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IMA 551C
October 1998
OPERATING MANUAL
SHIELD-ARC
®
500AS
(With 12 Volt Electrics - KA1353)
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 before you act and be careful.
THE LINCOLN ELECTRIC COMPANY
(AUSTRALIA) PTY. LTD.
A.B.N. 36 000 040 308
SYDNEY. AUSTRALIA
A Subsidiary of
THE LINCOLN ELECTRIC CO. U.S.A.
Associated Subsidiaries in Australasia, Asia, Canada, Europe, North and South America.
THE WORLD'S LEADER IN WELDING AND CUTTING PRODUCTS
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Summary of Contents for Lincoln Electric SHIELD-ARC 500AS
- Page 1 (With 12 Volt Electrics - KA1353) 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.
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Page 2: Arc Welding Safety Precautions
PROTECT YOURSELF AND OTHERS FROM POSSIBLE SERIOUS INJURY OR DEATH. READ AND UNDERSTAND BOTH THE SPECIFIC INFORMATION GIVEN IN THE OPERATING MANUAL FOR THE WELDER AND/OR OTHER EQUIPMENT TO BE USED AS WELL AS THE FOLLOWING GENERAL INFORMATION. ARC WELDING SAFETY PRECAUTIONS ARC RAYS can burn ELECTRIC SHOCK can kill 1. - Page 3 3. Should the primary cord be damaged, a special cord is required, and is available from Lincoln Electric. 4. Parts should be ordered from Lincoln, its offices or the nearest Authorised Field Service Shop. (The “Lincoln Service Directory”...
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Page 4: Welding, Emf & Pacemakers
WELDING, EMF & PACEMAKERS All welders should follow safe practices that minimise their Welders with pacemakers exposure to electric and magnetic fields (EMF). There is no question that the fields in arc welding can interfere For welders wearing implanted pacemakers, safe welding with a pacemakers function. -
Page 5: Instructions For Electromagnetic Compatibility
Welding equipment should be connected to the mains supply reproduced from British Standard EN 50199) according to the manufacturer’s recommendations.If interference • for using with other Lincoln Electric/LiquidArc equipment. occurs, it may be necessary to take additional precautions such • designed for industrial and professional use. -
Page 6: Specifications
SPECIFICATIONS Engine Welder ® Model Perkins 4/236 Diesel Model Shield-Arc 500AS KA1353 Capacity 3.86 litres (236 cu. ins.) Rated Output 475 amps @ 40 arc volts and 60% duty cycle Lubrication High pressure forced feed from rotary Rating to AS1966. 475 amps @ 39 arc volts and 60% duty cycle type oil pump 380 amps @ 36 arc volts and 100% duty cycle Cooling... - Page 7 For normal running, lubricating and maintenance instructions, HOW TO SET THE CONTROLS consult the engine instruction manual. For correct cooling air flow, Assume you want to make a vertical up weld using a 4.0mm the welder should be operated with the doors closed. electrode at about 135 amps.
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Page 8: Maintenance And Lubrication
MAINTENANCE AND LUBRICATION ENGINE 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 Cooling System slot. -
Page 9: Ground Test Procedure
After boost charge, check the level of electrolyte in all cells. BATTERY MAINTENANCE PROCEDURE Add additional electrolyte to bring the level to that shown on Keep the electrolyte levels about 6mm above the plates the labelling. DO NOT OVERFILL. Once the battery has and separators. -
Page 10: Troubleshooting
TROUBLESHOOTING READ IN CONJECTION WITH WIRING DIAGRAM AM3064MC on Page 18 TROUBLE CAUSE WHAT TO DO Machine fails to start Check for: Flat battery and/or faulty terminal connections. Charge battery and/or clean terminals. Key switch (4) faulty connection and/or loose wires. Repair or replace Starter Motor faulty (21). - Page 11 TROUBLESHOOTING READ IN CONJECTION WITH WIRING DIAGRAM AM3064MC on Page 18 TROUBLE CAUSE WHAT TO DO Machine fails to start Check for: Flat battery and/or faulty terminal connections. Charge battery and/or clean terminals. Key switch (4) faulty connection and/or loose wires. Repair or replace Starter Motor faulty (21).
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Page 12: Control Panel Assembly
Control Panel Assembly N.A. Ref: AL2353-1 (A28.4.93) AM3034-1 (18/9/91) Quote AP-34-D plus Machine code No., serial No., part description and item number. Item Part Name and Description Item Part Name and Description Control Panel Hex.S/T Screw Hex. Nut Nameplate Fastener Button Springwasher Rheostat Rd. - Page 13 General Assembly Parts List No. AP-34-C Note: In all parts lists, left and right hand side should be determined while standing facing the Generator end of the welder. See Page 19 (AP22) for listing of undercarriage parts. IMA 551C 500AS Page 13...
- Page 14 General Assembly Parts List No. AP-34-C When ordering parts quote AP-80-C, Machine serial & Code numbers, part description and item number. Item Part Name and Description Item Part Name and Description Chassis Assembly Warning Decal Lift Bale Assembly Engine Front End Frame Assembly Door Lock Rod Rear End Frame Assembly Door Handle...
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Page 15: Generator Brush Holder
Frame, Fuel Tank, Reactor and Air Cleaner Assembly (Plan View) Quote AP-34-E plus Machine Code No. and Serial No., part description and item number. Item Part Name and Description Item Part Name and Description Fuel Tank Assembly Spring Frame Assembly Reactor Brush holder Stud &... -
Page 16: Polarity Switch
Polarity Switch M7057 Quote AP-34-H plus Machine Code No. and Serial No., part description and item number. Item Part Name and Description Item Part Name and Description Bracket Assembly Compression Spring Hex. Nut Support Internal Starwasher Moving Arm Assembly Spacer Contact Panel Assembly 3⁄... - Page 17 Welding Generator and Coupling Quote AP-27-F plus Machine Code No. and Serial No. Item Part Name and Description Item Part Name and Description D.C. Frame 1 ⁄ 2 Hex. Head Screw H/T ( ˝ UNC x 1˝) Interpole Coil Assembly (Backplate to Frame) Interpole Pole Pieces Springwasher (Backplate to Frame)
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Page 18: Wiring Diagram
WIRING DIAGRAM Ref: AM3064MC (A26.8.98) Page 18 500AS IMA 551C... - Page 20 If working at remote sites, the highlighted items should be carried to support one 500AS machine for a period of one year. Other items are optional and could assist in minimising potential down time and delay. Lincoln Shield-Arc 500AS (KA1353) For codes 1297 & up Part No.
- Page 21 We respond to our customers based on the best information in our authorised Kubota service dealer) possession at that time. Lincoln Electric is not in a position to warrant or guarantee Ruggerini Engines and Accessories such advice and assumes no liability, with respect to such information or advice. We...