ELECTRICAL DIAGRAMS
G-26
RANGER 305D
SCHEMATIC - ENTIRE MACHINE - CODE 11123 (L12214) PAGE 2 OF 2
EN
-168
SO
LI
D
ED
G
E
L12214
RANGER 305D CE (EUROPE)
MACHINE SCHEMATIC
NONE
L12038
DEO
BAM
-
UNLESS OTHERW ISE SPEC IFIED 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
CRM3557
3
2
PA GE ___ O F ___
2
ENGINEERING CONTROLLED
M ANUFACTURER:
No
DOCUME
NT
NUMBER:
DOCUMENT
REVISION:
THIS D OCUME NT C ONTAINS 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 F OR 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:
L122
14
LEAD COLOR CODE:
B-BLACK
G-GREEN
O-ORANGE
R-RED
U-BLUE
W-WHITE
Y-YELLOW
COMPONENT VALUE UNITS:
CAPACITOR: MFD/VOLTS
RESISTOR: OHMS/WATTS
CONNECTOR PIN NUMBERS:
VIEW OF CONN
ECTOR ON
PCBOARD
1 2
6
7
1 2
LATCH
EX. 12 PIN C
ONNECTOR
LABELS:
COMMON
FRAME GROUND
EARTH GROUND
J7-1
J7-4
J7-5
+10V
+10V
J1- 10
J1-14
J1-11
TIG M ODE
ALL OTHER MODES
ARC
CONTROL
CIRC UI TRY
CONTROL
POINT
SELECT
VARIAB LE PINCH
PIPE ARC F ORCE
VARIAB LE ARC F ORCE
FIXED ARC FORCE
LOCAL
REMOTE
TOUCH START
OCV
J7-6
J7-7
J7-8
x80
G4109
(ONLY)
G4107
(ONLY)
47.5 ohm s
J3- 15
J6-2
J6-1
VOLTAGE FEEDBACK
CURRENT FEEDBACK
J5-10
J5-9
J5-8
J5-7
J5-6
J5-5
J5-4
J5-3
J5-2
J5-1
J4-10
J4-9
J4-8
J4-7
J4-6
J4-5
J4-4
J4-3
J4-2
J4-1
MACHINE /
MODE
LOGIC
(CPU)
HOLD (+5V=HOLD)
ON / OFF (+5V=ON)
ON / OFF (+5V=ON)
HOLD(+5V=HOLD)
J7-16
J7-9
J7- 10
J7- 11
J7- 12
J7- 13
J7-14
J7-15
TIG MODE
PIPE MODE
(NOT AVAILABLE ON AUSTRALIAN
VANTAGE 575)
N/A
N/A
N/A
ROCV ENABLE
(FOR AUSTRALIAN VANTAGE 575)
CV MODE
+15V
J1-5
J1-6
J1-7
J1-8
J1-13
+15V
J1-12
MACH SEL 4
MACH SEL 3
MACH SEL 2
MACH SEL 1
PRESET
CURRENT FEEDBACK
VOLTAGE
FEEDBACK
AMMETER
DISPLAY
VOLTMETER
DISPLAY
SELECT CONTROL POINT
FIXED HOT START
J3- 14
IDLE SWITCH SENSE
+15V
J3-7
J1-3
J1-4
+15V
(4)
(2)
2-4 SENSE
J3-4
J3-3
REG ULATING
AMPLIFIER
PW M
CHOPPER
CONTROL
CIRCUIT
CURRENT
LIM ITS,
AVERAGE,
ABSOLUTE,
& FO LDBACK
T
H
ERMAL
SH
UTD
O
W
N
THERMAL SHUTDOWN (if used)
CURRENT
FEEDBACK
CONTROL POINT
J3-12
J3-10
J3-11
J3-9
47.5 ohm
TRANSFORMER
+15V
+3.3V
-15V
+5V
J3-16
J3-8
-
+
40-100VDC
INPUT
FRAME
+15V
IDLE CONTROL
IDLE CONTROL
+15V COM
FRAME
V-BATTERY
J2-6
J2-4
J2-5
IDLE HOLD COIL
TOIDLE PULL COIL BOARD
HIGH = PULL TO LOW IDLE
FRAME
+15V COM
V-BATTERY
J2-1
FRAME
J2-8
J2-9
J2-10
RANGER OIL PRESSURE
STARTER BUTTON
FUEL SHUTDOWN
FRAME
V-BATTERY
FRAME
J2-7
J2-3
+12V ISOLATED CIRCUITRY FOR ENGINE FUNCTIONS
(NOT ALL MACHINES USE EVERY CIRCUIT)
- STUD
+ STUD
AUXILLARY
CURRENT
SENSE
-
+
10K
POT
10K
POT
10K
POT
AUXILIARY
SENSE
TOROID
MACHINE IDENTITY TABLE:
PINS JUMPERED TO SELECT MACHINE
1
2
3
4
A
TIG
PIPE
CC
CV
MODE
SELECTOR
SWITCH
(AUSTRAILIAN
VANTAGE 575 USES A
3 POSITION TOGGLE
SWITCH)
(77)
(76)
(75)
