Lincoln VANTAGE 500 User Manual

Vantage 500 CUMMINS

RETURN TO MAIN MENU

For use with machines having Code Numbers: 10996

Safety Depends on You

Lincoln arc welding and cutting
equipment is designed and
built with safety in mind.
However, your overall safety
can be increased by proper
installation . . . and thoughtful
operation on your part. DO

NOT INSTALL, OPERATE OR
REPAIR THIS EQUIPMENT
WITHOUT READING THIS
MANUAL AND THE SAFETY
PRECAUTIONS CONTAINED
THROUGHOUT. Most

importantly, think before you
act and be careful.

IM800

July, 2004

Cleveland, Ohio 44117-1199 USA Tel: [phone] Fax: [phone] Web Site: www.lincolnelectric.com

OPERATOR’S MANUAL

Copyright© 2004 Lincoln Global Inc.

• World’s Leader in Welding and Cutting Products •

• Sales and Service through Subsidiaries and Distributors Worldwide •

i SAFETY i

WARNING

CALIFORNIA PROPOSITION 65 WARNINGS

For Diesel Engines: diesel engine exhaust and
some of its constituents are known to the State of
California to cause cancer, birth defects, and other
reproductive harm.

ARC WELDING CAN BE HAZARDOUS. PROTECT YOURSELF AND OTHERS FROM POSSIBLE SERIOUS INJURY OR DEATH.
KEEP CHILDREN AWAY. PACEMAKER WEARERS SHOULD CONSULT WITH THEIR DOCTOR BEFORE OPERATING.

For Gasoline Engines: The engine exhaust from this
product contains chemicals known to the State of
California to cause cancer, birth defects, or other
reproductive harm.

Read and understand the following safety highlights. For additional safety information, it is strongly recommended that you
purchase a copy of “Safety in Welding & Cutting - ANSI Standard Z49.1” from the American Welding Society, PO Box
351040, Miami, Florida 33135 or CSA Standard W117.2-1974 or WTIA (Welding Technology Institute of Australia), PO Box
6165, Silverwater, NSW, 2128. A free copy of “Arc Welding Safety” booklet E205 is available from the Lincoln Electrical
Company, 22801 St Clair Avenue, Cleveland, Ohio 44117-1199.

BE SURE THAT ALL INSTALLATION, OPERATION, MAINTENANCE AND REPAIR PROCEDURES ARE
PERFORMED ONLY BY QUALIFIED INDIVIDUALS.

FOR ENGINE
powered equipment.

1.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.

1.h. To avoid scalding, do not remove the
radiator pressure cap when the engine is
hot.

ELECTRIC AND
MAGNETIC FIELDS
may be dangerous

1.c. Do not add fuel near an open flame, welding
arc or when the engine is running. Stop the
engine and allow it to cool before refuelling
to prevent spilled fuel from vaporizing on
contact with hot engine parts and igniting.
Do not spill fuel when filling tank. If fuel is
spilled, wipe it up and do not start engine
until fumes have been eliminated.

1.d.Keep all equipment, safety guards, covers and devices in
position and in good repair. Keep hands, hair, clothing and
tools away from V-belts, gears, fans and all other moving
parts when starting, operating or repairing equipment.

1.e.In some cases it may be necessary to remove safety guards
to perform required maintenance. Remove guards only when
necessary and replace them when the maintenance
requiring their removal is complete. Always use the greatest
care when working near moving parts.

1.f. Do not put your hands near the engine fan.
Do not attempt to override the governor or
idler by pushing on the throttle control rods
while the engine is running.

1.g.To prevent accidentally starting petrol engines while turning
the engine or welding generator during maintenance work,
disconnect the spark plug wires, distributor cap or magneto
wire as appropriate.

2.a.Electric current flowing through any conductor causes
localized Electric and Magnetic Fields (EMF). Welding
current creates EMF fields around welding cables and
welding machines.

2.b.EMF fields may interfere with some pacemakers and welders
having a pacemaker should consult their physician before
welding.

2.c. Exposure to EMF fields in welding may have other health
effects which are now not known.

2.d.All welders should use the following procedures in order to
minimize exposure to EMF fields from the welding circuit:

2.d.1. Route the electrode and work cables together.

Secure them with tape when possible.

2.d.2. Never coil the electrode lead around your body.

2.d.3. Do not place your body between the electrode

and work cables. If the electrode cable is on your
right side, the work cable should also be on your
right side.

2.d.4. Connect the work cable to the workplace as

close as possible to the area being welded.

2.d.5. Do not work next to welding power source.

Mar ‘95

ii SAFETY ii

ELECTRIC SHOCK
can kill.

3.a. The electrode and work (or ground) circuits
are electrically “hot” when the welder is on.
Do not touch these “hot” parts with your bare
skin or wet clothing. Wear dry, hole-free
gloves to insulate hands.

3.b. Insulate yourself from work and ground using dry
insulation. Make certain the insulation is large enough to
cover your full area of physical contact with work and
ground.

In addition to the normal safety precautions, if welding
must be performed under electrically hazardous
conditions (in damp locations or while wearing wet
clothing; on metal structures such as floors, gratings
or scaffolds; when in cramped positions such as
sitting, kneeling or lying, if there is a high risk of
unavoidable or accidental contact with the workpiece
or ground) use the following equipment:

• Semiautomatic DC Constant V

• DC Manual (Stick) Welder.

• AC Welder with Reduced Voltage Control.

