Manuals / Lincoln Electric / Lawn and Garden / Portable Generator

Lincoln Electric SVM192-A Problems Symptoms, Possible Areas Of Misadjustments, Output Problems

Models: SVM192-A

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PROBLEMS

F-6

TROUBLESHOOTING AND REPAIR

F-6

Observe Safety Guidelines detailed in the beginning of this manual.

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PROBLEMS

(SYMPTOMS)

No auxiliary power, welding output is normal. Engine runs normally.

POSSIBLE AREAS OF

MISADJUSTMENT(S)

OUTPUT PROBLEMS

1.If machine is equipped with cir- cuit breakers, check circuit breakers CB1 thru CB5. Reset if tripped.

2.Make sure the Output Control (R1) is set at the maximum posi- tion.

3.Check for loose or faulty plug(s) at the power receptacle(s).

RECOMMENDED

COURSE OF ACTION

1.Check the auxiliary power receptacles and associated wires for loose or faulty connec-

tions.

2. Perform the Auxiliary and

Field Winding Voltage Test.

3. If machine is equipped with cir- cuit breakers, check for faulty breakers and loose or faulty connections on associated wiring.

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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.

EAGLE™ 10,000

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Lincoln Electric SVM192-A Problems Symptoms, Possible Areas Of Misadjustments, Field Winding Voltage Test, Output Problems

