power arc 4000 manual
TRANSCRIPT
OPERATOR’S MANUAL
Safety Depends on YouLincoln arc welding and cuttingequipment is designed and builtwith safety in mind. However, youroverall safety can be increased byproper installation ... and thought-ful operation on your part. DONOT INSTALL, OPERATE ORREPAIR THIS EQUIPMENTWITHOUT READING THISMANUAL AND THE SAFETYPRECAUTIONS CONTAINEDTHROUGHOUT. And, mostimportantly, think before you actand be careful.
POWER-ARC ™ 4000For Machines with Code Number 10673, 10792, 10793, 10930
IM751-AMay, 2003
Various engine configurations are available and machine appearance will varyaccordingly.
ISO 9001
CERTIFICATE NUMBER: 30273
Designed and Manufactured Under aQuality Program Certified byABS Quality Evaluations, Inc.to ISO 9001 Requirements.
QMS
ANSI RAB
• 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 © 2003 Lincoln Global Inc.
FOR ENGINEpowered equipment.
1.a. Turn the engine off before troubleshooting and maintenancework 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 beforerefueling to prevent spilled fuel from vaporiz-ing on contact with hot engine parts andigniting. Do not spill fuel when filling tank. Iffuel is spilled, wipe it up and do not startengine 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 andtools away from V-belts, gears, fans and all other movingparts when starting, operating or repairing equipment.
____________________________________________________
1.e. In some cases it may be necessary to remove safetyguards to perform required maintenance. Removeguards only when necessary and replace them when themaintenance requiring their removal is complete.Always use the greatest care when working near movingparts.
___________________________________________________1.f. Do not put your hands near the engine fan.
Do not attempt to override the governor oridler by pushing on the throttle control rodswhile the engine is running.
___________________________________________________1.g. To prevent accidentally starting gasoline engines while
turning the engine or welding generator during maintenancework, disconnect the spark plug wires, distributor cap ormagneto wire as appropriate.
iSAFETYi
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 youpurchase a copy of “Safety in Welding & Cutting - ANSI Standard Z49.1” from the American Welding Society, P.O. Box351040, Miami, Florida 33135 or CSA Standard W117.2-1974. A Free copy of “Arc Welding Safety” booklet E205 is availablefrom the Lincoln Electric Company, 22801 St. Clair Avenue, Cleveland, Ohio 44117-1199.
BE SURE THAT ALL INSTALLATION, OPERATION, MAINTENANCE AND REPAIR PROCEDURES AREPERFORMED ONLY BY QUALIFIED INDIVIDUALS.
WARNING
Mar ‘95
ELECTRIC AND MAGNETIC FIELDSmay 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, andwelders having a pacemaker should consult their physicianbefore welding.
2.c. Exposure to EMF fields in welding may have other healtheffects which are now not known.
2.d. All welders should use the following procedures in order tominimize exposure to EMF fields from the welding circuit:
2.d.1. Route the electrode and work cables together - Securethem 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 andwork 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 aspossible to the area being welded.
2.d.5. Do not work next to welding power source.
1.h. To avoid scalding, do not remove theradiator pressure cap when the engine ishot.
CALIFORNIA PROPOSITION 65 WARNINGS
Diesel engine exhaust and some of its constituentsare known to the State of California to cause can-cer, birth defects, and other reproductive harm.
The engine exhaust from this product containschemicals known to the State of California to causecancer, birth defects, or other reproductive harm.
The Above For Diesel Engines The Above For Gasoline Engines
iiSAFETYii
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 flame-resistantmaterial to protect your skin and that of your helpers fromthe arc rays.
4.c. Protect other nearby personnel with suitable, non-flammablescreening and/or warn them not to watch the arc nor exposethemselves to the arc rays or to hot spatter or metal.
ELECTRIC SHOCK cankill.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 bareskin 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 fullarea of physical contact with work and ground.
In addition to the normal safety precautions, if weldingmust be performed under electrically hazardousconditions (in damp locations or while wearing wetclothing; on metal structures such as floors, gratings orscaffolds; when in cramped positions such as sitting,kneeling or lying, if there is a high risk of unavoidable oraccidental contact with the workpiece or ground) usethe 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 semiautomaticwelding gun are also electrically “hot”.
3.d. Always be sure the work cable makes a good electricalconnection with the metal being welded. The connectionshould 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 andwelding machine in good, safe operating condition. Replacedamaged insulation.
3.g. Never dip the electrode in water for cooling.
3.h. Never simultaneously touch electrically “hot” parts ofelectrode holders connected to two welders because voltagebetween the two can be the total of the open circuit voltageof both welders.
3.i. When working above floor level, use a safety belt to protectyourself from a fall should you get a shock.
3.j. Also see Items 6.c. and 8.
FUMES AND GASEScan be dangerous.5.a. Welding may produce fumes and gases
hazardous to health. Avoid breathing thesefumes and gases.When welding, keepyour head out of the fume. Use enoughventilation and/or exhaust at the arc to keep
fumes and gases away from the breathing zone. Whenwelding with electrodes which require specialventilation such as stainless or hard facing (seeinstructions on container or MSDS) or on lead orcadmium plated steel and other metals or coatingswhich produce highly toxic fumes, keep exposure aslow as possible and below Threshold Limit Values (TLV)using local exhaust or mechanical ventilation. Inconfined spaces or in some circumstances, outdoors, arespirator may be required. Additional precautions arealso required when welding on galvanized steel.
5.b. Do not weld in locations near chlorinated hydrocarbon vaporscoming from degreasing, cleaning or spraying operations.The heat and rays of the arc can react with solvent vapors toform phosgene, a highly toxic gas, and other irritating prod-ucts.
5.c. Shielding gases used for arc welding can displace air andcause 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 thisequipment and the consumables to be used, including thematerial safety data sheet (MSDS) and follow youremployer’s safety practices. MSDS forms are available fromyour welding distributor or from the manufacturer.
5.e. Also see item 1.b.
Mar ‘95
FOR ELECTRICALLYpowered equipment.
8.a. Turn off input power using the disconnectswitch at the fuse box before working onthe equipment.
8.b. Install equipment in accordance with the U.S. NationalElectrical Code, all local codes and the manufacturer’srecommendations.
8.c. Ground the equipment in accordance with the U.S. NationalElectrical Code and the manufacturer’s recommendations.
CYLINDER may explodeif damaged.7.a. Use only compressed gas cylinders
containing the correct shielding gas for theprocess used and properly operatingregulators designed for the gas and
pressure used. All hoses, fittings, etc. should be suitable forthe application and maintained in good condition.
7.b. Always keep cylinders in an upright position securelychained to an undercarriage or fixed support.
7.c. Cylinders should be located:• Away from areas where they may be struck or subjected tophysical damage.
• A safe distance from arc welding or cutting operations andany other source of heat, sparks, or flame.
7.d. Never allow the electrode, electrode holder or any otherelectrically “hot” parts to touch a cylinder.
7.e. Keep your head and face away from the cylinder valve outletwhen opening the cylinder valve.
7.f. Valve protection caps should always be in place and handtight except when the cylinder is in use or connected foruse.
7.g. Read and follow the instructions on compressed gascylinders, associated equipment, and CGA publication P-l,“Precautions for Safe Handling of Compressed Gases inCylinders,” available from the Compressed Gas Association1235 Jefferson Davis Highway, Arlington, VA 22202.
iiiSAFETYiii
Mar ‘95
WELDING SPARKS cancause fire or explosion.6.a. Remove fire hazards from the welding area.
If this is not possible, cover them to preventthe welding sparks from starting a fire.Remember that welding sparks and hot
materials from welding can easily go through small cracksand openings to adjacent areas. Avoid welding nearhydraulic 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 hazardoussituations. Refer to “Safety in Welding and Cutting” (ANSIStandard Z49.1) and the operating information for theequipment being used.
6.c. When not welding, make certain no part of the electrodecircuit is touching the work or ground. Accidental contactcan cause overheating and create a fire hazard.
6.d. Do not heat, cut or weld tanks, drums or containers until theproper steps have been taken to insure that such procedureswill not cause flammable or toxic vapors from substancesinside. They can cause an explosion even though they havebeen “cleaned”. For information, purchase “RecommendedSafe Practices for the Preparation for Welding and Cutting ofContainers and Piping That Have Held HazardousSubstances”, AWS F4.1 from the American Welding Society(see address above).
6.e. Vent hollow castings or containers before heating, cutting orwelding. They may explode.
6.f. Sparks and spatter are thrown from the welding arc. Wear oilfree protective garments such as leather gloves, heavy shirt,cuffless trousers, high shoes and a cap over your hair. Wearear plugs when welding out of position or in confined places.Always wear safety glasses with side shields when in awelding area.
6.g. Connect the work cable to the work as close to the weldingarea as practical. Work cables connected to the buildingframework or other locations away from the welding areaincrease the possibility of the welding current passingthrough lifting chains, crane cables or other alternate cir-cuits. This can create fire hazards or overheat lifting chainsor cables until they fail.
6.h. Also see item 1.c.
ivSAFETYiv
PRÉCAUTIONS DE SÛRETÉPour votre propre protection lire et observer toutes les instruc-tions et les précautions de sûreté specifiques qui parraissentdans ce manuel aussi bien que les précautions de sûretégénérales suivantes:
Sûreté Pour Soudage A L’Arc1. Protegez-vous contre la secousse électrique:
a. Les circuits à l’électrode et à la piéce sont sous tensionquand la machine à souder est en marche. Eviter toujourstout contact entre les parties sous tension et la peau nueou les vétements mouillés. Porter des gants secs et sanstrous pour isoler les mains.
b. Faire trés attention de bien s’isoler de la masse quand onsoude dans des endroits humides, ou sur un planchermetallique ou des grilles metalliques, principalement dans
les positions assis ou couché pour lesquelles unegrande partie du corps peut être en contact avec lamasse.
c. Maintenir le porte-électrode, la pince de masse, le câblede soudage et la machine à souder en bon et sûr étatdefonctionnement.
d.Ne jamais plonger le porte-électrode dans l’eau pour lerefroidir.
e. Ne jamais toucher simultanément les parties sous tensiondes porte-électrodes connectés à deux machines à soud-er parce que la tension entre les deux pinces peut être letotal de la tension à vide des deux machines.
f. Si on utilise la machine à souder comme une source decourant pour soudage semi-automatique, ces precautionspour le porte-électrode s’applicuent aussi au pistolet desoudage.
2. Dans le cas de travail au dessus du niveau du sol, se pro-téger contre les chutes dans le cas ou on recoit un choc. Nejamais enrouler le câble-électrode autour de n’importe quellepartie 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 appropriéainsi qu’un verre blanc afin de se protéger les yeux durayonnement de l’arc et des projections quand on soudeou quand on regarde l’arc.
b. Porter des vêtements convenables afin de protéger lapeau de soudeur et des aides contre le rayonnement del‘arc.
c. Protéger l’autre personnel travaillant à proximité ausoudage à l’aide d’écrans appropriés et non-inflamma-bles.
4. Des gouttes de laitier en fusion sont émises de l’arc desoudage. Se protéger avec des vêtements de protectionlibres 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 desoudage. Utiliser des lunettes avec écrans lateraux dans leszones où l’on pique le laitier.
6. Eloigner les matériaux inflammables ou les recouvrir afin deprévenir tout risque d’incendie dû aux étincelles.
7. Quand on ne soude pas, poser la pince à une endroit isolé dela masse. Un court-circuit accidental peut provoquer unéchauffement et un risque d’incendie.
8. S’assurer que la masse est connectée le plus prés possiblede la zone de travail qu’il est pratique de le faire. Si on placela masse sur la charpente de la construction ou d’autresendroits éloignés de la zone de travail, on augmente le risquede voir passer le courant de soudage par les chaines de lev-age, câbles de grue, ou autres circuits. Cela peut provoquerdes risques d’incendie ou d’echauffement des chaines et descâbles 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 tôlesgalvanisées plombées, ou cadmiées ou tout autre métal quiproduit des fumeés toxiques.
