Lincoln Electric Vantage 300 Operating instructions

Lincoln Electric Vantage 300 Operating instructions
Operator’s Manual
Vantage 300
®
For use with machines having Code Numbers:
11529, 11784, 11919, 12342,
12634, 12689
Register your machine:
www.lincolnelectric.com/register
Authorized Service and Distributor Locator:
www.lincolnelectric.com/locator
Need Help? Call 1.888.935.3877
to talk to a Service Representative
Hours of Operation:
8:00 AM to 6:00 PM (ET) Mon. thru Fri.
Save for future reference
Date Purchased
After hours?
Use “Ask the Experts” at lincolnelectric.com
A Lincoln Service Representative will contact you
no later than the following business day.
Code: (ex: 10859)
For Service outside the USA:
Email: [email protected]
Serial: (ex: U1060512345)
IM993-H
| Issue Date Nov-16
© Lincoln Global, Inc. All Rights Reserved.
THANK YOU FOR SELECTING
A QUALITY PRODUCT BY
LINCOLN ELECTRIC.
PLEASE EXAMINE CARTON AND EQUIPMENT FOR
DAMAGE IMMEDIATELY
When this equipment is shipped, title passes to the purchaser
upon receipt by the carrier. Consequently, claims for material
damaged in shipment must be made by the purchaser against the
transportation company at the time the shipment is received.
SAFETY DEPENDS ON YOU
Lincoln arc welding and cutting equipment is designed and built
with safety in mind. However, your overall safety can be increased
by proper installation ... and thoughtful operation on your part.
DO NOT INSTALL, OPERATE OR REPAIR THIS EQUIPMENT
WITHOUT READING THIS MANUAL AND THE SAFETY
PRECAUTIONS CONTAINED THROUGHOUT. And, most importantly,
think before you act and be careful.
WARNING
This statement appears where the information must be followed
exactly to avoid serious personal injury or loss of life.
CAUTION
This statement appears where the information must be followed
to avoid minor personal injury or damage to this equipment.
KEEP YOUR HEAD OUT OF THE FUMES.
DON’T get too close to the arc.
Use corrective lenses if necessary
to stay a reasonable distance
away from the arc.
READ and obey the Safety Data
Sheet (SDS) and the warning label
that appears on all containers of
welding materials.
USE ENOUGH VENTILATION or
exhaust at the arc, or both, to
keep the fumes and gases from
your breathing zone and the general area.
IN A LARGE ROOM OR OUTDOORS, natural ventilation may be
adequate if you keep your head out of the fumes (See below).
USE NATURAL DRAFTS or fans to keep the fumes away
from your face.
If you develop unusual symptoms, see your supervisor.
Perhaps the welding atmosphere and ventilation system
should be checked.
WEAR CORRECT EYE, EAR &
BODY PROTECTION
PROTECT your eyes and face with welding helmet
properly fitted and with proper grade of filter plate
(See ANSI Z49.1).
PROTECT your body from welding spatter and arc
flash with protective clothing including woolen
clothing, flame-proof apron and gloves, leather
leggings, and high boots.
PROTECT others from splatter, flash, and glare
with protective screens or barriers.
IN SOME AREAS, protection from noise may be appropriate.
BE SURE protective equipment is in good condition.
Also, wear safety glasses in work area
AT ALL TIMES.
SPECIAL SITUATIONS
DO NOT WELD OR CUT containers or materials which previously
had been in contact with hazardous substances unless they are
properly cleaned. This is extremely dangerous.
DO NOT WELD OR CUT painted or plated parts unless special
precautions with ventilation have been taken. They can release
highly toxic fumes or gases.
Additional precautionary measures
PROTECT compressed gas cylinders from excessive heat,
mechanical shocks, and arcs; fasten cylinders so they cannot fall.
BE SURE cylinders are never grounded or part of an
electrical circuit.
REMOVE all potential fire hazards from welding area.
ALWAYS HAVE FIRE FIGHTING EQUIPMENT READY FOR
IMMEDIATE USE AND KNOW HOW TO USE IT.
Safety 01 of 04 - 06/15/2016
SAFETY
SECTION A:
WARNINGS
CALIFORNIA PROPOSITION 65 WARNINGS
Diesel Engines
Diesel engine exhaust and some of its constituents are known
to the State of California to cause cancer, birth defects, and other
reproductive harm.
Gasoline Engines
The engine exhaust from this product contains chemicals known
to the State of California to cause cancer, birth defects, or other
reproductive harm.
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 you purchase a copy of “Safety in Welding & Cutting ANSI Standard Z49.1” from the American Welding Society,
P.O. Box 351040, Miami, Florida 33135 or CSA Standard
W117.2-1974. A Free copy of “Arc Welding Safety” booklet
E205 is available from the Lincoln Electric Company,
22801 St. Clair Avenue, Cleveland, Ohio 44117-1199.
BE SURE THAT ALL INSTALLATION, OPERATION,
MAINTENANCE AND REPAIR PROCEDURES ARE
PERFORMED ONLY BY QUALIFIED INDIVIDUALS.
1.d. Keep all equipment safety guards, covers
and devices in position and in good repair.
Keep hands, hair, clothing and tools away
from V-belts, gears, fans and all other
moving parts when starting, operating or
repairing equipment.
1.e. In some cases it may be necessary to remove safety guards to
perform required maintenance. 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.
1.f. Do not put your hands near the engine fan. Do not attempt to
override the governor or idler by pushing on the throttle control
rods while the engine is running.
1.g. To prevent accidentally starting gasoline engines while turning
the engine or welding generator during maintenance work,
disconnect the spark plug wires, distributor cap or magneto wire
as appropriate.
1.h. To avoid scalding, do not remove the radiator
pressure cap when the engine is hot.
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 welding.
FOR ENGINE POWERED
EQUIPMENT.
1.a. Turn the engine off before troubleshooting
and maintenance work unless the
maintenance work requires it to be running.
1.b. Operate engines in open, well-ventilated
areas or vent the engine exhaust fumes outdoors.
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 before
refueling to prevent spilled fuel from
vaporizing on contact with hot engine parts
and igniting. Do not spill fuel when filling
tank. If fuel is spilled, wipe it up and do not start engine until
fumes have been eliminated.
2.c. Exposure to EMF fields in welding may have other health effects
which are now not known.
2.d. All welders should use the following procedures in order to
minimize exposure to EMF fields from the welding circuit:
2.d.1. Route the electrode and work cables together - Secure
them 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 and work
cables. If the electrode cable is on your right side, the
work cable should also be on your right side.
2.d.4. Connect the work cable to the workpiece as close as possible to the area being welded.
2.d.5. Do not work next to welding power source.
Safety 02 of 04 - 06/15/2016
SAFETY
ELECTRIC SHOCK
CAN KILL.
ARC RAYS CAN BURN.
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.
4.a.
Use a shield with the proper filter and cover plates to protect your
eyes from sparks and the rays of the arc when welding or
observing open arc welding. Headshield and filter lens should
conform to ANSI Z87. I standards.
3.b. Insulate yourself from work and ground using dry insulation.
Make certain the insulation is large enough to cover your full area
of physical contact with work and ground.
4.b.
Use suitable clothing made from durable flame-resistant material
to protect your skin and that of your helpers from the arc rays.
4.c.
Protect other nearby personnel with suitable, non-flammable
screening and/or warn them not to watch the arc nor expose
themselves to the arc rays or to hot spatter or metal.
In addition to the normal safety precautions, if
welding must be performed under electrically
hazardous conditions (in damp locations or while
wearing wet clothing; on metal structures such as
floors, gratings or scaffolds; when in cramped
positions such as sitting, kneeling or lying, if there
is a high risk of unavoidable or accidental contact
with the workpiece or ground) use the 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 semiautomatic welding
gun are also electrically “hot”.
3.d. Always be sure the work cable makes a good electrical
connection with the metal being welded. The connection should
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 and
welding machine in good, safe operating condition. Replace
damaged insulation.
3.g. Never dip the electrode in water for cooling.
3.h. Never simultaneously touch electrically “hot” parts of electrode
holders connected to two welders because voltage between the
two can be the total of the open circuit voltage of both
welders.
FUMES AND GASES
CAN BE DANGEROUS.
5.a. Welding may produce fumes and gases
hazardous to health. Avoid breathing these fumes and gases.
When welding, keep your head out of the fume. Use enough
ventilation and/or exhaust at the arc to keep fumes and gases
away from the breathing zone. When welding hardfacing
(see instructions on container or SDS) or on lead
or cadmium plated steel and other metals or
coatings which produce highly toxic fumes, keep
exposure as low as possible and within applicable
OSHA PEL and ACGIH TLV limits using local
exhaust or mechanical ventilation unless exposure
assessments indicate otherwise. In confined
spaces or in some circumstances, outdoors, a
respirator may also be required. Additional
precautions are also required when welding
on galvanized steel.
5. b. The operation of welding fume control equipment is affected by
various factors including proper use and positioning of the
equipment, maintenance of the equipment and the specific
welding procedure and application involved. Worker exposure
level should be checked upon installation and periodically
thereafter to be certain it is within applicable OSHA PEL and
ACGIH TLV limits.
3.i. When working above floor level, use a safety belt to protect
yourself from a fall should you get a shock.
5.c. Do not weld in locations near chlorinated hydrocarbon vapors
coming from degreasing, cleaning or spraying operations. The
heat and rays of the arc can react with solvent vapors to form
phosgene, a highly toxic gas, and other irritating products.
3.j. Also see Items 6.c. and 8.
5.d. Shielding gases used for arc welding can displace air and cause
injury or death. Always use enough ventilation, especially in
confined areas, to insure breathing air is safe.
5.e. Read and understand the manufacturer’s instructions for this
equipment and the consumables to be used, including the
Safety Data Sheet (SDS) and follow your employer’s safety
practices. SDS forms are available from your welding
distributor or from the manufacturer.
5.f. Also see item 1.b.
Safety 03 of 04 - 06/15/2016
SAFETY
WELDING AND CUTTING
SPARKS CAN CAUSE
FIRE OR EXPLOSION.
6.a. Remove fire hazards from the welding area. If
this is not possible, cover them to prevent the welding sparks
from starting a fire. Remember that welding sparks and hot
materials from welding can easily go through small cracks and
openings to adjacent areas. Avoid welding near hydraulic 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 hazardous situations.
Refer to “Safety in Welding and Cutting” (ANSI Standard Z49.1)
and the operating information for the equipment being used.
6.c. When not welding, make certain no part of the electrode circuit is
touching the work or ground. Accidental contact can cause
overheating and create a fire hazard.
6.d. Do not heat, cut or weld tanks, drums or containers until the
proper steps have been taken to insure that such procedures
will not cause flammable or toxic vapors from substances inside.
They can cause an explosion even though they have been
“cleaned”. For information, purchase “Recommended Safe
Practices for the Preparation for Welding and Cutting of
Containers and Piping That Have Held Hazardous Substances”,
AWS F4.1 from the American Welding Society
(see address above).
6.e. Vent hollow castings or containers before heating, cutting or
welding. They may explode.
6.f. Sparks and spatter are thrown from the welding arc. Wear oil free
protective garments such as leather gloves, heavy shirt, cuffless
trousers, high shoes and a cap over your hair. Wear ear plugs
when welding out of position or in confined places. Always wear
safety glasses with side shields when in a welding area.
6.g. Connect the work cable to the work as close to the welding area
as practical. Work cables connected to the building framework or
other locations away from the welding area increase the
possibility of the welding current passing through lifting chains,
crane cables or other alternate circuits. This can create fire
hazards or overheat lifting chains or cables until they fail.
6.h. Also see item 1.c.
6.I. Read and follow NFPA 51B “Standard for Fire Prevention During
Welding, Cutting and Other Hot Work”, available from NFPA, 1
Batterymarch Park, PO box 9101, Quincy, MA 022690-9101.
6.j. Do not use a welding power source for pipe thawing.
CYLINDER MAY EXPLODE IF
DAMAGED.
7.a. Use only compressed gas cylinders containing
the correct shielding gas for the process used
and properly operating regulators designed for
the gas and pressure used. All hoses, fittings,
etc. should be suitable for the application and
maintained in good condition.
7.b. Always keep cylinders in an upright position securely chained to
an undercarriage or fixed support.
7.c. Cylinders should be located:
•
Away from areas where they may be struck or subjected
to physical damage.
•
A safe distance from arc welding or cutting operations
and any other source of heat, sparks, or flame.
7.d. Never allow the electrode, electrode holder or any other
electrically “hot” parts to touch a cylinder.
7.e. Keep your head and face away from the cylinder valve outlet
when opening the cylinder valve.
7.f. Valve protection caps should always be in place and hand tight
except when the cylinder is in use or connected for use.
7.g. Read and follow the instructions on compressed gas cylinders,
associated equipment, and CGA publication P-l, “Precautions for
Safe Handling of Compressed Gases in Cylinders,” available from
the Compressed Gas Association, 14501 George Carter Way
Chantilly, VA 20151.
FOR ELECTRICALLY
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 U.S. National Electrical
Code, all local codes and the manufacturer’s recommendations.
8.c. Ground the equipment in accordance with the U.S. National
Electrical Code and the manufacturer’s recommendations.
Refer to
http://www.lincolnelectric.com/safety
for additional safety information.
