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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3. Make sure lead 5 (white) is grounded to the machine frame (zero ohms).

4. Check for an open or grounded auxiliary winding in the stator, 6 to 3. See the Wiring Diagram.

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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F-7

TROUBLESHOOTING AND REPAIR

F-7

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

No auxiliary power - welding output		1.	Check circuit breakers CB1 and	1.	Check the auxiliary power re -
is normal - engine runs normally.			CB2. Reset if tripped.		ceptacles and associated wires
		2.	Make sure that the control rheo-		for loose or faulty connections.
		2.	Make sure that the control rheo-
			stat (R1) is set at “GENERATOR”	2.	Check the continuity (zero ohms)
			(maximum).		of leads 3, 3A, 3B; 6, 6A, 6B, 6C;
		3.	Check for loose or faulty plug at		and 5, 5A, 5B from the recepta-
		3.	Check for loose or faulty plug at		cles to the stator windings. See
			power receptacle.		cles to the stator windings. See
			power receptacle.		the Wiring Diagram.
					the Wiring Diagram.

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

Contents

View Safety Info View Safety Info View Safety Info View Safety Info Safety Depends on YouPOWERARC SERVICE MANUALPOWERARC iSAFETYiFOR ENGINE powered equipment ELECTRIC AND MAGNETIC FIELDS may be dangerousFUMES AND GASES SAFETYELECTRIC SHOCK can kill ARC RAYS can burnSPARKS can powered equipmentWELDING and CUTTING CYLINDER may explodeReturn to Master TOC Return to Master TOC Return to Master TOC PRÉCAUTIONS DE SÛRETÉSAFETY POWERARCReturn to Master TOC Return to Master TOC Return to Master TOC Electromagnetic Compatibility EMCSAFETY POWERARCReturn to Master TOC Return to Master TOC Return to Master TOC SAFETYPOWERARC Electromagnetic Compatibility EMCPage I - MASTER TABLE OF CONTENTS FOR ALL SECTIONSSafety POWERARCReturn to Master TOC TABLE OF CONTENTS - INSTALLATION SECTIONPOWERARC Return to Master TOC Return to Master TOC Return to Master TOCAC Auxiliary Power INSTALLATIONTECHNICAL SPECIFICATIONS - POWERARC DisplacementINSTALLATION SAFETY PRECAUTIONSLOCATION AND VENTILATION STORINGFUEL PRE-OPERATION ENGINE SERVICESTACKING TILTINGINSTALLATION PowerArc 5500 Typical Fuel ConsumptionMUFFLER DEFLECTOR SPARK ARRESTERWELDING CABLE CONNECTIONS POWERARC 5500 OUTPUT CONNECTIONSELECTRICAL OUTPUT CONNECTIONS Physical Location of Items and Components may vary by Code NoINSTALLATION AUXILIARY POWER RECEPTACLESPLUGS AND HAND-HELD EQUIPMENT MACHINE GROUNDINGPOWERARC PREMISES WIRINGCIRCUIT BREAKERS INSTALLATIONReturn to Section TOC INSTALLATIONPOWERARC Return to Section TOC Return to Section TOC Return to Section TOCReturn to Section TOC POWERARCReturn to Section TOC Return to Section TOCReturn to Master TOC TABLE OF CONTENTS - OPERATION SECTIONPOWERARC Return to Master TOC Return to Master TOC Return to Master TOCGENERAL DESCRIPTION SAFETY INSTRUCTIONSOPERATIONAL FEATURES AND CONTROLS OPERATIONPhysical Location of Components may vary by Code No CONTROLS AND SETTINGSLIMITATIONS OUTPUT PANEL CONTROLSPOWERARC ENGINE OPERATIONGASOLINE ENGINE CONTROLS See SPARK ARRESTER in the INSTALLATION section of this manualOPERATION BEFORE STARTING THE ENGINESTARTING THE ENGINE POWERARCRUNNING THE ENGINE GENERATOR OPERATIONSTOPPING THE ENGINE GENERAL INFORMATIONReturn