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IM834-B
August, 2005
RANGER 305G
For use with machines having Code Numbers: 11119, 11169, 11273
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 caref
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i i SAFETY WARNING CALIFORNIA PROPOSITION 65 WARNINGS Diesel engine exhaust and some of its constituents The engine exhaust from this product contains are known to the State of California to cause can- chemicals known to the State of California to cause cer, birth defects, and other reproductive harm. cancer, birth defects, or other reproductive harm. The Above For Diesel Engines The Above For Gasoline Engines ARC WELDING CAN BE HAZARDOUS. PROTECT YOURSELF AND OTHERS FROM POSSIBLE SERIOUS INJURY
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ii ii SAFETY ELECTRIC SHOCK can ARC RAYS can burn. 4.a. Use a shield with the proper filter and cover kill. plates to protect your eyes from sparks and 3.a. The electrode and work (or ground) circuits the rays of the arc when welding or observing are electrically “hot” when the welder is on. open arc welding. Headshield and filter lens Do not touch these “hot” parts with your bare should conform to ANSI Z87. I standards. skin or wet clothing. Wear dry, hole-free gloves to insulate hands. 4.b. Us
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iii iii SAFETY WELDING SPARKS can CYLINDER may explode cause fire or explosion. if damaged. 6.a. Remove fire hazards from the welding area. 7.a.Use only compressed gas cylinders If this is not possible, cover them to prevent containing the correct shielding gas for the the welding sparks from starting a fire. process used and properly operating Remember that welding sparks and hot regulators designed for the gas and materials from welding can easily go through small cracks pressure used. All hos
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iv iv SAFETY 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 7. Quand on ne soude pas, poser la pince à une endroit isolé de manuel aussi bien que les précautions de sûreté générales suiv- la masse. Un court-circuit accidental peut provoquer un antes: échauffement et un risqu
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v v for selecting a QUALITY product by Lincoln Electric. We want you to take pride in operating this Lincoln Electric Company product Thank You ��� as much pride as we have in bringing this product to 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
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vi vi TABLE OF CONTENTS Page Installation.......................................................................................................................Section A Technical Specifications.......................................................................................................A-1 Machine Specifications ........................................................................................................A-2 Safety Precautions .................................................
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vii vii TABLE OF CONTENTS Maintenance......................................................................................................Section D Safety Precautions ................................................................................................D-1 Routine Maintenance ............................................................................................D-1 Kohler Engine.......................................................................................................
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A-1 A-1 INSTALLATION TECHNICAL SPECIFICATIONS - RANGER 305G (K1726-2, K1726-3) INPUT - GASOLINE ENGINE Make/Model Description Speed (RPM) Displacement Starting Capacities cu. in. (cu. cm.) System 2 cylinder High Idle 3700 41(674) 12VDC Battery & Fuel: 12 gal. Kohler CH22 Starter 45.4 L (K1726-2, -3) 22 HP @ Bore x Stroke inch (mm) (Group 58; 435 Oil: 2.0 Qts 3600 RPM Full Load 3500 cold crank amps) 1.9 L Gasoline 3.03 x 2.85 (77 x 7
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A-2 A-2 INSTALLATION MACHINE SPECIFICATIONS - RANGER 305G (K1726-2, K1726-3) RECEPTACLES AND CIRCUIT BREAKERS 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 Power Full KVA (14-50R) Below code 11273 two 50AMP Below code 11273 Battery cicuit breakers we
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A-3 A-3 INSTALLATION LIFTING SAFETY PRECAUTIONS The RANGER 305G weighs approximately 530 lbs. WARNING 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 ADDITIONAL SAFETY PRECAUTIONS important safety precautions, detailed engine starting, operating and maintenance instructions, WARNING a
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A-4 A-4 INSTALLATION VEHICLE MOUNTING FUEL USE GASOLINE FUEL ONLY WARNING WARNING Improperly mounted concentrated loads may cause unstable vehicle handling and tires or other � Fill the fuel tank with clean, fresh fuel. The components to fail. capacity of the fuel tank is 12 gallons (45.4 liters). When the fuel gauge reads empty the � Only transport this Equipment on serviceable tank contains approximately 2 gallons(7.6 liters) vehicles which are rated and designed for such of reserve fuel.
