Lincoln Electric Ranger 305D Service Manual page 181

G-25
SCHEMATIC - ENTIRE MACHINE - CODE 11123 (L12214) PAGE 1 OF 2
POSITIVE
OUTPUT
TERMINAL
Located on back of
output panel
between terminals
NEGATIVE
OUTPUT
TERMINAL
Open Circuit Volts:
Max
CC 58
CV
58
Pipe 58
Tig 12
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CHANGE DETAIL: RELEASED "A.02" FROM "X"
E N G IN E E R IN G C O N T R O LLE D
No
M AN U FA C TU R E R :
R4 is located on front of
Shunt on back of positive
SH UNT fan baffle near top of
output terminal
50MV= 400 AMPS
machine
206B 206S 204S WELD CURRENT
FEED BACK SIGNAL
206A
206C
R4
BY-PASS
WIREFEEDER
50 OHM
PC BOARD
VOLTMETER
100 W
21
208C POLARITY
SWITCH
208
208A
B3
-OUTPUT
L1 CH O KE
B6
2 TURNS
THRU
Power Supply
Choke is beneath bearing end FERRITE
B7
to Control
of generator on support.
L6
Board
Min
L3
2 TURNS L5
58
THRU TWISTED
58
FERRITE TWISTED
2 TURNS
PAIR
26
THRU FERRITE PAIR
12
Control Board senses Weld Output
13 (J3-8) 14 (J3-16) 25 (J3-9)
from Current Feedback Shunt
204S (J6-1)
to activate idler.
206S (J6-2)
ARC VOLTAGE FEEDBACK SIGNAL
208B (J3-15) Control board common is
at welder positive output
10 V
77 (J7-1)
and shunt
OUTPUT 0-10 V
R1 76 (J7-4)
CONTROL 10K WELD CONTROL
0 V
75 (J7-5) PC BOARD
10 V
77A (J1-11)
P/N G4107-1
REMOTE
-15 V (W/O POT.)
(TO AMPHENOL)
76A (J1-14)
CONTROL 10K
0 V
75A (J1-10) Located on front of fan
baffle near top of
279 (J7-6)
machine.
ARC
R2 278 (J7-7)
CONTROL 10K
277 (J7-8)
TOROID-
SENSES AC
260A (J3-4)
POWER TO
261A (J3-3)
ACTIVATE
IDLER
Located on wiring behind
receptacles.
5K (J2-3)
Control board circuits associated with J2 a re part (J4-1 to 10)
(J5-1 to 10)
of engine electrical system and are common to
All leads
frame ground (negative battery terminal.
1 time thru
L8 ferrite L7
WELD AMMETER
WELD VOLTMETER
Meters display setpoint volts o r amps when not welding.
Meters display actual volts and am ps when welding.
Hold function displays actual volts and a m ps for
approximately 5 sec onds after welding stops.
During this hold display the right most decimal point w ill
blink.
J
31
A
32
I
41A
42VAC
K
42A
H
WORK 21
A
77B E
REMOTE 77A
B REMOTE
CONTROL 76B
F
CONTROL 76A
C
75B
G
75A
D
2B CONTACTOR
D
4A
E
4B
C
2A
F
GND-B
GROUND
B
GROUND GND-A
AMPHENOL
AMPHENOL
NOTE: This diagram is for reference only. It may not be accurate for all machines covered by this manual.
ELECTRICAL DIAGRAMS
CHOPPER PC BOARD
IGBT'S, FLYBACK DIODES AND
p/n Recti f ier mounted to generator support
FILTER CAPACITORS ARE INTEGRAL
L11845-1 above output choke.
TO CHOPPER MODULE AND NOT
INDIVIDUALLY REPLACEABLE. D1 - THREE PHASE BRIDGE RECTIFIER
+COM
B2
B5
10,000uF x4
Chopper is mounted on the back side of fan
baffle near top of machine. Requi r es added
+
FLYBACK
baffle for cooling ai r flow.
DIODES (6)
DC BUS VOLTAGE
FILTER
90+/-10VDC @ HI IDLE
CAPACITORS (4)
IGBT (8)
B1
E
C
-INPUT
B4
PWM Signal to Chopper
15 volt @ 20 kHz
B8
GATE SIGNAL
Rotor Flashing: +12 volts
TWISTED
TO AUX.
@ 0.5 amps
PAIR R3 located on front of fan baffle
until generator builds up
on left side nea r bottom of
then +50 volts @ 0 amps. OUTLETS
machine
23 (J3-10)
R3 25 OHM
ROTOR FLASHING
(J2-1) 200N AND
LOW IDLE SOLENOID HOLD COIL (0V @ LO W IDLE)
(J2-5) 215
AMPHENOLS
+15V @ LOW IDLE TO PULL COIL BOARD (VIA CIRCUIT
(J2-4) 404
BREAKERS)
0 V
Swich closed for high
(J3-14) 252
IDLER SWITCH
idle.
(J3-7) 251 2 TURNS THRU FERRITE
15 V
2A
(TO AMPHENOL)
15 V L2
(J1-4) 2
WELD TERM. SW.
