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POWER-ARC 4000 May, 2003




For Machines with Code Number 10673, 10792, 10793, 10930




Safety Depends on You
Lincoln arc welding and cutting
equipment is designed and built
with safety in mind. However, your
overall safety can be increased by
proper installation ... and thought-
ful operation on your part. DO
NOT INSTALL, OPERATE OR
REPAIR THIS EQUIPMENT
WITHOUT READING THIS
MANUAL AND THE SAFETY
PRECAUTIONS CONTAINED
THROUGHOUT. And, most Various engine configurations are available and machine appearance will vary
importantly, think before you act accordingly.
and be careful.




OPERATOR’S MANUAL

ISO 9001
ANSI RAB
QMS




Designed and Manufactured Under a
Quality Program Certified by
ABS Quality Evaluations, Inc.
to ISO 9001 Requirements.
Copyright © 2003 Lincoln Global Inc.
CERTIFICATE NUMBER: 30273




� World's Leader in Welding and Cutting Products �
� 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
i i
SAFETY
WARNING
CALIFORNIA PROPOSITION 65 WARNINGS
The engine exhaust from this product contains
Diesel engine exhaust and some of its constituents
chemicals known to the State of California to cause
are known to the State of California to cause can-
cancer, birth defects, or other reproductive harm.
cer, birth defects, and other reproductive harm.
The Above For Gasoline Engines
The Above For Diesel Engines
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 you
purchase a copy of “Safety in Welding & Cutting - ANSI Standard Z49.1� from the American Welding Society, P.O. Box
351040, Miami, Florida 33135 or CSA Standard W117.2-1974. A Free copy of “Arc Welding Safety� booklet E205 is available
from the Lincoln Electric Company, 22801 St. Clair Avenue, Cleveland, Ohio 44117-1199.

BE SURE THAT ALL INSTALLATION, OPERATION, MAINTENANCE AND REPAIR PROCEDURES ARE
PERFORMED ONLY BY QUALIFIED INDIVIDUALS.

FOR ENGINE 1.h. To avoid scalding, do not remove the
radiator pressure cap when the engine is
powered equipment. hot.
1.a. Turn the engine off before troubleshooting and maintenance
work unless the maintenance work requires it to be running.
____________________________________________________
1.b. Operate engines in open, well-ventilated
areas or vent the engine exhaust fumes
outdoors.

ELECTRIC AND
MAGNETIC FIELDS
____________________________________________________
may be dangerous
1.c. Do not add the fuel near an open flame
welding arc or when the engine is running.
Stop the engine and allow it to cool before 2.a. Electric current flowing through any conductor causes
refueling to prevent spilled fuel from vaporiz- localized Electric and Magnetic Fields (EMF). Welding
ing on contact with hot engine parts and current creates EMF fields around welding cables and
igniting. Do not spill fuel when filling tank. If welding machines
fuel is spilled, wipe it up and do not start
engine until fumes have been eliminated. 2.b. EMF fields may interfere with some pacemakers, and
____________________________________________________ welders having a pacemaker should consult their physician
1.d. Keep all equipment safety guards, covers and devices in before welding.
position and in good repair.Keep hands, hair, clothing and
tools away from V-belts, gears, fans and all other moving 2.c. Exposure to EMF fields in welding may have other health
parts when starting, operating or repairing equipment. effects which are now not known.
____________________________________________________
2.d. All welders should use the following procedures in order to
1.e. In some cases it may be necessary to remove safety
minimize exposure to EMF fields from the welding circuit:
guards to perform required maintenance. Remove
guards only when necessary and replace them when the
2.d.1. Route the electrode and work cables together - Secure
maintenance requiring their removal is complete.
them with tape when possible.
Always use the greatest care when working near moving
parts.
2.d.2. Never coil the electrode lead around your body.
___________________________________________________
1.f. Do not put your hands near the engine fan.
2.d.3. Do not place your body between the electrode and
Do not attempt to override the governor or
idler by pushing on the throttle control rods work cables. If the electrode cable is on your right
while the engine is running. side, the work cable should also be on your right side.

2.d.4. Connect the work cable to the workpiece as close as
possible to the area being welded.
___________________________________________________
1.g. To prevent accidentally starting gasoline engines while 2.d.5. Do not work next to welding power source.
turning the engine or welding generator during maintenance
work, disconnect the spark plug wires, distributor cap or
magneto wire as appropriate. Mar �95
ii ii
SAFETY
ARC RAYS can burn.
ELECTRIC SHOCK can
4.a. Use a shield with the proper filter and cover
kill. plates to protect your eyes from sparks and
3.a. The electrode and work (or ground) circuits
the rays of the arc when welding or observing
are electrically “hot� when the welder is on. open arc welding. Headshield and filter lens
Do not touch these “hot� parts with your bare should conform to ANSI Z87. I standards.
skin or wet clothing. Wear dry, hole-free
gloves to insulate hands. 4.b. Use suitable clothing made from durable flame-resistant
material to protect your skin and that of your helpers from
3.b. Insulate yourself from work and ground using dry insulation. the arc rays.
Make certain the insulation is large enough to cover your full
area of physical contact with work and ground. 4.c. Protect other nearby personnel with suitable, non-flammable
screening and/or warn them not to watch the arc nor expose
In addition to the normal safety precautions, if welding themselves to the arc rays or to hot spatter or metal.
must be performed under electrically hazardous
conditions (in damp locations or while wearing wet
FUMES AND GASES
clothing; on metal structures such as floors, gratings or
scaffolds; when in cramped positions such as sitting,
can be dangerous.
kneeling or lying, if there is a high risk of unavoidable or
accidental contact with the workpiece or ground) use 5.a. Welding may produce fumes and gases
the following equipment: hazardous to health. Avoid breathing these
� Semiautomatic DC Constant Voltage (Wire) Welder. fumes and gases.When welding, keep
� DC Manual (Stick) Welder. your head out of the fume. Use enough
ventilation and/or exhaust at the arc to keep
� AC Welder with Reduced Voltage Control.
fumes and gases away from the breathing zone. When
welding with electrodes which require special
3.c. In semiautomatic or automatic wire welding, the electrode,
ventilation such as stainless or hard facing (see
electrode reel, welding head, nozzle or semiautomatic
instructions on container or MSDS) or on lead or
welding gun are also electrically “hot�.
cadmium plated steel and other metals or coatings
which produce highly toxic fumes, keep exposure as
3.d. Always be sure the work cable makes a good electrical
low as possible and below Threshold Limit Values (TLV)
connection with the metal being welded. The connection
using local exhaust or mechanical ventilation. In
should be as close as possible to the area being welded.
confined spaces or in some circumstances, outdoors, a
respirator may be required. Additional precautions are
3.e. Ground the work or metal to be welded to a good electrical
also required when welding on galvanized steel.
(earth) ground.

5.b. Do not weld in locations near chlorinated hydrocarbon vapors
3.f. Maintain the electrode holder, work clamp, welding cable and
coming from degreasing, cleaning or spraying operations.
welding machine in good, safe operating condition. Replace
The heat and rays of the arc can react with solvent vapors to
damaged insulation.
form phosgene, a highly toxic gas, and other irritating prod-
ucts.
3.g. Never dip the electrode in water for cooling.

5.c. Shielding gases used for arc welding can displace air and
3.h. Never simultaneously touch electrically “hot� parts of
cause injury or death. Always use enough ventilation,
electrode holders connected to two welders because voltage
especially in confined areas, to insure breathing air is safe.
between the two can be the total of the open circuit voltage
of both welders.
5.d. Read and understand the manufacturer’s instructions for this
equipment and the consumables to be used, including the
3.i. When working above floor level, use a safety belt to protect
material safety data sheet (MSDS) and follow your
yourself from a fall should you get a shock.
employer’s safety practices. MSDS forms are available from
your welding distributor or from the manufacturer.
3.j. Also see Items 6.c. and 8.

5.e. Also see item 1.b.

Mar �95
iii iii
SAFETY
WELDING SPARKS can CYLINDER may explode
cause fire or explosion. if damaged.
6.a. Remove fire hazards from the welding area.
7.a. Use only compressed gas cylinders
If this is not possible, cover them to prevent
containing the correct shielding gas for the
the welding sparks from starting a fire.
process used and properly operating
Remember that welding sparks and hot
regulators designed for the gas and
materials from welding can easily go through small cracks
pressure used. All hoses, fittings, etc. should be suitable for
and openings to adjacent areas. Avoid welding near
the application and maintained in good condition.
hydraulic lines. Have a fire extinguisher readily available.
7.b. Always keep cylinders in an upright position securely
6.b. Where compressed gases are to be used at the job site,
chained to an undercarriage or fixed support.
special precautions should be used to prevent hazardous
situations. Refer to “Safety in Welding and Cutting� (ANSI
7.c. Cylinders should be located:
Standard Z49.1) and the operating information for the
� Away from areas where they may be struck or subjected to
equipment being used.
physical damage.
6.c. When not welding, make certain no part of the electrode
� A safe distance from arc welding or cutting operations and
circuit is touching the work or ground. Accidental contact
any other source of heat, sparks, or flame.
can cause overheating and create a fire hazard.
7.d. Never allow the electrode, electrode holder or any other
6.d. Do not heat, cut or weld tanks, drums or containers until the
electrically “hot� parts to touch a cylinder.
proper steps have been taken to insure that such procedures
will not cause flammable or toxic vapors from substances
7.e. Keep your head and face away from the cylinder valve outlet
inside. They can cause an explosion even though they have
when opening the cylinder valve.
been “cleaned�. For information, purchase “Recommended
Safe Practices for the Preparation for Welding and Cutting of
7.f. Valve protection caps should always be in place and hand
Containers and Piping That Have Held Hazardous
tight except when the cylinder is in use or connected for
Substances�, AWS F4.1 from the American Welding Society
use.
(see address above).
7.g. Read and follow the instructions on compressed gas
6.e. Vent hollow castings or containers before heating, cutting or
cylinders, associated equipment, and CGA publication P-l,
welding. They may explode.
“Precautions for Safe Handling of Compressed Gases in
Cylinders,� available from the Compressed Gas Association
6.f. Sparks and spatter are thrown from the welding arc. Wear oil
1235 Jefferson Davis Highway, Arlington, VA 22202.
free protective garments such as leather gloves, heavy shirt,
cuffless trousers, high shoes and a cap over your hair. Wear
ear plugs when welding out of position or in confined places.
FOR ELECTRICALLY
Always wear safety glasses with side shields when in a
powered equipment.
welding area.

6.g. Connect the work cable to the work as close to the welding
8.a. Turn off input power using the disconnect
area as practical. Work cables connected to the building
switch at the fuse box before working on
framework or other locations away from the welding area
the equipment.
increase the possibility of the welding current passing
through lifting chains, crane cables or other alternate cir-
8.b. Install equipment in accordance with the U.S. National
cuits. This can create fire hazards or overheat lifting chains
Electrical Code, all local codes and the manufacturer’s
or cables until they fail.
recommendations.
6.h. Also see item 1.c.
8.c. Ground the equipment in accordance with the U.S. National
Electrical Code and the manufacturer’s recommendations.



Mar �95
iv iv
SAFETY
5. Toujours porter des lunettes de sécurité dans la zone de
PRÉCAUTIONS DE SÛRETÉ soudage. Utiliser des lunettes avec écrans lateraux dans les
zones où l’on pique le laitier.
Pour votre propre protection lire et observer toutes les instruc-
tions et les précautions de sûreté specifiques qui parraissent
6. Eloigner les matériaux inflammables ou les recouvrir afin de
dans ce manuel aussi bien que les précautions de sûreté
prévenir tout risque d’incendie dû aux étincelles.
générales suivantes:

7. Quand on ne soude pas, poser la pince à une endroit isolé de
Sûreté Pour Soudage A L’Arc
la masse. Un court-circuit accidental peut provoquer un
1. Protegez-vous contre la secousse électrique:
échauffement et un risque d’incendie.
a. Les circuits à l’électrode et à la piéce sont sous tension
8. S’assurer que la masse est connectée le plus prés possible
quand la machine à souder est en marche. Eviter toujours
de la zone de travail qu’il est pratique de le faire. Si on place
tout contact entre les parties sous tension et la peau nue
la masse sur la charpente de la construction ou d’autres
ou les vétements mouillés. Porter des gants secs et sans
endroits éloignés de la zone de travail, on augmente le risque
trous pour isoler les mains.
de voir passer le courant de soudage par les chaines de lev-
b. Faire trés attention de bien s’isoler de la masse quand on
age, câbles de grue, ou autres circuits. Cela peut provoquer
soude dans des endroits humides, ou sur un plancher
des risques d’incendie ou d’echauffement des chaines et des
metallique ou des grilles metalliques, principalement dans
câbles jusqu’� ce qu’ils se rompent.
les positions assis ou couché pour lesquelles une
grande partie du corps peut être en contact avec la
9. Assurer une ventilation suffisante dans la zone de soudage.
masse.
Ceci est particuliérement important pour le soudage de tôles
c. Maintenir le porte-électrode, la pince de masse, le câble
galvanisées plombées, ou cadmiées ou tout autre métal qui
de soudage et la machine à souder en bon et sûr état
produit des fumeés toxiques.
defonctionnement.
d.Ne jamais plonger le porte-électrode dans l’eau pour le
10. Ne pas souder en présence de vapeurs de chlore provenant
refroidir.
d’opérations de dégraissage, nettoyage ou pistolage. La
e. Ne jamais toucher simultanément les parties sous tension
chaleur ou les rayons de l’arc peuvent réagir avec les
des porte-électrodes connectés à deux machines à soud-
vapeurs du solvant pour produire du phosgéne (gas forte-
er parce que la tension entre les deux pinces peut être le
ment toxique) ou autres produits irritants.
total de la tension à vide des deux machines.
f. Si on utilise la machine à souder comme une source de
11. Pour obtenir de plus amples renseignements sur la sûreté,
courant pour soudage semi-automatique, ces precautions
voir le code “Code for safety in welding and cutting� CSA
pour le porte-électrode s’applicuent aussi au pistolet de
Standard W 117.2-1974.
soudage.

