Lincoln POWER-ARC 4000 User Manual
OPERATOR’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 thoughtful operation on your part. DO
NOT INSTALL, OPERATE OR
REPAIR THIS EQUIPMENT
WITHOUT READING THIS
MANUAL AND THE SAFETY
PRECAUTIONS CONTAINED
THROUGHOUT. And, most
importantly, think before you act
and be careful.
POWER-ARC ™4000
For Machines with Code Number 10083, 10179, 10200, 10211, 10202, 10243, 10244, 10585, 10667,
10671, 10672, 10673, and 10866
IM488-E
February, 2004
Various engine configurations are available and machine appearance will vary
accordingly.
• 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
• World's Leader in Welding and Cutting Products •
Copyright © 2004 Lincoln Global Inc.
RETURN TO MAIN INDEX
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
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.
____________________________________________________
1.c. Do not add the fuel near an open flame
welding arc or when the engine is running.
Stop the engine and allow it to cool before
refueling to prevent spilled fuel from vaporizing on contact with hot engine parts and
igniting. Do not spill fuel when filling tank. If
fuel is spilled, wipe it up and do not start
engine until fumes have been eliminated.
____________________________________________________
1.d. Keep all equipment safety guards, covers and devices in
position and in good repair.Keep hands, hair, clothing and
tools away from V-belts, gears, fans and all other moving
parts when starting, operating or repairing equipment.
____________________________________________________
1.e. In some cases it may be necessary to remove safety
guards to perform required maintenance. Remove
guards only when necessary and replace them when the
maintenance requiring their removal is complete.
Always use the greatest care when working near moving
parts.
___________________________________________________
1.f. Do not put your hands near the engine fan.
Do not attempt to override the governor or
idler by pushing on the throttle control rods
while the engine is running.
___________________________________________________
1.g. To prevent accidentally starting gasoline engines while
turning the engine or welding generator during maintenance
work, disconnect the spark plug wires, distributor cap or
magneto wire as appropriate.
i
SAFETY
i
ARC WELDING CAN BE HAZARDOUS. PROTECT YOURSELF AND OTHERS FROM POSSIBLE SERIOUS INJURY OR DEATH.
KEEP CHILDREN AWAY. PACEMAKER WEARERS SHOULD CONSULT WITH THEIR DOCTOR BEFORE OPERATING.
Read and understand the following safety highlights. For additional safety information, it is strongly recommended that you
purchase a copy of “Safety in Welding & Cutting - ANSI Standard Z49.1” from the American Welding Society, P.O. Box
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.
WARNING
Mar ‘95
ELECTRIC AND
MAGNETIC FIELDS
may be dangerous
2.a. Electric current flowing through any conductor causes
localized Electric and Magnetic Fields (EMF). Welding
current creates EMF fields around welding cables and
welding machines
2.b. EMF fields may interfere with some pacemakers, and
welders having a pacemaker should consult their physician
before welding.
2.c. Exposure to EMF fields in welding may have other health
effects which are now not known.
2.d. All welders should use the following procedures in order to
minimize exposure to EMF fields from the welding circuit:
2.d.1.
Route the electrode and work cables together - Secure
them with tape when possible.
2.d.2. Never coil the electrode lead around your body.
2.d.3. Do not place your body between the electrode and
work cables. If the electrode cable is on your right
side, the work cable should also be on your right side.
2.d.4. Connect the work cable to the workpiece as close as
possible to the area being welded.
2.d.5. Do not work next to welding power source.
1.h. To avoid scalding, do not remove the
radiator pressure cap when the engine is
hot.
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 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 Diesel Engines
The Above For Gasoline Engines
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 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 and that of your helpers from
the arc rays.
4.c. Protect other nearby personnel with suitable, non-flammable
screening and/or warn them not to watch the arc nor expose
themselves to the arc rays or to hot spatter or metal.
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.
