Manuals / Lincoln Electric / Lawn and Garden / Portable Generator

Lincoln Electric SVM192-A F-11, Welding Problems, BridgePerformTestthe. Output Rectifier

Models: SVM192-A

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F-11

F-11

TROUBLESHOOTING AND REPAIR

F-11

Observe Safety Guidelines detailed in the beginning of this manual.

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PROBLEMS

(SYMPTOMS)

The welding arc is “cold.” Engine runs normally (3700 RPM no load). Auxiliary power is functioning nor- mally.

POSSIBLE AREAS OF

MISADJUSTMENT(S)

WELDING PROBLEMS

1.Check for loose or faulty connec- tions at the weld output terminals and welding cable connections.

2.The welding cable may be too long or coiled, causing an exces- sive voltage drop.

RECOMMENDED

COURSE OF ACTION

1.Check for the correct open cir- cuit voltage (OCV) at the welder output terminals (80VAC Max. 72VDC Max.). If the correct voltage is present at the output terminals, then check for loose

connections on the heavy cur-

DiagramEAGLE 8. See Wiringthe

.rent carrying leads inside

2.If the OCV is low at the welder outputThe Engineterminals,ThrottlethenAdjustmentPerform Test.

3.BridgePerformTestthe. Output Rectifier

4.Check for shorted or grounded windings in the reactor andWiringalso Diagramin the ain stator. See

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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 F-11, Welding Problems, BridgePerformTestthe. Output Rectifier, Troubleshooting And Repair

