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POWERARC
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For use with machine code number: 11182, 11187, 11215, 11329, 11403, 11404, 11405
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.
SVM197-A
January, 2010
®
5500
View Safety Info View Safety Info View Safety Info View Safety Info
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Cleveland, Ohio 44117-1199 U.S.A. TEL: 888.935.3877 FAX: 216.486.1751 WEB SITE: www.lincolnelectric.com
SERVICE MANUAL
Copyright © Lincoln Global Inc.
• World's Leader in Welding and Cutting Products •
• Sales and Service through Subsidiaries and Distributors Worldwide •
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i i
SAFETY
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
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.
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
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.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.
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.
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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
POWERARC® 5500
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ii ii
SAFETY
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 within applicable OSHA PEL and
ACGIH TLV limits 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. The operation of welding fume control equipment is affected
by various factors including proper use and positioning of the
equipment, maintenance of the equipment and the specific
welding procedure and application involved. Worker exposure level should be checked upon installation and periodically thereafter to be certain it is within applicable OSHA PEL
and ACGIH TLV limits.
5.c.
Do not weld in locations near chlorinated hydrocarbon
coming from degreasing, cleaning or spraying operations.
The heat and rays of the arc can react with solvent vapors
form phosgene, a highly toxic gas, and other irritating products.
vapors
to
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5.d. 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.e. 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.f. Also see item 1.b.
Jan ‘09
POWERARC® 5500
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iii iii
SAFETY
WELDING and CUTTING
SPARKS can
cause fire or explosion.
6.a.
Remove fire hazards from the welding area.
If this is not possible, cover them to prevent
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
been “cleaned”. For information, purchase “Recommended
Safe Practices for the
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.
Sparks and spatter are thrown from the welding arc. Wear oil
6.f.
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.
the welding sparks from starting a fire.
though
they have
Preparation
for Welding and Cutting of
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.
6.I. Read and follow NFPA 51B “ Standard for Fire Prevention
During Welding, Cutting and Other Hot Work”, available from
NFPA, 1 Batterymarch Park,PO box 9101, Quincy, Ma
022690-9101.
6.j. Do not use a welding power source for pipe thawing.
Refer to http://www.lincolnelectric.com/safety for additional safety information.
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Jan ‘09
POWERARC® 5500
Page 5
iv iv
SAFETY
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.
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.
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-inflammables.
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.
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.
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Mar ‘93
POWERARC® 5500
Page 6
v v
SAFETY
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 that implements a harmonized
standard: EN 60974-10 Electromagnetic Compatibility (EMC) Product Standard for Arc Welding Equipment.
It is for use with other Lincoln Electric equipment. It is designed for industrial and professional use.
Introduction
All electrical equipment generates small amounts of electromagnetic emission. Electrical emission may be
transmitted through power lines or radiated through space, similar to a radio transmitter. When emissions
are received by other equipment, electrical interference may result. Electrical emissions may affect many
kinds of electrical equipment; other nearby welding equipment, radio and TV reception, numerical controlled
machines, telephone systems, computers, etc. Be aware that interference may result and extra precautions
may be required when a welding power source is used in a domestic establishment.
Installation and Use
The user is responsible for installing and using the welding equipment according to the manufacturer’s
instructions. If electromagnetic disturbances are detected then it shall be the responsibility of the user of the
welding equipment to resolve the situation with the technical assistance of the manufacturer. In some cases
this remedial action may be as simple as earthing (grounding) the welding circuit, see Note. In other cases
it could involve construction of an electromagnetic screen enclosing the power source and the work complete with associated input filters. In all cases electromagnetic disturbances must be reduced to the point
where they are no longer troublesome.
Note: The welding circuit may or may not be earthed for safety reasons according to national
codes. Changing the earthing arrangements should only be authorized by a person who is
competent to access whether the changes will increase the risk of injury, e.g., by allowing
parallel welding current return paths which may damage the earth circuits of other equipment.
Assessment of Area
Before installing welding equipment the user shall make an assessment of potential electromagnetic problems in the surrounding area. The following shall be taken into account:
a) other supply cables, control cables, signaling and telephone cables; above, below and adjacent to the
welding equipment;
b) radio and television transmitters and receivers;
c) computer and other control equipment;
d) safety critical equipment, e.g., guarding of industrial equipment;
e) the health of the people around, e.g., the use of pacemakers and hearing aids;
f) equipment used for calibration or measurement
g) the immunity of other equipment in the environment. The user shall ensure that other equipment being
used in the environment is compatible. This may require additional protection measures;
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h) the time of day that welding or other activities are to be carried out.
L10093 3-1-96H
POWERARC® 5500
Page 7
vi vi
SAFETY
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 connected to the mains supply according to the manufacturer’s recommendations. If interference occurs, it may be necessary to take additional precautions such as filtering of the
mains supply. Consideration should be given to shielding the supply cable of permanently installed welding
equipment, in metallic conduit or equivalent. Shielding should be electrically continuous throughout its
length. The shielding should be connected to the welding power source so that good electrical contact is
maintained between the conduit and the welding power source enclosure.
Maintenance of the Welding Equipment
The welding equipment should be routinely maintained according to the manufacturer’s recommendations.
All access and service doors and covers should be closed and properly fastened when the welding equipment is in operation. The welding equipment should not be modified in any way except for those changes
and adjustments covered in the manufacturers instructions. In particular, the spark gaps of arc striking and
stabilizing devices should be adjusted and maintained according to the manufacturer’s recommendations.
Welding Cables
The welding cables should be kept as short as possible and should be positioned close together, running at
or close to floor level.
Equipotential Bonding
Bonding of all metallic components in the welding installation and adjacent to it should be considered.
However, metallic components bonded to the work piece will increase the risk that the operator could
receive a shock by touching these metallic components and the electrode at the same time. The operator
should be insulated from all such bonded metallic components.
Earthing of the Workpiece
Where the workpiece is not bonded to earth for electrical safety, not connected to earth because of its size
and position, e.g., ships hull or building steelwork, a connection bonding the workpiece to earth may reduce
emissions in some, but not all instances. Care should be taken to prevent the earthing of the workpiece
increasing the risk of injury to users, or damage to other electrical equipment. Where necessary, the connection of the workpiece to earth should be made by a direct connection to the workpiece, but in some
countries where direct connection is not permitted, the bonding should be achieved by suitable capacitance, selected according to national regulations.
Screening and Shielding
Selective screening and shielding of other cables and equipment in the surrounding area may alleviate
problems of interference. Screening of the entire welding installation may be considered for special applica-
1
tions.
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_________________________
1
Portions of the preceding text are contained in EN 60974-10: “Electromagnetic Compatibility (EMC)
product standard for arc welding equipment.”
POWERARC® 5500
L10093 3-1-96H
Page 8
I I
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- MASTER TABLE OF CONTENTS FOR ALL SECTIONS -
Page
Safety . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .i-iv
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Section A
Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Section B
Accessories . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Section C
Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Section D
Theory of Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Section E
Troubleshooting and Repair . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Section F
Electrical Diagrams . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Section G
Parts Manual . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .P-510
POWERARC® 5500
Page 9
A-1 A-1
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .A-1
Technical Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .A-2
Safety Precautions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .A-3
Location . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .A-3
Stacking, Tilting, Angle of Operation, Oil, Fuel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .A-4
Muffler, Spark Arrester . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .A-5
Component Locations, Output Connections . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .A-6
Cable Installation, Machine Grounding . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .A-7
Premises Wiring . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .A-8
TABLE OF CONTENTS - INSTALLATION SECTION
Electrical Device Use with the POWERARC® 5500 Table . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .A-9
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POWERARC® 5500
Page 10
A-2 A-2
INSTALLATION
TECHNICAL SPECIFICATIONS - POWERARC® 5500
INPUT - GASOLINE ENGINE
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 @
(11405) 3600 RPM
INPUT - HONDA GASOLINE ENGINE
INPUT - HONDA GASOLINE ENGINE
Honda 1 cyl., 3700 RPM 16.5 cu. in. Manual, Fuel: 1.6 gal. (6.1 l)
GX 270 VA2 4 cycle ± 50 RPM (270 cc) Recoil start;
Codes air-cooled OHV at no load Manual choke Oil: 1.2 qt. (1.1 l)
(11215) gasoline
(11404) 9 HP @
3600 RPM
RATED OUTPUT - WELDER
Duty Cycle Amps AC Volts at Rated Amperes
30% Duty Cycle 125 Amps AC Constant Current 20 VAC
60% Duty Cycle 100 Amps AC Constant Current 25 VAC
OUTPUT - WELDER AND GENERATOR
Welding Ranges Welder Open Circuit Voltage AC Auxiliary Power
70 - 125 Amps AC 62 VAC Max. 4000 Continuous Watts
5500 Surge Watts
PHYSICA
PHYSICAL DIMENSIONS
Height Width Depth Weight
20.9 in. 20 in. 30 in. 160 lb.
530 mm 508 mm 762 mm 72.5 kg
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POWERARC® 5500
Page 11
A-3 A-3
INSTALLATION
SAFETY PRECAUTIONS
Read this entire installation section before you
start installation.
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 POWERARC® 5500, 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 POWERARC® 5500 must 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 POWERARC® 5500 with the case
roof on and all machine components completely
assembled. This will protect you from the dangers of
moving parts, hot metal surfaces, 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 a gasoline stabilizing additive 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.
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7. Store in a clean, dry area.
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POWERARC® 5500
Page 12
A-4 A-4
INSTALLATION
STACKING
POWERARC® 5500 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.
LIFTING
The POWERARC® 5500 should be lifted by two people. (It weighs 160 lbs/72.5 kg.) Its welded tube roll
cage is designed to make lifting easy.
ANGLE OF OPERATION
Internal combustion engines are designed to run in a
level condition to achieve optimum performance. The
maximum angle of operation for the engine is 15
degrees from horizontal in any direction. Be certain to
place the machine on a firm, non-skid, structural supporting surface. Anchor unit if necessary.
If you are operating the engine at a slight angle, be certain to check the oil regularly and maintain a level, full
oil condition. The effective fuel capacity will also be
slightly less than the specified 1.6 gallon (6.1 liters).
FUEL
Fill the fuel tank with clean, fresh, regular grade leadfree gasoline. DO NOT MIX OIL WITH THE GASO-
LINE. Remove the fuel cap slowly to release pressure. Keep hands away from the engine muffler or
HOT engine parts.
WARNING
• Stop engine while fueling.
• Do not smoke when fueling.
• Keep sparks and flame away
from tank.
• Do not leave unattended while
fueling.
• Wipe up spilled fuel and allow
GASOLINE
can cause fire
or explosion.
fumes to clear before starting
engine.
• Do not overfill tank, fuel expansion may cause overflow.
GASOLINE FUEL ONLY
------------------------------------------------------------------------
The POWERARC® 5500 has a fuel tank mounted on
the engine. See the engine owner’s manual for more
details about fuel.
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PRE-OPERATION ENGINE SERVICE
Read and understand the information about the gasoline engine in the OPERATION and MAINTENANCE
sections of this manual and the engine owner’s manual before you operate the POWERARC® 5500.
OIL
The POWERARC® 5500 with the Robin / Subaru 9HP
engine and the POWERARC® 5500 with the Honda 9
HP engine are supplied with low oil protection. Both
engines are equipped with protection that will shut
down the engine in the event of a low oil condition. The
engine cannot be restarted until sufficient oil is added.
The POWERARC® 5500 is shipped with the engine
filled with SAE 10W-30 oil. CHECK THE OIL LEVEL
BEFORE YOU START THE ENGINE. This is an added
precaution. When full, the oil level should be at the top
of the fill plug hole. If it is not full, add enough oil to fill
it. Be sure the fill plug is tight. Change oil after the first
20 hours of operation. For more oil fill and service information, see the Engine owner’s manual.
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POWERARC® 5500
Page 13
A-5 A-5
INSTALLATION
PowerArc 5500 Typical Fuel Consumption
Robin / Subaru 9 HP Carb. Certified
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)
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)
MUFFLER DEFLECTOR
The POWERARC® 5500, Honda model, may or may
not be shipped with an exhaust deflector. If you
received one, you can mount it on the gasoline engine
if your needs so require.
To install the deflector, do the following:
• Align the holes on the deflector plate with the holes
on the muffler.
Position the deflector so that the opening points either
•
right, left, or downward, away from the operator.
Honda 9 HP
EX 27
Carb. Certified
.30 Gallons/Hour
(1.14 Liters/Hour)
.58 Gallons/Hour
(2.18 Liters/Hour)
.55 Gallons/Hour
(2.1 Liters/Hour)
.67 Gallons/Hour
(2.54 Liters/Hour)
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.
The Robin / Subaru and Honda models of the POWERARC® 5500 come with a spark arrester as standard
equipment. Refer to the engine owner’s manual for
proper maintenance.
CAUTION
CAUTION
Never position the deflector upward. Moisture or
debris can enter the engine and damage it. As a
general safety practice, position the deflector to
direct exhaust gases away from the operator’s
face and eyes.
-----------------------------------------------------------
• Fasten the deflector onto the muffler with the screws
provided.
NOTE: The deflector reduces generator output power
up to 100 watts.
An incorrect additional spark arrester may lead to
damage to the engine or reduce performance.
-----------------------------------------------------------
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POWERARC® 5500
Page 14
POWER ARCPOWER ARC 55550000
ELECTRODE SELECTION GUIDEELECTRODE SELECTION GUIDE
8080
9090
1
00100
7070
A
MPSAMPS
AMPSAMPS
AMPSAMPS
A
MPSAMPS
WARNINGWARNING
AMPSAMPS
1
25125
G
ENERATORGENERATOR
6
5
4
3
2
1
7
POWER ARCPOWER ARC 55550000
ELECTRODE SELECTION GUIDEELECTRODE SELECTION GUIDE
8080
9090
100100
7070
AMPSAMPS
A
MPSAMPS
AMPSAMPS
AMPSAMPS
WARNINGWARNING
AMPSAMPS
125125
GENERATORGENERATOR
8
7
6
5
3
1
2
4
9
A-6 A-6
INSTALLATION
POWERARC® 5500 OUTPUT CONNECTIONS
Physical Location of Items and Components may vary by Code No.
FIGURE A.1 (For Codes 11182, 11187, 11215)
1. CURRENT CONTROL DIAL
2. WELD OUTPUT TERMINALS (2)
3. GROUND STUD
4. CIRCUIT BREAKERS (2) - 20 AMP
5. RECEPTACLE - 240 VOLT, 20 AMP
6. DUPLEX RECEPTACLE - 120 VOLT, 20 AMP
7. TACHOMETER / HOUR METER
(CODE 11215 ONLY)
FIGURE A.2 (For Codes 11403, 11404)
1. CURRENT CONTROL DIAL
2. WELD OUTPUT TERMINALS (2)
3. GROUND STUD
4. CIRCUIT BREAKER- 20 AMP
5. RECEPTACLE - 240 VOLT, 20 AMP
6. DUPLEX RECEPTACLE - 120 VOLT, 20 AMP
7. TACHOMETER / HOUR METER
(CODE 11404 ONLY)
ELECTRICAL OUTPUT
CONNECTIONS
See Figure A.1 for the location of the current control
RECOMMENDED WELDING CABLE
TABLE A.1
SIZE AND LENGTH
dial, weld output terminals, ground stud, circuit breakers, 240 and 120 volt receptacles.
TOTAL COMBINED LENGTH OF ELECTRODE AND
WORK CABLES
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
Cable Size for
125 amp/
Cable Length 30% Duty Cycle
0-50 feet (0-15 meters) 6 AWG
50-100 feet (15-39 meters) 4 AWG
100-150 feet (30-46 meters) 3 AWG
150-200 feet (46-61 meters) 2 AWG
200-250 feet (61-76 meters) 1 AWG
lengths to reduce voltage drops.
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POWERARC® 5500
Page 15
A-7 A-7
INSTALLATION
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 welding cables.
2. Remove the 1/2 - 13 flanged nuts from the output
terminals.
3. Connect the electrode holder and work cables to
the weld output terminals. You can connect either
cable to either terminal, since the POWERARC®
5500 provides AC weld current.
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 termi-
nals to overheat. The terminals may eventually
melt.
WARNING
Do not ground the machine to a pipe that carries
explosive or combustible material.
When the POWERARC® 5500 is mounted on a truck
or a trailer, the machine generator ground
stud MUST be securely connected to the
metal frame of the vehicle. See Figure
A.1. The ground stud is marked with the
symbol.
PLUGS AND HAND-HELD EQUIPMENT
For further protection against electric shock, any electrical 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.
Ground fault protection is needed for hand held equipment.
WARNING
• 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 ACCES-
SORIES section of this manual for more information.
MACHINE GROUNDING
Because the POWERARC® 5500 creates
its own power from its gasoline-engine
driven generator, you do not need to
connect the machine frame to an earth
ground. However, for best protection against electrical
shock, connect a heavy gauge wire from the ground
stud located on the bottom center of the output panel
(see Figure A.1) to a suitable earth ground such as a
metal pipe driven into the ground.
Never operate this machine with damaged or
defective cords. All electrical equipment must be
in safe condition.
-------------------------------------------------------------
AUXILIARY POWER RECEPTACLES
The control panel of the POWERARC® 5500 features
two auxiliary power receptacles:
• A 20 amp, 120 volt duplex (double outlet) receptacle
• A 20 amp 240 volt simplex (single outlet) receptacle.
See Figure A.1.
Through these receptacles the machine can supply up
to 4,000 rated continuous watts and 5,500 surge watts
of single-phase AC power.
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POWERARC® 5500
Page 16
A-8 A-8
INSTALLATION
PREMISES WIRING
The POWERARC® 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 grounded" to a
"separately derived" system depending on whether
you want the unit to be "hard wired" or temporary to
the premises.
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 feed backing
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.
CIRCUIT BREAKERS
Auxiliary power is protected by circuit breaker. 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
overheat and/or
being used.
PPOOWWEERRAARRCC®®
cause damage to the equipment
5500 could
The POWERARC® 5500 does not have a combined
120/240 volt twist-lock receptacle and cannot be connected to a premises as described in other Lincoln literature.
Remember that the POWERARC® 5500 is intended
only for backup, intermittent use power. Oil level must
be checked after every 5 hours of use. It cannot withstand long-term use without proper maintenance. See
the MAINTENANCE section of this manual and the
engine owner’s manual for more information.
Certain electrical devices cannot be powered by the
POWERARC® 5500. Refer to Table A.2 for these
devices.
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POWERARC® 5500
Page 17
A-9 A-9
INSTALLATION
CAUTION
Certain Electrical devices cannot be powered by the POWERARC® 5500. See Table A.2.
TABLE A.2
ELECTRICAL DEVICE USE WITH THE POWERARC® 5500.
