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Fishman Loudbox 100 Musical Instrument User Manual

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2. 1 Safety Precautions ne Pee erdt pr eu odas A 2 Location Ventilation rione Ld A 2 Pre operation Engine Service sise A 3 Electrical Output Connections iunii PE edis et cnn hein ares er p e nia A 4 MM m Section B Safety eere e eer ARR RR RT ERR e FER B 1 General DescriptiQn iio ee e B 1 Recommended Applications ir ctt a B 2 Operational Features and Controls ss B 2 Design Features and Advantages sisi B 2 Welding Capabilliby cott ttt tert ie rcm i irse cir e E E HR E ER B 2 mc a a 2 Controls S ettings toa eta too m o Bt d Ra o B 3 Engine Operation cei nti oct pen itr re ae eoi ea oes E D Ra Ee a e Ced DE B 5 E Section C Section D Safety EE 0 1 Routine and Periodic Maintenance sise D 1 Major Component Locations iii oiii ai ab d a ie e a Deka E Bd dnd od e D 5 Theory of Operation o sente NEESER EEEE EE Section E Troubleshooting and Repair Section F Electrical ab EN e lue Ll PR b cet Section G Parts Manual iie d e e eee e eme nantes P 233 LINCOLN 5 POWER ARC 4000 Section TABLE OF CONTENTS Q E INST
3. U oe 0 9 0 sis 0 ME ut als T e EIE 22 HE NUT 2000 oio Ojo E E amp i 5 un 818 EJE D UV iac Return to Section TOC Return to Master TOC LINCOLN 2 POWER ARC 4000 12 95 Return to Section TOC Return to Master TOC Retum to Section TOC Return to Section TOC Return to Master TOC Return to Master TOC Return to Section TOC Return to Master TOC LINCOLN 5 18 TROUBLESHOOTING amp REPAIR NORMAL OPEN CIRCUIT WELD VOLTAGE WAVEFORM HIGH IDLE NO LOAD L LL __ 0 volts 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 Note Scope probes connected at machine output terminals SCOPE SETTINGS Volts Div 50V Div Horizontal Sweep 5 ms Div Coupling DC Internal POWER ARC 4000 19 TROUBLESHOOTING amp REPAIR NORMAL OPEN CIRCUIT VOLTAGE WAVEFORM 115 VAC SUPPLY HIGH IDLE NO LOAD 1 Period 16 2 ms 3700 rpm Return to Section TOC Return to Master TOC 0 volts 20 volts 5 ms Return to Section TOC Return to Master TOC This is the typi
4. H G g gt D 4 ac Retum to Master TOC Return to Master TOC Retum to Master TOC TABLE OF CONTENTS ACCESSORIES Accessories Section C Options ACCGSSOTIGS ciis cite e roe c E n C 1 Lincoln Electric ACCessOries 1 retire tta Dee E et i Manse eh re C 1 Briggs and Stratton 55 0 3 2 enne C 1 Semiautomatic Mig Welding with a Lincoln Weld Pak 100 or Weld Pak 125 C 1 Section C LINCOLN POWER ARC 4000 Return to Section TOC Return to Master TOC Return to Section TOC Return to Master TOC Ojo Fle G E 5 un 818 EJE D VU aic Return to Section TOC Return to Master 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 1 meters of 6 AWG electrode cable Fifteen feet 4 6 meters of 6 work cable Headshield with No 10 filter work clamp Insulated electrode holder and sample electrodes The cables are rated at 150 amps 4096 duty cycle Spark Arrester K883 1 A field installed kit for the 8 HP Briggs amp
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6. TRIDGE Remove the wing nut and cover Carefully remove the foam pre cleaner if equipped from the cartridge To service the pre cleaner 1 Wash in liquid detergent and water 2 Squeeze dry in a clean cloth 3 Saturate in clean engine oil 4 Squeeze in a clean absorbent cloth to remove all excess oil To service the cartridge 1 Tap gently on a clean surface 2 Replace if very dirty or wash in a non sudsing detergent and warm water solution 3 Rinse thoroughly from the mesh side with flowing water until the water is clear 4 Allow to stand and air dry before reinstalling Carefully place the pre cleaner back overthe cartridge and reinstall the air cleaner cover and wingnut CLEAN ENGINE Remove dirt and debris with a cloth or a brush Do not clean with a forceful spray of water Water might contaminate the fuel system CAUTION Periodically clean the muffler area to remove com bustible debris LINCOLN 5 Clean Rotating Screen See Figure 0 2 Clean the rotating screen on your machine s engine as often as needed to remove dirt or debris that may collect on the screen A dirty screen can result in engine over heating and damage FIGURE D 2 CLEAN ROTATING SCREEN FINGER GUARD DEBRIS GUARD 1 ROTATING SCREEN CLEAN COOLING SYSTEM See Figure D 3 Clean the internal cooling fins and surfaces to prevent over speeding overheating and engine damage Clean every 100 operating hours or as often
7. Return to Master TOC E 3 THEORY OF OPERATION FIGURE E 4 WELDING OUTPUT SHADE ENGINE MECHANICAL ROTATION RHEOSTAT WELD WINDING AND REACTOR The AC voltage developed in the stator weld winding is delivered through the reactor to the machine out put terminals The PowerArc 4000 provides the user with 125 amps of constant current AC welding for stick electrodes The reactor stores energy and this energy is released into the welding arc 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 with the recom mended electrodes BRIDGE REACTOR OUTPUT TERMINALS STATOR ROTOR 115 AND 230VAC RECEPTACLES AUXILIARY POWER OVERCURRENT PROTECTION The 4000 watt auxiliary power winding and circuitry is protected from an overload condition by two 20 amp circuit breakers The circuit breakers are located below the output receptacles They can be manually reset NOTE Unshaded areas of Block Logic Diagram are the subject of discussion POWER ARC 4000 LINCOLN 5 Section TABLE CONTENTS TROUBLE SHOOTING amp REPAIR SECTION g Troubleshooting amp Repair Section Section F 1 3 How to Use Troubleshooting Guide F 1 8 Troubleshooting Guide e e ei diet F1 F 9 Test Procedures Rotor Voltage Test ege nn Ni F 10 Rotor
8. Snap the capacitor back into the holder and then slide the unit back into position in the panel Check that the leads are not grounded and for clearance and tightness Replace the top cover of the control box and tighten the 4 sheet metal screws with the 5 16 nut driver POWER ARC 4000 29 TROUBLESHOOTING amp 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 elec trical shock please observe all safety notes and precautions detailed throughout this manu al Return to Section TOC Return to Master TOC If for any reason you do not understand the test procedures or are unable to perform the test repairs safely contact the Lincoln Electric Service Department for electrical trou bleshooting assistance before you proceed Call 216 383 2531 or 1 800 833 9353 WELD DESCRIPTION The following procedure will aid the technician in removing the stator and or rotor for main tenance or replacement of either component Return to Section TOC Return to Master TOC MATERIALS NEEDED Lincoln Electric Rotor Removal Kit 620925 FOR ROTOR REMOVAL ONLY 5 16 nut driver 1 2 socket wrench 6 socket extension Slot head screw driver 5 8 s
9. Test or replace Test the rheostat R1 Normal resistance is 3 3 ohms Seethe Rheostst Replacement drawing The rotor may be faulty Per form the Rotor Resistance Test CAUTION If for any reason you do not understand the test procedures or are unable to perform the test repairs safely tact the Lincoln Electric Service Department for electrical troubleshooting assistance before you proceed Call 216 383 2531 or 1 800 833 9353 LINCOLN amp POWER ARC 4000 Retum to Section TOC Return to Master Return to Section TOC Return to Section TOC Return to Master Return to Master Return to Section TOC Return to Master TOC TROUBLESHOOTING amp REPAIR TROUBLESHOOTING GUIDE PROBLEMS SYMPTOMS No weld output auxiliary power 230 115 VAC operates normally engine runs normally F 4 Observe Safety Guidelines detailed in the beginning of this manual POSSIBLE AREAS OF MISADJUSTMENT S OUTPUT PROBLEMS 1 Check the open circuit voltage OCV at the welder output ter minals is okay go to Step 2 below If OCV is not present at the welder output terminals contact your local Lincoln Electric Authorized Field Service Facility 2 Check the welding cables clamps and electrode holder for loose or broken connections RECOMMENDED COURSE OF ACTION 1 Check continuity zero ohms of lead W1A black from output terminal to reactor
10. amp REPAIR BRUSH REMOVAL AND REPLACEMENT WARNING Service and repair should be performed by only Lincoln Electric factory trained person nel Unauthorized repairs performed on this equipment may result in danger to the tech nician 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 If for any reason you do not understand the test procedures or are unable to perform the test repairs safely contact the Lincoln Electric Service Department for electrical trou bleshooting assistance before you proceed Call 216 383 2531 or 1 800 833 9353 olg WELD 918 s 918 DESCRIPTION EJE S E 5 The following procedure will aid the technician in accessing the generator brushes for ee maintenance or replacement MATERIALS NEEDED Small slot head screw driver 1 4 Nut driver Needle nose pliers oio Ojo amp 5 un 818 EJE D VU iac Return to Section TOC Return to Master TOC LINCOLN 5 POWER ARC 4000 Return to Section TOC Return to Master TOC Return to Section TOC Return to Section TOC Return to Master TOC Return to Master TOC Return to Section TOC Return to Master TOC LINCOLN 5 22 TROUBLESHOOTING amp REPAIR BRUSH REMOVAL AND REPLACEMENT cont
11. 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 automotive use A mini mum of 87 octane is recommended DO NOT MIX OIL WITH THE GASOLINE Use clean fresh lead free gasoline Leaded gasoline may be used if lead free is not available However lead free gasoline leaves fewer combustion deposits and gives longer valve life For engine protection from fuel deposits use Briggs amp Stratton Gasoline Additive part number 5041 Purchase gasoline in quantities that will be used within 30 days to assure freshness NOTE We DO NOT recommend using gasoline that contains alcohol such as gasohol However if gasoline with alcohol is used it MUST NOT contain more than 1096 Ethanol and MUST be removed from the engine during storage DO NOT use gasoline containing Methanol STARTING THE ENGINE NOTE Remove all loads connected to the AC power receptacles before starting the gasoline engine FOR A COLD ENGINE l Open the fuel shutoff valve on the bottom of the fuel tank 2 Place the choke lever in the lowest downward position 3 Pullslightly on the recoil starter handle until resistance is felt LINCOLN 5 Return to Section TOC Return to Master TOC Return to Section TOC Return to Section TOC Return to Master TOC Return to Master TOC Return to Section TOC Return to Master TO
12. E E amp i 5 un 818 EJE D VU iac Return to Section TOC Return to Master TOC F 27 TROUBLESHOOTING amp REPAIR CAPACITOR AND OR DIODE BRIDGE REMOVAL AND REPLACEMENT continued FIGURE F 8 DIODE BRIDGE LOCATION AND DISCHARGING THE FIELD CAPACITOR DIODE BRIDGE CAPACITOR PROCEDURE CAPACITOR REMOVAL AND REPLACEMENT 1 2 Remove the engine spark plug wire 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 Discharge the field capacitor by connect ing the jumper wire clips on the black and the red wire terminals on the top of the capacitor See Figure F 8 for location Leave the clips on for at least 5 seconds then remove Both the capacitor and the diode bridge are mounted in a molded plastic holder To remove it pull out on the top of the holder then slide it upward POWER ARC 4000 JUMPER Snap the capacitor out of the assembly Loosen the two screws on the top of the capacitor Lead 202A Red attaches to the positive terminal Leads 201 and 201A both Black attach to the negative terminal To replace the capacitor reattach the leads to their respective terminals 202A Red to positive 201 and 201A Black to negative and tighten the screws secure ly Snap the capacitor back into the mold ed plastic holder and slide the holder back into po
13. GENERA TOR maximum Check for loose or faulty plug at power receptacle Check the continuity Check the auxiliary power re ceptacles ands associated wires for loose or faulty connections zero ohms of leads 3 3A black 6 6A yellow and 5 white from the receptacles to the stator windings See the Wiring Dia gram Make sure lead 5 white is grounded to the machine frame zero ohms Check for an open or grounded auxiliary winding in the stator 6 yellow to 3 black See the Wiring Diagram CAUTION If for any reason you do not understand the test procedures or are unable to perform the test repairs safely tact the Lincoln Electric Service Department for electrical troubleshooting assistance before you proceed Call 216 383 2531 or 1 800 833 9353 POWER ARC 4000 LINCOLN B Retum to Section TOC Retum to Master TOC Return to Section TOC Return to Section TOC Return to Master TOC Retum to Master TOC Return to Section TOC Return to Master TOC F 6 TROUBLESHOOTING amp REPAIR TROUBLESHOOTING GUIDE PROBLEMS SYMPTOMS Low weld output and low auxiliary output Observe Safety Guidelines detailed in the beginning of this manual POSSIBLE AREAS OF MISADJUSTMENT S OUTPUT PROBLEMS 1 The generator brushes may be worn See the Maintenance sectionlof this manual or contact your local Lincoln Electric Authorized Field Service Faci
14. GROUND STUD 20 AMP CIRCUIT BREAKERS 2 20 AMP 240 VOLT RECEPTACLE 20 AMP 120 VOLT DUPLEX RECEPTACLE Ui BUNH GENERATOR WELDER CONTROLS See Figure B 1 for the location of the following fea tures 1 CURRENT CONTROL DIAL Adjusts continuous current output The amperages on the dial corre spond to the average amperages needed for spe cific Lincoln welder rods 2 ELECTRODE SELECTION GUIDE Provides rec ommended electrode type size and welder out put setting based on the thickness of the work POWER ARC 4000 POWER ARC 4000 WELD OUTPUT TERMINAL TO ELECTRODE HOLDER WITH 1 2 13 FLANGE NUT WELD OUTPUT TERMINAL TO ELECTRODE HOLDER WITH 1 2 13 FLANGE NUT Provides the connection point for either the electrode hold er or the work cable Because the POWER ARC 4000 is an AC output machine either output ter minal can be used for either cable WELD OUTPUT TERMINAL TO WORK WITH 1 2 13 FLANGE NUT Provides the connection point for either the electrode holder or the work cable Because the POWER ARC 4000 is an AC output machine either output terminal can be used for either cable LINCOLN 5 Return to Section TOC Return to Master TOC Return to Section TOC Return to Section TOC Return to Master TOC Return to Master TOC Return to Section TOC Return to Master TOC B 4 OPERATION GROUND STUD Provides a connection point for connecting the machine case to earth ground for the
15. HP Briggs amp Stratton gasoline engine controls include a recoil starter choke throttle control and piercing stop switch See ENGINE OPERATION in the OPERATION section ERATION sectionjof this manual for details about starting running stopping and breaking in the gaso line engine DESIGN FEATURES AND ADVANTAGES Stick welding SMAW process capability with out put range from 70 125 amps Single dial current output selection Work and Electrode welding cable mounting termi nals LINCOLN 5 Separate ground stud for safe connection of case to earth ground Single 20 amp 240 volt generator receptacle Duplex 20 amp 120 volt generator receptacle ntegrated generator output overload protection through two 20 amp circuit breakers Welded tube full roll cage frame protects engine and generator welder Lightweight portable design Rubber mounting isolates engine and generator from frame to prevent machine walking during use Lo Tone engine muffler for quieter operation A Super Lo Tone muffler is available from Briggs amp Stratton Easy starting Electronic Magnetron igni tion Optional Oil Gard low oil level engine shutdown available from Briggs amp Stratton WELDING CAPABILITY The POWER ARC 4000 is rated 125 amps 18 volts at 3096 duty cycle on a ten minute basis This means that you can load the welder to 125 amps for three minutes out of every ten min
