Page 2 - SAFETY; WARNING; CALIFORNIA PROPOSITION 65 WARNINGS; The Above For Diesel Engines
FOR ENGINEpowered 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 fumesoutdoors. ...
Page 3 - ii
ii SAFETY ii ARC RAYS can burn. 4.a. Use a shield with the proper filter and cover plates to protect your eyes from sparks andthe rays of the arc when welding or observingopen arc welding. Headshield and filter lensshould conform to ANSI Z87. I standards. 4.b. Use suitable clothing made from durable...
Page 4 - iii
FOR ELECTRICALLYpowered equipment. 8.a. Turn off input power using the disconnect switch at the fuse box before working onthe equipment. 8.b. Install equipment in accordance with the U.S. National Electrical Code, all local codes and the manufacturer srecommendations. 8.c. Ground the equipment in ac...
Page 5 - iv; PRÉCAUTIONS DE SÛRETÉ
iv SAFETY iv Mar. 93 PRÉCAUTIONS DE SÛRETÉ Pour votre propre protection lire et observer toutes les instruc- tions et les précautions de sûreté specifiques qui parraissent d a n s c e m a n u e l a u s s i b i e n q u e l e s p r é c a u t i o n s d e s û r e t é générales suivantes: Sûreté Pour Sou...
Page 6 - Please Examine Carton and Equipment For Damage Immediately
v v Thank Y You for selecting a QUALITY product by Lincoln Electric. We want you to take pride in operating this Lincoln Electric Company product••• as much pride as we have in bringing this product to you! Read this Operators Manual completely before attempting to use this equipment. Save this manu...
Page 7 - TABLE OF CONTENTS
Page Safety .................................................................................................................................................i-iv Install ation ...............................................................................................................................
Page 8 - INSTALLATION; INPUT - GASOLINE ENGINE
TECHNICAL SPECIFICATIONS - POWER-ARC 5500 Manufacturer Description Speed Displacement Ignition Capacities Robin / Subaru 1 cyl., 3700 RPM 16.17 cu. in. Manual, Fuel: 1.6 gal. (6.1 l) EX 27 4 cycle ± 50 RPM (265 cc) Recoil start; Codes air-cooled at no load Manual choke Oil: 1.1 qts.(1.0 l) (11182) O...
Page 9 - SAFETY PRECAUTIONS; ELECTRIC SHOCK can kill.; LOCATION AND VENTILATION; STORING
A-2 INSTALLATION POWER-ARC 5500 A-2 SAFETY PRECAUTIONS Read this entire installation section before youstart installation. D o n no t a a t t e m pt tt o u us e tt h i s e e q ui pm e n t u un t i l y y o u have tthor oughly rr ead a all tthe o operatio n a and m m ain- t e n a n c e m m a n u a l s...
Page 10 - PRE-OPERATION ENGINE SERVICE; FUEL; • Do not leave unattended while; GASOLINE FUEL ONLY
A-3 INSTALLATION POWER-ARC 5500 A-3 STACKING POWER-ARC 5500 machines CANNOT be stacked. TILTING Place the machine on a secure, level surface whenev-er you use it or store it. Any surfaces you place it onother than the ground must be firm, non-skid, andstructurally sound. The gasoline engine is desig...
Page 11 - Honda 9 HP; SPARK ARRESTER; MUFFLER DEFLECTOR; CAUTION; PowerArc 5500 Typical Fuel Consumption
No Load3700 RPM ±50 R.P.M.AC CC Weld Output125 Amps @ 20 VoltsAC CC Weld Output100 Amps @ 25 VoltsAuxiliary Power 4000Watts (120/240 Volts) Robin / Subaru 9 HP Carb. Certified EX 27 0.31 Gallons/Hour (1.17 Liters/Hour) .70 Gallons/Hour (2.66 Liters/Hour) .66 Gallons/Hour (2.48 Liters/Hour) .68 Gallo...
Page 12 - WELDING CABLE CONNECTIONS; Cable Size and Length; POWER-ARC 5500 OUTPUT CONNECTIONS
A-5 INSTALLATION POWER-ARC 5500 A-5 ELECTRICAL OUTPUT CONNECTIONS See Figure A.1 for the location of the current controld i a l , w e l d o u t p u t t e r m i n a l s , g r o u n d s t u d , c i r c u i tbreakers, 240 and 120 volt receptacles. WELDING CABLE CONNECTIONS Cable Size and Length Be sure...
