Lincoln Electric SVM103-A service manual Troubleshooting & Repair

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F-5

TROUBLESHOOTING & REPAIR

Observe Safety Guidelines

 

TROUBLESHOOTING GUIDE

detailed in the beginning of this manual.

 

 

 

 

PROBLEMS

POSSIBLE AREAS OF

RECOMMENDED

(SYMPTOMS)

MISADJUSTMENT(S)

COURSE OF ACTION

 

 

 

 

OUTPUT PROBLEMS

 

No auxiliary power - welding output

1. Check circuit breakers CB1 and

1. Check the auxiliary power re-

is normal - engine runs normally.

CB2. Reset if tripped.

ceptacles ands associated wires

 

2. Make sure that the control rheo-

for loose or faulty connections.

 

 

 

stat (R1) is set at “GENERA-

2. Check the continuity (zero

 

TOR” (maximum).

ohms) of leads 3, 3A (black); 6,

 

3. Check for loose or faulty plug at

6A (yellow); and 5 (white) from

 

the receptacles to the stator

 

power receptacle.

 

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.

 

 

 

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 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-ARCLocation and Ventilation Safety PrecautionsStoring 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 ControlsBefore Starting the Engine Engine OperationStarting the Engine Running the Engine Stopping the EngineBREAK-IN Period Generator Operation To USE the Generator AS AN Auxiliary Power SupplyGeneral Information Table B.3 Generator Power Applications Welding Operation To USE the POWER-ARC 4000 for WeldingAfter YOU Finish the Weld Welding Guidelines Material Thickness Electrode Type Size SettingStick 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 Lincoln Electric Accessories OPTIONS/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 GENERATOR/WELDER Maintenance Table D.2 Engine Maintenance PartsPart 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 Test Description Rotor Voltage TestMaterials 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 NUTNormal Open Circuit Weld Voltage Waveform Scope SettingsHigh Idle no Load Normal Open Circuit Voltage Waveform 115 VAC Supply Machine Loaded Typical Weld Output WaveformMachine 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-BOLTSReassembly Procedure Rotor Removal ProcedureRotor THRU-BOLT Feeler Gauge RotorEngine Output Auxiliary Power Receptacle OUTPUT1Retest After Repair WELDER/GENERATOR OUTPUT1POWER-ARC Electrical Diagrams Table of ContentsSection G Electrical Diagram POWER-ARCPOWER-ARC POWER-ARC
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