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Lincoln Electric IM894-B User's Manual

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4. edd ed ERA 5 Muffler Outlet EE A 5 Spark TEE A 5 Hemote GCOnltol e t recette uberem 5 A 5 Electrical Connections aide Dante A 6 Machine Grounding Aisne tirer ones A 6 Welding Mal tin apaa art Res e tr reta east een A 6 Welding Output Cables ES A 6 jer lecum A 6 Auxiliary Power Receptacles and Plugs A A 7 Standby Power Connections entren tea spen denk e A 7 Connection of Lincoln Electric Wire Feederz A 7 A 8 0 ei coe General mE For Auxiliary ee aa ee Engine RUE Fuel t m Welder Controls ica PA Engine Controls Fuel Consumption Starting and Stopping the Engine B 4 B 5 Welding Operations Le B 5 Duty Cycle and Electrode Information B 5 Constant Current Stick Welding nennen nennen B 5 Downhill Pipe Stick Welding AA 5 Tig B 6 Typical Current Ranges for Tungsten Electrodes B 6 Wire Welding 2 M B 7 GOUGING Secs e CER B 7 Auxiliary
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6. LINDYID TOHLNOO NYO HOIHM J9YLIOA 830334 201 OV NI 3SV3HONI NV 13S 3Md SI ONILLAS 9 HOIH SHL 30 3SV38ONI ASNVS 3TLLOSH L 3H L ONIGIHSHSAO ONILLAS HONH3AO9 SHL 9NIDNVHO LINN 9333 OL 9199 390419313 lt OL tc lt 931999 1OHLNOO 2697 318vo 1 OL jueuudinbe 14 sued Ajeouoeje jou og e esn jejsui pjnous peu enb Ajuo e sued deey e pes JALLVO3N 10991025 e eoejd ui uedo sjeued ejejedo jou oq e d WVYSVIC NOLLO3NNOO SH3Q 13M 500 CE LINCOLN epoo jueuidinbe BAIN e 104 eut 914A S si epoo 10 siy paJaAoo 9je1n22e eq jou 10 S SIUL 310 F 5 15959 6804 9 O 224 unns H 1 4
7. MR RM nn 7 Simultaneous Welding and Power Loads B 7 Extension Cord Recommendations ene B 7 500 Section C Field Installed Options Accessories C 1 viii TABLE OF CONTENTS Section D Safety Precautions sis D 1 ROUTING scene RAAN D 1 Engine Service Items D 1 Engine Oil Change ee m 0 2 Engine Oil Filter Change D 2 Air EE D 2 Service Instructions And Installation Tips for Engine Air Filter D 3 Cooling SyStelm d en eel D 4 Fan Belt CE D 4 STE D 4 Bleeding the Fuel System D 4 Fuel M D 5 Engine Adjustment sir D 5 Battery Maintenance 2 e dnd LL RUE D 5 Servicing Optional Spark Arrestor esseeseesseeesieesrtssirserissrissrrnsssrnnsrnnssrn nns D 5 Welder Generator Maintenance D 6 Si TES D 6 CIS ANING ea D 6 Brush Removal and Replacement D 6 Section E 7 How to Use Troubleshooting Guide E 1 Troubleshooting Guide E 2 thru E 6 Connection Diagrams Wiring Diagrams and Dimension Print Section F Parts ETT ETT DTE P 535 INSTALLATION 1 TECHNI
8. Nid tL ueuudinbe 14 2 5 sued Ajeouioeje jou esn jejsui pjnous jeuuosied AIUO e eJ0jeq sued wou 000 e peg Moyeg 3ALLVO3N 12euuoosiq e ui deeye sjeued jou oq e ONINHVM 77 SLOWSY TYNOILdO 1 NOLLO3NNOO 23V 5509 SCNT SH3Q 13M 3NION3 VANTAGE 500 CE LINCOLN E 58 F 3 0002 22 01 9341530 SV NOILISOd 3 Gl HOI NI HOLIMS 41101 ON WANVW 338 SNOILVOl1ddV 9340403 ANY ALVIGAWWI 41949 LNSYYND JHL ALIO VdVO 30 38 LSNW S318V9 ON OM 400419414 40 ALI V 10d 3H L HOLVIN OL HOLIMS YSLAWLIOA 830333 JHL NOILISOd AU V 10d 530 58715 0 41 1 OL 51899 ONIGTAM LOANNOD NOILISOd 1 ATALOWSY OL HOLIMS STVNINYSL H3QT3M 39 V Id 5 NI HOLIMS AGOW SHL 39 WANVW ONILVYAdO JHL NI GSLSIT SNOILVOISIOSdS 3AO8V LSh av LON AHOLOV SHL LV 13S 3Md SI 2 138 HONS3AO9 IHL 1041400 JHL NYO HOIHM 39V L 10A 830334 201 OV NI 3SV3SONI NV 9 3 TLLOSH L 3H L ONIGINYSAO ONILLAS
9. i il dl Sall Qual Y O Aral 33 EH A pil ell All dan DE ule die 0 Keep flammable materials away e Mantenga el material combustible fuera del rea de trabajo Gardez l cart de tout mat riel inflammable Entfernen Sie brennbarres Material e Mantenha inflam veis bem guarda dos e R 4 0 EA MR i 248 AIX nig ALU tg Wear eye ear and body protection e Prot jase los ojos los o dos y el cuerpo Prot gez vos yeux vos oreilles et votre corps Tragen Sie Augen Ohren und K r perschutz Use protec o para a vista ouvido e EROS 1 HERESESERISR ei 119 Sal dil s due de Lily usa y cil dl 4 3 READ AND UNDERSTAND THE MANUFACTURER S INSTRUCTION FOR THIS EQUIPMENT AND THE CONSUMABLES TO BE USED AND FOLLOW YOUR EMPLOYER S SAFETY PRACTICES SE RECOMIENDA LEER Y ENTENDER LAS INSTRUCCIONES DEL FABRICANTE PARA EL USO DE ESTE EQUIPO Y LOS CONSUMIBLES QUE VA A UTILIZAR SIGA LAS MEDIDAS DE SEGURIDAD DE SU SUPERVISOR LISEZ ET COMPRENEZ LES INSTRUCTIONS DU FABRICANT EN CE QUI REGARDE CET EQUIPMENT ET LES PRODUITS A ETRE EMPLOYES ET SUIVEZ LES PROCEDURES DE SECURITE DE VOTRE EMPLOYEUR LESEN SIE UND BEFOLGEN SIE DIE BETRIEBSANLEITUNG DER ANLAGE UND DEN ELEKTRODENEINSATZ DES HER STELLERS DIE
10. Ad 4101 HOIH SHL 30 3SV38ONI HHOM OL 0393 OL 21872 3004812313 A OWN 318 DIAGRAMS 51859 1 86 1 ueuudinbe 5 10 sued au Ajeouiooje jou esn jejsur pjnous peyijenb AIUO e Buras eJojeq syed dooye JALLVO3N 12euuo9sig e eoejd ui deey e uedo sjaued jou oq ONINHVM Y WVYSVId NOLLO3NNOO 1041802 41 1 31098 LIOA 1 9 98 SH3Q 13M ANISNA F 3 500 CE LINCOLN E 6 F 4 0002 22 01 0341630 SV NOILISOd HOI 1 0 NI HOLIMS 44101 39VId YN NOILISOd GATIOULNOD ATALOWSY OL HOLIMS S TIVNIWHA3L 830 13M 39V1ld ON NOLLISOd NI HOLIMS AOW 318 0 300819373 JHL ALI V lOd HOLVIN OL HOLIMS H3L3ILTOA 830332 NOLLISOd ALII V 10d 50115 LAdLAO OL S318V9 ONIGTAM LOANNOO ON WANVA 0 395 SNOILVO dd AYALA ANY 31VII3NWWI 471949 ALNG 1 JHL d3dOd 30 38 LSNW S3 18V9 ONIOTIM NI I31STTSNOILLVOIJIO3dS 3AO8V 15 LON OG AHOLOV 83QT3M 8 1
11. Terminals switch in wrong position Place switch in Weld Terminals On position when welding without control cable Faulty PC board or welder alterna VRD Lights don t light up tor Ensure VRD ON OFF switch is in the ON position If light is burned out replace both VRD lights Faulty OCV indicator PC board If all recommended possible areas of misadjustment have been checked and the problem persists Contact your local Lincoln Authorized Field Service Facility CAUTION If for any reason you do not understand the test procedures or are unable to perform the tests repairs safely contact your Local Lincoln Authorized Field Service Facility for technical troubleshooting assistance before you proceed VANTAGE 500 CE LINCOLN F 1 DIAGRAMS F 1 858 0002 22 01 SV NOILISOd NI HOLIMS 44101 SOV 1d NOILISOd NO S IVNIINSI3 L O OM NI HOLIMS STVNINYSL 9NIQT3M AHL SOV 1d NOILISOd NI HOLIMS 3 318 0 300812313 JHL 30 10d 3H L HOLVN OL HOLIMS YSLAWLIOA 830334 NOILISOd 0341530 58715 LAdLNO OL 31979 9NIQT3M LOANNOO WANVW ONILVYAdO 33 NOUT aav 3591113 ANY ALVIGAWWI 40 319A9 ALNG LNAYYNO 93403 30 38 LSNW 31899 390419573 OL MYOM OL
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13. 1 uolvis 2804 N H3ddOHO Aen p VS L 2 ANALNO 2902 d m m LM EM ZM SM Es ot sso o4 80458 8 055384405 509 98 SdWvoov AWOS 504 28 LNNHS SOd ANNHS SOd 1 8 390148 GAMBIA NMOHS SLN3NOdIWOO 1NOHJSVY2 TY 00 AE 29913 Had STOSWAS 1 NMOHS SSVd OL 9 9 8 Y SAYIT AHVITIXNY 97271939239 MOTA ASLL HLIM STAGOW HO ISN 862 LL 3002 ONIHIM 39 005 39V INVA F 5 500 CE LINCOLN E VANTAGE Jequinu epoo jueuidinbe y e 10 jueunjedeg saines eu M eu si epoo 1ejnonaed 40 4 siu 10 eq jou 104 S SIUL 310 F 6 05969 26 1 9 5 8 5804 TIOHINOO 9
14. 75 23 150 46 225 69 350 107 600 183 4800 60 18 30 53 84 137 9500 50 15 90 27 46 69 Conductor size is based on maximum 2 0 voltage drop VANTAGE 500 CE LINCOLN 1 ACCESSORIES 1 FIELD INSTALLED OPTIONS ACCESSORIES K903 1 SPARK ARRESTOR Includes a heavy gage steel approved spark arrestor clamp and adapter for mounting to the muffler exhaust pipe K704 ACCESSORY SET Includes 35 ft 10m of elec trode cable and 30 ft 9 1m of work cable headshield work clamp electrode holder Cables are rated at 400 amps 100 duty cycle K857 25 ft 7 6m or K857 1 100 ft 30 4m REMOTE CONTROL Portable control provides same dial range as the output con trol on the welder Has a convenient 6 pin plug for easy con nection to the welder K1858 1 Service Indicator Kit Provides a GO NO GO visual indication of air cleaner element useful service life Filter service based on restriction readings allows the longest life possible from the filter and best engine protec tion K2641 2 Trailer A 4 wheel steerable trailer for in plant and yard towing Comes standard with a Duo Hitch a 2 Ball and Lunette Eye combination hitch WIRE FEEDER OPTIONS K449 LN 25 Includes internal contactor for across the arc operation no control cable Provides cold electrode until gun trigger is pressed Includes gas solenoid For spools up to 446 20
15. nected to the TIG Module NOTE The TIG process is to receive a low voltage welding process There is no difference in operation with the VRD or Off for this mode For indicator light oper ation see table B 1 WIRE WELDING CV Connect a wire feeder to the 500 CE according to the instructions in INSTALLATION INSTRUCTIONS Section The 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 gas metal arc welding Welding can be finely tuned using the ARC CONTROL Turning the CONTROL clockwise from 10 soft to 10 crisp changes the arc from soft and washed in to crisp and narrow It acts as an inductance pinch control The proper setting depends on the procedure and operator prefer ence Start with the dial set at 0 NOTE In the CV Mode with the OCV Open Circuit Voltage is not reduced For indicator light operation see table B 1 ARC GOUGING The VANTAGEQ 500 CE can be used for arc gouging For optimal performance set the MODE switch to ARC GOUGING OPERATION B 7 Set the OUTPUT CONTROL knob to adjust output current to the desired level for the gouging electrode being used according to the ratings in the following Table B 4 TABLE B 4 Current Range DC electrode positive 60 90 Amps 90 150 Amps 200 250 Amps 1 4 6 4mm 300 40
16. 6 900 Watts Peak 6 900 Watts Continuous 50 Hz 230 Volts 1 Phase Euro 3 400 Watts Peak 3 400 Watts Continuous 50 Hz 230 Volts 1 Phase UK 3 400 Watts Peak 3 400 Watts Continuous 50 Hz 115 Volts 1 Phase UK STANDBY POWER CONNECTIONS The machine is suitable for temporary standby or emergency power using the engine manufacturer s recommended maintenance schedule The machine can be permanently installed as a standby power unit for 400 VAC three phase 21 amp service Connections must be made by a licensed electrician who can determine how the power can be adapted to the particular installation and comply with all applica ble electrical codes Take necessary steps to assure load is limited to the capacity of the 500 CE WARNING Only a licensed certified trained electrician should install the machine to a premises or resi dential electrical system Be certain that The installation complies with the National Electrical Code and all other applicable electri cal codes The premises is isolated and no feedback into the utility system can occur Certain laws require the premises to be isolated before the generator is linked to the premises Check your local requirements 1 Shut the welder off 2 For electrode Positive connect the electrode cable to the terminal of the welder and work cable to the terminal of the welder For elec trode Negative connect the
17. Open circuit breakers Reset breakers If breakers keep trip ping reduce power draw Faulty connections to auxiliary receptacles Check connections RCD tripped Clear any ground fault and reset RCD circuit by pressing Reset button Faulty PC board or welder alterna tor CAUTION If for any reason you do not understand the test procedures or are unable to perform the tests repairs safely contact your Local Lincoln Authorized Field Service Facility for technical troubleshooting assistance before you proceed VANTAGE 500 CE LINCOLN 8 E 6 TROUBLESHOOTING Observe all Safety Guidelines detailed throughout this manual The welding arc is cold The weld 1 ing arc is not stable or is not satis factory the engine runs normally The auxiliary power is normal Make sure the MODE selector Switch is in the correct position for the process being used For exam ple CV WIRE PIPE CC STICK Make sure the electrode wire gas voltage current etc is correct for the process being used Check for loose or faulty connec tions at the weld output terminals and welding cable connections The welding cables may be too long or coiled causing an excessive voltage drop Faulty Control Board No output in Pipe Mode Make sure VRD ON OFF toggle Switch is in the OFF position Poor work lead connection to work Make sure work clamp is tightly connected to clean base metal
