Lincoln Electric SVM197-A service manual Engine Operation, Gasoline Engine Controls

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B-4

OPERATION

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4.WELD OUTPUT TERMINAL (TO WORK) WITH 1/2

-13 FLANGE NUT: Provides the connection point for either the electrode holder or the work cable. (Because the POWERARC® 5500 is an AC output machine, either output terminal can be used for either cable.)

5.GROUND STUD: Provides a connection point for connecting the machine case to earth ground for the safest grounding procedure.

6.• 20 AMP CIRCUIT BREAKERS (2): Provide sepa- rate overload current protection for the 120 volt and 240 volt receptacles. (For codes 11182, 11187, 11215)

20 AMP CIRCUIT BREAKER: Provide separate overload current protection for the 120 volt and 240 volt receptacles. (For codes 11403, 11404)

7.20 AMP, 240 VOLT RECEPTACLE: Connection point for supplying 240 volt power to operate one electrical device.

8.20 AMP, 120 VOLT DUPLEX RECEPTACLE: Connection point for supplying 120 volt power to operate one or two electrical devices.

9.Tachometer / Hour meter: (For Code 11215, 11404 Only)

Records engine speed in RPMs, engine running time, and alerts the user to perform a specific engine main- tenance task by flashing corresponding messages. If the message reads “Chg Oil”, the user needs to change the oil in the engine. If the message reads “SVC AIR-FILTER”, the user needs to clean or if nec- essary,change the air filter. (See Honda Engine”s owners manual for more information). After mainte- nance task is preformed, the user is required to use the supplied Reset Tool to cancel flashing message and resume normal meter operation. (See MAINTE- NANCE SECTION for further details).

GASOLINE ENGINE CONTROLS

Refer to your engine manual for the location of the fol- lowing features:

1.FUEL SHUTOFF VALVE: Stops the flow of gaso- line from the fuel tank to the carburetor. Should be closed whenever you are finished using the POW- ERARC® 5500. Must be opened before you start the engine.

2.FUEL TANK AND CAP: See TECHNICAL SPECI- FICATIONS for capacity.

NOTE: If you use any other alternate fuel tank or supply, be sure to use a recommended in- line fuel filter.

3.MUFFLER: Reduces engine noise output. Both the Robin / Subaru and the Honda muffler serves as a spark arrester.

See SPARK ARRESTER in the INSTALLATION section of this manual.

4.“ON/OFF Switch: A two position switch located on the rear of the engine. In the “ON”(I) position, the engine ignition circuit is energized and the engine can be started by pulling the recoil rope starter. In the “OFF”(O) position, the electronic ignition is grounded and the engine shuts down.

5.AIR CLEANER: Filters intake air to the carburetor. See ENGINE MAINTENANCE in the MAINTE- NANCE section of the engine owner’s manual for details about the specific type of air cleaner to use.

6.CHOKE: Provides a richer air/fuel mix-

ture for cold engine starting conditions. See the topic ENGINE OPERATION, below, for details on setting the choke.

7.RECOIL STARTER: Manual, rope-type starter. The handle position allows easy starting from either ground level or pickup-truck level

8.OIL DRAIN PLUG: Permits convenient draining of engine oil during maintenance. Both sides of the engine are equipped with an oil drain plug.

9.OIL FILL PLUG: Permits convenient filling of engine oil during maintenance. Both sides of the engine are equipped with an oil fill plug.

ENGINE OPERATION

WARNING

DO NOT RUN THE ENGINE AT EXCESSIVE SPEEDS. The maximum allowable high idle speed for the POWERARC® 5500 is 3750 RPM, no load. Do NOT adjust the governor screw on the engine. Severe personal injury and damage to the machine can result if it is operated at speeds above the maximum rated speed.

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Read and understand all safety instructions included in the engine manufacturer’s ”Operating and Maintenance Instructions” manual that is shipped with the POWERARC® 5500.

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 PowerarcStoring Safety PrecautionsLocation and Ventilation Engine Exhaust can killPRE-OPERATION Engine Service Spark Arrester PowerArc 5500 Typical Fuel ConsumptionMuffler Deflector Honda 9 HPWelding Cable Connections Powerarc 5500 Output ConnectionsElectrical Output Connections Cable Size and LengthPlugs and HAND-HELD Equipment Auxiliary Power ReceptaclesCable Installation 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 Output Panel Controls Controls and SettingsLimitations Physical Location of Components may vary by Code NoEngine Operation Gasoline Engine ControlsBefore Starting the Engine Starting the EngineGeneral Information Generator OperationStopping the Engine 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 Arc Length Correct Welding PositionCorrect Way to Strike An Arc Correct Welding SpeedUse the following Common MetalsTypes of Welds Do the followingPenetration Welding in the Vertical PositionVertical-Up Welding Vertical-Down WeldingHardfacing To Reduce Wear How to Hardface the Sharp Edge Metal to Ground WearOverhead Welding Welding Sheet MetalWelding Cast Iron Cast Iron Plate PreparationLow Hydrogen Group AWS E7018 Selecting ElectrodesHigh-Speed Group AWS E6013 Out-of-Position Group AWS E6011Powerarc Table of Contents Accessories Section OPTIONS/ACCESSORIES AccessoriesLincoln Electric Accessories Table of Contents Maintenance Section Routine and Periodic Maintenance 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 Engine Control and Ignition Theory of OperationENGINE, 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 NeededFlashing Voltage Test Procedure 14TROUBLESHOOTING and REPAIRF-14Rotor 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 Normal Open Circuit Weld Voltage Waveform Scope SettingsHigh Idle no Load Normal Open Circuit Voltage Waveform 115 VAC Supply Machine Loaded Typical Weld Output WaveformMachine 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 Attachment for 202A Cable Tie Capacitor Procedure Capacitor Removal and REPLACE- MentCapacitor AND/OR Diode Bridge 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 Engine Output Auxiliary Power Receptacle OUTPUT1Retest After Repair 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