RETURN TO MAIN MENU POWER-ARC 4000 ™ For Machines with Code Number IM488-E February, 2004 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 thoughtful operation on your part.
i i SAFETY WARNING CALIFORNIA PROPOSITION 65 WARNINGS Diesel engine exhaust and some of its constituents are known to the State of California to cause cancer, birth defects, and other reproductive harm. The Above For Diesel Engines The engine exhaust from this product contains chemicals known to the State of California to cause cancer, birth defects, or other reproductive harm. The Above For Gasoline Engines ARC WELDING CAN BE HAZARDOUS.
ii ii SAFETY ARC RAYS can burn. 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.
iii iii SAFETY WELDING SPARKS can cause fire or explosion. 6.a. Remove fire hazards from the welding area. If this is not possible, cover them to prevent the welding sparks from starting a fire. Remember that welding sparks and hot materials from welding can easily go through small cracks and openings to adjacent areas. Avoid welding near hydraulic lines. Have a fire extinguisher readily available. 6.b.
iv iv SAFETY PRÉCAUTIONS DE SÛRETÉ Pour votre propre protection lire et observer toutes les instructions et les précautions de sûreté specifiques qui parraissent dans ce manuel aussi bien que les précautions de sûreté générales suivantes: Sûreté Pour Soudage A L’Arc 1. Protegez-vous contre la secousse électrique: a. Les circuits à l’électrode et à la piéce sont sous tension quand la machine à souder est en marche.
v v Thank You for selecting a QUALITY product by Lincoln Electric. We want you to take pride in operating this Lincoln Electric Company product ••• 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.
vi MASTER TABLE OF CONTENTS FOR ALL SECTIONS Page Safety.................................................................................................................................................i-iv Installation .............................................................................................................................Section A Technical Specifications .............................................................................................................A-1 Safety Precautions.
A-1 A-1 INSTALLATION TECHNICAL SPECIFICATIONS - POWER-ARC 4000 INPUT - BRIGGS KOOL-BORE® GASOLINE ENGINE Manufacturer Description Briggs & Stratton KoolBore® Plus 1 cyl., 4 cycle air-cooled gasoline 8 HP @ 3750 RPM Speed Displacement Ignition Capacities 3700 RPM ± 50 RPM at no load 19.4 cu. in. (319 cc) Manual, Recoil start; Manual choke Fuel: 1.0 gal. (3.8 l) Oil: 1.4 qt. (1.3 l) INPUT - BRIGGS VANGUARD® GASOLINE ENGINE Briggs & Stratton Vanguard® Model 185432 1 cyl.
A-2 INSTALLATION Read this entire installation section before you start installation. SAFETY PRECAUTIONS WARNING Do not attempt to use this equipment until you have thoroughly read all the operation and maintenance manuals supplied with your machine. They include important safety precautions; detailed engine starting, operating, and maintenance instructions; and parts lists. ELECTRIC SHOCK can kill. • Do not touch electrically live parts or electrodes with your skin or wet clothing.
A-3 INSTALLATION A-3 STACKING OIL POWER-ARC 4000 machines CANNOT be stacked. The Power-Arc 4000 with the Briggs and Stratton 8 HP engine produced after August 1998 and the Power-Arc 4000 with the Honda 9 HP engine are supplied with low oil shutdown protection. The PowerArc 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.
A-4 A-4 INSTALLATION Power-Arc 4000 Typical Fuel Consumption B&S 8 HP Carb. Certified Kool Bore® Plus No Load 3700 RPM ±50 R.P.M. AC CC Weld Output 125 Amps @ 18 Volts AC CC Weld Output 100 Amps @ 25 Volts Auxiliary Power 4000 Watts (120/240 Volts) 0.36 Gallons/Hour (1.37 Liters/Hour) 0.69 Gallons/Hour (2.63 Liters/Hour) 0.64 Gallons/Hour (2.41 Liters/Hour) 0.77 Gallons/Hour (2.92 Liters/Hour) B&S 9 HP Vanguard® Honda 9 HP Carb. Certified 0.33 Gallons/Hour (1.25 Liters/Hour) 0.76 Gallons/Hour (2.
A-5 A-5 INSTALLATION FIGURE A.1 - POWER-ARC 4000 OUTPUT CONNECTIONS 1 70 AMPS POWER ARC 4000 80 AMPS 125 90 AMPS GENERATOR AMPS 100 AMPS WARNING 6 ELECTRODE SELECTION GUIDE 5 3 4 2 1. CURRENT CONTROL DIAL 2. WELD OUTPUT TERMINALS (2) 3. GROUND STUD 4. CIRCUIT BREAKERS (2) - 20 AMP 5. RECEPTACLE - 240 VOLT, 20 AMP 6. DUPLEX RECEPTACLE - 120 VOLT, 20 AMP ELECTRICAL OUTPUT CONNECTIONS TABLE A.1 RECOMMENDED WELDING CABLE SIZE AND LENGTH See Figure A.
