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IM862-A
July, 2007
VANTAGE 500 DEUTZ
11415
For use with machines having Code Numbers:11180,
Safety Depends on You
Lincoln arc welding and cutting
equipment is designed and
built with safety in mind.
However, your overall safety
can be increased by proper
installation . . . and thoughtful
operation on your part. DO
NOT INSTALL, OPERATE
OR REPAIR THIS EQUIP-
MENT WITHOUT READING
THIS MANUAL AND THE
SAFETY PRECAUTIONS
CONTAINED THROUGHOUT.
Most importantly, think before
you act and be careful.
R
OPERATOR鈥橲 MANUAL
Copyright 漏 Lincoln Global Inc.
鈥? World's Leader in Welding and Cutting Products 鈥?
鈥? Sales and Service through Subsidiaries and Distributors Worldwide 鈥?
Cleveland, Ohio 44117-1199 U.S.A. TEL: 216.481.8100 FAX: 216.486.1751 WEB SITE: www.lincolnelectric.com
SAFETY
i i
WARNING
CALIFORNIA PROPOSITION 65 WARNINGS
The engine exhaust from this product contains
Diesel engine exhaust and some of its constituents
chemicals known to the State of California to cause
are known to the State of California to cause can-
cancer, birth defects, or other reproductive harm.
cer, birth defects, and other reproductive harm.
The Above For Gasoline Engines
The Above For Diesel Engines
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
purchase a copy of 鈥淪afety in Welding & Cutting - ANSI Standard Z49.1鈥? from the American Welding Society, P.O. Box
351040, Miami, Florida 33135 or CSA Standard W117.2-1974. A Free copy of 鈥淎rc Welding Safety鈥? booklet E205 is available
from the Lincoln Electric Company, 22801 St. Clair Avenue, Cleveland, Ohio 44117-1199.
BE SURE THAT ALL INSTALLATION, OPERATION, MAINTENANCE AND REPAIR PROCEDURES ARE
PERFORMED ONLY BY QUALIFIED INDIVIDUALS.
FOR ENGINE 1.h. To avoid scalding, do not remove the
powered equipment. radiator pressure cap when the engine is
hot.
1.a. Turn the engine off before troubleshooting and maintenance
work unless the maintenance work requires it to be running.
____________________________________________________
1.b. Operate engines in open, well-ventilated
areas or vent the engine exhaust fumes
outdoors.
ELECTRIC AND
MAGNETIC FIELDS
may be dangerous
____________________________________________________
1.c. Do not add the fuel near an open flame
welding arc or when the engine is running.
Stop the engine and allow it to cool before 2.a. Electric current flowing through any conductor causes
refueling to prevent spilled fuel from vaporiz- localized Electric and Magnetic Fields (EMF). Welding
ing on contact with hot engine parts and current creates EMF fields around welding cables and
igniting. Do not spill fuel when filling tank. If welding machines
fuel is spilled, wipe it up and do not start
engine until fumes have been eliminated. 2.b. EMF fields may interfere with some pacemakers, and
____________________________________________________ welders having a pacemaker should consult their physician
1.d. Keep all equipment safety guards, covers and devices in before welding.
position and in good repair.Keep hands, hair, clothing and
tools away from V-belts, gears, fans and all other moving 2.c. Exposure to EMF fields in welding may have other health
parts when starting, operating or repairing equipment. effects which are now not known.
____________________________________________________
2.d. All welders should use the following procedures in order to
1.e. In some cases it may be necessary to remove safety
minimize exposure to EMF fields from the welding circuit:
guards to perform required maintenance. Remove
guards only when necessary and replace them when the
2.d.1. Route the electrode and work cables together - Secure
maintenance requiring their removal is complete.
them with tape when possible.
Always use the greatest care when working near moving
parts.
2.d.2. Never coil the electrode lead around your body.
___________________________________________________
1.f. Do not put your hands near the engine fan.
2.d.3. Do not place your body between the electrode and
Do not attempt to override the governor or
idler by pushing on the throttle control rods work cables. If the electrode cable is on your right
while the engine is running. side, the work cable should also be on your right side.
2.d.4. Connect the work cable to the workpiece as close as
possible to the area being welded.
___________________________________________________
1.g. To prevent accidentally starting gasoline engines while 2.d.5. Do not work next to welding power source.
turning the engine or welding generator during maintenance
work, disconnect the spark plug wires, distributor cap or
Mar 驶95
magneto wire as appropriate.
SAFETY
ii ii
ARC RAYS can burn.
ELECTRIC SHOCK can
kill. 4.a. Use a shield with the proper filter and cover
plates to protect your eyes from sparks and
3.a. The electrode and work (or ground) circuits
the rays of the arc when welding or observing
are electrically 鈥渉ot鈥? when the welder is on. open arc welding. Headshield and filter lens
Do not touch these 鈥渉ot鈥? parts with your bare should conform to ANSI Z87. I standards.
skin or wet clothing. Wear dry, hole-free
gloves to insulate hands. 4.b. Use suitable clothing made from durable flame-resistant
material to protect your skin and that of your helpers from
3.b. Insulate yourself from work and ground using dry insulation. the arc rays.
Make certain the insulation is large enough to cover your full
area of physical contact with work and ground. 4.c. Protect other nearby personnel with suitable, non-flammable
screening and/or warn them not to watch the arc nor expose
In addition to the normal safety precautions, if welding themselves to the arc rays or to hot spatter or metal.
must be performed under electrically hazardous
conditions (in damp locations or while wearing wet
FUMES AND GASES
clothing; on metal structures such as floors, gratings or
scaffolds; when in cramped positions such as sitting,
can be dangerous.
kneeling or lying, if there is a high risk of unavoidable or
accidental contact with the workpiece or ground) use
the following equipment: 5.a. Welding may produce fumes and gases
hazardous to health. Avoid breathing these
鈥? Semiautomatic DC Constant Voltage (Wire) Welder.
fumes and gases.When welding, keep
鈥? DC Manual (Stick) Welder.
your head out of the fume. Use enough
鈥? AC Welder with Reduced Voltage Control.
ventilation and/or exhaust at the arc to keep
fumes and gases away from the breathing zone. When
3.c. In semiautomatic or automatic wire welding, the electrode,
welding with electrodes which require special
electrode reel, welding head, nozzle or semiautomatic
ventilation such as stainless or hard facing (see
welding gun are also electrically 鈥渉ot鈥?.
instructions on container or MSDS) or on lead or
cadmium plated steel and other metals or coatings
3.d. Always be sure the work cable makes a good electrical
which produce highly toxic fumes, keep exposure as
connection with the metal being welded. The connection
low as possible and below Threshold Limit Values (TLV)
should be as close as possible to the area being welded.
using local exhaust or mechanical ventilation. In
confined spaces or in some circumstances, outdoors, a
3.e. Ground the work or metal to be welded to a good electrical
respirator may be required. Additional precautions are
(earth) ground.
also required when welding on galvanized steel.
3.f. Maintain the electrode holder, work clamp, welding cable and
5. b. The operation of welding fume control equipment is affected
welding machine in good, safe operating condition. Replace
by various factors including proper use and positioning of
damaged insulation.
the equipment, maintenance of the equipment and the spe-
cific welding procedure and applicaiton involved. Worker
3.g. Never dip the electrode in water for cooling.
exposure level should be checked upon installation and
periodically thereafter to be certain it is within applicable
3.h. Never simultaneously touch electrically 鈥渉ot鈥? parts of
OSHA PEL and ACGIH TLV limits.
electrode holders connected to two welders because voltage
between the two can be the total of the open circuit voltage
5.c. Do not weld in locations near chlorinated hydrocarbon vapors
of both welders.
coming from degreasing, cleaning or spraying operations.
The heat and rays of the arc can react with solvent vapors to
3.i. When working above floor level, use a safety belt to protect
form phosgene, a highly toxic gas, and other irritating prod-
yourself from a fall should you get a shock.
ucts.
3.j. Also see Items 6.c. and 8.
5.d. Shielding gases used for arc welding can displace air and
cause injury or death. Always use enough ventilation,
especially in confined areas, to insure breathing air is safe.
5.e. Read and understand the manufacturer始s instructions for this
equipment and the consumables to be used, including the
material safety data sheet (MSDS) and follow your
employer始s safety practices. MSDS forms are available from
your welding distributor or from the manufacturer.
5.f. Also see item 1.b.
AUG 06
SAFETY
iii iii
WELDING and CUTTING CYLINDER may explode
SPARKS can if damaged.
cause fire or explosion. 7.a. Use only compressed gas cylinders
6.a. Remove fire hazards from the welding area. containing the correct shielding gas for the
If this is not possible, cover them to prevent process used and properly operating
the welding sparks from starting a fire. regulators designed for the gas and
Remember that welding sparks and hot pressure used. All hoses, fittings, etc. should be suitable for
materials from welding can easily go through small cracks the application and maintained in good condition.
and openings to adjacent areas. Avoid welding near
hydraulic lines. Have a fire extinguisher readily available. 7.b. Always keep cylinders in an upright position securely
chained to an undercarriage or fixed support.
6.b. Where compressed gases are to be used at the job site,
special precautions should be used to prevent hazardous 7.c. Cylinders should be located:
situations. Refer to 鈥淪afety in Welding and Cutting鈥? (ANSI 鈥? Away from areas where they may be struck or subjected to
Standard Z49.1) and the operating information for the physical damage.
equipment being used.
鈥? A safe distance from arc welding or cutting operations and
6.c. When not welding, make certain no part of the electrode any other source of heat, sparks, or flame.
circuit is touching the work or ground. Accidental contact
can cause overheating and create a fire hazard. 7.d. Never allow the electrode, electrode holder or any other
electrically 鈥渉ot鈥? parts to touch a cylinder.
6.d. Do not heat, cut or weld tanks, drums or containers until the
proper steps have been taken to insure that such procedures 7.e. Keep your head and face away from the cylinder valve outlet
will not cause flammable or toxic vapors from substances when opening the cylinder valve.
inside. They can cause an explosion even though they have
been 鈥渃leaned鈥?. For information, purchase 鈥淩ecommended 7.f. Valve protection caps should always be in place and hand
Safe Practices for the Preparation for Welding and Cutting of tight except when the cylinder is in use or connected for
Containers and Piping That Have Held Hazardous use.
Substances鈥?, AWS F4.1 from the American Welding Society
(see address above). 7.g. Read and follow the instructions on compressed gas
cylinders, associated equipment, and CGA publication P-l,
6.e. Vent hollow castings or containers before heating, cutting or 鈥淧recautions for Safe Handling of Compressed Gases in
welding. They may explode. Cylinders,鈥? available from the Compressed Gas Association
1235 Jefferson Davis Highway, Arlington, VA 22202.
6.f. Sparks and spatter are thrown from the welding arc. Wear oil
FOR ELECTRICALLY
free protective garments such as leather gloves, heavy shirt,
cuffless trousers, high shoes and a cap over your hair. Wear
powered equipment.
ear plugs when welding out of position or in confined places.
Always wear safety glasses with side shields when in a
welding area.
8.a. Turn off input power using the disconnect
6.g. Connect the work cable to the work as close to the welding switch at the fuse box before working on
area as practical. Work cables connected to the building the equipment.
framework or other locations away from the welding area
8.b. Install equipment in accordance with the U.S. National
increase the possibility of the welding current passing
Electrical Code, all local codes and the manufacturer始s
through lifting chains, crane cables or other alternate cir-
recommendations.
cuits. This can create fire hazards or overheat lifting chains
or cables until they fail.
8.c. Ground the equipment in accordance with the U.S. National
Electrical Code and the manufacturer始s recommendations.
6.h. Also see item 1.c.
Jan, 07
6.I. Read and follow NFPA 51B 鈥? Standard for Fire Prevention
During Welding, Cutting and Other Hot Work鈥?, available
from NFPA, 1 Batterymarch Park,PO box 9101, Quincy, Ma
022690-9101.
6.j. Do not use a welding power source for pipe thawing.
SAFETY
iv iv
PR脡CAUTIONS DE S脹RET脡 5. Toujours porter des lunettes de s茅curit茅 dans la zone de
soudage. Utiliser des lunettes avec 茅crans lateraux dans les
zones o霉 l始on pique le laitier.
