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Lincoln Electric SVM187-A service manual Steel Coil Insulator Contacts

Models: SVM187-A

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F-62

TROUBLESHOOTING AND REPAIR

F-62

OUTPUT CONTROL UNIT (VARIABLE REACTOR)

INSPECTION AND SERVICE PROCEDURE (continued)

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PROCEDURE

Servicing the rotating brush holder and output stud assembly:

Thoroughly clean and inspect the rotating brush holder assembly and the output stud assembly.

10.Examine the insulators on both assemblies. See Figure F.21. Replace any that are worn, damaged or missing. If the shaft insulation tube requires replacement, position the shaft and tube per Figure F.22, and torque the two 5/16-18 Hex head screws to 8 Ft-Lbs.

11.Disassemble the output stud assembly and check the insulating washers and tube. Replace them if they are damaged or worn and re-assemble the output stud assembly. See Figure F.21

12.Check for grounded output stud and brush holder assemblies by measuring the resistance as fol- lows:

From the steel shaft to the rotating brush holder

From the copper output stud to the output stud bracket

The resistance should be very high, 500,000 (500k) Ohms min.

If any of the contacts on the brush holder assembly are damaged, install all new contacts and new springs.

13.Assemble the flat washer, spring clip, and coil spring to the shaft. See figure F.21

14.Apply a thin layer of grease to both the output stud and the inside of the brush holder that mates to the output stud. Grease should also be applied to the area around the hole where the shaft passes through the front panel.

15.Insert the brush holder and output stud assembly through the output control unit and through the hole in the front panel. Be sure the output stud bracket is positioned correctly. The insulated stop should be on the left when facing the back on the output control unit.

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	FIGURE F.21 – INSULATOR & SPRING LOCATIONS
Steel	Coil	Insulator	Contacts	Output
Shaft	Spring	Tube	Contacts	Stud

Springs

				Insulator
				(Short Insulator Tube Not Shown)
	Spring	Flat	Brush
	Spring	Flat	Holder	Output
	Clip	Washer	Holder	Output
	Clip	Washer		Stud
				Stud

Bracket

SAE-400 SEVERE DUTY

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Lincoln Electric SVM187-A service manual Steel Coil Insulator Contacts