3.c. In semi-automatic or automatic wire welding, the
electrode, electrode reel, welding head, nozzle or semi­automatic welding gun are also electrically “hot”.

Always be sure the work cable makes a good electrical

3.d.
connection with the metal being welded. The connection
should be as close as possible to the area being welded.

3.e. Ground the work or metal to be welded to a good electrical
(earth) ground.

3.f. Maintain the electrode holder, work clamp, welding cable
and welding machine in good, safe operating condition.
Replace damaged insulation.

3.g. Never dip the electrode holder in water for cooling.

3.h. Never simultaneously touch electrically “hot” parts of
electrode holders connected to two welders because
voltage between the two can be the total of the open circuit
voltage of both welders.

3.i. When working above floor level, use a safety belt to
protect yourself from a fall should you get a shock.

3.j. Also see items 6c and 8.

oltage (Wire) Welder.

ARC RAYS can burn.

4 a Use a shield with the proper filter and cover

plates to protect your eyes from sparks and
the rays of the arc when welding or
observing open arc welding. Headshield
and filter lens should conform to ANSI
Z87.1 standards.

4.b.Use suitable clothing made from durable flame resistant
material to protect your skin and that of your helpers from the
arc rays.

4.c. Protect other nearby personnel with suitable non flammable
screening and/or warn them not to watch the arc or expose
themselves to the arc rays or to hot spatter or metal.

FUMES AND GASES
can be dangerous

5.a. Welding may produce fumes and gases
hazardous to health. Avoid breathing these
fumes and gases. When welding, keep your
head out of the fume. Use enough

keep fumes and gases away from the breathing zone. When

welding with electrodes which require special ventilation
such as stainless or hard facing (see instructions on
container or MSDS) or on lead or cadmium plated steel and
other metals or coatings which produce highly toxic fumes,
keep exposure as low as possible and below Threshold
Limit values (TLV) using local exhaust or mechanical
ventilation. In confined spaces or in some circumstances,
outdoors, a respirator may be required. Additional
precautions are also required when welding on galvanized
steel.

5.b.Do not weld in locations near chlorinated hydrocarbon
vapors coming from degreasing, cleaning or spraying
operations.
solvent vapors to form phosgene, a highly toxic gas, and
other irritating products.

5.c. Shielding gases used for arc welding can displace air and
cause injury or death. Always use enough ventilation,
especially in confined areas, to ensure breathing air is safe.

5.d.Read and understand the manufacturer’s instructions for this
equipment and the consumables to be used, including the
material safety data sheet (MSDS) and follow your
employer’s safety practices. MSDS forms are available from
your welding distributor or from the manufacturer.

5.e.Also see Item 1b.

ventilation and/or exhaust at the arc to

The heat and rays of the arc can react with

Mar ‘95

iii SAFETY iii

WELDING SPARKS can
cause fire or explosion

6 a Remove fire hazards from the welding area. If

this is not possible, cover them to prevent the
welding sparks from starting a fire. Remember

that welding sparks and hot materials from
welding can easily go through small cracks and openings to
adjacent areas. Avoid welding near hydraulic lines. Have a fire
extinguisher readily available.

6.b.Where compressed gases are to be used at the job site,

special precautions should be used to prevent hazardous
situations. Refer to AS1674 Parts 1 & 2 “Safety in Welding
and Cutting” (ANSI Standard Z49.1) and the operating
information for the equipment being used.

6.c. When not welding, make certain no part of the electrode

circuit is touching the work or ground. Accidental contact can
cause overheating and create a fire hazard.

6.d.Do not heat, cut or weld tanks, drums or containers until the

proper steps have been taken to insure that such procedures
will not cause flammable or toxic vapors from substances
inside. These can cause an explosion even though the
vessel has been “cleaned”. For information purchase
“Recommended Safe Practices for the Preparation for
Welding and Cutting of Containers and Piping that have held
Hazardous Substances”, AWS F4.1 from the American
Welding Society (see address above).

6.e.Vent hollow castings or containers before heating, cutting or

welding. They may explode.

6.f. Sparks and spatter are thrown from the welding arc. Wear oil

free protective garments such as leather gloves, heavy shirt,
cuffless trousers, high shoes and a cap over your hair. Wear
ear plugs when welding out of position or in confined places.
Always wear safety glasses with side shields when in a
welding area.

6.g.Connect the work cable to the work as close to the welding

area as possible. Work cables connected to the building
framework or other locations away from the welding area
increase the possibility of the welding current passing
through lifting chains, crane cables or other alternate circuits.
This can create fire hazards or overheat lifting chains or
cables until they fail.

6.h.Also see Item 1c.

CYLINDER may explode
if damaged

7.a. Use only compressed gas cylinders containing
the correct shielding gas for the process used
and properly operating regulators, designed
for the gas and pressure used. All hoses,

fittings, etc. should be suitable for the application and
maintained in good condition.

7.b.Always keep cylinders in an upright position and securely
chained to an undercarriage or fixed support.

7.c. Cylinders should be located :

• Away from areas where they may be struck or subjected to

physical damage.

• A safe distance from arc welding or cutting operations and

any other source of heat, sparks or flame.

7.d.Never allow the electrode, electrode holder, or any other
electrically “hot” parts to touch a cylinder.

7.e.Keep your head and face away from the cylinder valve outlet
when opening the cylinder valve.

