Lincoln Electric Portable Generator SVM103 A User Manual
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SVM103-A  
December 1995  
TM  
POWER-ARC 4000  
For use with machine code number 10083  
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 thoughtful  
operation on your part. DO  
NOT INSTALL, OPERATE OR  
REPAIR THIS EQUIPMENT  
WITHOUT READING THIS  
MANUAL AND THE SAFETY  
PRECAUTIONS CONTAINED  
THROUGHOUT. And, most  
importantly, think before you  
act and be careful.  
SERVICE MANUAL  
World’s Leader in Welding and Cutting Products  
Premier Manufacturer of Industrial Motors  
Sales and Service through subsidiaries and Distributors Worldwide  
22801 St. Clair Ave. Cleveland, Ohio 44117-1199 U.S.A. Tel. (216) 481-8100  
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ii  
SAFETY  
ARC RAYS can burn.  
ELECTRIC SHOCK can kill.  
3.a. The electrode and work (or ground) circuits  
are electrically “hot” when the welder is on.  
Do not touch these “hot” parts with your bare  
skin or wet clothing. Wear dry, hole-free  
gloves to insulate hands.  
4.a. Use a shield with the proper filter and cover  
plates to protect your eyes from sparks and  
the rays of the arc when welding or observing  
open arc welding. Headshield and filter lens  
should conform to ANSI Z87. I standards.  
4.b. Use suitable clothing made from durable flame-resistant  
material to protect your skin and that of your helpers from  
the arc rays.  
3.b. Insulate yourself from work and ground using dry insulation.  
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  
themselves to the arc rays or to hot spatter or metal.  
In addition to the normal safety precautions, if welding  
must be performed under electrically hazardous  
conditions (in damp locations or while wearing wet  
clothing; on metal structures such as floors, gratings or  
scaffolds; when in cramped positions such as sitting,  
kneeling or lying, if there is a high risk of unavoidable or  
accidental contact with the workpiece or ground) use  
the following equipment:  
FUMES AND GASES  
can be dangerous.  
5.a. Welding may produce fumes and gases  
hazardous to health. Avoid breathing these  
• Semiautomatic DC Constant Voltage (Wire) Welder.  
• DC Manual (Stick) Welder.  
• AC Welder with Reduced Voltage Control.  
fumes and gases.When welding, keep  
your head out of the fume. Use enough  
ventilation and/or exhaust at the arc to keep  
3.c. In semiautomatic or automatic wire welding, the electrode,  
electrode reel, welding head, nozzle or semiautomatic  
welding gun are also electrically “hot”.  
fumes and gases away from the breathing zone. When  
welding with electrodes which require special  
ventilation such as stainless or hard facing (see  
instructions on container or MSDS) or on lead or  
cadmium plated steel and other metals or coatings  
which produce highly toxic fumes, keep exposure as  
low as possible and below Threshold Limit Values (TLV)  
using local exhaust or mechanical ventilation. In  
confined spaces or in some circumstances, outdoors, a  
respirator may be required. Additional precautions are  
also required when welding on galvanized steel.  
3.d. Always be sure the work cable makes a good electrical  
connection with the metal being welded. The connection  
should be as close as possible to the area being welded.  
3.e. Ground the work or metal to be welded to a good electrical  
(earth) ground.  
3.f. Maintain the electrode holder, work clamp, welding cable  
and welding machine in good, safe operating condition. Replace  
damaged insulation.  
5.b. Do not weld in locations near chlorinated hydrocarbon vapors  
coming from degreasing, cleaning or spraying operations.  
The heat and rays of the arc can react with solvent vapors to  
form phosgene, a highly toxic gas, and other irritating  
products.  
3.g. Never dip the electrode in water for cooling.  
3.h. Never simultaneously touch electrically “hot” parts of  
electrode holders connected to two welders because voltage  
between the two can be the total of the open circuit voltage  
of both welders.  
5.c. Shielding gases used for arc welding can displace air and  
cause injury or death. Always use enough ventilation,  
especially in confined areas, to insure breathing air is safe.  
3.i. When working above floor level, use a safety belt to protect  
yourself from a fall should you get a shock.  
5.d. Read and understand the manufacturer’s instructions for this  
equipment and the consumables to be used, including the  
material safety data sheet (MSDS) and follow your  
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  
POWER-ARC 4000  
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iii  
SAFETY  
WELDING SPARKS can  
CYLINDER may explode  
if damaged.  
cause fire or explosion.  
6.a. Remove fire hazards from the welding area.  
If this is not possible, cover them to prevent  
7.a. Use only compressed gas cylinders  
containing the correct shielding gas for the  
the welding sparks from starting a fire.  
Remember that welding sparks and hot  
materials from welding can easily go through small cracks  
and openings to adjacent areas. Avoid welding near  
hydraulic lines. Have a fire extinguisher readily available.  
process used and properly operating  
regulators designed for the gas and  
pressure used. All hoses, fittings, etc. should be suitable for  
the application and maintained in good condition.  
7.b. Always keep cylinders in an upright position securely  
chained to an undercarriage or fixed support.  
6.b. Where compressed gases are to be used at the job site,  
special precautions should be used to prevent hazardous  
situations. Refer to “Safety in Welding and Cutting” (ANSI  
Standard Z49.1) and the operating information for the  
equipment being used.  
7.c. Cylinders should be located:  
•Away from areas where they may be struck or subjected to  
physical damage.  
6.c. When not welding, make certain no part of the electrode  
circuit is touching the work or ground. Accidental contact can  
cause overheating and create a fire hazard.  
•A safe distance from arc welding or cutting operations and  
any other source of heat, sparks, or flame.  
7.d. Never allow the electrode, electrode holder or any other  
electrically “hot” parts to touch a cylinder.  
6.d. Do not heat, cut or weld tanks, drums or containers until the  
proper steps have been taken to insure that such procedures  
will not cause flammable or toxic vapors from substances  
inside. They can cause an explosion even though they have  
been “cleaned”. For information, purchase “Recommended  
Safe Practices for the Preparation for Welding and Cutting of  
Containers and Piping That Have Held Hazardous  
Substances”, AWS F4.1 from the American Welding Society  
(see address above).  
7.e. Keep your head and face away from the cylinder valve outlet  
when opening the cylinder valve.  
7.f. Valve protection caps should always be in place and hand  
tight except when the cylinder is in use or connected for  
use.  
7.g. Read and follow the instructions on compressed gas  
cylinders, associated equipment, and CGA publication P-l,  
“Precautions for Safe Handling of Compressed Gases in  
Cylinders,” available from the Compressed Gas Association  
1235 Jefferson Davis Highway, Arlington, VA 22202.  
6.e. Vent hollow castings or containers before heating, cutting or  
welding. They may explode.  
6.f. Sparks and spatter are thrown from the welding arc. Wear oil  
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.  
Always wear safety glasses with side shields when in a  
welding area.  
FOR ELECTRICALLY  
powered equipment.  
6.g. Connect the work cable to the work as close to the welding  
area as practical. Work cables connected to the building  
framework or other locations away from the welding area  
increase the possibility of the welding current passing  
through lifting chains, crane cables or other alternate circuits.  
This can create fire hazards or overheat lifting chains or  
cables until they fail.  
8.a. Turn off input power using the disconnect  
switch at the fuse box before working on  
the equipment.  
8.b. Install equipment in accordance with the U.S. National  
Electrical Code, all local codes and the manufacturer’s  
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  
POWER-ARC 4000  
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iv  
SAFETY  
7. Quand on ne soude pas, poser la pince à une endroit isolé  
PRÉCAUTIONS DE SÛRETÉ  
de la masse. Un court-circuit accidental peut provoquer  
un échauffement et un risque d’incendie.  
Pour votre propre protection lire et observer toutes les instruc-  
tions et les précautions de sûreté specifiques qui parraissent  
dans ce manuel aussi bien que les précautions de sûreté  
générales suivantes:  
8. S’assurer que la masse est connectée le plus prés possi-  
ble de la zone de travail qu’il est pratique de la faire. Si on  
place la masse sur la charpente de la construction ou  
d’autres endroits éloignés de la zone de travail, on aug-  
mente le risque de voir passer le courant de soudage par  
les chaines de levage, câbles de grue, ou atres circuits.  
Cela peut provoquer des risques d’incendie ou d’echauffe-  
ment des chaines et des câbles jusqu’à ce qu’ils se  
rompent.  
Sûreté Pour Soudage A L’Arc  
1. Protegez-vous contre la secousse électrique:  
a. Les circuits à l’électrode et à la piéce sont sous ten-  
sion quand la machine à souder est en marche. Eviter  
toujours tout contact entre les parties sous tension et  
la peau nue ou les vétements mouillés. Porter des  
gants secs et sans trous pour isoler les mains.  
9. Assurer une ventilation suffisante dans la zone de  
soudage. Ceci est particuliérement important pour le  
soudage de tôles galvanisées plombées, ou cadmiées ou  
tout autre métal qui produit des fumées toxiques.  
b. Faire trés attention de bien s’isoler de la masse quand  
on soude dans des endroits humides, ou sur un  
plancher metallique ou des grilles metalliques, princi-  
palement dans les positions assis ou couché pour  
lesquelles une grande partie du corps peut être en  
contact avec la masse.  
10. Ne pas souder en présence de vapeurs de chlore  
provenant d’opéerations de dégraissage, nettoyage ou  
pistolage. La chaleur ou les rayons de l’arc peuvent réagir  
avec les vapeurs du solvant pour produire du phosgéne  
(gas fortement roxique) ou autres produits irritants.  
c. Maintenir le porte-électrode, la pince de masse, le  
câble de soudage et la machine à souder en bon et  
sûr état defonctionnement.  
PRÉCAUTIONS DE SÛRETÉ POUR LES  
MACHINES À SOUDER À TRANSFOR-  
MATEUR ET À REDRESSEUR  
d. Ne jamais plonger le porte-électrode dans l’eau pour  
le refroidir.  
e. Ne jamais toucher simultanément les parties sous  
tension des porte-électrodes connectés à deux  
machines à souder parce que la tension entre les  
deux pinces peut être le total de la tension à vide des  
deux machines.  
1. Relier à la terre le chassis du poste conformement au code  
de l’électricité et aux recommendations du fabricant. Le  
dispositif de montage ou la piece à souder doit être  
branché à une bonne mise à la terre.  
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 enroule le câble-électrode autour de n’importe  
quelle partie du corps.  
2. Autant que possible, l’installation et l’entretien du poste  
seront effectués par un électricien qualifié.  
3. Avant de faires des travaux à l’interieur de poste, la  
debrancher à l’interrupteur à la boite de fusibles.  
3. Un coup d’arc peut être plus sévère qu’un coup de soliel,  
donc:  
4. Garder tous les couvercles et dispostifis de sûreté à leur  
place.  
a. Utiliser un bon masque avec un verre filtrant appro-  
prié ainsi qu’un verre blanc afin de se protéger les  
yeux du rayonnement de l’arc et des projections  
quand on soude ou quand on regarde l’arc.  
b. Porter des vêtements convenables afin de protéger la  
peau de soudeur et des aides contre le rayon-  
nementde l’arc.  
c. Protéger l’autre personnel travaillant à proximité au  
soudage à l’aide d’écrans appropriés et non-inflam-  
mables.  
4. Des gouttes de laiter en fusion sont émises de l’arc de  
soudage. Se protéger avec es vêtements de protection  
libres de l’huile, tels que les gants en cuir, chemise  
épaisse, pantalons sans revers, et chaussures montantes.  
5. Toujours porter des lunettes de sécurité dans la zone de  
soudage. Utiliser des lunettes avec écrans lateraux dans  
les zones où l’on pique le laitier.  
6. Eloigner les matériaux inflammables ou les recouvrir afin  
de prévenir ttout risque d’incendie dû étincelles.  
POWER-ARC 4000  
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v
RETURN TO MAIN INDEX  
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  
Electrical Output Connections....................................................................................................A-4  
Operation...............................................................................................................................Section B  
Safety Instructions......................................................................................................................B-1  
General Description....................................................................................................................B-1  
Recommended Applications ......................................................................................................B-2  
Operational Features and Controls ............................................................................................B-2  
Design Features and Advantages ..............................................................................................B-2  
Welding Capability......................................................................................................................B-2  
Limitations .................................................................................................................................B-2  
Controls and Settings.................................................................................................................B-3  
Engine Operation........................................................................................................................B-5  
Accessories...........................................................................................................................Section C  
Maintenance .........................................................................................................................Section D  
Safety Precautions............................................................................................................................D-1  
Routine and Periodic Maintenance...................................................................................................D-1  
Major Component Locations ............................................................................................................D-5  
Theory of Operation .............................................................................................................Section E  
Troubleshooting and Repair ................................................................................................Section F  
Electrical Diagrams..............................................................................................................Section G  
Parts Manual.................................................................................................................................P-233  
POWER-ARC 4000  
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Section A  
TABLE OF CONTENTS  
- INSTALLATION SECTION -  
Installation  
Technical Specifications.............................................................................................................A-1  
Safety Precautions......................................................................................................................A-2  
Location and Ventilation .............................................................................................................A-2  
Storing .................................................................................................................................A-2  
Stacking................................................................................................................................A-3  
Tilting .................................................................................................................................A-3  
Lifting .................................................................................................................................A-3  
Pre-operation Engine Service.....................................................................................................A-3  
Oil ........................................................................................................................................A-3  
Fuel.......................................................................................................................................A-3  
Muffler Deflector...................................................................................................................A-3  
Spark Arrester ......................................................................................................................A-3  
Electrical Output Connections....................................................................................................A-4  
Welding Cable Connections.................................................................................................A-4  
Cable Size and Length............................................................................................A-4  
Cable Installation.....................................................................................................A-5  
Machine Grounding..............................................................................................................A-5  
Plugs and Hand-Held Equipment .......................................................................................A-5  
Auxiliary Power Receptacles................................................................................................A-5  
Premises Wiring....................................................................................................................A-6  
Circuit Breakers....................................................................................................................A-6  
POWER-ARC 4000  
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A-1  
INSTALLATION  
TECHNICAL SPECIFICATIONS - POWER-ARC 4000  
INPUT - GASOLINE ENGINE  
Manufacturer Description  
Speed  
Displacement  
Ignition  
Capacities  
Briggs &  
Stratton Cool-  
Bore®  
1 cyl.,  
4 cycle  
air-cooled  
gasoline  
8 HP @  
3750 RPM  
3700 RPM  
± 50 RPM  
at no load  
19.4 cu. in.  
(319 cc)  
Manual,  
Recoil  
start; Manual  
choke  
Fuel: 1.0 gal. (3.8 l)  
Oil: 1.4 qt. (1.3 l)  
RATED OUTPUT - WELDER  
Duty Cycle  
Amps  
125  
Volts at Rated Amperes  
30% Duty Cycle  
60% Duty Cycle  
18 VAC  
25 VAC  
100  
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  
20.9 in.  
530 mm  
Width  
20 in.  
Depth  
30 in.  
Weight  
160 lb.  
508 mm  
762 mm  
72.5 kg  
POWER-ARC 4000  
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A-2  
INSTALLATION  
Read this entire installation section before you  
start installation.  
LOCATION AND VENTILATION  
Whenever you use the POWER-ARC 4000, be sure  
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  
sources. Do not place the back end of the generator  
anywhere near hot engine exhaust from another  
machine. And of course, make sure that engine  
exhaust is ventilated to an open, outside area.  
SAFETY PRECAUTIONS  
WARNING  
Do not attempt to use this equipment until you have  
thoroughly read all the operation and maintenance  
manuals supplied with your machine. They include  
important safety precautions; detailed engine starting,  
operating, and maintenance instructions; and parts  
lists.  
The POWER-ARC 4000 may be used outdoors. Do  
not set the machine in puddles or otherwise submerge  
it in water. Such practices pose safety hazards and  
cause improper operation and corrosion of parts.  
