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Lincoln Electric SVM175-A CHOPPER MODULE REMOVALAND REPLACEMENT

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TROUBLESHOOTING & REPAIR

F-87 F-87

RANGER 305D

WARNING

CHOPPER MODULE REMOVALAND REPLACEMENT

Service and repair should be performed by only Lincoln Electric factory trained personnel.

Unauthorized repairs performed on this equipment may result in danger to the technician or

machine operator and will invalidate your factory warranty. For your safety and to avoid elec-

trical shock, please observe all safety notes and precautions detailed throughout this manual.

If for any reason you do not understand the test procedures or are unable to perform the

test/repairs safely,contact the Lincoln Electric Service Department for electrical troubleshoot-

ing assistance before you proceed. Call 1-888-935-3877.

DESCRIPTION

This procedure will aid the technician in the removal and replacement of the Chopper Module

Assembly.

Note: The Chopper Module assembly is removed and replaced as a unit. It contains no ser-

viceable parts.

MATERIALS NEEDED

Miscellaneous hand tools

Electrical thermal joint compound - (Dow Corning 340 - Lincoln T12837)

Contents

Main SVM175-A Ranger 305D July, 2007 SERVICE MANUAL Safety Depends on You FOR ENGINE powered equipment. WARNING ELECTRIC AND MAGNETIC FIELDS may be dangerous FUMES AND GASES can be dangerous. ii ARC RAYS can burn. AUG 06 ELECTRICSHOCKcankill. FOR ELECTRICALLY powered equipment. iii CYLINDER may explode if damaged. Mar 95 WELDING SPARKS can cause fire or explosion. PRCAUTIONS DE SRET iv PRCAUTIONS DE SRET POUR LES MACHINES SOUDER TRANSFORMATEUR ET REDRESSEUR Mar.93 iv MASTER TABLE OF CONTENTS FOR ALL SECTIONS - INSTALLATIONSECTION - TECHNICAL SPECIFICATIONS - INPUT - DIESEL ENGINE RECEPTACLESAND CIRCUIT BREAKERS RATED OUTPUT @ 104 F (40 C) - WELDER PHYSICALDIMENSIONS ENGINE TECHNICAL SPECIFICATIONS - INPUT - DIESEL ENGINE RECEPTACLESAND CIRCUIT BREAKERS RATED OUTPUT @ 40 C (104 F) - WELDER PHYSICAL DIMENSIONS ENGINE STORING STACKING ANGLE OF OPERATION LOCATION AND VENTILATION SAFETYPRECAUTIONS VEHICLE MOUNTING HIGH ALTITUDEOPERATION HIGH TEMPERATURE OPERATION Cold Weather Starting & Operation: LIFTING PRE-OPERATION ENGINE SERVICE OIL FUEL ENGINE COOLING SYSTEM BATTERYCONNECTION REMOTE CONTROL ELECTRICAL OUTPUT CONNECTIONS MACHINE GROUNDING Note: Different models appearance may vary slightly. ----------------------------------------------------------- AUXILIARY POWER RECEPTACLES STANDBY POWER CONNECTIONS WELDING OUTPUT CABLES CABLE INSTALLATION TABLEA.1 TOTAL COMBINED LENGTH OF ELECTRODE AND WORK CABLES Page FIGURE A.2 CONNECTION OF RANGER 305D TO PREMISES WIRING - OPERATION SECTION - Page DESIGN FEATURES CONTROL AND SETTINGS ENGINE CONTROLS (Figure B.1) 1. RUN.STOP SWITCH: 4. 