7.f. Valve protection caps should always be in place and hand­tight except when the cylinder is in use or connected for use.

7.g.Read and follow the instructions on compressed gas
cylinders, associated equipment, and CGA publication P-I,
“Precautions for Safe Handling of Compressed Gases in
Cylinders”, available from the Compressed Gas Association
1235 Jefferson Davis Highway, Arlington, VA 22202.

FOR ELECTRICALLY
powered equipment.

8.a. Turn off input power using the disconnect
switch at the fuse box before working on the
equipment.

8.b.Install equipment in accordance with the National Electrical
Code, all local codes and the manufacturer’s
recommendations.

8.c. Ground the equipment in accordance with the National
Electrical Code and the manufacturer’s recommendations.

Mar ‘95

iv SAFETY 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
suivantes:

Sûreté Pour Soudage A L’Arc

1. Protegez-vous contre la secousse électrique:

a.

Les circuits à l’électrode et à la piéce sont sous tension
quand la machine à souder est en marche. Eviter toujours
tout contact entre les parties sous tension et la peau nue
ou les vétements mouillés. Porter des gants secs et sans
trous pour isoler les mains.

b. Faire trés attention de bien s’isoler de la masse quand on

soude dans des endroits humides, ou sur un plancher
metallique ou des grilles metalliques, principalement dans
les positions assis ou couché pour lesquelles une grande
partie du corps peut être en contact avec la masse.

c. Maintenir le porte-électrode, la pince de masse, le câble de

soudage et la machine à souder en bon et sûr état
defonctionnement.

d.Ne jamais plonger le porte-électrode dans l’eau pour le

refroidir.

e. Ne jamais toucher simultanément les parties sous tension

des porte-électrodes connectés à deux machines à souder
parce que la tension entre les deux pinces peut être le total
de la tension à vide des deux machines.

f. Si on utilise la machine à souder comme une source de

courant pour soudage semi-automatique, ces precautions
pour le porte-électrode s’applicuent aussi au pistolet de
soudage.

6. Eloigner les matériaux inflammables ou les recouvrir afin de
prévenir tout risque d’incendie dû aux étincelles.

7. Quand on ne soude pas, poser la pince à une endroit isolé de
la masse. Un court-circuit accidental peut provoquer un
échauffement et un risque d’incendie.

8. S’assurer que la masse est connectée le plus prés possible de
la zone de travail qu’il est pratique de le faire. Si on place la
masse sur la charpente de la construction ou d’autres endroits
éloignés de la zone de travail, on augmente le risque de voir
passer le courant de soudage par les chaines de levage,
câbles de grue, ou autres circuits. Cela peut provoquer des
risques d’incendie ou d’echauffement des chaines et des
câbles jusqu’à ce qu’ils se rompent.

9. Assurer une ventilation suffisante dans la zone de soudage.
Ceci est particuliérement important pour le soudage de tôles
galvanisées plombées, ou cadmiées ou tout autre métal qui
produit des fumeés toxiques.

10. Ne pas souder en présence de vapeurs de chlore provenant
d’opérations de dégraissage, nettoyage ou pistolage. La
chaleur ou les rayons de l’arc peuvent réagir avec les vapeurs
du solvant pour produire du phosgéne (gas fortement toxique)
ou autres produits irritants.

11. Pour obtenir de plus amples renseignements sur la sûreté, voir
le code “Code for safety in welding and cutting” CSA Standard
W 117.2-1974.

2. Dans le cas de travail au dessus du niveau du sol, se protéger
contre les chutes dans le cas ou on recoit un choc. Ne jamais
enrouler le câble-électrode autour de n’importe quelle partie du
corps.

3. Un coup d’arc peut être plus sévère qu’un coup de soliel, donc:

a. Utiliser un bon masque avec un verre filtrant approprié ainsi

qu’un verre blanc afin de se protéger les yeux du
rayonnement de l’arc et des projections quand on soude ou
quand on regarde l’arc.

b. Porter des vêtements convenables afin de protéger la peau

de soudeur et des aides contre le rayonnement de l‘arc.

c. Protéger l’autre personnel travaillant à proximité au

soudage à l’aide d’écrans appropriés et non-inflammables.

4. Des gouttes de laitier en fusion sont émises de l’arc de
soudage. Se protéger avec des vêtements de protection libres
de l’huile, tels que les gants en cuir, chemise épaisse,
pantalons sans revers, et chaussures montantes.

5. Toujours porter des lunettes de sécurité dans la zone de
soudage. Utiliser des lunettes avec écrans lateraux dans les
zones où l’on pique le laitier.

PRÉCAUTIONS DE SÛRETÉ POUR
LES MACHINES À SOUDER À
TRANSFORMATEUR ET À
REDRESSEUR

1. Relier à la terre le chassis du poste conformement au code de
l’électricité et aux recommendations du fabricant. Le dispositif
de montage ou la piece à souder doit être branché à une
bonne mise à la terre.

2. Autant que possible, I’installation et l’entretien du poste seront
effectués par un électricien qualifié.

3. Avant de faires des travaux à l’interieur de poste, la
debrancher à l’interrupteur à la boite de fusibles.

4. Garder tous les couvercles et dispositifs de sûreté à leur place.

Mar. ‘93

v v

for selecting a QUALITY product by Lincoln Electric. We want you

Thank You

to take pride in operating this Lincoln Electric Company product •••
as much pride as we have in bringing this product to you!