Always operate the POWER-ARC 4000 with the case  
roof on and all machine components completely  
assembled. This will protect you from the dangers of  
moving parts, hot metal surfaces, and live electrical  
devices.  
ELECTRIC SHOCK can kill.  
• Do not touch electrically live  
parts or electrodes with your  
skin or wet clothing.  
STORING  
• Insulate yourself from the  
work and ground.  
1. Store the machine in a cool, dry place when it’s  
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  
hazards.  
•Always wear dry insulating gloves.  
ENGINE EXHAUST can kill.  
2. If you will be storing the machine for over 30 days,  
you should drain the fuel to protect fuel system  
and carburetor parts from gum deposits. Empty  
all fuel from the tank and run the engine until it  
stops from lack of fuel.  
• Use in open, well ventilated  
areas or vent exhaust to the  
outside.  
• Do not stack anything on or near the engine.  
3. You can store the machine for up to 24 months if  
you use Briggs & Stratton Gasoline Additive, Part  
No. 5041 (available from any Authorized Briggs &  
Stratton Service Center), in the fuel system. Mix  
the additive with the fuel in the tank and run the  
engine for a short time to circulate the additive  
through the carburetor.  
MOVING PARTS can injure.  
• Do not operate this equip-  
ment with any of its doors  
open or guards off.  
• Stop the engine before ser-  
vicing it.  
4. While the engine is still warm, drain the oil and  
refill with fresh 10W30 oil.  
• Keep away from moving parts.  
5. Remove the spark plug and pour approximately  
1/2 ounce (15 ml) of engine oil into the cylinder.  
Replace the spark plug and crank the engine  
slowly to distribute the oil.  
Only qualified personnel should install, use, or service  
this equipment.  
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  
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A-3  
INSTALLATION  
STACKING  
FUEL  
POWER-ARC 4000 machines CANNOT be stacked.  
Fill the fuel tank with clean, fresh, regular  
grade lead-free gasoline. DO NOT MIX  
OIL WITH THE GASOLINE.  
TILTING  
Place the machine on a secure, level surface whenev-  
er you use it or store it. Any surfaces you place it on  
other than the ground must be firm, non-skid, and  
structurally sound.  
The POWER-ARC 4000 has a plastic, 1.00  
gallon (3.8) fuel tank mounted on the engine. See the  
OPERATION and MAINTENANCE sections of this  
manual for more details about fuel.  
The gasoline engine is designed to run in a level posi-  
tion for best performance. It can operate at an angle,  
but this should never be more than 15 degrees in any  
direction. If you do operate it at a slight angle, be sure  
to check the oil regularly and keep the oil level full.  
Also, fuel capacity will be a little less at an angle.  
MUFFLER DEFLECTOR  
The POWER-ARC 4000 is shipped with an exhaust  
deflector. You can mount it yourself on the gasoline  
engine.  
To install the deflector, do the following:  
LIFTING  
• Align the holes on the deflector plate with the holes  
on the muffler.  
The POWER-ARC 4000 should be lifted by two peo-  
ple. (It weighs 160 lbs/72.5 kg.) Its welded tube roll  
cage is designed to make lifting easy.  
• Position the deflector so that the opening points  
either right, left, or downward, away from the opera-  
tor.  
PRE-OPERATION ENGINE SERVICE  
CAUTION  
Read and understand the information about the gaso-  
line engine in the OPERATION and MAINTENANCE  
sections of this manual before you operate the  
POWER-ARC 4000.  
Never position the deflector upward. Moisture or  
debris can enter the engine and damage it. As a gen-  
eral safety practice, position the deflector to direct  
exhaust gases away from the operator’s face and  
eyes.  
WARNING  
• Fasten the deflector onto the muffler with the screws  
provided.  
• Keep hands away from the engine muffler or HOT  
engine parts.  
NOTE: The deflector reduces generator output power  
up to 100 watts.  
• Stop the engine when fueling.  
• Do not smoke when fueling.  
SPARK ARRESTER  
• Remove the fuel cap slowly to release pressure.  
• Do not overfill the fuel tank.  
Gasoline engine mufflers may emit sparks when the  
engine is running. Some federal, state, or local laws  
require spark arresters in locations where unarrested  
sparks could present a fire hazard.  
• Wipe up spilled fuel and allow the fumes to clear  
before starting the engine.  
Standard mufflers and deflectors (like the ones includ-  
ed with the POWER-ARC 4000) do not act as spark  
arresters. When local laws require it, a spark arrester  
must be installed on the machine and properly main-  
tained. An optional spark arrester kit is available for  
your POWER-ARC 4000. See the ACCESSORIES  
section of this manual for more information.  
• Keep sparks and flame away from the fuel tank.  
OIL  
The POWER-ARC 4000 is shipped with  
the engine filled with SAE 10W-30 oil.  
CHECK THE OIL LEVEL BEFORE YOU START THE  
ENGINE. This is an added precaution. When full, the  
oil level should be at 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.  
CAUTION  
An incorrect spark arrester may lead to damage to the  
engine or reduce performance. A suitable spark  
arrester for the Briggs & Stratton 8 HP Cool Bore®  
engine is available as a Lincoln field-installed option.  
For more oil fill and service information, see the MAIN-  
TENANCE section of this manual.  
POWER-ARC 4000  
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A-4  
INSTALLATION  
FIGURE A.1 - POWER-ARC 4000 OUTPUT CONNECTIONS  
1
POWER ARC 4000  
80  
AMPS  
70  
AMPS  
125  
90  
AMPS  
AMPS  
GENERATOR  
100  
AMPS  
WARNING  
6
5
ELECTRODE SELECTION GUIDE  
3
4
2
1. CURRENT CONTROL DIAL  
2. WELD OUTPUT TERMINALS (2)  
3. GROUND STUD  
4. CIRCUIT BREAKERS (2) - 20 AMP  
5. RECEPTACLE - 240 VOLT, 20 AMP  
6. DUPLEX RECEPTACLE - 120 VOLT, 20 AMP  
ELECTRICAL OUTPUT  
CONNECTIONS  
TABLE A.1  
RECOMMENDED WELDING CABLE  
SIZE AND LENGTH  
See Figure A.1 for the location of the current control  
dial, weld output terminals, ground stud, circuit break-  
ers, 240 and 120 volt receptacles.  
TOTAL COMBINED LENGTH OF ELECTRODE  
AND WORK CABLES  
WELDING CABLE CONNECTIONS  
Cable Size for  
125 amp/  
30% Duty Cycle  
Cable Size and Length  
Be sure to use welding cables that are large enough.  
The correct size and length becomes especially  
important when you are welding at a distance from the  
welder.  
Cable Length  
0-50 feet (0-15 meters)  
50-100 feet (15-39 meters)  
100-150 feet (30-46 meters)  
150-200 feet (46061 meters)  
200-250 feet (61-76 meters)  
6 AWG  
4 AWG  
Table A.1 lists recommended cable sizes and lengths  
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.  
3 AWG  
2 AWG  
1 AWG  
POWER-ARC 4000  
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A-5  
INSTALLATION  
Cable Installation  
WARNING  
Install the welding cables to your POWER-ARC 4000  
as follows. See Figure A.1 for the location of parts.  
Do not ground the machine to a pipe that carries  
explosive or combustible material.  
1. The gasoline engine must be OFF to install weld-  
ing cables.  
2. Remove the 1/2 - 13 flanged nuts from the output  
terminals.  
When the POWER-ARC 4000 is mounted  
on a truck or a trailer, the machine gen-  
erator ground stud MUST be securely  
connected to the metal frame of the vehi-  
cle. See Figure A.1. The ground stud is  
marked with the symbol.  
3. Connect the electrode holder and work cables to  
the weld output terminals. You can connect either  
cable to either terminal, since the POWER-ARC  
4000 provides AC weld current.  
4. Tighten the flanged nuts securely.  
PLUGS AND HAND-HELD EQUIPMENT  
5. Be certain that the metal piece you are welding  
(the “work”) is securely connected to the work  
clamp and cable.  
For further protection against electric shock, any elec-  
trical equipment connected to the generator recepta-  
cles must use a three-blade, grounded type plug or an  
Underwriter’s Laboratories (UL) approved double  
insulation system with a two-blade plug. Lincoln  
offers an accessory plug kit that has the right type of  
plugs. See the ACCESSORIES section of this manu-  
al for details.  
6. Check and tighten the connections periodically.  
CAUTION  
• Loose connections will cause the output terminals to  
overheat. The terminals may eventually melt.  
If you need ground fault protection for hand-held  
equipment, in-line ground fault current interrupter  
(GFCI) cord sets that meet UL and OSHA require-  
ments are available from:  
• Do not cross the welding cables at the output termi-  
nal connection. Keep the cables isolated and sepa-  
rate from one another.  
Ericson Manufacturing Company  
Willoughby, Ohio 44094  
(216) 951-8000 (Ohio)  
1-800-972-5109 (outside Ohio)  
Lincoln Electric offers a welding accessory kit with the  
properly specified welding cables. See the ACCES-  
SORIES section of this manual for more information.  
AUXILIARY POWER RECEPTACLES  
The control panel of the POWER-ARC 4000 features  
two auxiliary power receptacles:  
MACHINE GROUNDING  
• A 20 amp, 120 volt duplex (double outlet) recepta-  
cle  
Because the POWER-ARC 4000 creates its own  
power from its gasoline-engine driven generator, you  
do not need to connect the machine frame to an earth  
ground. However, for best protection against electri-  
cal shock, connect a heavy gauge wire  
from the ground stud located on the  
bottom center of the output panel (see  
Figure A.1) to a suitable earth ground  
such as a metal pipe driven into the  
ground.  
• A 20 amp 240 volt simplex (single outlet) receptacle.  
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. The machine output volt-  
ages meet UL standards and fall within ± 10% of the  
rated voltage. The output frequency falls within ± 3%  
of rated frequency (60 Hz).  
POWER-ARC 4000  
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A-6  
INSTALLATION  
PREMISES WIRING  
CIRCUIT BREAKERS  
The POWER-ARC 4000 three-wire, grounded neutral  
generator allows it to be connected to premises  
wiring. However, the wiring procedure needed to  
meet the National Electric Code (NEC) regulations as  
well as city ordinances can be confusing. Matters get  
worse depending on whether you want the machine to  
be “hardwired” to the premises or only connected  
temporarily.  
The POWER-ARC 4000 has its own  
20 amp circuit breakers for overload  
protection. When the machine is  
operated in high temperature environments, the  
breakers may tend to trip at lower loads than normal-  
ly.  
CAUTION  
Never bypass the circuit breakers. Without overload  
protection, the power-arc 4000 could overheat and/or  
cause damage to the equipment being used.  
WARNING  
Only a licensed, certified, trained electrician should  
install the machine to a premises or residential electri-  
cal 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 isolated before the  
generator is linked to the premises. Check your  
state and local requirements.  
• A double pole, double throw transfer switch in con-  
junction with the properly rated double throw circuit  
breaker is connected between the generator power  
and the utility meter.  
The POWER-ARC 4000 (unlike other Lincoln Electric  
equipment) 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. The gasoline engine  
has a rated life of 500 hours. It cannot withstand long-  
term use without proper maintenance. See the MAIN-  
TENANCE section of this manual for more informa-  
tion.  
Certain electrical devices cannot be powered by the  
POWER-ARC 4000. Refer to Table A.2 for these  
devices.  
POWER-ARC 4000  
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A-7  
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  
light bulbs, electric range, hot  
pan, skillet, coffee maker.  
NONE  
Capacitive  
TV sets, radios, microwaves,  
appliances with electrical control.  
Voltage spikes or high voltage  
regulation can cause the capac-  
itative 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,  
drills, well pumps, grinders, small  
refrigerators, weed and hedge  
trimmers  
These devices require large  
current inrush for starting. (See  
Table B.3, GENERATOR POWER  
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,  
complicated electrical equipment.  
An inductive type line condition-  
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  
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Section B  
TABLE OF CONTENTS  
- OPERATION SECTION -  
Operation...............................................................................................................................Section B  
Safety Instructions......................................................................................................................B-1  
General Description....................................................................................................................B-1  
Recommended Applications ......................................................................................................B-2  
Generator  
Welder  
Operational Features and Controls ............................................................................................B-2  
Design Features and Advantages ..............................................................................................B-2  
Welding Capability......................................................................................................................B-2  
Limitations .................................................................................................................................B-2  
Controls and Settings ................................................................................................................B-3  
Generator/Welder Controls ..................................................................................................B-3  
Gasoline Engine Controls.....................................................................................................B-4  
Engine Operation........................................................................................................................B-5  
Before Starting the Engine ..................................................................................................B-5  
Starting the Engine ..............................................................................................................B-5  
Stopping the Engine ............................................................................................................B-6  
Running the Engine .............................................................................................................B-6  
Break-in Period ....................................................................................................................B-6  
Generator Operation...................................................................................................................B-7  
Welding Operation......................................................................................................................B-9  
Welding Guidelines...................................................................................................................B-10  
POWER-ARC 4000  
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B-1  
OPERATION  
OPERATING INSTRUCTIONS  
WARNING  
Read and understand this entire section before oper-  
ating your POWER-ARC 4000.  
ARC RAYS can burn.  
SAFETY INSTRUCTIONS  
• Wear eye, ear, and body protection.  
WARNING  
Do not attempt to use this equipment until you have  
thoroughly read all the operation and maintenance  
manuals supplied with your machine. They include  
important safety precautions; detailed engine starting,  
operating, and maintenance instructions; and parts  
lists.  
ENGINE EXHAUST can kill.  
• Use in open, well ventilated areas or  
vent exhaust to the outside.  
• Do not stack anything on or near the  
engine.  
ELECTRIC SHOCK can kill.  
MOVING PARTS can injure.  
• Do not touch electrically live parts or  
electrodes with your skin or wet cloth-  
ing.  
• Do not operate this equipment with  
any of its doors open or guards off.  
• Stop the engine before servicing it.  
• Insulate yourself from the work and ground.  
• Always wear dry insulating gloves.  
• Keep away from moving parts.  
Only qualified personnel should install, use, or ser-  
vice this equipment.  
FUMES AND GASES can be  
dangerous.  
• Keep your head out of fumes.  
GENERAL DESCRIPTION  
• Use ventilation or exhaust to remove  
fumes from breathing zone.  
The POWER-ARC 4000 is a low-cost generator/  
welder designed for home use and other non-com-  
mercial applications. As a generator it can supply up  
to 4,000 continuous watts (or 4,400 surge watts) of  
120/240 volt, single-phase AC power. As a welder it  
provides 125 amps of AC current for welding with AC  
stick electrodes. A single dial provides continuous  
adjustment of welding output. The machine is light-  
weight, portable, and can be lifted easily by two peo-  
ple.  
WELDING SPARKS can cause  
fire or explosion.  
• Keep flammable material away.  
• Do not weld on containers that have  
held combustibles.  
A Briggs & Stratton 8 HP standard Cool-Bore® air-  
cooled, gasoline engine powers the generator/welder.  
The engine has an approximate operating life of 500  
hours.  
POWER-ARC 4000  
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B-2  
OPERATION  
The POWER-ARC 4000 warranty covers the machine  
for one year from the date of purchase. For non-  
engine warranty claims, contact your nearest Lincoln  
Authorized Field Service Facility. For engine warranty  
claims, contact your nearest Briggs & Stratton service  
center.  
• Separate ground stud for safe connection of case to  
earth ground. Single 20 amp, 240 volt generator  
receptacle.  
• Duplex 20 amp, 120 volt generator receptacle.  
• Integrated generator output overload protection  
through two 20 amp circuit breakers.  
NOTE: The POWER-ARC 4000 is not meant for rental  
or other commercial use.  
• Welded-tube, full roll cage frame protects engine  
and generator/welder.  
• Lightweight, portable design.  
RECOMMENDED APPLICATIONS  
• Rubber mounting isolates engine and generator  
from frame to prevent machine “walking” during  
use.  
GENERATOR  
The POWER-ARC 4000 gives smooth AC generator  
output for medium use, non-commercial demands.  
