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Lincoln Electric SVM103-A CAPACITOR AND/OR DIODE BRIDGE REMOVAL AND REPLACEMENT

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POWER-ARC 4000

F-27 TROUBLESHOOTING & REPAIR

CAPACITOR AND/OR DIODE BRIDGE REMOVAL AND REPLACEMENT

(continued)

FIGURE F.8 - DIODE BRIDGE LOCATION AND DISCHARGING THE FIELD CAPACITOR

JUMPER

DIODE

BRIDGE

CAPACITOR

PROCEDURE - CAPACITOR

REMOVAL AND REPLACEMENT

1. Remove the engine spark plug wire.

2. With the 5/16” nut driver, remove the 4

sheet metal screws that hold the top cover

to the control box. Remove the top cover.

3. Discharge the field capacitor by connect-

ing the jumper wire clips on the black and

the red wire terminals on the top of the

capacitor. See Figure F.8 for location.

Leave the clips on for at least 5 seconds,

then remove.

4. Both the capacitor and the diode bridge

are mounted in a molded plastic holder.

To remove it, pull out on the top of the

holder, then slide it upward.

5. Snap the capacitor out of the assembly.

6. Loosen the two screws on the top of the

capacitor. Lead 202A (Red) attaches to

the positive (+) terminal. Leads 201 and

201A (both Black) attach to the negative (-

) terminal.

7. To replace the capacitor, reattach the

leads to their respective terminals (202A

Red to positive (+); 201 and 201A Black to

negative (-) and tighten the screws secure-

ly. Snap the capacitor back into the mold-

ed plastic holder and slide the holder back

into position in the panel. Replace the top

cover of the control box and tighten down

the 4 sheet metal screws with the 5/16” nut

driver.

