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Lincoln Electric POWERARC 5500 SVM197-A manual

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Table of contents for the manual

  • Page 1

    SVM197-A January , 2010 Safety Depends on Y ou 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 thoughtful operation on your part. DO NOT INST ALL, OPERA TE OR REP AIR THIS EQUIPMENT WITHOUT READ- ING THIS MANUAL AND THE SAFETY PRECAU[...]

  • Page 2

    POWERARC® 5500 SAFETY i i FOR ENGINE powered equipment. 1.a. T urn 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. _____________________[...]

  • Page 3

    SAFETY ii ii POWERARC® 5500 FUMES AND GASES can be dangerous. 5.a. Welding may produce fumes and gases hazardous to health. Avoid breathing these fumes and gases.When welding, keep your head out of the fume. Use enough ventilation and/or exhaust at the arc to keep fumes and gases away from the breathing zone. When welding with electrodes which req[...]

  • Page 4

    SAFETY iii iii POWERARC® 5500 Jan ‘09 FOR ELECTRICALL Y powered equipment. 8.a. T urn 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 acc[...]

  • Page 5

    SAFETY iv iv POWERARC® 5500 Mar ‘93 PRÉCAUTIONS DE SÛRETÉ Pour votre propre protection lire et observer toutes les instructions et les précautions de sûreté specifiques qui parraissent dans ce manuel aussi bien que les précautions de sûreté générales suiv- antes: Sûreté Pour Soudage A L ’Arc 1. Protegez-vous contre la secousse él[...]

  • Page 6

    SAFETY v v POWERARC® 5500 Electromagnetic Compatibility (EMC) Conformance Products displaying the CE mark are in conformity with European Community Council Directive of 3 May 1989 on the approximation of the laws of the Member States relating to electromagnetic compatibility (89/336/EEC). It was manufactured in conformity with a national standard [...]

  • Page 7

    SAFETY vi vi POWERARC® 5500 Electromagnetic Compatibility (EMC) The size of the surrounding area to be considered will depend on the structure of the building and other activities that are taking place. The surrounding area may extend beyond the boundaries of the premises. Methods of Reducing Emissions Mains Supply Welding equipment should be conn[...]

  • Page 8

    - MASTER T ABLE OF CONTENTS FOR ALL SECTIONS - I I POWERARC® 5500 Page S a f e t y ........................................................................... i - i v I n s t a l l a t i o n .................................................................. S e c t i o nA O p e r a t i o n ..........................................................[...]

  • Page 9

    T ABLE OF CONTENTS - INST ALLA TION SECTION A-1 A-1 POWERARC® 5500 I n s t a l l a t i o n ............................................................................. A - 1 T e c h n i c a l S p e c i f i c a t i o n s ................................................................ A - 2 S a f e t y P r e c a u t i o n s .......................[...]

  • Page 10

    TECHNICAL SPECIFICA TIONS - POWERARC® 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, 11187) OHC gasoline (11329, 11403) 9 HP @ (1140[...]

  • Page 11

    INST ALLA TION A-3 A-3 POWERARC® 5500 SAFETY PRECAUTIONS Read this entire installation section before you start installation. Do not attempt to use this equipment until you have thoroughly r ead all the operation and mainte- nance manuals supplied with your machine. They include important safety precautions; detailed engine starting, operating, an[...]

  • Page 12

    INST ALLA TION A-4 A-4 POWERARC® 5500 ST ACKING POWERARC® 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[...]

  • Page 13

    INST ALLA TION A-5 A-5 POWERARC® 5500 No Load 3700 RPM ±50 R.P .M. AC CC Weld Output 125 Amps @ 20 V olts AC CC Weld Output 100 Amps @ 25 V olts Auxiliary Power 4000 W atts (120/240 V olts) 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 Gal[...]

  • Page 14

    ELECTRICAL OUTPUT CONNECTIONS See Figure A.1 for the location of the curr ent control dial, weld output terminals, ground stud, cir cuit break- ers, 240 and 120 volt receptacles. WELDING CABLE CONNECTIONS Cable Size and Length Be sure to use welding cables that ar e large enough. The correct size and length becomes especially important when you are[...]

  • Page 15

    INST ALLA TION A-7 A-7 POWERARC® 5500 Cable Installation Install the welding cables to your POWERARC® 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 [...]

