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POWER-ARC
Safety Depends on You
Lincoln arc welding and cutting
equipment is designed and built
with safety in mind. However, your
overall safety can be increased by
proper installation ... and thought-
ful operation on your part. DO
NOT INSTALL, OPERATE OR
REPAIR THIS EQUIPMENT
WITHOUT
READING
MANUAL AND THE SAFETY
PRECAUTIONS CONTAINED
THROUGHOUT. And, most
importantly, think before you act
and be careful.
ISO 9001
ANSI
RAB
QMS
Designed and Manufactured Under a
Quality Program Certified by
ABS Quality Evaluations, Inc.
to ISO 9001 Requirements.
CERTIFICATE NUMBER: 30273
• Sales and Service through Subsidiaries and Distributors Worldwide •
Cleveland, Ohio 44117-1199 U.S.A. TEL: 216.481.8100 FAX: 216.486.1751 WEB SITE: www.lincolnelectric.com
RETURN TO MAIN MENU
For Machines with Code Number 11182, 11187, 11215, 11403, 11404
THIS
Various engine configurations are available and machine appearance will vary
accordingly.
OPERATOR'S MANUAL
• World's Leader in Welding and Cutting Products •
5500
™
Copyright © 2007 Lincoln Global Inc.
IM871-A
February, 2007
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Troubleshooting
Related Manuals for Lincoln Electric POWER-ARC IM871-A
Summary of Contents for Lincoln Electric POWER-ARC IM871-A
- Page 1 POWER-ARC For Machines with Code Number 11182, 11187, 11215, 11403, 11404 Safety Depends on You Lincoln arc welding and cutting equipment is designed and built with safety in mind. However, your overall safety can be increased by proper installation ... and thought- ful operation on your part.
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Page 2: Safety
351040, Miami, Florida 33135 or CSA Standard W117.2-1974. A Free copy of “Arc Welding Safety” booklet E205 is available from the Lincoln Electric Company, 22801 St. Clair Avenue, Cleveland, Ohio 44117-1199. BE SURE THAT ALL INSTALLATION, OPERATION, MAINTENANCE AND REPAIR PROCEDURES ARE PERFORMED ONLY BY QUALIFIED INDIVIDUALS. - Page 3 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. 3.b.
- Page 4 WELDING and CUTTING SPARKS can cause fire or explosion. 6.a. Remove fire hazards from the welding area. If this is not possible, cover them to prevent the welding sparks from starting a fire. Remember that welding materials from welding can easily go through small cracks and openings to adjacent areas.
- Page 5 PRÉCAUTIONS DE SÛRETÉ 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: Sûreté Pour Soudage A LʼArc 1. Protegez-vous contre la secousse électrique: a.
- Page 6 Electric for advice or information about their use of our products. We respond to our customers based on the best information in our posses- sion at that time. Lincoln Electric is not in a position to warrant or guarantee such advice, and assumes no liability, with respect to such infor- mation or advice.
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Page 7: Table Of Contents
Safety...i-iv Installation ...Section A A Technical Specifications ...A-1 Safety Precautions...A-2 Location and Ventilation ...A-2 Pre-operation Engine Service ...A-3, A-4 Electrical Output Connections ...A-5, A-6 Premises Wiring and Circuit Breakers ...A-7 Electrical Devises used with the POWER-ARC 5500 ...A-8 Operation ...Section B B Safety Instructions ...B-1 General Description ...B-1 Recommended Applications...B-1... -
Page 8: Installation
TECHNICAL SPECIFICATIONS - POWER-ARC 5500 Manufacturer Description Robin / Subaru 1 cyl., EX 27 4 cycle Codes air-cooled (11182) OHC gasoline (11187) 9 HP @ (11403) 3600 RPM INPUT - HONDA GASOLINE ENGINE INPUT - HONDA GASOLINE ENGINE Honda 1 cyl., GX 270 VA2 4 cycle Codes... -
Page 9: Safety Precautions
SAFETY PRECAUTIONS Read this entire installation section before you start installation. WARNING Do n n ot a a ttempt t t o u u se t t his e e quipment u u ntil y y ou have t t horoughly r r ead a a ll t t he o o peration a a nd m m ain- tenance m m anuals s s upplied w w ith y y our m m achine. -
Page 10: Pre-Operation Engine Service
STACKING POWER-ARC 5500 machines CANNOT be stacked. 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 gasoline engine is designed to run in a level posi- tion for best performance. -
Page 11: Spark Arrester
PowerArc 5500 Typical Fuel Consumption No Load 3700 RPM ±50 R.P.M. AC CC Weld Output 125 Amps @ 20 Volts AC CC Weld Output 100 Amps @ 25 Volts Auxiliary Power 4000 Watts (120/240 Volts) MUFFLER DEFLECTOR The POWER-ARC 5500, Honda model, may or may not be shipped with an exhaust deflector. -
Page 12: Electrical Output Connections
POWER-ARC 5500 OUTPUT CONNECTIONS Physical Location of Items and Components may vary by Code No. FIGURE A.1 (For Codes 11182, 11187, 11215) POWER ARC POWER ARC 55 AMPS AMPS AMPS AMPS AMPS AMPS AMPS AMPS GENERATOR GENERATOR AMPS AMPS WARNING WARNING ELECTRODE SELECTION GUIDE ELECTRODE SELECTION GUIDE... -
Page 13: Machine Grounding
