Instruction/ maintenance manual of the product E500 Lincoln Electric
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RED-D-ARC E500 IM656-A April, 2004 Red-D-Ar c Spec-Built W elding Equipment This RED-D-ARC welder is built to RED-D-ARC Extreme Duty design specifications by Lincoln Electric. Safety Depends on Y ou This welder is designed and built with safety in mind.
i SAFETY i FOR ENGINE powered equipment. 1.a. T urn 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.
ii SAFETY ii ARC RA YS 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.
iii SAFETY iii E500 FOR ELECTRICALL Y powered equipment. 8.a. T urn 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.
iv SAFETY iv E500 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 suiv- antes: Sûreté Pour Soudage A L ’Arc 1.
E500 T hank Y ou for selecting this QUALITY product. We want you to take pride in operating this product ••• as much pride as we have in bringing this product to you! Read this Operators Manual completely before attempting to use this equipment.
E500 vi T ABLE OF CONTENTS vi Page Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Secti on A Location . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
A-1 INST ALLA TION A-1 LOCA TION F ALLING EQUIPMENT can cause injury . • Do not lift this machine using lift bail if it is equipped with a heavy • accessory such as trailer or gas cylinder . • Lift only with equipment of adequate lifting capacity .
B-1 OPERA TION B-1 ELECTRIC SHOCK can kill. • Do not touch electrically live parts or electrode with skin or wet cloth- ing. • Insulate yourself from work and ground. • Always wear dry insulating gloves. FUMES AND GASES can be danger- ous. • Keep your head out of fumes.
C-1 MAINTENANCE C-1 ELECTRIC SHOCK can kill. • Have an electrician install and ser- vice this equipment. • T urn the input power off at the fuse box before working on equipment. • Do not touch electrically hot parts. GENERAL MAINTENANCE 1. The fan motor has sealed bearings which require no service.
E500 D-1 TROUBLESHOOTING D-1 If for any reason you do not understand the test procedures or are unable to perform the tests/repairs safely , contact your Local Authorized Field Service Facility for technical troubleshooting assistance before you proceed.
D-2 TROUBLESHOOTING D-2 Observe all Safety Guidelines detailed througout this manual If for any reason you do not understand the test procedures or are unable to perform the tests/repairs safely , contact your Local Authorized Field Service Facility for technical troubleshooting assistance before you proceed.
D-3 TROUBLESHOOTING D-3 Observe all Safety Guidelines detailed througout this manual If for any reason you do not understand the test procedures or are unable to perform the tests/repairs safely , contact your Local Authorized Field Service Facility for technical troubleshooting assistance before you proceed.
D-4 TROUBLESHOOTING D-4 Observe all Safety Guidelines detailed througout this manual If for any reason you do not understand the test procedures or are unable to perform the tests/repairs safely , contact your Local Authorized Field Service Facility for technical troubleshooting assistance before you proceed.
D-5 TROUBLESHOOTING D-5 Observe all Safety Guidelines detailed througout this manual If for any reason you do not understand the test procedures or are unable to perform the tests/repairs safely , contact your Local Authorized Field Service Facility for technical troubleshooting assistance before you proceed.
D-6 TROUBLESHOOTING D-6 Observe all Safety Guidelines detailed througout this manual If for any reason you do not understand the test procedures or are unable to perform the tests/repairs safely , contact your Local Authorized Field Service Facility for technical troubleshooting assistance before you proceed.
D-7 TROUBLESHOOTING D-7 E500 Low output, low OCV , or erratic welding T urn control pot. to minimum Check OCV OCV is 35-55V OCV is 40-45V OCV is 0 Rated OCV but OCV less than rated erratic welding but.
D-8 TROUBLESHOOTING D-8 TROUBLESHOOTING PROCEDURES PROCEDURE FOR REPLACING P .C. BOARD (The P .C. Board is located behind the front control panel. Remove the nameplate screws to loosen the control panel.) When the P .C. Board is to be replaced, follow this pro- cedure: Visually inspect P .