Pour votre propre protection lire et observer toutes les instructions
et les pr茅cautions de s没ret茅 specifiques qui parraissent dans ce
6. Eloigner les mat茅riaux inflammables ou les recouvrir afin de
manuel aussi bien que les pr茅cautions de s没ret茅 g茅n茅rales suiv-
pr茅venir tout risque d始incendie d没 aux 茅tincelles.
antes:
7. Quand on ne soude pas, poser la pince 脿 une endroit isol茅 de
S没ret茅 Pour Soudage A L始Arc
la masse. Un court-circuit accidental peut provoquer un
1. Protegez-vous contre la secousse 茅lectrique:
茅chauffement et un risque d始incendie.
a. Les circuits 脿 l始茅lectrode et 脿 la pi茅ce sont sous tension
8. S始assurer que la masse est connect茅e le plus pr茅s possible
quand la machine 脿 souder est en marche. Eviter toujours
de la zone de travail qu始il est pratique de le faire. Si on place
tout contact entre les parties sous tension et la peau nue
la masse sur la charpente de la construction ou d始autres
ou les v茅tements mouill茅s. Porter des gants secs et sans
endroits 茅loign茅s de la zone de travail, on augmente le risque
trous pour isoler les mains.
de voir passer le courant de soudage par les chaines de lev-
b. Faire tr茅s attention de bien s始isoler de la masse quand on
age, c芒bles de grue, ou autres circuits. Cela peut provoquer
soude dans des endroits humides, ou sur un plancher
des risques d始incendie ou d始echauffement des chaines et des
metallique ou des grilles metalliques, principalement dans
c芒bles jusqu始脿 ce qu始ils se rompent.
les positions assis ou couch茅 pour lesquelles une grande
partie du corps peut 锚tre en contact avec la masse.
9. Assurer une ventilation suffisante dans la zone de soudage.
c. Maintenir le porte-茅lectrode, la pince de masse, le c芒ble
Ceci est particuli茅rement important pour le soudage de t么les
de soudage et la machine 脿 souder en bon et s没r 茅tat
galvanis茅es plomb茅es, ou cadmi茅es ou tout autre m茅tal qui
defonctionnement.
produit des fume茅s toxiques.
d.Ne jamais plonger le porte-茅lectrode dans l始eau pour le
refroidir.
10. Ne pas souder en pr茅sence de vapeurs de chlore provenant
e. Ne jamais toucher simultan茅ment les parties sous tension
d始op茅rations de d茅graissage, nettoyage ou pistolage. La
des porte-茅lectrodes connect茅s 脿 deux machines 脿 souder
chaleur ou les rayons de l始arc peuvent r茅agir avec les vapeurs
parce que la tension entre les deux pinces peut 锚tre le
du solvant pour produire du phosg茅ne (gas fortement toxique)
total de la tension 脿 vide des deux machines.
ou autres produits irritants.
f. Si on utilise la machine 脿 souder comme une source de
courant pour soudage semi-automatique, ces precautions
11. Pour obtenir de plus amples renseignements sur la s没ret茅,
pour le porte-茅lectrode s始applicuent aussi au pistolet de
voir le code 鈥淐ode for safety in welding and cutting鈥? CSA
soudage.
Standard W 117.2-1974.
2. Dans le cas de travail au dessus du niveau du sol, se prot茅ger
contre les chutes dans le cas ou on recoit un choc. Ne jamais
enrouler le c芒ble-茅lectrode autour de n始importe quelle partie
PR脡CAUTIONS DE S脹RET脡 POUR
du corps.
LES MACHINES 脌 SOUDER 脌
3. Un coup d始arc peut 锚tre plus s茅v猫re qu始un coup de soliel,
TRANSFORMATEUR ET 脌
donc:
REDRESSEUR
a. Utiliser un bon masque avec un verre filtrant appropri茅
ainsi qu始un verre blanc afin de se prot茅ger les yeux du ray-
onnement de l始arc et des projections quand on soude ou
quand on regarde l始arc. 1. Relier 脿 la terre le chassis du poste conformement au code de
b. Porter des v锚tements convenables afin de prot茅ger la l始茅lectricit茅 et aux recommendations du fabricant. Le dispositif
peau de soudeur et des aides contre le rayonnement de de montage ou la piece 脿 souder doit 锚tre branch茅 脿 une
l驶arc. bonne mise 脿 la terre.
c. Prot茅ger l始autre personnel travaillant 脿 proximit茅 au
soudage 脿 l始aide d始茅crans appropri茅s et non-inflammables. 2. Autant que possible, I始installation et l始entretien du poste seront
effectu茅s par un 茅lectricien qualifi茅.
4. Des gouttes de laitier en fusion sont 茅mises de l始arc de
soudage. Se prot茅ger avec des v锚tements de protection libres 3. Avant de faires des travaux 脿 l始interieur de poste, la debranch-
de l始huile, tels que les gants en cuir, chemise 茅paisse, pan- er 脿 l始interrupteur 脿 la boite de fusibles.
talons sans revers, et chaussures montantes.
4. Garder tous les couvercles et dispositifs de s没ret茅 脿 leur
place.
Mar. 驶93
v v
for selecting a QUALITY product by Lincoln Electric. We want you
to take pride in operating this Lincoln Electric Company product
Thank You 鈥⑩?⑩?? as much pride as we have in bringing this product to you!
CUSTOMER ASSISTANCE POLICY
The business of The Lincoln Electric Company is manufacturing and selling high quality welding equipment, consumables, and cutting equip-
ment. Our challenge is to meet the needs of our customers and to exceed their expectations. On occasion, purchasers may ask Lincoln
Electric for advice or information about their use of our products. We respond to our customers based on the best information in our posses-
sion at that time. Lincoln Electric is not in a position to warrant or guarantee such advice, and assumes no liability, with respect to such infor-
mation or advice. We expressly disclaim any warranty of any kind, including any warranty of fitness for any customer始s particular purpose,
with respect to such information or advice. As a matter of practical consideration, we also cannot assume any responsibility for updating or
correcting any such information or advice once it has been given, nor does the provision of information or advice create, expand or alter any
warranty with respect to the sale of our products.
Lincoln Electric is a responsive manufacturer, but the selection and use of specific products sold by Lincoln Electric is solely within the control
of, and remains the sole responsibility of the customer. Many variables beyond the control of Lincoln Electric affect the results obtained in
applying these types of fabrication methods and service requirements.
Subject to Change 鈥? This information is accurate to the best of our knowledge at the time of printing. Please refer to www.lincolnelectric.com
for any updated information.
Please 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.
鈥? 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.
鈥? For On-Line Registration: Go to our WEB SITE at www.lincolnelectric.com. Choose 鈥淨uick Links鈥? and then
鈥淧roduct Registration鈥?. 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 provided for your protection.
The level of seriousness to be applied to each is explained below:
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 OF CONTENTS vi
vi
Page
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Section A
Technical Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .A-1
Safety Precautions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .A-2
Location / Ventilation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .A-2
Storing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .A-2
Stacking . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .A-2
Angle of Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .A-2
Lifting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .A-3
High Altitude Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .A-3
High Temperature Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .A-3
Towing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .A-3
Vehicle Mounting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .A-3
Pre-Operation Engine and Compressor Service . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .A-4
Oil . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .A-4
Fuel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .A-4
Fuel Cap . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .A-4
Engine Cooling System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .A-4
Battery Connection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .A-4
Muffler Outlet Pipe . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .A-5
Spark Arrestor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .A-5
Welding Terminals . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .A-5
Welding Output Cables . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .A-5
Machine Grounding . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .A-5
Remote Control . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .A-6
Auxiliary Power Receptacles . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .A-6
Standby Power Connections . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .A-6
Connection of Vantage 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
Engine Controls . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .B-2, B-3
Welder Controls . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .B-4
Auxiliary Power Controls . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .B-4
Engine Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .B-5
Starting the Engine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .B-5
Stopping the Engine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .B-5
Break-In Period . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .B-6
Typical Fuel Consumption . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .B-6
Duty Cycle . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .B-6
Welding Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .B-6
Stick Welding Mode . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .B-6
CC-Stick Mode . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .B-6
Downhill Pipe Mode . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .B-6
Touch Start TIG Mode . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .B-6
Vantage Settings when using K930-2 TIG Module . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .B-7
Typical Current Ranges for Tungsten Electrodes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .B-7
CV-Wire Mode . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .B-8
Arc Gouging . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .B-8
Paralleling . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .B-8
Auxiliary Power Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .B-8
Simultaneous Welding and Auxiliary Power Loads . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .B-8
Simultaneous Welding and Power Loads, Extension Cord Length Recommendations . . . . . . . . . . .B-9
TABLE OF CONTENTS
vii
Page
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,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
INSTALLATION
A-1 A-1
TECHNICAL SPECIFICATIONS - VANTAGE 500 DEUTZ (K2405-1)
INPUT - DIESEL ENGINE
Make /Model Description Speed (RPM) Displacement Starting Capacities
System
DEUTZ 4 cylinder High Idle 1890 190 cu. in 12VDC battery Fuel
F4L2011 48HP (36 kw) Low Idle 1425 (3.1L) & Starter 25 US gal.
Diesel Engine @ 1800 RPM Full Load 1800 (94.6L)
Bore x Stroke Oil:
2.5 US gal.
3.70鈥? x 4.41鈥? (9.5L)
(94mm x 112mm)
RATED OUTPUT @ 104掳F(40掳C) - WELDER
Duty Cycle Welding Output Volts 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
OUTPUT @ 104掳F(40掳C) - WELDER AND GENERATOR
Welding Range
30 - 575 Amps CC/CV
20 - 250 Amps TIG
Open Circuit Voltage
60 Max OCV @ 1900 RPM
Auxiliary Power (1)
120/240 VAC
12,000 WATTS, 60 Hz., Single Phase
20,000 WATTS, 60 Hz., Three Phase
PHYSICAL DIMENSIONS
Height (2) Width Depth Weight
42.0 in 31.5 in. 63.1 in. 1532lbs.
(1066.8 mm) (800.1mm) (1603mm) (695kg)
(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. Top of Enclosure. Add 8.9鈥? (226mm) for exhaust.
VANTAGE 500 DEUTZ
INSTALLATION
A-2 A-2
LOCATION / VENTILATION
Read this entire installation section before you
start installation.
The welder should be located to provide an unrestrict-
SAFETY PRECAUTIONS ed flow of clean, cool air to the cooling air inlets and to
avoid restricting the cooling air outlets. Also, locate
WARNING the welder so that the engine exhaust fumes are prop-
erly vented to an outside area.
Do not attempt to use this equipment until you
have thoroughly read all operating and mainte-
CAUTION
nance manuals supplied with your machine. They
include important safety precautions, detailed
DO NOT MOUNT OVER COMBUSTIBLE SUR-
engine starting, operating and maintenance
FACES
instructions and parts lists.
Where there is a combustible surface directly
ELECTRIC SHOCK can kill. under stationary or fixed electrical equipment, that
鈥? Do not touch electrically live parts surface should be covered with a steel plate at
such as output terminals or internal least .06鈥?(1.6mm) thick, which should extend not
wiring. less than 5.90鈥?(150mm) beyond the equipment on
all sides.
鈥? Insulate yourself from the work and
ground. ------------------------------------------------------------------------
STORING
鈥? Always wear dry insulating gloves.
------------------------------------------------------------------------
1. Store the machine in a cool, dry place when it is
ENGINE EXHAUST can kill. not in use. Protect it from dust and dirt. Keep it
where it can始t be accidentally damaged from con-
鈥? Use in open, well ventilated areas or
struction activities, moving vehicles, and other
vent exhaust outside
hazards.
2. Drain the engine oil and refill with fresh 10W30
------------------------------------------------------------------------
oil. Run the engine for about five minutes to cir-
MOVING PARTS can injure. culate oil to all the parts. See the MAINTE-
NANCE section of this manual for details on
鈥? Do not operate with doors open or
changing oil.
guards off.
3. Remove the battery, recharge it, and adjust the
鈥? Stop engine before servicing.
electrolyte level. Store the battery in a dry, dark
鈥? Keep away from moving parts place.
------------------------------------------------------------------------
Only qualified personnel should install, use or ser-
STACKING
vice this equipment.
VANTAGE 500 DEUTZ machines cannot be stacked.
------------------------------------------------------------------------
ANGLE OF OPERATION
To achieve optimum engine performance the VAN-
TAGE 500 DEUTZ should be run in a level position.
