Page 2 - SAFETY; PERFORMED ONLY BY QUALIFIED INDIVIDUALS.; WARNING; ELECTRIC AND; CALIFORNIA PROPOSITION 65 WARNINGS; The Above For Diesel Engines
POWERARC® 5500 SAFETY i i 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 engin...
Page 3 - ii; FUMES AND GASES
SAFETY ii ii POWERARC® 5500 FUMES AND GASES can be dangerous. 5.a. Welding may produce fumes and gases hazardous to health. Avoid breathing these fumes and gases.When welding, keep your head out of the fume. Use enough ventilation and/or exhaust at the arc to keep fumes and gases away from the breat...
Page 4 - iii; CYLINDER may explode; Refer to
SAFETY iii iii POWERARC® 5500 Jan ‘09 FOR ELECTRICALLYpowered 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 recommen...
Page 5 - iv; PRÉCAUTIONS DE SÛRETÉ; PRÉCAUTIONS DE SÛRETÉ POUR
SAFETY iv iv POWERARC® 5500 Mar ‘93 PRÉCAUTIONS DE SÛRETÉ Pour votre propre protection lire et observer toutes les instructions et les précautions de sûreté specifiques qui parraissent dans ce manuel aussi bien que les précautions de sûreté générales suiv- antes: Sûreté Pour Soudage A L’Arc 1. Prote...
Page 8 - - MASTER TABLE OF CONTENTS FOR ALL SECTIONS -; Operation
- MASTER TABLE OF CONTENTS FOR ALL SECTIONS - I I POWERARC® 5500 Page Safety . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .i-iv Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . ...
Page 9 - TABLE OF CONTENTS - INSTALLATION SECTION
TABLE OF CONTENTS - INSTALLATION SECTION A-1 A-1 POWERARC® 5500 Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .A-1 Technical Specifications . . . . . . . . . . . . . . . . . . . . ....
Page 10 - INPUT - GASOLINE ENGINE; INSTALLATION
TECHNICAL SPECIFICATIONS - POWERARC® 5500 Manufacturer Description Speed Displacement Ignition Capacities Robin / Subaru 1 cyl., 3700 RPM 16.17 cu. in. Manual, Fuel: 1.6 gal. (6.1 l) EX 27 4 cycle ± 50 RPM (265 cc) Recoil start; Codes air-cooled at no load Manual choke Oil: 1.1 qts.(1.0 l) (11182, 1...
Page 11 - SAFETY PRECAUTIONS; Read this entire installation section before you; LOCATION AND VENTILATION; STORING
INSTALLATION A-3 A-3 POWERARC® 5500 SAFETY PRECAUTIONS Read this entire installation section before you start installation. Do not attempt to use this equipment until youhave thoroughly read all the operation and mainte-nance manuals supplied with your machine. Theyinclude important safety precautio...
Page 12 - PRE-OPERATION ENGINE SERVICE; CHECK THE OIL LEVEL; FUEL; DO NOT MIX OIL WITH THE GASO-; GASOLINE FUEL ONLY; can cause fire
INSTALLATION A-4 A-4 POWERARC® 5500 STACKING POWERARC® 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 13 - Honda 9 HP; SPARK ARRESTER; PowerArc 5500 Typical Fuel Consumption; CAUTION
INSTALLATION A-5 A-5 POWERARC® 5500 No Load 3700 RPM ±50 R.P.M. AC CC Weld Output 125 Amps @ 20 Volts AC CC Weld Output 100 Amps @ 25 Volts Auxiliary Power 4000 Watts (120/240 Volts) Robin / Subaru 9 HP Carb. Certified EX 27 0.31 Gallons/Hour (1.17 Liters/Hour) .70 Gallons/Hour (2.66 Liters/Hour) .6...
Page 14 - WELDING CABLE CONNECTIONS; Cable Size and Length; POWERARC® 5500 OUTPUT CONNECTIONS
ELECTRICAL OUTPUTCONNECTIONS See Figure A.1 for the location of the current controldial, weld output terminals, ground stud, circuit break-ers, 240 and 120 volt receptacles. WELDING CABLE CONNECTIONS Cable Size and Length Be sure to use welding cables that are large enough.The correct size and lengt...
