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Land Pride AT3590 Lawn Mower User Manual

1. OV A Ge L GE EC NS h x H z i a _ HL PR E L H BS g DCH VTT Sa Y coe fe WA 1 0 Wa Tory e N ZS GA II NES a GI D LY IU EN pp L SSL O oS Y POWER ARC 5000 LINCOLN 6 28 96 M18053 Now Available 12th Edition The Procedure Handbook of Arc Welding With over 500 000 copies of previous editions published since 1933 the Procedure Handbook is considered by many to be the Bible of the arc welding industry This printing will go fast so don t delay Place your order now using the coupon below The hardbound book contains over 750 pages of welding information techniques and procedures Much of this material has never been included in any other book A must for all welders supervisors engineers and designer
2. o pisui pa3sed s apod Je n gt onued e Joy weep dYIDeds SUL enueu siy AO palano gt saulyeu US 103 BJeINDIe aq jou Aew 1 AO adualajal 10 SI Weep SIUL 3 LON LSTETS HL6 9T S AWAY NOYA GHMHIA NMOHS Ta 9 JALAN ANOH SATOVLAHDAA NERD aaNno HLON MOVIE 29 gt X AND A 3 Sa Z HoLIMS HOIIMS de 02 aors Nnu auvo TIO O a NOYLENOVN Ou 10 e r D O U Naas HLIHM ONIYIM HNIDNH sane AOCT ANIT Ns dap NMOYE DZOZ movie It D LS aan De E ry si ANIT _a ADVIE QE gt D HOVTE O GEN HsvTa 4 k we SE O SEW HOVTA annoup i o a9 TENVA T naaa F LNowd lt SENS NASUD gn la Ve en O ON gasN Q movida SN Ta v6 BS aLIHM _ woe woe atoz ovaa KO ws O za Ve TOZ O We Ei wowld E E Ge ve d e O O annouo zoz ta J qa 7 009 ES O E Ge Nino LHNOVUE TO aNa HOLWLS V A ween e VANO U me E aaa ooz A aaa a i E DT wzoz Y L J C L sanis Ladino ATLAN iir Gas Gi cl a HOLWLS anon aaa E HOVTE e Se gooz S 20 L i TM DATE DATE XYOM MOD a lt HOLOY O O LESTH aad WIM aTM S TOEMAS O zm dau azoz TWOIYLOS1a V A J AKA O HOLOVHY IT 0009 DAY AHMOd NYIADVIA ONIAIM F 1 POWER ARC 5000 LINCOLN POWER ARC 5000 DIMENSION PRINT DIAGRAMS
3. Figure B 3 The welding circuit for shielded metal arc welding POWER ARC 5000 LINCOLN amp B 12 The POWER ARC 5000 has a voltage output of up to 62 volts which can shock A WARNING ELECTRIC SHOCK can kill e Do not touch electrically live parts EN pa or electrode with skin or wet cloth ing Insulate yourself from work and ground Always wear dry insulating gloves ENGINE EXHAUST can kill amp e Use in open well ventilated areas i ON or vent exhaust outside e Do not stack anything on or near the engine MOVING PARTS can injure Do not operate with doors open or guards off NY Stop engine before servicing Keep away from moving parts Only qualified personnel should install use or service this equipment 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 B 3 by hold ing 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 B 4 ill
4. LOCATION AND VENTILATION Whenever you use the POWER ARC 5000 be sure that clean cooling air can flow through the machine s gasoline engine and the generator Avoid dusty dirty areas Also keep the machine away from heat sources Do not place the back end of the generator anywhere near hot engine exhaust from another machine And of course make sure that engine exhaust is ventilated to an open outside area The ambient temperature range for operating this machine is O F to 104 F 18 C to 40 C The POWER ARC 5000 may be used outdoors Do not set the machine in puddles or otherwise sub merge it in water Such practices pose safety haz ards and cause improper operation and corrosion of parts Always operate the POWER ARC 5000 with the case roof on and all machine components completely assembled This will protect you from the dangers of moving parts hot metal surfaces and live electrical devices STORING 1 Store the machine in a cool dry place when it s not in use Protect it from dust and dirt Keep it where it can t be accidentally damaged from con struction activities moving vehicles and other hazards 2 If you will be storing the machine for over 30 days you should drain the fuel to protect fuel system and carburetor parts from gum deposits Empty all fuel from the tank and run the engine until it stops from lack of fuel 3 You can store the machine for up to 24 months if you use Sta Bil additive o
5. 120 VOLT 15 AMP TWIST LOCK RECEPTACLE 120 VOLT 30 AMP TWIST LOCK RECEPTACLE 120 240 VOLT 30 AMP O ENGINE HOUR METER GENERATOR WELDER CONTROLS See Figure B 1 for the location of the following fea tures 1 CURRENT CONTROL DIAL Adjusts continuous current output The amperages on the dial corre spond to the average amperages needed for spe cific Lincoln welding electrodes ELECTRODE SELECTION GUIDE Provides rec ommended electrodes WELD OUTPUT TERMINALS TO ELECTRODE HOLDER HIGH RANGE AND LOW RANGE Pro vides the connection point for the electrode hold er cable WELD OUTPUT TERMINAL TO WORK Provides the connection point for the work cable GROUNDING TERMINAL Provides a connection point for connecting the machine to earth ground for the recommended grounding procedure 10 CIRCUIT BREAKERS 3 Provides separate overload current protection for the 120 volt and 120 240 volt receptacles 15 AMP 120 VOLT GFCI DUPLEX RECEPTACLE For supplying 120 volt power to operate one or two electrical devices 30 AMP 120 VOLT TWIST LOCK RECEPTACLE 120 volt power for higher power requirements 30 AMP 120 240 VOLT TWIST LOCK RECEPTACLE For supplying 240 volt power and for connection to 120 240 volt premises wiring ENGINE HOUR METER Records engine running time Use this meter to schedule engine mainte nance POWER ARC 5000 LINCOLN amp OPERATION B 4 FIGURE B 2 GASOLINE ENGINE CONTR
6. Current Control Dial to 125 150 Amps position for either a cold or hot engine As the machine is used some welding voltage may decrease at high current set tings The numbers listed on the dial correspond to the aver age amperage needed to weld specific Lincoln rods Refer to Table B 4 WELDING APPLICATIONS or the ELECTRODE SELECTION GUIDE on the machine nameplate for proper current and electrode settings POWER ARC 5000 LINCOLN B 10 OPERATION WELDING GUIDELINES TABLE B 4 WELDING APPLICATIONS ELECTRODE SELECTION GUIDE B 10 AWS ELECTRODE TYPE SIZE MATERIAL INITIAL RANGE CLASS THICKNESS SETTING E6011 FLEETWELD 180 3 32 1 8 amp THINNER 80 AMPS LOW FAST FREEZE 1 8 1 8 amp THICKER 100 AMPS LOW 5 32 1 4 amp THICKER 150 AMPS HIGH E6013 FLEETWELD 37 5 64 12 GA amp THINNER 70 AMPS LOW FAST FILL 3 32 1 8 amp THINNER 100 AMPS LOW 1 8 1 8 amp THICKER 150 AMPS HIGH E7014 FLEETWELD 47 3 32 1 8 amp THINNER 90 AMPS LOW FILL FREEZE 1 8 1 8 amp THICKER 150 AMPS HIGH E7018 LINCOLN 7018 AC 3 32 1 8 amp THINNER 80 AMPS LOW LOW HYDROGEN 1 8 1 8 amp THICKER 125 AMPS LOW E7024 1 JETWELD 1 3 32 1 8 amp THINNER 100 AMPS LOW FAST FILL 1 8 1 8 amp THICKER 150 AMPS HIGH BLUE MAX 308 16 3 32 12 GA 8 THINNER 80 AMPS LOW STAINLESS ELECTRODE 1 8 12 GA amp THICKER 100 AMPS LOW 5 32 10 GA amp THICKER 150
7. IAE SAAD HALO ett PAS EFSA HEHE Saal veel ZJ d Lala 2 y Llana J al ply all ol Gail call Gli ag ls Gras L LINCOLN e World s Leader in Welding and Cutting Products e Sales and Service through Subsidiaries and Distributors Worldwide Cleveland Ohio 44117 1199 U S A TEL 216 481 8100 FAX 216 486 1751 WEB SITE www lincolnelectric com
8. MAINTENANCE D 3 FIGURE DS CYLINDER HEAD TORQUE SEQUENCE Maintenance Every 5 Hours 25 Hours 50 Hours 100 Hours Operation or Daily or Yearly or Yearly or Yearly 100 300 Hours Check Oil Level e Change Oil Note 1 Clean Rotating Screen Finger e Guard or Debris Screen Note 2 Service Foam Pre Cleaner e Note 2 Replace Air Cleaner e Note 2 Clean Cooling System e Inspect Spark Arrester Option e Clean or Replace Spark Plug e Replace In Line Fuel Filter Option e Re Torque Cylinder Head Bolts e Change oil after first 5 hours then after every 50 hours or once a year Note 1 Change oil every 25 hours when operating under heavy load in high ambient temperatures Note 2 Clean more often under dusty conditions or when airborne debris is present TABLE D 2 ENGINE MAINTENANCE PARTS AS NEEDED Part Part Number OIL FILTER NONE SPARK PLUG RESISTOR B amp S 802592 CHAMPION RJ 19LM FUEL FILTER B amp S 394358 AIR CLEANER PANEL B amp S 494511 AIR PRE CLEANER B amp S 492889 CAN BE CLEANED AND REUSED POWER ARC 5000 LINCOLN D 4 MAINTENANCE D 4 GENERATOR WELDER MAINTENANCE STORAGE Store the POWER ARC 5000 in clean dry protected areas CLEANING Blow out the generator and controls periodically with low pressure air Do this at least once a week in particularly dirty areas BRUSH REMOVAL AND REPLACEMENT See Figure D
9. port channel on the alternator end Install the han dle Item 8 through the large holes in the channel and tighten the screws that were previously loos ened The height of the handle can be adjusted to suit the user Axle Item 5 Engine Support Channel 3 8 16 x 875 Hex Bolt 2 Lockwasher Tubular Frame Hex Nut Wheel w Item 6 Es Item 4 7 Hp Push Nut Rubber Isolator Item 1 Large Plain Washer Spacer Axle Support Bracket Item 3 Detail B Rubber Isolator Item 1 Detail A POWER ARC 5000 LINCOLN A 5 PRE OPERATION ENGINE SERVICE Read and understand the information about the gasoline engine in the OPERATION and MAINTENANCE sections of this manual before you operate the POWER ARC 5000 Keep hands away from the engine muffler or HOT engine parts e Stop the engine when fueling Do not smoke when fueling Remove the fuel cap slowly to release pressure Do not overfill the fuel tank e Wipe up spilled fuel and allow the fumes to clear before starting the engine Keep sparks and flame away from the fuel tank Zen OIL The POWER ARC 5000 is shipped with the engine filled with SAE 10W 30 oil CHECK THE OIL LEVEL BEFORE YOU START THE ENGINE If the oil level is not at the FULL mark on the dip stick add oil but do not overfill Be sure the dip stick cap is tight Change the oil
