Manuals / Lincoln Electric / Lawn and Garden / Portable Generator

Lincoln Electric SVM192-A Engine Problems, Troubleshooting And Repair, Problems Symptoms

Models: SVM192-A

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ENGINE PROBLEMS

F-8

TROUBLESHOOTING AND REPAIR

F-8

Observe Safety Guidelines detailed in the beginning of this manual.

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PROBLEMS

(SYMPTOMS)

Engine will not idle down to low speed. Machine has normal weld output and auxiliary power.

POSSIBLE AREAS OF

MISADJUSTMENT(S)

ENGINE PROBLEMS

1.Make sure the Idler Switch (S4) is in the “Auto” position.

2.Make sure there is NOT an exter- nal load on the weld terminals nor the auxiliary power recepta- cles.

RECOMMENDED

COURSE OF ACTION

1.With the Idler Switch (S4) in the “Auto” position, check for the presence of 12VDC at leads #213 to #215 located at the Idler Solenoid. If 12VDC is pre- sent and the Idler Solenoid is not activating, then the solenoid may be faulty or there is a mechanical restriction prevent- ing it from functioning.

2.If there is NOT 12VDC at leads

#213 to #215, then test for 12VDC from lead #213Wiringto Diagramground (lead #5). See

. If 12VDC is present, then check lead #215 for conti- nuity (zero ohms) from the Idler Solenoid to the Printed Circuit Board plug 3J1. If lead #215 is OK, then the Printed Circuit Board may be faulty. Replace.

3.If there is NOT 12VDC from lead #213 to ground (lead #5), then check the Idler Switch (S4) for proper operation and as- sociated wires for loose or faulty connections.

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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 Engine Problems, Troubleshooting And Repair, Problems Symptoms, Possible Areas Of Misadjustments