Type Common Electrical Devices Possible Concerns
Resistive Heaters, toasters, incandescent NONE
light bulbs, electric range, hot
pan, skillet, coffee maker.
Capacitive TV sets, radios, microwaves, Voltage spikes or high voltage
appliances with electrical control. regulation can cause the capac-
itative elements to fail. Surge
protection, transient protection,
and additional loading is recommended for 100% fail-safe
operation. DO NOT RUN
THESE DEVICES WITHOUT
ADDITIONAL RESISTIVE TYPE
LOADS.
Inductive Single-phase induction motors, These devices require large
drills, well pumps, grinders, small current inrush for starting. (See
refrigerators, weed and hedge Table B.3, GENERATOR POWER
trimmers APPLICATIONS, in the OPERA-
TION section of this manual for
required starting wattages.)
Some synchronous motors may
be frequency sensitive to attain
maximum output torque, but
they SHOULD BE SAFE from
any frequency induced failures.
Capacitive/Inductive Computers, high resolution TV sets, An inductive type line condition-
complicated electrical equipment. er along with transient and
surge protection is required, and
liabilities still exist. DO NOT
USE THESE DEVICES WITH A
POWERARC® 5500.
The Lincoln Electric Company is not responsible for any damage to electrical components improperly connected to the POWERARC® 5500.
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POWERARC® 5500
Page 18
A-10 A-10
NOTES
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POWERARC® 5500
Page 19
B-1 B-1
Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .B-1
Safety Instructions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .B-2
Output Panel Controls . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .B-3
Gasoline Engine Controls, Engine Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .B-4
Before Starting the Engine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .B-5
Stopping the Engine, Generator Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .B-6
Generator Power Applications Table . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .B-7
Welding Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .B-8
Welding Guidelines . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .B-9
TABLE OF CONTENTS - OPERATION SECTION
What Happens in the Arc? . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .B-10/B-11
Practice, Metals . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .B-12
Types of Welds . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .B-12/B16
Selecting Electrodes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .B-17
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POWERARC® 5500
Page 20
B-2 B-2
OPERATION
SAFETY INSTRUCTIONS
Read and understand this entire section before operating your POWERARC® 5500.
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.
FUMES AND GASES can be dangerous.
• Keep your head out of fumes.
• Use ventilation or exhaust to
remove fumes from breathing zone.
WELDING SPARKS can cause fire or explosion.
• Keep flammable material away.
• Do not weld on containers that have
held combustibles.
GENERAL DESCRIPTION
The POWERARC® 5500 is a generator/welder designed
for home use and other non-commercial applications. As
a generator it can supply up to 4,000 continuous watts
(or 5,500 surge watts) of 120/240 volt, single-phase AC
power. As a welder it provides 125 amps of AC constant
current for welding with AC stick electrodes. A single dial
provides continuous adjustment of welding output. The
machine is lightweight, portable, and can be lifted by two
people.
The Lincoln warranty covers the POWERARC® 5500
(excluding the engine) for 3 years from the date of purchase. The engine is covered by the engine manufacturer’s warranty policy.
RECOMMENDED APPLICATIONS
GENERATOR
The POWERARC® 5500 gives AC generator output for
medium use, non-commercial demands. For more details
on operating the generator, see GENERATOR OPERA-
TION in the OPERATION section of this manual.
WELDER
The POWERARC® 5500 provides excellent constant current AC welding output for stick (SMAW) welding. For
more details on using the machine as a welder, see
WELDING OPERATION in the OPERATION section of
this manual.
OPERATIONAL FEATURES AND
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ARC RAYS can burn.
• Wear eye, ear, and body protection.
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.
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CONTROLS
The POWERARC® 5500 was designed for simplicity.
Therefore, it has very few operating controls. A single
dial on the control panel lets you select either generator
or welding use. For welding, the same dial selects continuous current output over the machine’s 70 to 125 amp
range.
The gasoline engine controls include a recoil starter,
choke, and rotary stop switch. See ENGINE OPERA-
TION in the OPERATION section of this manual and the
engine owner’s manual for details about starting, running,
stopping, and breaking in the gasoline engine.
WELDING CAPABILITY
The POWERARC® 5500 is rated 125 amps, 20 volts at
30% duty cycle on a ten-minute basis. This means
that you can load the welder to 125 amps for three
minutes out of every ten-minute period. The machine
is also capable of higher duty cycles at lower output
currents. You can load the welder to 100 amps for six
minutes out of ten for a 60% duty cycle.
The current is continuously variable from 70 to 125
amps AC. The POWERARC® 5500 can weld with all
3/32 and most 1/8 inch diameter Lincoln AC electrodes.
POWERARC® 5500
Page 21
B-3 B-3
POWER ARC POWER ARC 55550000
ELECTRODE SELECTION GUIDEELECTRODE SELECTION GUIDE
8080
9090
100100
7
070
AMPSAMPS
AMPSAMPS
AMPSAMPS
AMPSAMPS
WARNINGWARNING
AMPSAMPS
125125
GENERATORGENERATOR
8
7
6
5
3
1
2
4
9
8080
9
090
100100
7070
AMPSAMPS
AMPSAMPS
AMPSAMPS
AMPSAMPS
WARNINGWARNING
AMPSAMPS
125125
GENERATORGENERATOR
E
LECTRODE SELECTION GUIDEELECTRODE SELECTION GUIDE
7
6
8
3
5
1
4
POWER ARC 5500POWER ARC 5500
2
9
OPERATION
OUTPUT PANEL CONTROLS
Physical Location of Components may vary by Code No.
FIGURE B.1 (For Codes 11182, 11187, 11215)
1. CURRENT CONTROL DIAL
2. ELECTRODE SELECTION GUIDE
3. WELD OUTPUT TERMINAL (TO ELECTRODE HOLDER) WITH
1/2 - 13 FLANGE NUT
4. WELD OUTPUT TERMINAL (TO WORK) WITH 1/2 - 13 FLANGE
NUT
5. GROUND STUD
6. 20 AMP CIRCUIT BREAKERS (2)
7. 20 AMP, 240 VOLT RECEPTACLE
8. 20 AMP, 120 VOLT DUPLEX RECEPTACLE
9. TACHOMETER / HOUR METER (CODE 11215 ONLY)
FIGURE B.2 (For Codes 11403, 11404)
1. CURRENT CONTROL DIAL
2. ELECTRODE SELECTION GUIDE
3. WELD OUTPUT TERMINAL (TO ELECTRODE HOLDER) WITH
1/2 - 13 FLANGE NUT
4. WELD OUTPUT TERMINAL (TO WORK) WITH 1/2 - 13 FLANGE
NUT
5. GROUND STUD
6. 20 AMP CIRCUIT BREAKER
7. 20 AMP, 240 VOLT RECEPTACLE
8. 20 AMP, 120 VOLT DUPLEX RECEPTACLE
9. TACHOMETER / HOUR METER (CODE 11404 ONLY)
LIMITATIONS
• The POWERARC® 5500 is not recommended for
any processes besides those that are normally performed using stick welding (SMAW) procedures.
• The POWERARC® 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 240 to 160 volts. Therefore, DO NOT
OPERATE ANY SENSITIVE ELECTRICAL EQUIPMENT WHILE YOU ARE WELDING.
CONTROLS AND SETTINGS
All generator/welder controls are located on the
Output Control Panel. Gasoline engine controls are
mounted on the engine. See Figures B.1 and B.2 and
the explanations that follow.
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GENERATOR/WELDER CONTROLS
See Figure B.1 for the location of the following features:
1. CURRENT CONTROL DIAL: Adjusts continuous
current output. The amperages on the dial correspond to the average amperages needed for specific Lincoln welding electrodes.
2. ELECTRODE SELECTION GUIDE: Provides recommended electrode type, size, and welder output setting based on the thickness of the work.
3. WELD OUTPUT TERMINAL (TO ELECTRODE
HOLDER) WITH 1/2 - 13 FLANGE NUT: Pro vides
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.)
POWERARC® 5500
Page 22
B-4 B-4
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 machine case to earth ground for
the safest grounding procedure.
6. • 20 AMP CIRCUIT BREAKERS (2): Provide sepa-
rate overload current protection for the 120 volt
and 240 volt receptacles. (For codes 11182,
11187, 11215)
• 20 AMP CIRCUIT BREAKER: Provide separate
overload current protection for the 120 volt and
240 volt receptacles. (For codes 11403, 11404)
7. 20 AMP, 240 VOLT RECEPTACLE: Connection
point for supplying 240 volt power to operate one
electrical device.
8. 20 AMP, 120 VOLT DUPLEX RECEPTACLE:
Connection point for supplying 120 volt power to
operate one or two electrical devices.
Tachometer / Hour meter: (For Code 11215, 11404
9.
Only)
Records engine speed in RPMs, engine running time,
and alerts the user to perform a specific engine maintenance task by flashing corresponding messages. If
the message reads “Chg Oil”, the user needs to
change the oil in the engine. If the message reads
“SVC AIR-FILTER”, the user needs to clean or if necessary,change the air filter. (See Honda Engine”s
owners manual for more information). After maintenance task is preformed, the user is required to use
the supplied Reset Tool to cancel flashing message
and resume normal meter operation. (See MAINTE-
NANCE SECTION for further details).
GASOLINE ENGINE CONTROLS
Refer to your engine manual for the location of the following features:
1. FUEL SHUTOFF VALVE: Stops the flow of gasoline from the fuel tank to the carburetor. Should be
closed whenever you are finished using the POWERARC® 5500. Must be opened before you start
the engine.
2. FUEL TANK AND CAP: See
FFIICCAATTIIOONNSS
for capacity.
TTEECCHHNNIICCAALL SSPPEECCII--
OPERATION
3. MUFFLER: Reduces engine noise output. Both
the Robin / Subaru and the Honda muffler serves
as a spark arrester.
See SPARK ARRESTER in the INSTALLATION
section of this manual.
4. “ON/OFF Switch: A two position switch located on
the rear of the engine. In the “ON”(I) position, the
engine ignition circuit is energized and the engine
can be started by pulling the recoil rope starter. In
the “OFF”(O) position, the electronic ignition is
grounded and the engine shuts down.
5. AIR CLEANER: Filters intake air to the carburetor.
See ENGINE MAINTENANCE in the MAINTE-
NANCE section of the engine owner’s manual for
details about the specific type of air cleaner to
use.
6. CHOKE: Provides a richer air/fuel mixture for cold engine starting conditions.
See the topic ENGINE OPERATION,
below, for details on setting the choke.
7. RECOIL STARTER: Manual, rope-type starter. The
handle position allows easy starting from either
ground level or pickup-truck level
8. OIL DRAIN PLUG: Permits convenient draining of
engine oil during maintenance. Both sides of the
engine are equipped with an oil drain plug.
9. OIL FILL PLUG: Permits convenient filling of
engine oil during maintenance. Both sides of the
engine are equipped with an oil fill plug.
ENGINE OPERATION
WARNING
DO NOT RUN THE ENGINE AT EXCESSIVE
SPEEDS. The maximum allowable high idle speed
for the POWERARC® 5500 is 3750 RPM, no load.
Do NOT adjust the governor screw on the engine.
Severe personal injury and damage to the machine
can result if it is operated at speeds above the
maximum rated speed.
-------------------------------------------------------------
Read and understand all safety instructions included
in the engine manufacturer’s ”Operating and
Maintenance Instructions” manual that is shipped with
the POWERARC® 5500.
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NOTE: If you use any other alternate fuel tank or
supply, be sure to use a recommended inline fuel filter.
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POWERARC® 5500
Page 23
B-5 B-5
OPERATION
BEFORE STARTING THE ENGINE
CHECK AND FILL THE ENGINE OIL LEVEL:
1. Place the machine on a level surface.
2. Open the oil fill plug.
3. Fill (if necessary) until oil flows out the top of the
fill plug hole.
4. Replace the fill plug and tighten securely.
CHECK AND FILL THE ENGINE FUEL TANK:
1. Remove the fuel tank cap.
2. Fill the tank to allow approximately 1/4
inch (5 mm) of tank space for fuel
expansion. DO NOT FILL THE TANK
TO THE POINT OF OVERFLOW.
3. Replace the fuel tank cap and tighten securely.
NOTE: The engine will operate satisfactorily on any
gasoline meant for automotive use. A minimum of 87 octane is recommended. DO NOT
MIX OIL WITH THE GASOLINE.
Use clean, fresh, lead-free gasoline. Leaded gasoline
may be used if lead-free is not available. However,
lead-free gasoline leaves fewer combustion deposits
and gives longer valve life. Purchase gasoline in quantities that will be used within 30 days, to assure freshness.
NOTE: We DO NOT recommend using gasoline that
contains alcohol, such as gasohol. However,
if gasoline with alcohol is used, it MUST NOT
contain more than 10% Ethanol and MUST be
removed from the engine during storage. DO
NOT use gasoline containing Methanol.
STARTING THE ENGINE
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 engine, first open the
choke (toward RUN) until the engine just begins to
run smoothly. Then open the choke in small steps,
allowing the engine to accept small changes in
speed and load, until the choke is fully open (in
RUN). During engine warm-up the equipment can
be operated.
FOR A “HOT” ENGINE:
1. Open the fuel shutoff valve.
2. Place the choke lever in the “RUN”
position. Closing the choke of a hot
engine will flood the carburetor and
prevent starting.
3. Pull slightly on the recoil starter handle until resistance is felt.
4. Pull the cord rapidly.
FOR BEST ENGINE STARTING:
• Always use fresh gasoline and be sure the filter is
clean and properly maintained.
• If you use an alternate fuel tank or supply, be sure
to install an in-line fuel filter.
• Do not pull the recoil starter with the
choke in the “CHOKE” position more
than one time. Repeated pulls on a
choked engine will flood the carburetor.
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NOTE: Remove all loads connected to the AC power
receptacles before starting the gasoline
engine. Put the “ON/OFF” Switch in the
“ON”(I) position.
FOR A “COLD” ENGINE:
1. Open the fuel shutoff valve.
2. Place the choke lever in the “CHOKE”
position.
3. Pull slightly on the recoil starter handle until resistance is felt.
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• If the engine will not start, see the TROUBLESHOOTING section of this or the engine
owner’s manual.
POWERARC® 5500
Page 24
B-6 B-6
OPERATION
STOPPING THE ENGINE
1. Remove all welding and generator power loads
and let the engine cool by running it for several
minutes.
2. Stop the engine by placing the “ON/OFF” switch
in the “OFF”(O) position.
3. Close the fuel shutoff valve.
WARNING
Close the fuel valve when the machine is transported to prevent fuel leakage from the carburetor.
Drain the tank before transporting the machine in
a vehicle.
For long periods of storage, turn off the fuel shutoff valve and let the engine run until there is no
more fuel in the line. Use a fuel additive such as
Sta-Bil to minimize fuel gum deposits.
-------------------------------------------------------------
GENERATOR OPERATION
CAUTION
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
Table A.2, ELECTRICAL DEVICE USE WITH THE
POWERARC® 5500, in the INSTALLATION section
of this manual.
-------------------------------------------------------------
GENERAL INFORMATION
The POWERARC® 5500 generator is rated at 4000
continuous watts (5500 surge watts). It provides both
120 volt and 240 volt power. You can draw up to 20
amps from either side of the 120 volt duplex receptacle, but no more than 33.3 amps from both sides at
once. Up to 16.7 amps can be drawn from the single
240 volt receptacle.
RUNNING THE ENGINE
The engine is set at the factory to run at high idle
speed when not under load. You should not adjust
this setting yourself.
BREAK-IN PERIOD
The engine will use a greater amount of oil during its
“break-in” period. Check the oil frequently during
break-in. For more details, see the MAINTENANCE
section in the engine owner’s manual.
CAUTION
During break-in, subject the POWERARC® 5500 to
only moderate loads. Avoid long periods running
at idle. Before stopping the engine, remove all
loads and allow the engine to cool several minutes.
-------------------------------------------------------------
Electrical loads in watts are calculated by multiplying
the voltage rating of the load by the number of amps
it draws. (This information is given on the load device
nameplate.) For example, a device rated 120 volts, 2
amps will need 240 watts of power (120 x 2 = 240).
You can use Table B.3, GENERATOR POWER APPLI-
CATIONS, to determine the wattage requirements of
the most common types of loads you can power with
the POWERARC® 5500. Be sure to read the notes at
the bottom of the table.
TO USE THE POWERARC® 5500 AS AN AUXILIARY POWER SUPPLY:
1. Start the gasoline engine. See ENGINE OPERA TION in this section of the manual and the engine
owner’s manual.
2. Set the current control dial on the output control
panel to “GENERATOR.” See Figure B.1.
3. Plug the load(s) into the appropriate 120 volt or
240 volt power receptacle.
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NOTE: During welding, the maximum generator out-
put for auxiliary loads is 100 watts.
NOTE: You can supply multiple loads as long as the
total load does not exceed 5,500 surge watts
or 4,000 Continuous watts. Be sure to start
the largest loads first.
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POWERARC® 5500
Page 25
B-7 B-7
GENERATOR POWER APPLICATIONS
Suggested Power Applications Running Watts *Start-up Watts
*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 Motor - 1 HP 1,000 2,500 - 4,000
Electric Range (1 element) 1,500
Electric Skillet 1,250
*Furnace Fan - 1/3 HP 1,200 3,000 - 4,800
Portable Grinder (4 1/2”) 600
Portable Grinder (7”) 2,000
Halogen Work Light 500
Hand Drill - 1/4” 500
Hand Drill - 3/8” 700
1500 Watt Heater 1,750
Hedge Trimmer 450
Light Bulb 100
Reciprocating Saw 900
Radial Arm Saw 2,600
Radio 50
*Refrigerator/Freezer (small) 600 1,500 - 2,400
Slow Cooker 200
*Submersible Pump - 1 HP 1,000 2,500 - 4,000
*Sump Pump 600 1,500 - 2,400
Toaster 1,100
Weed Trimmer 500
Lincoln Wire Feeder/Welder 4,000
OPERATION
TABLE B.3
(Continuous) (Surge)
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NOTES:
Wattages listed are approximate. Check your equipment for actual wattage.
Equipment with unusually high *START-UP WATTS are listed. For start-up of other tabled equipment that uses a
motor, allow up to 2 times the running watts shown above. For example a 1 HP motor requires approximately
1000 watts of power when running but may require (2.5 X 1000) = 2500 watts or (4.0 X 1000) = 4000 watts to
start.
Multiple loads can be used as long as the total load does not exceed 5,500 surge watts or 4,000 continuous
watts. Be certain to start the largest loads first.
Output rating in watts is equivalent to volt-amperes at unity power factor (resistive load) and is calculated as:
WATTS = VOLTS X AMPS DRAWN. for example a 120 volt device which is rated on its nameplate to draw 2
amps will need (120 VOLTS) X (2 AMPS) = 240 WATTS OF POWER. 1 KW = 1000 WATTS.
