Lincoln Electric ARC 5000 User Manual

POWER ARC ™5000

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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 thought­ful operation on your part. DO

NOT INSTALL, OPERATE OR
REPAIR THIS EQUIPMENT
WITHOUT READING THIS
MANUAL AND THE SAFETY
PRECAUTIONS CONTAINED
THROUGHOUT. And, most

importantly, think before you act
and be careful.

IM560-A

November, 1999

For Machines with Code Number 10255 and 10430

Date of Purchase:
Serial Number:
Code Number:
Model:
Where Purchased:

Cleveland, Ohio 44117-1199 U.S.A. TEL: [phone] FAX: [phone] WEB SITE: www.lincolnelectric.com

OPERATOR’S MANUAL

• World's Leader in Welding and Cutting Products •

• Sales and Service through Subsidiaries and Distributors Worldwide •

i

SAFETY

i

WARNING

CALIFORNIA PROPOSITION 65 WARNINGS

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

The Above For Diesel Engines

ARC WELDING CAN BE HAZARDOUS. PROTECT YOURSELF AND OTHERS FROM POSSIBLE SERIOUS INJURY OR DEATH.
KEEP CHILDREN AWAY. PACEMAKER WEARERS SHOULD CONSULT WITH THEIR DOCTOR BEFORE OPERATING.

Read and understand the following safety highlights. For additional safety information, it is strongly recommended that you
purchase a copy of “Safety in Welding & Cutting - ANSI Standard Z49.1” from the American Welding Society, P.O. Box
351040, Miami, Florida 33135 or CSA Standard W117.2-1974. A Free copy of “Arc Welding Safety” booklet E205 is available
from the Lincoln Electric Company, 22801 St. Clair Avenue, Cleveland, Ohio 44117-1199.

BE SURE THAT ALL INSTALLATION, OPERATION, MAINTENANCE AND REPAIR PROCEDURES ARE
PERFORMED ONLY BY QUALIFIED INDIVIDUALS.

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.

____________________________________________________

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

____________________________________________________

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 vaporiz­ing 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.

____________________________________________________

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.

____________________________________________________

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.

___________________________________________________

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.

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.

___________________________________________________

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.

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

ii

SAFETY

ii

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.

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.

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.

5.b.

Do not weld in locations near chlorinated hydrocarbon

coming from degreasing, cleaning or spraying operations.
The heat and rays of the arc can react with solvent vapors
form phosgene, a highly toxic gas, and other irritating
products.

5.c. 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.d. 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.e. Also see item 1.b.

Mar ‘95

vapors

to

iii

SAFETY

iii

WELDING 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.

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
been “cleaned”. For information, purchase “Recommended
Safe Practices for the
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.

Sparks and spatter are thrown from the welding arc. Wear oil

6.f.
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 cir­cuits. This can create fire hazards or overheat lifting chains
or cables until they fail.

6.h. Also see item 1.c.

Remember that welding sparks and hot

though

they have

Preparation

for Welding and Cutting of

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.

Mar ‘95

iv

SAFETY

iv

PRÉCAUTIONS DE SÛRETÉ

Pour votre propre protection lire et observer toutes les instruc­tions et les précautions de sûreté specifiques qui parraissent
dans ce manuel aussi bien que les précautions de sûreté
générales suivantes:

Sûreté Pour Soudage A L’Arc

1. Protegez-vous contre la secousse électrique:

a. Les circuits à l’électrode et à la piéce sont sous tension

quand la machine à souder est en marche. Eviter toujours
tout contact entre les parties sous tension et la peau nue
ou les vétements mouillés. Porter des gants secs et sans
trous pour isoler les mains.

b. Faire trés 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 couché pour lesquelles une
grande partie du corps peut être en contact avec la
masse.

c. Maintenir le porte-électrode, la pince de masse, le câble

de soudage et la machine à souder en bon et sûr état
defonctionnement.

d.Ne jamais plonger le porte-électrode dans l’eau pour le

refroidir.

e. Ne jamais toucher simultanément les parties sous tension

des porte-électrodes connectés à deux machines à soud­er parce que la tension entre les deux pinces peut être le
total de la tension à vide des deux machines.

f. Si on utilise la machine à souder comme une source de

courant pour soudage semi-automatique, ces precautions
pour le porte-électrode s’applicuent aussi au pistolet de
soudage.

5. Toujours porter des lunettes de sécurité dans la zone de
soudage. Utiliser des lunettes avec écrans lateraux dans les
zones où l’on pique le laitier.

