RETURN TO MAIN MENU IM10003-A ® VANTAGE 500-I For use with machines having Code Numbers: December, 2012 11576, 11954, 11961 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, OPERATE OR REPAIR THIS EQUIPMENT WITHOUT READING THIS MANUAL AND THE SAFETY PRECAUTIONS CONTAINED THROUGHOUT.
i i SAFETY WARNING CALIFORNIA PROPOSITION 65 WARNINGS Diesel engine exhaust and some of its constituents are known to the State of California to cause cancer, birth defects, and other reproductive harm. The Above For Diesel Engines The engine exhaust from this product contains chemicals known to the State of California to cause cancer, birth defects, or other reproductive harm. The Above For Gasoline Engines ARC WELDING CAN bE HAzARDOUS.
ii ii 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. 3.b. 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.
iii iii SAFETY WELDING and CUTTING SPARKS can 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 and 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. 6.b.
iv SAFETY PRÉCAUTIONS DE SÛRETÉ Pour votre propre protection lire et observer toutes les instructions et les précautions de sûreté specifiques qui parraissent dans ce manuel aussi bien que les précautions de sûreté générales suivantes: Sûreté Pour Soudage A L’Arc 1. Protegez-vous contre la secousse électrique: a. Les circuits à l’électrode et à la piéce sont sous tension quand la machine à souder est en marche.
v v Thank You 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 equipment. Our challenge is to meet the needs of our customers and to exceed their expectations.
vi vi TAbLE OF CONTENTS Page Installation.......................................................................................................................Section A Technical Specifications .......................................................................................................A-1 Safety Precautions ........................................................................................................A-2 Location and Ventilation ........................................................
vii TAbLE OF CONTENTS Maintenance......................................................................................................Section D Safety Precautions ................................................................................................D-1 Routine Maintenance ............................................................................................D-1 Engine Service Items.............................................................................................
A-1 A-1 INSTALLATION TECHNICAL SPECIFICATIONS - VANTAGE® 500-I (K2805-1) INPUT - DIESEL ENGINE Make/Model PERKINS (K2805-1) 404D-22 Description Speed (RPM) 4 cylinder 32.7 HP 1800 RPM naturally aspirated water cooled Diesel Engine Displacement cu. in. (ltrs.) Starting System Capacities 135.6(2.2) 12VDC Battery & Fuel: 20 gal. starter (75.7 L) Bore x Stroke inch (mm) (Group 34; 650 Oil: 8.45Qts. (8L) Full Load 1800 cold crank amps) 3.43 X 3.64 65 Amp Alternator Radiator Coolant: (87.1 x 92.
A-2 A-2 INSTALLATION 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.
A-3 A-3 INSTALLATION HIGH ALTITUDE OPERATION At higher altitudes, output derating may be necessary. For maximum rating, derate the machine 2.5% to 3.5% for every 1000 ft. (305m). Due to new EPA and other local emissions regulations, modifications to the engine for high altitude are restricted within the United States. For use above 6000 ft.(1828 m) an authorized Perkins engine field service shop should be contacted to determine if any adjustments can be made for operation in higher elevations.
A-4 A-4 INSTALLATION OIL The VANTAGE® 500-I 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.
A-5 A-5 INSTALLATION WELDING OUTPUT CAbLES 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: With the engine off connect the electrode and work cables to the output studs.
A-6 A-6 INSTALLATION AUXILIARY POWER RECEPTACLES RESIDUAL CURRENT DEVICE READY Start the engine and set the “IDLER” control switch to the “High Idle” mode. Voltage is now correct at the receptacles for auxiliary power. This must be done before a tripped GFCI can be reset properly. See the MAINTENANCE section for more detailed information on testing and resetting the GFCI.
A-7 A-7 INSTALLATION CONNECTION OF LINCOLN ELECTRIC WIRE FEEDERS WARNING Shut off welder before making any electrical connections. -----------------------------------------------------------------------Connection of LN-15 Across The-Arc Model to the VANTAGE® 500-I 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.
b-1 b-1 OPERATION SAFETY PRECAUTIONS WARNING WARNING ADD FUEL 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.
b-2 b-2 OPERATION FIGURE b.1 1 2 8 3 4 11 10 12 9 14 7 19 18 13 15 17 16 6 5 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 ARC GOUGING 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 control at the welder to the remote control.
b-3 b-3 OPERATION 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 mode 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.
