Lincoln Electric VANTAGE 500 (CE) IM894-B Operator'S Manual Download Page 10

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TABLE OF CONTENTS

Maintenance......................................................................................................Section D

Safety Precautions ................................................................................................D-1

Routine Maintenance ............................................................................................D-1

Engine Service Items.............................................................................................D-1

Engine Oil Change ..........................................................................................D-2

Engine Oil Filter Change .................................................................................D-2

Air Cleaner .....................................................................................................D-2

Service Instructions And Installation Tips for Engine Air Filter .......................D-3

Cooling System .....................................................................................................D-4

Fan Belt...........................................................................................................D-4

Fuel .................................................................................................................D-4

Bleeding the Fuel System ...............................................................................D-4

Fuel Filter ........................................................................................................D-5

Engine Adjustment ..........................................................................................D-5

Battery Maintenance .......................................................................................D-5

Servicing Optional Spark Arrestor ...................................................................D-5

Welder / Generator Maintenance ........................................................................D-6

Storage ...........................................................................................................D-6

Cleaning ..........................................................................................................D-6

Brush Removal and Replacement ..................................................................D-6

________________________________________________________________________

Troubleshooting ..............................................................................................Section E

How to Use Troubleshooting Guide.......................................................................E-1

Troubleshooting Guide.............................................................................E-2 thru E-6

________________________________________________________________________

Connection Diagrams, Wiring Diagrams and Dimension Print ...................Section F

________________________________________________________________________

Parts List .................................................................................................................P-535

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Summary of Contents for VANTAGE 500 (CE) IM894-B

Page 1: ...S MANUAL AND THE SAFE TY PRECAUTIONS CONTAINED THROUGHOUT And most importantly think before you act and be careful For use with machines having Code Numbers Equipped with VRD VOLTAGE REDUCTION DEVICE See Installation and Operation sections for an explanation 11298 11299 11524 11525 11574 11575 Sales and Service through Subsidiaries and Distributors Worldwide Cleveland Ohio 44117 1199 U S A TEL 216...

Page 2: ...R 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 availa...

Page 3: ...ever simultaneously touch electrically hot parts of electrode holders connected to two welders because voltage between the 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 3 j Also see Items 6 c and 8 ii SAFETY ii FUMES AND GASES can be dangerous 5 a Welding may produce fumes...

Page 4: ...s 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 touchin...

Page 5: ...propriés et non inflammables 4 Des gouttes de laitier en fusion sont émises de l arc de soudage Se protéger avec des vêtements de protection libres de l huile tels que les gants en cuir chemise épaisse pan talons sans revers et chaussures montantes 5 Toujours porter des lunettes de sécurité dans la zone de soudage Utiliser des lunettes avec écrans lateraux dans les zones où l on pique le laitier 6...

Page 6: ...ecially important when identifying the correct replacement parts On Line Product Registration Register your machine with Lincoln Electric either via fax or over the Internet For faxing Complete the form on the back of the warranty statement included in the literature packet accompanying this machine and fax the form per the instructions printed on it For On Line Registration Go to our WEB SITE at ...

Page 7: ...ation with the technical assistance of the manufacturer In some cases this remedial action may be as simple as earthing grounding the welding circuit see Note In other cases it could involve construction of an electromagnetic screen enclosing the power source and the work complete with associated input filters In all cases electromagnetic disturbances must be reduced to the point where they are no...

Page 8: ...uation with the technical assistance of the manufacturer In some cases this remedial action may be as simple as earthing grounding the welding circuit see Note In other cases it could involve construction of an electromagnetic screen enclosing the power source and the work complete with associated input filters In all cases electromagnetic disturbances must be reduced to the point where they are n...

Page 9: ... Lincoln Electric Wire Feeders A 7 A 8 ________________________________________________________________________________ Operation Section B Safety Precautions B 1 General Description B 1 For Auxiliary Power B 1 Engine Operation B 1 Add Fuel B 1 Break in Period B 1 Welder Controls B 2 B 3 Engine Controls B 4 Fuel Consumption B 4 Starting and Stopping the Engine B 4 B 5 Welding Operation B 5 Duty Cy...

Page 10: ...ng Optional Spark Arrestor D 5 Welder Generator Maintenance D 6 Storage D 6 Cleaning D 6 Brush Removal and Replacement D 6 ________________________________________________________________________ Troubleshooting Section E How to Use Troubleshooting Guide E 1 Troubleshooting Guide E 2 thru E 6 ________________________________________________________________________ Connection Diagrams Wiring Diagra...

Page 11: ...ronic with Full Flow Filter system Electric shutoff solenoid Indirect fuel injector AIR CLEANER ENGINE IDLER MUFFLER ENGINE PROTECTION Low noise Muffler Shutdown on low oil Single Element Automatic Idler Top outlet can be rotated pressure high engine Made from long life aluminized steel coolant temperature ENGINE WARRANTY 2 years 2000 hours all non electric components 3 years major non electric co...

