Page 2 - SAFETY; WARNING; CALIFORNIA PROPOSITION 65 WARNINGS; The Above For Diesel Engines
POWER-ARC 4000 SAFETY i 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. Operate engines in open, well-ventilated areas or vent the engine...
Page 3 - ii; ELECTRIC SHOCK can kill.
SAFETY POWER-ARC 4000 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 lensshould conform to ANSI Z87. I standards. 4.b. Use suitable clothing made ...
Page 4 - iii
POWER-ARC 4000 SAFETY iii 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, all local codes and the manufacturer’srecommendations. 8.c. ...
Page 5 - iv; PRÉCAUTIONS DE SÛRETÉ
SAFETY POWER-ARC 4000 iv PRÉCAUTIONS DE SÛRETÉ Pour votre propre protection lire et observer toutes les instruc-tions et les précautions de sûreté specifiques qui parraissentdans ce manuel aussi bien que les précautions de sûretégénérales suivantes: Sûreté Pour Soudage A L’Arc 1. Protegez-vous contr...
Page 6 - MASTER TABLE OF CONTENTS FOR ALL SECTIONS
Page Safety .................................................................................................................................................i-iv Installation ................................................................................................................................
Page 7 - TABLE OF CONTENTS; Installation; Section A
TABLE OF CONTENTS - INSTALLATION SECTION - Installation Technical Specifications .............................................................................................................A-1 Safety Precautions ..........................................................................................
Page 8 - INSTALLATION; TECHNICAL SPECIFICATIONS - POWER-ARC 4000
POWER-ARC 4000 INSTALLATION A-1 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 TECHNICAL SPECIFICATIONS - POWER-ARC 4000 INPUT - GASOLINE ENGINE Manufacturer Description Speed...
Page 9 - SAFETY PRECAUTIONS; LOCATION AND VENTILATION; STORING
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; detailed engine starting,operating,...
Page 10 - PRE-OPERATION ENGINE SERVICE; NOTE: The deflector reduces generator output power
POWER-ARC 4000 INSTALLATION A-3 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 STACKING POWER-ARC 4000 machines CANNOT be stacked. TILTING Place the machine on a secure, level...
Page 11 - WELDING CABLE CONNECTIONS; Cable Size and Length
ELECTRICAL OUTPUT CONNECTIONS See Figure A.1 for the location of the current controldial, weld output terminals, ground stud, circuit break-ers, 240 and 120 volt receptacles. WELDING CABLE CONNECTIONS Cable Size and Length Be sure to use welding cables that are large enough.The correct size and leng...
Page 12 - Cable Installation; MACHINE GROUNDING; CAUTION
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 electrode holder and work cables tothe...
Page 13 - PREMISES WIRING; CIRCUIT BREAKERS
PREMISES WIRING The POWER-ARC 4000 three-wire, grounded neutralgenerator allows it to be connected to premiseswiring. However, the wiring procedure needed tomeet the National Electric Code (NEC) regulations aswell as city ordinances can be confusing. Matters getworse depending on whether you want th...
Page 14 - ELECTRICAL DEVICE USE WITH THE POWER-ARC 4000.
POWER-ARC 4000 INSTALLATION A-7 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 Certain Electrical devices cannot be powered by the POWER-ARC 4000. See Table A.2. TABLE A.2 ELE...
Page 15 - Section B; Operation
POWER-ARC 4000 Section B Return to Master TOC Return to Master TOC Return to Master TOC Return to Master TOC TABLE OF CONTENTS - OPERATION SECTION - Operation ............................................................................................................................... Section B Saf...
Page 16 - OPERATING INSTRUCTIONS; GENERAL DESCRIPTION; 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 OPERATING INSTRUCTIONS Read and understand this entire section before oper-ating your POWER-ARC 4000. SAFETY INSTRUCTIONS Do not...
Page 17 - NOTE: The POWER-ARC 4000 is not meant for rental; RECOMMENDED APPLICATIONS; GENERATOR; WELDING CAPABILITY
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 The POWER-ARC 4000 warranty covers the machinefor one year from the date of purchase. For non-engine warranty claims, contact yo...
Page 18 - CONTROLS AND SETTINGS; FIGURE B.1 – OUTPUT PANEL CONTROLS
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 CONTROLS AND SETTINGS All generator/welder controls are located on theOutput Control Panel. Gasoline engine controls aremounted ...
