Lincoln Electric Fleet 500 Operator's Manual

Operator’s Manual

™

Fleet

500

For use with machines having Code Numbers:

12511

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www.lincolnelectric.com/register

Authorized Service and Distributor Locator:

www.lincolnelectric.com/locator

Save for future reference

Date Purchased

Code: (ex: 10859)

Serial: (ex: U1060512345)

IM10349 | Issue D ate Feb-16

© Lincoln Global, Inc. All Rights Reserved.

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to talk to a Service Representative

Hours of Operation:

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Use “Ask the Experts” at lincolnelectric.com
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no later than the following business day.

For Service outside the USA:

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THANK YOU FOR SELECTING
A QUALITY PRODUCT BY
LINCOLN ELEC TRIC.

PLEASE EXAMINE CARTON AND EQUIPMENT FOR
DAMAGE IMMEDIATELY

When this equipment is shipped, title passes to the purchaser
upon receipt by the carrier. Consequently, claims for material
damaged in shipment must be made by the purchaser against the
transportation company at the time the shipment is received.

SAFETY DEPENDS ON YOU

Lincoln arc welding and cutting equipment is designed and built
with safety in mind. However, your overall safety can be increased
by proper installation ... and thoughtful operation on your part.

DO NOT INSTALL, OPERATE OR REPAIR THIS EQUIPMENT
WITHOUT READING THIS MANUAL AND THE SAFETY
PRECAUTIONS CONTAINED THROUGHOUT. And, most importantly,

think before you act and be careful.

WARNING

This statement appears where the information must be followed
exactly to avoid serious personal injury or loss of life.

CAUTION

This statement appears where the information must be followed
to avoid minor personal injury or damage to this equipment.

KEEP YOUR HEAD OUT OF THE FUMES.

DON’T get too close to the arc.

se corrective lenses if necessary

U
to stay a reasonable distance
away from the arc.

READ and obey the Safety Data
Sheet (SDS) and the warning label
that appears on all containers of
welding materials.

USE ENOUGH VENTILATION or
exhaust at the arc, or both, to
keep the fumes and gases from
your breathing zone and the general area.

IN A LARGE ROOM OR OUTDOORS, natural ventilation may be
adequate if you keep your head out of the fumes (See below).

USE NATURAL DRAFTS or fans to keep the fumes away
from your face.

If you de velop unusual symptoms, see your supervisor.
Perhaps the welding atmosphere and ventilation system
should be checked.

WEAR CORRECT EYE, EAR &
BODY PROTECTION

PROTECT your eyes and face with welding helmet
properly fitted and with proper grade of filter plate
(See ANSI Z49.1).

PROTECT your body from welding spatter and arc
flash with protective clothing including woolen
clothing, flame-proof apron and gloves, leather
leggings, and high boots.

PROTECT others from splatter, flash, and glare
with protective screens or barriers.

IN SOME AREAS, protection from noise may be appropriate.

BE SURE protective equipment is in good condition.

Also, wear safety glasses in work area

AT ALL TIMES.

SPECIAL SITUATIONS

DO NOT WELD OR CUT containers or materials which previously
had been in contact with hazardous substances unless they are
properly cleaned. This is extremely dangerous.

DO NOT WELD OR CUT painted or plated parts unless special
precautions with ventilation have been taken. They can release
highly toxic fumes or gases.

Additional precautionary measures

PROTECT compressed gas cylinders from excessive heat,
mechanical shocks, and arcs; fasten cylinders so they cannot fall.

BE SURE cylinders are never grounded or part of an
electrical circuit.

REMOVE all potential fire hazards from welding area.

ALWAYS HAVE FIRE FIGHTING EQUIPMENT READY FOR
IMMEDIATE USE AND KNOW HOW TO USE IT.

Safety 01 of 04 - 06/15/2016

SECTION A:

WARNINGS

CALIFORNIA PROPOSITION 65 WARNINGS

Diesel Engines

Diesel engine exhaust and some of its constituents are known
to the State of California to cause cancer, birth defects, and other
reproductive harm.

Gasoline Engines

The engine exhaust from this product contains chemicals known
to the State of California to cause cancer, birth defects, or other
reproductive harm.

ARC WELDING CAN BE HAZARDOUS. PROTECT
YOURSELF AND OTHERS FROM POSSIBLE SERIOUS
INJURY OR DEATH. KEEP CHILDREN AWAY.
PACEMAKER WEARERS SHOULD CONSULT WITH
THEIR DOCTOR BEFORE OPERATING.

Read and understand the following safety highlights. For
additional safety information, it is strongly recommended
that you purchase a copy of “Safety in Welding & Cutting ­ANSI Standard Z49.1” from the American Welding Society,
P.O. Box 351040, Miami, Florida 33135 or CSA Standard
W117.2-1974. A Free copy of “Arc Welding Safety” booklet
E205 is available from the Lincoln Electric Company,
22801 St. Clair Avenue, Cleveland, Ohio 44117-1199.

BE SURE THAT ALL INSTALLATION, OPERATION,
MAINTENANCE AND REPAIR PROCEDURES ARE
PERFORMED ONLY BY QUALIFIED INDIVIDUALS.

SAFETY

1.d. Keep all equipment safety guards, covers
and devices in position and in good repair.
Keep hands, hair, clothing and tools away
from V-belts, gears, fans and all other
moving parts when starting, operating or
repairing equipment.

1.e. In some cases it may be necessary to remove safety guards to
perform required maintenance. Remove guards only when
necessary and replace them when the maintenance requiring

heir removal is complete. Always use the greatest care when

t
working near moving parts.

1.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.

1.g. To prevent accidentally starting gasoline engines while turning
the engine or welding generator during maintenance work,
disconnect the spark plug wires, distributor cap or magneto wire
as appropriate.

1.h. To avoid scalding, do not remove the radiator
pressure cap when the engine is

hot.

ELECTRIC AND
MAGNETIC FIELDS MAY
BE DANGEROUS

2.a. Electric current flowing through any conductor
causes localized Electric and Magnetic Fields (EMF).
Welding current creates EMF fields around welding cables
and welding machines

FOR ENGINE POWERED
EQUIPMENT.

1.a. Turn 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.

1.c. Do not add the fuel near an open flame
welding arc or when the engine is running.
Stop the engine and allow it to cool before
refueling to prevent spilled fuel from
vaporizing on contact with hot engine parts
and igniting. Do not spill fuel when filling
tank. If fuel is spilled, wipe it up and do not start engine until
fumes have been eliminated.

2.b. EMF fields may interfere with some pacemakers, and
welders having a pacemaker should consult their physician
before welding.

2.c. Exposure to EMF fields in welding may have other health effects
which are now not known.

2.d. All welders should use the following procedures in order to
minimize exposure to EMF fields from the welding circuit:

2.d.1. Route the electrode and work cables together - Secure
them with tape when possible.

2.d.2. Never coil the electrode lead around your body.

2.d.3. Do not place your body between the electrode and work
cables. If the electrode cable is on your right side, the
work cable should also be on your right side.

2.d.4. Connect the work cable to the workpiece as close as pos­sible to the area being welded.

2.d.5. Do not work next to welding power source.

Safety 02 of 04 - 06/15/2016

SAFETY

ELECTRIC SHOCK
CAN KILL.

3.a. The electrode and work (or ground) circuits are
electrically “hot” when the welder is on. Do
not touch these “hot” parts with your bare skin or wet clothing.
Wear dry, hole-free gloves to insulate hands.

3.b. Insulate yourself from work and ground using dry insulation.
Make certain the insulation is large enough to cover your full area

f physical contact with work and ground.

o

In addition to the normal safety precautions, if

welding must be performed under electrically
hazardous conditions (in damp locations or while
wearing wet clothing; on metal structures such as
floors, gratings or scaffolds; when in cramped
positions such as sitting, kneeling or lying, if there
is a high risk of unavoidable or accidental contact
with the workpiece or ground) use the following
equipment:

• Semiautomatic DC Constant Voltage (Wire) Welder.

• DC Manual (Stick) Welder.

• AC Welder with Reduced Voltage Control.

3.c. In semiautomatic or automatic wire welding, the electrode,
electrode reel, welding head, nozzle or semiautomatic welding
gun are also electrically “hot”.

3.d. Always be sure the work cable makes a good electrical
connection with the metal being welded. The connection should
be as close as possible to the area being welded.

3.e. Ground the work or metal to be welded to a good electrical (earth)
ground.

3.f. Maintain the electrode holder, work clamp, welding cable and
welding machine in good, safe operating condition. Replace
damaged insulation.

3.g. Never dip the electrode in water for cooling.

3.h. Never simultaneously touch electrically “hot” parts of electrode
holders connected to two welders because voltage

two can be the total of the open circuit voltage of both
welders.

3.i. When working above floor level, use a safety belt to protect
yourself from a fall should you get a shock.

between the

ARC RAYS 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.

4.b. Use suitable clothing made from durable flame-resistant material
to protect your skin and that of your helpers from the arc rays.

4.c. Protect other nearby personnel with suitable, non-flammable
screening and/or warn them not to watch the arc nor expose
themselves to the arc rays or to hot spatter or metal.

FUMES AND GASES
CAN BE DANGEROUS.

5.a. Welding may produce fumes and gases
hazardous to health. Avoid breathing these fumes and gases.
When welding, keep your head out of the fume. Use enough
ventilation and/or exhaust at the arc to keep fumes and gases
away from the breathing zone. When welding hardfacing

(see instructions on container or SDS) or on lead
or cadmium plated steel and other metals or
coatings which produce highly toxic fumes, keep
exposure as low as possible and within applicable
OSHA PEL and ACGIH TLV limits using local
exhaust or mechanical ventilation unless exposure
assessments indicate otherwise. In confined
spaces or in some circumstances, outdoors, a
respirator may also be required. Additional
precautions are also required when welding
on galvanized steel.

5. b. The operation of welding fume control equipment is affected by
various factors including proper use and positioning of the
equipment, maintenance of the equipment and the specific
welding procedure and application involved. Worker exposure
level should be checked upon installation and periodically
thereafter to be certain it is within applicable OSHA PEL and
ACGIH TLV limits.

5.c. Do not weld in locations near chlorinated hydrocarbon vapors
coming from degreasing, cleaning or spraying operations. The
heat and rays of the arc can react with solvent vapors to form
phosgene, a highly toxic gas, and other irritating products.

3.j. Also see It ems 6.c. and 8.

5.d. Shielding gases used for arc welding can displace air and

cause
injury or death. Always use enough ventilation, especially in
confined areas, to insure breathing air is safe.

5.e. Read and understand the manufacturer’s instructions for this

equipment and the consumables to be used, including the
Safety Data Sheet (SDS) and follow your employer’s safety
practices. SDS forms are available from your welding
distributor or from the manufacturer.

5.f. Also see item 1.b.

Safety 03 of 04 - 06/15/2016

SAFETY

WELDING AND CUTTING
SPARKS CAN CAUSE
FIRE OR EXPLOSION.

