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.
Need Help? Call 1.888.935.3877
to talk to a Service Representative
Hours of Operation:
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no later than the following business day.
For Service outside the USA:
Email: globalservice@lincolnelectric.com
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
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