Manuals / Lincoln Electric / Lawn and Garden / Portable Generator

Lincoln Electric SVM208-A Troubleshooting And Repair, F-11, Problems Symptoms, Welding Problems

Models: SVM208-A

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F-11

F-11	TROUBLESHOOTING AND REPAIR	F-11

Observe Safety Guidelines detailed in the beginning of this manual.

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PROBLEMS

(SYMPTOMS)

The welding arc is “cold.” The engine runs normally (3700 RPM, no load). Auxiliary power is func- tioning normally.

POSSIBLE AREAS OF

MISADJUSTMENT(S)

WELDING PROBLEMS

1.Check for loose or faulty con- nections at the weld output terminals and welding cable con- nections.

2.The welding cable may be too long or coiled, causing an exces- sive voltage drop.

RECOMMENDED

COURSE OF ACTION

1.Check for the correct open cir- cuit voltage (OCV) at the welder output terminals – 66 VAC is normal.

If the correct voltage is present at the output terminals, check for loose connections on the heavy current-carrying leads inside the BULLDOG 140. See the Wiring Diagram.

2.If the OCV is low at the welder output terminals, perform

Engine Throttle Adjustment Test .

3.Check for shorted or grounded windings in the reactor (L1) and also in the main stator. See the Wiring Diagram.

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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, F-11, Return to Master TOC Return to Master TOC Return to Master TOC

