Lincoln Electric VANTAGE 500 CUMMINS 500 Operator'S Manual Download Page 1

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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 •

OPERATOR’S MANUAL

July, 2007

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.

NOT INSTALL, OPERATE
OR REPAIR THIS EQUIP-
MENT WITHOUT READING
THIS MANUAL AND THE
SAFETY

PRECAUTIONS

CONTAINED THROUGHOUT.

Most importantly, think before
you act and be careful.

IM873-A

For use with machines having Code Numbers:

11181, 11416

VANTAGE 500 CUMMINS

Summary of Contents for VANTAGE 500 CUMMINS 500

Page 1: ...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...

Page 2: ...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...

Page 3: ...er 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...

Page 4: ...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 sp...

Page 5: ...appropri s et non inflammables 4 Des gouttes de laitier en fusion sont mises de l arc de soudage Se prot ger avec des v tements de protection libres de l huile tels que les gants en cuir chemise paiss...

Page 6: ...mportant 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...

Page 7: ...mises 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 C...

Page 8: ...ions D 1 Routine and Periodic Maintenance D 1 Engine Maintenance D 1 Air Filter D 1 D 2 Fuel Filters D 3 Cooling System D 3 Battery Handling D 3 Charging the Battery D 4 Nameplate Warning Decal Mainte...

Page 9: ...mps 100 500 Amps DC multi purpose 40 Volts 60 550 Amps DC multi purpose 36 volts 50 575 Amps DC multi purpose 35 volts PHYSICAL DIMENSIONS Height 2 Width Depth Weight 42 0 in 31 5 in 63 1 in 1443lbs 1...

Page 10: ...e area DO NOT MOUNT OVER COMBUSTIBLE SUR FACES Where there is a combustible surface directly under stationary or fixed electrical equipment that surface should be covered with a steel plate at least 0...

Page 11: ...that may be required TOWING The recommended trailer for use with this equipment for road in plant and yard towing by a vehicle 1 is Lincoln s K953 1 If the user adapts a non Lincoln trailer he must as...

Page 12: ...en INSTALLING A NEW BATTERY disconnect negative cable from old battery first and connect to new bat tery last A 4 INSTALLATION VANTAGE 500 CUMMINS A 4 PRE OPERATION ENGINE READ the engine operating an...

Page 13: ...TERMINALS The VANTAGE 500 CUMMINS is equipped with a toggle switch for selecting hot welding terminals when in the WELD TERMINALS ON position or cold welding termi nals when in the REMOTELY CONTROLLED...

Page 14: ...peres at unity power factor The maximum per missible current of the 240 VAC output is 50 A The 240 VAC single phase output can be split to provide two separate 120 VAC outputs with a maximum per missi...

Page 15: ...esired length The 50 amp 120 240 VAC plug is available in the optional K802N or K802R plug kits or by itself as T12153 9 4 Plug this cable into the 50 Amp 120 240 Volt recep tacle on the VANTAGE 500 C...

Page 16: ...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...

Page 17: ...al contactor the electrode is not energized until the gun trigger is closed If you are using an LN 25 without an internal con tactor the electrode will be energized when the VANTAGE 500 CUMMINS is sta...

Page 18: ...ys operate the welder with the Engine door closed and the side panels in place as these pro vide maximum protection from moving parts and insure proper cooling air flow GENERAL DESCRIPTION The VANTAGE...

Page 19: ...his can cause dam age to the ring gear and or starter motor 3 HOUR METER The hour meter displays the total time that the engine has been running This meter is a useful indi cator for scheduling preven...

Page 20: ...p switch is in the run position 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 position the idler op...

Page 21: ...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...

Page 22: ...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 R...

Page 23: ...g 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...

Page 24: ...zzle mm in Tungsten Tungsten Size 4 5 25 0 010 2 15 3 2 4 3 8 2 4 3 8 4 5 6 50 0 020 5 20 3 3 5 5 10 3 5 5 10 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 1...

Page 25: ...n testing and resetting the GFCI receptacle Start the engine and set the IDLER control switch to the desired operating mode Full power is available regardless of the welding control settings if no wel...

Page 26: ...75 150 125 53 107 42 84 69 53 46 38 300 600 225 450 250 300 250 200 91 183 69 137 76 91 76 61 Maximum Allowable Cord Length in ft m for Conductor Size Conductor size is based on maximum 2 0 voltage dr...

