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ELECTRICAL DIAGRAMS
G-4
RANGER 250
CONTROL INTER-CONNECTION DIAGRAM
PCB3
WELD CONTROL
PC BOARD
J1
J3
J6
J4
J11
J2
J5
J10
J7
J13
J12
J9
J8
115A 1J13 to 5J42 -15 VOLT POWER
101A 2J13 to 7J42 CIRCUIT GROUND
105A 3J13 to 2J42 - 5 VOLT POWER
116A 4J13 to 9J42 - 5 VOLT POWER
118A 5J13 to 10J42 +15 VOLTS MEA. TO CASE GND.
5F 7J13 to CASE FRONT GND. SCREW CASE GND.
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
PCB4
BATTERY
PC BOARD
PCB2
ANALOG POWER
PC BOARD
PCB5
BY-PASS
PC BOARD
1
77 1J7 to R1 OUTPUT CONTROL
76 2J7 to R1 OUTPUT CONTROL
75 3J6 to R1 OUTPUT CONTROL
75A 2J62 to 3J10 - 10K REMOTE
75B 3J62 to 14 PIN AMPHENOL PIN G
76A 4J62 to 2J10 - 10K REMOTE
77A 5J62 to 1J10 - 10K REMOTE
2 5J10 to WELD TERM. SWITCH
214 1J2 to MODE SWITCH - TERM.1 CV
218 6J2 to MODE SWITCH - TERM. 2 PIPE
220 7J2 to MODE SWITCH - TERM. 4 TIG
222 8J2 to MODE SWITCH - CENTER C1
231 1J11 to 2J33 THERMAL DISPLAY INDICATOR
233 4J11 to THERMOSTAT ON HEAT SINK
232 5J11 to THERMOSTAT ON HEAT SINK
230 6J11 to 1J33 THERMAL DISPLAY INDICATOR
277 1J9 to R2 ARC CONTROL - 10K
278 2J9 to R2 ARC CONTROL - 10K
279 3J9 to R2 ARC CONTROL - 10K
261A 9J12 to CURRENT SENSING TOROID
210D 14J12 to 12J43
215 15J12 to IDLE SOLENOID
208B 16J12 to NEG. OUTPUT STUD
25 1J12 to PIN 7 of P50 CHOPPER PWM SIGNAL
23 2J12 to PIN 9 of P50 CHOPPER PWM SIGNAL
251 7J12 to S4 IDLER CONTROL SWITCH
250 8J12 to S4 IDLER CONTROL SWITCH
260A 10J12 to CURRENT SENSING TOROID
204S 1J6 to SHUNT POS. - W10 SIDE
206S 2J6 to SHUNT NEG. - OUTPUT STUD SIDE
J60
J61
J62
206B 3J60 to POS. OUTPUT STUD
GND-K 5J60 to GND. SCREW
208 8J60 to NEG. OUTPUT STUD
2A 1J61 to WELD TERM. SWITCH
2B 2J61 to 14 PIN AMPHENOL PIN C
2C 3J61 to 6 PIN AMPHENOL PIN D
77B 6J62 to 14 PIN AMPHENOL PIN E
J50 - CONNECTS TO
PCB1 300 AMP
CHOPPER MODULE
75C 8J62 to 6 PIN AMPHENOL PIN C
76B 9J62 to 14 PIN AMPHENOL PIN F
76C 10J62 to 6 PIN AMPHENOL PIN B
77C 12J62 to 6 PIN AMPHENOL PIN A
4A 4J61 to WELD TERM. SWITCH
4B 5J61 to 14 PIN AMPHENOL PIN D
4C 6J61 to 6 PIN AMPHENOL PIN E
J42
J41
14 2J41 to NEG TERMINAL ON C2 - 85V SUPPLY
13 1J41 to POS TERMINAL ON C2 - 85V SUPPLY
77A 1J10 to 5J62 - 10K REMOTE
76A 2J10 to 4J62 - 10K REMOTE
75A 3J10 to 2J62 - 10K REMOTE
4 4J10 to WELD TERM. SWITCH
11 1J42 toPIN 3 of P50
105A 2J42 to3J13
5L 4J42 to GND. SCREW
115A 5J42 to 1J13
12 6J42 to PIN 1 of P50
101A 7J42 to 2J13
116A 9J42 to 4J13
118A 10J42 to 5J13
C1
C2
J43
224B 7J43 to HOUR METER
200 11J43 to POSITIVE BRUSH HOLDER
201D 1J43 to 14J12
211 2J43 to S2 START SWITCH
229 4J43 to 2J34 BATTERY DISPLAY PC BOARD
210B 5J43 to S2 START SWITCH
5K 9J43 to GROUND SCREW
228 6J43 to 1J34 BATTERY DISPLAY PC BOARD
+
GOLD
SILVER
GOLD
SILVER
HOUR METER
RUN STOP
SWITCH - S1
START BUTTON SWITCH - S2
IDLER SWITCH - S4
OUTPUT CONTROL
212
210A
210
211
211A
210A
210B
210C
J34
1
228
229
PCB7
BATTERY
DISPLAY
J33
230
231
PCB6
THERMAL
DISPLAY
WIRE FEEDER
VOLTMETER
SWITCH - S5
WELD TERMINALS
(CONTACTOR) SWITCH - S3
208A
21
206A
4A
4
2
2A
250
251
224
224B
5G
CASE FRONT - REAR VIEW
FRONT VIEW OF AMPHENOLS
NEGATIVE OUTPUT STUD
