Lincoln Electric IM805 manual

April, 2004 Safety Depends on Y ou Lincoln arc welding and cutting equipment is designed and built with safety in mind. However , your overall safety can be increased by proper installation . . . and thoughtful operation on your part. DO NOT INST ALL, OPERA TE OR REP AIR THIS EQUIPMENT WITHOUT READING THIS MANUAL AND THE SAFETY PRECAUTIONS CONT AIN[...]

ELECTRIC AND MAGNETIC FIELDS may be dangerous 2.a. Electric current flowing through any conductor causes localized Electric and Magnetic Fields (EMF). Welding current creates EMF fields around welding cables and welding machines. 2.b. EMF fields may interfere with some pacemakers and welders having a pacemaker should consult their physician before [...]

ELECTRIC SHOCK can kill. 3.a. The electrode and work (or ground) circuits are electrically “hot” when the welder is on. Do not touch these “hot” parts with your bare skin or wet clothing. Wear dry , hole-free gloves to insulate hands. 3.b. Insulate yourself from work and ground using dry insulation. Make certain the insulation is large enou[...]

FOR ELECTRICALL Y powered equipment. 8.a. Turn off input power using the disconnect switch at the fuse box before working on the equipment. 8.b. Install equipment in accordance with the National Electrical Code, all local codes and the manufacturer ’s recommendations. 8.c. Ground the equipment in accordance with the National Electrical Code and t[...]

iv SAFETY iv PRÉCAUTIONS DE SÛRETÉ Pour votre propre protection lire et observer toutes les instructions et les précautions de sûreté specifiques qui parraissent dans ce manuel aussi bien que les précautions de sûreté générales suivantes: Sûreté Pour Soudage A L ’Arc 1. Protegez-vous contre la secousse électrique: a. Les circuits à[...]

v v Thank You for selecting a QUALITY product by Lincoln Electric. We want you to 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 it handy for quick reference. Pay[...]

Page Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Section A T echnical Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .A-1 Safety Precautions . . . . . . . . . . .[...]

Accessories . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Section C Optional Field Installed Accessories . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .C-1 Maintenance . . . . . . . . . . . . . . . . . . . . .[...]

TECHNICAL SPECIFICA TIONS - V antage 500 DEUTZ (K2271-1) INPUT - DIESEL ENGINE Make /Model Description Speed (RPM) Displacement Starting Capacities System Deutz 3 cylinder High Idle 1900 173 cu. in 12VDC battery Fuel F3L 912 44HP (33 kw) (2.83L) & Starter (25 US gal) Diesel Engine @ 1800 RPM Full Load 1800 94.6L Bore x Stroke Oil: 9.5 QTS. 3.94[...]

Read this entire installation section before you start installation. SAFETY PRECAUTIONS Do not attempt to use this equipment until you have thoroughly read all operating and maintenance manuals supplied with your machine. They include important safety precautions, detailed engine starting, operating and maintenance instructions and parts lists. ELE[...]

LIFTING The V antage lift bale should be used to lift the machine. The V antage is shipped with the lift bale retracted. Before attempting to lift the V antage the lift bale must be secured in a raised position. Secure the lift bale as follows: a. Open the engine compartment door . b. Locate the 2 access holes on the upper middle region of compartm[...]

PRE-OPERA TION ENGINE SERVICE READ the engine operating and maintenance instructions supplied with this machine. Stop engine while fueling. • Do not smoke when fueling. • Keep sparks and flame away from tank. • Do not leave unattended while fueling. • Wipe up spilled fuel and allow fumes to clear before starting engine. • Do not overfill [...]

The V antage is shipped with the negative battery cable disconnected. Before you operate the machine, make sure the Engine Switch is in the OFF position and attach the disconnected cable securely to the negative (-) battery terminal. Remove the insulating cap from the negative battery terminal. Replace and tighten negative battery cable terminal. N[...]

REMOTE CONTROL OUTPUT The V antage is equipped with a 6-pin and a 14-pin connector . The 6-pin connector is for connecting the K857 or K857-1 Remote Control or for TIG welding, the K870 foot Amptrol or the K936-2 hand Amptrol. When in the CC-STICK, DOWNHILL PIPE, or CV - WIRE modes and when a remote control is connected to the 6- pin Connector , th[...]