  • Page 16

    INST ALLA TION A-8 A-8 POWERARC® 5500 PREMISES WIRING The POWERARC® 5500 three-wir e, grounded neutral generator allows it to be connected to premises wiring. However , the wiring procedur e needed to meet the National Electrical Code (NEC) regulations as well as city ordinances and can be confusing. The connec- tions could vary from a "comm[...]

  • Page 17

    Certain Electrical devices cannot be powered by the POWERARC® 5500. See T able A.2. T ABLE A.2 ELECTRICAL DEVICE USE WITH THE POWERARC® 5500. T ype Common Electrical Devices Possible Concerns Resistive Heaters, toasters, incandescent NONE light bulbs, electric range, hot pan, skillet, coffee maker . Capacitive TV sets, radios, microwaves, V oltag[...]

  • Page 18

    NOTES A-10 A-10 POWERARC® 5500 Return to Section TOC Return to Section TOC Return to Section TOC Return to Section TOC Return to Master TOC Return to Master TOC Return to Master TOC Return to Master TOC[...]

  • Page 19

    T ABLE OF CONTENTS - OPERA TION SECTION B-1 B-1 POWERARC® 5500 Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .B-1 Safety Instructions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .[...]

  • Page 20

    OPERA TION B-2 B-2 POWERARC® 5500 SAFETY INSTRUCTIONS Read and understand this entir e section before oper- ating your POWERARC® 5500. Do not attempt to use this equipment until you have thoroughly r ead all the operation and maintenance man- uals supplied with your machine. They include impor- tant safety pr ecautions; detailed engine starting, [...]

  • Page 21

    OPERA TION B-3 B-3 POWERARC® 5500 LIMIT A TIONS • The POWERARC® 5500 is not r ecommended for any processes besides those that are normally per- formed using stick welding (SMAW) procedur es. • The POWERARC® 5500 is not r ecommended for pipe thawing. • During welding, generator power is limited to 100 watts, and output voltages can drop fro[...]

  • Page 22

    OPERA TION B-4 B-4 POWERARC® 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 POWERARC® 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 ma[...]

  • Page 23

    OPERA TION B-5 B-5 POWERARC® 5500 4. Pull the cord rapidly . 5. If the engine does not start, open the choke slight- ly and pull the starter cord rapidly again. When the engine starts, gradually open the choke to the “RUN” position. T o open the choke fully requir es an engine warm-up period of several sec- onds to several minutes, depending o[...]

  • Page 24

    OPERA TION B-6 B-6 POWERARC® 5500 GENERA TOR OPERA TION Be sure that any electrical equipment plugged into the generator’ s AC power receptacles can withstand a ±10% voltage and a ±4% frequency variation. Some electronic devices cannot be powered by the POWERARC® 5500. Refer to T able A.2, ELECTRICAL DEVICE USE WITH THE POWERARC® 5500, in th[...]

  • Page 25

    T ABLE B.3 GENERA TOR POWER APPLICA TIONS Suggested Power Applications Running W atts *Start-up Watts (Continuous) (Surge) *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 Coffee Maker 1,000 *Deep Freezer 500 750 - 2,000 *Electric M[...]

  • Page 26

    OPERA TION B-8 B-8 POWERARC® 5500 WELDING OPERA TION GENERAL INFORMA TION ELECTRIC SHOCK can kill. • Do not touch electrically live parts or electrodes with your skin or wet cloth- ing. • Insulate yourself from the work and ground. • Always wear dry insulating gloves. ------------------------------------------------------------- The POWERARC[...]

  • Page 27

    OPERA TION B-9 B-9 POWERARC® 5500 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[...]

  • Page 28

    OPERA TION B-10 B-10 POWERARC® 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 man[...]

  • Page 29

    OPERA TION B-11 B-11 POWERARC® 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. Th[...]

  • Page 30

    OPERA TION B-12 B-12 POWERARC® 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), [...]

  • Page 31

    OPERA TION B-13 B-13 POWERARC® 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. W atch the molten metal to be sure it distributes itself evenly on both edges and in between the plates. Pene[...]

  • Page 32

    OPERA TION B-14 B-14 POWERARC® 5500 V ertical-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) 90-1 15 amps or [...]

  • Page 33

    OPERA TION B-15 B-15 POWERARC® 5500 Overhead Welding V arious 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 A WS 601 1 electrode on AC. 2. Put[...]

