Lincoln Electric SVM103-A Troubleshooting & Repair, HOW to USE Troubleshooting Guide

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TROUBLESHOOTING & REPAIR

HOW TO USE TROUBLESHOOTING GUIDE

WARNING

Service and repair should be performed by only Lincoln Electric Factory Trained Personnel. Unauthorized repairs performed on this equipment may result in danger to the technician and machine operator and will invalidate your factory warranty. For your safety and to avoid Electrical Shock, please observe all safety notes and precautions detailed throughout this manual.

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This Troubleshooting Guide is provided to help you locate and repair possible machine mal- functions. Simply follow the three-step proce- dure listed below.

Step 1. LOCATE PROBLEM (SYMPTOM). Look under the column labeled “ PROBLEM (SYMPTOMS). This column describes possible symptoms that the machine may exhibit. Find the listing that best describes the symptom that the machine is exhibiting. Symptoms are grouped into three main categories: Welding Problems, Engine Problems, and Output Problems.

Step 2. PERFORM EXTERNAL TESTS. The second column, labeled “POSSIBLE AREAS OF MISADJUSTMENT(S)”, lists the obvious external possibilities that may contribute to the machine symptom. Perform these tests/checks in the order listed. In general, these tests can be con- ducted without removing the case wrap-around cover.

Step 3. PERFORM COMPONENT TESTS. The last column, labeled “Recommended Course of Action lists the most likely components that may have failed in your machine. It also specifies the appropriate test procedure to verify that the subject component is either good or bad. If there are a number of possible components, check the components in the order listed to eliminate one possibility at a time until you locate the cause of your problem.

All of the referenced test procedures referred to in the Troubleshooting Guide are described in detail at the end of this chapter. Refer to the Troubleshooting and Repair Table of Contents to locate each specific Test Procedure. All of the referred to test points. components, terminal strips, etc., can be found on the referenced electrical wiring diagrams and schematics. Refer to the Electrical Diagrams Section Table of Contents to locate the appropriate diagram.

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CAUTION

If for any reason you do not understand the test procedures or are unable to perform the test/repairs safely, contact the Lincoln Electric Service Department for electrical troubleshooting assistance before you proceed. Call 216-383-2531 or 1-800—833-9353.

POWER-ARC 4000

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Contents POWER-ARC TM4000 Safety POWER-ARCElectric Shock can kill Welding Sparks can cause fire or explosion IiiPrécautions DE Sûreté Master Table of Contents for ALL Sections Table of Contents Installation Section Installation Technical Specifications POWER-ARCSafety Precautions Location and VentilationStoring PRE-OPERATION Engine Service Welding Cable Connections Power ARCElectrical Output Connections Cable Size and LengthMachine Grounding Auxiliary Power ReceptaclesCable Installation Plugs and HAND-HELD EquipmentPremises Wiring Circuit BreakersTable A.2 Electrical Device USE with the POWER-ARC Type Common Electrical Devices Possible ConcernsTable of Contents Operation Section Operating Instructions Safety InstructionsOperation General DescriptionRecommended Applications Operational Features and ControlsDesign Features Advantages Welding CapabilityControls and Settings GENERATOR/WELDER ControlsFigure B.2 Gasoline Engine Controls Gasoline Engine ControlsEngine Operation Before Starting the EngineStarting the Engine Stopping the Engine Running the EngineBREAK-IN Period To USE the Generator AS AN Auxiliary Power Supply Generator OperationGeneral Information Table B.3 Generator Power Applications To USE the POWER-ARC 4000 for Welding Welding OperationAfter YOU Finish the Weld Material Thickness Electrode Type Size Setting Welding GuidelinesStick Welding Welding Circuit ARCElectrode 12/95 POWER-ARCFour Factors of Successful Welding Correct WAY to Strike AN ARCCorrect ARC Length Correct Welding SpeedTable of Contents Accessories OPTIONS/ACCESSORIES Lincoln Electric AccessoriesBriggs and Stratton Accessories Table of Contents Maintenance Routine and Periodic Maintenance Engine MaintenanceFigure D.2 Clean Rotating SCREEN/FINGER GUARD/DEBRIS Guard Figure D.4 SET Spark Plug GAP Table D.2 Engine Maintenance Parts GENERATOR/WELDER MaintenancePart Part Number Figure D.6. Major Component Locations Table of Contents Theory of Operation Section Theory of Operation ENGINE, EXCITATION, Rotor and StatorRotor Field Feedback and Auxiliary Power Figure E.3 Field Excitation and Auxiliary PowerAuxiliary Power Overcurrent Protection Weld Winding and ReactorTable of Contents Trouble Shooting & Repair Section Troubleshooting & Repair HOW to USE Troubleshooting GuideTroubleshooting Guide Output ProblemsOr contact your local Lincoln Local Lincoln Electric Authorized Troubleshooting & Repair Troubleshooting & Repair Engine Problems Engine Problems Welding Problems Rotor Voltage Test Test DescriptionMaterials Needed Test Procedure Ground Stud Lead 200A Connection Output PanelRotor Resistance Test Slip RingsFigure F.3 Brushes Retained with Cable TIE Cable TIE BrushesEngine Throttle Adjustment Test Frequency Counter Method MarkStrobe-tach Method Oscilloscope MethodFigure F.5 Location of Engine Throttle Adjustment NUT NUTScope Settings Normal Open Circuit Weld Voltage WaveformHigh Idle no Load Normal Open Circuit Voltage Waveform 115 VAC Supply Typical Weld Output Waveform Machine LoadedMachine Loaded to 125 Amps AT 23 VAC Brush Removal and Replacement DescriptionProcedure Figure F.6 Brushes Retained with Cable TIEProcedure Rheostat Removal and Replacement Figure F.7 Rheostat Removal Capacitor AND/OR Diode Bridge Removal Replacement Capacitor AND/OR Diode Bridge Removal and Replacement Procedure Capacitor Removal and ReplacementProcedure Diode Bridge Removal and Replacement STATOR/ROTOR Removal and Replacement InstructionsOutput Stator Removal ProcedureTIE Wrap TerminalsThru Bolts Support Nuts POWER-ARC Figure F.10 Stator END Bracket Support and THRU-BOLTSRotor Removal Procedure Reassembly ProcedureRotor THRU-BOLT Feeler Gauge RotorEngine Output Auxiliary Power Receptacle OUTPUT1Retest After Repair WELDER/GENERATOR OUTPUT1POWER-ARC Table of Contents Electrical DiagramsSection G Electrical Diagram POWER-ARCPOWER-ARC POWER-ARC
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