Lincoln Electric 575 manual

February , 2003 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[...]

ELECTRIC AND MAGNETIC FIELDS may be dangerous 2.a. Electric current flowing through any conductor causes localised 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 SAFETY v WELDING, EMF & P ACEMAKERS All welders should follow safe practices that minimise their exposure to electric and magnetic fields (EMF). For welders wearing implanted pacemakers, safe welding practices are particularly important and additional procedures should be followed by those who have decided to continue to weld. (Hopefully in k[...]

This welding machine must be used by trained operators only . Read this manual carefully before attempting to use the welding machine. Conformance Products displaying the C-T ick mark are in conformity with Australian/New Zealand requirements for Electromagnetic Compatibility (EMC). They are: • manufactured in conformity with Australian/New Zeala[...]

W ARNING vii vii T hank Y ou 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! Please Examine Carton and Equipment for Damage Immediately When this equipment is shipped, title passes to the purchaser upon recei[...]

Page Safety . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . i-vi Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Section A T echnical Specifications . . . . . . . . . .[...]

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

TECHNICAL SPECIFICA TIONS - V antage 575 (K2170-1) INPUT - DIESEL ENGINE Make /Model Description Speed (RPM) Displacement Starting Capacities System Cummins 4 cylinder High Idle 1590 3.3L 12VDC battery Fuel 94.6L B3.3 36kw (48 HP) Low Idle 1300 (199 cu in) & Starter (25 US gal) Diesel Engine @ 1500 RPM Full Load 1500 Bore x Stroke Oil: 7.5L (2 [...]

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. • Keep hands away from the engine muffler or HOT engine parts. • Stop engine and allow to cool before fuelling. • Do not smoke when fuelling. • Fill fuel tank at a moderate rate and do not over-fill. • Wipe up spilled fuel and [...]

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 , the[...]

A-7 INST ALLA TION A-7 V antage 575 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 instruct[...]

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. • Shut the welder off. • For electrode Positi[...]

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 9) 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[...]

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 digital meters for the four welding modes. When in the CC-STICK, DOWNHILL PIPE or CV -WIRE modes and when a remote control is connected to the 6-Pin or 14-Pin Connector , the auto-sensing circuit automatical[...]

21. CIRCUIT BREAKERS These circuit breakers provide separate overload current protection for each 220V receptacle, the 42V AC AND 1 15V AC in the 14-Pin connector and battery circuit overload protection. 22. 220V AC RECEPT ACLES These three 220V AC receptacles provide up to 15 amp rating each. Refer to the AUXILIARY POWER RECEPT ACLES section in th[...]

B-6 OPERA TION B-6 V antage 575 BREAK-IN PERIOD The engine used to supply power for your welder is a heavy duty , industrial engine. It is designed and built for rugged use. It is very normal for any engine to use small quantities of oil until the break- in is accomplished. Check the oil level twice a day during the break-in period. In general this[...]

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 Aluminium Stainless Steel Nozzle mm (in) T ungsten T ungsten 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 ([...]

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-9 OPERA TION B-9 V antage 575 T ABLE B.4 V antage Simultaneous Welding and Power Loads * Each receptacle is limited to 15 amps. T ABLE B.5 V antage Extension Cord Length Recommendations Current Voltage Load Maximum Allowable Cord Length in m (ft) for Conductor Size (Amps) V olts) (W atts) 2.5 2 mm (14AWG) 4.0 2 mm (12A WG) 6.0 2 mm (10AWG) 10.0 2[...]

OPTIONAL FIELD INST ALLED ACCESSORIES KA1373 POWER PLUG KIT - Provides a plug for each receptacle. K857 8.5m or K857-20 20m (100ft.) REMOTE CONTROL - Portable control provides same dial range as the output control on the welder from a location up to the specified length from the welder . Has convenient plug for easy connection to the welder . The V[...]

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[...]

CHARGING THE BA TTER Y 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 cab[...]

