Instruction/ maintenance manual of the product SVM178-B Lincoln Electric
Go to page of 278
SVM178-B April, 201 1 Safety Depends on Y ou Lincoln arc welding and cutting equipment is designed and built with safety in mind. However , your overall safety can be increased by proper installation .
V ANT AGE® 500 SAFETY i i FOR ENGINE powered equipment. 1.a. T urn 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.
V ANT AGE® 500 SAFETY ii ii 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.
V ANT AGE® 500 SAFETY iii 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 manufacturer ’s recommendations.
V ANT AGE® 500 SAFETY iv iv 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 L’Arc 1.
V ANT AGE® 500 SAFETY Electromagnetic Compatibility (EMC) Confor mance P roducts displaying the CE mark are in conformity with European Community Council Directive of 1 5 Dec 2004 on the appro ximation of the laws of the Member Stat es relating to electromagnetic compatibilit y , 2004/1 08/EC .
V ANT AGE® 500 SAFETY Electromagnetic Compatibility (EMC) The size of the surrounding area to be considered will depend on the structure of the building and other activities that are taking place. The surr ounding ar ea ma y ext end bey ond the boundar ies of the premises.
- MASTER T ABLE OF CONTENTS FOR ALL SECTIONS - I I V ANT AGE® 500 Page Safety . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .i-iv Installation . . .
T ABLE OF CONTENTS - INST ALLA TION SECTION A1.1 A1.1 V ANT AGE® 500 Installation - V ANT AGE® 500 Deutz F3L912 (Code 10995) T echnical Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
INST ALLA TION A1.2 A1.2 V ANT AGE® 500 TECHNICAL SPECIFICA TIONS - V antage 500® DEUTZ (K2271-1) INPUT - DIESEL ENGINE Make /Model Description Speed (RPM) Displacement Starting Capacities System Deutz 3 cylinder High Idle 1900 173 cu. in 12VDC battery Fuel F3L 912 44HP (33 kw) (2.
INST ALLA TION A1.3 A1.3 V ANT AGE® 500 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.
INST ALLA TION A1.4 A1.4 V ANT AGE® 500 LIFTING The V antage® 500 lift bale should be used to lift the machine. The V antage® 500 is shipped with the lift bale retracted. Before attempting to lift the V antage® 500, secure the lift bale in a raised position.
INST ALLA TION A1.5 A1.5 V ANT AGE® 500 PRE-OPERA TION ENGINE SERVICE READ the engine operating and maintenance instruc- tions supplied with this machine. • Keep hands away from the engine muffler or HOT engine parts. • Stop engine and allow to cool before fueling.
INST ALLA TION A1.6 A1.6 V ANT AGE® 500 IMPORT ANT : T o prevent ELECTRICAL DAMAGE WHEN: a) Installing new batteries b) Using a booster Use correct polarity — Negative Ground. The V antage® 500 is shipped with the negative battery cable disconnected.
INST ALLA TION A1.7 A1.7 V ANT AGE® 500 WELDING OUTPUT CABLES With the engine off, route the electrode and work cables through 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 .
INST ALLA TION A1.8 A1.8 V ANT AGE® 500 Figure A1.1 Connection of the V antage® 500 to Premises Wiring 1. Install the double-pole, double-throw switch between the power company meter and the premises disconnect. Switch rating must be the same as or greater than the customer ’s premises disconnect and service over cur- rent protection.
T ABLE OF CONTENTS - OPERA TION SECTION B1.1 B1.1 V ANT AGE® 500 Operation - V ANT AGE® 500 Deutz F3L912 (Code 10995) Operating Instructions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
OPERA TION B1.2 B1.2 V ANT AGE® 500 OPERA TING INSTRUCTIONS Read and understand this entire section before oper- ating your V antage® 500. SAFETY INSTRUCTIONS Do not attempt to use this equipment until you have thoroughly read all operating and mainte- nance manuals supplied with your machine.
OPERA TION B1.3 B1.3 V ANT AGE® 500 RECOMMENDED APPLICA TIONS WELDER The V antage® 500 provides excellent constant current DC welding output for stick (SMA W) and TIG welding. The V antage® 500 also provides excellent constant voltage DC welding output for MIG (GMA W) and Innershield (FCA W) welding.
OPERA TION B1.4 B1.4 V ANT AGE® 500 ENGINE CONTROLS (Items 1 through 9) 1 . R UN ST O P SW IT CH T oggling 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 .
OPERA TION 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.
OPERA TION 13. WELDING TERMINALS SWITCH In the WELD TERMINALS ON position, the output is electrically hot all the time. In the REMOTEL Y CON- TROLLED position, the output is controlled by a wire feeder or amptrol device, and is electrically off until a remote switch is depressed.
OPERA TION ENGINE OPERA TION ST ARTING THE ENGINE 1. Open the engine compartment door and check that the fuel shutoff valve is in the open position (lever to be in line with the hose). 2. Check for proper oil level and coolant level. Close engine compartment door .
WELDER OPERA TION DUTY CYCLE Duty Cycle is the the ratio of the uninterrupted on-load duration to 10 minutes. The total time period of one complete on-load and no-load cycle is 10 minutes. For example, in the case of a 60% duty cycle, load is applied continuously for 6 minutes followed by a no- load period of 4 minutes.
OPERA TION B1.9 B1.9 V ANT AGE® 500 V ANT AGE 500 SETTINGS WHEN USING THE K799 HI-FREQ UNIT • Set the WELD MODE switch to the 20-250 setting (TIG). • Set the IDLER switch to the HIGH position. • Set the WELDING TERMINALS switch to the WELD TERMINALS ON position.
OPERA TION B1.10 B1.10 V ANT AGE® 500 WIRE FEED (CONST ANT VOL T AGE) WELDING Connect a wire feeder to the V antage® 500 and set welder controls according to the instructions listed ear- lier in this section.
OPERA TION B1.11 B1.11 V ANT AGE® 500 T ABLE B1.4 – V ANT AGE 500 EXTENSION CORD LENGTH RECOMMENDA TIONS Current (Amps) 15 15 20 20 25 30 38 50 V oltage (V olts) 120 240 120 240 240 240 240 240 Loa.
NOTES B1.12 B1.12 V ANT AGE® 500 Return to Section TOC Return to Section TOC Return to Section TOC Return to Section TOC Return to Master TOC Return to Master TOC Return to Master TOC Return to Maste.
T ABLE OF CONTENTS - ACCESSORIES SECTION C1.1 C1.1 V ANT AGE® 500 Accessories - V ANT AGE® 500 Deutz F3L912 (Code 10995) Options/Accessories . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
ACCESSORIES C1.2 C1.2 V ANT AGE® 500 K802N POWER PLUG KIT - Provides four 120V plugs rated at 20 amps each and one dual voltage, full KV A plug rated at 120/240V , 50 amps. The 20 amp/120V plug may not be compatible with NEMA common household receptacles.
ACCESSORIES C1.3 C1.3 V ANT AGE® 500 TIG OPTIONS K1783-9 PT A-26V TIG T orch Air Cooled 200 amp torch (2 piece) equipped with valve for gas flow control. 25 ft. (7.6m) length. KP509 Magnum Parts Kit for PT A-26V TIG T orch Magnum Parts Kit provides all the torch accessories you need to start welding.
NOTES C1.4 C1.4 V ANT AGE® 500 Return to Section TOC Return to Section TOC Return to Section TOC Return to Section TOC Return to Master TOC Return to Master TOC Return to Master TOC Return to Master .
T ABLE OF CONTENTS - MAINTENANCE SECTION D1.1 D1.1 V ANT AGE® 500 Maintenance - V ANT AGE® 500 Deutz F3L912 (Code 10995) Safety Precautions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
MAINTENANCE D1.2 D1.2 V ANT AGE® 500 SAFETY PRECAUTIONS • Have qualified personnel do all maintenance and troubleshooting work. • T urn the engine off before working inside the machine. • Remove covers or guards only when necessary to perform maintenance and replace them when the maintenance requiring their removal is com- plete.
MAINTENANCE D1.3 D1.3 V ANT AGE® 500 CHANGE THE OIL FIL TER: Change the oil filter the first time between 25 and 50 hours of operation. Then, under normal operating conditions, change the oil filter after every 250 hours of operation.
MAINTENANCE D1.4 D1.4 V ANT AGE® 500 FUEL FIL TERS: When working on the fuel system: • Keep naked lights away , do not smoke • Do not spill fuel The V antage® 500 is equipped with a Fuel Pre- Filter/W ater Separator Assembly located before the lift pump and a Secondary Fuel Filter located after the lift pump and before the fuel injectors.
MAINTENANCE D1.5 D1.5 V ANT AGE® 500 4. Slide the new element onto the grommet post on the bottom of the filter header until the element no longer easily moves up into the filter header . Now rotate the element (it may take almost 1 full turn) with a slight upward pressure until the element begins to further engage the header .
MAINTENANCE D1.6 D1.6 V ANT AGE® 500 BLEEDING THE FUEL SYSTEM: In the event the engine is operated until it runs out of fuel, you will need to bleed the fuel system in order to start the engine. Refer to the engine operation manual. AIR FIL TER Excessive air filter restriction will result in reduced engine life.
