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ELEcTricaL DiaGramS
G-6
vaNTaGE® 500
SchEmaTic - cOmpLETE machiNE - G4363 (cODE 10995 DEuTz) paGE 1
G4363
E
NGI
N
EE
RI
NG
CO
NT
RO
LLE
D
MA
NU
FA
CT
URE
R:
No
R
EL
EASE
D F
R
OM
X
A.01
G4363
VANTAGE500
(
DEUT
Z)
MACHI NE SCHEMAT I C
NONE
Reference
bmuter
D
RAWN
BY:
DESIG
N
I
NFO
RMATI
ON
ENG
I
NEER:
AP
PRO
VED
:
REFERE NCE:
EQ
UIP
M
ENT
TYPE:
SUBJECT:
SCA
L
E:
MATE RI AL
DI SPOS
IT
ION:
APPROVAL
DATE:
PROJECT
NUMBER:
UF
C
RM35043
1
PAGE ___ OF
___
2
DO
C
UM
E
NT
N
UM
BE
R:
DOCUMENT
REVI SI ON:
THIS DOCUMENT CONTAINS PROPRIETAR
Y
INFORMATION OWNED B
Y
LINCOLN GLOBA
L, INC.
AND MA
Y
NOT BE DUPLICATED, COMMUNICATED
TO O
THER PARTIES OR US
ED FOR
AN
Y
PURPOS
E WITHOU
T
THE EXPRES
S WRIT
TEN PERMISSION
OF LINCOLN GLOBAL, INC.
PRO
PRIETARY & C
ONFIDENTIAL:
A
T
HE I
NF
ORMA
T
IO
N
ON
T
HIS
PRIN
T
IS
F
OR
RE
F
ER
ENC
E
ON
LY.
C
O
MPON
EN
T
S
AND
CIRCUI
T
RY
MA
Y
BE
DIFFER
ENT
F
RO
M
AN
AC
T
UAL
M
ACHIN
E.
03/19/2003
CHANG
E
D
ET
AIL:
LE
A
D
C
OL
O
R
COD
E:
B-
BL
AC
K
O
R
GRAY
G-
GREEN
O-
ORANGE
R-
RE
D
O
R
PI
NK
U-
BL
UE
W-
W
HIT
E
Y-
Y
ELL
OW
C
OM
PONE
NT
V
AL
U
E
U
NIT
S:
CAPA
CIT
O
R: MF
D/
V
OLT
S
RE
SI
ST
O
R:
O
HM
S/
W
ATT
S
CONNE
CT
O
R
PI
N
N
UM
BER
S:
VI EW
OF
CONNEC
TO
RONPCBOARD
1
2
6
7
12
LA
TCH
EX.
12
PI N CONNEC
TO
R
LABELS:
C
OMM
ON
FR
AM
E
GROUND
EA
RT
H
GROUND
TH
RE
E
PHASE
RE
CTIFI
ER
3200uf
300vdc
SHUNT
50
M
V=400
AM
PS
206S
204S
LEFT CHOKE
CURRE
NT L
EV
EL
FE
E
D
BAC
K
SI
GN
AL
POSI TI VE
OUTPUT
TERMINAL
NEGATI VE
OUTPUT
TERMINAL
B
Y-
PASS
P
C
BOARD
206B
208
5A
120 V
AC
240 V
AC
120 V
AC
A
C
AU
X.
POWER
42 V
OLT
AC
WI
R
E F
EEDER
POWER
41
42
FO
U
R
P
OL
E 1800
R
PM
ALT
ERN
AT
OR
120 V
OLT
AC
POWE
R F
OR
R
OT
O
R FI
EL
DCI
RC
UIT
12 V
OLT
B
ATT
ERY
EN
GI
NE
ST
A
RT
ER
S
OL
EN
OI
D
ST
A
RT
B
UTT
O
N
S
WIT
CH
RU
N-STOP SWIT
CH
SHOWN I
N RUN
POS.
FR
AM
E
GROUND
W2
W2
W3
W3
W5
W4
W5
W4
W1
W1
W6
W6
3
5
6A
PERIPHERAL
PCBOARD
PULLCOIL
PCBOARD
(J31-9)
5T
229
(J31-4)
232F
405 (J31
-11)
(J32-6)
234
(J31-6)
262A
270 (J31
-8)
271 (J32
-7)
403 (J31
-3)
403 (J43
-7)
SENDER
SENDER
S
WIT
CH
TEM
PER
AT
URE
OIL
PRESSURE
S
WIT
CH
EN
G.