2. Dans le cas de travail au dessus du niveau du sol, se pro-
téger contre les chutes dans le cas ou on recoit un choc. Ne
jamais enrouler le câble-électrode autour de n’importe quelle
PRÉCAUTIONS DE SÛRETÉ POUR
partie du corps.
LES MACHINES À SOUDER À
3. Un coup d’arc peut être plus sévère qu’un coup de soliel,
TRANSFORMATEUR ET À
donc:
REDRESSEUR
a. Utiliser un bon masque avec un verre filtrant approprié
ainsi qu’un verre blanc afin de se protéger les yeux du
rayonnement de l’arc et des projections quand on soude 1. Relier à la terre le chassis du poste conformement au code
ou quand on regarde l’arc. de l’électricité et aux recommendations du fabricant. Le dis-
b. Porter des vêtements convenables afin de protéger la positif de montage ou la piece à souder doit être branché à
peau de soudeur et des aides contre le rayonnement de une bonne mise à la terre.
l‘arc.
c. Protéger l’autre personnel travaillant à proximité au 2. Autant que possible, I’installation et l’entretien du poste
soudage à l’aide d’écrans appropriés et non-inflamma- seront effectués par un électricien qualifié.
bles.
3. Avant de faires des travaux à l’interieur de poste, la
4. Des gouttes de laitier en fusion sont émises de l’arc de debrancher à l’interrupteur à la boite de fusibles.
soudage. Se protéger avec des vêtements de protection
libres de l’huile, tels que les gants en cuir, chemise épaisse, 4. Garder tous les couvercles et dispositifs de sûreté à leur
pantalons sans revers, et chaussures montantes. place.



Mar. �93
v v

for selecting a QUALITY product by Lincoln Electric. We want you

Thank You to take pride in operating this Lincoln Electric Company product
•â?¢â?? as much pride as we have in bringing this product to you!



Please Examine Carton and Equipment For Damage Immediately
When this equipment is shipped, title passes to the purchaser upon receipt by the carrier. Consequently, Claims
for material damaged in shipment must be made by the purchaser against the transportation company at the
time the shipment is received.

Please record your equipment identification information below for future reference. This information can be
found 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 you
have 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 packet
accompanying this machine and fax the form per the instructions printed on it.

� For On-Line Registration: Go to our WEB SITE at www.lincolnelectric.com. Choose “Quick Links� and then
“Product Registration�. Please complete the form and submit your registration.

Read this Operators Manual completely before attempting to use this equipment. Save this manual and keep it
handy 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:

WARNING
This statement appears where the information must be followed exactly to avoid serious personal injury or
loss of life.



CAUTION
This statement appears where the information must be followed to avoid minor personal injury or damage to
this equipment.
vi vi
MASTER TABLE OF CONTENTS FOR ALL SECTIONS

Page
Safety.................................................................................................................................................i-iv
Installation .............................................................................................................................Section A
Technical Specifications .............................................................................................................A-1
Safety Precautions......................................................................................................................A-2
Location and Ventilation .............................................................................................................A-2
Pre-operation Engine Service .............................................................................................A-3, A-4
Electrical Output Connections ....................................................................................................A-5


Operation...............................................................................................................................Section B
Safety Instructions ......................................................................................................................B-1
General Description ....................................................................................................................B-1
Recommended Applications.......................................................................................................B-1
Operational Features and Controls.............................................................................................B-1
Welding Capability ......................................................................................................................B-1
Limitations .................................................................................................................................B-2
Controls and Settings .................................................................................................................B-2
Engine Operation .........................................................................................................B-3 Thru B-6
Welding Operation .....................................................................................................B-7 Thru B-16


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

Maintenance..........................................................................................................................Section D
Safety Precautions ............................................................................................................................D-1
Routine and Periodic Maintenance ...................................................................................................D-1
General Assembly Exploded View ....................................................................................................D-6


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

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

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




POWER-ARC 4000
A-1 A-1
INSTALLATION

TECHNICAL SPECIFICATIONS - POWER-ARC 4000


INPUT - BRIGGS INTEK® GASOLINE ENGINE

Manufacturer Description Speed Displacement Ignition Capacities
Briggs & 1 cyl., 3700 RPM 18.64 cu. in. Manual, Fuel: 1.0 gal. (3.8 l)
Stratton Intek 4 cycle ± 50 RPM (305 cc) Recoil start;
Model air-cooled at no load Manual choke Oil: 28 oz (0.8 l)
OHV gasoline
8 HP @
3750 RPM
INPUT - HONDA GASOLINE ENGINE
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 start;
air-cooled OHV at no load Manual choke Oil: 1.16 qt. (1.11 l)
gasoline
9 HP @
3600 RPM

RATED OUTPUT - WELDER
Duty Cycle Amps Volts at Rated Amperes
30% Duty Cycle 125 20 VAC
60% Duty Cycle 100 25 VAC

OUTPUT - WELDER AND GENERATOR

Welding Ranges Welder Open Circuit Voltage AC Auxiliary Power
70 - 125 Amps 62 VAC Max. 4000 Continuous Watts
4400 Surge Watts

PHYSICAL DIMENSIONS

Height Width Depth Weight
20.9 in. 20 in. 30 in. 160 lb.
530 mm 508 mm 762 mm 72.5 kg




POWER-ARC 4000
A-2 A-2
INSTALLATION
SAFETY PRECAUTIONS LOCATION AND VENTILATION
Read this entire installation section before you Whenever you use the POWER-ARC 4000, be sure
start installation. that clean cooling air can flow through the machine’s
gasoline engine and the generator. Avoid dusty, dirty
areas. Also, keep the machine away from heat
WARNING sources. Do not place the back end of the generator
anywhere near hot engine exhaust from another
Do not attempt to use this equipment until you machine. And of course, make sure that engine
have thoroughly read all the operation and main- exhaust is ventilated to an open, outside area.
tenance manuals supplied with your machine.
The POWER-ARC 4000 may be used outdoors. Do
They include important safety precautions;
not set the machine in puddles or otherwise sub-
detailed engine starting, operating, and mainte-
merge it in water. Such practices pose safety haz-
nance instructions; and parts lists.
ards and cause improper operation and corrosion of
parts.
ELECTRIC SHOCK can kill. Always operate the POWER-ARC 4000 with the case
roof on and all machine components completely
� Do not touch electrically live
assembled. This will protect you from the dangers of
parts or electrodes with your
moving parts, hot metal surfaces, and live electrical
skin or wet clothing.
devices.
� Insulate yourself from the
STORING
work and ground.
1. Store the machine in a cool, dry place when it’s
•Always wear dry insulating gloves.
not in use. Protect it from dust and dirt. Keep it
where it can’t be accidentally damaged from con-
struction activities, moving vehicles, and other
ENGINE EXHAUST can kill.
hazards.
� Use in open, well ventilated
2. If you will be storing the machine for over 30
areas or vent exhaust to the
days, you should drain the fuel to protect fuel
outside.
system and carburetor parts from gum deposits.
� Do not stack anything on or Empty all fuel from the tank and run the engine
near the engine. until it stops from lack of fuel.
3. You can store the machine for up to 24 months if
you use Briggs & Stratton Gasoline Additive, Part
MOVING PARTS can injure.
No. 5041 (available from any Authorized Briggs &
� Do not operate this equip- Stratton Service Center), in the fuel system. Mix
ment with any of its doors the additive with the fuel in the tank and run the
open or guards off. engine for a short time to circulate the additive
through the carburetor.
� Stop the engine before ser-
vicing it. 4. While the engine is still warm, drain the oil and
refill with fresh oil per the engine manual.
� Keep away from moving parts.
5. Remove the spark plug and pour approximately
Only qualified personnel should install, use, or service
1/2 ounce (15 ml) of engine oil into the cylinder.
this equipment.
Replace the spark plug and crank the engine
slowly to distribute the oil.
6. Clean any dirt and debris from the cylinder and
cylinder head fins and housing, rotating screen,
and muffler areas.
7. Store in a clean, dry area.




POWER-ARC 4000
A-3 A-3
INSTALLATION
STACKING OIL
POWER-ARC 4000 machines CANNOT be stacked. The Power-Arc 4000 with the Briggs and Stratton 8
HP engine and the Power-Arc 4000 with the Honda 9
TILTING
HP engine are supplied with low oil protection. The
Power-Arc 4000 with the Briggs and Stratton 8 HP
Place the machine on a secure, level surface whenev-
engine is equipped with protection that will prevent
er you use it or store it. Any surfaces you place it on
the engine from starting if the oil level is low. The
other than the ground must be firm, non-skid, and
Power-Arc 4000 with the Honda 9 HP engine is
structurally sound.
equipped with protection that will shut down the
The gasoline engine is designed to run in a level posi-
engine in the event of a low oil condition. The engine
tion for best performance. It can operate at an angle,
cannot be restarted until sufficient oil is added.
but this should never be more than 15 degrees in any
The POWER-ARC 4000 is shipped with the engine
direction. If you do operate it at a slight angle, be sure
filled with SAE 10W-30 oil. CHECK THE OIL LEVEL
to check the oil regularly and keep the oil level full.
BEFORE YOU START THE ENGINE. This is an
Also, fuel capacity will be a little less at an angle.
added precaution. When full, the oil level should be at
LIFTING the top of the fill plug hole. If it is not full, add enough
oil to fill it. Be sure the fill plug is tight. Change oil
The POWER-ARC 4000 should be lifted by two peo-
after the first 5 hours of operation. If the POWER-ARC
ple. (It weighs 160 lbs/72.5 kg.) Its welded tube roll
4000 has a Honda engine, then change the oil after
cage is designed to make lifting easy.
the first 20 hours of operation.
For more oil fill and service information, see the
ANGLE OF OPERATION Engine owner’s manual.
Internal combustion engines are designed to run in a
level condition to achieve optimum performance. The
FUEL
maximum angle of operation for the engine is 15
degrees from horizontal in any direction. Be certain to
Fill the fuel tank with clean, fresh, regular grade lead-
place the machine on a firm, non-skid, structural sup-
free gasoline. DO NOT MIX OIL WITH
porting surface. Anchor unit if necessary.
THE GASOLINE.
If you are operating the engine at a slight angle, be
certain to check the oil regularly and maintain a level,
The POWER-ARC 4000 has a fuel tank
full oil condition. The effective fuel capacity will also
mounted on the engine. See the engine owner’s man-
be slightly less than the specified 1.00 gallon (3.8
ual for more details about fuel.
liters).

PRE-OPERATION ENGINE SERVICE
Read and understand the information about the gaso-
line engine in the OPERATION and MAINTENANCE
sections of this manual and the engine owner’s man-
ual before you operate the POWER-ARC 4000.

WARNING
� Keep hands away from the engine muffler or
HOT 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 clear
before starting the engine.
� Keep sparks and flame away from the fuel tank.

POWER-ARC 4000
A-4 A-4
INSTALLATION
PowerArc 4000 Typical Fuel Consumption

B&S 8 HP Carb. Certified Honda 9 HP
Intek Carb. Certified

No Load 0.28 Gallons/Hour .30 Gallons/Hour
3700 RPM ±50 R.P.M. (1.06 Liters/Hour) (1.14 Liters/Hour)
AC CC Weld Output .57 Gallons/Hour .58 Gallons/Hour
125 Amps @ 18 Volts (2.16 Liters/Hour) (2.18 Liters/Hour)
AC CC Weld Output .52 Gallons/Hour .55 Gallons/Hour
100 Amps @ 25 Volts (1.97 Liters/Hour) (2.1 Liters/Hour)
Auxiliary Power 4000 .59 Gallons/Hour .67 Gallons/Hour
Watts (120/240 Volts) (2.23 Liters/Hour) (2.54 Liters/Hour)

SPARK ARRESTER
MUFFLER DEFLECTOR
Gasoline engine mufflers may emit sparks when the
The POWER-ARC 4000, depending on model, may or
engine is running. Some federal, state, or local laws
may not be shipped with an exhaust deflector. If you
require spark arresters in locations where unarrested
received one, you can mount it on the gasoline
sparks could present a fire hazard.
engine if your needs so require.
Standard mufflers and deflectors (like the ones
To install the deflector, do the following:
included with the POWER-ARC 4000 Briggs &
� Align the holes on the deflector plate with the holes Stratton engines) do not act as spark arresters. When
on the muffler. local laws require it, a spark arrester must be installed
on the machine and properly maintained.
� Position the deflector so that the opening points either
right, left, or downward, away from the operator. An optional spark arrester kit is available for your
POWER-ARC 4000 Briggs & Stratton 8 HP Intek
CAUTION engine. See the ACCESSORIES section of this man-
ual for more information.
Never position the deflector upward. Moisture or
debris can enter the engine and damage it. As a
CAUTION
general safety practice, position the deflector to
direct exhaust gases away from the operator’s
face and eyes. An incorrect spark arrester may lead to damage to
the engine or reduce performance. A suitable
� Fasten the deflector onto the muffler with the
spark arrester for the Briggs & Stratton 8 HP Intek
screws provided.
engine is available from your local Briggs &
NOTE: The deflector reduces generator output Stratton engine dealer.
power up to 100 watts.

