Page 2 - SAFETY; WARNING; CALIFORNIA PROPOSITION 65 WARNINGS; The Above For Diesel Engines
Return to Master TOC Return to Master TOC Return to Master TOC Return to Master TOC FOR ENGINEpowered equipment. 1.a. Turn the engine off before troubleshooting and maintenance work unless the maintenance work requires it to be running. ____________________________________________________ 1.b. Opera...
Page 3 - ii
Return to Master TOC Return to Master TOC Return to Master TOC Return to Master TOC ii SAFETY ii ARC RAYS can burn. 4.a. Use a shield with the proper filter and cover plates to protect your eyes from sparks andthe rays of the arc when welding or observingopen arc welding. Headshield and filter lenss...
Page 4 - iii
Return to Master TOC Return to Master TOC Return to Master TOC Return to Master TOC FOR ELECTRICALLYpowered equipment. 8.a. Turn off input power using the disconnect switch at the fuse box before working onthe equipment. 8.b. Install equipment in accordance with the U.S. National Electrical Code, al...
Page 5 - iv; PRÉCAUTIONS DE SÛRETÉ
Return to Master TOC Return to Master TOC Return to Master TOC Return to Master TOC iv SAFETY iv PRÉCAUTIONS DE SÛRETÉ Pour votre propre protection lire et observer toutes les instruc- tions et les précautions de sûreté specifiques qui parraissent d a n s c e m a n u e l a u s s i b i e n q u e l e ...
Page 6 - Page; MASTER TABLE OF CONTENTS FOR ALL SECTIONS; RETURN TO MAIN INDEX
Page Safety .................................................................................................................................................i-iv Installation ................................................................................................................................
Page 7 - Installation; Tilting; TABLE OF CONTENTS; Section A
Return to Master TOC Return to Master TOC Return to Master TOC Return to Master TOC Page Installation ............................................................................................................................. Section A Technical Specifications ........................................
Page 8 - INSTALLATION; TECHNICAL SPECIFICATIONS - POWER-ARC 4000
A-2 Return to Section TOC Return to Section TOC Return to Section TOC Return to Section TOC Return to Master TOC Return to Master TOC Return to Master TOC Return to Master TOC INSTALLATION POWER-ARC 4000 A-2 TECHNICAL SPECIFICATIONS - POWER-ARC 4000 Duty Cycle 30% Duty Cycle 60% Duty Cycle Amps 125 ...
Page 9 - SAFETY PRECAUTIONS; ELECTRIC SHOCK can kill.; LOCATION AND VENTILATION; STORING; Return to Section TOC
A-3 INSTALLATION POWER-ARC 4000 A-3 Read this entire installation section before youstart installation. SAFETY PRECAUTIONS Do not attempt to use this equipment until you havethoroughly read all the operation and maintenancemanuals supplied with your machine. They includeimportant safety precautions;...
Page 10 - PRE-OPERATION ENGINE SERVICE; OPERATION; CHECK THE OIL LEVEL
A-4 INSTALLATION POWER-ARC 4000 A-4 STACKING POWER-ARC 4000 machines CANNOT be stacked. TILTING Place the machine on a secure, level surface whenev-er you use it or store it. Any surfaces you place it onother than the ground must be firm, non-skid, andstructurally sound. The gasoline engine is desig...
Page 11 - SPARK ARRESTER; ACCESSORIES; CAUTION; Power-Arc 4000 Typical Fuel Consumption
A-5 INSTALLATION A-5 Return to Section TOC Return to Section TOC Return to Section TOC Return to Section TOC Return to Master TOC Return to Master TOC Return to Master TOC Return to Master TOC SPARK ARRESTER Gasoline engine mufflers may emit sparks when theengine is running. Some federal, state, or ...
Page 12 - WELDING CABLE CONNECTIONS; Cable Size and Length
A-6 INSTALLATION POWER-ARC 4000 A-6 ELECTRICAL OUTPUT CONNECTIONS See Figure A.1 for the location of the current controld i a l , w e l d o u t p u t t e r m i n a l s , g r o u n d s t u d , c i r c u i tbreakers, 240 and 120 volt receptacles. WELDING CABLE CONNECTIONS Cable Size and Length Be sure...
