Lincoln | VANTAGE 500 | User's Manual | Lincoln VANTAGE 500 User's Manual

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July, 2004
Vantage 500 CUMMINS
For use with machines having Code Numbers:
10996
Safety Depends on You
Lincoln arc welding and cutting
equipment is designed and
built with safety in mind.
However, your overall safety
can be increased by proper
installation . . . and thoughtful
operation on your part. DO
NOT INSTALL, OPERATE OR
REPAIR THIS EQUIPMENT
WITHOUT READING THIS
MANUAL AND THE SAFETY
PRECAUTIONS CONTAINED
THROUGHOUT.
Most
importantly, think before you
act and be careful.
OPERATOR’S MANUAL
Copyright© 2004 Lincoln Global Inc.
• World’s Leader in Welding and Cutting Products •
• Sales and Service through Subsidiaries and Distributors Worldwide •
Cleveland, Ohio 44117-1199 USA Tel: 216.481.8100 Fax: 216.486.1751 Web Site: www.lincolnelectric.com
SAFETY
i
i
WARNING
CALIFORNIA PROPOSITION 65 WARNINGS
For Diesel Engines: diesel engine exhaust and
some of its constituents are known to the State of
California to cause cancer, birth defects, and other
reproductive harm.
For Gasoline Engines: The engine exhaust from this
product contains chemicals known to the State of
California to cause cancer, birth defects, or other
reproductive harm.
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 & Cutting - ANSI Standard Z49.1” from the American Welding Society, PO Box
351040, Miami, Florida 33135 or CSA Standard W117.2-1974 or WTIA (Welding Technology Institute of Australia), PO Box
6165, Silverwater, NSW, 2128. A free copy of “Arc Welding Safety” booklet E205 is available from the Lincoln Electrical
Company, 22801 St Clair Avenue, Cleveland, Ohio 44117-1199.
BE SURE THAT ALL INSTALLATION, OPERATION, MAINTENANCE AND REPAIR PROCEDURES ARE
PERFORMED ONLY BY QUALIFIED INDIVIDUALS.
FOR ENGINE
powered equipment.
1.h.
To avoid scalding, do not remove the
radiator pressure cap when the engine is
hot.
1.a Turn the engine off before troubleshooting and maintenance
work unless the maintenance work requires it to be running.
ELECTRIC AND
MAGNETIC FIELDS
may be dangerous
1.b. Operate engines in open, well ventilated
areas or vent the engine exhaust fumes
outdoors.
1.c. Do not add fuel near an open flame, welding
arc or when the engine is running. Stop the
engine and allow it to cool before refuelling
to prevent spilled fuel from vaporizing on
contact with hot engine parts and igniting.
Do not spill fuel when filling tank. If fuel is
spilled, wipe it up and do not start engine
until fumes have been eliminated.
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.
1.e.In some cases it may be necessary to remove safety 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.
1.f. Do not put your hands near the engine fan.
Do not attempt to override the governor or
idler by pushing on the throttle control rods
while the engine is running.
1.g.To prevent accidentally starting petrol engines while turning
the engine or welding generator during maintenance work,
disconnect the spark plug wires, distributor cap or magneto
wire as appropriate.
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.
2.b.EMF fields may interfere with some pacemakers and welders
having a pacemaker should consult their physician before
welding.
2.c. Exposure to EMF fields in welding may have other health
effects which are now not known.
2.d.All welders should use the following procedures in order to
minimize exposure to EMF fields from the welding circuit:
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.
2.d.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.d.4.
Connect the work cable to the workplace as
close as possible to the area being welded.
2.d.5.
Do not work next to welding power source.
Mar ‘95
SAFETY
ii
ARC RAYS can burn.
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 following equipment:
• Semiautomatic DC Constant Voltage (Wire) Welder.
• DC Manual (Stick) Welder.
• AC Welder with Reduced Voltage Control.
3.c.
In semi-automatic or automatic wire welding, the
electrode, electrode reel, welding head, nozzle or semiautomatic welding gun are also electrically “hot”.
3.d.
Always be sure the work cable makes a good electrical
connection with the metal being welded. The connection
should be as close as possible to the area being welded.
3.e.
Ground the work or metal to be welded to a good electrical
(earth) ground.
3.f.
Maintain the electrode holder, work clamp, welding cable
and welding machine in good, safe operating condition.
Replace damaged insulation.
3.g.
Never dip the electrode holder in water for cooling.
3.h.
Never simultaneously touch electrically “hot” parts of
electrode holders connected to two welders because
voltage between the two can be the total of the open circuit
voltage of both welders.
3.i.
When working above floor level, use a safety belt to
protect yourself from a fall should you get a shock.
3.j.
Also see items 6c and 8.
ii
4a
Use a shield with the proper filter and cover
plates to protect your eyes from sparks and
the rays of the arc when welding or
observing open arc welding. Headshield
and filter lens should conform to ANSI
Z87.1 standards.
4.b.Use suitable clothing made from durable flame resistant
material to protect your skin and that of your helpers from the
arc rays.
4.c. Protect other nearby personnel with suitable non flammable
screening and/or warn them not to watch the arc or 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, a respirator may be required. Additional
precautions are also required when welding on galvanized
steel.
5.b.Do not weld in locations near chlorinated hydrocarbon
vapors coming from degreasing, cleaning or spraying
operations. The heat and rays of the arc can react with
solvent vapors to form phosgene, a highly toxic gas, and
other irritating products.
5.c. Shielding gases used for arc welding can displace air and
cause injury or death. Always use enough ventilation,
especially in confined areas, to ensure breathing air is safe.
5.d.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.
5.e. Also see Item 1b.
Mar ‘95
SAFETY
iii
WELDING SPARKS can
cause fire or explosion
6 a Remove fire hazards from the welding area. If
this is not possible, cover them to prevent the
welding sparks from starting a fire. Remember
that welding sparks and hot materials from
welding can easily go through small cracks and openings to
adjacent areas. Avoid welding near hydraulic lines. Have a fire
extinguisher readily available.
6.b.Where compressed gases are to be used at the job site,
special precautions should be used to prevent hazardous
situations. Refer to AS1674 Parts 1 & 2 “Safety in Welding
and Cutting” (ANSI Standard Z49.1) and the operating
information for the equipment being used.
6.c. When not welding, make certain no part of the electrode
circuit is touching the work or ground. Accidental contact can
cause overheating and create a fire hazard.
6.d.Do not heat, cut or weld tanks, drums or containers until the
proper steps have been taken to insure that such procedures
will not cause flammable or toxic vapors from substances
inside. These can cause an explosion even though the
vessel has 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).
6.e.Vent hollow castings or containers before heating, cutting or
welding. They may explode.
iii
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.
7.b.Always keep cylinders in an upright position and securely
chained to an undercarriage or fixed support.
7.c. Cylinders should be located :
• Away from areas where they may be struck or subjected to
physical damage.
• A safe distance from arc welding or cutting operations and
any other source of heat, sparks or flame.
7.d.Never allow the electrode, electrode holder, or any other
electrically “hot” parts to touch a cylinder.
7.e.Keep your head and face away from the cylinder valve outlet
when opening the cylinder valve.
7.f. Valve protection caps should always be in place and handtight except when the cylinder is in use or connected for use.
7.g.Read and follow the instructions on compressed gas
cylinders, associated equipment, and CGA publication P-I,
“Precautions for Safe Handling of Compressed Gases in
Cylinders”, available from the Compressed Gas Association
1235 Jefferson Davis Highway, Arlington, VA 22202.
6.f. Sparks and spatter are thrown from the welding arc. Wear oil
free protective garments such as leather gloves, heavy shirt,
cuffless trousers, high shoes and a cap over your hair. Wear
ear plugs when welding out of position or in confined places.
Always wear safety glasses with side shields when in a
welding area.
6.g.Connect the work cable to the work as close to the welding
area as possible. 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 circuits.
This can create fire hazards or overheat lifting chains or
cables until they fail.
6.h. Also see Item 1c.
FOR ELECTRICALLY
powered equipment.
8.a. Turn off input power using the disconnect
switch at the fuse box before working on the
equipment.
8.b.Install equipment in accordance with the National Electrical
Code, all local codes and the manufacturer’s
recommendations.
8.c. Ground the equipment in accordance with the National
Electrical Code and the manufacturer’s recommendations.
Mar ‘95
SAFETY
iv
iv
PRÉCAUTIONS DE SÛRETÉ
6. Eloigner les matériaux inflammables ou les recouvrir afin de
prévenir tout risque d’incendie dû aux étincelles.
Pour votre propre protection lire et observer toutes les instructions
et les précautions de sûreté specifiques qui parraissent dans ce
manuel aussi bien que les précautions de sûreté générales
suivantes:
7. Quand on ne soude pas, poser la pince à une endroit isolé de
la masse. Un court-circuit accidental peut provoquer un
échauffement et un risque d’incendie.
Sûreté Pour Soudage A L’Arc
1. Protegez-vous contre la secousse électrique:
a. Les circuits à l’électrode et à la piéce sont sous tension
quand la machine à souder est en marche. Eviter toujours
tout contact entre les parties sous tension et la peau nue
ou les vétements mouillés. Porter des gants secs et sans
trous pour isoler les mains.
b. Faire trés attention de bien 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 couché pour lesquelles une grande
partie du corps peut être en contact avec la masse.
c. Maintenir le porte-électrode, la pince de masse, le câble de
soudage et la machine à souder en bon et sûr état
defonctionnement.
d.Ne jamais plonger le porte-électrode dans l’eau pour le
refroidir.
e. Ne jamais toucher simultanément les parties sous tension
des porte-électrodes connectés à deux machines à souder
parce que la tension entre les deux pinces peut être le total
de la tension à vide des deux machines.
f. Si on utilise la machine à souder comme une source de
courant pour soudage semi-automatique, ces precautions
pour le porte-électrode s’applicuent aussi au pistolet de
soudage.
2. Dans le cas de travail au dessus du niveau du sol, se protéger
contre les chutes dans le cas ou on recoit un choc. Ne jamais
enrouler le câble-électrode autour de n’importe quelle partie du
corps.