The maximum angle of operation for the Deutz engine
is 30 degrees in all directions. When operating the
welder at an angle, provisions must be made for
checking and maintaining the oil level at the normal
(FULL) oil capacity. Also the effective fuel capacity will
be slightly less than the specified 25 gal.(94.6 ltrs.).
VANTAGE 500 DEUTZ
INSTALLATION
A-3 A-3
TOWING
LIFTING
The recommended trailer for use with this equipment
The VANTAGE 500 DEUTZ lift bale should be used to
for road, in-plant and yard towing by a vehicle (1) is
lift the machine. The VANTAGE 500 DEUTZ is
Lincoln始s K953-1. If the user adapts a non-Lincoln
shipped with the lift bale retracted. Before attempting
trailer, he must assume responsibility that the method
to lift the VANTAGE 500 DEUTZ the lift bale must be
of attachment and usage does not result in a safety
secured in a raised position. Secure the lift bale as fol-
hazard nor damage the welding equipment. Some of
lows:
the factors to be considered are as follows:
a. Open the engine compartment door.
1. Design capacity of trailer vs. weight of Lincoln
b. Locate the 2 access holes on the upper middle equipment and likely additional attachments.
region of compartment wall just below the lift
2. Proper support of, and attachment to, the base
bale.
of the welding equipment so that there will be
c. Use the lifting strap to raise the lift bale to the no undue stress to the trailer始s framework.
full upright position. This will align the mount-
3. Proper placement of the equipment on the
ing holes on the lift bale with the access holes.
trailer to insure stability side to side and front
d. Secure the lift bale with 2 thread forming to back when being moved and when standing
screws. The screws are provided in the by itself.
shipped loose parts bag.
4. Typical conditions of use, such as travel
WARNING
speed, roughness of surface on which the
trailer will be operated, and environmental
conditions.
鈥? Lift only with equipment of ade-
5. Proper preventative maintenance of trailer.
quate lifting capacity.
6. Conformance with federal, state and local laws
鈥? Be sure machine is stable when
.
lifting.
(1)
鈥? Do not lift this machine using lift Consult applicable federal, state and local laws
bale if it is equipped with a heavy
(1)
regarding specific requirements for use on public
accessory such as trailer or gas
highways.
cylinder.
FALLING 鈥? Do not lift machine if lift bale is
VEHICLE MOUNTING
EQUIPMENT can damaged.
cause injury. 鈥? Do not operate machine while
WARNING
suspended from lift bale.
Improperly mounted concentrated loads may
------------------------------------------------------------------------
cause unstable vehicle handling and tires or other
HIGH ALTITUDE OPERATION components to fail.
鈥? Only transport this Equipment on serviceable
At higher altitudes, output derating may be necessary.
vehicles which are rated and designed for such
For maximum rating, derate the welder output 5% for
loads.
every 300 meters (984 ft.) above 1500 meters (4920
鈥? Distribute, balance and secure loads so vehicle
ft.). For output of 500A and below, derate the welder
is stable under conditions of use.
output 5% for every 300 meters (984 ft.) above 2100
鈥? Do not exceed maximum rated loads for compo-
meters (6888 ft.).
nents such as suspension, axles and tires.
Contact a Deutz Service Representative for any 鈥? Mount equipment base to metal bed or frame of
engine adjustments that may be required. vehicle.
鈥? Follow vehicle manufacturer始s instructions.
------------------------------------------------------------------------
HIGH TEMPERATURE OPERATION
At temperatures above 104掳F (40掳C), output voltage
derating may be necessary. For maximum output cur-
rent ratings, derate welder voltage rating 2 volts for
every 21掳F (10掳C) above 104掳F (40掳C).
VANTAGE 500 DEUTZ
INSTALLATION
A-4 A-4
ENGINE BREAK-IN
PRE-OPERATION ENGINE
READ the engine operating and maintenance instruc-
Lincoln Electric selects high quality, heavy-duty indus-
tions supplied with this machine.
trial engines for the portable welding machines we
WARNING
offer. While it is normal to see a small amount of
crankcase oil consumption during initial operation,
excessive oil use, wet stacking (oil or tar like sub-
鈥? Keep hands away from the engine stance at the exhaust port), or excessive smoke is not
muffler or HOT engine parts. normal.
鈥? Stop engine and allow to cool before
fuelling. Larger machines with a capacity of 350 amperes and
higher, which are operated at low or no-load condi-
鈥? Do not smoke when fuelling.
tions for extended periods of time are especially sus-
鈥? Fill fuel tank at a moderate rate and do not over- ceptible to the conditions described above. To
fill. accomplish successful engine break-in, most diesel-
鈥? Wipe up spilled fuel and allow fumes to clear powered equipment needs only to be run at a reason-
before starting engine. ably heavy load within the rating of the welder for
some period of time during the engine始s early life.
鈥? Keep sparks and flame away from tank.
However, if the welder is subjected to extensive light
------------------------------------------------------------------------ loading, occasional moderate to heavy loading of the
OIL engine may sometimes be necessary. Caution must
be observed in correctly loading a diesel/generator
The VANTAGE 500 DEUTZ is shipped with the
unit.
engine crankcase filled with high quality SAE 10W-30
oil (API class CD or better). Check the engine oil level
1. Connect the welder output studs to a suitable
before starting the engine. If it is not up to the full
resistive load bank. Note that any attempt to short
mark on the dip stick, add oil as required. Check the
the output studs by connecting the welding leads
oil level every four hours of running time during the
together, direct shorting of the output studs, or con-
first 35 running hours. Refer to the engine Operator始s
necting the output leads to a length of steel will
Manuals for specific oil recommendations and break-
result in catastrophic damage to the generator and
in information. The oil change interval is dependent on
voids the warranty.
the quality of the oil and the operating environment.
Refer to the engine Operator始s Manuals for the proper
2. Set the welder controls for an output current and
service and maintenance intervals.
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 cat-
FUEL USE DIESEL FUEL ONLY astrophic damage to the generator and voids the
warranty.
Fill the fuel tank with clean, fresh diesel fuel. The
capacity of the fuel tank is approximately 25 gallons
3. Periodically shut off the engine and check the
(95 liters). See engine Operator始s Manual for specific
crankcase oil level.
fuel recommendations. Running out of fuel may
require bleeding the fuel injection pump. NOTE:
BATTERY CONNECTION
Before starting the engine, open the fuel shutoff valve
(pointer to be in line with hose).
WARNING
FUEL CAP
Remove the plastic cap covering from the Fuel Tank GASES FROM BATTERY can explode.
Filler neck and install the Fuel Cap.
鈥? Keep sparks, flame and cigarettes
ENGINE COOLING SYSTEM away from battery.
To prevent EXPLOSION when:
The Deutz engine is air cooled by the belt driven axial
blower. The oil cooler and engine cooling fins should 鈥? INSTALLING A NEW BATTERY 鈥?
be blown out with compressed air or steam to main- disconnect negative cable from old
tain proper cooling. (See the engine Owners Manual battery first and connect to new bat-
for procedures and frequency). tery last.
VANTAGE 500 DEUTZ
INSTALLATION
A-5 A-5
WELDING TERMINALS
鈥? CONNECTING A BATTERY CHARGER 鈥? remove
The VANTAGE 500 DEUTZ is equipped with a toggle
battery from welder by disconnecting negative
switch for selecting "hot" welding terminals when in the
cable first, then positive cable and battery clamp.
"WELD TERMINALS ON" position or "cold" welding termi-
When reinstalling, connect negative cable last.
nals when in the "REMOTELY CONTROLLED" position.
Keep well ventilated.
WELDING OUTPUT CABLES
鈥? USING A BOOSTER 鈥? connect positive lead to
battery first then connect negative lead to nega-
With the engine off, route the electrode and work cables
tive battery lead at engine foot.
thru the strain relief bracket provided on the front of the
BATTERY ACID can burn eyes and base and connect to the terminals provided. These con-
skin. nections should be checked periodically and tightened if
鈥? Wear gloves and eye protection and necessary.
be careful when working near bat- Listed in Table A.1 are copper cable sizes recommended
tery. for the rated current and duty cycle. Lengths stipulated are
鈥? Follow instructions printed on bat- the distance from the welder to work and back to the
tery. welder again. Cable sizes are increased for greater lengths
primarily for the purpose of minimizing cable voltage drop.
IMPORTANT: To prevent ELECTRICAL DAMAGE
Table A.1 Combined Length of Electrode and Work
WHEN:
Cables.
a) Installing new batteries.
TOTAL COMBINED LENGTH OF ELEC-
b) Using a booster. TRODE AND WORK CABLES
Use correct polarity 鈥? Negative Ground. AMPS Up to 150ft 150-200ft 200-250ft
@100% Up to 492m 492-656m 656-820m
The VANTAGE 500 DEUTZ is shipped with the nega- Duty Cycle
tive battery cable disconnected. Before you operate
500 3/0 AWG 3/0 AWG 4/0 AWG
the machine, make sure the Engine Switch is in the
OFF position and attach the disconnected cable
securely to the negative (-) battery terminal.
MACHINE GROUNDING
Remove the insulating cap from the negative battery
Because this portable engine driven welder creates its own
terminal. Replace and tighten negative battery cable
power, it is not necessary to connect its frame to an earth
terminal. NOTE: This machine is furnished with a wet
ground, unless the machine is connected to premises
charged battery; if unused for several months, the bat-
wiring (home, shop, etc.).
tery may require a booster charge. Be sure to use the
correct polarity when charging the battery. To prevent dangerous electric shock, other equipment
powered by this engine driven welder must:
MUFFLER OUTLET PIPE
a) be grounded to the frame of the welder using a
Remove the plastic plug covering the muffler outlet grounded type plug, or
tube. Using the clamp provided secure the outlet pipe
b) be double insulated.
to the outlet tube with the pipe positioned such that it
When this welder is mounted on a truck or trailer, its frame
will direct the exhaust in the desired position.
must be securely connected to the metal frame of the vehi-
SPARK ARRESTOR cle. When this engine driven welder is connected to
premises wiring such as that in a home or shop, its frame
Some federal, state or local laws may require that
must be connected to the system earth ground. See further
petrol or diesel engines be equipped with exhaust
connection instructions in the section entitled 鈥淪tandby
spark arresters when they are operated in certain
Power Connections鈥? as well as the article on grounding in
locations where unarrested sparks may present a fire
the latest National Electrical Code and the local codes.
hazard. The standard muffler included with this welder
does not qualify as a spark arrestor. When required by In general, if the machine is to be grounded, it should be
local regulations, a suitable spark arrestor, must be connected with a #8 or larger copper wire to a solid earth
installed and properly maintained. ground such as a metal ground stake going into the ground
for at least 10Ft.(3.1m) or to the metal framework of a
CAUTION building which has been effectively grounded. The National
Electric Code lists a number of alternate means of ground-
ing electrical equipment. A machine grounding stud
An incorrect arrestor may lead to damage to the
marked with the symbol is provided on the front of the
engine or adversely affect performance.
welder.
---------------------------------------------------------------------
VANTAGE 500 DEUTZ
INSTALLATION
A-6 A-6
REMOTE CONTROL Note: The two 120V GFCI receptacles and the two
120 volt circuits of the 120/240V receptacle are con-
OUTPUT nected to different phases and can not be paralleled.
The VANTAGE 500 DEUTZ is equipped with a 6-pin
STANDBY POWER CONNECTIONS
and a 14-pin connector. The 6-pin connector is for
connecting the K857 or K857-1 Remote Control or for
The VANTAGE 500 DEUTZ is suitable for temporary,
TIG welding, the K870 foot Amptrol or the K936-2
standby or emergency power using the engine manu-
hand Amptrol. When in the CC-STICK, DOWNHILL
facturer始s recommended maintenance schedule.
PIPE, or CV-WIRE modes and when a remote control
is connected to the 6-pin Connector, the auto-sensing
The VANTAGE 500 DEUTZ can be permanently
circuit automatically switches the OUTPUT control
installed as a standby power unit for 240 volt-3 wire,
from control at the welder to remote control.
50 amp service. Connections must be made by a
licensed electrician who can determine how the
When in TOUCH START TIG mode and when a 120/240 VAC power can be adapted to the particular
Amptrol is connected to the 6-Pin Connector, the installation and comply with all applicable electrical
OUTPUT dial is used to set the maximum current codes. The following information can be used as a
range of the CURRENT CONTROL of the Amptrol. guide by the electrician for most applications. Refer to
the connection diagram shown in Figure A.2.
