Lincoln Electric SVM192-A service manual Engine and Rotor Removal Procedure

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F-49

TROUBLESHOOTING AND REPAIR

F-49

ENGINE/ROTOR REMOVAL AND REPLACEMENT (continued)

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ENGINE AND ROTOR REMOVAL

PROCEDURE

1. Refer to Figure F.12 for component locations.

2. Remove the engine spark plug wires.

3. With a 5/16” nut driver, remove the 6 sheet metal screws from the case top.

4. Remove the rubber gasket (cover seal) from the lift bail.

5. Remove the fuel cap. The rubber gasket for

the fill tube will come off with the case top.

6. Remove the case top, the reinstall the fuel cap.

7. WIth the 5/16” nut driver, remove the 5 screws holding the right case side and the 5 screws holding the left case side.

8. Remove the case sides by lifting up and out.

9. WIth a 3/8” wrench, remove the battery cover.

10. Disconnect the negative battery cable, then the positive battery cable. BE SURE TO DIS-

CONNECT THE NEGATIVE BATTERY CABLE FIRST. Remove the battery and set it aside.

11. With the diagonal cutters, cut the cable ties around the leads from the starter solenoid and disconnect the leads. Remove lead 209A from the harness bundle.

12. Disconnect the large black plug in front of the fuel tank spout.

13. With the 3/8” wrench, remove the cowling cov- ers at the rear on the stator, both sides of the machine.

14. WIth the 3/8” wrench, remove the two screws that hold the vertical fan baffle in place. Slide the baffle forward toward the rectifier bridge heat sink assembly.

15. Hold the rotor shaft with locking pliers and unscrew the blower fan. Turn the fan counter- clockwise. You do not need to remove the fan from the machine, but be sure it is completely unscrewed from the rotor shaft.

15.With a 1/4” nut driver, disconnect the engine choke cable from the engine. Mark the loca- tion of the retainer for reassembly. The other end can remain connected.

16.Disconnect the idle linkage by unsnapping the plastic clip at the engine end of the idler rod. Snap the clip back onto the rod to avoid losing it; remove the rod for reassembly.

17.Disconnect the fuel line from the fuel tank. Plug the hose and also plug the connection at the fuel tank to prevent the escape of gasoline fumes.

18.Cut the cable ties and remove leads 224C and 210 from the oil pressure switch.

19.With a 9/16” wrenches, remove the ground lead from the right engine foot mounting bolt.

20.With a 7/16” wrench, remove the brush holder bracket and leads #219 & 200A from the sta- tor frame.

21.Support the engine with a chain hoist. Lift bails are provided on the top of the engine for this purpose.

22.With a 9/16” wrench, remove the right and left engine foot mounting bolts.

23.With the 9/16” wrench, remove the four bolts that hold the stator to the engine. There is one lock washer per bolt.

24.With the chain hoist, unweight the engine gen- tly. Use a pry bar to carefully pry between the engine and the stator frame in order to unseat the bearing on the end of the rotor shaft. Separate the engine and rotor from the stator frame, supporting the rotor by hand to prevent damage to the rotor core.

25.Move the engine and rotor assembly to a bench. The engine is off balance with the rotor still attached; therefore, support the end of the rotor with a wooden two-by-four before unhooking the chain hoist.

