Manuals / Lincoln Electric / Power Tools / Welder

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

Models: SVM197-A

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F-5

TROUBLESHOOTING AND REPAIR

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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

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No weld output and no auxiliary out- 1. The generator brushes may be

put - engine runs normally.worn or faulty. See the Main- tenance section of this manual or contact your local Lincoln Electric Authorized Field Ser- vice Facility.

1.Perform the Rotor and Flashing Voltage Test .

2.The field capacitor (C1) or bridge (D1) may be faulty. Test or replace.

3.Test the rheostat (R1). Normal resistance is 3.3 ohms.

4.The rotor may be faulty. Perform the Rotor Resistance Test.

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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.

POWERARC® 5500

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Lincoln Electric SVM197-A Troubleshooting And Repair, Section TOC, to Master TOC, Problems, Possible Areas Of, Recommended

Contents

POWERARC Safety Depends on YouSERVICE MANUAL View Safety Info View Safety Info View Safety Info View Safety InfoFOR ENGINE powered equipment iSAFETYiELECTRIC AND MAGNETIC FIELDS may be dangerous POWERARCELECTRIC SHOCK can kill SAFETYARC RAYS can burn FUMES AND GASESWELDING and CUTTING powered equipmentCYLINDER may explode SPARKS canSAFETY PRÉCAUTIONS DE SÛRETÉPOWERARC Return to Master TOC Return to Master TOC Return to Master TOCSAFETY Electromagnetic Compatibility EMCPOWERARC Return to Master TOC Return to Master TOC Return to Master TOCPOWERARC SAFETYElectromagnetic Compatibility EMC Return to Master TOC Return to Master TOC Return to Master TOCSafety I - MASTER TABLE OF CONTENTS FOR ALL SECTIONSPOWERARC PagePOWERARC TABLE OF CONTENTS - INSTALLATION SECTIONReturn to Master TOC Return to Master TOC Return to Master TOC Return to Master TOCTECHNICAL SPECIFICATIONS - POWERARC INSTALLATIONDisplacement AC Auxiliary PowerLOCATION AND VENTILATION SAFETY PRECAUTIONSSTORING INSTALLATIONSTACKING PRE-OPERATION ENGINE SERVICETILTING FUELMUFFLER DEFLECTOR PowerArc 5500 Typical Fuel ConsumptionSPARK ARRESTER INSTALLATIONELECTRICAL OUTPUT CONNECTIONS POWERARC 5500 OUTPUT CONNECTIONSPhysical Location of Items and Components may vary by Code No WELDING CABLE CONNECTIONSPLUGS AND HAND-HELD EQUIPMENT AUXILIARY POWER RECEPTACLESMACHINE GROUNDING INSTALLATIONCIRCUIT BREAKERS PREMISES WIRINGINSTALLATION POWERARCPOWERARC INSTALLATIONReturn to Section TOC Return to Section TOC Return to Section TOC Return to Section TOCReturn to Section TOC POWERARCReturn to Section TOC Return to Section TOCPOWERARC TABLE OF CONTENTS - OPERATION SECTIONReturn to Master TOC Return to Master TOC Return to Master TOC Return to Master TOCOPERATIONAL FEATURES AND CONTROLS SAFETY INSTRUCTIONSOPERATION GENERAL DESCRIPTIONLIMITATIONS CONTROLS AND SETTINGSOUTPUT PANEL CONTROLS Physical Location of Components may vary by Code NoGASOLINE ENGINE CONTROLS ENGINE OPERATIONSee SPARK ARRESTER in the INSTALLATION section of this manual POWERARCSTARTING THE ENGINE BEFORE STARTING THE ENGINEPOWERARC OPERATIONSTOPPING THE ENGINE GENERATOR OPERATIONGENERAL INFORMATION RUNNING THE ENGINEOPERATION POWERARCReturn to Section TOC Return to Section TOC Return