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Lincoln Electric VANTAGE SVM178-B, Руководство по обслуживанию

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TABLE OF CONTENTS - TROUBLESHOOTING AND REPAIR

F-1

F-1

VANTAGE® 500

Troubleshooting and Repair  . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .F-1

How to Use Troubleshooting Guide  . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .F-2

PC Board Troubleshooting Procedures  . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .F-3

Troubleshooting Guide  . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .F-4

Test Procedures   . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .F-13

Case Cover Removal and Replacement Procedure  . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .F-13

Chopper Module Capacitor Discharge Procedure  . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .F-15

Chopper Module Resistance Test Procedure  . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .F-17

Idler Solenoid Test  . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .F-21

Shutdown Solenoid Test  . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .F-23

Engine Throttle Adjustment Test  . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .F-25

Rotor Resistance Test  . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .F-29

Flashing and Rotor Voltage Test  . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .F-31

Stator Voltage Test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .F-33

Output Rectifier Bridge Test  . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .F-37

Electronic Governor Test  . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .F-43

Charging Circuit Test  . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .F-45

Oscilloscope Waveforms   . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .F-47

Normal Open Circuit Voltage Waveform (115VAC Supply)  . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .F-47

Normal Open Circuit Voltage Waveform (Stick) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .F-48

Normal Weld Voltage Waveform (Stick CC)  . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .F-49

Normal Weld Voltage Waveform (Wire CV)  . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .F-50

Normal TIG Mode Voltage Waveform  . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .F-51

Normal Open Circuit Voltage Waveform (Wire CV Tap)  . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .F-52

Replacement Procedures   . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .F-53

Shutdown Solenoid Removal and Replacement  . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .F-53

Output Rectifier Bridge Removal and Replacement  . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .F-57

Stator/Rotor Removal and Replacement  . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .F-59

Retest After Repair   . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .F-68

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Содержание VANTAGE SVM178-B

Страница 1: ...UT And most importantly think before you act and be careful SERVICE MANUAL For use with machine code numbers 10995 10996 11180 11181 11415 11416 11468 VANTAGE 500 Sales and Service through Subsidiarie...

Страница 2: ...IR 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 S...

Страница 3: ...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 t...

Страница 4: ...r 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 Safet...

Страница 5: ...outtes de laitier en fusion sont mises de l arc de soudage Se prot ger avec des v tements de protection libres de l huile tels que les gants en cuir chemise paisse pan talons sans revers et chaussures...

Страница 6: ...e 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 e...

Страница 7: ...be kept as short as possible and should be positioned close together running at or close to floor level Equipotential Bonding Bonding of all metallic components in the welding installation and adjace...

Страница 8: ...eutz F3L912 Code 10995 C1 VANTAGE 500 Deutz F4L2011 Code 11180 11415 C2 VANTAGE 500 Deutz D2011L4i Code 11468 C3 VANTAGE 500 Cummins B3 3 Code 10996 C4 VANTAGE 500 Cummins B3 3 Code 11181 11416 C5 Mai...

Страница 9: ...owing A1 4 Vehicle Mounting A1 4 Pre Operation Engine Service A1 5 Oil A1 5 Fuel A1 5 Fuel Cap A1 5 Engine Cooling System A1 5 Battery Connection A1 5 Muffler Outlet Pipe A1 6 Spark Arrester A1 6 High...

Страница 10: ...50 575 Amps DC multi purpose 35 volts PHYSICAL DIMENSIONS Height 2 Width Depth Weight 42 0 in 31 5 in 63 1 in 1615 lbs 1066 8 mm 800 1mm 1603mm 733kg Approx 1 Output rating in watts is equivalent to...

Страница 11: ...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 a...

Страница 12: ...railer for use with this equipment for road in plant and yard towing by a vehicle1 is Lincoln s K2636 1 If the user adapts a non Lincoln trailer he must assume responsibility that the method of attach...

Страница 13: ...mmendations Running out of fuel may require bleeding the fuel injection pump NOTE Before starting the engine open the fuel shut off valve pointer to be in line with hose FUEL CAP Remove the plastic ca...

Страница 14: ...rsely affect performance HIGH FREQUENCY GENERATORS FOR TIG APPLICATIONS The K799 Hi Freq Unit obsolete and the K930 1 or 2 TIG Module are suitable for use with the Vantage 500 The Vantage 500 is equip...

Страница 15: ...k of a building which has been effectively grounded The U S National Electrical Code lists a number of alternate means of grounding electrical equipment A machine grounding stud marked with the symbol...

Страница 16: ...20 240 VAC plug NEMA Type 14 50 to the double pole circuit breaker using four conductor cable of the proper size and desired length The 50 amp 120 240 VAC plug is avail able in the optional K802R plug...

Страница 17: ...er Controls B1 6 Engine Operation B1 7 Starting the Engine B1 7 Stopping the Engine B1 7 Break In Period B1 7 Typical Fuel Consumption B1 7 Welder Operation B1 8 Stick Welding B1 8 Constant Current CC...

Страница 18: ...rate the welder with the hinged door closed and the side panels in place as these provide maxi mum protection from moving parts and insure proper cooling air flow GENERAL DESCRIPTION The Vantage 500 i...

Страница 19: ...ol panel Arc Control potentiometer in Wire and Stick modes for precise adjustment of arc characteristics Advanced circuitry to prevent pop outs in the five slope modes FOR AUXILIARY POWER 12 000 watts...

Страница 20: ...METER The hour meter displays the total time that the engine has been running This meter is a useful indicator for scheduling preventive maintenance 4 FUEL LEVEL GAUGE Displays the level of diesel fu...

Страница 21: ...mptrol 10 DIGITAL OUTPUT METERS Optional The digital meters allow the output voltage CV WIRE mode or current CC STICK DOWNHILL PIPE and TIG modes to be set prior to welding using the OUT PUT control k...

Страница 22: ...an be split for 120VAC single phase auxiliary power This receptacle has a 50 amp rating Refer to the AUX ILIARY POWER RECEPTACLES section in the installation chapter for further information about this...

Страница 23: ...requently started below 10 12 C it may be desirable to install the optional ether start kit K887 1 Installation and operating instructions are included in the kits STOPPING THE ENGINE Switch the RUN S...

Страница 24: ...acking of iron are key to fast travel speeds It is recommend ed that the ARC CONTROL be set initially at 0 TOUCH START TIG MODE The Vantage 500 can be used in a wide variety of DC TIG welding applicat...

Страница 25: ...0 5 20 3 5 10 3 5 5 10 3 5 0 40 1 0 15 80 3 5 10 3 5 5 10 3 5 1 16 1 6 70 150 10 20 5 10 3 5 9 13 4 6 5 6 3 32 2 4 150 250 15 30 13 17 6 8 11 15 5 7 6 7 8 1 8 3 2 250 400 25 40 15 23 7 11 11 15 5 7 5...

Страница 26: ...separate 120 VAC outputs with a maxi mum permissible current of 50 A per output to two sep arate 120 VAC branch circuits Output voltage is within 10 at all loads up to rated capacity NOTE The 120 240...

Страница 27: ...RD RECOMMENDATIONS An extension cord can be used with the auxiliary power outputs as long as it is of ample size Table B1 4 lists permissible extension cord lengths based on conduc tor size and auxili...

Страница 28: ...OTES B1 12 B1 12 VANTAGE 500 Return to Section TOC Return to Section TOC Return to Section TOC Return to Section TOC Return to Master TOC Return to Master TOC Return to Master TOC Return to Master TOC...

Страница 29: ...12 Code 10995 Options Accessories C1 1 Optional Field Installed Accessories C1 2 Plasma Cutting Option C1 2 TIG Welding Options C1 3 High Frequency Generators for TIG Applications C1 3 Wire Feeder Opt...

Страница 30: ...ETHER START KIT Provides maximum cold weather starting assistance for frequent starting below 10 12 C Required Ether tank is not provided with kit K899 1 SPARK ARRESTOR KIT Easily mounts to standard m...

Страница 31: ...te instructions on installation oper ation and maintenance WIRE FEEDER OPTIONS K449 LN 25 Wire Feeder Portable CC CV unit for flux cored and MIG welding Includes Gas Solenoid Internal Contactor K126 2...