18. e e 5 gt 49 AHS S tue Ab s i 04 oes abil e Do not operate with panel open or guards off No operar con panel abierto o guardas quitadas N op rez pas avec les panneaux ouverts ou avec les dispositifs de protection enlev s Anlage nie ohne Schutzgeh use oder Innenschutzverkleidung in Betrieb setzen e Mantenha se afastado das partes moventes opere com os paineis abertos ou guardas removidas NKZWREAN eERWALEFE 818885 BE EGIT BO BOSUR ERE EIE ezido sel AREY 13 ai Y e Aale ll Spanish AVISO DE PRECAUCION French ATTENTION German WARNUNG BIR Chinese Korean LEIA E COMPREENDA AS INSTRUCOES DO FABRICANTE PARA ESTE EQUIPAMENTO E AS PARTES DE USO E SIGA AS PR TICAS DE SEGURANCA DO EMPREGADOR 85 5 E CC EG CEA EECH HERE LTRHOR MEITR gt TFE o S DE t A9 BA DIR REX A RETARD MA lt gt lt gt 0 Zell E Catia d AA olg gaill giall LINCOLN World s Leader in Welding and Cutting Products Sales and Service through Subsidiaries and Distributors Worldwide Cleve
19. 0 AWG Cable Length 0 100 Ft 0 30 meters 2 0 AWG 100 150 Ft 30 46 meters 150 200 Ft 46 61 meters 3 0 AWG TABLE A 1 CABLE INSTALLATION Install the welding cables to your VANTAGE 500 CE as follows 1 The engine must be OFF to install welding cables 2 Remove the flanged nuts from the output terminals 3 Connect the electrode holder and work cables to the weld output terminals The terminals are identi fied on the case front 4 Tighten the flanged nuts securely 5 Be certain that the metal piece you are welding the work is properly connected to the work clamp and cable 6 Check and tighten the connections periodically CAUTION Loose connections will cause the output termi nals to overheat The terminals may eventually melt Do not cross the welding cables at the output ter minal connection Keep the cables isolated and separate from one another VANTAGE 500 CE LINCOLN 7 INSTALLATION A 7 AUXILIARY POWER CONNECTION OF LINCOLN ELECTRIC WIRE FEEDERS The auxiliary power capacity is 16 500 watts Peak Connection of LN 15 to the 500 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 permissible current of the 400 VAC output is 22 amps Output voltage is within 10 at all loads up to the rated capacity Single phase power is
20. Typically a forceful digging arc is preferred for root and hot passes A softer arc is preferred for fill and cap passes where weld puddle control and deposition stacking of iron are key to fast travel speeds It is recommended that the ARC CONTROL be set initially at 0 CV WIRE mode In this mode turning the ARC CONTROL clock wise from 10 soft to 10 crisp changes the arc from soft and washed in to crisp and narrow It acts as an inductance pinch control The proper setting depends on the procedure and operator preference Start with a setting of 0 5 WELD OUTPUT TERMINALS WITH FLANGE NUT Provides a connection point for the electrode and work cables 6 GROUND STUD D Provides a connection point for connect ing the machine case to earth ground 7 14 PIN For attaching wire feeder control cables Includes contactor closure circuit auto sensing remote control circuit and 42V power The remote control circuit operates the same as the 6 Pin Amphenol 8 6 PIN For attaching optional remote control equipment Includes auto sensing remote control circuit 9 WELD TERMINALS CONTROL SWITCH In the WELD TERMINALS ON position 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 th
21. cuir chemise paisse pan talons sans revers et chaussures montantes Toujours porter des lunettes de s curit dans la zone de soudage Utiliser des lunettes avec crans lateraux dans les zones l on pique le laitier LINCOLN 8 Relier la terre le chassis du poste conformement au code de l lectricit et aux recommendations du fabricant Le dispositif de montage ou la piece souder doit tre branch une bonne mise la terre Autant que possible l installation et l entretien du poste seront effectu s par un lectricien qualifi Avant de faires des travaux l interieur de poste la debranch er l interrupteur la boite de fusibles Garder tous les couvercles et dispositifs de s ret leur place V V for selecting a QUALITY product by Lincoln Electric We want you to take pride in operating this Lincoln Electric Company product as much pride as we have in bringing this product to you CUSTOMER ASSISTANCE POLICY The business of The Lincoln Electric Company is manufacturing and selling high quality welding equipment consumables and cutting equip ment Our challenge is to meet the needs of our customers and to exceed their expectations On occasion purchasers may ask Lincoln Electric for advice or information about their use of our products We respond to our customers based on the best information in our posses Sion at that time Lincoln Electric is not in a posi
22. dust an engine Be careful not to damage the sealing area on the tube Wipe both sides of the outlet tube clean 7 2 i e of the Inner edge of the outlet tube If your air cleaner is equipped with a Vacuator Valve Visually check and physically squeeze to make sure the valve is flexible and not inverted damaged or plugged Inspect the Old Filter for Leak Clues Visually inspect the old filter for any signs e of leaks A streak of dust on the clean side of the filter is a telltale sign Remove any cause of leaks before installing new filter d Inspect the New Filter for Damage Inspect the new filter carefully paying attention to the inside of the open end which is the TX sealing area NEVER install a damaged filter new Donaldson radial seal filter may have a dry lubricant on the seal to aid installation 5 Insert the New Radial Seal Filter Properly If you re servicing the safety filter this should be seated into position before installing the primary filter Insert the new filter carefully Seat the filter by hand making certain it is completely into the air cleaner housing before securing the cover in place The critical sealing area will stretch slightly adjust 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 co
23. fill Wipe up spilled fuel and allow fumes to clear before starting engine Keep sparks and flame away from tank VANTAGE 500 CE LINCOLN A 5 OIL cA The 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 operat ing 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 al fuel in U S A and Canada A WARNING Fill the fuel tank with clean fresh fuel The capacity of the tank is 15 gals 57 ltrs for Codes 11298 11299 20 gals 75 5 for Codes 11524 11525 11574 11575 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 fil ter sediment filter Which should be in the closed posi tion when the welder is not used for extended periods of time ENGINE COOLING SYSTEM A WARNING Air to cool the engine is draw
24. gun trigger is closed the current sens ing circuit will cause the 500 CE engine to go to the high idle speed the wire will begin to feed and the welding process started When welding is stopped the engine will revert to low idle speed after approximately 12 seconds unless welding is resumed If you are using an LN 25 without an internal tactor the electrode will be energized when the 500 CE is started VANTAGE 500 CE LINCOLN B 1 OPERATION B 1 SAFETY PRECAUTIONS WARNING Do not attempt to use this equipment until you have thoroughly read the engine manufacturer s manual supplied with your welder It includes important safety precautions detailed engine starting operating and maintenance instructions and parts lists ELECTRIC SHOCK can kill Do not touch electrically live parts or mu electrode with skin or wet clothing Insulate yourself from work and ground Always wear dry insulating gloves Always operate the welder with the hinged door closed and the side panels in place Read carefully the Safety Precautions page before operating this machine Always follow these and any other safety procedures included in this manual and in the Engine Instruction Manual GENERAL DESCRIPTION The 500 CE is a diesel engine powered DC multi process welding power source and AC power generator The engine drives a generator
25. in the environment The user shall ensure that other equipment being used in the environment is compatible This may require additional protection measures h the time of day that welding or other activities are to be carried out 110093 3 1 96H vii SAFETY vii Electromagnetic Compatibility EMC Conformance Products displaying the CE mark are in conformity with European Community Council Directive of 3 May 1989 on the approximation of the laws of the Member States relating to electromagnetic compatibility 89 336 EEC It was manufactured in conformity with a national standard that implements a harmonized standard EN 60974 10 Electromagnetic Compatibility EMC Product Standard for Arc Welding Equipment It is for use with other Lincoln Electric equipment It is designed for industrial and professional use Introduction All electrical equipment generates small amounts of electromagnetic emission Electrical emission may be transmitted through power lines or radiated through space similar to a radio transmitter When emissions are received by other equipment electrical interference may result Electrical emissions may affect many kinds of electrical equipment other nearby welding equipment radio and TV reception numerical controlled machines telephone systems computers etc Be aware that interference may result and extra precautions may be required when a welding power source is used in a domestic establish
26. kg 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 Ib 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 Gun for LN 25 K470 2 Magnum 300 MIG Gun for LN 15 Includes Connector Kit K466 10 Connector Kit for LN 15 K470 2 K1500 1 Gun Receiver Bushing for LN 15 amp K126 2 Note See Wire Feeder IM manuals for appropriate Drive Roll and Guide Tubes TIG OPTIONS K1783 9 Pro PTA 26V TIG Torch Air Cooled 200 amp torch 2 piece equipped with valve for gas flow control 25 ft 7 6m length KP509 Magnum Parts Kit for PTA 26V TIG Torch Magnum Parts Kit provides all the torch accessories you need to start welding Parts kit provides collets collet bod ies a black cap alumina nozzles and tungstens in a variety of sizes all packaged in an easy to carry reclosable sack K870 Foot Amptrol amp K963 3 Hand Amptrol amp K2347 1 Precision TIG 185 Ready Pak For AC TIG K2350 1 Invertec V205 T AC DC One Pak Package For AC TIG PLASMA CUTTING K1601 1 Pro Cut 55 Cuts metal using the 3 phase AC gen erator power from the engine driven welder Accepts 3 phase power VANTAGE 500 CE LINC
27. that supplies three phase power for the DC welding circuit single phase and Three Phase power for the AC auxil iary outlets The DC welding control system uses state of the art Chopper Technology for superior weld ing performance The VANTAGE 500 CE is fitted with a selectable VRD Voltage Reduction Device The VRD operates in the CC Stick mode reducing the OCV to 13 volts increasing operator safety when welding is performed in environments with increased hazard of electric shock such as wet areas and hot humid sweaty con ditions FOR AUXILIARY POWER d Start the engine and set the 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 oil if necessary to bring the level up to the full mark Do not overfill Close engine door Check radiator for proper coolant level Fill if nec essary See Engine Owner s Manual for specific oil and coolant recommendations WARNING ADD FUEL E Stop engine while fueling Do not smoke when fueling Keep sparks and flame away from tank e Do not leave unattended while fueling DIESEL FUEL Wi
28. to hold the glow plug button for up to an additional 10 seconds Release the engine START button immediately when the engine starts 7 The engine will run at high idle speed for approximately 12 seconds and then drop to low idle speed Allow the engine to warm up at low idle for several minutes before applying a load and or switching to high idle Allow a longer warm up time in cold weather 500 LINCOLN B 5 OPERATION B 5 NOTE If the unit fails to start turn Run Stop switch to off and repeat step 3 through step 7 after waiting 30 seconds CAUTION Do not allow the starter motor to run continuously for more than 20 seconds Do not push the START button while the engine is running because this can damage the ring gear and or the starter motor F the Engine Protection or Battery Charging Lights do not turn off shortly after starting the engine shut off the engine immediately and determine the cause NOTE When starting for the first time or after and extended period of time of not operating it will take longer than normal to start because the fuel pump has to fill the fuel system For best results bleed the fuel system as indicated in Maintenance Section of this manual STOPPING THE ENGINE Remove all welding and auxiliary power loads and allow the engine to run at low idle speed for a few minutes to cool the engine STOP the engine by placing the RUN STOP switch in the ST