MAINTENANCE D1.7 D1.7 V ANT AGE® 500 MAINTENANCE INSTRUCTIONS Return to Section TOC Return to Section TOC Return to Section TOC Return to Section TOC Return to Master TOC Return to Master TOC Return .
MAINTENANCE D1.8 D1.8 V ANT AGE® 500 COOLING SYSTEM The cooling system of the Deutz engine needs to be checked and cleaned periodically . Consult the engine Operation Manual for the proper frequency and proce- dure. COOLING BLOWER BEL T : The following procedure should be followed to replace the cooling blower belt: 1.
MAINTENANCE D1.9 D1.9 V ANT AGE® 500 T ABLE D1.1 DEUTZ ENGINE MAINTENANCE SCHEDULE FREQUENCY MAINTENANCE REQUIRED Daily or Before Starting Engine • Fill fuel tank. • Check oil level. • Check air cleaner for dirty , loose, or damaged parts. Replace if necessary .
MAINTENANCE D1.10 D1.10 V ANT AGE® 500 BA TTER Y MAINTENANCE GASES FROM BA TTER Y can explode. • Keep sparks, flame, and cigarettes away from battery . BA TTERY ACID can burn eyes and skin. • Wear gloves and eye protection and be careful when working near a bat- tery .
MAINTENANCE D1.11 D1.11 V ANT AGE® 500 WELDER/GENERA TOR MAINTENANCE STORAGE: Store the V antage 500 in clean, dry , pro- tected areas. CLEANING: Blow out the generator and controls peri- odically with low pressure air . Do this at least once a week in particularly dirty areas.
MAINTENANCE D1.12 D1.12 V ANT AGE® 500 WARNING 1 2 4 3 5 7 8 6 9 10 OFF FIGURE D1.5 – MAJOR COMPONENT LOCA TIONS 1. CONTROL P ANEL ASSEMBL Y 2. CONTROL BOX & OUTPUT ASSEMBL Y 3. POWER MODULE ASSEMBL Y 4. BASE & LIFT BALE ASSEMBL Y 5. FUEL T ANK & MOUNTING 6.
T ABLE OF CONTENTS - INST ALLA TION SECTION A2.1 A2.1 V ANT AGE® 500 Installation - V ANT AGE® 500 Deutz F4L201 1 (Codes 1 1 180,1 1415) T echnical Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
INST ALLA TION A2.2 A2.2 V ANT AGE® 500 TECHNICAL SPECIFICA TIONS - V ANT AGE 500 DEUTZ (K2405-1) INPUT - DIESEL ENGINE Make /Model Description Speed (RPM) Displacement Starting Capacities System DEUTZ 4 cylinder High Idle 1890 190 cu. in 12VDC battery Fuel F4L201 1 48HP (36 kw) Low Idle 1425 (3.
INST ALLA TION A2.3 A2.3 V ANT AGE® 500 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.
INST ALLA TION A2.4 A2.4 V ANT AGE® 500 LIFTING The V antage lift bale should be used to lift the machine. The V antage is shipped with the lift bale retracted. Before attempting to lift the V antage, secure the lift bale in a raised position. Secure the lift bale as follows: a.
INST ALLA TION A2.5 A2.5 V ANT AGE® 500 PRE-OPERA TION ENGINE SERVICE READ the engine operating and maintenance instruc- tions supplied with this machine. • Keep hands away from the engine muffler or HOT engine parts. • Stop engine and allow to cool before fueling.
INST ALLA TION A2.6 A2.6 V ANT AGE® 500 IMPORT ANT : T o prevent ELECTRICAL DAMAGE WHEN: a) Installing new batteries b) Using a booster Use correct polarity — Negative Ground.
INST ALLA TION A2.7 A2.7 V ANT AGE® 500 WELDING OUTPUT CABLES With the engine off, route the electrode and work cables through 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 .
INST ALLA TION A2.8 A2.8 V ANT AGE® 500 Figure A2.1 Connection of the V antage to Premises Wiring 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 cus- tomer ’s premises disconnect and service over current protection.
T ABLE OF CONTENTS - OPERA TION SECTION B2.1 B2.1 V ANT AGE® 500 Operation - V ANT AGE® 500 Deutz F4L201 1 (Codes 1 1 180,1 1415) Operating Instructions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
OPERA TION B2.2 B2.2 V ANT AGE® 500 OPERA TING INSTRUCTIONS Read and understand this entire section before oper- ating your V antage 500. SAFETY INSTRUCTIONS Do not attempt to use this equipment until you have thoroughly read all operating and mainte- nance manuals supplied with your machine.
OPERA TION B2.3 B2.3 V ANT AGE® 500 RECOMMENDED APPLICA TIONS WELDER The V antage 500 provides excellent constant current DC welding output for stick (SMA W) and TIG welding. The V antage 500 also provides excellent constant volt- age DC welding output for MIG (GMAW) and Innershield (FCA W) welding.
OPERA TION B2.4 B2.4 V ANT AGE® 500 ENGINE CONTROLS (Items 1 through 9) 1 . R UN ST O P SW IT CH T oggling 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 .
OPERA TION B2.5 B2.5 V ANT AGE® 500 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.
OPERA TION B2.6 B2.6 V ANT AGE® 500 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.
OPERA TION B2.7 B2.7 V ANT AGE® 500 20. CIRCUIT BREAKERS These circuit breakers provide separate overload current protection for each 120V circuit at the 240V single phase receptacle, each 120V singl.
WELDER OPERA TION DUTY CYCLE Duty Cycle is the the ratio of the uninterrupted on-load duration to 10 minutes. The total time period of one complete on-load and no-load cycle is 10 minutes. For example, in the case of a 60% duty cycle, load is applied continuously for 6 minutes followed by a no- load period of 4 minutes.
OPERA TION B2.9 B2.9 V ANT AGE® 500 V ANT AGE 500 SETTINGS WHEN USING THE K799 HI-FREQ UNIT • Set the WELD MODE switch to the 20-250 setting (TIG). • Set the IDLER switch to the HIGH position. • Set the WELDING TERMINALS switch to the WELD TERMINALS ON position.
OPERA TION B2.10 B2.10 V ANT AGE® 500 WIRE FEED (CONST ANT VOL T AGE) WELDING Connect a wire feeder to the V antage 500 and set welder controls according to the instructions listed ear- lier in this section.
OPERA TION B2.11 B2.11 V ANT AGE® 500 T ABLE B2.4 – V ANT AGE 500 EXTENSION CORD LENGTH RECOMMENDA TIONS Current (Amps) 15 15 20 20 25 30 38 50 V oltage (V olts) 120 240 120 240 240 240 240 240 Loa.
NOTES B2.12 B2.12 V ANT AGE® 500 Return to Section TOC Return to Section TOC Return to Section TOC Return to Section TOC Return to Master TOC Return to Master TOC Return to Master TOC Return to Maste.
T ABLE OF CONTENTS - ACCESSORIES SECTION C2.1 C2.1 V ANT AGE® 500 Accessories - V ANT AGE® 500 Deutz F4L201 1 (Codes 1 1 180, 1 1415) Options/Accessories . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
ACCESSORIES C2.2 C2.2 V ANT AGE® 500 K802N POWER PLUG KIT - Provides four 120V plugs rated at 20 amps each and one dual voltage, full KV A plug rated at 120/240V , 50 amps.
ACCESSORIES C2.3 C2.3 V ANT AGE® 500 TIG OPTIONS K1783-9 PT A-26V TIG T orch Air Cooled 200 amp torch (2 piece) equipped with valve for gas flow control. 25 ft. (7.6m) length. KP509 Magnum Parts Kit for PT A-26V TIG T orch Magnum Parts Kit provides all the torch accessories you need to start welding.
NOTES C2.4 C2.4 V ANT AGE® 500 Return to Section TOC Return to Section TOC Return to Section TOC Return to Section TOC Return to Master TOC Return to Master TOC Return to Master TOC Return to Master .
T ABLE OF CONTENTS - MAINTENANCE SECTION D2.1 D2.1 V ANT AGE® 500 Maintenance - V ANT AGE® 500 Deutz F4L201 1 (Codes 1 1 180,1 1415) Safety Precautions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
MAINTENANCE D2.2 D2.2 V ANT AGE® 500 SAFETY PRECAUTIONS • Have qualified personnel do all maintenance and troubleshooting work. • T urn the engine off before working inside the machine. • Remove covers or guards only when necessary to perform maintenance and replace them when the maintenance requiring their removal is com- plete.
MAINTENANCE D2.3 D2.3 V ANT AGE® 500 CHANGE THE OIL FIL TER Change the oil filter the first time between 25 and 50 hours of operation. Then, under normal operating con- ditions, change the oil filter after every 250 hours of operation.
MAINTENANCE D2.4 D2.4 V ANT AGE® 500 FUEL FIL TERS When working on the fuel system • Keep naked lights away , do not smoke ! • Do not spill fuel ! ------------------------------------------------.
MAINTENANCE D2.5 D2.5 V ANT AGE® 500 AIR FIL TER: Excessive air filter restriction will result in reduced engine life. 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.
MAINTENANCE D2.6 D2.6 V ANT AGE® 500 MAINTENANCE INSTRUCTIONS Return to Section TOC Return to Section TOC Return to Section TOC Return to Section TOC Return to Master TOC Return to Master TOC Return .