Contents

View Safety Info View Safety Info View Safety Info View Safety Info Safety Depends on YouJanuary SERVICE MANUALCALIFORNIA PROPOSITION 65 WARNINGS SAFETYFOR ENGINE powered equipment ELECTRIC AND MAGNETIC FIELDS may be dangerousFUMES AND GASES ELECTRIC SHOCK can killARC RAYS can burn can be dangerousSAFETY FOR ELECTRICALLY powered equipmentWELDING and CUTTING SPARKS can cause fire or explosion CYLINDER may explode if damagedReturn to Master TOC PRÉCAUTIONS DE SÛRETÉSAFETY Return to Master TOC Return to Master TOC Return to Master TOCReturn to Master TOC Return to Master TOC Return to Master TOC SAFETYElectromagnetic Compatibility EMC Installation and UseReturn to Master TOC Return to Master TOC Return to Master TOC SAFETYMaintenance of the Welding Equipment Electromagnetic Compatibility EMCBULLDOG I - MASTER TABLE OF CONTENTS FOR ALL SECTIONSSafety PageBULLDOG TABLE OF CONTENTS - INSTALLATION SECTIONReturn to Master TOC Return to Master TOC Return to Master TOC Return to Master TOCAC Auxiliary Power INSTALLATIONTECHNICAL SPECIFICATIONS - Bulldog 140 K2708-1 DisplacementINSTALLATION SAFETY PRECAUTIONSLOCATION AND VENTILATION STORINGFUEL PRE-OPERATION ENGINE SERVICESTACKING TILTINGBulldog 140 OUTPUT CONNECTIONS ELECTRICAL OUTPUT CONNEC- TIONSWELDING CABLE CONNECTIONS TABLE A.1 RECOMMENDED WELDING CABLE SIZE AND LENGTHINSTALLATION AUXILIARY POWER RECEPTACLESELECTRICAL CONNECTIONS PLUGS AND HAND-HELD EQUIPMENTReturn to Section TOC Return to Section TOC Return to Section TOC PREMISES WIRINGCIRCUIT BREAKERS INSTALLATIONReturn to Master TOC Return to Master TOC Return to Master TOC INSTALLATIONReturn to Section TOC Return to Section TOC Return to Section TOC Return to Section TOCBULLDOG TABLE OF CONTENTS - OPERATION SECTIONReturn to Master TOC Return to Master TOC Return to Master TOC Return to Master TOCGENERAL DESCRIPTION SAFETY INSTRUCTIONSOPERATIONAL FEATURES AND CONTROLS OPERATIONOUTPUT PANEL CONTROLS CONTROLS AND SETTINGSLIMITATIONS WELDER/GENERATOR CONTROLSReturn to Section TOC Return to Section TOC Return to Section TOC ENGINE OPERATIONGASOLINE ENGINE CONTROLS OPERATIONReturn to Section TOC Return to Section TOC Return to Section TOC BEFORE STARTING THE ENGINESTARTING THE ENGINE OPERATIONBREAK-IN PERIOD GENERATOR OPERATIONSTOPPING THE ENGINE RUNNING THE ENGINEReturn to Section TOC Return to Section TOC Return to Section TOC GENERATOR POWER APPLICATIONSSuggested Power Applications OPERATIONOPERATION WELDING OPERATIONCONTROL FUNCTION / OPERATION “Current Control Dial”Learning To Stick Weld Semi-automatic, Wire Welding With a Lincoln Wire Feeder / WelderWELDING GUIDELINES Stick WeldingB-10 What Happens in the Arc?OPERATION B-104. The Correct Welding Speed 1. The Correct Welding Position2. The Correct Way to Strike An Arc 3. The Correct Arc LengthOPERATION PRACTICETypes of Welds Common MetalsOPERATION Good1/2 Poor 12mm1/4 6mm 1/4 6mm 1/8 3.2mmOPERATION Veryshort 30-40How to Hardface the Sharp Edge Metal to Ground Wear Side ViewEnd View 3030When breaking the weld stays on one piece White brittlecold cast ironB-17 MotionsSelecting Electrodes OPERATIONReturn to Section TOC Return to Section TOCReturn to Section TOC Return to Section TOCBULLDOG TABLE OF CONTENTS - ACCESSORIES SECTIONReturn to Master TOC Return to Master TOC Return to Master TOC Return to Master TOCReturn to Section TOC Return to Section TOC