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POWERARC® 5500
Page 26
B-8 B-8
OPERATION
WELDING OPERATION
GENERAL INFORMATION
WARNING
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.
-------------------------------------------------------------
The POWERARC® 5500 has a voltage of up to 62
Volts AC which can shock. The POWERARC® 5500
generator/welder can deliver from 70 to 125 amps of
continuous welding output current. Output can be
adjusted by setting the current control dial on the output control panel.
You can get maximum welding output by setting the
dial to 125 AMPS. At high current settings like this,
some output may decrease as the machine is used. If
you are welding for a long time, you may need to turn
the dial slightly upward to maintain the same results.
The numbers on the dial correspond to the average
amps needed to weld using specific Lincoln welding
rods. Table B.4, WELDING APPLICATIONS, gives you
the recommended dial settings based on the thickness of the work and the size and type of rod you’re
using.
TO USE THE POWERARC® 5500 FOR WELDING:
1. Remove the flange nuts from the weld output terminals and place the work and electrode welding
cables over the terminals. (See Figure B.1)
Replace and tighten the flange nuts securely. Be
sure the connections are tight.
2. Select the appropriate electrode. (See
WELDING APPLICATIONS, or the ELECTRODE
SELECTION GUIDE on the machine Output
Control Panel.
3. Attach the work clamp securely to the work you
are welding.
TTaabbllee BB..44
7. Strike an arc and begin welding. For information
on welding techniques, see WELDING GUIDE-
LINES in this section of the manual.
AFTER YOU FINISH THE WELD:
1. Stop the gasoline engine. See ENGINE OPERATION in this section of the manual.
2. Allow the electrode and work to cool completely.
3. Remove the work clamp from the work.
4. Remove any remaining piece of electrode from the
electrode holder.
5. If you are finished using the POWERARC® 5500
for welding, disconnect the welding cables from
the weld output terminals. Reattach the flange
nuts and leave them on the terminals.
NOTE: 1. Welding current is continuously variable
with 60% duty cycle applying to output
currents 100 Amps and less and 30%
duty cycle applying to currents above 100
Amps.
2. Duty cycle is based on a ten minute period. The welder can be loaded to 125
Amps for three minutes out of every ten
minute period or to 100 Amps for six minutes out of every ten minute period.
CONTROL FUNCTION / OPERATION
“Current Control Dial”
Provides welding current adjustment from 70 through
125 Amps.
To obtain maximum weld output, turn the “Current
Control Dial” to “125 Amps” for either a cold or hot
engine. As the machine is used, some welding voltage
may decrease at high current settings. If you are welding for long periods of time, the dial may need to be
slightly turned upward to provide the same welding
results as when the machine was cold.
)
The numbers listed on the dial correspond to the average amperage needed to weld specific Lincoln rods.
Refer to Table B.4 “Welding Application Guides” and
“Electrode Selection Guide” listed on the machine
nameplate for proper current and electrode settings.
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4. Insert the electrode into the electrode holder.
5. Set the current control dial to the desired output
current.
6. Start the gasoline engine. See ENGINE OPERA-
TION in this section of the manual.
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POWERARC® 5500
Page 27
B-9 B-9
OPERATION
WELDING GUIDELINES
TABLE B.4
WELDING APPLICATIONS/ELECTRODE SELECTION GUIDE
Material Thickness Electrode Type Size Setting
FLEETWELD
1
AWS E6013
1/8” and thinner FLEETWELD
®
37 90 amps
®
180 3/32” 70 amps
AWS E6011
Lincoln 7018 AC 90 amps
AWS E7018
®
3/16” Maximum FLEETWELD
37 1/8” 125 amps
AWS E6013
®
5/16” Maximum FLEETWELD
180 1/8” 90 amps
AWS E6011
Any Thickness WEARSHIELD® ABR 1/8” 100 amps
NOTES:
The values listed are suggested settings. Actual setting may vary depending on individual preference
and/or specific application. Beginners should use
Lincoln E7018 AC.
For electrodes not listed, follow tables that are packed
with the electrodes.
Ask for the Lincoln WELD DIRECTORY (Publication
C2.10) for a complete listing of all Lincoln stick electrodes available.
1
AWS = American Welding Society
WARNING
ARC RAYS can burn.
• When using an open arc process, it
is necessary to use correct eye,
head and body protection.
------------------------------------------------------------------------
Semi-automatic, Wire Welding With a
Lincoln Wire Feeder / Welder
The POWERARC® 5500 generator power can be used to
supply power up to 4,000 watts continuous input power to
The
a Lincoln Wire Feeder/Welder.
is equipped with all the supplies needed for Flux-Cored
Arc Welding (FCAW). Also some Wire Feeder/Welders
come equipped with the essentials needed for Gas
Metal Arc Welding, GMAW, or MIG processes, while
others require the purchase of a conversion kit. These
products are available where Lincoln products are
Contact your local authorized Lincoln representa-
sold.
for more details.
tive
Wire Feeder/Welder
Stick Welding
Stick welding is probably the most familiar welding
process known. A coated ELECTRODE, the weld rod,
is clamped into an ELECTRODE HOLDER, an insulated 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. Quality Lincoln cables use many fine copper
wires with a very flexible insulating covering for the
electrode and work cables. When properly connected
to the OUTPUT STUDS of a high current power
source, the electrode melts and bonds the metal being
repaired. See “Cable Installation” section for proper
cable connection to a POWERARC®.
The POWERARC® provides excellent weld output
characteristics when used in combination with Lincoln
AC electrodes. Other AC electrodes may also be used.
Follow the settings listed in Table B.4 “Welding
Application Guide” and the “Electrode Selection Guide”
found on the nameplate of the machine.
Learning To Stick Weld
The serviceability of a product or structure utilizing this type of information is and must be the sole
responsibility of the builder/user. Many variables
beyond the control of The Lincoln Electric
Company affect the results obtained in applying
this type of information. These variables include,
but are not limited to, welding procedure, plate
chemistry and temperature, weldment design, fabrication methods and service requirements.
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POWERARC® 5500
Page 28
B-10 B-10
Covering
Electrode
Shielding Gases
Arc
Solidified Slag
Weld Metal
Base Metal
FIGURE 4 - The welding arc.
ARC
WORK CABLE
WORK
ELECTRODE CABLE
ELECTRODE HOLDER
ELECTRODE
WELDING MACHINE
AC OR DC POWER
SOURCE AND
CONTROLS
FIGURE 3 - The welding circuit for (Stick) shielded metal arc welding.FIGURE 3 - The welding circuit for (Stick) shielded metal arc welding.
OPERATION
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).
The operator’s knowledge of arc welding must go
beyond the arc itself. He must know how to control the
arc, and this requires a knowledge of the welding circuit and the equipment that provides the electric current used in the arc. Figure 3 is a diagram of the welding circuit. The circuit begins where the electrode cable
is attached to the welding machine and ends where the
work cable cable is attached to the machine. Current
flows through the electrode cable to the electrode holder, through the electrode holder to the electrode and
across the arc. On the work side of the arc, the current
flows through base metal to the work cable and back to
the welding machine. The circuit must be complete for
the current to flow. To weld, the work clamp must be
tightly connected to clean base metal. Remove paint,
rust,etc. as necessary to get a good connection.
Connect the work clamp as close as possible to the
area you wish to weld. Avoid allowing the welding circuit to pass through hinges, bearings, electronic components or similar devices that can be damaged.
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 3) by holding
the tip of the electrode 1/16 - 1/8” (1.6-3.2mm) away
from the work or base metal being welded. The electric arc is established in this gap and is held and moved
along the joint to be welded, melting the metal as it is
moved.
Arc welding is a manual skill requiring a steady hand,
good physical condition, and good eyesight. The operator controls the welding arc and, therefore, the quality of the weld made.
What Happens in the Arc?
Figure 4 illustrates the action that takes place in the
electric arc. It closely resembles what is actually seen
during welding.
The “arc stream” is seen in the middle of the picture.
This is the electric arc created by the electric current
flowing through the space between the end of the electrode and the work. The temperature of this arc is
about 6000°F (3300°C) which is more than enough to
melt metal. The arc is very bright, as well as hot, and
cannot be looked at with the naked eye without risking
painful and possibly permanent injury. A very dark lens,
specifically designed for arc welding must be used with
the handshield or headshield whenever viewing the
arc.
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Return to Section TOC Return to Section TOC Return to Section TOC Return to Section TOC
The arc melts the base metal and actually digs into it,
much like water through a garden hose nozzle digs into
the earth. The molten metal forms a pool or crater and
tends to flow away from the arc As it moves away from
the arc, it cools and solidifies. Slag forms on top of the
weld to protect it during cooling.
POWERARC® 5500
Page 29
B-11 B-11
15-20°
90°
side view
end view
Correct Welding Position
Ridge where puddle
solidifies
Molten puddle
OPERATION
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 electrode provides additional filler metal for the joint to fill
the groove or gap between the two pieces of the base
metal. The covering also melts or burns in the arc. It
has several functions. It makes the arc steadier, provides a shield of smoke-like gas around the arc to keep
oxygen and nitrogen in the air away from the molten
metal, and provides a flux for the molten pool. The flux
picks up impurities and forms a protective slag. The
principle differences between the various types of electrodes are in their coatings. By varying the coating, it is
possible to greatly alter the operating characteristics of
electrodes. By understanding the differences in the
various coatings, you will gain a better understanding
of selecting the best electrode for the job you have at
hand. In selecting an electrode, you should consider:
1. The type of deposit you want, e.g., mild steel, stainless, low alloy, hardfacing.
2. The thickness of the plate you want to weld.
3. The position it must be welded in (downhand, outof-position).
4. The surface condition of the metal to be welded.
5. Your ability to handle and obtain the desired electrode.
Four simple manipulations are of prime importance.
Without complete mastery of these four, further
attempts at welding are futile. With complete mastery
of the four, welding will be easy.
2. The Correct Way to Strike An Arc
Be sure the work clamp makes good electrical contact
to the work.
Lower your headshield and scratch the electrode slowly over the metal, and you will see sparks fly. While
scratching, lift the electrode 1/8” (3.2mm) and the arc
is established.
NOTE: If you stop moving the electrode while scratching, the electrode will stick. Most beginners try to strike
the arc by a fast jabbing motion down on the plate.
Result: They either stick their electrode or their motion
is so fast that they break the arc immediately.
3. The Correct Arc Length
The arc length is the distance from the tip of the electrode core wire to the base metal.
Once the arc has been established, maintaining the
correct arc length becomes extremely important. The
arc should be short, approximately 1/16 to 1/8” (1.6-
3.2mm) long. As the electrode burns off, the electrode
must be fed to the work to maintain correct arc length.
The easiest way to tell whether the arc has the correct
length is by listening to its sound. A nice, short arc has
a distinctive, “crackling” sound, very much like eggs
frying in a pan. The incorrect, long arc has a hollow,
blowing or hissing sound.
4. The Correct Welding Speed
1. The Correct Welding Position
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 righthanded). This enables you to see clearly what you are
doing.
Hold the electrode at a slight angle as shown in Figure 5.
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FIGURE 5
The important thing to watch while welding is the puddle of molten metal right behind the arc. DO NOT
WATCH THE ARC ITSELF. The appearance of the
puddle and the ridge where the molten puddle solidifies indicates correct welding speed. The ridge should
be approximately 3/8” (9.5mm) behind the electrode.
Most beginners tend to weld too fast, resulting in a thin,
uneven, “wormy” looking bead. They are not watching
the molten metal.
IMPORTANT: It is not generally necessary to weave
the arc forward, backward or sideways. Weld along at
a steady pace, and you will have an easier time.
NOTE: When welding on thin plate, you will find that
you have to increase the welding speed, whereas
when welding on heavy plate, it is necessary to go
more slowly to ensure fusion and penetration.
POWERARC® 5500
Page 30
B-12 B-12
Butt Joint
Lap Joint
Edge Joint
Fillet Joint
Corner Joint
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), or heavier.
Electrode: 1/8” (3.2mm) AWS 6011
(Fleetweld® 180)
OPERATION
These higher carbon steels can be welded successfully in most cases; however, care must be taken to follow
proper procedures, including preheating the metal to
be welded and, in some cases, carefully controlling the
temperature during and after the welding process. For
further information on identifying various types of steel
and other metals, and for proper procedures for welding them, we suggest you purchase a copy of “New
Lessons in Arc Welding”.
Regardless of the type of metal being welded, in order
to get a quality weld, it is important that it be free of oil,
paint, rust or other contaminant's.
Types of Welds
Current Setting: 90-125 Amps AC
Do the following:
1. Learn to strike the arc by scratching the electrode
over the plate. Be sure the angle of the electrode
is right and be sure to use both hands.
2. When you can strike an arc without sticking, practice the correct arc length. Learn to distinguish it by
its sound.
3. When you are sure that you can hold a short, crackling arc, start moving. Look at the molten puddle
constantly, and look for the ridge where the metal
solidifies.
4. Run beads on a flat plate. Run them parallel to the
top edge (the edge farthest away from you). This
gives you practice in running straight welds, and
also, it gives you an easy way to check your
progress. The 10th weld will look considerably better than the first weld. By constantly checking on
your mistakes and your progress, welding will soon
be a routine matter.
Common Metals
Five types of welding joints are: Butt Joints, Fillet
Joints, Lap Joints, Edge Joints and Corner Joints.
Of these, the Butt Joint and Fillet Joint are the most
common.
Butt Joints
Butt Joints are the most widely used Joints. Place two
plates side by side, leaving 1/16” (1.6mm) for thin
metal to 1/8” (3.2mm) for heavy metal space between
them in order to get deep penetration.
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Most metals found around the farm or small shop are
low carbon steel, sometimes referred to as mild steel.
Typical items made with this type of steel include most
sheet metal, plate, pipe and rolled shapes such as
channels, angle irons and “I” beams. This type of steel
can usually be easily welded without special precautions. Some steel, however, contains higher carbon.
Typical applications include wear plates, axles, connecting rods, shafts, plowshares and scraper blades.
POWERARC® 5500
Tack the plates at both ends, otherwise the heat will
cause the plates to move apart. (See drawing).
Page 31
B-13 B-13
end view side view
20°
90°
Poor
1/2"
(12mm)
1/4"
(6mm)
1/4"
(6mm)
Good
60°
4
3
2
1
1/8" (3.2mm)
45°
45°
1
1
2
2
3
4
Now weld the two plates together. Weld from left to
OPERATION
Fillet Joints
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.
When welding fillet joints, it is very important to hold
the electrode at a 45° angle between the two sides, or
the metal will not distribute itself evenly.
To make it easier to get the 45° angle, it is best to put
the electrode in the holder at a 45° angle, as shown.
Watch the molten metal to be sure it distributes itself
evenly on both edges and in between the plates.
Penetration
Unless a weld penetrates close to 100%, a butt joint
will be weaker than the material welded together.
In this example, the total weld is only 1/2 the thickness
of the material; thus, the weld is only approximately
half as strong as the metal.
In this example, the joint has been flame beveled or
ground prior to welding so that 100% penetration could
be achieved. The weld, if properly made, is as strong
or stronger than the original metal.
Multiple Pass Welds
Make multiple pass horizontal fillets as shown in the
sketch. Put the first bead in the corner with fairly high
current. Hold the electrode angle needed to deposit the
filler beads as shown putting the final bead against the
vertical plate.
Welding in the Vertical Position
Welding in the vertical position can be done either vertical-up or vertical-down. Vertical-up is used whenever a large, strong weld is desired. Vertical-down is used
primarily on sheet metal for fast, low penetrating welds.
Successive passes must be used to build up butt welds
on heavier metal.
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POWERARC® 5500
Page 32
B-14 B-14
Very
short
arc
30°-40°
Long arc
Short arc
NOTE: Holder end of electrode
is lower than arc.
OPERATION
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 3/32” (2.5mm) 70
amps AWS 6011.
2. When welding, the electrode should be kept horizontal or pointing slightly upwards. (See drawing
above).
8. When the arc is brought back to the now solidified
puddle, IT MUST BE SHORT, otherwise no metal
will be deposited, the puddle will melt again, and it
will “drip”.
9. It is important to realize that the process consists of
SLOW, DELIBERATE movements. There are no
fast motions.
Vertical-Down Welding
Vertical-down welds are applied at a fast pace. These
welds are therefore shallow and narrow, and are excellent for sheet metal. Do not use the vertical-down technique on heavy metal. The welds will not be strong
enough.
1. Use 1/8” (3.2m) or 3/32” (2.5mm) AWS 6011.
3. The arc is struck and metal deposited at the bottom
of the two pieces to be welded together.
4. Before too much molten metal is deposited, the arc
is SLOWLY moved 1/2-3/4” (12-20mm) upwards.
This takes the heat away from the molten puddle,
which solidifies. (If the arc is not taken away soon
enough, too much metal will be deposited, and it
will “drip”.)
5. The upward motion of the arc is caused by a very
slight wrist motion. Most definitely, the arm must not
move in and out, as this makes the entire process
very complicated and difficult to learn.
6. If the upward motion of the arc is done correctly
with a wrist motion, the arc will automatically
become a long arc that deposits little or no metal.
(See drawing above.)
7. During this entire process, the ONLY thing to watch
is the molten metal. As soon as it has solidified, the
arc is SLOWLY brought back, and another few
drops of metal are deposited. DO NOT FOLLOW
THE UP AND DOWN MOVEMENT OF THE ARC
WITH YOUR EYES. KEEP THEM ON THE
MOLTEN METAL.
2. On thin metal use 70-75 amps.
(14 ga. 75 A - 16 ga. 60 A.)
3. Hold the electrode in a 30-45° angle with the tip of
the electrode pointing upwards.
4. Hold a VERY SHORT arc, but do not let the electrode touch the metal.
5. An up and down whipping
motion will help prevent
burn-through on very thin plate.
6. Watch the molten metal carefully.
The important thing is to continue lowering the entire
arm as the weld is made so the angle of the electrode
does not change. Move the electrode fast enough so
that the slag does not catch up with the arc.
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POWERARC® 5500
Page 33
B-15 B-15
Side View
End View
30°
30°
OPERATION
Overhead Welding
Various techniques are used for overhead welding.
However, in the interest of simplicity for the inexperienced 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 electrode in he holder so it sticks straight
out.
3. Hold the electrode at an angle approximately 30°
off vertical, both seen from the side and seen from
end. (See drawing below.)
4. Move rapidly enough to stay ahead of the molten
slag. A whipping technique may be used to further
minimize burn through.
5. If you have a choice, use lap joints rather than fillets
or butts; the double thickness effect of a lap joint
makes it much easier to weld without burning
through.
Hardfacing (To Reduce Wear)
There are several kinds of wear. The two most often
encountered are:
1. Metal to Ground Wear: Plowshares, bulldozer
blades, buckets, cultivator shares, and other metal
parts moving in the soil.