V antage 500 DEUTZ A-7 INST ALLA TION A-7 2. T ake necessary steps to assure load is limited to the capacity of the V antage by installing a 50 amp, 240 V AC double pole circuit breaker . Maximum rated load for each leg of the 240 V AC auxiliary is 50 amps. Loading above the rated output will reduce output voltage below the allowable -10% of rated [...]

CONNECTION OF LINCOLN ELECTRIC WIRE FEEDERS Shut off welder before making any electrical connections. ------------------------------------------------------------------------------------- CONNECTION OF LN-7, LN-8 OR LN-742 TO THE V ANT AGE • Shut the welder off. • Connect the LN-7, LN-8 or LN-742 per instructions on the appropriate connection d[...]

V ANT AGE 500 DEUTZ A-9 INST ALLA TION A-9 CONNECTION OF THE LN-25 TO THE V ANT AGE The LN-25 with or without an internal contactor may be used with the V antage. See the appropriate connection diagram in the DIAGRAMS section. NOTE : The LN-25 (K431) Remote Control Module and (K432) Remote Cable are not recommended for use with the V antage. • Sh[...]

SAFETY INSTRUCTIONS Read and understand this entire section before operating your V antage. Do not attempt to use this equipment until you have thoroughly read all operating and maintenance manuals supplied with your machine. They include important safety precautions, detailed engine starting, operating and maintenance instructions and parts lists.[...]

ENGINE CONTROLS (Items 1 through 8) 1. RUN STOP SWITCH T oggling the switch to the RUN position energizes the fuel solenoid for approximately 30 seconds. The engine must be started within that time or the fuel solenoid will deenergize, and the switch must be toggled to reset the timer . 2. ST ART PUSHBUTTON Energizes the starter motor to crank the [...]

6. OIL PRESSURE GAUGE The gauge displays the engine oil pressure when the engine is running. 7. ENGINE PROTECTION The yellow engine protection light remains off with proper oil pressure and under normal operating temperatures. If the light turns on, the engine protection system will stop the engine. Check for proper oil level and add oil if necessa[...]

14. WIRE FEEDER VOL TMETER SWITCH: Matches the polarity of the wire feeder voltmeter to the polarity of the electrode. 15. 6 - PIN CONNECTOR For attaching optional remote control equipment. Includes auto- sensing remote control circuit. 16. 14 - PIN CONNECTOR For attaching wire feeder control cables. Includes contactor closure circuit, auto-sensing[...]

B-5 OPERA TION B-5 V antage 500 DEUTZ TYPICAL FUEL CONSUMPTION Refer to T able B.2 for typical fuel consumption of the V antage Engine for various operating scenarios. WELDER OPERA TION DUTY CYCLE Duty Cycle is the the ratio of the uninterrupted on-load duration to 10 minutes. The total time period of one complete on-load and no- load cycle is 10 m[...]

T able B.3 TYPICAL CURRENT RANGES (1) FOR TUNGSTEN ELECTRODES (2) DCEN (-) DCEP (+) Approximate Argon Gas Flow Rate l/min (c.f.m.) T ungsten Electrode 1%, 2% 1%, 2% TIG T ORCH Diameter Thoriated Thoriated Aluminum Stainless Steel Nozzle mm (in) T ungsten 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)[...]

CV -WIRE MODE Connect a wire feeder to the V antage and set welder controls according to the instructions listed earlier in this section. The V antage in the ”CV -WIRE” position, permits it to be used with a broad range of flux cored wire (Innershield and Outershield) electrodes and solid wires for MIG welding (gas metal arc welding). Welding c[...]

B-8 OPERA TION B-8 V antage 500 DEUTZ T ABLE B.5 V antage Extension Cord Length Recommendations Current (Amps) 15 15 20 20 25 30 38 50 V oltage (V olts) 120 240 120 240 240 240 240 240 Load (W atts) 1800 3600 2400 4800 6000 7200 9000 12000 30 60 (9) (18) 40 75 30 60 (12) (23) (9) (18) 75 150 50 100 90 75 (23) (46) (15) (30) (27) (23) 125 225 88 175[...]

