Troubleshooting
55Symptoms & remedies
| Symptom | Cause | Remedy |
|---|---|---|
| Major Physical or Electrical Damage is Evident | Contact your Local Lincoln Authorized Field Service Facility | If all recommended possible areas of misadjustment have been checked and the problem persists, Contact your local Lincoln Authorized Field Service Facility |
| Engine will not crank | Battery low | If all recommended possible areas of misadjustment have been checked and the problem persists, Contact your local Lincoln Authorized Field Service Facility |
| Engine will not crank | Loose battery cable connections which may need Inspected, cleaned or tighten | If all recommended possible areas of misadjustment have been checked and the problem persists, Contact your local Lincoln Authorized Field Service Facility |
| Engine will not crank | Faulty wiring in engine starting circuit | If all recommended possible areas of misadjustment have been checked and the problem persists, Contact your local Lincoln Authorized Field Service Facility |
| Engine will not crank | Faulty engine starter. Contact authorized local Engine Service Shop | If all recommended possible areas of misadjustment have been checked and the problem persists, Contact your local Lincoln Authorized Field Service Facility |
| Engine will not crank | Battery disconnect switch is in the off position | If all recommended possible areas of misadjustment have been checked and the problem persists, Contact your local Lincoln Authorized Field Service Facility |
| Engine will crank but not start | Out of fuel | If all recommended possible areas of misadjustment have been checked and the problem persists, Contact your local Lincoln Authorized Field Service Facility |
| Engine will crank but not start | Fuel shut off valve is in the off position make sure the valve lever is in a vertical direction | If all recommended possible areas of misadjustment have been checked and the problem persists, Contact your local Lincoln Authorized Field Service Facility |
| Engine will crank but not start | Engine shut down solenoid not pulling in | If all recommended possible areas of misadjustment have been checked and the problem persists, Contact your local Lincoln Authorized Field Service Facility |
| Engine will crank but not start | On/Off switch on for more than 30 sec. before starting, the On/Off switch will need to be switch off and turned back on | If all recommended possible areas of misadjustment have been checked and the problem persists, Contact your local Lincoln Authorized Field Service Facility |
| Engine will crank but not start | Fuel Filters dirty/clogged, main filter element and/or Inline Fuel Filter may need to be replaced | If all recommended possible areas of misadjustment have been checked and the problem persists, Contact your local Lincoln Authorized Field Service Facility |
| Engine will crank but not start | High water temperature or low oil pressure. (engine protection light lit) | If all recommended possible areas of misadjustment have been checked and the problem persists, Contact your local Lincoln Authorized Field Service Facility |
| Engine shuts down shortly after starting | Low oil pressure (engine protection light lit). Check oil level (Consult engine service dealer) | If all recommended possible areas of misadjustment have been checked and the problem persists, Contact your local Lincoln Authorized Field Service Facility |
| Engine shuts down shortly after starting | High water temperature. Check engine cooling system. (engine protection light lit) | If all recommended possible areas of misadjustment have been checked and the problem persists, Contact your local Lincoln Authorized Field Service Facility |
| Engine shuts down shortly after starting | Faulty oil pressure switch | If all recommended possible areas of misadjustment have been checked and the problem persists, Contact your local Lincoln Authorized Field Service Facility |
| Engine shuts down shortly after starting | Faulty water temperature switch. Contact authorized local Engine Service Shop | If all recommended possible areas of misadjustment have been checked and the problem persists, Contact your local Lincoln Authorized Field Service Facility |
| Engine shuts down while under a load | High water temperature | If all recommended possible areas of misadjustment have been checked and the problem persists, Contact your local Lincoln Authorized Field Service Facility |
| Engine runs rough | Dirty fuel or air filters may need cleaned/replaced | If all recommended possible areas of misadjustment have been checked and the problem persists, Contact your local Lincoln Authorized Field Service Facility |