6. Eloigner les matériaux inflammables ou les recouvrir afin de
prévenir tout risque d’incendie dû aux étincelles.

7. Quand on ne soude pas, poser la pince à une endroit isolé de
la masse. Un court-circuit accidental peut provoquer un
échauffement et un risque d’incendie.

8. S’assurer que la masse est connectée le plus prés 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 éloignés de la zone de travail, on augmente le risque
de voir passer le courant de soudage par les chaines de lev­age, câbles de grue, ou autres circuits. Cela peut provoquer
des risques d’incendie ou d’echauffement des chaines et des
câbles jusqu’à ce qu’ils se rompent.

9. Assurer une ventilation suffisante dans la zone de soudage.
Ceci est particuliérement important pour le soudage de tôles
galvanisées plombées, ou cadmiées ou tout autre métal qui
produit des fumeés toxiques.

10. Ne pas souder en présence de vapeurs de chlore provenant
d’opérations de dégraissage, nettoyage ou pistolage. La
chaleur ou les rayons de l’arc peuvent réagir avec les
vapeurs du solvant pour produire du phosgéne (gas forte­ment toxique) ou autres produits irritants.

11. Pour obtenir de plus amples renseignements sur la sûreté,
voir le code “Code for safety in welding and cutting” CSA
Standard W 117.2-1974.

2. Dans le cas de travail au dessus du niveau du sol, se pro­téger contre les chutes dans le cas ou on recoit un choc. Ne
jamais enrouler le câble-électrode autour de n’importe quelle
partie du corps.

3. Un coup d’arc peut être plus sévère qu’un coup de soliel,
donc:

a. Utiliser un bon masque avec un verre filtrant approprié

ainsi qu’un verre blanc afin de se protéger les yeux du
rayonnement de l’arc et des projections quand on soude
ou quand on regarde l’arc.

b. Porter des vêtements convenables afin de protéger la

peau de soudeur et des aides contre le rayonnement de
l‘arc.

c. Protéger l’autre personnel travaillant à proximité au

soudage à l’aide d’écrans appropriés et non-inflamma­bles.

4. Des gouttes de laitier en fusion sont émises de l’arc de
soudage. Se protéger avec des vêtements de protection
libres de l’huile, tels que les gants en cuir, chemise épaisse,
pantalons sans revers, et chaussures montantes.

PRÉCAUTIONS DE SÛRETÉ POUR
LES MACHINES À SOUDER À
TRANSFORMATEUR ET À
REDRESSEUR

1. Relier à la terre le chassis du poste conformement au code
de l’électricité et aux recommendations du fabricant. Le dis­positif de montage ou la piece à souder doit être branché à
une bonne mise à la terre.

2. Autant que possible, I’installation et l’entretien du poste
seront effectués par un électricien qualifié.

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

4. Garder tous les couvercles et dispositifs de sûreté à leur
place.

Mar. ‘93

for selecting a QUALITY product by Lincoln Electric. We want you

Thank You

to take pride in operating this Lincoln Electric Company product

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

Please Examine Carton and Equipment For Damage Immediately

When this equipment is shipped, title passes to the purchaser upon receipt by the carrier. Consequently, Claims
for material damaged in shipment must be made by the purchaser against the transportation company at the
time the shipment is received.

Please record your equipment identification information below for future reference. This information can be
found on your machine nameplate.

Model Name & Number _____________________________________

Code & Serial Number _____________________________________

Date of Purchase _____________________________________

Whenever you request replacement parts for or information on this equipment always supply the information
you have recorded above.

vv

Read this Operators Manual completely before attempting to use this equipment. Save this manual and keep it

handy for quick reference. Pay particular attention to the safety instructions we have provided for your protection.
The level of seriousness to be applied to each is explained below:

WARNING

This statement appears where the information must be followed exactly to avoid serious personal injury or
loss of life.

CAUTION

This statement appears where the information must be followed to avoid minor personal injury or damage to
this equipment.

vi vi

TABLE OF CONTENTS

Page

Safety.................................................................................................................................................i-iv

Installation.............................................................................................................................Section A

Technical Specifications.............................................................................................................A-1

Safety Precautions......................................................................................................................A-2

Location and Ventilation .............................................................................................................A-2

Assembly of Vibration Isolators to Bottom of Tube Frame.........................................................A-3

Assembly of Wheels and Handle to the Tube Frame..................................................................A-4

Pre-operation Engine Service.....................................................................................................A-5

Electrical Output Connections.........................................................................................A-6 to A-9

Operation...............................................................................................................................Section B

Safety Instructions......................................................................................................................B-1

General Description....................................................................................................................B-1

Recommended Applications.......................................................................................................B-2

Controls and Settings.................................................................................................................B-3

Engine Operation........................................................................................................................B-5

