TOC
TOC
G-4 ELECTRICAL DIAGRAMSG-4
CONTROL INTER-CONNECTION DIAGRAM
RANGER 250 CONTROL INT
Return to Section
Return to Master
212 1J43 to ENGINE CONNECTOR BLOCK | ENERGIZES KOHLER FUEL SOLENOID | |
211 2J43 to S2 START SWITCH | ||
ENERGIZES FUEL SOLENOID WHEN STARTING ENGINE | ||
229 4J43 to 2J34 BATTERY DISPLAY PC BOARD | ||
TO BATTERY CHARGER TROUBLE LIGHT | ||
210B 5J43 to S2 START SWITCH | ||
14V SUPPLY VOLT AGE FROM BATTERY | ||
228 6J43 to 1J34 BATTERY DISPLAY PC BOARD | ||
TO BATTERY CHARGER TROUBLE LIGHT | ||
224B 7J43 to HOUR METER | ||
BATTERY VOLT AGE FROM OIL PRESSURE SWITCH FOR FLASHING CIRCUIT | ||
5K 9J43 to GROUND SCREW | ||
GROUND TO FRAME | ||
200 11J43 to POSITIVE BRUSH HOLDER | ||
ROTOR FLASHING | ||
201D 1J43 to 14J12 | ||
IDLER CLAMPING DIODE CIRCUIT | ||
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1 | 1 | 1 |
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25 1J12 to PIN 7 of P50 CHOPPER PWM SIGNAL | CHOPPER | |||
23 2J12 to PIN 9 of P50 CHOPPER PWM SIGNAL | ||||
PWM SIGNAL - TWISTED PAIR | ||||
251 7J12 to S4 IDLER CONTROL SWITCH |
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250 8J12 to S4 IDLER CONTROL SWITCH |
| IDLER CONTROL | ||
261A 9J12 to CURRENT SENSING TOROID |
| AC POWER SENSE FOR IDLER | ||
260A 10J12 to CURRENT SENSING TOROID |
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210D 14J12 to 12J43 |
| IDLER CLAMPING DIODE CIRCUIT | ||
215 15J12 to IDLE SOLENOID |
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| OUTPUT TO IDLER SOLENOID, PULLS TO LOW IDLE | |||
208B 16J12 to NEG. OUTPUT STUD |
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| ARC VOLTAGE FEEDBACK | |||
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| 277 1J9 to R2 ARC CONTROL - 10K | ARC |
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| 278 2J9 to R2 ARC CONTROL - 10K |
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| 279 3J9 to R2 ARC CONTROL - 10K | CONTROL | ||
P3 JUMPER PLUG, PINS 1 AND 5
ARE JUMPERED T OGETHER
Section TOC
Master TOC
| PCB4 |
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| J1 | J3 | J6 | 1 |
| BATTERY |
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| PC BOARD | 1 | J8 |
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| J43 | J50 - CONNECTS TO |
| J9 | PCB3 |
| J4 |
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1 | PCB1 300 AMP | 1 | WELD CONTROL |
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| CHOPPER MODULE |
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| PC BOARD |
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C1 |
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| J5 |
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204S 1J6 to SHUNT POS. - W10 SIDE
206S 2J6 to SHUNT NEG. - OUTPUT STUD SIDE
2141J2 to MODE SWITCH - TERM.1 CV
218 6J2 to MODE SWITCH - TERM. 2 PIPE 220 7J2 to MODE SWITCH - TERM. 4 TI G
222 8J2 to MODE SWITCH - CENTER C1 
CURRENT LEVEL
FEEDBACK - TWISTED PAIR
2311J11 to 2J33 THERMAL DISPLAY INDICATOR
2334J11 to THERMOSTAT ON HEAT SINK
2325J11 to THERMOSTAT ON HEAT SINK
230 6J11 to 1J33 THERMAL DISPLAY INDICATOR
MODE
SELECTION
THERMAL PROTECTION
| START BUTTON SWITCH - S2 | RUN STOP |
| HOUR METER |
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IDLER SWITCH - S4 | SWITCH - S1 | PCB7 |
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| 221 (KOHLER ONLY) |
| BATTERY | + |
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| 5J (KOHLER ONLY) | 212 | J34 |
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250 | 210A | 211 | 210 210A |
| 224 | 224B | 5G | 5J |
211A |
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| 210B | 1 | 230 |
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| THERMAL |
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| 210C |
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| OUTPUT CONTROL |
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| R1 |
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| 10K |
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Section TOC
Return to
Master TOC
C2
CONTROL CIRCUIT | 13 1J41 to POS TERMINAL ON C2 - 85V SUPPLY | ||
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14 2J41 to NEG TERMINAL ON C2 - 85V SUPPLY |
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INPUT POWER |