Page 13 - Cable Installation; MACHINE GROUNDING; AUXILIARY POWER RECEPTACLES
A-7 INSTALLATION POWER-ARC 4000 A-7 Cable Installation Install the welding cables to your POWER-ARC 4000as follows. See Figure A.1 for the location of parts. 1. The gasoline engine must be OFF to install weld-ing cables. 2. Remove the 1/2 - 13 flanged nuts from the outputterminals. 3. Connect the el...
Page 14 - PREMISES WIRING; • The premises is isolated and no feedbacking; MAINTENANCE; CIRCUIT BREAKERS
A-8 INSTALLATION POWER-ARC 4000 A-8 PREMISES WIRING The POWER-ARC 4000 three-wire, grounded neutralg e n e r a t o r a l l o w s i t t o b e c o n n e c t e d t o p r e m i s e swiring. However, the wiring procedure needed tomeet the National Electric Code (NEC) regulations aswell as city ordinances...
Page 16 - NOTES
A-10 NOTES A-10 Return to Section TOC Return to Section TOC Return to Section TOC Return to Section TOC Return to Master TOC Return to Master TOC Return to Master TOC Return to Master TOC POWER-ARC 4000
Page 17 - Section B
Return to Master TOC Return to Master TOC Return to Master TOC Return to Master TOC TABLE OF CONTENTS - OPERATION SECTION - Section B Section B Operation ............................................................................................................................... Section B Safety I...
Page 18 - OPERATING INSTRUCTIONS; GENERAL DESCRIPTION
B-2 OPERATION B-2 OPERATING INSTRUCTIONS Read and understand this entire section before oper-ating your POWER-ARC 4000. SAFETY INSTRUCTIONS Do not attempt to use this equipment until you havethoroughly read all the operation and maintenancemanuals supplied with your machine. They includeimportant sa...
Page 19 - RECOMMENDED APPLICATIONS; GENERATOR; WELDING CAPABILITY
B-3 OPERATION B-3 The Lincoln warranty covers the Power Arc 4000(excluding the engine) for 1 year from the date of purchase. The engine is covered by the Briggs &Stratton warranty policy for a period of 1 year for consumer use or 90 days for commercial use. RECOMMENDED APPLICATIONS GENERATOR The...
Page 20 - CONTROLS AND SETTINGS; and; GENERATOR/WELDER CONTROLS; FIGURE B.1 – OUTPUT PANEL CONTROLS
B-4 OPERATION B-4 CONTROLS AND SETTINGS A l l g e n e r a t o r / w e l d e r c o n t r o l s a r e l o c a t e d o n t h eOutput Control Panel. Gasoline engine controls aremounted on the engine. See Figures B.1 and B.2 and the explanations that follow. GENERATOR/WELDER CONTROLS S e e F i g u r e B ...
Page 21 - GASOLINE ENGINE CONTROLS; in the; FIGURE B.2 – GASOLINE ENGINE CONTROLS
B-5 OPERATION B-5 5. GROUND STUD: Provides a connection point forconnecting the machine case to earth ground forthe safest grounding procedure. 6. 20 AMP CIRCUIT BREAKERS (2): Provide sepa-rate overload current protection for the 120 voltand 240 volt receptacles. GASOLINE ENGINE CONTROLS See Figure ...
Page 22 - ENGINE OPERATION; Operating and Maintenance; BEFORE STARTING THE ENGINE; CHECK AND FILL THE ENGINE OIL LEVEL:; STARTING THE ENGINE
B-6 OPERATION B-6 7. RECOIL STARTER: Manual, rope-type starter. The handle position allows easy starting fromeither ground level or pickup-truck level. 8. OIL DRAIN PLUG: Permits convenient draining of engine oil during maintenance. Both sides of theengine are equipped with an oil drain plug. 9. O I...
Page 23 - FOR BEST ENGINE STARTING:; BLESHOOTING; STOPPING THE ENGINE
B-7 OPERATION B-7 4. Pull the cord rapidly. 5. I f t h e e n g i n e d o e s n o t s t a r t , o p e n t h e c h o k eslightly (move lever upward) and pull the startercord rapidly again. When the engine starts, gradually open the choketo the “RUN” position. To open the choke fully,requires an engine...
