Lincoln Electric POWER-ARC 4000 Service Manual Download Page 6

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Safety

.................................................................................................................................................i-iv

Installation

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Section A

Technical Specifications .............................................................................................................A-2

Safety Precautions ......................................................................................................................A-3

Location and Ventilation .............................................................................................................A-3

Pre-operation Engine Service .....................................................................................................A-4

Electrical Output Connections ....................................................................................................A-6

Operation

...............................................................................................................................

Section B

Safety Instructions ......................................................................................................................B-2

General Description ....................................................................................................................B-2

Recommended Applications.......................................................................................................B-3

Operational Features and Controls.............................................................................................B-3

Design Features and Advantages...............................................................................................B-3

Welding Capability ......................................................................................................................B-3

Limitations .................................................................................................................................B-3

Controls and Settings .................................................................................................................B-4

Engine Operation ........................................................................................................................B-6

Generator Operation ...................................................................................................................B-8

Welding Operation ....................................................................................................................B-10

Welding Guidelines ...................................................................................................................B-11

Accessories

...........................................................................................................................

Section C

Maintenance

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Section D

Safety Precautions......................................................................................................................D-2

Routine and Periodic Maintenance.............................................................................................D-2

Major Component Locations ......................................................................................................D-6

Theory of Operation

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Section E

Troubleshooting and Repair

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Section F

Electrical Diagrams

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Section G

Parts List

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P233 or P352

MASTER TABLE OF CONTENTS FOR ALL SECTIONS

POWER-ARC 4000

RETURN TO MAIN INDEX

Summary of Contents for POWER-ARC 4000

Page 1: ...OUT And most importantly think before you act and be careful Return to Master TOC Return to Master TOC Return to Master TOC Return to Master TOC View Safety Info View Safety Info View Safety Info View...

Page 2: ...JURY OR DEATH KEEP CHILDREN AWAY PACEMAKER WEARERS SHOULD CONSULT WITH THEIR DOCTOR BEFORE OPERATING Read and understand the following safety highlights For additional safety information it is strongl...

Page 3: ...ork or metal to be welded to a good electrical earth ground 3 f Maintain the electrode holder work clamp welding cable and welding machine in good safe operating condition Replace damaged insulation 3...

Page 4: ...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 ad...

Page 5: ...proximit au soudage l aide d crans appropri s et non inflamma bles 4 Des gouttes de laitier en fusion sont mises de l arc de soudage Se prot ger avec des v tements de protection libres de l huile tels...

Page 6: ...gn Features and Advantages B 3 Welding Capability B 3 Limitations B 3 Controls and Settings B 4 Engine Operation B 6 Generator Operation B 8 Welding Operation B 10 Welding Guidelines B 11 Accessories...

Page 7: ...A 4 Lifting A 4 Pre operation Engine Service A 4 Oil A 4 Fuel A 4 Muffler Defelector A 4 Spark Arrester A 5 Electrical Output Connections A 6 Welding Cable Connections A 6 Cable Size and Length A 6 C...

Page 8: ...CAL DIMENSIONS Briggs Stratton Vanguard Model 185432 3700 RPM 50 RPM at no load Manual Recoil start Manual Choke 18 06 cu in 296 cc Fuel 1 6 gal 6 0 l Oil 1 25 qt 1 2 l 1 cyl 4 cycle air cooled OHV ga...

Page 9: ...n water Such practices pose safety haz ards and cause improper operation and corrosion of parts Always operate the POWER ARC 4000 with the case roof on and all machine components completely assembled...

Page 10: ...Briggs and Stratton 8 HP engine and the Power Arc 4000 with the Honda 9 HP engine are supplied with low oil protection The Power Arc 4000 with the Briggs and Stratton 8 HP engine is equipped with pro...

Page 11: ...e to the engine or reduce performance A suitable spark arrester for the Briggs Stratton 8 HP Cool Bore engine is available as a Lincoln field installed option CAUTION Power Arc 4000 Typical Fuel Consu...

