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500AS
IMA 551C
ENGINE
Cooling System
This welder is equipped with a pressure radiator. Keep the
radiator cap tight to prevent loss of coolant. Clean and flush the
cooling system periodically to prevent clogging the passages and
overheating the engine. Add Alfloc 2000 per container
instructions. When anti-freeze is required, always use the
permanent type.
Routine Maintenance
1.
See the engine manufacturer’s Operating Manual for
detailed engine maintenance and trouble shooting
instructions.
2.
Change the crankcase oil at regular intervals using the
proper grade of oil as recommended in the engine
operating manual.
3.
Change the oil filter in accordance with the instructions in
the engine operating manual. When the filter is changed
add oil to the crankcase to replace the oil held in the filter
during operation.
4.
Fan belts tend to loosen after the first 30 or 40 hours of
operation. Check and tighten if necessary.
DO NOT OVER TIGHTEN.
WELDER
Whenever possible have a qualified electrician do the needed
electrical maintenance and trouble shooting work. Turn the
engine off when working inside the machine.
Routine Maintenance
1.
AFTER 25 HOURS USE OF YOUR NEW WELDER,
CHECK ALL NUTS AND BOLTS FOR TIGHTNESS.
Thereafter check all nuts and bolts every 1000 hours of
operation.
2.
Blow out the welder and controls with an air hose at least
once every two months. In particularly dirty locations this
cleaning may be necessary once every week. Use low
pressure air to avoid driving dirt into the insulation.
3.
Current Control reactor brushes are silver graphite and
should not be greased. Keep the contacts clean.
4.
Keep electrode and work connections tight.
BEARINGS
Your welder is equipped with a double-shield ball bearing having
sufficient grease to last indefinitely under normal conditions.
Where the welder is used constantly or in excessively dirty
locations, it may be necessary to add 15 grams of grease per
year.
When greasing the bearing, keep all dirt out of the area. Wipe the
fitting completely clean and use clean grease and equipment.
More failures are caused by dirt introduced while greasing than
from insufficient grease.
COMMUTATOR AND BRUSHES
The generator and alternator brushes are properly adjusted when
the welder is shipped. They require no particular attention. DO
NOT SHIFT THE BRUSHES or adjust the rocker setting.
Periodically inspect the commutator and brushes.
Commutators and slip rings require little attention. However, if
they are black or appear uneven, have an experienced
maintenance person clean them with fine sandpaper or a
commutator stone. Never use emery cloth or paper for this
purpose.
Have an experienced maintenance person replace brushes when
they wear within 6mm of the pigtail. 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.
Sand new slip ring brushes by placing a piece of sandpaper
between the brushes and the slip ring with the abrasive side
against the brushes. With light finger pressure on the brushes,
pull the sand paper around the circumference of the rings only
until brushes are properly seated. Stone the slip rings with a 320
grit sanding stone. Slip rings must be clean and free from oil and
grease.
Lincoln generator brushes have a curved face to fit the
commutator. Seat these brushes by lightly stoning the
commutator as the armature rotates at full speed until contact is
made across the full face of the brushes. After stoning blow out
the dust with low pressure air.
BATTERY SAFETY, COMMISSIONING AND
RECHARGING INSTRUCTIONS
SAFETY WARNINGS
•
Battery electrolyte contains sulphuric acid which is
corrosive to skin and clothing.
•
Batteries also contain explosive gases.
•
When charging, provide adequate ventilation to allow the
safe escape of explosive gases.
•
Do not do anything to cause sparks near a battery. Keep
naked flames and cigarettes away from batteries.
•
If acid contacts eyes or skin flush immediately with large
quantities of clean drinking water.
•
In case of acid contacting the eyes, consult a doctor
immediately.
•
After use, wash out empty electrolyte bottles with water and
dispose of carefully. Do not use empty electrolyte bottles for
any other purpose.
•
Always keep batteries and electrolyte out of the reach of
children.
•
Dispose of old batteries carefully.
BATTERY CONDITIONING
1.
Remove the battery from the machine before filling or
recharging.
2.
Remove and retain vent plugs.
3.
Fill each cell of the battery to the top of the separators with
the correct grade electrolyte (ie. 1.260 specific gravity).
Using higher or lower specific gravity electrolyte than
recommended can impair the battery performance.
4.
Boost charge the battery at 15 amps until the specific
gravity of the electrolyte is 1.250 or higher and the
electrolyte temperature is at least 15.5°C. BOTH
CONDITIONS MUST BE MET. If the electrolyte bubbles
violently while charging, reduce the charging rate until the
excessive bubbling action subsides, then continue until
both the above conditions are achieved.
If the ambient temperature is 10°C or less, it is
imperative that these instructions be followed.
MAINTENANCE AND LUBRICATION
Uncovered rotating equipment can be dangerous. Use care
so your hands, clothing or tools do not catch in the
rotating parts. Protect yourself from particles that may be
thrown out by the rotating armature when stoning the
CAUTION
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