Lincoln Electric IM10158 User Manual

Operator’s Manual

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RANGER ® 305G EFI

For use with machines having Code Numbers:

12157, 12206

Save for future reference

Date Purchased

Code: (ex: 10859)

Serial: (ex: U1060512345)

IM10158-A | Issue D ate Aug-13

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THANK YOU FOR SELECTING

AT ALL

TIMES.

SPECIAL SITUATIONS

Additional precautionary measures

A QUALITY PRODUCT BY LINCOLN ELEC TRIC.

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 is received.

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 thoughtful 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.

WARNING

This statement appears where the information must be followed exactly to avoid serious personal injury or loss of life.

CAUTION

This statement appears where the information must be followed to avoid minor personal injury or damage to this equipment.

KEEP YOUR HEAD OUT OF THE FUMES.

DON’T get too close to the arc. Use

corrective lenses if necessary to stay a reasonable distance away from the arc.

READ and obey the Material Safety

Data Sheet (MSDS) and the warning label that appears on all containers of welding materials.

USE ENOUGH VENTILATION or

exhaust at the arc, or both, to keep the fumes and gases from your breathing zone and the general area.

IN A LARGE ROOM OR OUTDOORS, natural ventilation may be

adequate if you keep your head out of the fumes (See below).

USE NATURAL DRAFTS or fans to keep the fumes away from your

face.

If you de velop unusual symptoms, see your supervisor. Perhaps the welding atmosphere and ventilation system should be checked.

WEAR CORRECT EYE, EAR & BODY PROTECTION

PROTECT your eyes and face with welding helmet

properly fitted and with proper grade of filter plate (See ANSI Z49.1).

PROTECT your body from welding spatter and arc

flash with protective clothing including woolen clothing, flame-proof apron and gloves, leather leggings, and high boots.

PROTECT others from splatter, flash, and glare with

protective screens or barriers.

IN SOME AREAS, protection from noise may be

appropriate.

BE SURE protective equipment is in good condition.

Also, wear safety glasses in work area

DO NOT WELD OR CUT containers or materials which previously had

been in contact with hazardous substances unless they are properly cleaned. This is extremely dangerous.

DO NOT WELD OR CUT painted or plated parts unless special

precautions with ventilation have been taken. They can release highly toxic fumes or gases.

PROTECT compressed gas cylinders from excessive heat, mechanical

shocks, and arcs; fasten cylinders so they cannot fall.

BE SURE cylinders are never grounded or part of an electrical circuit. REMOVE all potential fire hazards from welding area. ALWAYS HAVE FIRE FIGHTING EQUIPMENT READY FOR

IMMEDIATE USE AND KNOW HOW TO USE IT.

SECTION A:

Diesel Engines

Gasoline Engines

WARNINGS

CALIFORNIA PROPOSITION 65 WARNINGS

Diesel engine exhaust and some of its constituents are known to the State of California to cause cancer, birth defects, and other reproductive harm.

The engine exhaust from this product contains chemicals known to the State of California to cause cancer, birth defects, or other reproductive harm.

ARC WELDING CAN BE HAZARDOUS. PROTECT YOURSELF AND OTHERS FROM POSSIBLE SERIOUS INJURY OR DEATH. KEEP CHILDREN AWAY. PACEMAKER WEARERS SHOULD CONSULT WITH THEIR DOCTOR BEFORE OPERATING.

Read and understand the following safety highlights. For additional safety information, it is strongly recommended that you purchase a copy of “Safety in Welding & Cutting - ANSI Standard Z49.1” from the American Welding Society, P.O. Box 351040, Miami, Florida 33135 or CSA Standard W117.2-1974. A Free copy of “Arc Welding Safety” booklet E205 is available from the Lincoln Electric Company, 22801 St. Clair Avenue, Cleveland, Ohio 44117-1199.

BE SURE THAT ALL INSTALLATION, OPERATION, MAINTENANCE AND REPAIR PROCEDURES ARE PERFORMED ONLY BY QUALIFIED INDIVIDUALS.

SAFETY

1.d. Keep all equipment safety guards, covers and devices in position and in good repair.Keep hands, hair, clothing and tools away from V-belts, gears, fans and all other moving parts when starting, operating or repairing equipment.

1.e. In some cases it may be necessary to remove safety guards to perform required maintenance. Remove guards only when necessary and replace them when the maintenance requiring their removal is complete. Always use the greatest care when working near moving parts.

1.f. Do not put your hands near the engine fan. Do not attempt to override the governor or idler by pushing on the throttle control rods while the engine is running.

1.g. To prevent accidentally starting gasoline engines while turning the engine or welding generator during maintenance work, disconnect the spark plug wires, distributor cap or magneto wire as appropriate.

1.h. To avoid scalding, do not remove the radiator pressure cap when the engine is

hot.

ELECTRIC AND MAGNETIC FIELDS MAY BE DANGEROUS

2.a. Electric current flowing through any conductor causes localized Electric and Magnetic Fields (EMF). Welding current creates EMF fields around welding cables and welding machines

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.

1.c. Do not add the fuel near an open flame welding arc or when the engine is running. Stop the engine and allow it to cool before refueling to prevent spilled fuel from vaporizing on contact with hot engine parts and igniting. Do not spill fuel when filling tank. If fuel is spilled, wipe it up and do not start engine until fumes have been eliminated.

2.b. EMF fields may interfere with some pacemakers, and welders having a pacemaker should consult their physician before welding.

2.c. Exposure to EMF fields in welding may have other health effects which are now not known.

2.d. All welders should use the following procedures in order to minimize exposure to EMF fields from the welding circuit:

2.d.1. Route the electrode and work cables together - Secure them with tape when possible.

2.d.2. Never coil the electrode lead around your body.

2.d.3. Do not place your body between the electrode and work cables. If the electrode cable is on your right side, the work cable should also be on your right side.

2.d.4. Connect the work cable to the workpiece as close as possible to the area being welded.

2.d.5. Do not work next to welding power source.

SAFETY

ELECTRIC SHOCK CAN KILL.