16. L1 See the Wiring Diagram Check continuity zero ohms of lead W2 black from output ter minal to stator winding See the Wiring Diagram Check continuity zero ohms of lead W1 black from reactor L1 to stator winding See the Wiring Diagram Check reactor L1 for continuity of winding See the Wiring Dia gram Check the stator for continuity of winding See the Wiring Dia gram Make certain the reactor and or stator are NOT grounded Mini mum acceptable resistance to ground is 500 K ohms CAUTION for any reason you do not understand the test procedures or are unable to perform the test repairs safely con tact the Lincoln Electric Service Department for electrical troubleshooting assistance before you proceed Call 216 383 2531 or 1 800 833 9353 LINCOLN 5 POWER ARC 4000 5 TROUBLESHOOTING amp REPAIR Observe Safety Guidelines TROUBLESHOOTING GUIDE detailed in the beginning of this manual PROBLEMS SYMPTOMS POSSIBLE AREAS OF MISADJUSTMENT S RECOMMENDED COURSE OF ACTION Return to Section TOC Return to Master TOC Return to Section TOC Return to Section TOC Return to Master TOC Return to Master TOC Return to Section TOC Return to Master TOC No auxiliary power welding output is normal engine runs normally OUTPUT PROBLEMS 1 Check circuit breakers CB1 and CB2 Reset if tripped Make sure that the control rheo stat R1 is set at
17. Ojo E x 5 un gis EJE plc ic Return to Section TOC Return to Master TOC E 1 THEORY OF OPERATION FIGURE E 2 ENGINE ROTOR AND STATOR ENGINE MECHANICAL ROTATION CAPACITOR RHEOSTAT ENGINE EXCITATION ROTOR AND STATOR A small DC voltage developed by the flywheel alterna tor in the Briggs amp Stratton engine is fed to the rotat ing field coil in the rotor via a brush and slip ring con figuration This excitation flashing voltage magnetizes the rotor lamination The rotor is mechan ically coupled to the engine The rotating magnet induces a voltage in the stationary windings of the main alternator stator BRIDGE REACTOR OUTPUT TERMINALS STATOR ROTOR 115 AND 230VAC RECEPTACLES Three separate and isolated windings are incorporated in the stator lamination assembly Each winding set has a different number of turns producing different magnitudes of AC output voltages The three windings are the weld winding the auxiliary power winding and the field feedback winding The field feedback wind ing provides rotor current during machine operation The output of the PowerArc 4000 is dependent two criteria the engine RPM and the amount of current in the rotor winding NOTE Unshaded areas of Block Logic Diagram are the subject of discussion POWER ARC 4000 LINCOLN 5 Return to Section TOC Return to Master TOC Return to Section TOC Return
18. Resistance Egi Li ir e Eee F 12 Engine Throttle Adjustment Test F 15 Oscilloscope Waveforms Normal Open Circuit Weld Voltage Waveform F 18 Normal Open Circuit Weld Voltage Waveform 115 VAC F 19 T Typical Weld Output Waveform Machine Loaded F 20 2 Replacement Procedures 7 Brush Removal and 21 Rheostat Removal and Replacement F 23 gt Capacitor and Diode Bridge Removal F 25 9 Stator Rotor Removal Replacement Kit 5 20925 F 27 F ES LATE passe T F 32 or 9 1n gt 8 a 0 or 1n gt 8 a oc LINCOLN POWER ARC 4000 Return to Section TOC Return to Master TOC Return to Section TOC Return to Master TOC Q O 32 o E El Return to Section Return to Master TOC o FH g gt 2 c c a o d F 1 TROUBLESHOOTING amp REPAIR HOW TO USE TROUBLESHOOTING GUIDE WARNING Service and repair should be performed by only Lincoln Electric Factory Trained Personnel Unauthorized
19. Section TOC Ojo i 5 un gis EJE D VU iac Return to Section TOC Return to Master TOC Return to Master TOC B 11 OPERATION FIGURE B 3 WELDING CIRCUIT CONNECTIONS POWER SOURCE ELECTRODE CABLE ELECTRODE HOLDER ELECTRODE OUTPUT TERMINALS WORK WORK CLAMP WORK CABLE RUND THE WELDING CIRCUIT When everything is connected properly the current from the power source causes the electrode to melt and bond the metal being welded Figure B 3 shows the components of the basic welding circuit The cir cuit starts at the electrode cable connection and ends at the work cable connection Current flows from the POWER ARC 4000 through the electrode cable the electrode holder the electrode and across the arc On the work side of the arc current flows through the work to the work clamp the work cable and back to the machine The circuit must be complete for current to flow That means the work clamp must be tightly connected to clean base metal You should remove any paint or rust as necessary to get a good connec tion Also you need to connect the work clamp as close as possible to the area you want to weld Avoid letting the welding circuit pass through hinges bear ings electronic components or similar devices that can be damaged by high current POWER ARC 4000 THE ARC The electric arc is made between the work and the tip of the electrode
20. Stratton Cool Bore engine The spark arrestor attaches to the muffler to reduce the change of sparks being emitted from the muffler Rotor Removal Kit 520925 A service kit with thru and impact bolts for removing the generator rotor from the tapered engine crankshaft BRIGGS AND STRATTON ACCESSORIES The following options accessories are available for your POWER ARC 4000 from your local Briggs amp Stratton Distributor Foam Pre cleaner REF 271794 Provides a foam cleaner for replacement around the paper cartridge air cleaner Increases protection in extremely dusty or dirty environments Oil Low Oil Shutdown Kit REF 398182 Installs in the crankcase access port standard on all POWER ARC models Senses low oil conditions and automatically stops the engine The engine cannot be restarted until sufficient oil is added Super Lo Tone Muffler Square REF 494221 Replaces the round Lo Tone muffler that comes installed on the engine Limits exhaust noise but reduces maximum generator output by 200 300 watts Muffler Guard REF 494868 Installs onto the muf fler with a supplied bracket Protects against acci dental contact with a hot muffler Must not be used in tandem with both a deflector and a spark arrester POWER ARC 4000 SEMIAUTOMATIC MIG WELDING WITH A LINCOLN WELD PAK 100 OR WELD PAK 125 In addition to using the accessories options listed above the POWER ARC 4000 generator can supply powe
21. TOC Return to Section TOC Ojo E amp un 818 EJE plc UV iac Return to Section TOC Return to Master TOC Return to Master TOC A 1 INSTALLATION TECHNICAL SPECIFICATIONS POWER ARC 4000 INPUT GASOLINE ENGINE Manufacturer Description Speed Displacement Ignition Capacities Briggs amp 1 cyl 3700 RPM 19 4 cu in Manual Fuel 1 0 gal 3 8 Stratton Cool 4 cycle 50 RPM 319 cc Recoil Bore air cooled at no load start Manual Oil 1 4 qt 1 3 I gasoline choke 8HP 3750 RPM RATED OUTPUT WELDER Duty Cycle Volts at Rated Amperes 3096 Duty Cycle 18 VAC 6096 Duty Cycle 25 VAC OUTPUT WELDER AND GENERATOR Welding Ranges Welder Open Circuit Voltage AC Auxiliary Power 70 125 Amps 62 VAC Max 4000 Continuous Watts 4400 Surge Watts PHYSICAL DIMENSIONS LINCOLN 5 POWER ARC 4000 Return to Section TOC Return to Master TOC Return to Section TOC Return to Section TOC Return to Master TOC Return to Master TOC Return to Section TOC Return to Master TOC A 2 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 p
22. You make a gap for the arc in the welding circuit by holding the electrode tip 1 16 to 1 8 inch 1 6 to 3 2 mm away from the work You must establish the arc and hold it as you move the arc along the joint you re welding The arc melts both the elec trode and the base metal of the work as you move Figure B 4 shows what s happening in the welding arc The arc itself is the electric current flowing between the tip of the electrode and the work Its temperature is about 6000 F 3316 C The arc is very bright and cannot be looked at with the naked eye without risk of painful and perhaps permanent injury A very dark lens specifically designed for arc welding must be used with the handshield or headshield when ever viewing the arc The arc melts the base metal and actually digs into it The molten metal forms a pool or crater and tends to flow away from the arc As it moves away it cools and solidifies Slag forms on the top of the weld and pro tects it as it cools LINCOLN Return to Section TOC Return to Master TOC Return to Section TOC Return to Section TOC Return to Master TOC Return to Master TOC Return to Section TOC Return to Master OPERATION FIGURE B 4 THE WELDING N 43 ELECTRODE COATING SHIELDING GAS ARC BASE METAL WELD METAL SOLIDIFIED SLAG Obviously stick arc welding is manual skill requir ing a steady hand good physic
23. as necessary FIGURE D 3 CLEAN COOLING SYSTEM 1 REMOVE CHAFF AND DIRT FROM THESE AREAS POWER ARC 4000 Return to Section Return to Master TOC Return to Section TOC Return to Master TOC oio Ojo amp sx 5 un 818 EJE D VU iac Return to Section TOC Return to Master TOC D 3 MAINTENANCE CLEAN OR REPLACE SPARK PLUG Clean or replace the spark plug after every 100 hours of opera tion 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 FIGURE D 4 SET SPARK PLUG GAP 1 SPARK PLUG STANDARD PART NO 492167 RESISTOR PART NO 802592 2 FEELER GAUGE 030 INCH 76mm CLEAN SPARK ARRESTER SCREEN If the muffler has the optional spark arrester assembly remove it every 50 hours or once a year whichever comes first and inspect it Clean the arrester Replace it if you find any damage REMOVE COMBUSTION DEPOSITS After every 100 to 300 hours of operation remove the engine cylinder head Scrape and wire brush the combustion deposits from the cylinder cylinder head top of the piston and around the valves Refit the gasket replace it if damaged and reassemble the cylinde
24. drop the washers into the machine Lift up the control box and unscrew the 4 rubber mounts Setthe control box onto the stator frame for the moment Pull apart the molex coupling that connects the stator to the wiring harness With the slot head screw driver remove the 6 sheet metal screws that hold the control panel to the control box 3 on each side You may need to use the 5 16 end wrench on the engine side because of limited clear ance Pull the panel away from the control box With the 9 16 open end wrench remove lead W2 Black from the output terminal See Figure F 9 for location With the diago nal cutters cut the cable tie that holds the two output leads together Pull lead W2 back out of the way screw the bolt back 10 11 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 Remove the brush holder assembly 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 With the 1 4 nut driver remove the 2 screws that hold the brush holder assembly in place With the needle nose pliers gently remove the black and the red wires Set the brush holder aside Pull the wires up into the control box Pull apart the molex coupling for the engine flywheel alternator This is
25. duty cycle Length refers to the distance from the welder to the work and back to the welder Cable diameters are increased for long cable lengths to reduce voltage drops LINCOLN 5 POWER ARC 4000 4 CIRCUIT BREAKERS 2 20 AMP 5 RECEPTACLE 240 VOLT 20 AMP 6 DUPLEX RECEPTACLE 120 VOLT 20 AMP 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 meters 6 AWG 50 100 feet 15 39 meters 4 AWG 100 150 feet 30 46 meters 3 AWG 150 200 feet 46061 meters 2 AWG 200 250 feet 61 76 meters 1 AWG POWER ARC 4000 Return to Section TOC Return to Master TOC Return to Section TOC Return to Master TOC Q O 32 o 4 E Return to Section Return to Master TOC o FH g gt 2 c i a o d A 5 INSTALLATION Cable Installation Install the welding cables to your POWER ARC 4000 as follows See Figure A 1 for the location of parts l The gasoline engine must be OFF to install weld ing 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 You can connect either cable to either terminal since the POWER ARC 4000 provides AC weld current 4 Tighten the flanged nuts securely 5 Be cer
26. open flame weld before welding ing arc or when the engine is running Stop the engine and allow it to cool before refuel ing to prevent spilled fuel from vaporizing on contact with hot engine parts igniting Do not spill fuel when filling tank If fuel is spilled it up and do not start engine until fumes All welders should use the following procedures in order to have been eliminated minimize exposure to EMF fields from the welding circuit Exposure to EMF fields in welding may have other health effects which are now not known i 0 5 gt 4 5 1 9 Keep all equipment safety guards covers and devices in posi 2 d 1 Route the electrode and work cables together Secure tion and in good repair Keep hands hair clothing and tools them with tape when possible away from V belts gears fans and all other moving parts when starting operating or repairing equipment 2 4 2 Never coil the electrode lead around your body 2 4 3 Do not place your body between the electrode and 1 e In some cases it may be necessary to remove safety work cables If the electrode cable is on your right guards to perform required maintenance Remove side the work cable should also be on your right side guards only when necessary and replace them when the maintenance requiring their removal is complete d 4 Connect the work cable to the workpiece as close as Always use the gre
27. rays or to hot spatter or metal FUMES AND GASES can be dangerous 5 a Welding may produce fumes and gases hazardous to health Avoid breathing these fumes and gases When welding keep your head out of the fume Use enough ventilation and or exhaust at the arc to keep fumes and gases away from the breathing zone When welding with electrodes which require special ventilation such as stainless or hard facing see instructions on container or MSDS or on lead or cadmium plated steel and other metals or coatings which produce highly toxic fumes keep exposure as low as possible and below Threshold Limit Values TLV using local exhaust or mechanical ventilation In confined spaces or in some circumstances outdoors a respirator may be required Additional precautions are also required when welding on galvanized steel Do not weld in locations near chlorinated hydrocarbon vapors coming from degreasing cleaning or spraying operations The heat and rays of the arc can react with solvent vapors to form phosgene a highly toxic gas and other irritating products Shielding gases used for arc welding can displace air and cause injury or death Always use enough ventilation especially in confined areas to insure breathing air is safe Read and understand the manufacturer s instructions for this equipment and the consumables to be used including the material safety data sheet MSDS and follow your employer s safety practice