Contents

Safety Depends on You View Safety Info View Safety Info View Safety Info View Safety InfoApril Return to Master TOC Return to Master TOC Return to Master TOCiSAFETYi FOR ENGINE powered equipmentELECTRIC AND MAGNETIC FIELDS may be dangerous CALIFORNIA PROPOSITION 65 WARNINGSSAFETY ELECTRIC SHOCK can killARC RAYS can burn FUMES AND GASESpowered equipment WELDINGCUTTING CYLINDER may explodePRÉCAUTIONS DE SÛRETÉ SAFETYReturn to Master TOC Return to Master TOC Return to Master TOC Return to Master TOCI - MASTER TABLE OF CONTENTS FOR ALL SECTIONS SafetyPage EAGLE 10,000TABLE OF CONTENTS - INSTALLATION SECTION Return to Master TOC Return to Master TOC Return to Master TOCReturn to Master TOC EAGLE 10,000INSTALLATION TECHNICAL SPECIFICATIONS - EAGLE 10,000 K2343-1,K2343-2Horsepower Displacement cu. in cu.cmSAFETY PRECAUTIONS See additional warning information at front of this operator’s manualMACHINE GROUNDING SPARK ARRESTERStop engine while fueling Do not smoke when fueling VEHICLE MOUNTINGFUEL GASOLINE FUEL ONLY Follow vehicle manufacturer’s instructionsADDITIONAL SAFETY PRECAUTIONS HIGH ALTITUDE OPERATION when liftingDo not lift this machine using heavy accessory such as trailCONNECTION OF LINCOLN ELECTRIC WIRE FEEDERS ADDITIONAL SAFETY PRECAUTIONSINSTRUCTIONS WELDER OPERATIONAUXILIARY POWER 120/240 VOLT DUAL VOLTAGE RECEPTACLE120 V DUPLEX RECEPTACLES MOTOR STARTINGTABLE l ELECTRICAL DEVICE USE WITH THE EAGLE 10,000Type Common Electrical DevicesAUXILIARY POWER WHILE WELDING SIMULTANEOUS WELDING AND POWERSTANDBY POWER CONNECTIONS the connection diagram shown inCONNECTION OF EAGLE 10,000 TO PREMISES WIRING Figure A.1Section TOC Master TOCTABLE OF CONTENTS - OPERATION SECTION Return to Master TOC Return to Master TOC Return to Master TOCReturn to Master TOC EAGLE 10,000ENGINE SWITCH OPERATIONGENERAL DESCRIPTION WELDER CONTROLS - FUNCTION AND OPERATIONRANGE SWITCH Range SettingOPERATIONB-3 EAGLE 10,000 APPROXIMATE FUEL CONSUMPTIONSTARTING/SHUTDOWN INSTRUCTIONS BREAK-IN PERIODSTARTING THE ENGINE Keep flammable material awayWIRE FEED WELDING PROCESSES WELDING PROCESSStick Constant Current Welding TIG CONSTANT CURRENT WELDINGWHEN NOT TYPICAL CURRENT RANGES 1 FOR TUNGSTEN ELECTRODES2Summary of Welding Processes CONTROLTABLE OF CONTENTS - ACCESSORIES SECTION Return to Master TOC Return to Master TOC Return to Master TOCReturn to Master TOC EAGLE 10,000ACCESSORIES OPTIONAL EQUIPMENT Field InstalledK1745-1 GAS CYLINDER HOLDER Return to Section TOC Return to Section TOC Return to Section TOCWIRE FEED RECOMMENDED EQUIPMENTPLASMA CUTTING STICKReturn to Section TOC Return to Section TOCReturn to Section TOC Return to Section TOCTABLE OF CONTENTS - MAINTENANCE SECTION Return to Master TOC Return to Master TOC Return to Master TOCReturn to Master TOC EAGLE 10,000MAINTENANCE SAFETY PRECAUTIONSRoutine Maintenance Kohler CH20S or CH23SAIR CLEANER AND OTHER MAINTENANCE OIL FILTER CHANGEMAINTENANCE Return to Section TOC Return to Section TOC Return to Section TOCENGINE ADJUSTMENTS BATTERYENGINE MAINTENANCE PARTS Pre-Cleaner1. CASEFRONT 2. OUTPUT RECTIFIER ASSEMBLY 3. BASE/UNDERCARRIAGE ASSEMBLY 4. ENGINE/ROTOR/STATOR ASSEMBLY5. CASE TOP & SIDES