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Lincoln Electric SVM103-C manual

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Table of contents for the manual

  • Page 1

    PO WER-ARC ™ 4000 For Machines with Code Numbers: 10200 10202 10243 10244 10585 10667 10671 10672 10673 10792 10793 10866 SER VICE MANUAL 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 thought- ful operation on [...]

  • Page 2

    Return to Master TOC Return to Master TOC Return to Master TOC Return to Master TOC FOR ENGINE powered equipment. 1.a. Turn the engine off before troubleshooting and maintenance work unless the maintenance work requires it to be running. ____________________________________________________ 1.b. Operate engines in open, well-ventilated areas or vent[...]

  • Page 3

    Return to Master TOC Return to Master TOC Return to Master TOC Return to Master TOC ii SAFETY ii ARC RA YS 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 Z87. I standards. 4.b. U[...]

  • Page 4

    Return to Master TOC Return to Master TOC Return to Master TOC Return to Master TOC FOR ELECTRICALL Y powered equipment. 8.a. Turn off input power using the disconnect switch at the fuse box before working on the equipment. 8.b. Install equipment in accordance with the U.S. National Electrical Code, all local codes and the manufacturer’s recommen[...]

  • Page 5

    Return to Master TOC Return to Master TOC Return to Master TOC Return to Master TOC iv SAFETY iv PRÉCAUTIONS DE SÛRETÉ Pour votre propre protection lire et observer toutes les instruc- tions et les précautions de sûreté specifiques qui parraissent dans ce manuel aussi bien que les précautions de sûreté générales suivantes: Sûreté Pour [...]

  • Page 6

    Page Safety .................................................................................................................................................i-iv Installation ............................................................................................................................. Section A Technical Specifications ..............[...]

  • Page 7

    Return to Master TOC Return to Master TOC Return to Master TOC Return to Master TOC Page Installation ............................................................................................................................. Section A Technical Specifications .......................................................................................[...]

  • Page 8

    A-2 Return to Section TOC Return to Section TOC Return to Section TOC Return to Section TOC Return to Master TOC Return to Master TOC Return to Master TOC Return to Master TOC INST ALLA TION POWER-ARC 4000 A-2 TECHNICAL SPECIFICA TIONS - POWER-ARC 4000 Duty Cycle 30% Duty Cycle 60% Duty Cycle Amps 125 100 V olts at Rated Amperes 20 VAC 25 VAC W eld[...]

  • Page 9

    A-3 INST ALLA TION POWER-ARC 4000 A-3 Read this entire installation section before you start installation. SAFETY PRECAUTIONS 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 ma[...]

  • Page 10

    A-4 INST ALLA TION POWER-ARC 4000 A-4 ST ACKING POWER-ARC 4000 machines CANNOT be stacked. TIL TING 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 p[...]

  • Page 11

    A-5 INST ALLA TION A-5 Return to Section TOC Return to Section TOC Return to Section TOC Return to Section TOC Return to Master TOC Return to Master TOC Return to Master TOC Return to Master TOC SP ARK ARRESTER Gasoline engine mufflers may emit sparks when the engine is running. Some federal, state, or local laws require spark arresters in location[...]

  • Page 12

    A-6 INST ALLA TION POWER-ARC 4000 A-6 ELECTRICAL OUTPUT CONNECTIONS See Figure A.1 for the location of the current control dial, weld output terminals, ground stud, circuit breakers, 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 [...]

  • Page 13

    A-7 INST ALLA TION POWER-ARC 4000 A-7 Cable Installation Install the welding cables to your POWER-ARC 4000 as follows. See Figure A.1 for the location of parts. 1. The gasoline engine must be OFF to install 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 ou[...]

  • Page 14

    A-8 INST ALLA TION POWER-ARC 4000 A-8 PREMISES WIRING The POWER-ARC 4000 three-wire, grounded neutral generator allows it to be connected to premises wiring. However, the wiring procedure needed to meet the National Electric Code (NEC) regulations as well as city ordinances can be confusing. The con- nections could vary from a “commonly grounded?[...]