6.a. Remove fire hazards from the welding area. If
this is not possible, cover them to prevent the welding sparks

rom starting a fire. Remember that welding sparks and hot

f
materials from welding can easily go through small cracks and
openings to adjacent areas. Avoid welding near hydraulic lines.
Have a fire extinguisher readily available.

6.b. Where compressed gases are to be used at the job site, special
precautions should be used to prevent hazardous situations.
Refer to “Safety in Welding and Cutting” (ANSI Standard Z49.1)
and the operating information for the equipment being used.

6.c. When not welding, make certain no part of the electrode circuit is
touching the work or ground. Accidental contact can cause
overheating and create a fire hazard.

6.d. Do not heat, cut or weld tanks, drums or containers until the
proper steps have been taken to insure that such procedures
will not cause flammable or toxic vapors from substances inside.
They can cause an explosion even though they have been
“cleaned”. For information, purchase “Recommended Safe
Practices for the Preparation for Welding and Cutting of
Containers and Piping That Have Held Hazardous Substances”,
AWS F4.1 from the American Welding Society
(see address above).

6.e. Vent hollow castings or containers before heating, cutting or
welding. They may explode.

6.f. Sparks and spatter are thrown from the welding arc. Wear oil free
protective garments such as leather gloves, heavy shirt, cuffless
trousers, high shoes and a cap over your hair. Wear ear plugs
when welding out of position or in confined places. Always wear
safety glasses with side shields when in a welding area.

6.g. Connect the work cable to the work as close to the welding area
as practical. Work cables connected to the building framework or
other locations away from the welding area increase the
possibility of the welding current passing through lifting chains,
crane cables or other alternate circuits. This can create fire
hazards or overheat lifting chains or cables until they fail.

6.h. Also see item 1.c.

CYLINDER MAY EXPLODE IF
DAMAGED.

7.a. Use only compressed gas cylinders containing
the correct shielding gas for the process used
and properly operating regulators designed for
the gas and pressure used. All hoses, fittings,

tc. should be suitable for the application and

e
maintained in good condition.

7.b. Always keep cylinders in an upright position securely chained to
an undercarriage or fixed support.

7.c. Cylinders should be located:

• Away from areas where they may be struck or subjected
to physical damage.

• A safe distance from arc welding or cutting operations
and any other source of heat, sparks, or flame.

7.d. Never allow the electrode, electrode holder or any other
electrically “hot” parts to touch a cylinder.

7.e. Keep your head and face away from the cylinder valve outlet
when opening the cylinder valve.

7.f. Valve protection caps should always be in place and hand tight
except when the cylinder is in use or connected for use.

7.g. Read and follow the instructions on compressed gas cylinders,
associated equipment, and CGA publication P-l, “Precautions for
Safe Handling of Compressed Gases in Cylinders,” available from
the Compressed Gas Association, 14501 George Carter Way
Chantilly, VA 20151.

FOR ELECTRICALLY
POWERED EQUIPMENT.

8.a. Turn 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.

6.I. Read and follow NFPA 51B “Standard for Fire Prevention During
Welding, Cutting and Other Hot Work”, available from NFPA, 1
Batterymarch Park, PO box 9101, Quincy, MA 022690-9101.

6.j. Do not use a welding power source for pipe thawing.

8.c. Ground the equipment in accordance with the U.S. National
Electrical Code and the manufacturer’s recommendations.

Refer to

http://www.lincolnelectric.com/safety

for additional safety information.

Safety 04 of 04 - 06/15/2016

TABLE OF CONTENTS

NSTALLATION ...........................................................................................................................SECTION A

I

TECHNICAL SPECIFICATIONS ...........................................................................................................A-1

LOCATION AND VENTILATION...........................................................................................................A-2

STACKING........................................................................................................................................A-2

ANGLE OF OPERATION.....................................................................................................................A-2

IFTING............................................................................................................................................A-2

L

HIGH ALTITUDE OPERATION.............................................................................................................A-2

HIGH TEMPERATURE OPERATION.....................................................................................................A-2

TOWING...........................................................................................................................................A-3

VEHICLE MOUNTING.........................................................................................................................A-3

FUEL ......................................................................................................................................A-3

ENGINE COOLING SYSTEM...............................................................................................................A-3

BATTERY CONNECTION....................................................................................................................A-3

MUFFLER OUTLET PIPE....................................................................................................................A-3

SPARK ARRESTER............................................................................................................................A-3

REMOTE CONTROL .........................................................................................................................A-4

ELECTRICAL CONNECTIONS.............................................................................................................A-4

OPERATION ................................................................................................................................SECTION B

GENERAL DESCRIPTION...................................................................................................................B-1

ENGINE OPERATION.........................................................................................................................B-1

ADD FUEL........................................................................................................................................B-1

BREAK-IN PERIOD............................................................................................................................B-1

WELDING CONTROLS ......................................................................................................................B-2

ENGINE OPERATION.........................................................................................................................B-3

WELDER OPERATION .......................................................................................................................B-4

AUXILIARY POWER: ..........................................................................................................................B-5

ACCESSORIES ............................................................................................................................SECTION C

MAINTENANCE...........................................................................................................................SECTION D

NAMEPLATES / WARNING DECALS MAINTENANCE...........................................................................D-1

ROUTINE MAINTENANCE..................................................................................................................D-1

ENGINE OIL CHANGE........................................................................................................................D-1

OIL FILTER CHANGE.........................................................................................................................D-2

AIR CLEANER...................................................................................................................................D-2

FUEL FILTERS..................................................................................................................................D-3

BLEEDING THE FUEL SYSTEM..........................................................................................................D-3

ENGINE ADJUSTMENT .....................................................................................................................D-5

BATTERY MAINTENANCE .................................................................................................................D-5

WELDER / GENERATOR MAINTENANCE............................................................................................D-6

GFCI TESTING AND RESETTING PROCEDURE....................................................................................D-6

TROUBLESHOOTING ...................................................................................................................SECTION E

DIAGRAMS .................................................................................................................................SECTION F

PARTS LIST...............................................................................................PARTS.LINCOLNELECTRIC.COM

CONTENT/DETAILS MAY BE CHANGED OR UPDATED WITHOUT NOTICE. FOR MOST CURRENT
INSTRUCTION MANUALS, GO TO PARTS.LINCOLNELECTRIC.COM.

6

teChniCal sPeCiFiCations - Fleet™ 500
(K4338-1)

INPUT - DIESEL ENGINE

Make/Model Description Speed (RPM) Displacement Starting System Capacities

INSTALLATIONFLEET™ 500

DEUTZ

D2011L03I

DIESEL ENGINE

EPA TIER 4I

COMPLIANT

3 CYLINDER
32HP (24 KW)
@ 1800 RPM.

IDLE 1890

FULL LOAD 1800

(2.05L)

BORE X STROKE

3.89" X 4.13"

12VDC BATTERY

& STARTER

(99MM X 105MM)

125 CU. IN

RATED OUTPUT @ 104° F (40° C) - WELDER

Welding Process

Welding Output

Current/Voltage/Duty Cycle

Output Range

Amps

400A / 36V / 100%

DC CONSTANT CURRENT

450A / 37V / 100%

30A TO 500A 82 VOLTS PEAK

500A / 33V / 100%

TIG 250A / 20V / 100% 20A TO 250A 82 VOLTS PEAK

RATED OUTPUT @ 104° F (40° C).- GENERATOR

Auxiliary Power1Single Phase 60 Hz AC

OUTLETS VOLTS AMPS POWER

1 120 20 2400 WATTS

FUEL

(25 US GAL)

94.6L

OIL:

6.3 QTS.

6.0L

Max. Weld OCV

Voltage @ 1800RPM

1 120 15 1800 WATTS

2 240 2 X 15 2 X 3600 WATTS

RECEPTACLES AND CIRCUIT BREAKERS

RECEPTACLES AUXILIARY POWER CIRCUIT BREAKER OTHER CIRCUIT BREAKERS

1 - 120VAC DUPLEX NEMA(5-20R) GFCI

PROTECTED

1 - 120VAC EUROPEAN (IEC-309)-GFCI

PROTECTED

1 - 20 AMP FOR 120 VAC DUPLEX (NEMA)

1 - 15 AMP FOR 120 VAC EUROPEAN (IEC-309)

20AMP FOR BATTERY CHARGING CIRCUIT

2 - 240VAC EUROPEAN (IEC-309) 2 - 15 AMP FOR 240 VAC EUROPEAN (IEC-309)

PHYSICAL DIMENSIONS

HEIGHT WIDTH DEPTH WEIGHT

36.87(2) IN.

936.5 MM

1. Output rating in watts is equivalent to volt-amperes at unity power factor. Output voltage is within ± 10% at all loads up to rated capacity. When welding, avail­able auxiliary power will be reduced.

2. To Top of enclosure, add 9.63”(244.6mm) to top of exhaust pipe.

28.28 IN

718.3 MM

65.1 IN.

1653.5 MM

1410 LBS.

(634 KG.)

A-1

INSTALLATIONFLEET™ 500

INSTALLATION

SAFETY PRECAUTIONS

WARNING

o not attempt to use this equipment until you have

D
thoroughly read the engine manufacturer’s manual
supplied with your welder. It includes important safety
precautions, detailed engine starting, operating and
maintenance instructions, and parts list

ELECTRIC SHOCK can kill.

• Do not touch electrically live parts or

electrode with skin or wet clothing.

• Insulate yourself from work and ground

• Always wear dry insulating gloves.

ENGINE EXHAUST can kill.

• Use in open, well ventilated areas or vent

exhaust outside.

MOVING PARTS can injure.

• Do not operate with doors open or

guards off.

• Stop engine before servicing.

• Keep away from moving parts.

liFting

The Fleet™ 500 weighs approximately 1410lbs. (639kg.) with a
empty fuel tank. A lift bail is mounted to the machine and should
always be used when lifting the machine.

Liftbale max lifting weight = 2600lbs

Do not exceed max lifting weight.

HIGH ALTITUDE OPERATION

At higher altitudes, output derating may be necessary. For
maximum rating, derate the welder output 5% for every 300
meters (984 ft.) above 1500 meters (4920 ft.). For output of 400A
and below, derate the welder output 5% for every 300 meters
(984 ft.) above 2100 meters (6888 ft.).

Contact a Deutz Service Representative for any engine
adjustments that may be required.

high temPerature oPeration

Tested for extreme temperature operation up to 55°C. Output
derated above 40°C.

OUTPUT RATINGS AT TEMPERATURES ABOVE 40°C

AMPS VOLTS Duty Cycle TEMPERATURE

500 33.0 50% 55

500 33.0 80% 50

See additional warning information at front of this
operator’s manual.

Only qualified personnel should install, use, or service
this equipment.

loCation and Ventilation

The welder should be located to provide an unrestricted flow of
clean, cool air to the cooling air inlets and to avoid restricting the
cooling air outlets. Locate the welder so that the engine exhaust
fumes are properly vented to an outside area.

staCKing

Fleet™ 500 machines cannot be stacked.

angle oF oPeration

Engines are designed to run in the level condition which is where
the optimum performance is achieved. The maximum angle of
continuous operation is 20 degrees in all directions, 30 degrees
Intermittent (less than 10 minutes continuous) in all directions. If
the engine is to be operated at an angle, provisions must be made
for checking and maintaining the oil level at the normal (FULL) oil
capacity in the crankcase.

