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

R E P A I R T H I S E Q U I P M E N T

W I T H O U T R E A D I N G T H I S

M A N U A L A N D T H E S A F E T Y

PRECAUTIONS CONTAINED T H R O U G H O U T . A n d , m o s t importantly, think before you act and be careful.

Various engine configurations are available and machine appearance will vary accordingly.

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SAFETY

i

Diesel engine exhaust and some of its constituents are known to the State of California to cause can- cer, birth defects, and other reproductive harm.

The Above For Diesel Engines

The engine exhaust from this product contains chemicals known to the State of California to cause cancer, birth defects, or other reproductive harm.

The Above For Gasoline Engines

FOR ENGINE powered equipment.

1.a. Turn the engine off before troubleshooting and maintenance work unless the maintenance work requires it to be running.

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1.b. Operate engines in open, well-ventilated areas or vent the engine exhaust fumes outdoors.

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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.

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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 parts when starting, operating or repairing equipment.

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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.

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1.f. Do not put your hands near the engine fan. Do not attempt to override the governor or idler by pushing on the throttle control rods while the engine is running.

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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.

1.h. To avoid scalding, do not remove the radiator pressure cap when the engine is hot.

ELECTRIC AND

MAGNETIC FIELDS may be dangerous

2.a. Electric current flowing through any conductor causes localized Electric and Magnetic Fields (EMF). Welding current creates EMF fields around welding cables and welding machines

2.b. EMF fields may interfere with some pacemakers, and welders having a pacemaker should consult their physician before welding.

2.c. Exposure to EMF fields in welding may have other health effects which are now not known.

2.d. All welders should use the following procedures in order to minimize exposure to EMF fields from the welding circuit:

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.

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 should also be on your right side.

2.d.4. Connect the work cable to the workpiece as close as possible to the area being welded.

2.d.5. Do not work next to welding power source.

Mar ???95

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.

3.c. In semiautomatic or automatic wire welding, the electrode, electrode reel, welding head, nozzle or semiautomatic welding gun are also electrically ???hot???.

3.d. 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.

3.e. Ground the work or metal to be welded to a good electrical (earth) ground.

3.f. Maintain the electrode holder, work clamp, welding cable and welding machine in good, safe operating condition. Replace damaged insulation.

3.g. Never dip the electrode in water for cooling.

3.h. 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.

3.i. When working above floor level, use a safety belt to protect yourself from a fall should you get a shock.

3.j. Also see Items 6.c. and 8.

ARC RAYS can burn.

4.a. Use a shield with the proper filter and cover plates to protect your eyes from sparks and the rays of the arc when welding or observing open arc welding. Headshield and filter lens should conform to ANSI Z87. I 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.

4.c. 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.

FUMES AND GASES can be dangerous.

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. The operation of welding fume control equipment is affected by various factors including proper use and positioning of the equipment, maintenance of the equipment and the spe- cific welding procedure and application involved. Worker exposure level should be checked upon installation and periodically thereafter to be certain it is within applicable OSHA PEL and ACGIH TLV limits.

5.c. 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 prod- ucts.

5.d. 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.

5.e. 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 or from the manufacturer.

5.f. Also see item 1.b.

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SAFETY

iii

WELDING and CUTTING

SPARKS can

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.

6.b. 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.

6.c. 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.

6.d. 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).

6.e. Vent hollow castings or containers before heating, cutting or welding. They may explode.

6.f. 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.

6.g. 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.

6.h. Also see item 1.c.

6.I. Read and folllow NFPA 51B ??? Standard for Fire Prevention During Welding, Cutting and Other Hot Work???, available from NFPA, 1 Batterymarch Park,PO box 9101, Quincy, Ma

022690-9101.

6.j. Do not use a welding power source for pipe thawing.

CYLINDER may explode 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.

7.b. Always keep cylinders in an upright position securely chained to an undercarriage or fixed support.

7.c. 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.

7.d. Never allow the electrode, electrode holder or any other electrically ???hot??? parts to touch a cylinder.

7.e. Keep your head and face away from the cylinder valve outlet when opening the cylinder valve.

7.f. Valve protection caps should always be in place and hand tight except when the cylinder is in use or connected for use.

7.g. 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.

8.b. Install equipment in accordance with the U.S. National

Electrical Code, all local codes and the manufacturer???s recommendations.

8.c. Ground the equipment in accordance with the U.S. National

Electrical Code and the manufacturer???s recommendations.

