Lincoln Electric POWERARC 5500 Service Manual
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Lincoln Electric POWERARC 5500 Service Manual

Lincoln Electric POWERARC 5500 Service Manual

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All manuals and user guides at all-guides.com
SVM197-A
January, 2010
®
POWERARC
5500
11182, 11187, 11215, 11329, 11403, 11404, 11405
For use with machine code number:
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 READ-
ING THIS MANUAL AND THE
SAFETY PRECAUTIONS CON-
TAINED THROUGHOUT.
And,
most importantly, think before you
act and be careful.
SERVICE MANUAL
Copyright © Lincoln Global Inc.
• World's Leader in Welding and Cutting Products •
• Sales and Service through Subsidiaries and Distributors Worldwide •
Cleveland, Ohio 44117-1199 U.S.A. TEL: 888.935.3877 FAX: 216.486.1751 WEB SITE: www.lincolnelectric.com

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  • Page 1 All manuals and user guides at all-guides.com SVM197-A January, 2010 ® POWERARC 5500 11182, 11187, 11215, 11329, 11403, 11404, 11405 For use with machine code number: Safety Depends on You Lincoln arc welding and cutting equipment is designed and built with safety in mind.

  • Page 2: California Proposition 65 Warnings

    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

    All manuals and user guides at all-guides.com SAFETY ELECTRIC SHOCK can kill. ARC RAYS can burn. 3.a. The electrode and work (or ground) circuits 4.a. Use a shield with the proper filter and cover are electrically “hot” when the welder is on. plates to protect your eyes from sparks and Do not touch these “hot”...
  • Page 4 All manuals and user guides at all-guides.com SAFETY WELDING and CUTTING CYLINDER may explode SPARKS can if damaged. cause fire or explosion. 7.a. Use only compressed cylinders 6.a. Remove fire hazards from the welding area. containing the correct shielding gas for the If this is not possible, cover them to prevent process used and properly operating the welding sparks from starting a fire.
  • Page 5 All manuals and user guides at all-guides.com SAFETY 6. Eloigner les matériaux inflammables ou les recouvrir afin de PRÉCAUTIONS DE SÛRETÉ prévenir tout risque d’incendie dû aux étincelles. Pour votre propre protection lire et observer toutes les instructions 7. Quand on ne soude pas, poser la pince à une endroit isolé de et les précautions de sûreté...
  • Page 6 (89/336/EEC). It was manufactured in conformity with a national standard that implements a harmonized standard: EN 60974-10 Electromagnetic Compatibility (EMC) Product Standard for Arc Welding Equipment. It is for use with other Lincoln Electric equipment. It is designed for industrial and professional use. Introduction All electrical equipment generates small amounts of electromagnetic emission.
  • Page 7 All manuals and user guides at all-guides.com SAFETY Electromagnetic Compatibility (EMC) The size of the surrounding area to be considered will depend on the structure of the building and other activities that are taking place. The surrounding area may extend beyond the boundaries of the premises. Methods of Reducing Emissions Mains Supply Welding equipment should be connected to the mains supply according to the manufacturer’s recommen-...
  • Page 8 All manuals and user guides at all-guides.com - MASTER TABLE OF CONTENTS FOR ALL SECTIONS - Page Safety ................i-iv Installation .
  • Page 9 All manuals and user guides at all-guides.com TABLE OF CONTENTS - INSTALLATION SECTION Installation ................A-1 Technical Specifications .
  • Page 10 All manuals and user guides at all-guides.com INSTALLATION TECHNICAL SPECIFICATIONS - POWERARC® 5500 INPUT - GASOLINE ENGINE Manufacturer Description Speed Displacement Ignition Capacities Robin / Subaru 1 cyl., 3700 RPM 16.17 cu. in. Manual, Fuel: 1.6 gal. (6.1 l) EX 27 4 cycle ±...

  • Page 11: Safety Precautions

    All manuals and user guides at all-guides.com INSTALLATION SAFETY PRECAUTIONS LOCATION AND VENTILATION Read this entire installation section before you Whenever you use the POWERARC® 5500, be sure that clean cooling air can flow through the machine’s start installation. gasoline engine and the generator. Avoid dusty, dirty areas.

