Lincoln Electric SVM103-A service manual Welding Operation, To USE the POWER-ARC 4000 for Welding

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B-9

 

 

OPERATION

WELDING OPERATION

3. Attach the work clamp securely to the work you

 

 

are welding.

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GENERAL INFORMATION

WARNING

Do not touch electrically live parts or elec- trodes with your skin or wet clothing.

Do not breathe welding fumes or gases.

Use ventilation or exhaust to remove weld- ing fumes from the breathing area.

Keep flammable material away.

Wear eye, ear, and body protection.

The POWER-ARC 4000 generator/welder can deliver from 70 to 125 amps of continuous welding output current . Output can be adjusted by setting the cur- rent control dial on the output control panel.

You can get maximum welding output by setting the dial to 125 AMPS. At high current settings like this, some output may decrease as the machine is used. If you are welding for a long time, you may need to turn the dial slightly upward to maintain the same results.

The numbers on the dial correspond to the average amps needed to weld using specific Lincoln welding rods. Table B.4, WELDING APPLICATIONS, gives you the recommended dial settings based on the thick- ness of the work and the size and type of rod you’re using.

TO USE THE POWER-ARC 4000 FOR WELDING:

1.Remove the flange nuts from the weld output ter- minals and place the work and electrode welding cables over the terminals. See Figure B.1. Replace and tighten the flange nuts securely. Be sure the connections are tight.

2.Select the appropriate electrode. See Table B.4, WELDING APPLICATIONS, or the ELECTRODE SELECTION GUIDE on the machine Output Control Panel.

4.Insert the electrode into the electrode holder.

5.Set the current control dial to the desired output current.

6.Start the gasoline engine. See ENGINE OPERA- TION in this section of the manual.

7.Strike an arc and begin welding. For information on welding techniques, see WELDING GUIDE- LINES in this section of the manual.

AFTER YOU FINISH THE WELD:

1.Stop the gasoline engine. See ENGINE OPERA- TION in this section of the manual.

2.Allow the electrode and work to cool completely.

3.Remove the work clamp from the work.

4.Remove any remaining piece of electrode from the electrode holder.

5.If you are finished using the POWER-ARC 4000 for welding, disconnect the welding cables from the weld output terminals. Reattach the flange nuts and leave them on the terminals.

POWER-ARC 4000

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Contents POWER-ARC TM4000 Safety POWER-ARCElectric Shock can kill Welding Sparks can cause fire or explosion IiiPrécautions DE Sûreté Master Table of Contents for ALL Sections Table of Contents Installation Section Installation Technical Specifications POWER-ARCSafety Precautions Location and VentilationStoring PRE-OPERATION Engine Service Power ARC Electrical Output ConnectionsWelding Cable Connections Cable Size and LengthAuxiliary Power Receptacles Cable InstallationMachine Grounding Plugs and HAND-HELD EquipmentPremises Wiring Circuit BreakersTable A.2 Electrical Device USE with the POWER-ARC Type Common Electrical Devices Possible ConcernsTable of Contents Operation Section Safety Instructions OperationOperating Instructions General DescriptionOperational Features and Controls Design Features AdvantagesRecommended Applications Welding CapabilityControls and Settings GENERATOR/WELDER ControlsFigure B.2 Gasoline Engine Controls Gasoline Engine ControlsEngine Operation Before Starting the EngineStarting the Engine Stopping the Engine Running the EngineBREAK-IN Period To USE the Generator AS AN Auxiliary Power Supply Generator OperationGeneral Information Table B.3 Generator Power Applications To USE the POWER-ARC 4000 for Welding Welding OperationAfter YOU Finish the Weld Material Thickness Electrode Type Size Setting Welding GuidelinesStick Welding Welding Circuit ARC12/95 POWER-ARC Four Factors of Successful WeldingElectrode Correct WAY to Strike AN ARCCorrect ARC Length Correct Welding SpeedTable of Contents Accessories OPTIONS/ACCESSORIES Lincoln Electric AccessoriesBriggs and Stratton Accessories Table of Contents Maintenance Routine and Periodic Maintenance Engine MaintenanceFigure D.2 Clean Rotating SCREEN/FINGER GUARD/DEBRIS Guard Figure D.4 SET Spark Plug GAP Table D.2 Engine Maintenance Parts GENERATOR/WELDER MaintenancePart Part Number Figure D.6. Major Component Locations Table of Contents Theory of Operation Section Theory of Operation ENGINE, EXCITATION, Rotor and StatorRotor Field Feedback and Auxiliary Power Figure E.3 Field Excitation and Auxiliary PowerAuxiliary Power Overcurrent Protection Weld Winding and ReactorTable of Contents Trouble Shooting & Repair Section Troubleshooting & Repair HOW to USE Troubleshooting GuideTroubleshooting Guide Output ProblemsOr contact your local Lincoln Local Lincoln Electric Authorized Troubleshooting & Repair Troubleshooting & Repair Engine Problems Engine Problems Welding Problems Rotor Voltage Test Test DescriptionMaterials Needed Test Procedure Ground Stud Lead 200A Connection Output PanelRotor Resistance Test Slip RingsFigure F.3 Brushes Retained with Cable TIE Cable TIE BrushesEngine Throttle Adjustment Test Mark Strobe-tach MethodFrequency Counter Method Oscilloscope MethodFigure F.5 Location of Engine Throttle Adjustment NUT NUTScope Settings Normal Open Circuit Weld Voltage WaveformHigh Idle no Load Normal Open Circuit Voltage Waveform 115 VAC Supply Typical Weld Output Waveform Machine LoadedMachine Loaded to 125 Amps AT 23 VAC Brush Removal and Replacement DescriptionProcedure Figure F.6 Brushes Retained with Cable TIEProcedure 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 ReplacementProcedure Diode Bridge Removal and Replacement STATOR/ROTOR Removal and Replacement InstructionsStator Removal Procedure TIE WrapOutput TerminalsThru Bolts Support Nuts POWER-ARC Figure F.10 Stator END Bracket Support and THRU-BOLTSRotor Removal Procedure Reassembly ProcedureRotor THRU-BOLT Feeler Gauge RotorAuxiliary Power Receptacle OUTPUT1 Retest After RepairEngine Output WELDER/GENERATOR OUTPUT1POWER-ARC Table of Contents Electrical DiagramsSection G Electrical Diagram POWER-ARCPOWER-ARC POWER-ARC