Lincoln Electric SVM103-A instruction

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Section F

TABLE OF CONTENTS

TROUBLE SHOOTING & REPAIR SECTION

Troubleshooting & Repair Section	Section F
Safety Precautions	F-1
How to Use Troubleshooting Guide	F-1
Troubleshooting Guide	F1 - F-9
Test Procedures
Rotor Voltage Test	F-10
Rotor Resistance Test	F-12
Engine Throttle Adjustment Test	F-15
Oscilloscope Waveforms
Normal Open Circuit Weld Voltage Waveform	F-18
Normal Open Circuit Weld Voltage Waveform (115 VAC Supply)	F-19
Typical Weld Output Waveform - Machine Loaded	F-20
Replacement Procedures
Brush Removal and Replacement	F-21
Rheostat Removal and Replacement	F-23
Capacitor and Diode Bridge Removal and Replacement	F-25
Stator/Rotor Removal and Replacement (Kit S20925)	F-27
Retest After Repair	F-32

POWER-ARC 4000

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Lincoln Electric SVM103-A service manual Table of Contents Trouble Shooting & Repair Section

Contents

POWER-ARC TM4000 POWER-ARC Safety Electric Shock can kill Iii 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 Installation Storing Safety PrecautionsLocation and Ventilation PRE-OPERATION Engine Service Electrical Output Connections Power ARCWelding Cable Connections Cable Size and Length Cable Installation Auxiliary Power ReceptaclesMachine Grounding Plugs and HAND-HELD Equipment Circuit Breakers Premises Wiring Type Common Electrical Devices Possible Concerns Table A.2 Electrical Device USE with the POWER-ARC Table of Contents Operation Section Operation Safety InstructionsOperating Instructions General Description Design Features Advantages Operational Features and ControlsRecommended Applications Welding Capability GENERATOR/WELDER Controls Controls and Settings Gasoline Engine Controls Figure B.2 Gasoline Engine Controls Starting the Engine Engine OperationBefore Starting the Engine BREAK-IN Period Stopping the EngineRunning the Engine General Information To USE the Generator AS AN Auxiliary Power SupplyGenerator Operation Table B.3 Generator Power Applications After YOU Finish the Weld To USE the POWER-ARC 4000 for WeldingWelding Operation Stick Welding Material Thickness Electrode Type Size SettingWelding Guidelines ARC Welding Circuit Four Factors of Successful Welding 12/95 POWER-ARCElectrode Correct WAY to Strike AN ARC Correct Welding Speed Correct ARC Length Table of Contents Accessories Briggs and Stratton Accessories OPTIONS/ACCESSORIESLincoln Electric Accessories Table of Contents Maintenance Engine Maintenance Routine and Periodic Maintenance Figure D.2 Clean Rotating SCREEN/FINGER GUARD/DEBRIS Guard Figure D.4 SET Spark Plug GAP Part Part Number Table D.2 Engine Maintenance PartsGENERATOR/WELDER Maintenance Figure D.6. Major Component Locations Table of Contents Theory of Operation Section ENGINE, EXCITATION, Rotor and Stator Theory of Operation Figure E.3 Field Excitation and Auxiliary Power Rotor Field Feedback and Auxiliary Power Weld Winding and Reactor Auxiliary Power Overcurrent Protection Table of Contents Trouble Shooting & Repair Section HOW to USE Troubleshooting Guide Troubleshooting & Repair Output Problems Troubleshooting Guide Or contact your local Lincoln Local Lincoln Electric Authorized Troubleshooting & Repair Troubleshooting & Repair Engine Problems Engine Problems Welding Problems Materials Needed Rotor Voltage TestTest Description Ground Stud Lead 200A Connection Output Panel Test Procedure Rotor Resistance Test Rings Slip Cable TIE Brushes Figure F.3 Brushes Retained with Cable TIE Engine Throttle Adjustment Test Strobe-tach Method MarkFrequency Counter Method Oscilloscope Method NUT Figure F.5 Location of Engine Throttle Adjustment NUT High Idle no Load Scope SettingsNormal Open Circuit Weld Voltage Waveform Normal Open Circuit Voltage Waveform 115 VAC Supply Machine Loaded to 125 Amps AT 23 VAC Typical Weld Output WaveformMachine Loaded Description Brush Removal and Replacement Figure F.6 Brushes Retained with Cable TIE Procedure Procedure Rheostat Removal and Replacement Figure F.7 Rheostat Removal Capacitor AND/OR Diode Bridge Removal Replacement Procedure Capacitor Removal and Replacement Capacitor AND/OR Diode Bridge Removal and Replacement Procedure Diode Bridge Removal and Replacement Instructions STATOR/ROTOR Removal and Replacement TIE Wrap Stator Removal ProcedureOutput Terminals Figure F.10 Stator END Bracket Support and THRU-BOLTS Thru Bolts Support Nuts POWER-ARC Rotor THRU-BOLT Rotor Removal ProcedureReassembly Procedure Rotor Feeler Gauge Retest After Repair Auxiliary Power Receptacle OUTPUT1Engine Output WELDER/GENERATOR OUTPUT1 POWER-ARC Section G Table of ContentsElectrical Diagrams POWER-ARC Electrical Diagram POWER-ARC POWER-ARC