Manuals / Lincoln Electric / Lawn and Garden / Portable Generator

Lincoln Electric SVM208-A Troubleshooting And Repair, Problems Symptoms, Output Problems, Bulldog

Models: SVM208-A

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PROBLEMS

F-6	TROUBLESHOOTING AND REPAIR	F-6

Observe Safety Guidelines detailed in the beginning of this manual.

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PROBLEMS

(SYMPTOMS)

No weld output - auxiliary power (230 - 115 VAC) operates normally - engine runs normally.

POSSIBLE AREAS OF

MISADJUSTMENT(S)

OUTPUT PROBLEMS

1.Check the open circuit voltage (OCV) at the welder output termi- nals. If OCV is okay, go to Step 2, below.

If OCV is not present at the welder output terminals, contact your local Lincoln Electric Authorized Field Service Facility.

2.Check the welding cables, clamps and electrode holder for loose or broken connections.

RECOMMENDED

COURSE OF ACTION

1.Check continuity (zero ohms) of lead W1A (black) from output terminal to reactor (L1). See the Wiring Diagram.

2.Check continuity (zero ohms) of lead W2 (black) from output ter- minal to stator winding. See the Wiring Diagram.

3.Check continuity (zero ohms) of lead W1 (black) from reactor (L1) to stator winding. See the Wiring Diagram.

4.Check reactor (L1) for continuity of winding. See the Wiring Dia- gram.

5.Check the stator for continuity of winding. See the Wiring Dia- gram.

6.Make certain the reactor and/or stator are NOT grounded. Mini- mum acceptable resistance to ground is 500 K-ohms.

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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

