SVM103-A TM View Safety Info Return to Master TOC RETURN TO MAIN INDEX POWER-ARC 4000 December 1995 For use with machine code number 10083 Return to Master TOC View Safety Info Return to Master TOC View Safety Info Return to Master TOC View Safety Info 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.
Return to Master TOC i SAFETY WARNING CALIFORNIA PROPOSITION 65 WARNINGS Diesel engine exhaust and some of its constituents are known to the State of California to cause cancer, birth defects, and other reproductive harm. The Above For Diesel Engines The engine exhaust from this product contains chemicals known to the State of California to cause cancer, birth defects, or other reproductive harm. The Above For Gasoline Engines ARC WELDING CAN BE HAZARDOUS.
ii Return to Master TOC Return to Master TOC SAFETY ELECTRIC SHOCK can kill. ARC RAYS can burn. 3.a. The electrode and work (or ground) circuits are electrically “hot” when the welder is on. Do not touch these “hot” parts with your bare skin or wet clothing. Wear dry, hole-free gloves to insulate hands. 4.a. Use a shield with the proper filter and cover plates to protect your eyes from sparks and the rays of the arc when welding or observing open arc welding.
Return to Master TOC iii SAFETY WELDING SPARKS can cause fire or explosion. 6.a. Remove fire hazards from the welding area. If this is not possible, cover them to prevent the welding sparks from starting a fire. Remember that welding sparks and hot materials from welding can easily go through small cracks and openings to adjacent areas. Avoid welding near hydraulic lines. Have a fire extinguisher readily available. Return to Master TOC 6.b.
iv Return to Master TOC SAFETY PRÉCAUTIONS DE SÛRETÉ Pour votre propre protection lire et observer toutes les instructions et les précautions de sûreté specifiques qui parraissent dans ce manuel aussi bien que les précautions de sûreté générales suivantes: Sûreté Pour Soudage A L’Arc 1. Protegez-vous contre la secousse électrique: a. Return to Master TOC b.
v RETURN TO MAIN INDEX MASTER TABLE OF CONTENTS FOR ALL SECTIONS Page Safety.................................................................................................................................................i-iv Installation .............................................................................................................................Section A Technical Specifications .............................................................................................................
Return to Master TOC Section A TABLE OF CONTENTS - INSTALLATION SECTION Installation Technical Specifications .............................................................................................................A-1 Safety Precautions......................................................................................................................A-2 Location and Ventilation .............................................................................................................A-2 Storing .
Return to Master TOC Return to Section TOC A-1 INSTALLATION TECHNICAL SPECIFICATIONS - POWER-ARC 4000 INPUT - GASOLINE ENGINE Manufacturer Description Return to Master TOC Return to Section TOC Briggs & Stratton CoolBore® 1 cyl., 4 cycle air-cooled gasoline 8 HP @ 3750 RPM Speed Displacement Ignition Capacities 3700 RPM ± 50 RPM at no load 19.4 cu. in. (319 cc) Manual, Recoil start; Manual choke Fuel: 1.0 gal. (3.8 l) Oil: 1.4 qt. (1.
A-2 Return to Master TOC Return to Master TOC Return to Section TOC Return to Section TOC INSTALLATION Read this entire installation section before you start installation. SAFETY PRECAUTIONS WARNING Do not attempt to use this equipment until you have thoroughly read all the operation and maintenance manuals supplied with your machine. They include important safety precautions; detailed engine starting, operating, and maintenance instructions; and parts lists. ELECTRIC SHOCK can kill.
Return to Master TOC Return to Master TOC Return to Section TOC Return to Section TOC A-3 INSTALLATION STACKING FUEL POWER-ARC 4000 machines CANNOT be stacked. TILTING Place the machine on a secure, level surface whenever you use it or store it. Any surfaces you place it on other than the ground must be firm, non-skid, and structurally sound. The POWER-ARC 4000 has a plastic, 1.00 gallon (3.8) fuel tank mounted on the engine.
