Manuals / Lincoln Electric / Lawn and Garden / Portable Generator

Lincoln Electric SVM208-A Troubleshooting And Repair, Problems, Possible Areas Of, Symptoms

Models: SVM208-A

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Electric Authorized Field Ser - vice Facility.

F-5	TROUBLESHOOTING AND REPAIR	F-5

Observe Safety Guidelines detailed in the beginning of this manual.

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PROBLEMS	POSSIBLE AREAS OF
(SYMPTOMS)	MISADJUSTMENT(S)
	OUTPUT PROBLEMS

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.

RECOMMENDED

COURSE OF ACTION

1.Perform the Rotor Voltage Test .

2.If the rotor voltage is zero to 3 VDC, check the flywheel alter- nator and associated wires 200A, 202, and 202A for conti- nuity. The voltage from lead 200A to ground should be at least 18 to 21 VDC at (3700 RPM). Normal voltage is 37.5- 42.5VDC. If the voltage is low or missing, the flywheel alterna- tor may be faulty. See the Wiring Diagram. Check diode D3 & lead #202C

3.Check lead 201B (green) for continuity (zero ohms) to ground. See wiring diagram.

4.The field capacitor (C1) or bridge (D2) may be faulty. Test or replace.

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

Rheostat Removal and Replacement Procedure.

6.The rotor may be faulty. Per- form the Rotor Resistance Test.

7.Perform Flashing Circuit 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.

BULLDOG® 140

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Lincoln Electric SVM208-A Troubleshooting And Repair, Return to Section TOC Return to Section TOC Return to Section TOC

