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Lincoln Electric 4000 Portable Generator User Manual

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1. Mar 93 for selecting a QUALITY product by Lincoln Electric We want you Thank You to take pride in operating this Lincoln Electric Company product eee as much pride as we have in bringing this product to you Please Examine Carton and Equipment For Damage Immediately When this equipment is shipped title passes to the purchaser upon receipt by the carrier Consequently Claims for material damaged in shipment must be made by the purchaser against the transportation company at the time the shipment is received Please record your equipment identification information below for future reference This information can be found on your machine nameplate Product Model Number Code Number or Date Code Serial Number Date Purchased Where Purchased Whenever you request replacement parts or information on this equipment always supply the information you have recorded above The code number is especially important when identifying the correct replacement parts On Line Product Registration Register your machine with Lincoln Electric either via fax or over the Internet For faxing Complete the form on the back of the warranty statement included in the literature packet accompanying this machine and fax the form per the instructions printed on it For On Line Registration Go to our WEB S TE at www lincolnelectric com Choose Quick Links and then Product Registration Plea
2. SE RECOMIENDA LEER Y ENTENDER LAS INSTRUCCIONES DEL FABRICANTE PARA EL USO DE ESTE EQUIPO Y LOS CONSUMIBLES QUE VA A UTILIZAR SIGA LAS MEDIDAS DE SEGURIDAD DE SU SUPERVISOR LISEZ ET COMPRENEZ LES INSTRUCTIONS DU FABRICANT EN CE QUI REGARDE CET EQUIPMENT ET LES PRODUITS A ETRE EMPLOYES ET SUIVEZ LES PROCEDURES DE SECURITE DE VOTRE EMPLOYEUR LESEN SIE UND BEFOLGEN SIE DIE BETRIEBSANLEITUNG DER ANLAGE UND DEN ELEKTRODENEINSATZ DES HER STELLERS DIE UNFALLVERHUTUNGSVORSCHRIFTEN DES ARBEITGEBERS SIND EBENFALLS ZU BEACHTEN Keep your head out of fumes Use ventilation or exhaust to remove fumes from breathing zone Los humos fuera de la zona de res piraci n Mantenga la cabeza fuera de los humos Utilice ventilaci n o aspiraci n para gases Gardez la t te l cart des fum es e Utilisez un ventilateur ou un aspira teur pour ter les fum es des zones de travail e Vermeiden Sie das Einatmen von Schweibrauch Sorgen Sie f r gute Be und Entl ftung des Arbeitsplatzes e Mantenha seu rosto da fumaca Use ventilac o e exhaust o para remover fumo da zona respirat ria eti ADP5o5UtRcocuc F n 9 BAPHECTIHIAEBELTIA DM CARE MES ie RS 106 2 6 e dz 347148 else sBxiqoesei SUAS MAS sis PARAH iz AMBHI Turn power off before servicing Desconectar el cable de ali mentaci n de poder de la maquina antes de iniciar cualquier servicio e D branchez le courant avant l entre
3. ALWAYS fill craters by drawing electrode away slowly ALWAYS keep these electrodes dry Electrodes when not used within a few hours after a container is opened must be stored in heated cabinets Motions POWER ARC 4000 LINCOLN P C1 ACCESSORIES C1 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 e 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 e Insulated electrode holder e Sample electrodes The cables are rated at 150 amps 4096 duty cycle Power Plug Kit K802U Provides three plugs two for the 120 volt duplex receptacle and one for the 240 volt receptacle Order K802T power plug kit for CSA model GFCI Receptacle Kit K896 3 Includes one UL approved 115 volt ground fault circuit interrupter duplex type receptacle with cover and installation instructions Replaces the factory installed 115 volt duplex receptacle Each side of the GFCI duplex is rated at 15 amps but the maximum total current from the GFCI duplex is limited to 20 amps 15 Amps for CSA model Undercarriage K882 2 2 wheeled hand movable undercarriage available for field installation Rotor Removal Kit 820925 A service kit with thru and impact bolts for removing the generat
4. Observe all Safety Guidelines detailed throughout this manual PROBLEMS POSSIBLE AREAS OF RECOMMENDED SYMPTOMS MISADJUSTMENT S COURSE OF ACTION PROBLEMS No generator power or welding output 1 Disconnect anything plugged into auxiliary receptacles and weld loads 2 Open lead in flashing or field circuit 3 Open flashing diode D1 4 Faulty brushes 5 Faulty rheostat R1 6 Faulty field rectifier D1 7 Faulty capacitor C1 8 Faulty stator field winding 9 Faulty rotor 10 Dirty slip rings clean slip rings when not in use If all recommended possible areas of misadjustment have been checked and the problem persists Contact your local Lincoln Authorized Field Service Facility Generator power is available but unit 1 Loose connection to output stud will not weld Work not connected Electrode holder loose No open circuit voltage at output studs Open lead in weld circuit Faulty reactor L1 Rheostat R1 lead broke 44 CAUTION If for any reason you do not understand the test procedures or are unable to perform the tests repairs safely contact your Local Lincoln Authorized Field Service Facility for technical troubleshooting assistance before you proceed POWER ARC 4000 LINCOLN E 3 TROUBLESHOOTING E 3 Observe all Safety Guidelines detailed throughout this manual PROBLEMS POSSIBLE AREAS OF RECOMMENDED SYMPTOMS MISADJUSTMENT S COURSE OF ACTION PROBLEMS Unit
5. VIM POWER ARC 4000 LINCOLN E F 3 09 WW 106 96121 6 61 8 9171 2011 134 134 066 88 06 1419373 NIOONIT DIAGRAMS 92 WW 809 00 0 434 000 4 LNIYd NOISNAWIG F 3 00706 dd POWER ARC 4000 LINCOLN P NOTES POWER ARC 4000 LINCOLN NOTES POWER ARC 4000 LINCOLN WARNING Spanish AVISO DE PRECAUCION French ATTENTION German WARNUNG ATEN AO dapanese it is BIR Korean Do not touch electrically live parts or electrode with skin or wet clothing Insulate yourself from work and ground No toque las partes o los electrodos bajo carga con la piel o ropa moja a Aislese del trabajo y de la tierra Ne laissez ni la peau ni des v te ments mouill s entrer en contact avec des pi ces sous tension e Isolez vous du travail et de la terre e Ber hren Sie kein
6. This heating and sudden cooling creates WHITE BRITTLE cast iron in the fusion zone See drawing below hot I White brittle cast iron This is the reason why welds in cast iron break Actually one piece of the broken cast iron has the entire weld on it and the other piece has no weld on it See drawing below OPERATION B 18 When breaking the weld stays on one piece To overcome this the welding operator has two choices 1 Preheat the entire casting to 500 1200 F 260 649 C If the cast iron is hot before welding there will be no sudden chilling which creates brittle white cast iron The entire casting will cool slowly 2 Weld 1 2 12 7mm at a time and do not weld at that spot again until the weld is cool This way no large amount of heat is put into the mass Most inexperienced welders will probably use the sec ond method because they have no way of preheating large castings Smaller castings can easily and should be preheated before welding A forge stove fire or the Arc Torch are all excellent means of pre heating When using the 1 2 12 7mm at a time method it is recommended to start 1 2 12 7mm away from the previous bead and weld into the previous bead This is called backstepping After welding Cast Iron protect the casting against fast cooling Put it in a container of warm dry sand or lime If sand or lime is not available cover it with sheet metal or any other non flamm
7. 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 LINCOLN B 1 OPERATION B 1 OPERATING INSTRUCTIONS Read and understand this entire section before oper ating your POWER ARC 4000 SAFETY INSTRUCTIONS A WARNING Do not attempt to use this equipment until you have thoroughly read all the operation and main tenance manuals supplied with your machine They include important safety precautions detailed engine starting operating and mainte nance instructions and parts lists e ELECTRIC SHOCK can kill Do not touch electrically live parts or electrodes with your skin or wet clothing e Insulate yourself from the work and ground e Always wear dry insulating gloves FUMES AND GASES can be dangerous e Keep your head out of fumes eUse ventilation or exhaust to remove fumes from breathing zone EU WELDING SPARKS can cause JE fire or explosion Keep flammable material away e Do not weld on containers that have held combustibles A WARNING ARC RAYS can burn e Wear eye ear and body protection 22 ENGINE EXHAUST can kill e Use in open well ventilated areas or vent exhaust to the outside Do not stack anything on or near the engine MOVING PARTS can injure Do not operate this equipment with AR A any of its
8. 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 draws This information is given on the load device nameplate For example a device rated 115 volts 2 amps will need 230 watts of power 115 x 2 230 You can use Table B 3 GENERATOR POWER APPLI CATIONS to determine the wattage 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 and the engine owner s manual 2 Set the 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 POWER ARC 4000 LINCOLN P Suggested Power Applications OPERATION TABLE B 3 GENERATOR POWER APPLICATIONS Running Watts Start up Watts Air Compressor 1 HP 2 000 4 000 8 000 Air Compressor 3 4 HP 1 250 3 100
9. corner and edge welds They can be used for repair work when dirt grease plating or paint cannot be completely cleaned from the steel These electrodes are typically used with motions A and B see draw ing for the first pass on vertical up welds OPERATION B 19 High Speed Group AWS E6013 This group includes electrodes which have a moder ately forceful arc and deposit rates between those of the out of position and high deposit electrodes They are primarily general purpose production elec trodes especially for downhill fillets and laps or short and irregular welds that change direction or position They are also widely used in maintenance and recom mended for sheet metal fillet and lap welds Motion D see drawing is generally used for vertical up welding but motions A and B are also suitable Low Hydrogen Group Stable Arc E7018 These electrodes are generally called low hydrogen The name comes from the fact that their coating contains little hydrogen in either moisture or chemical form Low hydrogen electrodes offer these benefits outstanding crack resistance lowest porosity on sulphur bearing steels and X ray quality deposit capa bility Thus they are the first choice when welding problem steels E7018 can be used in all positions with Motion C below recommended for the first pass on vertical up welds NEVER use a whipping technique or a long arc with these electrodes