Page 12: ...lengths to reduce voltage drops TABLE A 1 RECOMMENDED WELDING CABLE SIZE AND LENGTH TOTAL COMBINED LENGTH OF ELECTRODE AND WORK CABLES Cable Size for 125 amp Cable Length 30 Duty Cycle 0 50 feet 0 15...

Page 13: ...located on the bottom center of the out put panel see Figure A 1 to a suitable earth ground such as a metal pipe driven into the ground Do not ground the machine to a pipe that carries explosive or co...

Page 14: ...onnected between the generator power and the utility meter The POWER ARC 4000 does not have a combined 120 240 volt twist lock receptacle and cannot be connected to a premises as described in other Li...

Page 15: ...ent inrush for starting See refrigerators weed and hedge Table B 3 GENERATOR POWER trimmers APPLICATIONS in the OPERA TION section of this manual for required starting wattages Some synchronous motors...

Page 16: ...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 400...

Page 17: ...Capability B 3 Limitations B 3 Controls and Settings B 4 Generator Welder Controls B 4 Gasoline Engine Controls B 5 Engine Operation B 6 Before Starting the Engine B 6 Starting the Engine B 6 Stopping...

Page 18: ...ed areas or vent exhaust to the outside Do not stack anything on or near the engine MOVING PARTS can injure Do not operate this equipment with any of its doors open or guards off Stop the engine befor...

Page 19: ...amp 240 volt generator receptacle Duplex 20 amp 120 volt generator receptacle Integrated generator output overload protection through two 20 amp circuit breakers Welded tube full roll cage frame prot...

Page 20: ...he POWER ARC 4000 is an AC output machine either output terminal can be used for either cable 4 WELD OUTPUT TERMINAL TO WORK WITH 1 2 13 FLANGE NUT Provides the connection point for either the electro...

Page 21: ...unding the ignition circuit 5 AIR CLEANER Filters intake air to the carburetor See ENGINE MAINTENANCE in the MAINTE NANCE section of this manual for details about the specific type of air cleaner to u...

Page 22: ...f tank space for fuel expansion DO NOT FILL THE TANK TO THE POINT OF OVERFLOW 3 Replace the fuel tank cap and tighten securely NOTE The engine will operate satisfactorily on any gasoline meant for aut...

Page 23: ...E 1 Remove all welding and generator power loads and let the engine cool by running it for several minutes 2 Stop the engine by turning the Rotary Stop Switch on top of the engine to the OFF position...

Page 24: ...n on the load device nameplate For example a device rated 115 volts 2 amps will need 230 watts of power 115 x 2 230 You can use Table B 3 GENERATOR POWER APPLI CATIONS to determine the wattage require...

Page 25: ...rs may require as much as 4 times running watts to start TABLE B 1 GENERATOR POWER APPLICATIONS Suggested Power Applications Running Watts Start up Watts Air Compressor 3 4 HP 1 250 3 100 5 000 Airles...

Page 26: ...s section of the manual 7 Strike an arc and begin welding For information on welding techniques see WELDING GUIDELINES in this section of the manual AFTER YOU FINISH THE WELD 1 Stop the gasoline engin...

Page 27: ...Table B 2 Welding Application Chart and the Electrode Selection Guide found on the nameplate of the machine ARC RAYS can burn When using an open arc process it is necessary to use correct eye head and...

Page 28: ...essentials needed for Gas Metal Arc Welding GMAW or MIG process es Contact your local authorized Lincoln representative for more details Learning To Stick Weld The serviceability of a product or stru...

Page 29: ...rrent to the arc The electrode is composed of a core metal wire around which has been extruded and baked a chemical covering The core wire melts into the arc and tiny droplets of molten metal shoot ac...

Page 30: ...the arc has been established maintaining the correct arc length becomes extremely important The arc should be short approximately 1 16 to 1 8 1 6 3 2mm long As the electrode burns off the elec trode m...

Page 31: ...s Most metals found around the farm or small shop are low carbon steel sometimes referred to as mild steel Typical items made with this type of steel include most sheet metal plate pipe and rolled sha...

Page 32: ...ation could be achieved The weld if properly made is as strong or stronger than the original metal Successive passes must be used to build up butt welds on heavier metal Fillet Welds When welding fill...

