Lincoln Electric POWER ARC 5000 Operator'S Manual Download Page 26

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TABLE B.4

WELDING APPLICATIONS/ELECTRODE SELECTION GUIDE

AWS

ELECTRODE TYPE

SIZE

MATERIAL

INITIAL

RANGE

CLASS

THICKNESS

SETTING

E6011

FLEETWELD 180

3/32"

1/8" & THINNER

80 AMPS

LOW

"FAST FREEZE"

1/8"

1/8" & THICKER

100 AMPS

LOW

5/32"

1/4" & THICKER

150 AMPS

HIGH

E6013

FLEETWELD 37

5/64"

12 GA. & THINNER

70 AMPS

LOW

"FAST FILL"

3/32"

1/8" & THINNER

100 AMPS

LOW

1/8"

1/8" & THICKER

150 AMPS

HIGH

E7014

FLEETWELD 47

3/32"

1/8" & THINNER

90 AMPS

LOW

"FILL-FREEZE"

1/8"

1/8" & THICKER

150 AMPS

HIGH

E7018

LINCOLN 7018 AC

3/32"

1/8" & THINNER

80 AMPS

LOW

"LOW HYDROGEN"

1/8"

1/8" & THICKER

125 AMPS

LOW

E7024-1 JETWELD 1

3/32"

1/8" & THINNER

100 AMPS

LOW

“FAST FILL”

1/8"

1/8" & THICKER

150 AMPS

HIGH

BLUE MAX 308-16

3/32"

12 GA. & THINNER

80 AMPS

LOW

STAINLESS ELECTRODE 1/8"

12 GA. & THICKER

100 AMPS

LOW

5/32"

10 GA. & THICKER

150 AMPS

HIGH

SOFTWELD 99NI

3/32"

1/4" & THINNER

80 AMPS

LOW

CAST IRON ELECTRODE 1/8"

1/4" & THICKER

125 AMPS

LOW

WEARSHIELD ABR

1/8"

1/8" & THICKER

150 AMPS

HIGH

NOTES:

The values listed are suggested settings. Actual setting may vary depending on individual preference
and/or specific application.

B-10

OPERATION

B-10

POWER ARC 5000

WELDING GUIDELINES

Summary of Contents for POWER ARC 5000

Page 1: ...T READING THIS MANUAL AND THE SAFETY PRECAUTIONS CONTAINED THROUGHOUT And most importantly think before you act and be careful POWER ARC 5000 For Machines with Code Number 10255 and 10430 IM560 A November 1999 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 World s Leader in Welding...

Page 2: ...R WEARERS SHOULD CONSULT WITH THEIR DOCTOR BEFORE OPERATING Read and understand the following safety highlights For additional safety information it is strongly recommended that you purchase a copy of Safety in Welding Cutting ANSI Standard Z49 1 from the American Welding Society P O Box 351040 Miami Florida 33135 or CSA Standard W117 2 1974 A Free copy of Arc Welding Safety booklet E205 is availa...

Page 3: ...rical earth ground 3 f Maintain the electrode holder work clamp welding cable and welding machine in good safe operating condition Replace damaged insulation 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 ...

Page 4: ...event 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 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 Weldin...

Page 5: ...s et non inflamma bles 4 Des gouttes de laitier en fusion sont émises de l arc de soudage Se protéger avec des 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 Eloign...

Page 6: ...he information must be followed to avoid minor personal injury or damage to this equipment CAUTION Please Examine Carton and Equipment For Damage Immediately When this equipment is shipped title passes to the purchaser upon receipt by the carrier Consequently Claims for material damaged in shipment must be made by the purchaser against the transportation company at the time the shipment is receive...

Page 7: ...s A 6 to A 9 Operation Section B Safety Instructions B 1 General Description B 1 Recommended Applications B 2 Controls and Settings B 3 Engine Operation B 5 Generator Operation B 7 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 ...

Page 8: ... load Recoil start Oil 1 5 qt 1 42 l Plus gasoline Manual choke 11 HP 3600 RPM RATED OUTPUT WELDER Duty Cycle Amps Volts at Rated Amperes 40 Duty Cycle 150 25 VAC 60 Duty Cycle 125 25 VAC OUTPUT WELDER AND GENERATOR Welding Ranges Welder Open Circuit Voltage AC Auxiliary Power 70 150 Amps 62 VAC Max 5000 Watts 41 6 20 8 amps 120 240 volts 5 15 PHYSICAL DIMENSIONS Height Width Depth Weight 26 62 in...