Contents

Return to Master TOC Return to Master TOC Return to Master TOC Safety Depends on YouView Safety Info View Safety Info View Safety Info View Safety Info AprilCALIFORNIA PROPOSITION 65 WARNINGS iSAFETYiFOR ENGINE powered equipment ELECTRIC AND MAGNETIC FIELDS may be dangerousFUMES AND GASES SAFETYELECTRIC SHOCK can kill ARC RAYS can burnCYLINDER may explode powered equipmentWELDING CUTTINGReturn to Master TOC PRÉCAUTIONS DE SÛRETÉSAFETY Return to Master TOC Return to Master TOC Return to Master TOCEAGLE 10,000 I - MASTER TABLE OF CONTENTS FOR ALL SECTIONSSafety PageEAGLE 10,000 TABLE OF CONTENTS - INSTALLATION SECTIONReturn to Master TOC Return to Master TOC Return to Master TOC Return to Master TOCDisplacement cu. in cu.cm INSTALLATIONTECHNICAL SPECIFICATIONS - EAGLE 10,000 K2343-1,K2343-2 HorsepowerSPARK ARRESTER SAFETY PRECAUTIONSSee additional warning information at front of this operator’s manual MACHINE GROUNDINGFollow vehicle manufacturer’s instructions Stop engine while fueling Do not smoke when fuelingVEHICLE MOUNTING FUEL GASOLINE FUEL ONLYheavy accessory such as trail ADDITIONAL SAFETY PRECAUTIONS HIGH ALTITUDE OPERATIONwhen lifting Do not lift this machine usingWELDER OPERATION CONNECTION OF LINCOLN ELECTRIC WIRE FEEDERSADDITIONAL SAFETY PRECAUTIONS INSTRUCTIONSMOTOR STARTING AUXILIARY POWER120/240 VOLT DUAL VOLTAGE RECEPTACLE 120 V DUPLEX RECEPTACLESCommon Electrical Devices TABLE lELECTRICAL DEVICE USE WITH THE EAGLE 10,000 Typethe connection diagram shown in AUXILIARY POWER WHILE WELDINGSIMULTANEOUS WELDING AND POWER STANDBY POWER CONNECTIONSMaster TOC CONNECTION OF EAGLE 10,000 TO PREMISES WIRINGFigure A.1 Section TOCEAGLE 10,000 TABLE OF CONTENTS - OPERATION SECTIONReturn to Master TOC Return to Master TOC Return to Master TOC Return to Master TOCWELDER CONTROLS - FUNCTION AND OPERATION ENGINE SWITCHOPERATION GENERAL DESCRIPTIONEAGLE 10,000 APPROXIMATE FUEL CONSUMPTION RANGE SWITCHRange Setting OPERATIONB-3Keep flammable material away STARTING/SHUTDOWN INSTRUCTIONSBREAK-IN PERIOD STARTING THE ENGINETIG CONSTANT CURRENT WELDING WIRE FEED WELDING PROCESSESWELDING PROCESS Stick Constant Current WeldingCONTROL WHEN NOTTYPICAL CURRENT RANGES 1 FOR TUNGSTEN ELECTRODES2 Summary of Welding ProcessesEAGLE 10,000 TABLE OF CONTENTS - ACCESSORIES SECTIONReturn to Master TOC Return to Master TOC Return to Master TOC Return to Master TOCReturn to Section TOC Return to Section TOC Return to Section TOC ACCESSORIESOPTIONAL EQUIPMENT Field Installed K1745-1 GAS CYLINDER HOLDERSTICK WIRE FEEDRECOMMENDED EQUIPMENT PLASMA CUTTINGReturn to Section TOC Return to Section TOCReturn to Section TOC Return to Section TOCEAGLE 10,000 TABLE OF CONTENTS - MAINTENANCE SECTIONReturn to Master TOC Return to Master TOC Return to Master TOC Return to Master TOCKohler CH20S or CH23S MAINTENANCESAFETY PRECAUTIONS Routine MaintenanceReturn to Section TOC Return to Section TOC Return to Section TOC AIR CLEANER AND OTHER MAINTENANCEOIL FILTER CHANGE MAINTENANCEPre-Cleaner ENGINE ADJUSTMENTSBATTERY ENGINE MAINTENANCE PARTSFIGURE D.1 - MAJOR COMPONENT LOCATIONS 1. CASEFRONT 2. OUTPUT RECTIFIER ASSEMBLY3. BASE/UNDERCARRIAGE ASSEMBLY 4. ENGINE/ROTOR/STATOR