  • Page 15

    Certain Electrical devices cannot be powered by the POWER-ARC 4000. See Table A.2. TABLE A.2 ELECTRICAL DEVICE USE WITH THE POWER-ARC 4000. Type Common Electrical Devices Possible Concerns Resistive Heaters, toasters, incandescent NONE light bulbs, electric range, hot pan, skillet, coffee maker. Capacitive TV sets, radios, microwaves, Voltage spike[...]

  • Page 16

    A-10 NOTES A-10 Return to Section TOC Return to Section TOC Return to Section TOC Return to Section TOC Return to Master TOC Return to Master TOC Return to Master TOC Return to Master TOC POWER-ARC 4000[...]

  • Page 17

    Return to Master TOC Return to Master TOC Return to Master TOC Return to Master TOC T ABLE OF CONTENTS - OPERA TION SECTION - Section B Section B Operation ............................................................................................................................... Section B Safety Instructions ....................................[...]

  • Page 18

    B-2 OPERA TION B-2 OPERA TING INSTRUCTIONS Read and understand this entire section before oper- ating your POWER-ARC 4000. SAFETY INSTRUCTIONS Do not attempt to use this equipment until you have thoroughly read all the operation and maintenance manuals supplied with your machine. They include important safety precautions; detailed engine starting, [...]

  • Page 19

    B-3 OPERA TION B-3 The Lincoln warranty covers the Power Arc 4000 (excluding the engine) for 1 year from the date of purchase. The engine is covered by the Briggs & Stratton warranty policy for a period of 1 year for consumer use or 90 days for commercial use. RECOMMENDED APPLICA TIONS GENERA TOR The POWER-ARC 4000 gives AC generator output for[...]

  • Page 20

    B-4 OPERA TION B-4 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. GENERA TOR/WELDER CONTROLS See Figure B.1 for the location of the following features: 1. CURRENT CONTROL DIAL: Adjusts continuou[...]

  • Page 21

    B-5 OPERA TION B-5 5. GROUND STUD: Provides a connection point for connecting the machine case to earth ground for the safest grounding procedure. 6. 20 AMP CIRCUIT BREAKERS (2): Provide sepa- rate overload current protection for the 120 volt and 240 volt receptacles. GASOLINE ENGINE CONTROLS See Figure B.2 for the location of the following fea- tu[...]

  • Page 22

    B-6 OPERA TION B-6 7. RECOIL STARTER: Manual, rope-type starter. The handle position allows easy starting from either ground level or pickup-truck level. 8. OIL DRAIN PLUG: Permits convenient draining of engine oil during maintenance. Both sides of the engine are equipped with an oil drain plug. 9. OIL FILL PLUG: Permits convenient filling of engin[...]

  • Page 23

    B-7 OPERA TION B-7 4. Pull the cord rapidly. 5. If the engine does not start, open the choke slightly (move lever upward) and pull the starter cord rapidly again. When the engine starts, gradually open the choke to the “RUN” position. To open the choke fully, requires an engine warm-up period of several seconds to several minutes depending on t[...]

  • Page 24

    B-8 OPERA TION B-8 GENERA TOR OPERA TION Be sure that any electrical equipment plugged into the generator’s AC power receptacles can with- stand a ±10% voltage and a ±5% frequency varia- tion. Some electronic devices cannot be powered by the POWER-ARC 4000. Refer to Table A.2 , ELECTRICAL DEVICE USE WITH THE POWER- ARC 4000 , in the INSTALLATIO[...]

  • Page 25

    Return to Section TOC Return to Section TOC Return to Section TOC Return to Section TOC Return to Master TOC Return to Master TOC Return to Master TOC Return to Master TOC B-9 OPERA TION B-9 POWER-ARC 4000 NOTES: Wattages listed are approximate. Check your equipment for actual wattage. Equipment with unusually high *START-UP WATTS are listed. For s[...]