In addition to the normal safety precautions, if welding
must be performed under electrically hazardous
conditions (in damp locations or while wearing wet
clothing; on metal structures such as floors, gratings or
scaffolds; when in cramped positions such as sitting,
kneeling or lying, if there is a high risk of unavoidable or
accidental contact with the workpiece or ground) use
the following equipment:
• Semiautomatic DC Constant Voltage (Wire) Welder.
• DC Manual (Stick) Welder.
• AC Welder with Reduced Voltage Control.
3.c. In semiautomatic or automatic wire welding, the electrode,
electrode reel, welding head, nozzle or semiautomatic
welding gun are also electrically “hot”.
3.d. Always be sure the work cable makes a good electrical
connection with the metal being welded. The connection
should be as close as possible to the area being welded.
3.e. Ground the work or metal to be welded to a good electrical
(earth) ground.
3.f.
Maintain the electrode holder, work clamp, welding cable and
welding machine in good, safe operating condition. Replace
damaged insulation.
3.g. Never dip the electrode in water for cooling.
3.h. Never simultaneously touch electrically “hot” parts of
electrode holders connected to two welders because voltage
between the two can be the total of the open circuit voltage
of both welders.
3.i. When working above floor level, use a safety belt to protect
yourself from a fall should you get a shock.
3.j. Also see Items 6.c. and 8.
FUMES AND GASES
can be dangerous.
5.a. Welding may produce fumes and gases
hazardous to health. Avoid breathing these
fumes and gases.When welding, keep
your head out of the fume. Use enough
ventilation and/or exhaust at the arc to keep
fumes and gases away from the breathing zone. When
welding with electrodes which require special
ventilation such as stainless or hard facing (see
instructions on container or MSDS) or on lead or
cadmium plated steel and other metals or coatings
which produce highly toxic fumes, keep exposure as
low as possible and below Threshold Limit Values (TLV)
using local exhaust or mechanical ventilation. In
confined spaces or in some circumstances, outdoors, a
respirator may be required. Additional precautions are
also required when welding on galvanized steel.
5.b.
Do not weld in locations near chlorinated hydrocarbon
vapors
coming from degreasing, cleaning or spraying operations.
The heat and rays of the arc can react with solvent vapors
to
form phosgene, a highly toxic gas, and other irritating products.
5.c. Shielding gases used for arc welding can displace air and
cause injury or death. Always use enough ventilation,
especially in confined areas, to insure breathing air is safe.
5.d. Read and understand the manufacturer’s instructions for this
equipment and the consumables to be used, including the
material safety data sheet (MSDS) and follow your
employer’s safety practices. MSDS forms are available from
your welding distributor or from the manufacturer.
5.e. Also see item 1.b.
Mar ‘95
FOR ELECTRICALLY
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 Code and the manufacturer’s recommendations.
CYLINDER may explode
if damaged.
7.a. Use only compressed gas cylinders
containing the correct shielding gas for the
process used and properly operating
regulators designed for the gas and
pressure used. All hoses, fittings, etc. should be suitable for
the application and maintained in good condition.
7.b. Always keep cylinders in an upright position securely
chained to an undercarriage or fixed support.
7.c. Cylinders should be located:
• Away from areas where they may be struck or subjected to
physical damage.
• A safe distance from arc welding or cutting operations and
any other source of heat, sparks, or flame.
7.d. Never allow the electrode, electrode holder or any other
electrically “hot” parts to touch a cylinder.
7.e. Keep your head and face away from the cylinder valve outlet
when opening the cylinder valve.
7.f. Valve protection caps should always be in place and hand
tight except when the cylinder is in use or connected for
use.
7.g. Read and follow the instructions on compressed gas
cylinders, associated equipment, and CGA publication P-l,
“Precautions for Safe Handling of Compressed Gases in
Cylinders,” available from the Compressed Gas Association
1235 Jefferson Davis Highway, Arlington, VA 22202.
iii
SAFETY
iii
Mar ‘95
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. Where compressed gases are to be used at the job site,
special precautions should be used to prevent hazardous
situations. Refer to “Safety in Welding and Cutting” (ANSI
Standard Z49.1) and the operating information for the
equipment being used.