  • Page 12: Installation

    All manuals and user guides at all-guides.com INSTALLATION STACKING POWERARC® 5500 machines CANNOT be stacked. FUEL TILTING Fill the fuel tank with clean, fresh, regular grade lead- Place the machine on a secure, level surface whenev- free gasoline. DO NOT MIX OIL WITH THE GASO- er you use it or store it.

  • Page 13: Spark Arrester

    All manuals and user guides at all-guides.com INSTALLATION PowerArc 5500 Typical Fuel Consumption Robin / Subaru 9 HP Carb. Certified Honda 9 HP EX 27 Carb. Certified No Load 0.31 Gallons/Hour .30 Gallons/Hour 3700 RPM ±50 R.P.M. (1.17 Liters/Hour) (1.14 Liters/Hour) AC CC Weld Output .70 Gallons/Hour...
  • Page 14 All manuals and user guides at all-guides.com INSTALLATION POWERARC® 5500 OUTPUT CONNECTIONS Physical Location of Items and Components may vary by Code No. FIGURE A.1 (For Codes 11182, 11187, 11215) FIGURE A.2 (For Codes 11403, 11404) POWER ARC POWER ARC 55 5500 POWER ARC POWER ARC 55...

  • Page 15: Machine Grounding

    All electrical equipment must be and separate from one another. in safe condition. 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 POWERARC®...

  • Page 16: Premises Wiring

    All manuals and user guides at all-guides.com INSTALLATION PREMISES WIRING CIRCUIT BREAKERS The POWERARC® 5500 three-wire, grounded neutral generator allows it to be connected to premises Auxiliary power is protected by circuit breaker. When wiring. However, the wiring procedure needed to meet the machine is operated in high temperature environ- the National Electrical Code (NEC) regulations as well ments, the breakers may tend to trip at lower loads...
  • Page 17 DO NOT USE THESE DEVICES WITH A POWERARC® 5500. The Lincoln Electric Company is not responsible for any damage to electrical components improperly connect- ed to the POWERARC® 5500. POWERARC® 5500...
  • Page 18 All manuals and user guides at all-guides.com A-10 NOTES A-10 POWERARC® 5500...

  • Page 19: Table Of Contents

    All manuals and user guides at all-guides.com TABLE OF CONTENTS - OPERATION SECTION Operation ................B-1 Safety Instructions .

  • Page 20: Operation

    All manuals and user guides at all-guides.com OPERATION SAFETY INSTRUCTIONS GENERAL DESCRIPTION The POWERARC® 5500 is a generator/welder designed Read and understand this entire section before oper- for home use and other non-commercial applications. As ating your POWERARC® 5500. a generator it can supply up to 4,000 continuous watts WARNING (or 5,500 surge watts) of 120/240 volt, single-phase AC power.

  • Page 21: Operation

    All manuals and user guides at all-guides.com OPERATION OUTPUT PANEL CONTROLS Physical Location of Components may vary by Code No. FIGURE B.1 (For Codes 11182, 11187, 11215) FIGURE B.2 (For Codes 11403, 11404) POWER ARC 5500 POWER ARC 5500 POWER ARC POWER ARC 55 5500 AMPS...

  • Page 22: Engine Operation

    All manuals and user guides at all-guides.com OPERATION 4. WELD OUTPUT TERMINAL (TO WORK) WITH 1/2 3. MUFFLER: Reduces engine noise output. Both - 13 FLANGE NUT: Provides the connection point the Robin / Subaru and the Honda muffler serves for either the electrode holder or the work cable.

  • Page 23: Before Starting The Engine

    All manuals and user guides at all-guides.com OPERATION 4. Pull the cord rapidly. BEFORE STARTING THE ENGINE 5. If the engine does not start, open the choke slight- CHECK AND FILL THE ENGINE OIL LEVEL: ly and pull the starter cord rapidly again. 1.