PRO
T.
FU
EL
TEM
P.
241
228
238
405 (J43
-5)
271 (J43
-4)
200 (J43
-3)
SH
UT
DOWN
P
ULL
C
OIL
265 (B3)
5S (
B4)
232N (
B2)
SH
UT
DOWN
H
OL
D
C
OIL
+12
V
OLT
S
RUN
SENSE
NEG
EX
C.
POS
+
EN
GI
NE
ALT
ERN
AT
OR
EN
GI
NE
ST
A
RT
ER
+12
V
OLT
S
RUN
+12
V
OLT
S
RUN
201
200
200A
HOUR
MET
ER
+
21
WI
R
EF
EEDER
V
OLTM
ET
ER
P
OL
A
RIT
Y
S
WIT
CH
206A
208A
231
238A
+
160 V
DC
6
5H
270 (J43
-6)
_
+
236B
232H
232D
C
B 15
A
238B
236A
C
E
LEFT
CHOPPE
R
P
C
BOARD
G
AT
E SI
GN
AL
IG
BT (8)
B7
B8
B6
B3
B5
B2
B4
B1
+CO
M
FLY
BACK
DI
ODE
S (6)
FILTE
R
CAPA
CIT
OR
S (4)
+
10,000u
F x4
p/n L118
45-1
C
E
RI
G
HT
CHOPPPPE
R
P
C
BOA RD
G
AT
E SI
GN
AL
IG
BT (8)
B7
B8
B6
B3
B5
B2
B4
B1
+CO
M
FLY
BACK
DI
ODE
S (6)
FILTE
R
CAPA
CIT
OR
S (4)
+
10,000u
F x4
p/n L118
45-1
RIGHT
C
HOKE
D
C
BU
S
V
OLT
AGE
90+/-10V
D
C
@
HI I
DL
E
AR
C
V
OLT
AG
E F
EEDBAC
KSI
GN
AL
R1
O
UT
P
UT
CO
NT
R
OL 10
K
77 (J7-
1)
76 (J7-
4)
75 (J7-
5)
R2
ARC
CO
NT
R
OL 10
K
279 (J7
-6)
278 (J7
-7)
277 (J7
-8)
(J1-4)
2
(J1-3)
4
W
EL
D T
E
RM.
S
W.
MO
DE
S
WIT
CH
CC
CV
PI
PE
TIG
(J7-9)
214
(J7-14)
218
(J7-15)
220
(J7-16) 222
260 (J3
-4)
260 (J3
-3)
WE L DC ON T RO L
PCBOARD
204S (J6-1)
206S (J6-2)
208B (J3-15)
23(J3-10)
25(J3-9)
5G (J2-3)
R
EM
OT
E
CO
NT
R
OL 10
K
77A (J1-11)
76A (J1-14)
75A (J1-10)
10 V
0-10 V
0 V
10 V
-15 V (
W/
O
P
OT.)
0 V
15 V
0 V
TWI
ST
ED
P
AI
R
(TO
AM
PHEN
OL)
(TO
AM
PHEN
OL)
2A
4A
(TO
AM
PHEN
OL)
31
32
41A
A
B
C
D
E
F
77A
21
42A
75A
GN
D-
A
4A
2A
76A
77B
76B
75B
GROU
ND
AMPHEN
OL
IN
P
UT T
O
AM
PHEN
OL
115V
AC
CO
NT
AC
T
OR
W
OR
K
RE
MOT E
CO
NT
RO
L
42V
AC
GROU
ND
AMPHEN
OL
J
A
D
C
H
B
K
E
F
G
I
77B
76B
75B
GN
D-
B
4B
2B
4B
2B
13(J3-8)
14(J3-16)
(J1-5) 5
00
(J1-13)
500
500 I.D. J
UM
PE
R (
Part
of amphe
nol plug a
nd
lead asse
mbly.)
TWI
ST
ED
P
AI
R
TWI
ST
ED
P
AI
R
R
OT
O
R FL
AS
HI
NG
Located o
n back of
control pa
nel.
P/
N
G4107-1
Open
Circuit
Volts:
CC
Max
Min
5858
58
58
58
26
12
12
CV
P
ipe
Tig
Control board com
mon is
at welder positive outp
ut
and shunt
Control board circuits
associated with J2 are
part
of engine
electrical syst
em and a
re comm
on to
frame g
round (
negative b
attery te
rminal.
