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Lincoln Electric VANTAGE 500 User's Manual

1. VANTAGE 500 CUMMINS LINCOLN E NOTES VANTAGE 500 CUMMINS LINCOLN Spanish AVISO DE PRECAUCION French ATTENTION German WARNUNG 5 SE IR Chinese Korean Do not touch electrically live parts electrode with skin or wet clothing Insulate yourself from work and ground No toque las partes o los electrodos bajo carga con la piel o ropa moja a Aislese del trabajo de la tierra Ne laissez ni la peau ni des v te ments mouill s entrer en contact avec des pi ces sous tension Isolez vous du travail et de la terre Ber hren Sie keine stromf hrenden Teile oder Elektroden mit Ihrem oder feuchter Kleidung Isolieren Sie sich von den Elektroden und dem Erdboden e toque partes el tricas e elec trodos com a pele ou roupa molha da Isole se da e terra eoo SS MARHE FRANEACRHEUCE OMIM 7 Z p 5 Sr fE TE ATUBSHELTFEL amp ORAS RMI HR e SHES He sz se yya AU PHA e 2749 HAS ASAI OMAR Yt gow Gall el ja oye daa ag iY d ily gS welll AA Gadi Jai JS aua Vile woe Keep flammable materials away Mantenga el material combustible fuera del rea de trabajo Gardez l cart de tout mat riel inflammable Entfernen Sie brennbarres Material
2. deeye pee Ape g JAILVOAN osd e eoejd uispjenB deeye uedo sjaued ui ejejedo jou ONIN HV M YV WVYSVIG NOILOANNOO NN9 10085 2877 8877 01 1699 S83Q 13M 3NION3 VANTAGE 500 CUMMINS LINCOLN E CONNECTION DIAGRAMS F 3 F 3 586855 ALVINSNI ANY 5 321145 AN ATIVAGIAIQNI CASANN HOV3 SLVINSNI ON 1OHLNO9 3 10W3H OL GAHOLIMS ATIVOLIVINOLRV SI TOHLNOO d3Sn SI TOHLNOO LNd LNO SLOWSY 1VNOILdO dl O N NOILISOd 57899 H3Q33H OL HOLIMS 430334 3HIM 39V 1d 3HIM OL HOLIMS HO10313S JHL NOILISOd 3004191313 lt 19313S OL HOLIMS HALAWLIOA ASN ON IVANY ONILVYAdO 33 SHNLNA ALVIGAWWI dO 41949 ALNA LNSYYND JHL ALIOVdVO H3dOHd dO 38 LSNW 3149 ONIGTAM IVANVN 9NI1Vd3dO 20 OM 3NION3 JHL NI 031 SNOLLWOISIOAdS 3408Y 15 LON OG AHOLOVA SHL 135 384 SI 9NIL13S HONH3AO9 ANIONS JHL 38 AVN TOHLNO9 430334 3ulM SLIOA 071 H3AO 309 39VETOA SIHL 3I 39VLTOA OV 3H1 IHL NI 3SV3HONI NV 380V9 TIM 39VyNI1 AILLOHHL 3H1 ONIGIHE3AO HO ONILLAS HONH3AO9 JHL 9NISNVHO 3NI9N3 H9IH JHL 30 ASVSYONI 310W3H HN NOLLYVO 1VNOILLdO S47 u os LINN G33d4 SHIM OL Ke 219v9 2004193713 u O SL MYOM OL VS
3. moe 1 5 S zi 1 ES HOLIMS A1iuv1Od Hsntug 8002 102 1504 ALIEVIOd SAILISOd NI NMOHS HOLIMS DIAGRAMS xog 10H1NOO 30 HALN3O 4 D g 88 1 ANNOHD Auvrixnv 40 LH d B WOLLOG q aN9 d S S 9808 NO anis amp d 9802 FOND b 3 z HdddOHO G3LVINSNI s SPA AAA AA HO N 3 Adis 1 gg 3MHOH9 A18N3SSV EE eg 3s 3d s a 1 ONIGNIM AZt HOLVIS HOLIMS 83d Toyo 1 e Svad dud mS S Rn p lt lt NO anis ANNOHO mu rane LNdino ans ANNOYS Ke 10H STVNIWuaL m INAR iS voIvis S902 5 SdiNvoOv AWOS mme t Q31V9IQNI SIWI 1 QIOHOLL 1 SSYd SAVIT H3MOd AUVITIXNY 42913 SIOSWAS 1V9IH19313 SONIGNIM ABVITIXNY HOLVLS L 90t2M INVYSVIC ONIAIM 00S 39V LNVA EM vM 9171 18 34
4. NYO HOIHM 3SV11TOA 830334 OV JHL 35 NV 2SNV9 JOVANI 3TLLOSHL SHL SNIGISIH3AO ONILLAS HONS3AO9 SHL 9NISNVHO 3NISN3 310I H9IH 3H1 dO 3SV38ONI ANY NN 4 NOLNVO OHLNOO LNd1NO SIGN LINN 0993 34IM OL 37199 300410313 2 3ounos YIMOd 40 IWNIWYAL HOM OL SLO3NNOO YOM OL NOLLO3NNOO M3 L3IALLTOA Y30334 NOLLO3NNOO 20121 39HN0S YIMOd o N9 owas 19 ce d M WAGY ENS Hera an 04 13001 193NNOO lo e JONJHANY YACTAM 3NIONG NO 0381 LON 19 8 o 13 ueuudinbo 14 eorues Jo syed any uonoj jou ode esn jejsur pjnous jauuosied Ajuo e Buas e10Joq sued eme deey e peg 3ALLVO3N 12euuoosiq e ui deey e u do sjaued jou oq e ONINHVM WV WVYSVIG NOLL23NNOO l31dVQV 114V9 1OHLNOO 2987 OL SH3Q 13M 3NISN3 VANTAGE 500 CUMMINS LINCOLN E CONNECTION DIAGRAMS F 6 F 6 686525 ALVINSNI ANY SGV31 ON 71 GASNNN HOV3 31V INSNI NO OL HOLIMS HOLOATAS JHL NOILISOd 3903193713 Q3HIS3Q LOATAS OL HOLIMS H3 ESIALETOA ASN ON IWANVW 9NLIVH3dO 395 SNOI1VOIddV 31VIQ3NWNWI dO 41949 ALNA LN3HHDO AHL ALIOVdVO dO Ad LSNW
5. 0333 2004 OL NOUT 931899 300419313 MYOM OL JON3HdAV OW LNOO 51054 Nid 9 93189 1OWLNOO 78947 N 318v9 3 ON3HdNV Z NTOL 14 4 JO sured jou oqe esn jejsui pinous peuuosied e e10Jeq sued Aeme desye pee 12euuoosiq e ui e uedo sjaued jou e ONINYVM_ NOLLO3NNOO Z N1 SY30 13M 3NISN3 VANTAGE 500 CUMMINS LINCOLN E CONNECTION DIAGRAMS F 5 F 5 7181708 0002 22 01 IN WY VIN NOILONALSNI 3910 YAMOd OL 93458 d N X30334 o p 339 9 2 90731 38070 OL SUM NOILYTOSI SSN LAdLNO 303 TVN IS V LYH1 SH30333 SYIM 303 TN ATIVNGIAIGNI SQV31 GASNNN H9V3 31V10SNI ON NOILISOd AYIM AD NI HOLIMS 39Vld 81870 300819313 JHL dO ALIS V 10d JHL HOLY OL HOLIMS YSLAWLIOA Y30334 38IM JHL NOLLISOd ALINV10d 4341S30 401 9115 LAdLNO OL S318V9 LOANNOO NOILVO M dd 20 41949 ALNG ANY INTHANI 303 9371 38 LSNW 318V9 ONIGTAM 9 YSCTAM 3NISN3 JHL NI 931511 SNOILVOISIDAdS Wd dAO8V LSQ av LON OG 7 AYOL Y4 SHL LV 13S 3Md 19 113 YONYSAOS JHL LINDYIO JHL
6. NVO HOIHM 3SV1TOA Y30334 38IM OV IHL 3SV3SONI NV ASNVS TIM FILLOYHL AHL SNIGIHS3AO ONILLAS HONS3AOS 3HL 9NISNVHO Ad 3NISN3 H9IH JHL 30 3SV339NI NOUT OL HOLIMS LUVIS 23V PL UO o 1 ANVH L E96H T 300810313 HO 9189 TOULdWY 1003 0 84 a 9 6M ONILLIS LNdNI YSGNITAD SV9 OL 579 NO9UV ONZHd HALINMOT MOLE jueuudinbe 14 10 sued jou oqe pinous Buuosied e BUIDIAIAS e10Joq sued Aeme e pee 3ALLVO3N 19euuoosiq e eoej d ul deoye u do sjeued jou oq e ONINHVM WV NVHOVIA NOLL23NNOO 9IL 086 VANTAGE 500 CUMMINS LINCOLN E CONNECTION DIAGRAMS F 12 F 12 S L82 2S 0002 22 01 SV NOILISOd 310I HOI OLAV NI HOLIMS 44101 39 1 AN NOLLISOd GATIOULNOD ATALOWSY OL HOLIMS STVNINYAL 83Q 3M ON NOILISOd 3H1 NI HOLIMS 39VId ON 4199 300819313 SHL dO ALI V lOd JHL HOLVN OL HOLIMS YALAWLIOA 83033 38IM AHL NOILISOd ALINV10d 9381 39 401 58715 LNdLNO OL 318V9 ON TIM LOANNOO ON WANVA 9 SAS SNOILVONMddV 940413 ANY ALVIGAWW dO 319A9 LNAYYND AHL ALIOVdVO dO 38 LSNW S318V9 ONIO OM
7. ARC WELDING CAN BE HAZARDOUS PROTECT YOURSELF AND OTHERS FROM POSSIBLE SERIOUS INJURY OR DEATH KEEP CHILDREN AWAY PACEMAKER WEARERS SHOULD CONSULT WITH THEIR DOCTOR BEFORE OPERATING Read and understand the following safety highlights For additional safety information it is strongly recommended that you purchase a copy of Safety in Welding amp Cutting ANSI Standard Z49 1 from the American Welding Society Box 351040 Miami Florida 33135 or CSA Standard W117 2 1974 Free copy of Arc Welding Safety booklet 2205 is available from the Lincoln Electric Company 22801 St Clair Avenue Cleveland Ohio 44117 1199 SURE THAT ALL INSTALLATION OPERATION MAINTENANCE AND REPAIR PROCEDURES PERFORMED ONLY BY QUALIFIED INDIVIDUALS FOR ENGINE powered equipment 1 Turn the engine off before troubleshooting and maintenance work unless the maintenance work requires it to be running 3 SX 1 h To avoid scalding do not remove the radiator pressure cap when the engine is hot 1 b Operate engines in open well ventilated areas or vent the engine exhaust fumes outdoors ELECTRIC AND 3 m MAGNETIC FIELDS i may be dangerous 1 c Do not add the fuel near an open flame welding arc or when the engine is running Stop the engine and allow it to cool before refueling to prevent spilled fuel from vaporiz ing on contact with hot engine parts and igniting Do not s
8. The VANTAGE 500 CUMMINS can be permanently installed as a standby power unit for 240 volt 3 wire 50 amp service Connections must be made by a licensed electrician who can determine how the 120 240 VAC power can be adapted to the particular installation and comply with all applicable electrical codes The following information can be used as a guide by the electrician for most applications Refer to the connection diagram shown in Figure A 2 1 Install the double pole double throw switch between the power company meter and the premis es disconnect Switch rating must be the same or greater than the customer s premises disconnect and service over cur rent protection VANTAGE 500 CUMMINS LINCOLN 7 INSTALLATION 7 2 Take necessary steps to assure load is limited to 8 Install 50 amp 120 240 plug NEMA Type the capacity of the VANTAGE 500 CUMMINS by 14 50R to the double pole circuit breaker using 6 installing 50 amp 240 VAC double pole circuit or 4 conductor cable of the desired length The 50 breaker Maximum rated load for each leg of the amp 120 240 VAC plug is available in the optional 240 VAC auxiliary is 50 amps Loading above the K802N or K802R plug kits or by itself as T12153 9 rated output will reduce output voltage below the allowable 10 of rated voltage which may damage 4 Plug this cable into the 50 Amp 120 240 Volt recep appliances or other motor driven equipment and tacle on the VAN
9. 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 WEB SITE 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 A WARNING This statement appears where the information must be followed exactly to avoid serious personal injury or loss of life A CAUTION This statement appears where the information must be followed to avoid minor personal injury or damage to this equipment vi TABLE OF CONTENTS vi Page Section Technical Specifications A 1 Safety Precautions
10. LON Od AHOLOVH JHL LV 13S 2Hd SI ONILL3S HONYSAOD 3NION3 TOHLNOO JHL NYO HOIHM 39VLT1OA 420224 3HIM OV 3HL NI 3SV3HONI NV ASNVS 39VMNITA3TLLOHHL JHL 9NIGIHHJAO HO ONILLAS JHL ONIDSNVHO 3NION3 310 HOIH HO 3SV3HONI 9933 38IM OL 31875 390412373 AYOM OL 31875 IOHINODS6SH 318 lt 8 N1 OL juewudinbe siu ailes 10 syed j eoujoeje jou oqe pinous jeuuosied AIUO e syed e pes 4 JALLVO3N 1 euuoosiq e ul u do sjaued jou ONINHVM Y NOILO3NNOO 8 1 3NISN3 NOILNVI TONSAHdNV Nid tL VANTAGE 500 CUMMINS LINCOLN E CONNECTION DIAGRAMS F 9 F 9 8 765 0002 22 01 29 91538 SV NOILISOd 3101 HOI NI HOLIMS 41101 39V1d ON ONILVYSdO 33 SNOILYONddY denn ANY 31VIQ3NNI dO 319A9 ALAC ANY LN38869 AHL ALIOVdVO dO 38 LSNW S318V9 ONIGTAM 318V9 300819373 AHL dO SHL HOLVIA OL HOLIMS d313NLTOA 830334 38IM JHL NOILISOd Adv TOd 9341534 304 Santis LAdLNO OL 318V9 LOANNOSD ON NOILISOd 1 OL HOLIMS 6 1 Y3013M 39V 1d NOILISOd 34IM A9 IHL NI HOLIMS SGOW 39VId WANV
11. V NV ONILVYSdO Y3013M 3NISN3 JHL NI 031511 SNOILVOISIOAdS 3A08V LSNPAV LON OQ AHOLOV3 SHL 13 3 SI ONILL3S HONS3AO9 ANIONS JHL LINDYID TONLNOD SHL HOIHM 39 VL 10A 939333 38IM OV JHL NI 3SV3HONI NV ASNVO THM 31LLOSH L SHL ONIGIYYSAO ONILLAS SHONS3AO9 SHL 9NISNVHO A8 3NISN3 H9IH 3HL 30 3SV38ONI NOILNVO LINN 0333 38IM OL 300812313 AYOM OL 114V9 TOHLNO9 26947 3149 TJTONd3HdAV INdNI CYZ NTOL jueuudinbe eu 3919S 10 syed ant Ajeoujoeje yono jou oqe pinous jeuuosied AIUO e Buas sued e pee Moyeg JALLVON e eoe d ul deeye u do sjeued jou e ONINHVM YV WV49VIQ NOLLO3NNOO CRINU SYS 14M 3NION3 VANTAGE 500 CUMMINS LINCOLN E 13 DIMENSION PRINT F 13 2968 HOLVIQVH NI LNV 1002 QNVOINV L 1474 ALdW3 3NIDN3 NI TIO ALIAWYD dO H31N32 SNOLLV2O1310H ONILNNOW 331 ASVd 83d 3M dO NIA WO LLOS 8 T8EL LAAI 6421 85 05 76 OELE eut SET 7091 01 9
12. 414V9 3008129313 AHL dO ALIS V 10d JHL HOLVIN OL HOLIMS S313IALL 10A 83033 38IM dH1 NOILISOd ALINY Od Q38lS3d 59115 LAdLNO OL S318V9 LOANNOO WANVW ONILVH3d0 33 SNOILVONddV 391403 ANY ALVIGAWWI dO 41949 ALNG ANY 3HL ALIOVdVO s3dOsd dO 38 LSNN 91899 SNI HA 318vO 300819313 AYOM OL AYOM OL QV MYOM 3343334 38IM SCN1 310IN3H 1987 TYNOILdO JON3HdAV 14 JO sued jou oqe asn jeysul pinous jauuosied AIUO Buas sued Aeme deey pes 12euuoosiq e u e u do sjeued ejejedo jou oq e ONINHVM WV T104LNO9 3 0IN38 2589 TWNOILdO WVYSVIG NOLL23NNOO 3H L SSOUIVY S N 1 SYA TSM 3NION3 VANTAGE 500 CUMMINS LINCOLN E CONNECTION DIAGRAMS F 8 F 8 9 282725 000 NI HOLIMS 47101 3914 390419373 AHL dO ALIHV IOd AHL HOLVIN OL HOLIMS H3 L3IALL TOA Y30334 3HIM AHL NOLLISOd A LltiV 1Od Q3HIS3G SANLS LNdLNO OL S318VO9 LOANNOO ON 9NILVH3dO 33 5 34N1N1 ALVIGAWWI dO 41949 ALNG ANY LN3dtl19 ALIOVdVO dO LSNW S3 18VO ONIQTJM IVONY 9NILVH3dO H3Q T3M NI 151 SNOILVOI4d4IO3dS Wd dAO8V 15
13. Mantenha inflam veis bem guarda dos SODMTOBEEER EVA o iR aE L FRN o els Hc AIX uie ya OSa JA ALIM Aal Wear eye ear and body protection Prot jase los ojos los o dos y el cuerpo Prot gez vos yeux vos oreilles et votre corps Tragen Sie Augen Ohren und K r perschutz Use prote o para a vista ouvido corpo HAUSHERMRELTTF RER ez 212 Sol Soares y due de Lily us cl di en e READ AND UNDERSTAND THE MANUFACTURER S INSTRUCTION FOR THIS EQUIPMENT AND THE CONSUMABLES TO BE USED AND FOLLOW YOUR EMPLOYER S SAFETY PRACTICES SE RECOMIENDA LEER Y ENTENDER LAS INSTRUCCIONES DEL FABRICANTE PARA EL USO DE ESTE EQUIPO Y LOS CONSUMIBLES QUE VA A UTILIZAR SIGA LAS MEDIDAS DE SEGURIDAD DE SU SUPERVISOR LISEZ ET COMPRENEZ LES INSTRUCTIONS DU FABRICANT EN CE QUI REGARDE CET EQUIPMENT ET LES PRODUITS A ETRE EMPLOYES ET SUIVEZ LES PROCEDURES DE SECURITE DE VOTRE EMPLOYEUR LESEN SIE UND BEFOLGEN SIE DIE BETRIEBSANLEITUNG DER ANLAGE UND DEN ELEKTRODENEINSATZ DES HER STELLERS DIE UNFALLVERHUTUNGSVORSCHRIFTEN DES ARBEITGEBERS SIND EBENFALLS ZU BEACHTEN Keep your head out of fumes Use ventilation or exhaust to remove fumes from breathing zone Los humos fuera de la zona de res piraci n Mantenga la cabeza fuera de los humos Utilice ventilaci n o aspiraci