6.c. When not welding, make certain no part of the electrode
circuit is touching the work or ground. Accidental contact
can cause overheating and create a fire hazard.
6.d. Do not heat, cut or weld tanks, drums or containers until the
proper steps have been taken to insure that such procedures
will not cause flammable or toxic vapors from substances
inside. They can cause an explosion even
though
they have
been “cleaned”. For information, purchase “Recommended
Safe Practices for the
Preparation
for Welding and Cutting of
Containers and Piping That Have Held Hazardous
Substances”, AWS F4.1 from the American Welding Society
(see address above).
6.e. Vent hollow castings or containers before heating, cutting or
welding. They may explode.
6.f.
Sparks and spatter are thrown from the welding arc. Wear oil
free protective garments such as leather gloves, heavy shirt,
cuffless trousers, high shoes and a cap over your hair. Wear
ear plugs when welding out of position or in confined places.
Always wear safety glasses with side shields when in a
welding area.
6.g. Connect the work cable to the work as close to the welding
area as practical. Work cables connected to the building
framework or other locations away from the welding area
increase the possibility of the welding current passing
through lifting chains, crane cables or other alternate circuits. This can create fire hazards or overheat lifting chains
or cables until they fail.
6.h. Also see item 1.c.
iv
SAFETY
iv
Mar. ‘93
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. Eviter toujours
tout contact entre les parties sous tension et la peau nue
ou les vétements mouillés. Porter des gants secs et sans
trous pour isoler les mains.
b. Faire trés attention de bien s’isoler de la masse quand on
soude dans des endroits humides, ou sur un plancher
metallique ou des grilles metalliques, principalement dans
les positions assis ou couché pour lesquelles une
grande partie du corps peut être en contact avec la
masse.
c. Maintenir le porte-électrode, la pince de masse, le câble
de soudage et la machine à souder en bon et sûr état
defonctionnement.
d.Ne jamais plonger le porte-électrode dans l’eau pour le
refroidir.
e. Ne jamais toucher simultanément les parties sous tension
des porte-électrodes connectés à deux machines à souder parce que la tension entre les deux pinces peut être le
total de la tension à vide des deux machines.
f. Si on utilise la machine à souder comme une source de
courant pour soudage semi-automatique, ces precautions
pour le porte-électrode s’applicuent aussi au pistolet de
soudage.
2. Dans le cas de travail au dessus du niveau du sol, se protéger contre les chutes dans le cas ou on recoit un choc. Ne
jamais enrouler le câble-électrode autour de n’importe quelle
partie du corps.
3. Un coup d’arc peut être plus sévère qu’un coup de soliel,
donc:
a. Utiliser un bon masque avec un verre filtrant approprié
ainsi qu’un verre blanc afin de se protéger les yeux du
rayonnement de l’arc et des projections quand on soude
ou quand on regarde l’arc.
b. Porter des vêtements convenables afin de protéger la
peau de soudeur et des aides contre le rayonnement de
l‘arc.
c. Protéger l’autre personnel travaillant à proximité au
soudage à l’aide d’écrans appropriés et non-inflammables.
4. Des gouttes de laitier en fusion sont émises de l’arc de
soudage. Se protéger avec des vêtements de protection
libres de l’huile, tels que les gants en cuir, chemise épaisse,
pantalons sans revers, et chaussures montantes.
5. Toujours porter des lunettes de sécurité dans la zone de
soudage. Utiliser des lunettes avec écrans lateraux dans les
zones où l’on pique le laitier.
6. Eloigner les matériaux inflammables ou les recouvrir afin de
prévenir tout risque d’incendie dû aux étincelles.