Jan, 07

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SAFETY

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PR??CAUTIONS DE S??RET??

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:

a.Les circuits ?? l?????lectrode et ?? la pi??ce sont sous tension quand 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.

b.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

masse.

c.Maintenir le porte-??lectrode, la pince de masse, 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.

e.Ne jamais toucher simultan??ment les parties sous tension des porte-??lectrodes connect??s ?? deux machines ?? soud- er parce que la tension entre les deux pinces peut ??tre le total de la tension ?? vide des deux machines.

f.Si on utilise la machine ?? 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 partie du corps.

3.Un coup d???arc peut ??tre plus s??v??re qu???un coup de soliel, 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.

b. Porter des v??tements convenables afin de prot??ger la peau de soudeur et des aides contre le rayonnement de l???arc.

c. Prot??ger l???autre personnel travaillant ?? proximit?? au soudage ?? l???aide d?????crans appropri??s et non-inflamma- bles.

4.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.

5.Toujours porter des lunettes de s??curit?? dans la zone de soudage. Utiliser des lunettes avec ??crans lateraux dans les zones o?? l???on pique le laitier.

6.Eloigner les mat??riaux inflammables ou les recouvrir afin de pr??venir tout risque d???incendie d?? aux ??tincelles.

7.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.

8.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.

9.Assurer une ventilation suffisante dans la zone de soudage. 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.

10.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.

11.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.

PR??CAUTIONS DE S??RET?? POUR

LES MACHINES ?? SOUDER ??

TRANSFORMATEUR ET ??

REDRESSEUR

1.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.

2.Autant que possible, I???installation et l???entretien du poste seront effectu??s par un ??lectricien qualifi??.

3.Avant de faires des travaux ?? l???interieur de poste, la debrancher ?? l???interrupteur ?? la boite de fusibles.

4.Garder tous les couvercles et dispositifs de s??ret?? ?? leur place.

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Thank You

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for selecting a QUALITY product by Lincoln Electric. We want you to take pride in operating this Lincoln Electric Company product

????????? as much pride as we have in bringing this product to you!

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 main- tenance m anuals supplied w ith your m achine. T h e y i n c l u de i m por t a n t s a f e t y pr e c a u t io n s ; detailed engine starting, operating, and mainte- nance 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 outside.

??? 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 ser- vicing it.

???Keep away from moving parts.

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

LOCATION AND VENTILATION

Whenever you use the POWER-ARC 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 POWER-ARC 5500 must 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 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.

STACKING

POWER-ARC 5500 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,

FUEL

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

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 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

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.

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

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 POWER-ARC 5500.

OIL

The Power-Arc 5500 with the Robin / Subaru 9HP engine and the Power-Arc 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 POWER-ARC 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 information, see the Engine owner???s manual.

GASOLINE FUEL ONLY

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The POWER-ARC 5500 has a fuel tank mounted on the engine. See the engine owner???s manual for more details about fuel.

MUFFLER DEFLECTOR

The POWER-ARC 5500, Honda model, may or may not be shipped with an exhaust deflector. If you received one, you can mount it on the gasoline engine if your needs so require.

To install the deflector, do the following:

???Align the holes on the deflector plate with the holes on the muffler.

???Position the deflector so that the opening points either right, left, or downward, away from the operator.

CAUTION

Never position the deflector upward. Moisture or debris can enter the engine and damage it. As a general safety practice, position the deflector to direct exhaust gases away from the operator???s face and eyes.

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???Fasten the deflector onto the muffler with the screws provided.

NOTE: The deflector reduces generator output power up to 100 watts.

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 present a fire hazard.

The Robin / Subaru and Honda models of the Power- Arc 5500 come with a spark arrester as standard equipment. Refer to the engine owner???s manual for proper maintenance.

CAUTION

An incorrect additional spark arrester may lead to damage to the engine or reduce performance.

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1.CURRENT CONTROL DIAL

2.WELD OUTPUT TERMINALS (2)

3.GROUND STUD

4.CIRCUIT BREAKERS (2) - 20 AMP

5.RECEPTACLE - 240 VOLT, 20 AMP

6.DUPLEX RECEPTACLE - 120 VOLT, 20 AMP

7.TACHOMETER / HOURMETER (CODE 11215 ONLY)

ELECTRICAL OUTPUT

CONNECTIONS

See Figure A.1 for the location of the current control dial, weld output terminals, ground stud, circuit breakers, 240 and 120 volt receptacles.

