Page 2 - SAFETY; WARNING; CALIFORNIA PROPOSITION 65 WARNINGS; The Above For Diesel Engines
FOR ENGINEpowered equipment. 1.a. Turn the engine off before troubleshooting and maintenance work unless the maintenance work requires it to be running. ____________________________________________________ 1.b. Operate engines in open, well-ventilated areas or vent the engine exhaust fumes outdoors....
Page 3 - ii
ii SAFETY ii ARC RAYS can burn. 4.a. Use a shield with the proper filter and cover plates to protect your eyes from sparks andthe rays of the arc when welding or observingopen arc welding. Headshield and filter lensshould conform to ANSI Z87. I standards. 4.b. Use suitable clothing made from durable...
Page 4 - iii
FOR ELECTRICALLYpowered equipment. 8.a. Turn off input power using the disconnect switch at the fuse box before working onthe equipment. 8.b. Install equipment in accordance with the U.S. National Electrical Code, all local codes and the manufacturer’srecommendations. 8.c. Ground the equipment in ac...
Page 5 - iv; PRÉCAUTIONS DE SÛRETÉ
iv SAFETY iv Mar. ‘93 PRÉCAUTIONS DE SÛRETÉ Pour votre propre protection lire et observer toutes les instruc- tions et les précautions de sûreté specifiques qui parraissent d a n s c e m a n u e l a u s s i b i e n q u e l e s p r é c a u t i o n s d e s û r e t é générales suivantes: Sûreté Pour So...
Page 6 - Thank You; Please Examine Carton and Equipment For Damage Immediately
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! Read this Operators Manual completely before attempting to use this equipment. Save this manual...
Page 7 - Page; MASTER TABLE OF CONTENTS FOR ALL SECTIONS
Page Safety .................................................................................................................................................i-iv Installation ................................................................................................................................
Page 8 - TECHNICAL SPECIFICATIONS - POWER-ARC 4000; INSTALLATION
TECHNICAL SPECIFICATIONS - POWER-ARC 4000 INPUT - BRIGGS KOOL-BORE® GASOLINE ENGINE Manufacturer Description Speed Displacement Ignition Capacities Briggs & 1 cyl., 3700 RPM 19.4 cu. in. Manual, Fuel: 1.0 gal. (3.8 l) Stratton Kool- 4 cycle ± 50 RPM (319 cc) Recoil Bore ® Plus air-cooled at no l...
Page 9 - SAFETY PRECAUTIONS; ELECTRIC SHOCK can kill.; LOCATION AND VENTILATION; STORING
A-2 INSTALLATION POWER-ARC 4000 A-2 Read this entire installation section before youstart installation. SAFETY PRECAUTIONS Do not attempt to use this equipment until youhave thoroughly read all the operation and main-tenance manuals supplied with your machine.T h e y i n c l u d e i m p o r t a n t ...
Page 10 - POWER-ARC 4000 machines CANNOT be stacked.; PRE-OPERATION ENGINE SERVICE; equipped with
A-3 INSTALLATION POWER-ARC 4000 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 onother than the ground must be firm, non-skid, andstructurally sound. The gasoline engine is desig...
Page 11 - MUFFLER DEFLECTOR; To install the deflector, do the following:; SPARK ARRESTER; ACCESSORIES; ual for more information.; e n g i n e i s a v a i l a b l e a s a L i n c o l n f i e l d -; CAUTION; Kool Bore® Plus; Power-Arc 4000 Typical Fuel Consumption
A-4 INSTALLATION POWER-ARC 4000 A-4 MUFFLER DEFLECTOR The POWER-ARC 4000, depending on model, may ormay not be shipped with an exhaust deflector. If your e c e i v e d o n e , y o u c a n m o u n t i t o n t h e g a s o l i n eengine if your needs so require. To install the deflector, do the followi...
Page 12 - WELDING CABLE CONNECTIONS; Cable Size and Length
A-5 INSTALLATION POWER-ARC 4000 A-5 ELECTRICAL OUTPUT CONNECTIONS See Figure A.1 for the location of the current controld i a l , w e l d o u t p u t t e r m i n a l s , g r o u n d s t u d , c i r c u i tbreakers, 240 and 120 volt receptacles. WELDING CABLE CONNECTIONS Cable Size and Length Be sure...