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PCB2
1ANALOG POWER
J41 PC BOARD
1
J42
J13 | J7 J10 |
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| 77A 1J10 to 5J62 - 10K REMOTE |
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| 76A 2J10 to 4J62 - 10K REMOTE |
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| 77 1J7 to R1 OUTPUT CONTROL |
| 75A 3J10 to 2J62 - 10K REMOTE | REMOTE INPUTS | |
| 1 |
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| 76 2J7 to R1 OUTPUT CONTROL | OUTPUT | 4 4J10 to WELD TERM. SWITCH |
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| 75 3J6 to R1 OUTPUT CONTROL | CONTROL | 2 5J10 to WELD TERM. SWITCH |
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| 115A 1J13 to 5J42 |
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| 101A 2J13 to 7J42 CIRCUIT GROUND | POWER INPUTS | ||
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| 105A 3J13 to 2J42 - 5 VOLT POWER | |||
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| 116A 4J13 to 9J42 - 5 VOLT POWER | FROM ANALOG POWER PC BOARD | ||
| PCB5 | 118A 5J13 to 10J42 +15 VOLT S MEA. T O CASE GND. |
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| 5F 7J13 to CASE FRONT GND. SCREW CASE GND. |
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| J60 | 206B 3J60 to POS. OUTPUT STUD |
| TRANSIENT PROTECTION |
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| AND HIGH FREQ BYPASS |
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| 1 | 208 8J60 to NEG. OUTPUT STUD |
| ON OUTPUT TERMINALS |
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| 2A 1J61 to WELD TERM. SWITCH |
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| 2B 2J61 to 14 PIN AMPHENOL PIN C | REMOTE | ||
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| 2C 3J61 to 6 PIN AMPHENOL PIN D | ||
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| 4A 4J61 to WELD TERM. SWITCH | ||
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| 4B 5J61 to 14 PIN AMPHENOL PIN D | ||
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| J62 |
| 4C 6J61 to 6 PIN AMPHENOL PIN E |
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| 75A 2J62 to 3J10 - 10K REMOTE |
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| 75B 3J62 to 14 PIN AMPHENOL PIN G |
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| GND K | 76A 4J62 to 2J10 - 10K REMOTE |
| REMOTE |
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| 77A 5J62 to 1J10 - 10K REMOTE |
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| WELD MODE SWITCH - S6 |
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| WELD TERMINALS |
| ARC CONTROL |
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| (CONTACTOR) SWITCH - S3 |
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| R2 |
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| 218 | 3 | POS. 2 PIPE |
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| 10K |
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| 4 | POS. 3 |
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| 206A |
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| GND L GND M | ||
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| 4A | 2A |
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| GND J |
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| 2 | 277 276 | 275 |
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| GND G |
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| GND D |
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| GND C |
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| 50 AMP | 25 AMP |
| 20 AMP | GND B |
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| AMPHENOL 1 |
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| 3D | 3 |
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| 3A | GND A |
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AMPHENOL 2 |
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| GND C |
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| GOLD | 3A |
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| J102 | CB5 | CB7 |
| CB1 |
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C |
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B | D |
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| SILVER | 212 |
