Lincoln Electric ARC 5000 User Manual

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Lincoln Electric ARC 5000 User Manual

POWER ARC 5000

IM560-A

November, 1999

For Machines with Code Number 10255 and 10430

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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 thoughtful operation on your part. DO NOT INSTALL, OPERATE OR REPAIR THIS EQUIPMENT WITHOUT READING THIS MANUAL AND THE SAFETY PRECAUTIONS CONTAINED THROUGHOUT. And, most importantly, think before you act and be careful.

OPERATOR’S MANUAL

Date of Purchase:

Serial Number:

Code Number:

Model:

Where Purchased:

World's Leader in Welding and Cutting Products •

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

i

SAFETY

i

WARNING

CALIFORNIA PROPOSITION 65 WARNINGS

Diesel engine exhaust and some of its constituents are known to the State of California to cause cancer, birth defects, and other reproductive harm.

The Above For Diesel Engines

The engine exhaust from this product contains chemicals known to the State of California to cause cancer, birth defects, or other reproductive harm.

The Above For Gasoline Engines

ARC WELDING CAN BE HAZARDOUS. PROTECT YOURSELF AND OTHERS FROM POSSIBLE SERIOUS INJURY OR DEATH. KEEP CHILDREN AWAY. PACEMAKER 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 available from the Lincoln Electric Company, 22801 St. Clair Avenue, Cleveland, Ohio 44117-1199.

BE SURE THAT ALL INSTALLATION, OPERATION, MAINTENANCE AND REPAIR PROCEDURES ARE PERFORMED ONLY BY QUALIFIED INDIVIDUALS.

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.

____________________________________________________

1.c. Do not add the fuel near an open flame welding arc or when the engine is running.

Stop the engine and allow it to cool before refueling to prevent spilled fuel from vaporizing on contact with hot engine parts and igniting. Do not spill fuel when filling tank. If fuel is spilled, wipe it up and do not start engine until fumes have been eliminated.

____________________________________________________

1.d. Keep all equipment safety guards, covers and devices in position and in good repair.Keep hands, hair, clothing and tools away from V-belts, gears, fans and all other moving parts when starting, operating or repairing equipment.

____________________________________________________

1.e. In some cases it may be necessary to remove safety guards to perform required maintenance. Remove guards only when necessary and replace them when the maintenance requiring their removal is complete. Always use the greatest care when working near moving parts.

___________________________________________________

1.f. Do not put your hands near the engine fan.

Do not attempt to override the governor or idler by pushing on the throttle control rods while the engine is running.

___________________________________________________

1.g. To prevent accidentally starting gasoline engines while turning the engine or welding generator during maintenance work, disconnect the spark plug wires, distributor cap or magneto wire as appropriate.

1.h. To avoid scalding, do not remove the radiator pressure cap when the engine is hot.

ELECTRIC AND MAGNETIC FIELDS may be dangerous

2.a. Electric current flowing through any conductor causes localized Electric and Magnetic Fields (EMF). Welding current creates EMF fields around welding cables and welding machines

2.b. EMF fields may interfere with some pacemakers, and welders having a pacemaker should consult their physician before welding.

2.c. Exposure to EMF fields in welding may have other health effects which are now not known.

2.d. All welders should use the following procedures in order to minimize exposure to EMF fields from the welding circuit:

2.d.1. Route the electrode and work cables together - Secure them with tape when possible.

2.d.2. Never coil the electrode lead around your body.

2.d.3. Do not place your body between the electrode and work cables. If the electrode cable is on your right side, the work cable should also be on your right side.

2.d.4. Connect the work cable to the workpiece as close as possible to the area being welded.

2.d.5. Do not work next to welding power source.

Mar ‘95

ii

 

SAFETY

 

ii

 

 

 

 

 

 

 

 

 

ELECTRIC SHOCK can

kill.

3.a. The electrode and work (or ground) circuits are electrically “hot” when the welder is on. Do not touch these “hot” parts with your bare skin or wet clothing. Wear dry, hole-free

gloves to insulate hands.

3.b. Insulate yourself from work and ground using dry insulation. Make certain the insulation is large enough to cover your full area of physical contact with work and ground.

In addition to the normal safety precautions, if welding must be performed under electrically hazardous conditions (in damp locations or while wearing wet clothing; on metal structures such as floors, gratings or scaffolds; when in cramped positions such as sitting, kneeling or lying, if there is a high risk of unavoidable or accidental contact with the workpiece or ground) use the following equipment:

Semiautomatic DC Constant Voltage (Wire) Welder.

