Lincoln Electric IM742-A User Manual

RANGER 305
G
IM742-A
RETURN TO MAIN MENU
For use with machines having Code Numbers:
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.
10855,10955
G
August, 2002
Date of Purchase: Serial Number: Code Number: Model: Where Purchased:
Cleveland, Ohio 44117-1199 U.S.A. TEL: 216.481.8100 FAX: 216.486.1751 WEB SITE: www.lincolnelectric.com
OPERATOR’S MANUAL
Copyright © 2002 Lincoln Global Inc.
• World's Leader in Welding and Cutting Products •
• Sales and Service through Subsidiaries and Distributors Worldwide •
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SAFETY
i
WARNING
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 Above For Diesel Engines
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.
The engine exhaust from this product contains chemicals known to the State of California to cause cancer, birth defects, or other reproductive harm.
The Above For Gasoline Engines
FOR ENGINE powered equipment.
1.a. Turn the engine off before troubleshooting and maintenance work unless the maintenance work requires it to be running.
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1.b. Operate engines in open, well-ventilated areas or vent the engine exhaust fumes outdoors.
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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.
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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.
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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.
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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.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
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.
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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.
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.
Mar ‘95
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SAFETY
ii
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.
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 below Threshold Limit Values (TLV) 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.
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 between the 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.
3.j. Also see Items 6.c. and 8.
5.b.
Do not weld in locations near chlorinated hydrocarbon 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 outher irritating pro­ducts.
5.c. Shielding gases used for arc welding can displace air and cause injury or death. Always use enough ventilation, especially in confined areas, to insure breathing air is safe.
5.d. 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.e. Also see item 1.b.
vapors
Mar ‘95
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SAFETY
iii
WELDING 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.
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 been “cleaned”. For information, purchase “Recommended Safe Practices for the 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.
Sparks and spatter are thrown from the welding arc. Wear oil
6.f. 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.
Remember that welding sparks and hot
though
they have
Preparation
for Welding and Cutting of
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.
8.c. Ground the equipment in accordance with the U.S. National Electrical Code and the manufacturer’s recommendations.
Mar ‘95
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SAFETY
iv
PRÉCAUTIONS 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 suiv­antes:
Sûreté Pour Soudage A L’Arc
1. Protegez-vous contre la secousse électrique:
a. Les circuits à l’électrode et à la piéce sont sous tension
quand la machine à souder est en marche. Eviter toujours tout contact entre les parties sous tension et la peau nue ou les vétements mouillés. Porter des gants secs et sans trous pour isoler les mains.
b. Faire trés attention de bien s’isoler de la masse quand on
soude dans des endroits humides, ou sur un plancher metallique ou des grilles metalliques, principalement dans les positions assis ou couché pour lesquelles une grande partie du corps peut être en contact avec la masse.
c. Maintenir le porte-électrode, la pince de masse, le câble
de soudage et la machine à souder en bon et sûr état defonctionnement.
d.Ne jamais plonger le porte-électrode dans l’eau pour le
refroidir.
e. Ne jamais toucher simultanément les parties sous tension
des porte-électrodes connectés à deux machines à souder parce que la tension entre les deux pinces peut être le total de la tension à vide des deux machines.
f. Si on utilise la machine à souder comme une source de
courant pour soudage semi-automatique, ces precautions pour le porte-électrode s’applicuent aussi au pistolet de soudage.
zones où l’on pique le laitier.
6. Eloigner les matériaux inflammables ou les recouvrir afin de prévenir tout risque d’incendie dû aux étincelles.
7. Quand on ne soude pas, poser la pince à une endroit isolé de la masse. Un court-circuit accidental peut provoquer un échauffement et un risque d’incendie.
8. S’assurer que la masse est connectée le plus prés possible de la zone de travail qu’il est pratique de le faire. Si on place la masse sur la charpente de la construction ou d’autres endroits éloignés de la zone de travail, on augmente le risque de voir passer le courant de soudage par les chaines de lev­age, câbles de grue, ou autres circuits. Cela peut provoquer des risques d’incendie ou d’echauffement des chaines et des câbles jusqu’à ce qu’ils se rompent.
9. Assurer une ventilation suffisante dans la zone de soudage. Ceci est particuliérement important pour le soudage de tôles galvanisées plombées, ou cadmiées ou tout autre métal qui produit des fumeés toxiques.
