im10347 vantage 500-i
TRANSCRIPT
Operator’s Manual
VANTAGE ® 500-I
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IM10347-A | Issue D ate Nov-18
© Lincoln Global, Inc. All Rights Reserved.
For use with machines having Code Numbers:
12597, 12559
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Date Purchased
Code: (ex: 10859)
Serial: (ex: U1060512345)
THANK YOU FOR SELECTING A QUALITY PRODUCT BY LINCOLN ELEC TRIC.
PLEASE EXAMINE CARTON AND EQUIPMENT FORDAMAGE IMMEDIATELY
When this equipment is shipped, title passes to the purchaserupon receipt by the carrier. Consequently, claims for materialdamaged in shipment must be made by the purchaser against thetransportation company at the time the shipment is received.
SAFETY DEPENDS ON YOU
Lincoln arc welding and cutting equipment is designed and builtwith safety in mind. However, your overall safety can be increasedby proper installation ... and thoughtful operation on your part. DO NOT INSTALL, OPERATE OR REPAIR THIS EQUIPMENT WITHOUT READING THIS MANUAL AND THE SAFETYPRECAUTIONS CONTAINED THROUGHOUT. And, most importantly,think before you act and be careful.
This statement appears where the information must be followedexactly to avoid serious personal injury or loss of life.
This statement appears where the information must be followedto avoid minor personal injury or damage to this equipment.
KEEP YOUR HEAD OUT OF THE FUMES.
DON’T get too close to the arc.Use corrective lenses if necessaryto stay a reasonable distanceaway from the arc.
READ and obey the Safety DataSheet (SDS) and the warning labelthat appears on all containers ofwelding materials.
USE ENOUGH VENTILATION orexhaust at the arc, or both, tokeep the fumes and gases from your breathing zone and the general area.
IN A LARGE ROOM OR OUTDOORS, natural ventilation may beadequate if you keep your head out of the fumes (See below).
USE NATURAL DRAFTS or fans to keep the fumes away from your face.
If you de velop unusual symptoms, see your supervisor. Perhaps the welding atmosphere and ventilation system should be checked.
WEAR CORRECT EYE, EAR & BODY PROTECTION
PROTECT your eyes and face with welding helmetproperly fitted and with proper grade of filter plate(See ANSI Z49.1).
PROTECT your body from welding spatter and arcflash with protective clothing including woolenclothing, flame-proof apron and gloves, leatherleggings, and high boots.
PROTECT others from splatter, flash, and glarewith protective screens or barriers.
IN SOME AREAS, protection from noise may be appropriate.
BE SURE protective equipment is in good condition.
Also, wear safety glasses in work areaAT ALL TIMES.
SPECIAL SITUATIONS
DO NOT WELD OR CUT containers or materials which previouslyhad been in contact with hazardous substances unless they areproperly cleaned. This is extremely dangerous.
DO NOT WELD OR CUT painted or plated parts unless specialprecautions with ventilation have been taken. They can releasehighly toxic fumes or gases.
Additional precautionary measures
PROTECT compressed gas cylinders from excessive heat,mechanical shocks, and arcs; fasten cylinders so they cannot fall.
BE SURE cylinders are never grounded or part of an electrical circuit.
REMOVE all potential fire hazards from welding area.
ALWAYS HAVE FIRE FIGHTING EQUIPMENT READY FORIMMEDIATE USE AND KNOW HOW TO USE IT.
WARNING
CAUTION
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SECTION A:WARNINGS
CALIFORNIA PROPOSITION 65 WARNINGS
WARNING: Breathing diesel engine exhaustexposes you to chemicals known to the Stateof California to cause cancer and birth defects,
or other reproductive harm.• Always start and operate the engine in a
well-ventilated area.• If in an exposed area, vent the exhaust to the outside.• Do not modify or tamper with the exhaust system. • Do not idle the engine except as necessary.For more information go to www.P65 warnings.ca.gov/diesel
WARNING: This product, when used for welding or
cutting, produces fumes or gases which contain
chemicals known to the State of California to cause
birth defects and, in some cases, cancer. (California
Health & Safety Code § 25249.5 et seq.)
WARNING: Cancer and Reproductive Harm
www.P65warnings.ca.gov
ARC WELDING CAN BE HAZARDOUS. PROTECTYOURSELF AND OTHERS FROM POSSIBLE SERIOUSINJURY OR DEATH. KEEP CHILDREN AWAY. PACEMAKER WEARERS SHOULD CONSULT WITHTHEIR DOCTOR BEFORE OPERATING.
Read and understand the following safety highlights. Foradditional safety information, it is strongly recommended that you purchase a copy of “Safety in Welding & Cutting - ANSI Standard Z49.1” from the American Welding Society, P.O. Box 351040, Miami, Florida 33135 or CSA Standard W117.2-1974. A Free copy of “Arc Welding Safety” booklet E205 is available from the Lincoln Electric Company, 22801 St. Clair Avenue, Cleveland, Ohio 44117-1199.
BE SURE THAT ALL INSTALLATION, OPERATION,MAINTENANCE AND REPAIR PROCEDURES AREPERFORMED ONLY BY QUALIFIED INDIVIDUALS.
FOR ENGINE POWEREDEQUIPMENT.
1.a. Turn the engine off before troubleshootingand maintenance work unless themaintenance work requires it to be running.
1.b. Operate engines in open, well-ventilated areas or vent the engineexhaust fumes outdoors.
1.c. Do not add the fuel near an open flame weldingarc or when the engine is running. Stop theengine and allow it to cool before refueling toprevent spilled fuel from vaporizing on contact
with hot engine parts and igniting. Do not spill fuel when fillingtank. If fuel is spilled, wipe it up and do not start engine untilfumes have been eliminated.
1.d. Keep all equipment safety guards, covers and devices in position and in good repair.Keep hands, hair, clothing and tools away from V-belts, gears, fans and all other moving parts when starting, operating orrepairing equipment.
1.e. In some cases it may be necessary to remove safety guards toperform required maintenance. Remove guards only whennecessary and replace them when the maintenance requiringtheir removal is complete. Always use the greatest care whenworking near moving parts.
1.f. Do not put your hands near the engine fan. Do not attempt tooverride the governor or idler by pushing on the throttle controlrods while the engine is running.
1.g. To prevent accidentally starting gasoline engines while turningthe engine or welding generator during maintenance work,disconnect the spark plug wires, distributor cap or magneto wireas appropriate.
1.h. To avoid scalding, do not remove the radiatorpressure cap when the engine is hot.
ELECTRIC ANDMAGNETIC FIELDS MAYBE DANGEROUS
2.a. Electric current flowing through any conductorcauses localized Electric and Magnetic Fields (EMF). Welding current creates EMF fields around welding cables and welding machines
2.b. EMF fields may interfere with some pacemakers, and welders having a pacemaker should consult their physicianbefore welding.
2.c. Exposure to EMF fields in welding may have other health effectswhich are now not known.
2.d. All welders should use the following procedures in order tominimize exposure to EMF fields from the welding circuit:
2.d.1. Route the electrode and work cables together - Securethem with tape when possible.
2.d.2. Never coil the electrode lead around your body.
2.d.3. Do not place your body between the electrode and workcables. If the electrode cable is on your right side, thework cable should also be on your right side.
2.d.4. Connect the work cable to the workpiece as close as pos-sible to the area being welded.
2.d.5. Do not work next to welding power source.
SAFETY
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ELECTRIC SHOCK CAN KILL.
3.a. The electrode and work (or ground) circuits areelectrically “hot” when the welder is on. Donot touch these “hot” parts with your bare skin or wet clothing.Wear dry, hole-free gloves to insulate hands.
3.b. Insulate yourself from work and ground using dry insulation.Make certain the insulation is large enough to cover your full areaof physical contact with work and ground.
In addition to the normal safety precautions, if
welding must be performed under electrically
hazardous conditions (in damp locations or while
wearing wet clothing; on metal structures such as
floors, gratings or scaffolds; when in cramped
positions such as sitting, kneeling or lying, if there
is a high risk of unavoidable or accidental contact
with the workpiece or ground) use the following
equipment:
• Semiautomatic DC Constant Voltage (Wire) Welder.
• DC Manual (Stick) Welder.
• AC Welder with Reduced Voltage Control.
3.c. In semiautomatic or automatic wire welding, the electrode,electrode reel, welding head, nozzle or semiautomatic weldinggun are also electrically “hot”.
3.d. Always be sure the work cable makes a good electricalconnection with the metal being welded. The connection shouldbe 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 andwelding machine in good, safe operating condition. Replacedamaged insulation.
3.g. Never dip the electrode in water for cooling.
3.h. Never simultaneously touch electrically “hot” parts of electrodeholders connected to two welders because voltage between thetwo can be the total of the open circuit voltage of bothwelders.
3.i. When working above floor level, use a safety belt to protectyourself from a fall should you get a shock.
3.j. Also see It ems 6.c. and 8.
ARC RAYS CAN BURN.
4.a. Use a shield with the proper filter and cover plates to protect youreyes from sparks and the rays of the arc when welding orobserving open arc welding. Headshield and filter lens shouldconform to ANSI Z87. I standards.
4.b. Use suitable clothing made from durable flame-resistant materialto protect your skin and that of your helpers from the arc rays.
4.c. Protect other nearby personnel with suitable, non-flammablescreening and/or warn them not to watch the arc nor exposethemselves to the arc rays or to hot spatter or metal.
FUMES AND GASESCAN BE DANGEROUS.
5.a. Welding may produce fumes and gaseshazardous to health. Avoid breathing thesefumes and gases. When welding, keep your head out of the fume.Use enough ventilation and/or exhaust at the arc to keep fumesand gases away from the breathing zone. When welding
hardfacing (see instructions on container or SDS)
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
unless exposure assessments indicate otherwise.
In confined spaces or in some circumstances,
outdoors, a respirator may also be required.
Additional precautions are also required when
welding
on galvanized steel.
5. b. The operation of welding fume control equipment is affected byvarious factors including proper use and positioning of theequipment, maintenance of the equipment and the specificwelding procedure and application involved. Worker exposurelevel should be checked upon installation and periodicallythereafter to be certain it is within applicable OSHA PEL andACGIH TLV limits.
5.c. Do not weld in locations near chlorinated hydrocarbon vaporscoming from degreasing, cleaning or spraying operations. Theheat and rays of the arc can react with solvent vapors to formphosgene, a highly toxic gas, and other irritating products.
5.d. Shielding gases used for arc welding can displace air and causeinjury or death. Always use enough ventilation, especially inconfined areas, to insure breathing air is safe.
5.e. Read and understand the manufacturer’s instructions for thisequipment and the consumables to be used, including theSafety Data Sheet (SDS) and follow your employer’s safetypractices. SDS forms are available from your weldingdistributor or from the manufacturer.
5.f. Also see item 1.b.
SAFETY
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WELDING AND CUTTINGSPARKS CAN CAUSEFIRE OR EXPLOSION.
6.a. Remove fire hazards from the welding area. Ifthis is not possible, cover them to prevent the welding sparksfrom starting a fire. Remember that welding sparks and hotmaterials from welding can easily go through small cracks andopenings to adjacent areas. Avoid welding near hydraulic lines.Have a fire extinguisher readily available.
6.b. Where compressed gases are to be used at the job site, specialprecautions 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.
6.c. When not welding, make certain no part of the electrode circuit istouching the work or ground. Accidental contact can causeoverheating and create a fire hazard.
6.d. Do not heat, cut or weld tanks, drums or containers until theproper 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 SafePractices for the Preparation for Welding and Cutting ofContainers and Piping That Have Held Hazardous Substances”,AWS F4.1 from the American Welding Society (see address above).
6.e. Vent hollow castings or containers before heating, cutting orwelding. They may explode.
6.f. Sparks and spatter are thrown from the welding arc. Wear oil freeprotective garments such as leather gloves, heavy shirt, cufflesstrousers, high shoes and a cap over your hair. Wear ear plugswhen welding out of position or in confined places. Always wearsafety glasses with side shields when in a welding area.
6.g. Connect the work cable to the work as close to the welding areaas practical. Work cables connected to the building framework orother locations away from the welding area increase thepossibility of the welding current passing through lifting chains,crane cables or other alternate circuits. This can create firehazards or overheat lifting chains or cables until they fail.
