Lincoln Electric SHIELD-ARC 500AS, Operating Manual

Page 1: ...R IN WELDING AND CUTTING PRODUCTS SAFETY DEPENDS ON YOU Lincoln Electric welders are designed and built with safety in mind However your overall safety can be increased by proper installation and thoughtful operation on your part Read and observe the general safety precautions on page 2 and follow specific installation and operating instructions included in this manual Most importantly think befor...

Page 2: ...erstand 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 e Also see Item 7b 3 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...

Page 3: ...rds 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 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 g To prevent accidentally starting ...

Page 4: ...can interfere with a pacemakers function Generally the interference does not permanently damage the pacemaker Once the wearer leaves the arc welding environment or stops welding the pacemaker returns to normal functioning The welding arc has little or no effect on the operation of some pacemakers especially designs that are bi polar or designed to filter out such interference For a welder or anyon...

Page 5: ... or other activities are to be carried out The size of the surrounding area to be considered will depend on the structure of the building and other activities that are taking place The surrounding area may extend beyond the boundaries of the premises Methods of Reducing Emissions Mains Supply Welding equipment should be connected to the mains supply according to the manufacturer s recommendations ...

Page 6: ...from the motor and fit the air cleaner and exhaust silencer Air cleaner and exhaust fittings are packed inside the machine canopy on fuel tank rails behind the control panel 2 Ensure the crankcase oil level is at the Full mark on the dipstick Use the grade of oil recommended by the engine manufacturer N B Many oil companies market a product which meets the recommended MIL L 46152 SE CC and the hea...

Page 7: ...on of its dial the approximate welding current is indicated by the overhead and vertical scale on the Current Control dial Do not change the current control setting while welding HOW TO SET THE CONTROLS Assume you want to make a vertical up weld using a 4 0mm electrode at about 135 amps A snappy digging arc medium low open circuit voltage is required to give the best control of the arc in the whip...

Page 8: ...il A complete set of replacement brushes should be kept on hand Before fitting replacement brushes twist the brush pigtail at its entrance to the brush until the strands are tightly packed and no part of the pigtail protrudes beyond the brush surface in the pigtail slot When the brush is placed in the holder clear the pigtail from the side of the holder to allow free radial movement of the brush S...

Page 9: ...connect them together mounted on rear of control panel if fitted 6 Jumper the volt or amp meter terminals together also jumper together the hour meter terminals if fitted 7 Remove the earth leads from in all cases where fitted The bridge rectifier mounted on the brush holder bracket The water temperature gauge and sender The voltmeter The stop solenoid mounted in the engine fuel injector pump on k...

Page 10: ...may have a ground Locate and remove ground Engine speed low No load 1780 rpm Full load 1700 rpm Main brush holder rocker 7 moved position Realign drilled marker points Commutator may be dirty 7A Refer maintenance section page 5 Two segments on commutator 7A burnt open in that Repair or replace coil Short circuit in armature 7A 2 segments burnt in four Locate fault using growler and repair or repla...

Page 11: ...may have a ground Locate and remove ground Engine speed low No load 1780 rpm Full load 1700 rpm Main brush holder rocker 7 moved position Realign drilled marker points Commutator may be dirty 7A Refer maintenance section page 5 Two segments on commutator 7A burnt open in that Repair or replace coil Short circuit in armature 7A 2 segments burnt in four Locate fault using growler and repair or repla...

Page 12: ...1 Starwasher 1 Rd Hd Screw 1 Item Part Name and Description Qty 21 Hex S T Screw 2 22 Hex Nut 4 Springwasher 4 Rd Hd Screw 4 23 Hex Nut 2 Springwasher 2 Rd Hd Screw 2 29 Hex Nut 4 Starwasher 1 Rd Hd Screw 1 31 Aux Switch Decal 1 32 Code and Serial No Decal not shown 1 33 Hex Nut not shown 2 Starwasher mounts leads 2 Rd Hd Screw to Rheostat 2 34 Outlet Panel 1 35 Switch 1 36 Flange nut 1 37 Connect...