Page 12: ...kers 400V 3 Ph x 1 230V 1 Ph x 1 115V x 1 5 14 Pin Connector 6 Pin Connector 4 pole 25Amp 30mA trip current 3 Phase 25 Amp x 1 1 phase 15 Amp x 1 for 230V 30 Amp x 2 for 115V 400V 3 Ph x 1 230V 1 Ph x 2 14 Pin Connector 6 Pin Connector 4 pole 25Amp 30mA trip current 3 Phase 25 Amp x 1 1 phase 15 Amp x 2 10A for Engine Battery Charging Circuit 10A for Wire Feeder Power 5 Center Tapped to ground ...

Page 13: ...sibility of other safety issues such as heat generated damage burns and fires The machine is shipped with the VRD switch in the Off position To turn it On or Off Turn the engine Off Disconnect the negative battery cable Lower the control panel by removing 4 front panel screws See Figure A 1 Place the VRD switch in the On or Off position See Figure A 1 With the VRD switch in the On position the VRD...

Page 14: ...t 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 sp...

Page 15: ... VANTAGE 500 CE A 5 MUFFLER OUTLET PIPE 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 Tighten using a 9 16 14mm socket or wrench 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 cert...

Page 16: ...ding stud marked with the symbol is provided on the front of the welder WELDING TERMINALS The VANTAGE 500 CE is equipped with a toggle switch for selecting hot welding terminal when in the WELD TERMINALS ON position or cold welding terminal when in the REMOTELY CONTROLLED position WARNING WELDING OUTPUT CABLES With the engine off connect the electrode and work cables to the output studs The weldin...

Page 17: ...cess started When welding is stopped the engine will revert to low idle speed after approximately 12 seconds unless welding is resumed A 7 INSTALLATION VANTAGE 500 CE A 7 AUXILIARY POWER The auxiliary power capacity is 16 500 watts Peak 14 500 Watts Continuous of 50 Hz three phase power The auxiliary power capacity rating in watts is equivalent to volt amperes at unity power factor The max permiss...

Page 18: ... end of the lead This is a control lead to supply current to the wire feeder motor it does not carry welding current 4 Set the MODE switch to the CV WIRE position 5 Set the WELD TERMINALS switch to WELD TERMINALS ON 6 Set the ARC CONTROL knob to 0 initially and adjust to suit 7 Set the IDLE switch to the AUTO position When not welding the VANTAGE 500 CE engine will be at the low idle speed If you ...

Page 19: ...DLER control 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...

Page 20: ...mps the current range on the REMOTE CONTROL will be 40 200 amps rather than the full 40 300 amps Any current range that is less than the full range provides finer current resolution for more fine tun ing 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 Amptro...

Page 21: ...e output is electrically hot all the time In the REMOTELY CONTROLLED position the output is controlled by a wire feeder or amptrol device and is electrically off until a remote switch is depressed 10 WIRE FEEDER VOLTMETER SWITCH Matches the polarity of the wire feeder voltmeter to the polarity of the electrode 11 VRD Voltage Reduction Device INDICATOR LIGHTS On the front panel of the VANTAGE 500 C...

Page 22: ... 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 posi tion to reset the engine protection system and light 19 BATTERY CHARGING LIGHT A warning indica tor light for Low No battery charge The light is off when the systems are functioning p...

Page 23: ...ve is located on the fuel pre filter CAUTION The ARC CONTROL 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 pre vents sticking of the electrode to the plate while welding This can also increase spatter It is recommended that the ARC CONTROL be set to the mini...

Page 24: ...With the VRD switch in the ON position there is no output in the DOWNHILL PIPE mode For indicator light operation see table B 1 TIG WELDING The TOUCH START TIG setting of the 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 the...

Page 25: ...ference in operation with the VRD On or Off for this mode For indicator light oper ation see table B 1 WIRE WELDING CV Connect a wire feeder to the VANTAGE 500 CE according to the instructions in INSTALLATION INSTRUCTIONS Section The VANTAGE 500 CE in the CV WIRE mode permits it to be used with a broad range of flux cored wire Innershield and Outershield electrodes and solid wires for MIG welding ...

Page 26: ...g spools K1870 1 LN 15 Across the Arc Wire Feeder Portable lightweight compact CC CV unit for flux cored and MIG welding Includes Gas Solenoid adjustable flow meter and internal contactor For 10 15 lb 4 5 6 8kg spools Magnum Gun and Magnum Gun Connector Kit are required for gas shielded welding Innershield Gun is required for gasless welding K126 2 Magnum 350 Innershield Gun K1802 1 Magnum 300 MIG...

