Lincoln Electric SVM103-C service manual Operation, Operating Instructions, Safety Instructions

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B-2		OPERATION		B-2

OPERATING INSTRUCTIONS
OPERATING INSTRUCTIONS				WARNING

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Read and understand this entire section before oper- ating your POWER-ARC 4000.

SAFETY INSTRUCTIONS

WARNING

ARC RAYS can burn.

• Wear eye, ear, and body protection.

Do not attempt to use this equipment until you have					ENGINE EXHAUST can kill.
thoroughly read all the operation and maintenance					ENGINE EXHAUST can kill.
thoroughly read all the operation and maintenance
manuals supplied with your machine. They include					• Use in open, well ventilated areas or
important safety precautions; detailed engine starting,					vent exhaust to the outside.
operating, and maintenance instructions; and parts					• Do not stack anything on or near the
lists.					• Do not stack anything on or near the
lists.					engine.
					engine.

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ELECTRIC SHOCK can kill.

•Do not touch electrically live parts or electrodes with your skin or wet cloth- ing.

•Insulate yourself from the work and ground.

•Always wear dry insulating gloves.

FUMES AND GASES can be dangerous.

•Keep your head out of fumes.

•Use ventilation or exhaust to remove fumes from breathing zone.

WELDING SPARKS can cause fire or explosion.

•Keep flammable material away.

•Do not weld on containers that have held combustibles.

MOVING PARTS can injure.

•Do not operate this equipment with any of its doors open or guards off.

•Stop the engine before servicing it.

•Keep away from moving parts.

Only qualified personnel should install, use, or ser- vice this equipment.

GENERAL DESCRIPTION

The POWER-ARC 4000 is a generator/ welder designed for home use and other non-commercial applications. As a generator it can supply up to 4,000 continuous watts (or 4,400 surge watts) of 120/240 volt, single-phase AC power. As a welder it provides 125 amps of AC constant current for weld- ing with AC stick electrodes. A single dial provides continuous adjustment of welding output. The machine is lightweight, portable, and can be lifted by two people.

A Briggs & Stratton 8 HP Kool-Bore®Plus air-cooled, gasoline engine powers the generator/welder. The engine has an operating life of approximately 500 hours.

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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-ARCSafety Precautions Location and VentilationStoring PRE-OPERATION Engine Service Spark Arrester Cert. Kool BoreCable Size for Electrical Output ConnectionsWelding Cable Connections 125 ampAuxiliary Power Receptacles Machine GroundingPlugs 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 ReceptacleEngine Operation Before Starting the EngineStarting the Engine For a HOT Engine To USE the Generator AS AN Auxiliary Power Supply Generator OperationGeneral 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 WeldingOverhead Welding Hardfacing To Reduce WearWelding Sheet Metal Welding Cast Iron Cast Iron Plate PreparationHigh-Speed Group AWS E6013 Out-of-Position Group AWS E6011Low Hydrogen Group Stable-Arc E7018 Table of Contents Accessories Section Accessories OPTIONS/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 ProblemsOr contact your local Lincoln Electric Authorized Field SerVice 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 performStrobe-tach Method Frequency Counter MethodOscilloscope Method Wing NUT High Speed Stop Screw Scope 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 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 LocationSTATOR/ROTOR Removal and Replacement This procedure takes approximately 3 hours to performInstructions 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