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IM894-B
VANTAGE ® 500 (CE)
March, 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.
Equipped with VRD (VOLTAGE REDUCTION DEVICE)
See Installation and Operation sections for an explanation.
OPERATOR’S MANUAL
Copyright © Lincoln Global Inc.
• World's Leader in Welding and Cutting Products •
• Sales and Service through Subsidiaries and Distributors Worldwide •
Cleveland, Ohio 44117-1199 U.S.A. TEL: 216.481.8100 FAX: 216.486.1751 WEB SITE: www.lincolnelectric.com
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SAFETY
ARC RAYS can burn.
ELECTRIC SHOCK can
4.a. 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 Z87. I standards.
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.
4.b. Use suitable clothing made from durable flame-resistant
material to protect your skin and that of your helpers from
the arc rays.
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.
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.
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 with the workpiece or ground) use
the following equipment:
FUMES AND GASES
can be dangerous.
5.a. Welding may produce fumes and gases
hazardous to health. Avoid breathing these
• Semiautomatic DC Constant Voltage (Wire) Welder.
• DC Manual (Stick) Welder.
fumes and gases. When welding, keep
your head out of the fume. Use enough
ventilation and/or exhaust at the arc to keep
• AC Welder with Reduced Voltage Control.
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.
3.c. In semiautomatic or automatic wire welding, the electrode,
electrode reel, welding head, nozzle or semiautomatic
welding gun are also electrically “hot”.
3.d. 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.
3.e. Ground the work or metal to be welded to a good electrical
(earth) ground.
3.f. Maintain the electrode holder, work clamp, welding cable and
welding machine in good, safe operating condition. Replace
damaged insulation.
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.
3.g. Never dip the electrode in water for cooling.
3.h. 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.
5.c. Do not weld in locations near 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.
3.i. When working above floor level, use a safety belt to protect
yourself from a fall should you get a shock.
3.j. Also see Items 6.c. and 8.
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
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.
5.f. Also see item 1.b.
Jan ‘09
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SAFETY
WELDING and CUTTING
CYLINDER may explode
if damaged.
SPARKS can
cause fire or explosion.
7.a. Use only compressed gas cylinders
containing the correct shielding gas for the
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.
process used and properly operating
regulators designed for the gas and
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.
pressure used. All hoses, fittings, etc. should be suitable for
the application and maintained in good condition.
7.b. Always keep cylinders in an upright position securely
chained to an undercarriage or fixed support.
6.b. Where compressed gases are to be used at the job site,
special precautions should be used to prevent hazardous
situations. Refer to “Safety in Welding and Cutting” (ANSI
Standard Z49.1) and the operating information for the
equipment being used.
7.c. Cylinders should be located:
•Away from areas where they may be struck or subjected to
physical damage.
•A safe distance from arc welding or cutting operations and
any other source of heat, sparks, or flame.
6.c. When not welding, make certain no part of the electrode
circuit is touching the work or ground. Accidental contact
can cause overheating and create a fire hazard.
7.d. Never allow the electrode, electrode holder or any other
electrically “hot” parts to touch a cylinder.
6.d. 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).
7.e. Keep your head and face away from the cylinder valve outlet
when opening the cylinder valve.
7.f. Valve protection caps should always be in place and hand
tight except when the cylinder is in use or connected for
use.
7.g. Read and follow the instructions on compressed gas
cylinders, associated equipment, and CGA publication P-l,
“Precautions for Safe Handling of Compressed Gases in
Cylinders,” available from the Compressed Gas Association
1235 Jefferson Davis Highway, Arlington, VA 22202.
6.e. Vent hollow castings or containers before heating, cutting or
welding. They may explode.
6.f. 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.
FOR ELECTRICALLY
powered equipment.
8.a. Turn off input power using the disconnect
switch at the fuse box before working on
the equipment.
6.g. 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.
8.b. Install equipment in accordance with the U.S. National
Electrical Code, all local codes and the manufacturer’s
recommendations.
8.c. Ground the equipment in accordance with the U.S. National
Electrical Code and the manufacturer’s recommendations.
6.h. Also see item 1.c.
6.I. Read and follow NFPA 51B “ Standard for Fire Prevention
During Welding, Cutting and Other Hot Work”, available
from NFPA, 1 Batterymarch Park, PO box 9101, Quincy, Ma
022690-9101.
6.j. Do not use a welding power source for pipe thawing.
Jan ‘09
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SAFETY
PRÉCAUTIONS DE SÛRETÉ
6. Eloigner les matériaux inflammables ou les recouvrir afin de
prévenir tout risque d’incendie dû aux étincelles.
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 suiv-
antes:
7. Quand on ne soude pas, poser la pince à une endroit isolé de
la masse. Un court-circuit accidental peut provoquer un
échauffement et un risque d’incendie.
Sûreté Pour Soudage A L’Arc
8. S’assurer que la masse est connectée le plus prés 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 éloignés de la zone de travail, on augmente le risque
de voir passer le courant de soudage par les chaines de lev-
age, câbles de grue, ou autres circuits. Cela peut provoquer
des risques d’incendie ou d’echauffement des chaines et des
câbles jusqu’à ce qu’ils se rompent.
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. Eviter toujours
tout contact entre les parties sous tension et la peau nue
ou les vétements mouillés. Porter des gants secs et sans
trous pour isoler les mains.
b. Faire trés 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 couché pour lesquelles une grande
partie du corps peut être en contact avec la masse.
c. Maintenir le porte-électrode, la pince de masse, le câble
de soudage et la machine à souder en bon et sûr état
defonctionnement.
9. Assurer une ventilation suffisante dans la zone de soudage.
Ceci est particuliérement important pour le soudage de tôles
galvanisées plombées, ou cadmiées ou tout autre métal qui
produit des fumeés toxiques.
10. Ne pas souder en présence de vapeurs de chlore provenant
d’opérations de dégraissage, nettoyage ou pistolage. La
chaleur ou les rayons de l’arc peuvent réagir avec les vapeurs
du solvant pour produire du phosgéne (gas fortement toxique)
ou autres produits irritants.
d.Ne jamais plonger le porte-électrode dans l’eau pour le
refroidir.
e. Ne jamais toucher simultanément les parties sous tension
des porte-électrodes connectés à deux machines à souder
parce que la tension entre les deux pinces peut être le
total de la tension à vide des deux machines.
11. Pour obtenir de plus amples renseignements sur la sûreté,
voir le code “Code for safety in welding and cutting” CSA
Standard W 117.2-1974.
f. Si on utilise la machine à souder comme une source de
courant pour soudage semi-automatique, ces precautions
pour le porte-électrode s’applicuent aussi au pistolet de
soudage.
2. Dans le cas de travail au dessus du niveau du sol, se protéger
contre les chutes dans le cas ou on recoit un choc. Ne jamais
enrouler le câble-électrode autour de n’importe quelle partie
du corps.
PRÉCAUTIONS DE SÛRETÉ POUR
LES MACHINES À SOUDER À
TRANSFORMATEUR ET À
REDRESSEUR
3. Un coup d’arc peut être plus sévère qu’un coup de soliel,
donc:
a. Utiliser un bon masque avec un verre filtrant approprié
ainsi qu’un verre blanc afin de se protéger les yeux du ray-
onnement de l’arc et des projections quand on soude ou
quand on regarde l’arc.
