STATOR/ROTOR Removal and Replacement | Lincoln Electric SVM103-A

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F-29

TROUBLESHOOTING & REPAIR

STATOR/ROTOR REMOVAL AND REPLACEMENT

WARNING

Service and repair should be performed by only 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 elec- trical shock, please observe all safety notes and precautions detailed throughout this manu- al.

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 216-383-2531 or 1-800—833-9353 (WELD).

DESCRIPTION

The following procedure will aid the technician in removing the stator and/or rotor for main- tenance 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)

INSTRUCTIONS

For stator removal only, follow steps 1 -17 under STATOR REMOVAL PROCEDURE. For reassembly of stator, go to REASSEMBLY PROCEDURE steps 3 - 18.

For rotor removal, follow the STATOR REMOVAL PROCEDURE, ROTOR REMOVAL PRO- CEDURE, and REASSEMBLY PROCEDURE.

POWER-ARC 4000

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Lincoln Electric SVM103-A service manual STATOR/ROTOR Removal and Replacement, Instructions

Contents

POWER-ARC TM4000 Safety POWER-ARC Electric Shock can kill Welding Sparks can cause fire or explosion Iii Précautions DE Sûreté Master Table of Contents for ALL Sections Table of Contents Installation Section Installation Technical Specifications POWER-ARC Location and Ventilation Safety PrecautionsStoring PRE-OPERATION Engine Service Welding Cable Connections Power ARCElectrical Output Connections Cable Size and Length Machine Grounding Auxiliary Power ReceptaclesCable Installation Plugs and HAND-HELD Equipment Premises Wiring Circuit Breakers Table A.2 Electrical Device USE with the POWER-ARC Type Common Electrical Devices Possible Concerns Table of Contents Operation Section Operating Instructions Safety InstructionsOperation General Description Recommended Applications Operational Features and ControlsDesign Features Advantages Welding Capability Controls and Settings GENERATOR/WELDER Controls Figure B.2 Gasoline Engine Controls Gasoline Engine Controls Before Starting the Engine Engine OperationStarting the Engine Running the Engine Stopping the EngineBREAK-IN Period Generator Operation To USE the Generator AS AN Auxiliary Power SupplyGeneral Information Table B.3 Generator Power Applications Welding Operation To USE the POWER-ARC 4000 for WeldingAfter YOU Finish the Weld Welding Guidelines Material Thickness Electrode Type Size SettingStick Welding Welding Circuit ARC Electrode 12/95 POWER-ARCFour Factors of Successful Welding Correct WAY to Strike AN ARC Correct ARC Length Correct Welding Speed Table of Contents Accessories Lincoln Electric Accessories OPTIONS/ACCESSORIESBriggs and Stratton Accessories Table of Contents Maintenance Routine and Periodic Maintenance Engine Maintenance Figure D.2 Clean Rotating SCREEN/FINGER GUARD/DEBRIS Guard Figure D.4 SET Spark Plug GAP GENERATOR/WELDER Maintenance Table D.2 Engine Maintenance PartsPart Part Number Figure D.6. Major Component Locations Table of Contents Theory of Operation Section Theory of Operation ENGINE, EXCITATION, Rotor and Stator Rotor Field Feedback and Auxiliary Power Figure E.3 Field Excitation and Auxiliary Power Auxiliary Power Overcurrent Protection Weld Winding and Reactor Table of Contents Trouble Shooting & Repair Section Troubleshooting & Repair HOW to USE Troubleshooting Guide Troubleshooting Guide Output Problems Or contact your local Lincoln Local Lincoln Electric Authorized Troubleshooting & Repair Troubleshooting & Repair Engine Problems Engine Problems Welding Problems Test Description Rotor Voltage TestMaterials Needed Test Procedure Ground Stud Lead 200A Connection Output Panel Rotor Resistance Test Slip Rings Figure F.3 Brushes Retained with Cable TIE Cable TIE Brushes Engine Throttle Adjustment Test Frequency Counter Method MarkStrobe-tach Method Oscilloscope Method Figure F.5 Location of Engine Throttle Adjustment NUT NUT Normal Open Circuit Weld Voltage Waveform Scope SettingsHigh Idle no Load Normal Open Circuit Voltage Waveform 115 VAC Supply Machine Loaded Typical Weld Output WaveformMachine Loaded to 125 Amps AT 23 VAC Brush Removal and Replacement Description Procedure Figure F.6 Brushes Retained with Cable TIE Procedure Rheostat Removal and Replacement Figure F.7 Rheostat Removal Capacitor AND/OR Diode Bridge Removal Replacement Capacitor AND/OR Diode Bridge Removal and Replacement Procedure Capacitor Removal and Replacement Procedure Diode Bridge Removal and Replacement STATOR/ROTOR Removal and Replacement Instructions Output Stator Removal ProcedureTIE Wrap Terminals Thru Bolts Support Nuts POWER-ARC Figure F.10 Stator END Bracket Support and THRU-BOLTS Reassembly Procedure Rotor Removal ProcedureRotor THRU-BOLT Feeler Gauge Rotor Engine Output Auxiliary Power Receptacle OUTPUT1Retest After Repair WELDER/GENERATOR OUTPUT1 POWER-ARC Electrical Diagrams Table of ContentsSection G Electrical Diagram POWER-ARC POWER-ARC POWER-ARC