  • Page 34

    OPERA TION B-16 B-16 POWERARC® 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 [...]

  • Page 35

    OPERA TION B-17 B-17 POWERARC® 5500 High-Speed Group (A WS 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 [...]

  • Page 36

    NOTES B-18 B-18 POWERARC® 5500 Return to Section TOC Return to Section TOC Return to Section TOC Return to Section TOC Return to Master TOC Return to Master TOC Return to Master TOC Return to Master TOC[...]

  • Page 37

    T ABLE OF CONTENTS - ACCESSORIES SECTION C-1 C-1 POWERARC® 5500 Accessories . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .C-1 Options and Accessories . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . [...]

  • Page 38

    ACCESSORIES C-2 C-2 POWERARC® 5500 OPTIONS/ACCESSORIES LINCOLN ELECTRIC ACCESSORIES The following options/accessories are available for your POWERARC® 5500 from your local Lincoln Distributor . Accessory Kit (K875) – Includes the following: • T wenty feet (6.1 meters) of #6 AWG electrode cable with lug. • Fifteen feet (4.6 meters) of #6 wor[...]

  • Page 39

    T ABLE OF CONTENTS - MAINTENANCE SECTION D-1 D-1 POWERARC® 5500 Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .D-1 Safety Precautions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .[...]

  • Page 40

    MAINTENANCE D-2 D-2 POWERARC® 5500 SAFETY PRECAUTIONS • Have qualified personnel do all maintenance and troubleshooting work. • T urn the engine off before working inside the machine. • Remove guar ds only when necessary to perform maintenance and replace them when the main- tenance requiring their removal is complete. • If guards are miss[...]

  • Page 41

    MAINTENANCE D-3 D-3 POWERARC® 5500 F F U U E E L L : : At the end of each day’ s use, refill the fuel tank to minimize moisture condensa- tion 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[...]

  • Page 42

    Part Robin / Subaru Part # Honda Part # SP ARK PLUG NGK BR6 HS NGK BPR6ES (RESISTOR) DENSO W20EPR-U FUEL FIL TER NONE NONE AIR CLEANER P ANEL 279-32616-00 5266721 (17210-ZE2-505) (Pleated Paper) AIR PRE-CLEANER 279-3261 1-00 2538429 (17218-ZE2-821) (AS NEEDED) (CAN BE CLEANED AND REUSED AS NEEDED) MAINTENANCE D-4 D-4 POWERARC® 5500 Refer to T able[...]

  • Page 43

    MAINTENANCE D-5 D-5 POWERARC® 5500 GENERA TOR/WELDER MAINTENANCE S S T T O O R R A A G G E E : : Store the POWERARC® 5500 in clean, dry , protected areas. C C L L E E A A N N I I N N G G : : Blow out the generator and controls periodic ally with low pressure air . Do this at least once a week in particularly dirty areas. B B R R U U S S H H R R E[...]

  • Page 44

    MAINTENANCE D-6 D-6 POWERARC® 5500 8 7 6 5 1 2 3 4 1 . CRADLE ASSEMBL Y 2. ROTOR, BLOWER, AND BEARING ASSEMBL Y 3. ST A TOR ASSEMBL Y 4. BRUSH AND BRUSH HOLDER ASSEMBL Y 5. CONTROL BOX WELDED ASSEMBL Y 6. REACTOR ASSEMBL Y 7. OUTPUT TERMINAL ASSEMBL Y 8. OUTPUT P ANEL ASSEMBL Y FIGURE D.6. - MAJOR COMPONENT LOCA TIONS Return to Section TOC Return [...]

  • Page 45

    T ABLE OF CONTENTS-THEOR Y OF OPERA TION SECTION E-1 E-1 POWERARC® 5500 FIGURE E.1 – POWERARC® 5500 BLOCK LOGIC DIAGRAM Theory of Operation ....................... ...................................................................................... Section E Block Logic Diagram .................................................................[...]

  • Page 46

    THEOR Y OF OPERA TION E-2 E-2 POWERARC® 5500 ENGINE CONTROL AND IGNITION The engine ignition is cr eated and controlled by a fly- wheel type magneto cir cuit. This circuit is shorted to ground when the ON/OFF switch is moved to the OFF position, thus disabling the ignition circuit and shutting down the engine. In the event of a low oil level condi[...]