Page 24 - GENERATOR OPERATION; section of this; GENERAL INFORMATION; Start the gasoline engine. See
B-8 OPERATION B-8 GENERATOR OPERATION Be sure that any electrical equipment plugged intothe generator’s AC power receptacles can with-stand a ±10% voltage and a ±5% frequency varia-tion. Some electronic devices cannot be poweredby the POWER-ARC 4000. Refer to Table A.2 , ELECTRICAL DEVICE USE WITH T...
Page 25 - GENERATOR POWER APPLICATIONS
Return to Section TOC Return to Section TOC Return to Section TOC Return to Section TOC Return to Master TOC Return to Master TOC Return to Master TOC Return to Master TOC B-9 OPERATION B-9 POWER-ARC 4000 NOTES: Wattages listed are approximate. Check your equipment for actual wattage. Equipment with...
Page 26 - WELDING OPERATION; Do not breathe welding fumes or gases.
B-10 OPERATION B-10 WELDING OPERATION GENERAL INFORMATION Do not touch electrically live parts orelectrodes with your skin or wet cloth-ing. Do not breathe welding fumes or gases. Use ventilation or exhaust to removewelding fumes from the breathing area. Keep flammable material away. Wear eye, ear, ...
Page 27 - WELDING APPLICATIONS/ELECTRODE SELECTION GUIDE; WELDING GUIDELINES
Return to Section TOC Return to Section TOC Return to Section TOC Return to Section TOC Return to Master TOC Return to Master TOC Return to Master TOC Return to Master TOC B-11 OPERATION B-11 POWER-ARC 4000 TABLE B.2 WELDING APPLICATIONS/ELECTRODE SELECTION GUIDE Material Thickness Electrode Type Si...
Page 28 - “ C a b l e I n s t a l l a t i o n ”; • When using an open arc process,
Return to Section TOC Return to Section TOC Return to Section TOC Return to Section TOC Return to Master TOC Return to Master TOC Return to Master TOC Return to Master TOC B-12 OPERATION B-12 POWER-ARC 4000 Stick welding is probably the most familiar weldingprocess known. A coated ELECTRODE, the wel...
Page 29 - What Happens in the Arc?; W i t h o u t
Return to Section TOC Return to Section TOC Return to Section TOC Return to Section TOC Return to Master TOC Return to Master TOC Return to Master TOC Return to Master TOC B-13 OPERATION B-13 POWER-ARC 4000 The Power-Arc 4000 has a voltage output of up to 62volts which can shock. The electric arc is...
Page 30 - The Correct Welding Position; I f y o u s t o p m o v i n g t h e e l e c t r o d e w h i l e; The Correct Arc Length; It is not generally necessary to weave; side view; Molten puddle
Return to Section TOC Return to Section TOC Return to Section TOC Return to Section TOC Return to Master TOC Return to Master TOC Return to Master TOC Return to Master TOC B-14 OPERATION B-14 POWER-ARC 4000 1. The Correct Welding Position I l l u s t r a t e d i s t h e c o r r e c t w e l d i n g p...
Page 31 - PRACTICE; Learn to strike the arc by scratching the electrode; Common Metals; Butt Welds
Return to Section TOC Return to Section TOC Return to Section TOC Return to Section TOC Return to Master TOC Return to Master TOC Return to Master TOC Return to Master TOC B-15 OPERATION B-15 POWER-ARC 4000 PRACTICE The best way of getting practice in the four skills thatenable you to maintain: 1. C...
Page 32 - Penetration; Good
Return to Section TOC Return to Section TOC Return to Section TOC Return to Section TOC Return to Master TOC Return to Master TOC Return to Master TOC Return to Master TOC B-16 OPERATION B-16 POWER-ARC 4000 Now weld the two plates together. Weld from left toright (if right-handed). Point the electro...
Page 33 - Vertical-Down Welding
Return to Section TOC Return to Section TOC Return to Section TOC Return to Section TOC Return to Master TOC Return to Master TOC Return to Master TOC Return to Master TOC B-17 OPERATION B-17 POWER-ARC 4000 Vertical-Up Welding The problem, when welding vertical-up, is to put themolten metal where it...
Page 34 - Overhead Welding; Side View
Return to Section TOC Return to Section TOC Return to Section TOC Return to Section TOC Return to Master TOC Return to Master TOC Return to Master TOC Return to Master TOC B-18 OPERATION B-18 POWER-ARC 4000 Overhead Welding Various techniques are used for overhead welding.However, in the interest of...