MAINTENANCE D2.7 D2.7 V ANT AGE® 500 COOLING SYSTEM The cooling system of the Deutz engine needs to be checked and cleaned periodically . Consult the engine Operation Manual for the proper frequency and proce- dures. COOLING BLOWER BEL T : The following procedure should be followed to replace the cooling blower belt: 1.
MAINTENANCE D2.8 D2.8 V ANT AGE® 500 WELDER/GENERA TOR MAINTENANCE STORAGE: Store the V antage 500 in clean, dry , pro- tected areas. CLEANING: Blow out the generator and controls peri- odically with low pressure air . Do this at least once a week in particularly dirty areas.
MAINTENANCE D2.9 D2.9 V ANT AGE® 500 BA TTER Y MAINTENANCE GASES FROM BA TTER Y can explode. • Keep sparks, flame, and cigarettes away from battery . BA TTERY ACID can burn eyes and skin. • Wear gloves and eye protection and be careful when working near a bat- tery .
MAINTENANCE D2.10 D2.10 V ANT AGE® 500 WARNING W ARNING 1 1 2 2 4 4 6 6 3 3 5 5 7 7 10 10 9 9 FIGURE D2.6 – MAJOR COMPONENT LOCA TIONS 1. CONTROL P ANEL ASSEMBL Y 2. CONTROL BOX & OUTPUT ASSEMBL Y 3. POWER MODULE ASSEMBL Y 4. BASE & LIFT BALE ASSEMBL Y 5.
T ABLE OF CONTENTS - INST ALLA TION SECTION A3.1 A3.1 V ANT AGE® 500 Installation - V ANT AGE® 500 Deutz D201 1L4i (Code1 1468) T echnical Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
INST ALLA TION A3.2 A3.2 V ANT AGE® 500 TECHNICAL SPECIFICA TIONS - V ANT AGE® 500 DEUTZ (K2405-2) INPUT - DIESEL ENGINE Make /Model Description Speed (RPM) Displacement Starting Capacities System DEUTZ 4 cylinder High Idle 1890 190 cu. in 12VDC battery Fuel D 201 1 L4i 48HP (36 kw) Low Idle 1425 (3.
INST ALLA TION A3.3 A3.3 V ANT AGE® 500 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.
INST ALLA TION A3.4 A3.4 V ANT AGE® 500 LIFTING The V antage lift bale should be used to lift the machine. The V antage is shipped with the lift bale retracted. Before attempting to lift the V antage, secure the lift bale in a raised position. Secure the lift bale as follows: a.
INST ALLA TION A3.5 A3.5 V ANT AGE® 500 PRE-OPERA TION ENGINE SERVICE READ the engine operating and maintenance instruc- tions supplied with this machine. • Keep hands away from the engine muffler or HOT engine parts. • Stop engine and allow to cool before fueling.
INST ALLA TION A3.6 A3.6 V ANT AGE® 500 IMPORT ANT : T o prevent ELECTRICAL DAMAGE WHEN: a) Installing new batteries b) Using a booster Use correct polarity — Negative Ground.
INST ALLA TION A3.7 A3.7 V ANT AGE® 500 WELDING OUTPUT CABLES With the engine off, route the electrode and work cables through 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 .
INST ALLA TION A3.8 A3.8 V ANT AGE® 500 Figure A3.1 Connection of the V antage to Premises Wiring 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 cus- tomer ’s premises disconnect and service over current protection.
T ABLE OF CONTENTS - OPERA TION SECTION B3.1 B3.1 V ANT AGE® 500 Operation - V ANT AGE® 500 Deutz D201 1L4i (Code 1 1468) Operating Instructions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
OPERA TION B3.2 B3.2 V ANT AGE® 500 OPERA TING INSTRUCTIONS Read and understand this entire section before oper- ating your V antage 500. SAFETY INSTRUCTIONS Do not attempt to use this equipment until you have thoroughly read all operating and mainte- nance manuals supplied with your machine.
OPERA TION B3.3 B3.3 V ANT AGE® 500 RECOMMENDED APPLICA TIONS WELDER The V antage 500 provides excellent constant current DC welding output for stick (SMA W) and TIG welding. The V antage 500 also provides excellent constant volt- age DC welding output for MIG (GMAW) and Innershield (FCA W) welding.
OPERA TION B3.4 B3.4 V ANT AGE® 500 ENGINE CONTROLS (Items 1 through 9) 1 . R UN ST O P SW IT CH T oggling 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 .
OPERA TION B3.5 B3.5 V ANT AGE® 500 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.
OPERA TION B3.6 B3.6 V ANT AGE® 500 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.
OPERA TION B3.7 B3.7 V ANT AGE® 500 20. CIRCUIT BREAKERS These circuit breakers provide separate overload current protection for each 120V circuit at the 240V single phase receptacle, each 120V singl.
OPERA TION B3.8 B3.8 V ANT AGE® 500 WELDER OPERA TION DUTY CYCLE Duty Cycle is the the ratio of the uninterrupted on-load duration to 10 minutes. The total time period of one complete on-load and no-load cycle is 10 minutes.
OPERA TION B3.9 B3.9 V ANT AGE® 500 V ANT AGE 500 SETTINGS WHEN USING THE K799 HI-FREQ UNIT • Set the WELD MODE switch to the 20-250 setting (TIG). • Set the IDLER switch to the HIGH position. • Set the WELDING TERMINALS switch to the WELD TERMINALS ON position.
OPERA TION B3.10 B3.10 V ANT AGE® 500 WIRE FEED (CONST ANT VOL T AGE) WELDING Connect a wire feeder to the V antage 500 and set welder controls according to the instructions listed ear- lier in this section.
OPERA TION B3.11 B3.11 V ANT AGE® 500 T ABLE B3.4 – V ANT AGE 500 EXTENSION CORD LENGTH RECOMMENDA TIONS Current (Amps) 15 15 20 20 25 30 38 50 V oltage (V olts) 120 240 120 240 240 240 240 240 Loa.
NOTES B3.12 B3.12 V ANT AGE® 500 Return to Section TOC Return to Section TOC Return to Section TOC Return to Section TOC Return to Master TOC Return to Master TOC Return to Master TOC Return to Maste.
T ABLE OF CONTENTS - ACCESSORIES SECTION C3.1 C3.1 V ANT AGE® 500 Accessories - V ANT AGE® 500 Deutz F4L201 1 (Codes 1 1 180, 1 1415) Options/Accessories . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
ACCESSORIES C3.2 C3.2 V ANT AGE® 500 K802N POWER PLUG KIT - Provides four 120V plugs rated at 20 amps each and one dual voltage, full KV A plug rated at 120/240V , 50 amps.
ACCESSORIES C3.3 C3.3 V ANT AGE® 500 TIG OPTIONS K1783-9 PT A-26V TIG T orch Air Cooled 200 amp torch (2 piece) equipped with valve for gas flow control. 25 ft. (7.6m) length. KP509 Magnum Parts Kit for PT A-26V TIG T orch Magnum Parts Kit provides all the torch accessories you need to start welding.
NOTES C3.4 C3.4 V ANT AGE® 500 Return to Section TOC Return to Section TOC Return to Section TOC Return to Section TOC Return to Master TOC Return to Master TOC Return to Master TOC Return to Master .
T ABLE OF CONTENTS - MAINTENANCE SECTION D3.1 D3.1 V ANT AGE® 500 Maintenance - V ANT AGE® 500 Deutz D201 1L4i (Codes 1 1468) Safety Precautions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
MAINTENANCE D3.2 D3.2 V ANT AGE® 500 SAFETY PRECAUTIONS • Have qualified personnel do all maintenance and troubleshooting work. • T urn the engine off before working inside the machine. • Remove covers or guards only when necessary to perform maintenance and replace them when the maintenance requiring their removal is com- plete.
MAINTENANCE D3.3 D3.3 V ANT AGE® 500 CHANGE THE OIL FIL TER Change the oil filter the first time between 25 and 50 hours of operation. Then, under normal operating con- ditions, change the oil filter after every 250 hours of operation.
MAINTENANCE D3.4 D3.4 V ANT AGE® 500 FUEL FIL TERS When working on the fuel system • Keep naked lights away , do not smoke ! • Do not spill fuel ! The V ANT AGE 500 DEUTZ is equipped with a Fuel Filter/W ater Separator located after the lift pump and before fuel injectors.
MAINTENANCE D3.5 D3.5 V ANT AGE® 500 AIR FIL TER: Excessive air filter restriction will result in reduced engine life . 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.
MAINTENANCE D3.6 D3.6 V ANT AGE® 500 MAINTENANCE INSTRUCTIONS Return to Section TOC Return to Section TOC Return to Section TOC Return to Section TOC Return to Master TOC Return to Master TOC Return .
MAINTENANCE D3.7 D3.7 V ANT AGE® 500 COOLING SYSTEM The cooling system of the Deutz engine needs to be checked and cleaned periodically . Consult the engine Operation Manual for the proper frequency and proce- dures. COOLING BLOWER BEL T : The following procedure should be followed to replace the cooling blower belt: 1.
