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Lincoln Electric POWER ARC 5000 Operator's Manual

Lincoln electric welder user manual
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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.
Date of Purchase:
Serial Number:
Code Number:
Model:
Where Purchased:
• 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
For Machines with Code Number 10255 and 10430
RETURN TO MAIN MENU
THIS
OPERATOR'S MANUAL
• World's Leader in Welding and Cutting Products •
5000
™
IM560-A
November, 1999

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Summary of Contents for Lincoln Electric POWER ARC 5000

  • Page 1: Power Arc

    POWER ARC For Machines with Code Number 10255 and 10430 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.

  • 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

    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.
  • Page 4 WELDING 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 sparks and hot 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 L’Arc 1. Protegez-vous contre la secousse électrique: a.
  • Page 6 This statement appears where the information must be followed to avoid minor personal injury or damage to this equipment. for selecting a QUALITY product by Lincoln Electric. We want you to take pride in operating this Lincoln Electric Company product •••...

  • Page 7: Table Of Contents

    Welding Operation ...B-9 Learning to Stick Weld...B-11 Accessories...Section C Maintenance...Section D Safety Precautions ...D-1 Routine and Periodic Maintenance ...D-1 Major Component Locations...D-5 Troubleshooting and Repair ...Section E Electrical Diagrams...Section F Parts Manual...P277 Series TABLE OF CONTENTS POWER ARC 5000 Page...

  • Page 8: Installation

    TECHNICAL SPECIFICATIONS - POWER ARC 5000 Manufacturer Description Briggs & 1 cyl., Stratton 4 cycle Industrial air-cooled Plus gasoline 11 HP @ 3600 RPM Duty Cycle 40% Duty Cycle 60% Duty Cycle OUTPUT - WELDER AND GENERATOR Welding Ranges 70 - 150 Amps Height 26.62 in.

  • Page 9: Safety Precautions

    INSTALLATION LOCATION AND VENTILATION Whenever you use the POWER ARC 5000, 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.

  • Page 10: Assembly Of Vibration Isolators To Bottom Of Tube Frame

    Also, fuel capacity will be a little less at an angle. LIFTING The POWER ARC 5000 should be lifted by four peo- ple. (It weighs 208 lbs/94.3 kg.) Its welded tube roll cage is designed to make lifting easy.

  • Page 11: Assembly Of Wheels And Handle To The Tube Frame

    The height of the handle can be adjusted to suit the user. Figure A-2 Axle Item 5 POWER ARC 5000 Engine Support Channel 3/8-16 x .875 Hex Bolt (2) Lockwasher Tubular Frame Hex Nut...

  • Page 12: Pre-Operation Engine Service

    Fill the fuel tank with clean, fresh, regular grade lead-free gasoline. DO NOT MIX OIL WITH THE GASOLINE. The POWER ARC 5000 has a plastic, 5.5 gallon (20.8 L) fuel tank mounted above the generator. See the Briggs & Stratton Engine manual for more details about fuel.

  • Page 13: Electrical Output Connections

    FIGURE A.3 - POWER ARC 5000 OUTPUT CONNECTIONS 1. CURRENT CONTROL DIAL 2. ELECTRODE SELECTION GUIDE 3. WELD OUTPUT TERMINALS (TO ELECTRODE HOLDER, HIGH RANGE AND LOW RANGE) 4. WELD OUTPUT TERMINAL (TO WORK) 5. GROUNDING TERMINAL ELECTRICAL OUTPUT CONNECTIONS See Figure A.3 for the location of the current control...
  • Page 14 Do not ground the machine to a pipe that carries explosive or combustible material. When the POWER ARC 5000 is mounted on a truck or a trailer, the machine generator grounding terminal MUST be securely connected to the metal frame of the vehicle.
  • Page 15 It cannot withstand long-term use without proper maintenance. See the MAINTENANCE section of this manual for more information. Certain electrical devices cannot be powered by the POWER ARC 5000. Refer to Table A.2 for these devices. POWER ARC 5000 CAUTION...
  • Page 16 ELECTRICAL DEVICE USE WITH THE POWER ARC 5000. 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 5000. INSTALLATION TABLE A.2 Common Electrical Devices Heaters, toasters, incandescent light bulbs, electric range, hot pan, skillet, coffee maker.

  • Page 17: Operation

    OPERATING INSTRUCTIONS Read and understand this entire section before oper- ating your POWER ARC 5000. SAFETY INSTRUCTIONS 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;...