Generator Operation...................................................................................................................B-7

Welding Operation......................................................................................................................B-9

Learning to Stick Weld..............................................................................................................B-11

Accessories...........................................................................................................................Section C

Maintenance..........................................................................................................................Section D

Safety Precautions............................................................................................................................D-1

Routine and Periodic Maintenance...................................................................................................D-1

Major Component Locations.............................................................................................................D-5

Troubleshooting and Repair ................................................................................................Section E

Electrical Diagrams...............................................................................................................Section F

Parts Manual......................................................................................................................P277 Series

POWER ARC 5000

A-1

INSTALLATION

TECHNICAL SPECIFICATIONS - POWER ARC 5000

INPUT - GASOLINE ENGINE

Manufacturer Description Speed Displacement Ignition Capacities

A-1

Briggs & 1 cyl., 3700 RPM 24.4 cu. in. Electronic

Stratton 4 cycle ± 50 RPM (400 cc) Ignition;

Industrial air-cooled at no load Recoil start; Oil: 1.5 qt. (1.42 l)

Plus gasoline Manual choke

11 HP @

3600 RPM

Fuel: 5.5 gal. (20.8 l)

RATED OUTPUT - WELDER

Duty Cycle Amps Volts at Rated Amperes

40% Duty Cycle 150 25 VAC
60% Duty Cycle 125 25 VAC

OUTPUT - WELDER AND GENERATOR

Welding Ranges Welder Open Circuit Voltage AC Auxiliary Power

70 - 150 Amps 62 VAC Max. 5000 Watts 41.6/20.8 amps

120/240 volts, +5%, -15%

PHYSICAL DIMENSIONS

Height Width Depth Weight

26.62 in. 20 in. 29 in.
676 mm 508 mm 737 mm

POWER ARC 5000

208 lb. - 215 lb w/ undercarriage

94.3 kg. - 97.5 kg. w/ undercarriage

A-2

INSTALLATION

A-2

Read this entire installation section before you
start installation.

SAFETY PRECAUTIONS

WARNING

Do not attempt to use this equipment until you have
thoroughly read all the operation and maintenance
manuals supplied with your machine. They include
important safety precautions; detailed engine starting,
operating, and maintenance 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.

LOCATION AND VENTILATION

Whenever you use the POWER ARC 5000, 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
ambient temperature range for operating this machine
is 0°F to 104°F (-18°C to 40°C).

The POWER ARC 5000 may be used outdoors. Do
not set the machine in puddles or otherwise sub­merge it in water. Such practices pose safety haz­ards and cause improper operation and corrosion of
parts.

Always operate the POWER ARC 5000 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

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 service

this equipment.

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 con­struction 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 Sta-Bil® additive or Briggs & Stratton
Gasoline Additive, Part No. 5041 (available from
any Authorized Briggs & Stratton Service Center),
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.

POWER ARC 5000

A-3

INSTALLATION

A-3

STACKING

POWER ARC 5000 machines CANNOT be stacked.

TILTING

Place the machine on a secure, level surface whenev­er 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 posi­tion for best performance. It can operate at an angle,
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 5000 should be lifted by four peo­ple. (It weighs 208 lbs/94.3 kg.) Its welded tube roll
cage is designed to make lifting easy.

Figure A-1

ASSEMBLY OF VIBRATION ISOLATORS
TO BOTTOM OF TUBE FRAME ( If
wheels are not used)

Tools required - 9/16 wrench or socket.

If the supplied wheels are not used, it is important that the
isolators are installed to keep the machine stabilized when
operated on a smooth surface.

Install the four molded rubber vibration isolators to the bot­tom of the engine and alternator support channels using four
each of the supplied 3/8-16 X .875 hex head screws, lock­washers, and large plain washers (spacers). The large plain
washers (spacers) must be installed between the isolator
and the underside of the channels. See Figure A-1.

3/8-16 x .875 Hex Head Bolt

Lockwasher

Frame

Large Plain Washer (Spacer)
Rubber Isolator

POWER ARC 5000

A-4

INSTALLATION

Assembly of Wheels and Handle to the
Tube Frame

Tools Required - Two 9/16 wrenches or sockets, 3/8 wrench

or socket and a rubber mallet or wooden
block.

