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IM10064
VANTAGE ® 580
August, 2010
For use with machine having Code Number:
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 READ-
ING THIS MANUAL AND THE
SAFETY PRECAUTIONS CON-
TAINED THROUGHOUT. And,
most importantly, think before
you act and be careful.
Equipped with VRD (VOLTAGE REDUCTION DEVICE)
See Installation and Operation sections for an explanation.
OPERATORʼSꢀMANUAL
Copyright © Lincoln Global Inc.
• World's Leader in Welding and Cutting Products •
• Sales and Service through Subsidiaries and Distributors Worldwide •
Cleveland, Ohio 44117-1199 U.S.A. TEL: 216.481.8100 FAX: 216.486.1751 WEBꢀSITE: www.lincolnelectric.com
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SAFETY
ARC RAYS can burn.
ELECTRIC SHOCK can
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.
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.
4.b. Use suitable clothing made from durable flame-resistant
material to protect your skin and that of your helpers from
the arc rays.
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.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:
FUMES AND GASES
can be dangerous.
5.a. Welding may produce fumes and gases
hazardous to health. Avoid breathing these
• Semiautomatic DC Constant Voltage (Wire) Welder.
• DC Manual (Stick) Welder.
fumes and gases. When welding, keep
your head out of the fume. Use enough
ventilation and/or exhaust at the arc to keep
• AC Welder with Reduced Voltage Control.
fumes and gases away from the breathing zone. When
welding with electrodes which require special
ventilation such as stainless or hard facing (see
instructions on container or MSDS) 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. In confined spaces or in some circum-
stances, outdoors, a respirator may be required.
Additional precautions are also required when welding
on galvanized steel.
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.
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 spe-
cific 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.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.
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 prod-
ucts.
3.i. When working above floor level, use a safety belt to protect
yourself from a fall should you get a shock.
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 manufacturerʼs instructions for this
equipment and the consumables to be used, including the
material safety data sheet (MSDS) and follow your
employerʼs safety practices. MSDS forms are available from
your welding distributor or from the manufacturer.
5.f. Also see item 1.b.
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SAFETY
WELDING and CUTTING
CYLINDER may explode
if damaged.
SPARKS can
cause fire or explosion.
6.a. Remove fire hazards from the welding area.
7.a. Use only compressed gas cylinders
containing the correct shielding gas for the
If this is not possible, cover them to prevent
process used and properly operating
the welding sparks from starting a fire.
regulators designed for the gas and
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.
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.
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.
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.
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.
7.d. Never allow the electrode, electrode holder or any other
electrically “hot” parts to touch a cylinder.
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).
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
1235 Jefferson Davis Highway, Arlington, VA 22202.
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.
FOR ELECTRICALLY
powered equipment.
8.a. Turn off input power using the disconnect
switch at the fuse box before working on
the equipment.
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 cir-
cuits. This can create fire hazards or overheat lifting chains
or cables until they fail.
8.b. Install equipment in accordance with the U.S. National
Electrical Code, all local codes and the manufacturerʼs
recommendations.
8.c. Ground the equipment in accordance with the U.S. National
Electrical Code and the manufacturerʼs recommendations.
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.
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SAFETY
PRÉCAUTIONS DE SÛRETÉ
6. Eloigner les matériaux inflammables ou les recouvrir afin de
prévenir tout risque dʼincendie dû aux étincelles.
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 suiv-
antes:
7. Quand on ne soude pas, poser la pince à une endroit isolé de
la masse. Un court-circuit accidental peut provoquer un
échauffement et un risque dʼincendie.
Sûreté Pour Soudage A LʼArc
8. Sʼassurer que la masse est connectée le plus prés possible
de la zone de travail quʼil est pratique de le faire. Si on place
la masse sur la charpente de la construction ou dʼautres
endroits éloignés de la zone de travail, on augmente le risque
de voir passer le courant de soudage par les chaines de lev-
age, câbles de grue, ou autres circuits. Cela peut provoquer
des risques dʼincendie ou dʼechauffement des chaines et des
câbles jusquʼà ce quʼils se rompent.
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. Eviter toujours
tout contact entre les parties sous tension et la peau nue
ou les vétements mouillés. Porter des gants secs et sans
trous pour isoler les mains.
b. Faire trés attention de bien sʼisoler de la masse quand on
soude dans des endroits humides, ou sur un plancher
metallique ou des grilles metalliques, principalement dans
les positions assis ou couché pour lesquelles une grande
partie du corps peut être en contact avec la masse.
c. Maintenir le porte-électrode, la pince de masse, le câble
de soudage et la machine à souder en bon et sûr état
defonctionnement.
d.Ne jamais plonger le porte-électrode dans lʼeau pour le
refroidir.
e. Ne jamais toucher simultanément les parties sous tension
des porte-électrodes connectés à deux machines à souder
parce que la tension entre les deux pinces peut être le
total de la tension à vide des deux machines.
f. Si on utilise la machine à souder comme une source de
courant pour soudage semi-automatique, ces precautions
pour le porte-électrode sʼapplicuent aussi au pistolet de
soudage.
9. Assurer une ventilation suffisante dans la zone de soudage.
Ceci est particuliérement important pour le soudage de tôles
galvanisées plombées, ou cadmiées ou tout autre métal qui
produit des fumeés toxiques.
10. Ne pas souder en présence de vapeurs de chlore provenant
dʼopérations de dégraissage, nettoyage ou pistolage. La
chaleur ou les rayons de lʼarc peuvent réagir avec les vapeurs
du solvant pour produire du phosgéne (gas fortement toxique)
ou autres produits irritants.
11. Pour obtenir de plus amples renseignements sur la sûreté,
voir le code “Code for safety in welding and cutting” CSA
Standard W 117.2-1974.
2. Dans le cas de travail au dessus du niveau du sol, se protéger
contre les chutes dans le cas ou on recoit un choc. Ne jamais
enrouler le câble-électrode autour de nʼimporte quelle partie
du corps.
PRÉCAUTIONS DE SÛRETÉ POUR
LES MACHINES À SOUDER À
TRANSFORMATEUR ET À
REDRESSEUR
3. Un coup dʼarc peut être plus sévère quʼun coup de soliel,
donc:
a. Utiliser un bon masque avec un verre filtrant approprié
ainsi quʼun verre blanc afin de se protéger les yeux du ray-
onnement de lʼarc et des projections quand on soude ou
quand on regarde lʼarc.
b. Porter des vêtements convenables afin de protéger la
peau de soudeur et des aides contre le rayonnement de
lʻarc.
c. Protéger lʼautre personnel travaillant à proximité au
soudage à lʼaide dʼécrans appropriés et non-inflammables.
1. Relier à la terre le chassis du poste conformement au code de
lʼélectricité et aux recommendations du fabricant. Le dispositif
de montage ou la piece à souder doit être branché à une
bonne mise à la terre.
2. Autant que possible, Iʼinstallation et lʼentretien du poste seront
effectués par un électricien qualifié.
3. Avant de faires des travaux à lʼinterieur de poste, la debranch-
er à lʼinterrupteur à la boite de fusibles.
4. Des gouttes de laitier en fusion sont émises de lʼarc de
soudage. Se protéger avec des vêtements de protection libres
de lʼhuile, tels que les gants en cuir, chemise épaisse, pan-
talons sans revers, et chaussures montantes.
4. Garder tous les couvercles et dispositifs de sûreté à leur
place.
5. Toujours porter des lunettes de sécurité dans la zone de
soudage. Utiliser des lunettes avec écrans lateraux dans les
zones où lʼon pique le laitier.
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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.
It is for use with other Lincoln Electric equipment. It is designed for industrial and professional use.
Introduction
All electrical equipment generates small amounts of electromagnetic emission. Electrical emission may be
transmitted through power lines or radiated through space, similar to a radio transmitter. When emissions
are received by other equipment, electrical interference may result. Electrical emissions may affect many
kinds of electrical equipment; other nearby welding equipment, radio and TV reception, numerical controlled
machines, telephone systems, computers, etc. Be aware that interference may result and extra precautions
may be required when a welding power source is used in a domestic establishment.
Installation and Use
The user is responsible for installing and using the welding equipment according to the manufacturer’s
instructions. If electromagnetic disturbances are detected then it shall be the responsibility of the user of the
welding equipment to resolve the situation with the technical assistance of the manufacturer. In some cases
this remedial action may be as simple as earthing (grounding) the welding circuit, see Note. In other cases it
could involve construction of an electromagnetic screen enclosing the power source and the work complete
with associated input filters. In all cases electromagnetic disturbances must be reduced to the point where
they are no longer troublesome.
Note: The welding circuit may or may not be earthed for safety reasons according to national codes.
Changing the earthing arrangements should only be authorized by a person who is compe-
tent to access whether the changes will increase the risk of injury, e.g., by allowing parallel
welding current return paths which may damage the earth circuits of other equipment.
