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Lincoln Electric SVM208-A Rotor Removal Procedure, Reassembly Procedure, Rotor Thru-Bolt, F-47

Models: SVM208-A

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F-47

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F-47	TROUBLESHOOTING AND REPAIR	F-47

STATOR/ROTOR REMOVAL AND REPLACEMENT (continued)

FIGURE F.18 – ROTOR WITH STATOR REMOVED

ROTOR

THRU-BOLT

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ROTOR REMOVAL PROCEDURE

1.To remove the rotor, double check that the spark plug wire is disconnected. 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.18. 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 crankshaft, about 3/4”.

4.Turning it counterclockwise, screw in the reverse thread bolt from the kit into the rotor shaft until it bottoms 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 crankshaft. 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.

BULLDOG® 140

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Lincoln Electric SVM208-A Rotor Removal Procedure, Reassembly Procedure, Rotor Thru-Bolt, Troubleshooting And Repair, F-47

Contents

View Safety Info View Safety Info View Safety Info View Safety Info Safety Depends on YouJanuary SERVICE MANUALCALIFORNIA PROPOSITION 65 WARNINGS SAFETYFOR ENGINE powered equipment ELECTRIC AND MAGNETIC FIELDS may be dangerousFUMES AND GASES ELECTRIC SHOCK can killARC RAYS can burn can be dangerousSAFETY FOR ELECTRICALLY powered equipmentWELDING and CUTTING SPARKS can cause fire or explosion CYLINDER may explode if damagedReturn to Master TOC PRÉCAUTIONS DE SÛRETÉSAFETY Return to Master TOC Return to Master TOC Return to Master TOCReturn to Master TOC Return to Master TOC Return to Master TOC SAFETYElectromagnetic Compatibility EMC Installation and UseReturn to Master TOC Return to Master TOC Return to Master TOC SAFETYMaintenance of the Welding Equipment Electromagnetic Compatibility EMCBULLDOG I - MASTER TABLE OF CONTENTS FOR ALL SECTIONSSafety PageBULLDOG TABLE OF CONTENTS - INSTALLATION SECTIONReturn to Master TOC Return to Master TOC Return to Master TOC Return to Master TOCAC Auxiliary Power INSTALLATIONTECHNICAL SPECIFICATIONS - Bulldog 140 K2708-1 DisplacementINSTALLATION SAFETY PRECAUTIONSLOCATION AND VENTILATION STORINGFUEL PRE-OPERATION ENGINE SERVICESTACKING TILTINGBulldog 140 OUTPUT CONNECTIONS ELECTRICAL OUTPUT CONNEC- TIONSWELDING CABLE CONNECTIONS TABLE A.1 RECOMMENDED WELDING CABLE SIZE AND LENGTHINSTALLATION AUXILIARY POWER RECEPTACLESELECTRICAL CONNECTIONS PLUGS AND HAND-HELD EQUIPMENTReturn to Section TOC Return to Section TOC Return to Section TOC PREMISES WIRINGCIRCUIT BREAKERS INSTALLATIONReturn to Master TOC Return to Master TOC Return to Master TOC INSTALLATIONReturn to Section TOC Return to Section TOC Return to Section TOC Return