2. Metal to Metal Wear: Trunnions, shafts, rollers and
idlers, crane and mine car wheels, etc.
It is important to hold a VERY SHORT arc. (A long arc
will result in falling molten metal; a short arc will make
the metal stay.)
If necessary, and this is dictated by the appearance of
the molten puddle, a slight back and forth whipping
technique may be used to prevent “dripping”.
Welding Sheet Metal
Welding sheet metal presents an additional problemburn through. Follow these simple rules:
1. Hold a very short arc. This, together with the proper travel speed, will eliminate burn through.
2. Use 1/8” (3.2mm) or 3/32” (2.5mm) AWS 6011.
Each of these types of wear demands a different kind
of hardfacing electrode.
When applying the proper electrode, the service life of
the part will in most cases be more than double. For
instance, hardfacing of plowshares results in 3-5 times
more acreage plowed.
How to Hardface the Sharp Edge (Metal to Ground
Wear)
1. Grind the share, approximately one inch along the
edge, so the metal is bright and clean.
2. Place the share on an incline of approximately 2030°. The easiest way to do this is to put one end of
the share on a brick. (See drawings) Most users
will want to hardface the underside of the share, but
some might find that the wear is on the top side.
The important thing is to hardface the side that
wears.
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3. Use low amperage. 75 A for 1/8” (3.2mm) electrode, 70 A for 3/32” (2.5mm) electrode.
POWERARC® 5500
3. Use 1/8” (3.2mm) Wearshield at 80-100 A. Strike
the arc about one inch from the sharp edge.
Page 34
B-16 B-16
Work Table
Strike Arc
Here
Sharp Edge
Weaving Motion
Plow Share
Positioning of Share
Brick
1/2-3/4" width
(12-20mm)
hot
cold
cold
White brittle
cast iron
When breaking
the weld stays on
one piece
First weld from A to B; then
from C to A; then from D to C;
then from E to D; and so on.
BACKSTEPPING
(75mm)
3"
B
A
C
DE
OPERATION
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.)
To overcome this, the welding operator has two choices:
1. Preheat the entire casting to 500-1200°F (260649°C) If the cast iron is hot before welding, there
will be no sudden chilling which creates brittle white
cast iron. The entire casting will cool slowly.
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 will begin 6” (152mm) from
2. Weld 1/2” (12.7mm) at a time, and do not weld at
that spot again until the weld is cool.
the heel, the third weld 9” (229mm) from the heel,
etc.
This way, no large amount of heat is put into the mass.
Backstepping greatly reduces the chances for cracking
of the share, and it also greatly reduces warping.
NOTE: The entire process is rather fast. Many beginners go much too slowly when hardfacing plowshares,
running the risk of burning through the thin metal.
Welding Cast Iron
When welding on a piece of cold cast iron, the tremendous heat from the arc will be absorbed and distributed
rapidly into the cold mass. This heating and sudden
cooling creates WHITE, BRITTLE cast iron in the
fusion zone. (See drawing below.)
Most inexperienced welders will probably use the second method, because they have no way of preheating
large castings. Smaller castings can easily (and
should) be preheated before welding. A forge, stove,
fire, or the Arc Torch are all excellent means of preheating.
When using the 1/2” (12.7mm) at a time method, it is
recommended to start 1/2” (12.7mm) away from the
previous bead and weld into the previous bead. This is
called backstepping.
After welding Cast Iron, protect the casting against fast
cooling. Put it in a container of warm, dry sand or lime.
If sand or lime is not available, cover it with sheet metal
or any other non-flammable material that will diminish
drafts and retain heat.
Cast Iron Plate Preparation
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This is the reason why welds in cast iron break.
Actually, one piece of the broken cast iron has the
entire weld on it and the other piece has no weld on it.
(See drawing).
POWERARC® 5500
Wherever practical, the joint to be welded should be
“veed” out by grinding or filing to give complete penetration as shown in figures (a), (b) and (c) below. This
is especially important on thick castings where maximum strength is required.
Page 35
B-17 B-17
Three ways to prepare plates where
c
omplete penetration is necessary.
Scrap steel back-up strip
(
a)
(b)
(
c)
Single and double beads, with and without
beveling for tight, partial strength joints.
(d)
(e)
Motions
START
SIDE
VIEW
F
G
E
D
C
B
A
OPERATION
In some instances a back-up strip may be used and
plates may be gapped 1/8” (3.2mm) or more, as shown
in figure (b).
On sections where only a sealed joint is required and
strength is not important, the joint may be welded after
slightly veeing out the seam as shown in figure (d)
below.
Selecting Electrodes
Which electrode is best for the particular job . . . how
do you use it? These are important questions because
the cost, quality, and appearance of your work
depends on proper electrode selection and application.
MILD STEEL ELECTRODES may be classified into
the following groups:
High-Speed Group (AWS E6013)
This group includes electrodes which have a moderately forceful arc and deposit rates between those of
the out-of-position and high-deposit electrodes.
They are primarily general purpose production electrodes especially for downhill fillets and laps or short
and irregular welds that change direction or position.
They are also widely used in maintenance and recommended for sheet metal fillet and lap welds. Motion “D”
(see drawing) is generally used for vertical-up welding,
but motions “A” and “B” are also suitable.
Low Hydrogen Group (AWS E7018)
These electrodes are generally called “low hydrogen”.
The name comes from the fact that their coating contains little hydrogen in either moisture or chemical
form. Low hydrogen electrodes offer these benefits:
outstanding crack resistance, lowest porosity on sulphur bearing steels, and X-ray quality deposit capability. Thus, they are the first choice when welding “problem” steels. E7018 can be used in all positions, with
Motion “C” (below) recommended for the first pass on
vertical-up welds. NEVER use a whipping technique or
a long arc with these electrodes. ALWAYS fill craters
by drawing electrode away slowly. ALWAYS keep
these electrodes dry. Electrodes, when not used within
a few hours after a container is opened, must be stored
in heated cabinets.
Out-of-Position Group (AWS E6011)
This group includes electrodes which have a snappy,
deep penetrating arc and fast freezing deposits.
These electrodes are used for general purpose, allposition fabrication and repair welding. They are also
the best choice for pipe welding and sheet metal butt,
corner, and edge welds. They can be used for repair
work when dirt, grease, plating or paint cannot be completely cleaned from the steel. These electrodes are
typically used with motions “A” and “B” (see drawing)
for the first pass on vertical-up welds.
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POWERARC® 5500
Page 36
B-18 B-18
NOTES
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POWERARC® 5500
Page 37
C-1 C-1
Accessories . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .C-1
Options and Accessories . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .C-2
TABLE OF CONTENTS - ACCESSORIES SECTION
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POWERARC® 5500
Page 38
C-2 C-2
ACCESSORIES
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:
• Twenty feet (6.1 meters) of #6 AWG electrode cable
with lug.
• Fifteen feet (4.6 meters) of #6 work cable with lugs.
• Headshield with No. 10 filter
• Work clamp
• Insulated electrode holder
• Sample pack of mild steel electrodes 150 Amp
capacity.
Undercarriage (K882-2) - 2- wheeled, hand moving.
Rotor Removal Kit (S20925) – A service kit with thru
and impact bolts for removing the generator rotor from
the tapered engine crankshaft.
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POWERARC® 5500
Page 39
D-1 D-1
Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .D-1
Safety Precautions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .D-2
Fuel, Engine Adjustments . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .D-3
Spark Plug Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .D-4
Generator/Welder Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .D-5
Major Component Location . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .D-6
TABLE OF CONTENTS - MAINTENANCE SECTION
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POWERARC® 5500
Page 40
D-2 D-2
1
2
3
12345
T
O ELIMINATE
FLASHING HOLD
THE RESET TOOL
IN THIS AREA.
RESET TOOL
MAINTENANCE
SAFETY PRECAUTIONS
WARNING
• 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 maintenance requiring their removal is complete.
• If guards are missing from the machine, get
replacements from a Lincoln Distributor. See
the EXPLODED VIEW AND PARTS LIST at the
back of this manual.
-------------------------------------------------------------
Read the Safety Precautions in the front of this manual and in the engine owner’s manual before working on
the POWERARC® 5500.
Keep all equipment safety guards, covers, and
devices in position and in good repair. Keep your
hands, hair, clothing, and tools away from the recoil
housing, fans, and all other moving parts when starting, operating, or repairing this machine.
ROUTINE AND PERIODIC
MAINTENANCE
ENGINE MAINTENANCE
CAUTION
To prevent the engine from accidentally starting,
disconnect the spark plug lead before servicing
the engine.
Once Oil or Air filter service is completed,
Tachometer/Hour meter needs to be reset. The reset
procedure will stop the flashing of the display and will
trigger the meter to start counting the time for the next
engine service. To stop the flashing alert for Oil or Air
filter service, do the following: While alert message is
flashing, hold the tip of the reset tool against area
shown in figure D.1 for several seconds. The display
will stop flashing. The service interval has been reset
and the message alert should start flashing for the
next Oil or Air filter change.
FFIIGGUURREE DD..11
OOIILL::
Check the oil level after every 5
hours of
MAINTAIN THE OIL LEVEL. Change
the oil the first time after 20 hours of operation. Then,
under normal operating conditions, change the oil
after every 100 hours or once every 6 months
whichever occurs first. If the engine is operated under
heavy load or in high ambient temperatures, change
the oil every 25 hours.
Drain the oil from the drain plug located on either side
of the engine bottom, as shown in Figure D.2. Refill
through the oil fill plug until the oil reaches the top of
the fill hole. Use the grade and viscosity recommended in the engine owner’s manual.
operation or daily. BE SURE TO
FIGURE D.2 - OIL DRAIN AND REFILL
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-------------------------------------------------------------
See the engine owner’s manual for a summary of
maintenance intervals for the items listed below.
Follow either the hourly or the calendar intervals,
whichever come first. More frequent service may be
required, depending on your specific application and
operating conditions. Table D.1 shows engine mainte-
nance replacement parts and numbers.
If this Power Arc 5500 is equipped with a Tachometer
/Hour meter (See page B-3 & B-4), then use it’s flash
alert feature to determine the oil change intervals, as
well as times when air filter service is required.
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LOCATION
1. OIL DRAIN PLUG
2. OIL FILL PLUG
3. OIL LEVEL
POWERARC® 5500
Page 41
D-3 D-3
1
1
MAINTENANCE
FFUUEELL::
the fuel
tion and dirt contamination in the fuel line.
At the end of each day’s use, refill
tank to minimize moisture condensa-
ENGINE ADJUSTMENTS
WARNING
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 other adjustments to increase the maximum speed. Severe
personal injury and damage to the machine can
result if operated at speeds above maximum.
------------------------------------------------------------------------
Adjustments to the engine are to be made only by a
Lincoln Service Center or an authorized Field Service
Shop.
CAUTION
Do not use petroleum solvents such as kerosene
to clean the air cleaner. They may cause deterioration of the air cleaner. DO NOT OIL THE AIR
CLEANER OR USE PRESSURIZED AIR TO CLEAN
OR DRY THE AIR CLEANER.
Clean Rotating Screen: If your POWERARC® 5500 is
equipped with an engine that has a rotating screen,
you should clean it as often as needed, to remove dirt
or debris that may collect on the screen. A dirty screen
can result in engine overheating and damage. (See
Figure D.3).
FIGURE D.3 - CLEAN ROTATING
SCREEN/FINGER GUARD/DEBRIS GUARD
1. ROTATING SCREEN
CCLLEEAANN CCOOOOLLIINNGG SSYYSSTTEEMM::
the inter
speeding, overheating, and engine damage. Clean
every 100 operating hours or as often as necessary.
nal cooling fins and surfaces to prevent over-
See Figure D.4. Clean
-------------------------------------------------------------
To service the pre-cleaner:
1. Wash in liquid detergent and water.
2. Squeeze dry in a clean cloth.
3. Saturate in clean engine oil.
4. Squeeze in a clean, absorbent cloth to remove all
excess oil.
CCLLEEAANN EENNGGIINNEE::
brush. Do not clean with a forceful spray of water.
or a
Water might contaminate the fuel system.
Rem
ove dirt and debris with a cloth
CAUTION
Periodically clean the muffler area to remove combustible debris.
-------------------------------------------------------------
FIGURE D.4 - CLEAN COOLING SYSTEM
1. REMOVE DIRT FROM THESE AREAS.
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POWERARC® 5500
Page 42
D-4 D-4
2
1
MAINTENANCE
CCLLEEAANN OORR RREEPPLLAACCEE SSPPAARRKK PPLLUUGG::
replace
tion or every season, whichever comes first. Do not
blast the spark plug clean with an abrasive cleaning
device. Clean the plug by scraping it or by using a
wire brush. Wash the plug with a commercial solvent.
After cleaning or when installing a new spark plug, set
the terminal gap to .030 inch (.76 mm) with a feeler
gauge. See Figure D.5.
the spark plug after every 100 hours of opera-
Clean or
FIGURE D.5 - SET SPARK PLUG GAP
Use the engine owner’s manual for latest Plug Gap Info.
CCLLEEAANN SSPPAARRKK AARRRREESSTTEERR SSCCRREEEENN::
engine owner’
POWERARC® 5500 for the proper cleaning instructions.
s manual that was shipped with your
Refer to the
TABLE D.1
ENGINE MAINTENANCE PARTS
Part Robin / Subaru Part # Honda Part #
SPARK PLUG NGK BR6 HS NGK BPR6ES
(RESISTOR) DENSO W20EPR-U
FUEL FILTER NONE NONE
AIR CLEANER PANEL 279-32616-00 5266721 (17210-ZE2-505)
(Pleated Paper)
AIR PRE-CLEANER 279-32611-00 2538429 (17218-ZE2-821)
(AS NEEDED) (CAN BE CLEANED AND REUSED AS NEEDED)
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.
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POWERARC® 5500
Page 43
D-5 D-5
1
3
5
6
2
4
MAINTENANCE
GENERATOR/WELDER MAINTENANCE
SSTTOORRAA GGEE::
dry,
protected areas.
CCLLEEAANNIINNGG::
periodic
once a week in particularly dirty areas.
BBRRUUSSHH RREEMMOOVVAALL AANNDD RREEPPLLAACCEEMMEENNTT::
Figure
to wear and darken slightly. Inspect the brushes
when a general overhaul is necessary. Remove the
brushes and clean the slip rings with fine grit emery
paper.
Store the POWERARC® 5500 in clean,
Blow out the generator and controls
ally with low pressure air. Do this at least
See
D.5. It’s normal for the brushes and slip rings
CAUTION
Do not attempt to polish slip rings while engine is
running.
To reinstall the brushes, press them upward and
slide a cable tie or wooden stick through the brush
holder tabs. Install the brush holder into the bearing end bracket and secure with the screws previously removed. Remove the cable tie or wooden
stick and the brushes will seat onto the slip rings.
RREECCEEPPTTAACCLLEESS::
good condition.
from their surfaces and holes.
CCAABBLLEE CCOONNNNEECCTTIIOONNSS::
connections at
sure that the connections are always tight.
NOTE: Lincoln offers a rotor removal kit for any service which requires removal of the rotor from the
engine. See the ACCESSORIES section for further
details.
Removal of engine/generator assembly from the cradle can be achieved as follows:
• Remove the two 5/16-18 hex head cap screws
from the engine block via the access hole located
in the cradle cross support channel. Leave all other
engine mountings intact.
• Remove the two hex nuts from the isolator threaded posts at the stator support bracket located
opposite the engine. Leave all other stator mountings intact.
• With a jib hoist or crane, lift the unit upward and
remove loose cradle from engine/generator
assembly.
Kee
p the electrical receptacles in
Remove any dirt, oil, or other debris
Check the welding cable
the weld output terminals often. Be
FIGURE D.5. – BRUSH REMOVAL AND REPLACEMENT
1. GENERATOR END BRACKET
2. BRUSH HOLDER ASSEMBLY
3. COVER
4. SCREWS (2)
5. BRUSHES
6. CABLE TIE
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POWERARC® 5500
Page 44
D-6 D-6
8
7
6
5
1
2
3
4
FIGURE D.6. - MAJOR COMPONENT LOCATIONS
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
MAINTENANCE
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POWERARC® 5500
Page 45
E-1 E-1
ENGINE
STATOR
STATOR
ROTOR
REACTOR
BRIDGE
CAPACITOR
RHEOSTAT
230VAC
RECEPTACLES
OUTPUT
TERMINALS
ROTATION
MECHANICAL
SLIP
RINGS
ROTOR
MAGNETO
CIRCUIT
LOW OIL
SWITCH
RUN/STOP
SWITCH
CIRCUIT
BREAKER
115VAC
RECEPTACLES
CIRCUIT
BREAKER
TABLE OF CONTENTS-THEORY OF OPERATION SECTION
Theory of Operation .............................................................................................................Section E
Block Logic Diagram.......................................................................................................E-1
Engine Control & Ignition, Rotor and Stator ...................................................................E-2
Rotor Field Feedback and Auxiliary Power.....................................................................E-3
Welding Output ...............................................................................................................E-4
FIGURE E.1 – POWERARC® 5500 BLOCK LOGIC DIAGRAM
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POWERARC® 5500
Page 46
E-2 E-2
ENGINE
STATOR
STATOR
ROTOR
REACTOR
BRIDGE
CAPACITOR
RHEOSTAT
230VAC
RECEPTACLES
OUTPUT
TERMINALS
R
OTATION
MECHANICAL
SLIP
R
INGS
R
OTOR
M
AGNETO
CIRCUIT
LOW OIL
SWITCH
RUN/STOP
SWITCH
CIRCUIT
BREAKER
115VAC
RECEPTACLES
CIRCUIT
BREAKER
THEORY OF OPERATION
FIGURE E.2 – ENGINE CONTROL, IGNITION, ROTOR & STATOR
Return to Section TOC Return to Section TOC Return to Section TOC Return to Section TOC
ENGINE CONTROL AND IGNITION
The engine ignition is created and controlled by a flywheel type magneto circuit. 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 condition the Low Oil Level Switch will activate and short
the ignition circuit to ground. This will disable the ignition circuit and shut down the engine. This is a protective function to prevent damage to the engine if the
crankcase oil level is inadequate.
Return to Master TOC Return to Master TOC Return to Master TOC Return to Master TOC
NOTE: Unshaded areas of Block Logic
Diagram are the subject of discussion
ENGINE, EXCITATION, ROTOR
AND STATOR
A small voltage developed by the engine magneto is
fed through a diode to the rotating field coil in the rotor
via a brush and slip ring configuration. This excitation
(“flashing”) voltage mag ne tizes the rotor lamination.
The rotor is mechanically coupled to the engine. The
rotating magnet induces a voltage in the stationary
POWERARC® 5500
windings of the main alternator (stator).