For more details on operating the generator, see GEN-  
ERATOR OPERATION in the OPERATION section of  
this manual.  
• Lo-Tone® engine muffler for quieter operation. (A  
Super Lo-Tone® muffler is available from Briggs &  
Stratton.) Easy-starting Electronic Magnetron® igni-  
tion.  
• Optional Oil Gard® low oil level engine shutdown kit  
available from Briggs & Stratton.  
WELDER  
The POWER-ARC 4000 provides excellent constant  
current AC welding output for stick (SMAW) welding.  
For more details on using the machine as a welder,  
see WELDING OPERATION in the OPERATION sec-  
tion of this manual.  
WELDING CAPABILITY  
The POWER-ARC 4000 is rated 125 amps, 18 volts at  
30% duty cycle on a ten-minute basis. This means  
that you can load the welder to 125 amps for three  
minutes out of every ten-minute period. The machine  
is capable of higher duty cycles at lower output cur-  
rents. For example, you can load the welder to 100  
amps for six minutes out of ten for a 60% duty cycle.  
OPERATIONAL FEATURES AND  
CONTROLS  
The POWER-ARC 4000 was designed for simplicity.  
Therefore, it has very few operating controls. A single  
dial on the control panel lets you select either genera-  
tor or welding use. For welding, the same dial selects  
continuous current output over the machine’s 70 to  
125 amp range.  
The current is continuously variable from 70 to 125  
amps AC. The POWER-ARC 4000 can, therefore,  
weld with all 3/32 and most 1/8 inch diameter Lincoln  
AC electrodes.  
The 8 HP Briggs & Stratton gasoline engine controls  
include a recoil starter, choke, throttle control, and  
piercing stop switch. See ENGINE OPERATION in the  
OPERATION section of this manual for details about  
starting, running, stopping, and breaking in the gaso-  
line engine.  
LIMITATIONS  
• The POWER-ARC 4000 is not recommended for  
any processes besides those that are normally per-  
formed using stick welding (SMAW) procedures.  
• The POWER-ARC 4000 is not recommended for  
pipe thawing.  
DESIGN FEATURES AND  
ADVANTAGES  
• During welding, generator power is limited to 100  
watts, and output voltages can drop from 120 to 80  
volts and 240 to 160 volts. Therefore, DO NOT  
OPERATE ANY SENSITIVE ELECTRICAL EQUIP-  
MENT WHILE YOU ARE WELDING.  
• Stick welding (SMAW) process capability with out-  
put range from 70 - 125 amps.  
• Single-dial current output selection.  
• Work and Electrode welding cable mounting termi-  
nals.  
POWER-ARC 4000  
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B-3  
OPERATION  
CONTROLS AND SETTINGS  
All generator/welder controls are located on the  
Output Control Panel. Gasoline engine controls are  
mounted on the engine. See Figures B.1 and B.2 and  
the explanations that follow.  
FIGURE B.1 – OUTPUT PANEL CONTROLS  
1
POWER ARC 4000  
80  
AMPS  
70  
AMPS  
125  
90  
AMPS  
AMPS  
GENERATOR  
100  
AMPS  
WARNING  
8
7
2
ELECTRODE SELECTION GUIDE  
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  
3. WELD OUTPUT TERMINAL (TO ELECTRODE  
HOLDER) WITH 1/2 - 13 FLANGE NUT: Provides  
the connection point for either the electrode hold-  
er or the work cable. (Because the POWER-ARC  
4000 is an AC output machine, either output ter-  
minal can be used for either cable.)  
GENERATOR/WELDER CONTROLS  
See Figure B.1 for the location of the following fea-  
tures:  
1. CURRENT CONTROL DIAL: Adjusts continuous  
current output. The amperages on the dial corre-  
spond to the average amperages needed for spe-  
cific Lincoln welder rods.  
4. WELD OUTPUT TERMINAL (TO WORK) WITH 1/2  
- 13 FLANGE NUT: Provides the connection point  
for either the electrode holder or the work cable.  
(Because the POWER-ARC 4000 is an AC output  
machine, either output terminal can be used for  
either cable.)  
2. ELECTRODE SELECTION GUIDE: Provides rec-  
ommended electrode type, size, and welder out-  
put setting based on the thickness of the work.  
POWER-ARC 4000  
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B-4  
OPERATION  
5. GROUND STUD: Provides a connection point for  
connecting the machine case to earth ground for  
the safest grounding procedure.  
7. 20 AMP, 240 VOLT RECEPTACLE: Connection  
point for supplying 240 volt power to operate one  
electrical device.  
6. 20 AMP CIRCUIT BREAKERS (2): Provide sepa-  
rate overload current protection for the 120 volt  
and 240 volt receptacles.  
8. 20 AMP, 120 VOLT DUPLEX RECEPTACLE:  
Connection point for supplying 120 volt power to  
operate one or two electrical devices.  
FIGURE B.2 – GASOLINE ENGINE CONTROLS  
5
2
4
3
POWER ARC  
4000  
80  
AMPS  
70  
MIN.AMPS  
MAX.  
90  
AMPS  
100  
AMPS  
6
AIR  
IN  
ELECTRODE SELECTION GUIDE  
ENGINE  
EXHAUST  
R
LINCOLN  
7
ELECTRIC  
1
AIR  
OUT  
AIR  
OUT  
8
9
11  
10  
12  
1. FUEL SHUTOFF VALVE  
2. FUEL TANK AND CAP  
3. MUFFLER  
7. AIR MIXTURE ADJUSTMENT SCREW  
8. RECOIL STARTER  
9. CHOKE  
4. PIERCING STOP SWITCH  
5. AIR CLEANER  
10. FUEL MIXTURE ADJUSTMENT SCREW  
11. OIL DRAIN PLUG  
6. THROTTLE  
12. OIL FILL PLUG  
3. MUFFLER: Reduces engine noise output. Does  
not serve as a spark arrester. See SPARK  
ARRESTER in the INSTALLATION section of  
this manual.  
GASOLINE ENGINE CONTROLS  
See Figure B.2 for the location of the following fea-  
tures:  
1. FUEL SHUTOFF VALVE: Stops the flow of gaso-  
line from the fuel tank to the carburetor. Should  
be closed whenever you are finished using the  
POWER-ARC 4000. Must be opened before you  
start the engine.  
4. PIERCING STOP SWITCH: Stops the engine by  
grounding the spark plug.  
5. AIR CLEANER: Filters intake air to the carbure-  
tor. See ENGINE MAINTENANCE in the MAIN-  
TENANCE section of this manual for details  
about the specific type of air cleaner to use.  
2. FUEL TANK AND CAP: Holds 1.0 gallon (3.8  
liters) of unleaded gasoline. Contains a 50  
micron fuel filter molded at the outlet port.  
6. THROTTLE: Adjusts the running speed of the  
engine. The engine runs at high idle  
when not under load. Rotating the  
spring-loaded throttle clockwise can  
temporarily reduce engine speed to  
low idle speed. Releasing the throttle returns the  
speed to high idle.  
NOTE: If you use any other alternate fuel tank or  
supply, be sure to use a recommended  
in-line fuel filter.  
POWER-ARC 4000  
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B-5  
OPERATION  
7. AIR MIXTURE ADJUSTMENT SCREW: Adjusts the  
BEFORE STARTING THE ENGINE  
amount of air mixed with fuel to obtain the  
smoothest operation under load or at idle. The  
POWER-ARC 4000 is shipped with the proper  
adjustment already set. DO NOT ADJUST THE  
AIR MIXTURE SCREW WITHOUT FOLLOWING  
THE PROCEDURES OUTLINED BY BRIGGS &  
STRATTON.  
CHECK AND FILL THE ENGINE OIL LEVEL:  
1. Place the machine on a level  
surface.  
2. Open the oil fill plug.  
3. Fill (if necessary) until oil flows out the top of the fill  
plug hole.  
8. RECOIL STARTER: Manual, rope-type starter.  
The handle position allows easy starting from  
either ground level or pickup-truck level.  
4. Replace the fill plug and tighten securely.  
CHECK AND FILL THE ENGINE FUEL TANK:  
1. Remove the fuel tank cap.  
9. CHOKE: Provides a richer air/fuel  
mixture for cold engine starting con-  
ditions.  
See the topic ENGINE  
2. Fill the tank to allow approximately 1/4  
inch (5 mm) of tank space for fuel  
expansion. DO NOT FILL THE TANK  
TO THE POINT OF OVERFLOW.  
OPERATION, below, for details on setting the  
choke.  
10. FUEL MIXTURE ADJUSTMENT SCREW: Adjusts  
the amount of fuel mixed with air to obtain the  
smoothest operation under load or at idle. The  
POWER-ARC 4000 is shipped with the proper  
adjustment already set. DO NOT ADJUST THE  
FUEL MIXTURE SCREW WITHOUT FOLLOW-  
ING THE PROCEDURES OUTLINED BY BRIG-  
GS & STRATTON.  
3. Replace the fuel tank cap and tighten securely.  
NOTE: The engine will operate satisfactorily on any  
gasoline meant for automotive use. A mini-  
mum of 87 octane is recommended. DO NOT  
MIX OIL WITH THE GASOLINE.  
Use clean, fresh, lead-free gasoline. Leaded gasoline  
may be used if lead-free is not available. However,  
lead-free gasoline leaves fewer combustion deposits  
and gives longer valve life. For engine protection from  
fuel deposits, use Briggs & Stratton Gasoline Additive,  
part number 5041. Purchase gasoline in quantities  
that will be used within 30 days, to assure freshness.  
11. OIL DRAIN PLUG: Permits convenient draining of  
engine oil during maintenance. Both sides of the  
engine are equipped with an oil drain plug.  
12. OIL FILL PLUG: Permits convenient filling of  
engine oil during maintenance. Both sides of the  
engine are equipped with an oil fill plug.  
NOTE: We DO NOT recommend using gasoline that  
contains alcohol, such as gasohol. However,  
if gasoline with alcohol is used, it MUST NOT  
contain more than 10% Ethanol and MUST be  
removed from the engine during storage. DO  
NOT use gasoline containing Methanol.  
ENGINE OPERATION  
WARNING  
STARTING THE ENGINE  
DO NOT RUN THE ENGINE AT EXCESSIVE SPEEDS.  
The maximum allowable high idle speed for the  
POWER-ARC 4000 is 3750 RPM, no load. Do NOT  
adjust the governor screw on the engine. Severe per-  
sonal injury and damage to the machine can result if it  
is operated at speeds above the maximum rated  
speed.  
NOTE: Remove all loads connected to the AC power  
receptacles before starting the gasoline  
engine.  
FOR A “COLD” ENGINE:  
1. Open the fuel shutoff valve on the bottom of the  
fuel tank.  
2. Place the choke lever in the lowest, downward  
position.  
Read and understand all safety instructions included  
in the Briggs & Stratton Operating and Maintenance  
Instructions manual that is shipped with the POWER-  
ARC 4000.  
3. Pull slightly on the recoil starter handle  
until resistance is felt.  
POWER-ARC 4000  
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B-6  
OPERATION  
4. Pull the cord rapidly.  
FOR BEST ENGINE STOPPING:  
5. If the engine does not start, open the choke slight-  
ly (move lever upward) and pull the starter cord  
rapidly again.  
• Do not remove the rubber spark plug boot.  
• Be sure the piercing point on the piercing stop  
switch lever firmly contacts the spark plug.  
When the engine starts, gradually open the choke to  
the highest, upward position.  
• Do not apply excessive force to or bend the pierc-  
ing stop switch lever.  
FOR A “HOT” ENGINE:  
1. Open the fuel shutoff valve on the bottom of the  
fuel tank.  
WARNING  
Close the fuel valve when the machine is transported  
to prevent fuel leakage from the carburetor. Drain the  
tank before transporting the machine in a vehicle.  
2. Place the choke lever in the highest,  
upward position. Closing the choke  
of a hot engine will flood the carbu-  
retor and prevent starting.  
For long periods of storage, turn off the fuel shutoff  
valve (lowest, downward position) and let the engine  
run until there is no more fuel in the line. Use a fuel  
additive such as Sta-Bil to minimize fuel gum  
deposits.  
3. Pull slightly on the recoil starter handle until resis-  
tance is felt.  
4. Pull the cord rapidly.  
FOR BEST ENGINE STARTING:  
• Do not adjust air or fuel mixtures without following  
the procedures in the Briggs & Stratton Operating  
and Maintenance Instructions manual.  
RUNNING THE ENGINE  
The engine is set at the factory to run at high idle  
speed when not under load. You should not adjust  
this setting yourself.  
• Always use fresh gasoline and be sure the filter is  
clean and properly maintained.  
BREAK-IN PERIOD  
• If you use an alternate fuel tank or supply, be sure  
to install an in-line fuel filter.  
Any engine will use a small amount of oil during its  
“break-in” period. For the gasoline engine on the  
POWER-ARC 4000, break-in is about 12 running  
hours.  
• Do not pull the recoil starter with the  
choke in the downward position more  
than one time. Repeated pulls on a  
choked engine will flood the carburetor.  
Check the oil frequently during break-in. Change the  
oil after the first 5 hours of operation. For more  
details, see the MAINTENANCE section of this manu-  
al.  
• If you don’t feel resistance when you pull the recoil  
cord, gently hit the starter housing and/or pull the  
cord out to its fully extended position and wiggle it  
rapidly. Repeat this if necessary until the clutch  
engages the shaft and you feel resistance when you  
pull the cord.  
CAUTION  
• If the engine will not start, see the TROU-  
During break-in, subject the POWER-ARC 4000 to  
only moderate loads. Avoid long periods running at  
idle. Before stopping the engine, remove all loads and  
allow the engine to cool several minutes.  
BLESHOOTING section of this manual.  
STOPPING THE ENGINE  
1. Remove all welding and generator power loads  
and let the engine cool by running it for several  
minutes.  
2. Stop the engine by pressing downward on the  
piercing stop switch lever.  
3. Hold the lever down firmly until the engine com-  
pletely stops. Otherwise, the engine may restart  
or sputter as it stops.  
4. Close the fuel shutoff valve at the bottom of the  
fuel tank.  
POWER-ARC 4000  
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B-7  
OPERATION  
draws. (This information is given on the load device  
nameplate.) For example, a device rated 115 volts, 2  
amps will need 230 watts of power (115 x 2 = 230).  
GENERATOR OPERATION  
CAUTION  
You can use Table B.3, GENERATOR POWER APPLI-  
CATIONS, to determine the wattage requirements of  
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.  
Be sure that any electrical equipment plugged into the  
generator’s AC power receptacles can withstand a  
±10% voltage and a ±3% frequency variation. 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 INSTALLA-  
TION section of this manual.  
TO USE THE GENERATOR AS AN AUXILIARY  
POWER SUPPLY:  
1. Start the gasoline engine. See ENGINE OPERA-  
TION in this section of the manual.  
GENERAL INFORMATION  
2. Set the current control dial on the output control  
panel to “GENERATOR.” See Figure B.1.  
The POWER-ARC 4000 generator is rated at 4000  
continuous watts (4400 surge watts). It provides both  
120 volt and 240 volt power. You can draw up to 20  
amps from either side of the 120 volt duplex recepta-  
cle, but no more than 37 amps from both sides at  
once. Up to 18 amps can be drawn from the single  
240 volt receptacle.  
3. Plug the load(s) into the appropriate 120 volt or  
240 volt power receptacle.  
NOTE: During welding, the maximum generator out-  
put for auxiliary loads is 100 watts.  
NOTE: You can supply multiple loads as long as the  
total load does not exceed 4,000 watts. Be  
sure to start the largest loads first.  
