Lincoln Electric Vantage 500 Operator's Manual
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Lincoln Electric Vantage 500 Operator's Manual

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Operator's Manual
VANTAGE
Register your machine:
www.lincolnelectric.com/register
Authorized Service and Distributor Locator:
www.lincolnelectric.com/locator
Save for future reference
Date Purchased
Code:
(ex: 10859)
Serial:
(ex: U1060512345)
IM954-A
| Issue D ate 10-Feb
© Lincoln Global, Inc. All Rights Reserved.
500
®
For use with machines having Code Numbers:
11468, 11931, 11932, 11960
Need Help? Call 1.888.935.3877
to talk to a Service Representative
Hours of Operation:
8:00 AM to 6:00 PM (ET) Mon. thru Fri.
After hours?
Use "Ask the Experts" at lincolnelectric.com
A Lincoln Service Representative will contact you
no later than the following business day.
For Service outside the USA:
Email: globalservice@lincolnelectric.com

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  • Page 1 Operator’s Manual VANTAGE ® For use with machines having Code Numbers: 11468, 11931, 11932, 11960 Register your machine: Need Help? Call 1.888.935.3877 www.lincolnelectric.com/register to talk to a Service Representative Authorized Service and Distributor Locator: Hours of Operation: www.lincolnelectric.com/locator 8:00 AM to 6:00 PM (ET) Mon. thru Fri. Save for future reference After hours? Use “Ask the Experts”...

  • Page 2: California Proposition 65 Warnings

    351040, Miami, Florida 33135 or CSA Standard W117.2-1974. A Free copy of “Arc Welding Safety” 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.

  • Page 3: Electric Shock Can Kill

    SAFETY ARC RAYS can burn. ELECTRIC SHOCK can 4.a. Use a shield with the proper filter and cover kill. 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 “hot”...
  • Page 4 SAFETY 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.
  • Page 5 SAFETY 5. Toujours porter des lunettes de sécurité dans la zone de PRÉCAUTIONS DE SÛRETÉ soudage. Utiliser des lunettes avec écrans lateraux dans les zones où lʼon pique le laitier. Pour votre propre protection lire et observer toutes les instructions et les précautions de sûreté...
  • Page 6 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.

  • Page 7: Table Of Contents

    Connection of Lincoln Electric Wire Feeders ........A-8,...
  • Page 8 TABLE OF CONTENTS Page Accessories ..............Section C Optional Field Installed Accessories .

  • Page 9: Installation

    INSTALLATION TECHNICAL SPECIFICATIONS - VANTAGE® 500 DEUTZ (K2405-2, K2405-3, K2405-4) INPUT - DIESEL ENGINE Make /Model Description Speed (RPM) Displacement Starting Capacities System DEUTZ 4 cylinder High Idle 1890 190 cu. in 12VDC battery Fuel D 2011 L4i 48HP (36 kw) Low Idle 1425 (3.1L) &...

  • Page 10: Safety Precautions

    INSTALLATION Read this entire installation section before you LOCATION / VENTILATION 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.

  • Page 11: Lifting

    INSTALLATION TOWING LIFTING The recommended trailer for use with this equipment The VANTAGE® 500 DEUTZ lift bale should be used for road, in-plant and yard towing by a vehicle to lift the machine. The VANTAGE® 500 DEUTZ is Lincolnʼs K2636-1. If the user adapts a non-Lincoln shipped with the lift bale retracted.

  • Page 12: Oil

    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 offer. While it is normal to see a small amount of...

  • Page 13: Muffler Outlet Pipe

    INSTALLATION WELDING TERMINALS • CONNECTING A BATTERY CHARGER — remove battery from welder by disconnecting negative The VANTAGE® 500 DEUTZ is equipped with a toggle cable first, then positive cable and battery clamp. switch for selecting "hot" welding terminals when in the When reinstalling, connect negative cable last.

  • Page 14: Remote Control

    The auxiliary power capacity of the VANTAGE® 500 OUTPUT DEUTZ is 12,000 watts of 60 Hz, single phase or The VANTAGE 500 DEUTZ is equipped with a 6-pin 20,000 watts of 60Hz, three phase power. The auxil- and a 14-pin connector. The 6-pin connector is for...
  • Page 15 INSTALLATION 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.