10. Ne pas souder en présence de vapeurs de chlore provenantd’opérations de dégraissage, nettoyage ou pistolage. Lachaleur ou les rayons de l’arc peuvent réagir avec lesvapeurs du solvant pour produire du phosgéne (gas forte-ment 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” CSAStandard W 117.2-1974.
PRÉCAUTIONS DE SÛRETÉ POURLES MACHINES À SOUDER ÀTRANSFORMATEUR ET ÀREDRESSEUR
1. Relier à la terre le chassis du poste conformement au codede l’électricité et aux recommendations du fabricant. Le dis-positif de montage ou la piece à souder doit être branché àune bonne mise à la terre.
2. Autant que possible, I’installation et l’entretien du posteseront effectués par un électricien qualifié.
3. Avant de faires des travaux à l’ interieur de poste, ladebrancher à l’interrupteur à la boite de fusibles.
4. Garder tous les couvercles et dispositifs de sûreté à leurplace.
Mar. ‘93
vv
Thank You for selecting a QUALITY product by Lincoln Electric. We want youto 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 ithandy 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:
WARNINGThis statement appears where the information must be followed exactly to avoid serious personal injury orloss of life.
This statement appears where the information must be followed to avoid minor personal injury or damage tothis equipment.
CAUTION
Please Examine Carton and Equipment For Damage ImmediatelyWhen this equipment is shipped, title passes to the purchaser upon receipt by the carrier. Consequently, Claimsfor material damaged in shipment must be made by the purchaser against the transportation company at thetime the shipment is received.
Please record your equipment identification information below for future reference. This information can befound 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 youhave 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 packetaccompanying 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, A-4
Electrical Output Connections ....................................................................................................A-5
Operation ...............................................................................................................................Section B
Safety Instructions ......................................................................................................................B-1
General Description ....................................................................................................................B-1
Recommended Applications.......................................................................................................B-1
Operational Features and Controls.............................................................................................B-1
Welding Capability ......................................................................................................................B-1
Limitations .................................................................................................................................B-2
Controls and Settings .................................................................................................................B-2
Engine Operation .........................................................................................................B-3 Thru B-6
Welding Operation .....................................................................................................B-7 Thru B-16
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)...........................................................................PSeries
MASTER TABLE OF CONTENTS FOR ALL SECTIONSvi vi
POWER-ARC 4000
TECHNICAL SPECIFICATIONS - POWER-ARC 4000
INPUT - BRIGGS INTEK® GASOLINE ENGINE
Manufacturer Description Speed Displacement Ignition Capacities
Briggs & 1 cyl., 3700 RPM 18.64 cu. in. Manual, Fuel: 1.0 gal. (3.8 l)Stratton Intek 4 cycle ± 50 RPM (305 cc) Recoil start;
Model air-cooled at no load Manual choke Oil: 28 oz (0.8 l)OHV gasoline
8 HP @3750 RPM
INPUT - HONDA GASOLINE ENGINEINPUT - 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 start;
air-cooled OHV at no load Manual choke Oil: 1.16 qt. (1.11 l)gasoline9 HP @
3600 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-1INSTALLATION
POWER-ARC 4000
A-1
A-2INSTALLATION
POWER-ARC 4000
A-2
SAFETY PRECAUTIONSRead this entire installation section before youstart installation.
Do not attempt to use this equipment until youhave thoroughly read all the operation and main-tenance manuals supplied with your machine.They include important safety precautions;detailed engine starting, operating, and mainte-nance instructions; and parts lists.
ELECTRIC SHOCK can kill.
• Do not touch electrically liveparts or electrodes with yourskin or wet clothing.
• Insulate yourself from thework and ground.
•Always wear dry insulating gloves.
ENGINE EXHAUST can kill.
• Use in open, well ventilatedareas or vent exhaust to theoutside.
• Do not stack anything on ornear the engine.
MOVING PARTS can injure.
• Do not operate this equip-ment with any of its doorsopen or guards off.
• Stop the engine before ser-vicing it.
• Keep away from moving parts.
Only qualified personnel should install, use, or servicethis equipment.
LOCATION AND VENTILATIONWhenever you use the POWER-ARC 4000, be surethat clean cooling air can flow through the machine’sgasoline engine and the generator. Avoid dusty, dirtyareas. Also, keep the machine away from heatsources. Do not place the back end of the generatoranywhere near hot engine exhaust from anothermachine. And of course, make sure that engineexhaust is ventilated to an open, outside area.
The POWER-ARC 4000 may be used outdoors. Donot set the machine in puddles or otherwise sub-merge it in water. Such practices pose safety haz-ards and cause improper operation and corrosion ofparts.
Always operate the POWER-ARC 4000 with the caseroof on and all machine components completelyassembled. This will protect you from the dangers ofmoving parts, hot metal surfaces, and live electricaldevices.
STORING
1. Store the machine in a cool, dry place when it’snot in use. Protect it from dust and dirt. Keep itwhere it can’t be accidentally damaged from con-struction activities, moving vehicles, and otherhazards.
2. If you will be storing the machine for over 30days, you should drain the fuel to protect fuelsystem and carburetor parts from gum deposits.Empty all fuel from the tank and run the engineuntil it stops from lack of fuel.
3. You can store the machine for up to 24 months ifyou use Briggs & Stratton Gasoline Additive, PartNo. 5041 (available from any Authorized Briggs &Stratton Service Center), in the fuel system. Mixthe additive with the fuel in the tank and run theengine for a short time to circulate the additivethrough the carburetor.
4. While the engine is still warm, drain the oil andrefill with fresh oil per the engine manual.
5. Remove the spark plug and pour approximately1/2 ounce (15 ml) of engine oil into the cylinder.Replace the spark plug and crank the engineslowly to distribute the oil.
6. Clean any dirt and debris from the cylinder andcylinder head fins and housing, rotating screen,and muffler areas.
7. Store in a clean, dry area.
WARNING
A-3INSTALLATION
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 designed to run in a level posi-tion for best performance. It can operate at an angle,but this should never be more than 15 degrees in anydirection. If you do operate it at a slight angle, be sureto 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 peo-ple. (It weighs 160 lbs/72.5 kg.) Its welded tube rollcage is designed to make lifting easy.
ANGLE OF OPERATION
Internal combustion engines are designed to run in alevel condition to achieve optimum performance. Themaximum angle of operation for the engine is 15degrees from horizontal in any direction. Be certain toplace the machine on a firm, non-skid, structural sup-porting surface. Anchor unit if necessary.
If you are operating the engine at a slight angle, becertain to check the oil regularly and maintain a level,full oil condition. The effective fuel capacity will alsobe slightly less than the specified 1.00 gallon (3.8liters).
PRE-OPERATION ENGINE SERVICERead and understand the information about the gaso-line engine in the OPERATION and MAINTENANCEsections of this manual and the engine owner’s man-ual before you operate the POWER-ARC 4000.
• Keep hands away from the engine muffler orHOT 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 clearbefore starting the engine.
• Keep sparks and flame away from the fuel tank.
OIL
The Power-Arc 4000 with the Briggs and Stratton 8HP engine and the Power-Arc 4000 with the Honda 9HP engine are supplied with low oil protection. ThePower-Arc 4000 with the Briggs and Stratton 8 HPengine is equipped with protection that will preventthe engine from starting if the oil level is low. ThePower-Arc 4000 with the Honda 9 HP engine isequipped with protection that will shut down theengine in the event of a low oil condition. The enginecannot be restarted until sufficient oil is added.
The POWER-ARC 4000 is shipped with the enginefilled with SAE 10W-30 oil. CHECK THE OIL LEVELBEFORE YOU START THE ENGINE. This is anadded precaution. When full, the oil level should be atthe top of the fill plug hole. If it is not full, add enoughoil to fill it. Be sure the fill plug is tight. Change oilafter the first 5 hours of operation. If the POWER-ARC4000 has a Honda engine, then change the oil afterthe first 20 hours of operation.
For more oil fill and service information, see theEngine owner’s manual.
FUEL
Fill the fuel tank with clean, fresh, regular grade lead-free gasoline. DO NOT MIX OIL WITHTHE GASOLINE.
The POWER-ARC 4000 has a fuel tankmounted on the engine. See the engine owner’s man-ual for more details about fuel.
WARNING
No Load3700 RPM ±50 R.P.M.AC CC Weld Output125 Amps @ 18 VoltsAC CC Weld Output100 Amps @ 25 VoltsAuxiliary Power 4000Watts (120/240 Volts)
B&S 8 HP Carb. CertifiedIntek
0.28 Gallons/Hour(1.06 Liters/Hour).57 Gallons/Hour(2.16 Liters/Hour).52 Gallons/Hour(1.97 Liters/Hour).59 Gallons/Hour(2.23 Liters/Hour)
Honda 9 HPCarb. Certified
.30 Gallons/Hour(1.14 Liters/Hour).58 Gallons/Hour(2.18 Liters/Hour).55 Gallons/Hour(2.1 Liters/Hour).67 Gallons/Hour(2.54 Liters/Hour)
SPARK ARRESTER
Gasoline engine mufflers may emit sparks when theengine is running. Some federal, state, or local lawsrequire spark arresters in locations where unarrestedsparks could present a fire hazard.
Standard mufflers and deflectors (like the onesincluded with the POWER-ARC 4000 Briggs &Stratton engines) do not act as spark arresters. Whenlocal laws require it, a spark arrester must be installedon the machine and properly maintained.
An optional spark arrester kit is available for yourPOWER-ARC 4000 Briggs & Stratton 8 HP Intekengine. See the ACCESSORIES section of this man-ual for more information.
An incorrect spark arrester may lead to damage tothe engine or reduce performance. A suitablespark arrester for the Briggs & Stratton 8 HP Intekengine is available from your local Briggs &Stratton engine dealer.
The Power-Arc 4000 with the Honda engine comeswith a spark arrester as standard equipment. Refer tothe engine owner’s manual for proper maintenance.
A-4INSTALLATION
POWER-ARC 4000
A-4
MUFFLER DEFLECTOR
The POWER-ARC 4000, depending on model, may ormay not be shipped with an exhaust deflector. If youreceived one, you can mount it on the gasolineengine if your needs so require.
To install the deflector, do the following:
• Align the holes on the deflector plate with the holeson the muffler.
• Position the deflector so that the opening points eitherright, left, or downward, away from the operator.
Never position the deflector upward. Moisture ordebris can enter the engine and damage it. As ageneral safety practice, position the deflector todirect exhaust gases away from the operator’sface and eyes.
• Fasten the deflector onto the muffler with thescrews provided.
NOTE: The deflector reduces generator outputpower up to 100 watts.
CAUTION
CAUTION
PowerArc 4000 Typical Fuel Consumption
A-5INSTALLATION
POWER-ARC 4000
A-5
ELECTRICAL OUTPUT CONNECTIONSSee Figure A.1 for the location of the current controldial, weld output terminals, ground stud, circuitbreakers, 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 especiallyimportant when you are welding at a distance fromthe welder.
Table A.1 lists recommended cable sizes and lengthsfor rated current and duty cycle. Length refers to thedistance from the welder to the work and back to thewelder. Cable diameters are increased for long cablelengths to reduce voltage drops.