1. Relier à la terre le chassis du poste conformement au code de
l’électricité et aux recommendations du fabricant. Le dispositif
de montage ou la piece à souder doit être branché à une
bonne mise à la terre.
b. Porter des vêtements convenables afin de protéger la
peau de soudeur et des aides contre le rayonnement de
l‘arc.
2. Autant que possible, I’installation et l’entretien du poste seront
effectués par un électricien qualifié.
c. Protéger l’autre personnel travaillant à proximité au
soudage à l’aide d’écrans appropriés et non-inflammables.
3. Avant de faires des travaux à l’interieur de poste, la debranch-
er à l’interrupteur à la boite de fusibles.
4. Des gouttes de laitier en fusion sont émises de l’arc de
soudage. Se protéger avec des vêtements de protection libres
de l’huile, tels que les gants en cuir, chemise épaisse, pan-
talons sans revers, et chaussures montantes.
4. Garder tous les couvercles et dispositifs de sûreté à leur
place.
5. Toujours porter des lunettes de sécurité dans la zone de
soudage. Utiliser des lunettes avec écrans lateraux dans les
zones où l’on pique le laitier.
Mar. ‘93
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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!
Thank 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 position 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.
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 future 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 or loss of life.
CAUTION
This statement appears where the information must be followed to avoid minor personal injury or damage to this equipment.
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SAFETY
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 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 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;
c) 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 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.
L10093 3-1-96H
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vii
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SAFETY
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 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 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;
c) 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 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.
L10093 3-1-96H
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TABLE OF CONTENTS
Page
Installation.......................................................................................................................Section A
Technical Specifications.......................................................................................................A-1
Machine Specification ...................................................................................................A-2
Safety Precautions........................................................................................................A-3
VRD (Voltage Reduction Device)..................................................................................A-3
Location and Ventilation................................................................................................A-3
Stacking ........................................................................................................................A-3
Angle of Operation ........................................................................................................A-3
Lifting.............................................................................................................................A-3
High Altitude Operation.................................................................................................A-4
High Temperature Operation ........................................................................................A-4
Cold Weather Operation ......................................................................................................A-4
Towing..................................................................................................................................A-4
Vehicle Mounting..................................................................................................................A-4
Pre-Operation Engine Service..............................................................................................A-4
Oil..................................................................................................................................A-5
Fuel ...............................................................................................................................A-5
Engine Coolant..............................................................................................................A-5
Battery Connections......................................................................................................A-5
Muffler Outlet Pipe ........................................................................................................A-5
Spark Arrester...............................................................................................................A-5
Remote Control.............................................................................................................A-5
Electrical Connections..........................................................................................................A-6
Machine Grounding..............................................................................................................A-6
Welding Terminals................................................................................................................A-6
Welding Output Cables ........................................................................................................A-6
Cable Installation..................................................................................................................A-6
Auxiliary Power Receptacles and Plugs...............................................................................A-7
Standby Power Connections................................................................................................A-7
Connection of Lincoln Electric Wire Feeders.................................................................A-7,A-8
________________________________________________________________________________
Operation.........................................................................................................................Section B
Safety Precautions ..............................................................................................................B-1
General Description..............................................................................................................B-1
For Auxiliary Power ..............................................................................................................B-1
Engine Operation..................................................................................................................B-1
Add Fuel...............................................................................................................................B-1
Break in Period.....................................................................................................................B-1
Welder Controls.............................................................................................................B-2,B-3
Engine Controls....................................................................................................................B-4
Fuel Consumption.........................................................................................................B-4
Starting and Stopping the Engine...........................................................................B-4,B-5
Welding Operation................................................................................................................B-5
Duty Cycle and Electrode Information...........................................................................B-5
Constant Current (Stick) Welding.........................................................................................B-5
Downhill Pipe (Stick) Welding .......................................................................................B-5
Tig Welding ...................................................................................................................B-6
Typical Current Ranges for Tungsten Electrodes .........................................................B-6
Wire Welding-CV...........................................................................................................B-7
Arc Gouging ..................................................................................................................B-7
Auxiliary Power.....................................................................................................................B-7
Simultaneous Welding and Power Loads .....................................................................B-7
Extension Cord Recommendations...............................................................................B-7
________________________________________________________________________________
Accessories.....................................................................................................Section C
Field Installed Options / Accessories ...............................................................................C-1
________________________________________________________________________________
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TABLE OF CONTENTS
Maintenance......................................................................................................Section D
Safety Precautions ................................................................................................D-1
Routine Maintenance ............................................................................................D-1
Engine Service Items.............................................................................................D-1
Engine Oil Change..........................................................................................D-2
Engine Oil Filter Change.................................................................................D-2
Air Cleaner .....................................................................................................D-2
Service Instructions And Installation Tips for Engine Air Filter .......................D-3
Cooling System .....................................................................................................D-4
Fan Belt...........................................................................................................D-4
Fuel.................................................................................................................D-4
Bleeding the Fuel System...............................................................................D-4
Fuel Filter........................................................................................................D-5
Engine Adjustment..........................................................................................D-5
Battery Maintenance .......................................................................................D-5
Servicing Optional Spark Arrestor ...................................................................D-5
Welder / Generator Maintenance ........................................................................D-6
Storage ...........................................................................................................D-6
Cleaning..........................................................................................................D-6
Brush Removal and Replacement ..................................................................D-6
________________________________________________________________________
Troubleshooting..............................................................................................Section E
How to Use Troubleshooting Guide.......................................................................E-1
Troubleshooting Guide.............................................................................E-2 thru E-6
________________________________________________________________________
Connection Diagrams, Wiring Diagrams and Dimension Print...................Section F
________________________________________________________________________
Parts List.................................................................................................................P-535
________________________________________________________________________
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A-1
A-1
INSTALLATION
TECHNICAL SPECIFICATIONS - VANTAGE® 500 (CE) (K2503-1, -2, -3, -4)
INPUT - DIESEL ENGINE
Make/Model Description
Speed (RPM)
Displacement
cu. in. (ltrs.)
Starting
System
Capacities
Perkins
404C-22T
4 cylinder
37.2 HP
135.6(2.2)
12VDC Battery &
starter
Oil:
Fuel: 15 gal.
High Idle 1575
8.45Qts. (8L)
(57 L)
11298, 11299
1500 RPM
Bore x Stroke inch (mm) (Group 34; 650
Perkins
Turbo Charged Full Load 1575
water cooled
cold crank amps) Radiator
Coolant:
Fuel: 20 gal.
(75.7 L)
404D-22T
11524, 11525
11574, 11575
3.43 X 3.64
65 Amp Alternator
W / Built in Regulator 9.5 Qts. (9.0L)
Diesel Engine
Low Idle 1200 (87.1 x 92.5mm)
RATED OUTPUT @ 104° F (40° C) - WELDER
Welding Process
Welding Output
Current/Voltage/Duty Cycle
400A / 36V / 100%
450A / 38V / 60%
Output Range
Max. Weld OCV
@Rated Load RPM
DC Constant Current
30 TO 500 AMPS
(2)
60 Volts
300A / 32V / 100%
250A / 30V / 100%
400A / 36V / 100%
450A / 38V / 60%
DC Pipe Current
Touch-Start™TIG
40 TO 300 AMPS
20 TO 250 AMPS
DC Constant Voltage
Arc Gouging
14 TO 40 VOLTS
60 Volts
450A / 38V / 60%
90 TO 500 AMPS
.