1.CURRENT CONTROL DIAL

2.WELD OUTPUT TERMINALS (2)

3.GROUND STUD

4.CIRCUIT BREAKER- 20 AMP

5.RECEPTACLE - 240 VOLT, 20 AMP

6.DUPLEX RECEPTACLE - 120 VOLT, 20 AMP

7.TACHOMETER / HOURMETER (CODE 11404 ONLY)

TABLE A.1

RECOMMENDED WELDING CABLE

SIZE AND LENGTH

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.

TOTAL COMBINED LENGTH OF ELECTRODE AND

WORK CABLES

Cable Installation

Install the welding cables to your POWER-ARC 5500 as follows. See Figure A.1 for the location of parts.

1.The gasoline engine must be OFF to install weld- ing cables.

2.Remove the 1/2 - 13 flanged nuts from the output terminals.

3.Connect the electrode holder and work cables to the weld output terminals. You can connect either cable to either terminal, since the POWER-ARC 5500 provides AC weld current.

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.

CAUTION

???Loose connections will cause the output termi- nals to overheat. The terminals may eventually melt.

???Do not cross the welding cables at the output terminal connection. Keep the cables isolated and separate 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.

WARNING

Do not ground the machine to a pipe that carries explosive or combustible material.

When the POWER-ARC 5500 is mounted on a truck or a trailer, the machine generator

ground stud MUST be securely connect- ed to the metal frame of the vehicle. See Figure A.1. The ground stud is marked with the symbol.

PLUGS AND HAND-HELD EQUIPMENT

For further protection against electric shock, any electrical equipment connected to the generator receptacles must use a three-blade, grounded type plug or an Underwriter???s Laboratories (UL) approved double insulation system with a two-blade plug.

Ground fault protection is needed for hand held equipment.

WARNING

Never operate this machine with damaged or defective cords. All electrical equipment must be in safe condition.

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MACHINE GROUNDING

Because the POWER-ARC 5500 creates its own power from its gasoline-engine driven generator, you do not need to connect the machine frame to an earth ground. However, for best protection

against electrical shock, connect a heavy gauge wire from the ground stud located on the bottom center of the output panel (see Figure A.1) to a suitable earth ground such as a metal pipe driven into the ground.

AUXILIARY POWER RECEPTACLES

The control panel of the POWER-ARC 5500 features two auxiliary power receptacles:

???A 20 amp, 120 volt duplex (double outlet) recepta- cle

???A 20 amp 240 volt simplex (single outlet) recepta- cle.

See Figure A.1.

Through these receptacles the machine can supply up to 4,000 rated continuous watts and 5,500 surge watts of single-phase AC power.

PREMISES WIRING

The POWER-ARC 5500 three-wire, grounded neutral generator allows it to be connected to premises wiring. However, the wiring procedure needed to meet the National Electrical Code (NEC) regulations as well as city ordinances and can be confusing. The connections could vary from a "commonly grounded" to a "separately derived" system depending on whether you want the unit to be "hard wired" or tem- porary to the premises.

WARNING

Only a l ice nsed, c er t ified, tr a ine d e lect r ician should install the machine to a premises or resi- dential electrical system. Be certain that:

???The premises is isolated and no feed backing into the utility system can occur. Certain state and local laws require the premises to be isolat- ed before the generator is linked to the premis- es. Check your state and local requirements.

???A double pole, double throw transfer switch in conju nction w ith the pr ope r ly r ate d double throw circuit breaker is connected between the generator power and the utility meter.

The POWER-ARC 5500 does not have a combined 120/240 volt twist-lock receptacle and cannot be connected to a premises as described in other Lincoln literature.

Remember that the POWER-ARC 5500 is intended only for backup, intermittent use power. Oil level must be checked after every 5 hours of use. It cannot with- stand long-term use without proper maintenance. See the MAINTENANCE section of this manual and the engine owner???s manual for more information.

Certain electrical devices cannot be powered by the POWER-ARC 5500. Refer to Table A.2 for these devices.

CIRCUIT BREAKERS

Auxiliary power is protected by circuit breaker. When the machine is operated in high temperature environ- ments, the breakers may tend to trip at lower loads than normally.

CAUTION

Never bypass the circuit breakers. Without over- loa d pr otec tion, the POWER-ARC 5500 could overheat and/or cause damage to the equipment being used.

SAFETY INSTRUCTIONS

Read and understand this entire section before oper- ating your POWER-ARC 5500.