  • Page 16: Connection Of Lincoln Electric Wire Feeders

    INSTALLATION CONNECTION OF LINCOLN ELECTRIC • Across The-Arc Model: WIRE FEEDERS Attach the single lead from the front of the LN-15 to work using the spring clip at the end of the WARNING lead. This is a control lead to supply current to the wire feeder motor;...
  • Page 17 INSTALLATION 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®...

  • Page 18: Operation

    OPERATION SAFETY INSTRUCTIONS GENERAL DESCRIPTION The VANTAGE® 500 DEUTZ is a diesel engine-dri- Read and understand this entire section before ven welding power source. The machine uses a brush operating your VANTAGE® 500 DEUTZ. type alternating current generator for DC multi-pur- pose welding, for 120/240 VAC single phase and WARNING 240V three phase auxiliary standby power.

  • Page 19: Controls And Settings

    OPERATION CONTROLS AND SETTINGS All welder and engine controls are located on the case front panel. Refer to Figure B.1 and the explanations that follow. Figure B.1 Case Front Panel Controls ENGINE CONTROLS (Items 1 through 9) 3. HOUR METER The hour meter displays the total time that the 1.
  • Page 20 OPERATION 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.

  • Page 21: Welding Controls

    OPERATION WELDING CONTROLS (Items 10 through 19) Increasing the number from -10(Soft) to +10(Crisp) increas- es the short circuit current which results in a more forceful 10. OUTPUT CONTROL: The OUTPUT dial is used to pre- digging arc. Typically a forceful digging arc is preferred for set the output voltage or current as displayed on the dig- root and hot passes.

  • Page 22: Auxiliary Power Controls

    OPERATION 18. WELD OUTPUT TERMINALS + AND - 23. 240VAC THREE PHASE RECEPTACLE These 1/2” - 13 studs with flange nuts provide welding This is a 240VAC (15-50R) receptacle that provides connection points for the electrode and work cables. For 240VAC three phase auxiliary power.

  • Page 23: Break-In Period

    OPERATION BREAK-IN PERIOD current during stick welding. Increasing the number from - 10(Soft) to +10 (Crisp) increases the short circuit current The engine used to supply power for your welder is a heavy and prevents sticking of the electrode to the plate while duty, industrial engine.

  • Page 24: Typical Current Ranges For Tungsten Electrodes

    OPERATION The VANTAGE® 500 DEUTZ and any high frequency VANTAGE® 500 DEUTZ SETTINGS WHEN USING generating equipment must be properly grounded. THE K930-2 TIG MODULE See the K930-2 TIG Module operating manuals for • Set the WELD MODE switch to the “Touch Start TIG complete instructions on installation, operation, and 20-250 Setting”.

  • Page 25: Cv-Wire Mode

    OPERATION 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.
  • Page 26 OPERATION 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 12,000 20,000 ------ 12,000 17,800 ------ PLUS 12,000 14,000 ------ 12,000 12,000 12,000 ------ 10,000...

  • Page 27: Accessories

    Has convenient plug for easy connection to the K2340-1 Lockable Fuel Cap / Flash Arrester Kit-For welder. The VANTAGE 500 DEUTZ is equipped with a 6-pin use in locations where flash arrester safety is connector for connecting the remote control.
  • Page 28 ACCESSORIES WIRE FEEDER OPTIONS K2613-1 LN-25 PRO PORTABLE WIRE FEEDER-The MAXTRAC® wire drive enhances performance, while the replacement case, and many other upgrade options that can be installed in less then five minutes aid in the serviceability. KP1697-5/64 Drive Roll Kit- Includes: 2 polished U groove drive rolls, outer wire guide and inner wire guide for solid core wire.

  • Page 29: Maintenance

    MAINTENANCE SAFETY PRECAUTIONS AIR FILTER CAUTION WARNING • Excessive air filter restriction will result in • Have a qualified technician do the maintenance reduced engine life. and troubleshooting work. • Turn the engine off before working inside the WARNING machine. •...
  • Page 30 MAINTENANCE Service Instructions Service Instructions Single- and Two-Stage Engine Air Cleaners Single- and Two-Stage Engine Air Cleaners Inspect the New Filter for Damage Inspect the New Filter for Damage Remove the Filter Remove the Filter Inspect the new filter carefully, paying attention to Unfasten or unlatch the the inside of the open end, which is the service cover.

