Troubleshooting Guide - Lincoln Electric RANGER 305G EFI Service Manual

LINCOLN ELECTRIC

Troubleshooting guide

Observe Safety Guidelines
detailed in the beginning of this manual.
PROBLEMS
(SYMPTOMS)
Major physical or electrical
damage is evident.
No welding output or auxiliary
power. The engine operates
normally.
No welding output in any
mode. The auxiliary output is
normal. The engine operates
normally.
POSSIBLE AREAS OF
MISADJUSTMENT(S)
OUTPUT PROBLEMS
1. Contact your local
authorized Lincoln Electric
Service Facility.
1. Check for loose or faulty
connections at any leads
attached to either the auxiliary
output receptacles and/or the
weld output terminals. See
Wiring Diagram.
1. Place the welding terminals
switch in the "WELD
TERMINALS ON" position. If
the problem is solved, the fault
may be in the external control
cable or the attached wire
feeder, amptrol, arc start
switch, etc. (if used).
2. With the engine at high idle
(3700 RPM), the machine in the
CC-STICK mode, the output
control at maximum and the
welding terminals switch in the
"WELD TERMINALS ON"
position; check for the
presence of approximately 58
VDC, OCV (open circuit voltage)
at the weld output terminals.
3. If the correct OCV is present
at the welding output
terminals, check the welding
cables, connectors, work
clamps, electrode holder, etc.
for loose or faulty connections.
Ranger® 305G EFI Service Manual
TROUBLESHOOTING GUIDE
RECOMMENDED
COURSE OF ACTION
1. Contact the Lincoln Electric
Service Department at 1-888-
935-3877.
1. Check the brushes for wear
and proper contact to the rotor
slip rings.
2. Perform the Brush and Slip
Ring Service Procedure.
3. Perform the Rotor Voltage
Test Procedure.
4. Perform the Stator Voltage
Test Procedure.
1. Check for damaged
conductors or faulty
connections on the heavy
current carrying leads that
connect the output studs to the
chopper module and to the
output Rectifier. Also check the
shunt and choke assemblies for
damage and faulty connections.
2. Perform the Chopper
Module Function Test
Procedure.
3. Perform the Output Rectifier
Bridge Test Procedure.
4. Perform the Stator Voltage
Test Procedure.
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