Lincoln-electric IM488 POWER-ARC 4000 User Manual

OPERATOR’S MANUALSafety Depends on YouLincoln arc welding and cuttingequipment is designed and builtwith safety in mind. However, youroverall safety c

A-3INSTALLATION POWER-ARC 4000A-3STACKINGPOWER-ARC 4000 machines CANNOT be stacked.TILTINGPlace the machine on a secure, level surface whenev-er you

A-4INSTALLATION POWER-ARC 4000A-4MUFFLER DEFLECTORThe POWER-ARC 4000, depending on model, may ormay not be shipped with an exhaust deflector. If you

A-5INSTALLATION POWER-ARC 4000A-5ELECTRICAL OUTPUT CONNECTIONSSee Figure A.1 for the location of the current controldial, weld output terminals, gro

A-6INSTALLATION POWER-ARC 4000A-6Cable InstallationInstall the welding cables to your POWER-ARC 4000as follows. See Figure A.1 for the location of

A-7INSTALLATION POWER-ARC 4000A-7PREMISES WIRINGThe POWER-ARC 4000 three-wire, grounded neutralgenerator allows it to be connected to premiseswiring

A-8INSTALLATION POWER-ARC 4000A-8CAUTIONCertain Electrical devices cannot be powered by the POWER-ARC 4000. See Table A.2.TABLE A.2ELECTRICAL DEVIC

B-1OPERATIONB-1OPERATING INSTRUCTIONSRead and understand this entire section before oper-ating your POWER-ARC 4000.SAFETY INSTRUCTIONSDo not attempt t

B-2OPERATIONB-2The Lincoln warranty covers the Power Arc 4000(excluding the engine) for 2 years from the date ofpurchase. The engine is covered by the

B-3OPERATIONB-3CONTROLS AND SETTINGSAll generator/welder controls are located on theOutput Control Panel. Gasoline engine controls aremounted on the

B-4OPERATIONB-45. GROUND STUD: Provides a connection point forconnecting the machine case to earth ground forthe safest grounding procedure.6. 20 AMP

FOR ENGINEpowered equipment.1.a. Turn the engine off before troubleshooting and maintenancework unless the maintenance work requires it to be running.

B-5OPERATIONB-5ENGINE OPERATIONDO NOT RUN THE ENGINE AT EXCESSIVESPEEDS. The maximum allowable high idle speedfor the POWER-ARC 4000 is 3750 RPM, no

B-6OPERATIONB-64. Pull the cord rapidly.5. If the engine does not start, open the chokeslightly and pull the starter cord rapidly again.When the engin

B-7OPERATIONB-7GENERATOR OPERATIONBe sure that any electrical equipment plugged intothe generator’s AC power receptacles can with-stand a ±10% voltage

TABLE B.3GENERATOR POWER APPLICATIONSSuggested Power Applications Running Watts *Start-up Watts*Air Compressor - 1 HP 2,000 4,000 - 8,000*Air C

B-9OPERATIONB-9WELDING OPERATIONGENERAL INFORMATIONDo not touch electrically live parts orelectrodes with your skin or wet cloth-ing.Do not breathe we

B-10OPERATIONB-10POWER-ARC 4000TABLE B.4WELDING APPLICATIONS/ELECTRODE SELECTION GUIDEMaterial Thickness Electrode Type Size Setting1/8” and thinner F

B-11OPERATIONB-11POWER-ARC 4000Stick welding is probably the most familiar weldingprocess known. A coated ELECTRODE, the weldrod, is clamped into an

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

B-13OPERATIONB-13POWER-ARC 40001. The Correct Welding PositionIllustrated is the correct welding position forright-handed people. (For left-handed p

B-14OPERATIONB-14POWER-ARC 4000PRACTICEThe best way of getting practice in the four skills thatenable you to maintain:1. Correct Welding Position.2.

iiSAFETYiiARC RAYS can burn.4.a. Use a shield with the proper filter and coverplates to protect your eyes from sparks andthe rays of the arc when weld

B-15OPERATIONB-15POWER-ARC 4000Now weld the two plates together. Weld from left toright (if right-handed). Point the electrode down in hegap between