10. I Credit Card a Tasa no III III 11 Ep pes Mal LL lise THIS FORM TO ORDER Books OR FREE INFORMATIVE CATALOGS Lincoln Welding School Titles Price Code Quantity Cost I ED 80 New Lessons in Arc Welding 5 00 L JSerninar Information Procedure Handbook Twelfth Edition 15 00 PH How to Read Shop Drawings 4 50 H Educational Video Information ____ Tncentve Management 5500 M T y 0098 A New Approach to Industrial Economics 5 00 NA Lames F Lincoln Arc Welding The American Century of John C Lincoln 8500 AC J Foundation Book Information Welding Preheal Calculator 300 wee C T JFLF 515 Pipe Welding Charts 5450 eos I A SUBO eo Shipping Costs any l x y LS _ Order from BOOK DIVISION The Lincoln Electric Company 22801 St Clair Avenue Cleveland Ohio 44117 1199 Telephone 216 383 2211 or for fastest service FAX this completed form to 216 361 5901 Name Address Telephone Signature as it appears on Charge Card LE M TT U eee 2 WARNING Spanish AVISO DE PRECAUCION French ATTENTION German WARNUNG Portuguese ATEN AO Japanese it is BIR Korean Do not touch electrically live parts or electrode with skin or wet clothing Insulate yourself from work and ground No toque las partes o los electrodos bajo carga con la piel o ropa moja da O Aislese del traba
11. LINCOLN B 6 OPERATION B 6 4 Pull the cord rapidly 5 If the engine does not start open the choke Slightly move lever toward the RUN position and pull the starter cord rapidly again When the engine starts gradually open the choke to the RUN position FOR A HOT ENGINE 1 Open the fuel shutoff valve on the bottom of the fuel tank by turning it full counterclockwise 2 Place the choke lever in the RUN position Closing the choke of a hot x engine will flood the carburetor and prevent starting 3 Pull slightly on the recoil starter handle until resis tance 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 If the engine will not start see the TROU BLESHOOTING section of this manual 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 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 pushing the On Off Switch on the end of the engine to the OFF position 3 Hold the lever down firmly until the engine com pletely stops Otherwise the engine may restart or sputter as it stops 4 Cl
12. POWER ARC 5000 LINCOLN A 7 INSTALLATION A 7 Cable Installation Install the welding cables to your POWER ARC 5000 as follows See Figure A 3 for the location of parts 1 The gasoline engine must be OFF when connect ing the welding cables 2 Remove the 1 2 13 flanged nuts from the output terminals 3 Connect the electrode holder and work cables to the appropriate weld output terminals 4 Tighten the flanged nuts securely 5 Be certain that the metal piece you are welding the work is securely connected to the work clamp and cable 6 Check and tighten the connections periodically A CAUTION Loose connections will cause the output terminals to overheat The terminals may eventually melt Do not cross the welding cables at the output termi nal connection Keep the cables isolated and sepa rate from one another Lincoln Electric offers a welding accessory kit with the properly specified welding cables See the ACCESSORIES section of this manual for more infor mation MACHINE GROUNDING For protection against electrical shock connect a heavy gauge wire from the grounding terminal located on the bot tom center of the output panel to a suit able earth ground such as a metal pipe driven into the ground AA WARNING Do not ground the machine to a pipe that carries explosive or combustible material When the POWER ARC 5000 is mounted on a truck or a trailer the machine gen
13. le c ble de soudage et la machine souder en bon et s r tat defonctionnement d Ne jamais plonger le porte lectrode dans l eau pour le refroidir Ne jamais toucher simultan ment les parties sous tension des porte lectrodes connect s a deux machines a soud er parce que la tension entre les deux pinces peut tre le total de la tension a vide des deux machines Si on utilise la machine a souder comme une source de courant pour soudage semi automatique ces precautions pour le porte lectrode s applicuent aussi au pistolet de soudage 2 Dans le cas de travail au dessus du niveau du sol se pro t ger contre les chutes dans le cas ou on recoit un choc Ne jamais enrouler le c ble lectrode autour de n importe quelle PRECAUTIONS DE SURETE POUR partie du corps Ceci est particuli rement important pour le soudage de t les galvanis es plomb es ou cadmi es ou tout autre m tal qui produit des fume s toxiques Ne pas souder en pr sence de vapeurs de chlore provenant d op rations de d graissage nettoyage ou pistolage La chaleur ou les rayons de l arc peuvent r agir avec les vapeurs du solvant pour produire du phosg ne gas forte ment toxique ou autres produits irritants Pour obtenir de plus amples renseignements sur la s ret voir le code Code for safety in welding and cutting CSA Standard W 117 2 1974 LES MACHINES A SOUDER A Un coup d arc peut tre plus s v re qu un coup
14. shiny metal Check all electrode holder connec tions Refer to wiring diagram and check leads W1 W1A amp W2 black Check resistance from start to end of aluminum coil Replace reactor if necessary Refer to wiring diagram check lead 200 red check lead 202B red check rheostat tabs A CAUTION 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 POWER ARC 5000 LINCOLN E 2 TROUBLESHOOTING E 2 Observe all Safety Guidelines detailed throughout this manual PROBLEMS POSSIBLE AREAS OF RECOMMENDED SYMPTOMS MISADJUSTMENTS S COURSE OF ACTION PROBLEMS C Unit will weld but low or no generator 1 Circuit breaker open 1 Allow machine to cool by running at power is available no load Reduce load and press in circuit breaker Loose or open connection with elec D Check all plugs and cordsets for open trical plug in component or fault condition Current control dial not at 125 Turn dial to GENERATOR FOR GENERATOR POWER ALWAYS OPERATE WITH CURRENT CON TROL DIAL SET AT GENERATOR No open circuit voltage at receptacle H Refer to wiring diagram Check Open lead in receptacle circuit leads 3A 3B amp 3C black 6A 6B amp 6C yellow 5A white No open circuit voltage at rec
15. 6 It s normal for the brushes and slip rings 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 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 bear ing end bracket and secure with the screws previ ously removed Remove the cable tie or wooden stick and the brushes will seat onto the slip rings RECEPTACLES Keep the electrical receptacles in good condition Remove any dirt oil or other debris from their surfaces and holes CABLE CONNECTIONS Check the welding cable connections at the weld output terminals often Be sure that the connections are always tight FIGURE D 6 BRUSH REMOVAL AND REPLACEMENT GENERATOR END BRACKET BRUSH HOLDER ASSEMBLY COVER SCREWS 2 BRUSHES CABLE TIE POWER ARC 5000 LINCOLN D 5 MAINTENANCE D 5 FIGURE D 7 MAJOR COMPONENT LOCATIONS 1 OUTPUT PANEL ASSEMBLY 2 CONTROL BOX ASSEMBLY 3 ENGINE AND CRADLE ASSEMBLY 4 STATOR AND ROTOR ASSEMBLY POWER ARC 5000 LINCOLN amp E 1 TROUBLESHOOTING E 1 Observe all Safety Guidelines detailed throughout this manual PROBLEMS POSSIBLE AREAS OF RECOMMENDED SYMPTOMS MISADJUSTMENTS S COURSE OF ACTION A No generator power or
16. after the first 5 hours of operation For more oil fill and service information see the Briggs amp Stratton Engine manual INSTALLATION A 5 FUEL Fill the fuel tank with clean fresh regular grade lead free gasoline DO NOT MIX OIL WITH THE GASOLINE The POWER ARC 5000 has a plastic 5 5 gallon 20 8 L fuel tank mounted above the generator See the Briggs amp Stratton Engine manual for more details about fuel SPARK ARRESTER Gasoline engine mufflers may emit sparks when the engine is running Some federal state or local laws require spark arresters in locations where unarrested sparks could pre sent a fire hazard Standard mufflers do not act as spark arresters When local laws require it a spark arrester must be installed on the machine and properly maintained An optional spark arrester kit is available for your POWER ARC 5000 See the ACCESSORIES section of this manual for more information A CAUTION An incorrect spark arrester may lead to damage to the engine or reduce performance A suitable spark arrester for the Briggs amp Stratton 11 HP Industrial Plus engine is avail able as a Lincoln field installed option POWER ARC 5000 LINCOLN A 6 INSTALLATION A 6 FIGURE A 3 POWER ARC 5000 OUTPUT CONNECTIONS Ge WARNING k OY 1 CURRENT CONTROL DIAL 2 ELECTRODE SELECTION GUIDE 3 WELD OUTPUT TERMINALS TO ELECTRODE HOLDER HIGH RANGE AND LOW RANG
17. allow approximately 1 5 inches 38 mm from top of filler neck to allow 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 mini mum 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 For engine protection from fuel deposits use Briggs amp Stratton Gasoline Additive part number 5041 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 NOTE Remove all loads connected to the AC power receptacles before starting the gasoline engine Push the On Off Stop Switch to the ON position FOR A COLD ENGINE 1 Open the fuel shutoff valve on the bottom of the fuel tank by turning it full counterclockwise 2 Place the choke lever in the lowest downward position 3 Pull slightly on the recoil starter handle until resistance is felt POWER ARC 5000
