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Lincoln Electric SVM187-A service manual Adjustment Test

Models: SVM187-A

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

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

		OUTPUT PROBLEMS
Both the weld and auxiliary		Make sure the engine is	Perform the Engine RPM
output voltages are low		operating at the correct high idle	Adjustment Test .
		speed.	Perform the Brush and Slip
		Make sure that no load is	Perform the Brush and Slip
		Make sure that no load is	Ring Service Procedure.
		connected to either the weld or	Perform the Exciter Rotor
		auxiliary outputs.	Perform the Exciter Rotor
			Voltage Test.
			Perform Exciter Rotor
			Resistance and Ground Test.

There is no, or very low weld		Check that the electrode polarity	Perform the Brush and Slip
output, and no auxiliary output.		switch is not in the off position,	Ring Service Procedure.
		and that the remote/local switch	Perform the Exciter Rotor
		is in the local control position.	Perform the Exciter Rotor
		Check that the auxiliary power	Voltage Test.
		circuit breakers and GFCIs (if so	Perform the Exciter Rotor
		equipped) are not tripped.	Perform the Exciter Rotor
		equipped) are not tripped.	Resistance and Ground Test.
			Resistance and Ground Test.
		NOTE: GFCIs will not reliably
		reset, unless engine is operating
		at high idle RPM.
		Check all leads and cables for
		damaged or poor connections.

There is no, or very low weld		Check the polarity switch; make	Perform the Shunt Field Coil
output voltage.	The auxiliary	sure it is not in the off position.	Resistance and Ground Test.
output is normal.		Check that the remote/local	Perform the Shunt Field Circuit
		Check that the remote/local	Perform the Shunt Field Circuit
		switch is positioned correctly.	Voltage Test.
		If a remote current control is	Perform the Welding Generator
		being used, try switching to	Brush and Commutator
		local control. The remote	Inspection and Service
		current control may be faulty.	Procedure.
		Check all leads and cables for	Check for damaged or poor
		damaged or poor connections.	connections at the brush
			holders, series and interpole
			coils, weld output control unit,
			weld output terminals, and all
			the conductors connecting these
			components.
			The Armature may be faulty.

CAUTION

If for any reason you do not understand the test procedures or are unable to perform the tests/repairs safely, contact the Lincoln Electric Service Department for technical troubleshooting assistance before you proceed. Call 1-888-935-3877.

SAE-400 SEVERE DUTY

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Lincoln Electric SVM187-A service manual Adjustment Test

Contents

SAE-400 Severe Duty ISAFETYi SAE-400 Severe DutySafety Electric Shock can killFumes and Gases Can be dangerousIii Powered equipmentFor Electrically Précautions DE Sûreté Sûreté Pour Soudage a LʼArcElectromagnetic Compatibility EMC Safety Vii Master Table of Contents for ALL Sections Table of Contents Installation Section Height Width Depth Weight InstallationTechnical Specifications SAE-400 Severe Duty Safety Precautions LOCATION/VENTILATIONStacking Angle of OperationPRE-OPERATION Engine Service Engine BREAK-IN Engine Cooling SystemTable A.1 Combined Length of Electrode Work Cables Spark Arrestor Machine GroundingWelding Output Cables Table of Contents Operation Section Safety Instructions OperationOperating Instructions General DescriptionDesign Features and Advantages Duty Cycle For Auxiliary PowerOther Features For Stick WeldingEngine Controls Remote Control Auxiliary Power ControlsPolarity Switch Welder ControlsEngine Operation Cold Weather StartingStarting Instructions Stopping the EngineTypical Fuel Consumption SAE-400 Severe Duty Table of Contents Accessories Section Accessories Optional Field Installed AccessoriesOrder K1690-1 Gfci Receptacle KITTable of Contents Maintenance Section Maintenance Routine MaintenancePeriodic Maintenance Engine OIL ChangeBearing Maintenance Fuel PRE-FILTER/WATER Separator AssemblyCooling System Fuel FiltersSecondary Fuel Filter Engine Maintenance ComponentsWater Separator Element Ting Procedure Spark ArrestorFor machines with separate spark arresting unit 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 ProtectionBuilding output EXCITER/AUXILIARY Alternator OperationFlashing AC Auxiliary Output EXCITER/AUXILIARY AlternatorOperation Overview Excitation and field controlWelding Generator OPERA- Tion Producing weld currentReactor Assembly Series coils and reactorInterpole coils Welding Generator OperaTion SAE-400 Severe Duty 1TABLE of Contents Troubleshooting and Repair F-1 2TROUBLESHOOTING and Repair F-2 HOW to USE Troubleshooting GuideLocate Problem Symptom Course of ActionTroubleshooting and Repair PC Board Troubleshooting ProceduresAdjustment Test Troubleshooting and Repair Recommended Course of Action Problems SymptomsPossible Areas Misadjustments 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 Materials Needed Engine RPM Adjustment TestTest Description Strobe-Tach Method Engine RPM Adjustment TestTest Procedure Figure F.2 Engine Components Code 11199 Frequency counter methodLow idle adjustment Code 10856 only Engine RPM Adjustment ProcedureHigh Idle Adjustment Brush and Slip Ring Service Procedure Exciter / Auxiliary Power AlternatorProcedure Figure F.3 Exciter Cover Screw LocationsSeating brushes Cleaning slip ringsBrushes 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 CommutatorWelding Generator Brush and Commutator Inspection Pitted and Arc Damaged CommutatorUneven Commutator appearance 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 Coil Ground Test Shunt Field Coil Resistance and Ground TestShunt Coil Resistance Test Shunt Field Circuit Voltage Test Shunt Field Circuit Voltage Test Dead SHORT, 1ST STEP, and Open Reactor Tests Rotor Winding Movable Contacts Min. open PositionFirst Step Contact Contact Springs Position Insulated FillerRocker Adjustment Procedure Figure F.18 Rocker W/MARKS Factory set point drill marksCheck for Max output Rocker Adjustment ProcedureInitial rocker placement 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 DescriptionReplacing the Generator Frame Generator Frame Removal and ReplacementRemove the generator frame Generator Armature Removal and Replacement Replacing the armature Generator Armature Removal and ReplacementRemoving 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