Page 15 - Cable Installation; MACHINE GROUNDING; PLUGS AND HAND-HELD EQUIPMENT
INSTALLATION A-7 A-7 POWERARC® 5500 Cable Installation Install the welding cables to your POWERARC® 5500 as follows. See Figure A.1 for the location of parts. 1. The gasoline engine must be OFF to install weld-ing cables. 2. Remove the 1/2 - 13 flanged nuts from the outputterminals. 3. Connect the e...
Page 16 - PREMISES WIRING; • The premises is isolated and no feed backing; CIRCUIT BREAKERS
INSTALLATION A-8 A-8 POWERARC® 5500 PREMISES WIRING The POWERARC® 5500 three-wire, grounded neutralgenerator allows it to be connected to premiseswiring. However, the wiring procedure needed to meetthe National Electrical Code (NEC) regulations as wellas city ordinances and can be confusing. The con...
Page 18 - NOTES
NOTES A-10 A-10 POWERARC® 5500 Return to Section T OC Return to Section T OC Return to Section T OC Return to Section T OC Return to Master T OC Return to Master T OC Return to Master T OC Return to Master T OC
Page 19 - TABLE OF CONTENTS - OPERATION SECTION
TABLE OF CONTENTS - OPERATION SECTION B-1 B-1 POWERARC® 5500 Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .B-1 Safety Instructions . . . . . . . . . . . . . . . . . . . . . . . . . ...
Page 20 - OPERATION
OPERATION B-2 B-2 POWERARC® 5500 SAFETY INSTRUCTIONS Read and understand this entire section before oper-ating your POWERARC® 5500. Do not attempt to use this equipment until you havethoroughly read all the operation and maintenance man-uals supplied with your machine. They include impor-tant safety...
Page 21 - LIMITATIONS; CONTROLS AND SETTINGS; GENERATOR/WELDER CONTROLS; OUTPUT PANEL CONTROLS
OPERATION B-3 B-3 POWERARC® 5500 LIMITATIONS • The POWERARC® 5500 is not recommended for any processes besides those that are normally per-formed using stick welding (SMAW) procedures. • The POWERARC® 5500 is not recommended for pipe thawing. • During welding, generator power is limited to 100 watts...
Page 22 - GASOLINE ENGINE CONTROLS; ENGINE OPERATION
OPERATION B-4 B-4 POWERARC® 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 POWERARC® 5500 is an AC outputmachine, either output terminal can be used foreither cable.) 5. GROUND STUD: Provides...
Page 23 - FOR BEST ENGINE STARTING:; BEFORE STARTING THE ENGINE; CHECK AND FILL THE ENGINE OIL LEVEL:; STARTING THE ENGINE
OPERATION B-5 B-5 POWERARC® 5500 4. Pull the cord rapidly. 5. If the engine does not start, open the choke slight-ly and pull the starter cord rapidly again. When the engine starts, gradually open the choketo the “RUN” position. To open the choke fullyrequires an engine warm-up period of several sec...
Page 24 - GENERATOR OPERATION; GENERAL INFORMATION; TO USE THE POWERARC; STOPPING THE ENGINE
OPERATION B-6 B-6 POWERARC® 5500 GENERATOR OPERATION Be sure that any electrical equipment pluggedinto the generator’s AC power receptacles canwithstand a ±10% voltage and a ±4% frequencyvariation. Some electronic devices cannot bepowered by the POWERARC® 5500. Refer toTable A.2, ELECTRICAL DEVICE U...
Page 26 - WELDING OPERATION; ELECTRIC SHOCK can kill.; AFTER YOU FINISH THE WELD:; CONTROL FUNCTION / OPERATION
OPERATION B-8 B-8 POWERARC® 5500 WELDING OPERATION GENERAL INFORMATION ELECTRIC SHOCK can kill. • Do not touch electrically live parts or electrodes with your skin or wet cloth-ing. • Insulate yourself from the work and ground. • Always wear dry insulating gloves. -----------------------------------...