7. Quand on ne soud
e pas, poser la pince à une endroit isolé de
la masse. Un court-circuit accidental peut provoquer un
échauffement et un risque d’incendie.
8. S’assurer que la masse est connectée le plus prés possible
de la zone de travail qu’il est pratique de le faire. Si on place
la masse sur la charpente de la construction ou d’autres
endroits éloignés de la zone de travail, on augmente le risque
de voir passer le courant de soudage par les chaines de levage, câbles de grue, ou autres circuits. Cela peut provoquer
des risques d’incendie ou d’echauffement des chaines et des
câbles jusqu’à ce qu’ils se rompent.
9. Assurer une ventilation suffisante dans la zone de soudage.
Ceci est particuliérement important pour le soudage de tôles
galvanisées plombées, ou cadmiées ou tout autre métal qui
produit des fumeés toxiques.
10. Ne pas souder en présence de vapeurs de chlore provenant
d’opérations de dégraissage, nettoyage ou pistolage. La
chaleur ou les rayons de l’arc peuvent réagir avec les
vapeurs du solvant pour produire du phosgéne (gas fortement toxique) ou autres produits irritants.
11. Pour obtenir de plus amples renseignements sur la sûreté,
voir le code “Code for safety in welding and cutting” CSA
Standard W 117.2-1974.
PRÉCAUTIONS DE SÛRETÉ POUR
LES MACHINES À SOUDER À
TRANSFORMATEUR ET À
REDRESSEUR
1. Relier à la terre le chassis du poste conformement au code
de l’électricité et aux recommendations du fabricant. Le dispositif de montage ou la piece à souder doit être branché à
une bonne mise à la terre.
2. Autant que possible, I’installation et l’entretien du poste
seront effectués par un électricien qualifié.
3. Avant de faires des travaux à l’interieur de poste, la
debrancher à l’interrupteur à la boite de fusibles.
4. Garder tous les couvercles et dispositifs de sûreté à leur
place.
vv
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 particular attention to the safety instructions we have provided for your protection.
The level of seriousness to be applied to each is explained below:
WARNING
This statement appears where the information must be followed exactly to avoid serious personal injury or
loss of life.
This statement appears where the information must be followed to avoid minor personal injury or damage to
this equipment.
CAUTION
Please Examine Carton and Equipment For Damage Immediately
When this equipment is shipped, title passes to the purchaser upon receipt by the carrier. Consequently, Claims
for material damaged in shipment must be made by the purchaser against the transportation company at the
time the shipment is received.
Please record your equipment identification information below for future reference. This information can be
found on your machine nameplate.
Product _________________________________________________________________________________
Model Number ___________________________________________________________________________
Code Number or Date Code_________________________________________________________________
Serial Number____________________________________________________________________________
Date Purchased___________________________________________________________________________
Where Purchased_________________________________________________________________________
Whenever you request replacement parts or information on this equipment, always supply the information you
have recorded above. The code number is especially important when identifying the correct replacement parts.
On-Line Product Registration
- 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.
• For On-Line Registration: Go to our
WEB SITE at www.lincolnelectric.com. Choose “Quick Links” and then
“Product Registration”. Please complete the form and submit your registration.