Страница 32: ...NOTES C1 4 C1 4 VANTAGE 500 Return to Section TOC Return to Section TOC Return to Section TOC Return to Section TOC Return to Master TOC Return to Master TOC Return to Master TOC Return to Master TOC...

Страница 33: ...stem D1 8 Cooling Blower Belt D1 8 Engine Maintenance Schedules and Parts D1 9 Battery Maintenance D1 10 Cleaning the Battery D1 10 Checking Specific Gravity D1 10 Checking Electrolyte Level D1 10 Cha...

Страница 34: ...r a summary of maintenance inter vals for the items listed below Follow either the hourly or the calendar intervals whichever come first More frequent service may be required depending on your specifi...

Страница 35: ...ntil the gasket is evenly seated Then turn it down another 1 2 turn Do not overtighten the new filter 5 Refill the engine with the proper amount and type of oil as described in the Change the Oil sect...

Страница 36: ...d to remove the plug 4 Using a pair of pliers gently tug on the pull tabs of the pre filter screen in an alternating pattern to gradually remove the pre filter screen 5 Brush off any debris and rinse...

Страница 37: ...click you have not rotated the ring far enough and the element is not in the locked position Another indication that the ring is in the locked position is that one set it doesn t matter which one of...

Страница 38: ...one inch away from the ele ment Water Hose 40 psi maximum without nozzle 4 Soak the element in a mild detergent solution for 15 minutes Do not soak more than 24 hours Swish the element around in the...

Страница 39: ...7 D1 7 VANTAGE 500 MAINTENANCE INSTRUCTIONS Return to Section TOC Return to Section TOC Return to Section TOC Return to Section TOC Return to Master TOC Return to Master TOC Return to Master TOC Retur...

Страница 40: ...ne 7 See Figure D1 4 Loosen the alternator mounting bolts 1 2 3 and rotate the alternator toward the engine 8 Remove the old cooling blower belt and install a new one 9 Push outward on the alternator...

Страница 41: ...r Refer to your Deutz engine operation manual for periodic maintenance at 100 hours and beyond 1 125 Hours for severe conditions TABLE D1 2 ENGINE MAINTENANCE PARTS ITEM Air Cleaner Element Cooling Bl...

Страница 42: ...accumulation on the battery can lead to more rapid discharge and early battery failure CHECKING SPECIFIC GRAVITY Check each battery cell with a hydrometer A fully charged battery will have a specific...

Страница 43: ...sufficient grease to last indefinitely under normal service Where the welder is used constantly or in excessively dirty loca tions it may be necessary to add one half ounce of grease per year A pad o...

Страница 44: ...BOX OUTPUT ASSEMBLY 3 POWER MODULE ASSEMBLY 4 BASE LIFT BALE ASSEMBLY 5 FUEL TANK MOUNTING 6 ENGINE ASSEMBLY 7 GENERATOR 8 SOLENOID ASSEMBLY 9 CASEBACK 10 CASE TOP AND SIDES Return to Section TOC Retu...

Страница 45: ...4 Towing A2 4 Vehicle Mounting A2 4 Pre Operation Engine Service A2 5 Oil A2 5 Fuel A2 5 Fuel Cap A2 5 Engine Cooling System A2 5 Battery Connection A2 5 Muffler Outlet Pipe A2 6 Spark Arrester A2 6 H...

Страница 46: ...lti purpose 35 volts PHYSICAL DIMENSIONS Height 2 Width Depth Weight 42 0 in 31 5 in 63 1 in 1532lbs 1066 8 mm 800 1mm 1603mm 695kg Approx 1 Output rating in watts is equivalent to volt amperes at uni...

Страница 47: ...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 a...

Страница 48: ...for use with this equipment for road in plant and yard towing by a vehicle1 is Lincoln s K953 1 If the user adapts a non Lincoln trail er he must assume responsibility that the method of attachment a...

Страница 49: ...ndations Running out of fuel may require bleeding the fuel injection pump NOTE Before starting the engine open the fuel shut off valve pointer to be in line with hose FUEL CAP Remove the plastic cap c...

Страница 50: ...rsely affect performance HIGH FREQUENCY GENERATORS FOR TIG APPLICATIONS The K799 Hi Freq Unit obsolete and the K930 1 or 2 TIG Module are suitable for use with the Vantage 500 The Vantage 500 is equip...

Страница 51: ...ork of a building which has been effectively grounded The U S National Electrical Code lists a number of alternate means of grounding electrical equipment A machine grounding stud marked with the symb...

Страница 52: ...40 VAC plug NEMA Type 14 50 to the double pole circuit breaker using four conductor cable of the proper size and desired length The 50 amp 120 240 VAC plug is avail able in the optional K802R plug kit...

Страница 53: ...Power Controls B2 6 Engine Operation B2 7 Starting the Engine B2 7 Stopping the Engine B2 7 Break In Period B2 7 Typical Fuel Consumption B2 7 Welder Operation B2 8 Stick Welding B2 8 Constant Curren...

Страница 54: ...th the hinged door closed and the side panels in place as these provide maxi mum protection from moving parts and insure proper cooling air flow GENERAL DESCRIPTION The Vantage 500 is a diesel engine...

Страница 55: ...ol panel Arc Control potentiometer in Wire and Stick modes for precise adjustment of arc characteristics Advanced circuitry to prevent pop outs in the five slope modes FOR AUXILIARY POWER 12 000 watts...

Страница 56: ...TER The hour meter displays the total time that the engine has been running This meter is a useful indicator for scheduling preventive maintenance 4 FUEL LEVEL GAUGE Displays the level of diesel fuel...

Страница 57: ...ollows A In the High position the engine runs at the high idle speed controlled by the governor B In the Auto position the idler operates as follows a When switched from High to Auto or after starting...

Страница 58: ...more forceful digging arc Crisp Increasing the number from 10 Soft to 10 Crisp increases the short circuit current which results in a more forceful digging arc Typically a forceful digging arc is pref...

Страница 59: ...main on until the engine is started 6 Within 30 seconds press and hold the engine START button until the engine starts If the engine does not start within 30 seconds the RUN STOP switch must be return...

Страница 60: ...CH START TIG setting of the MODE switch is for DC TIG Tungsten Inert Gas welding To initiate a weld the OUTPUT CONTROL knob is first set to the desired current and the tungsten is touched to the work...

Страница 61: ...2 4 4 5 6 0 020 50 5 20 3 5 10 3 5 5 10 3 5 0 40 1 0 15 80 3 5 10 3 5 5 10 3 5 1 16 1 6 70 150 10 20 5 10 3 5 9 13 4 6 5 6 3 32 2 4 150 250 15 30 13 17 6 8 11 15 5 7 6 7 8 1 8 3 2 250 400 25 40 15 23...

Страница 62: ...output can be split to provide two separate 120 VAC outputs with a maxi mum permissible current of 50 A per output to two sep arate 120 VAC branch circuits Output voltage is within 10 at all loads up...

Страница 63: ...RD RECOMMENDATIONS An extension cord can be used with the auxiliary power outputs as long as it is of ample size Table B 5 lists permissible extension cord lengths based on conduc tor size and auxilia...

Страница 64: ...OTES B2 12 B2 12 VANTAGE 500 Return to Section TOC Return to Section TOC Return to Section TOC Return to Section TOC Return to Master TOC Return to Master TOC Return to Master TOC Return to Master TOC...

Страница 65: ...Codes 11180 11415 Options Accessories C2 2 Optional Field Installed Accessories C2 2 TIG Welding Options C2 3 Plasma Cutting Option C2 2 High Frequency Generators for TIG Applications C2 3 Wire Feeder...

Страница 66: ...1 Cable Rack K887 1 ETHER START KIT Provides maximum cold weather starting assistance for frequent starting below 10 12 C Required Ether tank is not provided with kit K899 1 SPARK ARRESTOR KIT Easily...

Страница 67: ...nstructions on installation oper ation and maintenance WIRE FEEDER OPTIONS K449 LN 25 Wire Feeder Portable CC CV unit for flux cored and MIG welding Includes Gas Solenoid Internal Contactor K126 2 Mag...

Страница 68: ...NOTES C2 4 C2 4 VANTAGE 500 Return to Section TOC Return to Section TOC Return to Section TOC Return to Section TOC Return to Master TOC Return to Master TOC Return to Master TOC Return to Master TOC...

