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Lincoln Electric POWER-ARC 4000 SVM103-A User Manual

Lincoln Electric POWER-ARC 4000 SVM103-A
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SVM103-A
December 1995
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
For use with machine code number 10083
POWER-ARC 4000
TM
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Table of Contents

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Lincoln Electric POWER-ARC 4000 SVM103-A Specifications

General IconGeneral
BrandLincoln Electric
ModelPOWER-ARC 4000 SVM103-A
CategoryWelding System
LanguageEnglish

Summary

Safety Introduction

Safety Depends on You

Emphasizes user responsibility for safety and the importance of reading the manual.

Safety Warnings and Precautions

California Proposition 65 Warnings

Warns about cancer, birth defects, and reproductive harm from engine exhaust.

Arc Welding Hazards

General warning about the hazards of arc welding and advising caution.

Engine-Powered Equipment Safety

Specific safety instructions for engine-powered equipment operation.

Electric and Magnetic Fields (EMF)

Discusses the potential health effects of EMF fields and precautions.

General Safety Precautions

Electric Shock Hazards

Details electrical shock hazards and necessary precautions during welding.

Arc Ray Burns Protection

Explains the dangers of arc rays and protective measures for eyes and skin.

Fumes and Gases Dangers

Covers hazards of welding fumes/gases and ventilation requirements.

Fire, Explosion, and Electrical Safety

Welding Spark Fire Risks

Warns about welding sparks causing fires and precautions to prevent them.

Compressed Gas Cylinder Safety

Safety precautions for handling compressed gas cylinders.

Electrical Equipment Safety

Electrical safety precautions for powered equipment installation and use.

French Safety Precautions

General and Specific Safety

General and specific safety precautions in French for welding machines.

Installation Procedures

Technical Specifications

Lists detailed technical specifications for the POWER-ARC 4000.

Installation Safety and Handling

Safety guidelines, location, storage, handling, and positioning instructions.

Pre-Operation Engine Setup

Tasks to perform on the engine before initial operation, including oil and fuel.

Exhaust and Spark Arresters

Information on mounting the muffler deflector and spark arresters.

Electrical Connections and Grounding

Guidance on connecting electrical outputs, welding cables, and grounding the machine.

Auxiliary Power and Premises Wiring

Safety for connected devices, auxiliary receptacles, premises wiring, and circuit breakers.

Technical Specifications Overview

Installation Safety and Setup

General Safety Precautions

General warnings and safety advice for operating the equipment.

Location and Ventilation Guidelines

Guidance on selecting an appropriate location and ensuring proper ventilation.

Machine Storage Instructions

Detailed instructions for storing the machine for short and long periods.

Engine Preparation for Operation

Stacking, Tilting, and Lifting

Guidelines on machine handling and positioning.

Pre-Operation Engine Checks

Tasks to perform on the engine before initial operation.

Oil and Fuel Management

Instructions for checking and filling engine oil and fuel.

Muffler Deflector and Spark Arresters

Details on mounting the exhaust deflector and spark arresters.

Electrical Output and Cable Connections

Cable Size and Length Recommendations

Table providing recommended welding cable sizes and lengths.

Cable Installation and Grounding

Welding Cable Installation

Step-by-step instructions for installing welding cables.

Machine Grounding Procedures

Information on grounding the machine for electrical shock protection.

Plugs and Auxiliary Receptacles

Safety advice for connected equipment and auxiliary receptacles.

Premises Wiring and Circuit Protection

Premises Wiring Considerations

Discusses connecting the generator to premises wiring and associated safety.

Circuit Breaker Functions

Information about the unit's circuit breakers and their function.

Electrical Device Compatibility

Operation Overview

Safety and General Information

Important safety guidelines and general description of the machine.

Applications and Capabilities

Suitable applications, welding capability, and limitations of the machine.

Controls and Engine Operation

Explanation of controls, engine operation, and break-in period.

Generator and Welding Operation

Instructions for operating the machine as a generator and welder.

Operating Instructions and Safety

General Operating Instructions

General instructions for operating the POWER-ARC 4000.

Key Safety Instructions

Crucial safety warnings and precautions for machine use.

Machine Description

An overview of the POWER-ARC 4000's design and purpose.

Operational Features and Capabilities

Recommended Applications

Suitable applications for the generator and welder functions.