SERVICE MANUAL Safety Depends on YouJanuary View Safety Info View Safety Info View Safety Info View Safety InfoELECTRIC AND MAGNETIC FIELDS may be dangerous SAFETYFOR ENGINE powered equipment CALIFORNIA PROPOSITION 65 WARNINGScan be dangerous ELECTRIC SHOCK can killARC RAYS can burn FUMES AND GASESCYLINDER may explode if damaged FOR ELECTRICALLY powered equipmentWELDING and CUTTING SPARKS can cause fire or explosion SAFETYReturn to Master TOC Return to Master TOC Return to Master TOC PRÉCAUTIONS DE SÛRETÉSAFETY Return to Master TOCInstallation and Use SAFETYElectromagnetic Compatibility EMC Return to Master TOC Return to Master TOC Return to Master TOCElectromagnetic Compatibility EMC SAFETYMaintenance of the Welding Equipment Return to Master TOC Return to Master TOC Return to Master TOCPage I - MASTER TABLE OF CONTENTS FOR ALL SECTIONSSafety BULLDOGReturn to Master TOC TABLE OF CONTENTS - INSTALLATION SECTIONReturn to Master TOC Return to Master TOC Return to Master TOC BULLDOGDisplacement INSTALLATIONTECHNICAL SPECIFICATIONS - Bulldog 140 K2708-1 AC Auxiliary PowerSTORING SAFETY PRECAUTIONSLOCATION AND VENTILATION INSTALLATIONTILTING PRE-OPERATION ENGINE SERVICESTACKING FUELTABLE A.1 RECOMMENDED WELDING CABLE SIZE AND LENGTH ELECTRICAL OUTPUT CONNEC- TIONSWELDING CABLE CONNECTIONS Bulldog 140 OUTPUT CONNECTIONSPLUGS AND HAND-HELD EQUIPMENT AUXILIARY POWER RECEPTACLESELECTRICAL CONNECTIONS INSTALLATIONINSTALLATION PREMISES WIRINGCIRCUIT BREAKERS Return to Section TOC Return to Section TOC Return to Section TOCReturn to Section TOC INSTALLATIONReturn to Section TOC Return to Section TOC Return to Section TOC Return to Master TOC Return to Master TOC Return to Master TOCReturn to Master TOC TABLE OF CONTENTS - OPERATION SECTIONReturn to Master TOC Return to Master TOC Return to Master TOC BULLDOGOPERATION SAFETY INSTRUCTIONSOPERATIONAL FEATURES AND CONTROLS GENERAL DESCRIPTIONWELDER/GENERATOR CONTROLS CONTROLS AND SETTINGSLIMITATIONS OUTPUT PANEL CONTROLSOPERATION ENGINE OPERATIONGASOLINE ENGINE CONTROLS Return to Section TOC Return to Section TOC Return to Section TOCOPERATION BEFORE STARTING THE ENGINESTARTING THE ENGINE Return to Section TOC Return to Section TOC Return to Section TOCRUNNING THE ENGINE GENERATOR OPERATIONSTOPPING THE ENGINE BREAK-IN PERIODOPERATION GENERATOR POWER APPLICATIONSSuggested Power Applications Return to Section TOC Return to Section TOC Return to Section TOC“Current Control Dial” WELDING OPERATIONCONTROL FUNCTION / OPERATION OPERATIONStick Welding Semi-automatic, Wire Welding With a Lincoln Wire Feeder / WelderWELDING GUIDELINES Learning To Stick WeldB-10 What Happens in the Arc?OPERATION B-103. The Correct Arc Length 1. The Correct Welding Position2. The Correct Way to Strike An Arc 4. The Correct Welding SpeedCommon Metals PRACTICETypes of Welds OPERATION1/8 3.2mm Good1/2 Poor 12mm1/4 6mm 1/4 6mm OPERATION30-40 Veryshort OPERATION3030 Side ViewEnd View How to Hardface the Sharp Edge Metal to Ground Wearcast iron White brittlecold When breaking the weld stays on one pieceOPERATION MotionsSelecting Electrodes B-17Return to Section TOC Return to Section TOCReturn to Section TOC Return to Section TOCReturn to Master TOC TABLE OF CONTENTS - ACCESSORIES SECTIONReturn to Master TOC Return to Master TOC Return to Master TOC BULLDOGLINCOLN ELECTRIC ACCESSORIES ACCESSORIESOPTIONS/ACCESSORIES