Lincoln Electric SVM103-C service manual Machine Grounding, Plugs and HAND-HELD Equipment

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A-7

 

INSTALLATION

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Cable Installation

 

 

 

 

 

 

WARNING

 

 

 

 

 

 

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Install the welding cables to your POWER-ARC 4000 as follows. See Figure A.1 for the location of parts.

1.The gasoline engine must be OFF to install weld- ing cables.

2.Remove the 1/2 - 13 flanged nuts from the output terminals.

3.Connect the electrode holder and work cables to the weld output terminals. You can connect either cable to either terminal, since the POWER- ARC 4000 provides AC weld current.

4.Tighten the flanged nuts securely.

5.Be certain that the metal piece you are welding (the “work”) is securely connected to the work clamp and cable.

6.Check and tighten the connections periodically.

CAUTION

•Loose connections will cause the output terminals to overheat. The terminals may eventually melt.

•Do not cross the welding cables at the output termi- nal connection. Keep the cables isolated and sepa- rate from one another.

Lincoln Electric offers a welding accessory kit with the properly specified welding cables. See the ACCESSORIES section of this manual for more infor- mation.

MACHINE GROUNDING

Because the POWER-ARC 4000 creates its own power from its gasoline-engine driven generator, you do not need to connect the machine frame to an earth

ground. However, for best protection against electri- cal shock, connect a heavy gauge wire from the ground stud located on the bottom center of the out- put panel (see Figure A.1) to a suitable earth ground such as a metal pipe driven into the ground.

Do not ground the machine to a pipe that carries explosive or combustible material.

When the POWER-ARC 4000 is mounted on a truck or a trailer, the machine gen- erator ground stud MUST be securely connected to the metal frame of the vehicle. See Figure A.1. The ground stud is marked with the symbol.

PLUGS AND HAND-HELD EQUIPMENT

For further protection against electric shock, any electrical equipment connected to the generator receptacles must use a three-blade, grounded type plug or an Underwriter’s Laboratories (UL) approved double insulation system with a two-blade plug. Lincoln offers an accessory plug kit that has the right type of plugs. See the ACCESSORIES section of this manual for details.

WARNING

Never operate this machine with damaged or defec- tive cords. All electrical equiptment must be in safe condition.

AUXILIARY POWER RECEPTACLES

The control panel of the POWER-ARC 4000 features two auxiliary power receptacles:

•A 20 amp, 120 volt duplex (double outlet) recepta- cle

•A 20 amp 240 volt simplex (single outlet) recepta- cle.

See Figure A.1.

Through these receptacles the machine can supply up to 4,000 rated continuous watts and 4,400 surge watts of single-phase AC power.

POWER-ARC 4000

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Contents Safety Depends on You POWER-ARCCalifornia Proposition 65 Warnings SafetyElectric 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 Technical Specifications POWER-ARC InstallationLocation and Ventilation Safety PrecautionsStoring PRE-OPERATION Engine Service Cert. Kool Bore Spark ArresterWelding Cable Connections Electrical Output ConnectionsCable Size for 125 ampMachine Grounding Auxiliary Power ReceptaclesPlugs and HAND-HELD Equipment Circuit Breakers Premises WiringThese Devices Without POWER-ARC Table of Contents Operation Section Operation Safety InstructionsOperating Instructions General DescriptionDesign Features Advantages Operational Features and ControlsRecommended Applications Welding CapabilityGENERATOR/WELDER Controls Controls and Settings20 AMP, 120 Volt Duplex Receptacle Gasoline Engine ControlsBefore Starting the Engine Engine OperationStarting the Engine For a HOT Engine Generator Operation To USE the Generator AS AN Auxiliary Power SupplyGeneral Information Suggested Power Applications Running Watts Start-up Watts Table B.1 Generator Power ApplicationsWelding Operation Table B.2 Welding APPLICATIONS/ELECTRODE Selection Guide Welding GuidelinesOperation What Happens in the Arc? Correct Welding Position Correct Arc Length Use the following PracticeDo the following Butt WeldsPenetration Fillet WeldsVertical-Down Welding Vertical-Up WeldingHardfacing To Reduce Wear Overhead WeldingWelding Sheet Metal Cast Iron Plate Preparation Welding Cast IronOut-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 Routine and Periodic Maintenance MaintenanceEngine Maintenance Engine AdjustmentsFigure D.2 Clean Rotating SCREEN/FINGER GUARD/DEBRIS Guard Table D.1 Engine Maintenance Schedule Do not attempt to polish slip rings while engine is running GENERATOR/WELDER MaintenanceFigure 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 Troubleshooting & Repair Section HOW to USE Troubleshooting Guide Troubleshooting & RepairOutput Problems TroubleshootingElectric Authorized Field Ser Or contact your local LincolnVice Facility Local Lincoln Electric Authorized Field Service FacilityTroubleshooting Rotor Resistance Test Engine Problems Troubleshooting Engine Throttle Adjustment Rotor Voltage Test This procedure takes approximately 15 minutes to performTest Description Materials NeededRotor Voltage Test Test ProcedureRotor Resistance Test This procedure takes approximately 25 minutes to performRotor Resistance Test Figure F.3 Brushes Retained with Cable TIE This procedure takes approximately 20 minutes to perform Engine Throttle Adjustment TestFrequency 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 Description Brush Removal and ReplacementProcedure Brush Removal and ReplacementProcedure Rheostat Removal and Replacement Figure F.7 Rheostat Removal This procedure takes approximately 35 minutes to perform Capacitor AND/OR Diode Bridge Removal and ReplacementFigure F.8 Location and Discharging the Field Capacitor Procedure Capacitor Removal and REPLACE- MentFigure F.8A Field Diode Bridge Location Procedure Field Diode Bridge Removal and ReplacementThis 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 Retest After Repair Auxiliary Power Receptacle OUTPUT1Engine Output WELDER/GENERATOR OUTPUT1Return to Section TOC Table of Contents Diagrams Section Wiring Diagram Power ARC DiagramsDIAGRAMSG-3 DIAGRAMSG-4 Dimension Print Power ARC Return to Section TOC SVM Error Reporting Form
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