• Sales and Service through Subsidiaries and Distributors Worldwide •

Cleveland, Ohio 44117-1199 U.S.A. TEL: 216.481.8100 FAX: 216.486.1751 WEB SITE: www.lincolnelectric.com

• World's Leader in Welding and Cutting Products •

OPERATOR’S MANUAL

Copyright © Lincoln Global Inc.

July, 2007

Safety Depends on YouLincoln arc welding and cuttingequipment is designed andbuilt with safety in mind.However, your overall safetycan be increased by properinstallation . . . and thoughtfuloperation on your part. DONOT INSTALL, OPERATEOR REPAIR THIS EQUIP-MENT WITHOUT READINGTHIS MANUAL AND THESAFETY PRECAUTIONSCONTAINED THROUGHOUT.Most importantly, think beforeyou act and be careful.

IM862-A

For use with machines having Code Numbers:11180, 11415

VANTAGE500DEUTZ

R

This manual covers equipment which is no longer in production by The Lincoln Electric Co. Speci�cations and availability of optional features may have changed.

FOR ENGINEpowered equipment.

1.a. Turn the engine off before troubleshooting and maintenancework unless the maintenance work requires it to be running.

____________________________________________________1.b. Operate engines in open, well-ventilated

areas or vent the engine exhaust fumesoutdoors.

____________________________________________________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 beforerefueling to prevent spilled fuel from vaporiz-ing on contact with hot engine parts andigniting. Do not spill fuel when filling tank. Iffuel is spilled, wipe it up and do not startengine until fumes have been eliminated.

____________________________________________________1.d. Keep all equipment safety guards, covers and devices in

position and in good repair.Keep hands, hair, clothing andtools away from V-belts, gears, fans and all other movingparts when starting, operating or repairing equipment.

____________________________________________________

1.e. In some cases it may be necessary to remove safetyguards to perform required maintenance. Removeguards only when necessary and replace them when themaintenance requiring their removal is complete.Always use the greatest care when working near movingparts.

___________________________________________________1.f. Do not put your hands near the engine fan.

Do not attempt to override the governor oridler by pushing on the throttle control rodswhile the engine is running.

___________________________________________________1.g. To prevent accidentally starting gasoline engines while

turning the engine or welding generator during maintenancework, disconnect the spark plug wires, distributor cap ormagneto wire as appropriate.

iSAFETYi

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 youpurchase a copy of “Safety in Welding & Cutting - ANSI Standard Z49.1” from the American Welding Society, P.O. Box351040, Miami, Florida 33135 or CSA Standard W117.2-1974. A Free copy of “Arc Welding Safety” booklet E205 is availablefrom the Lincoln Electric Company, 22801 St. Clair Avenue, Cleveland, Ohio 44117-1199.

BE SURE THAT ALL INSTALLATION, OPERATION, MAINTENANCE AND REPAIR PROCEDURES AREPERFORMED ONLY BY QUALIFIED INDIVIDUALS.

WARNING

Mar ʻ95

ELECTRIC ANDMAGNETIC FIELDSmay be dangerous

2.a. Electric current flowing through any conductor causeslocalized Electric and Magnetic Fields (EMF). Weldingcurrent creates EMF fields around welding cables andwelding machines

2.b. EMF fields may interfere with some pacemakers, andwelders having a pacemaker should consult their physicianbefore welding.

2.c. Exposure to EMF fields in welding may have other healtheffects which are now not known.

2.d. All welders should use the following procedures in order tominimize exposure to EMF fields from the welding circuit:

2.d.1. Route the electrode and work cables together - Securethem with tape when possible.

2.d.2. Never coil the electrode lead around your body.

2.d.3. Do not place your body between the electrode andwork cables. If the electrode cable is on your rightside, the work cable should also be on your right side.

2.d.4. Connect the work cable to the workpiece as close aspossible to the area being welded.

2.d.5. Do not work next to welding power source.

1.h. To avoid scalding, do not remove theradiator pressure cap when the engine ishot.

CALIFORNIA PROPOSITION 65 WARNINGS

Diesel engine exhaust and some of its constituentsare known to the State of California to cause can-cer, birth defects, and other reproductive harm.

The engine exhaust from this product containschemicals known to the State of California to causecancer, birth defects, or other reproductive harm.

The Above For Diesel Engines The Above For Gasoline Engines

iiSAFETYii

ARC RAYS can burn.4.a. Use a shield with the proper filter and cover

plates to protect your eyes from sparks andthe rays of the arc when welding or observingopen arc welding. Headshield and filter lensshould conform to ANSI Z87. I standards.

4.b. Use suitable clothing made from durable flame-resistantmaterial to protect your skin and that of your helpers fromthe arc rays.

4.c. Protect other nearby personnel with suitable, non-flammablescreening and/or warn them not to watch the arc nor exposethemselves to the arc rays or to hot spatter or metal.

ELECTRIC SHOCK cankill.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 bareskin or wet clothing. Wear dry, hole-free

gloves to insulate hands.

3.b. Insulate yourself from work and ground using dry insulation.Make certain the insulation is large enough to cover your fullarea of physical contact with work and ground.

In addition to the normal safety precautions, if weldingmust be performed under electrically hazardousconditions (in damp locations or while wearing wetclothing; on metal structures such as floors, gratings orscaffolds; when in cramped positions such as sitting,kneeling or lying, if there is a high risk of unavoidable oraccidental contact with the workpiece or ground) usethe following equipment:

• Semiautomatic DC Constant Voltage (Wire) Welder.• DC Manual (Stick) Welder.• AC Welder with Reduced Voltage Control.

3.c. In semiautomatic or automatic wire welding, the electrode,electrode reel, welding head, nozzle or semiautomaticwelding gun are also electrically “hot”.

3.d. Always be sure the work cable makes a good electricalconnection with the metal being welded. The connectionshould be as close as possible to the area being welded.

3.e. Ground the work or metal to be welded to a good electrical(earth) ground.

3.f. Maintain the electrode holder, work clamp, welding cable andwelding machine in good, safe operating condition. Replacedamaged insulation.

3.g. Never dip the electrode in water for cooling.

3.h. Never simultaneously touch electrically “hot” parts ofelectrode holders connected to two welders because voltagebetween the two can be the total of the open circuit voltageof both welders.

3.i. When working above floor level, use a safety belt to protectyourself from a fall should you get a shock.

3.j. Also see Items 6.c. and 8.

FUMES AND GASEScan be dangerous.5.a. Welding may produce fumes and gases

hazardous to health. Avoid breathing thesefumes and gases.When welding, keepyour head out of the fume. Use enoughventilation and/or exhaust at the arc to keep

fumes and gases away from the breathing zone. Whenwelding with electrodes which require specialventilation such as stainless or hard facing (seeinstructions on container or MSDS) or on lead orcadmium plated steel and other metals or coatingswhich produce highly toxic fumes, keep exposure aslow as possible and below Threshold Limit Values (TLV)using local exhaust or mechanical ventilation. Inconfined spaces or in some circumstances, outdoors, arespirator may be required. Additional precautions arealso required when welding on galvanized steel.

5. b. The operation of welding fume control equipment is affectedby various factors including proper use and positioning ofthe equipment, maintenance of the equipment and the spe-cific welding procedure and applicaiton involved. Workerexposure level should be checked upon installation andperiodically thereafter to be certain it is within applicableOSHA PEL and ACGIH TLV limits.

5.c. Do not weld in locations near chlorinated hydrocarbon vaporscoming from degreasing, cleaning or spraying operations.The heat and rays of the arc can react with solvent vapors toform phosgene, a highly toxic gas, and other irritating prod-ucts.

5.d. Shielding gases used for arc welding can displace air andcause injury or death. Always use enough ventilation,especially in confined areas, to insure breathing air is safe.

5.e. Read and understand the manufacturerʼs instructions for thisequipment and the consumables to be used, including thematerial safety data sheet (MSDS) and follow youremployerʼs safety practices. MSDS forms are available fromyour welding distributor or from the manufacturer.

5.f. Also see item 1.b.

AUG 06

iiiSAFETYiii

FOR ELECTRICALLYpowered equipment.

8.a. Turn off input power using the disconnectswitch at the fuse box before working onthe equipment.

8.b. Install equipment in accordance with the U.S. NationalElectrical Code, all local codes and the manufacturerʼsrecommendations.

8.c. Ground the equipment in accordance with the U.S. NationalElectrical Code and the manufacturerʼs recommendations.

CYLINDER may explodeif damaged.7.a. Use only compressed gas cylinders

containing the correct shielding gas for theprocess used and properly operatingregulators designed for the gas and

pressure used. All hoses, fittings, etc. should be suitable forthe application and maintained in good condition.

7.b. Always keep cylinders in an upright position securelychained to an undercarriage or fixed support.

7.c. Cylinders should be located:• Away from areas where they may be struck or subjected tophysical damage.

• A safe distance from arc welding or cutting operations andany other source of heat, sparks, or flame.

7.d. Never allow the electrode, electrode holder or any otherelectrically “hot” parts to touch a cylinder.

7.e. Keep your head and face away from the cylinder valve outletwhen opening the cylinder valve.

7.f. Valve protection caps should always be in place and handtight except when the cylinder is in use or connected foruse.

7.g. Read and follow the instructions on compressed gascylinders, associated equipment, and CGA publication P-l,“Precautions for Safe Handling of Compressed Gases inCylinders,” available from the Compressed Gas Association1235 Jefferson Davis Highway, Arlington, VA 22202.

Jan, 07

WELDING and CUTTINGSPARKS cancause fire or explosion.6.a. Remove fire hazards from the welding area.

If this is not possible, cover them to preventthe welding sparks from starting a fire.

Remember that welding sparks and hotmaterials from welding can easily go through small cracksand openings to adjacent areas. Avoid welding nearhydraulic lines. Have a fire extinguisher readily available.

6.b. Where compressed gases are to be used at the job site,special precautions should be used to prevent hazardoussituations. Refer to “Safety in Welding and Cutting” (ANSIStandard Z49.1) and the operating information for theequipment being used.

6.c. When not welding, make certain no part of the electrodecircuit is touching the work or ground. Accidental contactcan cause overheating and create a fire hazard.

6.d. Do not heat, cut or weld tanks, drums or containers until theproper steps have been taken to insure that such procedureswill not cause flammable or toxic vapors from substancesinside. They can cause an explosion even though they havebeen “cleaned”. For information, purchase “RecommendedSafe Practices for the Preparation for Welding and Cutting ofContainers and Piping That Have Held HazardousSubstances”, AWS F4.1 from the American Welding Society(see address above).

6.e. Vent hollow castings or containers before heating, cutting orwelding. They may explode.

6.f. Sparks and spatter are thrown from the welding arc. Wear oilfree protective garments such as leather gloves, heavy shirt,cuffless trousers, high shoes and a cap over your hair. Wearear plugs when welding out of position or in confined places.Always wear safety glasses with side shields when in awelding area.

6.g. Connect the work cable to the work as close to the weldingarea as practical. Work cables connected to the buildingframework or other locations away from the welding areaincrease the possibility of the welding current passingthrough lifting chains, crane cables or other alternate cir-cuits. This can create fire hazards or overheat lifting chainsor cables until they fail.

6.h. Also see item 1.c.

6.I. Read and follow NFPA 51B “ Standard for Fire PreventionDuring Welding, Cutting and Other Hot Work”, availablefrom NFPA, 1 Batterymarch Park,PO box 9101, Quincy, Ma022690-9101.

