Page 2
THANK YOU FOR SELECTING A QUALITY PRODUCT BY KEEP YOUR HEAD OUT OF THE FUMES. DON’T get too close to the arc. LINCOLN ELEC TRIC. Use corrective lenses if necessary to stay a reasonable distance away from the arc. READ and obey the Safety Data PLEASE EXAMINE CARTON AND EQUIPMENT FOR Sheet (SDS) and the warning label DAMAGE IMMEDIATELY...
Page 3
MAGNETIC FIELDS MAY W117.2-1974. A Free copy of “Arc Welding Safety” booklet BE DANGEROUS E205 is available from the Lincoln Electric Company, 22801 St. Clair Avenue, Cleveland, Ohio 44117-1199. 2.a. Electric current flowing through any conductor BE SURE THAT ALL INSTALLATION, OPERATION, causes localized Electric and Magnetic Fields (EMF).
Page 4
S FETY ELECTRIC SHOCK ARC RAYS CAN BURN. CAN KILL. 3.a. The electrode and work (or ground) circuits are 4.a. Use a shield with the proper filter and cover plates to protect your electrically “hot” when the welder is on. Do eyes from sparks and the rays of the arc when welding or not touch these “hot”...
Page 5
S FETY WELDING AND CUTTING CYLINDER MAY EXPLODE IF SPARKS CAN CAUSE DAMAGED. FIRE OR EXPLOSION. 7.a. Use only compressed gas cylinders containing the correct shielding gas for the process used 6.a. Remove fire hazards from the welding area. If and properly operating regulators designed for this is not possible, cover them to prevent the welding sparks the gas and pressure used.
LINCOLN ELECTRIC Fleet™ 650 Service Manual Fleet™ 650 Service Manual Last update: 2018/03/01 FLEET™ 650 ..............................1 Service Manual ..............................1 Troubleshooting & Repair ..........................3 HOW TO USE TROUBLESHOOTING GUIDE ..................... 3 PC BOARD TROUBLESHOOTING PROCEDURES ....................4 Troubleshooting guide ............................5 Test Procedures ..............................
Page 7
LINCOLN ELECTRIC Fleet™ 650 Service Manual CHOKE TEST PROCEDURE ..........................55 PIPE/GOUGE RANGE SWITCH AND WELD MODE SWITCH TEST PROCEDURE ..........57 THERMOSTAT TEST PROCEDURE......................... 60 Removal And Replacement Procedures ...................... 63 FLASHING DIODE (D1) & FIELD DIODE (D2) REMOVAL AND REPLACEMENT PROCEDURE ......63 FRONT PANEL REMOVAL AND REPLACEMENT PROCEDURE ...............
Troubleshooting & Repair HOW TO USE TROUBLESHOOTING GUIDE 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 and 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.
ELECTRIC SHOCK can kill. remove them until installation is complete. • If you return a PC board to The Lincoln Electric Company • Have an electrician install and service this for credit, it must be in the static-shielding bag. This will equipment.
7. Perform the Stator Voltage Test Procedure. 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.
Page 11
GFCI stator. receptacles. 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.
Page 12
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.
Page 13
1800 rpm. If not the machine can produce. perform engine maintenance. 3. If the current is correct try If the Fleet 650 has meters, increasing the “ARC CONTROL” make sure that they read the setting. same as the load bank meters.
Page 14
7. Replace the weld control board. 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.
Page 15
6. Replace the weld control board. 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.
Page 16
3. The weld control board may be defective. 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.
Page 17
(size, length, coils or bad connections). 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.
Page 18
Diagram. temperature condition. 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.
Page 19
3. Fuel injector may be clogged or malfunctioning. 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.
Page 20
3. The air filter may be clogged, replace if necessary. 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.
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.
Page 22
LINCOLN ELECTRIC Fleet™ 650 Service Manual 14. Perform any tests / replacement procedure. REPLACEMENT PROCEDURE 1. Position the engine case side onto the machine. 2. Using a 1/2” nutdriver, tighten the two bottom screws securing the engine case side to the machine.
Page 23
LINCOLN ELECTRIC Fleet™ 650 Service Manual Figure F.1 – Roof, fuel cap, cover seal, door slide, door assembly, fuel trough and right case side location Figure F.2 – Engine case side and front case side location...
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.
Page 25
LINCOLN ELECTRIC Fleet™ 650 Service Manual Figure F.3 – Chopper module board locations Figure F.4 – Chopper module board discharge...
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.
Page 27
LINCOLN ELECTRIC Fleet™ 650 Service Manual SEATING BRUSHES: 11. If brushes have been replaced, repositioned or are not making full contact with the slip rings, it may be necessary to re-seat them. This can be done by placing a strip of 180 grit sandpaper between the slip rings and the brushes, with the abrasive side against the brushes.
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.
Page 29
LINCOLN ELECTRIC Fleet™ 650 Service Manual Figure F.5 – Flashing diode (D1) & field diode (D2) location Figure F.6 – Flashing diode (D1) & field diode (D2) lead locations...