Page 35 - The bead should be put on with a weaving motion,; Welding Cast Iron; that spot again until the weld is cool.; Cast Iron Plate Preparation; hot
Return to Section TOC Return to Section TOC Return to Section TOC Return to Section TOC Return to Master TOC Return to Master TOC Return to Master TOC Return to Master TOC B-19 OPERATION B-19 POWER-ARC 4000 4. The bead should be put on with a weaving motion, and it should be 1/2-3/4” (12.7-19.0mm) w...
Page 36 - Selecting Electrodes; Motions
Return to Section TOC Return to Section TOC Return to Section TOC Return to Section TOC Return to Master TOC Return to Master TOC Return to Master TOC Return to Master TOC B-20 OPERATION B-20 POWER-ARC 4000 High-Speed Group (AWS E6013) This group includes electrodes which have a moder-ately forceful...
Page 37 - Accessories; Oil Gard; Section C
Return to Master TOC Return to Master TOC Return to Master TOC Return to Master TOC Page Accessories ........................................................................................................................... Section C Lincoln Electric Accessories .......................................
Page 38 - LINCOLN ELECTRIC ACCESSORIES
C-2 ACCESSORIES C-2 OPTIONS/ACCESSORIES LINCOLN ELECTRIC ACCESSORIES The following options/accessories are available fory o u r P O W E R - A R C 4 0 0 0 f r o m y o u r l o c a l L i n c o l nDistributor. Accessory Set (K875) – Includes the following: • T w e n t y f e e t ( 6 . 1 m e t e r s ) o f...
Page 39 - Section D
Return to Master TOC Return to Master TOC Return to Master TOC Return to Master TOC Page Installation ............................................................................................................................. Section D Safety Precautions...............................................
Page 40 - manual before working on; ENGINE MAINTENANCE; See; REFILL LOCATION; At the end of each day’s use, refill; ENGINE ADJUSTMENTS
D-2 MAINTENANCE D-2 SAFETY PRECAUTIONS • Have qualified personnel do all maintenance and troubleshooting work. • Turn the engine off before working inside the machine. • Remove guards only when necessary to per- form maintenance and replace them when themaintenance requiring their removal is com-ple...
Page 41 - Squeeze in a clean, absorbent cloth to remove all; Clean Rotating Screen:; the internal cooling fins and surfaces to prevent over-; C L E A N O R R E P L A C E S P A R K P L U G :; C l e a n o r; CLEAN SPARK ARRESTER SCREEN:; If the muffler
D-3 MAINTENANCE D-3 Do not use petroleum solvents such as keroseneto clean the air cleaner. They may cause deterio-ration of the air cleaner. DO NOT OIL THE AIRCLEANER OR USE PRESSURIZED AIR TO CLEANOR DRY THE AIR CLEANER. To service the pre-cleaner: 1. Wash in liquid detergent and water. 2. Squeeze...
Page 42 - ENGINE MAINTENANCE SCHEDULE
Return to Section TOC Return to Section TOC Return to Section TOC Return to Section TOC Return to Master TOC Return to Master TOC Return to Master TOC Return to Master TOC TABLE D.2 – ENGINE MAINTENANCE PARTS D-4 MAINTENANCE D-4 POWER-ARC 4000 TABLE D.1 ENGINE MAINTENANCE SCHEDULE Maintenance Every ...
Page 43 - GENERATOR/WELDER MAINTENANCE; B R U S H R E M O V A L A N D R E P L A C E M E N T :; Brush Removal and Replacement; FIGURE D.5. – BRUSH REMOVAL AND REPLACEMENT
Return to Section TOC Return to Section TOC Return to Section TOC Return to Section TOC Return to Master TOC Return to Master TOC Return to Master TOC Return to Master TOC D-5 MAINTENANCE D-5 POWER-ARC 4000 GENERATOR/WELDER MAINTENANCE STORAGE: Store the POWER-ARC 4000 in clean, dry, protected areas...
Page 45 - Section E
Return to Master TOC Return to Master TOC Return to Master TOC Return to Master TOC TABLE OF CONTENTS - THEORY OF OPERATION SECTION - Section E Section E POWER-ARC 4000 FIGURE E.1 – POWER-ARC 4000 BLOCK LOGIC DIAGRAM Theory of Operation ..................................................................