Assessment of Area
Before installing welding equipment the user shall make an assessment of potential electromagnetic prob-
lems in the surrounding area. The following shall be taken into account:
a) other supply cables, control cables, signaling and telephone cables; above, below and adjacent to the
welding equipment;
b) radio and television transmitters and receivers;
c) computer and other control equipment;
d) safety critical equipment, e.g., guarding of industrial equipment;
e) the health of the people around, e.g., the use of pacemakers and hearing aids;
f) equipment used for calibration or measurement
g) the immunity of other equipment in the environment. The user shall ensure that other equipment being
used in the environment is compatible. This may require additional protection measures;
h) the time of day that welding or other activities are to be carried out.
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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 recommenda-
tions. If interference occurs, it may be necessary to take additional precautions such as filtering of the mains
supply. Consideration should be given to shielding the supply cable of permanently installed welding equip-
ment, in metallic conduit or equivalent. Shielding should be electrically continuous throughout its length. The
shielding should be connected to the welding power source so that good electrical contact is maintained
between the conduit and the welding power source enclosure.
Maintenance of the Welding Equipment
The welding equipment should be routinely maintained according to the manufacturer’s recommendations.
All access and service doors and covers should be closed and properly fastened when the welding equip-
ment is in operation. The welding equipment should not be modified in any way except for those changes
and adjustments covered in the manufacturers instructions. In particular, the spark gaps of arc striking and
stabilizing devices should be adjusted and maintained according to the manufacturer’s recommendations.
Welding Cables
The welding cables should be kept as short as possible and should be positioned close together, running at
or close to floor level.
Equipotential Bonding
Bonding of all metallic components in the welding installation and adjacent to it should be considered.
However, metallic components bonded to the work piece will increase the risk that the operator could
receive a shock by touching these metallic components and the electrode at the same time. The operator
should be insulated from all such bonded metallic components.
Earthing of the Workpiece
Where the workpiece is not bonded to earth for electrical safety, not connected to earth because of its size
and position, e.g., ships hull or building steelwork, a connection bonding the workpiece to earth may reduce
emissions in some, but not all instances. Care should be taken to prevent the earthing of the workpiece
increasing the risk of injury to users, or damage to other electrical equipment. Where necessary, the connec-
tion of the workpiece to earth should be made by a direct connection to the workpiece, but in some countries
where direct connection is not permitted, the bonding should be achieved by suitable capacitance, selected
according to national regulations.
Screening and Shielding
Selective screening and shielding of other cables and equipment in the surrounding area may alleviate prob-
lems of interference. Screening of the entire welding installation may be considered for special
1.
applications
_________________________
1
Portions of the preceding text are contained in EN 60974-10: “Electromagnetic Compatibility (EMC) prod-
uct standard for arc welding equipment.”
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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!
Thank You
CUSTOMER ASSISTANCE POLICY
The business of The Lincoln Electric Company is manufacturing and selling high quality welding equipment, consumables, and cutting equip-
ment. 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 posses-
sion at that time. Lincoln Electric is not in a position to warrant or guarantee such advice, and assumes no liability, with respect to such infor-
mation or advice. We expressly disclaim any warranty of any kind, including any warranty of fitness for any customerʼs 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.
for any updated information.
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.
Please record your equipment identification information below for future reference. This information can be
found on your machine nameplate.
Product _________________________________________________________________________________
Model Number ___________________________________________________________________________
Code Number or Date Code_________________________________________________________________
Serial Number____________________________________________________________________________
Date Purchased___________________________________________________________________________
Where Purchased_________________________________________________________________________
Whenever you request replacement parts or information on this equipment, always supply the information you
have recorded above. The code number is especially important when identifying the correct replacement parts.
On-Line Product Registration
- Register your machine with Lincoln Electric either via fax or over the Internet.
• For faxing: Complete the form on the back of the warranty statement included in the literature packet
accompanying this machine and fax the form per the instructions printed on it.
• For On-Line Registration: Go to our WEBꢀSITE at www.lincolnelectric.com. Choose “Quick Links” and then
“Product Registration”. Please complete the form and submit your registration.
Read this Operators Manual completely before attempting to use this equipment. Save this manual and keep it
handy for quick reference. Pay particular attention to the safety instructions we have provided for your protection.
The level of seriousness to be applied to each is explained below:
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.
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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-2
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-3
Oil..................................................................................................................................A-3
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 and Plugs...............................................................................A-6
Standby Power Connections................................................................................................A-6
Connection of Lincoln Electric Wire Feeders................................................................A-7, A-8
________________________________________________________________________________
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 and Stopping the Engine...........................................................................B-4,B-5
Welding Operation................................................................................................................B-5
Duty Cycle and Electrode Information...........................................................................B-5
Constant Current (Stick) Welding.........................................................................................B-5
Downhill Pipe (Stick) Welding................................................................................B-5, 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,C-2
________________________________________________________________________________
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TABLE OF CONTENTS
Maintenance......................................................................................................Section D
Safety Precautions ................................................................................................D-1
Routine Maintenance ............................................................................................D-1
Engine Service Items.............................................................................................D-1
Engine Oil Change..........................................................................................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
________________________________________________________________________
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.....................................................................................................P-657 Series
________________________________________________________________________
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A-1
A-1
INSTALLATION
TECHNICAL SPECIFICATIONS - VANTAGE® 580 (K2963-1)
INPUT - DIESEL ENGINE
Make/Model
Description
Speed (RPM)
Displacement
cu. in. (ltrs.)
Starting
System
Capacities
4 cylinder
43 HP
135.6(2.2)
12VDC Battery &
starter
Fuel: 20 gal.
(75.7 L)
High Idle 1850
Full Load 1850
Low Idle 1400
PERKINS
404D-22T
1850 RPM
Turbo Charged
water cooled
Diesel Engine
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)
RATED OUTPUT @ 104° F (40° C) - WELDER
Welding Process
Welding Output
Current/Voltage/Duty Cycle
500A / 40V / 100%
525A / 38V / 60%
Output Range
Max. Weld OCV
@Rated Load RPM
DC Constant Current
30 TO 525 AMPS
(2)
60 Volts
300A / 32V / 100%
250A / 30V / 100%
500A / 40V / 100%
525A / 38V / 60%
DC Pipe Current
Touch-Start™TIG
DC Constant Voltage
40 TO 300 AMPS
20 TO 250 AMPS
14 TO 40 VOLTS
60 Volts
Arc Gouging
200 TO 580 AMPS
.
500A / 40V / 100%
RATED OUTPUT @ 40° C (104° F) - GENERATOR
(1)
Auxiliary Power (60 Hz)
Outlets x Phase
Voltage
415 Volts
240 Volts
Power
20 Kva
7.2 Kva
Amps
28 Amps
15 Amps
1 x 3ph
2 x 1ph
ENGINE
LUBRICATION
EMISSIONS
FUEL SYSTEM
GOVERNOR
Full Pressure
EPA Tier 4
Mechanical Fuel Pump, Auto air bleed
Interim Compliant system, Electric shutoff solenoid, Indirect fuel injection.
Electronic
with Full Flow Filter
AIR CLEANER
ENGINE IDLER
MUFFLER
Low noise Muffler:
ENGINE PROTECTION
Shutdown on low oil
pressure & high engine
coolant temperature
Single Element
Automatic Idler
Top outlet can be rotated.
Made from long life, aluminized steel.
ENGINE WARRANTY: 2 years / 2000 hours, all non-electric components, 3 years major non-electric compo-
nents . See Perkins warranty for details.
PHYSICAL DIMENSIONS
HEIGHT
35.94 in.
913 mm
WIDTH
27.05 in
687 mm
DEPTH
62.59 in.
1590 mm
WEIGHT
(4)
1290 lbs. (586kg.)
(1) 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.
(2) Reduced to less than 30V in the CC-stick Mode when VRD (VOLTAGE REDUCTION DEVICE) is on.
(3) Maximum per circuit breaker rating.
(4) To Top of enclosure. Add 7.35 (186.7mm) to top of exhaust. Add 3.87”(98.3mm) to top of Lift Bail.
VANTAGE® 580
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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.
(VRD)-VOLTAGE REDUCTION DEVICE
SWITCH IS LOCATED IN THIS AREA.
------------------------------------------------------------------------
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.
------------------------------------------------------------------------
ENGINEꢀEXHAUSTꢀcan kill.
• Use in open, well ventilated areas or
vent exhaust outside.
------------------------------------------------------------------------
MOVING PARTSꢀcan injure.
REMOVE 4 FRONT PANEL
SCREWS TO ACCESS
(VRD) SWITCH
• Do not operate with doors open or
guards off.
• Stop engine before servicing.
• Keep away from moving parts.
LOCATION AND VENTILATION
------------------------------------------------------------------------
See additional warning information at
The welder should be located to provide an unrestrict-
ed 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 prop-
erly vented to an outside area.
front of this operatorʼs manual.