10. Ne pas souder en présence de vapeurs de chlore provenant d’opérations de dégraissage, nettoyage ou pistolage. La chaleur ou les rayons de l’arc peuvent réagir avec les vapeurs du solvant pour produire du phosgéne (gas fortement toxique) ou autres produits irritants.
11. Pour obtenir de plus amples renseignements sur la sûreté, voir le code “Code for safety in welding and cutting” CSA Standard W 117.2-1974.
2. Dans le cas de travail au dessus du niveau du sol, se protéger contre les chutes dans le cas ou on recoit un choc. Ne jamais enrouler le câble-électrode autour de n’importe quelle partie du corps.
3. Un coup d’arc peut être plus sévère qu’un coup de soliel, donc:
a. Utiliser un bon masque avec un verre filtrant approprié
ainsi qu’un verre blanc afin de se protéger les yeux du ray­onnement de l’arc et des projections quand on soude ou quand on regarde l’arc.
b. Porter des vêtements convenables afin de protéger la
peau de soudeur et des aides contre le rayonnement de l‘arc.
c. Protéger l’autre personnel travaillant à proximité au
soudage à l’aide d’écrans appropriés et non-inflammables.
4. Des gouttes de laitier en fusion sont émises de l’arc de soudage. Se protéger avec des vêtements de protection libres de l’huile, tels que les gants en cuir, chemise épaisse, pan­talons sans revers, et chaussures montantes.
5. Toujours porter des lunettes de sécurité dans la zone de soudage. Utiliser des lunettes avec écrans lateraux dans les
PRÉCAUTIONS DE SÛRETÉ POUR LES MACHINES À SOUDER À TRANSFORMATEUR ET À REDRESSEUR
1. Relier à la terre le chassis du poste conformement au code de l’électricité et aux recommendations du fabricant. Le dispositif de montage ou la piece à souder doit être branché à une bonne mise à la terre.
2. Autant que possible, I’installation et l’entretien du poste seront effectués par un électricien qualifié.
3. Avant de faires des travaux à l’interieur de poste, la debranch­er à l’interrupteur à la boite de fusibles.
4. Garder tous les couvercles et dispositifs de sûreté à leur place.
Mar. ‘93
for selecting a QUALITY product by Lincoln Electric. We want you
Thank You
to take pride in operating this Lincoln Electric Company product
••• 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 is received.
Please record your equipment identification information below for future reference. This information can be found on your machine nameplate.
Model Name & Number _____________________________________
Code & Serial Number _____________________________________
Date of Purchase _____________________________________
Whenever you request replacement parts for or information on this equipment always supply the information you have recorded above.
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Read this Operators Manual completely before attempting to use this equipment. Save this manual and keep it
handy for quick reference. Pay particular attention to the safety instructions we have provided for your protection. The level of seriousness to be applied to each is explained below:
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.
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
Pre-Operation Engine Service..............................................................................................A-4
Oil..................................................................................................................................A-4
Fuel ...............................................................................................................................A-4
Engine Coolant..............................................................................................................A-4
Battery Connections......................................................................................................A-4
Muffler Outlet Pipe ........................................................................................................A-4
Spark Arrester ...............................................................................................................A-4
High Frequency Generators for Tig Applications ..........................................................A-4
Remote Control .............................................................................................................A-4
Electrical Connections..........................................................................................................A-5
Machine Grounding.......................................................................................................A-5
Welding Terminals ........................................................................................................A-5
Welding Output Cables .................................................................................................A-5
Cable Installation...........................................................................................................A-5
Auxiliary Power Receptacles and Plugs...............................................................................A-6
Standby Power Connections ................................................................................................A-6
Premises Wiring ...................................................................................................................A-7
Connection of Lincoln Electric Wire Feeders .......................................................................A-8
vi
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
DC Stick Welding ..........................................................................................................B-4
Constant Current (Stick) Welding..................................................................................B-4
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 PowerLoads........................................................B-6
Extension Cord Recommendations...............................................................................B-6
Auxiliary Power .............................................................................................................B-6
Simultaneous Welding and Auxiliary Power Loads.......................................................B-6
Accessories.....................................................................................................Section C
Options / Accessories and Compatible Lincoln Equipment.................................................C-1
vii
TABLE OF CONTENTS
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
Engine 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 Print ......................................................................Section F
Parts List..................................................................................................................P384
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
A-1
Kohler CH22 Starter 45.4 L
(K1726-1) 22 HP @
2 cylinder High Idle 3700 41(674)
Bore x Stroke inch (mm)
3600 RPM Full Load 3500 cold crank amps) 1.9 L
3.03 x 2.85 (77 x 72) Battery Charger
12VDC Battery &
(Group 58; 435 Oil: 2.0 Qts
Fuel: 12 gal.
