Tranz4mr’s KW Page

 
 

KW Checkout

  1. 1. UNPLUG THE POWER CORD FROM THE WALL OUTLET

  2. 2. Checkout the Bakelite Case for cracks & broken handles. Handles are expensive to replace. Cases are only available used.

  3. 3. Turn each of the 6 terminal Lugs until it’s tight.  If it turns past tight then the terminal needs to be replaced.

  4. 4. Carefully check the Power Cord for cracks and or missing bits of Insulation.

  5. 5. If the cord is good set the 2 handles to the ZERO position.

  6. 6. Plug the Cord into a wall outlet.

  7. 7. Does it make a loud Hum? Fix it Here.

  8. 8. Connect an AC Voltmeter to terminals A and U.

  9. 9. Slowly rotate the A handle while watching the meter. The voltage should start at 4 to 6 volts and rise slowly and steadily up to between 17.5 and 18 volts. The starting and final voltage depends on your home power voltage and varies by neighborhood. If the voltage is not steady or out of range you might have a problem.

  10. 10. Test the whistle circuit and compensation winding. With the A handle all the way up watch the AC voltage while slowly pushing the Whistle lever towards the A side. The voltage should increase by 5 volts and hold there until you release the whistle switch. If the voltage does not stay steady than the switch needs to be cleaned or replaced.

  11. 11. Test the direction button. With the A Handle all the way up watch the AC voltage while pushing  the  A “Direction” button down. The voltage should drop quickly to near zero volts until you release the direction switch. On release the voltage should return to where it was initially. If the voltage does not drop and then return on release than the switch needs to be cleaned.

  12. 12. Did the Whistle/Direction switch return to the center position when released? If it didn’t return to center then it needs to be cleaned, lubricated or replaced.

  13. 13. Connect the AC Voltmeter to Terminals D and U. Voltage should read about 18V. If not there is most likely a broken wire on the back of the terminal.

  14. 14. Connect the AC Voltmeter to Terminals C and U. Voltage should read about 18V. If not there is most likely a broken wire on the back of the terminal.

  15. 15. Connect the AC Voltmeter to Terminals C and D. Voltage should read about 14V. If not there is most likely a broken wire on the back of the terminal.

  16. 16. To test the Circuit Breaker set the A and B handles back to zero

  17. 17. Short across the terminals A and U with a screwdriver shaft.

  18. 18. Slowly rotate the A handle. The Circuit Breaker should trip within a second or so and the red light should come on.

  19. 19. Set the A handle back to zero and remove the short.  The red light should go out. Replace the Circuit Breaker if it doesn’t trip or it doesn’t reset. Repeat steps 16 through 19 for the B handle.

  20. 20. UNPLUG THE POWER CORD FROM THE WALL OUTLET

  1. 1. Verify that the Power Cord is unplugged!

  2. 2. Remove the top B handle by grabbing it at the center and pulling straight up while gently rocking side to side.

  3. 3. Remove the aluminum disc and the second A handle by lifting straight up.

  4. 4. Remove the 4 Phillips Head Screws that hold the KW top cover on.

  5. 5. Remove the KW top cover.

  1. 1. Check that the 2 carbon rollers are in good shape and roll easily. No flat spots or chips either! If any are bad or worn out replace them.

  2. 2. Check for loose solder joints especially on the larger wires. If they are loose re-solder them.

  3. 3. Check for loose wires. Especially the 4 that attach to the back of the terminals A, B, C and D.

  4. 4.Check that the two U terminals are attached to the brass strip. 

  5. 5. Check for wires that are burned or where insulation is falling off. Replace the insulation with shrink tube or better yet replace the wire.

  6. 6. Check the rectifier disc and the insulation washers. Are they burned, melted or loose? If so replace the disc and washer or replace it all with a new diode.

  7. 7. Replace the power cord if it has cracks, is missing insulation or the plug is bad.

  8. 8. Remove the spring connecting the two whistle switches. Clean the 2 rotating whistle switches with CRC QD Contact Cleaner whether they need it or not. Get it at Home Depot in the Electrical section.

  9. 9. Check that the two Whistle switches stop on the Bakelite studs molded into the bakelite top plate. These studs can crack off. If one is cracked off they can be replaced by drilling and tapping a 1/4” stud into the top plate. Put the whistle spring back on.

External Inspection

 

Remove the Cover

 

Internal Inspection