3.a. The electrode and work (or ground) circuits are electrically “hot” when the welder is on. Do not touch these “hot” parts with your bare skin or wet clothing. Wear dry, hole-free gloves to insulate hands.

3.b. Insulate yourself from work and ground using dry insulation. Make certain the insulation is large enough to cover your full area of physical contact with work and ground.

In addition to the normal safety precautions, if welding must be performed under electrically hazardous conditions (in damp locations or while wearing wet clothing; on metal structures such as floors, gratings or scaffolds; when in cramped positions such as sitting, kneeling or lying, if there is a high risk of unavoidable or accidental contact with the workpiece or ground) use the following equipment:

• Semiautomatic DC Constant Voltage (Wire) Welder.

• DC Manual (Stick) Welder.

• AC Welder with Reduced Voltage Control.

3.c. In semiautomatic or automatic wire welding, the electrode, electrode reel, welding head, nozzle or semiautomatic welding gun are also electrically “hot”.

3.d. Always be sure the work cable makes a good electrical connection with the metal being welded. The connection should be as close as possible to the area being welded.

3.e. Ground the work or metal to be welded to a good electrical (earth) ground.

3.f. Maintain the electrode holder, work clamp, welding cable and welding machine in good, safe operating condition. Replace damaged insulation.

3.g. Never dip the electrode in water for cooling.

3.h. Never simultaneously touch electrically “hot” parts of electrode holders connected to two welders because voltage

two can be the total of the open circuit voltage of both welders.

3.i. When working above floor level, use a safety belt to protect yourself from a fall should you get a shock.

between the

ARC RAYS 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 and that of your helpers from the arc rays.

4.c. Protect other nearby personnel with suitable, non-flammable screening and/or warn them not to watch the arc nor expose themselves to the arc rays or to hot spatter or metal.

FUMES AND GASES CAN BE DANGEROUS.

5.a. Welding may produce fumes and gases hazardous to health. Avoid breathing these fumes and gases. When welding, keep your head out of the fume. Use enough ventilation and/or exhaust at the arc to keep fumes

and gases away from the breathing zone. When welding

with electrodes which require special ventilation such as stainless or hard facing (see instructions on container or MSDS) or on lead or cadmium plated steel and other metals or coatings which produce highly toxic fumes, keep exposure as low as possible and within applicable OSHA PEL and ACGIH TLV limits using local exhaust or mechanical ventilation. In confined spaces or in some circumstances, outdoors, a respirator may be required. Additional precautions are also required when welding on galvanized steel.

5. b. The operation of welding fume control equipment is affected by various factors including proper use and positioning of the equipment, maintenance of the equipment and the specific welding procedure and application involved. Worker exposure level should be checked upon installation and periodically thereafter to be certain it is within applicable OSHA PEL and ACGIH TLV limits.

5.c. Do not weld in locations near chlorinated hydrocarbon vapors coming from degreasing, cleaning or spraying operations. The heat and rays of the arc can react with solvent vapors to form phosgene, a highly toxic gas, and other irritating products.

3.j. Also see It ems 6.c. and 8.

5.d. Shielding gases used for arc welding can displace air and

injury or death. Always use enough ventilation, especially in confined areas, to insure breathing air is safe.

5.e. Read and understand the manufacturer’s instructions for this

equipment and the consumables to be used, including the material safety data sheet (MSDS) and follow your employer’s safety practices. MSDS forms are available from your welding distributor or from the manufacturer.

5.f. Also see item 1.b.

cause

SAFETY

WELDING AND CUTTING SPARKS CAN CAUSE FIRE OR EXPLOSION.

6.a. Remove fire hazards from the welding area. If this is not possible, cover them to prevent the welding sparks from starting a fire. Remember that welding sparks and hot materials from welding can easily go through small cracks and openings to adjacent areas. Avoid welding near hydraulic lines. Have a fire extinguisher readily available.

6.b. Where compressed gases are to be used at the job site, special precautions should be used to prevent hazardous situations. Refer to “Safety in Welding and Cutting” (ANSI Standard Z49.1) and the operating information for the equipment being used.

6.c. When not welding, make certain no part of the electrode circuit is touching the work or ground. Accidental contact can cause overheating and create a fire hazard.

6.d. Do not heat, cut or weld tanks, drums or containers until the proper steps have been taken to insure that such procedures will not cause flammable or toxic vapors from substances inside. They can cause an explosion even though they have been “cleaned”. For information, purchase “Recommended Safe Practices for the Preparation for Welding and Cutting of Containers and Piping That Have Held Hazardous Substances”, AWS F4.1 from the American Welding Society (see address above).

6.e. Vent hollow castings or containers before heating, cutting or welding. They may explode.

6.f. Sparks and spatter are thrown from the welding arc. Wear oil free protective garments such as leather gloves, heavy shirt, cuffless trousers, high shoes and a cap over your hair. Wear ear plugs when welding out of position or in confined places. Always wear safety glasses with side shields when in a welding area.

6.g. Connect the work cable to the work as close to the welding area as practical. Work cables connected to the building framework or other locations away from the welding area increase the possibility of the welding current passing through lifting chains, crane cables or other alternate circuits. This can create fire hazards or overheat lifting chains or cables until they fail.

6.h. Also see item 1.c.

CYLINDER MAY EXPLODE IF DAMAGED.

7.a. Use only compressed gas cylinders containing the correct shielding gas for the process used and properly operating regulators designed for the gas and pressure used. All hoses, fittings, etc. should be suitable for the application and maintained in good condition.

7.b. Always keep cylinders in an upright position securely chained to an undercarriage or fixed support.

7.c. Cylinders should be located:

• Away from areas where they may be struck or subjected to physical damage.

• A safe distance from arc welding or cutting operations and any other source of heat, sparks, or flame.

7.d. Never allow the electrode, electrode holder or any other electrically “hot” parts to touch a cylinder.

7.e. Keep your head and face away from the cylinder valve outlet when opening the cylinder valve.

7.f. Valve protection caps should always be in place and hand tight except when the cylinder is in use or connected for use.

