Northern Amp Arc 7000 Service manual

Please read and save these instructions. Read through this owner’s manual carefully before
using product. Protect yourself and others by observing all safety information, warnings, and
cautions. Failure to comply with instructions could result in personal injury and/or damage to
product or property. Please retain instructions for future reference.
1
Operating Instructions and Parts Manual AAmmpp AArrcc 77000000
Welder/Generator
Description
The AMP Arc 7000 is a
welder/generator that features 6000
watts of continuous auxilliary power
while not welding and 6600 watts of
peak power. It also provides 60 - 185
amps DC weld power for stick
welding. Use electrodes up to 5/32"
for a single pass weld capacity of
3/8". Weld steel, stainless steel, cast
iron and hard surfacing. The
auxilliary power connections include
a 120V duplex receptacle and a
240V twistlock receptacle. This unit
is complete with weld cables, wheel kit and a top tray.
Specifications and Dimension
Model
spec
Amp Arc 7000
Generator
spec
AC
Frequency（Hz） 60
Voltage （V） 240/120
Rated current （A） 25/40
Max power （KW） 6.6
Rated power （KW） 6
phase Single phase
Power factor COSφ 1.0

Operating Instructions and Parts Manual
Northern Industrial Welding
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Amp Arc 7000
Amp Arc 7000
Excitation type Self-excitation
Working type 8 hours continuous
Welder
spec
DC
No load voltage （V）55-75
Rated current （A）150
Welding voltage(V）26-33
Welding current range
（A）
60-185
Duty cycle （%）30
Engine
spec
Engine model LCT414CC/LC190F★
Engine type Single tank, fan cooled,
four Stroke
Air displacement CC 414
Tank dia X journey mm 90×64
Rated rotation speed rpm 3600
Fuel Gasoline
Lubricator capacity 1.2 Qt.
Power 14HP
Start type Re-coil
Fuel capacity 5 Gallon
Structure Open style
Machine
Dimension mm 800×595×720
Net weight lbs 309 lbs
Fuel consumption rate g/HP-
H
230

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Amp Arc 7000
Amp Arc 7000
Removing from carton
1.1 Remove pallet and cartons, bags or Styrofoam containing the
welder/generator and accessories.
1.2 Check the contents with the packing list below.
1.3 After unpacking the unit, inspect carefully for any damage that may
have occurred during transit. Check for loose, missing, or damaged
parts. Shipping damage claim must be filed with carrier.
Know your Welder
ITEM QTY.
Amp Arc 7000 1 unit
Ground cable/clamp 1pc
Welding cable/electrode holder 1pc
Spark plug socket wrench 1 pc
Adjustable current switch 1pc
Moving kit 1set
Engine Manual 1set
Operator’s Manual 1set
MAX/MIN
Switch

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Amp Arc 7000
Amp Arc 7000
No description Qty Function
1 Weld output
connectors
2pcs The connectors for welding cable
and grounding cable when welding
2 Receptacle cover 1sets Prevent the water going into the
receptacle
3
Weld Amperage
Control
1pc
1、when welding, it is used to
adjust the weld amperage.
2、Attention: when the machine is
used only as generator, please
set this knob at the maximum
position
4 120v power supply
receptacle
2 120V 20A
5 240v twist lock
receptacle
1 240V 30A
6 Air switch 1 The main switch for the circuit
7 Circuit protection
switch
2 Prevent the two sockets from
overloading
8 Fan inset for
Engine
1 The inlet for the air
9 Fuel inlet for
engine
1 Adjust the fuel capacity
10 Starting handle 1 Start engine
11 Engine switch 1 Start the engine