DC Manual (Stick) Welder.

AC Welder with Reduced Voltage Control.

3.c. In semiautomatic or automatic wire welding, the electrode, electrode reel, welding head, nozzle or semiautomatic welding gun are also electrically “hot”.

3.d. Always be sure the work cable makes a good electrical connection with the metal being welded. The connection should be as close as possible to the area being welded.

3.e. Ground the work or metal to be welded to a good electrical (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.

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.

ARC RAYS 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 and that of your helpers from the arc rays.

4.c. Protect other nearby personnel with suitable, non-flammable screening and/or warn them not to watch the arc nor expose themselves to the arc rays or to hot spatter or metal.

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 require special ventilation such as stainless or hard facing (see instructions on container or MSDS) or on lead or cadmium plated steel and other metals or coatings which produce highly toxic fumes, keep exposure as low as possible and below Threshold Limit Values (TLV) using local exhaust or mechanical ventilation. In confined spaces or in some circumstances, outdoors, a respirator may be required. Additional precautions are also required when welding on galvanized steel.

5.b. Do not weld in locations near chlorinated hydrocarbon vapors coming from degreasing, cleaning or spraying operations.

The heat and rays of the arc can react with solvent vapors to form phosgene, a highly toxic gas, and other irritating products.

5.c. Shielding gases used for arc welding can displace air and cause injury or death. Always use enough ventilation, especially in confined areas, to insure breathing air is safe.

5.d. Read and understand the manufacturer’s instructions for this equipment and the consumables to be used, including the material safety data sheet (MSDS) and follow your employer’s safety practices. MSDS forms are available from your welding distributor or from the manufacturer.

5.e. Also see item 1.b.

Mar ‘95

iii

SAFETY

iii

WELDING SPARKS can

cause fire or explosion.

6.a. Remove fire hazards from the welding area. If this is not possible, cover them to prevent 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 Welding and Cutting” (ANSI

Standard Z49.1) and the operating information for the equipment being used.

6.c. When not welding, make certain no part of the electrode circuit is touching the work or ground. Accidental contact can cause overheating and create a fire hazard.

6.d. Do not heat, cut or weld tanks, drums or containers until the proper steps have been taken to insure that such procedures will not cause flammable or toxic vapors from substances inside. They can cause an explosion even though they have been “cleaned”. For information, purchase “Recommended Safe Practices for the Preparation for Welding and Cutting of Containers and Piping That Have Held Hazardous

Substances”, AWS F4.1 from the American Welding Society

(see address above).

6.e. Vent hollow castings or containers before heating, cutting or welding. They may explode.

6.f. Sparks and spatter are thrown from the welding arc. Wear oil free protective garments such as leather gloves, heavy shirt, cuffless trousers, high shoes and a cap over your hair. Wear ear plugs when welding out of position or in confined places. Always wear safety glasses with side shields when in a welding area.

6.g. Connect the work cable to the work as close to the welding area as practical. Work cables connected to the building framework or other locations away from the welding area increase the possibility of the welding current passing through lifting chains, crane cables or other alternate circuits. This can create fire hazards or overheat lifting chains or cables until they fail.

6.h. Also see item 1.c.

CYLINDER may explode

if damaged.

7.a. Use only compressed gas cylinders

containing the correct shielding gas for the process used and properly operating regulators designed for the gas and

pressure used. All hoses, fittings, etc. should be suitable for the application and maintained in good condition.

7.b. Always keep cylinders in an upright position securely chained to an undercarriage or fixed support.

7.c. Cylinders should be located:

Away from areas where they may be struck or subjected to physical damage.

A safe distance from arc welding or cutting operations and any other source of heat, sparks, or flame.

7.d. Never allow the electrode, electrode holder or any other electrically “hot” parts to touch a cylinder.

7.e. Keep your head and face away from the cylinder valve outlet when opening the cylinder valve.

7.f. Valve protection caps should always be in place and hand tight except when the cylinder is in use or connected for use.

7.g. Read and follow the instructions on compressed gas cylinders, associated equipment, and CGA publication P-l,

“Precautions for Safe Handling of Compressed Gases in Cylinders,” available from the Compressed Gas Association 1235 Jefferson Davis Highway, Arlington, VA 22202.

FOR ELECTRICALLY 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 Code and the manufacturer’s recommendations.

