Lincoln Electric SVM103-A service manual Local Lincoln Electric Authorized

Page 45

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TROUBLESHOOTING & REPAIR

F-4

 

 

 

TROUBLESHOOTING GUIDE

 

 

Observe Safety Guidelines

 

 

detailed in the beginning of this manual.

 

 

 

 

 

 

 

PROBLEMS

POSSIBLE AREAS OF

RECOMMENDED

 

 

 

(SYMPTOMS)

MISADJUSTMENT(S)

COURSE OF ACTION

 

 

 

 

 

 

 

 

 

 

 

OUTPUT PROBLEMS

 

 

 

 

 

No weld output - auxiliary power

1. Check the open circuit voltage

1.

Check continuity (zero ohms) of

 

(230 - 115 VAC) operates normally

(OCV) at the welder output ter-

 

lead W1A (black) from output

 

- engine runs normally.

minals. If OCV is okay, go to

 

terminal to reactor (L1). See the

 

 

Step 2, below.

 

Wiring Diagram.

 

 

 

 

If OCV is not present at the welder

2.

Check continuity (zero ohms) of

 

 

output terminals, contact your

 

lead W2 (black) from output ter-

 

 

local Lincoln Electric Authorized

 

minal to stator winding. See the

 

 

Field Service Facility.

 

Wiring Diagram.

 

 

 

 

2. Check the welding cables,

3.

Check continuity (zero ohms) of

 

 

clamps and electrode holder for

 

lead W1 (black) from reactor

 

 

loose or broken connections.

 

(L1) to stator winding. See the

 

 

 

 

Wiring Diagram.

 

 

 

 

 

4.

Check reactor (L1) for continuity

 

 

 

 

of winding. See the Wiring Dia-

 

 

 

 

gram.

 

 

 

 

 

5.

Check the stator for continuity

 

 

 

 

of winding. See the Wiring Dia-

 

 

 

 

gram.

 

 

 

 

 

6.

Make certain the reactor and/or

 

 

 

 

stator are NOT grounded. Mini-

 

 

 

 

mum acceptable resistance to

 

 

 

 

ground is 500 K-ohms.

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

CAUTION

If for any reason you do not understand the test procedures or are unable to perform the test/repairs safely, con- tact 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 POWER-ARC SafetyElectric Shock can kill Iii Welding Sparks can cause fire or explosionPrécautions DE Sûreté Master Table of Contents for ALL Sections Table of Contents Installation Section Technical Specifications POWER-ARC InstallationSafety Precautions Location and VentilationStoring PRE-OPERATION Engine Service Electrical Output Connections Power ARCWelding Cable Connections Cable Size and LengthCable Installation Auxiliary Power ReceptaclesMachine Grounding Plugs and HAND-HELD EquipmentCircuit Breakers Premises WiringType Common Electrical Devices Possible Concerns Table A.2 Electrical Device USE with the POWER-ARCTable of Contents Operation Section Operation Safety InstructionsOperating Instructions General DescriptionDesign Features Advantages Operational Features and ControlsRecommended Applications Welding CapabilityGENERATOR/WELDER Controls Controls and SettingsGasoline Engine Controls Figure B.2 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 ARC Welding CircuitFour Factors of Successful Welding 12/95 POWER-ARCElectrode Correct WAY to Strike AN ARCCorrect Welding Speed Correct ARC LengthTable of Contents Accessories OPTIONS/ACCESSORIES Lincoln Electric AccessoriesBriggs and Stratton Accessories Table of Contents Maintenance Engine Maintenance Routine and Periodic 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 ENGINE, EXCITATION, Rotor and Stator Theory of OperationFigure E.3 Field Excitation and Auxiliary Power Rotor Field Feedback and Auxiliary PowerWeld Winding and Reactor Auxiliary Power Overcurrent ProtectionTable of Contents Trouble Shooting & Repair Section HOW to USE Troubleshooting Guide Troubleshooting & RepairOutput Problems Troubleshooting GuideOr contact your local Lincoln Local Lincoln Electric Authorized Troubleshooting & Repair Troubleshooting & Repair Engine Problems Engine Problems Welding Problems Rotor Voltage Test Test DescriptionMaterials Needed Ground Stud Lead 200A Connection Output Panel Test ProcedureRotor Resistance Test Rings SlipCable TIE Brushes Figure F.3 Brushes Retained with Cable TIEEngine Throttle Adjustment Test Strobe-tach Method MarkFrequency Counter Method Oscilloscope MethodNUT Figure F.5 Location of Engine Throttle Adjustment 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 Description Brush Removal and ReplacementFigure F.6 Brushes Retained with Cable TIE ProcedureProcedure Rheostat Removal and Replacement Figure F.7 Rheostat Removal Capacitor AND/OR Diode Bridge Removal Replacement Procedure Capacitor Removal and Replacement Capacitor AND/OR Diode Bridge Removal and ReplacementProcedure Diode Bridge Removal and Replacement Instructions STATOR/ROTOR Removal and ReplacementTIE Wrap Stator Removal ProcedureOutput TerminalsFigure F.10 Stator END Bracket Support and THRU-BOLTS Thru Bolts Support Nuts POWER-ARCRotor Removal Procedure Reassembly ProcedureRotor THRU-BOLT Rotor Feeler GaugeRetest After Repair Auxiliary Power Receptacle OUTPUT1Engine Output WELDER/GENERATOR OUTPUT1POWER-ARC Table of Contents Electrical DiagramsSection G POWER-ARC Electrical DiagramPOWER-ARC POWER-ARC
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