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IM742-A
August, 2002
RANGER 305 G 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.
Da
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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 zones où l’on pique le laitier. PRÉCAUTIONS DE SÛRETÉ 6. Eloigner les matériaux inflammables ou les recouvrir afin de Pour votre propre protection lire et observer toutes les instructions prévenir tout risque d’incendie dû aux étincelles. et les précautions de sûreté specifiques qui parraissent dans ce manuel aussi bien que les précautions de sûreté générales suiv- 7. Quand on ne soude pas, poser la pince à une endroit isolé de antes: la masse. Un court-circuit accidental peut provo
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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 TABLE OF CONTENTS Page Installation.......................................................................................................................Section A Technical Specifications.......................................................................................................A-1 Machine Specifications ........................................................................................................A-2 Safety Precautions ....................................................
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vii TABLE OF CONTENTS Maintenance......................................................................................................Section D Safety Precautions ................................................................................................D-1 Routine Maintenance ............................................................................................D-1 Kohler Engine........................................................................................................D-1
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A-1 A-1 INSTALLATION TECHNICAL SPECIFICATIONS - Ranger 305G (K1726-1) 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 (K1726-1) 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 3.03 x 2.85 (77 x 72) Battery Charger RAT
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A-2 A-2 INSTALLATION MACHINE SPECIFICATIONS - Ranger 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 (14-50R) RANGER 305G
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A-3 A-3 INSTALLATION LIFTING SAFETY PRECAUTIONS The RANGER 305G weighs approximately 530 lbs. with a full tank of gasoline. A lift bail is mounted to the WARNING 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 The RANGER 305G is shipped with the negative bat- PRE-OPERATION ENGINE SERVICE tery cable disconnected. Make certain that the RUN- STOP switch is in the STOP position. Remove the two WARNING screws from the rear battery tray using a screwdriver or a 3/8" socket. Attach the negative battery cable to READ the engine operating and maintenance instruc- the negative battery terminal and tighten using a 1/2" tions supplied with this machine. socket or wrench. � Stop engine and
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A-5 A-5 INSTALLATION WELDING TERMINALS The 14 pin connector is used to directly connect a The RANGER 305G is equipped with a toggle switch wire feeder or TIG Module (K930-2) control cable. In for selecting "hot" welding terminal when in the the CV-WIRE mode, the RANGER 305G auto-sensing "WELD TERMINALS ON" position or "cold" welding circuit automatically makes the RANGER 305G terminal when in the "REMOTELY CONTROLLED" Output Control inactive and the wire feeder voltage position. control activ
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A-6 A-6 INSTALLATION STANDBY POWER CONNECTIONS CAUTION The RANGER 305G is suitable for temporary, standby � Loose connections will cause the output termi- or emergency power using the engine manufacturer’s nals to overheat. The terminals may eventually recommended maintenance schedule. melt. � Do not cross the welding cables at the output The RANGER 305G can be permanently installed as terminal connection. Keep the cables isolated a standby power unit for 240 VAC, 3 wire, single and separate
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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 CAUTION WIRE FEEDERS If you are using an LN-25 without an internal con- tactor, the electrode will be energized when the Connection of the LN-25 to the RANGER 305G Ranger 305G is started. ------------------------------------------------------------------------ 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- 2. Connect the LN-7 or LN-8 per instructions on the nect
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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 � Open top engine door and remove the engine oil have thoroughly read the engine manufacturer’s dipstick and wipe it with a clean cloth. Reinsert the manual supplied with your welder. It includes dipstick and check the level on the dipstick. important safety precautions, detailed engine starting, operating and maint
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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 3. WELD MODE SELECTOR SWITCH: (Provides four selectable welding modes) 1. OUTPUT CONTROL: CV-WIRE PIPE The CONTROL dial provides continuous control of the CC-STICK welding current or welding voltage depending on the TOUCH START TIG selected welding mode. This control is not active in the CC-STICK, PIPE, and CV-WIRE modes when a remote 4. ARC CONTROL : control or wire feeder with remote control is connected to either the
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B-3 B-3 OPERATION 5. WELD OUTPUT TERMINALS WITH 14. IDLER SWITCH- Has two positions as follows: FLANGE NUT: 1) In the HIGH position, the engine runs at the high Provides a connection point for the electrode and 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 � When switched from HIGH to AUTO or after start- machine case to earth ground for the safest ground
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B-4 B-4 OPERATION WELDER OPERATION � The engine will run at high idle speed for approxi- Stick Welding mately 12 seconds and then go to low idle speed. The RANGER 305G can be used with a broad range Allow the engine to warm up at low idle for several of DC stick electrodes. minutes before applying a load and/or switching to The MODE switch provides two stick welding settings high idle. Allow a longer warm up time in cold weath- as follows: er. Constant Current (CC-STICK) Welding CAUTION The CC