RATED OUTPUT @ 40° C (104° F) - GENERATOR
Auxiliary Power (1)
16,500 Watts Peak / 14,500 Watts Continuous, 50 Hz 400 Volts 3-Phase (Euro/UK)
(3)
6,900 Watts Peak / 6,900 Watts Continuous, 50 Hz 230 Volts 1-Phase (Euro)
(3)
3,400 Watts Peak / 3,400 Watts Continuous, 50 Hz 230 Volts 1-Phase (UK)
(3)
3,400 Watts Peak / 3,400 Watts Continuous, 50 Hz 115 Volts 1-Phase (UK)
Sound Levels (Sound power: 96 dB Lwa)
ENGINE
LUBRICATION
Full Pressure
EMISSIONS
(Codes 11298, 11299) EPA Tier Il
FUEL SYSTEM
GOVERNOR
Electronic
Mechanical Fuel Pump, Auto air bleed
(Codes 11524, 11525, 11574, 11575)
EPA Tier IV Interim Compliant
with Full Flow Filter
system, Electric shutoff solenoid, Indirect fuel injector.
AIR CLEANER
ENGINE IDLER
MUFFLER
ENGINE PROTECTION
Low noise Muffler:
Top outlet can be rotated.
Shutdown on low oil
pressure & high engine
Single Element
Automatic Idler
Made from long life, aluminized steel.
coolant temperature
ENGINE WARRANTY: 2 years / 2000 hours, all non-electric components, 3 years major non-electric components.
See Perkins warranty for details.
PHYSICAL DIMENSIONS
HEIGHT
WIDTH
27.05 in
687 mm
DEPTH
62.59 in.
1590 mm
WEIGHT
(4)
35.94 in.
1290 lbs. (586kg.)
913 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)
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A-2
A-2
INSTALLATION
MACHINE SPECIFICATIONS
MODEL NUMBERS
K2503-1, -3 (UK)
K2503-2, -4 (EUROPE)
400V (3 Ph) x 1
230V (1 Ph) x 2
14 Pin Connector
6 Pin Connector
Receptacles
400V (3 Ph) x 1
230V (1 Ph) x 1
115V x 1
14 Pin Connector
6 Pin Connector
(5)
4-pole, 25Amp
(30mA trip current)
3 Phase,25 Amp x 1
1 phase, 15 Amp x 2
Residual Current Device (RCD)
4-pole, 25Amp
(30mA trip current)
3 Phase,25 Amp x 1
1 phase, 15 Amp x 1 for 230V
30 Amp x 2 for 115V
Circuit Breakers (Thermal/Magnetic)
Other Circuit Breakers
10A for Engine Battery Charging Circuit
10A for Wire Feeder Power
(5) Center-Tapped to ground.
VANTAGE® 500 (CE)
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A-3
A-3
INSTALLATION
SAFETY PRECAUTIONS
FIGURE A.1
WARNING
(VRD)-VOLTAGE REDUCTION DEVICE
SWITCH IS LOCATED IN THIS AREA.
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.
• Insulate yourself from work and
ground
• Always wear dry insulating gloves.
------------------------------------------------------------------------
ENGINE EXHAUST can kill.
• Use in open, well ventilated areas or
vent exhaust outside.
REMOVE 4 FRONT PANEL
SCREWS TO ACCESS
(VRD) SWITCH
------------------------------------------------------------------------
MOVING PARTS can injure.
• Do not operate with doors open or
guards off.
LOCATION AND VENTILATION
• Stop engine before servicing.
• Keep away from moving parts.
------------------------------------------------------------------------
See additional warning information at
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.
front of this operator’s manual.
Only qualified personnel should install,
use, or service this equipment.
STACKING
VANTAGE® 500 (CE) machines cannot be stacked.
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.
ANGLE OF OPERATION
Engines are designed to run in the level condition
which is where the optimum performance is achieved.
The maximum angle of continuous 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.
The VRD reduces the OCV (Open Circuit Voltage) at the
welding output terminals while not welding to less than
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.
When operating the welder at an angle, the effective
fuel capacity will be slightly less than the amount
specified.
LIFTING
The VANTAGE® 500 (CE) weighs approximately
1405 lbs.(638kg.) for (Codes 11298, 11299),
1440lbs.(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.
The machine is shipped with the VRD switch in the “Off”
position. To turn it “On” or “Off”:
• Turn the engine “Off”.
• Disconnect the negative battery cable.
• Lower the control panel by removing 4 front
panel screws. (See Figure A.1)
• Place the VRD switch in the “On or “Off” position.
(See Figure A.1)
With the VRD switch in the “On” position, the VRD lights
are enabled.
VANTAGE® 500 (CE)
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A-4
A-4
INSTALLATION
1. Design capacity of trailer vs. weight of Lincoln equipment and
likely additional attachments.
WARNING
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.
• 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.
(1)
5. Conformance with federal, state and local laws.
FALLING
• Do not lift machine if lift bail is
damaged.
(1) Consult applicable federal, state and local laws regarding specific requirements for use on public
EQUIPMENT can
cause injury.
highways.
• Do not operate machine while
suspended from lift bail.
VEHICLE MOUNTING
------------------------------------------------------------------------
WARNING
Improperly mounted concentrated loads may
cause unstable vehicle handling and tires or other
components to fail.
HIGH ALTITUDE OPERATION
At higher altitudes, output derating may be necessary. For
maximum rating, derate the machine 1.0% for every 2000 ft.
(610m) up to 6000 ft. (1828m) and 2.0% for every 2000 ft.
(610m) over 6000 ft. (1828m). Due to new EPA and other
local emissions regulations, modifications to the engine for
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.
• 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.
------------------------------------------------------------------------
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:
PRE-OPERATION ENGINE SERVICE
READ the engine operating and maintenance instruc-
tions supplied with this machine.
With a fully charged battery and the proper oil, the
engine should start satisfactorily down to -15°F(-
26C°). 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.
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-
fill.
• Wipe up spilled fuel and allow fumes to clear
before starting engine.
Note: Extreme cold weather starting may require
longer glow plug operation.
• Keep sparks and flame away from tank.
------------------------------------------------------------------------
WARNING
Under no 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:
VANTAGE® 500 (CE)
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A-5
A-5
INSTALLATION
OIL
MUFFLER OUTLET PIPE
The VANTAGE® 500 (CE) is shipped with the engine crankcase
filled with high quality SAE 10W-30 Oil that meets classification CG-
4 or CH-4 for diesel engines. Check the oil level before starting the
engine. If it is not up to the full mark on the dip stick, add oil as
required. Check the oil level every four hours of running time during
the first 50 running hours. Refer to the engine Operator’s Manual for
specific oil recommendations and break-in information. The oil
change interval is dependent on the quality of the oil and the operat-
ing environment. Refer to the Engine Operator’s Manual for more
Using the clamp provided secure the outlet pipe to the outlet tube
with the pipe positioned such that it will direct the exhaust in the
desired direction. Tighten using a 9/16"(14mm) socket or wrench.