| Engine runs rough | Water in fuel | If all recommended possible areas of misadjustment have been checked and the problem persists, Contact your local Lincoln Authorized Field Service Facility |
| Engine will not shut off | Fuel Shutdown solenoid not functioning properly / linkage binding | If all recommended possible areas of misadjustment have been checked and the problem persists, Contact your local Lincoln Authorized Field Service Facility |
| Battery does not stay charged | Faulty battery | If all recommended possible areas of misadjustment have been checked and the problem persists, Contact your local Lincoln Authorized Field Service Facility |
| Battery does not stay charged | Faulty engine alternator | If all recommended possible areas of misadjustment have been checked and the problem persists, Contact your local Lincoln Authorized Field Service Facility |
| Battery does not stay charged | Loose or broken lead in charging circuit | If all recommended possible areas of misadjustment have been checked and the problem persists, Contact your local Lincoln Authorized Field Service Facility |
| Battery does not stay charged | Loose fan belt may need tightening | If all recommended possible areas of misadjustment have been checked and the problem persists, Contact your local Lincoln Authorized Field Service Facility |
| Engine will not idle down to low speed | Idler switch in HIGH idle position, make sure switch is set to AUTO | If all recommended possible areas of misadjustment have been checked and the problem persists, Contact your local Lincoln Authorized Field Service Facility |
| Engine will not idle down to low speed | External load on welder or auxiliary power | If all recommended possible areas of misadjustment have been checked and the problem persists, Contact your local Lincoln Authorized Field Service Facility |
| Engine will not idle down to low speed | Mechanical problem in idler solenoid linkage | If all recommended possible areas of misadjustment have been checked and the problem persists, Contact your local Lincoln Authorized Field Service Facility |
| Engine will not idle down to low speed | Faulty wiring in solenoid circuit | If all recommended possible areas of misadjustment have been checked and the problem persists, Contact your local Lincoln Authorized Field Service Facility |
| Engine will not idle down to low speed | No or low voltage @ idle solenoid | If all recommended possible areas of misadjustment have been checked and the problem persists, Contact your local Lincoln Authorized Field Service Facility |
| Engine will not idle down to low speed | Faulty idler solenoid | If all recommended possible areas of misadjustment have been checked and the problem persists, Contact your local Lincoln Authorized Field Service Facility |
| Engine will not idle down to low speed | Faulty, Weld Control PCB (Printed Circuit Board), Pull Coil /Battery PCB | If all recommended possible areas of misadjustment have been checked and the problem persists, Contact your local Lincoln Authorized Field Service Facility |
| Engine will not go to high idle when attempting to weld | Poor work lead connection to work | If all recommended possible areas of misadjustment have been checked and the problem persists, Contact your local Lincoln Authorized Field Service Facility |
| Engine will not go to high idle when attempting to weld | Broken idler solenoid spring | If all recommended possible areas of misadjustment have been checked and the problem persists, Contact your local Lincoln Authorized Field Service Facility |
| Engine will not go to high idle when attempting to weld | Welding Terminals switch in wrong position | If all recommended possible areas of misadjustment have been checked and the problem persists, Contact your local Lincoln Authorized Field Service Facility |
| Engine will not go to high idle when attempting to weld | No open circuit voltage at output studs | If all recommended possible areas of misadjustment have been checked and the problem persists, Contact your local Lincoln Authorized Field Service Facility |
| Engine will not go to high idle when attempting to weld | Faulty, Pull Coil/Battery PCB or Weld Control PCB | If all recommended possible areas of misadjustment have been checked and the problem persists, Contact your local Lincoln Authorized Field Service Facility |
| Engine will not go to high idle when using auxiliary power | Broken wire in auxiliary current sensor wiring | If all recommended possible areas of misadjustment have been checked and the problem persists, Contact your local Lincoln Authorized Field Service Facility |