3. Un coup d’arc peut être plus sévère qu’un coup de soliel, donc:
a. Utiliser un bon masque avec un verre filtrant approprié ainsi
qu’un verre blanc afin de se protéger les yeux du
rayonnement de l’arc et des projections quand on soude ou
quand on regarde l’arc.
b. Porter des vêtements convenables afin de protéger la peau
de soudeur et des aides contre le rayonnement de l‘arc.
c. Protéger l’autre personnel travaillant à proximité au
soudage à l’aide d’écrans appropriés et non-inflammables.
4. Des gouttes de laitier en fusion sont émises de l’arc de
soudage. Se protéger avec des vêtements de protection libres
de l’huile, tels que les gants en cuir, chemise épaisse,
pantalons sans revers, et chaussures montantes.
8. S’assurer que la masse est connectée le plus prés 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
éloignés de la zone de travail, on augmente le risque de voir
passer le courant de soudage par les chaines de levage,
câbles de grue, ou autres circuits. Cela peut provoquer des
risques d’incendie ou d’echauffement des chaines et des
câbles jusqu’à ce qu’ils se rompent.
9. Assurer une ventilation suffisante dans la zone de soudage.
Ceci est particuliérement important pour le soudage de tôles
galvanisées plombées, ou cadmiées ou tout autre métal qui
produit des fumeés toxiques.
10. Ne pas souder en présence de vapeurs de chlore provenant
d’opérations de dégraissage, nettoyage ou pistolage. La
chaleur ou les rayons de l’arc peuvent réagir avec les vapeurs
du solvant pour produire du phosgéne (gas fortement toxique)
ou autres produits irritants.
11. Pour obtenir de plus amples renseignements sur la sûreté, voir
le code “Code for safety in welding and cutting” CSA Standard
W 117.2-1974.
PRÉCAUTIONS DE SÛRETÉ POUR
LES MACHINES À SOUDER À
TRANSFORMATEUR ET À
REDRESSEUR
1. Relier à la terre le chassis du poste conformement au code de
l’électricité et aux recommendations du fabricant. Le dispositif
de montage ou la piece à souder doit être branché à une
bonne mise à la terre.
2. Autant que possible, I’installation et l’entretien du poste seront
effectués par un électricien qualifié.
3. Avant de faires des travaux à l’interieur de poste, la
debrancher à l’interrupteur à la boite de fusibles.
4. Garder tous les couvercles et dispositifs de sûreté à leur place.
5. Toujours porter des lunettes de sécurité dans la zone de
soudage. Utiliser des lunettes avec écrans lateraux dans les
zones où l’on pique le laitier.
Mar. ‘93
v
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Thank You
for selecting a QUALITY product by Lincoln Electric. We want you
to take pride in operating this Lincoln Electric Company product •••
as much pride as we have in bringing this product to you!
Please Examine Carton and Equipment For Damage Immediately
When this equipment is shipped, title passes to the purchaser upon receipt by the carrier. Consequently, Claims
for material damaged in shipment must be made by the purchaser against the transportation company at the time
the shipment is received.
Please record your equipment identification information below for future reference. This information can be found
on your machine nameplate.
Product _________________________________________________________________________________
Model Number ___________________________________________________________________________
Code Number or Date Code_________________________________________________________________
Serial Number____________________________________________________________________________
Date Purchased___________________________________________________________________________
Where Purchased_________________________________________________________________________
Whenever you request replacement parts or information on this equipment, always supply the information you
have recorded above. The code number is especially important when identifying the correct replacement parts.
On-Line Product Registration
- Register your machine with Lincoln Electric either via fax or over the Internet.
• For faxing: Complete the form on the back of the warranty statement included in the literature packet
accompanying this machine and fax the form per the instructions printed on it.
• For On-Line Registration: Go to our 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:
WARNING
This statement appears where the information must be followed exactly to avoid serious personal injury or
loss of life.
CAUTION
This statement appears where the information must be followed to avoid minor personal injury or damage to
this equipment.
vi
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TABLE OF CONTENTS
Page
Installation
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Section A
Technical Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .A-1
Safety Precautions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .A-2
Location / Ventilation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .A-2
Storing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .A-2
Stacking . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .A-2
Angle of Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .A-2
Lifting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .A-3
High Altitude Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .A-3
High Temperature Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .A-3
Towing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .A-3
Pre-Operation Engine Service . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .A-4
Oil . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .A-4
Fuel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .A-4
Fuel Cap . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .A-4
Engine Cooling System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .A-4
Battery Connection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .A-4
Muffler Outlet Pipe . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .A-5
Spark Arrestor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .A-5
Radiator Cap Cover . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .A-5
Air Cleaner Inlet Hood . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .A-5
Welding Terminals . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .A-5
Welding Output Cables . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .A-5
Machine Grounding . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .A-5
Remote Control . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .A-6
Auxiliary Power Receptacles . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .A-6
Standby Power Connections . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .A-6
Connection of Vantage Premises Wiring . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .A-7
Connection of Lincoln Electric Wire Feeders . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .A-8, A-9
Operation
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Section B
Safety Instructions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .B-1
General Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .B-1
Recommended Applications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .B-1
Controls and Settings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .B-2
Engine Controls . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .B-2, B-3
Welder Controls . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .B-4
Auxiliary Power Controls . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .B-4
Engine Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .B-5
Starting the Engine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .B-5
Stopping the Engine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .B-5
Break-In Period . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .B-6
Typical Fuel Consumption . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .B-6
Duty Cycle . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .B-6
Welding Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .B-6
Stick Welding Mode . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .B-6
CC-Stick Mode . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .B-6
Downhill Pipe Mode . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .B-6
Touch Start TIG Mode . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .B-6
Vantage Settings when using K930-2 TIG Module . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .B-7
Typical Current Ranges for Tungsten Electrodes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .B-7
CV-Wire Mode . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .B-8
Arc Gouging . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .B-8
Paralleling . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .B-8
Auxiliary Power Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .B-8
Simultaneous Welding and Auxiliary Power Loads . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .B-8
Simultaneous Welding and Power Loads, Extension Cord Length Recommendations . . . . . . . . . . .B-9
Vantage 500 CUMMINS
vii
vii
TABLE OF CONTENTS
Accessories
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Section C
Optional Field Installed Accessories . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .C-1
_________________________________________________________________________________________________
Maintenance
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Section D
Safety Precautions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .D-1
Routine and Periodic Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .D-1
Engine Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .D-1
Air Filter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .D-1
Fuel Filters . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .D-2
Cooling System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .D-2
Battery Handling . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .D-2
Charging the Battery . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .D-2
Nameplate / Warning Decal Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .D-3
Welder / Generator Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .D-3
Engine Maintenance Components . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .D-3
Troubleshooting
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Section E
Wiring, Connection Diagrams and Dimension Print . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Section F
Parts Lists
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .P-472 Series
Vantage 500 CUMMINS
INSTALLATION
A-1
A-1
TECHNICAL SPECIFICATIONS - Vantage 500 CUMMINS (K2272-1)
INPUT - DIESEL ENGINE
Make /Model
Description
Speed (RPM)
Displacement
Starting
System
Capacities
Cummins
B3.3
Diesel Engine
4 cylinder
56HP (42 kw)
@ 1800 RPM
High Idle 1900
Low Idle 1425
Full Load 1800
199 cu. in
(3.3L)
12VDC battery
& Starter
Fuel
(25 US gal)
94.6L
Oil:
(2 US gal)
7.5L
Coolant:
(2.6 US gal)
11.8L
Bore x Stroke
3.74” x 4.53”
(95mm x 115mm)
RATED OUTPUT @ 104°F(40°C) - WELDER
Duty Cycle
Welding Output
Volts at Rated Amps
100%
500 Amps (DC multi-purpose)
40 Volts
60%
550 Amps (DC multi-purpose)
36 volts
50%
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
(1)
120/240 VAC
12,000 WATTS, 60 Hz.
PHYSICAL DIMENSIONS
Height
(2)
42.0 in
(1066.8 mm)
1.
2.
Width
Depth
Weight
31.5 in.
(800.1mm)
63.1 in.
(1603mm)
1605 lbs.
(728kg)
(Approx)
Output rating in watts is equivalent to volt-amperes at unity power factor.
Output voltage is within +/- 10% at all loads up to rated capacity. When welding, available auxiliary power will be reduced.
Top of Enclosure. Add 8.8” (223.5mm) for exhaust.
Vantage 500 CUMMINS
INSTALLATION
A-2
Read this entire installation section before you start
installation.
A-2
LOCATION / VENTILATION
The welder should be located to provide an unrestricted flow of
clean, cool air to the cooling air inlets and to avoid restricting the
cooling air outlets. Also, locate the welder so that the engine
exhaust fumes are properly vented to an outside area.
SAFETY PRECAUTIONS
WARNING
Do not attempt to use this equipment until you have
thoroughly read all operating and maintenance 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.
CAUTION
DO NOT MOUNT OVER COMBUSTIBLE SURFACES
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.
--------------------------------------------------------------------------------------
• Insulate yourself from the work and ground.
• Always wear dry insulating gloves.
------------------------------------------------------------------------------------ENGINE EXHAUST can kill.
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 construction 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 circulate oil to all the parts.
See the MAINTENANCE 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.
• Use in open, well ventilated areas or vent
exhaust outside
------------------------------------------------------------------------------------MOVING PARTS can injure.
• Do not operate with doors open or guards off.
• Stop engine before servicing.
• Keep away from moving parts
-------------------------------------------------------------------------------------
STACKING
Only qualified personnel should install, use or service this
equipment.
Vantage machines cannot be stacked.
ANGLE OF OPERATION
To achieve optimum engine performance the Vantage should be
run in a level position. The maximum angle of operation for the
Cummins engine is 35 degrees in all directions. If the engine is to
be operated at an angle, provisions must be made for checking
and maintaining the oil level at the normal (FULL) oil capacity in
the crankcase. When operating the welder at an angle, the
effective fuel capacity will be slightly less than the specified 25
gallons.