A-4 Return to Master TOC Return to Section TOC INSTALLATION FIGURE A.1 - POWER-ARC 4000 OUTPUT CONNECTIONS 1 POWER ARC 4000 80 70 AMPS AMPS 125 90 AMPS GENERATOR AMPS 100 AMPS WARNING Return to Master TOC Return to Section TOC 6 ELECTRODE SELECTION GUIDE 5 3 4 2 Return to Master TOC Return to Section TOC 1. CURRENT CONTROL DIAL 2. WELD OUTPUT TERMINALS (2) 3. GROUND STUD ELECTRICAL OUTPUT CONNECTIONS See Figure A.
Return to Master TOC Return to Master TOC Return to Section TOC Return to Section TOC A-5 INSTALLATION Cable Installation WARNING Install the welding cables to your POWER-ARC 4000 as follows. See Figure A.1 for the location of parts. 1. The gasoline engine must be OFF to install welding cables. 2. Remove the 1/2 - 13 flanged nuts from the output terminals. 3. Connect the electrode holder and work cables to the weld output terminals.
A-6 Return to Master TOC Return to Section TOC INSTALLATION PREMISES WIRING CIRCUIT BREAKERS The POWER-ARC 4000 three-wire, grounded neutral generator allows it to be connected to premises wiring. However, the wiring procedure needed to meet the National Electric Code (NEC) regulations as well as city ordinances can be confusing. Matters get worse depending on whether you want the machine to be “hardwired” to the premises or only connected temporarily.
Return to Master TOC Return to Master TOC INSTALLATION CAUTION Certain Electrical devices cannot be powered by the POWER-ARC 4000. See Table A.2. TABLE A.2 ELECTRICAL DEVICE USE WITH THE POWER-ARC 4000. Type Common Electrical Devices Possible Concerns Resistive Heaters, toasters, incandescent light bulbs, electric range, hot pan, skillet, coffee maker. NONE Capacitive TV sets, radios, microwaves, appliances with electrical control.
Return to Master TOC Section B TABLE OF CONTENTS - OPERATION SECTION Operation...............................................................................................................................Section B Safety Instructions ......................................................................................................................B-1 General Description ....................................................................................................................
Return to Master TOC Return to Section TOC B-1 OPERATION OPERATING INSTRUCTIONS Read and understand this entire section before operating your POWER-ARC 4000. SAFETY INSTRUCTIONS Return to Master TOC ARC RAYS can burn. • Wear eye, ear, and body protection. WARNING Do not attempt to use this equipment until you have thoroughly read all the operation and maintenance manuals supplied with your machine.
B-2 Return to Master TOC Return to Section TOC OPERATION The POWER-ARC 4000 warranty covers the machine for one year from the date of purchase. For nonengine warranty claims, contact your nearest Lincoln Authorized Field Service Facility. For engine warranty claims, contact your nearest Briggs & Stratton service center. NOTE: The POWER-ARC 4000 is not meant for rental or other commercial use.
Return to Master TOC Return to Section TOC B-3 OPERATION CONTROLS AND SETTINGS All generator/welder controls are located on the Output Control Panel. Gasoline engine controls are mounted on the engine. See Figures B.1 and B.2 and the explanations that follow. FIGURE B.
B-4 Return to Master TOC Return to Section TOC OPERATION 5. GROUND STUD: Provides a connection point for connecting the machine case to earth ground for the safest grounding procedure. 7. 20 AMP, 240 VOLT RECEPTACLE: Connection point for supplying 240 volt power to operate one electrical device. 6. 20 AMP CIRCUIT BREAKERS (2): Provide separate overload current protection for the 120 volt and 240 volt receptacles. 8.
Return to Master TOC Return to Section TOC B-5 OPERATION 7. AIR MIXTURE ADJUSTMENT SCREW: Adjusts the amount of air mixed with fuel to obtain the smoothest operation under load or at idle. The POWER-ARC 4000 is shipped with the proper adjustment already set. DO NOT ADJUST THE AIR MIXTURE SCREW WITHOUT FOLLOWING THE PROCEDURES OUTLINED BY BRIGGS & STRATTON. Return to Master TOC Return to Section TOC 8. RECOIL STARTER: Manual, rope-type starter.
