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Operator’s Manual

Vantage

441X

/LE500X

www.lincolnelectric.com/register

Authorized Service and Distributor Locator:

www.lincolnelectric.com/locator

IM10528

Issue

D ate

May

- 2

For use with machines having Code Numbers:

12883, 1289

, 13195, 13196

Need Help? Call 1.888.935.3877

to talk to a Service Representative

Hours of Operation:

8:00 AM to 6:00 PM (ET) Mon. thru Fri.

After hours?

Use “Ask the Experts” at lincolnelectric.com
A Lincoln Service Representative will contact you
no later than the following business day.

For Service outside the USA:

Email: [email protected]

Save for future reference

Date Purchased

Code: (ex: 10859)

Serial: (ex: U1060512345)

Содержание Vantage 441X/LE500X

Страница 1: ...s having Code Numbers 12883 12890 13195 13196 Need Help Call 1 888 935 3877 to talk to a Service Representative Hours of Operation 8 00 AM to 6 00 PM ET Mon thru Fri After hours Use Ask the Experts at lincolnelectric com A Lincoln Service Representative will contact you no later than the following business day For Service outside the USA Email globalservice lincolnelectric com Save for future refe...

Страница 2: ...N 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 develop 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...

Страница 3: ... 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 their removal is complete Always use the greatest care when working near moving parts 1 f Do not put your hands near the engine fan ...

Страница 4: ...m 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 an...

Страница 5: ...ent 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 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...

Страница 6: ...TANDBY POWER CONNECTIONS A 7 WELDING OUTPUT CABLES A 8 PULSE WELDING A 8 CABLE INSTALLATION A 8 CABLE INDUCTANCE AND ITS EFFECTS ON WELDING A 9 CONTROL CABLE CONNECTIONS A 9 CROSSLINC TECHNOLOGY A 9 REMOTE CONTROL CONNECTIONS A 10 WELDING TERMINALS A 10 ACCESSORY CONNECTION DIAGRAMS A 11 CROSSLINC SETUP CV A 12 CROSSLINC SETUP CC A 12 DUAL ARC SETUP A 13 TIG MODULE A 14 SPOOL GUN MODULE A 14 OPERA...

Страница 7: ... POWER SOURCES C 2 MAINTENANCE SECTION D ROUTINE AND PERIODIC MAINTENANCE D 1 ENGINE MAINTENANCE D 2 AIR FILTER D 2 FUEL FILTERS D 4 COOLING SYSTEM D 4 CHECKING AND REPLACING COOLANT D 4 BATTERY HANDLING D 5 ENGINE OIL CHANGE D 5 TIGHTENING THE FAN BELT D 6 NAMEPLATES WARNING DECALS MAINTENANCE D 6 STORAGE D 6 GFCI MAINTENANCE D 7 TROUBLESHOOTING SECTION E WIRING CONNECTION DIAGRAMS AND DIMENSION ...

Страница 8: ...c Shock Welder Output Auto Idle Fire or explosion Voltage Output High Idle Battery explosion Amperage Output Start Battery acid A Welding Amperage Glow Plug Ur Reduced Open Circuit Voltage V Welding Voltage Protective Ground U0 Open Circuit Voltage CrossLinc Circuit Breaker I2 Output Current Status Indicator Wire Feeder U2 Output Voltage Mode Select Receptacle X Duty Cycle SMAW welding Positive Ou...

Страница 9: ...ocharged Water Cooled Diesel Engine Speed RPM Displacement High Idle 1800 Low Idle 1500 Full Load 134 cu in 2 2L Bore x Stroke 3 30 x 3 90 84mm x 100mm Starting System Capacities 12 VDC Battery and Starter with Automatic Glow Plugs Fuel 20 US gal 75 7L Oil 2 50 US gal 9 5L Cooling System 2 55 US gal 9 7L Battery Size BCI Group Size 34 800 Cold Crank Amps RATED OUTPUT 104 F 40 C WELDER Duty Cycle W...

Страница 10: ...ese guidelines may result in an overtemp condition resulting in engine shut down DO NOT MOUNT OVER COMBUSTIBLE SURFACES Where there is a combustible surface directly under stationary or fixed electrical equipment that surface should be covered with a steel plate at least 06 1 6mm thick which should extend not less than 5 90 150mm beyond the equipment on all sides WARNING WARNING WARNING VRD VOLTAG...