7.g. Read and follow the instructions on compressed gas cylinders, associated equipment, and CGA publication P-l, “Precautions for Safe Handling of Compressed Gases in

Cylinders,” available from the Compressed Gas Association 1235 Jefferson Davis Highway, Arlington, VA 22202.

FOR ELECTRICALLY 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.

6.I. Read and follow NFPA 51B “ Standard for Fire Prevention During Welding, Cutting and Other Hot Work”, available from NFPA, 1 Batterymarch Park, PO box 9101, Quincy, Ma 022690-9101.

6.j. Do not use a welding power source for pipe thawing.

8.c. Ground the equipment in accordance with the U.S. National Electrical Code and the manufacturer’s recommendations.

Refer to

http://www.lincolnelectric.com/safety

for additional safety information.

Welding Safety Interactive Web Guide for mobile devices

TABLE OF CONTENTS

Page

Installation.......................................................................................................................Section A

Technical Specifications.......................................................................................................A-1

Machine Specifications ........................................................................................................A-2

Safety Precautions........................................................................................................A-3

Location and Ventilation................................................................................................A-3

Stacking ........................................................................................................................A-3

Angle of Operation ........................................................................................................A-3

Lifting.............................................................................................................................A-3

Additional Safety Precautions .......................................................................................A-3

High Altitude Operation.................................................................................................A-3

High Temperature Operation ........................................................................................A-3

Towing...........................................................................................................................A-3

Vehicle Mounting...........................................................................................................A-4

Pre-Operation Engine Service..............................................................................................A-4

Oil..................................................................................................................................A-4

Fuel ...............................................................................................................................A-4

Engine Coolant..............................................................................................................A-4

Battery Connections......................................................................................................A-4

Muffler Outlet Pipe ........................................................................................................A-5

Spark Arrester...............................................................................................................A-5

High Frequency Generators for Tig Applications ..........................................................A-5

Remote Control.............................................................................................................A-5

Electrical Connections..........................................................................................................A-5

Machine Grounding.......................................................................................................A-5

Welding Terminals ........................................................................................................A-5

Welding Output Cables .................................................................................................A-6

Cable Installation...........................................................................................................A-6

Auxiliary Power Receptacles and Plugs...............................................................................A-6

Standby Power Connections................................................................................................A-6

Electrical Device Used with the RANGER

Premises Wiring...................................................................................................................A-8

Connection of Lincoln Electric Wire Feeders...............................................................A-9,A-10

________________________________________________________________________________

305G EFI.........................................................A-7

Operation.........................................................................................................................Section B

Safety Precautions ..............................................................................................................B-1

General Description..............................................................................................................B-1

Design Features...................................................................................................................B-1

Engine Operation..................................................................................................................B-1

Fuel ......................................................................................................................................B-1

Welder Controls....................................................................................................................B-2

Engine Controls....................................................................................................................B-3

Starting and Stopping the Engine .................................................................................B-3

Stopping .......................................................................................................................B-4

Welding Operation................................................................................................................B-4

Duty Cycle.....................................................................................................................B-4

DC Stick Welding ..........................................................................................................B-4

Constant Current (Stick) Welding..................................................................................B-4

Downhill Pipe Welding ..................................................................................................B-4

Fuel Consumption.........................................................................................................B-4

Tig Welding ...................................................................................................................B-5

Typical Current Ranges for Tungsten Electrodes .........................................................B-5

Wire Welding-CV...........................................................................................................B-5

Arc Gouging ..................................................................................................................B-6

Auxiliary Power .............................................................................................................B-6

Simultaneous Welding and Auxiliary Power Loads.......................................................B-6

Extension Cord Recommendations...............................................................................B-6

________________________________________________________________________________

Accessories.....................................................................................................Section C

Options / Accessories and Compatible Lincoln Equipment.................................................C-1

________________________________________________________________________________ _

vii vii

Maintenance......................................................................................................Section D

Safety Precautions ................................................................................................D-1

Routine Maintenance............................................................................................D-1

Kohler Engine........................................................................................................D-1

Engine Maintenance Components ........................................................................D-1

Engine Oil Change..........................................................................................D-2

Engine Oil Refill Capacities.............................................................................D-2

Oil Filter Change.............................................................................................D-2

Air Cleaner Service.........................................................................................D-2

Air Pre-Cleaner Service..................................................................................D-2

Air Filter Paper Element ........................................................................................D-3

Spark Plug ......................................................................................................D-3

Spark Plug Service .........................................................................................D-3

Fuel Filter........................................................................................................D-4

Engine Adjustment..........................................................................................D-4

Battery Maintenance.......................................................................................D-4

Servicing Optional Spark Arrestor...................................................................D-4

Welder / Generator Maintenance ........................................................................D-5

Storage ...........................................................................................................D-5

Cleaning..........................................................................................................D-5

Brush Removal and Replacement..................................................................D-5

________________________________________________________________________

Troubleshooting..............................................................................................Section E

How to Use Troubleshooting Guide.......................................................................E-1

Troubleshooting Guide ..........................................................................................E-2

Troubleshooting Guide..........................................................................................E-3

Troubleshooting Guide..........................................................................................E-4

Troubleshooting Guide ..........................................................................................E-5

Diagrams and Dimension Prints....................................................................Section F

Parts List.................................................................................................................P-742

________________________________________________________________________

TABLE OF CONTENTS

A-1

INSTALLATION

TECHNICAL SPECIFICATIONS - RANGER®305G EFI (K3928-1)

INPUT - GASOLINE ENGINE

A-1

Make/Model

(K3928-1)

Kohler

ECH740

Description

2 cylinder

25 HP @

3600 RPM

Gasoline

Engine

Speed (RPM)

High Idle 3700

Full Load 3500

Low Idle 2400

Displacement

cu. In.(cu. Cm.)