Page 27 - Stick Welding; Lincoln Wire Feeder / Welder; WELDING GUIDELINES; WELDING APPLICATIONS/ELECTRODE SELECTION GUIDE; Learning To Stick Weld
OPERATION B-9 B-9 POWERARC® 5500 Stick welding is probably the most familiar welding process known. A coated ELECTRODE, the weld rod, is clamped into an ELECTRODE HOLDER, an insulat- ed clamping device, which in turn connects to the ELECTRODE CABLE, a heavy wire. The WORK, the metal piece to be weld...
Page 28 - What Happens in the Arc?
OPERATION B-10 B-10 POWERARC® 5500 No one can learn to weld simply by reading about it. Skill comes only with practice. The following pages will help the inexperienced welder understand welding and develop his skill. For more detailed information, order a copy of the book “New Lessons in Arc Welding...
Page 29 - Without; The Correct Welding Position; FIGURE 5; The Correct Way to Strike An Arc
OPERATION B-11 B-11 POWERARC® 5500 The function of the covered electrode is much more than simply to carry current to the arc. The electrode is composed of a core metal wire around which has been extruded and baked a chemical covering. The core wire melts into the arc and tiny droplets of molten met...
Page 30 - PRACTICE; Common Metals; Butt Joints
OPERATION B-12 B-12 POWERARC® 5500 PRACTICE The best way of getting practice in the four skills that enable you to maintain: 1. Correct Welding Position. 2. Correct Way to Strike An Arc. 3. Correct Arc Length. 4. Correct Welding Speed. is to spend a little more time on the following exercise. Use th...
Page 31 - Penetration; Good
OPERATION B-13 B-13 POWERARC® 5500 Now weld the two plates together. Weld from left to right (if right-handed). Point the electrode down in he gap between the two plates, keeping the electrodes slightly tilted in the direction of travel. Watch the molten metal to be sure it distributes itself evenly...
Page 32 - Vertical-Down Welding
OPERATION B-14 B-14 POWERARC® 5500 Vertical-Up Welding The problem, when welding vertical-up, is to put the molten metal where it is wanted and make it stay there. If too much molten metal is deposited, gravity will pull it downwards and make it “drip”. Therefore, a certain technique has to be follo...
Page 33 - Overhead Welding; Side View
OPERATION B-15 B-15 POWERARC® 5500 Overhead Welding Various techniques are used for overhead welding. However, in the interest of simplicity for the inexperi- enced welder, the following technique will probably take care of his needs for overhead welding: 1. Use 1/8” (3.2mm) 90-105 A or 3/32” (2.5mm...
Page 34 - Welding Cast Iron; hot
OPERATION B-16 B-16 POWERARC® 5500 4. The bead should be put on with a weaving motion, and it should be 1/2-3/4” (12.7-19.0mm) wide. Do not let the arc blow over the edge, as that will dull the edge. (See drawing below.) 5. Use the back-stepping method. Begin to weld 3” (76mm) from the heel of the s...
Page 35 - Selecting Electrodes; Motions
OPERATION B-17 B-17 POWERARC® 5500 High-Speed Group (AWS E6013) This group includes electrodes which have a moder- ately forceful arc and deposit rates between those of the out-of-position and high-deposit electrodes. They are primarily general purpose production elec- trodes especially for downhill...
Page 37 - TABLE OF CONTENTS - ACCESSORIES SECTION
TABLE OF CONTENTS - ACCESSORIES SECTION C-1 C-1 POWERARC® 5500 Accessories . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .C-1 Options and Accessories . . . . . . . . . . . . . . . . . . . . . . . ...
Page 38 - ACCESSORIES; LINCOLN ELECTRIC ACCESSORIES
ACCESSORIES C-2 C-2 POWERARC® 5500 OPTIONS/ACCESSORIES LINCOLN ELECTRIC ACCESSORIES The following options/accessories are available foryour POWERARC® 5500 from your local LincolnDistributor. Accessory Kit (K875) – Includes the following: • Twenty feet (6.1 meters) of #6 AWG electrode cable with lug....