Page 46 - THEORY OF OPERATION
Return to Section TOC Return to Section TOC Return to Section TOC Return to Section TOC Return to Master TOC Return to Master TOC Return to Master TOC Return to Master TOC E-2 THEORY OF OPERATION E-2 POWER-ARC 4000 ENGINE, EXCITATION, ROTOR AND STATOR A small voltage developed by the engine magneto ...
Page 47 - FIGURE E.3 – FIELD EXCITATION AND AUXILIARY POWER
Return to Section TOC Return to Section TOC Return to Section TOC Return to Section TOC Return to Master TOC Return to Master TOC Return to Master TOC Return to Master TOC E-3 THEORY OF OPERATION E-3 POWER-ARC 4000 ROTOR FIELD FEEDBACK ANDAUXILIARY POWER The AC voltage developed in the field winding...
Page 48 - WELD WINDING AND REACTOR; FIGURE E.4 – WELDING OUTPUT
Return to Section TOC Return to Section TOC Return to Section TOC Return to Section TOC Return to Master TOC Return to Master TOC Return to Master TOC Return to Master TOC E-4 THEORY OF OPERATION E-4 POWER-ARC 4000 WELD WINDING AND REACTOR The AC voltage developed in the stator weld windingis delive...
Page 49 - Test Procedures; Section F
Return to Master TOC Return to Master TOC Return to Master TOC Return to Master TOC Troubleshooting & Repair Section ................................................................................. Section F How to Use Troubleshooting Guide .........................................................
Page 50 - TROUBLESHOOTING & REPAIR; S t e p 1 . L O C A T E P R O B L E M ( S Y M P T O M ); The; S t e p 3 . P E R F O R M C O M P O N E N T T E S T S; HOW TO USE TROUBLESHOOTING GUIDE
Return to Section TOC Return to Section TOC Return to Section TOC Return to Section TOC Return to Master TOC Return to Master TOC Return to Master TOC Return to Master TOC F-2 TROUBLESHOOTING & REPAIR F-2 POWER-ARC 4000 CAUTION This Troubleshooting Guide is provided to helpyou locate and repair ...
Page 51 - TROUBLESHOOTING; TROUBLESHOOTING GUIDE; - Observe all Safety Guidelines detailed throughout this manual; OUTPUT PROBLEMS
POWER-ARC 4000 F-3 TROUBLESHOOTING F-3 TROUBLESHOOTING GUIDE - Observe all Safety Guidelines detailed throughout this manual If for any reason you do not understand the test procedures or are unable to perform the tests/repairs safely, contact theLincoln Electric Service Department for technical tro...
Page 52 - Rotor Voltage Test; contact your local Lincoln
POWER-ARC 4000 F-4 TROUBLESHOOTING F-4 TROUBLESHOOTING GUIDE - Observe all Safety Guidelines detailed throughout this manual If for any reason you do not understand the test procedures or are unable to perform the tests/repairs safely, contact theLincoln Electric Service Department for technical tro...
Page 53 - Check the stator for continuity of; c o n t a c t y o u r; C h e c k t h e w e l d i n g c a b l e s ,
POWER-ARC 4000 F-5 TROUBLESHOOTING F-5 TROUBLESHOOTING GUIDE - Observe all Safety Guidelines detailed throughout this manual If for any reason you do not understand the test procedures or are unable to perform the tests/repairs safely, contact theLincoln Electric Service Department for technical tro...
Page 54 - C h e c k t h e a u x i l i a r y p o w e r r e -
POWER-ARC 4000 F-6 TROUBLESHOOTING F-6 TROUBLESHOOTING GUIDE - Observe all Safety Guidelines detailed throughout this manual If for any reason you do not understand the test procedures or are unable to perform the tests/repairs safely, contact theLincoln Electric Service Department for technical tro...
Page 56 - ENGINE PROBLEMS
POWER-ARC 4000 F-8 TROUBLESHOOTING F-8 TROUBLESHOOTING GUIDE - Observe all Safety Guidelines detailed throughout this manual If for any reason you do not understand the test procedures or are unable to perform the tests/repairs safely, contact theLincoln Electric Service Department for technical tro...