WARNING

Do not attempt to use this equipment until you have thoroughly read all the operation and main- tenance m anuals supplied w ith your m achine. T h e y i n c l u de i m por t a n t s a f e t y pr e c a u t io n s ; detailed engine starting, operating, and mainte- nance 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.

FUMES AND GASES can be dangerous.

??? Keep your head out of fumes.

??? Us e v e n t i l a t i o n o r e xh a u s t t o remove fumes from breathing zone.

WELDING SPARKS can cause fire or explosion.

???Keep flammable material away.

???Do not weld on containers that have held combustibles.

ARC RAYS can burn.

??? Wear eye, ear, and body protection.

ENGINE EXHAUST can kill.

??? 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.

???Do not operate this equipment with 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

The POWER-ARC 5500 is a generator/welder designed for home use and other non-commercial applications. As a generator it can supply up to 4,000 continuous watts (or 5,500 surge watts) of 120/240 volt, single- phase AC power. As a welder it provides 125 amps of AC constant current for welding with AC stick elec- trodes. A single dial provides continuous adjustment of welding output. The machine is lightweight, portable, and can be lifted by two people.

The Lincoln warranty covers the Power-Arc 5500 (excluding the engine) for 3 years from the date of pur- chase. The engine is covered by the engine manufactur- er???s warranty policy.

RECOMMENDED APPLICATIONS

GENERATOR

The POWER-ARC 5500 gives AC generator output for medium use, non-commercial demands. For more details on operating the generator, see GENERATOR OPERATION in the OPERATION section of this manual.

WELDER

The POWER-ARC 5500 provides excellent constant cur- rent AC welding output for stick (SMAW) welding. For more details on using the machine as a welder, see WELDING OPERATION in the OPERATION section of this manual.

OPERATIONAL FEATURES AND

CONTROLS

The POWER-ARC 5500 was designed for simplicity. Therefore, it has very few operating controls. A single dial on the control panel lets you select either generator or welding use. For welding, the same dial selects con- tinuous current output over the machine???s 70 to 125 amp range.

The gasoline engine controls include a recoil starter, choke, and rotary stop switch. See ENGINE OPERA- TION in the OPERATION section of this manual and the engine owner???s manual for details about starting, run- ning, stopping, and breaking in the gasoline engine.

WELDING CAPABILITY

The POWER-ARC 5500 is rated 125 amps, 20 volts at 30% duty cycle on a ten-minute basis. This means that you can load the welder to 125 amps for three 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 100 amps for six minutes out of ten for a 60% duty cycle.

The current is continuously variable from 70 to 125 amps AC. The POWER-ARC 5500 can weld with all 3/32 and most 1/8 inch diameter Lincoln AC elec- trodes.

1.CURRENT CONTROL DIAL

2.ELECTRODE SELECTION GUIDE

3.WELD OUTPUT TERMINAL (TO ELECTRODE HOLDER) WITH 1/2 - 13 FLANGE NUT

4.WELD OUTPUT TERMINAL (TO WORK) WITH 1/2 - 13

FLANGE NUT

5.GROUND STUD

6.20 AMP CIRCUIT BREAKERS (2)

7.20 AMP, 240 VOLT RECEPTACLE

8.20 AMP, 120 VOLT DUPLEX RECEPTACLE

9.TACHOMETER / HOURMETER (CODE 11215 ONLY)

1.CURRENT CONTROL DIAL

2.ELECTRODE SELECTION GUIDE

3.WELD OUTPUT TERMINAL (TO ELECTRODE HOLDER) WITH 1/2 - 13 FLANGE NUT

4.WELD OUTPUT TERMINAL (TO WORK) WITH 1/2 - 13

FLANGE NUT

5.GROUND STUD

6.20 AMP CIRCUIT BREAKER

7.20 AMP, 240 VOLT RECEPTACLE

8.20 AMP, 120 VOLT DUPLEX RECEPTACLE

9.TACHOMETER / HOURMETER (CODE 11404 ONLY)

LIMITATIONS

???The POWER-ARC 5500 is not recommended for any processes besides those that are normally per- formed using stick welding (SMAW) procedures.

???The POWER-ARC 5500 is not recommended for pipe thawing.

???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.

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.

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.

2.ELECTRODE SELECTION GUIDE: Provides rec- ommended electrode type, size, and welder out- put setting based on the thickness of the work.

3.WELD OUTPUT TERMINAL (TO ELECTRODE HOLDER) WITH 1/2 - 13 FLANGE NUT: Provides the connection point for either the electrode hold- er or the work cable. (Because the POWER-ARC 5500 is an AC output machine, either output ter- minal can be used for either cable.)