EAGLE™ 10,000

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Contents Eagle 10,000 Eagle 10,000 ISAFETYiElectric Shock can kill ARC Rays can burn SafetyFumes and Gases Can be dangerousWelding Cutting Powered equipmentCylinder may explode Sparks can cause fire or If damaged ExplosionSûreté Pour Soudage a L’Arc Précautions DE SûretéMaster Table of Contents for ALL Sections Table of Contents Installation Section Technical Specifications Eagle 10,000 K2343-1,K2343-2 InstallationHeight Width Depth Weight Machine Grounding Safety PrecautionsSpark Arrester TowingFuel Gasoline Fuel only Vehicle MountingFollow vehicle manufacturer’s instructions Do not overfill tank, fuel expansion may cause overflowAngle of Operation Additional Safety Precautions High Altitude OperationLifting Location / VentilationAdditional Safety Precautions Connection of Lincoln Electric Wire FeedersInstructions Welder Operation120/240 Volt Dual Voltage Receptacle Auxiliary PowerDuplex Receptacles Motor StartingThese Devices Without Electrical Device USE with the Eagle 10,000Additional Resistive Type LoadsSimultaneous Welding and Power Auxiliary Power While WeldingStandby Power Connections Connection diagram shown Eagle 10,000Figure A.1 Connection of Eagle 10,000 to Premises WiringTable of Contents Operation Section Operation Engine SwitchGeneral Description Welder Controls Function and OperationOPERATIONB-3 Range SwitchEagle 10,000 Approximate Fuel Consumption Control DialBREAK-IN Period STARTING/SHUTDOWN InstructionsStarting the Engine Stopping the EngineWelding Process Wire Feed Welding ProcessesTIG Constant Current Welding ARC GougingSummary of Welding Processes Typical Current Ranges 1 for Tungsten ELECTRODES2Table of Contents Accessories Section Optional Equipment Field Installed AccessoriesK1745-1 GAS Cylinder Holder Recommended Equipment Wire FeedPlasma Cutting Stick TIG WeldingEagle 10,000 Table of Contents Maintenance Section Safety Precautions MaintenanceEngine OIL Change Engine OIL Refill CapacitiesOIL Filter Change AIR Cleaner and Other MaintenanceEngine Adjustments Figure D.1 Major Component Locations Eagle 10,000 1TABLE of CONTENTS-THEORY of Operation Section E-1 Theory of Operation BATTERY, STARTER, ENGINE, ROTOR, STATOR, and Idler SolenoidFigure E.3 Rotor Field Feedback and Auxiliary Power Rotor Field Feedback Auxiliary PowerOutput BRIDGE, CHOKE, and Output Terminals Weld WINDING, REACTOR, and Range Switch1TABLE of Contents Troubleshooting and Repair F-1 HOW to USE Troubleshooting Guide 2TROUBLESHOOTING and REPAIRF-2PC Board Troubleshooting Procedures Troubleshooting and RepairPerform the Rotor Voltage Test Recommended Course of Action Problems Possible Areas Symptoms MisadjustmentsPossible Areas Misadjustments Problems SymptomsRotor Voltage2. PTestrform Engine Problems Wiring Charging Circuit Test BridgePerformTestthe. Output Rectifier Eagle 10,000 Test Description Rotor Voltage TestMaterials Needed Remove the case top, then reinstall the fuel cap Test ProcedureRotor Voltage Test Rotor Resistance Test Remove the case top, then replace the fuel cap Rotor Resistance TestTroubleshooting and Repair Eagle 10,000 Auxiliary and Field Winding Test To test the 115 VAC winding Auxiliary and Field Winding TestTo test the 230 VAC winding To test the field winding Eagle 10,000 Output Rectifier Bridge Test Figure F.4 Location of Output Rectifier Leads Output Rectifier Bridge TestCharging Circuit Test Figure F.5 Location of Voltage Regulator Charging Circuit TestEngine Throttle Adjustment Test Strobe-tach Method Engine Throttle Adjustment TestFrequency Counter Method Figure F.7Oscilloscope Method Vibratach Method Engine Throttle Adjustment TestNormal Open Circuit Voltage Waveform 115VAC Supply Scope SettingsHigh Idle no Load Output Control AT Maximum Machine Loaded Typical DC Weld Output Waveform CC ModeMachine Loaded to 200 Amps AT 26 VDC Abnormal Open Circuit DC Weld Voltage Waveform Normal Open Circuit DC Weld Voltage Waveform CC Mode Brush Removal and Replacement Procedure Brush Removal and ReplacementFigure F.9 Brush LEADS/BRUSHES Retained with Cable TIE Slip RingsEagle 10,000 Printed Circuit Board Removal Replacement Printed Circuit Board Removal ReplacementTroubleshooting and Repair Eagle 10,000 Output Rectifier Bridge Removal Replacement 43TROUBLESHOOTING and REPAIRF-43Output Rectifier Bridge Removal 44TROUBLESHOOTING and REPAIRF-4445TROUBLESHOOTING and REPAIRF-45 Eagle 10,000 Instructions ENGINE/ROTOR Removal and ReplacementFigure F.12 Component LOCATIONS, ENGINE/ROTOR Removal ENGINE/ROTOR Removal and ReplacementEngine and Rotor Removal Procedure Figure F.13 Engine and Rotor Removed from Stator THRU-BOLT Rotor Removal ProcedureReassembly Procedure Replacement KIT S20788ENGINE/ROTOR Removal Retest After Repair Auxiliary Power Receptacle OUTPUT1Engine Output Welder DC OUTPUT1Table of Contents Diagram Section Eagle 10,000 Kohler Electrical DiagramsWiring Diagram Code 11397 M21271 Terminal Schematic Complete Machine Code 11096 L12259Torroid Core located on Schematic Complete Machine Code 11397 L13104Schematic IDLER/FIELD Control P.C. Board L12197

SVM192-A specifications

Lincoln Electric's SVM192-A is a standout model in the sphere of welding machines, renowned for its advanced technology and versatility, making it a preferred choice among welding professionals and industrial applications. This single-phase inverter-based machine balances performance and portability, providing users with a reliable solution for a variety of welding tasks.

One of the key features of the SVM192-A is its capacity to perform multiple welding processes. It supports MIG, TIG, and stick welding, which allows users to switch between different techniques depending on the project requirements. This multi-functionality enhances the machine's utility, making it viable for various applications ranging from home projects to professional fabrication works.

The SVM192-A is equipped with Lincoln Electric’s proprietary technologies, including the advanced inverter technology, which ensures high efficiency and power output while maintaining a compact size. This inverter technology not only improves arc stability but also reduces power consumption and heat generation, making it a more eco-friendly option.

Key characteristics of the SVM192-A include a user-friendly digital display that provides clear settings for amperage, voltage, and other parameters, enabling precise control during welding. The machine also features a robust construction, designed to withstand tough working environments, ensuring longevity and minimal downtime.

Moreover, the SVM192-A incorporates safety features designed to protect the user and the machine, including overcurrent and thermal overload protection. This prioritization of safety ensures a worry-free operation, allowing welders to focus on their craft without the distraction of potential hazards.

Portability is another significant advantage of the SVM192-A. Weighing in at a lightweight design, it is easy to transport, making it ideal for mobile operations or jobs that require moving the equipment frequently.

In summary, the Lincoln Electric SVM192-A embodies versatility, efficiency, and durability, making it an exceptional choice for both novice and experienced welders. Its ability to handle multiple welding processes, combined with advanced technologies and user-friendly features, positions it as a top contender in the welding equipment market, suitable for a wide range of applications in various sectors.
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