The 14-pin connector is used to directly connect a 1. Install the double-pole, double-throw switch
wire feeder control cable. In the CV-WIRE mode, between the power company meter and the premis-
when the control cable is connected to the 14-pin con- es disconnect.
nector, the auto-sensing circuit automatically makes
the Output Control inactive and the wire feeder volt- Switch rating must be the same or greater than the
age control active customer始s premises disconnect and service over cur-
NOTE: When a wire feeder with a built in welding volt- rent protection.
age control is connected to the 14-pin connector, do
not connect anything to the 6-pin connector.
AUXILIARY POWER RECEPTACLES
The auxiliary power capacity of the VANTAGE 500
DEUTZ is 12,000 watts of 60 Hz, single phase or
20,000 watts of 60Hz, three phase power. The auxil-
iary power capacity rating in watts is equivalent to
volt-amperes at unity power factor. The maximum per-
missible current of the 240 VAC output is 50 A. The
240 VAC single phase output can be split to provide
two separate 120 VAC outputs with a maximum per-
missible current of 50 A per output to two separate
120 VAC branch circuits. The output voltage is within
卤 10% at all loads up to rated capacity.
The VANTAGE 500 DEUTZ has two 20 Amp-120VAC
single phase(5-20R) GFCI duplex receptacles, one 50
Amp-120/240 single phase VAC (14-50R) receptacle
and one 240VAC three phase (15-50R) receptacle.
The auxiliary power receptacles should only be used
with three wire grounded type plugs or approved dou-
ble 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.
A 240VAC 3 phase plug is provided loose with the
machine.
VANTAGE 500 DEUTZ
INSTALLATION
A-7 A-7
2. Take necessary steps to assure load is limited to 3. Install a 50 amp 120/240 VAC plug (NEMA Type
the capacity of the VANTAGE 500 DEUTZ by 14-50) to the double-pole circuit breaker using No.
installing a 50 amp, 240 VAC double pole circuit 6, 4 conductor cable of the desired length. (The 50
breaker. Maximum rated load for each leg of the amp, 120/240 VAC plug is available in the optional
240 VAC auxiliary is 50 amps. Loading above the K802R plug kit.)
rated output will reduce output voltage below the
allowable -10% of rated voltage which may damage 4. Plug this cable into the 50 Amp 120/240 Volt recep-
appliances or other motor-driven equipment and tacle on the VANTAGE 500 DEUTZ case front.
may result in overheating of the VANTAGE 500
DEUTZ engine.
Figure A.2 Connection of the VANTAGE 500 DEUTZ to Premises Wiring
240 VOLT
GROUNDED CONDUCTOR
POWER
240 Volt 120 VOLT
60 Hz.
COMPANY
3-Wire
120 VOLT
Service
METER
NEUTRAL
BUS
N
LOAD
DOUBLE POLE DOUBLE THROW
SWITCH RATING TO BE THE SAME
AS OR GREATER THAN PREMISES
SERVICE OVERCURRENT
PROTECTION.
PREMISES
DISCONNECT AND
SERVICE
GROUND OVERCURRENT
50AMP
PROTECTION
240 VOLT
DOUBLE
POLE
50 AMP, 120/240 CIRCUIT
VOLT PLUG 240 VOLT BREAKER
NEMA TYPE 14-50
GND
N
50 AMP, 120/240 VOLT
NOTE: No. 6 COPPER CONDUCTOR CABLE SEE
RECEPTACLE
NATIONAL ELECTRICAL CODE FOR ALTERNATE WIRE
SIZE RECOMMENDATIONS.
VANTAGE 500 DEUTZ
INSTALLATION
A-8 A-8
CONNECTION OF LINCOLN ELECTRIC
WIRE FEEDERS 鈥? Across The-Arc Model:
Attach the single lead from the front of the LN-15
WARNING
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 cur-
Shut off welder before making any electrical con- rent.
nections.
鈥? Control Cable Model:
------------------------------------------------------------------------
Connect Control Cable between Engine Welder
CONNECTION OF LN-7, LN-8 OR LN-742 and Feeder.
TO THE VANTAGE 500 DEUTZ
Set the MODE switch to the "CV-WIRE " position.
鈥? Shut the welder off.
鈥? Across The-Arc Model:
鈥? Connect the LN-7, LN-8 OR LN-742 per instructions
Set the "WELD TERMINALS" switch to "WELD
on the appropriate connection diagram in the DIA-
TERMINALS ON"
GRAMS section.
鈥? Control Cable Model:
鈥? Set the 鈥淲IRE FEEDER VOLTMETER鈥? switch to
Set the "WELD TERMINALS" switch to
either 鈥?+鈥? or 鈥?-鈥? as required by the electrode being
"REMOTELY CONTROLLED"
used.
Set the "WIRE FEEDER VOLTMETER" switch to
鈥? Set the 鈥淪ELECTOR鈥? switch to the 鈥淐V-WIRE鈥? posi-
either "+" or "-" as required by the electrode polar-
tion.
ity being used.
鈥? Adjust the 鈥淎RC CONTROL鈥? knob to desired
Set the "ARC CONTROL" knob to "0" initially and
Crispness. SOFT for MIG and CRISP for
adjust to suit.
Innershield.
Set the "IDLE" switch to the "AUTO IDLE" position
鈥? Set the 鈥淲ELDING TERMINALS鈥? switch to the
鈥淩EMOTELY CONTROLLED鈥? position.
鈥? Set the 鈥淚DLE鈥? switch to the 鈥淗IGH鈥? position.
CONNECTION OF LN-15 TO THE VAN-
TAGE 500 DEUTZ
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.
鈥? Shut the welder off.
鈥? 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.
VANTAGE 500 DEUTZ
INSTALLATION
A-9 A-9
CONNECTION OF THE LN-25 TO THE CONNECTION OF AN NA-3 AUTOMATIC
VANTAGE 500 DEUTZ WELDING SYSTEM TO THE VANTAGE 500
DEUTZ
The LN-25 with or without an internal contactor may
be used with the VANTAGE 500 DEUTZ. See the For connection diagrams and instructions for connect-
appropriate connection diagram in the DIAGRAMS ing an NA-3 Welding System to the VANTAGE 500
section. DEUTZ, refer to the NA-3 Welding System instruction
manual. The connection diagram for the LN-8 can be
NOTE: The LN-25 (K431) Remote Control Module
used for connecting the NA-3.
and (K432) Remote Cable are not recommended for
use with the VANTAGE 500 DEUTZ.
鈥? Set the Wire Feeder Voltage Switch to 115V.
CONNECTION OF MAGNUM SC SPOOL
鈥? Shut the welder off.
GUN TO THE VANTAGE 500 DEUTZ (SEE
鈥? For electrode Positive, connect the electrode cable
SECTION F)
from the LN-25 to the 鈥?+鈥? terminal of the welder and
work cable to the 鈥?-鈥? terminal of the welder. For elec-
CONNECTION OF PRINCE XL SPOOL
trode Negative, connect the electrode cable from the
LN-25 to the 鈥?-鈥? terminal of the welder and work
GUN TO THE VANTAGE 500 DEUTZ
cable to the 鈥?+鈥? terminal of the welder.
鈥? Attach the single lead from the front of the LN-25 to
Connection of the Prince XL Spool Gun requires the
work using the spring clip at the end of the lead. This
use of the K1849-1 Adapter Module.
is a sense lead to supply current to the wire feeder
motor; it does not carry welding current.
鈥? Shut the Welder off.
鈥? Set the SELECTOR switch to the 鈥淐V-WIRE鈥? posi-
tion. 鈥? For electrode Positive, connect the electrode cable
to the "+" terminal of the welder and work cable to
鈥? Set the 鈥淲ELDING TERMINALS鈥? switch to 鈥淲ELD the "-" terminal of the welder. For electrode
TERMINALS ON鈥? Negative, connect the electrode cable "-" terminal
of the welder and work cable to the "+" terminal of
鈥? Adjust the 鈥淎RC CONTROL鈥? knob to desired crisp-
the welder.
ness. Generally, welding is best if the 鈥淎RC CON-
TROL鈥? is set to SOFT for MIG and CRISP for
鈥? Connect the Control Cable of the Spool Gun to the
INNERSHIELD. You may however, want to start in
Adapter Module and connect the Control Cable of
the middle and adjust (as needed) from there.
the Adapter Module to the Welder.
鈥? Set the 鈥淚DLE鈥? switch to the 鈥淎UTO鈥? position. When 鈥? Connect the Gas Hose.
not welding, the VANTAGE 500 DEUTZ engine will
be at the low idle speed. If you are using an LN-25 鈥? Set the MODE switch to the "CV-WIRE " position.
with an internal contactor, the electrode is not ener-
gized until the gun trigger is closed. 鈥? Set the "WELD TERMINALS" switch to "WELD
TERMINALS ON".
CAUTION 鈥? Set the "ARC CONTROL" knob to "0" initially and
adjust to suit.
If you are using an LN-25 without an internal con-
tactor, the electrode will be energized when the
鈥? Set the "IDLE" switch to the "High" position
VANTAGE 500 DEUTZ is started.
------------------------------------------------------------------------
鈥? When the gun trigger is closed, the current sensing
circuit will cause the wire to begin to feed and the
welding process is started.
VANTAGE 500 DEUTZ
OPERATION
B-1 B-1
SAFETY INSTRUCTIONS GENERAL DESCRIPTION
The VANTAGE 500 DEUTZ is a diesel engine-driven
Read and understand this entire section before
welding power source. The machine uses a brush
operating your VANTAGE 500 DEUTZ.
type alternating current generator for DC multi-pur-
WARNING pose welding, for 120/240 VAC single phase and
240V three phase auxiliary standby power. The weld-
ing control system uses state of the art Chopper
Do not attempt to use this equipment until you
Technology鈩?.
have thoroughly read all operating and mainte-
nance manuals supplied with your machine. They
RECOMMENDED APPLICATIONS
include important safety precautions, detailed
engine starting, operating and maintenance
WELDER
instructions and parts lists.
ELECTRIC SHOCK can kill. The VANTAGE 500 DEUTZ provides excellent con-
stant current DC welding output for stick (SMAW) and
鈥? Do not touch electrically live parts
TIG welding. The VANTAGE 500 DEUTZ also pro-
such as output terminals or internal
vides excellent constant voltage DC welding output for
wiring.
MIG (GMAW), Innershield (FCAW), Outershield
鈥? Insulate yourself from the work and (FCAW-G) and Metal Core welding. In addition the
ground. VANTAGE 500 DEUTZ can be used for Arc Gouging
鈥? Always wear dry insulating gloves. with carbons up to 3/8鈥?(10mm) in diameter.
The VANTAGE 500 DEUTZ is not recommended for
------------------------------------------------------------------------
pipe thawing.
ENGINE EXHAUST can kill.
鈥? Use in open, well ventilated areas or
GENERATOR
vent exhaust outside
The VANTAGE 500 DEUTZ provides smooth 120/240 VAC
鈥? Do not stack anything near the engine.
single phase and 240V three phase output for auxiliary
------------------------------------------------------------------------ power and emergency standby power.
MOVING PARTS can injure.
鈥? Do not operate with doors open or
guards off.
鈥? Stop engine before servicing.
鈥? Keep away from moving parts
------------------------------------------------------------------------
Only qualified personnel should operate this
equipment.
ADDITIONAL SAFETY PRECAUTIONS
Always 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.
VANTAGE 500 DEUTZ
OPERATION
B-2 B-2
CONTROLS AND SETTINGS
All welder and engine controls are located on the case front panel. Refer to Figure B.1 and the explanations that follow.
Figure B.1 Case Front Panel Controls
6 9
5 7 8
4 10
3
11
13
20
12
21
15
14 19
23
1
22
2
16
18
17
ENGINE CONTROLS (Items 1 through 9) 3. HOUR METER
1. RUN STOP SWITCH The hour meter displays the total time that the
engine has been running. This meter is a useful indi-
Toggling the switch to the RUN position energizes
cator for scheduling preventive maintenance.
the fuel solenoid for approximately 30 seconds. The
engine must be started within that time or the fuel
solenoid will degenerize, and the switch must be 4. FUEL LEVEL GAUGE
toggled to reset the timer.
Displays the level of diesel fuel in the fuel tank.
