powerarc_4000

OPERATORS 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 10083, 10179, 10200, 10211, 10202, 10243, 10244, 10585, 10667,

10671, 10672, 10673, and 10866

IM488-EFebruary, 2004

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 2004 Lincoln Global Inc.

Downloaded from www.Manualslib.com manuals search engine

FOR ENGINEpowered equipment.

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

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1.b. Operate engines in open, well-ventilatedareas or vent the engine exhaust fumes outdoors.

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1.c. Do not add the fuel near an open flamewelding 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.

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1.d. Keep all equipment safety guards, covers and devices inposition 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.

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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.

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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.

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1.g. To prevent accidentally starting gasoline engines whileturning 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 WARNINGSDiesel 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 manufacturers instructions for thisequipment and the consumables to be used, including thematerial safety data sheet (MSDS) and follow youremployers 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 manufacturersrecommendations.

8.c. Ground the equipment in accordance with the U.S. NationalElectrical Code and the manufacturers 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

Mar. 93

PRCAUTIONS DE SRETPour votre propre protection lire et observer toutes les instruc-tions et les prcautions de sret specifiques qui parraissentdans ce manuel aussi bien que les prcautions de sretgnrales suivantes:

Sret Pour Soudage A LArc1. Protegez-vous contre la secousse lectrique:

a. Les circuits llectrode et la pice sont sous tensionquand la machine souder est en marche. Eviter toujourstout contact entre les parties sous tension et la peau nueou les vtements mouills. Porter des gants secs et sanstrous pour isoler les mains.

b. Faire trs attention de bien sisoler de la masse quand onsoude dans des endroits humides, ou sur un planchermetallique ou des grilles metalliques, principalement dans

les positions assis ou couch pour lesquelles unegrande partie du corps peut tre en contact avec lamasse.

c. Maintenir le porte-lectrode, la pince de masse, le cblede soudage et la machine souder en bon et sr tatdefonctionnement.

d.Ne jamais plonger le porte-lectrode dans leau pour lerefroidir.

e. Ne jamais toucher simultanment les parties sous tensiondes porte-lectrodes connects deux machines soud-er parce que la tension entre les deux pinces peut tre letotal de la tension vide des deux machines.

f. Si on utilise la machine souder comme une source decourant pour soudage semi-automatique, ces precautionspour le porte-lectrode sapplicuent aussi au pistolet desoudage.

2. Dans le cas de travail au dessus du niveau du sol, se pro-tger contre les chutes dans le cas ou on recoit un choc. Nejamais enrouler le cble-lectrode autour de nimporte quellepartie du corps.

3. Un coup darc peut tre plus svre quun coup de soliel,donc:

a. Utiliser un bon masque avec un verre filtrant appropriainsi quun verre blanc afin de se protger les yeux durayonnement de larc et des projections quand on soudeou quand on regarde larc.

b. Porter des vtements convenables afin de protger lapeau de soudeur et des aides contre le rayonnement delarc.

c. Protger lautre personnel travaillant proximit ausoudage laide dcrans appropris et non-inflamma-bles.

4. Des gouttes de laitier en fusion sont mises de larc desoudage. Se protger avec des vtements de protectionlibres de lhuile, tels que les gants en cuir, chemise paisse,pantalons sans revers, et chaussures montantes.

5. Toujours porter des lunettes de scurit dans la zone desoudage. Utiliser des lunettes avec crans lateraux dans leszones o lon pique le laitier.

6. Eloigner les matriaux inflammables ou les recouvrir afin deprvenir tout risque dincendie d aux tincelles.

7. Quand on ne soude pas, poser la pince une endroit isol dela masse. Un court-circuit accidental peut provoquer unchauffement et un risque dincendie.

8. Sassurer que la masse est connecte le plus prs possiblede la zone de travail quil est pratique de le faire. Si on placela masse sur la charpente de la construction ou dautresendroits loigns de la zone de travail, on augmente le risquede voir passer le courant de soudage par les chaines de lev-age, cbles de grue, ou autres circuits. Cela peut provoquerdes risques dincendie ou dechauffement des chaines et descbles jusqu ce quils se rompent.

9. Assurer une ventilation suffisante dans la zone de soudage.Ceci est particulirement important pour le soudage de tlesgalvanises plombes, ou cadmies ou tout autre mtal quiproduit des fumes toxiques.

