Lincoln Electric SVM197-A service manual Safety Precautions, Location and Ventilation, Storing

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A-3

INSTALLATION

A-3

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SAFETY PRECAUTIONS

Read this entire installation section before you start installation.

WARNING

Do not attempt to use this equipment until you have thoroughly read all the operation and mainte- nance manuals supplied with your machine. They include important safety precautions; detailed engine starting, operating, and maintenance instructions; and parts lists.

ELECTRIC SHOCK can kill.

• Do not touch electrically live parts or electrodes with your skin or wet clothing.

Insulate yourself from the work and ground.

•Always wear dry insulating gloves.

ENGINE EXHAUST can kill.

• Use in open, well ventilated areas or vent exhaust to the out- side.

• Do not stack anything on or near the engine.

MOVING PARTS can injure.

• Do not operate this equip- ment with any of its doors open or guards off.

• Stop the engine before servic- ing it.

• Keep away from moving parts.

Only qualified personnel should install, use, or service this equipment.

LOCATION AND VENTILATION

Whenever you use the POWERARC® 5500, be sure that clean cooling air can flow through the machine’s gasoline engine and the generator. Avoid dusty, dirty areas. Also, keep the machine away from heat sources. Do not place the back end of the generator anywhere near hot engine exhaust from another machine. And of course, make sure that engine exhaust is ventilated to an open, outside area.

The POWERARC® 5500 must be used outdoors. Do not set the machine in puddles or otherwise submerge it in water. Such practices pose safety hazards and cause improper operation and corrosion of parts.

Always operate the POWERARC® 5500 with the case roof on and all machine components completely assembled. This will protect you from the dangers of moving parts, hot metal surfaces, and live electrical devices.

STORING

1.Store the machine in a cool, dry place when it’s not in use. Protect it from dust and dirt. Keep it where it can’t be accidentally damaged from 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 a gasoline stabilizing additive in the fuel system. Mix the additive with the fuel in the tank and run the engine for a short time to circulate the additive through the carburetor.

4.While the engine is still warm, drain the oil and refill with fresh oil per the engine manual.

5.Remove the spark plug and pour approximately 1/2 ounce (15 ml) of engine oil into the cylinder. Replace the spark plug and crank the engine slowly to distribute the oil.

6.Clean any dirt and debris from the cylinder and cylinder head fins and housing, rotating screen, and muffler areas.

7.Store in a clean, dry area.

POWERARC® 5500

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Contents Powerarc ISAFETYi Electric Shock can kill ARC Rays can burn SafetyIii For ElectricallyPrécautions DE Sûreté Electromagnetic Compatibility EMC Safety Master Table of Contents for ALL Sections Table of Contents Installation Section Technical Specifications Powerarc InstallationEngine Exhaust can kill Safety PrecautionsLocation and Ventilation StoringPRE-OPERATION Engine Service Honda 9 HP PowerArc 5500 Typical Fuel ConsumptionMuffler Deflector Spark ArresterCable Size and Length Powerarc 5500 Output ConnectionsElectrical Output Connections Welding Cable ConnectionsMachine Grounding Auxiliary Power ReceptaclesCable Installation Plugs and HAND-HELD EquipmentCircuit Breakers Premises WiringType Common Electrical Devices Possible Concerns Table A.2 Electrical Device USE with the PowerarcPowerarc Table of Contents Operation Section Operation Physical Location of Components may vary by Code No Controls and SettingsLimitations Output Panel ControlsGasoline Engine Controls Engine OperationStarting the Engine Before Starting the EngineRunning the Engine Generator OperationStopping the Engine General InformationTable B.3 Generator Power Applications Control Function / Operation Current Control Dial Welding OperationWelding Guidelines Material Thickness Electrode Type Size SettingWelding circuit for Stick shielded metal arc welding What Happens in the Arc?Correct Welding Speed Correct Welding PositionCorrect Way to Strike An Arc Correct Arc LengthDo the following Common MetalsTypes of Welds Use the followingWelding in the Vertical Position PenetrationVertical-Down Welding Vertical-Up WeldingWelding Sheet Metal How to Hardface the Sharp Edge Metal to Ground WearOverhead Welding Hardfacing To Reduce WearCast Iron Plate Preparation Welding Cast IronOut-of-Position Group AWS E6011 Selecting ElectrodesHigh-Speed Group AWS E6013 Low Hydrogen Group AWS E7018Powerarc Table of Contents Accessories Section Lincoln Electric Accessories AccessoriesOPTIONS/ACCESSORIES Table of Contents Maintenance Section Engine Maintenance MaintenanceRoutine and Periodic Maintenance Figure D.3 Clean Rotating SCREEN/FINGER GUARD/DEBRIS Guard Engine AdjustmentsPart Robin / Subaru Honda Table D.1 Engine Maintenance PartsDo not attempt to polish slip rings while engine is running GENERATOR/WELDER MaintenanceFigure D.6. Major Component Locations 1TABLE of CONTENTS-THEORY of Operation Section E-1 ENGINE, EXCITATION, Rotor and Stator Theory of OperationEngine Control and Ignition Return Rotor Field Feedback Auxiliary PowerWeld Winding and Reactor Auxiliary Power Overcurrent Protection1TABLE of Contents Troubleshooting and Repair F-1 HOW to USE Troubleshooting Guide 2TROUBLESHOOTING and REPAIRF-2Troubleshooting and Repair Output Problems Perform the Rotor and Flashing Voltage Test Troubleshooting and Repair Troubleshooting and Repair Rotor Resistance Test Engine Problems Troubleshooting and Repair Engine Throttle Adjustment Test Powerarc Materials Needed Test DescriptionLead 14TROUBLESHOOTING and REPAIRF-14Rotor Voltage Test Procedure Flashing Voltage Test ProcedureRotor Resistance Test Procedure Rotor Resistance Test Procedure Figure F.3 Brushes Retained with Cable TIE Powerarc Engine Throttle Adjustment Test ROBIN/SUBARU Engine ROBIN/SUBARU Engine Engine Throttle Adjustment TestHigh Speed Stop Screw High Idle no Load Scope SettingsNormal Open Circuit Weld Voltage Waveform Normal Open Circuit Voltage Waveform 115 VAC Supply Machine Loaded to 125 Amps AT 23 VAC Typical Weld Output WaveformMachine Loaded Brush Removal and Replacement Procedure Brush Removal and Replacement Procedure Powerarc Rheostat Removal and Replacement Procedure Rheostat Removal and Replacement Procedure Troubleshooting and Repair Attachment for 201 201A Jumper Procedure Capacitor Removal and REPLACE- MentCapacitor AND/OR Diode Bridge Attachment for 202A Cable Tie CapacitorFigure F.10 Field Diode Bridge Location Procedure Field Diode Bridge Removal and ReplacementPowerarc STATOR/ROTOR Removal and Replacement Procedure STATOR/ROTOR Stator Removal ProcedureSection TOC Rotor Removal Procedure Procedure Reactor Bolts Lead WELDER/GENERATOR OUTPUT1 Auxiliary Power Receptacle OUTPUT1Retest After Repair Engine OutputPowerarc Table of Contents Diagram Section Wiring Diagram Codes 11182, 11187, 11329 S25984 Electrical DiagramsSwitch Wiring Diagram Codes 11403, 11405 S26829Wiring Diagram Code 11404 S26830 Wiring Diagram Power ARCWiring Diagram Code 11215 S26023 S26008 Schematic -CODES 11182, 11187, 11329 S26008S26881 Schematic Codes 11403, 11405 S26881S26882 Schematic Code 11404 S26882