  • Page 24: Stopping The Engine

    All manuals and user guides at all-guides.com OPERATION GENERATOR OPERATION STOPPING THE ENGINE 1. Remove all welding and generator power loads and let the engine cool by running it for several CAUTION minutes. 2. Stop the engine by placing the “ON/OFF” switch Be sure that any electrical equipment plugged in the “OFF”(O) position.

  • Page 25: Generator Power Applications Table

    All manuals and user guides at all-guides.com OPERATION TABLE B.3 GENERATOR POWER APPLICATIONS Suggested Power Applications Running Watts *Start-up Watts (Continuous) (Surge) *Air Compressor - 1 HP 2,000 4,000 - 8,000 *Air Compressor - 3/4 HP 1,250 3,100 - 5,000 *Airless Sprayer - 1/3 HP 1,500 - 2,400 Chain Saw...

  • Page 26: Welding Operation

    All manuals and user guides at all-guides.com OPERATION WELDING OPERATION 7. Strike an arc and begin welding. For information GENERAL INFORMATION on welding techniques, see WELDING GUIDE- LINES in this section of the manual. WARNING AFTER YOU FINISH THE WELD: ELECTRIC SHOCK can kill.

  • Page 27: Welding Guidelines

    Lincoln Wire Feeder/Welder. The Wire Feeder/Welder responsibility of the builder/user. Many variables is equipped with all the supplies needed for Flux-Cored beyond the control of The Lincoln Electric Arc Welding (FCAW). Also some Wire Feeder/Welders Company affect the results obtained in applying come equipped with the essentials needed for Gas this type of information.

  • Page 28: What Happens In The Arc

    All manuals and user guides at all-guides.com B-10 OPERATION B-10 No one can learn to weld simply by reading about it. The electric arc is made between the work and the tip Skill comes only with practice. The following pages will end of a small metal wire, the electrode, which is help the inexperienced welder understand welding and clamped in a holder that is held by the welder.
  • Page 29 All manuals and user guides at all-guides.com B-11 OPERATION B-11 The function of the covered electrode is much more 2. The Correct Way to Strike An Arc than simply to carry current to the arc. The electrode is composed of a core metal wire around which has been Be sure the work clamp makes good electrical contact extruded and baked a chemical covering.

  • Page 30: Types Of Welds

    All manuals and user guides at all-guides.com B-12 OPERATION B-12 PRACTICE These higher carbon steels can be welded successful- ly in most cases; however, care must be taken to follow The best way of getting practice in the four skills that proper procedures, including preheating the metal to enable you to maintain: be welded and, in some cases, carefully controlling the...
  • Page 31 All manuals and user guides at all-guides.com B-13 OPERATION B-13 Now weld the two plates together. Weld from left to Fillet Joints right (if right-handed). Point the electrode down in he gap between the two plates, keeping the electrodes slightly tilted in the direction of travel. When welding fillet joints, it is very important to hold the electrode at a 45°...
  • Page 32 All manuals and user guides at all-guides.com B-14 OPERATION B-14 8. When the arc is brought back to the now solidified Vertical-Up Welding puddle, IT MUST BE SHORT, otherwise no metal will be deposited, the puddle will melt again, and it will “drip”.
  • Page 33 All manuals and user guides at all-guides.com B-15 OPERATION B-15 4. Move rapidly enough to stay ahead of the molten Overhead Welding slag. A whipping technique may be used to further minimize burn through. Various techniques are used for overhead welding. 5.
  • Page 34 All manuals and user guides at all-guides.com B-16 OPERATION B-16 4. The bead should be put on with a weaving motion, When breaking and it should be 1/2-3/4” (12.7-19.0mm) wide. Do the weld stays on not let the arc blow over the edge, as that will dull one piece the edge.

