POWER-ARC TM4000 | Lincoln Electric SVM103-A instruction

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RETURN TO MAIN INDEX	SVM103-A

POWER-ARC TM4000	December 1995
For use with machine code number 10083

Safety Depends on You

Lincoln arc welding and cutting equipment is designed and built with safety in mind. However, your overall safety can be increased by proper installation . . . and thoughtful operation on your part. DO

NOT INSTALL, OPERATE OR REPAIR THIS EQUIPMENT WITHOUT READING THIS MANUAL AND THE SAFETY PRECAUTIONS CONTAINED THROUGHOUT. And, most importantly, think before you act and be careful.

SERVICE MANUAL


World’s Leader in Welding and Cutting Products			Premier Manufacturer of Industrial Motors

Sales and Service through subsidiaries and Distributors Worldwide

22801 St. Clair Ave. Cleveland, Ohio 44117-1199 U.S.A. Tel. (216) 481-8100

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Lincoln Electric SVM103-A service manual POWER-ARC TM4000

Contents

POWER-ARC TM4000 POWER-ARC Safety Electric Shock can kill Iii 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 Installation Location and Ventilation Safety PrecautionsStoring PRE-OPERATION Engine Service Electrical Output Connections Power ARCWelding Cable Connections Cable Size and Length Cable Installation Auxiliary Power ReceptaclesMachine Grounding Plugs and HAND-HELD Equipment Circuit Breakers Premises Wiring Type Common Electrical Devices Possible Concerns Table A.2 Electrical Device USE with the POWER-ARC Table of Contents Operation Section Operation Safety InstructionsOperating Instructions General Description Design Features Advantages Operational Features and ControlsRecommended Applications Welding Capability GENERATOR/WELDER Controls Controls and Settings Gasoline Engine Controls Figure B.2 Gasoline Engine Controls Before Starting the Engine Engine OperationStarting the Engine Running the Engine Stopping the EngineBREAK-IN Period Generator Operation To USE the Generator AS AN Auxiliary Power SupplyGeneral Information Table B.3 Generator Power Applications Welding Operation To USE the POWER-ARC 4000 for WeldingAfter YOU Finish the Weld Welding Guidelines Material Thickness Electrode Type Size SettingStick Welding ARC Welding Circuit Four Factors of Successful Welding 12/95 POWER-ARCElectrode Correct WAY to Strike AN ARC Correct Welding Speed Correct ARC Length Table of Contents Accessories Lincoln Electric Accessories OPTIONS/ACCESSORIESBriggs and Stratton Accessories Table of Contents Maintenance Engine Maintenance Routine and Periodic Maintenance Figure D.2 Clean Rotating SCREEN/FINGER GUARD/DEBRIS Guard Figure D.4 SET Spark Plug GAP GENERATOR/WELDER Maintenance Table D.2 Engine Maintenance PartsPart Part Number Figure D.6. Major Component Locations Table of Contents Theory of Operation Section ENGINE, EXCITATION, Rotor and Stator Theory of Operation Figure E.3 Field Excitation and Auxiliary Power Rotor Field Feedback and Auxiliary Power Weld Winding and Reactor Auxiliary Power Overcurrent Protection Table of Contents Trouble Shooting & Repair Section HOW to USE Troubleshooting Guide Troubleshooting & Repair Output Problems Troubleshooting Guide Or contact your local Lincoln Local Lincoln Electric Authorized Troubleshooting & Repair Troubleshooting & Repair Engine Problems Engine Problems Welding Problems Test Description Rotor Voltage TestMaterials Needed Ground Stud Lead 200A Connection Output Panel Test Procedure Rotor Resistance Test Rings Slip Cable TIE Brushes Figure F.3 Brushes Retained with Cable TIE Engine Throttle Adjustment Test Strobe-tach Method MarkFrequency Counter Method Oscilloscope Method NUT Figure F.5 Location of Engine Throttle Adjustment NUT 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 Replacement Figure F.6 Brushes Retained with Cable TIE Procedure Procedure Rheostat Removal and Replacement Figure F.7 Rheostat Removal Capacitor AND/OR Diode Bridge Removal Replacement Procedure Capacitor Removal and Replacement Capacitor AND/OR Diode Bridge Removal and Replacement Procedure Diode Bridge Removal and Replacement Instructions STATOR/ROTOR Removal and Replacement TIE Wrap Stator Removal ProcedureOutput Terminals Figure F.10 Stator END Bracket Support and THRU-BOLTS Thru Bolts Support Nuts POWER-ARC Reassembly Procedure Rotor Removal ProcedureRotor THRU-BOLT Rotor Feeler Gauge Retest After Repair Auxiliary Power Receptacle OUTPUT1Engine Output WELDER/GENERATOR OUTPUT1 POWER-ARC Electrical Diagrams Table of ContentsSection G POWER-ARC Electrical Diagram POWER-ARC POWER-ARC