18. bringing this product to you Please Examine Carton and Equipment For Damage Immediately When this equipment is shipped title passes to the purchaser upon receipt by the carrier Consequently Claims for material damaged in shipment must be made by the purchaser against the transportation company at the time the shipment is received Please record your equipment identification information below for future reference This information can be found on your machine nameplate Model Name amp Number Code amp Serial Number Date of Purchase Whenever you request replacement parts for or information on this equipment always supply the information you have recorded above Read this Operators Manual completely before attempting to use this equipment Save this manual and keep it handy for quick reference Pay particular attention to the safety instructions we have provided for your protection The level of seriousness to be applied to each is explained below A WARNING This statement appears where the information must be followed exactly to avoid serious personal injury or loss of life CAUTION This statement appears where the information must be followed to avoid minor personal injury or damage to this equipment vi TABLE OF CONTENTS Page Safety ee eee lee a ieee iia LIN E UE TEE SectionA Technical Specitications uuu Mae ua nani a aaah a ua da A 1 Safety ite UE aeren a dd A 2 Location and Ventilation c
19. intermittent use It cannot withstand long term use without proper maintenance See the MAINTENANCE section of this manual for more information CAUTION Certain electrical devices cannot be powered by the POWER ARC 5000 Refer to Table A 2 for these devices POWER ARC 5000 LINCOLN A 9 INSTALLATION TABLE A 2 A 9 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 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 refrigerators weed and hedge trimmers current inrush for starting See Table B 3 GENERATOR POWER 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 TV sets other electronic equipment An inductive type line condition e
20. should also be on your right side S Connect the work cable to the workpiece as close as possible to the area being welded 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 Do not work next to welding power source Mar 95 LINCOLN 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 In semiautomatic or automatic wire welding the electrode electrode reel w
21. to 100 a butt weld will be weaker than the material welded together 1 2 1 4 Poor 12mm 6mm 1 4 6mm 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 Good 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 t 1 8 3 2mm Successive passes must be used to build up butt welds on heavier metal OPERATION B 15 Fillet Welds When welding fillet welds 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 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 _ D ee E 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 POWER ARC 5000 LINCOLN B 16 Vertical U
22. to set for several minutes tion and carburetor flooded Follow Starting Shutdown Instructions section when starting the engine Fuel line clogged or closed Check line and or replace filter DO NOT RUN ENGINE WITHOUT AN IN LINE FUEL FILTER if using an alternate fuel tank or supply Recoil start will not engage with Gently hit the blower housing and or engine pull the rope to its fully extended position and rapidly wiggle Repeat until clutch engages with shaft and resistance is felt Fouled spark plug Replace spark plug Maintain proper spark gap Engine requires service to head Take the machine to an authorized head gasket and or valves Briggs amp Stratton Service Dealer Float open in carburetor amp gas leak f9 Close fuel shutoff valve Gently tap ing from bowl on carburetor bowl until float seats If gas still leaks repair carburetor per B amp S specifications Engine is siezed and recoil start will 110 Replace Engine not move A CAUTION 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 POWER ARC 5000 LINCOLN Joquunu BPOD 1u uudinb ay SAIN USsLUade ddI e 104 3u uiied q 2211195 y 0 HUM qIB lii S Weep ay 41 Sued inso 5z5u ayy JO uo UO BUIYDeW ay
23. welding out put B Generator power is available but unit will not weld PROBLEMS Open lead in flashing or field circuit Open flashing diode D1 Faulty brushes Faulty rheostat R1 5 Faulty field rectifier D1 Faulty capacitor C1 7 Faulty stator field winding Faulty rotor Dirty slip rings Loose connection to output stud Work not connected Electrode holder loose No open circuit voltage at output studs Open lead in weld circuit Faulty reactor L1 Rheostat R1 lead broke Refer to wiring diagram check lead 202C brown connection at oil gard switch in engine block check green GNDC lead con nected to bearing end bracket Check continuity in forward direction 202C brown and 202B red Check continuity and wear of brush Replace brush if necessary Rheostat resistance should be approximately 3 ohms when current control dial is set at 70 amps 5 Replace field rectifier Replace capacitor Disconnect lead 7A blue at D1 and check for continuity between leads 7A and 9A blue Remove brushes and check rotor resistance between slip rings It should read approximately 7 ohms See Generator Welder Maintenance section for brush installation procedure Clean slip rings with a fine git emery paper Check output studs and firmly tight en all connections Clean work clamp area of work to a
24. 875 hex head bolts lock washers and 3 8 16 hex nuts on each foot Detail A d Install the two axle support brackets Item 3 to the engine support channel using two each of the supplied 3 8 16 X 875 hex head bolts and lock washers two each of the supplied 3 8 16 hex nuts two each of the large plain washers spacers and two each of the vibration isolators Item 1 The two Figure A 2 Alternator Support Channel 3 8 16 Hex Nut 3 Lockwasher 3 3 8 16 x 875 Hex Bolt 3 E Sch Foot seas Item 2 3 8 16 x 875 Hex Bolt Lockwasher vibration isolators are installed in the inward holes furthest from the tube frame Refer to Figure A 2 Detail B The two large washers must be installed between the vibration isolators and the underside of the channel The remaining two large plain washers spacers are not used Install one of the push nuts Item 4 on one end of the axle Item 5 by supporting the axle vertical and tapping on the push nut with a rubber mallet or wooden block Install one wheel Item 6 on to the axle and slide the axle through the slots in the two axle support brackets The axle will rest on the two vibration iso lators when the machine is set on the ground pro viding a type of suspension for the axle Install the other wheel and push nut on the other end of the axle Loosen but do not remove the four screws that hold the handle clips Item 7 to the fuel tank sup
25. AMPS HIGH SOFTWELD 99NI 3 32 1 4 amp THINNER 80 AMPS LOW CAST IRON ELECTRODE 1 8 1 4 amp THICKER 125 AMPS LOW WEARSHIELD ABR 1 8 1 8 amp THICKER 150 AMPS HIGH NOTES The values listed are suggested settings Actual setting may vary depending on and or specific application POWER ARC 5000 LINCOLN individual preference B 11 Stick Welding A WARNING ARC RAYS can burn e When using an open arc process it is necessary to use correct eye head and body protection WX The Power Arc provides excellent weld output charac teristics when used in combination with Lincoln AC electrodes Other AC electrodes may also be used Follow the settings listed in Table B 4 Welding Applications Electrode Selection Guide found on the nameplate of the machine OPERATION Learning To Stick Weld The serviceability of a product or structure utilizing this type of information is and must be the sole responsi bility 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 weld ment design fabrication methods and service require ments No one can learn to weld simply by reading about it Skill comes only with practice The following pages will help the inexperienced w
26. Attach the work clamp securely to the work you are welding 4 Insert the electrode into the electrode holder 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 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 OPERA TION 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 POWER ARC 5000 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 125 Amps and less and 40 duty cycle applying to currents above 125 Amps 2 Duty cycle is based on a ten minute period The welder can be loaded to 150 Amps for four minutes out of every ten minute period or to 125 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 and from 90 through 150 Amps depending on which output terminal is used To obtain maximum weld output turn the
27. E 4 WELD OUTPUT TERMINAL TO WORK 5 GROUNDING TERMINAL ELECTRICAL OUTPUT CONNECTIONS See Figure A 3 for the location of the current control dial weld output terminals grounding terminal circuit breakers 240 and 120 volt receptacles WELDING CABLE CONNECTIONS Cable Size and Length Be sure to use welding cables that are large enough The correct size and length becomes especially important when you are welding at a distance from the welder Table A 1 lists recommended cable sizes and lengths for rated current and duty cycle Length refers to the distance from the welder to the work and back to the welder Cable diameters are increased for long cable lengths to reduce voltage drops E e POWER ARC 5000 WELDING ELECTRODES CIRCUIT BREAKERS 120 VOLTS 15 AMPS Pa e 30 AMPS Jel WORK LOW RANGE HIGH RAN L dh EA Q 120 SEN 30 AMPS ONO 6 CIRCUIT BREAKERS 3 7 GFCI DUPLEX RECEPTACLE 120 VOLT 15 AMP 8 TWIST LOCK RECEPTACLE 120 VOLT 30 AMP 9 TWIST LOCK RECEPTACLE 120 240 VOLT 30 AMP 10 ENGINE HOUR METER TABLE A 1 RECOMMENDED WELDING CABLE SIZE AND LENGTH TOTAL COMBINED LENGTH OF ELECTRODE AND WORK CABLES Cable Size for 150 amp Cable Length 40 Duty Cycle 0 50 feet 0 15 meters 6 AWG 50 100 feet 15 39 meters 4 AWG 100 150 feet 30 46 meters 3 AWG 150 200 feet 46061 meters 2 AWG 200 250 feet 61 76 meters 1 AWG
28. E UP AND DOWN MOVEMENT OF THE ARC WITH YOUR EYES KEEP THEM ON THE MOLTEN METAL OPERATION B 16 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 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 elec trode touch the metal 5 An up and down whipping e motion will help prevent arc burn through on very thin plate 9 y P 30 40 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 POWER ARC 5000 LINCOLN B 17 Overhead Welding Various techniques are used for overhead welding However in the interest of simplicity for the inexperi enced welder the f