TABLE A.1RECOMMENDED WELDING CABLE
SIZE AND LENGTH
TOTAL COMBINED LENGTH OF ELECTRODE ANDWORK 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
POWER ARC 4000
ELECTRODE SELECTION GUIDE
80
90
100
70
AMPSAMPS
AMPSAMPS
AMPSAMPSAMPSAMPS
WARNINGWARNING
AMPSAMPS125
GENERATORGENERATOR
6
5
43
2
17
FIGURE A.1 - POWER-ARC 4000 OUTPUT CONNECTIONS
1. CURRENT CONTROL DIAL2. WELD OUTPUT TERMINALS (2)3. GROUND STUD
4. CIRCUIT BREAKERS (2) - 20 AMP5. RECEPTACLE - 240 VOLT, 20 AMP6. DUPLEX RECEPTACLE - 120 VOLT, 20
AMP7. TACHOMETER / HOURMETER
(CODE 10930 ONLY)
A-6INSTALLATION
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 electrode holder and work cables tothe weld output terminals. You can connect eithercable to either terminal, since the POWER-ARC4000 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 workclamp and cable.
6. Check and tighten the connections periodically.
• Loose connections will cause the output termi-nals to overheat. The terminals may eventuallymelt.
• Do not cross the welding cables at the outputterminal connection. Keep the cables isolatedand separate from one another.
Lincoln Electric offers a welding accessory kit withthe properly specified welding cables. See theACCESSORIES section of this manual for more infor-mation.
MACHINE GROUNDINGBecause the POWER-ARC 4000 createsits own power from its gasoline-enginedriven generator, you do not need toconnect the machine frame to an earthground. However, for best protection
against electrical shock, connect a heavy gauge wirefrom the ground stud located on the bottom center ofthe output panel (see Figure A.1) to a suitable earthground such as a metal pipe driven into the ground.
Do not ground the machine to a pipe that carriesexplosive or combustible material.
When the POWER-ARC 4000 is mounted on a truckor a trai ler, the machine generatorground stud MUST be securely connect-ed to the metal frame of the vehicle. SeeFigure A.1. The ground stud is markedwith the symbol.
PLUGS AND HAND-HELD EQUIPMENTFor further protection against electric shock, anyelectrical equipment connected to the generatorreceptacles must use a three-blade, grounded typeplug or an Underwriter’s Laboratories (UL) approveddouble insulation system with a two-blade plug.Lincoln offers an accessory plug kit that has the righttype of plugs. See the ACCESSORIES section of thismanual for details.
Ground fault protection is needed for hand heldequipment.
Never operate this machine with damaged or defec-tive cords. All electrical equipment must be in safecondition.
AUXILIARY POWER RECEPTACLESThe control panel of the POWER-ARC 4000 featurestwo auxiliary power receptacles:
• A 20 amp, 120 volt duplex (double outlet) recepta-cle
• A 20 amp 240 volt simplex (single outlet) recepta-cle.
See Figure A.1.
Through these receptacles the machine can supplyup to 4,000 rated continuous watts and 4,400 surgewatts of single-phase AC power.
CAUTION
WARNING
WARNING
A-7INSTALLATION
POWER-ARC 4000
A-7
PREMISES WIRINGThe POWER-ARC 4000 three-wire, grounded neutralgenerator allows it to be connected to premiseswiring. However, the wiring procedure needed tomeet the National Electric Code (NEC) regulations aswell as city ordinances and can be confusing. Theconnections could vary from a "commonly grounded"to a "separately derived" system depending onwhether you want the unit to be "hard wired" or tem-porary to the premises.
Only a licensed, certified, trained electricianshould install the machine to a premises or resi-dential electrical system. Be certain that:
• The premises is isolated and no feedbackinginto the utility system can occur. Certain stateand local laws require the premises to be isolat-ed before the generator is linked to the premis-es. Check your state and local requirements.
• A double pole, double throw transfer switch inconjunction with the properly rated doublethrow circuit breaker is connected between thegenerator power and the utility meter.
The POWER-ARC 4000 does not have a combined120/240 volt twist-lock receptacle and cannot beconnected to a premises as described in otherLincoln literature.
Remember that the POWER-ARC 4000 is intendedonly for backup, intermittent use power. Oil level mustbe checked after every 5 hours of use. It cannot with-stand long-term use without proper maintenance.See the MAINTENANCE section of this manual andthe engine owner’s manual for more information.
Certain electrical devices cannot be powered by thePOWER-ARC 4000. Refer to Table A.2 for thesedevices.
CIRCUIT BREAKERS
The POWER-ARC 4000 has its own 20 amp circuitbreakers for overload protection. When the machineis operated in high temperature environments, thebreakers may tend to trip at lower loads than normal-ly.
Never bypass the circuit breakers. Without over-load protection, the power-arc 4000 could over-heat and/or cause damage to the equipment beingused.
CAUTION
WARNING
A-8INSTALLATION
POWER-ARC 4000
A-8
CAUTION
Certain Electrical devices cannot be powered by the POWER-ARC 4000. See Table A.2.
TABLE A.2ELECTRICAL DEVICE USE WITH THE POWER-ARC 4000.
Type Common Electrical Devices Possible Concerns
Resistive Heaters, toasters, incandescent NONElight bulbs, electric range, hot pan, skillet, coffee maker.
Capacitive TV sets, radios, microwaves, Voltage spikes or high voltageappliances with electrical control. regulation can cause the capaci-
tative elements to fail. Surgeprotection, transient protection,and additional loading is recom-mended for 100% fail-safeoperation. DO NOT RUNTHESE DEVICES WITHOUTADDITIONAL RESISTIVE TYPELOADS.
Inductive Single-phase induction motors, These devices require largedrills, well pumps, grinders, small current inrush for starting. (Seerefrigerators, weed and hedge Table B.3, GENERATOR POWERtrimmers APPLICATIONS, in the OPERA-
TION section of this manual forrequired starting wattages.)Some synchronous motors maybe frequency sensitive to attainmaximum output torque, butthey SHOULD BE SAFE fromany 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, andliabilities still exist. DO NOTUSE THESE DEVICES WITH APOWER-ARC 4000.
The Lincoln Electric Company is not responsible for any damage to electrical components improperly connect-ed to the POWER-ARC 4000.
B-1OPERATIONB-1SAFETY INSTRUCTIONSRead and understand this entire section before oper-ating your POWER-ARC 4000.
Do not attempt to use this equipment until youhave thoroughly read all the operation and main-tenance manuals supplied with your machine.They include important safety precautions;detailed engine starting, operating, and mainte-nance instructions; and parts lists.
ELECTRIC SHOCK can kill.• Do not touch electrically live parts
or electrodes with your skin or wetclothing.
• Insulate yourself from the work and ground.
• Always wear dry insulating gloves.
FUMES AND GASES can bedangerous.• Keep your head out of fumes.
• Use ventilation or exhaust toremove fumes from breathing zone.
WELDING SPARKS can causefire or explosion.• Keep flammable material away.
• Do not weld on containers that haveheld 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 nearthe 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 ser-vice this equipment.
GENERAL DESCRIPTIONThe POWER-ARC 4000 is a generator/welder designedfor home use and other non-commercial applications.As a generator it can supply up to 4,000 continuouswatts (or 4,400 surge watts) of 120/240 volt, single-phase AC power. As a welder it provides 125 amps ofAC constant current for welding with AC stick elec-trodes. A single dial provides continuous adjustment ofwelding output. The machine is lightweight, portable,and can be lifted by two people.
The Lincoln warranty covers the Power-Arc 4000(excluding the engine) for 2 years from the date of pur-chase. The engine is covered by the engine manufactur-er’s warranty policy.
RECOMMENDED APPLICATIONSGENERATORThe POWER-ARC 4000 gives AC generator output formedium use, non-commercial demands. For moredetails on operating the generator, see GENERATOROPERATION in the OPERATION section of this manual. WELDERThe POWER-ARC 4000 provides excellent constant cur-rent AC welding output for stick (SMAW) welding. Formore details on using the machine as a welder, seeWELDING OPERATION in the OPERATION section ofthis manual.
OPERATIONAL FEATURES AND CONTROLSThe POWER-ARC 4000 was designed for simplicity.Therefore, it has very few operating controls. A singledial on the control panel lets you select either generatoror welding use. For welding, the same dial selects con-tinuous current output over the machine’s 70 to 125amp range.The gasoline engine controls include a recoil starter,choke, and rotary stop switch. See ENGINE OPERA-TION in the OPERATION section of this manual and theengine owner’s manual for details about starting, run-ning, stopping, and breaking in the gasoline engine.
WELDING CAPABILITYThe POWER-ARC 4000 is rated 125 amps, 20 volts at30% duty cycle on a ten-minute basis. This meansthat you can load the welder to 125 amps for threeminutes out of every ten-minute period. The machineis also capable of higher duty cycles at lower outputcurrents. You can load the welder to 100 amps for sixminutes out of ten for a 60% duty cycle.The current is continuously variable from 70 to 125amps AC. The POWER-ARC 4000 can weld with all3/32 and most 1/8 inch diameter Lincoln AC elec-trodes.
POWER-ARC 4000
WARNING
B-2OPERATIONB-2
LIMITATIONS• The POWER-ARC 4000 is not recommended for
any processes besides those that are normally per-formed using stick welding (SMAW) procedures.
• The POWER-ARC 4000 is not recommended forpipe thawing.
• During welding, generator power is limited to 100watts, and output voltages can drop from 120 to 80volts and 240 to 160 volts. Therefore, DO NOTOPERATE ANY SENSITIVE ELECTRICAL EQUIP-MENT WHILE YOU ARE WELDING.
CONTROLS AND SETTINGSAll generator/welder controls are located on theOutput Control Panel. Gasoline engine controls aremounted on the engine. See Figures B.1 and B.2 andthe explanations that follow.
GENERATOR/WELDER CONTROLSSee Figure B.1 for the location of the following fea-tures:
1. CURRENT CONTROL DIAL: Adjusts continuouscurrent output. The amperages on the dial corre-spond to the average amperages needed for spe-cific Lincoln welder rods.
2. ELECTRODE SELECTION GUIDE: Provides rec-ommended electrode type, size, and welder out-put setting based on the thickness of the work.
3. WELD OUTPUT TERMINAL (TO ELECTRODEHOLDER) WITH 1/2 - 13 FLANGE NUT: Providesthe connection point for either the electrode hold-er or the work cable. (Because the POWER-ARC4000 is an AC output machine, either output ter-minal can be used for either cable.)
POWER-ARC 4000
POWER ARC 4000POWER ARC 4000
ELECTRODE SELECTION GUIDEELECTRODE SELECTION GUIDE
8080
9090
100100
7070
AMPSAMPS
AMPSAMPS
AMPSAMPSAMPSAMPS
WARNING
AMPSAMPS125125
GENERATORGENERATOR
8
7
65
3
1
2
4
9
FIGURE B.1 – OUTPUT PANEL CONTROLS
1. CURRENT CONTROL DIAL2. ELECTRODE SELECTION GUIDE3. WELD OUTPUT TERMINAL (TO ELECTRODE HOLDER) WITH 1/2 - 13 FLANGE NUT 4. WELD OUTPUT TERMINAL (TO WORK) WITH 1/2 - 13 FLANGE NUT5. GROUND STUD6. 20 AMP CIRCUIT BREAKERS (2)7. 20 AMP, 240 VOLT RECEPTACLE8. 20 AMP, 120 VOLT DUPLEX RECEPTACLE9. TACHOMETER / HOURMETER (CODE 10930 ONLY)
B-3OPERATIONB-3
POWER-ARC 4000
4. WELD OUTPUT TERMINAL (TO WORK) WITH 1/2- 13 FLANGE NUT: Provides the connection pointfor either the electrode holder or the work cable.(Because the POWER-ARC 4000 is an AC outputmachine, either output terminal can be used foreither cable.)
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: Connectionpoint for supplying 240 volt power to operate oneelectrical device.
8. 20 AMP, 120 VOLT DUPLEX RECEPTACLE:Connection point for supplying 120 volt power tooperate one or two electrical devices.