10. 30 The easiest way to do this is to put one end of the share on a brick See drawings Most users will want to hardface the underside of the share but some might find that the wear is on the top side The important thing is to hardface the side that wears 3 Use 1 8 3 2mm Wearshield at 80 100 A Strike the arc about one inch from the sharp edge POWER ARC 4000 LINCOLN P B 18 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 that will dull the edge See drawing below Strike Arc Work Table Here Brick T e Sharp Edge m Plow Share 1 2 3 4 width 12 20mm Positioning of Share Weaving Motion 5 Use the back stepping method Begin to weld 3 76mm from the heel of the share and weld to the heel The second weld will begin 6 152mm from the heel the third weld 9 229mm from the heel etc E First weld from A to B then from C to A then from D to C then from E to D and so on BACKSTEPPING Backstepping greatly reduces the chances for crack ing of the share and it also greatly reduces warping NOTE The entire process is rather fast Many begin ners go much too slowly when hardfacing plowshares running the risk of burning through the thin metal Welding Cast Iron When welding on a piece of cold cast iron the tremendous heat from the arc will be absorbed and distributed rapidly into the cold mass
11. P M 1 37 Liters Hour 1 25 Liters Hour AC CC Weld Output 0 69 Gallons Hour 0 76 Gallons Hour 125 Amps 18 Volts 2 63 Liters Hour 2 9 Liters Hour AC CC Weld Output 0 64 Gallons Hour 0 63 Gallons Hour Auxiliary Power 4000 0 77 Gallons Hour Watts 120 240 Volts 2 92 Liters Hour MUFFLER DEFLECTOR The POWER ARC 4000 depending on model may or may not be shipped with an exhaust deflector If you received one you can mount it on the gasoline engine if your needs so require To install the deflector do the following e Align the holes on the deflector plate with the holes on the muffler e Position the deflector so that the opening points either right left or downward away from the operator A CAUTION Never position the deflector upward Moisture or debris can enter the engine and damage it As a general safety practice position the deflector to direct exhaust gases away from the operator s face and eyes e Fasten the deflector onto the muffler with the screws provided NOTE The deflector reduces generator output power up to 100 watts Honda 9 HP Carb Certified 0 30 Gallons Hour 1 14 Liters Hour 0 58 Gallons Hour 2 18 Liters Hour 0 55 Gallons Hour 2 1 Liters Hour 0 67 Gallons Hour 2 54 Liters Hour 0 76 Gallons Hour 2 9 Liters Hour SPARK ARRESTER Gasoline engine mufflers may emit sparks when the engine is running Some federal state or local laws require spark arresters in l
12. and surfaces to prevent over speeding overheating and engine damage Clean every 100 operating hours or as often as necessary FIGURE D 3 CLEAN COOLING SYSTEM 1 REMOVE DIRT FROM THESE AREAS 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 sol vent 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 Use the engine owner s manual for latest Plug Gap Info CLEAN SPARK ARRESTER SCREEN If the muffler has the spark arrester assembly refer to the engine owner s manual that was shipped with your POWER ARC 4000 for the proper cleaning instructions POWER ARC 4000 LINCOLN B D 3 MAINTENANCE D 3 TABLE D 1 ENGINE MAINTENANCE PARTS Part B amp S 8 HP Kool Bore Part B amp S 9 HP Vanguard Part Honda Part SPARK PLUG B amp S 802592 B amp S 491055 NGK BPR6ES RESISTOR CHAMPION RJ19LM CHAMPION RC12YC DENSO W20EPR U AUTOLITE 3924 FUEL FILTER B amp S 394358 NONE NONE AIR CLEANER PANEL BSS 494511 B amp S 710266 5266721 17210 ZE2 505 Pleated Paper AIR PRE CLEANER B amp S 492889 B amp S 710268 2538429 17218 ZE2 821 AS NEEDED CAN BE CL
13. 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 gasoline engine controls include a recoil starter choke and rotary stop switch See ENGINE OPERA TION in the OPERATION section of this manual and the engine owner s manual for details about starting running stopping and breaking in the gasoline engine DESIGN FEATURES AND ADVANTAGES Stick welding SMAW process capability with out put range from 70 125 amps Single dial current output selection e Work and Electrode welding cable mounting termi nals e 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 Integrated generator output overload protection through two 20 amp circuit breakers Welded tube full roll cage frame protects engine and generator welder e Lightweight portable design e Rubber mounting isolates engine and generator from frame to prevent machine walking during use e Low noise engine muffler for quieter operation A Super Lo Tone muffler is available for the Briggs amp Stratton 8 HP Kool Bore engine Easy starting No Maintenance Electronic ignition e Low oil level engine shutdown protection is stan dard equipment on machines produced after Au
14. following equipment Semiautomatic DC Constant Voltage Wire Welder DC Manual Stick Welder AC Welder with Reduced Voltage Control In semiautomatic or automatic wire 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 and 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 B ARC RAYS can burn 4 a Use a shield with the proper filter and cover p 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 standards 4 b Use suitable clothing made from durable flame resistant material to protect your skin and that of yo
15. ia Peat cctesinite acaesas endasnatesiash En Eu fcis es ape B 2 LiMITATIONS vives uscevivel B 2 Controls and settings B 3 Engine ODOratlori EE B 5 Welding Operations esce Rada EE D edes inia dal B 9 ACCOSSOFIOS seeds edi pie ien era avr Section C Maintenance E Section D riu eC M D 1 Routine and Periodic Maintenance A D 1 General Assembly Exploded VIGW arti Ebo ct ec crx ree exa coe to ne tee A DAA EC HRK ed D 6 Troubleshooting and Repair Section E Electrical Diagrams E Section F Parts Manual B amp S 8 HP 8 Honda Engines P233 Series Parts Manual B amp S 9 HP Vanguard Engine c iii ida eene P352 Series POWER ARC 4000 LINCOLN A 1 INSTALLATION A 1 TECHNICAL SPECIFICATIONS POVVER ARC 4000 INPUT BRIGGS KOOL BORE GASOLINE ENGINE Manufacturer Description Speed Displacement Ignition Capacities Briggs amp 1cyl 3700 RPM 19 4 cu in Manual Fuel 1 0 gal 3 8 Stratton Kool 4 cycle 50 RPM 319 cc Recoil Bore Plus air cooled at no load start Manual Oil 1 4 qt 1 3 I gasoline choke 8 HP 3750 RPM INPUT BRIGGS VANGUARD GASOLINE ENGINE Briggs amp 1 cyl 3700 RPM 18 06 cu in Manual Fuel 1 6 gal 6 0 I Stratton 4 cycl
16. lunettes avec crans lateraux dans les zones ou l on pique le laitier Eloigner les mat riaux inflammables ou les recouvrir afin de pr venir tout risque d incendie d aux tincelles Quand on ne 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 possible de la zone de travail qu il est pratique de le faire Si on place la masse sur la charpente de la construction ou d autres endroits loign s de la zone de travail on augmente le risque de voir passer le courant de soudage par les chaines de lev age c bles de grue ou autres circuits Cela peut provoquer des risques d incendie ou d echauffement 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 fume s toxiques Ne pas souder en pr sence de vapeurs de chlore provenant d op rations 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 forte ment toxique ou autres produits irritants Pour obtenir de plus amples renseignements sur la s rete voir le code Code for safety in welding and cutting CSA Standard W 1
17. 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 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 10 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 Turn the Rotary Stop Switch to the ON position FOR A COLD ENGINE 1 Open the fuel shutoff valve 2 Place the choke lever in the CHOKE position 3 Pull slightly on the recoil starter handle until resis tance is felt POWER ARC 4000 LINCOLN P B 6 OPERATION B 6 Pull the cord rapidly If the engine does not start open the choke slightly 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 the temperature After starting the engine first open the choke toward RUN until the engine ju
18. over heat and or cause damage to the equipment being used POWER ARC 4000 LINCOLN INSTALLATION CAUTION Certain Electrical devices cannot be powered by the POWER ARC 4000 See Table A 2 TABLE A 2 ELECTRICAL DEVICE USE WITH THE POWER ARC 4000 Type Common Electrical Devices Possible Concerns Resistive Heaters toasters incandescent 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 capaci tative 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 drills well pumps grinders small refrigerators weed and hedge trimmers current inrush 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
19. the fuel shut off 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 The engine will use a greater amount of oil during its break in period Check the oil frequently during break in For more details see the MAINTENANCE section in the engine owner s manual 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 min utes POWER ARC 4000 LINCOLN P B 7 OPERATION B 7 GENERATOR OPERATION A CAUTION Be sure that any electrical equipment plugged into the generator s AC power receptacles can with stand a 10 voltage and a 4 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 INSTALLATION 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
20. tien e Strom vor Wartungsarbeiten abschalten Netzstrom v llig ff nen Maschine anhalten e N o opere com as tampas removidas e Desligue a corrente antes de fazer servico N o toque as partes el tricas nuas XFA IE ACE PRE RET BRAY FE dl Oya e HMDS RK SHA AUS XA e Do not operate with panel open or guards off e No operar con panel abierto o guardas quitadas e N op rez pas avec les panneaux ouverts ou avec les dispositifs de protection enlev s e Anlage nie ohne Schutzgeh use oder Innenschutzverkleidung in Betrieb setzen e Mantenha se afastado das partes moventes e N o opere com os paineis abertos ou guardas removidas NRIVOAN ERUALEEE CHkBEELZVCNEUS CHRRIARRARS EIE E Ro exo del Sepe 2521 HM else WARNING Spanish AVISO DE PRECAUCION French ATTENTION German WARNUNG ATENCAO it ie BIR Chinese Qai ge Iya d l ale ARA cs l Aa sq Sarin e A uui ARI ge saz ue Aie 4 pha NM eb y si jui ale Ads cuts Fi ai y e Aale A I all LEIA E COMPREENDA AS INSTRUCOES DO FABRICANTE PARA ESTE EQUIPAMENTO E AS PARTES DE USO E SIGA AS PRATICAS DE SEGURAN A DO EMPREGADOR SRM OBHOX HD OHBRBEE lt K MA ETHBRMLTF EW CL TRHORERMEI HS SUCR Rr de OE D ES o A amp oli HAMAS SAA HA zeit ele EFSA VT Aal veel Ad d illai aul y
