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Lincoln Electric IM805 User's Manual

1. syed wos Aeme dose pea Alayyeg SAILWDIN 122000259 e eoe d ui deey e uedo sjeued 93ejedo jou ONINHVM 7 NOLLO3NNOO OIL SH3T3M ANIONS Vantage 500 DEUTZ LINCOLN E DIAGRAMS F 13 F 13 CONNECTION DIAGRAM 918175 0002 60 qasis3d SV NOILISOd 3101 OLAV NI HOLIMS H3 dI SOV 1d TN NOILISOd A T310I38 OL HOLIMS 5 430 T3M 39 Vd ON NOILISOd NI HOLIMS SGOW 39 1 ATWO 300819313 JHL 30 ALISV 10d SHL HILVN HOLIMS YSLSWLIOA Y30334 SHIM JHL NOLLISOd ALISIV TOd 40441540 401 SANLS 1041010 OL 318V9 LO3NNOO 8N IVANY 9NILVS3dO 33 SNOLLVONddV FYNLAS ANY 31VIO3ANWI 30 31949 LN3HSCYO JHL ALIOVaVO Y3dOYd 38 LSAW 531872 9NIQT3M 3013M ANIONS 3H NI O31ST1SNOILVOIJIO3dS 3408Y LSNPAV LON Od AHOLOV4 AHL LV 13S 34d SI S9NILL3S YONYSAOD 3NION3 JHL 2 39 VIAVO NYO HOIHM 39V L1OA Y30334 38M SHL NI ASVSYONI NV ASNVO TIM ADVANI JILLOYHL ONICIHHAAO ONILLAS HON 3AO9 9NISNVHO A8 Wed ANIONS J101 H9IH 30 3SV3H9NI LINN 0333 38IM OL 31875 4100419414 OL 5792 1OHINO9 2697 ON Id d318v9 1 OL siy 2 sped j e2u1
2. Section Optional Field Installed Accessories C 1 Maintenance eiue ee eer rc e eux Gia ee ru Ue E ae Section D Safety Pr ca tlons ioi cede Pu D 1 Routine and Periodic Maintenance 1 D 1 Engine Maintenance Ry ee RIEF PRIORE eR eed eae dub oat Reden det D 1 imd c rr D 1 Fuel ur Rae Low RU dona iar d Ra D 2 Fuel Pre Filter Water Separator Assembly D 2 Water Separator 22 a tee SE ee Das bed de D 2 Secondary Fuel Filter 222234262484 Ere ek mex Re RR Ed vua D 2 Goolirig SySteli eos Ere ads ORE e ORI E RE RH D 3 Cooling Blower Bell 2422588 ses ten aee eps Reprod Ree eee nets D 3 Battery Handling ie eR Rh neo ix RR E Ren D 3 Charging the Battery 2242848500 oa RR pev P D 4 Nameplate Warning Decal D 4 Welder Generator Maintenance D 4 Engine Maintenance Components D 4 Troubleshooting 0280800006 ona Us GR v Section E Wiring Connection
3. jou esn e3sui jeuuosjed AIUO e Buas eJojeq sued pee Aeyeg 290002510 e ui spen deey e uedo sjoued 9je1edo jou oq ONINHVM 7 NOILO3NNOO 1 414V9 2987 544014 3NI9N3 Vantage 500 DEUTZ LINCOLN 2 DIAGRAMS F 6 F 6 CONNECTION DIAGRAM 686625 31V In SNI ANY 1 ATIVNGIAIGNI GASNNN HOV3 ALVINSNI AO 38IM OL HOLIMS HOLO3T3S JHL NOILISOd ALIHV10d 3004191313 Q38IS3Q 199135 OL HOLIMS H3ISIALTOA ASN WANVW ONIIV33dO 435 SNOIIVOIddV SYNLNA ANY SLVIGAWWI 40 41949 ALNA ANY LNIYYNO JHL ALIOVdVO H3dOHd LSNW 3 THVO ONIGTAM TWANVW 9NLIVS3dO S30 T3M 3NION3 SHL NI 031511 5 21 12446 3AO8V LSAPAV LON OG AHOLOV3 JHL 13S 38d SI ONILLAS ANIONS 1 Q39VIAVG 38 AV 51 2 12 TOHLNO9 830334 JYIM SETOA 0Y S309 39VETOA SIHL 41 SOVIIOA Ov IHL IHL NI 3SV389NI NV ASNVO 39 VMNTT 31LLOSHL JHL 9NIGISISAO ONILLAS SONS3AO9 JHL ONIONVHO Wd ANIONS 30 3SV389NI NOLLOVO LINN 9995 38HIM OL J18VO 3100419313 771 318VO TWSUYAAINN 2987 9613 YOM OL 300419313 T9
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5. 2004 Vantage 500 DEUTZ For use with machines having Code Numbers 10995 Safety Depends on You Lincoln arc welding and cutting equipment is designed and built with safety mind However your overall safety can be increased by proper installation and thoughtful operation on your part DO NOT INSTALL OPERATE OR REPAIR THIS EQUIPMENT WITHOUT READING THIS MANUAL AND THE SAFETY PRECAUTIONS CONTAINED THROUGHOUT Most importantly think before you act and be careful OPERATOR S MANUAL LINCOLN Copyright 2004 Lincoln Global Inc World s Leader in Welding and Cutting Products Sales and Service through Subsidiaries and Distributors Worldwide Cleveland Ohio 44117 1199 USA Tel 216 481 8100 Fax 216 486 1751 Web Site www lincolnelectric com i SAFETY i N CALIFORNIA PROPOSITION 65 WARNINGS For Diesel Engines diesel engine exhaust and some of its constituents are known to the State of California to cause cancer birth defects and other reproductive harm PERFORMED ONLY BY QUALIFIED INDIVIDUALS FOR ENGINE powered equipment 1 a Turn the engine off before troubleshooting and maintenance work unless the maintenance work requires it to be running 3 1 b Operate engines in open well ventilated areas or vent the engine exhaust fumes outdoors 1 c Do not add fuel near an open flame welding arc or when the engine is running Stop
6. Nid eL 0 9 JAIM 8 N1 jueuudinbe 10 2 5 10 sued jou OG esn jejsu pinous e 5 syed woy de9y a QV31 J3ALIVO3N 5 a eoe d ui spien6 des uedo sjeued um eje1edo jou oq e I ONINHVM 7 INVHOVIG NOLLO3NNOO 8 1 2983 Vantage 500 DEUTZ 7 DIAGRAMS CONNECTION DIAGRAM d EZELIN 0002 270 AN INE 3 8307139 SH OLNO ATAWSSSV 3 477 SN 3438 ZHL N3 8V 010 9 1 381 CN NMO S SMzZHOS IZAH 7 1 NIJ OH 108 SVH LIVE cv av ELM ACSINISSV 514 0 NO 130 Vid ON 39v 1d3M AINO 008 00 adNVWIAOS 3H L SNOLLONALSNI NOLLYTIVLSNI 712345 1V43d0 AN V AHON IH A4 1411N OL LON Sv NOLLVOO TLNBIN3ANOO V S HA1dVCY TAN SIN3NOdIAOO 914 9173 OL 29 171 LON L 8 Sv HOTS SIN3NO4IAC9 ANY OLLON SV N3 vL 38 OL 8 3492 MOZAS SNLLNAOW NI M NOILAWS SNOILONALSNI NOLLV TIV LSNI LA 4314v OV ATATIOHINO9 A Z10WE3 OL HOLIMS STYNINHEL ONICTIHM AHL LES 7 7 ALONZE OL HOLIMS ALOWSY VSO SEL LAS 461 SI T
7. 117134 345 p 9 2 50757 35019 OL AVTSY NOILV IOSI SSN 1014100 303 WNOIS V LVHL 5440333 401 60 31 GASNNN H9V3 SLWINSNI NOILISOd 38IM AO AHL NI HOLIMS 3dOIW SHL 39V 1d OL OL HOLIMS YSLAWLIOA 330333 38IM SHL NOILISOd ALISV 10d Q33 30 303 SONALS 015318 2 9NIQT3M L93NNOO 3149 3003193713 JHL 30 10 JHL NOILVOI Idd 40 41949 ALNG ANY 1 344092 401 09215 38 LSNW 31970 INONVIN ONLLVH3dO YSCTAM 3NION3 JHL NI 131511 SNOLIVOHIO3dS 3408Y 15 LON OG 3HL LV 145 SI ONILLAS YHONYSAOS ANIONS JHL 2 TOMINOO JHL 39VINvO NYO HOIHM 39vL 10A 303343 SHIM NI 3SV3SONI NV ASNVO ADVANI 3TLLOSHI JHL ONILLAS NONSHSACO SHL ONIONVHO Ad Wd 3NISN3 3 QI 30 3SV3HONI TOYLNOD LNdLNO 31084 NIA LINN G34 OL 37872 SGONLOATA NOILNVO Wl T DIAGRAMS CONNECTION DIAGRAM 304006 JO IYNINHAL HHOM OL S193NNOO OL NOLLO3NNOO AALANLIOA 410343 SZ NOILOANNOS 3IAV H3 424105 S3MOd O CND 0 LE o AN OWA o m HO M3H13901 193NNOO E OM 1d S3OMWfIOS NO LON 19 TWSYAAINN 2985 MET o Q jue udinbe sjy 9011195 10 sued
8. b Locate the 2 access holes on the upper middle region of compartment wall just below the lift bale c Use the lifting strap to raise the lift bale to the full upright position This will align the mounting holes on the lift bale with the access holes d Secure the lift bale with 2 thread forming screws The Screws are provided in the shipped loose parts bag WARNING Lift only with equipment of adequate lifting capacity Be sure machine is stable when lifting Do not lift this machine using lift bale if it is equipped with a heavy accessory such as trailer or gas cylinder FALLING EQUIPMENT damaged cause injury Do not lift machine if lift bale is Do not operate machine while suspended from lift bale HIGH ALTITUDE OPERATION At higher altitudes output derating may be necessary For maximum rating derate the welder output 5 for every 300 meters 984 ft above 1500 meters 4920 ft For output of 500A and below derate the welder output 5 for every 300 meters 984 ft above 2100 meters 6888 ft Contact a Deutz Service Representative for any engine adjustments that may be required HIGH TEMPERATURE OPERATION At temperatures above 40 C 104 F output voltage derating may be necessary For maximum output current ratings derate welder voltage rating 2 volts for every 10 C 21 F above 40 C 10492 TOWING The recommended trailer for use with this equipment
9. 300 400 Amps 5 16 350 450 Amps 3 8 450 575 Amps PARALLELING When paralleling machines in order to combine their outputs all units must be operated in the CC STICK mode only at the same output settings To achieve this turn the WELD MODE switch to the CC STICK position Operation in other modes may produce erratic outputs and large output imbalances between the units AUXILIARY POWER OPERATION Start the engine and set the IDLER control switch to the desired operating mode Full power is available regardless of the welding control settings if no welding current is being drawn The auxiliary power of the Vantage consists of two 20 Amp 120VAC 5 20R GFCI duplex receptacles and one 50 Amp 120 240 VAC 14 50R receptacle The 120 240VAC receptacle can be split for single phase 120 VAC operation The auxiliary power capacity is 12 000 watts of 60 Hz single phase power The auxiliary power capacity rating in watts is equivalent to volt amperes at unity power factor The maximum permissible current of the 240 VAC output is 50 A The 240 VAC output can be split to provide two separate 120 VAC outputs with a maximum permissible current of 50 A per output to two separate 120 branch circuits Output voltage is within gt 10 at all loads up to rated capaci NOTE The two 120V GFCI receptacles and the two 120V circuits of the 120 240V receptacle are connected to different phases and cannot be paralleled The auxiliary powe
10. The digital meters allow the output voltage CV WIRE mode or current CC STICK DOWNHILL PIPE and TIG modes to be set prior to welding using the OUTPUT control knob During welding the meters display the actual output voltage VOLTS and current AMPS A memory feature holds the display of both meters on the seven seconds after welding is stopped This allows the operator to read the actual current and voltage just prior to when welding was ceased While the display is being held the left most decimal point in each display will be flashing The accuracy of the meters is 3 11 WELD MODE SELECTOR SWITCH Provides four selectable welding modes CV WIRE DOWNHILL PIPE CC STICK TOUCH START TIG 12 ARC CONTROL The ARC CONTROL WIRE STICK knob is active in the WIRE and STICK modes and has different functions in these modes This control is not active in the TIG mode CC STICK mode In this mode the ARC CONTROL knob sets the short circuit current arc force during stick welding Increasing the number from 10 Soft to 10 Crisp increases the short circuit current and prevents sticking of the electrode to the plate while welding This can also increase spatter It is recommended that the ARC CONTROL be set to the minimum number without electrode sticking Start with a setting at 0 DOWNHILL PIPE mode In this mode the ARC CONTROL knob sets the short circuit current arc force during stick welding to adjust for a soft or a more fo
11. electrically hot parts to touch a cylinder 7 your head and face away from the cylinder valve outlet when opening the cylinder valve 7 f Valve protection caps should always be in place and hand tight except when the cylinder is in use or connected for use 7 g Read and follow the instructions on compressed gas cylinders associated equipment and CGA publication Precautions for Safe Handling of Compressed Gases in Oylinders available from the Compressed Gas Association 1235 Jefferson Davis Highway Arlington VA 22202 FOR ELECTRICALLY powered equipment 8 a Turn off input power using the disconnect Switch at the fuse box before working on the equipment 8 b Install equipment in accordance with the National Electrical Code all local codes and the manufacturer s recommendations 8 c Ground the equipment in accordance with the National Electrical Code and the manufacturer s recommendations Mar 95 LINCOLN B iv SAFETY iv PR CAUTIONS DE S RET Pour votre propre protection lire et observer toutes les instructions et les pr cautions de s ret specifiques qui parraissent dans ce manuel aussi bien que les pr cautions de s ret g n rales suivantes S ret Pour Soudage A L Arc 1 Protegez vous contre la secousse lectrique Les circuits l lectrode et la pi ce sont sous tension quand la machine souder est en marche Eviter toujours tout con
12. esn ejsui pinoys jeuuossed Ajuo e 5 210 9q syed Aeme e pea e ui uedo sjaued ui jou 00 ONINHVM WV WVYSVIG NOLLO3NNOO J INGOW 10 1 09 ALOWSY LIOA Ct b 729M 1 SH3Q TAM 3NION3 Vantage 500 DEUTZ LINCOLN DIAGRAMS F 11 F 11 CONNECTION DIAGRAM 2484926 0002 22 01 Q34I 3Q SV NOILISOd 3101 HO 1 NI HOLIMS 414101 39VId 3N NOILISOd S IVNIIWE3L NIHOLIMS S IVNINS L 9NIQT3M SHL 39V Id NOILISOd SHL NI HOLIMS AHL ON 31800 300819313 JHL ALIHV 10d AHL HOLVW OL HOLIMS S313IL 10A 830334 38IM FHL NOILISOd ALINY 10d Q38lIS3G SGNLS 531979 SNIQTJM LO3NNOO E N TWANVW 9NILV3340 33 4913 ONY ALVICANWI dO 31949 ALNG JHL ALIOVdVO 5 S3 18VO SNIQT3M 318v9 300812313 MOM OL Qv31dl10 Y30334 SN JOSLNOO 310N3H TON3HdAV Nid 9 Nid vl ueuudinbe siy 891198 10 sured Aj e2u199 9 uonoi JOU esn ejsu pinoys jeuuosied e Buras eJojeq sured deey e pes apeg JALLVO3N 1290002610 e eoe d ui e