Page
Safety.................................................................................................................................................i-iv
Installation .............................................................................................................................Section A
Technical Specifications .............................................................................................................A-1
Safety Precautions......................................................................................................................A-2
Location and Ventilation .............................................................................................................A-2
Pre-operation Engine Service .....................................................................................................A-3
Electrical Output Connections ....................................................................................................A-5
Operation...............................................................................................................................Section B
Safety Instructions ......................................................................................................................B-1
General Description ....................................................................................................................B-1
Recommended Applications.......................................................................................................B-2
Operational Features and Controls.............................................................................................B-2
Design Features and Advantages...............................................................................................B-2
Welding Capability......................................................................................................................B-2
Limitations .................................................................................................................................B-2
Controls and Settings .................................................................................................................B-3
Engine Operation ........................................................................................................................B-5
Welding Operation ......................................................................................................................B-9
Accessories...........................................................................................................................Section C
Maintenance..........................................................................................................................Section D
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
MASTER TABLE OF CONTENTS FOR ALL SECTIONS
vi vi
POWER-ARC 4000
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 load start; Manual Oil: 1.4 qt. (1.3 l)
gasoline choke
8 HP @
3750 RPM
INPUT - BRIGGS VANGUARD® GASOLINE ENGINE
Briggs & 1 cyl., 3700 RPM 18.06 cu. in. Manual, Fuel: 1.6 gal. (6.0 l)
Stratton 4 cycle ± 50 RPM (296 cc) Recoil
Vanguard® air-cooled OHV at no load start; Manual Oil: 1.25 qt. (1.2 l)
Model 185432 gasoline choke
9 HP @
3750 RPM
INPUT - HONDA GASOLINE ENGINE
Honda 1 cyl., 3700 RPM 16.5 cu. in. Manual, Fuel: 1.59 gal. (6.0 l)
GX 270 VA2 4 cycle ± 50 RPM (270 cc) Recoil
air-cooled OHV at no load start; Manual Oil: 1.16 qt. (1.11 l)
gasoline choke
9 HP @
3750 RPM
RATED OUTPUT - WELDER
Duty Cycle Amps Volts at Rated Amperes
30% Duty Cycle 125 20 VAC
60% Duty Cycle 100 25 VAC
OUTPUT - WELDER AND GENERATOR
Welding Ranges Welder Open Circuit Voltage AC Auxiliary Power
70 - 125 Amps 62 VAC Max. 4000 Continuous Watts
4400 Surge Watts
PHYSICAL DIMENSIONS
Height Width Depth Weight
20.9 in. 20 in. 30 in. 160 lb.
530 mm 508 mm 762 mm 72.5 kg
A-1
INSTALLATION
POWER-ARC 4000
A-1
A-2
INSTALLATION
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 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.
• Insulate yourself from the
work and ground.
•Always wear dry insulating gloves.
ENGINE EXHAUST can kill.
• Use in open, well ventilated
areas or vent exhaust to the
outside.
• Do not stack anything on or
near the engine.
MOVING PARTS can injure.
• Do not operate this equipment with any of its doors
open or guards off.
• Stop the engine before servicing it.
• Keep away from moving parts.
Only qualified personnel should install, use, or service
this equipment.
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. Do not place the back end of the generator
anywhere near hot engine exhaust from another
machine. And of course, make sure that engine
exhaust is ventilated to an open, outside area.
The POWER-ARC 4000 may be used outdoors. Do
not set the machine in puddles or otherwise submerge it in water. Such practices pose safety hazards and cause improper operation and corrosion of
parts.
Always operate the POWER-ARC 4000 with the case
roof on and all machine components completely
assembled. This will protect you from the dangers of
moving parts, hot metal surfaces, and live electrical
devices.
STORING
1. Store the machine in a cool, dry place when it’s
not in use. Protect it from dust and dirt. Keep it
where it can’t be accidentally damaged from construction activities, moving vehicles, and other
hazards.
2. If you will be storing the machine for over 30
days, you should drain the fuel to protect fuel
system and carburetor parts from gum deposits.
Empty all fuel from the tank and run the engine
until it stops from lack of fuel.
3. You can store the machine for up to 24 months if
you use Briggs & Stratton Gasoline Additive, Part
No. 5041 (available from any Authorized Briggs &
Stratton Service Center), in the fuel system. Mix
the additive with the fuel in the tank and run the
engine for a short time to circulate the additive
through the carburetor.
4. While the engine is still warm, drain the oil and
refill with fresh oil per the engine manual.
5. Remove the spark plug and pour approximately
1/2 ounce (15 ml) of engine oil into the cylinder.
Replace the spark plug and crank the engine
slowly to distribute the oil.