  • Page 26

    B-10 OPERA TION B-10 WELDING OPERA TION GENERAL INFORMA TION Do not touch electrically live parts or electrodes with your skin or wet cloth- ing. Do not breathe welding fumes or gases. Use ventilation or exhaust to remove welding fumes from the breathing area. Keep flammable material away. Wear eye, ear, and body protection. The POWER-ARC 4000 gene[...]

  • Page 27

    Return to Section TOC Return to Section TOC Return to Section TOC Return to Section TOC Return to Master TOC Return to Master TOC Return to Master TOC Return to Master TOC B-1 1 OPERA TION B-1 1 POWER-ARC 4000 TABLE B.2 WELDING APPLICATIONS/ELECTRODE SELECTION GUIDE Material Thickness Electrode Type Size Setting 1/8” and thinner FLEETWELD ® 37 3[...]

  • Page 28

    Return to Section TOC Return to Section TOC Return to Section TOC Return to Section TOC Return to Master TOC Return to Master TOC Return to Master TOC Return to Master TOC B-12 OPERA TION B-12 POWER-ARC 4000 Stick welding is probably the most familiar welding process known. A coated ELECTRODE, the weld rod, is clamped into an ELECTRODE HOLDER, an i[...]

  • Page 29

    Return to Section TOC Return to Section TOC Return to Section TOC Return to Section TOC Return to Master TOC Return to Master TOC Return to Master TOC Return to Master TOC B-13 OPERA TION B-13 POWER-ARC 4000 The Power-Arc 4000 has a voltage output of up to 62 volts which can shock. The electric arc is made between the work and the tip end of a smal[...]

  • Page 30

    Return to Section TOC Return to Section TOC Return to Section TOC Return to Section TOC Return to Master TOC Return to Master TOC Return to Master TOC Return to Master TOC B-14 OPERA TION B-14 POWER-ARC 4000 1. The Correct W elding Position Illustrated is the correct welding position for right-handed people. (For left-handed people it is opposite.)[...]

  • Page 31

    Return to Section TOC Return to Section TOC Return to Section TOC Return to Section TOC Return to Master TOC Return to Master TOC Return to Master TOC Return to Master TOC B-15 OPERA TION B-15 POWER-ARC 4000 PRACTICE The best way of getting practice in the four skills that enable you to maintain: 1. Correct Welding Position. 2. Correct Way to Strik[...]

  • Page 32

    Return to Section TOC Return to Section TOC Return to Section TOC Return to Section TOC Return to Master TOC Return to Master TOC Return to Master TOC Return to Master TOC B-16 OPERA TION B-16 POWER-ARC 4000 Now weld the two plates together. Weld from left to right (if right-handed). Point the electrode down in he gap between the two plates, keepin[...]

  • Page 33

    Return to Section TOC Return to Section TOC Return to Section TOC Return to Section TOC Return to Master TOC Return to Master TOC Return to Master TOC Return to Master TOC B-17 OPERA TION B-17 POWER-ARC 4000 Vertical-Up Welding The problem, when welding vertical-up, is to put the molten metal where it is wanted and make it stay there. If too much m[...]

  • Page 34

    Return to Section TOC Return to Section TOC Return to Section TOC Return to Section TOC Return to Master TOC Return to Master TOC Return to Master TOC Return to Master TOC B-18 OPERA TION B-18 POWER-ARC 4000 Overhead Welding Various techniques are used for overhead welding. However, in the interest of simplicity for the inexperi- enced welder, the [...]

  • Page 35

    Return to Section TOC Return to Section TOC Return to Section TOC Return to Section TOC Return to Master TOC Return to Master TOC Return to Master TOC Return to Master TOC B-19 OPERA TION B-19 POWER-ARC 4000 4. The bead should be put on with a weaving motion, and it should be 1/2-3/4” (12.7-19.0mm) wide. Do not let the arc blow over the edge, as [...]