6.h. Also see item 1.c.
6.I. Read and follow NFPA 51B “Standard for Fire Prevention DuringWelding, Cutting and Other Hot Work”, available from NFPA, 1Batterymarch Park, PO box 9101, Quincy, MA 022690-9101.
6.j. Do not use a welding power source for pipe thawing.
CYLINDER MAY EXPLODE IFDAMAGED.
7.a. Use only compressed gas cylinders containingthe correct shielding gas for the process usedand properly operating regulators designed forthe gas and pressure used. All hoses, fittings,etc. should be suitable for the application andmaintained in good condition.
7.b. Always keep cylinders in an upright position securely chained toan undercarriage or fixed support.
7.c. Cylinders should be located:
• Away from areas where they may be struck or subjectedto physical damage.
• A safe distance from arc welding or cutting operationsand any other source of heat, sparks, or flame.
7.d. Never allow the electrode, electrode holder or any otherelectrically “hot” parts to touch a cylinder.
7.e. Keep your head and face away from the cylinder valve outletwhen opening the cylinder valve.
7.f. Valve protection caps should always be in place and hand tightexcept 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 forSafe Handling of Compressed Gases in Cylinders,” available fromthe Compressed Gas Association, 14501 George Carter WayChantilly, VA 20151.
FOR ELECTRICALLYPOWERED EQUIPMENT.
8.a. Turn off input power using the disconnectswitch at the fuse box before working on the equipment.
8.b. Install equipment in accordance with the U.S. National ElectricalCode, all local codes and the manufacturer’s recommendations.
8.c. Ground the equipment in accordance with the U.S. NationalElectrical Code and the manufacturer’s recommendations.
Refer to
http://www.lincolnelectric.com/safety
for additional safety information.
SAFETY
Safety 04 of 04 - 5/16/2018
vi vi TABLE OF CONTENTS Page
Installation.......................................................................................................................Section A Technical Specifications.......................................................................................................A-1
Safety Precautions........................................................................................................ A-2 Location and Ventilation................................................................................................A-2 Stacking........................................................................................................................ A-2 Angle of Operation........................................................................................................ A-2
Lifting.............................................................................................................................A-2 High Altitude Operation................................................................................................. A-3 Welder Output Ratings at Temperatires above 40Cº....................................................A-3
Cold Weather Starting...................................................................................................A-3 Towing...........................................................................................................................A-3 Vehicle Mounting...........................................................................................................A-3 Pre-Operation Engine Service..............................................................................................A-3 Oil..................................................................................................................................A-4 Fuel............................................................................................................................... A-4 Engine Coolant..............................................................................................................A-4 Battery Connections......................................................................................................A-4 Muffler Outlet Pipe........................................................................................................ A-4 Spark Arrester............................................................................................................... A-4
Remote Control............................................................................................................. A-4 Electrical Connections..........................................................................................................A-5 Machine Grounding.......................................................................................................A-5 Welding Terminals........................................................................................................ A-5
Welding Output Cables................................................................................................. A-5Cable Installation...........................................................................................................A-5
Auxiliary Power Receptacles and Plugs...............................................................................A-6 Residual Current Device Ready........................................................................................... A-6 Standby Power Connections................................................................................................ A-6
Connection of Lincoln Electric Wire Feeders....................................................................... A-7________________________________________________________________________________
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-3,B-4 Fuel Consumption......................................................................................................... B-3 Starting and Stopping the Engine................................................................................. B-5 Welding Operation................................................................................................................B-5 Duty Cycle and Electrode Information...........................................................................B-5 Constant Current (Stick) Welding..................................................................................B-5 Downhill Pipe (Stick) Welding....................................................................................... B-6 Wire Welding-CV...........................................................................................................B-6 Arc Gouging.................................................................................................................. B-6 Tig Welding................................................................................................................... B-7 Typical Current Ranges for Tungsten Electrodes......................................................... B-7 Auxiliary Power.....................................................................................................................B-8 Simultaneous Welding and Power Loads..................................................................... B-8 Extension Cord Recommendations...............................................................................B-8________________________________________________________________________________
Accessories.....................................................................................................Section C Field Installed Options / Accessories ...............................................................................C-1________________________________________________________________________________
vii viiTABLE OF CONTENTSMaintenance......................................................................................................Section D
Safety Precautions................................................................................................ D-1Routine 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-5Battery 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 GFCI Testing and Resetting Procedure..........................................................D-6________________________________________________________________________ Troubleshooting.............................................................................................. Section E How to Use Troubleshooting Guide.......................................................................E-1 Troubleshooting Guide............................................................................ E-2 thru E-6________________________________________________________________________ Diagrams.......................................................................................................... Section F Instructions for Installing a Residual Current Device......................................F-1, F-2 Connection Diagram with Optional Remote Control.............................................. F-3 Wiring Diagrams.............................................................................................F-4, F-5 Dimension Print......................................................................................................F-6________________________________________________________________________ Parts List...................................................................................................P-608 SERIES________________________________________________________________________
VANTAGE® 500-I
(1) Output rating in watts is equivalent to volt-amperes at unity power factor. Output voltage is within ± 10% at all loads up torated capacity. When welding, available auxiliary power will be reduced.
* To Top of enclosure, add 10.28”(261.1mm) to top of exhaust pipe. Add 3.43”(87.1mm) to top of Lift Bail. For K3385-2 add5.01” (127.254mm) to top for spark arrestor.
(2) Maximum per circuit breaker rating.
A-1INSTALLATIONA-1TECHNICAL SPECIFICATIONS - VANTAGE® 500-I (K3385-1, K3385-2)
Make/Model Description Speed (RPM) Displacement Starting CapacitiesPERKINS cu. in. (ltrs.) System
4 cylinder 135.6(2.2) 12VDC Battery & Fuel: 20 gal.
K3385-1, 32.7 HP High Idle 1880 starter (75.7 L)K3385-2 1800 RPM Bore x Stroke inch (mm) (Group 34; 650 Oil: 8.45Qts. (8L)404D-22 naturally aspirated Full Load 1800 cold crank amps)
water cooled 3.43 X 3.64 65 Amp Alternator Radiator Coolant:Diesel Engine Low Idle 1400 (87.1 x 92.5mm) W/Built in Regulator 8.0 Qts. (7.6L)
INPUT - DIESEL ENGINE
RATED OUTPUT @ 104° F (40° C) - WELDER
HEIGHT WIDTH DEPTH WEIGHT35.94* in. 25.30 in 60.00 in. 913 mm 643 mm 1524 mm
LUBRICATION EMISSIONS FUEL SYSTEM GOVERNORFull Pressure EPA Tier 4 Mechanical Fuel Pump, Auto air bleed Mechanicalwith Full Flow Filter Interim Compliant system, Electric shutoff solenoid, Indirect fuel injector.
AIR CLEANER ENGINE IDLER MUFFLER ENGINE PROTECTIONLow noise Muffler: Shutdown on low oil
Single Element Automatic Idler Top outlet can be rotated. pressure & high engineMade from long life, aluminized steel. coolant temperature
K3385-2 uses a spark arrestorENGINE WARRANTY: 2 years / 2000 hours, all non-electric components, 3 years major non-electric compo-nents . See Perkins warranty for details.
Welding Process
DC Constant Current
DC Pipe CurrentTouch-Start™TIG
DC Constant Voltage
Arc Gouging
Output Range
30 TO 500 AMPS
40 TO 300 AMPS20 TO 250 AMPS
14 TO 36 VOLTS
90 to 450 Amps
Max. Weld OCV@Rated Load RPM
60 Volts
Welding OutputCurrent/Voltage/Duty Cycle
400A / 36V / 100%450A / 34V / 60%500A / 30V /40%
300A / 32V / 100%250A / 30V / 100%400A / 36V / 100%450A / 34V / 60%500A / 30V / 40%
400A / 36V / 100%
Auxiliary Power (1)
19,000 Watts Peak, / 16,400 Watts Continuous, 60 Hz, 380 Volts 3-Phase3,300 Watts Peak(2), / 3,300 Watts Continuous, 60 Hz, 220 Volts 1-Phase3,300 Watts Peak(2), / 3,300 Watts Continuous, 60 Hz, 220 Volts 1-Phase
PHYSICAL DIMENSIONS
ENGINE
RECEPTACLES AUXILIARY POWER CIRCUIT BREAKER OTHER CIRCUIT BREAKERS
2 - 240VAC European (IEC 309) 2 - 15 amp (2 -pole) for 240VAC European (IEC 309)1 - 380VAC 3-Phase European (IEC) 1 - 25 amp (3-pole) for 380 VAC 3-Phase (European)Residual Current Device 4-Pole, 25 amp, (30mA TRIP current)(RCD for K3385-2 ONLY)
MACHINE SPECIFICATIONS
RATED OUTPUT @ 104° F (40° C).- GENERATOR
1230 lbs. (559kg.)
10AMP for Battery Charging Circuit
A-2INSTALLATION
VANTAGE® 500-I
A-2SAFETY PRECAUTIONS
Only qualified personnel should install, use, or service this equipment.
Do not attempt to use this equipment until youhave thoroughly read the engine manufacturer’smanual supplied with your welder. It includesimportant safety precautions, detailed enginestarting, 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.
------------------------------------------------------------------------MOVING PARTS can injure.• Do not operate with doors open or
guards off.• Stop engine before servicing.• Keep away from moving parts.
------------------------------------------------------------------------See additional warning information atfront of this operator’s manual.
WARNING
• Lift only with equipment of ade-quate lifting capacity.
• Be sure machine is stable when lift-ing.
• Do not lift this machine using liftbail if it is equipped with a heavyaccessory such as trailer or gascylinder.
FALLING • Do not lift machine if lift bail is EQUIPMENT can damaged.
cause injury. • Do not operate machine while suspended from lift bail.------------------------------------------------------------------------
LOCATION AND VENTILATIONThe welder should be located to provide an unrestrict-ed flow of clean, cool air to the cooling air inlets and toavoid restricting the cooling air outlets. Also, locatethe welder so that the engine exhaust fumes are prop-erly vented to an outside area.
STACKINGVANTAGE® 500-I machines cannot be stacked.
ANGLE OF OPERATIONEngines are designed to run in the level conditionwhich is where the optimum performance is achieved.The maximum angle of continuous operation is 25degrees in all directions, 35 degrees Intermittent (lessthan 10 minutes continuous) in all directions. If theengine is to be operated at an angle, provisions mustbe made for checking and maintaining the oil level atthe normal (FULL) oil capacity in the crankcase.
When operating the welder at an angle, the effectivefuel capacity will be slightly less than the amountspecified.
WARNING
LIFTINGThe VANTAGE® 500-I weighs approximately 1345lbs.(611kg.) with a full tank of fuel 1230lbs.(559kg) lessfuel. A lift bail is mounted to the machine and shouldalways be used when lifting the machine.
A-3INSTALLATION
VANTAGE® 500-I
A-3HIGH ALTITUDE OPERATIONAt higher altitudes, output derating may be necessary. For max-imum rating, derate the machine 2.5% to 3.5% for every 1000 ft.(305m). Due to new EPA and other local emissions regulations,modifications to the engine for high altitude are restricted withinthe United States. For use above 6000 ft.(1828 m) an autho-rized Perkins engine field service shop should be contacted todetermine if any adjustments can be made for operation in high-er elevations.HIGH TEMPERATURE OPERATIONTested for extreme temperature operation up to 55°C. Outputderated above 40°C.
Cold weather starting:With a fully charged battery and the proper oil, the engineshould start satisfactorily down to -15°F(-26°C). If the enginemust be frequently started at or below 0°F (-18°C), it may bedesirable to install cold-starting aides. The use of No. 1Ddiesel fuel is recommended in place of No. 2D at tempera-tures below 23°F (-5°C). Allow the engine to warm up beforeapplying a load or switching to high idle.
Note: Extreme cold weather starting may requirelonger glow plug operation.Under no conditions should ether or other startingfluids 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 anon-Lincoln trailer, he must assume responsibility that themethod of attachment and usage does not result in a safetyhazard or damage the welding equipment. Some of the factorsto be considered are as follows:
1. Design capacity of trailer vs. weight of Lincoln equipment andlikely additional attachments.
2. Proper support of, and attachment to, the base of the weldingequipment so there will be no undue stress to the framework.