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.
Page 31
LINCOLN ELECTRIC Fleet™ 650 Service Manual Table F.2 – Engine shutdown relay resistance tests TEST POINT TEST POINT EXPECTED READING MACHINE CONDITION TERMINAL 87 TERMINAL 30 OPEN NO POWER APPLIED TO (HIGH RESISTANCE) RELAY COILS. TERMINAL 87A TERMINAL 30 CLOSED...
Page 32
LINCOLN ELECTRIC Fleet™ 650 Service Manual Figure F.8 – Engine shutdown relay terminal locations and schematic...
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.
Page 34
LINCOLN ELECTRIC Fleet™ 650 Service Manual 15. If the meter reads correctly, check the connections between the alternator and the battery. See Wiring Diagram. 16. If the voltage at both of the above test points reads the same or less than the battery voltage measurement in Step 4, the alternator is defective.
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.
Page 36
LINCOLN ELECTRIC Fleet™ 650 Service Manual Figure F.9 – Capacitor lead and terminal locations...
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.
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.
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.
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.
Page 41
LINCOLN ELECTRIC Fleet™ 650 Service Manual 12. If these voltage readings are not within the specified limits, check for loose connections or broken wires between the test points and the stator windings. If there are no wiring problems, the stator is defective and should be replaced.
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.
Page 43
LINCOLN ELECTRIC Fleet™ 650 Service Manual 8. Check for grounds by placing one of the ohmmeter probes on a clean, unpainted metal surface of the machine. Touch the other probe to each of the five rectifier terminals. The resistance to chassis ground from each terminal should be very high, 500,000 (500K) ohms minimum.
Page 44
LINCOLN ELECTRIC Fleet™ 650 Service Manual Figure F.12 – Output rectifier bridge lead locations...
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.
Page 46
17. Turn off the engine on the Fleet 650 machine. 18. Reconnect leads 23A, 25A, 23 and 25 and perform the Weld Control Board PWM Gate Signal Test Procedure.
Page 47
LINCOLN ELECTRIC Fleet™ 650 Service Manual Figure F.13 – Chopper module boards location Figure F.14 – Chopper module board terminal locations...
Page 48
LINCOLN ELECTRIC Fleet™ 650 Service Manual Figure F.15 – Welder output terminal locations...
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.
Page 50
LINCOLN ELECTRIC Fleet™ 650 Service Manual Table F.5 – Chopper module board resistance tests TEST POINT (+) TEST POINT (–) EXPECTED RESULT 0.3 VDC – 0.7 VDC 1.0 VDC – 1.4 VDC 0.3 VDC – 0.7 VDC 0.3 VDC – 0.7 VDC 1.0 VDC –...
Page 51
LINCOLN ELECTRIC Fleet™ 650 Service Manual Figure F.17 – Chopper module board terminal locations...
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.
Page 53
LINCOLN ELECTRIC Fleet™ 650 Service Manual Figure F.18 – Weld control board plug locations Figure F.19 – Weld control board plug J1 and J3 lead locations...
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.
Page 55
LINCOLN ELECTRIC Fleet™ 650 Service Manual The shunt used in this machine will produce 50 millivolts at a load of 400 amps or 8 amps per millivolt. To calculate the correct millivolt signal for a given load, you divide the number of amps displayed on the ammeter by 8.
Page 56
LINCOLN ELECTRIC Fleet™ 650 Service Manual Figure F.21 – Weld control board plug J3 and J6 lead locations...
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.
Page 58
LINCOLN ELECTRIC Fleet™ 650 Service Manual Table F.6 – Output control and arc control potentiometer test points POTENTIOMETER TEST POINTS OHMMETER READING OUTPUT CONTROL J7-5 (75) TO J7-1 (77) ABOUT 10K OHMS VALUE SHOULD SWEEP SMOOTHLY FROM 10K TO 0...
Page 59
LINCOLN ELECTRIC Fleet™ 650 Service Manual Figure F.23 – Weld control board plug J7 lead locations...
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.
Page 61
LINCOLN ELECTRIC Fleet™ 650 Service Manual Figure F.24 – Choke assembly locations Figure F.25 – Negative output terminal location...
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.
Page 63
LINCOLN ELECTRIC Fleet™ 650 Service Manual 17. Place the upper control panel into the closed position. 18. Using a 3/8” nutdriver, attach the four screws securing the upper control panel to the machine. 19. Perform the Case Cover Replacement Procedure.
Page 64
LINCOLN ELECTRIC Fleet™ 650 Service Manual Figure F.26 – Pipe/gouge range switch and weld mode switch locations Figure F.27 – Pipe/gouge range switch and weld mode switch lead locations...
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.
Page 66
LINCOLN ELECTRIC Fleet™ 650 Service Manual Figure F.28 – Thermostat location Figure F.29 – Weld control board plug J3 location...
Page 67
LINCOLN ELECTRIC Fleet™ 650 Service Manual Figure F.30 – Weld control board plug J3 lead locations...
