Chopper Module Removal and Replacement | Lincoln Electric SVM175-A

Return to Section TOC

Return to Section TOC

Return to Section TOC

Return to Section TOC

Return to Master TOC

Return to Master TOC

Return to Master TOC

Return to Master TOC

F-87

TROUBLESHOOTING & REPAIR

F-87

CHOPPER MODULE REMOVAL AND REPLACEMENT

WARNING

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)

RANGER 305D

Image 141

Lincoln Electric SVM175-A service manual Chopper Module Removal and Replacement, Description

Contents

RangerTM 305D Powered equipment SafetyFor Engine Electric Magnetic Fields Electric Shock can kill ARC Rays can burn Fumes and GasesCan be dangerous Cylinder may explode Welding Sparks canSAFETYCause fire or explosion If damaged For Electrically Précautions DE Sûreté Pour Précautions DE SûretéLES Machines À Souder À Transformateur ET À Master Table of Contents for ALL Sections Table of Contents Installation SectionSection A-1 Height Width Depth Weight InstallationAIR Cleaner Engine Idler Muffler Protection Lubrication Emissions Fuel System Governor Engine Warranty AIR CleanerEngine Protection Model Number Storing Safety PrecautionsStacking Angle of Operation Location and Ventilation Lifting High Temperature OperationTowing High Altitude Operation OIL PRE-OPERATION Engine Service Battery ConnectionMuffler Outlet Pipe Spark Arrester Remote Control Machine Grounding AccessoriesElectrical Output Connections Cable Installation Table A.1 Welding Output Cables Auxiliary Power ReceptaclesStandby Power Connections Total Combined Length Installation Premises or residential elec Figure A.2 Connection of Ranger 305D to Premises Wiring Section B-1 Operation Section Additional Safety Safety InstructionsPrecautions Operating Instructions Operation Design Features Control and SettingsOperation Figure B.1 Digital Output Meters Wire Feeder Voltmeter Switch Starting the Engine Engine OperationBefore Starting the Engine Stopping the Engine Diesel Fuel Stick Welding BREAK-IN PeriodTable B.2 Typical Current RANGES1 for Tungsten ELECTRODES2 Downhill Pipe Welding Wire WELDING-CV Auxiliary PowerSee Table B.2 for reference settings TIG Welding ARC Gouging Auxiliary Power Loads Ranger 305D Simultaneous Welding and Power LoadsSimultaneous Welding Ranger 305D Section C-1 Accessories Field Installed Options Options / AccessoriesTIG Welding Accessories Welding Accessories Wire Feeders Using K867 Universal Electric Wire FeedersConnection of Lincoln Connection of the Ranger 305D to Connection of the LN-25 to Ranger 305D Across the ARCSee Figure C.2 Volt Remote Output Control Module Connection Diagram Ranger 305D with 42 Volt RemoteOutput Control Module See Figure C.3 See Figure C.4 Connection Diagram with K857 Remote Control 7ACCESSORIESC-7 Connection of the LN-8 to Ranger 305D Using K595 Control Cable See Figure C.6 Connection of the LN-742 to Ranger 305D See Figure C.7 Figure C.7 Ranger 305D/LN-742 Connection Diagram Ranger 305D Section D-1 Maintenance Engine Maintenance Safety Precautions Routine and Periodic Maintenance Kubota D722 Diesel Engine Ranger 305D MAINTENANCED-3 See Table D.2 Engine Oil ChangeOil Filter Change Engine Oil Refill capacities 5MAINTENANCED-5 Cooling System AIR CleanerTightening the FAN Belt Do not remove cap if radiator is Battery Maintenance Engine Adjustment Charging the Battery Cleaning the BatteryWelder / Generator Checking the Electrolyte Level Gfci Receptacle Testing Resetting Procedure Maintenance Section E-1 Theory of Operation Section Battery Battery, Engine, Engine ProtectionTheory of Operation Charging System Engine Idle System Idle Solenoid Operation Idle Switch Operation Flashing Generating PowerBuilding Output AC output Weld Power Weld Power and ControlTechnology Fundamentals Weld Control and Feedback Remote output control Electronic Output ContactorDigital Meters 90 VDC Chopper Technology FundamentalsDiode Inductor ARC Pulse Width Modulation Minimum OutputMaximum Output Troubleshooting & Repair Section Troubleshooting & Repair Section Section FSection F-1 HOW to USE Troubleshooting Guide 2TROUBLESHOOTING & REPAIRF-2 PC Board Troubleshooting Procedures Troubleshooting & Repair3F-3 PC Board can be damaged by static electricity Troubleshooting Guide Engine Throttle TestsAdjus ment Test Brush and Slip Ring Symptoms Misadjustments Course of Action Problems Possible AreasThrottle Adjustment test Engine Throttle Adjustment Control Adjustment Test Switch Resistan Test Potentiometer ModeSwitch Resistance Test Control Potentiometer Mode Switch Test Chopper Module Resistance Switch Test, Remote MISC. Weld Issues Potentiometer Test Welding output in any mode Engine Alter Engine and Idle Problems Fuel Solenoid Test. See Fuel Solenoid Test Perform the Idle Solenoid Test Perform the Fuel Solenoid TestShutdown Solenoid Test Engine and Idle Problems If the solenoid does not hold Engine and Idle Problems Rottle Adjustment Test Test Description Case Cover Removal and Replacement ProcedureMaterials Needed 