3. Proper placement of the equipment on the trailer to insurestability side to side and front to back when being moved andwhen standing by itself while being operated or serviced.
4. Typical conditions of use, i.e., travel speed; roughness of sur-face on which the trailer will be operated; environmental con-ditions; like maintenance.
5. Conformance with federal, state and local laws.(1)(1) Consult applicable federal, state and local laws regarding specific requirements for use on public high-
ways.
NOTE: This machine is furnished with a wet charged bat-tery; if unused for several months, the battery may require abooster charge. Be careful to charge the battery with thecorrect polarity. (See Battery in “Maintenance Section”)
WARNING
VEHICLE MOUNTING
Improperly mounted concentrated loads maycause unstable vehicle handling and tires or othercomponents to fail.
• Only transport this Equipment on serviceablevehicles which are rated and designed for suchloads.
• Distribute, balance and secure loads so vehicleis 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 ofvehicle.
• Follow vehicle manufacturer’s instructions.------------------------------------------------------------------------
WARNING
PRE-OPERATION ENGINE SERVICEREAD the engine operating and maintenance instruc-tions supplied with this machine.
• 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.• Keep sparks and flame away from tank.------------------------------------------------------------------------
WARNING
A-4INSTALLATION
VANTAGE® 500-I
A-4Because this portable engine driven welder creates itsown power, it is not necessary to connect itsframe to an earth ground, unless the machineis connected to premises wiring (home, shop, etc.)
To prevent dangerous electric shock, other equipmentto which this engine driven welder supplies powermust:• Be grounded to the frame of the welder using a
grounded type plug or be double insulated.• Do not ground the machine to a pipe that carries
explosive or combustible material.
------------------------------------------------------------------------
When this welder is mounted on a truck or trailer, itsframe must be electrically bonded to the metal frameof the vehicle. Use a #8 or larger copper wire connect-ed between the machine grounding stud and theframe of the vehicle. When this engine driven welderis connected to premises wiring such as that in ahome or shop, its frame must be connected to thesystem earth ground. See further connection instruc-tions in the section entit led "Standby PowerConnections" as well as the article on grounding in thelatest National Electrical Code and the local code.
In general, if the machine is to be grounded, it shouldbe connected with a #8 or larger copper wire to a solidearth ground such as a metal water pipe going intothe ground for at least ten feet and having no insulat-ed joints, or to the metal framework of a buildingwhich has been effectively grounded.
The National Electrical Code lists a number of alter-nate means of grounding electrical equipment. Amachine grounding stud marked with the symbolis provided on the front of the welder.
WELDING TERMINALSThe VANTAGE® 500-I is equipped with a toggleswitch for selecting "hot" welding terminal when inthe "WELD TERMINALS ON" position or "cold" weld-ing terminal when in the "REMOTELY CON-TROLLED" position.
WARNING
WELDING OUTPUT CABLES With the engine off connect the electrode and workcables to the output studs. The welding process dic-tates the polarity of the electrode cable. These con-nections should be checked periodically and tightenedwith a 3/4" wrench.
Table A.1 lists recommended cable sizes and lengthsfor rated current and duty cycle. Length refers to thedistance from the welder to the work and back to thewelder. Cable diameters are increased for long cablelengths to reduce voltage drops.
TABLE A.1
CABLE INSTALLATIONInstall the welding cables to your VANTAGE® 500-I asfollows.
1. The engine must be OFF to install welding cables.2. Remove the flanged nuts from the output terminals3. Connect the electrode holder and work cables to
the weld output terminals. The terminals are identi-fied on the case front.
4. Tighten the flanged nuts securely.5. Be certain that the metal piece you are welding (the
“work”) is properly connected to the work clamp andcable.
6. Check and tighten the connections periodically.
• Loose connections will cause the output termi-nals to overheat. The terminals may eventuallymelt.
• Do not cross the welding cables at the output ter-minal connection. Keep the cables isolated andseparate from one another.
------------------------------------------------------------------------
TOTAL COMBINED LENGTH OFELECTRODE AND WORK CABLES
Cable Length
0-100 Ft. (0-30 meters)
100-150 Ft. (30-46 meters)
150-200 Ft. (46-61 meters)
Cable Size for 400 Amps
60% Duty Cycle2 / 0 AWG
2 / 0 AWG
3 / 0 AWG
CAUTION
A-5INSTALLATION
VANTAGE® 500-I
A-5AUXILIARY POWER RECEPTACLES
Start the engine and set the “IDLER” control switch tothe “High Idle” mode. Voltage is now correct at thereceptacles for auxiliary power. This must be donebefore a tripped GFCI can be reset properly. See theMAINTENANCE section for more detailed informationon testing and resetting the GFCI.
The auxiliary power of the VANTAGE® 500-I consistsof Single Phase and Three Phase 60Hz Power. Out putVoltage is within +/- 10% at loads up to rated capacity.
Single Phase:Two 220VAC (IEC 309) 15 amp receptacle is protectedby a 15 amp 2-pole circuit breaker that provides 3,300watts Peak / 3,300 watts Continuous power. The 2-polecircuit breaker disconnects both hot leads at the sametime. Maximum current is 15 amps.
Three-Phases:One 320VAC NEMA (15-50R) 50 amp receptacle isprotected by a 25 amp 3-pole circuit breaker that pro-vides 23,300 watts Peak / 16,500 watts Continuouspower. The 3-pole circuit breaker disconnects all 3Phases at the same time. Maximum current is 25amps.
RESIDUAL CURRENT DEVICE READY(K3385-1 only)
The Vantage 500-I is configured to allow for the addi-tion of a Residual Current Device (RCD) to protect the240V Single Phase Receptacle. The auxiliary powerarea on the front panel of the Vantage 500-I has ahole sized and shaped to accept a typical 2-pole(RCD). A coverplate with a label “RCD READY” cov-ers the hole and secures a mounting bracket on thebackside of the panel. See Section F Diagrams of thisOperator’s Manual for instructions on installing an(RCD).
Note: The (RCD) should be rated for 15 amps.
STANDBY POWER CONNECTIONS
The VANTAGE® 500-I is suitable for temporary,standby or emergency power using the engine manu-facturer’s recommended maintenance schedule.
Take necessary steps to assure load is limited to thecapacity of the VANTAGE® 500-I
• Only a licensed, certified, trained electricianshould install the machine to a premises or resi-dential electrical system. Be certain that:
• The installation complies with the NationalElectrical Code and all other applicable electricalcodes.
• The premises is isolated and no feedback intothe utility system can occur. Certain state andlocal laws require the premises to be isolatedbefore the generator is linked to the premises.Check your state and local requirements.
------------------------------------------------------------------------
WARNING
CONNECTION OF LINCOLN ELECTRICWIRE FEEDERS
Shut off welder before making any electrical con-nections.------------------------------------------------------------------------Connection of LN-15 Across The-Arc Model to theVANTAGE® 500-I
1. Shut the welder off.
2. For electrode Positive, connect the electrodecable to the "+" terminal of the welder and workcable 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-15to work using the spring clip at the end of the lead.This is a control lead to supply current to the wirefeeder motor; it does not carry welding current.
4. Set the MODE switch to the "CV-WIRE " position.
5. Set the "WELD TERMINALS" switch to "WELDTERMINALS ON".
6. Set the "ARC CONTROL" knob to "0" initially andadjust to suit.
7. Set the "IDLE" switch to the "AUTO" position.
8. When the gun trigger is closed, the current sens-ing circuit will cause the VANTAGE® 500-I engineto go to the high idle speed, the wire will begin tofeed and the welding process started. When weld-ing is stopped, the engine will revert to low idlespeed after approximately 12 seconds unlesswelding is resumed.
NOTE: LN-15 Control Cable Model will not work withthe Vantage 500-I.
Connection of the LN-25 PRO or LN-25 to the VAN-TAGE® 500-I
The LN-25 PRO or LN-25 with or without an internalcontactor may be used with the VANTAGE® 500-I.See the appropriate connection diagram in Section F.
NOTE: The LN-25 (K431) Remote Control Moduleand (K432) Remote Cable are not recommended foruse with the VANTAGE® 500-I.
A-6INSTALLATION
VANTAGE® 500-I
A-61. Shut the welder off.
2. For electrode Positive, connect the electrodecable from the Wire Feeder to the "+" terminal ofthe welder and work cable to the "-" terminal of thewelder. For electrode Negative, connect the elec-trode cable from the Wire Feeder to the "-" termi-nal of the welder and work cable to the "+" termi-nal of the welder.
3. Attach the single lead from the front of the WireFeeder to work using the spring clip at the end ofthe lead. This is a control lead to supply current tothe wire feeder motor; it does not carry weldingcurrent.
4. Set the MODE switch to the "CV-WIRE " position.
5. Set the "WELD TERMINALS" switch to "WELDTERMINALS ON"
6. Set the "ARC CONTROL" knob to "0" initially andadjust to suit.
7. Set the "IDLE" switch to the "AUTO" position.When not welding, the VANTAGE® 500-I enginewill be at the low idle speed. If you are using anLN-25 with an internal contactor, the electrode isnot energized until the gun trigger is closed.
8. When the gun trigger is closed, the current sens-ing circuit will cause the VANTAGE® 500-I engineto go to the high idle speed, the wire will begin tofeed and the welding process started. When weld-ing is stopped, the engine will revert to low idlespeed after approximately 12 seconds unlesswelding is resumed.
If you are using an LN-25 without an internal con-tactor, the electrode will be energized when theVANTAGE® 500-I is started.------------------------------------------------------------------------
WARNING
CAUTION
B-1OPERATION
VANTAGE® 500-I
B-1SAFETY PRECAUTIONS
Do not attempt to use this equipment until youhave thoroughly read the engine manufacturer’smanual supplied with your welder. It includesimportant safety precautions, detailed enginestarting, 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.
• Always operate the welder with the hinged doorclosed and the side panels in place.
• Read carefully the Safety Precautions pagebefore operating this machine. Always followthese and any other safety procedures includedin this manual and in the Engine InstructionManual.
------------------------------------------------------------------------
GENERAL DESCRIPTIONThe VANTAGE® 500-I is a diesel engine powered DCmulti-process welding power source and 120 / 240volt AC power generator. The engine drives a genera-tor that supplies three phase power for the DC weld-ing circuit, single phase and Three Phase power forthe AC auxiliary outlets. The DC welding control sys-tem uses state of the art Chopper Technology (CT™)for superior welding performance.
FOR AUXILIARY POWER:Start the engine and set the IDLER control switch tothe desired operating mode. Full power is availableregardless of the welding control settings providing nowelding current is being drawn.
ENGINE OPERATIONBefore 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 cleancloth. Reinsert the dipstick and check the level onthe dipstick.
• Add oil (if necessary) to bring the level up to the fullmark. Do not overfill. Close engine door.
• Check radiator for proper coolant level. (Fill if nec-essary).
• See Engine Owner’s Manual for specific oil andcoolant recommendations.
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 startingengine.
• Do not overfill tank, fuel expan-sion may cause overflow.
DIESEL FUEL ONLY------------------------------------------------------------------------• Remove the fuel tank cap.
• Fill the tank. DO NOT FILL THE TANK TO THEPOINT OF OVERFLOW.
• Replace the fuel cap and tighten securely.
• See Engine Owner’s Manual for specific fuel recom-mendations.
BREAK-IN PERIOD
The engine will use a small amount of oil during its“break-in” period. The break-in period is about 50 run-ning hours.
Check the oil every four hours during break-in.Change the oil after the first 50 hours of operation andevery 200 hours thereafter. Change the oil filter ateach oil change.
During break-in, subject the Welder to moderate
loads. Avoid long periods running at idle. Beforestopping the engine, remove all loads and allowthe engine to cool several minutes.------------------------------------------------------------------------
WARNINGWARNING
CAUTION
DIESEL FUELcan cause fire.
1
2
3
4
10
9
16
13
14
5
7
12
11
6
15
8
B-2OPERATIONB-2
WELDING CONTROLS (Figure B.1)
1. OUTPUT CONTROL- The OUTPUT dial is used topreset the output voltage or current as displayed on thedigital meters for the five welding modes. When in theARC GOUGING or CV-WIRE modes and when a remotecontrol is connected to the 6-Pin or 14-Pin Connector, theauto-sensing circuit automatically switches the OUTPUTCONTROL from control at the welder to the remote con-trol. When in the CC-STICK or DOWNHILL PIPE modeand when a remote control is connected to the 6-Pin or14-Pin connector, the output control is used to set themaximum current range of the remote.
