Lincoln Electric POWER-ARC 4000 Operator's Manual
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Lincoln Electric POWER-ARC 4000 Operator's Manual

Lincoln electric power-arc 4000 operator's manual
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See also: Service Manual
For Machines with Code Number
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
MANUAL AND THE SAFETY
PRECAUTIONS CONTAINED
THROUGHOUT. And, most
importantly, think before you act
and be careful.
ISO 9001
ANSI RAB
QMS
Designed and Manufactured Under a
Quality Program Certified by
ABS Quality Evaluations, Inc.
to ISO 9001 Requirements.
CERTIFICATE NUMBER: 30273
• Sales and Service through Subsidiaries and Distributors Worldwide •
Cleveland, Ohio 44117-1199 U.S.A. TEL: 216.481.8100 FAX: 216.486.1751 WEB SITE: www.lincolnelectric.com
RETURN TO MAIN INDEX
10083, 10179, 10200, 10211, 10202, 10243, 10244, 10585, 10667,
10671, 10672, 10673, and 10866
THIS
Various engine configurations are available and machine appearance will vary
accordingly.
OPERATOR'S MANUAL
• World's Leader in Welding and Cutting Products •
™
4000
Copyright © 2004 Lincoln Global Inc.
IM488-E
February, 2004

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  • Page 1 RETURN TO MAIN INDEX ™ 4000 10083, 10179, 10200, 10211, 10202, 10243, 10244, 10585, 10667, 10671, 10672, 10673, and 10866 Various engine configurations are available and machine appearance will vary accordingly. Copyright © 2004 Lincoln Global Inc. IM488-E February, 2004...

  • Page 2: California Proposition 65 Warnings

    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.
  • Page 3 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.
  • Page 4 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.
  • Page 5 PRÉCAUTIONS DE SÛRETÉ Pour votre propre protection lire et observer toutes les instruc- tions et les précautions de sûreté specifiques qui parraissent dans ce manuel aussi bien que les précautions de sûreté générales suivantes: Sûreté Pour Soudage A L’Arc 1. Protegez-vous contre la secousse électrique: a.
  • Page 6 The code number is especially important when identifying the correct replacement parts. - 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.

  • Page 7: Table Of Contents

    Safety Precautions ...D-1 Routine and Periodic Maintenance ...D-1 General Assembly Exploded View ...D-6 Troubleshooting and Repair ...Section E Electrical Diagrams...Section F Parts Manual (B&S 8 HP & Honda Engines)...P233 Series Parts Manual (B&S 9 HP Vanguard Engine)...P352 Series POWER-ARC 4000 Page...

  • Page 8: Technical Specifications

    TECHNICAL SPECIFICATIONS - POWER-ARC 4000 INPUT - BRIGGS KOOL-BORE® GASOLINE ENGINE Manufacturer Description Briggs & 1 cyl., Stratton Kool- 4 cycle Bore ® Plus air-cooled gasoline 8 HP @ 3750 RPM INPUT - BRIGGS VANGUARD® GASOLINE ENGINE Briggs & 1 cyl.,...

  • Page 9: Safety Precautions

    Only qualified personnel should install, use, or service this equipment. INSTALLATION 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.

  • Page 10: Pre-Operation Engine Service

    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 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"®...
  • Page 11 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.

  • Page 12: Electrical Output Connections

    FIGURE A.1 - POWER-ARC 4000 OUTPUT CONNECTIONS WARNING ELECTRODE SELECTION GUIDE 1. CURRENT CONTROL DIAL 2. WELD OUTPUT TERMINALS (2) 3. GROUND STUD ELECTRICAL OUTPUT CONNECTIONS See Figure A.1 for the location of the current control dial, weld output terminals, ground stud, circuit breakers, 240 and 120 volt receptacles.
  • Page 13 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.
  • Page 14 POWER-ARC 4000. Refer to Table A.2 for these devices. INSTALLATION CIRCUIT BREAKERS The POWER-ARC 4000 has its own 20 amp circuit breakers for overload protection. When the machine is operated in high temperature environments, the breakers may tend to trip at lower loads than normal- Never bypass the circuit breakers.
  • Page 15 ELECTRICAL DEVICE USE WITH THE POWER-ARC 4000. Type Resistive Capacitive Inductive Capacitive/Inductive The Lincoln Electric Company is not responsible for any damage to electrical components improperly connect- ed to the POWER-ARC 4000. INSTALLATION CAUTION TABLE A.2 Common Electrical Devices Heaters, toasters, incandescent light bulbs, electric range, hot pan, skillet, coffee maker.

  • Page 16: Safety Instructions

    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.

  • Page 17: Recommended Applications

    Gard® kit is available from Briggs & 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.

