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Lincoln Electric SVM187-A service manual Protection System Test

Models: SVM187-A

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F-13	TROUBLESHOOTING AND REPAIR			F-13
Observe Safety Guidelines detailed in the beginning of this manual.

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

		OUTPUT PROBLEMS
The engine starts normally, but		The oil pressure may be low.	The idle/engine protection PC
shuts down after running for		Check the oil level and add oil	board, alternator, oil pressure
several seconds.		as needed. If necessary, contact	switch, or engine coolant
		the engine manufacturer, or a	temperature switch may be
		qualified engine specialist to	faulty. Perform the Engine
		determine the cause of the low	Protection System Test .
		oil pressure condition, and make
		any required adjustments or
		repairs.
		The engine alternator belt may
		be loose or broken. Replace the
		belt and/or adjust the belt
		tension.
		The engine may be overheated.
		Contact the engine
		manufacturer, or a qualified
		engine specialist to determine
		the cause of the overheat
		condition, and make any
		required adjustments or repairs.

The engine will not develop full		Check that there is an adequate	Perform the Engine RPM
power.		supply of fresh clean fuel, and	Adjustment Test .
		that the fuel shut-off valve is fully	There may be internal problems
		open.	There may be internal problems
			with the engine. Contact the
		Check the fuel and air filters,	engine manufacturer or a
		replace if necessary.	qualified engine repair
			technician.

The engine will not shut down			Check the voltage at the
when the run/stop switch is			primary fuel solenoid.	If the
moved to the stop position.			voltage drops to zero when the
			switch is turned off, and the
			engine continues to run, there is
			likely a failure in the fuel
			system. Contact the engine
			manufacturer or a qualified
			engine technician.
			If the voltage remains at the
			solenoid after the switch is
			moved to the stop position, the
			run/stop switch has most likely
			failed.

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 Protection System Test

Contents

SAE-400 Severe Duty SAE-400 Severe Duty ISAFETYiElectric Shock can kill SafetyFumes and Gases Can be dangerousIii 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 LOCATION/VENTILATION Safety PrecautionsStacking Angle of OperationPRE-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 Operation Safety InstructionsOperating Instructions General DescriptionFor Auxiliary Power Design Features and Advantages Duty CycleOther Features For Stick WeldingEngine Controls Auxiliary Power Controls Remote ControlPolarity Switch Welder ControlsCold Weather Starting Engine OperationStarting Instructions Stopping the EngineTypical Fuel Consumption SAE-400 Severe Duty Table of Contents Accessories Section Optional Field Installed Accessories AccessoriesOrder K1690-1 Gfci Receptacle KITTable of Contents Maintenance Section Routine Maintenance MaintenancePeriodic Maintenance Engine OIL ChangeFuel PRE-FILTER/WATER Separator Assembly Bearing MaintenanceCooling System Fuel FiltersSecondary Fuel Filter Engine Maintenance ComponentsWater Separator Element Spark Arrestor Ting ProcedureFor 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 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 HOW to USE Troubleshooting Guide 2TROUBLESHOOTING and Repair F-2Locate Problem Symptom Course of ActionPC 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 appearancePitted and Arc Damaged Commutator Welding Generator Brush and Commutator InspectionUneven Commutator appearance Examine the brushesWeld 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 Min. open Position Rotor Winding Movable ContactsFirst Step Contact Contact Springs Position Insulated FillerRocker 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