29. FEATURES AND CONTROLS The POWER ARC 5000 was designed for simplicity Therefore it has very few operating controls A single dial on the control panel lets you select either genera tor or welding use For welding the same dial selects continuous current output over the machine s 70 to 125 amp low range and 90 to 150 amp high range The 11 HP Briggs amp Stratton gasoline engine controls include a recoil starter choke stop switch and low idle control See ENGINE OPERATION Section for details about starting running stopping and breaking in the gasoline engine GENERATOR The POWER ARC 5000 gives AC generator output for medium use commercial demands For more details on operating the generator see GENERATOR OPER ATION in this section of the manual WELDER The POWER ARC 5000 provides excellent constant current AC welding output for stick GMAW welding For more details on using the machine as a welder see WELDING OPERATION in this section of the manual WELDING CAPABILITY The POWER ARC 5000 is rated 150 amps 25 volts at 40 duty cycle on a ten minute basis This means that you can load the welder to 150 amps for four 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 125 amps for six minutes out of ten for a 60 duty cycle The current is continuously variable from 70 to 125 amps and 90 to 150 amps depending on which out pu
30. IM560 A POWER ARC 5000 Kee For Machines with Code Number 10255 and 10430 RETURN TO MAIN MENU 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 OPERATOR S MANUAL Date of Purchase ___ aa Serial Number E Code Number Model Where Purchased LINCOLN e World s Leader in Welding and Cutting Products e Sales and Service through Subsidiaries and Distributors Worldwide Cleveland Ohio 44117 1199 U S A TEL 216 481 8100 FAX 216 486 1751 WEB SITE www lincolnelectric com l SAFETY AA WARNING An CALIFORNIA PROPOSITION 65WARNINGS A 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 OR DEATH KEEP CHILDREN AWAY PACEMAKE
31. ODIC MAINTENANCE ENGINE MAINTENANCE CAUTION To prevent the engine from accidentally starting dis connect the spark plug lead before servicing the engine See Table D 1 for a summary of maintenance inter vals 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 2 shows engine maintenance replacement parts and numbers OIL Check the oil level after every 5 En hours of operation or daily BE SURE TO MAINTAIN THE OIL LEVEL Change the oil the first time after 5 hours of oper ation Then under normal operating conditions change the oil after every 50 hours or once a year 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 the side of the engine block or from the drain plug located at the bottom of the engine cover on the generator end Remove the oil dip stick and add 1 5 quarts of oil Check the level with the dip stick Do not overfill Use the grade and viscosity recommended in the Engine Owner s Manual FIGURE D 1 OIL DRAIN AND REFILL LOCATION 1 OIL DIP STICK OIL FILL TUBE 2 OIL DRAIN PLUGS FUEL At the end of each day s use refill the fuel tank to minimize moist
32. OLS OJO 2 ATT LINCOLN E FUEL SHUTOFF VALVE FUEL TANK AND CAP MUFFLER STOP SWITCH AIR CLEANER Qn OQ N GASOLINE ENGINE CONTROLS See Figure B 2 for the location of the following fea tures 1 FUEL SHUTOFF VALVE Stops the flow of gaso line from the fuel tank to the carburetor Should be closed by turning full clockwise whenever you are finished using the POWER ARC 5000 Open fuel shutoff valve by turning full counterclockwise before starting the engine FUEL TANK AND CAP Holds 5 5 gallons 20 8 liters of unleaded gasoline MUFFLER Reduces engine noise output Does not serve as a Spark arrester See SPARK ARRESTER in the INSTALLATION section of this manual STOP SWITCH Stops the engine by grounding the ignition circuit AIR CLEANER Filters intake air to the carburetor See ENGINE MAINTENANCE in the MAINTE NANCE section of this manual for details about the specific type of air cleaner to use GA CO O0 JO 10 CHOKE RECOIL STARTER OIL DRAIN PLUG OIL FILL AND DIP STICK LOW IDLE SPEED PULL DOWN NM CHOKE Provides a richer air fuel mixture for cold engine starting conditions See the topic ENGINE OPERATION below for details on setti
33. PM RATED OUTPUT WELDER Duty Cycle Amps Volts at Rated Amperes 40 Duty Cycle 150 25 VAC 60 Duty Cycle 125 25 VAC OUTPUT WELDER AND GENERATOR Welding Ranges Welder Open Circuit Voltage AC Auxiliary Power 70 150 Amps 62 VAC Max 5000 Watts 41 6 20 8 amps 120 240 volts 5 15 PHYSICAL DIMENSIONS Weight 208 lb 215 lb w undercarriage 94 3 kg 97 5 kg w undercarriage POWER ARC 5000 LINCOLN A 2 INSTALLATION A 2 Read this entire installation section before you start installation SAFETY PRECAUTIONS WARNING Do not attempt to use this equipment until you have thoroughly read all the operation and maintenance manuals supplied with your machine They include important safety precautions detailed engine starting operating and maintenance instructions and parts lists ELECTRIC SHOCK can kill e 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 e 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 se y Ke Stop the engine before ser vicing it Do not operate this equip ment with any of its doors open or guards off e Keep away from moving parts Only qualified personnel should install use or service this equipment
34. R 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 amp Cutting ANSI Standard 249 1 from the American Welding Society P O Box 351040 Miami Florida 33135 or CSA Standard W117 2 1974 A Free copy of Arc Welding Safety booklet E205 is available from the Lincoln Electric Company 22801 St Clair Avenue Cleveland Ohio 44117 1199 BE SURE THAT ALL INSTALLATION OPERATION MAINTENANCE AND REPAIR PROCEDURES ARE PERFORMED ONLY BY QUALIFIED INDIVIDUALS FOR ENGINE powered equipment 1 a Turn the engine off before troubleshooting and maintenance work unless the maintenance work requires it to be running 3 o A 1 h To avoid scalding do not remove the radiator pressure cap when the engine is hot 1 b Operate engines in open well ventilated areas or vent the engine exhaust fumes outdoors ELECTRIC AND MAGNETIC FIELDS may be dangerous 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 vaporiz ing 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 2 a Electric current flowing th
35. RNING Sec Do not touch electrically live parts or elec trodes with your skin or wet clothing E Arc Rays can burn When using an open arc process it is necessary to use correct eye head and body protection Do not breathe welding fumes or gases Use ventilation or exhaust to remove weld ing fumes from the breathing area Keep flammable material away Do not allow welding spatter and sparks to impinge on the fuel tank Do not allow a hot object such as a welding electrode to touch the fuel tank The POWER ARC 5000 generator welder can deliver from 70 to 150 amps of welding current for stick welding Output can be adjusted by setting the cur rent control dial on the output control panel 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 are using TO USE THE POWER ARC 5000 FOR STICK WELDING 1 The engine must be OFF when connecting the welding cables 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 Table B 4 WELDING APPLICATIONS or the ELECTRODE SELECTION GUIDE on the machine Output Control Panel 3
36. RUCTION FOR THIS EQUIPMENT AND THE CONSUMABLES TO BE USED AND FOLLOW YOUR EMPLOYER S SAFETY PRACTICES SE RECOMIENDA LEER Y ENTENDER LAS INSTRUCCIONES DEL FABRICANTE PARA EL USO DE ESTE EQUIPO Y LOS CONSUMIBLES QUE VA A UTILIZAR SIGA LAS MEDIDAS DE SEGURIDAD DE SU SUPERVISOR LISEZ ET COMPRENEZ LES INSTRUCTIONS DU FABRICANT EN CE QUI REGARDE CET EQUIPMENT ET LES PRODUITS A ETRE EMPLOYES ET SUIVEZ LES PROCEDURES DE SECURITE DE VOTRE EMPLOYEUR LESEN SIE UND BEFOLGEN SIE DIE BETRIEBSANLEITUNG DER ANLAGE UND DEN ELEKTRODENEINSATZ DES HER STELLERS DIE UNFALLVERHUTUNGSVORSCHRIFTEN DES ARBEITGEBERS SIND EBENFALLS ZU BEACHTEN Keep your head out of fumes Use ventilation or exhaust to remove fumes from breathing zone Los humos fuera de la zona de res piracion Mantenga la cabeza fuera de los humos Utilice ventilaci n o aspiraci n para gases Gardez la t te l cart des fum es e Utilisez un ventilateur ou un aspira teur pour ter les fum es des zones de travail Vermeiden Sie das Einatmen von Schweibrauch Sorgen Sie fiir gute Be und Entl ftung des Arbeitsplatzes Mantenha seu rosto da fuma a Use ventila o e exhaust o para remover fumo da zona respirat ria Es1 APSMERTLSICLT F n BAPHECTIHIEBLTIA DM ECETIA OCF AAA A ARE e zs SH7IAE YelsHiAle e S XACE E 2743 AAS AH FAAA H4 557E ABSHIAIS gal ys Jung dul ale SU ARA bi Ja A iail arin O gad adits BAL Ge
37. angerous 5 a Welding may produce fumes and gases hazardous to health Avoid breathing these fumes and gases When welding keep your head out of the fume Use enough ventilation and or exhaust at the arc to keep fumes and gases away from the breathing zone When welding with electrodes which require special ventilation such as stainless or hard facing see instructions on container or MSDS or on lead or cadmium plated steel and other metals or coatings which produce highly toxic fumes keep exposure as low as possible and below Threshold Limit Values TLV using local exhaust or mechanical ventilation In confined spaces or in some circumstances outdoors a respirator may be required Additional precautions are also required when welding on galvanized steel 5 b Do not weld in locations near chlorinated hydrocarbon vapors coming from degreasing cleaning or spraying operations The heat and rays of the arc can react with solvent vapors to form phosgene a highly toxic gas and other irritating products 5 c Shielding gases used for arc welding can displace air and cause injury or death Always use enough ventilation especially in confined areas to insure breathing air is safe 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 o