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 labelled “PROBLEM (SYMPTOMS)”. This column describes possible symptoms that the machine may exhibit. Find the listing that best descr[...]

E-2 TROUBLESHOOTING E-2 Observe all Safety Guidelines detailed throughout this manual V antage 575 CAUTION ºIf for any reason you do not understand the test procedures or are unable to perform the tests/repairs safely , contact your Local Lincoln Authorized Field Service Facility for technical troubleshooting assistance before you proceed. _______[...]

CAUTION V antage 575 E-3 TROUBLESHOOTING E-3 If for any reason you do not understand the test procedures or are unable to perform the tests/repairs safely , contact your Local Lincoln Authorized Field Service Facility for technical troubleshooting assistance before you proceed. _______________________________________________________________________[...]

PROBLEMS (SYMPTOMS) Engine goes to low idle but does not stay at low idle. 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 Peripheral PCB, Pull Coil/Battery PCB or Weld Control PCB. 1. Broke[...]

F-1 DIAGRAMS F-1 V antage 575 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. 200 200B 5H 201 200A 201A BRUSH 42B 41A ROTOR 232L 232K 6 BRUSH 1 5 VOLT METER 15 AMMETER PERIPHERAL [...]

V antage 575 F-2 DIAGRAMS F-2 CONNECTION DIAGRAM:[...]

F-3 DIAGRAMS F-3 V antage 575 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 GOVERNOR SETTING IS PRE-SET A T THE F ACT OR Y - 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 place . C[...]

F-4 DIAGRAMS F-4 V antage 575 CONNECTION DIAGRAM[...]

V antage 575 F-5 DIAGRAMS F-5 CONNECTION DIAGRAM[...]

V antage 575 F-6 DIAGRAMS F-6 CONNECTION DIAGRAM CA UTION : N.A. WELDING CABLE MUST BE OF PR OPER 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 21 B C[...]

V antage 575 F-7 DIAGRAMS F-7 CONNECTION DIAGRAM[...]

V antage 575 F-8 DIAGRAMS F-8 CONNECTION DIAGRAM[...]

V antage 575 F-9 DIAGRAMS F-9 CONNECTION DIAGRAM or service this equi pm ent. Only qualified personnel should install,use Keep away from moving parts. Keep guards in p lace. MOVING PART S can injure W ARN ING Do not touch electrically live parts. before servicing. Disconnect NEGATIVE (-) Battery lead Do not operate with panels open. ELECTRIC SHOC K[...]

V antage 575 F-10 DIAGRAMS F-10 CONNECTION DIAGRAM[...]

V antage 575 F-1 1 DIAGRAMS F-1 1 CONNECTION DIAGRAM[...]

V antage 575 F-12 DIAGRAMS F-12 CONNECTION DIAGRAM[...]

V antage 575 F-13 DIAGRAMS F-13 CONNECTION DIAGRAM[...]

V antage 575 F-14 DIAGRAMS F-14 DIMENSION PRINT TRAI LER MOUNT ING HOLE L OCATIONS. * 28.9 9 736.3 19.6 3 498.6 6.55 166.4 23.6 9 601.7 50.3 8 1279.7 54.4 4 1382.8 14.6 3 371.6 37.3 0 947.4 45.3 8 1152.7 63.1 0 1602.7 6.56 166.6 42.0 0 1066.8 50.8 1 1290.6 16.8 5 428 33.5 3 851.7 32.0 8 814.8 42.3 5 1075.7 31.5 0 800.1 45.6 7 1160 2.24 56.9 50.1 5 [...]

NOTES V antage 575[...]

NOTES V antage 575[...]

V antage 575 W ARNING A VISO DE PRECAUCION A TTENTION W ARNUNG A TEN ÇÃ O Spanish French German Portuguese Japanese Chinese Korean Arabic READ AND UNDERST AND THE MANUFACTURER’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 ABRIC[...]

V antage 575 W ARNING A VISO DE PRECAUCION A TTENTION W ARNUNG A TEN ÇÃ O 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 to r[...]

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[...]