Lincoln Electric IM640-A manual Symptoms Course of Action, Function Problems

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E-2

 

TROUBLESHOOTING

 

E-2

 

 

 

 

 

 

Observe all Safety Guidelines detailed throughout this manual

 

 

 

 

 

 

 

PROBLEMS

POSSIBLE CAUSE

RECOMMENDED

 

 

(SYMPTOMS)

COURSE OF ACTION

 

 

 

 

 

 

 

 

 

FUNCTION PROBLEMS

Machine fails to hold the “heat” constantly.

Rough or dirty commutator.

Brushes may be worn down to limit of life.

Brush springs may be broken.

Field circuit may have variable resis- tance connections or intermittent open circuit, due to loose connec- tions or broken wire.

Electrode or work lead connections may be poor.

Wrong grade of brushes may be installed on generator.

Field rheostat may be making poor contact and overheating.

“Current Control” may not be operat- ing properly.

“Current Control” brushholder con- tact springs may be worn out or missing. Contact surface may be dirty, rough and pitted.

“Current Control” brushholder sup- port stud and mating contact sur- faces may be dirty or pitted and burned.

Engine running at varying speeds.

True and clean commutator.

Replace brushes.

Replace brush springs.

Check field current with ammeter to discover varying current. This applies to both the main generator and exciter.

Tighten all connections.

Use only the recommended Lincoln brushes.

Inspect and clean rheostat.

Check for loose or missing set screw in control handles.

Inspect. Replace needed parts. Clean internal contact surface of control device. Do not lubricate. Smooth rough surfaces.

If brushholder internal contact sur- face is pitted and burned, replace the brushholder and support stud. If the contact surface is dirty, clean off the brushholder stud and internal contact surface. Apply mixture of three parts silicone grease and one part zinc powder (by weight) to stud.

Set welder controls for maximum output and weld. Then, while weld- ing, check engine rpm. The engine should be running at full speed. If indicator shows a significant differ- ence, consult your engine manual.

CAUTION

If for any reason you do not understand the test procedures or are unable to perform the tests/repairs safely, contact your Local Lincoln Authorized Field Service Facility for technical troubleshooting assistance before you proceed.

SAE400 & SAE400 WELD’N AIR

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Contents IM640-A Safety California Proposition 65 WarningsElectric Shock can kill Cylinder may explode if damaged Précautions DE Sûreté Sûreté Pour Soudage a L’ArcSafety Safety Thank You Table of Contents Height Width Depth Weight InstallationTechnical Specifications SAE400 & SAE400 WELD’N AIR Stacking Safety PrecautionsLOCATION/VENTILATION Angle of OperationTowing PRE-OPERATION Engine and Compressor ServiceHigh Altitude Operation Vehicle MountingEngine BREAK-IN Period Battery ConnectionEngine Cooling System Machine Grounding Welding Output CablesSpark Arrester Operation Safety InstructionsAdditional Safety Precautions Operating InstructionsDuty Cycle Design Features and AdvantagesRecommended Applications Engine Controls Welder ControlsAIR Compressor Controls SAE400 WELD’N AIR only Starting Instructions Engine OperationTypical Fuel Consumption Cold Weather StartingK1690-1 Gfci Receptacle KIT AccessoriesK2303-1 Sheet Metal KIT Routine Maintenance MaintenancePeriodic Maintenance Compressor AIR Receiver Tanks SAE400 WELD’N AIR onlyPRE Filter / Washer Separator Commutator and Brush MaintenanceFuel PRE-FILTER/WATER Separator Assembly Cooling System Water Separator Element Spark Arrestor Troubleshooting HOW to USE Troubleshooting GuideSymptoms Course of Action Function ProblemsRecommended Troubleshooting Problems Possible Cause Recommended Wiring Diagrams Wiring Diagram SAE-400 Weldn AIRWiring Diagram SAE-400 Perkins Control Wiring Diagram SAE-400 & Weldn AIR Dimension Print SAE400 & SAE400 WELD’NSAE400 & SAE400 WELD’N AIR Aviso DE Warnung
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