38. ck 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 the heel the third weld 9 229mm from the heel etc E 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 Backstepping greatly reduces the chances for crack ing of the share and it also greatly reduces warping NOTE The entire process is rather fast Many begin ners 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 hot IF White brittle cast iron 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 below OPERATION B 18 When breaking the weld stays on one piece To overcome this the welding operator has two choices 1 Preheat the entire casting to 500 1200 F 260 649 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 2 Weld 1 2 12 7mm at a time and do not weld at that spot again
39. ctrode holder or any other electrically hot parts to touch a cylinder Keep your head and face away from the cylinder valve outlet when opening the cylinder valve Valve protection caps should always be in place and hand tight except when the cylinder is in use or connected for use 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 Install equipment in accordance with the U S National Electrical Code all local codes and the manufacturer s recommendations Ground the equipment in accordance with the U S National Electrical Code and the manufacturer s recommendations Mar 95 i SAFETY i PRECAUTIONS DE SURETE 5 Toujours porter des lunettes de s curit dans la zone de Pour votre propre protection lire et observer toutes les instruc tions et les pr cautions de s ret specifiques qui parraissent dans ce manuel aussi bien que les pr cautions de s ret g n rales suivantes S ret Pour Soudage A L Arc 1 Protegez vous contre la secousse lectrique Les circuits l lectrode et la pi ce sont sous tension qua
40. de soliel TRANSFORMATEUR ET A REDRESSEUR donc a Utiliser un bon masque avec un verre filtrant appropri ainsi qu un verre blanc afin de se prot ger les yeux du rayonnement de l arc et des projections quand on soude ou quand on regarde l arc Porter des v tements convenables afin de prot ger la peau de soudeur et des aides contre le rayonnement de l arc Prot ger l autre personnel travaillant proximit au soudage l aide d crans appropri s et non inflamma bles Des gouttes de laitier en fusion sont mises de l arc de soudage Se prot ger avec des v tements de protection libres de l huile tels que les gants en cuir chemise paisse pantalons sans revers et chaussures montantes LINCOLN Relier la terre le chassis du poste conformement au code de l lectricit et aux recommendations du fabricant Le dis positif de montage ou la piece souder doit tre branch une bonne mise la terre Autant que possible l installation et l entretien du poste seront effectu s par un lectricien qualifi Avant de faires des travaux l interieur de poste la debrancher l interrupteur la boite de fusibles Garder tous les couvercles et dispositifs de s ret leur place Mar 93 v v for selecting a QUALITY product by Lincoln Electric We want you J hank You to take pride in operating this Lincoln Electric Company product ses as much pride as we have in
41. draw up to 15 amps from either side of the 120 volt duplex receptacle Up to 30amps can be drawn from the 120 volt Twist Lock recepta cle Up to 20 8 amps of 240 volt power can be drawn from the 120 240 volt Twist Lock receptacle 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 POWER ARC 5000 Be sure to read the notes at the bottom of the table TO USE THE GENERATOR AS AN AUXILIARY POWER SUPPLY 1 Start the gasoline engine See ENGINE OPERA TION in this section of the 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 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 4 000 watts Be sure to start the largest loads first POWER ARC 5000 LINCOLN B 8 OPERATION TABLE B 3 GENERATOR POWER APPLICATIONS Suggested Powe
42. e engine A4 MOVING PARTS can injure yr Do not operate this equipment with AR A 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 ser vice this equipment GENERAL DESCRIPTION 5000 Watt power generator and arc welder built into one machine High quality long life Briggs amp Stratton 11 HP Industrial Plus engine with cast iron cylinder 5 5 gallon fuel tank for long running times before refueling For commercial rental and home use 120 volt and 240 120 volt twist lock receptacles both rated at 30 Amps for easy reliable power connections Mating twist lock plugs are included 120 volt duplex ground fault circuit interruper GFCI receptacle is standard for safety and OSHA compliance on the job site 150 amp AC stick welder for welding with up to 5 32 dia welding rod Two welding ranges with continuous output con trol on each range Wheel kit and adjustable handle are included Rugged 1 1 4 dia tube frame for roll over protection M anual low idle Automatic shutdown if oil level is too low Hour meter for scheduled engine maintenance Two year warranty on welder generator and engine if non commercial use one year on engine if used for commercial purposes eee e e o POWER ARC 5000 LINCOLN B 2 OPERATION B 2 RECOMMENDED APPLICATIONS OPERATIONAL
43. elder 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 cir cuit and the equipment that provides the electric cur rent used in the arc Figure B 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 cir cuit 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 Arc Welding power source and controls Electrode Holder Electrode N Arc N Electrode Cable Work N Work i E p Work Clamp ii Work Cable
44. elding head nozzle or semiautomatic welding gun are also electrically hot 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 Ground the work or metal to be welded to a good electrical earth ground Maintain the electrode holder work clamp welding cable and welding machine in good safe operating condition Replace damaged insulation Never dip the electrode in water for cooling 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 When working above floor level use a safety belt to protect yourself from a fall should you get a shock Also see Items 6 c and 8 ARC RAYS can burn 4 a Use a shield with the proper filter and cover LE plates to protect your eyes from sparks and TT the rays of the arc when welding or observing open arc welding Headshield and filter lens should conform to ANSI Z87 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 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 3 FUMES AND GASES a can be d
45. 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 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 20 30 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 3 Use 1 8 3 2mm Wearshield at 80 100 A Strike the arc about one inch from the sharp edge POWER ARC 5000 LINCOLN B 18 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 Work Tabl Strike Arc ork Table Brick u gt y Here Sharp Edge ss Plow Share 1 2 3 4 width 12 20mm Positioning of Share Weaving Motion 5 Use the ba
46. eptacle Replace receptacle Rheostat R1 lead broke Refer to wiring diagram check lead 200B black check rheostat tabs D Engine runs erratically or stops run f1 Engine requires service to head car 1 Service engine as outlined in Engine ning buretor filters oil spark plug and or Maintenance section NEVER gas OPERATE THE ENGINE WITHOUT AN IN LINE FUEL FILTER when using an alternate fuel tank or sup ply E Engine sputters but will not start Bad gas bad filter air cleaner spark 1 Replace with clean or new parts plug and or breather A CAUTION 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 POWER ARC 5000 LINCOLN E 3 TROUBLESHOOTING E 3 Observe all Safety Guidelines detailed throughout this manual PROBLEMS POSSIBLE AREAS OF RECOMMENDED SYMPTOMS MISADJUSTMENTS S COURSE OF ACTION PROBLEMS F Engine will not start Spark plug boot or wire off loose or Dry and Place boot firmly onto spark wet plug Low oil and engine protection system 12 Check and fill oil to proper level will not allow engine to start Oil light may flash when attemting to start engine Fuel shutoff valve is closed Open valve by turning counterclock wise Choke left in lowest downward posi 4 Allow unit
47. erator grounding terminal MUST be securely connected to the metal frame of the vehicle See Figure A 3 The grounding terminal is marked with the symbol AUXILIARY POWER RECEPTACLES The control panel of the POWER ARC 5000 features three auxiliary power receptacles One 15 amp 120 volt ground fault circuit inter rupter GFCI duplex interrupter NENA Style 5 15R One 30 amp 120 volt Twist Lock receptacle NEMA Style L5 30R One 30 amp 120 240 volt Twist Lock receptacle NEMA Style L14 30R See Figure A 3 The receptacles are UL and CSA approved POWER ARC 5000 LINCOLN A 8 INSTALLATION A 8 3 WIRE CORD SET 10 AWG OR LARGER CONNECT BLACK WIRE TO TERMINAL WITH BRASS SCREW CONNECT WHITE WIRE TO TERMINAL WITH SILVER SCREW GREEN GROUND 120 VOLTS 30 AMPERE PLUG NEMA STYLE L5 30P Y HOT HOT GROUND 4WIRE CORD SET 10 AWG OR LA GREEN NEUT RGER x HOT GROUND oe Ae 240 VOLTS 30 AMPERE PLUG NEMA STYLE L14 30P POWER CORD CONNECTIONS TO TWIST LOCK PLUGS Refer to the appropriate diagram above for proper connection of power cord wires to the Twist Lock plug terminals Also read the instruction sheet supplied with the Twist lock plug PLUGS AND HAND HELD EQUIPMENT For further protection against electric shock any 120 volt hand held equipment connected to the generator receptacles must use a three blade grounded type plug or an Underwriter s Laboratories UL approved do