Contents

SAE-400 Severe Duty ISAFETYi SAE-400 Severe DutyFumes and Gases SafetyElectric Shock can kill Can be dangerousPowered equipment For ElectricallyIii Précautions DE Sûreté Sûreté Pour Soudage a LʼArcElectromagnetic Compatibility EMC Safety Vii Master Table of Contents for ALL Sections Table of Contents Installation Section Installation Technical Specifications SAE-400 Severe DutyHeight Width Depth Weight Stacking Safety PrecautionsLOCATION/VENTILATION Angle of OperationPRE-OPERATION Engine Service Engine BREAK-IN Engine Cooling SystemSpark Arrestor Machine Grounding Welding Output CablesTable A.1 Combined Length of Electrode Work Cables Table of Contents Operation Section Operating Instructions Safety InstructionsOperation General DescriptionOther Features Design Features and Advantages Duty CycleFor Auxiliary Power For Stick WeldingEngine Controls Polarity Switch Remote ControlAuxiliary Power Controls Welder ControlsStarting Instructions Engine OperationCold Weather Starting Stopping the EngineTypical Fuel Consumption SAE-400 Severe Duty Table of Contents Accessories Section Order AccessoriesOptional Field Installed Accessories K1690-1 Gfci Receptacle KITTable of Contents Maintenance Section Periodic Maintenance MaintenanceRoutine Maintenance Engine OIL ChangeCooling System Bearing MaintenanceFuel PRE-FILTER/WATER Separator Assembly Fuel FiltersEngine Maintenance Components Water Separator ElementSecondary Fuel Filter For machines with separate spark arresting unit Ting ProcedureSpark Arrestor For machines with integral spark arresting muf- flersSAE-400 Severe Duty 1TABLE of CONTENTS-THEORY of Operation Section E-1 Theory of Operation Engine Starting and PROTEC- TionAutomatic Engine Idle System Figure E.2 Engine Starting and ProtectionEXCITER/AUXILIARY Alternator Operation FlashingBuilding output EXCITER/AUXILIARY Alternator OperationAC Auxiliary Output Overview Excitation and field controlWelding Generator OPERA- Tion Producing weld currentReactor Assembly Series coils and reactorWelding Generator Opera TionInterpole coils SAE-400 Severe Duty 1TABLE of Contents Troubleshooting and Repair F-1 Locate Problem Symptom 2TROUBLESHOOTING and Repair F-2HOW to USE Troubleshooting Guide Course of ActionTroubleshooting and Repair PC Board Troubleshooting ProceduresAdjustment Test Troubleshooting and Repair Problems Symptoms Possible Areas MisadjustmentsRecommended Course of Action Possible Areas of Misadjustments Rocker Adjustment Procedure if necessaryTroubleshooting and Repair Adjustment Procedure Welding arc is loud and spatters excessively RPM Adjustment Test System Voltage Tests Protection System Test Perform the Engine Alternator Problems Symptoms Troubleshooting and Repair Low idle RPM may be too low. Perform the Engine Idle Troubleshooting and Repair Troubleshooting and Repair SAE-400 Severe Duty Engine RPM Adjustment Test Test DescriptionMaterials Needed Engine RPM Adjustment Test Test ProcedureStrobe-Tach Method Figure F.2 Engine Components Code 11199 Frequency counter methodEngine RPM Adjustment Procedure High Idle AdjustmentLow idle adjustment Code 10856 only Brush and Slip Ring Service Procedure Exciter / Auxiliary Power AlternatorProcedure Figure F.3 Exciter Cover Screw LocationsCleaning slip rings BrushesSeating brushes SAE-400 Severe Duty Exciter Rotor Voltage Test Test DescriptionExciter Rotor Voltage Test Figure F.6 Exciter Cover Screw LocationsFigure F.7 Exciter Rotor Voltage Test Circuit and Ground Test Exciter / Auxiliary Power Alternator Exciter Rotor Resistance and Ground TestStatic Tests Figure F.9 Slip Ring Locations Figure F.10 Slip Ring Locations Dynamic TestsFlashing Voltage Test Engine not runningFlashing Voltage Test Figure F.13 IDLER/ENGINE Protection PC Board Codes If battery voltage is detected Figure F.14 IDLER/ENGINE Protection PC Board Codes 11199Exciter Stator Short Circuit & Ground Test Test DescriptionExciter Stator Short Circuit & Ground Test Welding Generator Brush and Commutator Inspection Service Service Figure F.15 Generator Cover Screw LocationsNormal appearance Blackened CommutatorUneven Commutator appearance Welding Generator Brush and Commutator InspectionPitted and Arc Damaged Commutator Examine the brushesWeld Circuit Ground and Short Circuit Test Weld circuit ground test If the resistance is lower than 500k OhmsShunt Field Coil Resistance and Ground Test Shunt Field Coil Resistance and Ground Test Shunt Coil Resistance TestShunt Coil Ground Test Shunt Field Circuit Voltage Test Shunt Field Circuit Voltage Test Dead SHORT, 1ST STEP, and Open Reactor Tests First Step Rotor Winding Movable ContactsMin. open Position Contact Contact Springs Position Insulated FillerRocker Adjustment Procedure Figure F.18 Rocker W/MARKS Factory set point drill marksRocker Adjustment Procedure Initial rocker placementCheck for Max output SAE-400 Severe Duty Test Description Inspection and Service Procedure Output Control Unit Variable ReactorFigure F.20 Brush & Spring Winding Insulated Wedge Servicing the continuous control unitSteel Coil Insulator Contacts Figure F.22 Shaft & Tube Chamfered END of Shaft AT this ENDSAE-400 Severe Duty Engine Protection System Circuit Test Test Description66TROUBLESHOOTING and Repair F-66 Engine Protection System Circuit Test67TROUBLESHOOTING and Repair F-67 Figure F.24 Engine Alternator Code 11199 &11408SAE-400 Severe Duty Troubleshooting and Repair Engine Alternator TestRun/stop switch on Engine Alternator Test#59 #51 SAE-400 Severe Duty Engine Fuel System Voltage Tests Test DescriptionEngine Fuel System Voltage Tests Engine Fuel System Voltage Tests Figure F.28 PC BoardFor Codes 11199 Alternator Rotor Removal and Replacement Test DescriptionAlternator Rotor Removal and Replacement Rotor RemovalRotor Replacement SAE-400 Severe Duty Alternator Stator Removal and Replacement Test DescriptionAlternator Stator Removal and Replacement Alternator Stator Removal and Replacement Figure F.31 Rocker & Mark LocationsReplacing the Exciter Alternator Stator Generator Frame Removal and Replacement Test DescriptionGenerator Frame Removal and Replacement Remove the generator frameReplacing the Generator Frame Generator Armature Removal and Replacement Generator Armature Removal and Replacement Removing the ArmatureReplacing the armature Retest After Repair Table of Contents Diagram Section Electrical Diagrams Wiring Diagram SAE-400 Perkins M20544 M21283 Wiring Diagram Generator Frame M5570 Electrical Diagrams Schematic Complete Machine Code 11199 G4924 Schematic Complete Machine Code 11408 G5827 Section TOC Schematic IDLER/ENGINE Shutdown PC Board Code 10856 L11006-2 PC Board Assembly IDLER/ENGINE Shutdown PC Board L12400-2 Schematic IDLER/ENGINE Shutdown PC Board G4828-2