Troubleshooting & Repair | Lincoln Electric SVM103-A specification

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	TROUBLESHOOTING & REPAIR		F-6

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
Low weld output and low auxiliary	1. The generator brushes may be		1.	Perform the Rotor Voltage Test.
output.	worn.	See the Maintenance	2.	If the rotor voltage			is	low, the
	section of this manual or contact		2.	If the rotor voltage			is	low, the
	section of this manual or contact			field	capacitor	(C1)	or bridge
	your	local Lincoln Electric		field	capacitor	(C1)	or bridge
	your	local Lincoln Electric		(D1)	may be	faulty.		Test or
	Authorized Field Service Facility.			(D1)	may be	faulty.		Test or
	Authorized Field Service Facility.			replace.
				replace.
	2. The engine RPM may be low.		3.	Check the rheostat (R1). Normal
			3.	Check the rheostat (R1). Normal
				resistance is 3.3 ohm. See the
				Rheostat Replacement drawing.
			4.	The rotor may be faulty. Per-
				form the Rotor Resistance Test.
			5.	The engine RPM may be low.
				Perform the		Engine		Throttle
				Adjustment Test.
			6.	If engine idle RPM is okay, the
				engine may have lost horsepow-
				er and be in need of major
				repair.

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 47

Lincoln Electric SVM103-A service manual Troubleshooting & Repair

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 Cable Size and Length Power ARCElectrical Output Connections Welding Cable Connections Plugs and HAND-HELD Equipment Auxiliary Power ReceptaclesCable Installation Machine Grounding 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 General Description Safety InstructionsOperation Operating Instructions Welding Capability Operational Features and ControlsDesign Features Advantages Recommended Applications 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 Correct WAY to Strike AN ARC 12/95 POWER-ARCFour Factors of Successful Welding Electrode 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 Oscilloscope Method MarkStrobe-tach Method Frequency Counter 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 Terminals Stator Removal ProcedureTIE Wrap Output 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 WELDER/GENERATOR OUTPUT1 Auxiliary Power Receptacle OUTPUT1Retest After Repair Engine Output POWER-ARC Section G Table of ContentsElectrical Diagrams POWER-ARC Electrical Diagram POWER-ARC POWER-ARC