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ELECTRICAL DIAGRAMS
G-5
RANGER 250
SCHEMATIC - COMPLETE MACHINE
W3
W2
D1 - THREE PHASE BRIDGE RECTIFIER
D3
C3
800uf
150vdc
ROTOR FIELD
7
201
5H
200
200A
W1
C
E
IGBT MODULE - EMMITTER
IS COMMON TO HEATSINK
L1 CHOKE
D2 DIODE
MODULE
D4
CURRENT LEVEL FEED BACK
SIGNAL TO WELD CONTROL
PC BOARD
CHOPPER
PC BOARD
GATE SIGNAL
PWM SIGNAL FROM
WELD CONTROL
PC BOARD
C2
2400uf
100vdc
C1
2400uf
100vdc
R3
250 OHMS
25 W
ARC VOLTAGE FEEDBACK
3
5
6
GND E
120 V AC
240 V AC
120 V AC
AC
POWER
42 VOLT AC
WIRE FEEDER
POWER
41
42
9
TWO POLE 3600 RPM ALTERNATOR
13
14
105A
115A
101A
116A
118A
80V DC BUS VOLTAGE
R1
OUTPUT
CONTROL 10K
77
76
75
R2
ARC
CONTROL 10K
279
278
277
250
251
IDLER SWITCH
2
4
WELD TERMINALS
SWITCH
MODE
SWITCH
CC
CV
PIPE
TIG
214
218
220
222
260A
261A
TOROID-
SENSES WELD
CURRENT AND
AC POWER TO
ACTIVATE IDLER
IDLER COIL - PULLS TO
LOW IDLE
215
WELD CONTROL
PC BOARD
ANALOG
POWER PC
BOARD
42 VOLT AC
POWER FOR
ROTOR FIELD CIRCUIT
232
233
THERMOSTAT ON
CHOPPER MODULE
NORMALLY CLOSED
230
231
THERMAL
SHUTDOWN
DISPLAY
13 14
12 VOLT
BATTERY
210B
105A
115A
101A
116A
118A
229
228
BATERY CHARGER
TROUBLE LIGHT
DISPLAY
BATTERY
PC BOARD
200
ROTOR
FLASHING
5K
KOHLER
IGNITION
MODULE
BATTERY
CHARGING
MODULE
KOHLER FUEL
SHUTOFF
SOLENOID
ENGINE OIL PRESSURE SWITCH
OPENS ON LOW OIL PRESSURE
HOUR METER
211
225
224B
START BUTTON
SWITCH
RUN-STOP SWITCH
SHOWN IN RUN POS.
25A BATERY
CIRCUIT BREAKER
209
212
221
210C
204S
206S
208B
23
25
210D
210D
5L
5F
23
25
11
12
11
12
20V DC
5V
15V
COM
15V
15V TO GND.
FRAME
GROUND
REMOTE
CONTROL 10K
77A
76A
75A
ENGINE DIODES
ONAN
IGNITION
MODULE
SHUNT
50MV=400 AMPS
206S
204S
CURRENT LEVEL
FEED BACK SIGNAL
POSITIVE
OUTPUT
TERMINAL
NEGATIVE
OUTPUT
TERMINAL
BY-PASS
PC BOARD
206B
208
21
WIREFEEDER
VOLTMETER
POLARITY
SWITCH
206A
208A
ENGINE
STARTER
SOLENOID
ENGINE
STARTER
224
210
+
SLIP RINGS
50 V DC
+
+
10 V
0-10 V
0 V
10 V
-15 V (W/O POT.)
0 V
12 - 14 V
15 Ω
0 - .1V WHEN ON
0 V
15 V
15 V
0 V
L11480
C
G-5
NOTE: This diagram is for reference only. It may not be accurate for all machines covered by this manual.
ENHANCED
WIRING DIAGRAM