9. Tachometer / Hourmeter: (For Code 10930 Only)
Records engine speed in RPMs, engine runningtime, and alerts the user to perform a specificengine maintenance task by flashing correspond-ing messages. If the message reads “Chg Oil”, theuser needs to change the oil in the engine. If themessage reads “SVC AIR-FiILTER”, the userneeds to clean or if necessary,change the air filter.(See Honda Engine”s owners manual for moreinformation). After maintenance task is preformed,the user is required to use the supplied Reset Toolto cancel flashing message and resume normalmeter operation. (See page D-1 for futher details).
GASOLINE ENGINE CONTROLSRefer to your engine manual for the location of thefollowing features:
1. FUEL SHUTOFF VALVE: Stops the flow of gaso-line from the fuel tank to the carburetor. Shouldbe closed whenever you are finished using thePOWER-ARC 4000. Must be opened before youstart the engine.
2. FUEL TANK AND CAP: See TECHNICAL SPECI-FICATIONS for capacity.
NOTE: If you use any other alternate fuel tank orsupply, be sure to use a recommended in-line fuel filter.
3. MUFFLER: Reduces engine noise output. Briggs& Stratton muffler does not serve as a sparkarrester. Honda muffler does. See SPARKARRESTER in the INSTALLATION section of thismanual.
4. ROTARY STOP SWITCH: Stops the engine bygrounding the ignition circuit.
5. AIR CLEANER: Filters intake air to the carburetor.See ENGINE MAINTENANCE in the MAINTE-NANCE section of the engine owner’s manual fordetails about the specific type of air cleaner touse.
6. CHOKE: Provides a richer air/fuel mix-ture for cold engine starting condi-tions. See the topic ENGINE OPERA-TION, below, for details on setting thechoke.
7. RECOIL STARTER: Manual, rope-type starter.The handle position allows easy starting fromeither ground level or pickup-truck level
8. OIL DRAIN PLUG: Permits convenient draining ofengine oil during maintenance. Both sides of theengine are equipped with an oil drain plug.
9. OIL FILL PLUG: Permits convenient filling ofengine oil during maintenance. Both sides of theengine are equipped with an oil fill plug.
ENGINE OPERATION
DO NOT RUN THE ENGINE AT EXCESSIVESPEEDS. The maximum allowable high idle speedfor the POWER-ARC 4000 is 3750 RPM, no load.Do NOT adjust the governor screw on the engine.Severe personal injury and damage to themachine can result if it is operated at speedsabove the maximum rated speed.
Read and understand all safety instructions includedin the engine manufacturer’s Operating andMaintenance Instructions manual that is shippedwith the POWER-ARC 4000.
WARNING
4. Pull the cord rapidly.
5. If the engine does not start, open the chokeslightly 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 severalseconds to several minutes, depending on thetemperature. After starting the engine, first openthe choke (toward RUN) until the engine justbegins to run smoothly. Then open the choke insmall steps, allowing the engine to accept smallchanges in speed and load, until the choke is fullyopen (in RUN). During engine warm-up the equip-ment can be operated.
FOR A “HOT” ENGINE:
1. Open the fuel shutoff valve.
2. Place the choke lever in the “RUN”position. Closing the choke of a hotengine will flood the carburetor andprevent starting.
3. Pull slightly on the recoil starter handle until resis-tance is felt.
4. Pull the cord rapidly.
FOR BEST ENGINE STARTING:
• Always use fresh gasoline and be sure the filter isclean and properly maintained.
• If you use an alternate fuel tank or supply, be sureto install an in-line fuel filter.
• Do not pull the recoil starter with thechoke in the “CHOKE” position morethan one time. Repeated pulls on achoked engine will flood the carbure-tor.
• If the engine wil l not start, see the TROU-BLESHOOTING section of this or the engineowner’s manual.
speed when not under load. You should not adjustthis setting yourself.
B-4OPERATIONB-4
BEFORE STARTING THE ENGINECHECK AND FILL THE ENGINE OIL LEVEL:
1. Place the machine on a levelsurface.
2. Open the oil fill plug.
3. Fill (if necessary) until oil flows out the top of thefill plug hole.
4. Replace the fill plug and tighten securely.
CHECK AND FILL THE ENGINE FUEL TANK:
1. Remove the fuel tank cap.
2. Fill the tank to allow approximately 1/4inch (5 mm) of tank space for fuelexpansion. DO NOT FILL THE TANKTO THE POINT OF OVERFLOW.
3. Replace the fuel tank cap and tighten securely.
NOTE: The engine will operate satisfactorily on anygasoline meant for automotive use. A mini-mum of 87 octane is recommended. DO NOTMIX OIL WITH THE GASOLINE.
Use clean, fresh, lead-free gasoline. Leaded gasolinemay be used if lead-free is not available. However,lead-free gasoline leaves fewer combustion depositsand gives longer valve life. Purchase gasoline inquantities that will be used within 30 days, to assurefreshness.
NOTE: We DO NOT recommend using gasoline thatcontains alcohol, such as gasohol. However,if gasoline with alcohol is used, it MUST NOTcontain more than 10% Ethanol and MUSTbe removed from the engine during storage.DO NOT use gasoline containing Methanol.
STARTING THE ENGINENOTE: Remove all loads connected to the AC power
receptacles before starting the gasolineengine. Turn the Rotary Stop Switch to the“ON” position.
FOR A “COLD” ENGINE:
1. Open the fuel shutoff valve.
2. Place the choke lever in the “CHOKE”position.
3. Pull slightly on the recoil starter handle until resis-tance is felt.
POWER-ARC 4000
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 POWER-ARC 4000, in the INSTALLATION section of thismanual.
-----------------------------------------------------------
GENERAL INFORMATIONThe POWER-ARC 4000 generator is rated at 4000continuous watts (4400 surge watts). It provides both120 volt and 240 volt power. You can draw up to 20amps from either side of the 120 volt duplex recepta-cle, but no more than 37 amps from both sides atonce. Up to 18 amps can be drawn from the single240 volt receptacle.
Electrical loads in watts are calculated by multiplyingthe voltage rating of the load by the number of ampsit draws. (This information is given on the load devicenameplate.) For example, a device rated 115 volts, 2amps will need 230 watts of power (115 x 2 = 230).
You can use Table B.3, GENERATOR POWER APPLI-CATIONS, to determine the wattage requirements ofthe most common types of loads you can power withthe POWER-ARC 4000. Be sure to read the notes atthe bottom of the table.
TO USE THE GENERATOR AS AN AUXILIARYPOWER SUPPLY:
1. Start the gasoline engine. See ENGINE OPERA-TION in this section of the manual and the engineowner’s manual.
2. Set the current control dial on the output controlpanel to “GENERATOR.” See Figure B.1.
3. Plug the load(s) into the appropriate 120 volt or240 volt power receptacle.
NOTE: During welding, the maximum generator out-put for auxiliary loads is 100 watts.
NOTE: You can supply multiple loads as long as thetotal load does not exceed 4,000 watts. Besure to start the largest loads first.
CAUTION
B-5OPERATIONB-5
STOPPING THE ENGINE1. Remove all welding and generator power loads
and let the engine cool by running it for severalminutes.
2. Stop the engine by placing the ignition switch inthe “OFF” position.
3. Close the fuel shutoff valve.
Close the fuel valve when the machine is trans-ported to prevent fuel leakage from the carbure-tor. Drain the tank before transporting themachine in a vehicle.
For long periods of storage, turn off the fuel shut-off valve (lowest, downward position) and let theengine run until there is no more fuel in the line.Use a fuel additive such as Sta-Bil to minimize fuelgum deposits.
-----------------------------------------------------------
RUNNING THE ENGINEThe engine is set at the factory to run at high idlespeed when not under load. You should not adjustthis setting yourself.
BREAK-IN PERIODThe engine will use a greater amount of oil during its“break-in” period. Check the oil frequently duringbreak-in. For more details, see the MAINTENANCEsection in the engine owner’s manual.
During break-in, subject the POWER-ARC 4000 toonly moderate loads. Avoid long periods runningat idle. Before stopping the engine, remove allloads and allow the engine to cool several min-utes.
-------------------------------------------------------------
POWER-ARC 4000
CAUTION
WARNING
TABLE B.3GENERATOR 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 - 4,000
Electric Range (1 element) 1,500
Electric Skillet 1,250
*Furnace Fan - 1/3 HP 1,200 3,000 - 4,800
Portable Grinder (4 1/2”) 600
Portable Grinder (7”) 2,000
Halogen Work Light 500
Hand Drill - 1/4” 500
Hand Drill - 3/8” 700
1500 Watt Heater 1,750
Hedge Trimmer 450
Light Bulb 100
Reciprocating Saw 900
Radial Arm Saw 2,600
Radio 50
*Refrigerator/Freezer (small) 600 1,500 - 2,400
Slow Cooker 200
*Submersible Pump - 1 HP 1,000 2,500 - 4,000
*Sump Pump 600 1,500 - 2,400
Toaster 1,100
Weed Trimmer 500
Lincoln 100 or 125 Amp Wire Feeder/Welder 4,000
B-6OPERATIONB-6
POWER-ARC 4000
NOTES:
Wattages listed are approximate. Check your equipment for actual wattage.
Equipment with unusually high *START-UP WATTS are listed. For start-up of other tabled equipment, allow upto 2 times the running watts shown above. For example a 1 HP motor requires approximately 1000 watts ofpower when running but may require (2.5 X 1000) = 2500 watts or (4.0 X 1000) = 4000 watts to start.
Multiple loads can be used as long as the total load does not exceed 4,000 watts. Be certain to start the largestloads first.
Output rating in watts is equivalent to volt-amperes at unity power factor (resistive load) and is calculated as:WATTS = VOLTS X AMPS DRAWN. for example a 115 volt device which is rated on its nameplate to draw 2amps will need (115 VOLTS) X (2 AMPS) = 230 WATTS OF POWER. 1 KW = 1000 WATTS.
B-7OPERATIONB-7
WELDING OPERATION
GENERAL INFORMATION
• Do not touch electrically live parts orelectrodes with your skin or wet cloth-ing.
• Do not breathe welding fumes orgases.
• Use ventilation or exhaust to removewelding fumes from the breathingarea.
• Keep flammable material away.
• Wear eye, ear, and body protection.
The POWER-ARC 4000 generator/welder can deliverfrom 70 to 125 amps of continuous welding outputcurrent . Output can be adjusted by setting the cur-rent control dial on the output control panel.
You can get maximum welding output by setting thedial to 125 AMPS. At high current settings like this,some output may decrease as the machine is used.If you are welding for a long time, you may need toturn the dial slightly upward to maintain the sameresults.
The numbers on the dial correspond to the averageamps needed to weld using specific Lincoln weldingrods. Table B.4, WELDING APPLICATIONS, givesyou the recommended dial settings based on thethickness of the work and the size and type of rodyou’re using.
TO USE THE POWER-ARC 4000 FOR WELDING:
1. Remove the flange nuts from the weld output ter-minals and place the work and electrode weldingcables over the terminals. See Figure B.1.Replace and tighten the flange nuts securely. Besure the connections are tight.
2. Select the appropriate electrode. See Table B.4,WELDING APPLICATIONS, or the ELECTRODESELECTION GUIDE on the machine OutputControl Panel.
3. Attach the work clamp securely to the work youare welding.
4. Insert the electrode into the electrode holder.
5. Set the current control dial to the desired outputcurrent.
6. Start the gasoline engine. See ENGINE OPERA-TION in this section of the manual.
7. Strike an arc and begin welding. For informationon welding techniques, see WELDING GUIDE-LINES in this section of the manual.
AFTER YOU FINISH THE WELD:
1. Stop the gasoline engine. See ENGINE OPERA-TION in this section of the manual.
2. Allow the electrode and work to cool completely.
3. Remove the work clamp from the work.
4. Remove any remaining piece of electrode fromthe electrode holder.
5. If you are finished using the POWER-ARC 4000for welding, disconnect the welding cables fromthe weld output terminals. Reattach the flangenuts and leave them on the terminals.