Page 9: ...104 F 18 C to 40 C The POWER ARC 5000 may be used outdoors Do not set the machine in puddles or otherwise sub merge it in water Such practices pose safety haz ards and cause improper operation and corrosion of parts Always operate the POWER ARC 5000 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 li...

Page 10: ...0 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 ASSEMBLY OF VIBRATION ISOLATORS TO BOTTOM OF TUBE FRAME If wheels are not used Tools required 9 16 wrench or socket If the supplied wheels are not used it is important that the isolators are installed to keep the machine stabilized when operated on a smooth surface Install the fo...

Page 11: ...be installed between the vibration isolators and the underside of the channel The remaining two large plain washers spacers are not used e Install one of the push nuts Item 4 on one end of the axle Item 5 by supporting the axle vertical and tapping on the push nut with a rubber mallet or wooden block f Install one wheel Item 6 on to the axle and slide the axle through the slots in the two axle sup...

Page 12: ...il fill and service information see the Briggs Stratton Engine manual FUEL 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 SPARK ARRESTER Gasoline engine mufflers may emit sparks when the eng...

Page 13: ...pecially important when you are welding at a distance from the welder 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 POWER ARC 5000 1 7 8 5 3 4 2 6 9 10 120 VOLTS 15 AMPS 120 VOLTS 30 AMPS 120 240 VOLTS 3...

Page 14: ... properly specified welding cables See the ACCESSORIES section of this manual for more infor mation MACHINE GROUNDING For protection against electrical shock connect a heavy gauge wire from the grounding terminal located on the bot tom center of the output panel to a suit able earth ground such as a metal pipe driven into the ground Do not ground the machine to a pipe that carries explosive or com...

Page 15: ...ws 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 Only a licensed certified trained electrician should install the machine to a premises or residential elec...

Page 16: ...evices require large drills well pumps grinders small current inrush for starting See refrigerators weed and hedge Table B 3 GENERATOR POWER trimmers APPLICATIONS in the OPERA TION section of this manual for required starting wattages Some synchronous motors may be frequency sensitive to attain maximum output torque but they SHOULD BE SAFE from any frequency induced failures Capacitive Inductive C...

Page 17: ...jure Do not operate this equipment with any of its doors open or guards off Stop the engine before servicing it Keep away from moving parts Only qualified personnel should install use or ser vice this equipment GENERAL DESCRIPTION 5000 Watt power generator and arc welder built into one machine High quality long life Briggs Stratton 11 HP Industrial Plus engine with cast iron cylinder 5 5 gallon fu...

Page 18: ...achine as a welder see WELDING OPERATION in this section of the manual 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 You can load the welder to 125 amps for six minute...

Page 19: ...al devices 8 30 AMP 120 VOLT TWIST LOCK RECEPTACLE 120 volt power for higher power requirements 9 30 AMP 120 240 VOLT TWIST LOCK RECEPTACLE For supplying 240 volt power and for connection to 120 240 volt premises wiring 10 ENGINE HOUR METER Records engine running time Use this meter to schedule engine mainte nance POWER ARC 5000 POWER ARC 5000 1 7 8 5 3 4 2 6 9 10 120 VOLTS 15 AMPS 120 VOLTS 30 AM...

Page 20: ...out the specific type of air cleaner to use 6 CHOKE Provides a richer air fuel mixture for cold engine starting conditions See the topic ENGINE OPERATION below for details on setting the choke 7 RECOIL STARTER Manual rope type starter The handle position allows easy starting from either ground level or pickup truck level 8 OIL DRAIN PLUG Permits convenient draining of engine oil during maintenance...

Page 21: ...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 S...

Page 22: ...HE 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 pushing the On Off Switch on the end of the engine to the OFF position 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 by turning ...

Page 23: ...by multiplying the voltage rating of the load by the number of amps it draws This information is given on the load device nameplate For example a device rated 120 volts 2 amps will need 240 watts of power 120 x 2 240 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 5000 Be sure to read the n...

Page 24: ...CATIONS Suggested Power Applications Running Watts Start up Watts Air Compressor 3 4 HP 1 250 3 100 5 000 Airless Sprayer 1 3 HP 600 1 500 2 400 Chain Saw 1 200 Circular Saw 1 200 Coffee Maker 1 000 Deep Freezer 500 750 2 000 Electric Motor 1 HP 2 000 2 500 4 000 Electric Range 1 element 1 500 Electric Skillet 1 250 Furnace Fan 1 3 HP 1 200 3 000 4 800 Portable Grinder 4 1 2 600 Portable Grinder 7...