Three separate and isolated windings are incor porated
in the stator lamination assembly. Each winding set
has a different number of turns, producing different
magnitudes of AC output voltages. The three windings
are the weld winding, the auxiliary power winding and
the field feedback winding. The field feedback winding provides rotor current during machine operation.
The output of the POWERARC® 5500 is dependent
on two criteria: the engine RPM and the amount of
current in the rotor winding.
Page 47
E-3 E-3
ENGINE
STATOR
STATOR
ROTOR
REACTOR
BRIDGE
CAPACITOR
RHEOSTAT
230VAC
RECEPTACLES
OUTPUT
TERMINALS
ROTATION
MECHANICAL
SLIP
RINGS
ROTOR
MAGNETO
CIRCUIT
LOW OIL
SWITCH
RUN/STOP
SWITCH
CIRCUIT
BREAKER
115VAC
RECEPTACLES
CIRCUIT
BREAKER
THEORY OF OPERATION
FIGURE E.3 – ROTOR FIELD FEEDBACK AND AUXILIARY POWER
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ROTOR FIELD FEEDBACK AND
AUXILIARY POWER
The AC voltage developed in the field winding is fed to
the full wave bridge. The DC output of the bridge is filtered by the field capacitor and controlled by the output rheostat.
This filtered and controlled feedback voltage is fed to
the rotor winding via the brush and slip ring configuration. As the feedback voltage is increased or de creased, the outputs of the weld and auxiliary windings are likewise increased or decreased.
Return to Master TOC Return to Master TOC Return to Master TOC Return to Master TOC
NOTE: Unshaded areas of Block Logic
Diagram are the subject of discussion
When full field voltage is applied to the rotor and the
engine is running at high speed (3700 RPM), a 230
VAC voltage is developed in the stator auxiliary winding. This winding is tapped to provide 115 VAC. The
two voltages (115 VAC and 230 VAC) are connected to
the appropriate receptacles and offer 5500 watts
(total) of AC power.
POWERARC® 5500
Page 48
E-4 E-4
ENGINE
STATOR
STATOR
ROTOR
REACTOR
BRIDGE
CAPACITOR
RHEOSTAT
230VAC
RECEPTACLES
OUTPUT
TERMINALS
ROTATION
MECHANICAL
SLIP
R
INGS
R
OTOR
MAGNETO
CIRCUIT
LOW OIL
SWITCH
RUN/STOP
SWITCH
CIRCUIT
BREAKER
115VAC
RECEPTACLES
CIRCUIT
BREAKER
THEORY OF OPERATION
FIGURE E.4 – WELDING OUTPUT
Return to Section TOC Return to Section TOC Return to Section TOC Return to Section TOC
WELD WINDING AND REACTOR
The AC voltage developed in the stator weld winding
is delivered, through the reactor, to the machine output terminals. The POWERARC® 5500 provides the
user up to 125 amps of constant current AC welding
for stick electrodes. The reactor stores energy, and
this energy is released into the welding arc when the
AC voltage passes through the zero point. In this
manner the reactor enhances and stabilizes the AC
welding arc. The reactor is designed to provide optimum welding characteristics when used with the recommended electrodes.
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NOTE: Unshaded areas of Block Logic
Diagram are the subject of discussion
AUXILIARY POWER
OVERCURRENT PROTECTION
The POWERARC® 5500 watt auxiliary power winding
and circuitry is protected from an overload condition
by two 20 amp circuit breakers. The circuit breakers
are located below the output receptacles. They can
be manually reset.
POWERARC® 5500
Page 49
F-1 F-1
TABLE OF CONTENTS - TROUBLESHOOTING AND REPAIR
Troubleshooting and Repair . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .F-1
How to Use Troubleshooting Guide . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .F-2
PC Board Troubleshooting Procedures . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .F-3
Troubleshooting Guide . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .F-4
Test Procedures . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .F-13
Rotor Voltage and Flashing Test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .F-13
Rotor Resistance Test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .F-15
Engine Throttle Adjustment Test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . F-19
Waveforms . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .F-22
Removal and Replacement Procedures . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .F-25
Brush Removal and Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .F-25
Rheostat Removal and Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .F-29
Capacitor and/or Diode Bridge Removal and Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .F-31
Stator/Rotor Removal and Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .F-35
Retest and Repair . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .F-41
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POWERARC® 5500
Page 50
F-2 F-2
TROUBLESHOOTING AND REPAIR
HOW TO USE TROUBLESHOOTING GUIDE
WARNING
Service and Repair should only be performed by Lincoln Electric Factory Trained
Personnel. Unauthorized repairs performed on this equipment may result in danger to
the technician and machine operator and will invalidate your factory warranty. For your
safety and to avoid Electrical Shock, please observe all safety notes and precautions
detailed throughout this manual.
---------------------------------------------------------------------------------------------------------------------------
This Troubleshooting Guide is provided to
help you locate and repair possible machine
malfunctions. Simply follow the three-step
procedure listed below.
Step 1. LOCATE PROBLEM (SYMPTOM).
Look under the column labeled “PROBLEM
(SYMPTOMS)”. This column describes possible symptoms that the machine may exhibit. Find the listing that best describes the
symptom that the machine is exhibiting.
Symptoms are grouped into the following
categories: output problems, function problems, wire feeding problems, and welding
problems.
Step 2. PERFORM EXTERNAL TESTS.
The second column labeled “POSSIBLE
AREAS OF MISADJUSTMENT(S)” lists the
obvious external possibilities that may contribute to the machine symptom. Perform
these tests/checks in the order listed. In
general, these tests can be conducted without removing the case wrap-around cover.
Step 3. RECOMMENDED
COURSE OF ACTION
The last column labeled “Recommended
Course of Action” lists the most likely components that may have failed in your
machine. It also specifies the appropriate
test procedure to verify that the subject component is either good or bad. If there are a
number of possible components, check the
components in the order listed
one possibility at a time until you locate the
cause of your problem.
All of the referenced test procedures
referred to in the Troubleshooting Guide are
described in detail at the end of this chapter.
Refer to the Troubleshooting and Repair
Table of Contents to locate each specific
Test Procedure. All of the specified test
points, components, terminal strips, etc. can
be found on the referenced electrical wiring
diagrams and schematics. Refer to the
Electrical Diagrams Section Table of
Contents to locate the appropriate diagram.
to eliminate
Return to Section TOC Return to Section TOC Return to Section TOC Return to Section TOC
CAUTION
If for any reason you do not understand the test procedures or are unable to perform the
tests/repairs safely, contact the Lincoln Electric Service Department for technical troubleshooting
assistance before you proceed. Call 1-888-935-3877.
-----------------------------------------------------------------------------------------------------------------------------------
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POWERARC® 5500
Page 51
F-3 F-3
TROUBLESHOOTING AND REPAIR
PC BOARD TROUBLESHOOTING PROCEDURES
WARNING
ELECTRIC SHOCK
can kill.
•
Have an electrician install and
service this equipment. Turn the
input power OFF at the fuse box
before working on equipment. Do
not touch electrically hot parts.
CAUTION
Sometimes machine failures appear to be due to PC
board failures. These problems can sometimes be
traced to poor electrical connections. To avoid problems when troubleshooting and replacing PC boards,
please use the following procedure:
1. Determine to the best of your technical ability
that the PC board is the most likely component
causing the failure symptom.
2. Check for loose connections at the PC board
to assure that the P C board is p r o perly
connected.
3. If the problem persists, replace the suspect PC
board using standard practices to avoid static
electrical damage and electrical shock. Read
the warning inside the static resistant bag and
perform the following procedures:
PC board can be damaged by static electricity.
- Remove you r b o d y ’s static
charge before opening the staticshielding bag. Wear an anti-static
wrist stra p. For safe ty, use a 1
Meg ohm resistive cord connected
ATTENTION
Static-Sensitive
Devices
Handle only at
Static-Safe
Workstations
to a grounded p a r t of the
equipment frame.
- If you don’t have a wrist strap,
touch an un-painted, grounded,
part of the equipment frame. Keep
touchi n g th e fr a m e to pr e v e n t
static build-up. B e s u re not to
touch any electrically live parts at
the same time.
- Remove the PC board from the static-shielding bag
and place it directly into the equipment. Don’t set the
PC board on or near paper, plastic or cloth which
could have a static charge. If the PC board can’t be
installed immediately, put it back in the static-shielding bag.
- If the PC board uses protective shorting jumpers,
don’t remove them until installation is complete.
- If you return a PC board to The Lincoln Electric
Company for credit, it must be in the static-shielding
bag. This will prevent further damage and allow proper failure analysis.
4. Test the machin e to determine if the failure
sympto m has been c o r rected by t h e
replacement PC board.
NOTE: It is desirable to have a spare (known good)
PC board available for PC board troubleshooting.
NOTE: Allow the machine to heat up so that all
electrical components can reach their operating
temperature.
5. Remo v e the replacement PC b o a r d and
substi t u t e it with the orig i n a l PC board t o
recreate the original problem.
a. If the original problem does not reappear by
substituting the original board, then the PC
board was not the problem. Continue to look
for bad con nections in the control wiring
harness, junction blocks, and terminal strips.
b. If the original problem is recreated by the
substitution of the original board, then the PC
board w a s the problem . R e install the
replacement PC board and test the machine.
6. Alway s i n d icate t h a t this p r o c e dure w a s
follow e d when warranty repo r t s are to be
submitted.
NOTE: Following this procedure and writing on the
warranty report, “INSTALLED AND SWITCHED PC
BOARDS TO VERIFY PROBLEM,” will help avoid
denial of legitimate PC board warranty claims.
Return to Section TOC Return to Section TOC Return to Section TOC Return to Section TOC
- Tools which come in contact with the PC board must
be either conductive, anti-static or static-dissipative.
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POWERARC® 5500
Page 52
F-4 F-4
TROUBLESHOOTING GUIDE - Observe Safety Guidelines detailed in the beginning of this manual.
TROUBLESHOOTING AND REPAIR
PROBLEMS
(SYMPTOMS)
Major physical or electrical damage is evident.
POSSIBLE AREAS OF
MISADJUSTMENTS(S)
OUTPUT PROBLEMS
RECOMMENDED
COURSE OF ACTION
Contact the Lincoln Electric Service
Department at 1-888-935-3877.
Return to Section TOC Return to Section TOC Return to Section TOC Return to Section TOC
CAUTION
If for any reason you do not understand the test procedures or are unable to perform the tests/repairs safely,
contact the Lincoln Electric Service Department for technical troubleshooting assistance before you proceed.
Call 1-888-935-3877.
Return to Master TOC Return to Master TOC Return to Master TOC Return to Master TOC
POWERARC® 5500
Page 53
F-5 F-5
TROUBLESHOOTING GUIDE - Observe Safety Guidelines detailed in the beginning of this manual.
TROUBLESHOOTING AND REPAIR
PROBLEMS
(SYMPTOMS)
No weld output and no auxiliary output - engine runs normally.
POSSIBLE AREAS OF
MISADJUSTMENTS(S)
OUTPUT PROBLEMS
1. The generator brushes may be
worn or faulty. See the Main tenance section of this manual or
contact your local Lincoln
Electric Authorized Field Ser vice Facility.
RECOMMENDED
COURSE OF ACTION
1. Perform the Rotor and Flashing
Voltage Test.
2. The field capacitor (C1) or bridge
(D1) may be faulty. Test or
replace.
3. Test the rheostat (R1). Normal
resistance is 3.3 ohms.
4. The rotor may be faulty. Per form
the Rotor Resistance Test.
Return to Section TOC Return to Section TOC Return to Section TOC Return to Section TOC
CAUTION
If for any reason you do not understand the test procedures or are unable to perform the tests/repairs safely,
contact the Lincoln Electric Service Department for technical troubleshooting assistance before you proceed.
Call 1-888-935-3877.
Return to Master TOC Return to Master TOC Return to Master TOC Return to Master TOC
POWERARC® 5500
Page 54
F-6 F-6
TROUBLESHOOTING GUIDE - Observe Safety Guidelines detailed in the beginning of this manual.
TROUBLESHOOTING AND REPAIR
PROBLEMS
(SYMPTOMS)
No weld output - auxiliary power
(230 - 115 VAC) operates normally engine runs normally.
POSSIBLE AREAS OF
MISADJUSTMENTS(S)
OUTPUT PROBLEMS
1. Check the open circuit voltage
(OCV) at the welder output terminals. If OCV is okay, go to Step
2; below.
If OCV is not present at the welder
output terminals, contact your
local Lincoln Electric Authorized
Field Service Facility.
2. Check the welding cables,
clamps and electrode holder for
loose or broken connections.
RECOMMENDED
COURSE OF ACTION
1. Check continuity (zero ohms) of
lead W1A (black) from output terminal to reactor (L1). See the
Wiring Diagram.
2. Check continuity (zero ohms) of
lead W2 (black) from output
terminal to stator winding. See
the Wiring Diagram.
3. Check continuity (zero ohms) of
lead W1A (black) from reactor
(L1) to stator winding. See the
Wiring Diagram.
4. Check reactor (L1) for continuity
of winding. See the Wiring Dia gram.
5. Check the stator for continuity of
winding. See the Wiring Dia gram.
6. Make certain the reactor and/or
stator are NOT grounded. Mini mum acceptable resistance to
ground is 500 K-ohms.
Return to Section TOC Return to Section TOC Return to Section TOC Return to Section TOC
CAUTION
If for any reason you do not understand the test procedures or are unable to perform the tests/repairs safely,
contact the Lincoln Electric Service Department for technical troubleshooting assistance before you proceed.
Call 1-888-935-3877.
Return to Master TOC Return to Master TOC Return to Master TOC Return to Master TOC
POWERARC® 5500
Page 55
F-7 F-7
TROUBLESHOOTING GUIDE - Observe Safety Guidelines detailed in the beginning of this manual.
TROUBLESHOOTING AND REPAIR
PROBLEMS
(SYMPTOMS)
No auxiliary power - welding output is normal - engine runs normally.
POSSIBLE AREAS OF
MISADJUSTMENTS(S)
OUTPUT PROBLEMS
1. Check circuit breakers CB1 and
CB2. Reset if tripped.
2. Make sure that the control rheostat (R1) is set at “GENERATOR”
(maximum).
3. Check for loose or faulty plug at
power receptacle.
RECOMMENDED
COURSE OF ACTION
1. Check the auxiliary power re ceptacles and associated wires
for loose or faulty connections.
2. Check the continuity (zero ohms)
of leads 3, 3A, 3B; 6, 6A, 6B, 6C;
and 5, 5A, 5B from the receptacles to the stator windings. See
the Wiring Dia gram.
3. Make sure lead 5 (white) is
grounded to the machine frame
(zero ohms).
4. Check for an open or grounded
auxiliary winding in the stator, 6
to 3. See the Wiring Diagram.
Return to Section TOC Return to Section TOC Return to Section TOC Return to Section TOC
CAUTION
If for any reason you do not understand the test procedures or are unable to perform the tests/repairs safely,
contact the Lincoln Electric Service Department for technical troubleshooting assistance before you proceed.
Call 1-888-935-3877.
Return to Master TOC Return to Master TOC Return to Master TOC Return to Master TOC
POWERARC® 5500
Page 56
F-8 F-8
TROUBLESHOOTING GUIDE - Observe Safety Guidelines detailed in the beginning of this manual.
TROUBLESHOOTING AND REPAIR
PROBLEMS
(SYMPTOMS)
Low weld output and low auxiliary output.
POSSIBLE AREAS OF
MISADJUSTMENTS(S)
OUTPUT PROBLEMS
1. The generator brushes may be
worn. See the Maintenance section of this manual or contact
your local Lincoln Electric
Authorized Field Service Facility.
2. The engine RPM may be low.
RECOMMENDED
COURSE OF ACTION
1. Perform the Rotor Voltage Test.
2. If the rotor voltage is low, the field
capacitor (C1) or bridge (D1) may
be faulty. Test or replace.
3. Check the rheostat (R1). Normal
resistance is 3.3 ohm.
4. The rotor may be faulty. Per form
the Rotor Resistance Test.
5. The engine RPM may be low.
Perform the Engine Throttle
Adjust ment Test.
6. If engine idle RPM is okay, the
engine may have lost horsepower and be in need of major repair.
Return to Section TOC Return to Section TOC Return to Section TOC Return to Section TOC
CAUTION
If for any reason you do not understand the test procedures or are unable to perform the tests/repairs safely,
contact the Lincoln Electric Service Department for technical troubleshooting assistance before you proceed.
Call 1-888-935-3877.
Return to Master TOC Return to Master TOC Return to Master TOC Return to Master TOC
POWERARC® 5500
Page 57
F-9 F-9
TROUBLESHOOTING GUIDE - Observe Safety Guidelines detailed in the beginning of this manual.
TROUBLESHOOTING AND REPAIR
PROBLEMS
(SYMPTOMS)
Engine will not start.
POSSIBLE AREAS OF
MISADJUSTMENTS(S)
ENGINE PROBLEMS
1. Make sure the ON/OFF Switch is
in the “ON” position.
2. Check spark plug boot and wire
for loose or faulty connection.
3. Make sure that the fuel shutoff
valve is in the “ON” position.
4. Make certain that the engine has
adequate fuel and oil.
5. Adjust the choke to prevent carburetor flooding.
6. The recoil starter may not be
engaged with the engine. gently
hit the blower housing and/or pull
the rope to its fully extended
position and rapidly wiggle it.
Repeat until the clutch engages
with the engine shaft and resistance is felt.
RECOMMENDED
COURSE OF ACTION
1. Check the fuel line for breaks or
obstructions. Replace the fuel
filter. DO NOT RUN THE EN GINE WITHOUT AN IN-LINE
FUEL FILTER.
2. The spark plug may be faulty.
Replace.
3. Service the engine as outlined in
the Maintenance section of this
manual.
4. The engine magneto circuit may
be faulty. Consult engine
owner’s manual.
5. The engine may be faulty.
Replace.
7. Low oil and engine low oil shutdown protection will not allow
unit to start.
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CAUTION
If for any reason you do not understand the test procedures or are unable to perform the tests/repairs safely,
contact the Lincoln Electric Service Department for technical troubleshooting assistance before you proceed.
Call 1-888-935-3877.
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POWERARC® 5500
Page 58
F-10 F-10
TROUBLESHOOTING GUIDE - Observe Safety Guidelines detailed in the beginning of this manual.
TROUBLESHOOTING AND REPAIR
PROBLEMS
(SYMPTOMS)
Engine will not stop running.
Engine runs erratically or stops running.
POSSIBLE AREAS OF
MISADJUSTMENTS(S)
ENGINE PROBLEMS
1. Make sure the Run/Stop Switch
is in the “OFF” position.
1. Check the spark plug boot and
wire for loose or faulty connection.
2. The spark plug may be faulty.
Replace.