NOTE: 1. Welding current is continuously variablewith 60% duty cycle applying to outputcurrents 100 Amps and less and 30%duty cycle applying to currents above 100Amps.
2. Duty cycle is based on a ten minuteperiod. The welder can be loaded to 125Amps for three minutes out of every tenminute period or to 100 Amps for sixminutes out of every ten minute period.
CONTROL FUNCTION / OPERATION“Current Control Dial”Provides welding current adjustment from 70 through125 Amps.
To obtain maximum weld output, turn the “CurrentControl Dial” to “125 Amps” for either a cold or hotengine. As the machine is used, some welding volt-age may decrease at high current settings. If you arewelding for long periods of time, the dial may need tobe slightly turned upward to provide the same weldingresults as when the machine was cold.
The numbers listed on the dial correspond to the aver-age amperage needed to weld specific Lincoln rods.Refer to Table 2 “Welding Application Chart” and“Electrode Selection Guide” listed on the machinenameplate for proper current and electrode settings.
POWER-ARC 4000
WARNING
Stick welding is probably the most familiar weldingprocess known. A coated ELECTRODE, the weld rod,is clamped into an ELECTRODE HOLDER, an insulat-ed clamping device, which in turn connects to theELECTRODE CABLE, a heavy wire. The WORK, themetal piece to be welded, is connected to the WORKCABLE, a heavy wire which contains the WORKCLAMP. Quality Lincoln cables use many fine copperwires with a very flexible insulating covering for theelectrode and work cables. When properly connectedto the OUTPUT STUDS of a high current powersource, the electrode melts and bonds the metal beingrepaired. Refer to Figure 3 to see the circuit. See“Cable Installation” section for proper cable connec-tion to a Power-Arc.
The Power-Arc provides excellent weld output charac-teristics when used in combination with Lincoln ACelectrodes. Other AC electrodes may also be used.
Follow the settings l isted in Table 2 “WeldingApplication Chart” and the “Electrode Selection Guide”found on the nameplate of the machine.
ARC RAYS can burn.
• When using an open arc process,it is necessary to use correct eye,head and body protection.
Stick Welding
Semi-automatic, MIG Welding With aLincoln Weld Pak 100 or Weld Pak 125
The Power-Arc generator power can be used to supplypower to a Lincoln Weld-Pak 100 or Weld-Pak 125 wirefeed welder. The Weld-Pak is equipped with all thesupplies needed for Flux-Cored Arc Welding (FCAW),and is available where Lincoln products are sold.
A K610-1 MIG Conversion Kit is also available for theWeld-Pak which provides all the essentials needed forGas Metal Arc Welding, GMAW, or MIG processes.
B-8OPERATIONB-8
POWER-ARC 4000
Material Thickness Electrode Type Size Setting
1/8” and thinner FLEETWELD® 37 3/32” 90 amps1AWS E6013FLEETWELD® 180 70 ampsAWS E6011Lincoln 7018 AC 90 ampsAWS E7018
3/16” Maximum FLEETWELD® 37 1/8” 125 ampsAWS E6013
5/16” Maximum FLEETWELD® 180 1/8” 90 ampsAWS E6011
Any Thickness WEARSHIELD® ABR 1/8” 100 amps
WELDING GUIDELINESTABLE B.4
WELDING APPLICATIONS/ELECTRODE SELECTION GUIDE
NOTES:
The values listed are suggested settings. Actual set-ting may vary depending on individual preferenceand/or specific application. Beginners should useLincoln E7018 AC.
For electrodes not listed, follow tables that arepacked with the electrodes.
Ask for the Lincoln WELD DIRECTORY (PublicationM210) for a complete listing of all Lincoln stick elec-trodes available.1AWS = American Welding Society
Learning To Stick WeldThe serviceability of a product or structure utiliz-ing this type of information is and must be thesole responsibility of the builder/user. Many vari-ables beyond the control of The Lincoln ElectricCompany affect the results obtained in applyingthis type of information. These variables include,but are not limited to, welding procedure, platechemistry and temperature, weldment design, fab-rication methods and service requirements.
WARNING
B-9OPERATIONB-9
POWER-ARC 4000
No one can learn to weld simply by reading about it.Skill comes only with practice. The following pageswill help the inexperienced welder understand weldingand develop his skill. For more detailed information,order a copy of the book “New Lessons in ArcWelding.” (See Book Division section at rear of manual).
The operator’s knowledge of arc welding must gobeyond the arc itself. He must know how to control thearc, and this requires a knowledge of the welding cir-cuit and the equipment that provides the electric cur-rent used in the arc. Figure 3 is a diagram of the weld-ing circuit. The circuit begins where the electrodecable is attached to the welding machine and endswhere the work cable cable is attached to themachine. Current flows through the electrode cable tothe electrode holder, through the electrode holder tothe electrode and across the arc. On the work side ofthe arc, the current flows through base metal to thework cable and back to the welding machine. The cir-cuit must be complete for the current to flow. To weld,the work clamp must be tightly connected to cleanbase metal. Remove paint, rust,etc. as necessary toget a good connection. Connect the work clamp asclose as possible to the area you wish to weld. Avoidallowing the welding circuit to pass through hinges,bearings, electronic components or similar devicesthat can be damaged.
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 Figure 3) by hold-ing the tip of the electrode 1/16 - 1/8” (1.6-3.2mm)away from the work or base metal being welded. Theelectric arc is established in this gap and is held andmoved along the joint to be welded, melting the metalas it is moved.
Arc welding is a manual skill requiring a steady hand,good physical condition, and good eyesight. The oper-ator controls the welding arc and, therefore, the quali-ty of the weld made.
What Happens in the Arc?Figure 4 illustrates the action that takes place in theelectric arc. It closely resembles what is actually seenduring welding.
The “arc stream” is seen in the middle of the picture.This is the electric arc created by the electric currentflowing through the space between the end of theelectrode and the work. The temperature of this arc isabout 6000°F (3300°C) which is more than enough tomelt metal. The arc is very bright, as well as hot, andcannot be looked at with the naked eye without riskingpainful and possibly permanent injury. A very darklens, specifically designed for arc welding must beused with the handshield or headshield wheneverviewing the arc.
The arc melts the base metal and actually digs into it,much like water through a garden hose nozzle digsinto the earth. The molten metal forms a pool or craterand tends to flow away from the arc As it moves awayfrom the arc, it cools and solidifies. Slag forms on topof the weld to protect it during cooling.
MOVING PARTS can injure.• Do not operate with doors open or
guards off.• Stop engine before servicing.• Keep away from moving parts.
Only qualified personnel should install, use, orservice this equipment.
Covering
Electrode
Shielding Gases
ArcSolidified Slag
Weld Metal
Base Metal
FIGURE 4 - The welding arc.
The Power-Arc 4000 has a voltage output of up to 62volts which can shock.
ELECTRIC SHOCK can kill.• Do not touch electrically live parts
or electrode with skin or wet cloth-ing.
• Insulate yourself from work andground.
• Always wear dry insulating gloves.
ENGINE EXHAUST can kill.• Use in open, well ventilated areas
or vent exhaust outside.• Do not stack anything on or near
the engine.
WARNING
B-10OPERATIONB-10
POWER-ARC 4000
The function of the covered electrode is much morethan simply to carry current to the arc. The electrodeis composed of a core metal wire around which hasbeen extruded and baked a chemical covering. Thecore wire melts into the arc and tiny droplets of moltenmetal shoot across the arc into the molten pool. Theelectrode provides additional filler metal for the joint tofill the groove or gap between the two pieces of thebase metal. The covering also melts or burns in thearc. It has several functions. It makes the arc steadier,provides a shield of smoke-like gas around the arc tokeep oxygen and nitrogen in the air away from themolten metal, and provides a flux for the molten pool.The flux picks up impurities and forms a protectiveslag. The principle differences between the varioustypes of electrodes are in their coatings. By varyingthe coating, it is possible to greatly alter the operatingcharacteristics of electrodes. By understanding the dif-ferences in the various coatings, you will gain a betterunderstanding of selecting the best electrode for thejob you have at hand. In selecting an electrode, youshould consider:1. The type of deposit you want, e.g., mild steel,
stainless, low alloy, hardfacing.2. The thickness of the plate you want to weld.3. The position it must be welded in (downhand,
out-of-position).4. The surface condition of the metal to be welded.5. Your ability to handle and obtain the desired
electrode.Four simple manipulations are of prime importance.Without complete mastery of these four, furtherattempts at welding are futile. With complete masteryof the four, welding will be easy.1. The Correct Welding Position
I l lustrated is the correct welding posit ion forright-handed people. (For left-handed people it isopposite.)
Whenever possible, weld from left to right (if right-handed). This enables you to see clearly what youare doing.
Hold the electrode at a slight angle as shown inFigure 5.
Figure 5
15-20°
90°
side view end view
Correct Welding Position
2. The Correct Way to Strike An Arc
Be sure the work clamp makes good electrical contactto the work.Lower your headshield and scratch the electrodeslowly over the metal, and you will see sparks fly.While scratching, lift the electrode 1/8” (3.2mm) andthe arc is established.
NOTE: If you stop moving the electrode whilescratching, the electrode will stick. Most beginners tryto strike the arc by a fast jabbing motion down on theplate. Result: They either stick their electrode or theirmotion is so fast that they break the arc immediately.
3. The Correct Arc Length
The arc length is the distance from the tip of theelectrode core wire to the base metal.Once the arc has been established, maintaining thecorrect arc length becomes extremely important. Thearc should be short, approximately 1/16 to 1/8” (1.6-3.2mm) long. As the electrode burns off, the electrodemust be fed to the work to maintain correct arc length.
The easiest way to tell whether the arc has the correctlength is by listening to its sound. A nice, short arc hasa distinctive, “crackling” sound, very much like eggsfrying in a pan. The incorrect, long arc has a hollow,blowing or hissing sound.
4. The Correct Welding Speed
The important thing to watch while welding is the pud-dle of molten metal right behind the arc. DO NOTWATCH THE ARC ITSELF. The appearance of thepuddle and the ridge where the molten puddle solidi-fies indicates correct welding speed. The ridge shouldbe approximately 3/8” (9.5mm) behind the electrode.
Most beginners tend to weld too fast, resulting in athin, uneven, “wormy” looking bead. They are notwatching the molten metal.
IMPORTANT: It is not generally necessary to weavethe arc forward, backward or sideways. Weld along ata steady pace, and you will have an easier time.
NOTE: When welding on thin plate, you will find thatyou have to increase the welding speed, whereaswhen welding on heavy plate, it is necessary to gomore slowly to ensure fusion and penetration.
Ridge where puddlesolidifies
Molten puddle
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POWER-ARC 4000
PRACTICEThe 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 following:
Mild Steel Plate: 3/16” (4.8mm), or heavier.
Electrode: 1/8” (3.2mm) AWS 6011(Fleetweld® 180)
Current Setting: 90-125 Amps AC
Do the following:
1. Learn to strike the arc by scratching the electrodeover the plate. Be sure the angle of the electrodeis right and be sure to use both hands.
2. When you can strike an arc without sticking, prac-tice the correct arc length. Learn to distinguish itby its sound.
3. When you are sure that you can hold a short,crackling arc, start moving. Look at the moltenpuddle constantly, and look for the ridge where themetal solidifies.
4. Run beads on a flat plate. Run them parallel to thetop edge (the edge farthest away from you). Thisgives you practice in running straight welds, andalso, it gives you an easy way to check yourprogress. The 10th weld will look considerably bet-ter than the first weld. By constantly checking onyour mistakes and your progress, welding will soonbe a routine matter.