Page 19 - FIGURE B.2 – GASOLINE ENGINE CONTROLS; NOTE: If you use any other alternate fuel tank or
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 5. GROUND STUD: Provides a connection point forconnecting the machine case to earth ground forthe safest grounding procedure. 6....
Page 20 - ENGINE OPERATION; BEFORE STARTING THE ENGINE; CHECK AND FILL THE ENGINE OIL LEVEL:; STARTING THE ENGINE; NOTE: Remove all loads connected to the AC 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 7. AIR MIXTURE ADJUSTMENT SCREW: Adjusts the amount of air mixed with fuel to obtain thesmoothest operation under load or at idl...
Page 21 - FOR BEST ENGINE STARTING:; STOPPING THE ENGINE; FOR BEST ENGINE STOPPING:; RUNNING THE ENGINE
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 4. Pull the cord rapidly. 5. If the engine does not start, open the choke slight-ly (move lever upward) and pull the starter cor...
Page 22 - GENERATOR OPERATION; GENERAL INFORMATION; NOTE: You can supply multiple loads as long as the
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 GENERATOR OPERATION Be sure that any electrical equipment plugged into thegenerator’s AC power receptacles can withstand a±10% v...
Page 23 - 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 POWER-ARC 4000 B-8 TABLE B.3 GENERATOR POWER APPLICATIONS Suggested Power Applications Running Watts *Start-up Watts *Air Compre...
Page 24 - WELDING OPERATION; AFTER YOU FINISH THE WELD:
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 WELDING OPERATION GENERAL INFORMATION Do not touch electrically live parts or elec-trodes with your skin or wet clothing. Do not...
Page 25 - WELDING APPLICATIONS/ELECTRODE SELECTION GUIDE; NOTE: The serviceability of a product or structure; STICK WELDING; 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 POWER-ARC 4000 B-10 TABLE B.4 WELDING APPLICATIONS/ELECTRODE SELECTION GUIDE Material Thickness Electrode Type Size Setting 1/8”...
Page 26 - THE WELDING CIRCUIT; THE ARC; FIGURE B.3 – WELDING CIRCUIT CONNECTIONS
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 B-11 THE WELDING CIRCUIT When everything is connected properly, the currentfrom the power source causes the elect...
Page 27 - THE ELECTRODE; THE CORRECT WAY TO STRIKE AN ARC; FIGURE B.4 – THE WELDING ARC
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 B-12 1. ELECTRODE2. COATING3. SHIELDING GAS4. ARC5. BASE METAL6. WELD METAL7. SOLIDIFIED SLAG Obviously, stick ar...
Page 28 - THE CORRECT ARC LENGTH; FIGURE B.6 – MOLTEN METAL PUDDLE; NOTE: When welding on thin plate, you will find that
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 THE CORRECT ARC LENGTH The arc length is the distance from the tip of the elec-trode core wire to the base metal. Once you’ve es...
Page 29 - Accessories
Return to Master TOC Return to Master TOC Return to Master TOC Return to Master TOC TABLE OF CONTENTS - ACCESSORIES - Accessories ........................................................................................................................... Section C Options/Accessories....................
Page 30 - LINCOLN ELECTRIC ACCESSORIES; BRIGGS AND STRATTON ACCESSORIES; Oil Gard; ACCESSORIES
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 OPTIONS/ACCESSORIES LINCOLN ELECTRIC ACCESSORIES The following options/accessories are available foryour POWER-ARC 4000 from you...
Page 31 - Maintenance
Return to Master TOC Return to Master TOC Return to Master TOC Return to Master TOC TABLE OF CONTENTS -MAINTENANCE- Maintenance ......................................................................................................................... Section D Routine and Periodic Maintenance ..........
Page 32 - ENGINE MAINTENANCE; MAINTENANCE
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 SAFETY PRECAUTIONS • Have qualified personnel do all maintenance and troubleshooting work. • Turn the engine off before working ...
Page 34 - REMOVE COMBUSTION DEPOSITS:; 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 CLEAN OR REPLACE SPARK PLUG: Clean orreplace the spark plug after every 100 hours of opera-tion or every season, whichever comes...
Page 35 - TABLE D.2 – ENGINE MAINTENANCE PARTS; Part; GENERATOR/WELDER MAINTENANCE
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 D-4 TABLE D.2 – ENGINE MAINTENANCE PARTS Part Part Number OIL FILTER NONE SPARK PLUG (STANDARD) B&S 492167CHA...
