Lincoln Electric IM869-D manual Symptoms, Course of Action

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E-2

 

TROUBLESHOOTING

E-2

 

 

 

 

 

Observe all Safety Guidelines detailed throughout this manual

 

 

 

 

 

PROBLEMS

POSSIBLE

RECOMMENDED

 

(SYMPTOMS)

CAUSE

COURSE OF ACTION

 

 

 

 

FUNCTION PROBLEMS

Machine fails to hold the “heat” constantly.

1.Rough or dirty commutator.

2.Brushes may be worn down to limit of life.

3.Brush springs may be broken.

4.Field circuit may have variable resistance connections or inter- mittent open circuit, due to loose connections or broken wire.

5.Electrode or work lead connec- tions may be poor.

6.Wrong grade of brushes may be installed on generator.

7.Field rheostat may be making poor contact and overheating.

8.“Current Control” may not be operating properly.

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

10.“Current Control” brushholder support stud and mating contact surfaces may be dirty or pitted and burned.

11.Engine running at varying speeds.

1.True and clean commutator.

2.Replace brushes.

3.Replace brush springs.

4.Check field current with ammeter to discover varying current. This applies to both the main genera- tor and exciter.

5.Tighten all connections.

6.Use only the recommended Lincoln brushes.

7.Inspect and clean rheostat.

8.Check for loose or missing set screw in control handles.

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

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

11.Set welder controls for maximum output and weld. Then, while welding, check engine rpm. The engine should be running at full speed. If indicator shows a sig- nificant difference, 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.

SAE-400

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Contents IM869-D California Proposition 65 Warnings SafetyElectric Shock can kill Welding and Cutting Sparks can Cause fire or explosion Sûreté Pour Soudage a LʼArc Précautions DE SûretéThank You Table of Contents Technical Specifications SAE-400 K1278-7, K1278-9 InstallationHeight Width Depth Weight LOCATION/VENTILATION Safety PrecautionsStacking Angle of OperationHigh Altitude Operation PRE-OPERATION Engine ServiceTowing Vehicle MountingEngine Cooling System Battery ConnectionEngine BREAK-IN Period Welding Output Cables Spark ArresterMachine Grounding Table A.1 Combined Length of Electrode Work CablesAdditional Safety Precautions Safety InstructionsOperation Operating InstructionsRecommended Applications Design Features and AdvantagesDuty Cycle Welder Controls Engine ControlsAuxiliary Power Controls Remote ControlStarting Instructions Engine OperationStopping the Engine Cold Weather StartingPerkins 1104C-44 Perkins 1104A-44 Typical Fuel ConsumptionK1690-1 Gfci Receptacle KIT AccessoriesRoutine Maintenance MaintenancePeriodic Maintenance Bearing MaintenanceFuel PRE-FILTER/WATER Separator Assembly Commutator and Brush MaintenancePRE Filter / Water Separator Cooling SystemWater Separator Element Fuel PRE-FILTER/WATER Separator AssemblySpark Arrestor Gfci Receptacle Testing and RESET- Ting ProcedureSAE-400 with integral spark arresting mufflers HOW to USE Troubleshooting Guide TroubleshootingCourse of Action SymptomsRecommended Troubleshooting Problems Possible Recommended Wiring Diagrams Wiring Diagram SAE400 Wiring Diagram M8869-36 Dimension PrintSAE-400 SAE-400 Aviso DE Warnung