Common MetalsMost metals found around the farm or small shop arelow carbon steel, sometimes referred to as mild steel.Typical items made with this type of steel include mostsheet metal, plate, pipe and rolled shapes such aschannels, angle irons and “I” beams. This type ofsteel can usually be easily welded without specialprecautions. Some steel, however, contains highercarbon. Typical applications include wear plates,axles, connecting rods, shafts, plowshares andscraper blades.
These higher carbon steels can be welded successful-ly in most cases; however, care must be taken to fol-low proper procedures, including preheating the metalto be welded and, in some cases, carefully controllingthe temperature during and after the welding process.For further information on identifying various types ofsteel and other metals, and for proper procedures forwelding them, we suggest you purchase a copy of“New Lessons in Arc Welding” (See Book Divisionsection).
Regardless of the type of metal being welded, in orderto get a quality weld, it is important that it be free ofoil, paint, rust or other contaminants.
Types of Welds
Five types of welding joints are: Butt Joints, TeeJoints, Lap Joints, Edge Joints and Corner Joints.
Of these, the Butt Joint and Tee Joint are the mostcommon.
Butt Welds
Butt Joints are the most widely used Joints. Place twoplates side by side, leaving 1/16” (1.6mm) for thinmetal to 1/8” (3.2mm) for heavy metal space betweenthem in order to get deep penetration.
Tack the plates at both ends, otherwise the heat willcause the plates to move apart. (See drawing).
Butt Joint Lap Joint
Edge Joint Tee Joint Corner Joint
B-12OPERATIONB-12
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 both edges and in between the plates.
Penetration
Unless a weld penetrates close to 100%, a butt jointwill be weaker than the material welded together.
In this example, the total weld is only 1/2 the thicknessof the material; thus, the weld is only approximatelyhalf as strong as the metal.
In this example, the joint has been flame beveled orground prior to welding so that 100% penetrationcould be achieved. The weld, if properly made, is asstrong or stronger than the original metal.
Successive passes must be used to build up buttwelds on heavier metal.
Fillet Welds
When welding fillet welds, it is very important to holdthe electrode at a 45° angle between the two sides, orthe metal will not distribute itself evenly.
To make it easier to get the 45° angle, it is best to putthe electrode in the holder at a 45° angle, as shown.
Multiple Pass Welds
Make multiple pass horizontal fillets as shown in thesketch. Put the first bead in the corner with fairly highcurrent. Hold the electrode angle needed to depositthe filler beads as shown putting the final bead againstthe vertical plate.
Welding in the Vertical Position
Welding in the vertical position can be done eithervertical-up or vertical-down. Vertical-up is usedwhenever a large, strong weld is desired.Vertical-down is used primarily on sheet metal for fast,low penetrating welds.
end view side view
20°
90°
1
Good
60°4
3
2
1
1/8" (3.2mm)
45°
45°
112
2
34
B-13OPERATIONB-13
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:
1. Use 1/8” (3.2mm) 90-115 amps or 3/32” (2.5mm)70 amps AWS 6011.
2. When welding, the electrode should be kept hori-zontal or pointing slightly upwards. (See drawingabove).
3. The arc is struck and metal deposited at the bot-tom of the two pieces to be welded together.
4. Before too much molten metal is deposited, the arcis SLOWLY moved 1/2-3/4” (12-20mm) upwards.This takes the heat away from the molten puddle,which solidifies. (If the arc is not taken away soonenough, too much metal will be deposited, and itwill “drip”.)
5. The upward motion of the arc is caused by a veryslight wrist motion. Most definitely, the arm mustnot move in and out, as this makes the entireprocess very complicated and difficult to learn.
6. If the upward motion of the arc is done correctlywith a wrist motion, the arc will automaticallybecome a long arc that deposits little or no metal.(See drawing above.)
7. During this entire process, the ONLY thing towatch is the molten metal. As soon as it has solidi-fied, the arc is SLOWLY brought back, and anotherfew drops of metal are deposited. DO NOT FOL-LOW THE UP AND DOWN MOVEMENT OF THEARC WITH YOUR EYES. KEEP THEM ON THEMOLTEN METAL.
8. When the arc is brought back to the now solidifiedpuddle, IT MUST BE SHORT, otherwise no metalwill be deposited, the puddle will melt again, and itwill “drip”.
9. It is important to realize that the process consistsof SLOW, DELIBERATE movements. There are nofast motions.
Vertical-Down Welding
Vertical-down welds are applied at a fast pace. Thesewelds are therefore shallow and narrow, and areexcellent for sheet metal. Do not use the vertical-downtechnique on heavy metal. The welds will not bestrong enough.
1. Use 1/8” (3.2m) or 3/32” (2.5mm) AWS 6011.
2. On thin metal use 70-75 amps.(14 ga. 75 A - 16 ga. 60 A.)
3. Hold the electrode in a 30-45° angle with the tip ofthe electrode pointing upwards.
4. Hold a VERY SHORT arc, but do not let the elec-trode touch the metal.
5. An up and down whippingmotion will help preventburn-through on very thin plate.
6. Watch the molten metal carefully.
The important thing is to continue lowering the entirearm as the weld is made so the angle of the electrodedoes not change. Move the electrode fast enough sothat the slag does not catch up with the arc.
Veryshort
arc
30°-40°
Long arc
Short arc
NOTE: Holder end of electrodeis lower than arc.
B-14OPERATIONB-14
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) 70 AAWS 6011 electrode on AC.
2. Put the electrode in he holder so it sticks straightout.
3. Hold the electrode at an angle approximately 30°off vertical, both seen from the side and seen fromend. (See drawing below.)
It is important to hold a VERY SHORT arc. (A longarc will result in falling molten metal; a short arc willmake the metal stay.)
If necessary, and this is dictated by the appearance ofthe molten puddle, a slight back and forth whippingtechnique may be used to prevent “dripping”.
Welding Sheet Metal
Welding sheet metal presents an additional problem-burn through. Follow these simple rules:
1. Hold a very short arc. This, together with the prop-er travel speed, will eliminate burn through.
2. Use 1/8” (3.2mm) or 3/32” (2.5mm) AWS 6011.
3. Use low amperage. 75 A for 1/8” (3.2mm) elec-trode, 70 A for 3/32” (2.5mm) electrode.
4. Move rapidly enough to stay ahead of the moltenslag. A whipping technique may be used to furtherminimize burn through.
5. If you have a choice, use lap joints rather than fil-lets or butts; the double thickness effect of a lapjoint makes it much easier to weld without burningthrough.
Hardfacing (To Reduce Wear)
There are several kinds of wear. The two most oftenencountered are:
1. Metal to Ground Wear: Plowshares, bulldozerblades, buckets, cultivator shares, and other metalparts moving in the soil.
2. Metal to Metal Wear: Trunnions, shafts, rollers andidlers, crane and mine car wheels, etc.
Each of these types of wear demands a different kindof hardfacing electrode.
When applying the proper electrode, the service life ofthe part will in most cases be more than double. Forinstance, hardfacing of plowshares results in 3-5 timesmore acreage plowed.
How to Hardface the Sharp Edge (Metal to GroundWear)
1. Grind the share, approximately one inch along theedge, so the metal is bright and clean.
2. Place the share on an incline of approximately20-30°. The easiest way to do this is to put oneend of the share on a brick. (See drawings) Mostusers will want to hardface the underside of theshare, but some might find that the wear is on thetop side. The important thing is to hardface theside that wears.
3. Use 1/8” (3.2mm) Wearshield at 80-100 A. Strikethe arc about one inch from the sharp edge.
Side View End View
30°30°
B-15OPERATIONB-15
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 share and weld to theheel. The second weld will begin 6” (152mm) fromthe heel, the third weld 9” (229mm) from the heel,etc.
Backstepping greatly reduces the chances for crack-ing of the share, and it also greatly reduces warping.
NOTE: The entire process is rather fast. Many begin-ners go much too slowly when hardfacing plowshares,running the risk of burning through the thin metal.
Welding Cast Iron
When welding on a piece of cold cast iron, thetremendous heat from the arc will be absorbed anddistributed rapidly into the cold mass. This heatingand sudden cooling creates WHITE, BRITTLE castiron in the fusion zone. (See drawing below.)
This is the reason why welds in cast iron break.Actually, one piece of the broken cast iron has theentire weld on it and the other piece has no weld on it.(See drawing below.)
To overcome this, the welding operator has twochoices:
1. Preheat the entire casting to 500-1200°F (260-649°C) If the cast iron is hot before welding, therewill be no sudden chilling which creates brittlewhite cast iron. The entire casting will cool slowly.
2. Weld 1/2” (12.7mm) at a time, and do not weld atthat spot again until the weld is cool.
This way, no large amount of heat is put into themass.
Most inexperienced welders will probably use the sec-ond method, because they have no way of preheatinglarge castings. Smaller castings can easily (andshould) be preheated before welding. A forge, stove,fire, or the Arc Torch are all excellent means of pre-heating.
When using the 1/2” (12.7mm) at a time method, it isrecommended to start 1/2” (12.7mm) away from theprevious bead and weld into the previous bead. Thisis called backstepping.
After welding Cast Iron, protect the casting againstfast cooling. Put it in a container of warm, dry sand orlime.
If sand or lime is not available, cover it with sheetmetal or any other non-flammable material that willdiminish drafts and retain heat.
Cast Iron Plate Preparation
Wherever practical, the joint to be welded should be“veed” out by grinding or filing to give complete pene-tration as shown in figures (a), (b) and (c) below. Thisis especially important on thick castings where maxi-mum strength is required.
Work TableStrike ArcHere Sharp Edge
Weaving Motion
Plow Share
Positioning of Share
Brick
1/2-3/4" width(12-20mm)
hot
coldcold
White brittlecast iron
When breakingthe weld stays onone piece
First weld from A to B; thenfrom C to A; then from D to C;then from E to D; and so on.
BACKSTEPPING(75mm)
3"
B A C D E
B-16OPERATIONB-16
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 fillets and laps or shortand irregular welds that change direction or position.They are also widely used in maintenance and recom-mended for sheet metal fillet and lap welds. Motion“D” (see drawing) is generally used for vertical-upwelding, but motions “A” and “B” are also suitable.
Low Hydrogen Group (AWS E7018)
These electrodes are generally called “low hydrogen”.The name comes from the fact that their coatingcontains little hydrogen in either moisture or chemicalform. Low hydrogen electrodes offer these benefits:outstanding crack resistance, lowest porosity onsulphur bearing steels, and X-ray quality deposit capa-bility. Thus, they are the first choice when welding“problem” steels. E7018 can be used in all positions,with Motion “C” (below) recommended for the firstpass on vertical-up welds. NEVER use a whippingtechnique or a long arc with these electrodes.ALWAYS fill craters by drawing electrode away slowly.ALWAYS keep these electrodes dry. Electrodes, whennot used within a few hours after a container isopened, must be stored in heated cabinets.
In some instances a back-up strip may be used andplates may be gapped 1/8” (3.2mm) or more, asshown in figure (b).
On sections where only a sealed joint is required andstrength is not important, the joint may be welded afterslightly veeing out the seam as shown in figure (d)below.
Selecting Electrodes
Which electrode is best for the particular job . . . howdo you use it? These are important questions becausethe cost, quality, and appearance of your workdepends on proper electrode selection and applica-tion. MILD STEEL ELECTRODES may be classifiedinto the following groups:
Out-of-Position Group (AWS E6011)
This group includes electrodes which have a snappy,deep penetrating arc and fast freezing deposits.
These electrodes are used for general purpose, all-position fabrication and repair welding. They are alsothe best choice for pipe welding and sheet metal butt,corner, and edge welds. They can be used for repairwork when dirt, grease, plating or paint cannot becompletely cleaned from the steel. These electrodesare typically used with motions “A” and “B” (see draw-ing) for the first pass on vertical-up welds.
Three ways to prepare plates wherecomplete penetration is necessary.