2. GLOW PLUG PUSH BUTTON: 3. START PUSH BUTTON: ENGINE ALTERNATORTROUBLE LIGHT: WELDING CONTROLS 9. OUTPUT CONTROL 10. WELD MODE SELECTOR SWITCH: 11. ARC CONTROL ENGINE OPERATION BEFORE STARTING THE ENGINE STARTING THE ENGINE STOPPING THE ENGINE DIESELFUEL can cause fire. BREAK-IN PERIOD STICK WELDING TABLE B.2 - TYPICAL CURRENT RANGES 1 FOR TUNGSTEN ELECTRODES Constant Current (CC-STICK) Welding TIG WELDING WIRE WELDING-CV ARC GOUGING AUXILIARYPOWER SIMULTANEOUSWELDING AND AUXILIARY POWER LOADS Page - ACCESSORIES - OPTIONS / ACCESSORIES FIELD INSTALLED OPTIONS TIG WELDING ACCESSORIES SEMIAUTOMATIC FCAWAND MIG WELDINGACCESSORIES CONNECTION OF LINCOLN ELECTRIC WIRE FEEDERS CONNECTION OF THE RANGER 305D TO WIRE FEEDERS USING K867 UNIVERSAL ADAPTER (SEE FIGURE C.1) RANGER 305D ACROSS THE ARC (SEE FIGURE C.2.) FIGURE C.2 - Ranger 305D/LN-25 ACROSS THE ARC CONNECTION DIAGRAM +- RANGER 305D WITH 42 VOLT REMOTE OUTPUT CONTROL MODULE (SEE FIGURE C.3.) +- FIGURE C.3 - Ranger 305D/LN-25 WITH 42 VOLT REMOTE OUTPUT CONTROL MODULE CONNECTION DIAGRAM RANGER 305D ACROSS THE ARC WITH K857 REMOTE CONTROL (SEE FIGURE C.4.) +- FIGURE C.4 - Ranger 305D/LN-25 ACROSS THE ARC CONNECTION DIAGRAM WITH K857 REMOTE CONTROL CONNECTION OF THE LN-7 TO THE RANGER 305D USING K584 CONTROL CABLE (SEE FIGURE C.5.) FIGURE C.5 - Ranger 305D/LN-7 WITH 584 CONTROL CABLE CONNECTION DIAGRAM - CONNECTION OF THE LN-8 TO THE RANGER 305D USING K595 CONTROL CABLE (SEE FIGURE C.6.) FIGURE C.6 - Ranger 305D/LN-8 WITH K595 CONTROL CABLE CONNECTION DIAGRAM +- CONNECTION OF THE LN-742 TO THE RANGER 305D. (SEE FIGURE C.7.) FIGURE C.7 - Ranger 305D/LN-742 CONNECTION DIAGRAM +- Page -MAINTENANCE- SAFETYPRECAUTIONS WARNING ROUTINEANDPERIODIC MAINTENANCE ENGINEMAINTENANCE ITEM MAKE AND PARTNUMBER Page Page D-5 D-5 Service Instructions & Installation Tips For Engine Air Filter Release the 1 Avoid Dislodging 2 CleanSealing Surface 3 AIRCLEANER COOLING SYSTEM HOT COOLANT TIGHTENING THE FAN BELT FUEL SYSTEM SERVICE BLEEDING THE FUEL SYSTEM ENGINEADJUSTMENT BATTERYMAINTENANCE OVERSPEED IS HAZARDOUS CLEANING THE BATTERY CHECKING THE ELECTROLYTE LEVEL WELDER / GENERATOR MAINTENANCE GFCI RECEPTACLE TESTING AND RESETTING PROCEDURE Page Section E-1 Section E-1 ROTOR -THEORY OF OPERATION SECTION- FIGURE E.1 RANGER 305D BLOCK LOGIC DIAGRAM STATOR + GENERAL DESCRIPTION Battery, Engine, Engine Protection, and Charging System. BATTERY: Starting the engine: Engine Idle System Idle Switch Operation: Idle Solenoid Operation: Generating Power Weld Power and Control Page CHOPPER TECHNOLOGY FUNDAMENTALS E-8 PULSE WIDTH MODULATION: TROUBLESHOOTING & REPAIR SECTION HOW TO USE TROUBLESHOOTING GUIDE PC BOARD TROUBLESHOOTING PROCEDURES Page POWER OUTPUT PROBLEMS Page Page Page Page Page Page Page MISC. WELD ISSUES Page Page Page Page Page Page Page CASE COVER REMOVALAND REPLACEMENT PROCEDURE CASE COVER REMOVALAND REPLACEMENT PROCEDURE (continued) REMOVAL PROCEDURE REPLACEMENT PROCEDURE CHOPPER MODULE CAPACITOR DISCHARGE PROCEDURE CHOPPER MODULE CAPACITOR DISCHARGE PROCEDURE (continued) INSULATED GLOVES INSULATED PLIERS FUEL SHUTDOWN SOLENOID TEST FUEL SHUTDOWN SOLENOID TEST (continued) IDLEIDLE SOLENOIDSOLENOID SHUTDOWNSHUTDOWN SOLENOIDSOLENOID FUEL SHUTDOWN SOLENOID TEST (continued) P73 J73 Page ENGINE THROTTLE ADJUSTMENT TEST STROBE TACH MARK FAN