Lincoln Electric IM920 User Manual [en, de, es, fr]

RANGER 305G

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R

IM920

July, 2007

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.

11402, 11423

Cleveland, Ohio 44117-1199 U.S.A. TEL: [phone] FAX: [phone] WEB SITE: www.lincolnelectric.com

OPERATOR’S MANUAL

Copyright © 2007 Lincoln Global Inc.

• World's Leader in Welding and Cutting Products •

• Sales and Service through Subsidiaries and Distributors Worldwide •

i

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.

____________________________________________________

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.

____________________________________________________

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.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.

___________________________________________________

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 ʻ95

ii

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.

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.

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.

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 applicaiton 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
coming from degreasing, cleaning or spraying operations.
The heat and rays of the arc can react with solvent vapors
form phosgene, a highly toxic gas, and other irritating prod­ucts.

vapors

to

3.j. Also see Items 6.c. and 8.

5.d. 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.e. Read and understand the manufacturerʼs instructions for this

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

5.f. Also see item 1.b.

AUG 06

iii

SAFETY

iii

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

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
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.

the welding sparks from starting a fire.

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 manufacturerʼs
recommendations.

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

6.I. Read and folllow 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.

Jan, 07

iv

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 LʼArc

1. Protegez-vous contre la secousse électrique:

a. Les circuits à lʼélectrode 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 sʼisoler 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 lʼeau 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 sʼapplicuent aussi au pistolet de
soudage.

6. Eloigner les matériaux inflammables ou les recouvrir afin de
prévenir tout risque dʼincendie 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 dʼincendie.

8. Sʼassurer que la masse est connectée le plus prés possible
de la zone de travail quʼil est pratique de le faire. Si on place
la masse sur la charpente de la construction ou dʼautres
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 dʼincendie ou dʼechauffement des chaines et des
câbles jusquʼà ce quʼils 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
dʼopérations de dégraissage, nettoyage ou pistolage. La
chaleur ou les rayons de lʼarc 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 nʼimporte quelle partie
du corps.

3. Un coup dʼarc peut être plus sévère quʼun coup de soliel,
donc:

a. Utiliser un bon masque avec un verre filtrant approprié

ainsi quʼun verre blanc afin de se protéger les yeux du ray­onnement de lʼarc et des projections quand on soude ou
quand on regarde lʼarc.

b. Porter des vêtements convenables afin de protéger la

peau de soudeur et des aides contre le rayonnement de
lʻarc.

c. Protéger lʼautre personnel travaillant à proximité au

soudage à lʼaide dʼécrans appropriés et non-inflammables.

4. Des gouttes de laitier en fusion sont émises de lʼarc de
soudage. Se protéger avec des vêtements de protection libres
de lʼhuile, 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
zones où lʼon pique le laitier.

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
lʼélectricité 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, Iʼinstallation et lʼentretien du poste seront
effectués par un électricien qualifié.

3. Avant de faires des travaux à lʼinterieur de poste, la debranch­er à lʼinterrupteur à la boite de fusibles.

4. Garder tous les couvercles et dispositifs de sûreté à leur
place.

Mar. ʻ93

Thank You

vv

for selecting a QUALITY product by Lincoln Electric. We want you
to take pride in operating this Lincoln Electric Company product

••• as much pride as we have in bringing this product to you!

The business of The Lincoln Electric Company is manufacturing and selling high quality welding equipment, consumables, and cutting equip­ment. Our challenge is to meet the needs of our customers and to exceed their expectations. On occasion, purchasers may ask Lincoln
Electric for advice or information about their use of our products. We respond to our customers based on the best information in our posses­sion at that time. Lincoln Electric is not in a position to warrant or guarantee such advice, and assumes no liability, with respect to such infor­mation or advice. We expressly disclaim any warranty of any kind, including any warranty of fitness for any customerʼs particular purpose,
with respect to such information or advice. As a matter of practical consideration, we also cannot assume any responsibility for updating or
correcting any such information or advice once it has been given, nor does the provision of information or advice create, expand or alter any
warranty with respect to the sale of our products.

Lincoln Electric is a responsive manufacturer, but the selection and use of specific products sold by Lincoln Electric is solely within the control
of, and remains the sole responsibility of the customer. Many variables beyond the control of Lincoln Electric affect the results obtained in
applying these types of fabrication methods and service requirements.

Subject to Change – This information is accurate to the best of our knowledge at the time of printing. Please refer to www.lincolnelectric.com
for any updated information.

CUSTOMER ASSISTANCE POLICY

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.

