Manuals / Lincoln Electric / Power Tools / Welder

Lincoln Electric SVM175-A Remote Receptacle Resistance Test, Perform the Case Cover Replacement

Models: SVM175-A

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F-80			TROUBLESHOOTING & REPAIR								F-80
	REMOTE RECEPTACLE RESISTANCE TEST (continued)
						FIGURE F.18
				AMPHENOL 1
				EF	D	CL	BK		A	J
TEST PROCEDURE					MG		NH		I
1. Turn the machine off.							7.	If the resistance values are found to be too
2. Perform		the	Case Cover Removal
	Proced .							low, due to contaminated electrical compo-
3. Make sure that there are no devices of any								nents in the Amphenol harness assembly.
								Try removing the contamination and drying
	kind plugged into either Amphenol recepta-							the components completely. If the resistance
	cles.							values are still too low, replace the Amphenol
4. Remove Molex plug P1 from the control PC								harness assembly.
	board, see Control Inner-Connection						8.	If the values are incorrect for the last two
	Diagram.	Examine the Molex plug and the
	receptacle on the control PC board for dirt,							tests in the table, (Pin C to Pin D) check the
	corrosion, damaged or out-of-position pins.							welding terminal switch and the wiring con-
	Repair or replace any damaged components.							nected to that switch. See the wiring dia-
	Position the P1 plug so it can not make elec-							gram.		Repair any faulty connections	or
	trical contact with any other conductor or						9.	replace the switch if necessary.
	chassis ground.							Plug P1 back into the Control Pc board.
5. Perform the following resistance tests shown							10.	Perform the Case Cover Replacement
	in the following table. Be very careful not to							Procedure.
	damage or spread any of the connection pins
6.	in the Amphenol receptacle.			See Table F.4.
	If the measured resistance			does	not meet
	values specified, check for damage, dirt or
	moisture contamination in the Amphenol
	receptacles and the P1 Molex plug. Check
	for damaged or grounded wiring.

RANGER 305D

Image 134

Lincoln Electric SVM175-A Remote Receptacle Resistance Test, Perform the Case Cover Replacement, See Table F.4