A-6 A-6 INSTALLATION Cable Installation WARNING Install the welding cables to your POWER-ARC 4000 as follows. See Figure A.1 for the location of parts. 1. The gasoline engine must be OFF to install welding cables. 2. Remove the 1/2 - 13 flanged nuts from the output terminals. 3. Connect the electrode holder and work cables to the weld output terminals. You can connect either cable to either terminal, since the POWERARC 4000 provides AC weld current.
A-7 A-7 INSTALLATION PREMISES WIRING CIRCUIT BREAKERS The POWER-ARC 4000 three-wire, grounded neutral generator allows it to be connected to premises wiring. However, the wiring procedure needed to meet the National Electric Code (NEC) regulations as well as city ordinances 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 temporary to the premises.
A-8 A-8 INSTALLATION CAUTION Certain Electrical devices cannot be powered by the POWER-ARC 4000. See Table A.2. TABLE A.2 ELECTRICAL DEVICE USE WITH THE POWER-ARC 4000. Type Common Electrical Devices Possible Concerns Resistive Heaters, toasters, incandescent light bulbs, electric range, hot pan, skillet, coffee maker. NONE Capacitive TV sets, radios, microwaves, appliances with electrical control. Voltage spikes or high voltage regulation can cause the capacitative elements to fail.
B-1 B-1 OPERATION OPERATING INSTRUCTIONS WARNING Read and understand this entire section before operating your POWER-ARC 4000. ARC RAYS can burn. SAFETY INSTRUCTIONS • Wear eye, ear, and body protection. WARNING Do not attempt to use this equipment until you have thoroughly read all the operation and maintenance manuals supplied with your machine. They include important safety precautions; detailed engine starting, operating, and maintenance instructions; and parts lists. ENGINE EXHAUST can kill.
B-2 OPERATION 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 manufacturer’s warranty policy. RECOMMENDED APPLICATIONS B-2 • 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.
B-3 B-3 OPERATION CONTROLS AND SETTINGS All generator/welder controls are located on the Output Control Panel. Gasoline engine controls are mounted on the engine. See Figures B.1 and B.2 and the explanations that follow. FIGURE B.1 – OUTPUT PANEL CONTROLS 1 70 AMPS POWER ARC 4000 80 AMPS 125 90 AMPS GENERATOR AMPS 100 AMPS WARNING 8 2 ELECTRODE SELECTION GUIDE 7 3 1. 2. 3. 4. 5. 6. 7. 8.
B-4 OPERATION 5. GROUND STUD: Provides a connection point for connecting the machine case to earth ground for the safest grounding procedure. 6. 20 AMP CIRCUIT BREAKERS (2): Provide separate overload current protection for the 120 volt and 240 volt receptacles. 7. 20 AMP, 240 VOLT RECEPTACLE: Connection point for supplying 240 volt power to operate one electrical device. 8. 20 AMP, 120 VOLT DUPLEX RECEPTACLE: Connection point for supplying 120 volt power to operate one or two electrical devices.
B-5 OPERATION ENGINE OPERATION B-5 BEFORE STARTING THE ENGINE CHECK AND FILL THE ENGINE OIL LEVEL: 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. 1. Place the machine on a level surface. 2. Open the oil fill plug. 3.
B-6 B-6 OPERATION 4. Pull the cord rapidly. STOPPING THE ENGINE 5. If the engine does not start, open the choke slightly and pull the starter cord rapidly again. 1. Remove all welding and generator power loads and let the engine cool by running it for several minutes. 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.
B-7 OPERATION GENERATOR OPERATION B-7 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). CAUTION Be sure that any electrical equipment plugged into the generator’s AC power receptacles can withstand a ±10% voltage and a ±4% frequency variation. Some electronic devices cannot be powered by the POWER-ARC 4000. Refer to Table A.
B-8 B-8 OPERATION TABLE B.
B-9 B-9 OPERATION WELDING OPERATION 3. Attach the work clamp securely to the work you are welding. GENERAL INFORMATION 4. Insert the electrode into the electrode holder. 5. Set the current control dial to the desired output current. WARNING Do not touch electrically live parts or electrodes with your skin or wet clothing. Do not breathe welding fumes or gases. Use ventilation or exhaust to remove welding fumes from the breathing area. 6. Start the gasoline engine.