Mar ‘95

iv

SAFETY

iv

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 suivantes:

Sûreté Pour Soudage A L’Arc

1.Protegez-vous contre la secousse électrique:

a.Les circuits à l’électrode et à la piéce sont sous tension quand la machine à souder est en marche. Eviter toujours tout contact entre les parties sous tension et la peau nue ou les vétements mouillés. Porter des gants secs et sans trous pour isoler les mains.

b.Faire trés attention de bien s’isoler de la masse quand on soude dans des endroits humides, ou sur un plancher metallique ou des grilles metalliques, principalement dans les positions assis ou couché pour lesquelles une grande partie du corps peut être en contact avec la

masse.

c.Maintenir le porte-électrode, la pince de masse, le câble de soudage et la machine à souder en bon et sûr état

defonctionnement.

d.Ne jamais plonger le porte-électrode dans l’eau pour le refroidir.

e.Ne jamais toucher simultanément les parties sous tension des porte-électrodes connectés à deux machines à souder parce que la tension entre les deux pinces peut être le total de la tension à vide des deux machines.

f.Si on utilise la machine à souder comme une source de courant pour soudage semi-automatique, ces precautions pour le porte-électrode s’applicuent aussi au pistolet de soudage.

2.Dans le cas de travail au dessus du niveau du sol, se protéger contre les chutes dans le cas ou on recoit un choc. Ne jamais enrouler le câble-électrode autour de n’importe quelle partie du corps.

3.Un coup d’arc peut être plus sévère qu’un coup de soliel, donc:

a.Utiliser un bon masque avec un verre filtrant approprié

ainsi qu’un verre blanc afin de se protéger les yeux du rayonnement de l’arc et des projections quand on soude ou quand on regarde l’arc.

b.Porter des vêtements convenables afin de protéger la peau de soudeur et des aides contre le rayonnement de l‘arc.

c.Protéger l’autre personnel travaillant à proximité au

soudage à l’aide d’écrans appropriés 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.Eloigner les matériaux inflammables ou les recouvrir afin de prévenir tout risque d’incendie dû aux étincelles.

7.Quand on ne soude pas, poser la pince à une endroit isolé de la masse. Un court-circuit accidental peut provoquer un

échauffement et un risque d’incendie.

8.S’assurer que la masse est connectée le plus prés possible de la zone de travail qu’il est pratique de le faire. Si on place la masse sur la charpente de la construction ou d’autres endroits éloignés de la zone de travail, on augmente le risque de voir passer le courant de soudage par les chaines de levage, câbles de grue, ou autres circuits. Cela peut provoquer des risques d’incendie ou d’echauffement des chaines et des câbles jusqu’à ce qu’ils se rompent.

9.Assurer une ventilation suffisante dans la zone de soudage. Ceci est particuliérement important pour le soudage de tôles galvanisées plombées, ou cadmiées ou tout autre métal qui produit des fumeés toxiques.

10.Ne pas souder en présence de vapeurs de chlore provenant d’opérations de dégraissage, nettoyage ou pistolage. La chaleur ou les rayons de l’arc peuvent réagir avec les vapeurs du solvant pour produire du phosgéne (gas fortement toxique) ou autres produits irritants.

11.Pour obtenir de plus amples renseignements sur la sûreté, voir le code “Code for safety in welding and cutting” CSA Standard W 117.2-1974.

PRÉCAUTIONS DE SÛRETÉ POUR LES MACHINES À SOUDER À TRANSFORMATEUR ET À REDRESSEUR

1.Relier à la terre le chassis du poste conformement au code de l’électricité et aux recommendations du fabricant. Le dispositif de montage ou la piece à souder doit être branché à une bonne mise à la terre.

2.Autant que possible, I’installation et l’entretien du poste seront effectués par un électricien qualifié.

3.Avant de faires des travaux à l’interieur de poste, la debrancher à l’interrupteur à la boite de fusibles.

4.Garder tous les couvercles et dispositifs de sûreté à leur place.

Mar. ‘93

v

Thank You

v

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!

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 received.

Please record your equipment identification information below for future reference. This information can be found on your machine nameplate.

Model Name & Number _____________________________________

Code & Serial Number _____________________________________

Date of Purchase _____________________________________

Whenever you request replacement parts for or information on this equipment always supply the information you have recorded above.