Page 27: ...ight Kit K2640 1 Cable Rack K887 1 ETHER START KIT Provides maximum cold weath er starting assistance for frequent starting below 10 12 C Required Ether tank is not provided with kit K1847 1 SPARK ARR...

Page 28: ...05 T AC DC One Pak Package For AC TIG welding with square wave performance use the AC generator of the engine driven welder to supply the power Easy setup Includes torch parts kit regulator and hose k...

Page 29: ...nds Repeat the above drainage procedure until diesel fuel is detected in the container Check coolant level WEEKLY Blow out the machine with low pressure air periodical ly In particularly dirty locatio...

Page 30: ...the job of seating the filter but it will not Using the latches to push the filter in could cause damage to the housing and will void the warranty Donaldson filters with RadialSeal Sealing Technology...

Page 31: ...ect negative cable from old bat tery first and connect to new battery last CONNECTING A BATTERY CHARGER Remove battery from welder by dis connecting negative cable first then positive cable and batter...

Page 32: ...ctions of the battery charger manu facturer for proper charger settings and charging time NAMEPLATES WARNING DECALS MAIN TENANCE Whenever routine maintenance is performed on this machine or at least y...

Page 33: ...for this receptacle must not be tripped Reset if necessary Push the Reset button located on the GFCI recep tacle This will assure normal GFCI operation Plug a night light with an ON OFF switch or othe...

Page 34: ...SIBLE CAUSE lists the obvious external possibilities that may contribute to the machine symptom Step 3 RECOMMENDED COURSE OF ACTION This column provides a course of action for the Possible Cause gener...

Page 35: ...Service Shop 1 Out of fuel 2 Fuel shut off valve is in the off position make sure the valve lever is in the open position lever in line with the Hose 3 Engine shut down solenoid not pulling in 4 On Of...

Page 36: ...lty engine alternator 3 Loose or broken lead in charging circuit 4 Loose fan belt may need tighten ing 1 Idler switch in HIGH idle position make sure switch is set to AUTO 2 External load on welder or...

Page 37: ...eld Control PCB or electronic governor controller 1 Broken lead in rotor circuit 2 Faulty field diode module 3 Faulty Weld Control PCB 4 Faulty rotor 1 Faulty remote kit 2 Faulty output control potent...

Page 38: ...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...

Page 39: ...F 2 CONNECTION DIAGRAMS F 2 VANTAGE 500 CUMMINS...

Page 40: ...N 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 VOLT...

Page 41: ...F 4 CONNECTION DIAGRAMS F 4 VANTAGE 500 CUMMINS...

Page 42: ...F 5 CONNECTION DIAGRAMS F 5 VANTAGE 500 CUMMINS...

Page 43: ...REASE 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 FE...

Page 44: ...F 7 CONNECTION DIAGRAMS F 7 VANTAGE 500 CUMMINS...

Page 45: ...F 8 CONNECTION DIAGRAMS F 8 VANTAGE 500 CUMMINS...

Page 46: ...F 9 CONNECTION DIAGRAMS F 9 VANTAGE 500 CUMMINS...

Page 47: ...F 10 CONNECTION DIAGRAMS F 10 VANTAGE 500 CUMMINS...

Page 48: ...F 11 CONNECTION DIAGRAMS F 11 VANTAGE 500 CUMMINS...

Page 49: ...F 12 CONNECTION DIAGRAMS F 12 VANTAGE 500 CUMMINS...

Page 50: ...IATOR 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 3 32 08 814 8 33 53 851 7 42 35 1075 7 50 15 1273 8 16 85 428 63 10 1602 7 6 56 166 6 6 55 166 4 14 63 371 6 37 30...

Page 51: ...NOTES VANTAGE 500 CUMMINS...

Page 52: ...electrically live parts or electrode with skin or wet clothing Insulate yourself from work and ground No toque las partes o los electrodos bajo carga con la piel o ropa moja da Aislese del trabajo y...

Page 53: ...e Be und Entl ftung des Arbeitsplatzes Mantenha seu rosto da fuma a Use ventila o e exhaust o para remover fumo da zona respirat ria Turn power off before servicing Desconectar el cable de ali mentaci...

Page 54: ...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 Pr...

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