Lincoln Electric SVM208-A service manual Troubleshooting and Repair

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F-7	TROUBLESHOOTING AND REPAIR	F-7

Observe Safety Guidelines detailed in the beginning of this manual.

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PROBLEMS

(SYMPTOMS)

No auxiliary power - welding output is normal - engine runs normally.

POSSIBLE AREAS OF

MISADJUSTMENT(S)

OUTPUT PROBLEMS

1.Check circuit breakers CB1 and CB2. Reset if tripped.

2.Make sure that the control rheo- stat (R1) is set at “GENERATOR” (maximum).

3.Check for loose or faulty plug at power receptacle.

RECOMMENDED

COURSE OF ACTION

1.Check the auxiliary power re- ceptacles and associated wires for loose or faulty connections.

2.Check the continuity (zero ohms) of leads 3, 3A (black); 6, 6A (yellow); and 5 (white) from the receptacles to the stator windings. See the Wiring Dia- gram.

3.Make sure lead 5 (white) is grounded to the machine frame (zero ohms).

4.Check for an open or grounded auxiliary winding in the stator, 6 (yellow) to 3 (black). See the Wiring Diagram.

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CAUTION

If for any reason you do not understand the test procedures or are unable to perform the tests/repairs safely, contact the Lincoln Electric Service Department for technical troubleshooting assistance before you proceed. Call 1-888-935-3877.

BULLDOG® 140

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Contents Bulldog California Proposition 65 Warnings SafetyCan be dangerous Electric Shock can kill ARC Rays can burnCylinder may explode if damaged Welding and Cutting Sparks can cause fire or explosionIii Sûreté Pour Soudage a L’Arc Précautions DE SûretéSafety Methods of Reducing Emissions Mains Supply Master Table of Contents for ALL Sections Table of Contents Installation Section Technical Specifications Bulldog 140 K2708-1 InstallationEngine Exhaust can kill Safety PrecautionsLocation and Ventilation StoringOIL PRE-OPERATION Engine ServiceStacking TiltingWelding Cable Connections Electrical Output CONNEC- TionsTable A.1 Recommended Welding Cable Size and Length Plugs and HAND-HELD Equipment Auxiliary Power ReceptaclesCable Installation Electrical ConnectionsCircuit Breakers Premises WiringBulldog Ation. do not RUN TheseTable of Contents Operation Section Operation WELDER/GENERATOR Controls LimitationsOutput Panel Controls Gasoline Engine Controls Engine OperationStarting the Engine Before Starting the EngineGenerator Operation Table B.1 Generator Power Applications Control Function / Operation Welding OperationLearning To Stick Weld Material Thickness Electrode Type Size SettingWelding Guidelines Stick WeldingWhat Happens in the Arc? Side view Correct Welding PositionButt Joints PracticeUse the following Do the followingPenetration Fillet JointsVertical-Down Welding Vertical-Up WeldingHardfacing To Reduce Wear How to Hardface the Sharp Edge Metal to Ground WearOverhead Welding Welding Sheet MetalCast Iron Plate Preparation Welding Cast IronLow Hydrogen Group AWS E7018 High-Speed Group AWS E6013Out-of-Position Group AWS E6011 Bulldog Table of Contents Accessories Section OPTIONS/ACCESSORIES AccessoriesLincoln Electric Accessories Table of Contents Maintenance Section Maintenance Engine Maintenance Routine and Periodic MaintenanceLocation Return to Section TOC To Section TOC Engine AdjustmentsSpark Plug Service Table D.1 Engine Maintenance PartsOperational Clearance Screws Brushes GENERATOR/WELDER MaintenanceFigure D.7. Major Component Locations Bulldog 1TABLE of CONTENTS-THEORY of Operation Section E-1 ENGINE, EXCITATION, Rotor Stator Theory of OperationFigure E.3 Rotor Field Feedback and Auxiliary Power Rotor Field Feedback Auxiliary PowerWeld Winding and Reactor Auxiliary Power Overcurrent Protection1TABLE of Contents Troubleshooting and Repair F-1 HOW to USE Troubleshooting Guide Troubleshooting and RepairPC Board Troubleshooting Procedures Output Problems Perform the Rotor Voltage Test Electric Authorized Field Ser vice FacilityProblems Symptoms Troubleshooting and Repair Perform Field Diode Test Engine Problems Troubleshooting and Repair Engine Throttle Adjustment Test Bulldog Test Description Rotor Voltage TestMaterials Needed Rotor Voltage Test ProcedureLead 200A Connection Ground Stud Field Diode Bridge Test + ~ Field Diode Bridge TestRotor Flashing Circuit Test Figure F.3 Brush Holder Leads 201- and 202B + Rotor Flashing Circuit TestMoving Parts can injure Bulldog Rotor Resistance Test Rotor Resistance Test Figure F.6 Brushes Retained with Cable TIE Cable TIE BrushesBulldog Engine Throttle Adjustment Test ROBIN/SUBARU Engine Frequency Counter Method Engine Throttle Adjustment TestROBIN/SUBARU Engine Strobe-tach MethodHigh Speed Stop Screw Scope Settings High Idle no Load Normal Open Circuit Voltage Waveform 115VAC SupplyMachine Loaded Typical Weld Output WaveformMachine Loaded to 125 Amps AT 23 VAC Brush Removal and Replacement Cable TIE Brushes Brush Removal and ReplacementReturn to Section Return to Section TOC Bulldog Rheostat Removal and Replacement Figure F.11 Rheostat Removal Rheostat Removal and ReplacementCapacitor AND/OR Diode Bridge Removal and Replacement Procedure Capacitor Removal and Replacement Removal and ReplacementCapacitor AND/OR Diode Bridge Figure F.13 Field Diode Bridge Location Procedure Field Diode Bridge Removal and ReplacementBulldog Instructions STATOR/ROTOR Removal and ReplacementGeneratorengine STATOR/ROTOR Removal and ReplacementFigure F.15 Generator Components Troubleshooting and Repair Figure F.16 Output Lead Location TIE Wrap Terminals Stator Removal ProcedureNuts Thru Bolts SupportReassembly Procedure Rotor Removal ProcedureFigure F.19 Checking ROTOR-STATOR AIR GAP WELDER/GENERATOR OUTPUT1 Auxiliary Power Receptacle OUTPUT1Retest After Repair Engine OutputBulldog Table of Contents Diagram Section Wiring Diagram Bulldog S28101