Lincoln Electric POWER ARC 5000 manual

OPERA TOR’S MANUAL 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 THIS MANUAL AND THE SAFETY PRECAUTIONS CONT[...]

FOR ENGINE powered equipment. 1.a. Turn the engine off before troubleshooting and maintenance work unless the maintenance work requires it to be running. ____________________________________________________ 1.b. Operate engines in open, well-ventilated areas or vent the engine exhaust fumes outdoors. ________________________________________________[...]

ii SAFETY ii ARC RA YS can burn. 4.a. Use a shield with the proper filter and cover plates to protect your eyes from sparks and the rays of the arc when welding or observing open arc welding. Headshield and filter lens should conform to ANSI Z87. I standards. 4.b. Use suitable clothing made from durable flame-resistant material to protect your skin[...]

FOR ELECTRICALL Y powered equipment. 8.a. Turn off input power using the disconnect switch at the fuse box before working on the equipment. 8.b. Install equipment in accordance with the U.S. National Electrical Code, all local codes and the manufacturer’s recommendations. 8.c. Ground the equipment in accordance with the U.S. National Electrical C[...]

iv SAFETY iv PRÉCA UTIONS 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. Les circuits [...]

Thank You for selecting a QUALITY product by Lincoln Electric. We want you to take pride in operating this Lincoln Electric Company product ••• as much pride as we have in bringing this product to you! Read this Operators Manual completely before attempting to use this equipment. Save this manual and keep it handy for quick reference. Pay par[...]

Page Safety ............................................................................................................................... ..................i-iv Installation ............................................................................................................................. Section A Technical Specifications .............[...]

A-1 INST ALLA TION POWER ARC 5000 A-1 TECHNICAL SPECIFICA TIONS - POWER ARC 5000 INPUT - GASOLINE ENGINE Manufacturer Description Speed Displacement Ignition Capacities Briggs & 1 cyl., 3700 RPM 24.4 cu. in. Electronic Fuel: 5.5 gal. (20.8 l) Stratton 4 cycle ± 50 RPM (400 cc) Ignition; Industrial air-cooled at no load Recoil start; Oil: 1.5 q[...]

A-2 INST ALLA TION POWER ARC 5000 A-2 Read this entire installation section before you start installation. SAFETY PRECAUTIONS 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; detailed engine starting, operating, and ma[...]

A-3 INST ALLA TION POWER ARC 5000 A-3 ST A CKING POWER ARC 5000 machines CANNOT be stacked. TIL TING 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 [...]

A-4 INST ALLA TION POWER ARC 5000 A-4 Assembly of Wheels and Handle to the T ube Frame Tools Required - Two 9/16 wrenches or sockets, 3/8 wrench or socket and a rubber mallet or wooden block. Refer to Figure A-2 for illustration of proper assembly. a.) Set the machine on blocks so that it is raised up off the floor by approximately 6 inches. b.) In[...]

A-5 INST ALLA TION POWER ARC 5000 A-5 PRE-OPERA TION ENGINE SERVICE Read and understand the information about the gasoline engine in the OPERATION and MAINTENANCE sections of this manual before you operate the POWER ARC 5000. • Keep hands away from the engine muffler or HOT engine parts. • Stop the engine when fueling. • Do not smoke when fue[...]

TABLE A.1 RECOMMENDED WELDING CABLE SIZE AND LENGTH TOTAL COMBINED LENGTH OF ELECTRODE AND WORK CABLES Cable Size for 150 amp/ Cable Length 40% 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 (46061 meters) 2 AWG 200-250 feet (61-76 meters) 1 AWG A-6 INST ALLA TION POWER ARC 5[...]

A-7 INST ALLA TION POWER ARC 5000 A-7 Cable Installation Install the welding cables to your POWER ARC 5000 as follows. See Figure A.3 for the location of parts. 1. The gasoline engine must be OFF when connect- ing the welding cables. 2. Remove the 1/2 - 13 flanged nuts from the output terminals. 3. Connect the electrode holder and work cables to th[...]

A-8 INST ALLA TION POWER ARC 5000 A-8 PO WER CORD CONNECTIONS T O TWIST - LOCK PLUGS Refer to the appropriate diagram above for proper connection of power cord wires to the Twist-Lock plug terminals. Also, read the instruction sheet supplied with the Twist-lock plug. PLUGS AND HAND-HELD EQUIPMENT For further protection against electric shock, any 1[...]

