Lincoln Electric 500 Recommended, Course Of Action, Troubleshooting, Symptoms, Function Problems

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RECOMMENDED

E-4

 

TROUBLESHOOTING

E-4

 

 

 

 

 

Observe all Safety Guidelines detailed throughout this manual

 

 

 

 

 

PROBLEMS

POSSIBLE

RECOMMENDED

 

(SYMPTOMS)

CAUSE

COURSE OF ACTION

FUNCTION PROBLEMS

 

Engine goes to low idle but does not

1.

Weld Control PCB or electronic

 

stay at low idle.

 

governor controller.

 

 

 

 

 

No welding output or auxiliary out-

1.

Broken lead in rotor circuit.

 

put.

2.

Faulty field diode module.

 

 

3.

Faulty Weld Control PCB.

 

 

4.

Faulty rotor.

 

 

 

 

 

Welder has some/ no output and no

1.

Faulty remote kit.

 

control. Auxiliary output OK

2.

Faulty output control potentiome-

 

 

 

ter.

 

 

3.

Faulty output control wiring.

 

 

4.

Faulty Weld Control PCB or

 

 

 

Chopper PCB.

 

 

 

 

 

No welding output. Auxiliary output

1.

WELDING TERMINALS switch in

 

OK.

 

wrong position, be sure switch is

 

 

 

in WELDING TERMINALS

 

 

 

ALWAYS ON position.

 

 

2.

Faulty Weld Control PCB or

 

 

 

Chopper PCB.

 

 

 

 

 

No auxiliary power.

1.

GFCI Receptacle may have

 

 

 

tripped. Follow “GFCI Receptacle

 

 

 

Testing and Resetting Procedure”

 

 

 

in the MAINTENANCE section of

 

 

2.

this manual.

 

 

Open breakers may need to be

 

 

 

reset.

 

 

3.

Faulty receptacle.

 

 

4.

Faulty auxiliary circuit wiring.

 

 

 

 

 

 

 

 

If all recommended possible areas of misadjustment have been checked and the problem persists, Contact your local Lincoln Authorized Field Service Facility.

COURSE OF ACTIONCAUTION

If for any reason you do not understand the test procedures or are unable to perform the tests/repairs safely, contact your Local Lincoln Authorized Field Service Facility for technical troubleshooting assistance before you proceed.