K K eep t t he c c ables i i solated and s s eparate f f rom o o ne a a nother. Lincoln Electric offers a welding accessory kit with the properly specified welding cables. See the ACCESSORIES section of this manual for more infor- mation. -
Page 14: Premises Wiring
PREMISES WIRING The POWER-ARC 5500 three-wire, grounded neutral generator allows it to be connected to premises wiring. However, the wiring procedure needed to meet the National Electrical Code (NEC) regulations as well as city ordinances and can be confusing. The connections could vary from a "commonly grounded"... -
Page 15: Electrical Devises Used With The Power-Arc 5500
ELECTRICAL DEVICE USE WITH THE POWER-ARC 5500. Type Resistive Capacitive Inductive Capacitive/Inductive The Lincoln Electric Company is not responsible for any damage to electrical components improperly connect- ed to the POWER-ARC 5500. INSTALLATION CAUTION TABLE A.2 Common Electrical Devices Heaters, toasters, incandescent light bulbs, electric range, hot pan, skillet, coffee maker. -
Page 16: Operation
SAFETY INSTRUCTIONS Read and understand this entire section before oper- ating your POWER-ARC 5500. WARNING Do n n ot a a ttempt t t o u u se t t his e e quipment u u ntil y y ou have t t horoughly r r ead a a ll t t he o o peration a a nd m m ain- tenance m m anuals s s upplied w w ith y y our m m achine. -
Page 17: Limitations
Physical Location of Components may vary by Code No. FIGURE B.1 (For Codes 11182, 11187, 11215) POWER ARC 55 POWER ARC AMPS AMPS AMPS AMPS AMPS AMPS AMPS AMPS GENERATOR GENERATOR AMPS AMPS WARNING WARNING ELECTRODE SELECTION GUIDE ELECTRODE SELECTION GUIDE 1. -
Page 18: Engine Operation
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 5500 is an AC output machine, either output terminal can be used for either cable.) 5. -
Page 19: Before Starting The Engine
BEFORE STARTING THE ENGINE 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. 4. -
Page 20: Generator Operation
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 placing the “ON/OFF” switch in the “OFF”(O) position. 3. Close the fuel shutoff valve. WARNING Close t t he f f uel v v alve w w hen t t he m m achine i i s t t rans- ported t t o p p revent f f uel l l eakage f f rom t t he c c arbure-... - Page 21 GENERATOR POWER APPLICATIONS S S uggested P P ower A A pplications *Air Compressor - 1 HP *Air Compressor - 3/4 HP *Airless Sprayer - 1/3 HP Chain Saw Circular Saw Coffee Maker *Deep Freezer *Electric Motor - 1 HP Electric Range (1 element) Electric Skillet *Furnace Fan - 1/3 HP...
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Page 22: Welding Operation
WELDING OPERATION GENERAL INFORMATION WARNING ELECTRIC SHOCK can kill. • D D o n n ot t t ouch e e lectrically l l ive p p arts o o r electrodes w w ith y y our s s kin o o r w w et c c loth- ing. - Page 23 The serviceability of a product or structure utiliz- ing this type of information is and must be the sole responsibility of the builder/user. Many vari- ables beyond the control of The Lincoln Electric Company affect the results obtained in applying this type of information. These variables include,...
- Page 24 No one can learn to weld simply by reading about it. Skill comes only with practice. The following pages will help the inexperienced welder understand welding and develop his skill. For more detailed information, order a copy of the book “New Lessons in Arc Welding.”...
- Page 25 B-10 The function of the covered electrode is much more than simply to carry current to the arc. The electrode is composed of a core metal wire around which has been extruded and baked a chemical covering. The core wire melts into the arc and tiny droplets of molten metal shoot across the arc into the molten pool.
- Page 26 B-11 PRACTICE The best way of getting practice in the four skills that enable you to maintain: 1. Correct Welding Position. 2. Correct Way to Strike An Arc. 3. Correct Arc Length. 4. Correct Welding Speed. is to spend a little more time on the following exercise. Use the following: Mild Steel Plate: 3/16”...
- Page 27 B-12 Now weld the two plates together. Weld from left to right (if right-handed). Point the electrode down in he gap between the two plates, keeping the electrodes slightly tilted in the direction of travel. 90° end view Watch the molten metal to be sure it distributes itself evenly on both edges and in between the plates.
- Page 28 B-13 Vertical-Up Welding The problem, when welding vertical-up, is to put the molten metal where it is wanted and make it stay there. If too much molten metal is deposited, gravity will pull it downwards and make it “drip”. Therefore, a certain technique has to be followed: Long arc Short arc...
- Page 29 B-14 Overhead Welding Various techniques are used for overhead welding. However, in the interest of simplicity for the inexperi- enced welder, the following technique will probably take care of his needs for overhead welding: 1. Use 1/8” (3.2mm) 90-105 A or 3/32” (2.5mm) 70 A AWS 6011 electrode on AC.