TABLE A.2 ELECTRICAL DEVICE USE WITH THE POWER ARC 5000. Type Common Electrical Devices Possible Concerns Resistive Heaters, toasters, incandescent NONE light bulbs, electric range, hot pan, skillet, coffee maker. Capacitive Radios, microwaves, Voltage spikes or high voltage appliances with electronic control. regulation can cause the capaci- tativ[...]

B-1 OPERA TION B-1 OPERA TING INSTRUCTIONS Read and understand this entire section before oper- ating your POWER ARC 5000. SAFETY INSTRUCTIONS 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; detailed engine starting, [...]

B-2 OPERA TION B-2 RECOMMENDED APPLICA TIONS OPERA TIONAL FEA TURES AND CONTR OLS The POWER ARC 5000 was designed for simplicity. Therefore, it has very few operating controls. A single dial on the control panel lets you select either genera- tor or welding use. For welding, the same dial selects continuous current output over the machine’s 70 to[...]

B-3 OPERA TION B-3 GENERA T OR/WELDER CONTROLS See Figure B.1 for the location of the following fea- tures: 1. CURRENT CONTROL DIAL: Adjusts continuous current output. The amperages on the dial corre- spond to the average amperages needed for spe- cific Lincoln welding electrodes. 2. ELECTRODE SELECTION GUIDE: Provides rec- ommended electrodes. 3 .[...]

B-4 OPERA TION B-4 GASOLINE ENGINE CONTR OLS See Figure B.2 for the location of the following fea- tures: 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 be[...]

B-5 OPERA TION B-5 ENGINE OPERA TION 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. Read and understan[...]

B-6 OPERA TION B-6 4. Pull the cord rapidly. 5 . If the engine does not start, open the choke slightly (move lever toward the “RUN” position) and pull the starter cord rapidly again. When the engine starts, gradually open the choke to the “RUN” position. FOR A “HOT” ENGINE: 1. Open the fuel shutoff valve on the bottom of the fuel tank b[...]

B-7 OPERA TION B-7 GENERA TOR OPERA TION Be sure that any electrical equipment plugged into the generator’s AC power receptacles can withstand a +5%-15% voltage and a ±5% frequency variation. Some electronic devices cannot be powered by the POWER ARC 5000. Refer to Table A.2, ELECTRICAL DEVICE USE WITH THE POWER ARC 5000, in the INSTALLATION sec[...]

B-8 OPERA TION B-8 POWER ARC 5000 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 equipment listed in the table, multiply RUNNING WATTS by 2. Multiple loads can be used as long as the total load does not exceed 5,000 watts. Be sure to st[...]

B-9 OPERA TION B-9 WELDING OPERA TION GENERAL INFORMA TION Do not touch electrically live parts or elec- trodes with your skin or wet clothing. Arc Rays can burn. When using an open arc process, it is necessary to use correct eye, head and body protection. Do not breathe welding fumes or gases. Use ventilation or exhaust to remove weld- ing fumes f[...]

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[...]

B-11 OPERA TION B-11 POWER ARC 5000 The Power-Arc provides excellent weld output charac- teristics when used in combination with Lincoln AC electrodes. Other AC electrodes may also be used. Follow the settings listed in Table B.4 “Welding Applications/Electrode Selection Guide” found on the nameplate of the machine. ARC RAYS can burn. • When [...]

B-12 OPERA TION B-12 POWER ARC 5000 The POWER ARC 5000 has a voltage output of up to 62 volts which can shock. The electric arc is made between the work and the tip end of a small metal wire, the electrode, which is clamped in a holder that is held by the welder. A gap is made in the welding circuit (see Figure B.3) by hold- ing the tip of the elec[...]

B-13 OPERA TION B-13 POWER ARC 5000 1. The Correct W elding P osition Illustrated is the correct welding position for right-handed people. (For left-handed people it is opposite.) Whenever possible, weld from left to right (if right- handed). This enables you to see clearly what you are doing. Hold the electrode at a slight angle as shown in Figure[...]

B-14 OPERA TION B-14 POWER ARC 5000 PRA CTICE 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” (4.8mm), [...]

