Lincoln Electric 4000 manual

OPERA TOR’S MANUAL 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 CONT[...]

FOR ENGINE powered 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. ________________________________________________[...]

ii SAFETY ii ARC RA YS can burn. 4.a. Use a shield with the proper filter and cover 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. I standards. 4.b. Use suitable clothing made from durable flame-resistant material to protect your skin[...]

FOR ELECTRICALL Y powered equipment. 8.a. Turn off input power using the disconnect switch at the fuse box before working on the equipment. 8.b. Install equipment in accordance with the U.S. National Electrical Code, all local codes and the manufacturer’s recommendations. 8.c. Ground the equipment in accordance with the U.S. National Electrical C[...]

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 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[...]

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 and keep it handy for quick reference. Pay[...]

Page Safety .................................................................................................................................................i-iv Installation ............................................................................................................................. Section A Technical Specifications ..............[...]

TECHNICAL SPECIFICA TIONS - 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 load start; Manual Oil: 1.4 qt. (1.3 l) gasolin[...]

A-2 INST ALLA TION POWER-ARC 4000 A-2 Read this entire installation section before you start installation. SAFETY PRECAUTIONS 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 [...]

A-3 INST ALLA TION POWER-ARC 4000 A-3 ST ACKING POWER-ARC 4000 machines CANNOT be stacked. TIL TING 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 p[...]

A-4 INST ALLA TION POWER-ARC 4000 A-4 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: • Align the holes on the deflector plate with the holes on the muffl[...]

A-5 INST ALLA TION POWER-ARC 4000 A-5 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. WELDING CABLE CONNECTIONS Cable Size and Length Be sure to use welding cables that are large enough. The correct size and length becomes [...]

A-6 INST ALLA TION POWER-ARC 4000 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 ou[...]

A-7 INST ALLA TION POWER-ARC 4000 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 grou[...]

A-8 INST ALLA TION 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, electric range, hot pan, skillet, coffee maker. Capacit[...]

B-1 OPERA TION B-1 OPERA TING INSTRUCTIONS Read and understand this entire section before oper- ating your POWER-ARC 4000. SAFETY INSTRUCTIONS 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[...]

B-2 OPERA TION 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 APPLICA TIONS GENERA TOR The POWER-ARC 4000 gives AC generator output for medium use, non-commercial demands. For more details on operatin[...]

B-3 OPERA TION 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. GENERA TOR/WELDER CONTROLS See Figure B.1 for the location of the following fea- tures: 1. CURRENT CONTROL DIAL: Adjusts continu[...]

B-4 OPERA TION B-4 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 sepa- rate 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 [...]

B-5 OPERA TION B-5 ENGINE OPERA TION 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 [...]

B-6 OPERA TION B-6 4. Pull the cord rapidly. 5 . 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. Aft[...]

B-7 OPERA TION B-7 GENERA TOR OPERA TION 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 [...]

TABLE B.3 GENERATOR POWER APPLICATIONS Suggested 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 - 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 -[...]

B-9 OPERA TION B-9 WELDING OPERA TION GENERAL INFORMA TION 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. Wear eye, ear, and body protection. The POWER-ARC 4000 genera[...]

B-10 OPERA TION 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 E6011 Lincoln 7018 AC 90 amps AWS E7018 3/16” Maximum FLEETWELD ® 37 1/8” 125 amps AWS E6013 5/16” Maximum FLEE[...]

B-1 1 OPERA TION B-1 1 POWER-ARC 4000 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 wir[...]

B-12 OPERA TION B-12 POWER-ARC 4000 The Power-Arc 4000 has a voltage output of up to 62 volts which can shock. The electric arc is made between the work and the 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 electr[...]

B-13 OPERA TION B-13 POWER-ARC 4000 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[...]

B-14 OPERA TION B-14 POWER-ARC 4000 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), [...]

B-15 OPERA TION B-15 POWER-ARC 4000 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. Watch the molten metal to be sure it distributes itself evenly on both edges and in between the plates. Penetra[...]

B-16 OPERA TION B-16 POWER-ARC 4000 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: 1. Use 1/8 ” (3.2mm) 90-115 amps or[...]

B-17 OPERA TION 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 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[...]

B-18 OPERA TION 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. Do not let the arc blow over the edge, as that will dull the edge. (See drawing below.) 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 [...]

B-19 OPERA TION 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 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 th[...]

C-1 ACCESSORIES C-1 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: • Twenty feet (6.1 meters) of #6 AWG electrode cable • Fifteen feet (4.6 meters) of #6 work cable • Headshield with N[...]

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 the maintenance requiring their removal is com- plete. • If guards are missing from the mac[...]

D-2 MAINTENANCE D-2 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 en[...]

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-ZE2-505) (Pleated Paper) AIR PRE-CLEANER B&S [...]

D-4 MAINTENANCE D-4 POWER-ARC 4000 GENERA TOR/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 an[...]

D-5 MAINTENANCE D-5 POWER-ARC 4000 8 7 6 5 1 2 3 4 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 FIGURE D.6. - MAJOR COMPONENT LOCA TIONS[...]

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 Guide is provided to help you locate and repair p[...]

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 troubleshooting assistance before you proceed. CAUTION PROBLEMS[...]

E-3 TROUBLESHOOTING E-3 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 troubleshooting assistance before you proceed. CAUTION PROBLEMS[...]

E-4 TROUBLESHOOTING E-4 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 troubleshooting assistance before you proceed. CAUTION PROBLEMS[...]

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 diagram for a particular code is pasted inside the machine on one of the enclosure panels. If the diagram is illegible, write to the Service Department for a replacement. Give the equipment code numb[...]

F-2 DIAGRAMS F-2 POWER-ARC 4000 NOTE: This diagram is for reference only. It may not be accurate for all machines covered by this manual. The specific diagram for a particular code is pasted inside the machine on one of the enclosure panels. If the diagram is illegible, write to the Service Department for a replacement. Give the equipment code numb[...]

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[...]

NOTES POWER-ARC 4000[...]

NOTES POWER-ARC 4000[...]

W ARNING A VISO DE PRECAUCION A TTENTION W ARNUNG A TEN ÇÃ O Spanish French German Portuguese Japanese Chinese Korean Arabic READ AND UNDERST AND THE MANUF ACTURER’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 F ABRICANTE PARA EL[...]

W ARNING A VISO DE PRECAUCION A TTENTION W ARNUNG A TEN ÇÃ O Spanish French German Portuguese Japanese Chinese Korean Arabic LEIA E COMPREENDA AS INSTRUÇÕES DO F ABRICANTE PARA ESTE EQUIP AMENTO E AS PAR TES DE USO, E SIGA AS PRÁTICAS DE SEGURANÇA DO EMPREGADOR. ● Keep your head out of fumes. ● Use ventilation or exhaust to remove fumes f[...]

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