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Lincoln Electric Vantage 500 DEUTZ Operator'S Manual Download Page 8

Accessories

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

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

Maintenance

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

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

Air Filter  . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .D-1
Fuel Filters  . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .D-2
Fuel Pre-Filter/Water Separator Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .D-2
Water Separator  . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .D-2
Secondary Fuel Filter  . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .D-2
Cooling System  . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .D-3
Cooling Blower Belt  . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .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-472 Series

vii

vii

Vantage 500 DEUTZ

TABLE OF CONTENTS

Summary of Contents for Vantage 500 DEUTZ

Page 1: ...MENT WITHOUT READING THIS MANUAL AND THE SAFETY PRECAUTIONS CONTAINED THROUGHOUT Most importantly think before you act and be careful OPERATOR S MANUAL 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 IM80...

Page 2: ...tting 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...

Page 3: ...e dangerous 5 a Welding may produce 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...

Page 4: ...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 g Connect the work cable to the work as close to the welding area as possible ...

Page 5: ...s et non inflammables 4 Des gouttes de laitier en fusion sont émises de l arc de soudage Se protéger avec des vêtements de protection libres de l huile tels que les gants en cuir chemise épaisse pantalons sans revers et chaussures montantes 5 Toujours porter des lunettes de sécurité dans la zone de soudage Utiliser des lunettes avec écrans lateraux dans les zones où l on pique le laitier 6 Eloigne...

Page 6: ...nformation below for future reference This information can be found on your machine nameplate Product _______________________________________________________________________________ Model Number _________________________________________________________________________ Code Number or Date Code_______________________________________________________________ Serial Number______________________________...

Page 7: ...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 Engine Controls B 2 Welder Controls B 3 Auxiliary Power Controls B 4 Engine Operation B 4 Starting The Engine B 4 Stopping the Engine B 4 Typical Fuel Consumption B 5 Welding Operation B 5 Duty Cycle B 5 Stick Welding Mode B 5 CC Stick Mod...

Page 8: ...ter Separator Assembly D 2 Water Separator D 2 Secondary Fuel Filter D 2 Cooling System D 3 Cooling Blower Belt 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 472 Series vii vii Vantage 500 DEU...

Page 9: ...0 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 1 in 1615 lbs 1066 8 mm 800 1mm 1603mm 733kg Approx 1 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 T...

Page 10: ...bustible 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 beyond 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 activitie...

Page 11: ... welder voltage rating 2 volts for every 10 C 21 F above 40 C 104 F TOWING The recommended trailer for use with this equipment for road in plant and yard towing by a vehicle 1 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...

Page 12: ...st 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...

Page 13: ... 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 MACHINE...

Page 14: ...ible 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 one 50 Amp 120 240 VAC 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 t...

Page 15: ...or 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 receptacle on the Vantage case front Figure A 2 Connection of the Vantage to Premises Wiring 240 Volt 60 Hz 3 Wire Service POWER COMPANY METER 240 VOLT 120 VOLT 120 VOLT LOAD N NEUTRAL BUS GROUND PREMISES DISCONNECT AND SERVICE OVERCURRENT PROTECTION...

Page 16: ...inal 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 p...

Page 17: ...f you are using an LN 25 with an internal contactor the electrode is not energized until the gun trigger is closed 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 WELDIN...

Page 18: ...ONAL 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 standb...

Page 19: ...use damage 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 indicator for scheduling preventive maintenance 4 FUEL LEVEL GAUGE 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 ENGIN...

Page 20: ...e 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 MOD...

Page 21: ...d 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 ...

Page 22: ...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 ...

Page 23: ... 1 When used with argon gas The current ranges shown must be reduced when using argon helium or pure helium shielding gases 2 Tungsten electrodes are classified as follows by the American Welding Society AWS Pure EWP 1 Thoriated EWTh 1 2 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 ...

Page 24: ...ontrol 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...

Page 25: ...50 250 300 250 200 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 drop 14 AWG 12 AWG 10 AWG 8 AWG 6 AWG 4 AWG TABLE B 4 Vantage Simultaneous Welding and Power Loads Welding Output Permissible Power Watts Permissible Auxiliary at NEMA Voltage Unity Power Factor Current in Amperes V 04I 20 120VAC 10 240 VAC 10 0 250A ...

Page 26: ...th 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 a light package Order K953 1 Trailer K958 1 Ball Hitch K958 2 Lunette Eye Hitch K959 1 Fender Light Kit K965 1 Cable Rack K887 1 ETHER START KIT Provides maximum cold weather starting assistance for frequent starting...

Page 27: ...tion 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 el...

Page 28: ...r 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 wa...

Page 29: ...SION 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 ...

Page 30: ... 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 rin...