28. reason you do not understand the test procedures or are unable to perform the test repairs safely con tact the Lincoln Electric Service Department for electrical troubleshooting assistance before you proceed Call 216 383 2531 or 1 800 833 9353 LINCOLN 5 POWER ARC 4000 Return to Section Return to Master TOC Return to Section TOC Return to Section TOC Return to Master TOC Return to Master TOC Return to Section TOC Return to Master TOC F 3 TROUBLESHOOTING amp REPAIR Observe Safety Guidelines TROUBLESHOOTING GUIDE detailed in the beginning of this manual PROBLEMS POSSIBLE AREAS OF RECOMMENDED SYMPTOMS MISADJUSTMENT S COURSE OF ACTION OUTPUT PROBLEMS No weld output and no auxiliary 1 The generator brushes may be 1 Perform the Rotor Voltage Test output engine runs normally worn or faulty See the 2 If the rotor voltage is zero to 3 tenance section of this manual VDC check the flywheel alter or contact your local Lincoln d iated wi Electric Authorized Field Ser MAOT Lan 200 202 and 202 for conti VIGO SAME nuity The voltage from lead 200A to ground should be at least 18 to 21 VDC at high idle 3700 RPM Normal voltage is 46 VDC Ifthe voltage is low or missing the flywheel alternator may be faulty See the wiring diagram Check lead 201B green for continuity zero ohms to ground See wiring diagram The field capacitor C1 or bridge D1 may be faulty
29. sparks could present a fire hazard Standard mufflers and deflectors like the ones includ ed with the POWER ARC 4000 do not act as spark arresters When local laws require it a spark arrester must be installed on the machine and properly main tained An optional spark arrester kit is available for your POWER ARC 4000 See the ACCESSORIES section of this manual for more information CAUTION An incorrect spark arrester may lead to damage to the engine or reduce performance suitable spark arrester for the Briggs amp Stratton 8 HP Cool Bore engine is available as a Lincoln field installed option LINCOLN 5 Return to Section TOC Return to Master TOC Return to Section TOC Return to Section TOC Return to Master TOC Return to Master TOC Return to Section TOC Retum to Master TOC A 4 INSTALLATION FIGURE A 1 POWER ARC 4000 OUTPUT CONNECTIONS ELECTRODE SELECTION GUIDE 1 CURRENT CONTROL DIAL 2 WELD OUTPUT TERMINALS 2 3 GROUND STUD ELECTRICAL OUTPUT CONNECTIONS See Figure A 1 for the location of the current control dial 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 length becomes especially important when you are welding at a distance from the welder Table A 1 lists recommended cable sizes and lengths for rated current and
30. starter with the choke in the downward position more than one time Repeated pulls on a choked engine will flood the carburetor 2 Stop the engine by pressing downward on the piercing stop switch lever 3 Hold the lever down firmly until the engine com pletely stops Otherwise the engine may restart or sputter as it stops 4 Close the fuel shutoff valve at the bottom of the fuel tank LINCOLN amp FOR BEST ENGINE STOPPING Do not remove the rubber spark plug boot Be sure the piercing point on the piercing stop switch lever firmly contacts the spark plug Do not apply excessive force to or bend the pierc ing stop switch lever WARNING Close the fuel valve when the machine is transported to prevent fuel leakage from the carburetor Drain the tank before transporting the machine in a vehicle For long periods of storage turn off the fuel shutoff valve lowest downward position and let the engine run until there is no more fuel in the line Use a fuel additive such as Sta Bil to minimize fuel gum deposits RUNNING THE ENGINE The engine is set at the factory to run at high idle speed when not under load You should not adjust this setting yourself BREAK IN PERIOD Any engine will use a small amount of oil during its break in period For the gasoline engine on the POWER ARC 4000 break in is about 12 running hours Check the oil frequently during break in Change the oil after the first 5 hour
31. the single wire on the left side of the machine running from the engine to the stator Disconnect lead W1 Black that connects to the reactor lead Replace the nut split ring lock washer and flat washer finger tight on the bolt for reassembly Slide the control panel and box assembly out of the machine cradle Carefully pull the wire leads down through the box as you remove it Note that the reactor is loose inside the box and may slide around FIGURE F 9 OUTPUT LEAD LOCATION OUTPUT TERMINALS POWER ARC 4000 Return to Section TOC Return to Master TOC Return to Section TOC Return to Master TOC oio Ojo amp 5 un 818 EJE D VU iac Return to Section TOC Return to Master TOC F 31 12 13 14 TROUBLESHOOTING amp REPAIR STATOR ROTOR REMOVAL AND REPLACEMENT continued Slide a short length of 2 X 4 under the engine to support it when the stator is removed With the 1 2 socket wrench remove the 2 nuts that hold the stator end bracket support See Figure F 10 for location There are 2 split ring lock washers and 2 flat washers along with the nuts With the 7 16 socket and 7 16 end wrench remove the 4 thru bolts for the generator assembly See Figure F 10 Note the green grounding wire on the top right hand bolt It has a flat washer All 4 bolts have a split ring lock washer under the head and a shake proof star washer on the nut side The bo
32. to Section TOC Return to Master TOC Return to Master TOC Return to Section TOC Return to Master TOC E 2 THEORY OF OPERATION FIGURE E 3 FIELD EXCITATION AND AUXILIARY POWER ENGINE MECHANICAL ROTATION RHEOSTAT ROTOR FIELD FEEDBACK AND AUXILIARY POWER The AC voltage developed in the field winding is fed to the 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 to the rotor winding via the brush and slip ring configura tion As the feedback voltage is increased or de creased the outputs of the weld and auxiliary wind ings are likewise increased or decreased BRIDGE REACTOR OUTPUT TERMINALS STATOR ROTOR 115 AND 230VAC RECEPTACLES When full field voltage is applied to the rotor and the engine is running at high speed 3700 RPM a 230 VAC voltage is developed in the stator auxiliary wind ing This winding is tapped to provide 115 VAC The two voltages 115 and 230 connected to the appropriate receptacles and offer 4000 watts total of AC power NOTE Unshaded areas of Block Logic Diagram are the subject of discussion LINCOLN 5 POWER ARC 4000 Return to Section TOC Return to Master TOC Return to Section TOC Return to Master TOC Olio Ojo E o un 818 EJE D ic Return to Section TOC
33. ALLATION SECTION 5 Installation 8 5 Technical Specifications 5 inl nO d e A 1 Safety n en eed sae DR E PEE i Ee d shal e este A 2 Location and Ventilation scere ette tie deter RR i ho X iue Ee td o ae rt A 2 2 Stac kiN g need 3 ds 3 ee eerste re 3 Pre operation Engine Service sise 3 5 ne 3 0 3 gt 9 MUTE DEES HOM aa aad nea A 3 EE cete uini ria EE d A 3 Electrical Output Connections fines raesent c d ean A 4 Welding Cable Connections sn A 4 Cable Size and Length ste ect rn etienne A 4 Cable Installations cte tmt eee A 5 Machine Grounding p Fee cub A 5 Plugs and Hand Held Equipment is A 5 Auxiliary Power Receptacles sienne A 5 Premises Wiring uii Leer a A 6 Ic A 6 Q FH i 2 gt 2 a ac Return to Master TOC LINCOLN POWER ARC 4000 Return to Section Return to Master
34. C B 6 OPERATION 4 Pullthe cord rapidly 5 Ifthe engine does not start open the choke slight ly move lever upward and pull the starter cord rapidly again When the engine starts gradually open the choke to the highest upward position FOR A ENGINE l Open the fuel shutoff valve on the bottom of the fuel tank 2 Place the choke lever in the highest upward position Closing the choke of a hot engine will flood the carbu retor and prevent starting 3 Pull slightly on the recoil starter handle until resis tance is felt 4 Pullthe cord rapidly FOR BEST ENGINE STARTING Do not adjust air or fuel mixtures without following the procedures in the Briggs amp Stratton Operating and Maintenance Instructions manual Always use fresh gasoline and be sure the filter is clean and properly maintained f you use an alternate fuel tank or supply be sure to install an in line fuel filter If you don t feel resistance when you pull the recoil cord gently hit the starter housing and or pull the cord out to its fully extended position and wiggle it rapidly Repeat this if necessary until the clutch engages the shaft and you feel resistance when you pull the cord e If the engine will not start see the BLESHOOTING sectionlof this manual STOPPING THE ENGINE 1 Remove all welding and generator power loads and let the engine cool by running it for several minutes Do not pull the recoil
35. Master TOC Return to Master TOC Return to Section TOC Return to Master TOC F 9 TROUBLESHOOTING amp REPAIR Observe Safety Guidelines TROUBLESHOOTING GUIDE detailed in the beginning of this manual PROBLEMS POSSIBLE AREAS OF RECOMMENDED SYMPTOMS MISADJUSTMENT S COURSE OF ACTION WELDING PROBLEMS The welding arc is cold The 1 Check for loose or faulty con 1 Check for the correct open cir engine runs normally 3700 RPM nections at the weld output cuit voltage OCV at the welder no load Auxiliary power is func terminals and welding cable output terminals 62 VAC is tioning normally connections normal 2 The welding cable may be too If the correct voltage is present long or coiled causing an at the output terminals check excessive voltage drop for loose connections on the heavy current carrying leads inside the POWER ARC 4000 See the Wiring Diagram 2 If the OCV is low at the welder output _ terminals perform Engine Throttle Adjustment Check for shorted or grounded windings in the reactor L1 and also in the main stator See the Wiring Diagram CAUTION If for any reason you do not understand the test procedures or are unable to perform the test repairs safely tact the Lincoln Electric Service Department for electrical troubleshooting assistance before you proceed Call 216 383 2531 or 1 800 833 9353 LINCOLN amp POWER ARC 4000 Return to Section TOC Return t
36. OLDER ASSEMBLY COVER SCREWS 2 BRUSHES CABLE TIE OUBWN LINCOLN 5 POWER ARC 4000 LINCOLN 8 ROTOR BLOWER AND BEARING ASSEMBLY STATOR ASSEMBLY BRUSH AND BRUSH HOLDER ASSEMBLY CONTROL BOX WELDED ASSEMBLY REACTOR ASSEM BLY OUTPUT TERMINAL ASSEMBLY OUTPUT PANEL ASSEMBLY 1 CRADLE ASSEMBLY 2 3 4 5 6 7 8 MAINTENANCE FIGURE D 6 MAJOR COMPONENT LOCATIONS POWER ARC 4000 D 5 901 ISe W 0 uinjeu DO L18SeN 0 DOL 5 W 0 DOL 4 215 0 DOL uonoes o3 UNY DOL uon2es o3 UNY DOL uon2es o3 UNY DOL uonoes FH G g gt D 4 ac Retum to Master TOC Return to Master TOC Retum to Master TOC Section E TABLE OF CONTENTS THEORY OF OPERATION SECTION Theory of Operation Section E Power Supply Operation 1 0 0 0 ss E 1 E 3 Engine Excitation Rotor and Stator eee E 1 Rotor Field Feedback and Auxiliary Power E 2 Weld Winding arid Reactor issues Dea eb rte EL Ehe E E pa E 3 Auxiliary Power Overcurrent Protection ss E 4 REACTOR OUTPUT TERMINALS ENGINE MECHANICAL ROTATION 115 AND 230VAC RECEPTACLES RHEOSTAT PRIDGE FIGURE E 1 POWER ARC 4000 BLOCK LOGIC DIAGRAM LINCOLN POWER ARC 4000 Return to Section Return to Master TOC Return to Section TOC Return to Master TOC
37. ON GENERAL INFORMATION WARNING Le Do not touch electrically live parts or elec trodes with your skin or wet clothing Do not breathe welding fumes or gases 0 Use ventilation or exhaust to remove weld M ing fumes from the breathing area Keep flammable material away Wear eye ear and body protection The POWER ARC 4000 generator welder can deliver from 70 to 125 amps of continuous welding output current Output can be adjusted by setting the cur rent control dial on the output control panel You can get maximum welding output by setting the dial to 125 AMPS At high current settings like this some output may decrease as the machine is used If you are welding for a long time you may need to turn the dial slightly upward to maintain the same results The numbers on the dial correspond to the average amps needed to weld using specific Lincoln welding rods gives you the recommended dial settings based on the thick ness of the work and the size and type of rod you re using TO USE THE POWER ARC 4000 FOR WELDING 1 Remove the flange nuts from the weld output ter minals and place the work and electrode welding cables over the terminals See Replace and tighten the flange nuts securely Be sure the connections are tight 2 Select the appropriate electrode See Table B 4 or the ELECTRODE SELECTION GUIDE on the machine Output Control Panel POWER ARC 4000 3 Attach the work clamp securel
38. OR VOLTAGE TEST continued FIGURE F 1 LOCATION OF LEAD 200A FOR ROTOR VOLTAGE TEST LEAD 200A 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 Start the machine and run it at high idle Set the output control rheostat at the MAXIMUM or GENERATOR setting 3 Set the volt ohmmeter at the DC position POWER ARC 4000 Place the positive probe on lead 200A Blue and Brown wires joined together where it connects at the back of the rheo stat See Figure F 1 for location Place the negative probe on the machine ground stud or any other good unpainted ground Check the voltage GROUND STUD OUTPUT PANEL reading on the volt ohmmeter t should read 45 48 VDC If the voltage is low or not present the generator field circuit is not functioning correctly _ Proceed with the Resistance Test C1 R1 or D1 may also be faulty rotor voltage is correct the generator field is okay Replace the top cover on the control box Tighten the 4 sheet metal screws with the 5 16 nut driver LINCOLN 5 Return to Section TOC Return to Master TOC Return to Section TOC Return to Section TOC Return to Master TOC Return to Master TOC Return to Section TOC Return to Master TROUBLESHOOTING amp REPAIR ROTOR RESISTANCE TEST WARNING Service and repair should be performed by only Linc
39. OTECT YOURSELF AND OTHERS FROM POSSIBLE SERIOUS INJURY OR DEATH KEEP CHILDREN AWAY PACEMAKER WEARERS SHOULD CONSULT WITH THEIR DOCTOR BEFORE OPERAT ING Read and understand the following safety highlights For additional safety information it is strongly recommended that you purchase a copy of Safety in Welding amp Cutting ANSI Standard Z49 1 from the American Welding Society P O Box 351040 Miami Florida 33135 or CSA Standard W117 2 1974 A Free copy of Arc Welding Safety booklet E205 is available from the Lincoln Electric Company 22801 St Clair Avenue Cleveland Ohio 44117 1199 BE SURE THAT ALL INSTALLATION OPERATION MAINTENANCE AND REPAIR PROCEDURES ARE FOR ENGINE 1h To avoid scalding do not remove the radiator pressure cap when the engine is powered equipment hot 1 a Turn the engine off before troubleshooting and maintenance work unless the maintenance work requires it to be running 3 X Retum to Master TOC ELECTRIC AND 3 MAGNETIC FIELDS 1 b Operate engines in open well ventilated be dangerous areas or vent the engine exhaust fumes outdoors 2 a Electric current flowing through any conductor causes localized Electric and Magnetic Fields EMF Welding current creates EMF fields around welding cables and welding machines EMF fields may interfere with some pacemakers and welders having a pacemaker should consult their physician Do not add the fuel near an