B-15 OPERA TION B-15 POWER ARC 5000 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. Watch the molten metal to be sure it distributes itself evenly on both edges and in between the plates. Penetra[...]

B-16 OPERA TION B-16 POWER ARC 5000 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: 1. Use 1/8” (3.2mm) 90-115 amps or 3/3[...]

B-17 OPERA TION B-17 POWER ARC 5000 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. 2. Put the e[...]

B-18 OPERA TION B-18 POWER ARC 5000 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.) 5. Use the back-stepping method. Begin to weld 3” (76mm) from the heel of the share and weld to the heel. The second weld wi[...]

B-19 OPERA TION B-19 POWER ARC 5000 This group includes electrodes which have a moder- ately forceful arc and deposit rates between those of the out-of-position and high-deposit electrodes. They are primarily general purpose production elec- trodes especially for downhill fillets and laps or short and irregular welds that change direction or positi[...]

C-1 A CCESSORIES C-1 OPTIONS/ACCESSORIES LINCOLN ELECTRIC A CCESSORIES The following options/accessories are available for your POWER ARC 5000 from your local Lincoln Distributor. Accessory Set (K875) – Includes the following: • Twenty feet (6.1 meters) of #6 AWG electrode cable • Fifteen feet (4.6 meters) of #6 work cable • Headshield with[...]

D-1 MAINTENANCE D-1 SAFETY PRECAUTIONS • Have qualified personnel do all maintenance and troubleshooting work. • Turn the engine off before working inside the machine. • Remove guards only when necessary to perform maintenance and replace them when the mainte- nance requiring their removal is complete. • If guards are missing from the machi[...]

D-2 MAINTENANCE D-2 CLEAN AIR FILTER PRE-CLEANER Do not use petroleum solvents such as kerosene to clean the air pre-cleaner. They may cause deteriora- tion of the air pre-cleaner. DO NOT USE PRESSUR- IZED AIR TO CLEAN OR DRY THE AIR PRE-CLEANER. To service the pre-cleaner: 1. Wash in liquid detergent and water. 2. Squeeze dry in a clean cloth. 3. [...]

T ABLE D.1 ENGINE MAINTENANCE SCHEDULE Maintenance Every 5 Hours 25 Hours 50 Hours 100 Hours Operation or Daily or Yearly or Yearly or Yearly 100-300 Hours Check Oil Level ● Change Oil ◆● Note 1 Clean Rotating Screen, Finger ● Guard, or Debris Screen Note 2 Service Foam Pre-Cleaner ● Note 2 Replace Air Cleaner ● Note 2 Clean Cooling Sys[...]

D-4 MAINTENANCE D-4 POWER ARC 5000 GENERA T OR/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. It’s normal for the brushes a[...]

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 LOCA TIONS[...]

E-1 TR OUBLESHOO TING E-1 POWER ARC 5000 Observe all Safety Guidelines detailed throughout this manual 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. CA UTION PROBL[...]

E-2 TR OUBLESHOO TING E-2 POWER ARC 5000 Observe all Safety Guidelines detailed throughout this manual 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. CA UTION PROBL[...]

E-3 TR OUBLESHOO TING E-3 POWER ARC 5000 Observe all Safety Guidelines detailed throughout this manual 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. CA UTION PROBL[...]

F-1 DIA GRAMS F-1 POWER ARC 5000 NOTE: This diagram is for reference only. 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 num[...]

F-2 DIA GRAMS F-2 POWER ARC 5000 R 20.00 26.50 M18053 6-28-96 POWER ARC 5000 29.31 POWER ARC 5000 - DIMENSION PRINT[...]

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W ARNING A VISO DE PRECA UCION A TTENTION W ARNUNG A TENÇÃO Spanish French German Portuguese Japanese Chinese Korean Arabic READ AND UNDERST AND 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 F ABRICANTE P ARA EL [...]

W ARNING A VISO DE PRECA UCION A TTENTION W ARNUNG A TENÇÃO Spanish French German Portuguese Japanese Chinese Korean Arabic LEIA E COMPREENDA AS INSTRUÇÕES DO F ABRICANTE P ARA ESTE EQUIP AMENTO E AS P ARTES DE USO, E SIGA AS PRÁTICAS DE SEGURANÇA DO EMPREGADOR. ● Keep your head out of fumes. ● Use ventilation or exhaust to remove fumes f[...]

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