Lincoln Electric 5000 manual Troubleshooting, Possible Areas, Symptoms

E-1		TROUBLESHOOTING	E-1
	Observe all Safety Guidelines detailed throughout this manual
	PROBLEMS	POSSIBLE AREAS OF	RECOMMENDED
	(SYMPTOMS)	MISADJUSTMENTS(S)	COURSE OF ACTION

PROBLEMS

A.No generator power or welding out- 1. Open lead in flashing or field circuit. 1. Refer to wiring diagram. put.

-check lead 202C (brown) connection at oil-gard switch in engine block.

-check (green) GNDC lead con- nected to bearing end bracket.

2.	Open flashing diode (D1)	2.	Check continuity in forward direction
			202C (brown) and 202B (red)
3.	Faulty brushes.	3.	Check continuity and wear of brush.
			Replace brush if necessary.
4.	Faulty rheostat (R1).	4.	Rheostat resistance should be
			approximately 3 ohms when current
			control dial is set at “70 amps”.
5.	Faulty field rectifier (D1).	5.	Replace field rectifier.
6.	Faulty capacitor (C1).	6.	Replace capacitor.
7.	Faulty stator field winding.	7.	Disconnect lead 7A (blue) at D1 and
			check for continuity between leads
			7A and 9A (blue).
8.	Faulty rotor.	8.	Remove brushes and check rotor
			resistance between slip rings. It
			should read approximately 7 ohms.
			See “Generator / Welder
			Maintenance” section for brush
			installation procedure.
9. Dirty slip rings		9. Clean slip rings with a fine git emery
			paper.
B. Generator power is available but 1.	Loose connection to output stud.	1.	Check output studs and firmly tight-
unit will not weld.			en all connections.
		2.	Clean work clamp area of work to a
2.	Work not connected.
			shiny metal.
3.	Electrode holder loose.	3.	Check all electrode holder connec-
			tions.
4.	No open circuit voltage at output	4.	Refer to wiring diagram and check
	studs. Open lead in weld circuit.		leads W1, W1A, & W2 (black).
5.	Faulty reactor (L1).	5.	Check resistance from start to end of
			aluminum coil. Replace reactor if
			necessary.
6.	Rheostat (R1) lead broke	6.	Refer to wiring diagram.
			-	check lead 200 (red).
			-	check lead 202B (red).
			-	check rheostat tabs.

CAUTION

If for any reason you do not understand the test procedures or are unable to perform the tests/repairs safely, contact your Local Lincoln Authorized Field Service Facility for technical troubleshooting assistance before you proceed.

POWER ARC 5000