  • Page 36

    Return to Section TOC Return to Section TOC Return to Section TOC Return to Section TOC Return to Master TOC Return to Master TOC Return to Master TOC Return to Master TOC B-20 OPERA TION B-20 POWER-ARC 4000 High-Speed Group (AWS E6013) This group includes electrodes which have a moder- ately forceful arc and deposit rates between those of the out-[...]

  • Page 37

    Return to Master TOC Return to Master TOC Return to Master TOC Return to Master TOC Page Accessories ........................................................................................................................... Section C Lincoln Electric Accessories ......................................................................................[...]

  • Page 38

    C-2 ACCESSORIES C-2 OPTIONS/ACCESSORIES LINCOLN ELECTRIC ACCESSORIES The following options/accessories are available for your POWER-ARC 4000 from your local Lincoln Distributor. 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 N[...]

  • Page 39

    Return to Master TOC Return to Master TOC Return to Master TOC Return to Master TOC Page Installation ............................................................................................................................. Section D Safety Precautions .............................................................................................[...]

  • Page 40

    D-2 MAINTENANCE D-2 SAFETY PRECAUTIONS • Have qualified personnel do all maintenance and troubleshooting work. • Turn the engine off before working inside the machine. • Remove guards only when necessary to per- form maintenance and replace them when the maintenance requiring their removal is com- plete. • If guards are missing from the mac[...]

  • Page 41

    D-3 MAINTENANCE D-3 Do not use petroleum solvents such as kerosene to clean the air cleaner. They may cause deterio- ration of the air cleaner. DO NOT OIL THE AIR CLEANER OR USE PRESSURIZED AIR TO CLEAN OR DRY THE AIR CLEANER. To service the pre-cleaner: 1. Wash in liquid detergent and water. 2. Squeeze dry in a clean cloth. 3. Saturate in clean en[...]

  • Page 42

    Return to Section TOC Return to Section TOC Return to Section TOC Return to Section TOC Return to Master TOC Return to Master TOC Return to Master TOC Return to Master TOC TABLE D.2 – ENGINE MAINTENANCE PARTS D-4 MAINTENANCE D-4 POWER-ARC 4000 TABLE D.1 ENGINE MAINTENANCE SCHEDULE Maintenance Every 5 Hours 25 Hours 50 Hours 100 Hours Operation or[...]

  • Page 43

    Return to Section TOC Return to Section TOC Return to Section TOC Return to Section TOC Return to Master TOC Return to Master TOC Return to Master TOC Return to Master TOC D-5 MAINTENANCE D-5 POWER-ARC 4000 GENERA TOR/WELDER MAINTENANCE STORAGE: Store the POWER-ARC 4000 in clean, dry, protected areas. CLEANING: Blow out the generator and controls p[...]

  • Page 44

    Return to Section TOC Return to Section TOC Return to Section TOC Return to Section TOC Return to Master TOC Return to Master TOC Return to Master TOC Return to Master TOC D-6 MAINTENANCE D-6 POWER-ARC 4000 8 7 6 5 1 2 3 4 1 . CRADLE ASSEMBLY 2. ROTOR, BLOWER, AND BEARING ASSEMBLY 3. STATOR ASSEMBLY 4. BRUSH AND BRUSH HOLDER ASSEMBLY 5. CONTROL BOX[...]

  • Page 45

    Return to Master TOC Return to Master TOC Return to Master TOC Return to Master TOC T ABLE OF CONTENTS - THEOR Y OF OPERA TION SECTION - Section E Section E POWER-ARC 4000 FIGURE E.1 – POWER-ARC 4000 BLOCK LOGIC DIAGRAM Theory of Operation ............................................................................................................[...]

  • Page 46

    Return to Section TOC Return to Section TOC Return to Section TOC Return to Section TOC Return to Master TOC Return to Master TOC Return to Master TOC Return to Master TOC E-2 THEOR Y OF OPERA TION E-2 POWER-ARC 4000 ENGINE, EXCIT A TION, ROTOR AND ST A TOR A small voltage developed by the engine magneto is fed through a diode to the rotating field[...]