SPARK ARRESTER
Some federal, state or local laws may require that gasoline or diesel
engines be equipped with exhaust spark arresters when they are
operated in certain locations where unarrested sparks may present
a fire hazard. The standard muffler included with this welder does
not qualify as a spark arrester. When required by local regulations,
a suitable spark arrester, such as the K903-1 must be installed and
properly maintained.
details on the proper service and maintenance intervals.
FUEL
DIESEL FUEL ONLY-Low sulphur fuel or ultra low sulphur
WARNING
An incorrect spark arrestor may lead to damage to the engine
fuel in U.S.A. and Canada.
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.
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
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.
WARNING
Air to cool the engine is drawn in the side and exhausted
through radiator & case back. It is important that the intake and
exhaust air is not restricted. Allow a minimum clearance of 1ft.
(0.6m) from the case back and 16 in. (406mm) from either side
of the base to a vertical surface.
------------------------------------------------------------------------
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.
CAUTION
BATTERY CONNECTION
The 14-pin connector is used to directly connect a wire feeder con-
trol cable. In the CV-WIRE mode, when the control cable is con-
nected to the 14-pin connector, the auto-sensing circuit automatical-
ly makes the Output Control inactive and the wire feeder voltage
control active.
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.
WARNING
NOTE: When a wire feeder with a built in welding voltage con-
trol is connected to the 14-pin connector, do not connect any-
thing to the 6-pin connector.
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”)
------------------------------------------------------------------------
VANTAGE® 500 (CE)
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A-6
A-6
INSTALLATION
WELDING OUTPUT CABLES
ELECTRICAL CONNECTIONS
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.
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.)
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.
To prevent dangerous electric shock, other equipment
to which this engine driven welder supplies power
must:
TOTAL COMBINED LENGTH OF
ELECTRODE AND WORK CABLES
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
Cable Size for
Cable Length
400 Amps
60% Duty Cycle
2 / 0 AWG
explosive or combustible material.
0-100 Ft. (0-30 meters)
------------------------------------------------------------------------
When this welder is mounted on a truck or trailer, its
2 / 0 AWG
3 / 0 AWG
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
Connections" as well as the article on grounding in the
latest National Electrical Code and the local code.
100-150 Ft. (30-46 meters)
150-200 Ft. (46-61 meters)
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.
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.
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.
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.
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.
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.
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)
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A-7
A-7
INSTALLATION
CONNECTION OF LINCOLN ELECTRIC
WIRE FEEDERS
Connection of LN-15 to the VANTAGE® 500 (CE)
AUXILIARY POWER
The auxiliary power capacity is 16,500 watts Peak,
14,500 Watts Continuous of 50 Hz, three phase
power. The auxiliary power capacity rating in watts is
equivalent to volt-amperes at unity power factor. The
max permissible current of the 400 VAC output is 22
amps. Output voltage is within 10% at all loads up
to the rated capacity.
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.
Single phase power is:
• 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. Across The-Arc Model:
• 3,400 Watts Peak / 3,400 Watts Continuous, 50 Hz
115 Volts 1-Phase (UK).
• 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.
STANDBY POWER CONNECTIONS
The machine is suitable for temporary, standby or
emergency power using the engine manufacturer’s
recommended maintenance schedule.
• 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 (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.
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.
4. Control Cable Model:
• Take necessary steps to assure load is limited to
the capacity of the VANTAGE® 500 (CE).
• Connect Control Cable between Engine Welder
and Feeder.
WARNING
• Set the "WELD TERMINALS" switch to
"REMOTELY CONTROLLED"
• Only a licensed, certified, trained electrician
should install the machine to a premises or resi-
dential electrical system. Be certain that:
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.
• The installation complies with the National
Electrical Code and all other applicable electri-
cal codes.
7. Set the "ARC CONTROL" knob to "0" initially and
• 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.
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 VANTAGE® 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.
VANTAGE® 500 (CE)
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A-8
A-8
INSTALLATION
WARNING
Connection of the LN-25 to the VANTAGE® 500
(CE). Shut off welder before making any electrical
connections.
------------------------------------------------------------------------
The LN-25 with or without an internal contactor may
be used with the VANTAGE® 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 VANTAGE® 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. Set the MODE switch to the "CV-WIRE " position.
5. Set the "WELD TERMINALS" switch to "WELD
TERMINALS ON"
6. Set the "ARC CONTROL" knob to "0" initially and
adjust to suit.
7. Set the "IDLE" switch to the "AUTO" position.
When not welding, the VANTAGE® 500 (CE)
engine will be at the low idle speed. If you are
using an LN-25 with an internal contactor, the
electrode is not energized until the gun trigger is
closed.
8. When the gun trigger is closed, the current sens-
ing circuit will cause the VANTAGE® 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.
CAUTION
If you are using an LN-25 without an internal con-
tactor, the electrode will be energized when the
VANTAGE® 500 (CE) is started.
------------------------------------------------------------------------
VANTAGE® 500 (CE)
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B-1
B-1
OPERATION
• 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).
SAFETY PRECAUTIONS
WARNING
• See Engine Owner’s Manual for specific oil and
coolant recommendations.
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.
WARNING
------------------------------------------------------------------------
ELECTRIC SHOCK can kill.
ADD FUEL
• Stop engine while fueling.
• Do not smoke when fueling.
• Keep sparks and flame away
from tank.
• Do not leave unattended
while fueling.
• Wipe up spilled fuel and allow
fumes to clear before starting
engine.
• Do not touch electrically live parts or
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.
DIESEL FUEL
can cause fire.
• 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.
• 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.
GENERAL DESCRIPTION
The VANTAGE® 500 (CE) is a diesel engine powered
DC multi-process welding power source and AC
power generator. The engine drives a generator 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
• Fill the tank. DO NOT FILL THE TANK TO THE
POINT OF OVERFLOW.
• Replace the fuel cap and tighten securely.
C
of the art Chopper Technology
ing performance.
for superior weld-
T
R
• See Engine Owner’s Manual for specific fuel recom-
mendations.
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.
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.
FOR 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.
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.
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.
------------------------------------------------------------------------
VANTAGE® 500 (CE)
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B-2
B-2
OPERATION
FIGURE B.1
1
11
9
2
3
10
14
15
4
13
12
17
7
8
22
21
16
20
18
19
6
5
When in the TOUCH START TIG mode and when an Amptrol is
connected to the 6-Pin Connector, the OUTPUT dial is used to
set the maximum current range of the CURRENT CONTROL of
the Amptrol.
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 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 con-
trol at the welder to the remote control.
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
welding was ceased.
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
While the display is being held the left-most decimal point in
each display will be flashing. The accuracy of the meters is +/-
3%.
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.
3. WELD MODE SELECTOR SWITCH-
(Provides five selectable welding modes)
CV-WIRE
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 tun-
ing of the output.
ARC GOUGING
DOWNHILL PIPE
CC-STICK
TOUCH START TIG
VANTAGE® 500 (CE)
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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 and
ARC GOUGING mode.
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).
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.
The VRD “On/Off” switch inside the control panel must be “On” 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.
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. 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.
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 VRD 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.
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.
If the VRD is turned “On” and the lights don’t come “On”, refer to the
trouble shooting section.
TABLE B.1
5. WELD OUTPUT TERMINALS WITH FLANGE NUT-
VRD INDICATOR LIGHTS
Provides a connection point for the electrode and work cables.