21. will weld but low or no generator Circuit breaker open power is available Loose or open connection with elec trical plug in component Current control dial not at 125 No open circuit voltage at receptacle Open lead in receptacle circuit No open circuit voltage at receptacle Bad receptacle Rheostat R1 lead broke If all recommended possible areas of misadjustment have been RUN position checked and the problem persists Contact your local Lincoln Authorized Field Service Facility Engine runs erratically or stops running 1 Engine is not fully warmed up and engine choke is in the fully open Engine requires service to head car buretor filters oil spark plug and or gas Engine sputters but will not start Bad gas bad filter air cleaner spark plug and or breather 44 CAUTION If for any reason you do not understand the test procedures or are unable to perform the tests repairs safely contact your Local Lincoln Authorized Field Service Facility for technical troubleshooting assistance before you proceed POWER ARC 4000 LINCOLN E 4 TROUBLESHOOTING E 4 Observe all Safety Guidelines detailed throughout this manual PROBLEMS POSSIBLE AREAS OF RECOMMENDED SYMPTOMS MISADJUSTMENT S COURSE OF ACTION PROBLEMS Engine will not start Spark plug boot or wire off loose or wet Fuel shutoff valve is closed Low oil and engine low oil shutdown protection will not allow unit to s
22. 0 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 GASOLINE ENGINE CONTROLS Refer to your engine manual for the location of the following features 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 See TECHNICAL SPECI FICATIONS for capacity NOTE If you use any other alternate fuel tank or supply be sure to use a recommended in line fuel filter MUFFLER Reduces engine noise output Briggs amp Stratton muffler does not serve as a spark arrester Honda muffler does See SPARK ARRESTER in the INSTALLATION section of this manual ROTARY STOP SWITCH Stops the engine by grounding the ignition circuit AIR CLEANER Filters intake air to the carburetor See ENGINE MAINTENANCE in the MAINTE NANCE section of the engine owner s manual for details about the specific type of air cleaner to use OPERATION B 4 CHOKE Provides a richer air fuel mix ture for cold engine starting condi tions See the topic ENGINE OPERA TION below for details on setting the choke RECOIL STARTER Manual rope type starter The handle position allows easy starting from eith
23. 000 with the Honda 9 HP engine are sup plied with low oil shutdown protection The Power Arc 4000 with the Briggs and Stratton 8 HP engine produced before August 1998 is NOT equipped with an Oil Gard low oil shutdown protection device Oil must be regularly checked and added as needed However the engine block is equipped to accept an Oil Gard accessory kit available from authorized Briggs and Stratton Distributors An installed kit will sense low oil levels and will automatically shut down the engine The engine cannot be restarted until suffi cient oil is added The POWER ARC 4000 is shipped with the engine filled 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 If it is not full add enough oil to fill it Be sure the fill plug is tight Change oil after the first 5 hours of operation For more oil fill and service information see the Engine owner s manual FUEL Fill the fuel tank with clean fresh regular grade lead free gasoline DO NOT MIX OIL WITH THE GASOLINE The POWER ARC 4000 has a fuel tank mounted on the engine See the engine owner s manual for more details about fuel POWER ARC 4000 LINCOLN Y A 4 INSTALLATION A 4 Power Arc 4000 Typical Fuel Consumption B amp S 8 HP Carb Certified B amp S 9 HP Kool Bore Plus Vanguard No Load 0 36 Gallons Hour 0 33 Gallons Hour 3700 RPM 50 R
24. 14 ga 75 A 16 ga 60 A 3 Hold the electrode in a 30 45 angle vvith the tip of the electrode pointing upvvards 4 Hold a VERY SHORT arc but do not let the elec trode touch the metal 5 An up and down whipping NE motion will help prevent arc th h hin plate burn through on very thin plate 30 40 6 Watch the molten metal carefully The important thing is to continue lowering the entire arm as the weld is made so the angle of the electrode does not change Move the electrode fast enough so that the slag does not catch up with the arc POWER ARC 4000 LINCOLN P B 17 Overhead Welding Various techniques are used for overhead welding However in the interest of simplicity for the inexperi enced welder the following technique will probably take care of his needs for overhead welding 1 Use 1 8 3 2mm 90 105 A or 3 32 2 5mm 70 A AWS 6011 electrode on AC 2 Put the electrode in he holder so it sticks straight out 3 Hold the electrode at an angle approximately 30 off vertical both seen from the side and seen from end See drawing below Side View End View 52 1 302 302 It is important to hold a VERY SHORT arc A long arc will result in falling molten metal a short arc will make the metal stay If necessary and this is dictated by the appearance of the molten puddle a slight back and forth whipping technique may be used to prevent dripping Welding Sheet Meta
25. 17 2 1974 jamais enrouler le c ble lectrode autour de n importe quelle PR CAUTIONS DE S RET POUR partie du corps LES MACHINES SOUDER Un coup d arc peut tre plus s v re qu un coup de soliel TRANSFORMATEUR ET REDRESSEUR donc a Utiliser un bon masque avec un verre filtrant appropri 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 Porter des v tements convenables afin de prot ger la peau de soudeur et des aides contre le rayonnement de l arc Prot ger l autre personnel travaillant proximit au soudage l aide d crans appropri s et non inflamma bles Des gouttes de laitier en fusion sont mises de l arc de soudage Se prot ger avec des v tements de protection libres de l huile tels que les gants en cuir chemise paisse pantalons sans revers et chaussures montantes LINCOLN B Relier la terre le chassis du poste conformement au code de l lectricit et aux recommendations du fabricant Le dis positif 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 dispositifs de s ret leur place
26. 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 Motor 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 Freezer 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 tabled equipment allow up to 2 times the running watts shown above For example a 1 HP motor requires approximately 1000 watts of power when running but may require 2 5 X 1000 2500 watts or 4 0 X 1000 4000 watts to start Multiple loads can be used as long as the total load does not exceed 4 000 watts Be certain to start the largest loads first Output rating in watts is equivalent to volt amperes at unity power factor resistive load and is calculated as WATTS VOLTS X AMPS DRAWN for example a 115 volt device w
27. EANED AND REUSED AS NEEDED Refer to Table D 1 for engine maintenance parts The part numbers are accurate at the time of printing Verify the current part number by referring to the engine owner s manual Replace or clean engine maintenance parts per the interval outlined in the engine owner s manual POWER ARC 4000 LINCOLN D 4 MAINTENANCE D 4 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 general overhaul is necessary Remove the brushes and clean the slip rings with fine grit emery paper CAUTION Do not attempt to polish slip rings while engine is running 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 bear ing end bracket and secure with the screws previ ously removed Remove the cable tie or wooden stick and the brushes will seat onto the slip rings RECEPTACLES Keep the electrical receptacles in good condition Remove any dirt oil or other debris from their surfaces and holes CABLE CONNECTIONS Check the welding cable connections at the weld output termin
28. L z AAL ell Gail call caulas ag ls Ca L LINCOLN B e World s Leader in Welding and Cutting Products 5 e Sales and Service through Subsidiaries and Distributors Worldwide e Cleveland Ohio 44117 1199 U S A TEL 216 481 8100 FAX 216 486 1751 WEB SITE www lincolnelectric com
29. ODE SELECTION GUIDE WELD OUTPUT TERMINAL TO ELECTRODE HOLDER WITH 1 2 13 FLANGE NUT WELD OUTPUT TERMINAL TO WORK WITH 1 2 13 FLANGE NUT GROUND STUD 20 AMP CIRCUIT BREAKERS 2 20 AMP 240 VOLT RECEPTACLE 20 AMP 120 VOLT DUPLEX RECEPTACLE GENERATOR WELDER CONTROLS 3 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 4 ELECTRODE SELECTION GUIDE Provides rec ommended electrode type size and welder out put setting based on the thickness of the work WELD OUTPUT TERMINAL TO ELECTRODE HOLDER WITH 1 2 18 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 18 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 POWER ARC 4000 LINCOLN P B 4 GROUND STUD Provides a connection point for connecting the machine case to earth ground for the safest grounding procedure 20 AMP CIRCUIT BREAKERS 2 Provide sepa rate overload current protection for the 120 volt and 240 volt receptacles 2
30. OWER ARC 4000 generator can supply power 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 Pak and MIG Conversion Kit POWER ARC 4000 LINCOLN D 1 MAINTENANCE D 1 SAFETY PRECAUTIONS A WARNING 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 machine get replacements from a Lincoln Distributor See the EXPLODED VIEW AND PARTS LIST at the back of this manual Read the Safety Precautions in the front of this manu al and in the engine owner s 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 A CAUTION To prevent the engine from acc
31. VIS qau 8202 16914 Yad STOSWAS 1901410373 ue H 29901 22901 2901 9890 Greco 20201 00201 SIPOD 000 Ouv H3MOd INVHOVIG ONIHIM POWER ARC 4000 LINCOLN E CN LL episui pejsed s epoo sejnomed e 104 urejDeip l ds oul 2 NI00 2 6 LL NOLLdO 557 85 S3YIM 3LIHM 319V 1d3938 939 8 Q3AOWZ SI 9 39M MOV 18 GATIWLSNI 41 HOLMS NOILO3103d 110 MOT YOLVNY3L TV H3HMATI i dOLS NNY DIAGRAMS H9V14 LOZ BER Q4 009 Vioc F 2 Jequunu epoo 1ueuudinbe ay ap 3ueujeoe daiJ e jueunjedeg BdIAIBS eui 0 914A 66 51 uieJ6erp ay j sjeued eunsoj oue ay jo euo uo euiugoeul eui Jenueuu siu Aq paJeAoo saulyoeu IS 40 8721n99e eq jou AjUO eoue19Je1 JO S ureJDelp 5111 LON HV INO343 I3AIA NMOHS SLNANOdWOO LNOYS 3SVO TIV 18913 SIOSWAS 1VOIH LO3 T3 xov lg ge ALIHM VS Mov lg gloz ALON Eso N33H9 80 32018 ANIONS iv 17109 O MOTA N3349 89 89 v 31IHM 25 La HOIVIS A9V lg VA H9V14 cM 99801 12901 S3309 0007 DEV H3MOd WVHOVIO DNISIM 3 8 VON SLIHM vz ER voz voz WS N33Y9 O Pl p 2 9 c v 9 9 2 dag a UN Ca 1 ON izMovud ON3 sanis 1 41 Q Mov 18
