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ELECTRICAL DIAGRAMS
G-9
SCHEMATIC - ENTIRE MACHINE - CODE 11095 & 11253 ONLY - (L12257)
EN-168
L12257
RANGER 10,000 HONDA
MACHINE SCHEMATIC
NONE
L12249
BAM
BAM
-
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:
L12257
MATERIAL
DI SPOSI TI ON:
APPROVAL
DATE:
PROJECT
NUMBER:
UF
CRM33675
PAGE ___ OF ___
1
ENGINEERING CONTROLLED
MANUFACTURER:
No
DOCUMENT
NUMBER:
DOCUMENT
REVI SI ON:
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:
A
8/20/03
RELEASED A.01 FROM "X"
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)
TOROI D: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)
41TO 45 VAC
12 VOLT
BATTERY
FUEL
SHUTOFF
SOLENOID
ENGINE OIL
PRESSURE
SWI TCH
OPENS ON
LOW OIL
PRESSURE
HOUR
METER
224 (J1-9)
CB7 25A
209A
W
5E (J1-2)
FRAME
GROUND
ELECTRODE
TERMINAL
WOR K
TERMINAL
ENGINE
STARTER
SOLENOID
ENGINE
STARTER
B/Y
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.
PCBoard
located on rear
offan
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.
74 TO 78 VAC BETWEEN W1
AND W2 AT HIGH IDLE AND
MAXI MUM RHEOSTAT NO LOAD.
Rectifier mounted on top of choke and
AC reactor in front of generator..
RE SI S TANCE
APPROX. 5 OHMS @ 75F
Open Circuit Volts:
AC
Max
Mi n
76 38
68
34
32
18
DC
CV
Torroid Core located on
wiring behind receptacles.
Battery voltage:
12.6 volts at rest
14 volts engine running
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.
Fuel solenoid is mounted
on engine carburetor.
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
WE L D
WIND IN GS
AC tapped reactor mounted
on base in front of generator.
S1 - SELECTOR SWITCH
210DC/225AC
145
90
CV
REVOLVI NG
FIELDS
+
-
BRUSHES
B/Y
211
224A
254
2TURNS
2TURNS
CB1
40A
CB2
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 (0.1V PER AMP)
+
-
+
-
REVERSE VOLTAGE
PROTECTION DIODE
47.5
47.5
68.1K
HYSTERESIS SWITCH
FEEDBACK AMP
STATOR
EXCITATION
WIND IN GS
SUPPRESSOR FOR
D1 RECTIFIER
12 to 14 volts
across coil when
energized
44 TO 45
VAC
BETWEEN
GY LEADS
AT HIGH
IDLE
EXCITATIONWINDING
VOLTS MEASURED AT
MAX RHEOSTAT HIGH
IDLE NO LOAD
1
T
U
R
N
213A
GY
GY
W
CHARGE COIL
20 AMP
MODULE
RECTI FIER/ REGULATOR
6
5
4
2
3
1
-
+
D9
B
B/Y = BLACK/YELLOW
B=BLACK
GY = GRAY
W=WH ITE
LE
ADCOLOR CODE:
B/Y
225A
211B
D9 located on rear
of fan baffle onright
side of machine.
D9 BYPASSES
OIL PRESSURE
SWI TCH DURING
START
W
W/U
NOCONNECTION
B/R = BLACK/RED
W/U = WHITE/ BLUE
B/R
NOCONNECTION
6
3
5
IGNITION
MODULE
LEADS 3 AND 6 PASS
THROUGH TORROID
TWO TIMES IN
OPPOSITE DIRECTIONS
(OVER-CURRENT PROTECTED)
(OVER-CURRENT PROTECTED)
G-9
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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