(77B)
(76B)
(75B)
(277)
(278)
(279)
OUTPUT
CONTROL
REMOTE
CONTROL
ARC CONTROL
+ STUD
+ STUD
+ STUD
+ STUD
+ STUD
+ STUD
+ STUD
+ STUD
+ STUD
+ STUD
+ STUD
+ STUD
+ STUD
+ STUD
+ STUD
+ STUD
+ STUD
+ STUD
+ STUD
(206S)
(204S)
+
-
(208B)
METER (+) INPUT (0 - 2V) 1V = 100.0 ON METER
+
BATTERY POSITIVE
1
2
3
4
HOLD
COIL
PULL
COIL
IDLE
SOLENOID
BLK
RED
WHT
-
BATTERY NEGAT
IVE
PULL C
OIL
BOARD
FOR AUX USE: CONNECT
TOFRAME FOR HIGH IDLE
J2-12
J1-5 J1-6 J1-7 J1-8
M ACHINE
RANGER 250 G&D
J1-13
RANGER 305 G&D
J1-13
V ANTA GE 500
J1-13
V ANTA GE 575
J1-13
A IR VANTAGE 500
#1
CHOPP
ER
BOARD
#2
CHOPP
ER
BOARD
47.5 ohm
47.5 ohm
47.5 ohm
(ALL MACHINES)
(VANTAGE ONLY)
50mV = 400 AMPS
SHUNT
+
-
ROTOR
POSITIVE
BRUSH
NEGATIVE
BRUSH
+
-
CONTROL BOARD
POWER FROM
CHOPPER BOARD
FEEDBACK
CURRENT LIMITS
REGULATION MODE
METER (-) INPUT
METER (+) INPUT (0 - 2V) 1V = 1000 ON METER
METER (-) INPUT
BLINK (PULLED LOW AND HIGH
IN LOOKBACK TO FLASH
DECIMAL POINT)
BLINK (PULLED LOW AND HIGH
IN LOOKBACK TO FLASH
DECIMAL POINT)
+12V when starting the machine. (RUN switch ON and
Start Button Pressed and held., 0V when the machine
is not ON. +40V or more when the machine is running.
Other side of the Idle Hold Solenoid.
+0V when energized "LOW IDLE" +12V
when not energized. "HIGH IDLE"
+12V Battery Supply to
the Idle Hold Solenoid
+12V when the RUN switch is ON and the
START Button is held IN. If externally shorted
the PTC will change to high impedance
PWM SIGNAL (+12V ON MULTIMETER)
PWMCOMMON
PWM SIGNAL (+12V)
PWM COMMON
PTC
+ STUD is COMMON
FOR WELD CONTROL
CIRCUITS
CONNECTORS
J1 AMPHENOL & MACHINE ID JUMPER
J2 ENGINE 12V CONTROL FUNCTIONS
J3 CHOPPER PWM, POWER IN, (THERMAL OVERLOAD IF USED), VOLTAGE FEEDBACK
J4 AMMETER (NO CONNECTOR ON RANGER 250)
J5 VOLTMETER (NO CONNECTOR ON RANGER 250)
J6 SHUNT/CURRENT FEEDBACK
J7 OUTPUT CONTROL, ARC FORCE, MODE SELECT
FRAME IS COMMON FOR
ENGINE CONTROL CIRCUITS
PRESET
PRESET
DISPLAY WELD AMPS
DISPLAY WELD VOLTS
DISPLAY
PRESET
VALUE
+5V
+5V
+5V
DIODE ONLY ON -E
VERSION
AND A
BOVE
THE TOP END OF THE REMOTE POT IN
TIG MODE IS THE SETTING OF THE LOCAL
OUTPUT CONTROL POT.
IN EVERY OTHER MODE, THE REMOTE
POT WILL SET MACHINE TO MAX OUTPUT.
METERS OPTIONAL ON VANTAGE
NO J4 OR J5 ON RANGER 250
V-BATTERY
SEE SPECIFIC MACHINE SCHEMATIC FOR DETAILS ON
WHAT PARTS OF THE G4107/G4109 ARE USED IN EACH
APPLICATION. NOT ALL CIRCUITS ARE USED ALL THE TIME.
+15V
J7-2
WELDING
TERMINAL
CONTROL
SWITCH
SHOWN IN "ALWAYS
ON" POSITION
IDLER
CONTROL
SHOWN IN "HIGH" POSITION
G-26
NOTE: This diagram is for reference only. It may not be accurate for all machines covered by this manual.
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