Page 31: ... understand or are unable to perform the Recommended Course of Action safely contact your local Lincoln Authorized Field Service Facility HOW TO USE TROUBLESHOOTING GUIDE Service and Repair should only be performed by Lincoln Electric Factory Trained Personnel Unauthorized repairs performed on this equipment may result in danger to the technician and machine operator and will invalidate your facto...

Page 32: ...ngine protection light lit 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 1 High oil temperature 1 Dirty fuel or air filters m...

Page 33: ...INALS switch in wrong position be sure to place switch in WELDING TERMINALS ALWAYS ON position 2 Faulty Weld Control PCB Pull Coil Battery PCB or Chopper PCB 1 Open breakers 2 Faulty receptacle 3 Faulty auxiliary circuit wiring 4 GFCI tripped RECOMMENDED COURSE OF ACTION If all recommended possible areas of misadjustment have been checked and the problem persists Contact your local Lincoln Authori...

Page 34: ... SIDE CHOPPER PCB5 NEG POS NEG POS LEFT SIDE CHOPPER PCB6 B6 B5 B4 B1 B2 B3 13 14 B6 B5 B4 B1 B2 B3 1 8 9 1 6 J7 J3 1 9 16 8 1 6 7 12 1 16 9 8 6 10 J4 J5 6 10 CONTROL MODE SEL CHOPPER POWER PWM THERMAL 25A 23A 13 14 77 76 75 2 4 75A 76A 77A 271 200 500 239 CV CC TIG PIPE 405B R4 232B 232C 206C 208C B8 B7 B8 B7 INSULATED NEUTRAL STUD ON BOTTOM RIGHT OF CONTROL BOX GROUND STUD ON OUTPUT PANEL GND J ...

Page 35: ...Vantage 500 DEUTZ F 2 DIAGRAMS F 2 CONNECTION DIAGRAM ...

Page 36: ...UTION 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 WIRE FEEDER CONTROL CIRCUITS MAY BE THE ENGINE WELDER OPERATING MANUAL N A WELDING CABLE MUST BE OF PROPER CAPACITY FOR THE CURRENT AND DUTY CYCLE OF IMMEDIATE AND FUTURE APPILICATIONS SEE OPERA...

Page 37: ...F 4 DIAGRAMS F 4 Vantage 500 DEUTZ CONNECTION DIAGRAM ...

Page 38: ...Vantage 500 DEUTZ F 5 DIAGRAMS F 5 CONNECTION DIAGRAM ...

Page 39: ... 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 WIRE FEEDER CONTROL CIRCUITS MAY BE DAMAGED THE ENGINE GOVERNOR SETTING IS PRE SET AT THE FACTORY DO NOT ADJUST ABOVE RPM SPECIFICATIONS LISTED IN N B USE VOLTMETER SWITCH TO SELECT DESIRED ELECTRODE POL...

Page 40: ...Vantage 500 DEUTZ F 7 DIAGRAMS F 7 CONNECTION DIAGRAM ...

Page 41: ...Vantage 500 DEUTZ F 8 DIAGRAMS F 8 CONNECTION DIAGRAM ...

Page 42: ...T CAUTION 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 CIRCUIT THE ENGINE GOVERNOR SETTING IS PRE SET AT THE FACTORY DO NOT ADJUST ABOVE RPM SPECIFICATIONS LISTED IN THE ENGINE WELDER OPERATING MANUAL N A WELDING CABLES MUST BE OF PROPER CAPACITY FOR THE...

Page 43: ...Vantage 500 DEUTZ F 10 DIAGRAMS F 10 CONNECTION DIAGRAM ...

Page 44: ...Vantage 500 DEUTZ F 11 DIAGRAMS F 11 CONNECTION DIAGRAM ...

Page 45: ...Vantage 500 DEUTZ F 12 DIAGRAMS F 12 CONNECTION DIAGRAM ...

Page 46: ...Vantage 500 DEUTZ F 13 DIAGRAMS F 13 CONNECTION DIAGRAM ...

Page 47: ...31 50 45 67 10 22 BOTTOM VIEW OF WELDER BA CENTER OF GRAVITY WITH OIL IN ENGINE AND FULL FUEL TANK NOTE This diagram is for reference only 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 to the Service Department for a replacement Give the equipmen...

Page 48: ...NOTES VANTAGE 500 DEUTZ ...

Page 49: ... 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 vêtements mouillés entrer en contact avec des pièces sous tension Isolez vous du travail et de la terre Berühren Sie keine stromführenden Teile oder ...

Page 50: ...n Sie für gute Be und Entlüftung des Arbeitsplatzes Mantenha seu rosto da fumaça Use ventilação e exhaustão para remover fumo da zona respiratória Turn power off before servicing Desconectar el cable de alimentación de poder de la máquina antes de iniciar cualquier servicio Débranchez le courant avant l entretien Strom vor Wartungsarbeiten abschalten Netzstrom völlig öffnen Maschine anhalten Não o...

Page 51: ...d 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 ...

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