Vantage 500 CUMMINS
INSTALLATION
A-3
A-3
LIFTING
HIGH TEMPERATURE OPERATION
The Vantage lift bale should be used to lift the machine. The
Vantage is shipped with the lift bale retracted. Before attempting
to lift the Vantage the lift bale must be secured in a raised
position. Secure the lift bale as follows:
At temperatures above 40°C (104°F), output voltage derating
may be necessary. For maximum output current ratings, derate
welder voltage rating 2 volts for every 10°C (21°F) above 40°C
(104°F).
a. Open the engine compartment door.
b. Locate the 2 access holes on the upper middle region
of compartment wall just below the lift bale.
c. Use the lifting strap to raise the lift bale to the full upright
position. This will align the mounting holes on the lift
bale with the access holes.
d. Secure the lift bale with 2 thread forming screws. The
screws are provided in the shipped loose parts bag.
TOWING
The recommended trailer for use with this equipment for road, inplant and yard towing by a vehicle (1) is 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.
WARNING
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.
• Lift only with equipment of
adequate lifting capacity.
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.
• Be sure machine is stable
when lifting.
• Do not lift this machine
4. Typical conditions of use, such as travel speed,
roughness of surface on which the trailer will be
operated, and environmental conditions.
using lift bail if it is
equipped with a heavy
accessory such as
trailer or gas cylinder.
FALLING
EQUIPMENT can
cause injury.
• Do not lift machine if
5. Proper preventative maintenance of trailer.
6. Conformance with federal, state and local laws (1) .
(1)
Consult applicable federal, state and local laws regarding
specific requirements for use on public highways.
lift bail isdamaged.
• Do not operate machine
whilesuspended from lift
bail.
VEHICLE MOUNTING
Improperly mounted concentrated loads may cause unstable
vehicle handling and tires or other components to fail.
WARNING
------------------------------------------------------------------------------------
HIGH ALTITUDE OPERATION
At higher altitudes, output derating may be necessary. For
maximum rating, derate the welder output 4% for every 300
meters (984 ft.) above 1500 meters (4920 ft.). For output of 500A
and below, derate the welder output 4% for every 300 meters
(984 ft.) above 2100 meters (6888 ft.).
Contact a Cummins Service Representative for any engine
adjustments that may be required.
• Only transport this Equipment on serviceable vehicles
which are rated and designed for such loads.
• Distribute, balance and secure loads so vehicle is stable
under conditions of use.
• Do not exceed maximum rated loads for components such
as suspension, axles and tires.
• Mount equipment base to metal bed or frame of vehicle.
• Follow vehicle manufacturer’s instructions.
--------------------------------------------------------------------------------------
Vantage 500 CUMMINS
INSTALLATION
A-4
PRE-OPERATION ENGINE SERVICE
A-4
ENGINE COOLANT
READ the engine operating and maintenance instructions
supplied with this machine.
WARNING
WARNING
HOT COOLANT can burn skin.
• Stop engine while fueling.
•Do not remove cap if radiator is hot.
• Do not smoke when fueling.
• Keep sparks and flame away from tank.
-------------------------------------------------------------------------------------
• Do not leave unattended while fueling.
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 Operator’s Manual for
more information on coolant.
DIESEL FUEL • Wipe up spilled fuel and allow fumes to
can cause fire. clear before starting engine.
• Do not overfill tank, fuel expansion may
cause overflow.
BATTERY CONNECTION
DIESEL FUEL ONLY
----------------------------------------------------------------------
WARNING
OIL
GASES FROM BATTERY can explode.
The Vantage is shipped with the engine crankcase filled with high
quality SAE 10W-30 oil (API class CD or better). Check the oil
level before starting the engine. If it is not up to the full mark on
the dip stick, add oil as required. Check the oil level every four
hours of running time during the first 35 running hours. Refer to
the engine Operator’s Manual 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 Manual for the proper service and
maintenance intervals.
• Keep sparks, flame and cigarettes away from
battery.
FUEL USE DIESEL FUEL ONLY
Fill the fuel tank with clean, fresh diesel fuel. The capacity of the
fuel tank is approx 95 liters. See engine Operator’s Manual for
specific fuel recommendations. 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).
To prevent EXPLOSION when:
• INSTALLING A NEW BATTERY — disconnect
negative cable from old battery first and
connect to new battery last.
• CONNECTING A BATTERY CHARGER — remove battery
from welder by disconnecting 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 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.
FUEL CAP
Remove the plastic cap covering from the Fuel Tank Filler neck
and install the Fuel Cap.
IMPORTANT: To prevent ELECTRICAL DAMAGE WHEN:
a) Installing new batteries.
b) Using a booster.
Use correct polarity — Negative Ground.
Vantage 500 CUMMINS
INSTALLATION
A-5
The Vantage is shipped with the negative battery cable
disconnected. Before you operate the machine, make sure the
Engine Switch is in the OFF position and attach the disconnected
cable securely to the negative (-) battery terminal.
Remove the insulating cap from the negative battery terminal.
Replace and tighten negative battery cable terminal. NOTE: This
machine is furnished with a wet charged battery; 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 extension to the outlet
tube. Install the rain cap on the end of the outlet pipe extension.
SPARK ARRESTOR
Some federal, state or local laws may require that petrol or diesel
engines be equipped with exhaust spark arrestors when they are
operated in certain locations where unarrested 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.
CAUTION
A-5
WELDING TERMINALS
The Vantage is equipped with a toggle switch for selecting "hot"
welding terminals when in the "WELD TERMINALS ON" position
or "cold" welding terminals 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 connections 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
ELECTRODE AND WORK CABLES
AMPS
@100%
Duty Cycle
Up to 150ft
150-200ft
200-250ft
500
3/0 AWG
3/0 AWG
4/0 AWG
MACHINE GROUNDING
An incorrect arrestor may lead to damage to the engine or
adversely affect performance.
--------------------------------------------------------------------------------------
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:
RADIATOR CAP COVER
Install the radiator cap cover using the two screws which are
taped to the radiator cap cover.
a) be grounded to the frame of the welder using a
grounded type plug,
or
b) be double insulated.
AIR CLEANER INLET HOOD
Remove the plastic plug covering the air cleaner inlet. Install the
air cleaner inlet hood to the air cleaner.
When this welder is mounted on a truck or trailer, its frame must
be securely connected to the metal frame of the vehicle. When
this engine driven welder is connected to premises wiring such as
that in a home or shop, its frame must be connected to the system
earth ground. See further connection 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 10
Feet or to the metal framework of a building which has been
effectively grounded. The National Electric Code lists a number of
alternate means of grounding electrical equipment. A machine
grounding stud marked with the symbol
is provided on the
front of the welder.
Vantage 500 CUMMINS
INSTALLATION
A-6
A-6
STANDBY POWER CONNECTIONS
REMOTE CONTROL
OUTPUT
The Vantage 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 K936-2
hand Amptrol. When in the CC-STICK, DOWNHILL PIPE, or CVWIRE modes and when a remote control is connected to the 6pin 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 connector, the auto-sensing circuit
automatically makes the Output Control inactive and the wire
feeder voltage control active
The Vantage is suitable for temporary, standby or emergency
power using the engine manufacturer’s recommended
maintenance schedule.
The Vantage 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 premises disconnect.
Switch rating must be the same or greater than the customer’s
premises disconnect and service over current protection.
WARNING
NOTE: When a wire feeder with a built in welding voltage
control is connected to the 14-pin connector, do not connect
anything to the 6-pin connector.
--------------------------------------------------------------------------------------
AUXILIARY POWER RECEPTACLES
The auxiliary power capacity of the Vantage is 12,000 watts of 60
Hz, single phase 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 factor. The maximum permissible
current of the 240 VAC single phase output is 50 A. The 240 VAC
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. The output voltage is within ± 10% at
all loads up to rated capacity.
The Vantage has two 20 Amp-120VAC single phase (5-20R)
GFCI duplex receptacles and one 50 Amp-120/240 VAC single
phase (14-50R) receptacle and one 240VAC three phase (1550R) receptacle. The 120/240 VAC receptacle can be split for
single phase 120 VAC operation. 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.
NOTE: The two 120V GFCI receptacles and the two 120 volt
circuits of the 120/240V receptacle are connected to different
phases and can not be paralleled.
Vantage 500 CUMMINS
INSTALLATION
A-7
A-7
3. Install a 50 amp 120/240 VAC plug (NEMA Type 14-50) to the
double-pole circuit breaker using No. 6, 4 conductor cable of
the desired length. (The 50 amp, 120/240 VAC plug is
available in the optional K802R plug kit.)
2. Take necessary steps to assure load is limited to the capacity
of the Vantage by installing a 50 amp, 240 VAC double pole
circuit breaker. Maximum rated load for each leg of the 240
VAC auxiliary is 50 amps. Loading above the rated output will
reduce output voltage below the allowable -10% of rated
voltage which may damage appliances or other motor-driven
equipment and may result in overheating of the Vantage
engine.
4. Plug this cable into the 50 Amp 120/240 Volt receptacle on the
Vantage case front.
Figure A.2 Connection of the Vantage to Premises Wiring
240 VOLT
GROUNDED CONDUCTOR
POWER
240 Volt
60 Hz.
3-Wire
Service
120 VOLT
COMPANY
120 VOLT
METER
NEUTRAL
BUS
N
LOAD
DOUBLE POLE DOUBLE THROW
SWITCH RATING TO BE THE SAME
AS OR GREATER THAN PREMISES
SERVICE OVERCURRENT
PROTECTION.
GROUND
50AMP
240 VOLT
50 AMP, 120/240
VOLT PLUG
NEMA TYPE 14-50
240 VOLT
PREMISES
DISCONNECT AND
SERVICE
OVERCURRENT
PROTECTION
DOUBLE
POLE
CIRCUIT
BREAKER
GND
N
50 AMP, 120/240 VOLT
RECEPTACLE
NOTE: No. 6 COPPER CONDUCTOR CABLE SEE
NATIONAL ELECTRICAL CODE FOR ALTERNATE WIRE
SIZE RECOMMENDATIONS.
Vantage 500 CUMMINS
INSTALLATION
A-8
CONNECTION OF LINCOLN ELECTRIC
WIRE FEEDERS
A-8
CONNECTION OF AN LN-23P WIRE FEEDER TO
THE VANTAGE
• Shut the welder off.
Shut off welder before making any electrical connections.