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Northern Industrial Welding
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Amp Arc 7000
Amp Arc 7000
General Safety Information
1.1 Your Welding Environment
-Keep the environment you will be
welding in free from flammable
materials.
-Always keep a fire extinguisher
accessible to your welding
environment.
-Always have a qualified person
install and operate this equipment.
-Make sure the area is clean, dry and
ventilated. Do not operate the welder
in humid, wet or poorly ventilated
areas.
-Always have your welder maintained
by a qualified technician in
accordance with local, state and
national codes.
-Always be aware of your work
environment. Be sure to keep other
people, especially children, away
from you while welding.
-Keep harmful arc rays shielded from
the view of others.
-Keep the welder secure to prevent it
from tipping over or falling.
1.2 Your Welder’s Condition
-Check ground cable and welding
cable to be sure the insulation is not
damaged. Always replace or repair
damaged components before using
the welder.
-Check all components to ensure they
are clean and in good operating
condition before use.
1.3 Use of Your Welder
Do not operate the welder if the
output cable or electrode cable, are
wet. Do not immerse them in water.
These components and the welder
must be completely dry before
attempting to use them.
-Follow the instructions in this manual.
-Keep welder in the off position when
not in use.
-Connect ground lead as close to the
area being welded as possible to
ensure a good ground.
-Do not allow any body part to come
in contact with the welding electrode
if you are in contact with the material
being welded, ground or electrode
from another welder.
-Do not weld if you are in an awkward
position. Always have a secure
stance while welding to prevent
accidents. Wear a safety harness if
working above ground.
-Do not drape cables over or around
your body.
-Wear a full coverage helmet with
appropriate shade (see ANSI Z87.1
safety standard) and safety glasses
while welding.
-Wear proper gloves and protective
clothing to prevent your skin from
being exposed to hot metals, UV and
IR rays.
-Do not overuse or overheat your
welder. Allow proper cooling time
between duty cycles.
-Keep hands and fingers away from
moving parts.
-Do not point electrode at any body
part of yourself or anyone else.
-Always use this welder in the rated
duty cycle to prevent excessive heat
and failure.
1.4 Specific Areas of Danger,
Caution or Warning
Electrical Shock
Electric arc welders can
produce a shock that
can cause injury or
death. Touching electrically live parts

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Amp Arc 7000
Amp Arc 7000
can cause fatal shocks and severe
burns. While welding, all metal
components connected to the
electrode are electrically hot. Poor
ground connections are a hazard, so
secure the ground lead before
welding.
-Wear dry protective apparel: coat,
shirt, gloves and insulated footwear.
-Insulate yourself from the work piece.
Avoid contacting the work piece or
ground.
- Do not attempt to repair or maintain
the welder while the power is on.
-Inspect all cables and cords for any
exposed wire and replace
immediately if found.
-Use only recommended replacement
cables and cords.
-Always attach ground clamp to the
work piece or work table as close to
the weld area as possible.
-Do not touch the electrode and the
ground or grounded work piece at the
same time.
-Do not use a welder to thaw frozen
pipes. Fumes and Gases
-Fumes emitted from the
welding process displace
clean air and can result in
injury or death.
-Do not breathe in fumes emitted by
the welding process. Make sure your
breathing air is clean and safe.
-Work only in a well-ventilated area or
use a ventilation device to remove
welding fumes from the environment
where you will be working.
-Do not weld on coated materials
(galvanized, cadmium plated or
containing zinc, mercury or barium).
They will emit harmful fumes that are
dangerous to breathe. If necessary
use a ventilator, respirator with air
supply or remove the coating from the
material in the weld area.
-The fumes emitted from some
metals when heated are extremely
toxic. Refer to the material safety
data sheet for the manufacturer’s
instructions.
-Do not weld near materials that will
emit toxic fumes when heated.
Vapors from cleaners, sprays and
degreasers can be highly toxic when
heated. UV and IR Arc Rays
The welding arc
produces ultraviolet (UV)
and infrared (IR) rays
that can cause injury to your eyes
and skin. Do not look at the welding
arc without proper eye protection.
-Always use a helmet that covers
your full face from the neck to top of
head and to the back of each ear.
-Use a lens that meets ANSI
standards and safety glasses. For
welders under 160 Amps output, use
a shade 10 lens; for above 160 Amps,
use a shade 12. Refer to the ANSI
standard Z87.1 for more information.
-Cover all bare skin areas exposed to
the arc with protective clothing and
shoes. Flame-retardant cloth or
leather shirts, coats, pants or
coveralls are available for protection.
-Use screens or other barriers to
protect other people from the arc rays
emitted from your welding.
-Warn people in your welding area
when you are going to strike an arc
so they can protect themselves.

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Amp Arc 7000
Amp Arc 7000
Fire Hazards
Do not weld on containers
or pipes that contain or
have had flammable,
gaseous or liquid combustibles in
them. Welding creates sparks and
heat that can ignite flammable and
explosive materials.
-Do not operate any electric arc
welder in areas where flammable or
explosive materials are present.
-Remove all flammable materials
within 35 feet of the welding arc. If
removal is not possible, tightly cover
them with fireproof covers.
-Take precautions to ensure that
flying sparks do not cause fires or
explosions in hidden areas, cracks or
areas you cannot see.
-Keep a fire extinguisher close in the
case of fire.
-Wear garments that are oil-free with
no pockets or cuffs that will collect
sparks.
-Do not have on your person any
items that are combustible, such as
lighters or matches.
-Keep work lead connected as close
to the weld area as possible to
prevent any unknown, unintended
paths of electrical current from
causing electrical shock and fire
hazards.
Hot Materials
Welded materials are hot
and can cause severe
burns if handled improperly.
-Do not touch welded materials with
bare hands.
-Do not touch electrode after welding
until it has had time to cool down.
Sparks/Flying Debris
Welding creates hot
sparks that can cause
injury. Chipping slag off
welds creates flying debris.
-Wear protective apparel at all times:
ANSI-approved safety glasses or
shield, welder’s hat and ear plugs to
keep sparks out of ears and hair.
Electromagnetic Field
-Electromagnetic fields
can interfere with various
electrical and electronic
devices such as pacemakers.
-Consult your doctor before using any
electric arc welder or cutting device
-Keep people with pacemakers away
from your welding area when welding.
-Do not wrap cable around your body
while welding.
-Wrap electrode and ground cable
together whenever possible.
-Keep electrode and ground cables
on the same side of your body.
1.5 Proper Care, Maintenance and
Repair
-Always have power disconnected
when working on internal
components.
- Do not touch or handle PC board
without being properly grounded

