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Lincoln Electric Vantage 441X/LE500X Operator's Manual

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Operator's Manual
Vantage
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Date Purchased
Code: (ex: 10859)
Serial: (ex: U1060512345)
IM10528-C
| Issue D ate May - 22
© Lincoln Global, Inc. All Rights Reserved.
441X /LE500X
®
For use with machines having Code Numbers:
12883, 12890, 13195, 13196
Need Help? Call 1.888.935.3877
to talk to a Service Representative
Hours of Operation:
8:00 AM to 6:00 PM (ET) Mon. thru Fri.
After hours?
Use "Ask the Experts" at lincolnelectric.com
A Lincoln Service Representative will contact you
no later than the following business day.
For Service outside the USA:
Email: globalservice@lincolnelectric.com

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Summary of Contents for Lincoln Electric Vantage 441X/LE500X

  • Page 1 Operator’s Manual Vantage 441X /LE500X ® For use with machines having Code Numbers: 12883, 12890, 13195, 13196 Need Help? Call 1.888.935.3877 Register your machine: to talk to a Service Representative www.lincolnelectric.com/register Authorized Service and Distributor Locator: Hours of Operation: www.lincolnelectric.com/locator 8:00 AM to 6:00 PM (ET) Mon.
  • Page 2 THANK YOU FOR SELECTING A QUALITY PRODUCT BY KEEP YOUR HEAD OUT OF THE FUMES. DON’T get too close to the arc. LINCOLN ELEC TRIC. Use corrective lenses if necessary to stay a reasonable distance away from the arc. READ and obey the Safety Data PLEASE EXAMINE CARTON AND EQUIPMENT FOR Sheet (SDS) and the warning label DAMAGE IMMEDIATELY...
  • Page 3 P.O. Box 351040, Miami, Florida 33135 or CSA Standard W117.2. A Free copy of “Arc Welding Safety” booklet E205 2.a. Electric current owing through any conductor is available from the Lincoln Electric Company, 22801 causes localized Electric and Magnetic Fields (EMF). St. Clair Avenue, Cleveland, Ohio 44117-1199.
  • Page 4 SAFETY ELECTRIC SHOCK ARC RAYS CAN BURN. CAN KILL. 3.a. The electrode and work (or ground) circuits are 4.a. Use a shield with the proper filter and cover plates to protect your electrically “hot” when the welder is on. Do eyes from sparks and the rays of the arc when welding or not touch these “hot”...
  • Page 5 SAFETY WELDING AND CUTTING CYLINDER MAY EXPLODE IF SPARKS CAN CAUSE DAMAGED. FIRE OR EXPLOSION. 7.a. Use only compressed gas cylinders containing the correct shielding gas for the process used 6.a. Remove fire hazards from the welding area. If and properly operating regulators designed for this is not possible, cover them to prevent the welding sparks the gas and pressure used.
  • Page 6 TABLE OF CONTENTS...

