Lincoln Electric SVM197-A STATOR/ROTOR Removal and Replacement Procedure, Test Description

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F-35

TROUBLESHOOTING AND REPAIR

F-35

STATOR/ROTOR REMOVAL AND REPLACEMENT PROCEDURE

WARNING

Service and repair should be performed only by Lincoln Electric factory trained personnel. Unauthorized repairs performed on this equipment may result in danger to the technician or machine operator and will invalidate your factory warranty. For your safety and to avoid electrical shock, please observe all safety notes and precautions detailed throughout this manual.

If for any reason you do not understand the test procedures or are unable to perform the test/repairs safely, contact the Lincoln Electric Service Department for electrical trou- bleshooting assistance before you proceed. Call 1-888-935-3877.

TEST DESCRIPTION

The following procedure will aid the technician in removing the stator and/or rotor for maintenance or replacement of either component.

MATERIALS NEEDED

Lincoln Electric Rotor Removal Kit (S20925) - FOR ROTOR REMOVAL ONLY

5/16” nut driver 1/2” socket wrench 6” socket extension Slot head screw driver 5/8” socket wrench 7/16” socket wrench

7/16” open or box end wrench 3/4” socket or box end wrench 1/2” socket or box end wrench Needle nose pliers Diagonal cutters

Torque wrench (ft lbs)

Babbitt, leather, or wooden mallet Volt/ohmmeter

12” (long) feeler gauge (.010)

POWERARC® 5500

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Contents Powerarc ISAFETYi Electric Shock can kill ARC Rays can burn SafetyIii For ElectricallyPrécautions DE Sûreté Electromagnetic Compatibility EMC Safety Master Table of Contents for ALL Sections Table of Contents Installation Section Technical Specifications Powerarc InstallationEngine Exhaust can kill Safety PrecautionsLocation and Ventilation StoringPRE-OPERATION Engine Service Honda 9 HP PowerArc 5500 Typical Fuel ConsumptionMuffler Deflector Spark ArresterCable Size and Length Powerarc 5500 Output ConnectionsElectrical Output Connections Welding Cable ConnectionsMachine Grounding Auxiliary Power ReceptaclesCable Installation Plugs and HAND-HELD EquipmentCircuit Breakers Premises WiringType Common Electrical Devices Possible Concerns Table A.2 Electrical Device USE with the PowerarcPowerarc Table of Contents Operation Section Operation Physical Location of Components may vary by Code No Controls and SettingsLimitations Output Panel ControlsGasoline Engine Controls Engine OperationStarting the Engine Before Starting the EngineRunning the Engine Generator OperationStopping the Engine General InformationTable B.3 Generator Power Applications Control Function / Operation Current Control Dial Welding OperationWelding Guidelines Material Thickness Electrode Type Size SettingWelding circuit for Stick shielded metal arc welding What Happens in the Arc?Correct Welding Speed Correct Welding PositionCorrect Way to Strike An Arc Correct Arc LengthDo the following Common MetalsTypes of Welds Use the followingWelding in the Vertical Position PenetrationVertical-Down Welding Vertical-Up WeldingWelding Sheet Metal How to Hardface the Sharp Edge Metal to Ground WearOverhead Welding Hardfacing To Reduce WearCast Iron Plate Preparation Welding Cast IronOut-of-Position Group AWS E6011 Selecting ElectrodesHigh-Speed Group AWS E6013 Low Hydrogen Group AWS E7018Powerarc Table of Contents Accessories Section Lincoln Electric Accessories AccessoriesOPTIONS/ACCESSORIES Table of Contents Maintenance Section Engine Maintenance MaintenanceRoutine and Periodic Maintenance Figure D.3 Clean Rotating SCREEN/FINGER GUARD/DEBRIS Guard Engine AdjustmentsPart Robin / Subaru Honda Table D.1 Engine Maintenance PartsDo not attempt to polish slip rings while engine is running GENERATOR/WELDER MaintenanceFigure D.6. Major Component Locations 1TABLE of CONTENTS-THEORY of Operation Section E-1 ENGINE, EXCITATION, Rotor and Stator Theory of OperationEngine Control and Ignition Return Rotor Field Feedback Auxiliary PowerWeld Winding and Reactor Auxiliary Power Overcurrent Protection1TABLE of Contents Troubleshooting and Repair F-1 HOW to USE Troubleshooting Guide 2TROUBLESHOOTING and REPAIRF-2Troubleshooting 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 Materials Needed Test DescriptionLead 14TROUBLESHOOTING and REPAIRF-14Rotor Voltage Test Procedure Flashing Voltage Test ProcedureRotor Resistance Test Procedure Rotor Resistance Test Procedure Figure F.3 Brushes Retained with Cable TIE Powerarc Engine Throttle Adjustment Test ROBIN/SUBARU Engine ROBIN/SUBARU Engine Engine Throttle Adjustment TestHigh Speed Stop Screw High 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 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 201 201A Jumper Procedure Capacitor Removal and REPLACE- MentCapacitor AND/OR Diode Bridge Attachment for 202A Cable Tie CapacitorFigure F.10 Field Diode Bridge Location Procedure Field Diode Bridge Removal and ReplacementPowerarc STATOR/ROTOR Removal and Replacement Procedure STATOR/ROTOR Stator Removal ProcedureSection TOC Rotor Removal Procedure Procedure Reactor Bolts Lead WELDER/GENERATOR OUTPUT1 Auxiliary Power Receptacle OUTPUT1Retest After Repair Engine OutputPowerarc Table of Contents Diagram Section Wiring Diagram Codes 11182, 11187, 11329 S25984 Electrical DiagramsSwitch Wiring Diagram Codes 11403, 11405 S26829Wiring Diagram Code 11404 S26830 Wiring Diagram Power ARCWiring Diagram Code 11215 S26023 S26008 Schematic -CODES 11182, 11187, 11329 S26008S26881 Schematic Codes 11403, 11405 S26881S26882 Schematic Code 11404 S26882