EXAMPLE: When the OUTPUT CONTROL on the welderis set to 200 amps the current range on the remote controlwill be Min-200 amps, rather than the full Min-Max amps.Any current range that is less than the full range providesfiner current resolution for more fine tuning of the output.
In the CV-WIRE mode, if the feeder being used has a volt-age control when the wire feeder control cable is connect-ed to the 14-Pin Connector, the auto-sensing circuit auto-matically makes OUTPUT CONTROL inactive and thewire feeder voltage control active. Otherwise, the OUT-PUT CONTROL is used to preset the voltage.
When in the TOUCH START TIG mode and when anAmptrol is connected to the 6-Pin Connector, the OUT-PUT dial is used to set the maximum current range of theCURRENT CONTROL of the Amptrol.
2. DIGITAL OUTPUT METERS-The digital metersallow the output voltage (CV-WIRE mode) or current(CC-STICK, DOWN HILL PIPE and TIG modes) to be setprior to welding using the OUTPUT control dial. Duringwelding, the meter display the actual output voltage(VOLTS) and current (AMPS). A memory feature holdsthe display of both meters on for seven seconds afterwelding is stopped. This allows the operator to read theactual current and voltage just prior to when welding wasceased.
While the display is being held the left-most decimalpoint in each display will be flashing. The accuracy of themeters is +/- 3%.
3. WELD MODE SELECTOR SWITCH-(Provides Five selectable welding modes)CV-WIREARC GOUGINGDOWNHILL PIPECC-STICKTOUCH START TIG
FIGURE B.1
VANTAGE® 500-I
ENGINE CONTROLS: 9. RUN/STOP SWITCH - RUN position energizes the
engine prior to starting. STOP position stops the engine.The oil pressure interlock switch prevents battery drain ifthe switch is left in the RUN position and the engine isnot operating.
10. GLOW PLUG PUSH BUTTON -• When pushed activates the glow plugs. Glow plug
should not be activated for more than 20 seconds con-tinuously.
11. START PUSH BUTTON - Energizes the startermotor to crank the engine.
12. 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 follows:• When switched from HIGH to AUTO or after starting
the engine, the engine will operate at full speed forapproximately 12 seconds and then go to low idlespeed.
• When the electrode touches the work or power isdrawn for lights or tools (approximately 100 Watts mini-mum), the engine accelerates and operates at fullspeed.
• When welding ceases or the AC power load is turnedoff, a fixed time delay of approximately 12 secondsstarts. If the welding or AC power load is not restartedbefore the end of the time delay, the idler reduces theengine speed to low idle speed.
• The engine will automatically return to high idle speedwhen there is welding load or AC power load reapplied.
13. Dashboard Gauge- The dash board gauge displays 5 gauges:
3a. OIL PRESSURE - The gauge displays the engine oilpressure when the engine is running.
3b. ENGINE TEMPERATURE - The gauge displays the enginecoolant temperature.
3c. HOUR METER - The hour meter displays the total time thatthe engine has been running. This meter is a useful indicatorfor scheduling preventive maintenance.
3d. FUEL LEVEL Displays the level of diesel fuel in the fueltank.
The operator must watch the fuel level closely to preventrunning out of fuel and possibly having to bleed thesystem.
3e. BATTERY VOLTAGE INDICATOR - Displays the batteryvoltage and indicates that the charging system isfunctioning properly
B-3OPERATIONB-34. ARC CONTROL- The ARC CONTROL dial is active
in the CV-WIRE, CC-STICK and DOWNHILL PIPEmodes, and has different functions in these modes. Thiscontrol is not active in the TIG mode and ARCGOUGING mode.
CC-STICK mode: In this mode, the ARC CONTROL dialsets the short circuit current (arc-force) during stick weld-ing to adjust for a soft or crisp arc. Increasing the dialfrom –10 (soft) to +10 (crisp) increases the short circuitcurrent and prevents sticking of the electrode to the platewhile welding. This can also increase spatter. It is recom-mended that the ARC CONTROL be set to the minimumnumber without electrode sticking. Start with a setting at0.
DOWNHILL PIPE mode: In this mode, the ARC CON-TROL dial sets the short circuit current (arc-force) duringstick welding to adjust for a soft or a more forceful diggingarc (crisp). Increasing the number from –10 (soft) to +10(crisp) increases the short circuit current which results in amore forceful digging arc. Typically a forceful digging arcis preferred for root and hot passes. A softer arc is pre-ferred for fill and cap passes where weld puddle controland deposition ("stacking" of iron) are key to fast travelspeeds. It is recommended that the ARC CONTROL beset initially at 0.
CV-WIRE mode: In this mode, turning the ARC CON-TROL clock wise from –10 (soft) to +10 (crisp) changesthe arc from soft and washed-in to crisp and narrow. Itacts as an inductance/pinch control. The proper settingdepends on the procedure and operator preference. Startwith a setting of 0.
5. WELD OUTPUT TERMINALS WITH FLANGENUT- Provides a connection point for the electrode andwork cables.
6. GROUND STUD- Provides a connection point forconnecting the machine case to earth ground.
7. 6-PIN CONNECTOR- For attaching optional remotecontrol equipment. Includes auto-sensing remote controlcircuit.
8. WELD TERMINALS CONTROL SWITCH- In theWELD TERMINALS ON position, the output is electricallyhot all the time. In the REMOTELY CONTROLLED posi-tion, the output is controlled by a wire feeder or amptroldevice, and is electrically off until a remote switch isdepressed.
VANTAGE® 500-I
B-4OPERATIONB-4
14. ENGINE STOP SWITCH- Shuts down engine.
15. VRD (voltage reduction device) INDICATORLIGHTS- On the front panel of the Vantage 500-I are twoindicator lights. A red light when lit indicates OCV(OpenCircuit Voltage) is equal to or greater than 30V and a greenlight when lit indicates OCV(Open Circuit Voltage) is lessthan 30V.
The VRD “On/Off” switch inside the control panel must be“On” for the VRD function to be active and the lights to beenabled. When the machine is first started with VRDenabled, both lights will illuminate for 5 seconds.
These lights monitor the OCV(Open Circuit Voltage) andweld voltage at all times. In the CC-Stick mode when notwelding the green light will illuminate indicating that the VRDhas reduced the OCV to less than 30V. During welding thered light will illuminate whenever the arc voltage is equal toor greater than 30V. This means that the red and green lightmay alternate depending on the weld voltage. This is normaloperation.
If the red light remains illuminated when not welding in theCCstick mode, the VRD is not functioning properly. Pleaserefer to your local field service shop for service. If the VRDis turned “On” and the lights don’t come “On”, refer to thetrouble shooting section.
VANTAGE® 500-I
TABLE B.1VRD INDICATOR LIGHTS
MODE VRD "ON" VRD "OFF" CC-STICK OCV Green (OCV Reduced)
While Red or GreenWelding (Depends on Weld Voltage) *
CV-WIRE OCV Red (OCV Not Reduced)Weld Terminals OnRed (OCV Not Reduced)Weld Terminals Remotely ControlledGun Trigger ClosedGreen (No OCV)Weld Terminals Remotely ControlledGun Trigger Open No Lights
While Red or GreenWelding (Depends on Weld Voltage) *
PIPE OCV Green (No Output)While Not Applicable (No Output)Welding
ARC GOUGING OCV Green (No Output)While Not Applicable (No Output)Welding
TIG OCV Green (Process is Low Voltage)While Green (Process is Low Voltage)Welding
* It is normal for the lights to alternate between colors while welding.
16. CIRCUIT BREAKER- For protection ofBattery Charging Circuit.
TYPICAL VANTAGE® 500-I FUEL CONSUMPTIONTABLE B.1
PERKINS 404D-22Gal./Hr (Liters/Hr)
.26 (.97)
.42 (1.57)
1.18 (4.46)1.24 (4.68)
Running Time for20 gallons / hours
76.92
47.6216.9516.13
Low Idle - No Load1400 R.P.M.High Idle - No Load1880 R.P.M.DC Weld Output400 Amps @ 36 Volts 17,000 Watts 3 Phase
NOTE: This data is for reference only. Fuel consump-tion is approximate and can be influenced by manyfactors, including engine maintenance, environmentalconditions and fuel quality.
B-5OPERATIONB-5
STOPPING THE ENGINERemove all welding and auxiliary power loads andallow the engine to run at low idle speed for a fewminutes to cool the engine.
STOP the engine by placing the RUN-STOP switch inthe STOP position.NOTE: A fuel shut off valve is located on the fuel pre-
filter.
VANTAGE® 500-I
STARTING THE ENGINE1. Remove all plugs connected to the AC power recepta-
cles.2. Set IDLER switch to AUTO.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 upto an additional 10 seconds.
6. Release the engine START button immediately when theengine starts.
7. The engine will run at high idle speed for approximately12 seconds and then drop to low idle speed. Allow theengine to warm up at low idle for several minutes beforeapplying a load and/or switching to high idle. Allow alonger warm up time in cold weather.
NOTE: If the unit fails to start turn Run/Stop switchto off and repeat step 3 through step 7 afterwaiting 30 seconds.
• Do not allow the starter motor to run continuouslyfor more than 20 seconds.
• Do not push the START button while the engineis running because this can damage the ringgear and/or the starter motor.
• IF the Engine Protection or Battery ChargingLights do “not” turn off shortly after starting theengine shut off the engine immediately anddetermine the cause.
------------------------------------------------------------------------NOTE: When starting for the first time, or after andextended period of time of not operating, it will takelonger than normal to start because the fuel pumphas to fill the fuel system. For best results, bleed thefuel system as indicated in Maintenance Section ofthis manual.
CAUTION
ARC GOUGINGThe VANTAGE® 500-I can be used for arc gouging.For optimal performance, set the MODE switch toARC GOUGING.
Set the OUTPUT CONTROL knob to adjust outputcurrent to the desired level for the gouging electrodebeing used according to the ratings in the followingTable B.2.
Carbon Diameter Current Range (DC, elec-trode positive)
1/8"(3.2mm) 60-90 Amps
5/32"(4.0mm) 90-150 Amps
3/16"9(4.8mm) 200-250 Amps
1/4"(6.4mm) 300-400 Amps
5/16"(8.0mm) 400-Max.Amps
TABLE B.2
The ARC CONTROL is not active in the ARC GOUG-ING Mode. The ARC CONTROL is automatically setto maximum when the ARC GOUGING mode isselected which provides the best ARC GOUGING per-formance.
B-6OPERATIONB-6
VANTAGE® 500-I
WELDER OPERATIONDUTY CYCLEDuty Cycle is the percentage of time the load is beingapplied in a 10 minute period. For example a 60% dutycycle, represents 6 minutes of load and 4 minutes of noload in a 10 minute period.ELECTRODE INFORMATIONFor any electrode the procedures should be keptwithin the rating of the machine. For information onelectrodes and their proper application see(www.lincolnelectric.com) or the appropriate Lincolnpublication.
The VANTAGE® 500-I can be used with a broadrange of DC stick electrodes. The MODE switch pro-vides two stick welding settings as follows:
CONSTANT CURRENT (CC-STICK) WELDING
The CC-STICK position of the MODE switch isdesigned for horizontal and vertical-up welding with alltypes of electrodes, especially low hydrogen. TheOUTPUT CONTROL dial adjusts the full output rangefor stick welding.The ARC CONTROL dial sets the short circuit cur-rent (arc-force) during stick welding to adjust for asoft or crisp arc. Increasing the number from -10(soft) to +10(crisp) increases the short circuit cur-rent and prevents sticking of the electrode to theplate while welding. This can also increase spatter.It is recommended that the ARC CONTROL be setto the minimum number without electrode sticking.Start with the dial set at 0.
DOWNHILL PIPE WELDING
This slope controlled setting is intended for "out-of-position" and "down hill" pipe welding where theoperator would like to control the current level bychanging the arc length. The OUTPUT CONTROL dial adjusts the full outputrange for pipe welding.