  • Page 35: Selecting Electrodes

    All manuals and user guides at all-guides.com B-17 OPERATION B-17 In some instances a back-up strip may be used and High-Speed Group (AWS E6013) plates may be gapped 1/8” (3.2mm) or more, as shown This group includes electrodes which have a moder- in figure (b).
  • Page 36 All manuals and user guides at all-guides.com B-18 NOTES B-18 POWERARC® 5500...
  • Page 37 All manuals and user guides at all-guides.com TABLE OF CONTENTS - ACCESSORIES SECTION Accessories ................C-1 Options and Accessories .
  • Page 38 All manuals and user guides at all-guides.com ACCESSORIES OPTIONS/ACCESSORIES LINCOLN ELECTRIC ACCESSORIES The following options/accessories are available for your POWERARC® 5500 from your local Lincoln Distributor. Accessory Kit (K875) – Includes the following: • Twenty feet (6.1 meters) of #6 AWG electrode cable with lug.
  • Page 39 All manuals and user guides at all-guides.com TABLE OF CONTENTS - MAINTENANCE SECTION Maintenance ................D-1 Safety Precautions .

  • Page 40: Routine And Periodic Maintenance

    All manuals and user guides at all-guides.com MAINTENANCE SAFETY PRECAUTIONS Once Oil or Air filter service is completed, Tachometer/Hour meter needs to be reset. The reset procedure will stop the flashing of the display and will WARNING trigger the meter to start counting the time for the next engine service.

  • Page 41: Engine Adjustments

    All manuals and user guides at all-guides.com MAINTENANCE Clean Rotating Screen: If your POWERARC® 5500 is F F U U E E L L : : At the end of each day’s use, refill equipped with an engine that has a rotating screen, the fuel tank to minimize moisture condensa- you should clean it as often as needed, to remove dirt tion and dirt contamination in the fuel line.
  • Page 42 All manuals and user guides at all-guides.com MAINTENANCE C C L L E E A A N N O O R R R R E E P P L L A A C C E E S S P P A A R R K K P P L L U U G G : : Clean or replace the spark plug after every 100 hours of opera- tion or every season, whichever comes first.
  • Page 43 All manuals and user guides at all-guides.com MAINTENANCE R R E E C C E E P P T T A A C C L L E E S S : : Keep the electrical receptacles in GENERATOR/WELDER MAINTENANCE good condition. Remove any dirt, oil, or other debris S S T T O O R R A A G G E E : : Store the POWERARC®...
  • Page 44 All manuals and user guides at all-guides.com 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.
  • Page 45 All manuals and user guides at all-guides.com TABLE OF CONTENTS-THEORY OF OPERATION SECTION Theory of Operation ......................Section E Block Logic Diagram.......................E-1 Engine Control & Ignition, Rotor and Stator ..............E-2 Rotor Field Feedback and Auxiliary Power..............E-3 Welding Output .......................E-4 FIGURE E.1 – POWERARC® 5500 BLOCK LOGIC DIAGRAM REACTOR OUTPUT TERMINALS...

  • Page 46: Theory Of Operation

    All manuals and user guides at all-guides.com THEORY OF OPERATION FIGURE E.2 – ENGINE CONTROL, IGNITION, ROTOR & STATOR REACTOR OUTPUT TERMINALS STATOR ENGINE MECHANICAL ROTATION ROTOR ROTOR SLIP RINGS MAGNETO CIRCUIT STATOR CAPACITOR LOW OIL SWITCH CIRCUIT CIRCUIT BREAKER BREAKER RUN/STOP SWITCH...
  • Page 47 All manuals and user guides at all-guides.com THEORY OF OPERATION FIGURE E.3 – ROTOR FIELD FEEDBACK AND AUXILIARY POWER REACTOR OUTPUT TERMINALS STATOR ENGINE MECHANICAL ROTATION ROTOR ROTOR SLIP RINGS MAGNETO CIRCUIT STATOR CAPACITOR LOW OIL SWITCH CIRCUIT CIRCUIT BREAKER BREAKER RUN/STOP SWITCH...
  • Page 48 All manuals and user guides at all-guides.com THEORY OF OPERATION FIGURE E.4 – WELDING OUTPUT REACTOR OUTPUT TERMINALS STATOR ENGINE MECHANICAL ROTATION ROTOR ROTOR SLIP RINGS MAGNETO CIRCUIT STATOR CAPACITOR LOW OIL SWITCH CIRCUIT CIRCUIT BREAKER BREAKER RUN/STOP SWITCH BRIDGE RHEOSTAT 230VAC 115VAC...
  • Page 49 All manuals and user guides at all-guides.com TABLE OF CONTENTS - TROUBLESHOOTING AND REPAIR Troubleshooting and Repair ............. .F-1 How to Use Troubleshooting Guide .