b-4 b-4 OPERATION 14. ENGINE HOUR METER- Displays the total time that the engine has been running. This meter is useful for scheduling prescribed maintenance. 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 15. ENGINE PROTECTION LIGHT- A warning indicator light for Low Oil Pressure and/or Coolant Over Temperature.The light is off when the systems are functioning properly.
b-5 b-5 OPERATION (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 prevents 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 0.
b-6 b-6 OPERATION TIG WELDING The TOUCH START TIG setting of the MODE switch is for DC TIG (Tungsten Inert Gas) welding. To initiate a weld, the OUTPUT CONTROL dial is first set to the desired current and the tungsten is touched to the work. During the time the tungsten is touching the work there is very little voltage or current and, in general, no tungsten contamination. Then, the tungsten is gently lifted off the work in a rocking motion, which establishes the arc.
b-7 OPERATION b-7 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 the following Table B.4. TAbLE b.
C-1 ACCESSORIES FIELD INSTALLED OPTIONS / ACCESSORIES K2641-2 FOUR WHEELED STEERAbLE YARD TRAILER For in plant and yard towing. Comes standard with a Duo-Hitch™, a 2” Ball and Lunette Eye combination Hitch. K2636-1 TRAILER - Two-wheeled trailer with optional fender and light package. For highway use, consult applicable federal, state, and local laws regarding possible additional requirements. Comes standard with a Duo-Hitch™, a 2” Ball and Lunette Eye combination hitch.
D-1 MAINTENANCE D-1 Read the Safety Precautions in the front of this manual and in the Engine Owner’s Manual before working on this machine. SAFETY PRECAUTIONS 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.
D-2 D-2 MAINTENANCE ENGINE OIL CHANGE OIL FILTER CHANGE Drain the engine oil while the engine is warm to assure rapid and complete draining. It is recommended that each time the oil is changed the oil filter be changed as well. • Drain the oil. • Be sure the unit is off. Disconnect the negative battery cable to ensure safety. • Locate oil drain hose and valve in bottom of base and pull through the hole in the battery access panel on the welder.
D-3 MAINTENANCE VANTAGE® 500-I D-3
D-4 D-4 MAINTENANCE FUEL COOLING SYSTEM 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.
D-5 CLEANING THE bATTERY 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-filter. OVERSPEED IS HAzARDOUS The maximum allowable 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.
D-6 D-6 MAINTENANCE WELDER / GENERATOR MAINTENANCE GFCI TESTING PROCEDURE STORAGE: Store in clean, dry protected areas. The GFCI should be properly tested at least once every month or whenever it is tripped. To properly test and reset the GFCI: CLEANING: Blow out the generator and controls periodically with low pressure air. Do this at least once a week in particularly dirty areas. bRUSH REMOVAL AND REPLACEMENT: It’s normal for the brushes and slip rings to wear and darken slightly.
E-1 TROUbLESHOOTING E-1 HOW TO USE TROUbLESHOOTING GUIDE WARNING 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.
E-2 E-2 TROUbLESHOOTING Observe all Safety Guidelines detailed throughout this manual PRObLEMS (SYMPTOMS) POSSIbLE CAUSE RECOMMENDED COURSE OF ACTION Major Physical or Electrical Damage 1. Contact your local Lincoln is Evident. Authorized Field Service Facility. Engine will not "crank". 1. Battery is low, Charge Battery. 2. Loose battery cable connections. Inspect, clean and tighten terminals. 3. Faulty engine starter motor. Contact authorized local Engine Service Shop.
E-3 E-3 TROUbLESHOOTING Observe all Safety Guidelines detailed throughout this manual PRObLEMS (SYMPTOMS) POSSIbLE CAUSE RECOMMENDED COURSE OF ACTION Engine shuts down while under a 1. High radiator coolant temperaload. ture. Reduce load if it is exceeding 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. 1.
E-4 E-4 TROUbLESHOOTING Observe all Safety Guidelines detailed throughout this manual PRObLEMS (SYMPTOMS) POSSIbLE CAUSE Engine will not go to high idle when using auxiliary power. 1. Auxiliary power load is less than 100 watts. Idler may not respond with less than a 100 watt load. Set idler to "High". 2. Faulty PC board.(Control or Idler). Engine will not go to high idle under weld or auxiliary loading. 1. Faulty idler solenoid. Check for bent linkage or broken spring. 2. Faulty PC board.