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 ------- 80 Volts 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
10,000 Watts Peak, 9500 Watts Continuous, 60 Hz
120/240 Volts
1
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 Mechanical Governor with Full Flow Filter 5% Regulation
AIR CLEANER ENGINE IDLER MUFFLER ENGINE PROTECTION
Low noise Muffler: Top outlet Shutdown on low oil
Duel 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
A-2
INSTALLATION
MACHINE SPECIFICATIONS - Ranger 305G (K1726-1)
RECEPTACLES AUXILIARY POWER CIRCUIT BREAKER OTHER CIRCUIT BREAKERS
A-2
(2) 120VAC Duplex (5-20R) Two 20AMP for Two Duplex Recptacle (1) 120/240VAC Dual Voltage Two 50AMP for Dual Voltage
Full KVA (14-50R)
25AMP for Battery Charging Circuit 15AMP for 42V Wire Feeder Power
RANGER 305G
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.
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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.
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ENGINE EXHAUST can kill.
• Use in open, well ventilated areas or vent exhaust outside.
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MOVING PARTS can injure.
• Do not operate with doors open or guards off.
• Stop engine before servicing.
• Keep away from moving parts.
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See additional warning information at
front of this operator’s manual.
Only qualified personnel should install, use, or service this equipment.
LOCATION AND VENTILATION
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 305G machines cannot be stacked.
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.
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 PRECAUTIONS
WARNING
FALLING EQUIPMENT can cause injury.
• Do not lift this machine using lift bale if it is equipped with a heavy accessory such as trailer or gas cylinder.
• Lift only with equipment of ade­quate lifting capacity.
Be sure machine is stable when lifting.
-----------------------------------------------------------------------­HIGH ALTITUDE OPERATION
At higher altitudes, output de-rating may be necessary. For maximum rating, de-rate the welder output 3.5% for every 1000 ft. (305m). Contact an authorized engine service shop for modi­fications to operate above 5,000 ft. (1525m).
HIGH TEMPERATURE OPERATION
At temperatures above 40°C, output de-rating is necessary. For maximum output ratings, de-rate the welder output 2 volts for every 10°C above 40°C.
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 weld-
ing 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.
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.
(1)
RANGER 305G
A-4
INSTALLATION
A-4
PRE-OPERATION ENGINE SERVICE
WARNING
READ the engine operating and maintenance instruc­tions supplied with this machine.
• Stop engine and allow to cool before fueling
• Do not smoke when fueling
• Fill fuel tank at a moderate rate and do not over­fill.
• Wipe up spilled fuel and allow fumes to clear before starting engine
• Keep sparks and flame away from tank.
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OIL
The RANGER 305G 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.
FUEL
USE GASOLINE FUEL ONLY
WARNING
• Fill the fuel tank with clean, fresh fuel. The capacity of the fuel tank is 12 gallons (45.4 liters). When the fuel gauge reads empty the tank contains approximately 2 gallons of reserve fuel.
NOTE: The fuel tank is mounted below the engine
so a fuel shutoff valve is not required.
------------------------------------------------------------------------
ENGINE COOLING SYSTEM
WARNING
The RANGER 305G is shipped with the negative bat­tery cable disconnected. Make certain that the RUN­STOP 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.
NOTE: This machine is furnished with a wet charged battery; if unused for several months, the battery may require a booster charge. Be careful to charge the bat­tery with the correct polarity.
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.
SPARK 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 S24647 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 APPLICATIONS
The K930-2 TIG Module is suitable for use with the RANGER 305G. The RANGER 305G and any high frequency generating equipment must be properly grounded. See the K930-2 Operating Manual for com­pleted instructions on installation, operation, and maintenance.