The Power-Arc 4000 with the Honda engine comes
with a spark arrester as standard equipment. Refer to
the engine owner’s manual for proper maintenance.




POWER-ARC 4000
A-5 A-5
INSTALLATION
FIGURE A.1 - POWER-ARC 4000 OUTPUT CONNECTIONS

1
7


POWER ARC 4000
80
70 AMPS
AMPS




125 90
AMPS
AMPS
GENERATOR

100
AMPS



WARNING


6

ELECTRODE SELECTION GUIDE




5




3
4
2
1. CURRENT CONTROL DIAL 4. CIRCUIT BREAKERS (2) - 20 AMP
2. WELD OUTPUT TERMINALS (2) 5. RECEPTACLE - 240 VOLT, 20 AMP
3. GROUND STUD 6. DUPLEX RECEPTACLE - 120 VOLT, 20
AMP
7. TACHOMETER / HOURMETER
(CODE 10930 ONLY)


TABLE A.1
ELECTRICAL OUTPUT RECOMMENDED WELDING CABLE
SIZE AND LENGTH
CONNECTIONS
See Figure A.1 for the location of the current control
dial, weld output terminals, ground stud, circuit TOTAL COMBINED LENGTH OF ELECTRODE AND
breakers, 240 and 120 volt receptacles. WORK CABLES
Cable Size for
125 amp/
WELDING CABLE CONNECTIONS
Cable Length 30% Duty Cycle
Cable Size and Length
0-50 feet (0-15 meters) 6 AWG
Be sure to use welding cables that are large enough.
50-100 feet (15-39 meters) 4 AWG
The correct size and length becomes especially
100-150 feet (30-46 meters) 3 AWG
important when you are welding at a distance from
the welder.
150-200 feet (46061 meters) 2 AWG
Table A.1 lists recommended cable sizes and lengths
200-250 feet (61-76 meters) 1 AWG
for rated current and duty cycle. Length refers to the
distance from the welder to the work and back to the
welder. Cable diameters are increased for long cable
lengths to reduce voltage drops.


POWER-ARC 4000
A-6 A-6
INSTALLATION
Cable Installation
WARNING
Install the welding cables to your POWER-ARC 4000
Do not ground the machine to a pipe that carries
as follows. See Figure A.1 for the location of parts.
explosive or combustible material.
1. The gasoline engine must be OFF to install weld-
ing cables.
When the POWER-ARC 4000 is mounted on a truck
2. Remove the 1/2 - 13 flanged nuts from the output
or a trailer, the machine generator
terminals.
ground stud MUST be securely connect-
3. Connect the electrode holder and work cables to ed to the metal frame of the vehicle. See
the weld output terminals. You can connect either Figure A.1. The ground stud is marked
cable to either terminal, since the POWER-ARC with the symbol.
4000 provides AC weld current.
4. Tighten the flanged nuts securely.
5. Be certain that the metal piece you are welding
PLUGS AND HAND-HELD EQUIPMENT
(the “work�) is securely connected to the work
clamp and cable.
For further protection against electric shock, any
6. Check and tighten the connections periodically. electrical equipment connected to the generator
receptacles must use a three-blade, grounded type
plug or an Underwriter’s Laboratories (UL) approved
CAUTION
double insulation system with a two-blade plug.
Lincoln offers an accessory plug kit that has the right
� Loose connections will cause the output termi-
type of plugs. See the ACCESSORIES section of this
nals to overheat. The terminals may eventually
manual for details.
melt.
Ground fault protection is needed for hand held
� Do not cross the welding cables at the output
equipment.
terminal connection. Keep the cables isolated
and separate from one another.
Lincoln Electric offers a welding accessory kit with
WARNING
the properly specified welding cables. See the
ACCESSORIES section of this manual for more infor-
mation.
Never operate this machine with damaged or defec-
tive cords. All electrical equipment must be in safe
condition.
MACHINE GROUNDING
Because the POWER-ARC 4000 creates
its own power from its gasoline-engine
driven generator, you do not need to
AUXILIARY POWER RECEPTACLES
connect the machine frame to an earth
ground. However, for best protection The control panel of the POWER-ARC 4000 features
against electrical shock, connect a heavy gauge wire two auxiliary power receptacles:
from the ground stud located on the bottom center of
� A 20 amp, 120 volt duplex (double outlet) recepta-
the output panel (see Figure A.1) to a suitable earth
cle
ground such as a metal pipe driven into the ground.
� A 20 amp 240 volt simplex (single outlet) recepta-
cle.
See Figure A.1.
Through these receptacles the machine can supply
up to 4,000 rated continuous watts and 4,400 surge
watts of single-phase AC power.




POWER-ARC 4000
A-7 A-7
INSTALLATION
PREMISES WIRING CIRCUIT BREAKERS
The POWER-ARC 4000 three-wire, grounded neutral
generator allows it to be connected to premises
The POWER-ARC 4000 has its own 20 amp circuit
wiring. However, the wiring procedure needed to
breakers for overload protection. When the machine
meet the National Electric Code (NEC) regulations as
is operated in high temperature environments, the
well as city ordinances and can be confusing. The
breakers may tend to trip at lower loads than normal-
connections could vary from a "commonly grounded"
ly.
to a "separately derived" system depending on
whether you want the unit to be "hard wired" or tem-
porary to the premises.
CAUTION
Never bypass the circuit breakers. Without over-
WARNING load protection, the power-arc 4000 could over-
heat and/or cause damage to the equipment being
used.
Only a licensed, certified, trained electrician
should install the machine to a premises or resi-
dential electrical system. Be certain that:
� The premises is isolated and no feedbacking
into the utility system can occur. Certain state
and 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 in
conjunction with the properly rated double
throw circuit breaker is connected between the
generator power and the utility meter.


The POWER-ARC 4000 does not have a combined
120/240 volt twist-lock receptacle and cannot be
connected to a premises as described in other
Lincoln literature.
Remember that the POWER-ARC 4000 is intended
only for backup, intermittent use power. Oil level must
be checked after every 5 hours of use. It cannot with-
stand long-term use without proper maintenance.
See the MAINTENANCE section of this manual and
the engine owner’s manual for more information.
Certain electrical devices cannot be powered by the
POWER-ARC 4000. Refer to Table A.2 for these
devices.




POWER-ARC 4000
A-8 A-8
INSTALLATION

CAUTION
Certain Electrical devices cannot be powered by the POWER-ARC 4000. See Table A.2.


TABLE A.2
ELECTRICAL DEVICE USE WITH THE POWER-ARC 4000.


Type Common Electrical Devices Possible Concerns


Resistive Heaters, toasters, incandescent NONE
light bulbs, electric range, hot
pan, skillet, coffee maker.


Capacitive TV sets, radios, microwaves, Voltage spikes or high voltage
appliances with electrical control. regulation can cause the capaci-
tative elements to fail. Surge
protection, transient protection,
and additional loading is recom-
mended for 100% fail-safe
operation. DO NOT RUN
THESE DEVICES WITHOUT
ADDITIONAL RESISTIVE TYPE
LOADS.


Inductive Single-phase induction motors, These devices require large
drills, well pumps, grinders, small current inrush for starting. (See
refrigerators, weed and hedge Table B.3, GENERATOR POWER
trimmers APPLICATIONS, in the OPERA-
TION section of this manual for
required starting wattages.)
Some synchronous motors may
be frequency sensitive to attain
maximum output torque, but
they SHOULD BE SAFE from
any 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, and
liabilities still exist. DO NOT
USE THESE DEVICES WITH A
POWER-ARC 4000.




The Lincoln Electric Company is not responsible for any damage to electrical components improperly connect-
ed to the POWER-ARC 4000.




POWER-ARC 4000
B-1 B-1
OPERATION
SAFETY INSTRUCTIONS GENERAL DESCRIPTION
The POWER-ARC 4000 is a generator/welder designed
Read and understand this entire section before oper-
for home use and other non-commercial applications.
ating your POWER-ARC 4000.
As a generator it can supply up to 4,000 continuous
watts (or 4,400 surge watts) of 120/240 volt, single-
WARNING
phase AC power. As a welder it provides 125 amps of
Do not attempt to use this equipment until you AC constant current for welding with AC stick elec-
have thoroughly read all the operation and main- trodes. A single dial provides continuous adjustment of
tenance manuals supplied with your machine. welding output. The machine is lightweight, portable,
They include important safety precautions; and can be lifted by two people.
detailed engine starting, operating, and mainte-
nance instructions; and parts lists. The Lincoln warranty covers the Power-Arc 4000
(excluding the engine) for 2 years from the date of pur-
ELECTRIC SHOCK can kill.
chase. The engine is covered by the engine manufactur-
er’s warranty policy.
� Do not touch electrically live parts
or electrodes with your skin or wet
RECOMMENDED APPLICATIONS
clothing.
GENERATOR
� Insulate yourself from the work and ground.
The POWER-ARC 4000 gives AC generator output for
� Always wear dry insulating gloves.
medium use, non-commercial demands. For more
FUMES AND GASES can be details on operating the generator, see GENERATOR
OPERATION in the OPERATION section of this manual.
dangerous.
WELDER
� Keep your head out of fumes. The POWER-ARC 4000 provides excellent constant cur-
rent AC welding output for stick (SMAW) welding. For
� Use ventilation or exhaust to
more details on using the machine as a welder, see
remove fumes from breathing zone.
WELDING OPERATION in the OPERATION section of
WELDING SPARKS can cause this manual.
fire or explosion.
OPERATIONAL FEATURES AND
� Keep flammable material away.
CONTROLS
� Do not weld on containers that have
The POWER-ARC 4000 was designed for simplicity.
held combustibles.
Therefore, it has very few operating controls. A single
ARC RAYS can burn. dial on the control panel lets you select either generator
or welding use. For welding, the same dial selects con-
� Wear eye, ear, and body protection.
tinuous 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-
ENGINE EXHAUST can kill. TION in the OPERATION section of this manual and the
engine owner’s manual for details about starting, run-
� Use in open, well ventilated areas or ning, stopping, and breaking in the gasoline engine.
vent exhaust to the outside.
WELDING CAPABILITY
� Do not stack anything on or near
the engine. The POWER-ARC 4000 is rated 125 amps, 20 volts at
30% duty cycle on a ten-minute basis. This means
MOVING PARTS can injure.
that you can load the welder to 125 amps for three
� Do not operate this equipment with minutes out of every ten-minute period. The machine
any of its doors open or guards off. is also capable of higher duty cycles at lower output
currents. You can load the welder to 100 amps for six
� Stop the engine before servicing it.
minutes out of ten for a 60% duty cycle.
� Keep away from moving parts. The current is continuously variable from 70 to 125
amps AC. The POWER-ARC 4000 can weld with all
Only qualified personnel should install, use, or ser-
3/32 and most 1/8 inch diameter Lincoln AC elec-
vice this equipment.
trodes.

POWER-ARC 4000
B-2 B-2
OPERATION
1. CURRENT CONTROL DIAL: Adjusts continuous
LIMITATIONS
current output. The amperages on the dial corre-
� The POWER-ARC 4000 is not recommended for
spond to the average amperages needed for spe-
any processes besides those that are normally per-
cific Lincoln welder rods.
formed using stick welding (SMAW) procedures.
� The POWER-ARC 4000 is not recommended for 2. ELECTRODE SELECTION GUIDE: Provides rec-
pipe thawing. ommended electrode type, size, and welder out-
� During welding, generator power is limited to 100 put setting based on the thickness of the work.
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.
FIGURE B.1 � OUTPUT PANEL CONTROLS

9 1


POWER ARC 4000
80
70 AMPS
AMPS




125 90
AMPS
AMPS
GENERATOR

100
AMPS




WARNING


8
2 ELECTRODE SELECTION GUIDE




7




5
4 6
3
1. CURRENT CONTROL DIAL
2. ELECTRODE SELECTION GUIDE
3. WELD OUTPUT TERMINAL (TO ELECTRODE HOLDER) WITH 1/2 - 13 FLANGE NUT
4. WELD OUTPUT TERMINAL (TO WORK) WITH 1/2 - 13 FLANGE NUT
5. GROUND STUD
6. 20 AMP CIRCUIT BREAKERS (2)
7. 20 AMP, 240 VOLT RECEPTACLE
8. 20 AMP, 120 VOLT DUPLEX RECEPTACLE
9. TACHOMETER / HOURMETER (CODE 10930 ONLY)

3. WELD OUTPUT TERMINAL (TO ELECTRODE
CONTROLS AND SETTINGS HOLDER) WITH 1/2 - 13 FLANGE NUT: Provides
the connection point for either the electrode hold-
All generator/welder controls are located on the
er or the work cable. (Because the POWER-ARC
Output Control Panel. Gasoline engine controls are
4000 is an AC output machine, either output ter-
mounted on the engine. See Figures B.1 and B.2 and
minal can be used for either cable.)
the explanations that follow.