Please Examine Carton and Equipment For Damage Immediately

When this equipment is shipped, title passes to the purchaser upon receipt by the carrier. Consequently, Claims
for material damaged in shipment must be made by the purchaser against the transportation company at the time
the shipment is received.

Please record your equipment identification information below for future reference. This information can be found
on your machine nameplate.

Product _________________________________________________________________________________

Model Number ___________________________________________________________________________

Code Number or Date Code_________________________________________________________________

Serial Number____________________________________________________________________________

Date Purchased___________________________________________________________________________

Where Purchased_________________________________________________________________________

Whenever you request replacement parts or information on this equipment, always supply the information you
have recorded above. The code number is especially important when identifying the correct replacement parts.

On-Line Product Registration

- Register your machine with Lincoln Electric either via fax or over the Internet.

• For faxing: Complete the form on the back of the warranty statement included in the literature packet
accompanying this machine and fax the form per the instructions printed on it.

• For On-Line Registration: Go to our

“Product Registration”. Please complete the form and submit your registration.

Read this Operators Manual completely before attempting to use this equipment. Save this manual and keep it
handy for quick reference. Pay particular attention to the safety instructions we have provided for your protection.
The level of seriousness to be applied to each is explained below:

WEB SITE at www.lincolnelectric.com. Choose “Quick Links” and then

WARNING

This statement appears where the information must be followed exactly to avoid serious personal injury or
loss of life.

CAUTION

This statement appears where the information must be followed to avoid minor personal injury or damage to
this equipment.

vi vi

TABLE OF CONTENTS

Page

Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Section A

Technical Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .A-1

Safety Precautions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .A-2

Location / Ventilation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .A-2

Storing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .A-2

Stacking . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .A-2

Angle of Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .A-2

Lifting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .A-3

High Altitude Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .A-3

High Temperature Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .A-3

Towing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .A-3

Pre-Operation Engine Service . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .A-4

Oil . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .A-4

Fuel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .A-4

Fuel Cap . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .A-4

Engine Cooling System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .A-4

Battery Connection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .A-4

Muffler Outlet Pipe . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .A-5

Spark Arrestor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .A-5

Radiator Cap Cover . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .A-5

Air Cleaner Inlet Hood . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .A-5

Welding Terminals . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .A-5

Welding Output Cables . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .A-5

Machine Grounding . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .A-5

Remote Control . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .A-6

Auxiliary Power Receptacles . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .A-6

Standby Power Connections . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .A-6

Connection of Vantage Premises Wiring . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .A-7

Connection of Lincoln Electric Wire Feeders . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .A-8, A-9

Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Section B

Safety Instructions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .B-1

General Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .B-1

Recommended Applications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .B-1

Controls and Settings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .B-2

Engine Controls . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .B-2, B-3

Welder Controls . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .B-4

Auxiliary Power Controls . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .B-4

Engine Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .B-5

Starting the Engine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .B-5

Stopping the Engine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .B-5

Break-In Period . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .B-6

Typical Fuel Consumption . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .B-6

Duty Cycle . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .B-6

Welding Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .B-6

Stick Welding Mode . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .B-6

CC-Stick Mode . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .B-6

Downhill Pipe Mode . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .B-6

Touch Start TIG Mode . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .B-6

Vantage Settings when using K930-2 TIG Module . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .B-7

Typical Current Ranges for Tungsten Electrodes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .B-7

CV-Wire Mode . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .B-8

Arc Gouging . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .B-8

Paralleling . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .B-8

Auxiliary Power Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .B-8

Simultaneous Welding and Auxiliary Power Loads . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .B-8

Simultaneous Welding and Power Loads, Extension Cord Length Recommendations . . . . . . . . . . .B-9

Vantage 500 CUMMINS

vii vii

TABLE OF CONTENTS

Accessories . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Section C

Optional Field Installed Accessories . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .C-1

_________________________________________________________________________________________________

Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Section D

Safety Precautions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .D-1

Routine and Periodic Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .D-1

Engine Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .D-1

Air Filter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .D-1

Fuel Filters . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .D-2

Cooling System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .D-2

Battery Handling . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .D-2

Charging the Battery . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .D-2

Nameplate / Warning Decal Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .D-3

Welder / Generator Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .D-3

Engine Maintenance Components . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .D-3

Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Section E

Wiring, Connection Diagrams and Dimension Print . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Section F

Parts Lists . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .P-472 Series

Vantage 500 CUMMINS

A-1 INSTALLATION A-1

TECHNICAL SPECIFICATIONS - Vantage 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
B3.3 56HP (42 kw) Low Idle 1425 (3.3L) & Starter (25 US gal)
Diesel Engine @ 1800 RPM Full Load 1800 94.6L

Bore x Stroke Oil:

(2 US gal)

3.74” x 4.53” 7.5L
(95mm x 115mm) Coolant:

(2.6 US gal)

11.8L

RATED OUTPUT @ 104°F(40°C) - WELDER

Duty Cycle Welding Output Volts at Rated Amps

100% 500 Amps (DC multi-purpose) 40 Volts

60% 550 Amps (DC multi-purpose) 36 volts

50% 575 Amps (DC multi-purpose) 35 volts

OUTPUT @ 104°F(40°C) - WELDER AND GENERATOR

Welding Range

30 - 575 Amps CC/CV

20 - 250 Amps TIG

Open Circuit V

oltage

60 Max OCV @ 1900 RPM

Auxiliary Power

(1)

120/240 VAC

12,000 WATTS, 60 Hz.

