Lincoln POWER-ARC 4000 Recommended Applications, Operational Features and Controls, Limitations

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B-2

OPERATION

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The Lincoln warranty covers the Power Arc 4000 (excluding the engine) for 2 years from the date of purchase. The engine is covered by the engine manu- facturer’s warranty policy.

RECOMMENDED APPLICATIONS

GENERATOR

The POWER-ARC 4000 gives AC generator output for medium use, non-commercial demands. For more details on operating the generator, see GENERATOR OPERATION in the OPERATION section of this manu- al.

WELDER

The POWER-ARC 4000 provides excellent constant current 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 CONTROLS

The POWER-ARC 4000 was designed for simplicity. Therefore, it has very few operating controls. A single dial on the control panel lets you select either genera- tor or welding use. For welding, the same dial selects continuous current output over the machine’s 70 to 125 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 and the engine owner’s manual for details about starting, running, stopping, and breaking in the gasoline engine.

•Separate ground stud for safe connection of case to earth ground. Single 20 amp, 240 volt generator receptacle.

•Duplex 20 amp, 120 volt generator receptacle.

•Integrated generator output overload protection through two 20 amp circuit breakers.

•Welded-tube, full roll cage frame protects engine and generator/welder.

•Lightweight, portable design.

•Rubber mounting isolates engine and generator from frame to prevent machine “walking” during use.

•Low noise engine muffler for quieter operation. (A Super 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 after August 1998. On earlier engines an optional Oil Gard® kit is available from Briggs & Stratton.

WELDING CAPABILITY

The POWER-ARC 4000 is rated 125 amps, 20 volts at 30% duty cycle on a ten-minute basis. This means that you can load the welder to 125 amps for three minutes out of every ten-minute period. The machine is also capable of higher duty cycles at lower output currents. You can load the welder to 100 amps for six minutes out of ten for a 60% duty cycle.

The current is continuously variable from 70 to 125 amps AC. The POWER-ARC 4000 can weld with all 3/32 and most 1/8 inch diameter Lincoln AC elec- trodes.

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.

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 for pipe thawing.

•During welding, generator power is limited to 100 watts, and output voltages can drop from 120 to 80 volts and 240 to 160 volts. Therefore, DO NOT OPERATE ANY SENSITIVE ELECTRICAL EQUIP- MENT WHILE YOU ARE WELDING.

POWER-ARC 4000

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Contents POWER-ARC California Proposition 65 Warnings SafetyElectric Shock can kill Iii Welding Sparks can cause fire or explosionPrécautions DE Sûreté On-Line Product Registration Please Examine Carton and Equipment For Damage ImmediatelyMaster Table of Contents for ALL Sections Technical Specifications POWER-ARC InstallationLocation and Ventilation Safety PrecautionsStoring Engine Exhaust can killPRE-OPERATION Engine Service Muffler Deflector Power-Arc 4000 Typical Fuel ConsumptionSpark Arrester 8 HP Carb. Certified 9 HP Honda 9 HP Kool Bore PlusCable Size and Length Electrical Output ConnectionsWelding Cable Connections Cable Installation Auxiliary Power ReceptaclesMachine Grounding Plugs and HAND-HELD EquipmentCircuit Breakers Premises WiringType Common Electrical Devices Possible Concerns Table A.2 Electrical Device USE with the POWER-ARCOperation Safety InstructionsOperating Instructions General DescriptionDesign Features Advantages Operational Features and ControlsRecommended Applications Welding CapabilityGENERATOR/WELDER Controls Controls and SettingsGasoline Engine Controls Starting the Engine Engine OperationBefore Starting the Engine BREAK-IN Period Stopping the EngineRunning the Engine General Information Generator OperationTable B.3 Generator Power Applications Control Function / Operation Current Control Dial Welding OperationWelding Guidelines Material Thickness Electrode Type Size SettingStick Welding Welding arc What Happens in the Arc?Correct Way to Strike An Arc Correct Welding Position Correct Arc LengthCorrect Welding Speed Side viewTypes of Welds Common MetalsUse the following Do the followingFillet Welds PenetrationMultiple Pass Welds Welding in the Vertical PositionVertical-Down Welding Vertical-Up WeldingOverhead Welding How to Hardface the Sharp Edge Metal to Ground WearWelding Sheet Metal Hardfacing To Reduce WearCast Iron Plate Preparation Welding Cast IronOut-of-Position Group AWS E6011 Selecting ElectrodesHigh-Speed Group AWS E6013 Low Hydrogen Group Stable-Arc E7018Lincoln Electric Accessories AccessoriesOPTIONS/ACCESSORIES Routine and Periodic Maintenance MaintenanceEngine Maintenance Engine AdjustmentsFigure D.2 Clean Rotating SCREEN/FINGER GUARD/DEBRIS Guard Honda Table D.1 Engine Maintenance PartsPart Figure D.5. Brush Removal and Replacement GENERATOR/WELDER MaintenanceFigure D.6. Major Component Locations HOW to USE Troubleshooting Guide TroubleshootingPossible Areas SymptomsTroubleshooting Engine requires service to head, head gasket, and/or valves Diagrams S25341 Wiring Diagram Power ARC 4000 Codes 10671Dimension Print Power ARC POWER-ARC POWER-ARC Precaucion Warnung
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