Lincoln Electric SVM192-A service manual Problems Possible Areas Symptoms Misadjustments

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F-5

TROUBLESHOOTING AND REPAIR

F-5

Observe Safety Guidelines detailed in the beginning of this manual.

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PROBLEMS

POSSIBLE AREAS OF

 

(SYMPTOMS)

MISADJUSTMENT(S)

 

 

OUTPUT PROBLEMS

 

No weld output, the auxiliary power 1.

Check the open circuit voltage

(230-115VAC) is operating normal-

(OCV) at the welder output termi-

ly. Engine runs normally.

nals, engine at high idle (3650

 

RPM). Normal maximum is 73 to

 

80VAC. Normal DC maximum is

 

67 to 72VDC. If the OCV is OK

 

then proceed to Step #2. If the

 

OCV is not present at the welder

 

output

terminals, contact

your

 

local Lincoln

Authorized

Field

 

Service Facility.

 

2.

Check

the

welding cables,

 

clamps and electrode holder for

 

loose or broken connections.

RECOMMENDED

COURSE OF ACTION

1.Disconnect lead W1 from the Output Bridge (D1) and check

for the presence of 80VAC from gramstator winding. See wiringthe maindia-

. If the AC voltage is NOTlead W1 to lead W2 on

present, the winding in the sta- tor may be faulty. Check the winding for continuity and test to be sure it is NOT grounded to the stator iron. Replace if nec- essary. If the correct AC volt- age is present, proceed to step #2.

2. Check the Reactor, Range Switch (S1) and associated wires for loose or faulty connec- tions. Check the reactor wind- ing for continuity and test to be sure it is NOT grounded to the reactor iron.

3. Check the Choke (L1) and associated wires for loose or faulty connections. Check the choke winding for continuity and test to be sure it is NOT ground- ed to the choke iron.

4. Check the weld output terminals and associated wires for loose

or faulty connections.

5. PTestrform the Output Bridge

.

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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.