Safety 04 of 04 - 06/15/2016
TABLE OF CONTENTS
Page
Installation ................................................................................................................................................Section A
Technical Specifications................................................................................................................................A-1
Safety Precautions...................................................................................................................................A-2
VRD (Voltage Reduction Device) ............................................................................................................A-2
Location and Ventilation........................................................................................................................A-2
Stacking ...............................................................................................................................................A-2
Angle of Operation ................................................................................................................................A-2
Lifting......................................................................................................................................................A-3
High Altitude Operation .........................................................................................................................A-3
High Temperature Operation .................................................................................................................A-3
Cold Weather Operation ...........................................................................................................................A-3
Towing..................................................................................................................................................A-3
Vehicle Mounting ..................................................................................................................................A-3
Pre-Operation Engine Service .......................................................................................................................A-4
Oil ........................................................................................................................................................A-4
Fuel ......................................................................................................................................................A-4
Engine Coolant .....................................................................................................................................A-4
Battery Connections .............................................................................................................................A-4
Muffler Outlet Pipe................................................................................................................................A-4
Spark Arrester ......................................................................................................................................A-4
Remote Control........................................................................................................................................A-4
Electrical Connections...................................................................................................................................A-5
Machine Grounding...............................................................................................................................A-5
Welding Terminals ................................................................................................................................A-5
Welding Output Cables.............................................................................................................................A-5
Cable Installation .....................................................................................................................................A-5
Auxiliary Power Receptacles .........................................................................................................................A-6
Standby Power Connections..........................................................................................................................A-6
Premises Wiring .............................................................................................................................................A-7
Connection of Lincoln Electric Wire Feeders.............................................................................................A-8, A-9
_________________________________________________________________________________________
Operation Section B
Safety Precautions .......................................................................................................................................B-1
General Description.......................................................................................................................................B-1
For Auxiliary Power .......................................................................................................................................B-1
Engine Operation............................................................................................................................................B-1
Add Fuel .......................................................................................................................................................B-1
Break in Period .............................................................................................................................................B-1
Welder Controls .....................................................................................................................................B-2, B-3
Engine Controls.............................................................................................................................................B-4
Starting the Engine ...............................................................................................................................B-4
Stopping the Engine..............................................................................................................................B-5
Welding Operation.........................................................................................................................................B-5
Duty Cycle and Electrode Information....................................................................................................B-5
Constant Current (Stick) Welding...........................................................................................................B-5
Fuel Consumption.................................................................................................................................B-5
Downhill Pipe (Stick) Welding................................................................................................................B-6
Tig Welding...........................................................................................................................................B-6
Typical Current Ranges for Tungsten Electrodes....................................................................................B-6
Wire Welding-CV...................................................................................................................................B-7
Arc Gouging..........................................................................................................................................B-7
Auxiliary Power .............................................................................................................................................B-7
Simultaneous Welding and Power Loads...............................................................................................B-7
Extension Cord Recommendations........................................................................................................B-7
_________________________________________________________________________________________
Accessories .............................................................................................................................Section C
Field Installed Options / Accessories .........................................................................................................C-1
_________________________________________________________________________________________
2
TABLE OF CONTENTS
Page
Maintenance ..............................................................................................................................Section D
Safety Precautions.......................................................................................................................D-1
Routine Maintenance ....................................................................................................................D-1
Engine Service Items ...................................................................................................................D-1
Engine Oil Change ........................................................................................................D-1, D-2
Engine Oil Filter Change .......................................................................................................D-2
Air Cleaner ...........................................................................................................................D-2
Service Instructions And Installation Tips for Engine Air Filter................................................D-3
Cooling System............................................................................................................................D-4
Fan Belt ...............................................................................................................................D-4
Fuel .....................................................................................................................................D-4
Bleeding the Fuel System.....................................................................................................D-4
Fuel Filter.............................................................................................................................D-5
Engine Adjustment ..................................................................................................................D-5
Battery Maintenance...............................................................................................................D-5
Servicing Optional Spark Arrestor ..........................................................................................D-5
Welder / Generator Maintenance................................................................................................D-6
Storage ................................................................................................................................D-6
Cleaning...............................................................................................................................D-6
Brush Removal and Replacement.........................................................................................D-6
GFCI Testing and Resetting Procedure ..................................................................................D-6
________________________________________________________________________________
Troubleshooting.......................................................................................................................Section E
How to Use Troubleshooting Guide ...............................................................................................E-1
Troubleshooting Guide ....................................................................................................E-2 thru E-6
________________________________________________________________________________
Connection Diagrams, Wiring Diagrams and Dimension Print ..............................................Section F
________________________________________________________________________________
Parts List............................................[email protected]lincolnelectric.com
________________________________________________________________________________
3
GENERAL DESCRIPTION
VANTAGE® 300
General Description
The VANTAGE® 300 is a diesel engine powered DC multi-process
welding power source and 120 / 240 volt AC power generator. The
engine drives a generator that supplies three phase power for the
DC welding circuit, single phase and Three Phase power for the AC
auxiliary outlets. The DC welding control system uses state of the
art Chopper Technology (CT™) for superior welding performance.
The VANTAGE® 300 is fitted with a selectable VRD(Voltage
Reduction Device). The VRD operates in the CC-Stick mode
reducing the OCV to <13 volts, increasing operator safety when
welding is performed in environments with increased hazard of
electric shock such as wet areas and hot, humid sweaty
conditions.
4
VANTAGE® 300
INSTALLATION
TECHNICAL
SPECIFICATIONS
VantaGe® 300 (K2409-3, K2409-4,)
INPUT - DIESEL ENGINE
Make /Model
Description
Kubota*
V1505
4 Cylinder
naturally
aspirated
Water Cooled
Diesel Engine
Speed (RPM)
Displacement
High
1890 RPM
Full Load
1800 RPM
Low Idle
1350 RPM
91.41cu. in. (1.5ltr)
Bore x Stroke
3.07” x 3.09”
(78mm x 78mm)
Starting System
Capacities
ENGINE
FUEL SYSTEM
Mechanical Fuel Pump, Auto air bleed system
Electric shutoff solenoid Indirect fuel injector
AIR CLEANER
Single Element
MACHINE SPECIFICATIONS
RECEPTACLES
(2) 120VAC Duplex (5-20R)
GFCI Protected
(1) 120/240VAC Dual Voltage
Full KVA (14-50R)
(1) 240VAC 3-Phase (15-50R)
RATED OUTPUT @ 104°F(40°C) - WELDER
Welding Process
Welding Output
Output Range
Current/Voltage/Duty Cycle
300A / 32V / 100%
30 TO 400 AMPS
DC Constant Current
350A / 28V / 100%
DC Constant Voltage
Arc Gouging
300A / 32V / 100%
250A / 30V / 100%
300A / 32V / 100%
350A / 28V / 100%
300A / 32V / 100%
OUTPUT @ 104°F(40°C) - WELDER
GOVERNOR
Mechanical
Electronic
ENGINE IDLER
Automatic Idler
ENGINE PROTECTION
MUFFLER
Shutdown on low oil
Low noise Muffler:
pressure & high engine
Top outlet can be rotated
coolant temperature
Made from long life, aluminized steel.
ENGINE WARRANTY*:
2 year complete (parts and labor)
3rd. year major components (parts and labor)
12VDC Battery and starter
Fuel: 20gal.(75.7L)
(Group 34; Battery 535 cold
Oil: 6.4qts.(6.0L)
crank amps) Battery Charger Radiator Coolant:7.2qts.(6.8L)
DC Pipe Current
Touch-Start™TIG
EPA EMISSION
K2409-3
Tier 4 Interim
K2409-4
Tier 4 Final
LUBRICATION
Full Pressure
with Full Flow Filter
40 TO 300 AMPS
20 TO 250 AMPS
AUXILIARY POWER CIRCUIT BREAKER
Two 20AMP for Two Duplex Receptacle
(1) 50Amp for Dual Voltage and 3-Phase (3-pole)
OTHER CIRCUIT BREAKERS
14 TO 32 VOLTS
90 to 300 AMPS
10AMP for Engine Battery
Charging Circuit
10AMP for 42V Wire Feeder Power
Welding Range
30 - 600 Amps CC/CV
20 - 350 Amps TIG
Height
Open Circuit Voltage(2)
60 Max OCV @ 1800 RPM
Auxiliary Power (1)
11,500 Watts Peak, / 10,000 Watts Continuous,
60 Hz 120/240 Volts Single Phase
12,500 Watts Peak, /11,000 Watts Continuous,
60 Hz, 240 Volts 3-Phase
PHYSICAL DIMENSIONS
35.94** in. (913 mm)
Width
25.30 in. (643 mm
Depth
60.00 in. (1524 mm)
Weight
1035 lbs. (469kg.) (Approx.)
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.
* Engine warranty may vary outside of the USA. (See Engine warranty for details).
** To Top of enclosure, add 7.88”(200.2mm) to top of exhaust pipe. Add 4.012”(101.9mm) to top of Lift Bail.
(2)
Reduced to less than 30V in the stick mode when VRD (Voltage Reduction Device) is on.
(1)
Equipped with VRD (VOLTAGE REDUCTION DEVICE)
See Installation and Operation sections for an explanation.
A-1
VANTAGE® 300
INSTALLATION
FIGURE A.1
INSTALLATION
(VRD)-VOLTAGE REDUCTION DEVICE
SWITCH IS LOCATED IN THIS AREA.
SAFETY PRECAUTIONS
WARNING
Do not attempt to use this equipment until you have
thoroughly read the engine manufacturer’s manual supplied
with your welder. It includes important safety precautions,
detailed engine starting, operating and maintenance
instructions, and parts lists.
ELECTRIC SHOCK can kill.
•
Do not touch electrically live parts or
electrode with skin or wet clothing.
•
Insulate yourself from work and ground
•
Always wear dry insulating gloves.
REMOVE 4 FRONT PANEL
SCREWS TO ACCESS
(VRD) SWITCH
ENGINE EXHAUST can kill.
•
Use in open, well ventilated areas or vent
exhaust outside.
location anD Ventilation
The welder should be located to provide an unrestricted flow of
clean, cool air to the cooling air inlets and to avoid restricting the
cooling air outlets. Also, locate the welder so that the engine
exhaust fumes are properly vented to an outside area.
MOVING PARTS can injure.
•
Do not operate with doors open or
guards off.
•
Stop engine before servicing.
•
Keep away from moving parts.
stacKinG
VANTAGE® 300 machines cannot be stacked.
See additional warning information at front of
this operator’s manual.
Only qualified personnel should install, use, or
service this equipment.
VrD (VoltaGe reDUction DeVice)
The VRD feature provides additional safety in the CC-Stick mode
especially in an environment with a higher risk of electric shock
such as wet areas and hot humid sweaty conditions.
The VRD reduces the OCV (Open Circuit Voltage) at the welding
output terminals while not welding to less than 13V DC when the
resistance of the output circuit is above 200Ω (ohms).
The VRD requires that the welding cable connections be kept in
good electrical condition because poor connections will contribute
to poor starting. Having good electrical connections also limits the
possibility of other safety issues such as heat-generated damage,
burns and fires.
The machine is shipped with the VRD switch in the “Off” position.
To turn it “On” or “Off”.
• Turn the engine “Off”.
• Disconnect the negative battery cable.
• Lower the control panel by removing 4 front panel screws.
(See Figure A.1)
• Place the VRD switch in the “On” or “Off” position. (See Figure
A.1)
anGle oF operation
Engines are designed to run in the level condition which is where
the optimum performance is achieved. The maximum angle of
continuous operation is 20 degrees in all directions, 30 degrees
Intermittent (less than 10 minutes continuous) in all directions. If
the engine is to be operated at an angle, provisions must be made
for checking and maintaining the oil level at the normal (FULL) oil
capacity in the crankcase.
When operating the welder at an angle, the effective fuel capacity
will be slightly less than the amount specified.
With the VRD switch in the “On” position, the VRD lights are enabled.
A-2
VANTAGE® 300
INSTALLATION
liFtinG
The VANTAGE® 300 weighs approximately 1190 lbs. (540kg.) with
a full tank of fuel (1035 lbs. (470kg.) less fuel). A lift bail is
mounted to the machine and should always be used when lifting
the machine.
WARNING
FALLING EQUIPMENT can cause
injury.
•
Lift only with equipment of adequate
lifting capacity.
•
Be sure machine is stable when lifting.
•
Do not lift this machine using lift bail if it
is equipped with a heavy accessory such as trailer or
gas cylinder.
•
Do not lift machine if lift bail is damaged.
•
Do not operate machine while suspended from lift bail.
towinG
Use a recommended trailer for use with this equipment for road,
in-plant and yard towing by a vehicle(1). If the user adapts a nonLincoln trailer, he must assume responsibility that the method of
attachment and usage does not result in a safety hazard or
damage the welding equipment. Some of the factors to be
considered are as follows:
1. Design capacity of trailer vs. weight of Lincoln equipment and
likely additional attachments.
2. Proper support of, and attachment to, the base of the welding
equipment so there will be no undue stress to the framework.
3. Proper placement of the equipment on the trailer to insure
stability side to side and front to back when being moved and
when standing by itself while being operated or serviced.
4. Typical conditions of use, i.e., travel speed; roughness of
surface on which the trailer will be operated; environmental
conditions; like maintenance.
5. Conformance with federal, state and local laws.(1)
(1) Consult applicable federal, state and local laws regarding specific requirements for use on public highways.
HiGH altitUDe operation
At higher altitudes, output derating may be necessary. For
maximum rating, derate the machine 2.5% to 3.5% for every
1000 ft. (305m). Due to new EPA and other local emissions
regulations, modifications to the engine for high altitude are
restricted within the United States. For use above 6000 ft.(1828
m) an authorized engine field service shop should be contacted to
determine if any adjustments can be made for operation in higher
elevations.
VeHicle MoUntinG
WARNING
Improperly mounted concentrated loads may cause
unstable vehicle handling and tires or other components to
fail.
• Only transport this Equipment on serviceable vehicles
which are rated and designed for such loads.
• Distribute, balance and secure loads so vehicle is stable
under conditions of use.
HiGH teMperatUre operation
At temperatures above 104°F (40°C), Welder output derating is
necessary. For maximum output ratings, derate the welder output
2 volts for every 18°F (10°C) above 104°F (40°C).
• Do not exceed maximum rated loads for components
such as suspension, axles and tires.
• Mount equipment base to metal bed or frame of vehicle.
• Follow vehicle manufacturer’s instructions.
colD weatHer startinG:
With a fully charged battery and the proper oil, the engine should
start satisfactorily down to 5°F (-15°C). If the engine must be
frequently started at or below 23°F (-5°C), it may be desirable to
install cold-starting aides. The use of No. 1D diesel fuel is
recommended in place of No. 2D at temperatures below 23°F (5°C). Allow the engine to warm up before applying a load or
switching to high idle.
Note: Extreme cold weather starting may require longer glow plug
operation.
WARNING
Under no conditions should ether or other starting fluids be
used with this engine!
A-3
VANTAGE® 300
INSTALLATION
pre-operation enGine serVice
READ the engine operating and maintenance instructions supplied
with this machine.
enGine coolinG sYsteM
Air to cool the engine is drawn in the side and exhausted
through radiator & case back. It is important that the intake
and exhaust air is not restricted. Allow a minimum clearance
of 1ft. (0.6m) from the case back and 16in.(406mm) from
either side of the base to a vertical surface.
WARNING
• Stop engine and allow to cool before fueling
• Do not smoke when fueling.
• Fill fuel tank at a moderate rate and do not overfill.
BatterY connection
• Wipe up spilled fuel and allow fumes to clear before
starting engine.
CAUTION
• Keep sparks and flame away from tank.
Use caution as the electrolyte is a strong acid that can burn
skin and damage eyes.
oil
The VANTAGE® 300 is shipped with the engine crankcase filled
with high quality SAE 10W-30 Oil that meets classification CG-4 or
CH-4 for diesel engines. Check the oil level before starting the
engine. If it is not up to the full mark on the dip stick, add oil as
required. Check the oil level every four hours of running time
during the first 50 running hours. Refer to the engine Operator’s
Manual for specific oil recommendations and break-in
information. The oil change interval is dependent on the quality of
the oil and the operating environment. Refer to the Engine
Operator’s Manual for more details on the proper service and
maintenance intervals.
FUel
DIESEL FUEL ONLY- Low sulphur fuel or ultra low
sulphur fuel in U.S.A. and Canada.
WARNING
Fill the fuel tank with clean, fresh fuel. The capacity of the
tank is 20 gals. (75.7 ltrs). When the fuel gauge reads empty
the tank contains approximately 2 gals. (7.6ltrs.) of reserve
fuel.
The VANTAGE® 300 is shipped with the negative battery cable
disconnected. Make certain that the RUN-STOP switch is in the
STOP position. Remove the two screws from the battery tray using
a screwdriver or a 3/8" socket. Attach the negative battery cable
to the negative battery terminal and tighten using a 1/2" socket or
wrench.