Page 13: ... lists left and right hand side should be determined while standing facing the Generator end of the welder 1 8 22 52 15 17 20 16 36 53 57 54 56 12 2 55 30 31 59 58 28 33 10 45 32 4 32 29 25 7 11 6 3 62 61 51 1 42 43 2 41 41 4 5 38 See Page 19 AP22 for listing of undercarriage parts ...

Page 14: ...t Bale Assembly 2 3 Front End Frame Assembly 1 4 Rear End Frame Assembly 1 5 Door and Lower Panel Assembly 2 6 Engine Foot Assembly 2 7 Engine Mount Assembly includes 2 7A Washer 2 7B Nyloc Nut Z P 2 7C Distributor Washer 8 7D Rebound Mount 2 7E Hex Hd Bolt 2 7F Rubber Mount 2 8 Generator Mount Assembly includes 2 8A Distributor Washer 4 8B Rebound Washer 2 8C Rubber Mount 2 8D Washer 2 8E Hex Hd ...

Page 15: ...ote AP 34 E plus Machine Code No and Serial No part description and item number Item Part Name and Description Qty Brush Holder Assembly Includes 4 1 Brush Holder Stud 1 2 Retainer Assembly 1 3 Washer 1 4 Insulating Washer 2 5 Insulating Tube 1 6 Washer 1 7 Spring Clip 2 8 Spring 2 9 Lockwasher 3 8 1 10 Hex Head Bolt 3 8 W x 3 4 1 11 Hex Head Bolt 5 16 W x 1 2 1 12 Round Head Screw 5 16 W x 1 2 1 ...

Page 16: ...ame and Description Qty Slip Ring Brush Holder Assy Less item 13 1 1 Mounting Bracket 1 2 Mounting Bracket Support 1 3 5 16 Whit x 3 4 Hex Hd Bolt etc 2 4 Insulation 2 5 left Hand Brush Holder 1 6 Right Hand Brush holder 1 7 Insulating Washer 2 Item Part Name and Description Qty 8 3 16 Z P Flat Washer 4 9 3 16 Z P Lock Washer 2 10 3 16 Z P Hex Nut 2 11 3 16 x 11 4 Z P Rd Hd Screw 2 12 Spring 2 13 ...

Page 17: ...pling to Armature 24A Coupling Lock Tab 4 25 H H H T Screw 7 16 UNC x 1 8 Coupling to Flywheel 25A Spring Washer 7 16 8 26 Dowel not shown 2 27 Blower Segments 4 27B Coupling Disc Large Stainless steel 1 27C Backing Disc 71 2 dia Armature side 1 29 Generator brush 8 31 Main pole 4 Item Part Name and Description Qty 1 Stator and Baffle Assembly 1 2 Alternator Bracket 1 3 Hex Hd Screw High tensile 1...

Page 18: ...98 This diagram is typical of the machine s wiring For specific detail refer to the diagram attached to the machine itself If the diagram has been destroyed or defaced contact the factory quoting the machine s serial number and code number from the nameplate ...

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Page 20: ...diator hose 1 AL1835 Top radiator hose 1 AL2224A1 Bottom series coil 1 AL2224A2 Top series coil 1 AM2338 Blower segment assy 1 AM2373 1E Rotor assy 1 AM2464 1 Moulded output stud 2 AM2548 Muffler assy 1 AM3229 Brush holder assy 1 AS3289 3 Capacitor lead assy 1 AS4302 Temperature gauge 1 AT2996 2 Red light assy 1 AT3002 1 Oil pressure gauge 1 AT3024 Fuel tank cap 2 AT3061 6 Hose clamp 2 AT3081 Carb...

Page 21: ...able for the operation non operation or malfunction of any such battery CONDITION OF WARRANTY TO OBTAIN WARRANTY COVERAGE The purchaser must contact Lincoln or Lincoln s Authorised Service Facility about any defect claimed under Lincoln s warranty Determination of warranty on welding and cutting equipment will be made by Lincoln or Lincoln s Authorised Service Facility WARRANTY REPAIR If Lincoln o...