Страница 69: ...D2 7 Cooling Blower Belt D2 7 Engine Maintenance Schedules and Parts D2 8 Welder Generator Maintenance D2 8 Storage D2 8 Cleaning D2 8 Nameplates D2 8 Brush Removal and Replacement D2 8 Bearings D2 8...

Страница 70: ...ry cable before ser vicing the engine See the Service Plan section of the Engine Operation Manual for a summary of maintenance intervals for the items listed below Follow either the hourly or the cal...

Страница 71: ...evenly seated Then turn it down another 1 2 turn Do not overtighten the new filter 5 Refill the engine with the proper amount and type of oil as described in the Change the Oil section Start the engi...

Страница 72: ...tening will distort the threads filter element seal or filter can There is also a filter screen in the fuel pump that should be checked whenever the Fuel Filter Water Separator maintenance is performe...

Страница 73: ...24 hours Swish the element around in the solution to help remove dirt 5 Rinse elements from inside out with a gentle stream of water less than 40 psi to remove all suds and dirt 6 Dry the element befo...

Страница 74: ...6 D2 6 VANTAGE 500 MAINTENANCE INSTRUCTIONS Return to Section TOC Return to Section TOC Return to Section TOC Return to Section TOC Return to Master TOC Return to Master TOC Return to Master TOC Retur...

Страница 75: ...at the uppper right mounting bolt of the pulley guard 9 See Figure D3 5 Loosen the idler pulley mounting bolt and move the pulley toward the engine 10 Remove the old cooling blower belt and install a...

Страница 76: ...cient grease to last indefinitely under normal service Where the welder is used constantly or in excessively dirty locations it may be necessary to add one half ounce of grease per year A pad of greas...

Страница 77: ...accumulation on the battery can lead to more rapid discharge and early battery failure CHECKING SPECIFIC GRAVITY Check each battery cell with a hydrometer A fully charged battery will have a specific...

Страница 78: ...2 CONTROL BOX OUTPUT ASSEMBLY 3 POWER MODULE ASSEMBLY 4 BASE LIFT BALE ASSEMBLY 5 FUEL TANK MOUNTING 6 ENGINE ASSEMBLY 7 GENERATOR 8 SOLENOID ASSEMBLY 9 CASEBACK 10 CASE TOP AND SIDES Return to Sectio...

Страница 79: ...owing A3 4 Vehicle Mounting A3 4 Pre Operation Engine Service A3 5 Oil A3 5 Fuel A3 5 Fuel Cap A3 5 Engine Cooling System A3 5 Battery Connection A3 5 Muffler Outlet Pipe A3 6 Spark Arrester A3 6 High...

Страница 80: ...0 575 Amps DC multi purpose 35 volts PHYSICAL DIMENSIONS Height 2 Width Depth Weight 42 0 in 31 5 in 63 1 in 1532lbs 1066 8 mm 800 1mm 1603mm 695kg Approx 1 Output rating in watts is equivalent to vol...

Страница 81: ...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 a...

Страница 82: ...ler for use with this equipment for road in plant and yard towing by a vehicle1 is Lincoln s K2636 1 If the user adapts a non Lincoln trailer he must assume responsibility that the method of attachmen...

Страница 83: ...eding the fuel injection pump NOTE Before starting the engine open the fuel shutoff valve pointer to be in line with hose NOTE Before starting the engine open the fuel shut off valve pointer to be in...

Страница 84: ...rsely affect performance HIGH FREQUENCY GENERATORS FOR TIG APPLICATIONS The K799 Hi Freq Unit obsolete and the K930 1 or 2 TIG Module are suitable for use with the Vantage 500 The Vantage 500 is equip...

Страница 85: ...ork of a building which has been effectively grounded The U S National Electrical Code lists a number of alternate means of grounding electrical equipment A machine grounding stud marked with the symb...

Страница 86: ...40 VAC plug NEMA Type 14 50 to the double pole circuit breaker using four conductor cable of the proper size and desired length The 50 amp 120 240 VAC plug is avail able in the optional K802R plug kit...

Страница 87: ...wer Controls B3 6 Engine Operation B3 7 Starting the Engine B3 7 Stopping the Engine B3 7 Break In Period B3 7 Typical Fuel Consumption B3 7 Welder Operation B3 8 Stick Welding B3 8 Constant Current C...

Страница 88: ...th the hinged door closed and the side panels in place as these provide maxi mum protection from moving parts and insure proper cooling air flow GENERAL DESCRIPTION The Vantage 500 is a diesel engine...

Страница 89: ...ol panel Arc Control potentiometer in Wire and Stick modes for precise adjustment of arc characteristics Advanced circuitry to prevent pop outs in the five slope modes FOR AUXILIARY POWER 12 000 watts...

Страница 90: ...TER The hour meter displays the total time that the engine has been running This meter is a useful indicator for scheduling preventive maintenance 4 FUEL LEVEL GAUGE Displays the level of diesel fuel...

Страница 91: ...ollows A In the High position the engine runs at the high idle speed controlled by the governor B In the Auto position the idler operates as follows a When switched from High to Auto or after starting...

Страница 92: ...more forceful digging arc Crisp Increasing the number from 10 Soft to 10 Crisp increases the short circuit current which results in a more forceful digging arc Typically a forceful digging arc is pref...

Страница 93: ...main on until the engine is started 6 Within 30 seconds press and hold the engine START button until the engine starts If the engine does not start within 30 seconds the RUN STOP switch must be return...

Страница 94: ...welding applications The TOUCH START TIG setting of the MODE switch is for DC TIG Tungsten Inert Gas welding To initiate a weld the OUTPUT CONTROL knob is first set to the desired current and the tun...

Страница 95: ...2 4 4 5 6 0 020 50 5 20 3 5 10 3 5 5 10 3 5 0 40 1 0 15 80 3 5 10 3 5 5 10 3 5 1 16 1 6 70 150 10 20 5 10 3 5 9 13 4 6 5 6 3 32 2 4 150 250 15 30 13 17 6 8 11 15 5 7 6 7 8 1 8 3 2 250 400 25 40 15 23...

Страница 96: ...output can be split to provide two separate 120 VAC outputs with a maxi mum permissible current of 50 A per output to two sep arate 120 VAC branch circuits Output voltage is within 10 at all loads up...

Страница 97: ...RD RECOMMENDATIONS An extension cord can be used with the auxiliary power outputs as long as it is of ample size Table B 5 lists permissible extension cord lengths based on conduc tor size and auxilia...

Страница 98: ...OTES B3 12 B3 12 VANTAGE 500 Return to Section TOC Return to Section TOC Return to Section TOC Return to Section TOC Return to Master TOC Return to Master TOC Return to Master TOC Return to Master TOC...

Страница 99: ...Codes 11180 11415 Options Accessories C3 2 Optional Field Installed Accessories C3 2 Plasma Cutting Option C3 2 TIG Welding Options C3 3 High Frequency Generators for TIG Applications C3 3 Wire Feeder...

Страница 100: ...1 Cable Rack K887 1 ETHER START KIT Provides maximum cold weather starting assistance for frequent starting below 10 12 C Required Ether tank is not provided with kit K899 1 SPARK ARRESTOR KIT Easily...

Страница 101: ...nstructions on installation oper ation and maintenance WIRE FEEDER OPTIONS K449 LN 25 Wire Feeder Portable CC CV unit for flux cored and MIG welding Includes Gas Solenoid Internal Contactor KP653 3 32...

Страница 102: ...NOTES C3 4 C3 4 VANTAGE 500 Return to Section TOC Return to Section TOC Return to Section TOC Return to Section TOC Return to Master TOC Return to Master TOC Return to Master TOC Return to Master TOC...

Страница 103: ...7 Cooling Blower Belt D3 7 Engine Maintenance Schedules and Parts D3 8 Welder Generator Maintenance D3 8 Storage D3 8 Cleaning D3 8 Nameplates D3 8 Brush Removal and Replacement D3 8 Bearings D3 8 Re...

Страница 104: ...ry cable before ser vicing the engine See the Service Plan section of the Engine Operation Manual for a summary of maintenance intervals for the items listed below Follow either the hourly or the cal...

Страница 105: ...evenly seated Then turn it down another 1 2 turn Do not overtighten the new filter 5 Refill the engine with the proper amount and type of oil as described in the Change the Oil section Start the engi...