32. able material that will diminish drafts and retain heat Cast Iron Plate Preparation Wherever practical the joint to be welded should be veed out by grinding or filing to give complete pene tration as shown in figures a b and c below This is especially important on thick castings where maxi mum strength is required POWER ARC 4000 LINCOLN P B 19 In some instances a back up strip may be used and plates may be SCH 1 8 3 2mm or more as shown in figure b m Scrap up strip Three ways to prepare plates where complete penetration is necessary On sections where only a sealed joint is required and strength is not important the joint may be welded after slightly veeing out the seam as shown in figure d below d Single and double beads with and without beveling for tight partial strength joints Selecting Electrodes Which electrode is best for the particular job how do you use it These are important questions because the cost quality and appearance of your work depends on proper electrode selection and appli cation MILD STEEL ELECTRODES may be classi fied into the following groups Out of Position Group AWS E6011 This group includes electrodes which have a snappy deep penetrating arc and fast freezing deposits These electrodes are used for general purpose all position fabrication and repair welding They are also the best choice for pipe welding and sheet metal butt
33. als often Be sure that the connections are always tight NOTE Lincoln offers a rotor removal kit for any ser vice which requires removal of the rotor from the engine See the ACCESSORIES section for further details Removal of engine generator assembly from the cradle can be achieved as follows e Remove the two 5 16 18 hex head cap screws from the engine block via the access hole located in the cradle cross support channel Leave all other engine mountings intact e Remove the two hex nuts from the isolator thread ed posts at the stator support bracket located opposite the engine Leave all other stator mount ings intact e With a jib hoist or crane lift the unit upward and remove loose cradle from engine generator assembly FIGURE D 5 BRUSH REMOVAL AND REPLACEMENT GENERATOR END BRACKET BRUSH HOLDER ASSEMBLY COVER SCREWS 2 BRUSHES CABLE TIE POWER ARC 4000 LINCOLN D 5 MAINTENANCE FIGURE D 6 MAJOR COMPONENT LOCATIONS CRADLE ASSEMBLY ROTOR BLOWER AND BEARING ASSEMBLY STATOR ASSEMBLY BRUSH AND BRUSH HOLDER ASSEMBLY CONTROL BOX WELDED ASSEMBLY REACTOR ASSEMBLY OUTPUT TERMINAL ASSEMBLY 8 OUTPUT PANEL ASSEMBLY NO UE POWER ARC 4000 LINCOLN D 5 E 1 TROUBLESHOOTING E 1 HOW TO USE TROUBLESHOOTING GUIDE A WARNING Service and Repair should only be performed by Lincoln Electric Factory Trained Personnel Unauthorized r
34. an Underwriter s 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 section of this manual for details Ground fault protection is needed for hand held equipment WARNING Never operate this machine with damaged or defec tive cords All electrical equipment must be in safe condition AUXILIARY POWER RECEPTACLES The control panel of the POWER ARC 4000 features two auxiliary power receptacles e A 20 amp 120 volt duplex double outlet recepta cle e A 20 amp 240 volt simplex single outlet recepta cle 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 POWER ARC 4000 LINCOLN A 7 INSTALLATION A 7 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 and can be confusing The connections could vary from a commonly grounded to a separately derived system depending on whether you want the unit to be hard wired or tem porary to the premises WARNING Only a licensed certified trained electrician should install the machine to a premises or resi dential electrical system Be certain that e The premise
35. ave at hand In selecting an electrode you should consider 1 The type of deposit you want e g mild steel stainless low alloy hardfacing 2 The thickness of the plate you want to weld 3 The position it must be welded in downhand out of position 4 The surface condition of the metal to be welded 5 Your ability to handle and obtain the desired electrode Four simple manipulations are of prime importance Without complete mastery of these four further attempts at welding are futile With complete mastery of the four welding will be easy POWER ARC 4000 LINCOLN P B 13 1 The Correct Welding Position Illustrated is the correct welding position for right handed people For left handed people it is opposite Whenever possible weld from left to right if right handed This enables you to see clearly what you are doing Hold the electrode at a slight angle as shown in Figure 5 15 20 90 side view end view Correct Welding Position Figure 5 2 The Correct Way to Strike An Arc Be sure the work clamp makes good electrical contact to the work Lower your headshield and scratch the electrode slowly over the metal and you will see sparks fly While scratching lift the electrode 1 8 3 2mm and the arc is established NOTE If you stop moving the electrode while scratching the electrode will stick NOTE Most beginners try to strike the arc by a fast jabbing motion
36. current control SIZE AND LENGTH dial vveld output terminals ground stud circuit breakers 240 and 120 volt receptacles TOTAL COMBINED LENGTH OF ELECTRODE AND VVORK CABLES Cable Size for WELDING CABLE CONNECTIONS Cable Size and Length 125 amp Cable Length 30 Duty Cycle Be sure to use welding cables that are large enough The correct size and length becomes especially 0 50 feet 0 15 meters 6 AWG important when you are welding at a distance from 50 100 feet 15 39 meters 4 AWG the welder 100 150 feet 30 46 meters 3 AWG Table A 1 lists recommended cable sizes and lengths for rated current and duty cycle Length refers to the 150 200 feet 46061 meters 2 AWG distance from the welder to the work and back to the 200 250 feet 61 76 meters 1AWG welder Cable diameters are increased for long cable lengths to reduce voltage drops POWER ARC 4000 LINCOLN B A 6 INSTALLATION A 6 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 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 Be certain that the metal piece you are we
37. doors open or guards off e Stop the engine before servicing it e Keep away from moving parts Only qualified personnel should install use or ser vice this equipment GENERAL DESCRIPTION The POWER ARC 4000 is a generator welder designed for home use and other non commercial 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 constant current for welding with AC stick electrodes A single dial provides continuous adjustment of welding output The machine is light weight portable and can be lifted by two people POWER ARC 4000 LINCOLN P B 2 OPERATION B 2 The Lincoln warranty covers the Power Arc 4000 excluding the engine for 2 years from the date of purchase The engine is covered by the engine manu facturer s warranty policy RECOMMENDED APPLICATIONS GENERATOR The POWER ARC 4000 gives AC generator output for medium use non commercial demands For more details on operating the generator see GENERATOR OPERATION in the OPERATION section of this manu al WELDER The POWER ARC 4000 provides excellent constant current AC welding output for stick GMAW welding For more details on using the machine as a welder see WELDING OPERATION in the OPERATION sec tion of this manual OPERATIONAL FEATURES AND CONTROLS The POWER ARC 4000 was designed for simplicity Therefore it has very
38. down on the plate Result They either stick their electrode or their motion is so fast that they break the arc immediately OPERATION B 13 3 The Correct Arc Length The arc length is the distance from the tip of the electrode core wire to the base metal Once the arc has been established maintaining the correct arc length becomes extremely important The arc should be short approximately 1 16 to 1 8 1 6 3 2mm long As the electrode burns off the elec trode must be fed to the work to maintain correct arc length The easiest way to tell whether the arc has the correct length is by listening to its sound A nice short arc has a distinctive crackling sound very much like eggs frying in a pan The incorrect long arc has a hollow blowing or hissing sound 4 The Correct Welding Speed The important thing to watch while welding is the pud dle of molten metal right behind the arc DO NOT WATCH THE ARC ITSELF The appearance of the puddle and the ridge where the molten puddle solidi fies indicates correct welding speed The ridge should be approximately 3 8 9 5mm behind the electrode Ridge where puddle solidifies Molten puddle Most beginners tend to weld too fast resulting in a thin uneven wormy looking bead They are not watching the molten metal IMPORTANT It is not generally necessary to weave the arc forward backward or sideways Weld along at a steady pace and you will have a
39. e 50 RPM 296 cc Recoil Vanguard air cooled OHV at no load start Manual Oil 1 25 qt 1 2 Model 185432 gasoline choke 9 HP O 3 50 RPM INPUT HONDA GASOLINE ENGINE Honda 1 cyl 3700 RPM 16 5 cu in Manual Fuel 1 59 gal 6 0 GX 270 VA2 4 cycle z 50 RPM 270 cc Recoil air cooled OHV at no load start Manual Oil 1 16 qt 1 11 I gasoline choke 9 HP O 3750 RPM RATED OUTPUT WELDER Duty Cycle Amps Volts at Rated Amperes 3096 Duty Cycle 125 20 VAC 6096 Duty Cycle 100 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 POWER ARC 4000 LINCOLN B A 2 INSTALLATION A 2 Read this entire installation section before you start installation SAFETY PRECAUTIONS A WARNING Do not attempt to use this equipment until you have thoroughly read all the operation and main tenance manuals supplied with your machine They include important safety precautions detailed engine starting operating and mainte nance instructions and parts lists ELECTRIC SHOCK can kill e Do not touch electrically live parts or electrodes with your skin or wet clothing e Insulate yourself from the work and ground eAlways wear dry insulating gloves ENGINE EXHAUST can kill e Use in open well ventilated areas or vent exhaust to the outside Do not stack anything on o
40. e Preparation for Welding and Cutting of Containers and Piping 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 cir cuits This can create fire hazards or overheat lifting chains or cables until they fail 6 h Also see item 1 c LINCOLN B CYLINDER may explode ES 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 Cylinders should be loca