40. PLUG STANDARD B amp S 492167 CHAMPION J 19LM SPARK PLUG RESISTOR B amp S 802592 CHAMPION RJ 19LM AS NEEDED FUEL FILTER B amp S 298090 for 25i I D hose AIR CLEANER CARTRIDGE 865 393957 CAN BE CLEANED AND REUSED AIR PRE CLEANER B amp S 271794 CAN BE CLEANED AND REUSED GENERATOR WELDER MAINTENANCE STORAGE Store the POWER ARC 4000 in clean dry protected areas CLEANING Blow out the generator and controls periodically with low pressure air Do this at least once a week in particularly dirty areas BRUSH REMOVAL AND REPLACEMENT See Figure D 5 It s normal for the brushes and slip rings to wear and darken slightly Inspect the brushes when a generator overhaul is necessary Remove the brushes and clean the slip rings with fine grit sandpaper To reinstall the brushes press them upward and slide a cable tie or wooden stick through the brush holder tabs Install the brush holder into the bearing end bracket and secure with the screws previously 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 or other debris from their surfaces and holes CABLE CONNECTIONS Check the welding cable connections at the weld output terminals often Be sure that the connections are always firm FIGURE D 5 BRUSH REMOVAL AND REPLACEMENT GENERATOR END BRACKET BRUSH H
41. R ROTOR RESISTANCE TEST continued FIGURE BRUSHES RETAINED WITH CABLE TIE 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 A cable tie works well see Figure F 3 This will hold the brushes up so that you can easily install the holder Slip the holder into position in the gener ator end bracket Be careful not to loosen the 2 attached wires Reinstall and tighten the 2 screws with the 1 4 nut driver Slowly remove the non metallic retainer from the brush holder and let the brush es snap back against the slip rings Snap the brush holder cover back into position F 14 POWER ARC 4000 15 TROUBLESHOOTING amp REPAIR ENGINE THROTTLE ADJ USTMENT 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 elec trical shock please observe all safety notes and precautions detailed throughout this manu al Return to Section TOC Return to Master TOC If for any reason you do not understand the test procedures or are unable to perform the test repairs safely contact the Lincoln Electric Service Department
42. 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 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 DO NOT INSTALL OPERATE OR REPAIR THIS EQUIPMENT WITHOUT READING THIS MANUAL AND THE SAFETY PRECAUTIONS CONTAINED THROUGHOUT And most importantly think before you act and be careful POWER ARC 4000 SVM 103 A December 1995 For use with machine code number 10083 SERVICE MANUAL World s Leader in Welding and Cutting Products ELECTRIC LINCOLN Premier Manufacturer of Industrial Motors Sales and Service through subsidiaries and Distributors Worldwide 22801 St Clair Ave Cleveland Ohio 44117 1199 U S A Tel 216 481 8100 SAFETY Q P 5 CALIFORNIA PROPOSITION 65 WARNINGS m aX Diesel engine exhaust and some of its constituents The engine exhaust from this product contains 8 are known to the State of California to cause can chemicals known to the State of California to cause cer birth defects and other reproductive harm cancer birth defects or other reproductive harm 9 The Above For Diesel Engines The Above For Gasoline Engines ARC WELDING CAN BE HAZARDOUS PR
43. al condition and good eyesight The quality of the weld depends on the skill of the welder to hold and control the weld ing arc THE ELECTRODE Besides diameter the main difference between elec trodes is their type of coating This coating helps make the arc steady shields the arc to keep oxygen and nitrogen in the air away from the molten metal and provide a flux that picks up impurities which could weaken the weld The best coating for the job depends on a number of factors The type of deposit you want such as mild steel stainless steel low alloy or hardfacing The thickness of the plate you want to weld The position you will be welding in vertical hori zontal downhand out of position The surface condition of the work Yourability to handle and obtain the desired elec trode LINCOLN THE FOUR FACTORS OF SUCCESSFUL WELDING 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 The four factors include The Correct Welding Position The Correct Way to Strike an Arc The Correct Arc Length The Correct Welding Speed The Correct Welding Position Figure B 5 shows the correct position for right handed people If you are left handed the correct position is opposite the one shown Whenever pos sible weld from left to right so that you can see clearly what you are doing Notice that t
44. arts lists ELECTRIC SHOCK can kill e Do not touch electrically live parts or electrodes with your skin or wet clothing Insulate yourself from the work and ground Always wear dry insulating gloves ENGINE EXHAUST can kill DA Do not stack anything on or near the engine Use in open well ventilated areas or vent exhaust to the outside MOVING PARTS can injure Do not operate this equip x ment with any of its doors open or guards off Stop the engine before 5 vicing it Keep away from moving parts Only qualified personnel should install use or service this equipment LINCOLN 5 LOCATION AND VENTILATION Whenever you use the POWER ARC 4000 be sure that clean cooling air can flow through the machine s gasoline engine and the generator Avoid dusty dirty areas Also keep the machine away from heat sources Do not place the back end of the generator anywhere near hot engine exhaust from another machine And of course make sure that engine exhaust is ventilated to an open outside area The POWER ARC 4000 may be used outdoors Do not set machine in puddles or otherwise submerge itin water Such practices pose safety hazards 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 This will protect you from the dangers of moving parts hot m
45. ary to perform maintenance and replace them when the mainte nance requiring their removal is complete If guards are missing from the machine get replace ments from a Lincoln Distributor See the EXPLOD ED VIEW AND PARTS LIST at the back of this man ual Read the Safety Precautions in the front of this manu al and in the Briggs amp Stratton Operating and Maintenance Instructions manual before working on the POWER ARC 4000 Keep all equipment safety guards covers and devices in position and in good repair Keep your hands hair clothing and tools away from the recoil housing fans and all other moving parts when start ing operating or repairing this machine ROUTINE AND PERIODIC MAINTENANCE ENGINE MAINTENANCE CAUTION To prevent the engine from accidentally starting dis connect the spark plug lead before servicing the engine See Table D 1 for a summary of maintenance intervals for the items listed below Follow either the hourly or the calendar intervals whichever come first More fre quent service may be required depending on your specific application and operating conditions engine maintenance replacement parts and numbers POWER ARC 4000 OIL Check the oil level after every En 5 hours of operation or daily BE SURE TO MAINTAIN THE OIL LEVEL Change the oil the first time after 5 hours of operation Then under normal operating conditions change the oil after every 50 ho
46. atest care when working near moving possible to the area being welded parts Do not work next to welding power source 1 f Do not put your hands near the engine fan Do not attempt to override the governor or idler by pushing on the throttle con trol rods while the engine is running LINCOLN 5 POWER ARC 4000 Return to Master TOC Q H G g gt 8 c D 4 ac Retum to Master TOC Return to Master TOC Retum to Master TOC SAFETY ELECTRIC SHOCK can kill 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 3 b Insulate yourself from work and ground using dry insulation Make certain the insulation is large enough to cover your full area of physical contact with work and ground In addition to the normal safety precautions if welding must be performed under electrically hazardous conditions in damp locations or while wearing wet clothing on metal structures such as floors gratings or scaffolds when in cramped positions such as sitting kneeling or lying if there is a high risk of unavoidable or accidental contact with the workpiece or ground use the following equipment Semiautomatic DC Constant Voltage Wire Welder DC Manual Stick Welder AC Welder with Reduced Voltage Control In semiautomatic or automatic wi
47. breakers for overload protection When the machine is O O operated in high temperature environments the breakers may tend to trip at lower loads than normal ly CAUTION Never bypass the circuit breakers Without overload protection the power arc 4000 could overheat and or cause damage to the equipment being used POWER ARC 4000 Return to Section TOC Return to Master TOC Return to Section TOC Return to Master TOC Q O 32 o E El Return to Section Return to Master TOC o o g gt 2 c a o d A 7 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 drills well pumps grinders small refrigerators weed and hedge trimmers Type Common Electrical Devices Possible Concerns Resistive Heaters toasters incandescent NONE light bulbs electric range hot pan skillet coffee maker Capacitive TV sets radios microwaves Voltage spikes or high voltage appliances with electrical control regulation can cause the capac itative elements to fail Surge protection transient protection and additional loading is recom mended for 100 fail safe operation DO NOT RUN THESE DEVICES WITHOUT ADDITIONAL RESISTIVE TYPE LOADS Inductive Single phase induction motors These devices require large current i
48. cal 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 Note Scope probes connected at machine 115 VAC receptacle oio Ojo E 5 un 818 EJE D VU ec SCOPE SETTINGS Volts Div 50V Div Horizontal Sweep 5 ms Div Coupling stress DC Trigger Internal Return to Section TOC Return to Master TOC LINCOLN 5 POWER ARC 4000 Return to Section TOC Return to Master TOC Return to Section TOC Return to Section TOC Return to Master TOC Return to Master TOC Return to Section TOC Return to Master TOC LINCOLN 5 20 TROUBLESHOOTING amp REPAIR TYPICAL WELD OUTPUT WAVEFORM MACHINE LOADED TI 20 volts 5 ms 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 The mahine was loaded with a resistance grid bank Note Scope probes connected at machine output terminals SCOPE SETTINGS Volts Div 20V Div Horizontal Sweep 5 ms Div Coupling DC Internal POWER ARC 4000 F 21 TROUBLESHOOTING
49. d with SAE 10W 30 oil CHECK THE OIL LEVEL BEFORE YOU START THE ENGINE This is an added precaution When full the oil level should be at the top of the fill plug hole Fit is not full add enough oil to fill it Be sure the fill plug is tight For more oil fill and service information see the MAIN TENANCE sectionlof this manual POWER ARC 4000 OIL WITH THE GASOLINE The POWER ARC 4000 has a plastic 1 00 gallon 3 8 fuel tank mounted on the engine See the OPERATION and MAINTENANCE sections of this manual for more details about fuel MUFFLER DEFLECTOR The POWER ARC 4000 is shipped with an exhaust deflector You can mount it yourself on the gasoline engine To install the deflector do the following Align the holes on the deflector plate with the holes on the muffler Position the deflector so that the opening points either right left or downward away from the opera tor CAUTION Never position the deflector upward Moisture or debris can enter the engine and damageit gen eral safety practice position the deflector to direct exhaust gases away from the operator s face and eyes Fasten the deflector onto the muffler with the screws provided NOTE The deflector reduces generator output power up to 100 watts SPARK ARRESTER Gasoline engine mufflers may emit sparks when the engine is running Some federal state or local laws require spark arresters in locations where unarrested
50. e spring loaded brushes into the holder and slip a suitable non metal lic fairly stiff retainer through the slots at the top and bottom of the holder A cable tie works well see Figure F 6 This will hold the brushes up so that you can eas ily install the holder With the needle nose pliers reinstall the red and the black wires to the appropriate terminals on the brushes The red wire is inboard Slip the holder into position in the genera tor end bracket Be careful not to loosen the 2 attached wires 11 12 13 14 Reinstall and tighten the 2 screws with the 1 4 nut driver Slowly remove the non metallic retainer from the brush holder and let the brushes snap back against the slip rings Check the wire connections or clearance and tightness Snap the brush holder cover back into position LINCOLN 5 Return to Section TOC Return to Master TOC Return to Section TOC Return to Section TOC Return to Master TOC Return to Master TOC Return to Section TOC Return to Master F 24 TROUBLESHOOTING amp 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 elec trical shock please observe all safety notes and precaution
51. ec un verre filtrant appro pri ainsi qu un verre blanc afin de se prot ger les yeux du rayonnement de l arc et des projections quand on soude ou quand on regarde l arc b Porter des v tements convenables afin de prot ger la peau de soudeur et des aides contre le rayon nementde l arc Prot ger l autre personnel travaillant proximit au soudage l aide d crans appropri s et non inflam mables Des gouttes de laiter en fusion sont mises de l arc de soudage Se prot ger avec es v tements de protection libres de l huile tels que les gants en cuir chemise paisse pantalons sans revers et chaussures montantes Toujours porter des lunettes de s curit dans la zone de soudage Utiliser des lunettes avec crans lateraux dans les zones o l on pique le laitier Eloigner les mat riaux inflammables ou les recouvrir afin de pr venir ttout risque d incendie d tincelles LINCOLN 5 10 PR CAUTIONS DE S RET POUR LES MACHINES SOUDER TRANSFOR MATEUR ET REDRESSEUR 1 Quand soude pas poser la pince une endroit isol de la masse Un court circuit accidental peut provoquer un chauffement et un risque d incendie S assurer que la masse est connect e le plus pr s possi ble de la zone de travail qu il est pratique de la faire Sion place la masse sur la charpente de la construction ou d autres endroits loign s de la zone de travail on aug mente le risque de v
52. eded 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 WARNING Only a licensed certified trained electrician should install the machine to a premises or residential electri cal system Be certain that The premises is isolated and no feedbacking into the utility system can occur Certain state and local laws require the premises to be isolated before the generator is linked to the premises Check your state and local requirements A double pole double throw transfer switch in con junction with the properly rated double throw circuit breaker is connected between the generator power and the utility meter The POWER ARC 4000 unlike other Lincoln Electric equipment does not have a combined 120 240 volt twist lock receptacle and cannot be connected to a premises as described in other Lincoln literature Remember that the POWER ARC 4000 is intended only for backup intermittent use The gasoline engine has a rated life of 500 hours It cannot withstand long term use without proper maintenance See thel MATRE TENANCE section of this manual for more informa tion Certain electrical devices cannot be powered by the POWER ARC 4000 Refer to Table A 2 for these devices LINCOLN 5 CIRCUIT BREAKERS The POWER ARC 4000 has its own a 20 amp circuit