Electrical loads in watts are calculated by multiplying  
the voltage rating of the load by the number of amps it  
POWER-ARC 4000  
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B-8  
OPERATION  
TABLE B.3  
GENERATOR POWER APPLICATIONS  
Suggested Power Applications  
Running Watts  
*Start-up Watts  
*Air Compressor - 3/4 HP  
*Airless Sprayer - 1/3 HP  
Chain Saw 1,200  
1,250  
600  
3,100 - 5,000  
1,500 - 2,400  
Circular Saw  
1,200  
1,000  
500  
Coffee Maker  
*Deep Freezer  
750 - 2,000  
*Electric Motor - 1 HP  
Electric Range (1 element)  
Electric Skillet  
1,000  
1,500  
1,250  
1,200  
600  
2,500 - 4,000  
*Furnace Fan - 1/3 HP  
Portable Grinder (4 1/2”)  
Portable Grinder (7”)  
Halogen Work Light  
Hand Drill - 1/4”  
3,000 - 4,800  
2,000  
500  
500  
Hand Drill - 3/8”  
700  
1500 Watt Heater  
Hedge Trimmer  
1,750  
450  
Light Bulb 100  
Reciprocating Saw  
Radial Arm Saw  
900  
2,600  
Radio 50  
*Refrigerator/Freezer (small)  
Slow Cooker  
600  
200  
1,500 - 2,400  
*Submersible Pump - 1 HP  
*Sump Pump  
1,000  
600  
2,500 - 4,000  
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 equipment listed in  
the table, multiply RUNNING WATTS by 2.  
Multiple loads can be used as long as the total load does not exceed 4,000 watts. Be sure to start the  
largest loads first. For example, a 1 HP motor needs approximately 1,000 watts while running but may  
require 2,500 watts to start. Some inductive motors may require as much as 4 times running watts to  
start.  
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B-9  
OPERATION  
3. Attach the work clamp securely to the work you  
WELDING OPERATION  
are welding.  
GENERAL INFORMATION  
4. Insert the electrode into the electrode holder.  
5. Set the current control dial to the desired output  
current.  
WARNING  
6. Start the gasoline engine. See ENGINE OPERA-  
Do not touch electrically live parts or elec-  
TION in this section of the manual.  
trodes with your skin or wet clothing.  
7. Strike an arc and begin welding. For information  
on welding techniques, see WELDING GUIDE-  
LINES in this section of the manual.  
Do not breathe welding fumes or gases.  
AFTER YOU FINISH THE WELD:  
Use ventilation or exhaust to remove weld-  
ing fumes from the breathing area.  
1. Stop the gasoline engine. See ENGINE OPERA-  
TION in this section of the manual.  
2. Allow the electrode and work to cool completely.  
3. Remove the work clamp from the work.  
Keep flammable material away.  
Wear eye, ear, and body protection.  
4. Remove any remaining piece of electrode from the  
electrode holder.  
5. If you are finished using the POWER-ARC 4000 for  
welding, disconnect the welding cables from the  
weld output terminals. Reattach the flange nuts  
and leave them on the terminals.  
The POWER-ARC 4000 generator/welder can deliver  
from 70 to 125 amps of continuous welding output  
current . Output can be adjusted by setting the cur-  
rent control dial on the output control panel.  
You can get maximum welding output by setting the  
dial to 125 AMPS. At high current settings like this,  
some output may decrease as the machine is used. If  
you are welding for a long time, you may need to turn  
the dial slightly upward to maintain the same results.  
The numbers on the dial correspond to the average  
amps needed to weld using specific Lincoln welding  
rods. Table B.4, WELDING APPLICATIONS, gives you  
the recommended dial settings based on the thick-  
ness of the work and the size and type of rod you’re  
using.  
TO USE THE POWER-ARC 4000 FOR WELDING:  
1. Remove the flange nuts from the weld output ter-  
minals and place the work and electrode welding  
cables over the terminals. See Figure B.1.  
Replace and tighten the flange nuts securely. Be  
sure the connections are tight.  
2. Select the appropriate electrode. See Table B.4,  
WELDING APPLICATIONS, or the ELECTRODE  
SELECTION GUIDE on the machine Output  
Control Panel.  
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B-10  
OPERATION  
WELDING GUIDELINES  
TABLE B.4  
WELDING APPLICATIONS/ELECTRODE SELECTION GUIDE  
Material Thickness  
Electrode Type  
Size  
Setting  
1/8” and thinner  
FLEETWELD® 37  
1AWS E6013  
3/32”  
90 amps  
FLEETWELD® 180  
AWS E6011  
70 amps  
90 amps  
STABLE ARC™ 7018  
AWS E7018  
3/16” Maximum  
5/16” Maximum  
Any Thickness  
FLEETWELD® 37  
AWS E6013  
1/8”  
1/8”  
1/8”  
125 amps  
90 amps  
100 amps  
FLEETWELD® 180  
AWS E6011  
WEARSHIELD®  
NOTES:  
The values listed are suggested settings. Actual setting may vary depending on individual preference and/or spe-  
cific application. Beginners should use STABLE ARC E7018.  
For electrodes not listed, follow tables that are packed with the electrodes.  
Ask for the Lincoln WELD DIRECTORY (Publication M210) for a complete listing of all Lincoln stick electrodes  
available.  
1AWS = American Welding Society  
NOTE: The serviceability of a product or structure  
STICK WELDING  
utilizing this type of information is and must  
Stick welding is probably the most familiar welding  
be the sole responsibility of the builder/user.  
process known. A coated ELECTRODE, the welding  
Many variables beyond the control of The  
rod, is clamped into an ELECTRODE HOLDER, an  
Lincoln Electric Company affect the results  
insulated clamping device, which is connected to  
obtained in applying this type of informa-  
the ELECTRODE CABLE, a heavy wire. The WORK,  
tion. These variables include, but are not  
the piece of metal to be welded, is connected to the  
limited to, welding procedure, plate chem-  
WORK CABLE, a heavy wire with a WORK CLAMP  
istry and temperature, weldment design,  
on one end. The two cables connect to OUTPUT  
fabrication methods and service require-  
TERMINALS on the welder, which is a high current  
ments.  
power source. See Figure B.3.  
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B-11  
OPERATION  
FIGURE B.3 – WELDING CIRCUIT CONNECTIONS  
1
5
2
8
6
4
3
7
1. POWER SOURCE  
2. ELECTRODE CABLE  
3. ELECTRODE HOLDER  
4. ELECTRODE  
5. OUTPUT TERMINALS  
6. WORK  
7. WORK CLAMP  
8. WORK CABLE  
THE ARC  
THE WELDING CIRCUIT  
The electric arc is made between the work and the tip  
of the electrode. You make a gap for the arc in the  
welding circuit by holding the electrode tip 1/16 to 1/8  
inch (1.6 to 3.2 mm) away from the work. You must  
establish the arc and hold it as you move the arc along  
the joint you’re welding. The arc melts both the elec-  
trode and the base metal of the work as you move.  
When everything is connected properly, the current  
from the power source causes the electrode to melt  
and bond the metal being welded. Figure B.3. shows  
the components of the basic welding circuit. The cir-  
cuit starts at the electrode cable connection and ends  
at the work cable connection. Current flows from the  
POWER-ARC 4000 through the electrode cable, the  
electrode holder, the electrode, and across the arc.  
Figure B.4. shows what’s happening in the welding  
arc. The arc itself is the electric current flowing  
between the tip of the electrode and the work. Its  
temperature is about 6000°F (3316°C). The arc is very  
bright and cannot be looked at with the naked eye  
without risk of painful and perhaps permanent injury.  
A very dark lens specifically designed for arc welding  
must be used with the handshield or headshield when-  
ever viewing the arc.  
On the work side of the arc, current flows through the  
work to the work clamp, the work cable, and back to  
the machine. The circuit must be complete for current  
to flow. That means the work clamp must be tightly  
connected to clean base metal. You should remove  
any paint or rust as necessary to get a good connec-  
tion. Also, you need to connect the work clamp as  
close as possible to the area you want to weld. Avoid  
letting the welding circuit pass through hinges, bear-  
ings, electronic components or similar devices that  
can be damaged by high current.  
The arc melts the base metal and actually digs into it.  
The molten metal forms a pool or crater and tends to  
flow away from the arc. As it moves away, it cools and  
solidifies. Slag forms on the top of the weld and pro-  
tects it as it cools.  
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B-12  
OPERATION  
FIGURE B.4 – THE WELDING ARC  
THE FOUR FACTORS OF SUCCESSFUL  
WELDING  
Controlling the arc to make a successful weld  
depends on four factors. How well you control them  
will determine whether your welds succeed or fail.  
The four factors include:  
2
1
4
7
• The Correct Welding Position  
3
• The Correct Way to Strike an Arc  
5
• The Correct Arc Length The Correct Welding  
Speed  
6
• The Correct Welding Position  
Figure B.5 shows the correct position for right-  
handed people. (If you are left-handed, the correct  
position is opposite the one shown.) Whenever pos-  
sible, weld from left to right so that you can see  
clearly what you are doing. Notice that the electrode  
should be held at a slight angle, 15 to 20 degrees  
from the perpendicular.  
1. ELECTRODE  
2. COATING  
3. SHIELDING GAS  
4. ARC  
5. BASE METAL  
6. WELD METAL  
7. SOLIDIFIED SLAG  
FIGURE B.5 –  
CORRECT WELDING POSITION  
Obviously, stick arc welding is a manual skill requir-  
ing a steady hand, good physical condition, and  
good eyesight. The quality of the weld depends on  
the skill of the welder to hold and control the weld-  
ing arc.  
15-20°  
THE ELECTRODE  
90°  
end view  
Besides diameter, the main difference between elec-  
trodes is their type of coating. This coating helps  
make the arc steady, shields the arc to keep oxygen  
and nitrogen in the air away from the molten metal,  
and provide a flux that picks up impurities which  
could weaken the weld.  
side view  
THE CORRECT WAY TO STRIKE AN ARC  
First be sure that the work clamp is making a good  
connection to the work. Lower your headshield and  
scratch the electrode slowly over the metal. Sparks  
will fly. While scratching, lift the electrode 1/8 inch  
(3.2 mm) and the arc will be established.  
The best coating for the job depends on a number of  
factors:  
• The type of deposit you want, such as mild steel,  
stainless steel, low alloy, or hardfacing.  
NOTE: If you stop moving the electrode while  
scratching, the electrode will stick to the  
work.  
• The thickness of the plate you want to weld.  
• The position you will be welding in (vertical, hori-  
zontal, downhand, out-of-position).  
Most beginners try to strike the arc by a fast jabbing  
motion down onto the plate. Result: They either  
stick the electrode or their motion is so fast that they  
break the arc immediately.  
• The surface condition of the work.  
• Your ability to handle and obtain the desired elec-  
trode.  
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B-13  
OPERATION  
THE CORRECT ARC LENGTH  
FIGURE B.6 – MOLTEN METAL PUDDLE  
AND CORRECT WELD SPEED  
The arc length is the distance from the tip of the elec-  
trode core wire to the base metal.  
Once you’ve established the arc, maintaining the cor-  
rect arc length is critical. It should be short, 1/16 to  
1/8 inch (3.2 mm) long. As the electrode burns off, you  
must continue to feed it into the work to keep the arc  
length correct.  
1
3
2
The easiest way to tell if the arc length is correct is to  
listen to it. A nice, short arc has a distinctive “crack-  
ling” sound, like eggs frying in a pan. A long, incor-  
rect, arc has a hollow, blowing or hissing sound.  
4
1. ELECTRODE  
2. ARC  
3. RIDGE OF MOLTEN METAL  
4. WELD PUDDLE  
THE CORRECT WELDING SPEED  
To know whether your welding speed is correct, you  
must watch the puddle of molten metal behind the arc.  
DO NOT WATCH THE ARC ITSELF. The appearance  
of the puddle and the ridge where it solidifies tells the  
tale. The ridge should be approximately 3/8 inch (9.5  
mm) behind the electrode. See Figure B.6.  
Most beginners tend to weld too fast, which gives a  
thin, uneven, “wormy” looking bead. They are not  
watching the molten metal puddle.  
NOTE: When welding on thin plate, you will find that  
you have to increase welding speed. On  
heavy plate, you will have to go more slowly to  
ensure fusion and penetration.  
The key to developing welding skill is PRACTICE. No  
one can learn to weld just by reading about it. If you  
are an inexperienced welder, the information here will  
help you understand some basic welding principles  
you should know before you use your POWER-ARC  
4000 for stick welding. For more detailed information,  
order a copy of the book New Lessons in Arc Welding,  
available from the Book Division of Lincoln Electric.  
See the form located at the back of this manual for  
ordering information!  
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Section C  
TABLE OF CONTENTS  
- ACCESSORIES -  
Accessories...........................................................................................................................Section C  
Options/Accessories...................................................................................................................C-1  
Lincoln Electric Accessories ................................................................................................C-1  
Briggs and Stratton Accessories .........................................................................................C-1  
Semiautomatic Mig Welding with a Lincoln/Weld-Pak 100 or Weld-Pak 125...........................C-1  
POWER-ARC 4000  
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C-1  
ACCESSORIES  
OPTIONS/ACCESSORIES  
SEMIAUTOMATIC MIG WELDING  
WITH A LINCOLN WELD-PAK 100  
OR WELD-PAK 125  
LINCOLN ELECTRIC ACCESSORIES  
The following options/accessories are available for  
your POWER-ARC 4000 from your local Lincoln  
Distributor.  
In addition to using the accessories/options listed  
above, the POWER-ARC 4000 generator can supply  
power to a Lincoln ELectric Weld-Pak 100 or Weld-  
Pak 125 wire feed welder. The Weld-Pak comes with  
all the supplies needed for Flux-Cored Arc Welding  
(FCAW).  
Power Plug Kit (K802T) – Provides three plugs, two  
for the 120 volt duplex receptacle and one for the 240  
volt receptacle.  
Accessory Set (K875) – Includes the following:  
• Twenty feet (6.1 meters) of #6 AWG electrode cable  
• Fifteen feet (4.6 meters) of #6 work cable  
A K610-1 MIG (Metal Inert Gas) Conversion Kit is also  
available for the Weld-Pak. The kit provides every-  
thing needed for Gas Metal Arc Welding (GMAW) or  
MIG processes. Contact your local authorized Lincoln  
representative for details about the Weld-Pak and MIG  
Conversion Kit.  
• Headshield with No. 10 filter, work clamp  
• Insulated electrode holder and sample electrodes  
The cables are rated at 150 amps, 40% duty cycle.  
Spark Arrester (K883-1) – A field-installed kit for the  
8 HP Briggs & Stratton Cool-Bore® engine. The spark  
arrestor attaches to the muffler to reduce the change  
of sparks being emitted from the muffler.  
Rotor Removal Kit (S20925) – A service kit with thru  
and impact bolts for removing the generator rotor from  
the tapered engine crankshaft.  
BRIGGS AND STRATTON ACCESSORIES  
The following options/accessories are available for  
your POWER-ARC 4000 from your local Briggs &  
Stratton Distributor.  
Foam Pre-cleaner (REF 271794) – Provides a foam  
cleaner for replacement around the paper cartridge air  
cleaner. Increases protection in extremely dusty or  
dirty environments.  
Oil Gard® Low Oil Shutdown Kit (REF 398182) –  
Installs in the crankcase access port standard on all  
POWER-ARC models. Senses low oil conditions and  
automatically stops the engine. The engine cannot be  
restarted until sufficient oil is added.  
Super Lo-Tone® Muffler - Square (REF 494221) –  
Replaces the round Lo-Tone muffler that comes  
installed on the engine. Limits exhaust noise but  
reduces maximum generator output by 200-300 watts.  
Muffler Guard (REF 494868) – Installs onto the muf-  
fler with a supplied bracket. Protects against acci-  
dental contact with a hot muffler. Must not be used in  
tandem with both a deflector and a spark arrester.  
POWER-ARC 4000  
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Section D  
TABLE OF CONTENTS  
-MAINTENANCE-  
Maintenance .........................................................................................................................Section D  
Routine and Periodic Maintenance ............................................................................................D-1  
Engine Maintenance.............................................................................................................D-1  
Generator/Welder Maintenance...........................................................................................D-4  
Major Component Locations......................................................................................................D-5  
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D-1  
MAINTENANCE  
OIL: Check the oil level after every  
5 hours of operation or daily. BE  
SURE TO MAINTAIN THE OIL LEVEL.  