B-16OPERATIONB-16POWER-ARC 4000Vertical-Up WeldingThe problem, when welding vertical-up, is to put themolten metal where it is wanted and make it stay

B-17OPERATIONB-17POWER-ARC 4000Overhead WeldingVarious techniques are used for overhead welding.However, in the interest of simplicity for the inexper

B-18OPERATIONB-18POWER-ARC 40004. 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 bl

B-19OPERATIONB-19POWER-ARC 4000High-Speed Group (AWS E6013)This group includes electrodes which have a moder-ately forceful arc and deposit rates betw

C-1ACCESSORIESC-1OPTIONS/ACCESSORIESLINCOLN ELECTRIC ACCESSORIESThe following options/accessories are available foryour POWER-ARC 4000 from your local

D-1MAINTENANCED-1SAFETY PRECAUTIONS• Have qualified personnel do all maintenanceand troubleshooting work. • Turn the engine off before working insi

D-2MAINTENANCED-2Do not use petroleum solvents such as keroseneto clean the air cleaner. They may cause deterio-ration of the air cleaner. DO NOT O

PartB&S 8 HP Kool Bore Part # B&S 9 HP Vanguard Part # Honda Part #SPARK PLUG B&S 802592 B&S 491055 NGK BPR6ES(RESISTOR) CHAMPION RJ1

D-4MAINTENANCED-4POWER-ARC 4000GENERATOR/WELDER MAINTENANCESTORAGE: Store the POWER-ARC 4000 in clean,dry, protected areas.CLEANING: Blow out the gene

FOR ELECTRICALLYpowered equipment.8.a. Turn off input power using the disconnectswitch at the fuse box before working onthe equipment.8.b. Install equ

D-5MAINTENANCED-5POWER-ARC 4000876512341 . CRADLE ASSEMBLY2. ROTOR, BLOWER, AND BEARING ASSEMBLY 3. STATOR ASSEMBLY4. BRUSH AND BRUSH HOLDER ASSEMB

POWER-ARC 4000E-1TROUBLESHOOTINGE-1If for any reason you do not understand the test procedures or are unable to perform the tests/repairs safely, cont

E-2TROUBLESHOOTINGE-2POWER-ARC 4000Observe all Safety Guidelines detailed throughout this manualIf for any reason you do not understand the test proce

E-3TROUBLESHOOTINGE-3POWER-ARC 4000Observe all Safety Guidelines detailed throughout this manualIf for any reason you do not understand the test proce

E-4TROUBLESHOOTINGE-4POWER-ARC 4000Observe all Safety Guidelines detailed throughout this manualIf for any reason you do not understand the test proce

F-1DIAGRAMSF-1POWER-ARC 4000NOTE: This diagram is for reference only. It may not be accurate for all machines covered by this manual. The specific

F-2DIAGRAMSF-2POWER-ARC 4000NOTE: This diagram is for reference only. It may not be accurate for all machines covered by this manual. The specific

F-3DIAGRAMSF-3POWER-ARC 4000R30.0076220.885307.9220114.1636020.00508mmmmmmmm mmREF.REF.REF. REF.REF. 8-19-94 17196 M POWER ARC 4000

NOTESPOWER-ARC 4000

NOTESPOWER-ARC 4000

ivSAFETYivMar. ‘93PRÉCAUTIONS DE SÛRETÉPour votre propre protection lire et observer toutes les instruc-tions et les précautions de sûreté specifiques

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• Sales and Service through Subsidiaries and Distributors Worldwide •Cleveland, Ohio 44117-1199 U.S.A. TEL: 216.481.8100 FAX: 216.486.1751 WEB

vvThank Youfor selecting a QUALITY product by Lincoln Electric. We want youto take pride in operating this Lincoln Electric Company product••• as much

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TECHNICAL SPECIFICATIONS - POWER-ARC 4000INPUT - BRIGGS KOOL-BORE® GASOLINE ENGINEManufacturer Description Speed Displacement Ignition CapacitiesBrigg

A-2INSTALLATION POWER-ARC 4000A-2Read this entire installation section before youstart installation.SAFETY PRECAUTIONSDo not attempt to use this equ