  • Page 47

    THEOR Y OF OPERA TION E-3 E-3 POWERARC® 5500 ROTOR FIELD FEEDBACK AND AUXILIAR Y POWER The AC voltage developed in the field winding is fed to the full wave bridge. The DC output of the bridge is fil- tered by the field capacitor and controlled by the out- put rheostat. This filtered and controlled feedback voltage is fed to the r otor winding via[...]

  • Page 48

    THEOR Y OF OPERA TION E-4 E-4 POWERARC® 5500 WELD WINDING AND REACTOR The AC voltage developed in the stator weld winding is delivered, through the reactor , to the machine out- put terminals. The POWERARC® 5500 provides the user up to 125 amps of constant current AC welding for stick electrodes. The reactor stores ener gy , and this energy is re[...]

  • Page 49

    T ABLE OF CONTENTS - TROUBLESHOOTING AND REP AIR F-1 F-1 POWERARC® 5500 T roubleshooting and Repair . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .F-1 How to Use T roubleshooting Guide . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . [...]

  • Page 50

    POWERARC® 5500 TROUBLESHOOTING AND REP AIR F-2 F-2 This Troubleshooting Guide is provided to help you locate and repair possible machine malfunctions. Simply follow the three-step procedure listed below . Step 1. LOCA TE PROBLEM (SYMPTOM). Look under the column labeled “PROBLEM (SYMPTOMS)”. This column describes pos- sible symptoms that the ma[...]

  • Page 51

    POWERARC® 5500 TROUBLESHOOTING AND REP AIR F-3 F-3 Sometimes machine failures appear to be due to PC board failures. These problems can sometimes be traced to poor electrical connections. T o avoid prob- lems when troubleshooting and replacing PC boards, please use the following procedure: 1. Determine to the best of your technical ability that th[...]

  • Page 52

    TROUBLESHOOTING GUIDE - Observe Safety Guidelines detailed in the beginning of this manual. If for any reason you do n ot unde rstand the test procedures or are unable to perform the tests/rep airs safely , contact the Lincoln Electric Servic e Departm ent for technical troubleshoot ing assistance before you proceed. Call 1-888-935-3877. CAUTION TR[...]

  • Page 53

    TROUBLESHOOTING GUIDE - Observe Safety Guidelines detailed in the beginning of this manual. If for any reason you do n ot unde rstand the test procedures or are unable to perform the tests/rep airs safely , contact the Lincoln Electric Servic e Departm ent for technical troubleshoot ing assistance before you proceed. Call 1-888-935-3877. CAUTION TR[...]

  • Page 54

    TROUBLESHOOTING GUIDE - Observe Safety Guidelines detailed in the beginning of this manual. If for any reason you do n ot unde rstand the test procedures or are unable to perform the tests/rep airs safely , contact the Lincoln Electric Servic e Departm ent for technical troubleshoot ing assistance before you proceed. Call 1-888-935-3877. CAUTION TR[...]

  • Page 55

    TROUBLESHOOTING GUIDE - Observe Safety Guidelines detailed in the beginning of this manual. If for any reason you do n ot unde rstand the test procedures or are unable to perform the tests/rep airs safely , contact the Lincoln Electric Servic e Departm ent for technical troubleshoot ing assistance before you proceed. Call 1-888-935-3877. CAUTION TR[...]

  • Page 56

    TROUBLESHOOTING GUIDE - Observe Safety Guidelines detailed in the beginning of this manual. If for any reason you do n ot unde rstand the test procedures or are unable to perform the tests/rep airs safely , contact the Lincoln Electric Servic e Departm ent for technical troubleshoot ing assistance before you proceed. Call 1-888-935-3877. CAUTION TR[...]

  • Page 57

    TROUBLESHOOTING GUIDE - Observe Safety Guidelines detailed in the beginning of this manual. If for any reason you do n ot unde rstand the test procedures or are unable to perform the tests/rep airs safely , contact the Lincoln Electric Servic e Departm ent for technical troubleshoot ing assistance before you proceed. Call 1-888-935-3877. CAUTION TR[...]

