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

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F-26	TROUBLESHOOTING & REPAIR	F-26
	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 dri- ver, 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 terminals. Support the ter- minals 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-nut- ted 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 founda- tions.

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 rotation, minimum to maximum.

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

POWER-ARC 4000

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Contents POWER-ARC Safety Depends on YouSafety California Proposition 65 WarningsElectric 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 Installation Technical Specifications POWER-ARCStoring Safety PrecautionsLocation and Ventilation PRE-OPERATION Engine Service Spark Arrester Cert. Kool BoreCable Size for Electrical Output ConnectionsWelding Cable Connections 125 ampPlugs and HAND-HELD Equipment Auxiliary Power ReceptaclesMachine Grounding Premises Wiring Circuit BreakersThese Devices Without POWER-ARC Table of Contents Operation Section Operating Instructions Safety InstructionsOperation General DescriptionRecommended Applications Operational Features and ControlsDesign Features Advantages Welding CapabilityControls and Settings GENERATOR/WELDER ControlsGasoline Engine Controls 20 AMP, 120 Volt Duplex ReceptacleStarting the Engine Engine OperationBefore Starting the Engine For a HOT Engine General Information To USE the Generator AS AN Auxiliary Power SupplyGenerator Operation Table B.1 Generator Power Applications Suggested Power Applications Running Watts Start-up WattsWelding Operation Welding Guidelines Table B.2 Welding APPLICATIONS/ELECTRODE Selection GuideOperation What Happens in the Arc? Correct Welding Position Correct Arc Length Do the following PracticeUse the following Butt WeldsFillet Welds PenetrationVertical-Up Welding Vertical-Down WeldingWelding Sheet Metal Overhead WeldingHardfacing To Reduce Wear Welding Cast Iron Cast Iron Plate PreparationLow Hydrogen Group Stable-Arc E7018 High-Speed Group AWS E6013Out-of-Position Group AWS E6011 Table of Contents Accessories Section Lincoln Electric Accessories AccessoriesOPTIONS/ACCESSORIES Table of Contents Maintenance Section Engine Maintenance MaintenanceRoutine and Periodic Maintenance Engine AdjustmentsFigure D.2 Clean Rotating SCREEN/FINGER GUARD/DEBRIS Guard Table D.1 Engine Maintenance Schedule GENERATOR/WELDER Maintenance Do not attempt to polish slip rings while engine is runningFigure 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 Troubleshooting & Repair Section Troubleshooting & Repair HOW to USE Troubleshooting GuideTroubleshooting Output ProblemsVice Facility Or contact your local LincolnElectric Authorized Field Ser Field Service Facility Local Lincoln Electric AuthorizedTroubleshooting Rotor Resistance Test Engine Problems Troubleshooting Engine Throttle Adjustment Test Description This procedure takes approximately 15 minutes to performRotor Voltage Test Materials NeededTest Procedure Rotor Voltage TestThis procedure takes approximately 25 minutes to perform Rotor Resistance TestRotor Resistance Test Figure F.3 Brushes Retained with Cable TIE Engine Throttle Adjustment Test This procedure takes approximately 20 minutes to performOscilloscope Method Strobe-tach MethodFrequency Counter Method Wing NUT High Speed Stop Screw High Idle no Load Scope SettingsNormal Open Circuit Weld Voltage Waveform Normal Open Circuit Voltage Waveform 115 VAC Supply Machine Loaded to 125 Amps AT 23 VAC Typical Weld Output WaveformMachine Loaded Brush Removal and Replacement DescriptionBrush Removal and Replacement ProcedureProcedure Rheostat Removal and Replacement Figure F.7 Rheostat Removal Capacitor AND/OR Diode Bridge Removal and Replacement This procedure takes approximately 35 minutes to performProcedure Capacitor Removal and REPLACE- Ment Figure F.8 Location and Discharging the Field CapacitorProcedure Field Diode Bridge Removal and Replacement Figure F.8A Field Diode Bridge LocationInstructions STATOR/ROTOR Removal and ReplacementThis procedure takes approximately 3 hours to perform STATOR/ROTOR Removal and Replacement Troubleshooting & Repair Rotor Removal Procedure Figure F.12 Checking ROTOR-STATOR AIR GAP Engine Output Auxiliary Power Receptacle OUTPUT1Retest After Repair WELDER/GENERATOR OUTPUT1Return to Section TOC Table of Contents Diagrams Section Diagrams Wiring Diagram Power ARCDIAGRAMSG-3 DIAGRAMSG-4 Dimension Print Power ARC Return to Section TOC SVM Error Reporting Form