Summary of Contents for Lincoln Electric DUAL VANTAGE 800-I
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Operator’s Manual DUAL VANTAGE ® 800-I For use with machines having Code Numbers: 12581 Need Help? Call 1.888.935.3877 Register your machine: to talk to a Service Representative www.lincolnelectric.com/register 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”...
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THANK YOU FOR SELECTING A QUALITY PRODUCT BY KEEP YOUR HEAD OUT OF THE FUMES. DON’T get too close to the arc. LINCOLN ELEC TRIC. Use corrective lenses if necessary to stay a reasonable distance away from the arc. READ and obey the Safety Data PLEASE EXAMINE CARTON AND EQUIPMENT FOR Sheet (SDS) and the warning label DAMAGE IMMEDIATELY...
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W117.2-1974. A Free copy of “Arc Welding Safety” booklet E205 is available from the Lincoln Electric Company, 2.d. All welders should use the following procedures in order to 22801 St. Clair Avenue, Cleveland, Ohio 44117-1199.
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SAFETY ELECTRIC SHOCK ARC RAYS CAN BURN. CAN KILL. 3.a. The electrode and work (or ground) circuits are 4.a. Use a shield with the proper filter and cover plates to protect your electrically “hot” when the welder is on. Do eyes from sparks and the rays of the arc when welding or not touch these “hot”...
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SAFETY WELDING AND CUTTING CYLINDER MAY EXPLODE IF SPARKS CAN CAUSE DAMAGED. FIRE OR EXPLOSION. 7.a. Use only compressed gas cylinders containing the correct shielding gas for the process used 6.a. Remove fire hazards from the welding area. If and properly operating regulators designed for this is not possible, cover them to prevent the welding sparks the gas and pressure used.
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2004/108/EC. It was manufactured in conformity with a national standard that implements a harmonized standard: EN 60974-10 Electromagnetic Compatibility (EMC) Product Standard for Arc Welding Equipment. It is for use with other Lincoln Electric equipment. It is designed for industrial and professional use. Introduction All electrical equipment generates small amounts of electromagnetic emission.
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DUAL VANTAGE ® 800-I SAFETY Electromagnetic Compatibility (EMC) The size of the surrounding area to be considered will depend on the structure of the building and other activities that are taking place. The surrounding area may extend beyond the boundaries of the premises. Methods of Reducing Emissions Mains Supply Welding equipment should be connected to the mains supply according to the manufacturer’s recommenda-...
Remote Control ........................A-6 Auxiliary Power Receptacles ....................A-6 Standby Power Connections ..................A-6, A-7 Connection of Lincoln Electric Wire Feeders..............A-8, A-9 Connection of Wire Feeders With Control Cable (14 Pin)..........A-8 Connection of Across the Arc Wire Feeders ..............A-9 Electrical Device use with this Product................A-10 ________________________________________________________________________________ Operation.........................Section B...
SAFETY PRECAUTIONS DUAL VANTAGE ® 800-I INSTALLATION FIGURE A.1 WARNING (VRD)-VOLTAGE Do not attempt to use this equipment until you REDUCTION DEVICE have thoroughly read the engine manufacturer’s SWITCHES LOCATED manual supplied with your welder. It includes IN THESE AREAS. important safety precautions, detailed engine starting, operating and maintenance instructions, and parts lists.
DUAL VANTAGE ® 800-I INSTALLATION STACKING HIGH ALTITUDE OPERATION DUAL VANTAGE 800-I machines cannot be stacked. At higher altitudes, output derating may be necessary. For maxi- ® mum rating, derate the welder output 4% for every 300 meters (984 ANGLE OF OPERATION ft.) above 1500 meters (4920 ft.).
PRE-OPERATION ENGINE SERVICE DUAL VANTAGE ® 800-I INSTALLATION ENGINE COOLANT WARNING READ the engine operating and maintenance instruc- tions supplied with this machine. HOT COOLANT can burn skin. WARNING •Do not remove cap if radiator is hot. • Keep hands away from the engine muffler or HOT engine parts.
DUAL VANTAGE ® 800-I INSTALLATION The DUAL VANTAGE 800-I is shipped with the Listed in Table A.1 are copper cable sizes recom- ® negative battery cable disconnected. Before you mended for the rated current and duty cycle. Lengths operate the machine, make sure the Engine Switch stipulated are the distance from the welder to work is in the OFF position and attach the disconnected and back to the welder again.
DUAL VANTAGE ® 800-I INSTALLATION AUXILIARY POWER RECEPTACLES REMOTE CONTROL The DUAL VANTAGE 800-I is equipped with a 6-pin The auxiliary power of the DUAL VANTAGE 800-I ® ® and a 14-pin connector. The 6-pin connector is for consists of Single Phase 60Hz Power. Output Voltage connecting the K857 or K857-1 Remote Control or for is within +/- 10% at loads up to rated capacity.