Change the oil the first time after 5  
SAFETY PRECAUTIONS  
WARNING  
hours of operation. Then, under normal operating  
conditions, change the oil after every 50 hours or once  
a year, whichever occurs first. If the engine is operat-  
ed under heavy load or in high ambient temperatures,  
change the oil every 25 hours.  
• Have qualified personnel do all maintenance and  
troubleshooting work.  
• Turn the engine off before working inside the  
machine.  
Drain the oil from the drain plug located on either side  
of the engine bottom, as shown in Figure D.1. Refill  
through the oil fill plug until the oil reaches the top of  
the fill hole. Use SAE 10W-30 grade oil.  
• Remove guards only when necessary to perform  
maintenance and replace them when the mainte-  
nance requiring their removal is complete.  
• If guards are missing from the machine, get replace-  
ments from a Lincoln Distributor. See the EXPLOD-  
ED VIEW AND PARTS LIST at the back of this man-  
ual.  
FIGURE D.1 - OIL DRAIN AND  
REFILL LOCATION  
Read the Safety Precautions in the front of this manu-  
al and in the Briggs & Stratton Operating and  
Maintenance Instructions manual before working on  
the POWER-ARC 4000.  
Keep all equipment safety guards, covers, and  
devices in position and in good repair. Keep your  
hands, hair, clothing, and tools away from the recoil  
housing, fans, and all other moving parts when start-  
ing, operating, or repairing this machine.  
2
3
1
1. OIL DRAIN PLUG  
2. OIL FILL PLUG  
3. OIL LEVEL  
ROUTINE AND PERIODIC  
MAINTENANCE  
FUEL: At the end of each day’s use, refill  
the fuel tank to minimize moisture conden-  
sation and dirt contamination in the fuel  
line.  
ENGINE MAINTENANCE  
CAUTION  
To prevent the engine from accidentally starting, dis-  
connect the spark plug lead before servicing the  
engine.  
See Table D.1 for a summary of maintenance intervals  
for the items listed below. Follow either the hourly or  
the calendar intervals, whichever come first. More fre-  
quent service may be required, depending on your  
specific application and operating conditions. Table  
D.2 shows engine maintenance replacement parts and  
numbers.  
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D-2  
MAINTENANCE  
AIR CLEANER: Your air cleaner may  
have only the paper cartridge, or it may  
have the cartridge and a foam pre-clean-  
er. If it has the pre-cleaner, service the  
cartridge every 100 hours and the pre-  
cleaner every 25 hours or once a year, whichever  
comes first. If the air cleaner doesn’t have the pre-  
cleaner, service the cartridge every 25 hours or once a  
year, whichever comes first. Under dusty conditions,  
service more often.  
Clean Rotating Screen: See Figure D.2. Clean the  
rotating screen on your machineís engine as often as  
needed to remove dirt or debris that may collect on  
the screen. A dirty screen can result in engine over-  
heating and damage.  
FIGURE D.2 - CLEAN ROTATING  
SCREEN/FINGER GUARD/DEBRIS GUARD  
CAUTION  
Do not use petroleum solvents such as kerosene to  
clean the cartridge. They may cause deterioration of  
the cartridge. DO NOT OIL THE CARTRIDGE OR USE  
PRESSURIZED AIR TO CLEAN OR DRY THE CAR-  
TRIDGE.  
1
1. ROTATING SCREEN  
Remove the wing nut and cover. Carefully remove the  
foam pre-cleaner, if equipped, from the cartridge.  
CLEAN COOLING SYSTEM: See Figure D.3. Clean  
the internal cooling fins and surfaces to prevent over-  
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.  
3. Saturate in clean engine oil.  
FIGURE D.3 - CLEAN COOLING SYSTEM  
4. Squeeze in a clean, absorbent cloth to remove all  
excess oil.  
1
To service the cartridge:  
1. Tap gently on a clean surface.  
2. Replace if very dirty or wash in a non-sudsing  
detergent and warm water solution.  
3. Rinse thoroughly from the mesh side with flowing  
water until the water is clear.  
4. Allow to stand and air dry before reinstalling.  
1. REMOVE CHAFF AND DIRT FROM THESE AREAS.  
Carefully place the pre-cleaner back over the cartridge  
and reinstall the air cleaner cover and wingnut.  
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.  
CAUTION  
Periodically clean the muffler area to remove com-  
bustible debris.  
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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 solvent.  
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.4.  
CLEAN SPARK ARRESTER SCREEN: If the muffler  
has the optional spark arrester assembly, remove it  
every 50 hours or once a year, whichever comes first,  
and inspect it. Clean the arrester. Replace it if you find  
any damage.  
REMOVE COMBUSTION DEPOSITS: After every  
100 to 300 hours of operation, remove the engine  
cylinder head. Scrape and wire brush the combustion  
deposits from the cylinder, cylinder head, top of the  
piston, and around the valves. Refit the gasket  
(replace it if damaged) and reassemble the cylinder  
head and block. Turn down the screws finger tight  
with the three long screws around the exhaust valve (if  
so equipped). Torque the screws in a staggered  
sequence to 165 inch-pounds (19 N·m).  
FIGURE D.4 - SET SPARK PLUG GAP  
2
1
1. SPARK PLUG (STANDARD, PART NO. 492167; RESISTOR,  
PART NO. 802592)  
2. FEELER GAUGE (.030 INCH, 76mm)  
TABLE D.1  
ENGINE MAINTENANCE SCHEDULE  
Maintenance  
Operation  
Every 5 Hours  
or Daily  
25 Hours  
or Yearly  
50 Hours  
or Yearly  
100 Hours  
or Yearly  
100-300 Hours  
Check Oil Level  
●
Change Oil ◆  
● Note 1  
Clean Rotating Screen, Finger  
Guard, or Debris Screen  
●
Note 2  
Service Foam Pre-Cleaner or  
or Oil Foam® Element  
●
Note 2  
Service Air Cleaner Cartridge  
(if no pre-cleaner)  
●
Note 2  
Service Air Cleaner Cartridge  
(if pre-cleaner present)  
●
Note 2  
Clean Cooling System  
●
Inspect Spark Arrester (Option)  
Clean or Replace Spark Plug  
Replace In-Line Fuel Filter (Option)  
Remove Combustion Deposits  
●
●
●
●
◆ Change oil after first 5 hours, then after every 50 hours or once a year.  
Note 1: Change oil every 25 hours when operating under heavy load in high ambient temperatures.  
Note 2: Clean more often under dusty conditions or when airborne debris is present.  
POWER-ARC 4000  
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D-4  
MAINTENANCE  
TABLE D.2 – ENGINE MAINTENANCE PARTS  
Part  
Part Number  
OIL FILTER  
NONE  
SPARK PLUG (STANDARD)  
B&S 492167  
CHAMPION J19LM  
B&S 802592  
SPARK PLUG (RESISTOR)  
CHAMPION RJ19LM  
B&S 298090 (for .25î I.D. hose)  
B&S 393957  
FUEL FILTER  
AIR CLEANER CARTRIDGE  
(CAN BE CLEANED AND REUSED)  
B&S 271794  
(CAN BE CLEANED AND REUSED)  
AIR PRE-CLEANER  
(AS NEEDED)  
through the brush holder tabs. Install the brush  
holder into the bearing end bracket and secure with  
the screws previously removed. Remove the cable  
tie or wooden stick and the brushes will seat onto  
the slip rings.  
GENERATOR/WELDER MAINTENANCE  
STORAGE: Store the POWER-ARC 4000 in clean,  
dry, protected areas.  
CLEANING: Blow out the generator and controls  
periodically with low pressure air. Do this at least  
once a week in particularly dirty areas.  
RECEPTACLES: Keep the electrical receptacles in  
good condition. Remove any dirt, oil, or other debris  
from their surfaces and holes.  
BRUSH REMOVAL AND REPLACEMENT: See  
Figure D.5. It’s normal for the brushes and slip rings  
to wear and darken slightly. Inspect the brushes  
when a generator overhaul is necessary. Remove  
the brushes and clean the slip rings with fine grit  
sandpaper. To reinstall the brushes, press them  
upward and slide a cable tie or wooden stick  
CABLE CONNECTIONS: Check the welding cable  
connections at the weld output terminals often. Be  
sure that the connections are always firm.  
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  
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D-5  
MAINTENANCE  
FIGURE D.6. - MAJOR COMPONENT LOCATIONS  
7
6
5
8
1
3
1 . CRADLE ASSEMBLY  
4
2. ROTOR, BLOWER, AND BEARING ASSEMBLY  
3. STATOR ASSEMBLY  
2
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  
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Section E  
TABLE OF CONTENTS  
-THEORY OF OPERATION SECTION-  
Theory of Operation .............................................................................................................Section E  
Power Supply Operation ..............................................................................................E-1 - E-3  
Engine, Excitation, Rotor and Stator ..............................................................................E-1  
Rotor Field Feedback and Auxiliary Power.....................................................................E-2  
Weld Winding and Reactor.............................................................................................E-3  
Auxiliary Power Overcurrent Protection ................................................................................E-4  
REACTOR  
OUTPUT  
TERMINALS  
STATOR  
ROTOR  
ENGINE  
MECHANICAL  
ROTATION  
ROTOR  
SLIP  
RINGS  
STATOR  
CAPACITOR  
115 AND 230VAC  
RECEPTACLES  
BRIDGE  
RHEOSTAT  
FIGURE E.1 – POWER-ARC 4000 BLOCK LOGIC DIAGRAM  
POWER-ARC 4000  
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E-1  
THEORY OF OPERATION  
FIGURE E.2 – ENGINE, ROTOR AND STATOR  
REACTOR  
OUTPUT  
TERMINALS  
STATOR  
ENGINE  
MECHANICAL  
ROTATION  
ROTOR  
ROTOR  
SLIP  
RINGS  
STATOR  
CAPACITOR  
115 AND 230VAC  
RECEPTACLES  
BRIDGE  
RHEOSTAT  
Three separate and isolated windings are incorporated  
in the stator lamination assembly. Each winding set  
has a different number of turns, producing different  
magnitudes of AC output voltages. The three windings  
are the weld winding, the auxiliary power winding and  
the field feedback winding. The field feedback wind-  
ing provides rotor current during machine operation.  
The output of the PowerArc 4000 is dependent on two  
criteria: the engine RPM and the amount of current in  
the rotor winding.  
ENGINE, EXCITATION, ROTOR  
AND STATOR  
A small DC voltage developed by the flywheel alterna-  
tor in the Briggs & Stratton engine is fed to the rotat-  
ing field coil in the rotor via a brush and slip ring con-  
figuration.  
This excitation (“flashing”) voltage  
magnetizes the rotor lamination. The rotor is mechan-  
ically coupled to the engine. The rotating magnet  
induces a voltage in the stationary windings of the  
main alternator (stator).  
NOTE: Unshaded areas of Block Logic Diagram are the subject of discussion.  
POWER-ARC 4000  
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E-2  
THEORY OF OPERATION  
FIGURE E.3 – FIELD EXCITATION AND AUXILIARY POWER  
REACTOR  
OUTPUT  
TERMINALS  
STATOR  
ENGINE  
MECHANICAL  
ROTATION  
ROTOR  
ROTOR  
SLIP  
RINGS  
STATOR  
CAPACITOR  
115 AND 230VAC  
RECEPTACLES  
BRIDGE  
RHEOSTAT  
ROTOR FIELD FEEDBACK AND  
AUXILIARY POWER  
When full field voltage is applied to the rotor and the  
engine is running at high speed (3700 RPM), a 230  
VAC voltage is developed in the stator auxiliary wind-  
ing. This winding is tapped to provide 115 VAC. The  
two voltages (115 VAC and 230 VAC) are connected to  
the appropriate receptacles and offer 4000 watts  
(total) of AC power.  
The AC voltage developed in the field winding is fed to  
the full wave bridge. The DC output of the bridge is fil-  
tered by the field capacitor and controlled by the out-  
put rheostat.  
This filtered and controlled feedback voltage is fed to  
the rotor winding via the brush and slip ring configura-  
tion. As the feedback voltage is increased or de-  
creased, the outputs of the weld and auxiliary wind-  
ings are likewise increased or decreased.  
NOTE: Unshaded areas of Block Logic Diagram are the subject of discussion.  
POWER-ARC 4000  
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E-3  
THEORY OF OPERATION  
FIGURE E.4 – WELDING OUTPUT SHADE  
REACTOR  
OUTPUT  
TERMINALS  
STATOR  
ROTOR  
ENGINE  
MECHANICAL  
ROTATION  
ROTOR  
SLIP  
RINGS  
STATOR  
CAPACITOR  
115 AND 230VAC  
RECEPTACLES  
BRIDGE  
RHEOSTAT  
WELD WINDING AND REACTOR  
AUXILIARY POWER  
OVERCURRENT PROTECTION  
The AC voltage developed in the stator weld winding  
is delivered, through the reactor, to the machine out-  
put terminals. The PowerArc 4000 provides the user  
with 125 amps of constant current AC welding for  
stick electrodes. The reactor stores energy, and this  
energy is released into the welding arc when the AC  
voltage passes through the zero point. In this manner  
the reactor enhances and stabilizes the AC welding  
arc. The reactor is designed to provide optimum  
welding characteristics when used with the recom-  
mended electrodes.  
The 4000 watt auxiliary power winding and circuitry is  
protected from an overload condition by two 20 amp  
circuit breakers. The circuit breakers are located  
below the output receptacles. They can be manually  
reset.  
NOTE: Unshaded areas of Block Logic Diagram are the subject of discussion.  
POWER-ARC 4000  
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Section F  
TABLE OF CONTENTS  
TROUBLE SHOOTING & REPAIR SECTION  
Troubleshooting & Repair Section.................................................................................Section F  
Safety Precautions.................................................................................................................F-1  
How to Use Troubleshooting Guide......................................................................................F-1  
Troubleshooting Guide...................................................................................................F1 - F-9  
Test Procedures  
Rotor Voltage Test ........................................................................................................F-10  
Rotor Resistance Test...................................................................................................F-12  
Engine Throttle Adjustment Test...................................................................................F-15  
Oscilloscope Waveforms  
Normal Open Circuit Weld Voltage Waveform .............................................................F-18  
Normal Open Circuit Weld Voltage Waveform (115 VAC Supply)................................F-19  
Typical Weld Output Waveform - Machine Loaded .....................................................F-20  
Replacement Procedures  
Brush Removal and Replacement ................................................................................F-21  
Rheostat Removal and Replacement ..........................................................................F-23  
Capacitor and Diode Bridge Removal and Replacement.............................................F-25  
Stator/Rotor Removal and Replacement (Kit S20925) .................................................F-27  
Retest After Repair ..............................................................................................................F-32  
POWER-ARC 4000  
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F-1  
TROUBLESHOOTING & REPAIR  
HOW TO USE TROUBLESHOOTING GUIDE  
WARNING  
Service and repair should be performed by only 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 locate and repair possible machine mal-  
functions. Simply follow the three-step proce-  
dure listed below.  
Step 3. PERFORM COMPONENT TESTS. The  
last column, labeled “Recommended Course of  
Action lists the most likely components that may  
have failed in your machine. It also specifies the  
appropriate test procedure to verify that the  
subject component is either good or bad. If  
there are a number of possible components,  
check the components in the order listed to  
eliminate one possibility at a time until you  
locate the cause of your problem.  
Step 1. LOCATE PROBLEM (SYMPTOM).  
Look under the column labeled “ PROBLEM  
(SYMPTOMS). This column describes possible  
symptoms that the machine may exhibit. Find  
the listing that best describes the symptom that  
the machine is exhibiting. Symptoms are  
grouped into three main categories: Welding  
Problems, Engine Problems, and Output  
Problems.  