  • Page 31: Fuel Filters

    MAINTENANCE FUEL FILTERS BATTERY HANDLING GASES FROM BATTERY can explode. WARNING • Keep sparks, flame and cigarettes away from battery. When working on the fuel system • Keep naked lights away, do not smoke ! To prevent EXPLOSION when: • Do not spill fuel ! •...

  • Page 32: Charging The Battery

    MAINTENANCE CHARGING THE BATTERY WELDER / GENERATOR MAINTENANCE When you charge, jump, replace, or otherwise con- STORAGE nect battery cables to the battery, be sure the polarity Store the Air Vantage® in a clean, dry protected is correct. Improper polarity can damage the charging areas.

  • Page 33: How To Use Troubleshooting Guide

    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.

  • Page 34: Troubleshooting

    TROUBLESHOOTING Observe all Safety Guidelines detailed throughout this manual PROBLEMS POSSIBLE RECOMMENDED (SYMPTOMS) CAUSE COURSE OF ACTION ENGINE PROBLEMS Major Physical or Electrical Damage . Contact your Local Lincoln is Evident. Authorized Field Service Facility. Engine will not crank 1. Battery low. 2.
  • Page 35 TROUBLESHOOTING Observe all Safety Guidelines detailed throughout this manual PROBLEMS POSSIBLE RECOMMENDED (SYMPTOMS) CAUSE COURSE OF ACTION FUNCTION PROBLEMS Battery does not stay charged. 1. Faulty battery . 2. Faulty engine alternator. 3. Loose or broken lead in charging circuit. 4.
  • Page 36 TROUBLESHOOTING 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.
  • Page 37 DIAGRAMS VANTAGE® 500 DEUTZ...
  • Page 38 CONNECTION DIAGRAMS VANTAGE® 500 DEUTZ...
  • Page 39 CONNECTION DIAGRAMS VANTAGE® 500 DEUTZ...
  • Page 40 CONNECTION DIAGRAMS VANTAGE® 500 DEUTZ...
  • Page 41 CONNECTION DIAGRAMS VANTAGE® 500 DEUTZ...
  • Page 42 CONNECTION DIAGRAMS VANTAGE® 500 DEUTZ...
  • Page 43 CONNECTION DIAGRAMS VANTAGE® 500 DEUTZ...
  • Page 44 CONNECTION DIAGRAMS VANTAGE® 500 DEUTZ...
  • Page 45 CONNECTION DIAGRAMS VANTAGE® 500 DEUTZ...
  • Page 46 F-10 F-10 CONNECTION DIAGRAMS VANTAGE® 500 DEUTZ...
  • Page 47 F-11 F-11 CONNECTION DIAGRAMS VANTAGE® 500 DEUTZ...
  • Page 48 F-12 F-12 CONNECTION DIAGRAMS VANTAGE® 500 DEUTZ...
  • Page 49 F-13 F-13 DIMENSION PRINT VANTAGE® 500 DEUTZ...
  • Page 50 NOTES VANTAGE® 500 DEUTZ...
  • Page 51 Do not touch electrically live parts or Keep flammable materials away. Wear eye, ear and body protection. WARNING electrode with skin or wet clothing. Insulate yourself from work and ground. Spanish No toque las partes o los electrodos Mantenga el material combustible Protéjase los ojos, los oídos y el AVISO DE bajo carga con la piel o ropa moja-...
  • Page 52 Keep your head out of fumes. Turn power off before servicing. Do not operate with panel open or WARNING Use ventilation or exhaust to guards off. remove fumes from breathing zone. Spanish Los humos fuera de la zona de res- Desconectar el cable de ali- No operar con panel abierto o AVISO DE...
  • Page 53 Need Help? Lincoln Electric “Rapid Response” Service! Call 1.888.935.3877 to talk to a Service Representative Hours of Operation: 8:00 AM to 6:00 PM (ET) Mon. thru Fri. After hours? Use “Ask the Experts” at lincolnelectric.com A Lincoln Service Representative will contact you no later than the following business day.

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