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Portable welder generator runs but no power or weld

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earthwrks
Join Date: Dec 2003
Posts: 3853 Home Office in Flat Rock, Michigan
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2009-04-19          162167


I have a Lincoln Electric PowerArc 5000. It has a 11 HP Industrial Briggs & Stratton engine. Engine runs, but the welder generator won't make any power. Just before it stopped working the engine lugged like it never has before.

The service manual says the W/G (welder/gen.) requires 4-7 volts to send a "flash" of power to the W/G circuit. The power comes directly from the engine's Magnetron ignition coil and is picked up at the low-oil switch. Voltage was tested at about 3.5 volts so I replaced the Magnetron and now it's about 2.7, still not enough--even when not connected to the low oil switch. The local engine shop said the Magnetron doesn't MAKE power, even after showing them the circuit diagram (just in case anyone feels that the ignition coil isn't used for that purpose).

My buddy and I went through and tested everything the troubleshooting guide said to look for--everything is within spec. excpet for the Magnetron not making at least 4 volts. We were not able to test the capacitor. And I replaced the diode (bridge rectifier). The technician at Linclon said the GFI outlet is designed to not allow power to be made if there is less than 4 volts--how, I do not know, but I replaced it anyway.

Any ideas?




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Portable welder generator runs but no power or weld

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Murf
Join Date: Dec 1999
Posts: 7249 Toronto Area, Ontario, Canada
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2009-04-20          162171


Jeff, I'm not sure about you're particular unit, but do know that some gensets use a permanent magent setup to excite the field coils while others, like yours, use a power source such as the magneto to provide the starting power.

If your magneto is not making power I would suggest, especially if it's sat a while, that there was surface rust on the mag & coil and turning it over pushed the two out of range of each other. Since it is only the motion in close proximity to each other that generates the electricity the power drops fast if they move away from each other.

Take it apart and use some emery cloth on both to get them really clean, then reset them with the proper gap between them and see if it makes the proper voltage then.

Best of luck. ....


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Portable welder generator runs but no power or weld

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AnnBrush
Join Date: Mar 2004
Posts: 463 Troy OH
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2009-04-20          162179


Take it to your local industrial electric shop, they will tell you pretty rapidly whats wrong and then you can assess what to do.
Cheers Ann ....


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Portable welder generator runs but no power or weld

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earthwrks
Join Date: Dec 2003
Posts: 3853 Home Office in Flat Rock, Michigan
TractorPoint Premium Member -- 5 Tractors = Very Frequent Poster  View my Photos  Pics

2009-04-20          162192


I went to the local authorized repair shop today. $58 check-out fee. Not too bad. They feel at this time the stator/armature shorted out --which isn't made anymore; if it's the windings that's $800 plus labor. These guys handle the Ford Mo Co account so I hope they know what they're talking aboot, eh? ....


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Portable welder generator runs but no power or weld

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earthwrks
Join Date: Dec 2003
Posts: 3853 Home Office in Flat Rock, Michigan
TractorPoint Premium Member -- 5 Tractors = Very Frequent Poster  View my Photos  Pics

2009-04-23          162262


Well---they called and said it'sa $800 stator winding. Another $350 to replace it. A brand new unit is the same price for parts and labor. Ridiculous. SO off I got o se if it can be rewound. ....


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Portable welder generator runs but no power or weld

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earthwrks
Join Date: Dec 2003
Posts: 3853 Home Office in Flat Rock, Michigan
TractorPoint Premium Member -- 5 Tractors = Very Frequent Poster  View my Photos  Pics

2009-04-23          162272


A local coil rewinder wants $450 and can have it a few days. Going with them. ....


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Portable welder generator runs but no power or weld

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kwschumm
Join Date: Feb 2003
Posts: 5764 NW Oregon
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2009-04-23          162273


Don't know if that's a good price or not, but it reminds me of my life as a slot car racer as a kid. I used to wind, epoxy, time and balance my own armatures. Those were the days :)
....


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Portable welder generator runs but no power or weld

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earthwrks
Join Date: Dec 2003
Posts: 3853 Home Office in Flat Rock, Michigan
TractorPoint Premium Member -- 5 Tractors = Very Frequent Poster  View my Photos  Pics

2009-04-24          162282


Well it's $450 MORE than I want to pay LOL, but considering it's only half of what a new parts cost it seems like a bargain. It appears to be relativley easy to get the generator apart---I hope. ....


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Portable welder generator runs but no power or weld

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kthompson
Join Date: Oct 2005
Posts: 5275 South Carolina
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2009-04-24          162288


Sorry for the problem EW. Does remind me when you buy the price seems real high, when you are selling the price is too low. Just think you are wealthy per DC these days and they may send you a ribbon or something for your contribution to stimulate the economy. Now, don’t you feel much better? :) ....


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Portable welder generator runs but no power or weld

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earthwrks
Join Date: Dec 2003
Posts: 3853 Home Office in Flat Rock, Michigan
TractorPoint Premium Member -- 5 Tractors = Very Frequent Poster  View my Photos  Pics

2009-04-24          162298


Good ol' Kenny. Hey, I smell (SC) smoke---is THAT coming from your house? ....


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