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| TROUBLESHOOTING & REPAIR |
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| Observe Safety Guidelines |
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| detailed in the beginning of this manual. |
| TROUBLESHOOTING GUIDE | |||||||||
| PROBLEMS |
| POSSIBLE AREAS OF |
| RECOMMENDED |
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| (SYMPTOMS) |
| MISADJUSTMENT(S) |
| COURSE OF ACTION | |||||||
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| WELD OUTPUT PROBLEMS |
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| The machine will weld, but the |
| 7. The weld cables may be coiled, |
| 6. With the above load applied, the | |||||||
| welding arc is “cold”. The engine |
| or wrapped around metal reels |
| engine should maintain at least | |||||||
| runs normally and the auxiliary |
| or racks. This can cause exces- |
| 3350 RPM. If the engine cannot | |||||||
| power is normal. (continued) |
| sive electrical inductance in the |
| maintain this RPM, make sure | |||||||
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| weld circuit. Try welding after |
| there is an adequate supply of | ||||||
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| uncoiling the cables, or discon- |
| clean, fresh fuel. Check the fuel | ||||||
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| nect the existing cables and |
| filter and the air filter. | Replace | |||||
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| weld with a set of adequately |
| any filter that is dirty or dam- | ||||||
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| sized, short test cables. |
| aged. If this doesnʼt help, the | ||||||
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| engine should be serviced. | |||||
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| 7. Compare the volt and amp | |||||
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| readings shown on the external | |||||
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| meters with the readings dis- | |||||
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| played on the machineʼs front | |||||
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| panel. If these readings differ | |||||
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| significantly, perform the WELD | |||||
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| CONTROL FEEDBACK TEST. | |||||
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| 8. If the maximum weld output | |||||
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| cannot be obtained even though | |||||
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| the engine | maintains | correct | |||
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| RPM, and the front panel dis- | |||||
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| plays are | reading accurately. | ||||
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| Check for damaged conductors | |||||
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| and loose or damaged connec- | |||||
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| tions at each of the large weld- | |||||
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| current carrying conductors that | |||||
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| connect the stator, output rectifi- | |||||
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| er, chopper | module, | choke, | |||
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| shunt, and | output terminals. | ||||
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| See the wiring diagram. | |||||
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| 9. If all of the these connections | |||||
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| are good, perform the Rotor | |||||
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| Voltage | Test, | the | Stator | ||
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| Voltage | Test, | the | Output | ||
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| Rectifier Test, and the Power | |||||
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| Module Resistance Test.. | |||||
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| 10. Perform |
| the | CONTROL | ||
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| POTENTIOMETER | AND | ||||
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| TANCE TEST. Perform the | |||||
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| MODE | SWITCH | RESIS- | |||
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| REMOTE | RECEPTACLE | ||||
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| Replace the weld control PC | |||||
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| ESISTANCE |
| TEST. | ||
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| CAUTION |
| board. |
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| 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 troubleshooting assistance before you proceed. Call | |||||||||||
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| RANGER 305D |
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