When operating the welder at an angle, the effective fuel capacity
will be slightly less than the amount specified.

500 33.0 90% 45

A-2

INSTALLATIONFLEET™ 500

towing

Use a recommended trailer for use with this equipment for road,
in-plant and yard towing by a vehicle(1). If the user adapts a non­Lincoln trailer, he must assume responsibility that the method of
attachment and usage does not result in a safety hazard or

amage the welding equipment. Some of the factors to be

d
considered are as follows:

1. Design capacity of trailer vs. weight of Lincoln equipment and
likely additional attachments.

2. Proper support of, and attachment to, the base of the welding
equipment so there will be no undue stress to the framework.

3. Proper placement of the equipment on the trailer to insure
stability side to side and front to back when being moved and
when standing by itself while being operated or serviced.

4. Typical conditions of use, i.e., travel speed; roughness of surface
on which the trailer will be operated; environmental conditions;
like maintenance.

5. Conformance with federal, state and local laws.(1)

(1) Consult applicable federal, state and local laws regarding specific require-

ments for use on public highways.

VehiCle mounting

uel

F

USE DIESEL FUEL ONLY­Low Sulphur fuel or ultra low sulphur fuel in
USA and CANADA only.

WARNING

Fill the fuel tank with clean, fresh fuel. The capacity of
the tank is 25 US gals. (94.6 ltrs). When the fuel gauge
reads empty the tank contains approximately 2 gals.
(7.6ltrs.) of reserve fuel.

Note: A fuel shut off valve is located next to engine fuel pump.
Which should be in the closed position when the welder is not
used for extended period of time.

engine Cooling system

The Deutz engine is air cooled by a belt driven axial blower. The
oil cooler and engine cooling fins should be blown out with
compressed air or steam to maintain proper cooling (See the
engine Owners Manual for procedures and frequency).

battery ConneCtion

CAUTION

WARNING

Improperly mounted concentrated loads may cause
unstable vehicle handling and tires or other components
to fail.

• Only transport this Equipment on serviceable vehicles
which are rated and designed for such loads.

• Distribute, balance and secure loads so vehicle is
stable under conditions of use.

• Do not exceed maximum rated loads for components
such as suspension, axles and tires.

• Mount equipment base to metal bed or frame of vehicle.

• Follow vehicle manufacturer’s instructions.

Use caution as the electrolyte is a strong acid that can
burn skin and damage eyes.

The Fleet 500 is shipped with the negative battery cable
disconnected. Make certain that the RUN-STOP switch is in the
STOP position.

NOTE: This machine is furnished with a wet charged battery; if
unused for several months, the battery may require a booster
charge. Be careful to charge the battery with the correct polarity.
(See Battery in “Maintenance Section”)

muFFler outlet PiPe

Remove the plastic plug covering the muffler outlet tube. Using
the clamp provided secure the outlet pipe to the outlet tube with
the pipe positioned such that it will direct the exhaust in the
desired direction.

sParK arrester

Some federal, state or local laws may require that gasoline or
diesel engines be equipped with exhaust spark arresters when
they are operated in certain locations where unarrested sparks
may present a fire hazard.

The standard muffler included with this welder does not qualify as
a spark arrester. When required by local regulations, a suitable
spark arrester such as the K2864-1must be installed and properly
maintained.

WARNING

An incorrect spark arrestor may lead to damage to the
engine or adversely affect performance.

A-3

INSTALLATIONFLEET™ 500

emote Control

r

he Fleet™ 500 is equipped with a 6-pin connector. When a

T
remote control is connected to the 6-pin Connector, the auto­sensing circuit automatically switches the OUTPUT control from
control at the welder to remote control.

When in TOUCH START TIG mode and when a Amptrol is
connected to the 6-Pin Connector, the OUTPUT dial is used to set
the maximum current range of the CURRENT CONTROL of the
Amptrol.

Both in PIPE/GOUGE mode on low range and in STICK mode, when
a remote control is connected to the 6-Pin connector, the output
control is used to set the maximum current range of the remote.

EXAMPLE: When the OUTPUT CONTROL on the welder is set to
200 amps the current range on the remote control will be Min­200 amps, rather than the full Min-Max amps. Any current range
that is less than the full range provides finer current resolution for
more fine tuning of the output.

eleCtriCal ConneCtions

Machine Grounding

Because this portable engine driven welder creates its own power,
it is not necessary to connect its frame to an earth ground, unless
the machine is connected to premises wiring (home, shop, etc.)

To prevent dangerous electric shock, other equipment to which
this engine driven welder supplies power must:

WARNING

• Be grounded to the frame of the welder using a
grounded type plug or be double insulated.

• Do not ground the machine to a pipe that carries
explosive or combustible material.

When this welder is mounted on a truck or trailer, its frame must
be electrically bonded to the metal frame of the vehicle. Use a #8
or larger copper wire connected between the machine grounding
stud and the frame of the vehicle. When this engine driven welder
is connected to premises wiring such as that in a home or shop,
its frame must be connected to the system earth ground. See
further connection instructions in the section entitled "Standby
Power Connections" as well as the article on grounding in the
latest National Electrical Code and the local code.

In general, if the machine is to be grounded, it should be
connected with a #8 or larger copper wire to a solid earth ground
such as a metal water pipe going into the ground for at least ten
feet and having no insulated joints, or to the metal framework of a
building which has been effectively grounded.

The National Electrical Code lists a number of alternate means of
grounding electrical equipment. A machine grounding stud
marked with the symbol is provided on the front of the welder.

Welding OUTPUT Cables

With the engine off connect the electrode and work cables to the
output studs. The welding process dictates the polarity of the
electrode cable. These connections should be checked
periodically and tightened with a 3/4"(19mm) wrench.

Table A.1 lists recommended cable sizes and lengths for rated
current and duty cycle. Length refers to the distance from the
welder to the work and back to the welder. Cable diameters are
increased for long cable lengths to reduce voltage drops.

TABLE A.1

TOTAL COMBINED LENGTH OF ELECTRODE AND WORK CABLES

Cable Size for

Cable Length

400 Amps

60% Duty Cycle

0-100 FT. (0-30 METERS) 2 / 0 AWG

100-150 FT. (30-46 METERS) 2 / 0 AWG

150-200 FT. (46-61 METERS) 3 / 0 AWG

A-4

able Installation

C

nstall the welding cables to your Fleet™ 500 as follows.

I

. The engine must be OFF to install welding cables.

1

. Remove the flanged nuts from the output terminals

2

. Connect the electrode holder and work cables to the weld output

3

terminals. The terminals are identified on the case front.

4. Tighten the flanged nuts securely.

5. Be certain that the metal piece you are welding (the “work”) is
properly connected to the work clamp and cable.

6. Check and tighten the connections periodically.

WARNING

• Loose connections will cause the output terminals to
overheat. The terminals may eventually melt.

• Do not cross the welding cables at the output terminal
connection. Keep the cables isolated and separate from
one another.

INSTALLATIONFLEET™ 500

residual Current deViCe ready

The Fleet™ 500 is configured to allow for the addition of a
Residual Current Device (RCD) to protect the 2-240V Single Phase
Receptacles. The auxiliary power area on the front panel of the

leet™ 500 has a hole sized and shaped to accept a typical 2-

F
pole RCD along with a protective rubber boot. A cover plate with a
label “RCD READY” covers the hole and secures a mounting
bracket on the backside of the panel.

Note: The RCD should be rated for at least 30 Amps.

There are many suppliers of RCD’s. Examples are Allen Bradley,
part number 1492-RCD2A40 or Clipsal, part number 4RC240130.

The protective boot can be obtained from APM-Hexseal, part
number HE-1035

See Section G Diagrams of this Operator’s Manual for instructions
on installing an RCD and protective rubber boot.

AUXILIARY POWER RECEPTACLES

120 V Duplex Receptacles and GFCI

A GFCI protects the two 120V auxiliary power receptacles.

A GFCI (Ground Fault Circuit Interrupter) is a device to protect
against electric shock should a piece of defective equipment
connected to it develop a ground fault. If this situation should
occur, the GFCI will trip, removing voltage from the output of the
receptacle. If a GFCI is tripped see the MAINTENANCE section for
detailed information on testing and resetting it. A GFCI should be
properly tested at least once every month.

One - 120V European plug protected by 1 - 15A circuit breaker.

Two - 240V European plugs protected by 2 - 15A circuit breakers.

A-5

OPERATIONFLEET™ 500

OPERATION

SAFETY PRECAUTIONS

WARNING

Do not attempt to use this equipment until you have
thoroughly read the engine manufacturer’s manual
supplied with your welder. It includes important safety

recautions, detailed engine starting, operating and

p
maintenance instructions, and parts lists.

ELECTRIC SHOCK can kill.

• Do not touch electrically live parts or
electrode with skin or wet clothing.

• Insulate yourself from work and ground

• Always wear dry insulating gloves.

• Always operate the welder with the hinged door closed
and the side panels in place.

• Read carefully the Safety Precautions page before
operating this machine. Always follow these and any
other safety procedures included in this manual and in
the Engine Instruction Manual.

general desCriPtion

The Fleet™ 500 is a diesel engine powered DC multi-process
welding power source and AC power generator. The engine drives
a generator that supplies three phase power for the DC welding
circuit, single phase power for the AC auxiliary outlets. The DC
welding control system uses state of the art Chopper Technology
for superior welding performance.

For Auxiliary Power:

Start the engine and set the Weld Mode Selector switch to the
desired operating mode. Full power is available regardless of the
welding control settings providing no welding current is being
drawn.

engine oPeration

Before Starting the Engine:

• Be sure the machine is on a level surface.

• Open side engine door and remove the engine oil dipstick and
wipe it with a clean cloth. Reinsert the dipstick and check the
level on the dipstick.

• Add oil (if necessary) to bring the level up to the full mark. Do
not overfill. Close engine door.

• See Engine Owner’s Manual for specific oil recommendations.

add Fuel

WARNING

DIESEL FUEL can cause fire.

• Stop engine while fueling.

• Do not smoke when fueling.

• Keep sparks and flame away from tank.

• Do not leave unattended while fueling.

Wipe up spilled fuel and allow fumes to clear before

•
starting engine.

• Do not overfill tank, fuel expansion may cause overflow.

Diesel Fuel Only-Low Sulphur Fuel or Ultra Low Sulphur
in USA and Canada.

• Remove the fuel tank cap.

• Fill the tank. DO NOT FILL THE TANK TO THE POINT OF

OVERFLOW.

• Replace the fuel cap and tighten securely.

• See Engine Owner’s Manual for specific fuel recommendations.

breaK-in Period

Lincoln Electric selects high quality, heavy-duty industrial engines
for the portable welding machines we offer. While it is normal to
see a small amount of crankcase oil consumption during initial
operation, excessive oil use, wetstacking (oil or tar like substance
at the exhaust port), or excessive smoke is not normal.