21F-21 Replacement Procedure Case Cover Removal and Replacement Procedure 23F-23 Chopper Module Capacitor Discharge Procedure Perform the Case Cover Removal proce Test Procedure Fuel Shutdown Solenoid Test 26TROUBLESHOOTING & REPAIRF-26 Fuel Shutdown Solenoid TestSee Figure F.4 Fuel Solenoid Connections 27TROUBLESHOOTING & REPAIRF-27 Ranger 305D 29F-29 Engine Throttle Adjustment Test Strobe-Tach Method Engine Throttle Adjustment Test 31TROUBLESHOOTING & REPAIRF-31 Engine Throttle Adjustment TestFrequency Counter Method Low Idle adjustment High idle adjustmentVibratach Method 33F-33 Idler Solenoid Test Idler Solenoid Test 34TROUBLESHOOTING & REPAIRF-34 Description Engine Alternator Test 36TROUBLESHOOTING & REPAIRF-36 Test ProcedureEngine Alternator Test Brush and Slip Ring Service Procedure Perform the Case Cover Removal Procedure Brush and Slip Ring Service ProcedureCleaning slip rings Case Cover Replacement Procedure 39F-39 Rotor Resistance and Ground Test Static Rotor Resistance and Ground Test Static 40TROUBLESHOOTING & REPAIRF-40 Also referred to as flying resistance test Rotor Resistance and Ground Test Dynamic Rotor Resistance and Ground Test Dynamic Perform theifbrushnecessaryand.slip ring service procedure 43F-43 Rotor Voltage Test 44TROUBLESHOOTING & REPAIRF-44 TheEngineS Throttle Adjustment Test . tator ShortRotor Voltage Test Rotor Voltage Test Ranger 305D Engine Not Running Flashing Voltage Test Flashing Voltage Test Case Cover Removal Procedure Flashing Voltage Test 49TROUBLESHOOTING & REPAIRF-49 Ranger 305D 51F-51 Stator Voltage Tests Stator Voltage Tests To test the 120 VAC auxiliary windingTo test the 240 VAC auxiliary winding Stator Voltage Tests 53TROUBLESHOOTING & REPAIRF-53 To test the three-phase weld winding To test the 42 VAC wire feeder winding 55F-55 Stator Short Circuit & Ground Test Stator Short Circuit & Ground Test Perform Case Cover Removal Procedure 57F-57 Output Rectifier Bridge Test Dis harge procedure 58TROUBLESHOOTING & REPAIRF-58Output Rectifier Bridge Test Perform the Chopper Module Capacitor Figure F.16 SHUNT/RECTIFIER Leads Output Rectifier Bridge Test Table F.1 Diode Test Table Perform the Case Cover replacement Procedure Chopper Module Function Test Chopper Module Function Test Procedure. CaseCover Replacement Chopper Module Function TestWeld. Control Board PWM Gate Drive Test Ranger 305D Chopper Module Resistance Test Capacitor Discharge Procedure Chopper Module Resistance TestCase Cover Removal Rocedure Table F.2 Diode Test Table Ohmmeter Reading Ranger 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 Control Potentiometer and Mode Switch Resistance Test 76TROUBLESHOOTING & REPAIRF-76Perform .the Case cover Removal Procedure Cover Replacement procedure Table F.3 Mode Switch Ranger 305D Remote Receptacle Resistance Test Perform the Case Cover Replacement Remote Receptacle Resistance TestSee Table F.4 Table F.4 Welding Terminal Ohmmeter Ohmmeter Reading Ranger 305D Output Rectifier Bridge and Choke Removal Replacement Removal Procedure 84TROUBLESHOOTING & REPAIRF-84Discharge procedure Output Rectifier Bridge and Choke Removal and Replace Perform the Case Cover Removal Replacing the Output Rectifier Ranger 305D Chopper Module Removal and Replacement Procedure Chopper Module Removal and ReplacementTerminal Removal HL W8 HL W6 Replacement Ranger 305D STATOR/ROTOR Removal and Replacement STATOR/ROTOR Removal and Replacement 92TROUBLESHOOTING & REPAIRF-92Discharge Pr Cedure See Figure F.21 Figure F.22 Alternator Leads Figure F.21 Wire Guide Hole Do not Hold the Rotor by the Slip Rings Replacing the Rotor Figure F.23 DISC/RING Location Replacing the Stator Normal Open Circuit Voltage Waveform 120VAC Supply 97TROUBLESHOOTING & REPAIRF-97 98TROUBLESHOOTING & REPAIRF-98 Normal Open Circuit Voltage Waveform StickMAX Control POT High Idle no Load 99TROUBLESHOOTING & REPAIRF-99 Normal Weld Voltage Waveform Stick CCMachine Loaded to 300 Amps AT 27 Volts Normal Open Circuit Voltage Waveform Wire CV TAP 100TROUBLESHOOTING & REPAIRF-100 101TROUBLESHOOTING & REPAIRF-101 Normal Weld Voltage Waveform Wire CVMachine Loaded to 300 Amps AT 28 Volts Retest After Repair Auxiliary Power Output Electrical Diagrams Section Electrical Diagrams Section GSection G-1 Wiring Diagram Entire Machine Code 10926 G4250 Electrical Diagrams Wiring Diagram Entire Machine Codes 11121 G4571 Ranger 305D- Kubota Wiring Diagram Wiring Diagram Entire Machine Codes 11188, 11275 G4571-1 Ranger 305D- Kubota Wiring Diagram Wiring Diagram Entire Machine Codes 11027 G4226 Ranger 305D CE Kubota Wiring Diagram UK Alternator Wiring Diagram Entire Machine Codes 11122 G4572 Ranger 305D CE Kubota Wiring Diagram UK Wiring Diagram Entire Machine Codes 11039 G4409 Ranger 305D CE Kubota Wiring Diagram Europe Wiring Diagram Entire Machine Codes 11123 G4573 Ranger 305D CE Kubota Wiring Diagram -EUROPE Wiring 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 54811L PC Board Assembly Chopper PC BD ALL Codes L11845-1