41. e stromf hrenden Teile oder Elektroden mit Ihrem K rper oder feuchter Kleidung Isolieren Sie sich von den Elektroden und dem Erdboden e N o toque partes el tricas e elec trodos com a pele ou roupa molha da e Isole se da peca e terra e no n n ELE het EE LATE MLMPT APSSAPREBS NTUWSHILT FSU E GUB MU ES 74 Oa CRM ER ecu Xe sd EE a Sal HAR e sis Weal HAR AMI W ou g l el all Y O Y ll alaq a i 3460 All ll DIS dan ule Y Jio moe Keep flammable materials away Mantenga el material combustible fuera del area de trabajo Gardez l cart de tout mat riel inflammable Entfernen Sie brennbarres Material Mantenha inflamaveis bem guarda dos EY LU CIE REA ein 9 ES TF Z T eis d s Jo ALD al gll e Ac AI uie Wear eye ear and body protection Prot jase los ojos los o dos y el cuerpo Prot gez vos yeux vos oreilles et votre corps e Tragen Sie Augen Ohren und K r perschutz e Use protec o para a vista ouvido e corpo H HAUSHERMRELTTF iD RRR HEBS SOSRSHR ex 19 Gol Soares s ESSAI dise ule 1489 lag al ad ne Al READ AND UNDERSTAND THE MANUFACTURER S INSTRUCTION FOR THIS EQUIPMENT AND THE CONSUMABLES TO BE USED AND FOLLOW YOUR EMPLOYER S SAFETY PRACTICES
42. epairs 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 malfunctions Simply follow the three step procedure listed below Step 1 LOCATE PROBLEM SYMPTOM Look under the column labeled PROBLEM SYMP TOMS This column describes possible symptoms that the machine may exhibit Find the listing that best describes the symptom that the machine is exhibiting Step 2 POSSIBLE CAUSE The second column labeled POSSIBLE CAUSE lists the obvious external possibilities that may contribute to the machine symptom Step 3 RECOMMENDED COURSE OF ACTION This column provides a course of action for the Possible Cause generally it states to contact your local Lincoln Authorized Field Service Facility If you do not understand or are unable to perform the Recommended Course of Action safely contact your local Lincoln Authorized Field Service Facility 44 CAUTION If for any reason you do not understand the test procedures or are unable to perform the tests repairs safely contact your Local Lincoln Authorized Field Service Facility for technical troubleshooting assistance before you proceed POWER ARC 4000 LINCOLN B E 2 TROUBLESHOOTING E 2
43. er ground level or pickup truck level OIL DRAIN PLUG Permits convenient draining of engine oil during maintenance Both sides of the engine are equipped with an oil drain plug OIL FILL PLUG Permits convenient filling of engine oil during maintenance Both sides of the engine are equipped with an oil fill plug POWER ARC 4000 LINCOLN P B 5 OPERATION B 5 ENGINE OPERATION A 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 personal 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 engine manufacturer s Operating and Maintenance Instructions manual that is shipped with the POWER ARC 4000 BEFORE STARTING THE ENGINE CHECK AND FILL THE ENGINE OIL LEVEL 1 Place the machine on a level ES surface A Open the oil fill plug 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 Fill the tank to allow approximately 1 4 inch 5 mm of tank space for fuel expansion DO NOT FILL THE TANK TO THE POINT OF OVERFLOW 3 Replace the fuel tank cap and tighten securely NOTE The engine will operate satisfactorily on any gasoline
44. ernor or idler by pushing on the throttle control rods while the engine is running 2 d 3 Do not place your body between the electrode and work cables If the electrode cable is on your right side the work cable should also be on your right side X K Connect the work cable to the workpiece as close as possible to the area being welded 1 g To prevent accidentally starting gasoline engines while turning the engine or welding generator during maintenance work disconnect the spark plug wires distributor cap or magneto wire as appropriate Do not work next to welding power source Mar 95 LINCOLN 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
45. gust 1998 On earlier engines an optional Oil Gard kit is available from Briggs amp Stratton WELDING CAPABILITY The POWER ARC 4000 is rated 125 amps 20 volts at 30 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 minute period The machine is also capable of higher duty cycles at lower output currents 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 weld with all 3 32 and most 1 8 inch diameter Lincoln AC elec trodes LIMITATIONS e The POWER ARC 4000 is not recommended for any processes besides those that are normally per formed using stick welding SMAW procedures e 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 LINCOLN P 00 NO UP amp D B 3 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 OPERATION B 3 FIGURE B 1 OUTPUT PANEL CONTROLS POWER ARC 4000 ELECTRODE SELECTION GUIDE CURRENT CONTROL DIAL ELECTR
46. hich is rated on its nameplate to draw 2 amps will need 115 VOLTS X 2 AMPS 230 WATTS OF POWER POWER ARC 4000 LINCOLN P 1 KW 1000 WATTS B 9 OPERATION B 9 WELDING OPERATION GENERAL INFORMATION A WARNING 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 D 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 Table B 4 WELDING APPLICATIONS gives you the recommended dial settings based on the thickness 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 Figure B 1 Replace and tighten the flange nuts secu
47. identally starting disconnect the spark plug lead before servicing the engine See the engine owner s manual for a summary of maintenance intervals for the items listed below Follow either the hourly or the calendar intervals whichever come first More frequent service may be required depending on your specific application and operating conditions Table D 1 shows engine main tenance replacement parts and numbers OIL Check the oil level after every 5 En hours of operation or daily BE SURE TO MAINTAIN THE OIL LEVEL Change the oil the first time after 5 hours of opera tion Then under normal operating conditions change the oil after every 50 hours or once a year whichever occurs first If the engine is operated 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 the grade and viscosity recommend ed in the engine owner s manual FIGURE D 1 OIL DRAIN AND REFILL LOCATION 1 OIL DRAIN PLUG 2 OIL FILL PLUG 3 OIL LEVEL FUEL At the end of each day s use refill the fuel tank to minimize moisture conden sation and dirt contamination in the fuel line ENGINE ADJUSTMENTS A WARNING OVERSPEED IS HAZARDOUS The maximum allowable high idle speed for this machine is 3750 RPM no load DO NOT tam
48. l Welding sheet metal presents an additional problem burn through Follow these simple rules 1 Hold a very short arc This together with the prop er travel speed will eliminate burn through 2 Use 1 8 3 2mm or 3 32 2 5mm AWS 6011 3 Use low amperage 75 A for 1 8 3 2mm elec trode 70 A for 3 32 2 5mm electrode OPERATION B 17 4 Move rapidly enough to stay ahead of the molten slag A whipping technique may be used to further minimize burn through 5 f you have a choice use lap joints rather than fil lets or butts the double thickness effect of a lap joint makes it much easier to weld without burning through Hardfacing To Reduce Wear There are several kinds of wear The two most often encountered are 1 Metal to Ground Wear Plowshares bulldozer blades buckets cultivator shares and other metal parts moving in the soil 2 Metal to Metal Wear Trunnions shafts rollers and idlers crane and mine car wheels etc Each of these types of wear demands a different kind of hardfacing electrode When applying the proper electrode the service life of the part will in most cases be more than double For instance hardfacing of plowshares results in 3 5 times more acreage plowed How to Hardface the Sharp Edge Metal to Ground Wear 1 Grind the share approximately one inch along the edge so the metal is bright and clean 2 Place the share on an incline of approximately 20
49. l Dial Provides welding current adjustment from 70 through 125 Amps To obtain maximum weld output turn the Current Control Dial to 125 Amps for either a cold or hot engine As the machine is used some welding volt age may decrease at high current settings If you are welding for long periods of time the dial may need to be slightly turned upward to provide the same welding results as when the machine was cold The numbers listed on the dial correspond to the aver age amperage needed to weld specific Lincoln rods Refer to Table 2 Welding Application Chart and Electrode Selection Guide listed on the machine nameplate for proper current and electrode settings POWER ARC 4000 LINCOLN P B 10 OPERATION WELDING GUIDELINES TABLE B 4 WELDING APPLICATIONS ELECTRODE SELECTION GUIDE B 10 Material Thickness Electrode Type Size Setting 1 8 and thinner FLEETWELD 37 3 32 90 amps AWS E6013 FLEETWELD 180 70 amps AWS E6011 Lincoln 7018 AC 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 Thickness WEARSHIELD ABR 1 8 100 amps NOTES The values listed are suggested settings Actual setting may vary depending on individual preference and or specific application Beginners should use Lincoln E7018 AC For electrodes not listed follow tables that are packed with the electrodes Ask for
50. lding the work is securely connected to the work clamp and cable 6 Check and tighten the connections periodically A CAUTION e Loose connections will cause the output termi nals to overheat The terminals may eventually melt e Do not cross the welding cables at the output terminal connection Keep the cables isolated and separate from one another Lincoln Electric offers a welding accessory kit with the properly specified welding cables See the ACCESSORIES section of this manual for more infor mation 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 electrical shock connect a heavy gauge wire from the ground stud located on the bottom center of the output panel see Figure A 1 to a suitable earth ground such as a metal pipe driven into the ground A WARNING Do not ground the machine to a pipe that carries explosive or combustible material When the POWER ARC 4000 is mounted on a truck or a trailer the machine gen erator ground stud MUST be securely connected to the metal frame of the vehicle See Figure A 1 The ground stud is marked with the symbol PLUGS AND HAND HELD EQUIPMENT For further protection against electric shock any electrical equipment connected to the generator receptacles must use a three blade grounded type plug or