Larger machines with a capacity of 350 amperes and higher,
which are operated at low or no-load conditions for extended
periods of time are especially susceptible to the conditions
described above. To accomplish successful engine break-in, most
diesel-powered equipment needs only to be run at a reasonably
heavy load within the rating of the welder for some period of time
during the engine’s early life. However, if the welder is subjected
to extensive light loading, occasional moderate to heavy loading of
the engine may sometimes be necessary. Caution must be
observed in correctly loading a diesel/generator unit.

1. Connect the welder output studs to a suitable resistive load bank.
Note that any attempt to short the output studs by connecting the
welding leads together, direct shorting of the output studs, or
connecting the output leads to a length of steel will result in
catastrophic damage to the generator and voids the warranty.

2. Set the welder controls for an output current and voltage within
the welder rating and duty cycle. Note that any attempt to
exceed the welder rating or duty cycle for any period of time will
result in catastrophic damage to the generator and voids the
warranty.

3. Periodically shut off the engine and check the crankcase oil level.

CAUTION

During break-in, subject the Welder to moderate loads.
Avoid long periods running at idle. Before stopping the
engine, remove all loads and allow the engine to cool
several minutes.

B-1

FIGURE B.1

OPERATIONFLEET™ 500

10

9

8

6

7

15

22

16

4

2

1 23

4

42

5

11

12

14

13

21

23

17

18

19

20

22

welding Controls

(Figure B.1)

1. OUTPUT CONTROL- The OUTPUT dial is used to preset the output

voltage or current. When in the PIPE / GOUGE mode on high
range and when a remote control is connected to the 6-Pin, the
auto-sensing circuit automatically switches the OUTPUT
CONTROL from control at the welder to the remote control.

When in the CC-STICK or PIPE / GOUGE mode and when a remote

control is connected to the 6-Pin, the output control is used to
set the maximum current range of the remote.

EXAMPLE: When the OUTPUT CONTROL on the welder is set to

200 amps the current range on the remote control will be
Min-200 amps, rather than the full Min-Max amps. Any current
range that is less than the full range provides finer current
resolution for more fine tuning of the output.

When in the TOUCH START TIG mode and when an Amptrol is

connected to the 6-Pin Connector, the OUTPUT dial is used to set
the maximum current range of the CURRENT CONTROL of the
Amptrol.

2. WELD MODE SELECTOR SWITCH-

(Provides THREE selectable welding modes)

PIPE/GOUGE

CC-STICK

TOUCH START TIG

3. PIPE/ GOUGE RANGE selector switch - Used to select either

the LOW range (Black dial settings) or the HIGH range (Red dial
settings) on the output control dial when in PIPE/GOUGE. This
switch is not used in STICK or TIG modes.

4. ARC FORCE- The ARC FORCE dial is active in the PIPE/GOUGE
mode when on low range, and in the CC-STICK mode. This
control is not active in the PIPE/GOUGE mode when in high range
or when in TIG mode.

CC-STICK mode: In this mode, the ARC FORCE dial sets the short

circuit current (arc-force) during stick welding to adjust for a soft
or crisp arc. Increasing the dial from –10 (soft) to +10 (crisp)
increases the short circuit current and prevents sticking of the
electrode to the plate while welding. This can also increase
spatter. It is recommended that the ARC FORCE be set to the
minimum number without electrode sticking. Start with a setting
at 0.

PIPE mode: In this mode, the ARC FORCE dial sets the short

circuit current (arc-force) during stick welding to adjust for a soft
or a more forceful digging arc (crisp). Increasing the number
from –10 (soft) to +10 (crisp) increases the short circuit current
which results in a more forceful digging arc. Typically a forceful
digging arc is preferred for root and hot passes. A softer arc is
preferred for fill and cap passes where weld puddle control and
deposition ("stacking" of iron) are key to fast travel speeds. It is
recommended that the ARC FORCE be set initially at 0.

5. THERMAL PROTECTION INDICATOR LIGHT

6. RUN/STOP SWITCH - RUN position energizes the engine prior to

starting. STOP position stops the engine.

7. START PUSH BUTTON - Energizes the starter motor to crank the
engine.

8. 20AMP CIRCUIT BREAKER- For protection of Battery Charging
Circuit.

9. OIL PRESSURE GAUGE- An indicator of engine Oil Pressure.

B-2

0. ENGINE HOUR METER / FUEL GAUGE- Displays the total time

1

that the engine has been running. This meter is useful for
scheduling prescribed maintenance. Shows fuel level.

11. ENGINE TEMPERATURE GAUGE- An indicator of engine

temperature.

12. ENGINE PROTECTION LIGHT- A warning indicator light for Low

Oil Pressure and/or over Temperature.The light is off when the

ystems are functioning properly. The light will come on and the

s
engine will shutdown when there is Low Oil Pressure and/or the
engine is Over Temperature.

Note: The light remains off when the RUN-STOP switch is in the

"ON" position prior to starting the engine. However if the engine
is not started within 60 seconds the light will come on. When this
happens the RUN-STOP switch must be returned to the "OFF"
position to reset the engine protection system and light.

13. Battery Charging Light- A warning indicator light for Low/No

battery charge. The light is off when the systems are functioning
properly. The light will come on if there is a Low/No battery
condition but the machine will continue to run.

Note: The light may or may not come on when the RUN-STOP

switch is in the "ON" position. It will come on during cranking
and stay on until the engine starts. After starting the engine the
light will go off unless a Low/No battery charge condition exists.

14. 6-PIN CONNECTOR- For attaching optional remote control

equipment. Includes auto-sensing remote control circuit.

15. 15A CIRCUIT BREAKER- to protect 240V Euro plugs.

16. 240V EURO PLUGS

17. 20A CIRCUIT BREAKER

18. DUPLEX 120V NEMA RECEPTACLE

19. 20A CIRCUIT BREAKER

20. 120V EURO PLUG

21. 120V GFCI - protects both Nema duplex receptacle & 120V Euro

plug

22. OUTPUT STUD - provides a connection point for the electrode

and work cables.

23. GROUND STUD- Provides a connection point for connecting the

machine case to earth ground.

24. DIGITAL OUTPUT METERS (OPTIONAL) - The digital meters

allow the output voltage current (CC-STICK, PIPE, Arc Gouging
and TIG modes) to be set prior to welding using the OUTPUT
control dial. During welding, the meter display the actual output
voltage (VOLTS) and current (AMPS). A memory feature holds the
display of both meters on for seven seconds after welding is
stopped. This allows the operator to read the actual current and
voltage just prior to when welding was ceased.

While the display is being held the left-most decimal point in

each display will be flashing. The accuracy of the meters is
+/- 3%.

OPERATIONFLEET™ 500

engine oPeration

STARTING THE ENGINE

. Open the engine compartment door and check that the fuel shut

1

off valve located next to engine fuel pump in the open position
(lever to be in line with the hose).

2. Check for proper oil level. Close engine compartment door.

3. Remove all plugs connected to the AC power receptacles.

4. Set the RUN/STOP switch to “RUN”. Observe that the battery
charging light is on and fuel is in the fuel tank (see fuel gauge).

5. Within 30 seconds, press and hold the engine START button until
the engine starts.

6. Release the engine START button when the engine starts.

7. Check that the engine protection and battery charging lights are
off. The engine protection light is on after starting, the engine will
shutdown in a few seconds. Investigate any indicated problem.

8. Allow the engine to warm up for several minutes before applying
a load. Allow a longer warm up time in cold weather.

COLD WEATHER STARTING

With a fully charged battery and the proper weight oil, the engine
should start satisfactorily even down to about -15°C(5°F). If the
engine must be frequently started below -15°C(5°F), it may be
desirable to install additional starting aids. The use of No. 1D
diesel fuel is recommended in place of No. 2D at temperatures
below -5°C(23° F).

STOPPING THE ENGINE

Switch the RUN/STOP switch to “STOP”. This turns off the voltage
supplied to the shutdown solenoid. A backup shutdown can be
accomplished by shutting off the fuel valve located on the fuel
line.

Note: Place the Run/Stop switch in “Stop” position when engine is
not running - battery will be discharged otherwise.

B-3

welder oPeration

DUTY CYCLE

Duty Cycle is the percentage of time the load is being applied in a
10 minute period. For example a 60% duty cycle, represents 6
minutes of load and 4 minutes of no load in a 10 minute period.

ELECTRODE INFORMATION

For any electrode the procedures should be kept within the rating
of the machine. For information on electrodes and their proper
application see (www.lincolnelectric.com) or the appropriate
Lincoln publication.

The Fleet™ 500 can be used with a broad range of DC stick
electrodes. The WELD MODE switch provides two stick welding
settings as follows:

Constant Current (CC-STICK) Welding

The CC-STICK position on the WELD MODE switch is designed for
horizontal and vertical-up welding with all types of electrodes,
especially low hydrogen. The OUTPUT CONTROL dial adjusts the
full output range for stick welding. The PIPE/GOUGE range switch
is not used in STICK mode.

The ARC FORCE dial sets the short circuit current (arc-force)
during stick welding to adjust for a soft or crisp arc. Increasing the
number from -10(soft) to +10(crisp) increases the short circuit
current and prevents sticking of the electrode to the plate while
welding. This can also increase spatter. It is recommended that
the ARC FORCE be set to the minimum number without electrode
sticking. Start with the dial set at 0.

PIPE / GOUGE Mode

OPERATIONFLEET™ 500

This slope controlled setting is intended for "out-of-position" and
"down hill" pipe welding where the operator would like to control
the current level by changing the arc length.

The OUTPUT CONTROL dial in conjuction with the PIPE/GOUGE
range switch are used to adjusts the welding output in
PIPE/GOUGE mode.

The ARC FORCE dial sets the short circuit current (arc-force)
during stick welding to adjust for a soft or more forceful digging
arc (crisp). Increasing the number from -10(soft) to +10(crisp)
increases the short circuit current which results in a more forceful
digging arc.

Typically a forceful digging arc is preferred for root and hot
passes. A softer arc is preferred for fill and cap passes where
weld puddle control and deposition (“stacking” of iron) are key to
fast travel speeds. This can also increase spatter.

It is recommended that the ARC FORCE be set to the minimum
number without electrode sticking. Start with the dial set at 0.

TIG Welding

The TOUCH START TIG setting of the WELD MODE switch is for
DC TIG (Tungsten Inert Gas) welding. To initiate a weld, the
OUTPUT CONTROL dial is first set to the desired current and the
tungsten is touched to the work. During the time the tungsten is
touching the work there is very little voltage or current and, in
general, no tungsten contamination. Then, the tungsten is gently
lifted off the work in a rocking motion, which establishes the arc.