Page 13 - Cable Installation; Tighten the flanged nuts securely.; • Loose connections will cause the output termi-; section of this manual for more infor-; MACHINE GROUNDING; section of this; AUXILIARY POWER RECEPTACLES; cle
A-6 INSTALLATION POWER-ARC 4000 A-6 Cable Installation Install the welding cables to your POWER-ARC 4000as 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 outputterminals. 3. Connect the el...
Page 14 - PREMISES WIRING; • The premises is isolated and no feed backing; s e c t i o n o f t h i s m a n u a l a n d t h e; CIRCUIT BREAKERS
A-7 INSTALLATION POWER-ARC 4000 A-7 PREMISES WIRING The POWER-ARC 4000 three-wire, grounded neutralg e n e r a t o r a l l o w s i t t o b e c o n n e c t e d t o p r e m i s e swiring. However, the wiring procedure needed tomeet the National Electric Code (NEC) regulations aswell as city ordinances...
Page 15 - ELECTRICAL DEVICE USE WITH THE POWER-ARC 4000.
A-8 INSTALLATION POWER-ARC 4000 A-8 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, electri...
Page 16 - OPERATION; OPERATING INSTRUCTIONS; GENERAL DESCRIPTION
B-1 OPERATION B-1 OPERATING INSTRUCTIONS Read and understand this entire section before oper-ating your POWER-ARC 4000. SAFETY INSTRUCTIONS Do not attempt to use this equipment until youhave thoroughly read all the operation and main-tenance manuals supplied with your machine.T h e y i n c l u d e i...
Page 17 - RECOMMENDED APPLICATIONS; GENERATOR; WELDING CAPABILITY
B-2 OPERATION B-2 The Lincoln warranty covers the Power Arc 4000(excluding the engine) for 2 years from the date ofpurchase. The engine is covered by the engine manu-facturer’s warranty policy. RECOMMENDED APPLICATIONS GENERATOR The POWER-ARC 4000 gives AC generator output formedium use, non-commerc...
Page 18 - CONTROLS AND SETTINGS; GENERATOR/WELDER CONTROLS; FIGURE B.1 – OUTPUT PANEL CONTROLS
B-3 OPERATION B-3 CONTROLS AND SETTINGS A l l g e n e r a t o r / w e l d e r c o n t r o l s a r e l o c a t e d o n t h eOutput Control Panel. Gasoline engine controls aremounted on the engine. See Figures B.1 and B.2 andthe explanations that follow. GENERATOR/WELDER CONTROLS See Figure B.1 for th...
Page 19 - GASOLINE ENGINE CONTROLS; S P A R K
B-4 OPERATION B-4 5. GROUND STUD: Provides a connection point forconnecting the machine case to earth ground forthe safest grounding procedure. 6. 20 AMP CIRCUIT BREAKERS (2): Provide sepa-rate overload current protection for the 120 voltand 240 volt receptacles. 7. 20 AMP, 240 VOLT RECEPTACLE: Conn...
Page 20 - ENGINE OPERATION; O p e r a t i n g a n d; BEFORE STARTING THE ENGINE; CHECK AND FILL THE ENGINE OIL LEVEL:; STARTING THE ENGINE
B-5 OPERATION B-5 ENGINE OPERATION D O N O T R U N T H E E N G I N E A T E X C E S S I V ESPEEDS. The maximum allowable high idle speedfor the POWER-ARC 4000 is 3750 RPM, no load.Do NOT adjust the governor screw on the engine.S e v e r e p e r s o n a l i n j u r y a n d d a m a g e t o t h emachine...
Page 21 - FOR BEST ENGINE STARTING:; STOPPING THE ENGINE
B-6 OPERATION B-6 4. Pull the cord rapidly. 5. I f t h e e n g i n e d o e s n o t s t a r t , o p e n t h e c h o k eslightly and pull the starter cord rapidly again. When the engine starts, gradually open the choketo the “RUN” position. To open the choke fullyrequires an engine warm-up period of s...
Page 22 - GENERATOR OPERATION; GENERAL INFORMATION; Start the gasoline engine. See; TION; in this section of the manual and the engine
B-7 OPERATION B-7 GENERATOR OPERATION Be sure that any electrical equipment plugged intothe generator’s AC power receptacles can with-stand a ±10% voltage and a ±4% frequency varia-tion. Some electronic devices cannot be poweredby the POWER-ARC 4000. Refer to Table A.2,ELECTRICAL DEVICE USE WITH THE...