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 POWER-ARC 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 / Hourmeter: (For Code 11215, 11404 Only)

Records engine speed in RPMs, engine running time, and alerts the user to perform a specific engine maintenance task by flashing correspond- ing messages. If the message reads ???Chg Oil???, the user needs to change the oil in the engine. If the message reads ???SVC AIR-FiILTER???, the user needs to clean or if necessary,change the air filter. (See Honda Engine???s owners manual for more information). After maintenance task is preformed, the user is required to use the supplied Reset Tool to cancel flashing message and resume normal meter operation. (See page D-1 for futher details).

GASOLINE ENGINE CONTROLS

Refer to your engine manual for the location of the following 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 POWER-ARC 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 condi- tions. See the topic ENGINE OPERA- TION, 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

D O N O T R UN THE E NGI NE A T E X CE SSI VE SPEEDS. The maximum allowable high idle speed for the POWER-ARC 5500 is 3750 RPM, no load. Do NOT adjust the governor screw on the engine. Se ve r e p e r s o n a l i n j u r y a n d d a m a g e t o t h e machine can result if it is oper ated at speeds above the maximum rated speed.

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Read and understand all safety instructions included in the engine manufacturer???s O pe r a t i n g a n d Maintenance Instructions manual that is shipped with the POWER-ARC 5500.

BEFORE STARTING THE ENGINE

CHECK AND FILL THE ENGINE OIL LEVEL:

1. Place the machine on a level surface.

2.Open the oil fill plug.

3.Fill (if necessary) until oil flows out the top of the fill plug hole.

4.Replace the fill plug and tighten securely.

CHECK AND FILL THE ENGINE FUEL TANK:

1. Remove the fuel tank cap.

2. Fill the tank to allow approximately 1/4 inch (5 mm) of tank space 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. 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. Put the ???ON/OFF??? Switch in the ???ON???(I) position.

FOR A ???COLD??? ENGINE:

1. Open the fuel shutoff valve.

2. Place the choke lever in the ???CHOKE??? position.

3.Pull slightly on the recoil starter handle until resis- tance is felt.

4.Pull the cord rapidly.

5.If the engine does not start, open the choke slightly and pull the starter cord rapidly again.

When the engine starts, gradually open the choke to the ???RUN??? position. To open the choke fully requires an engine warm-up period of several seconds to several minutes, depending on the temperature. After starting the engine, first open the choke (toward RUN) until the engine just begins to run smoothly. Then open the choke in small steps, allowing the engine to accept small changes in speed and load, until the choke is fully open (in RUN). During engine warm-up the equip- ment can be operated.

FOR A ???HOT??? ENGINE:

1.Open the fuel shutoff valve.

2.Place the choke lever in the ???RUN???

position. Closing the choke of a hot 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.

???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 carbure- tor.

???If the engine will not start, see the T R O U - BLE SHOOTI NG section of this or the engine owner???s manual.

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 placing the ???ON/OFF??? switch in the ???OFF???(O) position.

3.Close the fuel shutoff valve.

WARNING

Close the fuel valve when the machine is trans- ported to prevent fuel leakage from the carbure- t o r . D r a i n t h e t a n k b e fo r e t r a n s po r t i ng t h e machine in a vehicle.

For long periods of storage, turn off the fuel shut- off valve and let the engine run until there is no more fuel in the line. Use a fuel additive such as Sta-Bil to minimize fuel gum deposits.

-----------------------------------------------------------

RUNNING THE ENGINE

The engine is set at the factory to run at high idle speed when not under load. You should not adjust this setting yourself.

BREAK-IN PERIOD

The engine will use a greater amount of oil during its ???break-in??? period. Check the oil frequently during break-in. For more details, see the MAINTENANCE section in the engine owner???s manual.

CAUTION

During break-in, subject the POWER-ARC 5500 to only moderate loads. Avoid long periods running at idle. Before stopping the engine, remove all loads and allow the engine to cool several min- utes.

-------------------------------------------------------------

GENERATOR OPERATION

CAUTION

Be sure that any electrical equipment plugged into the generator???s AC power receptacles can with- stand a ??10% voltage and a ??4% frequency varia- tion. Some electronic devices cannot be powered by the POWER-ARC 5500. Refer to Table A.2,

ELECTRICAL DEVICE USE WITH THE POWER- ARC 5500, in the INSTALLATION section of this manual.