B-4

OPERATIONFLEET™ 500

TABLE B.3

TYPICAL CURRENT RANGES

ungsten Electrode DCEN (-) DCEP (+) Approximate Argon Gas Flow TIG TORCH

T

Diameter in. (mm) Flow Rate C.F.H. ( l /min.) Nozzle Size (4), (5)

1%, 2% Thoriated 1%, 2% Thoriated Aluminum Stainless Steel

ungsten Tungsten

T

.010 (.25) 2-15 (3) 3-8 (2-4) 3-8 (2-4) #4, #5, #6

0.020 (.50) 5-20 (3) 5-10 (3-5) 5-10 (3-5)
.040 (1.0) 15-80 (3) 5-10 (3-5) 5-10 (3-5)

0

1/16 (1.6) 70-150 10-20 5-10 (3-5) 9-13 (4-6) #5, #6

/32 (2.4) 150-250 15-30 13-17 (6-8) 11-15 (5-7) #6, #7, #8

3
1/8 (3.2) 250-400 25-40 15-23 (7-11) 11-15 (5-7)

5/32 (4.0) 400-500 40-55 21-25 (10-12) 13-17 (6-8) #8, #10
3/16 (4.8) 500-750 55-80 23-27 (11-13) 18-22 (8-10)
1/4 (6.4) 750-1000 80-125 28-32 (13-15) 23-27 (11-13)

1) When used with argon gas. The current ranges shown must be reduced when using argon/helium or pure helium shielding gases.

(
(2) Tungsten electrodes are classified as follows by the American Welding Society (AWS):

Pure EWP

1% Thoriated EWTh-1

2% Thoriated EWTh-2

Though not yet recognized by the AWS, Ceriated Tungsten is now widely accepted as a substitute for 2% Thoriated Tungsten in AC and DC applications.

(3) DCEP is not commonly used in these sizes.

4) TIG torch nozzle "sizes" are in multiples of 1/16ths of an inch:

(

(5) TIG torch nozzles are typically made from alumina ceramic. Special applications may require lava nozzles, which are less prone to breakage, but cannot withstand high temperatures

and high duty cycles.

4 = 1/4 in. (6 mm)

#

5 = 5/16 in. (8 mm)

#

6 = 3/8 in. (10 mm)

#
# 7 = 7/16 in. (11 mm)
# 8 = 1/2 in. (12.5 mm)
#10 = 5/8 in. (16 mm)

(1)

FOR TUNGSTEN ELECTRODES

(2)

TABLE B.5 FLEET™ 500 SIMULTANEOUS

WELDING AND POWER LOADS

WELD
AMPS

150
250
350

PLUS

1 PHASE

WATTS AMPS

9,100 43
6,900 23
2,400 11

Fleet™ 500 Extension Cord Length Recommendations

(Use the shortest length extension cord possible sized per the following table.)

Current

(Amps)

15
20
15
20
44

Voltag
e Volts

120
120
240
240
240

Load

(Watts)

1800
2400
3600
4800
9500

14 AWG 12 AWG 10 AWG 8 AWG 6 AWG 4 AWG

30

60

(9)

(18)

Conductor size is based on maximum 2.0% voltage drop.

TABLE B.6

Maximum Allowable Cord Length in ft. (m) for Conductor Size

40
30
75
60

(12)

(9)
(23)
(18)

75

50
150
100

50

(23)
(15)
(46)
(30)
(15)

125

88
225
175

90

(38)
(27)
(69)
(53)
(27)

175
138
350
275
150

(53)
(42)

(107)

(84)
(46)

300
225
600
450
225

(91)

(69)
(183)
(137)

(69)

.

B-5

ABLE B.2

T

TYPICAL FLEET™ 500 FUEL CONSUMPTION

OPERATIONFLEET™ 500

Test Condition

FUEL CONSUMPTION

US gal/hr (litres/hr)

NO LOAD 0.50 ( 1.91)
200 A @ 28 V 100% 0.82 ( 3.11)
400 A @ 36 V 100% 1.39 (5.28)
500 A @ 33 V 100% 1.68 (6.37)

NOTE: This data is for reference only. Fuel consumption is approximate and

can be influenced by many factors, including engine maintenance, environ-

ental conditions and fuel quality

m

B-6

ACCESSORIES

FIELD INSTALLED OPTIONS / ACCESSORIES
are available at www.lincolnelectric.com.

Follow these steps:

1. Go to www.lincolnelectric.com

2. At the top of the screen to the far left click on Equipment, click
on Engine Driven Welders, click on Fleet on next shown scroll
down to Fleet™ 500 Engine Driven Welders

3. Click on VIEW DETAILS.

4. The next screen will have an Equipment Details section, click
on Accessories. This will show Category, Product Number and
Product Name of all currently available accessories.

ACCESSORIESFLEET™ 500

C-1

MAINTENANCEFLEET™ 500

MAINTENANCE

SAFETY PRECAUTIONS

WARNING

• Have qualified personnel do all maintenance and

troubleshooting work.

• Turn the engine off before working inside the machine

or servicing the engine.

• Remove guards only when necessary to perform

maintenance and replace them when the maintenance

equiring their removal is complete. If guards are

r
missing from the machine, obtain replacements from a
Lincoln Distributor. (See Operating Manual Parts List.)

Read the Safety Precautions in the front of this manual
and in the Engine Owner’s Manual before working on this
machine.

Keep all equipment safety guards, covers, and devices in
position and in good repair. Keep hands, hair, clothing,
and tools away from the gears, fans, and all other moving
parts when starting, operating, or repairing the
equipment.

namePlates / warning deCals maintenanCe

Whenever routine maintenance is performed on this machine or at
least yearly - inspect all nameplates and labels for legibility.
Replace those that are no longer clear. Refer to the parts list for
replacement items.

routine maintenanCe

At the end of each day’s use, refill the fuel tank to minimize
moisture condensation in the tank. Running out of fuel tends to
draw dirt into the fuel system. Also, check the crankcase oil level
and add oil if indicated.

engine oil Change

Drain the engine oil while the engine is warm to assure
rapid and complete draining. It is recommended that each time
the oil is changed the oil filter be changed as well.

• Be sure the unit is off. Disconnect the negative battery cable to
ensure safety.

• Locate oil drain hose and valve in bottom of base and pull
through the hole in the case back or side of the base on welder.

• Open oil drain valve by lifting up spring loaded lever and rotate
90° counterclockwise. Pull to open and drain the oil into a
suitable container for disposal.

• Close the drain valve by rotating lever 90° clockwise.

• Re-fill the crankcase to the upper limit mark on the dipstick with
the recommended oil (see engine operation manual OR engine
service items decal OR below). Replace and tighten the oil filler
cap securely.

• Push oil drain hose and valve back into unit, re-connect negative
battery cable, and close doors and engine top cover before
restarting unit.Wash your hands with soap and water after
handling used motor oil. Please dispose of used motor oil in a
manner that is compatible with the environment. We suggest
you take it in a sealed container to your local service station or
recycling center for reclamation. DO NOT throw it in the trash;
pour it on the ground or down a drain.

Use motor oil designed for diesel engines that meets requirements
for API service classification CC/CD/CE/CF/CF-4/CG-4 or CH-4.

ACEA E1/E2/E3. Always check the API service label on the oil
container to be sure it includes the letters indicated. (Note: An S­grade oil must not be used in a diesel engine or damage may
result. It IS permissible to use an oil that meets S and C grade
service classifications.)

SAE 10W30 is recommended for general, all temperature use, 5F
to 104F (-15C to 40C).

See engine owner’s manual for more specific information on oil
viscosity recommendations.

D-1

MAINTENANCEFLEET™ 500

il Filter Change

o

Drain the oil.

•

Remove the oil filter with an oil filter wrench and drain the oil into a

•
suitable container. Discard the used filter. Note: Care should be
taken during filter removal to not disrupt or damage in any way
the fuel lines.

• Clean the filter mounting base and coat the gasket of the new
filter with clean engine oil.

• Screw the new filter on by hand until the gasket contacts the
mounting base. Using an oil filter wrench, tighten the filter an
additional 1/2 to 7/8 of a turn.

• Refill the crankcase with the specified amount of the
recommended engine oil. Reinstall the oil filler cap and tighten
securely.

• Start the engine and check for oil filter leaks.

• Stop the engine and check the oil level. If necessary, add oil to the
upper limit mark on the dipstick.

WARNING

Never use gasoline or low flash point solvents for
cleaning the air cleaner element. A fire or explosion
could result.

ir Cleaner

a

he diesel engine is equipped with a dry type air filter. Never

T
apply oil to it. Service the air cleaner as follows:

Replace the element every 500 hours of operation. Under dusty
conditions, replace sooner.

CAUTION

Never run the engine without the air cleaner. Rapid
engine wear will result from contaminants, such as dust
and dirt being drawn into the engine.

D-2

Unfasten or unlatch the
service cover. Because
the filter fits tightly over the
outlet tube to create the critical seal, there will
be some initial resistance, similar to breaking
the seal on a jar. Gently move the end of the filter
back and forth to break the seal then rotate while
pulling straight out. Avoid knocking the filter
against the housing.

Remove the FilterRemove the Filter

R

otate the

fi

lter while
pulling
straight out.

If your air cleaner has a safety filter, replace it every third primary
filter change. Remove the safety filter as you would the primary
filter. Make sure you cover the air cleaner outlet tube to avoid any
unfiltered contaminant dropping into the engine.

If your air cleaner is equipped with a Vacuator Valve

Visually check and physically squeeze to make sure the
valve is flexible and not inverted, damaged or plugged.

Inspect the new filter carefully, paying attention to
t

he inside of the open end, which is the
sealing area. NEVER install a damaged
filter. A new Donaldson radial seal
filter may have a dry lubricant on the
seal to aid installation.

If you're servicing the safety filter, this should be seated into
position before installing the primary filter.

Insert the new filter carefully. Seat
the filter by hand, making certain it is
completely into the air cleaner housing
before securing the cover in place.

If the service cover hits the filter before it is fully in place, remove
the cover and push the filter (by hand) further into the air cleaner
and try again. The cover should go on with no extra force.

Once the filter is in place, secure the service cover.

Make sure that all mounting bands, clamps, bolts, and connections
in the entire air cleaner system are tight. Check for holes in piping
and repair if needed. Any leaks in your intake piping will send dust
directly to the engine!

The critical sealing area will stretch
slightly, adjust itself and distribute the sealing pressure evenly. To
complete a tight seal, apply pressure by hand at the outer rim of
the filter, not the flexible center. (Avoid pushing on the center of the
urethane end cap.) No cover pressure is required to hold the seal.
NEVER use the service cover to push the filter into place! Using the
cover to push the filter in could cause damage to the housing, cover
fasteners and will void the warranty.

Visually inspect the old filter for any signs
of leaks. A streak of dust on the clean side
of the filter is a telltale sign. Remove any
cause of leaks before installing new filter.

Clean Both Surfaces of the Outlet TubeClean Both Surfaces of the Outlet Tub e
and Check the Vacuator™ Valveand Check the Vacu a tor™ Valve

Inspect the OldInspect the Old
Filter for Leak CluesFilter for Leak Clues

Inspect the New Filter for DamageInspect the New Filter for Damage

Insert the New Radial Seal Filter ProperlyInsert the New Radial Seal Filter Properly

Check Connectors for Tight FitCheck Connectors for Tight Fit

NEVER use the service cover toNEVER use the service cover to
push the filter into place! Usingpush the filter into place! Using
the cover to push the filter in couldthe cover to push the filter in could
cause damage to the housing, covercause damage to the housing, cover
fasteners and will void the warranty.fasteners and will void the warranty.

