Instruction/ maintenance manual of the product VANTAGE 500 CUMMINS 500 Lincoln Electric
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• Sales and Service through Subsidiaries and Distributors Worldwide • Cleveland, Ohio 44117-1199 U.S.A. TEL: 216.481.8100 FAX: 216.486.1751 WEB SITE: www.lincolnelectric.com • World's Leader in Welding and Cutting Products • OPERA TOR’S MANUAL Copyright © 2007 Lincoln Global Inc.
FOR ENGINE powered equipment. 1.a. Turn the engine off before troubleshooting and maintenance work unless the maintenance work requires it to be running. ____________________________________________________ 1.b. Operate engines in open, well-ventilated areas or vent the engine exhaust fumes outdoors.
ii SAFETY ii ARC RA YS can burn. 4.a. Use a shield with the proper filter and cover plates to protect your eyes from sparks and the rays of the arc when welding or observing open arc welding. Headshield and filter lens should conform to ANSI Z87. I standards.
iii SAFETY iii FOR ELECTRICALL Y 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 U.S. National Electrical Code, all local codes and the manufacturerʼs recommendations.
iv SAFETY iv Mar. ʻ93 PRÉCAUTIONS DE SÛRETÉ Pour votre propre protection lire et observer toutes les instructions et les précautions de sûreté specifiques qui parraissent dans ce manuel aussi bien que les précautions de sûreté générales suiv- antes: Sûreté Pour Soudage A LʼArc 1.
v v 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! Read this Operators Manual completely before attempting to use this equipment.
vi vi T ABLE OF CONTENTS Page Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Section A Technical Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . .
vii vii T ABLE OF CONTENTS Page Accessories . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Section C Optional Field Installed Accessories . . . . . . . . . . . . .
A-1 INST ALLA TION VANTAGE 500 CUMMINS A-1 TECHNICAL SPECIFICA TIONS - V ANT AGE 500 CUMMINS (K2406-1) INPUT - DIESEL ENGINE Make /Model Description Speed (RPM) Displacement Starting Capacities System CUMMINS 4 cylinder High Idle 1890 199 cu. in 12VDC battery Fuel B3.
A-2 INST ALLA TION VANTAGE 500 CUMMINS A-2 Read this entire installation section before you start installation. SAFETY PRECAUTIONS Do not attempt to use this equipment until you have thoroughly read all operating and mainte- nance manuals supplied with your machine.
A-3 INST ALLA TION VANTAGE 500 CUMMINS A-3 LIFTING The VANTAGE 500 CUMMINS lift bail should be used to lift the machine. The VANTAGE 500 CUMMINS is shipped with the lift bail retracted. Before attempting to lift the VANTAGE 500 CUMMINS the lift bail must be secured in a raised position.
ENGINE BREAK-IN Lincoln Electric selects high quality, heavy-duty indus- trial engines for the portable welding machines we offer. While it is normal to see a small amount of crankcase oil consumption during initial operation, excessive oil use, wet stacking (oil or tar like sub- stance at the exhaust port), or excessive smoke is not normal.
A-5 INST ALLA TION VANTAGE 500 CUMMINS A-5 • CONNECTING A BATTERY CHARGER — remove bat- tery from welder by disconnecting negative cable first, then positive cable and battery clamp. When rein- stalling, connect negative cable last. Keep well venti- lated.
A-6 INST ALLA TION VANTAGE 500 CUMMINS A-6 REMOTE CONTROL OUTPUT The VANTAGE 500 CUMMINS is equipped with a 6- pin and a 14-pin connector. The 6-pin connector is for connecting the K857 or K857-1 Remote Control or for TIG welding, the K870 foot Amptrol or the K963-3 Hand Amptrol.
A-7 INST ALLA TION VANTAGE 500 CUMMINS A-7 2. Take necessary steps to assure load is limited to the capacity of the VANTAGE 500 CUMMINS 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.
A-8 INST ALLA TION VANTAGE 500 CUMMINS A-8 CONNECTION OF LINCOLN ELECTRIC WIRE FEEDERS Shut off welder before making any electrical con- nections. ------------------------------------------------------------------------ CONNECTION OF LN-7, LN-8 OR LN-742 TO THE V ANT AGE 500 CUMMINS • Shut the welder off.
A-9 INST ALLA TION VANTAGE 500 CUMMINS A-9 CONNECTION OF THE LN-25 TO THE V ANT AGE 500 CUMMINS The LN-25 with or without an internal contactor may be used with the VANTAGE 500 CUMMINS.
B-1 OPERA TION VANTAGE 500 CUMMINS B-1 SAFETY INSTRUCTIONS Read and understand this entire section before operating your VANTAGE 500 CUMMINS. Do not attempt to use this equipment until you have thoroughly read all operating and mainte- nance manuals supplied with your machine.