3. The fuel and air mixture may be
out of adjustment. Consult the
engine owner’s man ual.
4. The fuel supply may be con taminated with water.
RECOMMENDED
COURSE OF ACTION
1. Make sure the Run/Stop Switch
is functioning correctly. See
wiring diagram.
1. The engine may require service
to the head or carburetor.
2. The fuel pump may be faulty. See
the engine owner’s manual.
Engine sputters but will not start.
1. The spark plug may be faulty.
2. The fuel supply may be contaminated with water.
3. The air filter may be clogged.
Replace.
4. The fuel and air mixture may be
out of adjustment.
See the engine owner’s manual.
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CAUTION
If for any reason you do not understand the test procedures or are unable to perform the tests/repairs safely,
contact the Lincoln Electric Service Department for technical troubleshooting assistance before you proceed.
Call 1-888-935-3877.
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POWERARC® 5500
Page 59
F-11 F-11
TROUBLESHOOTING GUIDE - Observe Safety Guidelines detailed in the beginning of this manual.
TROUBLESHOOTING AND REPAIR
PROBLEMS
(SYMPTOMS)
The welding arc is “cold.” The engine runs normally (3700 RPM, no load). Auxiliary power is func tioning normally.
POSSIBLE AREAS OF
MISADJUSTMENTS(S)
WELDING PROBLEMS
1. Check for loose or faulty con nections at the weld output
terminals and welding cable connections.
2. The welding cable may be too
long or coiled, causing an excessive voltage drop.
RECOMMENDED
COURSE OF ACTION
1. Check for the correct open circuit voltage (OCV) at the welder
output terminals – 62 VAC is normal.
If the correct voltage is present
at the output terminals, check for
loose connections on the heavy
current-carrying leads inside the
POWERARC® 5500. See the
Wiring Diagram.
2. If the OCV is low at the welder
output terminals, perform
Engine Throttle Adjustment
Test.
3. Check for shorted or grounded
windings in the reactor (L1) and
also in the main stator.
See the Wiring Diagram.
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CAUTION
If for any reason you do not understand the test procedures or are unable to perform the tests/repairs safely,
contact the Lincoln Electric Service Department for technical troubleshooting assistance before you proceed.
Call 1-888-935-3877.
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POWERARC® 5500
Page 60
F-12 F-12
NOTES
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POWERARC® 5500
Page 61
F-13 F-13
TROUBLESHOOTING AND REPAIR
ROTOR VOLTAGE AND FLASHING VOLTAGE TEST PROCEDURE
WARNING
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 throughout this
manual.
If for any reason you do not understand the test procedures or are unable to perform the
test/repairs safely, contact the Lincoln Electric Service Department for electrical troubleshooting assistance before you proceed. Call 1-888-935-3877.
TEST DESCRIPTION
This test will determine if the correct DC voltage is being applied to the rotor at maximum
engine speed (3700 RPM). This information will aid the technician in determining if the
generator field is operating properly.
MATERIALS NEEDED
Volt/Ohmmeter
5/16” Nut driver
Wiring Diagram
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POWERARC® 5500
Page 62
F-14 F-14
200
LEAD 200
CONNECTION
GROUND STUD
OUTPUT PANEL
TROUBLESHOOTING AND REPAIR
ROTOR VOLTAGE AND FLASHING VOLTAGE TEST PROCEDURE
(continued)
ROTOR VOLTAGE TEST (continued)
FIGURE F.1 - LOCATION OF LEAD 200A FOR ROTOR VOLTAGE TEST
ROTOR VOLTAGE TEST PROCEDURE
1. 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.
2. Start the machine and run it at high idle. Set
the output control (rheostat) at the MAXIMUM
or GENERATOR setting.
3. Set the volt/ohmmeter at the DC position.
4. Place the positive probe on lead 200 where it
connects at the back of the rheostat (the middle wiper terminal). See Figure F.1 for location.
Place the negative probe on the machine
ground stud or any other good, unpainted
ground.
5. Check the voltage reading on the
volt/ohmmeter. It should read 45 - 48 VDC.
6. If the voltage is low or not present, the generator field circuit is not functioning correctly.
Proceed with Flashing Voltage Test
Procedure. C1, R1, or D1 may also be faulty.
See wiring diagram.
FLASHING VOLTAGE TEST
PROCEDURE
8. With the machine running at high idle
(3700RPM), the voltage from lead #205 (located at D2) to machine ground should be 1.5 to
2.0 VAC. If this voltage is not present, check
the continuity of lead #205 from the engine
module to D2. See the wiring diagram. If the
1.5 to 2.0 VAC is present, proceed to the next
step.
9. With the machine running at high idle
(3700RPM), the voltage from lead 202B (located at D2) to machine ground should be approximately 1.6 VDC. If this voltage is not present
and the correct AC voltage is present at lead
#205, then diode D2 may be faulty.
10. If the voltage readings are correct in the two
prior steps, check the continuity of leads #202,
#202B, #202A, #201, #201A and #201B. See
the wiring diagram. Also check the brushes for
good contact with the rotor slip rings.
11. Proceed with the Rotor Resistance Test.
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7. If rotor voltage is correct, the generator field is
okay. Replace the top cover on the control
box. Tighten the 8 sheet metal screws with the
5/16” nut driver.
POWERARC® 5500
Page 63
F-15 F-15
TROUBLESHOOTING AND REPAIR
ROTOR RESISTANCE TEST PROCEDURE
WARNING
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 throughout this
manual.
If for any reason you do not understand the test procedures or are unable to perform the
test/repairs safely, contact the Lincoln Electric Service Department for electrical troubleshooting assistance before you proceed. Call 1-888-935-3877.
TEST DESCRIPTION
This test will determine if there is a shorted winding in the rotor or if the rotor is
grounded.
MATERIALS NEEDED
Volt/Ohmmeter
1/4” Nut driver
Small slot head screw driver
Wiring Diagram
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POWERARC® 5500
Page 64
F-16 F-16
SLIP
RINGS
TROUBLESHOOTING AND REPAIR
ROTOR RESISTANCE TEST PROCEDURE (continued)
ROTOR RESISTANCE TEST (continued)
FIGURE F.2
LOCATION OF ROTOR SLIP RINGS - BRUSH HOLDER ASSEMBLY REMOVED
PROCEDURE
1. Conduct the test with the gasoline engine OFF.
2. Remove the spark plug wire to prevent accidental 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 cover.
Squeeze the 2 tabs and depress the cover at
the top with a screw driver or your fingernail.
The cover will drop open on its bottom hinge.
5. With the 1/4” nut driver, remove the 2 screws
that hold the brush holder assembly in place.
6. Slide the brush holder assembly out and lay it
aside, held by the 2 wires attached.
7. Measure the resistance across the rotor slip
rings.
A. Set the ohmmeter on the low scale (X1).
B. Place one meter probe on one of the rotor
slip rings. Place the other probe on the
other slip ring.
C. Check the resistance across the slip rings.
It should read 7 - 9 ohms.
8. Measure the resistance to ground.
A.. Set the ohmmeter on the high scale
(X100,000).
B. Place one probe on either of the slip rings.
Place the other probe on any good,
unpainted ground. Use the ground stud or
the rotor thru-bolt.
C. Check the resistance. It should read very
high, at least .5 meg. ohm (500,000 ohms).
If the resistance checks meet the specifications,
then the rotor is okay.
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POWERARC® 5500
Page 65
F-17 F-17
CABLE
TIE
BRUSHES
TROUBLESHOOTING AND REPAIR
ROTOR RESISTANCE TEST PROCEDURE (continued)
ROTOR RESISTANCE TEST (continued)
FIGURE F.3 - BRUSHES RETAINED WITH CABLE TIE
9. Reinstall the brush holder assembly after the
test. Depress the spring-loaded brushes into
the holder and slip a suitable non-metallic, fairly stiff retainer through the slots at the top and
bottom of the holder. A cable tie works well;
see Figure F.3. This will hold the brushes up so
that you can easily install the holder.
10. Slip the holder into position in the generator
end bracket. Be careful not to loosen the 2
attached wires.
11. Reinstall and tighten the 2 screws with the
1/4” nut driver.
12. Slowly remove the non-metallic retainer from
the brush holder and let the brushes snap
back against the slip rings.
13. Snap the brush holder cover back into posi-
tion.
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POWERARC® 5500
Page 66
F-18 F-18
NOTES
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POWERARC® 5500
Page 67
F-19 F-19
TROUBLESHOOTING AND REPAIR
ENGINE THROTTLE ADJUSTMENT TEST
ROBIN/SUBARU ENGINE
WARNING
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 throughout this
manual.
If for any reason you do not understand the test procedures or are unable to perform the
test/repairs safely, contact the Lincoln Electric Service Department for electrical troubleshooting assistance before you proceed. Call 1-888-935-3877.
TEST DESCRIPTION
If the machine output is low, this test will determine whether the gasoline engine high idle
speed is set for the correct maximum RPM.
MATERIALS NEEDED
Screwdriver
Frequency counter or strobe-tach or Oscilloscope
Black or red marking pencil
10mm Socket Wrench
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POWERARC® 5500
Page 68
F-20 F-20
MARK
TROUBLESHOOTING AND REPAIR
ENGINE THROTTLE ADJUSTMENT TEST
ROBIN/SUBARU ENGINE (continued)
FIGURE F.4 - MARK LOCATION
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 mark on one of the blower
paddles, which can be reached
through the vent slots in the end
bracket. See Figure F.4.
3. Connect the strobe-tach according
the manufacturer’s instructions.
4. Reconnect the spark plug wire and
start the engine. Direct the strobetach light on the blower paddle and
synchronize it to the rotating mark.
The tach should read 3700 RPM.
5. Using the 10mm socket wrench,
slightly loosen the throttle locking
nut. See Figure F.5.
5. Using the screwdriver adjust the
high speed stop screw until the tach
reads 3700 RPM. See Figure F.6.
Frequency Counter Method:
1. Plug the frequency counter into one
of the 115 VAC auxiliary receptacles.
2. Start the engine and check the
frequency counter. At the proper
RPM (3700), the counter should read
62 Hz.
3. Using the 10mm socket wrench,
slightly loosen the throttle locking
nut. See Figure F.5.
4. Using the screwdriver, adjust the
high speed stop screw until the frequency counter reads 3700 RPM.
See Figure F.6.
5. Re-tighten the throttle locking nut.
See Figure F.5.
Oscilloscope Method:
1. Connect the oscilloscope according
to the manufacturer’s instructions.
At 3700 RPM, the waveform should
exhibit a period of 16.2 milliseconds.
Refer to the NORMAL OPEN
CIRCUIT VOLTAGE WAVEFORM
(115 VAC SUPPLY) HIGH IDLE - NO
LOAD in this section of the manual.
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5. Re-tighten the throttle locking nut.
See Figure F.5.
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POWERARC® 5500
Page 69
F-21 F-21
THROTTLE
LOCKING
NUT
HIGH SPEED
STOP SCREW
TROUBLESHOOTING AND REPAIR
ENGINE THROTTLE ADJUSTMENT TEST
ROBIN/SUBARU ENGINE (continued)
FIGURE F.5 - LOCKING NUT LOCATION
2. Using the 10mm socket wrench, slightly loosen the throttle locking nut. See Figure F.5.
3. Using the screwdriver, adjust the high speed stop screw until the waveform period is 16.2 milliseconds. See
Figure F.6.
4. Re-tighten the throttle locking nut. See Figure F.5.
FIGURE F.6 - STOP SCREW LOCATION
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POWERARC® 5500
Page 70
F-22 F-22
TROUBLESHOOTING AND REPAIR
NORMAL OPEN CIRCUIT WELD VOLTAGE WAVEFORM
HIGH IDLE – NO LOAD
CH1
0 volts
50 volts
This is the typical AC output voltage
generated from a properly operating
machine. Note that each vertical
division represents 50 volts and that
each horizontal division represents 5
milliseconds in time.
Note: Scope probes connected at
machine output terminals.
SCOPE SETTINGS
Volts/Div.....................50V/Div.
Horizontal Sweep.....5 ms/Div.
Coupling ............................DC
Trigger .........................Internal
5 ms
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POWERARC® 5500
Page 71
F-23 F-23
TROUBLESHOOTING AND REPAIR
NORMAL OPEN CIRCUIT VOLTAGE WAVEFORM (115 VAC SUPPLY)
HIGH IDLE – NO LOAD
1 Period = 16.2 ms @ 3700 rpm
CH1
0 volts
50 volts
This is the typical AC output voltage
generated from a properly operating
machine. Note that each vertical
division represents 50 volts and that
each horizontal division represents 5
milliseconds in time.
Note: Scope probes connected at
machine 115 VAC receptacle.
SCOPE SETTINGS
Volts/Div.....................50V/Div.
Horizontal Sweep.....5 ms/Div.
Coupling ............................DC
Trigger .........................Internal
5 ms
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POWERARC® 5500
Page 72
F-24 F-24
TROUBLESHOOTING AND REPAIR
TYPICAL WELD OUTPUT WAVEFORM
MACHINE LOADED
CH1
0 volts
20 volts
5 ms
MACHINE LOADED TO 125 AMPS AT 23 VAC
This is the typical AC output voltage
generated from a properly operating
machine. Note that each vertical
division represents 20 volts and that
each horizontal division represents 5
milliseconds in time. The machine
was loaded with a resistance grid
bank.
Note: Scope probes connected at
machine output terminals.
SCOPE SETTINGS
Volts/Div.....................20V/Div.
Horizontal Sweep.....5 ms/Div.
Coupling ............................DC
Trigger .........................Internal
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POWERARC® 5500
Page 73
F-25 F-25
TROUBLESHOOTING AND REPAIR
BRUSH REMOVAL AND REPLACEMENT PROCEDURE
WARNING
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
throughout this manual.
If for any reason you do not understand the test procedures or are unable to perform the
test/repairs safely, contact the Lincoln Electric Service Department for electrical troubleshooting assistance before you proceed. Call 1-888-935-3877.
TEST DESCRIPTION
The following procedure will aid the technician in accessing the generator brushes for
maintenance or replacement.
MATERIALS NEEDED
Small slot head screw driver
1/4” Nut driver
Needle nose pliers
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POWERARC® 5500
Page 74
F-26 F-26
CABLE
TIE
BRUSHES
TROUBLESHOOTING AND REPAIR
BRUSH REMOVAL AND REPLACEMENT (continued)
FIGURE F.7 - BRUSHES RETAINED WITH CABLE TIE
PROCEDURE
1. Remove the spark plug wire.
2. Open the brush holder assembly
cover. Squeeze the 2 tabs and
depress the cover at the top with a
screw driver or your fingernail. The
cover will drop open on its bottom
hinge.
3. With the 1/4” nut driver, remove the
2 screws that hold the brush holder
assembly in place.
4. With the needle nose pliers, gently
remove the two white wires.
Note: Lead 202A is inboard. Lead 201A
is outboard.
5. To change the brushes, use the slot
head screw driver to pop off the
plastic retainer on the back of the
brush holder assembly.
6. Remove the old brush assemblies
and insert the new ones. One corner
of the terminal clip is beveled so that
the brush can go in only one way.
7. Snap the plastic retainer back onto
the brush holder. The brushes may
need some repositioning; wiggle
them slightly to help them seat properly.
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POWERARC® 5500
Page 75
F-27 F-27
TROUBLESHOOTING AND REPAIR
BRUSH REMOVAL AND REPLACEMENT (continued)
PROCEDURE (continued)
8. To reinstall the brush holder assembly, depress the spring-loaded
brushes into the holder and slip a
suitable non-metallic, fairly stiff
retainer through the slots at the top
and bottom of the holder. A cable
tie works well; see Figure F.7. This
will hold the brushes up so that you
can easily install the holder.
9. With the needle nose pliers, reinstall the two white wires to the
appropriate terminals on the brushes. Lead 202A is inboard.
10. Slip the holder into position in the
generator end bracket. Be careful
not to loosen the 2 attached wires.
11. Reinstall and tighten the 2 screws
with the 1/4” nut driver.
12. Slowly remove the non-metallic
retainer from the brush holder and
let the brushes snap back against
the slip rings.
13. Check the wire connections or
clearance and tightness.
14. Snap the brush holder cover back
into position.
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POWERARC® 5500
Page 76
F-28 F-28
NOTES
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POWERARC® 5500
Page 77
F-29 F-29
TROUBLESHOOTING AND REPAIR
RHEOSTAT REMOVAL AND REPLACEMENT PROCEDURE
WARNING
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 throughout this
manual.
If for any reason you do not understand the test procedures or are unable to perform the
test/repairs safely, contact the Lincoln Electric Service Department for electrical troubleshooting assistance before you proceed. Call 1-888-935-3877.
TEST DESCRIPTION
The following procedure will aid the technician in accessing and removing the output
control rheostat for maintenance or replacement.
MATERIALS NEEDED
3/32” Allen Wrench
5/16” Nut driver
Small slot head screw driver
9/16” Open or box end wrench
11/32” Open or box end wrench
Needle nose pliers
Wiring Diagram
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POWERARC® 5500
Page 78
F-30 F-30
TROUBLESHOOTING AND REPAIR
RHEOSTAT REMOVAL AND REPLACEMENT PROCEDURE (continued)
FIGURE F.8 - RHEOSTAT REMOVAL
See Figure F.8 for steps 3 - 9.
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 the
rheostat shaft. The shaft has a flat
for locating the knob at reassembly.
4. With a 9/16” open or box end
wrench, remove the nut that holds
the rheostat to the control panel.
Support the rheostat with your hand
as you turn the nut. There is a
shake-proof washer under the nut.
5. Pull the rheostat back out of the control panel and lay it out on its wires to
loosen the nuts that hold them.
6. With the 11/32” open or box end
wrench, remove the brass nuts from
the wire terminals. Support the terminals as you turn the wrench to
avoid ripping the terminals from their
foundations. Note the wire locations
for reassembly.
Note: The brass screws are double-nut-
ted with a shake-proof star washer under the screw head.
7. To reinstall the rheostat, replace
each of the brass screws. Place a
shake-proof star washer under the
head, insert the screw into the
rheostat and tighten down one nut.
Replace the appropriate wires and
tighten down the second nut.
Again, support the terminals as you
turn the wrench to avoid ripping the
terminals from their foundations.
8. Reassemble the rheostat to the
front of the control panel. Line up
the locating tab on the rheostat
with the slot on the control panel
hole.
9. Reassemble the shake-proof star
washer and nut and tighten securely with the 9/16” wrench.
10. Locate the flat spot on the shaft,
line up the knob locking screw,
push the knob onto the shaft and
tighten the screw with the allen
wrench.
11. Check the rheostat knob for proper
rotation, minimum to maximum.
12. Replace the top cover of the control box and tighten the 8 sheet
metal screws with the 5/16” nut driver.