Only qualified personnel should install,
use, or service this equipment.
VRD (VOLTAGE REDUCTION DEVICE)
STACKING
TheꢀVRD reduces the OCV (Open Circuit Voltage) at the
welding output terminals while not welding to less than 20V
DC when the resistance of the output circuit is above 200Ω
(ohms).
VANTAGE® 580 machines cannot be stacked.
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 25
degrees in all directions, 35 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.
Thisꢀfeature provides additional safety in environments
with a higher risk of electric shock such as wet areas and
hot humid sweaty conditions.
When VRD is “On” the DOWNHILL PIPE mode is not
available.
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 con-
nections also limits the possibility of other safety issues
such as heat-generated damage, burns and fires.
When operating the welder at an angle, the effective
fuel capacity will be slightly less than the amount
specified.
LIFTING
The machine is shipped with the VRD switch in the “On”
position. To turn it “On” or “Off”.
The VANTAGE® 580 weighs approximately 1460lbs.
(662kg.) with a full tank of fuel 1290lbs. (586kg) less
fuel. A lift bail is mounted to the machine and should
always be used when lifting the machine.
• 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)
VANTAGE® 580
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A-3
A-3
INSTALLATION
1. Design capacity of trailer vs. weight of Lincoln equipment and
likely additional attachments.
WARNING
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 sur-
face on which the trailer will be operated; environmental con-
ditions; like maintenance.
• Lift only with equipment of ade-
quate lifting capacity.
• Be sure machine is stable when lift-
ing.
• 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.
(1)
5. Conformance with federal, state and local laws.
(1)
ments for use on public highways.
VEHICLE MOUNTING
WARNING
FALLING
EQUIPMENT can
cause injury.
Consult applicable federal, state and local laws regarding specific require-
• Do not operate machine while
suspended from lift bail.
--------------------------------------------------------------------------------
HIGH ALTITUDE OPERATION
At higher altitudes, output derating may be necessary. For
maximum rating, derate the machine 1.0% for every 2000 ft.
(610m) up to 6000 ft. (1828m) and 2.0% for every 2000 ft.
(610m) over 6000 ft. (1828m). Due to new EPA and other
local emissions regulations, modifications to the engine for
high altitude are restricted within the United States. If
required contact an authorized Perkins engine field service
shop to determine if any adjustments can be made for oper-
ation in higher elevations.
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.
• Do not exceed maximum rated loads for compo-
nents such as suspension, axles and tires.
• Mount equipment base to metal bed or frame of
vehicle.
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).
• Follow vehicle manufacturerʼs instructions.
------------------------------------------------------------------------
PRE-OPERATION ENGINE SERVICE
READ the engine operating and maintenance instruc-
tions supplied with this machine.
Cold weather starting:
With a fully charged battery and the proper oil, the
engine should start satisfactorily down to -15°F(-
26C°). If the engine must be frequently started at or
below 0°F (-18°C), it may be desirable to install cold-
starting aides. The use of No. 1D diesel fuel is recom-
mended 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.
WARNING
• Stop engine and allow to cool before fueling.
• Do not smoke when fueling.
• Fill fuel tank at a moderate rate and do not over-
fill.
• Wipe up spilled fuel and allow fumes to clear
before starting engine.
Note: Extreme cold weather starting may require
longer glow plug operation.
• Keep sparks and flame away from tank.
------------------------------------------------------------------------
WARNING
Under no conditions should ether or other starting
fluids be used with this engine!
OIL
The VANTAGE® 580 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 Operatorʼs Manual
for specific oil recommendations and break-in information. The oil
change interval is dependent on the quality of the oil and the oper-
ating environment. Refer to the Engine Operatorʼs Manual for more
------------------------------------------------------------------------
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
non-Lincoln 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:
details on the proper service and maintenance intervals.
VANTAGE® 580
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A-4
A-4
INSTALLATION
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.
FUEL
USE DIESEL FUEL ONLY-
Low Sulphur fuel or ultra low sulphur fuel in USA and
CANADA only.
WARNING
WARNING
An incorrect spark arrestor may lead to damage to
the engine or adversely affect performance.
------------------------------------------------------------------------
REMOTE CONTROL
• 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® 580 is equipped with a 6-pin and a
14-pin connector. The 6-pin connector is for connect-
ing the K857 or K857-1 Remote Control or for TIG
welding, the K870 foot Amptrol or the K963-3 hand
Amptrol. When in the ARC GOUGING or CV-WIRE
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.
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.
NOTE: A fuel shut off valve is located on the pre-
filter/sediment filter. Which should be in the
closed position when the welder is not used for
extended periods of time.
--------------------------------------------------------------------------------
ENGINE COOLING SYSTEM
WARNING
Air to cool the engine is drawn in the side and exhaust-
ed through radiator & case back. It is important that the
intake and exhaust air is not restricted. Allow a mini-
mum clearance of 1ft. (0.6m) from the case back and 16
in. (406mm) from either side of the base to a vertical
surface.
When in DOWNHILL PIPE and CC-STICK modes if a
remote control is connected to the 6-Pin or 14 Pin
Connectors, the output is controlled by the remote and
the output control on the machine is used to set the
maximum current range for the remote.
--------------------------------------------------------------------------------
BATTERY CONNECTION
CAUTION
Use caution as the electrolyte is a strong acid that can
burn skin and damage eyes.
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 VANTAGE® 580 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"(10mm) socket.
Attach the negative battery cable to the negative battery ter-
minal and tighten using a 1/2"(13mm) socket or wrench.
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 inac-
tive and the wire feeder voltage control active.
Otherwise, the OUTPUT CONTROL is used to preset
the voltage.
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 bat-
tery 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"(14mm) socket or wrench.
WARNING
NOTE: When a wire feeder with a built in welding
voltage control is connected to the 14-pin connec-
tor, do not connect anything to the 6-pin connec-
tor.
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.
------------------------------------------------------------------------
VANTAGE® 580
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A-5
A-5
INSTALLATION
cables to the output studs. The welding process dic-
tates the polarity of the electrode cable. These con-
nections 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.)
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.
To prevent dangerous electric shock, other equipment
to which this engine driven welder supplies power
must:
TABLE A.1
• Be grounded to the frame of the welder using a
grounded type plug or be double insulated.
TOTAL COMBINED LENGTH OF
ELECTRODE AND WORK CABLES
WARNING
• Do not ground the machine to a pipe that carries
explosive or combustible material.
Cable Size for
Cable Length
400 Amps
60% Duty Cycle
2 / 0 AWG
------------------------------------------------------------------------
0-100 Ft. (0-30 meters)
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 connect-
ed 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 instruc-
tions in the section entitled "Standby Power
Connections" as well as the article on grounding in the
latest National Electrical Code and the local code.
2 / 0 AWG
3 / 0 AWG
100-150 Ft. (30-46 meters)
150-200 Ft. (46-61 meters)
CABLE INSTALLATION
Install the welding cables to your VANTAGE® 580 as
follows.
1. The engine must be OFF to install welding cables.
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 insulat-
ed joints, or to the metal framework of a building
which has been effectively grounded.
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 identi-
fied on the case front.
4. Tighten the flanged nuts securely.
The National Electrical Code lists a number of alter-
nate means of grounding electrical equipment. A
machine grounding stud marked with the symbol
is provided on the front of the welder.
5. Be certain that the metal piece you are welding (the
“work”) is properly connected to the work clamp and
cable.
WELDING TERMINALS
6. Check and tighten the connections periodically.
The VANTAGE® 580 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.
CAUTION
• Loose connections will cause the output termi-
nals to overheat. The terminals may eventually
melt.
• Do not cross the welding cables at the output ter-
minal connection. Keep the cables isolated and
separate from one another.
------------------------------------------------------------------------
WELDING OUTPUT CABLES
With the engine off connect the electrode and work
VANTAGE® 580
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A-6
A-6
INSTALLATION
2. Take necessary steps to assure load is limited to
the capacity of the VANTAGE® 580 by installing a
32 amp, 415 VAC three pole circuit breaker.
Loading above the rated output will reduce output
voltage below the allowable -10% of rated voltage
which may damage appliances or other motor-dri-
ven equipment and may result in overheating of the
VANTAGE® 580 engine.
3. Install a 32 amp 3 phase plug to the triple-pole cir-
cuit breaker using 6.02mm (minimum) x 4 conduc-
tor cable of the desired length.(1 x 32 amp / 415 V
& 2 x 15 amp / 240 V, plugs are available in the
optional KA1373-2 plug kit).
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
4. Plug this cable into the 3 phase receptacle on the
2 x 1 phase 15 amp Circuit Breakers
2 x 1 phase 240 volt 15 amp per outlet
VANTAGE® 580 case front.
Note: The single-phase outlets are from different
WARNING
phases and cannot be paralleled.