GENERATOR/WELDER CONTROLS
See Figure B.1 for the location of the following fea-
tures:
POWER-ARC 4000
B-3 B-3
OPERATION
4. WELD OUTPUT TERMINAL (TO WORK) WITH 1/2
3. MUFFLER: Reduces engine noise output. Briggs
- 13 FLANGE NUT: Provides the connection point
& Stratton muffler does not serve as a spark
for either the electrode holder or the work cable.
arrester. Honda muffler does. See SPARK
(Because the POWER-ARC 4000 is an AC output
ARRESTER in the INSTALLATION section of this
machine, either output terminal can be used for
manual.
either cable.)
4. ROTARY STOP SWITCH: Stops the engine by
5. GROUND STUD: Provides a connection point for
grounding the ignition circuit.
connecting the machine case to earth ground for
the safest grounding procedure. 5. AIR CLEANER: Filters intake air to the carburetor.
See ENGINE MAINTENANCE in the MAINTE-
6. 20 AMP CIRCUIT BREAKERS (2): Provide sepa-
NANCE section of the engine owner’s manual for
rate overload current protection for the 120 volt
details about the specific type of air cleaner to
and 240 volt receptacles.
use.
7. 20 AMP, 240 VOLT RECEPTACLE: Connection
6. CHOKE: Provides a richer air/fuel mix-
point for supplying 240 volt power to operate one
ture for cold engine starting condi-
electrical device.
tions. See the topic ENGINE OPERA-
8. 20 AMP, 120 VOLT DUPLEX RECEPTACLE: TION, below, for details on setting the
Connection point for supplying 120 volt power to choke.
operate one or two electrical devices.
7. RECOIL STARTER: Manual, rope-type starter.
9. Tachometer / Hourmeter: (For Code 10930 Only) The handle position allows easy starting from
either ground level or pickup-truck level
Records engine speed in RPMs, engine running
time, and alerts the user to perform a specific 8. OIL DRAIN PLUG: Permits convenient draining of
engine maintenance task by flashing correspond- engine oil during maintenance. Both sides of the
ing messages. If the message reads “Chg Oil�, the engine are equipped with an oil drain plug.
user needs to change the oil in the engine. If the
9. OIL FILL PLUG: Permits convenient filling of
message reads “SVC AIR-FiILTER�, the user
engine oil during maintenance. Both sides of the
needs to clean or if necessary,change the air filter.
engine are equipped with an oil fill plug.
(See Honda Engineâ€s owners manual for more
information). After maintenance task is preformed, ENGINE OPERATION
the user is required to use the supplied Reset Tool
to cancel flashing message and resume normal
WARNING
meter operation. (See page D-1 for futher details).

DO NOT RUN THE ENGINE AT EXCESSIVE
GASOLINE ENGINE CONTROLS SPEEDS. The maximum allowable high idle speed
for the POWER-ARC 4000 is 3750 RPM, no load.
Refer to your engine manual for the location of the
Do NOT adjust the governor screw on the engine.
following features:
Severe personal injury and damage to the
1. FUEL SHUTOFF VALVE: Stops the flow of gaso- machine can result if it is operated at speeds
line from the fuel tank to the carburetor. Should above the maximum rated speed.
be closed whenever you are finished using the
POWER-ARC 4000. Must be opened before you
start the engine. Read and understand all safety instructions included
in the engine manufacturer’s Operating and
2. FUEL TANK AND CAP: See TECHNICAL SPECI-
Maintenance Instructions manual that is shipped
FICATIONS for capacity.
with the POWER-ARC 4000.
NOTE: If you use any other alternate fuel tank or
supply, be sure to use a recommended in-
line fuel filter.




POWER-ARC 4000
B-4 B-4
OPERATION
4. Pull the cord rapidly.
BEFORE STARTING THE ENGINE
5. If the engine does not start, open the choke
CHECK AND FILL THE ENGINE OIL LEVEL:
slightly and pull the starter cord rapidly again.
1. Place the machine on a level
When the engine starts, gradually open the choke
surface.
to the “RUN� position. To open the choke fully
2. Open the oil fill plug. requires an engine warm-up period of several
seconds to several minutes, depending on the
3. Fill (if necessary) until oil flows out the top of the
temperature. After starting the engine, first open
fill plug hole.
the choke (toward RUN) until the engine just
4. Replace the fill plug and tighten securely. begins to run smoothly. Then open the choke in
small steps, allowing the engine to accept small
CHECK AND FILL THE ENGINE FUEL TANK:
changes in speed and load, until the choke is fully
1. Remove the fuel tank cap. open (in RUN). During engine warm-up the equip-
ment can be operated.
2. Fill the tank to allow approximately 1/4
inch (5 mm) of tank space for fuel
expansion. DO NOT FILL THE TANK
FOR A “HOT� ENGINE:
TO THE POINT OF OVERFLOW.
1. Open the fuel shutoff valve.
3. Replace the fuel tank cap and tighten securely.
2. Place the choke lever in the “RUN�
NOTE: The engine will operate satisfactorily on any
position. Closing the choke of a hot
gasoline meant for automotive use. A mini-
engine will flood the carburetor and
mum of 87 octane is recommended. DO NOT
prevent starting.
MIX OIL WITH THE GASOLINE.
3. Pull slightly on the recoil starter handle until resis-
Use clean, fresh, lead-free gasoline. Leaded gasoline
tance is felt.
may be used if lead-free is not available. However,
lead-free gasoline leaves fewer combustion deposits 4. Pull the cord rapidly.
and gives longer valve life. Purchase gasoline in
FOR BEST ENGINE STARTING:
quantities that will be used within 30 days, to assure
freshness. � Always use fresh gasoline and be sure the filter is
clean and properly maintained.
NOTE: We DO NOT recommend using gasoline that
contains alcohol, such as gasohol. However, � If you use an alternate fuel tank or supply, be sure
if gasoline with alcohol is used, it MUST NOT to install an in-line fuel filter.
contain more than 10% Ethanol and MUST
� Do not pull the recoil starter with the
be removed from the engine during storage.
choke in the “CHOKE� position more
DO NOT use gasoline containing Methanol.
than one time. Repeated pulls on a
STARTING THE ENGINE choked engine will flood the carbure-
tor.
NOTE: Remove all loads connected to the AC power
receptacles before starting the gasoline � If the engine will not start, see the TROU-
engine. Turn the Rotary Stop Switch to the BLESHOOTING section of this or the engine
“ON� position. owner’s manual.
FOR A “COLD� ENGINE: speed when not under load. You should not adjust
this setting yourself.
1. Open the fuel shutoff valve.
2. Place the choke lever in the “CHOKE�
position.
3. Pull slightly on the recoil starter handle until resis-
tance is felt.




POWER-ARC 4000
B-5 B-5
OPERATION
GENERATOR OPERATION
STOPPING THE ENGINE
1. Remove all welding and generator power loads
CAUTION
and let the engine cool by running it for several
minutes.
Be sure that any electrical equipment plugged into
2. Stop the engine by placing the ignition switch in
the generator’s AC power receptacles can with-
the “OFF� position.
stand a ±10% voltage and a ±4% frequency varia-
3. Close the fuel shutoff valve. tion. Some electronic devices cannot be powered
by the POWER-ARC 4000. Refer to Table A.2,
ELECTRICAL DEVICE USE WITH THE POWER-
ARC 4000, in the INSTALLATION section of this
manual.
WARNING
-----------------------------------------------------------
Close the fuel valve when the machine is trans-
GENERAL INFORMATION
ported to prevent fuel leakage from the carbure-
tor. Drain the tank before transporting the The POWER-ARC 4000 generator is rated at 4000
machine in a vehicle. continuous watts (4400 surge watts). It provides both
120 volt and 240 volt power. You can draw up to 20
For long periods of storage, turn off the fuel shut-
amps from either side of the 120 volt duplex recepta-
off valve (lowest, downward position) and let the
cle, but no more than 37 amps from both sides at
engine run until there is no more fuel in the line.
once. Up to 18 amps can be drawn from the single
Use a fuel additive such as Sta-Bil to minimize fuel
240 volt receptacle.
gum deposits.
Electrical loads in watts are calculated by multiplying
-----------------------------------------------------------
the voltage rating of the load by the number of amps
it draws. (This information is given on the load device
nameplate.) For example, a device rated 115 volts, 2
RUNNING THE ENGINE amps will need 230 watts of power (115 x 2 = 230).
The engine is set at the factory to run at high idle You can use Table B.3, GENERATOR POWER APPLI-
speed when not under load. You should not adjust CATIONS, to determine the wattage requirements of
this setting yourself. the most common types of loads you can power with
the POWER-ARC 4000. Be sure to read the notes at
the bottom of the table.
BREAK-IN PERIOD
The engine will use a greater amount of oil during its
TO USE THE GENERATOR AS AN AUXILIARY
“break-in� period. Check the oil frequently during
POWER SUPPLY:
break-in. For more details, see the MAINTENANCE
section in the engine owner’s manual. 1. Start the gasoline engine. See ENGINE OPERA-
TION in this section of the manual and the engine
CAUTION owner’s manual.
2. Set the current control dial on the output control
During break-in, subject the POWER-ARC 4000 to panel to “GENERATOR.� See Figure B.1.
only moderate loads. Avoid long periods running
3. Plug the load(s) into the appropriate 120 volt or
at idle. Before stopping the engine, remove all
240 volt power receptacle.
loads and allow the engine to cool several min-
utes. NOTE: During welding, the maximum generator out-
put for auxiliary loads is 100 watts.
-------------------------------------------------------------
NOTE: You can supply multiple loads as long as the
total load does not exceed 4,000 watts. Be
sure to start the largest loads first.




POWER-ARC 4000
B-6 B-6
OPERATION
TABLE B.3
GENERATOR 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

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 up
to 2 times the running watts shown above. For example a 1 HP motor requires approximately 1000 watts of
power 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 largest
loads 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 2
amps will need (115 VOLTS) X (2 AMPS) = 230 WATTS OF POWER. 1 KW = 1000 WATTS.




POWER-ARC 4000
B-7 B-7
OPERATION
WELDING OPERATION 3. Attach the work clamp securely to the work you
are welding.
GENERAL INFORMATION 4. Insert the electrode into the electrode holder.
WARNING 5. Set the current control dial to the desired output
current.
6. Start the gasoline engine. See ENGINE OPERA-
� Do not touch electrically live parts or TION in this section of the manual.
electrodes with your skin or wet cloth-
7. Strike an arc and begin welding. For information
ing.
on welding techniques, see WELDING GUIDE-
LINES in this section of the manual.
� Do not breathe welding fumes or AFTER YOU FINISH THE WELD:
gases.
1. Stop the gasoline engine. See ENGINE OPERA-
� Use ventilation or exhaust to remove TION in this section of the manual.
welding fumes from the breathing
2. Allow the electrode and work to cool completely.
area.
3. Remove the work clamp from the work.
4. Remove any remaining piece of electrode from
� Keep flammable material away.
the electrode holder.
� Wear eye, ear, and body protection.
5. If you are finished using the POWER-ARC 4000
for welding, disconnect the welding cables from
the weld output terminals. Reattach the flange
The POWER-ARC 4000 generator/welder can deliver
nuts and leave them on the terminals.
from 70 to 125 amps of continuous welding output
current . Output can be adjusted by setting the cur-
NOTE: 1. Welding current is continuously variable
rent control dial on the output control panel.
with 60% duty cycle applying to output
You can get maximum welding output by setting the currents 100 Amps and less and 30%
dial to 125 AMPS. At high current settings like this, duty cycle applying to currents above 100
some output may decrease as the machine is used. Amps.
If you are welding for a long time, you may need to
2. Duty cycle is based on a ten minute
turn the dial slightly upward to maintain the same
period. The welder can be loaded to 125
results.
Amps for three minutes out of every ten
The numbers on the dial correspond to the average minute period or to 100 Amps for six
amps needed to weld using specific Lincoln welding minutes out of every ten minute period.
rods. Table B.4, WELDING APPLICATIONS, gives
you the recommended dial settings based on the
CONTROL FUNCTION / OPERATION
thickness of the work and the size and type of rod
you’re using. “Current Control Dial�
Provides welding current adjustment from 70 through
125 Amps.
TO USE THE POWER-ARC 4000 FOR WELDING:
To obtain maximum weld output, turn the “Current
1. Remove the flange nuts from the weld output ter-
Control Dial� to �125 Amps� for either a cold or hot
minals and place the work and electrode welding
engine. As the machine is used, some welding volt-
cables over the terminals. See Figure B.1.
age may decrease at high current settings. If you are
Replace and tighten the flange nuts securely. Be
welding for long periods of time, the dial may need to
sure the connections are tight.
be slightly turned upward to provide the same welding
results as when the machine was cold.
2. Select the appropriate electrode. See Table B.4,
WELDING APPLICATIONS, or the ELECTRODE
The numbers listed on the dial correspond to the aver-
SELECTION GUIDE on the machine Output
age amperage needed to weld specific Lincoln rods.
Control Panel.
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
B-8 B-8
OPERATION
WELDING GUIDELINES
TABLE B.4
WELDING APPLICATIONS/ELECTRODE SELECTION GUIDE