2. START PUSHBUTTON
The operator must watch the fuel level closely to
Energizes the starter motor to crank the engine. prevent running out of fuel and possibly having
With the engine "Run / Stop" switch in the "Run" to bleed the system.
position, push and hold the Start button to crank the
5. ENGINE TEMPERATURE GAUGE
engine; release as the engine starts. Do not press
The gauge displays the engine coolant temperature.
while engine is running since this can cause dam-
age to the ring gear and/or starter motor
VANTAGE 500 DEUTZ
OPERATION
B-3 B-3
6. OIL PRESSURE GAUGE
The gauge displays the engine oil pressure when c. When welding ceases and the AC power load
the engine is running. is turned off, a fixed time delay of approximate-
ly 12 seconds starts.
d. If the welding or AC power load is not restart-
7. ENGINE PROTECTION
ed before the end of the time delay, the idler
The yellow engine protection light remains off with reduces the engine speed to low idle speed.
proper oil pressure and under normal operating tem-
e. The engine will automatically return to high
peratures. If the light turns on, the engine protection
idle speed when the welding load or A.C.
system will stop the engine. Check for proper oil
power load is reapplied.
level and add oil if necessary. Check for loose or
disconnected leads at the oil pressure sender locat-
ed on the engine. The light will remain on when the Idler Operational exceptions
engine has been shut down due to low oil pressure
When the WELDING TERMINALS switch is in the
or over-temperature condition.
鈥淩emotely Controlled鈥? position the idler will operate as
follows:
8. BATTERY CHARGING LIGHT a. When the triggering device (Amptrol, Arc Start
The yellow engine alternator light is off when battery Switch, etc.) is pressed the engine will accelerate
charging system is functioning normally. If light turns and operate at full speed provided a welding load is
on, the engine protection system will shut down the applied within approximately 12 seconds.
engine. Check the Engine cooling blower belt. 鈥? If the triggering device remains pressed but no weld-
Also, the alternator or the voltage regulator may not ing load is applied within approximately 12 seconds
be operating correctly. The light may also come on the engine may return to low idle speed.
due to a faulty flashing circuit. The light will remain
鈥? If the triggering device is released or welding ceases
on when the engine is stopped and the run/stop
the engine will return to low idle speed after approxi-
switch is in the run position.
mately 12 seconds.
9. IDLER SWITCH
Has two positions as follows:
A) In the 鈥淗igh鈥? position , the engine runs at the
high idle speed controlled by the governor.
B) In the 鈥淎uto鈥? / position, the idler
operates as follows:
a. When switched from 鈥淗igh鈥? to 鈥淎uto鈥? or after
starting the engine, the engine will operate at
full speed for approximately 12 seconds and
then go to low idle speed.
b. When the electrode touches the work or power
is drawn for lights or tools (approximately 100
Watts minimum) the engine accelerates and
operates at full speed.
VANTAGE 500 DEUTZ
OPERATION
B-4 B-4
WELDING CONTROLS (Items 10 through 19) DOWNHILL PIPE mode: In this mode, the ARC CONTROL
knob sets the short circuit current (arc-force) during stick
10. OUTPUT CONTROL: The OUTPUT dial is used to preset
welding to adjust for a soft or a more forceful digging arc
the output voltage or current as displayed on the digital
(Crisp). Increasing the number from -10(Soft) to +10(Crisp)
meters for the four welding modes. When in the CC-STICK,
increases the short circuit current which results in a more
DOWNHILL PIPE or CV-WIRE modes and when a remote
forceful digging arc. Typically a forceful digging arc is pre-
control is connected to the 6-Pin or 14-Pin Connector, the
ferred for root and hot passes. A softer arc is preferred for fill
auto-sensing circuit automatically switches the OUTPUT
and cap passes where weld puddle control and deposition
CONTROL from control at the welder to the remote control.
(鈥渟tacking鈥? of iron) are key to fast travel speeds. It is recom-
In the CV-WIRE mode, when the wire feeder control cable is
mended that the ARC CONTROL be set initially at 0.
connected to the 14-Pin Connector, the auto-sensing circuit
CV-WIRE mode: In this mode, turning the ARC CONTROL
automatically makes OUTPUT CONTROL inactive and the
knob from -10(soft) to +10(crisp) changes the arc from soft
wire feeder voltage control active.
and washed-in to crisp and narrow. It acts as an induc-
tance/pinch control. The proper setting depends on the proce-
When in the TOUCH START TIG mode and when a Amptrol dure and operator preference. Start with a setting of 0.
is connected to the 6-Pin Connector, the OUTPUT dial is
14. WELDING TERMINALS SWITCH
used to set the maximum current range of the CURRENT
In the WELD TERMINALS ON position, the output is electri-
CONTROL of the Amptrol.
cally hot all the time. In the REMOTELY CONTROLLED posi-
11. DIGITAL OUTPUT METERS:
tion, the output is controlled by a wire feeder or amptrol
The digital meters allow the output voltage (CV-WIRE mode) device, and is electrically off until a remote switch is
or current (CC-STICK, DOWNHILL PIPE and TIG modes) to depressed.
be set prior to welding using the OUTPUT control knob.
15. WIRE FEEDER VOLTMETER SWITCH:
During welding, the meters display the actual output voltage
Matches the polarity of the wire feeder voltmeter to the polari-
(VOLTS) and current (AMPS). A memory feature holds the
ty of the electrode.
display of both meters on the seven seconds after welding is
stopped. This allows the operator to read the actual current 16. 6 - PIN CONNECTOR
and voltage just prior to when welding was ceased. While the
For attaching optional remote control equipment. Includes
display is being held the left-most decimal point in each dis-
auto-sensing remote control circuit.
play will be flashing. The accuracy of the meters is 卤 3%.
17. 14 - PIN CONNECTOR
12. WELD MODE SELECTOR SWITCH:
For attaching wire feeder control cables. Includes contactor
(Provides four selectable welding modes)
closure circuit, auto-sensing remote control circuit, and
CV-WIRE 120VAC and 42VAC power.
DOWNHILL PIPE NOTE: When a wire feeder with a built in welding voltage con-
trol is connected to the 14-pin connector, do not connect any-
CC-STICK
thing to the 6-pin connector.
TOUCH START TIG
18. WELD OUTPUT TERMINALS + AND -
13. ARC CONTROL:
These 1/2鈥? - 13 studs with flange nuts provide welding con-
The ARC CONTROL WIRE/STICK knob is active in the WIRE
nection points for the electrode and work cables. For positive
and STICK modes, and has different functions in these
polarity welding the electrode cable connects to the 鈥?+鈥? termi-
modes. This control is not active in the TIG mode.
nal and the work cable connects to this 鈥?-鈥? terminal. For nega-
CC-STICK mode: In this mode, the ARC CONTROL knob tive polarity welding the work cable connects to the 鈥?+鈥? termi-
sets the short circuit current (arc-force) during stick welding. nal and the electrode cable connects to this 鈥?-鈥? terminal.
Increasing the number from -10(Soft) to +10(Crisp) increases
AUXILIARY POWER CONTROLS
the short circuit current and prevents sticking of the electrode
(Items 19-23)
to the plate while welding. This can also increase spatter. It is
recommended that the ARC CONTROL be set to the mini- 19. 120/240 VAC SINGLE PHASE RECEPTACLE
mum number without electrode sticking. Start with a setting at
This is a 120/240VAC (14-50R) receptacle that provides
0.
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 installa-
tion chapter for further information about this receptacle. Also
refer to the AUXILIARY POWER OPERATION section later in
this chapter.
VANTAGE 500 DEUTZ
OPERATION
B-5 B-5
20. CIRCUIT BREAKERS 5. Set the RUN/STOP switch to 鈥淩UN鈥?. Observe that
the engine protection and battery charging lights
These circuit breakers provide separate overload
are on. After 10 seconds, the engine protection light
current protection for each 120V circuit at the 240V
will turn off.
single phase receptacle, each 120V single phase
receptacle, the 240V three phase receptacle, the 6. Within 30 seconds, press and hold the engine
120VAC in the 14-Pin connector, the 42VAC in the START button until the engine starts.
14-Pin connector and battery circuit overload protec- 7. Release the engine START button when the engine
tion. starts.
8. Check that the engine protection and battery charg-
21. 120VAC SINGLE PHASE RECEPTACLES ing lights are off. The engine protection light is on
These two 120VAC (5-20R) receptacles with ground after starting, the engine will shutdown in a few sec-
fault circuit interruption protection provide 120VAC onds. Investigate any indicated problem.
single phase for auxiliary power. Each receptacle 9. Allow the engine to warm up at low idle speed for
has a 20 amp total rating. They are designed to pro- several minutes before applying a load and/or
tect the user from the hazards of ground faults. switching to high idle. Allow a longer warm up time
When the GFCI has tripped there will be no voltage in cold weather.
available from the receptacle. If the GFCI has
COLD WEATHER STARTING
tripped, any device plugged into the GFCI recepta-
cle should be unplugged and the reason for tripping With a fully charged battery and the proper weight oil,
the GFCI should be determined. If the device is the engine should start satisfactorily even down to
found to be damaged or defective, it should be about 0掳F(-18掳C). If the engine must be frequently
repaired or replaced before any further use. The started below 10掳(-12掳C), it may be desirable to install
GFCI should be checked for proper operation prior the optional ether start kit (K887-1). Installation and
to each use by pressing the test button. The GFCI operating instructions are included in the kits.
can be reset by pushing the reset button. Refer to
the AUXILIARY POWER RECEPTACLES section in
STOPPING THE ENGINE
the installation chapter for further information about
these receptacles. Also refer to the AUXILIARY
1. Switch the RUN/STOP switch to 鈥淪TOP鈥?. This turns
POWER OPERATION section later in this chapter.
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.
22. GROUND STUD
Provides a connection point for connecting the
machine case to earth ground. Refer to 鈥淢ACHINE
GROUNDING鈥? in the Installation chapter for proper
machine grounding information.
23. 240VAC THREE PHASE RECEPTACLE
This is a 240VAC (15-50R) receptacle that provides
240VAC three phase auxiliary power. This recepta-
cle has a 50 amp rating.
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).
2. Check for proper oil level. Close engine compart-
ment door.
3. Remove all plugs connected to the AC power
receptacles.
4. Set IDLER switch to 鈥淎UTO鈥?.
VANTAGE 500 DEUTZ
OPERATION
B-6 B-6
BREAK-IN PERIOD The ARC CONTROL knob sets the short circuit (arc-force)
current during stick welding. Increasing the number from -
The engine used to supply power for your welder is a heavy
10(Soft) to +10 (Crisp) increases the short circuit current
duty, industrial engine. It is designed and built for rugged
and prevents sticking of the electrode to the plate while
use. It is very normal for any engine to use small quantities
welding. This can also increase spatter. It is recommended
of oil until the break-in is accomplished. Check the oil level
that the ARC CONTROL be set to the minimum number
twice a day during the break-in period. In general this takes
without electrode sticking. Start with the knob set at 0.
50 to 100 hours of operation.
DOWNHILL PIPE MODE
IMPORTANT
This slope controlled setting is intended for 鈥渙ut-of-position鈥?
IN ORDER TO ACCOMPLISH THIS BREAK-IN, THE UNIT
and 鈥渄own hill鈥? pipe welding where the operator would like
SHOULD BE SUBJECTED TO HEAVY LOADS, WITHIN
to control the current level by changing the arc length. The
THE RATING OF THE MACHINE. AVOID LONG IDLE
OUTPUT CONTROL knob adjusts the full output range for
RUNNING PERIODS.
pipe welding.
TYPICAL FUEL CONSUMPTION The ARC CONTROL knob sets the short circuit current (arc-
force) during stick welding to adjust for a soft or a more
Refer to Table B.2 for typical fuel consumption of the VAN-
forceful digging arc (Crisp). Increasing the number from -
TAGE 500 DEUTZ Engine for various operating scenarios.
10(Soft) to +10(Crisp) increases the short circuit current
WELDER OPERATION which results in a more forceful digging arc. Typically a
forceful digging arc is preferred for root and hot passes. A
Table B.2
softer arc is preferred for fill and cap passes where weld
DEUTZ F4L2011 Engine Fuel Consumption
puddle control and deposition (鈥渟tacking鈥? of iron) are key to
fast travel speeds. It is recommended that the ARC CON-
DEUTZ F4L2011 Running Time for
48HP(36Kw) 25GAL.(94.6L)
TROL be set initially at 0.