14. Mantenha se afastado das partes moventes N o opere com os paineis abertos ou guardas removidas ONRWMPAN ERVALEEE CREATE e do Gel tee Asal OMAR Aga y Gils jlgall l a Ja y e S i di Spanish AVISO DE PRECAUCION French ATTENTION German WARNUNG BIR Chinese LEIA E COMPREENDA AS INSTRU ES DO FABRICANTE PARA ESTE EQUIPAMENTO E AS PARTES DE USO SIGA AS PRATICAS DE SEGURANCA DO EMPREGADOR gt RRVE NOX H ODI REE ERA 3880 CF EW TL TRHOREMEI HDT FEU SA EE DEI PR 3 ED WK HE BA MES f 59 EL 0 SAAD HA OK 4e EPA abal Z gl quil d AA PO Sal ag ls L LINCOLN 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 WEB SITE www lincolnelectric com
15. paisse pan talons sans revers et chaussures montantes LINCOLN Relier la terre le chassis du poste conformement au code de l lectricit et aux recommendations du fabricant Le dispositif de montage ou la piece souder doit tre branch une bonne mise la terre Autant que possible l installation et l entretien du poste seront effectu s par un lectricien qualifi Avant de faires des travaux l interieur de poste la debranch er l interrupteur la boite de fusibles Garder tous les couvercles et dispositifs de s ret leur place Mar 93 for selecting QUALITY product by Lincoln Electric We want you Thank You to take pride in operating this Lincoln Electric Company product as much pride as we have in bringing this product to you CUSTOMER ASSISTANCE POLICY The business of The Lincoln Electric Company is manufacturing and selling high quality welding equipment consumables and cutting 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 k
16. tion Control Cable Model Set the WELD TERMINALS switch to REMOTELY CONTROLLED Set the WIRE FEEDER VOLTMETER switch to either or as required by the electrode polar ity being used Set the ARC CONTROL knob to 0 initially and adjust to suit Set the IDLE switch to the AUTO IDLE posi tion VANTAGE 500 CUMMINS LINCOLN 9 INSTALLATION 9 CONNECTION OF THE LN 25 TO THE VANTAGE 500 CUMMINS The LN 25 with or without an internal contactor may be used with the VANTAGE 500 CUMMINS See the appropriate connection diagram in the DIAGRAMS section NOTE The LN 25 K431 Remote Control Module and K432 Remote Cable are not recommended for use with the VANTAGE 500 CUMMINS Shut the welder off 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 elec trode Negative connect the electrode cable from the LN 25 to the terminal of the welder and work cable to the terminal of the welder 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 sense lead to supply current to the wire feeder motor it does not carry welding current Set the SELECTOR switch to the CV WIRE posi tion Set the WELDING TERMINALS switch to WELD TERMINALS Adjust the ARC CONTROL
17. down hill pipe welding where the operator would like to control the current level by changing the arc length The OUTPUT CONTROL knob adjusts the full output range for pipe welding The ARC CONTROL knob sets the short circuit current arc force during stick welding to adjust for a soft or a more forceful digging arc Crisp Increasing the number from 10 Soft to 10 Crisp increases the short circuit current which results in a more forceful digging arc Typically a forceful digging arc is preferred for root and hot passes A softer arc is preferred for fill and cap passes where weld puddle control and deposition stacking of iron are key to fast travel speeds It is recommended that the ARC CON TROL be set initially at 0 TOUCH START TIG MODE The VANTAGE 500 CUMMINS can be used in a wide vari ety of DC TIG welding applications The TOUCH START TIG setting of the MODE switch is for DC TIG Tungsten Inert Gas welding To initiate a weld the OUTPUT CONTROL knob 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 avoids tungsten contamination Then the tungsten is gently lifted off the work in a rocking motion which establishes the arc To stop the arc simply lift the TIG torch away from the work piece When the arc voltage reaches approximately 30 volts the arc will go out and the machine wil
18. knob to desired crisp ness Generally welding is best if the ARC CON TROL is set to SOFT for MIG and CRISP for INNERSHIELD You may however want to start in the middle and adjust as needed from there Set the IDLE switch to the AUTO position When not welding the VANTAGE 500 CUMMINS 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 CAUTION If you are using an LN 25 without an internal con tactor the electrode will be energized when the VANTAGE 500 CUMMINS is started When the gun trigger is closed the current sensing circuit will cause the wire to begin to feed and the welding process is started CONNECTION OF AN NA 3 AUTOMATIC WELDING SYSTEM TO THE VANTAGE 500 CUMMINS For connection diagrams and instructions for connect ing an NA 3 Welding System to the VANTAGE 500 CUMMINS refer to the NA 3 Welding System instruc tion manual The connection diagram for the LN 8 can be used for connecting the NA 3 Set the Wire Feeder voltmeter to the proper polarity of the electrode CONNECTION OF MAGNUM SC SPOOL GUN TO THE VANTAGE 500 CUMMINS SEE SECTION F CONNECTION OF PRINCE XL SPOOL GUN TO THE VANTAGE 500 CUMMINS Connection of the Prince XL Spool Gun requires the use of the K1849 1 Adapter Module Shut the Welder off For electrode Positive connect the electrode cabl
19. 318VO ONIGTAM V N Kn 3NI9N3 IHL NI 013181 SNOLLVOISIOAdS 1510 LON OQ JHL 135 999 SI 9 1136 JHL 38 AVN SLINOHI9 1041409 830333 SHIM SITOA OF H3AO 309 39VITOA SIHL 31 39VITOA OV IHL IHL NI 3SV3HONI NY 380v9 31LLOHHL IHL DNIIHHAAO HO 35 HONU3AO9 IHL 3NI9N3 3101 HOIH IHL 40 3SV3HONI ANY bs NOILNVO LINN 38IM OL 3904195713 OL 318V9 LNdNI IVSH3AINn 298 9613 HOM OL 3qou1oa1Ta ION3HdAV O 9339333 8 jueuudinbo siy ales 10 syed ant AIR92119819 jou oq e esn eisui pinous I uuosi d AuO e sed Aeme de9y e av31AH3L1VA SALLVDAN 199uuo5Ssiq e eoejd u de9y e sjeued jou oq e up ONIAOW IP ub ONINHVM W INVHO9VIG NOILOANNOO 8 4981 HIONVWNOI VANTAGE 500 CUMMINS LINCOLN E CONNECTION DIAGRAMS F 7 F 7 18 5 0002 22 01 SV NOILISOd 4101 YO OLAY NI HOLIMS 44101 SOV1d NOILISOd S IVNIIAS3 L Q T3W SHL NI HOLIMS S IVNIIWSH3 EL ONIQT3M 39V ld NOILISOd AHL NI HOLIMS FOV ld
20. Depth Weight _ 42 0 in 315 in 63 1 in 1443lbs 1066 8 mm 800 1mm 1603mm 655kg Approx 1 Output rating in watts is equivalent to volt amperes at unity power factor Output voltage is within 1096 at all loads up to rated capacity When welding available auxiliary power will be reduced 2 Top of Enclosure Add 7 0 177 8mm for exhaust VANTAGE 500 CUMMINS LINCOLN 5 2 INSTALLATION 2 Read this entire installation section before you Start installation SAFETY PRECAUTIONS WARNING Do not attempt to use this equipment until you have thoroughly read all operating and mainte nance manuals supplied with your machine They include important safety precautions detailed engine starting operating and maintenance instructions and parts lists ELECTRIC SHOCK can kill e Do not touch electrically live parts such as output terminals or internal wiring Insulate yourself from the work and ground Always wear dry insulating gloves ENGINE EXHAUST can kill 3 Use in open well ventilated areas or vent exhaust outside 4 MOVING PARTS can injure Do not operate with doors open or guards off Stop engine before servicing Keep away from moving parts Only qualified personnel should install use or ser vice this equipment LOCATION VENTILATION The welder should be located to provide an unrestrict ed flow of clean cool air to the cooling a
21. Generator Maintenance D 4 Engine Maintenance Components D 4 GFCI Receptacle Testing and Restting Procedure D 5 Tro bleshooting aus dieu cos ENEE ESE lena ed Section E Wiring Connection Diagrams and Dimension Print Section F LISTS NT P 508 1 INSTALLATION 1 TECHNICAL SPECIFICATIONS VANTAGE 500 CUMMINS K2406 1 INPUT DIESEL ENGINE Make Model Description Speed RPM Starting Capacities System CUMMINS 4 cylinder High Idle 1890 199 cu in 12VDC battery Fuel B3 3 53HP 40 kw Low Idle 1400 3 3L amp Starter 25 US gal Diesel Engine 1800 RPM Full Load 1890 94 6L Bore x Stroke Oil 2 US gal 3 74 x 4 53 7 6L 95mm x 115mm Coolant 2 US gal 7 6L RATED OUTPUT 104 F 40 C WELDER Welding Output Volts at Rated Amps 500 Amps DC multi purpose 40 Volts 550 Amps DC multi purpose 36 volts 575 Amps DC multi purpose 35 volts OUTPUT 104 F 40 C WELDER AND GENERATOR Welding Range 30 575 Amps CC CV 20 250 Amps TIG Open Circuit Voltage 60 Max OCV 1900 RPM Auxiliary Power 120 240 VAC 12 000 WATTS 60 Hz Single Phase 20 000 WATTS 60 Hz Three Phase PHYSICAL DIMENSIONS __ Width
22. WEATHER STARTING With a fully charged battery and the proper weight oil the engine should start satisfactorily even down to about 0 F 18 C If the engine must be frequently started below 10 12 C it may be desirable to install the optional ether start kit K887 1 Installation and operating instructions are included in the kits STOPPING THE ENGINE 1 Switch the RUN STOP switch to STOP This turns off the voltage supplied to the shutdown solenoid A backup shutdown can be accomplished by shutting off the fuel valve located on the fuel line VANTAGE 500 CUMMINS LINCOLN 6 6 BREAK IN PERIOD The engine used to supply power for your welder is a heavy duty industrial engine It is designed and built for rugged use It is very normal for any engine to use small quantities of oil until the break in is accomplished Check the oil level twice a day during the break in period In general this takes 50 to 100 hours of operation IMPORTANT IN ORDER TO ACCOMPLISH THIS BREAK IN THE UNIT SHOULD BE SUBJECTED TO HEAVY LOADS WITHIN THE RATING OF THE MACHINE AVOID LONG IDLE RUNNING PERIODS TYPICAL FUEL CONSUMPTION Refer to Table B 2 for typical fuel consumption of the VAN TAGE 500 CUMMINS Engine for various operating scenar ios Table B 2 CUMMINS B3 3 Engine Fuel Consumption CUMMINS B3 3 53HP 40Kw 1800 RPM Running Time for 25GAL 94 6L Hours 43 Gal hour 58 1 62 L
23. hour Low Idle no load 1400 RPM High Idle no load 1890 RPM 66 Gal hour 38 2 5 L hour DC CC Weld Output 500 Amps 40 Volts 1 96 Gal hour 12 8 7 40 L hour 1 32 Gal hour 5 00 L hour Auxiliary Power 12 000 VA 1 84 Gal hour 6 97 L hour Auxiliary Power 20 000 VA 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 STICK WELDING MODE The VANTAGE 500 CUMMINS can be used with a broad range of DC stick electrodes The MODE switch provides two stick welding settings as fol lows CC STICK MODE The CC STICK position of the MODE switch is designed for horizontal vertical up and over head welding with all types of electrodes especially low hydrogen The OUTPUT CON TROL knob adjusts the full output range for stick welding The ARC CONTROL knob sets the short circuit arc force current during stick welding Increasing the number from 10 Soft to 10 Crisp increases the short circuit current and prevents sticking of the electrode to the plate while welding This can also increase spatter It is recommended that the ARC CONTROL be set to the minimum number without electrode sticking Start with the knob set at 0 DOWNHILL PIPE MODE This slope controlled setting is intended for out of position and
24. meters is 3 12 WELD MODE SELECTOR SWITCH Provides four selectable welding modes CV WIRE DOWNHILL PIPE CC STICK TOUCH START TIG 13 ARC CONTROL The ARC CONTROL WIRE STICK knob is active in the WIRE and STICK modes and has different functions in these modes This control is not active in the TIG mode CC STICK mode In this mode the ARC CONTROL knob sets the short circuit current arc force during stick welding Increasing the number from 10 Soft to 10 Crisp increases the short circuit current and prevents sticking of the electrode to the plate while welding This can also increase spatter It is recommended that the ARC CONTROL be set to the mini mum number without electrode sticking Start with a setting at 0 DOWNHILL PIPE mode In this mode the ARC CONTROL knob sets the short circuit current arc force during stick welding to adjust for a soft or a more forceful digging arc Crisp Increasing the number from 10 Soft to 10 Crisp increases the short circuit current which results in a more forceful digging arc Typically a forceful digging arc is pre ferred for root and hot passes A softer arc is preferred for fill and cap passes where weld puddle control and deposition stacking of iron are key to fast travel speeds It is recom mended that the ARC CONTROL be set initially at 0 CV WIRE mode In this mode turning the ARC CONTROL knob from 10 soft to 10 crisp changes the arc from soft and washed