Contents

January Safety Depends on YouSERVICE MANUAL View Safety Info View Safety Info View Safety Info View Safety InfoFOR ENGINE powered equipment SAFETYELECTRIC AND MAGNETIC FIELDS may be dangerous CALIFORNIA PROPOSITION 65 WARNINGSARC RAYS can burn ELECTRIC SHOCK can killcan be dangerous FUMES AND GASESWELDING and CUTTING SPARKS can cause fire or explosion FOR ELECTRICALLY powered equipmentCYLINDER may explode if damaged SAFETYSAFETY PRÉCAUTIONS DE SÛRETÉReturn to Master TOC Return to Master TOC Return to Master TOC Return to Master TOCElectromagnetic Compatibility EMC SAFETYInstallation and Use Return to Master TOC Return to Master TOC Return to Master TOCMaintenance of the Welding Equipment SAFETYElectromagnetic Compatibility EMC Return to Master TOC Return to Master TOC Return to Master TOCSafety I - MASTER TABLE OF CONTENTS FOR ALL SECTIONSPage BULLDOGReturn to Master TOC Return to Master TOC Return to Master TOC TABLE OF CONTENTS - INSTALLATION SECTIONReturn to Master TOC BULLDOGTECHNICAL SPECIFICATIONS - Bulldog 140 K2708-1 INSTALLATIONDisplacement AC Auxiliary PowerLOCATION AND VENTILATION SAFETY PRECAUTIONSSTORING INSTALLATIONSTACKING PRE-OPERATION ENGINE SERVICETILTING FUELWELDING CABLE CONNECTIONS ELECTRICAL OUTPUT CONNEC- TIONSTABLE A.1 RECOMMENDED WELDING CABLE SIZE AND LENGTH Bulldog 140 OUTPUT CONNECTIONSELECTRICAL CONNECTIONS AUXILIARY POWER RECEPTACLESPLUGS AND HAND-HELD EQUIPMENT INSTALLATIONCIRCUIT BREAKERS PREMISES WIRINGINSTALLATION Return to Section TOC Return to Section TOC Return to Section TOCReturn to Section TOC Return to Section TOC Return to Section TOC INSTALLATIONReturn to Section TOC Return to Master TOC Return to Master TOC Return to Master TOCReturn to Master TOC Return to Master TOC Return to Master TOC TABLE OF CONTENTS - OPERATION SECTIONReturn to Master TOC BULLDOGOPERATIONAL FEATURES AND CONTROLS SAFETY INSTRUCTIONSOPERATION GENERAL DESCRIPTIONLIMITATIONS CONTROLS AND SETTINGSWELDER/GENERATOR CONTROLS OUTPUT PANEL CONTROLSGASOLINE ENGINE CONTROLS ENGINE OPERATIONOPERATION Return to Section TOC Return to Section TOC Return to Section TOCSTARTING THE ENGINE BEFORE STARTING THE ENGINEOPERATION Return to Section TOC Return to Section TOC Return to Section TOCSTOPPING THE ENGINE GENERATOR OPERATIONRUNNING THE ENGINE BREAK-IN PERIODSuggested Power Applications GENERATOR POWER APPLICATIONSOPERATION Return to Section TOC Return to Section TOC Return to Section TOCCONTROL FUNCTION / OPERATION WELDING OPERATION“Current Control Dial” OPERATIONWELDING GUIDELINES Semi-automatic, Wire Welding With a Lincoln Wire Feeder / WelderStick Welding Learning To Stick WeldOPERATION What Happens in the Arc?B-10 B-102. The Correct Way to Strike An Arc 1. The Correct Welding Position3. The Correct Arc Length 4. The Correct Welding SpeedTypes of Welds PRACTICECommon Metals OPERATION1/2 Poor 12mm1/4 6mm 1/4 6mm Good1/8 3.2mm OPERATIONshort Very30-40 OPERATIONEnd View Side View3030 How to Hardface the Sharp Edge Metal to Ground Wearcold White brittlecast iron When breaking the weld stays on one pieceSelecting Electrodes MotionsOPERATION B-17Return to Section TOC Return to Section TOCReturn to Section TOC Return to Section TOCReturn to Master TOC Return to Master TOC Return to Master TOC TABLE OF CONTENTS - ACCESSORIES SECTIONReturn to Master TOC BULLDOGOPTIONS/ACCESSORIES ACCESSORIESLINCOLN ELECTRIC ACCESSORIES Return to Section