51. little less at an angle LIFTING The POWER ARC 4000 should be lifted by two peo ple It weighs 160 lbs 72 5 kg Its welded tube roll cage is designed to make lifting easy ANGLE OF OPERATION Internal combustion engines are designed to run ina level condition to achieve optimum performance The maximum angle of operation for the engine is 15 degrees from horizontal in any direction Be certain to place the machine on a firm non skid structural supporting surface Anchor unit if necessary If you are operating the engine at a slight angle be certain to check the oil regularly and maintain a level full oil condition The effective fuel capacity will also be slightly less than the specified 1 00 gallon 3 8 liters PRE OPERATION ENGINE SERVICE Read and understand the information about the gaso line engine in the OPERATION and MAINTENANCE sections of this manual and the engine owner s man ual before you operate the POWER ARC 4000 A WARNING e Keep hands away from the engine muffler or HOT engine parts e Stop the engine when fueling Do not smoke when fueling e Remove the fuel cap slowly to release pressure Do not overfill the fuel tank e Wipe up spilled fuel and allow the fumes to clear before starting the engine e Keep sparks and flame away from the fuel tank INSTALLATION A 3 OIL SpA The Power Arc 4000 with the Briggs and Stratton 8 HP engine produced after August 1998 and the Power Arc 4
52. mass POWER ARC 4000 For Machines with Code Number 10083 10179 10200 10211 10202 10243 10244 10585 10667 10671 10672 10673 and 10866 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 your part DO NOT INSTALL OPERATE OR REPAIR THIS EQUIPMENT WITHOUT READING THIS MANUAL AND THE SAFETY PRECAUTIONS CONTAINED THROUGHOUT And most Various engine configurations are available and machine appearance will vary importantly think before you act accordingly and be careful EEE OPERATOR S MANUAL ISO 9001 rm wb aus Designed and Ma der er LI NCOLM Copyright 2004 Lincoln Global Inc World s Leader in Welding and Cutting Products e Sales and Service through Subsidiaries and Distributors Worldwide e Cleveland Ohio 44117 1199 U S A TEL 216 481 8100 FAX 216 486 1751 WEB S TE www lincolnelectric com SAFETY WARNING A CALIFORNIA PROPOSITION 65 WARNINGS A Diesel engine exhaust and some of its constituents The engine exhaust from this product contains 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 The Above For Diesel Engines The Abo
53. n easier time NOTE When welding on thin plate you will find that you have to increase the welding speed whereas when welding on heavy plate it is necessary to go more slowly to ensure fusion and penetration POWER ARC 4000 LINCOLN P B 14 PRACTICE The best way of getting practice in the four skills that enable you to maintain 1 Correct Welding Position 2 Correct Way to Strike An Arc 3 Correct Arc Length 4 Correct Welding Speed is to spend a little more time on the following exercise Use the following Mild Steel Plate 3 16 4 8mm or heavier Electrode 1 8 3 2mm AWS 6011 Fleetweld 180 Current Setting 90 125 Amps AC Do the following 1 Learn to strike the arc by scratching the electrode over the plate Be sure the angle of the electrode is right and be sure to use both hands 2 When you can strike an arc without sticking prac tice the correct arc length Learn to distinguish it by its sound 3 When you are sure that you can hold a short crackling arc start moving Look at the molten puddle constantly and look for the ridge where the metal solidifies 4 Run beads on a flat plate Run them parallel to the top edge the edge farthest away from you This gives you practice in running straight welds and also it gives you an easy way to check your progress The 10th weld will look considerably bet ter than the first weld By constantly checking on your mistakes and your p
54. nd 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 practices MSDS forms are available from your welding distributor or from the manufacturer 5 e Also see item 1 b Mar 95 SAFETY 3 7 WELDING SPARKS can 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 th
55. ocations where unarrested sparks could present a fire hazard Standard mufflers and deflectors like the ones included with the POWER ARC 4000 Briggs amp Stratton engines do not act as spark arresters When local laws require it a spark arrester must be installed on the machine and properly maintained An optional spark arrester kit is available for your POWER ARC 4000 Briggs amp Stratton 8 HP Kool Bore engine See the ACCESSORIES section of this man ual for more information A CAUTION An incorrect spark arrester may lead to damage to the engine or reduce performance A suitable spark arrester for the Briggs amp Stratton 8 HP Kool Bore engine is available as a Lincoln field installed option A spark arrester is available for your POWER ARC 4000 Briggs amp Stratton 9 HP Vanguard engine from your local Briggs amp Stratton engine dealer The Power Arc 4000 with the Honda engine comes with a spark arrester as standard equipment Refer to the engine owner s manual for proper maintenance POWER ARC 4000 LINCOLN B A 5 INSTALLATION 7 FIGURE A 1 POVVER ARC 4000 OUTPUT CONNECTIONS POVVER ARC 4000 ELECTRODE SELECTION GUIDE 1 CURRENT CONTROL DIAL 4 CIRCUIT BREAKERS 2 20 AMP 2 WELD OUTPUT TERMINALS 2 5 RECEPTACLE 240 VOLT 20 AMP 3 GROUND STUD 6 DUPLEX RECEPTACLE 120 VOLT 20 AMP ELECTRICAL OUTPUT TABLE A 1 CONNECTIONS RECOMMENDED VVELDING CABLE See Figure A 1 for the location of the
56. or rotor from the tapered engine crankshaft BRIGGS AND STRATTON ACCESSORIES FOR THE 8 HP KOOL BORE ENGINE ONLY The following options accessories are available for your POWER ARC 4000 from your local Briggs amp Stratton Distributor Check with the distributor for availability of options accessories for the 9 HP Vanguard engine Foam Pre cleaner B amp S No 492889 Provides a foam pre cleaner for placement around the paper cartridge air cleaner Increases protection in extreme ly dusty or dirty environments Oil Gard Low Oil Shutdown Kit B amp S No 398182 Installs in the crankcase access port Senses low oil conditions and automatically stops the engine The engine cannot be restarted until sufficient oil is added It is recommended that the Oil Gard Kit be installed on Power Arc machines where the machine is subject to long periods of continuous running Super Lo Tone Muffler Square B amp S No 494221 Replaces the round Lo Tone muffler that comes installed on the engine Limits exhaust noise but reduces maximum generator output by 100 200 watts Muffler Guard B amp S No 494868 This guard installs onto the muffler via a supplied bracket and protects against incidental contact with a HOT muffler Do not use this guard in tandem with both a deflector and spark arrester SEMIAUTOMATIC MIG WELDING WITH A LINCOLN WELD PAK 100 OR WELD PAK 125 In addition to using the accessories options listed above the P
57. ore servicing Keep away from moving parts Only qualified personnel should install use or service this equipment The electric arc is made between the work and ihe tip end of a small metal wire the electrode which is clamped in a holder that is held by the welder A gap is made in the welding circuit see Figure 3 by hold ing the tip of the electrode 1 16 1 8 1 6 3 2mm away from the work or base metal being welded The electric arc is established in this gap and is held and moved along the joint to be welded melting the metal as it is moved Arc welding is a manual skill requiring a steady hand good physical condition and good eyesight The operator controls the welding arc and therefore the quality of the weld made What Happens in the Arc Figure 4 illustrates the action that takes place in the electric arc It closely resembles what is actually seen during welding The arc stream is seen in the middle of the picture This is the electric arc created by the electric current flowing through the space between the end of the electrode and the work The temperature of this arc is about 6000 F 3316 C which is more than enough to melt metal The arc is very bright as well as hot and OPERATION B 12 cannot be looked at with the naked eye without risking painful and possibly permanent injury A very dark lens specifically designed for arc welding must be used with the handshield or headshield whenever vie
58. per with the governor components or setting or make any other adjust ments to increase the maximum speed Severe personal injury and damage to the machine can result if operated at speeds above maximum Adjustments to the engine are to be made only by a Lincoln Service Center or an authorized Field Service Shop POWER ARC 4000 LINCOLN B D 2 MAINTENANCE D 2 CAUTION 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 engine oil 4 Squeeze in a clean absorbent cloth to remove all excess oil 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 combustible debris Clean Rotating Screen If your POWER ARC 4000 is equipped with an engine that has a rotating screen you should clean it as often as needed to remove dirt or debris that may collect on the screen A dirty screen can result in engine overheating and damage See Figure D 2 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
59. r near the engine MOVING PARTS can iniure X Ke e Stop the engine before ser vicing it Do not operate this equip ment with any of its doors open or guards off Keep away from moving parts Only qualified personnel should install use or service this equipment 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 the machine in puddles or otherwise sub merge it in water Such practices pose safety haz ards and cause improper operation and corrosion of parts Always operate the POWER ARC 4000 with the case roof on and all machine components completely assembled This will protect you from the dangers of moving parts hot metal surfaces and live electrical devices STORING 1 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 f you will be storing the machine for over 30 days you should drain the fuel to protect fuel system and carbu