All of the referenced test procedures referred to  
in the Troubleshooting Guide are described in  
detail at the end of this chapter. Refer to the  
Troubleshooting and Repair Table of Contents  
to locate each specific Test Procedure. All of  
the referred to test points. components, terminal  
strips, etc., can be found on the referenced  
electrical wiring diagrams and schematics.  
Refer to the Electrical Diagrams Section Table of  
Contents to locate the appropriate diagram.  
Step 2. PERFORM EXTERNAL TESTS. The  
second column, labeled “POSSIBLE AREAS OF  
MISADJUSTMENT(S)”, lists the obvious external  
possibilities that may contribute to the machine  
symptom. Perform these tests/checks in the  
order listed. In general, these tests can be con-  
ducted without removing the case wrap-around  
cover.  
CAUTION  
If for any reason you do not understand the test procedures or are unable to perform the test/repairs  
safely, contact the Lincoln Electric Service Department for electrical troubleshooting assistance before  
you proceed. Call 216-383-2531 or 1-800—833-9353.  
POWER-ARC 4000  
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F-2  
TROUBLESHOOTING & REPAIR  
TROUBLESHOOTING GUIDE  
Observe Safety Guidelines  
detailed in the beginning of this manual.  
PROBLEMS  
(SYMPTOMS)  
POSSIBLE AREAS OF  
MISADJUSTMENT(S)  
RECOMMENDED  
COURSE OF ACTION  
OUTPUT PROBLEMS  
Major physical or electrical damage Contact the Lincoln Electric Service  
is evident.  
Department at (216) 383-2531 or  
1-800-833-9353 (WELD).  
CAUTION  
If for any reason you do not understand the test procedures or are unable to perform the test/repairs safely, con-  
tact the Lincoln Electric Service Department for electrical troubleshooting assistance before you proceed. Call  
216-383-2531 or 1-800-833-9353.  
POWER-ARC 4000  
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F-3  
TROUBLESHOOTING & REPAIR  
Observe Safety Guidelines  
detailed in the beginning of this manual.  
TROUBLESHOOTING GUIDE  
PROBLEMS  
(SYMPTOMS)  
POSSIBLE AREAS OF  
MISADJUSTMENT(S)  
RECOMMENDED  
COURSE OF ACTION  
OUTPUT PROBLEMS  
No weld output and no auxiliary 1. The generator brushes may be 1. Perform the Rotor Voltage Test.  
output - engine runs normally.  
worn or faulty. See the Main-  
tenance section of this manual  
or contact your local Lincoln  
Electric Authorized Field Ser-  
vice Facility.  
2. If the rotor voltage is zero to 3  
VDC, check the flywheel alter-  
nator and associated wires  
200A, 202, and 202A for conti-  
nuity. The voltage from lead  
200A to ground should be at  
least 18 to 21 VDC at high idle  
(3700 RPM). Normal voltage is  
46 VDC. If the voltage is low or  
missing, the flywheel alternator  
may be faulty. See the wiring  
diagram.  
3. Check lead 201B (green) for  
continuity (zero ohms) to  
ground. See wiring diagram.  
4. The field capacitor (C1) or  
bridge (D1) may be faulty. Test  
or replace.  
5. Test the rheostat (R1). Normal  
resistance is 3.3 ohms. See the  
Rheostst Replacement drawing.  
6. The rotor may be faulty. Per-  
form the Rotor Resistance Test.  
CAUTION  
If for any reason you do not understand the test procedures or are unable to perform the test/repairs safely, con-  
tact the Lincoln Electric Service Department for electrical troubleshooting assistance before you proceed. Call  
216-383-2531 or 1-800-833-9353.  
POWER-ARC 4000  
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F-4  
TROUBLESHOOTING & REPAIR  
TROUBLESHOOTING GUIDE  
Observe Safety Guidelines  
detailed in the beginning of this manual.  
PROBLEMS  
(SYMPTOMS)  
POSSIBLE AREAS OF  
MISADJUSTMENT(S)  
RECOMMENDED  
COURSE OF ACTION  
OUTPUT PROBLEMS  
No weld output - auxiliary power 1. Check the open circuit voltage 1. Check continuity (zero ohms) of  
(230 - 115 VAC) operates normally  
- engine runs normally.  
(OCV) at the welder output ter-  
minals. If OCV is okay, go to  
Step 2, below.  
lead W1A (black) from output  
terminal to reactor (L1). See the  
Wiring Diagram.  
If OCV is not present at the welder 2. Check continuity (zero ohms) of  
output terminals, contact your  
local Lincoln Electric Authorized  
Field Service Facility.  
lead W2 (black) from output ter-  
minal to stator winding. See the  
Wiring Diagram.  
2. Check the welding cables, 3. Check continuity (zero ohms) of  
clamps and electrode holder for  
loose or broken connections.  
lead W1 (black) from reactor  
(L1) to stator winding. See the  
Wiring Diagram.  
4. Check reactor (L1) for continuity  
of winding. See the Wiring Dia-  
gram.  
5. Check the stator for continuity  
of winding. See the Wiring Dia-  
gram.  
6. Make certain the reactor and/or  
stator are NOT grounded. Mini-  
mum acceptable resistance to  
ground is 500 K-ohms.  
CAUTION  
If for any reason you do not understand the test procedures or are unable to perform the test/repairs safely, con-  
tact the Lincoln Electric Service Department for electrical troubleshooting assistance before you proceed. Call  
216-383-2531 or 1-800-833-9353.  
POWER-ARC 4000  
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F-5  
TROUBLESHOOTING & REPAIR  
Observe Safety Guidelines  
detailed in the beginning of this manual.  
TROUBLESHOOTING GUIDE  
PROBLEMS  
(SYMPTOMS)  
POSSIBLE AREAS OF  
MISADJUSTMENT(S)  
RECOMMENDED  
COURSE OF ACTION  
OUTPUT PROBLEMS  
No auxiliary power - welding output 1. Check circuit breakers CB1 and 1. Check the auxiliary power re-  
is normal - engine runs normally.  
CB2. Reset if tripped.  
ceptacles ands associated wires  
for loose or faulty connections.  
2. Make sure that the control rheo-  
stat (R1) is set at “GENERA- 2. Check the continuity (zero  
TOR” (maximum).  
ohms) of leads 3, 3A (black); 6,  
6A (yellow); and 5 (white) from  
the receptacles to the stator  
windings. See the Wiring Dia-  
gram.  
3. Check for loose or faulty plug at  
power receptacle.  
3. Make sure lead 5 (white) is  
grounded to the machine frame  
(zero ohms).  
4. Check for an open or grounded  
auxiliary winding in the stator, 6  
(yellow) to 3 (black). See the  
Wiring Diagram.  
CAUTION  
If for any reason you do not understand the test procedures or are unable to perform the test/repairs safely, con-  
tact the Lincoln Electric Service Department for electrical troubleshooting assistance before you proceed. Call  
216-383-2531 or 1-800-833-9353.  
POWER-ARC 4000  
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F-6  
TROUBLESHOOTING & REPAIR  
TROUBLESHOOTING GUIDE  
Observe Safety Guidelines  
detailed in the beginning of this manual.  
PROBLEMS  
(SYMPTOMS)  
POSSIBLE AREAS OF  
MISADJUSTMENT(S)  
RECOMMENDED  
COURSE OF ACTION  
OUTPUT PROBLEMS  
Low weld output and low auxiliary 1. The generator brushes may be 1. Perform the Rotor Voltage Test.  
output.  
worn. See the Maintenance  
section of this manual or contact  
your local Lincoln Electric  
Authorized Field Service Facility.  
2. If the rotor voltage is low, the  
field capacitor (C1) or bridge  
(D1) may be faulty. Test or  
replace.  
2. The engine RPM may be low.  
3. Check the rheostat (R1). Normal  
resistance is 3.3 ohm. See the  
Rheostat Replacement drawing.  
4. The rotor may be faulty. Per-  
form the Rotor Resistance Test.  
5. The engine RPM may be low.  
Perform the Engine Throttle  
Adjustment Test.  
6. If engine idle RPM is okay, the  
engine may have lost horsepow-  
er and be in need of major  
repair.  
CAUTION  
If for any reason you do not understand the test procedures or are unable to perform the test/repairs safely, con-  
tact the Lincoln Electric Service Department for electrical troubleshooting assistance before you proceed. Call  
216-383-2531 or 1-800-833-9353.  
POWER-ARC 4000  
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F-7  
TROUBLESHOOTING & REPAIR  
Observe Safety Guidelines  
detailed in the beginning of this manual.  
TROUBLESHOOTING GUIDE  
PROBLEMS  
(SYMPTOMS)  
POSSIBLE AREAS OF  
MISADJUSTMENT(S)  
RECOMMENDED  
COURSE OF ACTION  
ENGINE PROBLEMS  
Engine will not start.  
1. Make sure the piecing stop 1. Check the fuel line for breaks or  
switch is NOT touching the  
spark plug boot.  
obstructions. Replace the fuel  
filter. DO NOT RUN THE EN-  
GINE WITHOUT AN IN-LINE  
FUEL FILTER.  
2. Check spark plug boot and wire  
for loose or faulty connection.  
2. The spark plug may be faulty.  
Replace.  
3. Make sure that the fuel shutoff  
valve is in the farthest upward  
position.  
3. Service the engine as outlined  
in the Maintenance section of  
this manual.  
4. Make certain that the engine  
has adequate fuel and oil.  
4. The engine magneto may be  
5. Adjust the choke to prevent car-  
buretor flooding.  
faulty.  
Consult Briggs  
&
Stratton owner’s manual.  
6. The recoil starter may not be  
engaged with the engine. gen-  
tly hit the blower housing and/or  
pull the rope to its fully extend-  
ed position and rapidly wiggle it.  
Repeat until the clutch engages  
with the engine shaft and resis-  
tance is felt.  
5. The engine may be faulty.  
Replace.  
CAUTION  
If for any reason you do not understand the test procedures or are unable to perform the test/repairs safely, con-  
tact the Lincoln Electric Service Department for electrical troubleshooting assistance before you proceed. Call  
216-383-2531 or 1-800-833-9353.  
POWER-ARC 4000  
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F-8  
TROUBLESHOOTING & REPAIR  
TROUBLESHOOTING GUIDE  
Observe Safety Guidelines  
detailed in the beginning of this manual.  
PROBLEMS  
(SYMPTOMS)  
POSSIBLE AREAS OF  
MISADJUSTMENT(S)  
RECOMMENDED  
COURSE OF ACTION  
ENGINE PROBLEMS  
Engine will not stop running.  
1. The piercing stop switch may 1. Be sure the piercing stop switch  
not be contacting the spark  
plug. Make certain that the  
pointed end of the lever firmly  
contacts the spark plug tip.  
is securely mounted to the  
engine.  
Engine runs erratically or stops run- 1. Check the spark plug boot and 1. The engine may require service  
ning.  
wire for loose or faulty connec-  
tion.  
to the head or carburetor.  
2. The spark plug may be faulty.  
Replace.  
3. The fuel and air mixture may be  
out of adjustment. Consult  
Briggs & Stratton owner’s man-  
ual.  
4. The fuel supply may be con-  
taminated with water.  
Engine sputters but will not start.  
1. The spark plug may be faulty.  
Consult Briggs & Stratton owner’s  
manual.  
2. The fuel supply may be contam-  
inated with water.  
3. The air filter may be clogged.  
Replace.  
4. The fuel and air mixture may be  
out of adjustment.  
CAUTION  
If for any reason you do not understand the test procedures or are unable to perform the test/repairs safely, con-  
tact the Lincoln Electric Service Department for electrical troubleshooting assistance before you proceed. Call  
216-383-2531 or 1-800-833-9353.  
POWER-ARC 4000  
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F-9  
TROUBLESHOOTING & REPAIR  
Observe Safety Guidelines  
detailed in the beginning of this manual.  
TROUBLESHOOTING GUIDE  
PROBLEMS  
(SYMPTOMS)  
POSSIBLE AREAS OF  
MISADJUSTMENT(S)  
RECOMMENDED  
COURSE OF ACTION  
WELDING PROBLEMS  
The welding arc is “cold.” The 1. Check for loose or faulty con- 1. Check for the correct open cir-  
engine runs normally (3700 RPM,  
no load). Auxiliary power is func-  
tioning normally.  
nections at the weld output  
terminals and welding cable  
connections.  
cuit voltage (OCV) at the welder  
output terminals – 62 VAC is  
normal.  
2. The welding cable may be too  
long or coiled, causing an  
excessive voltage drop.  
If the correct voltage is present  
at the output terminals, check  
for loose connections on the  
heavy current-carrying leads  
inside the POWER-ARC 4000.  
See the Wiring Diagram.  
2. If the OCV is low at the welder  
output  
terminals,  
perform  
Engine Throttle Adjustment  
Test.  
3. Check for shorted or grounded  
windings in the reactor (L1) and  
also in the main stator.  
See the Wiring Diagram.  
CAUTION  
If for any reason you do not understand the test procedures or are unable to perform the test/repairs safely, con-  
tact the Lincoln Electric Service Department for electrical troubleshooting assistance before you proceed. Call  
216-383-2531 or 1-800-833-9353.  
POWER-ARC 4000  
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F-10  
TROUBLESHOOTING & REPAIR  
ROTOR VOLTAGE TEST  
WARNING  
Service and repair should be performed by only Lincoln Electric factory trained personnel.  
Unauthorized repairs performed on this equipment may result in danger to the technician or  
machine operator and will invalidate your factory warranty. For your safety and to avoid elec-  
trical shock, please observe all safety notes and precautions detailed throughout this manu-  
al.  
If for any reason you do not understand the test procedures or are unable to perform the  
test/repairs safely, contact the Lincoln Electric Service Department for electrical trou-  
bleshooting assistance before you proceed. Call 216-383-2531 or 1-800—833-9353  
(WELD).  
TEST DESCRIPTION  
This test will determine if the correct DC voltage is being applied to the rotor at maximum  
engine speed (3700 RPM). This information will aid the technician in determining if the gen-  
erator field is operating properly.  
MATERIALS NEEDED  
Volt/Ohmmeter  
5/16” Nut driver  
Wiring Diagram  
POWER-ARC 4000  
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F-11  
TROUBLESHOOTING & REPAIR  
ROTOR VOLTAGE TEST (continued)  
FIGURE F.1 - LOCATION OF LEAD 200A FOR ROTOR VOLTAGE TEST  
GROUND STUD  
LEAD 200A  
CONNECTION  
OUTPUT PANEL  
TEST PROCEDURE  
1. With the 5/16” nut driver, remove the 4  
sheet metal screws that hold the top cover  
to the control box. Remove the top cover.  
5. Check the voltage reading on the  
volt/ohmmeter. It should read 45 - 48  
VDC.  
2. Start the machine and run it at high idle.  
Set the output control (rheostat) at the  
MAXIMUM or GENERATOR setting.  
6. If the voltage is low or not present, the  
generator field circuit is not functioning  
correctly.  
Proceed with the Rotor  
Resistance Test. C1, R1, or D1 may also  
be faulty.  
3. Set the volt/ohmmeter at the DC position.  
4. Place the positive probe on lead 200A  
(Blue and Brown wires joined together)  
where it connects at the back of the rheo-  
stat. See Figure F.1 for location. Place  
the negative probe on the machine ground  
stud or any other good, unpainted ground.  
7. If rotor voltage is correct, the generator  
field is okay. Replace the top cover on the  
control box. Tighten the 4 sheet metal  
screws with the 5/16” nut driver.  
POWER-ARC 4000  
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F-12  
TROUBLESHOOTING & REPAIR  
ROTOR RESISTANCE TEST  
WARNING  
Service and repair should be performed by only Lincoln Electric factory trained personnel.  
Unauthorized repairs performed on this equipment may result in danger to the technician or  
machine operator and will invalidate your factory warranty. For your safety and to avoid elec-  
trical shock, please observe all safety notes and precautions detailed throughout this manu-  
al.  
