Lincoln Electric AIR VANTAGE 500 Operator'S Manual Download Page 8 | Manualshive

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Lincoln Electric AIR VANTAGE 500 Operator'S Manual Download Page 8

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TABLE OF CONTENTS

Page

Accessories

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Section C

Optional Field Installed Accessories . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .C-1

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Maintenance

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Section D

Safety Precautions  . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .D-1
Routine and Periodic Maintenance  . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .D-1
Engine Maintenance  . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .D-1

Air Filter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .D-1,D-2
Fuel Filters . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .D-3
Cooling System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .D-3
Battery Handling . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .D-3

Charging the Battery  . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .D-4
Nameplate / Warning Decal Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .D-4
Welder / Generator Maintenance  . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .D-4
Engine Maintenance Components  . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .D-4

Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Section E

Wiring, Connection Diagrams and Dimension Print . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Section F

Parts Lists

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .P- 508, P-718

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Summary of Contents for AIR VANTAGE 500

Page 1: ...r machine www lincolnelectric com register Authorized Service and Distributor Locator www lincolnelectric com locator Need Help Call 1 888 935 3877 to talk to a Service Representative Hours of Operati...

Page 2: ...KER 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 purchase a copy...

Page 3: ...r cooling 3 h Never simultaneously touch electrically hot parts of electrode holders connected to two welders because voltage between the two can be the total of the open circuit voltage of both welde...

Page 4: ...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...

Page 5: ...opri s et non inflammables 4 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 pa...

Page 6: ...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 t...

Page 7: ...Premises Wiring A 7 Connection of Lincoln Electric Wire Feeders A 8 A 9 Operation Section B Safety Instructions B 1 General Description B 1 Recommended Applications B 1 Controls and Settings B 2 Engi...

Page 8: ...ion D Safety Precautions D 1 Routine and Periodic Maintenance D 1 Engine Maintenance D 1 Air Filter D 1 D 2 Fuel Filters D 3 Cooling System D 3 Battery Handling D 3 Charging the Battery D 4 Nameplate...

Page 9: ...lts at Rated Amps 100 500 Amps DC multi purpose 40 Volts 60 550 Amps DC multi purpose 36 volts 50 575 Amps DC multi purpose 35 volts PHYSICAL DIMENSIONS Height 2 Width Depth Weight 42 0 in 31 5 in 63...

Page 10: ...side 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...

Page 11: ...necessary For maximum output cur rent ratings derate welder voltage rating 2 volts for every 21 F 10 C above 104 F 40 C TOWING The recommended trailer for use with this equipment for road in plant an...

Page 12: ...y To prevent EXPLOSION when INSTALLING A NEW BATTERY disconnect negative cable from old battery first and connect to new bat tery last WARNING PRE OPERATION ENGINE READ the engine operating and mainte...

Page 13: ...welding terminals when in the WELD TERMINALS ON position or cold welding termi nals when in the REMOTELY CONTROLLED position WELDING OUTPUT CABLES With the engine off route the electrode and work cab...

Page 14: ...welding voltage control is connected to the 14 pin connec tor do not connect anything to the 6 pin connec tor AUXILIARY POWER RECEPTACLES The auxiliary power capacity of the VANTAGE 500 DEUTZ is 12 0...

Page 15: ...r cable of the desired length The 50 amp 120 240 VAC plug is available in the optional K802R plug kit 4 Plug this cable into the 50 Amp 120 240 Volt recep tacle on the VANTAGE 500 DEUTZ case front Fig...

Page 16: ...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 te...

Page 17: ...ess Generally welding is best if the ARC CON TROL 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 Set the IDLE switch to th...

Page 18: ...lways operate the welder with the sliding door closed and the side panels in place as these pro vide maximum protection from moving parts and insure proper cooling air flow GENERAL DESCRIPTION The VAN...

Page 19: ...this can cause dam age to the ring gear and or starter motor 3 HOUR METER The hour meter displays the total time that the engine has been running This meter is a useful indi cator for scheduling preve...

Page 20: ...governor B In the Auto position the idler operates as follows a When switched from High to Auto or after starting the engine the engine will operate at full speed for approximately 12 seconds and then...

Page 21: ...g stick welding to adjust for a soft or a more forceful digging arc Crisp Increasing the number from 10 Soft to 10 Crisp increas es the short circuit current which results in a more forceful digging a...

Page 22: ...e 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 22 GROUND ST...

Page 23: ...ng 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...

Page 24: ...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 2...

Page 25: ...t the IDLER control switch to the desired operating mode Full power is available regardless of the welding control settings if no weld ing current is being drawn The auxiliary power of the VANTAGE 500...

Page 26: ...5 150 125 53 107 42 84 69 53 46 38 300 600 225 450 250 300 250 200 91 183 69 137 76 91 76 61 Maximum Allowable Cord Length in ft m for Conductor Size Conductor size is based on maximum 2 0 voltage dro...

Page 27: ...ual voltage plug rated at 120 240V 50 amps single phase 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 wel...

