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Lincoln Electric POWER-ARC 4000 Operator's Manual

Welder and generator
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See also: Service Manual
POWER-ARC
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 MENU
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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Summary of Contents for Lincoln Electric POWER-ARC 4000

  • Page 1 POWER-ARC 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...

  • Page 2: Safety

    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: Installation

    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 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.
  • 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: Operation

    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: Generator Operation

    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 1,000 1,500 1,250 1,200 2,000 1,750 2,600 1,000 1,100 4,000 POWER-ARC 4000 *Start-up Watts 4,000 - 8,000 3,100 - 5,000 1,500 - 2,400 750 - 2,000 2,500 - 4,000 3,000 - 4,800 1,500 - 2,400 2,500 - 4,000 1,500 - 2,400...

  • 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 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 Size ® 3/32” ® 90 amps ® 1/8” ® 1/8” ® 1/8” POWER-ARC 4000 B-10 Setting 90 amps 70 amps 125 amps 90 amps 100 amps...
  • Page 26 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,...
  • 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: Accessories

    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: Maintenance

    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...
  • 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 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.
  • 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

    4. No open circuit voltage at output studs. Open lead in weld circuit. 5. Faulty reactor (L1). 6. Rheostat (R1) lead broke CAUTION POWER-ARC 4000 RECOMMENDED COURSE OF ACTION If all recommended possible areas of misadjustment have been checked and the problem persists, Contact your local Lincoln Authorized Field Service Facility.
  • Page 43 2. Engine requires service to head, car- buretor, filters, oil, spark plug and/or gas. 1. Bad gas, bad filter, air cleaner, spark plug, and/or breather. CAUTION POWER-ARC 4000 RECOMMENDED COURSE OF ACTION If all recommended possible areas of misadjustment have been checked and the problem persists, Contact your local Lincoln Authorized Field Service Facility.
  • Page 44 10. Engine operated with low oil level. Engine is seized and recoil start will not move. CAUTION POWER-ARC 4000 RECOMMENDED COURSE OF ACTION If all recommended possible areas of misadjustment have been checked and the problem persists, Contact your local Lincoln Authorized Field Service Facility.
  • 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 ● ● ● ● ● ● ● ● ● ●...
  • Page 51 ● ● ● ● ● ● ● ● ● ● ● ● ● ● ● ● ● ● Spanish ● PRECAUCION French ● ATTENTION ● German WARNUNG Portuguese ● ● Japanese Chinese Korean Arabic WARNING AVISO DE ATENÇÃO...
  • 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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