Lincoln Electric POWER-ARC IM871-A 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. Us e suitable clothing made from durable flame-resistant material to protect your ski[...]

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 [...]

iv SAFETY iv Mar.  93 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 LʼArc 1. Protegez-vous contre la secousse électrique: a. Les[...]

v v Thank Y Y ou 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. [...]

Page Sa f e ty ............................................................................................................................... ..................i-iv I n s ta l l a t i on ............................................................................................................................. Se c t io n A A Technical Specificat[...]

TECHNICAL SPECIFICA TIONS - POWER-ARC 5500 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 ± 50 RPM (265 cc) Recoil start; Codes air-cooled at no load Manual choke Oil: 1.1 qts.(1.0 l) (11182) OHC gasoline (11187) 9 HP @ (11403) 3600 RPM INPU[...]

A-2 INST ALLA TION POWER-ARC 5500 A-2 SAFETY PRECAUTIONS Read this entire installation section before you start installation. D o n n o t a a t t e m pt t t o u u s e t t h i s e e q u i pm e n t u u n t i l y y o u h a ve t t h o r o u g h ly r r ead a a l l t t he o o p e r a ti o n a a n d m m a i n - t e n a n c e m m a n u a l s s s u p p l i [...]

A-3 INST ALLA TION POWER-ARC 5500 A-3 ST ACKING POWER-ARC 5500 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 p[...]

No Load 3700 RPM ±50 R.P.M. AC CC Weld Output 125 Amps @ 20 Volts AC CC Weld Output 100 Amps @ 25 Volts Auxiliary Power 4000 Watts (120/240 Volts) Robin / Subaru 9 HP Carb. Certified EX 27 0.31 Gallons/Hour (1.17 Liters/Hour) .70 Gallons/Hour (2.66 Liters/Hour) .66 Gallons/Hour (2.48 Liters/Hour) .68 Gallons/Hour (2.59 Liters/Hour) Honda 9 HP Carb[...]

A-5 INST ALLA TION POWER-ARC 5500 A-5 ELECTRICAL OUTPUT CONNECTIONS See Figure A.1 for the location of the current control dial, weld output terminals, ground stud, circuit breakers, 240 and 120 volt receptacles. WELDING CABLE CONNECTIONS Cable Size and Length Be sure to use welding cables that are large enough. The correct size and length becomes [...]

A-6 INST ALLA TION POWER-ARC 5500 A-6 Cable Installation Install the welding cables to your POWER-ARC 5500 as follows. See Figure A.1 for the location of parts. 1. The gasoline engine must be OFF to install weld- ing cables. 2. Remove the 1/2 - 13 flanged nuts from the output terminals. 3. Connect the electrode holder and work cables to the weld ou[...]

A-7 INST ALLA TION POWER-ARC 5500 A-7 PREMISES WIRING The POWER-ARC 5500 three-wire, grounded neutral generator allows it to be connected to premises wiring. However, the wiring procedure needed to meet the National Electrical Code (NEC) regulations as well as city ordinances and can be confusing. The connections could vary from a "commonly gr[...]

A-8 INST ALLA TION POWER-ARC 5500 A-8 CAUTION Certain Electrical devices cannot be powered by the POWER-ARC 5500. See Table A.2. TABLE A.2 ELECTRICAL DEVICE USE WITH THE POWER-ARC 5500. Type Common Electrical Devices Possible Concerns Resistive Heaters, toasters, incandescent NONE light bulbs, electric range, hot pan, skillet, coffee maker. Capacit[...]

B-1 OPERA TION B-1 SAFETY INSTRUCTIONS Read and understand this entire section before oper- ating your POWER-ARC 5500. D o n n o t a a t t e m p t t t o u u s e t t h i s e e q u i p m e n t u u n t i l y y o u h a ve t t h o r o u g h ly r r ead a a l l t t he o o p e r a ti o n a a n d m m a i n - t e n a n c e m m a n u a l s s s u p p l i e d w[...]

B-2 OPERA TION B-2 LIMIT A TIONS • The POWER-ARC 5500 is not recommended for any processes besides those that are normally per- formed using stick welding (SMAW) procedures. • The POWER-ARC 5500 is not recommended for pipe thawing. • During welding, generator power is limited to 100 watts, and output voltages can drop from 120 to 80 volts and[...]

B-3 OPERA TION B-3 POWER-ARC 5500 4. WELD OUTPUT TERMINAL (TO WORK) WITH 1/2 - 13 FLANGE NUT: Provides the connection point for either the electrode holder or the work cable. (Because the POWER-ARC 5500 is an AC output machine, either output terminal can be used for either cable.) 5. GROUND STUD: Provides a connection point for connecting the machi[...]

4. Pull the cord rapidly. 5 . If the engine does not start, open the choke slightly and pull the starter cord rapidly again. When the engine starts, gradually open the choke to the “RUN” position. To open the choke fully requires an engine warm-up period of several seconds to several minutes, depending on the temperature. After starting the eng[...]

GENERA TOR OPERA TION B B e s s u r e t t h a t a a ny e e l e ct r i c a l e e qu i pm e n t p p l u gg e d i i nt o t h e g g e n e r a t o r ’s A A C p p o w e r r r e c e p t a c l e s c c a n w w i t h - s t a nd a a ± ± 10% v v o l t a ge a a n d a a ± ± 4% f f r e q ue n c y v v a r i a - t io n . S S o m e e e l e ct r o n i c d d e v[...]

TABLE B.3 GENERATOR POWER APPLICATIONS S S u g g es t e d P P o w e r A A p pl i c a t io n s R R u n n i ng W W a t t s * St a r t -u p W W a t t s ( Co n t i n uo us ) ( ( Sur g e ) *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 600 1,500 - 2,400 Chain Saw 1,200 Circular Saw 1,200[...]

