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F-12
DIAGRAMS
F-12
RANGER 305G
NOTE: This diagram is for reference only. It may not be accurate for all machines covered by this manual. The specific diagram for a particular code is pasted inside
the machine on one of the enclosure panels. If the diagram is illegible, write to the Service Department for a replacement. Give the equipment code number..
CONTACTOR
CONTROL
SHOWN IN
"WELDING ON"
POSITION
WIRE FEED POWER
WINDING
42 VAC
+
+
C2
C1
J50
42 VAC
FIELD WINDING
GND. SCREW ON LEFT
INSIDE CASEFRONT
WHITE
211A
D3
ARC CONTROL
10K
ALL CASE FRONT COMPONENTS SHOWN VIEWED FROM REAR.
42
W3
CB7
25A
S1
9
7
W1
STATOR
WELD
WINDINGS
W3
W2
75
R1
76
77
277
278
CCW
OUTPUT CONT. POT
S3
2
GND-G
GND-D
GND-E
300 AMP
MODULE
SHUNT
50MV=400 AMPS
3
NEG. BRUSH
POS.BRUSH
ROTOR
5A
3D
3A
5A
5B
5C
3
6
3E
6F
BLACK
50A
50A
20A
20A
WHITE
BLACK
WHITE
WHITE
BLACK
BLACK
WHITE
BLACK
BLACK
SILVER
SILVER
STATOR AUX. WINDING
CONNECTORS VIEWED FROM INSERTION END
ELECTRICAL SYMBOLS PER E1537
FRAME GND.
5C
3A
3
6B
6
6B
CB1
CB2
CB5
CB6
6B
5B
J101
J102
J100
3E
6E
115/230V
10K
210
210A
212A
9
7
41
206B
206A
200A
200E
201
201A
200B
212
211
209E
209
32
3A
5C
+
HOUR METER224B
5
GND E
5
5E
5H
5G
HEATSINK
208
4
279
BOTTOM GND INSIDE CASEFRONT
PCB 1
D1 - THREE PHASE BRIDGE RECTIFIER
D2 DIODE
MODULE
W4
W5
W6
6
3
6
3
W10
W7
16
8
1
9
5
1
4
8
J1
P2-J2
6
10
P54 - J4
P5 - J5
2
1
P6-J6
3
1
2
4
P7-J7
P10-J10
3
1
2
4
J8
3
1
2
4
P9-J9
1
3
4
6
P11-J11
16
8
1
9
P12-J12
6
1
5
10
P42-J42
9
1
16
P43-J43
3
1
2
4
P41-J41
PCB4 BATTERY PC BOARD
PCB2 ANALOG POWER PC BOARD
PCB3 WELD CONTROL PC BOARD
Programing
Mode
Selection
Meter
Meter
6
1
5
10
Shunt
Output
Control
Hot Start
Pinch/
Arc Force
14 Pin
Ampenol
Thermal
Sense/
Idler/
PWM
204S
206S
75
76
77
279
277
278
77A
76A
75A
208B
251
250
260
215
25
23
222
214
220
218
S6 MODE SELECTOR SWITCH
2A
P34-J34
PCB7 Battery Display
P13-J13
POWER
5F
1
3
4
6
4
2
13
13
14
11
12
115A
118A
101A
105A
105A
115A
101A
116A
IDLE SOLENOID
5F
5G
206S
204S
14
206A
208B
A
4
3
2
1
222
TIG
CC
PIPE
CV
220
218
214
8
228
229
229
228
200
224B
CCW
R2
211
210B
210B
5K
210D
1
4
5
8
261
210D
B7
B3
B2
B1
P50
210C210C
215
116A
118A
PANEL RECEPTACLE CAVITY NUMBERING SEQUENCE
(VIEWED FROM LEAD SIDE OF RECEPTACLE)
9 PIN
J50
123
654
987
321
456
789
9 PIN
P50
987
654
123
11
12
23
25
L1 CHOKE
W9
W8
3
6
261
260
WRAP TWO TURNS #3 &
#6 LEADS IN DIRECTION
SHOWN THROUGH
TOROID
3
6
789
456
321
RANGER 305G WIRING DIAGRAM
1
G3743
1-3-2000C
IDLER CONTROL
SHOWN IN
"AUTO" POSITION
S4
250
251
S2
START
BUTTON
C3
800uf
150vdc
POSITIVE BRUSH CONNECTED
TO SLIP RING NEAREST
TO THE LAMINATION
WHITE
TERM.