MODE
CC-STICK OCV
While
VRD "ON"
Green (OCV Reduced)
Red or Green
VRD "OFF"
6. GROUND STUD-
Provides a connection point for connect-
Welding (Depends on Weld Voltage) *
ing the machine case to earth ground.
CV-WIRE OCV
Red (OCV Not Reduced)
Weld Terminals On
Red (OCV Not Reduced)
Weld Terminals Remotely Controlled
Gun Trigger Closed
Green (No OCV)
Weld Terminals Remotely Controlled
Gun Trigger Open
7. 14-PIN CONNECTOR- 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.
No Lights
While
Red or Green
Welding (Depends on Weld Voltage) *
8. 6-PIN CONNECTOR- For attaching optional remote control
PIPE
OCV
Green (No Output)
equipment. Includes auto-sensing remote control circuit.
While
Not Applicable (No Output)
Welding
ARC GOUGING OCV
9. WELD TERMINALS CONTROL SWITCH- In the WELD
Green (No Output)
Not Applicable (No Output)
TERMINALS ON position, the output is electrically hot all the time.
While
Welding
OCV
While
Welding
TIG
Green (Process is Low Voltage)
Green (Process is Low Voltage)
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.
* It is normal for the lights to alternate between colors while welding.
10. WIRE FEEDER VOLTMETER SWITCH-
Matches the polarity of the wire feeder voltmeter to the polarity of the
electrode.
VANTAGE® 500 (CE)
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B-4
B-4
OPERATION
18. ENGINE PROTECTION LIGHT- A warning indi-
cator light for Low Oil Pressure and/or Coolant Over
Temperature.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.
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.
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.
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.
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.
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 approximately 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.
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.
• 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.
20. COOLANT TEMPERATURE GAUGE- A indica-
tor of engine coolant temperature.
21. OIL PRESSURE GAUGE- A indicator of engine
Oil Pressure.
22. CIRCUIT BREAKER
16. ELECTRIC FUEL GAUGE- The electric fuel
gauge gives accurate and reliable indication as to
how much fuel is in the fuel tank.
STARTING THE ENGINE
1. Remove all plugs connected to the AC power recepta-
cles.
2. Set IDLER switch to AUTO.
17. ENGINE HOUR METER- Displays the total
time that the engine has been running. This meter
is useful for scheduling prescribed maintenance.
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 to hold the glow plug button for up to
an additional 10 seconds.
TABLE B.2
TYPICAL VANTAGE® 500 (CE) FUEL CONSUMPTION
PERKINS (404C-22T), (404D-22T)
Gal./Hr (Liters/Hr)
Running Time for 15 gallons / hours
6. Release the engine START button immediately when the
engine starts.
Codes 11298, 11299 Codes 11524, 11525
11574, 11575
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.
Low Idle - No Load
1200 R.P.M.
High Idle - No Load
1575 R.P.M.
DC Weld Output
450 Amps @ 38Volts
14,500 Watts 3 Phase
.31(1.16)
.47(1.78)
1.82(6.87)
1.35(5.11)
49.13
31.89
8.26
65.50
42.52
11.01
14.81
11.11
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.
VANTAGE® 500 (CE)
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B-5
B-5
OPERATION
NOTE: If the unit fails to start turn Run/Stop switch
The ARC CONTROL dial sets the short circuit current
(arc-force) during stick welding to adjust for a soft or
crisp arc. Increasing the number from -10(soft) to
+10(crisp) increases the short circuit current and pre-
vents sticking of the electrode to the plate while welding.
This can also increase spatter. It is recommended that
the ARC CONTROL be set to the minimum number
without electrode sticking. Start with the dial set at 0.
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.
• IF 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.
NOTE: Due to the low OCV with the VRD on, a very
slight delay during striking of the 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 .
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.
Once the arc is started, normal welding technique for
the application is then used.
STOP the engine by placing the RUN-STOP switch in
the STOP position.
B. For Re-Striking Electrodes
NOTE: A fuel shut off valve is located on the fuel pre-filter.
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.
WELDER OPERATION
DUTY CYCLE
Duty Cycle is the percentage of time the load is being
applied in a 10 minute period. For example a 60% duty
cycle, represents 6 minutes of load and 4 minutes of no
load in a 10 minute period.
E6010 - Push, Twist in Joint, Lift
E7018, E7024 - Push, Rock Back and Forth in Joint,
Lift.
ELECTRODE INFORMATION
Once the arc is started, normal welding technique for
the application is then used.
For any electrode the procedures should be kept within the
rating of the machine. For information on electrodes and
the appropriate Lincoln publication.
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.
The VANTAGE® 500 (CE) can be used with a broad range
of DC stick electrodes. The MODE switch provides two
stick welding settings as follows:
For indicator light operation, see table B.1.
DOWNHILL PIPE Welding
CONSTANT CURRENT (CC-STICK) WELDING
This slope controlled setting is intended for "out-of-posi-
tion" and "down hill" pipe welding where the operator
would like to control the current level by changing the
arc length.
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.
VANTAGE® 500 (CE)
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B-6
B-6
OPERATION
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 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.
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.
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.
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.
It is recommended that the ARC CONTROL be set to the
minimum number without electrode sticking. Start with
the dial set at 0.
The VANTAGE® 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 are for reference.
NOTE: With the VRD switch in the “ON” position there is
no output in the DOWNHILL PIPE mode. For indicator
light operation, see table B.1.
TIG WELDING
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.
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.
• Set the "IDLER" Switch to the "AUTO" position.
• Set the "WELDING TERMINALS" switch to the
"REMOTELY CONTROLLED" position.
TABLE B.3
(1)
(2)
TYPICAL CURRENT RANGES
FOR TUNGSTEN ELECTRODES
Tungsten Electrode
Diameter in. (mm)
DCEN (-)
DCEP (+)
Approximate Argon Gas Flow
Flow Rate C.F.H. ( l /min.)
TIG TORCH
Nozzle Size (4), (5)
1%, 2% Thoriated
Tungsten
1%, 2% Thoriated Aluminum
Tungsten
Stainless Steel
.010
0.020
0.040
(.25)
(.50)
(1.0)
2-15
5-20
15-80
(3)
(3)
(3)
3-8
5-10
5-10
(2-4)
(3-5)
(3-5)
3-8
5-10
5-10
(2-4)
(3-5)
(3-5)
#4, #5, #6
1/16
(1.6)
70-150
10-20
5-10
(3-5)
9-13
(4-6)
#5, #6
3/32
1/8
(2.4)
(3.2)
150-250
250-400
15-30
25-40
13-17
15-23
(6-8)
(7-11)
11-15
11-15
(5-7)
(5-7)
#6, #7, #8
5/32
3/16
1/4
(4.0)
(4.8)
(6.4)
400-500
500-750
750-1000
40-55
55-80
80-125
21-25
23-27
28-32
(10-12)
(11-13)
(13-15)
13-17
18-22
23-27
(6-8)
(8-10)
(11-13)
#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
EWP
1% Thoriated
2% 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.
# 5 = 5/16 in.
# 6 = 3/8 in.
# 7 = 7/16 in.
# 8 = 1/2 in.
#10 = 5/8 in.
(6 mm)
(8 mm)
(10 mm)
(11 mm)
(12.5 mm)
(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.