• Connect the LN-23P per instructions on the appropriate
connection diagram in the DIAGRAMS section. (NOTE): When
connecting an LN-23P to the Vantage, a K350-1 adapter kit
must be used.
-------------------------------------------------------------------------------------
• Set the “WIRE FEEDER VOLTMETER” switch to “-”.
CONNECTION OF LN-7, LN-8 OR LN-742 TO THE
VANTAGE
• Set the “SELECTOR” switch to “CV-WIRE” position.
WARNING
• Shut the welder off.
• Connect the LN-7, LN-8 OR LN-742 per instructions on the
appropriate connection diagram in the DIAGRAMS section.
• Set the “WIRE FEEDER VOLTMETER” switch to either “+” or “” as required by the electrode being used.
• Set the “WELDING TERMINALS” switch to “REMOTELY
CONTROLLED”.
• Set the ARC CONTROL to desired crispness.
• Set the “IDLE” switch to the “HIGH” position. If you are using an
LN-23P with the K350-1 adapter kit, the electrode is not
energized until the gun trigger is closed.
• Set the “SELECTOR” switch to the “CV-WIRE” position.
• Adjust the “ARC CONTROL” knob to desired Crispness. SOFT
for MIG and CRISP for INNERSHIELD.
• Set the “WELDING TERMINALS” switch to the “REMOTELY
CONTROLLED” position.
• Set the “IDLE” switch to the “HIGH” position.
CONNECTION OF LN-15 TO THE VANTAGE
These connections instructions apply to both the LN-15 AcrossThe-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 current.
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"
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 polarity being used.
• Set the "ARC CONTROL" knob to "0" initially and adjust to suit.
• Set the "IDLE" switch to the "High" position
Vantage 500 CUMMINS
INSTALLATION
A-9
A-9
CONNECTION OF THE LN-25 TO THE VANTAGE
The LN-25 with or without an internal contactor may be used with
the Vantage. 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.
• Shut the welder off.
CONNECTION OF PRINCE XL SPOOL GUN TO
THE VANTAGE
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 cable from the LN25 to the “+” terminal of the welder and work cable to the “-”
terminal of the welder. For electrode 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.
• 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.
• Connect the Control Cable of the Spool Gun to the Adapter
Module and connect the Control Cable of the Adapter Module
to the Welder.
• Set the SELECTOR switch to the “CV-WIRE” position.
• Connect the Gas Hose.
• Set the “WELDING
TERMINALS ON”
TERMINALS”
switch
to
“WELD
• Set the MODE switch to the "CV-WIRE " position.
• Adjust the “ARC CONTROL” knob to desired crispness.
Generally, welding is best if the “ARC CONTROL” 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 "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
• Set the “IDLE” switch to the “AUTO” position. When not welding,
the Vantage 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 contactor, the
electrode will be energized when the Vantage 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
For connection diagrams and instructions for connecting an NA-3
Welding System to the Vantage, refer to the NA-3 Welding
System instruction manual. The connection diagram for the LN-8
can be used for connecting the NA-3.
• Set the Wire Feeder Voltage Switch to 115V.
Vantage 500 CUMMINS
OPERATION
B-1
B-1
SAFETY INSTRUCTIONS
GENERAL DESCRIPTION
Read and understand this entire section before operating
The Vantage is a diesel engine-driven welding power source. The
machine uses a brush type alternating current generator for DC
multi-purpose welding and for 120/240 VAC auxiliary standby
power. The welding control system uses state of the art Chopper
Technology™.
your Vantage.
WARNING
Do not attempt to use this equipment until you have
thoroughly read all operating and maintenance 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.
RECOMMENDED APPLICATIONS
WELDER
The Vantage provides excellent constant current DC welding
output for stick (SMAW) and TIG welding. The Vantage also
provides excellent constant voltage DC welding output for MIG
(GMAW), Innershield (FCAW), Outersield (FCAW-G) and Metal
Core welding. In addition the Vantage can be used for Arc
Gouging with carbons up to 3/8”(10mm) in diameter.
The Vantage is not recommended for pipe thawing.
• Always wear dry insulating gloves.
-------------------------------------------------------------------------------------ENGINE EXHAUST can kill.
• Use in open, well ventilated areas or vent
exhaust outside
• Do not stack anything near the engine.
GENERATOR
The Vantage provides smooth 120/240 VAC output for auxiliary power
and emergency standby power.
-------------------------------------------------------------------------------------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 operate this equipment.
ADDITIONAL SAFETY PRECAUTIONS
Always operate the welder with the hinged door closed and
the side panels in place as these provide maximum
protection from moving parts and insure proper cooling air
flow.
Vantage 500 CUMMINS
OPERATION
B-2
B-2
CONTROLS AND SETTINGS
All welder 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
4
5
6
7
8
9
10
3
11
12
13
15
14
20
21
1
2
19
16
17
22
18
ENGINE CONTROLS (Items 1 through 9)
3. HOUR METER
1. RUN
The hour meter displays the total time that the engine has been
running. This meter is a useful indicator for scheduling preventive
maintenance.
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 deenergize, and
the switch must be toggled to reset the timer.
4. FUEL LEVEL GAUGE
Displays the level of diesel fuel in the fuel tank.
2. START PUSHBUTTON
Energizes the starter motor to crank the engine. With the engine
"Run / Stop" switch in the "Run" 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 damage to the
ring gear and/or starter motor.
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
The gauge displays the engine coolant temperature.
Vantage 500 CUMMINS
OPERATION
B-3
6. OIL PRESSURE GAUGE
The gauge displays the engine oil pressure when the engine is
running.
c. When welding ceases and the AC power load is turned
off, a fixed time delay of approximately 12 seconds
starts.
d. If the welding or AC power load is not restarted before
the end of the time delay, the idler reduces the engine
speed to low idle speed.
7. ENGINE PROTECTION
The yellow engine protection light remains off with proper oil
pressure and under normal operating temperatures. If the light
turns on, the engine protection system will stop the engine. Check
for proper oil level and add oil if necessary. 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 condition.
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.
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 accelerate and operate at full speed
provided a welding load is applied within approximately 12
seconds.
• 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.
9. IDLER SWITCH
Has two positions as follows:
A) In the “High” position
, the engine runs at the high idle
speed controlled by the governor.
B) In the “Auto”
follows:
B-3
/
position, the idler operates as
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.
Vantage 500 CUMMINS
B-4
OPERATION
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 autosensing 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.
B-4
CV-WIRE mode: In this mode, turning the ARC CONTROL knob
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 a setting of 0.
14. WELDING TERMINALS SWITCH
In the WELD TERMINALS ON position, the output is electrically
hot all the time. In the REMOTELY CONTROLLED position, the
output is controlled by a wire feeder or amptrol device, and is
electrically off until a remote switch is depressed.
15. WIRE FEEDER VOLTMETER SWITCH:
Matches the polarity of the wire feeder voltmeter to the polarity of
the electrode.
16. 6 - PIN CONNECTOR
11. DIGITAL OUTPUT METERS: (Optional Kit)
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). A 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 display will be flashing. The accuracy of the
meters is ± 3%.
For attaching optional remote control equipment. Includes autosensing 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 control
is connected to the 14-pin connector, do not connect anything to
the 6-pin connector.
12. WELD MODE SELECTOR SWITCH:
(Provides four selectable welding modes)
18. WELD OUTPUT TERMINALS + AND -
CV-WIRE
These 1/2 - 13 studs with flange nuts provide welding connection
points for the electrode and work cables. For positive polarity
welding the electrode cable connects to the “+” terminal and the
work cable connects to this “-” terminal. For negative polarity
welding the work cable connects to the “+” terminal and the
electrode cable connects to this “-” terminal.
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 minimum 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 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 CONTROL
be set initially at 0.
AUXILIARY POWER CONTROLS
(Items 19-22)
19. 120/240 VAC 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 installation chapter for further
information about this receptacle. Also refer to the AUXILIARY
POWER OPERATION section later in this chapter.
Vantage 500 CUMMINS
B-5
OPERATION
20. CIRCUIT BREAKERS
B-5
ENGINE OPERATION
These circuit breakers provide separate overload current
protection for each 120V circuit at the 240V receptacle, each
120V receptacle, the 120VAC in the 14-Pin connector, the 42VAC
in the 14-Pin connector and battery circuit overload protection.
21. 120VAC RECEPTACLES
These two 120VAC (5-20R) receptacles with ground fault circuit
interruption protection provide 120VAC for auxiliary power. Each
receptacle has a 20 amp total rating. They are designed to protect
the user from the hazards of ground faults. When the GFCI has
tripped there will be no voltage available from the receptacle. If
the GFCI has tripped, any device plugged into the GFCI
receptacle should be unplugged and the reason for tripping the
GFCI should be determined. If the device is found to be damaged
or defective, it should be repaired or replaced before any further
use. The GFCI should be checked for proper operation prior to
each use by pressing the test button. The GFCI can be reset by
pushing the reset button. Refer to the AUXILIARY POWER
RECEPTACLES section in the installation chapter for further
information about these receptacles. Also refer to the AUXILIARY
POWER OPERATION section later in this chapter.
STARTING THE ENGINE
1. Open the engine compartment door and check that the fuel
shutoff valve located to the left of the fuel filter housing 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. After 10 seconds,
the engine protection light will turn off.
6. Within 30 seconds, press and hold the engine START button
until the engine starts.
7. Release the engine START button when the engine starts.
8. Check that the engine protection and battery charging lights
are off. The engine protection light is on after starting, the
engine will shutdown in a few seconds. Investigate any
indicated problem.
9. Allow the engine to warm up at low idle speed for several
minutes before applying a load and/or switching to high idle.
Allow a longer warm up time in cold weather.
22. GROUND STUD
Provides a connection point for connecting the machine case to
earth ground. Refer to “MACHINE GROUNDING” in the
Installation chapter for proper machine grounding information.
COLD WEATHER STARTING
With a fully charged battery and the proper weight oil, the engine
should start satisfactorily even down to about -10°C. If the engine
must be frequently started below -40°C, it may be desirable to
install the optional ether start kit (K887-1). Installation and
operating instructions are included in the kit.
