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Old 08-25-2009, 06:26 PM
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lincoln electric welder

My weldpack HD100 just stopped working..it did not have an arc and it would not push any wire. I read through the troubleshooting guide in the manual. It said check the reset button to see if it was pushed out. negative. Then it said to check for faulty cord..no because you can hear the machine get the signal, the wire just doesn't feed..due to the fact that their is no arc it is obviously something way beyond a wire feed problem.it then said the machine can shut itself down due to overheating..it was on for only five minutes and i only struck several tack welds with it before it stopped on a 75 degree day. i opened the machine up and heard a rattle...turned out to be a small one inch piece of metal that fell off of who knows what..can't tell what its purpose was other than maybe it held a wire..cannot find any loose wires however....i have owned this machine for 20months and only used it a handful of times...i believe the warranty is only good for a year..anyone have good luck with lincoln electric taking blame and fixing a faulty machine after the warranty is up?? (in my humble opinion a piece of metal falling off the inside when it is sitting on the ground untouched is faulty)
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Old 08-25-2009, 08:16 PM
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I don't have a diagram for that machine handy at the minute (Ill see if i can dig one up and then post back), but if I understand you right the feed motor is not running at all. I'm not insulting your intelligence here, but if the machine has tapped voltage settings, make sure the switch is not stuck between positions. If that is ok, check out the switch itself to make sure no contacts are burned or loose. And off the top of my head if the above checks out its probably the board

Lincoln will probably not cover the machine if it is out of warranty. We get some of the industrial machines in with the transformer coils loose (which is a manufacturing defect) and they won't cover those.

Good luck and I'll see what I can find on the machine.
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Old 08-25-2009, 08:20 PM
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if this helps any....after it wouldn't work i turned the arc setting knob and it seemed to pull out a little and felt loose..after i opened up the case and messed with it, it seemed to tighten back up and i did not see how this could affect anything but then again i'm no expert
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Old 08-25-2009, 08:44 PM
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One thing I forgot to ask earlier, does the fan run?
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Old 08-25-2009, 08:53 PM
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fan runs...ok i just went to try it again..nothing until i fiddled with the settings knob...if i pull the knob out (remember i said it was a little loose) it started feeding wire.....of course then the wire got stuck while feeding through right where the handle curves..but that's no biggy...so apparently there are contact points on the knob that must be not contacting?? am i correct?
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Old 08-26-2009, 06:41 AM
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Quote:
Originally Posted by jasrking
My weldpack HD100 just stopped working..it did not have an arc and it would not push any wire. I read through the troubleshooting guide in the manual. It said check the reset button to see if it was pushed out. negative. Then it said to check for faulty cord..no because you can hear the machine get the signal, the wire just doesn't feed..due to the fact that their is no arc it is obviously something way beyond a wire feed problem.it then said the machine can shut itself down due to overheating..it was on for only five minutes and i only struck several tack welds with it before it stopped on a 75 degree day. i opened the machine up and heard a rattle...turned out to be a small one inch piece of metal that fell off of who knows what..can't tell what its purpose was other than maybe it held a wire..cannot find any loose wires however....i have owned this machine for 20months and only used it a handful of times...i believe the warranty is only good for a year..anyone have good luck with lincoln electric taking blame and fixing a faulty machine after the warranty is up?? (in my humble opinion a piece of metal falling off the inside when it is sitting on the ground untouched is faulty)
Thanks
I have had two of these welders of which I still have one left. Both developed that same problem that you are describing .The heat selector(or amperage) had developed corrosion on the contacts . All I did was rotate the switch back and forth briskly and got it to work for the work at hand. I cleaned the contacts at a later date by pulling the knob off (has a set screw)and unscrewing the flat nut holding the switch to the panel and pulling the switch out of the panel .I then used a small wire brush to clean the contacts. Both are still working fine.
If oldschoolrods can't find a diagram for it ,post back or send me a PM and I'll pull mine apart and take a picture of the diagram and post it.Mine no longer is set up like it came from the factory. I gutted it and use it as a wire feed for my alternator welder that I built. The control board went bad and the replacement was 107 bucks..........so I said nuts to that and built my own controller for about 12 bucks in Radio Shack parts.
Good Luck !
Kenny
Lost your job yet? Keep buying foreign.
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Old 08-26-2009, 11:57 AM
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lincoln welder.

Hi,i have 2 lincoln welders,if you use them to tack,sometimes you will get a haystack between the end of the housing and where the wire goes. turn the set screw out and pull the cable housing out ,and you will see the haystack at the welder end of the cable(actually between the cable and where the cable goes into the feed roller) using side cutters,cut the wire out,pull the wire thru the end,and reinsert the wire. it may work then. my welders are almost 15 years old,and other than the haystacks (maybe 15 times in 15 years) ive never had a problem.
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Old 08-26-2009, 02:06 PM
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alright ive found the problem..that lil piece of metal actually fell out of the backside of the control knob..it connects the copper on the knob to the copper pieces on the individual settings keeping the circuit in tact..it has a spring that pushes against it to keep the knob and metal tab under constant pressure. The plastic housing holding the spring and metal tab has fatigued (even though it has rarely been used) and has allowed the metal piece to slip out under the spring tension..have tried everything to fix it..now i am trying to expoxy the plastic where it is cracked together hoping that may solve the problem
thanks for all the help..could use and exploded diagram view of it just to make sure im assembling it right if anyone has one ..thanks
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Old 08-26-2009, 03:19 PM
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Thanks for posting back with the solution! That switch is likely available from anywhere that deals in lincoln parts, if you can't get it fixed.
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Old 08-26-2009, 04:13 PM
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Lincoln Arc Welder

There is no doubt that you have a bad wire feed switch. Do not operate the welder any more until you replace it. That little piece of metal may have come from the switsh inners.
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Old 08-26-2009, 04:19 PM
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not the wire feed switch.. ..this is the arc setting knob....i was able to reinstall the metal piece and use the welder..works fine..however i have no doubt when i go to move the knob a few more times it will fly back out..just an overall bad design by lincoln as the welder has only 2 hours of duty time on it
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Old 08-26-2009, 06:41 PM
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glad to hear its working...... I would think about changing out that switch though.
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Old 08-27-2009, 03:10 PM
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Quote:
Originally Posted by jasrking
My weldpack HD100 just stopped working..it did not have an arc and it would not push any wire. I read through the troubleshooting guide in the manual. It said check the reset button to see if it was pushed out. negative. Then it said to check for faulty cord..no because you can hear the machine get the signal, the wire just doesn't feed..due to the fact that their is no arc it is obviously something way beyond a wire feed problem.it then said the machine can shut itself down due to overheating..it was on for only five minutes and i only struck several tack welds with it before it stopped on a 75 degree day. i opened the machine up and heard a rattle...turned out to be a small one inch piece of metal that fell off of who knows what..can't tell what its purpose was other than maybe it held a wire..cannot find any loose wires however....i have owned this machine for 20months and only used it a handful of times...i believe the warranty is only good for a year..anyone have good luck with lincoln electric taking blame and fixing a faulty machine after the warranty is up?? (in my humble opinion a piece of metal falling off the inside when it is sitting on the ground untouched is faulty)
Thanks

Did you make sure you didn't hit your duty cycle? I used to have one of these and they would weld for a ten minutes of heavy welding and then shut down. I thought I blew it up. But I came back about two hous later and it worked fine....... I would bet you hit that.
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