HUB ENGINE SPEED CONTROL LEVER Page Page IDLER SOLENOID TEST IDLER SOLENOID TEST (continued) BLACK RED 215 WHITE P-72 J-72 ENGINE ALTERNATORTEST ENGINE ALTERNATOR TEST (continued) BRUSH AND SLIP RING SERVICE PROCEDURE BRUSH AND SLIP RING SERVICE PROCEDURE (continued) ROTOR RESISTANCEAND GROUND TEST (STATIC) ROTOR RESISTANCEAND GROUND TEST (STATIC)(continued) + - ROTOR RESISTANCEAND GROUND TEST (DYNAMIC) (Also referred to as flying resistance test) ROTOR RESISTANCEAND GROUND TEST (DYNAMIC) (continued) ROTOR VOLTAGETEST ROTOR VOLTAGETEST (continued) + - ROTOR VOLTAGETEST (continued) Page FLASHING VOLTAGE TEST (Engine Not Running) Page FLASHING VOLTAGETEST (continued) #229 The engine protection light should be off during this tes Page STATORVOLTAGE TESTS AMPHENOL 1 KEY POS. NEG. W3 W2 W1 W4,W5 W10 W6,W11 FROM SHUNT Page STATORSHORT CIRCUIT & GROUND TEST STATORSHORT CIRCUIT & GROUND TEST (continued) OUTPUT RECTIFIER BRIDGE TEST Page OUTPUT RECTIFIER BRIDGE TEST (continued) OR POS. NEG. W3 W2 W1 W4,W5 W10 W6,W11 Rectifier Terminal Connections CHOPPER MODULE FUNCTION TEST Page CHOPPER MODULE FUNCTION TEST (continued) TEST PROCEDURE (CONTINUED) Page CHOPPER MODULE RESISTANCE TEST Page CHOPPER MODULE RESISTANCE TEST (continued) Chopper Terminal Connections Page WELD CONTROL BOARD PWM GATE SIGNAL TEST WELD CONTROL BOARD PWM GATE SIGNAL TEST (continued) WELD CONTROL FEEDBACK TEST Page WELD CONTROL FEEDBACK TEST (continued) Page CONTROL POTENTIOMETER AND MODE SWITCH RESIS- TANCE TEST Page CONTROL POTENTIOMETER AND MODE SWITCH RESISTANCETEST (continued) POT/MODE SWITCH RESISTANCE TEST Page REMOTE RECEPTACLE RESISTANCETEST REMOTE RECEPTACLE RESISTANCETEST (continued) AMPHENOL 1 E I C D A AMPHENOL RESISTANCE TEST Page OUTPUT RECTIFIER BRIDGE AND CHOKE REMOVALAND REPLACEMENT OUTPUT RECTIFIER BRIDGE AND CHOKE REMOVALAND REPLACE- MENT (continued) REMOVALPROCEDURE REPLACEMENT PROCEDURE OUTPUT RECTIFIER BRIDGE AND CHOKE REMOVALAND REPLACE- MENT(continued) Replacing the Output Rectifier Page CHOPPER MODULE REMOVALAND REPLACEMENT CHOPPER MODULE REMOVALAND REPLACEMENT (continued) PROCEDURE TERMINAL LEADS B4 B5 HL W5, SL 13 B6 HL W8 B1 HL W6 B2 HL W4, SL 301 B3 HL W9, SL 302 CHOPPER MODULE REMOVALAND REPLACEMENT(continued) Replacement Page STATOR/ROTOR REMOVALAND REPLACEMENT Battery Terminals Remove Through Here HOLE Page Removing the Rotor COUPLING DISC CLAMPING RING Replacing the Stator NORMAL OPEN CIRCUIT VOLTAGEWAVEFORM (120VAC SUPPLY) HIGH IDLE NO LOAD NORMAL OPEN CIRCUIT VOLTAGEWAVEFORM (STICK) MAX CONTROL POT - HIGH IDLE - NO LOAD NORMAL WELD VOLTAGEWAVEFORM (STICK CC) MACHINE LOADED TO 300 AMPS AT27 VOLTS NORMAL OPEN CIRCUIT VOLTAGEWAVEFORM (WIRE CV TAP) MAX CONTROL POT - HIGH IDLE - NO LOAD NORMAL WELD VOLTAGEWAVEFORM (WIRE CV) MACHINE LOADED TO 300 AMPS AT28 VOLTS RETEST AFTER REPAIR ENGINE OUTPUT WELDER DC (STICK) OUTPUT (ARC control @ -10) WELDER CV (WIRE) OUTPUT (ARC Control @ +10) TOUCH START TIG (ARC Control @ +10) - ELECTRICAL DIAGRAMS SECTION - ELECTRICAL DIAGRAMS WIRING DIAGRAM - ENTIRE MACHINE - CODE 10926 (G4250) RANGER 305D- KUBOTA - WIRING DIAGRAM G-2 ELECTRICAL DIAGRAMS WIRING DIAGRAM - ENTIRE MACHINE - CODES 11121(G4571) HOT C ALTERNATOR RANGER 305D- KUBOTA - WIRING DIAGRAM FRAME GROUND G-4 ELECTRICAL DIAGRAMS WIRING DIAGRAM - ENTIRE MACHINE - CODES 11027 (G4226) RANGER 305D CE KUBOTA WIRING DIAGRAM - UK G-5 ELECTRICAL DIAGRAMS WIRING DIAGRAM - ENTIRE MACHINE - CODES 11122(G4572) RANGER 305D CE KUBOTA WIRING DIAGRAM - UK G-6 ELECTRICAL DIAGRAMS WIRING DIAGRAM - ENTIRE MACHINE - CODES 11189,11314 (G4572-1) RANGER 305D CE KUBOTA WIRING DIAGRAM - UK G-7 ELECTRICAL DIAGRAMS WIRING DIAGRAM - ENTIRE MACHINE - CODES 11039 (G4409) RANGER 305D CE KUBOTA - WIRING DIAGRAM - EUROPE G-8 ELECTRICAL DIAGRAMS WIRING DIAGRAM - ENTIRE MACHINE - CODES 11123(G4573) RANGER 305D CE KUBOTA WIRING DIAGRAM -EUROPE G-9 ELECTRICAL DIAGRAMS WIRING DIAGRAM - ENTIRE MACHINE - CODES 11190,11315 (G4573-1) RANGER 305D CE KUBOTA WIRING DIAGRAM -EUROPE G-10 ELECTRICAL DIAGRAMS SCHEMATIC - ENTIRE MACHINE - CODE 10926 (L11946)PAGE 1 OF 2 baffle near top of machine. Shunt on back of positive Chokeis beneath bearing end ELECTRICAL DIAGRAMS SCHEMATIC - ENTIRE MACHINE - CODE 10926 (L11946)PAGE 2 OF 2 2/5/03 NA CRM33549 L11943 ELECTRICAL DIAGRAMS G-13 G-13 SCHEMATIC - ENTIRE MACHINE - CODE 11121(L12212) PAGE 1 OF 2 of generator on support. baffle near top of ELECTRICAL DIAGRAMS SCHEMATIC - ENTIRE MACHINE - CODE 11121(L12212) PAGE 2 OF 2 RELEASED "A.02" FROM "X" G-14 ELECTRICAL DIAGRAMS SCHEMATIC - ENTIRE MACHINE - CODES 11188,11275 (L12212-1) PAGE 1 OF 2 on left side near bottom of G-15 ELECTRICAL DIAGRAMS SCHEMATIC - ENTIRE MACHINE - CODES 11188,11275 (L12212-1) PAGE 2 OF 2 L12212 G-16 ELECTRICAL DIAGRAMS SCHEMATIC - ENTIRE MACHINE - CODE 11027(L12039) PAGE 1 OF 2 bafflenear top of machine. G-17 ELECTRICAL DIAGRAMS SCHEMATIC - ENTIRE MACHINE - CODE 11027(L12039) PAGE 2 OF 2 6/20/03 UF CRM33673 EN-168 ELECTRICAL DIAGRAMS SCHEMATIC - ENTIRE MACHINE - CODE 11122(L12213) PAGE 1 OF 2 G-19 ELECTRICAL DIAGRAMS SCHEMATIC - ENTIRE MACHINE - CODE 11122(L12213) PAGE 2 OF 2 L12039 REL EASED "A.02" FROM "X" G-20 ELECTRICAL DIAGRAMS SCHEMATIC - ENTIRE MACHINE - CODES 11189,11314 (L12213-1) PAGE 1 OF 2 G-21 ELECTRICAL DIAGRAMS SCHEMATIC - ENTIRE MACHINE - CODES 11189,11314 (L12213-1) PAGE 2 OF 2 L12213 G-22 ELECTRICAL DIAGRAMS SCHEMATIC - ENTIRE MACHINE - CODE 11039(L12038) PAGE 1 OF 2 bafflenear top of machine. G-23 ELECTRICAL DIAGRAMS SCHEMATIC - ENTIRE MACHINE - CODE 11039(L12038) PAGE 2 OF 2 6/20/03 UF CRM33673 EN-168 ELECTRICAL DIAGRAMS SCHEMATIC - ENTIRE MACHINE - CODE 11123(L12214) PAGE 1 OF 2 G-25 ELECTRICAL DIAGRAMS SCHEMATIC - ENTIRE MACHINE - CODE 11123(L12214) PAGE 2 OF 2 L12038 RELEASED "A.02" FROM " X" G-26 ELECTRICAL DIAGRAMS SCHEMATIC - ENTIRE MACHINE - CODES 11190,11315 (L12214-1) PAGE 1 OF 2 G-27 ELECTRICAL DIAGRAMS SCHEMATIC - ENTIRE MACHINE - CODES 11190,11315 (L12214-1) PAGE 2 OF 2 L12214-1 G-28 Page Page Page Page Page Page Page ELECTRICAL DIAGRAMS Page ELECTRICAL DIAGRAMS 13 4 E3768-4 LABEL 12 2 S25347 T HERMAL INTERFACE PAD 10 280g. E2527 EPOXYENCAPSULATINGRESIN 91 M19436-7 POTTING T RAY