to Section TOC POWERARCOPERATION Return to Section TOC Return to Section TOC Return to Section TOCPOWERARC WELDING OPERATIONCONTROL FUNCTION / OPERATION “Current Control Dial” TO USE THE POWERARC 5500 FOR WELDINGLearning To Stick Weld Semi-automatic, Wire Welding With a Lincoln Wire Feeder / WelderWELDING GUIDELINES Stick WeldingB-10 What Happens in the Arc?POWERARC OPERATION4. The Correct Welding Speed 1. The Correct Welding Position2. The Correct Way to Strike An Arc 3. The Correct Arc LengthPOWERARC PRACTICECommon Metals Types of Welds1/8 3.2mm POWERARCOPERATION GoodB-14 POWERARCOPERATION B-14Side View How to Hardface the Sharp Edge Metal to Ground WearPOWERARC OPERATIONWhite brittle cast iron POWERARCOPERATION hot coldcoldMotions Selecting ElectrodesPOWERARC OPERATIONReturn to Section TOC POWERARCReturn to Section TOC Return to Section TOCReturn to Master TOC TABLE OF CONTENTS - ACCESSORIES SECTIONPOWERARC Return to Master TOC Return to Master TOC Return to Master TOCPOWERARC ACCESSORIESOPTIONS/ACCESSORIES LINCOLN ELECTRIC ACCESSORIESReturn to Master TOC TABLE OF CONTENTS - MAINTENANCE SECTIONPOWERARC Return to Master TOC Return to Master TOC Return to Master TOCFIGURE D.2 - OIL DRAIN AND REFILL MAINTENANCEROUTINE AND PERIODIC MAINTENANCE ENGINE MAINTENANCEMAINTENANCE ENGINE ADJUSTMENTSFIGURE D.3 - CLEAN ROTATING SCREEN/FINGER GUARD/DEBRIS GUARD FIGURE D.4 - CLEAN COOLING SYSTEMPOWERARC TABLE D.1 ENGINE MAINTENANCE PARTSFIGURE D.5 - SET SPARK PLUG GAP MAINTENANCEReturn to Master TOC Return to Master TOC GENERATOR/WELDER MAINTENANCEMAINTENANCE POWERARCMAINTENANCE FIGURE D.6. - MAJOR COMPONENT LOCATIONSBlock Logic Diagram E-1 TABLE OF CONTENTS-THEORY OF OPERATION SECTION E-1FIGURE E.1 - POWERARC 5500 BLOCK LOGIC DIAGRAM POWERARCPOWERARC THEORY OF OPERATIONENGINE CONTROL AND IGNITION ENGINE, EXCITATION, ROTOR AND STATORTHEORY OF OPERATION ROTOR FIELD FEEDBACK AND AUXILIARY POWERFIGURE E.3 - ROTOR FIELD FEEDBACK AND AUXILIARY POWER POWERARCTHEORY OF OPERATION AUXILIARY POWER OVERCURRENT PROTECTIONWELD WINDING AND REACTOR POWERARCReturn to Master TOC F-1 TABLE OF CONTENTS - TROUBLESHOOTING AND REPAIR F-1POWERARC Return to Master TOC Return to Master TOC Return to Master TOCPOWERARC F-2TROUBLESHOOTING AND REPAIRF-2HOW TO USE TROUBLESHOOTING GUIDE Step 1. LOCATE PROBLEM SYMPTOMReturn to Section Return to Section TOC TROUBLESHOOTING AND REPAIRPC BOARD TROUBLESHOOTING PROCEDURES POWERARCMISADJUSTMENTSS TROUBLESHOOTING AND REPAIRPROBLEMS SYMPTOMSMISADJUSTMENTSS TROUBLESHOOTING AND REPAIRPROBLEMS SYMPTOMSMISADJUSTMENTSS TROUBLESHOOTING AND REPAIRPROBLEMS SYMPTOMSMISADJUSTMENTSS TROUBLESHOOTING AND REPAIRPROBLEMS SYMPTOMSMISADJUSTMENTSS TROUBLESHOOTING AND REPAIRPROBLEMS SYMPTOMSMISADJUSTMENTSS TROUBLESHOOTING AND REPAIRPROBLEMS SYMPTOMSMISADJUSTMENTSS TROUBLESHOOTING AND REPAIRPROBLEMS SYMPTOMSMISADJUSTMENTSS TROUBLESHOOTING AND REPAIRPROBLEMS SYMPTOMSReturn to Section TOC POWERARCReturn to Section TOC Return to Section TOCTROUBLESHOOTING AND REPAIR ROTOR VOLTAGE AND FLASHING VOLTAGE TEST PROCEDURETEST DESCRIPTION MATERIALS NEEDEDFLASHING VOLTAGE TEST PROCEDURE F-14TROUBLESHOOTING AND REPAIRF-14ROTOR VOLTAGE AND FLASHING VOLTAGE TEST PROCEDURE continued ROTOR VOLTAGE TEST PROCEDURETEST DESCRIPTION ROTOR RESISTANCE TEST PROCEDURETROUBLESHOOTING AND REPAIR POWERARCPROCEDURE ROTOR RESISTANCE TEST PROCEDURE continuedROTOR RESISTANCE TEST continued TROUBLESHOOTING