  • Page 47

    Return to Section TOC Return to Section TOC Return to Section TOC Return to Section TOC Return to Master TOC Return to Master TOC Return to Master TOC Return to Master TOC E-3 THEOR Y OF OPERA TION E-3 POWER-ARC 4000 ROTOR FIELD FEEDBACK AND AUXILIAR Y POWER The AC voltage developed in the field winding is fed to the full wave bridge. The DC output[...]

  • Page 48

    Return to Section TOC Return to Section TOC Return to Section TOC Return to Section TOC Return to Master TOC Return to Master TOC Return to Master TOC Return to Master TOC E-4 THEOR Y OF OPERA TION E-4 POWER-ARC 4000 WELD WINDING AND REACTOR The AC voltage developed in the stator weld winding is delivered, through the reactor, to the machine out- p[...]

  • Page 49

    Return to Master TOC Return to Master TOC Return to Master TOC Return to Master TOC Troubleshooting & Repair Section ................................................................................. Section F How to Use Troubleshooting Guide ......................................................................................F-2 Troubleshootin[...]

  • Page 50

    Return to Section TOC Return to Section TOC Return to Section TOC Return to Section TOC Return to Master TOC Return to Master TOC Return to Master TOC Return to Master TOC F-2 TROUBLESHOOTING & REP AIR F-2 POWER-ARC 4000 CAUTION This Troubleshooting Guide is provided to help you locate and repair possible machine mal- functions. Simply follow t[...]

  • Page 51

    POWER-ARC 4000 F-3 TROUBLESHOOTING F-3 TROUBLESHOOTING GUIDE - Observe all Safety Guidelines detailed throughout this manual If for any reason you do not understand the test procedures or are unable to perform the tests/repairs safely, contact the Lincoln Electric Service Department for technical troubleshooting assistance before you proceed. Call [...]

  • Page 52

    POWER-ARC 4000 F-4 TROUBLESHOOTING F-4 TROUBLESHOOTING GUIDE - Observe all Safety Guidelines detailed throughout this manual If for any reason you do not understand the test procedures or are unable to perform the tests/repairs safely, contact the Lincoln Electric Service Department for technical troubleshooting assistance before you proceed. Call [...]

  • Page 53

    POWER-ARC 4000 F-5 TROUBLESHOOTING F-5 TROUBLESHOOTING GUIDE - Observe all Safety Guidelines detailed throughout this manual If for any reason you do not understand the test procedures or are unable to perform the tests/repairs safely, contact the Lincoln Electric Service Department for technical troubleshooting assistance before you proceed. Call [...]

  • Page 54

    POWER-ARC 4000 F-6 TROUBLESHOOTING F-6 TROUBLESHOOTING GUIDE - Observe all Safety Guidelines detailed throughout this manual If for any reason you do not understand the test procedures or are unable to perform the tests/repairs safely, contact the Lincoln Electric Service Department for technical troubleshooting assistance before you proceed. Call [...]

  • Page 55

    POWER-ARC 4000 F-7 TROUBLESHOOTING F-7 TROUBLESHOOTING GUIDE - Observe all Safety Guidelines detailed throughout this manual If for any reason you do not understand the test procedures or are unable to perform the tests/repairs safely, contact the Lincoln Electric Service Department for technical troubleshooting assistance before you proceed. Call [...]

  • Page 56

    POWER-ARC 4000 F-8 TROUBLESHOOTING F-8 TROUBLESHOOTING GUIDE - Observe all Safety Guidelines detailed throughout this manual If for any reason you do not understand the test procedures or are unable to perform the tests/repairs safely, contact the Lincoln Electric Service Department for technical troubleshooting assistance before you proceed. Call [...]

  • Page 57

    POWER-ARC 4000 F-9 TROUBLESHOOTING F-9 TROUBLESHOOTING GUIDE - Observe all Safety Guidelines detailed throughout this manual If for any reason you do not understand the test procedures or are unable to perform the tests/repairs safely, contact the Lincoln Electric Service Department for technical troubleshooting assistance before you proceed. Call [...]

