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B-9
OPERATION
B-9
WELDING OPERATION
GENERAL INFORMATION
Do not touch electrically live parts or
electrodes with your skin or wet cloth-
ing.
Do not breathe welding fumes or gases.
Use ventilation or exhaust to remove
welding fumes from the breathing area.
Keep flammable material away.
Wear eye, ear, and body protection.
The POWER-ARC 4000 generator/welder can deliver
from 70 to 125 amps of continuous welding output
current . Output can be adjusted by setting the cur-
rent control dial on the output control panel.
You can get maximum welding output by setting the
dial 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 to
turn the dial slightly upward to maintain the same
results.
The numbers on the dial correspond to the average
amps needed to weld using specific Lincoln welding
rods. Table B.4, WELDING APPLICATIONS, gives
you the recommended dial settings based on the
thickness of the work and the size and type of rod
you’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 welding
cables over the terminals. See Figure B.1.
Replace and tighten the flange nuts securely. Be
sure the connections are tight.
2. Select the appropriate electrode. See Table B.4,
WELDING APPLICATIONS, or the ELECTRODE
SELECTION GUIDE on the machine Output
Control Panel.
3. Attach the work clamp securely to the work you
are welding.
4. Insert the electrode into the electrode holder.
5. Set the current control dial to the desired output
current.
6. Start the gasoline engine. See ENGINE OPERA-
TION in this section of the manual.
7. Strike an arc and begin welding. For information
on 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 from
the electrode holder.
5. If you are finished using the POWER-ARC 4000
for welding, disconnect the welding cables from
the weld output terminals. Reattach the flange
nuts and leave them on the terminals.
NOTE: 1. Welding current is continuously variable
with 60% duty cycle applying to output
currents 100 Amps and less and 30%
duty cycle applying to currents above 100
Amps.
2. Duty cycle is based on a ten minute
period. The welder can be loaded to 125
Amps for three minutes out of every ten
minute period or to 100 Amps for six
minutes out of every ten minute period.
CONTROL FUNCTION / OPERATION
“Current Control Dial”
Provides welding current adjustment from 70 through
125 Amps.
To obtain maximum weld output, turn the “Current
Control Dial” to “125 Amps” for either a cold or hot
engine. As the machine is used, some welding volt-
age may decrease at high current settings. If you are
welding for long periods of time, the dial may need to
be slightly turned upward to provide the same welding
results 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 machine
nameplate for proper current and electrode settings.
POWER-ARC 4000
WARNING