B-2 OPERA TION B-2 ENGINE CONTROLS (Items 1 through 9) 1. RUN STOP SWITCH Toggling the switch to the RUN position energizes the fuel solenoid for approximately 30 seconds. The engine must be started within that time or the fuel solenoid will denergize, and the switch must be tog- gled to reset the timer.
B-3 OPERA TION B-3 6. OIL PRESSURE GAUGE The gauge displays the engine oil pressure when the engine is running. 7. ENGINE PROTECTION The yellow engine protection light remains off with proper oil pressure and under normal operating tem- peratures. If the light turns on, the engine protection system will stop the engine.
B-4 OPERA TION B-4 WELDING CONTROLS (Items 10 through 19) 10. OUTPUT CONTROL: The OUTPUT dial is used to preset the output voltage or current as displayed on the digital meters for the four welding modes.
B-5 OPERA TION B-5 20. CIRCUIT BREAKERS These circuit breakers provide separate overload current protection for each 120V circuit at the 240V single phase receptacle, each 120V single phase receptacle, the 240V three phase receptacle, the 120VAC in the 14-Pin connector, the 42VAC in the 14-Pin connector and battery circuit overload protec- tion.
B-6 OPERA TION B-6 BREAK-IN PERIOD The engine used to supply power for your welder is a heavy duty, industrial engine. It is designed and built for rugged use. It is very normal for any engine to use small quantities of oil until the break-in is accomplished.
B-7 OPERA TION B-7 The VANTAGE 500 CUMMINS and any high frequen- cy generating equipment must be properly grounded. See the K930-2 TIG Module operating manuals for complete instructions on installation, operation, and maintenance.
B-8 OPERA TION B-8 CV -WIRE MODE Connect a wire feeder to the VANTAGE 500 CUM- MINS and set welder controls according to the instruc- tions listed earlier in this section.
B-9 OPERA TION B-9 VANTAGE 500 CUMMINS TABLE B.5 VANTAGE 500 CUMMINS Extension Cord Length Recommendations Current (Amps) 15 15 20 20 25 30 38 50 Voltag e (Volts) 120 240 120 240 240 240 240 240 Load .
C-1 ACCESSORIES C-1 OPTIONAL FIELD INST ALLED ACCES- SORIES K802N POWER PLUG KIT - Provides four 120V plugs rated at 20 amps each and one dual voltage, full KVA plug rated at 120/240V, 50 amps. 120V plug may not be compatible with NEMA common household receptacles.
C-2 ACCESSORIES C-2 TIG OPTIONS K1783-9 PTA-26V TIG Torch Air Cooled 200 amp torch (2 piece) equipped with valve for gas flow control. 25 ft. (7.6m) length. KP509 Magnum Parts Kit for PTA-26V TIG Torch Magnum Parts Kit provides all the torch accessories you need to start welding.
D-1 MAINTENANCE D-1 VANTAGE 500 CUMMINS SAFETY PRECAUTIONS • 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.
D-2 MAINTENANCE D-2 VANTAGE 500 CUMMINS Service Instructions & Installation T ips For Engine Air Filter • Release the 1 Seal Carefully Unlatch and remove the service cover of the air cleaner. Make certain the latches are folded back against the cover so that they don t hinder filter removal/installation.
D-3 MAINTENANCE D-3 FUEL FIL TERS When working on the fuel system • Keep naked lights away, do not smoke ! • Do not spill fuel ! ------------------------------------------------------------------------ The VANTAGE 500 CUMMINS is equipped with a Fuel Filter located after the lift pump and before fuel injectors.
D-4 MAINTENANCE D-4 CHARGING THE BA TTER Y When you charge, jump, replace, or otherwise con- nect battery cables to the battery, be sure the polarity is correct. Improper polarity can damage the charging circuit. The VANTAGE 500 CUMMINS positive (+) battery terminal has a red terminal cover.
D-5 MAINTENANCE D-5 GFCI RECEPT ACLE TESTING AND RESET- TING PROCEDURE The GFCI receptacle should be properly tested at least once every month or whenever it is tripped. To properly test and reset the GFCI receptacle: • If the receptacle has tripped, first carefully remove any load and check it for damage.
E-1 TROUBLESHOOTING E-1 VANTAGE 500 CUMMINS 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.
E-2 TROUBLESHOOTING E-2 VANTAGE 500 CUMMINS Observe all Safety Guidelines detailed throughout this manual 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.
E-3 TROUBLESHOOTING E-3 VANTAGE 500 CUMMINS Observe all Safety Guidelines detailed throughout this manual 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.
E-4 TROUBLESHOOTING E-4 VANTAGE 500 CUMMINS Observe all Safety Guidelines detailed throughout this manual 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.
F-1 DIAGRAMS F-1 VANTAGE 500 CUMMINS 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.
F-2 CONNECTION DIAGRAMS F-2 VANTAGE 500 CUMMINS.