60. rely Be sure the connections are tight 2 Select the appropriate electrode See Table B 4 WELDING APPLICATIONS or the ELECTRODE SELECTION GUIDE on the machine Output Control Panel 3 Attach the work clamp securely to the work you are welding 4 Insert the electrode into the electrode holder 5 Set the current control dial to the desired output current 6 Start the gasoline engine See ENGINE OPERA TION in this section of the manual 7 Strike an arc and begin welding For information on welding techniques see WELDING GUIDE LINES in this section of the manual AFTER YOU FINISH THE WELD 1 Stop the gasoline engine See ENGINE OPERA TION in this section of the manual Allow the electrode and work to cool completely Remove the work clamp from the work Remove any remaining piece of electrode from the electrode holder 5 f 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 NOTE 1 Welding current is continuously variable with 60 duty cycle applying to output currents 100 Amps and less and 30 duty cycle applying to currents above 100 Amps 2 Duty cycle is based on a ten minute period The welder can be loaded to 125 Amps for three minutes out of every ten minute period or to 100 Amps for six minutes out of every ten minute period CONTROL FUNCTION OPERATION Current Contro
61. retor 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 oil per the engine manual 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 LINCOLN B A 3 STACKING POWER ARC 4000 machines CANNOT be stacked TILTING 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
62. rogress welding will soon be a routine matter Common Metals Most metals found around the farm or small shop are low carbon steel sometimes referred to as mild steel Typical items made with this type of steel include most sheet metal plate pipe and rolled shapes such as channels angle irons and I beams This type of steel can usually be easily welded without special precautions Some steel however contains higher carbon Typical applications include wear plates axles connecting rods shafts plowshares and scraper blades OPERATION B 14 These higher carbon steels can be welded successful ly in most cases however care must be taken to fol low proper procedures including preheating the metal to be welded and in some cases carefully controlling the temperature during and after the welding process For further information on identifying various types of steel and other metals and for proper procedures for welding them we suggest you purchase a copy of New Lessons in Arc Welding See Book Division section Regardless of the type of metal being welded in order to get a quality weld it is important that it be free of oil paint rust or other contaminants Types of Welds Five types of welding joints are Butt Welds Fillet Welds Lap Welds Edge Welds and Corner Welds Of these the Butt Weld and Fillet Weld are the most common Weld Lap Weld Edge Weld Fillet Weld Corner Weld Butt Weld
63. s Butt Welds are the most widely used welds Place two plates side by side leaving 1 16 1 6mm for thin metal to 1 8 3 2mm for heavy metal space between them in order to get deep penetration Tack the plates at both ends otherwise the heat will cause the plates to move apart See drawing E POWER ARC 4000 LINCOLN P B 15 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 keeping the electrodes slightly tilted in the direction of travel 209 end view 90 side view Watch the molten metal to be sure it distributes itself evenly on both edges and in between the plates Penetration Unless a weld penetrates close to 10096 a butt weld will be weaker than the material welded together 1 2 Poor 12mm dinm 1 4 6mm In this example the total weld is only 1 2 the thickness of the material thus the weld is only approximately half as strong as the metal Good In this example the joint has been flame beveled or ground prior to welding so that 100 penetration could be achieved The weld if properly made is as strong or stronger than the original metal 1 8 3 2mm Successive passes must be used to build up butt welds on heavier metal OPERATION B 15 Fillet Welds When welding fillet welds it is very important to hold the electrode at a 45 angle between the two sides or the metal will no
64. s and igniting Do not spill fuel when filling tank If fuel is spilled wipe it up and do not start engine until fumes have been eliminated 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 before welding 1 d Keep all equipment safety guards covers and devices in position and in good repair Keep hands hair clothing and tools away from V belts gears fans and all other moving parts when starting operating or repairing equipment Exposure to EMF fields in welding may have other health effects which are now not known All welders should use the following procedures in order to 1 e n some cases it may be necessary to remove safety m n minimize exposure to EMF fields from the welding circuit guards to perform required maintenance Remove guards only when necessary and replace them when the maintenance requiring their removal is complete Always use the greatest care when working near moving parts 2 d 1 Route the electrode and work cables together Secure them with tape when possible 2 d 2 Never coil the electrode lead around your body 1 f Do not put your hands near the engine fan Ny Do not attempt to override the gov
65. s is isolated and no feed backing into the utility system can occur Certain state and local laws require the premises to be isolat ed before the generator is linked to the premis es Check your state and local requirements e A double pole double throw transfer switch in conjunction with the properly rated double throw circuit breaker is connected between the generator power and the utility meter The POWER ARC 4000 does not have a combined 120 240 volt twist lock receptacle and cannot be connected to a premises as described in other Lincoln literature Remember that the POWER ARC 4000 is intended only for backup intermittent use power Oil level must be checked after every 5 hours of use The Briggs amp Stratton engines used on the Power Arc 4000 before August 1998 did not include a low oil shutdown option as standard equipment It cannot withstand long term use without proper maintenance See the MAINTENANCE section of this manual and the engine owner s manual for more information Certain electrical devices cannot be powered by the POWER ARC 4000 Refer to Table A 2 for these devices CIRCUIT BREAKERS o O The POVVER ARC 4000 has its ovvn 20 amp circuit breakers for overload protection VVhen the machine is operated in high temperature environments the breakers may tend to trip at lower loads than normal ly CAUTION Never bypass the circuit breakers Without over load protection the power arc 4000 could
66. s the heat away from the molten puddle which solidifies If the arc is not taken away soon enough too much metal will be deposited and it will drip 5 The upward motion of the arc is caused by a very slight wrist motion Most definitely the arm must not move in and out as this makes the entire process very complicated and difficult to learn 6 If the upward motion of the arc is done correctly with a wrist motion the arc will automatically become a long arc that deposits little or no metal See drawing above 7 During this entire process the ONLY thing to watch is the molten metal As soon as it has solidi fied the arc is SLOWLY brought back and another few drops of metal are deposited DO NOT FOLLOW THE UP AND DOWN MOVEMENT OF THE ARC WITH YOUR EYES KEEP THEM ON THE MOLTEN METAL OPERATION B 16 8 When the arc is brought back to the now solidified puddle IT MUST BE SHORT otherwise no metal will be deposited the puddle will melt again and it will drip 9 It is important to realize that the process consists of SLOW DELIBERATE movements There are no fast motions Vertical Down Welding Vertical down welds are applied at a fast pace These welds are therefore shallow and narrow and are excellent for sheet metal Do not use the vertical down technique on heavy metal The welds will not be strong enough 1 Use 1 8 3 2m or 3 32 2 5mm AWS 6011 2 On thin metal use 70 75 amps
67. se complete the form and submit your registration Read this Operators Manual completely before attempting to use this equipment Save this manual and keep it handy for quick reference Pay particular attention to the safety instructions we have provided for your protection The level of seriousness to be applied to each is explained below A WARNING This statement appears where the information must be followed exactly to avoid serious personal injury or loss of life A CAUTION This statement appears where the information must be followed to avoid minor personal injury or damage to this equipment MASTER TABLE OF CONTENTS FOR ALL SECTIONS Page Safety i iv DS tea Ath OM asics feces li A Section A Technical SpeclfICatloris 5 uo tam r Rx seu prey ark anma Eege a assent A 1 SEC Aa oil de ee et IS A 2 Location and Ventilation E A 2 Pre operation Engine SONICO cn eerta rr uc REX Ra EXE ERE Fra a ESAE ie A 3 Electrical Output Connections nennen RAYA ARAR rr nnn nnn A 5 Operation Me Section B ivit B 1 General Description EEN B 1 Recommended Applications tette ea dianas B 2 Operational Features and CGontrols EEN B 2 Design Features and aR pan apo EXE B 2 Welding Gapabllity 5 e toast sait eer En Serana
68. ssi 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 Les circuits l lectrode et la pi ce sont sous tension 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 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 principalement dans les positions assis ou couch pour lesquelles une grande partie du corps peut tre en contact avec la masse 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 Ne jamais toucher simultan ment les parties sous tension des porte lectrodes connect s deux machines soud er parce que la tension entre les deux pinces peut tre le total de la tension vide des deux machines Si on utilise la machine souder comme une source de courant pour soudage semi automatique ces precautions pour le porte lectrode s applicuent aussi au pistolet de soudage 2 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 soudage Utiliser des
69. st begins to run smoothly Then open the choke in small steps allowing the engine to accept small changes in speed and load until the choke is fully open in RUN During engine warm up the equip ment can be operated FOR A HOT ENGINE 1 Open the fuel shutoff valve 2 Place the choke lever in the RUN position Closing the choke of a hot engine will flood the carburetor and prevent starting 3 Pull slightly on the recoil starter handle until resis tance is felt 4 Pull the cord rapidly FOR BEST ENGINE STARTING e Always use fresh gasoline and be sure the filter is clean and properly maintained e f you use an alternate fuel tank or supply be sure to install an in line fuel filter e If the engine will not start see the TROU BLESHOOTING section of this or the engine owner s manual Do not pull the recoil starter with the choke in the CHOKE position more than one time Repeated pulls on a choked engine will flood the carburetor STOPPING THE ENGINE 1 Remove all welding and generator power loads and let the engine cool by running it for several minutes 2 Stop the engine by placing the ignition switch in the OFF position 3 Close the fuel shutoff valve A WARNING Close the fuel valve when the machine is trans ported to prevent fuel leakage from the carbure tor Drain the tank before transporting the machine in a vehicle For long periods of storage turn off
