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Lincoln Electric Power-Arc 5500, Operator'S Manual

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Lincoln Electric Power-Arc 5500 Operator'S Manual Download Page 7

Page

Safety

.................................................................................................................................................i-iv

Installation

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Section 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

Safety Instructions ......................................................................................................................B-1

General Description ....................................................................................................................B-1

Recommended Applications.......................................................................................................B-1

Operational Features and Controls.............................................................................................B-1

Welding Capability ......................................................................................................................B-1

Limitations .................................................................................................................................B-2

Controls and Settings .................................................................................................................B-2

Engine Operation .........................................................................................................B-3 Thru B-6

Welding Operation .....................................................................................................B-7 Thru B-16

Accessories

...........................................................................................................................

Section C

Maintenance

..........................................................................................................................

Section D

Safety Precautions ............................................................................................................................D-1

Routine and Periodic Maintenance ...................................................................................................D-1

General Assembly Exploded View ....................................................................................................D-5

Troubleshooting and Repair

................................................................................................

Section E

Electrical Diagrams and Dimension Print

...........................................................................

Section F

Parts Manual (Robin / Subaru)

......................................................................................

P-510  Series

MASTER TABLE OF CONTENTS FOR ALL SECTIONS

vi

vi

POWER-ARC 5500

Summary of Contents for Power-Arc 5500

Page 1: ... IM900 A December 2008 Various engine configurations are available and machine appearance will vary accordingly ISO 9001 CERTIFICATE NUMBER 30273 Designed and Manufactured Under a Quality Program Certified by ABS Quality Evaluations Inc to ISO 9001 Requirements QMS ANSI RAB Sales and Service through Subsidiaries and Distributors Worldwide Cleveland Ohio 44117 1199 U S A TEL 216 481 8100 FAX 216 48...

Page 2: ... 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 availab...

Page 3: ...ter 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 3 i When working above floor level use a safety belt to protect yourself from a fall should you get a shock 3 j Also see Items 6 c and 8 FUMES AND GASES can be dangerous 5 a Welding may produ...

Page 4: ... 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 Welding and Cutting ANSI Standard Z49 1 and the operating information for the equipment being used 6 c When not wel...

Page 5: ...propriés et non inflamma bles 4 Des gouttes de laitier en fusion sont émises de lʼarc de soudage Se protéger avec des vêtements de protection libres de lʼhuile 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 lʼon pique le laitier 6...

Page 6: ...important when identifying the correct replacement parts On Line Product Registration Register your machine with Lincoln Electric either via fax or over the Internet For faxing Complete the form on the back of the warranty statement included in the literature packet accompanying this machine and fax the form per the instructions printed on it For On Line Registration Go to our WEB SITE at www linc...

Page 7: ...al Description B 1 Recommended Applications B 1 Operational Features and Controls B 1 Welding Capability B 1 Limitations B 2 Controls and Settings B 2 Engine Operation B 3 Thru B 6 Welding Operation B 7 Thru B 16 Accessories Section C Maintenance Section D Safety Precautions D 1 Routine and Periodic Maintenance D 1 General Assembly Exploded View D 5 Troubleshooting and Repair Section E Electrical ...

Page 8: ...125 Amps AC Constant Current 20 VAC 60 Duty Cycle 100 Amps AC Constant Current 25 VAC Welding Ranges Welder Open Circuit Voltage AC Auxiliary Power 70 125 Amps AC 62 VAC Max 4000 Continuous Watts 5500 Surge Watts Height Width Depth Weight 20 9 in 20 in 30 in 160 lb 530 mm 508 mm 762 mm 72 5 kg A 1 INSTALLATION POWER ARC 5500 A 1 INPUT GASOLINE ENGINE RATED OUTPUT WELDER OUTPUT WELDER AND GENERATOR...

Page 9: ... to an open outside area The POWER ARC 5500 must 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 5500 with the case roof on and all machine components completely assembled This will protect you from the dangers of moving parts hot metal surfaces...

Page 10: ...ICE Read and understand the information about the gaso line engine in the OPERATION and MAINTENANCE sections of this manual and the engine owner s manu al before you operate the POWER ARC 5500 OIL The Power Arc 5500 with the Robin Subaru 9HP engine is supplied with low oil protection The engine is equipped with protection that will shut down the engine in the event of a low oil condition The engin...