NOTE: This machine is furnished with a wet charged battery; if
unused for several months, the battery may require a booster
charge. Be careful to charge the battery with the correct polarity.
(See Battery in “Maintenance Section”)
MUFFler oUtlet pipe
Using the clamp provided secure the outlet pipe to the outlet tube
with the pipe positioned such that it will direct the exhaust in the
desired direction. Tighten using a 9/16" socket or wrench.
sparK arrester
Some federal, state or local laws may require that gasoline or
diesel engines be equipped with exhaust spark arresters when
they are operated in certain locations where unarrested sparks
may present a fire hazard. The standard muffler included with this
welder does not qualify as a spark arrester. When required by local
regulations, a suitable spark arrester, such as the K1898-1 must
be installed and properly maintained.
NOTE: The fuel shut off valve should be in the closed position
when the welder is not used for extended periods of
time.
----------------------------------------------------------------------------
WARNING
An incorrect spark arrestor may lead to damage to the
engine or adversely affect performance.
A-4
VANTAGE® 300
INSTALLATION
reMote control
The VANTAGE® 300 is equipped with a 6-pin and a 14-pin
connector. When in the Arc Gouging or CV-WIRE modes and when
a remote control is connected to the 6-pin Connector, the autosensing circuit automatically switches the OUTPUT control from
control at the welder to remote control.
When in TOUCH START TIG mode and when a Amptrol is
connected to the 6-Pin Connector, the OUTPUT dial is used to set
the maximum current range of the CURRENT CONTROL of the
Amptrol.
When in the CC-STICK or DOWNHILL PIPE mode and when a
remote control is connected to the 6-Pin or 14-Pin connector, the
output control is used to set the maximum current range of the
remote.
EXAMPLE: When the OUTPUT CONTROL on the welder is set to
200 amps the current range on the remote control will be Min.200 amps, rather than the full Min.-Max. amps. Any current range
that is less than the full range provides finer current resolution for
more fine tuning of the output.
The 14-pin connector is used to directly connect a wire feeder
control cable. In the CV-WIRE mode, if the feeder being used has a
voltage control when the wire feeder control cable is connected to
the 14-Pin Connector, the auto-sensing circuit automatically
makes OUTPUT CONTROL inactive and the wire feeder voltage
control active. Otherwise, the OUTPUT CONTROL is used to preset
the voltage.
In general, if the machine is to be grounded, it should be
connected with a #8 or larger copper wire to a solid earth ground
such as a metal water pipe going into the ground for at least ten
feet and having no insulated joints, or to the metal framework of a
building which has been effectively grounded.
The National Electrical Code lists a number of alternate means of
grounding electrical equipment. A machine grounding stud marked
with the symbol
is provided on the front of the welder.
Welding TERMINALS
The VANTAGE® 300 is equipped with a toggle switch for selecting
"hot" welding terminal when in the "WELD TERMINALS ON"
position or "cold" welding terminal when in the "REMOTELY
CONTROLLED" position.
Welding OUTPUT Cables
With the engine off connect the electrode and work cables to the
output studs. The welding process dictates the polarity of the
electrode cable. These connections should be checked periodically
and tightened with a 3/4" wrench.
Table A.1 lists recommended cable sizes and lengths for rated
current and duty cycle. Length refers to the distance from the
welder to the work and back to the welder. Cable diameters are
increased for long cable lengths to reduce voltage drops.
TABLE A.1
WARNING
NOTE: When a wire feeder with a built in welding voltage
control is connected to the 14-pin connector, do not
connect anything to the 6-pin connector.
TOTAL COMBINED LENGTH OF
ELECTRODE AND WORK CABLES
Cable Length
electrical connections
Machine Grounding
0-100 Ft. (0-30 meters)
Because this portable engine driven welder creates its own power,
it is not necessary to connect its frame to an earth ground, unless
the machine is connected to premises wiring (home, shop, etc.)
WARNING
To prevent dangerous electric shock, other
equipment to which this engine driven welder
supplies power must:
•
Be grounded to the frame of the welder using a
grounded type plug.
•
Be double insulated.
•
Do not ground the machine to a pipe that carries
explosive or combustible material.
When this welder is mounted on a truck or trailer, its frame must
be electrically bonded to the metal frame of the vehicle. Use a #8
or larger copper wire connected between the machine grounding
stud and the frame of the vehicle. When this engine driven welder
is connected to premises wiring such as that in a home or shop,
its frame must be connected to the system earth ground. See
further connection instructions in the section entitled "Standby
Power Connections" as well as the article on grounding in the
latest National Electrical Code and the local code.
A-5
Cable Size for
400 Amps
60% Duty Cycle
2 / 0 AWG
100-150 Ft. (30-46 meters)
2 / 0 AWG
150-200 Ft. (46-61 meters)
3 / 0 AWG
VANTAGE® 300
INSTALLATION
Cable Installation
system must be at least equal to the current capacity of the
associated receptacle.
NOTE: The 240 V receptacle has two 120 V circuits, but are of
opposite polarities and cannot be paralleled.
All auxiliary power is protected by circuit breakers. The 120V has
20 Amp circuit breakers for each duplex receptacle. The 120/240V
Single Phase and the 240V Three-Phases have a 50 Amp 3-pole
Circuit Breaker that disconnects both hot leads and all Three
Phases simultaneously.
Install the welding cables to your VANTAGE® 300 as follows.
1. The engine must be OFF to install welding cables.
2. Remove the flanged nuts from the output terminals
3. Connect the electrode holder and work cables to the weld output terminals. The terminals are identified on the case front.
4. Tighten the flanged nuts securely.
5. Be certain that the metal piece you are welding (the “work”) is
properly connected to the work clamp and cable.
6. Check and tighten the connections periodically.
STANDBY POWER CONNECTIONS
The VANTAGE® 300 is suitable for temporary, standby or
emergency power using the engine manufacturer’s recommended
•
Loose connections will cause the output terminals to
maintenance schedule.
overheat. The terminals may eventually melt.
The VANTAGE® 300 can be permanently installed as a standby
•
Do not cross the welding cables at the output terminal
power unit for 240 VAC, 3 wire, single phase, 40 amp service.
connection. Keep the cables isolated and separate from Connections must be made by a licensed electrician who can
one another.
determine how the 120/240 VAC power can be adapted to the
particular installation and comply with all applicable electrical
codes.
• Install the double-pole, double-throw switch between the
power company meter and the premises disconnect. Switch
AUXILIARY POWER RECEPTACLES
rating must be the same or greater than the customer’s
Start the engine and set the “IDLER” control switch to the “High
premises disconnect and service over current protection.
Idle” mode. Voltage is now correct at the receptacles for auxiliary
• Take necessary steps to assure load is limited to the capacity
power. This must be done before a tripped GFCI can be reset
of the generator by installing a 50 amp, 240 VAC double pole
properly. See the MAINTENANCE section for more detailed
circuit breaker. Maximum rated load for each leg of the 240
information on testing and resetting the GFCI.
VAC auxiliary is 50 amperes. Loading above the rated output
The auxiliary power of the VANTAGE® 300 consists of two 20
will reduce output voltage below the allowable - 10% of rated
Amp-120 VAC (5-20R) duplex receptacles with GFCI protection,
voltage which may damage appliances or other motor-driven
one 50 Amp 120/240 VAC (14-50R) receptacle and one 50 Amp
equipment and may result in overheating of the engine and/or
240VAC Three-Phase (15-50R) receptacle.
alternator windings.
The auxiliary power capacity is 11,500 watts Peak, 10,000 Watts
• Install a 50 amp, 120/240 VAC plug (NEMA Type 14-50) to the
Continuous of 60 Hz, single phase power. The auxiliary power
double-pole circuit breaker using No. 6, 4 conductor cable of
capacity rating in watts is equivalent to volt-amperes at unity
the desired length. (The 50 amp, 120/240 VAC plug is
power factor. The max permissible current of the 240 VAC output
available in the optional K802R plug kit or as part number
is 42amps.
T12153-9.)
The 240 VAC output can be split to provide two separate 120 VAC
• Plug this cable into the 50 Amp, 120/240 Volt receptacle on
outputs with a max permissible current of 42 Amps per output to
the case front.
two separate 120 VAC branch circuits (these circuits cannot be
paralleled). Output voltage is within ± 10% at all loads up to rated
capacity.
The Three-Phases auxiliary power capacity is 12,500 watts peak,
11,000 watts continuous. The maximum current is 27 amps.
CAUTION
120 V Duplex Receptacles and GFCI
A GFCI protects the two 120V auxiliary power receptacles.
A GFCI (Ground Fault Circuit Interrupter) is a device to protect
against electric shock should a piece of defective equipment
connected to it develop a ground fault. If this situation should
occur, the GFCI will trip, removing voltage from the output of the
receptacle. If a GFCI is tripped see the MAINTENANCE section for
detailed information on testing and resetting it. A GFCI should be
properly tested at least once every month.
The 120 V auxiliary power receptacles should only be used with
three wire grounded type plugs or approved double insulated tools
with two wire plugs. The current rating of any plug used with the
A-6
VANTAGE® 300
INSTALLATION
connection oF VantaGe® 300 to preMises
wirinG
240 VOLT
GROUNDED CONDUCTOR
POWER
240 Volt
60 Hz.
3-Wire
Service
120 VOLT
COMPANY
120 VOLT
METER
NEUTRAL
BUS
N
LOAD
DOUBLE POLE DOUBLE THROW
SWITCH RATING TO BE THE SAME
AS OR GREATER THAN PREMISES
SERVICE OVERCURRENT
PROTECTION.
GROUND
50AMP
240 VOLT
50 AMP, 120/240
VOLT PLUG
NEMA TYPE 14-50
PREMISES
DISCONNECT AND
SERVICE
OVERCURRENT
PROTECTION
DOUBLE
POLE
CIRCUIT
BREAKER
240 VOLT
GND
N
50 AMP, 120/240 VOLT
RECEPTACLE
NOTE: No. 6 COPPER CONDUCTOR CABLE SEE
NATIONAL ELECTRICAL CODE FOR ALTERNATE WIRE
SIZE RECOMMENDATIONS.
WARNING
•
Only a licensed, certified, trained electrician should
install the machine to a premises or residential
electrical system. Be certain that:
•
The installation complies with the National Electrical
Code and all other applicable electrical codes.
•
The premises is isolated and no feedback into the utility
system can occur. Certain state and local laws require
the premises to be isolated before the generator is
linked to the premises. Check your state and local
requirements.
•
A double pole, double throw transfer switch in
conjunction with the properly rated double throw circuit
breaker is connected between the generator power and
the utility meter.
A-7
VANTAGE® 300
INSTALLATION
FIGURE A.2
connection oF lincoln electric
wire FeeDers
CONNECTION OF ACROSS THE ARC WIRE FEEDERS
TO THE VANTAGE 300
®
These connections instructions apply to both the LN-25 Pro and
Activ8 models. The feeders have an internal contactor and the
electrode is not energized until the gun trigger is closed. When the
gun trigger is closed the wire will begin to feed and the welding
process is started.
• Shut the welder off.
• For electrode Positive, connect the electrode cable to the "+"
terminal of the welder and work cable to the "-" terminal of the
welder. For electrode Negative, connect the electrode cable "-"
terminal of the welder and work cable to the "+" terminal of the
welder.
• Attach the single lead from the front of the feeder to work using
the spring clip at the end of the lead. This is a control lead to
supply current to the wire feeder motor; it does not carry welding current (See Figure A.8).
• Set the MODE switch to the "CV-WIRE" position (See Figure A.7).
• Set the "WELD TERMINALS" switch to "WELD TERMINALS ON"
• Set the "ARC CONTROL" knob to "0" initially and adjust to suit.
• Set the “REMOTE/LOCAL” switch to “LOCAL” control.
FIGURE A.3
A-8
Set Mode to
CV Wire
Weld
Terminals On
Set to Local
VANTAGE® 300
OPERATION
OPERATION
aDD FUel
SAFETY PRECAUTIONS
WARNING
WARNING
Do not attempt to use this equipment until you have
thoroughly read the engine manufacturer’s manual supplied
with your welder. It includes important safety precautions,
detailed engine starting, operating and maintenance
instructions, and parts lists.
ELECTRIC SHOCK can kill.
•
Do not touch electrically live parts or
electrode with skin or wet clothing.
•
Insulate yourself from work and ground
•
Always wear dry insulating gloves.
•
Always operate the welder with the hinged door closed
and the side panels in place.
•
Read carefully the Safety Precautions page before
operating this machine. Always follow these and any
other safety procedures included in this manual and in
the Engine Instruction Manual.
----------------------------------------------------------------For aUxiliarY power:
Start the engine and set the IDLER control switch to the desired
operating mode. Full power is available regardless of the welding
control settings providing no welding
current is being drawn.
enGine operation
Before Starting the Engine:
• Be sure the machine is on a level surface.
• Open side engine door and remove the engine oil dipstick and
wipe it with a clean cloth.
• Reinsert the dipstick and check the level on the dipstick.
• Add oil (if necessary) to bring the level up to the full mark. Do
not overfill. Close engine door.
• Check radiator for proper coolant level. (Fill if necessary).
• See Engine Owner’s Manual for specific oil and coolant
recommendations.
DIESEL FUEL can cause fire.
• 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 tank, fuel expansion may cause overflow.
DIESEL FUEL ONLY-Low sulphur fuel or ultra low sulphur
fuel in U.S.A. and Canada.
-------------------------------------------------------------------• Remove the fuel tank cap.
• Fill the tank. DO NOT FILL THE TANK TO THE POINT OF
OVERFLOW.
• Replace the fuel cap and tighten securely.
• See Engine Owner’s Manual for specific fuel recommendations.
BreaK-in perioD
The engine will use a small amount of oil during its “break-in”
period. The break-in period is about 50 running hours. Check the
oil every four hours during break-in.
CAUTION
During break-in, subject the Welder to moderate loads.
Avoid long periods running at idle. Before stopping the
engine, remove all loads and allow the engine to cool
several minutes.
B-1
VANTAGE® 300
welDinG controls (FiGUre B.1)
OPERATION
FIGURE B.1
1
11
2
9
3
10
4
14
13
15
12
17
8
22
7
23
16
21
20
18
19
5
1. OUTPUT CONTROL- The OUTPUT dial is used to preset the
output voltage or current as displayed on the digital meters for
the five welding modes. When in the Arc Gouging or CV-WIRE
modes and when a remote control is connected to the 6-Pin or
14-Pin Connector, the auto-sensing circuit automatically
switches the OUTPUT CONTROL from control at the welder to
the remote control.
When in the CC-STICK or DOWNHILL PIPE mode and when a
remote control is connected to the 6-Pin or 14-Pin
connector, the output control is used to set the maximum
current range of the remote.
EXAMPLE: When the OUTPUT CONTROL on the welder is set to
200 amps the current range on the remote control will be Min.200 amps, rather than the full Min.-Max. amps. Any current
range that is less than the full range provides finer current
resolution for more fine tuning of the output.
