RETURN TO MAIN MENU IM10064 VANTAGE ® 580 For use with machine having Code Number: August, 2010 11657 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 SAFETY Electromagnetic Compatibility (EMC) Conformance Products displaying the CE mark are in conformity with European Community Council Directive of 15 Dec 2004 on the approximation of the laws of the Member States relating to electromagnetic compatibility, 2004/108/EC. It was manufactured in conformity with a national standard that implements a harmonized standard: EN 60974-10 Electromagnetic Compatibility (EMC) Product Standard for Arc Welding Equipment.
vi SAFETY Electromagnetic Compatibility (EMC) The size of the surrounding area to be considered will depend on the structure of the building and other activities that are taking place. The surrounding area may extend beyond the boundaries of the premises. Methods of Reducing Emissions Mains Supply Welding equipment should be connected to the mains supply according to the manufacturer’s recommendations.
vii vii 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.
viii viii TABLE OF CONTENTS Page Installation.......................................................................................................................Section A Technical Specifications .......................................................................................................A-1 Safety Precautions ........................................................................................................A-2 VRD (Voltage Reduction Device) ..............................................
ix TABLE OF CONTENTS Maintenance......................................................................................................Section D Safety Precautions ................................................................................................D-1 Routine Maintenance ............................................................................................D-1 Engine Service Items.............................................................................................
A-1 A-1 INSTALLATION TECHNICAL SPECIFICATIONS - VANTAGE® 580 (K2963-1) INPUT - DIESEL ENGINE Make/Model Description PERKINS 404D-22T 4 cylinder 43 HP 1850 RPM Turbo Charged water cooled Diesel Engine Speed (RPM) Displacement cu. in. (ltrs.) Starting System Capacities 12VDC Battery & Fuel: 20 gal. starter (75.7 L) Bore x Stroke inch (mm) (Group 34; 650 Oil: 8.45Qts. (8L) cold crank amps) 3.43 X 3.64 65 Amp Alternator Radiator Coolant: (87.1 x 92.5mm) W / Built in Regulator 11.5 Qts. (10.9L) 135.
A-2 A-2 INSTALLATION SAFETY PRECAUTIONS With the VRD switch in the “On” position, the VRD lights are enabled. WARNING FIGURE A.1 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-3 WARNING • 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. FALLING EQUIPMENT can cause injury. A-3 INSTALLATION • Do not lift machine if lift bail is damaged. • Do not operate machine while suspended from lift bail. 1. Design capacity of trailer vs. weight of Lincoln equipment and likely additional attachments. 2.
A-4 A-4 INSTALLATION FUEL USE DIESEL FUEL ONLYLow Sulphur fuel or ultra low sulphur fuel in USA and CANADA only. 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 K903-1 must be installed and properly maintained. WARNING 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.
A-5 A-5 INSTALLATION 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"(19mm) wrench. ELECTRICAL CONNECTIONS MACHINE GROUNDING 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.
A-6 A-6 INSTALLATION AUXILIARY POWER RECEPTACLES The auxiliary power capacity of the VANTAGE® 580 is 20kVA of 60Hz three phase power protected by an RCD (Residual Current Device) and a 3 phase 32 amp circuit breaker. The auxiliary power capacity in watts equivalent to volt-amperes at unity power factor. This model has: 1 x 3 phase and neutral Residual Current Device (RCD) protection (30mA) 1 x 3 phase 32 amp Circuit Breaker 1 x 3 phase 415 volt 28 amp 2.
A-7 INSTALLATION CONNECTION OF LINCOLN ELECTRIC WIRE FEEDERS Connection of LN-7 or LN-8 to the VANTAGE® 580 A-7 4. Control Cable Model: • Connect Control Cable between Engine Welder and Feeder. 1. Shut the welder off. • Set the "WELD TERMINALS" switch to "REMOTELY CONTROLLED" 2. Connect the LN-7 or LN-8 per instructions on the appropriate connection diagram in Section F. • Set the MODE switch to the "CV-WIRE " position. 3.
A-8 INSTALLATION A-8 Spool Gun (K487-25) and Cobramatic to VANTAGE® 580 WARNING Connection of the LN-25 to the VANTAGE® 580 Shut off welder before making any electrical connections. -----------------------------------------------------------------------The LN-25 with or without an internal contactor may be used with the VANTAGE® 580 . See the appropriate connection diagram in Section F. • Shut the welder off. • Connect per instructions on the appropriate connection diagram in Section F. 1.
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 16 15 6 5 23 25 24 22 21 7 9 19 8 20 13 18 17 4 3 14 2 11 11 12 10 1 1 12 10 11 2 3 14 4 17 13 18 20 8 19 9 21 7 22 24 23 25 5 6 15 16 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 and ARC GOUGING 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.
B-4 OPERATION ENGINE CONTROLS: B-4 19. ENGINE HOUR METER- Displays the total time that the 13. 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. engine has been running. This meter is useful for scheduling prescribed maintenance. 20. CIRCUIT BREAKER- For protection of Battery Charging Circuit. 21.
B-5 OPERATION 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 determine the cause.
B-6 B-6 OPERATION 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.
B-7 B-7 OPERATION This will keep the "Solid State" contactor open and provide a "cold" electrode until the Amptrol or Arc Start Switch is pressed. When using the TIG Module, the OUTPUT CONTROL on the VANTAGE® 580 is used to set the maximum range of the CURRENT CONTROL on the TIG Module or an Amptrol if connected to the TIG Module. NOTE: The TIG process is to receive a low voltage welding process. There is no difference in operation with the VRD “On” or “Off” for this mode.
