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WELDING OPERATION
GENERAL INFORMATION
WARNING
Do not touch electrically live parts or elec- trodes with your skin or wet clothing.
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.Attach the work clamp securely to the work you are welding.
4.Insert the electrode into the electrode holder.
5.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 “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