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Lincoln Electric SVM187-A service manual Possible Areas of Misadjustments

Models: SVM187-A

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F-7

TROUBLESHOOTING AND REPAIR

F-7

Observe Safety Guidelines detailed in the beginning of this manual.

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PROBLEMS

(SYMPTOMS)

The weld output varies abnormally. Auxiliary voltage is normal. (continued)

POSSIBLE AREAS OF MISADJUSTMENT(S)

OUTPUT PROBLEMS

RECOMMENDED

COURSE OF ACTION

Examine polarity switch for poor electrical connections and damaged or burned contacts. Replace if necessary. If polarity switch contacts have excessive arc damage, check the 500 Ohm resistor.

Perform the Exciter Rotor

Resistance and Ground Test.

Perform the Shunt Field Coil

Resistance and Ground Test.

Check the Generator brush rocker position; perform the

Rocker Adjustment Procedure if necessary.

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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

Image 47

Lincoln Electric SVM187-A service manual Possible Areas of Misadjustments, Rocker Adjustment Procedure if necessary

Contents

SAE-400 Severe Duty SAE-400 Severe Duty ISAFETYiCan be dangerous SafetyElectric Shock can kill Fumes and GasesIii Powered equipmentFor Electrically Sûreté Pour Soudage a LʼArc Précautions DE SûretéElectromagnetic 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 Angle of Operation Safety PrecautionsLOCATION/VENTILATION StackingPRE-OPERATION Engine Service Engine Cooling System Engine BREAK-INTable A.1 Combined Length of Electrode Work Cables Spark Arrestor Machine GroundingWelding Output Cables Table of Contents Operation Section General Description Safety InstructionsOperation Operating InstructionsFor Stick Welding Design Features and Advantages Duty CycleFor Auxiliary Power Other FeaturesEngine Controls Welder Controls Remote ControlAuxiliary Power Controls Polarity SwitchStopping the Engine Engine OperationCold Weather Starting Starting InstructionsTypical Fuel Consumption SAE-400 Severe Duty Table of Contents Accessories Section K1690-1 Gfci Receptacle KIT AccessoriesOptional Field Installed Accessories OrderTable of Contents Maintenance Section Engine OIL Change MaintenanceRoutine Maintenance Periodic MaintenanceFuel Filters Bearing MaintenanceFuel PRE-FILTER/WATER Separator Assembly Cooling SystemSecondary Fuel Filter Engine Maintenance ComponentsWater Separator Element For machines with integral spark arresting muf- flers Ting ProcedureSpark Arrestor For machines with separate spark arresting unitSAE-400 Severe Duty 1TABLE of CONTENTS-THEORY of Operation Section E-1 Engine Starting and PROTEC- Tion Theory of OperationFigure E.2 Engine Starting and Protection Automatic Engine Idle SystemBuilding output EXCITER/AUXILIARY Alternator OperationFlashing AC Auxiliary Output EXCITER/AUXILIARY AlternatorOperation Excitation and field control OverviewProducing weld current Welding Generator OPERA- TionSeries coils and reactor Reactor AssemblyInterpole coils Welding Generator OperaTion SAE-400 Severe Duty 1TABLE of Contents Troubleshooting and Repair F-1 Course of Action 2TROUBLESHOOTING and Repair F-2HOW to USE Troubleshooting Guide Locate Problem SymptomPC Board Troubleshooting Procedures Troubleshooting and RepairAdjustment Test Troubleshooting and Repair Recommended Course of Action Problems SymptomsPossible Areas Misadjustments Rocker Adjustment Procedure if necessary Possible Areas of MisadjustmentsTroubleshooting 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 Frequency counter method Figure F.2 Engine Components Code 11199Low idle adjustment Code 10856 only Engine RPM Adjustment ProcedureHigh Idle Adjustment Exciter / Auxiliary Power Alternator Brush and Slip Ring Service ProcedureFigure F.3 Exciter Cover Screw Locations ProcedureSeating brushes Cleaning slip ringsBrushes SAE-400 Severe Duty Test Description Exciter Rotor Voltage TestFigure F.6 Exciter Cover Screw Locations Exciter Rotor Voltage TestFigure F.7 Exciter Rotor Voltage Test Circuit and Ground Test Exciter Rotor Resistance and Ground Test Exciter / Auxiliary Power AlternatorStatic Tests Figure F.9 Slip Ring Locations Dynamic Tests Figure F.10 Slip Ring LocationsEngine not running Flashing Voltage TestFlashing Voltage Test Figure F.13 IDLER/ENGINE Protection PC Board Codes Figure F.14 IDLER/ENGINE Protection PC Board Codes 11199 If battery voltage is detectedTest Description Exciter Stator Short Circuit & Ground TestExciter Stator Short Circuit & Ground Test Welding Generator Brush and Commutator Inspection Service Figure F.15 Generator Cover Screw Locations ServiceBlackened Commutator Normal appearanceExamine the brushes Welding Generator Brush and Commutator InspectionPitted and Arc Damaged Commutator Uneven Commutator appearanceWeld Circuit Ground and Short Circuit Test If the resistance is lower than 500k Ohms Weld circuit ground testShunt 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 Contact Contact Springs Position Insulated Filler Rotor Winding Movable ContactsMin. open Position First StepRocker Adjustment Procedure Factory set point drill marks Figure F.18 Rocker W/MARKSCheck for Max output Rocker Adjustment ProcedureInitial rocker placement SAE-400 Severe Duty Test Description Output Control Unit Variable Reactor Inspection and Service ProcedureServicing the continuous control unit Figure F.20 Brush & Spring Winding Insulated WedgeSteel Coil Insulator Contacts Chamfered END of Shaft AT this END Figure F.22 Shaft & TubeSAE-400 Severe Duty Test Description Engine Protection System Circuit TestEngine Protection System Circuit Test 66TROUBLESHOOTING and Repair F-66Figure F.24 Engine Alternator Code 11199 &11408 67TROUBLESHOOTING and Repair F-67SAE-400 Severe Duty Engine Alternator Test Troubleshooting and RepairEngine Alternator Test Run/stop switch on#59 #51 SAE-400 Severe Duty Test Description Engine Fuel System Voltage TestsEngine Fuel System Voltage Tests Figure F.28 PC Board Engine Fuel System Voltage TestsFor Codes 11199 Test Description Alternator Rotor Removal and ReplacementRotor Removal Alternator Rotor Removal and ReplacementRotor Replacement SAE-400 Severe Duty Test Description Alternator Stator Removal and ReplacementAlternator Stator Removal and Replacement Figure F.31 Rocker & Mark Locations Alternator Stator Removal and ReplacementReplacing the Exciter Alternator Stator Test Description Generator Frame Removal and ReplacementReplacing 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