Page 58 - WELDING PROBLEMS; If the OCV is low at the welder
POWER-ARC 4000 F-10 TROUBLESHOOTING F-10 TROUBLESHOOTING GUIDE - Observe all Safety Guidelines detailed throughout this manual If for any reason you do not understand the test procedures or are unable to perform the tests/repairs safely, contact theLincoln Electric Service Department for technical t...
Page 59 - ROTOR VOLTAGE TEST; TEST DESCRIPTION
F-11 TROUBLESHOOTING & REPAIR F-11 POWER-ARC 4000 ROTOR VOLTAGE TEST Service and repair should be performed by only Lincoln Electric factory trained personnel. Unauthorized repairsperformed on this equipment may result in danger to the technician or machine operator and will invalidate yourfacto...
Page 60 - TEST PROCEDURE; Start the machine and run it at high; FIGURE F.1 - LOCATION OF LEAD 200A FOR ROTOR VOLTAGE TEST; CONNECTION
F-12 TROUBLESHOOTING & REPAIR F-12 POWER-ARC 4000 TEST PROCEDURE 1. With the 5/16” nut driver, remove the 4 sheet metal screws that holdthe top cover to the control box.Remove the top cover. 2. Start the machine and run it at high idle. Set the output control (rheo-stat) at the MAXIMUM or GENERA...
Page 61 - ROTOR RESISTANCE TEST
F-13 TROUBLESHOOTING & REPAIR F-13 POWER-ARC 4000 ROTOR RESISTANCE TEST Service and repair should be performed by only Lincoln Electric factory trained personnel. Unauthorized repairsperformed on this equipment may result in danger to the technician or machine operator and will invalidate yourfa...
Page 62 - LOCATION OF ROTOR SLIP RINGS - BRUSH HOLDER ASSEMBLY REMOVED
F-14 TROUBLESHOOTING & REPAIR F-14 POWER-ARC 4000 TEST PROCEDURE 1. Conduct the test with the gasoline engine OFF. 2. Remove the spark plug wire to pre- vent accidental engine kickback orstarting. 3. I s o l a t e t h e r o t o r e l e c t r i c a l l y b y r e m o v i n g t h e g e n e r a t o ...
Page 63 - Reinstall the brush holder assembly; FIGURE F.3 - BRUSHES RETAINED WITH CABLE TIE
F-15 TROUBLESHOOTING & REPAIR F-15 POWER-ARC 4000 9. Reinstall the brush holder assembly after the test. Depress the spring-loaded brushes into the holder andslip a suitable non-metallic, fairlystiff retainer through the slots at thetop and bottom of the holder. Acable tie works well; see Figure...
Page 64 - ENGINE THROTTLE ADJUSTMENT TEST
F-16 TROUBLESHOOTING & REPAIR F-16 POWER-ARC 4000 ENGINE THROTTLE ADJUSTMENT TEST Service and repair should be performed by only Lincoln Electric factory trained personnel. Unauthorized repairsperformed on this equipment may result in danger to the technician or machine operator and will invalid...
Page 65 - Frequency Counter Method:; Figure
F-17 TROUBLESHOOTING & REPAIR F-17 POWER-ARC 4000 TEST PROCEDURE This test can be conducted by any ofthree methods. Strobe-tach Method: 1. S t o p t h e e n g i n e a n d r e m o v e t h e spark plug wire to prevent acciden-tal kickback or starting. 2. With the black or red marking pencil, place...
Page 66 - R e - t i g h t e n w i n g n u t u n t i l w a v e; FIGURE F.5 - LOCATION OF ENGINE THROTTLE ADJUSTMENT NUT; WING NUT
F-18 TROUBLESHOOTING & REPAIR F-18 POWER-ARC 4000 2. Loosen Wing Nut (Refer to Figure F.5) 3. Refering to Figure F.5, adjust high s p e e d s t o p s c r e w t o a d j u s t t h ewaveform period to 15.8 millisec-onds. 4. R e - t i g h t e n w i n g n u t u n t i l w a v e washer is completely co...
Page 67 - volts; SCOPE SETTINGS; NORMAL OPEN CIRCUIT WELD VOLTAGE WAVEFORM; HIGH IDLE – NO LOAD
Return to Section TOC Return to Section TOC Return to Section TOC Return to Section TOC Return to Master TOC Return to Master TOC Return to Master TOC Return to Master TOC F-19 TROUBLESHOOTING & REPAIR F-19 POWER-ARC 4000 CH1 0 volts 5 ms 50 volts SCOPE SETTINGS Volts/Div ....................50V...
