Lincoln Electric SVM197-A service manual ISAFETYi

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iSAFETYi

WARNING

CALIFORNIA PROPOSITION 65 WARNINGS

Diesel engine exhaust and some of its constituents

 

The engine exhaust from this product contains

are known to the State of California to cause can-

 

chemicals known to the State of California to cause

cer, birth defects, and other reproductive harm.

 

cancer, birth defects, or other reproductive harm.

 

 

 

The Above For Diesel Engines

 

The Above For Gasoline Engines

ARC WELDING can be hazardous. PROTECT YOURSELF AND OTHERS FROM POSSIBLE SERIOUS INJURY OR DEATH. KEEP CHILDREN AWAY. PACEMAKER WEARERS SHOULD CONSULT WITH THEIR DOCTOR BEFORE OPERATING.

Read and understand the following safety highlights. For additional safety information, it is strongly recommended that you purchase a copy of “Safety in Welding & Cutting - ANSI Standard Z49.1” from the American Welding Society, P.O. Box 351040, Miami, Florida 33135 or CSA Standard W117.2-1974. A Free copy of “Arc Welding Safety” booklet E205 is available from the Lincoln Electric Company, 22801 St. Clair Avenue, Cleveland, Ohio 44117-1199.

BE SURE THAT ALL INSTALLATION, OPERATION, MAINTENANCE AND REPAIR PROCEDURES ARE PERFORMED ONLY BY QUALIFIED INDIVIDUALS.

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FOR ENGINE powered equipment.

1.a. Turn the engine off before troubleshooting and maintenance work unless the maintenance work requires it to be running.

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1.b.Operate engines in open, well-ventilated areas or vent the engine exhaust fumes

outdoors.

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1.c. Do not add the fuel near an open flame weld- ing arc or when the engine is running. Stop the engine and allow it to cool before refuel- ing to prevent spilled fuel from vaporizing on contact with hot engine parts and igniting. Do not spill fuel when filling tank. If fuel is spilled, wipe it up and do not start engine until fumes

have been eliminated.

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1.d. Keep all equipment safety guards, covers and devices in posi- tion and in good repair.Keep hands, hair, clothing and tools away from V-belts, gears, fans and all other moving parts when starting, operating or repairing equipment.

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1.e. In some cases it may be necessary to remove safety guards to perform required maintenance. Remove guards only when necessary and replace them when the maintenance requiring their removal is complete. Always use the greatest care when working near moving parts.

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1.f. Do not put your hands near the engine fan. Do not attempt to override the governor or idler by pushing on the throttle control rods while the engine is running.

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1.g. To prevent accidentally starting gasoline engines while turning the engine or welding generator during maintenance work, disconnect the spark plug wires, distributor cap or magneto wire as appropriate.

1.h. To avoid scalding, do not remove the radiator pressure cap when the engine is hot.

ELECTRIC AND MAGNETIC FIELDS may be dangerous

2.a. Electric current flowing through any conductor causes localized Electric and Magnetic Fields (EMF). Welding current creates EMF fields around welding cables and welding machines

2.b. EMF fields may interfere with some pacemakers, and welders having a pacemaker should consult their physician before welding.

2.c. Exposure to EMF fields in welding may have other health effects which are now not known.

2.d. All welders should use the following procedures in order to minimize exposure to EMF fields from the welding circuit:

2.d.1. Route the electrode and work cables together - Secure them with tape when possible.

2.d.2. Never coil the electrode lead around your body.

2.d.3. Do not place your body between the electrode and work cables. If the electrode cable is on your right side, the work cable should also be on your right side.

2.d.4. Connect the work cable to the workpiece as close as possible to the area being welded.

2.d.5. Do not work next to welding power source.