  • Page 7: Table Of Contents

    TABLE OF CONTENTS CV-WIRE MODE ...............................B-12 ARC GOUGING MODE ...............................B-12 ARCLINK MODE ...............................B-12 PULSE WELDING..............................B-13 CROSSLINC ................................B-14 PARALLELING ................................B-14 AUXILIARY POWER OPERATION..........................B-15 SIMULTANEOUS WELDING AND AUXILIARY POWER LOADS ..................B-15 TYPICAL FUEL CONSUMPTION ..........................B-17 ACCESSORIES ..............................SECTION C CROSSLINC ACCESSORIES ............................C-1 GENERAL ACCESSORIES............................C-1 TIG ACCESSORIES ..............................C-1 WIRE FEEDERS &...
  • Page 8 VANTAGE 441X/LE500X ® GRAPHIC SYMBOLS The following graphics appear on the machine or in the manual. Warning or Caution Engine Downhill Pipe welding Instructions Remote Fumes and Gases Oil Pressure Arc Control Explosion Engine Temperature Pulse Arc Rays Engine Hours Voltmeter Polarity Moving Parts Fuel...
  • Page 9 VANTAGE 441X/LE500X INSTALLATION ® GENERAL DESCRIPTION OUTPUT @ 104°F(40°C) - WELD ER AND GENERATOR Welding Mode Output Range The Vantage ® 441X/LE500X is a diesel engine-driven welding power source. The machine uses a brush type alternating CC-Stick 30-525 Amps current generator for DC multi-purpose welding, for 120/240 Downhill Pipe (CC) 40-350 Amps VAC single phase and 240 VAC three phase auxiliary standby...
  • Page 10 VANTAGE 441X/LE500X INSTALLATION ® INSTALLATION FIGURE A.1 REMOVE 4 FRONT PANEL SCREWS TO ACCESS (VRD) SWITCH SAFETY PRECAUTIONS ON / OFF VRD SWITCH WARNING Do not attempt to use this equipment until you have thoroughly read all operating and maintenance manuals supplied with your machine.
  • Page 11 VANTAGE 441X/LE500X INSTALLATION ® STORING HIGH ALTITUDE OPERATION 1. Store the machine in a cool, dry place when it is not in use. At higher altitudes, output derating may be necessary. For Protect it from dust and dirt. Keep it where it can’t be maximum rating, derate the welder output in accordance with the accidentally damaged from construction activities, moving guidelines in Table A.1 below for this engine model from the...
  • Page 12 VANTAGE 441X/LE500X INSTALLATION ® WARNING TOWING Use a recommended trailer for use with this equipment for road, • Stop engine and allow to cool before fueling. in-plant and yard towing by a vehicle . If the user adapts a non- Lincoln trailer, they must assume responsibility that the method of •...
  • Page 13 VANTAGE 441X/LE500X INSTALLATION ® BATTERY CONNECTION SPARK ARRESTOR Some federal, state or local laws may require that gasoline or CAUTION diesel engines be equipped with exhaust spark arrestors when they are operated in certain locations where unarrested sparks Use caution as the electrolyte is a strong acid that can burn may present a re hazard.
  • Page 14 VANTAGE 441X/LE500X INSTALLATION ® MACHINE GROUNDING The 120 VAC auxiliary power receptacles should only be used with three wire grounded type plugs or approved double insulated tools Because this portable engine driven welder creates its own power, with two wire plugs. The current rating of any plug used with the it is not necessary to connect its frame to an earth ground, unless system must be at least equal to the current capacity of the the machine is connected to premises wiring (home, shop, etc.).
  • Page 15 VANTAGE 441X/LE500X INSTALLATION ® STANDBY POWER CONNECTIONS 2. Take necessary steps to assure load is limited to the capacity of the Vantage ® 441X/LE500X by installing a 50 amp, 240 VAC The Vantage 441X/LE500X is suitable for temporary, standby or ®...
  • Page 16 VANTAGE 441X/LE500X INSTALLATION ® CAUTION WELDING OUTPUT CABLES • Loose connections will cause the output terminals to With the engine off, route the electrode and work cables through overheat. The terminals may eventually melt. the strain relief bracket provided on the front of the base and connect to the terminals provided.
  • Page 17 VANTAGE 441X/LE500X INSTALLATION ® CABLE INDUCTANCE AND ITS EFFECTS ON CONTROL CABLE CONNECTIONS WELDING General Guidelines Excessive cable inductance will cause the welding performance to Genuine Lincoln control cables should be used at all times (except degrade. There are several factors that contribute to the overall where noted otherwise).
  • Page 18 VANTAGE 441X/LE500X INSTALLATION ® REMOTE CONTROL CONNECTIONS WELDING TERMINALS The Vantage ® 441X/LE500X is equipped with a 12-pin and a 14- The Vantage ® 441X /LE500X is equipped with a toggle switch for pin connector. To enable remote control capabilities, the selecting "hot"...
