Lincoln-electric IM10042 RANGER 305 G User Manual

Operator’s ManualRANGER ®305GRegister your machine: www.lincolnelectric.com/registerAuthorized Service and Distributor Locator: www.lincolnelectric.

A-3INSTALLATION RANGER® 305GA-3LIFTINGThe RANGER® 305G weighs approximately 539lbs.(244.5kg) with a full tank of gasoline. A lift bail ismounted to

A-4INSTALLATION RANGER® 305GA-41. Design capacity of trailer vs. Weight of Lincoln equipment andlikely additional attachments. 2. Proper support of,

A-5INSTALLATION RANGER® 305GA-5NOTE: This machine is furnished with a wet charged bat-tery; if unused for several months, the battery may require ab

A-6INSTALLATION RANGER® 305GA-6WELDING OUTPUT CABLES With the engine off connect the electrode and workcables to the output studs. The welding proce

A-7INSTALLATION RANGER® 305GA-7TABLE lllELECTRICAL DEVICE USE WITH THE RANGER® 305G.Type Common Electrical Devices Possible ConcernsResistive Heater

A-8INSTALLATION RANGER® 305GA-8240 Volt60 Hz.3-WireServicePOWERCOMPANYMETER240 VOLT120 VOLT120 VOLTLOADNNEUTRALBUSGROUNDPREMISESDISCONNECT A

A-9INSTALLATION RANGER 305GA-9CONNECTION OF LINCOLN ELECTRICWIRE FEEDERSConnection of LN-7 or LN-8 to the RANGER® 305G1. Shut the welder off.2. Con

A-10INSTALLATION RANGER® 305GA-107. Set the "IDLE" switch to the "AUTO" position.When not welding, the RANGER® 305G enginewill b

B-1OPERATIONRANGER® 305GB-1GENERAL DESCRIPTIONThe RANGER® 305G is a gasoline engine poweredDC multi-process welding power source and 120 / 240volt AC

B-2OPERATIONB-2WELDING CONTROLS1. OUTPUT CONTROL:The CONTROL dial provides continuous control of thewelding current or welding voltage depending on th

THANK YOU FOR SELECTING A QUALITY PRODUCT BY LINCOLN ELEC TRIC. PLEASE EXAMINE CARTON AND EQUIPMENT FORDAMAGE IMMEDIATELYWhen this equipment is ship

B-3OPERATIONB-3CV-WIRE mode: In this mode, turning the ARC CONTROLclockwise from –10 (soft) to +10 (crisp) changes the arc fromsoft and washed-in to c

B-4OPERATIONB-4Operating the starter motor for more than 5 sec-onds can damage the motor. If the engine fails tostart, release the switch and wait 10

B-5OPERATIONB-5TIG WELDINGThe TOUCH START TIG setting of the MODE switch is forDC TIG (Tungsten Inert Gas) welding. To initiate a weld, theCONTROL dia

Permissible Current in@120 VAC *80**60**46**36200B-6OPERATIONB-6ARC GOUGINGThe RANGER® 305G can be used for limited arcgouging. For optimal performa

C-1ACCESSORIESC-1OPTIONS/ACCESSORIES AND COM-PATIBLE LINCOLN EQUIPMENTK957-1 HEAVY DUTY, TWO WHEEL TRAILER FORSMALL WELDERSFor road, off-road and in-p

D-1MAINTENANCED-1RANGER® 305GKOHLER ENGINE (1) Service more frequently when used in dusty areas and/or at high ambienttemperatures.SAFETY PRECAUTIONS•

D-2MAINTENANCED-2Engine Oil ChangeDrain the oil while the engine is warm to assure rapidand complete draining.• Remove the oil filler cap and dipstic

D-3MAINTENANCED-3AIR FILTER PAPER ELEMENT• Loosen the cover retaining knob and remove thecover.• Remove the pre-cleaner from the paper element.• Remov

D-4MAINTENANCED-4FUEL FILTER• Check the fuel filter for water accumulation or sedi-ment.• Replace the fuel filter if it is found with excessivewater a

D-5MAINTENANCED-5RANGER® 305GWelder/Generator MaintenanceSTORAGE: Store the RANGER® 305G in clean, dryprotected areas.CLEANING: Blow out the generator

SECTION A:WARNINGS CALIFORNIA PROPOSITION 65 WARNINGSDiesel EnginesDiesel engine exhaust and some of its constituents are known to the State of Calif

E-1TROUBLESHOOTINGE-1RANGER® 305GIf for any reason you do not understand the test procedures or are unable to perform the tests/repairs safely, contac

E-2TROUBLESHOOTINGE-2RANGER® 305GObserve all Safety Guidelines detailed throughout this manualIf for any reason you do not understand the test procedu

E-3TROUBLESHOOTINGE-3RANGER® 305GObserve all Safety Guidelines detailed throughout this manualIf for any reason you do not understand the test procedu

E-4TROUBLESHOOTINGE-4RANGER® 305GObserve all Safety Guidelines detailed throughout this manualIf for any reason you do not understand the test procedu

E-5TROUBLESHOOTINGE-5RANGER® 305GObserve all Safety Guidelines detailed throughout this manualIf for any reason you do not understand the test procedu

F-1DIAGRAMSF-1RANGER® 305G

F-2DIAGRAMSF-2RANGER® 305G

F-3DIAGRAMSF-3RANGER® 305G

F-4DIAGRAMSF-4RANGER® 305G

F-5DIAGRAMSF-5RANGER® 305G

ELECTRIC SHOCK CAN KILL.3.a. The electrode and work (or ground) circuits areelectrically “hot” when the welder is on. Donot touch these “hot” parts wi

F-6DIAGRAMSF-6RANGER® 305Gor service this equipment.Only qualified personnel should install,useKeep away from moving parts.Keep guards in place.MOVING

F-7DIAGRAMSF-7RANGER® 305G

F-8DIAGRAMSF-8RANGER® 305G

F-9DIAGRAMSF-9RANGER® 305G 29/03

F-10DIAGRAMSF-10RANGER® 305G

F-11DIAGRAMSF-11RANGER® 305GNOTE: This diagram is for reference only. It may not be accurate for all machines covered by this manual. The specific

M22449ACIRCUITBREAKERS41.201046.517.50444.519.50495.316.75425.4TRUCK/UNDERCARRIAGE MOUNTING HOLES7.22183.324.86631.32.6266.5CENTER OF GRAVITY29.80756.