@1800 RPM (Hours)
TOUCH START TIG MODE
Low Idle - .47 Gal./hour 53
The VANTAGE 500 DEUTZ can be used in a wide variety of
no load 1425 RPM (1.8 L/hour)
DC TIG welding applications.
High Idle - .63 Gal./hour 40
The TOUCH START TIG setting of the MODE switch is for
no load 1900 RPM (2.4 L/hour)
DC TIG (Tungsten Inert Gas) welding. To initiate a weld, the
OUTPUT CONTROL knob is first set to the desired current
DC CC Weld 1.99 Gal./hour 12.6
Output 500 ( 7.53 L/hour)
and the tungsten is touched to the work. During the time the
Amps @ 40 Volts
tungsten is touching the work there is very little voltage or
current and, in general, avoids tungsten contamination.
Auxiliary Power 1.25 Gal./hour 20.0
Then, the tungsten is gently lifted off the work in a rocking
12,000 VA (4.73 L/hour)
motion, which establishes the arc.
Auxiliary Power 1.76 Gal./hour 14.2
To stop the arc, simply lift the TIG torch away from the work
20,000 VA (6.66 L/hour)
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
DUTY CYCLE
retouched to the work piece to restrike the arc. The arc may
Duty cycle is the percentage of time the load is being
also be started and stopped with an Amptrol or Arc Start
applied in a 10 minute period. For example, a 60% duty
Switch.
cycle represents 6 minutes of load and 4 minutes of no load
The ARC CONTROL is not active in the TIG mode.
in a 10 minute period.
In general the 驶Touch Start始 feature avoids tungsten contam-
STICK WELDING MODE
ination without the use of a Hi-frequency unit. If the use of a
The VANTAGE 500 DEUTZ can be used with a broad range high frequency generator is desired, the K930-2 TIG Module
of DC stick electrodes. can be used with the VANTAGE 500 DEUTZ. The settings
are for reference.
The MODE switch provides two stick welding settings as fol-
lows: The VANTAGE 500 DEUTZ is equipped with the required
R.F. bypass circuitry for the connection of high frequency
CC-STICK MODE
generating equipment.
The CC-STICK position of the MODE switch is designed for
horizontal, vertical-up and over head welding with all types
of electrodes, especially low hydrogen. The OUTPUT CON-
TROL knob adjusts the full output range for stick welding.
VANTAGE 500 DEUTZ
OPERATION
B-7 B-7
VANTAGE 500 DEUTZ SETTINGS WHEN USING
The VANTAGE 500 DEUTZ and any high frequency
THE K930-2 TIG MODULE
generating equipment must be properly grounded.
See the K930-2 TIG Module operating manuals for 鈥? Set the WELD MODE switch to the 鈥淭ouch Start Tig
complete instructions on installation, operation, and 20-250 Setting鈥?.
maintenance.
鈥? Set the IDLER switch to the 鈥淎UTO鈥? position.
When using the TIG Module, the OUTPUT control on
鈥? Set the WELDING TERMINALS switch to the
the VANTAGE 500 DEUTZ is used to set the maxi-
鈥淩emotely Controlled鈥? position. This will keep the
mum range of the CURRENT CONTROL on the TIG
solid state contactor open and provide a 鈥渃old鈥? elec-
Module or an Amptrol if connected to the TIG Module.
trode until the triggering device (Amptrol or Arc Start
Switch) is pressed.
Table B.3 TYPICAL CURRENT RANGES (1)
FOR TUNGSTEN ELECTRODES (2)
DCEN (-) DCEP (+) Approximate Argon Gas Flow Rate
l/min (c.f.m.)
Tungsten
Electrode 1%, 2% 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)
(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.
(3) DCEP is not commonly used in these sizes.
(4) TIG torch nozzle 鈥渟izes鈥? are in multiples of 1/16ths of an inch:
#4= 1/4 in. 6 mm
#5= 5/16 in. 8 mm
#6= 3/8 in. 10 mm
#7= 7/16 in. 11 mm
#8= 1/2 in. 12.5 mm
#10 = 5/8 in. 16 mm
(5) 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 and high duty cycles.
VANTAGE 500 DEUTZ
OPERATION
B-8 B-8
CV-WIRE MODE AUXILIARY POWER OPERATION
Connect a wire feeder to the VANTAGE 500 DEUTZ Start the engine and set the IDLER control switch to
and set welder controls according to the instructions the desired operating mode. Full power is available
listed earlier in this section. regardless of the welding control settings, if no weld-
ing current is being drawn.
The VANTAGE 500 DEUTZ in the 鈥滳V-WIRE鈥? posi-
tion, permits it to be used with a broad range of flux
The auxiliary power of the VANTAGE 500 DEUTZ
cored wire (Innershield and Outershield) electrodes
consists of two 20 Amp-120VAC single phase (5-20R)
and solid wires for MIG welding (gas metal arc weld-
GFCI duplex receptacles, one 50 Amp-120/240VAC
ing). Welding can be finely tuned using the 鈥淎RC
single phase (14-50R) receptacle and one 50 Amp
CONTROL鈥?. Turning the ARC CONTROL clockwise
240VAC three phase (15-50R) receptacle. The
from -10(soft) to +10(crisp) changes the arc from soft
120/240VAC receptacle can be split for single phase
and washed-in to crisp and narrow. It acts as an
120 VAC operation.
inductance/pinch control. The proper setting depends
on the procedure and operator preference. Start with
The auxiliary power capacity is 12,000 watts of 60 Hz,
the knob set at 0.
single phase power or 20,000 watts of 60Hz, three
For any electrodes, including the above recommenda- phase power. The auxiliary power capacity rating in
tions, the procedures should be kept within the rating watts is equivalent to volt-amperes at unity power fac-
of the machine. For additional electrode information, tor. The maximum permissible current of the 240 VAC
See www.lincolnelectric.com or the appropriate output is 50 A. The 240 VAC single phase output can
Lincoln publication. be split to provide two separate 120 VAC outputs with
ARC GOUGING a maximum permissible current of 50 A per output to
two separate 120 VAC branch circuits. Output voltage
For optimal performance when arc gouging, set the is within 卤 10% at all loads up to rated capacity.
VANTAGE 500 DEUTZ 鈥淲ELD MODE鈥? switch to the
鈥淐C - STICK鈥? position, and the 鈥淎RC CONTROL鈥? to NOTE: The two 120V GFCI receptacles and the two
10. 120V circuits of the 120/240V receptacle are connect-
ed to different phases and cannot be paralleled.
Set the 鈥淥UTPUT鈥? knob to adjust output current to the
desired level for the gouging electrode being used
The auxiliary power receptacles should only be used
according to the ratings in the following table:
with three wire grounded type plugs or approved dou-
ELECTRODE CURRENT RANGE
ble insulated tools with two wire plugs.
DIAMETER (DC, electrode positive)
The current rating of any plug used with the system
(1/8鈥?) 30-60 Amps
must be at least equal to the current capacity of the
(5/32鈥?) 90-150 Amps
associated receptacle.
(3/16鈥?) 200-250 Amps
(1/4鈥?) 300-400 Amps
SIMULTANEOUS WELDING AND AUXIL-
(5/16鈥?) 350-450 Amps
IARY POWER LOADS
(3/8鈥?) 450-575 Amps*
It must be noted that the above auxiliary power ratings
NOTE: If desired the CV mode can be used for Arc are with no welding load.
Gouging.
Simultaneous welding and power loads are specified
* Maximum current setting is limited to the VANTAGE in table B.4. The permissible currents shown assume
500 DEUTZ maximum of 575 Amps. that current is being drawn from either the 120 VAC or
240 VAC supply (not both at the same time).
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 errat-
ic outputs, and large output imbalances between the
units.
VANTAGE 500 DEUTZ
OPERATION
B-9 B-9
TABLE B.4 VANTAGE 500 DEUTZ SIMULTANEOUS WELDING AND POWER LOADS
WELD 1 PHASE 3 PHASE BOTH 1 AND 3 PHASE
AMPS WATTS AMPS WATTS AMPS WATTS AMPS
0 12,000 50 20,000 50 ------ 50
100 12,000 50 17,800 43 ------ 50
PLUS 12,000 OR OR ------
200 50 14,000 34 50
250 12,000 50 12,000 29 12,000 ------
300 10,000 42 10,000 24 10,000 ------
400 5,600 23 5,600 13 5,600 ------
500 0 0 0 0 0 0
TABLE B.5 VANTAGE 500 DEUTZ Extension Cord Length
Recommendations
Current Voltag Maximum Allowable Cord Length in ft. (m) for Conductor Size
(Amps) e Load 14 AWG 12 AWG 10 AWG 8 AWG 6 AWG 4 AWG
(Volts) (Watts)
15 120 1800 30 (9) 40 (12) 75 (23) 125 (38) 175 (53) 300 (91)
15 240 3600 60 (18) 75 (23) 150 (46) 225 (69) 350 (107) 600 (183)
20 120 2400 30 (9) 50 (15) 88 (27) 138 (42) 225 (69)
20 240 4800 60 (18) 100 (30) 175 (53) 275 (84) 450 (137)
25 240 6000 90 (27) 150 (46) 225 (69) 250 (76)
30 240 7200 75 (23) 120 (37) 175 (53) 300 (91)
38 240 9000 100 (30) 150 (46) 250 (76)
50 240 12000 125 (38) 200 (61)
Conductor size is based on maximum 2.0% voltage drop.
VANTAGE 500 DEUTZ
ACCESSORIES
C-1 C-1
OPTIONAL FIELD INSTALLED ACCES-
WARNING
SORIES
K802N POWER PLUG KIT - Provides four 120V plugs rated at 20 Pipe Thawing with an arc welder can cause fire,
amps each and one dual voltage, full KVA plug rated at explosion, damage to electric wiring or to the arc
120/240V, 50 amps. 120V plug may not be compatible with NEMA welder if done improperly. The use of an arc
common household receptacles. welder for pipe thawing is not approved by the
CSA, nor is it recommended or supported by
K802-R POWER PLUG KIT - Provides four 120V plugs rated 15 Lincoln Electric.
amps each and one dual voltage, full KVA plug rated at ------------------------------------------------------------------------
120/240V, 50 amps, 120V plug is compatible with NEMA common
household receptacles. K2356-1 Control Panel Cover Kit-Clear plexiglass
cover to protect control panel from dirt and debris, and
to visually monitor machine operation. Lockable to
K857 25 ft. (7.5 m) or K857-1 100 ft. (30.4 m) REMOTE CON-
deter vandalism.
TROL - Portable control provides same dial range as the output
control on the welder from a location up to the specified length K2340-1 Lockable Fuel Cap / Flash Arrester Kit-For
from the welder. Has convenient plug for easy connection to the use in locations where flash arrester safety is
required. Lockable fuel cap prevents tampering with
welder. The VANTAGE 500 DEUTZ is equipped with a 6-pin
fuel. Green cap color provides a visual reminder to
connector for connecting the remote control.
use diesel when refueling.
TIG OPTIONS
K704 ACCESSORY SET - Includes 35 feet (10 m) of
electrode cable and 30 feet (9 m) of work cable, head-
K1783-9 PTA-26V TIG Torch
shield, Filter plate, work clamp and electrode holder.
Air Cooled 200 amp torch (2 piece) equipped with
Cable is rated at 500 amps, 60% duty cycle. valve for gas flow control. 25 ft. (7.6m) length.
KP509 Magnum Parts Kit for PTA-26V TIG Torch
K2641-2 FOUR WHEELED STEERABLE YARD
Magnum Parts Kit provides all the torch accessories
TRAILER
you need to start welding. Parts kit provides collets,
For in plant and yard towing. Comes standard with a Duo-
collet bodies, a black cap, alumina nozzles and tung-
Hitch鈩?, a 2鈥? Ball and Lunette Eye combination hitch. stens in a variety of sizes, all packaged in an easy to
carry reclosable sack.
K2636-1 TRAILER - Two-wheeled trailer with optional fender
and light package. For highway use, consult applicable feder-
K870 Foot Amptrol庐-Varies current while welding for
al, state, and local laws regarding possible additional require-
making critical TIG welds and crater filling. Depress
ments. Comes standard with a Duo-Hitch鈩?, a 2鈥? Ball and pedal to increase current. Depressing pedal fully
Lunette Eye combination hitch. achieves maximum set current. Fully raising the pedal
Order: finishes the weld and starts the after flow cycle on
systems so equipped. Includes 25 ft. (7.6m) control
K2636-1 Trailer
cable.