13. or as required by the electrode polarity being used Set the ARC CONTROL knob to 0 initially and adjust to suit CONNECTION OF AN LN 23P WIRE FEEDER TO THE VANTAGE Shut the welder off Connect the LN 23P per instructions on the appropriate connection diagram in the DIAGRAMS section NOTE When connecting an LN 23P to the Vantage a K350 1 adapter kit must be used Set the WIRE FEEDER VOLTMETER switch to Set the SELECTOR switch to CV WIRE position Set the WELDING TERMINALS switch to REMOTELY CONTROLLED Set the ARC CONTROL to desired crispness f you are using an LN 23P with the K350 1 adapter kit the electrode is not energized until the gun trigger is closed Vantage 500 DEUTZ LINCOLN 5 9 INSTALLATION A 9 CONNECTION OF THE LN 25 TO THE VANTAGE The LN 25 with or without an internal contactor may be used with the Vantage See the appropriate connection diagram in the DIAGRAMS section NOTE The LN 25 K431 Remote Control Module and K432 Remote Cable are not recommended for use with the Vantage Shut the welder off For electrode Positive connect the electrode cable from the LN 25 to the terminal of the welder and work cable to the terminal of the welder For electrode Negative connect the electrode cable from the LN 25 to the terminal of the welder and work cable to the terminal of the welder Attach the single le
14. ppt IN 42 M solvis EM soda oms IMZ SM 9494 3ddOH9 1431 HOLIMS 3AILISOd NINMOHS HOLIMS 8802 ATl8W3SSV Wald SSVdA8 Pie mono vd 1ndLno NO lanis aunouo 5902 SdINVOO ANOS m 21 00S 39V LNVA Vantage 500 DEUTZ 2 DIAGRAMS CONNECTION DIAGRAM 9 18Lv S 0002 22 01 NOILISOd NI HOLIMS 47101 NOILISOd GSTIOULNOD AT310 38 OL HOLIMS S IVNIINS3 L FOV Id NOI LISOd 3l M A9 JHL NI HOLIMS 3HL32Vld Q38lIS30 50715 SATAVO ONITTAM LOANNOO EN NOILVO IddV 40 319A9 ALNG ANY LN3 Y N9 803 0343 38 LSNN S3 18VO9 RNV ONLLVH3SdO 330 TAM ANIONS JHL NI 931511 SNOLEVOI3IO3dS 3AO8V LSnfQv LON AHOLOV3 138 34d SI SNILLAS 3NISN3 2 JHL 39VIAVO NYO HOIHM 330333 38IM JHL 3SV3HONI NV 3env9 TIM 39VXNET 31LLOSHL JHL 9NIGISS3AO SNILE3S HON83AO9 JHL ONISNVHO A8 3NISN3 JHL 40 ASWAYONI 39unos FINGOW 1041 02 SHL 39VINVO NI L 10833 Q 1002 NOILISOd HOLIMS 1938809NI FINGON 31VH
15. Only qualified personnel should operate this equipment ADDITIONAL SAFETY PRECAUTIONS Always operate the welder with the hinged door closed and the side panels in place as these provide maximum protection from moving parts and insure proper cooling air flow GENERAL DESCRIPTION The Vantage is a diesel engine driven welding power source The machine uses a brush type alternating current generator for DC multi purpose welding and for 120 240 VAC auxiliary standby power The welding control system uses state of the art Chopper Technology RECOMMENDED APPLICATIONS WELDER The Vantage provides excellent constant current DC welding output for stick SMAW and TIG welding The Vantage also provides excellent constant voltage DC welding output for MIG GMAW Innershield FCAW Outershield FCAW G and Metal Core welding In addition the Vantage can be used for Arc Gouging with carbons up to 3 8 10mm in diameter The Vantage is not recommended for pipe thawing GENERATOR The Vantage provides smooth 120 240 VAC output for auxiliary power and emergency standby power Vantage 500 DEUTZ LINCOLN amp 2 OPERATION B 2 CONTROLS AND SETTINGS All welder and engine controls are located on the case front panel Refer to Figure 1 and the explanations that follow Figure B 1 Case Front Panel Controls ra U ENGINE CONTROLS Items 1 through 8 1 RUN STOP Q SWITCH Toggling the switch to the RUN posit
16. auxiliary is 50 amps Loading above the rated output will available in the optional K802R plug kit reduce output voltage below the allowable 10 of rated voltage which may damage appliances or other motor driven 4 Plug this cable into the 50 Amp 120 240 Volt receptacle on the equipment and may result in overheating of the Vantage Vantage case front engine Figure A 2 Connection of the Vantage to Premises Wiring 240 VOLT GROUNDED CONDUCTOR 240 Volt POWER B 120 VOLT a 60 Hz 3 Wire COMPANY NEUTRAL LOAD DOUBLE POLE DOUBLE THROW SWITCH RATING TO BE THE SAME AS OR GREATER THAN PREMISES SERVICE OVERCURRENT PROTECTION PREMISES DISCONNECT AND SERVICE OVERCURRENT 240 VOLT PROTECTION DOUBLE POLE CIRCUIT 240 VOLT BREAKER 50 AMP 120 240 VOLT PLUG NEMA TYPE 14 50 1 50 AMP 120 240 VOLT S NOTE No 6 COPPER CONDUCTOR CABLE SEE RECEPTACLE NATIONAL ELECTRICAL CODE FOR ALTERNATE WIRE SIZE RECOMMENDATIONS Vantage 500 DEUTZ LINCOLN 5 8 INSTALLATION A 8 CONNECTION OF LINCOLN ELECTRIC WIRE FEEDERS Shut off welder before making any electrical connections CONNECTION OF LN 7 LN 8 OR LN 742 TO THE VANTAGE Shut the welder off Connect the LN 7 LN 8 or LN 742 per instructions on the appropriate connection diagram in the DIAGRAMS section Set the WIRE FEEDER VOLTMETER switch to either or as required
17. by the electrode being used Set the SELECTOR switch to the CV WIRE position Adjust the ARC CONTROL knob to desired Crispness SOFT for MIG and CRISP for INNERSHIELD Set the WELDING TERMINALS switch to the REMOTELY CONTROLLED position CONNECTION OF LN 15 TO THE VANTAGE These connections instructions apply to both the LN 15 Across The Arc and Control Cable models The LN 15 has an internal contactor and the electrode is not energized until the gun trigger is closed When the gun trigger is closed the wire will begin to feed and the welding process is started Shut the welder off For electrode Positive connect the electrode cable to the terminal of the welder and work cable to the terminal of the welder For electrode Negative connect the electrode cable terminal of the welder and work cable to the terminal of the welder Across The Arc Model Attach the single lead from the front of the LN 15 to work using the spring clip at the end of the lead This is a control lead to supply current to the wire feeder motor it does not carry welding current Control Cable Model Connect Control Cable between Engine Welder and Feeder Set the MODE switch to the CV WIRE position Across The Arc Model Set the WELD TERMINALS switch to WELD TERMINALS ON Control Cable Model Set the WELD TERMINALS switch to REMOTELY CONTROLLED Set the WIRE FEEDER VOLTMETER switch to either
18. ek ERRARE a e eR AA EUR B 4 Starting The Engine cete ee tees ated eer ste B 4 Stopping the Engine vedic a cee due RR LPs bent B 4 Typical Fuel Consumption B 5 Welding Operation 2er Recien bee ba B 5 pneu sg 5 Stick Welding ER ERE a eleg ea e B 5 CC Stick Mode asce sirai bus PEO RR p EE VENTE ERRARE B 5 Downhill Pipe Mode eee ees Re teenie head B 5 Touch Start ome Rer 1 Rex POE ahead dca cs B 5 Vantage Settings when using HI FREQ Unit and TIG Module B 5 Typical Current Ranges for Tungsten Electrodes B 6 CV WireMOGe act pacers wide des Bake Ee Re M n B 7 Arc GOUGING 2 7 Parallelinig 7 Auxiliary Power Operation 1 B 7 Simultaneous Welding and Auxiliary Power Loads B 7 Simultaneous Welding and Power Loads Extension Cord Length Recommendations B 8 Vantage 500 DEUTZ LINCOLN 5 vii vii TABLE OF CONTENTS Accessories
19. for road in plant and yard towing by a vehicle is Lincoln s K953 1 If the user adapts a non Lincoln trailer he must assume responsibility that the method of attachment and usage does not result in a safety hazard nor damage the welding equipment Some of the factors to be considered are as follows 1 Design capacity of trailer vs weight of Lincoln equipment and likely additional attachments 2 Proper support of and attachment to the base of the welding equipment so that there will be no undue stress to the trailer s framework 3 Proper placement of the equipment on the trailer to insure stability side to side and front to back when being moved and when standing by itself 4 Typical conditions of use such as travel speed roughness of surface on which the trailer will be operated and environmental conditions 5 Proper preventative maintenance of trailer 6 Conformance with federal state and local laws Consult applicable federal state and local laws regarding specific requirements for use on public highways VEHICLE MOUNTING WARNING Improperly mounted concentrated loads may cause unstable vehicle handling and tires or other components to fail Only transport this Equipment on serviceable vehicles which are rated and designed for such loads Distribute balance and secure loads so vehicle is stable under conditions of use not exceed maximum rated loads for components such as susp
20. holder Cable is rated at 500 amps 60 duty cycle K767 2 FOUR WHEELED STEERABLE YARD TRAILER For in plant and yard towing K802N POWER PLUG KIT Provides four 120V plugs rated at 20 amps each and one dual voltage full KVA plug rated at 120 240V 50 amps 120V plug may not be compatible with NEMA common household receptacles K802 R POWER PLUG KIT Provides four 120V plugs rated 15 amps each and one dual voltage full KVA plug rated at 120 240V 50 amps 120V plug is compatible with NEMA common household receptacles K857 25 ft 7 5 m or K857 1 100 ft 30 4 m REMOTE CONTROL Portable control provides same dial range as the output control on the welder from a location up to the specified length from the welder Has convenient plug for easy connection to the welder The Vantage 500 DEUTZ is equipped with 6 pin connector for connecting the remote control K953 1 TRAILER Two wheeled trailer with optional fender and light package For highway use consult applicable federal state and local laws regarding possible additional requirements There is a choice of 2 hitches a fender amp a light package Order K953 1 Trailer K958 1 Ball Hitch K958 2 Lunette Eye Hitch K959 1 Fender amp Light Kit K965 1 Cable Rack K887 1 ETHER START KIT Provides maximum cold weather starting assistance for frequent starting below 10 F 12 2 C Required Ether tank is not provided with kit K899 1 SPARK ARRESTOR KIT Easily mounts to
21. may need to be replaced 6 High oil temperature or low oil pressure engine protection light lit If all recommended possible areas of misadjustment have been checked and the problem persists Contact your local Lincoln Authorized Field Service Facility Engine shuts down shortly after starting 1 Low oil pressure engine protection light lit Check oil level Consult engine service dealer 2 High oil temperature engine protection light lit 3 Faulty oil pressure switch 4 Faulty oil temperature switch Contact authorized local Engine Service Shop 5 Low output of battery charging alternator battery charging light lit Engine shuts down while under a load 1 High oil temperature Engine runs rough 1 Dirty fuel or air filters may need cleaned replaced 2 Water in fuel Engine will not shut off 1 Fuel Shutdown solenoid not functioning properly linkage binding elf for any reason you do not understand the test procedures 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 DEUTZ LINCOLN B 3 TROUBLESHOOTING E 3 PROBLEMS SYMPTOMS Battery does not stay charged POSSIBLE AREAS OF MISADJUSTMENT S 1 Faulty battery 2 Faulty engine alternator 3 Loose or broken lead in charging circuit 4 Loo
22. oxi re 5 EN AZL Waluvis GION31OS Sjeued einsojoue eui 1 10 eip oyioeds eu siu eyeinooe eq Jou 10 SI SIUL ILON HOVE 301S 1431NO Qnis 1 Zi ponco lennooc 9 TW wuahaluad aNIONa a zr annus er zlo HOSN3 AT va ose E omes dure HOLIMS HOSN3S SanivsadWwal 3 97 HOLIMS dOLS NNY lasez vaz HOLIMS 8 HOSN3S aYNSSJYd 110 1 s99 we NOLINS LYVLS GION31OS NMOGLNHS est 2 asr yanis E Wee anis Y ee mos panos 8262 i oe 2 2 107 ae H3 13IN YNOH vr aayos
23. standard muffler K949 1 OIL DRAIN KIT Includes ball valve hose and clamp K1751 1 COLD WEATHER KIT Air recirculation system maintain Deutz engine temperature in extremely cold weather conditions K1816 1 Full KVA Adapter Kit Plugs into the 120 240V NEMA 14 50R receptacle on the case front which accepts 4 prong plugs and converts it to NEMA 6 50R receptacle which accepts 3 prong plugs for connection to Lincoln Equipment with a NEMA 6 50P plug A WARNING Pipe Thawing with an arc welder can cause fire explosion damage to electric wiring or to the arc welder if done improperly The use of an arc welder for pipe thawing is not approved by the CSA nor is it recommended or supported by Lincoln Electric Vantage 500 DEUTZ LINCOLN amp D 1 MAINTENANCE D 1 SAFETY PRECAUTIONS Have a qualified technician do the maintenance and troubleshooting work Turn the engine off before working inside the machine Remove guards only when necessary and replace them when the maintenance requiring their removal is complete Always use the greatest care when working near moving parts Read the Safety Precautions in front of this manual and the engine instruction manual before working on this machine 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 or repairing the e