Page 39 - TABLE OF CONTENTS - MAINTENANCE SECTION
TABLE OF CONTENTS - MAINTENANCE SECTION D-1 D-1 POWERARC® 5500 Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .D-1 Safety Precautions . . . . . . . . . . . . . . . . . . . . . . . . . . ....
Page 40 - • Have qualified personnel do all maintenance and; ENGINE MAINTENANCE
MAINTENANCE D-2 D-2 POWERARC® 5500 SAFETY PRECAUTIONS • 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 main-tenance requiring their rem...
Page 41 - ENGINE ADJUSTMENTS; Clean Rotating Screen:
MAINTENANCE D-3 D-3 POWERARC® 5500 F FU UE EL L:: At the end of each day’s use, refill the fuel tank to minimize moisture condensa-tion and dirt contamination in the fuel line. ENGINE ADJUSTMENTS OVERSPEED IS HAZARDOUS - The maximum allowable high idle speed for this machine is 3750 RPM, no load. DO...
Page 42 - Part; 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) MAINT...
Page 43 - GENERATOR/WELDER MAINTENANCE
MAINTENANCE D-5 D-5 POWERARC® 5500 GENERATOR/WELDER MAINTENANCE S ST TO OR RA A G GE E:: Store the POWERARC® 5500 in clean, dry, protected areas. C CL LE EA A N NIIN NG G:: Blow out the generator and controls periodically with low pressure air. Do this at leastonce a week in particularly dirty areas...
Page 45 - TABLE OF CONTENTS-THEORY OF OPERATION SECTION; FIGURE E.1 – POWERARC® 5500 BLOCK LOGIC DIAGRAM
TABLE OF CONTENTS-THEORY OF OPERATION SECTION E-1 E-1 POWERARC® 5500 FIGURE E.1 – POWERARC® 5500 BLOCK LOGIC DIAGRAM Theory of Operation ............................................................................................................. Section E Block Logic Diagram ..........................
Page 46 - THEORY OF OPERATION; ENGINE CONTROL AND IGNITION
THEORY OF OPERATION E-2 E-2 POWERARC® 5500 ENGINE CONTROL AND IGNITION The engine ignition is created and controlled by a fly-wheel type magneto circuit. This circuit is shorted toground when the ON/OFF switch is moved to the OFFposition, thus disabling the ignition circuit and shuttingdown the engi...
Page 47 - FIGURE E.3 – ROTOR FIELD FEEDBACK AND AUXILIARY POWER
THEORY OF OPERATION E-3 E-3 POWERARC® 5500 ROTOR FIELD FEEDBACK ANDAUXILIARY POWER The AC voltage developed in the field winding is fed tothe full wave bridge. The DC output of the bridge is fil-tered by the field capacitor and controlled by the out-put rheostat. This filtered and controlled feedbac...
Page 48 - WELD WINDING AND REACTOR; FIGURE E.4 – WELDING OUTPUT
THEORY OF OPERATION E-4 E-4 POWERARC® 5500 WELD WINDING AND REACTOR The AC voltage developed in the stator weld windingis delivered, through the reactor, to the machine out-put terminals. The POWERARC® 5500 provides theuser up to 125 amps of constant current AC weldingfor stick electrodes. The react...
Page 49 - TABLE OF CONTENTS - TROUBLESHOOTING AND REPAIR
TABLE OF CONTENTS - TROUBLESHOOTING AND REPAIR F-1 F-1 POWERARC® 5500 Troubleshooting and Repair . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .F-1 How to Use Troubleshooting Guide . . . . . . . . . . . . . . . . . . . . . ....
Page 50 - TROUBLESHOOTING AND REPAIR; HOW TO USE TROUBLESHOOTING GUIDE; detailed throughout this manual.
POWERARC® 5500 TROUBLESHOOTING AND REPAIR F-2 F-2 This Troubleshooting Guide is provided to help you locate and repair possible machine malfunctions. Simply follow the three-step procedure listed below. Step 1. LOCATE PROBLEM (SYMPTOM). Look under the column labeled “PROBLEM (SYMPTOMS)”. This column...