Material Thickness Electrode Type Size Setting

1/8� and thinner FLEETWELD® 37 3/32� 90 amps
AWS E6013
1


FLEETWELD® 180 70 amps
AWS E6011
Lincoln 7018 AC 90 amps
AWS E7018
3/16� Maximum FLEETWELD® 37 1/8� 125 amps
AWS E6013
5/16� Maximum FLEETWELD® 180 1/8� 90 amps
AWS E6011
Any Thickness WEARSHIELD® ABR 1/8� 100 amps

NOTES: Stick Welding
The values listed are suggested settings. Actual set- Stick welding is probably the most familiar welding
ting may vary depending on individual preference process known. A coated ELECTRODE, the weld rod,
and/or specific application. Beginners should use is clamped into an ELECTRODE HOLDER, an insulat-
Lincoln E7018 AC. ed clamping device, which in turn connects to the
ELECTRODE CABLE, a heavy wire. The WORK, the
For electrodes not listed, follow tables that are
metal piece to be welded, is connected to the WORK
packed with the electrodes.
CABLE, a heavy wire which contains the WORK
Ask for the Lincoln WELD DIRECTORY (Publication CLAMP. Quality Lincoln cables use many fine copper
M210) for a complete listing of all Lincoln stick elec- wires with a very flexible insulating covering for the
trodes available. electrode and work cables. When properly connected
to the OUTPUT STUDS of a high current power
AWS = American Welding Society
1

source, the electrode melts and bonds the metal being
repaired. Refer to Figure 3 to see the circuit. See
Semi-automatic, MIG Welding With a
“Cable Installation� section for proper cable connec-
Lincoln Weld Pak 100 or Weld Pak 125 tion to a Power-Arc.
WARNING The Power-Arc provides excellent weld output charac-
ARC RAYS can burn. teristics when used in combination with Lincoln AC
electrodes. Other AC electrodes may also be used.
� When using an open arc process, Follow the settings listed in Table 2 “Welding
Application Chart� and the “Electrode Selection Guide�
it is necessary to use correct eye,
found on the nameplate of the machine.
head and body protection.
Learning To Stick Weld
The serviceability of a product or structure utiliz-
ing this type of information is and must be the
The Power-Arc generator power can be used to supply sole responsibility of the builder/user. Many vari-
power to a Lincoln Weld-Pak 100 or Weld-Pak 125 wire ables beyond the control of The Lincoln Electric
feed welder. The Weld-Pak is equipped with all the Company affect the results obtained in applying
supplies needed for Flux-Cored Arc Welding (FCAW), this type of information. These variables include,
and is available where Lincoln products are sold. but are not limited to, welding procedure, plate
chemistry and temperature, weldment design, fab-
A K610-1 MIG Conversion Kit is also available for the
rication methods and service requirements.
Weld-Pak which provides all the essentials needed for
Gas Metal Arc Welding, GMAW, or MIG processes.


POWER-ARC 4000
B-9 B-9
OPERATION
No one can learn to weld simply by reading about it. MOVING PARTS can injure.
Skill comes only with practice. The following pages � Do not operate with doors open or
will help the inexperienced welder understand welding guards off.
and develop his skill. For more detailed information,
� Stop engine before servicing.
order a copy of the book “New Lessons in Arc
� Keep away from moving parts.
Welding.� (See Book Division section at rear of manual).
The operator’s knowledge of arc welding must go Only qualified personnel should install, use, or
beyond the arc itself. He must know how to control the service this equipment.
arc, and this requires a knowledge of the welding cir-
cuit and the equipment that provides the electric cur-
The electric arc is made between the work and the tip
rent used in the arc. Figure 3 is a diagram of the weld-
end of a small metal wire, the electrode, which is
ing circuit. The circuit begins where the electrode
clamped in a holder that is held by the welder. A gap
cable is attached to the welding machine and ends
is made in the welding circuit (see Figure 3) by hold-
where the work cable cable is attached to the
ing the tip of the electrode 1/16 - 1/8� (1.6-3.2mm)
machine. Current flows through the electrode cable to
away from the work or base metal being welded. The
the electrode holder, through the electrode holder to
electric arc is established in this gap and is held and
the electrode and across the arc. On the work side of
moved along the joint to be welded, melting the metal
the arc, the current flows through base metal to the
as it is moved.
work cable and back to the welding machine. The cir-
cuit must be complete for the current to flow. To weld, Arc welding is a manual skill requiring a steady hand,
the work clamp must be tightly connected to clean good physical condition, and good eyesight. The oper-
base metal. Remove paint, rust,etc. as necessary to ator controls the welding arc and, therefore, the quali-
get a good connection. Connect the work clamp as ty of the weld made.
close as possible to the area you wish to weld. Avoid
allowing the welding circuit to pass through hinges,
bearings, electronic components or similar devices
What Happens in the Arc?
that can be damaged.
Figure 4 illustrates the action that takes place in the
electric arc. It closely resembles what is actually seen
during welding.
The “arc stream� is seen in the middle of the picture.
This is the electric arc created by the electric current
flowing through the space between the end of the
electrode and the work. The temperature of this arc is
about 6000°F (3300°C) which is more than enough to
melt metal. The arc is very bright, as well as hot, and
cannot be looked at with the naked eye without risking
The Power-Arc 4000 has a voltage output of up to 62
painful and possibly permanent injury. A very dark
volts which can shock.
lens, specifically designed for arc welding must be
WARNING used with the handshield or headshield whenever
viewing the arc.
ELECTRIC SHOCK can kill.
The arc melts the base metal and actually digs into it,
� Do not touch electrically live parts much like water through a garden hose nozzle digs
or electrode with skin or wet cloth-
into the earth. The molten metal forms a pool or crater
ing.
and tends to flow away from the arc As it moves away
� Insulate yourself from work and from the arc, it cools and solidifies. Slag forms on top
ground.
of the weld to protect it during cooling.
� Always wear dry insulating gloves. Covering
Electrode
ENGINE EXHAUST can kill. Arc
Solidified Slag
� Use in open, well ventilated areas Shielding Gases
or vent exhaust outside. Weld Metal
� Do not stack anything on or near
Base Metal
the engine.
FIGURE 4 - The welding arc.


POWER-ARC 4000
B-10 B-10
OPERATION
The function of the covered electrode is much more 2. The Correct Way to Strike An Arc
than simply to carry current to the arc. The electrode
is composed of a core metal wire around which has
Be sure the work clamp makes good electrical contact
been extruded and baked a chemical covering. The
to the work.
core wire melts into the arc and tiny droplets of molten
Lower your headshield and scratch the electrode
metal shoot across the arc into the molten pool. The
slowly over the metal, and you will see sparks fly.
electrode provides additional filler metal for the joint to
While scratching, lift the electrode 1/8� (3.2mm) and
fill the groove or gap between the two pieces of the
the arc is established.
base metal. The covering also melts or burns in the
arc. It has several functions. It makes the arc steadier,
NOTE: If you stop moving the electrode while
provides a shield of smoke-like gas around the arc to
scratching, the electrode will stick. Most beginners try
keep oxygen and nitrogen in the air away from the
to strike the arc by a fast jabbing motion down on the
molten metal, and provides a flux for the molten pool.
plate. Result: They either stick their electrode or their
The flux picks up impurities and forms a protective
motion is so fast that they break the arc immediately.
slag. The principle differences between the various
types of electrodes are in their coatings. By varying
3. The Correct Arc Length
the coating, it is possible to greatly alter the operating
characteristics of electrodes. By understanding the dif-
The arc length is the distance from the tip of the
ferences in the various coatings, you will gain a better
electrode core wire to the base metal.
understanding of selecting the best electrode for the
Once the arc has been established, maintaining the
job you have at hand. In selecting an electrode, you
correct arc length becomes extremely important. The
should consider:
arc should be short, approximately 1/16 to 1/8� (1.6-
1. The type of deposit you want, e.g., mild steel,
3.2mm) long. As the electrode burns off, the electrode
stainless, low alloy, hardfacing.
must be fed to the work to maintain correct arc length.
2. The thickness of the plate you want to weld.
3. The position it must be welded in (downhand,
The easiest way to tell whether the arc has the correct
out-of-position).
length is by listening to its sound. A nice, short arc has
4. The surface condition of the metal to be welded.
a distinctive, “crackling� sound, very much like eggs
5. Your ability to handle and obtain the desired
frying in a pan. The incorrect, long arc has a hollow,
electrode.
blowing or hissing sound.
Four simple manipulations are of prime importance.
Without complete mastery of these four, further
4. The Correct Welding Speed
attempts at welding are futile. With complete mastery
of the four, welding will be easy.
The important thing to watch while welding is the pud-
1. The Correct Welding Position
dle of molten metal right behind the arc. DO NOT
WATCH THE ARC ITSELF. The appearance of the
Illustrated is the correct welding position for
puddle and the ridge where the molten puddle solidi-
right-handed people. (For left-handed people it is
fies indicates correct welding speed. The ridge should
opposite.)
be approximately 3/8� (9.5mm) behind the electrode.
Whenever possible, weld from left to right (if right-
handed). This enables you to see clearly what you Ridge where puddle
are doing. solidifies

Molten puddle
Hold the electrode at a slight angle as shown in
Figure 5.
Most beginners tend to weld too fast, resulting in a
thin, uneven, “wormy� looking bead. They are not
watching the molten metal.
15-20°

IMPORTANT: It is not generally necessary to weave
the arc forward, backward or sideways. Weld along at
90°
a steady pace, and you will have an easier time.
side view end view
NOTE: When welding on thin plate, you will find that
Correct Welding Position you have to increase the welding speed, whereas
when welding on heavy plate, it is necessary to go
Figure 5 more slowly to ensure fusion and penetration.

POWER-ARC 4000
B-11 B-11
OPERATION
These higher carbon steels can be welded successful-
PRACTICE
ly in most cases; however, care must be taken to fol-
The best way of getting practice in the four skills that low proper procedures, including preheating the metal
enable you to maintain: to be welded and, in some cases, carefully controlling
the temperature during and after the welding process.
1. Correct Welding Position.
For further information on identifying various types of
2. Correct Way to Strike An Arc. steel and other metals, and for proper procedures for
welding them, we suggest you purchase a copy of
3. Correct Arc Length.
“New Lessons in Arc Welding� (See Book Division
4. Correct Welding Speed. section).
is to spend a little more time on the following exercise. Regardless of the type of metal being welded, in order
to get a quality weld, it is important that it be free of
oil, paint, rust or other contaminants.
Use the following:
Mild Steel Plate: 3/16� (4.8mm), or heavier.
Electrode: 1/8� (3.2mm) AWS 6011
Types of Welds
(Fleetweld® 180)

Current Setting: 90-125 Amps AC
Five types of welding joints are: Butt Joints, Tee
Joints, Lap Joints, Edge Joints and Corner Joints.
Do the following:
1. Learn to strike the arc by scratching the electrode Of these, the Butt Joint and Tee Joint are the most
over the plate. Be sure the angle of the electrode common.
is 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 it
by its sound.
3. When you are sure that you can hold a short,
Butt Joint Lap Joint
crackling arc, start moving. Look at the molten
puddle constantly, and look for the ridge where the
metal solidifies.
4. Run beads on a flat plate. Run them parallel to the
top edge (the edge farthest away from you). This
gives you practice in running straight welds, and Corner Joint
Tee Joint
Edge Joint
also, it gives you an easy way to check your
progress. The 10th weld will look considerably bet-
Butt Welds
ter than the first weld. By constantly checking on
your mistakes and your progress, welding will soon
be a routine matter.
Butt Joints are the most widely used Joints. Place two
plates side by side, leaving 1/16� (1.6mm) for thin
metal to 1/8� (3.2mm) for heavy metal space between
Common Metals
them in order to get deep penetration.
Most metals found around the farm or small shop are
low carbon steel, sometimes referred to as mild steel.
Typical items made with this type of steel include most Tack the plates at both ends, otherwise the heat will
sheet metal, plate, pipe and rolled shapes such as cause the plates to move apart. (See drawing).
channels, angle irons and “I� beams. This type of
steel can usually be easily welded without special
precautions. Some steel, however, contains higher
carbon. Typical applications include wear plates,
axles, connecting rods, shafts, plowshares and
scraper blades.


