Lincoln Electric IDEALARC DC-1000 Service Manual page 99

F-65
MAIN TRANSFORMER REMOVAL AND INSTALLATION (continued)
MAIN TRANSFORMER DISASSEMBLY
1. Perform Removal and Reassembly of Lift
Bale Procedure.
2. Remove lead #271 from resistor R3 (located
near the input contactor).
3. Separate the in-line connectors from leads #211
and #212. See Figure F.21.
4. Remove lead #256 from the choke thermostat.
5. Remove lead #220 from the reed switch (3CR).
6. Cut any necessary cable ties or restraints and
clear the leads necessary for the removal of the
top transformer iron.
7. Using a 3/8" socket wrench, remove two screws
mounting the input contactor bracket to the
case back assembly. With leads attached, care-
fully pull assembly up and out of the way. Set
assembly aside.
8. Using a 1/2" socket wrench, move 16 screws (8
on each side) from the transformer side brack-
ets. Taking note of placement, remove the four
brackets and two bottom spacers. See Figure
F.26.
9. Using a 3/4" wrench, remove the six nuts and
lock washers from the transformer threaded
rods. It may be necessary to hold the threaded
rods to keep them from turning.
10. Using a hoist, carefully lift the top iron from the
assembly. Note the placement of shims and
insulators.
NOTE: Some prying and jolting may be necessary
to free the iron from the coils. Replace any
coils that may be faulty. If any heavy alu-
minum secondary coils are to be replaced,
identify and label all leads to the trans-
former. The leads will have to be cut and
then TIG welded upon reassembly.
TROUBLESHOOTING AND REPAIR
IDEALARC
COIL REMOVAL AND REPLACEMENT
1. Label and disconnect leads to the coils that are
being removed or replaced (see Wiring
Diagram).
2. Refer to Figure F.26 for proper coil locations
(top, bottom, left, right, and center) of primary
and secondary coils. If secondary coils are to
be replaced, it will be necessary to cut the leads
and TIG weld upon reassembly.
3. Remove the coils:
a. Some prying and jolting may be necessary
to free the coils from the iron.
b. Note placement of insulation and wedges
for reassembly (especially primary coil to
lamination insulation and secondary to pri-
mary insulation).
4. Replace the coils:
a. Be sure to replace all insulation and
wedges that were removed (lamination to
coils, and primary to secondary coils).
b. Using a high temperature industrial epoxy,
such as Lincoln E1603, glue the coils in
place by applying the epoxy to the coil
sides along the lamination, cell insulation,
and wedges.
c. Glue the secondary coils in place from the
iron to the coil sides.
5. Re-TIG weld the secondary coil leads (if previ-
ously cut).
6. When reconnecting any aluminum leads, apply
a thin layer of Dow Corning 340 Heat Sink
Compound to mating surfaces.
® DC-1000
F-65