MAINTENANCE D3.8 D3.8 V ANT AGE® 500 WELDER/GENERA TOR MAINTENANCE STORAGE: Store the V antage 500 in clean, dry , pro- tected areas. CLEANING: Blow out the generator and controls peri- odically with low pressure air . Do this at least once a week in particularly dirty areas.
MAINTENANCE D3.9 D3.9 V ANT AGE® 500 BA TTER Y MAINTENANCE GASES FROM BA TTER Y can explode. • Keep sparks, flame, and cigarettes away from battery . BA TTERY ACID can burn eyes and skin. • Wear gloves and eye protection and be careful when working near a bat- tery .
MAINTENANCE D3.10 D3.10 V ANT AGE® 500 WARNING W ARNING 1 1 2 2 4 4 6 6 3 3 5 5 7 7 10 10 9 9 FIGURE D2.6 – MAJOR COMPONENT LOCA TIONS 1. CONTROL P ANEL ASSEMBL Y 2. CONTROL BOX & OUTPUT ASSEMBL Y 3. POWER MODULE ASSEMBL Y 4. BASE & LIFT BALE ASSEMBL Y 5.
T ABLE OF CONTENTS - INST ALLA TION SECTION A4.1 A4.1 V ANT AGE® 500 Installation - V ANT AGE® 500 Cummins B3.3 (Code 10996) T echnical Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
INST ALLA TION A4.2 A4.2 V ANT AGE® 500 TECHNICAL SPECIFICA TIONS - V antage 500 CUMMINS (K2272-1) INPUT - DIESEL ENGINE Make /Model Description Speed (RPM) Displacement Starting Capacities System Cummins 4 cylinder High Idle 1900 199 cu. in 12VDC battery Fuel B3.
INST ALLA TION A4.3 A4.3 V ANT AGE® 500 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.
INST ALLA TION A4.4 A4.4 V ANT AGE® 500 LIFTING The V antage lift bale should be used to lift the machine. The V antage is shipped with the lift bale retracted. Before attempting to lift the V antage, secure the lift bale in a raised position. Secure the lift bale as follows: a.
INST ALLA TION A4.5 A4.5 V ANT AGE® 500 PRE-OPERA TION ENGINE SERVICE READ the engine operating and maintenance instruc- tions supplied with this machine. • Keep hands away from the engine muffler or HOT engine parts. • Stop engine and allow to cool before fueling.
INST ALLA TION A4.6 A4.6 V ANT AGE® 500 IMPORT ANT : T o prevent ELECTRICAL DAMAGE WHEN: a) Installing new batteries b) Using a booster Use correct polarity — Negative Ground.
INST ALLA TION A4.7 A4.7 V ANT AGE® 500 WELDING OUTPUT CABLES With the engine off, route the electrode and work cables through 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 .
INST ALLA TION A4.8 A4.8 V ANT AGE® 500 Figure A4.1 Connection of the V antage to Premises Wiring 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 cus- tomer ’s premises disconnect and service over current protection.
T ABLE OF CONTENTS - OPERA TION SECTION B4.1 B4.1 V ANT AGE® 500 Operation - V ANT AGE® 500 Cummins B3.3 (Code 10996) Operating Instructions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
OPERA TION B4.2 B4.2 V ANT AGE® 500 OPERA TING INSTRUCTIONS Read and understand this entire section before oper- ating your V antage 500. SAFETY INSTRUCTIONS Do not attempt to use this equipment until you have thoroughly read all operating and mainte- nance manuals supplied with your machine.
OPERA TION B4.3 B4.3 V ANT AGE® 500 RECOMMENDED APPLICA TIONS WELDER The V antage 500 provides excellent constant current DC welding output for stick (SMA W) and TIG welding. The V antage 500 also provides excellent constant volt- age DC welding output for MIG (GMAW) and Innershield (FCA W) welding.
OPERA TION B4.4 B4.4 V ANT AGE® 500 ENGINE CONTROLS (Items 1 through 9) 1 . R UN ST O P SW IT CH T oggling 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 .
OPERA TION B4.5 B4.5 V ANT AGE® 500 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.
OPERA TION B4.6 B4.6 V ANT AGE® 500 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.
OPERA TION B4.7 B4.7 V ANT AGE® 500 20. CIRCUIT BREAKERS These circuit breakers provide separate overload current protection for each 120V circuit at the 240V single phase receptacle, each 120V singl.
OPERA TION B4.8 B4.8 V ANT AGE® 500 WELDER OPERA TION DUTY CYCLE Duty Cycle is the the ratio of the uninterrupted on-load duration to 10 minutes. The total time period of one complete on-load and no-load cycle is 10 minutes.
OPERA TION B4.9 B4.9 V ANT AGE® 500 V ANT AGE 500 SETTINGS WHEN USING THE K799 HI-FREQ UNIT • Set the WELD MODE switch to the 20-250 setting (TIG). • Set the IDLER switch to the HIGH position. • Set the WELDING TERMINALS switch to the WELD TERMINALS ON position.
OPERA TION B4.10 B4.10 V ANT AGE® 500 WIRE FEED (CONST ANT VOL T AGE) WELDING Connect a wire feeder to the V antage 500 and set welder controls according to the instructions listed ear- lier in this section.
OPERA TION B4.11 B4.11 V ANT AGE® 500 T ABLE B3.4 – V ANT AGE 500 EXTENSION CORD LENGTH RECOMMENDA TIONS Current (Amps) 15 15 20 20 25 30 38 50 V oltage (V olts) 120 240 120 240 240 240 240 240 Loa.
NOTES B4.12 B4.12 V ANT AGE® 500 Return to Section TOC Return to Section TOC Return to Section TOC Return to Section TOC Return to Master TOC Return to Master TOC Return to Master TOC Return to Maste.
T ABLE OF CONTENTS - ACCESSORIES SECTION C4.1 C4.1 V ANT AGE® 500 Accessories - V ANT AGE® 500 Cummins B3.3 (Code 10996) Options/Accessories . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
ACCESSORIES C4.2 C4.2 V ANT AGE® 500 K802N POWER PLUG KIT - Provides four 120V plugs rated at 20 amps each and one dual voltage, full KV A plug rated at 120/240V , 50 amps.
ACCESSORIES C4.3 C4.3 V ANT AGE® 500 TIG OPTIONS K1783-9 PT A-26V TIG T orch Air Cooled 200 amp torch (2 piece) equipped with valve for gas flow control. 25 ft. (7.6m) length. KP509 Magnum Parts Kit for PT A-26V TIG T orch Magnum Parts Kit provides all the torch accessories you need to start welding.
NOTES C4.4 C4.4 V ANT AGE® 500 Return to Section TOC Return to Section TOC Return to Section TOC Return to Section TOC Return to Master TOC Return to Master TOC Return to Master TOC Return to Master .
T ABLE OF CONTENTS - MAINTENANCE SECTION D4.1 D4.1 V ANT AGE® 500 Maintenance - V ANT AGE® 500 Cummins B3.3 (Code 10996) Safety Precautions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
MAINTENANCE D4.2 D4.2 V ANT AGE® 500 SAFETY PRECAUTIONS • Have qualified personnel do all maintenance and troubleshooting work. • T urn the engine off before working inside the machine. • Remove covers or guards only when necessary to perform maintenance and replace them when the maintenance requiring their removal is com- plete.
MAINTENANCE D4.3 D4.3 V ANT AGE® 500 3. Apply a thin coat of new oil to the rubber gasket on the new oil filter . 4. Spin the new filter onto the mounting adapter finger tight until the gasket is evenly seated. Then turn it down another 1/2 turn. Do not overtighten the new filter .
MAINTENANCE D4.4 D4.4 V ANT AGE® 500 FUEL FIL TERS When working on the fuel system • Keep naked lights away , do not smoke ! • Do not spill fuel ! The V ANT AGE 500 Cummins is equipped with a Fuel Filter/W ater Separator located after the lift pump and before fuel injectors.
MAINTENANCE D4.5 D4.5 V ANT AGE® 500 AIR FIL TER Excessive air filter restriction will result in reduced engine life. 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.
MAINTENANCE D4.6 D4.6 V ANT AGE® 500 MAINTENANCE INSTRUCTIONS Return to Section TOC Return to Section TOC Return to Section TOC Return to Section TOC Return to Master TOC Return to Master TOC Return .
MAINTENANCE D4.7 D4.7 V ANT AGE® 500 WELDER/GENERA TOR MAINTENANCE STORAGE: Store the V antage 500 in clean, dry , pro- tected areas. CLEANING: Blow out the generator and controls peri- odically with low pressure air . Do this at least once a week in particularly dirty areas.
MAINTENANCE D4.8 D4.8 V ANT AGE® 500 BA TTER Y MAINTENANCE GASES FROM BA TTER Y can explode. • Keep sparks, flame, and cigarettes away from battery . BA TTERY ACID can burn eyes and skin. • Wear gloves and eye protection and be careful when working near a battery .
MAINTENANCE D4.9 D4.9 V ANT AGE® 500 WARNING 1 2 4 3 5 7 6A 9 10 OFF FIGURE D.5 – MAJOR COMPONENT LOCA TIONS 1. CONTROL P ANEL ASSEMBL Y 2. CONTROL BOX & OUTPUT ASSEMBL Y 3. POWER MODULE ASSEMBL Y 4. BASE & LIFT BALE ASSEMBL Y 5. FUEL T ANK & MOUNTING 6A.