Page 28: ...tactor K126 2 Magnum 350 Innershield Gun for LN 25 For self shielded wire with 15 ft 4 5m cable For 062 3 32 1 6 2 4mm wire KP653 3 32 Drive Roll and Guide Tube Kit for LN 25 For 068 3 32 1 8 2 4mm co...

Page 29: ...to 3 seconds Repeat the above drainage procedure until diesel fuel is detected in the container WEEKLY Blow out the machine with low pressure air periodical ly In particularly dirty locations this ma...

Page 30: ...itself and distribute the sealing pressure evenly To complete a tight seal apply pressure by hand at the outer rim of the filter not the flexible center Avoid pushing on the center of the urethane end...

Page 31: ...battery last CONNECTING A BATTERY CHARGER Remove battery from welder by dis connecting negative cable first then positive cable and battery clamp When reinstalling connect negative cable last Keep wel...

Page 32: ...uctions of the battery charger manu facturer for proper charger settings and charging time NAMEPLATES WARNING DECALS MAIN TENANCE Whenever routine maintenance is performed on this machine or at least...

Page 33: ...IBLE 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 genera...

Page 34: ...e Service Shop 1 Out of fuel 2 Fuel shut off valve is in the off position make sure the valve lever is in the open position lever in line with the Hose 3 Engine shut down solenoid not pulling in 4 On...

Page 35: ...e fan belt may need tighten ing 1 Idler switch in HIGH idle position make sure switch is set to AUTO 2 External load on welder or auxil iary power 3 Mechanical problem in idler sole noid linkage 4 Fau...

Page 36: ...auxiliary power 1 Faulty Peripheral PCB Idler Engine Protection PCB or Weld Control PCB 1 Broken lead in rotor circuit 2 Faulty field diode module 3 Faulty Weld Control PCB 4 Faulty rotor 1 Faulty re...

Page 37: ...It may not be accurate for all machines covered by this manual The specific diagram for a particular code is pasted inside the machine on one of the enclosure panels If the diagram is illegible write...

Page 38: ...F 2 CONNECTION DIAGRAMS F 2 VANTAGE 500 DEUTZ...

Page 39: ...ANY INCREASE OF THE HIGH IDLE ENGINE RPM BY CHANGING THE GOVERNOR SETTING OR OVERRIDING THE THROTTLE LINKAGE WILL CAUSE AN INCREASE IN THE THE AC AUXILIARY VOLTAGE IF THIS VOLTAGE GOES OVER 140 VOLTS...

Page 40: ...F 4 CONNECTION DIAGRAMS F 4 VANTAGE 500 DEUTZ...

Page 41: ...F 5 CONNECTION DIAGRAMS F 5 VANTAGE 500 DEUTZ...

Page 42: ...ASE OF THE HIGH IDLE ENGINE RPM BY CHANGING THE GOVERNOR SETTING OR OVERRIDING THE THROTTLE LINKAGE WILL CAUSE AN INCREASE IN THE THE AC AUXILIARY VOLTAGE IF THIS VOLTAGE GOES OVER 140 VOLTS WIRE FEED...

Page 43: ...F 7 CONNECTION DIAGRAMS F 7 VANTAGE 500 DEUTZ...

Page 44: ...ION ANY INCREASE OF THE HIGH IDLE ENGINE RPM BY CHANGING THE GOVERNOR SETTING OR OVERRIDING THE THROTTLE LINKAGE WILL CAUSE AN INCREASE IN THE AC WIRE FEEDER VOLTAGE WHICH CAN DAMAGE THE CONTROL CIRCU...

Page 45: ...F 9 CONNECTION DIAGRAMS F 9 VANTAGE 500 DEUTZ...

Page 46: ...F 10 CONNECTION DIAGRAMS F 10 VANTAGE 500 DEUTZ...

Page 47: ...F 11 CONNECTION DIAGRAMS F 11 VANTAGE 500 DEUTZ...

Page 48: ...F 12 CONNECTION DIAGRAMS F 12 VANTAGE 500 DEUTZ...

Page 49: ...8962 5 A 28 99 19 63 6 53 24 97 6 55 23 69 50 38 54 44 14 63 37 30 45 38 6 56 42 00 50 81 15 50 31 50 45 67 BOTTOM VIEW OF WELDER BASE CENTER OF GRAVITY WITH OIL IN ENGINE AND EMPTY FUEL TANK 34 62 TR...

Page 50: ...NOTES VANTAGE 500 DEUTZ...

Page 51: ...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 moja da Aislese del trabajo y...

Page 52: ...e Be und Entl ftung des Arbeitsplatzes Mantenha seu rosto da fuma a Use ventila o e exhaust o para remover fumo da zona respirat ria Turn power off before servicing Desconectar el cable de ali mentaci...

Page 53: ...later than the following business day For Service outside the USA Email globalservice lincolnelectric com Cleveland Ohio 44117 1199 USA TEL 1 216 481 8100 FAX 1 216 486 1751 WEB SITE lincolnelectric...

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