45.6(747))

Bore x Stroke

inch (mm)

3.27 x 2.72 (83 x 69)

Starting System

12VDC Battery &

Starter

(Group 58; 435

Cold crank amps)

Battery Charger

RATED OUTPUT @ 104° F (40° C) - WELDER

Welding Output Volts at Rated Amps Duty Cycle Max. OCV @ 3700 RPM

CC STICK DC Output 29 Volts @ 305 Amps 100% CC STICK Output Range 20 to 305 Amps -------

PIPE DC Output 29 Volts @ 300 Amps 100% PIPE Output Range 40 to 300 Amps ------- 60 Volts

CC TIG DC Output 30 Volts @ 250 Amps 100%

TIG Output Range 20 to 250 Amps -------

CV WIRE DC Output 29 Volts @ 300 Amps 100% CV WIRE Output Range 14 to 29 volts -------

RATED OUTPUT @ 104° F (40° C).- GENERATOR

Auxiliary Power

12,000 Watts Peak, 9500 Watts Continuous, 60 Hz

120/240 Volts

Capacities

Fuel: 12 gal.

45.4 L

Oil: 2.0 qt.

1.9 ltr.

PHYSICAL DIMENSIONS

HEIGHT WIDTH DEPTH WEIGHT

30.00** in. 21.50 in 42.25 in.

762.0 mm 546.0 mm 1073.0 mm

510 lbs. (231kg.)

ENGINE COMPONENTS

LUBRICATION VALVE LIFTERS FUEL SYSTEM GOVERNOR

Full Pressure Hydraulic Mechanical Fuel Pump with Mechanical Governor

With Full Flow Filter additional electric fuel lift pump.

5% Regulation

AIR CLEANER ENGINE IDLER MUFFLER ENGINE PROTECTION

Low noise Muffler: Top outlet Shutdown on low oil

Dual Element Automatic Idler can be rotated. Made from pressure.

Long life, aluminized steel.

ENGINE WARRANTY: 2 year unlimited hours (See engine manufacturer warranty for details.) Kohler

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.

RANGER®305G EFI

A-2

INSTALLATION

MACHINE SPECIFICATIONS - RANGER®305G EFI (K3928-1)

RECEPTACLES AND CIRCUIT BREAKERS

RECEPTACLES AUXILIARY POWER CIRCUIT BREAKER OTHER CIRCUIT BREAKERS

A-2

(2) 120VAC Duplex (5-20R) Two 20AMP for Two Duplex Receptacle (1) 120/240VAC Dual Voltage One 50AMP for Dual Voltage (2-pole)

Full KVA (14-50R)

20AMP for Battery Charging Circuit

15AMP for 42V Wire Feeder Power

RANGER®305G EFI

A-3

INSTALLATION

SAFETY PRECAUTIONS

WARNING

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.

------------------------------------------------------------------------

ELECTRIC SHOCK can kill.

• Do not touch electrically live parts or electrode with skin or wet clothing.

• Insulate yourself from work and ground

• Always wear dry insulating gloves.

-------------------------------------------------------

ENGINEȊEXHAUSTȊcan kill.

• Use in open, well ventilated areas or vent exhaust outside.

--------------------------------------------------------

MOVING PARTSȊcan injure.

• Do not operate with doors open or guards off.

• Stop engine before servicing.

• Keep away from moving parts.

------------------------------------------------------------------------

See additional warning information at

front of this operators manual.

A-3

LIFTING

The RANGER 539lbs. (244.5kg) with a full tank of gasoline. A lift bail is mounted to the machine and should always be used when lifting the machine.

305G EFI weighs approximately

ADDITIONAL SAFETY PRECAUTIONS

WARNING

• Lift only with equipment of adequate lifting capacity.

• Be sure machine is stable when lifting.

• Do not lift this machine using lift bail if it is equipped with a heavy accessory such as trailer or gas cylinder.

FALLING • Do not lift machine if lift bail is

EQUIPMENT can damaged.

Cause injury. • Do not operate machine while

Suspended from lift bail.

------------------------------------------------------------------------

HIGH ALTITUDE OPERATION

At higher altitudes, Welder output de-rating may be necessary. For maximum rating, de-rate the welder output 3.5% for every 1000 ft. (im) above 3000 ft. (im).

Only qualified personnel should install, Use, or service this equipment.

LOCA TION AND VENTILA TION

The welder should be located to provide an unrestricted flow of clean, cool air to the cooling air inlets and to avoid restricting the cooling air outlets. Also, locate the welder so that the engine exhaust fumes are properly vented to an outside area.

STACKING

RANGER

ANGLE OF OPERATION

Engines are designed to run in the level condition which is where the optimum performance is achieved. The maximum angle of continuous operation is 15 degrees in any direction. If the engine is to be operated at an angle, provisions must be made for checking and maintaining the oil level at the normal (FULL) oil capacity in the crankcase.

When operating the welder at an angle, the effective fuel capacity will be slightly less than the specified 12 gallons.

305G EFI machines cannot be stacked.

RANGER®305G EFI

HIGH TEMPERATURE OPERATION

At temperatures above 40°C(104°F), Welder output de-rating is necessary. For maximum output ratings, de-rate the welder output 2 volts for every 10°C(50°F) above 40°C(104°F).

TOWING

The recommended trailer for use with this equipment for road, in-plant and yard towing by a vehicle(1) is Lincolns K957-1. If the user adapts a non-Lincoln trailer, he must assume responsibility that the method of attachment and usage does not result in a safety hazard nor damage the welding equipment. Some of the factors to be considered are as follows:

1. Design capacity of trailer vs. Weight of Lincoln equipment and likely additional attachments.

2. Proper support of, and attachment to, the base of the welding equipment so there will be no undue stress to the framework.

3. Proper placement of the equipment on the trailer to insure stability side to side and front to back when being moved and when standing by itself while being operated or serviced.

A-4

4. Typical conditions of use, i.e., travel speed; roughness of surface on which the trailer will be operated; environmental conditions; like maintenance.

5. Conformance with federal, state and local laws.

(1)

Consult applicable federal, state and local laws regarding specific requirements for use on public highways.

VEHICLE MOUNTING

INSTALLATION

(1)

WARNING

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 use.

• Do not exceed maximum rated loads for components such as suspension, axles and tires.

• Mount equipment base to metal bed or frame of vehicle.

• Follow vehicle manufactures instructions.