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A-5 A-5 INSTALLATION SPARK ARRESTER ELECTRICAL CONNECTIONS Some federal, state or local laws may require that gasoline or diesel engines be equipped with exhaust MACHINE GROUNDING spark arresters when they are operated in certain locations where unarrested sparks may present a fire Because this portable engine driven welder creates its hazard. The standard muffler included with this welder own power, it is not necessary to connect its frame to does not qualify as a spark arrester. When requir
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A-6 A-6 INSTALLATION WELDING OUTPUT CABLES The auxiliary power capacity is 10,000 watts Peak, 9500 Watts Continuous of 60 Hz, single phase power. The auxil- With the engine off connect the electrode and work iary power capacity rating in watts is equivalent to volt- cables to the output studs. The welding process dic- amperes at unity power factor. The max permissible current tates the polarity of the electrode cable. These con- of the 240 VAC output is 40 Amps. The 240 VAC output can nection
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A-7 A-7 INSTALLATION CONNECTION OF RANGER 305G TO PREMISES WIRING 240 VOLT GROUNDED CONDUCTOR POWER 240 Volt 120 VOLT 60 Hz. COMPANY 3-Wire 120 VOLT Service 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 GROUND OVERCURRENT 40AMP PROTECTION 240 VOLT DOUBLE POLE 50 AMP, 120/240 CIRCUIT VOLT PLUG 240 VOLT BREAKER NEMA TYPE 14-50 GND N 50 AMP, 120/240 VOLT NOTE: No. 6 COPPE
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A-8 A-8 INSTALLATION CONNECTION OF LINCOLN ELECTRIC WIRE FEEDERS � Set the "WIRE FEEDER VOLTMETER" switch to either "+" or "-" as required by the electrode polarity being used. Connection of LN-7 or LN-8 to the RANGER 305G � Set the "ARC CONTROL" knob to "0" initially and 1. Shut the welder off. adjust to suit. 2. Connect the LN-7 or LN-8 per instructions on the appropriate connection diagram in Section F � Set the "IDLE" switch to the "AUTO" position. 3. Set the "WIRE FEEDER VOLTMETER" switc
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A-9 A-9 INSTALLATION 7. Set the "IDLE" switch to the "AUTO" position. 3. Connect the Control Cable of the Spool Gun to the When not welding, the RANGER 305G engine will Adapter Module and connect the Control Cable of be at the low idle speed. If you are using an LN-25 the Adapter Module to the Welder. with an internal contactor, the electrode is not energized until the gun trigger is closed. 4. Connect the Gas Hose. 8. When the gun trigger is closed, the current sens- 5. Set the MODE switch t
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B-1 B-1 OPERATION SAFETY PRECAUTIONS DESIGN FEATURES Read and understand this entire section before operating your RANGER 305G FOR AUXILIARY POWER: Do not attempt to use this equipment until you Start the engine and set the IDLER control switch to have thoroughly read all operating and mainte- the desired operating mode. Full power is available nance manuals supplied with your machine. They regardless of the welding control settings providing no include important safety precautions, detailed
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B-2 B-2 OPERATION 16 1 15 14 2 13 3 12 11 4 10 9 8 7 5 6 WELDING CONTROLS 4. ARC CONTROL : 1. OUTPUT CONTROL: The ARC CONTROL WIRE/STICK dial is active in the WIRE, The CONTROL dial provides continuous control of the STICK and DOWN HILL PIPE modes, and has different func- welding current or welding voltage depending on the tions in these modes. This control is not active in the TIG mode. selected welding mode. This control is not active in the CC-STICK, DOWN HILL PIPE, and CV-WIRE modes CC-STIC
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B-3 B-3 OPERATION CV-WIRE mode: In this mode, turning the ARC CONTROL 13. START PUSH BUTTON clockwise from –10 (soft) to +10 (crisp) changes the arc from - Energizes the starter motor to crank the engine soft and washed-in to crisp and narrow. It acts as an induc- tance control. The proper setting depends on the procedure 14. IDLER SWITCH and operator preference. Start with a setting at 0. - Has two positions as follows: 1) In the HIGH position, the engine runs at the high 5. WELD OUTPUT TERMIN