53. ely to hold the end bracket for the next step Install the end bracket support POWER ARC 4000 33 TROUBLESHOOTING amp REPAIR STATOR ROTOR REMOVAL AND REPLACEMENT continued 6 Install the bottom two end bracket thru 10 Reinstall the brush holder assembly ne AND this section of Note The flat washer goes on the top right themanual hand thru bolt for the green ground wire Return to Section TOC Return to Master TOC 7 Tap the end bracket with the mallet as 11 Slide the control box back into place Pull oio Ojo amp 5 un 818 EJE D VU iac Return to Section TOC Return to Master TOC necessary to position it Tighten the bolts support the stator and ground wire up through to 22 25 ft lbs Alternate tightening in 12 Remove the control panel 2 screws and order to pull the assembly together even reconnect the output terminal leads W1 ly As you tighten look through the brush W2 Install a new cable tie to hold the housing access door and watch the bear leads together Reconnect the stator ing to judge end bracket movement and wire harness molex coupling Install the 6 alignment screws that hold the control panel to the 3 5 Check the rotor stator air gap with the doc long 010 feeler gauge The measurement 13 Connect the engine flywheel alternator 9 9 is taken through the brush holder access coupling see Fi
54. er TOC A 3 INSTALLATION STACKING FUEL POWER ARC 4000 machines CANNOT be stacked Fill the fuel tank with clean fresh regular TILTING grade lead free gasoline DO NOT MIX Place the machine on a secure level surface whenev er 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 gasoline engine is designed to run in a level posi tion for best performance It can operate at an angle but this should never be more than 15 degrees in any direction If you do operate it at a slight angle be sure to check the oil regularly and keep the oil level full Also fuel capacity will be a little less at an angle LIFTING The POWER ARC 4000 should be lifted by two peo ple It weighs 160 15 72 5 kg Its welded tube roll cage is designed to make lifting easy PRE OPERATION ENGINE SERVICE Read and understand the information about the gaso line engine in the OPERATION and MAINTENANCE sections of this manual before you operate the POWER ARC 4000 WARNING Keep hands away from the engine muffler or HOT engine parts Stop the engine when fueling Do not smoke when fueling Remove the fuel cap slowly to release pressure Do not overfill the fuel tank Wipe up spilled fuel and allow the fumes to clear before starting the engine Keep sparks and flame away from the fuel tank OIL The POWER ARC 4000 is shipped with the engine fille
55. es must use three blade grounded type plug or an Underwriters Laboratories UL approved double insulation system with a two blade plug Lincoln offers an accessory plug kit that has the right type of plugs See the ACCESSORIES sectionjof this manu al for details If you need ground fault protection for hand held equipment in line ground fault current interrupter GFCI cord sets that meet UL and OSHA require ments are available from Ericson Manufacturing Company Willoughby Ohio 44094 216 951 8000 Ohio 1 800 972 5109 outside Ohio AUXILIARY POWER RECEPTACLES The control panel of the POWER ARC 4000 features two auxiliary power receptacles A 20 amp 120 volt duplex double outlet recepta cle A 20 amp 240 volt simplex single outlet receptacle See Figure A 1 Through these receptacles the machine can supply up to 4 000 rated continuous watts and 4 400 surge watts of single phase AC power The machine output volt ages meet UL standards and fall within 1096 of the rated voltage The output frequency falls within 396 of rated frequency 60 Hz LINCOLN 5 Return to Section TOC Return to Master TOC Return to Section TOC Return to Section TOC Return to Master TOC Return to Master TOC Return to Section TOC Return to Master TOC INSTALLATION PREMISES WIRING The POWER ARC 4000 three wire grounded neutral generator allows it to be connected to premises wiring However the wiring procedure ne
56. etal surfaces and live electrical devices STORING l Store the machine in a cool dry place when it s not in use Protect it from dust and dirt Keep it where it can t be accidentally damaged from con struction activities moving vehicles and other hazards 2 Ifyou will be storing the machine for over 30 days you should drain the fuel to protect fuel system and carburetor parts from gum deposits Empty all fuel from the tank and run the engine until it stops from lack of fuel 3 You can store the machine for up to 24 months if you use Briggs amp Stratton Gasoline Additive Part No 5041 available from any Authorized Briggs amp Stratton Service Center in the fuel system Mix the additive with the fuel in the tank and run the engine for a short time to circulate the additive through the carburetor 4 While the engine is still warm drain the oil and refill with fresh 10W30 oil 5 Remove the spark plug and pour approximately 1 2 ounce 15 ml of engine oil into the cylinder Replace the spark plug and crank the engine slowly to distribute the oil 6 Clean any dirt and debris from the cylinder and cylinder head fins and housing rotating screen and muffler areas 7 Store in a clean dry area POWER ARC 4000 Return to Section Return to Master TOC Return to Section TOC Return to Master TOC Olio Ojo Fle E 5 un 818 EJE Bio VU aic Return to Section TOC Return to Mast
57. for electrical trou bleshooting assistance before you proceed Call 216 383 2531 or 1 800 833 9353 WELD Return to Section TOC Return to Master TOC TEST DESCRIPTION If the machine output is low this test will determine whether the gasoline engine high idle speed is set for the correct maximum RPM MATERIALS NEEDED 7 16 open end or box wrench Frequency counter or strobe tach Black or red marking pencil oio Ojo amp 5 un 818 EJE D VU iac Return to Section TOC Return to Master TOC LINCOLN 5 POWER ARC 4000 Return to Section TOC Return to Master TOC Return to Section TOC Return to Section TOC Return to Master TOC Return to Master TOC Return to Section TOC Return to Master TOC F 16 TROUBLESHOOTING amp REPAIR ENGINE THROTTLE USTMENT TEST continued FIGURE F 4 BLOWER PADDLE MARKED FOR STROBE TACH METHOD LINCOLN 5 TEST PROCEDURE This test can be conducted by any of three methods Strobe tach Method 1 Stop the engine and remove the spark plug wire to prevent accidental kickback or starting With the black or red marking pencil place a mark on one of the blower paddles which can be reached through the vent slots in the end bracket See Figure F 4 Connect the strobe tach according the manufacturer s instructions Reconnect the spark plug wire and start
58. gine Controls ss B 4 p Engine OBS rai vba ____6 6 ___ B 5 Before Starting the Engine alan Patines B 5 ES Starting the Engine tee AP LR ag B 5 E Stopping tlie 6 8 Running the B 6 ac Breakin Period 2 ete Ma than eines B 6 Generator Operation usines B 7 Welding Operation iia ere tert B 9 Welding 10 9 H 1n gt 8 a T or 1n gt 8 a oc LINCOLN POWER ARC 4000 Return to Section Return to Master TOC Return to Section TOC Return to Master TOC Ojo E un 818 EJE plc VU iac Return to Section TOC Return to Master TOC B 1 OPERATION OPERATING INSTRUCTIONS Read and understand this entire section before oper ating your POWER ARC 4000 SAFETY INSTRUCTIONS 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 Do not touch electrically live parts or electrodes with your ski
59. gure F12 Turn the engine me with the recoil starter rope slightly so that 14 Lift the control box and screw in the rub olo Re ber mountings Set the control box onto a j2 the rotor iron is up to take the measure the mountings ment The rotor has two flat sides which are not measured for air Slide in the 15 Install the front left hand washer and nut c gauge Then rotate the shaft 180 degrees that anchors the control box to the stator and measure again If the gauge does not frame Position the reactor and install the clear loosen the four end bracket thru remaining washers and nuts bolts reposition the end bracket retigh 16 Check all terminal connections for clear en the bolts and recheck the air gap ance ar ndina and Repeat until the proper 010 minimum air 9 9 9 gap is achieved 17 Replace the top cover to the control box 9 Tighten the end bracket support nuts and lock washers Remove the 2 X 4 engine 18 Conduct the procedure the following topic in this sec tion of the manual FIGURE F 12 CHECKING ROTOR STATOR AIR GAP POWER ARC 4000 STATOR LINCOLN amp Return to Section TOC Return to Master TOC Retum to Section TOC Return to Section TOC Return to Master TOC Return to Master TOC Return to Section TOC Return to Master TOC F 34 TROUBLESHOOTING amp REPAIR RETEST AFTER REPAIR Retest a machine fitis rejected
60. he electrode should be held at a slight angle 15 to 20 degrees from the perpendicular FIGURE B 5 CORRECT WELDING POSITION 15 20 90 side view end view THE CORRECT WAY TO STRIKE AN ARC First be sure that the work clamp is making a good connection to the work Lower your headshield and scratch the electrode slowly over the metal Sparks will fly While scratching lift the electrode 1 8 inch 3 2 mm and the arc will be established NOTE If you stop moving the electrode while scratching the electrode will stick to the work Most beginners try to strike the arc by a fast jabbing motion down onto the plate Result They either stick the electrode or their motion is so fast that they break the arc immediately 12 95 POWER ARC 4000 Return to Section Return to Master TOC Return to Section TOC Return to Master TOC AM un 9 5 4 ac Retum to Section TOC Return to Master TOC o FH g gt 2 c c a o d B 13 OPERATION 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 established the arc maintaining the cor rect 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 The easiest way to tell if the arc length is co
61. inate one possibility at a time until you locate the cause of your problem All of the referenced test procedures referred to in the Troubleshooting Guide are described in detail at the end of this chapter Refer to the Troubleshooting and Repair Table of Contents to locate each specific Test Procedure All of the referred to test points components terminal strips etc can be found on the referenced electrical wiring diagrams and schematics Refer to the Electrical Diagrams Section Table of Contents to locate the appropriate diagram CAUTION If for any reason you 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 Call 216 383 2531 or 1 800 833 9353 POWER ARC 4000 LINCOLN 5 Retum to Section TOC Return to Master Return to Section TOC Return to Section TOC Return to Master TOC Return to Master Return to Section TOC Return to Master TOC F 2 TROUBLESHOOTING amp REPAIR TROUBLESHOOTING GUIDE PROBLEMS SYMPTOMS Major physical or electrical damage is evident Observe Safety Guidelines detailed in the beginning of this manual POSSIBLE AREAS OF MISADJUSTMENT S OUTPUT PROBLEMS Contact the Lincoln Electric Service Department at 216 383 2531 or 1 800 833 9353 WELD RECOMMENDED COURSE OF ACTION CAUTION for any
62. inued FIGURE F 6 BRUSHES RETAINED WITH CABLE TIE PROCEDURE 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 fin gernail The cover will drop open on its bottom hinge 3 With the 1 4 nut driver remove the 2 screws that hold the brush holder assem bly 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 termi nal for the red wire To change the brushes use the slot head screw driver to pop off the plastic retainer on the back of the brush holder assembly Remove the old brush assemblies and insert the new ones One corner of the ter minal clip is beveled so that the brush can go in only one way Snap the plastic retainer back onto the brush holder The brushes may need some repositioning wiggle them slightly to help them seat properly on the slip rings POWER ARC 4000 Return to Section Return to Master TOC Return to Section TOC Return to Master TOC Ojo Fle E 5 un 818 EJE 2 D VU ec Return to Section TOC Return to Master TOC F 23 TROUBLESHOOTING amp REPAIR BRUSH REMOVAL AND REPLACEMENT continued PROCEDURE continued 8 10 POWER ARC 4000 To reinstall the brush holder assembly depress th
63. iping That Have Held Hazardous Substances AWS F4 1 from the American Welding Society see address above Vent hollow castings or containers before heating cutting or welding They may explode Sparks and spatter are thrown from the welding arc Wear oil free protective garments such as leather gloves heavy shirt cuffless trousers high shoes and a cap over your hair Wear ear plugs when welding out of position or in confined places Always wear safety glasses with side shields when in a welding area Connect the work cable to the work as close to the welding area as practical Work cables connected to the building framework or other locations away from the welding area increase the possibility of the welding current passing through lifting chains crane cables or other alternate circuits This can create fire hazards or overheat lifting chains or cables until they fail 6 h Also see item 1 c POWER ARC 4000 4 CYLINDER explode if damaged 7 a Use only compressed gas cylinders containing the correct shielding gas for the process used and properly operating regulators designed for the gas and pressure used All hoses fittings etc should be suitable for the application and maintained in good condition Always keep cylinders in an upright position securely chained to an undercarriage or fixed support Oylinders should be located Away from areas where they may be struck or subjected to ph
64. ke sure that the fuel shutoff valve is in the farthest upward position Make certain that the engine has adequate fuel and oil Adjust the choke to prevent car buretor flooding The recoil starter may not be engaged with the engine gen tly hit the blower housing and or pull the rope to its fully extend ed position and rapidly wiggle it Repeat until the clutch engages with the engine shaft and resis tance is felt 1 Check the fuel line for breaks or obstructions Replace the fuel filter DO NOT RUN THE EN GINE WITHOUT AN IN LINE FUEL FILTER The spark plug may be faulty Replace Service the engine as outlined in the Maintenance section of this manual The engine magneto may be faulty Consult Briggs amp Stratton owner s manual The engine may be faulty Replace CAUTION If for any reason you do not understand the test procedures or are unable to perform the test repairs safely tact the Lincoln Electric Service Department for electrical troubleshooting assistance before you proceed Call 216 383 2531 or 1 800 833 9353 POWER ARC 4000 LINCOLN B Retum to Section TOC Return to Master Return to Section TOC Return to Section TOC Return to Master Return to Master Return to Section TOC Return to Master TOC F 8 TROUBLESHOOTING amp REPAIR TROUBLESHOOTING GUIDE PROBLEMS SYMPTOMS Engine will not stop running Obse
