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ELECTRICAL DIAGRAMS
G-8
SCHEMATIC - ENTIRE MACHINE - CDE 11394 - (L13103)
EN-168
L13103
RANGER 10,000 PLUS (KOHLER)
MACHINE SCHEMATIC
NONE
L12249-1
MAP
DJS
-
UNLESS OTHERWISE SPECIFIED TOLERANCE
MANUFACTURING TOLERANCE PER E2056
ON 2 PLACE DECIMALS IS ± .02
ON 3 PLACE DECIMALS IS ± .002
ON ALL ANGLES IS ± .5 OF A DEGREE
WITH PUBLISHED STANDARDS.
MATERIAL TOLERANCE (" ") TO AGREE
t
DO NOT SCALE THIS DRAWING
DRAWN BY:
DESIGN INFORMATION
ENGINEER:
APPROVED:
REFERENCE:
EQUIPMENT TYPE:
SUBJECT:
SCALE:
L13103
MATERIAL
DISPOSITION:
APPROVAL
DATE:
PROJECT
NUMBER:
UF
CRM38313-B
PAGE ___ OF ___
1
ENGINEERING CONTROLLED
MANUFACTURER:
No
DOCUMENT
NUMBER:
DOCUMENT
REVISION:
THIS DOCUMENT CONTAINS PROPRIETARY INFORMATION OWNED BY LINCOLN GLOBAL, INC. AND MAY NOT BE DUPLICATED, COMMUNICATED
TO OTHER PARTIES OR USED FOR ANY PURPOSE WITHOUT THE EXPRESS WRITTEN PERMISSION OF LINCOLN GLOBAL, INC.
PROPRIETARY & CONFIDENTIAL:
B
4/12/2007
REVISED EQUIPMENT TYPE.
CHANGE DETAIL:
1
S
O
L
ID
E
D
G
E
STRP
W2
D1 - BRIDGE RECTIFIER
7
219 200A
W1
L1 CHOKE
3
5
6
GND E
120 V AC
240 V AC
120 V AC
STATOR AUXILIARY
POWER WINDINGS
9
TWO POLE 3600
RPM ALTERNATOR
R1
OUTPUT
CONTROL
10K
77A (J1-1)
76A (J1-8)
75A (J1-7)
260
(J2-4)
261
(J2-3)
TOROID: SENSES
WELD OR AC
POWER LOAD TO
ACTIVATE IDLER
IDLE SOLENOID COIL
-ENERGIZED FOR
LOW IDLE.
215 (J1-3)
FIELD & IDLE CONTROL
PC BOARD (L12198-1)
41 TO 45 VAC
12 VOLT
BATTERY
BATTERY
CHARGING
ALT/REG
FUEL
SHUTOFF
SOLENOID
ENGINE OIL
PRESSURE
SWITCH
OPENS ON
LOW OIL
PRESSURE
HOUR
METER
224 (J1-9)
CB7 25A
209A
208
5E (J1-2)
FRAME
GROUND
ENGINE DIODES
ELECTRODE
TERMINAL
WORK
TERMINAL
ENGINE
STARTER
SOLENOID
ENGINE
STARTER
224C
210
+
SLIP RINGS
10 TO 50 VDC AT
1.7 TO 6.8 AMPS
+
5.64 V
1.28 V
15 Ohms
213A (J2-1)
+14V @ NORMAL OIL PRES.
PC Board
located on rear
of fan
baffle near top
of machine.
Control board common is
one diode drop above
welder frame ground.
Choke mounted on base in
front of generator.
Rotor Flashing: 2.5
volts @ 0.5 amps.
until generator build-up.
74TO 78 VAC BETWEEN W1
AND W2 AT HIGH IDLE AND
MAXIMUM RHEOSTAT NO LOAD.
Rectifier mounted on top of choke and
AC reactor in front of generator..