24. the engine and allow it to cool before refuelling to prevent spilled fuel from vaporizing on contact with hot engine parts and igniting Do not spill fuel when filling tank If fuel is spilled wipe it up and do not start engine until fumes 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 or repairing equipment 1 e In some cases it may be necessary to remove safety guards to perform required maintenance Remove guards only when necessary and replace them when the maintenance requiring their removal is complete Always use the greatest care when working near moving parts 14 Do not put your hands near the engine fan Do not attempt to override the governor or idler by pushing on the throttle control rods AW while the engine is running 1 9 To prevent accidentally starting petrol engines while turning the engine or welding generator during maintenance work disconnect the spark plug wires distributor cap or magneto wire as appropriate ARC WELDING CAN BE HAZARDOUS PROTECT YOURSELF AND OTHERS FROM POSSIBLE SERIOUS INJURY OR DEATH KEEP CHILDREN AWAY PACEMAKER WEARERS SHOULD CONSULT WITH THEIR DOCTOR BEFORE OPERATING Read and understand the following safety highlights For additional safety information it is strongly recommended that you
25. welding They may explode 6 f Sparks and spatter are thrown from the welding arc Wear oil free protective garments such as leather gloves heavy shirt cuffless trousers high shoes and a cap over your hair Wear ear plugs when welding out of position or in confined places Always wear safety glasses with side shields when in a welding area 6 9 Connect the work cable to the work as close to the welding area as possible Work cables connected to the building framework or other locations away from the welding area increase the possibility of the welding current passing through lifting chains crane cables or other alternate circuits This can create fire hazards or overheat lifting chains or cables until they fail 6 h Also see Item 1c CYLINDER may explode if damaged 77 Use only compressed gas oylinders containing the correct shielding gas for the process used and properly operating regulators designed for the gas and pressure used All hoses fittings etc should be suitable for the application and maintained in good condition 7 b Always keep cylinders in an upright position and securely chained to an undercarriage or fixed support 7 c Oylinders should be located Away from areas where they may be struck or subjected to physical damage Asafe distance from arc welding or cutting operations and any other source of heat sparks or flame 7 d Never allow the electrode electrode holder or any other
26. 1 2 TIG TORCH Diameter Thoriated Thoriated Aluminum Stainless Steel Nozzle mm in Tungsten Tungsten Size 4 5 25 0 010 2 15 3 2 4 3 8 2 4 3 8 4 5 6 50 0 020 5 20 3 3 5 5 10 3 5 5 10 1 0 0 040 15 80 3 3 5 5 10 3 5 5 10 1 6 1 16 70 150 10 20 3 5 5 10 4 6 9 13 5 6 2 4 3 32 150 250 15 30 6 8 13 17 5 7 11 15 6 7 8 3 2 1 8 250 400 25 40 7 11 15 23 5 7 11 15 4 0 5 32 400 500 40 55 10 12 21 25 6 8 13 17 8 10 4 8 3 16 500 750 55 80 11 13 23 27 8 10 18 22 6 4 1 4 750 1000 80 125 13 15 28 32 11 13 23 27 When used with argon gas The current ranges shown must reduced when using argon helium or helium shielding gases Tungsten electrodes are classified as follows by the American Welding Society AWS Pure EWP 1 Thoriated EWTh 1 296 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 DCEP is not commonly used in these sizes TIG torch nozzle sizes are in multiples of 1 16ths of an inch 4 1 4 6 5 5 16 in 8 mm 6 3 8 10 7 7 16 11 mm 8 1 2 12 5 10 5 8in 16 TIG torch nozzles are typically made from alumina ceramic Special applications may require lava nozzles which are less prone to breakage but cannot withstand high temperatures
27. 12313 JHL lOd AHL HOLV OL HOLIMS HSLSNLIOA 830334 JHL NOILISOd 0341630 50718 OL STTHVO 9 LOANNOO 33 SNOILYONddY SYN LNA ANY SLVIGSWWI 40 319A9 ANY LN3SSf 12 AHL 804 ALIOVdV9 YAdOdd 30 38 LSNW 53 18 2 ONIGTAM INVI ONLLVH3dO 83013M 3NION3 JHL NI 031511 SNOLVOISIOAdS INdH 3AO8V LSNPaV LON OC ANOLOVS AHL 17 13S3Hd SI 9NILLJS YONYSAOD ANIONS JHL LINDYID SHL 39 VIAIVO NY HOIHM 39V L 10A 3333 OV NI 3SV3SONI NV 3Snv9 TIM 31LLOSHL SHL SNIGIHSSAO 9NI LE3S HON3AO9 JHL Ad Wd 3NIDN3 3 1l AHL ASWSYONI LINN 334 OL TOO 319 3008103 HHOM OL JON3Hdllv 10841 02 3103 Nld 9 Sul 414V9 104 100 F8 51972 TW JON3Hd AV LNdNI Z N1 OL 1 514 2 5 10 syed Aj e9139e e jou esn eysu Pinoys jeuuosied e syed desy e peaj Aiepeg 3ALLVO3N 1euucosiq e ul desye uedo sjeued e1e1edo jou e ONINHVM WV NOLLO3NNOO 2 1 SH3Q TSM 3NISN3 Vantage 500 DEUTZ LINCOLN E 5 1181906 0002 20 24334 y SHIM IU OL Loz 4987 1 ASVPTXOV INDINIXVIW NOILONALSNI 324006 YAMOd OL 33438
28. 2 Never coil the electrode lead around your body 2 d 3 Do not place your body between the electrode and work cables If the electrode cable is on your right side the work cable should also be on your right side 2 4 4 Connect the work cable to the workplace close as possible to the area being welded 2 d 5 Do not work next to welding power source Mar 95 LINCOLN B SAFETY ELECTRIC SHOCK can kill The electrode and work or ground circuits are electrically hot when the welder is on Do not touch these hot parts with your bare skin or wet clothing Wear dry hole free gloves to insulate hands Insulate yourself from work and ground using dry insulation Make certain the insulation is large enough to cover your full area of physical contact with work and ground 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 semi automatic or automatic wire welding the electrode electrode reel welding head nozzle or semi
29. 3dO OL ONILdWALLY 380438 48050712 12 1 02 NTIOONIT IHL NI SI HOLIMS FINGOW 104 INOO 1VH I 3415 38 FINGOW 1OH1NOO OL 418V9 OL 27870 LAdNI 219v143934 01 1697 ALOWSY 9 Bu a NN9 10085 GC 18v FINGOW 319V1d3039 95 8877 830332 38IM v Dou cm jueudmnbe siy 92i Jes 10 sjed Aye aupeje yanay jou esn jejsui pjnous jeuuo sec p Auge 810jeq w keme Alone 3ALLVO3N osd e deoye usdo sjgued ui 98900 jou ONIN SV NOLLO3NNOO NN9 100645 2877 8877 01 1699 SHA TSM ANIDNA Vantage 500 DEUTZ LINCOLN 8 F 3 DIAGRAMS CONNECTION DIAGRAM 886625 ALVINSNI ANY SAYFI 321195 YN GV31 GASNNN HOV3 SLVINSNI IOH1NOO 3 103 OL GSHOLIMS ATIVOILVNOLNY SI TOH LNOO G3Sh SI TOH LNOO LNdLNO SLOWSY dl ON NOILISOd 3 18VO 1 1 Y40334 34IM OL HOLIMS 30334 3HIM 39V Id AO ONIGTAM FIM OL HOLIMS 4HO1IO3T3S JHL NOILISOd ALIHV lOd 3008193713 Q3HIS3G LOATAS OL HOLIMS YSLAWLIOA ASN SN ONIIV33dO 338 39873 ANY 1 40 41949 ALNA ANY LNIYYNO JHL ALIOVdVO 38 15 318V9 ONIGTAM TWANVW 0 Y3013M ANIONS
30. 5 e Also see Item 1b Mar 95 LINCOLN 5 ii SAFETY ii z WELDING SPARKS cause fire or explosion 6 a Remove fire hazards from the welding area If this is not possible cover them to prevent the welding sparks from starting a fire Remember that welding sparks and hot materials from welding can easily go through small cracks and openings to adjacent areas Avoid welding near hydraulic lines Have a fire extinguisher readily available 6 b Where compressed gases are to be used at the job site special precautions should be used to prevent hazardous situations Refer to AS1674 Parts 1 amp 2 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 is touching the work or ground Accidental contact can cause overheating and create a fire hazard 6 d Do not heat cut or weld tanks drums or containers until the proper steps have been taken to insure that such procedures will not cause flammable or toxic vapors from substances inside These can cause an explosion even though the vessel has been cleaned For information purchase Recommended Safe Practices for the Preparation for Welding and Cutting of Containers and Piping that have held Hazardous Substances AWS F4 1 from the American Welding Society see address above 6 e Vent hollow castings or containers before heating cutting or
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32. A 4 AuurEeniddn dM A 5 Spark Arresto iiio secs se Buen RI pie Pagi Rie anb waa ee A 5 Welding letminals ize uem ei dx Rx GRE ERR e xa nine da Roa ba Rack A 5 Welding Output Cables 53 22 GE YA RC pales A 5 Machine Grounding se kee eae Sone 5 Remote Control si 6 Auxiliary Power Receptacles 1 40 1 A 6 Standby Power Connections A 6 Connection of Vantage Premises 0 A 7 Connection of Lincoln Electric Wire Feeders A 8 A 9 Operation Ur m xm Um mx rem ee Section B Safety Instructions bu Re RES e Rot bu Boot B 1 GeneralDeSCripliOi oa ides eee es Mi dep ames B 1 Recommended Applications 2 22 2 1 de B 1 Controls and Settings DO gala e M B 2 Engine e RN P B 2 Welder Controls seg cyrus rese S Reb s B 3 Auxiliary Power Coritrols Er EP GRE Ra EA EROR RUPEE EU B 4 Engine Operation 22 23 45 x
33. DEUTZ LINCOLN 5 2 INSTALLATION A 2 Read this entire installation section before you start installation SAFETY PRECAUTIONS Do not attempt to use this equipment until you have thoroughly read all operating and maintenance manuals supplied with your machine They include important safety precautions detailed engine starting operating and maintenance instructions and parts lists ELECTRIC SHOCK can kill Do not touch electrically live parts such as output terminals or internal wiring e Insulate yourself from the work and ground Always wear dry insulating gloves ENGINE EXHAUST can kill 3 Use in open well ventilated areas or vent exhaust outside JT MOVING PARTS can injure Do not operate with doors open or guards off Stop engine before servicing Keep away from moving parts Only qualified personnel should install use or service this equipment LOCATION VENTILATION The welder should be located to provide an unrestricted flow of clean cool air to the cooling air inlets and to avoid restricting the cooling air outlets Also locate the welder so that the engine exhaust fumes are properly vented to an outside area DO NOT MOUNT OVER COMBUSTIBLE SURFACES Where there is a combustible surface directly under stationary or fixed electrical equipment that surface should be covered with a steel plate at least 06 1 6mm thick which should extend not less than 5 90 150mm bey
34. Diagrams and Dimension Section F 5 Presa avi achat ce a dors P 472 Series Vantage 500 DEUTZ LINCOLN B 1 INSTALLATION A 1 TECHNICAL SPECIFICATIONS Vantage 500 DEUTZ K2271 1 INPUT DIESEL ENGINE Make Model Description Speed RPM Starting Capacities System Deutz 3 oylinder High Idle 1900 173 cu in 12VDC battery Fuel 912 44HP 33 kw 2 83L amp Starter 25 US gal Diesel Engine 1800 RPM Full Load 1800 94 6L Bore x Stroke Oil 9 5 QTS 3 94 x 4 72 9 0L 100mm x 120mm RATED OUTPUT 104 F 40 C WELDER Duty Cycle Welding Output Volts at Rated Amps 500 Amps DC multi purpose 40 Volts 550 Amps DC multi purpose 36 volts 575 Amps DC multi purpose 35 volts OUTPUT 104 F 40 C WELDER AND GENERATOR Welding Range 30 575 Amps CC CV 20 250 Amps TIG Open Circuit Voltage 60 1900 RPM Auxiliary Power 120 240 VAC 12 000 WATTS 60 Hz PHYSICAL DIMENSIONS Width Depth 42 0 in 31 5 in 63 1 in 1615 Ibs 1066 8 mm 800 1mm 1603mm 733kg Approx Output rating in watts is equivalent to volt amperes at unity power factor Output voltage is within 10 at all loads up to rated capacity When welding available auxiliary power will be reduced 2 Top of Enclosure Add 6 6 167 6mm for exhaust Vantage 500
35. JO3NNOOSIC 7 3I18v9 Y3 Lvov Nid oN AHVIIXDN OVA SEL 14M ANISNA nbe 5 4 eovues 10 sued 100 4 osr jj e1sul pinos ouuosiod poyenb KUO e aos 010J9q syed Keme s pee Aiau8g 3ALLVOO3N 4 ul sp erh Caoy s sjaued ui ado jou ONINHVM WV LINCOL DIAGRAMS F 8 F 8 CONNECTION DIAGRAM 182755 0002 22 01 0341534 SV NOI LISOd OLAV NI HOLIMS 4410 39V ld NOILISOd STVNIWYAL TAM JHL NI HOLIMS STVNINYSL ONIG TJA SOV Id LISOd 34IM A9 JHL HOLIMS SGOW SHL 39V Id ATV 3003123713 AHL ALlYY 10d JHL HO1VMW OL HOLMS YSLANLIOA 38IM JHL NOILISOd ALIS V 10d 038154 50015 LNdLNO OL 531979 ONICTAM LOANNOO WANVI 33 34N1N1 ANY ALVIGANW 30 31949 ALNG ONY LNSAYYND ALIOVdVO 30 38 LSAW S318V2 ONICTAM 20041927 OL OL 0 1 310 430333 1 310 124 O4 4884 TYNOILdO siy eames 10 sued jou esn ejsui poys e sued deey e pee Ajeneg JALLVO3N 251 eoej
36. OHINOO 0 LONGY 41 ON AONITTEM JAWA OL HOLIMS 80122725 ICON TI3V 35 4 N 4 7 0 HOLMS H3IS LLIOA 30594 3HIM FHL IAS 5 NYHL 42 5 S3NIHOVIN ZWOS NO ASO TONIWAAL 5 SYNLVE COLLE VA IHL CAddINOA S3NIHOVIN 3SOHL OL Aldd SALON ONIMOTIOJ JHL 1 INY Qv3 DIH0M 3NISN3S S v3 C3LD3NNOOSIQ JO ANE C3SOdX3 341 clH S TWN AXIL OL ONISNES 23NNO2 5 TVN 34LVIOM4 318 2 0 LOANVOODSIO A 318v 14 0 04 43 724 N VH 5 FONOUFL aVz19NISN38 3_NOY V JAIM Xz 13 Q343AO0 d38E 8 439WV THO c AEONISD OL 41 9341 HANOLSNI TION X3 38 OL Qv3159NISN38 39 V L10A ZLON3H SALdVCV NI d HIS M X20334 OL O3NNCO JASN SI c N INC AINO Jl 83215 ON 1V43dO 2 1 338 SNC Lv9l133v ALVIOZWNI 40 31949 ALNG 3HL ONV JH 9 38 ISP S3 TIVO INTIEM SNOLIOPTHISNI SNLEVH3dO 1 L 05 9 dEZ N1 31811 VdWO9 S33013M 3NI9N3 NVA9VIQ NOLL23NNOO 3004193734 THIN 8 424334 SHIM 40254 IM H31aVON dEz N1 Cvz1 m ONISNES Vantage 500 DEUTZ ON 060
