welder troubleshooting

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Hello, This is my first post here and I'm in a jamb. I have a Lincoln ZR-10 welder. I bought it in 2000. It's like the Ranger series of today. It sat up (indoors) for about 7 years. After that I got the engine running again, it only had like 10 hours on it. Now it still only has 120 hrs. One day it started to not produce enough power to weld. Sometimes after an hour of trying to strike an arc it would go to working. Seems like after it rains this problem starts, but all appears dry inside. Now it won't go to working. I've ran it for hours over a 3-4 day period.No rain with it on high idle. It seems as if it produces more spark with the fine adjustment turned lower, opposite of how it should work. Welding supply wants $85 an hour to check it out. I can't afford that, just use it for side jobs which are few and far between in this economy. Anybody know what could cause this? It seems like something simple.
Reply:O.K. This is why I think it's something simple, just don't know what. I went out right before dark and fired it up. After about 2-3 minutes of tapping the electrode to the ground, it starts working. After a frustrating weekend of trying. I welded what I'd been wanting to, a couple cracked spots on an old car frame. I welded one place, then it quit working, then started again. I covered it with a tarp because thunderstorms are coming. I can't keep it covered all the time because sometimes I have to drive the truck it's on. I'll see what it does tomorrow.
Reply:Welcome to the forum ccw.I'd start by checking for dirty slip rings on the rotor.  If you don't have access to a commutator stone, clean them with a fine sandpaper but do not use emery cloth.Also check for stuck brushes typically due to rusty brush holders.MM200 w/Spoolmatic 1Syncrowave 180SDBobcat 225G Plus - LP/NGMUTT Suitcase WirefeederWC-1S/Spoolmatic 1HF-251D-1PakMaster 100XL '68 Red Face Code #6633 projectStar Jet 21-110Save Second Base!
Reply:Thanks for your response and welcome. Last weekend I polished those slip rings and the brushes didn't seem stuck. I had noticed a couple times that the amperage would increase or decrease on it's own. That problem seemed to correct itself, but it's probably all related.
Reply:Clean the wiper and windings on the Fine Current Control rheostat same as you did the slip rings.  Go through and check all connections for corrosion and/or loose screws/terminals.  High humidity when raining could be providing the temporary 'fix' of a poor connection or dirty rheostat.MM200 w/Spoolmatic 1Syncrowave 180SDBobcat 225G Plus - LP/NGMUTT Suitcase WirefeederWC-1S/Spoolmatic 1HF-251D-1PakMaster 100XL '68 Red Face Code #6633 projectStar Jet 21-110Save Second Base!
Reply:Sounds like a good weekend project. Maybe it'll be dry by then. Thanks.
Reply:Keep us posted.MM200 w/Spoolmatic 1Syncrowave 180SDBobcat 225G Plus - LP/NGMUTT Suitcase WirefeederWC-1S/Spoolmatic 1HF-251D-1PakMaster 100XL '68 Red Face Code #6633 projectStar Jet 21-110Save Second Base!