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
OPERATION
B-6
BREAK-IN PERIOD
WELDER OPERATION
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 breakin is accomplished. Check the oil level twice a day during the
break-in period. In general this takes 50 to 100 hours of
operation.
DUTY CYCLE
IMPORTANT
B-6
Duty Cycle is the ratio of the uninterrupted on-load duration to 10
minutes. The total time period of one complete on-load and noload cycle is 10 minutes. For example, in the case of a 60% duty
cycle, load is applied continuously for 6 minutes followed by a noload period of 4 minutes.
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.
STICK WELDING MODE
ENGINE BREAK-IN
The MODE switch provides two stick welding settings as follows:
Lincoln Electric selects high quality, heavy-duty industrial 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, wetstacking (oil or tar like substance
at the exhaust port), or excessive smoke is not normal.
CC-STICK MODE
Larger machines with a capacity of 350 amperes and higher,
which are operated at low or no-load conditions for extended
periods of time are especially susceptible to the conditions
described above. To accomplish successful engine break-in,
most diesel-powered equipment needs only to be run at a
reasonably 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.
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.
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
connecting 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
catastrophic damage to the generator and voids the
warranty.
3. Periodically shut off the engine and check the
crankcase oil level.
TYPICAL FUEL CONSUMPTION
The Vantage can be used with a broad range of DC stick
electrodes.
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 CONTROL
knob adjusts the full output range for stick welding.
DOWNHILL PIPE MODE
This slope controlled setting is intended for “out-of-position” and
“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
CONTROL be set initially at 0.
TOUCH START TIG MODE
Refer to Table B.2 for typical fuel consumption of the Vantage’
Engine for various operating scenarios.
Table B.2
Cummins B3.3 Engine Fuel Consumption
Cummins B3.3
56HP(42Kw)
@1800 RPM
Running Time for
25GAL.(94.6L)
(Hours)
Low Idle no load 1425 RPM
.45 Gal./hour
(1.7 Lts./hour)
55.6
High Idle no load 1900 RPM
.81 Gal./hour
(3.1 Lts./hour)
30.9
DC CC Weld
Output 500
Amps @ 40 Volts
1.88 Gal./hour
(7.1 Lts./hour)
13.3
Auxiliary Power
12,000 VA
1.23 Gal./hour
(4.7 Lts./hour)
20.3
The Vantage can be used in a wide variety 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 will 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.
Vantage 500 CUMMINS
OPERATION
B-7
n general the ‘Touch Start’ feature avoids tungsten contamination
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. The settings are for reference.
The Vantage is equipped with the required R.F. bypass circuitry
for the connection of high frequency generating equipment.
The Vantage and any high frequency generating equipment must
be properly grounded. See the K930-2 TIG Module operating
manuals for complete instructions on installation, operation, and
maintenance.
B-7
VANTAGE SETTINGS WHEN USING THE K930-2
TIG MODULE
• Set the WELD MODE switch to the “Touch Start Tig 20-250
Setting”.
• Set the IDLER switch to the “AUTO” position.
• Set the WELDING TERMINALS switch to the “Remotely
Controlled” position. This will keep the solid state contactor open
and provide a “cold” electrode until the triggering device
(Amptrol or Arc Start Switch) is pressed.
When using the TIG Module, the OUTPUT control on the Vantage
is used to set the maximum range of the CURRENT CONTROL
on the TIG Module or an Amptrol if connected to the TIG Module.
Table B.3 TYPICAL CURRENT RANGES
FOR TUNGSTEN ELECTRODES (2)
(1)
DCEN (-)
DCEP (+)
Approximate Argon Gas Flow Rate
l/min (c.f.m.)
Tungsten
Electrode
Diameter
mm (in)
1%, 2%
Thoriated
Tungsten
1%, 2%
Thoriated
Tungsten
.25 (0.010)
2-15
(3)
.50 (0.020)
5-20
(3)
1.0 (0.040)
15-80
(3)
3-5 (5-10)
3-5 (5-10)
1.6 (1/16)
70-150
10-20
3-5 (5-10)
4-6 (9-13)
#5, #6
2.4 (3/32)
3.2 (1/8)
150-250
250-400
15-30
25-40
6-8 (13-17)
7-11 (15-23)
5-7 (11-15)
5-7 (11-15)
#6, #7, #8
4.0 (5/32)
4.8 (3/16)
400-500
500-750
40-55
55-80
10-12 (21-25)
11-13 (23-27)
6-8 (13-17)
8-10 (18-22)
6.4 (1/4)
750-1000
80-125
13-15 (28-32)
11-13 (23-27)
Stainless Steel
TIG TORCH
Nozzle
Size (4), (5)
2-4 (3-8)
2-4 (3-8)
#4, #5, #6
3-5 (5-10)
3-5 (5-10)
Aluminium
#8, #10
(1)
When used with argon gas. The current ranges shown must be reduced when using argon/helium or pure helium shielding gases.
(2)
Tungsten electrodes are classified as follows by the American Welding Society (AWS):
Pure
EWP
1% Thoriated
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.
(3)
(4)
DCEP is not commonly used in these sizes.
TIG torch nozzle “sizes” are in multiples of 1/16ths of an inch:
#4=
#5=
#6=
#7=
#8=
#10 =
(5)
1/4 in.
5/16 in.
3/8 in.
7/16 in.
1/2 in.
5/8 in.
6 mm
8 mm
10 mm
11 mm
12.5 mm
16 mm
TIG torch nozzles are typically made from alumina ceramic. Special applications may require lava nozzles, which are less prone to
breakage, but cannot withstand high temperatures and high duty cycles.
Vantage 500 CUMMINS
OPERATION
B-8
CV-WIRE MODE
Connect a wire feeder to the Vantage and set welder controls
according to the instructions listed earlier in this section.
The Vantage in the ”CV-WIRE” position, permits it to be used with
a broad range of flux cored wire (Innershield and Outershield)
electrodes and solid wires for MIG welding (gas metal arc
welding). Welding can be finely tuned using the “ARC
CONTROL”. Turning the ARC CONTROL clockwise from 10(soft) to +10(crisp) changes the arc from soft and washed-in to
crisp and narrow. It acts as an inductance/pinch control. The
proper setting depends on the procedure and operator
preference. Start with the knob set at 0.
For any electrodes, including the above recommendations, 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
NOTE: The two 120V GFCI receptacles and the two 120V circuits
of the 120/240V receptacle are connected to different phases and
cannot be paralleled.
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.
SIMULTANEOUS WELDING AND AUXILIARY
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).
For optimal performance when arc gouging, set the Vantage
“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
ratings in the following table:
* Maximum current setting is limited to the Vantage maximum of
575 Amps.
ELECTRODE
DIAMETER
(1/8”)
(5/32”)
(3/16”)
(1/4”)
(5/16”)
(3/8”)
B-8
CURRENT RANGE
(DC, electrode positive)
30-60 Amps
90-150 Amps
200-250 Amps
300-400 Amps
350-450 Amps
450-575 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
erratic outputs, and large output imbalances between the units.
AUXILIARY POWER OPERATION
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 welding current is being drawn.
The auxiliary power of the Vantage consists of two 20 Amp120VAC (5-20R) GFCI duplex receptacles and one 50 Amp120/240 VAC (14-50R) 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
phase power. The auxiliary power capacity rating in watts is
equivalent to volt-amperes at unity power factor. The maximum
permissible current of the 240 VAC output is 50 A. The 240 VAC
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.
Vantage 500 CUMMINS
OPERATION
B-9
B-9
TABLE B.4 Vantage Simultaneous Welding and Power Loads
Welding Output
at NEMA Voltage
(V=.04I + 20)
Permissible Power Watts
(Unity Power Factor)
0-250A/30V
350A/34V
400A/36V
450A/38V
500A/40V
Permissible Auxiliary
Current in Amperes
@ 120VAC * +/- 10%
@ 240 VAC +/- 10%
12,000
8,100
5,600
2,900
0
100**
68**
46
24
0
50
34
23
12
0
* Each duplex receptacle is limited to 20 amps.
** Not to exceed 50A per 120 VAC branch circuit when splitting the 240 VAC output.
TABLE B.5 Vantage Extension Cord Length Recommendations
Current Voltage Load
(Amps) (Volts) (Watts)
120
1800
15
3600
240
15
120
2400
20
240
4800
20
240
6000
25
240
7200
30
240
9000
38
50
240 12000
14 AWG
30
(9)
60
(18)
Maximum Allowable Cord Length in ft. (m) for Conductor Size
12 AWG
10 AWG
8 AWG
6 AWG
40
(12)
75
(23)
125
(38)
175
(53)
75
(23)
150
(46)
225
(69)
350
(107)
(27)
138
(42)
30
(9)
50
(15)
88
60
(18)
100
(30)
175
(53)
275
(84)
90
(27)
150
(46)
225
(69)
(53)
75
(23)
120
(37)
175
100
(30)
150
(46)
125
(38)
Conductor size is based on maximum 2.0% voltage drop.
Vantage 500 CUMMINS
4 AWG
300
(91)
(183)
600
225
(69)
450
(137)
(76)
250
300
(91)
250
(76)
(61)
200
ACCESSORIES
C-1
OPTIONAL FIELD INSTALLED ACCESSORIES
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.
K802-R 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 CONTROL 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 m) of electrode
cable and 30 feet (9 m) of work cable, headshield, work clamp
and electrode holder. Cable is rated at 500 amps, 60% duty cycle.
K767-2 FOUR WHEELED STEERABLE YARD TRAILER
For in plant and yard towing.
K953-1 TRAILER - Two-wheeled trailer with optional fender and light
package. For highway use, consult applicable federal, state, and local laws
regarding possible additional requirements. There is a choice of 2 hitches,
a fender & a light package. Order:
K953-1 Trailer
K958-1 Ball Hitch
K958-2 Lunette Eye Hitch
K959-1 Fender & Light Kit
K965-1 Cable Rack
K887-1 ETHER START KIT - Provides maximum cold weather starting
assistance for frequent starting below 25 oF(-4 oC). Required Ether tank is
not provided with kit. (Cannot be used with K1858-1 Service Indicator Kit
at the same time.)
K1847-1 SPARK ARRESTOR KIT - Easily mounts to standard muffler.