C-1 ACCESSORIES FIELD INSTALLED OPTIONS / ACCESSORIES MEDIUM WELDER TRAILER For heavy-duty road, off-road, plant and yard use. Includes pivoting jack stand, safety chains, and 13" wheels. Stiff .120" welded rectangular steel tube frame construction is phosphate etched and powder coat painted for superior rust and corrosion resistance. Low sway suspension gives outstand- ing stability with manageable tongue weight.
C-2 ACCESSORIES HAND AMPTROL® Provides 25 ft. (7.6 m) of remote current control for TIG welding. (6-pin plug connection). Velcro straps secure torch. Order K963-3 (one size fits all Pro-Torch® TIG Torches) C-2 INPUT CABLE (for SG CONTROL MODULE) For Lincoln engine power sources with 14-pin MStype connection, separate 115V NEMA receptacles and output stud connections.
D-1 MAINTENANCE SAFETY PRECAUTIONS D-1 Read the Safety Precautions in the front of this manual and in the Engine Ownerʼs Manual before working on this machine. 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.
D-2 D-2 MAINTENANCE ENGINE OIL CHANGE OIL FILTER 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. • Drain the oil. • 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.
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: Diesel Fuel Only - Low Sulphur Fuel COOLING SYSTEM or Ultra Low Sulphur Fuel in U.S.A. and CANADA only. WARNING 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.
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 1850 RPM, no load. Do NOT tamper with governor components or setting or make any other adjustments to increase the maximum speed.
D-6 MAINTENANCE D-6 GFCI MODULE TESTING AND RESETTING PROCEDURE WELDER / GENERATOR MAINTENANCE STORAGE: Store in clean, dry protected areas. 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: CLEANING: Blow out the generator and controls peri- • If the module has tripped, first carefully remove any odically with low pressure air. Do this at least once a load and check it for damage.
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). 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.
E-5 E-5 TROUBLESHOOTING Observe all Safety Guidelines detailed throughout this manual PROBLEMS (SYMPTOMS) POSSIBLE CAUSE No welding power output. 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. 3. Faulty PC board or welder alternator. Welder has output but no control. 1.
E-6 E-6 TROUBLESHOOTING Observe all Safety Guidelines detailed throughout this manual PROBLEMS (SYMPTOMS) POSSIBLE CAUSE RECOMMENDED COURSE OF ACTION The welding arc is “cold.” The weld- 1. Make sure the MODE selector ing arc is not stable or is not satis- switch is in the correct position for factory. the engine runs normally. the process being used. (For examThe auxiliary power is normal. ple, CV-WIRE, PIPE, CC-STICK.) 2. Make sure the electrode (wire, gas, voltage, current etc.
F-1 DIAGRAMS VANTAGE® 580 F-1
F-2 DIAGRAMS VANTAGE® 580 F-2
F-3 DIAGRAMS VANTAGE® 580 F-3
F-4 DIAGRAMS VANTAGE® 580 F-4
F-5 DIAGRAMS VANTAGE® 580 F-5
F-6 DIAGRAMS VANTAGE® 580 F-6
F-7 DIAGRAMS VANTAGE® 580 F-7
F-8 DIAGRAMS 2 9/03 30/9 2 F-8 VANTAGE® 580
F-9 DIAGRAMS VANTAGE® 580 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 included with the machine. If the diagram is illegible, write to the Service Department for a replacement. Give the equipment code number.
25.82 655.8 24.00 609.6 5.75 146.0 VANTAGE® 580 1.27 32.3 39.41 1001 35.94 913.0 16.75 425.4 NOTES: N.A. CENTER OF GRAVITY WITH OIL IN ENGINE, COOLANT IN RADIATOR, AND EMPTY FUEL TANK. 27.00 685.8 20.60 523.3 30.69 779.5 28.95 735.3 36.06 915.9 60.00 1524.0 55.50 1409.7 N.A. B 2 6.6 4 5 1. 48 11 52 .2 2. 75 .A.N 0 5. 55 7.9 04 1 0 0. 06 0. 42 51 5 9.8 2 3 .5 37 9 6. 03 5.9 7 7 60 .6 3 9. 51 9 0 6. 02 3. 32 5 28. 52 8 .5 56 57 .6 1 4. 52 4 0 0.7 2 8. 58 6 1 4. 93 10 01 7 2. 1 3.
G Do not touch electrically live WARNING Spanish AVISO DE PRECAUCION French ATTENTION German WARNUNG parts or electrode with skin or wet clothing. G Insulate yourself from work and ground. G No toque las partes o los elec- trodos bajo carga con la piel o ropa mojada. G Aislese del trabajo y de la tierra. G Ne laissez ni la peau ni des vêtements mouillés entrer en contact avec des pièces sous tension. G Isolez-vous du travail et de la terre.
G Keep your head out of fumes. G Use ventilation or exhaust to G Turn power off before servic- ing. G Do not operate with panel open or guards off. remove fumes from breathing zone. G Los humos fuera de la zona de respiración. G Mantenga la cabeza fuera de los humos. Utilice ventilación o aspiración para gases. G Gardez la tête à lʼécart des fumées.
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