Table of Contents
Advertisement
Quick Links
RETURN TO MAIN MENU
IM805
April, 2004
Vantage 500 DEUTZ
10995
For use with machines having Code Numbers:
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 EQUIPMENT
WITHOUT READING THIS
MANUAL AND THE SAFETY
PRECAUTIONS CONTAINED
THROUGHOUT.
Most
importantly, think before you
act and be careful.
OPERATOR'S MANUAL
Copyright© 2004 Lincoln Global Inc.
• World's Leader in Welding and Cutting Products •
• Sales and Service through Subsidiaries and Distributors Worldwide •
Cleveland, Ohio 44117-1199 USA Tel: 216.481.8100 Fax: 216.486.1751 Web Site: www.lincolnelectric.com
Advertisement
Table of Contents
Troubleshooting
Related Manuals for Lincoln Electric VANTAGE 500 DEUTZ IM805
Summary of Contents for Lincoln Electric VANTAGE 500 DEUTZ IM805
- Page 1 RETURN TO MAIN MENU IM805 April, 2004 Vantage 500 DEUTZ 10995 For use with machines having Code Numbers: 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 .
- Page 2 CALIFORNIA PROPOSITION 65 WARNINGS For Diesel Engines: diesel engine exhaust and some of its constituents are known to the State of California to cause cancer, birth defects, and other reproductive harm. ARC WELDING CAN BE HAZARDOUS. PROTECT YOURSELF AND OTHERS FROM POSSIBLE SERIOUS INJURY OR DEATH. KEEP CHILDREN AWAY.
- Page 3 ELECTRIC SHOCK can kill. 3.a. The electrode and work (or ground) circuits are electrically “hot” when the welder is on. Do not touch these “hot” parts with your bare skin or wet clothing. Wear dry, hole-free gloves to insulate hands. 3.b.
-
Page 4: Iii Safety
WELDING SPARKS can cause fire or explosion 6 a Remove fire hazards from the welding area. If this is not possible, cover them to prevent the welding sparks from starting a fire. Remember that welding sparks and hot materials from welding can easily go through small cracks and openings to adjacent areas. - Page 5 PRÉCAUTIONS DE SÛRETÉ Pour votre propre protection lire et observer toutes les instructions et les précautions de sûreté specifiques qui parraissent dans ce manuel aussi bien que les précautions de sûreté générales suivantes: Sûreté Pour Soudage A L’Arc 1. Protegez-vous contre la secousse électrique: a.
- Page 6 The code number is especially important when identifying the correct replacement parts. - Register your machine with Lincoln Electric either via fax or over the Internet. • 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.
-
Page 7: Table Of Contents
Connection of Lincoln Electric Wire Feeders ........ - Page 8 TABLE OF CONTENTS Accessories ..............Section C Optional Field Installed Accessories .
-
Page 9: Installation
TECHNICAL SPECIFICATIONS - Vantage 500 DEUTZ (K2271-1) Make /Model Description Deutz 3 cylinder F3L 912 44HP (33 kw) Diesel Engine @ 1800 RPM RATED OUTPUT @ 104°F(40°C) - WELDER Duty Cycle 100% OUTPUT @ 104°F(40°C) - WELDER AND GENERATOR Height Width 42.0 in 31.5 in. -
Page 10: Safety Precautions
Read this entire installation section before you start installation. SAFETY PRECAUTIONS WARNING Do not attempt to use this equipment until you have thoroughly read all operating and maintenance manuals supplied with your machine. They include important safety precautions, detailed engine starting, operating and maintenance instructions and parts lists. -
Page 11: Lifting
LIFTING The Vantage lift bale should be used to lift the machine. The Vantage is shipped with the lift bale retracted. Before attempting to lift the Vantage the lift bale must be secured in a raised position. Secure the lift bale as follows: a. -
Page 12: Pre-Operation Engine Service
Remove the plastic cap covering from the Fuel Tank Filler neck and install the Fuel Cap. ENGINE BREAK-IN Lincoln Electric selects high quality, heavy-duty industrial engines for the portable welding machines we offer. While it is normal to see a small amount of crankcase oil... -
Page 13: Muffler Outlet Pipe
The Vantage is shipped with the negative battery cable disconnected. Before you operate the machine, make sure the Engine Switch is in the OFF position and attach the disconnected cable securely to the negative (-) battery terminal. Remove the insulating cap from the negative battery terminal. Replace and tighten negative battery cable terminal. -
Page 14: Remote Control
REMOTE CONTROL OUTPUT The Vantage is equipped with a 6-pin and a 14-pin connector. The 6-pin connector is for connecting the K857 or K857-1 Remote Control or for TIG welding, the K870 foot Amptrol or the K936-2 hand Amptrol. When in the CC-STICK, DOWNHILL PIPE, or CV- WIRE modes and when a remote control is connected to the 6- pin Connector, the auto-sensing circuit automatically switches the OUTPUT control from control at the welder to remote control. - Page 15 2. Take necessary steps to assure load is limited to the capacity of the Vantage by installing a 50 amp, 240 VAC double pole circuit breaker. Maximum rated load for each leg of the 240 VAC auxiliary is 50 amps. Loading above the rated output will reduce output voltage below the allowable -10% of rated voltage which may damage appliances or other motor-driven equipment and may result in overheating of the Vantage...