Contents

April Safety Depends on YouView Safety Info View Safety Info View Safety Info View Safety Info Return to Master TOC Return to Master TOC Return to Master TOCELECTRIC AND MAGNETIC FIELDS may be dangerous iSAFETYiFOR ENGINE powered equipment CALIFORNIA PROPOSITION 65 WARNINGSARC RAYS can burn SAFETYELECTRIC SHOCK can kill FUMES AND GASESCUTTING powered equipmentWELDING CYLINDER may explodeReturn to Master TOC Return to Master TOC Return to Master TOC PRÉCAUTIONS DE SÛRETÉSAFETY Return to Master TOCPage I - MASTER TABLE OF CONTENTS FOR ALL SECTIONSSafety EAGLE 10,000Return to Master TOC TABLE OF CONTENTS - INSTALLATION SECTIONReturn to Master TOC Return to Master TOC Return to Master TOC EAGLE 10,000Horsepower INSTALLATIONTECHNICAL SPECIFICATIONS - EAGLE 10,000 K2343-1,K2343-2 Displacement cu. in cu.cmMACHINE GROUNDING SAFETY PRECAUTIONSSee additional warning information at front of this operator’s manual SPARK ARRESTERFUEL GASOLINE FUEL ONLY Stop engine while fueling Do not smoke when fuelingVEHICLE MOUNTING Follow vehicle manufacturer’s instructionsDo not lift this machine using ADDITIONAL SAFETY PRECAUTIONS HIGH ALTITUDE OPERATIONwhen lifting heavy accessory such as trailINSTRUCTIONS CONNECTION OF LINCOLN ELECTRIC WIRE FEEDERSADDITIONAL SAFETY PRECAUTIONS WELDER OPERATION120 V DUPLEX RECEPTACLES AUXILIARY POWER120/240 VOLT DUAL VOLTAGE RECEPTACLE MOTOR STARTINGType TABLE lELECTRICAL DEVICE USE WITH THE EAGLE 10,000 Common Electrical DevicesSTANDBY POWER CONNECTIONS AUXILIARY POWER WHILE WELDINGSIMULTANEOUS WELDING AND POWER the connection diagram shown inSection TOC CONNECTION OF EAGLE 10,000 TO PREMISES WIRINGFigure A.1 Master TOCReturn to Master TOC TABLE OF CONTENTS - OPERATION SECTIONReturn to Master TOC Return to Master TOC Return to Master TOC EAGLE 10,000GENERAL DESCRIPTION ENGINE SWITCHOPERATION WELDER CONTROLS - FUNCTION AND OPERATIONOPERATIONB-3 RANGE SWITCHRange Setting EAGLE 10,000 APPROXIMATE FUEL CONSUMPTIONSTARTING THE ENGINE STARTING/SHUTDOWN INSTRUCTIONSBREAK-IN PERIOD Keep flammable material awayStick Constant Current Welding WIRE FEED WELDING PROCESSESWELDING PROCESS TIG CONSTANT CURRENT WELDINGSummary of Welding Processes WHEN NOTTYPICAL CURRENT RANGES 1 FOR TUNGSTEN ELECTRODES2 CONTROLReturn to Master TOC TABLE OF CONTENTS - ACCESSORIES SECTIONReturn to Master TOC Return to Master TOC Return to Master TOC EAGLE 10,000K1745-1 GAS CYLINDER HOLDER ACCESSORIESOPTIONAL EQUIPMENT Field Installed Return to Section TOC Return to Section TOC Return to Section TOCPLASMA CUTTING WIRE FEEDRECOMMENDED EQUIPMENT STICKReturn to Section TOC Return to Section TOCReturn to Section TOC Return to Section TOCReturn to Master TOC TABLE OF CONTENTS - MAINTENANCE SECTIONReturn to Master TOC Return to Master TOC Return to Master TOC EAGLE 10,000Routine Maintenance MAINTENANCESAFETY PRECAUTIONS Kohler CH20S or CH23SMAINTENANCE AIR CLEANER AND OTHER MAINTENANCEOIL FILTER CHANGE Return to Section TOC Return to Section TOC Return to Section TOCENGINE MAINTENANCE PARTS ENGINE ADJUSTMENTSBATTERY Pre-Cleaner5. CASE TOP & SIDES 1. CASEFRONT 2. OUTPUT RECTIFIER ASSEMBLY3. BASE/UNDERCARRIAGE ASSEMBLY 4. ENGINE/ROTOR/STATOR ASSEMBLY