  • Page 18: Recommended Applications

    OPERATION WELDING CAPABILITY The POWER ARC 5000 is rated 150 amps, 25 volts at 40% duty cycle on a ten-minute basis. This means that you can load the welder to 150 amps for four minutes out of every ten-minute period. The machine is also capable of higher duty cycles at lower output currents.

  • Page 19: Controls And Settings

    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. CURRENT CONTROL DIAL 2.

  • Page 20: Engine Operation

    1. FUEL SHUTOFF VALVE: Stops the flow of gaso- line from the fuel tank to the carburetor. Should be closed by turning full clockwise whenever you are finished using the POWER ARC 5000. Open fuel shutoff valve by turning full counterclockwise before starting the engine.

  • Page 21: Engine Operation

    DO NOT RUN THE ENGINE AT EXCESSIVE SPEEDS. The maximum allowable high idle speed for the POWER ARC 5000 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.
  • Page 22 5 hours of operation. For more details, see the MAINTENANCE section of this manu- CAUTION During break-in, subject the POWER ARC 5000 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.

  • Page 23: Generator Operation

    CATIONS, to determine the wattage requirements of the most common types of loads you can power with the POWER ARC 5000. Be sure to read the notes at the bottom of the table. TO USE THE GENERATOR AS AN AUXILIARY POWER SUPPLY: 1.
  • Page 24 1,000 2,000 1,500 1,250 1,200 2,000 1,750 2,600 2,000 1,100 3,000-4,600 POWER ARC 5000 *Start-up Watts 3,100 - 5,000 1,500 - 2,400 750 - 2,000 2,500 - 4,000 3,000 - 4,800 1,500 - 2,400 2,500 - 4,000 1,500 - 2,400...

  • Page 25: Welding Operation

    3. Remove the work clamp from the work. 4. Remove any remaining piece of electrode from the electrode holder. 5. If you are finished using the POWER ARC 5000 for welding, disconnect the welding cables from the weld output terminals. Reattach the flange nuts and leave them on the terminals.

  • Page 26: Welding Guidelines

    12 GA. & THINNER 12 GA. & THICKER 5/32" 10 GA. & THICKER 3/32" 1/4" & THINNER 1/4" & THICKER 1/8" 1/8" & THICKER POWER ARC 5000 B-10 INITIAL RANGE SETTING 80 AMPS 100 AMPS 150 AMPS HIGH 70 AMPS...

  • Page 27: Learning To Stick Weld

    Many variables beyond the control of The Lincoln Electric Company affect the results obtained in applying this type of information. These variables include, but are not limited to, welding...
  • Page 28 B-12 The POWER ARC 5000 has a voltage output of up to 62 volts which can shock. WARNING ELECTRIC SHOCK can kill. • Do not touch electrically live parts or electrode with skin or wet cloth- ing. • Insulate yourself from work and ground.
  • Page 29 NOTE: When welding on thin plate, you will find that you have to increase the welding speed, whereas when welding on heavy plate, it is necessary to go more slowly to ensure fusion and penetration. POWER ARC 5000 B-13 Molten puddle...
  • Page 30 1/8” (3.2mm) for heavy metal space between them in order to get deep penetration. Tack the plates at both ends, otherwise the heat will cause the plates to move apart. (See drawing). POWER ARC 5000 B-14 Lap Weld Corner Weld...
  • Page 31 Welding in the vertical position can be done either vertical-up or vertical-down. Vertical-up is used whenever a large, strong weld is desired. Vertical-down is used primarily on sheet metal for fast, low penetrating welds. POWER ARC 5000 B-15 45° 45°...
  • Page 32 The important thing is to continue lowering the entire arm as the weld is made so the angle of the electrode does not change. Move the electrode fast enough so that the slag does not catch up with the arc. POWER ARC 5000 B-16 Very short...
  • Page 33 The important thing is to hardface the side that wears. 3. Use 1/8” (3.2mm) Wearshield at 80-100 A. Strike the arc about one inch from the sharp edge. POWER ARC 5000 B-17...
  • Page 34 “veed” out by grinding or filing to give complete pene- tration as shown in figures (a), (b) and (c) below. This is especially important on thick castings where maxi- mum strength is required. In some instances a back- POWER ARC 5000 B-18 When breaking the weld stays on...
  • Page 35 ALWAYS fill craters by drawing electrode away slowly. ALWAYS keep these electrodes dry. Electrodes, when not used within a few hours after a container is opened, must be stored in heated cabinets. POWER ARC 5000 B-19 Motions START SIDE...

