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ELECTRICAL DIAGRAMS
RANGER 305D
SCHEMATIC - ENTIRE MACHINE - CODE 11121 (L12212) PAGE 1 OF 2
EN -168
S
O
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ID
E
D
G
E
L12212
RANGER 305D
MACHINE SCHEMATIC
NONE
L11946
DEO
BAM
-
UNLESS OTHERW ISE SPEC IF IED TOLERAN CE
MANUFAC TURIN G TOLERANCE PER E205 6
ON 2 PLAC E DECIMA LS IS ± .02
ON 3 PLACE DECIMALS IS ± .002
ON ALL ANG LES IS ± .5 OF A DEGREE
WITH PUB LISHED S TANDARDS.
MA TERIA L TOL ERANCE (" ") TO AGREE
t
DO NOT SCALE THIS DRAWING
DRAWN BY:
DESIGN INFORMATION
ENGINEER:
APPRO VED:
REFERENCE:
EQUIPMENT TYPE:
SUBJECT:
SCALE:
MATERIAL
DISPOSITION:
APPROVAL
DATE:
PROJECT
NUMBER:
UF
CRM35573
1
PA GE ___ O F ___
2
ENGINEERING CONTROLLED
MANUFACTURER:
No
DOCUMENT
NUMBER:
DOCUMENT
REVISION:
THIS D O CUME NT C O NTAINS PR OP RIETARY INF ORMATION OW NE D BY LINC OLN GLOBAL, INC. A ND MAY N OT BE D UPLICATE D, COMMU NICATE D
TO OT HE R PARTIES O R USE D FO R ANY PU RP OSE WIT HOUT T HE EX PRESS W RITTE N PE RMISSION OF LIN COLN GLOBAL, INC.
PROPRIETARY & CONFIDENTIAL:
A
12/11/2003
RELEASED "A.02" FROM "X"
CHANGE DETAIL:
L12212
W3
W2
D1 - THREE PHASE BRIDGE RECTIFIER
D
3
C3
800uf
150vdc
7
201
5H
200
200A
W1
C
E
L1 CHOKE
CHOPPER PC BOARD
GATE SIGNAL
ARC VOLTAGE FEEDBACK SIGNAL
3
5
6
GND E
120 V AC
240 V AC
120 V AC
TO AUX.
OUTLETS
AND
AMPHENOLS
(VIA CIRCUIT
BREAKERS)
42 VOLT AC
WIRE FEEDER
POWER
41
42
9
TWO POLE 3600 RPM ALTERNATOR
DC BUS VOLTAGE
90+/-10VDC @ HI IDLE
R1
OUTPUT
CONTROL 10K
77 (J7-1)
76 (J7-4)
75 (J7-5)
R2
ARC
CONTROL 10K
279 (J7-6)
278 (J7-7)
277 (J7-8)
(J3-14) 252
(J3-7) 251
IDLER SWITCH
(J1-4) 2
(J1-3) 4
WELD TERM. SW.
MODE
SWITCH
CC
CV
PIPE
TIG
(J7-9) 214
(J7-14) 218
(J7-15) 220
(J7-16) 222
260A (J3-4)
261A (J3-3)
TOROID-
SENSES AC
POWER TO
ACTIVATE
IDLER
WELD CONTROL
PC BOARD
42 VOLT AC
POWER FOR
ROTOR FIELD CIRCUIT
12 VOLT
BATTERY
(J2-7) 210B
(J2-5) 215
(J2-4) 404
(J2-1) 200N
ELECTRIC
FUEL
PUMP
OILPRESSURE
SWITCH
(CLOSES ON
LOW OIL
PRESSURE)
HOUR METER
(J2-9) 224B
GLOWPLUG
SWITCH S7
RUN-STOP SWITCH
(SHOWN IN RUN)
15A BATTERY
CIRCUIT BREAKER
209
212
204S (J6-1)
206S (J6-2)
208B (J3-15)
23 (J3-10)
25 (J3-9)
5K (J2-3)
FRAME
GROUND
REMOTE
CONTROL 10K
77A (J1-11)
76A (J1-14)
75A (J1-10)
SH UNT
50MV= 400 AMPS
206S
204S
WELD CURRENT
FEED BACK SIGNAL
POSITIVE
OUTPUT
TERMINAL
NEGATIVE
OUTPUT
TERMINAL
BY-PASS
PC BOARD
208C
208
21
WIREFEEDER
VOLTMETER
POLARITY
SWITCH
206A
208A
STARTER
SOLENOID
STARTER
MOTOR
224
210
+
SLIP RINGS
50 V DC
+
+
10 V
0-10 V
0 V
10 V
-15 V (W/O POT.)
0 V
0 V
15 V
15 V
0 V
IGBT (8)
TWISTED
PAIR
(TO AMPHENOL)
(TO AMPHENOL)
2A
4A
(TO AMPHENOL)
206C
206B
31
32
41A
A
B
C
D
E
F
77A
21
42A
75A
GND-A
4A
2A
76A
77B
76B
75B
REMOTE
GROUND
AMPHENOL
CONTROL
INPUT TO
AMPHENOL
115VAC
CONTACTOR
WORK
REMOTE
CONTROL
42VAC
GROUND
AMPHENOL
J
A
D
C
H
B
K
E
F
G
I
77B
76B
75B
GND-B
4B
2B
4B
2B
+12 to 14V @ RUN (INPUT)
B7
B8
B6
B3
B5
B2
B4
B1
+COM
-INPUT
-OUTPUT
+12 to 14V @ NORMAL OIL PRES. (INPUT)
R3 25 OHM
13 (J3-8)
14 (J3-16)
(J1-7) 305
(J1-12) 305
305 I.D. JUMPER (Part
of amphenol plug and
lead assembly.)
