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IM560-A
™
November, 1999
POWER ARC 5000
For Machines with Code Number 10255 and 10430
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 thought-
ful 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.
OPERATO
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i i SAFETY WARNING CALIFORNIA PROPOSITION 65 WARNINGS Diesel engine exhaust and some of its constituents The engine exhaust from this product contains are known to the State of California to cause can- chemicals known to the State of California to cause cer, birth defects, and other reproductive harm. cancer, birth defects, or other reproductive harm. The Above For Diesel Engines The Above For Gasoline Engines ARC WELDING CAN BE HAZARDOUS. PROTECT YOURSELF AND OTHERS FROM POSSIBLE SERIOUS INJURY
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ii ii SAFETY ELECTRIC SHOCK can ARC RAYS can burn. 4.a. Use a shield with the proper filter and cover kill. plates to protect your eyes from sparks and 3.a. The electrode and work (or ground) circuits the rays of the arc when welding or observing are electrically “hot” when the welder is on. open arc welding. Headshield and filter lens Do not touch these “hot” parts with your bare should conform to ANSI Z87. I standards. skin or wet clothing. Wear dry, hole-free gloves to insulate hands. 4.b. Us
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iii iii SAFETY WELDING SPARKS can CYLINDER may explode cause fire or explosion. if damaged. 6.a. Remove fire hazards from the welding area. 7.a.Use only compressed gas cylinders If this is not possible, cover them to prevent containing the correct shielding gas for the the welding sparks from starting a fire. process used and properly operating Remember that welding sparks and hot regulators designed for the gas and materials from welding can easily go through small cracks pressure used. All hos
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iv iv SAFETY 5. Toujours porter des lunettes de sécurité dans la zone de PRÉCAUTIONS DE SÛRETÉ soudage. Utiliser des lunettes avec écrans lateraux dans les zones où l’on pique le laitier. Pour votre propre protection lire et observer toutes les instruc- tions et les précautions de sûreté specifiques qui parraissent 6. Eloigner les matériaux inflammables ou les recouvrir afin de dans ce manuel aussi bien que les précautions de sûreté prévenir tout risque d’incendie dû aux étincelles. générales su
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v v for selecting a QUALITY product by Lincoln Electric. We want you to take pride in operating this Lincoln Electric Company product Thank You ��� as much pride as we have in bringing this product to you! Please Examine Carton and Equipment For Damage Immediately When this equipment is shipped, title passes to the purchaser upon receipt by the carrier. Consequently, Claims for material damaged in shipment must be made by the purchaser against the transportation company at the time the shipment
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vi vi TABLE OF CONTENTS Page Safety.................................................................................................................................................i-iv Installation .............................................................................................................................Section A Technical Specifications .............................................................................................................A-1 Safety Precautions...........
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A-1 A-1 INSTALLATION TECHNICAL SPECIFICATIONS - POWER ARC 5000 INPUT - GASOLINE ENGINE Manufacturer Description Speed Displacement Ignition Capacities Briggs & 1 cyl., 3700 RPM 24.4 cu. in. Electronic Fuel: 5.5 gal. (20.8 l) Stratton 4 cycle ± 50 RPM (400 cc) Ignition; Industrial air-cooled at no load Recoil start; Oil: 1.5 qt. (1.42 l) Plus gasoline Manual choke 11 HP @ 3600 RPM RATED OUTPUT - WELDER Duty Cycle Amps Volts at Rated Amperes 40% Duty Cycle 150 25 VAC 60% Duty Cycle 125 25 VAC
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A-2 A-2 INSTALLATION Read this entire installation section before you LOCATION AND VENTILATION start installation. Whenever you use the POWER ARC 5000, be sure that clean cooling air can flow through the machine’s gasoline engine and the generator. Avoid dusty, dirty SAFETY PRECAUTIONS areas. Also, keep the machine away from heat sources. Do not place the back end of the generator WARNING anywhere near hot engine exhaust from another machine. And of course, make sure that engine Do not at
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A-3 A-3 INSTALLATION STACKING ASSEMBLY OF VIBRATION ISOLATORS TO BOTTOM OF TUBE FRAME ( If POWER ARC 5000 machines CANNOT be stacked. wheels are not used) TILTING Tools required - 9/16 wrench or socket. Place the machine on a secure, level surface whenev- er you use it or store it. Any surfaces you place it on If the supplied wheels are not used, it is important that the other than the ground must be firm, non-skid, and isolators are installed to keep the machine stabilized when structurally
