 RANGER 305G or ser vice t his equi pm ent. On ly qualified personnel should install,use Keep away from movi ng parts. Keep guards in place. MOVING PART S can injure WA R N I N G Do not touch electrically live pa rts. before servicing. Disconnect NEGATI VE (- ) Bat te ry lead Do not operate with panels open. ELECTRIC SH OCK can kill ...
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Lincoln Electric IM834-B - page 41
F-7 DIAGRAMS F-7 RANGER 305G ...
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Lincoln Electric IM834-B - page 42
F-8 DIAGRAMS F-8 RANGER 305G ...
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Lincoln Electric IM834-B - page 43
F-9 DIAGRAMS F-9 RANGER 305G 2 9/03 ...
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Lincoln Electric IM834-B - page 44
F-10 DIAGRAMS F-10 RANGER 305G ...
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Lincoln Electric IM834-B - page 45
F-11 DIAGRAMS F-11 RANGER 305G NOTE: This diagram is for reference only. It may not be accurate for all machines covered by this manual. The specific diagram for a particular code is pasted inside the machine on one of the enclosure panels. If the diagram is illegible, write to the Service Department for a replacement. Give the equipment code numbe ...
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Lincoln Electric IM834-B - page 46
F-12 DIMENSION PRINT F-12 RANGER 305G ...
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Lincoln Electric IM834-B - page 47
W ARNING AV I S O D E PRECAUCION A TTENTION W ARNUNG A TENÇÃO Spanish French German Portuguese Japanese Chinese Korean Arabic READ AND UNDERST AND THE MANUF ACTURER’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 F ABRICANTE P ARA ...
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Lincoln Electric IM834-B - page 48
W ARNING AV I S O D E PRECAUCION A TTENTION W ARNUNG A TENÇÃO Spanish French German Portuguese Japanese Chinese Korean Arabic LEIA E COMPREENDA AS INSTRUÇÕES DO F ABRICANTE P ARA ESTE EQUIP AMENTO E AS P AR TES DE USO, E SIGA AS PRÁTICAS DE SEGURANÇA DO EMPREGADOR. ● Keep your head out of fumes. ● Use ventilation or exhaust to remove fume ...
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Lincoln Electric IM834-B - page 49
• Sales and Service through Subsidiaries and Distributors Worldwide • Cleveland, Ohio 44117-1199 U.S.A. TEL: 216.481.8100 FAX: 216.486.1751 WEB SITE: www.lincolnelectric.com • World's Leader in Welding and Cutting Products • ...
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