5K
5L
5L
L2
L3
TWISTED PAIR
+
+
3
1
2
4
W6
W11
PC BOARD TO
HEAT SINK CONN.
PC BOARD TO
HEAT SINK CONN.
POS
KOHLER ENGINE COMPONENTS
12 VOLT
BATTERY
-
B-
AC
AC
B
+
GND-H
GROUNDING THIS CIRCUIT
STOPS THE ENGINE
IGNITION
MODULE
STARTER
1
2
3
P51
J51
OIL
PRESSURE
SWITCH
V
WHITE
R
ENGINE
GROUND
FRAME
GROUND
FUEL
SHUTOFF
SOLENOID
ENGINE TERMINAL
BLOCK
4
224E
210E
REGULATOR
FLYWHEEL ALTERNATOR
212E
GND J
+
STARTER
CR1
SOLENOID
R
U
225E
211E
224
221
5J
5J
225
NEG
NEG
W11
(LOCATED BELOW
TERMINAL 2)
S1RUN-STOP
SWITCH
(SHOWN IN
RUN POS.)
12
7
6
1
1
2
1
2
3
4
1
3
1
4
6
5
86
10
L2, L3: RF CHOKES
16
9
8
1
CB8
JUMPER
PLUG
P3
4
1
3
6
J3
Machine
Selection
4
1
3
6
GND-B
GND. SCREW ON
CENTER BAFFLE
TOP GND. SCREW ON
INSIDE OF CASE FRONT
GND-L
GND-A
FRAME GND.
GND M
LEAD COLOR CODE:
B=BLACK OR GRAY
R=RED OR PINK
W=WHITE
G=GREEN (W/YELLOW STRIPE)
GND-J
FRAME GND.
GREEN
GREEN
GREEN
CND-C
4
5
1
GND-K
41A
42A
15A
208A
21
S5
VOLTMETER
POLARITY
SWITCH
206A
SHOWN IN
POSITIVE (+)
POSITION
P52 J52
1
2
3
4
5
6
7
8
9
10
211E
212E
211A
5H
212A
210E
221
200E
224E
210
209E
221E
224
5E
225
209
225E
200
221E
210E
224
5H
31
6
1
5
10
AMPS
M1
M2
M3
M1
M2
M3
M4
M9
M5
M10
M10
M9
M6
M5
M4
JUMPER
PLUG
P3
4
1
3
6
J3
4
1
3
6
M6
VOLTS
M1
M2
M3
M10
M9
M6
M5
M4
1
5
1
5
M1
M2
M3
M4
M9
M5
M10
M6
1
5
1
5
M1
M2
M3
M4
M9
M5
M10
1
5
1
5
M1
M2
M3
M4
M5
M10
11
M1
M2
M3
M4
M5
M10
11
M1
M2
M3
M4
M5
M10
1
5
1
5
M1
M2
M3
M4
M9
M5
M10
M6
1
5
1
5
M1
M2
M3
M4
M9
M5
M10
M6
1
5
1
5
M1
M2
M3
M4
M9
M5
M10
1
5
1
5
M1
M2
M3
M4
M9
M5
M10
1
5
1
5
M1
M2
M3
M4
M9
M5
M10
1
5
1
5
M1
M2
M3
M4
M9
M5
M10
1
2
3
4
5
6
7
8
9
10
P4 J54
M1
M2
M3
M4
M5
M6
M9
M10
M1
M2
M3
M4
M5
M6
M9
M10
31
32
GND-B
A
B
C
D
E
F
77B
21
75B
GND-A
41A
42A
76B
115VAC
CONTACTOR
77B
76B
WORK
75B
REMOTE
CONTROL
42VAC
GROUND
AMPHENOL 1
REMOTE
CONTACTOR
GROUND
AMPHENOL 2
CONTROL
J
A
D
C
H
B
K
E
F
G
I
208C
206C
BYPASS
FILTER
ASSEMBLY
GND-K
GND-B
4B
2B
2B
4B
208C
206C
206B
4A
77A
76A
75A
2A
4A