B-7 OPERA TION B-7 WELDING OPERA TION GENERAL INFORMA TION ELECTRIC SHOCK can kill. • D D o n n o t t t o u c h e e l e c t r i c a l l y l l i v e p p a r t s o o r el e c t r o de s w w i t h y y o u r s s k i n o o r w w e t c c l o t h - i n g. • I I n s u la t e y y o u r s e lf f f r o m t t he w w o r k a a n d g g r o u n d. • A A l w[...]

Stick welding is probably the most familiar welding process known. A coated ELECTRODE, the weld rod, is clamped into an ELECTRODE HOLDER, an insulat- ed clamping device, which in turn connects to the ELECTRODE CABLE, a heavy wire. The WORK, the metal piece to be welded, is connected to the WORK CABLE, a heavy wire which contains the WORK CLAMP. Qua[...]

B-9 OPERA TION B-9 POWER-ARC 5500 No one can learn to weld simply by reading about it. Skill comes only with practice. The following 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[...]

B-10 OPERA TION B-10 POWER-ARC 5500 The function of the covered electrode is much more than simply to carry current to the arc. The electrode is composed of a core metal wire around which 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[...]

B-1 1 OPERA TION B-1 1 POWER-ARC 5500 PRACTICE 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-12 OPERA TION B-12 POWER-ARC 5500 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-13 OPERA TION B-13 POWER-ARC 5500 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-14 OPERA TION B-14 POWER-ARC 5500 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-15 OPERA TION B-15 POWER-ARC 5500 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-16 OPERA TION B-16 POWER-ARC 5500 High-Speed Group (AWS E6013) 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 th[...]

C-1 ACCESSORIES C-1 OPTIONS/ACCESSORIES LINCOLN ELECTRIC ACCESSORIES The following options/accessories are available for your POWER-ARC 5500 from your local Lincoln Distributor. A cc e s s o r y K K i t ( ( K 87 5) – Includes the following: • Twenty feet (6.1 meters) of #6 AWG electrode cable with lug. • Fifteen feet (4.6 meters) of #6 work c[...]

D-1 MAINTENANCE D-1 POWER-ARC 5500 SAFETY PRECAUTIONS • H H a v e q q u a l i f i e d p p e r s o n n e l d d o a a l l m m a i n t e n a n c e a n d t t r o u bl e s h oo t i n g w w o r k . • T T u r n t t h e e e n g i n e o o f f b b e f o r e w w o r k i n g i i n s i d e t t h e m a c h i n e . • R R e m o v e g g u a r d s o o n l y w [...]

D-2 MAINTENANCE D-2 F UE L : At the end of each day’s use, refill the fuel tank to minimize moisture conden- sation and dirt contamination in the fuel line. ENGINE ADJUSTMENTS OVERSPEED IS HAZARDOUS - The maximum allowable high idle speed for this machine is 3750 RPM, no load. DO NOT tamper with the governor components or setting or make any othe[...]

D-3 MAINTENANCE D-3 POWER-ARC 5500 Refer to Table D.1 for engine maintenance parts. The part numbers are accurate at the time of printing. (Verify the current part number by referring to the engine owner s manual. Replace or clean engine maintenance parts per the interval outlined in the engine owner s manual. Part Robin / Subaru Part # Honda[...]

D-4 MAINTENANCE D-4 POWER-ARC 5500 GENERA TOR/WELDER MAINTENANCE ST O R AG E : Store the POWER-ARC 5500 in clean, dry, protected a reas. C L E A N I N G: Blow out the generator and controls periodically with low pressure air. Do this at least once a week in particularly dirty areas. B R U S H R R E M O V A L A A N D R R E P L A C E M E N T : See Fi[...]

D-5 MAINTENANCE D-5 POWER-ARC 5500 8 7 6 5 1 2 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 LOCA TIONS[...]

POWER-ARC 5500 E-1 TROUBLESHOOTING E-1 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. CAUTION This Troubleshooting Guide is provided to help you locate and repair p[...]

E-2 TROUBLESHOOTING E-2 POWER-ARC 5500 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. CAUTION PROBLEMS[...]

E-3 TROUBLESHOOTING E-3 POWER-ARC 5500 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. CAUTION PROBLEMS[...]

E-4 TROUBLESHOOTING E-4 POWER-ARC 5500 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. CAUTION PROBLEMS[...]

F-1 DIAGRAMS F-1 POWER-ARC 5500 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 numb[...]

F-2 DIAGRAMS F-2 POWER-ARC 5500 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 numb[...]

F-3 DIAGRAMS F-3 POWER-ARC 5500 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 numb[...]

F-4 DIAGRAMS F-4 POWER-ARC 5500 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 numb[...]

F-5 DIAGRAMS F-5 POWER-ARC 5500 M 17196 A. 0 1 R EL ECTR IC LI NCOLN 20. 00 20. 88 7. 92 14. 16 30. 00 DIMENSION PRINT POWER ARC 5500[...]

NOTES[...]

W ARNING AV I S O D E PRECAUCION A TTENTION W ARNUNG A TENÇÃO Spanish French German Portuguese Japanese Chinese Korean Arabic READ AND UNDERST AND THE MANUF ACTURER’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 [...]

W ARNING AV I S O D E PRECAUCION 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 PAR TES DE USO, E SIGA AS PRÁTICAS DE SEGURANÇA DO EMPREGADOR. ● Keep your head out of fumes. ● Use ventilation or exhaust to remove fumes[...]

• 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 and Cutting Products •[...]