by Peter W. Sun Mar 12, 2017 8:45 am
A bunch of things. And why I dislike unmetered Variacs so much!
First tests with the unit turned OFF and all caps discharged and the tubes OUT.
a) Measure resistance from each tab of the quad-cap to the chassis. It should be substantial-to-infinite in every case. If it is not, one/another/more sections of the cap are shorting. This cap *WILL NOT REFORM*, it needs to be replaced.
b) Measure resistance across each component on the PC board. Are there any differences one-to-the-other channel? If so, start there.
NEXT: You mentioned that you tested the tubes. How, and with what, did you do this? If an emissions-tester, does it have tests for "Shorts" and "Gas"? If so, did each tube test good? Same question if a GM tester? And if a GM tester, how did you pair the output tubes at re-installation?
a) Install all the tubes, not including the 5AR4. Measure the filament voltages at each tube. Measure at the rectifier socket. They should be at/about 6.3 and 5 V respectively, with a 117V input +/- a few fractions of a volt.
b) Measure the bias voltage at the front sockets - it should be somewhere between 0.9 and 2.3V or so. This is separately rectified via the selenium rectifier under the chassis. Twiddle the adjustment pot - is there a response on each channel? If all is good, so far, shut off and cool down.
c) NOW. Do you have access to an ammeter and do you know how to use it? If so, set it up to measure the developed load as B+ ramps up in the amp as the rectifier starts to pass DC. You should be somewhere about 1.3A when the amp is fully warmed up. Too little/too much are problems. Too little, 80%+ of the time is a bad rectifier. 15% of the time, an open winding on the transformer. 5% of the time, something else. Too much is 90% of the time a shorting section in the quad-cap, 10% of the time, something else such as a partially shorting winding or tube.
d) WITH GREAT CARE AND CAUTION - as I expect you do not have or use an isolation transformer (separate rant) - and with the amp on its side so you can reach the quad-cap tabs, install the rectifier and turn on the amp. Keeping a sharp eye on the ammeter, measure the voltage-to-chassis at each tab of the quad-cap. Those voltages will be listed in the manual (readily available on-line) but the 'first' tab should be nearly/a bit over 450VDC. I use shrink-tubing on my tester probes when working at these voltages to prevent inadvertent shorts. Just the tiniest bit of tip exposed.
If the tubes are free of shorts or gas, and good (via a reliable tester, not just a VOM on the filament pins), and all the voltages are present and correct, I suspect something mechanical. If you have the old phenolic (brown) board, check all the traces for cracks or breaks. If your amp is wired with solid wire, check _EVERY_ connection to make sure that it is intact and that the insulation is not holding the connection in place thereby fooling you. Check the "stereo/mono" switch. A good many of these have gone "open" over the years - invisibly. Check each socket and make sure nothing is loose.
If there are discrepancies - start with those. The 5AR4 comes first to mind. If you have a known-good 5U4 sitting about, use that. It de-rates the amp by about 20%, but is perfectly adequate to drive it for testing purpose, and even permanently if you do not mind the de-rate - and set the bias properly.
That is about all I can suggest from 20,000 feet and without the amp in front of me. If you were nearby this could go further, but I have no idea where you are.