10. Ne pas souder en prsence de vapeurs de chlore provenantdoprations de dgraissage, nettoyage ou pistolage. Lachaleur ou les rayons de larc peuvent ragir avec lesvapeurs du solvant pour produire du phosgne (gas forte-ment toxique) ou autres produits irritants.

11. Pour obtenir de plus amples renseignements sur la sret,voir le code Code for safety in welding and cutting CSAStandard W 117.2-1974.

PRCAUTIONS DE SRET POURLES MACHINES SOUDER TRANSFORMATEUR ET REDRESSEUR

1. Relier la terre le chassis du poste conformement au codede llectricit et aux recommendations du fabricant. Le dis-positif de montage ou la piece souder doit tre branch une bonne mise la terre.

2. Autant que possible, Iinstallation et lentretien du posteseront effectus par un lectricien qualifi.

3. Avant de faires des travaux l interieur de poste, ladebrancher linterrupteur la boite de fusibles.

4. Garder tous les couvercles et dispositifs de sret leurplace.


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 thenProduct Registration. Please complete the form and submit your registration.


Page

Safety.................................................................................................................................................i-iv

Installation .............................................................................................................................Section A

Technical Specifications .............................................................................................................A-1

Safety Precautions......................................................................................................................A-2

Location and Ventilation .............................................................................................................A-2

Pre-operation Engine Service .....................................................................................................A-3

Electrical Output Connections ....................................................................................................A-5

Operation ...............................................................................................................................Section B

Safety Instructions ......................................................................................................................B-1

General Description ....................................................................................................................B-1

Recommended Applications.......................................................................................................B-2

Operational Features and Controls.............................................................................................B-2

Design Features and Advantages...............................................................................................B-2

Welding Capability ......................................................................................................................B-2

Limitations .................................................................................................................................B-2

Controls and Settings .................................................................................................................B-3

Engine Operation ........................................................................................................................B-5

Welding Operation ......................................................................................................................B-9

Accessories...........................................................................................................................Section C

Maintenance..........................................................................................................................Section D

Safety Precautions ............................................................................................................................D-1

Routine and Periodic Maintenance ...................................................................................................D-1

General Assembly Exploded View ....................................................................................................D-6

Troubleshooting and Repair ................................................................................................Section E

Electrical Diagrams...............................................................................................................Section F

Parts Manual (B&S 8 HP & Honda Engines)....................................................................P233 Series

Parts Manual (B&S 9 HP Vanguard Engine)....................................................................P352 Series

MASTER TABLE OF CONTENTS FOR ALL SECTIONSvi vi

POWER-ARC 4000


TECHNICAL SPECIFICATIONS - POWER-ARC 4000

INPUT - BRIGGS KOOL-BORE GASOLINE ENGINE

Manufacturer Description Speed Displacement Ignition Capacities Briggs & 1 cyl., 3700 RPM 19.4 cu. in. Manual, Fuel: 1.0 gal. (3.8 l)

Stratton Kool- 4 cycle 50 RPM (319 cc) RecoilBore Plus air-cooled at no load start; Manual Oil: 1.4 qt. (1.3 l)

gasoline choke8 HP @

3750 RPM

INPUT - BRIGGS VANGUARD GASOLINE ENGINEBriggs & 1 cyl., 3700 RPM 18.06 cu. in. Manual, Fuel: 1.6 gal. (6.0 l)Stratton 4 cycle 50 RPM (296 cc) Recoil

Vanguard air-cooled OHV at no load start; Manual Oil: 1.25 qt. (1.2 l)Model 185432 gasoline choke

9 HP @3750 RPM

INPUT - HONDA GASOLINE ENGINE

Honda 1 cyl., 3700 RPM 16.5 cu. in. Manual, Fuel: 1.59 gal. (6.0 l)GX 270 VA2 4 cycle 50 RPM (270 cc) Recoil

air-cooled OHV at no load start; Manual Oil: 1.16 qt. (1.11 l)gasoline choke9 HP @

3750 RPM

RATED OUTPUT - WELDER

Duty Cycle Amps Volts at Rated Amperes30% Duty Cycle 125 20 VAC

60% Duty Cycle 100 25 VAC

OUTPUT - WELDER AND GENERATOR

Welding Ranges Welder Open Circuit Voltage AC Auxiliary Power70 - 125 Amps 62 VAC Max. 4000 Continuous Watts

4400 Surge Watts

PHYSICAL DIMENSIONS

Height Width Depth Weight20.9 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

Read this entire installation section before youstart installation.