  • Page 50: Troubleshooting And Repair

    HOW TO USE TROUBLESHOOTING GUIDE WARNING Service and Repair should only be performed by Lincoln Electric Factory Trained Personnel. Unauthorized repairs performed on this equipment may result in danger to the technician and machine operator and will invalidate your factory warranty. For your safety and to avoid Electrical Shock, please observe all safety notes and precautions detailed throughout this manual.

  • Page 51: Pc Board Troubleshooting Procedures

    Do not touch electrically hot parts. - If you return a PC board to The Lincoln Electric Company for credit, it must be in the static-shielding bag. This will prevent further damage and allow prop- CAUTION er failure analysis.
  • Page 52 Department at 1-888-935-3877. CAUTION If for any reason you do not understand the test procedures or are unable to perform the tests/repairs safely, contact the Lincoln Electric Service Department for technical troubleshooting assistance before you proceed. Call 1-888-935-3877. POWERARC® 5500...

  • Page 53: Rotor Resistance Test

    Rotor Resistance Test. CAUTION If for any reason you do not understand the test procedures or are unable to perform the tests/repairs safely, contact the Lincoln Electric Service Department for technical troubleshooting assistance before you proceed. Call 1-888-935-3877. POWERARC® 5500...
  • Page 54 500 K-ohms. CAUTION If for any reason you do not understand the test procedures or are unable to perform the tests/repairs safely, contact the Lincoln Electric Service Department for technical troubleshooting assistance before you proceed. Call 1-888-935-3877. POWERARC® 5500...
  • Page 55 3. See the Wiring Diagram. CAUTION If for any reason you do not understand the test procedures or are unable to perform the tests/repairs safely, contact the Lincoln Electric Service Department for technical troubleshooting assistance before you proceed. Call 1-888-935-3877. POWERARC® 5500...
  • Page 56 CAUTION If for any reason you do not understand the test procedures or are unable to perform the tests/repairs safely, contact the Lincoln Electric Service Department for technical troubleshooting assistance before you proceed. Call 1-888-935-3877. POWERARC® 5500...
  • Page 57 CAUTION If for any reason you do not understand the test procedures or are unable to perform the tests/repairs safely, contact the Lincoln Electric Service Department for technical troubleshooting assistance before you proceed. Call 1-888-935-3877. POWERARC® 5500...
  • Page 58 CAUTION If for any reason you do not understand the test procedures or are unable to perform the tests/repairs safely, contact the Lincoln Electric Service Department for technical troubleshooting assistance before you proceed. Call 1-888-935-3877. POWERARC® 5500...

  • Page 59: Engine Throttle Adjustment Test

    See the Wiring Diagram. CAUTION If for any reason you do not understand the test procedures or are unable to perform the tests/repairs safely, contact the Lincoln Electric Service Department for technical troubleshooting assistance before you proceed. Call 1-888-935-3877. POWERARC® 5500...
  • Page 60 All manuals and user guides at all-guides.com F-12 NOTES F-12 POWERARC® 5500...

  • Page 61: Test Description

    ROTOR VOLTAGE AND FLASHING VOLTAGE TEST PROCEDURE WARNING Service and repair should be performed only by 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 electrical shock, please observe all safety notes and precautions detailed throughout this manual.