Contents

RangerTM 305D For Engine SafetyPowered equipment Electric Magnetic FieldsCan be dangerous Electric Shock can kill ARC Rays can burnFumes and Gases Cause fire or explosion If damaged Welding Sparks canSAFETYCylinder may explode For ElectricallyLES Machines À Souder À Précautions DE SûretéPrécautions DE Sûreté Pour Transformateur ET ÀMaster Table of Contents for ALL Sections Section A-1 Table of ContentsInstallation Section AIR Cleaner Engine Idler Muffler Protection InstallationHeight Width Depth Weight Lubrication Emissions Fuel System GovernorEngine Protection AIR CleanerEngine Warranty Model NumberStacking Safety PrecautionsStoring Angle of Operation Location and VentilationTowing High Temperature OperationLifting High Altitude OperationMuffler Outlet Pipe PRE-OPERATION Engine Service Battery ConnectionOIL Spark ArresterElectrical Output Connections Remote Control Machine GroundingAccessories Standby Power Connections Welding Output Cables Auxiliary Power ReceptaclesCable Installation Table A.1 Total Combined LengthInstallation Figure A.2 Connection of Ranger 305D to Premises Wiring Premises or residential elecOperation Section Section B-1Precautions Safety InstructionsAdditional Safety Operating Instructions OperationOperation Design FeaturesControl and Settings Figure B.1 Wire Feeder Voltmeter Switch Digital Output MetersBefore Starting the Engine Engine OperationStarting the Engine Stopping the Engine Diesel FuelTable B.2 Typical Current RANGES1 for Tungsten ELECTRODES2 BREAK-IN PeriodStick Welding Downhill Pipe WeldingSee Table B.2 for reference settings Auxiliary PowerWire WELDING-CV TIG Welding ARC GougingSimultaneous Welding Auxiliary Power LoadsRanger 305D Simultaneous Welding and Power Loads Ranger 305D Accessories Section C-1TIG Welding Accessories Options / AccessoriesField Installed Options Welding AccessoriesConnection of Lincoln Electric Wire FeedersWire Feeders Using K867 Universal Connection of the Ranger 305D toSee Figure C.2 Connection of the LN-25 toRanger 305D Across the ARC Output Control Module See Figure C.3 Volt Remote Output Control Module Connection DiagramRanger 305D with 42 Volt Remote Connection Diagram with K857 Remote Control See Figure C.47ACCESSORIESC-7 Ranger 305D Using K595 Control Cable See Figure C.6 Connection of the LN-8 toFigure C.7 Ranger 305D/LN-742 Connection Diagram Connection of the LN-742 to Ranger 305D See Figure C.7Ranger 305D Maintenance Section D-1Safety Precautions Routine and Periodic Maintenance Engine MaintenanceMAINTENANCED-3 Kubota D722 Diesel Engine Ranger 305DOil Filter Change Engine Oil ChangeSee Table D.2 Engine Oil Refill capacities5MAINTENANCED-5 Tightening the FAN Belt AIR CleanerCooling System Do not remove cap if radiator isEngine Adjustment Battery MaintenanceWelder / Generator Cleaning the BatteryCharging the Battery Checking the Electrolyte LevelGfci Receptacle Testing Resetting Procedure Maintenance Theory of Operation Section Section E-1Theory of Operation Battery, Engine, Engine ProtectionBattery Charging SystemIdle Solenoid Operation Idle Switch Operation Engine Idle SystemBuilding Output Generating PowerFlashing AC outputTechnology Fundamentals Weld Power and ControlWeld Power Weld Control and FeedbackDigital Meters Remote output controlElectronic Output Contactor Diode Chopper Technology Fundamentals90 VDC Inductor ARCMaximum Output Pulse Width ModulationMinimum Output Section F-1 Troubleshooting & Repair SectionTroubleshooting & Repair Section Section F 2TROUBLESHOOTING & REPAIRF-2 HOW to USE Troubleshooting Guide3F-3 Troubleshooting & RepairPC Board Troubleshooting Procedures PC Board can be damaged by static electricityTroubleshooting Guide Adjus ment Test TestsEngine Throttle Brush and Slip RingThrottle Adjustment test Problems Possible AreasSymptoms Misadjustments Course of Action Engine Throttle AdjustmentControl Adjustment Test Switch Resistance Test Potentiometer ModeSwitch Resistan Test ControlPotentiometer Mode Switch Test Switch Test, Remote Chopper Module ResistanceMISC. Weld Issues Welding output in any mode Potentiometer TestEngine and Idle Problems Engine AlterFuel Solenoid Test Fuel Solenoid Test. SeeShutdown Perform the Fuel Solenoid TestPerform the Idle Solenoid Test Solenoid TestEngine and Idle Problems If the solenoid does not hold Engine and Idle Problems Rottle Adjustment Test Materials Needed Case Cover Removal and Replacement ProcedureTest Description 21F-21Case Cover Removal and Replacement Procedure Replacement ProcedureChopper Module Capacitor Discharge Procedure 23F-23Test Procedure Perform the Case Cover Removal proceFuel Shutdown Solenoid Test See 26TROUBLESHOOTING & REPAIRF-26Fuel Shutdown Solenoid Test 27TROUBLESHOOTING & REPAIRF-27 Figure F.4 Fuel Solenoid ConnectionsRanger 305D Engine Throttle Adjustment Test 29F-29Engine Throttle Adjustment Test Strobe-Tach MethodFrequency Counter Method 31TROUBLESHOOTING & REPAIRF-31Engine Throttle Adjustment Test Vibratach Method Low Idle adjustmentHigh idle adjustment Idler Solenoid Test 33F-3334TROUBLESHOOTING & REPAIRF-34 Idler Solenoid TestEngine Alternator Test DescriptionEngine Alternator Test 36TROUBLESHOOTING & REPAIRF-36Test Procedure Brush and