  • Page 58

    TROUBLESHOOTING GUIDE - Observe Safety Guidelines detailed in the beginning of this manual. If for any reason you do n ot unde rstand the test procedures or are unable to perform the tests/rep airs safely , contact the Lincoln Electric Servic e Departm ent for technical troubleshoot ing assistance before you proceed. Call 1-888-935-3877. CAUTION TR[...]

  • Page 59

    TROUBLESHOOTING GUIDE - Observe Safety Guidelines detailed in the beginning of this manual. If for any reason you do n ot unde rstand the test procedures or are unable to perform the tests/rep airs safely , contact the Lincoln Electric Servic e Departm ent for technical troubleshoot ing assistance before you proceed. Call 1-888-935-3877. CAUTION TR[...]

  • Page 60

    NOTES F-12 F-12 POWERARC® 5500 Return to Section TOC Return to Section TOC Return to Section TOC Return to Section TOC Return to Master TOC Return to Master TOC Return to Master TOC Return to Master TOC[...]

  • Page 61

    Service and repair should be performed only by Lincoln Electric factory trained personnel. Unauthorized repairs performed on this equipment may result in danger to the technician or machine operator and will invalidate your factory warranty . For your safety and to avoid electrical shock, please observe all safety notes and precautions detailed thr[...]

  • Page 62

    ROT OR VOL T AGE AND FLASHING VOL T AGE TEST PROCEDURE (continued) TROUBLESHOOTING AND REP AIR F-14 F-14 POWERARC® 5500 ROTOR VOL T AGE TEST PROCEDURE 1. With the 5/16” nut driver , r emove the 8 sheet metal scr ews that hold the top cover to the control box. Remove the top cover . 2. Start the machine and run it at high idle. Set the output con[...]

  • Page 63

    Service and repair should be performed only by Lincoln Electric factory trained personnel. Unauthorized repairs performed on this equipment may result in danger to the technician or machine operator and will invalidate your factory warranty . For your safety and to avoid electrical shock, please observe all safety notes and precautions detailed thr[...]

  • Page 64

    ROT OR RESIST ANCE TEST PROCEDURE (continued) PROCEDURE 1. Conduct the test with the gasoline engine OFF . 2. Remove the spark plug wire to prevent acci- dental engine kickback or starting. 3. Isolate the rotor electrically by removing the generator brushes. Refer to Figure F .2 as you perform the remaining steps. 4. Open the brush holder assembly [...]

  • Page 65

    ROT OR RESIST ANCE TEST PROCEDURE (continued) 9. Reinstall the brush holder assembly after the test. Depr ess the spring-loaded brushes into the holder and slip a suitable non-metallic, fair- ly stiff retainer through the slots at the top and bottom of the holder . A cable tie works well; see Figur e F .3. This w ill hold the brushes up so that you[...]

  • Page 66

    NOTES F-18 F-18 POWERARC® 5500 Return to Section TOC Return to Section TOC Return to Section TOC Return to Section TOC Return to Master TOC Return to Master TOC Return to Master TOC Return to Master TOC[...]

  • Page 67

    Service and repair should be performed only by Lincoln Electric factory trained personnel. Unauthorized repairs performed on this equipment may result in danger to the technician or machine operator and will invalidate your factory warranty . For your safety and to avoid electrical shock, please observe all safety notes and precautions detailed thr[...]

  • Page 68

    ENGINE THROTTLE ADJUSTMENT TEST ROBIN/SUBARU ENGINE (continued) TROUBLESHOOTING AND REP AIR F-20 F-20 POWERARC® 5500 TEST PROCEDURE This test can be conducted by any of three methods. Strobe-tach Method: 1. Stop the engine and remove the spark plug wire to prevent accidental kickback or starting. 2. With the black or red marking pencil, place a ma[...]

  • Page 69

    TROUBLESHOOTING AND REP AIR F-21 F-21 POWERARC® 5500 ENGINE THROTTLE ADJUSTMENT TEST ROBIN/SUBARU ENGINE (continued) THRO T TLE L OCKING NUT FIGURE F .5 - LOCKING NUT LOCA TION HIGH SPEED ST OP SCREW FIGURE F .6 - STOP SCREW LOCA TION 2. Using the 10mm socket wrench, slightly loosen the throttle locking nut. See Figure F .5. 3. Using the scr ewdri[...]