------------------------------------------------------------------------

PRE-OPERATION ENGINE SERVICE

READ the engine operating and maintenance instructions supplied with this machine.

WARNING

• Stop engine while fueling.

• Do not smoke when fueling.

• Keep sparks and flame away from tank.

• Do not leave unattended while fueling.

• Wipe up spilled fuel and allow

GASOLINE

Can cause fire Or explosion.

fumes to clear before starting engine.

• Do not overfill tank, fuel expansion may cause overflow.

GASOLINE FUEL ONLY

------------------------------------------------------------------------

OIL

The RANGER®305G EFI is shipped with the engine crankcase filled with high quality SAE 10W-30 oil. Check the oil level before starting the engine. If it is not up to the full mark on the dip stick, add oil as required. Check the oil level every four hours of running time during the first 25 running hours. Refer to the engine Operators Manual for specific oil recommendations and break-in information. The oil change interval is dependent on the quality of the oil and the operating environment. Refer to the Engine Operators Manual for the proper service and maintenance intervals.

A-4

FUEL

USE GASOLINE FUEL ONLY

WARNING

• Fill the fuel tank with clean, fresh fuel. Observe the fuel gauge while filling to prevent overfilling. Stop fueling once the gauge reads full. Do not top off tank. Be sure to leave filler neck empty to allow room for expansion. The capacity of the fuel tank is 12 gallons (45.4 liters). When the fuel gauge reads empty the tank contains approximately 2 gallons(7.6 liters) of reserve fuel.

FULL

NOTE: The fuel tank is mounted below the engine so a

fuel shutoff valve is not required.

--------------------------------------------------------------------------------

ENGINE COOLING SYSTEM

WARNING

Air to cool the engine is drawn in lower set of louvers on the case back. It is important that the intake air is not restricted. Allow a minimum clearance of 2 feet (Im) from the case back to a vertical surface.

BATTERY CONNECTION

CAUTION

Use caution as the electrolyte is a strong acid that can burn skin and damage eyes.

--------------------------------------------------------------------------------

The RANGER®305G EFI is shipped with the negative battery cable disconnected. Make certain that the RUN-STOP switch is in the STOP position. Remove the two screws from the rear battery tray using a screwdriver or a 3/8" socket. Attach the negative battery cable to the negative battery terminal and tighten using a 1/2" socket or wrench.

• Do not allow battery cables to touch opposing terminals. When connecting battery cables attach positive (+) cable to positive (+) battery terminal first, followed by negative (-) cable to negative (-) battery terminal.

• Never start engine when cables are loose or poorly connected to battery terminals.

• Never diconnect battery while engine is running.

NOTE: This machine is furnished with a wet charged bat-

tery; if unused for several months, the battery may require a booster charge. Be careful to charge the battery with the correct polarity.

RANGER®305G EFI

A-5

INSTALLATION

MUFFLER OUTLET PIPE

Using the clamp provided secure the outlet pipe to the outlet tube with the pipe positioned such that it will direct the exhaust in the desired direction. Tighten using a 9/16" socket or wrench.

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. When required by local regulations, a suitable spark arrester, such as the K1898-1 must be installed and properly maintained.

CAUTION

An incorrect spark arrestor may lead to damage to the engine or adversely affect performance.

------------------------------------------------------------------------

HIGH FREQUENCY GENERATORS FOR TIG APPLICA TIONS

The K930-2 TIG Module is suitable for use with the RANGER

any high frequency generating equipment must be properly grounded. See the K930-2 Operating Manual for completed instructions on installation, operation, and maintenance.

REMOTE CONTROL

The RANGER®305G EFI is equipped with a 6-pin and a 14-pin connector. The 6-pin connector is for connecting the K857 or K857-1 Remote Control (optional) or for TIG welding, the K870 foot Amptrol or the K963-3 hand Amptrol.

When in the CC-STICK, PIPE, and CV-WIRE modes and when a remote control is connected to the

Amphenol, the auto-sensing circuit in the RANGER 305G EFI automatically switches the OUTPUT control from control at the welder to remote control.

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 sensing circuit automatically makes the RANGER

305G EFI Output Control inactive and the wire feeder voltage control active when the control cable is connected to the 14-pin connector. NOTE: When a wire feeder with a built in welding voltage control is connected to the 14-pin connector, do not connect anything to the 6-pin connector.

305G EFI. The RANGER®305G EFI and

305G EFI auto-

ELECTRICAL CONNECTIONS

MACHINE GROUNDING

Because this portable engine driven welder creates its own power, it is not necessary to connect its frame to an earth ground, unless the machine is connected to premises wiring (home, shop, etc.)

To prevent dangerous electric shock, other equipment to which this engine driven welder supplies power must:

WARNING

• Be grounded to the frame of the welder using a grounded type plug.

• Be double insulated. Do not ground the machine to a pipe that carries explosive or combustible material.

------------------------------------------------------------------------

When this welder is mounted on a truck or trailer, its frame must be electrically connected to the metal frame of the vehicle, use a #8 or larger copper wire connected between the machine grounding stud and frame of the vehicle. When this engine driven welder is connected to premises wiring such as that in a home or shop, its frame must be connected to the system earth ground. See further connection instructions in the section entitled "Standby Power Connections" as well as the article on grounding in the latest U.S. National Electrical Code and the local code.

In general, if the machine is to be grounded, it should be connected with a #8 or larger copper wire to a solid earth ground such as a metal water pipe going into the ground for at least ten feet and having no insulated joints, or to the metal framework of a building which has been effectively grounded.

The U.S. National Electrical Code lists a number of

alternate means of grounding electrical equipment. A machine grounding stud marked with the symbol is provided on the front of the welder.

WELDING TERMINALS

The RANGER®305G EFI is equipped with a toggle switch for selecting "hot" welding terminal when in the

"WELD TERMINALS ON" position or "cold" welding terminal when in the "REMOTELY CONTROLLED" position.

A-5

RANGER®305G EFI

A-6

INSTALLATION

WELDING OUTPUT CABLES

With the engine off connect the electrode and work cables to the output studs. The welding process dictates the polarity of the electrode cable. These connections should be checked periodically and tightened with a 3/4" wrench.