The ARC CONTROL dial sets the short circuit cur-rent (arc-force) during stick welding to adjust for asoft or more forceful digging arc (crisp). Increasingthe number from -10(soft) to +10(crisp) increasesthe short circuit current which results in a moreforceful digging arc.
Typically a forceful digging arc is preferred for rootand hot passes. A softer arc is preferred for fill andcap passes where weld puddle control and deposi-tion (“stacking” of iron) are key to fast travelspeeds. This can also increase spatter.
It is recommended that the ARC CONTROL be set tothe minimum number without electrode sticking. Startwith the dial set at 0.
WIRE WELDING-CVConnect a wire feeder to the VANTAGE® 500-Iaccording to the instructions in INSTALLATIONINSTRUCTIONS Section.
The VANTAGE® 500-I in the CV-WIRE mode, permitsit to be used with a broad range of flux cored wire(Innershield and Outershield) electrodes and solidwires for MIG welding (gas metal arc welding).Welding can be finely tuned using the ARC CON-TROL. Turning the ARC CONTROL clockwise from –10 (soft) to +10 (crisp) changes the arc from soft andwashed-in to crisp and narrow. It acts as an induc-tance/pinch control. The proper setting depends on theprocedure and operator preference. Start with the dialset at 0.
OIL The VANTAGE® 500-I is shipped with the enginecrankcase filled with high quality SAE 10W-30 Oil thatmeets classification CG-4 or CH-4 for diesel engines.Check the oil level before starting the engine. If it is notup to the full mark on the dip stick, add oil as required.Check the oil level every four hours of running time dur-ing the first 50 running hours. Refer to the engineOperator’s Manual for specific oil recommendations andbreak-in information. The oil change interval is depen-dent on the quality of the oil and the operating environ-ment. Refer to the Engine Operator’s Manual for moredetails on the proper service and maintenance intervals.
FUELUSE DIESEL FUEL ONLY
• Fill the fuel tank with clean, fresh fuel. Thecapacity of the tank is 20 gals. (75.7 ltrs). Whenthe fuel gauge reads empty the tank containsapproximately 2 gals. (7.6ltrs.) of reserve fuel.
NOTE: A fuel shut off valve is located on the pre-filter/sediment filter. Which should be inthe closed position when the welder is notused for extended periods of time.
------------------------------------------------------------------------ENGINE COOLING SYSTEM
Air to cool the engine is drawn in the side andexhausted through radiator & case back. It isimportant that the intake and exhaust air is notrestricted. Allow a minimum clearance of 1ft.(0.6m) from the case back and 16in.(406mm) fromeither side of the base to a vertical surface.------------------------------------------------------------------------BATTERY CONNECTION
Use caution as the electrolyte is a strong acid thatcan burn skin and damage eyes.------------------------------------------------------------------------
The VANTAGE® 500-I is shipped with the negativebattery cable disconnected. Make certain that theRUN-STOP switch is in the STOP position. Removethe two screws from the battery tray using a screw-driver or a 3/8" socket. Attach the negative batterycable to the negative battery terminal and tightenusing a 1/2" socket or wrench.
WARNING
B-7INSTALLATION
VANTAGE® 500-I
B-7
MUFFLER OUTLET PIPEUsing the clamp provided secure the outlet pipe to the outlettube with the pipe positioned such that it will direct theexhaust in the desired direction. Tighten using a 9/16" sock-et or wrench.
SPARK ARRESTERSome federal, state or local laws may require that gasolineor diesel engines be equipped with exhaust spark arresterswhen they are operated in certain locations where unarrest-ed sparks may present a fire hazard. The standard mufflerincluded with this welder does not qualify as a sparkarrester. When required by local regulations, a suitablespark arrester, such as the K903-1 must be installed andproperly maintained.An incorrect spark arrestor may lead to damage to theengine or adversely affect performance.------------------------------------------------------------------------REMOTE CONTROL
The VANTAGE® 500-I is equipped with a 6-pin connector.When in the ARC GOUGING or CV-WIRE modes and when aremote control is connected to the 6-pin Connector, the auto-sensing circuit automatically switches the OUTPUT control fromcontrol at the welder to remote control.When in TOUCH START TIG mode and when a Amptrol is con-nected to the 6-Pin Connector, the OUTPUT dial is used to setthe maximum current range of the CURRENT CONTROL of theAmptrol.When in the CC-STICK or DOWNHILL PIPE mode and when aremote control is connected to the 6-Pin connector, the outputcontrol is used to set the maximum current range of the remote.
EXAMPLE: When the OUTPUT CONTROL on the welder is setto 200 amps the current range on the remote control will beMin-200 amps, rather than the full Min-Max amps. Any currentrange that is less than the full range provides finer current reso-lution for more fine tuning of the output.
ELECTRICAL CONNECTIONS
MACHINE GROUNDING
CAUTION
WARNING
WARNING
TYPICAL CURRENT RANGES (1) FOR TUNGSTEN ELECTRODES(2)Tungsten Electrode DCEN (-) DCEP (+) Approximate Argon Gas Flow TIG TORCH Diameter in. (mm) Flow Rate C.F.H. ( l /min.) Nozzle Size (4), (5)
1%, 2% Thoriated 1%, 2% Thoriated Aluminum Stainless SteelTungsten Tungsten
.010 (.25) 2-15 (3) 3-8 (2-4) 3-8 (2-4) #4, #5, #60.020 (.50) 5-20 (3) 5-10 (3-5) 5-10 (3-5)0.040 (1.0) 15-80 (3) 5-10 (3-5) 5-10 (3-5)
1/16 (1.6) 70-150 10-20 5-10 (3-5) 9-13 (4-6) #5, #6
3/32 (2.4) 150-250 15-30 13-17 (6-8) 11-15 (5-7) #6, #7, #81/8 (3.2) 250-400 25-40 15-23 (7-11) 11-15 (5-7)
5/32 (4.0) 400-500 40-55 21-25 (10-12) 13-17 (6-8) #8, #103/16 (4.8) 500-750 55-80 23-27 (11-13) 18-22 (8-10)1/4 (6.4) 750-1000 80-125 28-32 (13-15) 23-27 (11-13)
(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 EWP1% Thoriated EWTh-12% Thoriated EWTh-2
Though not yet recognized by the AWS, Ceriated Tungsten is now widely accepted as a substitute for 2% Thoriated Tungsten in AC and DC applications.(3) DCEP is not commonly used in these sizes.(4) TIG torch nozzle "sizes" are in multiples of 1/16ths of an inch:
# 4 = 1/4 in. (6 mm)# 5 = 5/16 in. (8 mm)# 6 = 3/8 in. (10 mm)# 7 = 7/16 in. (11 mm)# 8 = _ in. (12.5 mm)#10 = 5/8 in. (16 mm)
(5) TIG torch nozzles are typically made from alumina ceramic. Special applications may require lava nozzles, which are less prone to breakage, but cannot withstand high temperaturesand high duty cycles.
B-8OPERATIONB-8
TABLE B.3
VANTAGE® 500-I
TIG WELDING
The TOUCH START TIG setting of the MODE switchis for DC TIG (Tungsten Inert Gas) welding. To initiatea weld, the OUTPUT CONTROL dial is first set to thedesired current and the tungsten is touched to thework. During the time the tungsten is touching thework there is very little voltage or current and, in gen-eral, no tungsten contamination. Then, the tungsten isgently lifted off the work in a rocking motion, whichestablishes the arc.
When in the TOUCH START TIG mode and when aAmptrol is connected to the 6-Pin connector the OUT-PUT CONTROL dial is used to set the maximum cur-rent range of the current control of the Amptrol.
The ARC CONTROL is not active in the TIG mode. ToSTOP a weld, simply pull the TIG torch away from thework. When the arc voltage reaches approximately 30 Voltsthe arc will go out and the machine will reset the cur-rent to the Touch Start level.
To reinitiate the arc, retouch the tungsten to the workand lift. Alternatively, the weld can be stopped byreleasing the Amptrol or arc start switch.
The VANTAGE® 500-I can be used in a wide varietyof DC TIG welding applications. In general the ‘TouchStart’ feature allows contamination free starting with-out the use of a Hi-frequency unit. If desired, theK930-2 TIG Module can be used with the VANTAGE®500-I. The settings are for reference.
VANTAGE® 500-I settings when using the K930-2TIG Module with an Amptrol or Arc Start Switch:
• Set the MODE Switch to the TOUCH START TIGsetting.
• Set the "IDLER" Switch to the "AUTO" position.
• Set the "WELDING TERMINALS" switch to the"REMOTELY CONTROLLED" position. This willkeep the "Solid State" contactor open and provide a"cold" electrode until the Amptrol or Arc StartSwitch is pressed.
When using the TIG Module, the OUTPUT CONTROLon the VANTAGE® 500-I is used to set the maximumrange of the CURRENT CONTROL on the TIGModule or an Amptrol if connected to the TIG Module.
AUXILIARY POWER:Start the engine and set the IDLER control switch tothe desired operating mode. Full power is availableregardless of the welding control settings providing nowelding current is being drawn.
Simultaneous Welding and Auxiliary Power LoadsThe auxiliary power ratings are with no welding load.Simultaneous welding and power loads are specifiedin the following Table B.4.
WeldAmps
0100200300400500
1 PHASE (220V)Per ReceptacleWATTS AMPS3300 153300 153300 153300 151700 7
0
3 PHASE
WATTS AMPS16,450 2514,100 2110,900 166,900 102,200 3
0 0
BOTH 1 & 3 PHASE
WATTS AMPS- 25- 25- 25
4,700 -1,700 -
0 -
VANTAGE® 500-I Simultaneous Welding and Power Loads
PLUS OROR
VANTAGE® 500-I
B-9OPERATIONB-9
TABLE B.4
VANTAGE® 500-I Extension Cord Length Recommendations(Use the shortest length extension cord possible sized per the following table.)
Current(Amps)
1520152044
Voltage Volts
120120240240240
Load(Watts)18002400360048009500
30
60
(9)
(18)
40307560
(12)(9)
(23)(18)
7550
15010050
(23)(15)(46)(30)(15)
12588
22517590
(38)(27)(69)(53)(27)
175138350275150
(53)(42)
(107)(84)(46)
300225600450225
(91)(69)
(183)(137)(69)
Maximum Allowable Cord Length in ft. (m) for Conductor Size
Conductor size is based on maximum 2.0% voltage drop.
14 AWG 12 AWG 10 AWG 8 AWG 6 AWG 4 AWG
TABLE B.5
C-1ACCESSORIESC-1FIELD INSTALLED OPTIONS /ACCESSORIES K2641-2 FOUR WHEELED STEERABLE YARDTRAILERFor in plant and yard towing. Comes standard with aDuo-Hitch™, a 2” Ball and Lunette Eye combinationHitch.
K2636-1 TRAILER - Two-wheeled trailer with optionalfender and light package. For highway use, consultapplicable federal, state, and local laws regardingpossible additional requirements. Comes standardwith a Duo-Hitch™, a 2” Ball and Lunette Eye combi-nation hitch. Order:K2636-1 Trailer K2639-1 Fender & Light KitK2640-1 Cable Storage Rack
K903-1 SPARK ARRESTOR - Includes a heavy gagesteel, approved spark arrestor, clamp and adapter formounting to the muffler exhaust pipe.
K704 ACCESSORY SET - Includes 35 ft. (10m) ofelectrode cable and 30 ft. (9.1m) of work cable, headshield, work clamp electrode holder. Cables are ratedat 400 amps, 100% duty cycle.
K857 25 ft (7.6m) or K857-1 100 ft. (30.4m)REMOTE CONTROLPortable control provides same dial range as the out-put control on the welder. Has a convenient 6 pin plugfor easy connection to the welder.
K2627-2 REMOTE OUTPUT CONTROL WITH 120VAC RECEPTACLE-Remote output control box withtwo 120V AC receptacles having GFCI (Ground FaultCircuit Interruption) protection. One cord for bothremote and power. 100 ft. (30.5m) length. Permitremote adjustment of weld output and power for tools(such as a grinder) at the work. 20 amp capacity.
K1858-1 SERVICE INDICATOR KIT- Provides a GO /NO-GO visual indication of air cleaner element usefulservice life. Filter service based on restriction readingsallows the longest life possible from the filter and bestengine protection.