Scrap steel back-up strip(a) (b) (c)
Single and double beads, with and withoutbeveling for tight, partial strength joints.
(d) (e)
Motions
START
SIDEVIEW
F
G
E
D
C
B
A
C-1ACCESSORIESC-1
OPTIONS/ACCESSORIES
LINCOLN ELECTRIC ACCESSORIESThe following options/accessories are available foryour POWER-ARC 4000 from your local LincolnDistributor.
Accessory Set (K875) – Includes the following:
• Twenty feet (6.1 meters) of #6 AWG electrodecable
• Fifteen feet (4.6 meters) of #6 work cable
• Headshield with No. 10 filter
• Work clamp
• Insulated electrode holder
• Sample electrodes
The cables are rated at 150 amps, 40% duty cycle.
Power Plug Kit (K802U) – Provides three plugs, twofor the 120 volt duplex receptacle and one for the 240volt receptacle.
GFCI Receptacle Kit (K896-3) - Includes one ULapproved 115 volt ground fault circuit interrupterduplex type receptacle with cover and installationinstructions. Replaces the factory installed 115 voltduplex receptacle. Each side of the GFCI duplex israted at 15 amps but the maximum total current fromthe GFCI duplex is limited to 20 amps.
Undercarriage (K882-2) - 2- wheeled, hand moving.
Friction Pad Kit (K935-1) - Four rubber isolators thatattach to the bottom of the tube frame to preventmovement on smooth surfaces.
Rotor Removal Kit (S20925) – A service kit with thruand impact bolts for removing the generator rotorfrom the tapered engine crankshaft.
BRIGGS AND STRATTON ACCESSORIES(FOR THE 8 HP INTEK ENGINE ONLY)The following options/accessories are available foryour POWER-ARC 4000 from your local Briggs &Stratton Distributor.
Foam Pre-cleaner (B&S No. 493537) - Provides afoam pre-cleaner for placement around the papercartridge air cleaner. Increases protection in extreme-ly dusty or dirty environments.
Spark Arrester (B&S No. 399541) - The sparkarrestor attaches to the muffler to reduce the chanceof sparks being emitted from the muffler.
Muffler Guard (B&S No. 695386) - This guard installsonto the muffler via supplied hardware and protectsagainst incidental contact with a “HOT” muffler.
SEMIAUTOMATIC MIG WELDINGWITH A LINCOLN WELD-PAK 100OR WELD-PAK 125In addition to using the accessories/options listedabove, the POWER-ARC 4000 generator can supplypower to a Lincoln ELectric Weld-Pak 100 or Weld-Pak 125 wire feed welder. The Weld-Pak comes withall the supplies needed for Flux-Cored Arc Welding(FCAW).
A MIG (Metal Inert Gas) Conversion Kit is also avail-able for the Weld-Pak. The kit provides everythingneeded for Gas Metal Arc Welding (GMAW) or MIGprocesses. Contact your local authorized Lincolnrepresentative for details about the Weld-Pak andMIG Conversion Kit.
POWER-ARC 4000
D-1MAINTENANCED-1
POWER-ARC 4000
SAFETY PRECAUTIONS
• Have qualified personnel do all maintenanceand troubleshooting work.
• Turn the engine off before working inside themachine.
• Remove guards only when necessary to per-form maintenance and replace them when themaintenance requiring their removal is com-plete.
• If guards are missing from the machine, getreplacements from a Lincoln Distributor. Seethe EXPLODED VIEW AND PARTS LIST at theback of this manual.
-------------------------------------------------------------
Read the Safety Precautions in the front of this manu-al and in the engine owner’s manual before workingon the POWER-ARC 4000.
Keep all equipment safety guards, covers, anddevices in position and in good repair. Keep yourhands, hair, clothing, and tools away from the recoilhousing, fans, and all other moving parts when start-ing, operating, or repairing this machine.
ROUTINE AND PERIODIC MAINTENANCE
ENGINE MAINTENANCE
To prevent the engine from accidentally starting,disconnect the spark plug lead before servicingthe engine.
-----------------------------------------------------------
See the engine owner’s manual for a summary ofmaintenance intervals for the items listed below.Follow either the hourly or the calendar intervals,whichever come first. More frequent service may berequired, depending on your specific application andoperating conditions. Table D.1 shows engine main-tenance replacement parts and numbers.
If this Power Arc 4000 is equipped with aTachometer/Hourmeter (See page B-3), then use itflash alert feature to determine the oil change inter-vals, as well as times when air filter service isrequired.
Once Oil or Air f i lter service is completed,Tachometer/Hourmeter needs to be reset. The resetprocedure will stop the flashing of the display and willtrigger the meter to start counting the time for thenext engine service. To stop the flashing alert for Oilor Air filter service, do the following: While alert mes-sage is flashing, hold the tip of the rest tool againstarea shown in figure D.1 for several seconds. The dis-play will stop flashing. The service interval has beenreset and the message alert should start flashing forthe next Oil or Air filter change.
FIGURE D.1
OIL: Check the oil level after every 5hours of operation or daily. BE SURETO MAINTAIN THE OIL LEVEL.
Change the oil the first time after 5 hours of opera-tion. (20 hours on Honda engines.) Then, under nor-mal operating conditions, change the oil after every50 hours or once a year, whichever occurs first. (100hours or every 6 months on Honda engines.) If theengine is operated under heavy load or in high ambi-ent temperatures, change the oil every 25 hours.
Drain the oil from the drain plug located on either sideof the engine bottom, as shown in Figure D.2. Refillthrough the oil fill plug until the oil reaches the top ofthe fill hole. Use the grade and viscosity recommend-ed in the engine owner’s manual.
FIGURE D.2 - OIL DRAIN AND REFILLLOCATION
1. OIL DRAIN PLUG2. OIL FILL PLUG3. OIL LEVEL
CAUTION
1 2 3
12345
TO ELIMINATEFLASHING HOLDTHE RESET TOOLIN THIS AREA.
RESET TOOL
WARNING
D-2MAINTENANCED-2FUEL: At the end of each day’s use, refill
the fuel tank to minimize moisture conden-sation and dirt contamination in the fuel line.
ENGINE ADJUSTMENTS
OVERSPEED IS HAZARDOUS - The maximumallowable high idle speed for this machine is 3750RPM, no load. DO NOT tamper with the governorcomponents or setting or make any other adjust-ments to increase the maximum speed. Severepersonal injury and damage to the machine canresult if operated at speeds above maximum.
------------------------------------------------------------------------Adjustments to the engine are to be made only by aLincoln Service Center or an authorized Field ServiceShop.
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 dry in a clean cloth.
3. Saturate in clean engine oil.
4. Squeeze in a clean, absorbent cloth to remove allexcess oil.
CLEAN ENGINE: Remove dirt and debris with a clothor a brush. Do not clean with a forceful spray ofwater. Water might contaminate the fuel system.
Periodically clean the muffler area to removecombustible debris.
-----------------------------------------------------------
Clean Rotating Screen: If your POWER-ARC 4000 isequipped with an engine that has a rotating screen,you should clean it as often as needed, to remove dirtor debris that may collect on the screen. A dirtyscreen can result in engine overheating and damage.(See Figure D.3).
FIGURE D.3 - CLEAN ROTATINGSCREEN/FINGER GUARD/DEBRIS GUARD
1. ROTATING SCREEN
CLEAN COOLING SYSTEM: See Figure D.4. Cleanthe internal cooling fins and surfaces to prevent over-speeding, overheating, and engine damage. Cleanevery 100 operating hours or as often as necessary.
FIGURE D.4 - CLEAN COOLING SYSTEM1. REMOVE DIRT FROM THESE AREAS.
POWER-ARC 4000
CAUTION
CAUTION
1
1
WARNING
D-3MAINTENANCED-3
POWER-ARC 4000
Refer to Table D.1 for engine maintenance parts. The part numbers are accurate at the time of printing. (Verifythe current part number by referring to the engine owner’s manual.
Replace or clean engine maintenance parts per the interval outlined in the engine owner’s manual.
Part B&S 8 HP Intek Part # Honda Part #
SPARK PLUG B&S 491055 NGK BPR6ES
(RESISTOR) CHAMPION RC12YC DENSO W20EPR-U
FUEL FILTER NONE NONE
AIR CLEANER PANEL B&S 491588 (5043) 5266721 (17210-ZE2-505)
(Pleated Paper)
AIR PRE-CLEANER B&S 493537 2538429 (17218-ZE2-821)
(AS NEEDED) (CAN BE CLEANED AND REUSED AS NEEDED)
CLEAN OR REPLACE SPARK PLUG: Clean orreplace the spark plug after every 100 hours of opera-tion or every season, whichever comes first. Do notblast the spark plug clean with an abrasive cleaningdevice. Clean the plug by scraping it or by using awire brush. Wash the plug with a commercial sol-vent. After cleaning or when installing a new sparkplug, set the terminal gap to .030 inch (.76 mm) with afeeler gauge. See Figure D.5.
FIGURE D.5 - SET SPARK PLUG GAPUse the engine owner’s manual for latest Plug Gap Info.
CLEAN SPARK ARRESTER SCREEN: If the mufflerhas the spark arrester assembly, refer to the engineowner’s manual that was shipped with your POWER-ARC 4000 for the proper cleaning instructions.
2
1
TABLE D.1ENGINE MAINTENANCE PARTS
D-4MAINTENANCED-4
POWER-ARC 4000
GENERATOR/WELDER MAINTENANCESTORAGE: Store the POWER-ARC 4000 in clean,dry, protected areas.
CLEANING: Blow out the generator and controlsperiodically with low pressure air. Do this at leastonce a week in particularly dirty areas.
BRUSH REMOVAL AND REPLACEMENT: SeeFigure D.5. It’s normal for the brushes and sliprings to wear and darken slightly. Inspect thebrushes when a general overhaul is necessary.Remove the brushes and clean the slip rings withfine grit emery paper.
Do not attempt to polish slip rings while engineis running.
To reinstall the brushes, press them upward andslide a cable tie or wooden stick through the brushholder tabs. Install the brush holder into the bear-ing end bracket and secure with the screws previ-ously removed. Remove the cable tie or woodenstick and the brushes will seat onto the slip rings.
RECEPTACLES: Keep the electrical receptacles ingood condition. Remove any dirt, oil, or otherdebris from their surfaces and holes.
CABLE CONNECTIONS: Check the welding cableconnections at the weld output terminals often. Besure that the connections are always tight.
NOTE: Lincoln offers a rotor removal kit for any ser-vice which requires removal of the rotor from theengine. See the ACCESSORIES section for furtherdetails.
Removal of engine/generator assembly from thecradle can be achieved as follows:
• Remove the two 5/16-18 hex head cap screwsfrom the engine block via the access hole locatedin the cradle cross support channel. Leave allother engine mountings intact.
• Remove the two hex nuts from the isolator thread-ed posts at the stator support bracket locatedopposite the engine. Leave all other stator mount-ings intact.
• With a jib hoist or crane, lift the unit upward andremove loose cradle from engine/generatorassembly.
1
35
624
FIGURE D.5. – BRUSH REMOVAL AND REPLACEMENT
1. GENERATOR END BRACKET2. BRUSH HOLDER ASSEMBLY3. COVER4. SCREWS (2)5. BRUSHES6. CABLE TIE
CAUTION
D-5MAINTENANCED-5
POWER-ARC 4000
8
76
5
1
2
3
41 . CRADLE ASSEMBLY2. ROTOR, BLOWER, AND BEARING ASSEMBLY 3. STATOR ASSEMBLY4. BRUSH AND BRUSH HOLDER ASSEMBLY5. CONTROL BOX WELDED ASSEMBLY6. REACTOR ASSEMBLY7. OUTPUT TERMINAL ASSEMBLY8. OUTPUT PANEL ASSEMBLY
FIGURE D.6. - MAJOR COMPONENT LOCATIONS
POWER-ARC 4000
E-1TROUBLESHOOTINGE-1
If for any reason you do not understand the test procedures or are unable to perform the tests/repairs safely, contact yourLocal Lincoln Authorized Field Service Facility for technical troubleshooting assistance before you proceed.