6. Clean any dirt and debris from the cylinder and
cylinder head fins and housing, rotating screen,
and muffler areas.
7. Store in a clean, dry area.
WARNING
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 whenever 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 position for best performance. It can operate at an angle,
but this should never be more than 15 degrees in any
direction. If you do operate it at a slight angle, be
sure to check the oil regularly and keep the oil level
full. Also, fuel capacity will be a little less at an angle.
LIFTING
The POWER-ARC 4000 should be lifted by two people. (It weighs 160 lbs/72.5 kg.) Its welded tube roll
cage is designed to make lifting easy.
ANGLE OF OPERATION
Internal combustion engines are designed to run in a
level condition to achieve optimum performance. The
maximum angle of operation for the engine is 15
degrees from horizontal in any direction. Be certain
to place the machine on a firm, non-skid, structural
supporting surface. Anchor unit if necessary.
If you are operating the engine at a slight angle, be
certain to check the oil regularly and maintain a level,
full oil condition. The effective fuel capacity will also
be slightly less than the specified 1.00 gallon (3.8
liters).
PRE-OPERATION ENGINE SERVICE
Read and understand the information about the gasoline engine in the OPERATION and MAINTENANCE
sections of this manual and the engine owner’s manual before you operate the POWER-ARC 4000.
• Keep hands away from the engine muffler or
HOT engine parts.
• Stop the engine when fueling.
• Do not smoke when fueling.
• Remove the fuel cap slowly to release pressure.
• Do not overfill the fuel tank.
• Wipe up spilled fuel and allow the fumes to clear
before starting the engine.
• Keep sparks and flame away from the fuel tank.
OIL
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.
However, the engine block is equipped to accept an
"Oil Gard"® accessory kit available from authorized
Briggs and Stratton Distributors. An installed kit will
sense low oil levels and will automatically shut down
the engine. The engine cannot be restarted until sufficient oil is added.
The POWER-ARC 4000 is shipped with the engine
filled with SAE 10W-30 oil. CHECK THE OIL LEVEL
BEFORE YOU START THE ENGINE. This is an
added precaution. When full, the oil level should be
at the top of the fill plug hole. If it is not full, add
enough oil to fill it. Be sure the fill plug is tight.
Change oil after the first 5 hours of operation.
For more oil fill and service information, see the
Engine owner’s manual.
FUEL
Fill the fuel tank with clean, fresh, regular
grade lead-free gasoline. DO NOT MIX
OIL WITH THE GASOLINE.
The POWER-ARC 4000 has a fuel tank mounted on
the engine. See the engine owner’s manual for more
details about fuel.
WARNING
A-4
INSTALLATION
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 muffler.
•
Position the deflector so that the opening points either
right, left, or downward, away from the operator.
Never position the deflector upward. Moisture or
debris can enter the engine and damage it. As a
general safety practice, position the deflector to
direct exhaust gases away from the operator’s
face and eyes.
• Fasten the deflector onto the muffler with the
screws provided.
NOTE: The deflector reduces generator output
power up to 100 watts.
SPARK ARRESTER
Gasoline engine mufflers may emit sparks when the
engine is running. Some federal, state, or local laws
require spark arresters in locations where unarrested
sparks could present a fire hazard.
Standard mufflers and deflectors (like the ones
included with the POWER-ARC 4000 Briggs &
Stratton engines) do not act as spark arresters. When
local laws require it, a spark arrester must be installed
on the machine and properly maintained
.
An optional spark arrester kit is available for your
POWER-ARC 4000 Briggs & Stratton 8 HP Kool-Bore
engine. See the ACCESSORIES section of this manual for more information.
An incorrect spark arrester may lead to damage to
the engine or reduce performance. A suitable
spark arrester for the Briggs & Stratton 8 HP Kool
Bore
®
engine is available as a Lincoln field-
installed option.
A spark arrester is available for your POWER-ARC
4000 Briggs & Stratton 9 HP Vanguard engine from
your local Briggs & Stratton engine dealer.