  • Page 19 VANTAGE 441X/LE500X INSTALLATION ® For electrode negative, connect the electrode cable “-” terminal of the welder and work cable to the “+” terminal of ACCESSORY CONNECTION DIAGRAMS the welder. Installation diagrams for common setups are included on the following pages. WARNING •...
  • Page 20 VANTAGE 441X/LE500X INSTALLATION ® CROSSLINC SETUP CV FIGURE A.7 Item Desc. Machine Vantage 441X K4535-1 ® Machine LE500X K5174-1 Feeder LN-25X w/TVT K4267-2 K126 ® PRO Innershield ® 350A FCAW-SS Welding K126-12 Gun 15 ft 1/16-5/64 Weld Power Cable - Lug to Work Lug (3/0, 600A, 60%) - 35 K1842-35...
  • Page 21 VANTAGE 441X/LE500X INSTALLATION ® DUAL ARC SETUP FIGURE A.9 Item Desc. Machine Vantage ® 441X K4535-1 LE500X K5174-1 Machine Feeder LN-25X w/TVT K4267-2 K126 ® PRO Innershield ® 350A FCAW-SS Welding K126-12 Gun 15 ft 1/16-5/64 Weld Power Cable - Lug to Work Lug (3/0, 600A, 60%) - 35 K1842-35...
  • Page 22 VANTAGE 441X/LE500X INSTALLATION ® TIG MODULE Item Desc. Machine Vantage ® 441X K4535-1 Machine LE500X K5174-1 FIGURE A.10 Accessory TIG Module K930-2 Control Cable 9 - 14 Pin Cable K936-1 Torch PTA-26 (25 ft) K1783-4 Foot Pedal Foot Amptrol (25 ft) K870 Electrode Cable Weld Power Cable - Lug to Lug (3/0, 600A,...
  • Page 23 VANTAGE 441X/LE500X OPERATION ® OPERATION RECOMMENDED APPLICATIONS WELDER - The Vantage 441X/LE500X provides excellent ® SAFETY INSTRUCTIONS constant current DC welding output for stick (SMAW) and TIG Read and understand this entire section (GTAW) weld-ing. The Vantage 441X/LE500X also provides ®...
  • Page 24 VANTAGE 441X/LE500X OPERATION ® STARTING THE ENGINE ADD FUEL 1. Remove all plugs connected to the AC power receptacles. WARNING 2. Set RUN / STOP / IDLE switch to AUTO IDLE / RUN position. DIESEL FUEL can cause re. 3. Press START / GLOW PLUG switch and hold until machine •...
  • Page 25 VANTAGE 441X/LE500X OPERATION ® CONTROLS AND SETTINGS All welder and engine controls are located on the case front panel. Refer to Figure B.1 and the explanations that follow. 1D. FUEL LEVEL - Displays the level of diesel fuel in the fuel tank. SYSTEM CONTROLS The operator must watch the fuel level closely to prevent 1.
  • Page 26 VANTAGE 441X/LE500X OPERATION ® 3. CROSSLINC INDICATOR LIGHT - When a CrossLinc 8. 42V / 120V WIRE FEEDER VOLTAGE SWITCH enabled device is connected with the machine using the stan- Toggles output of 14-pin connector to voltage requirement of dard weld power cable and the device's sense lead is attached wire feeder.
  • Page 27 VANTAGE 441X/LE500X OPERATION ® 11. START / GLOW PLUG SWITCH - Energizes the starter 16. HIDDEN MENU BUTTON - The hidden setup menu can motor to crank the engine. With the engine RUN /STOP / IDLE be accessed any time the machine is on with the engine run- switch in the "RUN"...
  • Page 28 VANTAGE 441X/LE500X OPERATION ® 26. 240 VAC THREE PHASE RECEPTACLE - This is a 32. DIAGNOSTIC PLUG - This is used by field service 240 VAC (15-50R) receptacle that provides 240 VAC three shops to connect and troubleshoot engine error codes, found on the firewall inside the machine.
  • Page 29 VANTAGE 441X/LE500X OPERATION ® FIGURE B.9 HIDDEN SETUP MENU FUNCTIONS HOT START CONTROL Hot start can be set based off weld mode. Non-applicable weld REMOTE CONNECTOR SELECTION FOR STICK modes will not display hot start. AND DOWNHILL PIPE MODES. The left display will show “Hot” and “Strt” alternately at 0.5 second intervals.
  • Page 30 VANTAGE 441X/LE500X OPERATION ® CROSSLINC IN CV MODES RESET BACK TO DEFAULT SETTINGS CrossLinc can be enabled for CV modes (VRD will be off in CV Pressing and holding the hidden reset push button for 5 seconds modes). will cause certain stored values to be reset to defaults. The stored The left display will show "CUC"...
  • Page 31 ® the builder/user. Many variables beyond the control of The 441X/LE500X . Lincoln Electric Company affect the results obtained in In non-synergic modes, the WFS control behaves like a applying these programs. These variables include, but are conventional power source where WFS and voltage are not limited to, welding procedure, plate chemistry and independent adjustments.
  • Page 32 VANTAGE 441X/LE500X OPERATION ® WELDER OPERATION HIGH FREQUENCY TIG OPTIONS CC-STICK MODE In general the ‘Touch Start’ feature avoids tungsten contamination The Vantage ® 441X/LE500X can be used with a broad range of DC without the use of a high frequency unit. If the use of a high stick electrodes.
  • Page 33 VANTAGE 441X/LE500X OPERATION ® SETTINGS WHEN USING THE K930-2 TIG MODULE • Set the WELD MODE switch to the TOUCH START TIG setting. • Set the RUN / STOP / IDLE switch to the AUTO IDLE / RUN position. • Set the WELDING TERMINALS switch to the REMOTELY CONTROLLED position.