AND REPAIRROTOR RESISTANCE TEST continued TROUBLESHOOTING AND REPAIRROTOR RESISTANCE TEST PROCEDURE continued POWERARCReturn to Section TOC POWERARCReturn to Section TOC Return to Section TOCTEST DESCRIPTION ENGINE THROTTLE ADJUSTMENT TEST ROBIN/SUBARU ENGINETROUBLESHOOTING AND REPAIR POWERARCPOWERARC ENGINE THROTTLE ADJUSTMENT TEST ROBIN/SUBARU ENGINE continuedTEST PROCEDURE TROUBLESHOOTING AND REPAIRHIGH SPEED STOP SCREW TROUBLESHOOTING AND REPAIRENGINE THROTTLE ADJUSTMENT TEST ROBIN/SUBARU ENGINE continued POWERARCTROUBLESHOOTING AND REPAIR SCOPE SETTINGSNORMAL OPEN CIRCUIT WELD VOLTAGE WAVEFORM HIGH IDLE - NO LOADPOWERARC NORMAL OPEN CIRCUIT VOLTAGE WAVEFORM 115 VAC SUPPLYTROUBLESHOOTING AND REPAIR SCOPE SETTINGSTROUBLESHOOTING AND REPAIR TYPICAL WELD OUTPUT WAVEFORMMACHINE LOADED MACHINE LOADED TO 125 AMPS AT 23 VACTEST DESCRIPTION BRUSH REMOVAL AND REPLACEMENT PROCEDURETROUBLESHOOTING AND REPAIR POWERARCPOWERARC BRUSH REMOVAL AND REPLACEMENT continuedPROCEDURE TROUBLESHOOTING AND REPAIRPOWERARC TROUBLESHOOTING AND REPAIRBRUSH REMOVAL AND REPLACEMENT continued PROCEDURE continuedReturn to Section TOC POWERARCReturn to Section TOC Return to Section TOCTEST DESCRIPTION RHEOSTAT REMOVAL AND REPLACEMENT PROCEDURETROUBLESHOOTING AND REPAIR POWERARCPOWERARC RHEOSTAT REMOVAL AND REPLACEMENT PROCEDURE continuedTROUBLESHOOTING AND REPAIR PROCEDURETEST DESCRIPTION CAPACITOR AND/OR DIODE BRIDGE REMOVAL AND REPLACEMENT PROCEDURETROUBLESHOOTING AND REPAIR POWERARCTROUBLESHOOTING AND REPAIR REMOVAL AND REPLACEMENT PROCEDURE continuedPROCEDURE - CAPACITOR REMOVAL AND REPLACE- MENT CAPACITOR AND/OR DIODE BRIDGEPOWERARC PROCEDURE - FIELD DIODE BRIDGE REMOVAL AND REPLACEMENTTROUBLESHOOTING AND REPAIR REMOVAL AND REPLACEMENT PROCEDURE continuedReturn to Section TOC POWERARCReturn to Section TOC Return to Section TOCTEST DESCRIPTION STATOR/ROTOR REMOVAL AND REPLACEMENT PROCEDURETROUBLESHOOTING AND REPAIR POWERARCPOWERARC STATOR/ROTOR REMOVAL AND REPLACEMENT PROCEDURE continuedSTATOR REMOVAL PROCEDURE TROUBLESHOOTING AND REPAIRSection TOC TROUBLESHOOTING AND REPAIRSTATOR/ROTOR REMOVAL AND REPLACEMENT PROCEDURE continued POWERARCSTATOR/ROTOR REMOVAL AND REPLACEMENT PROCEDURE continued ROTOR REMOVAL PROCEDUREREASSEMBLY PROCEDURE TROUBLESHOOTING AND REPAIR23. Conduct the Retest After Repair Procedure TROUBLESHOOTING AND REPAIRSTATOR/ROTOR REMOVAL AND REPLACEMENT PROCEDURE continued ProcedureREACTOR BOLTS TROUBLESHOOTING AND REPAIRSTATOR/ROTOR REMOVAL AND REPLACEMENT PROCEDURE continued POWERARCWELDER/GENERATOR OUTPUT1 AUXILIARY POWER RECEPTACLE OUTPUT1RETEST AFTER REPAIR ENGINE OUTPUTReturn to Section TOC POWERARCReturn to Section TOC Return to Section TOCReturn to Master TOC TABLE OF CONTENTS - DIAGRAM SECTIONPOWERARC Return to Master TOC Return to Master TOC Return to Master TOCELECTRICAL DIAGRAMS WIRING DIAGRAM - POWER ARCWIRING DIAGRAM - CODES 11182, 11187, 11329 S25984 S26829 WIRING DIAGRAM - CODES 11403, 11405 S26829WIRING DIAGRAM - POWER ARC ELECTRICAL DIAGRAMSELECTRICAL SYMBOLS PER E1537 WIRING DIAGRAM - POWER ARCWIRING DIAGRAM - CODE 11404 S26830 ELECTRICAL DIAGRAMSWIRING DIAGRAM - POWER ARC WIRING DIAGRAM - CODE 11215 S26023ELECTRICAL DIAGRAMS TEMPERATURE POWER ARCMACHINE SCHEMATIC CONNECTORMACHINE SCHEMATIC POWER ARC 5500 SUBARU ROBINSCHEMATIC - CODES 11403, 11405 S26881 S26881MACHINE SCHEMATIC POWER ARC 5500 HONDASCHEMATIC - CODE 11404 S26882 S26882