If for any reason you do not understand the test procedures or are unable to perform the  
test/repairs safely, contact the Lincoln Electric Service Department for electrical trou-  
bleshooting assistance before you proceed. Call 216-383-2531 or 1-800—833-9353 (WELD).  
TEST DESCRIPTION  
This test will determine if there is a shorted winding in the rotor or if the rotor is grounded.  
MATERIALS NEEDED  
Volt/Ohmmeter  
1/4” Nut driver  
Small slot head screw driver  
Wiring Diagram  
POWER-ARC 4000  
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F-13  
TROUBLESHOOTING & REPAIR  
ROTOR RESISTANCE TEST (continued)  
FIGURE F.2  
LOCATION OF ROTOR SLIP RINGS - BRUSH HOLDER ASSEMBLY REMOVED  
SLIP  
RINGS  
TEST PROCEDURE  
1. Conduct the test with the gasoline engine  
OFF.  
7. Measure the resistance across the rotor  
slip rings.  
2. Remove the spark plug wire to prevent  
accidental engine kickback or starting.  
A. Set the ohmmeter on the low scale  
(X1).  
3. Isolate the rotor electrically by removing  
the generator brushes. Refer to Figure F.2  
as you perform the remaining steps.  
B. Place one meter probe on one of the  
rotor slip rings. Place the other  
probe on the other slip ring.  
4. Open the brush holder assembly cover.  
Squeeze the 2 tabs and depress the cover  
at the top with a screw driver or your fin-  
gernail. The cover will drop open on its  
bottom hinge.  
C. Check the resistance across the slip  
rings. It should read 7 - 8 ohms.  
8. Measure the resistance to ground.  
A.. Set the ohmmeter on the high scale  
(X100,000).  
5. With the 1/4” nut driver, remove the 2  
screws that hold the brush holder assem-  
bly in place.  
B. Place one probe on either of the slip  
rings. Place the other probe on any  
good, unpainted ground. Use the  
ground stud or the rotor thru-bolt.  
6. Slide the brush holder assembly out and  
lay it aside, held by the 2 wires attached.  
C. Check the resistance. It should read  
very high, at least .5 megohm  
(500,000 ohms).  
If the resistance checks meet the specifica-  
tions, then the rotor is okay.  
POWER-ARC 4000  
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F-14  
TROUBLESHOOTING & REPAIR  
ROTOR RESISTANCE TEST (continued)  
FIGURE F.3 - BRUSHES RETAINED WITH CABLE TIE  
CABLE  
TIE  
BRUSHES  
9. Reinstall the brush holder assembly after  
the test. Depress the spring-loaded  
brushes into the holder and slip a suitable  
non-metallic, fairly stiff retainer through  
the slots at the top and bottom of the  
holder. A cable tie works well; see Figure  
F.3. This will hold the brushes up so that  
you can easily install the holder.  
10. Slip the holder into position in the gener-  
ator end bracket. Be careful not to  
loosen the 2 attached wires.  
11. Reinstall and tighten the 2 screws with  
the 1/4” nut driver.  
12. Slowly remove the non-metallic retainer  
from the brush holder and let the brush-  
es snap back against the slip rings.  
13. Snap the brush holder cover back into  
position.  
POWER-ARC 4000  
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F-15  
TROUBLESHOOTING & REPAIR  
ENGINE THROTTLE ADJUSTMENT TEST  
WARNING  
Service and repair should be performed by only Lincoln Electric factory trained personnel.  
Unauthorized repairs performed on this equipment may result in danger to the technician or  
machine operator and will invalidate your factory warranty. For your safety and to avoid elec-  
trical shock, please observe all safety notes and precautions detailed throughout this manu-  
al.  
If for any reason you do not understand the test procedures or are unable to perform the  
test/repairs safely, contact the Lincoln Electric Service Department for electrical trou-  
bleshooting assistance before you proceed. Call 216-383-2531 or 1-800—833-9353  
(WELD).  
TEST DESCRIPTION  
If the machine output is low, this test will determine whether the gasoline engine high idle  
speed is set for the correct maximum RPM.  
MATERIALS NEEDED  
7/16” open end or box wrench  
Frequency counter or strobe-tach  
Black or red marking pencil  
POWER-ARC 4000  
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F-16  
TROUBLESHOOTING & REPAIR  
ENGINE THROTTLE ADJUSTMENT TEST (continued)  
FIGURE F.4 - BLOWER PADDLE MARKED FOR STROBE-TACH METHOD  
MARK  
Frequency Counter Method:  
TEST PROCEDURE  
1. Plug the frequency counter into one of the  
115 VAC auxiliary receptacles.  
This test can be conducted by any of three  
methods.  
2. Start the engine and check the frequency  
counter. At the proper RPM (3700), the  
counter should read 61.7 Hz.  
Strobe-tach Method:  
1. Stop the engine and remove the spark plug  
wire to prevent accidental kickback or  
starting.  
3. Use the 7/16 wrench to turn in the spring-  
loaded adjustment nut. Increase the high  
idle speed until the frequency counter  
reads 61.7 Hz. See Figure F.5 for location  
of the adjustment nut.  
2. With the black or red marking pencil, place  
a mark on one of the blower paddles,  
which can be reached through the vent  
slots in the end bracket. See Figure F.4.  
Oscilloscope Method:  
3. Connect the strobe-tach according the  
manufacturer’s instructions.  
1. Connect the oscilloscope according to the  
manufacturer’s instructions. At 3700 RPM,  
the waveform should exhibit a period of  
16.2 milliseconds. Refer to the NORMAL  
OPEN CIRCUIT VOLTAGE WAVEFORM  
(115 VAC SUPPLY) HIGH IDLE - NO LOAD  
in this section of the manual.  
4. Reconnect the spark plug wire and start  
the engine. Direct the strobe-tach light on  
the blower paddle and synchronize it to the  
rotating mark. The tach should read 3700  
RPM.  
5. Use the 7/16 wrench to turn in the spring-  
loaded adjustment nut. Increase the high  
idle speed until the tach reads 3700 RPM.  
See Figure F.5 for location of the adjust-  
ment nut.  
POWER-ARC 4000  
12/95  
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F-17  
TROUBLESHOOTING & REPAIR  
ENGINE THROTTLE ADJUSTMENT TEST (continued)  
2. Use the 7/16 wrench to turn in the spring-loaded  
adjustment nut. Increase the high idle speed to  
adjust the waveform period to 16.2 milliseconds.  
See Figure F.5 for location of the adjustment nut.  
FIGURE F.5 - LOCATION OF ENGINE THROTTLE ADJUSTMENT NUT  
NUT  
POWER-ARC 4000  
12/95  
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F-18  
TROUBLESHOOTING & REPAIR  
NORMAL OPEN CIRCUIT WELD VOLTAGE WAVEFORM  
HIGH IDLE – NO LOAD  
CH1  
0 volts  
5 ms  
50 volts  
This is the typical AC output voltage  
generated from a properly operating  
machine. Note that each vertical  
division represents 50 volts and that  
each horizontal division represents 5  
milliseconds in time.  
Note: Scope probes connected at  
machine output terminals.  
SCOPE SETTINGS  
Volts/Div ....................50V/Div.  
Horizontal Sweep ....5 ms/Div.  
Coupling ............................DC  
Trigger.........................Internal  
POWER-ARC 4000  
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F-19  
TROUBLESHOOTING & REPAIR  
NORMAL OPEN CIRCUIT VOLTAGE WAVEFORM (115 VAC SUPPLY)  
HIGH IDLE – NO LOAD  
1 Period = 16.2 ms @ 3700 rpm  
CH1  
0 volts  
5 ms  
20 volts  
This is the typical AC output voltage  
generated from a properly operating  
machine. Note that each vertical  
division represents 50 volts and that  
each horizontal division represents 5  
milliseconds in time.  
Note: Scope probes connected at  
machine 115 VAC receptacle.  
SCOPE SETTINGS  
Volts/Div ....................50V/Div.  
Horizontal Sweep ....5 ms/Div.  
Coupling ............................DC  
Trigger.........................Internal  
POWER-ARC 4000  
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F-20  
TROUBLESHOOTING & REPAIR  
TYPICAL WELD OUTPUT WAVEFORM  
MACHINE LOADED  
CH1  
0 volts  
5 ms  
20 volts  
MACHINE LOADED TO 125 AMPS AT 23 VAC  
This is the typical AC output voltage  
generated from a properly operating  
machine. Note that each vertical  
division represents 20 volts and that  
each horizontal division represents 5  
milliseconds in time. The mahine  
was loaded with a resistance grid  
bank.  
Note: Scope probes connected at  
machine output terminals.  
SCOPE SETTINGS  
Volts/Div ....................20V/Div.  
Horizontal Sweep ....5 ms/Div.  
Coupling ............................DC  
Trigger.........................Internal  
POWER-ARC 4000  
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F-21  
TROUBLESHOOTING & REPAIR  
BRUSH REMOVAL AND REPLACEMENT  
WARNING  
Service and repair should be performed by only Lincoln Electric factory trained person-  
nel. Unauthorized repairs performed on this equipment may result in danger to the tech-  
nician or 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.  
If for any reason you do not understand the test procedures or are unable to perform the  
test/repairs safely, contact the Lincoln Electric Service Department for electrical trou-  
bleshooting assistance before you proceed. Call 216-383-2531 or 1-800—833-9353  
(WELD).  
DESCRIPTION  
The following procedure will aid the technician in accessing the generator brushes for  
maintenance or replacement.  
MATERIALS NEEDED  
Small slot head screw driver  
1/4” Nut driver  
Needle nose pliers  
POWER-ARC 4000  
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F-22  
TROUBLESHOOTING & REPAIR  
BRUSH REMOVAL AND REPLACEMENT (continued)  
FIGURE F.6 - BRUSHES RETAINED WITH CABLE TIE  
CABLE  
TIE  
BRUSHES  
PROCEDURE  
1. Remove the spark plug wire.  
5. To change the brushes, use the slot head  
screw driver to pop off the plastic retainer  
on the back of the brush holder assembly.  
2. Open the brush holder assembly cover.  
Squeeze the 2 tabs and depress the cover  
at the top with a screw driver or your fin-  
gernail. The cover will drop open on its  
bottom hinge.  
6. Remove the old brush assemblies and  
insert the new ones. One corner of the ter-  
minal clip is beveled so that the brush can  
go in only one way.  
3. With the 1/4” nut driver, remove the 2  
screws that hold the brush holder assem-  
bly in place.  
7. Snap the plastic retainer back onto the  
brush holder. The brushes may need some  
repositioning; wiggle them slightly to help  
them seat properly on the slip rings.  
4. With the needle nose pliers, gently remove  
the black and the red wires.  
Note: The red wire is inboard. “RED” is  
marked on the brush holder beside the termi-  
nal for the red wire.  
POWER-ARC 4000  
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F-23  
TROUBLESHOOTING & REPAIR  
BRUSH REMOVAL AND REPLACEMENT (continued)  
PROCEDURE (continued)  
11. Reinstall and tighten the 2 screws with the  
8. To reinstall the brush holder assembly,  
depress the spring-loaded brushes into  
the holder and slip a suitable non-metal-  
lic, fairly stiff retainer through the slots at  
the top and bottom of the holder. A cable  
tie works well; see Figure F.6. This will  
hold the brushes up so that you can eas-  
ily install the holder.  
1/4” nut driver.  
12. Slowly remove the non-metallic retainer  
from the brush holder and let the brushes  
snap back against the slip rings.  
13. Check the wire connections or clearance  
and tightness.  
14. Snap the brush holder cover back into  
position.  
9. With the needle nose pliers, reinstall the  
red and the black wires to the appropriate  
terminals on the brushes. The red wire is  
inboard.  
10. Slip the holder into position in the genera-  
tor end bracket. Be careful not to loosen  
the 2 attached wires.  
POWER-ARC 4000  
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F-24  
TROUBLESHOOTING & REPAIR  
RHEOSTAT REMOVAL AND REPLACEMENT  
WARNING  
Service and repair should be performed by only Lincoln Electric factory trained personnel.  
Unauthorized repairs performed on this equipment may result in danger to the technician or  
machine operator and will invalidate your factory warranty. For your safety and to avoid elec-  
trical shock, please observe all safety notes and precautions detailed throughout this manu-  
al.  
If for any reason you do not understand the test procedures or are unable to perform the  
test/repairs safely, contact the Lincoln Electric Service Department for electrical trou-  
bleshooting assistance before you proceed. Call 216-383-2531 or 1-800—833-9353 (WELD).  
DESCRIPTION  
The following procedure will aid the technician in accessing and removing the output control  
rheostat for maintenance or replacement.  
MATERIALS NEEDED  
5/16” Nut driver  
Small slot head screw driver  
9/16” Open or box end wrench  
5/16” Open or box end wrench  
Needle nose pliers  
Wiring Diagram  
POWER-ARC 4000  
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F-25  
TROUBLESHOOTING & REPAIR  
RHEOSTAT REMOVAL AND REPLACEMENT  
FIGURE F.7 - RHEOSTAT REMOVAL  
See Figure F.7 for steps 3 - 9.  
PROCEDURE  
1. Remove the spark plug wire.  
7. To reinstall the rheostat, replace each of  
the brass screws. Place a shake-proof  
star washer under the head, insert the  
screw into the rheostat and tighten down  
one nut. Replace the appropriate wires  
and tighten down the second nut. Again,  
support the terminals as you turn the  
wrench to avoid ripping the terminals  
from their foundations.  
2. With the 5/16” nut driver, remove the 4  
sheet metal screws that hold the top cover  
to the control box. Remove the top cover.  
3. With the small slot head screw driver,  
loosen the screw that holds the knob to  
the rheostat shaft. The shaft has a flat for  
locating the knob at reassembly.  
4. With a 9/16” open or box end wrench,  
remove the nut that holds the rheostat to  
the control panel. Support the rheostat  
with your hand as you turn the nut. There  
is a shake-proof washer under the nut.  
8. Reassemble the rheostat to the front of  
the control panel. Line up the locating  
tab on the rheostat with the slot on the  
control panel hole.  
9. Reassemble the shake-proof star washer  
and nut and tighten securely with the  
9/16” wrench.  
5. Pull the rheostat back out of the control  
panel and lay it out on its wires to loosen  
the nuts that hold them.  
10. Locate the flat spot on the shaft, line up  
the knob locking screw, push the knob  
onto the shaft and tighten the screw with  
the small slot head screw driver.  
6. With the 5/16” open or box end wrench,  
remove the brass nuts from the wire termi-  
nals. Support the terminals as you turn  
the wrench to avoid ripping the terminals  
from their foundations. Note the wire  
locations for reassembly.  
11. Check the rheostat knob for proper rota-  
tion, minimum to maximum.  
12. Replace the top cover of the control box  
and tighten the 4 sheet metal screws with  
the 5/16” nut driver.  
Note: The brass screws are double-nutted  
with a shake-proof star washer under the  
screw head.  
POWER-ARC 4000  
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F-26  
TROUBLESHOOTING & REPAIR  
CAPACITOR AND/OR DIODE BRIDGE REMOVAL AND  
REPLACEMENT  
WARNING  
Service and repair should be performed by only Lincoln Electric factory trained personnel.  
Unauthorized repairs performed on this equipment may result in danger to the technician or  
machine operator and will invalidate your factory warranty. For your safety and to avoid elec-  
trical shock, please observe all safety notes and precautions detailed throughout this manu-  
al.  
If for any reason you do not understand the test procedures or are unable to perform the  
test/repairs safely, contact the Lincoln Electric Service Department for electrical trou-  
bleshooting assistance before you proceed. Call 216-383-2531 or 1-800—833-9353  
(WELD).  
DESCRIPTION  
The following procedure will aid the technician in accessing and removing the capacitor and  
diode bridge for maintenance or replacement of either component.  
