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THE LINCOLN ELECTRIC CO.

Cleveland, Ohio, U.S.A. - Subsidiary companies established in Australasia, Asia, Canada, Europe, North and South America.

Print 30 4/03

The Lincoln Electric Company
(Australia) Pty. Ltd.

A.B.N. 36 000 040 308

35 Bryant Street, Padstow, Sydney 2211, Australia

Telephone:

(02) 9772-7222

Fax: (02) 9792-2420

International:

Ph: +61 2 9772-7222 Fax: +61 2 9792-2420

In Australia, Lincoln Technical Sales Representatives are located in,

Mackay, Brisbane, Newcastle, Sydney, Melbourne, Adelaide and Perth. To

contact your local Lincoln Technical Sales Representative, call 

1300 728

720

(for the cost of a local call).  Lincoln products are sold primarily

through its distributors. Our Regional Office locations are:

Northern Region: Unit 1/15 Westgate St, Wacol, Qld, 4076

(07) 3271 3000

Central Region: 35 Bryant Street, Padstow, NSW, 2211

(02) 9772-7222

Southern Region: 1-3 Grange Road, Cheltenham, Vic, 3192 (03) 9584-9299

Western Region

:

25 Barker Street, Belmont, WA, 6104

(08) 9277-8744

New Zealand: 5-7 Westech Place, Kelston, Auckland

(9) 813 3422

Singapore: 11 Pandan Crescent, Singapore

(65) 6773 6689

LIMITED WARRANTY

STATEMENT OF LIMITED WARRANTY

The Lincoln Electric Company (Australia) Pty Limited ("Lincoln") warrants all new
machinery and equipment ("goods") manufactured by Lincoln against defects in
workmanship and material subject to certain limitations hereinafter provided.

This warranty is void if Lincoln or its Authorised Service Facility finds that the
equipment has been subjected to improper installation, improper care or abnormal
operations.

PERIOD OF WARRANTY "LINCOLN BRANDED GOODS"

The period from the commencement of the warranty in respect of goods covered by
this warranty shall be as follows:

Three Years

All Lincoln welding machines, wire feeders and plasma cutting machines unless listed
below.

Two Years

All Weldanpowers, Rangers, Invertec V140-S, V160-S, V160-T, V160-TP, V205-T,
Pro-Cut 25.

One Year
•  

Invertec V130-S, V130-T, V260-S, V260-T, PC100, PC60.

•  All water coolers (internal and external).
•  Arc welding and cutting robots and robotic controllers.
•  All stick electrodes, welding wires and fluxes.
•  All Environmental Systems equipment, including portable units, central units and

accessories. (Does not include consumable items listed under 30-day warranty).

•  All welding and cutting accessories including wire feed modules, undercarriages,

field installed options that are sold separately, unattached options, welding supplies,
standard accessory sets, replacement parts. (Does not include expendable parts and
guns/torches listed under 90 and 30 day warranties)

•  All “Pro Torch” TIG torches.

90 Days
•  

All Gun and Cable Assemblies (manufactured by Lincoln) and Spool guns.

•  All MIG, TIG and Plasma Torches

30 Days
•  

All consumable items that may be used with the environmental systems described
above. This includes hoses, filters, belts and hose adapters.

•  Expendable Parts - Lincoln is not responsible for the replacement of any expendable

part that is required due to normal wear.

ENGINE WARRANTY

To the extent permitted by law Lincoln shall be entitled to in its absolute discretion repair
all engines and engine accessories however Lincoln shall not be held responsible for any
such repair which shall be the sole responsibility of the engine manufacturer which
provides for warranties for the period and subject to any limitations provided for by those
manufacturers of the respective engines and engine accessories.

Three Years*

Onan Performer Engines and Accessories

*Subject to conditions

(Warranty service can only be carried out an

imposed by Onan.

authorised Onan service dealer)

Cummins Engines and Accessories

*Subject to conditions

(Warranty service can only be carried out an

imposed by Cummins

authorised Cummins service dealer)

Two Years

Perkins Engines and Accessories
(The Perkins Distributor Organisation

*Subject to conditions

provides all warranty service (accessories

imposed by Perkins

included) for the Perkins Engines powering
goods manufactured by Lincoln.

Briggs & Stratton Vanguard Engines

*The Magnetron ignition

and Accessories. (Warranty service can only

system is warranted by

be carried out by an authorised Briggs & Stratton

Briggs & Stratton for 5 years.

service dealer).