Refer to Figure A-2 for illustration of proper assembly.

a.) Set the machine on blocks so that it is raised up off

the floor by approximately 6 inches.

b.) Install two of the vibration isolators (Item 1) to the

bottom of each foot (Item 2) using one each of the
supplied 3/8-16 X .875 hex head bolts and lock­washers on each foot. (Detail A)

c.) Install the two feet to the alternator support channel

using three each of the supplied 3/8-16 X .875 hex
head bolts, lock-washers, and 3/8 - 16 hex nuts on
each foot. (Detail A)

d.) Install the two axle support brackets (Item 3) to the

engine support channel using two each of the
supplied 3/8-16 X .875 hex head bolts and lock­washers, two each of the supplied 3/8-16 hex nuts,
two each of the large plain washers (spacers), and
two each of the vibration isolators (Item 1). The two

A-4

vibration isolators are installed in the inward holes
furthest from the tube frame. Refer to Figure A-2
Detail B. The two large washers must be installed
between the vibration isolators and the underside
of the channel. The remaining two large plain
washers (spacers)are not used.

e.) Install one of the push nuts (Item 4) on one end of

the axle (Item 5) by supporting the axle vertical and
tapping on the push nut with a rubber mallet or
wooden block.

f.) Install one wheel (Item 6) on to the axle and slide

the axle through the slots in the two axle support
brackets. The axle will rest on the two vibration iso­lators when the machine is set on the ground pro­viding a type of suspension for the axle.

g.) Install the other wheel and push nut on the other

end of the axle.

h.) Loosen but do not remove the four screws that

hold the handle clips (Item 7) to the fuel tank sup­port channel on the alternator end. Install the han­dle (Item 8) through the large holes in the channel
and tighten the screws that were previously loos­ened. The height of the handle can be adjusted to
suit the user.

Alternator Support Channel

3/8-16 Hex Nut (3)

Lockwasher (3)

3/8-16 x .875 Hex Bolt (3)

Foot
Item 2

3/8-16 x .875 Hex Bolt

Lockwasher

Figure A-2

Engine Support Channel

3/8-16 x .875 Hex Bolt (2)

Axle
Item 5

Rubber Isolator

8

Item 1

Large Plain Washer
(Spacer)

Lockwasher

Hex Nut

Axle Support Bracket
Item 3

Tubular Frame

Wheel
Item 6

Push Nut
Item 4

Detail B

7

3

1

6

4

5

Detail A

Rubber Isolator
Item 1

2

1

POWER ARC 5000

A-5

INSTALLATION

PRE-OPERATION ENGINE SERVICE

Read and understand the information about the gasoline
engine in the OPERATION and MAINTENANCE sections of
this manual before you operate the POWER ARC 5000.

WARNING

• Keep hands away from the engine muffler or HOT engine
parts.

• Stop the engine when fueling.

• Do not smoke when fueling.

• Remove the fuel cap slowly to release pressure.

• Do not overfill the fuel tank.

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

• Keep sparks and flame away from the fuel tank.

A-5

FUEL

Fill the fuel tank with clean, fresh, regular grade
lead-free gasoline. DO NOT MIX OIL WITH

THE GASOLINE.

The POWER ARC 5000 has a plastic, 5.5 gallon (20.8 L) fuel
tank mounted above the generator. See the Briggs &
Stratton Engine manual for more details about fuel.

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.

Standard mufflers do not act as spark arresters. When
local laws require it, a spark arrester must be installed on
the machine and properly maintained. An optional spark
arrester kit is available for your POWER ARC 5000. See the
ACCESSORIES section of this manual for more information.

OIL

The POWER ARC 5000 is shipped with the engine filled
with SAE 10W-30 oil. CHECK THE OIL LEVEL BEFORE
YOU START THE ENGINE. If the oil level is not at the
“FULL” mark on the dip-stick, add oil but do not overfill. Be
sure the dip-stick cap is tight. Change the oil after the

first 5 hours of operation.

For more oil fill and service information, see the Briggs &
Stratton Engine manual.

An incorrect spark arrester may lead to damage to the
engine or reduce performance. A suitable spark arrester for
the Briggs & Stratton 11 HP Industrial Plus engine is avail­able as a Lincoln field-installed option.

CAUTION

POWER ARC 5000

A-6

INSTALLATION

FIGURE A.3 - POWER ARC 5000 OUTPUT CONNECTIONS

1

10

POWER ARC 5000

6

WARNING

A-6

2

WELDING ELECTRODES

9

WORK LOW RANGE HIGH RANGE

CIRCUIT BREAKERS

120/240 VOLTS 30 AMPS

4

1. CURRENT CONTROL DIAL

2. ELECTRODE SELECTION GUIDE

3. WELD OUTPUT TERMINALS (TO ELECTRODE HOLDER,

HIGH RANGE AND LOW RANGE)

4. WELD OUTPUT TERMINAL (TO WORK)

5. GROUNDING TERMINAL

ELECTRICAL OUTPUT
CONNECTIONS

See Figure A.3 for the location of the current control
dial, weld output terminals, grounding terminal, circuit
breakers, 240 and 120 volt receptacles.