Page 51 - PC BOARD TROUBLESHOOTING PROCEDURES
POWERARC® 5500 TROUBLESHOOTING AND REPAIR F-3 F-3 Sometimes machine failures appear to be due to PC board failures. These problems can sometimes be traced to poor electrical connections. To avoid prob- lems when troubleshooting and replacing PC boards, please use the following procedure: 1. Determin...
Page 52 - TROUBLESHOOTING GUIDE; OUTPUT PROBLEMS
TROUBLESHOOTING GUIDE - Observe Safety Guidelines detailed in the beginning of this manual. 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 y...
Page 54 - contact your
TROUBLESHOOTING GUIDE - Observe Safety Guidelines detailed in the beginning of this manual. 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 y...
Page 57 - ENGINE PROBLEMS
TROUBLESHOOTING GUIDE - Observe Safety Guidelines detailed in the beginning of this manual. 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 y...
Page 59 - WELDING PROBLEMS
TROUBLESHOOTING GUIDE - Observe Safety Guidelines detailed in the beginning of this manual. 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 y...
Page 61 - ROTOR VOLTAGE AND FLASHING VOLTAGE TEST PROCEDURE
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 obse...
Page 62 - ROTOR VOLTAGE TEST PROCEDURE; FLASHING VOLTAGE TEST; ROTOR VOLTAGE TEST; FIGURE F.1 - LOCATION OF LEAD 200A FOR ROTOR VOLTAGE TEST
ROTOR VOLTAGE AND FLASHING VOLTAGE TEST PROCEDURE (continued) TROUBLESHOOTING AND REPAIR F-14 F-14 POWERARC® 5500 ROTOR VOLTAGE TEST PROCEDURE 1. With the 5/16” nut driver, remove the 8 sheet metal screws that hold the top cover to thecontrol box. Remove the top cover. 2. Start the machine and run i...
Page 63 - ROTOR RESISTANCE TEST PROCEDURE
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 obse...
Page 64 - ROTOR RESISTANCE TEST PROCEDURE (continued); PROCEDURE; ROTOR RESISTANCE TEST; LOCATION OF ROTOR SLIP RINGS - BRUSH HOLDER ASSEMBLY REMOVED
ROTOR RESISTANCE TEST PROCEDURE (continued) PROCEDURE 1. Conduct the test with the gasoline engine OFF. 2. Remove the spark plug wire to prevent acci- dental engine kickback or starting. 3. Isolate the rotor electrically by removing the generator brushes. Refer to Figure F.2 as youperform the remain...
Page 65 - FIGURE F.3 - BRUSHES RETAINED WITH CABLE TIE
ROTOR RESISTANCE TEST PROCEDURE (continued) 9. Reinstall the brush holder assembly after the test. Depress the spring-loaded brushes intothe holder and slip a suitable non-metallic, fair-ly stiff retainer through the slots at the top andbottom of the holder. A cable tie works well;see Figure F.3. Th...
Page 67 - ENGINE THROTTLE ADJUSTMENT TEST
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 obse...
Page 68 - TEST PROCEDURE; Frequency Counter Method:
ENGINE THROTTLE ADJUSTMENT TEST ROBIN/SUBARU ENGINE (continued) TROUBLESHOOTING AND REPAIR F-20 F-20 POWERARC® 5500 TEST PROCEDURE This test can be conducted by any ofthree methods. Strobe-tach Method: 1. Stop the engine and remove the spark plug wire to prevent accidentalkickback or starting. 2. Wi...
Page 70 - SCOPE SETTINGS; NORMAL OPEN CIRCUIT WELD VOLTAGE WAVEFORM; HIGH IDLE – NO LOAD
TROUBLESHOOTING AND REPAIR F-22 F-22 POWERARC® 5500 CH1 0 volts 5 ms 50 volts SCOPE SETTINGS Volts/Div .....................50V/Div.Horizontal Sweep.....5 ms/Div.Coupling ............................DCTrigger .........................Internal This is the typical AC output voltagegenerated from a pro...
