Lincoln Electric RANGER 405D Operating Manual page 36

PROBLEM / TROUBLE
A: Engine will not start.
1. Starter motor not
operating
2. Engine cranking but
not firing
3. Engine starts, runs for
approx 10 seconds
and then stops
B: No weld output and no
auxiliary power output.
C: No weld output but
auxiliary power
functions correctly.
D: No auxiliary power but
weld output functions
correctly.
E: Engine won't accelerate I)
to high idle speed.
F: Engine fails to drop to
low idle speed after
current stops (a 12 sec
delay is built in).
Page 36
TROUBLESHOOTING GUIDE
POSSIBLE CAUSE
I) Faulty or flat battery
II) Dirty battery terminals
III) Faulty wiring
IV) Faulty key switch
V) Faulty starter motor
I) Out of fuel
II) Fuel solenoid faulty
III) Engine protective relay R3 not being
activated by idler/watcher PCB
IV) R3 relay faulty
V) Faulty engine fuel system
VI) Idle/throttle setting incorrect
VII) Output Failure light illuminated
I) Engine protection alarm on.
Check front panel LED lights:
a) Oil pressure (too low)
b) Water temperature (too high)
c) Welding Output Failure
II) Welder over temperature
a) Stator winding too hot
b) Choke winding too hot
III) Fuel system
IV) Faulty idler/watcher PCB
I) Faulty wiring
II) Faulty brushes
III) Circuit breakers tripped
IV) Faulty rotor control / weld control PCB
V) Faulty rotor (rotor resistance ≈ 11 ohms)
l) OCV Output Control Switch in 'Welding
Output OFF' position
II) OCV Output Control - switched to
welding output 'off' position
IlI) Output terminal switch in '
switch.
no remote control connected
IV) Faulty wiring
V) Faulty Rotor/weld control PCB
VI) Faulty rectifier
VlI) Faulty choke/inductor
V I l I) Faulty stator
I) RCD tripped
II) Circuit breaker tripped
III) Faulty stator
IV) Faulty wiring/connections
Not enough welding current being drawn
II) Not enough auxiliary current being drawn
III) Faulty idle switch
IV) Faulty wiring
V) Faulty aux current sensor PCB
VI) Faulty idler solenoid
VII) Faulty throttle linkages
VIII)Faulty engine protection/idler PCB
IX) Faulty relay R1 and/or R2
X) Faulty Rotor/weld control PCB
I) Current still remains flowing in aux or
weld circuits
II) Idler switch in ' ' position
II) Faulty aux current sensor PCB
IV) Faulty engine protection/idler PCB
V) Faulty rotor/weld control PCB
VI) Faulty relay R1 and/or R2
VII) Faulty idler solenoid
V I I I ) Faulty throttle linkages
REMEDY
Replace or recharge
Clean
Repair/replace
Replace
Repair/replace
Refuel & bleed per engine operating manual
Replace
Refer to PCB Troubleshooting page 18
Replace
Refer engine operating manual
Repair/replace
Turn key switch to 'OFF' position and then
immediately retry to start. If light persists
repair/replace failed output components
Check oil level
Check fan belt, radiator restriction, clear
machine cooling air passages
Take to Authorised Field Service Shop.
Clear machine cooling air passages, check
Duty Cycle exceeded
Duty Cycle exceeded
Refer engine operating manual
Refer to PCB Trouble Shooting page 18
Repair/replace (refer wiring diagram)
Replace
Reset
Refer PCB Trouble Shooting page 18
Replace
Switch to 'Welding Output ON' position
Switch to 'on' position
' position with Switch to 'I' position or connect a remote
Repair/replace (refer wiring diagram)
Refer PCB Trouble Shooting page 18
Replace
Replace
Replace
Correct leakage fault & reset
Correct fault & reset
Replace
Repair/replace (refer wiring diagram)
Increase current or switch to ' ' position
Increase current or switch ' ' position
Replace
Repair/replace (refer wiring diagram)
Refer PCB Trouble Shooting page 18
Replace
Repair/replace
Refer PCB Trouble Shooting page 18
Replace
Refer PCB Trouble Shooting page 18
Idle only takes place when all loads are r e m o v e d
Switch to
Refer PCB Trouble Shooting page 18
Refer PCB Trouble Shooting page 18
Refer PCB Trouble Shooting page 18
Replace
Repair/replace
Repair/replace
Ranger 405D
position
IMA 608D