65. lity 2 The engine RPM may be low RECOMMENDED COURSE OF ACTION Perform the Rotor Voltage Test If the rotor voltage is low the field capacitor C1 or bridge 01 may be faulty Test or replace Check the rheostat R1 Normal resistance is 3 3 ohm See the Rheostat Replacement drawing The rotor may be faulty Per form the Rotor Resistance Test The engine RPM may be low Perform the Engine Throttle Adjustment Test If engine idle RPM is okay the engine may have lost horsepow er and be in need of major repair CAUTION for any reason you do not understand the test procedures or are unable to perform the test repairs safely con tact the Lincoln Electric Service Department for electrical troubleshooting assistance before you proceed Call 216 383 2531 or 1 800 833 9353 LINCOLN 5 POWER ARC 4000 F 7 TROUBLESHOOTING amp REPAIR Observe Safety Guidelines TROUBLESHOOTING GUIDE detailed in the beginning of this manual PROBLEMS POSSIBLE AREAS OF RECOMMENDED SYMPTOMS MISADJUSTMENT S COURSE OF ACTION Return to Section TOC Return to Master TOC Return to Section TOC Return to Section TOC Return to Master TOC Return to Master TOC Return to Section TOC Return to Master TOC Engine will not start ENGINE PROBLEMS Make sure the piecing stop switch is NOT touching the spark plug boot Check spark plug boot and wire for loose or faulty connection Ma
66. lt The thru bolt has a star washer and lock washer beveled to con form to the rotor shaft Pull out the thru bolt Install the long thru bolt supplied with Lincoln Electric Rotor Removal Kit 520925 The slot head must face out Screw in the bolt with the slot head screw driver until the bolt bottoms out on the engine crankshaft about 3 4 Tuming it counterclockwise screw in the reverse thread bolt from the kit into the rotor shaft until it bottoms out on the thru bolt With an impact wrench tighten the reverse thread bolt until the rotor 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 crankshaft Slide the rotor and blower press fitted to the rotor the rest of the way off the crank shaft REASSEMBLY PROCEDURE 1 ubricate the tapered engine crankshaft Slide the rotor onto the shaft Coat rotor thru bolt threads with Lincoln E177 R retaining compound Locktite 277 Place the beveled lock washers onto the thru bolt and insert it into the rotor shaft Hold the rotor and tighten the thru bolt to 22 25 ft Ibs Carefully install the stator with the leads at the 1 o clock position IMPROPER HAN DLING OF THE STATOR CAN RESULT IN SHORTED WINDINGS AND OR LOST OUTPUT Install the end bracket Slide it on and install the two top thru bolts loos
67. lts must point toward the engine for reassembly 15 16 17 Lift up the stator and slide out the sup port bracket The engine will now rest on the 2 X 4 With the babbitt leather wooden mallet tap off the end bracket Alternate sides as you tap watch the bearing to judge the amount of movement you re getting Once the end bracket is off carefully pull off the stator IMPROPER HANDLING OF THE STATOR CAN RESULT IN SHORTED WINDINGS AND OR LOST OUTPUT FIGURE F 10 STATOR END BRACKET SUPPORT AND THRU BOLTS POWER ARC 4000 SUPPORT LINCOLN 5 Return to Section TOC Return to Master TOC Return to Section TOC Return to Section TOC Return to Master TOC Return to Master TOC Return to Section TOC Return to Master TOC LINCOLN 5 32 TROUBLESHOOTING amp REPAIR STATOR ROTOR REMOVAL AND REPLACEMENT continued FIGURE F 11 ROTOR WITH STATOR REMOVED ROTOR THRU BOLT ROTOR REMOVAL PROCEDURE 1 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 With an impact wrench remove the rotor thru bolt See Figure F 11 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 to loosen the thru bo
68. n or wet cloth ing Insulate yourself from the work and ground Always wear dry insulating gloves FUMES AND GASES can be 3 dangerous Keep your head out of fumes Use ventilation or exhaust to remove fumes from breathing zone uS WELDING SPARKS can cause Tex X fire or explosion Keep flammable material away Do not weld on containers that have held combustibles POWER ARC 4000 WARNING Z ARC RAYS can burn 122 Wear eye ear and body protection ENGINE EXHAUST can kill Use in open well ventilated areas or vent exhaust to the outside aD M Do not stack anything or near the engine a MOVING PARTS can injure 26 Do not operate this equipment with any of its doors open or guards off Stop the engine before servicing it Keep away from moving parts Only qualified personnel should install use or ser vice this equipment GENERAL DESCRIPTION The POWER ARC 4000 is a low cost generator welder designed for home use and other non com mercial applications As a generator it can supply up to 4 000 continuous watts or 4 400 surge watts of 120 240 volt single phase AC power As a welder it provides 125 amps of AC current for welding with AC stick electrodes single dial provides continuous adjustment of welding output The machine is light weight portable and can be lifted easily by two peo ple A Briggs amp Stratton 8 HP standa
69. ne by grounding the spark plug AIR CLEANER Filters intake air to the carbure tor SeelENGINE MAINTENANCE in the MAIN ENANCE section of this manual for details about the specific type of air cleaner to use THROTTLE Adjusts the running speed of the engine The engine runs at high idle when not under load Rotating the spring loaded throttle clockwise can temporarily reduce engine speed to low idle speed Releasing the throttle returns the speed to high idle POWER ARC 4000 Return to Section Return to Master TOC Return to Section TOC Return to Master TOC Q O un 9 5 4 ac Retum to Section TOC Return to Master TOC Q o FH g gt 2 c a ac B 5 OPERATION 7 AIR MIXTURE ADJ USTMENT 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 amp STRATTON 8 RECOIL STARTER Manual rope type starter The handle position allows easy starting from either ground level or pickup truck level 9 CHOKE Provides a richer air fuel mixture for cold engine starting con ditions See the topic ENGINE OPERATION below for details on setting the choke 10 FUEL MIXTURE ADJUSTMENT SCREW Adjusts the amount of fuel mixed wi
70. ng Isolate the rotor electrically by removing the generator brushes Refer to Figure F 2 as you perform the remaining steps Open the brush holder assembly cover Squeeze the 2 tabs and depress the cover at the top with a screw driver or your fin gernail The cover will drop open on its bottom hinge With the 1 4 nut driver remove the 2 screws that hold the brush holder assem bly in place Slide the brush holder assembly out and lay it aside held by the 2 wires attached 7 Measure the resistance across 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 slip rings It should read 7 8 ohms Measure the resistance to ground A Set the ohmmeter on the high scale X100 000 B Place one probe on either of the slip rings Place the other probe on any good unpainted ground Use the ground stud or the rotor thru bolt C Checkthe resistance It should read very high at least 5 megohm 500 000 ohms If the resistance checks meet the specifica tions then the rotor is okay LINCOLN 5 Return to Section TOC Return to Master TOC Return to Section TOC Return to Section TOC Return to Master TOC Return to Master TOC Return to Section TOC Return to Master TOC LINCOLN 5 10 11 12 13 TROUBLESHOOTING amp REPAI
71. nrush for starting See Table B 3 GENERATOR POWER APPLICATIONS in the OPERA TION section of this manual for required starting wattages Some synchronous motors may be frequency sensitive to attain maximum output torque but they SHOULD BE SAFE from any frequency induced failures Capacitive Inductive Computers high resolution TV sets complicated electrical equipment An inductive type line condition er along with transient and surge protection is required and liabilities still exist DO NOT USE THESE DEVICES WITH A POWER ARC 4000 The Lincoln Electric Company is not responsible for any damage to electrical components improperly connect ed to the POWER ARC 4000 POWER ARC 4000 Section TABLE CONTENTS Q 8 OPERATION SECTION 9 ence Section B 5 Safety Instr cHOTs i e reo nadie tpa cdi o eder bo rr e e na B 1 8 General Description cte A a 1 c Recommended Applications sise B 2 g Generator Welder Operational Features and Controls EENEN EEEE B 2 Design Features and Advantages ii B 2 Welding Capability cicer ort nen nin tente faces rese et tcd ds B 2 2 Controls and Settings 3 Generator Welder Controls i tette e tente eec D ere it be Pe eR e B 3 Gasoline En
72. o Master TOC Return to Section TOC Return to Section TOC Return to Master TOC Return to Master TOC Return to Section TOC Return to Master LINCOLN 5 TROUBLESHOOTING amp 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 elec trical shock please observe all safety notes and precautions detailed throughout this manu al If for any reason you do not understand the test procedures or are unable to perform the test repairs safely contact the Lincoln Electric Service Department for electrical trou bleshooting assistance before you proceed Call 216 383 2531 or 1 800 833 9353 WELD TEST DESCRIPTION This test will determine if the correct DC voltage is being applied to the rotor at maximum engine speed 3700 RPM This information will aid the technician in determining if the gen erator field is operating properly MATERIALS NEEDED Volt Ohmmeter 5 16 Nut driver Wiring Diagram F 10 POWER ARC 4000 Return to Section Return to Master TOC Return to Section TOC Return to Master TOC Ojo E 818 EJE D VU iac Return to Section TOC Return to Master TOC TROUBLESHOOTING amp REPAIR ROT
73. ocket wrench 7 16 socket wrench 7 16 open or box end wrench 3 4 socket or box end wrench 1 2 socket or box end wrench Needle nose pliers Diagonal cutters Torque wrench ft lbs Babbitt leather or wooden mallet Volt ohmmeter 12 long feeler gauge 010 oio Ojo Fle E 5 un 818 EJE D VU ec INSTRUCTIONS For stator removal only follow steps 1 17 under STATOR REMOVAL PROCEDURE For reassembly of stator go to REASSEMBLY PROCEDURE steps 3 18 For rotor removal follow the STATOR REMOVAL PROCEDURE ROTOR REMOVAL PRO CEDURE and REASSEMBLY PROCEDURE Return to Section TOC Return to Master TOC LINCOLN 5 POWER ARC 4000 Return to Section TOC Return to Master TOC Return to Section TOC Return to Section TOC Return to Master TOC Return to Master TOC Return to Section TOC Retum to Master TOC F 30 TROUBLESHOOTING amp REPAIR STATOR ROTOR REMOVAL AND REPLACEMENT continued STATOR REMOVAL PROCEDURE 1 LINCOLN 5 Remove engine spark plug wire to prevent accidental kickback or starting 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 Remove the 4 1 2 nuts and washers that anchor the control box to the stator frame Two of the nuts also anchor the reactor The reactor must be moved over to access the front left hand nut anchoring the control box Be careful not to
74. oir passer le courant de soudage par les chaines de levage c bles de grue ou atres circuits Cela peut provoquer des risques d incendie ou d echauffe ment des chaines et des c bles jusqu ce qu ils se rompent Assurer une ventilation suffisante dans la zone de soudage Ceci est particuli rement important pour le soudage de t les galvanis es plomb es ou cadmi es ou tout autre m tal qui produit des fum es toxiques Ne pas souder en pr sence de vapeurs de chlore provenant d op erations de d graissage nettoyage ou pistolage La chaleur ou les rayons de l arc peuvent r agir avec les vapeurs du solvant pour produire du phosg ne gas fortement roxique ou autres produits irritants Relier la terre le chassis du poste conformement au code de l lectricit et aux recommendations du fabricant Le dispositif de montage ou la piece souder doit tre branch une bonne mise la terre Autant que possible l installation et l entretien du poste seront effectu s par un lectricien qualifi Avant de faires des travaux l interieur de poste la debrancher l interrupteur la boite de fusibles Garder tous les couvercles et dispostifis de s ret leur place POWER ARC 4000 RETURN MAIN INDEX MASTER TABLE OF CONTENTS FOR ALL SECTIONS Page ise EM i iv Installation 233 cic Section A 5
75. oln 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 elec trical shock please observe all safety notes and precautions detailed throughout this manu al If for any reason you do not understand the test procedures or are unable to perform the test repairs safely contact the Lincoln Electric Service Department for electrical trou bleshooting assistance before you proceed Call 216 383 2531 or 1 800 833 9353 WELD TEST DESCRIPTION This test will determine if there is a shorted winding in the rotor or if the rotor is grounded MATERIALS NEEDED Volt Ohmmeter 1 4 Nut driver Small slot head screw driver Wiring Diagram LINCOLN POWER ARC 4000 Return to Section TOC Return to Master TOC Return to Section TOC Return to Master TOC oio Ojo amp 5 un 818 EJE D VU iac Return to Section TOC Return to Master TOC F 13 TROUBLESHOOTING amp REPAIR ROTOR RESISTANCE TEST continued FIGURE F 2 LOCATION OF ROTOR SLIP RINGS BRUSH HOLDER ASSEMBLY REMOVED TEST PROCEDURE 1 POWER ARC 4000 Conduct the test with the gasoline engine OFF Remove the spark plug wire to prevent accidental engine kickback or starti
76. ostat with your hand as you turn the nut There is a shake proof washer under the nut Pull the rheostat back out of the control panel and lay it out on its wires to loosen the nuts that hold them With the 5 16 open or box end wrench remove the brass nuts from the wire termi nals Support the terminals as you turn the wrench to avoid ripping the terminals from their foundations the wire locations for reassembly Note The brass screws are double nutted with a shake proof star washer under the screw head POWER ARC 4000 10 11 12 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 appropriate wires and tighten down the second nut Again support the terminals as you turn the wrench to avoid ripping the terminals from their foundations Reassemble the rheostat to the front of the control panel Line up the locating tab on the rheostat with the slot on the control panel hole Reassemble the shake proof star washer and nut and tighten securely with the 9 16 wrench Locate the flat spot on the shaft line up the knob locking screw push the knob onto the shaft and tighten the screw with the small slot head screw driver Check the rheostat knob for proper rota tion minimum to maximum Replace the top cover of the control box and tighten the 4 sheet metal scre
77. r 1 HP 1 000 2 500 4 000 Electric Range 1 element 1 500 Electric Skillet 1 250 Furnace Fan 1 3 HP 1 200 3 000 4 800 Portable Grinder 4 1 2 600 Portable Grinder 7 2 000 Halogen Work Light 500 Hand Drill 1 4 500 Hand Drill 3 8 700 1500 Watt Heater 1 750 Hedge Trimmer 450 Light Bulb 100 Reciprocating Saw 900 Radial Arm Saw 2 600 Radio 50 Refrigerator F reezer small 600 1 500 2 400 Slow Cooker 200 Submersible Pump 1 HP 1 000 2 500 4 000 Sump Pump 600 1 500 2 400 Toaster 1 100 Weed Trimmer 500 Lincoln 100 or 125 Amp Wire Feeder Welder 4 000 NOTES Wattages listed are approximate Check your equipment for actual wattage Equipment with unusually high START UP WATTS are listed For start up of other equipment listed in the table multiply RUNNING WATTS by 2 Multiple loads can be used as long as the total load does not exceed 4 000 watts Be sure to start the largest loads first For example a 1 HP motor needs approximately 1 000 watts while running but may require 2 500 watts to start Some inductive motors may require as much as 4 times running watts to start LINCOLN amp POWER ARC 4000 Return to Section Return to Master TOC Return to Section TOC Return to Master TOC Q O o un 9 d c 5 4 oc Retum to Section TOC Return to Master TOC o FH g gt a ec B 9 OPERATION WELDING OPERATI