Return to Section TOC Return to Section TOC Return to Section TOCReturn to Master TOC TABLE OF CONTENTS - MAINTENANCE SECTIONReturn to Master TOC Return to Master TOC Return to Master TOC BULLDOGReturn to Section TOC MAINTENANCEReturn to Section TOC Return to Section TOCFIGURE D.1 - OIL DRAIN AND REFILL ROUTINE AND PERIODIC MAINTENANCEENGINE MAINTENANCE LOCATIONFIGURE D.2 - CLEAN AREA ENGINE ADJUSTMENTSMAINTENANCE FIGURE D.3 - CLEAN COOLING SYSTEMOPERATIONAL CLEARANCE TABLE D.1 ENGINE MAINTENANCE PARTSSPARK PLUG SERVICE MAINTENANCEMAINTENANCE GENERATOR/WELDER MAINTENANCEFIGURE D.6. - BRUSH REMOVAL AND REPLACEMENT 1. BRUSH, BRUSH HOLDER ASSEMBLY 2. BEARING BRACKET END COVER1. CRADLE ASSEMBLY 2. ROTOR, BLOWER, AND BEARING ASSEMBLY FIGURE D.7. - MAJOR COMPONENT LOCATIONSMAINTENANCE 3. STATOR ASSEMBLYReturn to Section TOC Return to Section TOCReturn to Section TOC Return to Section TOCREACTOR OUTPUT TERMINALS STATOR ROTOR STATOR E-1 TABLE OF CONTENTS-THEORY OF OPERATION SECTION E-1ENGINE FIGURE E.1 BLOCK LOGIC DIAGRAMFIGURE E.2 - ENGINE, EXCITATION, ROTOR AND STATOR THEORY OF OPERATIONENGINE, EXCITATION, ROTOR AND STATOR Return to Master TOC to Master TOCTHEORY OF OPERATION ROTOR FIELD FEEDBACK AND AUXILIARY POWERFIGURE E.3 - ROTOR FIELD FEEDBACK AND AUXILIARY POWER Return to Master TOC to Master TOCReturn to Master TOC to Master TOC WELD WINDING AND REACTORTHEORY OF OPERATION ReturnReturn to Master TOC F-1 TABLE OF CONTENTS - TROUBLESHOOTING AND REPAIR F-1Return to Master TOC Return to Master TOC Return to Master TOC BULLDOGStep 1. LOCATE PROBLEM SYMPTOM TROUBLESHOOTING AND REPAIRHOW TO USE TROUBLESHOOTING GUIDE Return to Section TOCReturn to Section Return to Section TOC PC BOARD TROUBLESHOOTING PROCEDURESTROUBLESHOOTING AND REPAIR Return to Master TOCSYMPTOMS TROUBLESHOOTING AND REPAIRPROBLEMS MISADJUSTMENTSSYMPTOMS TROUBLESHOOTING AND REPAIRPROBLEMS MISADJUSTMENTSPOSSIBLE AREAS OF MISADJUSTMENTS TROUBLESHOOTING AND REPAIRPROBLEMS SYMPTOMS OUTPUT PROBLEMSPOSSIBLE AREAS OF MISADJUSTMENTS TROUBLESHOOTING AND REPAIRPROBLEMS SYMPTOMS OUTPUT PROBLEMSPOSSIBLE AREAS OF MISADJUSTMENTS TROUBLESHOOTING AND REPAIRPROBLEMS SYMPTOMS OUTPUT PROBLEMSPOSSIBLE AREAS OF MISADJUSTMENTS TROUBLESHOOTING AND REPAIRPROBLEMS SYMPTOMS ENGINE PROBLEMSSYMPTOMS TROUBLESHOOTING AND REPAIRPROBLEMS MISADJUSTMENTSPOSSIBLE AREAS OF MISADJUSTMENTS TROUBLESHOOTING AND REPAIRPROBLEMS SYMPTOMS WELDING PROBLEMSReturn to Section TOC Return to Section TOCReturn to Section TOC Return to Section TOCMATERIALS NEEDED ROTOR VOLTAGE TESTTEST DESCRIPTION TROUBLESHOOTING AND REPAIRLEAD 200A CONNECTION PROCEDUREROTOR VOLTAGE TEST continued GROUND STUDTEST DESCRIPTION FIELD DIODE BRIDGE TESTTROUBLESHOOTING AND REPAIR MATERIALS NEEDEDTROUBLESHOOTING AND REPAIR FIELD DIODE BRIDGE TEST continued+ ~ PROCEDURETEST DESCRIPTION ROTOR “FLASHING” CIRCUIT TESTTROUBLESHOOTING AND REPAIR MATERIALS NEEDED202A+ ROTOR “FLASHING” CIRCUIT TEST continued201A TROUBLESHOOTING AND REPAIRReturn to Section TOC Return to Section TOC Return to Section TOC TROUBLESHOOTING AND REPAIRROTOR “FLASHING” CIRCUIT TEST continued Return to Section TOCReturn to Section TOC Return to Section TOCReturn to Section TOC Return to Section TOCTEST DESCRIPTION ROTOR RESISTANCE TESTTROUBLESHOOTING AND REPAIR MATERIALS NEEDEDTROUBLESHOOTING AND REPAIR ROTOR RESISTANCE TEST continuedSLIP RINGS