One Year*

Kubota Engines and Accessories

*Subject to conditions

(Warranty service can only be carried out an

imposed by Kubota.

authorised Kubota service dealer)

Ruggerini Engines and Accessories
(Warranty service can only be carried out by
authorised Lincoln Field Service Shop or
the engine distributors authorised by the
Lincoln branch office).

BATTERY WARRANTY
Lincoln supplies certain batteries in connection with its supply of goods and the
purchaser acknowledges that any such battery is warranted by its manufacturer and
any claim in respect of such a battery whether as to a defect in the battery or as to
damage consequential upon a defect in a battery shall be made by the purchaser to
the manufacturer of the battery and the purchaser shall not hold Lincoln in any way
liable 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 or Lincoln’s Authorised Service Facility confirms the existence of a defect
covered by this warranty, the defect will be corrected by repair or replacement at
Lincoln’s option.

At Lincoln’s request, the purchaser must return, to Lincoln or its Authorised Service
Facility, any "Goods" claimed defective under Lincoln’s warranty.

FREIGHT COSTS
The purchaser is responsible for shipment to and from the Lincoln Authorised Service
Facility.

WARRANTY LIMITATIONS
Certain conditions warranties and obligations are implied by law (for example under the
Trade Practices Act 1974) and cannot be excluded or modified ("the statutory
warranties").

Where the statutory warranties do apply then any express warranties given by Lincoln
(the "express warranties") are given in addition and without derogation from the statutory
warranties. Apart from the express warranties and (in cases where they apply by law but
not otherwise) the statutory warranties Lincoln gives no warranties whether express or
implied by operation of law or otherwise in respect of any goods manufactured or
supplied by Lincoln or by its authorised distributor.

Any warranty whether express or statutory and the term of any such warranty as set out
herein commences on the date Lincoln or Lincoln’s authorised distributorship forwards
the goods from the premises of Lincoln or Lincoln’s authorised distributor to the
purchaser.

In respect of any claim under the warranty herein provided a purchaser must furnish
Lincoln with written notice of any claim under the warranty within the time period of the
warranty as further specified herein.

The extent of Lincoln’s warranty whether express or statutory is limited to a liability to
repair, replace or pay to the purchaser an amount equal to:

a)

The cost of replacing the goods;

b)

The cost of obtaining equivalent goods; or

c)

The cost of having the goods repaired whichever remedy in its absolute
discretion Lincoln chooses.

Upon request by Lincoln the purchaser must permit Lincoln to inspect the goods the
subject of any claim under this warranty and Lincoln may at its absolute discretion
repair or replace the goods F.O.B. at its own premises or at such other premises as
Lincoln may designate provided that all freight charges to and from Lincoln’s premises
or such other premises as Lincoln may designate shall be paid by the purchaser.

Subject to the express and statutory warranties hereinbefore provided Lincoln provides
no other warranties in respect of the manufacture or sale of goods and in particular
Lincoln shall have no responsibility or liability in respect of:

a)

Repairs done to Lincoln’s goods and undertaken by the purchaser outside Lincoln’s
premises without written authority from Lincoln obtained prior to any such repair;

b)

Any damage or failure of the goods as a result of normal wear and tear or the
neglect misuse abuse or failure to properly service goods by any purchaser.

The liability of Lincoln is limited as hereinbefore provided and Lincoln shall not be liable
for any incidental special or consequential damage suffered by a purchaser whether or
not arising out of circumstances known or foreseeable known by Lincoln and in particular
arising out of the supply of goods to a purchaser or the use of goods by a purchaser
whether based on breach of contract negligence or tort.

CUSTOMER ASSISTANCE POLICY
The business of The Lincoln Electric Company is manufacturing and selling high
quality welding equipment, consumables, and cutting equipment. Our challenge is to
meet the needs of our customers and to exceed their expectations. On occasion,
purchasers may ask Lincoln Electric for advice or information about their use of our
products. We respond to our customers based on the best information in our
possession at that time. Lincoln Electric is not in a position to warrant or guarantee
such advice and assumes no liability, with respect to such information or advice. We
expressly disclaim any warranty of any kind, including any warranty of fitness for any
customer’s particular purpose, with respect to such information or advice. As a matter
of practical consideration, we also cannot assume any responsibility for updating or
correcting any such information or advice once it has been given, nor does the
provision of information or advice create, expand or alter any warranty with respect to
the sale of our products.

Lincoln Electric is a responsive manufacturer, but the selection and use of specific
products sold by Lincoln Electric is solely within the control of, and remains the sole
responsibility of the customer. Many variables beyond the control of Lincoln Electric
affect the results obtained in applying this type of fabrication methods and service
requirements.

Summary of Contents for SHIELD-ARC 500AS

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 ...

Page 19: ......

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...

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