-
Page 16: Connection Of Lincoln Electric Wire Feeders
CONNECTION OF LINCOLN ELECTRIC WIRE FEEDERS WARNING Shut off welder before making any electrical connections. ------------------------------------------------------------------------------------- CONNECTION OF LN-7, LN-8 OR LN-742 TO THE VANTAGE • Shut the welder off. • Connect the LN-7, LN-8 or LN-742 per instructions on the appropriate connection diagram in the DIAGRAMS section. - Page 17 CONNECTION OF THE LN-25 TO THE VANTAGE The LN-25 with or without an internal contactor may be used with the Vantage. See the appropriate connection diagram in the DIAGRAMS section. NOTE: The LN-25 (K431) Remote Control Module and (K432) Remote Cable are not recommended for use with the Vantage. •...
-
Page 18: Operation
SAFETY INSTRUCTIONS Read and understand this entire section before operating your Vantage. WARNING Do not attempt to use this equipment until you have thoroughly read all operating and maintenance manuals supplied with your machine. They include important safety precautions, detailed engine starting, operating and maintenance instructions and parts lists. -
Page 19: Controls And Settings
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 8) 1. RUN STOP SWITCH Toggling the switch to the RUN position energizes the fuel solenoid for approximately 30 seconds. - Page 20 6. OIL PRESSURE GAUGE The gauge displays the engine oil pressure when the engine is running. 7. ENGINE PROTECTION The yellow engine protection light remains off with proper oil pressure and under normal operating temperatures. If the light turns on, the engine protection system will stop the engine. Check for proper oil level and add oil if necessary.
-
Page 21: Auxiliary Power Controls
14. WIRE FEEDER VOLTMETER SWITCH: Matches the polarity of the wire feeder voltmeter to the polarity of the electrode. 15. 6 - PIN CONNECTOR For attaching optional remote control equipment. Includes auto- sensing remote control circuit. 16. 14 - PIN CONNECTOR For attaching wire feeder control cables. -
Page 22: Typical Fuel Consumption
TYPICAL FUEL CONSUMPTION Refer to Table B.2 for typical fuel consumption of the Vantage Engine for various operating scenarios. Table B.2 Deutz F3L912 Engine Fuel Consumption Deutz B3.3 Running Time for 44HP(33Kw) 25Gal.(94.6 L) @1800 RPM High Idle - .66 Gal./hour no load 1900 RPM (2.50 Lts./hour) DC CC Weld... -
Page 23: Typical Current Ranges For Tungsten Electrodes
Table B.3 TYPICAL CURRENT RANGES DCEN (-) Tungsten Electrode 1%, 2% Diameter Thoriated mm (in) Tungsten .25 (0.010) 2-15 .50 (0.020) 5-20 1.0 (0.040) 15-80 1.6 (1/16) 70-150 2.4 (3/32) 150-250 3.2 (1/8) 250-400 4.0 (5/32) 400-500 4.8 (3/16) 500-750 6.4 (1/4) 750-1000 When used with argon gas. -
Page 24: Cv-Wire Mode
CV-WIRE MODE Connect a wire feeder to the Vantage and set welder controls according to the instructions listed earlier in this section. The Vantage in the ”CV-WIRE” position, permits it to be used with a broad range of flux cored wire (Innershield and Outershield) electrodes and solid wires for MIG welding (gas metal arc welding). - Page 25 TABLE B.4 Vantage Simultaneous Welding and Power Loads Welding Output Permissible Power Watts at NEMA Voltage (Unity Power Factor) (V=.04I + 20) 0-250A/30V 350A/34V 400A/36V 450A/38V 500A/40V * Each duplex receptacle is limited to 20 amps. ** Not to exceed 50A per 120 VAC branch circuit when splitting the 240 VAC output. TABLE B.5 Vantage Extension Cord Length Recommendations Current Voltage...