6.j. Do not use a welding power source for pipe thawing.

ivSAFETYiv

Mar. ʻ93

PRÉCAUTIONS DE SÛRETÉPour votre propre protection lire et observer toutes les instructionset les précautions de sûreté specifiques qui parraissent dans cemanuel aussi bien que les précautions de sûreté générales suiv-antes:

Sûreté Pour Soudage A LʼArc1. Protegez-vous contre la secousse électrique:

a. Les circuits à lʼélectrode et à la piéce sont sous tensionquand la machine à souder est en marche. Eviter toujourstout contact entre les parties sous tension et la peau nueou les vétements mouillés. Porter des gants secs et sanstrous pour isoler les mains.

b. Faire trés attention de bien sʼisoler de la masse quand onsoude dans des endroits humides, ou sur un planchermetallique ou des grilles metalliques, principalement dansles positions assis ou couché pour lesquelles une grandepartie du corps peut être en contact avec la masse.

c. Maintenir le porte-électrode, la pince de masse, le câblede soudage et la machine à souder en bon et sûr étatdefonctionnement.

d.Ne jamais plonger le porte-électrode dans lʼeau pour lerefroidir.

e. Ne jamais toucher simultanément les parties sous tensiondes porte-électrodes connectés à deux machines à souderparce que la tension entre les deux pinces peut être letotal de la tension à vide des deux machines.

f. Si on utilise la machine à souder comme une source decourant pour soudage semi-automatique, ces precautionspour le porte-électrode sʼapplicuent aussi au pistolet desoudage.

2. Dans le cas de travail au dessus du niveau du sol, se protégercontre les chutes dans le cas ou on recoit un choc. Ne jamaisenrouler le câble-électrode autour de nʼimporte quelle partiedu corps.

3. Un coup dʼarc peut être plus sévère quʼun coup de soliel,donc:

a. Utiliser un bon masque avec un verre filtrant appropriéainsi quʼun verre blanc afin de se protéger les yeux du ray-onnement de lʼarc et des projections quand on soude ouquand on regarde lʼarc.

b. Porter des vêtements convenables afin de protéger lapeau de soudeur et des aides contre le rayonnement delʻarc.

c. Protéger lʼautre personnel travaillant à proximité ausoudage à lʼaide dʼécrans appropriés et non-inflammables.

4. Des gouttes de laitier en fusion sont émises de lʼarc desoudage. Se protéger avec des vêtements de protection libresde lʼhuile, tels que les gants en cuir, chemise épaisse, pan-talons sans revers, et chaussures montantes.

5. Toujours porter des lunettes de sécurité dans la zone desoudage. Utiliser des lunettes avec écrans lateraux dans leszones où lʼon pique le laitier.

6. Eloigner les matériaux inflammables ou les recouvrir afin deprévenir tout risque dʼincendie dû aux étincelles.

7. Quand on ne soude pas, poser la pince à une endroit isolé dela masse. Un court-circuit accidental peut provoquer unéchauffement et un risque dʼincendie.

8. Sʼassurer que la masse est connectée le plus prés possiblede la zone de travail quʼil est pratique de le faire. Si on placela masse sur la charpente de la construction ou dʼautresendroits éloignés de la zone de travail, on augmente le risquede voir passer le courant de soudage par les chaines de lev-age, câbles de grue, ou autres circuits. Cela peut provoquerdes risques dʼincendie ou dʼechauffement des chaines et descâbles jusquʼà ce quʼils se rompent.

9. Assurer une ventilation suffisante dans la zone de soudage.Ceci est particuliérement important pour le soudage de tôlesgalvanisées plombées, ou cadmiées ou tout autre métal quiproduit des fumeés toxiques.

10. Ne pas souder en présence de vapeurs de chlore provenantdʼopérations de dégraissage, nettoyage ou pistolage. Lachaleur ou les rayons de lʼarc peuvent réagir avec les vapeursdu solvant pour produire du phosgéne (gas fortement toxique)ou autres produits irritants.

11. Pour obtenir de plus amples renseignements sur la sûreté,voir le code “Code for safety in welding and cutting” CSAStandard W 117.2-1974.

PRÉCAUTIONS DE SÛRETÉ POURLES MACHINES À SOUDER ÀTRANSFORMATEUR ET ÀREDRESSEUR

1. Relier à la terre le chassis du poste conformement au code delʼélectricité et aux recommendations du fabricant. Le dispositifde montage ou la piece à souder doit être branché à unebonne mise à la terre.

2. Autant que possible, Iʼinstallation et lʼentretien du poste seronteffectués par un électricien qualifié.

3. Avant de faires des travaux à lʼinterieur de poste, la debranch-er à lʼinterrupteur à la boite de fusibles.

4. Garder tous les couvercles et dispositifs de sûreté à leurplace.

vv

Thank You for selecting a QUALITY product by Lincoln Electric. We want youto take pride in operating this Lincoln Electric Company product••• as much pride as we have in bringing this product to you!

Read this Operators Manual completely before attempting to use this equipment. Save this manual and keep ithandy 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:

WARNINGThis statement appears where the information must be followed exactly to avoid serious personal injury or loss of life.

This statement appears where the information must be followed to avoid minor personal injury or damage to this equipment.

CAUTION

Please Examine Carton and Equipment For Damage ImmediatelyWhen this equipment is shipped, title passes to the purchaser upon receipt by the carrier. Consequently, Claimsfor material damaged in shipment must be made by the purchaser against the transportation company at thetime the shipment is received.

Please record your equipment identification information below for future reference. This information can befound 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 youhave 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.• 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.• For On-Line Registration: Go to our WEB SITE at www.lincolnelectric.com. Choose “Quick Links” and then

“Product Registration”. Please complete the form and submit your registration.

CUSTOMER ASSISTANCE POLICYThe 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 LincolnElectric 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 customerʼs particular purpose,with respect to such information or advice. As a matter of practical consideration, we also cannot assume any responsibility for updating orcorrecting any such information or advice once it has been given, nor does the provision of information or advice create, expand or alter anywarranty 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 controlof, and remains the sole responsibility of the customer. Many variables beyond the control of Lincoln Electric affect the results obtained inapplying these types of fabrication methods and service requirements.

Subject to Change – This information is accurate to the best of our knowledge at the time of printing. Please refer to www.lincolnelectric.comfor any updated information.

vi vi TABLE OF CONTENTSPage

Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Section ATechnical Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .A-1Safety Precautions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .A-2Location / Ventilation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .A-2

Storing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .A-2Stacking . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .A-2Angle of Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .A-2Lifting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .A-3High Altitude Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .A-3High Temperature Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .A-3Towing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .A-3Vehicle Mounting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .A-3

Pre-Operation Engine and Compressor Service . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .A-4Oil . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .A-4Fuel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .A-4Fuel Cap . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .A-4Engine Cooling System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .A-4Battery Connection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .A-4Muffler Outlet Pipe . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .A-5Spark Arrestor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .A-5

Welding Terminals . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .A-5Welding Output Cables . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .A-5

Machine Grounding . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .A-5Remote Control . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .A-6Auxiliary Power Receptacles . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .A-6Standby Power Connections . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .A-6Connection of Vantage Premises Wiring . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .A-7Connection of Lincoln Electric Wire Feeders . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .A-8, A-9

Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Section BSafety Instructions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .B-1General Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .B-1

Recommended Applications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .B-1Controls and Settings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .B-2

Engine Controls . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .B-2, B-3Welder Controls . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .B-4Auxiliary Power Controls . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .B-4

Engine Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .B-5Starting the Engine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .B-5Stopping the Engine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .B-5

Break-In Period . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .B-6Typical Fuel Consumption . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .B-6Duty Cycle . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .B-6

Welding Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .B-6Stick Welding Mode . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .B-6CC-Stick Mode . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .B-6Downhill Pipe Mode . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .B-6Touch Start TIG Mode . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .B-6Vantage Settings when using K930-2 TIG Module . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .B-7

Typical Current Ranges for Tungsten Electrodes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .B-7CV-Wire Mode . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .B-8Arc Gouging . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .B-8Paralleling . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .B-8

Auxiliary Power Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .B-8Simultaneous Welding and Auxiliary Power Loads . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .B-8

Simultaneous Welding and Power Loads, Extension Cord Length Recommendations . . . . . . . . . . .B-9

vii TABLE OF CONTENTSPage

Accessories . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Section COptional Field Installed Accessories . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .C-1

_________________________________________________________________________________________________

Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Section DSafety Precautions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .D-1Routine and Periodic Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .D-1Engine Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .D-1

Air Filter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .D-1,D-2Fuel Filters . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .D-3Cooling System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .D-3Battery Handling . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .D-3

Charging the Battery . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .D-4Nameplate / Warning Decal Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .D-4Welder / Generator Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .D-4Engine Maintenance Components . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .D-4

Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Section E

Wiring, Connection Diagrams and Dimension Print . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Section F

Parts Lists . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .P- 508

A-1INSTALLATION

VANTAGE 500 DEUTZ

A-1

TECHNICAL SPECIFICATIONS - VANTAGE 500 DEUTZ (K2405-1)

INPUT - DIESEL ENGINE

Make /Model Description Speed (RPM) Displacement Starting CapacitiesSystem

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” x 4.41” (9.5L)(94mm x 112mm)

RATED OUTPUT @ 104°F(40°C) - WELDERDuty 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

PHYSICAL DIMENSIONSHeight (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” (226mm) for exhaust.

OUTPUT @ 104°F(40°C) - WELDER AND GENERATOR

Welding Range

30 - 575 Amps CC/CV20 - 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

A-2INSTALLATION

VANTAGE 500 DEUTZ

A-2

Read this entire installation section before youstart installation.

SAFETY PRECAUTIONS

Do not attempt to use this equipment until youhave thoroughly read all operating and mainte-nance manuals supplied with your machine. Theyinclude important safety precautions, detailedengine starting, operating and maintenanceinstructions and parts lists.

ELECTRIC SHOCK can kill.

• Do not touch electrically live partssuch as output terminals or internalwiring.

• Insulate yourself from the work andground.

• Always wear dry insulating gloves.

------------------------------------------------------------------------

ENGINE EXHAUST can kill.

• Use in open, well ventilated areas orvent exhaust outside

------------------------------------------------------------------------

MOVING PARTS can injure.

• Do not operate with doors open orguards off.

• Stop engine before servicing.

• Keep away from moving parts

------------------------------------------------------------------------

Only qualified personnel should install, use or ser-vice this equipment.

------------------------------------------------------------------------

LOCATION / VENTILATIONThe welder should be located to provide an unrestrict-ed flow of clean, cool air to the cooling air inlets and toavoid restricting the cooling air outlets. Also, locatethe welder so that the engine exhaust fumes are prop-erly vented to an outside area.

DO NOT MOUNT OVER COMBUSTIBLE SUR-FACESWhere there is a combustible surface directlyunder stationary or fixed electrical equipment, thatsurface should be covered with a steel plate atleast .06”(1.6mm) thick, which should extend notless than 5.90”(150mm) beyond the equipment onall sides.

------------------------------------------------------------------------

STORING1. Store the machine in a cool, dry place when it is

not in use. Protect it from dust and dirt. Keep itwhere it canʼt be accidentally damaged from con-struction activities, moving vehicles, and otherhazards.

2. Drain the engine oil and refill with fresh 10W30oil. Run the engine for about five minutes to cir-culate oil to all the parts. See the MAINTE-NANCE section of this manual for details onchanging oil.

3. Remove the battery, recharge it, and adjust theelectrolyte level. Store the battery in a dry, darkplace.

STACKINGVANTAGE 500 DEUTZ machines cannot be stacked.

