Lincoln Electric SVM103-A service manual Troubleshooting & Repair

Page 47

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TROUBLESHOOTING & REPAIR

F-6

 

 

 

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

 

 

 

 

 

 

Low weld output and low auxiliary

1. The generator brushes may be

1.

Perform the Rotor Voltage Test.

output.

worn.

See the Maintenance

2.

If the rotor voltage

is

low, the

 

section of this manual or contact

 

 

field

capacitor

(C1)

or bridge

 

your

local Lincoln Electric

 

 

 

(D1)

may be

faulty.

Test or

 

Authorized Field Service Facility.

 

 

 

replace.

 

 

 

 

 

 

 

 

 

 

 

2. The engine RPM may be low.

3.

Check the rheostat (R1). Normal

 

 

 

 

 

 

 

resistance is 3.3 ohm. See the

 

 

 

 

Rheostat Replacement drawing.

 

 

 

4.

The rotor may be faulty. Per-

 

 

 

 

form the Rotor Resistance Test.

 

 

 

5.

The engine RPM may be low.

 

 

 

 

Perform the

Engine

Throttle

 

 

 

 

Adjustment Test.

 

 

 

 

 

6.

If engine idle RPM is okay, the

 

 

 

 

engine may have lost horsepow-

 

 

 

 

er and be in need of major

 

 

 

 

repair.

 

 

 

 

 

 

 

 

 

 

 

 

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 InstallationStoring Safety PrecautionsLocation and Ventilation PRE-OPERATION Engine Service Cable Size and Length Power ARCElectrical Output Connections Welding Cable ConnectionsPlugs and HAND-HELD Equipment Auxiliary Power ReceptaclesCable Installation Machine GroundingCircuit Breakers Premises WiringType Common Electrical Devices Possible Concerns Table A.2 Electrical Device USE with the POWER-ARCTable of Contents Operation Section General Description Safety InstructionsOperation Operating InstructionsWelding Capability Operational Features and ControlsDesign Features Advantages Recommended ApplicationsGENERATOR/WELDER Controls Controls and SettingsGasoline Engine Controls Figure B.2 Gasoline Engine ControlsStarting the Engine Engine OperationBefore Starting the Engine BREAK-IN Period Stopping the EngineRunning the Engine General Information To USE the Generator AS AN Auxiliary Power SupplyGenerator Operation Table B.3 Generator Power Applications After YOU Finish the Weld To USE the POWER-ARC 4000 for WeldingWelding Operation Stick Welding Material Thickness Electrode Type Size SettingWelding Guidelines ARC Welding CircuitCorrect WAY to Strike AN ARC 12/95 POWER-ARCFour Factors of Successful Welding ElectrodeCorrect Welding Speed Correct ARC LengthTable of Contents Accessories Briggs and Stratton Accessories OPTIONS/ACCESSORIESLincoln Electric 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 Part Part Number Table D.2 Engine Maintenance PartsGENERATOR/WELDER Maintenance 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 Materials Needed Rotor Voltage TestTest Description 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 Oscilloscope Method MarkStrobe-tach Method Frequency Counter MethodNUT Figure F.5 Location of Engine Throttle Adjustment NUTHigh Idle no Load Scope SettingsNormal Open Circuit Weld Voltage Waveform Normal Open Circuit Voltage Waveform 115 VAC Supply Machine Loaded to 125 Amps AT 23 VAC Typical Weld Output WaveformMachine Loaded 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 ReplacementTerminals Stator Removal ProcedureTIE Wrap OutputFigure F.10 Stator END Bracket Support and THRU-BOLTS Thru Bolts Support Nuts POWER-ARCRotor THRU-BOLT Rotor Removal ProcedureReassembly Procedure Rotor Feeler GaugeWELDER/GENERATOR OUTPUT1 Auxiliary Power Receptacle OUTPUT1Retest After Repair Engine OutputPOWER-ARC Section G Table of ContentsElectrical Diagrams POWER-ARC Electrical DiagramPOWER-ARC POWER-ARC
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