-
Page 26: Accessories
The use of an arc welder for pipe thawing is not approved by the CSA, nor is it recommended or supported by Lincoln Electric. ------------------------------------------------------------------------------------- Vantage 500 DEUTZ... -
Page 27: Maintenance
SAFETY PRECAUTIONS WARNING • Have a qualified technician do the maintenance and troubleshooting work. • Turn the engine off before working inside the machine. • Remove guards only when necessary and replace them when the maintenance requiring their removal is complete. •... -
Page 28: Fuel Filters
7. Inspect for holes and tears by looking through the element toward a bright light. Check for damaged gaskets or dented metal parts. Do not reuse damaged elements. Protect element from dust and damage during drying and storage. 8. Reinstall air filter element. After six cleanings replace air filter. -
Page 29: Cooling System
COOLING SYSTEM The cooling system of the Deutz engine needs to be checked and cleaned periodically. Consult the engine owners manual for the proper frequency and procedure. COOLING BLOWER BELT The following procedure should be followed to replace the cooling blower belt: 1. -
Page 30: Charging The Battery
CHARGING THE BATTERY When you charge, jump, replace, or otherwise connect battery cables to the battery, be sure the polarity is correct. Improper polarity can damage the charging circuit. The Vantage positive (+) battery terminal has a red terminal cover. If you need to charge the battery with an external charger, disconnect the negative cable first, then the positive cable before you attach the charger leads. -
Page 31: How To Use Troubleshooting Guide
HOW TO USE TROUBLESHOOTING GUIDE Service and Repair should only be performed by Lincoln Electric Factory Trained Personnel. Unauthorized repairs performed on this equipment may result in danger to the technician and machine operator and will invalidate your factory warranty. For your safety and to avoid Electrical Shock, please observe all safety notes and precautions detailed throughout this manual. -
Page 32: Troubleshooting
Observe all Safety Guidelines detailed throughout this manual PROBLEMS (SYMPTOMS) Major Physical or Electrical Damage is Evident. Engine will not crank Engine will crank but not start. Engine shuts down shortly after starting. Engine shuts down while under a load. Engine runs rough. - Page 33 PROBLEMS (SYMPTOMS) Battery does not stay charged. No welding output or auxiliary output. Welder has some/ no output and no control. Auxiliary output OK No welding output. Auxiliary output OK. No auxiliary power. 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.
- Page 34 ENHANCED DIAGRAM DIAGRAMS 208B Vantage 500 DEUTZ 232F 405A 262A...
- Page 35 DIAGRAMS CONNECTION DIAGRAM: Vantage 500 DEUTZ...
- Page 36 DIAGRAMS CONNECTION DIAGRAM: Vantage 500 DEUTZ...
- Page 37 DIAGRAMS CONNECTION DIAGRAM Vantage 500 DEUTZ...
- Page 38 DIAGRAMS CONNECTION DIAGRAM Vantage 500 DEUTZ...
- Page 39 DIAGRAMS CONNECTION DIAGRAM Vantage 500 DEUTZ...
- Page 40 DIAGRAMS CONNECTION DIAGRAM Vantage 500 DEUTZ...
- Page 41 DIAGRAMS CONNECTION DIAGRAM Vantage 500 DEUTZ...
- Page 42 DIAGRAMS CONNECTION DIAGRAM Vantage 500 DEUTZ...
- Page 43 DIAGRAMS F-10 F-10 CONNECTION DIAGRAM Vantage 500 DEUTZ...
- Page 44 DIAGRAMS F-11 F-11 CONNECTION DIAGRAM Vantage 500 DEUTZ...
- Page 45 DIAGRAMS F-12 F-12 CONNECTION DIAGRAM Vantage 500 DEUTZ...
- Page 46 DIAGRAMS F-13 F-13 CONNECTION DIAGRAM Vantage 500 DEUTZ...
- Page 47 DIAGRAMS F-14 F-14 DIMENSION PRINT Vantage 500 DEUTZ...
- Page 48 NOTES VANTAGE 500 DEUTZ...
- Page 49 ● WARNING ● Spanish ● AVISO DE PRECAUCION ● French ● ATTENTION ● ● German WARNUNG ● Portuguese ● ATENÇÃO ● Japanese Chinese Korean Arabic ● ● ● ● ● Vantage 500 DEUTZ ● ● ● ● ●...
- Page 50 ● ● ● ● ● ● ● ● ● ● ● ● ● ● ● ● ● ● ● ● ● ● ● Vantage 500 DEUTZ WARNING Spanish AVISO DE PRECAUCION French ATTENTION German WARNUNG Portuguese ATENÇÃO Japanese Chinese Korean Arabic...
- Page 51 World’s Leader in Welding and Cutting Products • Sales and Service through Subsidiaries and Distributors Worldwide • Cleveland, Ohio 44117-1199 USA Tel: 216.481.8100 Fax: 216.486.1751 Web Site: www.lincolnelectric.com...