Page 24 - WELDING OPERATION; Do not breathe welding fumes or gases.; Welding current is continuously variable
B-9 OPERATION B-9 WELDING OPERATION GENERAL INFORMATION Do not touch electrically live parts orelectrodes with your skin or wet cloth-ing. Do not breathe welding fumes or gases. Use ventilation or exhaust to removewelding fumes from the breathing area. Keep flammable material away. Wear eye, ear, an...
Page 25 - WELDING APPLICATIONS/ELECTRODE SELECTION GUIDE; WELDING GUIDELINES
B-10 OPERATION B-10 POWER-ARC 4000 TABLE B.4 WELDING APPLICATIONS/ELECTRODE SELECTION GUIDE Material Thickness Electrode Type Size Setting 1/8” and thinner FLEETWELD ® 37 3/32” 90 amps 1 AWS E6013 FLEETWELD ® 180 70 amps AWS E6011Lincoln 7018 AC 90 amps AWS E7018 3/16” Maximum FLEETWELD ® 37 1/8” 12...
Page 26 - • When using an open arc process,
B-11 OPERATION B-11 POWER-ARC 4000 Stick welding is probably the most familiar weldingprocess known. A coated ELECTRODE, the weldrod, is clamped into an ELECTRODE HOLDER, aninsulated clamping device, which in turn connects tothe ELECTRODE CABLE, a heavy wire. The WORK,the metal piece to be welded, i...
Page 27 - What Happens in the Arc?
B-12 OPERATION B-12 POWER-ARC 4000 The Power-Arc 4000 has a voltage output of up to 62volts which can shock. The electric arc is made between the work and the tipend of a small metal wire, the electrode, which isclamped in a holder that is held by the welder. A gapis made in the welding circuit (see...
Page 28 - The Correct Welding Position; Figure 5; The Correct Way to Strike An Arc; I f y o u s t o p m o v i n g t h e e l e c t r o d e w h i l e; The Correct Arc Length; It is not generally necessary to weave; side view; Molten puddle
B-13 OPERATION B-13 POWER-ARC 4000 1. The Correct Welding Position I l l u s t r a t e d i s t h e c o r r e c t w e l d i n g p o s i t i o n f o rright-handed people. (For left-handed people it isopposite.) Whenever possible, weld from left to right (if right-handed). This enables you to see clear...
Page 29 - PRACTICE; is to spend a little more time on the following exercise.; Common Metals; Butt Welds
B-14 OPERATION B-14 POWER-ARC 4000 PRACTICE The best way of getting practice in the four skills thatenable 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...
Page 30 - Penetration; Good
B-15 OPERATION B-15 POWER-ARC 4000 Now weld the two plates together. Weld from left toright (if right-handed). Point the electrode down in hegap between the two plates, keeping the electrodesslightly tilted in the direction of travel. Watch the molten metal to be sure it distributes itselfevenly on ...
Page 31 - Vertical-Down Welding
B-16 OPERATION B-16 POWER-ARC 4000 Vertical-Up Welding The problem, when welding vertical-up, is to put themolten metal where it is wanted and make it staythere. If too much molten metal is deposited, gravitywill pull it downwards and make it “drip”. Therefore, acertain technique has to be followed:...
Page 32 - Overhead Welding; Side View
B-17 OPERATION B-17 POWER-ARC 4000 Overhead Welding Various techniques are used for overhead welding.However, in the interest of simplicity for the inexperi-enced welder, the following technique will probablytake care of his needs for overhead welding: 1. Use 1/8” (3.2mm) 90-105 A or 3/32” (2.5mm) 7...
Page 33 - The bead should be put on with a weaving motion,; Welding Cast Iron; that spot again until the weld is cool.; Cast Iron Plate Preparation; hot
B-18 OPERATION B-18 POWER-ARC 4000 4. The bead should be put on with a weaving motion, and it should be 1/2-3/4” (12.7-19.0mm) wide. Donot let the arc blow over the edge, as that will dullthe edge. (See drawing below.) 5. Use the back-stepping method. Begin to weld 3” (76mm) from the heel of the sha...
Page 34 - Selecting Electrodes; Motions
B-19 OPERATION B-19 POWER-ARC 4000 High-Speed Group (AWS E6013) This group includes electrodes which have a moder-ately forceful arc and deposit rates between those ofthe out-of-position and high-deposit electrodes. They are primarily general purpose production elec-trodes especially for downhill fi...