ANGLE OF OPERATIONTo achieve optimum engine performance the VAN-TAGE 500 DEUTZ should be run in a level position.The maximum angle of operation for the Deutz engineis 30 degrees in all directions. When operating thewelder at an angle, provisions must be made forchecking and maintaining the oil level at the normal(FULL) oil capacity. Also the effective fuel capacity willbe slightly less than the specified 25 gal.(94.6 ltrs.).

WARNING

CAUTION

A-3INSTALLATION

VANTAGE 500 DEUTZ

A-3

LIFTINGThe VANTAGE 500 DEUTZ lift bale should be used tolift the machine. The VANTAGE 500 DEUTZ isshipped with the lift bale retracted. Before attemptingto lift the VANTAGE 500 DEUTZ the lift bale must besecured in a raised position. Secure the lift bale as fol-lows:

a. Open the engine compartment door.

b. Locate the 2 access holes on the upper middleregion of compartment wall just below the liftbale.

c. Use the lifting strap to raise the lift bale to thefull upright position. This will align the mount-ing holes on the lift bale with the access holes.

d. Secure the lift bale with 2 thread formingscrews. The screws are provided in theshipped loose parts bag.

• Lift only with equipment of ade-quate lifting capacity.

• Be sure machine is stable whenlifting.

• Do not lift this machine using liftbale if it is equipped with a heavyaccessory such as trailer or gascylinder.

FALLING • Do not lift machine if lift bale is

EQUIPMENT can damaged.

cause injury. • Do not operate machine while

suspended from lift bale.

------------------------------------------------------------------------

HIGH ALTITUDE OPERATION

At higher altitudes, output derating may be necessary.For maximum rating, derate the welder output 5% forevery 300 meters (984 ft.) above 1500 meters (4920ft.). For output of 500A and below, derate the welderoutput 5% for every 300 meters (984 ft.) above 2100meters (6888 ft.).

Contact a Deutz Service Representative for anyengine adjustments that may be required.

HIGH TEMPERATURE OPERATIONAt temperatures above 104°F (40°C), output voltagederating may be necessary. For maximum output cur-rent ratings, derate welder voltage rating 2 volts forevery 21°F (10°C) above 104°F (40°C).

TOWINGThe recommended trailer for use with this equipmentfor road, in-plant and yard towing by a vehicle (1) isLincolnʼs K953-1. If the user adapts a non-Lincolntrailer, he must assume responsibility that the methodof attachment and usage does not result in a safetyhazard nor damage the welding equipment. Some ofthe factors to be considered are as follows:

1. Design capacity of trailer vs. weight of Lincolnequipment and likely additional attachments.

2. Proper support of, and attachment to, the baseof the welding equipment so that there will beno undue stress to the trailerʼs framework.

3. Proper placement of the equipment on thetrailer to insure stability side to side and frontto back when being moved and when standingby itself.

4. Typical conditions of use, such as travelspeed, roughness of surface on which thetrailer will be operated, and environmentalconditions.

5. Proper preventative maintenance of trailer.

6. Conformance with federal, state and local laws(1) .

(1) Consult applicable federal, state and local lawsregarding specific requirements for use on publichighways.

VEHICLE MOUNTING

Improperly mounted concentrated loads maycause unstable vehicle handling and tires or othercomponents to fail.

• Only transport this Equipment on serviceablevehicles which are rated and designed for suchloads.

• Distribute, balance and secure loads so vehicleis stable under conditions of use.

• Do not exceed maximum rated loads for compo-nents such as suspension, axles and tires.

• Mount equipment base to metal bed or frame ofvehicle.

• Follow vehicle manufacturerʼs instructions.------------------------------------------------------------------------

WARNING

WARNING

A-4INSTALLATION

VANTAGE 500 DEUTZ

A-4

PRE-OPERATION ENGINE READ the engine operating and maintenance instruc-tions supplied with this machine.

• Keep hands away from the enginemuffler or HOT engine parts.

• Stop engine and allow to cool beforefuelling.

• Do not smoke when fuelling.

• Fill fuel tank at a moderate rate and do not over-fill.

• Wipe up spilled fuel and allow fumes to clearbefore starting engine.

• Keep sparks and flame away from tank.

------------------------------------------------------------------------OILThe VANTAGE 500 DEUTZ is shipped with theengine crankcase filled with high quality SAE 10W-30oil (API class CD or better). Check the engine oil levelbefore starting the engine. If it is not up to the fullmark on the dip stick, add oil as required. Check theoil level every four hours of running time during thefirst 35 running hours. Refer to the engine OperatorʼsManuals for specific oil recommendations and break-in information. The oil change interval is dependent onthe quality of the oil and the operating environment.Refer to the engine Operatorʼs Manuals for the properservice and maintenance intervals.

FUEL USE DIESEL FUEL ONLYFill the fuel tank with clean, fresh diesel fuel. Thecapacity of the fuel tank is approximately 25 gallons(95 liters). See engine Operatorʼs Manual for specificfuel recommendations. Running out of fuel mayrequire bleeding the fuel injection pump. NOTE:Before starting the engine, open the fuel shutoff valve(pointer to be in line with hose).

FUEL CAPRemove the plastic cap covering from the Fuel TankFiller neck and install the Fuel Cap.

ENGINE COOLING SYSTEMThe Deutz engine is air cooled by the belt driven axialblower. The oil cooler and engine cooling fins shouldbe blown out with compressed air or steam to main-tain proper cooling. (See the engine Owners Manualfor procedures and frequency).

ENGINE BREAK-IN

Lincoln Electric selects high quality, heavy-duty indus-trial engines for the portable welding machines weoffer. While it is normal to see a small amount ofcrankcase oil consumption during initial operation,excessive oil use, wet stacking (oil or tar like sub-stance at the exhaust port), or excessive smoke is notnormal.

Larger machines with a capacity of 350 amperes andhigher, which are operated at low or no-load condi-tions for extended periods of time are especially sus-ceptible to the conditions described above. Toaccomplish successful engine break-in, most diesel-powered equipment needs only to be run at a reason-ably heavy load within the rating of the welder forsome period of time during the engineʼs early life.However, if the welder is subjected to extensive lightloading, occasional moderate to heavy loading of theengine may sometimes be necessary. Caution mustbe observed in correctly loading a diesel/generatorunit.

1. Connect the welder output studs to a suitableresistive load bank. Note that any attempt to shortthe output studs by connecting the welding leadstogether, direct shorting of the output studs, or con-necting the output leads to a length of steel willresult in catastrophic damage to the generator andvoids the warranty.

2. Set the welder controls for an output current andvoltage within the welder rating and duty cycle.Note that any attempt to exceed the welder ratingor duty cycle for any period of time will result in cat-astrophic damage to the generator and voids thewarranty.

3. Periodically shut off the engine and check thecrankcase oil level.

BATTERY CONNECTION

GASES FROM BATTERY can explode.

• Keep sparks, flame and cigarettesaway from battery.

To prevent EXPLOSION when:

• INSTALLING A NEW BATTERY —disconnect negative cable from oldbattery first and connect to new bat-tery last.

WARNING

WARNING

A-5INSTALLATION

VANTAGE 500 DEUTZ

A-5

• CONNECTING A BATTERY CHARGER — removebattery from welder by disconnecting negativecable first, then positive cable and battery clamp.When reinstalling, connect negative cable last.Keep well ventilated.

• USING A BOOSTER — connect positive lead tobattery first then connect negative lead to nega-tive battery lead at engine foot.

BATTERY ACID can burn eyes andskin.

• Wear gloves and eye protection andbe careful when working near bat-tery.

• Follow instructions printed on bat-tery.

IMPORTANT: To prevent ELECTRICAL DAMAGEWHEN:

a) Installing new batteries.

b) Using a booster.

Use correct polarity — Negative Ground.

The VANTAGE 500 DEUTZ is shipped with the nega-tive battery cable disconnected. Before you operatethe machine, make sure the Engine Switch is in theOFF position and attach the disconnected cablesecurely to the negative (-) battery terminal.

Remove the insulating cap from the negative batteryterminal. Replace and tighten negative battery cableterminal. NOTE: This machine is furnished with a wetcharged battery; if unused for several months, the bat-tery may require a booster charge. Be sure to use thecorrect polarity when charging the battery.

MUFFLER OUTLET PIPERemove the plastic plug covering the muffler outlettube. Using the clamp provided secure the outlet pipeto the outlet tube with the pipe positioned such that itwill direct the exhaust in the desired position.

SPARK ARRESTORSome federal, state or local laws may require thatpetrol or diesel engines be equipped with exhaustspark arresters when they are operated in certainlocations where unarrested sparks may present a firehazard. The standard muffler included with this welderdoes not qualify as a spark arrestor. When required bylocal regulations, a suitable spark arrestor, must beinstalled and properly maintained.

An incorrect arrestor may lead to damage to theengine or adversely affect performance.

---------------------------------------------------------------------

WELDING TERMINALSThe VANTAGE 500 DEUTZ is equipped with a toggleswitch for selecting "hot" welding terminals when in the"WELD TERMINALS ON" position or "cold" welding termi-nals when in the "REMOTELY CONTROLLED" position.

WELDING OUTPUT CABLESWith the engine off, route the electrode and work cablesthru the strain relief bracket provided on the front of thebase and connect to the terminals provided. These con-nections should be checked periodically and tightened ifnecessary.

Listed in Table A.1 are copper cable sizes recommendedfor the rated current and duty cycle. Lengths stipulated arethe distance from the welder to work and back to thewelder again. Cable sizes are increased for greater lengthsprimarily for the purpose of minimizing cable voltage drop.

Table A.1 Combined Length of Electrode and WorkCables.

MACHINE GROUNDINGBecause this portable engine driven welder creates its ownpower, it is not necessary to connect its frame to an earthground, unless the machine is connected to premiseswiring (home, shop, etc.).

To prevent dangerous electric shock, other equipmentpowered by this engine driven welder must:

a) be grounded to the frame of the welder using agrounded type plug, or

b) be double insulated.

When this welder is mounted on a truck or trailer, its framemust be securely connected to the metal frame of the vehi-cle. When this engine driven welder is connected topremises wiring such as that in a home or shop, its framemust be connected to the system earth ground. See furtherconnection instructions in the section entitled “StandbyPower Connections” as well as the article on grounding inthe latest National Electrical Code and the local codes.

In general, if the machine is to be grounded, it should beconnected with a #8 or larger copper wire to a solid earthground such as a metal ground stake going into the groundfor at least 10Ft.(3.1m) or to the metal framework of abuilding which has been effectively grounded. The NationalElectric Code lists a number of alternate means of ground-ing electrical equipment. A machine grounding studmarked with the symbol is provided on the front of thewelder.

CAUTION

AMPS Up to 150ft 150-200ft 200-250ft@100% Up to 492m 492-656m 656-820m

Duty Cycle

500 3/0 AWG 3/0 AWG 4/0 AWG

TOTAL COMBINED LENGTH OF ELEC-TRODE AND WORK CABLES

A-6INSTALLATION

VANTAGE 500 DEUTZ

A-6

REMOTE CONTROL

OUTPUT

The VANTAGE 500 DEUTZ is equipped with a 6-pinand a 14-pin connector. The 6-pin connector is forconnecting the K857 or K857-1 Remote Control or forTIG welding, the K870 foot Amptrol or the K936-2hand Amptrol. When in the CC-STICK, DOWNHILLPIPE, or CV-WIRE modes and when a remote controlis connected to the 6-pin Connector, the auto-sensingcircuit automatically switches the OUTPUT controlfrom control at the welder to remote control.

When in TOUCH START TIG mode and when aAmptrol is connected to the 6-Pin Connector, theOUTPUT dial is used to set the maximum currentrange of the CURRENT CONTROL of the Amptrol.