  • Page 62: Ground Stud

    All manuals and user guides at all-guides.com F-14 TROUBLESHOOTING AND REPAIR F-14 ROTOR VOLTAGE AND FLASHING VOLTAGE TEST PROCEDURE (continued) ROTOR VOLTAGE TEST (continued) FIGURE F.1 - LOCATION OF LEAD 200A FOR ROTOR VOLTAGE TEST GROUND STUD LEAD 200 CONNECTION OUTPUT PANEL ROTOR VOLTAGE TEST PROCEDURE FLASHING VOLTAGE TEST...
  • Page 63 ROTOR RESISTANCE TEST PROCEDURE WARNING Service and repair should be performed only by 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 electrical shock, please observe all safety notes and precautions detailed throughout this manual.
  • Page 64 All manuals and user guides at all-guides.com F-16 TROUBLESHOOTING AND REPAIR F-16 ROTOR RESISTANCE TEST PROCEDURE (continued) ROTOR RESISTANCE TEST (continued) FIGURE F.2 LOCATION OF ROTOR SLIP RINGS - BRUSH HOLDER ASSEMBLY REMOVED SLIP RINGS PROCEDURE 1. Conduct the test with the gasoline engine OFF. 7.
  • Page 65 All manuals and user guides at all-guides.com F-17 TROUBLESHOOTING AND REPAIR F-17 ROTOR RESISTANCE TEST PROCEDURE (continued) ROTOR RESISTANCE TEST (continued) FIGURE F.3 - BRUSHES RETAINED WITH CABLE TIE CABLE BRUSHES 9. Reinstall the brush holder assembly after the test. Depress the spring-loaded brushes into the holder and slip a suitable non-metallic, fair- ly stiff retainer through the slots at the top and bottom of the holder.
  • Page 66 All manuals and user guides at all-guides.com F-18 NOTES F-18 POWERARC® 5500...
  • Page 67 ROBIN/SUBARU ENGINE WARNING Service and repair should be performed only by 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 electrical shock, please observe all safety notes and precautions detailed throughout this manual.

  • Page 68: Test Procedure

    All manuals and user guides at all-guides.com F-20 TROUBLESHOOTING AND REPAIR F-20 ENGINE THROTTLE ADJUSTMENT TEST ROBIN/SUBARU ENGINE (continued) FIGURE F.4 - MARK LOCATION MARK TEST PROCEDURE Frequency Counter Method: 1. Plug the frequency counter into one This test can be conducted by any of of the 115 VAC auxiliary receptacles.
  • Page 69 All manuals and user guides at all-guides.com F-21 TROUBLESHOOTING AND REPAIR F-21 ENGINE THROTTLE ADJUSTMENT TEST ROBIN/SUBARU ENGINE (continued) FIGURE F.5 - LOCKING NUT LOCATION THROTTLE LOCKING 2. Using the 10mm socket wrench, slightly loosen the throttle locking nut. See Figure F.5. 3.

