Manuals / Lincoln Electric / Power Tools / Welder

Lincoln Electric SVM197-A Troubleshooting And Repair, Return to Section TOC, Return to Master TOC

Models: SVM197-A

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F-4

TROUBLESHOOTING AND REPAIR

F-4

TROUBLESHOOTING GUIDE - Observe Safety Guidelines detailed in the beginning of this manual.

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

	OUTPUT PROBLEMS

Major physical or electrical damage		Contact the Lincoln Electric Service
is evident.		Department at 1-888-935-3877.

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.

POWERARC® 5500

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Lincoln Electric SVM197-A Troubleshooting And Repair, Return to Section TOC Return to Section TOC Return to Section TOC

Contents

Safety Depends on You POWERARCSERVICE MANUAL View Safety Info View Safety Info View Safety Info View Safety InfoiSAFETYi FOR ENGINE powered equipmentELECTRIC AND MAGNETIC FIELDS may be dangerous POWERARCSAFETY ELECTRIC SHOCK can killARC RAYS can burn FUMES AND GASESpowered equipment WELDING and CUTTINGCYLINDER may explode SPARKS canPRÉCAUTIONS DE SÛRETÉ SAFETYPOWERARC Return to Master TOC Return to Master TOC Return to Master TOCElectromagnetic Compatibility EMC SAFETYPOWERARC Return to Master TOC Return to Master TOC Return to Master TOCSAFETY POWERARCElectromagnetic Compatibility EMC Return to Master TOC Return to Master TOC Return to Master TOCI - MASTER TABLE OF CONTENTS FOR ALL SECTIONS SafetyPOWERARC PageTABLE OF CONTENTS - INSTALLATION SECTION POWERARCReturn to Master TOC Return to Master TOC Return to Master TOC Return to Master TOCINSTALLATION TECHNICAL SPECIFICATIONS - POWERARCDisplacement AC Auxiliary PowerSAFETY PRECAUTIONS LOCATION AND VENTILATIONSTORING INSTALLATIONPRE-OPERATION ENGINE SERVICE STACKINGTILTING FUELPowerArc 5500 Typical Fuel Consumption MUFFLER DEFLECTORSPARK ARRESTER INSTALLATIONPOWERARC 5500 OUTPUT CONNECTIONS ELECTRICAL OUTPUT CONNECTIONSPhysical Location of Items and Components may vary by Code No WELDING CABLE CONNECTIONSAUXILIARY POWER RECEPTACLES PLUGS AND HAND-HELD EQUIPMENTMACHINE GROUNDING INSTALLATIONPREMISES WIRING CIRCUIT BREAKERSINSTALLATION POWERARCINSTALLATION POWERARCReturn to Section TOC Return to Section TOC Return to Section TOC Return to Section TOCPOWERARC Return to Section TOCReturn to Section TOC Return to Section TOCTABLE OF CONTENTS - OPERATION SECTION POWERARCReturn to Master TOC Return to Master TOC Return to Master TOC Return to Master TOCSAFETY INSTRUCTIONS OPERATIONAL FEATURES AND CONTROLSOPERATION GENERAL DESCRIPTIONCONTROLS AND SETTINGS LIMITATIONSOUTPUT PANEL CONTROLS Physical Location of Components may vary by Code NoENGINE OPERATION GASOLINE ENGINE CONTROLSSee SPARK ARRESTER in the INSTALLATION section of this manual POWERARCBEFORE STARTING THE ENGINE STARTING THE ENGINEPOWERARC OPERATIONGENERATOR OPERATION STOPPING THE ENGINEGENERAL INFORMATION RUNNING THE ENGINEPOWERARC OPERATIONReturn to Section TOC Return to Section TOC Return to Section TOC Return to Section TOCWELDING OPERATION CONTROL FUNCTION / OPERATION “Current Control Dial”TO USE THE POWERARC 5500 FOR WELDING POWERARCSemi-automatic, Wire Welding With a Lincoln Wire Feeder / Welder WELDING GUIDELINESStick Welding Learning To Stick WeldWhat Happens in the