Product _________________________________________________________________________________

Model Number ___________________________________________________________________________

Code Number or Date Code_________________________________________________________________

Serial Number____________________________________________________________________________

Date Purchased___________________________________________________________________________

Where Purchased_________________________________________________________________________

Whenever you request replacement parts or information on this equipment, always supply the information you
have recorded above. The code number is especially important when identifying the correct replacement parts.

On-Line Product Registration

- Register your machine with Lincoln Electric either via fax or over the Internet.

• For faxing: Complete the form on the back of the warranty statement included in the literature packet
accompanying this machine and fax the form per the instructions printed on it.

• For On-Line Registration: Go to our

“Product Registration”. Please complete the form and submit your registration.

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:

WEB SITE at www.lincolnelectric.com. Choose “Quick Links” and then

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.

vi

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

Premises Wiring ...................................................................................................................A-7

Connection of Lincoln Electric Wire Feeders.................................................................A-8,A-9

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

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

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

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

________________________________________________________________________

TABLE OF CONTENTS

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.................................................................................................................P-491

________________________________________________________________________

A-1

INSTALLATION

TECHNICAL SPECIFICATIONS - RANGER 305G (K1726-4, K1726-5)

INPUT - GASOLINE ENGINE

Make/Model Description Speed (RPM) Displacement Starting Capacities

cu. in. (cu. cm.) System

A-1

2 cylinder High Idle 3700 41(674)

(K1726 -4,-5) 23 HP @

Kohler CH23S 3600 RPM Full Load 3500 cold crank amps) 1.9 L

Gasoline
Engine

Low Idle 2400

Bore x Stroke inch (mm)

3.15 x 2.64 (80 x 67) Battery Charger

12VDC Battery &

Starter 45.4 L

(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 ------- 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

10,500 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 Additional electric fuel lift pump

5% Regulation on K1726-5.

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

A-2

INSTALLATION

MACHINE SPECIFICATIONS - RANGER 305G (K1726-4, K1726-5)

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

A-3

INSTALLATION

SAFETY PRECAUTIONS

WARNING

Do not attempt to use this equipment until you
have thoroughly read the engine manufacturerʼs
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.

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

ENGINE EXHAUST can kill.

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

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

MOVING PARTS can 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 operatorʼs 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

• Lift only with equipment of
adequate lifting capacity.

• Be sure machine is stable
when lifting.

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

FALLING • Do not lift machine if lift bale is

EQUIPMENT can damaged.

cause injury. • Do not operate machine while

suspended from lift bale.

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

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. (305m) above 3000 ft.
(914m). If operation will consistently be at altitudes
above 5,000 ft. (1525m), a carburetor jet designed for
high altitudes should be installed. This will result in
better fuel economy, cleaner exhaust and longer
spark plug life. It will not give increased power.
Contact your local authorized engine service shop for
high altitude jet kits that are available from the engine
manufacturer.

CAUTION

Do not operate with a high altitude jet installed at
altitudes below 5000 ft. This will result in the
engine running too lean and result in higher
engine operating temperatures which can shorten
engine life.

-----------------------------------------------------------------------­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, in­plant and yard towing by a vehicle(1) is Lincolnʼs 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:

RANGER 305G

A-4

INSTALLATION

A-4

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.

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

(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 manufactureʼs instructions.

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

PRE-OPERATION ENGINE SERVICE

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

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 Operatorʼs 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 Operatorʼs
Manual for the proper service and maintenance inter­vals.

FUEL

USE GASOLINE FUEL ONLY

• 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(7.6 liters)
of reserve fuel.

NOTE: The fuel tank is mounted below the engine

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

ENGINE COOLING SYSTEM

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

WARNING

• Stop engine while fueling.

GASOLINE

can cause fire
or explosion.

• Do not smoke when fueling.

• Keep sparks and flame away
from tank.

• Do not leave unattended while
fueling.

• Wipe up spilled fuel and allow
fumes to clear before starting
engine.

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

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

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

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.

GASOLINE FUEL ONLY

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

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.

WARNING

so a fuel shutoff valve is not required.

WARNING

CAUTION

RANGER 305G

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.

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 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 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.

REMOTE CONTROL

The RANGER 305G 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 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 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.

A-5

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 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.

RANGER 305G

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. (30-46m 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 10,500 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 is suitable for temporary, standby or
emergency power using the engine manufacturerʼs recom­mended maintenance schedule.

CABLE INSTALLATION

Install the welding cables to your RANGER 305G 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.

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 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 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 cus­tomerʼs 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.)

• Plug this cable into the 50 Amp, 120/240 Volt receptacle
on the RANGER 305G case front.

RANGER 305G

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