OPTIONAL FIELD INST ALLED ACCESSORIES K704 ACCESSOR Y SET - Includes 35 feet (10 m) of electrode cable and 30 feet (9 m) of work cable, headshield, work clamp and electrode holder . Cable is rated at 500 amps, 60% duty cycle. K767-2 FOUR WHEELED STEERABLE Y ARD TRAILER - For in plant and yard towing. K802N POWER PLUG KIT - Provides four 120V plugs [...]

SAFETY PRECAUTIONS • Have a qualified technician do the maintenance and troubleshooting work. • T urn the engine off before working inside the machine. • Remove guards only when necessary and replace them when the maintenance requiring their removal is complete. • Always use the greatest care when working near moving parts. ----------------[...]

7. Inspect for holes and tears by looking through the element toward a bright light. Check for damaged gaskets or dented metal parts. Do not reuse damaged elements. Protect element from dust and damage during drying and storage. 8. Reinstall air filter element. After six cleanings replace air filter . A cleaned filter will have approximately 70% of[...]

V ANT AGE 500 DEUTZ COOLING SYSTEM The cooling system of the Deutz engine needs to be checked and cleaned periodically . Consult the engine owners manual for the proper frequency and procedure. COOLING BLOWER BEL T The following procedure should be followed to replace the cooling blower belt: 1. Allow the machine to cool. 2. Unfasten and slide the [...]

CHARGING THE BA TTERY When you charge, jump, replace, or otherwise connect battery cables to the battery , be sure the polarity is correct. Improper polarity can damage the charging circuit. The V antage positive (+) battery terminal has a red terminal cover . If you need to charge the battery with an external charger , disconnect the negative cabl[...]

This T roubleshooting Guide is provided to help you locate and repair possible machine malfunctions. Simply follow the three- step procedure listed below . Step 1. LOCA TE PROBLEM (SYMPTOM). Look under the column labeled “PROBLEM (SYMPTOMS)”. This column describes possible symptoms that the machine may exhibit. Find the listing that best descri[...]

PROBLEMS (SYMPTOMS) Major Physical or Electrical Damage is Evident. Engine will not crank Engine will crank but not start. Engine shuts down shortly after starting. Engine shuts down while under a load. Engine runs rough. Engine will not shut off POSSIBLE AREAS OF MISADJUSTMENT(S) 1. Contact your Local Lincoln Authorized Field Service Facility . 1.[...]

PROBLEMS (SYMPTOMS) Battery does not stay charged. No welding output or auxiliary output. Welder has some/ no output and no control. Auxiliary output OK No welding output. Auxiliary output OK. No auxiliary power . POSSIBLE AREAS OF MISADJUSTMENT(S) 1. Faulty battery . 2. Faulty engine alternator . 3. Loose or broken lead in charging circuit. 4. Loo[...]

F-1 DIAGRAMS F-1 V antage 500 DEUTZ NOTE: This diagram is for reference only . It may not be accurate for all machines covered by this manual. The specific dia- gram for your particular machine is pasted inside the machine on one of the enclosure panels. OUTPUT CONTROL CCW RECTIFIER BRIDGE HOUR METER ALT 75 PINCH POT 278 SILVER - 232R 238A 231 42A [...]

V antage 500 DEUTZ F-2 DIAGRAMS F-2 CONNECTION DIAGRAM:[...]

F-3 DIAGRAMS F-3 V antage 500 DEUTZ CONNECTION DIAGRAM: GND 75 76 77 GREEN K291 OR K404 75 INPUT CABLE 76 N.E. 77 K775 OPTIONAL REMOTE CONTR OL D AMAGED . THE ENGINE GO VERNOR SETTING IS PRE-SET A T THE F ACT ORY - DO NO T ADJUST ABO VE RPM SPECIFICA TIONS LISTED IN 81 42 41 31 31 32 32 2 2 4 4 21 21 GND 82 N.D . LN-7 WIRE FEEDER Keep guards in pla[...]