TOC Return to Section TOC Return to Section TOCReturn to Master TOC Return to Master TOC Return to Master TOC TABLE OF CONTENTS - MAINTENANCE SECTIONReturn to Master TOC BULLDOGReturn to Section TOC MAINTENANCEReturn to Section TOC Return to Section TOCENGINE MAINTENANCE ROUTINE AND PERIODIC MAINTENANCEFIGURE D.1 - OIL DRAIN AND REFILL LOCATIONMAINTENANCE ENGINE ADJUSTMENTSFIGURE D.2 - CLEAN AREA FIGURE D.3 - CLEAN COOLING SYSTEMSPARK PLUG SERVICE TABLE D.1 ENGINE MAINTENANCE PARTSOPERATIONAL CLEARANCE MAINTENANCEFIGURE D.6. - BRUSH REMOVAL AND REPLACEMENT GENERATOR/WELDER MAINTENANCEMAINTENANCE 1. BRUSH, BRUSH HOLDER ASSEMBLY 2. BEARING BRACKET END COVERMAINTENANCE FIGURE D.7. - MAJOR COMPONENT LOCATIONS1. CRADLE ASSEMBLY 2. ROTOR, BLOWER, AND BEARING ASSEMBLY 3. STATOR ASSEMBLYReturn to Section TOC Return to Section TOCReturn to Section TOC Return to Section TOCENGINE E-1 TABLE OF CONTENTS-THEORY OF OPERATION SECTION E-1REACTOR OUTPUT TERMINALS STATOR ROTOR STATOR FIGURE E.1 BLOCK LOGIC DIAGRAMENGINE, EXCITATION, ROTOR AND STATOR THEORY OF OPERATIONFIGURE E.2 - ENGINE, EXCITATION, ROTOR AND STATOR Return to Master TOC to Master TOCFIGURE E.3 - ROTOR FIELD FEEDBACK AND AUXILIARY POWER ROTOR FIELD FEEDBACK AND AUXILIARY POWERTHEORY OF OPERATION Return to Master TOC to Master TOCTHEORY OF OPERATION WELD WINDING AND REACTORReturn to Master TOC to Master TOC ReturnReturn to Master TOC Return to Master TOC Return to Master TOC F-1 TABLE OF CONTENTS - TROUBLESHOOTING AND REPAIR F-1Return to Master TOC BULLDOGHOW TO USE TROUBLESHOOTING GUIDE TROUBLESHOOTING AND REPAIRStep 1. LOCATE PROBLEM SYMPTOM Return to Section TOCTROUBLESHOOTING AND REPAIR PC BOARD TROUBLESHOOTING PROCEDURESReturn to Section Return to Section TOC Return to Master TOCPROBLEMS TROUBLESHOOTING AND REPAIRSYMPTOMS MISADJUSTMENTSPROBLEMS TROUBLESHOOTING AND REPAIRSYMPTOMS MISADJUSTMENTSPROBLEMS SYMPTOMS TROUBLESHOOTING AND REPAIRPOSSIBLE AREAS OF MISADJUSTMENTS OUTPUT PROBLEMSPROBLEMS SYMPTOMS TROUBLESHOOTING AND REPAIRPOSSIBLE AREAS OF MISADJUSTMENTS OUTPUT PROBLEMSPROBLEMS SYMPTOMS TROUBLESHOOTING AND REPAIRPOSSIBLE AREAS OF MISADJUSTMENTS OUTPUT PROBLEMSPROBLEMS SYMPTOMS TROUBLESHOOTING AND REPAIRPOSSIBLE AREAS OF MISADJUSTMENTS ENGINE PROBLEMSPROBLEMS TROUBLESHOOTING AND REPAIRSYMPTOMS MISADJUSTMENTSPROBLEMS SYMPTOMS TROUBLESHOOTING AND REPAIRPOSSIBLE AREAS OF MISADJUSTMENTS WELDING PROBLEMSReturn to Section TOC Return to Section TOCReturn to Section TOC Return to Section TOCTEST DESCRIPTION ROTOR VOLTAGE TESTMATERIALS NEEDED TROUBLESHOOTING AND REPAIRROTOR VOLTAGE TEST continued PROCEDURELEAD 200A CONNECTION GROUND STUDTROUBLESHOOTING AND REPAIR FIELD DIODE BRIDGE TESTTEST DESCRIPTION MATERIALS NEEDED+ ~ FIELD DIODE BRIDGE TEST continuedTROUBLESHOOTING AND REPAIR PROCEDURETROUBLESHOOTING AND REPAIR ROTOR “FLASHING” CIRCUIT TESTTEST DESCRIPTION MATERIALS NEEDED201A ROTOR “FLASHING” CIRCUIT TEST continued202A+ TROUBLESHOOTING AND REPAIRROTOR “FLASHING” CIRCUIT TEST continued TROUBLESHOOTING AND REPAIRReturn to Section TOC Return to Section TOC Return to Section TOC Return to Section TOCReturn to Section TOC Return to Section TOCReturn to Section TOC Return to Section TOCTROUBLESHOOTING AND REPAIR ROTOR RESISTANCE TESTTEST DESCRIPTION MATERIALS NEEDEDSLIP RINGS ROTOR RESISTANCE TEST continuedTROUBLESHOOTING AND REPAIR PROCEDURETROUBLESHOOTING AND REPAIR CABLE TIE BRUSHESROTOR RESISTANCE