Page 68 - NORMAL OPEN CIRCUIT VOLTAGE WAVEFORM (115 VAC SUPPLY)
Return to Section TOC Return to Section TOC Return to Section TOC Return to Section TOC Return to Master TOC Return to Master TOC Return to Master TOC Return to Master TOC F-20 TROUBLESHOOTING & REPAIR F-20 POWER-ARC 4000 SCOPE SETTINGS Volts/Div ....................50V/Div.Horizontal Sweep........
Page 69 - TYPICAL WELD OUTPUT WAVEFORM; MACHINE LOADED
Return to Section TOC Return to Section TOC Return to Section TOC Return to Section TOC Return to Master TOC Return to Master TOC Return to Master TOC Return to Master TOC F-21 TROUBLESHOOTING & REPAIR F-21 POWER-ARC 4000 CH1 0 volts 5 ms 20 volts This is the typical AC output voltagegenerated f...
Page 70 - BRUSH REMOVAL AND REPLACEMENT; DESCRIPTION
F-22 TROUBLESHOOTING & REPAIR F-22 POWER-ARC 4000 BRUSH REMOVAL AND REPLACEMENT Service and repair should be performed by only Lincoln Electric factory trained personnel. Unauthorized repairsperformed on this equipment may result in danger to the technician or machine operator and will invalidat...
Page 71 - PROCEDURE; O p e n t h e b r u s h h o l d e r a s s e m b l y; FIGURE F.6 - BRUSHES RETAINED WITH CABLE TIE
Return to Section TOC Return to Section TOC Return to Section TOC Return to Section TOC Return to Master TOC Return to Master TOC Return to Master TOC Return to Master TOC F-23 TROUBLESHOOTING & REPAIR F-23 POWER-ARC 4000 PROCEDURE 1. Remove the spark plug wire. 2. O p e n t h e b r u s h h o l ...
Page 73 - RHEOSTAT REMOVAL AND REPLACEMENT
F-25 TROUBLESHOOTING & REPAIR F-25 POWER-ARC 4000 RHEOSTAT REMOVAL AND REPLACEMENT Service and repair should be performed by only Lincoln Electric factory trained personnel. Unauthorized repairsperformed on this equipment may result in danger to the technician or machine operator and will invali...
Page 74 - W i t h a 9 / 1 6 ” o p e n o r b o x e n d
F-26 TROUBLESHOOTING & REPAIR F-26 POWER-ARC 4000 PROCEDURE 1. Remove the spark plug wire. 2. With the 5/16” nut driver, remove the 4 sheet metal screws that holdthe top cover to the control box.Remove the top cover. 3. With the small slot head screw dri- ver, loosen the screw that holds thek n ...
Page 75 - CAPACITOR AND/OR DIODE BRIDGE REMOVAL AND REPLACEMENT
F-27 TROUBLESHOOTING & REPAIR F-27 POWER-ARC 4000 CAPACITOR AND/OR DIODE BRIDGE REMOVAL AND REPLACEMENT Service and repair should be performed by only Lincoln Electric factory trained personnel. Unauthorized repairsperformed on this equipment may result in danger to the technician or machine ope...
Page 76 - D i s c h a r g e t h e f i e l d c a p a c i t o r b y; FIGURE F.8 - LOCATION AND DISCHARGING THE FIELD CAPACITOR; Attachment for
Return to Section TOC Return to Section TOC Return to Section TOC Return to Section TOC Return to Master TOC Return to Master TOC Return to Master TOC Return to Master TOC F-28 TROUBLESHOOTING & REPAIR F-28 POWER-ARC 4000 PROCEDURE - CAPACITORREMOVAL AND REPLACE-MENT 1. Remove the engine spark p...
Page 77 - PROCEDURE - FIELD DIODE BRIDGE REMOVAL AND REPLACEMENT
F-29 TROUBLESHOOTING & REPAIR F-29 POWER-ARC 4000 1. Remove the engine spark plug wire. 2. With the 5/16” nut driver, remove the sheet metal screws that hold thet o p c o v e r t o t h e c o n t r o l b o x .Remove the top cover. 3. With the 5/16” nut driver and wrench r e m o v e t h e s c r e ...