B-6 Return to Master TOC Return to Section TOC OPERATION 4. Pull the cord rapidly. FOR BEST ENGINE STOPPING: 5. If the engine does not start, open the choke slightly (move lever upward) and pull the starter cord rapidly again. • Do not remove the rubber spark plug boot. When the engine starts, gradually open the choke to the highest, upward position. Return to Master TOC Return to Section TOC 2. Place the choke lever in the highest, upward position.
Return to Master TOC Return to Section TOC B-7 OPERATION GENERATOR OPERATION CAUTION Be sure that any electrical equipment plugged into the generator’s AC power receptacles can withstand a ±10% voltage and a ±3% frequency variation. Some electronic devices cannot be powered by the POWERARC 4000. Refer to Table A.2, ELECTRICAL DEVICE USE WITH THE POWER-ARC 4000, in the INSTALLATION section of this manual.
B-8 Return to Master TOC Return to Master TOC Return to Master TOC Return to Section TOC Return to Section TOC Return to Section TOC OPERATION TABLE B.
Return to Master TOC Return to Section TOC B-9 OPERATION WELDING OPERATION GENERAL INFORMATION WARNING Do not touch electrically live parts or electrodes with your skin or wet clothing. 3. Attach the work clamp securely to the work you are welding. 4. Insert the electrode into the electrode holder. 5. Set the current control dial to the desired output current. 6. Start the gasoline engine. See ENGINE OPERATION in this section of the manual.
B-10 Return to Master TOC Return to Section TOC OPERATION WELDING GUIDELINES TABLE B.
Return to Master TOC Return to Section TOC B-11 OPERATION FIGURE B.3 – WELDING CIRCUIT CONNECTIONS 1 5 Return to Master TOC Return to Section TOC 2 Return to Master TOC Return to Master TOC Return to Section TOC 8 4 3 1. 2. 3. 4. 5. 6. 7. 8.
B-12 Return to Master TOC Return to Section TOC OPERATION FIGURE B.4 – THE WELDING ARC THE FOUR FACTORS OF SUCCESSFUL WELDING 2 Controlling the arc to make a successful weld depends on four factors. How well you control them will determine whether your welds succeed or fail.
B-13 Return to Master TOC Return to Section TOC OPERATION THE CORRECT ARC LENGTH The arc length is the distance from the tip of the electrode core wire to the base metal. FIGURE B.6 – MOLTEN METAL PUDDLE AND CORRECT WELD SPEED Once you’ve established the arc, maintaining the correct arc length is critical. It should be short, 1/16 to 1/8 inch (3.2 mm) long. As the electrode burns off, you must continue to feed it into the work to keep the arc length correct.
TABLE OF CONTENTS - ACCESSORIES Accessories...........................................................................................................................Section C Options/Accessories...................................................................................................................C-1 Lincoln Electric Accessories ................................................................................................C-1 Briggs and Stratton Accessories .....................................
Return to Master TOC Return to Section TOC C-1 ACCESSORIES OPTIONS/ACCESSORIES LINCOLN ELECTRIC ACCESSORIES The following options/accessories are available for your POWER-ARC 4000 from your local Lincoln Distributor. Power Plug Kit (K802T) – Provides three plugs, two for the 120 volt duplex receptacle and one for the 240 volt receptacle. Accessory Set (K875) – Includes the following: • Twenty feet (6.
TABLE OF CONTENTS -MAINTENANCEMaintenance .........................................................................................................................Section D Routine and Periodic Maintenance ............................................................................................D-1 Engine Maintenance.............................................................................................................D-1 Generator/Welder Maintenance ..................................................
D-1 Return to Master TOC Return to Section TOC MAINTENANCE SAFETY PRECAUTIONS WARNING • Have qualified personnel do all maintenance and troubleshooting work. • Turn the engine off before working inside the machine. Return to Master TOC Return to Master TOC Return to Master TOC Return to Section TOC Return to Section TOC Return to Section TOC • Remove guards only when necessary to perform maintenance and replace them when the maintenance requiring their removal is complete.