37. OTE When a wire feeder with a built in welding voltage control is connected to the 14 pin connector do not connect anything to the 6 pin connector 17 WELD OUTPUT TERMINALS AND These 1 2 13 studs with flange nuts provide welding connection points for the electrode and work cables For positive polarity welding the electrode cable connects to the terminal and the work cable connects to this terminal For negative polarity welding the work cable connects to the terminal and the electrode cable connects to this terminal AUXILIARY POWER CONTROLS Items 18 21 18 120 240 VAC RECEPTACLE This is a 120 240VAC 14 50R receptacle that provides 240VAC or can be split for 120VAC single phase auxiliary power This receptacle has a 50 amp rating Refer to the AUXILIARY POWER RECEPTACLES section in the installation chapter for further information about this receptacle Also refer to the AUXILIARY POWER OPERATION section later in this chapter X 19 CIRCUIT BREAKERS O These circuit breakers provide separate overload current protection for each 120V circuit at the 240V receptacle each 120V receptacle the 120VAC in the 14 Pin connector the 42VAC in the 14 Pin connector and battery circuit overload protection 20 120VAC GFCI RECEPTACLES These two 120VAC 5 20R receptacles with ground fault circuit interruption protection provide 120VAC for auxiliary power Each receptacle has a 20 amp total r
38. R Korean ecran S458 XE Sup Asal TAY AXE ole Arabic doas ulli sla Quali Y O eal ay gl ui sli Alta DA de Do not touch electrically live parts or electrode with skin or wet clothing Insulate yourself from work and ground No toque las partes o los electrodos bajo carga con la piel o ropa mojada Aislese del trabajo y de la tierra Ne laissez ni la peau ni des v tements mouill s entrer en contact avec des pi ces sous tension Isolez vous du travail et de la terre Ber hren Sie keine stromf hrenden Teile oder Elektroden mit Ihrem oder feuchter Kleidung Isolieren Sie sich von den Elektroden und dem Erdboden toque partes el tricas electrodos com a pele ou roupa molhada Isole se da e terra Mi HE 7 5 SAP BBS 9 ecran 8428 su DSS Sup YAR HNL ans AXE ALL ule Keep flammable materials away Mantenga el material combustible fuera del rea de trabajo Gardez l cart de tout mat riel inflammable Entfernen Sie brennbarres Material e Mantenha in
39. SHL 031511 SNOLLWOISIOAdS 3AO8V 5 LON OQ AHOLOV3 145 344 SI 9 135 9 3NI9N3 Q39VIAVG 38 SLINOHI9 10 1 00 8303343 38IM SLIOA 07 5309 39VETOA SIHL 3139 VETOA Ov IHL 3SV389NI NY ASNVO 39VMINTT 31LLOSH L ONIGINYSAO ONILLAS JHL 9NISNVHO 3NION3 3101 JHL 40 ASVIHINI 1 SLOWSY TWNOILdO 92 7 HN NOLLAVO LINN 9993 OL 300312313 TOv 1627 MHOM OL TWSYAAINN 2987 AYOM OL 30019313 299990 JAIM ZN1 51 5 esn ejsu pos jeuuosied peyijenb e sued feme des g eoejd ui spien6 S uiVd ONIAOW 90900 sued jou og eJojeq QV31 AYA 3ALIVO3N 5 sjeued uj ejeJedo jou 0g ONINHVM Wf go NOLLO3NNOO Z N1 8274 12987 H3ONVWINOO Vantage 500 DEUTZ DIAGRAMS F 4 F 4 CONNECTION DIAGRAM v 181ye8 0002 22 01 NOILISOd NI HOLIMS 414101 QN NOILISOd HOLIMS 39914 O N 3004
40. aci n o aspiraci n para gases Gardez la t te l cart des fum es Utilisez un ventilateur ou un aspirateur pour ter les fum es des zones de travail e Vermeiden Sie das Einatmen von Schweibrauch Sorgen Sie f r gute Be und Entl ftung des Arbeitsplatzes Mantenha seu rosto da fumaca Use ventilac o e exhaust o para remover fumo da zona respirat ria B EI ELBAN EM EAL FEL REPRE TEL TPE SUR D s ERHALE HAS MNS Tx Turn power off before servicing Desconectar el cable de alimentaci n de poder de la m quina antes de iniciar cualquier servicio e D branchez le courant avant l entretien Strom vor Wartungsarbeiten abschalten Netzstrom v llig ffnen Maschine anhalten N o opere com as tampas removidas Desligue a corrente antes de fazer servi o N o toque as partes el tricas nuas BGXLBRTRERBA UvV HACNEUd CSHELH YYNENAJ 7 we uexod HEHHE UNSS nili Do not operate with panel open or guards off No operar con panel abierto 0 guardas quitadas N op rez pas avec les panneaux ouverts ou avec les dispositifs de protection enlev s Anlage nie ohne Schutzgeh use oder Innenschutzverkleidung in Betrieb setzen e Mantenha se afastado das partes moventes opere com os pa
41. ad from the front of the LN 25 to work using the spring clip at the end of the lead This is a sense lead to supply current to the wire feeder motor it does not carry welding current e Set the SELECTOR switch to the CV WIRE position Set the WELDING TERMINALS switch to WELD TERMINALS ON Adjust the ARC CONTROL knob to desired crispness Generally welding is best if the ARC CONTROL is set to SOFT for MIG and CRISP for INNERSHIELD You may however want to start in the middle and adjust as needed from there elf you are using an LN 25 with an internal contactor the electrode is not energized until the gun trigger is closed A CAUTION If you are using an LN 25 without an internal contactor the electrode will be energized when the Vantage is started When the gun trigger is closed the current sensing circuit will cause the wire to begin to feed and the welding process is started CONNECTION OF AN NA 3 AUTOMATIC WELDING SYSTEM TO THE VANTAGE For connection diagrams and instructions for connecting an NA 3 Welding System to the Vantage refer to the NA 3 Welding System instruction manual The connection diagram for the LN 8 can be used for connecting the NA 3 CONNECTION OF PRINCE XL SPOOL GUN TO THE VANTAGE Connection of the Prince XL Spool Gun requires the use of the K1849 1 Adapter Module Shut the Welder off For electrode Positive connect the electrode cable to the ter
42. and high duty cycles Vantage 500 DEUTZ LINCOLN 5 7 7 CV WIRE MODE Connect a wire feeder to the Vantage and set welder controls according to the instructions listed earlier in this section The Vantage in the CV WIRE position permits it to be used with a broad range of flux cored wire Innershield and Outershield electrodes and solid wires for MIG welding gas metal arc welding Welding can be finely tuned using the ARC CONTROL Turning the ARC CONTROL clockwise from 10 soft to 10 crisp changes the arc from soft and washed in to crisp and narrow It acts as an inductance pinch control The proper setting depends on the procedure and operator preference Start with the knob set at 0 For any electrodes the procedures should be kept within the rating of the machine For additional electrode information See www lincolnelectric com or the appropriate Lincoln publication ARC GOUGING For optimal performance when arc gouging set the Vantage WELD MODE switch to the CC STICK position and the ARC CONTROL to 10 Set the OUTPUT knob to adjust output current to the desired level for the gouging electrode being used according to the ratings in the following table Maximum current setting is limited to the Vantage maximum of 575 Amps ELECTRODE CURRENT RANGE DIAMETER DC electrode positive 1 8 30 60 Amps 5 32 90 150 Amps 3 16 200 250 Amps 1 47
43. any debris and rinse in diesel fuel 6 Re install the pre filter screen into the upper cavity of the filter header making sure the four pull tabs are pointing up Putting your fingers on the pull tabs push down evenly until the lower body of the pre filter screen contacts the floor of the upper cavity 7 Re insert the large white volume plug into the upper cavity 8 Place the O ring onto the angled seal surface of the filter header and re install the plastic cap Make sure its flange rests on the O ring 9 Screw on the cap ring and tighten hand tight 10 Remember to open the fuel shutoff valve Lever in line with the hose before starting the engine WATER SEPARATOR ELEMENT The water separator element is a two stage filter with a special filtration water separating media and an expanded water reservoir providing maximum protection against water in the fuel The recommended change interval for the water separator element is 1 000 hours The procedure for changing the element is as follows 1 Close the fuel shutoff valve Lever should be perpendicular to the hose located on the side of the Fuel Pre Filter Water Separator Assembly 2 Rotate the quick change ring located just below filter header clockwise approximately 1 2 turn and slide it down and off of the element 3 Grasp the element and pull down with a slight rocking motion to remove the element from the grommet post on the bottom of the filter header 4 Slid
44. ated on the engine The light will remain on when the engine has been shut down due to low oil pressure or over temperature condition 8 BATTERY CHARGING LIGHT The yellow engine alternator light is off when battery charging system is functioning normally If light turns on the engine protection system will shut down the engine Check the Engine cooling blower belt Also the alternator or the voltage regulator may not be operating correctly The light may also come on due to a faulty flashing circuit The light will remain on when the engine is stopped and the run stop switch is in the run position WELDING CONTROLS Items 9 through 17 9 OUTPUT CONTROL The OUTPUT dial is used to preset the output voltage or current as displayed on the digital meters for the four welding modes When in the CC STICK DOWNHILL PIPE or CV WIRE modes and when a remote control is connected to the 6 Pin or 14 Pin Connector the auto sensing circuit automatically Switches the OUTPUT CONTROL from control at the welder to the remote control In the CV WIRE mode when the wire feeder control cable is connected to the 14 pin connector the auto sensing circuit automatically makes OUTPUT CONTROL inactive and the wire feeder voltage control active When in the TOUCH START TIG mode and when a Amptrol is connected to the 6 pin Connector the OUTPUT dial is used to set the maximum current range of the CURRENT CONTROL of the Amptrol 10 DIGITAL OUTPUT METERS
45. ating They are designed to protect the user from the hazards of ground faults When the GFCI has tripped there will be no voltage available from the receptacle If the GFCI has tripped any device plugged into the GFCI receptacle should be unplugged and the reason for tripping the GFCI should be determined If the device is found to be damaged or defective it should be repaired or replaced before any further use The GFCI should be checked for proper operation prior to each use by pressing the test button The GFCI can be reset by pushing the reset button Refer to the AUXILIARY POWER RECEPTACLES section in the installation chapter for further information about these receptacles Also refer to the AUXILIARY POWER OPERATION section later in this chapter 21 GROUND STUD Provides connection point for connecting the machine case to earth ground Refer to MACHINE GROUNDING in the Installation chapter for proper machine grounding information ENGINE OPERATION STARTING THE ENGINE 1 Open the engine compartment door and check that the fuel shutoff valve located to the left of the fuel filter housing is in the open position lever to be in line with the hose Check for proper level Close engine compartment Remove all plugs connected to the AC power receptacles 4 Set the RUN STOP switch to RUN Observe that the engine protection and battery charging lights are on After 10 seconds the engine prote
46. automatic welding gun are also electrically hot Always be sure the work cable makes a good electrical connection with the metal being welded The connection should be as close as possible to the area being welded Ground the work or metal to be welded to a good electrical earth ground Maintain the electrode holder work clamp welding cable and welding machine in good safe operating condition Replace damaged insulation Never dip the electrode holder in water for cooling Never simultaneously touch electrically hot parts of electrode holders connected to two welders because voltage between the two can be the total of the open circuit voltage of both welders When working above floor level use a safety belt to protect yourself from a fall should you get a shock Also see items 6c and 8 ARC RAYS can burn 4 4 Use shield with the proper filter and cover plates to protect your eyes from sparks and the rays of the arc when welding or observing open arc welding Headshield and filter lens should conform to ANSI Z87 1 standards 4 b Use suitable clothing made from durable flame resistant material to protect your skin and that of your helpers from the arc rays 4 c Protect other nearby personnel with suitable non flammable screening and or warn them not to watch the arc or expose themselves to the arc rays or to hot spatter or metal FUMES AND GASES can be dangerous 5 a Welding may pro