DUAL VANTAGE ® 800-I INSTALLATION STANDBY POWER CONNECTIONS The DUAL VANTAGE 800-I is suitable for temporary, ® standby or emergency power using the engine manu- WARNING facturer’s recommended maintenance schedule. The DUAL VANTAGE 800-I can be permanently • Only a licensed, certified, trained electrician should ®...
DUAL VANTAGE ® 800-I INSTALLATION FIGURE A.2 CONNECTION OF WIRE FEEDERS WITH CONTROL CABLE (14 PIN) WARNING Set Mode to CV Wire Set Weld Set Weld Terminals Shut off welder before making any electrical connections. Terminals to Remote to Remote ------------------------------------------------------------------ Set Mode Set Polarity...
DUAL VANTAGE ® 800-I INSTALLATION FIGURE A.4 CONNECTION OF ACROSS THE ARC WIRE FEEDERS TO THE DUAL VANTAGE ® 800-I Set Weld Terminals These connections instructions apply to both the LN-25 Pro and to 'ON' Set Weld Activ8 models. The feeders have an internal contactor and the Set Mode to Set Mode to Terminals...
DO NOT USE THESE DEVICES WITH THIS PRODUCT. The Lincoln Electric Company is not responsible for any damage to electrical components improperly connected to this product. A-10...
DUAL VANTAGE ® 800-I OPERATION The DUAL VANTAGE 800-I is fitted with a selectable ® VRD(Voltage Reduction Device). The VRD operates OPER TION in the CC-Stick mode reducing the OCV to <30 volts, SAFETY PRECAUTIONS increasing operator safety when welding is per- formed in environments with increased hazard of electric shock such as wet areas and hot, humid Read and understand this entire section before...
DUAL VANTAGE ® 800-I OPERATION BREAK-IN PERIOD WARNING No break in period is required for the Cummins ADD FUEL engine. • Stop engine while fueling. RECOMMENDED APPLICATIONS • Do not smoke when fueling. • Keep sparks and flame away The DUAL VANTAGE 800-I provides excellent con- from tank.
DUAL VANTAGE ® 800-I OPERATION FIGURE B.2 – – WELDING CONTROLS (Figure B.2) When in the TOUCH START TIG mode and when 1. OUTPUT CONTROL- The OUTPUT dial is an Amptrol is connected to the 6-Pin Connector, used to preset the output voltage or current as dis- the OUTPUT dial is used to set the maximum cur- played on the digital meters for the five welding rent range of the CURRENT CONTROL of the...
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4. ARC CONTROL DUAL VANTAGE ® 800-I OPERATION 10. WELD TERMINALS CONTROL SWITCH- - The ARC CONTROL dial is active in the CV-WIRE, CC-STICK and DOWNHILL PIPE modes, In the WELD TERMINALS ON position, the output is and has different functions in these modes. This control is electrically hot all the time.
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Can also be used to jump-start speed. the DUAL VANTAGE 800-I. • The engine will automatically return to high idle speed when there is welding load or AC power 22.
DUAL VANTAGE ® 800-I OPERATION ENGINE OPERATION STOPPING THE ENGINE 1. Switch the RUN/STOP switch to “STOP”. This turns STARTING THE ENGINE off the voltage supplied to the shutdown solenoid. A 1. Open the engine compartment door and check that backup shutdown can be accomplished by shutting the fuel shutoff valve located to the left of the fuel off the fuel valve located on the fuel line.
DUAL VANTAGE ® 800-I OPERATION WELDER OPERATION B. For Re-Striking Electrodes Some electrodes form a cone at the end of the elec- trode after the welding arc has been broken, particu- DUTY CYCLE larly iron powder and low hydrogen electrodes. This Duty Cycle is the percentage of time the load is being cone will need to be broken off in order to have the applied in a 10 minute period.
DUAL VANTAGE ® 800-I OPERATION TIG WELDING If desired, the K930-2 TIG Module can be used with the DUAL VANTAGE 800-I. The settings are for ref- ® erence. The TOUCH START TIG setting of the MODE switch is for DC TIG (Tungsten Inert Gas) welding. To initiate a DUAL VANTAGE 800-I settings when using the weld, the OUTPUT CONTROL dial is first set to the...
DUAL VANTAGE ® 800-I OPERATION WIRE WELDING-CV PARALLELING Connect a wire feeder to the DUAL VANTAGE 800-I ® according to the instructions in INSTALLATION When paralleling machines in order to combine their outputs, all units must be operated in the CC-STICK INSTRUCTIONS Section.
DUAL VANTAGE AUXILIARY POWER OPERATION ® 800-I OPERATION SIMULTANEOUS WELDING AND AUXIL- IARY POWER LOADS Start the engine and set the IDLER control switch to It must be noted that the above auxiliary power ratings the desired operating mode. Full power is available are with no welding load.
