background image

D-4

MAINTENANCE

D-4

COOLING SYSTEM

HOT COOLANT

can burn skin.

•  Do  not  remove  cap  if  radiator  is

hot.

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

Check  the  coolant  level  by  observing  the  level  in  the

radiator  and  recovery  bottle.  Add  50/50  antifreeze  /

water  solution  if  the  level  is  close  to  or  below  the

"LOW"  mark.  do  not  fill  above  the  "FULL"  mark.

Remove  radiator  cap  and  add  coolant  to  radiator.  Fill

up  to  the  top  of  the  tube  in  the  radiator  filler  neck

which  includes  a  connecting  hose  coming  from  the

thermostat housing.

To  drain  the  coolant,  open  the  valve  at  the  bottom  of

the  radiator.  Open  the  radiator  cap  to  allow  complete

drainage.  (Tighten  the  valve  and  refill  with  a  50/50

antifreeze/water  solution.)  Use  an  automotive  grade

(low  silicate)  ethylene  glycol  antifreeze.  The  cooling

system  capacity  is  9.5  quarts  (9.0L.).  Squeeze  upper

and lower radiator hoses while filling to bleed air from

system coolant. Replace and tighten the radiator cap.

Always  premix  the  antifreeze  and  clean  tap  water

before  adding  to  the  radiator.  It  is  very  important

that  a  precise  50/50  solution  be  used  with  this

engine  year  round.  This  gives  proper  cooling  dur-

ing hot weather and freezing protection to -34° F (-

37° C).

Cooling  solution  exceeding  50%  ethylene  glycol

can  result  in  engine  overheating  and  damage  to

the  engine.  Coolant  solution  must  be  premixed

before adding to radiator.

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

Periodically remove the dirt from the radiator fins.

Periodically  check  the  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 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 tem-

peratures below 23°F (-5°C).  Do not use kerosene.

See  the  Engine  Operator's  Manual  for  instructions  on

replacing the fuel filter.

BLEEDING THE FUEL SYSTEM

You may need to bleed air from the fuel system if  the

fuel  filter  or  fuel  lines  have  been  detached,  the  fuel

tank has been ran empty or after periods of long stor-

age.  It is recommended that the fuel shutoff valve be

closed during periods of non-use.

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 prim-

ing lever. Tighten bleed fitting on injector manifold.

5.  Follow  normal  STARTING  procedures  until  engine

starts.

VANTAGE

®

500 (CE)

WARNING

CAUTION

WARNING

Содержание VANTAGE 500 (CE) IM894-B

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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 ...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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 ...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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 ...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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 ...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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 ...

Страница 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...

Страница 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 ...

Страница 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 ...

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

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

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

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

Страница 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 ...

Страница 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 ...

Страница 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 ...

Страница 46: ...NOTES VANTAGE 500 CE ...

Страница 47: ...NOTES VANTAGE 500 CE ...

Страница 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...

Страница 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...

Страница 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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