Local Lincoln Electric Authorized | Lincoln Electric SVM103-A

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	TROUBLESHOOTING & REPAIR				F-4
	TROUBLESHOOTING & REPAIR
TROUBLESHOOTING GUIDE				Observe Safety Guidelines
		detailed in the beginning of this manual.

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

		OUTPUT PROBLEMS
	No weld output - auxiliary power	1. Check the open circuit voltage	1.	Check continuity (zero ohms) of
	(230 - 115 VAC) operates normally	(OCV) at the welder output ter-		lead W1A (black) from output
	- engine runs normally.	minals. If OCV is okay, go to		terminal to reactor (L1). See the
		Step 2, below.		Wiring Diagram.
		If OCV is not present at the welder	2.	Check continuity (zero ohms) of
		output terminals, contact your		lead W2 (black) from output ter-
		local Lincoln Electric Authorized		minal to stator winding. See the
		Field Service Facility.		Wiring Diagram.
		2. Check the welding cables,	3.	Check continuity (zero ohms) of
		clamps and electrode holder for		lead W1 (black) from reactor
		loose or broken connections.		(L1) to stator winding. See the
				Wiring Diagram.
			4.	Check reactor (L1) for continuity
				of winding. See the Wiring Dia-
				gram.
			5.	Check the stator for continuity
				of winding. See the Wiring Dia-
				gram.
			6.	Make certain the reactor and/or
				stator are NOT grounded. Mini-
				mum acceptable resistance to
				ground is 500 K-ohms.

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 45

Lincoln Electric SVM103-A service manual Local Lincoln Electric Authorized

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 Safety Precautions Location and VentilationStoring 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 Engine Operation Before Starting the EngineStarting the Engine Stopping the Engine Running the EngineBREAK-IN Period To USE the Generator AS AN Auxiliary Power Supply Generator OperationGeneral Information Table B.3 Generator Power Applications To USE the POWER-ARC 4000 for Welding Welding OperationAfter YOU Finish the Weld Material Thickness Electrode Type Size Setting Welding GuidelinesStick Welding 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 OPTIONS/ACCESSORIES Lincoln Electric AccessoriesBriggs and Stratton 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 Table D.2 Engine Maintenance Parts GENERATOR/WELDER MaintenancePart Part Number 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 Rotor Voltage Test Test DescriptionMaterials Needed 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 Scope Settings Normal Open Circuit Weld Voltage WaveformHigh Idle no Load Normal Open Circuit Voltage Waveform 115 VAC Supply Typical Weld Output Waveform Machine LoadedMachine Loaded to 125 Amps AT 23 VAC 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 Removal Procedure Reassembly ProcedureRotor THRU-BOLT Rotor Feeler Gauge Retest After Repair Auxiliary Power Receptacle OUTPUT1Engine Output WELDER/GENERATOR OUTPUT1 POWER-ARC Table of Contents Electrical DiagramsSection G POWER-ARC Electrical Diagram POWER-ARC POWER-ARC