K2639-1 Fender & Light Kit
K2640-1 Cable Rack
K963-2 Hand Amptrol庐-Varies current for making
critical TIG welds. Fastens to the torch for convenient
K887-1 ETHER START KIT - Provides maximum cold weath- thumb control. Comes with a 25 ft. (7.6m) cable. (For
larger handle 18 or 26 series torches.)
er starting assistance for frequent starting below 10掳(-12掳C).
Required Ether tank is not provided with kit.
K2347-1 Precision TIG 185 Ready-Pak
For AC TIG Welding with square wave performance
K899-1 SPARK ARRESTOR KIT - Easily mounts to standard use the AC generator of the Engine-Driven Welder to
muffler. supply the power. Easy setup. Includes torch, foot
amptrol, gas regulator and hose. Requires the
K1816-1 Full KVA adapter kit.
K1816-1 Full KVA Adapter Kit - Plugs into the
120/240V NEMA 14-50R receptacle on the case front
K2350-1 Invertec庐 V205-T AC/DC One-Pak鈩? Package
(which accepts 4-prong plugs) and converts it to a For AC TIG welding with square wave performance,
NEMA 6-50R receptacle (which accepts 3-prong use the AC generator of the engine-driven welder to
supply the power. Easy setup. Includes torch, parts
plugs) for connection to Lincoln Equipment with a
kit, regulator and hose kit, Twist-Mate鈩? torch adapter,
NEMA 6-50P plug,
work cable with Twist-Mate end and foot Amptrol庐.
T12153-9 Full-KVA Power Plug-One dual voltage
plug rated at 120/240V, 50 amps, single phase.
VANTAGE 500 DEUTZ
ACCESSORIES
C-2 C-2
WIRE FEEDER OPTIONS
K449 LN-25 Wire Feeder
Portable CC/CV unit for flux-cored and MIG welding.
Includes Gas Solenoid & Internal Contactor.
K126-2 Magnum庐 350 Innershield Gun (for LN-25)
For self-shielded wire with 15 ft. (4.5m) cable. For
.062-3/32鈥? (1.6-2.4mm) wire.
KP653-3/32 Drive Roll and Guide Tube Kit (for LN-25)
For .068-3/32鈥? (1.8-2.4mm) cored or solid steel wire.
K1802-1 Magnum庐 300 MIG Gun
For .035-.045 (0.9-1.2mm) gas shielded wire.
Includes 15 ft. gun and cable assembly and connector
kit.
KP653-035S Drive Roll and Guide Tube Kit (for LN-25)
For .035-.040鈥? (0.9-1.0mm) solid steel wire.
K487-25 Magnum SG Spool Gun
Hand held semiautomatic wire feeder. Requires SG
Control Module and Input Cable.
K488 SG Control Module
The Interface between the power source and the
spool gun. Provides control of the wire speed and gas
flow. For use with a spool gun.
K691-10 Input Cable (For SG Control Module)
For Lincoln engine power sources with 14-pin MS-
type connection, separate 115V NEMA receptacles
and output stud connections.
PLASMA CUTTING
K1581-1 Pro-cut 80
Cuts mild steel using the 3-phase AC generator power
from the engine driven welder.
VANTAGE 500 DEUTZ
MAINTENANCE
D-1 D-1
SAFETY PRECAUTIONS AIR FILTER
CAUTION
WARNING
鈥? Have a qualified technician do the maintenance 鈥? Excessive air filter restriction will result in
and troubleshooting work. reduced engine life.
WARNING
鈥? Turn the engine off before working inside the
machine.
鈥? Remove guards only when necessary and 鈥? Never use gasoline or low flash point solvents
replace them when the maintenance requiring for cleaning the air cleaner element. A fire or
their removal is complete. explosion could result.
鈥? Always use the greatest care when working near
CAUTION
moving parts.
------------------------------------------------------------------------
鈥? Never run the engine without the air cleaner.
Read the Safety Precautions in front of this manual Rapid engine wear will result from contaminants,
and the engine instruction manual before working on such as dust and dirt being drawn into the
this machine. engine.
---------------------------------------------------------------------
Keep all equipment safety guards, covers and devices
The diesel engine is equipped with a dry type air filter.
in position and in good repair. Keep hands, hair, cloth-
Never apply oil to it. Service the air cleaner as follows:
ing and tools away from V-belts, gears, fans and all
other moving parts when starting, operating or repair-
Replace the element as indicated by the service indi-
ing the equipment.
cator. (See Service Instructions and Installation Tips
ROUTINE AND PERIODIC MAINTENANCE for Engine Air Filter.)
DAILY
鈥? Check the Engine oil level.
鈥? Refill the fuel tank to minimize moisture condensa-
tion in the tank.
鈥? 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 container.
WEEKLY
Blow out the machine with low pressure air periodical-
ly. In particularly dirty locations, this may be required
once a week.
ENGINE MAINTENANCE
Refer to the 鈥淪ERVICE PLAN鈥? section of the Engine
Operator始s Manual for the recommended maintenance
schedule of the following:
a) Engine Oil and Filter
b) Air Cleaner
c) Fuel Filter - and Delivery System
d) Alternator Belt
e) Battery
f) Cooling System
Refer to Table D.1 at the end of this section for vari-
ous engine maintenance components.
VANTAGE 500 DEUTZ
MAINTENANCE
D-2 D-2
VANTAGE 500 DEUTZ
MAINTENANCE
D-3 D-3
FUEL FILTERS BATTERY HANDLING
GASES FROM BATTERY can explode.
WARNING 鈥? Keep sparks, flame and cigarettes
away from battery.
When working on the fuel system
鈥? Keep naked lights away, do not smoke ! To prevent EXPLOSION when:
鈥? Do not spill fuel ! 鈥? INSTALLING A NEW BATTERY - dis-
connect negative cable from old bat-
tery first and connect to new battery
last.
------------------------------------------------------------------------
The VANTAGE 500 DEUTZ is equipped with a Fuel
鈥? CONNECTING A BATTERY CHARGER
Filter located after the lift pump and before fuel injec-
- Remove battery from welder by dis-
tors.The procedure for changing the filter is as follows.
connecting negative cable first, then
1. Close the fuel shutoff valve. positive cable and battery clamp.
When reinstalling, connect negative
2. Clean the area around the fuel filter head. Remove
cable last. Keep well ventilated.
the filter. Clean the gasket surface of the filter head
and replace the o-ring.
3. Fill the clean filter with clean fuel, and lubricate the 鈥? USING A BOOSTER - connect positive
o-ring seal with clean lubricating oil. lead to battery first then connect nega-
tive lead to engine foot.
4. Install the filter as specified by the filter manufactur-
er.
WARNING
BATTERY ACID CAN BURN EYES AND
SKIN.
鈥? Wear gloves and eye protection and
Mechanical overtightening will distort the threads,
be careful when working near battery.
filter element seal or filter can.
Follow instructions printed on battery.
------------------------------------------------------------------------
------------------------------------------------------------------------
COOLING SYSTEM PREVENTING ELECTRICAL DAMAGE
The cooling system of the Deutz engine needs to be 1. When replacing, jumping, or otherwise connecting
checked and cleaned periodically. (Consult the engine the battery to the battery cables, the proper polarity
Owners Manual for the proper procedures and fre- must be observed. Failure to observe the proper
quency). polarity could result in damage to the charging cir-
cuit. The positive (+) battery cable has a red termi-
nal cover.
2. 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 the RUN/STOP switch to stop when engine is
not running.
PREVENTING BATTERY BUCKLING
Tighten nuts on battery clamp until snug.
VANTAGE 500 DEUTZ
MAINTENANCE
D-4 D-4
CHARGING THE BATTERY WELDER / GENERATOR MAINTENANCE
When you charge, jump, replace, or otherwise con-
nect battery cables to the battery, be sure the polarity
STORAGE
is correct. Improper polarity can damage the charging
circuit. The VANTAGE 500 DEUTZ positive (+) battery Store the Air Vantage in a clean, dry protected areas.
terminal has a red terminal cover.
If you need to charge the battery with an external
CLEANING
charger, disconnect the negative cable first, then the
positive cable before you attach the charger leads. Blow out the generator and controls periodically with
after the battery is charged, reconnect the positive low pressure air. do this at least once a week in partic-
battery cable first and the negative cable last. Failure ularly dirty areas.
to do so can result in damage to the internal charger
components.
BRUSH REMOVAL AND REPLACEMENT
Follow the instructions of the battery charger manu-
facturer for proper charger settings and charging time. It is normal for the brushes and slip rings to wear and
darken slightly. Inspect the brushes when a generator
overhaul is necessary.
NAMEPLATES / WARNING DECALS MAIN- Do not attempt to polish slip rings while the
TENANCE engine is running.
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.
VANTAGE 500 DEUTZ
TROUBLESHOOTING
E-1 E-1
HOW TO USE TROUBLESHOOTING GUIDE
WARNING
Service and Repair should only be performed by Lincoln Electric Factory Trained Personnel.
Unauthorized repairs performed on this equipment may result in danger to the technician and
machine operator and will invalidate your factory warranty. For your safety and to avoid Electrical
Shock, please observe all safety notes and precautions detailed throughout this manual.
__________________________________________________________________________
Step 3. RECOMMENDED COURSE OF ACTION
This Troubleshooting Guide is provided to help you
locate and repair possible machine malfunctions. This column provides a course of action for the
Simply follow the three-step procedure listed below. Possible Cause, generally it states to contact your
local Lincoln Authorized Field Service Facility.
Step 1. LOCATE PROBLEM (SYMPTOM).
Look under the column labeled 鈥淧ROBLEM (SYMP- If you do not understand or are unable to perform the
TOMS)鈥?. This column describes possible symptoms Recommended Course of Action safely, contact your
that the machine may exhibit. Find the listing that local Lincoln Authorized Field Service Facility.
best describes the symptom that the machine is
exhibiting.
Step 2. POSSIBLE CAUSE.
The second column labeled 鈥淧OSSIBLE CAUSE鈥? lists
the obvious external possibilities that may contribute
to the machine symptom.
CAUTION
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
TROUBLESHOOTING
E-2 E-2
Observe all Safety Guidelines detailed throughout this manual
PROBLEMS POSSIBLE RECOMMENDED
(SYMPTOMS) CAUSE COURSE OF ACTION
ENGINE PROBLEMS
Major Physical or Electrical Damage 1. Contact your Local Lincoln
is Evident. Authorized 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 If all recommended possible areas
position make sure the valve of misadjustment have been
lever is in the open position (lever checked and the problem persists,
in-line with the Hose). Contact your local Lincoln
3. Engine shut down solenoid not Authorized Field Service Facility.
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 fil-
ter element and/or Inline Fuel
Filter may need to be replaced.
6. High oil temperature or low oil
pressure. (engine protection light
lit)
Engine shuts down shortly after 1. Low oil pressure (engine protec-
starting. tion light lit). Check oil level
(Consult engine service dealer).
2. High oil temperature. Check
engine cooling system. (engine
protection light lit).
3. Faulty oil pressure switch.
4. Faulty oil temperature switch.
Contact authorized local Engine
Service Shop.
Engine shuts down while under a 1. High oil temperature.
load.
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 func-
tioning properly.
CAUTION
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
TROUBLESHOOTING
E-3 E-3
Observe all Safety Guidelines detailed throughout this manual
PROBLEMS POSSIBLE RECOMMENDED
(SYMPTOMS) CAUSE COURSE OF ACTION
FUNCTION PROBLEMS
Battery does not stay charged. 1. Faulty battery .
2. Faulty engine alternator.
3. Loose or broken lead in charging
circuit.
4. Loose fan belt may need tighten-
ing.
Engine will not idle down to low 1. Idler switch in HIGH idle position,
speed. make sure switch is set to AUTO.
2. External load on welder or auxil-
iary power.
3. Mechanical problem in idler sole-
noid linkage. If all recommended possible areas of
4. Faulty wiring in solenoid circuit. misadjustment have been checked
5. No or low voltage @ idle solenoid and the problem persists, Contact
6. Faulty idler solenoid. your local Lincoln Authorized
7. Faulty, Weld Control PCB Field Service Facility.
(Printed Circuit Board), Pull
Coil/Battery PCB.