Page 25: ...the electrode holder 5 Set the current control dial to the desired output current 6 Start the gasoline engine See ENGINE OPERA TION in this section of the manual 7 Strike an arc and begin welding For information on welding techniques see WELDING GUIDE LINES in this section of the manual AFTER YOU FINISH THE WELD 1 Stop the gasoline engine See ENGINE OPERA TION in this section of the manual 2 Allow...

Page 26: ...0 AMPS HIGH E7018 LINCOLN 7018 AC 3 32 1 8 THINNER 80 AMPS LOW LOW HYDROGEN 1 8 1 8 THICKER 125 AMPS LOW E7024 1 JETWELD 1 3 32 1 8 THINNER 100 AMPS LOW FAST FILL 1 8 1 8 THICKER 150 AMPS HIGH BLUE MAX 308 16 3 32 12 GA THINNER 80 AMPS LOW STAINLESS ELECTRODE 1 8 12 GA THICKER 100 AMPS LOW 5 32 10 GA THICKER 150 AMPS HIGH SOFTWELD 99NI 3 32 1 4 THINNER 80 AMPS LOW CAST IRON ELECTRODE 1 8 1 4 THICK...

Page 27: ...ing 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 See Book Division section at rear of manual The operator s knowledge of arc welding must go beyond the arc itself He must know how to control the arc and this requires a knowledge of the welding cir cuit and the equipment that provi...

Page 28: ...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 The electrode provides additional filler metal for the joint to fill the groove or gap between the two pieces of the base metal The covering also melts or burns in the arc It has several functions It makes the arc stead ier provides a shield o...

Page 29: ...mportant The arc should be short approximately 1 16 to 1 8 1 6 3 2mm long As the electrode burns off the elec trode must be fed to the work to maintain correct arc length The easiest way to tell whether the arc has the correct length is by listening to its sound A nice short arc has a distinctive crackling sound very much like eggs frying in a pan The incorrect long arc has a hollow blowing or his...

Page 30: ...rred to as mild steel Typical items made with this type of steel include most sheet metal plate pipe and rolled shapes such as channels angle irons and I beams This type of steel can usually be easily welded without special precautions Some steel however contains higher carbon Typical applications include wear plates axles connecting rods shafts plowshares and scraper blades These higher carbon st...

Page 31: ...iginal metal Successive passes must be used to build up butt welds on heavier metal Fillet Welds When welding fillet welds it is very important to hold the electrode at a 45 angle between the two sides or the metal will not distribute itself evenly To make it easier to get the 45 angle it is best to put the electrode in the holder at a 45 angle as shown Multiple Pass Welds Make multiple pass horiz...

Page 32: ...LY thing to watch is the molten metal As soon as it has solidi fied the arc is SLOWLY brought back and another few drops of metal are deposited DO NOT FOLLOW THE UP AND DOWN MOVEMENT OF THE ARC WITH YOUR EYES KEEP THEM ON THE MOLTEN METAL 8 When the arc is brought back to the now solidified puddle IT MUST BE SHORT otherwise no metal will be deposited the puddle will melt again and it will drip 9 I...

Page 33: ...lag A whipping technique may be used to further minimize burn through 5 If you have a choice use lap joints rather than fil lets or butts the double thickness effect of a lap joint makes it much easier to weld without burning through Hardfacing To Reduce Wear There are several kinds of wear The two most often encountered are 1 Metal to Ground Wear Plowshares bulldozer blades buckets cultivator sha...

Page 34: ...tes brittle white cast iron The entire casting will cool slowly 2 Weld 1 2 12 7mm at a time and do not weld at that spot again until the weld is cool This way no large amount of heat is put into the mass Most inexperienced welders will probably use the sec ond method because they have no way of preheating large castings Smaller castings can easily and should be preheated before welding A forge sto...

Page 35: ...s when not used within a few hours after a container is opened must be stored in heated cabinets up strip may be used and plates may be gapped 1 8 3 2mm or more as shown in figure b 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 Selecting Electrodes Which electrode is best for the...

Page 36: ...nsulated electrode holder Sample electrodes The cables are rated at 150 amps 40 duty cycle Spark Arrester K883 2 A field installed kit for the 11 HP Briggs Stratton engine Rotor Removal Kit S20925 A service kit for removing the generator rotor from the tapered engine crankshaft BRIGGS AND STRATTON ACCESSORIES The following options accessories are available for your POWER ARC 5000 from your local B...

Page 37: ... D 2 shows engine maintenance replacement parts and numbers 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 hours of oper ation Then under normal operating conditions change the oil after every 50 hours or once a year whichever occurs first If the engine is operated under heavy load or in high ambient tempera...