  • Page 34: Cv-Wire Mode

    VANTAGE 441X/LE500X OPERATION ® CV-WIRE MODE NOTE: If desired the CV-WIRE mode can be used for arc gouging applications. Connect a wire feeder to the Vantage ® 441X/LE500X and set welder controls according to the instructions listed earlier in this section.

  • Page 35: Pulse Welding

    VANTAGE 441X/LE500X OPERATION ® PULSE WELDING UltimArc™ Control Pulse welding procedures are set by controlling an overall “arc UltimArc™ Control adjusts the focus or shape of the arc. length” variable. When pulse welding, the arc voltage is highly UltimArc™ Control is adjustable from -10.0 to +10.0 with a dependent upon the waveform.

  • Page 36: Crosslinc

    VANTAGE 441X/LE500X OPERATION ® TABLE B.4 The following modes can be accessed via an ArcLink feeder: ® Synergic CV Modes Metal- Steel Stainless Flux C ore Alum inu m Cored Diameter Argon Argon Argon CO 2 Tri-M ix Argon M ix 4043 5356 M ix...

  • Page 37: Auxiliary Power Operation

    VANTAGE 441X/LE500X OPERATION ® AUXILIARY POWER OPERATION SIMULTANEOUS WELDING AND AUXILIARY POWER LOADS Start the engine and set the RUN / STOP / IDLE switch to the desired operating mode. Full power is available regardless of the The auxiliary power capacity previously stated is maintained welding control settings, if no welding current is being drawn.
  • Page 38 VANTAGE 441X/LE500X OPERATION ® GFCI MODULE WARNING • An electric shock can result in serious injury or death. • Always perform the GFCI test before using the generator. If the GFCI system fails the test, the machine must be repaired by an authorized service center. •...

  • Page 39: Typical Fuel Consumption

    VANTAGE 441X/LE500X OPERATION ® TYPICAL FUEL CONSUMPTION Refer to Table B.7 for typical fuel consumption of the Vantage ® 441X/LE500X Engine for various operating scenarios. TABLE B.7 (Perkins 404F-E22T) Fuel Consumption RUN TIME (HRS.) GAL. / HR. L / HR. WITH FULL TANK* High Idle...

  • Page 40: Accessories

    VANTAGE 441X/LE500X ACCESSORIES ® ACCESSORIES Spark Arrestor Mounts to exhaust tube to signi cantly reduce spark emissions. Order: K2864-1 CROSSLINC ACCESSORIES ® Perkins Engine Service Kit LN-25X One easy-to-purchase kit including all the needed engine lters to True Voltage Technology (TVT) is now included with the LN-25X maintain peak welder performance.

  • Page 41: Wire Feeders & Guns

    VANTAGE 441X/LE500X ACCESSORIES ® POWER SOURCES TIG Module Square Wave TIG 200 Supplies high frequency for superior starting, contactor control, remote control capability, and a gas valve for AC or DC TIG Portable TIG and stick welding machine that provides smooth and welding.

  • Page 42: Maintenance

    VANTAGE 441X/LE500X MAINTENANCE ® MAINTENANCE ROUTINE AND PERIODIC MAINTENANCE DAILY SAFETY PRECAUTIONS • Check the engine oil level. READ AND UNDERSTAND ENTIRE SECTION BEFORE • Re ll the fuel tank to minimize moisture condensation in the OPERATING MACHINE. tank. • Open the water drain valve located on the bottom of the water WARNING separator element 1 or 2 turns and allow to drain into a container suitable for diesel fuel for 2 to 3 seconds.

  • Page 43: Engine Maintenance

    VANTAGE 441X/LE500X MAINTENANCE ® ENGINE MAINTENANCE Refer to the SERVICE PLAN section of the Engine Operator’s Manual for the recommended maintenance schedule of the following: a) Engine Oil and Filter b) Air Cleaner c) Fuel Filter and Delivery System d) Alternator Belt e) Battery f) Cooling System Refer to Table D.1 at the end of this section for various engine...
  • Page 44 VANTAGE 441X/LE500X ® MAINTENANCE Service Instructions Service Instructions Single- and Two-Stage Engine Air Cleaners Single- and Two-Stage Engine Air Cleaners Inspect the New Filter for Damage Inspect the New Filter for Damage Remove the Filter Remove the Filter Inspect the new filter carefully, paying attention to Unfasten or unlatch the the inside of the open end, which is the service cover.