K2679-1 COLD WEATHER HEATER AND TARP KITFor engine starting and operation in extreme coldweather conditions down to -40ºF / -40ºC (with theuse of OW40 synthetic oil and arctic diesel fuel),includes 120VAC engine block heater, and radiatorgrill tarp.
Invertec V275-SGet a second arc for Stick or DC TIG welding from the3-phase AC generator power of the Vantage 500-I.Run 200 amps from the V275-S and 200 amps fromthe Vantage 500-I at the same time. RequiresT12153-10 Full-KVA 3-phase plug. See bulletinE2.161 for Invertec V275-S accessoies including plugoptions.Order K2269-1 (Accepts Twist-Mate™ Plugs)Order K2269-3 (Accepts Tweco®)Tweco® is a registered trademark of Thermadyne.
WIRE FEEDER OPTIONSK2613-1 LN-25 PRO Wire Feeder- Portable CC/CVunit for flux-cored and MIG welding with MAXTRAC®wire drive system. Includes gas solenoid and internalcontactor.
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 arerequired for gas-shielded welding. Innershield Gun isrequired for gasless welding.
K126-2 Magnum 350 Innershield GunK1802-1 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 appropriateDrive Roll and Guide Tubes.TIG OPTIONSK1783-9 Pro -Torch® PTA-26V TIG TorchAir Cooled 200 amp torch (2 piece) equipped withvalve for gas flow control. 25 ft. (7.6m) length.KP509 Magnum Parts Kit for PTA-26V TIG TorchMagnum Parts Kit provides all the torch accessoriesyou need to start welding. Parts kit provides collets,collet bodies, a black cap, alumina nozzles and tung-stens in a variety of sizes, all packaged in an easy tocarry reclosable sack.K870 Foot Amptrol®K963-3 Hand Amptrol®
PLASMA CUTTINGK1580-1 Pro-Cut 55Cuts metal using the 3-phase AC generator powerfrom the engine driven welder.
VANTAGE® 500-I
D-1MAINTENANCED-1
VANTAGE® 500-I
SAFETY PRECAUTIONS
• Have qualified personnel do all maintenanceand troubleshooting work.
• Turn the engine off before working inside themachine or servicing the engine.
• Remove guards only when necessary toperform maintenance and replace them whenthe maintenance requiring their removal iscomplete. If guards are missing from themachine, obtain replacements from a LincolnDistributor. (See Operating Manual Parts List.)
WARNING
Read the Safety Precautions in the front of thismanual and in the Engine Owner’s Manual beforeworking on this machine.
Keep all equipment safety guards, covers, anddevices in position and in good repair. Keephands, hair, clothing, and tools away from thegears, fans, and all other moving parts whenstarting, operating, or repairing the equipment.------------------------------------------------------------------------
Routine Maintenance
At the end of each day’s use, refill the fuel tank tominimize moisture condensation in the tank. Runningout of fuel tends to draw dirt into the fuel system.Also, check the crankcase oil level and add oil ifindicated.
D-2MAINTENANCED-2ENGINE OIL CHANGE
Drain the engine oil while the engine is warm to assurerapid and complete draining. It is recommended thateach time the oil is changed the oil filter be changed aswell.
• Be sure the unit is off. Disconnect the negative bat-tery cable to ensure safety.
• Locate oil drain hose and valve in bottom of baseand pull through the hole in the battery access panelon the welder.
• Open oil drain valve by lifting up spring loaded leverand rotate 90° counterclockwise. Pull to open anddrain the oil into a suitable container for disposal.
• Close the drain valve by rotating lever 90° clockwise.
• Re-fill the crankcase to the upper limit mark on thedipstick with the recommended oil (see engine oper-ation manual OR engine service items decal ORbelow). Replace and tighten the oil filler cap secure-ly.
• Push oil drain hose and valve back into unit, re-con-nect negative battery cable, and close doors andengine top cover before restarting unit. Wash yourhands with soap and water after handling used motoroil. Please dispose of used motor oil in a mannerthat is compatible with the environment. We suggestyou take it in a sealed container to your local servicestation or recycling center for reclamation. DO NOTthrow it in the trash; pour it on the ground or down adrain.
Use motor oil designed for diesel engines that meetsrequirements for API service classif icationCC/CD/CE/CF/CF-4/CG-4 or CH-4.
ACEA E1/E2/E3. Always check the API service labelon the oil container to be sure it includes the lettersindicated. (Note: An S-grade oil must not be used in adiesel engine or damage may result. It IS permissibleto use an oil that meets S and C grade service classifi-cations.)
SAE 10W30 is recommended for general, all tempera-ture use, 5F to 104F (-15C to 40C).
See engine owner’s manual for more specific informa-tion on oil viscosity recommendations.
OIL FILTER CHANGE
• Drain the oil.
• Remove the oil filter with an oil filter wrench anddrain the oil into a suitable container. Discard theused filter. Note: Care should be taken during filterremoval to not disrupt or damage in any way the fuellines.
• Clean the filter mounting base and coat the gasketof 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 therecommended engine oil. Reinstall the oil filler capand tighten securely.
• Start the engine and check for oil filter leaks.
• Stop the engine and check the oil level. If neces-sary, add oil to the upper limit mark on the dipstick.
• Never use gasoline or low flash point solventsfor cleaning the air cleaner element. A fire orexplosion could result.
• Never run the engine without the air cleaner.Rapid engine wear will result from contaminants,such as dust and dirt being drawn into theengine.
------------------------------------------------------------------------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.
VANTAGE® 500-I
CAUTION
WARNING
D-3MAINTENANCED-3
VANTAGE® 500-I
D-4MAINTENANCED-4COOLING SYSTEM
HOT COOLANT can burn skin.
• Do not remove cap if radiator ishot.
------------------------------------------------------------------------Check the coolant level by observing the level in theradiator 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. Fillup to the top of the tube in the radiator filler neckwhich includes a connecting hose coming from thethermostat housing.
To drain the coolant, open the valve at the bottom ofthe radiator. Open the radiator cap to allow completedrainage. (Tighten the valve and refill with a 50/50antifreeze/water solution.) Use an automotive grade(low silicate) ethylene glycol antifreeze. The coolingsystem capacity is 8.0 quarts (7.6L.). Squeeze upperand lower radiator hoses while filling to bleed air fromsystem coolant. Replace and tighten the radiator cap.
Always premix the antifreeze and clean tap waterbefore adding to the radiator. It is very importantthat a precise 50/50 solution be used with thisengine year round. This gives proper cooling dur-ing hot weather and freezing protection to -34° F (-37° C).
Cooling solution exceeding 50% ethylene glycolcan result in engine overheating and damage tothe engine. Coolant solution must be premixedbefore 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 andthe battery lose its charge. Check tightness by press-ing on the belt midway between the pulleys. It shoulddeflect about .25 in.(6.4 mm) under a load of 20 lbs.(9Kg).
FUEL
At the end of each day’s use, refill the fuel tank to min-imize moisture condensation and dirt contamination inthe fuel line. Do not overfill; leave room for the fuel toexpand.
Use only fresh No. 2D diesel fuel, the use of No. 1Ddiesel fuel is recommended in place of No. 2D at tem-peratures below 23°F (-5°C). Do not use kerosene.
See the Engine Operator's Manual for instructions onreplacing the fuel filter.
BLEEDING THE FUEL SYSTEM
You may need to bleed air from the fuel system if thefuel filter or fuel lines have been detached, the fueltank has been ran empty or after periods of long stor-age. It is recommended that the fuel shutoff valve beclosed during periods of non-use.
To avoid personal injury, do not bleed a hotengine. This could cause fuel to spill onto a hotexhaust manifold, creating a danger of fire.------------------------------------------------------------------------Bleed the fuel system as follows:
1. Fill the fuel tank with fuel.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 couldtake 20-30 seconds of rapid operation of the prim-ing lever. Tighten bleed fitting on injector manifold.
5. Follow normal STARTING procedures until enginestarts.
VANTAGE® 500-I
WARNING
CAUTION
WARNING
D-5MAINTENANCED-5
FUEL FILTER1. Check the fuel filter and fuel pre-filter for water
accumulation or sediment.
2. Replace the fuel filter if it is found with excessivewater accumulation or sediment. Empty fuel pre-fil-ter.
ENGINE ADJUSTMENTAdjustments to the engine are to be made only by aLincoln Service Center or an authorized Field ServiceShop.
BATTERY MAINTENANCETo access the battery, remove the battery tray fromthe front of the machine with 3/8” nut driver or flathead screw driver. Pull the tray out of machine farenough to disconnect the negative and then positivebattery cables. The tray can then be tilted and lifted toremove the entire tray and battery from the machinefor easy service.
GASES FROM BATTERY can explode.l Keep sparks, flame and cigarettes
away from battery.
To prevent EXPLOSION when:l INSTALLING A NEW BATTERY — disconnect
negative cable from old battery first and con-nect to new battery last.
l CONNECTING A BATTERY CHARGER —remove battery from welder by disconnectingnegative cable first, then positive cable andbattery clamp. When reinstalling, connect
negative cable last. Keep well ventilated.l 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 andskin.l Wear gloves and eye protection
and be careful when working nearbattery.
l Follow instructions printed on battery.VANTAGE® 500-I
OVERSPEED IS HAZARDOUSThe maximum allowable high idle speed for thismachine is 1890 RPM, no load. Do NOT tamperwith governor components or setting or make anyother adjustments to increase the maximumspeed. Severe personal injury and damage to themachine can result if operated at speeds abovemaximum.
CLEANING THE BATTERYKeep the battery clean by wiping it with a damp clothwhen dirty. If the terminals appear corroded, discon-nect the battery cables and wash the terminals with anammonia solution or a solution of 1/4 pound (0.1113kg) of baking soda and 1 quart (0.9461L) of water. Besure the battery vent plugs (if equipped) are tight sothat none of the solution enters the cells.After cleaning, flush the outside of the battery, the bat-tery compartment, and surrounding areas with clearwater. Coat the battery terminals lightly with petroleumjelly 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 dischargeand early battery failure.
CHECKING THE ELECTROLYTE LEVEL
If battery cells are low, fill them to the neck of the fillerhole with distilled water and recharge. If one cell islow, check for leaks.
CHARGING THE BATTERYWhen you charge, jump, replace, or otherwise con-nect battery cables to the battery, be sure the polarityis correct. Improper polarity can damage the chargingcircuit. The VANTAGE® 500-I positive (+) battery ter-minal has a red terminal cover.
If you need to charge the battery with an externalcharger, disconnect the negative cable first, then thepositive cable before you attach the charger leads.After the battery is charged, reconnect the positivebattery cable first and the negative cable last. Failureto do so can result in damage to the internal chargercomponents.Follow the instructions of the battery charger manu-facturer for proper charger settings and charging time.
SERVICING OPTIONAL SPARKARRESTORClean every 100 hours.
WARNING
WARNING
• MUFFLER MAY BE HOT
• ALLOW ENGINE TO COOL BEFORE INSTALLINGTHE SPARK ARRESTER!
• DO NOT OPERATE ENGINE WHILE INSTALLINGTHE SPARK ARRESTER!
D-6MAINTENANCED-6
VANTAGE® 500-I
WELDER / GENERATORMAINTENANCE
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 aweek in particularly dirty areas.
BRUSH REMOVAL AND REPLACEMENT: It’s nor-mal for the brushes and slip rings to wear and darkenslightly. Inspect the brushes when a generator over-haul is necessary.
• Do not attempt to polish slip rings while theengine is running.
GFCI TesTInG AnD ReseTTInG PROCeDURe
The GFCI should be properly tested at least once every month orwhenever it is tripped. To properly test and reset the GFCI:
• If the GFCI has tripped, first carefully remove any load andcheck it for damage.
• If the equipment has been shut down, it must be restarted.
• The equipment needs to be operating at high idle speed andany necessary adjustments made on the control panel sothat the equipment is providing at least 80 volts to thereceptacle input terminals.
• The circuit breaker for this receptacle must not be tripped.Reset if necessary.
• Push the "Reset" button located on the GFCI. This willassure normal GFCI operation.
• Plug a night-light (with an "ON/OFF" switch) or otherproduct (such as a lamp) into the Duplex receptacle and turnthe product "ON".
• Push the "Test" button located on the GFCI. The night-lightor other product should go "OFF".
