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Lincoln Electric SVM103-C ROTOR REMOVAL , REASSEMBLY PROCEDURE

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F-33

TROUBLESHOOTING & REPAIR

F-33

POWER-ARC 4000

ROTOR REMOVAL

PROCEDURE

1. To remove the rotor, double check

that the spark plug wire is discon-

nected. You will be turning the rotor

during this procedure, and this

could accidentally cause engine

kickback.

2. With an impact wrench, remove the

rotor thru-bolt. See Figure F.11. If

an impact wrench is not available,

use the 1/2” box wrench. Hold the

rotor with one hand and shock the

wrench with the mallet to loosen the

thru-bolt. The thru-bolt has a star

washer and lock washer, beveled to

conform to the rotor shaft. Pull out

the thru-bolt.

3. Install the long thru-bolt supplied

with Lincoln Electric Rotor Removal

Kit S20925. The slot head must

face out. Screw in the bolt with the

slot head screw driver until the bolt

bottoms out on the engine crank-

shaft, about 3/4”.

4. Turning it counterclockwise, screw

in the reverse thread bolt from the

kit into the rotor shaft until it bot-

toms out on the thru-bolt.

5. With an impact wrench, tighten the

reverse thread bolt until the rotor pops

off the engine crankshaft. If an impact

wrench is not available, use the 1/2”

box wrench. Hold the rotor with one

hand and shock the wrench with the

mallet until the rotor pops off the

engine crankshaft.

6. Slide the rotor and blower (press-fitted

to the rotor) the rest of the way off the

crankshaft.

REASSEMBLY PROCEDURE

1. Lubricate the tapered engine crank-

shaft. Slide the rotor onto the shaft.

2. Coat the rotor thru-bolt threads with

Lincoln E177-R retaining compound

(Locktite( 277). Place the beveled lock

washers onto the thru-bolt and insert it

into the rotor shaft. Hold the rotor and

tighten the thru-bolt to 22 - 25 ft lbs.

3. Carefully install the stator, with the

leads at the 1 o’ clock position.

IMPROPER HANDLING OF THE

STATOR CAN RESULT IN SHORTED

WINDINGS AND/OR LOST OUTPUT.

4. Install the end bracket. Slide it on and

install the two top thru-bolts loosely to

hold the end bracket for the next step.

5. Install the end bracket support.

STATOR/ROTOR REMOVAL AND REPLACEMENT (continued)

