RETURN TO MAIN MENU VANTAGE® 300 For use with machines having Code Numbers: IM992 November, 2010 11528 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.
i i SAFETY WARNING CALIFORNIA PROPOSITION 65 WARNINGS Diesel engine exhaust and some of its constituents are known to the State of California to cause cancer, birth defects, and other reproductive harm. The Above For Diesel Engines The engine exhaust from this product contains chemicals known to the State of California to cause cancer, birth defects, or other reproductive harm. The Above For Gasoline Engines ARC WELDING CAN BE HAZARDOUS.
ii ii SAFETY ELECTRIC SHOCK can kill. 3.a. The electrode and work (or ground) circuits are electrically “hot” when the welder is on. Do not touch these “hot” parts with your bare skin or wet clothing. Wear dry, hole-free gloves to insulate hands. 3.b. Insulate yourself from work and ground using dry insulation. Make certain the insulation is large enough to cover your full area of physical contact with work and ground.
iii iii 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.
iv SAFETY PRÉCAUTIONS DE SÛRETÉ Pour votre propre protection lire et observer toutes les instructions et les précautions de sûreté specifiques qui parraissent dans ce manuel aussi bien que les précautions de sûreté générales suivantes: Sûreté Pour Soudage A LʼArc 1. Protegez-vous contre la secousse électrique: a. Les circuits à lʼélectrode et à la piéce sont sous tension quand la machine à souder est en marche.
v v Thank You for selecting a QUALITY product by Lincoln Electric. We want you to take pride in operating this Lincoln Electric Company product ••• as much pride as we have in bringing this product to you! 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.
vi vi TABLE OF CONTENTS Page Installation ..........................................................................................................................Section A Technical Specifications ...............................................................................................A-1, A-2 Safety Precautions ........................................................................................................A-3 VRD (Voltage Reduction Device) .................................................
vii TABLE OF CONTENTS Maintenance......................................................................................................Section D Safety Precautions ................................................................................................D-1 Routine Maintenance ............................................................................................D-1 Engine Oil Filter Change.................................................................................D-2 Air Cleaner ..........
A-1 A-1 INSTALLATION TECHNICAL SPECIFICATIONS - VANTAGE® 300 (K2499-3) INPUT - DIESEL ENGINE Make/Mode Description Horsepower Operating Displacement cu. in. (ltrs.) @ 1800 RPM Speed (RPM) Bore x Stroke inch (mm) 4 Cylinder naturally K2499-3 aspirated Deutz* D2008 L4 Water Cooled Diesel Engine 24 HP High 1800 RPM Full Load 1800 RPM Low Idle 1400 RPM 95 (1.56) 3.0 x 3.4 (76 x 86) Capacities Starting Systems 12VDC Battery Fuel: 20gal.(75.7L) and starter Oil: 7.8qts.(7.
A-2 INSTALLATION A-2 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) AUXILIARY POWER CIRCUIT BREAKER Two 20AMP for Two Duplex Receptacle OTHER CIRCUIT BREAKERS 10AMP for Engine Battery Charging Circuit (1) 50Amp for Dual Voltage and 3-Phase (3-pole) 10AMP for 42V Wire Feeder Power VANTAGE® 300
A-3 A-3 INSTALLATION SAFETY PRECAUTIONS FIGURE A.1 WARNING (VRD)-VOLTAGE REDUCTION DEVICE SWITCH IS LOCATED IN THIS AREA. Do not attempt to use this equipment until you have thoroughly read the engine manufacturerʼs manual supplied with your welder. It includes important safety precautions, detailed engine starting, operating and maintenance instructions, and parts lists. -----------------------------------------------------------------------ELECTRIC SHOCK can kill.
A-4 LIFTING The VANTAGE® 300 weighs approximately 1305 lbs. (592kg.) with a full tank of fuel (1150 lbs. (522kg.) less fuel). A lift bail is mounted to the machine and should always be used when lifting the machine. WARNING HIGH ALTITUDE OPERATION FALLING EQUIPMENT can cause injury. A-4 INSTALLATION TOWING Use a recommended trailer for use with this equipment for road, in-plant and yard towing by a vehicle(1).