PHYSICAL DIMENSIONS

Height

(1066.8 mm) (800.1mm) (1603mm) (728kg)

1. Output rating in watts is equivalent to volt-amperes at unity power factor.
Output voltage is within +/- 10% at all loads up to rated capacity. When welding, available auxiliary power will be reduced.

2. Top of Enclosure. Add 8.8” (223.5mm) for exhaust.

(2)

Width Depth Weight

42.0 in 31.5 in. 63.1 in. 1605 lbs.

(Approx)

Vantage 500 CUMMINS

A-2 INSTALLATION A-2

Read this entire installation section before you start
installation.

SAFETY PRECAUTIONS

WARNING

Do not attempt to use this equipment until you have
thoroughly read all operating and maintenance manuals
supplied with your machine. They include important safety
precautions, detailed engine starting, operating and
maintenance instructions and parts lists.

ELECTRIC SHOCK can kill.

• Do not touch electrically live parts such as
output terminals or internal wiring.

• Insulate yourself from the work and ground.

• Always wear dry insulating gloves.

-------------------------------------------------------------------------------------

ENGINE EXHAUST can kill.

•

Use in open, well ventilated areas or vent
exhaust outside

-------------------------------------------------------------------------------------

MOVING PARTS can injure.

• Do not operate with doors open or guards off.

• Stop engine before servicing.

• Keep away from moving parts

-------------------------------------------------------------------------------------

Only qualified personnel should install, use or service this
equipment.

LOCATION / VENTILATION

The welder should be located to provide an unrestricted flow of
clean, cool air to the cooling air inlets and to avoid restricting the
cooling air outlets. Also, locate the welder so that the engine
exhaust fumes are properly vented to an outside area.

CAUTION

DO NOT MOUNT OVER COMBUSTIBLE SURFACES

Where there is a combustible surface directly under stationary or
fixed electrical equipment, that surface should be covered with a
steel plate at least .06”(1.6mm) thick, which should extend not
less than 5.90”(150mm) beyond the equipment on all sides.

--------------------------------------------------------------------------------------

STORING

1. Store the machine in a cool, dry place when it is not in use.
Protect it from dust and dirt. Keep it where it can’t be
accidentally damaged from construction activities, moving
vehicles, and other hazards.

2. Drain the engine oil and refill with fresh 10W30 oil. Run the
engine for about five minutes to circulate oil to all the parts.
See the MAINTENANCE section of this manual for details
on changing oil.

3. Remove the battery, recharge it, and adjust the electrolyte
level. Store the battery in a dry, dark place.

STACKING

Vantage machines cannot be stacked.

ANGLE OF OPERATION

To achieve optimum engine performance the Vantage should be
run in a level position. The maximum angle of operation for the
Cummins engine is 35 degrees in all directions. If the engine is to
be operated at an angle, provisions must be made for checking
and maintaining the oil level at the normal (FULL) oil capacity in
the crankcase. When operating the welder at an angle, the
effective fuel capacity will be slightly less than the specified 25
gallons.

Vantage 500 CUMMINS

A-3 INSTALLATION A-3

LIFTING

The Vantage lift bale should be used to lift the machine. The
Vantage is shipped with the lift bale retracted. Before attempting
to lift the Vantage the lift bale must be secured in a raised
position. Secure the lift bale as follows:

a. Open the engine compartment door.

b. Locate the 2 access holes on the upper middle region

of compartment wall just below the lift bale.

c. Use the lifting strap to raise the lift bale to the full upright

position. This will align the mounting holes on the lift
bale with the access holes.

d. Secure the lift bale with 2 thread forming screws. The

screws are provided in the shipped loose parts bag.

WARNING

• Lift only with equipment of
adequate lifting capacity.

• Be sure machine is stable
when lifting.

• Do not lift this machine
using lift bail if it is
equipped with a heavy

accessory such as
trailer or gas cylinder.

FALLING • Do not lift machine if

EQUIPMENT can lift bail isdamaged.

cause injury. • Do not operate machine

whilesuspended from lift
bail.

HIGH TEMPERATURE OPERATION

At temperatures above 40°C (104°F), output voltage derating
may be necessary. For maximum output current ratings, derate
welder voltage rating 2 volts for every 10°C (21°F) above 40°C
(104°F).

TOWING

The recommended trailer for use with this equipment for road, in­plant and yard towing by a vehicle
user adapts a non-Lincoln trailer, he must assume responsibility
that the method of attachment and usage does not result in a
safety hazard nor damage the welding equipment. Some of the
factors to be considered are as follows:

1. Design capacity of trailer vs. weight of Lincoln
equipment and likely additional attachments.

2. Proper support of, and attachment to, the base of the
welding equipment so that there will be no undue stress
to the trailer’s framework.

3. Proper placement of the equipment on the trailer to
insure stability side to side and front to back when being
moved and when standing by itself.

4. Typical conditions of use, such as travel speed,
roughness of surface on which the trailer will be
operated, and environmental conditions.

5. Proper preventative maintenance of trailer.

6. Conformance with federal, state and local laws

(1)

Consult applicable federal, state and local laws regarding
specific requirements for use on public highways.

(1)

is Lincoln’s K953-1. If the

(1)

.

VEHICLE MOUNTING

Improperly mounted concentrated loads may cause unstable
vehicle handling and tires or other components to fail.