SAFETY PRECAUTIONS

Do not attempt to use this equipment until youhave thoroughly read all the operation and main-tenance manuals supplied with your machine.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 yourskin or wet clothing.

Insulate yourself from thework and ground.

Always wear dry insulating gloves.

ENGINE EXHAUST can kill. Use in open, well ventilated

areas 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 machinesgasoline 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.

STORING1. Store the machine in a cool, dry place when its

not in use. Protect it from dust and dirt. Keep itwhere it cant 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-3STACKINGPOWER-ARC 4000 machines CANNOT be stacked.

TILTINGPlace 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, besure to check the oil regularly and keep the oil levelfull. Also, fuel capacity will be a little less at an angle.

LIFTINGThe 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 OPERATIONInternal 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 certainto place the machine on a firm, non-skid, structuralsupporting 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 owners 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.

OILThe Power-Arc 4000 with the Briggs and Stratton 8HP engine produced after August 1998 and thePower-Arc 4000 with the Honda 9 HP engine are sup-plied with low oil shutdown protection. The Power-Arc 4000 with the Briggs and Stratton 8 HP engineproduced before August 1998 is NOT equipped withan "Oil Gard" low oil shutdown protection device.Oil must be regularly checked and added as needed.However, the engine block is equipped to accept an"Oil Gard" accessory kit available from authorizedBriggs and Stratton Distributors. An installed kit willsense low oil levels and will automatically shut downthe engine. The engine cannot be restarted until suffi-cient 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 beat the top of the fill plug hole. If it is not full, addenough oil to fill it. Be sure the fill plug is tight.Change oil after the first 5 hours of operation.

For more oil fill and service information, see theEngine owners manual.

FUELFill the fuel tank with clean, fresh, regulargrade lead-free gasoline. DO NOT MIXOIL WITH THE GASOLINE.

The POWER-ARC 4000 has a fuel tank mounted onthe engine. See the engine owners manual for moredetails about fuel.

WARNING


A-4INSTALLATION

POWER-ARC 4000

A-4

MUFFLER DEFLECTORThe 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 operatorsface and eyes.

Fasten the deflector onto the muffler with thescrews provided.

NOTE: The deflector reduces generator outputpower up to 100 watts.

SPARK ARRESTERGasoline 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 Kool-Boreengine. 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 KoolBore engine is available as a Lincoln field-installed option.

A spark arrester is available for your POWER-ARC4000 Briggs & Stratton 9 HP Vanguard engine fromyour local Briggs & Stratton engine dealer.

The Power-Arc 4000 with the Honda engine comeswith a spark arrester as standard equipment. Refer tothe engine owners manual for proper maintenance.

CAUTION

CAUTION

No Load3700 RPM 50 R.P.M.AC CC Weld Output125 Amps @ 18 VoltsAC CC Weld Output100 Amps @ 25 VoltsAuxil iary Power 4000Watts (120/240 Volts)

B&S 8 HP Carb. CertifiedKool Bore Plus

0.36 Gallons/Hour(1.37 Liters/Hour)0.69 Gallons/Hour(2.63 Liters/Hour)0.64 Gallons/Hour(2.41 Liters/Hour)0.77 Gallons/Hour(2.92 Liters/Hour)

B&S 9 HPVanguard

0.33 Gallons/Hour(1.25 Liters/Hour)0.76 Gallons/Hour(2.9 Liters/Hour)

0.63 Gallons/Hour(2.4 Liters/Hour)


Honda 9 HPCarb. Certified

0.30 Gallons/Hour(1.14 Liters/Hour)0.58 Gallons/Hour(2.18 Liters/Hour)0.55 Gallons/Hour(2.1 Liters/Hour)


Power-Arc 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 CONNECTIONSCable Size and LengthBe 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

AMPS

AMPS

AMPSAMPS

WARNING

AMPS125

GENERATOR

6

5

432

1

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, 20AMP


A-6INSTALLATION

POWER-ARC 4000

A-6

Cable InstallationInstall 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 connecteither cable to either terminal, since the POWER-ARC 4000 provides AC weld current.

4. Tighten the flanged nuts securely.

5. Be certain that the metal piece you are welding(the work) is securely connected to the 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 mountedon a truck or a trailer, the machine gen-erator ground stud MUST be securelyconnected to the metal frame of thevehicle. See Figure A.1. The groundstud is marked with 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 Underwriters 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 feed backinginto 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. The Briggs &Stratton engines used on the Power-Arc 4000 beforeAugust 1998 did not include a low oil shutdownoption as standard equipment. It cannot withstandlong-term use without proper maintenance. See theMAINTENANCE section of this manual and theengine owners 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.