Страница 11: ...ate lifting capacity Be sure machine is stable when lifting Do not lift this machine using lift bale if it is equipped with a heavy accessory such as trailer or gas cylinder Do not lift machine if lift bale is damaged Do not operate machine while suspended from lift bale HIGH ALTITUDE OPERATION At higher altitudes output derating may be necessary For maximum rating derate the welder output in acco...

Страница 12: ...low vehicle manufacturer s instructions Do not install equipment where air flow is restricted Equipment or the engine may overheat Do not weld on the base Welding on the base may cause fuel tank explosion or fire Always ground the equipment frame to the vehicle frame to prevent electric shock and static electricity hazards Do not place propane or shielding gas tanks near hot air or exhaust PRE OPE...

Страница 13: ...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 IMPORTANT To prevent ELECTRICAL DAMAGE WHEN a Installing new batteries b Using a booster Use correct polarity Negative Ground EXHAUST OUTLET PIPE Remove cap from DOC pipe protrudin...

Страница 14: ...he auxiliary power capacity is 11 000 watts continuous of 60 Hz single phase power The auxiliary power capacity rating in watts is equivalent to volt amperes at unity power factor The 240 VAC output can be split to provide two separate 120 VAC outputs with a max permissible current of 50 amps per output to two separate 120 VAC branch circuits NOTE These circuits are opposite polarities and cannot ...

Страница 15: ... load for each leg of the 240 VAC auxiliary is 50 amps Loading above the rated output will reduce output voltage below the allowable 10 of rated voltage which may damage appliances or other motor driven equipment and may result in overheating of the engine and or alternate windings 3 Install a 50 amp 120 240 VAC plug NEMA Type 14 50P to the double pole circuit breaker using No 6 4 conductor cable ...

Страница 16: ... the electrode holder and work cables to the weld output 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 Loose connections will cause the output terminals to overheat The terminals may eventually m...

Страница 17: ...00X to the wire feeder The control cable consists of two power leads one twisted pair for digital communication and one lead for voltage sensing The 5 pin ArcLink connection on the Vantage 441X LE500X is located on control panel The control cable is keyed and polarized to prevent improper connection Best results will be obtained when control cables are routed separate from the weld cables especial...

Страница 18: ...the preset arc current is set through the 12 pin connector The remote input sets the arc current preset over the full range from minimum to maximum The left digital output display will show the maximum setting for the arc current preset range as set by the OUTPUT CONTROL knob CONSTANT VOLTAGE WELD MODES For operation with a control cable wire feeder With the CV WIRE weld mode selector switch posit...

Страница 19: ...ions on the Vantage 441X LE500X will be dependent on the type of accessory chosen Reference Table A 4 and Figure A 6 for guidance on how to properly set up each accessory WARNING FIGURE A 6 ACCESSORY WELD MODE SWITCH WELD TERMINALS SWITCH LOCAL REMOTE SWITCH 115 42VAC SWITCH CrossLinc Feeder CV ON REMOTE N A CrossLinc Remote Stick Tig Gouging ON REMOTE N A Across The Arc Feeder Non CrossLinc CV ON...

Страница 20: ...ft 15 3 m K2485 3 Adapter Lug to Tweco Style Receptacle Adapter K2487 1 Item Desc K Machine Vantage 441X K4535 1 Remote CrossLinc Remote K4345 1 Weld Power Weld Cable Tweco Plug Receptacle 3 0 600A 60 50 ft 15 3 m K2485 3 Weld Power Cable Weld Cable Tweco Male Open End 3 0 600A 60 10 ft 3 m K2483 3 Electrode Holder EH 405HD Electrode Holder 400A 60 Duty Cycle K909 8 Adapter Lug to Tweco Style Rece...

Страница 21: ... 15 ft 1 16 5 64 K126 12 Work Cable Weld Power Cable Lug to Lug 3 0 600A 60 35 ft 10 6 m K1842 35 Work Clamp GC 500 Work Clamp 500A 60 Duty Cycle K910 2 Weld Power Cable Weld Cable Tweco Plug Receptacle 3 0 600A 60 50 ft 15 3 m K2485 3 Adapter Lug to Tweco Style Receptacle Adapter K2487 1 Machine Invertec V275 S K2269 1 VANTAGE 441X LE500X Machine LE500X K5174 1 ...

