Lincoln Electric SVM197-A service manual PRE-OPERATION Engine Service

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A-4

INSTALLATION

A-4

Master TOC

STACKING

POWERARC® 5500 machines CANNOT be stacked.

TILTING

FUEL

Fill the fuel tank with clean, fresh, regular grade lead-

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

free gasoline. DO NOT MIX OIL WITH THE GASO-

LINE. Remove the fuel cap slowly to release pres- sure. Keep hands away from the engine muffler or HOT engine parts.

WARNING

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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 POWERARC® 5500 should be lifted by two peo- ple. (It weighs 160 lbs/72.5 kg.) Its welded tube roll cage is designed to make lifting easy.

ANGLE OF OPERATION

Internal combustion engines are designed to run in a level condition to achieve optimum performance. The

GASOLINE

can cause fire or explosion.

•Stop engine while fueling.

•Do not smoke when fueling.

•Keep sparks and flame away from tank.

•Do not leave unattended while fueling.

•Wipe up spilled fuel and allow fumes to clear before starting engine.

•Do not overfill tank, fuel expan- sion may cause overflow.

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maximum angle of operation for the engine is 15 degrees from horizontal in any direction. Be certain to place the machine on a firm, non-skid, structural sup- porting surface. Anchor unit if necessary.

If you are operating the engine at a slight angle, be cer- tain to check the oil regularly and maintain a level, full oil condition. The effective fuel capacity will also be slightly less than the specified 1.6 gallon (6.1 liters).

GASOLINE FUEL ONLY

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The POWERARC® 5500 has a fuel tank mounted on the engine. See the engine owner’s manual for more details about fuel.

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PRE-OPERATION ENGINE SERVICE

Read and understand the information about the gaso- line engine in the OPERATION and MAINTENANCE sections of this manual and the engine owner’s manu- al before you operate the POWERARC® 5500.

OIL

The POWERARC® 5500 with the Robin / Subaru 9HP engine and the POWERARC® 5500 with the Honda 9 HP engine are supplied with low oil protection. Both engines are equipped with protection that will shut down the engine in the event of a low oil condition. The engine cannot be restarted until sufficient oil is added.

The POWERARC® 5500 is shipped with the engine filled with SAE 10W-30 oil. CHECK THE OIL LEVEL BEFORE YOU START THE ENGINE. This is an added precaution. When full, the oil level should be at the top of the fill plug hole. If it is not full, add enough oil to fill it. Be sure the fill plug is tight. Change oil after the first 20 hours of operation. For more oil fill and service infor- mation, see the Engine owner’s manual.

POWERARC® 5500

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Contents Powerarc ISAFETYi Safety Electric Shock can kill ARC Rays can burnFor Electrically IiiPrécautions DE Sûreté Electromagnetic Compatibility EMC Safety Master Table of Contents for ALL Sections Table of Contents Installation Section Installation Technical Specifications PowerarcSafety Precautions Location and VentilationStoring Engine Exhaust can killPRE-OPERATION Engine Service PowerArc 5500 Typical Fuel Consumption Muffler DeflectorSpark Arrester Honda 9 HPPowerarc 5500 Output Connections Electrical Output ConnectionsWelding Cable Connections Cable Size and LengthAuxiliary Power Receptacles Cable InstallationPlugs and HAND-HELD Equipment Machine GroundingPremises Wiring Circuit BreakersTable A.2 Electrical Device USE with the Powerarc Type Common Electrical Devices Possible ConcernsPowerarc Table of Contents Operation Section Operation Controls and Settings LimitationsOutput Panel Controls Physical Location of Components may vary by Code NoEngine Operation Gasoline Engine ControlsBefore Starting the Engine Starting the EngineGenerator Operation Stopping the EngineGeneral Information Running the EngineTable B.3 Generator Power Applications Welding Operation Control Function / Operation Current Control DialMaterial Thickness Electrode Type Size Setting Welding GuidelinesWhat Happens in the Arc? Welding circuit for Stick shielded metal arc weldingCorrect Welding Position Correct Way to Strike An ArcCorrect Arc Length Correct Welding SpeedCommon Metals Types of WeldsUse the following Do the followingPenetration Welding in the Vertical PositionVertical-Up Welding Vertical-Down WeldingHow to Hardface the Sharp Edge Metal to Ground Wear Overhead WeldingHardfacing To Reduce Wear Welding Sheet MetalWelding Cast Iron Cast Iron Plate PreparationSelecting Electrodes High-Speed Group AWS E6013Low Hydrogen Group AWS E7018 Out-of-Position Group AWS E6011Powerarc Table of Contents Accessories Section Accessories OPTIONS/ACCESSORIESLincoln Electric Accessories Table of Contents Maintenance Section Maintenance Routine and Periodic MaintenanceEngine Maintenance Engine Adjustments Figure D.3 Clean Rotating SCREEN/FINGER GUARD/DEBRIS GuardTable D.1 Engine Maintenance Parts Part Robin / Subaru HondaGENERATOR/WELDER Maintenance Do not attempt to polish slip rings while engine is runningFigure D.6. Major Component Locations 1TABLE of CONTENTS-THEORY of Operation Section E-1 Theory of Operation Engine Control and IgnitionENGINE, EXCITATION, Rotor and Stator Rotor Field Feedback Auxiliary Power ReturnAuxiliary Power Overcurrent Protection Weld Winding and Reactor1TABLE of Contents Troubleshooting and Repair F-1 2TROUBLESHOOTING and REPAIRF-2 HOW to USE Troubleshooting GuideTroubleshooting 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 Test Description Materials Needed14TROUBLESHOOTING and REPAIRF-14 Rotor Voltage Test ProcedureFlashing Voltage Test Procedure LeadRotor Resistance Test Procedure Rotor Resistance Test Procedure Figure F.3 Brushes Retained with Cable TIE Powerarc Engine Throttle Adjustment Test ROBIN/SUBARU Engine Engine Throttle Adjustment Test ROBIN/SUBARU EngineHigh Speed Stop Screw Scope Settings Normal Open Circuit Weld Voltage WaveformHigh Idle no Load Normal Open Circuit Voltage Waveform 115 VAC Supply Typical Weld Output Waveform Machine LoadedMachine Loaded to 125 Amps AT 23 VAC Brush Removal and Replacement Procedure Brush Removal and Replacement Procedure Powerarc Rheostat Removal and Replacement Procedure Rheostat Removal and Replacement Procedure Troubleshooting and Repair Procedure Capacitor Removal and REPLACE- Ment Capacitor AND/OR Diode BridgeAttachment for 202A Cable Tie Capacitor Attachment for 201 201A JumperProcedure Field Diode Bridge Removal and Replacement Figure F.10 Field Diode Bridge LocationPowerarc STATOR/ROTOR Removal and Replacement Procedure Stator Removal Procedure STATOR/ROTORSection TOC Rotor Removal Procedure Procedure Reactor Bolts Lead Auxiliary Power Receptacle OUTPUT1 Retest After RepairEngine Output WELDER/GENERATOR OUTPUT1Powerarc Table of Contents Diagram Section Electrical Diagrams Wiring Diagram Codes 11182, 11187, 11329 S25984Wiring Diagram Codes 11403, 11405 S26829 SwitchWiring Diagram Power ARC Wiring Diagram Code 11404 S26830Wiring Diagram Code 11215 S26023 Schematic -CODES 11182, 11187, 11329 S26008 S26008Schematic Codes 11403, 11405 S26881 S26881Schematic Code 11404 S26882 S26882
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