The 14-pin connector is used to directly connect awire feeder control cable. In the CV-WIRE mode,when the control cable is connected to the 14-pin con-nector, the auto-sensing circuit automatically makesthe Output Control inactive and the wire feeder volt-age control active

NOTE: When a wire feeder with a built in welding volt-age control is connected to the 14-pin connector, donot connect anything to the 6-pin connector.

AUXILIARY POWER RECEPTACLESThe auxiliary power capacity of the VANTAGE 500DEUTZ is 12,000 watts of 60 Hz, single phase or20,000 watts of 60Hz, three phase power. The auxil-iary power capacity rating in watts is equivalent tovolt-amperes at unity power factor. The maximum per-missible current of the 240 VAC output is 50 A. The240 VAC single phase output can be split to providetwo separate 120 VAC outputs with a maximum per-missible current of 50 A per output to two separate120 VAC branch circuits. The output voltage is within± 10% at all loads up to rated capacity.

The VANTAGE 500 DEUTZ has two 20 Amp-120VACsingle phase(5-20R) GFCI duplex receptacles, one 50Amp-120/240 single phase VAC (14-50R) receptacleand one 240VAC three phase (15-50R) receptacle.The auxiliary power receptacles should only be usedwith three wire grounded type plugs or approved dou-ble insulated tools with two wire plugs. The currentrating of any plug used with the system must be atleast equal to the current capacity of the associatedreceptacle.A 240VAC 3 phase plug is provided loose with themachine.

Note: The two 120V GFCI receptacles and the two120 volt circuits of the 120/240V receptacle are con-nected to different phases and can not be paralleled.

STANDBY POWER CONNECTIONS

The VANTAGE 500 DEUTZ is suitable for temporary,standby or emergency power using the engine manu-facturerʼs recommended maintenance schedule.

The VANTAGE 500 DEUTZ can be permanentlyinstalled as a standby power unit for 240 volt-3 wire,50 amp service. Connections must be made by alicensed electrician who can determine how the120/240 VAC power can be adapted to the particularinstallation and comply with all applicable electricalcodes. The following information can be used as aguide by the electrician for most applications. Refer tothe connection diagram shown in Figure A.2.

1. Install the double-pole, double-throw switchbetween the power company meter and the premis-es disconnect.

Switch rating must be the same or greater than thecustomerʼs premises disconnect and service over cur-rent protection.

A-7INSTALLATION

VANTAGE 500 DEUTZ

A-7

2. Take necessary steps to assure load is limited tothe capacity of the VANTAGE 500 DEUTZ byinstalling a 50 amp, 240 VAC double pole circuitbreaker. Maximum rated load for each leg of the240 VAC auxiliary is 50 amps. Loading above therated output will reduce output voltage below theallowable -10% of rated voltage which may damageappliances or other motor-driven equipment andmay result in overheating of the VANTAGE 500DEUTZ engine.

3. Install a 50 amp 120/240 VAC plug (NEMA Type14-50) to the double-pole circuit breaker using No.6, 4 conductor cable of the desired length. (The 50amp, 120/240 VAC plug is available in the optionalK802R plug kit.)

4. Plug this cable into the 50 Amp 120/240 Volt recep-tacle on the VANTAGE 500 DEUTZ case front.

Figure A.2 Connection of the VANTAGE 500 DEUTZ to Premises Wiring

240 Volt-60 Hz.-3-Wire-Service

POWER--

COMPANY--

METER

240 VOLT

120 VOLT

120 VOLT

LOADN

NEUTRALBUS

GROUND

PREMISES-DISCONNECT AND-

SERVICE-OVERCURRENT-

PROTECTION

GND

N

NOTE: No. 6 COPPER CONDUCTOR CABLE SEE-NATIONAL ELECTRICAL CODE FOR ALTERNATE WIRE-

SIZE RECOMMENDATIONS.

240 VOLT

GROUNDED CONDUCTOR

50AMP-240 VOLT

DOUBLE-POLE-

CIRCUIT-BREAKER

DOUBLE POLE DOUBLE THROWSWITCH RATING TO BE THE SAMEAS OR GREATER THAN PREMISESSERVICE OVERCURRENTPROTECTION.

50 AMP, 120/240-VOLT PLUG-

NEMA TYPE 14-50

50 AMP, 120/240 VOLT-RECEPTACLE

A-8INSTALLATION

VANTAGE 500 DEUTZ

A-8

CONNECTION OF LINCOLN ELECTRICWIRE FEEDERS

Shut off welder before making any electrical con-nections.

------------------------------------------------------------------------

CONNECTION OF LN-7, LN-8 OR LN-742TO THE VANTAGE 500 DEUTZ• Shut the welder off.

• Connect the LN-7, LN-8 OR LN-742 per instructionson the appropriate connection diagram in the DIA-GRAMS section.

• Set the “WIRE FEEDER VOLTMETER” switch toeither “+” or “-” as required by the electrode beingused.

• Set the “SELECTOR” switch to the “CV-WIRE” posi-tion.

• Adjust the “ARC CONTROL” knob to desiredCrispness. SOFT for MIG and CRISP forInnershield.

• Set the “WELDING TERMINALS” switch to the“REMOTELY CONTROLLED” position.

• Set the “IDLE” switch to the “HIGH” 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. TheLN-15 has an internal contactor and the electrode isnot energized until the gun trigger is closed. When thegun trigger is closed the wire will begin to feed and thewelding process is started.

• Shut the welder off.

• For electrode Positive, connect the electrode cableto the "+" terminal of the welder and work cable tothe "-" terminal of the welder. For electrodeNegative, connect the electrode cable "-" terminal ofthe welder and work cable to the "+" terminal of thewelder.

• Across The-Arc Model:Attach the single lead from the front of the LN-15to work using the spring clip at the end of thelead. This is a control lead to supply current to thewire feeder motor; it does not carry welding cur-rent.

• Control Cable Model:Connect Control Cable between Engine Welderand Feeder.

Set the MODE switch to the "CV-WIRE " position.

• Across The-Arc Model:Set the "WELD TERMINALS" switch to "WELDTERMINALS ON"

• Control Cable Model:Set the "WELD TERMINALS" switch to"REMOTELY CONTROLLED"

Set the "WIRE FEEDER VOLTMETER" switch toeither "+" or "-" as required by the electrode polar-ity being used.

Set the "ARC CONTROL" knob to "0" initially andadjust to suit.

Set the "IDLE" switch to the "AUTO IDLE" position

WARNING

A-9INSTALLATION

VANTAGE 500 DEUTZ

A-9

CONNECTION OF THE LN-25 TO THEVANTAGE 500 DEUTZThe LN-25 with or without an internal contactor maybe used with the VANTAGE 500 DEUTZ. See theappropriate connection diagram in the DIAGRAMSsection.

NOTE: The LN-25 (K431) Remote Control Moduleand (K432) Remote Cable are not recommended foruse with the VANTAGE 500 DEUTZ.

• Shut the welder off.

• For electrode Positive, connect the electrode cablefrom the LN-25 to the “+” terminal of the welder andwork cable to the “-” terminal of the welder. For elec-trode Negative, connect the electrode cable from theLN-25 to the “-” terminal of the welder and workcable to the “+” terminal of the welder.

• Attach the single lead from the front of the LN-25 towork using the spring clip at the end of the lead. Thisis a sense lead to supply current to the wire feedermotor; it does not carry welding current.

• Set the SELECTOR switch to the “CV-WIRE” posi-tion.

• Set the “WELDING TERMINALS” switch to “WELDTERMINALS ON”

• Adjust the “ARC CONTROL” knob to desired crisp-ness. Generally, welding is best if the “ARC CON-TROL” is set to SOFT for MIG and CRISP forINNERSHIELD. You may however, want to start inthe middle and adjust (as needed) from there.

• Set the “IDLE” switch to the “AUTO” position. Whennot welding, the VANTAGE 500 DEUTZ engine willbe at the low idle speed. If you are using an LN-25with an internal contactor, the electrode is not ener-gized until the gun trigger is closed.

If you are using an LN-25 without an internal con-tactor, the electrode will be energized when theVANTAGE 500 DEUTZ is started.------------------------------------------------------------------------• When the gun trigger is closed, the current sensing

circuit will cause the wire to begin to feed and thewelding process is started.

CONNECTION OF AN NA-3 AUTOMATICWELDING SYSTEM TO THE VANTAGE 500DEUTZFor connection diagrams and instructions for connect-ing an NA-3 Welding System to the VANTAGE 500DEUTZ, refer to the NA-3 Welding System instructionmanual. The connection diagram for the LN-8 can beused for connecting the NA-3.

• Set the Wire Feeder Voltage Switch to 115V.

CONNECTION OF MAGNUM SC SPOOLGUN TO THE VANTAGE 500 DEUTZ (SEESECTION F)

CONNECTION OF PRINCE XL SPOOLGUN TO THE VANTAGE 500 DEUTZ

Connection of the Prince XL Spool Gun requires theuse of the K1849-1 Adapter Module.

• Shut the Welder off.

• For electrode Positive, connect the electrode cableto the "+" terminal of the welder and work cable tothe "-" terminal of the welder. For electrodeNegative, connect the electrode cable "-" terminalof the welder and work cable to the "+" terminal ofthe welder.

• Connect the Control Cable of the Spool Gun to theAdapter Module and connect the Control Cable ofthe Adapter Module to the Welder.

• Connect the Gas Hose.

• Set the MODE switch to the "CV-WIRE " position.

• Set the "WELD TERMINALS" switch to "WELDTERMINALS ON".

• Set the "ARC CONTROL" knob to "0" initially andadjust to suit.

• Set the "IDLE" switch to the "High" position

CAUTION

B-1OPERATION

VANTAGE 500 DEUTZ

B-1

SAFETY INSTRUCTIONSRead and understand this entire section beforeoperating your VANTAGE 500 DEUTZ.

Do not attempt to use this equipment until youhave thoroughly read all operating and mainte-nance manuals supplied with your machine. Theyinclude important safety precautions, detailedengine starting, operating and maintenanceinstructions and parts lists.

ELECTRIC SHOCK can kill.

• Do not touch electrically live partssuch as output terminals or internalwiring.

• Insulate yourself from the work andground.

• Always wear dry insulating gloves.

------------------------------------------------------------------------

ENGINE EXHAUST can kill.

• Use in open, well ventilated areas orvent exhaust outside

• Do not stack anything near the engine.

------------------------------------------------------------------------

MOVING PARTS can injure.

• Do not operate with doors open orguards off.

• Stop engine before servicing.

• Keep away from moving parts

------------------------------------------------------------------------

Only qualified personnel should operate thisequipment.

ADDITIONAL SAFETY PRECAUTIONSAlways operate the welder with the sliding doorclosed and the side panels in place as these pro-vide maximum protection from moving parts andinsure proper cooling air flow.

GENERAL DESCRIPTIONThe VANTAGE 500 DEUTZ is a diesel engine-drivenwelding power source. The machine uses a brushtype alternating current generator for DC multi-pur-pose welding, for 120/240 VAC single phase and240V three phase auxiliary standby power. The weld-ing control system uses state of the art ChopperTechnology™.

RECOMMENDED APPLICATIONS

WELDERThe VANTAGE 500 DEUTZ provides excellent con-stant current DC welding output for stick (SMAW) andTIG welding. The VANTAGE 500 DEUTZ also pro-vides excellent constant voltage DC welding output forMIG (GMAW), Innershield (FCAW), Outershield(FCAW-G) and Metal Core welding. In addition theVANTAGE 500 DEUTZ can be used for Arc Gougingwith carbons up to 3/8”(10mm) in diameter.