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 (0.6m) 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.
------------------------------------------------------------------------
RANGER 305G
REMOTE CONTROL
The RANGER 305G is equipped with a 6 pin and a 14 pin Amphenol 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 K812 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 automatically switches the OUTPUT control from control at the welder to remote control.
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 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.
INSTALLATION
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
A-5
WELDING TERMINALS
The RANGER 305G 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.
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. (0-30meters)
Cable Size for
305 Amps
100% Duty Cycle
1 / 0 AWG
• 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 securely connected to the metal 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.
100-150 Ft. (30-46m meters)
150-200 Ft. (46-61 meters)
CABLE INSTALLATION
Install the welding cables to your RANGER 305G as follows.
1. The gasoline 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.
2 / 0 AWG
3 / 0 AWG
RANGER 305G
A-6
INSTALLATION
CAUTION
• Loose connections will cause the output termi­nals 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 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 auxiliary power capacity is 10,000 watts Peak, 9500 Watts Continuous of 60 Hz, single phase power. The auxiliary power capacity rating in watts is equiva­lent to volt-amperes 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.
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.
A-6
STANDBY POWER CONNECTIONS
The RANGER 305G is suitable for temporary, standby or emergency power using the engine manufacturer’s recommended maintenance schedule.
The RANGER 305G can be permanently installed as a 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 305G by installing a 40 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 305G engine and/or alternator windings.
• 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.)
NOTE: The 240 V receptacle has two 120 V circuits, but are of opposite polarities and cannot be paralleled.
RANGER 305G
• Plug this cable into the 50 Amp, 120/240 Volt recep­tacle on the RANGER 305G case front.
A-7
240 Volt
60 Hz.
3-Wire
Service
INSTALLATION
CONNECTION OF RANGER 305G 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
120 VOLT
40AMP
240 VOLT
GROUNDED CONDUCTOR
NEUTRAL BUS
GROUND
A-7
N
PREMISES
DISCONNECT AND
SERVICE
OVERCURRENT
PROTECTION
LOAD
DOUBLE
50 AMP, 120/240
VOLT PLUG
NEMA TYPE 14-50
240 VOLT
50 AMP, 120/240 VOLT
RECEPTACLE
POLE
CIRCUIT
BREAKER
GND
N
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
A-8
INSTALLATION
A-8
CONNECTION OF LINCOLN ELECTRIC WIRE FEEDERS
Connection of the LN-25 to the RANGER 305G
WARNING
Shut off welder before making any electrical con­nections.
------------------------------------------------------------------------
The LN-25 with or without an external contactor may be used with the RANGER 305G. See the 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 305G.
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.
7. Set the "IDLE" switch to the "AUTO" position. When not welding, the RANGER 305G 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 sens­ing circuit will cause the RANGER 305G 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.
CAUTION
If you are using an LN-25 without an internal con­tactor, the electrode will be energized when the Ranger 305G is started.
-----------------------------------------------------------------------­Connection of LN-7 or LN-8 to the RANGER 305G
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 an LN-23P Wire Feeder to the RANGER 305G
1. Shut the welder off.
2. Connect the LN-23P as per instructions on the appropriate connection diagram in Section F. (NOTE): When connecting an LN-23P to the RANGER 305G, a K350-1 adapter kit must be used.
3. Set the "VOLTMETER" switch to "-".
4. Set the "MODE" switch to "CV WIRE " position.
5. Set the "WELD TERMINALS" switch to "REMOTELY CONTROLLED".
6. Set the "ARC CONTROL" knob to "0" initially and adjust to suit.
7. Set the "IDLE" switch to the "AUTO" position. When not welding, the RANGER 305G engine will be at the low idle speed. If you are using an LN­23P with the K350-1 adapter kit, the electrode is not energized until the gun trigger is closed. When the gun trigger is closed, the current sens­ing circuit will cause the RANGER 305G engine to go to the high idle speed, the wire will begin to feed and the welding process can be started. When welding is stopped, the engine will revert to low idle speed after approximately 12 seconds unless welding is resumed.
Connection of LN-742, Spool Gun, and Cobramatic to RANGER 305G
1. Shut the welder off.
2. Connect per instructions on the appropriate con­nection diagram in Section F.
RANGER 305G
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