Page 33: ...at deposits little or no metal See drawing above 7 During this entire process the ONLY thing to watch is the molten metal As soon as it has solid ified the arc is SLOWLY brought back and anoth er few...

Page 34: ...ode 70 A for 3 32 2 5mm electrode 4 Move rapidly enough to stay ahead of the molten slag A whipping technique may be used to fur ther minimize burn through 5 If you have a choice use lap joints rather...

Page 35: ...C If the cast iron is hot before welding there will be no sudden chilling which creates brittle white cast iron The entire casting will cool slowly 2 Weld 1 2 12 7mm at a time and do not weld at that...

Page 36: ...ith these electrodes ALWAYS fill craters by drawing electrode away slow ly ALWAYS keep these electrodes dry Electrodes when not used within a few hours after a container is opened must be stored in he...

Page 37: ...Power Plug Kit K802T C 2 GFCI Receptacle Kit K896 3 C 2 Undercarriage K882 2 C 2 Rotor Removal Kit C 2 Briggs and Stratton Accessories C 2 Foam Pre Cleaner C 2 Oil Gard Low Oil Shutdown Kit C 2 Super...

Page 38: ...cleaner B S No 492889 Provides a foam pre cleaner for placement around the paper cartridge air cleaner Increases protection in extreme ly dusty or dirty environments Oil Gard Low Oil Shutdown Kit B S...

Page 39: ...2 Engine Adjustments D 2 Clean Engine D 3 Clean Cooling System D 3 Spark Plug D 3 Clean Spark Arrestor Screen D 3 Engine Maintenance Schedule D 4 Engine Maintenance Parts D 4 Generator Welder Mainten...

Page 40: ...s and numbers OIL Check the oil level after every 5 hours of operation or daily BE SURE TO MAINTAIN THE OIL LEVEL Change the oil the first time after 5 hours of opera tion Then under normal operating...

Page 41: ...ean the internal cooling fins and surfaces to prevent over speeding overheating and engine damage Clean every 100 operating hours or as often as necessary FIGURE D 3 CLEAN COOLING SYSTEM 1 REMOVE DIRT...

Page 42: ...stem Inspect Spark Arrester Option Clean or Replace Spark Plug Replace In Line Fuel Filter Option Remove Combustion Deposits Change oil after first 5 hours then after every 50 hours or once a year Not...

Page 43: ...with the screws previ ously removed Remove the cable tie or wooden stick and the brushes will seat onto the slip rings RECEPTACLES Keep the electrical receptacles in good condition Remove any dirt oil...

Page 44: ...urn to Master TOC Return to Master TOC D 6 MAINTENANCE D 6 POWER ARC 4000 8 7 6 5 1 2 3 4 1 CRADLE ASSEMBLY 2 ROTOR BLOWER AND BEARING ASSEMBLY 3 STATOR ASSEMBLY 4 BRUSH AND BRUSH HOLDER ASSEMBLY 5 CO...

Page 45: ...0 BLOCK LOGIC DIAGRAM Theory of Operation Section E Power Supply Operation E 1 E 4 Engine Excitation Rotor and Stator E 2 Rotor Field Feedback and Auxiliary Power E 3 Weld Winding and Reactor E 4 Auxi...

Page 46: ...of the main alternator stator Three separate and isolated windings are incor porated in the stator lamination assembly Each winding set has a different number of turns produc ing different magnitudes...

Page 47: ...igu ration As the feedback voltage is increased or de creased the outputs of the weld and auxiliary wind ings are likewise increased or decreased When full field voltage is applied to the rotor and th...

Page 48: ...rc when the AC voltage passes through the zero point In this manner the reactor enhances and stabilizes the AC welding arc The reactor is designed to provide optimum welding characteristics when used...

Page 49: ...Oscilloscope Waveforms Normal Open Circuit Weld Voltage Waveform F 19 Normal Open Circuit Weld Voltage Waveform 115 VAC Supply F 20 Typical Weld Output Waveform Machine Loaded F 21 Replacement Proced...