NOTES D4.10 D4.10 V ANT AGE® 500 Return to Section TOC Return to Section TOC Return to Section TOC Return to Section TOC Return to Master TOC Return to Master TOC Return to Master TOC Return to Maste.
T ABLE OF CONTENTS - INST ALLA TION SECTION A5.1 A5.1 V ANT AGE® 500 Installation - V ANT AGE® 500 Cummins B3.3 (Code 1 1 181, 1 1416) T echnical Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
INST ALLA TION A5.2 A5.2 V ANT AGE® 500 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.
INST ALLA TION A5.3 A5.3 V ANT AGE® 500 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.
INST ALLA TION A5.4 A5.4 V ANT AGE® 500 LIFTING The V antage lift bale should be used to lift the machine. The V antage is shipped with the lift bale retracted. Before attempting to lift the V antage, secure the lift bale in a raised position. Secure the lift bale as follows: a.
INST ALLA TION A5.5 A5.5 V ANT AGE® 500 PRE-OPERA TION ENGINE SERVICE READ the engine operating and maintenance instruc- tions supplied with this machine. • Keep hands away from the engine muf- fler or HOT engine parts. • Stop engine and allow to cool before fueling.
INST ALLA TION A5.6 A5.6 V ANT AGE® 500 IMPORT ANT : T o prevent ELECTRICAL DAMAGE WHEN: a) Installing new batteries b) Using a booster Use correct polarity — Negative Ground.
INST ALLA TION A5.7 A5.7 V ANT AGE® 500 WELDING OUTPUT CABLES With the engine off, route the electrode and work cables through 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 .
INST ALLA TION A5.8 A5.8 V ANT AGE® 500 Figure A5.1 Connection of the V antage to Premises Wiring 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 cus- tomer ’s premises disconnect and service over current protection.
T ABLE OF CONTENTS - OPERA TION SECTION B5.1 B5.1 V ANT AGE® 500 Operation - V ANT AGE® 500 Cummins B3.3 (Codes 1 1 181 & 1 1416) Operating Instructions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
OPERA TION B5.2 B5.2 V ANT AGE® 500 OPERA TING INSTRUCTIONS Read and understand this entire section before oper- ating your V antage 500. SAFETY INSTRUCTIONS Do not attempt to use this equipment until you have thoroughly read all operating and maintenance man- uals supplied with your machine.
OPERA TION B5.3 B5.3 V ANT AGE® 500 RECOMMENDED APPLICA TIONS WELDER The V antage 500 provides excellent constant current DC welding output for stick (SMA W) and TIG welding. The V antage 500 also provides excellent constant volt- age DC welding output for MIG (GMAW) and Innershield (FCA W) welding.
OPERA TION B5.4 B5.4 V ANT AGE® 500 ENGINE CONTROLS (Items 1 through 9) 1 . R UN ST O P SW IT CH T oggling 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 .
OPERA TION B5.5 B5.5 V ANT AGE® 500 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.
OPERA TION B5.6 B5.6 V ANT AGE® 500 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.
OPERA TION B5.7 B5.7 V ANT AGE® 500 20. CIRCUIT BREAKERS These circuit breakers provide separate overload current protection for each 120V circuit at the 240V single phase receptacle, each 120V singl.
OPERA TION B5.8 B5.8 V ANT AGE® 500 WELDER OPERA TION DUTY CYCLE Duty Cycle is the the ratio of the uninterrupted on-load duration to 10 minutes. The total time period of one complete on-load and no-load cycle is 10 minutes.
OPERA TION B5.9 B5.9 V ANT AGE® 500 V ANT AGE 500 SETTINGS WHEN USING THE K799 HI-FREQ UNIT • Set the WELD MODE switch to the 20-250 setting (TIG). • Set the IDLER switch to the HIGH position. • Set the WELDING TERMINALS switch to the WELD TERMINALS ON position.
OPERA TION B5.10 B5.10 V ANT AGE® 500 WIRE FEED (CONST ANT VOL T AGE) WELDING Connect a wire feeder to the V antage 500 and set welder controls according to the instructions listed ear- lier in this section.
OPERA TION B5.11 B5.11 V ANT AGE® 500 SIMUL T ANEOUS WELDING AND AUXILIAR Y POWER LOADS It must be noted that the auxiliary power ratings are with no welding load.
NOTES B5.12 B5.12 V ANT AGE® 500 Return to Section TOC Return to Section TOC Return to Section TOC Return to Section TOC Return to Master TOC Return to Master TOC Return to Master TOC Return to Maste.
T ABLE OF CONTENTS - ACCESSORIES SECTION C5.1 C5.1 V ANT AGE® 500 Accessories - V ANT AGE® 500 Cummins B3.3 (Codes 1 1 181 &1 1416) Options/Accessories . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
ACCESSORIES C5.2 C5.2 V ANT AGE® 500 K802N POWER PLUG KIT - Provides four 120V plugs rated at 20 amps each and one dual voltage, full KV A plug rated at 120/240V , 50 amps.
ACCESSORIES C5.3 C5.3 V ANT AGE® 500 TIG OPTIONS K1783-9 PT A-26V TIG T orch Air Cooled 200 amp torch (2 piece) equipped with valve for gas flow control. 25 ft. (7.6m) length. KP509 Magnum Parts Kit for PT A-26V TIG T orch Magnum Parts Kit provides all the torch accessories you need to start welding.
NOTES C5.4 C5.4 V ANT AGE® 500 Return to Section TOC Return to Section TOC Return to Section TOC Return to Section TOC Return to Master TOC Return to Master TOC Return to Master TOC Return to Master .
T ABLE OF CONTENTS - MAINTENANCE SECTION D5.1 D5.1 V ANT AGE® 500 MAINTENANCE - V ANT AGE 500 CUMMINS (CODE 1 1 181 & 1 1416) Safety Precautions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
MAINTENANCE D5.2 D5.2 V ANT AGE® 500 SAFETY PRECAUTIONS • Have qualified personnel do all maintenance and troubleshooting work. • T urn the engine off before working inside the machine. • Remove covers or guards only when necessary to perform maintenance and replace them when the maintenance requiring their removal is complete.
MAINTENANCE D5.3 D5.3 V ANT AGE® 500 3. Apply a thin coat of new oil to the rubber gasket on the new oil filter . 4. Spin the new filter onto the mounting adapter finger tight until the gasket is evenly seated. Then turn it down another 1/2 turn. Do not overtighten the new filter .
MAINTENANCE D5.4 D5.4 V ANT AGE® 500 FUEL FIL TERS When working on the fuel system • Keep naked lights away , do not smoke ! • Do not spill fuel ! ------------------------------------------------.
MAINTENANCE D5.5 D5.5 V ANT AGE® 500 AIR FIL TER: Excessive air filter restriction will result in reduced engine life. 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.
MAINTENANCE D5.6 D5.6 V ANT AGE® 500 MAINTENANCE INSTRUCTIONS Return to Section TOC Return to Section TOC Return to Section TOC Return to Section TOC Return to Master TOC Return to Master TOC Return .
MAINTENANCE D5.7 D5.7 V ANT AGE® 500 WELDER/GENERA TOR MAINTENANCE STORAGE: Store the V antage 500 in clean, dry , pro- tected areas. CLEANING: Blow out the generator and controls peri- odically with low pressure air . Do this at least once a week in particularly dirty areas.
MAINTENANCE D5.8 D5.8 V ANT AGE® 500 BA TTER Y MAINTENANCE GASES FROM BA TTER Y can explode. • Keep sparks, flame, and cigarettes away from battery . BA TTERY ACID can burn eyes and skin. • Wear gloves and eye protection and be careful when working near a battery .
MAINTENANCE D5.9 D5.9 V ANT AGE® 500 WARNING 1 2 4 3 5 7 6A 9 10 OFF FIGURE D5.4 – MAJOR COMPONENT LOCA TIONS 1. CONTROL P ANEL ASSEMBL Y 2. CONTROL BOX & OUTPUT ASSEMBL Y 3. POWER MODULE ASSEMBL Y 4. BASE & LIFT BALE ASSEMBL Y 5. FUEL T ANK & MOUNTING 6A.
NOTES D5.10 D5.10 V ANT AGE® 500 Return to Section TOC Return to Section TOC Return to Section TOC Return to Section TOC Return to Master TOC Return to Master TOC Return to Master TOC Return to Maste.
T ABLE OF CONTENTS-THEOR Y OF OPERA TION SECTION E-1 E-1 V ANT AGE® 500 Theory of Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .E-1 General Description .
THEOR Y OF OPERA TION E-2 E-2 V ANT AGE® 500 FIGURE E.2 - BA TTER Y , ENGINE, ROTOR, PULL COIL BOARD AND PERIPHERAL BOARD (ENGINE PROTECTION NOTE: Unshaded areas of Block Logic Diagram are the subjec.
THEOR Y OF OPERA TION E-3 E-3 V ANT AGE® 500 FIGURE E.3 - WELD WINDINGS, RECTIFIER, POWER MODULES AND FEEDBACK WELD WINDINGS, RECTIFIER, POWER MODULES AND FEEDBACK The three-phase stator weld windings are connected to a three-phase rectifier bridge.