CAUTION
This Troubleshooting Guide is provided to help youlocate and repair possible machine malfunctions.Simply follow the three-step procedure listed below.
Step 1. LOCATE PROBLEM (SYMPTOM).Look under the column labeled “PROBLEM (SYMP-TOMS)”. This column describes possible symptomsthat the machine may exhibit. Find the listing thatbest describes the symptom that the machine isexhibiting.
Step 2. POSSIBLE CAUSE.The second column labeled “POSSIBLE CAUSE” liststhe obvious external possibilities that may contributeto the machine symptom.
Step 3. RECOMMENDED COURSE OF ACTIONThis column provides a course of action for thePossible Cause, generally it states to contact yourlocal Lincoln Authorized Field Service Facility.
If you do not understand or are unable to perform theRecommended Course of Action safely, contact yourlocal Lincoln Authorized Field Service Facility.
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 andmachine operator and will invalidate your factory warranty. For your safety and to avoid ElectricalShock, please observe all safety notes and precautions detailed throughout this manual.
__________________________________________________________________________
WARNING
E-2TROUBLESHOOTINGE-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 yourLocal Lincoln Authorized Field Service Facility for technical troubleshooting assistance before you proceed.
CAUTION
PROBLEMS
PROBLEMS(SYMPTOMS)
POSSIBLE AREAS OFMISADJUSTMENT(S)
RECOMMENDEDCOURSE OF ACTION
No generator power or welding output.
Generator power is available but unitwill not weld.
1. Disconnect anything plugged intoauxiliary receptacles and weld loads.
2. Open lead in flashing or field circuit.
3. Open flashing diode (D1)
4. Faulty brushes.
5. Faulty rheostat (R1).
6. Faulty field rectifier (D1).
7. Faulty capacitor (C1).
8. Faulty stator field winding.
9. Faulty rotor.
10. Dirty slip rings, clean slip rings whennot in use.
1. Loose connection to output stud.
2. Work not connected.
3. Electrode holder loose.
4. No open circuit voltage at outputstuds. Open lead in weld circuit.
5. Faulty reactor (L1).
6. Rheostat (R1) lead broke
If all recommended possible areasof misadjustment have beenchecked and the problem persists,Contact your local LincolnAuthorized Field Service Facility.
E-3TROUBLESHOOTINGE-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 yourLocal Lincoln Authorized Field Service Facility for technical troubleshooting assistance before you proceed.
CAUTION
PROBLEMS
PROBLEMS(SYMPTOMS)
POSSIBLE AREAS OFMISADJUSTMENT(S)
RECOMMENDEDCOURSE OF ACTION
Unit will weld but low or no generatorpower is available.
Engine runs erratically or stops running.
Engine sputters but will not start.
1. Circuit breaker open.
2. Loose or open connection with elec-trical plug-in component.
3. Current control dial not at “125”.
4. No open circuit voltage at receptacle.Open lead in receptacle circuit.
5. No open circuit voltage at receptacle.Bad receptacle.
6. Rheostat (R1) lead broke.
1. Engine is not fully warmed-up andengine choke is in the fully open(RUN) position.
2. Engine requires service to head, car-buretor, filters, oil, spark plug and/orgas.
1. Bad gas, bad filter, air cleaner, sparkplug, and/or breather.
If all recommended possible areasof misadjustment have beenchecked and the problem persists,Contact your local LincolnAuthorized Field Service Facility.
E-4TROUBLESHOOTINGE-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 yourLocal Lincoln Authorized Field Service Facility for technical troubleshooting assistance before you proceed.
CAUTION
PROBLEMS
PROBLEMS(SYMPTOMS)
POSSIBLE AREAS OFMISADJUSTMENT(S)
RECOMMENDEDCOURSE OF ACTION
Engine will not start. 1. Spark plug boot or wire off, loose orwet.
2. Fuel shutoff valve is closed.
3. Low oil and engine low oil shutdownprotection will not allow unit to start. Light in ON-OFF switch will Flashwhen the engine is cranked.(Engines equipped with low oil shutdown protection only).
4. Choke left in full choke position andcarburetor flooded.
5. Fuel line clogged or closed.
6. Recoil start will not engage withengine.
7. Fouled spark plug.
8. Engine requires service to head,head gasket, and/or valves.
9. Float open in carburetor & gas leak-ing from bowl.
10. Engine operated with low oil level.Engine is seized and recoil start willnot move.
If all recommended possible areasof misadjustment have beenchecked and the problem persists,Contact your local LincolnAuthorized Field Service Facility.
F-1DIAGRAMSF-1
POWER-ARC 4000
NO
TE
: T
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dia
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m is
fo
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9A
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7A
600
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BLA
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200A
200
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GR
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GR
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GR
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GN
DC
65
37
9
12/0
1
(+)
LOW
OIL
PROT
ECTIO
NSW
ITCH
(IF IN
STAL
LED)
F-2DIAGRAMSF-2
POWER-ARC 4000
NO
TE
: T
his
dia
gra
m is
fo
r re
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onl
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It m
ay n
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If
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Ser
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Giv
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num
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.
S253
41
12/0
1
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RO
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(+) (-)
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EN
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G
MA
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SW
ITC
H
9A
20
2A
7A
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W
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1
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N/S
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3C
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D
9A
7A
20A
5A
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WH
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5B
5A
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6C
BL
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6C
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WH
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LIN
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5A
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WH
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BL
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GR
EE
N
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3.3
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OR
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56
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S
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1
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AC
TO
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BL
AC
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BLA
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9
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(IF IN
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HM
5WR2
F-3DIAGRAMSF-3
POWER-ARC 4000
NO
TE
: T
his
dia
gra
m is
fo
r re
fere
nce
onl
y.
It m
ay n
ot
be
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rate
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hine
s co
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d b
y th
is m
anua
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pec
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If
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le, w
rite
to
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Ser
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Dep
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for
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pla
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Giv
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men
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num
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160-
1
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RO
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(+) (-)
(+)
(-)
EN
GIN
E W
IRIN
G
MA
GSW
ITCH
9A
202A
7A
600
FD
CC
W
A
201A
201
RE
D
RUN/
STOP
NO
TE:
ALL
CA
SE
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T C
OM
PO
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IEW
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GR
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D2 20
2C B
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D20
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HIT
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R
34
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EN
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ET
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GR
EE
N
GR
EE
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C
65
37
9
(+)
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PROT
ECTIO
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ITCH
(IF IN
STAL
LED)
TAC
HO
ME
TER
/ H
OU
RM
ETE
R
203
WR
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AR
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ND
SP
AR
K P
LUG
WIR
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TIM
ES
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ING
DIA
GR
AM
PO
WE
R A
RC
400
0 (F
OR
CO
DE
109
30 O
NLY
)
F-4DIAGRAMSF-4
POWER-ARC 4000
R
30.0
076
2
20.8
853
0
7.92
201
14.1
636
0
20.0
050
8m
m
mm
mm
mm
mmR
EF.
REF
.
REF
.R
EF.
REF
.
8-
19-9
4
1719
6
M
P
OW
ER
AR
C 4
00
0
D
IME
NS
ION
PR
INT
NOTES
NOTES
WARNING
AVISO DEPRECAUCION
ATTENTION
WARNUNG
ATENÇÃO
Spanish
French
German
Portuguese
Japanese
Chinese
Korean
Arabic
READ AND UNDERSTAND THE MANUFACTURER’S INSTRUCTION FOR THIS EQUIPMENT AND THE CONSUMABLES TO BEUSED AND FOLLOW YOUR EMPLOYER’S SAFETY PRACTICES.
SE RECOMIENDA LEER Y ENTENDER LAS INSTRUCCIONES DEL FABRICANTE PARA EL USO DE ESTE EQUIPO Y LOSCONSUMIBLES QUE VA A UTILIZAR, SIGA LAS MEDIDAS DE SEGURIDAD DE SU SUPERVISOR.
LISEZ ET COMPRENEZ LES INSTRUCTIONS DU FABRICANT EN CE QUI REGARDE CET EQUIPMENT ET LES PRODUITS AETRE EMPLOYES ET SUIVEZ LES PROCEDURES DE SECURITE DE VOTRE EMPLOYEUR.
LESEN SIE UND BEFOLGEN SIE DIE BETRIEBSANLEITUNG DER ANLAGE UND DEN ELEKTRODENEINSATZ DES HER-STELLERS. DIE UNFALLVERHÜTUNGSVORSCHRIFTEN DES ARBEITGEBERS SIND EBENFALLS ZU BEACHTEN.
● Do not touch electrically live parts orelectrode with skin or wet clothing.
● Insulate yourself from work andground.
● No toque las partes o los electrodosbajo carga con la piel o ropa moja-da.
● Aislese del trabajo y de la tierra.
● Ne laissez ni la peau ni des vête-ments mouillés entrer en contactavec des pièces sous tension.
● Isolez-vous du travail et de la terre.
● Berühren Sie keine stromführendenTeile oder Elektroden mit IhremKörper oder feuchter Kleidung!
● Isolieren Sie sich von denElektroden und dem Erdboden!
● Não toque partes elétricas e elec-trodos com a pele ou roupa molha-da.
● Isole-se da peça e terra.
● Keep flammable materials away.
● Mantenga el material combustiblefuera del área de trabajo.
● Gardez à l’écart de tout matérielinflammable.
● Entfernen Sie brennbarres Material!
● Mantenha inflamáveis bem guarda-dos.
● Wear eye, ear and body protection.
● Protéjase los ojos, los oídos y elcuerpo.
● Protégez vos yeux, vos oreilles etvotre corps.
● Tragen Sie Augen-, Ohren- und Kör-perschutz!
● Use proteção para a vista, ouvido ecorpo.
WARNING
AVISO DEPRECAUCION
ATTENTION
WARNUNG
ATENÇÃO
Spanish
French
German
Portuguese
Japanese
Chinese
Korean
Arabic
LEIA E COMPREENDA AS INSTRUÇÕES DO FABRICANTE PARA ESTE EQUIPAMENTO E AS PARTES DE USO, E SIGA ASPRÁTICAS DE SEGURANÇA DO EMPREGADOR.
● Keep your head out of fumes.● Use ventilation or exhaust to
remove fumes from breathing zone.
● Los humos fuera de la zona de res-piración.
● Mantenga la cabeza fuera de loshumos. Utilice ventilación oaspiración para gases.
● Gardez la tête à l’écart des fumées.● Utilisez un ventilateur ou un aspira-
teur pour ôter les fumées des zonesde travail.
● Vermeiden Sie das Einatmen vonSchweibrauch!
● Sorgen Sie für gute Be- undEntlüftung des Arbeitsplatzes!
● Mantenha seu rosto da fumaça.● Use ventilação e exhaustão para
remover fumo da zona respiratória.
● Turn power off before servicing.
● Desconectar el cable de ali-mentación de poder de la máquinaantes de iniciar cualquier servicio.
● Débranchez le courant avant l’entre-tien.
● Strom vor Wartungsarbeitenabschalten! (Netzstrom völlig öff-nen; Maschine anhalten!)
● Não opere com as tampas removidas.● Desligue a corrente antes de fazer
serviço.● Não toque as partes elétricas nuas.
● Do not operate with panel open orguards off.
● No operar con panel abierto oguardas quitadas.
● N’opérez pas avec les panneauxouverts ou avec les dispositifs deprotection enlevés.
● Anlage nie ohne Schutzgehäuseoder Innenschutzverkleidung inBetrieb setzen!
● Mantenha-se afastado das partesmoventes.
● Não opere com os paineis abertosou guardas removidas.
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