to Section TOC Return to Section TOCCONTROL FUNCTION / OPERATION “Current Control Dial” WELDING OPERATIONTO USE THE POWERARC 5500 FOR WELDING POWERARCWELDING GUIDELINES Semi-automatic, Wire Welding With a Lincoln Wire Feeder / WelderStick Welding Learning To Stick WeldPOWERARC What Happens in the Arc?OPERATION B-102. The Correct Way to Strike An Arc 1. The Correct Welding Position3. The Correct Arc Length 4. The Correct Welding SpeedCommon Metals PRACTICETypes of Welds POWERARCOPERATION POWERARCGood 1/8 3.2mmOPERATION POWERARCB-14 B-14POWERARC How to Hardface the Sharp Edge Metal to Ground WearOPERATION Side ViewOPERATION POWERARChot coldcold White brittle cast ironPOWERARC Selecting ElectrodesOPERATION MotionsReturn to Section TOC POWERARCReturn to Section TOC Return to Section TOCPOWERARC TABLE OF CONTENTS - ACCESSORIES SECTIONReturn to Master TOC Return to Master TOC Return to Master TOC Return to Master TOCOPTIONS/ACCESSORIES ACCESSORIESLINCOLN ELECTRIC ACCESSORIES POWERARCPOWERARC TABLE OF CONTENTS - MAINTENANCE SECTIONReturn to Master TOC Return to Master TOC Return to Master TOC Return to Master TOCROUTINE AND PERIODIC MAINTENANCE MAINTENANCEENGINE MAINTENANCE FIGURE D.2 - OIL DRAIN AND REFILLFIGURE D.3 - CLEAN ROTATING SCREEN/FINGER GUARD/DEBRIS GUARD ENGINE ADJUSTMENTSFIGURE D.4 - CLEAN COOLING SYSTEM MAINTENANCEFIGURE D.5 - SET SPARK PLUG GAP TABLE D.1 ENGINE MAINTENANCE PARTSMAINTENANCE POWERARCMAINTENANCE GENERATOR/WELDER MAINTENANCEPOWERARC Return to Master TOC Return to Master TOCMAINTENANCE FIGURE D.6. - MAJOR COMPONENT LOCATIONSFIGURE E.1 - POWERARC 5500 BLOCK LOGIC DIAGRAM E-1 TABLE OF CONTENTS-THEORY OF OPERATION SECTION E-1POWERARC Block Logic DiagramENGINE CONTROL AND IGNITION THEORY OF OPERATIONENGINE, EXCITATION, ROTOR AND STATOR POWERARCFIGURE E.3 - ROTOR FIELD FEEDBACK AND AUXILIARY POWER ROTOR FIELD FEEDBACK AND AUXILIARY POWERPOWERARC THEORY OF OPERATIONWELD WINDING AND REACTOR AUXILIARY POWER OVERCURRENT PROTECTIONPOWERARC THEORY OF OPERATIONPOWERARC F-1 TABLE OF CONTENTS - TROUBLESHOOTING AND REPAIR F-1Return to Master TOC Return to Master TOC Return to Master TOC Return to Master TOCHOW TO USE TROUBLESHOOTING GUIDE F-2TROUBLESHOOTING AND REPAIRF-2Step 1. LOCATE PROBLEM SYMPTOM POWERARCPC BOARD TROUBLESHOOTING PROCEDURES TROUBLESHOOTING AND REPAIRPOWERARC Return to Section Return to Section TOCPROBLEMS TROUBLESHOOTING AND REPAIRSYMPTOMS MISADJUSTMENTSSPROBLEMS TROUBLESHOOTING AND REPAIRSYMPTOMS MISADJUSTMENTSSPROBLEMS TROUBLESHOOTING AND REPAIRSYMPTOMS MISADJUSTMENTSSPROBLEMS TROUBLESHOOTING AND REPAIRSYMPTOMS MISADJUSTMENTSSPROBLEMS TROUBLESHOOTING AND REPAIRSYMPTOMS MISADJUSTMENTSSPROBLEMS TROUBLESHOOTING AND REPAIRSYMPTOMS MISADJUSTMENTSSPROBLEMS TROUBLESHOOTING AND REPAIRSYMPTOMS MISADJUSTMENTSSPROBLEMS TROUBLESHOOTING AND REPAIRSYMPTOMS MISADJUSTMENTSSReturn to Section TOC POWERARCReturn to Section TOC Return to Section TOCTEST DESCRIPTION ROTOR VOLTAGE AND FLASHING VOLTAGE TEST PROCEDUREMATERIALS NEEDED TROUBLESHOOTING AND REPAIRROTOR VOLTAGE AND FLASHING VOLTAGE TEST PROCEDURE continued F-14TROUBLESHOOTING AND REPAIRF-14ROTOR VOLTAGE TEST PROCEDURE FLASHING VOLTAGE TEST PROCEDURETROUBLESHOOTING AND REPAIR ROTOR RESISTANCE TEST PROCEDUREPOWERARC TEST DESCRIPTIONROTOR RESISTANCE TEST continued ROTOR RESISTANCE TEST PROCEDURE continuedTROUBLESHOOTING AND REPAIR PROCEDUREROTOR RESISTANCE TEST PROCEDURE