E-5 E-5 TROUbLESHOOTING Observe all Safety Guidelines detailed throughout this manual PRObLEMS (SYMPTOMS) POSSIbLE CAUSE No welding power output. 1. Poor work lead connection to work. Make sure work clamp is tightly connected to clean base metal. 2. "Weld Terminals" switch in wrong position. Place switch in "Weld Terminals On" position when welding without control cable. 3. Faulty PC board or welder alternator. Welder has output but no control. 1.
E-6 E-6 TROUbLESHOOTING Observe all Safety Guidelines detailed throughout this manual PRObLEMS (SYMPTOMS) POSSIbLE CAUSE RECOMMENDED COURSE OF ACTION The welding arc is “cold.” The weld- 1. Make sure the MODE selector ing arc is not stable or is not satis- switch is in the correct position for factory. the engine runs normally. the process being used. (For examThe auxiliary power is normal. ple, CV-WIRE, PIPE, CC-STICK.) 2. Make sure the electrode (wire, gas, voltage, current etc.
F-1 F-1 DIAGRAMS INSTRUCTIONS FOR INSTALLING A RESIDUAL CURRENT DEVICE TO PROTECT THE 240V SINGLE PHASE RECEPTACLE WARNING Do not operate with covers removed Disconnect input power before servicing Do not touch electrically live parts ELECTRIC SHOCK CAN KILL Only qualified persons should install, use or service this equipment 1. TURN OFF THE ENGINE AND DISCONNECT THE NEGATI VE BATTERY CABLE. 2. REMOVE THE FOUR SCREWS THAT SECURE THE UPPER CONTROL PANEL AND OPEN THE PANEL. 3.
F-2 F-2 DIAGRAMS 4. ROUTE LEADS 3C & 6D THROUGH RCD O PENING AS SHOWN (SEE FIGURE 2). CUT BO TH LEADS AS SHOWN. 5. STRIP ALL FOUR LEADS 13MM (.50”). RCD OPENING 6D 3C 6D CUT LEAD 3C FIGURE 2 6. CONNECT LEADS FROM CIRCUIT BREAKERS TO RCD AS SHOWN (SEE FIGURE 3). NOTE LEAD CONFIG URATIO N. 7. TIGHTEN LEADS TO 2.4NM (21 IN. LBS.) MOUNT RCD TO PANEL USING MOUNTING BRACKET AND SCREWS SET ASIDE IN STEP 3. CIRCUIT BREAKERS 6D 3C 6D 3C FIGURE 3 8. SECURE UPPER CONTROL PANEL IN PLACE. 9.
VANTAGE® 500-I + _ ENGINE WELDER TO WORK 6 PIN CONNECTOR ELECTRODE CABLE LN-25 PRO, LN-25 OR LN-15 WIRE FEEDER TO WORK WORK CLIP LEAD OPTIONAL REMOTE CONTROL Keep guards in place. Keep away from moving parts. Only qualified personnel should install,use or service this equipment. Do not operate with panels open. Disconnect NEGATIVE (-) Battery lead before servicing. Do not touch electrically live parts. DIAGRAMS S24787-1 A N.A.
NOTE: This diagram is for reference only. It may not be accurate for all machines covered by this manual. The specific diagram for a particular code is included with the machine. If the diagram is illegible, write to the Service Department for a replacement. Give the equipment code number.
NOTE: This diagram is for reference only. It may not be accurate for all machines covered by this manual. The specific diagram for a particular code is included with the machine. If the diagram is illegible, write to the Service Department for a replacement. Give the equipment code number.
F-6 DIMENSION PRINT VANTAGE® 500-I F-6
l Do not touch electrically live parts or WARNING Spanish AVISO DE PRECAUCION French ATTENTION German WARNUNG Portuguese ATENÇÃO l Keep flammable materials away. l Wear eye, ear and body protection. l Mantenga el material combustible l Protéjase los ojos, los oídos y el electrode with skin or wet clothing. l Insulate yourself from work and ground. l No toque las partes o los electrodos bajo carga con la piel o ropa mojada. l Aislese del trabajo y de la tierra.
l Keep your head out of fumes. l Use ventilation or exhaust to l Turn power off before servicing. l Do not operate with panel open or guards off. remove fumes from breathing zone. l Los humos fuera de la zona de res- piración. l Mantenga la cabeza fuera de los humos. Utilice ventilación o aspiración para gases. l Gardez la tête à l’écart des fumées. l Utilisez un ventilateur ou un aspira- l Desconectar el cable de ali- mentación de poder de la máquina antes de iniciar cualquier servicio.
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