In the CV-WIRE mode, if the feeder being used has a voltage
control when the wire feeder control cable is connected to the
14-Pin Connector, the auto-sensing circuit automatically makes
OUTPUT CONTROL inactive and the wire feeder voltage control
active. Otherwise, the OUTPUT CONTROL is used to preset the
voltage.
When in the TOUCH START TIG mode and when an Amptrol is
connected to the 6-Pin Connector, the OUTPUT dial is used to
set the maximum current range of the CURRENT CONTROL of
the Amptrol.
6
2. DIGITAL OUTPUT METERS-The digital meters allow the
output voltage (CV-WIRE mode) or current (CC-STICK,DOWN
HILL PIPE and TIG modes) to be set prior to welding using the
OUTPUT control dial. During welding, the meter display the
actual output voltage (VOLTS) and current (AMPS). A memory
feature holds the display of both meters on for seven seconds
after welding is stopped. This allows the operator to read the
actual current and voltage just prior to when welding was
ceased.
While the display is being held the left-most decimal point in
each display will be flashing. The accuracy of the meters is
+/- 3%.
3. WELD MODE SELECTOR SWITCH(Provides Five selectable welding modes)
CV-WIRE
Arc Gouging
DOWNHILL PIPE
CC-STICK
TOUCH START TIG
B-2
VANTAGE® 300
OPERATION
4. ARC CONTROL- The ARC CONTROL dial is active in the CVWIRE, CC-STICK and DOWNHILL PIPE modes, and has
different functions in these modes. This control is not active in
the TIG mode.
CC-STICK mode: In this mode, the ARC CONTROL dial sets the
short circuit current (arc-force) during stick welding to adjust
for a soft or crisp arc. Increasing the dial from –10 (soft) to
+10 (crisp) increases the short circuit current and prevents
sticking of the electrode to the plate while welding. This can
also increase spatter. It is recommended that the ARC
CONTROL be set to the minimum number without electrode
sticking. Start with a setting at 0.
DOWNHILL PIPE mode: In this mode, the ARC CONTROL dial
sets the short circuit current (arc-force) during stick welding
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 more
forceful digging arc. Typically a forceful digging arc is
preferred for root and hot passes. A softer arc is preferred for
fill and cap passes where weld puddle control and deposition
("stacking" of iron) are key to fast travel speeds. It is
recommended that the ARC CONTROL be set initially at 0.
CV-WIRE mode: In this mode, turning the ARC CONTROL clock
wise from –10 (soft) to +10 (crisp) changes the arc from soft
and washed-in to crisp and narrow. It acts as an
inductance/pinch control. The proper setting depends on the
procedure and operator preference. Start with a setting of 0.
5. WELD OUTPUT TERMINALS WITH FLANGE NUT- Provides a
connection point for the electrode and work cables.
6. GROUND STUDProvides a connection point for
connecting the machine case to earth ground.
7. 14-PIN CONNECTOR- For attaching wire feeder control cables.
Includes contactor closure circuit, auto-sensing remote
control circuit, and 120V and 42V power. The remote control
circuit operates the same as the 6 Pin Amphenol.
8. 6-PIN CONNECTOR- For attaching optional remote control
equipment. Includes auto-sensing remote control circuit.
9. WELD TERMINALS CONTROL SWITCH- In the WELD
TERMINALS ON position, the output is electrically hot all the
time. In the REMOTELY CONTROLLED position, the output is
controlled by a wire feeder or amptrol device, and is
electrically off until a remote switch is depressed.
10. WIRE FEEDER VOLTMETER SWITCH: Matches the polarity of
the wire feeder voltmeter to the polarity of the electrode.
11. VRD (Voltage Reduction Device) INDICATOR LIGHTS- On the
front panel of the Vantage 300 are two indicator lights. A red
light when lit indicates OCV(Open Circuit Voltage) is equal to
or greater than 30V and a green light when lit indicates
OCV(Open Circuit Voltage) is less than 30V.
The VRD “On/Off” switch inside the control panel must be
“On” for the VRD function to be active and the lights to be
enabled. When the machine is first started with VRD enabled,
both lights will illuminate for 5 seconds.
These lights monitor the OCV(Open Circuit Voltage) and weld
voltage at all times. In the CC-Stick mode when not welding
the green light will illuminate indicating that the VRD has
reduced the OCV to less than 30V. During welding the red
light will illuminate whenever the arc voltage is equal to or
greater than 30V. This means that the red and green light may
alternate depending on the weld voltage. This is normal
operation.
If the red light remains illuminated when not welding in the
CC-stick mode, the VRD is not functioning properly. Please
refer to your local field service shop for service.
If the VRD is turned “On” and the lights don’t come “On”, refer
to the trouble shooting section.
TABLE B.1
MODE
CC-STICK
CV-WIRE
PIPE
ARC GOUGING
TIG
OCV
While
Welding
OCV
While
Welding
OCV
While
Welding
OCV
While
Welding
OCV
While
Welding
VRD INDICATOR LIGHTS
VRD "ON"
Green (OCV Reduced)
Red or Green
(Depends on Weld Voltage) *
Red (OCV Not Reduced)
Weld Terminals On
Red (OCV Not Reduced)
Weld Terminals Remotely Controlled
Gun Trigger Closed
Green (No OCV)
Weld Terminals Remotely Controlled
Gun Trigger Open
Red or Green
(Depends on Weld Voltage) *
Green (No Output)
Not Applicable (No Output)
VRD "OFF"
No Lights
Green (No Output)
Not Applicable (No Output)
Green (Process is Low Voltage)
Green (Process is Low Voltage)
* It is normal for the lights to alternate between colors while welding.
B-3
VANTAGE® 300
OPERATION
enGine controls:
12. RUN/STOP SWITCH - RUN position energizes the engine prior
to starting. STOP position stops the engine. The oil pressure
interlock switch prevents battery drain if the switch is left in
the RUN position and the engine is not operating.
13. GLOW PLUG PUSH BUTTON - When pushed activates
the glow plugs. Glow plug should not be activated for more
than 20 seconds continuously.
14. START PUSH BUTTON - Energizes the starter motor to crank
the engine.
15. IDLER SWITCH- Has two positions as follows:
1) In the HIGH
position, the engine runs at the high idle
speed controlled by the engine governor.
2) In the AUTO
position, the idler operates as
follows:
• When switched from HIGH to AUTO or after starting the
engine, the engine will operate at full speed for approximately 12 seconds and then go to low idle speed.
• When the electrode touches the work or power is drawn for
lights or tools (approximately 100 Watts minimum), the
engine accelerates and operates at full speed.
• When welding ceases or the AC power load is turned off, a
fixed time delay of approximately 12 seconds starts. If the
welding or AC power load is not restarted before the end of
the time delay, the idler reduces the engine speed to low
idle speed.
• The engine will automatically return to high idle speed when
there is welding load or AC power load reapplied.
16. ELECTRIC FUEL GAUGE- The electric fuel gauge gives accurate
and reliable indication as to how much fuel is in the fuel tank.
17. ENGINE HOUR METER- Displays the total time that the engine
has been running. This meter is useful for scheduling
prescribed maintenance.
18. ENGINE PROTECTION LIGHT- A warning indicator light for Low
Oil Pressure and/or Coolant Over Temperature.The light is off
when the systems are functioning properly. The light will
come on and the engine will shutdown when there is Low Oil
Pressure and/or the Coolant is Over Temperature.
Note: The light remains off when the RUN-STOP switch is in
the "ON" position prior to starting the engine.However if the
engine is not started within 60 seconds the light will come on.
When this happens the RUN-STOP switch must be returned to
the "OFF" position to reset the engine protection system and
light.
20. COOLANT TEMPERATURE GAUGE-A indicator of engine coolant
temperature.
21. OIL PRESSURE GAUGE- A indicator of engine Oil Pressure.
22. CIRCUIT BREAKER- For protection of Battery Charging Circuit.
23. CIRCUIT BREAKER- For protection of 42V Wire Feeder circuit.
startinG tHe enGine
1. Remove all plugs connected to the AC power receptacles.
2. Set IDLER switch to AUTO.
3. Press Glow Plug Button and hold 15 to 20 seconds.
4. Set the RUN/STOP switch to RUN.
5. Press START button until the engine starts or for up to 10
seconds. Continue to hold the glow plug button for up to an
additional 10 seconds.
6. Release the engine START button immediately when the engine
starts.
7. The engine will run at high idle speed for approximately 12
seconds and then drop to low idle speed. Allow the engine to
warm up at low idle for several minutes before applying a
load and/or switching to high idle. Allow a longer warm up
time in cold weather.
NOTE: If the unit fails to start turn run/stop switch to off and
repeat step 3 through step 7 after waiting 30 seconds.
CAUTION
•
Do not allow the starter motor to run continuously for
more than 20 seconds.
•
Do not push the START button while the engine is
running because this can damage the ring gear and/or
the starter motor.
•
IF the Engine Protection or Battery Charging Lights do
“not” turn off shortly after starting the engine shut off
the engine immediately and deter mine the cause.
-------------------------------------------------------------------NOTE: When starting for the first time, or after and extended
period of time of not operating, it will take longer than normal to
start because the fuel pump has to fill the fuel system. For best
results, bleed the fuel system as indicated in Maintenance Section
of this manual.
19. Battery Charging Light- A warning indicator light for Low/No
battery charge. The light is off when the systems are
functioning properly. The light will come on if there is a
Low/No battery condition but the machine will continue to
run.
Note: The light may or may not come on when the RUN-STOP
switch is in the "ON" position. It will come on during cranking
and stay on until the engine starts. After starting the engine
the light will go off unless a Low/No battery charge condition
exists.
B-4
VANTAGE® 300
OPERATION
The ARC CONTROL dial sets the short circuit current (arc-force)
during stick welding to adjust for a soft or crisp arc. Increasing the
number from -10(soft) to +10(crisp) increases the short circuit
current and prevents sticking of the electrode to the plate while
welding. This can also increase spatter. It is recommended that
the ARC CONTROL be set to the minimum number without
electrode sticking. Start with the dial set at 0.
Note: Due to the low OCV with the VRD on, a very slight delay
during striking of the electrodes may occur. Due to the
requirement of the resistance in the circuit to be low for a VRD to
operate, a good metal-to-metal contact must be made between
the metal core of the electrode and the job.
A poor connection anywhere in the welding output circuit may
limit the operation of the VRD. This includes a good connection of
the work clamp to the job. The work clamp should be connected
as close as practical to where the welding will be performed.
A. For New Electrodes
E6010 - Touch, Lift to Start the Arc
E7018, E7024 - Touch, Rock Back and Forth in Joint, Lift .
Once the arc is started, normal welding technique for the application is then used.
B. For Re-Striking Electrodes
Some electrodes form a cone at the end of the electrode after the
welding arc has been broken, particularly iron powder and low
hydrogen electrodes. This cone will need to be broken off in order
to have the metal core of the electrode make contact.
E6010 - Push, Twist in Joint, Lift
E7018, E7024 - Push, Rock Back and Forth in Joint, Lift.
Once the arc is started, normal welding technique for the
application is then used.
For other electrodes the above techniques should be tried first and
varied as needed to suit operator preference. The goal for
successful starting is good metal to metal contact.
For indicator light operation, see Table B.1.
stoppinG tHe enGine
Remove all welding and auxiliary power loads and allow the
engine to run at low idle speed for a few minutes to cool the
engine.
STOP the engine by placing the RUN-STOP switch in the STOP
position.
NOTE: A fuel shut off valve is located on the fuel pre-filter.
welDer operation
DUTY CYCLE
Duty Cycle is the percentage of time the load is being applied in a
10 minute period. For example a 60% duty cycle, represents 6
minutes of load and 4 minutes of no load in a 10 minute period.
ELECTRODE INFORMATION
For any electrode the procedures should be kept within the rating
of the machine. For information on electrodes and their proper
application see (www.lincolnelectric.com) or the appropriate
Lincoln publication.
The VANTAGE® 300 can be used with a broad range of DC stick
electrodes. The MODE switch provides two stick welding settings
as follows:
Constant Current (CC-STICK) Welding
The CC-STICK position of the MODE switch is designed for
horizontal and vertical-up welding with all types of electrodes,
especially low hydrogen. The output CONTROL dial adjusts the full
output range for stick welding.
TABLE B.2
TYPICAL VANTAGE 300 FUEL CONSUMPTION
®
Low Idle - No Load 1350 R.P.M. (Kubota)
Kubota V1505
Gal./Hr (Liters/Hr)
.29 (1.10)
Running Time for
20 gallons - (Hours)
68.96
High Idle - No Load 1890 R.P.M. (Kubota)
.40 (1.52)
49.76
.66 (2.50)
30.23
.87 (3.30)
22.91
1.17 (4.41)
17.15
1.10 (4.15)
.89 (3.36)
.73 (2.75)
.56 (2.14)
18.23
22.15
27.53
35.41
DC Weld Output
150 Amps @ 20 Volts
DC Weld Output
250 Amps @ 24 Volts
DC Weld Output
300 Amps @ 32 Volts
10,000 Watts
7,500 Watts
5,000 Watts
2,500 Watts
NOTE: This data is for reference only. Fuel consumption is approximate and can be influenced by many factors, including
engine maintenance, environmental conditions and fuel quality.
B-5
VANTAGE® 300
OPERATION
DOWNHILL PIPE Welding
The ARC CONTROL is not active in the TIG mode. To STOP a weld,
simply pull the TIG torch away from the work. When the arc
voltage reaches approximately 30 Volts the arc will go out and the
machine will reset the current to the Touch Start level.
To reinitiate the arc, retouch the tungsten to the work and lift.
Alternatively, the weld can be stopped by releasing the Amptrol or
arc start switch.
This slope controlled setting is intended for "out-of-position" and
"down hill" pipe welding where the operator would like to control
the current level by changing the arc length.
The output CONTROL dial adjusts the full output range for pipe
welding.
The ARC CONTROL dial sets the short circuit current (arc-force)
during stick welding to adjust for a soft or more forceful digging
arc (crisp). Increasing the number from -10(soft) to +10(crisp)
increases the short circuit current which results in a more forceful
digging arc.Typically a forceful digging arc is preferred for root
and hot passes. A softer arc is preferred for fill and cap passes
where weld puddle control and deposition (“stacking” of iron) are
key to fast travel speeds. This can also increase spatter.
It is recommended that the ARC CONTROL be set to the minimum
number without electrode sticking. Start with the dial set at 0.
NOTE: With the VRD switch in the “ON” position there is no output in
the DOWNHILL PIPE mode. For indicator light operation, see Table
B.1.
The VANTAGE® 300 can be used in a wide variety of DC TIG
welding applications. In general the ‘Touch Start’ feature allows
contamination free starting without the use of a Hi-frequency unit.
If desired, the K930-2 TIG Module can be used with the
VANTAGE® 300. The settings are for reference.
VANTAGE® 300 settings when using the K930-2 TIG Module with
an Amptrol or Arc Start Switch:
• Set the MODE Switch to the TOUCH START TIG setting.