Page 35 - LINCOLN ELECTRIC ACCESSORIES; Oil Gard
C-1 ACCESSORIES C-1 OPTIONS/ACCESSORIES LINCOLN ELECTRIC ACCESSORIES The following options/accessories are available fory o u r P O W E R - A R C 4 0 0 0 f r o m y o u r l o c a l L i n c o l nDistributor. Accessory Set (K875) – Includes the following: • T w e n t y f e e t ( 6 . 1 m e t e r s ) o f...
Page 36 - MAINTENANCE; • Have qualified personnel do all maintenance; ENGINE MAINTENANCE; Check the oil level after every 5; REFILL LOCATION; At the end of each day’s use, refill; ENGINE ADJUSTMENTS
D-1 MAINTENANCE D-1 SAFETY PRECAUTIONS • Have qualified personnel do all maintenance and troubleshooting work. • Turn the engine off before working inside the machine. • Remove guards only when necessary to per- form maintenance and replace them when themaintenance requiring their removal is com-ple...
Page 37 - Squeeze in a clean, absorbent cloth to remove all; Clean Rotating Screen:; C l e a n o r; CLEAN SPARK ARRESTER SCREEN:; If the muffler
D-2 MAINTENANCE D-2 Do not use petroleum solvents such as keroseneto clean the air cleaner. They may cause deterio-ration of the air cleaner. DO NOT OIL THE AIRCLEANER OR USE PRESSURIZED AIR TO CLEANOR DRY THE AIR CLEANER. To service the pre-cleaner: 1. Wash in liquid detergent and water. 2. Squeeze...
Page 38 - Part; 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 (RESISTOR) CHAMPION RJ19LM CHAMPION RC12YC DENSO W20EPR-U AUTOLITE 3924 FUEL FILTER B&S 394358 NONE NONE AIR CLEANER PANEL B&S 494511 B&S 710266 5266721 (17210...
Page 39 - GENERATOR/WELDER MAINTENANCE; B R U S H R E M O V A L A N D R E P L A C E M E N T :; FIGURE D.5. – BRUSH REMOVAL AND REPLACEMENT
D-4 MAINTENANCE D-4 POWER-ARC 4000 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 leastonce a week in particularly dirty areas. B R U S H R E M O V A L A N D R...
Page 41 - TROUBLESHOOTING; Local Lincoln Authorized Field Service Facility; for technical troubleshooting assistance before you proceed.; Step 3. RECOMMENDED COURSE OF ACTION; HOW TO USE TROUBLESHOOTING GUIDE
POWER-ARC 4000 E-1 TROUBLESHOOTING E-1 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. CAUTION This Troubleshooting...
Page 42 - Observe all Safety Guidelines detailed throughout this manual; PROBLEMS
E-2 TROUBLESHOOTING E-2 POWER-ARC 4000 Observe all Safety Guidelines detailed throughout this manual If for any reason you do not understand the test procedures or are unable to perform the tests/repairs safely, contact your Local Lincoln Authorized Field Service Facility for technical troubleshooti...
Page 45 - DIAGRAMS
F-1 DIAGRAMS F-1 POWER-ARC 4000 NOTE: This diagram is for reference only. It may not be accurate for all machines covered by this manual. The specific diag ram for a particular code is pasted inside the machine on one of the enclosure panels. If the diagram is illegible, write to the Service Departm...
Page 47 - POWER ARC 4000
F-3 DIAGRAMS F-3 POWER-ARC 4000 R 30.00 762 20.88 530 7.92 201 14.16 360 20.00 508 mm mm mm mm mm REF. REF. REF. REF. REF. 8-19-94 17196 M POWER ARC 4000 DIMENSION PRINT
Page 48 - NOTES
Lincoln 500
Manual
Lincoln 1961
Manual
Lincoln 1132-080-A
Manual
Lincoln 16900
Manual
Lincoln 1133-000-A
Manual
Lincoln 1455-000-N
Manual
Lincoln 1400
Manual
Lincoln 1997
Manual
Lincoln 1164-000-EA
Manual
Lincoln 2004 LS
Manual
Lincoln II - Advantage Series
Manual
Lincoln 1200
Manual
Lincoln 2008 Town Car
Manual
Lincoln 1457
Manual
Lincoln 1421-000-E
Manual
Lincoln 2007
Manual
Lincoln 1300 Series
Manual
Lincoln ML-2
Manual
Lincoln 2008 Mark LT
Manual
Lincoln 3270
Manual