29. 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 WARNING 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 maxi mum current range of the CURRENT CONTROL of the Amptrol The 14 pin connector is used to directly con
30. 0 Amps 3 8 10 0mm 400 Max Amps The ARC CONTROL is not active in the ARC GOUG ING Mode The ARC CONTROL is automatically set to maximum when the ARC GOUGING mode is selected which provides the best ARC GOUGING formance Carbon Diameter 1 8 3 2mm 5 32 4 0mm 3 16 9 4 8mm NOTE With the VRD switch in the ON position there is no output in the Arc Gouging Mode For indicator light operation see table 1 AUXILIARY POWER Start the engine and set the 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 Simultaneous Welding and Auxiliary Power Loads The auxiliary power ratings are with no welding load Simultaneous welding and power loads are specified in Table B 5 TABLE B 5 SIMULTANEOUS WELDING AND AUXILIARY POWER OUTPUT AMPS NOT WELDING WATTS 14 500 AMPS 400V 3 PHASE 21 0 17 5 100 11 100 200 8 900 300 4 900 400 700 450 0 Max 0 TABLE B 6 500 CE Extension Cord Length Recommendations Use the shortest length extension cord possible sized per the following table Maximum Allowable Cord Length in ft m for Conductor Size 4 AWG 15 120 1800 30 9 40 12 75 23 125 38 175 53 300 91 20 120 2400 _ 30 9 15 88 27 138 42 225 69 15 240 3600 60 18
31. 1B Standard for Fire Prevention During Welding Cutting and Other Hot Work available from NFPA 1 Batterymarch Park PO box 9101 Quincy Ma 022690 9101 Do not use a welding power source for pipe thawing LINCOLN 8 CYLINDER may explode if damaged 3 S 7 Use only compressed gas cylinders containing the correct shielding gas for the process used and properly operating regulators designed for the gas and pressure used All hoses fittings etc should be suitable for the application and maintained in good condition Always keep cylinders in an upright position securely chained to an undercarriage or fixed support Oylinders should be located Away from areas where they may be struck or subjected to physical damage safe distance from arc welding or cutting operations and any other source of heat sparks or flame Never allow the electrode electrode holder or any other electrically hot parts to touch a cylinder Keep your head and face away from the cylinder valve outlet when opening the cylinder valve Valve protection caps should always be in place and hand tight except when the cylinder is in use or connected for use Read and follow the instructions on compressed gas cylinders associated equipment and CGA publication PL Precautions for Safe Handling of Compressed Gases in Oylinders available from the Compressed Gas Association 1235 Jefferson Davis Hi
32. 25 500 750 23 27 750 1000 28 32 Approximate Argon Gas Flow Flow Rate C F H 1 min 1 296 Thoriated 196 2 Thoriated Aluminum Stainless Steel Tungsten Tungsten TIG TORCH Nozzle Size 4 5 34 5 6 5 6 6 7 8 8 10 1 When used with argon gas The current ranges shown must be reduced when using argon helium or pure helium shielding gases 2 Tungsten electrodes are classified as follows by the American Welding Society AWS Pure 196 Thoriated 296 Thoriated EWTh 1 EWTh 2 Though not yet recognized by the AWS Ceriated Tungsten is now widely accepted as a substitute for 2 Thoriated Tungsten in AC and DC applications 3 DCEP is not commonly used in these sizes 4 TIG torch nozzle sizes are in multiples of 1 16ths of an inch 4 1 4 in 6 mm 5 5 16 in 6 3 8 in 10 mm 7 7 16 in 11 mm 8 1 2 12 5 10 5 8 in 16 mm 5 TIG torch nozzles are typically made from alumina ceramic Special applications may require lava nozzles which are less prone to breakage but cannot withstand high temperatures and high duty cycles VANTAGE 500 CE LINCOLN B 7 This will keep the Solid State contactor open and provide a cold electrode until the Amptrol or Arc Start Switch is pressed When using the TIG Module the OUTPUT CONTROL on the VANTAGE 500 CE is used to set the maximum range of the CURRENT CONTROL on the TIG Module or an Amptrol if con
33. AFETY vi Electromagnetic Compatibility EMC Conformance Products displaying the CE mark are in conformity with European Community Council Directive of 3 May 1989 on the approximation of the laws of the Member States relating to electromagnetic compatibility 89 336 EEC It was manufactured in conformity with a national standard that implements a harmonized standard EN 60974 10 Electromagnetic Compatibility EMC Product Standard for Arc Welding Equipment It is for use with other Lincoln Electric equipment It is designed for industrial and professional use Introduction All electrical equipment generates small amounts of electromagnetic emission Electrical emission may transmitted through power lines or radiated through space similar to a radio transmitter When emissions are received by other equipment electrical interference may result Electrical emissions may affect many kinds of electrical equipment other nearby welding equipment radio and TV reception numerical controlled machines telephone systems computers etc Be aware that interference may result and extra precautions may be required when a welding power source is used in a domestic establishment Installation and Use The user is responsible for installing and using the welding equipment according to the manufacturer s instructions If electromagnetic disturbances are detected then it shall be the responsibility of the user of the welding equipme
34. CAL SPECIFICATIONS 500 CE K2503 1 2 3 4 INPUT DIESEL ENGINE Make Model Description Speed RPM Displacement Starting Capacities Cu in Itrs System Perkins 4 cylinder 135 6 2 2 12VDC Battery amp Oil 404C 22T 37 2 High Idle 1575 starter 8 4505 8L 11298 11299 1500 RPM Bore x Stroke inch mm Group 34 650 Turbo Charged Full Load 1575 cold crank amps Radiator Fuel 20 gal water cooled 3 43 X 3 64 65 Amp Alternator Coolant 75 7 L 11574 11575 Diesel Engine Low Idle 1200 87 1 x 92 5 W Built in Regulator 9 5 Qts 9 0L RATED OUTPUT 104 F 40 C WELDER Current Voltage Duty Cycle Rated Load RPM DC Constant Current 400A 36V 100 450A 38V 760 DC Pipe Current 300A 32V 10096 40 TO 300 AMPS olts Touch Start TIG 250A 30V 100 20 TO 250 AMPS 400A 36V 100 D Vol C Constant Voltage 450A 7 38V 7 60 14 TO 40 VOLTS 60 Volts Arc Gouging 450A 38V 6096 90 TO 500 AMPS RATED OUTPUT 40 C 104 GENERATOR Auxiliary Power 16 500 Watts Peak 14 500 Watts Continuous 50 Hz 400 Volts 3 Phase Euro UK 6 900 Watts Peak 6 900 Watts Continuous 50 Hz 230 Volts 1 Phase Euro 3 400 Watts Peak 3 400 Watts Continuous 50 Hz 230 Volts 1 Phase UK 3 400 Watts Peak 3 400 Watts Continuous 50 Hz 115 Volts 1 Phase UK Sound Levels Sound power 96 dB Lwa ENGINE LUBRICATION MM Pressure ee 1298 11299 EPA Ti
35. G or CV WIRE modes and when a remote control is connected to the 6 Pin or 14 Pin Connector the auto sensing circuit automatically switches the OUTPUT CONTROL from con trol at the welder to the remote control In the CV WIRE mode if the feeder being used has a voltage con trol when the wire feeder control cable is connected to the 14 Pin Connector the auto sensing circuit automatically makes OUTPUT CONTROL inactive and the wire feeder voltage control active Otherwise the OUTPUT CONTROL is used to preset the voltage When in the DOWNHILL PIPE mode and when REMOTE CON TROL is connected to the 6 Pin or 14 Pin Connector the OUT PUT CONTROL is used to set the maximum current range of the OUTPUT 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 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 digital meters allow the output voltage CV WIRE mode or current CC STICK DOWN HILL PIPE ARC GOUGING and TIG modes to be set prior to welding using the OUTPUT control dial During welding the meter display the actual output voltage VOLTS and current AMPS A memory feature holds the display of both meters on for seven seconds after welding is stopped This allows the oper ator to read the actual current and voltage just prior to when weldi
36. 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 MAINTENANCE OIL FILTER CHANGE Drain the oil Remove the oil filter with an oil filter wrench and drain the oil into a suitable container Discard the used filter Note Care should be taken during filter removal to not disrupt or damage in any way the fuel lines Clean the filter mounting base and coat the gasket of the new filter with clean engine oil Screw the new filter on by hand until the gasket con tacts the mounting base Using an oil filter wrench tighten the filter an additional 1 2 to 7 8 of a turn Refill the crankcase with the specified amount of the recommended engine oil Reinstall the oil filler cap and tighten securely Start the engine and check for oil filter leaks Stop the engine and check the oil level If neces sary add oil to the upper limit mark on the dipstick A WARNING Never use gasoline or low flash point solvents for cleaning the air cleaner element A fire or explosion could result CAUTION Never run the engine without the air cleaner Rapid engine wear will result from contaminants such as dust and dirt being drawn into the engine AIR CLEANER The diesel engine is equipped with a dry type air
37. NG Service and Repair should only be performed by Lincoln Electric Factory Trained Personnel Unauthorized repairs performed on this equipment may result in danger to the technician and machine operator and will invalidate your factory warranty For your safety and to avoid Electrical Shock please observe all safety notes and precautions detailed throughout this manual This Troubleshooting Guide is provided to help you locate and repair possible machine malfunctions Simply follow the three step procedure listed below Step 1 LOCATE PROBLEM SYMPTOM Look under the column labeled PROBLEM SYMP TOMS This column describes possible symptoms that the machine may exhibit Find the listing that best describes the symptom that the machine is exhibiting Step 2 POSSIBLE CAUSE The second column labeled POSSIBLE 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 Authorized Field Service Facility CAUTION If for any reason you do not understand the test procedures or are unable to perform the tests repairs safely contact your Local Lincoln Authorized Field Service Facility for technic
38. OLN 8 D 1 MAINTENANCE D 1 SAFETY PRECAUTIONS A WARNING Have qualified personnel do all maintenance and troubleshooting work Turn the engine off before working inside the machine or servicing the engine Remove guards only when necessary to perform maintenance and replace them when the maintenance requiring their removal is complete If guards are missing from the machine obtain replacements from a Lincoln Distributor See Operating Manual Parts List 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 Maintenance At the end of each day s use refill the fuel tank to minimize moisture condensation in the tank Running out of fuel tends to draw dirt into the fuel system Also check the crankcase oil level and add oil if indicated ENGINE SERVICE EVERY DAY OR EVERY 8 HOURS EVERY 250 HOURS OR 6 MONTHS EVERY 500 HOURS OR 12 MONTHS EVERY 1000 HOURS MAINTENANCE ITEM TYPE OR QUANTITY DENEN Cooantievel Concentration of antifreeze ________ 50 50 Water Ethylene Glycol _ Coolant NOTE 3 9590 Engine oil level NOTE 1 Engine oil NOTE1 amp 3 8459 8L including filte
39. OP position NOTE A fuel shut off valve is located on the fuel pre filter WELDER OPERATION DUTY CYCLE Duty Cycle is the percentage of time the load is being applied in a 10 minute period For example a 6096 duty cycle represents 6 minutes of load and 4 minutes of no load in a 10 minute period ELECTRODE INFORMATION For any electrode the procedures should be kept within the rating of the machine For information on electrodes and their proper application see www lincolnelectric com or the appropriate Lincoln publication The VANTAGEQ 500 CE can be used with a broad range of DC stick electrodes The MODE switch provides two stick welding settings as follows CONSTANT CURRENT CC STICK WELDING The CC STICK position of the MODE switch is designed for horizontal and vertical up welding with all types of elec trodes especially low hydrogen The OUTPUT CONTROL dial adjusts the full output range for stick welding 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 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 minimum number without electrode sticking Start with the dial set at O NOTE Due to the low OCV with the VRD on a very slight delay during striking of th