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B-7
B-7
OPERATION
This will keep the "Solid State" contactor open and provide a
"cold" electrode until the Amptrol or Arc Start Switch is pressed.
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.
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-
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 “On” or “Off” for this mode. For indicator light oper-
ation, see table B.1.
TABLE B.4
Carbon Diameter
Current Range (DC, electrode
positive)
1/8"(3.2mm)
5/32"(4.0mm)
3/16"9(4.8mm)
1/4"(6.4mm)
3/8"(10.0mm)
60-90 Amps
90-150 Amps
200-250 Amps
300-400 Amps
400-Max.Amps
WIRE WELDING-CV
Connect a wire feeder to the VANTAGE® 500 (CE) according
to the instructions in INSTALLATION INSTRUCTIONS Section.
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 per-
formance.
The VANTAGE® 500 (CE) in the CV-WIRE mode, permits it to
be used with a broad range of flux cored wire (Innershield and
Outershield) electrodes and solid wires for MIG welding (gas
metal arc welding). Welding can be finely tuned using the ARC
CONTROL. Turning the ARC 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: With the VRD switch in the “ON” position there
is no output in the Arc Gouging Mode. For indicator
light operation, see table B.1.
AUXILIARY POWER:
NOTE: In the CV-Mode with VRD “On”, the OCV(Open Circuit
Voltage) is not reduced. For indicator light operation,
see table B.1.
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.
ARC GOUGING
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.
The VANTAGE® 500 (CE) can be used for arc gouging.
For optimal performance, set the MODE switch to ARC
GOUGING.
TABLE B.5
SIMULTANEOUS WELDING AND AUXILIARY POWER OUTPUT
WELDING OUTPUT
AUXILIARY POWER OUTPUT AUXILIARY POWER OUTPUT
(AMPS)
NOT WELDING
(WATTS)
14,500
11,100
8,900
4,900
700
(AMPS @ 400V, 3-PHASE)
21.0
17.5
12.8
7.1
1.0
0
100
200
300
400
450
Max.
0
0
0
TABLE B.6
VANTAGE® 500 (CE) Extension Cord Length Recommendations
(Use the shortest length extension cord possible sized per the following table.)
Current Voltage Load
(Amps) Volts (Watts)
Maximum Allowable Cord Length in ft. (m) for Conductor Size
12 AWG 10 AWG 8 AWG 6 AWG
14 AWG
4 AWG
15
20
15
20
44
120
120
240
240
240
1800
2400
3600
4800
9500
30
(9)
40
(12)
(9)
(23)
(18)
75
(23)
(15)
(46)
(30)
(15)
125
(38)
(27)
(69)
(53)
(27)
175
(53)
(42)
(107)
(84)
(46)
300
(91)
(69)
(183)
(137)
(69)
30
75
60
50
150
100
50
88
225
175
90
138
350
275
150
225
600
450
225
60
(18)
Conductor size is based on maximum 2.0% voltage drop.
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C-1
C-1
ACCESSORIES
FIELD INSTALLED OPTIONS /
ACCESSORIES
TIG OPTIONS
K1783-9 Pro -Torch® PTA-26V TIG Torch
Air Cooled 200 amp torch (2 piece) equipped with valve for
gas flow control. 25 ft. (7.6m) length.
K903-1 SPARK ARRESTOR - Includes a heavy gage steel,
approved spark arrestor, clamp and adapter for mounting to
the muffler exhaust pipe.
®
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.
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.
K870 Foot Amptrol®
K963-3 Hand Amptrol®
K857 25 ft (7.6m) or K857-1 100 ft. (30.4m) REMOTE
CONTROL
K2347-1 Precision TIG 185 Ready-Pak(For AC TIG)
K2350-1 Invertec® V205-T AC/DC One-Pak™ Package
(For AC TIG)
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.
PLASMA CUTTING
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.
K1601-1 Pro-Cut 55-Cuts metal using the 3-phase AC gen-
erator power from the engine driven welder. Accepts 3-
phase power.
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 44lb. (20 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 lb. (4.5-6.8kg) spools.
®
®
Magnum Gun and Magnum Gun Connector Kit are
required for gas-shielded welding. Innershield Gun is
required for gasless welding.
®
K126-2 Magnum 350 Innershield Gun
®
K1802-1 Magnum 300 MIG 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 & K126-2)
Note: See Wire Feeder IM manuals for appropriate Drive
Roll and Guide Tubes.
VANTAGE® 500 (CE)
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D-1
D-1
MAINTENANCE
SAFETY PRECAUTIONS
Read the Safety Precautions in the front of this
manual and in the Engine Owner’s Manual before
working on this machine.
WARNING
• Have qualified personnel do all maintenance
and troubleshooting work.
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
• 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.)
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.
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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.
• 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.
• 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.
• 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.
• 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.
°
• Start the engine and check for oil filter leaks.
• 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.
• Stop the engine and check the oil level. If neces-
sary, add oil to the upper limit mark on the dipstick.
• 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.
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.
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 IS permissible
to use an oil that meets S and C grade service classifi-
cations.)
AIR CLEANER
The diesel engine is equipped with a dry type air 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.
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.
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D-3
D-3
MAINTENANCE
Service Instructions
Single- and Two-Stage Engine Air Cleaners
Inspeect thee New Filter for Damage
Removee the Filter
Inspect the new filter carefully, paying attention to
the inside of the open end, which is the
sealing area. NEVER install a damaged
filter. A new Donaldson radial seal
filter may have a dry lubricant on the
seal to aid installation.
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
the seal on a jar. Gently move the end of the filter
back and forth to break the seal then rotate while
pulling straight out. Avoid knocking the filter
against the housing.
Rotate the
filter while
pulling
straight out.
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.
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.
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.
Clean Booth Surfaces of the Outlet Tube
and Check the Vacuuator™™ Valve
The critical sealing area will stretch
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 "dust" an engine! Be careful not to damage the sealing area
on the tube.
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 cover pressure is required to hold the seal.
NEVER use the service cover to push the filter into place! Using the
cover to push the filter in could cause damage to the housing, cover
fasteners 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.
Wipe both sides
of the outlet
tube clean.
Once the filter is in place, secure the service cover.
Outer edge of the
Inner edge of the
outlet tube
Caution
outlet tube
NEVER use the service cover to
push the filter iinto placce! Using
the cover to push the filter in could
cause damage to the housing, cover
fasteners and will void the warranty.
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.
Inspecct the Old
Filteer forr Leak Clues
Check Connnectorss for Tiigght 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!
Visually inspect the old filter for any signs
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.
VANTAGE® 500 (CE)
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D-4
D-4
MAINTENANCE
FUEL
COOLING SYSTEM
WARNING
At the end of each day’s use, refill the fuel tank to min-
imize moisture condensation and dirt contamination in
the fuel line. Do not overfill; leave room for the fuel to
expand.
HOT COOLANT can burn skin.
• Do not remove cap if radiator is
hot.
Use only fresh No. 2D diesel fuel, the use of No. 1D
diesel fuel is recommended in place of No. 2D at tem-
peratures below 23°F (-5°C). Do not use kerosene.
------------------------------------------------------------------------
Check the coolant level by observing the level in the
radiator and recovery bottle. Add 50/50 antifreeze /
water solution if the level is close to or below the
"LOW" mark. do not fill above the "FULL" mark.