FIGURE D.1 - MAJOR COMPONENT LOCATIONSReturn to Section TOC Return to Section TOCReturn to Section TOC Return to Section TOCE-1 TABLE OF CONTENTS-THEORY OF OPERATION SECTION E-1 FIGURE E.1 BLOCK LOGIC DIAGRAMReturn to Master TOC TOC Return to Master Return to Master TOCBATTERY, STARTER, ENGINE, ROTOR, STATOR, AND IDLER SOLENOID THEORY OF OPERATIONReturn to Section Section TOC Return to Master Master TOCROTOR FIELD FEEDBACK AND AUXILIARY POWER FIGURE E.3 - ROTOR FIELD FEEDBACK AND AUXILIARY POWERTHEORY OF OPERATION Return to Section TOC Return to Section TOCWELD WINDING, REACTOR, AND RANGE SWITCH FIGURE E.4 - WELD WINDING, REACTOR, AND RANGE SWITCHOUTPUT BRIDGE, CHOKE, AND OUTPUT TERMINALS THEORY OF OPERATIONF-1 TABLE OF CONTENTS - TROUBLESHOOTING AND REPAIR F-1 Return to Master TOC Return to Master TOC Return to Master TOCReturn to Master TOC EAGLE 10,000F-2TROUBLESHOOTING AND REPAIRF-2 HOW TO USE TROUBLESHOOTING GUIDECOURSE OF ACTION Return to Section TOC Return to Section TOC Return to Section TOCTROUBLESHOOTING AND REPAIR PC BOARD TROUBLESHOOTING PROCEDURESPC board can be damaged by static electricity Return to SectionPROBLEMS SYMPTOMSMISADJUSTMENTS OUTPUT PROBLEMSRECOMMENDED COURSE OF ACTION TROUBLESHOOTING AND REPAIRPROBLEMS SYMPTOMSPROBLEMS SYMPTOMS POSSIBLE AREAS OF MISADJUSTMENTSField Winding Voltage Test TROUBLESHOOTING AND REPAIRRotor Voltage2. PTestrform the TROUBLESHOOTING AND REPAIRPROBLEMS SYMPTOMSENGINE PROBLEMS TROUBLESHOOTING AND REPAIRPROBLEMS SYMPTOMS POSSIBLE AREAS OF MISADJUSTMENTSWiring TROUBLESHOOTING AND REPAIRPROBLEMS SYMPTOMSF-10 Charging Circuit TestTROUBLESHOOTING AND REPAIR PROBLEMSWELDING PROBLEMS F-113. BridgePerformTestthe. Output Rectifier TROUBLESHOOTING AND REPAIRF-12 F-12Return to Section TOC Return to Section TOCROTOR VOLTAGE TEST TEST DESCRIPTIONMATERIALS NEEDED F-13TEST PROCEDURE 4. Remove the case top, then reinstall the fuel capROTOR VOLTAGE TEST continued F-14ROTOR RESISTANCE TEST F-15TROUBLESHOOTING AND REPAIR TEST DESCRIPTIONROTOR RESISTANCE TEST continued F-16FIGURE F.2 - LOCATION OF ROTOR SLIP RINGS 4. Remove the case top, then replace the fuel capF-17 TROUBLESHOOTING AND REPAIRROTOR RESISTANCE TEST continued Return to Section TOC Return to Section TOC Return to Section TOCF-18 F-18Return to Section TOC Return to Section TOCAUXILIARY AND FIELD WINDING TEST F-19TROUBLESHOOTING AND REPAIR TEST DESCRIPTIONAUXILIARY AND FIELD WINDING TEST continued F-20FIGURE F.3 - LOCATION OF LEADS #3 AND #5 Return to Section TOC Section TOCF-21 Return to Section Return to Section TOC Return to Section TOCTo test the field winding TROUBLESHOOTING AND REPAIRF-22 F-22Return to Section TOC Return to Section TOCOUTPUT RECTIFIER BRIDGE TEST F-23TROUBLESHOOTING AND REPAIR TEST DESCRIPTIONOUTPUT RECTIFIER BRIDGE TEST continued ENGINEF-24 FIGURE F.4 - LOCATION OF OUTPUT RECTIFIER LEADSCHARGING CIRCUIT TEST F-25TROUBLESHOOTING AND REPAIR TEST DESCRIPTIONCHARGING CIRCUIT TEST continued F-26FIGURE F.5 - LOCATION OF VOLTAGE REGULATOR TROUBLESHOOTING AND REPAIRENGINE THROTTLE ADJUSTMENT TEST F-27TROUBLESHOOTING AND REPAIR TEST DESCRIPTIONENGINE THROTTLE ADJUSTMENT TEST continued F-28FIGURE F.6 - BLOWER PADDLE MARKED FOR