40. The light is off when the systems are func tioning properly The light will come on and the engine will shutdown when there is Low Oil Pressure and or the Coolant is Over Temperature Note The light remains 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 functioning properly The light will come on if there is a Low No battery condition but the machine will continue to run Note The light may or may not come on when the RUN STOP switch is in the ON position It will come on dur ing cranking and stay on until the engine starts After starting the engine the light will go off unless a Low No battery charge condition exists 20 COOLANT TEMPERATURE GAUGE A indica tor of engine coolant temperature 21 OIL PRESSURE GAUGE A indicator of engine Oil Pressure 22 CIRCUIT BREAKER STARTING THE ENGINE 1 Remove all plugs connected to the AC power recepta cles 2 Set IDLER switch to AUTO lt 3 7 3 Press Glow Plug Button and hold 15 to 20 seconds 4 Set the RUN STOP switch to RUN 5 Press START button until the engine starts or for up to 10 seconds Continue
41. UNFALLVERHUTUNGSVORSCHRIFTEN DES ARBEITGEBERS SIND EBENFALLS ZU BEACHTEN Keep your head out of fumes Use ventilation or exhaust to remove fumes from breathing zone Los humos fuera de la zona de res piraci n e Mantenga la cabeza fuera de los humos Utilice ventilaci n o aspiraci n para gases Gardez la t te l cart des fum es Utilisez un ventilateur ou un aspira teur pour ter les fum es des zones de travail e Vermeiden Sie das Einatmen von Schweibrauch Sorgen Sie f r gute Be und Entl ftung des Arbeitsplatzes e Mantenha seu rosto da fumaca Use ventila o exhaust o para remover fumo da zona respirat ria 6 5 44550 aes E fE FE MK BE SALE S XACE E 2342 HHPI ASH 7177471 aal laa EAU gaal ja aah Aen Mit ge pal 9 Turn power off before servicing Desconectar el cable de ali mentaci n de poder de la m quina antes de iniciar cualquier servicio e D branchez le courant avant l entre tien Strom vor Wartungsarbeiten abschalten Netzstrom v llig ff nen Maschine anhalten N o opere com as tampas removidas Desligue a corrente antes de fazer servico e toque as partes el tricas nuas e FHIR lt 8 21
42. VANTAGE 500 CE ch 2010 For use with machines having Code Numbers 11298 11299 11524 11525 11574 11575 Safety Depends on You Lincoln arc welding and cutting equipment is designed and built with safety in mind However your overall safety can be increased by proper installation and thoughtful operation on your part DO NOT INSTALL OPER ATE OR REPAIR THIS EQUIP MENT WITHOUT READING THIS MANUAL AND THE SAFE TY PRECAUTIONS CONTAINED THROUGHOUT And most importantly think before you act and be careful 97 9 ISG 4 2 DOS Vi 3 Equipped with VRD VOLTAGE REDUCTION DEVICE See Installation and Operation sections for an explanation OPERATOR S MANUAL C and Manufactured Under a by 5 Quality to ISO 9001 Requirement EE Copyright O Lincoln Global Inc LINCOLN World s Leader in Welding and Cutting Products Sales and Service through Subsidiaries and Distributors Worldwide Cleveland Ohio 44117 1199 U S A 216 481 8100 216 486 1751 WEB SITE www lincolnelectric com SAFETY AA WARNING gt CALIFORNIA PROPOSITION 65 WARNINGS gt Diesel engine exhaust and some of its constituents The engine exhaust from this product contains are known to the State of California to cause can chemicals known to the State of California to cause cer birth defects and other reproductive harm cancer birth defect
43. VRD INDICATOR LIGHT VRD ON VRD OFF MODE Green OCV Reduced While Red or Green Welding Depends on Weld Voltage CV WIRE OCV Red OCV Not Reduced Weld Terminals On Red OCV Not Reduced Weld Terminals Remotely Controlled Gun Trigger Closed Weld Terminals Remotely Controlled Gun Trigger Open Whi Red or Green Welding Depends on Weld Voltage DO ARC GOUGIN Green No Output While Not Applicable No Output Welding IG OCV Green Process is Low Voltage While Green Process is Low Voltage Welding is normal for the lights to alternate between colors while welding VANTAGE 500 CE LINCOLN B 4 ENGINE CONTROLS 12 RUN STOP SWITCH RUN position ener gizes the engine prior to starting STOP position stops the engine The oil pressure interlock switch prevents battery drain if the switch is left in the RUN position and the engine is not operating 13 GLOW PLUG PUSH BUTTON When pushed activates the glow plugs Glow plug should not be activated for more than 20 seconds continuously 14 START PUSH BUTTON Energizes the starter motor to crank the engine 15 IDLER SWITCH Has two positions as follows 1 In the HIGH position the engine runs at the high idle speed controlled by the engine governor 2 In the AUTO position the idler operates as fol lows When switched from HIGH to AUTO or after starting the engine the engine will operate at full speed for appr
44. Was Ors z 17 9 QN9 dm MOHD 98 55 300 g HOLIMS 193155 ANALNO SNITTIM 3727143239 HAMOG _ No anis SSVdAB viv WIRING DIAGRAM woe IMA K i M 301915 J l anwa pA Andino 990 509 68 50428 uossauddns LNNHS SOd ANNHS SOd 390148 NMOHS SLNINOdWOD 1NOHJ3SV2 TV SS3NUVH OLN 3UV 3 9 10 29913 H3d STOSWAS 1 GIOUOL seva oL 2 ADS 1 MOTA 6130001 HO 32 005 39V INVA 92911 7411 SZSLL 6621 53009 ONS 00S 39V LNVA F 6 500 CE VANTAGE LINCOLN DIMENSION PRINT F 7 F 7 ZvO L1
45. able high idle speed for this machine is 1890 RPM no load Do NOT tamper with governor components or setting or make any other adjustments to increase the maximum speed Severe personal injury and damage to the machine can result if operated at speeds above maximum ENGINE ADJUSTMENT Adjustments to the engine are to be made only by a Lincoln Service Center or an authorized Field Service Shop BATTERY MAINTENANCE To access the battery remove the battery tray from the front of the machine with 3 8 nut driver or flat head screw driver Pull the tray out of machine far enough to disconnect the negative and then positive battery cables The tray can then be tilted and lifted to remove the entire tray and battery from the machine for easy service WARNING we GASES FROM BATTERY can explode e Keep sparks flame and cigarettes away from battery To prevent EXPLOSION when INSTALLING A NEW BATTERY disconnect negative cable from old battery first and con nect to new battery last CONNECTING A BATTERY CHARGER remove battery from welder by disconnecting negative cable first then positive cable and battery clamp When reinstalling connect negative cable last Keep well ventilated e USING A BOOSTER connect positive lead to battery first then connect negative lead to neg ative battery lead at engine foot BATTERY ACID can burn eyes and skin ae e Wear gloves and eye protection and be careful when work
46. al troubleshooting assistance before you proceed VANTAGE 500 CE LINCOLN 8 2 TROUBLESHOOTING 2 Observe all Safety Guidelines detailed throughout this manual Authorized Field Service Facility Engine will not crank Battery is low Charge Battery Loose battery cable connections Inspect clean and tighten terminals Faulty engine starter motor Contact authorized local Engine Service Shop Engine will crank but not start Fuel shut off valve on Main Fuel Filter in the OFF position Open valve vertical position of handle Fuel Filters dirty clogged Check and replace main filter element and or Inline Fuel Filter Out of fuel Fill tank and bleed fuel system High coolant temperature or low oil pressure indictor lights lit If all recommended possible areas Check oil and coolant levels Fill misadjustment have been required Check for loose bro checked and the problem persists ken fan belt Contact your local Lincoln Faulty fuel shutdown solenoid Authorized Field Service Facility Check that shutdown solenoid is functioning properly and not bind ing contact authorized engine service shop Faulty fuel pump Check for fuel flow through filters Contact autho rized local Engine Service Shop Engine shuts down shortly after High coolant temperature or low starting oil pressure indictor light lit Change oil and oil filters and fill to proper level Check and fi
47. and auxiliary output Engine runs rough Auxiliary power load is less than 100 watts Idler may not respond with less than a 100 watt load Set idler to High Faulty PC board Control or Idler Faulty idler solenoid Check for bent linkage or broken spring Faulty PC board Control or Idler Fuel filter clogged Replace Air filter clogged clean or replace High idle setting incorrect check and adjust if required Valves out of adjustment Fuel contaminated with water or sediment Check fuel pre filter and empty of water bleed fuel system Replace fuel in tank if needed Broken spring on Idle Solenoid solenoid linkage binding Faulty PC board Control or Idler low idle speed set too low on idle solenoid Fuel Shutdown solenoid not func tioning properly linkage binding Stop engine by shutting off valve located on main fuel filter Contact authorized local Engine Service Shop Fuel filter dirty clogged Replace Air filter dirty clogged Replace Air Filter Element Fouled fuel injector s Contact authorized Engine Service Shop Fuel contaminated with water Check water separator for water Clean and replace as needed Replace fuel in tank Cracked or loose fuel hose Replace hose and tighten clamps Valves out of adjustment Contact authorized local Engine Service Shop CAUTION If for any reason you do not understand the test proce
48. ar chlorinated hydrocarbon vapors coming from degreasing cleaning or spraying operations The heat and rays of the arc can react with solvent vapors to form phosgene a highly toxic gas and other irritating prod ucts 5 d Shielding gases used for arc welding can displace air and cause injury or death Always use enough ventilation especially in confined areas to insure breathing air is safe 5 e Read and understand the manufacturer s instructions for this 54 LINCOLN 8 equipment and the consumables to be used including the material safety data sheet MSDS and follow your employer s safety practices MSDS forms are available from your welding distributor or from the manufacturer Also see item 1 b Jan 09 SAFETY WELDING and CUTTING gt SPARKS cause fire or explosion 6 a Remove fire hazards from the welding area If this is not possible cover them to prevent the welding sparks from starting a fire Remember that welding sparks hot materials from welding can easily go through small cracks and openings to adjacent areas Avoid welding near hydraulic lines Have a fire extinguisher readily available 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 When not welding make certai
49. cking motion which establishes the arc When in the TOUCH START TIG mode and when a Amptrol is connected to the 6 Pin connector the OUT PUT CONTROL dial is used to set the maximum cur rent range of the current control of the Amptrol The ARC CONTROL is not active in the TIG mode To STOP a weld simply pull the TIG torch away from the work When the arc voltage reaches approximately 30 Volts the arc will go out and the machine will reset the cur rent to the Touch Start level To reinitiate the arc retouch the tungsten to the work and lift Alternatively the weld can be stopped by releasing the Amptrol or arc start switch The 500 CE can be used in a wide vari ety of DC TIG welding applications In general the Touch Start feature allows contamination free start ing without the use of a Hi frequency unit If desired the K930 2 TIG Module can be used with the VAN TAGE 500 CE The settings for reference VANTAGE 500 CE settings when using the K930 2 TIG Module with an Amptrol or Arc Start Switch Set the MODE Switch to the TOUCH START TIG setting Set the IDLER Switch to the AUTO position Set the WELDING TERMINALS switch to the REMOTELY CONTROLLED position TABLE B 3 TYPICAL CURRENT RANGES 1 FOR TUNGSTEN ELECTRODESO Tungsten Electrode DCEP Diameter in mm DCEN 2 15 3 8 5 20 5 10 15 80 70 150 5 10 150 250 13 17 250 400 15 23 400 500 21