-----------------------------------------------------------

GENERAL INFORMATION

The POWER-ARC 5500 generator is rated at 4000 continuous watts (5500 surge watts). It provides both 120 volt and 240 volt power. You can draw up to 20 amps from either side of the 120 volt duplex recepta- cle, but no more than 33.3 amps from both sides at once. Up to 16.7 amps can be drawn from the single 240 volt 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 5500. Be sure to read the notes at the bottom of the table.

TO USE THE POWER - ARC 5500 AS AN AUXIL-

IARY POWER SUPPLY:

1.Start the gasoline engine. See ENGINE OPERA- TION in this section of the manual and the engine owner???s 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 5,500 surge watts or 4,000 Continuous watts. Be sure to start the largest loads first.

WELDING OPERATION

GENERAL INFORMATION

WARNING

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.

-----------------------------------------------------------

The POWER-ARC 5500 has a voltage of up to 62 Volts AC which can shock. The POWER-ARC 5500 generator/welder can deliver from 70 to 125 amps of continuous welding output current. Output can be adjusted by setting the current control dial on the out- put control panel.

You can get maximum welding output by setting the dial to 125 AMPS. At high current settings like this, some output may decrease as the machine is used. If you are welding for a long time, you may need to turn the dial slightly upward to maintain the same results.

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???re using.

TO USE THE POWER-ARC 5500 FOR WELDING:

1.Remove the flange nuts from the weld output ter- minals 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 5500 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 100 Amps and less and 30% duty cycle applying to currents above 100 Amps.

2.Duty cycle is based on a ten minute period. The welder can be loaded to 125 Amps for three minutes out of every ten minute period or to 100 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.

To obtain maximum weld output, turn the ???Current Control Dial??? to ???125 Amps??? for either a cold or hot engine. As the machine is used, some welding volt- age may decrease at high current settings. If you are welding for long periods of time, the dial may need to be slightly turned upward to provide the same welding results as when the machine was cold.

The numbers listed on the dial correspond to the aver- age amperage needed to weld specific Lincoln rods. Refer to Table B.4 ???Welding Application Guidet??? and ???Electrode Selection Guide??? listed on the machine nameplate for proper current and electrode settings.

NOTES:

The values listed are suggested settings. Actual set- ting may vary depending on individual preference and/or specific application. Beginners should use Lincoln E7018 AC.

For electrodes not listed, follow tables that are packed with the electrodes.

Ask for the Lincoln WELD DIRECTORY (Publication C2.10) for a complete listing of all Lincoln stick elec- trodes available.

1AWS = American Welding Society

WARNING

ARC RAYS can burn.

??? When using an open arc process, it is necessary to use correct eye, head and body protection.

------------------------------------------------------------------------

Stick Welding

Stick welding is probably the most familiar welding process known. A coated ELECTRODE, the weld rod, is clamped into an ELECTRODE HOLDER, an insulat- ed clamping device, which in turn connects to the ELECTRODE CABLE, a heavy wire. The WORK, the metal piece to be welded, is connected to the WORK CABLE, a heavy wire which contains the WORK CLAMP. Quality Lincoln cables use many fine copper wires with a very flexible insulating covering for the electrode and work cables. When properly connected to the OUTPUT STUDS of a high current power source, the electrode melts and bonds the metal being repaired. See ???Cable Installation??? section for proper cable connection to a Power-Arc.

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 Application Guide??? and the ???Electrode Selection Guide??? found on the nameplate of the machine.

Semi-automatic, Wire Welding With a

Lincoln Wire Feeder / Welder

The Power-Arc 5500 generator power can be used to supply power up to 4,000 watts continuous input power to a Lincoln Wire Feeder/Welder. The Wire Feeder/Welder is equipped with all the supplies need- ed for Flux-Cored Arc Welding (FCAW). Also some Wire Feeder/Welders come equipped with the essen- tials needed for Gas Metal Arc Welding, GMAW, or MIG processes, while others require the purchase of a conversion kit. These products are availible where Lincoln products are sold. Contact your local autho- rized Lincoln representative for more details.

Learning To Stick Weld

The serviceability of a product or structure utiliz- ing this type of information is and must be the sole responsibility of the builder/user. Many vari- ables 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, weldment design, fab- rication methods and service requirements.

No one can learn to weld simply by reading about it. Skill comes only with practice. The following pages will help the inexperienced welder 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 3 is a diagram of the weld- ing 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.