to Section TOCBULLDOG TABLE OF CONTENTS - OPERATION SECTIONReturn to Master TOC Return to Master TOC Return to Master TOC Return to Master TOCGENERAL DESCRIPTION SAFETY INSTRUCTIONSOPERATIONAL FEATURES AND CONTROLS OPERATIONOUTPUT PANEL CONTROLS CONTROLS AND SETTINGSLIMITATIONS WELDER/GENERATOR CONTROLSReturn to Section TOC Return to Section TOC Return to Section TOC ENGINE OPERATIONGASOLINE ENGINE CONTROLS OPERATIONReturn to Section TOC Return to Section TOC Return to Section TOC BEFORE STARTING THE ENGINESTARTING THE ENGINE OPERATIONBREAK-IN PERIOD GENERATOR OPERATIONSTOPPING THE ENGINE RUNNING THE ENGINEReturn to Section TOC Return to Section TOC Return to Section TOC GENERATOR POWER APPLICATIONSSuggested Power Applications OPERATIONOPERATION WELDING OPERATIONCONTROL FUNCTION / OPERATION “Current Control Dial”Learning To Stick Weld Semi-automatic, Wire Welding With a Lincoln Wire Feeder / WelderWELDING GUIDELINES Stick WeldingB-10 What Happens in the Arc?OPERATION B-104. The Correct Welding Speed 1. The Correct Welding Position2. The Correct Way to Strike An Arc 3. The Correct Arc LengthOPERATION PRACTICETypes of Welds Common MetalsOPERATION Good1/2 Poor 12mm1/4 6mm 1/4 6mm 1/8 3.2mmOPERATION Veryshort 30-40How to Hardface the Sharp Edge Metal to Ground Wear Side ViewEnd View 3030When breaking the weld stays on one piece White brittlecold cast ironB-17 MotionsSelecting Electrodes OPERATIONReturn to Section TOC Return to Section TOCReturn to Section TOC Return to Section TOCBULLDOG TABLE OF CONTENTS - ACCESSORIES SECTIONReturn to Master TOC Return to Master TOC Return to Master TOC Return to Master TOCReturn to Section TOC Return to Section TOC Return to Section TOC ACCESSORIESOPTIONS/ACCESSORIES LINCOLN ELECTRIC ACCESSORIESBULLDOG TABLE OF CONTENTS - MAINTENANCE SECTIONReturn to Master TOC Return to Master TOC Return to Master TOC Return to Master TOCReturn to Section TOC MAINTENANCEReturn to Section TOC Return to Section TOCLOCATION ROUTINE AND PERIODIC MAINTENANCEENGINE MAINTENANCE FIGURE D.1 - OIL DRAIN AND REFILLFIGURE D.3 - CLEAN COOLING SYSTEM ENGINE ADJUSTMENTSMAINTENANCE FIGURE D.2 - CLEAN AREAMAINTENANCE TABLE D.1 ENGINE MAINTENANCE PARTSSPARK PLUG SERVICE OPERATIONAL CLEARANCE1. BRUSH, BRUSH HOLDER ASSEMBLY 2. BEARING BRACKET END COVER GENERATOR/WELDER MAINTENANCEFIGURE D.6. - BRUSH REMOVAL AND REPLACEMENT MAINTENANCE3. STATOR ASSEMBLY FIGURE D.7. - MAJOR COMPONENT LOCATIONSMAINTENANCE 1. CRADLE ASSEMBLY 2. ROTOR, BLOWER, AND BEARING ASSEMBLYReturn to Section TOC Return to Section TOCReturn to Section TOC Return to Section TOCFIGURE E.1 BLOCK LOGIC DIAGRAM E-1 TABLE OF CONTENTS-THEORY OF OPERATION SECTION E-1ENGINE REACTOR OUTPUT TERMINALS STATOR ROTOR STATORReturn to Master TOC to Master TOC THEORY OF OPERATIONENGINE, EXCITATION, ROTOR AND STATOR FIGURE E.2 - ENGINE, EXCITATION, ROTOR