RESISTANCE
APPROX. 5 OHMS @ 75F
Open Circuit Volts:
AC
Max
Min
7638
68
34
32
18
DC
CV
Torroid Core located on
wiring behind receptacles.
Battery voltage:
12.6 volts at rest
14 volts engine running
J51-2
J51-3
J51-4
Resistance of fuel
solenoid cannot be
accurately
measured through
diodes.
J51 - Engine
Connector
If engine oil pressure drops below safe
operating pressure, the oil pressure
switch opens removing 12 volts from
circuit 224 shutting off fuel solenoid to
stop engine. Hourmeter will also stop
running and PCB1 will denergize idle
solenoid.
224C
Fuel solenoid is mounted
on engine carburetor.
Engine diodes
are in engine
wire harness.
C1
33 TO 37 VAC BETWEEN W1
AND C1 AT HIGH IDLE AND
MAXIMUM RHEOSTAT NO LOAD.
S1
R1
R3
R5
S2
E
S2
POLARITY
SWITCH
DC+
AC
DC-
DC-
DC+
AC
AC TAPPED REACTOR
STATOR
WELD
WINDINGS
AC tapped reactor mounted
on base in front of generator.
S1 - SELECTOR SWITCH
210DC/225AC
145
90
CV
REVOLVING
FIELDS
+
-
BRUSHES
U
RR
GND
B+
AC
AC
211
224A
254
2 TURNS
2 TURNS
CB1
40A
CB4
20A
CB3
20A
6A
3A
J4
12
11
GND-G
6B
3B
GND-D
GND-C
J2
J3
5L
5K
10 (J1-6)
8 (J1-12)
7
9
219
(J1-5)
200A
(J1-11)
OFF
S3
AUTO IDLE (2)
HIGH IDLE (3)
START (4)
208C
213
Idle solenoid is
located on top of
generator stator
assembly
+14V IN AUTO IDLE / OV IN HIGH IDLE
+BAT (1)
+14V RUN
12
3
CONNECTOR PIN NUMBERS:
7
6
12
12
34
J1J2
1
4
2
3
S3 OPERATION
OFF
AUTO
HIGH
START
1
2
3
4
X
X
X
XX
XX
X
X= CLOSED CIRCUIT
.05
5K
130V
38J
LOAD
SENSOR
+10V
+
-
IDLE TIMER
20
FIELD
FLASHING
CIRCUIT
+10V
+10 VOLT
REGULATOR
CIRCUIT
(12 SEC.)
+10V
IDLE SOLENOID
COIL
SWITCHING
TRANSISTOR
FLYBACK
DIODE
LEVEL
CHANGING
AND DRIVER
CIRCUIT
FLYBACK
DIODE
0.1
FIELD
CURRENT
FEEDBACK
RESISTOR
FIELD CURRENT
SWITCHING
TRANSISTOR
+
4700uF
80VDC
FIELD CURRENT FEEDBACK
+
-
+
-
REVERSE VOLTAGE
PROTECTION DIODE
47.5
47.5
68.1K
HYSTERESIS SWITCH
FEEDBACK AMP
STATOR
EXCITATION
WINDINGS
SUPPRESSOR FOR
D1 RECTIFIER
12 to 14 volts
across coil when
energized
44 TO 45 VAC
BETWEEN AC
TERMINALS
AT HIGH IDLE
EXCITATION WINDING
VOLTS MEASURED AT
MAX RHEOSTAT HIGH
IDLE NO LOAD
J51-1
NO CONNECTION
IGNITION
MODULE
6
3
5
1
T
U
R
N
LEADS 3 AND 6 PASS
THROUGH TORROID
TWO TIMES IN
OPPOSITE DIRECTIONS
(OVER-CURRENT PROTECTED)
(OVER-CURRENT PROTECTED)
G-8
NOTE: This diagram is for reference only. It may not be accurate for all machines covered by this manual.
RANGER® 10,000 & RANGER® 10,000 PLUS
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