Lincoln Electric SVM197-A specs

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F-30

TROUBLESHOOTING AND REPAIR

F-30

RHEOSTAT REMOVAL AND REPLACEMENT PROCEDURE (continued)

FIGURE F.8 - RHEOSTAT REMOVAL

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See Figure F.8 for steps 3 - 9.

PROCEDURE

1.Remove the spark plug wire.

2.With the 5/16” nut driver, remove the 8 sheet metal screws that hold the top cover to the control box. Remove the top cover.

3.With the allen wrench, 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 con- trol panel and lay it out on its wires to loosen the nuts that hold them.

6.With the 11/32” 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 wash- er 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 secure- ly 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 allen wrench.

11.Check the rheostat knob for proper rotation, minimum to maximum.

12.Replace the top cover of the con- trol box and tighten the 8 sheet metal screws with the 5/16” nut dri- ver.

POWERARC® 5500

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Lincoln Electric SVM197-A service manual Rheostat Removal and Replacement Procedure

Contents

Powerarc ISAFETYi Safety Electric Shock can kill ARC Rays can burn For Electrically Iii Précautions DE Sûreté Electromagnetic Compatibility EMC Safety Master Table of Contents for ALL Sections Table of Contents Installation Section Installation Technical Specifications Powerarc Storing Safety PrecautionsLocation and Ventilation Engine Exhaust can kill PRE-OPERATION Engine Service Spark Arrester PowerArc 5500 Typical Fuel ConsumptionMuffler Deflector Honda 9 HP Welding Cable Connections Powerarc 5500 Output ConnectionsElectrical Output Connections Cable Size and Length Plugs and HAND-HELD Equipment Auxiliary Power ReceptaclesCable Installation Machine Grounding Premises Wiring Circuit Breakers Table A.2 Electrical Device USE with the Powerarc Type Common Electrical Devices Possible Concerns Powerarc Table of Contents Operation Section Operation Output Panel Controls Controls and SettingsLimitations Physical Location of Components may vary by Code No Engine Operation Gasoline Engine Controls Before Starting the Engine Starting the Engine General Information Generator OperationStopping the Engine Running the Engine Table B.3 Generator Power Applications Welding Operation Control Function / Operation Current Control Dial Material Thickness Electrode Type Size Setting Welding Guidelines What Happens in the Arc? Welding circuit for Stick shielded metal arc welding Correct Arc Length Correct Welding PositionCorrect Way to Strike An Arc Correct Welding Speed Use the following Common MetalsTypes of Welds Do the following Penetration Welding in the Vertical Position Vertical-Up Welding Vertical-Down Welding Hardfacing To Reduce Wear How to Hardface the Sharp Edge Metal to Ground WearOverhead Welding Welding Sheet Metal Welding Cast Iron Cast Iron Plate Preparation Low Hydrogen Group AWS E7018 Selecting ElectrodesHigh-Speed Group AWS E6013 Out-of-Position Group AWS E6011 Powerarc Table of Contents Accessories Section Accessories OPTIONS/ACCESSORIESLincoln Electric Accessories Table of Contents Maintenance Section Maintenance Routine and Periodic MaintenanceEngine Maintenance Engine Adjustments Figure D.3 Clean Rotating SCREEN/FINGER GUARD/DEBRIS Guard Table D.1 Engine Maintenance Parts Part Robin / Subaru Honda GENERATOR/WELDER Maintenance Do not attempt to polish slip rings while engine is running Figure D.6. Major Component Locations 1TABLE of CONTENTS-THEORY of Operation Section E-1 Theory of Operation Engine Control and IgnitionENGINE, EXCITATION, Rotor and Stator Rotor Field Feedback Auxiliary Power Return Auxiliary Power Overcurrent Protection Weld Winding and Reactor 1TABLE of Contents Troubleshooting and Repair F-1 2TROUBLESHOOTING and REPAIRF-2 HOW to USE Troubleshooting Guide Troubleshooting and Repair Output Problems Perform the Rotor and Flashing Voltage Test Troubleshooting and Repair Troubleshooting and Repair Rotor Resistance Test Engine Problems Troubleshooting and Repair Engine Throttle Adjustment Test Powerarc Test Description Materials Needed Flashing Voltage Test Procedure 14TROUBLESHOOTING and REPAIRF-14Rotor Voltage Test Procedure Lead Rotor Resistance Test Procedure Rotor Resistance Test Procedure Figure F.3 Brushes Retained with Cable TIE Powerarc Engine Throttle Adjustment Test ROBIN/SUBARU Engine Engine Throttle Adjustment Test ROBIN/SUBARU Engine High Speed Stop Screw Scope 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 Procedure Brush Removal and Replacement Procedure Powerarc Rheostat Removal and Replacement Procedure Rheostat Removal and Replacement Procedure Troubleshooting and Repair Attachment for 202A Cable Tie Capacitor Procedure Capacitor Removal and REPLACE- MentCapacitor AND/OR Diode Bridge Attachment for 201 201A Jumper Procedure Field Diode Bridge Removal and Replacement Figure F.10 Field Diode Bridge Location Powerarc STATOR/ROTOR Removal and Replacement Procedure Stator Removal Procedure STATOR/ROTOR Section TOC Rotor Removal Procedure Procedure Reactor Bolts Lead Engine Output Auxiliary Power Receptacle OUTPUT1Retest After Repair WELDER/GENERATOR OUTPUT1 Powerarc Table of Contents Diagram Section Electrical Diagrams Wiring Diagram Codes 11182, 11187, 11329 S25984 Wiring Diagram Codes 11403, 11405 S26829 Switch Wiring Diagram Power ARC Wiring Diagram Code 11404 S26830 Wiring Diagram Code 11215 S26023 Schematic -CODES 11182, 11187, 11329 S26008 S26008 Schematic Codes 11403, 11405 S26881 S26881 Schematic Code 11404 S26882 S26882