PROCEDUREROTOR RESISTANCE TEST continued CABLE TIE BRUSHESTROUBLESHOOTING AND REPAIR 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 TOCTEST DESCRIPTION ENGINE THROTTLE ADJUSTMENT TEST ROBIN/SUBARU ENGINETROUBLESHOOTING AND REPAIR MATERIALS NEEDEDPROCEDURE ENGINE THROTTLE ADJUSTMENT TEST ROBIN/SUBARU ENGINE continuedTROUBLESHOOTING AND REPAIR Return to Section TOCHIGH SPEED STOP SCREW TROUBLESHOOTING AND REPAIRENGINE THROTTLE ADJUSTMENT TEST ROBIN/SUBARU ENGINE continued THROTTLE LOCKING NUTReturn to Section TOC Return to Section TOC SCOPE SETTINGSTROUBLESHOOTING AND REPAIR Return to Master TOC Return to Master TOCTROUBLESHOOTING AND REPAIR NORMAL OPEN CIRCUIT VOLTAGE WAVEFORM 115VAC SUPPLYHIGH IDLE - NO LOAD SCOPE SETTINGSMACHINE LOADED TO 125 AMPS AT 23 VAC TYPICAL WELD OUTPUT WAVEFORMMACHINE LOADED TROUBLESHOOTING AND REPAIRTEST DESCRIPTION BRUSH REMOVAL AND REPLACEMENTTROUBLESHOOTING AND REPAIR MATERIALS NEEDEDTROUBLESHOOTING AND REPAIR BRUSH REMOVAL AND REPLACEMENT continuedCABLE TIE BRUSHES PROCEDUREF-33 TROUBLESHOOTING AND REPAIRBRUSH REMOVAL AND REPLACEMENT continued F-33Return to Section TOC Return to Section TOCReturn to Section TOC Return to Section TOCTEST DESCRIPTION RHEOSTAT REMOVAL AND REPLACEMENTTROUBLESHOOTING AND REPAIR MATERIALS NEEDEDPROCEDURE RHEOSTAT REMOVAL AND REPLACEMENT continuedTROUBLESHOOTING AND REPAIR Return to Section TOC Return to Section TOCTEST DESCRIPTION CAPACITOR AND/OR DIODE BRIDGE REMOVAL AND REPLACEMENTTROUBLESHOOTING AND REPAIR MATERIALS NEEDEDTROUBLESHOOTING AND REPAIR CAPACITOR AND/OR DIODE BRIDGE REMOVAL AND REPLACEMENT continuedPROCEDURE - CAPACITOR REMOVAL AND REPLACEMENT Attachment for 202 202A +CAPACITOR AND/OR DIODE BRIDGE REMOVAL AND REPLACEMENT continued PROCEDURE - FIELD DIODE BRIDGE REMOVAL AND REPLACEMENTTROUBLESHOOTING AND REPAIR Return to Section TOC Return to Section TOCReturn to Section TOC Return to Section TOCReturn to Section TOC Return to Section TOCTROUBLESHOOTING AND REPAIR STATOR/ROTOR REMOVAL AND REPLACEMENTINSTRUCTIONS TEST DESCRIPTIONPROCEDURE STATOR/ROTOR REMOVAL AND REPLACEMENT continuedTROUBLESHOOTING AND REPAIR GENERATORENGINEReturn to Section TOC Return to Section TOC Section TOC TROUBLESHOOTING AND REPAIRSTATOR/ROTOR REMOVAL AND REPLACEMENT continued Return to Master TOC Return to Master TOC Master TOCReturn to Section TOC Return to Section TOC Return to Section TOC TROUBLESHOOTING AND REPAIRSTATOR/ROTOR REMOVAL AND REPLACEMENT continued Return to Section TOCSTATOR/ROTOR REMOVAL AND REPLACEMENT continued STATOR REMOVAL PROCEDURETROUBLESHOOTING AND REPAIR Return to Section TOC Return to Section TOCNUTS THRU BOLTS THRU BOLTSSUPPORT TROUBLESHOOTING AND REPAIRTROUBLESHOOTING AND REPAIR ROTOR REMOVAL PROCEDUREREASSEMBLY PROCEDURE STATOR/ROTOR REMOVAL AND REPLACEMENT continuedto Section TOC TROUBLESHOOTING AND REPAIRSTATOR/ROTOR REMOVAL AND REPLACEMENT continued to Master TOCENGINE OUTPUT AUXILIARY POWER RECEPTACLE OUTPUT1RETEST AFTER REPAIR WELDER/GENERATOR OUTPUT1Return to Section TOC Return to Section TOCReturn to Section TOC Return to Section TOCReturn to Master TOC TABLE OF CONTENTS - DIAGRAM SECTIONReturn to Master TOC Return to Master TOC Return to Master TOC BULLDOGL15064 ElEcTrical DiaGramSWiriNG DiaGram - cOmplETE machiNE - l15064 WIRING DIAGRAM - BULLDOGENGINEERING CONTROLLED SchEmaTic - cOmplETE machiNE - S28101SUBJECT MANUFACTURER