Remove radiator cap and add coolant to radiator. Fill
up to the top of the tube in the radiator filler neck
which includes a connecting hose coming from the
thermostat housing.
See the Engine Operator's Manual for instructions on
replacing the fuel filter.
BLEEDING THE FUEL SYSTEM
You may need to bleed air from the fuel system if the
fuel filter or fuel lines have been detached, the fuel
tank has been ran empty or after periods of long stor-
age. It is recommended that the fuel shutoff valve be
closed during periods of non-use.
To 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.
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:
CAUTION
1. Fill the fuel tank with fuel.
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).
2. Open the fuel shut off valve.
3. Loosen bleed fitting on the fuel injector manifold.
4. Operate hand priming lever until fuel comes out the
bleed screw on the injector manifold. This could
take 20-30 seconds of rapid operation of the prim-
ing lever. Tighten bleed fitting on injector manifold.
5. Follow normal STARTING procedures until engine
starts.
Cooling solution exceeding 50% ethylene glycol
can result in engine overheating and damage to
the engine. Coolant solution must be premixed
before adding to radiator.
------------------------------------------------------------------------
Periodically remove the dirt from the radiator fins.
Periodically check the fan belt and radiator hoses.
Replace if signs of deterioration are found.
TIGHTENING THE FAN BELT
If the fan belt is loose, the engine can overheat and
the battery lose its charge. Check tightness by press-
ing on the belt midway between the pulleys. It should
deflect about .25 in.(6.4 mm) under a load of 20 lbs.(9
Kg).
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D-5
D-5
MAINTENANCE
CLEANING THE BATTERY
FUEL FILTER
1. Check the fuel filter and fuel pre-filter for water
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.
accumulation or sediment.
2. Replace the fuel filter if it is found with excessive
water accumulation or sediment. Empty fuel pre-fil-
ter.
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.
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. Severe personal injury and damage to the
machine can result if operated at speeds above
maximum.
CHECKING THE ELECTROLYTE LEVEL
ENGINE ADJUSTMENT
Adjustments to the engine are to be made only by a
Lincoln Service Center or an authorized Field Service
Shop.
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
BATTERY MAINTENANCE
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.
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.
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
battery cable first and the negative cable last. Failure
to do so can result in damage to the internal charger
components.
WARNING
GASES FROM BATTERY can explode.
G Keep sparks, flame and cigarettes
away from battery.
Follow the instructions of the battery charger manu-
facturer for proper charger settings and charging time.
To prevent EXPLOSION when:
G INSTALLING A NEW BATTERY — disconnect
negative cable from old battery first and con-
nect to new battery last.
SERVICING OPTIONAL SPARK
ARRESTOR
Clean every 100 hours.
G 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.
WARNING
• MUFFLER MAY BE HOT
G 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.
• ALLOW ENGINE TO COOL BEFORE INSTALLING
THE SPARK ARRESTER!
• DO NOT OPERATE ENGINE WHILE INSTALLING
THE SPARK ARRESTER!
G
Wear gloves and eye protection
and be careful when working near
battery.
G Follow instructions printed on battery.
VANTAGE® 500 (CE)
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D-6
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.
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E-1
E-1
TROUBLESHOOTING
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.
__________________________________________________________________________
This Troubleshooting Guide is provided to help you
locate and repair possible machine malfunctions.
Simply follow the three-step procedure listed below.
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.
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.
If you do not understand or are unable to perform the
Recommended Course of Action safely, contact your
local Lincoln Authorized Field Service Facility.
Step 2. POSSIBLE CAUSE.
The second column labeled “POSSIBLE CAUSE” lists
the obvious external possibilities that may contribute
to the machine symptom.
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)
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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.
Engine will "crank" but not start.
1. Fuel shut off valve on Main Fuel
Filter in the OFF position. Open
valve (vertical) position of handle.
2. Fuel Filters dirty/clogged. Check
and replace main filter element
and/or Inline Fuel Filter.
3. Out of fuel. Fill tank and bleed fuel
system.
4. High coolant temperature or low
oil pressure. (indictor lights lit)
I
f all recommended possible areas
Check oil and coolant levels. Fill if of misadjustment have been
required. Check for loose or bro- checked and the problem persists,
ken fan belt.
Contact your local Lincoln
5. Faulty fuel shutdown solenoid. Authorized Field Service Facility.
Check that shutdown solenoid is
functioning properly and not bind-
ing/ contact authorized engine
service shop.
6. Faulty fuel pump. Check for fuel
flow through filters. Contact autho-
rized local Engine Service Shop.
Engine shuts down shortly after
starting.
1. High coolant temperature or low
oil pressure. (indictor light lit)
Change oil and oil filters and fill to
proper level. Check and fill coolant
level. Check for loose or broken
fan belt. Start engine and look for
leaks.
2. Faulty oil pressure switch or other
engine component. Contact
authorized local Engine Service
Shop.
3. 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.
VANTAGE® 500 (CE)
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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 tempera-
load.
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.
1. Dirty fuel or air filters. Inspect and
clean/replace filters as needed.
Inspect and clean/replace filters
as needed.
2. Water in fuel. If water found in
tank. Empty fuel tank and refill
then purge fuel lines.
Battery does not stay charged.
1. Faulty battery. Replace.
Engine alternator trouble light is on 2. Loose connections at battery or
while machine is running.
alternator. Clean and tighten con-
nections.
If all recommended possible areas of
misadjustment have been checked
and the problem persists, Contact
your local Lincoln Authorized
Field Service Facility.
3. Faulty engine alternator or charg-
er module. Consult authorized
Engine Service Shop.
Engine will not idle down to low 1. Idler switch in High idle position.
speed.
Set switch to Auto.
2. External load on welder or auxil-
iary power. Remove all external
loads.
3. Faulty PC board or idler sole-
noid.
Engine will not go to high idle when 1. Poor work lead connection to
attempting to weld.
work. Make sure work clamp is
tightly connected to clean base
metal.
2. "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.
3. 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.
VANTAGE® 500 (CE)
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E-4
E-4
TROUBLESHOOTING
Observe all Safety Guidelines detailed throughout this manual
PROBLEMS
(SYMPTOMS)
POSSIBLE
CAUSE
RECOMMENDED
COURSE OF ACTION
Engine will not go to high idle when 1. Auxiliary power load is less than
using auxiliary power.
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 1. Faulty idler solenoid. Check for
under weld or auxiliary loading.
bent linkage or broken spring.
2. Faulty PC board.(Control or Idler).
Engine does not develop full 1. Fuel filter clogged, Replace.
power. Engine runs rough.
2. Air filter clogged, clean or replace.
3. High idle setting incorrect, check
and adjust if required.
4. Valves out of adjustment.
5. Fuel contaminated with water or
sediment. Check fuel pre-filter
and empty of water, bleed fuel
system. Replace fuel in tank if
needed.
Engine will not go to high idle when 1. Broken spring on Idle Solenoid,
attempting to weld or using auxil-
iary power. Switching to manual
high idle does not work.
solenoid linkage binding, Faulty If all recommended possible areas
PC board (Control or Idler), low of misadjustment have been
idle speed set too low on idle checked and the problem persists,
solenoid.
Contact your local Lincoln
Authorized Field Service Facility.