EAGLE™ 10,000

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Contents Eagle 10,000 Eagle 10,000 ISAFETYiElectric Shock can kill ARC Rays can burn SafetyFumes and Gases Can be dangerousWelding Cutting Powered equipmentCylinder may explode Sparks can cause fire or If damaged ExplosionSûreté Pour Soudage a L’Arc Précautions DE SûretéMaster Table of Contents for ALL Sections Table of Contents Installation Section Height Width Depth Weight InstallationTechnical Specifications Eagle 10,000 K2343-1,K2343-2 Machine Grounding Safety PrecautionsSpark Arrester TowingFuel Gasoline Fuel only Vehicle MountingFollow vehicle manufacturer’s instructions Do not overfill tank, fuel expansion may cause overflowAngle of Operation Additional Safety Precautions High Altitude OperationLifting Location / VentilationAdditional Safety Precautions Connection of Lincoln Electric Wire FeedersInstructions Welder Operation120/240 Volt Dual Voltage Receptacle Auxiliary PowerDuplex Receptacles Motor StartingThese Devices Without Electrical Device USE with the Eagle 10,000Additional Resistive Type LoadsSimultaneous Welding and Power Auxiliary Power While WeldingStandby Power Connections Connection diagram shown Eagle 10,000Figure A.1 Connection of Eagle 10,000 to Premises WiringTable of Contents Operation Section Operation Engine SwitchGeneral Description Welder Controls Function and OperationOPERATIONB-3 Range SwitchEagle 10,000 Approximate Fuel Consumption Control DialBREAK-IN Period STARTING/SHUTDOWN InstructionsStarting the Engine Stopping the EngineWelding Process Wire Feed Welding ProcessesTIG Constant Current Welding ARC GougingSummary of Welding Processes Typical Current Ranges 1 for Tungsten ELECTRODES2Table of Contents Accessories Section K1745-1 GAS Cylinder Holder AccessoriesOptional Equipment Field Installed Recommended Equipment Wire FeedPlasma Cutting Stick TIG WeldingEagle 10,000 Table of Contents Maintenance Section Safety Precautions MaintenanceEngine OIL Change Engine OIL Refill CapacitiesOIL Filter Change AIR Cleaner and Other MaintenanceEngine Adjustments Figure D.1 Major Component Locations Eagle 10,000 1TABLE of CONTENTS-THEORY of Operation Section E-1 Theory of Operation BATTERY, STARTER, ENGINE, ROTOR, STATOR, and Idler SolenoidFigure E.3 Rotor Field Feedback and Auxiliary Power Rotor Field Feedback Auxiliary PowerOutput BRIDGE, CHOKE, and Output Terminals Weld WINDING, REACTOR, and Range Switch1TABLE of Contents Troubleshooting and Repair F-1 HOW to USE Troubleshooting Guide 2TROUBLESHOOTING and REPAIRF-2PC Board Troubleshooting Procedures Troubleshooting and RepairPerform the Rotor Voltage Test Recommended Course of Action Problems Possible Areas Symptoms MisadjustmentsPossible Areas Misadjustments Problems SymptomsRotor Voltage2. PTestrform Engine Problems Wiring Charging Circuit Test BridgePerformTestthe. Output Rectifier Eagle 10,000 Materials Needed Rotor Voltage TestTest Description Rotor Voltage Test Test ProcedureRemove the case top, then reinstall the fuel cap Rotor Resistance Test Remove the case top, then replace the fuel cap Rotor Resistance TestTroubleshooting and Repair Eagle 10,000 Auxiliary and Field Winding Test To test the 230 VAC winding Auxiliary and Field Winding TestTo test the 115 VAC winding To test the field winding Eagle 10,000 Output Rectifier Bridge Test Figure F.4 Location of Output Rectifier Leads Output Rectifier Bridge TestCharging Circuit Test Figure F.5 Location of Voltage Regulator Charging Circuit TestEngine Throttle Adjustment Test Strobe-tach Method Engine Throttle Adjustment TestFrequency Counter Method Figure F.7Oscilloscope Method Vibratach Method Engine Throttle Adjustment TestHigh Idle no Load Output Control AT Maximum Scope SettingsNormal Open Circuit Voltage Waveform 115VAC Supply Machine Loaded to 200 Amps AT 26 VDC Typical DC Weld Output Waveform CC ModeMachine Loaded Abnormal Open Circuit DC Weld Voltage Waveform Normal Open Circuit DC Weld Voltage Waveform CC Mode Brush Removal and Replacement Procedure Brush Removal and ReplacementFigure F.9 Brush LEADS/BRUSHES Retained with Cable TIE Slip RingsEagle 10,000 Printed Circuit Board Removal Replacement Printed Circuit Board Removal ReplacementTroubleshooting and Repair Eagle 10,000 Output Rectifier Bridge Removal Replacement 43TROUBLESHOOTING and REPAIRF-43Output Rectifier Bridge Removal 44TROUBLESHOOTING and REPAIRF-4445TROUBLESHOOTING and REPAIRF-45 Eagle 10,000 Instructions ENGINE/ROTOR Removal and ReplacementFigure F.12 Component LOCATIONS, ENGINE/ROTOR Removal ENGINE/ROTOR Removal and ReplacementEngine and Rotor Removal Procedure Figure F.13 Engine and Rotor Removed from Stator THRU-BOLT Rotor Removal ProcedureENGINE/ROTOR Removal Replacement KIT S20788Reassembly Procedure Retest After Repair Auxiliary Power Receptacle OUTPUT1Engine Output Welder DC OUTPUT1Table of Contents Diagram Section Eagle 10,000 Kohler Electrical DiagramsWiring Diagram Code 11397 M21271 Terminal Schematic Complete Machine Code 11096 L12259Torroid Core located on Schematic Complete Machine Code 11397 L13104Schematic IDLER/FIELD Control P.C. Board L12197

SVM192-A specifications

Lincoln Electric's SVM192-A is a standout model in the sphere of welding machines, renowned for its advanced technology and versatility, making it a preferred choice among welding professionals and industrial applications. This single-phase inverter-based machine balances performance and portability, providing users with a reliable solution for a variety of welding tasks.

One of the key features of the SVM192-A is its capacity to perform multiple welding processes. It supports MIG, TIG, and stick welding, which allows users to switch between different techniques depending on the project requirements. This multi-functionality enhances the machine's utility, making it viable for various applications ranging from home projects to professional fabrication works.

The SVM192-A is equipped with Lincoln Electric’s proprietary technologies, including the advanced inverter technology, which ensures high efficiency and power output while maintaining a compact size. This inverter technology not only improves arc stability but also reduces power consumption and heat generation, making it a more eco-friendly option.

Key characteristics of the SVM192-A include a user-friendly digital display that provides clear settings for amperage, voltage, and other parameters, enabling precise control during welding. The machine also features a robust construction, designed to withstand tough working environments, ensuring longevity and minimal downtime.

Moreover, the SVM192-A incorporates safety features designed to protect the user and the machine, including overcurrent and thermal overload protection. This prioritization of safety ensures a worry-free operation, allowing welders to focus on their craft without the distraction of potential hazards.

Portability is another significant advantage of the SVM192-A. Weighing in at a lightweight design, it is easy to transport, making it ideal for mobile operations or jobs that require moving the equipment frequently.

In summary, the Lincoln Electric SVM192-A embodies versatility, efficiency, and durability, making it an exceptional choice for both novice and experienced welders. Its ability to handle multiple welding processes, combined with advanced technologies and user-friendly features, positions it as a top contender in the welding equipment market, suitable for a wide range of applications in various sectors.
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