Lincoln Electric SVM103-C service manual Procedure Field Diode Bridge Removal and Replacement

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F-29	TROUBLESHOOTING & REPAIR	F-29
	TROUBLESHOOTING & REPAIR

CAPACITOR AND/OR DIODE BRIDGE REMOVAL AND REPLACEMENT

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FIGURE F.8A - FIELD DIODE BRIDGE LOCATION

200 (Red)

7A	+

Feild Diode Bridge

201 (Black)	9A	Field Diode Bridge
201B (Black)		Field Diode Bridge
201B (Black)
	–

PROCEDURE - FIELD DIODE BRIDGE REMOVAL AND REPLACEMENT

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1.Remove the engine spark plug wire.

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

3.With the 5/16” nut driver and wrench remove the screws that hold the control panel in place. Move the panel aside as far as the leads will allow.

4.Discharge the field capacitor by connecting the jumper wire clips on the black and the red wire terminals on the top of the capacitor. See Figure F.8 for location. Leave the clips on for at least 5 seconds, then remove.

5.The field diode bridge is mounted to the sheet metal just above the capacitor. See Figure F.8A. Remove it using the slot head screw driver.

6.With the needle nose pliers, gently remove the wires from the diode bridge.

7.Replace the wires to their appropri- ate locations on the new diode bridge:

Lead 200 attached to the positive (+) terminal. Depending on the bridge used, this corner may be beveled and/or marked with a + sign.

Lead 201 and 201B are piggy-backed on the negative (–) terminal, which will always be located diagonally across from the positive (+) terminal.

Leads 9A and 7A are attached to the AC side of the bridge and are attached to the other two corner terminals. Either lead can go on either terminal.

8.Mount the field diode bridge using the screw. Use the slot head screw- driver.

9.Check that the leads are not grounded and for clearance and tightness.

10.Replace the control panel and tighten the sheet metal screws with the 5/16” nut driver and 5/16” wrench.

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

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 InstallationStoring Safety PrecautionsLocation and Ventilation PRE-OPERATION Engine Service Cert. Kool Bore Spark ArresterWelding Cable Connections Electrical Output ConnectionsCable Size for 125 ampPlugs and HAND-HELD Equipment Auxiliary Power ReceptaclesMachine Grounding 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 ControlsStarting the Engine Engine OperationBefore Starting the Engine For a HOT Engine General Information To USE the Generator AS AN Auxiliary Power SupplyGenerator Operation 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 WeldingWelding Sheet Metal Overhead WeldingHardfacing To Reduce Wear Cast Iron Plate Preparation Welding Cast IronLow 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 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 TroubleshootingVice Facility Or contact your local LincolnElectric Authorized Field Ser 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 TestOscilloscope 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 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 ReplacementInstructions 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 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