  • Page 70

    TROUBLESHOOTING AND REP AIR F-22 F-22 POWERARC® 5500 CH1 0 volts 5 ms 50 volts SCOPE SETTINGS V olts/Div .....................50V/Div . Horizontal Sweep.....5 ms/Div . Coupling ............................DC T rigger .........................Internal This is the typical AC output voltage generated from a properly operating machine. Note that each [...]

  • Page 71

    TROUBLESHOOTING AND REP AIR F-23 F-23 POWERARC® 5500 SCOPE SETTINGS V olts/Div .....................50V/Div . Horizontal Sweep.....5 ms/Div . Coupling ............................DC T rigger .........................Internal CH1 0 volts 5 ms 50 volts This is the typical AC output voltage generated from a properly operating machine. Note that each [...]

  • Page 72

    TROUBLESHOOTING AND REP AIR F-24 F-24 POWERARC® 5500 CH1 0 volts 5 ms 20 volts This is the typical AC output voltage generated from a properly operating machine. Note that each vertical division repr esents 20 volts and that each horizontal division represents 5 milliseconds in time. The machine was loaded with a resistance grid bank. Note: Scope [...]

  • Page 73

    Service and repair should be performed only by Lincoln Electric factory trained person- nel. Unauthorized repairs performed on this equipment may result in danger to the tech- nician or machine operator and will invalidate your factory warranty . For your safety and to avoid electrical shock, please observe all safety notes and precautions detailed[...]

  • Page 74

    TROUBLESHOOTING AND REP AIR F-26 F-26 POWERARC® 5500 PROCEDURE 1. Remove the spark plug wire. 2. Op en the brush hol der assem bly cover . Squeeze the 2 tabs and depress the cover at the top with a screw driver or your finger nail. The cover will drop open on its bottom hinge. 3. With the 1/4” nut driver , remove the 2 screws that hold the brush[...]

  • Page 75

    TROUBLESHOOTING AND REP AIR F-27 F-27 POWERARC® 5500 PROCEDURE (continued) 8. T o reinstall the brush holder assem- bly , depress the spring-loaded brushes into the holder and slip a suitable non-metallic, fairly stiff retainer thr ough the slots at the top and bottom of the holder . A cable tie works well; see Figure F .7 . This will hold the bru[...]

  • Page 76

    NOTES F-28 F-28 POWERARC® 5500 Return to Section TOC Return to Section TOC Return to Section TOC Return to Section TOC Return to Master TOC Return to Master TOC Return to Master TOC Return to Master TOC[...]

  • Page 77

    Service and repair should be performed only by Lincoln Electric factory trained personnel. Unauthorized repairs performed on this equipment may result in danger to the technician or machine operator and will invalidate your factory warranty . For your safety and to avoid electrical shock, please observe all safety notes and precautions detailed thr[...]

  • Page 78

    RHEOST A T REMOV AL AND REPLACEMENT PROCEDURE (continued) TROUBLESHOOTING AND REP AIR F-30 F-30 POWERARC® 5500 PROCEDURE 1. Remove the spark plug wire. 2. With the 5/16” nut driver , remove the 8 sheet metal screws that hold the top cover to the control box. Remove the top cover . 3. With the allen wrench, loosen the screw that holds the knob to[...]

  • Page 79

    Service and repair should be performed only by Lincoln Electric factory trained personnel. Unauthorized repairs performed on this equipment may result in danger to the technician or machine operator and will invalidate your factory warranty . For your safety and to avoid electrical shock, please observe all safety notes and precautions detailed thr[...]

  • Page 80

    CAP ACITOR AND/OR DIODE BRIDGE REMOV AL AND REPLACEMENT PROCEDURE (continued) TROUBLESHOOTING AND REP AIR F-32 F-32 POWERARC® 5500 FIGURE F .9 - LOCA TION AND DISCHARGING THE FIELD CAP ACITOR PROCEDURE - CAP ACITOR REMOV AL AND REPLACE- MENT 1. Remove the engine spark plug wire. 2. With the 5/16” nut driver , remove the 8 sheet metal screws that[...]

  • Page 81

    CAP ACITOR AND/OR DIODE BRIDGE REMOV AL AND REPLACEMENT PROCEDURE (continued) TROUBLESHOOTING AND REP AIR F-33 F-33 POWERARC® 5500 FIGURE F .10 - FIELD DIODE BRIDGE LOCA TION 1. Remove the engine spark plug wire. 2. With the 5/16” nut driver , remove the 8 sheet metal screws that hold the top cover to the control box. Remove the top cover . 3. W[...]