Page 38: ...and surfaces to prevent over speeding overheating and engine damage Clean every 100 operating hours or as often as necessary using a brush and low pressure air FIGURE D 3 CLEAN COOLING SYSTEM 1 REMOVE DIRT FROM THESE AREAS 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 a...

Page 39: ... Fuel Filter Option Re Torque Cylinder Head Bolts 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 TABLE D 2 ENGINE MAINTENANCE PARTS Part Part Number OIL FILTER NONE SPARK PLUG RESISTOR B S 802592 CHA...

Page 40: ...rings while engine is running To reinstall the brushes press them upward and slide a cable tie or wooden stick through the brush holder tabs Install the brush holder into the bear ing end bracket and secure with the screws previ ously removed Remove the cable tie or wooden stick and the brushes will seat onto the slip rings RECEPTACLES Keep the electrical receptacles in good condition Remove any d...

Page 41: ...D 5 MAINTENANCE D 5 POWER ARC 5000 1 OUTPUT PANEL ASSEMBLY 2 CONTROL BOX ASSEMBLY 3 ENGINE AND CRADLE ASSEMBLY 4 STATOR AND ROTOR ASSEMBLY FIGURE D 7 MAJOR COMPONENT LOCATIONS ...

Page 42: ...stat R1 lead broke 1 Refer to wiring diagram check lead 202C brown connection at oil gard switch in engine block check green GNDC lead con nected to bearing end bracket 2 Check continuity in forward direction 202C brown and 202B red 3 Check continuity and wear of brush Replace brush if necessary 4 Rheostat resistance should be approximately 3 ohms when current control dial is set at 70 amps 5 Repl...

Page 43: ...25 4 No open circuit voltage at receptacle Open lead in receptacle circuit 5 No open circuit voltage at receptacle 6 Rheostat R1 lead broke 1 Engine requires service to head car buretor filters oil spark plug and or gas 1 Bad gas bad filter air cleaner spark plug and or breather 1 Allow machine to cool by running at no load Reduce load and press in circuit breaker 2 Check all plugs and cordsets fo...

Page 44: ...h engine 7 Fouled spark plug 8 Engine requires service to head head gasket and or valves 9 Float open in carburetor gas leak ing from bowl 10 Engine is siezed and recoil start will not move 1 Dry and Place boot firmly onto spark plug 2 Check and fill oil to proper level 3 Open valve by turning counterclock wise 4 Allow unit to set for several minutes Follow Starting Shutdown Instructions section w...

Page 45: ...B3 3C R BLACK RED 9A BLUE 7A BLUE 30A 15A X W 120V LINE GND 120 240V HOT Y LINE WHITE 2 PANEL GROUND FRONT GROUND STATOR END OUTPUT STUDS WORK ELEC LO ROTOR R1 CCW 100W 3D BLACK 3 3 PER E1537 3B SYMBOLS BLACK ELECTRICAL WIRING DIAGRAM POWER ARC 5000 L1 GNDE 201B BLACK REACTOR STATOR W1B 202 202A RED C1 600 FD GREEN GNDG 5C WHITE GREEN 5B WHITE 201 D1 BLACK 9A 201A BLACK 1 6 WHITE 6A 5 4 6B 3A 7 3 ...

Page 46: ...F 2 DIAGRAMS F 2 POWER ARC 5000 R 20 00 26 50 M18053 6 28 96 POWER ARC 5000 29 31 POWER ARC 5000 DIMENSION PRINT ...

Page 47: ...lletin ED 80 or call 216 383 2259 and ask for the Welding School Registrar Lincoln Welding School BASIC COURSE 700 00 5 weeks of fundamentals There is a 10 discount on all orders of 50 00 or more for shipment at one time to one location Orders of 50 or less before discount or orders outside of North America must be prepaid with charge check or money order in U S Funds Only Prices include shipment ...

Page 48: ...electrically live parts or electrode with skin or wet clothing Insulate yourself from work and ground No toque las partes o los electrodos bajo carga con la piel o ropa moja da Aislese del trabajo y de la tierra Ne laissez ni la peau ni des vête ments mouillés entrer en contact avec des pièces sous tension Isolez vous du travail et de la terre Berühren Sie keine stromführenden Teile oder Elektrode...

Page 49: ...gute Be und Entlüftung des Arbeitsplatzes Mantenha seu rosto da fumaça Use ventilação e exhaustão para remover fumo da zona respiratória Turn power off before servicing Desconectar el cable de ali mentación de poder de la máquina antes de iniciar cualquier servicio Débranchez le courant avant l entre tien Strom vor Wartungsarbeiten abschalten Netzstrom völlig öff nen Maschine anhalten Não opere co...

Page 50: ...s 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 World s Leader in Welding and Cutting Products ...

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