B-10 B-10 OPERATION WELDING GUIDELINES TABLE B.4 WELDING APPLICATIONS/ELECTRODE SELECTION GUIDE Material Thickness Electrode Type Size Setting 1/8” and thinner FLEETWELD 37 AWS E6013 FLEETWELD® 180 AWS E6011 Lincoln 7018 AC AWS E7018 3/32” 90 amps ® 1 70 amps 90 amps 3/16” Maximum FLEETWELD® 37 AWS E6013 1/8” 125 amps 5/16” Maximum FLEETWELD® 180 AWS E6011 1/8” 90 amps Any Thickness WEARSHIELD® ABR 1/8” 100 amps NOTES: The values listed are suggested settings.
B-11 OPERATION Semi-automatic, MIG Welding With a Lincoln Weld Pak 100 or Weld Pak 125 WARNING ARC RAYS can burn. • When using an open arc process, it is necessary to use correct eye, head and body protection. The Power-Arc generator power can 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.
B-12 B-12 OPERATION The Power-Arc 4000 has a voltage output of up to 62 volts which can shock. WARNING ELECTRIC SHOCK can kill. • Do not touch electrically live parts or electrode with skin or wet clothing. • Insulate yourself from work and ground. 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 viewing the arc.
B-13 B-13 OPERATION 1. The Correct Welding Position 3. The Correct Arc Length Illustrated is the correct welding position for right-handed people. (For left-handed people it is opposite.) The arc length is the distance from the tip of the electrode core wire to the base metal. Whenever possible, weld from left to right (if righthanded). This enables you to see clearly what you are doing. Hold the electrode at a slight angle as shown in Figure 5.
B-14 B-14 OPERATION 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.
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. 20° end view B-15 OPERATION 90° side view 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 not distribute itself evenly.
B-16 B-16 OPERATION 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: Long arc 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.
B-17 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. Overhead Welding Various techniques are used for overhead welding. However, in the interest of simplicity for the inexperienced welder, the following technique will probably take care of his needs for overhead welding: 5.
B-18 OPERATION 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.) Work Table Strike Arc Here Brick Sharp Edge 1/2-3/4" width (12-20mm) Weaving Motion Plow Share Positioning of Share 5. Use the back-stepping method. Begin to weld 3” (76mm) from the heel of the share and weld to the heel.
B-19 B-19 OPERATION In some instances a back-up strip may be used and plates may be gapped 1/8” (3.2mm) or more, as shown in figure (b). (a) (b) High-Speed Group (AWS E6013) This group includes electrodes which have a moderately forceful arc and deposit rates between those of the out-of-position and high-deposit electrodes. Scrap steel back-up strip (c) Three ways to prepare plates where complete penetration is necessary.
C-1 ACCESSORIES OPTIONS/ACCESSORIES C-1 BRIGGS AND STRATTON ACCESSORIES (FOR THE 8 HP KOOL BORE ENGINE ONLY) LINCOLN ELECTRIC ACCESSORIES The following options/accessories are available for your POWER-ARC 4000 from your local Lincoln Distributor. The following options/accessories are available for your POWER-ARC 4000 from your local Briggs & Stratton Distributor. Check with the distributor for availability of options/accessories for the 9 HP Vanguard engine.
D-1 D-1 MAINTENANCE SAFETY PRECAUTIONS 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 perform maintenance and replace them when the maintenance requiring their removal is complete. OIL: Check the oil level after every 5 hours of operation or daily. BE SURE TO MAINTAIN THE OIL LEVEL. Change the oil the first time after 5 hours of operation.
D-2 D-2 MAINTENANCE CAUTION Do not use petroleum solvents such as kerosene to clean the air cleaner. They may cause deterioration of the air cleaner. DO NOT OIL THE AIR CLEANER OR USE PRESSURIZED AIR TO CLEAN OR DRY THE AIR CLEANER. CLEAN COOLING SYSTEM: See Figure D.3. Clean the internal cooling fins and surfaces to prevent overspeeding, overheating, and engine damage. Clean every 100 operating hours or as often as necessary. 1 To service the pre-cleaner: 1. Wash in liquid detergent and water. 2.
D-3 D-3 MAINTENANCE TABLE D.1 ENGINE MAINTENANCE PARTS Part B&S 8 HP Kool Bore Part # B&S 9 HP Vanguard Part # Honda Part # SPARK PLUG B&S 802592 B&S 491055 NGK BPR6ES CHAMPION RJ19LM CHAMPION RC12YC DENSO W20EPR-U (RESISTOR) AUTOLITE 3924 FUEL FILTER B&S 394358 AIR CLEANER PANEL B&S 494511 NONE NONE B&S 710266 5266721 (17210-ZE2-505) B&S 710268 2538429 (17218-ZE2-821) (Pleated Paper) AIR PRE-CLEANER (AS NEEDED) B&S 492889 (CAN BE CLEANED AND REUSED AS NEEDED) Refer to Table D.