THEOR Y OF OPERA TION E-4 E-4 V ANT AGE® 500 FIGURE E.4 - POWER MODULES AND WELD CONTROL BOARD WELD CONTROL BOARD The 80 VDC derived from the filter capacitors on the Power Modules, supplies various regulated DC volt- ages to operate the Weld Control PC board circuitry .
THEOR Y OF OPERA TION E-5 E-5 V ANT AGE® 500 INSULA TED GA TE BIPOLAR TRANSIST OR (IGBT) OPERA TION An IGBT is a type of transistor . IGBT s are semicon- ductors well suited for high frequency switching and high current applications. Drawing A in Figure E.
THEOR Y OF OPERA TION E-6 E-6 V ANT AGE® 500 PULSE WIDTH MODULA TION The term PULSE WIDTH MODULA TION is used to describe how much time is devoted to conduction in the cycle.
THEOR Y OF OPERA TION E-7 E-7 V ANT AGE® 500 CHOPPER TECHNOLOGY FUNDAMENT ALS The new era of welding machines such as the V antage 500, employ a technology whereby a DC source is turned on and off (chopped up) at high speed, then smoothed through an inductor to control an arc.
NOTES E-8 E-8 V ANT AGE® 500 Return to Section TOC Return to Section TOC Return to Section TOC Return to Section TOC Return to Master TOC Return to Master TOC Return to Master TOC Return to Master TO.
T ABLE OF CONTENTS - TROUBLESHOOTING AND REP AIR F-1 F-1 V ANT AGE® 500 T roubleshooting and Repair . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .F-1 How to Use T roubleshooting Guide .
TROUBLESHOOTING AND REP AIR F-2 F-2 V ANT AGE® 500 This T roubleshooting Guide is provided to help you locate and repair possible machine malfunctions. Simply follow the three-step procedure listed below . Step 1. LOCA TE PROBLEM (SYMPTOM). Look under the column labeled “PROBLEM (SYMPTOMS)”.
TROUBLESHOOTING AND REP AIR F-3 F-3 V ANT AGE® 500 Sometimes machine failures appear to be due to PC board failures. These problems can sometimes be traced to poor electrical connections. T o avoid prob- lems when troubleshooting and replacing PC boards, please use the following procedure: 1.
OUTPUT PROBLEMS Observe Safety Guidelines detailed in the beginning of this manual. PROBLEMS (SYMPTOMS) POSSIBLE AREAS OF MISADJUSTMENT(S) RECOMMENDED COURSE OF ACTION If for any reason you do not und.
OUTPUT PROBLEMS Observe Safety Guidelines detailed in the beginning of this manual. PROBLEMS (SYMPTOMS) POSSIBLE AREAS OF MISADJUSTMENT(S) RECOMMENDED COURSE OF ACTION If for any reason you do not und.
OUTPUT PROBLEMS Observe Safety Guidelines detailed in the beginning of this manual. PROBLEMS (SYMPTOMS) POSSIBLE AREAS OF MISADJUSTMENT(S) RECOMMENDED COURSE OF ACTION If for any reason you do not und.
FUNCTION PROBLEMS Observe Safety Guidelines detailed in the beginning of this manual. PROBLEMS (SYMPTOMS) POSSIBLE AREAS OF MISADJUSTMENT(S) RECOMMENDED COURSE OF ACTION If for any reason you do not u.
FUNCTION PROBLEMS Observe Safety Guidelines detailed in the beginning of this manual. PROBLEMS (SYMPTOMS) POSSIBLE AREAS OF MISADJUSTMENT(S) RECOMMENDED COURSE OF ACTION If for any reason you do not u.
ENGINE PROBLEMS Observe Safety Guidelines detailed in the beginning of this manual. PROBLEMS (SYMPTOMS) POSSIBLE AREAS OF MISADJUSTMENT(S) RECOMMENDED COURSE OF ACTION If for any reason you do not und.
ENGINE PROBLEMS Observe Safety Guidelines detailed in the beginning of this manual. PROBLEMS (SYMPTOMS) POSSIBLE AREAS OF MISADJUSTMENT(S) RECOMMENDED COURSE OF ACTION If for any reason you do not und.
ENGINE PROBLEMS Observe Safety Guidelines detailed in the beginning of this manual. PROBLEMS (SYMPTOMS) POSSIBLE AREAS OF MISADJUSTMENT(S) RECOMMENDED COURSE OF ACTION If for any reason you do not und.
WELDING PROBLEMS Observe Safety Guidelines detailed in the beginning of this manual. PROBLEMS (SYMPTOMS) POSSIBLE AREAS OF MISADJUSTMENT(S) RECOMMENDED COURSE OF ACTION If for any reason you do not un.
Service and repair should be performed by only Lincoln Electric factory trained personnel. Unauthorized repairs performed on this equipment may result in danger to the technician or machine operator and will invalidate your factory warranty .
FIGURE F .1 – DOOR REMOV AL CASE COVER REMOV AL AND REPLACEMENT PROCEDURE (continued) PROCEDURE 1. T urn the engine off. 2. Using the 3/8" wrench, remove the battery cover . Slide the battery out and disconnect the negative battery cable. 3. Unlatch and open the engine service access door .
Service and repair should be performed by only Lincoln Electric factory trained personnel. Unauthorized repairs performed on this equipment may result in danger to the technician or machine operator and will invalidate your factory warranty .
B1 B2 B3 B4 B5 B6 B7 B8 POWER RESIST OR INSULA TED GLOVE FIGURE F .2 – CHOPPER MODULE CAP ACITOR TERMINAL DISCHARGE CHOPPER MODULE CAP ACIT OR DISCHARGE PROCEDURE (CONTINUED) PROCEDURE 1. Turn engine off. 2. Perform the Case Cover Removal Procedure.
Service and repair should be performed by only Lincoln Electric factory trained personnel. Unauthorized repairs performed on this equipment may result in danger to the technician or machine operator and will invalidate your factory warranty .
B1 B4 B5 B6 B2 B3 87 W8 LEAD W7 LEAD POS LEAD POS LEAD NEG LEAD NEG LEAD 88 PWM Input Present Power at Recitifier Bridge Chopper Operating LED3 LED2 LED1 LXX XX X- X FIGURE F .3 – LEADS & TERMINALS CHOPPER MODULE RESIST ANCE TEST (CONTINUED) PROCEDURE 1.
T ABLE F .1 – CHOPPER TEST T ABLE CHOPPER MODULE RESIST ANCE TEST (CONTINUED) TROUBLESHOOTING AND REP AIR F-19 F-19 V ANT AGE® 500 B5 B6 6k to 9k B6 B5 6k to 9k B4 B5 200k or higher B5 B4 400k or h.
NOTES F-20 F-20 V ANT AGE® 500 Return to Section TOC Return to Section TOC Return to Section TOC Return to Section TOC Return to Master TOC Return to Master TOC Return to Master TOC Return to Master .
Service and repair should be performed by only Lincoln Electric factory trained personnel. Unauthorized repairs performed on this equipment may result in danger to the technician or machine operator and will invalidate your factory warranty .
Shutdown Solenoid Idler Solenoid FIGURE F .4 – IDLER SOLENOID LEAD TERMINALS IDLER SOLENOID TEST PROCEDURE (CONTINUED) TEST PROCEDURE 1. T urn the engine off.
Service and repair should be performed by only Lincoln Electric factory trained personnel. Unauthorized repairs performed on this equipment may result in danger to the technician or machine operator and will invalidate your factory warranty .
Shutdown Solenoid Idler Solenoid FIGURE F .5 – SHUTDOWN SOLENOID SHUTDOWN SOLENOID TEST PROCEDURE TEST PROCEDURE 1. T urn the engine off. 2. Unlatch, lift, and secure the right side engine ser- vice access door .
Service and repair should be performed by only Lincoln Electric factory trained personnel. Unauthorized repairs performed on this equipment may result in danger to the technician or machine operator and will invalidate your factory warranty .
OFF MARK BLOWER PADDLE HERE FIGURE F .6 – STROBE MARK LOCA TION ENGINE THROTTLE ADJUSTMENT TEST PROCEDURE (CONTINUED) PROCEDURE Strobe-tach Method 1. Conduct this procedure with the engine OFF . 2. Unlatch, lift and secure the right side engine ser- vice access door .
Shutdown Solenoid LEFT SIDE Idler Solenoid Adjusting Collar Locking Nut Adjusting Screw Locking Nut FIGURE F .7 – HIGH AND LOW IDLE ADJUSTMENTS - CUMMINS ENGINE ONL Y ENGINE THROTTLE ADJUSTMENT TEST PROCEDURE (CONTINUED) PROCEDURE Frequency Counter Method 1.
ENGINE THROTTLE ADJUSTMENT TEST PROCEDURE (CONTINUED) PROCEDURE Oscilloscope Method 1. Connect the oscilloscope to the 1 15 V AC recepta- cle, according to the manufacturer ’s instructions. At HIGH IDLE (1900 RPM), the waveform should exhibit a period of 15.
Service and repair should be performed by only Lincoln Electric factory trained personnel. Unauthorized repairs performed on this equipment may result in danger to the technician or machine operator and will invalidate your factory warranty .