Table A.1 lists recommended cable sizes and lengths for rated current and duty cycle. Length refers to the distance from the welder to the work and back to the welder. Cable diameters are increased for long cable lengths to reduce voltage drops.

TABLE A-1

TOTAL COMBINED LENGTH OF

ELECTRODE AND WORK CABLES

Cable Length

0-100Ft. (0-30 meters)

100-150 Ft. (Im meters) 150-200 Ft. (46-61 meters)

Cable Size for

305 Amps

100% Duty Cycle

1 / 0 AWG

2 / 0 AWG

3 / 0 AWG

A-6

The auxiliary power capacity is 12,000 watts Peak, 9500 Watts Continuous of 60 Hz, single phase power. The auxiliary power capacity rating in watts is equivalent to voltamperes at unity power factor. The max permissible current of the 240 VAC output is 40 Amps. The 240 VAC output can be split to provide two separate 120 VAC outputs with a max permissible current of 40 Amps per output to two separate 120 VAC branch circuits (these circuits cannot be paralleled). Output voltage is within ± 10% at all loads up to rated capacity. All auxiliary power is protected by circuit breakers.

The 120 V auxiliary power receptacles should only be used with three wire grounded type plugs or approved double insulated tools with two wire plugs. The current rating of any plug used with the system must be at least equal to the current capacity of the associated receptacle.

NOTE: The 240 V receptacle has two 120 V circuits, but are of opposite polarities and cannot be paralleled.

STANDBY POWER CONNECTIONS

The RANGER®305G EFI is suitable for temporary, standby or emergency power using the engine manufacturers recommended maintenance schedule.

CABLE INSTALLATION

Install the welding cables to your RANGER EFI as follows.

1. The engine must be OFF to install welding cables.

2. Remove the flanged nuts from the output terminals.

3. Connect the electrode holder and work cables to the weld output terminals. The terminals are identified on the case front.

4. Tighten the flanged nuts securely.

5. Be certain that the metal piece you are welding (the “work”) is properly connected to the work clamp and cable.

6. Check and tighten the connections periodically.

305G

CAUTION

• Loose connections will cause the output termi-

nals to overheat. The terminals may eventually melt.

• Do not cross the welding cables at the output

terminal connection. Keep the cables isolated and separate from one another.

------------------------------------------------------------------------

AUXILIARY POWER RECEPTACLES

The auxiliary power of the RANGER®305G EFI consists of two 20 Amp-120 VAC (5-20R) duplex receptacles and one 50 Amp 120/240 VAC (14-50R) receptacle. The 240 VAC receptacle can be split for single phase 120 VAC operation.

The RANGER standby power unit for 240 VAC, 3 wire, single phase, 40 amp service. Connections must be made by a licensed electrician who can determine how the 120/240 VAC power can be adapted to the particular installation and comply with all applicable electrical codes.

• Install the double-pole, double-throw switch between the power company meter and the premises disconnect. Switch rating must be the same or greater than the customers premises disconnect and service over current protection.

• Take necessary steps to assure load is limited to the capacity of the RANGER

amp, 240 VAC double pole circuit breaker. Maximum rated load for each leg of the 240 VAC auxiliary is 40 amperes. Loading above the rated output will reduce output voltage below the allowable - 10% of rated voltage which may damage appliances or other motor-driven equipment and may result in overheating of the

RANGER

• Install a 50 amp, 120/240 VAC plug (NEMA Type 14-50) to the double-pole circuit breaker using No. 6, 4 conductor cable of the desired length. (The 50 amp, 120/240 VAC plug is available in the optional K802R plug kit or as part number T12153-9.)

• Plug this cable into the 50 Amp, 120/240 Volt receptacle on the RANGER

305G EFI can be permanently installed as a

305G EFI by installing a 40

305G EFI engine and/or alternator windings.

305G EFI case front.

RANGER®305G EFI

A-7

ELECTRICAL DEVICE USE WITH THE RANGER

Type Common Electrical Devices Possible Concerns

Resistive Heaters, toasters, incandescent NONE

light bulbs, electric range, hot pan, skillet, coffee maker.

Capacitive TV sets, radios, microwaves, Voltage spikes or high voltage

appliances with electrical control. regulation can cause the capaci-

Inductive Single-phase induction motors, These devices require large

drills, well pumps, grinders, small current inrush for starting. refrigerators, weed and hedge Some synchronous motors may trimmers be frequency sensitive to attain

INSTALLATION

TABLE lll

305G EFI.

tative elements to fail. Surge protection, transient protection, and additional loading is recommended for 100% fail-safe oper-

ation. DO NOT RUN THESE

DEVICES WITHOUT ADDITIONAL RESISTIVE TYPE LOADS.

maximum output torque, but they SHOULD BE SAFE from any frequency induced failures.

A-7

Capacitive/Inductive Computers, high resolution TV sets, An inductive type line condition-

complicated electrical equipment. er along with transient and

surge protection is required, and liabilities still exist. DO NOT

USE THESE DEVICES WITH A

RANGER

The Lincoln Electric Company is not responsible for any damage to electrical components improperly connected to the RANGER

305G EFI.

305G EFI

RANGER®305G EFI

A-8

240 Volt

60 Hz.

3-Wire

Service

INSTALLATION

CONNECTION OF RANGER®305G EFI TO PREMISES WIRING

240 VOLT

POWER

COMPANY

METER

DOUBLE POLE DOUBLE THROW SWITCH RATING TO BE THE SAME AS OR GREATER THAN PREMISES SERVICE OVERCURRENT PROTECTION.

120 VOLT

40AMP

240 VOLT

GROUNDED CONDUCTOR

NEUTRAL BUS

GROUND

PREMISES

DISCONNECT AND

OVERCURRENT

PROTECTION

SERVICE

A-8

LOAD

DOUBLE

50 AMP, 120/240

VOLT PLUG

NEMA TYPE 14-50

240 VOLT

50 AMP, 120/240 VOLT

RECEPTACLE

POLE

CIRCUIT

BREAKER

GND

NOTE: No. 6 COPPER CONDUCTOR CABLE SEE

NATIONAL ELECTRICAL CODE FOR ALTERNATE WIRE

SIZE RECOMMENDATIONS.