25. porte lectrode dans l eau pour le refroidir Ne jamais toucher simultan ment les parties sous tension des porte lectrodes connect s deux machines souder parce que la tension entre les deux pinces peut tre le total de la tension vide des deux machines Si on utilise la machine souder comme une source de courant pour soudage semi automatique ces precautions pour le porte lectrode s applicuent aussi au pistolet de soudage 2 Dans le cas de travail au dessus du niveau du sol se prot ger contre les chutes dans le cas ou on recoit un choc Ne jamais enrouler le c ble lectrode autour de n importe quelle partie du corps PR CAUTIONS DE S RET POUR soudage Utiliser des lunettes avec crans lateraux dans les zones l on pique le laitier Eloigner les mat riaux inflammables ou les recouvrir afin de pr venir tout risque d incendie d aux tincelles Quand on ne soude pas poser la pince une endroit isol de la masse Un court circuit accidental peut provoquer un chauffement et un risque d incendie S assurer que la masse est connect e le plus pr s possible de la zone de travail qu il est pratique de le faire Si on place la masse sur la charpente de la construction ou d autres endroits loign s de la zone de travail on augmente le risque de voir passer le courant de soudage par les chaines de lev age c bles de grue ou autres circuits Cela peut provoquer des risques d incend
26. power load is not restart The gauge displays the engine oil pressure when the engine is running 7 ENGINE PROTECTION The yellow engine protection light remains off with proper oil pressure and under normal operating tem peratures If the light turns on the engine protection system will stop the engine Check for proper oil and coolant levels and add oil and or coolant if neces sary Check for loose or disconnected leads at the oil pressure sender located on the engine The light will remain on when the engine has been shut down due to low oil pressure or over temperature condi tion NOTE This engine is equipped with an electronic governor system The engine speed ramps up during a warm up period The complete cycle takes approximately 3 minutes This allows the engine cylinder temperature to build up slowly before going to full speed This feature is bypassed if the engine is already warm The Engine may produce White Smoke for a few minutes at low tem peratures Do not apply a load to the machine during the warm up period 8 BATTERY CHARGING LIGHT The yellow engine alternator light is off when battery charging system is functioning normally If light turns on the alternator or the voltage regulator may not be operating correctly The light will remain on when the engine is stopped and the run stop switch is in the run position 9 IDLER SWITCH Has two positions as follows In the High position lt t
27. ratings in the following table ELECTRODE CURRENT RANGE DIAMETER DC electrode positive 1 8 30 60 Amps 5 32 90 150 Amps 3 16 200 250 1 4 300 400 5 16 350 450 3 8 450 575 Amps NOTE If desired the CV mode can be used for Arc Gouging Maximum current setting is limited to the VANTAGE 500 CUMMINS maximum of 575 Amps PARALLELING When paralleling machines in order to combine their outputs all units must be operated in the CC STICK mode only at the same output settings To achieve this turn the WELD MODE switch to the CC STICK position Operation in other modes may produce errat ic outputs and large output imbalances between the units AUXILIARY POWER OPERATION receptacle is tripped See the MAINTE NANCE section for detailed information on testing and resetting the GFCI receptacle Start the engine and set the IDLER control switch to the desired operating mode Full power is available regardless of the welding control settings if no weld ing current is being drawn The auxiliary power of the VANTAGE 500 CUMMINS consists of two 20 Amp 120VAC single phase 5 20R GFCI duplex receptacles one 50 Amp 120 240VAC single phase 14 50R receptacle and one 50 Amp 240VAC three phase 15 50R receptacle The 120 240VAC receptacle can be split for single phase 120 VAC operation The auxiliary power capacity is 12 000 watts of 60 Hz single pha
28. tripped Follow GFCI Receptacle Testing and Resetting Procedure in the MAINTENANCE section of this manual Open breakers may need to be reset Faulty receptacle Faulty auxiliary circuit wiring 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 500 CUMMINS LINCOLN Jequunu epoo jueuudinbe y SAIN e 2901S U O s ou sjeued y JO euo uo y episul pejsed si epoo e oul Jenueui siy Aq peJeAoo 20 eq jou Aew 3 S 5141 310 1 1169 YOLYNLOY 2 4 2 9 qloN31os 43491 OILINOVN 4 2 2 conse 11098 and lana ed 2s ee IOHLNOO 5 2808 TOHLNOD JO HOVE HONH3AOS el 1 1 305 1431 9018 941099 ONG 310GON ee u3ddOHO d KE DEN TIOHLNOO a IdION310S e HONHHAOS 3 p p q 9 q
29. 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 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 Read and understand the manufacturer s instructions for this equipment and the consumables to be used including the material safety data sheet MSDS and follow your employer s safety practices MSDS forms are available from your welding distributor or from the manufacturer Also see item 1 b SAFETY WELDING and CUTTING gt SPARKS cause fire or explosion 6 a Remove fire hazards from the welding area If this is not possible cover them to prevent the welding sparks from starting a fire Remember that welding sparks and hot materials from welding can easily go through small cracks and openings to adjacent areas Avoid welding near hydraulic lines Have a fire extinguisher readily available 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 249 1 and the operating information for the equipment being used When not welding make certain no part of the electrode circuit is touching the work or groun
30. 00 CUMMINS LINCOLN D 2 MAINTENANCE D 2 Service Instructions amp Installation Tips For Engine Air Filter Check the Old Filter for Leak Clues 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 Release the Seal Carefully Unlatch and remove the service cover of the air cleaner Make certain the latches are folded back against the cover so that they don t hinder filter removal installation Most latches are spring loaded to fold back when open The filter fits tightly over the outlet tube creating the critical seal on the inside diameter of the filter endcap The filter should be removed gently to reduce the amount of dust dislodged 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 Inspect the New Filter for Damage Inspect the new filter carefully paying attention to the inside of the open end which is the sealing area NEVER install a damaged filter Avoid Dislodging Dust from the Filter Gently pull the filter off the outlet tube and out of the housing Avoid knocking the filter against the housing Insert the New RadialSeal Filter by Hand Insert carefully Seat the new filter by hand Donaldson filters with RadialSeal Sealing Tec
31. 09 INVHOVIG DNIYIM SNIANINO 006 39V LNVA F 1 VANTAGE 500 CUMMINS LINCOLN E CONNECTION DIAGRAMS F 2 F 2 8 8 65 0002 22 01 NOLLISOd 4101 HOI NI HOLIMS 417101 39VId ON NOILISOd GSTIOUNLNOD ATALOWSY OL HOLIMS STVNINYAL ONIO OM 39V Id NOLLISOd AYIM AD IHL NI HOLIMS 3QOW 39Vld ON ALINV10d 9341534 58718 LAdLNO OL 53189 ON OW LOANNOOD dO 41949 ALN 1N33309 303 9371 38 LSNN S418V9 ONIO DM WANVW 9NILVe3dO H3Q713M 3NISN3 JHL 931511 SNOILVOISIOAdS 3AO8V LSNPAV LON OG 4301993 JHL LV 135 344 SI 9NLLL3S HONS3AO9 3NION3 LINDYIO TOHLNOO JHL NYO HOIHM 39V L10A 830334 FIM OV JHL NI 3SV3SONI NV ASNVS 39 VMNIT 31LLOSH L SHL HO ONILLAS HONS3AO9 9 Ad 3NISN3 HOIH AHL dO 3SV339NI ANY 194N0S YAMOd TINGON TOHLNOI SHL OL 39VIAVG NI LINSSY NOILISOd HOLIMS L938809NI 31000IN 314340 OL 3401438 050 38019010 LOV LNOO IHL NI SI HOLIMS IAOW JINGOW 103109 LVHL 38 NOUT JINON TOHLNO9 OL 57875 330819313 OL 3199 LNdNI 3191439234 01 169 JLOWSY Nid 9 q 9 10085 SC 18V JINON 10HLNO9 MTT 9S 887 Y30334 SUM Nld vl juewdmbe siy eoi Jes Jo syed au je 2139818 jou oqe esn esu pjnous puuo 598 p Auo e Jes 01 4 syed
32. EEN EE ER Qe a u s RER ee twee A 2 Location Ventilation A 2 in RTL Se A 2 ee Al 2 Angle of Operation A 2 ENNO EET A 3 High Altitude Operation A 3 High Temperature Operation A 3 TOWING sergiden oh end on dee oad deeds dad ead oes E A 3 Vehicle Mo nitlnig seawater tenons Pineal n eee ees A 3 Pre Operation Engine and Compressor Service A 4 s 4 Fuel ais TT 4 AM TEENS 4 Engine Coolant 2 24 23 4 Battery Connection 4 Muffler Outlet Pipe ge aQ 5 Spark Arrestor 5 Welding Terminal dent tend wui UR 5 Welding Output Cables A 5 Machine Grounding x p RE ERR dee LET REA A d 5 Remote Control Pha UR an RD ale we nce wal gale RT a CRIT alata A 6 Auxiliary Power Receptacles lllseeesseeeeeeee ne A 6 Standby Power Connections A 6 Conn
33. EPTACLE TESTING AND RESET TING PROCEDURE The GFCI receptacle should be properly tested at least once every month or whenever it is tripped To properly test and reset the GFCI receptacle If the receptacle has tripped first carefully remove any load and check it for damage If the equipment has been shut down it must be restarted The equipment needs to be operating at high idle speed and any necessary adjustments made on the control panel so that the equipment is providing at least 80 volts to the receptacle input terminals The circuit breaker for this receptacle must not be tripped Reset if necessary Push the Reset button located on the recep tacle This will assure normal GFCI operation Plug night light with an ON OFF switch or other product such as a lamp into the GFCI receptacle and turn the product ON Push the Test button located on the GFCI recepta cle The night light or other product should go OFF Push the Reset button again The light or other product should go again If the light or other product remains ON when the Test button is pushed the GFCI is not working prop erly or has been incorrectly installed miswired If your GFCI is not working properly contact a qualified certified electrician who can assess the situation rewire the GFCI if necessary or replace the device VANTAGE 500 CUMMINS LINCOLN 8 TROUBLESHOOTING E HOW
34. HAAINN 298 3HOM OL 3004193713 318VO FOE HO 1627 TONSHdNY Nid vL 939333 jueuudinbe silu 1 10 syed jou oq e sn IIe1su jeuuosied luO e urnes syed des e Qva1AHuaLiva C 3ALIVO3N 199uuoSsiq e ootd ui e uedo sjeued jou oq e ub 5 14 ONIAOW IP uo HDOHS 21419113 ONINHVM W INVHOVIG NOI LO3NNOO Z N1 8773 2984 H3 NVWINOO VANTAGE 500 CUMMINS LINCOLN E CONNECTION DIAGRAMS F 4 F 4 7 282705 0002 22 01 NOILISOd HOI NI HOLIMS 43141 39V1d ON NOILISOd AHL NI HOLIMS SCOW 9 21875 2300419373 dO ALI V 10d JHL HOLVIA OL HOLIMS HAL3NLTIOA 830333 38IM NOILISOd ALIWV10d 9331 34 304 SAGNLS LAGLNO OL 318V9 LOANNOO ON WANVW ONILVYSdO 395 SNOILVON 1ddV SYNLAd ANY 31VIQ3NNI dO 41949 ALNG ANY LNAYYND JHL ALIO VavO dO 38 LSNW S318V9 ONIGTAM WANVW ONILVYSdO YSCTSM ANIONS SHL NI 931511 SNOILVOISIOAdS 3AO8V 15 LON OG 7 AYOLOVA SHL 13S 3Md SI SNILL3S HONS3AOO9 SNIDNA TOHLNOO JHL NYO HOIHM SOVLIOA 830333 38IM OV JHL NI SSVSYONI NV ASNVO 39 VXNI131LLOSHL JHL 9NIGIHS3AO ONILLAS HONS3AO9 SHL Ad 3NISN3 H9IH SHL 30 3SV339NI
35. HINE GROUNDING in the Installation chapter for proper machine grounding information 23 240VAC THREE PHASE RECEPTACLE This is a 240VAC 15 50R receptacle that provides 240VAC three phase auxiliary power This recepta cle has a 50 amp rating ENGINE OPERATION STARTING THE ENGINE 1 Open the engine compartment door and check that the fuel shutoff valve is in the open position lever to be in line with the hose 2 Check for proper oil level and coolant level Close engine compartment door 3 Remove all plugs connected to the AC power receptacles 4 Set IDLER switch to AUTO 5 Set the RUN STOP switch to RUN Observe that the engine protection and battery charging lights are on The engine protection light may turn off after 5 seconds or remain on until the engine is started 6 Within 30 seconds press and hold the engine START button until the engine starts If the engine does not start within 30 seconds the RUN STOP switch must be returned to the STOP position then return to step 5 7 Release the engine START button when the engine starts 8 Check that the engine protection and battery charg ing lights are off Investigate any indicated problem NOTE The engine will go through a 3 minute warm up cycle if cold If the engine coolant is still warm from recent operation the engine will go immediately to high idle and then to low idle if the idle switch is in the AUTO position COLD
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37. July 2007 VANTAGE 500 CUMMINS For use with machines having Code Numbers 11181 11416 SAFEEY dEPEndS on Hall 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 EQUIP MENT WITHOUT READING THIS MANUAL AND THE SAFETY PRECAUTIONS CONTAINED THROUGHOUT Most importantly think before you act and be careful OPERATOR S MANUAL 1309001 ANSI RABE Desigi d Quality Progra ABS Quality E Inc to ISO 9001 Requirements CERTIFICATE NUMBER 30273 LI NCOLN Copyright 2007 Lincoln Global Inc World s Leader 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 WEB SITE www lincolnelectric com l SAFETY i WARNING CALIFORNIA PROPOSITION 65 WARNINGS A Diesel engine exhaust and some of its constituents The engine exhaust from this product contains are known to the State of California to cause can chemicals known to the State of California to cause cer birth defects and other reproductive harm cancer birth defects or other reproductive harm The Above For Diesel Engines The Above For Gasoline Engines