  • Page 18: Controls And Settings

    4. WELD OUTPUT TERMINAL (TO WORK) WITH 1/2 - 13 FLANGE NUT: Provides the connection point for either the electrode holder or the work cable. (Because the POWER-ARC 4000 is an AC output machine, either output terminal can be used for either cable.)
  • Page 19 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. 2. FUEL TANK AND CAP: See TECHNICAL SPECI- FICATIONS for capacity.

  • Page 20: Engine Operation

    WARNING DO NOT RUN THE ENGINE AT EXCESSIVE SPEEDS. The maximum allowable high idle speed for the POWER-ARC 4000 is 3750 RPM, no load. Do NOT adjust the governor screw on the engine. Severe personal injury and damage to the machine can result if it is operated at speeds above the maximum rated speed.
  • Page 21 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.
  • Page 22 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.
  • Page 23 *Submersible Pump - 1 HP *Sump Pump Toaster Weed Trimmer Lincoln 100 or 125 Amp Wire Feeder/Welder 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.

  • Page 24: Welding Operation

    3. Remove the work clamp from the work. 4. Remove any remaining piece of electrode from the electrode holder. 5. If you are finished using the POWER-ARC 4000 for welding, disconnect the welding cables from the weld output terminals. Reattach the flange nuts and leave them on the terminals.
  • Page 25 Beginners should use Lincoln E7018 AC. For electrodes not listed, follow tables that are packed with the electrodes. Ask for the Lincoln WELD DIRECTORY (Publication M210) for a complete listing of all Lincoln stick electrodes available. AWS = American Welding Society OPERATION TABLE B.4...
  • Page 26 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.
  • Page 27 B-12 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 cloth- ing. • Insulate yourself from work and ground.
  • Page 28 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 B-13 Molten puddle...
  • Page 29 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). POWER-ARC 4000 B-14 Lap Weld Corner Weld...
  • Page 30 Welding in the Vertical Position Welding in the vertical position can be done either vertical-up or vertical-down. 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 B-15 45° 45°...
  • Page 31 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 B-16 Very short...
  • Page 32 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 B-17...
  • Page 33 “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 B-18 When breaking the weld stays on...
  • Page 34 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. POWER-ARC 4000 B-19 Motions START SIDE...
  • Page 35 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 & Stratton Distributor. Check with the distributor for availability of options/accessories for the 9 HP Vanguard engine.

  • Page 36: Routine And Periodic Maintenance

    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 WARNING...
  • Page 37 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.
  • Page 38 TABLE D.1 B&S 9 HP Vanguard Part # B&S 491055 CHAMPION RC12YC AUTOLITE 3924 NONE B&S 710266 B&S 710268 (CAN BE CLEANED AND REUSED AS NEEDED) POWER-ARC 4000 Honda Part # NGK BPR6ES DENSO W20EPR-U NONE 5266721 (17210-ZE2-505) 2538429 (17218-ZE2-821)
  • Page 39 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.
  • Page 40 FIGURE D.6. - MAJOR COMPONENT LOCATIONS 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. OUTPUT PANEL ASSEMBLY POWER-ARC 4000...

  • Page 41: How To Use Troubleshooting Guide

    HOW TO USE TROUBLESHOOTING GUIDE 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.

  • Page 42: Troubleshooting

    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. TROUBLESHOOTING POSSIBLE AREAS OF...
  • Page 43 Engine sputters but will not start. 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. TROUBLESHOOTING...
  • Page 44 Engine will not start. 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. TROUBLESHOOTING POSSIBLE AREAS OF...
  • Page 45 DIAGRAMS POWER-ARC 4000...
  • Page 46 DIAGRAMS POWER-ARC 4000...
  • Page 47 DIAGRAMS POWER-ARC 4000...
  • Page 48 NOTES POWER-ARC 4000...
  • Page 49 NOTES POWER-ARC 4000...
  • Page 50 WARNING Spanish AVISO DE PRECAUCION French ATTENTION German WARNUNG Portuguese ATENÇÃO Japanese Chinese Korean Arabic READ AND UNDERSTAND THE MANUFACTURER’S INSTRUCTION FOR THIS EQUIPMENT AND THE CONSUMABLES TO BE USED AND FOLLOW YOUR EMPLOYER’S SAFETY PRACTICES. 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.
  • Page 51 Keep your head out of fumes. Turn power off before servicing. Use ventilation or exhaust to remove fumes from breathing zone. Los humos fuera de la zona de res- Desconectar el cable de ali- piración. mentación de poder de la máquina Mantenga la cabeza fuera de los antes de iniciar cualquier servicio.
  • Page 52 • World's Leader in Welding and Cutting Products • • Sales and Service through Subsidiaries and Distributors Worldwide • Cleveland, Ohio 44117-1199 U.S.A. TEL: 216.481.8100 FAX: 216.486.1751 WEB SITE: www.lincolnelectric.com...

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