• Set the "IDLER" Switch to the "AUTO" position.
• Set the "WELDING TERMINALS" switch to the "REMOTELY
CONTROLLED" position. This will keep the "Solid State"
contactor open and provide a "cold" electrode until the Amptrol
or Arc Start Switch is pressed.
TIG Welding
When using the TIG Module, the output CONTROL on the
The TOUCH START TIG setting of the MODE switch is for DC TIG
VANTAGE® 300 is used to set the maximum range of the
(Tungsten Inert Gas) welding. To initiate a weld, the output
CURRENT CONTROL on the TIG Module or an Amptrol if connected
CONTROL dial is first set to the desired current and the tungsten is to the TIG Module.
touched to the work. During the time the tungsten is touching the
work there is very little voltage or current and, in general, no
tungsten contamination. Then, the tungsten is gently lifted off the
work in a rocking motion, which establishes the arc.
When in the touch start TIG mode and when a Amptrol is
connected to the 6-Pin connector the output CONTROL dial is used
to set the maximum current range of the current control of the
Amptrol.
TABLE B.3
TYPICAL CURRENT RANGES (1) FOR TUNGSTEN ELECTRODES(2)
Tungsten Electrode
DCEN (-)
DCEP (+)
Approximate Argon Gas Flow
Diameter in. (mm)
TIG TORCH
Flow Rate C.F.H. ( l /min.)
1%, 2% Thoriated
Tungsten
1%, 2% Thoriated
Tungsten
Aluminum
Nozzle Size (4), (5)
Stainless Steel
.010
0.020
0.040
(.25)
(.50)
(1.0)
2-15
5-20
15-80
(3)
(3)
(3)
3-8
5-10
5-10
(2-4)
(3-5)
(3-5)
3-8
5-10
5-10
(2-4)
(3-5)
(3-5)
#4, #5, #6
1/16
(1.6)
70-150
10-20
5-10
(3-5)
9-13
(4-6)
#5, #6
3/32
1/8
(2.4)
(3.2)
150-250
250-400
15-30
25-40
13-17
15-23
(6-8)
(7-11)
11-15
11-15
(5-7)
(5-7)
#6, #7, #8
5/32
3/16
1/4
(4.0)
(4.8)
(6.4)
400-500
500-750
750-1000
40-55
55-80
80-125
21-25
23-27
28-32
(10-12)
(11-13)
(13-15)
13-17
18-22
23-27
(6-8)
(8-10)
(11-13)
#8, #10
(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
EWP
1% Thoriated
EWTh-1
2% Thoriated
EWTh-2
Though not yet recognized by the AWS, Ceriated Tungsten is now widely accepted as a substitute for 2% Thoriated Tungsten in AC and 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 = _ 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 to breakage, but cannot withstand high temperatures and high duty cycles.
B-6
VANTAGE® 300
OPERATION
WIRE WELDING-CV
Connect a wire feeder to the VANTAGE® 300 according to the
instructions in INSTALLATION INSTRUCTIONS Section.
The VANTAGE® 300 in the CV-WIRE mode, 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 can be finely tuned using the ARC CONTROL.
Turning the ARC CONTROL clockwise from –10 (soft) to +10 (crisp)
changes the arc from soft and washed-in to crisp and narrow. It
acts as an inductance/pinch control. The proper setting depends
on the procedure and operator preference. Start with the dial set
at 0.
NOTE: In the CV-Mode with VRD “On”, the OCV(Open Circuit
Voltage) is not reduced. For indicator light operation, see
Table B.1.
ARC GOUGING
The VANTAGE 300 can be used for arc gouging. For optimal
performance, set the MODE switch to Arc Gouging.
Set the OUTPUT CONTROL knob to adjust output current to the
desired level for the gouging electrode being used according to
the ratings in the following Table B.4.
The ARC CONTROL is not active in the ARC GOUGING Mode. The
ARC CONTROL is automatically set to maximum when the ARC
GOUGING mode is selected which provides the best ARC GOUGING
performance.
NOTE: With the VRD switch in the “ON” position there is no output
in the Arc Gouging Mode. For indicator light operation, see Table
B.1.
Auxiliary Power:
Start the engine and set the IDLER control switch to the desired
operating mode. Full power is available regardless of the welding
control settings providing no welding current is being drawn.
Simultaneous Welding and Auxiliary Power Loads
The auxiliary power ratings are with no welding load.
Simultaneous welding and power loads are specified in the
following table. The permissible currents shown assume that
current is being drawn from either the 120 VAC or 240 VAC supply
(not both at the same time).
TABLE B.4
Current Range (DC, electrode
positive)
60-90 Amps
90-150 Amps
200-250 Amps
300-MAX Amps
Carbon Diameter
1/8"
5/32"
3/16"
1/4"
TABLE B.5
VANTAGE® 300 Simultaneous Welding and Power Loads
Weld
Amps
0
100
200
250
300
400
PLUS
WATTS
10,000
8300
5300
3500
400
0
1 PHASE
AMPS
42
35
22
15
2
0
OR
WATTS
11,000
8500
5700
3500
800
0
3 PHASE
AMPS
27
20
14
8
2
0
OR
BOTH 1 & 3 PHASE
WATTS
AMPS
10,000
8300
5300
3500
400
0
0
TABLE B.6 VANTAGE® 300 Extension Cord Length Recommendations
(Use the shortest length extension cord possible sized per the following table.)
Current
(Amps)
15
20
15
20
44
Voltage
Volts
120
120
240
240
240
Load
(Watts)
1800
2400
3600
4800
9500
Maximum Allowable Cord Length in ft. (m) for Conductor Size
12 AWG
10 AWG
8 AWG
6 AWG
40
(12)
75
(23)
125
(38)
175
(53)
30
(9)
50
(15)
88
(27)
138
(42)
(18)
75
(23)
150
(46)
225
(69)
350
(107)
60
(18)
100
(30)
175
(53)
275
(84)
50
(15)
90
(27)
150
(46)
Conductor size is based on maximum 2.0% voltage drop.
14 AWG
30
(9)
60
B-7
4 AWG
300
(91)
225
(69)
600
(183)
450
(137)
225
(69)
VANTAGE® 300
ACCESSORIES
ACCESSORIES
FIELD INSTALLED OPTIONS / ACCESSORIES
K2641-2 Four Wheeled Steerable Yard Trailer - For 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 fender and
light package. For highway use, consult applicable federal,
state, and local laws regarding possible additional
requirements. Comes standard with a Duo-Hitch™, a 2” Ball
and Lunette Eye combination hitch. Order:
K2636-1 Trailer
K2639-1 Fender & Light Kit
K2640-1 Cable Storage Rack
K1898-1 SPARK ARRESTOR - Easily mounts to standard muffler.
K704 ACCESSORY SET - Includes 35 ft. (10m) of electrode cable
and 30 ft. (9.1m) of work cable, headshield, work clamp
electrode holder. Cables are rated at 400 amps, 100% duty
cycle.
K857 25 ft (7.6m) or K857-1 100 ft. (30.4m) REMOTE CONTROL Portable control provides same dial range as the output
control on the welder. Has a convenient 6 pin plug for easy
connection to the welder.
K2467-1 - Digital weld meters kit with easy to read digital meters
for volts and amps. Easy to install.
K802N POWER PLUG KIT - Provides four 120 volt plugs rated at 20
amps each and one dual voltage, full KVA plug rated at
120/240 volts, 50 amps.
K802R POWER PLUG KIT - Provides four 120 volt plugs rated at 15
amps each and one dual voltage, full KVA plug rated at
120/240 volts, 50 amps.
T12153-9 50 AMP, 120/240V POWER PLUG (1-Phase)
T12153-10 50 AMP, 240V POWER PLUG (3-Phase)
K1816-1 FULL KVA ADAPTER KIT - Plugs into the 120/240V NEMA
14-50R receptacle on the case front (which accepts 4-prong
plugs) and converts it to a NEMA 6-50R receptacle, (which
accepts 3-prong plugs.) For connection of Lincoln equipment
with NEMA 6-50 Plug.
WIRE FEEDER OPTIONS
K2613-1 LN-25 PRO Portable Wire Feeder-The MAXTRAC® wire
drive enhances performance, while the replacement case,
and many other upgrade options that can be installed in less
then five minutes aid in the serviceability.
KP1697-5/64 Drive Roll Kit- Includes: 2 polished U groove drive
rolls, outer wire guide and inner wire guide for solid core
wire. (Used on LN-25 Pro)
KP1697-068 Drive Roll Kit- Includes: 2 polished U groove drive
rolls, outer wire guide and inner wire guide for solid core
wire. (Used on LN-25 Pro)
KP1696-1 DRIVE ROLL KIT- Includes: 2 V groove drive rolls and
inner wire guide for Steel Wires. (Used on LN-25 Pro)
Magnum Gun and Magnum Gun Connector Kit are required for
gas-shielded welding. Innershield Gun is required for gasless
welding.
K126-2 Magnum 350 Innershield Gun
K1802-1 Magnum 300 MIG Gun (for LN-25)
K470-2 Magnum 300 MIG Gun (for LN-15, Includes Connector Kit)
K466-10 Connector Kit (for LN-15, K470-2)
K1500-1 Gun Receiver Bushing (for LN-15 & K126-2)
K487-25 Magnum SG Spool Gun - Hand held semiautomatic wire
feeder. Requires SG Control Module and Input Cable.
K488 SG Control Module (For Magnum Spool Gun) - The Interface
between the power source and the spool gun. Provides
control of the wire speed and gas flow. 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 receptacles and output stud connections.
Note: See Wire Feeder IM manuals for appropriate Drive Roll and
Guide Tubes.
TIG Options
K1783-9 Pro -Torch® PTA-26V TIG Torch - Air Cooled 200 amp
torch (2 piece) equipped with valve for gas flow control. 25 ft.
(7.6m) length.
KP509 Magnum Parts Kit for PTA-26V TIG Torch - Magnum Parts
Kit provides all the torch accessories you need to start
welding. Parts kit provides collets, collet bodies, a black cap,
alumina nozzles and tungstens in a variety of sizes, all
packaged in an easy to carry reclosable sack.
K870 Foot Amptrol®
K963-3 Hand Amptrol®
K2535-1 Precision TIG 225 Ready-Pak(For AC TIG)
C-1
VANTAGE® 300
MAINTENANCE
MAINTENANCE
Safety Precautions
•
Have qualified personnel do all maintenance and
troubleshooting work.
•
Turn the engine off before working inside the machine
or servicing the engine.
•
Remove guards only when necessary to perform
maintenance and replace them when the maintenance
requiring their removal is complete. If guards are
missing from the machine, obtain replacements from a
Lincoln Distributor. (See Operating Manual Parts List.)
Read the Safety Precautions in the front of this manual and
in the Engine Owner’s Manual before working on this
machine.
Keep all equipment safety guards, covers, and devices in
position and in good repair. Keep hands, hair, clothing, and
tools away from the gears, fans, and all other moving parts
when starting, operating, or repairing the equipment.
FIGURE D.1
EVERY DAY OR EVERY 8 HOURS
FIRST SERVICE (50 HOURS)
ENGINE SERVICE ITEMS
KUBOTA V1505 (22 HP)
EVERY 100 HOURS OR 3 MONTHS
EVERY 200 HOURS OR 4 MONTHS
EVERY 400 HOURS OR 9 MONTHS
EVERY 500 HOURS OR ANNUALLY
EVERY 1000 HOURS OR 2 YEARS
ENGINE SERVICE (NOTE 2)
I
MAINTENANCE ITEM
TYPE, QTY. OR SERVICE NOTE
Coolant level
Radiator core
Coolant
Engine oil level
Engine oil (1)
Engine oil filter
Water separator / fuel sedimenter
Fuel filter (in-line)
Check at overflow bottle.
6.3 quarts, 6.0L (including filter)
Kubota# HH160-32093/LECO# S30694-1
Kubota# 15831-43380/LECO# S30694-3
Kubota# 12581-43012/LECO# S30694-2
Fan belt
Kubota# 16282-97010 (37.5")/LECO#S30694-4
R
Air filter element
Donaldson # P822686/LECO#M19801-1A
I
Battery
BCI Group 34
R = Replace
(1) Consult Engine Operators Manual for oil recommendations.
C
I
R
R
R
R
I
I
R
R
I
I = Inspect
C = Clean
GENUINE PARTS, SERVICE, DISTRIBUTOR
USA (800) 532-9808
CANADA (905) 294-7477
www.kubotaengine.com
R
50/50 Mixture ethylene glycol/water
See Engine Manual for complete engine care. Give Engine
Specification and Serial Number when ordering parts.
These preventive maintenance periods
apply to average conditions of operation.
If necessary use shorter periods.
WARRANTY WORK PERFORMED ON THE ENGINE CONTAINED IN THIS MACHINE, IF NOT BILLABLE TO THE
ENGINE MANUFACTURER, SHOULD BE PRE-APPROVED BY CALLING THE LINCOLN ELECTRIC COMPANY AT 888-935-3877
S26073 VM
D-1
VANTAGE® 300
MAINTENANCE
Oil Filter Change
roUtine Maintenance
At the end of each day’s use, refill the fuel tank to minimize
moisture condensation in the tank. Running out of fuel tends to
draw dirt into the fuel system. Also, check the crankcase oil level
and add oil if indicated.
Engine Oil Change
Drain the engine oil while the engine is warm to assure rapid and
complete draining. It is recommended that each time the oil is
changed the oil filter be changed as well.
• Be sure the unit is off. Disconnect the negative battery cable
to ensure safety.
• Locate oil drain hose and valve in bottom of base and pull
through the hole in the battery access panel on the welder.
• Remove the cap from the drain valve. Push valve in and twist
counterclockwise. Pull to open and drain the oil into a suitable
container for disposal.
• Close the drain valve by pushing in and twisting clockwise.
Replace the cap.
• Re-fill the crankcase to the upper limit mark on the dipstick
with the recommended oil (see engine operation manual OR
engine service items decal OR below). Replace and tighten
the oil filler cap securely.
• Push oil drain hose and valve back into unit, re-connect
negative battery cable, and close doors and engine top cover
before restarting unit.Wash your hands with soap and water
after handling used motor oil. Please dispose of used motor
oil in a manner that is compatible with the environment. We
suggest you take it in a sealed container to your local service
station or recycling center for reclamation. DO NOT throw it in
the trash; pour it on the ground or down a drain.
Use motor oil designed for diesel engines that meets requirements
for API service classification CC/CD/CE/CF/CF-4/CG-4 or CH-4.
ACEA E1/E2/E3. Always check the API service label on the oil
container to be sure it includes the letters indicated. (Note: An Sgrade oil must not be used in a diesel engine or damage may
result. It IS permissible to use an oil that meets S and C grade
service classifications.)
SAE 10W30 is recommended for general, all temperature use, 5F
to 104F (-15C to 40C).
See engine owner’s manual for more specific information on oil
viscosity recommendations.
•
•
Drain the oil.