SLIP RINGS BRUSH HOLDER ASSEMBL Y ACCESS P ANEL FIGURE F .8 – ROTOR BRUSH LEADS ROT OR RESIST ANCE TEST (CONTINUED) PROCEDURE 1. Conduct this test with the engine off. 2. Using the 3/8" wrench, remove the right front case side. 3. Using the 3/8" wrench, remove the brush holder access panel.
Service and repair should be performed by only Lincoln Electric factory trained personnel. Unauthorized repairs performed on this equipment may result in danger to the technician or machine operator and will invalidate your factory warranty .
#200A #200B #201 FIGURE F .9 – ROTOR BRUSH LOCA TION FLASHING AND ROT OR VOL T AGE TEST (CONTINUED) PROCEDURE 1. Using the 3/8" wrench, remove the sheet metal screws from the right front case side. 2. Carefully remove the right case side. 3. Set the volt/ohmmeter to the DC volts position.
Service and repair should be performed by only Lincoln Electric factory trained personnel. Unauthorized repairs performed on this equipment may result in danger to the technician or machine operator and will invalidate your factory warranty .
FIGURE F .10 – FRONT CONTROL P ANEL REMOV AL ST A T OR VOL T AGE TEST (CONTINUED) PROCEDURE 1. T urn the engine off. 2. Using the 3/8" wrench, remove the screws holding the front control panel to the case top and sides. 3. Carefully lower the front control panel.
32 32A 42A 42B 236A CB6 CB5 CB3 CB2 J13 CB1 3C 6D 3D 6 4 3 5C 5E 6B 6C 3B 4A GND-L STATOR LEADS 3A GND-C GND-D 6E 5B J12 J10 GND-E J11 238B Back of Control Panel T ypical 3Ø Auxiliary Machine FIGURE F .
WELD WINDING LEAD CONNECTIONS W1 W6 W3 W2 W5 W4 FIGURE F .12 – OUTPUT RECTIFIER DIODE BRIDGE ST A T OR VOL T AGE TEST (CONTINUED) 1. Locate the weld winding leads connected to the three-phase output rectifier diode bridge. See Figure F .12. 2. Check for approximately 68V AC from: W1/W6 to W2/W3.
Service and repair should be performed by only Lincoln Electric factory trained personnel. Unauthorized repairs performed on this equipment may result in danger to the technician or machine operator and will invalidate your factory warranty .
FIGURE F .13 – DOOR REMOV AL OUTPUT RECTIFIER BRIDGE TEST (CONTINUED) PROCEDURE 1. T urn the engine off. 2. Perform Case Cover Removal Procedure . 3. Perform Chopper Module Capacitor Discharge Procedure . 4. Using the 3/8" wrench, remove the three screws holding the lower front panel (output panel) to the case front assembly .
WELD WINDING LEAD CONNECTIONS W1 W6 W3 W2 W5 W4 FIGURE F .14 – DIODE LEAD REMOV AL OUTPUT RECTIFIER BRIDGE TEST (CONTINUED) 9. Using the 7/16” wrench, remove the stator leads from the three AC terminals. Label leads for reassembly . Note leads and AC terminals place- ment for reassembly .
OUTPUT RECTIFIER BRIDGE TEST (CONTINUED) TROUBLESHOOTING AND REP AIR F-40 F-40 V ANT AGE® 500 FIGURE F .15 – DIODE LEAD REMOV AL AC 1 + - D.C. D.C. 1 2 3 AC DC+ DC- + - AC 1,2,3 1 2 3 Return to Sec.
OUTPUT RECTIFIER BRIDGE TEST (CONTINUED) TROUBLESHOOTING AND REP AIR F-41 F-41 V ANT AGE® 500 T ABLE F .2 – DIODE TEST T ABLE AC1 DC(+) Forward Bias (Low Resistance) AC2 DC(+) Forward Bias (Low Res.
NOTES F-42 F-42 V ANT AGE® 500 Return to Section TOC Return to Section TOC Return to Section TOC Return to Section TOC Return to Master TOC Return to Master TOC Return to Master TOC Return to Master .
Service and repair should be performed by only Lincoln Electric factory trained personnel. Unauthorized repairs performed on this equipment may result in danger to the technician or machine operator and will invalidate your factory warranty .
ELECTRONIC GOVERNOR TEST (CONTINUED) TEST PROCEDURE CHECK CONTROLLER 1. T urn the Run/Stop switch to Run. Do not start engine. 2. The engine protection light should be ON for 5 sec- onds then go out. 3. After 30 additional seconds the light should come back on.
Service and repair should be performed by only Lincoln Electric factory trained personnel. Unauthorized repairs performed on this equipment may result in danger to the technician or machine operator and will invalidate your factory warranty .
#239 #281 #238 FIGURE F .16 – ENGINE AL TERNA TOR LOCA TION (DEUTZ 10995) CHARGING CIRCUIT TEST (CONTINUED) PROCEDURE 1. T urn engine off. 2. Using the 3/8" wrench, remove the left rear case cover . (remove right rear case cover for Cummins engine 10996) 3.
This is the typical auxiliary output volt- age generated from a properly operat- ing machine. Note that each vertical division represents 50 volts and that each horizontal division represents 5 milliseconds in time. Note: Scope probes connected at machine 1 15V AC receptacle.
0 volts 50V 5ms This is the typical DC open circuit out- put voltage generated from a properly operating machine in the Constant Current (CC)mode. Note that each vertical division repre- sents 50 volts and that each horizon- tal division represents 5 milliseconds in time.
0 volts 20V 0.1ms This is the typical DC output voltage generated from a properly operating machine in the Constant Current (CC) mode. Note that each vertical division repre- sents 20 volts and that each horizon- tal division represents 0.1 millisec- onds in time.
0 volts 10V 5 µs This is the typical output voltage gen- erated from a properly operating machine in the TIG Mode. Note that each vertical division repre- sents 10 volts and that each horizontal division represents 50 microseconds in time. The machine was loaded with a resis- tance grid bank to 200 amps at 16 VDC.
0 volts 50V 5MS This is the typical auxiliary output volt- age generated from a properly operat- ing machine in the CV mode. Note that each vertical division repre- sents 50 volts and that each horizontal division represents 5 milliseconds in time. SCOPE SETTINGS V olts/Div .
0 volts 20V 0.1ms This is the typical DC output voltage generated from a properly operating machine in the Constant V oltage (CV) mode. Note that each vertical division repre- sents 20 volts and that each horizon- tal division represents 5 milliseconds in time.
Service and repair should be performed by only Lincoln Electric factory trained personnel. Unauthorized repairs performed on this equipment may result in danger to the technician or machine operator and will invalidate your factory warranty .
Leads 262, 232M, 265 FIGURE F .17 – SHUTDOWN SOLENOID LEAD CONNECTIONS SHUTDOWN SOLENOID REMOV AL AND REPLACEMENT (DEUTZ) PROCEDURE 1. T urn engine off. 2. Unlatch, lift and secure the engine access door . 3. Locate and remove the spade connectors that attach the shutdown solenoid terminals to the wiring harness leads.
Shutdwn Solenoid Idler Solenoid LEADS 262 232M 265 FIGURE F .18 – SHUTDOWN SOLENOID LINKAGE ARM ASSEMBL Y SHUTDOWN SOLENOID REMOV AL AND REPLACEMENT (CUMMINS) PROCEDURE 1.
NOTES F-56 F-56 V ANT AGE® 500 Return to Section TOC Return to Section TOC Return to Section TOC Return to Section TOC Return to Master TOC Return to Master TOC Return to Master TOC Return to Master .
Service and repair should be performed by only Lincoln Electric factory trained personnel. Unauthorized repairs performed on this equipment may result in danger to the technician or machine operator and will invalidate your factory warranty .
OUTPUT RECTIFIER BRIDGE 2 7/16" BOL TS 2 7/16" BOL TS 2 1/2" NUTS CHOPPER MODULES (2) HEA TSINKS FIGURE F .19 – DOOR REMOV AL OUTPUT RECTIFIER REMOV AL AND REPLACEMENT PROCEDURE (continued) PROCEDURE 1. T urn the engine off. 2. Perform the output panel removal as described in the Case Cover Removal procedure.
Service and repair should be performed by only Lincoln Electric factory trained personnel. Unauthorized repairs performed on this equipment may result in danger to the technician or machine operator and will invalidate your factory warranty .
PLUG FUEL LINES U-BOL TS (2 ) LEADS #229 AND #242D { FIGURE F .20 – FUEL T ANK REMOV AL DET AILS ST A T OR/ROTOR REMOV AL AND REPLACEMENT (CONTINUED) PROCEDURE Refer to Figure F .20. 1. T urn the engine off and disconnect battery leads and drain fuel.
#201A 6 #200D #4 FIL TER CAP ACITOR FIELD DIODE RECTIFIER BRIDGE FIGURE F .21 – PLUG J52/FIL TER CAP ACITOR/FIELD RECTIFIER BRIDGE DISCONNECTION ST A T OR/ROTOR REMOV AL AND REPLACEMENT (CONTINUED) 1 1.
CONTROL BOX PULL COIL PC BOARD (LEADS #265 & #227 12 VDC STUD LEADS #232L & #232M FIGURE F .22 – BRUSH HOLDER AND LEAD REMOV AL ST A T OR/ROTOR REMOV AL AND REPLACEMENT (CONTINUED) PROCEDURE 1. T urn the engine off. 2. Using the 3/8" wrench, remove the battery cover .