F-4 DIAGRAMS F-4 V antage 500 DEUTZ CONNECTION DIAGRAM[...]

V antage 500 DEUTZ F-5 DIAGRAMS F-5 CONNECTION DIAGRAM[...]

V antage 500 DEUTZ F-6 DIAGRAMS F-6 CONNECTION DIAGRAM CA UTION : N.A. WELDING CABLE MUST BE OF PROPER CAP ACITY FOR THE CURRENT AND DUTY CYCLE OF IMMEDIA TE AND FUTURE APPICA TIONS. SEE OPERA TING MANUAL. 75 32 31 41 42 N.C. INSULA TE EACH UNUSED LEAD INDIVIDUALL Y . N.D . SPLICE LEADS AND INSULA TE. THE ENGINE WELDER OPERA TING MANUAL. GND 31 4 2[...]

V antage 500 DEUTZ F-7 DIAGRAMS F-7 CONNECTION DIAGRAM[...]

V antage 500 DEUTZ F-8 DIAGRAMS F-8 CONNECTION DIAGRAM[...]

V antage 500 DEUTZ F-9 DIAGRAMS F-9 CONNECTION DIAGRAM or ser vice t his equi pm ent. Only qualified per s onnel should install,use Keep away from moving parts. Keep guards in place. MOVING PART S can injure WA R N I N G Do not touch electrically live pa r ts. before servicing. Disconnect NEGATIVE (-) Ba ttery lead Do not operate with panels open. [...]

V antage 500 DEUTZ F-10 DIAGRAMS F-10 CONNECTION DIAGRAM[...]

V antage 500 DEUTZ F-1 1 DIAGRAMS F-1 1 CONNECTION DIAGRAM[...]

V antage 500 DEUTZ F-12 DIAGRAMS F-12 CONNECTION DIAGRAM[...]

V antage 500 DEUTZ F-13 DIAGRAMS F-13 CONNECTION DIAGRAM[...]

V antage 500 DEUTZ F-14 DIAGRAMS F-14 DIMENSION PRINT TRAIL ER MOUNTING HOL E LOCAT IONS. * M18962-1 A 28.9 9 1.26 19.6 3 6.53 24.9 7 6.55 23.6 9 50.3 8 54.4 4 14.6 3 37.3 0 45.3 8 63.1 0 6.56 42.0 0 48.6 4 23.3 8 31.1 3 32.0 8 49.0 5 31.5 0 45.6 7 10.2 2 * * * * BOTTOM VI EW OF WELDER BA CE NTER OF GR AV ITY W ITH O IL IN ENGIN E A ND FULL FU EL T[...]

NOTES V ANT AGE 500 DEUTZ[...]

V antage 500 DEUTZ W ARNING A VISO DE PRECAUCION A TTENTION W ARNUNG A TENÇÃO Spanish French German Portuguese Japanese Chinese Korean Arabic READ AND UNDERST AND THE MANUF ACTURER’S INSTRUCTION FOR THIS EQUIPMENT AND THE CONSUMABLES TO BE USED AND FOLLOW YOUR EMPLOYER’S SAFETY PRACTICES. SE RECOMIENDA LEER Y ENTENDER LAS INSTRUCCIONES DEL F [...]

V antage 500 DEUTZ W ARNING A VISO DE PRECAUCION A TTENTION W ARNUNG A TENÇÃO Spanish French German Portuguese Japanese Chinese Korean Arabic LEIA E COMPREENDA AS INSTRUÇÕES DO F ABRICANTE P ARA ESTE EQUIPAMENTO E AS P ARTES DE USO, E SIGA AS PRÁTICAS DE SEGURANÇA DO EMPREGADOR. ● Keep your head out of fumes. ● Use ventilation or exhaust [...]

World’ s Leader in Welding and Cutting Products • Sales and Service through Subsidiaries and Distributors Worldwide • Cleveland, Ohio 441 17-1 199 USA T el: 216.481.8100 Fax: 216.486.1751 Web Site: www .lincolnelectric.com[...]