47. by changing the arc length The OUTPUT CONTROL knob adjusts the full output range for pipe welding The ARC CONTROL knob sets the short circuit current arc force during stick welding to adjust for a soft or a more forceful digging arc Crisp Increasing the number from 10 Soft to 10 Crisp increases the short circuit current which results in a more forceful digging arc Typically a forceful digging arc is preferred for root and hot passes A softer arc is preferred for fill and cap passes where weld puddle control and deposition stacking of iron are key to fast travel speeds It is recommended that the ARC CONTROL be set initially at 0 TOUCH START TIG MODE The Vantage can be used in a wide variety of DC TIG welding applications The TOUCH START TIG setting of the MODE switch is for DC TIG Tungsten Inert Gas welding To initiate a weld the OUTPUT CONTROL knob is first set to the desired current and the tungsten is touched to the work During the time the tungsten is touching the work there is very little voltage or current and in general avoids tungsten contamination Then the tungsten is gently lifted off the work in a rocking motion which establishes the arc To stop the arc simply lift the TIG torch away from the work piece When the arc voltage reaches approximately 30 volts the arc will go out and the machine will automatically reset to the touch start current level The tungsten may then be retouched to the work p
48. complete information on service intervals and element changing procedures Vantage 500 DEUTZ LINCOLN 5 D 3 MAINTENANCE D 3 COOLING SYSTEM The cooling system of the Deutz engine needs to be checked and cleaned periodically Consult the engine owners manual for the proper frequency and procedure COOLING BLOWER BELT The following procedure should be followed to replace the cooling blower belt 1 Allow the machine to cool 2 Unfasten and slide the battery holder out from the welder 3 Disconnect the negative battery cable 4 Remove engine case side 5 Loosen air cleaner hose clamp and detach hose 6 Remove the engine end panel with air box and air cleaner attached for access to the engine 7 Loosen the alternator mounting bolts and rotate the alternator towards the engine 8 Remove the old cooling blower belt and install a new one 9 Adjust the cold belt tension to 63 73 Ibs midway between any two pulleys 10 Reinstall the air cleaner hose engine case side and end panel Reattach the negative battery cable Slide in and refasten the battery holder 11 Check the cooling blower belt tension after 100 hours of operation Follow steps 1 2 3 4 5 6 9 amp 10 BATTERY HANDLING GASES FROM BATTERY can explode Keep sparks flame and cigarettes away from battery Lh To prevent EXPLOSION when INSTALLING A NEW BATTERY disconnect negative cable from old battery first and connect to new battery las
49. ction light will turn off 5 Within 30 seconds press and hold the engine START button until the engine starts Release the engine START button when the engine starts N Check that the engine protection and battery charging lights are off The engine protection light is on after starting the engine will shutdown in a few seconds Investigate any indicated problem 8 Allow the engine to warm up for several minutes before applying a load Allow a longer warm up time in cold weather COLD WEATHER STARTING With a fully charged battery and the proper weight oil the engine should start satisfactorily even down to about O F If the engine must be frequently started below 10 F it may be desirable to install the optional ether start kit K825 1 Installation and operating instructions are included in the kit STOPPING THE ENGINE 1 Switch the RUN STOP switch to STOP This turns off the voltage supplied to the shutdown solenoid A backup shutdown can be accomplished by shutting off the fuel valve located on the fuel line Vantage 500 DEUTZ LINCOLN amp 5 5 TYPICAL FUEL CONSUMPTION Refer to Table B 2 for typical fuel consumption of the Vantage Engine for various operating scenarios Table B 2 Deutz F3L912 Engine Fuel Consumption Deutz B3 3 Running Time for 44HP 33Kw 25Gal 94 6 L 1800 RPM Hours High Idle 66 Gal hour 37 9 no load 1900 RPM 2 50 Lts hour DC CC We
50. d ui spjen6 uado sjeued ui eyejedo jou oq e ONINHVM WV 310 38 2987 TYNOILdO INVS9VIO NOILLO3NNOO 23V JHL SSOHDV SCNT SH3Q13M 3NION3 JON3HdIAV TONAHANY Nid 9 Vantage 500 DEUTZ LINCOLN E 9 9 8 705 000 1 NOILISOd NI HOLIMS 43101 39VId 918 5 300319313 JHL 30 ALI V 10d JHL HOLVIN OL HOLIMS YALAWLTIOA 830334 38IM NOILISOd ALII V TOd Q38IS30 804 Sands 318V9 LOANNOO IVONVIN ONILVYAdO 33 5 39813 ANY ALVIGSWWI 40 371949 ALAC ANY LN38S0 AHL ALIOVdVO 38 15 S318V9 ONIQT3M WANVA 0 Y3073M ANIONS NI 93151 SNOLLVOISIOAdS 3A08V LSNPAV LON OG AHOLOV4 DIAGRAMS CONNECTION DIAGRAM 13S 3Hd SI 9NILL3S HONS3AO9 3NION3 JHL 39VIAVO HOIHM 830334 SHIM JHL NI 3SV3HONI NV ASNVO TIM 39 VMNTFT 31LLOSH L JHL SNIGISSISAO ONILLAS JHL ONIONVHO 3NION3 3101 30 3SV389NI LINA 9995 OL 114v9 320412313 MYOM OL 318V9 1OH LNOO 9695 318v9 8 NTOL jueuudinbe siy 2 5 syed asn je sul pjnous jauuosied peyrjenb e 5 eJ0Jeq syed Aeme pee JALLVO3N 19euuoosig
51. duce fumes and gases hazardous to health Avoid breathing these fumes and gases When welding keep your head out of the fume Use enough ventilation and or exhaust at the arc to keep fumes and gases away from the breathing zone When welding with electrodes which require special ventilation such as stainless or hard facing see instructions on container or MSDS or on lead or cadmium plated steel and other metals or coatings which produce highly toxic fumes keep exposure as low as possible and below Threshold Limit values TLV using local exhaust or mechanical ventilation In confined spaces or in some circumstances outdoors a respirator may be required Additional precautions are also required when welding on galvanized steel 5 b Do not weld in locations near chlorinated hydrocarbon vapors coming from degreasing cleaning or spraying operations The heat and rays of the arc can react with Solvent vapors to form phosgene a highly toxic gas and other irritating products 5 c Shielding gases used for arc welding can displace air and cause injury or death Always use enough ventilation especially in confined areas to ensure breathing air is safe 5 4 Read and understand the manufacturer s instructions for this equipment and the consumables to be used including the material safety data sheet MSDS and follow your employer s safety practices MSDS forms are available from your welding distributor or from the manufacturer
52. e eoe d ui d y e uedo sjeued ejeJedo jou ONINSHVM 77 NVYSVId NOLLO3NNOO 8 N 1 SH3Q 13M NOILOVO Vantage 500 DEUTZ LINCOLN 8 DIAGRAMS F 10 F 10 CONNECTION DIAGRAM 181728 0002 22 01 4341830 SV NOLLISOd 41d HO NI HOLIMS 43101 2 4 0 335 SNOLLVOl 1ddV 34043 ANY 40 31949 ANY LN3SDO JHL 303 ALIO VaVO 43d0Hd 40 38 LSNN S318VO ATV 200415313 JHL HOLVIN OL HOLIMS YSLAWLIOA 830333 38IM JHL NOI LISOd 40341530 SANLS 318VO LOANNOO NOILISOd GATIONLNOO AT3L0IN38 OL HOLIMS SIVNINAZL H3013M FOV 1d NOILISOd JHL NI HOLIMS SQOW 39Vld SNILV3340 330 T3M ANIONS JHL NI 03151 SNOLLV2I3lI9348S 3AO8V LSNPAV LON ANOLOVA SHL 185 484 SI 9NLLL3S HONN3AO9 ANIONS JHL TONLNOD NI HOIHM 3 3033 3M OV JHL NI ASVAYONI NV ASNVO TIM ATLLOMHL ONILLAS HONH3AO9 JHL ONIONVHI Wd 3NION3 JO 3SV3HONI OL NOILOVO LINN 1333 OL 51875 300412313 A T18N3SSV 318V9 LNANI 929 431872 TONSHdNV 92 OL Nid 7L jueuudinbe siy 10 sued 621422 9 jou
53. e the new element onto the grommet post on the bottom of the filter header until the element no longer easily moves up into the filter header Now rotate the element may take almost 1 full turn with a slight upward pressure until the element begins to further engage the header With the proper orientation now established apply additional pressure to seat the element in the filter header You should feel the element pop into place when properly seated Note The element will only go on one way Never use excessive force when mounting the element to the header Slide the quick change ring up over the element and rotate counter clockwise until an audible click or pop is heard If you do not hear the click you have not rotated the ring far enough and the element is not in the locked position Another indication that the ring is in the locked position is that one set it doesn t matter which one of arrows located on the outside of the ring should be located directly under the air vent valve 9 Open the fuel shutoff valve lever in line with the hose 7 Open the air vent valve on the front of the filter header until fuel emerges free of air bubbles and then close the air vent valve Note Consult your engine operation manual for information on air bleeding the entire fuel system SECONDARY FUEL FILTER The Secondary Fuel Filter is a spin on cartridge type mount directly to the engine Consult your engine operation manual for
54. ension axles and tires Mount equipment base to metal bed or frame of vehicle Follow vehicle manufacture s instructions Vantage 500 DEUTZ LINCOLN 5 4 INSTALLATION 4 PRE OPERATION ENGINE SERVICE READ the engine operating and maintenance instructions supplied with this machine WARNING Stop engine while fueling Do not smoke when fueling Keep sparks and flame away from tank Do not leave unattended while fueling DIESEL FUEL Wipe up spilled fuel and allow can cause fire fumes to clear before starting engine Do not overfill tank fuel expansion may cause overflow DIESEL FUEL ONLY OIL The Vantage is shipped with the engine crankcase filled with high quality SAE 10W 30 oil API class CD or better Check the oil level before starting the engine If it is not up to the full mark on the dip stick add oil as required Check the oil level every four hours of running time during the first 35 running hours Refer to the engine Operator s Manual for specific oil recommendations and break in information The oil change interval is dependent on the quality of the oil and the operating environment Refer to the engine Operators Manual for the proper service and maintenance intervals FUEL USE DIESEL FUEL ONLY Fill the fuel tank with clean fresh diesel fuel The capacity of the fuel tank is approx 95 liters See engine Operators Manual for specific fuel recommendations Running o
55. flam veis bem guardados e RAPTUELONM COREE e 18 FAM 0125 axe Ai ug y l e Wear eye ear and body protection Prot jase los ojos los o dos y el cuerpo Prot gez vos yeux vos oreilles et votre corps Tragen Sie Augen Ohren und K r perschutz Use protec o para a vista ouvido e corpo amp U CT 845 HEBSISSERURHR ex 19 So BEAUTE diis die READ AND UNDERSTAND THE MANUFACTURER S INSTRUCTION FOR THIS EQUIPMENT AND THE CONSUMABLES BE USED AND FOLLOW YOUR EMPLOYER S SAFETY PRACTICES SE RECOMIENDA LEER Y ENTENDER LAS INSTRUCCIONES DEL FABRICANTE PARA EL USO DE ESTE EQUIPO Y LOS CONSUMIBLES QUE VA A UTILIZAR SIGA LAS MEDIDAS DE SEGURIDAD DE SU SUPERVISOR LISEZ ET COMPRENEZ LES INSTRUCTIONS DU FABRICANT EN CE QUI REGARDE CET EQUIPMENT ET LES PRODUITS A ETRE EMPLOYES ET SUIVEZ LES PROCEDURES DE SECURITE DE VOTRE EMPLOYEUR LESEN SIE UND BEFOLGEN SIE DIE BETRIEBSANLEITUNG DER ANLAGE UND DEN ELEKTRODENEINSATZ DES HERSTELLERS DIE UNFALLVERHUTUNGSVORSCHRIFTEN DES ARBEITGEBERS SIND EBENFALLS ZU BEACHTEN Vantage 500 DEUTZ LINCOLN amp Keep your head out of fumes Use ventilation or exhaust to remove fumes from breathing zone Los humos fuera de la zona de respiraci n e Mantenga la caheza fuera de los humos Utilice ventil
56. gine block just below the lift pump The Secondary Fuel Filter is mounted directly to the engine just above the oil filter FUEL PRE FILTER WATER SEPARATOR ASSEMBLY The pre filter is a 150 micron screen designed to protect against gross fuel contamination of the water separator element and the Secondary Fuel Filter If the pre filter becomes plugged it may be removed inspected cleaned and reinstalled In general this only needs to be done with each water separator element change about every 1 000 hrs However if at any time excessive fuel contamination is suspected or a sudden fall off in engine performance is detected the pre filter screen should be inspected and cleaned Follow the following procedure 1 Close the fuel shutoff valve Lever should be perpendicular to the hose located on the side of the Fuel Pre Filter Water Separator Assembly 2 Unscrew the cap ring located on the top of the filter header and remove the plastic center cap and O ring 3 Remove the large white volume plug located directly under the center cap in the upper cavity of the filter header Use a small screwdriver or similar device to lift the plug part way out of the cavity to assist with its removal Be careful not to damage the pre filter screen with the tool used to remove the plug 4 Using a pair of pliers gently tug on the pull tabs of the pre filter screen in an alternating pattern to gradually remove the pre filter screen 5 Brush off