F-3 CONNECTION DIAGRAMS F-3 VANTAGE 500 CUMMINS GND 75• 76 77 GREEN K291 OR K404 75 INPUT CABLE 76 N.E. 77 K775 OPTIONAL• REMOTE CONTR OL D AMAGED . THE ENGINE GO VERNOR SETTING IS PRE-SET A T THE F ACT ORY - DO NO T ADJUST ABOVE RPM SPECIFICA TIONS LISTED IN 81• 42 41 31 31 32 32 2 2 4 4 21 21 GND 82 N.
F-4 CONNECTION DIAGRAMS F-4 VANTAGE 500 CUMMINS.
F-5 CONNECTION DIAGRAMS F-5 VANTAGE 500 CUMMINS.
F-6 CONNECTION DIAGRAMS F-6 VANTAGE 500 CUMMINS CA UTION : N.A. WELDING CABLE MUST BE OF PR OPER CAP ACITY FOR THE CURRENT AND DUTY CYCLE OF IMMEDIA TE AND FUTURE• APPICA TIONS. SEE OPERA TING MANUAL. 75 32 31 41 42 N.C. INSULA TE EACH UNUSED LEAD INDIVIDU ALL Y .
F-7 CONNECTION DIAGRAMS F-7 VANTAGE 500 CUMMINS.
F-8 CONNECTION DIAGRAMS F-8 VANTAGE 500 CUMMINS.
F-9 CONNECTION DIAGRAMS F-9 VANTAGE 500 CUMMINS.
F-10 CONNECTION DIAGRAMS F-10 VANTAGE 500 CUMMINS.
F-11 CONNECTION DIAGRAMS F-11 VANTAGE 500 CUMMINS.
F-12 CONNECTION DIAGRAMS F-12 VANTAGE 500 CUMMINS.
F-13 DIMENSION PRINT F-13 VANTAGE 500 CUMMINS * * * * BOT TOM VI EW OF WELDER BASE. N.A. CENTER OF GRAVITY WITH OIL IN ENGINE, EM PTY F UEL TA NK AND CO OLANT IN RADIATO R. M18962-3 B 2.24 56.9 5.86 148.8 45.67 1160 31.50 800.1 42.00 1066.8 46.35 1177.
NOTES VANTAGE 500 CUMMINS.
W ARNING AV I S O D E PRECAUCION A TTENTION W ARNUNG A TENÇÃO Spanish French German Portuguese Japanese Chinese Korean Arabic READ AND UNDERST AND THE MANUF ACTURER’S INSTRUCTION FOR THIS EQUIPMENT AND THE CONSUMABLES TO BE USED AND FOLLOW YOUR EMPLOYER’S SAFETY PRACTICES.
W ARNING AV I S O D E PRECAUCION A TTENTION W ARNUNG A TENÇÃO Spanish French German Portuguese Japanese Chinese Korean Arabic LEIA E COMPREENDA AS INSTRUÇÕES DO F ABRICANTE P ARA ESTE EQUIP AMENTO E AS P ARTES DE USO, E SIGA AS PRÁTICAS DE SEGURANÇA DO EMPREGADOR.
• Sales and Service through Subsidiaries and Distributors Worldwide • Cleveland, Ohio 44117-1199 U.S.A. TEL: 216.481.8100 FAX: 216.486.1751 WEB SITE: www.
An important point after buying a device Lincoln Electric VANTAGE 500 CUMMINS 500 (or even before the purchase) is to read its user manual. We should do this for several simple reasons:
If you have not bought Lincoln Electric VANTAGE 500 CUMMINS 500 yet, this is a good time to familiarize yourself with the basic data on the product. First of all view first pages of the manual, you can find above. You should find there the most important technical data Lincoln Electric VANTAGE 500 CUMMINS 500 - thus you can check whether the hardware meets your expectations. When delving into next pages of the user manual, Lincoln Electric VANTAGE 500 CUMMINS 500 you will learn all the available features of the product, as well as information on its operation. The information that you get Lincoln Electric VANTAGE 500 CUMMINS 500 will certainly help you make a decision on the purchase.
If you already are a holder of Lincoln Electric VANTAGE 500 CUMMINS 500, but have not read the manual yet, you should do it for the reasons described above. You will learn then if you properly used the available features, and whether you have not made any mistakes, which can shorten the lifetime Lincoln Electric VANTAGE 500 CUMMINS 500.
However, one of the most important roles played by the user manual is to help in solving problems with Lincoln Electric VANTAGE 500 CUMMINS 500. Almost always you will find there Troubleshooting, which are the most frequently occurring failures and malfunctions of the device Lincoln Electric VANTAGE 500 CUMMINS 500 along with tips on how to solve them. Even if you fail to solve the problem, the manual will show you a further procedure – contact to the customer service center or the nearest service center