Page 37 - Section E; FIGURE E.1 – POWER-ARC 4000 BLOCK LOGIC DIAGRAM
Theory of Operation ............................................................................................................. Section E Power Supply Operation ..............................................................................................E-1 - E-3 Engine, Excitation, Rotor and Sta...
Page 38 - THEORY OF OPERATION
ENGINE, EXCITATION, ROTOR AND STATOR A small DC voltage developed by the flywheel alterna-tor in the Briggs & Stratton engine is fed to the rotat-ing field coil in the rotor via a brush and slip ring con-figuration. This excitation (“flashing”) voltagemagnetizes the rotor lamination. The rotor i...
Page 39 - FIGURE E.3 – FIELD EXCITATION AND AUXILIARY POWER
ROTOR FIELD FEEDBACK ANDAUXILIARY POWER The AC voltage developed in the field winding is fed tothe full wave bridge. The DC output of the bridge is fil-tered by the field capacitor and controlled by the out-put rheostat. This filtered and controlled feedback voltage is fed tothe rotor winding via th...
Page 40 - WELD WINDING AND REACTOR; FIGURE E.4 – WELDING OUTPUT SHADE
WELD WINDING AND REACTOR The AC voltage developed in the stator weld windingis delivered, through the reactor, to the machine out-put terminals. The PowerArc 4000 provides the userwith 125 amps of constant current AC welding forstick electrodes. The reactor stores energy, and thisenergy is released ...
Page 41 - Section F
Troubleshooting & Repair Section.................................................................................Section F Safety Precautions.................................................................................................................F-1 How to Use Troubleshooting Guide ........
Page 42 - HOW TO USE TROUBLESHOOTING GUIDE; TROUBLESHOOTING & REPAIR
HOW TO USE TROUBLESHOOTING GUIDE Service and repair should be performed by only Lincoln Electric Factory Trained Personnel.Unauthorized repairs performed on this equipment may result in danger to the technician and machineoperator and will invalidate your factory warranty. For your safety and to avo...
Page 43 - TROUBLESHOOTING GUIDE; OUTPUT PROBLEMS
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 TROUBLESHOOTING & REPAIR POWER-ARC 4000 F-2 TROUBLESHOOTING GUIDE Observe Safety Guidelines detailed in the beginning of thi...
Page 48 - ENGINE PROBLEMS
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 TROUBLESHOOTING & REPAIR F-7 Observe Safety Guidelines TROUBLESHOOTING GUIDE detailed in the beginning of thi...
Page 50 - WELDING PROBLEMS
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 TROUBLESHOOTING & REPAIR F-9 Observe Safety Guidelines TROUBLESHOOTING GUIDE detailed in the beginning of thi...
Page 51 - ROTOR VOLTAGE TEST; TEST DESCRIPTION
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 TROUBLESHOOTING & REPAIR POWER-ARC 4000 F-10 ROTOR VOLTAGE TEST Service and repair should be performed by only Lincoln Elect...
Page 52 - FIGURE F.1 - LOCATION OF LEAD 200A FOR ROTOR VOLTAGE TEST; CONNECTION; TEST PROCEDURE
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 TROUBLESHOOTING & REPAIR F-11 ROTOR VOLTAGE TEST (continued) FIGURE F.1 - LOCATION OF LEAD 200A FOR ROTOR VOL...
Page 53 - ROTOR RESISTANCE TEST
ROTOR RESISTANCE TEST Service and repair should be performed by only Lincoln Electric factory trained personnel.Unauthorized repairs performed on this equipment may result in danger to the technician ormachine operator and will invalidate your factory warranty. For your safety and to avoid elec-tric...
Page 54 - LOCATION OF ROTOR SLIP RINGS - BRUSH HOLDER ASSEMBLY REMOVED
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 TROUBLESHOOTING & REPAIR F-13 ROTOR RESISTANCE TEST (continued) FIGURE F.2 LOCATION OF ROTOR SLIP RINGS - BRU...
Page 55 - FIGURE F.3 - BRUSHES RETAINED WITH CABLE TIE; CABLE
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 TROUBLESHOOTING & REPAIR POWER-ARC 4000 F-14 ROTOR RESISTANCE TEST (continued) FIGURE F.3 - BRUSHES RETAINED WITH CABLE TIE ...