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| 120/240 V AC | GND G | 5A |
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| GOLD | CB6 | CB8 |
| 5K | GND E | |
KEY |
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| J101 | 6F | 42A |
| 6E | 5L |
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| SILVER | 50 AMP | 15 AMP |
| 20 AMP |
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| GND D | 5B |
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Return to
11 1J42 toPIN 3 of P50 |
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| CHOPPER POWER SUPPLY, 20V |
105A 2J42 to3J13 |
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| WELD BOARD POWER SUPPLY, +5V TO CIRCUIT GROUND | |
5L 4J42 to GND. SCREW |
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| FRAME GROUND | |
115A 5J42 to 1J13 |
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| WELD BOARD POWER SUPPLY, +15V TO CIRCUIT GROUND | |
12 6J42 to PIN 1 of P50 |
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| CHOPPER POWER SUPPLY, 20V | |
101A 7J42 to 2J13 |
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| CIRCUIT GROUND | |
116A 9J42 to 4J13 |
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| WELD BOARD POWER SUPPLY, | |
118A 10J42 to 5J13 |
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| WELD BOARD POWER SUPPLY, +15V TO CASE GROUND | |
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77B 6J62 to 14 PIN AMPHENOL PIN E | OUTPUT CONTROL | |
75C | 8J62 to 6 PIN AMPHENOL PIN C |
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76B | 9J62 to 14 PIN AMPHENOL PIN F |
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76C | 10J62 to 6 PIN AMPHENOL PIN B |
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GND L | 77C 12J62 to 6 PIN AMPHENOL PIN A |
208 |
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SHUNT |
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208A | 206A | |
208B | 206B | |
POSITIVE OUTPUT STID | ||
NEGATIVE OUTPUT STUD | ||
204S | 206S |
CASE FRONT - REAR VIEW
BLOWER BAFLE - SIDE OPPOSITE BLOWER
TOC
TOC
6 12
511
410
3 9
KEY
12NEG CHOPPER POWER SUPPLY 20 V DC MEASURED WITH
1 | 3 | 11 | POS CONNECTOR UNPLUGGED |
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| C | CONTROL |
| C | B | A | |
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CONTACTOR | D | B |
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CONTROL |
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CONTROL |
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E | REMOTE |
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GROUND | 210 (TO |
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| 212A (TOBATTERY | BATTERY | 3 | 1 | TO OIL | ||
120 V AC FOR WIRE FEDER | SWITCH) | 1 | 3 | CHARGER | |||||
CHARGER CIRCUIT |
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| 2 | PRESSURE | ||
| 224 (TO HOUR | 2 | 4 | BREAKER) | IGNITION | 4 | SWITCH | ||
| METER POS.) |
| CIRCUIT +12V |
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221 (TO |
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| 3 | 1 | IGNITION GROUND | ||
SWITCH) | 1 | 3 | TO FUEL | TO STOP ENGINE | ||||
BUTTON SWITCH) | ||||||||
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212A (TO BATTERY |
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| 225 (TO BATTERY | 4 | 2 |
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CHARGER CIRCUIT |
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Return to Section
Return to Master
F | CONTROL |
1 | 7 |
7 | 9 | 23 NEG TWISTED PAIR - PWM SIGNAL |
F | G H |
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GROUND |
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42 V AC FOR WIRE FEDER | 224A | ENGINE SIDE |
| WELDER HARNESS SIDE | |
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BREAKER)
WELDER HARNESS SIDE
ENGINE SIDE
| 12 V DC MEASURED WITH |
25 | POS CONNECTOR UNPLUGGED |
KEY |
KEY |
LEAD ENTRY VIEW |
LEAD ENTRY VIEW |
21 |
LEAD ENTRY VIEW
LEAD ENTRY VIEW
TYPICAL MOLEX CONNECTOR
P50 - LEAD END VIEW
FRONT VIEW OF AMPHENOLS
ENGINE CONECTOR BLOCK |
ONAN P216 ENGINE |
ENGINE CONECTOR BLOCK
KOHLER CH20 ENGINE
G3817
NOTE: This diagram is for reference only. It may not be accurate for all machines covered by this manual.
RANGER 250