Page 13 - Cable Installation; MACHINE GROUNDING
A-6 INSTALLATION POWER-ARC 5500 A-6 Cable Installation Install the welding cables to your POWER-ARC 5500as follows. See Figure A.1 for the location of parts. 1. The gasoline engine must be OFF to install weld-ing cables. 2. Remove the 1/2 - 13 flanged nuts from the outputterminals. 3. Connect the el...
Page 14 - PREMISES WIRING
A-7 INSTALLATION POWER-ARC 5500 A-7 PREMISES WIRING The POWER-ARC 5500 three-wire, grounded neutralg e n e r a t o r a l l o w s i t t o b e c o n n e c t e d t o p r e m i s e swiring. However, the wiring procedure needed tomeet the National Electrical Code (NEC) regulationsas well as city ordinanc...
Page 15 - ELECTRICAL DEVICE USE WITH THE POWER-ARC 5500.
A-8 INSTALLATION POWER-ARC 5500 A-8 CAUTION Certain Electrical devices cannot be powered by the POWER-ARC 5500. See Table A.2. TABLE A.2 ELECTRICAL DEVICE USE WITH THE POWER-ARC 5500. Type Common Electrical Devices Possible Concerns Resistive Heaters, toasters, incandescent NONE light bulbs, electri...
Page 16 - OPERATION; SAFETY INSTRUCTIONS; Only q; GENERAL DESCRIPTION; GENERATOR; WELDING CAPABILITY
B-1 OPERATION B-1 SAFETY INSTRUCTIONS Read and understand this entire section before oper-ating your POWER-ARC 5500. D o n no t a a t t e m pt tt o u us e tt h i s e e q ui pm e n t u un t i l y y o u have tthor oughly rr ead a all tthe o operatio n a and m m ain- t e n a n c e m m a n u a l s s s u...
Page 17 - LIMITATIONS; • The POWER-ARC 5500 is not recommended for; CONTROLS AND SETTINGS; GENERATOR/WELDER CONTROLS; OUTPUT PANEL CONTROLS
B-2 OPERATION B-2 LIMITATIONS • The POWER-ARC 5500 is not recommended for any processes besides those that are normally per-formed using stick welding (SMAW) procedures. • The POWER-ARC 5500 is not recommended for pipe thawing. • During welding, generator power is limited to 100 watts, and output vo...
Page 18 - GASOLINE ENGINE CONTROLS; ENGINE OPERATION
B-3 OPERATION B-3 POWER-ARC 5500 4. WELD OUTPUT TERMINAL (TO WORK) WITH 1/2- 13 FLANGE NUT: Provides the connection pointfor either the electrode holder or the work cable.(Because the POWER-ARC 5500 is an AC outputmachine, either output terminal can be used foreither cable.) 5. GROUND STUD: Provides...
Page 19 - FOR BEST ENGINE STARTING:; BEFORE STARTING THE ENGINE; CHECK AND FILL THE ENGINE OIL LEVEL:; STARTING THE ENGINE
4. Pull the cord rapidly. 5. I f t h e e n g i n e d o e s n o t s t a r t , o p e n t h e c h o k eslightly and pull the starter cord rapidly again. When the engine starts, gradually open the choketo the “RUN” position. To open the choke fullyrequires an engine warm-up period of severalseconds to s...
Page 20 - GENERATOR OPERATION; GENERAL INFORMATION; STOPPING THE ENGINE
GENERATOR OPERATION B Be s sur e tthat a any e electri cal e equipm ent p plugged ii nt o t he g g ene ra to r ’s A A C p po w er rr ece pta cl es c ca n w w i t h- st and a a ± ±10% v vol tage a and a a ± ±4% ff requency v vari a- tio n. S Som e e electr onic d devices c cannot b be p po wer ed b y...
Page 21 - GENERATOR POWER APPLICATIONS
TABLE B.3 GENERATOR POWER APPLICATIONS S Sugg es ted P Po wer A Appli cations R Runni ng W Watts * Star t-up W Watts (Co nt inuo us ) ((Sur ge) *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...