K949-2 OIL DRAIN KIT - Includes ball valve, hose and clamp.
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,
K1858-1 Service Indicator Kit - Provides a GO / NO-GO visual indication of
air cleaner element useful service life. Filter service based on restriction
readings allows the longest life possible from the filter and best engine
protection. (Cannot be used with K887-1 Ether Start Kit at the same time.)
WARNING
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.
-------------------------------------------------------------------------------------
Vantage 500 CUMMINS
C-1
MAINTENANCE
D-1
SAFETY PRECAUTIONS
D-1
ENGINE MAINTENANCE
Refer to the “Periodic Checks” section of the Engine Operator’s
Manual for the recommended maintenance schedule of the
following:
WARNING
• Have a qualified technician do the maintenance and
troubleshooting work.
• Turn 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.
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 various engine
maintenance components.
AIR FILTER
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 the equipment.
CAUTION
EXCESSIVE AIR FILTER RESTRICTION WILL RESULT IN
REDUCED ENGINE LIFE.
ROUTINE AND PERIODIC
MAINTENANCE
-------------------------------------------------------------------------------------The air filter element is a dry cartridge type. It can be cleaned and
reused; however, damaged elements should not be reused. Stop
engine after 100 hours of running time and clean filter element ,
replace the filter if necessary. Service air cleaner regularly
according to Engine Operator’s Manual.
DAILY
• Check the crankcase oil level .
• Refill the fuel tank to minimize moisture condensation in the
tank.
• Open the water 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.
1. Locate the air filter canister located behind the engine door on
the top of the engine.
2. Remove air filter element.
3. Remove loose dirt from element with compressed air or water
hose directed from inside out.
Compressed Air: 100 psi maximum with nozzles at least
one inch away from element.
Water Hose: 40 psi maximum without nozzle.
4. Soak element in a mild detergent solution for 15 minutes. Do
not soak more than 24 hours. Swish element around in the
solution to help remove dirt.
WEEKLY
Blow out the machine with low pressure air periodically. In
particularly dirty locations, this may be required once a week.
5. Rinse elements from inside out with a gentle stream of water
(less than 40 psi) to remove all suds and dirt.
6. Dry element before reuse with warm air at less than 160°F
(71°C). Do not use a light bulb to dry the element.
Vantage 500 CUMMINS
MAINTENANCE
D-2
7. Inspect for holes and tears by looking through the element
toward a bright light. Check for damaged gaskets or dented
metal parts. Do not reuse damaged elements. Protect element
from dust and damage during drying and storage.
D-2
BATTERY HANDLING
GASES FROM BATTERY can explode.
• Keep sparks, flame and cigarettes away from
battery.
8. Reinstall air filter element.
After six cleanings replace air filter. A cleaned filter will have
approximately 70% of the life of a new filter element. A restricted
filter element may not appear excessively dirty.
To prevent EXPLOSION when:
• INSTALLING A NEW BATTERY - disconnect
negative cable from old battery first and
connect to new battery last.
FUEL FILTERS
• CONNECTING A BATTERY CHARGER Remove battery from welder by disconnecting
negative cable first, then positive cable and
battery clamp. When reinstalling, connect
negative cable last. Keep well ventilated.
WARNING
When working on the fuel system
• Keep naked lights away, do not smoke !
• Do not spill fuel !
• USING A BOOSTER - connect positive lead to
battery first then connect negative lead to
engine foot.
--------------------------------------------------------------------------------------
BATTERY ACID CAN BURN EYES AND SKIN.
The Vantage 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 oring.
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 manufacturer.
WARNING
Mechanical overtightening will distort the threads, filter
element seal or filter can.
--------------------------------------------------------------------------------------
• 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 circuit. The positive (+) battery cable has a red
terminal cover.
2. If the battery requires charging from an external charger,
disconnect the negative battery cable 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
COOLING SYSTEM
Turn the RUN/STOP switch to stop when engine is not running.
The Vantage is equipped with a pressure radiator. Keep the
radiator cap tight to prevent loss of coolant. Clean and flush the
coolant system periodically to prevent clogging the passage and
over-heating the engine. When antifreeze is needed, always use
the permanent type.
PREVENTING BATTERY BUCKLING
Tighten nuts on battery clamp until snug.
Vantage 500 CUMMINS
MAINTENANCE
D-3
CHARGING THE BATTERY
When you charge, jump, replace, or otherwise connect battery
cables to the battery, be sure the polarity is correct. Improper
polarity can damage the charging circuit. The Vantage 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 manufacturer for
proper charger settings and charging time.
D-3
WELDER / GENERATOR
MAINTENANCE
STORAGE
Store the Vantage 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 particularly dirty areas.
BRUSH REMOVAL AND REPLACEMENT
NAMEPLATES / WARNING DECALS
MAINTENANCE
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 item number.
It is normal for the brushes and slip rings to wear and darken
slightly. Inspect the brushes when a generator overhaul is
necessary.
WARNING
Do not attempt to polish slip rings while the engine is
running.
--------------------------------------------------------------------------------------
Table D.1 Engine Maintenance Components
ITEM
MAKE
PART NUMBER
SERVICE INTERVAL
Air Cleaner Element
Donaldson
AC
Fleetguard
P181052
A302C
AF437K
Replace every 200 hours. (Replace more
often when used in dusty and / or
high ambient temperature conditions)
Oil Filer
Cummins
Fleetguard
C6002112110
LF3855
Replace every 750 hours or 12 months,
whichever is less.
Fan Belt
Cummins
C0412021748
Inspect every 1000 hours or 12 months,
whichever is less.
Fuel Strainer
Cummins
Fleetguard
3826094
FF5079
Inspect and replace monthly, as
required. Replace annually.
Fuel Filter /
Water Separator
Cummins
Fleetguard
C6003112130
FS19594
Replace every 500 hours or 6 months,
whichever is less.
Battery
-----
BCI GROUP 34
Inspect every 500 hours
Engine Oil Change
See Manual
-----
Change every 750 hours or 3 months,
whichever is less. Check daily.
.
Vantage 500 CUMMINS
TROUBLESHOOTING
E-1
E-1
HOW TO USE TROUBLESHOOTING GUIDE
WARNING
Service and Repair should only be performed by Lincoln Electric Factory Trained Personnel. Unauthorized repairs
performed on this equipment may result in danger to the technician and machine operator and will invalidate your factory
warranty. For your safety and to avoid Electrical Shock, please observe all safety notes and precautions detailed
throughout this manual.
_______________________________________________________________________________________________
This Troubleshooting Guide is provided to help you locate and
repair possible machine malfunctions. Simply follow the threestep procedure listed below.
Step 1. LOCATE PROBLEM (SYMPTOM).
Look under the column labeled “PROBLEM (SYMPTOMS)”. This
column describes possible symptoms that the machine may
exhibit. Find the listing that best describes the symptom that the
machine is exhibiting.
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.
Step 2. POSSIBLE CAUSE.
The second column labeled “POSSIBLE CAUSE” lists the
obvious external possibilities that may contribute to the machine
symptom.
CAUTION
If for any reason you do not understand the test procedures or are unable to perform the tests/repairs safely, contact your Local Lincoln
Authorized Field Service Facility for technical troubleshooting assistance before you proceed.
Vantage 500 CUMMINS
TROUBLESHOOTING
E-2
E-2
Observe all Safety Guidelines detailed throughout this manual
PROBLEMS
(SYMPTOMS)
POSSIBLE AREAS OF
MISADJUSTMENT(S)
RECOMMENDED
COURSE OF ACTION
ENGINE PROBLEMS
Major Physical or Electrical Damage is 1. Contact your Local Lincoln Authorized
Field Service Facility.
Evident.
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 a vertical
direction.
3. Engine shut down solenoid not pulling in.
4. On/Off switch on for more than 30 sec.
before starting, the On/Off switch will
need to be switch off and turned back on.
5. Fuel Filters dirty/clogged, main filter
element and/or Inline Fuel Filter may
need to be replaced.
Engine shuts down shortly after starting.
6. High water temperature or low oil
pressure. (engine protection light lit)
If all recommended possible areas
of misadjustment have been
checked and the problem persists,
1. Low oil pressure (engine protection light
Contact your local Lincoln
lit). Check oil level (Consult engine
Authorized Field Service Facility.
service dealer).
2. High water 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 a load.
1. High water temperature.
Engine runs rough.
1. Dirty fuel or air filters may need
cleaned/replaced.
2. Water in fuel.
Engine will not shut off.
1. Fuel Shutdown solenoid not functioning
properly / linkage binding.
CAUTION
ºIf 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
TROUBLESHOOTING
E-3
PROBLEMS
(SYMPTOMS)
POSSIBLE AREAS OF
MISADJUSTMENT(S)
E-3
RECOMMENDED
COURSE OF ACTION
FUNCTION PROBLEMS
Battery does not stay charged.
1. Faulty battery .
2. Faulty engine alternator.
3. Loose or broken lead in charging circuit.
4. Loose fan belt may need tightening.
Engine will not idle down to low
speed.
1. Idler switch in HIGH idle position, make
sure switch is set to AUTO.
2. External load on welder or auxiliary
power.
3. Mechanical problem in idler solenoid
linkage.
4. Faulty wiring in solenoid circuit.
5. No or low voltage @ idle solenoid
6. Faulty idler solenoid.
7. Faulty, Weld Control PCB, Pull Coil
/Battery PCB
Engine will not go to high idle when
attempting to weld.
1. Poor work lead connection to work.
2. Broken idler solenoid spring.
3. Welding Terminals switch in wrong
position.
If all recommended possible areas
of misadjustment have been
checked and the problem persists,
Contact your local Lincoln
Authorized Field Service Facility.
4. No open circuit voltage at output studs.
5. Faulty, Pull Coil/Battery PCB or Weld
Control PCB.
Engine will not go to high idle when using
auxiliary power.
1. Broken wire in auxiliary current sensor
wiring.
2. Auxiliary power load is less than 100
watts.