ASSEMBLY 5. CASE TOP & SIDESReturn to Section TOC Return to Section TOCReturn to Section TOC Return to Section TOCReturn to Master Return to Master TOC E-1 TABLE OF CONTENTS-THEORY OF OPERATION SECTION E-1FIGURE E.1 BLOCK LOGIC DIAGRAM Return to Master TOC TOCReturn to Master Master TOC BATTERY, STARTER, ENGINE, ROTOR, STATOR, AND IDLER SOLENOIDTHEORY OF OPERATION Return to Section Section TOCReturn to Section TOC Return to Section TOC ROTOR FIELD FEEDBACK AND AUXILIARY POWERFIGURE E.3 - ROTOR FIELD FEEDBACK AND AUXILIARY POWER THEORY OF OPERATIONTHEORY OF OPERATION WELD WINDING, REACTOR, AND RANGE SWITCHFIGURE E.4 - WELD WINDING, REACTOR, AND RANGE SWITCH OUTPUT BRIDGE, CHOKE, AND OUTPUT TERMINALSEAGLE 10,000 F-1 TABLE OF CONTENTS - TROUBLESHOOTING AND REPAIR F-1Return to Master TOC Return to Master TOC Return to Master TOC Return to Master TOCReturn to Section TOC Return to Section TOC Return to Section TOC F-2TROUBLESHOOTING AND REPAIRF-2HOW TO USE TROUBLESHOOTING GUIDE COURSE OF ACTIONReturn to Section TROUBLESHOOTING AND REPAIRPC BOARD TROUBLESHOOTING PROCEDURES PC board can be damaged by static electricityOUTPUT PROBLEMS PROBLEMSSYMPTOMS MISADJUSTMENTSSYMPTOMS RECOMMENDED COURSE OF ACTIONTROUBLESHOOTING AND REPAIR PROBLEMSTROUBLESHOOTING AND REPAIR PROBLEMS SYMPTOMSPOSSIBLE AREAS OF MISADJUSTMENTS Field Winding Voltage TestSYMPTOMS Rotor Voltage2. PTestrform theTROUBLESHOOTING AND REPAIR PROBLEMSPOSSIBLE AREAS OF MISADJUSTMENTS ENGINE PROBLEMSTROUBLESHOOTING AND REPAIR PROBLEMS SYMPTOMSSYMPTOMS WiringTROUBLESHOOTING AND REPAIR PROBLEMSPROBLEMS F-10Charging Circuit Test TROUBLESHOOTING AND REPAIRTROUBLESHOOTING AND REPAIR WELDING PROBLEMSF-11 3. BridgePerformTestthe. Output RectifierReturn to Section TOC F-12F-12 Return to Section TOCF-13 ROTOR VOLTAGE TESTTEST DESCRIPTION MATERIALS NEEDEDF-14 TEST PROCEDURE4. Remove the case top, then reinstall the fuel cap ROTOR VOLTAGE TEST continuedTEST DESCRIPTION ROTOR RESISTANCE TESTF-15 TROUBLESHOOTING AND REPAIR4. Remove the case top, then replace the fuel cap ROTOR RESISTANCE TEST continuedF-16 FIGURE F.2 - LOCATION OF ROTOR SLIP RINGSReturn to Section TOC Return to Section TOC Return to Section TOC F-17TROUBLESHOOTING AND REPAIR ROTOR RESISTANCE TEST continuedReturn to Section TOC F-18F-18 Return to Section TOCTEST DESCRIPTION AUXILIARY AND FIELD WINDING TESTF-19 TROUBLESHOOTING AND REPAIRReturn to Section TOC Section TOC AUXILIARY AND FIELD WINDING TEST continuedF-20 FIGURE F.3 - LOCATION OF LEADS #3 AND #5TROUBLESHOOTING AND REPAIR F-21Return to Section Return to Section TOC Return to Section TOC To test the field windingReturn to Section TOC F-22F-22 Return to Section TOCTEST DESCRIPTION OUTPUT RECTIFIER BRIDGE TESTF-23 TROUBLESHOOTING AND REPAIRFIGURE F.4 - LOCATION OF OUTPUT RECTIFIER LEADS OUTPUT RECTIFIER BRIDGE TEST continuedENGINE F-24TEST DESCRIPTION CHARGING CIRCUIT TESTF-25 TROUBLESHOOTING AND REPAIRTROUBLESHOOTING AND REPAIR CHARGING CIRCUIT TEST continuedF-26 FIGURE F.5 - LOCATION OF VOLTAGE REGULATORTEST DESCRIPTION ENGINE THROTTLE ADJUSTMENT TESTF-27 TROUBLESHOOTING AND REPAIRStrobe-tach Method ENGINE THROTTLE ADJUSTMENT TEST continuedF-28 FIGURE F.6 - BLOWER