CautionCaution

Use a clean cloth to wipe the filter sealing surface and the inside of
the outlet tube. Contaminant on the sealing surface could hinder an
effective seal and cause leakage. Make sure that all contaminant is
removed before the new filter is inserted. Dirt accidently transferred
to the inside of the outlet tube will reach the engine and cause
wear. Engine manufacturers say that it takes only a few grams of
dirt to "dust" an engine! Be careful not to damage the sealing area
on the tube.

Wipe both sides
of the outlet
tube clean.

Outer edge of the
outlet tube

Inner edge of the
outlet tube

Service InstructionsService Instructions

Single- and Two-Stage Engine Air CleanersSingle- and Two-Stage Engine Air Cleaners

MAINTENANCEFLEET™ 500

D-3

Fuel Filters

WARNING

When working on the fuel system

• Keep naked lights away, do not smoke !

• Do not spill fuel !

------------------------------------------------------------------------

The Fleet™ 500 is equipped with a Fuel Filter/Water Separator
Assembly located after the lift pump and before the fuel
injectors. The Fuel Filter/Water Separator is mounted to the engine
block just left of the lift pump.

1. Close the fuel shutoff valve.

2. Clean the area around the fuel filter head. Remove the filter.
Clean the gasket surface of the filter head and replace the o-ring.

3. Fill the clean filter with clean fuel, and lubricate the o-ring seal
with clean lubricating oil.

4. Install the filter as specified by the filter manufacturer.

Mechanical overtightening will distort the threads, filter element
seal or filter can.

FUEL: Diesel Fuel Only - Low Sulphur
Fuel or Ultra Low Sulphur Fuel in U.S.A.
and CANADA only.

At the end of each day’s use, refill the fuel tank to minimize
moisture condensation and dirt contamination in the fuel line. Do
not overfill; leave room for the fuel to expand.

Use only fresh No. 2D diesel fuel, the use of No. 1D diesel fuel is
recommended in place of No. 2D at temperatures below 23°F (­5°C). Do not use kerosene.

See the Engine Operator's Manual for instructions on replacing the
fuel filter.

MAINTENANCEFLEET™ 500

leeding the Fuel system

b

ou may need to bleed air from the fuel system if the fuel filter or

Y
fuel lines have been detached, the fuel tank has been ran empty
or after periods of long storage. It is recommended that the fuel
shutoff valve be closed during periods of non-use.

WARNING

To avoid personal injury, do not bleed a hot engine. This
could cause fuel to spill onto a hot exhaust manifold,
creating a danger of fire.

Bleed the fuel system as follows:

1. Fill the fuel tank with fuel.

2. Open the fuel shut off valve.

3. Loosen bleed fitting on the fuel injector manifold.

4. Operate hand priming lever until fuel comes out the bleed
screw on the injector manifold. This could take 20-30 seconds
of rapid operation of the priming lever. Tighten bleed fitting on
injector manifold.

5. Follow normal STARTING procedures until engine starts.

D-4

MAINTENANCEFLEET™ 500

engine adJustment

Adjustments to the engine are to be made only by a Lincoln
Service Center or an authorized Field Service Shop.

battery maintenanCe

To access the battery, remove the battery tray from the front of
the machine with 3/8” nut driver or flat head screw driver. Pull the
tray out of machine far enough to disconnect the negative and
then positive battery cables. The tray can then be tilted and lifted
to remove the entire tray and battery from the machine for easy
service.

WARNING

GASES FROM BATTERY can
explode.

• Keep sparks, flame and cigarettes away
from battery.

To prevent EXPLOSION when:

• INSTALLING A NEW BATTERY — disconnect negative
cable from old battery first and connect to new battery
last.

• CONNECTING A BATTERY CHARGER — remove
battery from welder by disconnecting negative cable
first, then positive cable and battery clamp. When
reinstalling, connect negative cable last. Keep well
ventilated.

• USING A BOOSTER — connect positive lead to battery
first then connect negative lead to negative battery lead
at engine foot.

BATTERY ACID can burn eyes and
skin.

• Wear gloves and eye protection and be
careful when working near battery.

• Follow instructions printed on battery.

LEANING THE BATTERY

C

eep the battery clean by wiping it with a damp cloth when dirty.

K
If the terminals appear corroded, disconnect the battery cables
and wash the terminals with an ammonia solution or a solution of
1/4 pound (0.1113 kg) of baking soda and 1 quart (0.9461L) of
water. Be sure the battery vent plugs (if equipped) are tight so that
none of the solution enters the cells.

After cleaning, flush the outside of the battery, the battery
compartment, and surrounding areas with clear water. Coat the
battery terminals lightly with petroleum jelly or a non-conductive
grease to retard corrosion.

Keep the battery clean and dry. Moisture accumulation on the
battery can lead to more rapid discharge and early battery failure.

CHECKING THE ELECTROLYTE LEVEL

If battery cells are low, fill them to the neck of the filler hole with
distilled water and recharge. If one cell is low, check for leaks.

CHARGING THE BATTERY

When you charge, jump, replace, or otherwise connect battery
cables to the battery, be sure the polarity is correct. Improper
polarity can damage the charging circuit. The Fleet™ 500 positive
(+) battery terminal has a red terminal cover.

If you need to charge the battery with an external charger,
disconnect the negative cable first, then the positive cable before
you attach the charger leads. After the battery is charged,
reconnect the positive battery cable first and the negative cable
last. Failure to do so can result in damage to the internal charger
components.

Follow the instructions of the battery charger manufacturer for
proper charger settings and charging time.

SERVICING OPTIONAL SPARK ARRESTOR

Clean every 100 hours.

WARNING

MUFFLER MAY BE HOT

• ALLOW ENGINE TO COOL BEFORE INSTALLING THE
SPARK ARRESTER!

• DO NOT OPERATE ENGINE WHILE INSTALLING THE
SPARK ARRESTER!

------------------------------------------------------------------------

D-5

MAINTENANCEFLEET™ 500

elder / generator maintenanCe

w

TORAGE:

S

LEANING:Blow out the generator and controls periodically with

C

tore in clean, dry protected areas.

S

low pressure air. Do this at least once a week in particularly dirty
areas.

BRUSH REMOVAL AND REPLACEMENT:

It’s normal for the brushes
and slip rings to wear and darken slightly. Inspect the brushes
when a generator overhaul is necessary.

CAUTION

• Do not attempt to polish slip rings while the engine is

running.

WARNING

Service and Repair should only be performed by Lincoln
Electric Factory Trained Personnel. Unauthorized repairs
performed on this equipment may result in danger to the
technician and machine operator and will invalidate your
factory warranty. For your safety and to avoid Electrical
Shock, please observe all safety notes and precautions.

gFCi testing and resetting ProCedure

The GFCI should be properly tested at least once every month or
whenever it is tripped. To properly test and reset the GFCI:

• If the GFCI has tripped, first carefully remove any load and check
it for damage.

• If the equipment has been shut down, it must be restarted.

• The equipment needs to be operating at high idle speed and any
necessary adjustments made on the control panel so that the
equipment is providing at least 80 volts to the receptacle input
terminals.

• The circuit breaker for this receptacle must not be tripped. Reset
if necessary.

• Push the "Reset" button located on the GFCI. This will assure
normal GFCI operation.

• Plug in night-light (with an "ON/OFF" switch) or other product
(such as a lamp) into the duplex receptacle and turn the product
"ON".

• Push the "Test" button located on the GFCI. The night-light or
other product should go "OFF".

• Push the "Reset" button, again. The light or other product should
go "ON" again.

If the light or other product remains "ON" when the "Test" button
is pushed, the GFCI is not working properly or has been incorrectly
installed (miswired). If your GFCI is not working properly, contact a
qualified, certified electrician who can assess the situation, rewire
the GFCI if necessary or replace the device.

D-6

how to use troubleshooting guide

WARNING

Service and Repair should only be performed by Lincoln
Electric Factory Trained Personnel. Unauthorized repairs
performed on this equipment may result in danger to the
technician and machine operator and will invalidate your
factory warranty. For your safety and to avoid Electrical
Shock, please observe all safety notes and precautions
detailed throughout this manual.

This Troubleshooting Guide is provided to help you locate and repair
possible machine malfunctions. Simply follow the three-step
procedure listed below.

Step 1. LOCATE PROBLEM (SYMPTOM).

Look under the column labeled “PROBLEM (SYMPTOMS)”. This
column describes possible symptoms that the machine may exhibit.
Find the listing that best describes the symptom that the machine is
exhibiting.

Step 2. POSSIBLE CAUSE.

The second column labeled “POSSIBLE CAUSE” lists the obvious
external possibilities that may contribute to the machine symptom.

Step 3. RECOMMENDED COURSE OF ACTION

This column provides a course of action for the Possible Cause,
generally it states to contact your local Lincoln Authorized Field
Service Facility.

If you do not understand or are unable to perform the Recommended
Course of Action safely, contact your local Lincoln Authorized Field
Service Facility.

TROUBLESHOOTINGFLEET™ 500

If for any reason you do not understand the test procedures or are unable to perform the tests/repairs safely, contact your
Lincoln Authorized Service Facility for technical troubleshooting assistance before you proceed.

WWW.LINCOLNELECTRIC.COM/LOCATOR

E-1

Observe all Safety Guidelines detailed throughout this manual

PROBLEMS

(SYMPTOMS)

Major Physical or Electrical Damage is
Evident.

Engine will not "crank". 1. Battery is low, Charge Battery.

Engine will "crank" but not start. 1. Fuel shut off valve on in the OFF position.

1. Contact your local Lincoln Authorized Field
Service Facility.

2. Loose battery cable connections.

Inspect, clean and tighten terminals.

3. Faulty engine starter motor. Contact
authorized local Engine Service Shop.

Open valve (vertical) position of handle.

2. Fuel Filters dirty/clogged. Check and
replace main filter element and/or Inline
Fuel Filter.

3. Out of fuel. Fill tank and bleed fuel system.

POSSIBLE

CAUSE

TROUBLESHOOTINGFLEET™ 500

RECOMMENDED

COURSE OF ACTION

4. Faulty fuel shutdown solenoid. Check that
shutdown solenoid is functioning properly
and not binding/ contact authorized engine
service shop.

5. Faulty fuel pump. Check for fuel flow
through filters. Contact authorized local
Engine Service Shop.

6. High oil temperature or low oil pressure
(engine protection light on)

7. ON / OFF switch on for more than 60
seconds before starting. The ON / OFF
switch will need to be switched off and
turned back on. Defective CR3. Replace
CR3.

Engine shuts down shortly after starting. 1. Low oil pressure (engine protection light

lit). Check oil level (Consult engine service
dealer).

2. High oil temperature. (engine protection

light lit).

3. Faulty oil pressure switch.

4. Faulty oil temperature switch. Contact

authorized local Engine Service Shop.

5. Low output of battery charging alternator

(battery charging light lit).

If all recommended possible areas of misad­justment have been checked and the problem
persists, Contact your local Lincoln Authorized
Field Service Facility.