Remove the oil filter with an oil filter wrench and drain the oil
into a suitable container. Discard the used filter. Note: Care
should be taken during filter removal to not disrupt or damage
in any way the fuel lines.
•
Clean the filter mounting base and coat the gasket of the
new filter with clean engine oil.
Screw the new filter on by hand until the gasket contacts the
mounting base. Using an oil filter wrench, tighten the filter an
additional 1/2 to 7/8 of a turn.
Refill the crankcase with the specified amount of the
recommended engine oil. Reinstall the oil filler cap and
tighten securely.
Start the engine and check for oil filter leaks.
Stop the engine and check the oil level. If necessary, add oil to
the upper limit mark on the dipstick.
•
•
•
•
WARNING
Never use gasoline or low flash point solvents for cleaning
the air cleaner element. A fire or explosion could result.
CAUTION
Never run the engine without the air cleaner. Rapid engine
wear will result from contaminants, such as dust and dirt
being drawn into the engine.
air cleaner
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 every 500 hours of operation. Under dusty
conditions, replace sooner.
D-2
VANTAGE® 300
MAINTENANCE
Service Instructions
Single- and Two-Stage Engine Air Cleaners
Inspect the New Filter for Damage
Remove the Filter
Rotate the
filter while
pulling
straight out.
Unfasten or unlatch the
service cover. Because
the filter fits tightly over the
outlet tube to create the critical seal, there will
be some initial resistance, similar to breaking
the seal on a jar. Gently move the end of the filter
back and forth to break the seal then rotate while
pulling straight out. Avoid knocking the filter
against the housing.
If your air cleaner has a safety filter, replace it every third primary
filter change. Remove the safety filter as you would the primary
filter. Make sure you cover the air cleaner outlet tube to avoid any
unfiltered contaminant dropping into the engine.
Insert the New Radial Seal Filter Properly
If you're servicing the safety filter, this should be seated into
position before installing the primary filter.
Insert the new filter carefully. Seat
the filter by hand, making certain it is
completely into the air cleaner housing
before securing the cover in place.
Clean Both Surfaces of the Outlet Tube
and Check the Vacuator™ Valve
Use a clean cloth to wipe the filter sealing surface and the inside of
the outlet tube. Contaminant on the sealing surface could hinder an
effective seal and cause leakage. Make sure that all contaminant is
removed before the new filter is inserted. Dirt accidently transferred
to the inside of the outlet tube will reach the engine and cause
wear. Engine manufacturers say that it takes only a few grams of
dirt to "dust" an engine! Be careful not to damage the sealing area
on the tube.
Wipe both sides
of the outlet
tube clean.
Outer edge of the
outlet tube
Inspect the new filter carefully, paying attention to
the inside of the open end, which is the
sealing area. NEVER install a damaged
filter. A new Donaldson radial seal
filter may have a dry lubricant on the
seal to aid installation.
The critical sealing area will stretch
slightly, adjust itself and distribute the sealing pressure evenly. To
complete a tight seal, apply pressure by hand at the outer rim of
the filter, not the flexible center. (Avoid pushing on the center of the
urethane end cap.) No cover pressure is required to hold the seal.
NEVER use the service cover to push the filter into place! Using the
cover to push the filter in could cause damage to the housing, cover
fasteners and will void the warranty.
If the service cover hits the filter before it is fully in place, remove
the cover and push the filter (by hand) further into the air cleaner
and try again. The cover should go on with no extra force.
Once the filter is in place, secure the service cover.
Caution
Inner edge of the
outlet tube
NEVER use the service cover to
push the filter into place! Using
the cover to push the filter in could
cause damage to the housing, cover
fasteners and will void the warranty.
If your air cleaner is equipped with a Vacuator Valve
Visually check and physically squeeze to make sure the
valve is flexible and not inverted, damaged or plugged.
Inspect the Old
Filter for Leak Clues
Check Connectors for Tight Fit
Visually inspect the old filter for any signs
of leaks. A streak of dust on the clean side
of the filter is a telltale sign. Remove any
cause of leaks before installing new filter.
Make sure that all mounting bands, clamps, bolts, and connections
in the entire air cleaner system are tight. Check for holes in piping
and repair if needed. Any leaks in your intake piping will send dust
directly to the engine!
D-3
VANTAGE® 300
MAINTENANCE
BleeDinG tHe FUel sYsteM
You may need to bleed air from the fuel system if the fuel filter or
fuel lines have been detached, the fuel tank has been ran empty
or after periods of long storage. It is recommended that the fuel
shutoff valve be closed during periods of non-use.
coolinG sYsteM
WARNING
HOT COOLANT can burn skin.
Do not remove cap if radiator is hot.
WARNING
Check the coolant level by observing the level in the radiator and
recovery bottle. Add 50/50 antifreeze / water solution if the level is
close to or below the "LOW" mark. do not fill above the "FULL"
mark. Remove radiator cap and add coolant to radiator. Fill up to
the top of the tube in the radiator filler neck which includes a
connecting hose coming from the thermostat housing.
To drain the coolant, open the valve at the bottom of the radiator.
Open the radiator cap to allow complete drainage. (Tighten the
valve and refill with a 50/50 antifreeze/water solution.) Use an
automotive grade (low silicate) ethylene glycol antifreeze. The
cooling system capacity is 7.2 qts. (6.8L.). Squeeze upper and
lower radiator hoses while filling to bleed air from system coolant.
Replace and tighten the radiator cap.
CAUTION
Always premix the antifreeze and clean tap water before
adding to the radiator. It is very important that a precise
50/50 solution be used with this engine year round. This
gives proper cooling during hot weather and freezing
protection to -34° F (-37° C).
To avoid personal injury, do not bleed a hot engine. This
could cause fuel to spill onto a hot exhaust manifold,
creating a danger of fire.
Bleed the fuel system as follows:
1. Fill the fuel tank with fuel.
2. Open the fuel shut off valve.
3. Open bleed fitting on fuel sedimenter, the sedimenter should
gravity fill itself with fuel.
4. Tighten the bleed fitting on fuel sedimenter after sedimenter
fills with fuel.
5. Loosen bleed fitting on the fuel injector manifold.
6. Operate hand priming lever until fuel comes out the bleed
screw on the injector manifold. This could take 20-30 seconds
of rapid operation of the priming lever. Tighten bleed fitting on
injector manifold.
7. Follow normal STARTING procedures until engine starts.
Cooling solution exceeding 50% ethylene glycol can result
in engine overheating and damage to the engine. Coolant
solution must be premixed before adding to radiator.
Periodically remove the dirt from the radiator fins.
Periodically check the fan belt and radiator hoses. Replace if
signs of deterioration are found.
tiGHteninG tHe Fan Belt
If the fan belt is loose, the engine can overheat and the battery
lose its charge. Check tightness by pressing on the belt midway
between the pulleys. It should deflect about .25 in.(6.4 mm) under
a load of 20 lbs.(9 Kg).
FUel
DIESEL FUEL ONLY-Low sulphur fuel or ultra low sulphur fuel in
U.S.A. and Canada.
At the end of each day’s use, refill the fuel tank to minimize
moisture condensation and dirt contamination in the fuel line. Do
not overfill; leave room for the fuel to expand.
Use only fresh No. 2D diesel fuel, the use of No. 1D diesel fuel is
recommended in place of No. 2D at temperatures below 23°F (5°C). Do not use kerosene.
See the Engine Operator's Manual for instructions on replacing the
fuel filter.
D-4
VANTAGE® 300
MAINTENANCE
CLEANING THE BATTERY
FUel Filter
1. Check the fuel filter and fuel pre-filter for water accumulation
or sediment.
2. Replace the fuel filter if it is found with excessive water
accumulation or sediment. Empty fuel pre-filter.
Keep the battery clean by wiping it with a damp cloth when dirty. If
the terminals appear corroded, disconnect the battery cables and
wash the terminals with an ammonia solution or a solution of 1/4
pound (0.1113 kg) of baking soda and 1 quart (0.9461) of water.
Be sure the battery vent plugs (if equipped) are tight so that none
of the solution enters the cells.
After cleaning, flush the outside of the battery, the battery
compartment, and surrounding areas with clear water. Coat the
battery terminals lightly with petroleum jelly or a non-conductive
grease to retard corrosion.
Keep the battery clean and dry. Moisture accumulation on the
battery can lead to more rapid discharge and early battery failure.
enGine aDJUstMent
Adjustments to the engine are to be made only by a Lincoln
Service Center or an authorized Field Service Shop.
WARNING
CHECKING THE ELECTROLYTE LEVEL
OVERSPEED IS HAZARDOUS
The maximum allowable high idle speed for this machine is
1890 RPM no load. Do NOT tamper with governor
components or setting or make any other adjustments to
increase the maximum speed. Severe personal injury and
damage to the machine can result if operated at speeds
above maximum.
If battery cells are low, fill them to the neck of the filler hole with
distilled water and recharge. If one cell is low, check for leaks.
CHARGING THE BATTERY
When you charge, jump, replace, or otherwise connect battery
cables to the battery, be sure the polarity is correct. Improper
BatterY Maintenance
polarity can damage the charging circuit. The VANTAGE® 300
positive
(+) battery terminal has a red terminal cover.
To access the battery, remove the battery tray from the front of the
machine with 3/8” nut driver or flat head screw driver. Pull the tray If you need to charge the battery with an external charger,
out of machine far enough to disconnect the negative and then
disconnect the negative cable first, then the positive cable before
positive battery cables. The tray can then be tilted and lifted to
you attach the charger leads. After the battery is charged,
remove the entire tray and battery from the machine for easy
reconnect the positive battery cable first and the negative cable
service.
last. Failure to do so can result in damage to the internal charger
components.
WARNING
Follow the instructions of the battery charger manufacturer for
proper
charger settings and charging time.
Gases from battery can explode.
•
Keep sparks, flame and cigarettes away from battery.
serVicinG optional sparK arrestor
Clean every 100 hours.
To prevent EXPLOSION when:
•
•
•
INSTALLING A NEW BATTERY —
disconnect negative cable from old
battery first and connect to new battery
last.
WARNING
MUFFLER MAY BE HOT
CONNECTING A BATTERY CHARGER — remove battery
from welder by disconnecting negative cable first, then
positive cable and battery clamp. When reinstalling,
connect negative cable last.Keep well ventilated.
• ALLOW ENGINE TO COOL BEFORE INSTALLING THE
SPARK ARRESTER!
• DO NOT OPERATE ENGINE WHILE INSTALLING THE
SPARK ARRESTER!
USING A BOOSTER — connect positive lead to battery
first then connect negative lead to negative battery lead
at engine foot.
BATTERY ACID can burn eyes
and skin.
•
Wear gloves and eye protection and be
careful when working near battery.
•
Follow instructions printed on battery.
D-5
VANTAGE® 300
MAINTENANCE
welDer / Generator Maintenance
STORAGE: Store in clean, dry protected areas.
CLEANING: Blow out the generator and controls periodically with
low pressure air. Do this at least once a week in particularly dirty
areas.
BRUSH REMOVAL AND REPLACEMENT: It’s normal for the brushes and slip rings to wear and darken slightly. Inspect the brushes
when a generator overhaul is necessary.
CAUTION
Do not attempt to polish slip rings while the engine is
running.
WARNING
Service and Repair should only be performed by Lincoln
Electric Factory Trained Personnel. Unauthorized repairs
performed on this equipment may result in danger to the
technician and machine operator and will invalidate your
factory warranty. For your safety and to avoid Electrical
Shock, please observe all safety notes and precautions.
GFci testinG anD resettinG proceDUre
The GFCI should be properly tested at least once every month or
whenever it is tripped. To properly test and reset the GFCI:
• If the GFCI has tripped, first carefully remove any load and
check it for damage.
•
•
If the equipment has been shut down, it must be restarted.
The equipment needs to be operating at high idle speed and
any necessary adjustments made on the control panel so that
the equipment is providing at least 80 volts to the receptacle
input terminals.
• The circuit breaker for this receptacle must not be tripped.
Reset if necessary.
• Push the "Reset" button located on the GFCI. This will assure
normal GFCI operation.
• Plug a night-light (with an "ON/OFF" switch) or other product
(such as a lamp) into the Duplex receptacle and turn the
product "ON".
• Push the "Test" button located on the GFCI. The night-light or
other product should go "OFF".
• Push the "Reset" button, again. The light or other product
should go "ON" again.
If the light or other product remains "ON" when the "Test" button
is pushed, the GFCI is not working properly or has been incorrectly
installed (miswired). If your GFCI is not working properly, contact a
qualified, certified electrician who can assess the situation, rewire
the GFCI if necessary or replace the device.
D-6
VANTAGE® 300
TROUBLE SHOOTING
TROUBLESHOOTING
How to Use troUblesHooting gUide
WARNING
Service and Repair should only be performed by Lincoln
Electric Factory Trained Personnel. Unauthorized repairs
performed on this equipment may result in danger to the
technician and machine operator and will invalidate your
factory warranty. For your safety and to avoid Electrical
Shock, please observe all safety notes and precautions
detailed throughout this manual.
This Troubleshooting Guide is provided to help you locate and
repair possible machine malfunctions. Simply follow the threestep procedure listed below.
Step 1. LOCATE PROBLEM (SYMPTOM).
Look under the column labeled “PROBLEM (SYMPTOMS)”. This
column describes possible symptoms that the machine may
exhibit. Find the listing that best describes the symptom that the
machine is exhibiting.
Step 2. POSSIBLE CAUSE.
The second column labeled “POSSIBLE CAUSE” lists the obvious
external possibilities that may contribute to the machine symptom.
Step 3. RECOMMENDED COURSE OF ACTION
This column provides a course of action for the Possible Cause,
generally it states to contact your local Lincoln Authorized Field
Service Facility.
If you do not understand or are unable to perform the
Recommended Course of Action safely, contact your local Lincoln
Authorized Field Service Facility.
If for any reason you do not understand the test procedures or are unable to perform the tests/repairs safely, contact your
Lincoln Authorized Service Facility for technical troubleshooting assistance before you proceed.
WWW.LINCOLNELECTRIC.COM/LOCATOR
E-1
VANTAGE® 300
TROUBLE SHOOTING
Observe all Safety Guidelines detailed throughout this manual
PROBLEMS
(SYMPTOMS)
POSSIBLE
CAUSE
RECOMMENDED
COURSE OF ACTION
Major Physical or Electrical Damage is 1. Contact your local Lincoln Authorized
Evident.
Field Service Facility.
Engine will not "crank".
1. Battery is low, Charge Battery.
2. Loose battery cable connections.
Inspect, clean and tighten terminals.
3. Faulty engine starter motor. Contact
authorized local Engine Service Shop.
Engine will "crank" but not start.
1. Fuel shut off valve on Main Fuel Filter in
the OFF position. Open valve (vertical)
position of handle.
2. Fuel Filters dirty/clogged. Check and
replace main filter element and/or Inline
Fuel Filter.
3. Out of fuel. Fill tank and bleed fuel system.
4. High coolant temperature or low oil pressure. (indictor lights lit) Check oil and
coolant levels. Fill if required. Check for
loose or broken fan belt.