• Push the "Reset" button, again. The light or other productshould go "ON" again.
If the light or other product remains "ON" when the "Test"button is pushed, the GFCI is not working properly or has beenincorrectly installed (miswired). If your GFCI is not workingproperly, contact a qualified, certified electrician who can assessthe situation, rewire the GFCI if necessary or replace the device.
For GFCI Models that have the appearance as shown in FigureD.2, please use the following information and troubleshootingguide listed below. For all other GFCI models, please use theGFCI testing and resetting procedure listed previously.
FIGURE D.2
• The GFCI automatically monitors ground fault circuit inter-rupting functionality every (3) hours or less, and it alsoautomatically tests within (5) seconds of power to thedevice.
• If the GFCI device can no longer provide GFCI protection itwill deny power and provide a visual indication that it nolonger can provide protection.
TROUBLESHOOTING GUIDELINES:
• If the line conductor is incorrectly wired to the load terminal,power to the receptacle will be denied. This includes initialinstallation and any subsequent reinstallations.
• Visual indicators: Green LED on represents power at theface of the receptacle; solid Red LED on indicates a tripcondition and load is off. A flashing red LED indicates thatthe GFCI is no longer functioning and needs replaced.
• Reverse Wire Safety Feature: The GFCI will not have powerat both the face and downstream if the line and load arereverse wired. Additionally, the unit will not be able to resetunder a reversed wiring condition. If the line conductor isincorrectly wired to the load terminal, power to thereceptacle will be denied. This includes initial installationand any subsequent reinstallations.
• (GFCI no longer functioning): A rapid flashing red LED willindicate that the unit can no longer provide ground faultprotection. This indication will occur regardless of thespecific test mode that is being conducted, automatic ormanual.
• If your GFCI is no longer working properly, contact aqualified, certified electrician who can assess the situationand rewire the GFCI if necessary or replace the device.
Green Light
Red LightWARNING
• Service and Repair should only be performed byLincoln Electric Factory Trained Personnel.Unauthorized repairs performed on this equip-ment may result in danger to the technician andmachine operator and will invalidate your factorywarranty. For your safety and to avoid ElectricalShock, please observe all safety notes and pre-cautions.
CAUTION
D-7NOTES D-7
VANTAGE® 500-I
E-1TROUBLESHOOTINGE-1
VANTAGE® 500-I
If for any reason you do not understand the test procedures or are unable to perform the tests/repairs safely, contact yourLocal Lincoln Authorized Field Service Facility for technical troubleshooting assistance before you proceed.
CAUTION
This Troubleshooting Guide is provided to help youlocate and repair possible machine malfunctions.Simply follow the three-step procedure listed below.
Step 1. LOCATE PROBLEM (SYMPTOM).Look under the column labeled “PROBLEM (SYMP-TOMS)”. This column describes possible symptomsthat the machine may exhibit. Find the listing thatbest describes the symptom that the machine isexhibiting.
Step 2. POSSIBLE CAUSE.The second column labeled “POSSIBLE CAUSE” liststhe obvious external possibilities that may contributeto the machine symptom.
Step 3. RECOMMENDED COURSE OF ACTIONThis column provides a course of action for thePossible Cause, generally it states to contact yourlocal Lincoln Authorized Field Service Facility.
If you do not understand or are unable to perform theRecommended Course of Action safely, contact yourlocal Lincoln Authorized Field Service Facility.
HOW TO USE TROUBLESHOOTING GUIDE
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 andmachine operator and will invalidate your factory warranty. For your safety and to avoid ElectricalShock, please observe all safety notes and precautions detailed throughout this manual.
__________________________________________________________________________
WARNING
E-2TROUBLESHOOTINGE-2
VANTAGE® 500-I
Observe all Safety Guidelines detailed throughout this manual
If for any reason you do not understand the test procedures or are unable to perform the tests/repairs safely, contact yourLocal Lincoln Authorized Field Service Facility for technical troubleshooting assistance before you proceed.
CAUTION
PROBLEMS(SYMPTOMS)
POSSIBLECAUSE
RECOMMENDEDCOURSE OF ACTION
Major Physical or Electrical Damageis Evident.
Engine will not "crank".
Engine will "crank" but not start.
Engine shuts down shortly afterstarting.
1. Contact your local LincolnAuthorized Field ServiceFacility.
1. Battery is low, Charge Battery.2. Loose battery cable connections.
Inspect, clean and tighten terminals.3. Faulty engine starter motor.
Contact authorized local EngineService Shop.
1. Fuel shut off valve on Main FuelFilter in the OFF position. Openvalve (vertical) position of handle.
2. Fuel Filters dirty/clogged. Checkand replace main filter elementand/or Inline Fuel Filter.
3. Out of fuel. Fill tank and bleed fuelsystem.
4. High coolant temperature or lowoil pressure. (indictor lights lit)Check oil and coolant levels. Fill ifrequired. Check for loose or bro-ken fan belt.
5. Faulty fuel shutdown solenoid.Check that shutdown solenoid isfunctioning properly and not bind-ing/ contact authorized engineservice shop.
6. Faulty fuel pump. Check for fuelflow through filters. Contact autho-rized local Engine Service Shop.
1. High coolant temperature or lowoil pressure. (indictor light lit)Change oil and oil filters and fill toproper level. Check and fill coolantlevel. Check for loose or brokenfan belt. Start engine and look forleaks.
2. Faulty oil pressure switch or otherengine component. Contactauthorized local Engine ServiceShop.
3. Faulty Idler/Protection Board.
If all recommended possible areasof misadjustment have beenchecked and the problem persists,Contact your local LincolnAuthorized Field Service Facility.
E-3TROUBLESHOOTINGE-3Observe all Safety Guidelines detailed throughout this manual
If for any reason you do not understand the test procedures or are unable to perform the tests/repairs safely, contact yourLocal Lincoln Authorized Field Service Facility for technical troubleshooting assistance before you proceed.
CAUTION
PROBLEMS(SYMPTOMS)
POSSIBLECAUSE
RECOMMENDEDCOURSE OF ACTION
Engine shuts down while under aload.
Engine runs rough.
Battery does not stay charged.Engine alternator trouble light is onwhile machine is running.
Engine will not idle down to lowspeed.
Engine will not go to high idle whenattempting to weld.
1. High radiator coolant tempera-ture. Reduce load if it is exceed-ing machine rating. Add coolantto system if low. Clean fins onradiator if dirty. Tighten fan belt ifloose. Remove objects blockingor close to intake openings onboth sides of base and exhaustend (case back).
1. Dirty fuel or air filters. Inspect andclean/replace filters as needed.Inspect and clean/replace filtersas needed.
2. Water in fuel. If water found intank. Empty fuel tank and refillthen purge fuel lines.
1. Faulty battery. Replace.2. Loose connections at battery or
alternator. Clean and tighten con-nections.
3. Faulty engine alternator or charg-er module. Consult authorizedEngine Service Shop.
1. Idler switch in High idle position.Set switch to Auto.
2. External load on welder or auxil-iary power. Remove all externalloads.
3. Faulty PC board or idler sole-noid.
1. Poor work lead connection towork. Make sure work clamp istightly connected to clean basemetal.
2. "Contactor" switch is in wrongposition. Set to "Welding On" whenwelding without a control cable.Refer to Operations chapter for prop-er use of this switch.
3. Faulty PC board. Low idle speedset to low.
If all recommended possible areas ofmisadjustment have been checkedand the problem persists, Contactyour local Lincoln AuthorizedField Service Facility.
VANTAGE® 500-I
E-4TROUBLESHOOTINGE-4
VANTAGE® 500-I
Observe all Safety Guidelines detailed throughout this manual
If for any reason you do not understand the test procedures or are unable to perform the tests/repairs safely, contact yourLocal Lincoln Authorized Field Service Facility for technical troubleshooting assistance before you proceed.
CAUTION
PROBLEMS(SYMPTOMS)
POSSIBLECAUSE
RECOMMENDEDCOURSE OF ACTION
Engine will not go to high idle whenusing auxiliary power.
Engine wil l not go to high idleunder weld or auxiliary loading.
Engine does not develop ful lpower. Engine runs rough.
Engine will not go to high idle whenattempting to weld or using auxil-iary power. Switching to manualhigh idle does not work.
Engine will not shut off.
Engine does not develop full power.Low weld and auxil iary output.Engine runs rough.
1. Auxiliary power load is less than100 watts. Idler may not respondwith less than a 100 watt load. Setidler to "High".
2. Faulty PC board.(Control or Idler).
1. Faulty idler solenoid. Check forbent linkage or broken spring.
2. Faulty PC board.(Control or Idler).
1. Fuel filter clogged, Replace.2. Air filter clogged, clean or replace.3. High idle setting incorrect, check
and adjust if required.4. Valves out of adjustment.5. Fuel contaminated with water or
sediment. Check fuel pre-filterand empty of water, bleed fuelsystem. Replace fuel in tank ifneeded.
1. Broken spring on Idle Solenoid,solenoid linkage binding, FaultyPC board (Control or Idler), lowidle speed set too low on idlesolenoid.
1. Fuel Shutdown solenoid not func-tioning properly / linkage binding.Stop engine by shutting off valvelocated on main fuel filter. Contactauthorized local Engine ServiceShop.
1. Fuel filter dirty/clogged. Replace.2. Air filter dirty/clogged. Replace Air
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. Contactauthorized local Engine ServiceShop.
If all recommended possible areasof misadjustment have beenchecked and the problem persists,Contact your local LincolnAuthorized Field Service Facility.
E-5TROUBLESHOOTINGE-5
VANTAGE® 500-I
Observe all Safety Guidelines detailed throughout this manual
If for any reason you do not understand the test procedures or are unable to perform the tests/repairs safely, contact yourLocal Lincoln Authorized Field Service Facility for technical troubleshooting assistance before you proceed.
CAUTION
PROBLEMS(SYMPTOMS)
POSSIBLECAUSE
RECOMMENDEDCOURSE OF ACTION
No welding power output.
Welder has output but no control.
No auxiliary power.
1. Poor work lead connection towork. Make sure work clamp istightly connected to clean basemetal.
2. "Weld Terminals" switch in wrongposition. Place switch in "WeldTerminals On" posit ion whenwelding without control cable.
3. Faulty PC board or welder alterna-tor.
1. Poor remote/control cable connec-tion to 6-pin or 14-pin connector.Check connections.
2. Faulty remote cable or faulty wirefeeder or wire feeder cable.Replace if necessary.
3. Faulty control potentiometer or PCboard.
1. Open circuit breakers. Reset breakers. If breakers keep trippingreduce power draw.
2. GFCI may have tripped.Follow “GFCI Testing and Resetting Procedure” in the MAIN-TENANCE section of this manual.
3. Faulty connections to auxiliaryreceptacles. Check connections.
4. Faulty PC board or welder alterna-tor.
If all recommended possible areasof misadjustment have beenchecked and the problem persists,Contact your local LincolnAuthorized Field Service Facility.
E-6TROUBLESHOOTINGE-6Observe all Safety Guidelines detailed throughout this manual
If for any reason you do not understand the test procedures or are unable to perform the tests/repairs safely, contact yourLocal Lincoln Authorized Field Service Facility for technical troubleshooting assistance before you proceed.
CAUTION
PROBLEMS(SYMPTOMS)
POSSIBLECAUSE
RECOMMENDEDCOURSE OF ACTION
The welding arc is “cold.” The weld-ing arc is not stable or is not satis-factory. the engine runs normally.The auxiliary power is normal.
No output in Pipe Mode.
1. Make sure the MODE selectorswitch is in the correct position forthe process being used. (For exam-ple, CV-WIRE, PIPE, CC-STICK.)
2. Make sure the electrode (wire, gas,voltage, current etc.) is correct forthe process being used.
3. Check for loose or faulty connec-tions at the weld output terminalsand welding cable connections.
4. The welding cables may be too longor coiled, causing an excessivevoltage drop.
5. Faulty Control Board.
1. Poor work lead connection towork. Make sure work clamp istightly connected to clean basemetal.
2. "Weld Terminals" switch in wrongposition. Place switch in "WeldTerminals On" posit ion whenwelding without control cable.
3. Faulty PC board or welder alterna-tor
If all recommended possible areas ofmisadjustment have been checkedand the problem persists, Contactyour local Lincoln AuthorizedField Service Facility.