TEST continued Return to Section TOC Return to Section TOC Return to Section TOCReturn to Section TOC Return to Section TOCReturn to Section TOC Return to Section TOCTROUBLESHOOTING AND REPAIR ENGINE THROTTLE ADJUSTMENT TEST ROBIN/SUBARU ENGINETEST DESCRIPTION MATERIALS NEEDEDTROUBLESHOOTING AND REPAIR ENGINE THROTTLE ADJUSTMENT TEST ROBIN/SUBARU ENGINE continuedPROCEDURE Return to Section TOCENGINE THROTTLE ADJUSTMENT TEST ROBIN/SUBARU ENGINE continued TROUBLESHOOTING AND REPAIRHIGH SPEED STOP SCREW THROTTLE LOCKING NUTTROUBLESHOOTING AND REPAIR SCOPE SETTINGSReturn to Section TOC Return to Section TOC Return to Master TOC Return to Master TOCHIGH IDLE - NO LOAD NORMAL OPEN CIRCUIT VOLTAGE WAVEFORM 115VAC SUPPLYTROUBLESHOOTING AND REPAIR SCOPE SETTINGSMACHINE LOADED TYPICAL WELD OUTPUT WAVEFORMMACHINE LOADED TO 125 AMPS AT 23 VAC TROUBLESHOOTING AND REPAIRTROUBLESHOOTING AND REPAIR BRUSH REMOVAL AND REPLACEMENTTEST DESCRIPTION MATERIALS NEEDEDCABLE TIE BRUSHES BRUSH REMOVAL AND REPLACEMENT continuedTROUBLESHOOTING AND REPAIR PROCEDUREBRUSH REMOVAL AND REPLACEMENT continued TROUBLESHOOTING AND REPAIRF-33 F-33Return to Section TOC Return to Section TOCReturn to Section TOC Return to Section TOCTROUBLESHOOTING AND REPAIR RHEOSTAT REMOVAL AND REPLACEMENTTEST DESCRIPTION MATERIALS NEEDEDTROUBLESHOOTING AND REPAIR RHEOSTAT REMOVAL AND REPLACEMENT continuedPROCEDURE Return to Section TOC Return to Section TOCTROUBLESHOOTING AND REPAIR CAPACITOR AND/OR DIODE BRIDGE REMOVAL AND REPLACEMENTTEST DESCRIPTION MATERIALS NEEDEDPROCEDURE - CAPACITOR REMOVAL AND REPLACEMENT CAPACITOR AND/OR DIODE BRIDGE REMOVAL AND REPLACEMENT continuedTROUBLESHOOTING AND REPAIR Attachment for 202 202A +TROUBLESHOOTING AND REPAIR PROCEDURE - FIELD DIODE BRIDGE REMOVAL AND REPLACEMENTCAPACITOR AND/OR DIODE BRIDGE REMOVAL AND REPLACEMENT continued Return to Section TOC Return to Section TOCReturn to Section TOC Return to Section TOCReturn to Section TOC Return to Section TOCINSTRUCTIONS STATOR/ROTOR REMOVAL AND REPLACEMENTTROUBLESHOOTING AND REPAIR TEST DESCRIPTIONTROUBLESHOOTING AND REPAIR STATOR/ROTOR REMOVAL AND REPLACEMENT continuedPROCEDURE GENERATORENGINESTATOR/ROTOR REMOVAL AND REPLACEMENT continued TROUBLESHOOTING AND REPAIRReturn to Section TOC Return to Section TOC Section TOC Return to Master TOC Return to Master TOC Master TOCSTATOR/ROTOR REMOVAL AND REPLACEMENT continued TROUBLESHOOTING AND REPAIRReturn to Section TOC Return to Section TOC Return to Section TOC Return to Section TOCTROUBLESHOOTING AND REPAIR STATOR REMOVAL PROCEDURESTATOR/ROTOR REMOVAL AND REPLACEMENT continued Return to Section TOC Return to Section TOCSUPPORT THRU BOLTS THRU BOLTSNUTS TROUBLESHOOTING AND REPAIRREASSEMBLY PROCEDURE ROTOR REMOVAL PROCEDURETROUBLESHOOTING AND REPAIR STATOR/ROTOR REMOVAL AND REPLACEMENT continuedSTATOR/ROTOR REMOVAL AND REPLACEMENT continued TROUBLESHOOTING AND REPAIRto Section TOC to Master TOCRETEST AFTER REPAIR AUXILIARY POWER RECEPTACLE OUTPUT1ENGINE OUTPUT WELDER/GENERATOR OUTPUT1Return to Section TOC Return to Section TOCReturn to Section TOC Return to Section TOCReturn to Master TOC Return to Master TOC Return to Master TOC TABLE OF CONTENTS - DIAGRAM SECTIONReturn to Master TOC BULLDOGWiriNG DiaGram - cOmplETE machiNE - l15064 ElEcTrical DiaGramSL15064 WIRING DIAGRAM - BULLDOGSUBJECT SchEmaTic - cOmplETE machiNE - S28101ENGINEERING CONTROLLED MANUFACTURER