AND STATORReturn to Master TOC to Master TOC ROTOR FIELD FEEDBACK AND AUXILIARY POWERFIGURE E.3 - ROTOR FIELD FEEDBACK AND AUXILIARY POWER THEORY OF OPERATIONReturn WELD WINDING AND REACTORTHEORY OF OPERATION Return to Master TOC to Master TOCBULLDOG F-1 TABLE OF CONTENTS - TROUBLESHOOTING AND REPAIR F-1Return to Master TOC Return to Master TOC Return to Master TOC Return to Master TOCReturn to Section TOC TROUBLESHOOTING AND REPAIRHOW TO USE TROUBLESHOOTING GUIDE Step 1. LOCATE PROBLEM SYMPTOMReturn to Master TOC PC BOARD TROUBLESHOOTING PROCEDURESTROUBLESHOOTING AND REPAIR Return to Section Return to Section TOCMISADJUSTMENTS TROUBLESHOOTING AND REPAIRPROBLEMS SYMPTOMSMISADJUSTMENTS TROUBLESHOOTING AND REPAIRPROBLEMS SYMPTOMSOUTPUT PROBLEMS TROUBLESHOOTING AND REPAIRPROBLEMS SYMPTOMS POSSIBLE AREAS OF MISADJUSTMENTSOUTPUT PROBLEMS TROUBLESHOOTING AND REPAIRPROBLEMS SYMPTOMS POSSIBLE AREAS OF MISADJUSTMENTSOUTPUT PROBLEMS TROUBLESHOOTING AND REPAIRPROBLEMS SYMPTOMS POSSIBLE AREAS OF MISADJUSTMENTSENGINE PROBLEMS TROUBLESHOOTING AND REPAIRPROBLEMS SYMPTOMS POSSIBLE AREAS OF MISADJUSTMENTSMISADJUSTMENTS TROUBLESHOOTING AND REPAIRPROBLEMS SYMPTOMSWELDING PROBLEMS TROUBLESHOOTING AND REPAIRPROBLEMS SYMPTOMS POSSIBLE AREAS OF MISADJUSTMENTSReturn to Section TOC Return to Section TOCReturn to Section TOC Return to Section TOCTROUBLESHOOTING AND REPAIR ROTOR VOLTAGE TESTTEST DESCRIPTION MATERIALS NEEDEDGROUND STUD PROCEDUREROTOR VOLTAGE TEST continued LEAD 200A CONNECTIONMATERIALS NEEDED FIELD DIODE BRIDGE TESTTROUBLESHOOTING AND REPAIR TEST DESCRIPTIONPROCEDURE FIELD DIODE BRIDGE TEST continued+ ~ TROUBLESHOOTING AND REPAIRMATERIALS NEEDED ROTOR “FLASHING” CIRCUIT TESTTROUBLESHOOTING AND REPAIR TEST DESCRIPTIONTROUBLESHOOTING AND REPAIR ROTOR “FLASHING” CIRCUIT TEST continued201A 202A+Return to Section TOC TROUBLESHOOTING AND REPAIRROTOR “FLASHING” CIRCUIT TEST continued Return to Section TOC Return to Section TOC Return to Section TOCReturn to Section TOC Return to Section TOCReturn to Section TOC Return to Section TOCMATERIALS NEEDED ROTOR RESISTANCE TESTTROUBLESHOOTING AND REPAIR TEST DESCRIPTIONPROCEDURE ROTOR RESISTANCE TEST continuedSLIP RINGS TROUBLESHOOTING AND REPAIRReturn to Section TOC Return to Section TOC Return to Section TOC CABLE TIE BRUSHESTROUBLESHOOTING AND REPAIR ROTOR RESISTANCE TEST continuedReturn to Section TOC Return to Section TOCReturn to Section TOC Return to Section TOCMATERIALS NEEDED ENGINE THROTTLE ADJUSTMENT TEST ROBIN/SUBARU ENGINETROUBLESHOOTING AND REPAIR TEST DESCRIPTIONReturn to Section TOC ENGINE THROTTLE ADJUSTMENT TEST ROBIN/SUBARU ENGINE continuedTROUBLESHOOTING AND REPAIR PROCEDURETHROTTLE LOCKING NUT TROUBLESHOOTING AND REPAIRENGINE THROTTLE ADJUSTMENT TEST ROBIN/SUBARU ENGINE continued HIGH SPEED STOP SCREWReturn to Master TOC Return to