Or contact your local Lincoln | Lincoln Electric SVM103-A guide

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F-3		TROUBLESHOOTING & REPAIR
		TROUBLESHOOTING & REPAIR
Observe Safety Guidelines				TROUBLESHOOTING GUIDE
detailed in the beginning of this manual.

	PROBLEMS		POSSIBLE AREAS OF	RECOMMENDED
	(SYMPTOMS)		MISADJUSTMENT(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	2. If the rotor voltage is zero to 3
			tenance section of this manual	VDC, check the flywheel alter-
			or contact your local Lincoln	VDC, check the flywheel alter-
			or contact your local Lincoln	nator and	associated wires
			Electric Authorized Field Ser-	nator and	associated wires
			Electric Authorized Field Ser-	200A, 202, and 202A for conti-
			vice Facility.	200A, 202, and 202A for conti-
			vice Facility.	nuity. The voltage from lead
				nuity. The voltage from lead
				200A to ground should be at
				least 18 to 21 VDC at high idle
				(3700 RPM). Normal voltage is
				46 VDC. If the voltage is low or
				missing, the flywheel alternator
				may be faulty. See the wiring
				diagram.
				3. Check lead 201B (green) 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. Per-
				form the Rotor Resistance Test.

CAUTION

If for any reason you do not understand the test procedures or are unable to perform the test/repairs safely, con- tact the Lincoln Electric Service Department for electrical troubleshooting assistance before you proceed. Call 216-383-2531 or 1-800-833-9353.

POWER-ARC 4000

Image 44

Lincoln Electric SVM103-A service manual Or contact your local Lincoln

Contents

POWER-ARC TM4000 Safety POWER-ARC Electric Shock can kill Welding Sparks can cause fire or explosion Iii Précautions DE Sûreté Master Table of Contents for ALL Sections Table of Contents Installation Section Installation Technical Specifications POWER-ARC Storing Safety PrecautionsLocation and Ventilation PRE-OPERATION Engine Service Power ARC Electrical Output ConnectionsWelding Cable Connections Cable Size and Length Auxiliary Power Receptacles Cable InstallationMachine Grounding Plugs and HAND-HELD Equipment Premises Wiring Circuit Breakers Table A.2 Electrical Device USE with the POWER-ARC Type Common Electrical Devices Possible Concerns Table of Contents Operation Section Safety Instructions OperationOperating Instructions General Description Operational Features and Controls Design Features AdvantagesRecommended Applications Welding Capability Controls and Settings GENERATOR/WELDER Controls Figure B.2 Gasoline Engine Controls 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 Welding Circuit ARC 12/95 POWER-ARC Four Factors of Successful WeldingElectrode Correct WAY to Strike AN ARC Correct ARC Length Correct Welding Speed Table of Contents Accessories Briggs and Stratton Accessories OPTIONS/ACCESSORIESLincoln Electric Accessories Table of Contents Maintenance Routine and Periodic Maintenance Engine 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 Theory of Operation ENGINE, EXCITATION, Rotor and Stator Rotor Field Feedback and Auxiliary Power Figure E.3 Field Excitation and Auxiliary Power Auxiliary Power Overcurrent Protection Weld Winding and Reactor Table of Contents Trouble Shooting & Repair Section Troubleshooting & Repair HOW to USE Troubleshooting Guide Troubleshooting Guide Output Problems 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 Test Procedure Ground Stud Lead 200A Connection Output Panel Rotor Resistance Test Slip Rings Figure F.3 Brushes Retained with Cable TIE Cable TIE Brushes Engine Throttle Adjustment Test Mark Strobe-tach MethodFrequency Counter Method Oscilloscope Method Figure F.5 Location of Engine Throttle Adjustment NUT 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 Brush Removal and Replacement Description Procedure Figure F.6 Brushes Retained with Cable TIE Procedure Rheostat Removal and Replacement Figure F.7 Rheostat Removal Capacitor AND/OR Diode Bridge Removal Replacement Capacitor AND/OR Diode Bridge Removal and Replacement Procedure Capacitor Removal and Replacement Procedure Diode Bridge Removal and Replacement STATOR/ROTOR Removal and Replacement Instructions Stator Removal Procedure TIE WrapOutput Terminals Thru Bolts Support Nuts POWER-ARC Figure F.10 Stator END Bracket Support and THRU-BOLTS Rotor THRU-BOLT Rotor Removal ProcedureReassembly Procedure Feeler Gauge Rotor Auxiliary Power Receptacle OUTPUT1 Retest After RepairEngine Output WELDER/GENERATOR OUTPUT1 POWER-ARC Section G Table of ContentsElectrical Diagrams Electrical Diagram POWER-ARC POWER-ARC POWER-ARC