50. conds unless welding is resumed VANTAGE 500 CE LINCOLN 8 A 8 INSTALLATION WARNING Connection of the LN 25 to the 500 CE Shut off welder before making any electrical connections The LN 25 with or without an internal contactor may be used with the 500 CE See the appropriate connection diagram in Section F NOTE The LN 25 K431 Remote Control Module and K432 Remote Cable are not recommended for use with the 500 CE 1 Shut the welder off 2 For electrode Positive connect the electrode cable to the terminal of the welder and work cable to the terminal of the welder For elec trode Negative connect the electrode cable to the terminal of the welder and work cable to the terminal of the welder 3 Attach the single lead from the front of the LN 25 to work using the spring clip at the end of the lead This is a control lead to supply current to the wire feeder motor it does not carry welding current 4 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 are using an LN 25 with an internal contactor the electrode is not energized until the gun trigger is closed 8 When the
51. d 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 speed roughness of sur face on which the trailer will be operated environmental con ditions like maintenance 5 Conformance with federal state and local laws 1 Consult applicable federal state and local laws regarding specific requirements for use on public highways VEHICLE MOUNTING WARNING Improperly mounted concentrated loads may cause unstable vehicle handling and tires or other components to fail Only transport this Equipment on serviceable vehicles which are rated and designed for such loads Distribute balance and secure loads so vehicle is stable under conditions of use Do not exceed maximum rated loads for compo nents such as suspension axles and tires Mount equipment base to metal bed or frame of vehicle Follow vehicle manufacturer s instructions PRE OPERATION ENGINE SERVICE READ the engine operating and maintenance instruc tions supplied with this machine A WARNING Stop engine and allow to cool before fueling Do not smoke when fueling Fill fuel tank at a moderate rate and do not over
52. d the problem persists Contact Engine Service Shop your local Lincoln Authorized Field Service Facility Engine will not idle down to low ldler switch in High idle position speed Set switch to Auto External load on welder or auxil iary power Remove all external loads Faulty PC board or idler sole noid Engine will not go to high idle when Poor work lead connection to attempting to weld work Make sure work clamp is tightly connected to clean base metal Contactor switch is in wrong position Set to Welding On when welding without a control cable Refer to Operations chapter for prop er use of this switch Faulty PC board Low idle speed set to low CAUTION If for any reason you do not understand the test procedures or are unable to perform the tests repairs safely contact your Local Lincoln Authorized Field Service Facility for technical troubleshooting assistance before you proceed 500 LINCOLN 8 TROUBLESHOOTING Observe all Safety Guidelines detailed throughout this manual Engine will not go to high idle when using auxiliary power Engine will not go to high idle under weld or auxiliary loading Engine does not develop full power Engine runs rough Engine will not go to high idle when attempting to weld or using auxil iary power Switching to manual high idle does not work Engine will not shut off Engine does not develop full power Low weld
53. dures or are unable to perform the tests repairs safely contact your Local Lincoln Authorized Field Service Facility for technical troubleshooting assistance before you proceed VANTAGE 500 LINCOLN 8 If all recommended possible areas of misadjustment have been checked and the problem persists Contact your local Lincoln Authorized Field Service Facility E 5 TROUBLESHOOTING 5 Observe all Safety Guidelines detailed throughout this manual No welding power output Poor work lead connection to work Make sure work clamp is tightly connected to clean base metal Terminals switch in wrong position Place switch in Weld Terminals On position when welding without control cable Faulty PC board or welder alterna tor Welder has output but no control Poor remote control cable connec tion to 6 pin or 14 pin connector Check connections Faulty remote cable or faulty wire feeder or wire feeder cable Replace if necessary Faulty control potentiometer or PC board If all recommended possible areas Wire feeder does not work when 1 Wire Feeder Power circuit breakerlof misadjustment have been control cable is connected to 14 pin open Check 42V beaker and checked and the problem persists connector reset if tripped Contact your local Lincoln Faulty control cable Repair or Authorized Field Service Facility replace cable Faulty wire feeder Replace wire feeder No auxiliary power
54. e electrodes may occur Due to the requirement of the resistance in the circuit to be low for a VRD to operate a good metal to metal con tact must be made between the metal core of the elec trode and the job A poor connection anywhere in the welding output circuit may limit the operation of the VRD This includes a good connection of the work clamp to the job The work clamp should be connected as close as practical to where the welding will be per formed A For New Electrodes E6010 Touch Lift to Start the Arc E7018 E7024 Touch Rock Back and Forth in Joint Lift Once the arc is started normal welding technique for the application is then used B For Re Striking Electrodes Some electrodes form a cone at the end of the elec trode after the welding arc has been broken particularly iron powder and low hydrogen electrodes This cone will need to be broken off in order to have the metal core of the electrode make contact E6010 Push Twist in Joint Lift E7018 E7024 Push Rock Back and Forth in Joint Lift Once the arc is started normal welding technique for the application is then used For other electrodes the above techniques should be tried first and varied as needed to suit operator prefer ence The goal for successful starting is good metal to metal contact For indicator light operation see table B 1 DOWNHILL PIPE Welding This slope controlled setting is intended for out of posi tion and do
55. e fan Do not attempt to override the governor or idler by pushing on the throttle control rods while the engine is running 2 d 3 Do not place your body between the electrode and work cables If the electrode cable is on your right side the work cable should also be on your right side Connect the work cable to the workpiece as close as possible to the area being welded 1 0 To prevent accidentally starting gasoline engines while turning the engine or welding generator during maintenance work disconnect the spark plug wires distributor cap or magneto wire as appropriate Do not work next to welding power source Mar 95 LINCOLN 8 SAFETY ELECTRIC SHOCK can kill 3 a The electrode and work or ground circuits are electrically hot when the welder is on Do not touch these hot parts with your bare skin or wet clothing Wear dry hole free gloves to insulate hands Insulate yourself from work and ground using dry insulation Make certain the insulation is large enough to cover your full area of physical contact with work and ground In addition to the normal safety precautions if welding must be performed under electrically hazardous conditions in damp locations or while wearing wet clothing on metal structures such as floors gratings or scaffolds when in cramped positions such as sitting kneeling or lying if there is a high risk of unavoidable or accidental contact wi
56. e masse le c ble de soudage et la machine souder en bon et s r tat defonctionnement d Ne jamais plonger le porte lectrode dans l eau pour le refroidir Ne jamais toucher simultan ment les parties sous tension des porte lectrodes connect s deux machines souder parce que la tension entre les deux pinces peut tre le total de la tension vide des deux machines Si on utilise la machine souder comme une source de courant pour soudage semi automatique ces precautions pour le porte lectrode s applicuent aussi au pistolet de soudage Eloigner les mat riaux inflammables ou les recouvrir afin de pr venir tout risque d incendie d aux tincelles Quand on ne soude pas poser la pince une endroit isol de la masse Un court circuit accidental peut provoquer un chauffement et un risque d incendie S assurer que la masse est connect e le plus pr s possible de la zone de travail qu il est pratique de le faire Si on place la masse sur la charpente de la construction ou d autres endroits loign s de la zone de travail on augmente le risque de voir passer le courant de soudage par les chaines de lev age c bles de grue ou autres circuits Cela peut provoquer des risques d incendie ou d echauffement des chaines et des cables jusqu ce qu ils se rompent Assurer une ventilation suffisante dans la zone de soudage Ceci est particuli rement important pour le soudage de t les galvanis es pl
57. e 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 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 is recommended that the fuel shutoff valve be closed during periods of non use WARNING 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 Fill the fuel tank with fuel Open the fuel shut off valve Loosen bleed fitting on the fuel injector manifold 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 02 D VANTAGE 500 LINCOLN 8 D 5 MAINTENANCE D 5 FUEL FILTER 1 Check the fuel filter and fuel pre filter for water accumulation or sediment 2 Replace the fuel filter if it is found with excessive water accumulation or sediment Empty fuel pre fil ter OVERSPEED IS HAZARDOUS The maximum allow
58. e wire feeder voltmeter to the polarity of the electrode OPERATION B 3 11 VRD Voltage Reduction Device INDICATOR LIGHTS On the front panel of the VANTAGE 500 CE are two indicator lights A red light when lit indicates OCV Open Circuit Voltage is equal to or greater than 32V for Codes 11298 11299 30V for Codes 11524 11525 11574 11575 and a green light when lit indicates OCV Open Circuit Voltage is less than 32V for Codes 11298 11299 30V for Codes 11524 11525 11574 11575 The VRD On Off switch inside the control panel must be for the VRD function to be active and the lights to be enabled When the machine is first started with VRD enabled both lights will illumi nate for 5 seconds These lights monitor the OCV Open Circuit Voltage and weld voltage at all times In the CC Stick mode when not welding the green light will illuminate indicating that the has reduced the OCV to less than 32V During welding the red light will illuminate whenever the arc voltage is equal to or greater than 32V This means that the red and green light may alternate depending on the weld voltage This is normal operation If the red light remains illuminated when not welding in the CC stick mode the VRD is not functioning properly Please refer to your local field service shop for service If the is turned On and the lights don t come refer to the trouble shooting section TABLE B 1
59. electrode cable to the terminal of the welder and work cable to the terminal of the welder 3 Across The Arc Model Attach the single lead from the front of the LN 15 to work using the spring clip at the end of the lead This is a control lead to supply current to the wire feeder motor it does not carry welding current Set the WELD TERMINALS switch to WELD TERMINALS ON When the gun trigger is closed the current sens ing circuit will cause the VANTAGE 500 engine to go to the high idle speed the wire will begin to feed and the welding process started When welding is stopped the engine will revert to low idle speed after approximately 12 seconds unless welding is resumed 4 Control Cable Model Connect Control Cable between Engine Welder and Feeder e Set the WELD TERMINALS switch to REMOTELY CONTROLLED 5 Set the MODE switch to the CV WIRE position 6 Set the WIRE FEEDER VOLTMETER switch to either or as required by the electrode polari ty being used 7 Set the CONTROL knob to O initially and adjust to suit 8 Set the IDLE switch to the AUTO position 9 When the gun trigger is closed the current sens ing circuit will cause the 500 CE engine to go to the high idle speed the wire will begin to feed and the welding process started When welding is stopped the engine will revert to low idle speed after approximately 12 se