70. t distribute itself evenly To make it easier to get the 45 angle it is best to put the electrode in the holder at a 45 angle as shown Multiple Pass Welds Make multiple pass horizontal fillets as shown in the sketch Put the first bead in the corner with fairly high current Hold the electrode angle needed to deposit the filler beads as shown putting the final bead against the vertical plate D 5757777 VVelding in the Vertical Position VVelding in the vertical position can be done either vertical up or vertical dovvn Vertical up is used whenever a large strong weld is desired Vertical down is used primarily on sheet metal for fast low penetrating welds POWER ARC 4000 LINCOLN P B 16 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 molten metal is deposited gravity will pull it downwards and make it drip Therefore a certain technique has to be followed Short arc NOTE Holder end of electrode is lower than arc 1 Use 1 8 3 2mm 90 115 amps or 3 32 2 5mm 70 amps AWS 6011 2 When welding the electrode should be kept hori zontal or pointing slightly upwards See drawing above 3 The arc is struck and metal deposited at the bot tom of the two pieces to be welded together 4 Before too much molten metal is deposited the arc is SLOWLY moved 1 2 3 4 12 20mm upwards This take
71. t provides the electric cur rent used in the arc Figure 3 is a diagram of the weld ing circuit The circuit begins where the electrode cable is attached to the welding machine and ends where the work cable cable is attached to the machine Current flows through the electrode cable to the electrode holder through the electrode holder to the electrode and across the arc On the work side of the arc the current flows through base metal to the work cable and back to the welding machine The cir cuit must be complete for the current to flow To weld the work clamp must be tightly connected to clean base metal Remove paint rust etc as necessary to get a good connection Connect the work clamp as close as possible to the area you wish to weld Avoid allowing the welding circuit to pass through hinges bearings electronic components or similar devices that can be damaged POWER ARC 4000 LINCOLN P B 12 The Power Arc 4000 has a voltage output of up to 62 volts which can shock A WARNING ELECTRIC SHOCK can kill pen e Do not touch electrically live parts or electrode with skin or wet cloth ing Insulate yourself from work and ground Always wear dry insulating gloves ENGINE EXHAUST can kill a Use in open well ventilated areas GA or vent exhaust outside Do not stack anything on or near the engine MOVING PARTS can injure e Do not operate with doors open or guards off A Stop engine bef
72. tart Light in On Off switch will flash when engine is cranked Engines equipped with low oil shutdown pro tection only Choke left in full choke position and carburetor flooded Fuel line clogged or closed If all recommended possible areas of misadjustment have been Recoil start will not engage with checked and the problem persists engine Contact your local Lincoln Authorized Field Service Facility Fouled spark plug Engine requires service to head head gasket and or valves Float open in carburetor amp gas leak ing from bowl Engine operated with low oil level Engine is seized and recoil start will not move 44 CAUTION If for any reason you do not understand the test procedures or are unable to perform the tests repairs safely contact your Local Lincoln Authorized Field Service Facility for technical troubleshooting assistance before you proceed POWER ARC 4000 LINCOLN Jequunu epoo jueuudinbe ay SAID 8 e 104 esmas eui 0 AUM si urej6erp v j sjeued einsoj oue ey jo euo uo eui 091265 RS itt 434 MIA NMOHS ER S3HIM 3LIHM SLNANOdWOO LNOYS ASVO TIV 319V1d3038 1949 ALON qaduvosiq 9 SI 9 29718 G3TIVISNI di HOLIMS ALIHM VS NOLL93108d xovg 110 MOT 8102 CH ONIHIM 3NION3 lt NMOU8 0202 O 4 ea HOL
73. ted Away from areas where they may be struck or subjected to physical 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 P I 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 i SAFETY i PR CAUTIONS DE S RET 5 Toujours porter des lunettes de s curit dans la zone de Pour votre propre protection lire et observer toutes les instruc tions et les pr cautions de s rete specifiques qui parraissent dans ce manuel au
74. the Lincoln WELD DIRECTORY Publication M210 for a complete listing of all Lincoln stick electrodes available AWS American Welding Society POWER ARC 4000 LINCOLN P B 11 Semi automatic MIG Welding With a Lincoln Weld Pak 100 or Weld Pak 125 A WARNING ARC RAYS can burn When using an open arc process it is necessary to use correct eye head and body protection 14 Power Arc generator power be used to supply power to a Lincoln Weld Pak 100 or Weld Pak 125 wire feed welder The Weld Pak is equipped with all the supplies needed for Flux Cored Arc Welding FCAW and is available where Lincoln products are sold A K610 1 MIG Conversion Kit is also available for the Weld Pak which provides all the essentials needed for Gas Metal Arc Welding GMAW or MIG processes Contact your local authorized Lincoln representative for more details Stick Welding Stick welding is probably the most familiar welding process known A coated ELECTRODE the weld rod is clamped into an ELECTRODE HOLDER an insulated clamping device which in turn connects to the ELECTRODE CABLE a heavy wire The WORK the metal piece to be welded is connected to the WORK CABLE a heavy wire which contains the WORK CLAMP Quality Lincoln cables use many fine copper wires with a very flexible insulating covering for the electrode and work cables When properly con nected to the OUTPUT STUDS of a high current power source the elec
75. trode melts and bonds the metal being repaired Refer to Figure 3 to see the cir cuit See Cable Installation section for proper cable connection to a Povver Arc The Povver Arc provides excellent vveld output charac teristics vvhen used in combination vvith Lincoln AC electrodes Other AC electrodes may also be used Follovv the settings listed in Table 2 VVelding Application Chart and the Electrode Selection Guide found on the nameplate of the machine OPERATION Learning To Stick Weld The serviceability of a product or structure utiliz ing this type of information is and must be the sole responsibility of the builder user Many vari ables beyond the control of The Lincoln Electric Company affect the results obtained in applying this type of information These variables include but are not limited to welding procedure plate chemistry and temperature weldment design fab rication methods and service requirements No one can learn to weld simply by reading about it Skill comes only with practice The following pages will help the inexperienced welder understand welding and develop his skill For more detailed information order a copy of the book New Lessons in Arc Welding See Book Division section at rear of manual The operators knowledge of arc welding must go beyond the arc itself He must know how to control the arc and this requires a knowledge of the welding cir cuit and the equipment tha
76. ur 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 rays or to hot spatter or metal 3 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 prod ucts 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 understa
77. ve For Gasoline Engines ARC WELDING CAN BE HAZARDOUS PROTECT YOURSELF AND OTHERS FROM POSSIBLE SERIOUS INJURY OR DEATH KEEP CHILDREN AWAY PACEMAKER WEARERS SHOULD CONSULT WITH THEIR DOCTOR BEFORE OPERATING Read and understand the following safety highlights For additional safety information it is 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 PERFORMED ONLY BY QUALIFIED INDIVIDUALS A FOR ENGINE powered equipment 1 a Turn the engine off before troubleshooting and maintenance work unless the maintenance work requires it to be running 9 cm 1 h To avoid scalding do not remove the radiator pressure cap when the engine is hot 1 b Operate engines in open well ventilated areas or vent the engine exhaust fumes outdoors ELECTRIC AND 3 MAGNETIC FIELDS may be dangerous 1 c Do not add the fuel near an open flame welding arc or when the engine is running Stop the engine and allow it to cool before refueling to prevent spilled fuel from vaporiz ing on contact with hot engine part
78. wing the arc The arc melts the base metal and actually digs into it much like water through a garden hose nozzle digs into the earth The molten metal forms a pool or crater and tends to flow away from the arc As it moves away from the arc it cools and solidifies Slag forms on top of the weld to protect it during cooling Electrode FIGURE 4 The welding arc The function of the covered electrode is much more than simply to carry current to the arc The electrode is composed of a core metal wire around which has been extruded and baked a chemical covering The core wire melts into the arc and tiny droplets of molten metal shoot across the arc into the molten pool The electrode provides additional filler metal for the joint to fill the groove or gap between the two pieces of the base metal The covering also melts or burns in the arc It has several functions It makes the arc stead ier provides a shield of smoke like gas around the arc to keep oxygen and nitrogen in the air away from the molten metal and provides a flux for the molten pool The flux picks up impurities and forms a protective slag The principle differences between the various types of electrodes are in their coatings By varying the coating it is possible to greatly alter the operating characteristics of electrodes By understanding the differences in the various coatings you will gain a bet ter understanding of selecting the best electrode for the job you h

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