  • Page 70: Scope Settings

    All manuals and user guides at all-guides.com F-22 TROUBLESHOOTING AND REPAIR F-22 NORMAL OPEN CIRCUIT WELD VOLTAGE WAVEFORM HIGH IDLE – NO LOAD 0 volts 5 ms 50 volts This is the typical AC output voltage generated from a properly operating machine.
  • Page 71 All manuals and user guides at all-guides.com F-23 TROUBLESHOOTING AND REPAIR F-23 NORMAL OPEN CIRCUIT VOLTAGE WAVEFORM (115 VAC SUPPLY) HIGH IDLE – NO LOAD 1 Period = 16.2 ms @ 3700 rpm 0 volts 5 ms 50 volts This is the typical AC output voltage generated from a properly operating machine.
  • Page 72 All manuals and user guides at all-guides.com F-24 TROUBLESHOOTING AND REPAIR F-24 TYPICAL WELD OUTPUT WAVEFORM MACHINE LOADED 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.
  • Page 73 BRUSH REMOVAL AND REPLACEMENT PROCEDURE WARNING Service and repair should be performed only by 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.
  • Page 74 All manuals and user guides at all-guides.com F-26 TROUBLESHOOTING AND REPAIR F-26 BRUSH REMOVAL AND REPLACEMENT (continued) FIGURE F.7 - BRUSHES RETAINED WITH CABLE TIE CABLE BRUSHES PROCEDURE 1. Remove the spark plug wire. 5. To change the brushes, use the slot head screw driver to pop off the 2.
  • Page 75 All manuals and user guides at all-guides.com F-27 TROUBLESHOOTING AND REPAIR F-27 BRUSH REMOVAL AND REPLACEMENT (continued) (continued) PROCEDURE 8. To reinstall the brush holder assem- 11. Reinstall and tighten the 2 screws bly, depress the spring-loaded with the 1/4” nut driver. brushes into the holder and slip a 12.
  • Page 76 All manuals and user guides at all-guides.com F-28 NOTES F-28 POWERARC® 5500...
  • Page 77 RHEOSTAT REMOVAL AND REPLACEMENT PROCEDURE WARNING Service and repair should be performed only by 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 electrical shock, please observe all safety notes and precautions detailed throughout this manual.
  • Page 78 All manuals and user guides at all-guides.com F-30 TROUBLESHOOTING AND REPAIR F-30 RHEOSTAT REMOVAL AND REPLACEMENT PROCEDURE (continued) FIGURE F.8 - RHEOSTAT REMOVAL See Figure F.8 for steps 3 - 9. PROCEDURE 7. To reinstall the rheostat, replace each of the brass screws. Place a 1.
  • Page 79 REMOVAL AND REPLACEMENT PROCEDURE WARNING Service and repair should be performed only by 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 electrical shock, please observe all safety notes and precautions detailed throughout this manual.
  • Page 80 All manuals and user guides at all-guides.com F-32 TROUBLESHOOTING AND REPAIR F-32 CAPACITOR AND/OR DIODE BRIDGE REMOVAL AND REPLACEMENT PROCEDURE (continued) FIGURE F.9 - LOCATION AND DISCHARGING THE FIELD CAPACITOR Attachment for Attachment for 202A 201A Jumper Cable Tie Capacitor PROCEDURE - CAPACITOR REMOVAL AND REPLACE- MENT...
  • Page 81 All manuals and user guides at all-guides.com F-33 TROUBLESHOOTING AND REPAIR F-33 CAPACITOR AND/OR DIODE BRIDGE REMOVAL AND REPLACEMENT PROCEDURE (continued) FIGURE F.10 - FIELD DIODE BRIDGE LOCATION Feild Diode Bridge 201B – PROCEDURE - FIELD DIODE BRIDGE REMOVAL AND REPLACEMENT Lead 200 attached to the positive (+) 1.
  • Page 82 All manuals and user guides at all-guides.com F-34 NOTES F-34 POWERARC® 5500...
  • Page 83 STATOR/ROTOR REMOVAL AND REPLACEMENT PROCEDURE WARNING Service and repair should be performed only by 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 electrical shock, please observe all safety notes and precautions detailed throughout this manual.
  • Page 84 All manuals and user guides at all-guides.com F-36 TROUBLESHOOTING AND REPAIR F-36 STATOR/ROTOR REMOVAL AND REPLACEMENT PROCEDURE (continued) STATOR REMOVAL PROCEDURE Unplug the large molex plug. See Figure Remove engine spark plug wire to prevent F.16. accidental kickback or starting. With the 5/16”...
  • Page 85 All manuals and user guides at all-guides.com F-37 TROUBLESHOOTING AND REPAIR F-37 STATOR/ROTOR REMOVAL AND REPLACEMENT PROCEDURE (continued) 14. Slide a short length of 2 X 4 under 17. Lift up the stator and slide out the the engine to support it when the support bracket.

  • Page 86: Reassembly Procedure

    Lincoln E177-R retaining compound 3. Install the long thru-bolt supplied (Locktite( 277). Place the beveled lock with Lincoln Electric Rotor Removal washers onto the thru-bolt and insert it Kit S20925. The slot head must face into the rotor shaft. Hold the rotor and out.

  • Page 87: Feeler Gauge

    All manuals and user guides at all-guides.com F-39 TROUBLESHOOTING AND REPAIR F-39 STATOR/ROTOR REMOVAL AND REPLACEMENT PROCEDURE (continued) 6. Install the bottom two end bracket thru- 12. Reconnect the output lead W2 to the output bolts. terminal. 7. Tap the end bracket with the mallet as nec- 13.
  • Page 88 All manuals and user guides at all-guides.com F-40 TROUBLESHOOTING AND REPAIR F-40 STATOR/ROTOR REMOVAL AND REPLACEMENT PROCEDURE (continued) FIGURE F.15 LEAD 205 AND MORE REACTOR BOLTS (2) LEAD CONNECTIONS LEAD #205 FIGURE F.16 MOLEX PLUG AND BOLT/SCREW LOCATION GROUNDING SCREW 2 BOLTS SHEET METAL SCREWS (5 PLACES)