  • Page 58

    POWER-ARC 4000 F-10 TROUBLESHOOTING F-10 TROUBLESHOOTING GUIDE - Observe all Safety Guidelines detailed throughout this manual If for any reason you do not understand the test procedures or are unable to perform the tests/repairs safely, contact the Lincoln Electric Service Department for technical troubleshooting assistance before you proceed. Cal[...]

  • Page 59

    F-11 TROUBLESHOOTING & REP AIR F-11 POWER-ARC 4000 ROTOR VOL T AGE TEST Service and repair should be performed by only Lincoln Electric factory trained personnel. Unauthorized repairs performed on this equipment may result in danger to the technician or machine operator and will invalidate your factory warranty. For your safety and to avoid ele[...]

  • Page 60

    F-12 TROUBLESHOOTING & REP AIR F-12 POWER-ARC 4000 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. 2. Start the machine and run it at high idle. Set the output control (rheo- stat) at the MAXIMUM or GENERA- TOR setting. 3. Set the volt/ohmmeter at t[...]

  • Page 61

    F-13 TROUBLESHOOTING & REP AIR F-13 POWER-ARC 4000 ROTOR RESIST ANCE TEST Service and repair should be performed by only Lincoln Electric factory trained personnel. Unauthorized repairs performed on this equipment may result in danger to the technician or machine operator and will invalidate your factory warranty. For your safety and to avoid e[...]

  • Page 62

    F-14 TROUBLESHOOTING & REP AIR F-14 POWER-ARC 4000 TEST PROCEDURE 1. Conduct the test with the gasoline engine OFF. 2. Remove the spark plug wire to pre- vent accidental engine kickback or starting. 3. Isolate the rotor electrically by removing the generator brushes. Refer to Figure F.2 as you perform the remaining steps. 4. Open the brush hold[...]

  • Page 63

    F-15 TROUBLESHOOTING & REP AIR F-15 POWER-ARC 4000 9. Reinstall the brush holder assembly after the test. Depress the spring- loaded brushes into the holder and slip a suitable non-metallic, fairly stiff retainer through the slots at the top and bottom of the holder. A cable tie works well; see Figure F.3. This will hold the brushes up so that [...]

  • Page 64

    F-16 TROUBLESHOOTING & REP AIR F-16 POWER-ARC 4000 ENGINE THROTTLE ADJUSTMENT TEST Service and repair should be performed by only Lincoln Electric factory trained personnel. Unauthorized repairs performed on this equipment may result in danger to the technician or machine operator and will invalidate your factory warranty. For your safety and t[...]

  • Page 65

    F-17 TROUBLESHOOTING & REP AIR F-17 POWER-ARC 4000 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 acciden- tal kickback or starting. 2. With the black or red marking pencil, place a mark on one of the blower paddles, which can be reached through[...]

  • Page 66

    F-18 TROUBLESHOOTING & REP AIR F-18 POWER-ARC 4000 2. Loosen Wing Nut (Refer to Figure F.5) 3. Refering to Figure F.5, adjust high speed stop screw to adjust the waveform period to 15.8 millisec- onds. 4. Re-tighten wing nut until wave washer is completely compressed. ENGINE THROTTLE ADJUSTMENT TEST (continued) FIGURE F.5 - LOCATION OF ENGINE T[...]

  • Page 67

    Return to Section TOC Return to Section TOC Return to Section TOC Return to Section TOC Return to Master TOC Return to Master TOC Return to Master TOC Return to Master TOC F-19 TROUBLESHOOTING & REP AIR F-19 POWER-ARC 4000 CH1 0 volts 5 ms 50 volts SCOPE SETTINGS Volts/Div ....................50V/Div. Horizontal Sweep.....5 ms/Div. Coupling ...[...]