• Only a licensed, certified, trained electrician
should install the machine to a premises or resi-
dential electrical system. Be certain that:
The auxiliary power receptacles should only be used
with three or four wire earthed type plugs or approved
double insulated tools. The current rating of any plug
used with the system must be at least equal to the cur-
rent capacity of the associated receptacle.
• The installation complies with the National
Electrical Code and all other applicable electri-
cal codes.
• The premises is isolated and no feedback into
the utility system can occur. Certain laws require
the premises to be isolated before the generator
is linked to the premises. Check your local
requirements.
STANDBY POWER CONNECTIONS
The VANTAGE® 580 is suitable for temporary, stand-
by or emergency power using the engine manufactur-
erʼs recommended maintenance schedule.
------------------------------------------------------------------------
The VANTAGE® 580 can be permanently installed as
a standby power unit for 415/240 volt (60 Hz).
Connections must be made by a licensed electrician
who can determine how the 415/240 VAC power can
be adapted to the particular installation and comply
with all applicable electrical codes. The following infor-
mation can be used as a guide by the electrician for
most applications.
1. Install an isolation switch between the power com-
pany meter and the premises disconnect.(The VAN-
TAGE® 580 and the power company supplies must
not be connected together).
Switch rating must be the same or greater than the
customerʼs premises disconnect and service over
current protection.
VANTAGE® 580
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A-7
A-7
INSTALLATION
4. Control Cable Model:
CONNECTION OF LINCOLN ELECTRIC
WIRE FEEDERS
• Connect Control Cable between Engine Welder
and Feeder.
Connection of LN-7 or LN-8 to the VANTAGE® 580
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.
• Set the "WIRE FEEDER VOLTMETER" switch to
either "+" or "-" as required by the electrode polar-
ity being used.
3. Set the "WIRE FEEDER VOLTMETER" switch to
either "+" or "-" as required by the electrode being
used.
• Set the "ARC CONTROL" knob to "0" initially and
adjust to suit.
4. Set the "MODE" switch to the "CV WIRE " posi-
tion.
5. Set the "ARC CONTROL" knob to "0" initially and
adjust to suit.
• Set the "IDLE" switch to the "AUTO" position.
• When the gun trigger is closed, the current sens-
ing circuit will cause the VANTAGE® 580 engine
to go to the high idle speed, the wire will begin to
feed and the welding process started. When
welding is stopped, the engine will revert to low
idle speed after approximately 12 seconds unless
welding is resumed.
6. Set the "WELD TERMINALS" switch to the
"REMOTELY CONTROLLED" position.
7. Set the "IDLE" switch to the "HIGH" position.
Connection of LN-15 to the VANTAGE® 580
1. Shut the welder off.
2. For electrode Positive, connect the electrode
cable to the "+" terminal of the welder and work
cable to the "-" terminal of the welder. For elec-
trode Negative, connect the electrode cable to the
"-" terminal of the welder and work cable to the "+"
terminal of the welder.
3. Across The-Arc Model:
• Attach the single lead from the front of the LN-15
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.
• Set the "WELD TERMINALS" switch to "WELD
TERMINALS ON".
• When the gun trigger is closed, the current sens-
ing circuit will cause the VANTAGE® 580 engine
to go to the high idle speed, the wire will begin to
feed and the welding process started. When
welding is stopped, the engine will revert to low
idle speed after approximately 12 seconds
unless welding is resumed.
VANTAGE® 580
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A-8
A-8
INSTALLATION
Spool Gun (K487-25) and Cobramatic to VAN-
WARNING
TAGE® 580
Connection of the LN-25 to the VANTAGE® 580
Shut off welder before making any electrical con-
nections.
• Shut the welder off.
• Connect per instructions on the appropriate connec-
tion diagram in Section F.
------------------------------------------------------------------------
The LN-25 with or without an internal contactor may
be used with the VANTAGE® 580 . See the appropri-
ate connection diagram in Section F.
1. Shut the welder off.
2. For electrode Positive, connect the electrode
cable from the LN-25 to the "+" terminal of the
welder and work cable to the "-" terminal of the
welder. For electrode Negative, connect the elec-
trode cable from the LN-25 to the "-" terminal of
the welder and work cable to the "+" terminal of
the welder.
3. Attach the single lead from the front of the LN-25
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.
4. Set the MODE switch to the "CV-WIRE " position.
5. Set the "WELD TERMINALS" switch to "WELD
TERMINALS ON"
6. Set the "ARC CONTROL" knob to "0" initially and
adjust to suit.
7. Set the "IDLE" switch to the "AUTO" position.
When not welding, the VANTAGE® 580 engine
will be at the low idle speed. If you are using an
LN-25 with an internal contactor, the electrode is
not energized until the gun trigger is closed.
8. When the gun trigger is closed, the current sens-
ing circuit will cause the VANTAGE® 580 engine
to go to the high idle speed, the wire will begin to
feed and the welding process started. When weld-
ing is stopped, the engine will revert to low idle
speed after approximately 12 seconds unless
welding is resumed.
CAUTION
If you are using an LN-25 without an internal con-
tactor, the electrode will be energized when the
VANTAGE® 580 is started.
------------------------------------------------------------------------
VANTAGE® 580
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B-1
B-1
OPERATION
• 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 nec-
essary).
SAFETY PRECAUTIONS
WARNING
• See Engine Ownerʼs Manual for specific oil and
coolant recommendations.
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.
WARNING
ADD FUEL
------------------------------------------------------------------------
ELECTRIC SHOCK can kill.
• Stop engine while fueling.
• Do not smoke when fueling.
• Keep sparks and flame away
from tank.
• Do not touch electrically live parts or
electrode with skin or wet clothing.
• Insulate yourself from work and
ground
• Do not leave unattended while
fueling.
• Always wear dry insulating gloves.
• Wipe up spilled fuel and allow
• Always operate the welder with the hinged door
closed and the side panels in place.
DIESEL FUEL
fumes to clear before starting
can cause fire.
engine.
• 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.
• Do not overfill tank, fuel expan-
sion may cause overflow.
Diesel Fuel Only-Low Sulphur Fuel or Ultra Low
Sulphur in USA and Canada.
------------------------------------------------------------------------
• Remove the fuel tank cap.
GENERAL DESCRIPTION
• Fill the tank. DO NOT FILL THE TANK TO THE
POINT OF OVERFLOW.
The VANTAGE® 580 is a diesel engine powered DC
multi-process welding power source and 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
• Replace the fuel cap and tighten securely.
• See Engine Ownerʼs Manual for specific fuel recom-
mendations.
C
T
R
the art Chopper Technology
performance.
for superior welding
C
T
R
BREAK-IN PERIOD
The VANTAGE® 580 is fitted with a selectable
VRD(Voltage Reduction Device). The VRD operates
in all modes except DOWNHILL PIPE, reducing the
OCV to <20 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.
The engine will use a small amount of oil during its
“break-in” period. The break-in period is about 50 run-
ning hours.Check the oil every four hours during
break-in.
Change the oil after the first 50 hours of operation and
every 200 hours thereafter. Change the oil filter at
each oil change.
FOR AUXILIARY POWER:
During break-in, subject the Welder to moderate
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.
CAUTION
loads. Avoid long periods running at idle. Before
stopping the engine, remove all loads and allow
the engine to cool several minutes.
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.
VANTAGE® 580
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B-2
B-2
OPERATION
FIGURE B.1
1
2
1
2
13
12
1
12
10
11
14
2
3
4
17
18
13
20
8
9
19
21
22
7
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 dis-
played 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 cir-
cuit automatically switches the OUTPUT CONTROL
from control at the welder to the remote control.
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.
2. DIGITAL OUTPUT METERS-The digital
meters allow the output voltage (CV-WIRE mode)
or current (CC-STICK, DOWNHILL PIPE, ARC
GOUGING and TIG modes) to be set prior to weld-
ing 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 sec-
onds after welding is stopped. This allows the oper-
ator to read the actual current and voltage just prior
to when welding was ceased.
When in DOWNHILL PIPE and CC-STICK modes if
a remote control is connected to the 6-Pin or 14 Pin
Connectors, the output is controlled by the remote
and the output control on the machine is used to set
the maximum current range for 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.
While the display is being held the left-most deci-
mal 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
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 CON-
TROL inactive and the wire feeder voltage control
active. Otherwise, the OUTPUT CONTROL is used
to preset the voltage
ARC GOUGING
DOWNHILL PIPE
CC-STICK
TOUCH START TIG
VANTAGE® 580
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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.
11. WIRE FEEDER VOLTMETER SWITCH:
Matches the polarity of the wire feeder voltmeter to the
polarity of the electrode.
12. VRD (Voltage Reduction Device) INDICATOR
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 elec-
trode sticking. Start with a setting at 0.
LIGHTS- On the front panel of the VANTAGE® 580 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.