78. r head and block Turn down the screws finger tight with the three long screws around the exhaust valve if so equipped Torque the screws in a staggered sequence to 165 inch pounds 19 N m TABLE D 1 ENGINE MAINTENANCE SCHEDULE Maintenance Operation Every 5 Hours or Daily 25 Hours or Yearly 50 Hours or Yearly 100 Hours or Yearly 100 300 Hours Check Oil Level e Change Oil Note 1 Clean Rotating Screen Finger e Guard or Debris Screen Note 2 Service Foam Pre Cleaner or or Oil Foam Element Note 2 Service Air Cleaner Cartridge if no pre cleaner Note 2 Service Air Cleaner Cartridge if pre cleaner present Note 2 Clean Cooling System 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 Note 1 Change oil every 25 hours when operating under heavy load in high ambient temperatures Note 2 Clean more often under dusty conditions or when airborne debris is present POWER ARC 4000 LINCOLN 5 Return to Section TOC Return to Master TOC Return to Section TOC Return to Section TOC Return to Master TOC Return to Master TOC Return to Section TOC Return to Master TOC D 4 MAINTENANCE TABLE D 2 ENGINE MAINTENANCE PARTS Part Part Number OIL FILTER NONE SPARK
79. r to a Lincoln ELectric Weld Pak 100 or Weld Pak 125 wire feed welder The Weld Pak comes with all the supplies needed for Flux Cored Arc Welding FCAW A K610 1 MIG Metal Inert Gas Conversion Kit is also available for the Weld Pak The kit provides every thing needed for Gas Metal Arc Welding GMAW or MIG processes Contact your local authorized Lincoln representative for details about the Weld P ak and MIG Conversion Kit LINCOLN 5 FH G g gt D 4 ac Retum to Master TOC Return to Master TOC Retum to Master TOC TABLE OF CONTENTS MAINTENANCE n Section D Routine and Periodic Maintenance sise D 1 Engine Mairntenahce io an Ba aie ead Bu D 1 Generator W elder Maintenance in D 4 Major Component Locations eco trn epe el to eda E D 5 Section D LINCOLN POWER ARC 4000 Return to Section Return to Master TOC Return to Section TOC Return to Master TOC Q O ded o Return to Section Return to Master TOC o o g gt c a ac D 1 MAINTENANCE SAFETY PRECAUTIONS A WARNING Have qualified personnel do all maintenance and troubleshooting work the engine off before working inside the machine Remove guards only when necess
80. rd Cool Bore air cooled gasoline engine powers the generator welder The engine has an approximate operating life of 500 hours LINCOLN 5 Return to Section TOC Return to Master TOC Return to Section TOC Return to Section TOC Return to Master TOC Return to Master TOC Return to Section TOC Return to Master TOC B 2 OPERATION The POWER ARC 4000 warranty covers the machine for one year from the date of purchase For non engine warranty claims contact your nearest Lincoln Authorized Field Service Facility For engine warranty claims contact your nearest Briggs amp Stratton service center NOTE The POWER ARC 4000 is not meant for rental or other commercial use RECOMMENDED APPLICATIONS GENERATOR The POWER ARC 4000 gives smooth AC generator output for medium use non commercial demands For more details on operating the generator see GEN ERATOR OPERATION in the OPERATION section of this manual WELDER The POWER ARC 4000 provides excellent constant current welding output for stick GMAW welding For more details on using the machine as a welder see tion of this manual OPERATIONAL FEATURES AND CONTROLS The POWER ARC 4000 was designed for simplicity Therefore it has very few operating controls A single dial on the control panel lets you select either genera tor or welding use For welding the same dial selects continuous current output over the machine s 70 to 125 amp range The 8
81. re welding the electrode electrode reel welding head nozzle or semiautomatic welding gun are also electrically hot Always be sure the work cable makes a good electrical connection with the metal being welded The connection should be as close as possible to the area being welded Ground the work or metal to be welded to a good electrical earth ground Maintain the electrode holder work clamp welding cable welding machine in good safe operating condition Replace damaged insulation Never dip the electrode in water for cooling Never simultaneously touch electrically hot parts of electrode holders connected to two welders because voltage between the two can be the total of the open circuit voltage of both welders When working above floor level use a safety belt to protect yourself from a fall should you get a shock Also see Items 6 c and 8 LINCOLN 5 Also see item 1 5 ARC RAYS can burn 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 Headshield and filter lens should conform to ANSI 787 standards 4 b Use suitable clothing made from durable flame resistant material to protect your skin and that of your helpers from the arc rays Protect other nearby personnel with suitable non flammable screening and or warn them not to watch the arc nor expose themselves to the arc
82. repairs performed on this equipment may result in danger to the technician and 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 This Troubleshooting Guide is provided to help you locate and repair possible machine mal functions Simply follow the three step proce dure listed below Step 1 LOCATE PROBLEM SYMPTOM Look under the column labeled PROBLEM SYMPTOMS This column describes possible symptoms that the machine may exhibit Find the listing that best describes the symptom that the machine is exhibiting Symptoms grouped into three main categories Welding Problems Engine Problems and Output Problems Step 2 PERFORM EXTERNAL TESTS The second column labeled POSSIBLE AREAS OF MISADJ 05 5 lists the obvious external possibilities that may contribute to the machine symptom Perform these tests checks in the order listed In general these tests can be con ducted without removing the case wrap around cover Step 3 PERFORM COMPONENT TESTS The last column labeled Recommended Course of Action lists the most likely components that may have failed in your machine It also specifies the appropriate test procedure to verify that the subject component is either good or bad there are a number of possible components check the components in the order listed to elim
83. rrect is to listen to it A nice short arc has a distinctive crack ling sound like eggs frying in a pan A long incor rect arc has a hollow blowing or hissing sound THE CORRECT WELDING SPEED To know whether your welding speed is correct you must watch the puddle of molten metal behind the arc DO NOT WATCH THE ARC ITSELF The appearance of the puddle and the ridge where it solidifies tells the tale The ridge should be approximately 3 8 inch 9 5 mm behind the electrode See Figure B 6 POWER ARC 4000 FIGURE B 6 MOLTEN METAL PUDDLE AND CORRECT WELD SPEED ELECTRODE ARC RIDGE OF MOLTEN METAL WELD PUDDLE Most beginners tend to weld too fast which gives a thin uneven wormy looking bead They are not watching the molten metal puddle NOTE When welding on thin plate you will find that you have to increase welding speed On heavy plate you will have to go more slowly to ensure fusion and penetration The key to developing welding skill is PRACTICE No one can learn to weld just by reading about it If you are an inexperienced welder the information here will help you understand some basic welding principles you should know before you use your POWER ARC 4000 for stick welding For more detailed information order a copy of the book New Lessons in Arc Welding available from the Book Division of Lincoln Electric See the form located at the back of this manual for ordering information LINCOLN 5
84. rve Safety Guidelines detailed in the beginning of this manual POSSIBLE AREAS OF MISADJUSTMENT S ENGINE PROBLEMS 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 RECOMMENDED COURSE OF ACTION Be sure the piercing stop switch is securely mounted to the engine Engine runs erratically or stops run ning Check the spark plug boot and wire for loose or faulty connec tion The spark plug may be faulty Replace The fuel and air mixture may be out of adjustment Consult Briggs amp Stratton owner s man ual The fuel supply may be con taminated with water The engine may require service to the head or carburetor Engine sputters but will not start The spark plug may be faulty The fuel supply may be contam inated with water The air filter may be clogged Replace The fuel and air mixture may be out of adjustment Consult Briggs amp Stratton owner s manual CAUTION for any reason you do not understand the test procedures or are unable to perform the test repairs safely con tact the Lincoln Electric Service Department for electrical troubleshooting assistance before you proceed Call 216 383 2531 or 1 800 833 9353 LINCOLN 5 POWER ARC 4000 Return to Section TOC Return to Master TOC Return to Section TOC Return to Section TOC Return to
85. s MSDS forms are available from your welding distributor or from the manufacturer Mar 95 POWER ARC 4000 FH gt 8 D 4 ac Return to Master TOC Retum to Master TOC Retum to Master TOC SAFETY 7 WELDING SPARKS lt gt 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 Where compressed gases are to be used at the job site special precautions should be used to prevent hazardous situations Refer to Safety in Welding and Cutting ANSI Standard Z49 1 and the operating information for the equipment being used When not welding make certain no part of the electrode circuit is touching the work or ground Accidental contact can cause overheating and create a fire hazard Do not heat cut or weld tanks drums or containers until the proper steps have been taken to insure that such procedures will not cause flammable or toxic vapors from substances inside They can cause an explosion even though they have been cleaned For information purchase Recommended Safe Practices for the Preparation for Welding and Cutting of Containers and P
86. s ce manuel aussi bien que les pr cautions de s ret g n rales suivantes S ret Pour Soudage A L Arc 1 Protegez vous contre la secousse lectrique a Lescircuits l lectrode et la pi ce sont sous ten sion quand la machine souder est en marche Eviter toujours tout contact entre les parties sous tension et la peau nue ou les v tements mouill s Porter des gants secs et sans trous pour isoler les mains b Faire tr s attention de bien s isoler de la masse quand on soude dans des endroits humides ou sur un plancher metallique ou des grilles metalliques princi palement dans les positions assis ou couch pour lesquelles une grande partie du corps peut tre en contact avec la masse c Maintenir le porte lectrode la pince de masse le c ble de soudage et la machine souder en bon et s r tat defonctionnement d Ne jamais plonger le porte lectrode dans l eau pour le refroidir e Ne jamais toucher simultan ment les parties sous tension des porte lectrodes connect s deux machines souder parce que la tension entre les deux pinces peut tre le total de la tension vide des deux machines Dans le cas de travail au dessus du niveau du sol se pro t ger contre les chutes dans le cas ou on recoit un choc Ne jamais enroule le c ble lectrode autour de n importe quelle partie du corps Un coup d arc peut tre plus s v re qu un coup de soliel donc a Utiliser un bon masque av
87. s detailed throughout this manu al If for any reason you do not understand the test procedures or are unable to perform the test repairs safely contact the Lincoln Electric Service Department for electrical trou bleshooting assistance before you proceed Call 216 383 2531 or 1 800 833 9353 WELD DESCRIPTION The following procedure will aid the technician in accessing and removing the output control rheostat for maintenance or replacement MATERIALS NEEDED 5 16 Nut driver Small slot head screw driver 9 16 Open or box end wrench 5 16 Open or box end wrench Needle nose pliers Wiring Diagram LINCOLN POWER ARC 4000 Return to Section TOC Return to Master TOC Return to Section TOC Return to Master TOC oio Ojo Fle E 5 un 818 EJE D VU ec Return to Section TOC Return to Master TOC F 25 TROUBLESHOOTING amp REPAIR RHEOSTAT REMOVAL AND REPLACEMENT FIGURE F 7 RHEOSTAT REMOVAL See Figure F 7 for steps 3 9 PROCEDURE 1 2 Remove the spark plug wire 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 With the small slot head screw driver loosen the screw that holds the knob to the rheostat shaft The shaft has a flat for locating the knob at reassembly With a 9 16 open or box end wrench remove the nut that holds the rheostat to the control panel Support the rhe
88. s of operation For more details see the MAINTENANCE sectionjof this manu al CAUTION During break in subject the POWER ARC 4000 to only moderate loads Avoid long periods running at idle Before stopping the engine remove all loads and allow the engine to cool several minutes POWER ARC 4000 Return to Section TOC Return to Master TOC Return to Section TOC Return to Master TOC AM un 9 5 4 ac Retum to Section TOC Return to Master TOC o FH gt 2 c c a o d OPERATION GENERATOR OPERATION A CAUTION Be sure that any electrical equipment plugged into the generators AC power receptacles can withstand 10 voltage and a 3 frequency variation Some electronic devices cannot be powered by the POWER ARC 4000 Refer to ELECTRICAL DEVICE USE WITH THE POWER ARC 4000 in the INSTALLA TION section of this manual GENERAL INFORMATION The POWER ARC 4000 generator is rated at 4000 continuous watts 4400 surge watts It provides both 120 volt and 240 volt power You can draw up to 20 amps from either side of the 120 volt duplex recepta cle but no more than 37 amps from both sides at once Up to 18 amps can be drawn from the single 240 volt receptacle Electrical loads in watts are calculated by multiplying the voltage rating of the load by the number of amps it POWER ARC 4000 draws This information is given on the load de
89. safest grounding procedure 20 AMP CIRCUIT BREAKERS 2 Provide sepa rate overload current protection for the 120 volt and 240 volt receptacles 7 8 20 AMP 240 VOLT RECEPTACLE Connection point for supplying 240 volt power to operate one electrical device 20 AMP 120 VOLT DUPLEX RECEPTACLE Connection point for supplying 120 volt power to operate one or two electrical devices FIGURE B 2 GASOLINE ENGINE CONTROLS FUEL SHUTOFF VALVE FUEL TANK AND CAP MUFFLER PIERCING STOP SWITCH AIR CLEANER THROTTLE H GASOLINE ENGINE CONTROLS See Figure B 2 for the location of the following fea tures 1 FUEL SHUTOFF VALVE Stops the flow of gaso line from the fuel tank to the carburetor Should be closed whenever you are finished using the POWER ARC 4000 Must be opened before you start the engine FUEL TANK AND CAP Holds 1 0 gallon 3 8 liters of unleaded gasoline Contains a 50 micron fuel filter molded at the outlet port NOTE If you use any other alternate fuel tank or supply be sure to use a recommended in line fuel filter LINCOLN 5 oo 10 11 12 Z E LL gt AIR MIXTURE ADJUSTMENT SCREW RECOIL STARTER CHOKE FUEL MIXTURE ADJ USTMENT SCREW OIL DRAIN PLUG OIL FILL PLUG MUFFLER Reduces engine noise output Does not serve as a spark arrester See SPARK ARRESTER in the INSTALLATION section of this manual PIERCING STOP SWITCH Stops the engi