The VANTAGE 500 DEUTZ is not recommended forpipe thawing.

GENERATORThe VANTAGE 500 DEUTZ provides smooth 120/240 VACsingle phase and 240V three phase output for auxiliarypower and emergency standby power.

WARNING

B-2OPERATIONB-2

ENGINE CONTROLS (Items 1 through 9)

1. RUN STOP SWITCH

Toggling the switch to the RUN position energizesthe fuel solenoid for approximately 30 seconds. Theengine must be started within that time or the fuelsolenoid will degenerize, and the switch must betoggled to reset the timer.

2. START PUSHBUTTON

Energizes the starter motor to crank the engine.With the engine "Run / Stop" switch in the "Run"position, push and hold the Start button to crank theengine; release as the engine starts. Do not presswhile engine is running since this can cause dam-age to the ring gear and/or starter motor

3. HOUR METER

The hour meter displays the total time that theengine has been running. This meter is a useful indi-cator for scheduling preventive maintenance.

4. FUEL LEVEL GAUGE

Displays the level of diesel fuel in the fuel tank.

The operator must watch the fuel level closely toprevent running out of fuel and possibly havingto bleed the system.

5. ENGINE TEMPERATURE GAUGE

The gauge displays the engine coolant temperature.

VANTAGE 500 DEUTZ

Figure B.1 Case Front Panel Controls

3

4 5 6 7 8 9 10

11

12

15

14

13

1

2

17

21

16

18

22

23

19

20

CONTROLS AND SETTINGSAll welder and engine controls are located on the case front panel. Refer to Figure B.1 and the explanations that follow.

B-3OPERATIONB-3

6. OIL PRESSURE GAUGE

The gauge displays the engine oil pressure whenthe engine is running.

7. ENGINE PROTECTION

The yellow engine protection light remains off withproper oil pressure and under normal operating tem-peratures. If the light turns on, the engine protectionsystem will stop the engine. Check for proper oillevel and add oil if necessary. Check for loose ordisconnected leads at the oil pressure sender locat-ed on the engine. The light will remain on when theengine has been shut down due to low oil pressureor over-temperature condition.

8. BATTERY CHARGING LIGHT

The yellow engine alternator light is off when batterycharging system is functioning normally. If light turnson, the engine protection system will shut down theengine. Check the Engine cooling blower belt.Also, the alternator or the voltage regulator may notbe operating correctly. The light may also come ondue to a faulty flashing circuit. The light will remainon when the engine is stopped and the run/stopswitch is in the run position.

9. IDLER SWITCH

Has two positions as follows:

A) In the “High” position , the engine runs at thehigh idle speed controlled by the governor.

B) In the “Auto” / position, the idleroperates as follows:

a. When switched from “High” to “Auto” or afterstarting the engine, the engine will operate atfull speed for approximately 12 seconds andthen go to low idle speed.

b. When the electrode touches the work or poweris drawn for lights or tools (approximately 100Watts minimum) the engine accelerates andoperates at full speed.

c. When welding ceases and the AC power loadis turned off, a fixed time delay of approximate-ly 12 seconds starts.

d. If the welding or AC power load is not restart-ed before the end of the time delay, the idlerreduces the engine speed to low idle speed.

e. The engine will automatically return to highidle speed when the welding load or A.C.power load is reapplied.

Idler Operational exceptions

When the WELDING TERMINALS switch is in the“Remotely Controlled” position the idler will operate asfollows:

a. When the triggering device (Amptrol, Arc StartSwitch, etc.) is pressed the engine will accelerateand operate at full speed provided a welding load isapplied within approximately 12 seconds.

• If the triggering device remains pressed but no weld-ing load is applied within approximately 12 secondsthe engine may return to low idle speed.

• If the triggering device is released or welding ceasesthe engine will return to low idle speed after approxi-mately 12 seconds.

VANTAGE 500 DEUTZ

B-4OPERATIONB-4

WELDING CONTROLS (Items 10 through 19)10. OUTPUT CONTROL: The OUTPUT dial is used to preset

the output voltage or current as displayed on the digitalmeters for the four welding modes. When in the CC-STICK,DOWNHILL PIPE or CV-WIRE modes and when a remotecontrol is connected to the 6-Pin or 14-Pin Connector, theauto-sensing circuit automatically switches the OUTPUTCONTROL from control at the welder to the remote control.In the CV-WIRE mode, when the wire feeder control cable isconnected to the 14-Pin Connector, the auto-sensing circuitautomatically makes OUTPUT CONTROL inactive and thewire feeder voltage control active.

When in the TOUCH START TIG mode and when a Amptrolis connected to the 6-Pin Connector, the OUTPUT dial isused to set the maximum current range of the CURRENTCONTROL of the Amptrol.

11. DIGITAL OUTPUT METERS:

The digital meters allow the output voltage (CV-WIRE mode)or current (CC-STICK, DOWNHILL PIPE and TIG modes) tobe set prior to welding using the OUTPUT control knob.During welding, the meters display the actual output voltage(VOLTS) and current (AMPS). A memory feature holds thedisplay of both meters on the seven seconds after welding isstopped. This allows the operator to read the actual currentand voltage just prior to when welding was ceased. While thedisplay is being held the left-most decimal point in each dis-play will be flashing. The accuracy of the meters is ± 3%.

12. WELD MODE SELECTOR SWITCH:

(Provides four selectable welding modes)

CV-WIRE

DOWNHILL PIPE

CC-STICK

TOUCH START TIG

13. ARC CONTROL:

The ARC CONTROL WIRE/STICK knob is active in the WIREand STICK modes, and has different functions in thesemodes. This control is not active in the TIG mode.

CC-STICK mode: In this mode, the ARC CONTROL knobsets the short circuit current (arc-force) during stick welding.Increasing the number from -10(Soft) to +10(Crisp) increasesthe short circuit current and prevents sticking of the electrodeto the plate while welding. This can also increase spatter. It isrecommended that the ARC CONTROL be set to the mini-mum number without electrode sticking. Start with a setting at0.

DOWNHILL PIPE mode: In this mode, the ARC CONTROLknob sets the short circuit current (arc-force) during stickwelding to adjust for a soft or a more forceful digging arc(Crisp). Increasing the number from -10(Soft) to +10(Crisp)increases the short circuit current which results in a moreforceful digging arc. Typically a forceful digging arc is pre-ferred for root and hot passes. A softer arc is preferred for filland cap passes where weld puddle control and deposition(“stacking” of iron) are key to fast travel speeds. It is recom-mended that the ARC CONTROL be set initially at 0.

CV-WIRE mode: In this mode, turning the ARC CONTROLknob from -10(soft) to +10(crisp) changes the arc from softand washed-in to crisp and narrow. It acts as an induc-tance/pinch control. The proper setting depends on the proce-dure and operator preference. Start with a setting of 0.

14. WELDING TERMINALS SWITCH

In the WELD TERMINALS ON position, the output is electri-cally hot all the time. In the REMOTELY CONTROLLED posi-tion, the output is controlled by a wire feeder or amptroldevice, and is electrically off until a remote switch isdepressed.

15. WIRE FEEDER VOLTMETER SWITCH:

Matches the polarity of the wire feeder voltmeter to the polari-ty of the electrode.

16. 6 - PIN CONNECTOR

For attaching optional remote control equipment. Includesauto-sensing remote control circuit.

17. 14 - PIN CONNECTOR

For attaching wire feeder control cables. Includes contactorclosure circuit, auto-sensing remote control circuit, and120VAC and 42VAC power.

NOTE: When a wire feeder with a built in welding voltage con-trol is connected to the 14-pin connector, do not connect any-thing to the 6-pin connector.

18. WELD OUTPUT TERMINALS + AND -

These 1/2” - 13 studs with flange nuts provide welding con-nection points for the electrode and work cables. For positivepolarity welding the electrode cable connects to the “+” termi-nal and the work cable connects to this “-” terminal. For nega-tive polarity welding the work cable connects to the “+” termi-nal and the electrode cable connects to this “-” terminal.

AUXILIARY POWER CONTROLS(Items 19-23)

19. 120/240 VAC SINGLE PHASE RECEPTACLE

This is a 120/240VAC (14-50R) receptacle that provides240VAC or can be split for 120VAC single phase auxiliarypower. This receptacle has a 50 amp rating. Refer to theAUXILIARY POWER RECEPTACLES section in the installa-tion chapter for further information about this receptacle. Alsorefer to the AUXILIARY POWER OPERATION section later inthis chapter.

VANTAGE 500 DEUTZ

B-5OPERATIONB-5

20. CIRCUIT BREAKERS

These circuit breakers provide separate overloadcurrent protection for each 120V circuit at the 240Vsingle phase receptacle, each 120V single phasereceptacle, the 240V three phase receptacle, the120VAC in the 14-Pin connector, the 42VAC in the14-Pin connector and battery circuit overload protec-tion.

21. 120VAC SINGLE PHASE RECEPTACLES

These two 120VAC (5-20R) receptacles with groundfault circuit interruption protection provide 120VACsingle phase for auxiliary power. Each receptaclehas a 20 amp total rating. They are designed to pro-tect the user from the hazards of ground faults.When the GFCI has tripped there will be no voltageavailable from the receptacle. If the GFCI hastripped, any device plugged into the GFCI recepta-cle should be unplugged and the reason for trippingthe GFCI should be determined. If the device isfound to be damaged or defective, it should berepaired or replaced before any further use. TheGFCI should be checked for proper operation priorto each use by pressing the test button. The GFCIcan be reset by pushing the reset button. Refer tothe AUXILIARY POWER RECEPTACLES section inthe installation chapter for further information aboutthese receptacles. Also refer to the AUXILIARYPOWER OPERATION section later in this chapter.

22. GROUND STUD

Provides a connection point for connecting themachine case to earth ground. Refer to “MACHINEGROUNDING” in the Installation chapter for propermachine grounding information.

23. 240VAC THREE PHASE RECEPTACLE

This is a 240VAC (15-50R) receptacle that provides240VAC three phase auxiliary power. This recepta-cle has a 50 amp rating.

ENGINE OPERATION

STARTING THE ENGINE1. Open the engine compartment door and check that

the fuel shutoff valve located to the left of the fuelfilter housing is in the open position (lever to be inline with the hose).

2. Check for proper oil level. Close engine compart-ment door.

3. Remove all plugs connected to the AC powerreceptacles.

4. Set IDLER switch to “AUTO”.

5. Set the RUN/STOP switch to “RUN”. Observe thatthe engine protection and battery charging lightsare on. After 10 seconds, the engine protection lightwill turn off.

6. Within 30 seconds, press and hold the engineSTART button until the engine starts.

7. Release the engine START button when the enginestarts.

8. Check that the engine protection and battery charg-ing lights are off. The engine protection light is onafter starting, the engine will shutdown in a few sec-onds. Investigate any indicated problem.

9. Allow the engine to warm up at low idle speed forseveral minutes before applying a load and/orswitching to high idle. Allow a longer warm up timein cold weather.

COLD WEATHER STARTING

With a fully charged battery and the proper weight oil,the engine should start satisfactorily even down toabout 0°F(-18°C). If the engine must be frequentlystarted below 10°(-12°C), it may be desirable to installthe optional ether start kit (K887-1). Installation andoperating instructions are included in the kits.

STOPPING THE ENGINE1. Switch the RUN/STOP switch to “STOP”. This turns

off the voltage supplied to the shutdown solenoid. Abackup shutdown can be accomplished by shuttingoff the fuel valve located on the fuel line.