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A-4 A-4 INSTALLATION vibration isolators are installed in the inward holes Assembly of Wheels and Handle to the furthest from the tube frame. Refer to Figure A-2 Tube Frame Detail B. The two large washers must be installed between the vibration isolators and the underside Tools Required - Two 9/16 wrenches or sockets, 3/8 wrench of the channel. The remaining two large plain or socket and a rubber mallet or wooden washers (spacers)are not used. block. e.) Install one of the push nuts (Item 4)
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A-5 A-5 INSTALLATION FUEL PRE-OPERATION ENGINE SERVICE Fill the fuel tank with clean, fresh, regular grade Read and understand the information about the gasoline lead-free gasoline. DO NOT MIX OIL WITH engine in the OPERATION and MAINTENANCE sections of THE GASOLINE. this manual before you operate the POWER ARC 5000. The POWER ARC 5000 has a plastic, 5.5 gallon (20.8 L) fuel WARNING tank mounted above the generator. See the Briggs & Stratton Engine manual for more details about fuel. � Keep
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A-6 A-6 INSTALLATION FIGURE A.3 - POWER ARC 5000 OUTPUT CONNECTIONS 1 10 POWER ARC 5000 6 WARNING WELDING ELECTRODES 120 VOLTS 15 AMPS CIRCUIT BREAKERS 2 7 120/240 VOLTS 30 AMPS 9 120 VOLTS 30 AMPS 8 WORK LOW RANGE HIGH RANGE 3 5 4 1. CURRENT CONTROL DIAL 6. CIRCUIT BREAKERS (3) 2. ELECTRODE SELECTION GUIDE 7. GFCI DUPLEX RECEPTACLE - 120 VOLT, 15 AMP 3. WELD OUTPUT TERMINALS (TO ELECTRODE HOLDER, 8. TWIST-LOCK RECEPTACLE - 120 VOLT, 30 AMP HIGH RANGE AND LOW RANGE) 9. TWIST-LOCK RECEP
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A-7 A-7 INSTALLATION Cable Installation WARNING Install the welding cables to your POWER ARC 5000 as follows. See Figure A.3 for the location of parts. Do not ground the machine to a pipe that carries 1. The gasoline engine must be OFF when connect- explosive or combustible material. ing the welding cables. 2. Remove the 1/2 - 13 flanged nuts from the output When the POWER ARC 5000 is mounted on a truck terminals. or a trailer, the machine generator grounding terminal 3. Connect the electr
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A-8 A-8 INSTALLATION meet the National Electric Code (NEC) regulations as POWER CORD CONNECTIONS TO TWIST- well as city ordinances can be confusing. Matters get LOCK PLUGS worse depending on whether you want the machine Refer to the appropriate diagram above for proper to be “hardwired” to the premises or only connected connection of power cord wires to the Twist-Lock plug temporarily. terminals. Also, read the instruction sheet supplied WARNING with the Twist-lock plug. Only a licensed, ce
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A-9 A-9 INSTALLATION TABLE A.2 ELECTRICAL DEVICE USE WITH THE POWER ARC 5000. Type Common Electrical Devices Possible Concerns Resistive Heaters, toasters, incandescent NONE light bulbs, electric range, hot pan, skillet, coffee maker. Capacitive Radios, microwaves, Voltage spikes or high voltage appliances with electronic control. regulation can cause the capaci- tative elements to fail. Surge protection, transient protection, and additional loading is recom- mended for 100% fail-safe opera
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B-1 B-1 OPERATION OPERATING INSTRUCTIONS WARNING Read and understand this entire section before oper- ating your POWER ARC 5000. ARC RAYS can burn. SAFETY INSTRUCTIONS � Wear eye, ear, and body protection. WARNING Do not attempt to use this equipment until you have ENGINE EXHAUST can kill. thoroughly read all the operation and maintenance manuals supplied with your machine. They include � Use in open, well ventilated areas or important safety precautions; detailed engine starting, vent exhaust
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B-2 B-2 OPERATION RECOMMENDED APPLICATIONS WELDING CAPABILITY The POWER ARC 5000 is rated 150 amps, 25 volts at OPERATIONAL FEATURES AND CONTROLS 40% duty cycle on a ten-minute basis. This means The POWER ARC 5000 was designed for simplicity. that you can load the welder to 150 amps for four Therefore, it has very few operating controls. A single minutes out of every ten-minute period. The machine dial on the control panel lets you select either genera- is also capable of higher duty cycles a
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B-3 B-3 OPERATION 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. FIGURE B.1 – OUTPUT PANEL CONTROLS 1 10 POWER ARC 5000 6 WARNING WELDING ELECTRODES 120 VOLTS 15 AMPS CIRCUIT BREAKERS 2 7 120/240 VOLTS 30 AMPS 9 120 VOLTS 30 AMPS 8 WORK LOW RANGE HIGH RANGE 3 5 4 1. CURRENT CONTROL DIAL 2. ELECTRODE SELECTION GUIDE 3. WELD OUTPUT TERMINAL
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B-4 B-4 OPERATION FIGURE B.2 – GASOLINE ENGINE CONTROLS 2 9 3 POWER ARC 5000 6 4 5 7 10 18 1. FUEL SHUTOFF VALVE 6. CHOKE 2. FUEL TANK AND CAP 7. RECOIL STARTER 3. MUFFLER 8. OIL DRAIN PLUG 4. STOP SWITCH 9. OIL FILL AND DIP-STICK 5. AIR CLEANER 10. LOW IDLE SPEED PULL DOWN GASOLINE ENGINE CONTROLS See Figure B.2 for the location of the following fea- tures: 1. FUEL SHUTOFF VALVE: Stops the flow of gaso- 6. CHOKE: Provides a richer air/fuel mixture for cold line from the fuel tank to th