D-2 Return to Master TOC Return to Section TOC MAINTENANCE AIR CLEANER: Your air cleaner may have only the paper cartridge, or it may have the cartridge and a foam pre-cleaner. If it has the pre-cleaner, service the cartridge every 100 hours and the precleaner every 25 hours or once a year, whichever comes first. If the air cleaner doesn’t have the precleaner, service the cartridge every 25 hours or once a year, whichever comes first. Under dusty conditions, service more often.
Return to Master TOC Return to Section TOC D-3 MAINTENANCE CLEAN OR REPLACE SPARK PLUG: Clean or replace the spark plug after every 100 hours of operation or every season, whichever comes first. Do not blast the spark plug clean with an abrasive cleaning device. Clean the plug by scraping it or by using a wire brush. Wash the plug with a commercial solvent. After cleaning or when installing a new spark plug, set the terminal gap to .030 inch (.76 mm) with a feeler gauge. See Figure D.4.
D-4 Return to Master TOC Return to Section TOC MAINTENANCE TABLE D.2 – ENGINE MAINTENANCE PARTS Part Part Number OIL FILTER SPARK PLUG (STANDARD) NONE B&S 492167 CHAMPION J19LM B&S 802592 CHAMPION RJ19LM B&S 298090 (for .25î I.D.
D-5 Return to Master TOC Return to Section TOC MAINTENANCE FIGURE D.6. - MAJOR COMPONENT LOCATIONS 7 6 5 8 Return to Master TOC Return to Section TOC 1 3 Return to Section TOC Return to Master TOC Return to Section TOC Return to Master TOC 4 POWER-ARC 4000 2 1 . CRADLE ASSEMBLY 2. ROTOR, BLOWER, AND BEARING ASSEMBLY 3. STATOR ASSEMBLY 4. BRUSH AND BRUSH HOLDER ASSEMBLY 5. CONTROL BOX WELDED ASSEMBLY 6. REACTOR ASSEMBLY 7. OUTPUT TERMINAL ASSEMBLY 8.
Return to Master TOC Section E TABLE OF CONTENTS -THEORY OF OPERATION SECTIONTheory of Operation .............................................................................................................Section E Power Supply Operation ..............................................................................................E-1 - E-3 Engine, Excitation, Rotor and Stator ..............................................................................E-1 Rotor Field Feedback and Auxiliary Power........
THEORY OF OPERATION Return to Master TOC Return to Section TOC E-1 FIGURE E.
E-2 Return to Master TOC Return to Section TOC THEORY OF OPERATION FIGURE E.3 – FIELD EXCITATION AND AUXILIARY POWER REACTOR OUTPUT TERMINALS Return to Master TOC Return to Section TOC STATOR ENGINE MECHANICAL ROTATION ROTOR SLIP RINGS ROTOR STATOR CAPACITOR RHEOSTAT Return to Master TOC Return to Section TOC 115 AND 230VAC RECEPTACLES ROTOR FIELD FEEDBACK AND AUXILIARY POWER The AC voltage developed in the field winding is fed to the full wave bridge.
THEORY OF OPERATION Return to Master TOC Return to Section TOC E-3 FIGURE E.
TABLE OF CONTENTS TROUBLE SHOOTING & REPAIR SECTION Troubleshooting & Repair Section.................................................................................Section F Safety Precautions.................................................................................................................F-1 How to Use Troubleshooting Guide ......................................................................................F-1 Troubleshooting Guide..........................................................
Return to Master TOC Return to Master TOC Return to Master TOC Return to Section TOC Return to Section TOC Return to Section TOC F-1 TROUBLESHOOTING & REPAIR HOW TO USE TROUBLESHOOTING GUIDE WARNING 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 machine operator and will invalidate your factory warranty.
F-2 Return to Master TOC Return to Section TOC TROUBLESHOOTING & REPAIR TROUBLESHOOTING GUIDE PROBLEMS (SYMPTOMS) POSSIBLE AREAS OF MISADJUSTMENT(S) RECOMMENDED COURSE OF ACTION OUTPUT PROBLEMS Contact the Lincoln Electric Service Department at (216) 383-2531 or 1-800-833-9353 (WELD). Return to Section TOC Return to Master TOC Return to Section TOC Return to Master TOC Return to Master TOC Major physical or electrical damage is evident.