Page 22 - WELDING OPERATION; Welding current is continuously variable
B-7 OPERATION B-7 WELDING OPERATION GENERAL INFORMATION ELECTRIC SHOCK can kill. • D D o n no t tto uc h e e le ct r ic al ly ll iv e p pa r ts o or el ectro des w wi th y your s s k in o o r w w et c cl oth- ing. • IInsulate y your self ffr om tthe w w or k a and g g ro und. • A A lways w wear d dr...
Page 23 - Stick Welding; WELDING GUIDELINES; WELDING APPLICATIONS/ELECTRODE SELECTION GUIDE; Learning To Stick Weld
Stick welding is probably the most familiar weldingprocess known. A coated ELECTRODE, the weld rod,is clamped into an ELECTRODE HOLDER, an insulat-ed clamping device, which in turn connects to theELECTRODE CABLE, a heavy wire. The WORK, themetal piece to be welded, is connected to the WORKC A B L E ...
Page 24 - What Happens in the Arc?
B-9 OPERATION B-9 POWER-ARC 5500 No one can learn to weld simply by reading about it.Skill comes only with practice. The following pageswill help the inexperienced welder understand weldingand develop his skill. For more detailed information,o r d e r a c o p y o f t h e b o o k “ N e w L e s s o n ...
Page 25 - W i t h o u t; The Correct Welding Position; Figure 5; side view; The Correct Way to Strike An Arc; Molten puddle
B-10 OPERATION B-10 POWER-ARC 5500 The function of the covered electrode is much morethan simply to carry current to the arc. The electrodeis composed of a core metal wire around which hasbeen extruded and baked a chemical covering. Thecore wire melts into the arc and tiny droplets of moltenmetal sh...
Page 26 - PRACTICE; is to spend a little more time on the following exercise.; Common Metals; Butt Joints
B-11 OPERATION B-11 POWER-ARC 5500 PRACTICE The best way of getting practice in the four skills thatenable 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...
Page 27 - Penetration; Good
B-12 OPERATION B-12 POWER-ARC 5500 Now weld the two plates together. Weld from left toright (if right-handed). Point the electrode down in hegap between the two plates, keeping the electrodesslightly tilted in the direction of travel. Watch the molten metal to be sure it distributes itselfevenly on ...
Page 28 - Vertical-Down Welding
B-13 OPERATION B-13 POWER-ARC 5500 Vertical-Up Welding The problem, when welding vertical-up, is to put themolten metal where it is wanted and make it staythere. If too much molten metal is deposited, gravitywill pull it downwards and make it “drip”. Therefore, acertain technique has to be followed:...
Page 29 - Overhead Welding; Side View
B-14 OPERATION B-14 POWER-ARC 5500 Overhead Welding Various techniques are used for overhead welding.However, in the interest of simplicity for the inexperi-enced welder, the following technique will probablytake care of his needs for overhead welding: 1. Use 1/8” (3.2mm) 90-105 A or 3/32” (2.5mm) 7...
Page 30 - The bead should be put on with a weaving motion,; Welding Cast Iron; that spot again until the weld is cool.; Cast Iron Plate Preparation; hot
B-15 OPERATION B-15 POWER-ARC 5500 4. The bead should be put on with a weaving motion, and it should be 1/2-3/4” (12.7-19.0mm) wide. Donot let the arc blow over the edge, as that will dullthe edge. (See drawing below.) 5. Use the back-stepping method. Begin to weld 3” (76mm) from the heel of the sha...
Page 31 - Selecting Electrodes; Motions
B-16 OPERATION B-16 POWER-ARC 5500 High-Speed Group (AWS E6013) This group includes electrodes which have a moder-ately forceful arc and deposit rates between those ofthe out-of-position and high-deposit electrodes. They are primarily general purpose production elec-trodes especially for downhill fi...
Page 32 - ACCESSORIES; LINCOLN ELECTRIC ACCESSORIES
C-1 ACCESSORIES C-1 OPTIONS/ACCESSORIES LINCOLN ELECTRIC ACCESSORIES The following options/accessories are available fory o u r P O W E R - A R C 5 5 0 0 f r o m y o u r l o c a l L i n c o l nDistributor. Acces so ry K K it ((K 875) – Includes the following: • T w e n t y f e e t ( 6 . 1 m e t e r ...