Страница 106: ...tening will distort the threads filter element seal or filter can There is also a filter screen in the fuel pump that should be checked whenever the Fuel Filter Water Separator maintenance is performe...

Страница 107: ...24 hours Swish the element around in the solution to help remove dirt 5 Rinse elements from inside out with a gentle stream of water less than 40 psi to remove all suds and dirt 6 Dry the element befo...

Страница 108: ...6 D3 6 VANTAGE 500 MAINTENANCE INSTRUCTIONS Return to Section TOC Return to Section TOC Return to Section TOC Return to Section TOC Return to Master TOC Return to Master TOC Return to Master TOC Retur...

Страница 109: ...r right mounting bolt of the pulley guard 8 See Figure D3 5 Loosen the idler pulley mounting bolt and move the pulley toward the engine 9 Remove the old cooling blower belt and install a new one 10 Pu...

Страница 110: ...cient grease to last indefinitely under normal service Where the welder is used constantly or in excessively dirty locations it may be necessary to add one half ounce of grease per year A pad of greas...

Страница 111: ...accumulation on the battery can lead to more rapid discharge and early battery failure CHECKING SPECIFIC GRAVITY Check each battery cell with a hydrometer A fully charged battery will have a specific...

Страница 112: ...2 CONTROL BOX OUTPUT ASSEMBLY 3 POWER MODULE ASSEMBLY 4 BASE LIFT BALE ASSEMBLY 5 FUEL TANK MOUNTING 6 ENGINE ASSEMBLY 7 GENERATOR 8 SOLENOID ASSEMBLY 9 CASEBACK 10 CASE TOP AND SIDES Return to Sectio...

Страница 113: ...Towing A4 4 Vehicle Towing A4 4 Pre Operation Engine Service A4 5 Oil A4 5 Fuel A4 5 Fuel Cap A4 5 Engine Cooling System A4 5 Battery Connection A4 5 Muffler Outlet Pipe A4 6 Spark Arrester A4 6 High...

Страница 114: ...rpose 36 volts 50 575 Amps DC multi purpose 35 volts PHYSICAL DIMENSIONS Height 2 Width Depth Weight 42 0 in 31 5 in 63 1 in 1605 lbs 1066 8 mm 800 1mm 1603mm 728kg Approx 1 Output rating in watts is...

Страница 115: ...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 a...

Страница 116: ...iler for use with this equipment for road in plant and yard towing by a vehicle1 is Lincoln s K953 1 If the user adapts a non Lincoln trail er he must assume responsibility that the method of attachme...

Страница 117: ...ction pump NOTE Before starting the engine open the fuel shutoff valve pointer to be in line with hose NOTE Before starting the engine open the fuel shut off valve pointer to be in line with hose FUEL...

Страница 118: ...rsely affect performance HIGH FREQUENCY GENERATORS FOR TIG APPLICATIONS The K799 Hi Freq Unit obsolete and the K930 1 or 2 TIG Module are suitable for use with the Vantage 500 The Vantage 500 is equip...

Страница 119: ...ork of a building which has been effectively grounded The U S National Electrical Code lists a number of alternate means of grounding electrical equipment A machine grounding stud marked with the symb...

Страница 120: ...40 VAC plug NEMA Type 14 50 to the double pole circuit breaker using four conductor cable of the proper size and desired length The 50 amp 120 240 VAC plug is avail able in the optional K802R plug kit...

Страница 121: ...iliary Power Controls B4 6 Engine Operation B4 7 Starting the Engine B4 7 Stopping the Engine B4 7 Typical Fuel Consumption B4 7 Welder Operation B4 8 Stick Welding B4 8 Constant Current CC Welding B4...

Страница 122: ...e this equipment ADDITIONAL SAFETY PRECAUTIONS Always operate the welder with the hinged door closed and the side panels in place as these provide maxi mum protection from moving parts and insure prop...

Страница 123: ...control panel Arc Control potentiometer in Wire and Stick modes for precise adjustment of arc characteristics Advanced circuitry to prevent pop outs in the five slope modes FOR AUXILIARY POWER 12 000...

Страница 124: ...R METER The hour meter displays the total time that the engine has been running This meter is a useful indicator for scheduling preventive maintenance 4 FUEL LEVEL GAUGE Displays the level of diesel f...

Страница 125: ...e will operate at full speed for approximately 12 seconds and then go to low idle speed b When the electrode touches the work or power is drawn for lights or tools approximately 100 Watts minimum the...

Страница 126: ...more forceful digging arc Crisp Increasing the number from 10 Soft to 10 Crisp increases the short circuit current which results in a more forceful digging arc Typically a forceful digging arc is pref...

Страница 127: ...6 Within 30 seconds press and hold the engine START button until the engine starts If the engine does not start within 30 seconds the RUN STOP switch must be returned to the STOP position then return...

Страница 128: ...d puddle control and deposition stacking of iron are key to fast travel speeds It is recommend ed that the ARC CONTROL be set initially at 0 TOUCH START TIG MODE The Vantage can be used in a wide vari...

Страница 129: ...2 4 4 5 6 0 020 50 5 20 3 5 10 3 5 5 10 3 5 0 40 1 0 15 80 3 5 10 3 5 5 10 3 5 1 16 1 6 70 150 10 20 5 10 3 5 9 13 4 6 5 6 3 32 2 4 150 250 15 30 13 17 6 8 11 15 5 7 6 7 8 1 8 3 2 250 400 25 40 15 23...

Страница 130: ...output can be split to provide two separate 120 VAC outputs with a maxi mum permissible current of 50 A per output to two sep arate 120 VAC branch circuits Output voltage is within 10 at all loads up...

Страница 131: ...RD RECOMMENDATIONS An extension cord can be used with the auxiliary power outputs as long as it is of ample size Table B 5 lists permissible extension cord lengths based on conduc tor size and auxilia...

Страница 132: ...OTES B4 12 B4 12 VANTAGE 500 Return to Section TOC Return to Section TOC Return to Section TOC Return to Section TOC Return to Master TOC Return to Master TOC Return to Master TOC Return to Master TOC...

Страница 133: ...3 Code 10996 Options Accessories C4 1 Optional Field Installed Accessories C4 2 Plasma Cutting Option C4 2 TIG Welding Options C4 3 High Frequency Generators for TIG Applications C4 3 Wire Feeder Opt...

Страница 134: ...SPARK ARRESTOR KIT Easily mounts to standard muffler K949 1 Oil Drain Kit includes ball valve hose and clamp K1816 1 Full KVA Adapter Kit Plugs into the 120 240V NEMA 14 50R receptacle on the case fr...

Страница 135: ...nstructions on installation oper ation and maintenance WIRE FEEDER OPTIONS K449 LN 25 Wire Feeder Portable CC CV unit for flux cored and MIG welding Includes Gas Solenoid Internal Contactor K126 2 Mag...

Страница 136: ...NOTES C4 4 C4 4 VANTAGE 500 Return to Section TOC Return to Section TOC Return to Section TOC Return to Section TOC Return to Master TOC Return to Master TOC Return to Master TOC Return to Master TOC...

Страница 137: ...r Filter D4 5 Engine Maintenance Schedules and Parts D4 7 Welder Generator Maintenance D4 7 Storage D4 7 Cleaning D4 7 Nameplates D4 7 Brush Removal and Replacement D4 7 Bearings D4 7 Receptacles D4 7...

Страница 138: ...ating conditions OIL Check the oil level after every 8 hours of operation or daily BE SURE TO MAINTAIN THE OIL LEVEL Change the oil the first time between 25 and 50 hours of operation Then under norma...

Страница 139: ...om for the fuel to expand Refer to your engine operation manual for recom mended grade of fuel COOLING SYSTEM To avoid scalding do not loosen or remove the radiator cap while the engine is hot The VAN...

Страница 140: ...ean lubricating oil 4 Install the filter as specified by the filter manufactur er 5 Open the fuel valve and check for leaks Mechanical overtightening will distort the threads filter element seal or fi...

Страница 141: ...he element around in the solution to help remove dirt 5 Rinse elements from inside out with a gentle stream of water less than 40 psi to remove all suds and dirt 6 Dry the element before reuse with wa...

