Lincoln Electric SVM103-A service manual Stator Removal Procedure, TIE Wrap, Output, Terminals

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F-30

TROUBLESHOOTING & REPAIR

STATOR/ROTOR REMOVAL AND REPLACEMENT (continued)

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STATOR REMOVAL PROCEDURE

1.Remove engine spark plug wire to prevent accidental kickback or starting.

2.With the 5/16” nut driver, remove the 4 sheet metal screws that hold the top cover to the control box. Remove the top cover.

3.Remove the 4 1/2” nuts and washers that anchor the control box to the stator frame. Two of the nuts also anchor the reactor. The reactor must be moved over to access the front left hand nut anchoring the control box. Be careful not to drop the washers into the machine.

4.Lift up the control box and unscrew the 4 rubber mounts. Set the control box onto the stator frame for the moment.

5.Pull apart the molex coupling that connects the stator to the wiring harness.

6.With the slot head screw driver, remove the 6 sheet metal screws that hold the control panel to the control box - 3 on each side. You may need to use the 5/16” end wrench on the engine side because of limited clear- ance. Pull the panel away from the control box.

7.With the 9/16” open end wrench, remove lead W2 (Black) from the output terminal. See Figure F.9 for location. With the diago- nal cutters, cut the cable tie that holds the two output leads together. Pull lead W2 back out of the way; screw the bolt back

into the output terminal hole loosely for reassembly. Set the control panel back on the control box and hold it in place with 1 sheet metal screw in each side.

8.Remove the brush holder assembly. Open the brush holder assembly cover. Squeeze the 2 tabs and depress the cover at the top with a screw driver or your fingernail. The cover will drop open on its bottom hinge. With the 1/4” nut driver, remove the 2 screws that hold the brush holder assembly in place. With the needle nose pliers, gently remove the black and the red wires. Set the brush holder aside. Pull the wires up into the control box.

9.Pull apart the molex coupling for the engine flywheel alternator. This is the single wire on the left side of the machine, running from the engine to the stator.

10.Disconnect lead W1 (Black) that connects to the reactor lead. Replace the nut, split- ring lock washer, and flat washer finger tight on the bolt for reassembly.

11.Slide the control panel and box assembly out of the machine cradle. Carefully pull the wire leads down through the box as you remove it. Note that the reactor is loose inside the box and may slide around.

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FIGURE F.9 - OUTPUT LEAD LOCATION

TIE WRAP

W2

W1

OUTPUT

TERMINALS

POWER-ARC 4000

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Contents POWER-ARC TM4000 POWER-ARC SafetyElectric Shock can kill Iii Welding Sparks can cause fire or explosionPrécautions 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 Cable Size and Length Power ARCElectrical Output Connections Welding Cable ConnectionsPlugs and HAND-HELD Equipment Auxiliary Power ReceptaclesCable Installation Machine GroundingCircuit Breakers Premises WiringType Common Electrical Devices Possible Concerns Table A.2 Electrical Device USE with the POWER-ARCTable of Contents Operation Section General Description Safety InstructionsOperation Operating InstructionsWelding Capability Operational Features and ControlsDesign Features Advantages Recommended ApplicationsGENERATOR/WELDER Controls Controls and SettingsGasoline Engine Controls Figure B.2 Gasoline Engine ControlsStarting the Engine Engine OperationBefore Starting the Engine BREAK-IN Period Stopping the EngineRunning the Engine General Information To USE the Generator AS AN Auxiliary Power SupplyGenerator Operation Table B.3 Generator Power Applications After YOU Finish the Weld To USE the POWER-ARC 4000 for WeldingWelding Operation Stick Welding Material Thickness Electrode Type Size SettingWelding Guidelines ARC Welding CircuitCorrect WAY to Strike AN ARC 12/95 POWER-ARCFour Factors of Successful Welding ElectrodeCorrect Welding Speed Correct ARC LengthTable of Contents Accessories Briggs and Stratton Accessories OPTIONS/ACCESSORIESLincoln Electric Accessories Table of Contents Maintenance Engine Maintenance Routine and Periodic MaintenanceFigure D.2 Clean Rotating SCREEN/FINGER GUARD/DEBRIS Guard Figure D.4 SET Spark Plug GAP Part Part Number Table D.2 Engine Maintenance PartsGENERATOR/WELDER Maintenance Figure 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 Trouble Shooting & Repair Section HOW to USE Troubleshooting Guide Troubleshooting & RepairOutput Problems Troubleshooting GuideOr contact your local Lincoln Local Lincoln Electric Authorized Troubleshooting & Repair Troubleshooting & Repair Engine Problems Engine Problems Welding Problems Materials Needed Rotor Voltage TestTest Description Ground Stud Lead 200A Connection Output Panel Test ProcedureRotor Resistance Test Rings SlipCable TIE Brushes Figure F.3 Brushes Retained with Cable TIEEngine Throttle Adjustment Test Oscilloscope Method MarkStrobe-tach Method Frequency Counter MethodNUT Figure F.5 Location of Engine Throttle Adjustment NUTHigh 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 ReplacementFigure F.6 Brushes Retained with Cable TIE ProcedureProcedure Rheostat Removal and Replacement Figure F.7 Rheostat Removal Capacitor AND/OR Diode Bridge Removal Replacement Procedure Capacitor Removal and Replacement Capacitor AND/OR Diode Bridge Removal and ReplacementProcedure Diode Bridge Removal and Replacement Instructions STATOR/ROTOR Removal and ReplacementTerminals Stator Removal ProcedureTIE Wrap OutputFigure F.10 Stator END Bracket Support and THRU-BOLTS Thru Bolts Support Nuts POWER-ARCRotor THRU-BOLT Rotor Removal ProcedureReassembly Procedure Rotor Feeler GaugeWELDER/GENERATOR OUTPUT1 Auxiliary Power Receptacle OUTPUT1Retest After Repair Engine OutputPOWER-ARC Section G Table of ContentsElectrical Diagrams POWER-ARC Electrical DiagramPOWER-ARC POWER-ARC
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