57. iece to restrike the arc The arc may also be started and stopped with an Amptrol or Arc Start Switch The ARC CONTROL is not active in the TIG mode In general the Touch Start feature avoids tungsten contamination without the use of a Hi frequency unit If the use of a high frequency generator is desired the K930 2 TIG Module can be used with the Vantage The settings are for reference The Vantage is equipped with the required R F bypass circuitry for the connection of high frequency generating equipment The Vantage and any high frequency generating equipment must be properly grounded See the K930 2 TIG Module operating manuals for complete instructions on installation operation and maintenance When using the TIG Module the OUTPUT control on the Vantage is used to set the maximum range of the CURRENT CONTROL on the TIG Module or an Amptrol if connected to the TIG Module VANTAGE SETTINGS WHEN USING THE K930 2 TIG MODULE Set the WELD MODE switch to the setting e Set the WELDING TERMINALS switch to the Remotely Controlled position This will keep the solid state contactor open and provide a cold electrode until the triggering device Amptrol or Arc Start Switch is pressed Vantage 500 DEUTZ LINCOLN amp 6 OPERATION B 6 Table TYPICAL CURRENT RANGES FOR TUNGSTEN ELECTRODES 2 DCEN DCEP Approximate Argon Gas Flow Rate l min c f m Tungsten Electrode 1 2
58. ineis abertos ou guardas removidas BrxAphbH ERUMLINE ord un ger sm s ae 1h Ma ex Lai WARNING Spanish AVISO DE PRECAUCION French ATTENTION German WARNUNG ATEN AO Japanese 29 KLIP Zro SAP CB ATUBS ELTFEL BR ER d 24 fe BC CERE RR Heal AU AL BAS ARE HSR slay ay svt gh pile ag S Y LEIA E COMPREENDA AS INSTRUCOES DO FABRICANTE PARA ESTE EQUIPAMENTO E AS PARTES DE USO E SIGA AS PR TICAS DE SEGURANCA DO EMPREGADOR kosdegEHODX h m mEtcoO amp es OT FEL LLET TEE EIET E Ol oj SA CAE Af rig pili Vantage 500 DEUTZ LINCOLN 5 LINCOLN amp World s Leader in Welding and Cutting Products Sales and Service through Subsidiaries and Distributors Worldwide Cleveland Ohio 44117 1199 USA Tel 216 481 8100 Fax 216 486 1751 Web Site www lincolnelectric com
59. ion energizes the fuel solenoid for approximately 30 seconds The engine must be started within that time or the fuel solenoid will deenergize and the switch must be toggled to reset the timer 2 START PUSHBUTTON Energizes the starter motor to crank the engine With the engine Run Stop switch in the Run position push and hold the Start button to crank the engine release as the engine starts Do not press while engine is running since this can cause damage to the ring gear and or starter motor YOO 3 HOUR METER The hour meter displays the total time that the engine has been running This meter is a useful indicator for scheduling preventive maintenance 4 FUEL LEVEL GAUGE gi Displays the level of diesel fuel in the fuel tank The operator must watch the fuel level closely to prevent running out of fuel and possibly having to bleed the system 5 ENGINE TEMPERATURE GAUGE The gauge displays the engine temperature Vantage 500 DEUTZ LINCOLN amp B 3 OPERATION B 3 6 OIL PRESSURE GAUGE Em The gauge displays the engine oil pressure when the engine is running 7 ENGINE PROTECTION The yellow engine protection light remains off with proper oil pressure and under normal operating temperatures If the light turns on the engine protection system will stop the engine Check for proper oil level and add oil if necessary Check for loose or disconnected leads at the oil pressure sender loc
60. ld 1 94 Gal hour 12 9 Output 500 7 34 Lts hour Amps Q 40 Volts 1 31 Gal hour 19 1 4 96 Lts hour Auxiliary Power 12 000 VA WELDER OPERATION DUTY CYCLE Duty Cycle is the the ratio of the uninterrupted on load duration to 10 minutes The total time period of one complete on load and no load cycle is 10 minutes For example in the case of a 60 duty cycle load is applied continuously for 6 minutes followed by a no load period of 4 minutes STICK WELDING MODE The Vantage can be used with a broad range of DC stick electrodes The MODE switch provides two stick welding settings as follows CC STICK MODE The CC STICK position of the MODE switch is designed for horizontal vertical up and overhead welding with all types of electrodes especially low hydrogen The OUTPUT CONTROL knob adjusts the full output range for stick welding The ARC CONTROL knob sets the short circuit arc force current during stick welding Increasing the number from 10 Soft to 10 Crisp increases the short circuit current and prevents sticking of the electrode to the plate while welding This can also increase spatter It is recommended that the ARC CONTROL be set to the minimum number without electrode sticking Start with the knob set at 0 DOWNHILL PIPE MODE This slope controlled setting is intended for out of position and down hill pipe welding where the operator would like to control the current level
61. minal of the welder and work cable to the terminal of the welder For electrode Negative connect the electrode cable terminal of the welder and work cable to the terminal of the welder Connect the Control Cable of the Spool Gun to the Adapter Module and connect the Control Cable of the Adapter Module to the Welder Connect the Gas Hose Set the MODE switch to the CV WIRE position Set the WELD TERMINALS switch to WELD TERMINALS ON Set the ARC CONTROL knob to 0 initially and adjust to suit VANTAGE 500 DEUTZ LINCOLN amp B 1 OPERATION B 1 SAFETY INSTRUCTIONS Read and understand this entire section before operating your Vantage Do not attempt to use this equipment until you have thoroughly read all operating and maintenance manuals supplied with your machine They include important safety precautions detailed engine starting operating and maintenance instructions and parts lists ELECTRIC SHOCK can kill e Do not touch electrically live parts such as output terminals or internal wiring Insulate yourself from the work and ground Always wear dry insulating gloves ENGINE EXHAUST can kill 3 Use in open well ventilated areas or vent exhaust outside M Do not stack anything near the engine MOVING PARTS can injure Do not operate with doors open guards off Stop engine before servicing Keep away from moving parts
62. ns la zone de soudage Ceci est particuli rement important pour le soudage de t les galvanis es plomb es ou cadmi es ou tout autre m tal qui produit des fume s toxiques Ne pas souder en pr sence de vapeurs de chlore provenant d op rations de d graissage nettoyage ou pistolage La chaleur ou les rayons de l arc peuvent r agir avec les vapeurs du solvant pour produire du phosg ne gas fortement toxique ou autres produits irritants 11 Pour obtenir de plus amples renseignements sur la s ret voir le code Code for safety in welding and cutting CSA Standard W 117 2 1974 PR CAUTIONS DE S RET POUR LES MACHINES SOUDER TRANSFORMATEUR ET REDRESSEUR 1 Relier la terre le chassis du poste conformement au code de l lectricit et aux recommendations du fabricant Le dispositif de montage ou la piece souder doit tre branch une bonne mise la terre 2 Autant que possible l installation et l entretien du poste seront effectu s par un lectricien qualifi 3 Avant de faires des travaux l interieur de poste la debrancher l interrupteur la boite de fusibles 4 Garder tous les couvercles et dispositifs de s ret leur place Mar 93 LINCOLN amp V V for selecting a QUALITY product by Lincoln Electric We want You you to take pride in operating this Lincoln Electric Company product as much pride as we have in bringing this product to you Plea
63. ns quand on soude ou quand on regarde l arc b Porter des v tements convenables afin de prot ger la peau de soudeur et des aides contre le rayonnement de l arc c Prot ger l autre personnel travaillant proximit au soudage l aide d crans appropri s et non inflammables Des gouttes de laitier en fusion sont mises de l arc de soudage Se prot ger avec des v tements de protection libres de l huile tels que les gants en cuir chemise paisse pantalons sans revers et chaussures montantes Toujours porter des lunettes de s curit dans la zone de soudage Utiliser des lunettes avec crans lateraux dans les zones l on pique le laitier 6 Eloigner les mat riaux inflammables ou les recouvrir afin de pr venir tout risque d incendie d aux tincelles Quand on ne soude pas poser la pince une endroit isol de la masse Un court circuit accidental peut provoquer un chauffement et un risque d incendie S assurer que la masse est connect e le plus pr s possible de la zone de travail qu il est pratique de le faire Si on place la masse sur la charpente de la construction ou d autres endroits loign s de la zone de travail on augmente le risque de voir passer le courant de soudage par les chaines de levage c bles de grue ou autres circuits Cela peut provoquer des risques d incendie ou d echauffement des chaines et des c bles jusqu ce qu ils se rompent Assurer une ventilation suffisante da
64. o prevent ELECTRICAL DAMAGE WHEN a Installing new batteries b Using a booster Use correct polarity Negative Ground Vantage 500 DEUTZ LINCOLN B 5 INSTALLATION A 5 The Vantage is shipped with the negative battery cable disconnected Before you operate the machine make sure the Engine Switch is in the OFF position and attach the disconnected cable securely to the negative battery terminal Remove the insulating cap from the negative battery terminal Replace and tighten negative battery cable terminal NOTE This machine is furnished with a wet charged battery if unused for several months the battery may require a booster charge Be sure to use the correct polarity when charging the battery MUFFLER OUTLET PIPE Remove the plastic plug covering the muffler outlet tube Using the clamp provided secure the outlet pipe to the outlet tube with the pipe positioned such that it will direct the exhaust in the desired position SPARK ARRESTOR Some federal state or local laws may require that petrol or diesel engines be equipped with exhaust spark arrestors when they are operated in certain locations where unarrested sparks may present a fire hazard The standard muffler included with this welder does not qualify as a spark arrestor When required by local regulations a suitable spark arrestor must be installed and properly maintained An incorrect arrestor may lead to damage to the engine or adversely affect perfo
65. ond the equipment on all sides STORING 1 Store the machine in a cool dry place when it is not in use Protect it from dust and dirt Keep it where it can t be accidentally damaged from construction activities moving vehicles and other hazards 2 Drain the engine oil and refill with fresh 10W30 oil Run the engine for about five minutes to circulate oil to all the parts See the MAINTENANCE section of this manual for details on changing oil 3 Remove the battery recharge it and adjust the electrolyte level Store the battery in a dry dark place STACKING Vantage machines cannot be stacked ANGLE OF OPERATION To achieve optimum engine performance the Vantage should be run in a level position The maximum angle of operation for the Deutz engine is 30 degrees fore and aft 40 degrees right and 45 degrees left If the engine is to be operated at an angle provisions must be made for checking and maintaining the oil level at the normal FULL oil capacity in the crankcase When operating the welder at an angle the effective fuel capacity will be slightly less than the specified 25 gallons Vantage 500 DEUTZ LINCOLN B 3 INSTALLATION A 3 LIFTING The Vantage lift bale should be used to lift the machine The Vantage is shipped with the lift bale retracted Before attempting to lift the Vantage the lift bale must be secured in a raised position Secure the lift bale as follows a Open the engine compartment door
66. polarity is correct Improper polarity can damage the charging circuit The Vantage positive battery terminal has a red terminal cover If you need to charge the battery with an external charger disconnect the negative cable first then the positive cable before you attach the charger leads after the battery is charged reconnect the positive battery cable first and the negative cable last Failure to do so can result in damage to the internal charger components Follow the instructions of the battery charger manufacturer for proper charger settings and charging time NAMEPLATES WARNING DECALS MAINTENANCE Whenever routine maintenance is performed on this machine or at least yearly inspect all nameplates and labels for legibility Replace those which are no longer clear Refer to the parts list for the replacement item number WELDER GENERATOR MAINTENANCE STORAGE Store the Vantage in clean dry protected areas CLEANING Blow out the generator and controls periodically with low pressure air do this at least once a week in particularly dirty areas BRUSH REMOVAL AND REPLACEMENT It is normal for the brushes and slip rings to wear and darken slightly Inspect the brushes when a generator overhaul is necessary WARNING Do not attempt to polish slip rings while the engine is running Table D 1 Engine Maintenance Components ITEM Air Cleaner Element Cooling Blower Belt Oil Filter Element Purola