ELECTRODE HOLDER

WELDING MACHINE

AC OR DC POWERELECTRODE

SO RCE AND

CONTROLS

ARC

WORK

WORK CABLE

ELECTRODE CABLE

FIG RE 3 - The welding circuit for (Stick) shielded metal arc welding.

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 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 oper- ator controls the welding arc and, therefore, the quali- ty of the weld made.

What Happens in the Arc?

Figure 4 illustrates 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 (3300??C) which is more than enough to melt metal. The arc is very bright, as well as hot, and 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.

Covering

Electrode

Arc

Solidified Slag

Shielding Gases

Weld Metal

Base Metal

FIGURE 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 joint 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 steadier, 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 dif- ferences in the various coatings, you will gain a better 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.

1. The Correct Welding Position

Illustrated is the correct welding position for right-handed people. (For left-handed people it 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 5.

Correct Welding Position

Figure 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. 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.

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 electrode 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 incorrect, 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

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: It is 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.

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.

Do the following:

1.Learn to strike the arc by scratching 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 welded successful- ly in most cases; however, care must be taken to fol- low proper procedures, including preheating the metal to be welded and, 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 suggest 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 Joints, Fillet Joints, Lap Joints, Edge Joints and Corner Joints.

Of these, the Butt Joint and Fillet Joint are the most common.

Butt Joints

Butt Joints are the most widely used Joints. 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).

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.

20??

Watch the molten metal to be sure it distributes itself evenly on both edges and in between the plates.

Fillet Joints

When welding fillet joints, 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.

45??

Penetration

Unless a weld penetrates close to 100%, a butt joint will be weaker than the material welded together.

1/2"

Poor (12mm) 1/4" (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

45??

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.

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.

60??

4

3

2

1

1/8" (3.2mm)

Successive passes must be used to build up butt welds on heavier metal.

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.

Vertical-Up 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:

Long arc

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 FOL-

LOW THE UP AND DOWN MOVEMENT OF THE

ARC WITH YOUR EYES. KEEP THEM ON THE

MOLTEN METAL.

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.

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.

Overhead Welding

Various techniques are used for overhead welding. However, in the interest of simplicity for the inexperi- enced welder, the following 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.)

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.

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 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.

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.)

5.Use the back-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.

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.)

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 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.

hot

coldcold

White brittle cast iron

Cast Iron Plate Preparation

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.)

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-up strip may be used and plates may be gapped 1/8??? (3.2mm) or more, as shown in figure (b).

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 the seam as shown in figure (d) below.

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 applica- tion. MILD STEEL ELECTRODES may be classified into the following groups:

Out-of-Position Group (AWS E6011)

High-Speed Group (AWS E6013)

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 welds. Motion ???D??? (see drawing) is generally used for vertical-up welding, but motions ???A??? and ???B??? are also suitable.

Low Hydrogen Group (AWS 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.

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.

Motions

E

D

START F

C

B G

SIDE

AVIEW

SAFETY PRECAUTIONS

WARNING

???Have qualified personnel do all maintenance and troubleshooting work.

???Turn the engine off before working inside the machine.

???Remove guards only when necessary to per- form maintenance and replace them when the maintenance requiring their removal is com - plete.

???If guards ar e missing from the m achine, get replacements from a Lincoln Distributor. See the EXPLODED VIEW AND PARTS LIST at the back of this manual.

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Read the Safety Precautions in the front of this manu- al and in the engine owner???s manual before working on the POWER-ARC 5500.

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 PERIODIC

MAINTENANCE

ENGINE MAINTENANCE

CAUTION

To prevent the engine from accidentally starting, disconnect the spark plug lead before servicing the engine.

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See the engine owner???s manual for a summary of maintenance intervals 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.1 shows engine main- tenance replacement parts and numbers.

If this Power Arc 5500 is equipped with a Tachometer/Hourmeter (See page B-3), then use it flash alert feature to determine the oil change inter- vals, as well as times when air filter service is required.

Once Oil or Air filter service is completed, Tachometer/Hourmeter needs to be reset. The reset procedure will stop the flashing of the display and will trigger the meter to start counting the time for the next engine service. To stop the flashing alert for Oil or Air filter service, do the following: While alert mes- sage is flashing, hold the tip of the rest tool against area shown in figure D.1 for several seconds. The dis- play will stop flashing. The service interval has been reset and the message alert should start flashing for the next Oil or Air filter change.

RESET TOOL

TO ELIMINATE

FLASHING HOLD

THE RESET TOOL

IN THIS AREA.