A-5 A-5 INSTALLATION PRE-OPERATION ENGINE SERVICE ENGINE COOLING SYSTEM READ the engine operating and maintenance instructions supplied with this machine. 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. • Wipe up spilled fuel and allow fumes to clear before starting engine. • Keep sparks and flame away from tank.
A-6 A-6 INSTALLATION REMOTE CONTROL The VANTAGE® 300 is equipped with a 6-pin and a 14-pin connector. The 6-pin connector is for connecting the K857 or K857-1 Remote Control or for TIG welding, the K870 foot Amptrol or the K963-3 hand Amptrol. When in the CC-STICK, Arc Gouging, or CVWIRE modes and when a remote control is connected to the 6-pin Connector, the auto-sensing circuit automatically switches the OUTPUT control from control at the welder to remote control.
A-7 INSTALLATION WELDING OUTPUT CABLES AUXILIARY POWER RECEPTACLES 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.
A-8 INSTALLATION 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.
A-9 A-9 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.
A-10 INSTALLATION CONNECTION OF LINCOLN ELECTRIC WIRE FEEDERS Connection of LN-7 or LN-8 to the VANTAGE® 300 1. Shut the welder off. 2. Connect the LN-7 or LN-8 per instructions on the appropriate connection diagram in Section F. 3. Set the "WIRE FEEDER VOLTMETER" switch to either "+" or "-" as required by the electrode being used. 4. Set the "MODE" switch to the "CV WIRE " position. 5. Set the "ARC CONTROL" knob to "0" initially and adjust to suit. 6.
A-11 INSTALLATION A-11 Spool Gun (K487-25) and Cobramatic to VANTAGE® 300 WARNING Connection of the LN-25 to the VANTAGE® 300 Shut off welder before making any electrical connections. -----------------------------------------------------------------------The LN-25 with or without an internal contactor may be used with the VANTAGE® 300. See the appropriate connection diagram in Section F. • Shut the welder off. • Connect per instructions on the appropriate connection diagram in Section F.
B-1 B-1 OPERATION SAFETY PRECAUTIONS WARNING Do not attempt to use this equipment until you have thoroughly read the engine manufacturerʼs 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.
B-2 B-2 OPERATION FIGURE B.1 1 11 2 9 3 10 4 14 13 15 12 17 8 22 7 16 23 21 18 20 19 5 6 WELDING CONTROLS (Figure B.1) 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.
B-3 B-3 OPERATION 4. ARC CONTROL- The ARC CONTROL dial is active in the CV-WIRE, 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.
B-4 B-4 OPERATION ENGINE CONTROLS: 19. BATTERY CHARGING LIGHT- A warning 12. RUN/STOP SWITCH - RUN position energizes the 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.
B-5 B-5 OPERATION 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 prefilter. WELDER OPERATION DUTY CYCLE Duty Cycle is the percentage of time the load is being applied in a 10 minute period.
B-6 B-6 OPERATION Once the arc is started, normal welding technique for the application is then used. 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. 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. TIG WELDING For indicator light operation, see table B.1.
B-7 B-7 OPERATION 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.
C-1 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.
D-1 MAINTENANCE SAFETY PRECAUTIONS D-1 • Close the drain valve by pushing in and twisting clockwise. Replace the cap. WARNING • 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.
D-2 D-2 MAINTENANCE • Stop the engine and check the oil level. If necessary, add oil to the upper limit mark on the dipstick. OIL FILTER CHANGE • 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. WARNING • Never use gasoline or low flash point solvents for cleaning the air cleaner element.
D-3 D-3 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.
D-4 D-4 MAINTENANCE FUEL COOLING SYSTEM WARNING Diesel Fuel Only - Low sulphur fuel or ultra low HOT COOLANT can burn skin. • Do not remove cap if radiator is hot. -----------------------------------------------------------------------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.
D-5 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. OVERSPEED IS HAZARDOUS The maximum allowable high idle speed for this machine is 1800 R.P.M. no load. Do NOT tamper with governor components or setting or make any other adjustments to increase the maximum speed.