WARNING

• Only a licensed, certified, trained electrician should install the machine to a premises or residential electrical system. Be certain that:

• The installation complies with the National Electrical Code and all other applicable electrical codes.

• The premises is isolated and no feedback into the utility system can occur. Certain state and local

laws require the premises to be isolated before the Generator is linked to the premises. Check your state and local requirements.

• A double pole, double throw transfer switch in conjunction with the properly rated double throw

circuit breaker is connected between the generator power and the utility meter.

RANGER®305G EFI

A-9

INSTALLATION

A-9

CONNECTION OF LINCOLN ELECTRIC WIRE FEEDERS

Connection of LN-7 or LN-8 to the RANGER®305G EFI

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 by the electrode being used.

4. Set the "MODE" switch to the "CV WIRE " position.

5. Set the "ARC CONTROL" knob to "0" initially and adjust to suit.

6 Set the "WELD TERMINALS" switch to the

"REMOTELY CONTROLLED" position.

7. Set the "IDLE" switch to the "HIGH" position.

Connection of LN-15 to the RANGER

These connections instructions apply to both the LN15 Across The-Arc and Control Cable models. The LN-15 has an internal contactor and the electrode is not energized until the gun trigger is closed. When the gun trigger is closed the wire will begin to feed and the welding process is started.

• Shut the welder off.

• For electrode Positive, connect the electrode cable to the "+" terminal of the welder and work cable to the "-" terminal of the welder. For electrode Negative, connect the electrode cable "-" terminal of the welder and work cable to the "+" terminal of the welder.

• Across The-Arc Model:

Attach the single lead from the front of the LN-15 to work using the spring clip at the end of the lead. This is a control lead to supply current to the wire feeder motor; it does not carry welding current.

Set the "WELD TERMINALS" switch to "WELD TERMINALS ON"

• Control Cable Model:

305G EFI

• Set the "WIRE FEEDER VOLTMETER" switch to

either "+" or "-" as required by the electrode polarity being used.

• Set the "ARC CONTROL" knob to "0" initially and adjust to suit.

• Set the "IDLE" switch to the "AUTO" position.

WARNING

Connection of the LN-25 to the RANGER EFI

• Shut off welder before making any electrical connections.

------------------------------------------------------------------------

The LN-25 with or without an internal contactor may be used with the RANGER

appropriate connection diagram in Section F. NOTE: The LN-25 (K431) Remote Control Module

and (K432) Remote Cable are not recommended for use with the RANGER

1. Shut the welder off.

2. For electrode Positive, connect the electrode cable from the LN-25 to the "+" terminal of the welder and work cable to the "-" terminal of the welder. For electrode Negative, connect the electrode cable from the LN-25 to the "-" terminal of the welder and work cable to the "+" terminal of the welder.

3. Attach the single lead from the front of the LN-25 to work using the spring clip at the end of the lead. This is a control lead to supply current to the wire feeder motor; it does not carry welding current.

4. Set the MODE switch to the "CV-WIRE " position.

5. Set the "WELD TERMINALS" switch to "WELD TERMINALS ON"

6. Set the "ARC CONTROL" knob to "0" initially and adjust to suit.

305G EFI.

305G EFI. See the

305G

Connect Control Cable between Engine Welder and Feeder.

Set the "WELD TERMINALS" switch to "REMOTELY CONTROLLED"

• Set the MODE switch to the "CV-WIRE " position.

RANGER 305G

A-10

7. Set the "IDLE" switch to the "AUTO" position. When not welding, the RANGER

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-

ng circuit will cause the RANGER

i engine to go to the high idle speed, the wire will begin to feed and the welding process started. When welding is stopped, the engine will revert to low idle speed after approximately 12 seconds unless welding is resumed.

INSTALLATION

305G EFI

CAUTION

If you are using an LN-25 without an internal contactor, the electrode will be energized when the

RANGER

------------------------------------------------------------------------

Connection of LN-742,K487-25 Spool Gun, and Cobramatic to RANGER

305G EFI is started.

305G EFI

A-10

1. Shut the welder off.

2. Connect per instructions on the appropriate connection diagram in Section F.

RANGER®305G EFI

B-1

OPERATION

B-1

SAFETY PRECAUTIONS

Read and understand this entire section before operating your RANGER

Do not attempt to use this equipment until you have thoroughly read all operating and maintenance manuals supplied with your machine. They include important safety precautions, detailed engine starting, operating and maintenance instructions and parts lists.

ELECTRIC SHOCK can kill.

•Do not touch electrically live parts such as output terminals or internal wiring.

•Insulate yourself from the work and ground.

•Always wear dry insulating gloves.

------------------------------------------------------------------------

ENGINE EXHAUST can kill.

•Use in open, well ventilated areas or vent exhaust outside

•Do not stack anything near the engine.

------------------------------------------------------------------------

MOVING PARTS can injure.

•Do not operate with doors open or guards off.

305G EFI

DESIGN FEATURES

FOR AUXILIARY POWER:

Start the engine and set the IDLER control switch to the desired operating mode. Full power is available regardless of the welding control settings providing no welding current is being drawn.

The auxiliary power of the RANGER sists of two 20 Amp-120 VAC (5-20R) duplex receptacles and one 50 Amp 120/240 VAC (14-50R) receptacle. The 240 VAC receptacle can be split for single phase 120 VAC operation.

ENGINE OPERATION

Before Starting the Engine:

• Be sure the machine is on a level surface.

• Open top engine door and remove the engine oil dipstick and wipe it with a clean cloth. Reinsert the dipstick and check the level on the dipstick.

• Add oil (if necessary) to bring the level up to the full mark. Do not overfill. Close engine door.

• See Engine Owners Manual for specific oil recommendations.

ADD FUEL

305G EFI con-

•Stop engine before servicing.

•Keep away from moving parts

------------------------------------------------------------------------

• Only qualified personnel should operate this equipment.