  • Page 89: Retest After Repair

    All manuals and user guides at all-guides.com F-41 TROUBLESHOOTING AND REPAIR F-41 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.
  • Page 90 All manuals and user guides at all-guides.com F-42 NOTES F-42 POWERARC® 5500...
  • Page 91 All manuals and user guides at all-guides.com TABLE OF CONTENTS - DIAGRAM SECTION Electrical Diagrams ..............G-1 Wiring Diagram (Codes 11182, 11187, 11329) (S25984) .

  • Page 92: Electrical Diagrams

    All manuals and user guides at all-guides.com ELECTRICAL DIAGRAMS WIRING DIAGRAM - CODES 11182, 11187, 11329 (S25984) WIRING DIAGRAM - POWER ARC 5500 REACTOR 202B OUTPUT STUDS ROTOR STATOR 200A 100W GND-C 202A 600 µ FD STATOR END 202B 201A BRACKET GROUND GND-D...

  • Page 93: Wiring Diagram (Codes 11403, 11405) (S26829

    All manuals and user guides at all-guides.com ELECTRICAL DIAGRAMS WIRING DIAGRAM - CODES 11403, 11405 (S26829) WIRING DIAGRAM - POWER ARC 5500 REACTOR 202B OUTPUT STUDS ROTOR 3.3 Ohms STATOR 200A 100W GND-C 202A 600 µ FD STATOR END 202B 201A BRACKET GROUND...

  • Page 94: Wiring Diagram (Code 11404) (S26830

    All manuals and user guides at all-guides.com ELECTRICAL DIAGRAMS WIRING DIAGRAM - CODE 11404 (S26830) WIRING DIAGRAM - POWER ARC 5500 WRAP AROUND SPARK PLUG WIRE FOUR TIMES 04/02/200 TACHOMETER/ HOURMETER 202B OUTPUT STUDS ROTOR 3.3 Ohms STATOR 200A 100W GND-C 202A 600 µ...

  • Page 95: Wiring Diagram (Code 11215) (S26023

    All manuals and user guides at all-guides.com ELECTRICAL DIAGRAMS WIRING DIAGRAM - CODE 11215 (S26023) WIRING DIAGRAM - POWER ARC 5500 WRAP AROUND SPARK PLUG WIRE FOUR TIMES 04/26/200 TACHOMETER/ HOURMETER 202B OUTPUT STUDS ROTOR STATOR 200A 100W GND-C 202A 600 µ...
  • Page 96 All manuals and user guides at all-guides.com ELECTRICAL DIAGRAMS SCHEMATIC -CODES 11182, 11187, 11329 (S26008) ENGINEERING CONTROLLED CHANGE DETAIL: Released A.03 from X MANUFACTURER: Hourmeter is powered by an internal non-replaceable battery. STATOR RPM and running time is measured by detector wire wrapped L1 - REACTOR WELD OUTPUT around the sparkplug wire.
  • Page 97 All manuals and user guides at all-guides.com ELECTRICAL DIAGRAMS SCHEMATIC - CODES 11403, 11405 (S26881) CHANGE DETAIL: ENGINEERING CONTROLLED MANUFACTURER: STATOR L1 - REACTOR WELD OUTPUT STUDS Locatedinsideenclosureontopof generator. 60 VAC 60 VAC IF OIL LEVEL IS TOO LOW OIL LEVEL WELD @ MAX @ MAX...
  • Page 98 All manuals and user guides at all-guides.com ELECTRICAL DIAGRAMS SCHEMATIC - CODE 11404 (S26882) ENGINEERING CONTROLLED CHANGE DETAIL: MANUFACTURER: Hourmeter is powered by an internal non-replaceable battery. STATOR L1 - REACTOR RPM and running time is measured by detector wire wrapped WELD OUTPUT around the sparkplug wire.

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