Lincoln Electric SVM128-A service manual Troubleshooting & Repair

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F-46

F-46

TROUBLESHOOTING & REPAIR

GENERATOR FRAME REMOVAL

AND REPLACEMENT (continued)

31.Re-attach the positive output terminal cable.

32.Attach the cable retainer to the fuel tank rail. Set the fuel tank into position on the rails and secure it with the four bolts, washers, and nuts.

33.Attach the fuel return line at the top of the fuel tank. Remove the plug from the fuel line and attach it to the fuel bowl.

34.Perform the replacement procedures according to each of the following:

Alternator Stator Removal and Replacement

Alternator Rotor Removal and Replacement

Before installing the machine case top and sides, be sure to replace any cable ties cut during disas- sembly.

SA-250

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Contents SHIELD-ARCTMSA-250 Safety SA-250Electric 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 SA-250Location and Ventilation Safety PrecautionsStoring PRE-OPERATION Engine Service Cooling System MufflerExhaust Spark Arrester TrailerElectrical Output Connections Welding Cable ConnectionsMachine Grounding Auxiliary Power RECEPTACLES, PLUGS, and HAND-HELD EquipmentCircuit Breakers SA-250 Table of Contents Operation Section Safety Instructions OperationOperating Instructions General DescriptionOperational Features and Controls Design FeaturesRecommended Applications WelderWelding Capability LimitationsControls and Settings WELDER/GENERATOR ControlsControl of Welding Current Current Range SelectorDiesel Engine Controls Figure B.3 Diesel Engine ControlsEngine Operation Before Starting the EngineStarting the Engine Check and fill the engine fuel tankCold Weather Starting Stopping the EngineBREAK-IN Period Welding Operation After you finish weldingTable B.1 Range Settings for Wire SIZE/SPEED Auxiliary Power 12B-12Table of Contents Accessories OPTIONS/ACCESSORIES TIG Welding Accessories Semiautomatic Welding AccessoriesConnection of Lincoln Electric Wire Feeders Connection of the LN-7 toPIN Amphenol Connection of the LN-25 to Unused Lead IndividuallyFigure C.4 SA-250/LN-25 Across the ARC Connection Diagram Control K487-25 Table of Contents Maintenance Routine and Periodic Maintenance Engine MaintenanceFigure D.1 OIL Drain and Refill Eliminate Air from the Fuel System HOW to Eliminate AIR from the Fuel System Self-vent method Figure D.4 Eliminating AIR from the Fuel SystemFigure D.5 Engine Coolant Drain Plug Figure D.6 Tightening the FAN Belt Daily or Before Starting EngineFirst 25-50 Hours EveryBattery Maintenance Cleaning the BatteryWELDER/GENERATOR Maintenance Idler Maintenance Figure D.5 Major Component Locations SA-250 Table of Contents Theory of Operation Section ALTERNATOR, and Protection Theory of OperationCircuits Excitation Flashing Auxiliary and Field Feedback CoilsCurrent Range Selector Interpole and Series Coils Fine Current AdjustmentEngine Idler Circuit DC Generator Machines Mechanical CouplingSA-250 Table of Contents Troubleshooting & Repair Section Troubleshooting & Repair HOW to USE Troubleshooting GuidePC Board Troubleshooting Procedures PC Board can be damaged by static electricityObserve Safety Guidelines Troubleshooting GuideDetailed in the beginning of this manual Shunt Field Winding Test Field Shunt Winding Test Output Problems Function Problems Function Problems Troubleshooting & Repair Problems Possible Areas Symptoms Misadjustments Course of ActionWelding Problems Test Description Alternator Rotor TestMaterials Needed Test Procedure Slip Rings BrushesFigure F.2 Measuring Rotor Resistance Figure F.3 Measuring Rotor Resistance to Ground Field Shunt Winding Test Field Shunt Winding Test PIN TAB Idler Solenoid Test Idler Solenoid Test Engine Throttle Adjustment Test Engine Throttle Adjustment Test Strobe Tach MethodFrequency Counter Method Oscilloscope MethodAdjusting Screw Locking NUT Flashing the Fields DescriptionProcedure Do not remove brush holderNormal Open Circuit Voltage Waveform 115VAC Supply Scope SettingsHigh Idle no Load Fine Current Control Rheostat AT Maximum Normal Open Circuit DC Weld Voltage Waveform Machine Loaded Selector Switch AT Maximum Position Typical DC Weld Output Voltage WaveformAlternator Rotor Removal Replacement Replacement Alternator Rotor RemovalLoosen Screws Alternator Cover Slip Rings Brushes Figure F.13 Rotor Removal Replacement Alternator Stator Removal and Replacement Procedure Alternator Stator RemovalField Bridge Rectifier VAC Receptacle Circuit Breaker Genernator Brush HOLDER/COIL Cables Figure F.18 Drill Spot Locations Generator Frame Removal and Replacement Generator Frame Removal See Figure F.19 for steps 4 Figure F.20 Wire and Selector Switch Connections Figure F.21 Case Front Removal Rope Sling ENGINE/GENERATOR Mounting Holes Troubleshooting & Repair Generator Armature Removal and Replacement Generator Armature Removal Figure F.23 Blower Paddle RemovalAC Auxiliary Power Receptacle Output Retest After RepairEngine Output Welder DC OutputSA-250 Electrical Diagrams Section Section G SA-250 Electrical Diagrams Wiring DiagramWire Feed Module Wiring Diagram Idler PC Board M13708 Schematic Idler PC Board M13708 Components SVM Error Reporting Form