DOWNHILL PIPE mode: In this mode, the ARC CONTROL
dial sets the short circuit current (arc-force) during stick weld-
ing 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 dig-
ging arc. Typically a forceful digging arc is preferred for root
and hot passes. A softer arc is preferred for fill and cap pass-
es 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.
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.
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 induc-
tance/pinch control. The proper setting depends on the proce-
dure and operator preference. Start with a setting of 0.
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 donʼt come “On”,
refer to the trouble shooting section.
5. WELD OUTPUT TERMINALS WITH FLANGE
NUT- Provides a connection point for the electrode and
TABLE B.1
work cables.
VRD INDICATOR LIGHTS
MODE
CC-STICK OCV
While
VRD "ON"
Green (OCV Reduced)
Red or Green
VRD "OFF"
No Lights
6. GROUND STUD-
Provides a connection point for
connecting the machine case to earth ground.
Welding (Depends on Weld Voltage) *
CV-WIRE OCV
Green (OCV Reduced)
Green (No OCV)
7. 14-PIN CONNECTOR- For attaching wire feeder control
cables. Includes contactor closure circuit, auto-sensing
remote control circuit, and 42V power. The remote control
circuit operates the same as the 6 Pin Amphenol.
Weld Terminals Remotely Controlled
Gun Trigger Open
While
Red or Green
Welding (Depends on Weld Voltage) *
PIPE
OCV
Green (No Output)
While
Not Applicable (No Output)
8. 42V / 115V WIRE FEEDER VOLTAGE SWITCH:
Toggles output of 14-pin connector to voltage requirement
of Wire Feeder. (Located above 14-pin connector.)
Welding
ARC GOUGING OCV
Green (OCV Reduced)
(Depends on Weld Voltage) *
While
Welding
TIG
OCV
Green (Process is Low Voltage)
Green (Process is Low Voltage)
While
9. 6-PIN CONNECTOR- For attaching optional remote con-
Welding
trol equipment. Includes auto-sensing remote control circuit.
* It is normal for the lights to alternate between colors while welding.
10. 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 electri-
cally off until a remote switch is depressed.
VANTAGE® 580
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B-4
B-4
OPERATION
ENGINE CONTROLS:
19. ENGINE HOUR METER- Displays the total time that the
engine has been running. This meter is useful for scheduling
prescribed maintenance.
13. RUN/STOP SWITCH -
-RUN position energizes the engine prior to starting. STOP posi-
tion 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.
20. CIRCUIT BREAKER- For protection of Battery Charging
Circuit.
21. ELECTRIC FUEL GAUGE- The electric fuel gauge gives
accurate and reliable indication as to how much fuel is in the
fuel tank.
14. GLOW PLUG PUSH BUTTON -
• When pushed activates the glow plugs. Glow plug should not
be activated for more than 20 seconds continuously.
22. COOLANT TEMPERATURE GAUGE- A indicator of
15. ENGINE STOP SWITCH
Shutʼs down engine.
engine coolant temperature.
23. OIL PRESSURE GAUGE- A indicator of engine Oil
16. BATTERY DISCONNECT SWITCH
Pressure.
Battery disconnect switch provides lockout/tagout capability.
Switch is conveniently located on the front bottom of the
24. ENGINEꢀPROTECTION 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.
machine.
17. START PUSH BUTTON - Energizes the starter motor to
crank the engine.
18. 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.
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 hap pens the RUN-STOP switch must be returned
to the "OFF" position to reset the engine protection system and
light.
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.
25. 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.
• 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.
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.
• The engine will automatically return to high idle speed when
there is welding load or AC power load reapplied.
STARTING THE ENGINE
TABLE B.2
1. Remove all plugs connected to the AC power receptacles.
2. Set IDLER switch to AUTO.
TYPICAL VANTAGE® 580 FUEL CONSUMPTION
PERKINS 404D-22T
Gal./Hr (Liters/Hr)
.38(1.44)
Running Time for
20 gallons / hours
52.63
3. Press Glow Plug Button and hold 15 to 20 seconds.
4. Set the RUN/STOP switch to RUN.
Low Idle - No Load
1400 R.P.M.
5. Press START button until the engine starts or for up to 10 sec-
onds. Continue to hold the glow plug button for up to an addition-
al 10 seconds.
High Idle - No Load
1850 R.P.M.
.59(2.23)
2.15(8.14)
1.91(7.23)
1.1 (4.16)
33.90
9.30
DC Weld Output
500 Amps @ 40Volts
20,000 Watts 3 Phase
6. Release the engine START button immediately when the engine
starts.
10.47
22.03
7. The engine will run at high idle speed for approximately 12 sec-
onds 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 switch-
ing to high idle. Allow a longer warm up time in cold weather.
7,200 Watts 1 Phase
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.
VANTAGE® 580
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B-5
B-5
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 pre-
vents 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: 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.
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 resis-
tance 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 per-
formed.
• 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.
-----------------------------------------------------------------------
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.
A. For New Electrodes
E6010 - Touch, Lift to Start the Arc
E7018, E7024 - Touch, Rock Back and Forth in
Joint, Lift .
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.
Once the arc is started, normal welding technique
for the application is then used.
STOP the engine by placing the RUN-STOP switch in
the STOP position.
B. For Re-Striking Electrodes
NOTE: A fuel shut off valve is located on the fuel pre-filter.
Some electrodes form a cone at the end of the
electrode after the welding arc has been broken,
particularly iron powder and low hydrogen elec-
trodes. This cone will need to be broken off in order
to have the metal core of the electrode make con-
tact.
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.
E6010 - Push, Twist in Joint, Lift
E7018, E7024 - Push, Rock Back and Forth in
Joint, Lift.
ELECTRODE INFORMATION
For any electrode the procedures should be kept with-
in the rating of the machine. For information on elec-
electric.com) or the appropriate Lincoln publication.
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.
The VANTAGE® 580 can be used with a broad range of
DC stick electrodes. The MODE switch provides two
stick welding settings as follows:
For indicator light operation, see Table B.1.
CONSTANT CURRENT (CC-STICK)
WELDING
DOWNHILL PIPE 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.
This slope controlled setting is intended for "out-of-
position" and "down hill" pipe welding where the oper-
ator would like to control the current level by changing
the arc length.
VANTAGE® 580
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B-6
B-6
OPERATION
When in the TOUCH START TIG mode and when a
Amptrol is connected to the 6-Pin connector the OUT-
PUT CONTROL dial is used to set the maximum cur-
rent range of the current control of the Amptrol.
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 pass-
es 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 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 cur-
rent 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.
The VANTAGE® 580 can be used in a wide variety of
DC TIG welding applications. In general the ʻTouch
Startʼ feature allows contamination free starting with-
out the use of a Hi-frequency unit. If desired, the
K930-2 TIG Module can be used with the VANTAGE®
580 . The settings are for reference.
TIG WELDING
The TOUCH START TIG setting of the MODE switch is
for DC TIG (Tungsten Inert Gas) welding. To initiate a
weld, the OUTPUT CONTROL dial is first set to the
desired current and the tungsten is 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.
VANTAGE® 580 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.
TABLE B.3
(1)
(2)
TYPICAL CURRENT RANGES
FOR TUNGSTEN ELECTRODES
Tungsten Electrode
Diameter in. (mm)
DCEN (-)
DCEP (+)
Approximate Argon Gas Flow
Flow Rate C.F.H. ( l /min.)
TIG TORCH
Nozzle Size (4), (5)
1%, 2% Thoriated
Tungsten
1%, 2% Thoriated Aluminum
Tungsten
Stainless Steel
.010
(.25)
2-15
5-20
(3)
(3)
(3)
3-8
(2-4)
(3-5)
(3-5)
3-8
(2-4)
(3-5)
(3-5)
#4, #5, #6
0.020
0.040
(.50)
(1.0)
5-10
5-10
5-10
5-10
15-80
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)
11-15
11-15
(5-7)
(5-7)
#6, #7, #8
(7-11)
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
(8-10)
(11-13)
(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
2% Thoriated
EWTh-1
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.
# 5 = 5/16 in.
# 6 = 3/8 in.
# 7 = 7/16 in.
# 8 = 1/2 in.
#10 = 5/8 in.
(6 mm)
(8 mm)
(10 mm)
(11 mm)
(12.5 mm)
(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.
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B-7
B-7
OPERATION
This will keep the "Solid State" contactor open and provide a
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.
"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 CUR-
RENT CONTROL on the TIG Module or an Amptrol if connect-
ed to the TIG Module.
TABLE B.4
Current Range (DC,
electrode positive)
60-90 Amps
Mode
Carbon Diameter
1/8"(3.2mm)
5/32"(4.0mm)
3/16"9(4.8mm)
1/4"(6.4mm)
CC-STICK
CC-STICK
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. For indicator light oper-
90-150 Amps
200-250 Amps
300-400 Amps
400-Max.Amps
ARC GOUGE
ARC GOUGE
ARC GOUGE
ation, see Table B.1
.