Page 57 - ENGINE THROTTLE ADJUSTMENT TEST (continued); MARK; Frequency Counter Method:
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 TROUBLESHOOTING & REPAIR POWER-ARC 4000 F-16 ENGINE THROTTLE ADJUSTMENT TEST (continued) FIGURE F.4 - BLOWER PADDLE MARKED F...
Page 58 - NUT; FIGURE F.5 - LOCATION OF ENGINE THROTTLE ADJUSTMENT NUT
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 TROUBLESHOOTING & REPAIR F-17 ENGINE THROTTLE ADJUSTMENT TEST (continued) NUT FIGURE F.5 - LOCATION OF ENGINE...
Page 59 - SCOPE SETTINGS; NORMAL OPEN CIRCUIT WELD VOLTAGE WAVEFORM; HIGH IDLE – NO LOAD
TROUBLESHOOTING & REPAIR POWER-ARC 4000 F-18 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 CH1 0 volts 5 ms 50 volts SCOPE SETTINGS Volts/Div ....................50V/Div....
Page 60 - NORMAL OPEN CIRCUIT VOLTAGE WAVEFORM (115 VAC SUPPLY)
POWER-ARC 4000 TROUBLESHOOTING & REPAIR F-19 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 SCOPE SETTINGS Volts/Div ....................50V/Div.Horizontal Sweep ....5 ms/...
Page 61 - TYPICAL WELD OUTPUT WAVEFORM; MACHINE LOADED
TROUBLESHOOTING & REPAIR POWER-ARC 4000 F-20 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 CH1 0 volts 5 ms 20 volts This is the typical AC output voltagegenerated from a...
Page 62 - BRUSH REMOVAL AND REPLACEMENT; DESCRIPTION
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 TROUBLESHOOTING & REPAIR F-21 BRUSH REMOVAL AND REPLACEMENT WARNING Service and repair should be performed by...
Page 63 - BRUSH REMOVAL AND REPLACEMENT (continued); FIGURE F.6 - BRUSHES RETAINED WITH CABLE TIE; PROCEDURE
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 TROUBLESHOOTING & REPAIR POWER-ARC 4000 F-22 BRUSH REMOVAL AND REPLACEMENT (continued) FIGURE F.6 - BRUSHES RETAINED WITH CA...
Page 66 - RHEOSTAT 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 POWER-ARC 4000 F-25 TROUBLESHOOTING & REPAIR RHEOSTAT REMOVAL AND REPLACEMENT FIGURE F.7 - RHEOSTAT REMOVAL See Figure F.7 f...
Page 68 - CAPACITOR AND/OR DIODE BRIDGE 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 POWER-ARC 4000 F-27 TROUBLESHOOTING & REPAIR CAPACITOR AND/OR DIODE BRIDGE REMOVAL AND REPLACEMENT (continued) FIGURE F.8 - ...
Page 70 - Lincoln Electric Rotor Removal Kit (S20925) - FOR ROTOR REMOVAL ONLY; INSTRUCTIONS
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 F-29 TROUBLESHOOTING & REPAIR WARNING STATOR/ROTOR REMOVAL AND REPLACEMENT Service and repair should be perfo...
Page 71 - TIE WRAP; STATOR REMOVAL PROCEDURE
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 TROUBLESHOOTING & REPAIR F-30 STATOR/ROTOR REMOVAL AND REPLACEMENT (continued) FIGURE F.9 - OUTPUT LEAD LOCAT...
Page 72 - BOLTS; FIGURE F.10 – STATOR END BRACKET SUPPORT AND THRU-BOLTS
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 TROUBLESHOOTING & REPAIR F-31 STATOR/ROTOR REMOVAL AND REPLACEMENT (continued) THRU- BOLTS THRU-BOLTS NUTS SU...
Page 73 - ROTOR; ROTOR REMOVAL PROCEDURE
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 TROUBLESHOOTING & REPAIR F-32 STATOR/ROTOR REMOVAL AND REPLACEMENT (continued) FIGURE F.11 - ROTOR WITH STATO...
Page 75 - 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 POWER-ARC 4000 TROUBLESHOOTING & REPAIR F-34 RETEST AFTER REPAIR Retest a machine: • If it is rejected under test for any re...
Page 76 - NOTES
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 NOTES F-35