  • Page 68

    Return to Section TOC Return to Section TOC Return to Section TOC Return to Section TOC Return to Master TOC Return to Master TOC Return to Master TOC Return to Master TOC F-20 TROUBLESHOOTING & REP AIR F-20 POWER-ARC 4000 SCOPE SETTINGS Volts/Div ....................50V/Div. Horizontal Sweep.....5 ms/Div. Coupling ............................D[...]

  • Page 69

    Return to Section TOC Return to Section TOC Return to Section TOC Return to Section TOC Return to Master TOC Return to Master TOC Return to Master TOC Return to Master TOC F-21 TROUBLESHOOTING & REP AIR F-21 POWER-ARC 4000 CH1 0 volts 5 ms 20 volts This is the typical AC output voltage generated from a properly operating machine. Note that each[...]

  • Page 70

    F-22 TROUBLESHOOTING & REP AIR F-22 POWER-ARC 4000 BRUSH REMOV AL AND REPLACEMENT 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[...]

  • Page 71

    Return to Section TOC Return to Section TOC Return to Section TOC Return to Section TOC Return to Master TOC Return to Master TOC Return to Master TOC Return to Master TOC F-23 TROUBLESHOOTING & REP AIR F-23 POWER-ARC 4000 PROCEDURE 1. Remove the spark plug wire. 2. Open the brush holder assembly cover. Squeeze the 2 tabs and depress the cover [...]

  • Page 72

    F-24 TROUBLESHOOTING & REP AIR F-24 POWER-ARC 4000 PROCEDURE (continued) 8. To reinstall the brush holder assembly, depress the spring- loaded brushes into the holder and slip a suitable non-metallic, fairly stiff retainer through the slots at the top and bottom of the holder. A cable tie works well; see Figure F.6 . This will hold the brushes [...]

  • Page 73

    F-25 TROUBLESHOOTING & REP AIR F-25 POWER-ARC 4000 RHEOST A T REMOV AL AND REPLACEMENT 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 a[...]

  • Page 74

    F-26 TROUBLESHOOTING & REP AIR F-26 POWER-ARC 4000 PROCEDURE 1. Remove the spark plug wire. 2. With the 5/16” nut driver, remove the 4 sheet metal screws that hold the top cover to the control box. Remove the top cover. 3. With the small slot head screw dri- ver, loosen the screw that holds the knob to the rheostat shaft. The shaft has a flat[...]

  • Page 75

    F-27 TROUBLESHOOTING & REP AIR F-27 POWER-ARC 4000 CAP ACITOR AND/OR DIODE BRIDGE REMOV AL AND REPLACEMENT 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 warrant[...]

  • Page 76

    Return to Section TOC Return to Section TOC Return to Section TOC Return to Section TOC Return to Master TOC Return to Master TOC Return to Master TOC Return to Master TOC F-28 TROUBLESHOOTING & REP AIR F-28 POWER-ARC 4000 PROCEDURE - CAP ACITOR REMOV AL AND REPLACE- MENT 1. Remove the engine spark plug wire. 2. With the 5/16” nut driver, rem[...]

  • Page 77

    F-29 TROUBLESHOOTING & REP AIR F-29 POWER-ARC 4000 1. Remove the engine spark plug wire. 2. With the 5/16” nut driver, remove the sheet metal screws that hold the top cover to the control box. Remove the top cover. 3. With the 5/16” nut driver and wrench remove the screws that hold the control panel in place. Move the panel aside as far as [...]

  • Page 78

    F-30 TROUBLESHOOTING & REP AIR F-30 POWER-ARC 4000 ST A TOR/ROTOR REMOV AL AND REPLACEMENT 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 safe[...]

  • Page 79

    Return to Section TOC Return to Section TOC Return to Section TOC Return to Section TOC Return to Master TOC Return to Master TOC Return to Master TOC Return to Master TOC F-31 TROUBLESHOOTING & REP AIR F-31 POWER-ARC 4000 ST A TOR REMOV AL PROCEDURE 1. Remove engine spark plug wire to prevent accidental kickback or starting. 2. With the 5/16?[...]