Read this Operators Manual completely before attempting to use this equipment. Save this manual and keep it handy for quick reference. Pay particular attention to the safety instructions we have provided for your protection. The level of seriousness to be applied to each is explained below:

WARNING

This statement appears where the information must be followed exactly to avoid serious personal injury or loss of life.

CAUTION

This statement appears where the information must be followed to avoid minor personal injury or damage to this equipment.

vi

 

vi

 

TABLE OF CONTENTS

 

 

 

 

Page

 

Safety.................................................................................................................................................

i-iv

 

 

 

 

 

Installation .............................................................................................................................

Section A

 

Technical Specifications .............................................................................................................

A-1

 

Safety Precautions......................................................................................................................

A-2

 

Location and Ventilation .............................................................................................................

A-2

 

Assembly of Vibration Isolators to Bottom of Tube Frame.........................................................

A-3

 

Assembly of Wheels and Handle to the Tube Frame..................................................................

A-4

 

Pre-operation Engine Service .....................................................................................................

A-5

 

Electrical Output Connections .........................................................................................

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 E

 

 

 

 

 

Electrical Diagrams...............................................................................................................

Section F

 

 

 

 

 

Parts Manual......................................................................................................................

P277 Series

POWER ARC 5000

A-1

INSTALLATION

A-1

 

 

 

TECHNICAL SPECIFICATIONS - 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 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.

 

 

20 in.

 

29 in.

 

208 lb. - 215 lb w/ undercarriage

676 mm

 

 

508 mm

 

737 mm

 

94.3 kg. - 97.5 kg. w/ undercarriage

 

 

 

 

 

 

 

 

 

 

POWER ARC 5000

A-2

INSTALLATION

A-2

 

 

 

Read this entire installation section before you start installation.

SAFETY PRECAUTIONS

WARNING

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 maintenance instructions; and parts lists.

ELECTRIC SHOCK can kill.

Do not touch electrically live parts or electrodes with your skin or wet clothing.

Insulate yourself from the work and ground.

•Always wear dry insulating gloves.

ENGINE EXHAUST can kill.

Use in open, well ventilated areas or vent exhaust to the outside.

Do not stack anything on or near the engine.

MOVING PARTS can injure.

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 service this equipment.

LOCATION AND VENTILATION

Whenever you use the POWER ARC 5000, be sure that clean cooling air can flow through the machine’s gasoline engine and the generator. Avoid dusty, dirty areas. Also, keep the machine away from heat sources. Do not place the back end of the generator anywhere near hot engine exhaust from another machine. And of course, make sure that engine exhaust is ventilated to an open, outside area. The ambient temperature range for operating this machine is 0°F to 104°F (-18°C to 40°C).

The POWER ARC 5000 may be used outdoors. Do not set the machine in puddles or otherwise submerge it in water. Such practices pose safety hazards 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 live electrical devices.

STORING

1.Store the machine in a cool, dry place when it’s not in use. Protect it from dust and dirt. Keep it where it can’t be accidentally damaged from construction activities, moving vehicles, and other hazards.

2.If you will be storing the machine for over 30 days, you should drain the fuel to protect fuel system and carburetor parts from gum deposits. Empty all fuel from the tank and run the engine until it stops from lack of fuel.

3.You can store the machine for up to 24 months if you use Sta-Bil® additive or Briggs & Stratton Gasoline Additive, Part No. 5041 (available from any Authorized Briggs & Stratton Service Center), in the fuel system. Mix the additive with the fuel in the tank and run the engine for a short time to circulate the additive through the carburetor.

4.While the engine is still warm, drain the oil and refill with fresh oil per the engine manual.

5.Remove the spark plug and pour approximately 1/2 ounce (15 ml) of engine oil into the cylinder. Replace the spark plug and crank the engine slowly to distribute the oil.

6.Clean any dirt and debris from the cylinder and cylinder head fins and housing, rotating screen, and muffler areas.

7.Store in a clean, dry area.

POWER ARC 5000

A-3

INSTALLATION

A-3

 

 

 

STACKING

POWER ARC 5000 machines CANNOT be stacked.

TILTING

Place the machine on a secure, level surface whenever 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 position for best performance. It can operate at an angle, but this should never be more than 15 degrees in any direction. If you do operate it at a slight angle, be sure to check the oil regularly and keep the oil level full. Also, fuel capacity will be a little less at an angle.

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 four molded rubber vibration isolators to the bottom of the engine and alternator support channels using four each of the supplied 3/8-16 X .875 hex head screws, lockwashers, and large plain washers (spacers). The large plain washers (spacers) must be installed between the isolator and the underside of the channels. See Figure A-1.