MATERIALS NEEDED  
5/16” Nut driver  
Jumper wire with alligator clips on each end for discharging the field capacitor  
Slot head screw driver  
Needle nose pliers  
Wiring Diagram  
POWER-ARC 4000  
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F-27  
TROUBLESHOOTING & REPAIR  
CAPACITOR AND/OR DIODE BRIDGE REMOVAL AND REPLACEMENT  
(continued)  
FIGURE F.8 - DIODE BRIDGE LOCATION AND DISCHARGING THE FIELD CAPACITOR  
DIODE  
BRIDGE  
JUMPER  
CAPACITOR  
PROCEDURE - CAPACITOR  
REMOVAL AND REPLACEMENT  
1. Remove the engine spark plug wire.  
5. Snap the capacitor out of the assembly.  
2. With the 5/16” nut driver, remove the 4  
sheet metal screws that hold the top cover  
to the control box. Remove the top cover.  
6. Loosen the two screws on the top of the  
capacitor. Lead 202A (Red) attaches to  
the positive (+) terminal. Leads 201 and  
201A (both Black) attach to the negative (-  
) terminal.  
3. Discharge the field capacitor by connect-  
ing the jumper wire clips on the black and  
the red wire terminals on the top of the  
capacitor. See Figure F.8 for location.  
Leave the clips on for at least 5 seconds,  
then remove.  
7. To replace the capacitor, reattach the  
leads to their respective terminals (202A  
Red to positive (+); 201 and 201A Black to  
negative (-) and tighten the screws secure-  
ly. Snap the capacitor back into the mold-  
ed plastic holder and slide the holder back  
into position in the panel. Replace the top  
cover of the control box and tighten down  
the 4 sheet metal screws with the 5/16” nut  
driver.  
4. Both the capacitor and the diode bridge  
are mounted in a molded plastic holder.  
To remove it, pull out on the top of the  
holder, then slide it upward.  
POWER-ARC 4000  
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F-28  
TROUBLESHOOTING & REPAIR  
CAPACITOR AND/OR DIODE BRIDGE REMOVAL AND REPLACEMENT  
(continued)  
Lead 201 (Black) and 201B (Green) are pig-  
gybacked on the negative (-) terminal, which will  
always be located diagonally across from the  
positive (+) terminal.  
PROCEDURE - DIODE BRIDGE  
REMOVAL AND REPLACEMENT  
1. To remove the diode bridge, first you will  
have to remove the field capacitor. Follow  
Steps 1 - 5 on capacitor removal and  
replacement procedure.  
The 2 Blue leads are the AC side of the  
bridge and attach to the other two corners.  
Either lead can go on either terminal.  
2. Depress the retainer clip on the molded  
plastic holder and slide the diode bridge  
out.  
5. Slide the bridge back into the molded plas-  
tic holder until the retainer clip snaps it  
securely in place. Snap the capacitor back  
into the holder and then slide the unit back  
into position in the panel.  
3. With the needle nose pliers, gently remove  
the 4 wires from the diode bridge.  
4. Replace the wires to their appropriate loca-  
tions on the new diode bridge:  
6. Check that the leads are not grounded and  
for clearance and tightness.  
Lead 200 (Red) attaches to the positive (+)  
terminal. Depending on the bridge used, this  
corner may be beveled and/or marked with a +  
sign.  
7. Replace the top cover of the control box  
and tighten the 4 sheet metal screws with  
the 5/16” nut driver.  
POWER-ARC 4000  
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F-29  
TROUBLESHOOTING & REPAIR  
STATOR/ROTOR REMOVAL AND REPLACEMENT  
WARNING  
Service and repair should be performed by only Lincoln Electric factory trained personnel.  
Unauthorized repairs performed on this equipment may result in danger to the technician or  
machine operator and will invalidate your factory warranty. For your safety and to avoid elec-  
trical shock, please observe all safety notes and precautions detailed throughout this manu-  
al.  
If for any reason you do not understand the test procedures or are unable to perform the  
test/repairs safely, contact the Lincoln Electric Service Department for electrical trou-  
bleshooting assistance before you proceed. Call 216-383-2531 or 1-800—833-9353  
(WELD).  
DESCRIPTION  
The following procedure will aid the technician in removing the stator and/or rotor for main-  
tenance or replacement of either component.  
MATERIALS NEEDED  
Lincoln Electric Rotor Removal Kit (S20925) - FOR ROTOR REMOVAL ONLY  
5/16” nut driver  
1/2” socket wrench  
6” socket extension  
Slot head screw driver  
5/8” socket wrench  
7/16” socket wrench  
7/16” open or box end wrench  
3/4” socket or box end wrench  
1/2” socket or box end wrench  
Needle nose pliers  
Diagonal cutters  
Torque wrench (ft lbs)  
Babbitt, leather, or wooden mallet  
Volt/ohmmeter  
12” (long) feeler gauge (.010)  
INSTRUCTIONS  
For stator removal only, follow steps 1 -17 under STATOR REMOVAL PROCEDURE. For  
reassembly of stator, go to REASSEMBLY PROCEDURE steps 3 - 18.  
For rotor removal, follow the STATOR REMOVAL PROCEDURE, ROTOR REMOVAL PRO-  
CEDURE, and REASSEMBLY PROCEDURE.  
POWER-ARC 4000  
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F-30  
TROUBLESHOOTING & REPAIR  
STATOR/ROTOR REMOVAL AND REPLACEMENT (continued)  
into the output terminal hole loosely for  
reassembly. Set the control panel back on  
the control box and hold it in place with 1  
sheet metal screw in each side.  
STATOR REMOVAL PROCEDURE  
1. Remove engine spark plug wire to prevent  
accidental kickback or starting.  
2. With the 5/16” nut driver, remove the 4  
sheet metal screws that hold the top cover  
to the control box. Remove the top cover.  
8. Remove the brush holder assembly. Open  
the brush holder assembly cover. Squeeze  
the 2 tabs and depress the cover at the top  
with a screw driver or your fingernail. The  
cover will drop open on its bottom hinge.  
With the 1/4” nut driver, remove the 2  
screws that hold the brush holder assembly  
in place. With the needle nose pliers, gently  
remove the black and the red wires. Set the  
brush holder aside. Pull the wires up into  
the control box.  
3. Remove the 4 1/2” nuts and washers that  
anchor the control box to the stator frame.  
Two of the nuts also anchor the reactor.  
The reactor must be moved over to access  
the front left hand nut anchoring the control  
box. Be careful not to drop the washers into  
the machine.  
4. Lift up the control box and unscrew the 4  
rubber mounts. Set the control box onto the  
stator frame for the moment.  
9. Pull apart the molex coupling for the engine  
flywheel alternator. This is the single wire on  
the left side of the machine, running from  
the engine to the stator.  
5. Pull apart the molex coupling that connects  
the stator to the wiring harness.  
10. Disconnect lead W1 (Black) that connects  
to the reactor lead. Replace the nut, split-  
ring lock washer, and flat washer finger  
tight on the bolt for reassembly.  
6. With the slot head screw driver, remove the  
6 sheet metal screws that hold the control  
panel to the control box - 3 on each side.  
You may need to use the 5/16” end wrench  
on the engine side because of limited clear-  
ance. Pull the panel away from the control  
box.  
11. Slide the control panel and box assembly  
out of the machine cradle. Carefully pull  
the wire leads down through the box as  
you remove it. Note that the reactor is  
loose inside the box and may slide around.  
7. With the 9/16” open end wrench, remove  
lead W2 (Black) from the output terminal.  
See Figure F.9 for location. With the diago-  
nal cutters, cut the cable tie that holds the  
two output leads together. Pull lead W2  
back out of the way; screw the bolt back  
FIGURE F.9 - OUTPUT LEAD LOCATION  
TIE WRAP  
OUTPUT  
TERMINALS  
POWER-ARC 4000  
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F-31  
TROUBLESHOOTING & REPAIR  
STATOR/ROTOR REMOVAL AND REPLACEMENT (continued)  
12. Slide a short length of 2 X 4 under the  
engine to support it when the stator is  
removed.  
15. Lift up the stator and slide out the sup-  
port bracket. The engine will now rest on  
the 2 X 4.  
13. With the 1/2” socket wrench, remove the  
2 nuts that hold the stator end bracket  
support. See Figure F.10 for location.  
There are 2 split-ring lock washers and 2  
flat washers along with the nuts.  
16. With the babbitt/leather/wooden mallet,  
tap off the end bracket. Alternate sides  
as you tap; watch the bearing to judge  
the amount of movement you’re getting.  
17. Once the end bracket is off, carefully pull  
off the stator. IMPROPER HANDLING  
OF THE STATOR CAN RESULT IN  
SHORTED WINDINGS AND/OR LOST  
OUTPUT.  
14. With the 7/16” socket and 7/16” end  
wrench, remove the 4 thru-bolts for the  
generator assembly. See Figure F.10.  
Note the green grounding wire on the top  
right hand bolt. It has a flat washer. All 4  
bolts have a split-ring lock washer under  
the head and a shake-proof star washer  
on the nut side. The bolts must point  
toward the engine for reassembly.  
FIGURE F.10 – STATOR END BRACKET SUPPORT AND THRU-BOLTS  
THRU-  
BOLTS  
THRU-  
BOLTS  
SUPPORT  
NUTS  
POWER-ARC 4000  
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F-32  
TROUBLESHOOTING & REPAIR  
STATOR/ROTOR REMOVAL AND REPLACEMENT (continued)  
FIGURE F.11 - ROTOR WITH STATOR REMOVED  
ROTOR  
THRU-BOLT  
wrench with the mallet until the rotor pops  
off the engine crankshaft.  
ROTOR REMOVAL PROCEDURE  
1. To remove the rotor, double check that the  
spark plug wire is disconnected. You will  
be turning the rotor during this procedure,  
and this could accidentally cause engine  
kickback.  
6. Slide the rotor and blower (press-fitted to  
the rotor) the rest of the way off the crank-  
shaft.  
REASSEMBLY PROCEDURE  
2. With an impact wrench, remove the rotor  
thru-bolt. See Figure F.11. If an impact  
wrench is not available, use the 1/2” box  
wrench. Hold the rotor with one hand and  
shock the wrench with the mallet to loosen  
the thru-bolt. The thru-bolt has a star  
washer and lock washer, beveled to con-  
form to the rotor shaft. Pull out the thru-  
bolt.  
1. ubricate the tapered engine crankshaft.  
Slide the rotor onto the shaft.  
2. Coat the rotor thru-bolt threads with Lincoln  
E177-R retaining compound (Locktite( 277).  
Place the beveled lock washers onto the  
thru-bolt and insert it into the rotor shaft.  
Hold the rotor and tighten the thru-bolt to  
22 - 25 ft lbs.  
3. Install the long thru-bolt supplied with  
Lincoln Electric Rotor Removal Kit S20925.  
The slot head must face out. Screw in the  
bolt with the slot head screw driver until the  
bolt bottoms out on the engine crankshaft,  
about 3/4”.  
3. Carefully install the stator, with the leads at  
the 1 o’ clock position. IMPROPER HAN-  
DLING OF THE STATOR CAN RESULT IN  
SHORTED WINDINGS AND/OR LOST  
OUTPUT.  
4. Install the end bracket. Slide it on and  
install the two top thru-bolts loosely to hold  
the end bracket for the next step.  
4. Turning it counterclockwise, screw in the  
reverse thread bolt from the kit into the rotor  
shaft until it bottoms out on the thru-bolt.  
5. Install the end bracket support.  
5. With an impact wrench, tighten the reverse  
thread bolt until the rotor pops off the  
engine crankshaft. If an impact wrench is  
not available, use the 1/2” box wrench.  
Hold the rotor with one hand and shock the  
POWER-ARC 4000  
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F-33  
TROUBLESHOOTING & REPAIR  
STATOR/ROTOR REMOVAL AND REPLACEMENT (continued)  
6. Install the bottom two end bracket thru-  
bolts.  
10. Reinstall the brush holder assembly.  
Refer to the topic “BRUSH REMOVAL  
AND REPLACEMENT” in this section of  
the manual.  
Note: The flat washer goes on the top right  
hand thru-bolt for the green ground wire.  
11. Slide the control box back into place. Pull  
the stator and ground wire up through.  
7. Tap the end bracket with the mallet as  
necessary to position it. Tighten the bolts  
to 22 - 25 ft lbs. Alternate tightening in  
order to pull the assembly together even-  
ly. As you tighten, look through the brush  
housing access door and watch the bear-  
ing to judge end bracket movement and  
alignment.  
12. Remove the control panel (2 screws) and  
reconnect the output terminal leads (W1,  
W2). Install a new cable tie to hold the  
leads together. Reconnect the stator  
wire/harness molex coupling. Install the 6  
screws that hold the control panel to the  
box.  
8. Check the rotor-stator air gap with the  
long .010 feeler gauge. The measurement  
is taken through the brush holder access  
door; see Figure F12. Turn the engine  
with the recoil starter rope slightly so that  
the rotor “iron” is up to take the measure-  
ment. (The rotor has two flat sides, which  
are not measured for air gap.) Slide in the  
gauge. Then rotate the shaft 180 degrees  
and measure again. If the gauge does not  
clear, loosen the four end bracket thru-  
bolts, reposition the end bracket, retight-  
en the bolts, and recheck the air gap.  
Repeat until the proper .010 minimum air  
gap is achieved.  
13. Connect the engine flywheel alternator  
coupling.  
14. Lift the control box and screw in the rub-  
ber mountings. Set the control box onto  
the mountings.  
15. Install the front left hand washer and nut  
that anchors the control box to the stator  
frame. Position the reactor and install the  
remaining washers and nuts.  
16. Check all terminal connections for clear-  
ance, grounding, and tightness.  
17. Replace the top cover to the control box  
and tighten the 4 nuts.  
9. Tighten the end bracket support nuts and  
lock washers. Remove the 2 X 4 engine  
support.  
18. Conduct the “RETEST AFTER REPAIR”  
procedure, the following topic in this sec-  
tion of the manual.  
FIGURE F.12 - CHECKING ROTOR-STATOR AIR GAP  
FEELER GAUGE  
STATOR  
ROTOR  
POWER-ARC 4000  
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F-34  
TROUBLESHOOTING & REPAIR  
RETEST AFTER REPAIR  
Retest a machine:  
• If it is rejected under test for any reason that requires you to remove any mechanical part which could affect the  
machine’s electrical characteristics.  
OR  
• If you repair or replace any electrical components.  
ENGINE OUTPUT  
No Load RPM  
3725  
Load RPM  
3650  
Maximum Speed  
Minimum Speed  
3675  
3400  
WELDER/GENERATOR OUTPUT1  
Output Control  
Field Volts  
Field Amps  
Open Circuit  
Volts  
Load Volts  
Load Amps  
Maximum  
Minimum  
43 - 49  
–
4.8 - 5.8  
–
60 - 63  
55 - 60  
12 - 25  
14 - 27  
120 - 125  
75 - 85  
AUXILIARY POWER RECEPTACLE OUTPUT1  
230 Volt Receptacle  
Open Circuit Load Volts  
115 Volt Receptacle2  
Output  
Control  
Load Amps  
Open Circuit  
Volts  
Load Volts  
Load Amps  
Volts  
Maximum  
255 - 267  
215 - 230  
18 - 20  
127 - 133  
112 - 120  
18 - 20  
1 Current Control Dial set at MAXIMUM or GENERATOR.  
2 Output values of each receptacle can vary within the range shown  
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POWER-ARC 4000  
F-35  
NOTES  
POWER-ARC 4000  
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Section G  
TABLE OF CONTENTS  
- ELECTRICAL DIAGRAMS -  
Electrical Diagrams.........................................................................................................Section G  
PowerArc 4000......................................................................................................................G-1  
POWER-ARC 4000  
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G-1  
- ELECTRICAL DIAGRAM -  
WIRING DIAGRAM – Code 10083  
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.  
POWER-ARC 4000  
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G-2  
NOTES  
POWER-ARC 4000  
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G-3  
NOTES  
POWER-ARC 4000  
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