FIGURE D.1 - MAJOR COMPONENT LOCATIONSReturn to Section TOC Return to Section TOCReturn to Section TOC Return to Section TOCReturn to Master TOC TOC E-1 TABLE OF CONTENTS-THEORY OF OPERATION SECTION E-1FIGURE E.1 BLOCK LOGIC DIAGRAM Return to Master Return to Master TOCReturn to Section Section TOC BATTERY, STARTER, ENGINE, ROTOR, STATOR, AND IDLER SOLENOIDTHEORY OF OPERATION Return to Master Master TOCTHEORY OF OPERATION ROTOR FIELD FEEDBACK AND AUXILIARY POWERFIGURE E.3 - ROTOR FIELD FEEDBACK AND AUXILIARY POWER Return to Section TOC Return to Section TOCOUTPUT BRIDGE, CHOKE, AND OUTPUT TERMINALS WELD WINDING, REACTOR, AND RANGE SWITCHFIGURE E.4 - WELD WINDING, REACTOR, AND RANGE SWITCH THEORY OF OPERATIONReturn to Master TOC F-1 TABLE OF CONTENTS - TROUBLESHOOTING AND REPAIR F-1Return to Master TOC Return to Master TOC Return to Master TOC EAGLE 10,000COURSE OF ACTION F-2TROUBLESHOOTING AND REPAIRF-2HOW TO USE TROUBLESHOOTING GUIDE Return to Section TOC Return to Section TOC Return to Section TOCPC board can be damaged by static electricity TROUBLESHOOTING AND REPAIRPC BOARD TROUBLESHOOTING PROCEDURES Return to SectionMISADJUSTMENTS PROBLEMSSYMPTOMS OUTPUT PROBLEMSPROBLEMS RECOMMENDED COURSE OF ACTIONTROUBLESHOOTING AND REPAIR SYMPTOMSField Winding Voltage Test PROBLEMS SYMPTOMSPOSSIBLE AREAS OF MISADJUSTMENTS TROUBLESHOOTING AND REPAIRPROBLEMS Rotor Voltage2. PTestrform theTROUBLESHOOTING AND REPAIR SYMPTOMSPROBLEMS SYMPTOMS ENGINE PROBLEMSTROUBLESHOOTING AND REPAIR POSSIBLE AREAS OF MISADJUSTMENTSPROBLEMS WiringTROUBLESHOOTING AND REPAIR SYMPTOMSTROUBLESHOOTING AND REPAIR F-10Charging Circuit Test PROBLEMS3. BridgePerformTestthe. Output Rectifier WELDING PROBLEMSF-11 TROUBLESHOOTING AND REPAIRReturn to Section TOC F-12F-12 Return to Section TOCMATERIALS NEEDED ROTOR VOLTAGE TESTTEST DESCRIPTION F-13ROTOR VOLTAGE TEST continued TEST PROCEDURE4. Remove the case top, then reinstall the fuel cap F-14TROUBLESHOOTING AND REPAIR ROTOR RESISTANCE TESTF-15 TEST DESCRIPTIONFIGURE F.2 - LOCATION OF ROTOR SLIP RINGS ROTOR RESISTANCE TEST continuedF-16 4. Remove the case top, then replace the fuel capROTOR RESISTANCE TEST continued F-17TROUBLESHOOTING AND REPAIR Return to Section TOC Return to Section TOC Return to Section TOCReturn to Section TOC F-18F-18 Return to Section TOCTROUBLESHOOTING AND REPAIR AUXILIARY AND FIELD WINDING TESTF-19 TEST DESCRIPTIONFIGURE F.3 - LOCATION OF LEADS #3 AND #5 AUXILIARY AND FIELD WINDING TEST continuedF-20 Return to Section TOC Section TOCTo test the field winding F-21Return to Section Return to Section TOC Return to Section TOC TROUBLESHOOTING AND REPAIRReturn to Section TOC F-22F-22 Return to Section TOCTROUBLESHOOTING AND REPAIR OUTPUT RECTIFIER BRIDGE TESTF-23 TEST DESCRIPTIONF-24 OUTPUT RECTIFIER BRIDGE TEST continuedENGINE FIGURE F.4 - LOCATION OF OUTPUT RECTIFIER LEADSTROUBLESHOOTING AND REPAIR CHARGING CIRCUIT TESTF-25 TEST DESCRIPTIONFIGURE F.5 - LOCATION OF VOLTAGE REGULATOR CHARGING CIRCUIT TEST continuedF-26 TROUBLESHOOTING AND REPAIRTROUBLESHOOTING AND REPAIR ENGINE THROTTLE ADJUSTMENT TESTF-27 TEST DESCRIPTIONFIGURE F.6 - BLOWER PADDLE MARKED FOR STROBE-TACH METHOD ENGINE THROTTLE ADJUSTMENT