90. sition in the panel Replace the top cover of the control box and tighten down the 4 sheet metal screws with the 5 16 nut driver LINCOLN 5 Return to Section TOC Return to Master TOC Return to Section TOC Return to Section TOC Return to Master TOC Return to Master TOC Return to Section TOC Return to Master TOC F 28 TROUBLESHOOTING amp 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 Depress the retainer clip on the molded plastic holder and slide the diode bridge out With the needle nose pliers gently remove the 4 wires from the diode bridge Replace the wires to their appropriate loca tions on the new diode bridge Lead 200 Red attaches to the positive terminal Depending on the bridge used this corner may be beveled and or marked with a sign LINCOLN 5 Lead 201 Black and 2018 Green pig gybacked on the negative terminal which will always be located diagonally across from the positive terminal The 2 Blue leads are the AC side of the bridge and attach to the other two corners Either lead can go on either terminal 5 Slide the bridge back into the molded plas tic holder until the retainer clip snaps it securely in place
91. ss WEARSHIELD 1 8 100 amps NOTES The values listed are suggested settings Actual setting may vary depending on individual preference and or spe cific application Beginners should use STABLE ARC E7018 For electrodes not listed follow tables that are packed with the electrodes Ask for the Lincoln WELD DIRECTORY Publication M210 for a complete listing of all Lincoln stick electrodes available AWS American Welding Society NOTE The serviceability of a product or structure utilizing this type of information is and must be the sole responsibility of the builder user Many variables beyond the control of The Lincoln Electric Company affect the results obtained in applying this type of informa tion These variables include but are not limited to welding procedure plate chem istry and temperature weldment design fabrication methods and service require ments LINCOLN 5 STICK WELDING Stick welding is probably the most familiar welding process known coated ELECTRODE the welding rod is clamped into an ELECTRODE HOLDER an insulated clamping device which is connected to the ELECTRODE CABLE a heavy wire The WORK the piece of metal to be welded is connected to the WORK CABLE a heavy wire with a WORK CLAMP on one end The two cables connect to OUTPUT TERMINALS on the welder which is a high current power source See Figure B 3 POWER ARC 4000 Return to Section TOC Return to Master TOC Return to
92. tain that the metal piece you are welding the work is securely connected to the work clamp and cable 6 Check and tighten the connections periodically CAUTION Loose connections will cause the output terminals to overheat The terminals may eventually melt Do not cross the welding cables at the output termi nal connection Keep the cables isolated and sepa rate from one another Lincoln Electric offers a welding accessory kit with the properly specified welding cables See the SORIES section of this manual for more information MACHINE GROUNDING Because the POWER ARC 4000 creates its own power from its gasoline engine driven generator you do not need to connect the machine frame to an earth ground However for best protection against electri cal shock connect a heavy gauge wire from the ground stud located on the bottom center of the output panel see Figure 1 a suitable earth ground such as a metal pipe driven into the ground POWER ARC 4000 WARNING Do not ground the machine to a pipe that carries explosive or combustible material When the POWER ARC 4000 is mounted truck or a trailer the machine erator ground stud MUST be securely connected to the metal frame of the vehi cle See The ground stud is marked with the symbol PLUGS AND HAND HELD EQUIPMENT For further protection against electric shock any elec trical equipment connected to the generator recepta cl
93. th air 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 FUEL MIXTURE SCREW WITHOUT FOLLOW ING THE PROCEDURES OUTLINED BY BRIG GS amp STRATTON 11 OIL DRAIN PLUG Permits convenient draining of engine oil during maintenance Both sides of the engine are equipped with an oil drain plug 12 OIL FILL PLUG Permits convenient filing of engine oil during maintenance Both sides of the engine are equipped with an oil fill plug ENGINE OPERATION WARNING DO NOT RUN THE ENGINE AT EXCESSIVE SPEEDS The maximum allowable high idle speed for the POWER ARC 4000 is 3750 RPM no load Do NOT adjust the governor screw on the engine Severe per sonal injury and damage to the machine can result if it is operated at speeds above the maximum rated speed Read and understand all safety instructions included in the Briggs amp Stratton Operating and Maintenance Instructions manual that is shipped with the POWER ARC 4000 POWER ARC 4000 BEFORE STARTING THE ENGINE CHECK AND FILL THE ENGINE OIL LEVEL dA 1 Place the machine on a level surface 2 Open the oil fill plug 3 Fill if necessary until oil flows out the top of the fill plug hole 4 Replace the fill plug and tighten securely CHECK AND FILL THE ENGINE FUEL TANK 1 Remove the fuel tank cap 2 Fillthetank to allow approximately 1 4 inch 5 mm of tank space for fuel
94. the engine Direct the strobe tach light on the blower paddle and synchronize itto the rotating mark The tach should read 3700 RPM Use the 7 16 wrench to turn in the spring loaded adjustment nut Increase the high idle speed until the tach reads 3700 RPM See Figure Es for location of the adjust ment nut Frequency Counter Method 1 Plug the frequency counter into one of the 115 VAC auxiliary receptacles Start the engine and check the frequency counter At the proper RPM 3700 the counter should read 61 7 Hz Use the 7 16 wrench to turn in the spring loaded adjustment nut Increase the high idle speed until the frequency counter reads 61 7 Hz See Figure F 5 for location of the adjustment nut Oscilloscope Method 1 Connect the oscilloscope according to the manufacturer s instructions At 3700 RPM the waveform should exhibit a period of 16 2 milliseconds Refer to the NORMAL OPEN CIRCUIT VOLTAGE WAVEFORM 115 SUPPLY HIGH IDLE NO LOAD in this section of the manual 12 95 POWER ARC 4000 17 TROUBLESHOOTING amp REPAIR ENGINE THROTTLE ADJ USTMENT 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 Section TOC Return to Master TOC FIGURE F 5 LOCATION OF ENGINE THROTTLE ADJUSTMENT NUT
95. 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 ENGINE OUTPUT No Load RPM Load RPM Maximum Speed 3725 3650 Minimum Speed 3675 3400 WELDER GENERATOR OUTPUT Output Control Field Volts Field Amps Open Circuit Load Volts Load Amps Volts Maximum 43 49 4 8 5 8 60 63 12 25 120 125 Minimum 55 60 14 27 75 85 AUXILIARY POWER RECEPTACLE OUTPUT Output Open Circuit Load Volts Load Amps Load Volts Load Amps Control Volts Volts 255 267 215 230 18 20 127 133 112 120 18 20 1Current Control Dial set at MAXIMUM or GENERATOR Output values of each receptacle can vary within the range shown LINCOLN 9 12 95 POWER ARC 4000 LINCOLN 8 lt tc cc 9 o LL 901 ISe W 9014 5 0 DOL JaISeW 0 DO LJ81SeN 0 301 uonoes oj 301 uonoes oj 301 U0N2S oj UNY DOL uon2es unge Section G TABLE OF CONTENTS ELECTRICAL DIAGRAMS Electrical Diagrams cmt nete ite cede d cee PR a Rn grad Section G PowerAIc 40005 steer id G 1 g F i 8 Return to Master Return to Master TOC Return to Master TOC LINCOLN amp POWER ARC 4000
96. urs or once a year whichever occurs first If the engine is operat ed under heavy load or in high ambient temperatures change the oil every 25 hours Drain the oil from the drain plug located on either side of the engine bottom as shown in Figure D 1 Refill through the oil fill plug until the oil reaches the top of the fill hole Use SAE 10W 30 grade oil FIGURE D 1 OIL DRAIN AND REFILL LOCATION 1 OIL DRAIN PLUG 2 OIL FILL PLUG 3 OIL LEVEL FUEL Atthe end of each day s use refill the fuel tank to minimize moisture conden sation and dirt contamination in the fuel line LINCOLN 5 Return to Section Return to Master TOC Retum to Section TOC Return to Section TOC Return to Master TOC Retum to Master TOC Return to Section TOC Return to Master TOC D 2 MAINTENANCE AIR CLEANER Your air cleaner may have only the paper cartridge or it may have the cartridge and a foam pre clean er If it has the pre cleaner service the cartridge every 100 hours and the pre cleaner every 25 hours or once a year whichever comes first If the air cleaner doesn t have the pre cleaner service the cartridge every 25 hours or once a year whichever comes first Under dusty conditions service more often CAUTION Do not use petroleum solvents such as kerosene to clean the cartridge They may cause deterioration of the cartridge DO NOT OIL THE CARTRIDGE OR USE PRESSURIZED AIR TO CLEAN OR DRY THE CAR
97. ute period The machine is capable of higher duty cycles at lower output cur rents For example you can load the welder to 100 amps for six minutes out of ten for a 60 duty cycle The current is continuously variable from 70 to 125 amps AC The POWER ARC 4000 can therefore weld with all 3 32 and most 1 8 inch diameter Lincoln AC electrodes LIMITATIONS The POWER ARC 4000 is not recommended for any processes besides those that are normally per formed using stick welding GMAW procedures The POWER ARC 4000 is not recommended for pipe thawing During welding generator power is limited to 100 watts and output voltages can drop from 120 to 80 volts and 240 to 160 volts Therefore DO NOT OPERATE ANY SENSITIVE ELECTRICAL EQUIP MENT WHILE YOU ARE WELDING POWER ARC 4000 Return to Section Return to Master TOC Return to Section TOC Return to Master TOC 9 o un 9 5 ac Retum to Section TOC Return to Master TOC o g gt a ac 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 1 OUTPUT PANEL CONTROLS ELECTRODE SELECTION GUIDE CURRENT CONTROL DIAL ELECTRODE SELECTION GUIDE WELD OUTPUT TERMINAL TO WORK WITH 1 2 13 FLANGE NUT
98. vice 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 requirements of the most common types of loads you can power with the POWER ARC 4000 Be sure to read the notes at the bottom of the table TO USE THE GENERATOR AS AN AUXILIARY POWER SUPPLY 1 Start the gasoline engine See ENGINE OPERA TION in this section of the manual 2 Setthe current control dial on the output control panel to GENERATOR See Figure B 1 3 Plug the load s into the appropriate 120 volt or 240 volt power receptacle NOTE During welding the maximum generator out put for auxiliary loads is 100 watts NOTE You can supply multiple loads as long as the total load does not exceed 4 000 watts Be sure to start the largest loads first LINCOLN 5 Return to Section TOC Return to Master TOC Retum to Section TOC Return to Section TOC Return to Master TOC Return to Master TOC Return to Section TOC Retum to Master TOC B 8 OPERATION TABLE B 3 GENERATOR POWER APPLICATIONS Suggested Power Applications Running Watts Start up Watts Air Compressor 3 4 HP 1 250 3 100 5 000 Airless Sprayer 1 3 HP 600 1 500 2 400 Chain Saw 1 200 Circular Saw 1 200 Coffee Maker 1 000 Deep Freezer 500 750 2 000 Electric Moto
99. ws with the 5 16 nut driver LINCOLN Return to Section TOC Return to Master TOC Return to Section TOC Return to Section TOC Return to Master TOC Return to Master TOC Return to Section TOC Return to Master TOC F 26 TROUBLESHOOTING amp 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 For your safety and to avoid elec trical shock please observe all safety notes and precautions detailed throughout this manu al If for any reason you do not understand the test procedures or are unable to perform the test repairs safely contact the Lincoln Electric Service Department for electrical trou bleshooting assistance before you proceed Call 216 383 2531 or 1 800 833 9353 WELD DESCRIPTION The following procedure will aid the technician in accessing and removing the capacitor and diode bridge for maintenance or replacement of either component MATERIALS NEEDED 5 16 Nut driver J umper wire with alligator clips on each end for discharging the field capacitor Slot head screw driver Needle nose pliers Wiring Diagram LINCOLN POWER ARC 4000 Return to Section TOC Return to Master TOC Return to Section TOC Return to Master TOC oio Ojo
100. y 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 TION in this section of the manual 7 Strike an arc and begin welding For information on welding techniques see WELDING GUIDE LINES lin this section of the manual AFTER YOU FINISH THE WELD 1 one the gasoline engine See ENGINE OPERA in this section of the manual 2 Allow the electrode and work to cool completely 3 Remove the work clamp from the work 4 Remove any remaining piece of electrode from the electrode holder 5 If you are finished using the POWER ARC 4000 for welding disconnect the welding cables from the weld output terminals Reattach the flange nuts and leave them on the terminals LINCOLN amp Return to Section TOC Return to Master TOC Return to Section TOC Return to Section TOC Return to Master TOC Return to Master TOC Return to Section TOC Return to Master TOC B 10 OPERATION WELDING GUIDELINES TABLE B 4 WELDING APPLICATIONS ELECTRODE SELECTION GUIDE Material Thickness Electrode Type Size Setting 1 8 and thinner FLEETWELD 37 3 32 90 amps AWS E6013 FLEETWELD 180 70 amps AWS E6011 STABLE 7018 90 amps AWS E7018 3 16 Maximum FLEETWELD 37 1 8 125 amps AWS E6013 5 16 Maximum FLEETWELD 180 1 8 90 amps AWS E6011 Any Thickne
101. ysical damage A safe distance from arc welding or cutting operations and any other source of heat sparks or flame Never allow the electrode electrode holder or any other electrically hot parts to touch a cylinder Keep your head and face away from the cylinder valve outlet when opening the cylinder valve Valve protection caps should always be in place and hand tight except when the cylinder is in use or connected for use Read and follow the instructions on compressed gas cylinders associated equipment and CGA publication Precautions for Safe Handling of Compressed Gases in Cylinders available from the Compressed Gas Association 1235 Jefferson Davis Highway Arlington VA 22202 FOR ELECTRICALLY powered equipment 8 a Turn off input power using the disconnect switch at the fuse box before working on the equipment Install equipment in accordance with the U S National Electrical Code all local codes and the manufacturer s recommendations Ground the equipment in accordance with the U S National Electrical Code and the manufacturer s recommendations Mar 95 LINCOLN 5 Q o FH g gt 8 a ac Return to Master TOC Retum to Master TOC Retum to Master TOC SAFETY PR CAUTIONS DE S RET Pour votre propre protection lire et observer toutes les instruc tions et les pr cautions de s ret specifiques qui parraissent dan

Fishman Loudbox 100 Musical Instrument User Manual

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