Lincoln Electric SVM103-C service manual Rheostat Removal and Replacement, Description

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F-25	TROUBLESHOOTING & REPAIR	F-25
	TROUBLESHOOTING & REPAIR

RHEOSTAT REMOVAL AND REPLACEMENT

WARNING

Service and repair should be performed by only Lincoln Electric factory trained personnel. Unauthorized repairs performed on this equipment may result in danger to the technician or machine operator and will invalidate your factory warranty. For your safety and to avoid electrical shock, please observe all safety notes and precautions detailed throughout this manual.

If for any reason you do not understand the test procedures or are unable to perform the test/repairs safely, contact the Lincoln Electric Service Department for electrical troubleshooting assistance before you proceed. Call 1-800—833-9353 (WELD).

DESCRIPTION

The following procedure will aid the technician in accessing and removing the output control rheostat for main- tenance or replacement.

MATERIALS NEEDED

5/16” Nut driver

Small slot head screw driver 9/16” Open or box end wrench 5/16” Open or box end wrench Needle nose pliers

Wiring Diagram

This procedure takes approximately 25 minutes to perform.

POWER-ARC 4000

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Contents Safety Depends on You POWER-ARCCalifornia Proposition 65 Warnings SafetyElectric Shock can kill Welding Sparks can cause fire or explosion Précautions DE Sûreté Master Table of Contents for ALL Sections Table of Contents Installation Section Technical Specifications POWER-ARC InstallationLocation and Ventilation Safety PrecautionsStoring PRE-OPERATION Engine Service Cert. Kool Bore Spark ArresterWelding Cable Connections Electrical Output ConnectionsCable Size for 125 ampMachine Grounding Auxiliary Power ReceptaclesPlugs and HAND-HELD Equipment Circuit Breakers Premises WiringThese Devices Without POWER-ARC Table of Contents Operation Section Operation Safety InstructionsOperating Instructions General DescriptionDesign Features Advantages Operational Features and ControlsRecommended Applications Welding CapabilityGENERATOR/WELDER Controls Controls and Settings20 AMP, 120 Volt Duplex Receptacle Gasoline Engine ControlsBefore Starting the Engine Engine OperationStarting the Engine For a HOT Engine Generator Operation To USE the Generator AS AN Auxiliary Power SupplyGeneral Information Suggested Power Applications Running Watts Start-up Watts Table B.1 Generator Power ApplicationsWelding Operation Table B.2 Welding APPLICATIONS/ELECTRODE Selection Guide Welding GuidelinesOperation What Happens in the Arc? Correct Welding Position Correct Arc Length Use the following PracticeDo the following Butt WeldsPenetration Fillet WeldsVertical-Down Welding Vertical-Up WeldingHardfacing To Reduce Wear Overhead WeldingWelding Sheet Metal Cast Iron Plate Preparation Welding Cast IronOut-of-Position Group AWS E6011 High-Speed Group AWS E6013Low Hydrogen Group Stable-Arc E7018 Table of Contents Accessories Section OPTIONS/ACCESSORIES AccessoriesLincoln Electric Accessories Table of Contents Maintenance Section Routine and Periodic Maintenance MaintenanceEngine Maintenance Engine AdjustmentsFigure D.2 Clean Rotating SCREEN/FINGER GUARD/DEBRIS Guard Table D.1 Engine Maintenance Schedule Do not attempt to polish slip rings while engine is running GENERATOR/WELDER MaintenanceFigure D.6. Major Component Locations Table of Contents Theory of Operation Section ENGINE, EXCITATION, Rotor and Stator Theory of OperationFigure E.3 Field Excitation and Auxiliary Power Rotor Field Feedback and Auxiliary PowerWeld Winding and Reactor Auxiliary Power Overcurrent ProtectionTable of Contents Troubleshooting & Repair Section HOW to USE Troubleshooting Guide Troubleshooting & RepairOutput Problems TroubleshootingElectric Authorized Field Ser Or contact your local LincolnVice Facility Local Lincoln Electric Authorized Field Service FacilityTroubleshooting Rotor Resistance Test Engine Problems Troubleshooting Engine Throttle Adjustment Rotor Voltage Test This procedure takes approximately 15 minutes to performTest Description Materials NeededRotor Voltage Test Test ProcedureRotor Resistance Test This procedure takes approximately 25 minutes to performRotor Resistance Test Figure F.3 Brushes Retained with Cable TIE This procedure takes approximately 20 minutes to perform Engine Throttle Adjustment TestFrequency Counter Method Strobe-tach MethodOscilloscope Method Wing NUT High Speed Stop Screw Normal Open Circuit Weld Voltage Waveform Scope SettingsHigh Idle no Load Normal Open Circuit Voltage Waveform 115 VAC Supply Machine Loaded Typical Weld Output WaveformMachine Loaded to 125 Amps AT 23 VAC Description Brush Removal and ReplacementProcedure Brush Removal and ReplacementProcedure Rheostat Removal and Replacement Figure F.7 Rheostat Removal This procedure takes approximately 35 minutes to perform Capacitor AND/OR Diode Bridge Removal and ReplacementFigure F.8 Location and Discharging the Field Capacitor Procedure Capacitor Removal and REPLACE- MentFigure F.8A Field Diode Bridge Location Procedure Field Diode Bridge Removal and ReplacementThis procedure takes approximately 3 hours to perform STATOR/ROTOR Removal and ReplacementInstructions STATOR/ROTOR Removal and Replacement Troubleshooting & Repair Rotor Removal Procedure Figure F.12 Checking ROTOR-STATOR AIR GAP Retest After Repair Auxiliary Power Receptacle OUTPUT1Engine Output WELDER/GENERATOR OUTPUT1Return to Section TOC Table of Contents Diagrams Section Wiring Diagram Power ARC DiagramsDIAGRAMSG-3 DIAGRAMSG-4 Dimension Print Power ARC Return to Section TOC SVM Error Reporting Form