Table of Contents Maintenance Section | Lincoln Electric SVM197-A

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D-1

TABLE OF CONTENTS - MAINTENANCE SECTION

D-1

Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .D-1

Safety Precautions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .D-2

Fuel, Engine Adjustments . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .D-3

Spark Plug Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .D-4

Generator/Welder Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .D-5

Major Component Location . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .D-6

POWERARC® 5500

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Lincoln Electric SVM197-A service manual Table of Contents Maintenance Section

Contents

Powerarc ISAFETYi Electric Shock can kill ARC Rays can burn Safety Iii For Electrically Précautions DE Sûreté Electromagnetic Compatibility EMC Safety Master Table of Contents for ALL Sections Table of Contents Installation Section Technical Specifications Powerarc Installation Engine Exhaust can kill Safety PrecautionsLocation and Ventilation Storing PRE-OPERATION Engine Service Honda 9 HP PowerArc 5500 Typical Fuel ConsumptionMuffler Deflector Spark Arrester Cable Size and Length Powerarc 5500 Output ConnectionsElectrical Output Connections Welding Cable Connections Machine Grounding Auxiliary Power ReceptaclesCable Installation Plugs and HAND-HELD Equipment Circuit Breakers Premises Wiring Type Common Electrical Devices Possible Concerns Table A.2 Electrical Device USE with the Powerarc Powerarc Table of Contents Operation Section Operation Physical Location of Components may vary by Code No Controls and SettingsLimitations Output Panel Controls Gasoline Engine Controls Engine Operation Starting the Engine Before Starting the Engine Running the Engine Generator OperationStopping the Engine General Information Table B.3 Generator Power Applications Control Function / Operation Current Control Dial Welding Operation Welding Guidelines Material Thickness Electrode Type Size Setting Welding circuit for Stick shielded metal arc welding What Happens in the Arc? Correct Welding Speed Correct Welding PositionCorrect Way to Strike An Arc Correct Arc Length Do the following Common MetalsTypes of Welds Use the following Welding in the Vertical Position Penetration Vertical-Down Welding Vertical-Up Welding Welding Sheet Metal How to Hardface the Sharp Edge Metal to Ground WearOverhead Welding Hardfacing To Reduce Wear Cast Iron Plate Preparation Welding Cast Iron Out-of-Position Group AWS E6011 Selecting ElectrodesHigh-Speed Group AWS E6013 Low Hydrogen Group AWS E7018 Powerarc Table of Contents Accessories Section Accessories OPTIONS/ACCESSORIESLincoln Electric Accessories Table of Contents Maintenance Section Maintenance Routine and Periodic MaintenanceEngine Maintenance Figure D.3 Clean Rotating SCREEN/FINGER GUARD/DEBRIS Guard Engine Adjustments Part Robin / Subaru Honda Table D.1 Engine Maintenance Parts Do not attempt to polish slip rings while engine is running GENERATOR/WELDER Maintenance Figure D.6. Major Component Locations 1TABLE of CONTENTS-THEORY of Operation Section E-1 Theory of Operation Engine Control and IgnitionENGINE, EXCITATION, Rotor and Stator Return Rotor Field Feedback Auxiliary Power Weld Winding and Reactor Auxiliary Power Overcurrent Protection 1TABLE of Contents Troubleshooting and Repair F-1 HOW to USE Troubleshooting Guide 2TROUBLESHOOTING and REPAIRF-2 Troubleshooting and Repair Output Problems Perform the Rotor and Flashing Voltage Test Troubleshooting and Repair Troubleshooting and Repair Rotor Resistance Test Engine Problems Troubleshooting and Repair Engine Throttle Adjustment Test Powerarc Materials Needed Test Description Lead 14TROUBLESHOOTING and REPAIRF-14Rotor Voltage Test Procedure Flashing Voltage Test Procedure Rotor Resistance Test Procedure Rotor Resistance Test Procedure Figure F.3 Brushes Retained with Cable TIE Powerarc Engine Throttle Adjustment Test ROBIN/SUBARU Engine ROBIN/SUBARU Engine Engine Throttle Adjustment Test High Speed Stop Screw Scope Settings Normal Open Circuit Weld Voltage WaveformHigh Idle no Load Normal Open Circuit Voltage Waveform 115 VAC Supply Typical Weld Output Waveform Machine LoadedMachine Loaded to 125 Amps AT 23 VAC Brush Removal and Replacement Procedure Brush Removal and Replacement Procedure Powerarc Rheostat Removal and Replacement Procedure Rheostat Removal and Replacement Procedure Troubleshooting and Repair Attachment for 201 201A Jumper Procedure Capacitor Removal and REPLACE- MentCapacitor AND/OR Diode Bridge Attachment for 202A Cable Tie Capacitor Figure F.10 Field Diode Bridge Location Procedure Field Diode Bridge Removal and Replacement Powerarc STATOR/ROTOR Removal and Replacement Procedure STATOR/ROTOR Stator Removal Procedure Section TOC Rotor Removal Procedure Procedure Reactor Bolts Lead WELDER/GENERATOR OUTPUT1 Auxiliary Power Receptacle OUTPUT1Retest After Repair Engine Output Powerarc Table of Contents Diagram Section Wiring Diagram Codes 11182, 11187, 11329 S25984 Electrical Diagrams Switch Wiring Diagram Codes 11403, 11405 S26829 Wiring Diagram Code 11404 S26830 Wiring Diagram Power ARC Wiring Diagram Code 11215 S26023 S26008 Schematic -CODES 11182, 11187, 11329 S26008 S26881 Schematic Codes 11403, 11405 S26881 S26882 Schematic Code 11404 S26882