LIFTING

The POWER ARC 5000 should be lifted by four people. (It weighs 208 lbs/94.3 kg.) Its welded tube roll cage is designed to make lifting easy.

Figure A-1

3/8-16 x .875 Hex Head Bolt

Lockwasher

Frame

Large Plain Washer (Spacer)

Rubber Isolator

POWER ARC 5000

A-4

INSTALLATION

A-4

 

 

 

Assembly of Wheels and Handle to the Tube 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.)

Install two of the vibration isolators (Item 1) to the

 

bottom of each foot (Item 2) using one each of the

 

supplied 3/8-16 X .875 hex head bolts and lock-

 

washers on each foot. (Detail A)

c.)

Install the two feet to the alternator support channel

 

using three each of the supplied 3/8-16 X .875 hex

 

head bolts, lock-washers, and 3/8 - 16 hex nuts on

 

each foot. (Detail A)

d.)

Install the two axle support brackets (Item 3) to the

 

engine support channel using two each of the

 

supplied 3/8-16 X .875 hex head bolts and lock-

 

washers, two each of the supplied 3/8-16 hex nuts,

 

two each of the large plain washers (spacers), and

 

two each of the vibration isolators (Item 1). The two

Figure A-2

8

Alternator Support Channel

3/8-16 Hex Nut (3)

Lockwasher (3)

3/8-16 x .875 Hex Bolt (3)

Foot

Item 2

3/8-16 x .875 Hex Bolt

Lockwasher

Rubber Isolator

 

 

Item 1

2

1

 

 

Detail A

vibration isolators are installed in the inward holes furthest from the tube frame. Refer to Figure A-2 Detail B. The two large washers must 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 support brackets. The axle will rest on the two vibration isolators when the machine is set on the ground providing a type of suspension for the axle.

g.) Install the other wheel and push nut on the other end of the axle.

h.) Loosen but do not remove the four screws that hold the handle clips (Item 7) to the fuel tank support channel on the alternator end. Install the handle (Item 8) through the large holes in the channel and tighten the screws that were previously loosened. The height of the handle can be adjusted to suit the user.

 

Engine Support Channel

 

 

3/8-16 x .875 Hex Bolt (2)

 

Axle

 

 

Item 5

Lockwasher

Tubular Frame

 

 

 

Hex Nut

 

 

 

Wheel

 

 

Item 6

 

 

Push Nut

 

 

Item 4

Rubber Isolator

Item 1

Large Plain Washer

(Spacer)

Axle Support Bracket Item 3

Detail B

7

3

1

6 4

5

POWER ARC 5000

A-5

INSTALLATION

A-5

 

 

 

PRE-OPERATION ENGINE SERVICE

Read and understand the information about the gasoline engine in the OPERATION and MAINTENANCE sections of this manual operate the POWER ARC 5000.

WARNING

Keep hands away from the engine muffler or HOT engine parts.

Stop the engine when fueling.

Do not smoke when fueling.

Remove the fuel cap slowly to release pressure.

Do not overfill the fuel tank.

Wipe up spilled fuel and allow the fumes to clear before starting the engine.

Keep sparks and flame away from the fuel tank.

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 engine is running. Some federal, state, or local laws require spark arresters in locations where unarrested sparks could present a fire hazard.

Standard mufflers do not act as spark arresters. When local laws require it, a spark arrester must be installed on the machine and properly maintained. An optional spark arrester kit is available for your POWER ARC 5000. See the ACCESSORIES section of this manual for more information.

OIL

The POWER ARC 5000 is shipped with the engine filled with SAE 10W-30 oil. CHECK THE OIL LEVEL BEFORE YOU START THE ENGINE. If the oil level is not at the “FULL” mark on the dip-stick, add oil but do not overfill. Be sure the dip-stick cap is tight. Change the oil after the first 5 hours of operation.

For more oil fill and service information, see the Briggs & Stratton Engine manual.

CAUTION

An incorrect spark arrester may lead to damage to the engine or reduce performance. A suitable spark arrester for the Briggs & Stratton 11 HP Industrial Plus engine is available as a Lincoln field-installed option.