3/8"(10.0mm)
WIRE WELDING-CV
Connect a wire feeder to the VANTAGE® 580 according to the
instructions in INSTALLATION INSTRUCTIONS Section.
The ARC CONTROL is not active in the ARC GOUG-
ING Mode. The ARC CONTROL is automatically set
to maximum when the ARC GOUGING mode is
selected which provides the best ARC GOUGING per-
formance.
The VANTAGE® 580 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 prefer-
ence. Start with the dial set at 0.
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 Table B.5.
ARC GOUGING
The VANTAGE® 580 can be used for arc gouging. For
optimal performance, set the MODE per TABLE B.4.
TABLE B.5 VANTAGE® 580 PERKINS SIMULTANEOUS WELDING AND POWER LOADS
Permissible Auxiliary
WELDING
OUTPUT
PERMISSIBLE
POWER-WATTS
Current in Amperes
(Unity Power Factor)
@ 415V 10%
@ 240V 10%*
500A/40V
350A/34V
200A/30V
150A/26V
90A/24V
0
0
0
0
8,100
14 amp/phase
18.5 amp/phase
23.6 amp/phase
26.4 amp/phase
28 amp/phase
30*
30*
30*
30*
30*
12,000
16,000
18,000
20,000
* Each receptacle is limited to 15 amps.
TABLE B.6
VANTAGE® 580 PERKINS Extension Cord Length Recommendations
(Use the shortest length extension cord possible sized per the following table.)
Maximum Allowable Cord Length in m (ft.) for Conductor Size
Current
(Amps)
Load
Voltage
(Volts)
2
2
2
2
2
2
(Watts)
2.5 mm 14AWG 4.0 mm 12AWG 6.0 mm 10AWG 10.0 mm 8AWG 16.0 mm 6AWG 25.0 mm 4AWG
15
3,600
240
18
(60) (225) (350)
23 (75) 46
107 183 (600)
(150)
69
Conductor size is based on maximum 2.0% voltage drop.
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C-1
C-1
ACCESSORIES
DOCKING KIT
FIELD INSTALLED OPTIONS /
ACCESSORIES
Secures the K2642-1 Polarity/Multi-Process Switch to
the engine-driven welder roof. Release latch permits
removal of K2642-1 Polarity/Multi-Process Switch.
Made from stainless steel for rust-free operation. For
all Lincoln Chopper Technology® engine-driven
welders.
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 resis-
tance. Low sway suspension gives outstand- ing sta-
bility with manageable tongue weight. Wheel bearings
are packed with high viscosity, high pressure, low
washout Lubriplate® grease. Includes a Duo-HitchTM
– a 2" Ball/Lunette Eye combination hitch. Overall
width 60".
Order K2663-1
STICK OPTIONS
ACCESSORY KIT
Includes 35 ft. (10.7 m) 2/0 electrode cable with lug,
30 ft. (9.1 m) 2/0 work cable with lugs, headshield, fil-
ter plate, cover plate, work clamp and electrode hold-
er. 400 amp capacity.
Order:
K2636-1 Trailer
Order K704
K2639-1 Fender & Light Kit
K2640-1 Cable Rack
REMOTE OUTPUT CONTROL
Consists of a control box with choice of two cable
lengths. Permits remote adjustment of output.
Order:
FOUR-WHEELED STEERABLE YARD TRAILER
For off-road, plant and yard use. Includes an automat-
ically engaging drawbar lock when the drawbar is
raised to the verticle position. 13" wheels. Wheel bear-
ings are packed with high viscosity, high pressure, low
washout Lubriplate® grease. Stiff 3/16" welded rec-
tangular steel frame con- struction is phosphate
etched and powder-coat painted for superior rust and
corrosion resistance. Also includes a Duo-HitchTM – a
2" Ball/ Lunette Eye combination hitch. Overall width:
55".
K857 for 25 ft. (7.6 m)
K857-1 for 100 ft. (30.5 m)
TIG OPTIONS
PRO-TORCH® PTA-26V TIG TORCH
Air-cooled 200 amp torch (2 piece) equipped with
valve for gas flow control. 25 ft. (7.6 m) length.
Order K1783-9
Order K2641-2
SPARK ARRESTOR KIT
Mounts to Muffler Exhust Tube. Virtually eliminates
spark emissions.
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 back cap, alumina nozzles and tung-
stens in a variety of sizes, all packaged in an easy to
carry reclosable sack.
Order K903-1
POLARITY/MULTI-PROCESS SWITCH
For easy polarity switching. Example: DC- stick root
pass on pipe & DC+ stick for hot, full and cap passes.
Also for an easy process change. Example: DC+ stick
root pass on pipe & DC- Innershield® self- shielded
flux-cored wirre for hot, fill and cap passes. 6 & 14-pin
remote connections can be made to this unit. For all
Lincoln Chopper Technology® engine-driven welders.
Mounts on roof with K2663-1 Docking Kit.
Order KP509
FOOT AMPTROL®
Provides 25 ft. (7.6 m) of remote output control for TIG
welding. (6-pin plug con- nection).
Order K870
Order K2642-1
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C-2
C-2
ACCESSORIES
HAND AMPTROL®
INPUT CABLE (for SG CONTROL MODULE)
Provides 25 ft. (7.6 m) of remote current control for
TIG welding. (6-pin plug connection). Velcro straps
secure torch.
For Lincoln engine power sources with 14-pin MS-
type connection, separate 115V NEMA receptacles
and output stud connections.
Order K963-3 (one size fits all Pro-Torch® TIG
Torches)
Order K691-10
WIRE FEEDER OPTIONS
LN-25 PRO WIRE FEEDER
Portable CC/CV unit for flux-cored and MIG welding
with MAXTRAC® wire drive system. Includes gas
solenoid and inter- nal contactor
Order K2613-1
MAGNUM® 350 INNERSHIELD GUN (for LN-25
PRO)
For self-shielded wire with 15 ft. (4.5 m) cable. For
.062"-3/32" (1.6-2.4 mm) wire.
Order K126-2
DRIVE ROLL AND GUIDE TUBE KIT (for LN-25
PRO)
For cored or solid steel wire.
Order:
KP1697-068 for .068"-.072" (1.8 mm)
KP1697-5/64 for 5/64" (2.0 mm)
MAGNUM® 300 MIG GUN
For .035"-.045" (0.9-1.2 mm) gas- shielded wire with
15 ft. (4.5 m) cable.
LN-25 PRO
Order:K1802-1 (Includes Connector Kit)
DRIVE ROLL AND GUIDE TUBE KIT (for LN-25
PRO)
For .035" and .045" (0.9-1.1 mm) solid steel wire.
Order KP1696-1
MAGNUM® SG SPOOL GUN
Hand held semiautomatic wire feeder. Requires SG
Control Module and Input Cable.
Order K487-25
SG CONTROL MODULE
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.
Order K488
VANTAGE® 580
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D-1
D-1
MAINTENANCE
SAFETY PRECAUTIONS
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.
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.
------------------------------------------------------------
• 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.)
Routine Maintenance
At the end of each dayʼs 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.
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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.
• 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.
• Be sure the unit is off. Disconnect the negative bat-
tery 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.
• 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 con-
tacts the mounting base. Using an oil filter wrench,
tighten the filter an additional 1/2 to 7/8 of a turn.
• Open oil drain valve by lifting up spring loaded lever
and rotate 90 counterclockwise. Pull to open and
°
drain the oil into a suitable container for disposal.
• Refill the crankcase with the specified amount of the
recommended engine oil. Reinstall the oil filler cap
and tighten securely.
• Close the drain valve by rotating lever 90 clockwise.
°
• Re-fill the crankcase to the upper limit mark on the
dipstick with the recommended oil (see engine oper-
ation manual OR engine service items decal OR
below). Replace and tighten the oil filler cap secure-
ly.
• Start the engine and check for oil filter leaks.
• Stop the engine and check the oil level. If neces-
sary, add oil to the upper limit mark on the dipstick.
• Push oil drain hose and valve back into unit, re-con-
nect 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 sta-
tion or recycling center for reclamation. DO NOT
throw it in the trash; pour it on the ground or down a
drain.
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.
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.
------------------------------------------------------------------------
AIR CLEANER
ACEA E1/E2/E3. Always check the API service label
on the oil container to be sure it includes the letters
indicated. (Note: An S-grade 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 classifi-
cations.)
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.
SAE 10W30 is recommended for general, all tempera-
ture use, 5F to 104F (-15C to 40C).
See engine ownerʼs manual for more specific informa-
tion on oil viscosity recommendations.
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D-3
D-3
MAINTENANCE
Serviice Innsstructtions
Single- and Two-Stage Engine Air Cleaners
Inspect tthe New FFiilter forr Damage
Remove the Filter
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.
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.
Rotate the
filter while
pulling
straight out.