12345

FIGURE D.1

OIL: Check the oil level after every 5 hours of operation or daily. BE SURE

TO MAINTAIN THE OIL LEVEL. Change the oil the first time after 20 hours of opera- tion. Then, under normal operating conditions, change the oil after every 100 hours or once every 6 months whichever occurs first. If the engine is oper- ated under heavy load or in high ambient tempera- tures, change the oil every 25 hours.

Drain the oil from the drain plug located on either side of the engine bottom, as shown in Figure D.2. Refill through the oil fill plug until the oil reaches the top of the fill hole. Use the grade and viscosity recommend- ed in the engine owner???s manual.

FIGURE D.2 - OIL DRAIN AND REFILL

LOCATION

1.OIL DRAIN PLUG

2.OIL FILL PLUG

3.OIL LEVEL

FUEL: At the end of each day???s use, refill the fuel tank to minimize moisture conden- sation and dirt contamination in the fuel line.

ENGINE ADJUSTMENTS

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 adjust- ments to increase the maximum speed. Severe personal injury and damage to the machine can result if operated at speeds above maximum.

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Adjustments to the engine are to be made only by a Lincoln Service Center or an authorized Field Service Shop.

CAUTION

Do not use petroleum solvents such as kerosene to clean the air cleaner. They may cause deterio- ration of the air cleaner. DO NOT OIL THE AIR

CLEANER OR USE PRESSURIZED AIR TO CLEAN

OR DRY THE AIR CLEANER.

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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 m uffler ar ea to r em ove combustible debris.

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Clean Rotating Screen: If your POWER-ARC 5500 is equipped with an engine that has a rotating screen, you should clean it as often as needed, to remove dirt or debris that may collect on the screen. A dirty screen can result in engine overheating and damage. (See Figure D.3).

1

FIGURE D.3 - CLEAN ROTATING

SCREEN/FINGER GUARD/DEBRIS GUARD

1. ROTATING SCREEN

CLEAN COOLING SYSTEM: See Figure D.4. 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.

FIGURE D.4 - CLEAN COOLING SYSTEM

1. REMOVE DIRT FROM THESE AREAS.

GENERATOR/WELDER MAINTENANCE

STORAGE: Store the POWER-ARC 5500 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.5. 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.

NOTE: Lincoln offers a rotor removal kit for any ser- vice which requires removal of the rotor from the engine. See the ACCESSORIES section for further details.

Removal of engine/generator assembly from the cradle can be achieved as follows:

???Remove the two 5/16-18 hex head cap screws from the engine block via the access hole located in the cradle cross support channel. Leave all other engine mountings intact.

???Remove the two hex nuts from the isolator thread- ed posts at the stator support bracket located opposite the engine. Leave all other stator mount- ings intact.

???With a jib hoist or crane, lift the unit upward and remove loose cradle from engine/generator assembly.

This Troubleshooting Guide is provided to help you locate and repair possible machine malfunctions. Simply follow the three-step procedure listed below.

Step 1. LOCATE PROBLEM (SYMPTOM).

Look under the column labeled ???PROBLEM (SYMP- TOMS)???. This column describes possible symptoms that the machine may exhibit. Find the listing that best describes the symptom that the machine is exhibiting.

Step 2. POSSIBLE CAUSE.

The second column labeled ???POSSIBLE CAUSE??? lists the obvious external possibilities that may contribute to the machine symptom.

Step 3. RECOMMENDED COURSE OF ACTION

This column provides a course of action for the Possible Cause, generally it states to contact your local Lincoln Authorized Field Service Facility.

If you do not understand or are unable to perform the Recommended Course of Action safely, contact your local Lincoln Authorized Field Service Facility.

2. Loose or open connection with elec- trical plug-in component.

3. Current control dial not at ???125???.

4. No open circuit voltage at receptacle. Open lead in receptacle circuit.

5. No open circuit voltage at receptacle. Bad receptacle.

6. Rheostat (R1) lead broke.

Engine runs erratically or stops running. 1. Engine is not fully warmed-up and engine choke is in the fully open (RUN) position.

2. Engine requires service to head, car- buretor, filters, oil, spark plug and/or gas.

If all recommended possible areas of misadjustment have been checked and the problem persists,

Contact your local Lincoln Authorized Field Service Facility.

Engine sputters but will not start.

1.Bad gas, bad filter, air cleaner, spark plug, and/or breather.

If all recommended possible areas of misadjustment have been checked and the problem persists,

Contact your local Lincoln Authorized Field Service Facility.