If for any reason you do not understand the test procedures or are unable to perform the tests/repairs safely, contact your

Lincoln Authorized Service Facility for technical troubleshooting assistance before you proceed.

WWW.LINCOLNELECTRIC.COM/LOCATOR

E-2

Observe all Safety Guidelines detailed throughout this manual

PROBLEMS

(SYMPTOMS)

Engine shuts down while under a load. 1. High oil temperature

POSSIBLE

CAUSE

TROUBLESHOOTINGFLEET™ 500

RECOMMENDED

COURSE OF ACTION

ngine runs rough.

E

Battery does not stay charged.

Engine alternator trouble light is on while
machine is running.

Engine does not develop full power. Low
weld and auxiliary output. Engine runs
rough.

. Dirty fuel or air filters. Inspect and

1

clean/replace filters as needed. Inspect
and clean/replace filters as needed.

2. Water in fuel. If water found in tank. Empty
fuel tank and refill then purge fuel lines.

3. Fuel injector clogged or malfunctioning.

1. Faulty battery. Replace.

2. Loose connections at battery or alternator.
Clean and tighten connections.

3. Faulty engine alternator or charger
module. Consult authorized Engine Service
Shop.

4. Loose fan belt may need tightening.

1. Fuel filter dirty/clogged. Replace.

2. Air filter dirty/clogged. Replace Air Filter
Element.

3. Fouled fuel injector(s). Contact authorized
Engine Service Shop.

If all recommended possible areas of misad­justment have been checked and the problem
persists, Contact your local Lincoln Authorized
Field Service Facility.

4. Fuel contaminated with water. Check
water separator for water. Clean and
replace as needed. Replace fuel in tank.

5. Cracked or loose fuel hose. Replace hose
and tighten clamps.

6. Valves out of adjustment. Contact
authorized local Engine Service Shop.

If for any reason you do not understand the test procedures or are unable to perform the tests/repairs safely, contact your
Lincoln Authorized Service Facility for technical troubleshooting assistance before you proceed.

WWW.LINCOLNELECTRIC.COM/LOCATOR

E-3

Observe all Safety Guidelines detailed throughout this manual

PROBLEMS

(SYMPTOMS)

Engine does not develop full power. Engine
runs rough.

Engine does not develop full power. Low
weld and auxiliary output. Engine runs
rough.

POSSIBLE

CAUSE

1. Fuel filter clogged, Replace.

2. Air filter clogged, clean or replace.

3. High idle setting incorrect, check and
adjust if required.

4. Valves out of adjustment.

5. Fuel contaminated with water or
sediment. Check fuel pre-filter and empty
of water, bleed fuel system. Replace fuel in
tank if needed.

1. Fuel filter dirty/clogged. Replace.

2. Air filter dirty/clogged. Replace Air Filter
Element.

3. Fouled fuel injector(s). Contact authorized
Engine Service Shop.

4. Fuel contaminated with water. Check
water separator for water. Clean and
replace as needed. Replace fuel in tank.

TROUBLESHOOTINGFLEET™ 500

RECOMMENDED

COURSE OF ACTION

If all recommended possible areas of misad­justment have been checked and the problem
persists, Contact your local Lincoln Authorized
Field Service Facility.

5. Cracked or loose fuel hose. Replace hose
and tighten clamps.

6. Valves out of adjustment. Contact
authorized local Engine Service Shop.

If for any reason you do not understand the test procedures or are unable to perform the tests/repairs safely, contact your
Lincoln Authorized Service Facility for technical troubleshooting assistance before you proceed.

WWW.LINCOLNELECTRIC.COM/LOCATOR

E-4

Observe all Safety Guidelines detailed throughout this manual

PROBLEMS

(SYMPTOMS)

No welding power output. 1. Poor work lead connection to work. Make

sure work clamp is tightly connected to
clean base metal.

2. Faulty PC board or welder alternator.

Welder has output but no control. 1. Poor remote/control cable connection to 6-

pin connector. Check connections.

2. Faulty remote cable Replace if necessary.

3. Faulty control potentiometer or PC board.

No auxiliary power. 1. Open circuit breakers. Reset breakers. If

breakers keep tripping reduce power draw.

2. GFCI may have tripped.

Follow “GFCI Testing and Resetting

Procedure” in the MAINTENANCE section of
this manual.

POSSIBLE

CAUSE

TROUBLESHOOTINGFLEET™ 500

RECOMMENDED

COURSE OF ACTION

3. Faulty connections to auxiliary receptacles.
Check connections.

4. Faulty welder alternator.

The welding arc is “cold.” The welding arc is
not stable or is not satisfactory. the engine
runs normally. The auxiliary power is normal.

No output in PIPE/GOUGE Mode. 1. Poor work lead connection to work. Make

1. Make sure the WELD MODE selector switch
is in the correct position for the process
being used. (For example, PIPE, CC-STICK.)

2. Make sure the electrode (voltage, current
etc.) is correct for the process being used.

3. Check for loose or faulty connections at the
weld output terminals and welding cable
connections.

4. The welding cables may be too long or
coiled, causing an excessive voltage drop.

5. Faulty Control Board.

sure work clamp is tightly connected to
clean base metal.

If all recommended possible areas of misad­justment have been checked and the problem
persists, Contact your local Lincoln Authorized
Field Service Facility.

If for any reason you do not understand the test procedures or are unable to perform the tests/repairs safely, contact your
Lincoln Authorized Service Facility for technical troubleshooting assistance before you proceed.

WWW.LINCOLNELECTRIC.COM/LOCATOR

2. "Weld Mode Selector" switch in wrong
position. Place switch in PIPE/GOUGE mode
and select correct low or high range

3. Faulty PC board or welder alternator.

E-5

DIAGRAMSFLEET™ 500

238A

G7156PRINT

A.03

FLEET 500 (K4338-1) WIRING DIAGRAM

ALTERNATOR

STARTER

SOLENOID

STARTING

MOTOR

5F

239

ENGINE SUPPORT

LEFT SIDE

+

-

12V

BATTERY

COOLANT TEMPERATURE

SENSOR & SWITCH

OIL PRESSURE

SENSOR & SWITCH

RUN/STOP

SWITCH

SWITCH

SWITCH

SHOWN IN "RUN" POSITION

235

238B

CB5

20A

G

241

228

229

5J

WK

FUEL LVL.

SENSOR

SENSOR

SENSOR

238A

231

+

-

POS NEG

ENGINE BLOCK

LEFT SIDE

GND-M

POSITIVE BRUSH

CONNECTED TO SLIP

RING NEAREST TO

THE LAMINATION

5H

200B

201

200A

201A

BRUSH

ROTOR

BRUSH

201

+

-

+

-

232C

FUEL /

HOUR

OIL

PRESSURE

241

228

5L

232B

5M

COOLANT

TEMPERATURE

232K

5K

4

1 4

1

4

1

J53

J52

J51

12VDC INSULATED STUD

ON FRONT PANEL

232C

232A

232M

-

4200MFD

300V

GND-K

D+

D2

12 VOLT GROUND

STUD ON PC BOARD

BRACKET

B3

B2

B1

B6

B5

B4

C9

C8

B8

B7

PCB 1

HEATSINK

300 AMP

MODULE

C10

C11

L1 CHOKE

301

R4

B3

B2

B1

B6

B5 B4

C9

C8

B8

B7

PCB 1

HEATSINK

300 AMP

MODULE

C10

C11

206S

204S

Shunt

1

2

PCB2 WELD CONTROL PC BOARD

L3

9

1

1

6

8

P1 - J1

Amphenol,

Model

Select,

Hot Start

1

6

8

P3-J3

Sense/

Idler/

PWM

14

23

25

L5

1

9

7

1

1

2

6

P2 - J2

Engine &

Battery

Function

9

1

1

6

8

P7 - J7

77

76

75

277

279

218

220

222

Key

Output &

Arc Cont.

Mode

Select

L8

L7

P5 - J5

Voltmeter

P4 - J4

Ammeter

M10

M5

M9

M4

M3

M2

M1

515

1

M10

M5

M9

M4

M3

M2

M1

515

1

M10

M5

M9

M4

M3

M2

M1

515

1

M10

M5

M9

M4

M3

M2

M1

515

1

M6

M10

M5

M9

M4

M3

M2

M1

515

1

M6

M10

M5

M9

M4

M3

M2

M1

515

1

M10

M5

M4

M3

M2

M1

11

M10

M5

M4

M3

M2

M1

11

M10

M5

M4

M3

M2

M1

515

1

M10

M5

M9

M4

M3

M2

M1

515

1

M6

M10

M5

M9

M4

M3

M2

M1

515

1

M4

M5

M6

M9

M10

M3
M2
M1

VOLTS

M6

M4

M5

M6

M9

M10

M10

M5

M9

M4

M3

M2

M1

M3
M2
M1

AMPS

1

0

5

1

6

1

0

5

1

6

1

0

6

P6-J6

25A

23A

23A

25A

25

23

W4 & W5

W2 & W3

W1 & W6

STATOR

WELD

WINDINGS

W6

W6

W1

W1

W4

W5

W4

W5

W3

W3

W2

W2

+

-

W10

W4

W4

W6

W6

W10

L2

CHOKE

W8

W9

W7

W5

W11

14

13

W4A

W4A

W6A

W5A

W11A

W9A

W8A

L4

208B

208B

13

W7A

BYPASS

FILTER

ASSEMBLY

206S

204S

TWISTED PAIR

240V/15A

1 PHASE

(BLUE)

120V/16A

1 PHASE

(YELLOW)

J10

J12

L/+

L/+

235A

232P

232K

278

76A

77A

75A

Key

MODE SWITCH

3A

SILVER

J11

15A

CB2

2

0

A

CB1

NEUTRAL STUD ON AUXILIARY

POWER RECEPTACLE PANEL

5E

GND-D

GND-D

GND-G

GND-G

GND-E

GND-E

LINE

6K

3A

1C

GND-B

A

BCD

E

F

CONTACTOR

GROUND

AMPHENOL 2

77A

76A

75A

REMOTE

CONTROL

LOA

D

HOT

WHITE

GFCI

C

6G

6F

5C

5C

5B

5B

6G

5W

15A

6L

231

229

+

ALT

239

ENG

PROT

232D

234

2

3

5

6

8 7

232A

D1

232M

204C

+

R1

204B

85

30

87A

86

CR1

87

226

232P

232E

START BUTTON

234

5Z

CR3

+

-

COM

NO

235A

235

235

TIMER DELAY

RELAY

232N

5

5A

C

3

3A

247

247

5W

240V/15A

1 PHASE

(BLUE)

J9

L/+

1B

5

5D

15A

11

GND-C

GND-C

STATOR AUXILIARY WINDINGS

302

302

232N

5A

GND-A

5H

5Z

5J

GND-K

CB4

CB3

12 VOLT

GROUND STUD

ON LOWER

FRONT PANEL

GND-A

5K

GND-B

5M

5T

5T

12 VOLT GROUND

STUD BY GAUGES

232E

232H

236B

208

206

GND-M

5L

ELECTRICAL SYMBOLS PER E1537

ALL CASEFRONT COMPONENTS SHOWN

VIEWED FROM REAR

5S

232B

CHOPPER

THERMAL

LIGHT

294

295

(SILVER)

294

295

250A

250

250A

250B

CHOPPER B

CHOPPER A

250

250B

236A

PIPE/GOUGE

4

3

1

5

2

JP2

222

TIG

6

220

JP1

4

3

1

5

2

6

ARC CONTROL

278

279

CCW

R2

277

R1

76

77

CCW

OUTPUT CONT. POT

75

JP2

218

217

RANGE SELECT SWITCH

217

+

RED

BLK

2 3

SHUTDOWN

SOLENOID

P54

J54

226

5S

JP1

RECTIFIER BRIDGE

JP3

G-1

NOTE: This diagram is for reference only. It may not be accurate for all machines covered by this manual. The specific diagram for a particular code is included

with the machine. If the diagram is illegible, write to the Service Department for a replacement. Give the equipment code number.

