Lincoln Electric SVM134-A service manual Main Generator

Page 50

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F-6

 

 

 

 

 

 

F-6

 

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

 

 

 

 

 

 

 

 

The welding output varies abnor-

1. Check for loose or faulty weld-

1. Check the fine current control

 

mally. The auxiliary output remains

ing cables.

 

field rheostat for resistance and

 

constant. The engine is operating

2. This may be a normal condition.

 

proper operation. Normal resis-

 

correctly.

 

tance is 64 ohms. Check asso-

 

The machine will normally lose

 

 

 

 

ciated wires for loose or faulty

 

 

some output as the components

 

 

 

 

connections.

See

the

Wiring

 

 

are heated.

 

 

 

 

Diagram.

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

3. Check for loose, worn, dirty or

2.

Perform

the

Main

Generator

 

 

poorly seated main DC genera-

 

 

 

Shunt Field Winding Test.

 

 

tor brushes.

 

 

 

 

 

 

 

 

 

 

 

 

4. The main armature commutator

3.

Check

the

current

range

 

 

 

selector switch and contacts for

 

 

may need cleaning.

 

 

 

 

proper operation.

 

 

 

 

 

 

 

 

 

 

 

 

 

4. While the machine is loaded,

 

 

 

 

check the interpole and series

 

 

 

 

coils for signs of “arcing.” This

 

 

 

 

condition would indicate short-

 

 

 

 

ed turns in the “arcing” coil.

 

 

 

5. The main armature may be

 

 

 

 

faulty. Check for grounds.

 

 

 

 

 

 

 

 

 

 

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 1-800-833-9353.

CLASSIC I

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Page 49 Page 51
Contents Classic I TM Safety California Proposition 65 WarningsElectric Shock can kill Welding Sparks can cause fire or explosion IiiPrécautions DE Sûreté Sûreté Pour Soudage a L’ArcMaster Table of Contents for ALL Sections Table of Contents Installation Section Installation Technical Specifications ClassicStoring Safety PrecautionsLocation and Ventilation PRE-OPERATION Engine Service Exhaust Spark Arrester Cooling SystemMuffler TrailersMachine Grounding Figure A.1 Ground Stud LocationWelding Cable Connections Auxiliary Power Receptacle PLUGS, and HAND-HELD EquipmentElectrical Output Connections Cable size for combined lengthClassic Table of Contents Operation Section Operating Instructions Safety InstructionsOperation Welder Operational Features and ControlsRecommended Applications GeneratorControls and Settings WELDER/GENERATOR ControlsControl of Welding Current Figure B.2 Current ControlsGasoline Engine Controls Return Section TOCStarting the Engine Engine OperationBefore Starting the Engine BREAK-IN Period Stopping the EngineCold Weather Starting Welding Operation After you finish weldingAuxiliary Power Table B.1 Range Settings for Wire SIZE/SPEEDTable of Contents Accessories OPTIONS/ACCESSORIES Semiautomatic Welding AccessoriesConnection of the LN-25 to Connection of Lincoln Electric Wire FeedersWire Feed Module see Figure C.1 Classic I Across the ARC withClassic Table of Contents Maintenance Safety Precautions Routine and Periodic Maintenance Engine MaintenanceFigure D.1 OIL Drain and Refill MAX MIN Figure D.2A Engine Coolant Drain Plug Set the terminal gap with a feeler gauge or gapping After cleaning or when installing a new spark plugGap Specifications 0.032 inch .8 mm Tool. See Figure D.4Battery Maintenance Classic I charging system is NegativeWELDER/GENERATOR Maintenance Return to Section Return to Section TOCIdler Maintenance Figure D.5 Major Component Locations Classic Table of Contents Theory of Operation Section General Description BATTERY, STARTER, Engine Alternator and OIL Switch CircuitTheory of Operation Main SHUNT, Interpole and Series Coils ENGINE, Main Generator Armature and Frame and DC ExciterExcitation Flashing Engine Idler Circuit Fine Current AdjustmentCurrent Range Selector DC Generator Machines Return to Section TOC Table of Contents Troubleshooting & Repair Section Troubleshooting & Repair HOW to USE Troubleshooting GuidePC Board Troubleshooting Procedures PC Board can be damaged by static electricityDetailed in the beginning of this manual Troubleshooting GuideObserve Safety Guidelines Shunt Field Winding Test Main Generator Throttle Adjustment Test Output Problems Function Problems Troubleshooting & Repair Engine Problems Welding Problems Materials Needed DC Exciter TestTest Description Test Procedure DC Exciter TestFigure F.2 Exciter Cover Removal Small Flex Lead Solid Shunt Coil and Series Coil Resistance TestsIdler Solenoid Test Troubleshooting & Repair Main Generator Shunt Field Winding Test Main Generator Shunt Field Winding Test Figure F.6 Plug P10 PIN Assignments TAB Engine Throttle Adjustment Test Engine Throttle Adjustment Test Strobe Tach MethodEngine Throttle Adjustment Test Adjust High IdleAdjust Low Idle Flashing the Fields DescriptionProcedure Flashing the FieldsFigure F.11 Brush HOLDER/BATTERY Jumper Connections High Idle no Load Fine Current Control Rheostat AT Maximum Scope SettingsNormal Open Circuit Voltage Waveform 115VDC Supply Normal Open Circuit DC Weld Voltage Waveform Machine Loaded Selector Switch AT Maximum Typical DC Weld Voltage WaveformDC Exciter Armature and Field Coils Removal and Replacement DC Exciter Armature and Field Coils DC Exciter Armature Removal ProcedureReassembly Field Coils Removal Procedure Perform the DC Exciter Armature Removal ProcedureMain Generator Frame Removal and Replacement Replacement Main Generator Frame Removal Bolt / NUTPerform the DC Exciter Armature Removal Figure F.16 Selector Switch Lead Removal Terminal LeadFigure F.18 Choke Control Cable Removal Loosen Here Main Generator Frame Removal Figure F.20 Front Panel Fastener Removal Troubleshooting & Repair Feet Remove Mounting NUTS, Washers BoltsPerform the DC Exciter Armature Reassembly Procedure Main Generator Armature Removal and Replacement Main Generator Armature Removal Armature is now free to be removed from the engineEngine Output DC Auxiliary Power Receptacle OutputRetest After Repair Welder DC OutputElectrical Diagrams Section Electrical Diagrams Wiring Diagram ClassicWire Feed Module Wiring Diagram Wiring Diagram Wire Feed ModuleSchematic Idler PC Board 16990 MPC Board Assembly Idler PC Board Idler
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