Arc? POWERARCOPERATION B-101. The Correct Welding Position 2. The Correct Way to Strike An Arc3. The Correct Arc Length 4. The Correct Welding SpeedPRACTICE Common MetalsTypes of Welds POWERARCPOWERARC OPERATIONGood 1/8 3.2mmPOWERARC OPERATIONB-14 B-14How to Hardface the Sharp Edge Metal to Ground Wear POWERARCOPERATION Side ViewPOWERARC OPERATIONhot coldcold White brittle cast ironSelecting Electrodes POWERARCOPERATION MotionsPOWERARC Return to Section TOCReturn to Section TOC Return to Section TOCTABLE OF CONTENTS - ACCESSORIES SECTION POWERARCReturn to Master TOC Return to Master TOC Return to Master TOC Return to Master TOCACCESSORIES OPTIONS/ACCESSORIESLINCOLN ELECTRIC ACCESSORIES POWERARCTABLE OF CONTENTS - MAINTENANCE SECTION POWERARCReturn to Master TOC Return to Master TOC Return to Master TOC Return to Master TOCMAINTENANCE ROUTINE AND PERIODIC MAINTENANCEENGINE MAINTENANCE FIGURE D.2 - OIL DRAIN AND REFILLENGINE ADJUSTMENTS FIGURE D.3 - CLEAN ROTATING SCREEN/FINGER GUARD/DEBRIS GUARDFIGURE D.4 - CLEAN COOLING SYSTEM MAINTENANCETABLE D.1 ENGINE MAINTENANCE PARTS FIGURE D.5 - SET SPARK PLUG GAPMAINTENANCE POWERARCGENERATOR/WELDER MAINTENANCE MAINTENANCEPOWERARC Return to Master TOC Return to Master TOCFIGURE D.6. - MAJOR COMPONENT LOCATIONS MAINTENANCEE-1 TABLE OF CONTENTS-THEORY OF OPERATION SECTION E-1 FIGURE E.1 - POWERARC 5500 BLOCK LOGIC DIAGRAMPOWERARC Block Logic DiagramTHEORY OF OPERATION ENGINE CONTROL AND IGNITIONENGINE, EXCITATION, ROTOR AND STATOR POWERARCROTOR FIELD FEEDBACK AND AUXILIARY POWER FIGURE E.3 - ROTOR FIELD FEEDBACK AND AUXILIARY POWERPOWERARC THEORY OF OPERATIONAUXILIARY POWER OVERCURRENT PROTECTION WELD WINDING AND REACTORPOWERARC THEORY OF OPERATIONF-1 TABLE OF CONTENTS - TROUBLESHOOTING AND REPAIR F-1 POWERARCReturn to Master TOC Return to Master TOC Return to Master TOC Return to Master TOCF-2TROUBLESHOOTING AND REPAIRF-2 HOW TO USE TROUBLESHOOTING GUIDEStep 1. LOCATE PROBLEM SYMPTOM POWERARCTROUBLESHOOTING AND REPAIR PC BOARD TROUBLESHOOTING PROCEDURESPOWERARC Return to Section Return to Section TOCTROUBLESHOOTING AND REPAIR PROBLEMSSYMPTOMS MISADJUSTMENTSSTROUBLESHOOTING AND REPAIR PROBLEMSSYMPTOMS MISADJUSTMENTSSTROUBLESHOOTING AND REPAIR PROBLEMSSYMPTOMS MISADJUSTMENTSSTROUBLESHOOTING AND REPAIR PROBLEMSSYMPTOMS MISADJUSTMENTSSTROUBLESHOOTING AND REPAIR PROBLEMSSYMPTOMS MISADJUSTMENTSSTROUBLESHOOTING AND REPAIR PROBLEMSSYMPTOMS MISADJUSTMENTSSTROUBLESHOOTING AND REPAIR PROBLEMSSYMPTOMS MISADJUSTMENTSSTROUBLESHOOTING AND REPAIR PROBLEMSSYMPTOMS MISADJUSTMENTSSPOWERARC Return to Section TOCReturn to Section TOC Return to Section TOCROTOR VOLTAGE AND FLASHING VOLTAGE TEST PROCEDURE TEST DESCRIPTIONMATERIALS NEEDED TROUBLESHOOTING AND REPAIRF-14TROUBLESHOOTING AND REPAIRF-14 ROTOR VOLTAGE AND FLASHING VOLTAGE TEST PROCEDURE continuedROTOR VOLTAGE TEST PROCEDURE FLASHING VOLTAGE TEST PROCEDUREROTOR RESISTANCE TEST PROCEDURE TROUBLESHOOTING AND REPAIRPOWERARC TEST DESCRIPTIONROTOR RESISTANCE TEST PROCEDURE continued ROTOR RESISTANCE TEST continuedTROUBLESHOOTING AND REPAIR PROCEDURETROUBLESHOOTING AND REPAIR ROTOR RESISTANCE TEST PROCEDURE continuedPOWERARC ROTOR RESISTANCE TEST continuedPOWERARC Return to Section TOCReturn to Section TOC Return to Section TOCENGINE THROTTLE ADJUSTMENT TEST ROBIN/SUBARU ENGINE TROUBLESHOOTING