120 VOLTS 15 AMPS

7

120 VOLTS 30 AMPS

3

6. CIRCUIT BREAKERS (3)

7. GFCI DUPLEX RECEPTACLE - 120 VOLT, 15 AMP

8. TWIST-LOCK RECEPTACLE - 120 VOLT, 30 AMP

9. TWIST-LOCK RECEPTACLE - 120/240 VOLT, 30 AMP

10. ENGINE HOUR METER

TOTAL COMBINED LENGTH OF ELECTRODE AND

5

RECOMMENDED WELDING CABLE

SIZE AND LENGTH

WORK CABLES

8

TABLE A.1

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.

POWER ARC 5000

Cable Size for

150 amp/

Cable Length 40% Duty Cycle

0-50 feet (0-15 meters) 6 AWG
50-100 feet (15-39 meters) 4 AWG
100-150 feet (30-46 meters) 3 AWG
150-200 feet (46061 meters) 2 AWG
200-250 feet (61-76 meters) 1 AWG

A-7

INSTALLATION

A-7

Cable Installation

Install the welding cables to your POWER ARC 5000
as follows. See Figure A.3 for the location of parts.

1. The gasoline engine must be OFF
ing the welding cables.

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

3. Connect the electrode holder and work cables to
the appropriate weld output terminals.

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.

when connect-

CAUTION

• Loose connections will cause the output terminals

to overheat. The terminals may eventually melt.

• Do not cross the welding cables at the output termi-

nal connection. Keep the cables isolated and sepa­rate from one another.

WARNING

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

When the POWER ARC 5000 is mounted on a truck
or a trailer, the machine generator grounding terminal
MUST be securely connected to the metal frame of
the vehicle. See Figure A.3. The grounding terminal
is marked with the symbol.

AUXILIARY POWER RECEPTACLES

The control panel of the POWER ARC 5000 features
three auxiliary power receptacles:

• One 15 amp, 120 volt ground fault circuit inter­rupter (GFCI) duplex interrupter (NENA Style 5­15R).

• One 30 amp 120 volt Twist-Lock receptacle (NEMA
Style L5-30R).

• One 30 amp 120/240 volt Twist-Lock receptacle
(NEMA Style L14-30R).

Lincoln Electric offers a welding accessory kit with
the properly specified welding cables. See the
ACCESSORIES section of this manual for more infor­mation.

MACHINE GROUNDING

For protection against electrical shock,
connect a heavy gauge wire from the
grounding terminal located on the bot-

tom center of the output panel to a suit­able earth ground such as a metal pipe driven into the
ground.

See Figure A.3.
The receptacles are UL and CSA approved.

POWER ARC 5000

A-8

INSTALLATION

A-8

POWER CORD CONNECTIONS TO TWIST­LOCK PLUGS

Refer to the appropriate diagram above for proper
connection of power cord wires to the Twist-Lock plug
terminals. Also, read the instruction sheet supplied
with the Twist-lock plug.

PLUGS AND HAND-HELD EQUIPMENT

For further protection against electric shock, any 120
volt hand-held 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.

CIRCUIT BREAKERS

The POWER ARC 5000 has circuit
breakers for overload protection.
When the machine is operated in high
temperature environments, the
breakers may tend to trip at lower loads than normal­ly.

CAUTION

Never bypass the circuit breakers. Without overload
protection, the POWER ARC 5000 could overheat
and/or cause damage to the equipment being used.

PREMISES WIRING

The POWER ARC 5000 three-wire, grounded neutral
generator allows it to be connected to premises
wiring. However, the wiring procedure needed to

meet the National Electric Code (NEC) regulations as
well as city ordinances can be confusing. Matters get
worse depending on whether you want the machine
to be “hardwired” to the premises or only connected
temporarily.

WARNING

Only a licensed, certified, trained electrician should
install the machine to a premises or residential electri­cal system. Be certain that:

• The premises is isolated and no feedbacking into
the utility system can occur. Certain state and
local laws require the premises to be isolated
before the generator is linked to the premises.
Check your state and local requirements.

• A double pole, double throw transfer switch in con­junction with the properly rated double throw cir­cuit breaker is connected between the generator
power and the utility meter.

Remember that the POWER ARC 5000 is intended
only for backup, intermittent use. It cannot withstand
long-term use without proper maintenance. See the
MAINTENANCE section of this manual for more
information.

CAUTION

Certain electrical devices cannot be powered by the
POWER ARC 5000. Refer to Table A.2 for these
devices.

POWER ARC 5000