Return to Section TOC ACCESSORIESOPTIONS/ACCESSORIES LINCOLN ELECTRIC ACCESSORIESBULLDOG TABLE OF CONTENTS - MAINTENANCE SECTIONReturn to Master TOC Return to Master TOC Return to Master TOC Return to Master TOCReturn to Section TOC MAINTENANCEReturn to Section TOC Return to Section TOCLOCATION ROUTINE AND PERIODIC MAINTENANCEENGINE MAINTENANCE FIGURE D.1 - OIL DRAIN AND REFILLFIGURE D.3 - CLEAN COOLING SYSTEM ENGINE ADJUSTMENTSMAINTENANCE FIGURE D.2 - CLEAN AREAMAINTENANCE TABLE D.1 ENGINE MAINTENANCE PARTSSPARK PLUG SERVICE OPERATIONAL CLEARANCE1. BRUSH, BRUSH HOLDER ASSEMBLY 2. BEARING BRACKET END COVER GENERATOR/WELDER MAINTENANCEFIGURE D.6. - BRUSH REMOVAL AND REPLACEMENT MAINTENANCE3. STATOR ASSEMBLY FIGURE D.7. - MAJOR COMPONENT LOCATIONSMAINTENANCE 1. CRADLE ASSEMBLY 2. ROTOR, BLOWER, AND BEARING ASSEMBLYReturn to Section TOC Return to Section TOCReturn to Section TOC Return to Section TOCFIGURE E.1 BLOCK LOGIC DIAGRAM E-1 TABLE OF CONTENTS-THEORY OF OPERATION SECTION E-1ENGINE REACTOR OUTPUT TERMINALS STATOR ROTOR STATORReturn to Master TOC to Master TOC THEORY OF OPERATIONENGINE, EXCITATION, ROTOR AND STATOR FIGURE E.2 - ENGINE, EXCITATION, ROTOR AND STATORReturn to Master TOC to Master TOC ROTOR FIELD FEEDBACK AND AUXILIARY POWERFIGURE E.3 - ROTOR FIELD FEEDBACK AND AUXILIARY POWER THEORY OF OPERATIONReturn WELD WINDING AND REACTORTHEORY OF OPERATION Return to Master TOC to Master TOCBULLDOG F-1 TABLE OF CONTENTS - TROUBLESHOOTING AND REPAIR F-1Return to Master TOC Return to Master TOC Return to Master TOC Return to Master TOCReturn to Section TOC TROUBLESHOOTING AND REPAIRHOW TO USE TROUBLESHOOTING GUIDE Step 1. LOCATE PROBLEM SYMPTOMReturn to Master TOC PC BOARD TROUBLESHOOTING PROCEDURESTROUBLESHOOTING AND REPAIR Return to Section Return to Section TOCMISADJUSTMENTS TROUBLESHOOTING AND REPAIRPROBLEMS SYMPTOMSMISADJUSTMENTS TROUBLESHOOTING AND REPAIRPROBLEMS SYMPTOMSOUTPUT PROBLEMS TROUBLESHOOTING AND REPAIRPROBLEMS SYMPTOMS POSSIBLE AREAS OF MISADJUSTMENTSOUTPUT PROBLEMS TROUBLESHOOTING AND REPAIRPROBLEMS SYMPTOMS POSSIBLE AREAS OF MISADJUSTMENTSOUTPUT PROBLEMS TROUBLESHOOTING AND REPAIRPROBLEMS SYMPTOMS POSSIBLE AREAS OF MISADJUSTMENTSENGINE PROBLEMS TROUBLESHOOTING AND REPAIRPROBLEMS SYMPTOMS POSSIBLE AREAS OF MISADJUSTMENTSMISADJUSTMENTS TROUBLESHOOTING AND REPAIRPROBLEMS SYMPTOMSWELDING PROBLEMS TROUBLESHOOTING AND REPAIRPROBLEMS SYMPTOMS POSSIBLE AREAS OF MISADJUSTMENTSReturn to Section TOC Return to Section TOCReturn to Section TOC Return to Section TOCTROUBLESHOOTING AND REPAIR ROTOR VOLTAGE TESTTEST DESCRIPTION MATERIALS NEEDEDGROUND STUD PROCEDUREROTOR VOLTAGE TEST continued LEAD 200A CONNECTIONMATERIALS NEEDED FIELD DIODE BRIDGE TESTTROUBLESHOOTING AND REPAIR TEST DESCRIPTIONPROCEDURE FIELD DIODE BRIDGE TEST continued+ ~ TROUBLESHOOTING AND REPAIRMATERIALS NEEDED ROTOR “FLASHING” CIRCUIT TESTTROUBLESHOOTING AND REPAIR TEST DESCRIPTIONTROUBLESHOOTING AND REPAIR ROTOR “FLASHING” CIRCUIT TEST continued201A 202A+Return to Section TOC TROUBLESHOOTING AND REPAIRROTOR “FLASHING” CIRCUIT 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 TOCMATERIALS NEEDED ROTOR RESISTANCE TESTTROUBLESHOOTING AND REPAIR TEST DESCRIPTIONPROCEDURE ROTOR RESISTANCE TEST continuedSLIP RINGS TROUBLESHOOTING AND REPAIRReturn to Section TOC Return to Section TOC Return to Section TOC CABLE TIE BRUSHESTROUBLESHOOTING