POWER-ARC 4000
B-12 B-12
OPERATION
Now weld the two plates together. Weld from left to Fillet Welds
right (if right-handed). Point the electrode down in he
gap between the two plates, keeping the electrodes
slightly tilted in the direction of travel. When welding fillet welds, it is very important to hold
the electrode at a 45° angle between the two sides, or
the metal will not distribute itself evenly.
20°


90°
end view side view To make it easier to get the 45° angle, it is best to put
the electrode in the holder at a 45° angle, as shown.
Watch the molten metal to be sure it distributes itself
evenly on both edges and in between the plates. 45°




45°
Penetration


Unless a weld penetrates close to 100%, a butt joint
Multiple Pass Welds
will be weaker than the material welded together.

1 Make multiple pass horizontal fillets as shown in the
sketch. Put the first bead in the corner with fairly high
current. Hold the electrode angle needed to deposit
the filler beads as shown putting the final bead against
the vertical plate.



In this example, the total weld is only 1/2 the thickness 4
of the material; thus, the weld is only approximately 3
2 1 2
half as strong as the metal. 1

Good



Welding in the Vertical Position


In this example, the joint has been flame beveled or Welding in the vertical position can be done either
ground prior to welding so that 100% penetration vertical-up or vertical-down. Vertical-up is used
could be achieved. The weld, if properly made, is as whenever a large, strong weld is desired.
strong or stronger than the original metal. Vertical-down is used primarily on sheet metal for fast,
low penetrating welds.
60°
4

3
2

1
1/8" (3.2mm)
Successive passes must be used to build up butt
welds on heavier metal.
POWER-ARC 4000
B-13 B-13
OPERATION
8. When the arc is brought back to the now solidified
Vertical-Up Welding
puddle, IT MUST BE SHORT, otherwise no metal
will be deposited, the puddle will melt again, and it
will “drip�.
The problem, when welding vertical-up, is to put the
molten metal where it is wanted and make it stay
there. If too much molten metal is deposited, gravity
9. It is important to realize that the process consists
will pull it downwards and make it “drip�. Therefore, a
of SLOW, DELIBERATE movements. There are no
certain technique has to be followed:
fast motions.
Long arc




Vertical-Down Welding
Short arc

NOTE: Holder end of electrode
is lower than arc.
Vertical-down welds are applied at a fast pace. These
1. Use 1/8� (3.2mm) 90-115 amps or 3/32� (2.5mm)
welds are therefore shallow and narrow, and are
70 amps AWS 6011.
excellent for sheet metal. Do not use the vertical-down
technique on heavy metal. The welds will not be
strong enough.
2. When welding, the electrode should be kept hori-
zontal or pointing slightly upwards. (See drawing
above).
1. Use 1/8� (3.2m) or 3/32� (2.5mm) AWS 6011.


3. The arc is struck and metal deposited at the bot-
2. On thin metal use 70-75 amps.
tom of the two pieces to be welded together.
(14 ga. 75 A - 16 ga. 60 A.)


4. Before too much molten metal is deposited, the arc
3. Hold the electrode in a 30-45° angle with the tip of
is SLOWLY moved 1/2-3/4� (12-20mm) upwards.
the electrode pointing upwards.
This takes the heat away from the molten puddle,
which solidifies. (If the arc is not taken away soon
enough, too much metal will be deposited, and it
4. Hold a VERY SHORT arc, but do not let the elec-
will “drip�.)
trode touch the metal.

Very
5. The upward motion of the arc is caused by a very
5. An up and down whipping short
slight wrist motion. Most definitely, the arm must arc
motion will help prevent
not move in and out, as this makes the entire
burn-through on very thin plate.
30°-40°
process very complicated and difficult to learn.

6. Watch the molten metal carefully.
6. If the upward motion of the arc is done correctly
with a wrist motion, the arc will automatically
become a long arc that deposits little or no metal.
The important thing is to continue lowering the entire
(See drawing above.)
arm as the weld is made so the angle of the electrode
does not change. Move the electrode fast enough so
that the slag does not catch up with the arc.
7. During this entire process, the ONLY thing to
watch is the molten metal. As soon as it has solidi-
fied, the arc is SLOWLY brought back, and another
few drops of metal are deposited. DO NOT FOL-
LOW THE UP AND DOWN MOVEMENT OF THE
ARC WITH YOUR EYES. KEEP THEM ON THE
MOLTEN METAL.


POWER-ARC 4000
B-14 B-14
OPERATION
4. Move rapidly enough to stay ahead of the molten
Overhead Welding
slag. A whipping technique may be used to further
minimize burn through.
Various techniques are used for overhead welding.
5. If you have a choice, use lap joints rather than fil-
However, in the interest of simplicity for the inexperi-
lets or butts; the double thickness effect of a lap
enced welder, the following technique will probably
joint makes it much easier to weld without burning
take care of his needs for overhead welding:
through.


1. Use 1/8� (3.2mm) 90-105 A or 3/32� (2.5mm) 70 A
AWS 6011 electrode on AC.
Hardfacing (To Reduce Wear)

2. Put the electrode in he holder so it sticks straight
There are several kinds of wear. The two most often
out.
encountered are:

3. Hold the electrode at an angle approximately 30°
1. Metal to Ground Wear: Plowshares, bulldozer
off vertical, both seen from the side and seen from
blades, buckets, cultivator shares, and other metal
end. (See drawing below.)
parts moving in the soil.
End View
Side View
2. Metal to Metal Wear: Trunnions, shafts, rollers and
idlers, crane and mine car wheels, etc.
30°
30°
Each of these types of wear demands a different kind
of hardfacing electrode.
It is important to hold a VERY SHORT arc. (A long
arc will result in falling molten metal; a short arc will
make the metal stay.)
When applying the proper electrode, the service life of
the part will in most cases be more than double. For
instance, hardfacing of plowshares results in 3-5 times
If necessary, and this is dictated by the appearance of
more acreage plowed.
the molten puddle, a slight back and forth whipping
technique may be used to prevent “dripping�.

How to Hardface the Sharp Edge (Metal to Ground
Wear)
Welding Sheet Metal
1. Grind the share, approximately one inch along the
edge, so the metal is bright and clean.
Welding sheet metal presents an additional problem-
burn through. Follow these simple rules:
2. Place the share on an incline of approximately
20-30°. The easiest way to do this is to put one
1. Hold a very short arc. This, together with the prop-
end of the share on a brick. (See drawings) Most
er travel speed, will eliminate burn through.
users will want to hardface the underside of the
share, but some might find that the wear is on the
top side. The important thing is to hardface the
2. Use 1/8� (3.2mm) or 3/32� (2.5mm) AWS 6011.
side that wears.


3. Use low amperage. 75 A for 1/8� (3.2mm) elec-
3. Use 1/8� (3.2mm) Wearshield at 80-100 A. Strike
trode, 70 A for 3/32� (2.5mm) electrode.
the arc about one inch from the sharp edge.


POWER-ARC 4000
B-15 B-15
OPERATION
4. The bead should be put on with a weaving motion,
and it should be 1/2-3/4� (12.7-19.0mm) wide. Do When breaking
not let the arc blow over the edge, as that will dull the weld stays on
the edge. (See drawing below.) one piece
Strike Arc
Work Table Here
Sharp Edge
To overcome this, the welding operator has two
Brick
choices:

1/2-3/4" width
Plow Share
1. Preheat the entire casting to 500-1200°F (260-
(12-20mm)
Positioning of Share Weaving Motion 649°C) If the cast iron is hot before welding, there
will be no sudden chilling which creates brittle
white cast iron. The entire casting will cool slowly.

5. Use the back-stepping method. Begin to weld 3�
(76mm) from the heel of the share and weld to the 2. Weld 1/2� (12.7mm) at a time, and do not weld at
heel. The second weld will begin 6� (152mm) from that spot again until the weld is cool.
the heel, the third weld 9� (229mm) from the heel,
etc.
This way, no large amount of heat is put into the
mass.
A
B C D E First weld from A to B; then
from C to A; then from D to C;
3" Most inexperienced welders will probably use the sec-
then from E to D; and so on.
(75mm)
ond method, because they have no way of preheating
BACKSTEPPING
large castings. Smaller castings can easily (and
should) be preheated before welding. A forge, stove,
fire, or the Arc Torch are all excellent means of pre-
heating.
Backstepping greatly reduces the chances for crack-
ing of the share, and it also greatly reduces warping.

When using the 1/2� (12.7mm) at a time method, it is
recommended to start 1/2� (12.7mm) away from the
NOTE: The entire process is rather fast. Many begin-
previous bead and weld into the previous bead. This
ners go much too slowly when hardfacing plowshares,
is called backstepping.
running the risk of burning through the thin metal.


After welding Cast Iron, protect the casting against
Welding Cast Iron
fast cooling. Put it in a container of warm, dry sand or
When welding on a piece of cold cast iron, the lime.
tremendous heat from the arc will be absorbed and
distributed rapidly into the cold mass. This heating
and sudden cooling creates WHITE, BRITTLE cast If sand or lime is not available, cover it with sheet
iron in the fusion zone. (See drawing below.) metal or any other non-flammable material that will
diminish drafts and retain heat.
hot

White brittle
Cast Iron Plate Preparation
cast iron
cold
cold

Wherever practical, the joint to be welded should be
This is the reason why welds in cast iron break.
“veed� out by grinding or filing to give complete pene-
Actually, one piece of the broken cast iron has the
tration as shown in figures (a), (b) and (c) below. This
entire weld on it and the other piece has no weld on it.
is especially important on thick castings where maxi-
(See drawing below.)
mum strength is required.

POWER-ARC 4000
B-16 B-16
OPERATION
In some instances a back-up strip may be used and High-Speed Group (AWS E6013)
plates may be gapped 1/8� (3.2mm) or more, as
This group includes electrodes which have a moder-
shown in figure (b).
ately forceful arc and deposit rates between those of
the out-of-position and high-deposit electrodes.
Scrap steel back-up strip
(b) (c)
(a)
They are primarily general purpose production elec-
Three ways to prepare plates where
trodes especially for downhill fillets and laps or short
complete penetration is necessary.
and irregular welds that change direction or position.
On sections where only a sealed joint is required and They are also widely used in maintenance and recom-
strength is not important, the joint may be welded after mended for sheet metal fillet and lap welds. Motion
slightly veeing out the seam as shown in figure (d) “D� (see drawing) is generally used for vertical-up
below. welding, but motions “A� and “B� are also suitable.




Low Hydrogen Group (AWS E7018)


(d) (e) These electrodes are generally called “low hydrogen�.
Single and double beads, with and without The name comes from the fact that their coating
beveling for tight, partial strength joints.
contains little hydrogen in either moisture or chemical
form. Low hydrogen electrodes offer these benefits:
outstanding crack resistance, lowest porosity on
sulphur bearing steels, and X-ray quality deposit capa-
Selecting Electrodes bility. Thus, they are the first choice when welding
“problem� steels. E7018 can be used in all positions,
with Motion “C� (below) recommended for the first
Which electrode is best for the particular job . . . how pass on vertical-up welds. NEVER use a whipping
do you use it? These are important questions because technique or a long arc with these electrodes.
the cost, quality, and appearance of your work ALWAYS fill craters by drawing electrode away slowly.
depends on proper electrode selection and applica- ALWAYS keep these electrodes dry. Electrodes, when
tion. MILD STEEL ELECTRODES may be classified not used within a few hours after a container is
into the following groups: opened, must be stored in heated cabinets.


Out-of-Position Group (AWS E6011)


This group includes electrodes which have a snappy, Motions
deep penetrating arc and fast freezing deposits.
E

These electrodes are used for general purpose, all- D
position fabrication and repair welding. They are also START F
the best choice for pipe welding and sheet metal butt, C
corner, and edge welds. They can be used for repair
work when dirt, grease, plating or paint cannot be
B G
completely cleaned from the steel. These electrodes
are typically used with motions “A� and “B� (see draw- SIDE
A
ing) for the first pass on vertical-up welds. VIEW




POWER-ARC 4000
C-1 C-1
ACCESSORIES
OPTIONS/ACCESSORIES BRIGGS AND STRATTON ACCESSORIES
(FOR THE 8 HP INTEK ENGINE ONLY)
LINCOLN ELECTRIC ACCESSORIES
The following options/accessories are available for
The following options/accessories are available for your POWER-ARC 4000 from your local Briggs &
your POWER-ARC 4000 from your local Lincoln Stratton Distributor.
Distributor.
Foam Pre-cleaner (B&S No. 493537) - Provides a
foam pre-cleaner for placement around the paper
cartridge air cleaner. Increases protection in extreme-
Accessory Set (K875) � Includes the following:
ly dusty or dirty environments.
� Twenty feet (6.1 meters) of #6 AWG electrode
cable
Spark Arrester (B&S No. 399541) - The spark
� Fifteen feet (4.6 meters) of #6 work cable
arrestor attaches to the muffler to reduce the chance
� Headshield with No. 10 filter of sparks being emitted from the muffler.
� Work clamp
� Insulated electrode holder Muffler Guard (B&S No. 695386) - This guard installs
onto the muffler via supplied hardware and protects
� Sample electrodes
against incidental contact with a “HOT� muffler.
The cables are rated at 150 amps, 40% duty cycle.