WARNING

CAUTION


A-8INSTALLATION

POWER-ARC 4000

A-8

CAUTIONCertain 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-1OPERATING INSTRUCTIONSRead and understand this entire section before oper-ating your POWER-ARC 4000.

SAFETY INSTRUCTIONS

Do not attempt to use this equipment until youhave thoroughly read all the operation and main-tenance manuals supplied with your machine.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.


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/welderdesigned for home use and other non-commercialapplications. As a generator it can supply up to 4,000continuous watts (or 4,400 surge watts) of 120/240volt, single-phase AC power. As a welder it provides125 amps of AC constant current for welding with ACstick electrodes. A single dial provides continuousadjustment of welding output. The machine is light-weight, portable, and can be lifted by two people.

POWER-ARC 4000

WARNING

WARNING


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 engine manu-facturers warranty policy.

RECOMMENDED APPLICATIONS

GENERATORThe 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 manu-al.

WELDERThe POWER-ARC 4000 provides excellent constantcurrent AC welding output for stick (SMAW) welding.For more details on using the machine as a welder,see WELDING OPERATION in the OPERATION sec-tion of this 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 genera-tor or welding use. For welding, the same dial selectscontinuous current output over the machines 70 to125 amp 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 andthe engine owners manual for details about starting,running, stopping, and breaking in the gasolineengine.

DESIGN FEATURES AND ADVANTAGES Stick welding (SMAW) process capability with out-

put range from 70 - 125 amps.

Single-dial current output selection.

Work and Electrode welding cable mounting termi-nals.

Separate ground stud for safe connection of caseto earth ground. Single 20 amp, 240 volt generatorreceptacle.

Duplex 20 amp, 120 volt generator receptacle.

Integrated generator output overload protectionthrough two 20 amp circuit breakers.

Welded-tube, full roll cage frame protects engineand generator/welder.

Lightweight, portable design.

Rubber mounting isolates engine and generatorfrom frame to prevent machine walking duringuse.

Low noise engine muffler for quieter operation. (ASuper Lo-Tone muffler is available for the Briggs &Stratton 8 HP Kool Bore engine.)

Easy-starting, No Maintenance, Electronic ignition.

Low oil level engine shutdown protection is stan-dard equipment on machines produced afterAugust 1998. On earlier engines an optional OilGard kit is available from Briggs & Stratton.

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.

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.

POWER-ARC 4000


B-3OPERATIONB-3CONTROLS 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.)

4. WELD OUTPUT TERMINAL (TO WORK) WITH 1/2- 13 FLANGE NUT: Provides the connectionpoint for either the electrode holder or the workcable. (Because the POWER-ARC 4000 is an ACoutput machine, either output terminal can beused for either cable.)

POWER-ARC 4000

POWER ARC 4000

ELECTRODE SELECTION GUIDE

80

90

100

70

AMPS

AMPS

AMPSAMPS

WARNING

AMPS125

GENERATOR

8

7

653

1

2

4

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 RECEPTACLE


B-4OPERATIONB-45. GROUND STUD: Provides a connection point for

connecting 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.

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 owners 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.

POWER-ARC 4000


B-5OPERATIONB-5ENGINE 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 manufacturers Operating andMaintenance Instructions manual that is shippedwith the POWER-ARC 4000.

BEFORE STARTING THE ENGINECHECK AND FILL THE ENGINE OIL LEVEL:1. Place the machine on a level

surface.

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 approximately1/4 inch (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 theON position.

FOR A COLD ENGINE:1. Open the fuel shutoff valve.

2. Place the choke lever in the CHOKEposition.

3. Pull slightly on the recoil starter handle until resis-tance is felt.

POWER-ARC 4000

WARNING


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 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 RUNposition. 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 is

clean 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 carburetor.

If the engine wil l not start, see the TROU-BLESHOOTING section of this or the engineowners manual.

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 itsbreak-in period. Check the oil frequently duringbreak-in. For more details, see the MAINTENANCEsection in the engine owners 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

WARNING

CAUTION


B-7OPERATIONB-7GENERATOR OPERATION

Be sure that any electrical equipment plugged intothe generators 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 amps

it 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 engineowners 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.

POWER-ARC 4000

CAUTION


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-8OPERATIONB-8

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-9OPERATIONB-9WELDING OPERATION

GENERAL INFORMATION

Do not touch electrically live parts orelectrodes with your skin or wet cloth-ing.

