Table of Contents Maintenance Section | Lincoln Electric SVM103-C

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Section D

Section D

TABLE OF CONTENTS

- MAINTENANCE SECTION -

	Page
Installation	Section D
Safety Precautions	D-2
Routine and Periodic Maintenance	D-2
Engine Maintenance	D-2
Oil	D-2
Fuel	D-2
Engine Adjustments	D-2
Clean Engine	D-3
Clean Cooling System	D-3
Spark Plug	D-3
Clean Spark Arrestor Screen	D-3
Engine Maintenance Schedule	D-4
Engine Maintenance Parts	D-4
Generator/Welder Maintenance	D-5
Storage	D-5
Cleaning	D-5
Brush Removal and Replacement	D-5
Receptacles	D-5
Cable Connections	D-5
Major Component Locations	D-6

POWER-ARC 4000

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Lincoln Electric SVM103-C service manual Table of Contents Maintenance Section

Contents

Safety Depends on You POWER-ARC California Proposition 65 Warnings Safety Electric 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 Installation Safety Precautions Location and VentilationStoring PRE-OPERATION Engine Service Cert. Kool Bore Spark Arrester 125 amp Electrical Output ConnectionsWelding Cable Connections Cable Size for Auxiliary Power Receptacles Machine GroundingPlugs and HAND-HELD Equipment Circuit Breakers Premises Wiring These Devices Without POWER-ARC Table of Contents Operation Section General Description Safety InstructionsOperation Operating Instructions Welding Capability Operational Features and ControlsDesign Features Advantages Recommended Applications GENERATOR/WELDER Controls Controls and Settings 20 AMP, 120 Volt Duplex Receptacle Gasoline Engine Controls Engine Operation Before Starting the EngineStarting the Engine For a HOT Engine To USE the Generator AS AN Auxiliary Power Supply Generator OperationGeneral Information Suggested Power Applications Running Watts Start-up Watts Table B.1 Generator Power Applications Welding Operation Table B.2 Welding APPLICATIONS/ELECTRODE Selection Guide Welding Guidelines Operation What Happens in the Arc? Correct Welding Position Correct Arc Length Butt Welds PracticeUse the following Do the following Penetration Fillet Welds Vertical-Down Welding Vertical-Up Welding Overhead Welding Hardfacing To Reduce WearWelding Sheet Metal Cast Iron Plate Preparation Welding Cast Iron High-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 Adjustments MaintenanceRoutine and Periodic Maintenance Engine Maintenance Figure 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 Maintenance 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 Troubleshooting & Repair Section HOW to USE Troubleshooting Guide Troubleshooting & Repair Output Problems Troubleshooting Or contact your local Lincoln Electric Authorized Field SerVice Facility Local Lincoln Electric Authorized Field Service Facility Troubleshooting Rotor Resistance Test Engine Problems Troubleshooting Engine Throttle Adjustment Materials Needed This procedure takes approximately 15 minutes to performRotor Voltage Test Test Description Rotor Voltage Test Test Procedure Rotor Resistance Test This procedure takes approximately 25 minutes to perform Rotor Resistance Test Figure F.3 Brushes Retained with Cable TIE This procedure takes approximately 20 minutes to perform Engine Throttle Adjustment Test Strobe-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 Description Brush Removal and Replacement Procedure Brush Removal and Replacement Procedure Rheostat Removal and Replacement Figure F.7 Rheostat Removal This procedure takes approximately 35 minutes to perform Capacitor AND/OR Diode Bridge Removal and Replacement Figure F.8 Location and Discharging the Field Capacitor Procedure Capacitor Removal and REPLACE- Ment Figure F.8A Field Diode Bridge Location Procedure Field Diode Bridge Removal and Replacement STATOR/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 WELDER/GENERATOR OUTPUT1 Auxiliary Power Receptacle OUTPUT1Retest After Repair Engine Output Return to Section TOC Table of Contents Diagrams Section Wiring Diagram Power ARC Diagrams DIAGRAMSG-3 DIAGRAMSG-4 Dimension Print Power ARC Return to Section TOC SVM Error Reporting Form