VANTAGE 500 DEUTZ

B-6OPERATIONB-6

BREAK-IN PERIODThe engine used to supply power for your welder is a heavyduty, industrial engine. It is designed and built for ruggeduse. It is very normal for any engine to use small quantitiesof oil until the break-in is accomplished. Check the oil leveltwice a day during the break-in period. In general this takes50 to 100 hours of operation.

IMPORTANT

IN ORDER TO ACCOMPLISH THIS BREAK-IN, THE UNITSHOULD BE SUBJECTED TO HEAVY LOADS, WITHINTHE RATING OF THE MACHINE. AVOID LONG IDLERUNNING PERIODS.

TYPICAL FUEL CONSUMPTIONRefer to Table B.2 for typical fuel consumption of the VAN-TAGE 500 DEUTZ Engine for various operating scenarios.

WELDER OPERATION

DUTY CYCLE

Duty cycle is the percentage of time the load is beingapplied in a 10 minute period. For example, a 60% dutycycle represents 6 minutes of load and 4 minutes of no loadin a 10 minute period.

STICK WELDING MODE

The VANTAGE 500 DEUTZ can be used with a broad rangeof DC stick electrodes.

The MODE switch provides two stick welding settings as fol-lows:

CC-STICK MODE

The CC-STICK position of the MODE switch is designed forhorizontal, vertical-up and over head welding with all typesof electrodes, especially low hydrogen. The OUTPUT CON-TROL knob adjusts the full output range for stick welding.

The ARC CONTROL knob sets the short circuit (arc-force)current during stick welding. Increasing the number from -10(Soft) to +10 (Crisp) increases the short circuit currentand prevents sticking of the electrode to the plate whilewelding. This can also increase spatter. It is recommendedthat the ARC CONTROL be set to the minimum numberwithout electrode sticking. Start with the knob set at 0.

DOWNHILL PIPE MODE

This slope controlled setting is intended for “out-of-position”and “down hill” pipe welding where the operator would liketo control the current level by changing the arc length. TheOUTPUT CONTROL knob adjusts the full output range forpipe welding.

The ARC CONTROL knob sets the short circuit current (arc-force) during stick welding to adjust for a soft or a moreforceful digging arc (Crisp). Increasing the number from -10(Soft) to +10(Crisp) increases the short circuit currentwhich results in a more forceful digging arc. Typically aforceful digging arc is preferred for root and hot passes. Asofter arc is preferred for fill and cap passes where weldpuddle control and deposition (“stacking” of iron) are key tofast travel speeds. It is recommended that the ARC CON-TROL be set initially at 0.

TOUCH START TIG MODE

The VANTAGE 500 DEUTZ can be used in a wide variety ofDC TIG welding applications.

The TOUCH START TIG setting of the MODE switch is forDC TIG (Tungsten Inert Gas) welding. To initiate a weld, theOUTPUT CONTROL knob is first set to the desired currentand the tungsten is touched to the work. During the time thetungsten is touching the work there is very little voltage orcurrent and, in general, avoids tungsten contamination.Then, the tungsten is gently lifted off the work in a rockingmotion, which establishes the arc.

To stop the arc, simply lift the TIG torch away from the workpiece. When the arc voltage reaches approximately 30 volts,the arc will go out and the machine will automatically resetto the touch start current level. The tungsten may then beretouched to the work piece to restrike the arc. The arc mayalso be started and stopped with an Amptrol or Arc StartSwitch.

The ARC CONTROL is not active in the TIG mode.

In general the ʻTouch Startʼ feature avoids tungsten contam-ination without the use of a Hi-frequency unit. If the use of ahigh frequency generator is desired, the K930-2 TIG Modulecan be used with the VANTAGE 500 DEUTZ. The settingsare for reference.

The VANTAGE 500 DEUTZ is equipped with the requiredR.F. bypass circuitry for the connection of high frequencygenerating equipment.

VANTAGE 500 DEUTZ

Table B.2DEUTZ F4L2011 Engine Fuel Consumption

DEUTZ F4L2011 Running Time for48HP(36Kw) 25GAL.(94.6L)@1800 RPM (Hours)

Low Idle - .47 Gal./hour 53no load 1425 RPM (1.8 L/hour)

High Idle - .63 Gal./hour 40no load 1900 RPM (2.4 L/hour)

DC CC Weld 1.99 Gal./hour 12.6Output 500 ( 7.53 L/hour)Amps @ 40 Volts

Auxiliary Power 1.25 Gal./hour 20.012,000 VA (4.73 L/hour)

Auxiliary Power 1.76 Gal./hour 14.220,000 VA (6.66 L/hour)

B-7OPERATIONB-7

The VANTAGE 500 DEUTZ and any high frequencygenerating equipment must be properly grounded.See the K930-2 TIG Module operating manuals forcomplete instructions on installation, operation, andmaintenance.

When using the TIG Module, the OUTPUT control onthe VANTAGE 500 DEUTZ is used to set the maxi-mum range of the CURRENT CONTROL on the TIGModule or an Amptrol if connected to the TIG Module.

VANTAGE 500 DEUTZ SETTINGS WHEN USINGTHE K930-2 TIG MODULE

• Set the WELD MODE switch to the “Touch Start Tig20-250 Setting”.

• Set the IDLER switch to the “AUTO” position.

• Set the WELDING TERMINALS switch to the“Remotely Controlled” position. This will keep thesolid state contactor open and provide a “cold” elec-trode until the triggering device (Amptrol or Arc StartSwitch) is pressed.

VANTAGE 500 DEUTZ

Table B.3 TYPICAL CURRENT RANGES (1)

FOR TUNGSTEN ELECTRODES (2)

DCEN (-) DCEP (+) Approximate Argon Gas Flow Ratel/min (c.f.m.)

TungstenElectrode 1%, 2% 1%, 2% TIG TORCHDiameter Thoriated Thoriated Aluminum Stainless Steel Nozzlemm (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, #83.2 (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, #104.8 (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 EWP1% Thoriated EWTh-12% Thoriated EWTh-2

Though not yet recognized by the AWS, Ceriated Tungsten is now widely accepted as a substitute for 2% Thoriated Tungsten in ACand DC applications.

(3) DCEP is not commonly used in these sizes.

(4) TIG torch nozzle “sizes” 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 tobreakage, but cannot withstand high temperatures and high duty cycles.

B-8OPERATIONB-8

CV-WIRE MODEConnect a wire feeder to the VANTAGE 500 DEUTZand set welder controls according to the instructionslisted earlier in this section.

The VANTAGE 500 DEUTZ in the ”CV-WIRE” posi-tion, permits it to be used with a broad range of fluxcored wire (Innershield and Outershield) electrodesand solid wires for MIG welding (gas metal arc weld-ing). Welding can be finely tuned using the “ARCCONTROL”. Turning the ARC CONTROL clockwisefrom -10(soft) to +10(crisp) changes the arc from softand washed-in to crisp and narrow. It acts as aninductance/pinch control. The proper setting dependson the procedure and operator preference. Start withthe knob set at 0.

For any electrodes, including the above recommenda-tions, the procedures should be kept within the ratingof the machine. For additional electrode information,See www.lincolnelectric.com or the appropriateLincoln publication.

ARC GOUGINGFor optimal performance when arc gouging, set theVANTAGE 500 DEUTZ “WELD MODE” switch to the“CC - STICK” position, and the “ARC CONTROL” to10.

Set the “OUTPUT” knob to adjust output current to thedesired level for the gouging electrode being usedaccording to the ratings in the following table:

NOTE: If desired the CV mode can be used for ArcGouging.

* Maximum current setting is limited to the VANTAGE500 DEUTZ maximum of 575 Amps.

PARALLELINGWhen paralleling machines in order to combine theiroutputs, all units must be operated in the CC-STICKmode only at the same output settings. To achievethis, turn the WELD MODE switch to the CC-STICKposition. Operation in other modes may produce errat-ic outputs, and large output imbalances between theunits.

AUXILIARY POWER OPERATIONStart the engine and set the IDLER control switch tothe desired operating mode. Full power is availableregardless of the welding control settings, if no weld-ing current is being drawn.

The auxiliary power of the VANTAGE 500 DEUTZconsists of two 20 Amp-120VAC single phase (5-20R)GFCI duplex receptacles, one 50 Amp-120/240VACsingle phase (14-50R) receptacle and one 50 Amp240VAC three phase (15-50R) receptacle. The120/240VAC receptacle can be split for single phase120 VAC operation.

The auxiliary power capacity is 12,000 watts of 60 Hz,single phase power or 20,000 watts of 60Hz, threephase power. The auxiliary power capacity rating inwatts is equivalent to volt-amperes at unity power fac-tor. The maximum permissible current of the 240 VACoutput is 50 A. The 240 VAC single phase output canbe split to provide two separate 120 VAC outputs witha maximum permissible current of 50 A per output totwo separate 120 VAC branch circuits. Output voltageis within ± 10% at all loads up to rated capacity.

NOTE: The two 120V GFCI receptacles and the two120V circuits of the 120/240V receptacle are connect-ed to different phases and cannot be paralleled.

The auxiliary power receptacles should only be usedwith three wire grounded type plugs or approved dou-ble insulated tools with two wire plugs.

The current rating of any plug used with the systemmust be at least equal to the current capacity of theassociated receptacle.

SIMULTANEOUS WELDING AND AUXIL-IARY POWER LOADSIt must be noted that the above auxiliary power ratingsare with no welding load.

Simultaneous welding and power loads are specifiedin table B.4. The permissible currents shown assumethat current is being drawn from either the 120 VAC or240 VAC supply (not both at the same time).

VANTAGE 500 DEUTZ

ELECTRODE CURRENT RANGEDIAMETER (DC, electrode positive)

(1/8”) 30-60 Amps(5/32”) 90-150 Amps(3/16”) 200-250 Amps(1/4”) 300-400 Amps(5/16”) 350-450 Amps(3/8”) 450-575 Amps*

B-9OPERATIONB-9

VANTAGE 500 DEUTZ

TABLE B.5 VANTAGE 500 DEUTZ Extension Cord LengthRecommendations

Current(Amps)

1515202025303850

Voltage

(Volts)120240120240240240240240

Load(Watts)180036002400480060007200900012000

3060

(9)(18)

40753060

(12)(23)(9)

(18)

7515050

1009075

(23)(46)(15)(30)(27)(23)

12522588

175150120100

(38)(69)(27)(53)(46)(37)(30)

175350138275225175150125

(53)(107)(42)(84)(69)(53)(46)(38)

300600225450250300250200

(91)(183)(69)

(137)(76)(91)(76)(61)

Maximum Allowable Cord Length in ft. (m) for Conductor Size

Conductor size is based on maximum 2.0% voltage drop.

14 AWG 12 AWG 10 AWG 8 AWG 6 AWG 4 AWG

TABLE B.4 VANTAGE 500 DEUTZ SIMULTANEOUS WELDING AND POWER LOADS

WELDAMPS

0100200250300400500

1 PHASEWATTS AMPS

12,000 5012,000 5012,000 5012,000 5010,000 425,600 23

0 0

3 PHASEWATTS AMPS

20,000 5017,800 4314,000 3412,000 2910,000 245,600 13

0 0

BOTH 1 AND 3 PHASEWATTS AMPS------ 50------ 50------ 5012,000 ------10,000 ------5,600 ------0 0

PLUS OR OR

C-1ACCESSORIESC-1

OPTIONAL FIELD INSTALLED ACCES-SORIES

K802N POWER PLUG KIT - Provides four 120V plugs rated at 20amps each and one dual voltage, full KVA plug rated at120/240V, 50 amps. 120V plug may not be compatible with NEMAcommon household receptacles.