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Amp Arc 7000
Amp Arc 7000
with a wrist strap. Put PC board in
static proof bag to move or ship.
-Do not put hands or fingers near
moving parts such as drive rolls of
fan
Assembly
1. Open the box, and take out
machine and accessory.
2. Install the wheel on the axle, then
the flap washer and the last is the
cotter pin, assemble one side then
the another side.
3.Use the lifting set to uplift the
machine.
4. Axle components will be
assembled with bolts and nuts to
install in the axle mounting plate.
5. Install the handle on the machine
by bolts and nuts
6. Make the machine down from the
lifting set.
Installation
1. Fill the engine with oil and fuel
before operating it.
2. Connect the welding cable and
grounding cable.
3. Start the engine and after the
engine is running smoothly and
allowed to warm up, you are ready to
weld.
Operation
1. Follow the assembly and
installation instructions tp prepare
the welder/generator.
2. Securely connect the supplied
welding cables. Tight connections
prevent sparking and damage
from heat.
3. Operate this unit in a weld
ventilated area. Do not cover and
keep free of all debris to ensure
proper cooling.
4. Choose the correct welding
electrode for the material being
welded
5. Follow the engine's manual for
proper steps to start the engine.
Allow the engine proper time to
warm up before using the
welder/generator.
When only using the welding
power function, please turn off the
output power to prevent misuse to
endanger people's health
When only use the dynamo,
welding cables should be promptly
removed. And adjust current knob
to the maximum to ensure that the
output voltage.
6. Use the weld amperage control
to set proper amperage for your
weld job.
7. See the following table for
suggested amperage settings for
different diameter welding rods.
Diameter 5/64" 3/32" 1/8" 5/32"
Welding
current 50-60 60-80 100-130 140-190
Maintenance
The welder needs the regular
maintenance as following:
Periodically clean dust, dirt, grease,
etc. from your welder. Every six
months, or as necessary, remove the
cover panel from the welder and air-
blow any dust and dirt that may have
accumulated inside the welder.
Replace ground cable, ground clamp,
or electrode assembly when
damaged or worn.

Operating Instructions and Parts Manual
Northern Industrial Welding
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Amp Arc 7000
Amp Arc 7000
MINOR AND ROUTINE
MAINTENANCE
Store in a clean dry location free from
corrosive gas, dust and high humidity.
Temperatures should range from
23°F–104°F and a relative humidity
less than 90%.
THERE IS A PERMANENT
CONDUCTOR BETWEEN THE
GENERATOR (STATOR WINDING)
AND THE FRAME

Operating Instructions and Parts Manual
Northern Industrial Welding
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Amp Arc 7000
Amp Arc 7000
Trouble shooting Chart
Symptom (s) Possible Causes(s) Corrective Action(s)
Engine does not
start, does not
operate or
operates poorly
See engine manual See engine manual
Wrong voltage 1.Duty cycle is short circuit
2.RPM is wrong
3.Rotor line is short circuit
4.Generator line is broken
1.Check
2.Adjust the RPM to
rating
3.Repair
4.Repair
Can’t reach the
rated voltage
1.Exciting voltage is too
low
2.The load is too huge
3.Generator wire is
damaged
4. RPM is too low
1.Adjust the welding
current to the max
2.Decrease the load to
the rating
3.Repair
4.Increase the RPM
Voltage dropped
considerably
when loading
1.The wire between the
generator and load is too
long, or section surface is
too small
2.Principal windings and
loop are damaged
3.Load is ahead of the
power rating
1.Narrow the gap, and
make the wire more
thick
2.Replace the Generator
3.Decrease the loading to
the power rating
Welding current
is wrong
Welding winding is
damaged
Replace the Generator
Welding current
is too low
RPM is too low Adjust accelerator and
increase the RPM