Return to Master TOC Return to Section TOC F-3 TROUBLESHOOTING & REPAIR PROBLEMS (SYMPTOMS) POSSIBLE AREAS OF MISADJUSTMENT(S) RECOMMENDED COURSE OF ACTION OUTPUT PROBLEMS 1. The generator brushes may be worn or faulty. See the Maintenance section of this manual or contact your local Lincoln Electric Authorized Field Service Facility. Return to Master TOC No weld output and no auxiliary output - engine runs normally.
F-4 Return to Master TOC Return to Master TOC Return to Section TOC Return to Section TOC TROUBLESHOOTING & REPAIR TROUBLESHOOTING GUIDE PROBLEMS (SYMPTOMS) Observe Safety Guidelines detailed in the beginning of this manual. POSSIBLE AREAS OF MISADJUSTMENT(S) RECOMMENDED COURSE OF ACTION OUTPUT PROBLEMS No weld output - auxiliary power (230 - 115 VAC) operates normally - engine runs normally. 1. Check the open circuit voltage (OCV) at the welder output terminals.
Return to Master TOC Return to Section TOC F-5 TROUBLESHOOTING & REPAIR Observe Safety Guidelines detailed in the beginning of this manual. TROUBLESHOOTING GUIDE PROBLEMS (SYMPTOMS) RECOMMENDED COURSE OF ACTION POSSIBLE AREAS OF MISADJUSTMENT(S) OUTPUT PROBLEMS No auxiliary power - welding output is normal - engine runs normally. 1. Check circuit breakers CB1 and CB2. Reset if tripped. 3. Check for loose or faulty plug at power receptacle.
F-6 Return to Master TOC Return to Section TOC TROUBLESHOOTING & REPAIR TROUBLESHOOTING GUIDE PROBLEMS (SYMPTOMS) Observe Safety Guidelines detailed in the beginning of this manual. POSSIBLE AREAS OF MISADJUSTMENT(S) OUTPUT PROBLEMS Low weld output and low auxiliary output. 1. The generator brushes may be worn. See the Maintenance section of this manual or contact your local Lincoln Electric Authorized Field Service Facility.
Return to Master TOC Return to Section TOC F-7 TROUBLESHOOTING & REPAIR TROUBLESHOOTING GUIDE Observe Safety Guidelines detailed in the beginning of this manual. PROBLEMS (SYMPTOMS) POSSIBLE AREAS OF MISADJUSTMENT(S) ENGINE PROBLEMS Engine will not start. 1. Make sure the piecing stop switch is NOT touching the spark plug boot. 3. Make sure that the fuel shutoff valve is in the farthest upward position.
F-8 Return to Master TOC Return to Master TOC Return to Section TOC Return to Section TOC TROUBLESHOOTING & REPAIR TROUBLESHOOTING GUIDE PROBLEMS (SYMPTOMS) Observe Safety Guidelines detailed in the beginning of this manual. POSSIBLE AREAS OF MISADJUSTMENT(S) RECOMMENDED COURSE OF ACTION ENGINE PROBLEMS Engine will not stop running. 1. The piercing stop switch may not be contacting the spark plug. Make certain that the pointed end of the lever firmly contacts the spark plug tip. 1.
Return to Master TOC Return to Section TOC F-9 TROUBLESHOOTING & REPAIR Observe Safety Guidelines detailed in the beginning of this manual. TROUBLESHOOTING GUIDE PROBLEMS (SYMPTOMS) RECOMMENDED COURSE OF ACTION WELDING PROBLEMS Return to Master TOC Return to Master TOC Return to Master TOC Return to Section TOC Return to Section TOC The welding arc is “cold.” The engine runs normally (3700 RPM, no load). Auxiliary power is functioning normally.
F-10 Return to Master TOC Return to Section TOC TROUBLESHOOTING & REPAIR ROTOR VOLTAGE TEST WARNING 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 or machine operator and will invalidate your factory warranty. For your safety and to avoid electrical shock, please observe all safety notes and precautions detailed throughout this manual.