38. MMINS LINCOLN 4 OPERATION B 4 WELDING CONTROLS Items 10 through 19 10 OUTPUT CONTROL The OUTPUT dial is used to preset the output voltage or current as displayed on the digital meters for the four welding modes When in the CC STICK DOWNHILL PIPE or CV WIRE modes and when a remote control is connected to the 6 Pin or 14 Pin Connector the auto sensing circuit automatically switches the OUTPUT CONTROL from control at the welder to the remote control In the CV WIRE mode when the wire feeder control cable is connected to the 14 Pin Connector the auto sensing circuit automatically makes OUTPUT CONTROL inactive and the wire feeder voltage control active When in the 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 11 DIGITAL OUTPUT METERS The digital meters allow the output voltage CV WIRE mode or current CC STICK DOWNHILL PIPE and TIG modes to be set prior to welding using the OUTPUT control knob During welding the meters display the actual output voltage VOLTS and current AMPS memory feature holds the display of both meters on the seven seconds after welding is stopped This allows the operator to read the actual current and voltage just prior to when welding was ceased While the display is being held the left most decimal point in each dis play will be flashing The accuracy of the
39. NG SYSTEM The VANTAGE 500 CUMMINS is equipped with a pressure radiator Keep the radiator cap tight to pre vent loss of coolant Clean and flush the coolant sys tem periodically to prevent clogging the passage and over heating the engine When antifreeze is needed always use the permanent type BATTERY HANDLING GASES FROM BATTERY can explode sparks flame and cigarettes i away from battery y To prevent EXPLOSION when INSTALLING A NEW BATTERY dis connect negative cable from old bat tery first and connect to new battery last CONNECTING A CHARGER Remove battery from welder by dis connecting negative cable first then positive cable and battery clamp When reinstalling connect negative cable last Keep well ventilated USING A BOOSTER connect positive lead to battery first then connect nega tive lead to engine foot c BATTERY ACID CAN BURN EYES AND SKIN Wear gloves and eye protection and be careful when working near battery Follow instructions printed on battery PREVENTING ELECTRICAL DAMAGE 1 When replacing jumping or otherwise connecting the battery to the battery cables the proper polarity must be observed Failure to observe the proper polarity could result in damage to the charging cir cuit The positive battery cable has a red termi nal cover 2 f the battery requires charging from an external charger disconnect the negative battery cab
40. ON ONILVWYSdO 33 SNOI1VO9I 1ddV 591413 ANY ALVIGSWWI 30 41949 ANY ALIOVdVO 43d0 d dO 38 LSNN 31895 SNIQTJM 3189 300819313 MYOM OL OL 4781 HOM 45343334 38IM GC N1 1091105 310 53 WNOILdO JON3HdAV 9 TON3HdAV jueuudinbe siy ales Jo sued Ajeoujoeje jou oqe sn pezsu pnoys Iguuosi d peyrjenb e BUIDIMIAS sued Aeme deeye peaj JAI LV 3N 19uU09SIQ e eoejd u do sjoued jou oq e ONINHVM Y TOULNOO SLOWSY L H TYNOILdO WVYSVIG NOIL JNNO9 AHL 5509 SC NT 6 3NISN3 VANTAGE 500 CUMMINS LINCOLN E CONNECTION DIAGRAMS F 11 F 11 6 28 75 0002 22 01 4341520 Sv NOILISOd H IH OLAV NI HOLIMS 414101 39VId TN NOILISOd ALOWSY NI HOLIMS LAdLNO 39V Id ON NOILISOd 911 SHL NI HOLIMS SGOW 3HL 39V1ld ON ALINV10d 0341 1 50715 LNdLAO OL 531979 ONIGTAM LO3NNOO WANVA ONILVYAdO 33 SNOILVOr adv SYNLNA ANY ALVIGSWWI dO 31949 ALNG LNSYYND SHL 804 ALIOVdVO dO 38 LSNW S318V9 WANVA 4340 43073M d3NISN3 SHL NI GALS SNOILVOISIOSdS dAO8V LSNPAV LON OG 7 AYOLOVS JHL 13S 3Md SI ONILL3S HONS3AO9 SNIDNA SHL LINDYID TOHINOO SHL
41. R Two wheeled trailer with optional fender and light package For highway use consult applicable feder al state and local laws regarding possible additional require ments Comes standard with a Duo Hitch a 2 Ball and Lunette Eye combination hitch a fender amp a light package Order K2636 1 Trailer K958 1 Ball Hitch K958 2 Lunette Eye Hitch K2639 1 Fender amp Light Kit K2640 1 Cable Rack K887 1 ETHER START KIT Provides maximum cold weath er starting assistance for frequent starting below 10 12 C Required Ether tank is not provided with kit K1847 1 SPARK ARRESTOR KIT Easily mounts to stan dard muffler K1816 1 Full KVA Adapter Kit Plugs into the 120 240V NEMA 14 50R receptacle on the case front which accepts 4 prong plugs and converts it to a NEMA 6 50R receptacle which accepts 3 prong plugs for connection to Lincoln Equipment with a NEMA 6 50P plug T12153 9 Full KVA Power Plug One dual voltage A WARNING plug rated at 120 240V 50 amps single phase Pipe Thawing with an arc welder can cause fire explosion damage to electric wiring or to the arc welder if done improperly The use of an arc welder for pipe thawing is not approved by the CSA nor is it recommended or supported by Lincoln Electric K2356 1 Control Panel Cover Kit Clear plexiglass cover to protect control panel from dirt and debris and to visually monitor machine operation Lockable to deter vandalism K2340 1 Locka
42. RK CABLES AMPS Up to 200ft 1200 250ft 100 Up to 656m 656 820m Duty Cycle 500 3 0 AWG 4 0 AWG 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 To prevent dangerous electric shock other equipment powered by this engine driven welder must a be grounded to the frame of the welder using a grounded type plug or b be double insulated When this welder is mounted on a truck or trailer its frame must be securely connected to the metal frame of the vehi cle When this engine driven welder is connected to premises wiring such as that in a home or shop its frame must be connected to the system earth ground See further connection instructions in the section entitled Standby Power Connections as well as the article on grounding in the latest National Electrical Code and the local codes 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 ground stake going into the ground for at least 10Ft 3 1m or to the metal framework of a building which has been effectively grounded The National Electric Code lists a number of alternate means of ground ing electrical equipment A machine grounding stud marked with the symbol is provided on the front of the welder
43. TAGE 500 CUMMINS case front may result in overheating of the VANTAGE 500 CUMMINS engine Figure A 2 Connection of the VANTAGE 500 CUMMINS to Premises Wiring 240 VOLT GROUNDED CONDUCTOR 240 Volt POWER I20VOLT Pa 60 Hz 3 Wire COMPANY N Service METER LOAD DOUBLE POLE DOUBLE THROW SWITCH RATING TO BE THE SAME AS OR GREATER THAN PREMISES SERVICE OVERCURRENT PROTECTION PREMISES DISCONNECT AND SERVICE GROUND OVERCURRENT 240 VOLT PROTECTION DOUBLE POLE CIRCUIT 240 VOLT BREAKER 50 AMP 120 240 VOLT PLUG NEMA TYPE 14 50 1 bj A 50 AMP 120 240 VOLT lt g Zes z NOTE No 6 COPPER CONDUCTOR CABLE SEE RECEPTACLE NATIONAL ELECTRICAL CODE FOR ALTERNATE WIRE SIZE RECOMMENDATIONS VANTAGE 500 CUMMINS LINCOLN 8 INSTALLATION 8 CONNECTION OF LINCOLN ELECTRIC WIRE FEEDERS WARNING Shut off welder before making any electrical con nections CONNECTION OF LN 7 LN 8 OR LN 742 TO THE VANTAGE 500 CUMMINS Shut the welder Connect LN 7 LN 8 OR LN 742 per instructions on the appropriate connection diagram in the DIA GRAMS section Set the WIRE FEEDER VOLTMETER switch to either or as required by the electrode being used Set the SELECTOR switch to the CV WIRE posi tion Adjust the ARC CONTROL knob to desired Crispness SOFT for MIG and CRISP for Innershield Set t
44. TO USE TROUBLESHOOTING GUIDE WARNING Service and Repair should only be performed by Lincoln Electric Factory 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 1 LOCATE PROBLEM 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 Step 2 POSSIBLE CAUSE The second column labeled POSSIBLE CAUSE lists the obvious external possibilities that may contribute to the machine symptom Step 3 RECOMMENDED COURSE OF ACTION This column provides a course of action for the Possible Cause generally it states to contact your local Lincoln Authorized Field Service Facility If you do not understand or are unable to perform the Recommended Course of Action safely contact your local Lincoln Authorized Field Service Facility CAUTION If for any reason you do not understand the test procedures or are unable to perform the tests repairs safely contact your Local Linc
45. Turn off input power using the disconnect Switch at the fuse box before working on the equipment Install equipment in accordance with the U S National Electrical Code all local codes and the manufacturer s recommendations Ground the equipment in accordance with the U S National Electrical Code and the manufacturer s recommendations SAFETY i PR CAUTIONS DE S RET 5 Toujours porter des lunettes de s curit dans la zone de Pour votre propre protection lire et observer toutes les instructions et les pr cautions de s ret specifiques qui parraissent dans ce manuel aussi bien que les pr cautions de s ret g n rales suiv antes S ret Pour Soudage A L Arc 1 Protegez vous contre la secousse lectrique a Les circuits l lectrode et la pi ce sont sous tension quand la machine souder est en marche Eviter toujours tout contact entre les parties sous tension et la peau nue ou les v tements mouill s Porter des gants secs et sans trous pour isoler les mains Faire tr s attention de bien s isoler 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 couch pour lesquelles une grande partie du corps peut tre en contact avec la masse Maintenir le porte lectrode la pince de masse le c ble de soudage et la machine souder en bon et s r tat defonctionnement d Ne jamais plonger le
46. VANTAGE 500 CUMMINS LINCOLN 5 6 INSTALLATION 6 REMOTE CONTROL OUTPUT The VANTAGE 500 CUMMINS is equipped with a 6 pin and a 14 pin connector The 6 pin connector is for connecting the K857 or K857 1 Remote Control or for TIG welding the K870 foot Amptrol or the K963 3 Hand Amptrol When in the CC STICK DOWNHILL PIPE 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 The 14 pin connector is used to directly connect a wire feeder control cable In the CV WIRE mode when the control cable is connected to the 14 pin con nector the auto sensing circuit automatically makes the Output Control inactive and the wire feeder volt age control active NOTE When a wire feeder with a built in welding volt age control is connected to the 14 pin connector do not connect anything to the 6 pin connector AUXILIARY POWER RECEPTACLES Start the engine and set the IDLER control switch to the High Idle mode Voltage is now correct at the receptacles for auxiliary power This must be done before a tripped GFCI receptacle can be reset proper ly See the MAINTENANCE section for detailed infor mation on te
47. W 830 13M ANIONS JHL NI 091511 SNOILVOISIOAdS dAO8V LSAPAV LON OG AYOL V4 SHL 13S 3Md SI SNIL13S YONYSAOD 3NISN3 1031 09 JHL HOIHM SOVLIOA Y30334 38IM OV IHL SSVSYONI NV 2SNV9 39 VMNTT ATLLOYHL 3H1 SNIGISSISAO HO ONILLAS HONS3AO9 JHL 9NIDNVHO Ad SNIDNA 3101 H9IH 3H1 30 ASVIHINI HHOM OL NOILOVO 9935 38IM OL 91992 390819513 AT8IN3SSV 318V 1 dNI 9 9 47875 d lt LNANI SZ N1 OL Ju uudinb siy 2 JO sued uonoj jou oqe sn lle1su pinous peyijenb AIUO e Buras sued Aeme dose pee JALLVO3N 12euuoosiq e eoe d ui e u do sjeued jou oq e ONINHVM WV NOLLO3NNOO TINGON 108 LNOO LAdLNO 31034 LIOA L V699 S N 1 S83Q 13M 3NION3 VANTAGE 500 CUMMINS LINCOLN E CONNECTION DIAGRAMS F 10 F 10 C 18vCS 0002 22 01 294 538 SV NOILISOd 4101 HOI NI HOLIMS 47101 SOV1d FN NOILISOd S IVNIWSH3 L SHL NI HOLIMS S IVNIINS3 L ONIO OW NOILISOd 3H1 NI HOLIMS SGOW 39 Id O N 318V9 3008193713 JHL dO AHL HOLVW OL HOLIMS HSLSWLIOA 3539335 38IM AHL NOILISOd ALINY 10d 9341 34 50115 LAdLNO OL 31899 SNIQT3M LO3NNOO
48. able 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 Follow vehicle manufacturer s instructions VANTAGE 500 CUMMINS LINCOLN 5 4 INSTALLATION 4 PRE OPERATION ENGINE READ the engine operating and maintenance instruc tions supplied with this machine A WARNING Keep hands away from the engine muf fler or HOT engine parts 74 Stop engine and allow to cool before fuelling Do not smoke when fuelling Fill fuel tank at a moderate rate and do not over fill Wipe up spilled fuel and allow fumes to clear before starting engine Keep sparks and flame away from tank The VANTAGE 500 CUMMINS is shipped with the engine crankcase filled with high quality SAE 10W 30 oil API class CD or better Check the engine 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 35 run ning hours Refer to the engine Operator s Manuals for specific oil recommendations and break in information The oil change interval is dependent on the quality of the oil and the operating environment Refer to the engine Operator s Manuals for t