67. provided for your protection The level of seriousness to be applied to each is explained below A WARNING This statement appears where the information must be followed exactly to avoid serious personal injury or loss of life CAUTION This statement appears where the information must be followed to avoid minor personal injury or damage to this equipment TABLE CONTENTS Page Installation RR RE ERU x RUE Section A Technical Specifications arr ht RT RE V FIDE RE RCRUM ead A 1 Safety Precautions iiu 2 Eocation EO ee 2 2555 2 Site dme cec A 2 Angle of Operation 222 Eee re Re ey ees aa Ge EU dee A 2 A 3 High Altitude Operation orte mhey e Rep AER tee es A 3 High Temperature Operation wae de ds 3 M ET A 3 Pre Operation Engine Service 4 a TT 4 gl ETT A 4 Fuel ix anas osx ai once RS o ed Ree EEE daim gU A 4 Engine Break In Engine Cooling System 4 Battery Connection ee crad RR oka E bee he wd nee eee aa ee dew
68. purchase a copy of Safety in Welding amp Cutting ANSI Standard Z49 1 from the American Welding Society PO Box 351040 Miami Florida 33135 or CSA Standard W117 2 1974 or WTIA Welding Technology Institute of Australia PO Box 6165 Silverwater NSW 2128 A free copy of Arc Welding Safety booklet E205 is available from the Lincoln Electrical Company 22801 St Clair Avenue Cleveland Ohio 44117 1199 BE SURE THAT ALL INSTALLATION OPERATION MAINTENANCE AND REPAIR PROCEDURES ARE For Gasoline Engines The engine exhaust from this product contains chemicals known to the State of California to cause cancer birth defects or other reproductive harm To avoid scalding do not remove the radiator pressure cap when the engine is hot ELECTRIC AND MAGNETIC FIELDS may be dangerous 2 a Electric current flowing through any conductor causes 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 physician before welding 2 c Exposure to EMF fields in welding may have other health effects which are now not known 2 4 welders should use the following procedures in order to minimize exposure to EMF fields from the welding circuit 2 d 1 Route the electrode and work cables together Secure them with tape when possible 2 d
69. quipment ROUTINE AND PERIODIC MAINTENANCE DAILY Check the crankcase oil level Refill the fuel tank to minimize moisture condensation in the tank Open the water drain valve located on the bottom of the water separator element 1 or 2 turns and allow to drain into a container suitable for diesel fuel for 2 to 3 seconds Repeat the above drainage procedure until diesel fuel is detected in the co WEEKLY Blow out the machine with low pressure air periodically In particularly dirty locations this may be required once a week ENGINE MAINTENANCE Refer to the Periodic Checks 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 Cooling Blower Belt e Battery f Cooling System Refer to Table D 1 at the end of this section for various engine maintenance components AIR FILTER EXCESSIVE AIR FILTER RESTRICTION WILL RESULT IN REDUCED ENGINE LIFE The air filter element is a dry cartridge type It can be cleaned and reused however damaged elements should not be reused Stop engine after 100 hours of running time and clean filter element replace the filter if necessary Service air cleaner regularly according to Engine Operator s Manual 1 Locate the air filter canister located behind the engine door on the top of the engine 2 Remove air filter element 3 Remove loose dirt f
70. r receptacles should only be used with three wire grounded type plugs or approved double insulated tools with two wire plugs The current rating of any plug used with the system must be at least equal to the current capacity of the associated receptacle SIMULTANEOUS WELDING AND AUXILIARY POWER LOADS It must be noted that the above auxiliary power ratings are with no welding load Simultaneous welding and power loads are specified in table B 4 The permissible currents shown assume that current is being drawn from either the 120 VAC or 240 VAC supply not both at the same time Vantage 500 DEUTZ LINCOLN amp B 8 OPERATION B 8 TABLE B 4 Vantage Simultaneous Welding and Power Loads elding Output Permissible Power Watts at NEMA Voltage Unity Power Factor 041 20 0 250A 30V 500A 40V Each duplex receptacle is limited to 20 amps Not to exceed 50A per 120 VAC branch circuit when splitting the 240 VAC output TABLE B 5 Vantage Extension Cord Length Recommendations Current Voltage Load Maximum Allowable Cord Length in ft m for Conductor Size ps Volts Watts 14 Te 225 Tos x AWG 8 AWG 6 AWG 4 AWG 30 60 ii B Conductor size is based on maximum 2 0 voltage drop Vantage 500 DEUTZ LINCOLN B 1 ACCESSORIES OPTIONAL FIELD INSTALLED ACCESSORIES K704 ACCESSORY SET Includes 35 feet 10 m of electrode cable and 30 feet 9 m of work cable headshield work clamp and electrode
71. rally it states to contact your local Lincoln Authorized Field Service Facility If you do not understand or are unable to perform the Recommended Course of Action safely contact your local Lincoln Authorized Field Service Facility 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 DEUTZ LINCOLN 5 2 TROUBLESHOOTING E 2 Observe all Safety Guidelines detailed throughout this manual PROBLEMS POSSIBLE AREAS OF RECOMMENDED SYMPTOMS MISADJUSTMENT S COURSE OF ACTION ENGINE PROBLEMS Major Physical or Electrical Damage is 1 Contact your Local Lincoln Authorized Evident Field Service Facility Engine will not crank 1 Battery low 2 Loose battery cable connections which may need Inspected cleaned or tighten 3 Faulty wiring in engine starting circuit 4 Faulty engine starter Contact authorized local Engine Service Shop Engine will crank but not start 1 Out of fuel 2 Fuel shut off valve is in the off position make sure the valve lever is in a vertical direction 3 Engine shut down solenoid not pulling in 4 On Off switch on for more than 30 sec before starting the On Off switch will need to be switch off and turned back on 5 Fuel Filters dirty clogged main filter element and or Inline Fuel Filter
72. rceful digging arc Crisp Increasing the number from 10 Soft to 10 Crisp increases the short circuit current which results in a more forceful digging arc Typically a forceful digging arc is preferred for root and hot passes A softer arc is preferred for fill and cap passes where weld puddle control and deposition stacking of iron are key to fast travel speeds It is recommended that the ARC CONTROL be set initially at O CV WIRE mode In this mode turning the ARC CONTROL knob from 10 soft to 10 changes the arc from soft and washed in to crisp and narrow It acts as an inductance pinch control The proper setting depends on the procedure and operator preference Start with a setting of 0 13 WELDING TERMINALS SWITCH In the WELD TERMINALS ON position the output is electrically hot all the time In the REMOTELY CONTROLLED position the output is controlled by a wire feeder or amptrol device and is electrically off until a remote switch is depressed Vantage 500 DEUTZ LINCOLN 5 B 4 OPERATION B 4 14 WIRE FEEDER VOLTMETER SWITCH Matches the polarity of the wire feeder voltmeter to the polarity of the electrode 15 6 PIN CONNECTOR For attaching optional remote control equipment Includes auto sensing remote control circuit 16 14 PIN CONNECTOR For attaching wire feeder control cables Includes contactor closure circuit auto sensing remote control circuit and 120VAC and 42VAC power N
73. rmance WELDING TERMINALS The Vantage is equipped with a toggle switch for selecting hot welding terminals when in the WELD TERMINALS ON position or cold welding terminals when in the REMOTELY CONTROLLED position WELDING OUTPUT CABLES With the engine off route the electrode and work cables thru the strain relief bracket provided on the front of the base and connect to the terminals provided These connections should be checked periodically and tightened if necessary Listed in Table A 1 are copper cable sizes recommended for the rated current and duty cycle Lengths stipulated are the distance from the welder to work and back to the welder again Cable sizes are increased for greater lengths primarily for the purpose of minimizing cable voltage drop Table A 1 Combined Length of Electrode and Work Cables TOTAL COMBINED LENGTH OF ELECTRODE AND WORK CABLES AMPS Up to 150ft 150 200ft 200 250ft 100 Duty Cycle 500 3 0 AWG 3 0 AWG 4 0 AWG MACHINE GROUNDING Because this portable engine driven welder creates its own power it is not necessary to connect its frame to an earth ground unless the machine is connected to premises wiring home shop etc To prevent dangerous electric shock other equipment powered by this engine driven welder must a be grounded to the frame of the welder using grounding type plug b be double insulated When this welder is mounted on a t
74. rom element with compressed air or water hose directed from inside out Compressed Air 100 psi maximum with nozzles at least one inch away from element Water Hose 40 psi maximum without nozzle 4 Soak element in a mild detergent solution for 15 minutes Do not soak more than 24 hours Swish element around in the solution to help remove dirt 5 Rinse elements from inside out with a gentle stream of water less than 40 psi to remove all suds and dirt 6 Dry element before reuse with warm air at less than 160 F 71 C Do not use a light bulb to dry the element Vantage 500 DEUTZ LINCOLN B D 2 MAINTENANCE D 2 7 Inspect for holes and tears by looking through the element toward a bright light Check for damaged gaskets or dented metal parts Do not reuse damaged elements Protect element from dust and damage during drying and storage 8 Reinstall air filter element After six cleanings replace air filter A cleaned filter will have approximately 70 of the life of a new filter element A restricted filter element may not appear excessively dirty FUEL FILTERS WARNING When working on the fuel system Keep naked lights away do not smoke Do not spill fuel The Vantage is equipped with a Fuel Pre Filter Water Separator Assembly located before the lift pump and a Secondary Fuel Filter located after the lift pump and before the fuel injectors The Fuel Pre Filter Water Separator is mounted to the en
75. ruck or trailer its frame must be securely connected to the metal frame of the vehicle When this engine driven welder is connected to premises wiring such as that in a home or shop its frame must be connected to the system earth ground See further connection instructions in the section entitled Standby Power Connections well as the article on grounding in the latest National Electrical Code and the local codes In general if the machine is to be grounded it should be connected with a 8 or larger copper wire to a solid earth ground such as a metal ground stake going into the ground for at least 10 Feet or to the metal framework of a building which has been effectively grounded The National Electric Code lists a number of alternate means of grounding electrical equipment A machine grounding stud marked with the symbol is provided on the front of the welder Vantage 500 DEUTZ LINCOLN amp 6 INSTALLATION A 6 REMOTE CONTROL OUTPUT The Vantage is equipped with a 6 pin and a 14 pin connector The 6 pin connector is for connecting the K857 or K857 1 Remote Control or for TIG welding the K870 foot Amptrol or the K936 2 hand Amptrol When in the CC STICK DOWNHILL PIPE or CV WIRE modes and when remote control is connected to the 6 pin Connector the auto sensing circuit automatically switches the OUTPUT control from control at the welder to remote control When in TOUCH START TIG mode and when a Amptrol is connec