48. g easy Figure A 1 INSTALLATION A 3 ASSEMBLY OF VIBRATION ISOLATORS TO BOTTOM OF TUBE FRAME If wheels are not used Tools required 9 16 wrench or socket If the supplied wheels are not used it is important that the isolators are installed to keep the machine stabilized when operated on a smooth surface Install the four molded rubber vibration isolators to the bot tom of the engine and alternator support channels using four each of the supplied 3 8 16 X 875 hex head screws lock washers and large plain washers spacers The large plain washers spacers must be installed between the isolator and the underside of the channels See Figure A 1 3 8 16 x 875 Hex Head Bolt Lockwasher L Frame E Large Plain Washer Spacer Rubber Isolator L POWER ARC 5000 LINCOLN A 4 INSTALLATION A 4 Assembly of Wheels and Handle to the Tube Frame Tools Required Two 9 16 wrenches or sockets 3 8 wrench or socket and a rubber mallet or wooden block Refer to Figure A 2 for illustration of proper assembly a Set the machine on blocks so that it is raised up off the floor by approximately 6 inches b Install two of the vibration isolators Item 1 to the bottom of each foot Item 2 using one each of the supplied 3 8 16 X 875 hex head bolts and lock washers on each foot Detail A c Install the two feet to the alternator support channel using three each of the supplied 3 8 16 X
49. ia an u u ana ne are as A 2 Assembly of Vibration Isolators to Bottom of Tube Frame A 3 Assembly of Wheels and Handle to the Tube Frame A 4 Pre operation Engine Service siennes A 5 Electrical Output Connections A A 6 to A 9 Operations bcd uae a anda nek Ae ine ae ee i ea a ee Section B Safety IRStr ctlonS uu n n dies Aula ete ii Ah ede tlie awia y te B 1 General DES elle 1 a titan Le AR A DA Num QS LE eh ee B 1 Recommended Applications seen B 2 Controls and Settings u u u nied TEE B 3 Engine Op rations coe ee ann AAA LA Ra usa B 5 Generator Operations fasses Ghani oan Pete EAA nn tia B 7 Welding Operation diia lid dic B 9 Learning to Stick Weld sana Ea B 11 ACCESSONES ci m Sun dad eel dad hain he nuit ht end Lee Section C Maintenance tn S he anand nonin nid ae Section D Safety Mel D 1 Routine and Periodic Maintenance D 1 Major Component Locations sise D 5 Troubleshooting and Repair Section E Electrical DIagramMS lt u u D S l S egene Section F Parts Malal a buah tt Eeer P277 Series POWER ARC 5000 LINCOLN vi A 1 INSTALLATION A 1 TECHNICAL SPECIFICATIONS POWER ARC 5000 INPUT GASOLINE ENGINE Manufacturer Description Speed Displacement Ignition Capacities Briggs amp 1 cyl 3700 RPM 24 4 cu in Electronic Fuel 5 5 gal 20 8 Stratton 4 cycle 50 RPM 400 cc Ignition Industrial air cooled at no load Recoil start Oil 1 5 qt 1 42 I Plus gasoline Manual choke 11 HP o 3600 R
50. is opposite Whenever possible weld from left to right if right handed This enables you to see clearly what you are doing Hold the electrode at a slight angle as shown in Figure B 5 15 20 I l 90 side view end view Correct Welding Position Figure B 5 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 NOTE 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 OPERATION B 13 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 elec trode 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 incor
51. jo y de la tierra O Ne laissez ni la peau ni des v te ments mouill s entrer en contact avec des pi ces sous tension e solez vous du travail et de la terre e Ber hren Sie keine stromf hrenden Teile oder Elektroden mit Ihrem K rper oder feuchter Kleidung Isolieren Sie sich von den Elektroden und dem Erdboden e Nao toque partes el tricas e elec trodos com a pele ou roupa molha da O Isole se da peca e terra o REPOR iHe ELE Chi suc F J T 19697 Z p OS 363 NTWSHRELTFSU e RREAN DEBREREAR SFR MAIER d TH e small S458 N2 Jy Ez Siss a Sal HAR e 2x9 HIE Weal HAR A L gone ll el all Qual YO Arca das 29 SONT gh la gS ell Aal dal Jai P dua e die aa Keep flammable materials away Mantenga el material combustible fuera del area de trabajo e Gardez l cart de tout mat riel inflammable Entfernen Sie brennbarres Material Mantenha inflamaveis bem guarda dos CRAP TUSEOOM CORRE HN LU THEN EA ep Ed T IF PF o LS AS Aal He Ad d s s UE dall pis Wear eye ear and body protection Prot jase los ojos los oidos y el cuerpo Prot gez vos yeux vos oreilles et votre corps e Tragen Sie Augen Ohren und K r perschutz e Use protec o para a vista ouvido e corpo e B HRUSBCRBRELTE iD RR HRARGHRBAR ex 19 Sal Seats HSSHAR Adi y due de Lily lan Gl ysl o A ag READ AND UNDERSTAND THE MANUFACTURER S INST
52. ll zg ct e Turn power off before servicing Desconectar el cable de ali mentaci n de poder de la maquina antes de iniciar cualquier servicio D branchez le courant avant l entre tien e Strom vor Wartungsarbeiten abschalten Netzstrom v llig ff nen Maschine anhalten Nao opere com as tampas removidas Desligue a corrente antes de fazer servico Nao toque as partes el tricas nuas XVLFFYA Y EAKCRUD PRE EFFERRI YA DBF MTF etna RE m e pHo HAS el ett Als Aie Alt a NM pity gl Jl ale Do not operate with panel open or guards off No operar con panel abierto o guardas quitadas e N op rez pas avec les panneaux ouverts ou avec les dispositifs de protection enlev s Anlage nie ohne Schutzgeh use oder Innenschutzverkleidung in Betrieb setzen Mantenha se afastado das partes moventes Nao opere com os paineis abertos ou guardas removidas NAWPAN EDVYALEEE HR ES U t AC SEU ERAS ARETES Ro exo Yel HAE 13 HA L t Cols 13 la lu Jato Yo Aale Viel Al Aaaa WARNING Spanish AVISO DE PRECAUCION French ATTENTION German WARNUNG Portuguese ATEN AO Japanese it is BIR LEIA E COMPREENDA AS INSTRU ES DO FABRICANTE PARA ESTE EQUIPAMENTO E AS PARTES DE USO E SIGA AS PRATICAS DE SEGURANCA DO EMPREGADOR SRM OBHOX HD OHBRBEE lt K MA ETHBRMLT EW CL TRHORERE HS lt F ux HAM SUCR UR fit ND RES AMENER RAR sp J A BS EE ECKE
53. nd 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 sug gest you purchase a copy of New Lessons in Arc Welding See Book Division section 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 contaminants Types of Welds Five types of welding joints are Butt Welds Fillet Welds Lap Welds Edge Welds and Corner Welds Of these the Butt Weld and Fillet Weld are the most common LILI Butt Weld Lap Weld Edge Weld Fillet Weld Corner Weld Butt Welds Butt Welds are the most widely used welds 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 Tack the plates at both ends otherwise the heat will cause the plates to move apart See drawing POWER ARC 5000 LINCOLN B 15 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 209 end view 90 side view 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
54. nd la machine souder est en marche Eviter toujours tout contact entre les parties sous tension et la peau nue ou les v tements mouill s Porter des gants secs et sans trous pour isoler les mains Faire tr s 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 couch pour lesquelles une grande partie du corps peut tre en contact avec la soudage Utiliser des lunettes avec crans lateraux dans les zones o l on pique le laitier Eloigner les mat riaux inflammables ou les recouvrir afin de pr venir tout risque d incendie d aux tincelles Quand on ne soude pas poser la pince une endroit isol de la masse Un court circuit accidental peut provoquer un chauffement et un risque d incendie S assurer que la masse est connect e le plus pr s 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 loign s de la zone de travail on augmente le risque de voir passer le courant de soudage par les chaines de lev age c bles de grue ou autres circuits Cela peut provoquer des risques d incendie ou d echauffement des chaines et des c bles jusqu ce qu ils se rompent masse 9 Assurer une ventilation suffisante dans la zone de soudage Maintenir le porte lectrode la pince de masse
55. ng cutting or welding They may explode Sparks and spatter are thrown from the welding arc Wear oil free protective garments such as leather gloves heavy shirt cuffless trousers high shoes and a cap over your hair Wear ear plugs when welding out of position or in confined places Always wear safety glasses with side shields when in a welding area 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 cir cuits This can create fire hazards or overheat lifting chains or cables until they fail Also see item 1 c LINCOLN CYLINDER may explode SEL s 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 Always keep cylinders in an upright position securely chained to an undercarriage or fixed support 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 Never allow the electrode ele
56. ng the choke RECOIL STARTER Manual rope type starter The handle position allows easy starting from either ground level or pickup truck level OIL DRAIN PLUG Permits convenient draining of engine oil during maintenance OIL FILL AND DIP STICK Permits convenient checking of oil level and filling of engine oil LOW IDLE SPEED PULL DOWN Pull this lever out and latch it to reduce the engine idle to 2200 RPM when a low idle is desired Release lever and let engine return to high idle 3700 RPM before aplying any type of load POWER ARC 5000 LINCOLN amp B 5 OPERATION B 5 ENGINE OPERATION WARNING DO NOT RUN THE ENGINE AT EXCESSIVE SPEEDS The maximum allowable high idle speed for the POWER ARC 5000 is 3750 RPM no load Do NOT adjust the governor screw on the engine Severe per sonal 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 Briggs amp Stratton Operating and Maintenance Instructions manual that is shipped with the POWER ARC 5000 BEFORE STARTING THE ENGINE CHECK AND FILL THE ENGINE OIL LEVEL AENA Place the machine on a level surface Remove the oil fill cap and dip stick 3 Fill if necessary to the full mark on the dip stick Do NOT overfill 4 Replace the oil fill cap and tighten securely CHECK AND FILL THE ENGINE FUEL TANK 1 Remove the fuel tank cap 2 Fill the tank to