Страница 142: ...6 D4 6 VANTAGE 500 MAINTENANCE INSTRUCTIONS Return to Section TOC Return to Section TOC Return to Section TOC Return to Section TOC Return to Master TOC Return to Master TOC Return to Master TOC Retur...

Страница 143: ...fittings completely clean and use clean equipment More bearing failures are caused by dirt introduced during greasing than from insufficient grease RECEPTACLES Keep the electrical receptacles in good...

Страница 144: ...ccumulation on the battery can lead to more rapid discharge and early battery failure CHECKING SPECIFIC GRAVITY Check each battery cell with a hydrometer A fully charged battery will have a specific g...

Страница 145: ...TPUT ASSEMBLY 3 POWER MODULE ASSEMBLY 4 BASE LIFT BALE ASSEMBLY 5 FUEL TANK MOUNTING 6A ENGINE ASSEMBLY 7 GENERATOR FRAME 8 SOLENOID ASSEMBLY 9 CASEBACK 10 CASE TOP AND SIDES Return to Section TOC Ret...

Страница 146: ...OTES D4 10 D4 10 VANTAGE 500 Return to Section TOC Return to Section TOC Return to Section TOC Return to Section TOC Return to Master TOC Return to Master TOC Return to Master TOC Return to Master TOC...

Страница 147: ...4 Towing A5 4 Vehicle Mounting A5 4 Pre Operation Engine Service A5 5 Oil A5 5 Fuel A5 5 Fuel Cap A5 5 Engine Cooling System A5 5 Battery Connection A5 5 Muffler Outlet Pipe A5 6 Spark Arrester A5 6 H...

Страница 148: ...mps DC multi purpose 35 volts PHYSICAL DIMENSIONS Height 2 Width Depth Weight 42 0 in 31 5 in 63 1 in 1443lbs 1066 8 mm 800 1mm 1603mm 655kg Approx 1 Output rating in watts is equivalent to volt amper...

Страница 149: ...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 a...

Страница 150: ...iler for use with this equipment for road in plant and yard towing by a vehicle1 is Lincoln s K953 1 If the user adapts a non Lincoln trail er he must assume responsibility that the method of attachme...

Страница 151: ...ction pump NOTE Before starting the engine open the fuel shutoff valve pointer to be in line with hose NOTE Before starting the engine open the fuel shut off valve pointer to be in line with hose FUEL...

Страница 152: ...rsely affect performance HIGH FREQUENCY GENERATORS FOR TIG APPLICATIONS The K799 Hi Freq Unit obsolete and the K930 1 or 2 TIG Module are suitable for use with the Vantage 500 The Vantage 500 is equip...

Страница 153: ...ork of a building which has been effectively grounded The U S National Electrical Code lists a number of alternate means of grounding electrical equipment A machine grounding stud marked with the symb...

Страница 154: ...40 VAC plug NEMA Type 14 50 to the double pole circuit breaker using four conductor cable of the proper size and desired length The 50 amp 120 240 VAC plug is avail able in the optional K802R plug kit...

Страница 155: ...Auxiliary Power Controls B5 6 Engine Operation B5 7 Starting the Engine B5 7 Stopping the Engine B5 7 Typical Fuel Consumption B5 7 Welder Operation B5 8 Stick Welding B5 8 Constant Current CC Weldin...

Страница 156: ...te this equipment ADDITIONAL SAFETY PRECAUTIONS Always operate the welder with the hinged door closed and the side panels in place as these provide maxi mum protection from moving parts and insure pro...

Страница 157: ...ntrol potentiometer in Wire and Stick modes for precise adjustment of arc characteristics Advanced circuitry to prevent pop outs in the five slope modes FOR AUXILIARY POWER 12 000 watts of 120 240 VAC...

Страница 158: ...METER The hour meter displays the total time that the engine has been running This meter is a useful indicator for scheduling preventive maintenance 4 FUEL LEVEL GAUGE Displays the level of diesel fue...

Страница 159: ...ollows A In the High position the engine runs at the high idle speed controlled by the governor B In the Auto position the idler operates as follows a When switched from High to Auto or after starting...

Страница 160: ...more forceful digging arc Crisp Increasing the number from 10 Soft to 10 Crisp increases the short circuit current which results in a more forceful digging arc Typically a forceful digging arc is pref...

Страница 161: ...light may turn off after 5 seconds or remain on until the engine is started 6 Within 30 seconds press and hold the engine START button until the engine starts If the engine does not start within 30 s...

Страница 162: ...d puddle control and deposition stacking of iron are key to fast travel speeds It is recommend ed that the ARC CONTROL be set initially at 0 TOUCH START TIG MODE The Vantage can be used in a wide vari...

Страница 163: ...2 4 4 5 6 0 020 50 5 20 3 5 10 3 5 5 10 3 5 0 40 1 0 15 80 3 5 10 3 5 5 10 3 5 1 16 1 6 70 150 10 20 5 10 3 5 9 13 4 6 5 6 3 32 2 4 150 250 15 30 13 17 6 8 11 15 5 7 6 7 8 1 8 3 2 250 400 25 40 15 23...

Страница 164: ...s turn the WELD MODE switch to the CC STICK position Operation in other modes may produce erratic outputs and large output imbalances between the units AUXILIARY POWER OPERATION If a GFCI receptacle i...

Страница 165: ...1 AND 3 PHASE WATTS AMPS 50 50 50 12 000 10 000 5 600 0 0 PLUS OR OR TABLE B5 5 VANTAGE 500 CUMMINS Extension Cord Length Recommendations Current Amps 15 15 20 20 25 30 38 50 Voltage Volts 120 240 120...

Страница 166: ...OTES B5 12 B5 12 VANTAGE 500 Return to Section TOC Return to Section TOC Return to Section TOC Return to Section TOC Return to Master TOC Return to Master TOC Return to Master TOC Return to Master TOC...

Страница 167: ...Codes 11181 11416 Options Accessories C5 1 Optional Field Installed Accessories C5 2 Plasma Cutting Option C5 2 TIG Welding Options C5 3 High Frequency Generators for TIG Applications C5 3 Wire Feeder...

Страница 168: ...SPARK ARRESTOR KIT Easily mounts to standard muffler K949 1 Oil Drain Kit includes ball valve hose and clamp K1816 1 Full KVA Adapter Kit Plugs into the 120 240V NEMA 14 50R receptacle on the case fr...

Страница 169: ...nstructions on installation oper ation and maintenance WIRE FEEDER OPTIONS K449 LN 25 Wire Feeder Portable CC CV unit for flux cored and MIG welding Includes Gas Solenoid Internal Contactor K126 2 Mag...

Страница 170: ...NOTES C5 4 C5 4 VANTAGE 500 Return to Section TOC Return to Section TOC Return to Section TOC Return to Section TOC Return to Master TOC Return to Master TOC Return to Master TOC Return to Master TOC...

Страница 171: ...r Filter D5 5 Engine Maintenance Schedules and Parts D5 7 Welder Generator Maintenance D5 7 Storage D5 7 Cleaning D5 7 Nameplates D5 7 Brush Removal and Replacement D5 7 Bearings D5 7 Receptacles D5 7...

Страница 172: ...ting conditions OIL Check the oil level after every 8 hours of operation or daily BE SURE TO MAINTAIN THE OIL LEVEL Change the oil the first time between 25 and 50 hours of operation Then under normal...

Страница 173: ...om for the fuel to expand Refer to your engine operation manual for recom mended grade of fuel COOLING SYSTEM To avoid scalding do not loosen or remove the radiator cap while the engine is hot The VAN...

Страница 174: ...ean lubricating oil 4 Install the filter as specified by the filter manufactur er 5 Open the fuel valve and check for leaks Mechanical overtightening will distort the threads filter element seal or fi...

Страница 175: ...e element around in the solution to help remove dirt 5 Rinse elements from inside out with a gentle stream of water less than 40 psi to remove all suds and dirt 6 Dry the element before reuse with war...

Страница 176: ...6 D5 6 VANTAGE 500 MAINTENANCE INSTRUCTIONS Return to Section TOC Return to Section TOC Return to Section TOC Return to Section TOC Return to Master TOC Return to Master TOC Return to Master TOC Retur...

Страница 177: ...fittings completely clean and use clean equipment More bearing failures are caused by dirt introduced during greasing than from insufficient grease RECEPTACLES Keep the electrical receptacles in good...