| Engine will not go to high idle when using auxiliary power | Auxiliary power load is less than 100 watts | If all recommended possible areas of misadjustment have been checked and the problem persists, Contact your local Lincoln Authorized Field Service Facility |
| Engine will not go to high idle when using auxiliary power | Faulty Pull Coil/Battery PCB or Weld Control PCB | If all recommended possible areas of misadjustment have been checked and the problem persists, Contact your local Lincoln Authorized Field Service Facility |
| Engine goes to low idle but does not stay at low idle | Faulty Peripheral PCB, Pull Coil/Battery PCB or Weld Control PCB | If all recommended possible areas of misadjustment have been checked and the problem persists, Contact your local Lincoln Authorized Field Service Facility |
| No welding output or auxiliary output | Broken lead in rotor circuit | If all recommended possible areas of misadjustment have been checked and the problem persists, Contact your local Lincoln Authorized Field Service Facility |
| No welding output or auxiliary output | Faulty field diode module | If all recommended possible areas of misadjustment have been checked and the problem persists, Contact your local Lincoln Authorized Field Service Facility |
| No welding output or auxiliary output | Faulty Weld Control PCB | If all recommended possible areas of misadjustment have been checked and the problem persists, Contact your local Lincoln Authorized Field Service Facility |
| No welding output or auxiliary output | Faulty rotor | If all recommended possible areas of misadjustment have been checked and the problem persists, Contact your local Lincoln Authorized Field Service Facility |
| Welder has some/ no output and no control. Auxiliary output OK | Faulty remote kit | If all recommended possible areas of misadjustment have been checked and the problem persists, Contact your local Lincoln Authorized Field Service Facility |
| Welder has some/ no output and no control. Auxiliary output OK | Faulty output control potentiometer | If all recommended possible areas of misadjustment have been checked and the problem persists, Contact your local Lincoln Authorized Field Service Facility |
| Welder has some/ no output and no control. Auxiliary output OK | Faulty output control wiring | If all recommended possible areas of misadjustment have been checked and the problem persists, Contact your local Lincoln Authorized Field Service Facility |
| Welder has some/ no output and no control. Auxiliary output OK | Faulty Weld Control PCB, Pull Coil/Battery PCB or Chopper PCB | If all recommended possible areas of misadjustment have been checked and the problem persists, Contact your local Lincoln Authorized Field Service Facility |
| No welding output. Auxiliary output OK | WELDING TERMINALS switch in wrong position, be sure switch is in WELDING TERMINALS ALWAYS ON position | If all recommended possible areas of misadjustment have been checked and the problem persists, Contact your local Lincoln Authorized Field Service Facility |
| No welding output. Auxiliary output OK | Faulty Weld Control PCB, Pull Coil/Battery PCB or Chopper PCB | If all recommended possible areas of misadjustment have been checked and the problem persists, Contact your local Lincoln Authorized Field Service Facility |
| No auxiliary power | GFCI Receptacle may have tripped. Follow "GFCI Receptacle Testing and Resetting Procedure" in the MAINTENANCE section of this manual | If all recommended possible areas of misadjustment have been checked and the problem persists, Contact your local Lincoln Authorized Field Service Facility |
| No auxiliary power | Open breakers may need to be reset | If all recommended possible areas of misadjustment have been checked and the problem persists, Contact your local Lincoln Authorized Field Service Facility |
| No auxiliary power | Faulty receptacle | If all recommended possible areas of misadjustment have been checked and the problem persists, Contact your local Lincoln Authorized Field Service Facility |
| No auxiliary power | Faulty auxiliary circuit wiring | If all recommended possible areas of misadjustment have been checked and the problem persists, Contact your local Lincoln Authorized Field Service Facility |
| No auxiliary power | GFCI tripped | If all recommended possible areas of misadjustment have been checked and the problem persists, Contact your local Lincoln Authorized Field Service Facility |
Fault codes and symptom→remedy steps extracted from this unit’s service/owner documentation; verify against the official manual before servicing.
Available documents
Operator's manual
About
Lincoln Electric 500 CUMMINS — welder. Specifications and parts compiled from manufacturer documents.