Operational Features and Controls

Description of the machine's simple controls and features.

Design Features and Welding Capability

Highlights key design aspects, benefits, and welding output.

Operational Limitations

Important restrictions on the machine's usage.

Controls and Settings Explained

Generator/Welder Controls

Description of controls for generator and welder functions.

Control Panel and Engine Components

Control Panel Features

Identification of control panel features like breakers and receptacles.

Gasoline Engine Controls Identification

Identifies and explains the controls on the gasoline engine.

Engine Operation Procedures

Control Adjustments

Details adjustments for air mixture, fuel mixture, and oil/fuel levels.

Starting the Engine

Step-by-step guide for starting the engine.

Engine Starting, Stopping, and Break-in

Engine Starting Procedures

Specific steps for starting a cold or hot engine.

Engine Stopping and Fuel Safety

Procedures and warnings for safely stopping the engine and fuel handling.

Engine Break-in Period

Guidelines for the engine's initial break-in period.

Generator Operation Guide

Generator Cautionary Notes

Important cautions regarding generator use with electrical equipment.

Using the Generator for Power Supply

Step-by-step guide for using the generator.

Generator Power Application Chart

Welding Operation Instructions

Welding Setup and Execution

Step-by-step instructions for welding and safety warnings.

Post-Weld Procedures

Procedures to follow after completing welding.

Welding Guidelines and Process

Welding Applications and Electrode Selection

Table of suggested welding settings based on material and electrode.

Stick Welding Process Explained

Explanation of the stick welding process and circuit.

Welding Circuit and Arc Fundamentals

The Welding Circuit

Explains the basic components and flow of a welding circuit.

Understanding the Welding Arc

Describes the formation and characteristics of the welding arc.

Achieving Successful Welds

Factors for Successful Welding

Lists the key factors for achieving successful welds.

Correct Welding Position and Arc Strike

Guidance on proper welding posture, angles, and arc initiation.

Welding Arc Length and Speed Control

Maintaining Correct Arc Length

Explains how to maintain the optimal arc length during welding.

Controlling Welding Speed

Guidance on maintaining the correct welding speed by observing the puddle.

Available Accessories

Accessory Options Overview

Lists available optional accessories.

Lincoln Electric Accessories

Specific accessories offered by Lincoln Electric.

Briggs and Stratton Accessories

Specific accessories offered by Briggs & Stratton.

Specific Accessory Details

Lincoln Electric Accessories Details

Details Lincoln Electric accessories like plug kits and accessory sets.

MIG Welding Compatibility

Information on using the generator to power MIG welders.

Briggs & Stratton Accessories Details

Details Briggs & Stratton accessories like air filters and mufflers.

Maintenance Overview

Routine and Periodic Maintenance

Overview of regular maintenance tasks.

Engine Maintenance Procedures

Specific maintenance procedures for the engine.

Generator/Welder Maintenance

Maintenance procedures for the generator and welder components.

Major Component Locations

Diagrams showing the location of major machine components.

Engine Maintenance and Safety

Maintenance Safety Precautions

General safety guidelines for performing maintenance.

Engine Oil Management

Instructions for checking and changing engine oil.

Routine Maintenance Schedule

Directs user to Table D.1 for maintenance intervals.

Engine Component Maintenance

Air Cleaner Service

Instructions for cleaning and servicing the air cleaner.

Cooling System and Engine Cleaning

Procedures for cleaning the rotating screen, engine, and cooling system.

Engine Component Maintenance Details

Spark Plug and Spark Arrester Care

Instructions for cleaning or replacing the spark plug and servicing the spark arrester.

Combustion Deposit Removal

Instructions for removing carbon deposits from the engine.

Engine Maintenance Schedule Summary

Table summarizing maintenance intervals based on hours or time.

Generator/Welder Maintenance Procedures

Storage and Cleaning

Guidelines for storing and cleaning the machine.

Brush and Cable Connection Maintenance

Procedures for maintaining brushes and cable connections.

Major Component Locations Diagram

Theory of Operation Overview

Power Supply Principles

How the machine generates and supplies power.

Engine, Rotor, and Stator Interaction

Details the interplay of engine, rotor, and stator in power generation.

Rotor Feedback and Auxiliary Power

Explains how rotor feedback affects auxiliary power output.

Weld Winding and Reactor Function

Describes the function of the weld winding and reactor.