Page 27: ...r See Operating Manual Parts List WARNING 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 Routine Maintenan...

Page 28: ...the oil container to be sure it includes the letters indicated Note An S grade 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 classifi cations SAE 10W30 is recommended for general all tempera ture use 5F to 104F 15C to 40C See engine owner s manual for more specific informa tion on oil viscosity recommendations OIL FILT...

Page 29: ...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 an...

Page 30: ...he fan belt and radiator hoses Replace if signs of deterioration are found TIGHTENING THE FAN BELT If the fan belt is loose the engine can overheat and the battery lose its charge Check tightness by press ing on the belt midway between the pulleys It should deflect about 25 in 6 4 mm under a load of 20 lbs 9 Kg FUEL At the end of each day s use refill the fuel tank to min imize moisture condensati...

Page 31: ...to the machine can result if operated at speeds above maximum CLEANING THE BATTERY Keep the battery clean by wiping it with a damp cloth when dirty If the terminals appear corroded discon nect 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 tha...

Page 32: ...p rings to wear and darken slightly Inspect the brushes when a generator over haul is necessary 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 equip ment may result in danger to the technician and machine operator and will invalidate your factory...

Page 33: ...BLE 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 Author...

Page 34: ...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 4 High coolant temperature or low oil pressure indictor lights lit Check oil and coolant levels Fill if required Check for loose or bro ken fan belt 5 Faulty fuel shutdown solenoid Check that shutdown solenoid is functioning properly...

Page 35: ... sides of base and exhaust end case back 1 Dirty fuel or air filters Inspect and 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 1 Faulty battery Replace 2 Loose connections at battery or alternator Clean and tighten con nections 3 Faulty engine alternator or charg er module Consult ...

Page 36: ...nkage or broken spring 2 Faulty PC board Control or Idler 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 Broken spring on Idle Solenoid solenoid linkage bindi...

Page 37: ... Weld Terminals On position when welding without control cable 3 Faulty PC board or welder alterna tor 1 Poor remote control cable connec tion to 6 pin or 14 pin connector Check connections 2 Faulty remote cable or faulty wire feeder or wire feeder cable Replace if necessary 3 Faulty control potentiometer or PC board 1 Wire Feeder Power circuit breaker open Check 42V beaker and reset if tripped 2 ...

Page 38: ...ure the electrode wire gas voltage current etc is correct for the process being used 3 Check for loose or faulty connec tions 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 1 Make sure VRD ON OFF toggle switch is in the OFF position 2 Poor work lead connection to work Make sure work ...

Page 39: ...F 1 DIAGRAMS F 1 VANTAGE 500 CE ...

Page 40: ...F 2 DIAGRAMS F 2 VANTAGE 500 CE ...

Page 41: ...F 3 DIAGRAMS F 3 VANTAGE 500 CE ...

Page 42: ...F 4 DIAGRAMS F 4 VANTAGE 500 CE ...

Page 43: ...or 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 ...

Page 44: ...or 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 ...

Page 45: ...85 8 5 75 146 0 35 94 913 0 24 00 609 6 39 41 1001 20 60 523 3 28 95 735 3 36 06 915 9 30 81 782 6 60 00 1524 0 16 75 425 4 N A N A CENTER OF GRAVITY WITH OIL IN ENGINE COOLANT IN RADIATOR AND EMPTY FUEL TANK 1 27 32 3 46 47 1180 36 6 03 153 25 62 59 1589 8 1 73 43 95 ...

Page 46: ...NOTES VANTAGE 500 CE ...

Page 47: ...NOTES VANTAGE 500 CE ...

Page 48: ...electrically live parts or electrode with skin or wet clothing Insulate yourself from work and ground No toque las partes o los electrodos bajo carga con la piel o ropa moja da Aislese del trabajo y de la tierra Ne laissez ni la peau ni des vête ments mouillés entrer en contact avec des pièces sous tension Isolez vous du travail et de la terre Berühren Sie keine stromführenden Teile oder Elektrode...

Page 49: ...gute Be und Entlüftung des Arbeitsplatzes Mantenha seu rosto da fumaça Use ventilação e exhaustão para remover fumo da zona respiratória Turn power off before servicing Desconectar el cable de ali mentación de poder de la máquina antes de iniciar cualquier servicio Débranchez le courant avant l entre tien Strom vor Wartungsarbeiten abschalten Netzstrom völlig öff nen Maschine anhalten Não opere co...

Page 50: ...s and Service through Subsidiaries and Distributors Worldwide Cleveland Ohio 44117 1199 U S A TEL 216 481 8100 FAX 216 486 1751 WEB SITE www lincolnelectric com World s Leader in Welding and Cutting Products ...

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