SEMIAUTOMATIC MIG WELDING
Power Plug Kit (K802U) � Provides three plugs, two
WITH A LINCOLN WELD-PAK 100
for the 120 volt duplex receptacle and one for the 240
volt receptacle. OR WELD-PAK 125
In addition to using the accessories/options listed
GFCI Receptacle Kit (K896-3) - Includes one UL above, the POWER-ARC 4000 generator can supply
approved 115 volt ground fault circuit interrupter power to a Lincoln ELectric Weld-Pak 100 or Weld-
duplex type receptacle with cover and installation Pak 125 wire feed welder. The Weld-Pak comes with
instructions. Replaces the factory installed 115 volt all the supplies needed for Flux-Cored Arc Welding
duplex receptacle. Each side of the GFCI duplex is (FCAW).
rated at 15 amps but the maximum total current from
A MIG (Metal Inert Gas) Conversion Kit is also avail-
the GFCI duplex is limited to 20 amps.
able for the Weld-Pak. The kit provides everything
needed for Gas Metal Arc Welding (GMAW) or MIG
processes. Contact your local authorized Lincoln
Undercarriage (K882-2) - 2- wheeled, hand moving.
representative for details about the Weld-Pak and
MIG Conversion Kit.
Friction Pad Kit (K935-1) - Four rubber isolators that
attach to the bottom of the tube frame to prevent
movement on smooth surfaces.


Rotor Removal Kit (S20925) � A service kit with thru
and impact bolts for removing the generator rotor
from the tapered engine crankshaft.




POWER-ARC 4000
D-1 D-1
MAINTENANCE
Once Oil or Air filter service is completed,
SAFETY PRECAUTIONS Tachometer/Hourmeter needs to be reset. The reset
procedure will stop the flashing of the display and will
WARNING trigger the meter to start counting the time for the
next engine service. To stop the flashing alert for Oil
or Air filter service, do the following: While alert mes-
� Have qualified personnel do all maintenance
sage is flashing, hold the tip of the rest tool against
and troubleshooting work.
area shown in figure D.1 for several seconds. The dis-
play will stop flashing. The service interval has been
� Turn the engine off before working inside the
reset and the message alert should start flashing for
machine.
the next Oil or Air filter change.
� Remove guards only when necessary to per- RESET TOOL
form maintenance and replace them when the
maintenance requiring their removal is com-
plete.
� If guards are missing from the machine, get TO ELIMINATE
replacements from a Lincoln Distributor. See FLASHING HOLD
THE RESET TOOL
the EXPLODED VIEW AND PARTS LIST at the IN THIS AREA.
back of this manual.
12345
-------------------------------------------------------------
Read the Safety Precautions in the front of this manu-
FIGURE D.1
al and in the engine owner’s manual before working
OIL: Check the oil level after every 5
on the POWER-ARC 4000.
hours of operation or daily. BE SURE
Keep all equipment safety guards, covers, and
TO MAINTAIN THE OIL LEVEL.
devices in position and in good repair. Keep your
Change the oil the first time after 5 hours of opera-
hands, hair, clothing, and tools away from the recoil
tion. (20 hours on Honda engines.) Then, under nor-
housing, fans, and all other moving parts when start-
mal operating conditions, change the oil after every
ing, operating, or repairing this machine.
50 hours or once a year, whichever occurs first. (100
hours or every 6 months on Honda engines.) If the
engine is operated under heavy load or in high ambi-
ROUTINE AND PERIODIC ent temperatures, change the oil every 25 hours.
MAINTENANCE Drain the oil from the drain plug located on either side
of the engine bottom, as shown in Figure D.2. Refill
ENGINE MAINTENANCE through the oil fill plug until the oil reaches the top of
the fill hole. Use the grade and viscosity recommend-
CAUTION
ed in the engine owner’s manual.

To prevent the engine from accidentally starting,
disconnect the spark plug lead before servicing
the engine.
-----------------------------------------------------------
2 3
See the engine owner’s manual for a summary of 1
maintenance intervals for the items listed below.
FIGURE D.2 - OIL DRAIN AND REFILL
Follow either the hourly or the calendar intervals,
LOCATION
whichever come first. More frequent service may be
required, depending on your specific application and 1. OIL DRAIN PLUG
operating conditions. Table D.1 shows engine main- 2. OIL FILL PLUG
tenance replacement parts and numbers. 3. OIL LEVEL

If this Power Arc 4000 is equipped with a
Tachometer/Hourmeter (See page B-3), then use it
flash alert feature to determine the oil change inter-
vals, as well as times when air filter service is
required.


POWER-ARC 4000
D-2 D-2
MAINTENANCE
FUEL: At the end of each day’s use, refill Clean Rotating Screen: If your POWER-ARC 4000 is
the fuel tank to minimize moisture conden- equipped with an engine that has a rotating screen,
sation and dirt contamination in the fuel line. you should clean it as often as needed, to remove dirt
or debris that may collect on the screen. A dirty
screen can result in engine overheating and damage.
ENGINE ADJUSTMENTS
(See Figure D.3).
WARNING
OVERSPEED IS HAZARDOUS - The maximum
allowable high idle speed for this machine is 3750
RPM, no load. DO NOT tamper with the governor
components or setting or make any other adjust-
ments to increase the maximum speed. Severe
personal injury and damage to the machine can
1
result if operated at speeds above maximum.
------------------------------------------------------------------------
Adjustments to the engine are to be made only by a
Lincoln Service Center or an authorized Field Service
FIGURE D.3 - CLEAN ROTATING
Shop.
SCREEN/FINGER GUARD/DEBRIS GUARD
CAUTION
1. ROTATING SCREEN
Do not use petroleum solvents such as kerosene
to clean the air cleaner. They may cause deterio-
ration of the air cleaner. DO NOT OIL THE AIR CLEAN COOLING SYSTEM: See Figure D.4. Clean
CLEANER OR USE PRESSURIZED AIR TO CLEAN the internal cooling fins and surfaces to prevent over-
OR DRY THE AIR CLEANER. speeding, overheating, and engine damage. Clean
every 100 operating hours or as often as necessary.
-----------------------------------------------------------
To service the pre-cleaner:
1. Wash in liquid detergent and water.
2. Squeeze dry in a clean cloth. 1
3. Saturate in clean engine oil.
4. Squeeze in a clean, absorbent cloth to remove all
excess oil.


CLEAN ENGINE: Remove dirt and debris with a cloth
or a brush. Do not clean with a forceful spray of
water. Water might contaminate the fuel system.
FIGURE D.4 - CLEAN COOLING SYSTEM
CAUTION
1. REMOVE DIRT FROM THESE AREAS.
Periodically clean the muffler area to remove
combustible debris.
-----------------------------------------------------------




POWER-ARC 4000
D-3 D-3
MAINTENANCE
CLEAN OR REPLACE SPARK PLUG: Clean or
replace the spark plug after every 100 hours of opera-
tion or every season, whichever comes first. Do not
blast the spark plug clean with an abrasive cleaning
device. Clean the plug by scraping it or by using a
wire brush. Wash the plug with a commercial sol-
vent. After cleaning or when installing a new spark
plug, set the terminal gap to .030 inch (.76 mm) with a
feeler gauge. See Figure D.5.

2




1


FIGURE D.5 - SET SPARK PLUG GAP
Use the engine owner’s manual for latest Plug Gap Info.



CLEAN SPARK ARRESTER SCREEN: If the muffler
has the spark arrester assembly, refer to the engine
owner’s manual that was shipped with your POWER-
ARC 4000 for the proper cleaning instructions.




TABLE D.1
ENGINE MAINTENANCE PARTS

Part B&S 8 HP Intek Part # Honda Part #


SPARK PLUG B&S 491055 NGK BPR6ES
(RESISTOR) CHAMPION RC12YC DENSO W20EPR-U


FUEL FILTER NONE NONE
AIR CLEANER PANEL B&S 491588 (5043) 5266721 (17210-ZE2-505)
(Pleated Paper)
AIR PRE-CLEANER B&S 493537 2538429 (17218-ZE2-821)
(AS NEEDED) (CAN BE CLEANED AND REUSED AS NEEDED)
Refer to Table D.1 for engine maintenance parts. The part numbers are accurate at the time of printing. (Verify
the current part number by referring to the engine owner’s manual.

Replace or clean engine maintenance parts per the interval outlined in the engine owner’s manual.




POWER-ARC 4000
D-4 D-4
MAINTENANCE
RECEPTACLES: Keep the electrical receptacles in
GENERATOR/WELDER MAINTENANCE
good condition. Remove any dirt, oil, or other
STORAGE: Store the POWER-ARC 4000 in clean, debris from their surfaces and holes.
dry, protected areas.
CABLE CONNECTIONS: Check the welding cable
CLEANING: Blow out the generator and controls connections at the weld output terminals often. Be
periodically with low pressure air. Do this at least sure that the connections are always tight.
once a week in particularly dirty areas.
NOTE: Lincoln offers a rotor removal kit for any ser-
BRUSH REMOVAL AND REPLACEMENT: See vice which requires removal of the rotor from the
Figure D.5. It’s normal for the brushes and slip engine. See the ACCESSORIES section for further
rings to wear and darken slightly. Inspect the details.
brushes when a general overhaul is necessary.
Removal of engine/generator assembly from the
Remove the brushes and clean the slip rings with
cradle can be achieved as follows:
fine grit emery paper.
� Remove the two 5/16-18 hex head cap screws
from the engine block via the access hole located
CAUTION
in the cradle cross support channel. Leave all
other engine mountings intact.
Do not attempt to polish slip rings while engine
is running. � Remove the two hex nuts from the isolator thread-
ed posts at the stator support bracket located
opposite the engine. Leave all other stator mount-
To reinstall the brushes, press them upward and ings intact.
slide a cable tie or wooden stick through the brush
� With a jib hoist or crane, lift the unit upward and
holder tabs. Install the brush holder into the bear-
remove loose cradle from engine/generator
ing end bracket and secure with the screws previ-
assembly.
ously removed. Remove the cable tie or wooden
stick and the brushes will seat onto the slip rings.




FIGURE D.5. � BRUSH REMOVAL AND REPLACEMENT


4 2 6




5
3

1

1. GENERATOR END BRACKET
2. BRUSH HOLDER ASSEMBLY
3. COVER
4. SCREWS (2)
5. BRUSHES
6. CABLE TIE




POWER-ARC 4000
D-5 D-5
MAINTENANCE

FIGURE D.6. - MAJOR COMPONENT LOCATIONS




7
6


5
8


1




3




1 . CRADLE ASSEMBLY
4 2 2. ROTOR, BLOWER, AND BEARING ASSEMBLY
3. STATOR ASSEMBLY
4. BRUSH AND BRUSH HOLDER ASSEMBLY
5. CONTROL BOX WELDED ASSEMBLY
6. REACTOR ASSEMBLY
7. OUTPUT TERMINAL ASSEMBLY
8. OUTPUT PANEL ASSEMBLY




POWER-ARC 4000
E-1 E-1
TROUBLESHOOTING
HOW TO USE TROUBLESHOOTING GUIDE




WARNING
Service and Repair should only be performed by Lincoln Electric Factory Trained Personnel.
Unauthorized repairs performed on this equipment may result in danger to the technician and
machine operator and will invalidate your factory warranty. For your safety and to avoid Electrical
Shock, please observe all safety notes and precautions detailed throughout this manual.
__________________________________________________________________________
This Troubleshooting Guide is provided to help you Step 3. RECOMMENDED COURSE OF ACTION
locate and repair possible machine malfunctions. This column provides a course of action for the
Simply follow the three-step procedure listed below. Possible Cause, generally it states to contact your
local Lincoln Authorized Field Service Facility.
Step 1. LOCATE PROBLEM (SYMPTOM).
Look under the column labeled “PROBLEM (SYMP- If you do not understand or are unable to perform the
TOMS)�. This column describes possible symptoms Recommended Course of Action safely, contact your
that the machine may exhibit. Find the listing that local Lincoln Authorized Field Service Facility.
best describes the symptom that the machine is
exhibiting.

Step 2. POSSIBLE CAUSE.
The second column labeled “POSSIBLE CAUSE� lists
the obvious external possibilities that may contribute
to the machine symptom.




CAUTION
If for any reason you do not understand the test procedures or are unable to perform the tests/repairs safely, contact your
Local Lincoln Authorized Field Service Facility for technical troubleshooting assistance before you proceed.




POWER-ARC 4000
E-2 E-2
TROUBLESHOOTING
Observe all Safety Guidelines detailed throughout this manual
PROBLEMS POSSIBLE AREAS OF RECOMMENDED
(SYMPTOMS) MISADJUSTMENT(S) COURSE OF ACTION
PROBLEMS
No generator power or welding output. 1. Disconnect anything plugged into
auxiliary receptacles and weld loads.

2. Open lead in flashing or field circuit.

3. Open flashing diode (D1)

4. Faulty brushes.
5. Faulty rheostat (R1).
6. Faulty field rectifier (D1).
7. Faulty capacitor (C1).
8. Faulty stator field winding.
9. Faulty rotor.
10. Dirty slip rings, clean slip rings when
not in use.