Contents

Main SVM103-A POWER-ARC 4000 December 1995 Safety Depends on You SERVICE MANUAL i WARNING ELECTRIC AND MAGNETIC FIELDS may be dangerous ii ARC RAYS can burn. ELECTRIC SHOCK can kill. FUMES AND GASES can be dangerous. POWER-ARC 4000 iii FOR ELECTRICALLY powered equipment. CYLINDER may explode if damaged. WELDING SPARKS can cause fire or explosion. iv PRCAUTIONS DE SRET PRCAUTIONS DE SRET POUR LES MACHINES SOUDER TRANSFOR- MATEUR ET REDRESSEUR MASTER TABLE OF CONTENTS FOR ALL SECTIONS - INSTALLATION SECTION - Page SAFETY PRECAUTIONS LOCATION AND VENTILATION STORING STACKING TILTING PRE-OPERATION ENGINE SERVICE OIL FUEL MUFFLER DEFLECTOR SPARK ARRESTER ELECTRICAL OUTPUT CONNECTIONS WELDING CABLE CONNECTIONS FIGURE A.1 - POWER-ARC 4000 OUTPUT CONNECTIONS MACHINE GROUNDING PLUGS AND HAND-HELD EQUIPMENT AUXILIARY POWER RECEPTACLES PREMISES WIRING CIRCUIT BREAKERS Page - OPERATION SECTION - OPERATING INSTRUCTIONS SAFETY INSTRUCTIONS ELECTRIC SHOCK can kill. FUMES AND GASES can be dangerous. WELDING SPARKS can cause fire or explosion. RECOMMENDED APPLICATIONS GENERATOR WELDER OPERATIONAL FEATURES AND CONTROLS DESIGN FEATURES AND ADVANTAGES CONTROLS AND SETTINGS 8 FIGURE B.1 OUTPUT PANEL CONTROLS GENERATOR/WELDER CONTROLS 2345 8 9 FIGURE B.2 GASOLINE ENGINE CONTROLS GASOLINE ENGINE CONTROLS ENGINE OPERATION BEFORE STARTING THE ENGINE STARTING THE ENGINE STOPPING THE ENGINE RUNNING THE ENGINE BREAK-IN PERIOD GENERATOR OPERATION GENERAL INFORMATION Page WELDING OPERATION GENERAL INFORMATION WELDING GUIDELINES STICK WELDING THE WELDING CIRCUIT 68 THE ARC 34 FIGURE B.3 WELDING CIRCUIT CONNECTIONS THE ELECTRODE THE FOUR FACTORS OF SUCCESSFUL WELDING 35 FIGURE B.5 CORRECT WELDING POSITION 74 FIGURE B.6 MOLTEN METAL PUDDLE AND CORRECT WELD SPEED Page OPTIONS/ACCESSORIES LINCOLN ELECTRIC ACCESSORIES BRIGGS AND STRATTON ACCESSORIES SEMIAUTOMATIC MIG WELDING WITH A LINCOLN WELD-PAK 100 OR WELD-PAK 125 Page SAFETY PRECAUTIONS ROUTINE AND PERIODIC MAINTENANCE ENGINE MAINTENANCE FIGURE D.1 - OIL DRAIN AND REFILL LOCATION FIGURE D.2 - CLEAN ROTATING SCREEN/FINGER GUARD/DEBRIS GUARD FIGURE D.3 - CLEAN COOLING SYSTEM FIGURE D.4 - SET SPARK PLUG GAP TABLE D.2 ENGINE MAINTENANCE PARTS GENERATOR/WELDER MAINTENANCE FIGURE D.5. BRUSH REMOVAL AND REPLACEMENT FIGURE D.6. - MAJOR COMPONENT LOCATIONS -THEORY OF OPERATION SECTION- FIGURE E.1 POWER-ARC 4000 BLOCK LOGIC DIAGRAM ENGINE, EXCITATION, ROTOR AND STATOR FIGURE E.2 ENGINE, ROTOR AND STATOR ROTOR FIELD FEEDBACK AND AUXILIARY POWER FIGURE E.3 FIELD EXCITATION AND AUXILIARY POWER WELD WINDING AND REACTOR FIGURE E.4 WELDING OUTPUT SHADE AUXILIARY POWER OVERCURRENT PROTECTION TROUBLE SHOOTING & REPAIR SECTION HOW TO USE TROUBLESHOOTING GUIDE Page Page Page Page Page Page ENGINE PROBLEMS WELDING PROBLEMS ROTOR VOLTAGE TEST ROTOR VOLTAGE TEST (continued) FIGURE F.1 - LOCATION OF LEAD 200A FOR ROTOR VOLTAGE TEST ROTOR RESISTANCE TEST ROTOR RESISTANCE TEST (continued) FIGURE F.2 LOCATION OF ROTOR SLIP RINGS - BRUSH HOLDER ASSEMBLY REMOVED ROTOR RESISTANCE TEST (continued) FIGURE F.3 - BRUSHES RETAINED WITH CABLE TIE ENGINE THROTTLE ADJUSTMENT TEST ENGINE THROTTLE ADJUSTMENT TEST (continued) FIGURE F.4 - BLOWER PADDLE MARKED FOR STROBE-TACH METHOD Page NORMAL OPEN CIRCUIT WELD VOLTAGE WAVEFORM HIGH IDLE NO LOAD NORMAL OPEN CIRCUIT VOLTAGE WAVEFORM (115 VAC SUPPLY) HIGH IDLE NO LOAD MACHINE LOADED TO 125 AMPS AT 23 VAC TYPICAL WELD OUTPUT WAVEFORM MACHINE LOADED BRUSH REMOVAL AND REPLACEMENT BRUSH REMOVAL AND REPLACEMENT (continued) FIGURE F.6 - BRUSHES RETAINED WITH CABLE TIE PROCEDURE BRUSH REMOVAL AND REPLACEMENT (continued) PROCEDURE (continued) Page RHEOSTAT REMOVAL AND REPLACEMENT FIGURE F.7 - RHEOSTAT REMOVAL PROCEDURE CAPACITOR AND/OR DIODE BRIDGE REMOVAL AND REPLACEMENT CAPACITOR AND/OR DIODE BRIDGE REMOVAL AND REPLACEMENT FIGURE F.8 - DIODE BRIDGE LOCATION AND DISCHARGING THE FIELD CAPACITOR PROCEDURE - CAPACITOR REMOVAL AND REPLACEMENT PROCEDURE - DIODE BRIDGE REMOVAL AND REPLACEMENT STATOR/ROTOR REMOVAL AND REPLACEMENT INSTRUCTIONS TROUBLESHOOTING & REPAIR FIGURE F.9 - OUTPUT LEAD LOCATION STATOR REMOVAL PROCEDURE FIGURE F.10 STATOR END BRACKET SUPPORT AND THRU-BOLTS TROUBLESHOOTING & REPAIR FIGURE F.11 - ROTOR WITH STATOR REMOVED ROTOR REMOVAL PROCEDURE REASSEMBLY PROCEDURE FIGURE F.12 - CHECKING ROTOR-STATOR AIR GAP TROUBLESHOOTING & REPAIR RETEST AFTER REPAIR ENGINE OUTPUT WELDER/GENERATOR OUTPUT AUXILIARY POWER RECEPTACLE OUTPUT Page Page - ELECTRICAL DIAGRAM - Return to Section TOC Return to Section TOC Return to Section TOC Return to Section TOC G-1 WIRING DIAGRAM Code 10083