57. ng 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 prac tice 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 bet ter than the first weld By constantly checking on your mistakes and your progress welding will soon be a routine matter Common Metals 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 These higher carbon steels can be OPERATION B 14 welded successfully in most cases however care must be taken to follow proper procedures including preheating the metal to be welded a
58. oint 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 stead ier 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 bet ter 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 out of 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 POWER ARC 5000 LINCOLN B 13 1 The Correct Welding Position Illustrated is the correct welding position for right handed people For left handed people it
59. ollowing 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 Side View End View ESAS l I d 30 30 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 problem burn through Follow these simple rules 1 Hold a very short arc This together with the prop er travel speed will eliminate burn through 2 Use 1 8 3 2mm or 3 32 2 5mm AWS 6011 3 Use low amperage 75 A for 1 8 3 2mm elec trode 70 A for 3 32 2 5mm electrode OPERATION B 17 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 fil lets 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
60. ose the fuel shutoff valve at the bottom of the fuel tank by turning it full clockwise For long peri ods of storage close 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 min imize fuel gum deposits WARNING Close the fuel valve when the machine is transported to prevent fuel leakage from the carburetor BREAK IN PERIOD The engine will use a greater amount of oil during its break in period The break in is about 12 running hours Check the oil frequently during break in Change the oil after the first 5 hours of operation For more details see the MAINTENANCE section of this manu al CAUTION During break in subject the POWER ARC 5000 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 POWER ARC 5000 LINCOLN B 7 OPERATION B 7 GENERATOR OPERATION CAUTION Be sure that any electrical equipment plugged into the generator s AC power receptacles can withstand a 5 15 voltage and a 5 frequency variation Some electronic devices cannot be powered by the POWER ARC 5000 Refer to Table A 2 ELECTRICAL DEVICE USE WITH THE POWER ARC 5000 in the INSTALLATION section of this manual GENERAL INFORMATION The POWER ARC 5000 generator is rated at 5000 continuous watts It provides both 120 volt and 240 volt power You can
61. over heating and damage FIGURE D 2 CLEAN ROTATING SCREEN FINGER GUARD DEBRIS GUARD 1 ROTATING SCREEN CLEAN COOLING SYSTEM See Figure D 3 Clean the internal cooling fins and surfaces to prevent over speeding overheating and engine damage Clean every 100 operating hours or as often as necessary using a brush and low pressure air FIGURE D 3 CLEAN COOLING SYSTEM 1 REMOVE DIRT FROM THESE AREAS CLEAN OR REPLACE SPARK PLUG Clean or replace the spark plug after every 100 hours of opera 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 sol vent 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 4 FIGURE D 4 SET SPARK PLUG GAP Use the Briggs amp Stratton Engine Manual for latest Plug Gap Info CLEAN SPARK ARRESTER SCREEN If the muffler has the optional spark arrester assembly remove it every 50 hours or once a year whichever comes first and inspect it Clean the arrester Replace it if you find any damage CYLINDER HEAD TORQUE PROCEDURE Use a torque wrench and tighten the cylinder head bolts to 165 inch pounds in the sequence shown in Figure D 5 This procedure is to be performed after the first 100 300 hours of operation POWER ARC 5000 LINCOLN D 3
62. p 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 Short arc NOTE Holder end of electrode is lower than arc 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 hori zontal or pointing slightly upwards See drawing above 3 The arc is struck and metal deposited at the bot tom 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 solidi fied the arc is SLOWLY brought back and another few drops of metal are deposited DO NOT FOLLOW TH
63. r Applications Running Watts Start up Watts 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 2 000 2 900 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 2 000 2 500 4 000 Sump Pump 600 1 500 2 400 Toaster 1 100 Weed Trimmer 500 Lincoln 100 or 125 Amp Wire Feeder Welder 3 000 4 600 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 equipment listed in the table multiply RUNNING WATTS by 2 Multiple loads can be used as long as the total load does not exceed 5 000 watts Be sure to start the largest loads first For example a 1 HP motor needs approximately 2 000 watts while running but may require 2 500 watts to start Some inductive motors may require as much as 4 times running watts to start POWER ARC 5000 LINCOLN B 9 OPERATION B 9 WELDING OPERATION GENERAL INFORMATION WA
64. r Briggs amp Stratton Gasoline Additive Part No 5041 available from any Authorized Briggs amp Stratton Service Center in the fuel system Mix the additive with the fuel in the tank and run the engine for a short time to circulate the additive through the carburetor 4 While the engine is still warm drain the oil and refill with fresh oil per the engine manual 5 Remove the spark plug and pour approximately 1 2 ounce 15 ml of engine oil into the cylinder Replace the spark plug and crank the engine Slowly to distribute the oil 6 Clean any dirt and debris from the cylinder and cylinder head fins and housing rotating screen and muffler areas 7 Store in a clean dry area POWER ARC 5000 LINCOLN A 3 STACKING POWER ARC 5000 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 on other than the ground must be firm non skid and structurally sound The gasoline engine is designed to run in a level posi tion 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 POWER ARC 5000 should be lifted by four peo ple It weighs 208 lbs 94 3 kg Its welded tube roll cage is designed to make liftin
65. r along with transient and surge protection is required and liabilities still exist DO NOT USE THESE DEVICES WITHA POWER ARC 5000 The Lincoln Electric Company is not responsible for any damage to electrical components improperly connect ed to the POWER ARC 5000 POWER ARC 5000 LINCOLN B 1 OPERATION B 1 OPERATING INSTRUCTIONS Read and understand this entire section before oper ating your POWER ARC 5000 SAFETY INSTRUCTIONS 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 e 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 FUMES AND GASES can be dangerous Keep your head out of fumes e Use ventilation or exhaust to remove fumes from breathing zone ay WELDING SPARKS can cause JE fire or explosion Keep flammable material away e Do not weld on containers that have held combustibles AA WARNING 4 ARC RAYS can burn Wear eye ear and body protection L ENGINE EXHAUST can kill Use in open well ventilated areas or vent exhaust to the outside Do not stack anything on or near th
66. r from the manufacturer 5 e Also see item 1 b Mar 95 LINCOLN SAFETY 7 WELDING SPARKS can lt gt cause fire or explosion 6 a Remove fire hazards from the welding area If this is not possible cover them to prevent the welding sparks from starting a fire Remember that welding sparks and hot materials from welding can easily go through small cracks and openings to adjacent areas Avoid welding near hydraulic lines Have a fire extinguisher readily available 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 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 Do not heat cut or weld tanks drums or containers until the proper steps have been taken to insure that such procedures will not cause flammable or toxic vapors from substances inside They can cause an explosion even though they have been cleaned For information purchase Recommended Safe Practices for the Preparation for Welding and Cutting of Containers and Piping That Have Held Hazardous Substances AWS F4 1 from the American Welding Society see address above Vent hollow castings or containers before heati
67. rect long arc has a hollow blowing or hissing sound 4 The Correct Welding Speed The important thing to watch while welding is the pud dle 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 solidi fies indicates correct welding speed The ridge should be approximately 3 8 9 5mm behind the electrode Ridge where puddle solidifies K Molten puddle Most beginners tend to weld too fast resulting in a thin uneven wormy looking bead They are not watching the molten metal IMPORTANT Itis 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 POWER ARC 5000 LINCOLN B 14 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 Current Setting 90 125 Amps AC Do the following 1 Learn to strike the arc by scratchi
68. rough any conductor causes localized Electric and Magnetic Fields EMF Welding current creates EMF fields around welding cables and welding machines EMF fields may interfere with some pacemakers and welders having a pacemaker should consult their physician before welding 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 Pn Exposure to EMF fields in welding may have other health parts when starting operating or repairing equipment effects which are now not known All welders should use the following procedures in order to minimize exposure to EMF fields from the welding circuit 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 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 e Do not attempt to override the governor or idler by pushing on the throttle control rods while the engine is running 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
