Lincoln Electric 300 D manual Welder Troubleshooting, Causes, What To Do

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WELDER TROUBLESHOOTING

 

 

E-2

 

 

 

 

TROUBLESHOOTING

E-2

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

WELDER TROUBLESHOOTING

 

 

 

 

 

 

 

 

 

 

 

 

 

 

TROUBLE

 

 

CAUSES

 

WHAT TO DO

 

 

 

 

 

 

 

 

 

 

 

 

 

1.

Machine fails to hold

 

a.

Rough or dirty commutator.

a.

Commutator should be turned or

 

 

 

 

the output (heat) consistently.

 

 

 

 

cleaned.

 

 

 

 

 

 

 

b.

Brushes may be worn down to

b.

Replace brushes.

 

 

 

 

 

 

 

 

limit.

 

 

 

 

 

 

 

 

 

c.

Field circuit may have variable

c.

Check field current with ammeter to

 

 

 

 

 

 

 

 

resistance connection or

 

discover varying current. This

 

 

 

 

 

 

 

 

intermittent open circuit due to

 

applies to both the main generator

 

 

 

 

 

 

 

 

loose connection or broken wire.

 

and exciter.

 

 

 

 

 

 

 

d.

Electrode lead or work lead

d.

Tighten all connections.

 

 

 

 

 

 

 

 

connection may be poor.

 

 

 

 

 

 

 

 

 

e.

Wrong grade of brushes may

e.

Use Lincoln brushes.

 

 

 

 

 

 

 

 

have been installed on generator.

 

 

 

 

 

 

 

 

 

f.

Field rheostat may be making

f.

Inspect and clean the rheostat.

 

 

 

 

 

 

 

 

poor contact and overheating.

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

2.

Welder starts but fails

 

a.

Generator or exciter brushes

a.

Be sure that all brushes bear on the

 

 

 

 

to generate current.

 

 

may be loose or missing.

 

commutator and have proper spring

 

 

 

 

 

 

 

 

 

 

tension.

 

 

 

 

 

 

 

b.

Exciter may not be operating.

b.

Check exciter output voltage with

 

 

 

 

 

 

 

 

 

 

voltmeter or lamp.

 

 

 

 

 

 

 

c.

Field circuit of generator or

c.

Check for open circuits in rheostat,

 

 

 

 

 

 

 

 

exciter may be open.

 

field leads, and field coils. Check

 

 

 

 

 

 

 

 

 

 

rectifier bridge.

 

 

 

 

 

 

 

d.

Exciter may have lost excitation.

d.

Flash fields. (1) Check flashing

 

 

 

 

 

 

 

 

 

 

diode at 5 o’clock brushholder in

 

 

 

 

 

 

 

 

 

 

generator.

 

 

 

 

 

 

 

e.

Series field and armature circuit

e.

Check circuit with ringer or voltmeter.

 

 

 

 

 

 

 

 

may be open-circuited.

 

 

 

 

 

 

 

 

 

 

 

 

 

 

(1)FLASHING THE FIELDS:

1.Stop the engine welder and remove the cover from the exciter.

2.Turn the “Fine Current Adjustment” (rheostat) to “100” on the dial.

3.Using a 12 volt automotive battery, connect it’s negative terminal to the negative brushholder. The negative brushholder is the one nearest to the rotor lamination. See the wiring diagram. With the engine NOT running, touch the positive battery terminal to the positive brushholder. Remove the battery from the circuit.

4.Replace the exciter cover. Start the welder and the generator voltage should build up.

3.

Welding arc is loud and

a.

Current setting may be too high.

a.

Check setting and current output with ammeter.

 

spatters excessively

 

 

 

 

 

 

b.

Polarity may be wrong.

b.

Check polarity. Try reversing polarity or try an

 

 

 

 

 

electrode of the opposite polarity.

4.

Welding current too great or too

a.

Exciter output low causing low output

a.

Check exciter field circuit.