3. Faulty Pull Coil/Battery PCB 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
TROUBLESHOOTING
E-4
PROBLEMS
(SYMPTOMS)
POSSIBLE AREAS OF
MISADJUSTMENT(S)
E-4
RECOMMENDED
COURSE OF ACTION
FUNCTION PROBLEMS
Engine goes to low idle but does not stay at 1. Faulty Peripheral PCB, Pull Coil/Battery
low idle.
PCB or Weld Control PCB.
No welding output or auxiliary output.
1. Broken lead in rotor circuit.
2. Faulty field diode module.
3. Faulty Weld Control P.C. Board.
4. Faulty rotor.
Welder has some/ no output and no control. 1. Faulty remote kit.
Auxiliary output OK
2. Faulty output control potentiometer.
3. Faulty output control wiring.
4. Faulty Weld Control PCB, Pull
Coil/Battery PCB or Chopper PCB.
No welding output. Auxiliary output OK.
No auxiliary power.
1. WELDING TERMINALS switch in wrong
position, be sure switch is in WELDING
TERMINALS ALWAYS ON position.
If all recommended possible areas
2. Faulty Weld Control PCB, Pull
of misadjustment have been
Coil/Battery PCB or Chopper PCB.
checked and the problem persists,
Contact your local Lincoln
Authorized Field Service Facility.
1. Open breakers may need to be reset.
2. Faulty receptacle.
3. Faulty auxiliary circuit wiring.
4. GFCI tripped.
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
208
-
J
77A
77B
76A
76B
75A
75B
2A
2B
4A
4B
GND-B
8
16
1
9
6
J1
AMPHENOL,I.D.
6
8
1
M3 M5 M9
M2 M4
M6 M10
1
J7
CONTROL, MODE SEL.
3 TURNS
THRU
TOROID
9
1
M1
AMMETER
M6
B5
B6
B1
13 14
NEG
10
NEG
POS
9
1
M3 M5 M9
M2 M4
M6 M10
23A
25A
23
25
8
1
7
16
J3
CHOPPER, POWER, PWM, THERMAL
M1
12
J2
ENGINE,PERIPHERAL
6
J4
AMMETER
5
B1
B2
B3
NEG
POS
B2
VOLTMETER
B7
B8
B8 B7
POS
B4
RIGHT SIDE
CHOPPER
PCB5
13A 14A
W9
W10
B7
B8
B8 B7
POS
NEG
B4
B3
NEG
NEG
W4
W4
16
8
232E
ALT
243
222
A
W6
W6
W1
W1
41A
41
J31
76
R1
75
1
9
PERIPHERAL BD
PCB1
405B
405A
SILVER
ENG
PROT
GOLD
247
77
VIEWED
FROM
BACK
CCW
6
12
J32
1
7
WELDING TERMINAL
CONTROL SWITCH
42A
42B
279
232A
J30
6
1
201
200B
3200MFD
300V
BRUSH
4
1
5L
12 VOLT GROUND
STUD ON LEFT SIDE
BACK OF CONTROL BOX
5T
5M
5K
5N
5J
J52
232C 5L
241
4
5S
COOLANT
TEMPERATURE
2
200A
201A
6
1
J51
232K 5K
229
4
FUEL
5
1
232R
262A
232E
262
5H
200
GROUND STUD ON
RECEPTACLE PANEL
HOUR METER
201
POSITIVE BRUSH CONNECTED
TO SLIP RING NEAREST
TO THE LAMINATION
ROTOR
BRUSH
2A
J53
232B 5M
228
4
OIL
PRESSURE
GND-D
GND-E
GND-C
5
GND-H
AUXILIARY GROUND STUD, BOTTOM
CENTER OF CONTROL BOX
GND-J
GND-B
GND-A
GND-F
GROUND STUD ON
CONTROL PANEL
SHOWN IN "ALWAYS ON" POSITION
4A
PROGRAMMING
3
1
4
10A
CB6
VIEWED FROM BACK
232B
232C
232K
232M
232N
232R
278
10K
12VDC
INSULATED
STUD
277
32
PINCH POT
42
RECTIFIER
BRIDGE
W1 & W6
STATOR 42V WINDING
STATOR
WELD
WINDINGS
OUTPUT CONTROL
220 4
TIG
CV
214
1
218
2
PIPE
CC 3
W5
W5
W2 & W3
W3 W2
W3 W2
MODE SELECTOR
SWITCH
S5
NEG
NEG
W4 & W5
J43
8
4
PCB8
PULL COIL BD
B4 B3 B2 B1
227
265
232N
5S
32
32A
11
8
12
8
9
232H
RUN
STOP
236B
232A
236A
CB5
20A
IDLER
CONTROL
SHOWN IN
"HIGH" POSITION
CB4
50A
RUN/STOP
SWITCH
256
20A
CB1
9
32A
CB3
50A
CB2
6B
3
3A
SHOWN IN "RUN" POSITION
232D
257
AUTO
HIGH
6A
260
261
20A
232
232F
J54
PULL
COIL
262
2
4
265
232M
3
WHT
RED
BLK
HOLD
COIL
J55
P55
J10
11
238
238B
231
IG
P L
B
1
PULL
COIL
226
2
232L
3
227
4
WHT
RED
BLK
HOLD
COIL
G
SENSOR
WK
SWITCH
234
235
5E
5C
5B
OIL PRESSURE
SENSOR & SWITCH
228
STARTING
MOTOR
238A
6
IDLER
SOLENOID
5C
12
5 5A
5J
229
SENSOR
5N
235
ENGINE
SUPPORT
LEFT SIDE
G4329
A.02
12V BATTERY
ENGINE BLOCK
-
+
FUEL LVL.
SENSOR
SWITCH
ALTERNATOR
243
STARTER
SOLENOID
241
5A
3
INSULATED
NEUTRAL
STUD ON
BOTTOM
RIGHT OF
CONTROL
31 5H BOX
COOLANT TEMPERATURE
SENSOR & SWITCH
231
238A
6
GND-C
115/230V
6A
STATOR AUXILIARY WINDINGS
START BUTTON
1
232
P54
GND-E
GND-D
5E
5B
SHUTDOWN
SOLENOID
HOT (GOLD)
J11
HOT (GOLD)
SILVER
J12
SILVER
AUXILIARY POWER LEADS PASS THROUGH
TOROID TWICE IN DIRECTION INDICATED
This diagram is for reference only. It may not be accurate for all machines covered by this manual. The specific dia- gram for your particular machine is pasted inside the machine on one of
the enclosure panels.
204S
2
J6
1 SHUNT
WELD BOARD
PCB3
10
6
J5
VOLT METER
5
208B
32
41A
42A
L1 CHOKE
208C
R4
B5
LEFT SIDE
CHOPPER
PCB6
14
VANGAGE 500 CUMMINS WIRING DIAGRAM
ENHANCED DIAGRAM
NOTE:
3 TURNS
THRU
TOROID
21
77B
76B
75B
4B
2B
GND-A
21
1
206S
A
B
C
CONTACTOR
D
E
F
GROUND
REMOTE
CONTROL
31
32
41A
42A
AMPHENOL 1
F
G
D
C
B
A
I
K
H
E
AMPHENOL 2
GROUND
CONTACTOR
REMOTE
CONTROL
WORK
42VAC
115VAC
+
POLARITY
SWITCH
M6
206A
208B
BYPASS
FILTER
ASSEMBLY
GND-J
GROUND STUD
ON OUTPUT PANEL
SWITCH SHOWN IN
POSITIVE POLARITY
POSITION
208A
I
GND-K
M9
+
206B
M10
206A
222
206S
M3
-
M2
50MV=400AMPS
M1
B6
M10
206C
76A
M1
M2
M3
M4
M5
214
77
218
220
277
M9
M4
M5
204S
500
250
25
23
25A
23A
260
261
250
257
208B
256
13
232D
226
404
5G
76
75
279
278
2
77A
4
75A
270
+
262A
+
POS
POS
POS
POS
5T
+
W7
W8
405
232F
403
405A
-
234
+
-
Vantage 500 CUMMINS
247
DIAGRAMS
405B
271
405
281
270
200
403
271
F-1
F-1
F-2
DIAGRAMS
CONNECTION DIAGRAM:
Vantage 500 CUMMINS
F-2
Vantage 500 CUMMINS
TO WORK
K867 UNIVERSAL
ADAPTER PLUG
77
76
75
GND
21
4
2
32
31
41
42
81
82
SPARE
}
N.E.
21
4
2
32
31
77
76
75
GND
N.D.
N.E. SPLICE LEADS AND INSULATE.
N.D. INSULATE EACH UNUSED LEAD INDIVIDUALLY.
N.C. IF OPTIONAL REMOTE OUTPUT CONTROL IS USED,CONTROL IS AUTOMATICALLY SWITCHED TO REMOTE CONTROL.
PLACE WIRE FEEDER SWITCH TO "WIRE FEEDER WITH CONTROL CABLE POSITION.
N.B. USE VOLTMETER SWITCH TO SELECT DESIRED ELECTRODE POLARITY. POSITION THE "SELECTOR" SWITCH TO "WIRE WELDING CV".
N.A. WELDING CABLE MUST BE OF PROPER CAPACITY FOR THE CURRENT AND DUTY CYCLE OF IMMEDIATE AND FUTURE
APPILICATIONS. SEE OPERATING MANUAL.
GREEN
or service this equipment.
Only qualified personnel should install,use
Keep away from moving parts.
Keep guards in place.
ANY INCREASE OF THE HIGH IDLE ENGINE RPM BY CHANGING THE GOVERNOR SETTING OR OVERRIDING THE THROTTLE LINKAGE WILL CAUSE
AN INCREASE IN THE THE AC AUXILIARY VOLTAGE. IF THIS VOLTAGE GOES OVER 140 VOLTS, WIRE FEEDER CONTROL CIRCUITS MAY BE
DAMAGED. THE ENGINE GOVERNOR SETTING IS PRE-SET AT THE FACTORY - DO NOT ADJUST ABOVE RPM SPECIFICATIONS LISTED IN
THE ENGINE WELDER OPERATING MANUAL.
ELECTRODE CABLE
TO WIRE FEED UNIT
TO WORK
Do not touch electrically live parts.
before servicing.
}
CAUTION :
ELECTRODE
14 PIN
AMPHENOL
Do not operate with panels open.