60. er Mechanical Fuel Pump Auto air bleed Electronic with Full Flow Filter system Electric shutoff solenoid Indirect fuel injector EPA Tier Interim AIR CLEANER ENGINE IDLER MUFFLER ENGINE PROTECTION Low noise Muffler Shutdown on low oil Single Element Automatic Idler Top outlet can be rotated pressure amp high engine Made from long life aluminized steel coolant temperature WARRANTY 2 years 2000 hours all non electric components 3 years major non electric components See Perkins warranty for details PHYSICAL DIMENSIONS 4 35 94 in 27 05 in 62 59 in 1290 Ibs 586kg 913 mm 687 mm 1590 mm 1 Output rating in watts is equivalent to volt amperes at unity power factor Output voltage is within 10 at all loads up to rated capacity When welding available auxiliary power will be reduced 2 Reduced to less than 32V for Codes 11298 11299 30V for Codes 11524 11525 11574 11575 in the CC stick Mode when VRD VOLTAGE REDUCTION DEVICE is on 3 Maximum per circuit breaker rating 4 To Top of enclosure Add 7 35 186 7mm to top of exhaust Add 3 87 98 3mm to top of Lift Bail VANTAGE 500 CE LINCOLN 2 INSTALLATION A 2 MACHINE SPECIFICATIONS Receptacles 400V e Ph x 1 07 8 Ph x 1 230V 1 Ph x 1 230V 1 Ph x 2 115V x19 14 Pin Connector 14 Pin Connector 6 Pin Connector 6 Pin Connector 30mA trip current 30mA trip current Circuit Breakers Thermal Magnetic 3 Phase 25 Am
61. filter Never apply oil to it Service the air cleaner as follows Replace the element every 500 hours of operation Under dusty conditions replace sooner VANTAGE 500 LINCOLN 8 MAINTENANCE Service Instructions Single and Two Stage Engine Air Cleaners 1 Remove the Filter Unfasten or unlatch the service cover Because the filter fits tightly over the outlet tube to create the critical seal there will be some initial resistance similar to breaking Rotate the filter while the seal on a jar Gently move the end of the filter back and forth to break the seal then rotate while straight out pulling straight out Avoid knocking the filter against the housing If your air cleaner has a safety filter replace it every third primary filter change Remove the safety filter as you would the primary filter Make sure you cover the air cleaner outlet tube to avoid any unfiltered contaminant dropping into the engine 2 Clean Both Surfaces of the Outlet Tube and Check the Vacuator Valve Use a clean cloth to wipe the filter sealing surface and the inside of the outlet tube Contaminant on the sealing surface could hinder an effective seal and cause leakage Make sure that all contaminant is removed before the new filter is inserted Dirt accidently transferred to the inside of the outlet tube will reach the engine and cause wear Engine manufacturers say that it takes only a few grams of dirt to
62. ghway Arlington VA 22202 FOR ELECTRICALLY powered equipment 8 a Turn off input power using the disconnect switch at the fuse box before working on the equipment Install equipment in accordance with the U S National Electrical Code all local codes and the manufacturer s recommendations Ground the equipment in accordance with the U S National Electrical Code and the manufacturer s recommendations Refer to http www lincolnelectric com safety for additional safety information Jan 09 SAFETY PR CAUTIONS DE S RET Pour votre propre protection lire et observer toutes les instructions et les pr cautions de s ret specifiques qui parraissent dans ce manuel aussi bien que les pr cautions de s ret g n rales suiv antes 6 S ret Pour Soudage A L Arc 1 Protegez vous contre la secousse lectrique a Les circuits l lectrode et la pi ce sont sous tension quand la machine souder est en marche Eviter toujours tout contact entre les parties sous tension et la peau nue ou les v tements mouill s Porter des gants secs et sans trous pour isoler les mains Faire tr s attention de bien s isoler de la masse quand on soude dans des endroits humides ou sur un plancher metallique ou des grilles metalliques principalement dans les positions assis ou couch pour lesquelles une grande partie du corps peut tre en contact avec la masse Maintenir le porte lectrode la pince d
63. han 32V for Codes 11298 11299 30V for Codes 11524 11525 11574 11575 DC when the resistance of the out put circuit is above 200 ohms The VRD requires that the welding cable connections be kept in good electrical condition because poor connections will contribute to poor starting Having good electrical con nections also limits the possibility 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 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 e 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 are enabled INSTALLATION A 3 FIGURE A 1 VRD VOLTAGE REDUCTION DEVICE SWITCH IS LOCATED IN THIS AREA REMOVE 4 FRONT PANEL SCREWS TO ACCESS VRD SWITCH LOCATION AND VENTILATION The welder should be located to provide an unrestrict ed flow of clean cool air to the cooling air inlets and to avoid restricting the cooling air outlets Also locate the welder so that the engine exhaust fumes are prop erly vented to an outside area STACKING VANTAGE 500 CE machines cannot be stacked ANGLE OF OPERATION Engines are designed to run in the level condition which is where the optimum performance is achieved The maximum angle of con
64. hanged as well Be sure the unit is off Disconnect the negative bat tery cable to ensure safety Locate oil drain hose and valve in bottom of base and pull through the hole in the battery access panel on the welder Open oil drain valve by lifting up spring loaded lever and rotate 90 counterclockwise Pull to open and drain the oil into a suitable container for disposal Close the drain valve by rotating lever 90 clockwise Re fill the crankcase to the upper limit mark on the dipstick with the recommended oil See engine oper ation manual OR engine service items decal OR below Replace and tighten the oil filler cap secure ly Push oil drain hose and valve back into unit re con nect negative battery cable and close doors and engine top cover before restarting unit Wash your hands with soap and water after handling used motor oil Please dispose of used motor oil in a manner that is compatible with the environment We suggest you take it in a sealed container to your local service station or recycling center for reclamation DO NOT throw it in the trash pour it on the ground or down a drain Use motor oil designed for diesel engines that meets requirements for API service classification CC CD CE CF CF 4 CG 4 or CH 4 ACEA E1 E2 E3 Always check the API service label on 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
65. hat of your helpers from the arc rays 4 c Protect other nearby personnel with suitable non flammable screening and or warn them not to watch the arc nor expose themselves to the arc rays or to hot spatter or metal gt FUMES AND GASES can be dangerous 5 a Welding may produce fumes and gases hazardous to health Avoid breathing these fumes and gases When welding keep your head out of the fume Use enough ventilation and or exhaust at the arc to keep fumes and gases away from the breathing zone When welding with electrodes which require special ventilation such as stainless or hard facing see instructions on container or MSDS or on lead or cadmium plated steel and other metals or coatings which produce highly toxic fumes keep exposure as low as possible and within applicable OSHA PEL and ACGIH TLV limits using local exhaust or mechanical ventilation In confined spaces or in some circum stances outdoors a respirator may be required Additional precautions are also required when welding on galvanized steel 5 b The operation of welding fume control equipment is affected by various factors including proper use and positioning of the equipment maintenance of the equipment and the spe cific welding procedure and application involved Worker exposure level should be checked upon installation and periodically thereafter to be certain it is within applicable OSHA PEL and ACGIH TLV limits 5 c Do not weld in locations ne
66. hermostat 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 20 105 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 leav
67. high altitude are restricted within the United States If required contact an authorized Perkins engine field service shop to determine if any adjustments can be made for oper ation in higher elevations HIGH TEMPERATURE OPERATION At temperatures above 104 F 40 C Welder output derating is necessary For maximum output ratings derate the welder output 2 volts for every 18 F 10 C above 104 F 40 C Cold weather starting With a fully charged battery and the proper oil the engine should start satisfactorily down to 15 F 26 If the engine must be frequently started at or below 0 F 18 C it may be desirable to install cold starting aides The use of No 1D diesel fuel is recom mended in place of No 2D at temperatures below 23 F 5 C Allow the engine to warm up before applying a load or switching to high idle Note Extreme cold weather starting may require longer glow plug operation WARNING Under conditions should ether or other starting fluids be used with this engine TOWING Use a recommended trailer for use with this equipment for road in plant and yard towing by a vehicle 1 If the user adapts a non Lincoln trailer he must assume responsibility that the method of attachment and usage does not result in a safety hazard or damage the welding equipment Some of the factors to be considered are as follows INSTALLATION 4 1 Design capacity of trailer vs weight of Lincoln equipment an
68. ing near battery e Follow instructions printed on battery 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 that none of the solution enters the cells After cleaning flush the outside of the battery the bat tery compartment and surrounding areas with clear water Coat the battery terminals lightly with petroleum jelly or a non conductive grease to retard corrosion Keep the battery clean and dry Moisture accumula tion on the battery can lead to more rapid discharge and early battery failure CHECKING THE ELECTROLYTE LEVEL If battery cells are low fill them to the neck of the filler hole with distilled water and recharge If one cell is low check for leaks CHARGING THE BATTERY When you charge jump replace or otherwise con nect battery cables to the battery be sure the polarity is correct Improper polarity can damage the charging circuit The VANTAGE 500 CE positive battery terminal has a red terminal cover If you need to charge the battery with an external charger disconnect the negative cable first then the positive cable before you attach the charger leads After the battery is charged reconnect the positive bat
69. land Ohio 44117 1199 U S A 216 481 8100 216 486 1751 WEB SITE www lincolnelectric com
70. ll coolant level Check for loose or broken fan belt Start engine and look for leaks Faulty oil pressure switch or other engine component Contact authorized local Engine Service Shop Faulty Idler Protection Board CAUTION If for any reason you do not understand the test procedures or are unable to perform the tests repairs safely contact your Local Lincoln Authorized Field Service Facility for technical troubleshooting assistance before you proceed 500 LINCOLN E 3 TROUBLESHOOTING E 3 Observe all Safety Guidelines detailed throughout this manual High radiator coolant tempera ture Reduce load if it is exceed ing machine rating Add coolant to system if low Clean fins on radiator if dirty Tighten fan belt if loose Remove objects blocking or close to intake openings on both sides of base and exhaust end case back Engine runs rough Dirty fuel or air filters Inspect and clean replace filters as needed Inspect and clean replace filters as needed Water in fuel If water found in tank Empty fuel tank and refill then purge fuel lines Battery does not stay charged Faulty battery Replace Engine alternator trouble light is 2 Loose connections at battery or while machine is running alternator Clean and tighten con nections If all recommended possible areas of Faulty engine alternator or charg misadjustment have been checked er module Consult authorized an
71. lt 0 0 a 6 9 25 Y 2 ez A 65 Javas sao v nos LE HOL HOL 4 GAMBIA HOLIMS NOLLISOd NI NMOHS 5 eH 7TOHLNOO HOLIMS IOHLNO9 7IVNIIWH3 L 1 1 SE NOLLISOd e HOH 102 vo NOLLVNIWY 1 Wa 3HLOL 15 drS 1 HSNYE deine N3I3WLTOA 330334 38M 12 13 4 1041NOO NI 15 ANNOYS Noung 59 MOTO nid ds SEN 8902 982 m NOLLISOd NI NMOHS lt 2 SLOVINOD HOLIMS vor 5 812 E ONIGNIM HOLVLS Crus 2 EE