 

small compared to indication on

 

compared to dial indication.

 

 

 

the dial.

 

 

 

 

 

 

b.

Operating speed too low or too high.

b.

Adjust speed with screw stops at throttle linkage.

 

 

 

 

 

(High idle - 1800 RPM, Low idle - 1375 RPM)

5.

Arc continuously pops out.

a.

“Current Range Selector” switch may be

a.

Set the switch at the center of the current range

 

 

 

set at an intermediate position.

 

desired.

 

 

 

 

 

 

CLASSIC 300D

Image 24
Contents Sales and Service through Subsidiaries and Distributors Worldwide 300 DCLASSIC IM631-BSAFETY FOR ENGINE powered equipmentELECTRIC AND MAGNETIC FIELDS may be dangerous CALIFORNIA PROPOSITION 65 WARNINGSELECTRIC SHOCK can kill ARC RAYS can burnFUMES AND GASES can be dangerous Semiautomatic DC Constant Voltage Wire Welder DC Manual Stick WelderFOR ELECTRICALLY powered equipment CYLINDER may explode if damagedWELDING SPARKS can cause fire or explosion PRÉCAUTIONS DE SÛRETÉ Mar. ‘93Please Examine Carton and Equipment For Damage Immediately On-Line Product RegistrationThank You TABLE OF CONTENTS Section ASection B Section CINSTALLATION TECHNICAL SPECIFICATIONS - CLASSIC 300DPERKINS 104-22 DIESEL ENGINE TYPICAL FUEL CONSUMPTION DATA PHYSICAL DIMENSIONS2DESIGN FEATURES GENERAL DESCRIPTIONPRE-OPERATION INSTALLATION WARNING See additional warning information at thefront of this operator’s manual Exhaust Spark ArresterPRE-OPERATION SERVICE TRAILER See Optional FeaturesVEHICLE MOUNTING POLARITY CONTROL AND CABLE SIZESBattery Charging ENGINE BREAK-INTo prevent EXPLOSION when To prevent ELECTRICAL DAMAGE whenOPERATION ENGINE OPERATIONWELDER OPERATION The AC auxiliary power, supplied as a standard, has a rating of 3.0 kVA of 115/230 VAC 60 hertz ACCESSORIES OPTIONAL FEATURES Field InstalledSTICK OPTIONS TIG OPTIONS062-3/32” 1.6-2.8mm wire MAINTENANCE MAINTENANCESee additional warning information at front of this operator’s manual Idler Maintenance NameplatesPurging Air from Fuel System Perkins 104-22 Engine 3. Idler solenoid is activated for high idleENGINE SERVICE 5/06S20919-2 ENGINE SERVICE EVERY 400 HOURS OR 12 MONTHSI = Inspect GFCI RECEPTACLE TESTING AND RESET TING PROCEDURE If the equipment has been shut down, it must be restartedTROUBLESHOOTING TROUBLESHOOTINGWELDER TROUBLESHOOTING TROUBLECAUSES WHAT TO DOELECTRONIC IDLER TROUBLESHOOTING GUIDE ELECTRONIC IDLER TROUBLESHOOTING GUIDE ENGINE TROUBLESHOOTING DIAGRAMS K924-4 REMOTE CONTROL OPTIONALWIRE FEED MODULE OPTIONAL WIRE FEEDL11865 CLASSIC 300D WIRING DIAGRAM FOR CODES 10911 AND ABOVEWHEN MAKING THESE CONNECTIONS THERMOSTAT * MACHINE MUST NOT BE RUNNINGY GB W K2464-1 REMOTE CONTROL WIRING / CONNECTION DIAGRAMCV WIRE CONTROL POT CCW S26097CONTROL PANEL S10766PRECAUCION WARNUNGATENÇÃO AVISO DEWARNUNG ATENÇÃOKeep your head out of fumes Sales and Service through Subsidiaries and Distributors Worldwide Worlds Leader in Welding and Cutting Products
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300 D specifications

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