Lincoln Electric SVM128-A service manual Table of Contents Troubleshooting & Repair Section

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Section F-1

Section F-1

TABLE OF CONTENTS

TROUBLESHOOTING & REPAIR SECTION

Troubleshooting & Repair Section	Section F
How to Use Troubleshooting Guide	F-2
PC Board Troubleshooting Procedures	F-3
Troubleshooting Guide	F-4 - F-12
Test Procedures	F-13
Alternator Rotor Test	F-13
Field Shunt Winding Test	F-17
Idler Solenoid Test	F-20
Engine Throttle Adjustment Test	F-22
Flashing the Fields	F-26
Oscilloscope Waveforms	F-28
Normal Open Circuit Voltage Waveform (115VAC Supply)	F-28
Normal Open Circuit DC Weld Voltage Waveform	F-29
Typical DC Weld Output Voltage Waveform	F-30
Replacement Procedures	F-31
Alternator Rotor Removal and Replacement	F-31
Alternator Stator Removal and Replacement	F-36
Generator Frame Removal and Replacement	F-41
Generator Armature Removal and Replacement	F-47
Retest After Repair	F-49

SA-250

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Contents SHIELD-ARCTMSA-250 SA-250 SafetyElectric Shock can kill Iii Welding Sparks can cause fire or explosionSûreté Pour Soudage a L’Arc Précautions DE SûretéMaster Table of Contents for ALL Sections Table of Contents Installation Section Technical Specifications SA-250 InstallationLocation and Ventilation Safety PrecautionsStoring PRE-OPERATION Engine Service Trailer Cooling SystemMuffler Exhaust Spark ArresterWelding Cable Connections Electrical Output ConnectionsMachine Grounding Auxiliary Power RECEPTACLES, PLUGS, and HAND-HELD EquipmentCircuit Breakers SA-250 Table of Contents Operation Section General Description Safety InstructionsOperation Operating InstructionsWelder Operational Features and ControlsDesign Features Recommended ApplicationsLimitations Welding CapabilityWELDER/GENERATOR Controls Controls and SettingsCurrent Range Selector Control of Welding CurrentFigure B.3 Diesel Engine Controls Diesel Engine ControlsCheck and fill the engine fuel tank Engine OperationBefore Starting the Engine Starting the EngineCold Weather Starting Stopping the EngineBREAK-IN Period After you finish welding Welding OperationTable B.1 Range Settings for Wire SIZE/SPEED 12B-12 Auxiliary PowerTable of Contents Accessories OPTIONS/ACCESSORIES Semiautomatic Welding Accessories TIG Welding AccessoriesConnection of the LN-7 to Connection of Lincoln Electric Wire FeedersPIN Amphenol Unused Lead Individually Connection of the LN-25 toFigure C.4 SA-250/LN-25 Across the ARC Connection Diagram Control K487-25 Table of Contents Maintenance Engine Maintenance Routine and Periodic MaintenanceFigure D.1 OIL Drain and Refill Eliminate Air from the Fuel System HOW to Eliminate AIR from the Fuel System Figure D.4 Eliminating AIR from the Fuel System Self-vent methodFigure D.5 Engine Coolant Drain Plug Figure D.6 Tightening the FAN Belt Every Daily or BeforeStarting Engine First 25-50 HoursCleaning the Battery Battery MaintenanceWELDER/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 Auxiliary and Field Feedback Coils Excitation Flashing Current Range Selector Interpole and Series Coils Fine Current Adjustment Engine Idler Circuit Mechanical Coupling DC Generator MachinesSA-250 Table of Contents Troubleshooting & Repair Section HOW to USE Troubleshooting Guide Troubleshooting & RepairPC Board can be damaged by static electricity PC Board Troubleshooting ProceduresObserve 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 Symptoms Misadjustments Course of Action Problems Possible AreasWelding Problems Test Description Alternator Rotor TestMaterials Needed Slip Rings Brushes Test ProcedureFigure 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 Strobe Tach Method Engine Throttle Adjustment TestOscilloscope Method Frequency Counter MethodAdjusting Screw Locking NUT Description Flashing the FieldsDo not remove brush holder ProcedureNormal Open Circuit Voltage Waveform 115VAC Supply Scope SettingsHigh Idle no Load Fine Current Control Rheostat AT Maximum Normal Open Circuit DC Weld Voltage Waveform Typical DC Weld Output Voltage Waveform Machine Loaded Selector Switch AT Maximum PositionAlternator Rotor Removal Replacement Alternator Rotor Removal ReplacementLoosen Screws Alternator Cover Slip Rings Brushes Figure F.13 Rotor Removal Replacement Alternator Stator Removal and Replacement Alternator Stator Removal ProcedureField Bridge Rectifier VAC Receptacle Circuit Breaker Genernator Brush HOLDER/COIL Cables Figure F.18 Drill Spot Locations Generator Frame Removal and Replacement See Figure F.19 for steps 4 Generator Frame RemovalFigure 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 Figure F.23 Blower Paddle Removal Generator Armature RemovalWelder DC Output AC Auxiliary Power Receptacle OutputRetest After Repair Engine OutputSA-250 Electrical Diagrams Section Section G SA-250 Wiring Diagram Electrical DiagramsWire Feed Module Wiring Diagram Idler PC Board M13708 Schematic Idler PC Board M13708 Components SVM Error Reporting Form