72. ment Installation and Use The user is responsible for installing and using the welding equipment according to the manufacturer s instructions If electromagnetic disturbances are detected then it shall be the responsibility of the user of the welding equipment to resolve the situation 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 longer troublesome Note The welding circuit may or may not be earthed for safety reasons according to national codes Changing the earthing arrangements should only be authorized by a person who is compe tent to access whether the changes will increase the risk of injury e g by allowing parallel welding current return paths which may damage the earth circuits of other equipment Assessment of Area Before installing welding equipment the user shall make an assessment of potential electromagnetic prob lems in the surrounding area The following shall be taken into account a other supply cables control cables signaling and telephone cables above below and adjacent to the welding equipment b radio and television transmitters and receivers computer and othe
73. n in the side and exhausted through radiator amp 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 A CAUTION 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 INSTALLATION 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
74. n no part of the electrode circuit is touching the work or ground Accidental contact can cause overheating and create a fire hazard Do not heat cut or weld tanks drums or containers until the proper steps have been taken to insure that such procedures will not cause flammable or toxic vapors from substances inside They can cause an explosion even though they have been cleaned For information purchase Recommended Safe Practices for the Preparation for Welding and Cutting of Containers and Piping That Have Held Hazardous Substances AWS F4 1 from the American Welding Society see address above Vent hollow castings or containers before heating cutting or welding They may explode Sparks and spatter are thrown from the welding arc Wear oil free protective garments such as leather gloves heavy shirt cuffless trousers high shoes and a cap over your hair Wear ear plugs when welding out of position or in confined places Always wear safety glasses with side shields when in a welding area Connect the work cable to the work as close to the welding area as practical Work cables connected to the building framework or other locations away from the welding area increase the possibility of the welding current passing through lifting chains crane cables or other alternate cir cuits This can create fire hazards or overheat lifting chains or cables until they fail Also see item 1 c Read and follow NFPA 5
75. nect 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 WARNING NOTE When wire feeder with a built in welding voltage trol is connected to the 14 pin connector do not connect any thing to the 6 pin connector VANTAGE 500 CE LINCOLN A 6 ELECTRICAL CONNECTIONS MACHINE GROUNDING Because this portable engine driven welder creates its own power it is not necessary to connect its frame to an earth ground unless the machine is connected to premises wiring home shop etc To prevent dangerous electric shock other equipment to which this engine driven welder supplies power must A WARNING Be grounded to the frame of the welder using a grounded type plug or be double insulated Do not ground the machine to a pipe that carries explosive or combustible material When this welder is mounted on a truck or trailer its frame must be electrically bonded to the metal frame of the vehicle Use a 8 or larger copper wire connect ed between the machine grounding stud and the frame of the vehicle When this engine driven welder is connected to premises wiring such as that in a home or shop its frame must be connected to the system earth ground See further connection instruc tions in the section entitled Standby Power C
76. ng was ceased While the display is being held the left most decimal point in each display will be flashing The accuracy of the meters is 396 3 WELD MODE SELECTOR SWITCH Provides five selectable welding modes CV WIRE amps rather than the full 40 300 amps Any current range that is less ARC GOUGING than the full range provides finer current resolution for more fine tun DOWNHILL PIPE ing of the output CC STICK TOUCH START TIG VANTAGE 500 CE LINCOLN B 3 4 ARC CONTROL The ARC CONTROL dial is active in the CV WIRE CC STICK and DOWNHILL PIPE modes and has different functions in these modes This control is not active in the TIG and ARC GOUGING mode CC STICK mode In this mode the ARC CONTROL dial sets the short circuit current arc force during stick welding to adjust for a soft or crisp arc Increasing the dial from 10 soft to 10 crisp increas es the short circuit current and prevents sticking of the electrode to the plate while welding This can also increase spatter It is recom mended that the ARC CONTROL be set to the minimum number with out electrode sticking Start with a setting at 0 DOWNHILL PIPE mode In this mode the ARC CONTROL dial sets the short circuit current arc force during stick welding to adjust for a soft or a 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
77. nt to resolve the situation 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 longer troublesome Note The welding circuit may or may not be earthed for safety reasons according to national codes Changing the earthing arrangements should only be authorized by a person who is compe tent to access whether the changes will increase the risk of injury by allowing parallel welding current return paths which may damage the earth circuits of other equipment Assessment of Area Before installing welding equipment the user shall make an assessment of potential electromagnetic prob lems in the surrounding area The following shall be taken into account a other supply cables control cables signaling and telephone cables above below and adjacent to the welding equipment b radio and television transmitters and receivers computer and other control equipment d safety critical equipment e g guarding of industrial equipment e the health of the people around e g the use of pacemakers and hearing aids f equipment used for calibration or measurement g the immunity of other equipment
78. omb es ou cadmi es ou tout autre m tal qui produit des fume s toxiques Ne pas souder en pr sence de vapeurs de chlore provenant d op rations de d graissage nettoyage ou pistolage La chaleur ou les rayons de l arc peuvent r agir avec les vapeurs du solvant pour produire du phosg ne gas fortement toxique ou autres produits irritants Pour obtenir de plus amples renseignements sur la s ret voir le code Code for safety in welding and cutting CSA Standard W 117 2 1974 2 Dans le cas de travail au dessus du niveau du sol se prot ger PR CAUTIONS DE S RET POU R contre les chutes dans le cas ou on recoit un choc Ne jamais enrouler le c ble lectrode autour de n importe quelle partie LES MACHINES SOUDER SES TRANSFORMATEUR ET A Un coup d arc peut tre plus s v re qu un coup de soliel REDRESSEUR donc a Utiliser un bon masque avec un verre filtrant appropri 1 ainsi qu un verre blanc afin de se prot ger les yeux du ray onnement de l arc et des projections quand on soude ou quand on regarde l arc b Porter des v tements convenables afin de prot ger la peau de soudeur et des aides contre le rayonnement de l arc c Prot ger l autre personnel travaillant proximit au soudage l aide d crans appropri s et non inflammables Des gouttes 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
79. onnections as well as the article on grounding in the latest National Electrical Code and the local code In general if the machine is to be grounded it should be connected with a 8 or larger copper wire to a solid earth ground such as a metal water pipe going into the ground for at least ten feet and having no insulat ed joints or to the metal framework of a building which has been effectively grounded The National Electrical Code lists a number of alter nate means of grounding electrical equipment 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 INSTALLATION A 6 WELDING OUTPUT CABLES With the engine off connect the electrode and work cables to the output studs The welding process dic tates the polarity of the electrode cable These con nections should be checked periodically and tightened with a 3 4 19mm wrench Table A 1 lists recommended cable sizes and lengths for rated current and duty cycle Length refers to the distance from the welder to the work and back to the welder Cable diameters are increased for long cable lengths to reduce voltage drops TOTAL COMBINED LENGTH OF ELECTRODE AND WORK CABLES Cable Size for 400 Amps 60 Duty Cycle 2
80. oximately 12 seconds and then go to low idle speed When the electrode touches the work or power is drawn for lights or tools approximately 100 Watts minimum the engine accelerates and operates at full speed When welding ceases or the AC power load is turned off a fixed time delay of approximately 12 seconds starts If the welding or AC power load is not restarted before the end of the time delay the idler reduces the engine speed to low idle speed The engine will automatically return to high idle speed when there is welding load or AC power load reapplied 16 ELECTRIC FUEL GAUGE The electric fuel gauge gives accurate and reliable indication as to how much fuel is in the fuel tank 17 ENGINE HOUR METER Displays the total time that the engine has been running This meter is useful for scheduling prescribed maintenance TABLE B 2 TYPICAL VANTAGE 500 CE FUEL CONSUMPTION NEN PERKINS 404 227 4040 2017 Running Time for 15 gallons hours Gal Hr Liters Hr Codes 11524 11525 11574 11575 Ge 1200 R P M 42 52 31 1575 450 Amps 38Volts 14300 Vats 3 Phase NOTE This data is for reference only Fuel consumption is approximate and can be influenced by many factors including engine maintenance environmental conditions and fuel quality 11 01 14 81 OPERATION B 4 18 ENGINE PROTECTION LIGHT A warning indi cator light for Low Oil Pressure and or Coolant Over Temperature
81. p x 1 3 Phase 25 Amp x 1 1 phase 15 Amp x 1 for 230V 1 phase 15 Amp x 2 30 Amp x 2 for 115V 10A for Engine Battery Charging Circuit 10A for Wire Feeder Power Other Circuit Breakers 5 Center Tapped to ground VANTAGE 500 CE LINCOLN 8 A 3 SAFETY PRECAUTIONS WARNING Do not attempt to use this equipment until you have thoroughly read the engine manufacturer s manual supplied with your welder It includes important safety precautions detailed engine starting operating and maintenance instructions and parts lists ELECTRIC SHOCK can kill Do not touch electrically live parts or electrode with skin or wet clothing e insulate yourself from work and ground Always wear dry insulating gloves D ENGINE EXHAUST can kill Use in open well ventilated areas or vent exhaust outside MOVING PARTS can injure Do not operate with doors open or guards off Stop engine before servicing Keep away from moving parts See additional warning information at front of this operator s manual Only qualified personnel should install use or service this equipment VRD VOLTAGE REDUCTION DEVICE The VRD feature provides additional safety in the CC Stick mode especially in an environment with a higher risk of electric shock such as wet areas and hot humid sweaty conditions The VRD reduces the OCV Open Circuit Voltage at the welding output terminals while not welding to less t
82. pe up spilled fuel and allow can cause fire fumes to clear before starting engine Do not overfill tank fuel expansion may cause over flow DIESEL FUEL ONLY Low sulphur fuel or ultra low sulphur fuel in U S A and Canada Remove the fuel tank cap Fill the tank DO NOT FILL THE TANK TO THE POINT OF OVERFLOW Replace the fuel cap and tighten securely See Engine Owner s Manual for specific fuel recom mendations BREAK IN PERIOD The engine will use a small amount of oil during its break in period The break in period is about 50 run ning hours Check the oil every four hours during break in Change the oil after the first 50 hours of operation and every 200 hours thereafter Change the oil filter at each oil change CAUTION During break in subject the Welder to moderate loads Avoid long periods running at idle Before stopping the engine remove all loads and allow the engine to cool several minutes VANTAGE 500 CE LINCOLN B 2 OPERATION FIGURE B 1 eg 7 2 7 __ RO m TN p 99 When in the TOUCH START TIG mode and when an Amptrol is WELDING CONTROLS Figure B 1 1 OUTPUT CONTROL The OUTPUT dial is used to preset the output voltage or current as displayed on the digital meters for the five welding modes When in the CC STICK DOWNHILL PIPE ARC GOUGIN