POWER ARC 5000

A-6

INSTALLATION

A-6

 

 

 

FIGURE A.3 - POWER ARC 5000 OUTPUT CONNECTIONS

1

10

POWER ARC 5000

6

2

9

WARNING

 

 

 

 

 

 

 

 

 

 

WELDING ELECTRODES

CIRCUIT BREAKERS

120 VOLTS 15 AMPS

 

 

 

 

120/240 VOLTS 30 AMPS

120 VOLTS 30 AMPS

WORK

LOW RANGE HIGH RANGE

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

7

8

 

4

3

5

 

 

1.

CURRENT CONTROL DIAL

6.

CIRCUIT BREAKERS (3)

2.

ELECTRODE SELECTION GUIDE

7.

GFCI DUPLEX RECEPTACLE - 120 VOLT, 15 AMP

3.

WELD OUTPUT TERMINALS (TO ELECTRODE HOLDER,

8.

TWIST-LOCK RECEPTACLE - 120 VOLT, 30 AMP

 

HIGH RANGE AND LOW RANGE)

9.

TWIST-LOCK RECEPTACLE - 120/240 VOLT, 30 AMP

4.

WELD OUTPUT TERMINAL (TO WORK)

10. ENGINE HOUR METER

5.

GROUNDING TERMINAL

 

 

ELECTRICAL OUTPUT

CONNECTIONS

See Figure A.3 for the location of the current control dial, weld output terminals, grounding terminal, 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 especially 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.

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

 

 

POWER ARC 5000

A-7

INSTALLATION

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 connecting the welding cables.

2.Remove the 1/2 - 13 flanged nuts from the output terminals.

3.Connect the electrode holder and work cables to the appropriate weld output terminals.

4.Tighten the flanged nuts securely.

5.Be certain that the metal piece you are welding (the “work”) is securely connected to the work clamp and cable.

6.Check and tighten the connections periodically.

CAUTION

Loose connections will cause the output terminals to overheat. The terminals may eventually melt.

Do not cross the welding cables at the output terminal connection. Keep the cables isolated and separate from one another.

Lincoln Electric offers a welding accessory kit with the properly specified welding cables. See the ACCESSORIES section of this manual for more information.

MACHINE GROUNDING

For protection against electrical shock, connect a heavy gauge wire from the grounding terminal located on the bottom center of the output panel to a suit-

able earth ground such as a metal pipe driven into the ground.

WARNING

Do not ground the machine to a pipe that carries explosive or combustible material.

When the POWER ARC 5000 is mounted on a truck or a trailer, the machine generator grounding terminal MUST be securely connected to the metal frame of the vehicle. See Figure A.3. The grounding terminal is marked with the symbol.

AUXILIARY POWER RECEPTACLES

The control panel of the POWER ARC 5000 features three auxiliary power receptacles:

One 15 amp, 120 volt ground fault circuit interrupter (GFCI) duplex interrupter (NENA Style 5- 15R).

One 30 amp 120 volt Twist-Lock receptacle (NEMA Style L5-30R).

One 30 amp 120/240 volt Twist-Lock receptacle (NEMA Style L14-30R).

See Figure A.3.

The receptacles are UL and CSA approved.

POWER ARC 5000

A-8

INSTALLATION

A-8

 

 

 

POWER CORD CONNECTIONS TO TWISTLOCK 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 120 volt hand-held equipment connected to the generator receptacles must use a three-blade, grounded type plug or an Underwriter’s Laboratories (UL) approved double insulation system with a two-blade plug.

CIRCUIT BREAKERS

The POWER ARC 5000 has circuit

breakers for overload protection. When the machine is operated in high temperature environments, the

breakers may tend to trip at lower loads than normally.

CAUTION

Never bypass the circuit breakers. Without overload protection, the POWER ARC 5000 could overheat and/or cause damage to the equipment being used.

PREMISES WIRING

The POWER ARC 5000 three-wire, grounded neutral generator allows 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.

WARNING

Only a licensed, certified, trained electrician should install the machine to a premises or residential electrical system. Be certain that:

The premises is isolated and no feedbacking into the utility system can occur. Certain state and local laws require the premises to be isolated before the generator is linked to the premises. Check your state and local requirements.

A double pole, double throw transfer switch in conjunction with the properly rated double throw circuit breaker is connected between the generator power and the utility meter.

Remember that the POWER ARC 5000 is intended only for backup, intermittent use. It cannot withstand long-term use without proper maintenance. See the MAINTENANCE section of this manual for more information.

CAUTION

Certain electrical devices cannot be powered by the POWER ARC 5000. Refer to Table A.2 for these devices.

POWER ARC 5000

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