Lincoln Electric SVM103-C service manual PRE-OPERATION Engine Service

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INSTALLATION

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STACKING

POWER-ARC 4000 machines CANNOT be stacked.

TILTING

Place the machine on a secure, level surface whenev- er you use it or store it. Any surfaces you place it on other than the ground must be firm, non-skid, and structurally sound.

The gasoline engine is designed to run in a level posi- tion for best performance. It can operate at an angle, but this should never be more than 15 degrees in any direction. If you do operate it at a slight angle, be sure to check the oil regularly and keep the oil level full. Also, fuel capacity will be a little less at an angle.

LIFTING

The POWER-ARC 4000 should be lifted by two peo- ple. (It weighs 160 lbs/72.5 kg.) Its welded tube roll cage is designed to make lifting easy.

OIL

The Power-Arc 4000 with the Briggs and Stratton 8 HP engine and the Power-Arc

4000 with the Honda 9 HP engine are supplied with low oil protection. The Power-Arc 4000 with the Briggs and Stratton 8 HP engine is equipped with protection that will prevent the engine from starting if the oil level is low. The Power-Arc 4000 with the Honda 9 HP engine is equipped with protection that will shut down the engine in the event of a low oil condition. The engine cannot be restarted until suffi- cient oil is added.

The POWER-ARC 4000 is shipped with the engine filled with SAE 10W-30 oil. CHECK THE OIL LEVEL BEFORE YOU START THE ENGINE. This is an added precaution. When full, the oil level should be at the top of the fill plug hole. If it is not full, add enough oil to fill it. Be sure the fill plug is tight. Change oil after the first 5 hours of operation.

For more oil fill and service information, see the Briggs & Stratton Engine manual.

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ANGLE OF OPERATION

Internal combustion engines are designed to run in a level condition to achieve optimum performance. The maximum angle of operation for the engine 15 degrees from horizontal in any direction. Be certain to place the machine on a firm, non-skid, structural supporting surface. Anchor unit if necessary.

If you are operating the engine at a slight angle, be certain to check the oil regularly and maintain a level, full oil condition. The effective fuel capacity will also be slightly less than the specified 1.00 gallon (3.8

liters).

PRE-OPERATION ENGINE SERVICE

Read and understand the information about the gaso- line engine in the OPERATION and MAINTENANCE sections of this manual before you operate the POWER-ARC 4000.

WARNING

•Keep hands away from the engine muffler or HOT engine parts.

•Stop the engine when fueling.

•Do not smoke when fueling.

•Remove the fuel cap slowly to release pressure.

•Do not overfill the fuel tank.

•Wipe up spilled fuel and allow the fumes to clear before starting the engine.

•Keep sparks and flame away from the fuel tank.

FUEL

Fill the fuel tank with clean, fresh, regular grade lead- free gasoline. DO NOT MIX OIL WITH THE GASO-

LINE.

The POWER-ARC 4000 has a plastic, 1.0 gallon (3.8L) fuel tank mounted on the engine. See the Briggs & Stratton Engine manual for more details about fuel.

MUFFLER DEFLECTOR

The POWER-ARC 4000 is shipped with an exhaust deflector. You can mount it yourself on the gasoline engine.

To install the deflector, do the following:

•Align the holes on the deflector plate with the holes on the muffler.

•Position the deflector so that the opening points either right, left, or downward, away from the operator.

CAUTION

Never position the deflector upward. Moisture or debris can enter the engine and damage it. As a general safety practice, position the deflector to direct exhaust gases away from the operator’s face and eyes.

•Fasten the deflector onto the muffler with the screws provided.

NOTE: The deflector reduces generator output power up to 100 watts.

