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Observe Safety Guidelines TROUBLESHOOTING GUIDE
detailed in the beginning of this manual.
CAUTION
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
1-800-833-9353.
PROBLEMS
(SYMPTOMS)
POSSIBLE AREAS OF
MISADJUSTMENT(S)
RECOMMENDED
COURSE OF ACTION
OUTPUT PROBLEMS
Major physical or electrical damage
is evident.
1. Contact your local Lincoln
Authorized Field Service
Facility.
1. Contact the Lincoln Electric
Service Department at 1-800-
833-9353 (WELD)
No welding output in neither Stick
or CV modes. The engine operates
normally. The auxiliary output is
normal.
1. Place the Welding Terminals
Switch in the "ALWAYS ON"
position. If the problem is
solved, the fault may be in the
external control cable (if used),
leads #2 and #4. See the
Wiring Diagram.
2. With the engine at high idle
(1900RPM), the machine in the
Stick mode and the OUTPUT
CONTROL at maximum, check
for the presence of approxi-
mately 87VDC (open circuit volt-
age) at the output terminals.
3. If the correct OCV is present at
the welding output terminals
check the welding cables,
clamps and electrode holder for
loose or faulty connections.
1. Check for loose or faulty con-
nections on the heavy current
carrying leads between the out-
put bridge, the power modules,
the choke and the output termi-
nals.
2. Check the Welding Terminals
Switch and associated leads.
See the Wiring Diagram.
3. Check gate leads #23, #23A,
#25 and #25A for loose or faulty
connections. See the Wiring
Diagram.
4. Perform the Stator Voltage
Test.
5. Perform the Output Rectifier
Bridge Test.
6. Perform the Power Module
Test.
7. Perform the Analog Power
Supply PC Board Test.
8. The Weld Control PC Board
may be faulty.
9. See the Start-Up and OCV
Diagnostic Chart.
F-4 F-4
TROUBLESHOOTING & REPAIR
COMMANDER 500
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