49. age Settings when using K930 2 TIG B 7 Typical Current Ranges for Tungsten Electrodes B 7 C V Wire Mode iei acte sa tur e lus eA ete une de B 8 AC GOUQUIAG Dc 8 Parallel as sas desean sete delent EE 8 Auxiliary Power Operation 8 Simultaneous Welding and Auxiliary Power Loads B 8 Simultaneous Welding and Power Loads Extension Cord Length Recommendations B 9 vii TABLE OF CONTENTS vii Page Accessories aussi eines eed Q WW OC UE RC 8 w NN RR CO ee Section C Optional Field Installed Accessories C 1 Maintenance gx acri ans UC ER OR oa CR GER UE C E DECR OR EUR RT Section D Safety Pr cautions usuyasa Pi bet Soe dur PG P e uui Era FOREN bandas D 1 Routine and Periodic Maintenance nh D 1 Engine Maintenance ous ex Re been eae ated beet tn nes D 1 d DEEN D 1 D 2 he d KO Er tel heh iat eee Ca Sa D 3 SYSTE ee duo ee acne agate le aha ne D 3 Battery E TET D 3 Charging the Battery D 4 Nameplate Warning Decal Maintenance D 4 Welder
50. and engine controls are located on the case front panel Refer to Figure B 1 and the explanations that follow Figure B 1 Case Front Panel Controls ve Cy E text Je LI LA V u v ges O Tu 0 test ek ZC RE M ENGINE CONTROLS Items 1 through 9 1 RUN STOP SWITCH Toggling the switch to the RUN position energizes the fuel solenoid for approximately 30 seconds The engine must be started within that time or the fuel solenoid will denergize and the switch must be tog gled to reset the timer 2 START PUSHBUTTON Energizes the starter motor to crank the engine With the engine Run Stop switch in the position push and hold the Start button to crank the engine release as the engine starts Do not press while engine is running since this can cause age to the ring gear and or starter motor 3 HOUR METER The hour meter displays the total time that the engine has been running This meter is a useful indi cator for scheduling preventive maintenance 4 FUEL LEVEL GAUGE m Displays the level of diesel fuel in the fuel tank The operator must watch the fuel level closely to prevent running out of fuel and possibly having to bleed the system 5 ENGINE TEMPERATURE GAUGE VE The gauge displays the engine coolant temperature VANTAGE 500 CUMMINS LINCOLN 3 OPERATION B 3 6 OIL PRESSURE GAUGE BESCH d If the welding
51. ble K963 3 Hand Amptrol amp Varies current for making critical TIG welds Fastens to the torch for convenient thumb control Comes with a 25 ft 7 6m cable One size fits all Pro Torch TIG Torches K2347 1 Precision TIG 185 Ready Pak For AC TIG Welding with square wave performance use the AC generator of the Engine Driven Welder to supply the power Easy setup Includes torch foot amptrol gas regulator and hose Requires the K1816 1 Full KVA adapter kit K2350 1 Invertec V205 T AC DC One Pak Package For AC TIG welding with square wave performance use the AC generator of the engine driven welder to supply the power Easy setup Includes torch parts kit regulator and hose kit Twist Mate torch adapter work cable with Twist Mate end and foot Amptrol WIRE FEEDER OPTIONS K449 LN 25 Wire Feeder Portable CC CV unit for flux cored and MIG welding Includes Gas Solenoid amp Internal Contactor K126 2 Magnum 350 Innershield Gun for LN 25 For self shielded wire with 15 ft 4 5m cable For 062 3 32 1 6 2 4mm wire KP653 3 32 Drive Roll and Guide Tube Kit for LN 25 For 068 3 32 1 8 2 4mm cored or solid steel wire K1802 1 Magnum 300 MIG Gun For 035 045 0 9 1 2mm gas shielded wire Includes 15 ft gun and cable assembly and connector kit KP653 035S Drive Roll and Guide Tube Kit for LN 25 For 035 040 0 9 1 0mm solid steel wire K487 25 Magnum SG Spool Gun Hand held semiautoma
52. ble Cord Length in ft m for Conductor Size id Load 14 AWG 12 AWG 10 AWG 8 AWG 6 AWG 4 AWG a O Om E 30 60 Conductor size is based on maximum 2 0 voltage drop VANTAGE 500 CUMMINS LINCOLN C1 ACCESSORIES 1 OPTIONAL FIELD INSTALLED ACCES SORIES K802N POWER PLUG KIT Provides four 120V plugs rated at 20 amps each and one dual voltage full KVA plug rated at 120 240V 50 amps 120V plug may not be compatible with NEMA common household receptacles K802R POWER PLUG KIT Provides four 120V plugs rated 15 amps each and one dual voltage full KVA plug rated at 120 240V 50 amps 120V plug is compatible with NEMA common household receptacles K857 25 ft 7 5 m or K857 1 100 ft 30 4 m REMOTE CON TROL Portable control provides same dial range as the output control on the welder from a location up to the specified length from the welder Has convenient plug for easy connection to the welder The VANTAGE 500 CUMMINS is equipped with a 6 pin connector for connecting the remote control K704 ACCESSORY SET Includes 35 feet 10 of electrode cable and 30 feet 9 of work cable shield Filter plate work clamp and electrode holder Cable is rated at 500 amps 60 duty cycle K2641 2 FOUR WHEELED STEERABLE YARD TRAILER For in plant and yard towing Comes standard with a Duo Hitch a 2 Ball and Lunette Eye combination hitch K2636 1 TRAILE
53. ble Fuel Cap Flash Arrester Kit For use in locations where flash arrester safety is required Lockable fuel cap prevents tampering with fuel Green cap color provides a visual reminder to use diesel when refueling K1858 1 Service Indicator Kit Provides a GO NO GO visual indication of air cleaner element useful ser vice life Filter service based on restriction readings allows the longest life possible from the filter and best engine protection K2359 1 Cold Weather Heater and Tarp Kit For extreme cold conditions where normal engine starting is not sufficient Includes oil pan heater engine water heater Battery Heater and radiator grill tarp VANTAGE 500 CUMMINS LINCOLN 2 ACCESSORIES 2 TIG OPTIONS K1783 9 PTA 26V TIG Torch Air Cooled 200 amp torch 2 piece equipped with valve for gas flow control 25 ft 7 6m length KP509 Magnum Parts Kit for PTA 26V TIG Torch Magnum Parts Kit provides all the torch accessories you need to start welding Parts kit provides collets collet bodies a black cap alumina nozzles and tung stens in a variety of sizes all packaged in an easy to carry reclosable sack K870 Foot Amptrol Varies current while welding for making critical TIG welds and crater filling Depress pedal to increase current Depressing pedal fully achieves maximum set current Fully raising the pedal finishes the weld and starts the after flow cycle on so equipped Includes 25 ft 7 6m control ca
54. d Accidental contact can cause overheating and create a fire hazard 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 Vent hollow castings or containers before heating cutting or welding They may explode 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 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 Also see item 1 c Read and follow NFPA 51B Standard for Fire Prevention During Welding Cutting an
55. d Other Hot Work available from NFPA 1 Batterymarch Park PO box 9101 Quincy Ma 022690 9101 Do not use a welding power source for pipe thawing LINCOLN 5 CYLINDER may explode if damaged 7 a Use only compressed gas cylinders containing the correct shielding gas for the process used and properly operating regulators designed for the gas and pressure used All hoses fittings etc should be suitable for the application and maintained in good condition Always keep cylinders in an upright position securely chained to an undercarriage or fixed support 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 Never allow the electrode electrode holder or any other electrically hot parts to touch a cylinder Keep your head and face away from the cylinder valve outlet when opening the cylinder valve Valve protection caps should always be in place and hand tight except when the cylinder is in use or connected for use Read and follow the instructions on compressed gas cylinders associated equipment and CGA publication 1 Precautions for Safe Handling of Compressed Gases in Cylinders available from the Compressed Gas Association 1235 Jefferson Davis Highway Arlington VA 22202 FOR ELECTRICALLY powered equipment 8
56. e to the terminal of the welder and work cable to the terminal of the welder For electrode Negative connect the electrode cable terminal of the welder and work cable to the terminal of the welder Connect the Control Cable of the Spool Gun to the Adapter Module and connect the Control Cable of the Adapter Module to the Welder Connect the Gas Hose Set the MODE switch to the CV WIRE position Set the WELD TERMINALS switch to WELD TERMINALS ON Set the ARC CONTROL knob to 0 initially and adjust to suit Set the IDLE switch to the High position VANTAGE 500 CUMMINS LINCOLN 1 OPERATION B 1 SAFETY INSTRUCTIONS Read and understand this entire section before operating your VANTAGE 500 CUMMINS A WARNING Do not attempt to use this equipment until you have thoroughly read all operating and mainte nance manuals supplied with your machine They include important safety precautions detailed engine starting operating and maintenance instructions and parts lists ELECTRIC SHOCK can kill Do not touch electrically live parts such as output terminals or internal wiring Insulate yourself from the work and ground e gt ENGINE EXHAUST can kill a Use in open well ventilated areas or vent exhaust outside Do not stack anything near the engine Always wear dry insulating gloves MOVING PARTS can injure D
57. ection of Vantage Premises Wiring A 7 Connection of Lincoln Electric Wire Feeders A 8 A 9 Operation Nx meu eu chew ede eR ee Section B Safety Instructions 2 esee eee ede be Ee ae eee eee Tee ee Rede weed B 1 General Description e szi u soe eet E eto RO qaspa aq de eee B 1 Recommended Applications B 1 Controls and Settings d UOI E B 2 Engine Controls eda top aem ee X dues dte ua B 2 B 3 Welder CONITOIS usuyasa 4 Auxiliary Power Controls B 4 Engine Operation 2 22e etus Ee le us EEN A eed B 5 Starting whe ok a ee 5 Stopping the Engine cien nd tape eRe 5 Bieak Ini Period ied wae ae weeks BS NR ecd dans ha ae ui 6 Typical Fuel Consumption B 6 DULY Pays u a Sata a ata B 6 Welding Op rations mmm 6 Stick Welding Mode B 6 CC Stick Modes se Haven Es d diee wed Yate dupa sae be B 6 Downhill Pipe Mode xe Re aana o Rs ren eee B 6 Touch Start TIG Mode iilud xe peux de x Rack qhepata ben ah OR ees B 6 Vant
58. er drain valve located on the bottom of the water separator element 1 or 2 turns and allow to drain into a container suitable for diesel fuel for 2 to 3 seconds Repeat the above drainage procedure until diesel fuel is detected in the container Check coolant level WEEKLY Blow out the machine with low pressure air periodical ly In particularly dirty locations this may be required once a week ENGINE MAINTENANCE Refer to the Periodic Checks section of the Engine Operator s Manual for the recommended maintenance schedule of the following a Engine Oil and Filter b Air Cleaner c Fuel Filter and Delivery System d Alternator Belt e Battery f Cooling System Refer to Table D 1 at the end of this section for vari ous engine maintenance components AIR FILTER CAUTION Excessive air filter restriction will result reduced engine life 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 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 as indicated by the service indi cator See Service Instructions and Installation Tips for Engine Air Filter VANTAGE 5
59. f your helpers from the arc rays 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 FUMES AND GASES can be dangerous 5 a Welding may produce fumes and gases hazardous to health Avoid breathing these fumes and gases When welding keep your head out of the fume Use enough ventilation and or exhaust at the arc to keep fumes and gases away from the breathing zone When welding 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 below Threshold Limit Values TLV using local exhaust or mechanical ventilation In confined spaces or in some circumstances outdoors respirator may be required Additional precautions are also required when welding on galvanized steel 3 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 PEL and ACGIH TLV limits Do not weld in locations near chlorinated hydrocarbon
60. he WELDING TERMINALS switch to the REMOTELY CONTROLLED position Set the IDLE switch to the HIGH position CONNECTION OF LN 15 TO THE VAN TAGE 500 CUMMINS These connections instructions apply to both the LN 15 Across The Arc and Control Cable models The LN 15 has an internal contactor and the electrode is not energized until the gun trigger is closed When the gun trigger is closed the wire will begin to feed and the welding process is started Shut the welder off For electrode Positive connect the electrode cable to the terminal of the welder and work cable to the terminal of the welder For electrode Negative connect the electrode cable terminal of the welder and work cable to the terminal of the welder 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 cur rent Control Cable Model Connect Control Cable between Engine Welder and Feeder Set the MODE switch to the CV WIRE position Across The Arc Model Set the WELD TERMINALS switch to WELD TERMINALS ON Set the WIRE FEEDER VOLTMETER switch to either or as required by the electrode polar ity being used Set the ARC CONTROL knob to 0 initially and adjust to suit Set the IDLE switch to the AUTO IDLE posi