ADDITIONAL SAFETY PRECAUTIONS

Always operate the welder with the hinged door closed and the side panels in place as these provide maximum protection from moving parts and insure proper cooling air flow.

GENERAL DESCRIPTION

The RANGER®305G EFI is a gasoline engine powered DC multi-process welding power source and 120 / 240 volt AC power generator. The engine drives a generator that supplies three phase power for the DC welding circuit and single phase power for the AC auxiliary outlets. The DC welding control system uses state of the art Chopper Technology for superior welding performance.

Code 12157 and above meet EPA evaporative emission requirements.

WARNING

GASOLINE can cause fire or explosion.

• Stop engine when fueling.

• Do not smoke when fueling.

• Do not overfill tank.

• Avoid contact with skin or

breathing of vapor.

• Keep sparks and flame away from tank.

------------------------------------------------------------------------

• Remove the fuel tank cap.

• Fill tank until the fuel gauge reads full. DO NOT TOP OFF TANK. Be sure to leave filler neck empty for expansion.

• Replace the fuel cap and tighten securely.

• See Engine Owners Manual for specific fuel recommendations.

FULL

RANGER®305G EFI

B-2

OPERATION

B-2

14 13

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 or 14 pin Amphenol.

2. DIGITAL OUTPUT METERS

The digital meters allow the output voltage (CV-WIRE mode) or current (CC-STICK, DOWN HILL PIPE and TIG modes) to be set prior to welding using the OUTPUT control dial. During welding, the meter display the actual output voltage (VOLTS) and current (AMPS). A memory feature holds the display of both meters on for seven seconds after welding is stopped. This allows the operator to read the actual current and voltage just prior to when welding was ceased. While the display is being held the left-most decimal point in each display will be flashing. The accuracy of the meters is +/- 3%.

3. WELD MODE SELECTOR SWITCH:

(Provides four selectable welding modes)

CV-WIRE DOWN HILL PIPE CC-STICK TOUCH START TIG

RANGER®305G EFI

8 7 6

4. ARC CONTROL:

The ARC CONTROL WIRE/STICK dial is active in the WIRE, STICK and DOWN HILL PIPE modes, and has different functions in these modes. This control is not active in the TIG mode.

CC-STICK mode: In this mode, the ARC CONTROL dial sets the short circuit current (arc-force) during stick welding to adjust for a soft or crisp arc. Increasing the number from -10 (soft) to +10(crisp) increases the short circuit current and prevents sticking of the electrode to the plate while welding. This can also increase spatter. It is recommended that the ARC CONTROL be set to the minimum number without electrode sticking. Start with a setting at

DOWNHILL PIPE MODE: In this mode, the ARC CONTROL dial sets the short circuit current (arc force) during stick welding to adjust for a soft or a more forceful digging arc (crisp). Increasing the number from -10(soft) to +10(crisp) increases the short circuit current which results in a more forceful digging arc. Typically a forceful digging arc is preferred for root and hot passes. A softer arc is preferred for fill and cap passes where weld puddle control and deposition (“stacking” of iron) are key to fast travel speeds. It is recommended that the ARC CONTROL be set initially at 0.

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 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.

OPERATION

12. START PUSH BUTTON

- Energizes the starter motor to crank the engine

13. IDLER SWITCH

- Has two positions as follows:

1) In the HIGH position, the engine runs at the high

2) In the AUTO position, the idler operates as follows:

6. GROUND STUD:

Provides a connection point for connecting the machine case to earth ground for the safest grounding procedure.

7. 14 PIN CONNECTOR:

For attaching wire feeder control cables to the RANGER 305G EFI. Includes contactor closure circuit , auto-sensing remote control circuit, and 120V and 42V power. The remote control circuit operates the same as the 6 Pin Amphenol.

8. 6 PIN CONNECTOR:

For attaching optional remote control equipment. When in the CC-STICK, PIPE, and CV-WIRE modes and when a remote control is connected to the Amphenol, the auto-sens-

ing circuit in the RANGER the OUTPUT control from control at the welder to remote control.

When using the TOUCH START TIG Module connected to the RANGER control on the front of the RANGER

the maximum current range of the CURRENT CONTROL on the TIG Module.

305G EFI automatically switches

mode with a TIG

305G EFI, the OUTPUT

305G EFI is used to set

14. ELECTRIC FUEL GAUGE / HOUR METER

The electric fuel gauge gives accurate and reliable indication as to how much fuel is in the fuel tank. The hour meter displays the total time that the engine has been running. This meter is useful for scheduling prescribed maintenance.

STARTING AND STOPPING THE ENGINE

B-3

idle speed controlled by the engine governor.

• When switched from HIGH to AUTO or after starting the engine, the engine will operate at full speed for approximately 12 seconds and then go to low idle speed.

• When the electrode touches the work or power is drawn for lights or Tools (approximately 100 Watts minimum), the engine accelerates and operates at full speed.

• When welding ceases or the AC power load is turned off, a fixed time delay of approximately 12 seconds starts. If the welding or AC power Load is not restarted before the end of the time delay, the idler reduces the engine speed to low idle speed.

• The engine will automatically return to high idle

speed when there is welding load or AC power load reapplied.

9. WELD TERMINALS CONTROL SWITCH:

In the WELD TERMINALS ON position, the output is electrically hot all the time. In the REMOTELY CONTROLLED position, the output is controlled by a wire feeder or amptrol device, and is electrically off until a remote switch is

depressed.

10. WIRE FEEDER VOLTMETER SWITCH:

Matches the polarity of the wire feeder voltmeter to the polarity of the electrode.

ENGINE CONTROLS:

11. RUN/STOP SWITCH

engine prior to starting. STOP position stops the engine. The oil pressure interlock switch prevents battery drain if the switch is left in the RUN position and the engine is not operating.

- RUN position energizes the

RANGER®305G EFI

• Remove all plugs connected to the AC power receptacles.

• Set IDLER switch to AUTO.

• Set the RUN/STOP switch to RUN.

• Press and hold the engine START button until the

engine starts.

• Release the engine START button when the engine

starts.

• 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.

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