Insert the Neww Radial Seeal Filteerr Properly
If you're servicing the safety filter, this should be seated into
position before installing the primary filter.
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 filter carefully. Seat
the filter by hand, making certain it is
completely into the air cleaner housing
before securing the cover in place.
Clean BBoth Surfaces of the Outlet Tube
and Check the Vacuator™ Valve
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
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.
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.
Wipe both sides
of the outlet
tube clean.
Once the filter is in place, secure the service cover.
Outer edge of the
Inner edge of the
outlet tube
Caution
outlet tube
NEVER usse the sseervice ccover to
push the ffilter innto placcee! Using
the cover tto push thhe filterr in could
cause damage to the housing, cover
fasteners and will voidd the warrranty.
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 Leeak Clues
Check Connnectorrs for Tiight Fit
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!
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.
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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.
At the end of each dayʼs use, refill the fuel tank to min-
imize moisture condensation and dirt contamination in
the fuel line. Do not overfill; leave room for the fuel to
expand.
• Do not remove cap if radiator is
hot.
Use only fresh No. 2D diesel fuel, the use of No. 1D
diesel fuel is recommended in place of No. 2D at tem-
peratures below 23°F (-5°C). Do not use kerosene.
------------------------------------------------------------------------
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.
See the Engine Operator's Manual for instructions on
replacing the fuel filter.
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 stor-
age. It is recommended that the fuel shutoff valve be
closed during periods of non-use.
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 is11.5 quarts (10.9L). Squeeze upper
and lower radiator hoses while filling to bleed air from
system coolant. Replace and tighten the radiator cap.
WARNING
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:
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 dur-
ing hot weather and freezing protection to -34° F (-
37° C).
1. Fill the fuel tank with fuel.
2. Open the fuel shut off valve.
3. Loosen bleed fitting on the fuel injector manifold.
4. 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 prim-
ing lever. Tighten bleed fitting on injector manifold.
5. 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 press-
ing on the belt midway between the pulleys. It should
deflect about .25 in.(6.4 mm) under a load of 20 lbs.(9
Kg).
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D-5
D-5
MAINTENANCE
CLEANING THE BATTERY
FUEL FILTER
Keep the battery clean by wiping it with a damp cloth
when dirty. If the terminals appear corroded, discon-
nect 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 (0.9461L) of water. Be
sure the battery vent plugs (if equipped) are tight so
that none of the solution enters the cells.
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-fil-
ter.
After cleaning, flush the outside of the battery, the bat-
tery 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 accumula-
tion on the battery can lead to more rapid discharge
and early battery failure.
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. Severe personal injury and damage to the
machine can result if operated at speeds above
maximum.
CHECKING THE ELECTROLYTE LEVEL
ENGINE ADJUSTMENT
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.
Adjustments to the engine are to be made only by a
Lincoln Service Center or an authorized Field Service
Shop.
CHARGING THE BATTERY
BATTERY MAINTENANCE
When you charge, jump, replace, or otherwise con-
nect battery cables to the battery, be sure the polarity
is correct. Improper polarity can damage the charging
circuit. The VANTAGE® 580 positive (+) battery termi-
nal 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 out of machine far
enough to disconnect the negative and then positive
battery cables. The tray can then be tilted and lifted to
remove the entire tray and battery from the machine
for easy service.
If you need to charge the battery with an external
charger, disconnect the negative cable first, then the
positive cable before you attach the charger leads.
After the battery is charged, reconnect the positive
battery cable first and the negative cable last. Failure
to do so can result in damage to the internal charger
components.
WARNING
GASES FROM BATTERY can explode.
G
Keep sparks, flame and cigarettes
away from battery.
Follow the instructions of the battery charger manu-
facturer for proper charger settings and charging time.
To prevent EXPLOSION when:
G INSTALLING A NEW BATTERY — disconnect
negative cable from old battery first and con-
nect to new battery last.
SERVICING OPTIONAL SPARK
ARRESTOR
G
CONNECTING A BATTERY CHARGER —
Clean every 100 hours.
remove battery from welder by disconnecting
negative cable first, then positive cable and
battery clamp. When reinstalling, connect
negative cable last. Keep well ventilated.
WARNING
G USING A BOOSTER — connect positive lead to
battery first then connect negative lead to neg-
ative battery lead at engine foot.
BATTERY ACID can burn eyes and
skin.
• MUFFLER MAY BE HOT
• ALLOW ENGINE TO COOL BEFORE INSTALLING
THE SPARK ARRESTER!
G Wear gloves and eye protection
and be careful when working near
battery.
• DO NOT OPERATE ENGINE WHILE INSTALLING
THE SPARK ARRESTER!
------------------------------------------------------------------------
G Follow instructions printed on battery.
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D-6
D-6
MAINTENANCE
GFCI MODULE TESTING AND RESETTING
WELDER / GENERATOR
MAINTENANCE
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 peri-
odically with low pressure air. Do this at least once a
week in particularly dirty areas.
• If the module has tripped, first carefully remove any
load and check it for damage.
• If the equipment has been shut down, it must be
restarted.
BRUSH REMOVAL AND REPLACEMENT: Itʼs nor-
mal for the brushes and slip rings to wear and darken
slightly. Inspect the brushes when a generator over-
haul is necessary.
• 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.
CAUTION
• Push the "Reset" button located on the GFCI module.
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".
• Do not attempt to polish slip rings while the
engine is running.
• Push the "Test" button located on the GFCI module.
The night-light or other product should go "OFF".
• Push the "Reset" button, again. The light or other
product should go "ON" again.
WARNING
• Service and Repair should only be performed by
Lincoln Electric Factory Trained Personnel.
Unauthorized repairs performed on this equip-
ment 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 pre-
cautions.
If the light or other product remains "ON" when the
"Test" button is pushed, the GFCI module is not work-
ing properly or has been incorrectly installed (miswired).
If your GFCI module is not working properly, contact a
qualified, certified electrician who can assess the situa-
tion, rewire the GFCI module if necessary or replace
the device.
------------------------------------------------------------------------
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E-1
E-1
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 three-step procedure listed below.
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.
Step 1. LOCATE PROBLEMꢀ(SYMPTOM).
Look under the column labeled “PROBLEM (SYMP-
TOMS)”. This column describes possible symptoms
that the machine may exhibit. Find the listing that
best describes the symptom that the machine is
exhibiting.
If you do not understand or are unable to perform the
Recommended Course of Action safely, contact your
local Lincoln Authorized Field Service Facility.
Step 2. POSSIBLE CAUSE.
The second column labeled “POSSIBLE CAUSE” lists
the obvious external possibilities that may contribute
to the machine symptom.
CAUTION
If for any reason you do not understand the test procedures or are unable to perform the tests/repairs safely, contact your
Local Lincoln Authorized Field Service Facility for technical troubleshooting assistance before you proceed.
VANTAGE® 580
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E-2
E-2
TROUBLESHOOTING
Observe all Safety Guidelines detailed throughout this manual
PROBLEMS
POSSIBLE
RECOMMENDED
(SYMPTOMS)
CAUSE
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.
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)
I
f all recommended possible areas
Check oil and coolant levels. Fill if of misadjustment have been
required. Check for loose or bro- checked and the problem persists,
ken fan belt.
Contact your local Lincoln
5. Faulty fuel shutdown solenoid. Authorized Field Service Facility.
Check that shutdown solenoid is
functioning properly and not bind-
ing/ contact authorized engine
service shop.
6. Faulty fuel pump. Check for fuel
flow through filters. Contact autho-
rized local Engine Service Shop.
Engine shuts down shortly after
starting.
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.
CAUTION
If for any reason you do not understand the test procedures or are unable to perform the tests/repairs safely, contact your
Local Lincoln Authorized Field Service Facility for technical troubleshooting assistance before you proceed.
VANTAGE® 580
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E-3
E-3
TROUBLESHOOTING
Observe all Safety Guidelines detailed throughout this manual
PROBLEMS
POSSIBLE
RECOMMENDED
(SYMPTOMS)
CAUSE
COURSE OF ACTION
Engine shuts down while under a 1. High radiator coolant tempera-
load.
ture. Reduce load if it is exceed-
ing 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.
Battery does not stay charged.
1. Faulty battery. Replace.
Engine alternator trouble light is on 2. Loose connections at battery or
while machine is running.
alternator. Clean and tighten con-
nections.
If all recommended possible areas of
misadjustment have been checked
and the problem persists, Contact
your local Lincoln Authorized
Field Service Facility.
3. Faulty engine alternator or charg-
er module. Consult authorized
Engine Service Shop.
Engine will not idle down to low 1. Idler switch in High idle position.
speed.
Set switch to Auto.
2. External load on welder or auxil-
iary power. Remove all external
loads.
3. Faulty PC board or idler sole-
noid.
Engine will not go to high idle when 1. Poor work lead connection to
attempting to weld.
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 prop-
er use of this switch.