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.
Page 69
LINCOLN ELECTRIC Fleet™ 650 Service Manual Figure F.31 – Flashing diode (D1) & field diode (D2) lead locations Figure F.32 – Diode mounting hardware locations...
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.
Page 71
LINCOLN ELECTRIC Fleet™ 650 Service Manual 13. Using a hoist and appropriate rigging attached to the lift bail, lower the machine onto the wood framing, if necessary. 14. Using a 3/8” nutdriver, attach the two screws and washers securing the mounting bracket to the wood framing, if necessary.
Page 72
LINCOLN ELECTRIC Fleet™ 650 Service Manual 14. Using a 1/2” open-end wrench, attach the lower front panel screw securing the front panel to the base of the machine. 15. Using a hoist and appropriate rigging attached to the lift bail, lower the machine onto the wood framing, if necessary.
Page 73
LINCOLN ELECTRIC Fleet™ 650 Service Manual Figure F.34 – Lift bail and front panel mounting screw locations Figure F.35 – Engine shutdown relay and mounting bracket location...
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.
Page 75
LINCOLN ELECTRIC Fleet™ 650 Service Manual 2. Using a 1/2” nutdriver, attach the two nuts, lock washers and four flat washers securing the output rectifier bridge to the shelf. 3. Carefully apply a thin coating of Penetrox heat sink compound to the mating surfaces of the leads.
Page 76
LINCOLN ELECTRIC Fleet™ 650 Service Manual Figure F.37 – Output rectifier bridge mounting nut locations...
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.
Page 78
LINCOLN ELECTRIC Fleet™ 650 Service Manual 5. Carefully apply a thin coating of Penetrox heat sink compound to the mating surfaces of the leads and terminals B1, B2, B3, B4, B5 and B6 of each chopper module board. See Wiring Diagram.
Page 79
LINCOLN ELECTRIC Fleet™ 650 Service Manual Figure F.39 – Chopper module board mounting screw locations...
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.
Page 81
LINCOLN ELECTRIC Fleet™ 650 Service Manual Figure F.40 – Weld control board plug locations Figure F.41 – Weld control board mounting screw locations...
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.
Page 83
LINCOLN ELECTRIC Fleet™ 650 Service Manual REPLACEMENT PROCEDURE 1. Carefully position the new choke assembly(s) onto the choppers and chokes bracket. 2. Using a 1/2” socket and a 1/2” open-end wrench, attach the two bolts, nuts and flat washers securing the choke assembly to the choppers and chokes bracket.
Page 84
LINCOLN ELECTRIC Fleet™ 650 Service Manual Figure F.43 – Weld control board plug J3 location Figure F.44 – Choppers and chokes bracket mounting screw locations...
Page 85
LINCOLN ELECTRIC Fleet™ 650 Service Manual Figure F.45 – Choke terminals and choke mounting hardware locations...
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.
Page 87
LINCOLN ELECTRIC Fleet™ 650 Service Manual Figure F.46 – Upper control panel mounting screw locations Figure F.47 – Pipe/gouge range switch lead and mounting screw locations...
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.
Page 89
LINCOLN ELECTRIC Fleet™ 650 Service Manual Figure F.48 – Upper control panel mounting screw locations Figure F.49 – Weld mode switch leads and mounting hardware locations...
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.
Page 91
LINCOLN ELECTRIC Fleet™ 650 Service Manual Figure F.50 – Thermostat lead and mounting screw locations...
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.
Page 93
LINCOLN ELECTRIC Fleet™ 650 Service Manual 7. Perform the Retest After Repair Procedure. Figure F.51 – Fuel level sender lead locations...
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.
Page 95
LINCOLN ELECTRIC Fleet™ 650 Service Manual 11. Using a 1/2” nutdriver, remove the remaining three screws securing the fuel tank shield to the shelf. See Figure F.53. Remove the fuel tank shield. 12. Carefully route leads thru the holes in the shelf.
Page 96
LINCOLN ELECTRIC Fleet™ 650 Service Manual 5. Using a hoist and the appropriate rigging attached to the stator frame, lift the stator frame up slightly off of the rubber mounts. 6. Remove the wood or steel blocking from under the flywheel housing.
Page 97
LINCOLN ELECTRIC Fleet™ 650 Service Manual Figure F.52 – Field capacitor lead locations Figure F.53 – PCB bracket ground stud, shelf and fuel tank shield locations...
Page 98
LINCOLN ELECTRIC Fleet™ 650 Service Manual Figure F.54 – Choppers and chokes bracket mounting screw, fan baffle, lift bail frame, left and right baffle locations Figure F.55 – Rotor and stator mounting hardware locations...
LINCOLN ELECTRIC Fleet™ 650 Service Manual RETEST AFTER REPAIR Retest a machine: • If it is rejected under test for any reason that requires you to remove any part which could affect the machine’s electrical characteristics. • If you repair or replace any electrical components.