Slip Ring Service Procedure Cleaning slip rings Brush and Slip Ring Service ProcedurePerform the Case Cover Removal Procedure Case Cover Replacement ProcedureRotor Resistance and Ground Test Static 39F-3940TROUBLESHOOTING & REPAIRF-40 Rotor Resistance and Ground Test StaticRotor Resistance and Ground Test Dynamic Also referred to as flying resistance testPerform theifbrushnecessaryand.slip ring service procedure Rotor Resistance and Ground Test DynamicRotor Voltage Test 43F-43Rotor Voltage Test 44TROUBLESHOOTING & REPAIRF-44TheEngineS Throttle Adjustment Test . tator Short Rotor Voltage Test Ranger 305D Flashing Voltage Test Engine Not RunningCase Cover Removal Procedure Flashing Voltage Test49TROUBLESHOOTING & REPAIRF-49 Flashing Voltage TestRanger 305D Stator Voltage Tests 51F-51To test the 240 VAC auxiliary winding Stator Voltage TestsTo test the 120 VAC auxiliary winding 53TROUBLESHOOTING & REPAIRF-53 Stator Voltage TestsTo test the 42 VAC wire feeder winding To test the three-phase weld windingStator Short Circuit & Ground Test 55F-55Perform Case Cover Removal Procedure Stator Short Circuit & Ground TestOutput Rectifier Bridge Test 57F-57Output Rectifier Bridge Test 58TROUBLESHOOTING & REPAIRF-58Dis harge procedure Perform the Chopper Module CapacitorOutput Rectifier Bridge Test Figure F.16 SHUNT/RECTIFIER LeadsPerform the Case Cover replacement Procedure Table F.1 Diode Test TableChopper Module Function Test Chopper Module Function Test Weld. Control Board PWM Gate Drive Test Procedure. CaseCover ReplacementChopper Module Function Test Ranger 305D Chopper Module Resistance Test Case Cover Removal Rocedure Capacitor Discharge ProcedureChopper Module Resistance Test Ohmmeter Reading Table F.2 Diode Test TableRanger 305D Weld Control Board PWM Gate Signal Test Weld Control Board PWM Gate Signal Test Weld Control Feedback Test Weld Control Feedback Test Return to Section Ranger 305D Control Potentiometer and Mode Switch Resis Tance Test Perform .the Case cover Removal Procedure 76TROUBLESHOOTING & REPAIRF-76Control Potentiometer and Mode Switch Resistance Test Cover Replacement procedureMode Switch Table F.3Ranger 305D Remote Receptacle Resistance Test See Table F.4 Perform the Case Cover ReplacementRemote Receptacle Resistance Test Welding Terminal Ohmmeter Ohmmeter Reading Table F.4Ranger 305D Output Rectifier Bridge and Choke Removal Replacement Discharge procedure 84TROUBLESHOOTING & REPAIRF-84Removal Procedure Output Rectifier Bridge and Choke Removal and ReplaceReplacing the Output Rectifier Perform the Case Cover RemovalRanger 305D Chopper Module Removal and Replacement Terminal Chopper Module Removal and ReplacementProcedure RemovalReplacement HL W8 HL W6Ranger 305D STATOR/ROTOR Removal and Replacement Discharge Pr Cedure 92TROUBLESHOOTING & REPAIRF-92STATOR/ROTOR Removal and Replacement See Figure F.21Figure F.21 Wire Guide Hole Figure F.22 Alternator LeadsDo not Hold the Rotor by the Slip Rings Figure F.23 DISC/RING Location Replacing the RotorReplacing the Stator 97TROUBLESHOOTING & REPAIRF-97 Normal Open Circuit Voltage Waveform 120VAC SupplyMAX Control POT High Idle no Load 98TROUBLESHOOTING & REPAIRF-98Normal Open Circuit Voltage Waveform Stick Machine Loaded to 300 Amps AT 27 Volts 99TROUBLESHOOTING & REPAIRF-99Normal Weld Voltage Waveform Stick CC 100TROUBLESHOOTING & REPAIRF-100 Normal Open Circuit Voltage Waveform Wire CV TAPMachine Loaded to 300 Amps AT 28 Volts 101TROUBLESHOOTING & REPAIRF-101Normal Weld Voltage Waveform Wire CV Auxiliary Power Output Retest After RepairSection G-1 Electrical Diagrams SectionElectrical Diagrams Section G Electrical Diagrams Wiring Diagram Entire Machine Code 10926 G4250Ranger 305D- Kubota Wiring Diagram Wiring Diagram Entire Machine Codes 11121 G4571Ranger 305D- Kubota Wiring Diagram Wiring Diagram Entire Machine Codes 11188, 11275 G4571-1Ranger 305D CE Kubota Wiring Diagram UK Wiring Diagram Entire Machine Codes 11027 G4226Wiring Diagram Entire Machine Codes 11122 G4572 AlternatorRanger 305D CE Kubota Wiring Diagram UK Ranger 305D CE Kubota Wiring Diagram Europe Wiring Diagram Entire Machine Codes 11039 G4409Ranger 305D CE Kubota Wiring Diagram -EUROPE Wiring Diagram Entire Machine Codes 11123 G4573Wiring Diagram Entire Machine Codes 11190, 11315 G4573-1 L11946 +12V Isolated Circuitry for Engine Functions L12212 Machine Schematic L12212-1 L12212-1 L12039 Diagrams L12213 Schematic Entire Machine Code 11122 L12213 page 2 L12213-1 Schematic Entire Machine Codes 11189, 11314 L12213-1 page 2 Schematic Entire Machine Code 11039 L12038 page 1 Schematic Entire Machine Code 11039 L12038 L12214 Schematic Entire Machine Code 11123 L12214 page 2 L12214-1 L12214-1 Schematic Weld Control PC BD ALL Codes G4108-1 PG 1 Schematic Weld Control PC BD ALL Codes G4108-1 PG 2 Schematic Weld Control PC BD ALL Codes G4108-1 PG 3 Schematic Weld Control PC BD ALL Codes G4108-1 PG 4 Schematic Weld Control PC BD ALL Codes G4108-1 PG 5 PC Board Assembly Weld Control PC BD ALL Codes G4107-1 Schematic Pull Coil PC BD ALL Codes G4117-1 PC Board Assembly Pull Coil PC BD ALL Codes L11768-1 Schematic Chopper PC BD ALL Codes M19792-1 PC Board Assembly Chopper PC BD ALL Codes L11845-1 54811L