D-6 MAINTENANCE WELDER / GENERATOR MAINTENANCE D-6 GFCI MODULE TESTING AND RESETTING PROCEDURE The GFCI module should be properly tested at least once every month or whenever it is tripped. To properly test and reset the GFCI module: 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.
E-1 TROUBLESHOOTING E-1 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.
E-2 E-2 TROUBLESHOOTING Observe all Safety Guidelines detailed throughout this manual PROBLEMS (SYMPTOMS) POSSIBLE CAUSE RECOMMENDED COURSE OF ACTION Major Physical or Electrical Damage 1. Contact your local Lincoln is Evident. Authorized 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.
E-3 E-3 TROUBLESHOOTING Observe all Safety Guidelines detailed throughout this manual PROBLEMS (SYMPTOMS) POSSIBLE CAUSE RECOMMENDED COURSE OF ACTION Engine shuts down while under a 1. High radiator coolant temperaload. ture. 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.
E-4 E-4 TROUBLESHOOTING 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). 3. Faulty Electronic Governor controller. Engine will not go to high idle under weld or auxiliary loading. 1. Faulty idler solenoid.
E-5 E-5 TROUBLESHOOTING Observe all Safety Guidelines detailed throughout this manual PROBLEMS (SYMPTOMS) POSSIBLE CAUSE RECOMMENDED COURSE OF ACTION Engine does not develop full power. 1. Fuel filter dirty/clogged. Replace. Low weld and auxiliary output. 2. Air filter dirty/clogged. Replace Engine runs rough. Air Filter 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.
E-6 E-6 TROUBLESHOOTING 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.
F-1 DIAGRAMS VANTAGE® 300 F-1
F-2 DIAGRAMS VANTAGE® 300 F-2
F-3 DIAGRAMS VANTAGE® 300 F-3
F-4 DIAGRAMS VANTAGE® 300 F-4
F-5 DIAGRAMS VANTAGE® 300 F-5
F-6 DIAGRAMS VANTAGE® 300 F-6
F-7 DIAGRAMS VANTAGE® 300 F-7
F-8 DIAGRAMS VANTAGE® 300 F-8
F-9 DIAGRAMS VANTAGE® 300 F-9
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.
VANTAGE® 300 1.27 32.3 35.94 913 39.41 1001 14.30 363.2 29.60 751.8 28.95 20.60 735.3 523.3 N.A. CENTER OF GRAVITY WITH OIL IN ENGINE, COOLANT IN RADIATOR, AND EMPTY FUEL TANK. 24.00 609.6 5.75 146.0 27.00 685.8 25.82 655.8 60.00 1524.0 55.50 1409.7 N.A. C .A.N 05.55 7.9041 00.06 0. 4251 03.41 2.3 63 14.93 1001 00.72 28.52 8.5 86 8.556 72.1 3.23 49.5 3 319 00.42 6.9 06 5 7.5 0.6 41 .KNA T LE UF Y TPME DNA , ROTA IDAR NI TNA LOO C ,ENIG NE NI LIO H TI W YTI VARG FO RE TNE C .A.N 5 9.
NOTES VANTAGE® 300
l Do not touch electrically llive Keep flammable materials WARNING Spanish AVISO DE PRECAUCION French ATTENTION German WARNUNG Portuguese ATENÇÃO l Wear eye, ear and body pro parts or electrode with skinaway. or wet clothing. l Insulate yourself from work and ground. tection. l No toque las partes o los l Mantenga el material com - electrodos bajo carga con la bustible fuera del piel o ropa mojada. trabajo. l Aislese del trabajo y de la tierra.
l Keep your head out of fumes. l Use ventilation or exhaust to remove fumes from breathing zone. l Turn power off before ser l Do not operate with panel vicing. open or guards off. WARNING Spanish l No operar con panel abierto l Desconectar el cable de- ali o guardas quitadas. AVISO DE PRECAUCION l Los humos fuera de la zona mentaci n de poder de la de respiraci n. m quina antes de iniciar l Mantenga la cabeza fuera de cualquier servicio. los humos. Utilice venti l laci n o aspiraci n para gases.
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