  • Page 82

    NOTES F-34 F-34 POWERARC® 5500 Return to Section TOC Return to Section TOC Return to Section TOC Return to Section TOC Return to Master TOC Return to Master TOC Return to Master TOC Return to Master TOC[...]

  • Page 83

    Service and repair should be performed only by Lincoln Electric factory trained personnel. Unauthorized repairs performed on this equipment may result in danger to the technician or machine operator and will invalidate your factory warranty . For your safety and to avoid electrical shock, please observe all safety notes and precautions detailed thr[...]

  • Page 84

    TROUBLESHOOTING AND REP AIR F-36 F-36 POWERARC® 5500 ST A TOR/ROTOR REMOV AL AND REPLACEMENT PROCEDURE (continued) ST A TOR REMOV AL PROCEDURE 1. Remove engine spark plug wire to prevent accidental kickback or starting. 2. With the 5/16” nut driver , remove the 8 sheet metal screws that hold the top cover to the control box. Remove the top cover[...]

  • Page 85

    ST A TOR/ROTOR REMOV AL AND REPLACEMENT PROCEDURE (continued) TROUBLESHOOTING AND REP AIR F-37 F-37 POWERARC® 5500 14. Slide a short length of 2 X 4 under the engine to support it when the stator is removed. 15. With the 1/2” wrench, remove the 2 nuts that hold the stator end brack- et support. See Figure F .12 for location. There ar e 2 split-r[...]

  • Page 86

    TROUBLESHOOTING AND REP AIR F-38 F-38 POWERARC® 5500 ST A TOR/ROTOR REMOV AL AND REPLACEMENT PROCEDURE (continued) ROTOR REMOV AL PROCEDURE 1. T o r emove the r otor , double check that the spark plug wire is discon- nected. Y ou will be tur ning the rotor during this pr ocedure, and this could accidentally cause engine kickback. 2. With an impact[...]

  • Page 87

    TROUBLESHOOTING AND REP AIR F-39 F-39 POWERARC® 5500 ST A TOR/ROTOR REMOV AL AND REPLACEMENT PROCEDURE (continued) 6. Install the bottom two end bracket thru- bolts. 7. T ap the end bracket with the mallet as nec- essary to position it. Tighten the bolts to 4.5 - 5.5 ft lbs. Alternate tightening in order to pull the assembly together evenly . As y[...]

  • Page 88

    REACTOR BOL TS (2) LEAD #205 LEAD CONNECTIONS FIGURE F .15 LEAD 205 AND MORE GROUNDING SCREW 2 BOL TS SHEET ME T AL SCRE WS (5 PLACES) MOLEX PL UG FIGURE F .16 MOLEX PLUG AND BOL T/SCREW LOCA TION ST A TOR/ROTOR REMOV AL AND REPLACEMENT PROCEDURE (continued) TROUBLESHOOTING AND REP AIR F-40 F-40 POWERARC® 5500 Return to Section TOC Return to Secti[...]

  • Page 89

    RETEST AFTER REP AIR Retest a machine: • If it is rejected under test for any reason that requires you to remove any mechanical part which could affect the machine’ s electrical characteristics. OR • If you repair or replace any electrical components. ENGINE OUTPUT No Load RPM Load RPM Maximum Speed 3725 3650 Minimum Speed 3675 3400 WELDER/GE[...]

  • Page 90

    NOTES F-42 F-42 POWERARC® 5500 Return to Section TOC Return to Section TOC Return to Section TOC Return to Section TOC Return to Master TOC Return to Master TOC Return to Master TOC Return to Master TOC[...]

  • Page 91

    T ABLE OF CONTENTS - DIAGRAM SECTION G-1 G-1 POWERARC® 5500 Electrical Diagrams . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .G-1 Wiring Diagram (Codes 1 1 182, 1 1 187, 1 1329) (S25984) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .[...]

  • Page 92

    ELECTRICAL DIAGRAMS G-2 POWERARC® 5500 WIRING DIAGRAM - CODES 1 1182, 1 1187, 1 1329 (S25984) S25984 ENGINE WIRING MAG SWITCH RUN/ ST OP WIRI NG DI AGRAM - PO WER ARC 550 0 A SWITCH LOW OIL MODULE GROUND BRAC KET STATOR E ND 20 1B (+) 9 7 3 5 6 GND-C 2 GND-D W1 W2 W1A REAC T OR 1 L1 OU T PU TS T U DS 65 4 3 STAT OR W 100W 3.3 R1 6C 5A 5B 5B 2 0A 6[...]

