F-12
DIAGRAMS
F-12
RANGER 305G
NOTE: This diagram is for reference only. It may not be accurate for all machines covered by this manual. The specific diagram for a particular code is pasted inside
the machine on one of the enclosure panels. If the diagram is illegible, write to the Service Department for a replacement. Give the equipment code number..
CONTACTOR
CONTROL
SHOWN IN
"WELDING ON"
POSITION
WIRE FEED POWER
WINDING
42 VAC
+
+
C2
C1
J50
42 VAC
FIELD WINDING
GND. SCREW ON LEFT
INSIDE CASEFRONT
WHITE
211A
D3ARC CONTROL
10K
ALL CASE FRONT COMPONENTS SHOWN VIEWED FROM REAR.
42
W3
CB7
25A
S1
9
7
W1
STATOR
WELD
WINDINGS
W3
W2
75
R1
76
77
277
278
CCW
OUTPUT CONT. POT
S3
2
GND-G
GND-D
GND-E
300 AMP
MODULE
SHUNT
50MV=400 AMPS
3
NEG. BRUSH
POS.BRUSH
ROTOR
5A
3D 3A
5A
5B
5C
3
6
3E
6F
BLACK
50A
50A
20A
20A
WHITE
BLACK
WHITE WHITE
BLACK
BLACK
WHITE
BLACK
BLACK
SILVER
SILVER
STATOR AUX. WINDING
CONNECTORS VIEWED FROM INSERTION END
ELECTRICAL SYMBOLS PER E1537
FRAME GND.
5C
3A3
6B
6
6B
CB1
CB2
CB5
CB6
6B
5B
J101
J102
J100
3E
6E
115/230V
10K
210
210A
212A
9
7
41
206B
206A
200A
200E
201
201A
200B
212
211
209E
209
32
3A
5C
+HOUR METER224B
5
GND E
5
5E
5H
5G
HEATSINK
208
4
279
BOTTOM GND INSIDE CASEFRONT
PCB 1D1 - THREE PHASE BRIDGE RECTIFIERD2 DIODEMODULEW4W5W66
3
6
3
W10W716
8
1
9
5
14
8
J1P2-J2610
P54 - J4P5 - J52
1
P6-J63
12
4
P7-J7P10-J103
12
4
J83
12
4
P9-J913
46
P11-J1116
8
1
9
P12-J126
15
10
P42-J429
1
16
P43-J433
12
4
P41-J41PCB4 BATTERY PC BOARDPCB2 ANALOG POWER PC BOARDPCB3 WELD CONTROL PC BOARDProgramingModeSelectionMeterMeter6
15
10
ShuntOutputControlHot StartPinch/Arc Force14 PinAmpenolThermalSense/Idler/PWM204S
206S
75
76
77
279
277
278
77A
76A
75A
208B
251
250
260
215
25
23
222
214
220
218
S6 MODE SELECTOR SWITCH
2A
P34-J34PCB7 Battery DisplayP13-J13POWER5F
13
46
4
2
13
13
14
11
12
115A
118A101A
105A
105A
115A
101A
116A
IDLE SOLENOID
5F
5G
206S204S
14
206A
208B
A
4
3
2
1
222
TIG
CC
PIPE
CV
220
218
214
8
228
229
229
228
200
224B
CCW
R2
211
210B
210B
5K
210D
14
58
261
210D
B7
B3
B2
B1
P50
210C210C
215
116A
118A
PANEL RECEPTACLE CAVITY NUMBERING SEQUENCE(VIEWED FROM LEAD SIDE OF RECEPTACLE)9 PIN
J50
123
654
987
321
456
789
9 PIN
P50
987
654
123
11
12
23
25
L1 CHOKE
W9W83
6
261260
WRAP TWO TURNS #3 &
#6 LEADS IN DIRECTION
SHOWN THROUGH
TOROID
3
6
789
456
321
RANGER 305G WIRING DIAGRAM
1G37431-3-2000CIDLER CONTROL
SHOWN IN
"AUTO" POSITION
S4 250
251
S2
START
BUTTON
C3
800uf
150vdc
POSITIVE BRUSH CONNECTEDTO SLIP RING NEARESTTO THE LAMINATIONWHITETERM.5K
5L
5L
L2L3TWISTED PAIR
+
+
3
12
4
W6W11PC BOARD TO
HEAT SINK CONN.