Страница 22: ...Control Cable 9 14 Pin Cable K936 1 Torch PTA 26 25 ft K1783 4 Foot Pedal Foot Amptrol 25 ft K870 Electrode Cable Power Source to Module Weld Power Cable Lug to Lug 3 0 600A 60 10 ft 3 m K1842 10 Work Cable Power Source to Module Weld Power Cable Lug to Lug 3 0 600A 60 10 ft 3 m K1842 10 Work Lead Work Lead Lug GC500 Ground Clamp 2 0 350A 60 15 ft 15 3 m K2150 10 Adapter Lug to Tweco Style Recepta...

Страница 23: ... Always operate the welder with the sliding door closed and the side panels in place as these provide maximum protection from moving parts and insure proper cooling air flow RECOMMENDED APPLICATIONS WELDER The Vantage 441X LE500X provides excellent constant current DC welding output for stick SMAW and TIG GTAW weld ing The Vantage 441X LE500X also provides excellent constant voltage DC welding out...

Страница 24: ...vel on the dipstick Add oil if necessary to bring the level up to the full mark Do not overfill Close engine door Check radiator for proper coolant level Fill if necessary See Engine Owner s Manual for specific oil and coolant recommendations STARTING THE ENGINE 1 Remove all plugs connected to the AC power receptacles 2 Set RUN STOP IDLE switch to AUTO IDLE RUN position 3 Press START GLOW PLUG swi...

Страница 25: ... voltage are white They will turn red when outside normal operating ranges 2 DIGITAL OUTPUT METERS The digital meters allow the preset arc output voltage CV WIRE mode or preset arc current CC STICK DOWNHILL PIPE ARC GOUGING and TIG modes to be set prior to welding using the OUTPUT CONTROL dial During welding the meters will display the actual output voltage VOLTS and current AMPS A memory feature ...

Страница 26: ...e when the electrode short circuits to the work Increasing the pinch from 10 to 10 may reduce spatter while decreasing the pinch will make the puddle more fluid resulting in a flatter and smoother weld bead 7 WELD MODE SELECTOR SWITCH Provides six selectable welding modes CV WIRE DOWNHILL PIPE CC STICK TOUCH START TIG ARC GOUGING ARCLINK 8 42V 120V WIRE FEEDER VOLTAGE SWITCH Toggles output of 14 p...

Страница 27: ...OCV to less than 30V During welding the red light will illuminate whenever the arc voltage is equal to or greater than 30V This means that the red and green light may alternate depending on the weld voltage This is normal operation If the red light remains illuminated or both VRD lights flash when not welding the VRD is not functioning properly Please refer to your local field service shop for ser...

Страница 28: ...hops to connect and troubleshoot engine error codes found on the firewall inside the machine Figure B 4 FIGURE B 4 FIGURE B 5 LED CONDITION DEFINITION Steady Green System is communicating normally Blinking Green Occurs during a reset and indicates the power source is identifying each component in the system This is normal for up to 15 seconds after power up or if the system configuration is change...

Страница 29: ...ure B 7 FC gS Figure B 8 or MIG Figure B 9 This setting will be stored in system memory and will be remembered between machine power cycles This setting will only be visible if the process selection switch is in the CV Wire position FIGURE B 7 FIGURE B 8 FIGURE B 9 REMOTE CONNECTOR SELECTION FOR STICK AND DOWNHILL PIPE MODES Select between the 12 pin or 14 pin connector for remote poten tiometer i...

Страница 30: ...ting of 5 on the display 0 at the attribute The work point values will all be reset to the minimum from the weld table for each respective weld mode The alternate CV mode selection will revert back to the Flux Cored Arc Welding Self Shielding FCAW SS setting The remote pot connector choice will revert back to the 12 pin connector When the reset occurs the left display will show deF and the right d...

Страница 31: ...e different configuration options your system may not have all of the following adjustments See ACCESSORIES section for kits and options available to use with the Vantage 441X LE500X visit lincolnelectric com or contact your local Lincoln Electric sales representatives 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 repres...

Страница 32: ...ng applications The TOUCH START TIG setting of the MODE switch is for DC TIG welding To initiate a weld the OUTPUT CONTROL knob 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 this avoids tungsten conta mination Then the tungsten is gently lifted off the work in a ro...