Return to Master TOC Return to Section TOC F-11 TROUBLESHOOTING & REPAIR ROTOR VOLTAGE TEST (continued) FIGURE F.1 - LOCATION OF LEAD 200A FOR ROTOR VOLTAGE TEST GROUND STUD Return to Master TOC Return to Section TOC A 200 LEAD 200A CONNECTION OUTPUT PANEL Return to Section TOC Return to Master TOC Return to Section TOC Return to Master TOC TEST PROCEDURE 1. 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. 5.
F-12 Return to Master TOC Return to Section TOC TROUBLESHOOTING & REPAIR ROTOR RESISTANCE TEST WARNING 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 or machine operator and will invalidate your factory warranty. For your safety and to avoid electrical shock, please observe all safety notes and precautions detailed throughout this manual.
Return to Section TOC Return to Master TOC Return to Section TOC Return to Master TOC F-13 TROUBLESHOOTING & REPAIR ROTOR RESISTANCE TEST (continued) FIGURE F.2 LOCATION OF ROTOR SLIP RINGS - BRUSH HOLDER ASSEMBLY REMOVED SLIP RINGS Return to Master TOC Return to Section TOC TEST PROCEDURE 1. Conduct the test with the gasoline engine OFF. 7. Measure the resistance across the rotor slip rings. 2. Remove the spark plug wire to prevent accidental engine kickback or starting. A.
Return to Master TOC Return to Section TOC TROUBLESHOOTING & REPAIR F-14 ROTOR RESISTANCE TEST (continued) FIGURE F.3 - BRUSHES RETAINED WITH CABLE TIE Return to Master TOC Return to Master TOC Return to Section TOC Return to Section TOC CABLE TIE BRUSHES 9. Reinstall the brush holder assembly after the test. Depress the spring-loaded brushes into the holder and slip a suitable non-metallic, fairly stiff retainer through the slots at the top and bottom of the holder.
TROUBLESHOOTING & REPAIR Return to Master TOC Return to Section TOC F-15 ENGINE THROTTLE ADJUSTMENT TEST WARNING Return to Master TOC Return to Section TOC 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 or machine operator and will invalidate your factory warranty.
F-16 Return to Master TOC Return to Section TOC TROUBLESHOOTING & REPAIR ENGINE THROTTLE ADJUSTMENT TEST (continued) FIGURE F.4 - BLOWER PADDLE MARKED FOR STROBE-TACH METHOD Return to Master TOC Return to Master TOC Return to Section TOC Return to Section TOC MARK TEST PROCEDURE Frequency Counter Method: This test can be conducted by any of three methods. 1. Plug the frequency counter into one of the 115 VAC auxiliary receptacles. Strobe-tach Method: 2.
Return to Master TOC Return to Section TOC F-17 TROUBLESHOOTING & REPAIR ENGINE THROTTLE ADJUSTMENT TEST (continued) 2. Use the 7/16 wrench to turn in the spring-loaded adjustment nut. Increase the high idle speed to adjust the waveform period to 16.2 milliseconds. See Figure F.5 for location of the adjustment nut. Return to Master TOC Return to Master TOC Return to Master TOC Return to Section TOC Return to Section TOC Return to Section TOC FIGURE F.
F-18 Return to Master TOC Return to Section TOC TROUBLESHOOTING & REPAIR NORMAL OPEN CIRCUIT WELD VOLTAGE WAVEFORM HIGH IDLE – NO LOAD Return to Master TOC Return to Section TOC CH1 0 volts Return to Master TOC Return to Section TOC 50 volts 5 ms This is the typical AC output voltage generated from a properly operating machine. Note that each vertical division represents 50 volts and that each horizontal division represents 5 milliseconds in time.
Return to Master TOC Return to Section TOC F-19 TROUBLESHOOTING & REPAIR NORMAL OPEN CIRCUIT VOLTAGE WAVEFORM (115 VAC SUPPLY) HIGH IDLE – NO LOAD 1 Period = 16.2 ms @ 3700 rpm Return to Master TOC Return to Section TOC CH1 0 volts Note: Scope probes connected at machine 115 VAC receptacle. SCOPE SETTINGS Volts/Div ....................50V/Div. Horizontal Sweep ....5 ms/Div. Coupling ............................DC Trigger.........................
