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OIL                                 

The VANTAGE® 500 (CE) is shipped with the engine crankcase

filled with high quality SAE 10W-30 Oil that meets classification CG-

4 or CH-4 for diesel engines.  Check the oil level before starting the

engine. If it is not up to the full mark on the dip stick, add oil as

required. Check the oil level every four hours of running time during

the first 50 running hours. Refer to the engine Operator’s Manual for

specific oil recommendations and break-in information. The oil

change interval is dependent on the quality of the oil and the oper-

ating environment. Refer to the Engine Operator’s Manual for more

details on the proper service and maintenance intervals.

FUEL

DIESEL FUEL ONLY-

Low sulphur fuel or ultra low sulphur

fuel in U.S.A. and Canada.

•  Fill the fuel tank with clean, fresh fuel. The capacity of the

tank is 15 gals. (57 ltrs) for (Codes 11299 and below), 20 gals.

(75.5) for (Codes above 11299). 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  on the pre-filter/sedi-

ment filter. Which should be in the closed position

when the welder is not used for extended periods of

time.

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

ENGINE COOLING SYSTEM

Air to cool the engine is drawn in the side and exhausted

through radiator & case back. It is important that the intake and

exhaust air is not restricted. Allow a minimum clearance of 1ft.

(0.6m) from the case back and 16 in. (406mm) from either side

of the base to a vertical surface

.

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

BATTERY CONNECTION

Use caution as the electrolyte is a strong acid that can burn

skin and damage eyes.

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

The VANTAGE® 500 (CE) is shipped with the negative battery

cable disconnected. Make certain that the RUN-STOP switch is in

the STOP position. Remove the two screws from the battery tray

using a screwdriver or a 3/8"(10mm) socket. Attach the negative

battery cable to the negative battery terminal and tighten using a

1/2"(13mm) socket or wrench.

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”)

A-5

INSTALLATION   

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 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 K903-1 must be installed and

properly maintained.

An incorrect spark arrestor may lead to damage to the engine

or adversely affect performance.

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

REMOTE CONTROL

The VANTAGE® 500 (CE) is equipped with a 6-pin and a 14-pin

connector. The 6-pin connector is for connecting the K857 or K857-

1 Remote Control or for TIG welding, the K870 foot Amptrol or the

K936-3 hand Amptrol. When in the CC-STICK, ARC GOUGING or

CV-WIRE modes and when a remote control is connected to the 6-

pin Connector, the auto-sensing circuit automatically switches the

OUTPUT control from control at the welder to remote control.
When in the DOWNHILL PIPE mode and when REMOTE CON-

TROL is connected to the 6-Pin or 14-Pin Connector, the OUTPUT

CONTROL is used to set the maximum current range of the OUT-

PUT CONTROL 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 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 tuning of the output.

When in TOUCH START TIG mode and when a Amptrol is connect-

ed to the 6-Pin Connector, the OUTPUT dial is used to set the max-

imum current range of the CURRENT CONTROL of the Amptrol.
The 14-pin connector is used to directly connect a wire feeder con-

trol cable. In the CV-WIRE mode, when the control cable is con-

nected to the 14-pin connector, the auto-sensing circuit automatical-

ly makes the Output Control inactive and the wire feeder voltage

control active.

NOTE: When a wire feeder with a built in welding voltage con-

trol is connected to the 14-pin connector, do not connect any-

thing to the 6-pin connector.

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

WARNING

CAUTION

WARNING

WARNING

WARNING

Содержание Vantage 500 CE

Страница 1: ...298 11299 11524 11525 11574 11575 11963 12196 12333 12364 12657 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 Sa...

Страница 2: ...s compatible This may require additional protection measures h the time of day that welding or other activities are to be carried out The size of the surrounding area to be considered will depend on the structure of the building and other activities that are taking place The surrounding area may extend beyond the boundaries of the premises methods of reduCIng emIssIons Mains Supply Welding equipme...

Страница 3: ... 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 4: ...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 5: ...tem 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 components Welding Process DC Con...

Страница 6: ...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 7: ...f 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 lights LO...

Страница 8: ...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 9: ...TAGE 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 certain ...

Страница 10: ...t A machine grounding 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...

Страница 11: ...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 12: ... 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 13: ...e IDLER 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 ...

Страница 14: ...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 Amptrol 2 DIGITAL OUTPUT METERS The digita...

Страница 15: ...ition the 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 VANTA...

Страница 16: ...s off when the RUN STOP switch is in the ON position prior to starting the engine However if the engine is not started within 60 seconds the light will come on When this happens the RUN STOP switch must be returned to the OFF 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...

Страница 17: ...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 18: ...at 0 NOTE 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 th...

Страница 19: ...fference 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 20: ...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 21: ... Perkins 140517050 C Drain water separator fuel strainer R Water separator element Lincoln M20840 A R Fuel filter canister Perkins 130366120 I Tension of alternator drive belt I Alternator drive belt wear R Alternator drive belt Perkins 080109107 C Air filter earlier check may be req d R Air filter element Donaldson P821575 R Renew the engine breather I Tighten cylinder head I Valve clearances Int...

Страница 22: ...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 23: ...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 24: ...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 25: ...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 26: ...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 27: ...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 28: ...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 29: ... 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 30: ...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 31: ... 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 32: ...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 33: ...F 1 DIAGRAMS F 1 VANTAGE 500 CE ...

Страница 34: ...F 2 DIAGRAMS F 2 VANTAGE 500 CE ...

Страница 35: ...F 3 DIAGRAMS F 3 VANTAGE 500 CE ...

Страница 36: ...F 4 DIAGRAMS F 4 VANTAGE 500 CE ...

Страница 37: ...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 38: ...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 39: ...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 40: ...3 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 N B CASE FRONT GRAPHICS MAY NOT MATCH ALL CODES NOTES C ...

Страница 41: ...NOTES VANTAGE 500 CE ...

Страница 42: ...stomer s particular purpose with respect to such information or advice As a matter of practical consideration we also cannot assume any responsibility for updating or correcting any such information or advice once it has been given nor does the provision of information or advice create expand or alter any warranty with respect to the sale of our products Lincoln Electric is a responsive manufactur...

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