61. he engine runs at the high idle speed controlled by the governor B In the Auto lt lt gt position the idler operates as follows a 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 b 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 c When welding ceases and the AC power load is turned off a fixed time delay of approximate ly 12 seconds starts ed before the end of the time delay the idler reduces the engine speed to low idle speed e The engine will automatically return to high idle speed when the welding load or A C power load is reapplied Idler Operational exceptions When the WELDING TERMINALS switch is in the Remotely Controlled position the idler will operate as follows a When the triggering device Amptrol Arc Start Switch etc is pressed the engine will acceler ate and operate at full speed provided a weld ing load is applied within approximately 12 sec onds If the triggering device remains pressed but no welding load is applied within approximately 12 seconds the engine may return to low idle speed If the triggering device is released or welding ceases the engine will return to low idle speed after approximately 12 seconds VANTAGE 500 CU
62. he proper service and mainte nance intervals m FUEL USE DIESEL FUEL ONLY Fill the fuel tank with clean fresh diesel fuel The capaci ty of the fuel tank is approximately 25 gallons 95 liters See engine Operator s Manual for specific fuel recom mendations Running out of fuel may require bleeding the fuel injection pump NOTE Before starting the engine open the fuel shutoff valve pointer to be in line with hose FUEL CAP Remove the plastic cap covering from the Fuel Tank Filler neck and install the Fuel Cap ENGINE COOLANT WARNING die HOT COOLANT can burn skin not remove radiator is hot The welder is shipped with the engine and radiator filled with a 50 mixture of ethylene glycol and water See the MAINTENANCE section and the engine Owners Manual for more information on coolant ENGINE BREAK IN Lincoln Electric selects high quality heavy duty indus trial engines for the portable welding machines we offer While it is normal to see a small amount of crankcase oil consumption during initial operation excessive oil use wet stacking oil or tar like sub stance at the exhaust port or excessive smoke is not normal Larger machines with a capacity of 350 amperes and higher which are operated at low or no load condi tions for extended periods of time are especially sus ceptible to the conditions described above To accomplish successful engine break in most diese
63. hnology are self aligning self centering and self sealing A new filter has a dry lubricant to aid installation The critical sealing area will stretch slightly adjust itself and distribute the sealing pressure evenly To complete a tight seal apply pressure by hand at the outer rim of the filter not the flexible center Avoid pushing on the center of the urethane end cap No cover pressure is required to hold the seal Again do NOT use the service cover to push the filter into place When the filter in is place put the service cover back on making sure the Vacuator Valve points down Inspect the Vacuator Valve for cracks or dust hang ups to insure that it is functioning properly Re fasten the latches Check Connections for Tight Fit Make sure that all clamps bolts and connections in the entire air intake system are tight Check for holes in piping and repair if needed Clean Sealing Surface of the Outlet Tube Use a clean cloth to wipe the sealing surface Dust on the outside diameter of the outlet tube could hinder an effective seal and cause leakage Make sure that all contaminant is removed before the new filter is inserted Clean the Inside of the Outlet Tube Carefully wipe the inside of the outlet tube with a clean cloth Dirt accidently transferred to the inside of the outlet tube will reach the engine and cause wear Engine manufacturers says that it takes only a few grams of dirt to dus
64. ie ou d echauffement des chaines et des c bles jusqu ce qu ils se rompent Assurer une ventilation suffisante dans la zone de soudage Ceci est particuli rement important pour le soudage de t les galvanis es plomb es ou cadmi es ou tout autre m tal qui produit des fume s toxiques Ne pas souder en pr sence de vapeurs de chlore provenant d op rations de d graissage nettoyage ou pistolage La chaleur ou les rayons de l arc peuvent r agir avec les vapeurs du solvant pour produire du phosg ne gas fortement toxique ou autres produits irritants Pour obtenir de plus amples renseignements sur la s ret voir le code Code for safety in welding and cutting CSA Standard W 117 2 1974 Un coup d arc peut tre plus s v re qu un coup de soliel LES MACHINES SOUDER TRANSFORMATEUR a Utiliser bon masque avec un verre filtrant appropri REDRESSEUR ainsi qu un verre blanc afin de se prot ger les yeux du ray onnement de l arc et des projections quand on soude ou quand on regarde l arc 1 Porter des v tements convenables afin de prot ger la peau de soudeur et des aides contre le rayonnement de l arc Prot ger l autre personnel travaillant proximit au soudage l aide d crans appropri s et non inflammables Des gouttes de laitier en fusion sont mises de l arc de soudage Se prot ger avec des v tements de protection libres de l huile tels que les gants en cuir chemise
65. in to crisp and narrow It acts as an inductance pinch control The proper setting depends on the procedure and operator preference Start with a setting of 0 14 WELDING TERMINALS SWITCH In the WELD TERMINALS ON position the output is electri cally hot all the time In the REMOTELY CONTROLLED posi tion the output is controlled by a wire feeder or amptrol device and is electrically off until a remote switch is depressed 15 WIRE FEEDER VOLTMETER SWITCH Matches the polarity of the wire feeder voltmeter to the polari ty of the electrode 16 6 PIN CONNECTOR For attaching optional remote control equipment Includes auto sensing remote control circuit 17 14 PIN CONNECTOR For attaching wire feeder control cables Includes contactor closure circuit auto sensing remote control circuit and 120VAC and 42VAC power NOTE When a wire feeder with a built in welding voltage con trol is connected to the 14 pin connector do not connect any thing to the 6 pin connector 18 WELD OUTPUT TERMINALS AND These 1 2 13 studs with flange nuts provide welding con nection points for the electrode and work cables For positive polarity welding the electrode cable connects to the termi nal and the work cable connects to this terminal nega tive polarity welding the work cable connects to the termi nal and the electrode cable connects to this terminal AUXILIARY POWER CONTROLS I
66. ind including any warranty of fitness for any customer s particular purpose with respect to such information or advice As a matter of practical consideration we also cannot assume any responsibility for updating or correcting any such information or advice once it has been given nor does the provision of information or advice create expand or alter any warranty with respect to the sale of our products Lincoln Electric is a responsive manufacturer but the selection and use of specific products sold by Lincoln Electric is solely within the control of and remains the sole responsibility of the customer Many variables beyond the control of Lincoln Electric affect the results obtained in applying these types of fabrication methods and service requirements Subject to Change This information is accurate to the best of our knowledge at the time of printing Please refer to www lincolnelectric com for any updated information 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
67. ines be equipped with exhaust spark arresters when they are operated in certain locations where unarrest ed sparks may present a fire hazard The standard muffler included with this welder does not qualify as a spark arrestor When required by local regulations a suitable spark arrestor must be installed and properly maintained A CAUTION An incorrect arrestor may lead to damage to the engine or adversely affect performance AIR CLEANER INLET HOOD Remove the plastic plug covering the air cleaner inlet Install the air cleaner inlet hood to the air cleaner WELDING TERMINALS The VANTAGE 500 CUMMINS is equipped with a toggle switch for selecting hot welding terminals when in the WELD TERMINALS ON position or cold welding termi nals when in the REMOTELY CONTROLLED position WELDING OUTPUT CABLES With the engine off route the electrode and work cables thru the strain relief bracket provided on the front of the base and connect to the terminals provided These con nections should be checked periodically and tightened if necessary Listed in Table A 1 are copper cable sizes recommended for the rated current and duty cycle Lengths stipulated are the distance from the welder to work and back to the welder again Cable sizes are increased for greater lengths primarily for the purpose of minimizing cable voltage drop Table A 1 Combined Length of Electrode and Work Cables TOTAL COMBINED LENGTH OF ELEC TRODE AND WO
68. ir 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 CAUTION DO MOUNT OVER COMBUSTIBLE SUR FACES Where there is a combustible surface directly under stationary or fixed electrical equipment that surface should be covered with a steel plate at least 06 1 6mm thick which should extend not less than 5 90 150mm beyond the equipment on all sides STORING 1 Store the machine in a cool dry place when it is not in use Protect it from dust and dirt Keep it where it can t be accidentally damaged from con struction activities moving vehicles and other hazards 2 Drain the engine oil and refill with fresh 10W30 oil Run the engine for about five minutes to cir culate oil to all the parts See the MAINTE NANCE section of this manual for details on changing oil 3 Remove the battery recharge it and adjust the electrolyte level Store the battery in a dry dark place STACKING VANTAGE 500 CUMMINS machines cannot be stacked ANGLE OF OPERATION To achieve optimum engine performance the VAN TAGE 500 CUMMINS should be run in a level posi tion The maximum angle of operation for the Cummins engine is 35 degrees in all directions When operating the welder at an angle provisions must be made for checking and maintaining the oil level at the normal FULL oil capacity Also the effective fuel capacity
69. l powered equipment needs only to be run at a reason ably heavy load within the rating of the welder for some period of time during the engine s early life However if the welder is subjected to extensive light loading occasional moderate to heavy loading of the engine may sometimes be necessary Caution must be observed in correctly loading a diesel generator unit 1 Connect the welder output studs to a suitable resistive load bank Note that any attempt to short the output studs by connecting the welding leads together direct shorting of the output studs or con necting the output leads to a length of steel will result in catastrophic damage to the generator and voids the warranty 2 Set the welder controls for an output current and voltage within the welder rating and duty cycle Note that any attempt to exceed the welder rating or duty cycle for any period of time will result in cat astrophic damage to the generator and voids the warranty 3 Periodically shut off the engine and check the crankcase oil level BATTERY CONNECTION A WARNING GASES FROM BATTERY explode Keep sparks flame and cigarettes away from battery To prevent EXPLOSION when INSTALLING A NEW BATTERY disconnect negative cable from old battery first and connect to new bat tery last VANTAGE 500 CUMMINS LINCOLN 5 INSTALLATION 5 CONNECTING A BATTERY CHARGER remove bat tery from welder disconnecti
70. l automatically reset to the touch start current level The tungsten may then be retouched to the work piece to restrike the arc The arc may also be started and stopped with an Amptrol or Arc Start Switch The ARC CONTROL is not active in the TIG mode In general the Touch Start feature avoids tungsten contam ination without the use of a Hi frequency unit If the use of a high frequency generator is desired the K930 2 TIG Module can be used with the VANTAGE 500 CUMMINS The set tings are for reference The VANTAGE 500 CUMMINS is equipped with the required R F bypass circuitry for the connection of high fre quency generating equipment VANTAGE 500 CUMMINS LINCOLN 7 OPERATION B 7 The VANTAGE 500 CUMMINS and any high frequen VANTAGE 500 CUMMINS SETTINGS WHEN USING cy generating equipment must properly grounded THE K930 2 TIG MODULE the K930 2 TIG Module operating manuals for Set the WELD MODE switch to the Touch Start Tig complete instructions on installation operation and 20 250 Setting maintenance When using the TIG Module the OUTPUT control on the VANTAGE 500 CUMMINS is used to set the maxi Set the IDLER switch to the AUTO position Set the WELDING TERMINALS switch to the mum range of the CURRENT CONTROL on the TIG Remotely Controlled position This will keep the Module or an Amptrol if connected to the TIG Module solid state contactor open and provide a c