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POWERARC® 5500
Page 79
F-31 F-31
TROUBLESHOOTING AND REPAIR
CAPACITOR AND/OR DIODE BRIDGE
REMOVAL AND REPLACEMENT PROCEDURE
WARNING
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 throughout this
manual.
If for any reason you do not understand the test procedures or are unable to perform the
test/repairs safely, contact the Lincoln Electric Service Department for electrical troubleshooting assistance before you proceed. Call 1-888-935-3877.
TEST DESCRIPTION
The following procedure will aid the technician in accessing and removing the capacitor
and diode bridge for maintenance or replacement of either component.
MATERIALS NEEDED
5/16” Nut driver
5/16” Wrench
Jumper wire with alligator clips on each end for discharging the field capacitor
Phillips head screw driver
Needle nose pliers
Wiring Diagram
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POWERARC® 5500
Page 80
F-32 F-32
201
201A
(-)
202
202A
(+)
Attachment for
Attachment for
Jumper
Capacitor
Cable Tie
TROUBLESHOOTING AND REPAIR
CAPACITOR AND/OR DIODE BRIDGE
REMOVAL AND REPLACEMENT PROCEDURE (continued)
FIGURE F.9 - LOCATION AND DISCHARGING THE FIELD CAPACITOR
PROCEDURE - CAPACITOR
REMOVAL AND REPLACEMENT
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. With the 5/16” nut driver and wrench,
remove the 6 screws that hold the
control panel in place (2 in the front, 2
in the back, 2 in the bottom). Move
the panel aside as far as the leads will
allow.
4. Discharge the field capacitor by connecting the jumper wire clips on the
black and the red wire terminals on
the top of the capacitor. See Figure
F.9 for location. Leave the clips on
for at least 5 seconds, then remove.
5. The capacitor is mounted in a molded plastic holder. To remove it, pull
out on the top of the holder, then
slide it upward.
6. Snap the capacitor out of the assembly.
7. Loosen the two screws on the top of
the capacitor. Leads 202A and 202
attach to the positive (+) terminal.
Leads 201 and 201A attach to the
negative (-) terminal.
8. To replace the capacitor, reattach the
leads to their respective terminals
(202A and 202 to positive (+); 201
and 201A to negative (-) and tighten
the screws securely. Snap the
capacitor back into the molded plastic holder. Replace the control panel
and top cover of the control box and
tighten down the sheet metal screws
with the 5/16” nut driver.
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POWERARC® 5500
Page 81
F-33 F-33
Feild Diode Bridge
TROUBLESHOOTING AND REPAIR
CAPACITOR AND/OR DIODE BRIDGE
REMOVAL AND REPLACEMENT PROCEDURE (continued)
FIGURE F.10 - FIELD DIODE BRIDGE LOCATION
200
7A
201
201B
–
+
9A
PROCEDURE - FIELD DIODE BRIDGE REMOVAL AND REPLACEMENT
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. With the 5/16” nut driver and wrench,
remove the 6 screws that hold the
control panel in place (2 in the front, 2
in the back, 2 in the bottom). Move
the panel aside as far as the leads will
allow.
4. Discharge the field capacitor by connecting the jumper wire clips on the
black and the red wire terminals on
the top of the capacitor. See Figure
F.9 for location. Leave the clips on
for at least 5 seconds, then remove.
5. The field diode bridge (D1) is mounted to the sheet metal just above the
capacitor. See Figure F.9. Remove
it using the phillips head screw driver.
Lead 200 attached to the positive (+)
terminal. Depending on the bridge
used, this corner may be beveled
and/or marked with a + sign.
Lead 201 and 201B are piggy-backed
on the negative (–) terminal, which will
always be located diagonally across
from the positive (+) terminal.
Leads 9A and 7A are attached to the
AC side of the bridge and are attached
to the other two corner terminals. Either
lead can go on either terminal.
8. Mount the field diode bridge using
the screw. Use the slot head screwdriver.
9. Check that the leads are not
grounded and for clearance and
tightness.
10. Replace the control panel and
tighten the sheet metal screws
with the 5/16” nut driver and 5/16”
wrench.
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6. With the needle nose pliers, gently
remove the wires from the field
diode bridge. Note lead locations.
7. Replace the wires to their appropriate locations on the new diode
bridge:
POWERARC® 5500
11. Replace the top cover of the control box and tighten the sheet
metal screws with the 5/16” nut driver.
12. The flashing diode (D2) is located
just above the field capacitor and
may be removed by cutting the
cable tie.
Page 82
F-34 F-34
NOTES
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POWERARC® 5500
Page 83
F-35 F-35
TROUBLESHOOTING AND REPAIR
STATOR/ROTOR REMOVAL AND REPLACEMENT PROCEDURE
WARNING
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 throughout this
manual.
If for any reason you do not understand the test procedures or are unable to perform the
test/repairs safely, contact the Lincoln Electric Service Department for electrical troubleshooting assistance before you proceed. Call 1-888-935-3877.
TEST DESCRIPTION
The following procedure will aid the technician in removing the stator and/or rotor for
maintenance or replacement of either component.
MATERIALS NEEDED
Lincoln Electric Rotor Removal Kit (S20925) - FOR ROTOR REMOVAL ONLY
5/16” nut driver
1/2” socket wrench
6” socket extension
Slot head screw driver
5/8” socket wrench
7/16” socket wrench
7/16” open or box end wrench
3/4” socket or box end wrench
1/2” socket or box end wrench
Needle nose pliers
Diagonal cutters
Torque wrench (ft lbs)
Babbitt, leather, or wooden mallet
Volt/ohmmeter
12” (long) feeler gauge (.010)
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POWERARC® 5500
Page 84
F-36 F-36
OUTPUT
TERMINALS
W
1
W
2
TIE WRAP
TROUBLESHOOTING AND REPAIR
STATOR/ROTOR
REMOVAL AND REPLACEMENT PROCEDURE (continued)
STATOR REMOVAL PROCEDURE
1. Remove engine spark plug wire to prevent
accidental kickback or starting.
9. Unplug the large molex plug. See Figure
F.16.
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 slot head screw driver, remove the
6 sheet metal screws that hold the control
panel to the control box - 2 on each side
and 2 on the bottom. You may need to use
the 5/16” end wrench on the engine side
because of limited clearance. Pull the
panel away from the control box.
4. Using the 7/16” wrench, remove the two
bolted reactor lead connections. See
Figure F.15.
5. Using the 1/2” socket wrench, remove the
two bolts and star washers mounting the
reactor to the stator assembly. See Figure
F.15.
6. Carefully remove the reactor.
7. Using the 1/2” socket wrench, remove the
two remaining bolts and star washers
securing the control box to the stator
assembly. See Figure F.16.
8. Using the 5/16” wrench, remove the five
sheet metal screws securing the control
box to the stator frame. CAUTION: One of
the screws secures the green grounding
lead to the frame of the machine. See
Figure F.16.
10. Carefully remove the flashing lead #205
from diode D2 and clear lead from the con-
trol box. See Figure F.15.
11. With the 9/16” open end wrench, remove
lead W2 from the output terminal. With
the diagonal cutters, cut the cable tie that
holds the two output leads together. Pull
lead W2 back out of the way. Screw the
bolt back into the output terminal hole
loosely for reassembly. See Figure F.11.
12. Remove the brush holder assembly. Open
the brush holder assembly cover.
Squeeze the 2 tabs and depress the cover
at the top with a screw driver or your fingernail. The cover will drop open on its
bottom hinge. With the 1/4” nut driver,
remove the 2 screws that hold the brush
holder assembly in place. With the needle
nose pliers, gently remove the two leads
#201 and #202A. Note lead placement for
reassembly. Set the brush holder aside.
Pull the wires up into the control box.
13. Slide the control panel and box assembly
out of the machine cradle. Carefully pull
the wire leads down through the box as
you remove it.
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FIGURE F.11 - OUTPUT LEAD LOCATION
POWERARC® 5500
Page 85
F-37 F-37
THRU-
BOLTS
THRUBOLTS
NUTS
SUPPORT
TROUBLESHOOTING AND REPAIR
STATOR/ROTOR
REMOVAL AND REPLACEMENT PROCEDURE (continued)
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 bracket support. See Figure F.12 for
location. There are 2 split-ring lock
washers along with the nuts.
16. With the 7/16” socket and 7/16”
end wrench, remove the 4 thrubolts for the generator assembly.
See Figure F.12. All 4 bolts have a
split-ring lock washer under the
head and a shake-proof star washer on the nut side. The bolts must
point toward the engine for
reassembly.
17. Lift up the stator and slide out the
support bracket. The engine will
now rest on the 2 X 4.
18. With the babbitt/leather/wooden
mallet, tap off the end bracket.
Alternate sides as you tap; watch
the bearing to judge the amount of
movement you’re getting.
19. Once the end bracket is off, carefully pull off the stator. IMPROPER
HANDLING OF THE STATOR CAN
RESULT IN SHORTED WINDINGS
AND/OR LOST OUTPUT.
FIGURE F.12 – STATOR END BRACKET SUPPORT AND THRU-BOLTS
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POWERARC® 5500
Page 86
F-38 F-38
TROUBLESHOOTING AND REPAIR
STATOR/ROTOR
REMOVAL AND REPLACEMENT PROCEDURE (continued)
FIGURE F.13 - ROTOR WITH STATOR REMOVED
ROTOR REMOVAL
PROCEDURE
1. To remove the rotor, double check
that the spark plug wire is disconnected. You will be turning the rotor
during this procedure, and this could
accidentally cause engine kickback.
2. With an impact wrench, remove the
rotor thru-bolt. See Figure F.13. If an
impact wrench is not available, use
the 1/2” box wrench. Hold the rotor
with one hand and shock the wrench
with the mallet to loosen the thrubolt. The thru-bolt has a star washer and lock washer, beveled to conform to the rotor shaft. Pull out the
thru-bolt.
3. Install the long thru-bolt supplied
with Lincoln Electric Rotor Removal
Kit S20925. The slot head must face
out. Screw in the bolt with the slot
head screw driver until the bolt bottoms out on the engine crankshaft,
about 3/4”.
4. Turning it counterclockwise, screw in
the reverse thread bolt from the kit
into the rotor shaft until it bottoms
out on the thru-bolt.
5. With an impact wrench, tighten the
reverse thread bolt until the rotor
pops off the engine crankshaft. If an
impact wrench is not available, use the
1/2” box wrench. Hold the rotor with
one hand and shock the wrench with
the mallet until the rotor pops off the
engine crankshaft.
6. Slide the rotor and blower (press-fitted
to the rotor) the rest of the way off the
crankshaft.
REASSEMBLY PROCEDURE
1. Lubricate the tapered engine crankshaft. Slide the rotor onto the shaft.
2. Coat the rotor thru-bolt threads with
Lincoln E177-R retaining compound
(Locktite( 277). Place the beveled lock
washers onto the thru-bolt and insert it
into the rotor shaft. Hold the rotor and
tighten the thru-bolt to 22 - 25 ft lbs.
3. Carefully install the stator, with the
leads at the 1 o’ clock position.
IMPROPER HANDLING OF THE
STATOR CAN RESULT IN SHORTED
WINDINGS AND/OR LOST OUTPUT.
4. Install the end bracket. Slide it on and
install the two top thru-bolts loosely to
hold the end bracket for the next step.
5. Install the end bracket support.
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POWERARC® 5500
Page 87
F-39 F-39
ROTOR
STATOR
FEELER GAUGE
TROUBLESHOOTING AND REPAIR
STATOR/ROTOR
REMOVAL AND REPLACEMENT PROCEDURE (continued)
6. Install the bottom two end bracket thrubolts.
12. Reconnect the output lead W2 to the output
terminal.
7. Tap the end bracket with the mallet as necessary to position it. Tighten the bolts to
4.5 - 5.5 ft lbs. Alternate tightening in order
to pull the assembly together evenly. As
you tighten, look through the brush housing
access door and watch the bearing to
judge end bracket movement and alignment.
8. Check the rotor-stator air gap with the long
.010 feeler gauge. The measurement is
taken through the brush holder access
door; see Figure F14. Turn the engine with
the recoil starter rope slightly so that the
rotor “iron” is up to take the measurement.
(The rotor has two flat sides, which are not
measured for air gap.) Slide in the gauge.
Then rotate the shaft 180 degrees and measure again. If the gauge does not clear,
loosen the four end bracket thru-bolts,
reposition the end bracket, retighten the
bolts, and recheck the air gap. Repeat until
the proper .010 minimum air gap is
achieved.
9. Tighten the end bracket support nuts and
lock washers. Remove the 2 X 4 engine
support.
10. Position the control box into place.
11. Reinstall the brush holder assembly. Refer
to the Brush Removal and Replacement
Procedure.
13. Install a new cable tie to hold the leads
together.
14. Reconnect the large molex plug.
15. Install the five sheet metal screws that
secure the control box to the stator frame.
Be sure to connect the green ground lead to
the screw previously removed.
16. Reconnect the flashing lead #205 to diode
D2. Secure lead in control box.
17. Using the 6 sheet metal screws previously
removed, mount the control box panel to
the control box.
18. Using the 1/2” wrench replace the 2 bolts
and star washers securing the control box
to the stator frame.
19. Carefully set the reactor in place and secure
with the two remaining bolts and star washers.
20. Reconnect the reactor leads.
21. Check all terminal connections for clearance, grounding, and tightness.
22. Replace the top cover to the control box
and tighten the 8 screws.
23. Conduct the Retest After Repair
Procedure.
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FIGURE F.14 - CHECKING ROTOR-STATOR AIR GAP
POWERARC® 5500
Page 88
REACTOR BOLTS (2)
LEAD #205
LEAD
CONNECTIONS
GROUNDING SCREW
2 BOLTS
SHEET METAL SCREWS
(5 PLACES)
MOLEX PLUG
F-40 F-40
TROUBLESHOOTING AND REPAIR
STATOR/ROTOR
REMOVAL AND REPLACEMENT PROCEDURE (continued)
FIGURE F.15 LEAD 205 AND MORE
FIGURE F.16 MOLEX PLUG AND BOLT/SCREW LOCATION
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POWERARC® 5500
Page 89
F-41 F-41
TROUBLESHOOTING AND REPAIR
RETEST AFTER REPAIR
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/GENERATOR OUTPUT
1
Output Control Field Volts Field Amps Open Circuit Load Volts Load Amps
Volts
Maximum 43 - 49 4.8 - 5.8 60 - 63 12 - 25 120 - 125
Minimum ––55 - 60 14 - 27 75 - 85
AUXILIARY POWER RECEPTACLE OUTPUT
230 Volt Receptacle 115 Volt Receptacle
1
22
Output Open Circuit Load Volts Load Amps Open Circuit Load Volts Load Amps
Control Volts Volts
Maximum 236 - 248 215 - 230 18 - 20 123 - 129 112 - 120 18 - 20
1
Current Control Dial set at MAXIMUM or GENERATOR.
2
Output values of each receptacle can vary within the range shown
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POWERARC® 5500
Page 90
F-42 F-42
NOTES
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POWERARC® 5500
Page 91
G-1 G-1
Electrical Diagrams . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .G-1
Wiring Diagram (Codes 11182, 11187, 11329) (S25984) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .G-2
Wiring Diagram (Codes 11403, 11405) (S26829) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .G-3
Wiring Diagram (Code 11404) (S26830) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .G-4
Wiring Diagram (Code 11215) (S26023) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .G-5
Schematic – Complete Machine (Codes 11182, 11187, 11329) (S26008) . . . . . . . . . . . . . . . . . . . . . . . . .G-6
Schematic – Complete Machine (Codes 11403, 11405) (S26881) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .G-7
Schematic – Complete Machine (Code 11404) (S26882) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .G-8
TABLE OF CONTENTS - DIAGRAM SECTION
* NOTE: Many PC Board Assemblies are now totally encapsulated, surface mounted and or multi-lay-
ered and are therefore considered to be unserviceable. Assembly drawings of these boards are
no longer provided.
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POWERARC® 5500
Page 92
S25984
ENGINE WIRING
MAG
SWITCH
RUN/
ST
OP
WIRING DIAGRAM - POWER ARC 5500
A
SWITCH
LOW OIL
MODULE
GROUND
BRAC
KET
STATOR E
ND
20
1B
(+)
973
5
6
GND-C
2
GND-D
W1
W2
W1A
REACTOR
1
L1
OUTPU
TSTU
DS
6543
STAT
OR
W
100W
3.3
R1
6C
5A
5B
5B
2
0A
6A
3A
5A
2
0A
7A
9A
202
20
2B
200
200A
202
205
D2
ELECTRICAL SYMBOLS PER E1537.
GND-A
GND
-B
3B
6B
C
B1
C
B2
20
1B
3C
201
20
1A
A
CCW
600 µ FD
7A
20
2A
9A
(-)
(+)
(-)
(+)
R
OTOR
C1
D1
N
OTE:
ALL C
ASE FRONTCOMP
ONE
NTS S
HOWN
VE
IWED FR
OMREA
R.
3B
20
2B
3C
G-2
WIRING DIAGRAM - CODES 11182, 11187, 11329 (S25984)
ELECTRICAL DIAGRAMS
G-2
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NOTE: This diagram is for reference only. It may not be accurate for all machines covered by this manual. The wiring diagram specific to your code is pasted inside one of the enclosure panels of your machine.
POWERARC® 5500
Page 93
S26829
ENGINE WIRING
MAG
SWITCH
RUN/
ST
OP
WIRING DIAGRAM - POWER ARC 5500
A
SWITCH
LOW OIL
MODULE
GROUND
BRAC
KET
STATOR E
ND
20
1B
(+)
973
5
6
GND-C
2
GND-D
W1
W2
W1A
REACTOR
1
L1
OUTPU
TSTU
DS
6543
STAT
OR
100W
3.3
Ohms
R1
6C
5A
5B
5B
6A
3A
5A
2
0A
7A
9A
202
20
2B
200
200A
202
205
D2
ELECTRICAL SYMBOLS PER E1537.
GND-A
GND
-B
3B
6B
C
B1
20
1B
3C
201
20
1A
A
CCW
600 µ FD
7A
20
2A
9A
(-)
(+)
(-)
(+)
R
OTOR
C1
D1
N
OTE:
ALL C
ASE FRONTCOMP
ONE
NTS S
HOWN
VIE
WED FR
OMREA
R.
3B
20
2B
3C
G-3
WIRING DIAGRAM - CODES 11403, 11405 (S26829)
ELECTRICAL DIAGRAMS
G-3
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
NOTE: This diagram is for reference only. It may not be accurate for all machines covered by this manual. The wiring diagram specific to your code is pasted inside one of the enclosure panels of your machine.
