Lincoln Electric SVM103-C Or contact your local Lincoln, Electric Authorized Field Ser

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F-4		TROUBLESHOOTING	F-4
		TROUBLESHOOTING

	TROUBLESHOOTING GUIDE - Observe all Safety Guidelines detailed throughout this manual

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

OUTPUT PROBLEMS

No weld output and no auxiliary 1. The generator brushes may be 1. Perform the Rotor Voltage Test.

output - engine runs normally. worn or faulty. See the Main- 2. If the rotor voltage is zero to 3 tenance section of this manual

or contact your local Lincoln

VDC, check the flywheel alterna- tor and associated wires 202

Electric Authorized Field Ser-

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vice Facility.

and 202A for continuity. The voltage from lead 202 to ground should be at least 0.5 to 1.5 VDC at high idle (3700 RPM). Normal voltage is approximately 45 VDC. If the voltage is low or missing, the flashing circuit may be faulty. See the wiring dia- gram. Check diode D2 & lead #202C.

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3. Check lead 201B for continuity (zero ohms) to ground. See wiring diagram.

4. The field capacitor (C1) or bridge

(D1) may be faulty. Test or replace.

5. Test the rheostat (R1). Normal resistance is 3.3 ohms. See the Rheostst Replacement drawing.

6. The rotor may be faulty. Perform the Rotor Resistance Test.

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 POWER-ARC Safety Depends on YouSafety California Proposition 65 WarningsElectric 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 Installation Technical Specifications POWER-ARCLocation and Ventilation Safety PrecautionsStoring PRE-OPERATION Engine Service Spark Arrester Cert. Kool BoreElectrical Output Connections Welding Cable ConnectionsCable Size for 125 ampMachine Grounding Auxiliary Power ReceptaclesPlugs and HAND-HELD Equipment Premises Wiring Circuit BreakersThese Devices Without POWER-ARC Table of Contents Operation Section Safety Instructions OperationOperating Instructions General DescriptionOperational Features and Controls Design Features AdvantagesRecommended Applications Welding CapabilityControls and Settings GENERATOR/WELDER ControlsGasoline Engine Controls 20 AMP, 120 Volt Duplex ReceptacleBefore Starting the Engine Engine OperationStarting the Engine For a HOT Engine Generator Operation To USE the Generator AS AN Auxiliary Power SupplyGeneral Information Table B.1 Generator Power Applications Suggested Power Applications Running Watts Start-up WattsWelding Operation Welding Guidelines Table B.2 Welding APPLICATIONS/ELECTRODE Selection GuideOperation What Happens in the Arc? Correct Welding Position Correct Arc Length Practice Use the followingDo the following Butt WeldsFillet Welds PenetrationVertical-Up Welding Vertical-Down WeldingHardfacing To Reduce Wear Overhead WeldingWelding Sheet Metal Welding Cast Iron Cast Iron Plate PreparationOut-of-Position Group AWS E6011 High-Speed Group AWS E6013Low Hydrogen Group Stable-Arc E7018 Table of Contents Accessories Section OPTIONS/ACCESSORIES AccessoriesLincoln Electric Accessories Table of Contents Maintenance Section Maintenance Routine and Periodic MaintenanceEngine Maintenance Engine AdjustmentsFigure D.2 Clean Rotating SCREEN/FINGER GUARD/DEBRIS Guard Table D.1 Engine Maintenance Schedule GENERATOR/WELDER Maintenance Do not attempt to polish slip rings while engine is runningFigure D.6. Major Component Locations Table of Contents Theory of Operation Section Theory of Operation ENGINE, EXCITATION, Rotor and StatorRotor Field Feedback and Auxiliary Power Figure E.3 Field Excitation and Auxiliary PowerAuxiliary Power Overcurrent Protection Weld Winding and Reactor Table of Contents Troubleshooting & Repair Section Troubleshooting & Repair HOW to USE Troubleshooting GuideTroubleshooting Output ProblemsElectric Authorized Field Ser Or contact your local LincolnVice Facility Field Service Facility Local Lincoln Electric AuthorizedTroubleshooting Rotor Resistance Test Engine Problems Troubleshooting Engine Throttle Adjustment This procedure takes approximately 15 minutes to perform Rotor Voltage TestTest Description Materials NeededTest Procedure Rotor Voltage TestThis procedure takes approximately 25 minutes to perform Rotor Resistance TestRotor Resistance Test Figure F.3 Brushes Retained with Cable TIE Engine Throttle Adjustment Test This procedure takes approximately 20 minutes to performFrequency Counter Method Strobe-tach MethodOscilloscope Method Wing NUT High 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 DescriptionBrush Removal and Replacement ProcedureProcedure Rheostat Removal and Replacement Figure F.7 Rheostat Removal Capacitor AND/OR Diode Bridge Removal and Replacement This procedure takes approximately 35 minutes to performProcedure Capacitor Removal and REPLACE- Ment Figure F.8 Location and Discharging the Field CapacitorProcedure Field Diode Bridge Removal and Replacement Figure F.8A Field Diode Bridge LocationThis procedure takes approximately 3 hours to perform STATOR/ROTOR Removal and ReplacementInstructions STATOR/ROTOR Removal and Replacement Troubleshooting & Repair Rotor Removal Procedure Figure F.12 Checking ROTOR-STATOR AIR GAP Auxiliary Power Receptacle OUTPUT1 Retest After RepairEngine Output WELDER/GENERATOR OUTPUT1Return to Section TOC Table of Contents Diagrams Section Diagrams Wiring Diagram Power ARCDIAGRAMSG-3 DIAGRAMSG-4 Dimension Print Power ARC Return to Section TOC SVM Error Reporting Form