Lincoln Electric SVM103-C service manual For a HOT Engine

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OPERATION

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4.Pull the cord rapidly.

5.If the engine does not start, open the choke slightly (move lever upward) and pull the starter cord rapidly again.

When the engine starts, gradually open the choke to the “RUN” position. To open the choke fully, requires an engine warm-up period of several seconds to several minutes depending on the temprature. After starting the engine, first open the choke (toward RUN) until the engine just begins to run smoothly. Then open the choke in small steps, allowing the engine to accept small changes in speed and load, until the choke is fully open (in RUN). During engine warm-up the equiptment can be operated.

FOR A “HOT” ENGINE:

STOPPING THE ENGINE

1.Remove all welding and generator power loads and let the engine cool by running it for several minutes.

2.Stop the engine by turning the Rotary Stop Switch on top of the engine to the “OFF” position.

3.Hold the lever down firmly until the engine com- pletely stops. Otherwise, the engine may restart or sputter as it stops.

4.Close the fuel shutoff valve at the bottom of the fuel tank.

WARNING

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1.Open the fuel shutoff valve on the bottom of the fuel tank.

2.Place the choke lever in the highest, upward position. Closing the choke of a hot engine will flood the carbure- tor and prevent starting.

3.Pull slightly on the recoil starter handle until resis- tance is felt.

4.Pull the cord rapidly.

FOR BEST ENGINE STARTING:

•Always use fresh gasoline and be sure the filter is clean and properly maintained.

•If you use an alternate fuel tank or supply, be sure to install an in-line fuel filter.

•Do not pull the recoil starter with the choke in the downward position more than one time. Repeated pulls on a choked engine will flood the carburetor.

•If the engine will not start, see the TROU- BLESHOOTING section of this manual.

Close the fuel valve when the machine is trans- ported to prevent fuel leakage from the carbure- tor. Drain the tank before transporting the machine in a vehicle.

For long periods of storage, turn off the fuel shut- off valve (lowest, downward position) and let the engine run until there is no more fuel in the line. Use a fuel additive such as Sta-Bil to minimize fuel gum deposits.

RUNNING THE ENGINE

The engine is set at the factory to run at high idle speed when not under load. You should not adjust this setting yourself.

BREAK-IN PERIOD

The engine will use a greater amount of oil during its “break-in” period. The break-in is about 12 running hours.

Check the oil frequently during break-in. Change the oil after the first 5 hours of operation. For more details, see the MAINTENANCE section of the engine owner’s manual.

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CAUTION

During break-in, subject the POWER-ARC 4000 to only moderate loads. Avoid long periods running at idle. Before stopping the engine, remove all loads and allow the engine to cool several min- utes.

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 InstallationStoring Safety PrecautionsLocation and Ventilation PRE-OPERATION Engine Service Cert. Kool Bore Spark Arrester125 amp Electrical Output ConnectionsWelding Cable Connections Cable Size forPlugs and HAND-HELD Equipment Auxiliary Power ReceptaclesMachine Grounding Circuit Breakers Premises WiringThese Devices Without POWER-ARC Table of Contents Operation Section General Description Safety InstructionsOperation Operating InstructionsWelding Capability Operational Features and ControlsDesign Features Advantages Recommended Applications GENERATOR/WELDER Controls Controls and Settings20 AMP, 120 Volt Duplex Receptacle Gasoline Engine ControlsStarting the Engine Engine OperationBefore Starting the Engine For a HOT Engine General Information To USE the Generator AS AN Auxiliary Power SupplyGenerator Operation 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 Butt Welds PracticeUse the following Do the followingPenetration Fillet WeldsVertical-Down Welding Vertical-Up WeldingWelding Sheet Metal Overhead WeldingHardfacing To Reduce Wear Cast Iron Plate Preparation Welding Cast IronLow Hydrogen Group Stable-Arc E7018 High-Speed Group AWS E6013Out-of-Position Group AWS E6011 Table of Contents Accessories Section Lincoln Electric Accessories AccessoriesOPTIONS/ACCESSORIES Table of Contents Maintenance Section Engine Adjustments MaintenanceRoutine and Periodic Maintenance Engine MaintenanceFigure 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 TroubleshootingVice Facility Or contact your local LincolnElectric Authorized Field Ser Local Lincoln Electric Authorized Field Service FacilityTroubleshooting Rotor Resistance Test Engine Problems Troubleshooting Engine Throttle Adjustment Materials Needed This procedure takes approximately 15 minutes to performRotor Voltage Test Test DescriptionRotor 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 TestOscilloscope Method Strobe-tach MethodFrequency Counter Method Wing NUT High Speed Stop Screw High 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 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 ReplacementInstructions STATOR/ROTOR Removal and ReplacementThis procedure takes approximately 3 hours to perform STATOR/ROTOR Removal and Replacement Troubleshooting & Repair Rotor Removal Procedure Figure F.12 Checking ROTOR-STATOR AIR GAP WELDER/GENERATOR OUTPUT1 Auxiliary Power Receptacle OUTPUT1Retest After Repair Engine OutputReturn 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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