PADDLE MARKED FOR STROBE-TACH METHODto Section HIGH IDLE ADJUSTMENT NUTLOW IDLE ADJUSTMENT NUT F-29Vibratach Method ENGINE THROTTLE ADJUSTMENT TEST continuedF-30 Oscilloscope MethodF-31 SCOPE SETTINGSNORMAL OPEN CIRCUIT VOLTAGE WAVEFORM 115VAC SUPPLY HIGH IDLE - NO LOAD - OUTPUT CONTROL AT MAXIMUMF-32 TYPICAL DC WELD OUTPUT WAVEFORM CC MODEMACHINE LOADED MACHINE LOADED TO 200 AMPS AT 26 VDCTROUBLESHOOTING AND REPAIR ABNORMAL OPEN CIRCUIT DC WELD VOLTAGE WAVEFORMONE OUTPUT DIODE NOT FUNCTIONING F-33SCOPE SETTINGS NORMAL OPEN CIRCUIT DC WELD VOLTAGE WAVEFORM CC MODEF-34 TROUBLESHOOTING AND REPAIRTEST DESCRIPTION BRUSH REMOVAL AND REPLACEMENTF-35 TROUBLESHOOTING AND REPAIRF-36 BRUSH REMOVAL AND REPLACEMENT continuedPROCEDURE 5. Remove the case top, then reinstall the fuel capF-37 SLIP RINGSto Section TOC to Master TOCReturn to Section TOC F-38F-38 Return to Section TOCTEST DESCRIPTION PRINTED CIRCUIT BOARD REMOVAL AND REPLACEMENTF-39 TROUBLESHOOTING AND REPAIRTROUBLESHOOTING AND REPAIR PRINTED CIRCUIT BOARD REMOVAL AND REPLACEMENT continuedF-40 FIGURE F.10 - PRINTED CIRCUIT BOARD LOCATIONReturn to Section TOC Return to Section TOC Return to Section TOC F-41TROUBLESHOOTING AND REPAIR PRINTED CIRCUIT BOARD REMOVAL AND REPLACEMENT continuedReturn to Section TOC F-42F-42 Return to Section TOCMATERIALS NEEDED F-43TROUBLESHOOTING AND REPAIRF-43OUTPUT RECTIFIER BRIDGE REMOVAL AND REPLACEMENT TEST DESCRIPTIONL1 TO CHOKE W1 F-44TROUBLESHOOTING AND REPAIRF-44OUTPUT RECTIFIER BRIDGE REMOVAL AND REPLACEMENT continued TO POLARITY SWITCH 3 1/2 MOUNTING SCREWS ENGINE NO NUTReturn to Section TOC F-45TROUBLESHOOTING AND REPAIRF-45OUTPUT RECTIFIER BRIDGE REMOVAL AND REPLACEMENT continued Return to Section Return to Section TOC Return to Section TOCReturn to Section TOC F-46F-46 Return to Section TOCLincoln Electric Rotor Removal Kit S20788 - FOR ROTOR REMOVAL ONLY ENGINE/ROTOR REMOVAL AND REPLACEMENTINSTRUCTIONS F-47TROUBLESHOOTING AND REPAIR ENGINE/ROTOR REMOVAL AND REPLACEMENT continuedF-48 FIGURE F.12 - COMPONENT LOCATIONS, ENGINE/ROTOR REMOVALENGINE/ROTOR REMOVAL AND REPLACEMENT continued ENGINE AND ROTOR REMOVAL PROCEDUREF-49 TROUBLESHOOTING AND REPAIRTHRU-BOLT ROTOR REMOVAL PROCEDUREF-50 FIGURE F.13 - ENGINE AND ROTOR REMOVED FROM STATORTROUBLESHOOTING AND REPAIR ENGINE/ROTOR REMOVAL AND REPLACEMENT KIT S20788 continuedREASSEMBLY PROCEDURE F-51ENGINE OUTPUT AUXILIARY POWER RECEPTACLE OUTPUT1Range Switch RETEST AFTER REPAIREAGLE 10,000 TABLE OF CONTENTS - DIAGRAM SECTIONReturn to Master TOC Return to Master TOC Return to Master TOC Return to Master TOCEAGLE 10,000 KOHLER ELECTRICAL DIAGRAMSWIRING DIAGRAM - CODE 11096 M20317 ELECTRICAL SYMBOLS PER E1537EAGLE 10,000 KOHLER WIRING DIAGRAM - CODE 11397 - M21271ELECTRICAL DIAGRAMS ELECTRICAL SYMBOLS PER E1537ELECTRODE SCHEMATIC - COMPLETE MACHINE - CODE 11096 L12259Return to Section TOC Return to Master TOCReturn to Section TOC Return to Section TOC Return to Section TOC SCHEMATIC - COMPLETE MACHINE - CODE 11397 L13104POSITIVE ELECTRICAL DIAGRAMSReturn to Section TOC SCHEMATIC - IDLER/FIELD CONTROL P.C. BOARD L12197ELECTRICAL DIAGRAMS Return to Section TOC Return to Section TOC Return to Section TOC