Lincoln Electric Cross Country 300 Service Manual page 19

LINCOLN ELECTRIC
Observe Safety Guidelines
detailed in the beginning of this manual.
PROBLEMS
(SYMPTOMS)
The machine will weld but the
welding arc is "COLD". The
engine runs normally and the
auxiliary power is normal.
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.
POSSIBLE AREAS OF
MISADJUSTMENT(S)
OUTPUT PROBLEMS
1. Make sure the machine is
properly set for the electrode
and process being used. Check
electrode size, weld mode
selector switch setting and
amps or voltage setting. If
shielding gas is used make sure
of correct type and gas flow.
2. Make sure the process does
not demand more power than
the machine can produce.
3. If the current is correct try
increasing the "ARC CONTROL"
setting.
4. Check for loose or faulty
connections at the weld output
terminals and welding cable
connections.
5. Check for good connections
between the work cable and
the work piece.
6. The weld cables may be too
long or too small diameter
causing excessive voltage drop.
7. The weld cables should not
be coiled or wrapped around
metal racks or reels. This can
cause excessive inductance in
the weld circuit. Try welding
with a short set of adequately
sized weld cables.
CAUTION
Cross Country™ 300 Service Manual
TROUBLESHOOTING GUIDE
RECOMMENDED
COURSE OF ACTION
1. Disconnect all external
equipment and perform a
"load" test using a resistive
load bank and accurate meters.
Adjust the load for about 300
amps at 32 volts; check that the
engine speed holds at 1800
RPM. If not perform engine
maintenance.
2. Perform the Weld Control
Feedback Test Procedure.
3. If the maximum weld output
cannot be obtained and the
front panel displays are reading
accurately, check for damaged
conductors or loose
connections in the large current
carrying conductors of the
stator, output rectifier bridge,
chopper module, choke, shunt
and output terminals. See
Wiring Diagram.
4. If all these connections are
good perform the Rotor
Voltage Test Procedure, the
Stator Voltage Test Procedure,
the Output Rectifier Bridge
Test Procedure, the Chopper
Module Resistance Test
Procedure and the Chopper
Module Function Test
Procedure.
5. Perform the Weld Mode
Selector Switch Test Procedure.
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