Overcurrent Protection Mechanisms

How auxiliary power is protected from overloads.

Engine, Excitation, Rotor, and Stator Operation

Rotor Field Feedback and Auxiliary Power Explained

Weld Winding, Reactor, and Protection

Weld Winding and Reactor Functionality

Explains the role of the weld winding and reactor in arc stability.

Auxiliary Power Overcurrent Protection

Describes the circuit breakers protecting auxiliary power.

Troubleshooting and Repair Introduction

Troubleshooting Safety and Guide Usage

Safety guidelines and instructions for using the troubleshooting guide.

Troubleshooting Problem Categories

Overview of troubleshooting categories: problems, tests, and actions.

Diagnostic Procedures

Detailed test procedures for diagnosing faults.

Replacement Procedures

Step-by-step procedures for replacing components.

How to Use the Troubleshooting Guide

Troubleshooting Guide: Output Problems

Output Problem Diagnosis

Steps to diagnose why the machine has no weld or auxiliary output.

Troubleshooting Guide: Output Issues

No Weld Output with Normal Auxiliary Power

Specific checks and tests for output-related issues.

Troubleshooting Guide: Output Problems

No Weld Output, Auxiliary Power Operates

Further troubleshooting steps for output problems.

Troubleshooting Guide: Auxiliary Power Issues

No Auxiliary Power with Normal Weld Output

Checks for issues with auxiliary power and normal output.

Troubleshooting Guide: Low Output Conditions

Low Weld and Auxiliary Output

Troubleshooting low weld and auxiliary output, and engine RPM.

Troubleshooting Guide: Engine Problems

Engine Will Not Start

Steps to diagnose why the engine will not start.

Troubleshooting Guide: Engine Performance

Engine Stopping and Running Issues

Troubleshooting for engine stopping issues and erratic running.

Troubleshooting Guide: Welding Arc Issues

Cold Welding Arc Diagnosis

Steps to diagnose a 'cold' welding arc.

Rotor Voltage Test Procedure

Rotor Voltage Test Description

Procedure to test DC voltage applied to the rotor.

Rotor Voltage Test Continuation

Rotor Resistance Test Procedure

Rotor Resistance Test Description

Procedure to determine if the rotor winding is shorted or grounded.

Rotor Resistance Test Steps

Rotor Resistance Test Completion

Engine Throttle Adjustment Test

Throttle Adjustment Test Description

Test to determine if engine high idle speed is set correctly.

Throttle Adjustment Test Methods

Throttle Adjustment Test: Waveform Adjustment

Normal Open Circuit Weld Voltage Waveform

Open Circuit Voltage Waveform (115 VAC)

Typical Weld Output Waveform (Machine Loaded)

Brush Removal and Replacement Procedure

Brush Removal/Replacement Description

Procedure to access generator brushes for maintenance or replacement.

Brush Removal and Replacement Steps

Brush Removal and Replacement Completion

Rheostat Removal and Replacement Procedure

Rheostat Removal/Replacement Description

Procedure to access and remove the output control rheostat.

Rheostat Removal and Replacement Steps

Capacitor and Diode Bridge Removal Procedure

Capacitor/Diode Bridge Removal Description

Procedure to access and remove capacitor and diode bridge.

Capacitor Removal and Replacement Steps

Diode Bridge Removal and Replacement Steps

Stator/Rotor Removal and Replacement Overview

Stator/Rotor Removal Description

Procedure for removing and replacing the stator and/or rotor.

Stator Removal Procedure Continued

Stator Removal Procedure Continued

Rotor Removal and Reassembly Procedures

Rotor Removal Steps

Step-by-step instructions for removing the rotor.

Reassembly Steps

Step-by-step instructions for reassembling the rotor and related parts.

Stator/Rotor Reassembly and Air Gap Check

Post-Repair Retesting and Specifications

Retest After Repair Guidelines

Procedures for retesting the machine after repairs.

Engine Output Specifications

Specifications for engine speed under no load and load conditions.

Welder/Generator Output Specifications

Specifications for welder and generator output values.

Auxiliary Power Receptacle Specifications

Specifications for 115V and 230V auxiliary power receptacles.

Electrical Diagrams

PowerArc 4000 Wiring Diagram

Specific wiring diagram for the PowerArc 4000.

Wiring Diagram - Code 10083

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