AND REPAIRPOWERARC TEST DESCRIPTIONENGINE THROTTLE ADJUSTMENT TEST ROBIN/SUBARU ENGINE continued TEST PROCEDURETROUBLESHOOTING AND REPAIR POWERARCTROUBLESHOOTING AND REPAIR ENGINE THROTTLE ADJUSTMENT TEST ROBIN/SUBARU ENGINE continuedPOWERARC HIGH SPEED STOP SCREWSCOPE SETTINGS NORMAL OPEN CIRCUIT WELD VOLTAGE WAVEFORMHIGH IDLE - NO LOAD TROUBLESHOOTING AND REPAIRNORMAL OPEN CIRCUIT VOLTAGE WAVEFORM 115 VAC SUPPLY TROUBLESHOOTING AND REPAIRSCOPE SETTINGS POWERARCTYPICAL WELD OUTPUT WAVEFORM MACHINE LOADEDMACHINE LOADED TO 125 AMPS AT 23 VAC TROUBLESHOOTING AND REPAIRBRUSH REMOVAL AND REPLACEMENT PROCEDURE TROUBLESHOOTING AND REPAIRPOWERARC TEST DESCRIPTIONBRUSH REMOVAL AND REPLACEMENT continued PROCEDURETROUBLESHOOTING AND REPAIR POWERARCTROUBLESHOOTING AND REPAIR BRUSH REMOVAL AND REPLACEMENT continuedPROCEDURE continued POWERARCPOWERARC Return to Section TOCReturn to Section TOC Return to Section TOCRHEOSTAT REMOVAL AND REPLACEMENT PROCEDURE TROUBLESHOOTING AND REPAIRPOWERARC TEST DESCRIPTIONRHEOSTAT REMOVAL AND REPLACEMENT PROCEDURE continued TROUBLESHOOTING AND REPAIRPROCEDURE POWERARCCAPACITOR AND/OR DIODE BRIDGE REMOVAL AND REPLACEMENT PROCEDURE TROUBLESHOOTING AND REPAIRPOWERARC TEST DESCRIPTIONREMOVAL AND REPLACEMENT PROCEDURE continued PROCEDURE - CAPACITOR REMOVAL AND REPLACE- MENTCAPACITOR AND/OR DIODE BRIDGE TROUBLESHOOTING AND REPAIRPROCEDURE - FIELD DIODE BRIDGE REMOVAL AND REPLACEMENT TROUBLESHOOTING AND REPAIRREMOVAL AND REPLACEMENT PROCEDURE continued POWERARCPOWERARC Return to Section TOCReturn to Section TOC Return to Section TOCSTATOR/ROTOR REMOVAL AND REPLACEMENT PROCEDURE TROUBLESHOOTING AND REPAIRPOWERARC TEST DESCRIPTIONSTATOR/ROTOR REMOVAL AND REPLACEMENT PROCEDURE continued STATOR REMOVAL PROCEDURETROUBLESHOOTING AND REPAIR POWERARCTROUBLESHOOTING AND REPAIR STATOR/ROTOR REMOVAL AND REPLACEMENT PROCEDURE continuedPOWERARC Section TOCROTOR REMOVAL PROCEDURE REASSEMBLY PROCEDURETROUBLESHOOTING AND REPAIR STATOR/ROTOR REMOVAL AND REPLACEMENT PROCEDURE continuedTROUBLESHOOTING AND REPAIR STATOR/ROTOR REMOVAL AND REPLACEMENT PROCEDURE continuedProcedure 23. Conduct the Retest After Repair ProcedureTROUBLESHOOTING AND REPAIR STATOR/ROTOR REMOVAL AND REPLACEMENT PROCEDURE continuedPOWERARC REACTOR BOLTSAUXILIARY POWER RECEPTACLE OUTPUT1 RETEST AFTER REPAIRENGINE OUTPUT WELDER/GENERATOR OUTPUT1POWERARC Return to Section TOCReturn to Section TOC Return to Section TOCTABLE OF CONTENTS - DIAGRAM SECTION POWERARCReturn to Master TOC Return to Master TOC Return to Master TOC Return to Master TOCELECTRICAL DIAGRAMS WIRING DIAGRAM - POWER ARCWIRING DIAGRAM - CODES 11182, 11187, 11329 S25984 WIRING DIAGRAM - CODES 11403, 11405 S26829 WIRING DIAGRAM - POWER ARCELECTRICAL DIAGRAMS S26829WIRING DIAGRAM - POWER ARC WIRING DIAGRAM - CODE 11404 S26830ELECTRICAL DIAGRAMS ELECTRICAL SYMBOLS PER E1537WIRING DIAGRAM - POWER ARC WIRING DIAGRAM - CODE 11215 S26023ELECTRICAL DIAGRAMS POWER ARC MACHINE SCHEMATICCONNECTOR SCHEMATIC -CODES 11182, 11187, 11329 S26008POWER ARC 5500 SUBARU ROBIN SCHEMATIC - CODES 11403, 11405 S26881S26881 MACHINE SCHEMATICPOWER ARC 5500 HONDA SCHEMATIC - CODE 11404 S26882S26882 MACHINE SCHEMATIC

PROBLEMS

POSSIBLE AREAS OF

RECOMMENDED

(SYMPTOMS)

MISADJUSTMENTS(S)

COURSE OF ACTION

OUTPUT PROBLEMS

Department at 1-888-935-3877.