F-13DIMENSION PRINTF-13RANGER® 305GM24958ACIRCUITBREAKERS41.201046.517.50444.519.50495.3TRUCK/UNDERCARRIAGE MOUNTING HOLES7.22183.329.80756.9INCHMM10.

NOTES RANGER® 305G

RANGER®305GP-640P-640PARTS LIST FORRanger®305GThis parts list is provided as an informative guide only.It was accurate at the time of printing. These

WELDING AND CUTTINGSPARKS CAN CAUSEFIRE OR EXPLOSION.6.a. Remove fire hazards from the welding area. Ifthis is not possible, cover them to prevent the

RANGER®305GJan-14P-640-AP-640-AILLUSTRATION OF SUB-ASSEMBLIES7564123

RANGER®305GJan-14Do Not use this Parts List for a machine if its code number is not listed. Contact the Service Department for anycode numbers not lis

RANGER®305GJan-14P-640-CP-640-CControl Panel Assembly1A1A41A41A3A3A3333333325258A8A343435A35A38A38A37375A5A4A4A52C52C52E52E52B52B27B27B50A50A50B50B952

1 Case Front Assembly (G3666-49), Includes: NSS 1X1A Case Front G3860-8 1 X3A Top Bezel G3593 1 X3B Self Tapping Screw (Not Shown) S24738-1 7 X4A Righ

RANGER®305GJan-14P-640-DP-640-DCase Front Assembly242420A20A50A50A50B50B49A49A2222212120C20C11A11A11B11B131313131414151515154545404039397A7A7B7B7C7C7E

7A Output Terminal Assembly, Includes: (1/2 Per Asbly) T14166-9 2 X7B Output Stud Nut T3960 2 X7C Self Tapping Screw S8025-91 4 X7D 1/2-13 x .875 HHCS

RANGER®305GJan-14P-640-EP-640-EBase/Fuel Tank/Battery Assembly4F4F4D4D4E4E2B2B15N5N5K5K5B5B5C5C5D5D5G5G5A5A5M5M5L5L5N5N5J5J10A10A2A2A17A17A17G17G17F17

1 Base G3870 1 XXXX2A Engine Cross Support L11147-1 1 XXXX2B Thread Forming Screw S9225-68 8 XXXX4 Fuel Tank & Assembly, Includes: L12164-1 1 X •

21 Flex Tube (Not Shown) (Fuel Tank Vent Hose) T10642-339 1 • X • •Jan-14RANGER®305GUse only the parts marked “x” in the column under theheading numbe

RANGER®305GNOTES

vi vi TABLE OF CONTENTSPageInstallation...

RANGER®305GJan-14P-640-FP-640-FEngine Assembly2A2A1C1C1A1A1B1B1E1E1E1E1F1F2B2B

1A Engine - Kohler (M21300) NSS 1X••1A Engine - Kohler (M22704) NSS 1•X•1A Engine - Kohler (M24866) NSS 1 ••X1B Rubber Mounting S24344 2 X X X1C 3/8-1

P-640-GP-640-G Jan-14Blower Baffle AssemblyRANGER®305G7215154A4A16168A8A8C8C8D8D8E8E8F8F15A5A5B5B9A9A9B9B9H9H9K9K9J9J9F9F9E9E9D9D3A3A3C3C3B3B3H3H3F3F3

Jan-14RANGER®305GUse only the parts marked “x” in the column under theheading number called for in the model index page.# Indicates a change this prin

RANGER®305GJan-14P-640-HP-640-HStator/Rotor Assembly1A1A1G1G1D1D1F1F8A8A8B8B11111010121213139A9A4A4A7A7A5D5D5A5A5B5B5E5E5F5F1C1C1B1B1E1E7F7F4B4B4C4C

1A Rotor & Shaft Assembly L11086-2 1 X1B Centering Washer S20110-3 1 X1C Special Hex Head Bolt T14843-6 1 X1D Tolerance Ring S18044-9 1 X1E Blower

RANGER®305GJan-14P-640-JP-640-JCovers & Case Back Assembly9A9A9B9B1818202014141616874B4B121223234A4A24242B2B6B6B6A6A131315156C6C21215A5A15152A2A1A

1A Case Side (Right) G3510 1 XXXX1B Thread Forming Screw (Not Shown) S9225-68 3 XXXX2A Case Side (Left) G3511 1 XXXX2B Thread Forming Screw S9225-68 3

CUSTOMER ASSISTANCE POLICYThe business of The Lincoln Electric Company is manufacturing andselling high quality welding equipment, consumables, and cu

vii viiTABLE OF CONTENTSMaintenance...Section DSafe

RANGER® 305G1. Output rating in watts is equivalent to volt-amperes at unity power factor. Output voltage is within ± 10% at all loads up torated capa

A-2INSTALLATION RANGER® 305GA-2MACHINE SPECIFICATIONS - RANGER® 305G (K1726-5)RECEPTACLES AUXILIARY POWER CIRCUIT BREAKER OTHER C