TEST continuedF-28 Strobe-tach MethodF-29 HIGH IDLE ADJUSTMENT NUTLOW IDLE ADJUSTMENT NUT to SectionOscilloscope Method ENGINE THROTTLE ADJUSTMENT TEST continuedF-30 Vibratach MethodHIGH IDLE - NO LOAD - OUTPUT CONTROL AT MAXIMUM SCOPE SETTINGSNORMAL OPEN CIRCUIT VOLTAGE WAVEFORM 115VAC SUPPLY F-31MACHINE LOADED TO 200 AMPS AT 26 VDC TYPICAL DC WELD OUTPUT WAVEFORM CC MODEMACHINE LOADED F-32F-33 ABNORMAL OPEN CIRCUIT DC WELD VOLTAGE WAVEFORMONE OUTPUT DIODE NOT FUNCTIONING TROUBLESHOOTING AND REPAIRTROUBLESHOOTING AND REPAIR NORMAL OPEN CIRCUIT DC WELD VOLTAGE WAVEFORM CC MODEF-34 SCOPE SETTINGSTROUBLESHOOTING AND REPAIR BRUSH REMOVAL AND REPLACEMENTF-35 TEST DESCRIPTION5. Remove the case top, then reinstall the fuel cap BRUSH REMOVAL AND REPLACEMENT continuedPROCEDURE F-36to Master TOC SLIP RINGSto Section TOC F-37Return to Section TOC F-38F-38 Return to Section TOCTROUBLESHOOTING AND REPAIR PRINTED CIRCUIT BOARD REMOVAL AND REPLACEMENTF-39 TEST DESCRIPTIONFIGURE F.10 - PRINTED CIRCUIT BOARD LOCATION PRINTED CIRCUIT BOARD REMOVAL AND REPLACEMENT continuedF-40 TROUBLESHOOTING AND REPAIRPRINTED CIRCUIT BOARD REMOVAL AND REPLACEMENT continued F-41TROUBLESHOOTING AND REPAIR Return to Section TOC Return to Section TOC Return to Section TOCReturn to Section TOC F-42F-42 Return to Section TOCTEST DESCRIPTION F-43TROUBLESHOOTING AND REPAIRF-43OUTPUT RECTIFIER BRIDGE REMOVAL AND REPLACEMENT MATERIALS NEEDEDTO POLARITY SWITCH 3 1/2 MOUNTING SCREWS ENGINE NO NUT F-44TROUBLESHOOTING AND REPAIRF-44OUTPUT RECTIFIER BRIDGE REMOVAL AND REPLACEMENT continued L1 TO CHOKE W1Return to Section Return to Section TOC Return to Section TOC F-45TROUBLESHOOTING AND REPAIRF-45OUTPUT RECTIFIER BRIDGE REMOVAL AND REPLACEMENT continued Return to Section TOCReturn to Section TOC F-46F-46 Return to Section TOCF-47 ENGINE/ROTOR REMOVAL AND REPLACEMENTINSTRUCTIONS Lincoln Electric Rotor Removal Kit S20788 - FOR ROTOR REMOVAL ONLYFIGURE F.12 - COMPONENT LOCATIONS, ENGINE/ROTOR REMOVAL ENGINE/ROTOR REMOVAL AND REPLACEMENT continuedF-48 TROUBLESHOOTING AND REPAIRTROUBLESHOOTING AND REPAIR ENGINE AND ROTOR REMOVAL PROCEDUREF-49 ENGINE/ROTOR REMOVAL AND REPLACEMENT continuedFIGURE F.13 - ENGINE AND ROTOR REMOVED FROM STATOR ROTOR REMOVAL PROCEDUREF-50 THRU-BOLTF-51 ENGINE/ROTOR REMOVAL AND REPLACEMENT KIT S20788 continuedREASSEMBLY PROCEDURE TROUBLESHOOTING AND REPAIRRETEST AFTER REPAIR AUXILIARY POWER RECEPTACLE OUTPUT1Range Switch ENGINE OUTPUTReturn to Master TOC TABLE OF CONTENTS - DIAGRAM SECTIONReturn to Master TOC Return to Master TOC Return to Master TOC EAGLE 10,000ELECTRICAL SYMBOLS PER E1537 ELECTRICAL DIAGRAMSWIRING DIAGRAM - CODE 11096 M20317 EAGLE 10,000 KOHLERELECTRICAL SYMBOLS PER E1537 WIRING DIAGRAM - CODE 11397 - M21271ELECTRICAL DIAGRAMS EAGLE 10,000 KOHLERReturn to Master TOC SCHEMATIC - COMPLETE MACHINE - CODE 11096 L12259Return to Section TOC ELECTRODEELECTRICAL DIAGRAMS SCHEMATIC - COMPLETE MACHINE - CODE 11397 L13104POSITIVE Return to Section TOC Return to Section TOC Return to Section TOCReturn to Section TOC Return to Section TOC Return to Section TOC SCHEMATIC - IDLER/FIELD CONTROL P.C. BOARD L12197ELECTRICAL DIAGRAMS Return to Section TOC