continued TROUBLESHOOTING AND REPAIRPOWERARC ROTOR RESISTANCE TEST continuedReturn to Section TOC POWERARCReturn to Section TOC Return to Section TOCTROUBLESHOOTING AND REPAIR ENGINE THROTTLE ADJUSTMENT TEST ROBIN/SUBARU ENGINEPOWERARC TEST DESCRIPTIONTEST PROCEDURE ENGINE THROTTLE ADJUSTMENT TEST ROBIN/SUBARU ENGINE continuedTROUBLESHOOTING AND REPAIR POWERARCENGINE THROTTLE ADJUSTMENT TEST ROBIN/SUBARU ENGINE continued TROUBLESHOOTING AND REPAIRPOWERARC HIGH SPEED STOP SCREWNORMAL OPEN CIRCUIT WELD VOLTAGE WAVEFORM SCOPE SETTINGSHIGH IDLE - NO LOAD TROUBLESHOOTING AND REPAIRTROUBLESHOOTING AND REPAIR NORMAL OPEN CIRCUIT VOLTAGE WAVEFORM 115 VAC SUPPLYSCOPE SETTINGS POWERARCMACHINE LOADED TYPICAL WELD OUTPUT WAVEFORMMACHINE LOADED TO 125 AMPS AT 23 VAC TROUBLESHOOTING AND REPAIRTROUBLESHOOTING AND REPAIR BRUSH REMOVAL AND REPLACEMENT PROCEDUREPOWERARC TEST DESCRIPTIONPROCEDURE BRUSH REMOVAL AND REPLACEMENT continuedTROUBLESHOOTING AND REPAIR POWERARCBRUSH REMOVAL AND REPLACEMENT continued TROUBLESHOOTING AND REPAIRPROCEDURE continued POWERARCReturn to Section TOC POWERARCReturn to Section TOC Return to Section TOCTROUBLESHOOTING AND REPAIR RHEOSTAT REMOVAL AND REPLACEMENT PROCEDUREPOWERARC TEST DESCRIPTIONTROUBLESHOOTING AND REPAIR RHEOSTAT REMOVAL AND REPLACEMENT PROCEDURE continuedPROCEDURE POWERARCTROUBLESHOOTING AND REPAIR CAPACITOR AND/OR DIODE BRIDGE REMOVAL AND REPLACEMENT PROCEDUREPOWERARC TEST DESCRIPTIONPROCEDURE - CAPACITOR REMOVAL AND REPLACE- MENT REMOVAL AND REPLACEMENT PROCEDURE continuedCAPACITOR AND/OR DIODE BRIDGE TROUBLESHOOTING AND REPAIRTROUBLESHOOTING AND REPAIR PROCEDURE - FIELD DIODE BRIDGE REMOVAL AND REPLACEMENTREMOVAL AND REPLACEMENT PROCEDURE continued POWERARCReturn to Section TOC POWERARCReturn to Section TOC Return to Section TOCTROUBLESHOOTING AND REPAIR STATOR/ROTOR REMOVAL AND REPLACEMENT PROCEDUREPOWERARC TEST DESCRIPTIONSTATOR REMOVAL PROCEDURE STATOR/ROTOR REMOVAL AND REPLACEMENT PROCEDURE continuedTROUBLESHOOTING AND REPAIR POWERARCSTATOR/ROTOR REMOVAL AND REPLACEMENT PROCEDURE continued TROUBLESHOOTING AND REPAIRPOWERARC Section TOCREASSEMBLY PROCEDURE ROTOR REMOVAL PROCEDURETROUBLESHOOTING AND REPAIR STATOR/ROTOR REMOVAL AND REPLACEMENT PROCEDURE continuedSTATOR/ROTOR REMOVAL AND REPLACEMENT PROCEDURE continued TROUBLESHOOTING AND REPAIRProcedure 23. Conduct the Retest After Repair ProcedureSTATOR/ROTOR REMOVAL AND REPLACEMENT PROCEDURE continued TROUBLESHOOTING AND REPAIRPOWERARC REACTOR BOLTSRETEST AFTER REPAIR AUXILIARY POWER RECEPTACLE OUTPUT1ENGINE OUTPUT WELDER/GENERATOR OUTPUT1Return to Section TOC POWERARCReturn to Section TOC Return to Section TOCPOWERARC TABLE OF CONTENTS - DIAGRAM SECTIONReturn to Master TOC Return to Master TOC Return to Master TOC Return to Master TOCWIRING DIAGRAM - CODES 11182, 11187, 11329 S25984 WIRING DIAGRAM - POWER ARCELECTRICAL DIAGRAMS WIRING DIAGRAM - POWER ARC WIRING DIAGRAM - CODES 11403, 11405 S26829ELECTRICAL DIAGRAMS S26829WIRING DIAGRAM - CODE 11404 S26830 WIRING DIAGRAM - POWER ARCELECTRICAL DIAGRAMS ELECTRICAL SYMBOLS PER E1537ELECTRICAL DIAGRAMS WIRING DIAGRAM - CODE 11215 S26023WIRING DIAGRAM - POWER ARC MACHINE SCHEMATIC POWER ARCCONNECTOR SCHEMATIC -CODES 11182, 11187, 11329 S26008SCHEMATIC - CODES 11403, 11405 S26881 POWER ARC 5500 SUBARU ROBINS26881 MACHINE SCHEMATICSCHEMATIC - CODE 11404 S26882 POWER ARC 5500 HONDAS26882 MACHINE SCHEMATIC