71. le first and then the positive battery cable before attaching the charger leads Failure to do so can result in damage to the internal charger components When reconnecting the cables connect the positive cable first and the negative cable last PREVENTING BATTERY DISCHARGE Turn the RUN STOP switch to stop when engine is not running PREVENTING BATTERY BUCKLING Tighten nuts on battery clamp until snug VANTAGE 500 CUMMINS LINCOLN 0 4 MAINTENANCE D 4 CHARGING THE BATTERY 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 500 CUMMINS positive battery terminal has a red terminal cover 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 Follow the instructions of the battery charger facturer for proper charger settings and charging time NAMEPLATES WARNING DECALS MAIN TENANCE Whenever routine maintenance is performed on this machine or at least yearly inspect all nameplates and labels for legibility Replace those which are no longer clear Refer to the parts list for the replacement ite
72. m number WELDER GENERATOR MAINTENANCE STORAGE Store the Vantage 500 in a clean dry protected areas CLEANING Blow out the generator and controls periodically with low pressure air do this at least once a week in partic ularly dirty areas BRUSH REMOVAL AND REPLACEMENT is normal for the brushes and slip rings to wear and darken slightly Inspect the brushes when a generator overhaul is necessary Do not attempt to polish slip rings while the engine is running REPLACEMENT SERVICE ITEMS ITEM MAKE PART NUMBER SERVICE INTERVAL WITHSETWCE NBCATOR CLEAN AS NEEDED REPLACEAS AIR CLEANER ELEMENT DONALDSON P822768 FLEETGUARD AF25436 INDICATED THE SERVICE INDICATOR ECHO SERVICE CLEAN AS NEEDED REP ACE EVERY 200 HOURS OIL FILTER CUMMINS C6002 112110 FLEETGUARD LF16011 3 MONTHS WHICHEVER IS LESS FAN BELT CUMMINS 60412021748 FUEL STRAINER CUMMINS 3826084 FLEETGUARD FF5079 FUEL FILTER WATER SEPARATOR ENGINE OIL CHANGE SEE MANUAL REPLACE EVERY 750 HOURS OR INSPECT EVERY 1000 HOURS OR 12 MONTHS WHICHEVER 1 LESS INSPECT AND REPLACE MONTHLY AS REQUIRED REPLACE ANNUALLY FLEETGUARD FS19594 REPLACE EVERY 590 HOURS OR MONTHS WHICHEVER IS LESS BATTERY B GROUP 34 INSPECT EVERY 500 HOURS CHANGE EVERY 750 HOURS OR 3 MONTHS WHICHEVER IS LESS CHECK DAILY 525755 VANTAGE 500 CUMMINS LINCOLN D 5 MAINTENANCE D 5 GFCI REC
73. n para gases e Gardez la t te l cart des fum es Utilisez un ventilateur ou un aspira teur pour ter les fum es des zones de travail Vermeiden Sie das Einatmen von Schweibrauch Sorgen Sie fiir gute Be und Entl ftung des Arbeitsplatzes e Mantenha seu rosto da fumaca Use ventila o exhaust o para remover fumo da zona respirat ria Feu CORAVHELTIBELTFEL e manm e SSeS 2475 e 57 HHPI Ash 71294714 37 amp Q all oe Saye dui ay e CY jul baa jja A Z e J Ge call us e Turn power off before servicing Desconectar el cable de ali mentaci n de poder de la maquina antes de iniciar cualquier servicio e D branchez le courant avant l entre tien Strom vor Wartungsarbeiten abschalten Netzstrom v llig ff nen Maschine anhalten opere com as tampas removidas Desligue corrente antes de fazer servico toque as partes el tricas nuas e X7TTLZA KR UAURBUD FTF e HENKE SHA AHS aLi ii alil e Do not operate with panel open or guards off No operar con panel abierto 0 guardas quitadas N op rez pas avec les panneaux ouverts ou avec les dispositifs de protection enlev s Anlage nie ohne Schutzgeh use oder Innenschutzverkleidung in Betrieb setzen
74. ng Terminals switch in wrong position No open circuit voltage at output studs Faulty electronic governor con troller or Weld Control PCB Broken wire in auxiliary current sensor wiring Auxiliary power load is less than 100 watts Faulty electronic governor con troller or Weld Control PCB 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 500 CUMMINS LINCOLN 5 4 TROUBLESHOOTING E 4 Observe all Safety Guidelines detailed throughout this manual FUNCTION PROBLEMS Engine goes to low idle but does not 1 Weld Control PCB or electronic governor controller No welding output or auxiliary out 1 Broken lead in rotor circuit Faulty field diode module Faulty Weld Control PCB Faulty rotor Welder has some no output and nol Faulty remote kit control Auxiliary output OK Faulty output control potentiome ter Faulty output control wiring Faulty Weld Control PCB or Chopper PCB WELDING TERMINALS switch in wrong position be sure switch is in ALWAYS ON position misadjustment have been checked Faulty Weld Control PCB orland the problem persists Contact Chopper PCB your local Lincoln Authorized Field Service Facility No auxiliary power GFCI Receptacle may have
75. ng negative cable first then positive cable and battery clamp When rein Stalling connect negative cable last Keep well venti lated USING BOOSTER connect positive lead to battery first then connect negative lead to negative battery lead at engine foot BATTERY ACID can burn eyes and skin Wear gloves and eye protection and be careful when working near battery Follow instructions printed on battery IMPORTANT To prevent ELECTRICAL DAMAGE WHEN a Installing new batteries b Using a booster Use correct polarity Negative Ground The VANTAGE 500 CUMMINS is shipped with the negative battery cable disconnected Before you operate the machine make sure the Engine Switch is in the OFF posi tion and attach the disconnected cable securely to the nega tive battery terminal Remove the insulating cap from the negative battery termi nal Replace and tighten negative battery cable terminal NOTE This machine is furnished with a wet charged bat tery if unused for several months the battery may require a booster charge Be sure to use the correct polarity when charging the battery MUFFLER OUTLET PIPE Remove the plastic plug covering the muffler outlet tube 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 position SPARK ARRESTOR Some federal state or local laws may require that petrol or diesel eng
76. 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 VANTAGE 500 CUMMINS LINCOLN 8 OPERATION B 8 CV WIRE MODE Connect a wire feeder to the VANTAGE 500 CUM MINS and set welder controls according to the instruc tions listed earlier in this section The VANTAGE 500 CUMMINS the CV WIRE position permits it to be used with a broad range of flux cored wire Innershield and Outershield elec trodes and solid wires for MIG welding gas metal arc welding Welding can be finely tuned using the ARC CONTROL Turning the ARC CONTROL clockwise from 10 soft to 10 crisp changes the arc from soft and washed in to crisp and narrow It acts as an inductance pinch control The proper setting depends on the procedure and operator preference Start with the knob set at For any electrodes including the above recommenda tions the procedures should be kept within the rating of the machine For additional electrode information See www lincolnelectric com or the appropriate Lincoln publication ARC GOUGING For optimal performance when arc gouging set the VANTAGE 500 CUMMINS WELD MODE switch to the CC STICK position and the ARC CONTROL to 10 Set the OUTPUT knob to adjust output current to the desired level for the gouging electrode being used according to the
77. o not operate with doors open or guards off CS Stop engine before servicing Keep away from moving parts Only qualified personnel should operate this equipment ADDITIONAL SAFETY PRECAUTIONS Always operate the welder with the Engine door closed and the side panels in place as these pro vide maximum protection from moving parts and insure proper cooling air flow GENERAL DESCRIPTION The VANTAGE 500 CUMMINS is a diesel engine dri ven welding power source The machine uses a brush type alternating current generator for DC multi pur pose welding for 120 240 VAC single phase and 240V three phase auxiliary standby power The weld ing control system uses state of the art Chopper Technology RECOMMENDED APPLICATIONS WELDER The VANTAGE 500 CUMMINS provides excellent constant current DC welding output for stick SMAW and TIG welding The VANTAGE 500 CUMMINS also provides excellent constant voltage DC welding output for MIG GMAW Innershield FCAW Outershield FCAW G and Metal Core welding In addition the VANTAGE 500 CUMMINS can be used for Arc Gouging with carbons up to 3 8 10mm in diameter The VANTAGE 500 CUMMINS is not recommended for pipe thawing GENERATOR The VANTAGE 500 CUMMINS provides smooth 120 240 VAC single phase and 240V three phase output for auxiliary power and emergency standby power VANTAGE 500 CUMMINS LINCOLN 2 OPERATION B 2 CONTROLS AND SETTINGS All welder
78. old elec trode until the triggering device Amptrol or Arc Start Switch is pressed Table TYPICAL CURRENT RANGES FOR TUNGSTEN ELECTRODES DCEN DCEP Approximate Argon Gas Flow Rate l min c f m Tungsten Electrode 1 2 1 2 TIG TORCH Diameter Thoriated Thoriated Aluminum Stainless Steel Nozzle mm in Tungsten Tungsten Size 4 5 25 0 010 2 15 2 4 3 8 2 4 3 8 4 5 6 50 0 020 5 20 3 5 5 10 3 5 5 10 1 0 0 040 15 80 3 5 5 10 3 5 5 10 1 6 1 16 70 150 3 5 5 10 4 6 9 13 5 6 2 4 3 32 150 250 6 8 13 17 5 7 11 15 6 7 8 3 2 1 8 250 400 7 11 15 23 5 7 11 15 4 0 5 32 400 500 10 12 21 25 6 8 13 17 8 10 4 8 3 16 500 750 11 13 23 27 8 10 18 22 6 4 1 4 750 1000 13 15 28 32 11 13 23 27 When used with argon gas The current ranges shown must be reduced when using argon helium or pure helium shielding gases Tungsten electrodes are classified as follows by the American Welding Society AWS Pure EWP 1 Thoriated EWTh 1 2 Thoriated EWTh 2 Though not yet recognized by the AWS Ceriated Tungsten is now widely accepted as a substitute for 2 Thoriated Tungsten in AC and DC applications DCEP is not commonly used in these sizes TIG torch nozzle sizes are in multiples of 1 16ths of an inch 4 1 4 in 6 mm 5 5 16 in 8 mm 6 3 8 in 10 7 7 16 in 11 8 1 2 in 12 5 10 5 8 in 16 mm TIG torch
79. oln Authorized Field Service Facility for technical troubleshooting assistance before you proceed VANTAGE 500 CUMMINS LINCOLN 2 TROUBLESHOOTING E 2 Observe all Safety Guidelines detailed throughout this manual PROBLEMS POSSIBLE RECOMMENDED SYMPTOMS CAUSE COURSE OF ACTION ENGINE PROBLEMS Major Physical or Electrical Damage 1 Contact your Local Lincoln Engine will not crank 1 Battery low 2 Loose battery cable connections which may need Inspected cleaned or tighten 3 Faulty wiring in engine starting circuit 4 Faulty engine starter Contact authorized local Engine Service Shop Engine will crank but not start 1 Out of fuel 2 Fuel shut off valve is in the off position make sure the valve lever is in the open position lever in line with the Hose 3 Engine shut down solenoid not pulling in 4 On Off switch for more than 30 sec before starting the On Off switch will need to be switch off and turned back on If all recommended possible areas 5 Fuel Filters dirty clogged main fil of misadjustment have been ter and or inline Fuel Filter ele checked and the problem persists ment may need to be replaced Contact your local Lincoln 6 High water temperature or low oil Authorized Field Service Facility pressure engine protection light lit Engine shuts down shortly after 1 Low oil pressure engine protec tion light lit Check oil level Consult engine service dealer 2 High wate
80. or every 300 meters 984 ft above 2100 meters 6888 ft Contact a Cummins Service Representative for any engine adjustments that may be required TOWING The recommended trailer for use with this equipment for road in plant and yard towing by a vehicle mis Lincoln s K953 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 nor damage the welding equipment Some of the factors to be considered are as follows 1 Design capacity of trailer vs weight of Lincoln equipment and likely additional attachments 2 Proper support of and attachment to the base of the welding equipment so that there will be no undue stress to the trailer s 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 4 Typical conditions of use such as travel speed roughness of surface on which the trailer will be operated and environmental conditions 5 Proper preventative maintenance of trailer 6 Conformance with federal state and local laws Consult applicable federal state and local laws regarding specific requirements for use on public highways VEHICLE MOUNTING WARNING Improperly mounted concentrated loads may cause unstable vehicle handling and tires or other components to fail Only transport this Equipment on service