DUAL VANTAGE ® 800-I ACCESSORIES CCESSORIES OPTIONAL FIELD INSTALLED ACCESSORIES K2637-2 Large Trailer K2639-1 Fender Kit K2640-1 Cable Rack K2641-2 Four Wheel Trailer K857 Remote Control K857-1 Remote Control K2642-1 Polarity Multiprocess Switch K2663-1 Docking Kit K2613-5A1 Ln-25 PRO with K126 PRO Gun K126-12 K126 PRO Gun KP1696-068 Drive Roll Kit K12038-2 Invertec PC610 Plasma...
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DUAL VANTAGE ® 800-I MAINTENANCE ENGINE MAINTENANCE M INTEN NCE Refer to the “Periodic Checks” section of the Engine Operator’s Manual for the recommended maintenance SAFETY PRECAUTIONS schedule of the following: a) Engine Oil and Filter WARNING b) Air Cleaner c) Fuel Filter - and Delivery System •...
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DUAL VANTAGE ® 800-I 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.
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DUAL VANTAGE ® 800-I FIGURE D.1 MAINTENANCE FUEL FILTERS WARNING When working on the fuel system: • Keep naked lights away, do not smoke! • Do not spill fuel! ------------------------------------------------------------------------- 800-I is equipped with a Fuel The DUAL VANTAGE ® Filter located after the lift pump and before fuel injec- tors.The procedure for changing the filter is as follows.
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DUAL VANTAGE ® 800-I MAINTENANCE BATTERY HANDLING CHARGING THE BATTERY GASES FROM BATTERY can explode. When you charge, jump, replace, or otherwise con- nect battery cables to the battery, be sure the polarity • Keep sparks, flame and cigarettes is correct. Improper polarity can damage the charging away from battery.
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NAMEPLATES / WARNING DECALS DUAL VANTAGE ® 800-I MAINTENANCE MAINTENANCE Whenever routine maintenance is performed on this machine - or at least yearly - inspect all nameplates and labels for legibility. Replace those which are no longer clear. Refer to the parts list for the replacement item number.
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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.
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DUAL VANTAGE ® 800-I TROUBLESHOOTING Observe all Safety Guidelines detailed throughout this manual PROBLEMS POSSIBLE RECOMMENDED (SYMPTOMS) CAUSE COURSE OF ACTION 1. Contact your local Lincoln Major Physical or Electrical Damage Authorized Field Service is Evident. Facility. Engine will not crank 1.
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DUAL VANTAGE ® 800-I TROUBLESHOOTING Observe all Safety Guidelines detailed throughout this manual PROBLEMS POSSIBLE RECOMMENDED (SYMPTOMS) CAUSE COURSE OF ACTION Battery does not stay charged. 1. Faulty battery . 2. Faulty engine alternator. 3. Loose or broken lead in charging circuit.
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DUAL VANTAGE ® 800-I TROUBLESHOOTING Observe all Safety Guidelines detailed throughout this manual PROBLEMS POSSIBLE RECOMMENDED (SYMPTOMS) CAUSE COURSE OF ACTION Welder has some/ no output and no con- 1. Faulty remote kit. trol. Auxiliary output OK. 2. Faulty output control potentiometer. 3.
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Radiator & Case Back Asbly P-796-K.jpg Dual Vantage 800-I (Cummins) - 12581...
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DOOR WELDED ASSEMBLY 9SM20241 DOOR LATCH 9ST12584-6 RIVET 9ST14882-2 DOOR BUMPER 9ST12584-6 RIVET 9ST14882 DOOR BUMPER 9SS27368-6 LOGO DECAL 9SM21908 FAMILY NAME LOGO 9SL17074 REAR NAMEPLATE 9SM21436 CARBON MONOXIDE WARNING DECAL 9SS12934-1 COVER SEAL Dual Vantage 800-I (Cummins) - 12581...
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Covers Assembly PART NUMBER DESCRIPTION 9SS27368-6 LOGO DECAL 9SM21908-1 FAMILY NAME LOGO 9SS20145-1 WARNING DECAL Dual Vantage 800-I (Cummins) - 12581...
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WARNING Do not touch electrically live parts or Keep flammable materials away. Wear eye, ear and body protection. electrode with skin or wet clothing. Insulate yourself from work and AVISO DE ground. Spanish PRECAuCION No toque las partes o los electrodos Mantenga el material combustible Protéjase los ojos, los oídos y el bajo carga con la piel o ropa moja-...
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WARNING Keep your head out of fumes. Turn power off before servicing. Do not operate with panel open or Use ventilation or exhaust to guards off. remove fumes from breathing zone. AVISO DE Spanish PRECAuCION Los humos fuera de la zona de res- Desconectar el cable de ali- No operar con panel abierto o piración.
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Lincoln Electric for advice or information about their use of our products. We respond to our customers based on the best information in our possession at that time. Lincoln Electric is not in a position to warrant or guarantee such advice, and assumes no liability, with respect to such information or advice.