Lincoln Electric SVM103-A Recommended Applications, Operational Features and Controls

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B-2

OPERATION

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The POWER-ARC 4000 warranty covers the machine for one year from the date of purchase. For non- engine warranty claims, contact your nearest Lincoln Authorized Field Service Facility. For engine warranty claims, contact your nearest Briggs & Stratton service center.

NOTE: The POWER-ARC 4000 is not meant for rental or other commercial use.

RECOMMENDED APPLICATIONS

GENERATOR

The POWER-ARC 4000 gives smooth AC generator output for medium use, non-commercial demands. For more details on operating the generator, see GEN- ERATOR OPERATION in the OPERATION section of this manual.

WELDER

The POWER-ARC 4000 provides excellent constant current AC welding output for stick (SMAW) welding. For more details on using the machine as a welder, see WELDING OPERATION in the OPERATION sec- tion of this manual.

OPERATIONAL FEATURES AND CONTROLS

The POWER-ARC 4000 was designed for simplicity. Therefore, it has very few operating controls. A single dial on the control panel lets you select either genera- tor or welding use. For welding, the same dial selects continuous current output over the machine’s 70 to 125 amp range.

The 8 HP Briggs & Stratton gasoline engine controls include a recoil starter, choke, throttle control, and piercing stop switch. See ENGINE OPERATION in the OPERATION section of this manual for details about starting, running, stopping, and breaking in the gaso- line engine.

DESIGN FEATURES AND

ADVANTAGES

Stick welding (SMAW) process capability with out- put range from 70 - 125 amps.

Single-dial current output selection.

Work and Electrode welding cable mounting termi- nals.

Separate ground stud for safe connection of case to earth ground. Single 20 amp, 240 volt generator receptacle.

Duplex 20 amp, 120 volt generator receptacle.

Integrated generator output overload protection through two 20 amp circuit breakers.

Welded-tube, full roll cage frame protects engine and generator/welder.

Lightweight, portable design.

Rubber mounting isolates engine and generator from frame to prevent machine “walking” during use.

Lo-Tone®engine muffler for quieter operation. (A Super Lo-Tone®muffler is available from Briggs & Stratton.) Easy-starting Electronic Magnetron® igni- tion.

Optional Oil Gard® low oil level engine shutdown kit available from Briggs & Stratton.

WELDING CAPABILITY

The POWER-ARC 4000 is rated 125 amps, 18 volts at 30% duty cycle on a ten-minute basis. This means that you can load the welder to 125 amps for three minutes out of every ten-minute period. The machine is capable of higher duty cycles at lower output cur- rents. For example, you can load the welder to 100 amps for six minutes out of ten for a 60% duty cycle.

The current is continuously variable from 70 to 125 amps AC. The POWER-ARC 4000 can, therefore, weld with all 3/32 and most 1/8 inch diameter Lincoln AC electrodes.

LIMITATIONS

The POWER-ARC 4000 is not recommended for any processes besides those that are normally per- formed using stick welding (SMAW) procedures.

The POWER-ARC 4000 is not recommended for pipe thawing.

During welding, generator power is limited to 100 watts, and output voltages can drop from 120 to 80 volts and 240 to 160 volts. Therefore, DO NOT OPERATE ANY SENSITIVE ELECTRICAL EQUIP- MENT WHILE YOU ARE WELDING.

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 Electrical Output Connections Power ARCWelding Cable Connections Cable Size and LengthCable Installation Auxiliary Power ReceptaclesMachine Grounding Plugs and HAND-HELD EquipmentCircuit Breakers Premises WiringType Common Electrical Devices Possible Concerns Table A.2 Electrical Device USE with the POWER-ARCTable of Contents Operation Section Operation Safety InstructionsOperating Instructions General DescriptionDesign Features Advantages Operational Features and ControlsRecommended Applications Welding CapabilityGENERATOR/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 CircuitFour Factors of Successful Welding 12/95 POWER-ARCElectrode Correct WAY to Strike AN ARCCorrect 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 Strobe-tach Method MarkFrequency Counter Method Oscilloscope 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 ReplacementTIE Wrap Stator Removal ProcedureOutput TerminalsFigure F.10 Stator END Bracket Support and THRU-BOLTS Thru Bolts Support Nuts POWER-ARCRotor THRU-BOLT Rotor Removal ProcedureReassembly Procedure Rotor Feeler GaugeRetest After Repair Auxiliary Power Receptacle OUTPUT1Engine Output WELDER/GENERATOR OUTPUT1POWER-ARC Section G Table of ContentsElectrical Diagrams POWER-ARC Electrical DiagramPOWER-ARC POWER-ARC