D-4 MAINTENANCE 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.
D-5 D-5 MAINTENANCE FIGURE D.6. - MAJOR COMPONENT LOCATIONS 7 6 5 8 1 3 4 2 1 . CRADLE ASSEMBLY 2. ROTOR, BLOWER, AND BEARING ASSEMBLY 3. STATOR ASSEMBLY 4. BRUSH AND BRUSH HOLDER ASSEMBLY 5. CONTROL BOX WELDED ASSEMBLY 6. REACTOR ASSEMBLY 7. OUTPUT TERMINAL ASSEMBLY 8.
E-1 TROUBLESHOOTING E-1 HOW TO USE TROUBLESHOOTING GUIDE WARNING Service and Repair should only be performed by Lincoln Electric Factory Trained Personnel. Unauthorized repairs performed on this equipment may result in danger to the technician and machine operator and will invalidate your factory warranty. For your safety and to avoid Electrical Shock, please observe all safety notes and precautions detailed throughout this manual.
E-2 E-2 TROUBLESHOOTING Observe all Safety Guidelines detailed throughout this manual PROBLEMS (SYMPTOMS) POSSIBLE AREAS OF MISADJUSTMENT(S) No generator power or welding output. 1. Disconnect anything plugged into auxiliary receptacles and weld loads. RECOMMENDED COURSE OF ACTION PROBLEMS 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.
E-3 E-3 TROUBLESHOOTING Observe all Safety Guidelines detailed throughout this manual PROBLEMS (SYMPTOMS) POSSIBLE AREAS OF MISADJUSTMENT(S) RECOMMENDED COURSE OF ACTION PROBLEMS Unit will weld but low or no generator power is available. 1. Circuit breaker open. 2. Loose or open connection with electrical plug-in component. 3. Current control dial not at “125”. 4. No open circuit voltage at receptacle. Open lead in receptacle circuit. 5. No open circuit voltage at receptacle. Bad receptacle. 6.
E-4 E-4 TROUBLESHOOTING Observe all Safety Guidelines detailed throughout this manual PROBLEMS (SYMPTOMS) POSSIBLE AREAS OF MISADJUSTMENT(S) RECOMMENDED COURSE OF ACTION PROBLEMS Engine will not start. 1. Spark plug boot or wire off, loose or wet. 2. Fuel shutoff valve is closed. 3. Low oil and engine low oil shutdown protection will not allow unit to start. Light in On-Off switch will flash when engine is cranked. (Engines equipped with low oil shutdown protection only). 4.
GNDC GNDC GREEN POWER-ARC 4000 6B 3C BLACK 6C BLACK 5A 5 5B 3 5A WHITE WHITE 5 STATOR ELECTRICAL 20A 3B BLACK CB1 3A 3 7 1 PER E1537. SYMBOLS 7A 4 201B BLACK 9 9A ROTOR 201A BLACK (-) (+) RED 202A 200 RED 200A CCW WHITE WIRES GREEN 6C BLACK MAG D1 5B 5A WHITE LINE HOT LINE (IF INSTALLED) (-) (+) (+) SWITCH RUN/STOP & DISCARDED 3C IS REMOVED OPTION RED 202 202C BROWN D2 BLACK WIRE 7A GFCI RECEPTACLE SWITCH PROTECTION LOW OIL 9A 3.
POWER-ARC 4000 GNDB GREEN 6A 6 6B YELLOW 5 5B 3 20A 3B BLACK CB1 3A 3 7 1 7A 4 9A 201B BLACK 9 ROTOR ELECTRICAL SYMBOLS PER E1537.
R 530 mm 20.88 REF. POWER-ARC 4000 14.16 360 mm 7.92 201 mm REF. 762 mm 508 mm REF. 30.00 REF. POWER ARC 4000 20.00 REF.
NOTES POWER-ARC 4000
NOTES POWER-ARC 4000
● Do not touch electrically live parts or WARNING Spanish AVISO DE PRECAUCION French ATTENTION German WARNUNG Portuguese ATENÇÃO ● Keep flammable materials away. ● Wear eye, ear and body protection. ● Mantenga el material combustible ● Protéjase los ojos, los oídos y el 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 mojada. ● Aislese del trabajo y de la tierra.
● Keep your head out of fumes. ● Use ventilation or exhaust to ● Turn power off before servicing. ● Do not operate with panel open or guards off. remove fumes from breathing zone. ● Los humos fuera de la zona de res- piración. ● Mantenga la cabeza fuera de los humos. Utilice ventilación o aspiración para gases. ● Gardez la tête à l’écart des fumées. ● Utilisez un ventilateur ou un aspira- ● Desconectar el cable de ali- mentación de poder de la máquina antes de iniciar cualquier servicio.
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