  • Page 36: Accessories

    BRIGGS AND STRATTON ACCESSORIES The following options/accessories are available for your POWER ARC 5000 from your local Briggs & Stratton Distributor. Exhaust Deflector (B&S No.393761) - Used to deflect engine exhaust down. Attaches to the muffler with four screws.

  • Page 37: Maintenance

    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 5000. Keep all equipment safety guards, covers, and devices in position and in good repair. Keep your...
  • Page 38 CYLINDER HEAD TORQUE PROCEDURE: Use a torque wrench and tighten the cylinder head bolts to 165 inch pounds in the sequence shown in Figure D.5. This procedure is to be performed after the first 100-300 hours of operation. POWER ARC 5000...

  • Page 39: Engine Maintenance Schedule

    Note 2 ● Note 2 ● Part Number NONE B&S 802592 CHAMPION RJ19LM B&S 394358 B&S 494511 B&S 492889 (CAN BE CLEANED AND REUSED) POWER ARC 5000 100 Hours or Yearly 100-300 Hours ● Note 2 ● ● ● ●...
  • Page 40 GENERATOR/WELDER MAINTENANCE STORAGE: Store the POWER ARC 5000 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 REMOVAL AND REPLACEMENT: See Figure D.6.

  • Page 41: Major Component Locations

    MAINTENANCE FIGURE D.7. - MAJOR COMPONENT LOCATIONS 1 . OUTPUT PANEL ASSEMBLY 2. CONTROL BOX ASSEMBLY 3. ENGINE AND CRADLE ASSEMBLY 4. STATOR AND ROTOR ASSEMBLY POWER ARC 5000...

  • Page 42: Troubleshooting

    4. No open circuit voltage at output studs. Open lead in weld circuit. 5. Faulty reactor (L1). 6. Rheostat (R1) lead broke CAUTION POWER ARC 5000 RECOMMENDED COURSE OF ACTION 1. Refer to wiring diagram. - check lead 202C (brown) connection at oil-gard switch in engine block.
  • Page 43 1. Bad gas, bad filter, air cleaner, spark plug, and/or breather. CAUTION POWER ARC 5000 RECOMMENDED COURSE OF ACTION 1. Allow machine to cool by running at no load. Reduce load and press in circuit breaker.
  • Page 44 9. Float open in carburetor & gas leak- ing from bowl. 10. Engine is siezed and recoil start will not move. CAUTION POWER ARC 5000 RECOMMENDED COURSE OF ACTION 1. Dry and Place boot firmly onto spark plug. 2. Check and fill oil to proper level.
  • Page 45 DIAGRAMS POWER ARC 5000...
  • Page 46 DIAGRAMS POWER ARC 5000...
  • Page 47 Address: Telephone: _______________________________________________ |_|_| |_|_| Exp Date Month BOOK DIVISION, The Lincoln Electric Company, 22801 St. Clair Avenue, Cleveland, Ohio 44117-1199 for fastest service, FAX this completed form to: 216-361-5901 Telephone: 216-383-2211 or, Titles: Price New Lessons in Arc Welding $5.00...
  • Page 48 ● WARNING ● Spanish ● AVISO DE PRECAUCION ● French ● ATTENTION ● ● German WARNUNG ● Portuguese ● ATENÇÃO ● Japanese Chinese Korean Arabic READ AND UNDERSTAND THE MANUFACTURER’S INSTRUCTION FOR THIS EQUIPMENT AND THE CONSUMABLES TO BE USED AND FOLLOW YOUR EMPLOYER’S SAFETY PRACTICES. SE RECOMIENDA LEER Y ENTENDER LAS INSTRUCCIONES DEL FABRICANTE PARA EL USO DE ESTE EQUIPO Y LOS CONSUMIBLES QUE VA A UTILIZAR, SIGA LAS MEDIDAS DE SEGURIDAD DE SU SUPERVISOR.
  • Page 49 ● ● Keep your head out of fumes. Turn power off before servicing. ● Use ventilation or exhaust to remove fumes from breathing zone. ● Los humos fuera de la zona de res- ● Desconectar el cable de ali- piración. mentación de poder de la máquina ●...
  • 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...

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