ALTERNATOR
IGN
L
BAT
FUEL
SOLENOID
PULL
HOLD
BLACK
WHITE
RED
START BUTTON
SWITCH S2
GLOWPLUGS
YELLOW
ENGINE
PROTECTION
LIGHT
CR1
9
B
A
3
COOLANT
TEMPERATURE
SWITCH
(CLOSES ON HIGH
TEMPERATURE
ABOVE 230F)
IDLE
SOLENOID
PULL
HOLD
BLACK
WHITE
RED
404 (J43-8)
PULL COIL
PC BOARD
B2
B1
B4
+15V @ LOW IDLE TO PULL COIL BOARD
LOW IDLE SOLENOID HOLD COIL (0V @ LOW IDLE)
60 TO 65 VAC PHASE TO PHASE
BETWEEN W1, W2 AND W3
AT HIGH IDLE
210
210
229
225
223
211
209
209
231
215
232
D4
TWISTED
PAIR
REVOLVING FIELD
FIELD RESISTANCE
APPROX. 5 OHMS @ 75F
ENGINE
PROTECTION
RELAY
GLOWPLUG SWITCH ENERGIZES
ELECTRIC FUEL PUMP AND FUEL
SOLENOID HOLD COIL THRU D4. IT
ALSO FUNCTIONS AS AN ENGINE
PROTECTION BYPASS UNTIL OIL
PRESSURE BUILDS UP.
IF COOLANT TEMP SWITCH OR OIL PRESSURE SWITCH
CLOSE, CR1 ENERGIZES OPENING CONTACTS AND
SHUTTING OFF FUEL SOLENOID TO STOP ENGINE.
FUEL SOLENOID PULL
COIL IS ENERGIZED BY
STARTER SOLENOID.
TWISTED
PAIR
FLYBACK
DIODES (6)
FILTER
CAPACITORS (4)
+
IGBT'S, FLYBACK DIODES AND
FILTER CAPACITORS ARE INTEGRAL
TOCHOPPER MODULE AND NOT
INDIVIDUALLY REPLACEABLE.
ROTOR FLASHING
R4
50 OHM
100 W
10,000uF x4
Shunt onback of positive
output terminal
Choke is beneath bearing end
of generator on support.
Rectifier mounted to generator support
above output choke.
Located on front of fan
baffle near top of
machine.
R3 located on front of fan baffle
on left side near bottom of
machine
R4 islocated on front of
fan baffle near top of
machine
C3 and D3 located onrear of fan baffle
on left side of machine.
Relay CR1 and D4 located on fron
baffle on right side of machine.
Located next to
control board.
P/N G4107-1
Located on wiring behind
receptacles.
Open Circuit Volts:
CC
Max
Min
58 58
58
58
58
26
12
12
CV
Pipe
Tig
Located on back of
output panel
between terminals
Control board common is
at welder positive output
and shunt
Control board circuits associated with J2 are part
of engine electrical system and are common to
frame ground (negative battery terminal.
Rotor Flashing: +12 volts
@ 0.5 amps
until generator builds up
then +50 volts @ 0 amps.
Swich closed for high
idle.
Battery voltage:
12.6 volts at rest
14 volts engine
running
PL
1
P/N
L11768-1
TIMER
CIRCUIT
+15V @ LOW
IDLE
FUEL
SOLENOID
AND FUEL
PUMP
ENERGIZED
FOR RUN
S1
0.2 OHM
11 OHMS
0.2 OHM
11 OHMS
WELD AMMETER
WELD VOLTMETER
(J4-1 to 10) (J5-1 to 10)
Meters display setpoint volts or amps when not welding.
Meters display actual volts and amps when welding.
Hold function displays actual volts and ampsfor
approximately 5 seconds after welding stops.
During this hold display the right most decimal point will
blink.
Power Supply
to Control
Board
PWM Signal to Chopper
15 volt @ 20 kHz
p/n
L11845-1
FUEL SENDER
2 TURNS
THRU
FERRITE
L4
2 TURNS THRU FERRITE
L3
2 TURNS
THRU FERRITE
L5
2 TURNS
THRU
FERRITE
2 TURNS THRU
FERRITE
L2
L6
240-265 OHMS EMPTY
20-35 OHMS FULL
FUEL
GAUGE
1
4
L8 L7
J73-3
P73-3
J74
P74
P74
J74
P73-2
J73-2
J73-4
P73-4
J72-3
P72-3
P72-4
J72-4 J72-2
P72-2
Control Board senses Weld Output
from Current Feedback Shunt
to activate idler.
Chopper is mounted on the back side of fan
baffle near top of machine. Requires added
baffle for cooling air flow.
All leads
1 time thru
ferrite
All leads
1 time thru
ferrite
IDLE SOLENOID
ENERGIZED FOR
LOW IDLE
NOTE: This diagram is for reference only. It may not be accurate for all machines covered by this manual.
G-13 G-13