Page 50: ...specifies the appropriate test procedure to verify that the subject component is either good or bad If there are a number of possible com ponents check the components in the order listed to eliminate...

Page 51: ...nt for technical troubleshooting assistance before you proceed Call 1 800 833 9353 OUTPUT PROBLEMS PROBLEMS SYMPTOMS POSSIBLE AREAS OF MISADJUSTMENTS S RECOMMENDED COURSE OF ACTION Major physical or e...

Page 52: ...oltage from lead 202 to ground should be at least 0 5 to 1 5 VDC at high idle 3700 RPM Normal voltage is approximately 45 VDC If the voltage is low or missing the flashing circuit may be faulty See th...

Page 53: ...put terminal to stator winding See the Wiring Diagram 3 Check continuity zero ohms of lead W1 black from reactor L1 to stator winding See the Wiring Diagram 4 Check reactor L1 for continuity of windin...

Page 54: ...iliary power re ceptacles and associated wires for loose or faulty connections 2 Check the continuity zero ohms of leads 3 3A 3B 6 6A 6B 6C and 5 5A 5B from the recepta cles to the stator windings See...

Page 55: ...e is low the field capacitor C1 or bridge D1 may be faulty Test or replace 3 Check the rheostat R1 Normal resistance is 3 3 ohm See the Rheostat Replacement drawing 4 The rotor may be faulty Perform t...

Page 56: ...onsult engine owner s manual 5 The engine may be faulty Replace 1 Make sure the ON OFF Switch is in the ON position 2 Check spark plug boot and wire for loose or faulty connection 3 Make sure that the...

Page 57: ...See wiring diagram 1 The engine may require service to the head or carburetor 2 The fuel pump may be faulty Consult Briggs Stratton Consult Briggs Stratton owner s manual 1 Make sure the Rotary Switch...

Page 58: ...r cuit voltage OCV at the welder output terminals 62 VAC is normal If the correct voltage is present at the output terminals check for loose connections on the heavy current carrying leads inside the...

Page 59: ...ble to perform the test repairs safely contact the Lincoln Electric Service Department for electrical troubleshooting assistance before you proceed Call 1 800 833 9353 WELD TEST DESCRIPTION This test...

Page 60: ...d unpainted ground 5 Check the voltage reading on the volt ohmmeter It should read 45 48 VDC 6 If the voltage is low or not present the generator field circuit is not functioning correctly Proceed wit...

Page 61: ...o not understand the test procedures or are unable to perform the test repairs safely contact the Lincoln Electric Service Department for electrical troubleshooting assistance before you proceed Call...

Page 62: ...oss the rotor slip rings A Set the ohmmeter on the low scale X1 B Place one meter probe on one of the rotor slip rings Place the other probe on the other slip ring C Check the resistance across the sl...

Page 63: ...er into position in the generator end bracket Be careful not to loosen the 2 attached wires 11 Reinstall and tighten the 2 screws with the 1 4 nut driver 12 Slowly remove the non metallic retainer fro...

Page 64: ...est procedures or are unable to perform the test repairs safely contact the Lincoln Electric Service Department for electrical troubleshooting assistance before you proceed Call 1 800 833 9353 WELD TE...

Page 65: ...sher is completely compressed Frequency Counter Method 1 Plug the frequency counter into one of the 115 VAC auxiliary recepta cles 2 Start the engine and check the frequency counter At the proper RPM...

Page 66: ...millisec onds 4 Re tighten wing nut until wave washer is completely compressed ENGINE THROTTLE ADJUSTMENT TEST continued FIGURE F 5 LOCATION OF ENGINE THROTTLE ADJUSTMENT NUT Return to Section TOC Ret...

Page 67: ...olts 5 ms 50 volts SCOPE SETTINGS Volts Div 50V Div Horizontal Sweep 5 ms Div Coupling DC Trigger Internal This is the typical AC output voltage generated from a properly operating machine Note that e...

Page 68: ...0V Div Horizontal Sweep 5 ms Div Coupling DC Trigger Internal CH1 0 volts 5 ms 20 volts This is the typical AC output voltage generated from a properly operating machine Note that each vertical divi s...