D-9 TROUBLESHOOTING D-9 Check the resistance reading between 75 on the ter- minal strip and 21 1 on SW #2. The reading must be 10K ohms. No reading will indicate an open rheostat and a low reading will indicate a shorted or partially shorted rheostat; in either case, replace.
D-10 TROUBLESHOOTING D-10 5. An open gate circuit will have an infinite or high resistance. A good gate circuit will read a low resis- tance, but not zero ohms. BA TTER Y TEST Check the batteries by shorting leads (A) and (C), then close switch SW-1. Replace batteries if voltage is less than 3 volts.
E-1 WIRING DIAGRAM - CODE 10649 ONL Y E-1 E500 ELECTRICAL SYMBOLS PER E1537 LEGEND D5 D6 D7 POCKET AMPTROL SENSING BRIDGE L1 DC OUTPUT FILTER R1 R2 R3 R4 TO GROUND PER NATIONAL ELECTRICAL CODE H3 H2 H.
E500 E-2 WIRING DIAGRAM - CODE 1 1042 & UP E-2 ELECTRICAL SYMBOLS PER E1537 LEGEND L1 DC OUTPUT FILTER R1 R2 R3 TO GROUND PER NATIONAL ELECTRICAL CODE H3 H2 H1 X2 X1 T2 TO SUPPLY LINES DIAL SELECT.
E500 E-3 DIAGRAMS E-3 Part No. T ype A B C D F G H M12244-7 E500 32.00 15.39 3092 1.44 30.02± .1 1 33.07± .06 .94 M12244-7 7-7-78.
E500 NOTES.
E500 NOTES.
W ARNING A VISO DE PRECAUCION A TTENTION W ARNUNG A TENÇÃO Spanish French German Portuguese Japanese Chinese Korean Arabic READ AND UNDERST AND THE MANUF ACTURER’S INSTRUCTION FOR THIS EQUIPMENT AND THE CONSUMABLES TO BE USED AND FOLLOW YOUR EMPLOYER’S SAFETY PRACTICES.
W ARNING A VISO DE PRECAUCION A TTENTION W ARNUNG A TENÇÃO Spanish French German Portuguese Japanese Chinese Korean Arabic LEIA E COMPREENDA AS INSTRUÇÕES DO F ABRICANTE PARA ESTE EQUIP AMENTO E AS P ARTES DE USO, E SIGA AS PRÁTICAS DE SEGURANÇA DO EMPREGADOR.
• Sales and Service through Subsidiaries and Distributors Worldwide • Cleveland, Ohio 441 17-1 199 U.S.A. TEL: 216.481.8100 F AX: 216.486.1751 WEB SITE: www .
An important point after buying a device Lincoln Electric E500 (or even before the purchase) is to read its user manual. We should do this for several simple reasons:
If you have not bought Lincoln Electric E500 yet, this is a good time to familiarize yourself with the basic data on the product. First of all view first pages of the manual, you can find above. You should find there the most important technical data Lincoln Electric E500 - thus you can check whether the hardware meets your expectations. When delving into next pages of the user manual, Lincoln Electric E500 you will learn all the available features of the product, as well as information on its operation. The information that you get Lincoln Electric E500 will certainly help you make a decision on the purchase.
If you already are a holder of Lincoln Electric E500, but have not read the manual yet, you should do it for the reasons described above. You will learn then if you properly used the available features, and whether you have not made any mistakes, which can shorten the lifetime Lincoln Electric E500.
However, one of the most important roles played by the user manual is to help in solving problems with Lincoln Electric E500. Almost always you will find there Troubleshooting, which are the most frequently occurring failures and malfunctions of the device Lincoln Electric E500 along with tips on how to solve them. Even if you fail to solve the problem, the manual will show you a further procedure – contact to the customer service center or the nearest service center