83. r Engineoilfiter Perkins 140517050 Drain water separator amp fuel strainer ater separator element or Fuel filter canister Tension of alternator drivebet 2 Alternator drive belt wear J 0002 s Afemstordrvebet Perkins 8 Air filter earlier check be required Airfilterelement_ Donaldson 87821975 n Renew the engine 1 1 clearances Intake 008 exhaust 008 E AI nuts and bolts for tightness EN Injector performance Contact Perkins leaks or engine damage Battery Clean turbocharger impeller casting and the turbocharger compressor casting Inspect Clean R Replace Notes 1 Consult Engine Operators Manual for oil recommendations 2 Consult Engine Operators Manual for additional maintenance schedule information 3 Fill slowly Ensure correct quantity is used Above operations to be carried out by trained personnel with reference to the workshop manual where necessary These preventative maintenance periods apply to average conditions of operation If necessary use shorter periods S26617 VM VANTAGE 500 CE LINCOLN D 2 ENGINE OIL CHANGE qs Drain the engine oil while the engine is warm to assure rapid and complete draining It is recommended that each time the oil is changed the oil filter be c
84. r control equipment d safety critical equipment e g guarding of industrial equipment e the health of the people around e g the use of pacemakers and hearing aids f equipment used for calibration or measurement g the immunity of other equipment in the environment The user shall ensure that other equipment being used in the environment is compatible This may require additional protection measures h the time of day that welding or other activities are to be carried out 110093 3 1 96 viii TABLE OF CONTENTS Page E Section A Technical SpeciticatiOrs eso ze Na A 1 Machine Specification EON 2 Safety aD A 3 Voltage Reduction Device issu Locatiorr and Ventllatior uoti eer peti Mee Angle Of Operation V M oot EU LI I A 3 IGM DE 4 High Temperature Operation 4 Cold Weather Operation TOWING N teams Pre Operation Engine 4 A 5 Fuel nire rene A 5 00 5 Battery 2 2
85. re reference This information can be found on your machine nameplate Product Model Number Code Number or Date Code Serial Number Date Purchased Where Purchased Whenever you request replacement parts or information on this equipment always supply the information you have recorded above The code number is especially 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 www lincolnelectric com Choose Quick Links and then Product Registration Please complete the form and submit your registration Read this Operators Manual completely before attempting to use this equipment Save this manual and keep it handy for quick reference Pay particular attention to the safety instructions we have provided for your protection The level of seriousness to be applied to each is explained below WARNING This statement appears where the information must be followed exactly to avoid serious personal injury loss of life This statement appears where the information must be followed to avoid minor personal injury or damage to this equipment S
86. s or other reproductive harm The Above For Diesel Engines The Above For Gasoline Engines ARC WELDING CAN BE HAZARDOUS PROTECT YOURSELF AND OTHERS FROM POSSIBLE SERIOUS INJURY OR DEATH KEEP CHILDREN AWAY PACEMAKER 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 amp Cutting ANSI Standard Z49 1 from the American Welding Society P O Box 351040 Miami Florida 33135 CSA Standard W117 2 1974 A Free copy of Arc Welding Safety booklet E205 is available from the Lincoln Electric Company 22801 St Clair Avenue Cleveland Ohio 44117 1199 BE SURE THAT ALL INSTALLATION OPERATION MAINTENANCE AND REPAIR PROCEDURES ARE PERFORMED ONLY BY QUALIFIED INDIVIDUALS powered equipment 1 Turn the engine off before troubleshooting and maintenance work unless the maintenance work requires it to be running 1 h To avoid scalding do not remove the radiator pressure cap when the engine is hot 1 b Operate engines in open well ventilated areas or vent the engine exhaust fumes outdoors 1 c Do not add the fuel near an open flame welding arc or when the engine is running Stop the engine and allow it to cool before refueling to prevent spilled fuel from vaporiz ing on contact with hot engine parts and igni
87. tery cable first and the negative cable last Failure to do so can result in damage to the internal charger components Follow the instructions of the battery charger manu facturer for proper charger settings and charging time SERVICING OPTIONAL SPARK ARRESTOR Clean every 100 hours WARNING MUFFLER MAY BE HOT ALLOW ENGINE TO COOL BEFORE INSTALLING THE SPARK ARRESTER DO NOT OPERATE ENGINE WHILE INSTALLING THE SPARK ARRESTER VANTAGE 500 LINCOLN 8 D 6 MAINTENANCE WELDER GENERATOR MAINTENANCE STORAGE Store in clean dry protected areas CLEANING Blow out the generator and controls peri odically with low pressure air Do this at least once a week in particularly dirty areas BRUSH REMOVAL AND REPLACEMENT It s nor mal for the brushes and slip rings to wear and darken slightly Inspect the brushes when a generator over haul is necessary CAUTION 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 warranty For your safety and to avoid Electrical Shock please observe all safety notes and pre cautions VANTAGE 500 LINCOLN 8 D 6 1 TROUBLESHOOTING 1 HOW TO USE TROUBLESHOOTING GUIDE WARNI
88. th the workpiece or ground use the following equipment Semiautomatic DC Constant Voltage Wire Welder DC Manual Stick Welder AC Welder with Reduced Voltage Control In semiautomatic or automatic wire welding the electrode electrode reel welding head nozzle or semiautomatic welding gun are also electrically hot Always be sure the work cable makes a good electrical connection with the metal being welded The connection should be as close as possible to the area being welded Ground the work or metal to be welded to a good electrical earth ground Maintain the electrode holder work clamp welding cable and welding machine in good safe operating condition Replace damaged insulation Never dip the electrode in water for cooling Never 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 When working above floor level use a safety belt to protect yourself from a fall should you get a shock Also see Items 6 c and 8 ARC RAYS can burn 4 8 Use a shield with the proper filter and cover plates to protect your eyes from sparks and the rays of the arc when welding or observing open arc welding Headshield and filter lens should conform to ANSI 287 standards 4 b Use suitable clothing made from durable flame resistant material to protect your skin and t
89. ting Do not spill fuel when filling tank If fuel is spilled wipe it up and do not start engine until fumes have been eliminated ELECTRIC AND MAGNETIC FIELDS may dangerous 2 a Electric current flowing through any conductor causes localized Electric and Magnetic Fields EMF Welding current creates EMF fields around welding cables and welding machines EMF fields may interfere with some pacemakers and welders having a pacemaker should consult their physician before welding 1 d Keep all equipment safety guards covers and devices in position and in good repair Keep hands hair clothing and tools away from V belts gears fans and all other moving parts when starting operating or repairing equipment Exposure to EMF fields in welding may have other health effects which are now not known All welders should use the following procedures in order to minimize exposure to EMF fields from the welding circuit In some cases it may be necessary to remove safety guards to perform required maintenance Remove guards only when necessary and replace them when the maintenance requiring their removal is complete Always use the greatest care when working near moving parts 2 d 1 Route the electrode and work cables together Secure them with tape when possible 2 d 2 Never coil the electrode lead around your 1 f Do not put your hands near the engin
90. tinuous operation is 25 degrees in all directions 35 degrees Intermittent less than 10 minutes continuous in all directions If the engine is to be operated at an angle provisions must be made for checking and maintaining the oil level at the normal FULL oil capacity in the crankcase When operating the welder at an angle the effective fuel capacity will be slightly less than the amount specified LIFTING The 500 CE weighs approximately 14051bs 638kg for Codes 11298 11299 14401bs 653kg for Codes 11524 11525 11574 11575 with a full tank of fuel 1290lbs 586kg less fuel A lift bail is mounted to the machine and should always be used when lifting the machine VANTAGE 500 CE LINCOLN A 4 WARNING e Lift only with equipment of ade quate lifting capacity Be sure machine is stable when lift ing Do not lift this machine using lift bail if it is equipped with a heavy accessory such as trailer or gas cylinder FALLING EQUIPMENT can cause injury Do not lift machine if lift bail is damaged Do not operate machine while suspended from lift bail HIGH ALTITUDE OPERATION At higher altitudes output derating may be necessary For maximum rating derate the machine 1 096 for every 2000 ft 610m up to 6000 ft 1828m and 2 096 for every 2000 ft 610m over 6000 ft 1828m Due to new EPA and other local emissions regulations modifications to the engine for
91. tion to warrant or guarantee such advice and assumes no liability with respect to such infor mation or advice We expressly disclaim any warranty of any kind including any warranty of fitness for any customer 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 manufacturer but the selection and use of specific products sold by Lincoln Electric is solely within the control of and remains the sole responsibility of the customer Many variables beyond the control of Lincoln Electric affect the results obtained in applying these types of fabrication methods and service requirements Subject to Change This information is accurate to the best of our knowledge at the time of printing Please refer to www lincolnelectric com for any updated information Please Examine Carton and Equipment For Damage Immediately When this equipment is shipped title passes to the purchaser upon receipt by the carrier Consequently Claims for material damaged in shipment must be made by the purchaser against the transportation company at the time the shipment is received Please record your equipment identification information below for futu
92. ver pressure is required to hold the seal NEVER use the service cover to push the filter into place Using the cover to push the filter in could cause damage to the housing cover fasteners and will void the warranty If the service cover hits the filter before it is fully in place remove the cover and push the filter by hand further into the air cleaner and try again The cover should go on with no extra force Once the filter is in place secure the service cover A Caution NEVER use the service cover to push the filter into place Using the cover to push the filter in could cause damage to the housing cover fasteners and will void the warranty 6 Check Connectors for Tight Fit Make sure that all mounting bands clamps bolts and connections in the entire air cleaner system are tight Check for holes in piping and repair if needed Any leaks in your intake piping will send dust directly to the engine VANTAGE 500 CE LINCOLN 8 D 4 MAINTENANCE D 4 COOLING SYSTEM A WARNING 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 t
93. wn hill pipe welding where the operator would like to control the current level by changing the arc length VANTAGE 500 CE LINCOLN B 6 OPERATION B 6 The OUTPUT CONTROL dial adjusts the full output range for pipe welding The ARC CONTROL dial sets the short circuit current arc force during stick welding to adjust for a soft or 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 preferred for root and hot passes A softer arc is preferred for fill and cap pass es where weld puddle control and deposition stacking of iron are key to fast travel speeds This can also increase spatter It is recommended that the ARC CONTROL be set to the minimum number without electrode sticking Start with the dial set at 0 NOTE With the switch in the 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 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 there is very little voltage or current and in general no tungsten contamination Then the tungsten is gently lifted off the work in a ro

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