76. se Examine Carton and Equipment For Damage Immediately When this equipment is shipped title passes to the purchaser upon receipt by the carrier Consequently Claims for material damaged in shipment must be made by the purchaser against the transportation company at the time the shipment is received Please record your equipment identification information below for future reference This information can be found on your machine nameplate Product Model Number Code Number or Date Code Serial Number Date Purchased Where Purchased Whenever you request replacement parts or information on this equipment always supply the information you have recorded above The code number is especially important when identifying the correct replacement parts On Line Product Registration Register your machine with Lincoln Electric either via fax or over the Internet For faxing Complete the form on the back of the warranty statement included in the literature packet accompanying this machine and fax the form per the instructions printed on it For On Line Registration Go to our WEB SITE at www lincolnelectric com Choose Quick Links and then Product Registration Please complete the form and submit your registration Read this Operators Manual completely before attempting to use this equipment Save this manual and keep it handy for quick reference Pay particular attention to the safety instructions we have
77. se fan belt may need tightening No welding output or auxiliary output 1 Broken lead in rotor circuit 2 Faulty field diode module 3 Faulty Weld Control P C Board 4 Faulty rotor Welder has some no output and no control Auxiliary output OK Faulty remote kit Faulty output control potentiometer Faulty output control wiring Faulty Weld Control PCB Pull Coil Battery PCB or Chopper PCB gt mo No welding output Auxiliary output OK 1 WELDING TERMINALS switch in wrong position be sure to place switch in WELDING TERMINALS ALWAYS ON position Faulty Weld Control PCB Pull Coil Battery PCB or Chopper PCB m No auxiliary power Open breakers Faulty receptacle Faulty auxiliary circuit wiring GFCI tripped Sons RECOMMENDED COURSE OF ACTION FUNCTION PROBLEMS If all recommended possible areas of misadjustment have been checked and the problem persists Contact your local Lincoln Authorized Field Service Facility If for any reason you do not understand the test procedures or are unable to perform the tests repairs safely contact your Local Lincoln CAUTION Authorized Field Service Facility for technical troubleshooting assistance before you proceed Vantage 500 DEUTZ LINCOLN amp LL ENHANCED DIAGRAM DIAGRAMS 10 euo uo y episul peysed si cvevo mg E 19078 ANIONS YOLVNYALTV
78. t CONNECTING A BATTERY CHARGER Remove battery from welder by disconnecting negative cable first then positive cable and battery clamp When reinstalling connect negative cable last Keep well ventilated USING A BOOSTER connect positive lead to battery first then connect negative lead to engine foot 4 BATTERY ACID CAN BURN EYES AND SKIN Wear gloves and eye protection and be careful when working near battery Follow instructions printed on battery PREVENTING ELECTRICAL DAMAGE 1 When replacing jumping or otherwise connecting the battery to the battery cables the proper polarity must be observed Failure to observe the proper polarity could result in damage to the charging circuit The positive battery cable has a red terminal cover D If the battery requires charging from an external charger disconnect the negative battery cable first and then the positive battery cable before attaching the charger leads Failure to do So can result in damage to the internal charger components When reconnecting the cables connect the positive cable first and the negative cable last PREVENTING BATTERY DISCHARGE Turn off the RUN STOP to stop when engine is not running PREVENTING BATTERY BUCKLING Tighten nuts on battery clamp until snug VANTAGE 500 DEUTZ LINCOLN 5 D 4 MAINTENANCE D 4 CHARGING THE BATTERY When you charge jump replace or otherwise connect battery cables to the battery be sure the
79. tact entre les parties sous tension et la peau nue ou les v tements mouill s Porter des gants secs et sans trous pour isoler les mains Faire tr s attention de bien s isoler de la masse quand on soude dans des endroits humides ou sur un plancher metallique ou des grilles metalliques principalement dans les positions assis ou couch pour lesquelles une grande partie du corps peut tre en contact avec la masse Maintenir le porte lectrode la pince de masse le c ble de soudage et la machine souder en bon et s r tat defonctionnement d Ne jamais plonger le porte lectrode dans l eau pour le refroidir e Ne jamais toucher simultan ment les parties sous tension des porte lectrodes connect s deux machines souder parce que la tension entre les deux pinces peut tre le total de la tension vide des deux machines f Si on utilise la machine souder comme une source de courant pour soudage semi automatique ces precautions pour le porte lectrode s applicuent aussi au pistolet de soudage 2 Dans le cas de travail au dessus du niveau du sol se prot ger contre les chutes dans le cas ou on recoit un choc Ne jamais enrouler le c ble lectrode autour de n importe quelle partie du Corps Un coup d arc peut tre plus s v re qu un coup de soliel donc a Utiliser un bon masque avec un verre filtrant appropri ainsi qu un verre blanc afin de se prot ger les yeux du rayonnement de l arc et des projectio
80. ted to the 6 Pin Connector the OUTPUT dial is used to set the maximum current range of the CURRENT CONTROL of the Amptrol The 14 pin connector is used to directly connect a wire feeder control cable In the CV WIRE mode when the control cable is connected to the 14 pin connector the auto sensing circuit automatically makes the Output Control inactive and the wire feeder voltage control active NOTE When a wire feeder with a built in welding voltage control is connected to the 14 pin connector do not connect anything to AUXILIARY POWER RECEPTACLES The auxiliary power capacity of the Vantage is 12 000 watts of 60 Hz single phase power The auxiliary power capacity rating in watts is equivalent to volt amperes at unity power factor The maximum permissible current of the 240 VAC output is 50 A The 240 VAC output can be split to provide two separate 120 VAC outputs with a maximum permissible current of 50 A per output to two separate 120 VAC branch circuits The output voltage is within 10 at all loads up to rated capacity The Vantage has two 20 Amp 120VAC 5 20R GFCI duplex receptacles and 50 120 240 14 50R receptacle The 120 240 VAC receptacle can be split for single phase 120 VAC operation The auxiliary power receptacles should only be used with three wire grounded type plugs or approved double insulated tools with two wire plugs The current rating of any plug used with the system must be at least equal
81. teel will result in catastrophic damage to the generator and voids the warranty 2 Set the welder controls for an output current and voltage within the welder rating and duty cycle Note that any attempt to exceed the welder rating or duty cycle for any period of time will result in catastrophic damage to the generator and voids the warranty 3 Periodically shut off the engine and check the crankcase oil level ENGINE COOLING SYSTEM The Deutz engine is air cooled by a belt driven axial blower The oil cooler and engine cooling fins should be blown out with compressed air or steam to maintain proper cooling See the engine Owners Manual for procedures and frequency BATTERY CONNECTION GASES FROM BATTERY can explode Keep sparks flame and cigarettes away from battery To prevent EXPLOSION when INSTALLING A NEW BATTERY disconnect negative cable from old battery first and connect to new battery last CONNECTING A BATTERY CHARGER remove battery from welder by disconnecting negative cable first then positive cable and battery clamp When reinstalling connect negative cable last Keep well ventilated USING A BOOSTER connect positive lead to battery first then connect negative lead to negative battery lead at engine foot BATTERY ACID can burn eyes and skin Wear gloves and eye protection and be careful when working near battery Follow instructions printed on battery IMPORTANT T
82. to the current capacity of the associated receptacle NOTE The two 120V GFCI receptacles and the two 120 volt circuits of the 120 240V receptacle are connected to different phases and can not be paralleled STANDBY POWER CONNECTIONS The Vantage is suitable for temporary standby or emergency power using the engine manufacturers recommended maintenance schedule The Vantage can be permanently installed as a standby power unit for 240 volt 3 wire 50 amp service Connections must made by a licensed electrician who can determine how the 120 240 VAC 60Hz power can be adapted to the particular installation and comply with all applicable electrical codes The following information can be used as a guide by the electrician for most applications Refer to the connection diagram shown in Figure A 2 1 Install the double pole double throw switch between the power company meter and the premises disconnect Switch rating must be the same or greater than the customer s premises disconnect and service over current protection Vantage 500 DEUTZ LINCOLN 5 7 INSTALLATION A 7 2 Take necessary steps to assure load is limited to the capacity 3 Install a 50 amp 120 240 VAC plug NEMA Type 14 50 to the of the Vantage by installing a 50 amp 240 VAC double pole double pole circuit breaker using No 6 4 conductor cable of circuit breaker Maximum rated load for each leg of the 240 the desired length The 50 amp 120 240 VAC plug is VAC
83. tor Fuel Filter Element PART NUMBER Donaldson P181052 AC 02 Lincoln Gates 7585 T13536 3 1174418 PER2168 1820 PH3776 1174423 Purolator PC42 Water Separator Element Fuel Pre Filter Screen Lincoln Stanadyne Lincoln Stanadyne 3358 P4102 M16890 C 31572 M16890 B 29575 BCI Group 34 Vantage 500 DEUTZ LINCOLN 5 1 TROUBLESHOOTING E 1 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 and machine operator and will invalidate your factory warranty For your safety and to avoid Electrical Shock please observe all safety notes and precautions detailed throughout this manual This Troubleshooting Guide is provided to help you locate and repair possible machine malfunctions Simply follow the three step procedure listed below Step 1 LOCATE PROBLEM SYMPTOM Look under the column labeled PROBLEM SYMPTOMS This column describes possible symptoms that the machine may exhibit Find the listing that best describes the symptom that the machine is exhibiting Step 2 POSSIBLE CAUSE The second column labeled POSSIBLE CAUSE lists the obvious external possibilities that may contribute to the machine symptom Step 3 RECOMMENDED COURSE OF ACTION This column provides a course of action for the Possible Cause gene
84. uedo sjeued ejejedo jou 0q e ONINHVM 7 TOULNOD ALOWSY IWNOILdO NOILOANNOD 93V 5504 S2 N1 S3Q713M ANIDNA Vantage 500 DEUTZ LINCOLN 8 DIAGRAMS F 12 F 12 CONNECTION DIAGRAM 6 8 25 0002 2 0 a3asisad sv NOILISOd NI HOLIMS 101 39V Td NOILISOd IOHINOO SLOWSY NI HOLIMS 1081NO2 LAdLNO 39V Id NOILISOd 911 3HL NI HOLIMS SGOW 39V 1d 10d 341544 401 SALS LAdLNO 318v9 LOANNOS ONILVYSdO 335 SNOILVOl laav ANY SLVIGANW 319A9 ANY LN388n9 JHL 303 ALIOVdVO 38 LSNW 318VO WANVIN ONILVH3d0 S3Q 13M 3NISN3 SHL NI 93151 SNOILVOISIOSdS 3AO8V LSNTAV LON 00 AHOLOV4 JHL LV 13S 38d SI 911 135 HONS3AOO 3NION3 JHL SHL 39VI AVO NYO HOIHM 39 VL 10A 30333 39IM NI SSVSYONI NV 3Snv9 39VMNIT31LLOSHL 3HL 9NIGIHS3AO ONILLAS HONYSAOS JHL ONISNVHO INdH ANIONS 410 JHL 3SV3SONI OL HOLIMS LUVIS MO caf ANVH 1 96 n 30041977 40 OULdINY 1004 0483 18 2 IOHLNOO 967 ONILLH 1fidNI SV9 OL SVO NO9sV ON3HdlV H313NMO TH YOLVINDT siy 991 105 10 sued jou esn ejsui pjnous jsuuosied
85. ut of fuel may require bleeding the fuel injection pump NOTE Before starting the engine open the fuel shutoff valve pointer to be in line with hose FUEL CAP Remove the plastic cap covering from the Fuel Tank Filler neck and install the Fuel Cap ENGINE BREAK IN Lincoln Electric selects high quality heavy duty industrial engines for the portable welding machines we offer While it is normal to see a small amount of crankcase oil consumption during initial operation excessive oil use wetstacking oil or tar like substance at the exhaust port or excessive smoke is not normal Larger machines with a capacity of 350 amperes and higher which are operated at low or no load conditions for extended periods of time are especially susceptible to the conditions described above To accomplish successful engine break in most diesel powered equipment needs only to be run at a reasonably heavy load within the rating of the welder for some period of time during the engine s early life However if the welder is subjected to extensive light loading occasional moderate to heavy loading of the engine may sometimes be necessary Caution must be observed in correctly loading a diesel generator unit 1 Connect the welder output studs to a suitable resistive load bank Note that any attempt to short the output studs by connecting the welding leads together direct shorting of the output studs or connecting the output leads to a length of s

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