Rotor Flashing: +12 volts
@ 0.5 amps
until gene
rator buil
ds up
then +160 volts @ 0 am
ps.
W
EL
D
AMM
ET
ER
W
EL
D
V
OLTM
ET
ER
(J4-1 to
10)
(J5-1 to
10)
Meters dis
play setpoin
t volts or a
mps when not welding.
Meters dis
play actual v
olts and a
mps when
welding.
Hold function displays act
ual volts an
d amps fo
r
approxim
ately 5 seco
nds after welding stop
s.
During this hold display t
he right
most deci
mal point will
blink.
23A(J3-12)
25A(J3-11)
14A
13A
14
13
TWI
ST
ED
P
AI
R
(J2-6) 2
32D
+12
V F
R
OM
RU
N/
ST
O
P
S
WIT
CH
R4
50
OH
M
100 W
R4 is located on top of
chopper
power module
assembly.
5J
1
1
1
4
4
4
281 (J43
-2)
405A (J31-12)
239 (J32
-8)
243 (J32
-4)
+12
V
OLT
S
RUN
IG
BT'
S, FL
YBAC
K
DI
ODE
S
AND
FILTE
R
CAPA
CIT
OR
S
AR
E I
NT
EGR
AL
TO
CHOPPE
R M
OD
UL
E
S
AN
D
N
OT
INDI
VI
DU
ALL
Y
RE
PL
ACEA
BL
E.
STAT
OR
W
EL
D
WI
N
DI
NGS
R
OT
O
R FI
EL
D
SLI
P
RI
NGS
RE
MOT E
CO
NT
RO
L
OIL
PRES
S.
FU
EL L
VL.
SENSOR
Chokes are mounted
on
power module assem
bly
behind ou
tput ter
minal pan
el.
Po
wer
Supply
to Control
Board
P
WM
S
ignal to Chopper
15 volt @ 20 kHz
Chopper modules a
re located
on power
module as
sembly be
hind outp
ut termin
al
panel.
Rectifier is located on
power module
assemblybe
hind outp
ut
control pa
nel.
Shunt on back of positiv
e
output te
rminal
Located o
n back of
output pa
nel
between terminals
60 TO 65 V
A
C
PHAS
E T
O
PHASE
AT
HI
G
H IDL
E
REV
OL
VI
N
G FI
EL
D
RE
SI
ST
ANC
E
APPRO
X.
25 O
HM
S
@ 75F
Field capa
citor and
diode brid
ge
located on
lower rear of fan b
affle
on right si
de of mac
hine.
Battery voltage:
12.6 volts
at rest
14 volts en
gine
running
Located o
n lower left
side of con
trol
compart
ment
Located o
n rear
of control
panel
left side.
0.2 O
HM
11 O
HM
S
Oil
Pressure
S
witch
closes on low
oil pressur
e.
Temper
ature S
witch
closes on hi
gh
tempera
ture.
Engine protection
circuit. La
mp test
and 30sec
ond
delay one
ngine
start.
+20
Volts from pull
coil board
+10
Volts
Voltage
Regulators
+10
Volts
+20
Volts
3/4 Second
Timer
YEL
LO
W
LED
230 O
HM
S
EM
PT
Y
30 O
HM
S F
ULL
10 O
HM
S
@ 0
P
SI
100 O
HM
S
@ 75
P
S1
500-600
O
HM
S
C
OL
D
50-100 OHM
S
H
OT
(S
E
E
SHE
ET 2 F
OR
SIMPLIFI
ED
CO
NT
R
OL
BOARD
SCH
EM
ATI
C)
(SIM
PLIFI
E
D
BOARD
SCH
EM
ATI
C)
(SIM
PLIFI
ED
BOARD
SCH
EM
ATI
C)
250 (J3
-5)
250 (J3
-1)
Jumper
required
for outp
ut.
AL
T.
YEL
LO
W
LED
247 (J32
-1)
ALT
ERN
AT
O
R FL
AS
HI
NG
No alternator
output sh
utdown
(fan belt breakage
)
Low oil
pressure
or
high
tempera
ture
shutdown
256 (J3
-7)
256 (J3
-14)
Jumpers
replace idl
e torroid
and idle sel
ector switch.
G-6
NOTE: This diagram is for reference only. It may not be accurate for all machines covered by this manual.
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