81. pill fuel when filling tank If fuel is spilled wipe it up and do not start engine until fumes have been eliminated 2 a Electric current flowing through any conductor causes localized Electric and Magnetic Fields EMF Welding current creates EMF fields around welding cables and welding machines EMF fields may interfere with some pacemakers and welders having a pacemaker should consult their physician before welding 1 d Keep all equipment safety guards covers and devices in position and in good repair Keep hands hair clothing and tools away from V belts gears fans and all other moving parts when starting operating or repairing equipment Exposure to EMF fields in welding may have other health effects which are now not known All welders should use the following procedures in order to 1 e In some cases it may be necessary to remove safety adi minimize exposure to EMF fields from the welding circuit guards to perform required maintenance Remove guards only when necessary and replace them when the maintenance requiring their removal is complete Always use the greatest care when working near moving parts 2 d 1 Route the electrode and work cables together Secure them with tape when possible 2 d 2 Never coil the electrode lead around your body 1 f Do not put your hands near the engine fan Do not attempt to override the idle
82. r by pushing on the throttle control rods while the engine is running 2 4 3 Do not place your body between the electrode and work cables If the electrode cable is on your right side the work cable should also be on your right side 2 4 4 Connect the work cable to the workpiece as close as possible to the area being welded 1 9 To prevent accidentally starting gasoline engines while turning the engine or welding generator during maintenance work disconnect the spark plug wires distributor cap or magneto wire as appropriate 2 d 5 Do not work next to welding power source Mar 95 LINCOLN SAFETY ELECTRIC SHOCK can kill 3 a The electrode and work or ground circuits are electrically hot when the welder is on Do not touch these hot parts with your bare skin or wet clothing Wear dry hole free gloves to insulate hands 3 b Insulate yourself from work and ground using dry insulation Make certain the insulation is large enough to cover your full area of physical contact with work and ground 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 follo
83. r temperature Check engine cooling system engine protection light lit 3 Faulty oil pressure switch 4 Faulty water temperature switch Contact authorized local Engine Service Shop Engine shuts down while under alt High water temperature load Engine runs rough 1 Dirty fuel or air filters may need cleaned replaced 2 Water in fuel Engine will not shut off 1 Electronic Governor not function ing properly 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 500 CUMMINS LINCOLN E 3 TROUBLESHOOTING E 3 Observe all Safety Guidelines detailed throughout this manual FUNCTION PROBLEMS Battery does not stay charged Faulty battery Faulty engine alternator Loose or broken lead in charging circuit Loose fan belt may need tighten ing Idler switch in HIGH idle position make sure switch is set to AUTO External load on welder or auxil iary power Faulty Weld Control PCB Engine will not go to high idle when 1 Printed Circuit Board or elec If all recommended possible areas of tronic governor controller misadjustment have been checked and the problem persists Contact Poor work lead connection tolyour local Lincoln Authorized Work Field Service Facility Weldi
84. se power or 20 000 watts of 60Hz three phase power The auxiliary power capacity rating in watts is equivalent to volt amperes at unity power fac tor The maximum permissible current of the 240 VAC output is 50 A The 240 VAC single phase output can be split to provide two separate 120 VAC outputs with a maximum permissible current of 50 A per output to two separate 120 VAC branch circuits Output voltage is within 10 at all loads up to rated capacity NOTE The two 120V GFCI receptacles and the two 120V circuits of the 120 240V receptacle are connect ed to different phases and cannot be paralleled The auxiliary power receptacles should only be used with three wire grounded type plugs or approved dou ble insulated tools with two wire plugs The current rating of any plug used with the system must be at least equal to the current capacity of the associated receptacle SIMULTANEOUS WELDING AND AUXIL IARY POWER LOADS It must be noted that the above auxiliary power ratings are with no welding load Simultaneous welding and power loads are specified in table B 4 The permissible currents shown assume that current is being drawn from either the 120 VAC or 240 VAC supply not both at the same time VANTAGE 500 CUMMINS LINCOLN 9 OPERATION 9 TABLE 4 500 CUMMINS SIMULTANEOUS WELDING AND POWER LOADS TABLE B 5 VANTAGE 500 CUMMINS Extension Cord Length Recommendations Maximum Allowa
85. sting and resetting the GFCI receptacle The auxiliary power capacity of the VANTAGE 500 CUMMINS is 12 000 watts of 60 Hz single phase or 20 000 watts of 60Hz three phase power The auxil iary power capacity rating in watts is equivalent to volt amperes at unity power factor The maximum per missible current of the 240 VAC output is 50 A The 240 VAC single phase output can be split to provide two separate 120 VAC outputs with a maximum per missible current of 50 A per output to two separate 120 VAC branch circuits The output voltage is within x 1096 at all loads up to rated capacity The VANTAGE 500 CUMMINS has two 20 Amp 120VAC single phase 5 20R GFCI duplex recepta cles one 50 Amp 120 240 single phase 14 508 receptacle and one 240VAC three phase 15 50R receptacle The auxiliary power receptacles should only be used with three wire grounded type plugs or approved double insulated tools with two wire plugs The current rating of any plug used with the system must be at least equal to the current capacity of the associated receptacle A 240VAC 3 phase plug is provided loose with the machine Note The two 120V GFCI receptacles and the two 120 volt circuits of the 120 240V receptacle are con nected to different phases and can not be paralleled STANDBY POWER CONNECTIONS The VANTAGE 500 CUMMINS is suitable for tempo rary standby or emergency power using the engine manufacturer s recommended maintenance schedule
86. t an engine Be careful not to damage the sealing area on the tube making certain it is completely into the air cleaner housing before latching the cover in place If the cover hits the filter before it is fully in place remove the cover and push by hand the filter further into the air cleaner and try again The cover should go on with no extra force Never use the latches on the cover to force the filter into the air cleaner It is tempting to assume the cover will do the job of seating the filter but it will not Using the latches to push the filter in could cause damage to the housing and will void the warranty VANTAGE 500 CUMMINS LINCOLN D 3 MAINTENANCE D 3 FUEL FILTERS WARNING When working on the fuel system 2 Keep naked lights away do not y Do not spill fuel The VANTAGE 500 CUMMINS is equipped with a Fuel Filter located after the lift pump and before fuel injectors The procedure for changing the filter is as follows 1 Close the fuel shutoff valve 2 Clean the area around the fuel filter head Remove the filter Clean the gasket surface of the filter head and replace the o ring 3 Fill the clean filter with clean fuel and lubricate the o ring seal with clean lubricating oil 4 Install the filter as specified by the filter manufactur er A WARNING Mechanical overtightening will distort the threads filter element seal or filter can COOLI
87. tems 19 23 19 120 240 VAC SINGLE PHASE RECEPTACLE This is a 120 240VAC 14 50R receptacle that provides 240VAC or can be split for 120VAC single phase auxiliary power This receptacle has a 50 amp rating Refer to the AUXILIARY POWER RECEPTACLES section in the installa tion chapter for further information about this receptacle Also refer to the AUXILIARY POWER OPERATION section later in this chapter VANTAGE 500 CUMMINS LINCOLN 5 OPERATION B 5 20 CIRCUIT BREAKERS These circuit breakers provide separate overload current protection for each 120V circuit at the 240V single phase receptacle each 120V single phase receptacle the 240V three phase receptacle the 120VAC in the 14 Pin connector the 42VAC in the 14 Pin connector and battery circuit overload protec tion 21 120VAC SINGLE PHASE RECEPTACLES These two 120VAC 5 20R receptacles with GFCI protection provide 120VAC single phase for auxiliary power Each receptacle has a 20 amp total rating They are designed to protect the user from the haz ards of ground faults When the GFCI has tripped there will be no voltage available from the recepta cle Refer to the AUXILIARY POWER RECEPTA CLES section in the installation chapter for further information about these receptacles Also refer to the AUXILIARY POWER OPERATION section later in this chapter 22 GROUND STUD Provides a connection point for connecting the machine case to earth ground Refer to MAC
88. tic wire feeder Requires SG Control Module and Input Cable K488 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 K691 10 Input Cable For SG Control Module For Lincoln engine power sources with 14 pin MS type connection separate 115V NEMA receptacles and output stud connections PLASMA CUTTING K1581 1 Pro cut 80 Cuts mild steel using the 3 phase AC generator power from the engine driven welder VANTAGE 500 CUMMINS LINCOLN D 1 MAINTENANCE D 1 SAFETY PRECAUTIONS WARNING Have a qualified technician do the maintenance and troubleshooting work the engine off before working inside the machine Remove guards only when necessary and replace them when the maintenance requiring their removal is complete Always use the greatest care when working near moving parts Read the Safety Precautions in front of this manual and the engine instruction manual before working on this machine Keep all equipment safety guards covers and devices in position and in good repair Keep hands hair cloth ing and tools away from V belts gears fans and all other moving parts when starting operating or repair ing the equipment ROUTINE AND PERIODIC MAINTENANCE DAILY Check the Engine oil level Refill the fuel tank to minimize moisture condensa tion in the tank Open the wat
89. will be slightly less than the specified 25 gal 94 6 Itrs VANTAGE 500 CUMMINS LINCOLN 5 3 INSTALLATION 3 LIFTING The VANTAGE 500 CUMMINS lift bail should be used to lift the machine The VANTAGE 500 CUMMINS is shipped with the lift bail retracted Before attempting to lift the VANTAGE 500 CUMMINS the lift bail must be secured in a raised position Secure the lift bail as follows a Open the engine compartment door b Locate the 2 access holes on the upper middle region of compartment wall just below the lift bail c Use the lifting strap to raise the lift bail to the full upright position This will align the mount ing holes on the lift bail with the access holes d Secure the lift bail with 2 thread forming screws The screws are provided in the shipped loose parts bag A WARNING Lift only with equipment of ade quate lifting capacity Be sure machine is stable when lifting Do not lift this machine using lift bail if it is equipped with a heavy accessory such as trailer or gas cylinder Do not lift machine if lift bail is FALLING EQUIPMENT can damaged cause injury 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 welder output 596 for every 300 meters 984 ft above 1500 meters 4920 ft For output of 500A and below derate the welder output 5926 f
90. wing equipment Semiautomatic DC Constant Voltage Wire Welder DC Manual Stick Welder AC Welder with Reduced Voltage Control In semiautomatic or automatic wire welding the electrode electrode reel welding head nozzle or semiautomatic welding gun are also electrically hot 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 Ground the work or metal to be welded to a good electrical earth ground Maintain the electrode holder work clamp welding cable and welding machine in good safe operating condition Replace damaged insulation Never dip the electrode in water for cooling 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 When working above floor level use a safety belt to protect yourself from a fall should you get a shock Also see Items 6 c and 8 ARC RAYS can burn 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 287 standards 4 b Use suitable clothing made from durable flame resistant SE AUG 06 LINCOLN 5 material to protect your skin and that o

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