Capacitor Discharge Procedure - Lincoln Electric Cross Country 300 Service Manual

LINCOLN ELECTRIC
CAPACITOR DISCHARGE PROCEDURE
Service and repair should be performed by only Lincoln Electric factory trained personnel. Unauthorized
repairs performed on this equipment may result in danger to the technician or machine operator and will
invalidate your factory warranty. For your safety and to avoid electrical shock, please observe all safety
notes and precautions detailed throughout this manual. If for any reason you do not understand the test
procedures or are unable to perform the test/repairs safely, contact the Lincoln Electric Service Department
for electrical troubleshooting assistance before you proceed. Call 1-888-935-3877.
TEST DESCRIPTION
This procedure will ensure that the Field Capacitor and the large Capacitors in the Chopper Module have
been discharged.
MATERIALS NEEDED
Volt/Ohmmeter
Resistor (25-1000 ohms and 25 watts minimum) Lincoln Part #S01404-114 works well for this purpose
Electrically Insulated Gloves
Electrically Insulated Pliers
Jumper Leads
Wiring Diagram
TEST PROCEDURE
1. Turn off the engine on the Cross Country 300 machine.
2. Perform the Case Cover Removal Procedure.
3. Locate the field capacitor. See Figure F.3. See Wiring Diagram.
4. Using a volt/ohmmeter, check the DC voltage at the terminals of the field capacitor. See Figure F.4.
See Wiring Diagram.
5. If any voltage is present, discharge the capacitor using the high wattage resistor (25-1000 ohms @
25 watts minimum), electrically insulated gloves and pliers. Hold the resistor on the capacitor
terminals for ten seconds. See Figure F.4. See Wiring Diagram.
6. Using a volt/ohmmeter, check the DC voltage at the terminals of the filed capacitor. The voltage
should be zero. If any voltage remains, repeat the discharge procedure until the voltage is zero.
7. Locate the chopper module and capacitor assembly on the power module panel. See Figure F.5.
See Wiring Diagram.
NOTE: NEVER USE A SHORTING STRAP TO DISCHARGE CAPACITORS.
8. If the Lincoln recommended resistor or an equivalent resistor is used, the capacitors can be
discharged by holding the resistor terminals with insulated pliers and using the resistor terminals to
bridge chopper module terminals B1 to B2 and B4 to B5. See Figure F.6. See Wiring Diagram. DO
NOT TOUCH THE TERMINALS OR METAL PARTS OF THE PLIERS WITH YOUR BARE HANDS. Hold the
resistor in place for about ten seconds.
Cross Country™ 300 Service Manual
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