K802-R POWER PLUG KIT - Provides four 120V plugs rated 15amps each and one dual voltage, full KVA plug rated at120/240V, 50 amps, 120V plug is compatible with NEMA commonhousehold receptacles.

K857 25 ft. (7.5 m) or K857-1 100 ft. (30.4 m) REMOTE CON-TROL - Portable control provides same dial range as the outputcontrol on the welder from a location up to the specified lengthfrom the welder. Has convenient plug for easy connection to thewelder. The VANTAGE 500 DEUTZ is equipped with a 6-pinconnector for connecting the remote control.

K704 ACCESSORY SET - Includes 35 feet (10 m) ofelectrode cable and 30 feet (9 m) of work cable, head-shield, Filter plate, work clamp and electrode holder.Cable is rated at 500 amps, 60% duty cycle.

K2641-2 FOUR WHEELED STEERABLE YARDTRAILERFor in plant and yard towing. Comes standard with a Duo-Hitch™, a 2” Ball and Lunette Eye combination hitch.

K2636-1 TRAILER - Two-wheeled trailer with optional fenderand light package. For highway use, consult applicable feder-al, state, and local laws regarding possible additional require-ments. Comes standard with a Duo-Hitch™, a 2” Ball andLunette Eye combination hitch. Order:K2636-1 TrailerK2639-1 Fender & Light KitK2640-1 Cable Rack

K887-1 ETHER START KIT - Provides maximum cold weath-er starting assistance for frequent starting below 10°(-12°C).Required Ether tank is not provided with kit.

K899-1 SPARK ARRESTOR KIT - Easily mounts to standardmuffler.

K1816-1 Full KVA Adapter Kit - Plugs into the120/240V NEMA 14-50R receptacle on the case front(which accepts 4-prong plugs) and converts it to aNEMA 6-50R receptacle (which accepts 3-prongplugs) for connection to Lincoln Equipment with aNEMA 6-50P plug,

T12153-9 Full-KVA Power Plug-One dual voltageplug rated at 120/240V, 50 amps, single phase.

Pipe Thawing with an arc welder can cause fire,explosion, damage to electric wiring or to the arcwelder if done improperly. The use of an arcwelder for pipe thawing is not approved by theCSA, nor is it recommended or supported byLincoln Electric.------------------------------------------------------------------------

K2356-1 Control Panel Cover Kit-Clear plexiglasscover to protect control panel from dirt and debris, andto visually monitor machine operation. Lockable todeter vandalism.

K2340-1 Lockable Fuel Cap / Flash Arrester Kit-Foruse in locations where flash arrester safety isrequired. Lockable fuel cap prevents tampering withfuel. Green cap color provides a visual reminder touse diesel when refueling.

TIG OPTIONSK1783-9 PTA-26V TIG TorchAir Cooled 200 amp torch (2 piece) equipped withvalve for gas flow control. 25 ft. (7.6m) length.

KP509 Magnum Parts Kit for PTA-26V TIG TorchMagnum Parts Kit provides all the torch accessoriesyou need to start welding. Parts kit provides collets,collet bodies, a black cap, alumina nozzles and tung-stens in a variety of sizes, all packaged in an easy tocarry reclosable sack.

K870 Foot Amptrol®-Varies current while welding formaking critical TIG welds and crater filling. Depresspedal to increase current. Depressing pedal fullyachieves maximum set current. Fully raising the pedalfinishes the weld and starts the after flow cycle onsystems so equipped. Includes 25 ft. (7.6m) controlcable.

K963-2 Hand Amptrol®-Varies current for makingcritical TIG welds. Fastens to the torch for convenientthumb control. Comes with a 25 ft. (7.6m) cable. (Forlarger handle 18 or 26 series torches.)

K2347-1 Precision TIG 185 Ready-PakFor AC TIG Welding with square wave performanceuse the AC generator of the Engine-Driven Welder tosupply the power. Easy setup. Includes torch, footamptrol, gas regulator and hose. Requires theK1816-1 Full KVA adapter kit.

K2350-1 Invertec® V205-T AC/DC One-Pak™ PackageFor AC TIG welding with square wave performance,use the AC generator of the engine-driven welder tosupply the power. Easy setup. Includes torch, partskit, regulator and hose kit, Twist-Mate™ torch adapter,work cable with Twist-Mate end and foot Amptrol®.

VANTAGE 500 DEUTZ

WARNING

C-2ACCESSORIESC-2

WIRE FEEDER OPTIONS

K449 LN-25 Wire FeederPortable CC/CV unit for flux-cored and MIG welding.Includes Gas Solenoid & Internal Contactor.

K126-2 Magnum® 350 Innershield Gun (for LN-25)For self-shielded wire with 15 ft. (4.5m) cable. For.062-3/32” (1.6-2.4mm) wire.

KP653-3/32 Drive Roll and Guide Tube Kit (for LN-25)For .068-3/32” (1.8-2.4mm) cored or solid steel wire.

K1802-1 Magnum® 300 MIG GunFor .035-.045 (0.9-1.2mm) gas shielded wire.Includes 15 ft. gun and cable assembly and connectorkit.

KP653-035S Drive Roll and Guide Tube Kit (for LN-25)For .035-.040” (0.9-1.0mm) solid steel wire.

K487-25 Magnum SG Spool GunHand held semiautomatic wire feeder. Requires SGControl Module and Input Cable.

K488 SG Control ModuleThe Interface between the power source and thespool gun. Provides control of the wire speed and gasflow. 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 receptaclesand output stud connections.

PLASMA CUTTING

K1581-1 Pro-cut 80Cuts mild steel using the 3-phase AC generator powerfrom the engine driven welder.

VANTAGE 500 DEUTZ

D-1MAINTENANCED-1

VANTAGE 500 DEUTZ

SAFETY PRECAUTIONS

• Have a qualified technician do the maintenanceand troubleshooting work.

• Turn the engine off before working inside themachine.

• Remove guards only when necessary andreplace them when the maintenance requiringtheir removal is complete.

• Always use the greatest care when working nearmoving parts.

------------------------------------------------------------------------

Read the Safety Precautions in front of this manualand the engine instruction manual before working onthis machine.

Keep all equipment safety guards, covers and devicesin position and in good repair. Keep hands, hair, cloth-ing and tools away from V-belts, gears, fans and allother moving parts when starting, operating or repair-ing the equipment.

ROUTINE AND PERIODIC MAINTENANCE

DAILY

• Check the Engine oil level.

• Refill the fuel tank to minimize moisture condensa-tion in the tank.

• Open the water drain valve located on the bottom ofthe water separator element 1 or 2 turns and allowto drain into a container suitable for diesel fuel for 2to 3 seconds. Repeat the above drainage procedureuntil 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 requiredonce a week.

ENGINE MAINTENANCERefer to the “SERVICE PLAN” section of the EngineOperatorʼs Manual for the recommended maintenanceschedule of the following:

a) Engine Oil and Filterb) Air Cleanerc) Fuel Filter - and Delivery Systemd) Alternator Belte) Batteryf) Cooling System

Refer to Table D.1 at the end of this section for vari-ous engine maintenance components.

WARNING

AIR FILTER

• Excessive air filter restriction will result inreduced engine life.

• Never use gasoline or low flash point solventsfor cleaning the air cleaner element. A fire orexplosion could result.

• Never run the engine without the air cleaner.Rapid engine wear will result from contaminants,such as dust and dirt being drawn into theengine.

---------------------------------------------------------------------The diesel engine is equipped with a dry type air filter.Never apply oil to it. Service the air cleaner as follows:

Replace the element as indicated by the service indi-cator. (See Service Instructions and Installation Tipsfor Engine Air Filter.)

CAUTION

CAUTION

WARNING

D-2MAINTENANCED-2

VANTAGE 500 DEUTZ

D-3MAINTENANCED-3

FUEL FILTERS

When working on the fuel system

• Keep naked lights away, do not smoke !

• Do not spill fuel !

------------------------------------------------------------------------

The VANTAGE 500 DEUTZ is equipped with a FuelFilter located after the lift pump and before fuel injec-tors.The procedure for changing the filter is as follows.

1. Close the fuel shutoff valve.

2. Clean the area around the fuel filter head. Removethe filter. Clean the gasket surface of the filter headand replace the o-ring.

3. Fill the clean filter with clean fuel, and lubricate theo-ring seal with clean lubricating oil.

4. Install the filter as specified by the filter manufactur-er.

Mechanical overtightening will distort the threads,filter element seal or filter can.

------------------------------------------------------------------------

COOLING SYSTEMThe cooling system of the Deutz engine needs to bechecked and cleaned periodically. (Consult the engineOwners Manual for the proper procedures and fre-quency).

BATTERY HANDLING

GASES FROM BATTERY can explode.

• Keep sparks, flame and cigarettesaway from battery.

To prevent EXPLOSION when:

• INSTALLING A NEW BATTERY - dis-connect negative cable from old bat-tery first and connect to new batterylast.

• CONNECTING A BATTERY CHARGER- Remove battery from welder by dis-connecting negative cable first, thenpositive cable and battery clamp.When reinstalling, connect negativecable last. Keep well ventilated.

• USING A BOOSTER - connect positivelead to battery first then connect nega-tive lead to engine foot.

BATTERY ACID CAN BURN EYES ANDSKIN.

• Wear gloves and eye protection andbe careful when working near battery.Follow instructions printed on battery.

------------------------------------------------------------------------

PREVENTING ELECTRICAL DAMAGE1. When replacing, jumping, or otherwise connecting

the battery to the battery cables, the proper polaritymust be observed. Failure to observe the properpolarity 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 externalcharger, disconnect the negative battery cable firstand then the positive battery cable before attachingthe charger leads. Failure to do so can result indamage to the internal charger components. Whenreconnecting the cables, connect the positive cablefirst and the negative cable last.

PREVENTING BATTERY DISCHARGETurn the RUN/STOP switch to stop when engine isnot running.

PREVENTING BATTERY BUCKLINGTighten nuts on battery clamp until snug.

VANTAGE 500 DEUTZ

WARNING

WARNING

D-4MAINTENANCED-4

CHARGING THE BATTERYWhen you charge, jump, replace, or otherwise con-nect battery cables to the battery, be sure the polarityis correct. Improper polarity can damage the chargingcircuit. The VANTAGE 500 DEUTZ positive (+) batteryterminal has a red terminal cover.

If you need to charge the battery with an externalcharger, disconnect the negative cable first, then thepositive cable before you attach the charger leads.after the battery is charged, reconnect the positivebattery cable first and the negative cable last. Failureto do so can result in damage to the internal charger

components.

Follow the instructions of the battery charger manu-facturer for proper charger settings and charging time.

NAMEPLATES / WARNING DECALS MAIN-TENANCEWhenever routine maintenance is performed on thismachine - or at least yearly - inspect all nameplatesand labels for legibility. Replace those which are nolonger clear. Refer to the parts list for the replacementitem number.

WELDER / GENERATOR MAINTENANCE

STORAGEStore the Air Vantage in a clean, dry protected areas.

CLEANINGBlow out the generator and controls periodically withlow pressure air. do this at least once a week in partic-ularly dirty areas.

BRUSH REMOVAL AND REPLACEMENTIt is normal for the brushes and slip rings to wear anddarken slightly. Inspect the brushes when a generatoroverhaul is necessary.

Do not attempt to polish slip rings while theengine is running.