F-20 Return to Section TOC Return to Master TOC Return to Section TOC Return to Master TOC TROUBLESHOOTING & REPAIR TYPICAL WELD OUTPUT WAVEFORM MACHINE LOADED CH1 0 volts 20 volts 5 ms Return to Master TOC Return to Section TOC MACHINE LOADED TO 125 AMPS AT 23 VAC This is the typical AC output voltage generated from a properly operating machine. Note that each vertical division represents 20 volts and that each horizontal division represents 5 milliseconds in time.
Return to Master TOC Return to Master TOC Return to Section TOC Return to Section TOC F-21 TROUBLESHOOTING & REPAIR BRUSH REMOVAL AND REPLACEMENT WARNING 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 or machine operator and will invalidate your factory warranty.
F-22 Return to Master TOC Return to Section TOC TROUBLESHOOTING & REPAIR BRUSH REMOVAL AND REPLACEMENT (continued) FIGURE F.6 - BRUSHES RETAINED WITH CABLE TIE Return to Master TOC Return to Section TOC CABLE TIE BRUSHES PROCEDURE Return to Master TOC Return to Section TOC 1. Remove the spark plug wire. 2. Open the brush holder assembly cover. Squeeze the 2 tabs and depress the cover at the top with a screw driver or your fingernail. The cover will drop open on its bottom hinge. 3.
Return to Master TOC Return to Master TOC Return to Master TOC Return to Master TOC Return to Section TOC Return to Section TOC Return to Section TOC Return to Section TOC F-23 TROUBLESHOOTING & REPAIR BRUSH REMOVAL AND REPLACEMENT (continued) PROCEDURE (continued) 8. To reinstall the brush holder assembly, depress the spring-loaded brushes into the holder and slip a suitable non-metallic, fairly stiff retainer through the slots at the top and bottom of the holder.
F-24 Return to Master TOC Return to Section TOC TROUBLESHOOTING & REPAIR RHEOSTAT REMOVAL AND REPLACEMENT WARNING 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 or machine operator and will invalidate your factory warranty. For your safety and to avoid electrical shock, please observe all safety notes and precautions detailed throughout this manual.
Return to Section TOC Return to Master TOC Return to Section TOC Return to Master TOC F-25 TROUBLESHOOTING & REPAIR RHEOSTAT REMOVAL AND REPLACEMENT FIGURE F.7 - RHEOSTAT REMOVAL See Figure F.7 for steps 3 - 9. PROCEDURE Return to Master TOC Return to Section TOC 1. Remove the 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.
F-26 Return to Master TOC Return to Master TOC Return to Section TOC Return to Section TOC TROUBLESHOOTING & REPAIR CAPACITOR AND/OR DIODE BRIDGE REMOVAL AND REPLACEMENT WARNING 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 or machine operator and will invalidate your factory warranty.
F-27 Return to Master TOC Return to Section TOC TROUBLESHOOTING & REPAIR CAPACITOR AND/OR DIODE BRIDGE REMOVAL AND REPLACEMENT (continued) FIGURE F.8 - DIODE BRIDGE LOCATION AND DISCHARGING THE FIELD CAPACITOR DIODE BRIDGE Return to Master TOC Return to Section TOC JUMPER CAPACITOR Return to Section TOC Return to Master TOC Return to Section TOC Return to Master TOC PROCEDURE - CAPACITOR REMOVAL AND REPLACEMENT 1. Remove the engine spark plug wire. 5. Snap the capacitor out of the assembly.
F-28 Return to Master TOC Return to Section TOC TROUBLESHOOTING & REPAIR CAPACITOR AND/OR DIODE BRIDGE REMOVAL AND REPLACEMENT (continued) PROCEDURE - DIODE BRIDGE REMOVAL AND REPLACEMENT 1. To remove the diode bridge, first you will have to remove the field capacitor. Follow Steps 1 - 5 on capacitor removal and replacement procedure. Return to Master TOC Return to Master TOC Return to Master TOC Return to Section TOC Return to Section TOC Return to Section TOC 2.