The Power-Arc 4000 with the Honda engine comes
with a spark arrester as standard equipment. Refer to
the engine owner’s manual for proper maintenance.
CAUTION
CAUTION
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)
B&S 8 HP Carb. Certified
Kool Bore® Plus
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®
0.33 Gallons/Hour
(1.25 Liters/Hour)
0.76 Gallons/Hour
(2.9 Liters/Hour)
0.63 Gallons/Hour
(2.4 Liters/Hour)
0.76 Gallons/Hour
(2.9 Liters/Hour)
Honda 9 HP
Carb. Certified
0.30 Gallons/Hour
(1.14 Liters/Hour)
0.58 Gallons/Hour
(2.18 Liters/Hour)
0.55 Gallons/Hour
(2.1 Liters/Hour)
0.67 Gallons/Hour
(2.54 Liters/Hour)
Power-Arc 4000 Typical Fuel Consumption
A-5
INSTALLATION
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 especially
important when you are welding at a distance from
the welder.
Table A.1 lists recommended cable sizes and lengths
for rated current and duty cycle. Length refers to the
distance from the welder to the work and back to the
welder. Cable diameters are increased for long cable
lengths to reduce voltage drops.
TABLE A.1
RECOMMENDED WELDING CABLE
SIZE AND LENGTH
TOTAL COMBINED LENGTH OF ELECTRODE AND
WORK CABLES
Cable Size for
125 amp/
Cable Length 30% Duty Cycle
0-50 feet (0-15 meters) 6 AWG
50-100 feet (15-39 meters) 4 AWG
100-150 feet (30-46 meters) 3 AWG
150-200 feet (46061 meters) 2 AWG
200-250 feet (61-76 meters) 1 AWG
FIGURE A.1 - POWER-ARC 4000 OUTPUT CONNECTIONS
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
1
80
AMPS
70
AMPS
125
AMPS
GENERATOR
100
AMPS
WARNING
ELECTRODE SELECTION GUIDE
2
POWER ARC 4000
90
AMPS
6
5
3
4
A-6
INSTALLATION
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 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.
4. Tighten the flanged nuts securely.
5. Be certain that the metal piece you are welding
(the “work”) is securely connected to the work
clamp and cable.
6. Check and tighten the connections periodically.
• Loose connections will cause the output termi-
nals to overheat. The terminals may eventually
melt.
• Do not cross the welding cables at the output
terminal connection. Keep the cables isolated
and separate from one another.
Lincoln Electric offers a welding accessory kit with
the properly specified welding cables. See the
ACCESSORIES section of this manual for more information.
MACHINE GROUNDING
Because the POWER-ARC 4000 creates
its own power from its gasoline-engine
driven generator, you do not need to
connect the machine frame to an earth
ground. However, for best protection
against electrical shock, connect a heavy gauge wire
from the ground stud located on the bottom center of
the output panel (see Figure A.1) to a suitable earth
ground such as a metal pipe driven into the ground.
Do not ground the machine to a pipe that carries
explosive or combustible material.
When the POWER-ARC 4000 is mounted
on a truck or a trailer, the machine generator ground stud MUST be securely
connected to the metal frame of the
vehicle. See Figure A.1. The ground
stud is marked with the symbol.
PLUGS AND HAND-HELD EQUIPMENT
For further protection against electric shock, any
electrical equipment connected to the generator
receptacles must use a three-blade, grounded type
plug or an 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.
Ground fault protection is needed for hand held
equipment.
Never operate this machine with damaged or defective cords. All electrical equipment must be in safe
condition.
AUXILIARY POWER RECEPTACLES
The control panel of the POWER-ARC 4000 features
two auxiliary power receptacles:
• A 20 amp, 120 volt duplex (double outlet) receptacle
• A 20 amp 240 volt simplex (single outlet) receptacle.
See Figure A.1.