------------------------------------------------------------------------------------

HIGH ALTITUDE OPERATION

At higher altitudes, output derating may be necessary. For
maximum rating, derate the welder output 4% for every 300
meters (984 ft.) above 1500 meters (4920 ft.). For output of 500A
and below, derate the welder output 4% for every 300 meters
(984 ft.) above 2100 meters (6888 ft.).

Contact a Cummins Service Representative for any engine
adjustments that may be required.

WARNING

• Only transport this Equipment on serviceable vehicles
which are rated and designed for such loads.

• Distribute, balance and secure loads so vehicle is stable
under conditions of use.

• Do not exceed maximum rated loads for components such
as suspension, axles and tires.

• Mount equipment base to metal bed or frame of vehicle.

• Follow vehicle manufacturer’s instructions.

--------------------------------------------------------------------------------------

Vantage 500 CUMMINS

A-4 INSTALLATION A-4

PRE-OPERATION ENGINE SERVICE

READ the engine operating and maintenance instructions
supplied with this machine.

WARNING

• Stop engine while fueling.

• Do not smoke when fueling.

• Keep sparks and flame away fr

• Do not leave unattended while fueling.

DIESEL FUEL
can cause fire.

----------------------------------------------------------------------

• Wipe up spilled fuel and allow fumes to

clear before starting engine.

• Do not overfill tank, fuel expansion may

cause overflow.

DIESEL FUEL ONLY

OIL

The Vantage is shipped with the engine crankcase filled with high
quality SAE 10W-30 oil (API class CD or better). Check the oil
level before starting the engine. If it is not up to the full mark on
the dip stick, add oil as required. Check the oil level every four
hours of running time during the first 35 running hours. Refer to
the engine Operator’s Manual for specific oil recommendations
and break-in information. The oil change interval is dependent on
the quality of the oil and the operating environment. Refer to the
engine Operator’s Manual for the proper service and
maintenance intervals.

FUEL USE DIESEL FUEL ONLY

Fill the fuel tank with clean, fresh diesel fuel. The capacity of the
fuel tank is approx 95 liters. See engine Operator’s Manual for
specific fuel recommendations. Running out of fuel may
require bleeding the fuel injection pump. NOTE: Before
starting the engine, open the fuel shutoff valve (pointer to be in
line with hose).

om tank.

ENGINE COOLANT

WARNING

HOT COOLANT can burn skin.

•Do not remove cap if radiator is hot.

-------------------------------------------------------------------------------------

The welder is shipped with the engine and radiator filled with a
50% mixture of ethylene glycol and water
MAINTENANCE section and the engine Operator’s Manual for
more information on coolant.

. See the

BATTERY CONNECTION

WARNING

GASES FROM BATTERY can explode.

• Keep sparks, flame and cigarettes away from
battery.

To prevent EXPLOSION when:

• INSTALLING A NEW BATTERY — disconnect
negative cable from old battery first and
connect to new battery last.

• CONNECTING A BATTERY CHARGER — remove battery
from welder by disconnecting negative cable first, then
positive cable and battery clamp. When reinstalling,
connect negative cable last. Keep well ventilated.

• USING A BOOSTER — connect positive lead to battery first
then connect negative lead to negative battery lead at
engine foot.

BATTERY ACID can burn eyes and skin.

• Wear gloves and eye protection and be careful
when working near battery.

• Follow instructions printed on battery.

FUEL CAP

Remove the plastic cap covering from the Fuel Tank Filler neck
and install the Fuel Cap.

Vantage 500 CUMMINS

IMPORTANT: To prevent ELECTRICAL DAMAGE WHEN:

a) Installing new batteries.

b) Using a booster.

Use correct polarity — Negative Ground.

A-5 INSTALLATION A-5

The Vantage is shipped with the negative battery cable
disconnected. Before you operate the machine, make sure the
Engine Switch is in the OFF position and attach the disconnected
cable securely to the negative (-) battery terminal.

Remove the insulating cap from the negative battery terminal.
Replace and tighten negative battery cable terminal. NOTE: This
machine is furnished with a wet charged battery; if unused for
several months, the battery may require a booster charge. Be
sure to use the correct polarity when charging the battery.

MUFFLER OUTLET PIPE

Remove the plastic plug covering the muffler outlet tube. Using
the clamp provided secure the outlet pipe extension to the outlet
tube. Install the rain cap on the end of the outlet pipe extension.

SPARK ARRESTOR

Some federal, state or local laws may require that petrol or diesel
engines be equipped with exhaust spark arrestors when they are
operated in certain locations where unarrested sparks may
present a fire hazard. The standard muffler included with this
welder does not qualify as a spark arrestor. When required by
local regulations, a suitable spark arrestor, must be installed and
properly maintained.

CAUTION

An incorrect arrestor may lead to damage to the engine or
adversely affect performance.

--------------------------------------------------------------------------------------

RADIATOR CAP COVER

Install the radiator cap cover using the two screws which are
taped to the radiator cap cover.

AIR CLEANER INLET HOOD

Remove the plastic plug covering the air cleaner inlet. Install the
air cleaner inlet hood to the air cleaner.

WELDING TERMINALS

The Vantage is equipped with a toggle switch for selecting "hot"
welding terminals when in the "WELD TERMINALS ON" position
or "cold" welding terminals when in the "REMOTELY
CONTROLLED" position.

WELDING OUTPUT CABLES

With the engine off, route the electrode and work cables thru the
strain relief bracket provided on the front of the base and connect
to the terminals provided. These connections should be checked
periodically and tightened if necessary.