Page 71 - NORMAL OPEN CIRCUIT VOLTAGE WAVEFORM (115 VAC SUPPLY)
TROUBLESHOOTING AND REPAIR F-23 F-23 POWERARC® 5500 SCOPE SETTINGS Volts/Div .....................50V/Div.Horizontal Sweep.....5 ms/Div.Coupling ............................DCTrigger .........................Internal CH1 0 volts 5 ms 50 volts This is the typical AC output voltagegenerated from a pro...
Page 72 - TYPICAL WELD OUTPUT WAVEFORM; MACHINE LOADED
TROUBLESHOOTING AND REPAIR F-24 F-24 POWERARC® 5500 CH1 0 volts 5 ms 20 volts This is the typical AC output voltagegenerated from a properly operatingmachine. Note that each verticaldivision represents 20 volts and thateach horizontal division represents 5milliseconds in time. The machinewas loaded ...
Page 73 - TEST DESCRIPTION; BRUSH REMOVAL AND REPLACEMENT
Service and repair should be performed only by Lincoln Electric factory trained person- nel. Unauthorized repairs performed on this equipment may result in danger to the tech- nician or machine operator and will invalidate your factory warranty. For your safety and to avoid electrical shock, please ...
Page 74 - FIGURE F.7 - BRUSHES RETAINED WITH CABLE TIE
TROUBLESHOOTING AND REPAIR F-26 F-26 POWERARC® 5500 PROCEDURE 1. Remove the spark plug wire. 2. Open the brush holder assembly cover. Squeeze the 2 tabs anddepress the cover at the top with ascrew driver or your fingernail. Thecover will drop open on its bottomhinge. 3. With the 1/4” nut driver, rem...
Page 77 - RHEOSTAT REMOVAL AND REPLACEMENT
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 obse...
Page 79 - CAPACITOR AND/OR DIODE BRIDGE
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 obse...
Page 80 - FIGURE F.9 - LOCATION AND DISCHARGING THE FIELD CAPACITOR; PROCEDURE - CAPACITOR
CAPACITOR AND/OR DIODE BRIDGE REMOVAL AND REPLACEMENT PROCEDURE (continued) TROUBLESHOOTING AND REPAIR F-32 F-32 POWERARC® 5500 FIGURE F.9 - LOCATION AND DISCHARGING THE FIELD CAPACITOR PROCEDURE - CAPACITOR REMOVAL AND REPLACE- MENT 1. Remove the engine spark plug wire. 2. With the 5/16” nut driver...
Page 81 - FIGURE F.10 - FIELD DIODE BRIDGE LOCATION; PROCEDURE - FIELD DIODE BRIDGE REMOVAL AND REPLACEMENT
CAPACITOR AND/OR DIODE BRIDGE REMOVAL AND REPLACEMENT PROCEDURE (continued) TROUBLESHOOTING AND REPAIR F-33 F-33 POWERARC® 5500 FIGURE F.10 - FIELD DIODE BRIDGE LOCATION 1. Remove the engine spark plug wire. 2. With the 5/16” nut driver, remove the 8 sheet metal screws that hold thetop cover to the ...
Page 83 - FOR ROTOR REMOVAL ONLY; STATOR/ROTOR REMOVAL AND REPLACEMENT
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 obse...
Page 84 - REMOVAL AND REPLACEMENT; STATOR REMOVAL PROCEDURE
TROUBLESHOOTING AND REPAIR F-36 F-36 POWERARC® 5500 STATOR/ROTOR REMOVAL AND REPLACEMENT PROCEDURE (continued) STATOR REMOVAL PROCEDURE 1. Remove engine spark plug wire to prevent accidental kickback or starting. 2. With the 5/16” nut driver, remove the 8 sheet metal screws that hold the top coverto...
Page 85 - BOLTS
STATOR/ROTOR REMOVAL AND REPLACEMENT PROCEDURE (continued) TROUBLESHOOTING AND REPAIR F-37 F-37 POWERARC® 5500 14. Slide a short length of 2 X 4 under the engine to support it when thestator is removed. 15. With the 1/2” wrench, remove the 2 nuts that hold the stator end brack-et support. See Figure...