DIAGRAMSFLEET™ 500

NOTE:

N.A. CENTER OF GRAVITY WITH OIL IN ENGINE AND EMPTY FUEL TANK.

36.91

937.6

39.91

1013.7

1.34

34.2

22.50

571.5

45.96

1167.4

65.00

1651

30.00

762.1

59.50

1511.3

28.82

732.1

27.00

685.8

N.A.

33.50

850.9

33.75

857.2

9.76

247.9

7.15

181.7

12.75

323.8

G-2

R

ELECTRIC

SHOCK

CAN KILL

WARNING

Do not operate with covers removed

Disconnect input power before servicing

Do not touch electrically live parts

Only qualified persons should install,
u

se or service this equipment

1. TURN OFF THE ENGINE AND DISCONNECT THE NEGATIVE BATTERY CABLE.

2. REMOVE THE SCREWS THAT SECURE THE UPPER CONTROL PANEL AND
OPEN THE PANEL.

3. WHILE HOLDING THE RCD MOUNTING BRACKET REMOVE THE TWO SCREWS
SECURING THE COVER PLATE AND RCD MOUNTING BRACKET. SET THE RCD
MOUNTING BRACKET AND SCREWS ASIDE AND DISCARD COVER PLATE.
(SEE FIGURE 1).

INSTRUCTIONS FOR INSTALLING A RESIDUAL CURRENT DEVICE

TO PROTECT THE 240V SINGLE PHASE RECEPTACLE

LOWER CONTROL
PANEL

FIGURE 1

RCD MOUNTING
BRACKET

COVER PLATE

DIAGRAMSFLEET™ 500

G-3

DIAGRAMSFLEET™ 500

Sales and Service through Subsidiaries and Distributors Worldwide

Cleveland, Ohio 44117-1199 U.S.A.

R

THE LINCOLN ELECTRIC COMPANY

World's Leader in Welding and Cutting Products

M25504

A.01

M

4. LOCATE LEADS 5D, 5E & C (SEE FIGURE 2). CUT LEADS AT DISTANCES GIVEN
BELOW. STRIP ALL ENDS OF CUT LEADS 13MM (.50 in.)

5. CONNECT LEADS 5D & 5E FROM THE 240V EURO RECEPTACLES TO RCD (N – ON

TOP) AS SHOWN & TIGHTEN LEADS TO 2.4NM (21 in-lb). (SEE FIGURE 3).

6. CONNECT 4” “C” LEAD FROM CIRCUIT BREAKER TO RCD (1)

7. CONNECT ORIGINAL “C” LEAD (FROM STATOR) TO RCD (2)

8. CONNECT LEADS 5D & 5E CUT LEADS FROM NEUTRAL STUD TO RCD (N -

BOTTOM)

9. COAT AREA WHERE LEADS CONNECT TO RCD WITH A SILICONE RUBBER RTV

SEALANT.

10. MOUNT RCD & PROTECTIVE BOOT TO PANEL USING MOUNTING BRACKET &

SCREWS SET ASIDE IN STEP 3.

11. CHECK WIRING PER FIG.4

11. SECURE UPPER CONTROL PANEL IN PLACE.

12. RECONNECT NEGATIVE BATTERY CABLE.
THE UNIT IS NOW READY FOR OPERATION

I

CIRCUIT
BREAKER

L

FIGURE 2

FIGURE 3

R

RCD

240V EURO RECEPTACLES

240V EURO
RECEPTACLE

REAR VIEW

FRONT VIEW

PROTECTIVE
BOOT

NEUTRAL STUD

5D

5

E

RCD OPENING

C

N

N12

5D

5E

5D & 5E LEAD ENDS
TO BE TWISTED TOGETHER
BEFORE INSERTING INTO RCD

5D

5

E

5D & 5E LEAD ENDS
TO BE TWISTED TOGETHER
BEFORE INSERTING INTO RCD

STATOR WINDING

STATOR WINDING LEAD

CUT C LEAD 4"
FROM .25 QUICK
CONNECT TERMINAL

CUT LEAD 5D
8" FROM EURO PLUG

CUT LEAD 5E - 8" FROM EURO PLUG

C

C

NEUTRAL
STUD

G-4

DIAGRAMSFLEET™ 500

240V/15A

1 PHASE

(BLUE)

120V/16A

1 PHASE

(YELLOW)

J10

J12

L/+

SILVER

J11

15A

CB2

2

0

A

CB1

NEUTRAL STUD ON AUXILIARY

POWER RECEPTACLE PANEL

GND-G

GND-G

GND-E

GND-E

LINE

6K

LOA

D

HOT

WHITE

GFCI

6G

6F

5C

5B

5B

6G

5W

6L

5W

5

STATOR AUXILIARY WINDINGS

5A

RCD

N

1

N

2

5D

5D

5E

5E

TWIST LEADS 5D & 5E

BEFORE INSERT INTO

RCD - N POSITION

240V/15A

1 PHASE

(BLUE)

J9

L/+

1B

15A

CB4

L/+

1C

15A

CB3

5C

GND-C

GND-D

5D

5D

5E

5E

11

C

C

C

5

5A

3

3A

RCD WIRING CONNECTION DIAGRAM - FIG. 4

G-5

WARNING

panish

S

AVISO DE

PRECAUCION

French

ATTENTION

erman

G

WARNUNG

Portuguese

ATENÇÃO

Japanese

Chinese

l Do not touch electrically live parts or

electrode with skin or wet clothing.

l Insulate yourself from work and

ground.

l

No toque las partes o los electrodos
bajo carga con la piel o ropa moja­da.

l

Aislese del trabajo y de la tierra.

l

Ne laissez ni la peau ni des vête­ments mouillés entrer en contact
avec des pièces sous tension.

l Isolez-vous du travail et de la terre.

l

Berühren Sie keine stromführenden
Teile oder Elektroden mit Ihrem
Körper oder feuchter Kleidung!

l Isolieren Sie sich von den

Elektroden und dem Erdboden!

l Não toque partes elétricas e elec-

trodos com a pele ou roupa molha­da.

l

Isole-se da peça e terra.

l Keep flammable materials away.

l

Mantenga el material combustible
fuera del área de trabajo.

l Gardez à l’écart de tout matériel

inflammable.

l Entfernen Sie brennbarres Material!

l

Mantenha inflamáveis bem guarda­dos.

l Wear eye, ear and body protection.

l

Protéjase los ojos, los oídos y el
cuerpo.

l Protégez vos yeux, vos oreilles et

votre corps.

l Tragen Sie Augen-, Ohren- und Kör-

perschutz!

l

Use proteção para a vista, ouvido e
corpo.

Korean

Arabic

READ AND UNDERSTAND THE MANUFACTURER’S INSTRUCTION FOR THIS EQUIPMENT AND THE CONSUMABLES TO BE
USED AND FOLLOW YOUR EMPLOYER’S SAFETY PRACTICES.

SE RECOMIENDA LEER Y ENTENDER LAS INSTRUCCIONES DEL FABRICANTE PARA EL USO DE ESTE EQUIPO Y LOS
CONSUMIBLES QUE VA A UTILIZAR, SIGA LAS MEDIDAS DE SEGURIDAD DE SU SUPERVISOR.

LISEZ ET COMPRENEZ LES INSTRUCTIONS DU FABRICANT EN CE QUI REGARDE CET EQUIPMENT ET LES PRODUITS A
ETRE EMPLOYES ET SUIVEZ LES PROCEDURES DE SECURITE DE VOTRE EMPLOYEUR.

LESEN SIE UND BEFOLGEN SIE DIE BETRIEBSANLEITUNG DER ANLAGE UND DEN ELEKTRODENEINSATZ DES HER­STELLERS. DIE UNFALLVERHÜTUNGSVORSCHRIFTEN DES ARBEITGEBERS SIND EBENFALLS ZU BEACHTEN.

l Keep your head out of fumes.
l Use ventilation or exhaust to

remove fumes from breathing zone.

l Los humos fuera de la zona de res-

piración.

l

Mantenga la cabeza fuera de los
humos. Utilice ventilación o
aspiración para gases.

l

Gardez la tête à l’écart des fumées.

l

Utilisez un ventilateur ou un aspira­teur pour ôter les fumées des zones
de travail.

l Turn power off before servicing.

l

Desconectar el cable de ali­mentación de poder de la máquina
antes de iniciar cualquier servicio.

l

Débranchez le courant avant l’entre­tien.

l Do not operate with panel open or

guards off.

l

No operar con panel abierto o
guardas quitadas.

l N’opérez pas avec les panneaux

ouverts ou avec les dispositifs de
protection enlevés.

WARNING

panish

S

AVISO DE

PRECAUCION

French

ATTENTION

l Vermeiden Sie das Einatmen von

Schweibrauch!

l

Sorgen Sie für gute Be- und
Entlüftung des Arbeitsplatzes!

l Mantenha seu rosto da fumaça.
l Use ventilação e exhaustão para

remover fumo da zona respiratória.

l Strom vor Wartungsarbeiten

abschalten! (Netzstrom völlig öff­nen; Maschine anhalten!)

l Não opere com as tampas removidas.
l

Desligue a corrente antes de fazer
serviço.

l

Não toque as partes elétricas nuas.

l Anlage nie ohne Schutzgehäuse

oder Innenschutzverkleidung in
Betrieb setzen!

l

Mantenha-se afastado das partes
moventes.

l Não opere com os paineis abertos

ou guardas removidas.

erman

G

WARNUNG

Portuguese

ATENÇÃO

Japanese

Chinese

Korean

Arabic

LEIA E COMPREENDA AS INSTRUÇÕES DO FABRICANTE PARA ESTE EQUIPAMENTO E AS PARTES DE USO, E SIGA AS
PRÁTICAS DE SEGURANÇA DO EMPREGADOR.

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,

urchasers may ask Lincoln Electric for advice or information

p
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 these types of fabrication
methods and service requirements.

Subject to Change – This information is accurate to the best of our
knowledge at the time of printing. Please refer to
www.lincolnelectric.com for any updated information.

TABLE OF CONTENTS
INSTALLATION
OPERATION
ACCESSORIES
MAINTENANCE
TROUBLESHOOTING
DIAGRAMS