VANTAGE® 500-I
E-7NOTES E-7
VANTAGE® 500-I
F-1DIAGRAMSF-1
VANTAGE® 500-I
ELECTRICSHOCK
CAN KILL
WARNINGDo not operate with covers removed
Disconnect input power before servicing
Do not touch electrically live parts
Only qualified persons should install,use or service this equipment
1. TURN OFF THE ENGINE AND DISCONNECT THE NEGATIVE BATTERY CABLE. 2. REMOVE THE FOUR SCREWS THAT SECURE THE UPPER CONTROL PANEL AND
OPEN THE PANEL. 3. WHILE HOLDING THE RCD MOUNTING BRACKET REMOVE THE TWO SCREWS
SECURING THE COVER PLATE AND RCD MOUNTING BRACKET. SET THE RCD MOUNTING BRACKET AND SCREWS ASIDE AND DISCARD COVER PLATE. (SEE FIGURE 1).
����������������������� ����������������������������������������������������������
FIGURE 1
UPPER CONTROLPANEL
RCD MOUNTINGBRACKET
COVER PLATE
F-2DIAGRAMSF-2
VANTAGE® 500-I
Sales and Service through Subsidiaries and Distributors WorldwideCleveland, Ohio 44117-1199 U.S.A.
RTHE LINCOLN ELECTRIC COMPANY
World's Leader in Welding and Cutting Products
M22156-1 PRINTA.02
4. CUT RING TERMINALS OFF OF LEADS 5B, 5C, 5E AND SKIN INSULATIONBY 0.75 in. CONNECT LEADS FROM CIRCUIT BREAKERS TO RCD ASSHOWN (SEE FIGURE 3). NOTE LEAD CONFIGURATION. USE LEADS 1A, 2B, 3C, M1A, M2B, M3C, AND 5HB PROVIDED IN BAG WITH LITERATUREPACK. DISCARD LEAD 5HA.
5. TIGHTEN LEADS TO 2.4NM (21 IN. LBS.) MOUNT RCD TO PANEL USINGMOUNTING BRACKET AND SCREWS SET ASIDE IN STEP 3.
6. SECURE UPPER CONTROL PANEL IN PLACE.
7. RECONNECT NEGATIVE BATTERY CABLE.
THE UNIT IS NOW READY FOR OPERATION
FIGURE 3
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F-3DIAGRAMSF-3
VANTAGE® 500-I
or s
ervi
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is e
quip
men
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nly
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ified
per
sonn
el s
houl
d in
stal
l,use
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ay fr
om m
ovin
g pa
rts.
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ards
in p
lace
.M
OV
ING
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RT
S c
an in
jure
WA
RN
ING
Do
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ouch
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ctric
ally
live
par
ts.
befo
re s
ervi
cing
.D
isco
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t NE
GA
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-) B
atte
ry le
adD
o no
t ope
rate
with
pan
els
open
.E
LE
CT
RIC
SH
OC
K c
an k
ill
14 P
IN
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ECTO
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AY N
OT
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ACH
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)
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ORK
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R LN
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WIR
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EDER
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TE C
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+_
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. W
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ST B
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F PR
OPE
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ITY
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RR
ENT
AND
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TY C
YCLE
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ATIN
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DS
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IRED
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OSI
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/LN-
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ORK
S24
787-
1
A
ENG
INE
WEL
DER
F-4WIRING DIAGRAMF-4
VANTAGE® 500-I
NOTE
: Th
is d
iagr
am is
for r
efer
ence
onl
y.
It m
ay n
ot b
e ac
cura
te fo
r all
mac
hine
s co
vere
d by
this
man
ual.
The
spe
cific
dia
gram
for a
par
ticul
ar c
ode
is in
clud
edwi
th th
e m
achi
ne.
If th
e di
agra
m is
ille
gibl
e, w
rite
to th
e Se
rvic
e De
partm
ent f
or a
repl
acem
ent.
Giv
e th
e eq
uipm
ent c
ode
num
ber.
RE
CTI
FIE
R B
RID
GE
STA
RT
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TTO
N
222
217
218
12
322
0A
4
206S
50M
V=5
00A
MP
S
W4
& W
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2 &
W3
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& W
6
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GN
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IN C
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OR
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B7
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E
BY
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TER
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SE
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LY
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10
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220
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LT M
ETE
R
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15
AM
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TER
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2523
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278279
277
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ES
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ING
DIA
GR
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FE
RR
ITE
VANT
AGE
500-
I WIR
ING
DIAG
RAM
FOR
COD
ES 1
2559
F-5DIAGRAMSF-5
VANTAGE® 500-I
NOTE
: Th
is dia
gram
is fo
r ref
eren
ce o
nly.
It m
ay n
ot b
e ac
cura
te fo
r all m
achin
es co
vere
d by
this
man
ual.
The
spec
ific d
iagra
m fo
r a p
artic
ular c
ode
is inc
luded
with
the
mac
hine.
If t
he d
iagra
m is
illeg
ible,
writ
e to
the
Serv
ice D
epar
tmen
t for
a re
place
men
t. G
ive th
e eq
uipm
ent c
ode
num
ber.
RE
CTI
FIE
R B
RID
GE
STA
RT
BU
TTO
N
222
217
218
12
322
0A
4
206S
50M
V=5
00A
MP
S
W4
& W
5W
2 &
W3
W1
& W
6
204S
GN
D-B
A B C D E F
6 P
IN C
ON
NE
CTO
R
2A 4A75A
76A
77A
-+
2325
B2-
PO
S
B4-
NE
G
B4-
NE
G
B5-
PO
S
B1-
NE
G
B2-
PO
S
CH
OP
PE
RP
CB
313
C
14
B6B5
B4
B1
B2
B3
CC TI
G
PIP
E
B8
B7
GR
OU
ND
ED
BY
MO
UN
TIN
G
GN
D-J
GN
D-B
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PO
S
B1-
NE
G
L1 C
HO
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BY
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SS
FILT
ER
AS
SE
MB
LY
RE
MO
TEC
ON
TRO
L
CO
NTA
CTO
R
GR
OU
ND
VO
LTM
ETE
RA
MM
ETE
R
M1 M
2M3 M
4M
5M
6M9 M
10M
1 M2M
3 M4
M5
M6M
9 M10
15
220
VO
LT M
ETE
R
M1M2M3M4M5
M6
M9
M10
15
AM
ME
TER
M1M2
M3
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M6
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M10
2523
VR
D W
ELD
BO
AR
D
278279
277
2 120
4S20
6S
208C 256
260
214
PC
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1 916
8 16
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1
169
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CO
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, PO
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WM
, TH
ER
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L
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77
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24
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HU
NT
J1A
MP
HE
NO
L,I.D
.J2
EN
GIN
E,P
ER
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ER
AL
232K
12 V
OLT
GR
OU
ND
STU
D O
N U
PP
ER
CO
NTR
OL
PA
NE
L
5J5K
RU
N/S
TOP
SW
ITC
HSH
OWN
IN "R
UN" P
OSIT
ION
238B
236A
CB
510
A
236B
STO
P
RU
N
238A
231
SENS
OR
SENS
OR
FUE
L LE
VE
LS
EN
SO
R
WK
235
234
A
5J229
228
241
G
234
SW
ITC
H
SW
ITC
H
OIL
PR
ES
SU
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2597
L171
54
F-8NOTES F-8
VANTAGE® 500-I
WARNING
AVISO DEPRECAuCION
ATTENTION
WARNuNG
ATENÇÃO
Spanish
French
German
Portuguese
Japanese
Chinese
Korean
Arabic
READ AND UNDERSTAND THE MANUFACTURER’S INSTRUCTION FOR THIS EQUIPMENT AND THE CONSUMABLES TO BEUSED AND FOLLOW YOUR EMPLOYER’S SAFETY PRACTICES.
SE RECOMIENDA LEER Y ENTENDER LAS INSTRUCCIONES DEL FABRICANTE PARA EL USO DE ESTE EQUIPO Y LOSCONSUMIBLES 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 AETRE 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.
l Do not touch electrically live parts orelectrode with skin or wet clothing.
l Insulate yourself from work andground.
l No toque las partes o los electrodosbajo carga con la piel o ropa moja-da.
l Aislese del trabajo y de la tierra.
l Ne laissez ni la peau ni des vête-ments mouillés entrer en contactavec des pièces sous tension.
l Isolez-vous du travail et de la terre.
l Berühren Sie keine stromführendenTeile oder Elektroden mit IhremKörper oder feuchter Kleidung!
l Isolieren Sie sich von denElektroden und dem Erdboden!
l Não toque partes elétricas e elec-trodos com a pele ou roupa molha-da.
l Isole-se da peça e terra.
l Keep flammable materials away.
l Mantenga el material combustiblefuera del área de trabajo.
l Gardez à l’écart de tout matérielinflammable.
l Entfernen Sie brennbarres Material!
l Mantenha inflamáveis bem guarda-dos.
l Wear eye, ear and body protection.
l Protéjase los ojos, los oídos y elcuerpo.
l Protégez vos yeux, vos oreilles etvotre corps.
l Tragen Sie Augen-, Ohren- und Kör-perschutz!
l Use proteção para a vista, ouvido ecorpo.
WARNING
AVISO DEPRECAuCION
ATTENTION
WARNuNG
ATENÇÃO
Spanish
French
German
Portuguese
Japanese
Chinese
Korean
Arabic
LEIA E COMPREENDA AS INSTRUÇÕES DO FABRICANTE PARA ESTE EQUIPAMENTO E AS PARTES DE USO, E SIGA ASPRÁTICAS DE SEGURANÇA DO EMPREGADOR.
l Keep your head out of fumes.l Use ventilation or exhaust to
remove fumes from breathing zone.
l Los humos fuera de la zona de res-piración.
l Mantenga la cabeza fuera de loshumos. Utilice ventilación oaspiración para gases.
l Gardez la tête à l’écart des fumées.l Utilisez un ventilateur ou un aspira-
teur pour ôter les fumées des zonesde travail.
l Vermeiden Sie das Einatmen vonSchweibrauch!
l Sorgen Sie für gute Be- undEntlüftung des Arbeitsplatzes!
l Mantenha seu rosto da fumaça.l Use ventilação e exhaustão para
remover fumo da zona respiratória.
l Turn power off before servicing.
l Desconectar el cable de ali-mentación de poder de la máquinaantes de iniciar cualquier servicio.
l Débranchez le courant avant l’entre-tien.
l Strom vor Wartungsarbeitenabschalten! (Netzstrom völlig öff-nen; Maschine anhalten!)
l Não opere com as tampas removidas.l Desligue a corrente antes de fazer
serviço.l Não toque as partes elétricas nuas.
l Do not operate with panel open orguards off.
l No operar con panel abierto oguardas quitadas.
l N’opérez pas avec les panneauxouverts ou avec les dispositifs deprotection enlevés.
l Anlage nie ohne Schutzgehäuseoder Innenschutzverkleidung inBetrieb setzen!
l Mantenha-se afastado das partesmoventes.
l Não opere com os paineis abertosou guardas removidas.
CUSTOMER ASSISTANCE POLICY
The business of The Lincoln Electric Company is manufacturing andselling high quality welding equipment, consumables, and cuttingequipment. Our challenge is to meet the needs of our customers andto exceed their expectations. On occasion, purchasers may askLincoln Electric for advice or information about their use of ourproducts. We respond to our customers based on the best informationin our possession at that time. Lincoln Electric is not in a position towarrant or guarantee such advice, and assumes no liability, withrespect to such information or advice. We expressly disclaim anywarranty of any kind, including any warranty of fitness for anycustomer’s particular purpose, with respect to such information oradvice. As a matter of practical consideration, we also cannot assumeany responsibility for updating or correcting any such information oradvice once it has been given, nor does the provision of informationor advice create, expand or alter any warranty with respect to the saleof our products.
Lincoln Electric is a responsive manufacturer, but the selection anduse of specific products sold by Lincoln Electric is solely within thecontrol of, and remains the sole responsibility of the customer. Manyvariables beyond the control of Lincoln Electric affect the resultsobtained in applying these types of fabrication methods and servicerequirements.
Subject to Change – This information is accurate to the best of ourknowledge at the time of printing. Please refer to www.lincolnelectric.com for any updated information.
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