STROBE-TACH METHOD Strobe-tach MethodHIGH IDLE ADJUSTMENT NUT LOW IDLE ADJUSTMENT NUTF-29 to SectionENGINE THROTTLE ADJUSTMENT TEST continued F-30Oscilloscope Method Vibratach MethodSCOPE SETTINGS NORMAL OPEN CIRCUIT VOLTAGE WAVEFORM 115VAC SUPPLYHIGH IDLE - NO LOAD - OUTPUT CONTROL AT MAXIMUM F-31TYPICAL DC WELD OUTPUT WAVEFORM CC MODE MACHINE LOADEDMACHINE LOADED TO 200 AMPS AT 26 VDC F-32ABNORMAL OPEN CIRCUIT DC WELD VOLTAGE WAVEFORM ONE OUTPUT DIODE NOT FUNCTIONINGF-33 TROUBLESHOOTING AND REPAIRNORMAL OPEN CIRCUIT DC WELD VOLTAGE WAVEFORM CC MODE F-34TROUBLESHOOTING AND REPAIR SCOPE SETTINGSBRUSH REMOVAL AND REPLACEMENT F-35TROUBLESHOOTING AND REPAIR TEST DESCRIPTIONBRUSH REMOVAL AND REPLACEMENT continued PROCEDURE5. Remove the case top, then reinstall the fuel cap F-36SLIP RINGS to Section TOCto Master TOC F-37F-38 F-38Return to Section TOC Return to Section TOCPRINTED CIRCUIT BOARD REMOVAL AND REPLACEMENT F-39TROUBLESHOOTING AND REPAIR TEST DESCRIPTIONPRINTED CIRCUIT BOARD REMOVAL AND REPLACEMENT continued F-40FIGURE F.10 - PRINTED CIRCUIT BOARD LOCATION TROUBLESHOOTING AND REPAIRF-41 TROUBLESHOOTING AND REPAIRPRINTED CIRCUIT BOARD REMOVAL AND REPLACEMENT continued Return to Section TOC Return to Section TOC Return to Section TOCF-42 F-42Return to Section TOC Return to Section TOCF-43TROUBLESHOOTING AND REPAIRF-43 OUTPUT RECTIFIER BRIDGE REMOVAL AND REPLACEMENTTEST DESCRIPTION MATERIALS NEEDEDF-44TROUBLESHOOTING AND REPAIRF-44 OUTPUT RECTIFIER BRIDGE REMOVAL AND REPLACEMENT continuedTO POLARITY SWITCH 3 1/2 MOUNTING SCREWS ENGINE NO NUT L1 TO CHOKE W1F-45TROUBLESHOOTING AND REPAIRF-45 OUTPUT RECTIFIER BRIDGE REMOVAL AND REPLACEMENT continuedReturn to Section Return to Section TOC Return to Section TOC Return to Section TOCF-46 F-46Return to Section TOC Return to Section TOCENGINE/ROTOR REMOVAL AND REPLACEMENT INSTRUCTIONSF-47 Lincoln Electric Rotor Removal Kit S20788 - FOR ROTOR REMOVAL ONLYENGINE/ROTOR REMOVAL AND REPLACEMENT continued F-48FIGURE F.12 - COMPONENT LOCATIONS, ENGINE/ROTOR REMOVAL TROUBLESHOOTING AND REPAIRENGINE AND ROTOR REMOVAL PROCEDURE F-49TROUBLESHOOTING AND REPAIR ENGINE/ROTOR REMOVAL AND REPLACEMENT continuedROTOR REMOVAL PROCEDURE F-50FIGURE F.13 - ENGINE AND ROTOR REMOVED FROM STATOR THRU-BOLTENGINE/ROTOR REMOVAL AND REPLACEMENT KIT S20788 continued REASSEMBLY PROCEDUREF-51 TROUBLESHOOTING AND REPAIRAUXILIARY POWER RECEPTACLE OUTPUT1 Range SwitchRETEST AFTER REPAIR ENGINE OUTPUTTABLE OF CONTENTS - DIAGRAM SECTION Return to Master TOC Return to Master TOC Return to Master TOCReturn to Master TOC EAGLE 10,000ELECTRICAL DIAGRAMS WIRING DIAGRAM - CODE 11096 M20317ELECTRICAL SYMBOLS PER E1537 EAGLE 10,000 KOHLERWIRING DIAGRAM - CODE 11397 - M21271 ELECTRICAL DIAGRAMSELECTRICAL SYMBOLS PER E1537 EAGLE 10,000 KOHLERSCHEMATIC - COMPLETE MACHINE - CODE 11096 L12259 Return to Section TOCReturn to Master TOC ELECTRODESCHEMATIC - COMPLETE MACHINE - CODE 11397 L13104 POSITIVEELECTRICAL DIAGRAMS Return to Section TOC Return to Section TOC Return to Section TOCSCHEMATIC - IDLER/FIELD CONTROL P.C. BOARD L12197 ELECTRICAL DIAGRAMSReturn to Section TOC Return to Section TOC Return to Section TOC Return to Section TOC