Return to Master TOC Return to Section TOC F-29 TROUBLESHOOTING & REPAIR STATOR/ROTOR REMOVAL AND REPLACEMENT WARNING 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 or machine operator and will invalidate your factory warranty. For your safety and to avoid electrical shock, please observe all safety notes and precautions detailed throughout this manual.
F-30 Return to Master TOC Return to Master TOC Return to Master TOC Return to Section TOC Return to Section TOC Return to Section TOC TROUBLESHOOTING & REPAIR STATOR/ROTOR REMOVAL AND REPLACEMENT (continued) into the output terminal hole loosely for reassembly. Set the control panel back on the control box and hold it in place with 1 sheet metal screw in each side. STATOR REMOVAL PROCEDURE 1. Remove engine spark plug wire to prevent accidental kickback or starting. 2.
Return to Master TOC Return to Master TOC Return to Section TOC Return to Section TOC F-31 TROUBLESHOOTING & REPAIR STATOR/ROTOR REMOVAL AND REPLACEMENT (continued) 12. Slide a short length of 2 X 4 under the engine to support it when the stator is removed. 15. Lift up the stator and slide out the support bracket. The engine will now rest on the 2 X 4. 13. With the 1/2” socket wrench, remove the 2 nuts that hold the stator end bracket support. See Figure F.10 for location.
F-32 Return to Master TOC Return to Section TOC TROUBLESHOOTING & REPAIR STATOR/ROTOR REMOVAL AND REPLACEMENT (continued) FIGURE F.11 - ROTOR WITH STATOR REMOVED Return to Master TOC Return to Section TOC ROTOR THRU-BOLT 1. To remove the rotor, double check that the spark plug wire is disconnected. You will be turning the rotor during this procedure, and this could accidentally cause engine kickback. Return to Master TOC Return to Section TOC ROTOR REMOVAL PROCEDURE 2.
Return to Master TOC Return to Master TOC Return to Master TOC TROUBLESHOOTING & REPAIR STATOR/ROTOR REMOVAL AND REPLACEMENT (continued) 6. Install the bottom two end bracket thrubolts. Note: The flat washer goes on the top right hand thru-bolt for the green ground wire. 7. Tap the end bracket with the mallet as necessary to position it. Tighten the bolts to 22 - 25 ft lbs. Alternate tightening in order to pull the assembly together evenly.
F-34 Return to Master TOC Return to Section TOC TROUBLESHOOTING & REPAIR RETEST AFTER REPAIR Retest a machine: • If it is rejected under test for any reason that requires you to remove any mechanical part which could affect the machine’s electrical characteristics. OR • If you repair or replace any electrical components.
Return to Section TOC Return to Master TOC Return to Section TOC Return to Master TOC Return to Master TOC Return to Section TOC Return to Master TOC Return to Section TOC F-35 POWER-ARC 4000 NOTES
TABLE OF CONTENTS - ELECTRICAL DIAGRAMS Electrical Diagrams.........................................................................................................Section G PowerArc 4000......................................................................................................................
POWER-ARC 4000 GNDB GREEN 6A BLACK 3B YELLOW 6B YELLOW CB2 YELLOW (STATOR TO END BRACKET) GNDC GREEN GREEN 6 STATOR 3 7 BLUE 9 BLUE 202 BLACK 3A CB1 BLACK GNDD GREEN 5 WHITE 201B GREEN BLACK 201A (-) BROWN 9 (-) 7 200A BLUE SHOWN VIEWED FROM REAR. 8-19-94 S20903 SWITCH RUN/STOP PER E1537.
Return to Section TOC Return to Master TOC Return to Section TOC Return to Master TOC Return to Master TOC Return to Section TOC Return to Master TOC Return to Section TOC NOTES G-2 POWER-ARC 4000
Return to Section TOC Return to Master TOC Return to Section TOC Return to Master TOC Return to Master TOC Return to Section TOC Return to Master TOC Return to Section TOC G-3 POWER-ARC 4000 NOTES