3. Faulty PC board. Low idle speed
set to low.
CAUTION
If for any reason you do not understand the test procedures or are unable to perform the tests/repairs safely, contact your
Local Lincoln Authorized Field Service Facility for technical troubleshooting assistance before you proceed.
VANTAGE® 580
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E-4
E-4
TROUBLESHOOTING
Observe all Safety Guidelines detailed throughout this manual
PROBLEMS
POSSIBLE
RECOMMENDED
(SYMPTOMS)
CAUSE
COURSE OF ACTION
Engine will not go to high idle when 1. Auxiliary power load is less than
using auxiliary power.
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 1. Faulty idler solenoid. Check for
under weld or auxiliary loading.
bent linkage or broken spring.
2. Faulty PC board.(Control or Idler).
Engine does not develop full 1. Fuel filter clogged, Replace.
power. Engine runs rough.
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 1. Broken spring on Idle Solenoid,
attempting to weld or using auxil-
iary power. Switching to manual
high idle does not work.
solenoid linkage binding, Faulty If all recommended possible areas
PC board (Control or Idler), low of misadjustment have been
idle speed set too low on idle checked and the problem persists,
solenoid.
Contact your local Lincoln
Authorized Field Service Facility.
Engine will not shut off.
1. Fuel Shutdown solenoid not func-
tioning properly / linkage binding.
Stop engine by shutting off valve
located on main fuel filter. Contact
authorized local Engine Service
Shop.
Engine does not develop full power. 1. Fuel filter dirty/clogged. Replace.
Low weld and auxiliary output. 2. Air filter dirty/clogged. Replace Air
Engine runs rough.
Filter Element.
3. Fouled fuel injector(s). Contact
authorized Engine Service Shop.
4. Fuel contaminated with water.
Check water separator 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.
CAUTION
If for any reason you do not understand the test procedures or are unable to perform the tests/repairs safely, contact your
Local Lincoln Authorized Field Service Facility for technical troubleshooting assistance before you proceed.
VANTAGE® 580
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E-5
E-5
TROUBLESHOOTING
Observe all Safety Guidelines detailed throughout this manual
PROBLEMS
POSSIBLE
RECOMMENDED
(SYMPTOMS)
CAUSE
COURSE OF ACTION
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 alterna-
tor.
Welder has output but no control.
1. Poor remote/control cable connec-
tion to 6-pin or 14-pin connector.
Check connections.
2. Faulty remote cable or faulty wire
feeder or wire feeder cable.
Replace if necessary.
3. Faulty control potentiometer or PC
board.
I
f all recommended possible areas
Wire feeder does not work when 1. Wire Feeder Power circuit breaker of misadjustment have been
control cable is connected to 14 pin open. Check 42V beaker and checked and the problem persists,
connector.
reset if tripped.
Contact your local Lincoln
Authorized Field Service Facility.
2. Faulty control cable. Repair or
replace cable.
3. Faulty wire feeder. Replace wire
feeder.
1. Open circuit breakers. Reset
breakers. If breakers keep tripping
reduce power draw.
No auxiliary power.
2. GFCI module may have tripped.
Follow “GFCI Module Testing and
Resetting Procedure” in the MAIN-
TENANCE section of this manual.
3. Faulty connections to auxiliary
receptacles. Check connections.
4. Faulty PC board or welder alterna-
tor.
CAUTION
If for any reason you do not understand the test procedures or are unable to perform the tests/repairs safely, contact your
Local Lincoln Authorized Field Service Facility for technical troubleshooting assistance before you proceed.
VANTAGE® 580
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E-6
E-6
TROUBLESHOOTING
Observe all Safety Guidelines detailed throughout this manual
PROBLEMS
POSSIBLE
RECOMMENDED
(SYMPTOMS)
CAUSE
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 exam-
The auxiliary power is normal.
No output in Pipe Mode.
VRD Lights donʼt light up.
ple, CV-WIRE, PIPE, CC-STICK.)
2. Make sure the electrode (wire, gas,
voltage, current etc.) is correct for
the process being used.
3. Check for loose or faulty connec-
tions at the weld output terminals
and welding cable connections.
4. The welding cables may be too long
or coiled, causing an excessive
voltage drop.
If all recommended possible areas of
misadjustment have been checked
and the problem persists, Contact
your local Lincoln Authorized
Field Service Facility.
5. Faulty Control Board.
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 alterna-
tor.
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.
CAUTION
If for any reason you do not understand the test procedures or are unable to perform the tests/repairs safely, contact your
Local Lincoln Authorized Field Service Facility for technical troubleshooting assistance before you proceed.
VANTAGE® 580
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F-1
F-1
DIAGRAMS
VANTAGE® 580
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F-2
F-2
DIAGRAMS
VANTAGE® 580
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F-3
F-3
DIAGRAMS
VANTAGE® 580
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F-4
F-4
DIAGRAMS
VANTAGE® 580
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F-5
F-5
DIAGRAMS
VANTAGE® 580
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F-6
F-6
DIAGRAMS
VANTAGE® 580
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F-7
F-7
DIAGRAMS
VANTAGE® 580
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F-8
F-8
DIAGRAMS
VANTAGE® 580
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F-9
F-9
DIAGRAMS
VANTAGE® 580
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F-10
F-10
WIRING DIAGRAM
VANTAGE® 580
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F-11
F-11
DIMENSION PRINT
VANTAGE® 580
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G Do not touch electrically live
parts or electrode with skin or
wet clothing.
G Keep flammable materials
G Wear eye, ear and body pro-
away.
tection.
WARNING
G Insulate yourself from work
and ground.
Spanish
G No toque las partes o los elec-
trodos bajo carga con la piel o
ropa mojada.
G Mantenga el material com-
bustible fuera del área de tra-
bajo.
G Protéjase los ojos, los oídos y
AVISO DE
PRECAUCION
French
el cuerpo.
G Aislese del trabajo y de la tier-
ra.
G Protégez vos yeux, vos
G Ne laissez ni la peau ni des
vêtements mouillés entrer en
contact avec des pièces sous
tension.
G Gardez à lʼécart de tout
oreilles et votre corps.
ATTENTION
GermWan ARNUNG
matériel inflammable.
G Isolez-vous du travail et de la
terre.
G Tragen Sie Augen-, Ohren-
G Entfernen Sie brennbarres
und Kör-perschutz!
Material!
G Berühren Sie keine strom-
führenden Teile oder
Portuguese
Elektroden mit Ihrem Körper
oder feuchter Kleidung!
G Isolieren Sie sich von den
Elektroden und dem
G Use proteção para a vista,
ATENÇÃO
ouvido e corpo.
G Mantenha inflamáveis bem
Japanese
Chinese
Korean
Arabic
READ AND UNDERSTAND THE MANUFACTURERʼS INSTRUCTION FOR THIS EQUIPMENT AND THE
CONSUMABLES TO BE USED AND FOLLOW YOUR EMPLOYERʼS 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 ELEKTRO-
DENEINSATZ DES HERSTELLERS. DIE UNFALLVERHÜTUNGSVORSCHRIFTEN DES ARBEITGEBERS
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G Keep your head out of fumes.
G Use ventilation or exhaust to
remove fumes from breathing
zone.
G Turn power off before servic-
G Do not operate with panel
ing.
open or guards off.
WARNING
Spanish
G No operar con panel abierto o
G Los humos fuera de la zona de
respiración.
G Desconectar el cable de ali-
mentación de poder de la
máquina antes de iniciar
cualquier servicio.
guardas quitadas.
AVISO DE
PRECAUCION
French
G Mantenga la cabeza fuera de
los humos. Utilice ventilación
o aspiración para gases.
G Nʼopérez pas avec les pan-
neaux ouverts ou avec les dis-
positifs de protection enlevés.
G Gardez la tête à lʼécart des
G Débranchez le courant avant
fumées.
ATTENTION
lʼentretien.
G Utilisez un ventilateur ou un
aspirateur pour ôter les
fumées des zones de travail.
German
G Anlage nie ohne
Schutzgehäuse oder
Innenschutzverkleidung in
Betrieb setzen!
G Strom vor Wartungsarbeiten
abschalten! (Netzstrom völlig
öffnen; Maschine anhalten!)
G Vermeiden Sie das Einatmen
von Schweibrauch!
WARNUNG
G Sorgen Sie für gute Be- und
Entlüftung des Arbeitsplatzes!
Portuguese
G Mantenha-se afastado das
partes moventes.
ATENÇÃO
G Não opere com as tampas
G Mantenha seu rosto da
removidas.
G Não opere com os paineis
fumaça.
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.
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• World's Leader in Welding and Cutting Products •
• Sales and Service through Subsidiaries and Distributors Worldwide •
Cleveland, Ohio 44117-1199 U.S.A. TEL: 216.481.8100 FAX: 216.486.1751 WEBꢀSITE: www.lincolnelectric.com
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