VANTAGE 500 CUMMINS

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Contents VANTAGE 500 CUMMINS For use with machines having Code NumbersIM873-A OPERATOR’S MANUALFOR ENGINE powered equipment SAFETYELECTRIC AND MAGNETIC FIELDS may be dangerous CALIFORNIA PROPOSITION 65 WARNINGSARC RAYS can burn ELECTRIC SHOCK can killFUMES AND GASES can be dangerous WELDING and CUTTING SPARKS can FOR ELECTRICALLY powered equipmentcause fire or explosion CYLINDER may explode if damagedMar. ʻ93 PRÉCAUTIONS DE SÛRETÉThank You On-LineProduct RegistrationTechnical Specifications TABLE OF CONTENTSSafety Precautions Pre-OperationEngine and Compressor ServiceEngine Maintenance Routine and Periodic MaintenanceBattery Handling Charging the BatteryPHYSICAL DIMENSIONS INSTALLATIONINPUT - DIESEL ENGINE RATED OUTPUT @ 104F40C - WELDERLOCATION / VENTILATION SAFETY PRECAUTIONSSTORING STACKINGHIGH ALTITUDE OPERATION LIFTINGTOWING VEHICLE MOUNTINGPRE-OPERATIONENGINE BATTERY CONNECTIONFUEL USE DIESEL FUEL ONLY FUEL CAPMUFFLER OUTLET PIPE AIR CLEANER INLET HOODSPARK ARRESTOR WELDING TERMINALSAUXILIARY POWER RECEPTACLES REMOTE CONTROLSTANDBY POWER CONNECTIONS OUTPUTINSTALLATION CONNECTION OF LN-7, LN-8OR LN-742 CONNECTION OF LINCOLN ELECTRIC WIRE FEEDERSTO THE VANTAGE 500 CUMMINS CONNECTION OF LN-15TO THE VAN- TAGE 500 CUMMINSCONNECTION OF THE LN-25TO THE VANTAGE 500 CUMMINS ADDITIONAL SAFETY PRECAUTIONS SAFETY INSTRUCTIONSOPERATION GENERAL DESCRIPTIONCONTROLS AND SETTINGS 9. IDLER SWITCH 8. BATTERY CHARGING LIGHT6. OIL PRESSURE GAUGE 7. ENGINE PROTECTIONWELDING CONTROLS Items 10 through AUXILIARY POWER CONTROLS21. 120VAC SINGLE PHASE RECEPTACLES ENGINE OPERATION23. 240VAC THREE PHASE RECEPTACLE 20. CIRCUIT BREAKERSTYPICAL FUEL CONSUMPTION BREAK-INPERIODWELDER OPERATION DUTY CYCLEFOR TUNGSTEN ELECTRODES Table B.3 TYPICAL CURRENT RANGESAUXILIARY POWER OPERATION CV-WIREMODESIMULTANEOUS WELDING AND AUXIL- IARY POWER LOADS ARC GOUGINGPLUS OPTIONAL FIELD INSTALLED ACCES- SORIES ACCESSORIEST12153-9 Full-KVAPower Plug-Onedual voltage plug rated at 120/240V, 50 amps, single phaseTIG OPTIONS WIRE FEEDER OPTIONSPLASMA CUTTING SAFETY PRECAUTIONS MAINTENANCEROUTINE AND PERIODIC MAINTENANCE ENGINE MAINTENANCE3Clean Sealing Surface of the Outlet Tube D-2MAINTENANCED-24Clean the Inside of the Outlet Tube 1Release the Seal CarefullyPREVENTING BATTERY BUCKLING PREVENTING BATTERY DISCHARGEFUEL FILTERS COOLING SYSTEMWELDER / GENERATOR MAINTENANCE STORAGE CHARGING THE BATTERYCLEANING BRUSH REMOVAL AND REPLACEMENTGFCI RECEPTACLE TESTING AND RESET TING PROCEDURE HOW TO USE TROUBLESHOOTING GUIDE TROUBLESHOOTINGStep 1. LOCATE PROBLEM SYMPTOM Step 2. POSSIBLE CAUSEENGINE PROBLEMS SYMPTOMSPROBLEMS POSSIBLEFUNCTION PROBLEMS COURSE OF ACTION RECOMMENDEDEnhanced Diagram DIAGRAMSCONNECTION DIAGRAMS COMMANDER / K867 / K775 / LN-7CONNECTION DIAGRAM CONNECTION DIAGRAMS CONNECTION DIAGRAMS COMMANDER / K867 / LN-8CONNECTION DIAGRAM CONNECTION DIAGRAMS CONNECTION DIAGRAMS CONNECTION DIAGRAMS F-10 F-11 F-12 F-13 F-13M18962-3 BOTTOM VIEW OF WELDER BASEVANTAGE 500 CUMMINS WARNUNG PRECAUCIONATENÇÃO AVISO DEATENÇÃO WARNUNGWorlds Leader in Welding and Cutting Products
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500 specifications

The Lincoln Electric 500 is a hallmark of innovation in arc welding technology, designed to cater to the rigorous demands of both industrial applications and serious hobbyist projects. This powerful machine is known for its reliability, versatility, and user-friendly design, making it an essential tool for professional welders and those looking to tackle various welding tasks with ease.

One of the standout features of the Lincoln Electric 500 is its robust power output. With a capability of up to 500 amps, it can handle a wide range of welding processes, including Stick, TIG, and MIG welding. This flexibility allows welders to use the machine for different types of metals, including steel, stainless steel, and aluminum, making it suitable for diverse applications from automotive to construction industries.

The machine's digital interface enhances user experience by providing precise control over the welding parameters. The intuitive display allows for easy adjustments of voltage and wire speed, ensuring optimal welding conditions are achieved. This feature is especially beneficial for beginners who may require additional support as they learn the intricacies of welding.

The Lincoln Electric 500 is also equipped with advanced technologies that enhance efficiency and welding quality. One such technology is the inverter system, which optimizes the power source for superior arc stability and improved penetration. This results in cleaner welds with minimal spatter, reducing the need for post-welding cleanup. Furthermore, the machine’s duty cycle is impressive, meaning it can operate for extended periods without overheating, a critical factor in high-production environments.

Another significant characteristic of the Lincoln Electric 500 is its portability. Weighing in at a manageable level and designed with built-in carrying handles, it’s easy to transport between job sites. This feature is particularly valuable for mobile welders who need to work in various locations.

Safety is paramount in welding operations, and the Lincoln Electric 500 integrates various safety features designed to protect the user. Overload protection and thermal overload indicators help prevent damage to the machine and injury to the operator, ensuring a reliable and safe working environment.

Overall, the Lincoln Electric 500 stands out not only for its performance but also for its thoughtful engineering that prioritizes user safety, comfort, and versatility. It is a dependable choice for anyone looking to produce high-quality welds while enjoying the benefits of advanced welding technology.