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ROTOR

THRU-BOLT

FIGURE F.11 - ROTOR WITH STATOR REMOVED

Contents

Main POWER-ARC 4000 SERVICE MANUAL SVM103-C April, 2002 For Machines with code Number 10083 Refer to SVM103-A (on Service Navigator CD) WARNING ELECTRIC AND MAGNETIC FIELDS may be dangerous ii ARC RAYS can burn. ELECTRIC SHOCK can kill. FUMES AND GASES can be dangerous. FOR ELECTRICALLY powered equipment. CYLINDER may explode if damaged. iii WELDING SPARKS can cause fire or explosion. iv PRCAUTIONS DE SRET PRCAUTIONS DE SRET POUR LES MACHINES SOUDER TRANSFORMATEUR ET REDRESSEUR MASTER TABLE OF CONTENTS FOR ALL SECTIONS TABLE OF CONTENTS - INSTALLATION SECTION - A-2 TECHNICAL SPECIFICATIONS - POWER-ARC 4000 Duty Cycle Amps Volts at Rated Amperes Welding Ranges SAFETY PRECAUTIONS LOCATION AND VENTILATION STORING A-4 A-4 STACKING PRE-OPERATION ENGINE SERVICE OIL FUEL MUFFLER DEFLECTOR A-5 SPARK ARRESTER A-6 ELECTRICAL OUTPUT CONNECTIONS WELDING CABLE CONNECTIONS POWER ARC 4000 A-7 MACHINE GROUNDING PLUGS AND HAND-HELD EQUIPMENT AUXILIARY POWER RECEPTACLES A-8 A-8 PREMISES WIRING CIRCUIT BREAKERS A-9 Page TABLE OF CONTENTS - OPERATION SECTION - B-2 OPERATING INSTRUCTIONS SAFETY INSTRUCTIONS ELECTRIC SHOCK can kill. FUMES AND GASES can be dangerous. WELDING SPARKS can cause fire or explosion. RECOMMENDED APPLICATIONS GENERATOR WELDER OPERATIONAL FEATURES AND CONTROLS DESIGN FEATURES AND ADVANTAGES CONTROLS AND SETTINGS GENERATOR/WELDER CONTROLS POWER ARC 4000 B-5 GASOLINE ENGINE CONTROLS B-6 ENGINE OPERATION BEFORE STARTING THE ENGINE STARTING THE ENGINE B-7 STOPPING THE ENGINE RUNNING THE ENGINE BREAK-IN PERIOD B-8 GENERATOR OPERATION GENERAL INFORMATION TO USE THE GENERATOR AS AN AUXILIARY POWER SUPPLY: B-9 B-10 WELDING OPERATION GENERAL INFORMATION CONTROL FUNCTION / OPERATION Current Control Dial B-11 WELDING GUIDELINES Stick Welding Semi-automatic, MIG Welding With a Lincoln Weld Pak 100 or Weld Pak 125 Learning To Stick Weld B-12 Stick Welding B-12 Semi-automatic, MIG Welding With a Lincoln Weld Pak 100 or Weld Pak 125 Learning To Stick Weld B-13 What Happens in the Arc? B-14 1. The Correct Welding Position 2. The Correct Way to Strike An Arc 3. The Correct Arc Length 4. The Correct Welding Speed PRACTICE Common Metals Types of Welds B-16 Good 60 4 3 2 1 1/8" (3.2mm) B-17 B-18 Side View End View 30 30 B-19 hot cold cold White brittle cast iron When breaking the weld stays on one piece B-20 Motions TABLE OF CONTENTS - ACCESSORIES SECTION - C-2 ACCESSORIES C-2 OPTIONS/ACCESSORIES LINCOLN ELECTRIC ACCESSORIES BRIGGS AND STRATTON ACCESSORIES (FOR THE 8 HP KOOL BORE ENGINE ONLY) TABLE OF CONTENTS - MAINTENANCE SECTION - D-2 SAFETY PRECAUTIONS ROUTINE AND PERIODIC MAINTENANCE ENGINE MAINTENANCE ENGINE ADJUSTMENTS D-3 D-4 D-5 GENERATOR/WELDER MAINTENANCE D-6 TABLE OF CONTENTS - THEORY OF OPERATION SECTION - ENGINE, EXCITATION, ROTOR AND STATOR ROTOR FIELD FEEDBACK AND AUXILIARY POWER WELD WINDING AND REACTOR AUXILIARY POWER OVERCURRENT PROTECTION TABLE OF CONTENTS - TROUBLESHOOTING & REPAIR SECTION - HOW TO USE TROUBLESHOOTING GUIDE Page Page Page Page Page Page Page Page ROTOR VOLTAGE TEST ROTOR VOLTAGE TEST (continued) ROTOR RESISTANCE TEST Page ROTOR RESISTANCE TEST (continued) ENGINE THROTTLE ADJUSTMENT TEST Page ENGINE THROTTLE ADJUSTMENT TEST (continued) SCOPE SETTINGS NORMAL OPEN CIRCUIT WELD VOLTAGE WAVEFORM HIGH IDLE NO LOAD SCOPE SETTINGS NORMAL OPEN CIRCUIT VOLTAGE WAVEFORM (115 VAC SUPPLY) HIGH IDLE NO LOAD SCOPE SETTINGS MACHINE LOADED TO 125 AMPS AT 23 VAC TYPICAL WELD OUTPUT WAVEFORM MACHINE LOADED BRUSH REMOVAL AND REPLACEMENT BRUSH REMOVAL AND REPLACEMENT (continued) PROCEDURE (continued) Page RHEOSTAT REMOVAL AND REPLACEMENT Page PROCEDURE - CAPACITOR REMOVALAND REPLACE- MENT PROCEDURE - FIELD DIODE BRIDGE REMOVALAND REPLACEMENT STATOR/ROTOR REMOVAL AND REPLACEMENT INSTRUCTIONS STATOR REMOVAL PROCEDURE W1 Page ROTOR REMOVAL REASSEMBLY PROCEDURE Page RETEST AFTER REPAIR ENGINE OUTPUT WELDER/GENERATOR OUTPUT AUXILIARY POWER RECEPTACLE OUTPUT Page Page G-2 DIAGRAMS 65379 GNDC W1A L1 Page Page G-5 DIAGRAMS DIMENSION PRINT - POWER ARC 4000 Return to Section TOC Return to Section TOC Return to Section TOC Return to Section TOC G-5 POWER-ARC 4000 Page SVM ERROR REPORTING FORM