Mar ‘95

POWERARC® 5500

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Contents Powerarc ISAFETYi Safety Electric Shock can kill ARC Rays can burnFor Electrically IiiPrécautions DE Sûreté Electromagnetic Compatibility EMC Safety Master Table of Contents for ALL Sections Table of Contents Installation Section Installation Technical Specifications PowerarcStoring Safety PrecautionsLocation and Ventilation Engine Exhaust can killPRE-OPERATION Engine Service Spark Arrester PowerArc 5500 Typical Fuel ConsumptionMuffler Deflector Honda 9 HPWelding Cable Connections Powerarc 5500 Output ConnectionsElectrical Output Connections Cable Size and LengthPlugs and HAND-HELD Equipment Auxiliary Power ReceptaclesCable Installation Machine GroundingPremises Wiring Circuit BreakersTable A.2 Electrical Device USE with the Powerarc Type Common Electrical Devices Possible ConcernsPowerarc Table of Contents Operation Section Operation Output Panel Controls Controls and SettingsLimitations Physical Location of Components may vary by Code NoEngine Operation Gasoline Engine ControlsBefore Starting the Engine Starting the EngineGeneral Information Generator OperationStopping the Engine Running the EngineTable B.3 Generator Power Applications Welding Operation Control Function / Operation Current Control DialMaterial Thickness Electrode Type Size Setting Welding GuidelinesWhat Happens in the Arc? Welding circuit for Stick shielded metal arc weldingCorrect Arc Length Correct Welding PositionCorrect Way to Strike An Arc Correct Welding SpeedUse the following Common MetalsTypes of Welds Do the followingPenetration Welding in the Vertical PositionVertical-Up Welding Vertical-Down WeldingHardfacing To Reduce Wear How to Hardface the Sharp Edge Metal to Ground WearOverhead Welding Welding Sheet MetalWelding Cast Iron Cast Iron Plate PreparationLow Hydrogen Group AWS E7018 Selecting ElectrodesHigh-Speed Group AWS E6013 Out-of-Position Group AWS E6011Powerarc Table of Contents Accessories Section Lincoln Electric Accessories AccessoriesOPTIONS/ACCESSORIES Table of Contents Maintenance Section Engine Maintenance MaintenanceRoutine and Periodic Maintenance Engine Adjustments Figure D.3 Clean Rotating SCREEN/FINGER GUARD/DEBRIS GuardTable D.1 Engine Maintenance Parts Part Robin / Subaru HondaGENERATOR/WELDER Maintenance Do not attempt to polish slip rings while engine is runningFigure D.6. Major Component Locations 1TABLE of CONTENTS-THEORY of Operation Section E-1 ENGINE, EXCITATION, Rotor and Stator Theory of OperationEngine Control and Ignition Rotor Field Feedback Auxiliary Power ReturnAuxiliary Power Overcurrent Protection Weld Winding and Reactor1TABLE of Contents Troubleshooting and Repair F-1 2TROUBLESHOOTING and REPAIRF-2 HOW to USE Troubleshooting GuideTroubleshooting and Repair Output Problems Perform the Rotor and Flashing Voltage Test Troubleshooting and Repair Troubleshooting and Repair Rotor Resistance Test Engine Problems Troubleshooting and Repair Engine Throttle Adjustment Test Powerarc Test Description Materials NeededFlashing Voltage Test Procedure 14TROUBLESHOOTING and REPAIRF-14Rotor Voltage Test Procedure LeadRotor Resistance Test Procedure Rotor Resistance Test Procedure Figure F.3 Brushes Retained with Cable TIE Powerarc Engine Throttle Adjustment Test ROBIN/SUBARU Engine Engine Throttle Adjustment Test ROBIN/SUBARU EngineHigh Speed Stop Screw High 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 Brush Removal and Replacement Procedure Brush Removal and Replacement Procedure Powerarc Rheostat Removal and Replacement Procedure Rheostat Removal and Replacement Procedure Troubleshooting and Repair Attachment for 202A Cable Tie Capacitor Procedure Capacitor Removal and REPLACE- MentCapacitor AND/OR Diode Bridge Attachment for 201 201A JumperProcedure Field Diode Bridge Removal and Replacement Figure F.10 Field Diode Bridge LocationPowerarc STATOR/ROTOR Removal and Replacement Procedure Stator Removal Procedure STATOR/ROTORSection TOC Rotor Removal Procedure Procedure Reactor Bolts Lead Engine Output Auxiliary Power Receptacle OUTPUT1Retest After Repair WELDER/GENERATOR OUTPUT1Powerarc Table of Contents Diagram Section Electrical Diagrams Wiring Diagram Codes 11182, 11187, 11329 S25984Wiring Diagram Codes 11403, 11405 S26829 SwitchWiring Diagram Power ARC Wiring Diagram Code 11404 S26830Wiring Diagram Code 11215 S26023 Schematic -CODES 11182, 11187, 11329 S26008 S26008Schematic Codes 11403, 11405 S26881 S26881Schematic Code 11404 S26882 S26882