69. s Many welding instructors will want to use the book as a reference for all students by taking advantage of the low quantity discount prices which include shipping by 4th class parcel post 15 00 postage paid U S A Mainland How To Read Shop Drawings The book contains the latest information and application data on the American Welding Society Standard Welding Symbols Detailed discussion tells how engineers and draftsmen use the short cut language of symbols to pass on assembly and welding information to shop personnel Practical exercises and examples develop the reader s ability to visualize mechanically drawn objects as they will appear in their assembled form 187 pages with more than 100 illustrations Size 8 1 2 x 11 Durable cloth covered board binding 4 50 postage paid U S A Mainland There is a 10 discount on all orders of 50 00 or more for shipment at one time to one location New Lessons in Arc Welding Lessons simply written cover manipulatory techniques machine and electrode characteristics related subjects such as distortion and supplemental information on arc welding applications speeds and costs Practice materials exercises questions and answers are suggested for each lesson 528 pages well illustrated 6 x 9 size bound in simulated gold embossed leather 5 00 postage paid U S A Mainland Need Welding Training The Lincoln Electric Company operates the oldest and mos
70. t range is selected The POWER ARC 5000 can weld with all 3 32 most 1 8 and some 5 32 diam eter Lincoln AC electrodes LIMITATIONS e The POWER ARC 5000 is not recommended for any processes besides those that are normally per formed using stick welding SMAW procedures The POWER ARC 5000 is not recommended for pipe thawing The POWER ARC 5000 is not recommended for AC TIG welding 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 EQUIP MENT WHILE YOU ARE WELDING e POWER ARC 5000 LINCOLN B 3 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 2 3 4 5 6 7 8 9 1 OPERATION B 3 e POWER ARC 5000 WELDING ELECTRODES CIRCUIT BREAKERS 120 VOLTS 15 AMPS POCO k lt q 9 120 240 VOLTS 30 AMPS _ 7 x 7 OF Q 120 VOLTS 30 AMPS WORK LOW RANGE HIGH RANGED a WELD OUTPUT TERMINALS TO ELECTRODE HOLDER HIGH RANGE AND LOW RANGE CURRENT CONTROL DIAL ELECTRODE SELECTION GUIDE WELD OUTPUT TERMINAL TO WORK GROUNDING TERMINAL CIC GFCI DUPLEX RECEPTACLE 120 VOLT 15 AMP GFCI DUPLEX RECEPTACLE
71. t respected Arc Welding School in the United States at its corporate headquarters in Cleveland Ohio Over 100 000 stu dents have graduated Tuition is low and the training is hands on For details write Lincoln Welding School 22801 St Clair Ave Cleveland Ohio 44117 1199 and ask for bulletin ED 80 or call 216 383 2259 and ask for the Welding School Registrar Lincoln Welding School BASIC COURSE 5 weeks of fundamentals A 700 00 lorders of 50 or less before discount or orders outside of North America must be prepaid with charge check or money order in U S Funds Only l IPrices include shipment by 4 th Class Book Rate for U S A Mainland Only Please allow up to 4 weeks for delivery IUPS Shipping for North America Only All prepaid orders that request UPS shipment please add I 5 00 For order value up to 49 99 l 10 00 For order value between 50 00 amp 99 99 l 15 00 For order value between 100 00 amp 149 00 l IFor North America invoiced orders over 50 00 8 credit card orders if UPS is requested it will be invoiced or charged to you at cost Outside U S A Mainland order must be prepaid in U S Funds Please add 2 00 per book for surface mail or 15 00 per book for air parcel post shipment IMETHOD OF PAYMENT Sorry No C O D Orders I CHECK ONE _ Please Invoice only if order is over PI Invoi ly if order i 50 00 I Check or Money Order Enclosed U S Funds only
72. the seam as shown in figure d below d Single and double beads with and without beveling for tight partial strength joints 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 appli cation MILD STEEL ELECTRODES may be classi fied into the following groups 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 all position 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 draw ing for the first pass on vertical up welds High Speed Group AWS E6013 OPERATION B 19 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 fillets and laps or short and irregular welds that change direction or position They are also widely used in maintenance and recom mended for sheet metal fillet and lap
73. ty cycle Spark Arrester K883 2 A field installed kit for the 11 HP Briggs amp Stratton engine Rotor Removal Kit S20925 A service kit for removing the generator rotor from the tapered engine crankshaft BRIGGS AND STRATTON ACCESSORIES The following options accessories are available for your POWER ARC 5000 from your local Briggs amp Stratton Distributor Exhaust Deflector B amp S No 393761 Used to deflect engine exhaust down Attaches to the muffler with four screws POWER ARC 5000 LINCOLN C 1 D 1 MAINTENANCE D 1 SAFETY PRECAUTIONS WARNING e Have qualified personnel do all maintenance and troubleshooting work Turn the engine off before working inside the machine e Remove guards only when necessary to perform maintenance and replace them when the mainte nance 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 manu al and in the Briggs amp Stratton Operating and Maintenance Instructions manual before working on the POWER ARC 5000 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 start ing operating or repairing this machine ROUTINE AND PERI
74. uble insulation system with a two blade plug CIRCUIT BREAKERS The POWER ARC 5000 has circuit breakers for overload protection When the machine is operated in high O O temperature environments the breakers may tend to trip at lower loads than normal ly CAUTION Never bypass the circuit breakers Without overload protection the POWER ARC 5000 could overheat and or cause damage to the equipment being used PREMISES WIRING The POWER ARC 5000 three wire grounded neutral generator allows it to be connected to premises wiring However the wiring procedure needed to meet the National Electric Code NEC regulations as well as city ordinances can be confusing Matters get worse depending on whether you want the machine to be hardwired to the premises or only connected temporarily AA WARNING Only a licensed certified trained electrician should install the machine to a premises or residential electri cal system Be certain that e The premises is isolated and no feedbacking into the utility system can occur Certain state and local laws require the premises to be isolated before the generator is linked to the premises Check your state and local requirements e A double pole double throw transfer switch in con junction with the properly rated double throw cir cuit breaker is connected between the generator power and the utility meter Remember that the POWER ARC 5000 is intended only for backup
75. until the weld is cool This way no large amount of heat is put into the mass Most inexperienced welders will probably use the sec ond 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 pre heating 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 Wherever practical the joint to be welded should be veed out by grinding or filing to give complete pene tration as shown in figures a b and c below This is especially important on thick castings where maxi mum strength is required In some instances a back POWER ARC 5000 LINCOLN B 19 up strip may be used and plates may be gapped 1 8 3 2mm or more as shown in w AD Scrap E up strip Three ways to prepare plates where complete penetration is necessary On sections where only a sealed joint is required and strength is not important the joint may be welded after slightly veeing out
76. ure conden sation and dirt contamination in the fuel line ENGINE ADJUSTMENTS A 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 operat ed at speeds above maximum Adjustments to the engine are to be made only by a Lincoln Service Center or an authorized Field Service Shop POWER ARC 5000 LINCOLN D 2 MAINTENANCE D 2 CLEAN AIR FILTER PRE CLEANER CAUTION Do not use petroleum solvents such as kerosene to clean the air pre cleaner They may cause deteriora tion of the air pre cleaner DO NOT USE PRESSUR IZED AIR TO CLEAN OR DRY THE AIR PRE CLEANER 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 CLEAN ENGINE Remove dirt and debris with a cloth or a brush Do not clean with a forceful spray of water Water might contaminate the fuel system CAUTION Periodically clean the muffler area to remove com bustible debris Clean Rotating Screen See Figure D 2 Clean the rotating screen on your machine s engine as often as needed to remove dirt or debris that may collect on the screen A dirty screen can result in engine
77. ustrates 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 3316 C which is more than enough to melt metal The arc is very bright as well as hot and OPERATION B 12 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 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 Electrode d AN id Gases Z Weld Metal ISA see yy FIGURE B 4 The welding arc 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 j
78. welds Motion D see drawing is generally used for vertical up welding but motions A and B are also suitable Low Hydrogen Group Stable Arc 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 capa bility 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 Motions POWER ARC 5000 LINCOLN En ACCESSORIES OPTIONS ACCESSORIES LINCOLN ELECTRIC ACCESSORIES The following options accessories are available for your POWER ARC 5000 from your local Lincoln Distributor Accessory Set K875 Includes the following Twenty feet 6 1 meters of 6 AWG electrode cable Fifteen feet 4 6 meters of 6 work cable Headshield with No 10 filter Work clamp Insulated electrode holder Sample electrodes The cables are rated at 150 amps 40 du

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