- Page 30 B-15 4. The bead should be put on with a weaving motion, and it should be 1/2-3/4” (12.7-19.0mm) wide. Do not let the arc blow over the edge, as that will dull the edge. (See drawing below.) Strike Arc Work Table Here Brick Plow Share...
- Page 31 B-16 In some instances a back-up strip may be used and plates may be gapped 1/8” (3.2mm) or more, as shown in figure (b). Scrap steel back-up strip Three ways to prepare plates where complete penetration is necessary. On sections where only a sealed joint is required and strength is not important, the joint may be welded after slightly veeing out the seam as shown in figure (d) below.
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Page 32: Accessories
OPTIONS/ACCESSORIES LINCOLN ELECTRIC ACCESSORIES The following options/accessories are available for your POWER-ARC 5500 from your local Lincoln Distributor. Accessory K K it ( ( K875) – Includes the following: • Twenty feet (6.1 meters) of #6 AWG electrode cable with lug. -
Page 33: Maintenance
SAFETY PRECAUTIONS WARNING • H H ave q q ualified p p ersonnel d d o a a ll m m aintenance and t t roubleshooting w w ork. • T T urn t t he e e ngine o o ff b b efore w w orking i i nside t t he machine. -
Page 34: Engine Adjustments
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 ADJUSTMENTS WARNING OVERSPEED IS HAZARDOUS - The maximum allowable high idle speed for this machine is 3750 RPM, no load. - Page 35 CL EA N O O R R R E PL A CE S S PA R K P P LUG: 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.
- Page 36 GENERATOR/WELDER MAINTENANCE STORAGE: Store the POWER-ARC 5500 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. BRUSH R R EMOVAL A A ND R R EPLACEMENT: See Figure D.5.
- Page 37 MAINTENANCE FIGURE D.6. - MAJOR COMPONENT LOCATIONS 1 . CRADLE ASSEMBLY 2. ROTOR, BLOWER, AND BEARING ASSEMBLY 3. STATOR ASSEMBLY 4. BRUSH AND BRUSH HOLDER ASSEMBLY 5. CONTROL BOX WELDED ASSEMBLY 6. REACTOR ASSEMBLY 7. OUTPUT TERMINAL ASSEMBLY 8. OUTPUT PANEL ASSEMBLY POWER-ARC 5500...
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Page 38: How To Use Troubleshooting Guide
HOW TO USE TROUBLESHOOTING GUIDE Service and Repair should only be performed by Lincoln Electric Factory Trained Personnel. Unauthorized repairs performed on this equipment may result in danger to the technician and machine operator and will invalidate your factory warranty. For your safety and to avoid Electrical Shock, please observe all safety notes and precautions detailed throughout this manual. -
Page 39: Troubleshooting
Observe all Safety Guidelines detailed throughout this manual PROBLEMS (SYMPTOMS) No generator power or welding output. Generator power is available but unit will not weld. If for any reason you do not understand the test procedures or are unable to perform the tests/repairs safely, contact your Local Lincoln Authorized Field Service Facility for technical troubleshooting assistance before you proceed. - Page 40 Observe all Safety Guidelines detailed throughout this manual PROBLEMS (SYMPTOMS) Unit will weld but low or no generator power is available. Engine runs erratically or stops running. Engine sputters but will not start. If for any reason you do not understand the test procedures or are unable to perform the tests/repairs safely, contact your Local Lincoln Authorized Field Service Facility for technical troubleshooting assistance before you proceed.
- Page 41 Observe all Safety Guidelines detailed throughout this manual PROBLEMS (SYMPTOMS) Engine will not start. If for any reason you do not understand the test procedures or are unable to perform the tests/repairs safely, contact your Local Lincoln Authorized Field Service Facility for technical troubleshooting assistance before you proceed. TROUBLESHOOTING POSSIBLE CAUSE...
- Page 42 DIAGRAMS Enhanced Diagram POWER-ARC 5500...
- Page 43 DIAGRAMS POWER-ARC 5500...
- Page 44 DIAGRAMS POWER-ARC 5500...
- Page 45 DIAGRAMS POWER-ARC 5500...
- Page 46 DIAGRAMS POWER-ARC 5500...
- Page 47 NOTES...
- Page 48 ● WARNING ● Spanish ● AVISO DE PRECAUCION ● French ● ATTENTION ● ● German WARNUNG ● Portuguese ● ATENÇÃO ● Japanese Chinese Korean Arabic ● ● ● ● ● ● ● ● ● ●...
- Page 49 ● ● ● ● ● ● ● ● ● ● ● ● ● ● ● ● ● ● Spanish ● PRECAUCION French ● ATTENTION ● German Portuguese ● ● Japanese Chinese Korean Arabic WARNING AVISO DE WARNUNG ATENÇÃO...
- Page 50 • World's Leader in Welding and Cutting Products • • Sales and Service through Subsidiaries and Distributors Worldwide • Cleveland, Ohio 44117-1199 U.S.A. TEL: 216.481.8100 FAX: 216.486.1751 WEB SITE: www.lincolnelectric.com...