Page 86 - REASSEMBLY PROCEDURE
TROUBLESHOOTING AND REPAIR F-38 F-38 POWERARC® 5500 STATOR/ROTOR REMOVAL AND REPLACEMENT PROCEDURE (continued) ROTOR REMOVAL PROCEDURE 1. To remove the rotor, double check that the spark plug wire is discon-nected. You will be turning the rotorduring this procedure, and this couldaccidentally cause ...
Page 88 - FIGURE F.16 MOLEX PLUG AND BOLT/SCREW LOCATION
REACTOR BOLTS (2) LEAD #205 LEADCONNECTIONS FIGURE F.15 LEAD 205 AND MORE GROUNDING SCREW 2 BOLTS SHEET METAL SCREWS (5 PLACES) MOLEX PLUG FIGURE F.16 MOLEX PLUG AND BOLT/SCREW LOCATION STATOR/ROTOR REMOVAL AND REPLACEMENT PROCEDURE (continued) TROUBLESHOOTING AND REPAIR F-40 F-40 POWERARC® 5500 Ret...
Page 89 - RETEST AFTER REPAIR; ENGINE OUTPUT
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 3...
Page 91 - TABLE OF CONTENTS - DIAGRAM SECTION
TABLE OF CONTENTS - DIAGRAM SECTION G-1 G-1 POWERARC® 5500 Electrical Diagrams . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .G-1 Wiring Diagram (Codes 11182, 11187, 11329) (S25984) . . . . . . . . . . . . . . ...
Page 92 - ELECTRICAL DIAGRAMS; WIRING DIAGRAM - POWER ARC 5500; REACTOR
ELECTRICAL DIAGRAMS G-2 POWERARC® 5500 WIRING DIAGRAM - CODES 11182, 11187, 11329 (S25984) S25984 ENGINE WIRING MAG SWITCH RUN/STOP WIRING DIAGRAM - POWER ARC 5500 A SWITCH LOW OIL MODULE GROUND BRACKET STATOR END 201B (+) 9 7 3 5 6 GND-C 2 GND-D W 1 W 2 W 1A REACTOR 1 L1 OUTPUT STUDS 6 5 4 3 STATOR...
Page 94 - STATOR
ELECTRICAL DIAGRAMS G-4 POWERARC® 5500 WIRING DIAGRAM - CODE 11404 (S26830) A S26830 D1 C1 ROTOR (+) (-) (+) (-) ENGINE W IRING MAG SWITCH 9A 202A 7A 600 µ FD CCW A 201A 201 RUN/STOP 3C 201B 6B 3B GND-B GND-A WIRING DIAGRAM - POWER ARC 5500 D2 205 202 200A 200 202B 202 9A 7A 5B 5B 5A 6C R1 3.3 Ohms1...
Page 96 - MACHINE SCHEMATIC; NONE; DO NOT SCALE THIS DRAWING; UF; REVOLVING FIELDS
ELECTRICAL DIAGRAMS G-6 POWERARC® 5500 SCHEMATIC -CODES 11182, 11187, 11329 (S26008) S26008 POW ER ARC 5500 MACHINE SCHEMATIC NONE S21455 MAP BAM - DO NOT SCALE THIS DRAWING DRAWN BY: DESIGN INFORMATION ENGINEER: APPROVED: EQUIPMENT TYPE: SUBJECT: SCALE: UF CRM35633 1 PAGE ___ OF ___ 1 ENGINEERING C...
Page 97 - NA
ELECTRICAL DIAGRAMS G-7 POWERARC® 5500 SCHEMATIC - CODES 11403, 11405 (S26881) S26881 POW ER ARC 5500 (SUBARU ROBIN) MACHINE SCHEMATIC NONE S26008 MAP DJS - DO NOT SCALE THIS DRAWING DRAWN BY: DESIGN INFORMATION ENGINEER: APPROVED: EQUIPMENT TYPE: SUBJECT: SCALE: NA CRM38121 1 PAGE ___ OF ___ 1 ENGI...