5. ON/OFF switch on for more then 60 seconds before starting. The ON/OFF switch
will need to be switched off and turned
back on.
6. Faulty fuel shutdown solenoid. Check
that shutdown solenoid is functioning
properly and not binding / contact authorized engine service shop. (Kubota Only)
7. Electronic Governor Controller not functioning properly. (Deutz only)
8. Faulty fuel pump. Check for fuel flow
through filters. Contact authorized local
Engine Service Shop.
Engine shuts down shortly after starting.
If all recommended possible areas of misadjustment have been checked and the
problem persists, Contact your local
Lincoln Authorized Field Service Facility.
1. High coolant temperature or low oil pressure. (indictor light lit) Change oil and oil
filters and fill to proper level. Check and
fill coolant level. Check for loose or broken fan belt. Start engine and look for
leaks.
2. Faulty oil pressure switch or other engine
component. Contact authorized local
Engine Service Shop.
3. Faulty Idler/Protection Board.
If for any reason you do not understand the test procedures or are unable to perform the tests/repairs safely, contact your
Lincoln Authorized Service Facility for technical troubleshooting assistance before you proceed.
WWW.LINCOLNELECTRIC.COM/LOCATOR
E-2
VANTAGE® 300
TROUBLE SHOOTING
Observe all Safety Guidelines detailed throughout this manual
PROBLEMS
(SYMPTOMS)
POSSIBLE
CAUSE
Engine shuts down while under a load.
1. High radiator coolant temperature.
Reduce load if it is exceeding machine
rating. Add coolant to system if low.
Clean fins on radiator if dirty. Tighten fan
belt if loose. Remove objects blocking or
close to intake openings on both sides of
base and exhaust end (case back).
Engine runs rough.
1. Dirty fuel or air filters. Inspect and
clean/replace filters as needed. Inspect
and clean/replace filters as needed.
2. Water in fuel. If water found in tank.
Empty fuel tank and refill then purge fuel
lines.
RECOMMENDED
COURSE OF ACTION
Battery does not stay charged.
1. Faulty battery. Replace.
Engine alternator trouble light is on while 2. Loose connections at battery or alternamachine is running.
tor. Clean and tighten connections.
3. Faulty engine alternator or charger module. Consult authorized Engine Service
Shop.
Engine will not idle down to low speed.
Engine will not go to high idle when
attempting to weld.
If all recommended possible areas of mis1. Idler switch in High idle position.
adjustment have been checked and the
Set switch to Auto.
problem persists, Contact your local
2. External load on welder or auxiliary Lincoln Authorized Field Service Facility.
power. Remove all external loads.
3. Faulty PC board or idler solenoid.
1. Poor work lead connection to work.
Make sure work clamp is tightly connected to clean base metal.
2. "Contactor" switch is in wrong position.
Set to "Welding On" when welding without a
control cable. Refer to Operations chapter
for proper use of this switch.
3. Faulty PC board. Low idle speed set to
low.
If for any reason you do not understand the test procedures or are unable to perform the tests/repairs safely, contact your
Lincoln Authorized Service Facility for technical troubleshooting assistance before you proceed.
WWW.LINCOLNELECTRIC.COM/LOCATOR
E-3
VANTAGE® 300
TROUBLE SHOOTING
Observe all Safety Guidelines detailed throughout this manual
PROBLEMS
(SYMPTOMS)
POSSIBLE
CAUSE
Engine will not go to high idle when using
auxiliary power.
1. Auxiliary power load is less than 100
watts. Idler may not respond with less than
a 100 watt load. Set idler to "High".
2. Faulty PC board.(Control or Idler).
Engine will not go to high idle under weld
or auxiliary loading.
1. Faulty idler solenoid. Check for bent
linkage or broken spring.
2. Faulty PC board.(Control or Idler).
Engine does not develop full power.
Engine runs rough.
1. Fuel filter clogged, Replace.
2. Air filter clogged, clean or replace.
3. High idle setting incorrect, check and
adjust if required.
4. Valves out of adjustment.
5. Fuel contaminated with water or sediment. Check fuel pre-filter and empty of
water, bleed fuel system. Replace fuel in
tank if needed.
Engine will not go to high idle when
attempting to weld or using auxiliary
power. Switching to manual high idle does
not work.
Engine will not shut off.
RECOMMENDED
COURSE OF ACTION
If all recommended possible areas of mis1. Broken spring on Idle Solenoid, solenoid adjustment have been checked and the
linkage binding, low idle speed set too problem persists, Contact your local
Lincoln Authorized Field Service Facility.
low on idle solenoid.
2. Faulty PC Board (Control or Idler).
1. Fuel Shutdown solenoid not functioning
properly / linkage binding. Stop engine
by shutting off valve located on main
fuel filter. Contact authorized local
Engine Service Shop.
If for any reason you do not understand the test procedures or are unable to perform the tests/repairs safely, contact your
Lincoln Authorized Service Facility for technical troubleshooting assistance before you proceed.
WWW.LINCOLNELECTRIC.COM/LOCATOR
E-4
VANTAGE® 300
TROUBLE SHOOTING
Observe all Safety Guidelines detailed throughout this manual
PROBLEMS
(SYMPTOMS)
POSSIBLE
CAUSE
RECOMMENDED
COURSE OF ACTION
Engine does not develop full power. Low 1. Fuel filter dirty/clogged. Replace.
weld and auxiliary output. Engine runs 2. Air filter dirty/clogged. Replace Air Filter
rough.
Element.
3. Fouled fuel injector(s). Contact authorized
Engine Service Shop.
4. Fuel contaminated with water. Check
Main Filter Bowl and Inline Fuel filters for
water. Clean and replace as needed.
Replace fuel in tank.
5. Cracked or loose fuel hose. Replace hose
and tighten clamps.
6. Valves out of adjustment. Contact authorized local Engine Service Shop.
No welding power output.
Welder has output but no control.
1. Poor work lead connection to work. Make
sure work clamp is tightly connected to
clean base metal.
2. "Weld Terminals" switch in wrong position. Place switch in "Weld Terminals On"
position when welding without control
cable.
If all recommended possible areas of mis3. Faulty PC board or welder alternator.
adjustment have been checked and the
1. Poor remote/control cable connection to problem persists, Contact your local
6-pin or 14-pin connector. Check connec- Lincoln Authorized Field Service Facility.
tions.
2. Faulty remote cable or faulty wire feeder
or wire feeder cable. Replace if necessary.
3. Faulty control potentiometer or PC board.
Wire feeder does not work when control 1. Wire Feeder Power circuit breaker open.
Check 42V and 120V beakers and reset if
cable is connected to 14 pin connector.
tripped.
2. Faulty control cable. Repair or replace
cable.
3. Faulty wire feeder. Replace wire feeder.
If for any reason you do not understand the test procedures or are unable to perform the tests/repairs safely, contact your
Lincoln Authorized Service Facility for technical troubleshooting assistance before you proceed.
WWW.LINCOLNELECTRIC.COM/LOCATOR
E-5
VANTAGE® 300
TROUBLE SHOOTING
Observe all Safety Guidelines detailed throughout this manual
PROBLEMS
(SYMPTOMS)
No auxiliary power.
POSSIBLE
CAUSE
RECOMMENDED
COURSE OF ACTION
1. Open circuit breakers. Reset
breakers. If breakers keep tripping
reduce power draw.
2. GFCI may have tripped. Follow “GFCI
Testing and Resetting Procedure” in the
MAINTENANCE section of this manual.
3. Faulty connections to auxiliary receptacles. Check connections.
4. Faulty PC board or welder alternator.
The welding arc is “cold.” The welding arc 1. Make sure the MODE selector switch is in
is not stable or is not satisfactory. the
engine runs normally. The auxiliary power is the correct position for the process being
normal.
used. (For example, CV-WIRE, PIPE, CCSTICK.)
2. Make sure the electrode (wire, gas, voltage,
current etc.) is correct for the process
being used.
3. Check for loose or faulty connections at the
weld output terminals and welding cable
connections.
4. The welding cables may be too long or
coiled, causing an excessive voltage drop.
5. Faulty Control Board.
No output in Pipe Mode.
1. Make sure VRD ON/OFF toggle switch is in
the “OFF” position.
2. Poor work lead connection to work. Make
sure work clamp is tightly connected to
clean base metal.
3. "Weld Terminals" switch in wrong position. Place switch in "Weld Terminals On"
position when welding without control
cable.
4. Faulty PC board or welder alternator.
VRD Lights don’t light up.
1. Ensure VRD ON/OFF switch is in the “ON”
position.
2. If light is burned out, replace both VRD
lights.
3. Faulty OCV indicator PC board.
If all recommended possible areas of misadjustment have been checked and the
problem persists, Contact your local
Lincoln Authorized Field Service Facility.
If for any reason you do not understand the test procedures or are unable to perform the tests/repairs safely, contact your
Lincoln Authorized Service Facility for technical troubleshooting assistance before you proceed.
WWW.LINCOLNELECTRIC.COM/LOCATOR
E-6
VANTAGE® 300
DIAGRAMS
E-7
VANTAGE® 300
DIAGRAMS
E-8
VANTAGE® 300
2
9/03
DIAGRAMS
E-9
J
21
77B
76B
75B
4B
2B
GND-A
31
32
41A
42A
AMPHENOL 1
F
G
D
C
B
A
I
K
H
E
208C
208B
77A
77B
76A
76B
75A
75B
2A
2B
4A
4B
GND-B
8
9
1
GND-M
GND-A
GND-B
M3 M5 M9
M2 M4
M6 M10
1
9
16
13C 13 23 25
215
216
6
1
B4
B6 CHOKE
B6
B5
B4-NEG
B5-POS
10
9
1
M3 M5 M9
M2 M4
M6 M10
12
J2
ENGINE,PERIPHERAL
6
J4
AMMETER
5
M1
8
1
7
214
CV
10
W5
W5
W4
W4
W4 & W5
B1
6
10
232F
232
247
234
263
262
226
CCW
B3
227
J61
4
J33
1
10
6
R2
4
6
3
6
3
3
J32
1
4
271
2
B2
14C
VRD DISPLAY
PCB4
279
10K
13C
1
J60
VIEWED
FROM
BACK
278
277
VRD
RED
298
5
B4
299
208B 206B
297
296A
75
1
VRD
GREEN
296
VIEWED 10K
FROM
BACK
77
76
R1
CCW
41
42
OUTPUT CONTROL ARC CONTROL
41A
W1 & W6
10A
CB6
42A
ROTOR
201
BRUSH
240V
3PH
J13
3B
3200MFD
300V
BRUSH
200B
WELDING TERMINAL
CONTROL SWITCH
SHOWN IN "ALWAYS ON" POSITION
Y
5R
1
5S
5G
5T
5M
5L
J53
232B 5M
228
4
4A
6D
6C
4
6C
Z
200A
5J
200
5H
5T
1
J51
232K 5K
229
4
X
5D
W
GND-C
120/240V
FUEL
263
12 VOLT GROUND STUD
ON UPPER CONTROL PANEL
5K
1
J52
232C 5L
241
4
3D
J10
3C
HOUR METER
201A
6A
COOLANT
OIL
PRESSURE TEMPERATURE
2A
2
4
4A
X
GND-L
4A
3C
260
261
GROUND STUD ON AUXILIARY
POWER RECEPTACLE PANEL
GND-D
GND-E
5
50A
3 POLE
CB1
POSITIVE BRUSH CONNECTED
TO SLIP RING NEAREST
TO THE LAMINATION
201
31
GND-J
GND-K
GND-C
GND-L
ELECTRICAL SYMBOLS PER E1537
ALL CASEFRONT COMPONENTS SHOWN VIEWED FROM REAR
STATOR 42V WINDING
W6
W6
W1
W1
IDLER/ENGINE SHUTDOWN P.C. BD.
1
J31
5
5R
243
5S
ENG
PROT
247
ALT
232N
TIG 4
CC
3
2
GOUGE 1
PIPE
232M
220
222
218
217
STATOR
WELD
WINDINGS
W3 W2
W3 W2
W2 & W3
RECTIFIER BRIDGE
MODE SELECTOR SWITCH
S5
CHOPPER
PCB3
16
J3
CHOPPER, POWER, PWM, THERMAL
296 298
296A
AMMETER
GROUND STUD IN UPPER CONTROL PANEL
J1
CONNECTOR ,I.D.
J7
CONTROL, MODE SEL.
8
B7 B8
13C 13 23 25
B3 CHOKE
B3
CONTACTS SHOWN
IN OFF POSITION
GND-J
B1
B2
VRD OFF/ON SWITCH
VOLTMETER
M1
32
41A
42A
L1 CHOKE
B3 CHOKE
B6 CHOKE
15
13A
14C
14
B1-NEG
B2-POS
POS-SHUNT
B2-POS
B5-POS
+
B
W
SILVER
W
20A
HOLD
COIL
GND-E
CB3
20A
GFCI
MODULE
J12
LOAD
LINE
10A
CB5
238C
232F
232N 232
232B 232K
232C
STOP
RUN
RUN/STOP
SWITCH
236A
IDLER
CONTROL
SWITCH
SHOWN IN
"HIGH" POSITION
239
GND-K
P56
J56
232L
233
238C
238B
SHOWN IN "RUN" POSITION
236B
236A
257
AUTO
32A
GND-D
32A
B
6E
B
PULL
COIL
W
SLIVER
J11
20A
B
262
233
P55
J55
1
232M
243
6A
W
4
5H
W
W
5D
31
PULL
COIL
227
SWITCH
4
G
SENSOR
WK
234
235
OIL PRESSURE
SENSOR & SWITCH
226
232L
1
RED
WHT
BLK
HOLD
COIL
IDLER
SOLENOID
W
6A
238A
231
IG
L
+
235
ENGINE BLOCK
-
G6300
A
GENERATOR SUPPORT
12V BATTERY
+
FUEL LVL.
SENSOR
SWITCH
ALTERNATOR
STARTER
SOLENOID
SENSOR
3
NEUTRAL STUD ON
AUXILIARY POWER
RECEPTACLE PANEL
5A
5 5A
COOLANT TEMPERATURE
SENSOR & SWITCH
238A
231
238 STARTING
MOTOR
229
5J
241
228
238B
START BUTTON
P54
J54
6
STATOR AUXILIARY WINDINGS
GFCI LINE
MODULE LOAD
SHUTDOWN
GLOW GLOW PLUG SOLENOID
BUTTON
PLUGS
6E
HIGH
256
32
Y
6D
CB2
20A
3D
W
AUXILIARY POWER LEADS PASS THROUGH
TOROID THREE TIMES IN DIRECTION INDICATED
NOTE: This diagram is for reference only. It may not be accurate for all machines covered by this manual. The specific diagram for a particular code is incuded with the machine. If the diagram is illegible,
write to the Service Department for a replacement. Give the equipment code number.