Master TOC SCOPE SETTINGSTROUBLESHOOTING AND REPAIR Return to Section TOC Return to Section TOCSCOPE SETTINGS NORMAL OPEN CIRCUIT VOLTAGE WAVEFORM 115VAC SUPPLYHIGH IDLE - NO LOAD TROUBLESHOOTING AND REPAIRTROUBLESHOOTING AND REPAIR TYPICAL WELD OUTPUT WAVEFORMMACHINE LOADED MACHINE LOADED TO 125 AMPS AT 23 VACMATERIALS NEEDED BRUSH REMOVAL AND REPLACEMENTTROUBLESHOOTING AND REPAIR TEST DESCRIPTIONPROCEDURE BRUSH REMOVAL AND REPLACEMENT continuedCABLE TIE BRUSHES TROUBLESHOOTING AND REPAIRF-33 TROUBLESHOOTING AND REPAIRBRUSH REMOVAL AND REPLACEMENT continued F-33Return to Section TOC Return to Section TOCReturn to Section TOC Return to Section TOCMATERIALS NEEDED RHEOSTAT REMOVAL AND REPLACEMENTTROUBLESHOOTING AND REPAIR TEST DESCRIPTIONReturn to Section TOC Return to Section TOC RHEOSTAT REMOVAL AND REPLACEMENT continuedTROUBLESHOOTING AND REPAIR PROCEDUREMATERIALS NEEDED CAPACITOR AND/OR DIODE BRIDGE REMOVAL AND REPLACEMENTTROUBLESHOOTING AND REPAIR TEST DESCRIPTIONAttachment for 202 202A + CAPACITOR AND/OR DIODE BRIDGE REMOVAL AND REPLACEMENT continuedPROCEDURE - CAPACITOR REMOVAL AND REPLACEMENT TROUBLESHOOTING AND REPAIRReturn to Section TOC Return to Section TOC PROCEDURE - FIELD DIODE BRIDGE REMOVAL AND REPLACEMENTTROUBLESHOOTING AND REPAIR CAPACITOR AND/OR DIODE BRIDGE REMOVAL AND REPLACEMENT continuedReturn to Section TOC Return to Section TOCReturn to Section TOC Return to Section TOCTEST DESCRIPTION STATOR/ROTOR REMOVAL AND REPLACEMENTINSTRUCTIONS TROUBLESHOOTING AND REPAIRGENERATORENGINE STATOR/ROTOR REMOVAL AND REPLACEMENT continuedTROUBLESHOOTING AND REPAIR PROCEDUREReturn to Master TOC Return to Master TOC Master TOC TROUBLESHOOTING AND REPAIRSTATOR/ROTOR REMOVAL AND REPLACEMENT continued Return to Section TOC Return to Section TOC Section TOCReturn to Section TOC TROUBLESHOOTING AND REPAIRSTATOR/ROTOR REMOVAL AND REPLACEMENT continued Return to Section TOC Return to Section TOC Return to Section TOCReturn to Section TOC Return to Section TOC STATOR REMOVAL PROCEDURETROUBLESHOOTING AND REPAIR STATOR/ROTOR REMOVAL AND REPLACEMENT continuedTROUBLESHOOTING AND REPAIR THRU BOLTS THRU BOLTSSUPPORT NUTSSTATOR/ROTOR REMOVAL AND REPLACEMENT continued ROTOR REMOVAL PROCEDUREREASSEMBLY PROCEDURE TROUBLESHOOTING AND REPAIRto Master TOC TROUBLESHOOTING AND REPAIRSTATOR/ROTOR REMOVAL AND REPLACEMENT continued to Section TOCWELDER/GENERATOR OUTPUT1 AUXILIARY POWER RECEPTACLE OUTPUT1RETEST AFTER REPAIR ENGINE OUTPUTReturn to Section TOC Return to Section TOCReturn to Section TOC Return to Section TOCBULLDOG TABLE OF CONTENTS - DIAGRAM SECTIONReturn to Master TOC Return to Master TOC Return to Master TOC Return to Master TOCWIRING DIAGRAM - BULLDOG ElEcTrical DiaGramSWiriNG DiaGram - cOmplETE machiNE - l15064 L15064MANUFACTURER SchEmaTic - cOmplETE machiNE - S28101SUBJECT ENGINEERING CONTROLLED