Engine will not shut off.
1. 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.
Engine does not develop full power. 1. Fuel filter dirty/clogged. Replace.
Low weld and auxiliary output. 2. Air filter dirty/clogged. Replace Air
Engine runs rough.
Filter Element.
3. Fouled fuel injector(s). Contact
authorized Engine Service Shop.
4. Fuel contaminated with water.
Check water separator for water.
Clean and replace as needed.
Replace fuel in tank.
5. Cracked or loose fuel hose.
Replace hose and tighten clamps.
6. Valves out of adjustment. Contact
authorized local Engine Service
Shop.
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)
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E-5
E-5
TROUBLESHOOTING
Observe all Safety Guidelines detailed throughout this manual
PROBLEMS
(SYMPTOMS)
POSSIBLE
CAUSE
RECOMMENDED
COURSE OF ACTION
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 alterna-
tor.
Welder has output but no control.
1. Poor remote/control cable connec-
tion to 6-pin or 14-pin connector.
Check connections.
2. Faulty remote cable or faulty wire
feeder or wire feeder cable.
Replace if necessary.
3. Faulty control potentiometer or PC
board.
I
f all recommended possible areas
Wire feeder does not work when 1. Wire Feeder Power circuit breaker of 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
2. Faulty control cable. Repair or
replace cable.
Authorized Field Service Facility.
3. Faulty wire feeder. Replace wire
feeder.
No auxiliary power.
1. Open circuit breakers. Reset
breakers. If breakers keep trip-
ping, reduce power draw.
2. Faulty connections to auxiliary
receptacles. Check connections.
3. RCD tripped. Clear any ground
fault and reset RCD circuit by
pressing "Reset" button.
4. 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)
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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 exam-
The auxiliary power is normal.
No output in Pipe Mode.
VRD Lights don’t light up.
ple, CV-WIRE, PIPE, CC-STICK.)
2. Make sure the electrode (wire, gas,
voltage, current etc.) is correct for
the process being used.
3. Check for loose or faulty connec-
tions at the weld output terminals
and welding cable connections.
4. The welding cables may be too long
or coiled, causing an excessive
voltage drop.
If all recommended possible areas of
misadjustment have been checked
and the problem persists, Contact
your local Lincoln Authorized
Field Service Facility.
5. Faulty Control Board.
1. Make sure VRD ON/OFF toggle
switch is in the “OFF” position.
2. Poor work lead connection to
work. Make sure work clamp is
tightly connected to clean base
metal.
3. "Weld Terminals" switch in wrong
position. Place switch in "Weld
Terminals On" position when
welding without control cable.
4. Faulty PC board or welder alterna-
tor.
1. Ensure VRD ON/OFF switch is in
the “ON” position.
2. If light is burned out, replace both
VRD lights.
3. Faulty OCV indicator PC 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.
VANTAGE® 500 (CE)
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F-1
F-1
DIAGRAMS
VANTAGE® 500 (CE)
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F-2
F-2
DIAGRAMS
VANTAGE® 500 (CE)
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F-3
F-3
DIAGRAMS
VANTAGE® 500 (CE)
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F-4
F-4
DIAGRAMS
VANTAGE® 500 (CE)
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F-5
F-5
WIRING DIAGRAM
VANTAGE® 500 (CE)
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F-6
F-6
WIRING DIAGRAM
VANTAGE® 500 (CE)
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F-7
F-7
DIMENSION PRINT
VANTAGE® 500 (CE)
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NOTES
VANTAGE® 500 (CE)
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NOTES
VANTAGE® 500 (CE)
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G Do not touch electrically live parts or
electrode with skin or wet clothing.
G Insulate yourself from work and
ground.
G Keep flammable materials away.
G Wear eye, ear and body protection.
WARNING
Spanish
G No toque las partes o los electrodos G Mantenga el material combustible
G Protéjase los ojos, los oídos y el
bajo carga con la piel o ropa moja-
da.
G Aislese del trabajo y de la tierra.
fuera del área de trabajo.
cuerpo.
AVISO DE
PRECAUCION
French
G Ne laissez ni la peau ni des vête-
ments mouillés entrer en contact
avec des pièces sous tension.
G Gardez à l’écart de tout matériel
inflammable.
G Protégez vos yeux, vos oreilles et
votre corps.
ATTENTION
G Isolez-vous du travail et de la terre.
German
G Berühren Sie keine stromführenden
Teile oder Elektroden mit Ihrem
Körper oder feuchter Kleidung!
G Isolieren Sie sich von den
G Entfernen Sie brennbarres Material! G Tragen Sie Augen-, Ohren- und Kör-
perschutz!
WARNUNG
Elektroden und dem Erdboden!
Portuguese
G Não toque partes elétricas e elec-
trodos com a pele ou roupa molha-
da.
G Mantenha inflamáveis bem guarda- G Use proteção para a vista, ouvido e
dos.
corpo.
ATENÇÃO
G Isole-se da peça e terra.
Japanese
Chinese
Korean
Arabic
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 UNFALLVERHÜTUNGSVORSCHRIFTEN DES ARBEITGEBERS SIND EBENFALLS ZU BEACHTEN.
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G Keep your head out of fumes.
G Use ventilation or exhaust to
remove fumes from breathing zone.
G Turn power off before servicing.
G Do not operate with panel open or
guards off.
WARNING
Spanish
G Los humos fuera de la zona de res-
piración.
G Mantenga la cabeza fuera de los
humos. Utilice ventilación o
aspiración para gases.
G Desconectar el cable de ali-
mentación de poder de la máquina
antes de iniciar cualquier servicio.
G No operar con panel abierto o
guardas quitadas.
AVISO DE
PRECAUCION
French
G Débranchez le courant avant l’entre- G N’opérez pas avec les panneaux
tien.
G Gardez la tête à l’écart des fumées.
G Utilisez un ventilateur ou un aspira-
teur pour ôter les fumées des zones
de travail.
ouverts ou avec les dispositifs de
protection enlevés.
ATTENTION
German
G Strom vor Wartungsarbeiten
abschalten! (Netzstrom völlig öff-
nen; Maschine anhalten!)
G Anlage nie ohne Schutzgehäuse
oder Innenschutzverkleidung in
Betrieb setzen!
G Vermeiden Sie das Einatmen von
Schweibrauch!
G Sorgen Sie für gute Be- und
Entlüftung des Arbeitsplatzes!
WARNUNG
Portuguese
G Não opere com as tampas removidas.
G Desligue a corrente antes de fazer
serviço.
G Mantenha-se afastado das partes
moventes.
G Não opere com os paineis abertos
ou guardas removidas.
G Mantenha seu rosto da fumaça.
G Use ventilação e exhaustão para
remover fumo da zona respiratória.
ATENÇÃO
G Não toque as partes elétricas nuas.
Japanese
Chinese
Korean
Arabic
LEIA E COMPREENDA AS INSTRUÇÕES DO FABRICANTE PARA ESTE EQUIPAMENTO E AS PARTES DE USO, E SIGA AS
PRÁTICAS DE SEGURANÇA DO EMPREGADOR.
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• World's Leader in Welding and Cutting Products •
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Cleveland, Ohio 44117-1199 U.S.A. TEL: 216.481.8100 FAX: 216.486.1751 WEB SITE: www.lincolnelectric.com
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