J6
2
1 SHUNT
WELD BOARD
PCB3
10
6
J5
VOLT METER
5
1
206S
204S
A
REMOTE
B
CONTROL
C
CONTACTOR
D
E
F
GROUND
21
SWITCH CONTACTS
SHOWN IN "+" POSITION
206B
16
WELDING OUTPUT
TERMINAL
BYPASS
FILTER
ASSEMBLY
GND-M
AMPHENOL 2
GROUND
CONTACTOR
REMOTE
CONTROL
WORK
42VAC
115VAC
206S
WIRE
FEEDER
VOLTMETER
SWITCH
208A
206A
208A
208
208D
206
I
WELDING OUTPUT
TERMINAL
M6
206A
-
206C
+
50MV=400AMPS
M9
R4
222
204S
M9
+
M10
M1
M2
M3
M4
M5
214
216
217
77
215
218
220
277
M1
M6
M3
M2
M10
M4
M5
14
POS-SHUNT
405
76
75
279
278
76A
300
300
2
77A
4
75A
250
25
23
260
261
250
257
208C
256
13
5G
+
B1-NEG
B4-NEG
200
+
+
-
E-10
405
-
-
-
VANTAGE 300 WIRING DIAGRAM CODE 11529
VANTAGE® 300
DIAGRAMS
J
21
77B
76B
75B
4B
2B
GND-A
31
32
41A
42A
AMPHENOL 1
F
G
D
C
B
A
I
K
H
E
208C
208B
77A
77B
76A
76B
75A
75B
2A
2B
4A
4B
GND-B
8
16
9
1
GND-M
GND-A
GND-B
M3 M5 M9
M2 M4
M6 M10
1
9
16
215
216
6
1
J1
CONNECTOR ,I.D.
J7
CONTROL, MODE SEL.
8
B6 CHOKE
B6
B5
B4
10
9
1
M3 M5 M9
M2 M4
M6 M10
12
J2
ENGINE,PERIPHERAL
6
J4
AMMETER
5
M1
8
1
7
214
CV
10
W5
W5
W4
W4
W4 & W5
B1
6
10
232F
232
247
234
263
262
226
CCW
B3
227
J61
4
J33
1
10
6
R2
4
6
3
6
3
3
J32
1
4
271
2
B2
14C
VRD DISPLAY
PCB4
279
10K
13C
1
J60
VIEWED
FROM
BACK
278
277
VRD
RED
298
5
B4
299
208B 206B
297
296A
75
1
VRD
GREEN
296
VIEWED 10K
FROM
BACK
77
76
R1
CCW
41
42
OUTPUT CONTROL ARC CONTROL
41A
W1 & W6
10A
CB6
42A
ROTOR
201
BRUSH
240V
3PH
J13
3B
3200MFD
300V
BRUSH
200B
WELDING TERMINAL
CONTROL SWITCH
SHOWN IN "ALWAYS ON" POSITION
Y
6C
Z
5R
1
5S
5G
5T
5M
5L
J53
232B 5M
228
4
4A
200A
5J
200
5H
5T
1
J51
232K 5K
229
4
X
5D
W
GND-C
120/240V
FUEL
263
12 VOLT GROUND STUD
ON UPPER CONTROL PANEL
5K
1
J52
232C 5L
241
4
3D
J10
3C
HOUR METER
201A
6A
COOLANT
OIL
PRESSURE TEMPERATURE
2A
2
4
4A
X
GND-L
4A
3C
6D
6C
4
260
261
GROUND STUD ON AUXILIARY
POWER RECEPTACLE PANEL
GND-D
GND-E
5
50A
3 POLE
CB1
POSITIVE BRUSH CONNECTED
TO SLIP RING NEAREST
TO THE LAMINATION
201
31
GND-J
GND-K
GND-C
GND-L
ELECTRICAL SYMBOLS PER E1537
ALL CASEFRONT COMPONENTS SHOWN VIEWED FROM REAR
STATOR 42V WINDING
W6
W6
W1
W1
IDLER/ENGINE SHUTDOWN P.C. BD.
1
J31
5
5R
243
5S
ENG
PROT
247
ALT
232N
TIG 4
CC
3
2
GOUGE 1
PIPE
232M
220
222
218
217
STATOR
WELD
WINDINGS
W3 W2
W3 W2
W2 & W3
RECTIFIER BRIDGE
MODE SELECTOR SWITCH
S5
CHOPPER
PCB3
16
J3
CHOPPER, POWER, PWM, THERMAL
296 298
296A
AMMETER
GROUND STUD IN UPPER CONTROL PANEL
13C 13 23 25
B3 CHOKE
B3
B7 B8
13C 13 23 25
CONTACTS SHOWN
IN OFF POSITION
GND-J
B1
B2
VRD OFF/ON SWITCH
VOLTMETER
M1
32
41A
42A
L1 CHOKE
B3 CHOKE
B6 CHOKE
15
13A
14C
14
B4-NEG
B5-POS
POS-SHUNT
B2-POS
B5-POS
+
GND-D
HOT
5C
WHITE
GFCI
20A
10A
CB5
238C
232F
232N 232
232B 232K
232C
STOP
RUN
RUN/STOP
SWITCH
236A
IDLER
CONTROL
SWITCH
SHOWN IN
"HIGH" POSITION
239
232L
3F
HOLD
COIL
GND-E
GND-K
P56
J56
233
238C
238B
SHOWN IN "RUN" POSITION
236B
236A
257
AUTO
32A
32A
3E
5B
SILVER
CB2
6E
PULL
COIL
6F
262
233
P55
J55
1
232M
243
6A
4
5H
5F
5C
5D
31
PULL
COIL
227
SWITCH
4
G
SENSOR
WK
234
235
OIL PRESSURE
SENSOR & SWITCH
226
232L
1
RED
WHT
BLK
HOLD
COIL
IDLER
SOLENOID
6G
6A
238A
231
IG
L
+
235
ENGINE BLOCK
-
G7137
A
GENERATOR SUPPORT
12V BATTERY
+
FUEL LVL.
SENSOR
SWITCH
ALTERNATOR
STARTER
SOLENOID
SENSOR
3
NEUTRAL STUD ON
AUXILIARY POWER
RECEPTACLE PANEL
5A
5 5A
COOLANT TEMPERATURE
SENSOR & SWITCH
238A
231
238 STARTING
MOTOR
229
5J
241
228
238B
START BUTTON
P54
J54
5F
WHITE
HOT
5E
GFCI
20A
SILVER
6
STATOR AUXILIARY WINDINGS
J11
CB3
SHUTDOWN
GLOW GLOW PLUG SOLENOID
BUTTON
PLUGS
6E
HIGH
256
32
Y
6D
3D
J12
AUXILIARY POWER LEADS PASS THROUGH
TOROID THREE TIMES IN DIRECTION INDICATED
NOTE: This diagram is for reference only. It may not be accurate for all machines covered by this manual. The specific diagram for a particular code is incuded with the machine. If the diagram is illegible,
write to the Service Department for a replacement. Give the equipment code number.
J6
2
1 SHUNT
WELD BOARD
PCB3
10
6
J5
VOLT METER
5
1
206S
204S
A
REMOTE
B
CONTROL
C
CONTACTOR
D
E
F
GROUND
21
SWITCH CONTACTS
SHOWN IN "+" POSITION
206B
AMPHENOL 2
GROUND
CONTACTOR
REMOTE
CONTROL
WORK
42VAC
115VAC
WELDING OUTPUT
TERMINAL
BYPASS
FILTER
ASSEMBLY
GND-M
WELDING OUTPUT
TERMINAL
206S
WIRE
FEEDER
VOLTMETER
SWITCH
208A
206A
208A
208
208D
206
206C
+
I
206A
-
M6
B1-NEG
B2-POS
14
50MV=400AMPS
M9
+
R4
222
LINE
204S
M9
LOAD
+
M10
M1
M2
M3
M4
M5
214
216
217
77
215
218
220
277
M1
M6
M3
M2
M10
M4
M5
LINE
POS-SHUNT
405
76
75
279
278
76A
300
300
2
77A
4
75A
250
25
23
260
261
250
257
208C
256
13
5G
LOAD
B1-NEG
B4-NEG
200
+
+
-
E-11
405
-
-
-
VANTAGE 300 WIRING DIAGRAM CODE 11784, 11919, 12342, 12634, 12689
VANTAGE® 300
DIAGRAMS
25.82
655.8
24.00
609.6
5.75
146.0
E-12
1.27
32.3
35.94
913
39.41
1001
15.00
381
N.A. CENTER OF GRAVITY WITH OIL IN ENGINE, COOLANT IN RADIATOR, AND EMPTY FUEL TANK.
N.B. CASEFRONT GRAPHICS MAY NOT MATCH ALL CODES.
27.00
685.8
20.60
523.3
28.50
723.9
28.95
735.3
60.00
1524.0
55.50
1409.7
N.A.
2.25
57.2
E
L12573
44.25
1123.95
VANTAGE® 300
DIAGRAMS
WARNING
AVISO DE
PRECAuCION
Spanish
l Do not touch electrically live parts or
l No toque las partes o los electrodos
bajo carga con la piel o ropa mojada.
l Aislese del trabajo y de la tierra.
French
l Ne laissez ni la peau ni des vête-
German
l Berühren Sie keine stromführenden
ATTENTION
WARNuNG
Portuguese
ATENÇÃO
Japanese
l Keep flammable materials away.
l Wear eye, ear and body protection.
l Mantenga el material combustible
l Protéjase los ojos, los oídos y el
electrode with skin or wet clothing.
l Insulate yourself from work and
ground.
ments mouillés entrer en contact
avec des pièces sous tension.
l Isolez-vous du travail et de la terre.
fuera del área de trabajo.
l Gardez à l’écart de tout matériel
inflammable.
l Entfernen Sie brennbarres Material!
Teile oder Elektroden mit Ihrem
Körper oder feuchter Kleidung!
l Isolieren Sie sich von den
Elektroden und dem Erdboden!
l Não toque partes elétricas e elec-
trodos com a pele ou roupa molhada.
l Isole-se da peça e terra.
cuerpo.
l Protégez vos yeux, vos oreilles et
votre corps.
l Tragen Sie Augen-, Ohren- und Kör-
perschutz!
l Mantenha inflamáveis bem guarda-
dos.
l Use proteção para a vista, ouvido e
corpo.
Chinese
Korean
Arabic
READ AND UNDERSTAND 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 FABRICANTE PARA EL USO DE ESTE EQUIPO Y LOS
CONSUMIBLES 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 A
ETRE EMPLOYES ET SUIVEZ LES PROCEDURES DE SECURITE DE VOTRE EMPLOYEUR.
LESEN SIE UND BEFOLGEN SIE DIE BETRIEBSANLEITUNG DER ANLAGE UND DEN ELEKTRODENEINSATZ DES HERSTELLERS. DIE UNFALLVERHÜTUNGSVORSCHRIFTEN DES ARBEITGEBERS SIND EBENFALLS ZU BEACHTEN.
l Keep your head out of fumes.
l Use ventilation or exhaust to
l Turn power off before servicing.
l Do not operate with panel open or
guards off.
remove fumes from breathing zone.
l Los humos fuera de la zona de res-
piración.
l Mantenga la cabeza fuera de los
humos. Utilice ventilación o
aspiración para gases.
l Gardez la tête à l’écart des fumées.
l Utilisez un ventilateur ou un aspira-
l Desconectar el cable de ali-
mentación de poder de la máquina
antes de iniciar cualquier servicio.
l Débranchez le courant avant l’entre-
tien.
teur pour ôter les fumées des zones
de travail.
l Vermeiden Sie das Einatmen von
Schweibrauch!
l Sorgen Sie für gute Be- und
Entlüftung des Arbeitsplatzes!
l Mantenha seu rosto da fumaça.
l Use ventilação e exhaustão para
remover fumo da zona respiratória.
l Strom vor Wartungsarbeiten
l No operar con panel abierto o
guardas quitadas.
l N’opérez pas avec les panneaux
ouverts ou avec les dispositifs de
protection enlevés.
l Anlage nie ohne Schutzgehäuse
abschalten! (Netzstrom völlig öffnen; Maschine anhalten!)
oder Innenschutzverkleidung in
Betrieb setzen!
l Não opere com as tampas removidas.
l Desligue a corrente antes de fazer
l Mantenha-se afastado das partes
serviço.
l Não toque as partes elétricas nuas.
moventes.
l Não opere com os paineis abertos
ou guardas removidas.
WARNING
AVISO DE
PRECAuCION
Spanish
French
ATTENTION
German
WARNuNG
Portuguese
ATENÇÃO
Japanese
Chinese
Korean
Arabic
LEIA E COMPREENDA AS INSTRUÇÕES DO FABRICANTE PARA ESTE EQUIPAMENTO E AS PARTES DE USO, E SIGA AS
PRÁTICAS DE SEGURANÇA DO EMPREGADOR.
cUstoMer assistance policY
The business of The Lincoln Electric Company is manufacturing
and selling high quality welding equipment, consumables, and
cutting equipment. Our challenge is to meet the needs of our
customers and to exceed their expectations. On occasion,
purchasers may ask Lincoln Electric for advice or information
about their use of our products. We respond to our customers
based on the best information in our possession at that time.
Lincoln Electric is not in a position to warrant or guarantee such
advice, and assumes no liability, with respect to such information
or advice. We expressly disclaim any warranty of any kind,
including any warranty of fitness for any customer’s particular
purpose, with respect to such information or advice. As a matter of
practical consideration, we also cannot assume any responsibility
for updating or correcting any such information or advice once it
has been given, nor does the provision of information or advice
create, expand or alter any warranty 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 control of, and remains the sole responsibility of the
customer. Many variables beyond the control of Lincoln Electric
affect the results obtained in applying 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.com for any updated information.
TABLE OF CONTENTS
GENERAL DESCRIPTION
INSTALLATION
TECHNICAL SPECIFICATIONS
VRD (VOLTAGE REDUCTION DEVICE)
SAFETY PRECAUTIONS
Location and Ventilation
LIFTING
TOWING
VEHICLE MOUNTING
PRE-OPERATION ENGINE SERVICE
OIL
FUEL
ENGINE COOLING SYSTEM
BATTERY CONNECTION
MUFFLER OUTLET PIPE
SPARK ARRESTER
REMOTE CONTROL
ELECTRICAL CONNECTIONS
Welding TERMINALS
Welding OUTPUT Cables
AUXILIARY POWER RECEPTACLES
STANDBY POWER CONNECTIONS
CONNECTION OF VANTAGE
300 TO PREMISES WIRING
CONNECTION OF LINCOLN ELECTRIC WIRE
FEEDERS
OPERATION
SAFETY PRECAUTIONS
For Auxiliary Power
ENGINE OPERATION
WELDING CONTROLS
ENGINE CONTROLS
STOPPING THE ENGINE
FUEL CONSUMPTION
TIG Welding
WIRE WELDING-CV
ARC GOUGING
Auxiliary Power
ACCESSORIES
MAINTENANCE
Air Cleaner
GFCI Testing AND RESETTING PROCEDURE
TROUBLE SHOOTING
How to Use Troubleshooting Guide
DIAGRAMS
Was this manual useful for you? yes no
Thank you for your participation!

* Your assessment is very important for improving the work of artificial intelligence, which forms the content of this project

Download PDF

advertisement