Through these receptacles the machine can supply
up to 4,000 rated continuous watts and 4,400 surge
watts of single-phase AC power.
CAUTION
WARNING
WARNING
A-7
INSTALLATION
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 grounded"
to a "separately derived" system depending on
whether you want the unit to be "hard wired" or temporary to the premises.
Only a licensed, certified, trained electrician
should install the machine to a premises or residential electrical system. Be certain that:
• The premises is isolated and no feed backing
into the utility system can occur. Certain state
and local laws require the premises to be isolated before the generator is linked to the premises. Check your state and local requirements.
• A double pole, double throw transfer switch in
conjunction with the properly rated double
throw circuit breaker is connected between the
generator power and the utility meter.
The POWER-ARC 4000 does not have a combined
120/240 volt twist-lock receptacle and cannot be
connected to a premises as described in other
Lincoln literature.
Remember that the POWER-ARC 4000 is intended
only for backup, intermittent use power. Oil level must
be checked after every 5 hours of use. The Briggs &
Stratton engines used on the Power-Arc 4000 before
August 1998 did not include a low oil shutdown
option as standard equipment. It cannot withstand
long-term use without proper maintenance. See the
MAINTENANCE section of this manual and the
engine owner’s manual for more information.
Certain electrical devices cannot be powered by the
POWER-ARC 4000. Refer to Table A.2 for these
devices.
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 normally.
Never bypass the circuit breakers. Without overload protection, the power-arc 4000 could overheat and/or cause damage to the equipment being
used.
WARNING
CAUTION
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, electric range, hot
pan, skillet, coffee maker.
Capacitive TV sets, radios, microwaves, Voltage spikes or high voltage
appliances with electrical control. regulation can cause the capaci-
tative elements to fail. Surge
protection, transient protection,
and additional loading is recommended for 100% fail-safe
operation. DO NOT RUN
THESE DEVICES WITHOUT
ADDITIONAL RESISTIVE TYPE
LOADS.
Inductive Single-phase induction motors, These devices require large
drills, well pumps, grinders, small current inrush for starting. (See
refrigerators, weed and hedge Table B.3, GENERATOR POWER
trimmers APPLICATIONS, in the OPERA-
TION section of this manual for
required starting wattages.)
Some synchronous motors may
be frequency sensitive to attain
maximum output torque, but
they SHOULD BE SAFE from
any frequency induced failures.
Capacitive/Inductive Computers, high resolution TV sets, An inductive type line condition-
complicated electrical equipment. er along with transient and
surge protection is required, and
liabilities still exist. DO NOT
USE THESE DEVICES WITH A
POWER-ARC 4000.
The Lincoln Electric Company is not responsible for any damage to electrical components improperly connected to the POWER-ARC 4000.
B-1
OPERATION
B-1
OPERATING INSTRUCTIONS
Read and understand this entire section before operating your POWER-ARC 4000.
SAFETY INSTRUCTIONS
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.
• Insulate yourself from the work and ground.
• Always wear dry insulating gloves.
FUMES AND GASES can be
dangerous.
• Keep your head out of fumes.
• Use ventilation or exhaust to
remove fumes from breathing zone.
WELDING SPARKS can cause
fire or explosion.
• Keep flammable material away.
• Do not weld on containers that have
held combustibles.
ARC RAYS can burn.
• Wear eye, ear, and body protection.
ENGINE EXHAUST can kill.
• Use in open, well ventilated areas
or vent exhaust to the outside.
• Do not stack anything on or near
the engine.
MOVING PARTS can injure.
• Do not operate this equipment with
any of its doors open or guards off.
• Stop the engine before servicing it.
• Keep away from moving parts.
Only qualified personnel should install, use, or service 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. As a welder it provides
125 amps of AC constant current for welding with AC
stick electrodes. A single dial provides continuous
adjustment of welding output. The machine is lightweight, portable, and can be lifted by two people.
POWER-ARC 4000
WARNING
WARNING
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