Listed in Table A.1 are copper cable sizes recommended for the
rated current and duty cycle. Lengths stipulated are the distance
from the welder to work and back to the welder again. Cable sizes
are increased for greater lengths primarily for the purpose of
minimizing cable voltage drop.

Table A.1 Combined Length of Electrode and Work Cables.

TOTAL COMBINED LENGTH OF

ELECTRODE AND WORK CABLES

AMPS Up to 150ft 150-200ft 200-250ft

@100%

Duty Cycle

500 3/0 AWG 3/0 AWG 4/0 AWG

MACHINE GROUNDING

Because this portable engine driven welder creates its own
power, it is not necessary to connect its frame to an earth ground,
unless the machine is connected to premises wiring (home, shop,
etc.).

To prevent dangerous electric shock, other equipment powered
by this engine driven welder must:

a) be grounded to the frame of the welder using a

grounded type plug,

or

b) be double insulated.

When this welder is mounted on a truck or trailer, its frame must
be securely connected to the metal frame of the vehicle. When
this engine driven welder is connected to premises wiring such as
that in a home or shop, its frame must be connected to the system
earth ground. See further connection instructions in the section
entitled “Standby Power Connections” as well as
the article on grounding in the latest National Electrical Code and
the local codes.

In general, if the machine is to be grounded, it should be
connected with a #8 or larger copper wire to a solid earth ground
such as a metal ground stake going into the ground for at least 10
Feet or to the metal framework of a building which has been
effectively grounded. The National Electric Code lists a number of
alternate means of grounding electrical equipment. A machine
grounding stud marked with the symbol is provided on the
front of the welder.

Vantage 500 CUMMINS

A-6 INSTALLATION A-6

REMOTE CONTROL

OUTPUT

The Vantage is equipped with a 6-pin and a 14-pin connector. The
6-pin connector is for connecting the K857 or K857-1 Remote
Control or for TIG welding, the K870 foot Amptrol or the K936-2
hand Amptrol. When in the CC-STICK, DOWNHILL PIPE, or CV­WIRE modes and when a remote control is connected to the 6­pin Connector, the auto-sensing circuit automatically switches the
OUTPUT control from control at the welder to remote control.

When in TOUCH START TIG mode and when a Amptrol is
connected to the 6-Pin Connector, the OUTPUT dial is used to set
the maximum current range of the CURRENT CONTROL of the
Amptrol.

The 14-pin connector is used to directly connect a wire feeder
control cable. In the CV-WIRE mode, when the control cable is
connected to the 14-pin connector, the auto-sensing circuit
automatically makes the Output Control inactive and the wire
feeder voltage control active

WARNING

NOTE: When a wire feeder with a built in welding voltage
control is connected to the 14-pin connector, do not connect
anything to the 6-pin connector.

--------------------------------------------------------------------------------------

STANDBY POWER CONNECTIONS

The Vantage is suitable for temporary, standby or emergency
power using the engine manufacturer’s recommended
maintenance schedule.

The Vantage can be permanently installed as a standby power
unit for 240 volt-3 wire, 50 amp service. Connections must be
made by a licensed electrician who can determine how the
120/240 VAC power can be adapted to the particular installation
and comply with all applicable electrical codes. The following
information can be used as a guide by the electrician for most
applications. Refer to the connection diagram shown in Figure
A.2.

1. Install the double-pole, double-throw switch between the power
company meter and the premises disconnect.

Switch rating must be the same or greater than the customer’s
premises disconnect and service over current protection.

AUXILIARY POWER RECEPTACLES

The auxiliary power capacity of the Vantage is 12,000 watts of 60
Hz, single phase power or 20,000 watts of 60Hz, three phase
power. The auxiliary power capacity rating in watts is equivalent
to volt-amperes at unity power factor. The maximum permissible
current of the 240 VAC single phase output is 50 A. The 240 VAC
output can be split to provide two separate 120 VAC outputs with
a maximum permissible current of 50 A per output to two separate
120 VAC branch circuits. The output voltage is within ± 10% at
all loads up to rated capacity.

The Vantage has two 20 Amp-120VAC single phase (5-20R)
GFCI duplex receptacles and one 50 Amp-120/240 VAC single
phase (14-50R) receptacle and one 240VAC three phase (15­50R) receptacle. The 120/240 VAC receptacle can be split for
single phase 120 VAC operation. The auxiliary power receptacles
should only be used with three wire grounded type plugs or
approved double insulated tools with two wire plugs. The current
rating of any plug used with the system must be at least equal to
the current capacity of the associated receptacle.

NOTE: The two 120V GFCI receptacles and the two 120 volt
circuits of the 120/240V receptacle are connected to different
phases and can not be paralleled.

Vantage 500 CUMMINS

A-7 INSTALLATION A-7

2. Take necessary steps to assure load is limited to the capacity
of the Vantage by installing a 50 amp, 240 VAC double pole
circuit breaker. Maximum rated load for each leg of the 240
VAC auxiliary is 50 amps. Loading above the rated output will
reduce output voltage below the allowable -10% of rated
voltage which may damage appliances or other motor-driven
equipment and may result in overheating of the Vantage
engine.

