Lincoln Electric SVM197-A service manual 1TABLE of Contents Troubleshooting and Repair F-1

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F-1TABLE OF CONTENTS - TROUBLESHOOTING AND REPAIR F-1

Troubleshooting and Repair . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .F-1

How to Use Troubleshooting Guide	. .F-2
PC Board Troubleshooting Procedures	. .F-3
Troubleshooting Guide	. .F-4
Test Procedures	.F-13
Rotor Voltage and Flashing Test	.F-13
Rotor Resistance Test	.F-15
Engine Throttle Adjustment Test	F-19
Waveforms	.F-22
Removal and Replacement Procedures	.F-25
Brush Removal and Replacement	.F-25

Rheostat Removal and Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .F-29 Capacitor and/or Diode Bridge Removal and Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .F-31 Stator/Rotor Removal and Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .F-35 Retest and Repair . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .F-41

POWERARC® 5500

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Contents Powerarc ISAFETYi Electric Shock can kill ARC Rays can burn SafetyIii For ElectricallyPrécautions DE Sûreté Electromagnetic Compatibility EMC Safety Master Table of Contents for ALL Sections Table of Contents Installation Section Technical Specifications Powerarc InstallationLocation and Ventilation Safety PrecautionsStoring Engine Exhaust can killPRE-OPERATION Engine Service Muffler Deflector PowerArc 5500 Typical Fuel ConsumptionSpark Arrester Honda 9 HPElectrical Output Connections Powerarc 5500 Output ConnectionsWelding Cable Connections Cable Size and LengthCable Installation Auxiliary Power ReceptaclesPlugs and HAND-HELD Equipment Machine GroundingCircuit Breakers Premises WiringType Common Electrical Devices Possible Concerns Table A.2 Electrical Device USE with the PowerarcPowerarc Table of Contents Operation Section Operation Limitations Controls and SettingsOutput Panel Controls Physical Location of Components may vary by Code NoGasoline Engine Controls Engine OperationStarting the Engine Before Starting the EngineStopping the Engine Generator OperationGeneral Information Running the EngineTable B.3 Generator Power Applications Control Function / Operation Current Control Dial Welding OperationWelding Guidelines Material Thickness Electrode Type Size SettingWelding circuit for Stick shielded metal arc welding What Happens in the Arc?Correct Way to Strike An Arc Correct Welding PositionCorrect Arc Length Correct Welding SpeedTypes of Welds Common MetalsUse the following Do the followingWelding in the Vertical Position PenetrationVertical-Down Welding Vertical-Up WeldingOverhead Welding How to Hardface the Sharp Edge Metal to Ground WearHardfacing To Reduce Wear Welding Sheet MetalCast Iron Plate Preparation Welding Cast IronHigh-Speed Group AWS E6013 Selecting ElectrodesLow Hydrogen Group AWS E7018 Out-of-Position Group AWS E6011Powerarc Table of Contents Accessories Section OPTIONS/ACCESSORIES AccessoriesLincoln Electric Accessories Table of Contents Maintenance Section Routine and Periodic Maintenance MaintenanceEngine Maintenance Figure D.3 Clean Rotating SCREEN/FINGER GUARD/DEBRIS Guard Engine AdjustmentsPart Robin / Subaru Honda Table D.1 Engine Maintenance PartsDo not attempt to polish slip rings while engine is running GENERATOR/WELDER MaintenanceFigure D.6. Major Component Locations 1TABLE of CONTENTS-THEORY of Operation Section E-1 Engine Control and Ignition Theory of OperationENGINE, EXCITATION, Rotor and Stator Return Rotor Field Feedback Auxiliary PowerWeld Winding and Reactor Auxiliary Power Overcurrent Protection1TABLE of Contents Troubleshooting and Repair F-1 HOW to USE Troubleshooting Guide 2TROUBLESHOOTING and REPAIRF-2Troubleshooting 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 Materials Needed Test DescriptionRotor Voltage Test Procedure 14TROUBLESHOOTING and REPAIRF-14Flashing 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 ROBIN/SUBARU Engine Engine Throttle Adjustment TestHigh Speed Stop Screw Normal 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 Procedure Brush Removal and Replacement Procedure Powerarc Rheostat Removal and Replacement Procedure Rheostat Removal and Replacement Procedure Troubleshooting and Repair Capacitor AND/OR Diode Bridge Procedure Capacitor Removal and REPLACE- MentAttachment for 202A Cable Tie Capacitor Attachment for 201 201A JumperFigure F.10 Field Diode Bridge Location Procedure Field Diode Bridge Removal and ReplacementPowerarc STATOR/ROTOR Removal and Replacement Procedure STATOR/ROTOR Stator Removal ProcedureSection TOC Rotor Removal Procedure Procedure Reactor Bolts Lead Retest After Repair Auxiliary Power Receptacle OUTPUT1Engine Output WELDER/GENERATOR OUTPUT1Powerarc Table of Contents Diagram Section Wiring Diagram Codes 11182, 11187, 11329 S25984 Electrical DiagramsSwitch Wiring Diagram Codes 11403, 11405 S26829Wiring Diagram Code 11404 S26830 Wiring Diagram Power ARCWiring Diagram Code 11215 S26023 S26008 Schematic -CODES 11182, 11187, 11329 S26008S26881 Schematic Codes 11403, 11405 S26881S26882 Schematic Code 11404 S26882