------------------------------------------------------------------------

VANTAGE 500 DEUTZ

E-1TROUBLESHOOTINGE-1

VANTAGE 500 DEUTZ

If for any reason you do not understand the test procedures or are unable to perform the tests/repairs safely, contact yourLocal Lincoln Authorized Field Service Facility for technical troubleshooting assistance before you proceed.

CAUTION

This Troubleshooting Guide is provided to help youlocate and repair possible machine malfunctions.Simply follow the three-step procedure listed below.

Step 1. LOCATE PROBLEM (SYMPTOM).Look under the column labeled “PROBLEM (SYMP-TOMS)”. This column describes possible symptomsthat the machine may exhibit. Find the listing thatbest describes the symptom that the machine isexhibiting.

Step 2. POSSIBLE CAUSE.The second column labeled “POSSIBLE CAUSE” liststhe obvious external possibilities that may contributeto the machine symptom.

Step 3. RECOMMENDED COURSE OF ACTIONThis column provides a course of action for thePossible Cause, generally it states to contact yourlocal Lincoln Authorized Field Service Facility.

If you do not understand or are unable to perform theRecommended Course of Action safely, contact yourlocal Lincoln Authorized Field Service Facility.

HOW TO USE TROUBLESHOOTING GUIDE

Service and Repair should only be performed by Lincoln Electric Factory Trained Personnel.Unauthorized repairs performed on this equipment may result in danger to the technician andmachine operator and will invalidate your factory warranty. For your safety and to avoid ElectricalShock, please observe all safety notes and precautions detailed throughout this manual.

__________________________________________________________________________

WARNING

E-2TROUBLESHOOTINGE-2

VANTAGE 500 DEUTZ

Observe all Safety Guidelines detailed throughout this manual

If for any reason you do not understand the test procedures or are unable to perform the tests/repairs safely, contact yourLocal Lincoln Authorized Field Service Facility for technical troubleshooting assistance before you proceed.

CAUTION

PROBLEMS(SYMPTOMS)

POSSIBLE CAUSE

RECOMMENDEDCOURSE OF ACTION

Major Physical or Electrical Damageis Evident.Engine will not crank

Engine will crank but not start.

Engine shuts down shortly afterstarting.

Engine shuts down while under aload.

Engine runs rough.

Engine will not shut off.

1. Contact your Local LincolnAuthorized Field Service Facility.

1. Battery low. 2. Loose battery cable connections

which may need Inspected,cleaned or tighten.

3. Faulty wiring in engine startingcircuit.

4. Faulty engine starter. Contactauthorized local Engine ServiceShop.

1. Out of fuel. 2. Fuel shut off valve is in the off

position make sure the valvelever is in the open position (leverin-line with the Hose).

3. Engine shut down solenoid notpulling in.

4. On/Off switch on for more than 30sec. before starting, the On/Offswitch will need to be switch offand turned back on.

5. Fuel Filters dirty/clogged, main fil-ter element and/or Inline FuelFilter may need to be replaced.

6. High oil temperature or low oilpressure. (engine protection lightlit)

1. Low oil pressure (engine protec-tion l ight l i t). Check oil level(Consult engine service dealer).

2. High oil temperature. Checkengine cooling system. (engineprotection light lit).

3. Faulty oil pressure switch.4. Faulty oil temperature switch.

Contact authorized local EngineService Shop.

1. High oil temperature.

1. Dirty fuel or air filters may needcleaned/replaced.

2. Water in fuel.

1. Fuel Shutdown solenoid not func-tioning properly.

If all recommended possible areasof misadjustment have beenchecked and the problem persists,Contact your local LincolnAuthorized Field Service Facility.

ENGINE PROBLEMS

E-3TROUBLESHOOTINGE-3

VANTAGE 500 DEUTZ

Observe all Safety Guidelines detailed throughout this manual

If for any reason you do not understand the test procedures or are unable to perform the tests/repairs safely, contact yourLocal Lincoln Authorized Field Service Facility for technical troubleshooting assistance before you proceed.

CAUTION

PROBLEMS(SYMPTOMS)

POSSIBLE CAUSE

RECOMMENDEDCOURSE OF ACTION

Battery does not stay charged.

Engine will not idle down to lowspeed.

Engine will not go to high idle whenattempting to weld.

Engine will not go to high idle whenusing auxiliary power.

1. Faulty battery . 2. Faulty engine alternator. 3. Loose or broken lead in charging

circuit. 4. Loose fan belt may need tighten-

ing.

1. Idler switch in HIGH idle position,make sure switch is set to AUTO.

2. External load on welder or auxil-iary power.

3. Mechanical problem in idler sole-noid linkage.

4. Faulty wiring in solenoid circuit. 5. No or low voltage @ idle solenoid 6. Faulty idler solenoid. 7. Faulty, Weld Control PCB

(Printed Circuit Board), PullCoil/Battery PCB.

1. Poor work lead connection towork.

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 currentsensor wiring.

2. Auxiliary power load is less than100 watts.

3. Faulty Pull Coil/Battery PCB. orWeld Control PCB.

If all recommended possible areas ofmisadjustment have been checkedand the problem persists, Contactyour local Lincoln AuthorizedField Service Facility.

FUNCTION PROBLEMS

E-4TROUBLESHOOTINGE-4

VANTAGE 500 DEUTZ

Observe all Safety Guidelines detailed throughout this manual

If for any reason you do not understand the test procedures or are unable to perform the tests/repairs safely, contact yourLocal Lincoln Authorized Field Service Facility for technical troubleshooting assistance before you proceed.

CAUTION

PROBLEMS(SYMPTOMS)

POSSIBLE CAUSE

RECOMMENDEDCOURSE OF ACTION

Engine goes to low idle but does notstay at low idle.

No welding output or auxiliary out-put.

Welder has some/ no output and nocontrol. Auxiliary output OK

No welding output. Auxiliary outputOK.

No auxiliary power.

1. Faulty Peripheral PCB,Idler/Engine Protection PCB orWeld Control PCB.

1. Broken lead in rotor circuit.2. Faulty field diode module. 3. Faulty Weld Control PCB. 4. Faulty rotor.

1. Faulty remote kit. 2. Faulty output control potentiome-

ter. 3. Faulty output control wiring.4. Faulty Weld Control PCB,

Idler/Engine Protection PCB orChopper PCB.

1. WELDING TERMINALS switch inwrong position, be sure switch isin WELDING TERMINALSALWAYS ON position.

2. Faulty Weld Control PCB,Idler/Engine Protection PCB orChopper PCB.

1. Open breakers may need to bereset.

2. Faulty receptacle. 3. Faulty auxiliary circuit wiring.4. GFCI tripped.

If all recommended possible areas ofmisadjustment have been checkedand the problem persists, Contactyour local Lincoln AuthorizedField Service Facility.

FUNCTION PROBLEMS

F-1DIAGRAMSF-1

VANTAGE 500 DEUTZ

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VANTAGE 500 DEUTZ

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VANTAGE 500 DEUTZ

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F-4CONNECTION DIAGRAMSF-4

VANTAGE 500 DEUTZ

F-5CONNECTION DIAGRAMSF-5

VANTAGE 500 DEUTZ

F-6CONNECTION DIAGRAMSF-6

VANTAGE 500 DEUTZ

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F-8CONNECTION DIAGRAMSF-8

VANTAGE 500 DEUTZ

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F-9CONNECTION DIAGRAMSF-9

VANTAGE 500 DEUTZ

F-10CONNECTION DIAGRAMSF-10

VANTAGE 500 DEUTZ

F-11CONNECTION DIAGRAMSF-11

VANTAGE 500 DEUTZ

F-12CONNECTION DIAGRAMSF-12

VANTAGE 500 DEUTZ

F-13DIMENSION PRINTF-13

VANTAGE 500 DEUTZ

M18

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9

NOTES

VANTAGE 500 DEUTZ

NOTES

VANTAGE 500 DEUTZ

WARNING

AVISO DEPRECAUCION

ATTENTION

WARNUNG

ATENÇÃO

Spanish

French

German

Portuguese

Japanese

Chinese

Korean

Arabic

READ AND UNDERSTAND THE MANUFACTURER’S INSTRUCTION FOR THIS EQUIPMENT AND THE CONSUMABLES TO BEUSED AND FOLLOW YOUR EMPLOYER’S SAFETY PRACTICES.

SE RECOMIENDA LEER Y ENTENDER LAS INSTRUCCIONES DEL FABRICANTE PARA EL USO DE ESTE EQUIPO Y LOSCONSUMIBLES 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 AETRE 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 UNFALLVERHÜTUNGSVORSCHRIFTEN DES ARBEITGEBERS SIND EBENFALLS ZU BEACHTEN.

● Do not touch electrically live parts orelectrode with skin or wet clothing.

● Insulate yourself from work andground.

● No toque las partes o los electrodosbajo carga con la piel o ropa moja-da.

● Aislese del trabajo y de la tierra.

● Ne laissez ni la peau ni des vête-ments mouillés entrer en contactavec des pièces sous tension.

● Isolez-vous du travail et de la terre.

● Berühren Sie keine stromführendenTeile oder Elektroden mit IhremKörper oder feuchter Kleidung!

● Isolieren Sie sich von denElektroden und dem Erdboden!

● Não toque partes elétricas e elec-trodos com a pele ou roupa molha-da.

● Isole-se da peça e terra.

● Keep flammable materials away.

● Mantenga el material combustiblefuera del área de trabajo.

● Gardez à l’écart de tout matérielinflammable.

● Entfernen Sie brennbarres Material!

● Mantenha inflamáveis bem guarda-dos.

● Wear eye, ear and body protection.

● Protéjase los ojos, los oídos y elcuerpo.

● Protégez vos yeux, vos oreilles etvotre corps.

● Tragen Sie Augen-, Ohren- und Kör-perschutz!

● Use proteção para a vista, ouvido ecorpo.

WARNING

AVISO DEPRECAUCION

ATTENTION

WARNUNG

ATENÇÃO

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LEIA E COMPREENDA AS INSTRUÇÕES DO FABRICANTE PARA ESTE EQUIPAMENTO E AS PARTES DE USO, E SIGA ASPRÁTICAS DE SEGURANÇA DO EMPREGADOR.

● Keep your head out of fumes.● Use ventilation or exhaust to

remove fumes from breathing zone.

● Los humos fuera de la zona de res-piración.

● Mantenga la cabeza fuera de loshumos. Utilice ventilación oaspiración para gases.

● Gardez la tête à l’écart des fumées.● Utilisez un ventilateur ou un aspira-

teur pour ôter les fumées des zonesde travail.

● Vermeiden Sie das Einatmen vonSchweibrauch!

● Sorgen Sie für gute Be- undEntlüftung des Arbeitsplatzes!

● Mantenha seu rosto da fumaça.● Use ventilação e exhaustão para

remover fumo da zona respiratória.

● Turn power off before servicing.

● Desconectar el cable de ali-mentación de poder de la máquinaantes de iniciar cualquier servicio.

● Débranchez le courant avantl’entretien.

● Strom vor Wartungsarbeitenabschalten! (Netzstrom völlig öff-nen; Maschine anhalten!)

● Não opere com as tampas removidas.● Desligue a corrente antes de fazer

serviço.● Não toque as partes elétricas nuas.

● Do not operate with panel open orguards off.

● No operar con panel abierto oguardas quitadas.

● N’opérez pas avec les panneauxouverts ou avec les dispositifs deprotection enlevés.

● Anlage nie ohne Schutzgehäuseoder Innenschutzverkleidung inBetrieb setzen!

● Mantenha-se afastado das partesmoventes.

● Não opere com os paineis abertosou guardas removidas.

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