AND REPAIR ROTOR RESISTANCE TEST continuedReturn to Section TOC Return to Section TOCReturn to Section TOC Return to Section TOCMATERIALS NEEDED ENGINE THROTTLE ADJUSTMENT TEST ROBIN/SUBARU ENGINETROUBLESHOOTING AND REPAIR TEST DESCRIPTIONReturn to Section TOC ENGINE THROTTLE ADJUSTMENT TEST ROBIN/SUBARU ENGINE continuedTROUBLESHOOTING AND REPAIR PROCEDURETHROTTLE LOCKING NUT TROUBLESHOOTING AND REPAIRENGINE THROTTLE ADJUSTMENT TEST ROBIN/SUBARU ENGINE continued HIGH SPEED STOP SCREWReturn to Master TOC Return to Master TOC SCOPE SETTINGSTROUBLESHOOTING AND REPAIR Return to Section TOC Return to Section TOCSCOPE SETTINGS NORMAL OPEN CIRCUIT VOLTAGE WAVEFORM 115VAC SUPPLYHIGH IDLE - NO LOAD TROUBLESHOOTING AND REPAIRTROUBLESHOOTING AND REPAIR TYPICAL WELD OUTPUT WAVEFORMMACHINE LOADED MACHINE LOADED TO 125 AMPS AT 23 VACMATERIALS NEEDED BRUSH REMOVAL AND REPLACEMENTTROUBLESHOOTING AND REPAIR TEST DESCRIPTIONPROCEDURE BRUSH REMOVAL AND REPLACEMENT continuedCABLE TIE BRUSHES TROUBLESHOOTING AND REPAIRF-33 TROUBLESHOOTING AND REPAIRBRUSH REMOVAL AND REPLACEMENT continued F-33Return to Section TOC Return to Section TOCReturn to Section TOC Return to Section TOCMATERIALS NEEDED RHEOSTAT REMOVAL AND REPLACEMENTTROUBLESHOOTING AND REPAIR TEST DESCRIPTIONReturn to Section TOC Return to Section TOC RHEOSTAT REMOVAL AND REPLACEMENT continuedTROUBLESHOOTING AND REPAIR PROCEDUREMATERIALS NEEDED CAPACITOR AND/OR DIODE BRIDGE REMOVAL AND REPLACEMENTTROUBLESHOOTING AND REPAIR TEST DESCRIPTIONAttachment for 202 202A + CAPACITOR AND/OR DIODE BRIDGE REMOVAL AND REPLACEMENT continuedPROCEDURE - CAPACITOR REMOVAL AND REPLACEMENT TROUBLESHOOTING AND REPAIRReturn to Section TOC Return to Section TOC PROCEDURE - FIELD DIODE BRIDGE REMOVAL AND REPLACEMENTTROUBLESHOOTING AND REPAIR CAPACITOR AND/OR DIODE BRIDGE REMOVAL AND REPLACEMENT continuedReturn to Section TOC Return to Section TOCReturn to Section TOC Return to Section TOCTEST DESCRIPTION STATOR/ROTOR REMOVAL AND REPLACEMENTINSTRUCTIONS TROUBLESHOOTING AND REPAIRGENERATORENGINE STATOR/ROTOR REMOVAL AND REPLACEMENT continuedTROUBLESHOOTING AND REPAIR PROCEDUREReturn to Master TOC Return to Master TOC Master TOC TROUBLESHOOTING AND REPAIRSTATOR/ROTOR REMOVAL AND REPLACEMENT continued Return to Section TOC Return to Section TOC Section TOCReturn to Section TOC TROUBLESHOOTING AND REPAIRSTATOR/ROTOR REMOVAL AND REPLACEMENT continued Return to Section TOC Return to Section TOC Return to Section TOCReturn to Section TOC Return to Section TOC STATOR REMOVAL PROCEDURETROUBLESHOOTING AND REPAIR STATOR/ROTOR REMOVAL AND REPLACEMENT continuedTROUBLESHOOTING AND REPAIR THRU BOLTS THRU BOLTSSUPPORT NUTSSTATOR/ROTOR REMOVAL AND REPLACEMENT continued ROTOR REMOVAL PROCEDUREREASSEMBLY PROCEDURE TROUBLESHOOTING AND REPAIRto Master TOC TROUBLESHOOTING AND REPAIRSTATOR/ROTOR REMOVAL AND REPLACEMENT continued to Section TOCWELDER/GENERATOR OUTPUT1 AUXILIARY POWER RECEPTACLE OUTPUT1RETEST AFTER REPAIR ENGINE OUTPUTReturn to Section TOC Return to Section TOCReturn to Section TOC Return to Section TOCBULLDOG TABLE OF CONTENTS - DIAGRAM SECTIONReturn to Master TOC Return to Master TOC Return to Master TOC Return to Master TOCWIRING DIAGRAM - BULLDOG ElEcTrical DiaGramSWiriNG DiaGram - cOmplETE machiNE - l15064 L15064MANUFACTURER SchEmaTic - cOmplETE machiNE - S28101SUBJECT ENGINEERING CONTROLLED