Page 33 - MAINTENANCE; ENGINE MAINTENANCE
D-1 MAINTENANCE D-1 POWER-ARC 5500 SAFETY PRECAUTIONS • H H a v e q qu a l i f i e d p p e r s o n n e l d d o a a l l m m a i n t e n a n c e and ttr oubl eshoo ting w w or k . • T T u r n tt he e e n g i ne o o f f b b ef o r e w w o r k i n g ii ns i de tt he m achine. • R R e m o v e g g u a r d...
Page 34 - ENGINE ADJUSTMENTS
D-2 MAINTENANCE D-2 FUEL: At the end of each day’s use, refill the fuel tank to minimize moisture conden-sation and dirt contamination in the fuel line. ENGINE ADJUSTMENTS O V E R S P E E D I S H A Z A R D O U S - T h e m a x i m u mallowable high idle speed for this machine is 3750RPM, no load. DO ...
Page 35 - Part; ENGINE MAINTENANCE PARTS
D-3 MAINTENANCE D-3 POWER-ARC 5500 Refer to Table D.1 for engine maintenance parts. The part numbers are accurate at the time of printing. (Verifythe 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...
Page 36 - GENERATOR/WELDER MAINTENANCE
D-4 MAINTENANCE D-4 POWER-ARC 5500 GENERATOR/WELDER MAINTENANCE ST ORAGE: Store the POWER-ARC 5500 in clean,dry, protected areas. CL EA N ING: Blow out the generator and controlsperiodically with low pressure air. Do this at leastonce a week in particularly dirty areas. B R U S H R R E M O V A L A A...
Page 38 - TROUBLESHOOTING; Local Lincoln Authorized Field Service Facility; for technical troubleshooting assistance before you proceed.; Step 3. RECOMMENDED COURSE OF ACTION; HOW TO USE TROUBLESHOOTING GUIDE
POWER-ARC 5500 E-1 TROUBLESHOOTING E-1 If for any reason you do not understand the test procedures or are unable to perform the tests/repairs safely, contact your Local Lincoln Authorized Field Service Facility for technical troubleshooting assistance before you proceed. CAUTION This Troubleshooting...
Page 39 - Observe all Safety Guidelines detailed throughout this manual; PROBLEMS
E-2 TROUBLESHOOTING E-2 POWER-ARC 5500 Observe all Safety Guidelines detailed throughout this manual If for any reason you do not understand the test procedures or are unable to perform the tests/repairs safely, contact your Local Lincoln Authorized Field Service Facility for technical troubleshooti...
Page 42 - DIAGRAMS; Enhanced Diagram
F-1 DIAGRAMS F-1 POWER-ARC 5500 NOTE: This diagram is for reference only. It may not be accurate for all machines covered by this manual. The specific diag ram for a particular code is pasted inside the machine on one of the enclosure panels. If the diagram is illegible, write to the Service Departm...
Page 46 - DIMENSION PRINT POWER ARC 5500
F-5 DIAGRAMS F-5 POWER-ARC 5500 M 17196 A. 0 1 R EL EC TR IC LI N C O L N 20. 00 20. 88 7. 92 14. 16 30. 00 DIMENSION PRINT POWER ARC 5500
Page 47 - NOTES
Lincoln Electric 305G
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Lincoln Electric IM646-A
Manual
Lincoln Electric 309
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Lincoln Electric MB232
Manual
Lincoln Electric IM889-A
Manual
Lincoln Electric AC-1200
Manual
Lincoln Electric L12810-6
Manual
Lincoln Electric S350
Manual
Lincoln Electric 248HO
Manual
Lincoln Electric IM794
Manual
Lincoln Electric 350
Manual
Lincoln Electric IM690-A
Manual
Lincoln Electric 300 D
Manual
Lincoln Electric TIG 175 PRO
Manual
Lincoln Electric SVM103-A
Manual
Lincoln Electric IM834-B
Manual
Lincoln Electric LA-17
Manual
Lincoln Electric IM972
Manual
Lincoln Electric 250LX
Manual