Страница 178: ...ccumulation on the battery can lead to more rapid discharge and early battery failure CHECKING SPECIFIC GRAVITY Check each battery cell with a hydrometer A fully charged battery will have a specific g...

Страница 179: ...UTPUT ASSEMBLY 3 POWER MODULE ASSEMBLY 4 BASE LIFT BALE ASSEMBLY 5 FUEL TANK MOUNTING 6A ENGINE ASSEMBLY 7 GENERATOR FRAME 8 SOLENOID ASSEMBLY 9 CASEBACK 10 CASE TOP AND SIDES Return to Section TOC Re...

Страница 180: ...OTES D5 10 D5 10 VANTAGE 500 Return to Section TOC Return to Section TOC Return to Section TOC Return to Section TOC Return to Master TOC Return to Master TOC Return to Master TOC Return to Master TOC...

Страница 181: ...e Feeder No 120 VAC on EURO Models THREE PHASE RECTIFIER __ __ TO WELD CONTROL BOARD _ _ START BUTTON BATTERY ON STARTER 12 VDC RUN ENGINE SENSORS OIL PRESSURE WATER TEMP PERIPHERAL PCB PULL COIL PCB...

Страница 182: ...MS typel Connector The engine alternator supplies charging current for the battery circuit The Peripheral board monitors the engine sensors and will shut the engine off in the event of low oil pressu...

Страница 183: ...erminals and current feedback from the shunt is fed to the Weld Control PC board as a means of controlling the output NOTE Unshaded areas of Block Logic Diagram are the subject of discussion ENGINE RO...

Страница 184: ...GINE ROTOR STATOR AUXILIARY WINDINGS W E L D W I N D I G MECHANICAL ROTATION ALTERNATOR OUTPUT CONTROL MODE SELECT SWITCH SLIP RINGS ARC CONTROL WELD CONTROL BOARD VOLTMETER AMMETER 42 VAC and 120VAC...

Страница 185: ...nal a positive DC voltage relative to the source is applied to the gate terminal of the IGBT the device is capable of conducting current A voltage sup ply connected to the drain terminal will allow th...

Страница 186: ...up conducting for 2 microsecond The dwell time off time is 48 microseconds Since only 2 microsec onds of the 50 microsecond time period is devoted to conducting the output power is minimized MAXIMUM O...

Страница 187: ...rolled The following diagram depicts the current flow in the system when the switch is open and closed When the switch is closed current is applied through the inductor to the arc When the switch open...

Страница 188: ...NOTES E 8 E 8 VANTAGE 500 Return to Section TOC Return to Section TOC Return to Section TOC Return to Section TOC Return to Master TOC Return to Master TOC Return to Master TOC Return to Master TOC...

Страница 189: ...st F 31 Stator Voltage Test F 33 Output Rectifier Bridge Test F 37 Electronic Governor Test F 43 Charging Circuit Test F 45 Oscilloscope Waveforms F 47 Normal Open Circuit Voltage Waveform 115VAC Supp...

Страница 190: ...nents in the order listed to eliminate one possibility at a time until you locate the cause of your problem All of the referenced test procedures referred to in the Troubleshooting Guide are described...

Страница 191: ...per plastic or cloth which could have a static charge If the PC board can t be installed immediately put it back in the static shield ing bag If the PC board uses protective shorting jumpers don t rem...

Страница 192: ...iring Diagram 2 With the engine at high idle 1900RPM the machine in the Stick mode and the OUTPUT CONTROL at maximum check for the presence of approxi mately 87VDC open circuit volt age at the output...

Страница 193: ...rm the Flashing and Rotor Voltage Test If the flashing voltage is not pre sent the leads 6 5H 200B 201 or 200 may be faulty See the Wiring Diagram Also make sure that lead 5P has continuity zero ohms...

Страница 194: ...age feedback leads for loose or faulty con nections See the Wiring Diagram 4 Perform the Chopper Module Test 5 The Weld Control PC board may be faulty 6 Pull coil board may be faulty Except tier II Cu...

Страница 195: ...mote control unit may be defective 3 Check the Amphenol connec tions and associated wiring 1 Check Plug J11 on the Weld Control PC board for loose or faulty connections 2 The Weld Control PC board may...

Страница 196: ...y be faulty 3 The wire feeder may be faulty 1 Check for the presence of appropriate source voltage at the 14 pin amphenol 2 If the appropriate voltage 42 VAC or 115 VAC is NOT pre sent at the 14 pin a...

Страница 197: ...engine oil temperature may be too high Check cooling sys tem 4 The battery voltage may be too low 5 ON OFF switch has been on for more than 30 seconds before starting cycle switch OFF then ON 1 The s...

Страница 198: ...C board should normally supply 10VDC to the shutdown solenoid via leads 252 and 262 See the Wiring Diagram except tier II Cummins code 11181 4 Tier II Cummins electronic gov ernor control board may be...

Страница 199: ...nsing toroid for loose or faulty con nections See the Wiring Diagram 2 Make sure leads 3 and 6A pass through the toroid twice in opposite directions 3 The current sensing toroid may be faulty 4 Pull c...

Страница 200: ...ose connection on the heavy current carrying leads inside the Vantage 500 See the Wiring Diagram 2 If the OCV is low at the welder output terminals perform the Engine Throttle Adjustment Test 3 Perfor...

Страница 201: ...assistance before you proceed Call 1 888 935 3877 TEST DESCRIPTION This procedure will aid the technician in the removal and replacement of the case sheet metal covers MATERIALS NEEDED 3 8 wrench 7 16...

Страница 202: ...8 wrench remove the screws from the top front of the roof assembly and the screws from the sides of the control box Carefully lower the front control panel 6 With the 9 16 wrench remove the exhaust pi...

Страница 203: ...e Department for electrical trou bleshooting assistance before you proceed Call 1 888 935 3877 TEST DESCRIPTION This procedure will insure that the large capacitors in the chopper modules have been di...

Страница 204: ...acitors can be discharged by holding the resistor with insulated pliers and using the resistor terminals to bridge chopper module terminals B1 to B2 and B4 to B5 DO NOT TOUCH THE TER MINALS OR METAL P...

Страница 205: ...the Lincoln Electric Service Department for electrical trou bleshooting assistance before you proceed Call 1 888 935 3877 TEST DESCRIPTION This test will help determine if the chopper module is shorte...

Страница 206: ...wrench remove the negative jumper strap attaching the power capacitors to the Power Module PC Board 6 Check resistance with analog ohmmeter per the Chopper Test Table F 1 Note Make sure the bolts do...

Страница 207: ...00k or higher B6 B4 400k or higher B2 B3 6k to 9k B3 B2 6k to 9k B4 B2 200k or higher B2 B4 400k or higher B4 B3 200k or higher B3 B4 400k or higher CHOPPER TEST CHOPPER TERMINAL CONNECTIONS OHMMETER...

Страница 208: ...NOTES F 20 F 20 VANTAGE 500 Return to Section TOC Return to Section TOC Return to Section TOC Return to Section TOC Return to Master TOC Return to Master TOC Return to Master TOC Return to Master TOC...

Страница 209: ...e you proceed Call 1 888 935 3877 TEST DESCRIPTION This test will determine if the idler solenoid is capable of functioning when it is energized with 12VDC MATERIALS NEEDED External 12VDC supply 30 am...

Страница 210: ...l supply con nected to terminals 232M and 265 for longer than three seconds will damage the coil The solenoid should deactivate when the 12VDC is removed 6 If the solenoid does not operate properly ch...

Страница 211: ...e before you proceed Call 1 888 935 3877 TEST DESCRIPTION This test will determine if the shutdown solenoid is capable of functioning when it is ener gized with 12VDC MATERIALS NEEDED External 12VDC s...

Страница 212: ...he external supply con nected to terminals 232M and 265 for longer than three seconds will damage the coil The solenoid should deactivate when the 12VDC is removed 6 If the solenoid does not operate p...

Страница 213: ...this test will determine whether the engine is operat ing at the correct speed RPM during both HIGH and LOW idle conditions Directions for adjusting the throttle to the correct RPM are given MATERIALS...

Страница 214: ...500 RPM Cummins 1425 6 If either of the readings is incorrect adjust the throttle as follows Adjust HIGH IDLE Use the 10mm wrench to loosen the locking nut See Figure F 7 for location of the adjusting...