If all recommended possible areas
of misadjustment have been
checked and the problem persists,
Contact your local Lincoln
Authorized Field Service Facility.




Generator power is available but unit 1. Loose connection to output stud.
will not weld.

2. Work not connected.

3. Electrode holder loose.



4. No open circuit voltage at output
studs. Open lead in weld circuit.

5. Faulty reactor (L1).




6. Rheostat (R1) lead broke




CAUTION
If for any reason you do not understand the test procedures or are unable to perform the tests/repairs safely, contact your
Local Lincoln Authorized Field Service Facility for technical troubleshooting assistance before you proceed.
POWER-ARC 4000
E-3 E-3
TROUBLESHOOTING
Observe all Safety Guidelines detailed throughout this manual
PROBLEMS POSSIBLE AREAS OF RECOMMENDED
(SYMPTOMS) MISADJUSTMENT(S) COURSE OF ACTION
PROBLEMS
Unit will weld but low or no generator 1. Circuit breaker open.
power is available.


2. Loose or open connection with elec-
trical plug-in component.

3. Current control dial not at �125�.




4. No open circuit voltage at receptacle.
Open lead in receptacle circuit.

5. No open circuit voltage at receptacle.
Bad receptacle.

6. Rheostat (R1) lead broke.




If all recommended possible areas
Engine runs erratically or stops running. 1. Engine is not fully warmed-up and
of misadjustment have been
engine choke is in the fully open
checked and the problem persists,
(RUN) position.
Contact your local Lincoln
Authorized Field Service Facility.



2. Engine requires service to head, car-
buretor, filters, oil, spark plug and/or
gas.




Engine sputters but will not start. 1. Bad gas, bad filter, air cleaner, spark
plug, and/or breather.




CAUTION
If for any reason you do not understand the test procedures or are unable to perform the tests/repairs safely, contact your
Local Lincoln Authorized Field Service Facility for technical troubleshooting assistance before you proceed.
POWER-ARC 4000
E-4 E-4
TROUBLESHOOTING
Observe all Safety Guidelines detailed throughout this manual
PROBLEMS POSSIBLE AREAS OF RECOMMENDED
(SYMPTOMS) MISADJUSTMENT(S) COURSE OF ACTION
PROBLEMS
Engine will not start. 1. Spark plug boot or wire off, loose or
wet.


2. Fuel shutoff valve is closed.


3. Low oil and engine low oil shutdown
protection will not allow unit to start.
Light in ON-OFF switch will Flash
when the engine is cranked.
(Engines equipped with low oil shut
down protection only).


4. Choke left in full choke position and
carburetor flooded.



5. Fuel line clogged or closed.


If all recommended possible areas
of misadjustment have been
6. Recoil start will not engage with checked and the problem persists,
engine.
Contact your local Lincoln
Authorized Field Service Facility.


7. Fouled spark plug.



8. Engine requires service to head,
head gasket, and/or valves.


9. Float open in carburetor & gas leak-
ing from bowl.



10. Engine operated with low oil level.
Engine is seized and recoil start will
not move.




CAUTION
If for any reason you do not understand the test procedures or are unable to perform the tests/repairs safely, contact your
Local Lincoln Authorized Field Service Facility for technical troubleshooting assistance before you proceed.
POWER-ARC 4000
WIRING DIAGRAM - POWER ARC 4000 (Code 10673)
F-1



L1



ELECTRICAL
W1A REACTOR
SYMBOLS
BLACK W2
BLACK 202B RED
PER E1537.


OUTPUT STUDS
W1
CCW
ROTOR R1
BLACK
202
3.3
STATOR 202
100W RED
200A
STATOR END RED
(+)
BRACKET GNDC (+)
202A
GROUND GREEN
RED 200 RED
5 3 7 9
6
C1
(-) D1
6 5 3
2 600 FD
1 4 201A
9A
BLACK 7A
201
3A
GNDC 6A
(-)
CB2 5A (+)
BLACK
GREEN 20A
WHITE
20A 9A
CB1
5B 7A
D2
WHITE
6B
GNDA
YELLOW
GREEN
202C BROWN



GNDB ENGINE WIRING
GREEN
DIAGRAMS




POWER-ARC 4000
6C
5B
BLACK MAG RUN/STOP
LOW OIL
201B
SWITCH
PROTECTION
BLACK
SWITCH
5A WHITE
3B (IF INSTALLED)
BLACK

BLACK WIRE
6C BLACK
3C 3C IS REMOVED
HOT
& DISCARDED
BLACK LINE
GREEN
WHITE
LINE

5A
NOTE: GFCI RECEPTACLE
WHITE WIRES 5B
ALL CASE FRONT COMPONENTS
OPTION
SHOWN VIEWED FROM REAR.
12/01


S22160




NOTE: This diagram is for reference only. It may not be accurate for all machines covered by this manual. The specific diagram for a particular code is pasted inside
the machine on one of the enclosure panels. If the diagram is illegible, write to the Service Department for a replacement. Give the equipment code number.
F-1
WIRING DIAGRAM - POWER ARC 4000 (CODES 10792, 10793)
F-2




L1


W1A REACTOR
R2
BLACK W2
50 OHM
BLACK
5W
202B
RED
OUTPUT STUDS W1 CCW
R1
ROTOR
BLACK
3.3 OHM
STATOR
100W
200A
STATOR END
(+)
BRACKET GNDC (+)
202A
GROUND GREEN RED 200 RED
5 3 7 9
6 (-) C1
D1 RED
600 FD
5
6 3
2 1 4 201A
9A 7A
BLACK
201
3A
GNDC 6A
CB2 5A (-)
BLACK
GREEN 20A
WHITE
20A 9A
CB1
5B 7A
WHITE
GND D 6B
GNDA
YELLOW
GREEN
BOLT AT
ENGINE
BLOCK
ENGINE WIRING
GNDB
GREEN
MAG
6C
DIAGRAMS




POWER-ARC 4000
5B FLYWHEEL
BLACK LOW OIL RUN/STOP
201B ALTERNATOR
PROTECTION SWITCH
BLACK SWITCH
5A WHITE (IF INSTALLED)
3B
BLACK
BLACK WIRE
6C BLACK
3C 3C IS REMOVED
HOT & DISCARDED
BLACK LINE
GREEN
WHITE
LINE
5A
GFCI RECEPTACLE
WHITE WIRES 5B
OPTION
NOTE: ELECTRICAL SYMBOLS PER E1537.
ALL CASE FRONT COMPONENTS
SHOWN VIEWED FROM REAR.

12/01


S25341
NOTE: This diagram is for reference only. It may not be accurate for all machines covered by this manual. The specific diagram for a particular code is pasted inside
the machine on one of the enclosure panels. If the diagram is illegible, write to the Service Department for a replacement. Give the equipment code number.
F-2
WIRING DIAGRAM POWER ARC 4000 (FOR CODE 10930 ONLY)
F-3



L1 WRAP AROUND
203 SPARK PLUG WIRE
FOUR TIMES
ELECTRICAL
W1A REACTOR TACHOMETER/
SYMBOLS
BLACK W2
HOURMETER
BLACK 202B RED
PER E1537.




A
OUTPUT STUDS W1 CCW
ROTOR R1
BLACK
202
3.3 W
STATOR 202
100W RED
200A
STATOR END RED
(+)
BRACKET GNDC (+)
202A
GROUND GREEN RED 200 RED
5 3 7 9
6
C1
(-) D1
6 5 3
2 600 FD
1 4 201A
9A
BLACK 7A
201
GNDC 3A
6A (-)
CB2 5A (+)
BLACK
GREEN 20A
WHITE
20A 9A
CB1
5B 7A D2
WHITE
6B
GNDA
WHITE
GREEN
202C BROWN


GNDB
DIAGRAMS




POWER-ARC 4000
ENGINE WIRING
GREEN

6C
5B
BLACK MAG RUN/STOP
LOW OIL
201B
SWITCH
PROTECTION
BLACK
SWITCH
5A WHITE
3B (IF INSTALLED)
BLACK
BLACK WIRE
6C BLACK
3C 3C IS REMOVED
HOT & DISCARDED
BLACK LINE
GREEN
WHITE
LINE
5A
NOTE: GFCI RECEPTACLE
WHITE WIRES 5B
ALL CASE FRONT COMPONENTS
OPTION A
SHOWN VIEWED FROM REAR.
S22160-1
NOTE: This diagram is for reference only. It may not be accurate for all machines covered by this manual. The specific diagram for a particular code is pasted inside
the machine on one of the enclosure panels. If the diagram is illegible, write to the Service Department for a replacement. Give the equipment code number.
F-3
F-4




POWER ARC 4000
DIMENSION PRINT


REF. REF.
20.00 30.00
508 mm 762 mm




REF.
20.88
530 mm
R
DIAGRAMS




POWER-ARC 4000
8-19-94
REF. REF.
M 17196
7.92 14.16
201 mm 360 mm
F-4
NOTES
NOTES
G Do not touch electrically live parts or G Keep flammable materials away. G Wear eye, ear and body protection.

WARNING electrode with skin or wet clothing.
G Insulate yourself from work and
ground.
Spanish
G No toque las partes o los electrodos G Mantenga el material combustible G Protéjase los ojos, los oídos y el
AVISO DE bajo carga con la piel o ropa moja- fuera del área de trabajo. cuerpo.
da.
PRECAUCION G Aislese del trabajo y de la tierra.

French G Ne laissez ni la peau ni des vête- G Gardez à l’écart de tout matériel G Protégez vos yeux, vos oreilles et
ments mouillés entrer en contact inflammable. votre corps.
ATTENTION avec des pièces sous tension.
G Isolez-vous du travail et de la terre.

G Berühren Sie keine stromführenden
German G Entfernen Sie brennbarres Material! G Tragen Sie Augen-, Ohren- und Kör-
Teile oder Elektroden mit Ihrem perschutz!
WARNUNG Körper oder feuchter Kleidung!
G Isolieren Sie sich von den
Elektroden und dem Erdboden!
Portuguese
G Não toque partes elétricas e elec- G Mantenha inflamáveis bem guarda- G Use proteção para a vista, ouvido e
trodos com a pele ou roupa molha- dos. corpo.
ATENÇÃO da.
G Isole-se da peça e terra.

Japanese




Chinese




Korean




Arabic




READ AND UNDERSTAND THE MANUFACTURER’S INSTRUCTION FOR THIS EQUIPMENT AND THE CONSUMABLES TO BE
USED AND FOLLOW YOUR EMPLOYER’S SAFETY PRACTICES.

SE RECOMIENDA LEER Y ENTENDER LAS INSTRUCCIONES DEL FABRICANTE PARA EL USO DE ESTE EQUIPO Y LOS
CONSUMIBLES QUE VA A UTILIZAR, SIGA LAS MEDIDAS DE SEGURIDAD DE SU SUPERVISOR.

LISEZ ET COMPRENEZ LES INSTRUCTIONS DU FABRICANT EN CE QUI REGARDE CET EQUIPMENT ET LES PRODUITS A
ETRE EMPLOYES ET SUIVEZ LES PROCEDURES DE SECURITE DE VOTRE EMPLOYEUR.

LESEN SIE UND BEFOLGEN SIE DIE BETRIEBSANLEITUNG DER ANLAGE UND DEN ELEKTRODENEINSATZ DES HER-
STELLERS. DIE UNFALLVERHÃœTUNGSVORSCHRIFTEN DES ARBEITGEBERS SIND EBENFALLS ZU BEACHTEN.
G Keep your head out of fumes. G Turn power off before servicing. G Do not operate with panel open or
G Use ventilation or exhaust to
WARNING
guards off.
remove fumes from breathing zone.

Spanish
G Los humos fuera de la zona de res- G Desconectar el cable de ali- G No operar con panel abierto o
AVISO DE
piración. mentación de poder de la máquina guardas quitadas.
G Mantenga la cabeza fuera de los antes de iniciar cualquier servicio.
PRECAUCION
humos. Utilice ventilación o
aspiración para gases.
French
G Débranchez le courant avant l’entre- G N’opérez pas avec les panneaux
G Gardez la tête à l’écart des fumées.
G Utilisez un ventilateur ou un aspira- tien. ouverts ou avec les dispositifs de
ATTENTION
protection enlevés.
teur pour ôter les fumées des zones
de travail.

German
G Strom vor Wartungsarbeiten G Anlage nie ohne Schutzgehäuse
G Vermeiden Sie das Einatmen von
abschalten! (Netzstrom völlig öff- oder Innenschutzverkleidung in
Schweibrauch!
WARNUNG
G Sorgen Sie für gute Be- und nen; Maschine anhalten!) Betrieb setzen!
Entlüftung des Arbeitsplatzes!

Portuguese
G Não opere com as tampas removidas. G Mantenha-se afastado das partes
G Mantenha seu rosto da fumaça.
G Desligue a corrente antes de fazer
G Use ventilação e exhaustão para moventes.
ATENÇÃO
serviço. G Não opere com os paineis abertos
remover fumo da zona respiratória.
G Não toque as partes elétricas nuas. ou guardas removidas.

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