(J1-3) 4
0 V
(TO AMPHENOL)
CV 4A
(J7-9) 214
PIPE
(J7-14) 218
MODE
CC SWITCH
TIG
(J7-15) 220
(J7-16) 222
+12 to 14V @ NORMAL OIL PRES. (INPUT)
(J2-9) 224B
+12 to 14V @ RUN (INPUT)
(J2-7) 210B
GLOWPLUG
SWITCH S7
(J1-7) 305
GLOWPLUGS
(J1-12) 305
223
All leads
305 I.D. JUMPER (Part
1 time thru
15A BATTERY
of amphenol plug and
ferrite
CIRCUIT BREAKER
lead assembly.)
209 212
210
START BUTTON
SWITCH S2
2 TURNS THRU
FERRITE
209
NO CONNECTION
209
+
BAT
L4
77B
IGN
76B
INPUT TO
L
75B
AMPHENOL
ALTERNATOR
4B
FRAME
GROUND
2B Battery voltage:
12.6 volts at rest
1 14 volts engine
4
running
FUEL SENDER
FUEL
GAUGE
240-265 OHMS EMPTY PROPRIETARY & CONFIDENTIAL:
20-35 OHMS FULL UNLESS OTHERW ISE SPEC IF IE D TOLERAN CE
DESIGN INFORM ATION
MANUFAC TURIN G TOLERANCE PER E205 6
ON 2 PLAC E DECIMA LS IS ± .02
ON 3 P LACE D ECIM ALS IS ± .002 DRAW N BY:
ON ALL ANG LES IS ± .5 OF A DEGREE
t E NGINEER:
MA TERIA L TOL ERANCE (" ") TO AGREE
WITH PUB LISHED S TANDARDS.
DO NO T SCALE TH IS D RAW ING
APPRO VED:
W1
60 TO 65 VAC PHASE TO PHASE
BETWEEN W1, W2 AND W3
AT HIGH IDLE
W2
TWO POLE 3600 RPM ALTERNATOR
W3
C
C3 and D3 locate d on rear of fan baffle
A-B-C 400 VAC, 3 PH.
on left side of machine.
A-5 SLIP RINGS
A
B-5 230 VAC, 1 PH. 200
5 C-5
50 V DC
200A
C3
B
800uf
41
150vdc
42 VOLT AC
201
WIRE FEEDER
5H
POWER
42
REVOLVING FIELD
42 VOLT AC
FIELD RESISTANCE
POWER FOR
APPROX. 5 OHMS @ 75F
ROTOR FI E LD CIRCUIT
7
9
210
GLOWPLUG SWITCH ENERGIZES
IF COOLANT TEMP SWITCH OR OIL PRESSURE SWITCH
ELECTRIC FUEL PUMP AND FUEL
CLOSE, CR1 ENERGIZES OPENING CONTACTS AND
SOLENOID HOLD COIL THRU D4. IT
SHUTTING OFF FUEL S OLENOID TO STOP ENGINE.
ALSO FUNCTIONS AS AN ENGINE
PROTECTION BYPASS UNTIL OIL YELLOW
ENGINE
PRESSURE BUILDS UP. ENGINE
PROTECTION
PROTECTION
RELAY
B
9
LIGHT
S1
RUN-STOP SWITCH CR1 PL
3
(SHOWN IN RUN) 1
A
210
224
211
FUEL SOLENOID PULL
COIL IS ENERGIZED BY
D4
STARTER SOLENOID.
+15V @ LOW
231
IDLE
225
J73-4
J73-2 229
P73-4
P73-2
J74
STARTER
FUEL
RED
SOLENOID WHITE
SOLENOID P74
12 VOLT
PULL
ELECTRIC
BATTERY
0.2 OHM
FUEL
STARTER
HOLD
PUMP
MOTOR
11 OHMS
OIL PRESSURE COOLANT
BLACK
P73-3 P74
SWITCH TEMPERATURE
FUEL
SWITCH
SOLENOID (CLOSES ON
J73-3 J74
LOW OIL (CLOSES ON HIGH
AND FUEL
PRESSURE) TEMPERATURE
PUMP
ABOVE 230F)
ENERGIZED
FOR RUN
THIS D O C UME NT C O NTAINS PR OP RIETARY INF O RMATION O W NE D BY LINC OLN GLOBAL, INC. A
TO OT HE R PARTIES O R USE D F O R ANY PU RP OSE WIT H O UT T HE EX PRESS W RITTE N PE RMISSION
RANGER 305D CE (EUROPE)
EQUIPMENT TYPE:
REFERENCE:
L12038 MACHINE SCHEMATIC
DEO SUBJECT:
SCALE:
BAM
MATERIAL APPROVAL PROJECT CRM35573
UF
12/11/2003
NONE
-
DISPOSITION: DATE: NUMBER:
G-25
+
D
3
Relay CR1 and D4 locate d on fron
baffle on right side of machin e.
IDLE SOLENOID
ENERGIZED FOR
LOW IDLE
J72-3
P72-3
IDLE
BLACK
SOLENOID
PULL
0.2 OHM
HOLD
11 OHMS
WHITE RED
P72-4 P72-2
215
J72-4 J72-2
232
+
HOUR METER
404 (J43-8) B2
TIMER
B1
CIRCUIT
PULL COIL
PC BOARD
B4
P/N
L11768-1
Located next to
control board.
N D MAY N OT BE D UPLICATE D, COMMU NICATE D
OF LIN C OLN GLOBAL, INC.
1 2
PA GE ___ O F ___
DOCUMENT
DOCUMENT
NUMBER: REVISION:
L12214 A
RANGER 305D