  • Page 80

    F-32 TROUBLESHOOTING & REP AIR F-32 POWER-ARC 4000 12. Slide a short length of 2 X 4 under the engine to support it when the stator is removed. 1 3 . 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.[...]

  • Page 81

    F-33 TROUBLESHOOTING & REP AIR F-33 POWER-ARC 4000 ROTOR REMOV AL PROCEDURE 1. To remove the rotor, double check that the spark plug wire is discon- nected. You will be turning the rotor during this procedure, and this could accidentally cause engine kickback. 2. With an impact wrench, remove the rotor thru-bolt. See Figure F.11. If an impact w[...]

  • Page 82

    F-34 TROUBLESHOOTING & REP AIR F-34 POWER-ARC 4000 6. Install the bottom two end bracket thru- bolts. Note: The flat washer goes on the top right hand thru-bolt for the green ground wire. 7. Tap the end bracket with the mallet as nec- essary to position it. Tighten the bolts to 4.5 - 5.5 ft lbs. Alternate tightening in order to pull the assembl[...]

  • Page 83

    Return to Section TOC Return to Section TOC Return to Section TOC Return to Section TOC Return to Master TOC Return to Master TOC Return to Master TOC Return to Master TOC F-35 TROUBLESHOOTING & REP AIR F-35 POWER-ARC 4000 RETEST AFTER REP AIR Retest a machine: • If it is rejected under test for any reason that requires you to remove any mech[...]

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    NOTES Return to Section TOC Return to Section TOC Return to Section TOC Return to Section TOC Return to Master TOC Return to Master TOC Return to Master TOC Return to Master TOC[...]

  • Page 85

    Return to Master TOC Return to Master TOC Return to Master TOC Return to Master TOC Page DIAGRAMS SECTION ........................................................................................................... Section G Wiring Diagram (S22160) ......................................................................................................[...]

  • Page 86

    G-2 DIAGRAMS G-2 POWER-ARC 4000 Return to Section TOC Return to Section TOC Return to Section TOC Return to Section TOC Return to Master TOC Return to Master TOC Return to Master TOC Return to Master TOC S22160 D1 C1 ROTOR (+) (-) (+) (-) ENGINE WIRING MAG SWITCH 9A 202A 7A 600 FD CCW 201A 201 RED RUN/STOP NOTE: ALL CASE FRONT COMPONENTS SHOWN VIEW[...]

  • Page 87

    G-3 DIAGRAMS G-3 POWER-ARC 4000 Return to Section TOC Return to Section TOC Return to Section TOC Return to Section TOC Return to Master TOC Return to Master TOC Return to Master TOC Return to Master TOC[...]

  • Page 88

    G-4 DIAGRAMS G-4 POWER-ARC 4000 Return to Section TOC Return to Section TOC Return to Section TOC Return to Section TOC Return to Master TOC Return to Master TOC Return to Master TOC Return to Master TOC[...]

  • Page 89

    G-5 DIAGRAMS G-5 POWER-ARC 4000 Return to Section TOC Return to Section TOC Return to Section TOC Return to Section TOC Return to Master TOC Return to Master TOC Return to Master TOC Return to Master TOC R 30.00 762 20.88 530 7.92 201 14.16 360 20.00 508 mm mm mm mm mm REF. REF. REF. REF. REF. DIMENSION PRINT - POWER ARC 4000 M17196 8-19-94[...]

  • Page 90

    NOTES Return to Section TOC Return to Section TOC Return to Section TOC Return to Section TOC Return to Master TOC Return to Master TOC Return to Master TOC Return to Master TOC[...]

  • Page 91

    SVM ERROR REPORTING FORM We need to know if there are errors in our manuals. We also value any suggestions as to additional tests or procedures that would make this SVM a better tool for you. If you discover new or different “Problems or Symptoms” that are not covered in the three col- umn troubleshooting chart, please share this information wi[...]