Страница 33: ... 11 15 6 7 8 3 2 1 8 250 400 25 40 7 11 15 23 5 7 11 15 4 0 5 32 400 500 40 55 10 12 21 25 6 8 13 17 8 10 4 8 3 16 500 750 55 80 11 13 23 27 8 10 18 22 6 4 1 4 750 1000 80 125 13 15 28 32 11 13 23 27 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 Socie...

Страница 34: ...TPUT CONTROL knob to adjust output current to the desired level for the gouging electrode being used according to the ratings in Table B 3 below If gouging above 450 amps it is recommended to set the machine to HIGH IDLE Maximum current setting is limited to the Vantage 441X LE500X maximum of 525 amps TABLE B 3 NOTE If desired the CV WIRE mode can be used for arc gouging applications ARCLINK MODE ...

Страница 35: ...al stick out while welding Electrical stick out is the distance from the contact tip to the work piece The Vantage 441X LE500X waveforms are optimized for a 0 75 stick out The adaptive behavior supports a range of stick outs from 0 50 to 1 25 At very low or high wire feed speeds the adaptive range may be less due to reaching physical limitations of the welding process UltimArc Control UltimArc Con...

Страница 36: ...the power source by sending a signal through the electrode cable To start CrossLinc simply connect the weld cables and sense lead per the CrossLinc device s instructions Select the desired weld mode with the machine When weld output is ON the CrossLinc device will automatically link to the machine The CrossLinc light will be on to show active communication When CrossLinc is active the remote contr...

Страница 37: ...he current rating of any plug used with the system must be at least equal to the current capacity of the associated receptacle SIMULTANEOUS WELDING AND AUXILIARY POWER LOADS The auxiliary power capacity previously stated is maintained without any welding load If a welding load is present the available auxiliary power will decrease Simultaneous welding and power loads are specified in Table B 5 The...

Страница 38: ...utton The STATUS LED should turn green If the STATUS LED does not turn red and green as indicated or flashes red the GFCI failed the test and should be replaced An electric shock can result in serious injury or death Always perform the GFCI test before using the generator If the GFCI system fails the test the machine must be repaired by an authorized service center If the GFCI fails to trip when t...

Страница 39: ...rkins 404F E22T Fuel Consumption Full Tank equals 20 gal 75 7L GAL HR L HR RUN TIME HRS WITH FULL TANK High Idle 0 65 2 46 30 7 Low Idle 0 41 1 57 48 3 100A 24V 0 71 2 69 28 2 200A 28V 0 85 3 20 23 7 300A 32V 1 13 4 29 17 7 400A 36V 1 50 5 60 13 5 520A 41V 1 62 6 11 12 4 11kW Single Phase Power 1 19 4 51 16 8 13kW Three Phase Power 1 65 6 24 12 1 VANTAGE 441X LE500X ...

Страница 40: ...20 amps each and one dual voltage full KVA plug rated at 115 230V 50 amps Order K802N Polarity Multi Process Switch Offers easy polarity switching and process changes for all Lincoln Chopper Technology engine driven welders Order K2642 1 Polarity Multi Process Switch Spark Arrestor Order K2864 1 Remote Output Control Portable control provides same dial range as the output control on the welder The...

Страница 41: ...nd flux cored welding The push and turn digital controls and color display screen make setup and operation intuitive and easy while the all metal wire drive and sturdy sheet metal construction make it rugged and ready for any job Runs off auxiliary power to provide an additional welding arc Order K3963 1 Tomahawk 1000 Plasma Cutter Cuts metal using the AC generator power from the engine driven wel...

Страница 42: ...wer to the machine Use Personal Protective Equipment PPE including safety glasses dust mask and gloves to avoid injury This also applies to persons who enter the work area MOVING PARTS can injure Do not operate with doors open or guards off Stop engine before servicing Keep away from moving parts Have qualified personnel do all maintenance and troubleshooting work ROUTINE AND PERIODIC MAINTENANCE ...

Страница 43: ...id engine wear will result from contaminants such as dust and dirt being drawn into the engine The diesel engine is equipped with a dry type air filter Never apply oil to it Service the air cleaner per instructions on page D 3 Replace air filter element as needed per the service indicator If no indicator is present clean as needed and replace every 1000 hours of operation Under dusty conditions re...

Страница 44: ...te 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 war...