PC BOARD TO
HEAT SINK CONN.
POS
KOHLER ENGINE COMPONENTS12 VOLT
BATTERY
-
B-
AC AC
B
+
GND-H
GROUNDING THIS CIRCUIT
STOPS THE ENGINE
IGNITION
MODULE
STARTER
123P51J51OILPRESSURESWITCHVWHITE RENGINE
GROUNDFRAME GROUNDFUEL
SHUTOFF
SOLENOID
ENGINE TERMINALBLOCK 4224E
210E REGULATOR
FLYWHEEL ALTERNATOR
212E
GND J
+STARTER
CR1
SOLENOID
RU225E
211E
224
221
5J
5J
225
NEG
NEG
W11(LOCATED BELOW
TERMINAL 2)
S1RUN-STOP
SWITCH
(SHOWN IN
RUN POS.)
12761
1
21234131
46586 10L2, L3: RF CHOKES16981
CB8
JUMPER
PLUG
P34
13
6
J3MachineSelection4
13
6
GND-B
GND. SCREW ON
CENTER BAFFLE
TOP GND. SCREW ONINSIDE OF CASE FRONTGND-L
GND-A
FRAME GND.
GND M
LEAD COLOR CODE:
B=BLACK OR GRAY
R=RED OR PINK
W=WHITE
G=GREEN (W/YELLOW STRIPE)
GND-J
FRAME GND.
GREEN
GREEN
GREEN
CND-C
451
GND-K
41A
42A
15A
208A
21
S5
VOLTMETER
POLARITY
SWITCH
206A
SHOWN IN
POSITIVE (+)
POSITION
P52 J521
2
3
4
5
6
7
8
9
10
211E212E211A5H212A210E221200E224E210209E221E2245E225209225E200221E210E224
5H
31
6
15
10
AMPSM1
M2
M3
M1
M2
M3
M4
M9 M5
M10
M10
M9
M6
M5
M4
JUMPER
PLUG
P34
13
6
J34
13
6
M6
VOLTSM1
M2
M3
M10
M9
M6
M5
M4
15
15
M1
M2
M3
M4
M9 M5
M10
M6
15
15
M1
M2
M3
M4
M9 M5
M10
15
15
M1
M2
M3
M4
M5
M10
11
M1
M2
M3
M4
M5
M10
11
M1
M2
M3
M4
M5
M10
15
15
M1
M2
M3
M4
M9 M5
M10
M6
15
15
M1
M2
M3
M4
M9 M5
M10
M6
15
15
M1
M2
M3
M4
M9 M5
M10
15
15
M1
M2
M3
M4
M9 M5
M10
15
15
M1
M2
M3
M4
M9 M5
M10
15
15
M1
M2
M3
M4
M9 M5
M10
1
2
3
4
5
6
7
8
9
10
P4 J54
M1
M2
M3
M4
M5
M6
M9
M10
M1
M2
M3
M4
M5
M6
M9
M10
31
32
GND-BABCDEF77B21
75B
GND-A
41A
42A
76B
115VAC
CONTACTOR
77B76BWORK
75BREMOTE
CONTROL
42VAC
GROUND
AMPHENOL 1REMOTE
CONTACTOR
GROUND
AMPHENOL 2CONTROL
JADCHBKEFGI208C
206C
BYPASS
FILTER
ASSEMBLY
GND-K
GND-B4B2B2B4B208C
206C
206B
4A
77A76A75A2A4A