Do not breathe welding fumes or gases.

Use ventilation or exhaust to removewelding fumes from the breathing area.

Keep flammable material away.

Wear eye, ear, 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 rodyoure 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 / OPERATIONCurrent 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 andElectrode Selection Guide listed on the machinenameplate for proper current and electrode settings.

POWER-ARC 4000

WARNING


B-10OPERATIONB-10

POWER-ARC 4000

TABLE B.4WELDING APPLICATIONS/ELECTRODE SELECTION GUIDE

Material Thickness Electrode Type Size Setting1/8 and thinner FLEETWELD 37 3/32 90 amps

1AWS 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

NOTES:

The values listed are suggested settings. Actual setting may vary depending on individual preference and/orspecific application. Beginners should use Lincoln E7018 AC.

For electrodes not listed, follow tables that are packed with the electrodes.

Ask for the Lincoln WELD DIRECTORY (Publication M210) for a complete listing of all Lincoln stick electrodesavailable.1AWS = American Welding Society

WELDING GUIDELINES


B-11OPERATIONB-11

POWER-ARC 4000

Stick welding is probably the most familiar weldingprocess known. A coated ELECTRODE, the weldrod, is clamped into an ELECTRODE HOLDER, aninsulated clamping device, which in turn connects tothe ELECTRODE CABLE, a heavy wire. The WORK,the metal piece to be welded, is connected to theWORK CABLE, a heavy wire which contains theWORK CLAMP. Quality Lincoln cables use many finecopper wires with a very flexible insulating coveringfor the electrode and work cables. When properly con-nected to the OUTPUT STUDS of a high currentpower source, the electrode melts and bonds themetal being repaired. Refer to Figure 3 to see the cir-cuit. See Cable Installation section for proper cableconnection 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 Guidefound 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.

WARNING

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.Contact your local authorized Lincoln representative formore details.

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.

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 operators 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.


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POWER-ARC 4000

The Power-Arc 4000 has a voltage output of up to 62volts which can shock.

The electric arc is made between the work and the tipend of a small metal wire, the electrode, which isclamped in a holder that is held by the welder. A gapis made in the welding circuit (see 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. Theoperator controls the welding arc and, therefore, thequality 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 6000F (3316C) which is more than enough tomelt metal. The arc is very bright, as well as hot, and

cannot 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 orcrater and tends to flow away from the arc. As itmoves away from the arc, it cools and solidifies. Slagforms on top of the weld to protect it during cooling.

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 stead-ier, provides a shield of smoke-like gas around the arcto keep 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 thedifferences in the various coatings, you will gain a bet-ter understanding of selecting the best electrode forthe job you have at hand. In selecting an electrode,you should 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.

ELECTRIC SHOCK can kill. Do not touch electrically live parts

or electrode with skin or wet cloth-ing.

Insulate yourself from work andground.


WARNING

ENGINE EXHAUST can kill. Use in open, well ventilated areas

or vent exhaust outside. Do not stack anything on or near

the engine.

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.


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POWER-ARC 4000

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

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.

NOTE: Most beginners try to strike the arc by a fastjabbing motion down on the plate. Result: They eitherstick their electrode or their motion is so fast that theybreak 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 elec-trode must be fed to the work to maintain correct arclength.

The easiest way to tell whether the arc has the correctlength is by listening to its sound. A nice, short archas a distinctive, crackling sound, very much likeeggs frying in a pan. The incorrect, long arc has ahollow, 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.

15-20

90

side view end viewCorrect Welding Position

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 electrode

over 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 ofNew 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 Welds, FilletWelds, Lap Welds, Edge Welds and Corner Welds.

Of these, the Butt Weld and Fillet Weld are the mostcommon.

Butt Welds

Butt Welds are the most widely used welds. Placetwo plates 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 Weld Lap Weld

Edge Weld Fillet Weld Corner Weld


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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 weldwill 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

Poor1/2"

(12mm) 1/4"(6mm)

1/4"(6mm)

Good

604

32

1

1/8" (3.2mm)

45

45

112 2

34


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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 NOTFOLLOW THE UP AND DOWN MOVEMENT OFTHE ARC WITH YOUR EYES. KEEP THEM ONTHE MOLTEN 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 areno fast 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-down technique on heavy metal. The welds will notbe strong 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.


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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 30off 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

3030


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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 IronWhen 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 c

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