Page 78 - STATOR/ROTOR REMOVAL AND REPLACEMENT; FOR ROTOR REMOVAL ONLY; INSTRUCTIONS
F-30 TROUBLESHOOTING & REPAIR F-30 POWER-ARC 4000 STATOR/ROTOR REMOVAL AND REPLACEMENT Service and repair should be performed by only Lincoln Electric factory trained personnel. Unauthorized repairsperformed on this equipment may result in danger to the technician or machine operator and will in...
Page 79 - STATOR REMOVAL PROCEDURE; TIE WRAP
Return to Section TOC Return to Section TOC Return to Section TOC Return to Section TOC Return to Master TOC Return to Master TOC Return to Master TOC Return to Master TOC F-31 TROUBLESHOOTING & REPAIR F-31 POWER-ARC 4000 STATOR REMOVAL PROCEDURE 1. Remove engine spark plug wire to prevent accid...
Page 80 - Slide a short length of 2 X 4 under
F-32 TROUBLESHOOTING & REPAIR F-32 POWER-ARC 4000 12. Slide a short length of 2 X 4 under the engine to support it when thestator is removed. 13. W i t h t h e 1 / 2 ” s o c k e t w r e n c h , remove the 2 nuts that hold thestator end bracket support. SeeFigure F.10 for location. There are2 spl...
Page 81 - REASSEMBLY PROCEDURE; shaft. Slide the rotor onto the shaft.
F-33 TROUBLESHOOTING & REPAIR F-33 POWER-ARC 4000 ROTOR REMOVAL PROCEDURE 1. To remove the rotor, double check that the spark plug wire is discon-nected. You will be turning the rotord u r i n g t h i s p r o c e d u r e , a n d t h i sc o u l d a c c i d e n t a l l y c a u s e e n g i n ekickb...
Page 82 - “ B R U S H R E M O V A L A N D
F-34 TROUBLESHOOTING & REPAIR F-34 POWER-ARC 4000 6. Install the bottom two end bracket thru- bolts. Note: The flat washer goes on the top righthand thru-bolt for the green ground wire. 7. Tap the end bracket with the mallet as nec- essary to position it. Tighten the bolts to4.5 - 5.5 ft lbs. Al...
Page 83 - RETEST AFTER REPAIR; ENGINE OUTPUT
Return to Section TOC Return to Section TOC Return to Section TOC Return to Section TOC Return to Master TOC Return to Master TOC Return to Master TOC Return to Master TOC F-35 TROUBLESHOOTING & REPAIR F-35 POWER-ARC 4000 RETEST AFTER REPAIR Retest a machine: • If it is rejected under test for a...
Page 85 - DIAGRAMS SECTION; Section G
Return to Master TOC Return to Master TOC Return to Master TOC Return to Master TOC Page DIAGRAMS SECTION ........................................................................................................... Section G Wiring Diagram (S22160) .......................................................
Page 86 - DIAGRAMS; WIRING DIAGRAM - POWER ARC 4000
G-2 DIAGRAMS G-2 POWER-ARC 4000 Return to Section TOC Return to Section TOC Return to Section TOC Return to Section TOC Return to Master TOC Return to Master TOC Return to Master TOC Return to Master TOC S22160 D1 C1 ROTOR (+) (-) (+) (-) ENGINE WIRING MAG SWITCH 9A 202A 7A 600 FD CCW 201A 201 RED R...
Page 89 - DIMENSION PRINT - POWER ARC 4000
G-5 DIAGRAMS G-5 POWER-ARC 4000 Return to Section TOC Return to Section TOC Return to Section TOC Return to Section TOC Return to Master TOC Return to Master TOC Return to Master TOC Return to Master TOC R 30.00 762 20.88 530 7.92 201 14.16 360 20.00 508 mm mm mm mm mm REF. REF. REF. REF. REF. DIMEN...
Page 91 - SVM ERROR REPORTING FORM; Please give detailed description below:
SVM ERROR REPORTING FORM We need to know if there are errors in our manuals. We also value any suggestions as toadditional tests or procedures that would make this SVM a better tool for you. If you discover new or different “Problems or Symptoms” that are not covered in the three col-umn troubleshoo...
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