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TB 302 (dc only unit) Help!!

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  • TB 302 (dc only unit) Help!!

    Hello all,
    I just got my used TB 302 DC only unit. It welds great, on the run idle setting it will "idle up" when I strike the ark and will hold the idle up for a few seconds after I am done welding...... NOw If I plug something into the generator side and the unit is in the idle run setting, it will not kick up and produces low power, but if I manually turn it to the run setting it idles up and I have all the power I need, Any suggestions on where to look for what part is in need of repair

    Thanks
    D

  • #2
    Idle pickup toroid has failed and needs to be replaced

    Comment


    • #3
      Welcome to the forum K&D welding.
      Lincoln A/C 225
      Everlast PA200

      Comment


      • #4
        Thanks Cruz,
        I will looking in to it,

        Comment


        • #5
          Cruz is that the same as a current transducer? Sorry for the slew of questions I am new to fixing. Also finding part numbers seems a bit of a pain, I think the PN is #168829
          thanks again

          Comment


          • #6
            Yes, CT1

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            • #7
              I suggest you check it before just replacing it. CTs can but rarely fail.

              You haven't offered a unit SN but you should have 0VAC at CT1 leads (PC2 RC11 pins 1 & 3) with no auxiliary load and around 3.6VAC with a 100W light bulb load.

              If CT1 checks out then you've got a PC2 board problem.
              MM200 w/spot controller and Spoolmatic 1
              Syncrowave 180 SD
              Bobcat 225G Plus LPG/NG w/14-pin*
              *Homemade Suitcase Wire Feeder
              *HF-251D-1
              *WC-1S & Spoolmatic 1
              PakMaster 100XL
              Marquette "Star Jet" 21-110

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              • #8
                sorry the SN is LH300258Q, I hope its a quick fix, I am ok with just turning it to run and than back to idle run when I don't need full power but I really want the machine to be 100% functional.
                thank again

                Comment


                • #9
                  Use the values I posted previously to check CT1.

                  Also check the harness connectors at PC1 (RC21) and PC2 (RC16) for poor/corroded connections.
                  MM200 w/spot controller and Spoolmatic 1
                  Syncrowave 180 SD
                  Bobcat 225G Plus LPG/NG w/14-pin*
                  *Homemade Suitcase Wire Feeder
                  *HF-251D-1
                  *WC-1S & Spoolmatic 1
                  PakMaster 100XL
                  Marquette "Star Jet" 21-110

                  Comment


                  • #10
                    You should get 66 ohms on a resistance test
                    Last edited by cruizer; 05-14-2014, 11:12 AM.

                    Comment


                    • #11
                      That too.

                      Thanks cruiser.
                      MM200 w/spot controller and Spoolmatic 1
                      Syncrowave 180 SD
                      Bobcat 225G Plus LPG/NG w/14-pin*
                      *Homemade Suitcase Wire Feeder
                      *HF-251D-1
                      *WC-1S & Spoolmatic 1
                      PakMaster 100XL
                      Marquette "Star Jet" 21-110

                      Comment


                      • #12
                        Ok, SO I had the cover off today, Turns out I don't have my muliti-meter. So I can not report on any of the checks that you told me to do ( hope to get one). But I did see that slip rings look like they could be dressed, The have dark streaks in them and I could only see about and 1/8 or so of carbon left on the brushes, The unit has 2600 hrs on it and it looks like it never really had any maintenance done to it. I didn't notice any power problems (other than not kicking up when in idle/run on the generator side). I was welding 1/4 jet rod with it a also plugged my 211 on the 220 side and welded all day.

                        Being that I just bought it, I just want a solid base line and 100% working machine
                        thanks
                        D

                        Comment


                        • #13
                          I would sure use a stone on the slip rings and put new brushes on it.

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                          • #14
                            Originally posted by Kpack View Post
                            I would sure use a stone on the slip rings and put new brushes on it.
                            Actually if you use a fine grit emery, sprayed with brake clean, that's best. No reason to change out the brush cartridge. Might only show an 1/8", but they are spring loaded and thats all that shows out of the cartridge

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                            • #15
                              Cruzier I thought 2600 hrs was a lot on a set of brushes. So you like Emory cloth and brake cleaner better than a commutator stone ?

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