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ELECTRICAL DIAGRAMS
G-3
RANGER 250
WIRING DIAGRAM - RANGER 250 ONAN
CONTACTOR
CONTROL
SHOWN IN
"WELDING ON"
POSITION
WIRE FEED POWER
WINDING
42 VAC
+
+
C2
C1
25 watts
250 ohms
J50
42 VAC
FIELD WINDING
CENTER GND. SCREW ON
INSIDE OF CASE FRONT
WHITE
211A
D3
ARC CONTROL
10K
ALL CASE FRONT COMPONENTS SHOWN VIEWED FROM REAR.
31
15A
CB8
42A
42
W3
CB7
GND-B
42A
25A
GND-A
21
S1
41A
9
7
W1
STATOR
WELD
WINDINGS
W3
W2
75
R1
76
77
277
278
CCW
OUTPUT CONT. POT
S3
2
GND-G
CND-C
GND-D
GND-E
300 AMP
MODULE
SHUNT
50MV=400 AMPS
3
AMPHENOL 1
75B
77B
76B
2B
4B
32
NEG. BRUSH
POS.BRUSH
ROTOR
5A
3D
3A
5A
5B
5C
3
6
3E
6F
BLACK
35A
35A
20A
20A
WHITE
BLACK
WHITE
WHITE
BLACK
GREEN
GREEN
GREEN
GREEN
BLACK
WHITE
BLACK
BLACK
SILVER
SILVER
STATOR AUX. WINDING
CONNECTORS VIEWED FROM INSERTION END
ELECTRICAL SYMBOLS PER E1537
FRAME GND.
5C
FRAME GND.
3A
3
6B
6
6B
CB1
CB2
CB5
CB6
6B
5B
B
K
I
G
F
E
H
C
D
A
J
GROUND
42VAC
REMOTE
CONTROL
WORK
CONTACTOR
115AC
J101
J102
J100
3E
6E
115/230V
10K
STARTER
GND-H
FRAME
GROUND
FLYWHEEL ALTERNATOR
B+
AC
AC
B-
REGULATOR
1
23
4
P51
J51
CAPACITOR
S1RUN-STOP
SWITCH
(SHOWN IN
RUN POS.)
224
210
212 A
210A
212A
9
7
41
206B
206A
200A
200
201
201A
200B
212
211
209
209
32
3A
5C
+
HOUR METER
224B
5
GND-E
5
5H
5H
5G
GND-J
HEATSINK
208A
208
21
S5
VOLTMETER
POLARITY
SWITCH
4
279
41A
GND. SCREW ON
CENTER BAFFLE
BOTTOM GND. SCREW ON
INSIDE OF CASE FRONT
PCB 1
D1 - THREE PHASE BRIDGE RECTIFIER
D2 DIODE
MODULE
W4
W5
W6
R3
6
3
6
3
W10
W7
16
8
1
9
5
1
4
8
J1
P2-J2
6
1
5
10
J4
J5
2
1
P6-J6
3
1
2
4
P7-J7
P10-J10
3
12
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
260A
215
25
23
222
214
220
218
S6 MODE SELECTOR SWITCH
2A
4A
P34-J34
PCB7 Battery Display
P33-J33
PCB6 Thermal Display
P13-J13
POWER
5F
1
3
4
6
4
2
13
252
253
13
14
11
12
115A
118A
101A
105A
105A
115A
101A
116A
IDLE SOLENOID
5F
5G
206S
204S
14
GND-J
TS1
206A
208B
SHOWN IN
POSITIVE (+)
POSITION
C1
4
3
2
1
222
TIG
CC
PIPE
CV
220
218
214
8
228
229
229
228
200
224B
CCW
R2
212 A
224A
210
211
230
231
230
231
232
233
233
232
210B
210B
5K
210D
1
4
5
8
261A
210D
12
7
6
1
+
B7
B3
B2
B1
P50
210C210C
215
116A
118A
GND-A
4C
GND-B
2C
AMPHENOL 2
75C
77C
76C
F
E
D
C
B
A
GROUND
CONTACTOR
CONTROL
REMOTE
PANEL RECEPTACLE CAVITY NUMBERING SEQUENCE
(VIEWED FROM LEAD SIDE OF RECEPTACLE)
9 PIN
J50
123
654
987
321
456
789
9 PIN
J50
987
654
123
11
12
23
25
L1 CHOKE
1
2
1
2
3
4
1
3
1
5
14
4
6
5
86
10
LEAD COLOR CODE:
B=BLACK OR GRAY
R=RED OR PINK
W=WHITE
G=GREEN (W/YELLOW STRIPE)
W9
W8
3
6
261
WRAP TWO TURNS #3 &
#6 LEADS IN DIRECTION
SHOWN THROUGH
TOROID
3
6
789
456
321
RANGER 250 ONAN - WIRING DIAGRAM
4-14-2000
G3675
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
12 VOLT
BATTERY
ENGINE
GROUND
ENGINE
TERMINAL BLOCK
OIL
PRESSURE
SWITCH
ONAN ENGINE COMPONENTS
IGNITION
CONTROL
TO
SPARK
PLUGS
CR1
STARTER
SOLENOID
WHITE
TERM.
TOP GND. SCREW ON
INSIDE OF CASE FRONT
31
5K
GND-K
GND-L
5L
5L
GND-M
L2
L3
TWISTED PAIR
TWISTED PAIR
+
+
D4
3
1
2
4
3
1
2
4
W6
W11
NEG
PC BOARD TO
HEAT SINK CONN.
PC BOARD TO
HEAT SINK CONN.
POS
260
260A
261A
L2, L3: RF CHOKES
NEG
W11
(LOCATED BELOW
TERMINAL 1)
JUMPER
PLUG
P3
P61
J61
BYPASS
PC BOARD
206B
208
2A
4A
2B
4B
2C
4C
75A
75B
75C
76A
76B
76C
77A
77B
77C
P60
J60
P62
J62
GND-K
16
9
8
1
5
8
4
1
12
7
6
1
6
4
3
1
4
1
3
6
J3
Machine
Selection
4
1
3
6
G-3
NOTE: This diagram is for reference only. It may not be accurate for all machines covered by this manual. The wiring diagram specific to your code is pasted inside one of the enclosure panels of your machine.