POWERARC® 5500
Page 94
A
S26830
D1
C1
R
OTOR
(+)
(-)
(+)
(-)
EN
GINEWIRING
M
AG
SWITCH
9A
20
2A
7A
600 µ FD
CCW
A
20
1A
201
RUN/STO
P
3C
20
1B
6B
3B
GND
-B
GND
-A
WIRING DIAGRA
M -
POWER 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
56
OUTPU
TSTU
DS
L1
1
04/02/200
7
W1A
W2
W1
GND-D
2
GND-C
6
5
379
(+)
LOWOIL
P
ROTECTION
SWITCH
(IF IN
STALLE
D)
TAC
HOM
ETE
R/
HO
URM
ETE
R
203
WR
AP A
ROUND
SPARK PLUGWIRE
FOUR TIMES
20
1B
GROUND
BRAC
KET
STATOR E
ND
ELECTRICAL SYMBOLS PER E1537.
N
OTE:
C
ASE FRONTCOMP
ONE
NTS S
HOWN
VIE
WED FR
OMREA
R
20
2B
3C
3B
2
0A
C
B1
3A
6A
5A
G-4
WIRING DIAGRAM - CODE 11404 (S26830)
ELECTRICAL DIAGRAMS
G-4
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
NOTE: This diagram is for reference only. It may not be accurate for all machines covered by this manual. The wiring diagram specific to your code is pasted inside one of the enclosure panels of your machine.
POWERARC® 5500
Page 95
A
S26023
D1
C1
R
OTOR
(+)
(-)
(+)
(-)
EN
GINEWIRING
M
AG
SWITCH
9A
20
2A
7A
600 µ FD
CCW
A
20
1A
201
RUN/STO
P
3C
20
1B
C
B2
C
B1
6B
3B
GND
-B
GND
-A
WIRING DIAGRA
M -
POWER 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
100W
W
STAT
OR
3
4
56
OUTPU
TSTU
DS
L1
1
04/26/200
6
W1A
W2
W1
GND-D
2
GND-C
6
5
379
(+)
LOWOIL
P
ROTECTION
SWITCH
(IF IN
STALLE
D)
TAC
HOM
ETE
R/
HO
URM
ETE
R
203
WR
AP A
ROUND
SPARK PLUGWIRE
FOUR TIMES
20
1B
GROUND
BRAC
KET
STATOR E
ND
ELECTRICAL SYMBOLS PER E1537.
N
OTE:
C
ASE FRONTCOMP
ONE
NTS S
HOWN
VE
IWED FR
OMREA
R
20
2B
3C
3B
G-5
WIRING DIAGRAM - CODE 11215 (S26023)
ELECTRICAL DIAGRAMS
G-5
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
NOTE: This diagram is for reference only. It may not be accurate for all machines covered by this manual. The wiring diagram specific to your code is pasted inside one of the enclosure panels of your machine.
POWERARC® 5500
Page 96
S26008
POWER ARC
5500
MACHINESCHEM
AT
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NONE
S21455
MAP
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MMUNICATED
TOOTHER P
ARTIES OR USED FOR ANYPURPOS
EWI
THO
UT THEEXPRE
SS W
RITTENPERMISS
ION OF LINCOL
N GLOBAL,INC.
PROPRIETA RY & CONFIDENTIAL:
08/25/20
04
WITHPUBLISHEDSTANDARDS.
MAT
ERIAL T
OLERANCE(" ")
TOAGREE
ON
ALL AN
GLES IS ± .5OF ADEG
REE
t
ON 3PLACE DE
CIMALSIS
± .0
02
ON
2 PLACE DEC
IMALS IS ±
.02
U
NLESSOTHERWI
SE SPECIF
IED TOLE
RANCE:
MAN
UFACTURING
TOLERAN
CE PER E2056
CHANGED
ETA
IL:
REFERENC
E:
MA
TERIAL
DISPOSITION:
APPROVAL
D
ATE
:
PR
OJECT
N
UMBE
R:
DOC
UME
NT
N
UMBE
R:
DOC
UME
NT
R
EVISION:
S26008
EXCITER
WINDING
7
9
7
9
A
C
A
C
(+
)
(-)
+
RHEOSTAT
N/C
N/C
REVOLVING FIELDS
(ROTOR)
7 OHMS @ 75
vF
9 OHMS @ OPERATING
TEMPERATURE
CW
40 TO 45
VDC
MAX
RHEOSTAT
AUX.
POWER
WINDING
3
6
3
6
5
6 CAVITY
CONNECTOR
STATOR
END
BRKT.
GROUND
OIL LEVEL
SWITCH
CB2
20
A
CB1
20
A
130 VAC@ MAX
RHEOSTAT/
NO L
OAD
130 VAC
@ MAX
RHEOSTAT/
NO L
OAD
WELD
WINDING
W1
W2
60 VAC
@MAX
RHEOSTAT/
NO LOAD
60 VAC
@MAX
RHEOSTAT/
NO LOAD
L1 - REACTOR
STATOR
A
C
A
C
(
+
)
(
-
)
5
RECP PANELGND STUD
2
WELD OUTPUT
STUDS
J1 240V
20A
35 VAC
MAX
RHEOSTAT
MODULE
(OIL L
EVE
L)
ENGINE
MAGNE
TO
IGN
ITIO
N
N/C N/C
Y
Y/R
B/Y
BO
STOP RUN
SPARK
PLUG
205
FL
ASH FROM
ENGINE
M
AGNE
TO
B = BLACK Y = YELLOW
O = ORANGE Y/R = YELLOW/RED STRIPE
N/C = NO CONNECTION B/Y = BLACK/YELLOW STRIPE
GND-C GND-D
MAX RHEOSTAT FIELD AMPS =
5.75 TO 6.0 @ 75 deg F
4.25 TO 4.5 @ OPERATING
TEMPERATURE
FLASHING AMPS TO ROTOR WITH GENERATOR
LEAD 7 DICONNECTED AND ENGINE RUNNING
AT 3700 RPM = 0.15 TO 0.25 AMPS
Located on top
of engi ne
blow
er
housi ng.
Locat ed inside engi ne blow
er
housing.
Mounted t o si de
of engine bl ock
below
r
un/stop
switch.
Locat ed inside engi ne c
ra
nkcase.
Locat ed inside encl os
ur
e on top of generator.
Receptacl es l ocated on con
tr
ol panel.
C
ir
cuitbreakers l ocated
und
er
neath control
panel bel ow
r
ecept acles
Connect
or
located i nside
enclos
ur
eat
top of
gen
erator
.
Rheostat l ocated
on con
tr
ol panel.
Excitation
r
ectifierlocated in
enclos
ur
e on sheet metal at
top of gen
eratornear
bearing end.
Flashi ng
r
ectifierand
filt
er
capacit
or
loc ated i n encl osure
behind con
tr
ol panel
in molded pl astic
mounti ng
br
acket.
3.3 Ohms/ 100 Watt
600 uf
IF OIL LEVEL IS TOO LOW OIL LEVEL
SWITCH CLOSES GROUNDING
ENGINE MAGNETO VIA OIL LEVEL
MODULE PREVENTING ENGINE
FROM STARTING OR RUNNING.
SWITCH
(ON SOME MODELS)
HOURMETER/
TACHOMETER
If equipped ,
ho
ur
met
er
/t achomet
er
located
on con
tr
ol
panel.
Hourmeteris powered by an internal no
n-r
eplaceable battery.
RPM and
r
unning time is measured by detectorwirewrapped
ar
ound the sparkplug wire.Meterdisplays RPM while engine
is
r
unning, and accumulated engine running hours when
engine is stopped. S
er
vice engine message is reset by
passing a magnet ac
ro
ss thefront of the meterdisplay.
G-6
ENHANCED DIAGRAM
SCHEMATIC -CODES 11182, 11187, 11329 (S26008)
ELECTRICAL DIAGRAMS
G-6
Return to Master TOC Return to Master TOC Return to Master TOC Return to Master TOC
Return to Section TOC Return to Section TOC Return to Section TOC Return to Section TOC
NOTE: This diagram is for reference only. It may not be accurate for all machines covered by this manual.
POWERARC® 5500
Page 97
S26881
POWER ARC
5500
(SUBARU ROBIN)
MACHIN
E
SCHEM
AT
IC
NONE
S26008
MAP
DJS
-
DO NOTSCAL
E THISDRAWING
D
RAWNBY:
DESIG
NINFORMATION
ENGI
NEER
:
APPROVE
D:
EQ
UIPMENT TYPE:
SUBJECT:
SC
ALE
:
NA
CR
M38
121
1
PAGE ___ OF __
_
1
ENGINEE
RINGCO
NTROLL
ED
MANUF
ACTURER:
No
NE
W
A
THISDOCUMENT CO
NTAINS
PROPRIETARYINFORMATION OWNE
D BYLIN
COL
N GLOBAL,IN
C. ANDMAY NOT BE D
UPLICAT
ED, CO
MMUNICATED
TOOTHER P
ARTIES OR USED FOR ANYPURPOS
EWI
THO
UT THE EXPRE
SS W
RITTENPERMISS
ION OF LINCOL
N GLOBAL,INC.
PROPRIETA RY & CONFIDENTIAL:
11/09/20
06
WITHPUBLISHEDSTANDARDS.
MAT
ERIAL T
OLERANCE(" ")
TOAGREE
ON
ALL AN
GLES IS ± .5OF ADEG
REE
t
ON 3PLACE DE
CIMALSIS
± .0
02
ON
2 PLACEDEC
IMALS IS ±
.02
U
NLESSOTHERWI
SE SPECIF
IED TOLE
RANCE:
MAN
UFACTURING
TOLERAN
CE PER E2056
CHANGED
ETA
IL:
REFERENC
E:
MA
TERIAL
DISPOSITION:
APPROVAL
D
ATE
:
PR
OJECT
N
UMBE
R:
DOC
UME
NT
N
UMBE
R:
DOC
UME
NT
R
EVISION:
S26881
EXCITER
WINDING
7
9
7
9
A
C
A
C
(+
)
(-)
+
RHEOSTAT
N/C
N/C
REVOLVING FIELDS
(ROTOR)
7 OHMS @ 75
vF
9 OHMS @ OPERATING
TEMPERATURE
CW
40 TO 45
VDC
MAX
RHEOSTAT
AUX.
POWER
WINDING
3
6
3
6
5
6 CAVITY
CONNECTOR
STATOR
END
BRKT.
GROUND
OIL LEVEL
SWITCH
CB1
20
A
130 VAC@ MAX
RHEOSTAT/
NO L
OAD
130 VAC
@ MAX
RHEOSTAT/
NO L
OAD
WELD
WINDING
W1
W2
60 VAC
@MAX
RHEOSTAT/
NO LOAD
60 VAC
@MAX
RHEOSTAT/
NO LOAD
L1 - REACTOR
STATOR
A
C
A
C
(
+
)
(
-
)
5
RECP PANELGND STUD
2
WELD OUTPUT
STUDS
J1 240V
20A
35 VAC
MAX
RHEOSTAT
MODULE
(OIL L
EVE
L)
ENGINE
MAGNE
TO
IGN
ITIO
N
N/C N/C
Y
Y/R
B/Y
BO
STOP RUN
SPARK
PLUG
205
FL
ASH FROM
ENGINE
M
AGNE
TO
B = BLACK Y = YELLOW
O = ORANGE Y/R = YELLOW/RED STRIPE
N/C = NO CONNECTION B/Y = BLACK/YELLOW STRIPE
GND-C GND-D
MAX RHEOSTAT FIELD AMPS =
5.75 TO 6.0 @ 75 deg F
4.25 TO 4.5 @ OPERATING
TEMPERATURE
FLASHING AMPS TO ROTOR WITH GENERATOR
LEAD 7 DICONNECTED AND ENGINE RUNNING
AT 3700 RPM = 0.15 TO 0.25 AMPS
Located on top
of engi ne
blow
er
housi ng.
Locat ed inside engi ne blow
er
housing.
Mounted t o si de
of engine bl ock
below
r
un/stop
switch.
Locat ed inside engi ne c
ra
nkcase.
Locat ed inside encl os
ur
e on top of generator.
Receptacl es l ocated on con
tr
ol panel.
C
ir
cuitbreakers l ocated
und
er
neath control panel bel ow recept acles
Connect
or
located i nside
enclos
ur
eat
top of
gen
erator
.
Rheostat l ocated
on con
tr
ol panel.
Excitation
r
ectifierlocated in
enclos
ur
e on sheet metal at
top of gen
eratornear
bearing end.
Flashi ng
r
ectifierand
filt
er
capacit
or
loc ated i n encl osure
behind con
tr
ol panel
in molded pl astic
mounti ng
br
acket.
3.3 Ohms/ 100 Watt
600 uf
IF OIL LEVEL IS TOO LOW OIL LEVEL
SWITCH CLOSES GROUNDING
ENGINE MAGNETO VIA OIL LEVEL
MODULE PREVENTING ENGINE
FROM STARTING OR RUNNING.
SWITCH
G-7
ENHANCED DIAGRAM
SCHEMATIC - CODES 11403, 11405 (S26881)
ELECTRICAL DIAGRAMS
G-7
Return to Master TOC Return to Master TOC Return to Master TOC Return to Master TOC
Return to Section TOC Return to Section TOC Return to Section TOC Return to Section TOC
NOTE: This diagram is for reference only. It may not be accurate for all machines covered by this manual.
POWERARC® 5500
Page 98
S26882
POWER ARC
5500
(HONDA)
MACHIN
E
SCHEM
AT
IC
NONE
S26008
MAP
DJS
-
DO NOTSCAL
E THISDRAWING
D
RAWNBY:
DESIG
NINFORMATION
ENGI
NEER
:
APPROVE
D:
EQ
UIPMENT TYPE:
SUBJECT:
SC
ALE
:
NA
CR
M38
121
1
PAGE ___ OF __
_
1
ENGINEE
RINGCO
NTROLL
ED
MANUF
ACTURER:
No
NE
W
A
THISDOCUMENT CO
NTAINS
PROPRIETARYINFORMATION OWNE
D BYLIN
COL
N GLOBAL,IN
C. ANDMAY NOT BE D
UPLICAT
ED, CO
MMUNICATED
TOOTHER P
ARTIES OR USED FOR ANY PURPOS
EWI
THO
UT THEEXPRE
SS W
RITTENPERMISS
ION OF LINCOL
N GLOBAL,INC.
PROPRIETA RY & CONFIDENTIAL:
11/13/20
06
WITHPUBLISHEDSTANDARDS.
MAT
ERIAL T
OLERANCE(" ")
TOAGREE
ON
ALL AN
GLES IS ±.5OF ADEG
REE
t
ON 3PLACE DE
CIMALSIS
± .0
02
ON
2 PLACEDEC
IMALS IS ±
.02
U
NLESSOTHERWI
SE SPECIF
IED TOLE
RANCE:
MAN
UFACTURING
TOLERAN
CE PER E2056
CHANGED
ETA
IL:
REFERENC
E:
MA
TERIAL
DISPOSITION:
APPROVAL
D
ATE
:
PR
OJECT
N
UMBE
R:
DOC
UME
NT
N
UMBE
R:
DOC
UME
NT
R
EVISION:
S26882
EXCITER
WINDING
7
9
7
9
A
C
A
C
(+
)
(-)
+
RHEOSTAT
N/C
N/C
REVOLVING FIELDS
(ROTOR)
7 OHMS @ 75
vF
9 OHMS @ OPERATING
TEMPERATURE
CW
40 TO 45
VDC
MAX
RHEOSTAT
AUX.
POWER
WINDING
3
6
3
6
5
6 CAVITY
CONNECTOR
STATOR
END
BRKT.
GROUND
OIL LEVEL
SWITCH
CB2
20
A
CB1
20
A
130 VAC@ MAX
RHEOSTAT/
NO L
OAD
130 VAC
@ MAX
RHEOSTAT/
NO L
OAD
WELD
WINDING
W1
W2
60 VAC
@MAX
RHEOSTAT/
NO LOAD
60 VAC
@MAX
RHEOSTAT/
NO LOAD
L1 - REACTOR
STATOR
A
C
A
C
(
+
)
(
-
)
5
RECP PANELGND STUD
2
WELD OUTPUT
STUDS
J1 240V
20A
35 VAC
MAX
RHEOSTAT
ENGINE
MAGNE
TO
IGN
ITIO
N
STOP RUN
SPARK
PLUG
205
FL
ASH FROM
ENGINE
M
AGNE
TO
GND-C GND-D
MAX RHEOSTAT FIELD AMPS =
5.75 TO 6.0 @ 75 deg F
4.25 TO 4.5 @ OPERATING
TEMPERATURE
FLASHING AMPS TO ROTOR WITH GENERATOR
LEAD 7 DICONNECTED AND ENGINE RUNNING
AT 3700 RPM = 0.15 TO 0.25 AMPS
Located on top
of engi ne
blow
er
housi ng.
Locat ed inside engi ne blow
er
housing.
Mounted t o si de
of engine bl ock
below
r
un/stop
switch.
Locat ed inside engi ne c
ra
nkcase.
Locat ed inside encl os
ur
e on top of generator.
Receptacl es l ocated on con
tr
ol panel.
C
ir
cuitbreakers l ocated
und
er
neath control
panel bel ow
r
ecept acles
Connect
or
located i nside
enclos
ur
eat
top of
gen
erator
.
Rheostat l ocated
on con
tr
ol panel.
Excitation
r
ectifierlocated in
enclos
ur
e on sheet metal at
top of gen
eratornear
bearing end.
Flashi ng
r
ectifierand
filt
er
capacit
or
loc ated i n encl osure
behind con
tr
ol panel
in molded pl astic
mounti ng
br
acket.
3.3 Ohms/ 100 Watt
600 uf
IF OIL LEVEL IS TOO LOW OIL LEVEL
SWITCH CLOSES GROUNDING
ENGINE MAGNETO VIA OIL LEVEL
MODULE PREVENTING ENGINE
FROM STARTING OR RUNNING.
SWITCH
HOURMETER/
TACHOMETER
If equipped ,
ho
ur
met
er
/t achomet
er
located
on con
tr
ol
panel.
Hourmeteris powered by an internal no
n-r
eplaceable battery.
RPM and
r
unning time is measured by detectorwirewrapped
ar
ound the sparkplug wire. Meterdisplays RPM while engine
is
r
unning, and accumulated engine running hourswhen
engine is stopped. S
er
vice engine message is reset by
passing a magnet ac
ro
ss thefront of the meterdisplay.
G-8
ENHANCED DIAGRAM
SCHEMATIC - CODE 11404 (S26882)
ELECTRICAL DIAGRAMS
G-8
Return to Master TOC Return to Master TOC Return to Master TOC Return to Master TOC
Return to Section TOC Return to Section TOC Return to Section TOC Return to Section TOC
NOTE: This diagram is for reference only. It may not be accurate for all machines covered by this manual.
POWERARC® 5500
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