  • Page 93

    ELECTRICAL DIAGRAMS G-3 POWERARC® 5500 WIRING DIAGRAM - CODES 1 1403, 11405 (S26829) S26829 ENGINE WIRING MAG SWITCH RUN/ ST OP WIRI NG DI AGRAM - PO WER ARC 550 0 A SWITCH LOW OIL MODULE GROUND BRAC KET STATOR E ND 20 1B (+) 9 7 3 5 6 GND-C 2 GND-D W1 W2 W1A REAC T OR 1 L1 OU T PU TS T U DS 65 4 3 STAT OR 100W 3.3 Ohms R1 6C 5A 5B 5B 6A 3A 5A 2 0[...]

  • Page 94

    ELECTRICAL DIAGRAMS G-4 POWERARC® 5500 WIRING DIAGRAM - CODE 1 1404 (S26830) A S26830 D1 C1 R OTOR (+) (-) (+) (-) EN GIN E W IRING M AG S WI TCH 9A 20 2A 7A 600 µ F D CCW A 20 1A 201 RUN/ S TO P 3C 20 1B 6B 3B GND -B GND -A W IRI NG DIA GRA M - POW ER ARC 5500 D2 205 202 200A 200 20 2B 202 9A 7A 5B 5B 5A 6C R1 3.3 Ohms 100W STAT OR 3 4 5 6 OU T [...]

  • Page 95

    ELECTRICAL DIAGRAMS G-5 POWERARC® 5500 WIRING DIAGRAM - CODE 1 1215 (S26023) A S26023 D1 C1 R OTOR (+) (-) (+) (-) EN GIN E W IRING M AG S WI TCH 9A 20 2A 7A 600 µ F D CCW A 20 1A 201 RUN/ S TO P 3C 20 1B C B2 C B1 6B 3B GND -B GND -A W IRI NG DIA GRA M - POW ER ARC 5500 D2 205 202 200A 200 20 2B 202 9A 7A 2 0A 5A 3A 6A 2 0A 5B 5B 5A 6C R1 3.3 10[...]

  • Page 96

    ELECTRICAL DIAGRAMS G-6 POWERARC® 5500 SCHEMA TIC -CODES 11 182, 1 1187, 1 1329 (S26008) S26008 POW ER A RC 5500 MACHIN E SCHEM AT IC NONE S21455 MAP BAM - DO N OT S CA L E TH IS D RA WING D RAW N BY: DESIG NI N FO R MA T IO N ENGI NEER : APP R OVE D: EQ UIPMENT TYPE: SUBJECT: SC ALE : UF CR M35 633 1 PAGE _ _ _ OF __ _ 1 EN GI NEE RIN G CO NTR OL[...]

  • Page 97

    ELECTRICAL DIAGRAMS G-7 POWERARC® 5500 SCHEMA TIC - CODES 11403, 1 1405 (S26881) S26881 POW ER A RC 5500 (SUBA RU RO BI N) MACHIN E SCHEM AT IC NONE S26008 MAP DJS - DO N OT S CA L E TH IS D RA WING D RAW N BY: DESIG NI N FO R MA T IO N ENGI NEER : APP R OVE D: EQ UIPMENT TYPE: SUBJECT: SC ALE : NA CR M38 121 1 PAGE _ _ _ OF __ _ 1 EN GI NEE RIN G[...]

  • Page 98

    ELECTRICAL DIAGRAMS G-8 POWERARC® 5500 SCHEMA TIC - CODE 11404 (S26882) S26882 POW ER A RC 5500 (HONDA) MACHIN E SCHEM AT IC NONE S26008 MAP DJS - DO N OT S CA L E TH IS D RA WING D RAW N BY: DESIG NI N FO R MA T IO N ENGI NEER : APP R OVE D: EQ UIPMENT TYPE: SUBJECT: SC ALE : NA CR M38 121 1 PAGE _ _ _ OF __ _ 1 EN GI NEE RIN G CO NTR OL L ED M A[...]