Lincoln Electric SVM103-C service manual Troubleshooting, Output Problems

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	F-3		TROUBLESHOOTING	F-3
			TROUBLESHOOTING

		TROUBLESHOOTING GUIDE - Observe all Safety Guidelines detailed throughout this manual

		PROBLEMS	POSSIBLE AREAS OF	RECOMMENDED
		(SYMPTOMS)	MISADJUSTMENTS(S)	COURSE OF ACTION

			OUTPUT PROBLEMS

	Major physical or electrical damage		Contact the Lincoln Electric Service
	is evident.		Department at 1-800-833-9353
			(WELD).

CAUTION

If for any reason you do not understand the test procedures or are unable to perform the tests/repairs safely, contact the Lincoln Electric Service Department for technical troubleshooting assistance before you proceed. Call 1-800-833-9353

POWER-ARC 4000

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Contents Safety Depends on You POWER-ARCCalifornia Proposition 65 Warnings SafetyElectric Shock can kill Welding Sparks can cause fire or explosion Précautions DE Sûreté Master Table of Contents for ALL Sections Table of Contents Installation Section Technical Specifications POWER-ARC InstallationSafety Precautions Location and VentilationStoring PRE-OPERATION Engine Service Cert. Kool Bore Spark Arrester125 amp Electrical Output ConnectionsWelding Cable Connections Cable Size forAuxiliary Power Receptacles Machine GroundingPlugs and HAND-HELD Equipment Circuit Breakers Premises WiringThese Devices Without POWER-ARC Table of Contents Operation Section General Description Safety InstructionsOperation Operating InstructionsWelding Capability Operational Features and ControlsDesign Features Advantages Recommended ApplicationsGENERATOR/WELDER Controls Controls and Settings20 AMP, 120 Volt Duplex Receptacle Gasoline Engine ControlsEngine Operation Before Starting the EngineStarting the Engine For a HOT Engine To USE the Generator AS AN Auxiliary Power Supply Generator OperationGeneral Information Suggested Power Applications Running Watts Start-up Watts Table B.1 Generator Power ApplicationsWelding Operation Table B.2 Welding APPLICATIONS/ELECTRODE Selection Guide Welding GuidelinesOperation What Happens in the Arc? Correct Welding Position Correct Arc Length Butt Welds PracticeUse the following Do the followingPenetration Fillet WeldsVertical-Down Welding Vertical-Up WeldingOverhead Welding Hardfacing To Reduce WearWelding Sheet Metal Cast Iron Plate Preparation Welding Cast IronHigh-Speed Group AWS E6013 Out-of-Position Group AWS E6011Low Hydrogen Group Stable-Arc E7018 Table of Contents Accessories Section Accessories OPTIONS/ACCESSORIESLincoln Electric Accessories Table of Contents Maintenance Section Engine Adjustments MaintenanceRoutine and Periodic Maintenance Engine MaintenanceFigure D.2 Clean Rotating SCREEN/FINGER GUARD/DEBRIS Guard Table D.1 Engine Maintenance Schedule Do not attempt to polish slip rings while engine is running GENERATOR/WELDER MaintenanceFigure D.6. Major Component Locations Table of Contents Theory of Operation Section ENGINE, EXCITATION, Rotor and Stator Theory of OperationFigure E.3 Field Excitation and Auxiliary Power Rotor Field Feedback and Auxiliary PowerWeld Winding and Reactor Auxiliary Power Overcurrent ProtectionTable of Contents Troubleshooting & Repair Section HOW to USE Troubleshooting Guide Troubleshooting & RepairOutput Problems TroubleshootingOr contact your local Lincoln Electric Authorized Field SerVice Facility Local Lincoln Electric Authorized Field Service FacilityTroubleshooting Rotor Resistance Test Engine Problems Troubleshooting Engine Throttle Adjustment Materials Needed This procedure takes approximately 15 minutes to performRotor Voltage Test Test DescriptionRotor Voltage Test Test ProcedureRotor Resistance Test This procedure takes approximately 25 minutes to performRotor Resistance Test Figure F.3 Brushes Retained with Cable TIE This procedure takes approximately 20 minutes to perform Engine Throttle Adjustment TestStrobe-tach Method Frequency Counter MethodOscilloscope Method Wing NUT High Speed Stop Screw Scope Settings Normal Open Circuit Weld Voltage WaveformHigh Idle no Load Normal Open Circuit Voltage Waveform 115 VAC Supply Typical Weld Output Waveform Machine LoadedMachine Loaded to 125 Amps AT 23 VAC Description Brush Removal and ReplacementProcedure Brush Removal and ReplacementProcedure Rheostat Removal and Replacement Figure F.7 Rheostat Removal This procedure takes approximately 35 minutes to perform Capacitor AND/OR Diode Bridge Removal and ReplacementFigure F.8 Location and Discharging the Field Capacitor Procedure Capacitor Removal and REPLACE- MentFigure F.8A Field Diode Bridge Location Procedure Field Diode Bridge Removal and ReplacementSTATOR/ROTOR Removal and Replacement This procedure takes approximately 3 hours to performInstructions STATOR/ROTOR Removal and Replacement Troubleshooting & Repair Rotor Removal Procedure Figure F.12 Checking ROTOR-STATOR AIR GAP WELDER/GENERATOR OUTPUT1 Auxiliary Power Receptacle OUTPUT1Retest After Repair Engine OutputReturn to Section TOC Table of Contents Diagrams Section Wiring Diagram Power ARC DiagramsDIAGRAMSG-3 DIAGRAMSG-4 Dimension Print Power ARC Return to Section TOC SVM Error Reporting Form