POSITIVE OUTPUT STID
204S
206S
SHUNT
5C
3E
GND C
6F
J100
120/240 V AC
GND G
5A
3D
GND D
5B
6E
3
3A
3E
6
6B
6F
CB5
CB6
3A
3D, 32
6B
6E
CB2
CB1
CB7
42A
CB8
42
209
212A
212
BLOWER BAFLE - SIDE OPPOSITE BLOWER
R1
10K
R2
10K
J102
J101
5J
13
79
P50 - LEAD END VIEW
25
23
TWISTED PAIR - PWM SIGNAL
12 V DC MEASURED WITH
CONNECTOR UNPLUGGED
POS
NEG
12
11
POS
NEG
CHOPPER POWER SUPPLY
20 V DC MEASURED WITH
CONNECTOR UNPLUGGED
77 76
75
277 276
275
208
208A
208B
206A
206B
2
3
4
5
7
8
9
10
11
12
1
6
TYPICAL MOLEX
CONNECTOR
50 AMP
50 AMP
20 AMP
20 AMP
15 AMP
25 AMP
GND K
GND L
GND E
GND M
RANGER 250 CONTROL INTER-CONNECTION DIAGRAM
5L
5K
5G
5F
5H
31
5
5A
5B
5C
GND L
GND J
GND G
GND D
GND C
GND B
GND A
REMOTE
OUTPUT CONTROL
REMOTE
CONTACTOR
CONTROL
TRANSIENT PROTECTION
AND HIGH FREQ BYPASS
ON OUTPUT TERMINALS
POWER INPUTS
FROM ANALOG POWER PC BOARD
OUTPUT
CONTROL
ARC
CONTROL
CURRENT LEVEL
FEEDBACK - TWISTED PAIR
MODE
SELECTION
THERMAL
PROTECTION
REMOTE INPUTS
CHOPPER
PWM SIGNAL - TWISTED PAIR
IDLER CONTROL
AC POWER SENSE FOR IDLER
OUTPUT TO IDLER SOLENOID, PULLS TO LOW IDLE
ARC VOLTAGE FEEDBACK
IDLER CLAMPING DIODE CIRCUIT
ROTOR FLASHING
ENERGIZES FUEL SOLENOID WHEN STARTING ENGINE
14V SUPPLY VOLTAGE FROM BATTERY
TO BATTERY CHARGER TROUBLE LIGHT
TO BATTERY CHARGER TROUBLE LIGHT
BATTERY VOLTAGE FROM OIL PRESSURE SWITCH FOR FLASHING CIRCUIT
GROUND TO FRAME
IDLER CLAMPING DIODE CIRCUIT
P3 JUMPER PLUG, PINS 1 AND 5
ARE JUMPERED TOGETHER
CHOPPER POWER SUPPLY, 20V
CHOPPER POWER SUPPLY, 20V
WELD BOARD POWER SUPPLY, +5V TO CIRCUIT GROUND
CIRCUIT GROUND
FRAME GROUND
WELD BOARD POWER SUPPLY, +15V TO CIRCUIT GROUND
WELD BOARD POWER SUPPLY, +15V TO CASE GROUND
WELD BOARD POWER SUPPLY, +5V TO CIRCUIT GROUNDWELD BOARD POWER SUPPLY, +5V TO CIRCUIT GROUNDWELD BOARD POWER SUPPLY, +5V TO CIRCUIT GROUND
WELD BOARD POWER SUPPLY, -15V TO CIRCUIT GROUND
CONTROL CIRCUIT
INPUT POWER
KEY
ARC CONTROL
WELD MODE SWITCH - S6
1
2
3
4
C1
222
214
218
220
POS. 1 CV-WIRE
POS. 2 PIPE
POS. 3 CC-STICK
POS. 4 TOUCH START TIG
G3817
1
AMPHENOL 2
KEY
F
E
D
C
B
A
AMPHENOL 1
N
M
L
K
J
I
H
G
F
E
D
C
B
A
KEY
CONTACTOR
CONTROL
REMOTE
CONTROL
KEY
F
E
D
C
B
A
GROUND
CONTACTOR
CONTROL
21 -WORK SENSE
GROUND
REMOTE
CONTROL
N
M
L
K
J
I
H
G
F
E
D
C
B
A
KEY
42 V AC FOR WIRE FEDER
120 V AC FOR WIRE FEDER
1
9
7
3
212 1J43 to ENGINE CONNECTOR BLOCK
ENERGIZES KOHLER FUEL SOLENOID
221 (KOHLER ONLY)
5J (KOHLER ONLY)
1
2
3
4
ENGINE CONECTOR BLOCK
ONAN P216 ENGINE
1
2
3
4
1
2
3
4
1
2
3
4
ENGINE CONECTOR BLOCK
KOHLER CH20 ENGINE
ENGINE SIDE
LEAD ENTRY VIEW
WELDER HARNESS SIDE
LEAD ENTRY VIEW
ENGINE SIDE
LEAD ENTRY VIEW
WELDER HARNESS SIDE
LEAD ENTRY VIEW
TO OIL
PRESSURE
SWITCH
BATTERY
CHARGER
IGNITION
CIRCUIT +12V
224A
224 (TO HOUR
METER POS.)
210 (TO
RUN-STOP
SWITCH)
212A (TOBATTERY
CHARGER CIRCUIT
BREAKER)
TO FUEL
SHUTOFF
SOLENOID
IGNITION GROUND
TO STOP ENGINE
BATTERY
CHARGER
225 (TO BATTERY
PC BOARD)
221A (TO START
BUTTON SWITCH)
221 (TO
RUN-STOP
SWITCH)
212A (TO BATTERY
CHARGER CIRCUIT
BREAKER)
G-4
NOTE: This diagram is for reference only. It may not be accurate for all machines covered by this manual.