Страница 215: ...t HIGH IDLE Use the 10mm wrench to loosen the locking nut See Figure F 7 for location of the adjusting screw and locking nut Turn the threaded screw counter clockwise to increase the HIGH IDLE speed A...

Страница 216: ...nds Retighten the locking nut Adjust LOW IDLE First make sure there is no load on the machine Set the IDLE switch to AUTO and wait for the engine to change to low idle speed Use the 10mm wrench to loo...

Страница 217: ...est procedures or are unable to perform the test repairs safely contact the Lincoln Electric Service Department for electrical trou bleshooting assistance before you proceed Call 1 888 935 3877 TEST D...

Страница 218: ...ne meter probe on either of the slip rings Place the other probe on any good unpainted ground The resistance should be very high at least 500 000 ohms 7 If the test does not meet the resistance specif...

Страница 219: ...ct the Lincoln Electric Service Department for electrical trou bleshooting assistance before you proceed Call 1 888 935 3877 TEST DESCRIPTION This test will determine if the correct DC voltage is bein...

Страница 220: ...ge reading is low or not present the gen erator field is not functioning properly Perform the Rotor Resistance Test Also check the field diode rectifier bridge filter capacitor and associated leads an...

Страница 221: ...test procedures or are unable to perform the test repairs safely contact the Lincoln Electric Service Department for electrical trou bleshooting assistance before you proceed Call 1 888 935 3877 TEST...

Страница 222: ...the green ground lead will still be attached AUXILIARY POWER AND WELD WIND INGS TEST Start the engine and run at high idle 1900 RPM Do not load welding or auxiliary power See Figure F11 and the appro...

Страница 223: ...ON BACK OF CONTROL PANEL STATOR VOLTAGE TEST CONTINUED TROUBLESHOOTING AND REPAIR F 35 F 35 VANTAGE 500 3A 236A 238B CB3 CB5 CB1 CB4 CB6 CB2 42B 6B 11 32A 12 5C GND C 5E GND D 8 9 5B J11 J10 GND E J1...

Страница 224: ...also the Rotor Resistance Test 4 Also check leads 6F and 5P for loose or faulty connections to the field bridge See the Wiring Diagram 5 If the tests in Steps 6 and 7 are OK and the stator voltages ar...

Страница 225: ...oln Electric Service Department for electrical trou bleshooting assistance before you proceed Call 1 888 935 3877 TEST DESCRIPTION This test will determine if the rectifier is grounded or if there are...

Страница 226: ...rectifier as follows Mark leads W1 W2 and W3 so they can be prop erly reconnected after the test is complete Remove these leads and position them so they do not come in contact with any part of the r...

Страница 227: ...diodes again Diodes should have a low resistance in one polarity and very high resistance in the opposite polarity See diode test Table F 2 One open diode will not be detected 13 Replace rectifier br...

Страница 228: ...40 F 40 VANTAGE 500 FIGURE F 15 DIODE LEAD REMOVAL AC 1 D C D C 1 2 3 AC DC DC AC 1 2 3 1 2 3 Return to Section TOC Return to Section TOC Return to Section TOC Return to Section TOC Return to Master...

Страница 229: ...Bias High Resistance AC2 DC ReverseBias High Resistance AC3 DC ReverseBias High Resistance DC AC1 ReverseBias High Resistance DC AC2 ReverseBias High Resistance DC AC3 ReverseBias High Resistance DIOD...

Страница 230: ...NOTES F 42 F 42 VANTAGE 500 Return to Section TOC Return to Section TOC Return to Section TOC Return to Section TOC Return to Master TOC Return to Master TOC Return to Master TOC Return to Master TOC...

Страница 231: ...cal trou bleshooting assistance before you proceed Call 1 888 935 3877 TEST DESCRIPTION This test will help determine if the Electronic Governor is operating properly MATERIALS NEEDED Volt Ohmmeter An...

Страница 232: ...inkage rod from fuel control lever at injection pump 2 Loosen lock nut on fuel lever off stop screw 3 Adjust fuel lever stop screw clockwise down until engine will just start and run slowly while hold...

Страница 233: ...ou bleshooting assistance before you proceed Call 1 888 935 3877 TEST DESCRIPTION This test will determine if the engine alternator and associated circuitry are functioning properly MATERIALS NEEDED 3...

Страница 234: ...DC 7 Set the voltmeter for DC volts and measure the DC volts at lead 281 232 Cummins to engine ground See the Wiring Diagram Normal is 13 2 to 14 5 VDC NOTE Lead 281 232 Cummins carries the flash ing...

Страница 235: ...cted at machine 115VAC receptacle SCOPE SETTINGS Volts Div 50V Div Horizontal Sweep 5 ms Div Coupling DC Trigger Internal NORMAL OPEN CIRCUIT VOLTAGE WAVEFORM 115VAC SUPPLY HIGH IDLE NO LOAD TROUBLESH...

Страница 236: ...on represents 5 milliseconds in time SCOPE SETTINGS Volts Div 50V Div Horizontal Sweep 5 ms Div Coupling DC Trigger Internal NORMAL OPEN CIRCUIT VOLTAGE WAVEFORM STICK MAX TAP MAX CONTROL POT HIGH IDL...

Страница 237: ...e machine was loaded with a resistance grid bank to 500 amps at 40 volts SCOPE SETTINGS Volts Div 20V Div Horizontal Sweep 0 1 ms Div Coupling DC Trigger Internal NORMAL WELD VOLTAGE WAVEFORM STICK CC...

Страница 238: ...machine was loaded with a resis tance grid bank to 200 amps at 16 VDC SCOPE SETTINGS Volts Div 10V Div Horizontal Sweep 05 ms Div Coupling DC Trigger Internal NORMAL TIG MODE VOLTAGE WAVEFORM LOADED...

Страница 239: ...n represents 5 milliseconds in time SCOPE SETTINGS Volts Div 50V Div Horizontal Sweep 5 ms Div Coupling DC Trigger Internal NORMAL OPEN CIRCUIT VOLTAGE WAVEFORM WIRE CV HIGH IDLE NO LOAD TROUBLESHOOTI...

Страница 240: ...machine was loaded with a resistance grid bank to 500 amps at 40 volts SCOPE SETTINGS Volts Div 20V Div Horizontal Sweep 0 1ms Div Coupling DC Trigger Internal NORMAL WELD VOLTAGE WAVEFORM WIRE CV MA...

Страница 241: ...ce before you proceed Call 1 888 935 3877 TEST DESCRIPTION This procedure will aid the technician in the removal and replacement of the shutdown solenoid MATERIALS NEEDED 7 16 Wrench 10mm wrench Long...

Страница 242: ...n from the solenoid linkage assembly 6 Remove the solenoid assembly 7 Replace any faulty or worn parts and reassemble the solenoid assembly REASSEMBLY 1 Reassemble the pivot pin and retaining ring to...

Страница 243: ...ing and pivot pin from the solenoid linkage assembly 6 Remove the solenoid assembly 7 Replace any faulty or worn parts and reassemble the solenoid assembly REASSEMBLY 1 Reassemble the pivot pin and re...

Страница 244: ...NOTES F 56 F 56 VANTAGE 500 Return to Section TOC Return to Section TOC Return to Section TOC Return to Section TOC Return to Master TOC Return to Master TOC Return to Master TOC Return to Master TOC...

Страница 245: ...orm the test repairs safely contact the Lincoln Electric Service Department for electrical trou bleshooting assistance before you proceed Call 1 888 935 3877 TEST DESCRIPTION The following procedure w...

Страница 246: ...ing the 7 16 wrench remove the appropriate stator leads and AC terminals leads Refer to Figure F 19 Label the leads for reassembly 5 Using 7 16 socket remove 4 bolts holding power module assembly to b...

Страница 247: ...nt for electrical trou bleshooting assistance before you proceed Call 1 888 935 3877 TEST DESCRIPTION The following procedure will aid the technician in removing and replacing the Vantage 500 stator a...

Страница 248: ...ng the 3 8 wrench remove leads 229 white and 242D from the fuel level sensor Label the leads for reassembly 7 Turn the fuel off at the shutoff valve Remove and plug the fuel return line 8 Remove and p...

