Lincoln Electric SVM103-A service manual Figure F.7 Rheostat Removal

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F-25

TROUBLESHOOTING & REPAIR

RHEOSTAT REMOVAL AND REPLACEMENT

FIGURE F.7 - RHEOSTAT REMOVAL

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See Figure F.7 for steps 3 - 9.

PROCEDURE

1.Remove the spark plug wire.

2.With the 5/16” nut driver, remove the 4 sheet metal screws that hold the top cover to the control box. Remove the top cover.

3.With the small slot head screw driver, loosen the screw that holds the knob to the rheostat shaft. The shaft has a flat for locating the knob at reassembly.

4.With a 9/16” open or box end wrench, remove the nut that holds the rheostat to the control panel. Support the rheostat with your hand as you turn the nut. There is a shake-proof washer under the nut.

5.Pull the rheostat back out of the control panel and lay it out on its wires to loosen the nuts that hold them.

6.With the 5/16” open or box end wrench, remove the brass nuts from the wire termi- nals. Support the terminals as you turn the wrench to avoid ripping the terminals from their foundations. Note the wire locations for reassembly.

Note: The brass screws are double-nutted with a shake-proof star washer under the screw head.

7.To reinstall the rheostat, replace each of the brass screws. Place a shake-proof star washer under the head, insert the screw into the rheostat and tighten down one nut. Replace the appropriate wires and tighten down the second nut. Again, support the terminals as you turn the wrench to avoid ripping the terminals from their foundations.

8.Reassemble the rheostat to the front of the control panel. Line up the locating tab on the rheostat with the slot on the control panel hole.

9.Reassemble the shake-proof star washer and nut and tighten securely with the 9/16” wrench.

10.Locate the flat spot on the shaft, line up the knob locking screw, push the knob onto the shaft and tighten the screw with the small slot head screw driver.

11.Check the rheostat knob for proper rota- tion, minimum to maximum.

12.Replace the top cover of the control box and tighten the 4 sheet metal screws with the 5/16” nut driver.

POWER-ARC 4000

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Contents POWER-ARC TM4000 Safety POWER-ARCElectric Shock can kill Welding Sparks can cause fire or explosion IiiPrécautions DE Sûreté Master Table of Contents for ALL Sections Table of Contents Installation Section Installation Technical Specifications POWER-ARCSafety Precautions Location and VentilationStoring PRE-OPERATION Engine Service Welding Cable Connections Power ARCElectrical Output Connections Cable Size and LengthMachine Grounding Auxiliary Power ReceptaclesCable Installation Plugs and HAND-HELD EquipmentPremises Wiring Circuit BreakersTable A.2 Electrical Device USE with the POWER-ARC Type Common Electrical Devices Possible ConcernsTable of Contents Operation Section Operating Instructions Safety InstructionsOperation General DescriptionRecommended Applications Operational Features and ControlsDesign Features Advantages Welding CapabilityControls and Settings GENERATOR/WELDER ControlsFigure B.2 Gasoline Engine Controls Gasoline Engine ControlsEngine Operation Before Starting the EngineStarting the Engine Stopping the Engine Running the EngineBREAK-IN Period To USE the Generator AS AN Auxiliary Power Supply Generator OperationGeneral Information Table B.3 Generator Power Applications To USE the POWER-ARC 4000 for Welding Welding OperationAfter YOU Finish the Weld Material Thickness Electrode Type Size Setting Welding GuidelinesStick Welding Welding Circuit ARCElectrode 12/95 POWER-ARCFour Factors of Successful Welding Correct WAY to Strike AN ARCCorrect ARC Length Correct Welding SpeedTable of Contents Accessories OPTIONS/ACCESSORIES Lincoln Electric AccessoriesBriggs and Stratton Accessories Table of Contents Maintenance Routine and Periodic Maintenance Engine MaintenanceFigure D.2 Clean Rotating SCREEN/FINGER GUARD/DEBRIS Guard Figure D.4 SET Spark Plug GAP Table D.2 Engine Maintenance Parts GENERATOR/WELDER MaintenancePart Part Number Figure D.6. Major Component Locations Table of Contents Theory of Operation Section Theory of Operation ENGINE, EXCITATION, Rotor and StatorRotor Field Feedback and Auxiliary Power Figure E.3 Field Excitation and Auxiliary PowerAuxiliary Power Overcurrent Protection Weld Winding and ReactorTable of Contents Trouble Shooting & Repair Section Troubleshooting & Repair HOW to USE Troubleshooting GuideTroubleshooting Guide Output ProblemsOr contact your local Lincoln Local Lincoln Electric Authorized Troubleshooting & Repair Troubleshooting & Repair Engine Problems Engine Problems Welding Problems Rotor Voltage Test Test DescriptionMaterials Needed Test Procedure Ground Stud Lead 200A Connection Output PanelRotor Resistance Test Slip RingsFigure F.3 Brushes Retained with Cable TIE Cable TIE BrushesEngine Throttle Adjustment Test Frequency Counter Method MarkStrobe-tach Method Oscilloscope MethodFigure F.5 Location of Engine Throttle Adjustment NUT NUTScope Settings Normal Open Circuit Weld Voltage WaveformHigh Idle no Load Normal Open Circuit Voltage Waveform 115 VAC Supply Typical Weld Output Waveform Machine LoadedMachine Loaded to 125 Amps AT 23 VAC Brush Removal and Replacement DescriptionProcedure Figure F.6 Brushes Retained with Cable TIEProcedure Rheostat Removal and Replacement Figure F.7 Rheostat Removal Capacitor AND/OR Diode Bridge Removal Replacement Capacitor AND/OR Diode Bridge Removal and Replacement Procedure Capacitor Removal and ReplacementProcedure Diode Bridge Removal and Replacement STATOR/ROTOR Removal and Replacement InstructionsOutput Stator Removal ProcedureTIE Wrap TerminalsThru Bolts Support Nuts POWER-ARC Figure F.10 Stator END Bracket Support and THRU-BOLTSRotor Removal Procedure Reassembly ProcedureRotor THRU-BOLT Feeler Gauge RotorEngine Output Auxiliary Power Receptacle OUTPUT1Retest After Repair WELDER/GENERATOR OUTPUT1POWER-ARC Table of Contents Electrical DiagramsSection G Electrical Diagram POWER-ARCPOWER-ARC POWER-ARC