Page 11: ...PARK ARRESTER 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 The Power Arc 5500 is supplied with a spark arrester as standard equipment Refer to the engine owner s manual for proper maintenance An incorrect additional spark arrester may lead to damage to th...

Page 12: ...125 amp Cable Length 30 Duty Cycle 0 50 feet 0 15 meters 6 AWG 50 100 feet 15 39 meters 4 AWG 100 150 feet 30 46 meters 3 AWG 150 200 feet 46 61 meters 2 AWG 200 250 feet 61 76 meters 1 AWG POWER ARC 5500 POWER ARC 5500 ELECTRODE SELECTION GUIDE ELECTRODE SELECTION GUIDE 80 80 90 90 100 100 70 AMPS AMPS AMPS AMPS AMPS AMPS AMPS AMPS WARNING WARNING AMPS AMPS 125 125 GENERATOR GENERATOR 6 5 4 3 2 1...

Page 13: ... to an earth ground However for best protection against electrical 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 Do not ground the machine to a pipe that carries explosive or combustible material When the POWER ARC 5500 is mounted on a truck or a trailer th...

Page 14: ...row transfer switch in conjunction with the properly rated double throw circuit breaker is connected between the generator power and the utility meter The POWER ARC 5500 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 5500 is intended only for backup intermittent use power Oil lev...

Page 15: ...ONAL RESISTIVE TYPE LOADS Inductive Single phase induction motors These devices 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 ...

Page 16: ...t of welding output The machine is lightweight portable and can be lifted by two people The Lincoln warranty covers the Power Arc 5500 excluding the engine for 3 years from the date of purchase The engine is covered by the engine manufacturer s warranty policy RECOMMENDED APPLICATIONS GENERATOR The POWER ARC 5500 gives AC generator output for medium use non commercial demands For more details on o...

Page 17: ... 1 2 13 FLANGE NUT Provides the connection point for either the electrode hold er or the work cable Because the POWER ARC 5500 is an AC output machine either output ter minal can be used for either cable POWER ARC 5500 POWER ARC 5500 POWER ARC 5500 ELECTRODE SELECTION GUIDE ELECTRODE SELECTION GUIDE 80 90 100 100 70 70 AMPS AMPS AMPS AMPS AMPS AMPS AMPS AMPS WARNING WARNING AMPS AMPS 125 125 GENER...

Page 18: ...fler serves as a spark arrester See SPARK ARRESTER in the INSTALLATION section of this manual 4 ON OFF Switch A two position switch located on the rear of the engine In the ON I position the engine ignition circuit is energized and the engine can be started by pulling the recoil rope starter In the OFF O position the electronic ignition is grounded and the engine shuts down 5 AIR CLEANER Filters i...

Page 19: ... OPERATION B 4 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 Replace the fill plug and tighten securely CHECK AND FILL THE ENGINE FUEL TANK 1 Remove the fuel tank cap 2 Fill the tank to allow approximately 1 4 inch 5 mm of tank space for fuel expa...

Page 20: ...al on the output control panel to GENERATOR See Figure B 1 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 5 500 surge watts or 4 000 Continuous watts Be sure to start the largest loads first CAUTION B 5 OPERATI...

Page 21: ...4 000 Sump Pump 600 1 500 2 400 Toaster 1 100 Weed Trimmer 500 Lincoln Wire Feeder Welder 4 000 B 6 OPERATION B 6 POWER ARC 5500 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 tabled equipment that uses a motor allow up to 2 times the running watts shown above For example a 1 HP motor requi...

Page 22: ...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 the electrode and work to cool completely 3 Remove the...

Page 23: ...some Wire Feeder Welders come equipped with the essen tials needed for Gas Metal Arc Welding GMAW or MIG processes while others require the purchase of a conversion kit These products are available where Lincoln products are sold Contact your local autho rized Lincoln representative for more details B 8 OPERATION B 8 POWER ARC 5500 Material Thickness Electrode Type Size Setting FLEETWELD 37 90 amp...

Page 24: ...rcuit see Figure 3 by hold ing the tip of the electrode 1 16 1 8 1 6 3 2mm away from the work or base metal being welded The electric arc is established in this gap and is held and moved along the joint to be welded melting the metal as it is moved Arc welding is a manual skill requiring a steady hand good physical condition and good eyesight The oper ator controls the welding arc and therefore th...