Engine will not go to high idle when 1. Poor work lead connection to
attempting to weld. work.
2. Broken idler solenoid spring.
3. Welding Terminals switch in
wrong position.
4. No open circuit voltage at output
studs.
5. Faulty, Pull Coil/Battery PCB. or
Weld Control PCB.
1. Broken wire in auxiliary current
sensor wiring.
Engine will not go to high idle when 2. Auxiliary power load is less than
using auxiliary power. 100 watts.
3. Faulty Pull Coil/Battery PCB. or
Weld Control PCB.
CAUTION
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
TROUBLESHOOTING
E-4 E-4
Observe all Safety Guidelines detailed throughout this manual
PROBLEMS POSSIBLE RECOMMENDED
(SYMPTOMS) CAUSE COURSE OF ACTION
FUNCTION PROBLEMS
Engine goes to low idle but does not 1. Faulty Peripheral PCB,
stay at low idle. Idler/Engine Protection PCB or
Weld Control PCB.
No welding output or auxiliary out- 1. Broken lead in rotor circuit.
put. 2. Faulty field diode module.
3. Faulty Weld Control PCB.
4. Faulty rotor.
Welder has some/ no output and no 1. Faulty remote kit.
control. Auxiliary output OK 2. Faulty output control potentiome- If all recommended possible areas of
ter. misadjustment have been checked
3. Faulty output control wiring. and the problem persists, Contact
4. Faulty Weld Control PCB, your local Lincoln Authorized
Idler/Engine Protection PCB or Field Service Facility.
Chopper PCB.
No welding output. Auxiliary output 1. WELDING TERMINALS switch in
OK. wrong position, be sure switch is
in WELDING TERMINALS
ALWAYS ON position.
2. Faulty Weld Control PCB,
Idler/Engine Protection PCB or
Chopper PCB.
No auxiliary power. 1. Open breakers may need to be
reset.
2. Faulty receptacle.
3. Faulty auxiliary circuit wiring.
4. GFCI tripped.
CAUTION
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
F-1
DIAGRAMS
VANTAGE 500 DEUTZ
Enhanced Diagram
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 equipment code number.
F-1
CONNECTION DIAGRAMS
F-2 F-2
VANTAGE 500 DEUTZ
F-3
COMMANDER / K867 / K775 / LN-7 CONNECTION DIAGRAM
WARNING
Do not operate with panels open. Keep guards in place.
Keep away from moving parts.
Disconnect NEGATIVE (-) BATTERY LEAD
before servicing. Only qualified personnel should install,use
or service this equipment.
Do not touch electrically live parts.
SPARE
82
LN-7
81 N.D.
WIRE
42 FEEDER
41
}
31 31
32 32
14 PIN 2 2
AMPHENOL
4 4
ELECTRODE TO WORK 21 21
K291 OR K404
K867 UNIVERSAL
GND INPUT CABLE
GND
ADAPTER PLUG
GREEN
VANTAGE 500 DEUTZ
75 75
TO WORK
76 76
ELECTRODE CABLE 77 77
TO WIRE FEED UNIT
}
K775 OPTIONAL
CONNECTION DIAGRAMS
N.E. REMOTE CONTROL
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 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
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 OPERATING MANUAL.
N.B. USE VOLTMETER SWITCH TO SELECT DESIRED ELECTRODE POLARITY. POSITION THE "SELECTOR" SWITCH TO "WIRE WELDING CV".
PLACE WIRE FEEDER SWITCH TO "WIRE FEEDER WITH CONTROL CABLE POSITION.
N.C. IF OPTIONAL REMOTE OUTPUT CONTROL IS USED,CONTROL IS AUTOMATICALLY SWITCHED TO REMOTE CONTROL.
N.D. INSULATE EACH UNUSED LEAD INDIVIDUALLY.
N.E. SPLICE LEADS AND INSULATE.
7-2000
S23983
F-3
CONNECTION DIAGRAMS
F-4 F-4
VANTAGE 500 DEUTZ
CONNECTION DIAGRAMS
F-5 F-5
VANTAGE 500 DEUTZ
COMMANDER / K867 / LN-8 CONNECTION DIAGRAM
F-6
WARNING
Do not operate with panels open. Keep guards in place.
Keep away from moving parts.
Disconnect NEGATIVE (-) BATTERY LEAD
before servicing. Only qualified personnel should install,use
or service this equipment.
Do not touch electrically live parts.
SPARE
82 LN-8
WIRE
81 N.C.
FEEDER
42
41
}
31 31
32 32
14 PIN
AMPHENOL
2 2
4 4
ELECTRODE TO WORK 21 21 K196
K867 UNIVERSAL
GND INPUT CABLE
GND
ADAPTER PLUG
VANTAGE 500 DEUTZ
75 A
TO WORK
76 B
ELECTRODE CABLE
77 C
TO WIRE FEED UNIT
}
CAUTION :
CONNECTION DIAGRAMS
N.D.
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
DAMAGED. 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 CABLE MUST BE OF PROPER CAPACITY FOR THE CURRENT AND DUTY CYCLE OF IMMEDIATE AND FUTURE
APPICATIONS. SEE OPERATING MANUAL.
N.B. USE VOLTMETER SWITCH TO SELECT DESIRED ELECTRODE POLARITY. POSITION THE SELECTOR SWITCH TO "WIRE WELDING CV".
N.C. INSULATE EACH UNUSED LEAD INDIVIDUALLY.
N.D. SPLICE LEADS AND INSULATE.
7-2000
S23989
F-6
CONNECTION DIAGRAMS
F-7 F-7
VANTAGE 500 DEUTZ
F-8
ENGINE WELDERS / LN-8 CONNECTION DIAGRAM
WARNING
MOVING PARTS can injure
ELECTRIC SHOCK can kill
Do not operate with panels open. Keep guards in place.
Keep away from moving parts.
Disconnect NEGATIVE (-) Battery lead
before servicing. Only qualified personnel should install,use
or service this equipment.
Do not touch electrically live parts.
14 PIN LN-8 INPUT
AMPHENOL CABLE PLUG
K595 CONTROL CABLE
_
+
TO WORK
ELELCTRODE CABLE
VANTAGE 500 DEUTZ
TO WIRE FEED UNIT
CAUTION:
CONNECTION DIAGRAMS
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 鈥? DO NOT ADJUST ABOVE RPM SPECIFICATIONS LISTED IN THE ENGINE WELDER OPERATING MANUAL.
N.A. WELDING CABLES MUST BE OF PROPER CAPACITY FOR THE CURRENT AND DUTY CYCLE OF IMMEDIATE AND FUTURE
APPLICATIONS. SEE OPERATING MANUAL.
N.B. CONNECT WELDING CABLES TO OUTPUT STUDS FOR DESIRED POLARITY. POSITION THE WIRE FEEDER VOLTMETER SWITCH TO
MATCH THE POLARITY OF THE ELECTRODE CABLE.
N.C. PLACE IDLER SWITCH IN 鈥淗IGH鈥? POSITION.
4-14-2000
F-8
S24787-6
CONNECTION DIAGRAMS
F-9 F-9
VANTAGE 500 DEUTZ
CONNECTION DIAGRAMS
F-10 F-10
VANTAGE 500 DEUTZ
CONNECTION DIAGRAMS
F-11 F-11
VANTAGE 500 DEUTZ
CONNECTION DIAGRAMS
F-12 F-12
VANTAGE 500 DEUTZ
F-13
9.70
38.19
32.18
50.81
45.67
CENTER OF GRAVITY WITH OIL 42.00
IN ENGINE AND EMPTY FUEL TANK
15.50
34.62 6.56 31.50
45.38 * 37.30
14.63
* 6.55
VANTAGE 500 DEUTZ
* TRAILER MOUNTING HOLE LOCATIONS.
DIMENSION PRINT
28.99
24.97
*
6.53
*
19.63
23.69
50.38
54.44
BOTTOM VIEW OF WELDER BASE
A
M18962-5
F-13
NOTES
VANTAGE 500 DEUTZ
NOTES
VANTAGE 500 DEUTZ
WARNING
G Do not touch electrically live parts or G Keep flammable materials away. G Wear eye, ear and body protection.
electrode with skin or wet clothing.
AVISO DE
G Insulate yourself from work and
ground.
Spanish
PRECAUCION
G No toque las partes o los electrodos G Mantenga el material combustible G Prot茅jase los ojos, los o铆dos y el
bajo carga con la piel o ropa moja- fuera del 谩rea de trabajo. cuerpo.
da.
G Aislese del trabajo y de la tierra.
ATTENTION
French G Ne laissez ni la peau ni des v锚te- G Gardez 脿 l鈥櫭ヽart de tout mat茅riel G Prot茅gez vos yeux, vos oreilles et
ments mouill茅s entrer en contact inflammable. votre corps.
avec des pi猫ces sous tension.
G Isolez-vous du travail et de la terre.
WARNUNG
German G Ber眉hren Sie keine stromf眉hrenden G Entfernen Sie brennbarres Material! G Tragen Sie Augen-, Ohren- und K枚r-
Teile oder Elektroden mit Ihrem perschutz!
K枚rper oder feuchter Kleidung!
G Isolieren Sie sich von den
ATEN脟脙O
Portuguese
Elektroden und dem Erdboden!
G N茫o toque partes el茅tricas e elec- G Mantenha inflam谩veis bem guarda- G Use prote莽茫o para a vista, ouvido e
trodos com a pele ou roupa molha- dos. corpo.
da.
G Isole-se da pe莽a e terra.
Japanese
Chinese
Korean
Arabic
READ AND UNDERSTAND THE MANUFACTURER鈥橲 INSTRUCTION FOR THIS EQUIPMENT AND THE CONSUMABLES TO BE
USED AND FOLLOW YOUR EMPLOYER鈥橲 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 HER-
STELLERS. DIE UNFALLVERH脺TUNGSVORSCHRIFTEN DES ARBEITGEBERS SIND EBENFALLS ZU BEACHTEN.
WARNING
G Keep your head out of fumes. G Turn power off before servicing. G Do not operate with panel open or
G Use ventilation or exhaust to guards off.
AVISO DE
remove fumes from breathing zone.
Spanish
PRECAUCION
G Los humos fuera de la zona de res- G Desconectar el cable de ali- G No operar con panel abierto o
piraci贸n. mentaci贸n de poder de la m谩quina guardas quitadas.
G Mantenga la cabeza fuera de los antes de iniciar cualquier servicio.
humos. Utilice ventilaci贸n o
ATTENTION
aspiraci贸n para gases.
French
G D茅branchez le courant avant G N鈥檕p茅rez pas avec les panneaux
G Gardez la t锚te 脿 l鈥櫭ヽart des fum茅es.
G Utilisez un ventilateur ou un aspira- l鈥檈ntretien. ouverts ou avec les dispositifs de
protection enlev茅s.
teur pour 么ter les fum茅es des zones
WARNUNG
de travail.
German
G Strom vor Wartungsarbeiten G Anlage nie ohne Schutzgeh盲use
G Vermeiden Sie das Einatmen von
abschalten! (Netzstrom v枚llig 枚ff- oder Innenschutzverkleidung in
Schweibrauch!
G Sorgen Sie f眉r gute Be- und nen; Maschine anhalten!) Betrieb setzen!
Entl眉ftung des Arbeitsplatzes!
ATEN脟脙O
Portuguese
G N茫o opere com as tampas removidas. G Mantenha-se afastado das partes
G Mantenha seu rosto da fuma莽a.
G Desligue a corrente antes de fazer
G Use ventila莽茫o e exhaust茫o para moventes.
servi莽o. G N茫o opere com os paineis abertos
remover fumo da zona respirat贸ria.
G N茫o toque as partes el茅tricas nuas. ou guardas removidas.
Japanese
Chinese
Korean
Arabic
LEIA E COMPREENDA AS INSTRU脟脮ES DO FABRICANTE PARA ESTE EQUIPAMENTO E AS PARTES DE USO, E SIGA AS
PR脕TICAS DE SEGURAN脟A DO EMPREGADOR.
鈥? World's Leader in Welding and Cutting Products 鈥?
鈥? Sales and Service through Subsidiaries and Distributors Worldwide 鈥?
Cleveland, Ohio 44117-1199 U.S.A. TEL: 216.481.8100 FAX: 216.486.1751 WEB SITE: www.lincolnelectric.com
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