Page 69: ...cal AC output voltage generated from a properly operating machine Note that each vertical divi sion represents 20 volts and that each horizontal division represents 5 milliseconds in time The mahine w...

Page 70: ...do not understand the test procedures or are unable to perform the test repairs safely contact the Lincoln Electric Service Department for electrical troubleshooting assistance before you proceed Cal...

Page 71: ...in place 4 With the needle nose pliers gently remove the black and the red wires Note The red wire is inboard RED is marked on the brush holder beside the terminal for the red wire 5 To change the br...

Page 72: ...iate terminals on the brushes The red wire is inboard 10 Slip the holder into position in the generator end bracket Be careful not to loosen the 2 attached wires 11 Reinstall and tighten the 2 screws...

Page 73: ...e unable to perform the test repairs safely contact the Lincoln Electric Service Department for electrical troubleshooting assistance before you proceed Call 1 800 833 9353 WELD DESCRIPTION The follow...

Page 74: ...r the screw head 7 To reinstall the rheostat replace each of the brass screws Place a shake proof star washer under the head insert the screw into the rheostat and tighten down one nut Replace the app...

Page 75: ...orm the test repairs safely contact the Lincoln Electric Service Department for electrical troubleshooting assistance before you proceed Call 1 800 833 9353 WELD DESCRIPTION The following procedure wi...

Page 76: ...s on for at least 5 seconds then remove 5 The capacitor is mounted in a mold ed plastic holder To remove it pull out on the top of the holder then slide it upward 6 Snap the capacitor out of the assem...

Page 77: ...n the bridge used this corner may be beveled and or marked with a sign Lead 201 and 201B are piggy backed on the negative terminal which will always be located diagonally across from the positive term...

Page 78: ...stator and or rotor for maintenance or replace ment of either component MATERIALS NEEDED Lincoln Electric Rotor Removal Kit S20925 FOR ROTOR REMOVAL ONLY 5 16 nut driver 1 2 socket wrench 6 socket ex...

Page 79: ...al See Figure F 9 for location With the diag onal cutters cut the cable tie that holds the two output leads together Pull lead W2 back out of the way screw the bolt back into the output terminal hole...

Page 80: ...proof star washer on the nut side The bolts must point toward the engine for reassembly 15 Lift up the stator and slide out the support bracket The engine will now rest on the 2 X 4 16 With the babbit...

Page 81: ...or pops off the engine crankshaft If an impact wrench is not available use the 1 2 box wrench Hold the rotor with one hand and shock the wrench with the mallet until the rotor pops off the engine cran...

Page 82: ...d lock washers Remove the 2 X 4 engine support 10 Reinstall the brush holder assembly Refer to the topic BRUSH REMOVAL AND REPLACEMENT in this section of the manual 11 Slide the control box back into...

Page 83: ...replace any electrical components ENGINE OUTPUT No Load RPM Load RPM Maximum Speed 3725 3650 Minimum Speed 3675 3400 WELDER GENERATOR OUTPUT1 Output Control Field Volts Field Amps Open Circuit Load Vo...

Page 84: ...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...

Page 85: ...eturn to Master TOC Return to Master TOC Page DIAGRAMS SECTION Section G Wiring Diagram S22160 G 2 Wiring Diagram S22160 1 G 3 Wiring Diagram S25341 G 4 Dimension Print G 5 TABLE OF CONTENTS DIAGRAMS...

Page 86: ...R E1537 3C 201B GREEN CB2 CB1 YELLOW 6B GREEN BLACK 3B BLACK BLACK GNDB GNDA ELECTRICAL SYMBOLS WHITE BLACK BLACK WIRING DIAGRAM POWER ARC 4000 D2 202C BROWN 202 RED 200A 200 RED 202B RED 202 RED 9A 7...

Page 87: ...3 DIAGRAMS G 3 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 TO...

Page 88: ...4 DIAGRAMS G 4 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 TO...

Page 89: ...ion 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 m...

Page 90: ...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...

Page 91: ..._________________________________ ___________________________________________________________________________ ___________________________________________________________________________ ______________...

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