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Northern Industrial Welding
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Amp Arc 7000
Amp Arc 7000
Main Circuit chart

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Northern Industrial Welding
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Amp Arc 7000
Amp Arc 7000
Spare parts list
17
18
16
1311 12
15
14
9
8
7
10
6
5
4
3
2
1
19
20
21
22
23
24
25
26
27
28
293031323334353637
38
39
40
41

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Amp Arc 7000
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Repair Parts List
Reference
number Description Part number Qty
1 Single joint cover 2.05.05.601 1
2 Double joint cover 2.05.05.602 1
3 European fast socket 2.07.57.127 2
4 Regulating current knob 2.07.11.047 1
5 Welding bottom-board 1.1.01.04.0356 1
6 AC reactor 1.1.04.03.1211 1
7 Thick loop 2.04.31.019 1
8 Six-foot post head 2.05.05.909 1
9 Connecting sheet 1.1.02.01.7862 1
10 Double three-hole socket125V 2.07.57.923 2
11 Anti-loose sockets 250V 2.07.73.1021 1
12 Magnetic hydraulic circuit
breaker 2.07.80.314 1
13 Rectifier bridge 2.07.37.603 1
14 Welder cover 1.1.01.01.0317 1
15 Breaker 2.07.80.302 2
16 BCI type arm-wire resistor 2.07.04.804 1
17 AVR 2.07.99.691 1
18 Regulator 1.1.04.01.1227 1
19 Tank 2.07.40.618 1
20 Tank bottom-board 1.1.02.01.7
975
1
21 Engine 2.07.40.506 1
22 Muffler left housing plate 2.16.03.685 1

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Amp Arc 7000
Amp Arc 7000
23 Muffler front housing plate 2.16.03.687 1
24 L type supporter 2.16.03.683 2
25 Handle 1.2.01.01.3243 2
26 Muffler right housing plate 2.16.03.686 1
27 Hexagon flange screw 2.06.01.056 8
28 Rack form 1.1.01.04.0354 1
29 Wheel 2.05.07.2116 2
30 Pin 2.06.17.008 2
31 Hexagon screw 2.06.01.064 4
32 Flap washer 2.06.17.010 4
33 Axle 1.2.02.04.0118 1
34 Flap washer 2.06.17.005 4
35 Spring washer 2.06.18.005 4
36 Hexagon nut 2.06.14.005 4
37 Damping feet 2.05.05.126 4
38 Dynamo 2.07.40.617 1
39 Cross-flow pipe 2.05.05.907 1
40 Electric cabinet component 1.2.01.01.3241 1
41 Pallet component 1.1.01.04.0353 1

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Northern Industrial Welding
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Amp Arc 7000
Amp Arc 7000
Other Safety and Standards Information
This manual is designed to inform the operator of safety and general use of this
model only. For further information about welding safety refer to the following
standards and comply with them where applicable.
• ANSI Standard Z49.1 — SAFETY IN
WELDING AND CUTTING obtainable
from: American Welding Society 550 NW
Le Jeune Road, Miami, FL 33126
Tel. [phone]
Fax [phone]
www.amweld.org or www.aws.org
• ANSI Standard Z87.1 — SAFE PRACTICE
FOR OCCUPATION AND EDUCATIONAL
EYE AND FACE PROTECTION
Obtainable from: American National
Standards Institute (ANSI) 11 West 42nd
St. New York, NY 10036
Tel. [phone]
Fax [phone] www.ansi.org
• NFPA Standard 51B — CUTTING AND
WELDING PROCESS obtainable from:
National Fire Protection Association,
1 Batterymarch Park, P.O. Box 9101
Quincy, MA 02269-9101
Tel. [phone]
Fax [phone] www.nfpa.org
• OSHA Standard 29 CFR, Part 1910,
Subpart Q. —WELDING, CUTTING AND
BRAZING obtainable from your state
OSHA office or from: U. S. Dept. of Labor
OSHA, Office of Public Affairs Room
N3647, 200 Constitution Ave. NW
Washington, DC 20210 www.osha.gov
• CSA Standard W117.2 — Code for
SAFETY IN WELDING AND CUTTING
Obtainable from: Canadian Standards
Association, 178 Rexdale Blvd.,
Etobicoke, Ontario M9W 1R3
www.csa.ca

Operating Instructions and Parts Manual
Northern Industrial Welding
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Amp Arc 7000
Amp Arc 7000
• American Welding Society Standard A6.0
—WELDING AND CUTTING CONTAINERS
WHICH HAVE HELD COMBUSTIBLES
Obtainable from: American
Welding Society, 550 NW Le Jeune Road
Miami, FL 33126
Tel. [phone]
Fax [phone]
www.amweld.org or www.aws.org