Disconnect NEGATIVE (-) BATTERY LEAD
WARNING
COMMANDER / K867 / K775 / LN-7 CONNECTION DIAGRAM
K775 OPTIONAL
REMOTE CONTROL
K291 OR K404
INPUT CABLE
LN-7
WIRE
FEEDER
DIAGRAMS
S23983
7-2000
F-3
F-3
CONNECTION DIAGRAM:
F-4
DIAGRAMS
CONNECTION DIAGRAM
Vantage 500 CUMMINS
F-4
F-5
DIAGRAMS
CONNECTION DIAGRAM
Vantage 500 CUMMINS
F-5
Vantage 500 CUMMINS
TO WORK
K867 UNIVERSAL
ADAPTER PLUG
77
76
75
GND
21
4
2
32
31
41
42
81
82
SPARE
}
N.D.
N.C.
C
B
A
GND
21
4
2
32
31
or service this equipment.
Only qualified personnel should install,use
Keep away from moving parts.
Keep guards in place.
N.D. SPLICE LEADS AND INSULATE.
N.C. INSULATE EACH UNUSED LEAD INDIVIDUALLY.
N.A. WELDING CABLE MUST BE OF PROPER CAPACITY FOR THE CURRENT AND DUTY CYCLE OF IMMEDIATE AND FUTURE
APPICATIONS. SEE OPERATING MANUAL.
N.B. USE VOLTMETER SWITCH TO SELECT DESIRED ELECTRODE POLARITY. POSITION THE SELECTOR SWITCH TO "WIRE WELDING CV".
ANY INCREASE OF THE HIGH IDLE ENGINE RPM BY CHANGING THE GOVERNOR SETTING OR OVERRIDING THE THROTTLE LINKAGE WILL CAUSE
AN INCREASE IN THE THE AC AUXILIARY VOLTAGE. IF THIS VOLTAGE GOES OVER 140 VOLTS, WIRE FEEDER CONTROL CIRCUITS MAY BE
DAMAGED. THE ENGINE GOVERNOR SETTING IS PRE-SET AT THE FACTORY - DO NOT ADJUST ABOVE RPM SPECIFICATIONS LISTED IN
THE ENGINE WELDER OPERATING MANUAL.
ELECTRODE CABLE
TO WIRE FEED UNIT
TO WORK
14 PIN
AMPHENOL
Do not touch electrically live parts.
before servicing.
}
CAUTION :
ELECTRODE
Do not operate with panels open.
Disconnect NEGATIVE (-) BATTERY LEAD
WARNING
COMMANDER / K867 / LN-8 CONNECTION DIAGRAM
INPUT CABLE
K196
FEEDER
WIRE
LN-8
DIAGRAMS
S23989
7-2000
F-6
F-6
CONNECTION DIAGRAM
F-7
DIAGRAMS
CONNECTION DIAGRAM
Vantage 500 CUMMINS
F-7
F-8
DIAGRAMS
CONNECTION DIAGRAM
Vantage 500 CUMMINS
F-8
Vantage 500 CUMMINS
+
_
ELECTRODE CABLE
TO WIRE FEED UNIT
K595 CONTROL CABLE
TO LN-8 INPUT
CABLE PLUG
TO WORK
Keep guards in place.
Keep away from moving parts.
Only qualified personnel should install,use
or service this equipment.
Do not operate with panels open.
Disconnect NEGATIVE (-) Battery lead
before servicing.
Do not touch electrically live parts.
N.A. WELDING CABLES MUST BE OF PROPER CAPACITY FOR THE CURRENT AND DUTY CYCLE OF IMMEDIATE AND FUTURE
APPLICATIONS. SEE OPERATING MANUAL.
N.B. CONNECT WELDING CABLES TO OUTPUT STUDS FOR DESIRED POLARITY. POSITION THE WIRE FEEDER VOLTMETER SWITCH TO
MATCH THE POLARITY OF THE ELECTRODE CABLE.
N.C. PLACE IDLER SWITCH IN “HIGH” POSITION.
DIAGRAMS
S24787-6
4-14-2000
ANY INCREASE OF THE HIGH IDLE ENGINE RPM BY CHANGING THE GOVERNOR SETTING OR OVERRIDING THE THROTTLE LINKAGE WILL CAUSE
AN INCREASE IN THE AC WIRE FEEDER VOLTAGE, WHICH CAN DAMAGE THE CONTROL CIRCUIT. THE ENGINE GOVERNOR SETTING IS PRE-SET
AT THE FACTORY – DO NOT ADJUST ABOVE RPM SPECIFICATIONS LISTED IN THE ENGINE WELDER OPERATING MANUAL.
CAUTION:
14 PIN
AMPHENOL
MOVING PARTS can injure
ELECTRIC SHOCK can kill
WARNING
ENGINE WELDERS /LN-8 CONNECTION DIAGRAM
F-9
F-9
CONNECTION DIAGRAM
F-10
DIAGRAMS
CONNECTION DIAGRAM
Vantage 500 CUMMINS
F-10
F-11
DIAGRAMS
CONNECTION DIAGRAM
Vantage 500 CUMMINS
F-11
F-12
DIAGRAMS
CONNECTION DIAGRAM
Vantage 500 CUMMINS
F-12
F-13
DIAGRAMS
CONNECTION DIAGRAM
Vantage 500 CUMMINS
F-13
50.38
54.44
BOTTOM VIEW OF WELDER BASE.
19.63
23.69
42.35
50.15
63.10
45.38
* 37.30
14.63
* 6.55
CHANGE DETAIL: Revised overall height dimension.
6.53
*
24.97
6.56
*
42.00
46.35
50.81
31.50
5.86
* TRAILER MOUNTING HOLE LOCATIONS.
Ref.
DIMENSION PRINT
M18962-3
A. 0 2
N.A. CENTER OF GRAVITY WITH OIL IN ENGINE, EMPTY FUEL TANK AND COOLANT IN RADIATOR.
45.67
2.24
DIAGRAMS
NOTE: This diagram is for reference only. It may not be accurate for all machines covered by this manual. The specific diagram for a particular code is pasted inside the machine on one of the enclosure
panels. If the diagram is illegible, write to the Service Department for a replacement. Give the equipment code number.
Vantage 500 CUMMINS
28.99
16.85
N.A.
33.53
32.08
ENGINEERING CONTROLLED
MANUFACTURER: No
F-14
F-14
l Do not touch electrically live parts or
WARNING
Spanish
AVISO DE
PRECAUCION
French
ATTENTION
German
WARNUNG
Portuguese
ATENÇÃO
l Keep flammable materials away.
l Wear eye, ear and body protection.
l Mantenga el material combustible
l Protéjase los ojos, los oídos y el
electrode with skin or wet clothing.
l Insulate yourself from work and
ground.
l No toque las partes o los electrodos
bajo carga con la piel o ropa
mojada.
l Aislese del trabajo y de la tierra.
l Ne laissez ni la peau ni des
vêtements mouillés entrer en contact
avec des pièces sous tension.
l Isolez-vous du travail et de la terre.
l Berühren Sie keine stromführenden
fuera del área de trabajo.
l Gardez à l’écart de tout matériel
inflammable.
l Entfernen Sie brennbarres Material!
Teile oder Elektroden mit Ihrem
Körper oder feuchter Kleidung!
l Isolieren Sie sich von den
Elektroden und dem Erdboden!
l Não toque partes elétricas e
electrodos com a pele ou roupa
molhada.
l Isole-se da peça e terra.
cuerpo.
l Protégez vos yeux, vos oreilles et
votre corps.
l Tragen Sie Augen-, Ohren- und Kör-
perschutz!
l Mantenha inflamáveis bem
guardados.
l Use proteção para a vista, ouvido e
corpo.
Japanese
Chinese
Korean
Arabic
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
HERSTELLERS. DIE UNFALLVERHÜTUNGSVORSCHRIFTEN DES ARBEITGEBERS SIND EBENFALLS ZU BEACHTEN.
Vantage 500 CUMMINS
l Keep your head out of fumes.
l Use ventilation or exhaust to
l Turn power off before servicing.
l Do not operate with panel open or
guards off.
remove fumes from breathing zone.
l Los humos fuera de la zona de
respiración.
l Mantenga la cabeza fuera de los
humos. Utilice ventilación o
aspiración para gases.
l Gardez la tête à l’écart des fumées.
l Utilisez un ventilateur ou un
aspirateur pour ôter les fumées des
zones de travail.
l Desconectar el cable de
alimentación de poder de la
máquina antes de iniciar cualquier
servicio.
l Mantenha seu rosto da fumaça.
l Use ventilação e exhaustão para
remover fumo da zona respiratória.
guardas quitadas.
l N’opérez pas avec les panneaux
l Débranchez le courant avant
l’entretien.
ouverts ou avec les dispositifs de
protection enlevés.
l Anlage nie ohne Schutzgehäuse
l Vermeiden Sie das Einatmen von
Schweibrauch!
l Sorgen Sie für gute Be- und
Entlüftung des Arbeitsplatzes!
l No operar con panel abierto o
l Strom vor Wartungsarbeiten
abschalten! (Netzstrom völlig
öffnen; Maschine anhalten!)
oder Innenschutzverkleidung in
Betrieb setzen!
l Mantenha-se afastado das partes
l Não opere com as tampas removidas.
l Desligue a corrente antes de fazer
serviço.
l Não toque as partes elétricas nuas.
moventes.
l Não opere com os paineis abertos
WARNING
Spanish
AVISO DE
PRECAUCION
French
ATTENTION
German
WARNUNG
Portuguese
ATENÇÃO
ou guardas removidas.
Japanese
Chinese
Korean
Arabic
LEIA E COMPREENDA AS INSTRUÇÕES DO FABRICANTE PARA ESTE EQUIPAMENTO E AS PARTES DE USO,
E SIGA AS PRÁTICAS DE SEGURANÇA DO EMPREGADOR.
Vantage 500 CUMMINS
World’s Leader in Welding and Cutting Products
• Sales and Service through Subsidiaries and Distributors Worldwide •
Cleveland, Ohio 44117-1199 USA Tel: 216.481.8100 Fax: 216.486.1751 Web Site: www.lincolnelectric.com
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