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Lincoln Electric 10708 manual

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Table of contents for the manual

  • Page 1

    Ranger 305 G OPERA TOR’S MANUAL IM674 August, 2001 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[...]

  • 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. ________________________________________________[...]

  • 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[...]

  • 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[...]

  • Page 5

    iv SAFETY iv PRÉCA UTIONS 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 [...]

  • Page 6

    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 par[...]

  • Page 7

    vi T ABLE OF CONTENTS Page Installation ................................................................................................................... ....Section A Technical Specifications .......................................................................................................A-1 Machine Specifications .........................[...]

  • Page 8

    vii T ABLE OF CONTENTS Maintenance ......................................................................................................Section D Safety Precautions ................................................................................................D-1 Routine Maintenance ................................................................[...]

  • 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 - Rang er 305G (K1726-1) Make/Model Description Speed (RPM) Displacement Starting Capa[...]

  • Page 10

    A-2 INST ALLA TION RANGER 305G A-2 MA CHINE SPECIFICA TIONS - Rang er 305G (K1726-1) RECEPTACLES AUXILIARY POWER CIRCUIT BREAKER OTHER CIRCUIT BREAKERS (2) 120VAC Duplex (5-20R) Two 20AMP for Two Duplex Recptacle 25AMP for Battery Charging Circuit (1) 120/240VAC Dual Voltage Two 50AMP for Dual Voltage 15AMP for 42V Wire Feeder Power Full KVA (14-50[...]

  • 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 PRECA UTIONS FALLING EQUIPMENT can cause injury. • Do not lift this machine using lift bale if it is equipped with a heav[...]

  • Page 12

    A-4 INST ALLA TION RANGER 305G A-4 5. Conformance with federal, state and local laws. (1) (1) Consult applicable federal, state and local laws regarding specific requirements for use on public highways. PRE-OPERA TION ENGINE SER VICE READ the engine operating and maintenance instruc- tions supplied with this machine. • Stop engine and allow to co[...]

  • Page 13

    A-5 INST ALLA TION RANGER 305G A-5 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 con[...]

  • Page 14

    A-6 INST ALLA TION RANGER 305G A-6 • Do not cross the welding cables at the output terminal connection. Keep the cables isolated and separate from one another. ------------------------------------------------------------------------ A UXILIAR Y PO WER RECEPT ACLES The auxiliary power of the RANGER 305G consists of two 20 Amp-120 VAC (5-20R) duple[...]

  • 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[...]

  • Page 16

    A-8 INST ALLA TION RANGER 305G A-8 CONNECTION OF LINCOLN ELECTRIC WIRE FEEDERS Connection of the LN-25 to the RANGER 305G 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 appro[...]

  • Page 17

    B-1 OPERA TION RANGER 305G B-1 SAFETY PRECA UTIONS 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. ------------------------------------------[...]

  • Page 18

    B-2 OPERA TION B-2 WELDING CONTROLS 1. OUTPUT CONTR OL: 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[...]

  • Page 19

    B-3 OPERA TION B-3 It acts as an inductance control. The proper setting depends on the procedure and operator preference. Start with a setting at 0. 5. WELD OUTPUT TERMINALS WITH FLANGE NUT : Provides a connection point for the electrode and work cables. 6. GR OUND STUD: (graphic) Provides a connection point for connecting the machine case to earth[...]

  • Page 20

    B-4 OPERA TION B-4 • 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 weather. Operating the starter motor for more than 5 sec- onds can damage th[...]

  • Page 21

    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 current 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 tung[...]

  • Page 22

    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 ratings in the following table. Electrode Diameter Current[...]

  • Page 23

    C-1 A CCESSORIES C-1 OPTIONS/A CCESSORIES 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.). K1737-1 FOUR WHEEL ALL-TERRAIN UNDERCAR- [...]

  • Page 24

    D-1 MAINTENANCE D-1 RANGER 305G K OHLER ENGINE (1) Service more frequently when used in dusty areas and/or at high ambient temperatures. SAFETY PRECA UTIONS • 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 necessar[...]

  • Page 25

    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 [...]

  • Page 26

    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[...]

  • Page 27

    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. B A TTER Y MAINTENANCE To access t[...]

  • Page 28

    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[...]

  • Page 29

    E-1 TR OUBLESHOO TING 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. CA UTION This Troubleshooting Guide is provided to help you locate and repair p[...]

  • Page 30

    E-2 TR OUBLESHOO TING 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. CA UTION PROBLEMS[...]

  • Page 31

    E-3 TR OUBLESHOO TING 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. CA UTION PROBLEMS[...]

  • Page 32

    E-4 TR OUBLESHOO TING 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. CA UTION PROBLEMS[...]

  • Page 33

    E-5 TR OUBLESHOO TING 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. CA UTION PROBLEMS[...]

  • Page 34

    F-1 DIA GRAMS F-1 RANGER 305G[...]

  • Page 35

    F-2 DIA GRAMS F-2 RANGER 305G[...]

  • Page 36

    F-3 DIA GRAMS F-3 RANGER 305G[...]

  • Page 37

    F-4 DIA GRAMS F-4 RANGER 305G[...]

  • Page 38

    F-5 DIA GRAMS F-5 RANGER 305G[...]

  • Page 39

    F-6 DIA GRAMS F-6 RANGER 305G or ser vice t his e quip m ent. On ly qualified personnel should install,use Keep away from movi ng parts. Keep guards in place. MOVING PART S can injure W ARNING Do not touch electricall y live parts. before servicing. Disconnect NEGATIVE (-) Bat tery lead Do not operate with panels open. ELECTRIC SH OCK can kill 14 P[...]

  • Page 40

    F-7 DIA GRAMS F-7 RANGER 305G[...]

  • Page 41

    F-8 DIA GRAMS F-8 RANGER 305G[...]

  • Page 42

    F-9 DIA GRAMS F-9 RANGER 305G[...]

  • Page 43

    F-10 DIA GRAMS F-10 RANGER 305G[...]

  • Page 44

    F-11 DIA GRAMS F-11 RANGER 305G[...]

  • Page 45

    F-12 DIA GRAMS F-12 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 numb[...]

  • Page 46

    3-2000 M19410 41.20 17.50 19.50 42.10 20.80 "A" "B" CENTER OF GRAVITY WITH OIL IN ENGINE AND EMPTY FUEL TANK 29.88 33.62 36.24 10.28 10.78 TRUCK/UNDERCARRIAGE MOUNTING HO LES 7.22 24.86 2.6 F-13 DIA GRAMS F-13 RANGER 305G DIMENSION PRINT RANGER 305G DIMENSION “ A ” DIMENSION “ B ” 23.50 16.75[...]

  • Page 47

    NO TES RANGER 305G[...]

  • Page 48

    W ARNING A VISO DE PRECA UCION A TTENTION W ARNUNG A TEN ÇÃ O 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 [...]

  • Page 49

    W ARNING A VISO DE PRECA UCION A TTENTION W ARNUNG A TEN ÇÃ O Spanish French German Portuguese Japanese Chinese Korean Arabic LEIA E COMPREENDA AS INSTRUÇÕES DO F ABRICANTE P ARA ESTE EQUIP AMENTO E AS PAR TES DE USO, E SIGA AS PRÁTICAS DE SEGURANÇA DO EMPREGADOR. ● Keep your head out of fumes. ● Use ventilation or exhaust to remove fumes[...]

  • Page 50

    • 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 •[...]