6 SCREWS SHROUD ACOUSTICAL FOAM FIGURE F .24 – DOOR REMOV AL ST A T OR/ROTOR REMOV AL AND REPLACEMENT (CONTINUED) 18. See Figure F .24. With the 5/16" wrench, remove the six screws that hold the top and bottom of the alternator shroud together .
CENTER P ANEL LIFT FRAME WELDMENT BASE FUEL T ANK SUPPORTS F AN BAFFLE FIGURE F .25 – LIFT FRAME AND ASSOCIA TED COMPONENT REMOV AL ST A T OR/ROTOR REMOV AL AND REPLACEMENT (CONTINUED) In steps 20 – 24, the lift frame weldment, fuel tank sup- ports, and fan baffle are removed as a unit.
BOL TS (4) F AN HUB MOUNTING FOOT FL YWHEEL SPLASH PLA TE F AN NU T ST A TOR / ENGINE MOUNTING BOL TS & LOCK W ASHERS BEARING FIGURE F .26 – ST A TOR REMOV AL ST A T OR/ROTOR REMOV AL AND REPLACEMENT (CONTINUED) PROCEDURE First, cut any necessary cable ties in order to free the stator leads from the bundle of leads running to the control box.
FLEX PLA TE BLOWER SEGMENT (4) ROT OR FIGURE F .27 – ROTOR REMOV AL ST A T OR/ROTOR REMOV AL AND REPLACEMENT (CONTINUED) PROCEDURE Refer to Figure F .27 for rotor removal. 1. Support the rotor with the hoist. 2. Using the 5/8" wrench, remove the flex plate bolts, lock washers, and four blower segments.
ST A T OR/ROTOR REMOV AL AND REPLACEMENT (CONTINUED) LEAD RECONNECTION CHECKLIST ENGINE n Leads #5I and #229 to fuel level sensor n Brush leads #201(-) and #200B(+) n Leads #5H, and #201A, #200, #200A.
TROUBLESHOOTING AND REP AIR F-68 F-68 V ANT AGE® 500 RETEST AFTER REP AIR Retest a machine: • If it is rejected under test for any reason that requires you to remove any mechanical part which could af fect the machine’s electrical characteristics.
TROUBLESHOOTING AND REP AIR F-69 F-69 V ANT AGE® 500 RETEST AFTER REP AIR (CONTINUED) TOUCH ST ART TIG MODE OUTPUT Mode Selector Open Circuit Short Circuit Switch Fine Control V oltage Current TIG 20.
NOTES F-70 F-70 V ANT AGE® 500 Return to Section TOC Return to Section TOC Return to Section TOC Return to Section TOC Return to Master TOC Return to Master TOC Return to Master TOC Return to Master .
T ABLE OF CONTENTS - DIAGRAM SECTION G-1 G-1 V ANT AGE® 500 Electrical Diagrams . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .G-1 Wiring Diagram (G4342 Code 10995 Deutz) .
ELEcTricaL DiaGramS G-2 v aNT aGE® 500 WiriNG DiaGram - v aNT aGE®500 - G4342 (cODE 1 1095 DEuTz) O UTP UT CO NT R OL C CW RE CTI FIE R B RI D GE HOU R M ETER ALT 75 PIN C H P OT 278 SILVER - 232 R .
ELEcTricaL DiaGramS G-3 v aNT aGE® 500 WiriNG DiaGram - v aNT aGE® 500 - G4329 (cODE 10996) C B6 10A 42A 42 RE CTI FIE R B RI D GE 238A 231 42A 41A 243 232 41 START B UTT ON 238 222 MOD E SELECTO R .
ELEcTricaL DiaGramS G-4 v aNT aGE® 500 WiriNG DiaGram - v aNT aGE® 500 - G4847 (cODES 1 1 180,1 1415 & 1 1468) C B6 10A 42A 42 RE CTI FIE R B RI D GE 42A 41A 41 222 MOD E SELECTO R SW ITC H 206A.
ELEcTricaL DiaGramS G-5 v aNT aGE® 500 WiriNG DiaGram - v aNT aGE® 500 - G4971 (cODES 1 1 181 &1 1416) C B6 10A 42A 42 RE CTI FIE R B RI D GE 42A 41A 243 232 41 START B UTT ON 238 222 M OD E SEL.
ELEcTricaL DiaGramS G-6 v aNT aGE® 500 SchEma Tic - cOmpLETE machiNE - G4363 (cODE 10995 DEuTz) p aGE 1 G 4363 E NGI N EE RI NG CO NT RO LLE D MA NU FA CT U RE R: No R EL EASE D F R OM X A.
ELEcTricaL DiaGramS G-7 v aNT aGE® 500 SchEma Tic - cOmpLETE machiNE - G4363 (cODE 10995 DEuTz) p aGE 2 E N -1 7 0 G 4363 E NGI N EE RI NG CO NT RO LLE D MA NU FA CT U RE R: No R EL EASE D F R OM X A.
ELEcTricaL DiaGramS G-8 v aNT aGE® 500 SchEma Tic - cOmpLETE machiNE - G4442 (cODE 10996 cummiNS) p aGE1 G 4442 E NGI N EE RI NG CO NT RO LLE D MA NU FA CT U RE R: No R EL EASE D F R OM X A.
ELEcTricaL DiaGramS G-9 v aNT aGE® 500 SchEma Tic - cOmpLETE machiNE - G4442 (cODE 10996 cummiNS) p aGE 2 G 4442 E NGI N EE RI NG CO NT RO LLE D MA NU FA CT U RE R: No R EL EASE D F R OM X A.
ELEcTricaL DiaGramS G-10 v aNT aGE® 500 SchEma Tic - cOmpLETE machiNE - G4848 (cODES 1 1 180, 1 1415 & 1 1468 DEuTz) p aGE 1 G4848 VA NTA GE 500 DE UT Z MAC HI N E SC HEM ATIC NONE G4487 B.
ELEcTricaL DiaGramS G-11 v aNT aGE® 500 SchEma Tic - cOmpLETE machiNE - G4848 (cODES 1 1 180, 1 1415 & 1 1468 DEuTz) p aGE 2 G4848 VA NTA GE 500 DE UT Z MAC HI N E SC HEM ATIC NONE G4487 B.
ELEcTricaL DiaGramS G-12 v aNT aGE® 500 SchEma Tic - cOmpLETE machiNE - G4791 (cODES 1 1 181 & 1 1416 cummiNS) p aGE 1 G-12 NOTE: This diagram is for reference only .
ELEcTricaL DiaGramS G-13 v aNT aGE® 500 SchEma Tic - WELD cONTrOL BOarD - G4108 p aGE 1 G-13 NOTE: This diagram is for reference only . It may not be accurate for all machines covered by this manual.
ELEcTricaL DiaGramS G-14 v aNT aGE® 500 SchEma Tic - WELD cONTrOL BOarD - G4801-1 p aGE 2 G-14 NOTE: This diagram is for reference only . It may not be accurate for all machines covered by this manual.
ELEcTricaL DiaGramS G-15 v aNT aGE® 500 SchEma Tic - WELD cONTrOL BOarD - G4801-1 p aGE 3 G-15 NOTE: This diagram is for reference only . It may not be accurate for all machines covered by this manual.
ELEcTricaL DiaGramS G-16 v aNT aGE® 500 SchEma Tic - WELD cONTrOL BOarD - G4801-1 p aGE 4 G-16 NOTE: This diagram is for reference only . It may not be accurate for all machines covered by this manual.
ELEcTricaL DiaGramS G-17 v aNT aGE® 500 SchEma Tic - WELD cONTrOL BOarD - p aGE 5 G-17 NOTE: This diagram is for reference only . It may not be accurate for all machines covered by this manual.
ELEcTricaL DiaGramS G-18 v aNT aGE® 500 SchEma Tic - chOppEr pc BOarD - m19792-1 G-18 NOTE: This diagram is for reference only . It may not be accurate for all machines covered by this manual.
ELEcTricaL DiaGramS G-19 v aNT aGE® 500 SchEma Tic - pEriphEraL BOarD - G3663 G-19 NOTE: This diagram is for reference only . It may not be accurate for all machines covered by this manual.
ELEcTricaL DiaGramS G-20 v aNT aGE® 500 SchEma Tic puLL cOiL/Ba TTEr y BOarD - G41 17-1 G-20 NOTE: This diagram is for reference only . It may not be accurate for all machines covered by this manual.
An important point after buying a device Lincoln Electric SVM178-B (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 SVM178-B 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 SVM178-B - thus you can check whether the hardware meets your expectations. When delving into next pages of the user manual, Lincoln Electric SVM178-B you will learn all the available features of the product, as well as information on its operation. The information that you get Lincoln Electric SVM178-B will certainly help you make a decision on the purchase.
If you already are a holder of Lincoln Electric SVM178-B, 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 SVM178-B.
However, one of the most important roles played by the user manual is to help in solving problems with Lincoln Electric SVM178-B. Almost always you will find there Troubleshooting, which are the most frequently occurring failures and malfunctions of the device Lincoln Electric SVM178-B 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