  • Page 45: Fuel Filters

    VANTAGE 441X/LE500X MAINTENANCE ® FUEL FILTERS COOLING SYSTEM The cooling system of the engine needs to be checked and WARNING cleaned periodically. (Consult the Engine Owner's Manual for the proper procedures and frequency). When working on the fuel system Coolant needs to be added at the radiator filler neck after •...

  • Page 46: Battery Handling

    VANTAGE 441X/LE500X MAINTENANCE ® BATTERY HANDLING ENGINE OIL CHANGE Drain the engine oil while the engine is warm to assure rapid and WARNING complete draining. It is recommended that each time the oil is changed the oil lter be changed as well. GASES FROM BATTERY can •...

  • Page 47: Tightening The Fan Belt

    These preventative maintenance periods apply to average conditions of operation. If necessary use shorter periods. WARRANTY WORK PERFORMED ON THE ENGINE CONTAINED IN THIS MACHINE, IF NOT BILLABLE TO THE ENGINE MANUFACTURER, SHOULD BE PRE-APPROVED BY CALLING THE LINCOLN ELECTRIC COMPANY AT 888-935-3877 S33316 VM...

  • Page 48: Gfci Maintenance

    VANTAGE 441X/LE500X MAINTENANCE ® GFCI MAINTENANCE WARNING • An electric shock can result in serious injury or death. • Always perform the GFCI test before using the generator. If the GFCI system fails the test, the machine must be repaired by an authorized service center.

  • Page 49: Troubleshooting

    VANTAGE 441X/LE500X TROUBLESHOOTING ® TROUBLESHOOTING HOW TO USE TROUBLESHOOTING GUIDE WARNING Service and Repair should only be performed by Lincoln Electric Factory Trained Personnel. Unauthorized repairs performed on this equipment may result in danger to the technician and machine operator and will invalidate your factory warranty.
  • Page 50 VANTAGE 441X/LE500X TROUBLESHOOTING ® Observe all Safety Guidelines detailed throughout this manual PROBLEMS POSSIBLE RECOMMENDED (SYMPTOMS) CAUSE COURSE OF ACTION ENGINE PROBLEMS Major Physical or Electrical Damage . Contact your Local Lincoln is Evident. Authorized Field Service Facility. 1. Battery low. Engine will not crank 2.
  • Page 51 VANTAGE 441X/LE500X TROUBLESHOOTING ® Observe all Safety Guidelines detailed throughout this manual PROBLEMS POSSIBLE RECOMMENDED (SYMPTOMS) CAUSE COURSE OF ACTION FUNCTION PROBLEMS Battery does not stay charged. 1. Faulty battery. 2. Faulty engine alternator. 3. Loose or broken lead in charging circuit.
  • Page 52 VANTAGE 441X/LE500X TROUBLESHOOTING ® Observe all Safety Guidelines detailed throughout this manual PROBLEMS POSSIBLE RECOMMENDED (SYMPTOMS) CAUSE COURSE OF ACTION FUNCTION PROBLEMS 1. Open breakers may need to be No auxiliary power. reset. 2. Faulty receptacle. 3. Faulty auxiliary circuit wiring. 4.
  • Page 53 VANTAGE 441X/LE500X WIRING DIAGRAMS ®...
  • Page 54 VANTAGE 441X/LE500X DIMENSION PRINT ®...
  • Page 55 WARNING Do not touch electrically live parts or Keep flammable materials away. Wear eye, ear and body protection. electrode with skin or wet clothing. Insulate yourself from work and AVISO DE ground. Spanish PRECAuCION No toque las partes o los electrodos Mantenga el material combustible Protéjase los ojos, los oídos y el bajo carga con la piel o ropa moja-...
  • Page 56 WARNING Keep your head out of fumes. Turn power off before servicing. Do not operate with panel open or Use ventilation or exhaust to guards off. remove fumes from breathing zone. AVISO DE Spanish PRECAuCION Los humos fuera de la zona de res- Desconectar el cable de ali- No operar con panel abierto o piración.
  • Page 57 We respond to our customers based on the best information in our possession at that time. Lincoln Electric is not in a position to warrant or guarantee such advice, and assumes no liability, with respect to such information or advice.

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