Страница 45: ... refill with a 50 50 antifreeze water solution Use an automotive grade low silicate ethylene glycol antifreeze The cooling system capacity is 2 55 US gal 9 7L Squeeze upper and lower radiator hoses while filling to bleed air from system coolant Replace and tighten the radiator cap Periodically remove the dirt from the radiator fins Periodically check the fan belt and radiator hoses Replace if sign...

Страница 46: ...attery charger manufacturer for proper charger settings and charging time 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 ...

Страница 47: ... I Tighten cylinder head I Valve clearances Intake 008 exhaust 008 I Electrical systems I All nuts and bolts for tightness I Injector performance Contact Perkins I Leaks or engine damage I Battery BCI Group 34 C Clean turbocharger impeller casting and the turbocharger compressor casting Engine Service Kit K3598 3 ENGINE SERVICE NOTE 2 EVERY DAY OR EVERY 8 HOURS FIRST SERVICE 20 50 HOURS EVERY 100 ...

Страница 48: ... to it but trips each time an appliance is connected to it the appliance has a ground fault and needs to be repaired or replaced DO NOT USE THE APPLIANCE IF THIS CONDITION OCCURS A REAL SHOCK HAZARD MAY EXIST Due to the risk of power interruption do not power life support equipment from this machine GFCI s do not protect against short circuits or overloads Unplug accessories and tools before attem...

Страница 49: ...l 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...

Страница 50: ...t your Field Service Facility 6 Check 20A Breaker CB7 Starter Relay 1 Out of fuel 2 Fuel shut off valve is in the off position make sure the valve lever is in the open position lever in line with the Hose 3 Engine shut down solenoid not pulling in 4 Fuel Filters dirty clogged main filter element and or Inline Fuel Filter may need to be replaced 5 High oil temperature or low oil pressure engine pro...

Страница 51: ...ge at output studs 4 Check Engine CAN Leads for proper connection 1 Broken wire in auxiliary current sensing wiring 2 Auxiliary power load is less than 100 watts 3 Check Engine CAN Leads for proper connection If all recommended possible areas of misadjustment have been checked and the problem persists Contact your local Lincoln Authorized Field Service Facility FUNCTION PROBLEMS Observe all Safety...

Страница 52: ...RIC COM LOCATOR PROBLEMS SYMPTOMS POSSIBLE CAUSE 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 FUNCTION PROBLEMS Observe all Safety Guidelines detailed throughout this manual No auxiliary power 1 Open breakers may need to be reset 2 Faulty receptacle 3 Faulty au...

Страница 53: ...INDINGS BYPASS FILTER ASSEMBLY GROUND STUD ON CONTROL PANEL I W1 W6 W2 W3 W4 W5 50MV 400AMPS RECTIFIER BRIDGE N 2E 08 G B CHOKE 206C 208C 204S 206S 206A 206E 206 GND J GND A 208B CHOKE W10 W9 ALPS POS POS NEG NEG W5 W5 W4 W4 W1 W1 W6 W6 W3 W2 W3 W2 67 208B 204S W9 POS NEG NEG POS 283 284 14 13 208E 208 206C GND BLOCK GND F 5N 76C 75C TRU REMOTE CONNECTIONS 22 23 CAN B HIGH SAE J1939 CAN B LOW SAE ...

Страница 54: ...MPTY FUEL TANK N B TRAILER MOUNTING HOLES 28 82 732 2 75 69 8 N A 39 12 993 7 30 00 762 27 00 685 8 22 42 569 4 33 33 846 6 33 00 838 2 14 50 368 3 65 10 1653 7 1 63 41 4 39 90 1013 5 59 50 1511 3 N B N B 43 27 1099 1 7 35 186 6 51 64 1311 7 45 98 1167 8 43 11 1095 1 VANTAGE 441X LE500X ...

Страница 55: ...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 moja da l Aislese del trabajo y de la tierra l Ne laissez ni la peau ni des vête ments 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 ...

Страница 56: ... und Entlüftung des Arbeitsplatzes l Mantenha seu rosto da fumaça l Use ventilação e exhaustão para remover fumo da zona respiratória l Turn power off before servicing l Desconectar el cable de ali mentación de poder de la máquina antes de iniciar cualquier servicio l Débranchez le courant avant l entre tien l Strom vor Wartungsarbeiten abschalten Netzstrom völlig öff nen Maschine anhalten l Não o...

Страница 57: ...stomer s particular purpose with respect to such information or advice As a matter of practical consideration we also cannot assume any respon sibility 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 manufactu...

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