Page 25: ... the electrode at a slight angle as shown in Figure 5 Figure 5 15 20 90 side view end view Correct Welding Position 2 The Correct Way to Strike An Arc Be sure the work clamp makes good electrical contact to the work Lower your headshield and scratch the electrode slowly over the metal and you will see sparks fly While scratching lift the electrode 1 8 3 2mm and the arc is established NOTE If you s...

Page 26: ...d 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 steel...

Page 27: ...iginal metal Successive passes must be used to build up butt welds on heavier metal Fillet Joints When welding fillet joints 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 hor...

Page 28: ...Y 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 FOL LOW 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 29: ...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 30: ...ng which creates 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 weldin...

Page 31: ...ry Electrodes when not used within a few hours after a container is opened must be stored in heated cabinets 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 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 Elect...

Page 32: ...ncludes the following 20 Ft 6 1m 6 welding cable with lug 15 Ft 4 6 6 work cable with lugs 200 amp electrode holder Light duty work clamp Sample electrode pack Welding Gloves Helmet Chipping Hammer and Brush Undercarriage K882 2 2 wheeled hand moving Rotor Removal Kit S20925 A service kit with thru and impact bolts for removing the generator rotor from the tapered engine crankshaft POWER ARC 5500 ...

Page 33: ... the spark plug lead before servicing the engine See the engine owner s manual for a summary of maintenance intervals for the items listed below Follow either the hourly or the calendar intervals whichever come first More frequent service may be required depending on your specific application and operating conditions Table D 1 shows engine main tenance replacement parts and numbers OIL Check the o...

Page 34: ...er 1 Wash in liquid detergent and water 2 Squeeze dry in a clean cloth 3 Saturate in clean engine oil 4 Squeeze in a clean absorbent cloth to remove all excess oil 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 Periodically clean the muffler area to remove combustible debris Clean Rotating Screen If yo...

Page 35: ...ean 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 sol vent 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 5 FIGURE D...

Page 36: ...ACLES Keep the electrical receptacles in good condition Remove any dirt oil or other debris from their surfaces and holes CABLE CONNECTIONS Check the welding cable connections at the weld output terminals often Be sure that the connections are always tight NOTE Lincoln offers a rotor removal kit for any ser vice which requires removal of the rotor from the engine See the ACCESSORIES section for fu...

Page 37: ... 3 4 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 FIGURE D 6 MAJOR COMPONENT LOCATIONS ...

Page 38: ...BLE CAUSE lists the obvious external possibilities that may contribute to the machine symptom Step 3 RECOMMENDED COURSE OF ACTION This column provides a course of action for the Possible Cause generally it states to contact your local Lincoln Authorized Field Service Facility If you do not understand or are unable to perform the Recommended Course of Action safely contact your local Lincoln Author...

Page 39: ...able but unit will not weld 1 Disconnect anything plugged into auxiliary receptacles and weld loads 2 Open lead in flashing or field circuit 3 Open flashing diode D1 4 Faulty brushes 5 Faulty rheostat R1 6 Faulty field rectifier D1 7 Faulty capacitor C1 8 Faulty stator field winding 9 Faulty rotor 10 Dirty slip rings clean slip rings when not in use 1 Loose connection to output stud 2 Work not con...

Page 40: ...stops running Engine sputters but will not start 1 Circuit breaker open 2 Loose or open connection with elec trical plug in component 3 Current control dial not at 125 4 No open circuit voltage at receptacle Open lead in receptacle circuit 5 No open circuit voltage at receptacle Bad receptacle 6 Rheostat R1 lead broke 1 Engine is not fully warmed up and engine choke is in the fully open RUN positi...

Page 41: ...losed 3 Low oil and engine low oil shutdown protection will not allow unit to start Light in ON OFF switch will Flash when the engine is cranked Engines equipped with low oil shut down protection only 4 Choke left in full choke position and carburetor flooded 5 Fuel line clogged or closed 6 Recoil start will not engage with engine 7 Fouled spark plug 8 Engine requires service to head head gasket a...

Page 42: ...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 If the diagram is illegible write to the Service Department for a replacement Give the equipment code number ...

Page 43: ...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 If the diagram is illegible write to the Service Department for a replacement Give the equipment code number ...

Page 44: ...F 3 DIAGRAMS F 3 POWER ARC 5500 M17196 A 01 R ELECTRIC LINCOLN 20 00 20 88 7 92 14 16 30 00 DIMENSION PRINT POWER ARC 5500 ...

Page 45: ...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 46: ...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 47: ...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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