POWER-ARC 4000

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Contents POWER-ARC Safety Depends on YouSafety California Proposition 65 WarningsElectric Shock can kill Welding Sparks can cause fire or explosion Précautions DE Sûreté Master Table of Contents for ALL Sections Table of Contents Installation Section Installation Technical Specifications POWER-ARCLocation and Ventilation Safety PrecautionsStoring PRE-OPERATION Engine Service Spark Arrester Cert. Kool BoreCable Size for Electrical Output ConnectionsWelding Cable Connections 125 ampMachine Grounding Auxiliary Power ReceptaclesPlugs and HAND-HELD Equipment Premises Wiring Circuit BreakersThese Devices Without POWER-ARC Table of Contents Operation Section Operating Instructions Safety InstructionsOperation General DescriptionRecommended Applications Operational Features and ControlsDesign Features Advantages Welding CapabilityControls and Settings GENERATOR/WELDER ControlsGasoline Engine Controls 20 AMP, 120 Volt Duplex ReceptacleBefore Starting the Engine Engine OperationStarting the Engine For a HOT Engine Generator Operation To USE the Generator AS AN Auxiliary Power SupplyGeneral Information Table B.1 Generator Power Applications Suggested Power Applications Running Watts Start-up WattsWelding Operation Welding Guidelines Table B.2 Welding APPLICATIONS/ELECTRODE Selection GuideOperation What Happens in the Arc? Correct Welding Position Correct Arc Length Do the following PracticeUse the following Butt WeldsFillet Welds PenetrationVertical-Up Welding Vertical-Down WeldingHardfacing To Reduce Wear Overhead WeldingWelding Sheet Metal Welding Cast Iron Cast Iron Plate PreparationOut-of-Position Group AWS E6011 High-Speed Group AWS E6013Low Hydrogen Group Stable-Arc E7018 Table of Contents Accessories Section OPTIONS/ACCESSORIES AccessoriesLincoln Electric Accessories Table of Contents Maintenance Section Engine Maintenance MaintenanceRoutine and Periodic Maintenance Engine AdjustmentsFigure D.2 Clean Rotating SCREEN/FINGER GUARD/DEBRIS Guard Table D.1 Engine Maintenance Schedule GENERATOR/WELDER Maintenance Do not attempt to polish slip rings while engine is runningFigure 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 Troubleshooting & Repair Section Troubleshooting & Repair HOW to USE Troubleshooting GuideTroubleshooting Output ProblemsElectric Authorized Field Ser Or contact your local LincolnVice Facility Field Service Facility Local Lincoln Electric AuthorizedTroubleshooting Rotor Resistance Test Engine Problems Troubleshooting Engine Throttle Adjustment Test Description This procedure takes approximately 15 minutes to performRotor Voltage Test Materials NeededTest Procedure Rotor Voltage TestThis procedure takes approximately 25 minutes to perform Rotor Resistance TestRotor Resistance Test Figure F.3 Brushes Retained with Cable TIE Engine Throttle Adjustment Test This procedure takes approximately 20 minutes to performFrequency Counter Method Strobe-tach MethodOscilloscope Method Wing NUT High Speed Stop Screw 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 DescriptionBrush Removal and Replacement ProcedureProcedure Rheostat Removal and Replacement Figure F.7 Rheostat Removal Capacitor AND/OR Diode Bridge Removal and Replacement This procedure takes approximately 35 minutes to performProcedure Capacitor Removal and REPLACE- Ment Figure F.8 Location and Discharging the Field CapacitorProcedure Field Diode Bridge Removal and Replacement Figure F.8A Field Diode Bridge LocationThis procedure takes approximately 3 hours to perform STATOR/ROTOR Removal and ReplacementInstructions STATOR/ROTOR Removal and Replacement Troubleshooting & Repair Rotor Removal Procedure Figure F.12 Checking ROTOR-STATOR AIR GAP Engine Output Auxiliary Power Receptacle OUTPUT1Retest After Repair WELDER/GENERATOR OUTPUT1Return to Section TOC Table of Contents Diagrams Section Diagrams Wiring Diagram Power ARCDIAGRAMSG-3 DIAGRAMSG-4 Dimension Print Power ARC Return to Section TOC SVM Error Reporting Form
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