Страница 249: ...rew driver disconnect leads 200A 200B and 201A or remove screw cap bracket and remove cap from the filter capacitor 12 Label and remove leads 5H and 201A 200A and 6A from the field diode rectifier bri...

Страница 250: ...r of the door hinge assembly where it attaches to the roof Remove the support rod TROUBLESHOOTING AND REPAIR F 62 F 62 VANTAGE 500 FIGURE F 23 CONTROL BOX CONNECTIONS 200A 200B 201 Refer to Figure F 2...

Страница 251: ...the alternator shroud together 19 With the 7 16 wrench remove the two nuts lock washers and flat washers that hold the bottom of the shroud to the machine base Remove the shroud TROUBLESHOOTING AND RE...

Страница 252: ...ft frame weldment 22 With the 3 8 wrench remove the nuts lock wash ers and flat washers from the two studs that hold the fan baffle to the machine base 23 Using the 3 4 wrench remove the four bolts lo...

Страница 253: ...lace 4 Using two air impact from bottom wrench on top remove the nut lock washer and carriage bolt holding the alternator mounting foot to the machine base Do this on each side 5 Using the 3 8 wrench...

Страница 254: ...to the engine flywheel INSTALL STATOR Be sure the engine is blocked securely and the stator is supported with the hoist Watch bearing housing install tolerance ring and install bearing cover plate Whe...

Страница 255: ...ectifier OUTPUT PANEL AND CONTROL BOX n Leads 232N and 227 to Pull Coil PC board n Leads 232L and 232N to 12 VDC insulated stud n Leads 200A 200B and 201 and 201A to the field capacitor TROUBLESHOOTIN...

Страница 256: ...0 NA High Idle 1890 1910 1750 1890 WELDER DC STICK OUTPUT Mode Selector Open Circuit Switch Fine Control Voltage Load Volts Load Amps 30 575 Setting Maximum 55 60 39 5 42 0 565 585 WELDER CV WIRE OUTP...

Страница 257: ...10 15 18 28 TIG 20 250 A Minimum 10 15 18 28 AUXILIARY POWER OUTPUT 230 Volt Receptacle 115 Volt Receptacles Open Circuit Open Circuit Voltage Load Volts Load Amps Voltage Load Volts Load Amps 230 26...

Страница 258: ...NOTES F 70 F 70 VANTAGE 500 Return to Section TOC Return to Section TOC Return to Section TOC Return to Section TOC Return to Master TOC Return to Master TOC Return to Master TOC Return to Master TOC...

Страница 259: ...Complete Machine G4848 Codes 11180 11415 11468 Deutz G 10 G 11 Schematic Complete Machine G4791 Codes 11181 1416 Cummins G 12 Schematic Weld Control PC Board G4108 1 G 13 thru G 17 Schematic Chopper P...

Страница 260: ...M RIGHT OF CONTROL BOX GROUND STUD ON OUTPUT PANEL GND J 12 VOLT GROUND STUD ON LEFT SIDE BACK OF CONTROL BOX 5N 5S 5L 5M 5T GND A GND B 31 5H GND J L1 CHOKE 5J 5K 5K 5A 5B 5 GND C GND E GND D M1 M2 M...

Страница 261: ...8 6 10 J4 J5 6 10 CONTROL MODE SEL CHOPPER POWER PWM THERMAL 25A 23A 13 14 77 76 75 2 4 75A 76A 77A 500 J6 SHUNT J1 AMPHENOL I D J2 ENGINE PERIPHERAL ALT 405A 247 243 405B 232E GOLD SILVER ENG PROT P...

Страница 262: ...05A 247 243 405B GOLD SILVER ENG PROT PROGRAMMING 9 16 1 8 J31 5T 270 262A 405 232F 1 6 12 7 J32 234 271 247 3 4 1 J30 6 405A 239 232M 232K 232A 232R 232B 232C 12VDC INSULATED STUD 232C OIL PRESSURE 2...

Страница 263: ...PROT GOVERNOR CONTROL MODULE 404 5T 270 262A 405 232F 1 6 12 7 J31 234 271 SHLD 232K 232A 232B 232C 12VDC INSULATED STUD 232C OIL PRESSURE 241 228 5L 229 232B 5M COOLANT TEMPERATURE 232K 5K 4 1 4 1 4...

Страница 264: ...B 75B GROUND AMPHENOL INPUT TO AMPHENOL 115VAC CONTACTOR W ORK REMOTE CONTROL 42VAC GROUND AMPHENOL J A D C H B K E F G I 77B 76B 75B GND B 4B 2B 4B 2B 13 J3 8 14 J3 16 J1 5 500 J1 13 500 500 I D JUMP...

Страница 265: ...3 11 J3 9 47 5 ohm TRANSFORMER 15V 3 3V 15V 5V J3 16 J3 8 40 100VDC INPUT FRAME 15V COM 12VISOLATEDCIRCUITRYFORENGINEFUNCTIONS STUD STUD 10K POT 10K POT 10K POT MACHINE IDENTITY TABLE PINS JUMPERED TO...

Страница 266: ...A 4A 2A 76A 77B 76B 75B GROUND AMPHENOL INPUT TO AMPHENOL 115VAC CONTACTOR W ORK REMOTE CONTROL 42VAC GROUND AMPHENOL J A D C H B K E F G I 77B 76B 75B GND B 4B 2B 4B 2B 13 J3 8 14 J3 16 J1 5 500 J1 1...

Страница 267: ...FRAME J2 6 J2 4 J2 5 IDLE HOLD COIL TO IDLE PULL COIL BOARD HIGH PULL TO LOW IDLE FRAME 15V COM 12VISOLATEDCIRCUITRYFORENGINEFUNCTIONS STUD STUD AUXILLARY CURRENT SENSE 10K POT 10K POT 10K POT AUXILI...

Страница 268: ...cles Open Circuit Volts CC Max Min 58 58 58 58 58 26 12 12 CV Pipe Tig Control board common is at welder positive output and shunt Control board circuits associated with J2 are part of engine electric...

Страница 269: ...UXILIARY SENSE TOROID MACHINE IDENTITY TABLE PINS JUMPERED TO SELECTMACHINE 1 2 3 4 A TIG PIPE CC CV MODE SELECTOR SW ITCH AUSTRAILIAN VANTAGE 575 USES A 3 POSITION TOGGLE SWITCH 77 76 75 77B 76B 75B...

Страница 270: ...uF 100V 9 J5 4 J5 3 J5 2 J5 1 J5 DZ1 1W 5 1V DZ9 1W 5 1V D16 1A 1000V DZ4 5W 10V R37 700 5W D34 1A 400V D28 1A 400V D33 1A 400V D27 1A 400V D22 1A 1000V R158 5 1K 5W C32 22uF 63V DZ3 5W 20V LED10 05A...

Страница 271: ...G 13 NOTE This diagram is for reference only It may not be accurate for all machines covered by this manual Return to Section TOC Return to Section TOC Return to Section TOC Return to Section TOC Retu...

Страница 272: ...G 14 NOTE This diagram is for reference only It may not be accurate for all machines covered by this manual Return to Section TOC Return to Section TOC Return to Section TOC Return to Section TOC Ret...

Страница 273: ...G 15 NOTE This diagram is for reference only It may not be accurate for all machines covered by this manual Return to Section TOC Return to Section TOC Return to Section TOC Return to Section TOC Ret...

Страница 274: ...G 16 NOTE This diagram is for reference only It may not be accurate for all machines covered by this manual Return to Section TOC Return to Section TOC Return to Section TOC Return to Section TOC Ret...

Страница 275: ...7 NOTE This diagram is for reference only It may not be accurate for all machines covered by this manual Return to Section TOC Return to Section TOC Return to Section TOC Return to Section TOC Return...

Страница 276: ...8 NOTE This diagram is for reference only It may not be accurate for all machines covered by this manual Return to Section TOC Return to Section TOC Return to Section TOC Return to Section TOC Return...

Страница 277: ...NOTE This diagram is for reference only It may not be accurate for all machines covered by this manual Return to Section TOC Return to Section TOC Return to Section TOC Return to Section TOC Return to...

Страница 278: ...G 20 NOTE This diagram is for reference only It may not be accurate for all machines covered by this manual Return to Section TOC Return to Section TOC Return to Section TOC Return to Section TOC Retu...

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