Figure A.2 Connection of the Vantage to Premises Wiring

240 VOLT

240 Volt

60 Hz.
3-Wire

Service

DOUBLE POLE DOUBLE THROW
SWITCH RATING TO BE THE SAME
AS OR GREATER THAN PREMISES
SERVICE OVERCURRENT
PROTECTION.

POWER

COMPANY

METER

120 VOLT

120 VOLT

3. Install a 50 amp 120/240 VAC plug (NEMA Type 14-50) to the
double-pole circuit breaker using No. 6, 4 conductor cable of
the desired length. (The 50 amp, 120/240 VAC plug is
available in the optional K802R plug kit.)

4. Plug this cable into the 50 Amp 120/240 Volt receptacle on the
Vantage case front.

GROUNDED CONDUCTOR

NEUTRAL
BUS

N

LOAD

50 AMP, 120/240

VOLT PLUG

NEMA TYPE 14-50

50 AMP, 120/240 VOLT

RECEPTACLE

240 VOLT

50AMP

240 VOLT

DOUBLE

POLE

CIRCUIT

BREAKER

GND

DISCONNECT AND

GROUND

N

NOTE: No. 6 COPPER CONDUCTOR CABLE SEE

NATIONAL ELECTRICAL CODE FOR ALTERNATE WIRE

SIZE RECOMMENDATIONS.

OVERCURRENT

PROTECTION

PREMISES

SERVICE

Vantage 500 CUMMINS

A-8 INSTALLATION A-8

CONNECTION OF LINCOLN ELECTRIC
WIRE FEEDERS

WARNING

Shut off welder before making any electrical connections.

-------------------------------------------------------------------------------------

CONNECTION OF LN-7, LN-8 OR LN-742 TO THE
VANTAGE

• Shut the welder off.

• Connect the LN-7, LN-8 OR LN-742 per instructions on the
appropriate connection diagram in the DIAGRAMS section.

• Set the “WIRE FEEDER VOLTMETER” switch to either “+” or “­” as required by the electrode being used.

• Set the “SELECTOR” switch to the “CV-WIRE” position.

• Adjust the “ARC CONTROL” knob to desired Crispness. SOFT
for MIG and CRISP for INNERSHIELD.

• Set the “WELDING TERMINALS” switch to the “REMOTELY
CONTROLLED” position.

• Set the “IDLE” switch to the “HIGH” position.

CONNECTION OF LN-15 TO THE VANTAGE

CONNECTION OF AN LN-23P WIRE FEEDER TO
THE VANTAGE

• Shut the welder off.

• Connect the LN-23P per instructions on the appropriate
connection diagram in the DIAGRAMS section. (NOTE): When
connecting an LN-23P to the Vantage, a K350-1 adapter kit
must be used.

• Set the “WIRE FEEDER VOLTMETER” switch to “-”.

• Set the “SELECTOR” switch to “CV-WIRE” position.

• Set the “WELDING TERMINALS” switch to “REMOTELY

CONTROLLED”.

• Set the ARC CONTROL to desired crispness.

• Set the “IDLE” switch to the “HIGH” position. If you are using an

LN-23P with the K350-1 adapter kit, the electrode is not
energized until the gun trigger is closed.

These connections instructions apply to both the LN-15 Across­The-Arc and Control Cable models. The LN-15 has an internal
contactor and the electrode is not energized until the gun trigger
is closed. When the gun trigger is closed the wire will begin to
feed and the welding process is started.

• Shut the welder off.

• For electrode Positive, connect the electrode cable to the "+"
terminal of the welder and work cable to the "-" terminal of the
welder. For electrode Negative, connect the electrode cable "-"
terminal of the welder and work cable to the "+" terminal of the
welder.

• Across-The-Arc Model:

Attach the single lead from the front of the LN-15 to work
using the spring clip at the end of the lead. This is a control
lead to supply current to the wire feeder motor; it does not
carry welding current.

Control Cable Model:

Connect Control Cable between Engine Welder and Feeder.

• Set the MODE switch to the "CV-WIRE " position.

• Across-The-Arc Model:

Set the "WELD TERMINALS" switch to "WELD TERMINALS
ON"

Control Cable Model:

Set the "WELD TERMINALS" switch to "REMOTELY
CONTROLLED"

• Set the "WIRE FEEDER VOLTMETER" switch to either "+" or
"-" as required by the electrode polarity being used.

• Set the "ARC CONTROL" knob to "0" initially and adjust to suit.

• Set the "IDLE" switch to the "High" position

Vantage 500 CUMMINS

A-9 INSTALLATION A-9

CONNECTION OF THE LN-25 TO THE VANTAGE

The LN-25 with or without an internal contactor may be used with
the Vantage. See the appropriate connection diagram in the
DIAGRAMS section.

NOTE: The LN-25 (K431) Remote Control Module and (K432)
Remote Cable are not recommended for use with the V

• Shut the welder off.

• For electrode Positive, connect the electrode cable from the LN­25 to the “+” terminal of the welder and work cable to the “-”
terminal of the welder. For electrode Negative, connect the
electrode cable from the LN-25 to the “-” terminal of the welder
and work cable to the “+” terminal of the welder.

• Attach the single lead from the front of the LN-25 to work using
the spring clip at the end of the lead. This is a sense lead to
supply current to the wire feeder motor; it does not carry welding
current.

• Set the SELECTOR switch to the “CV-WIRE” position.

• Set the “WELDING TERMINALS” switch to “WELD
TERMINALS ON”

• Adjust the “ARC CONTROL” knob to desired crispness.

Generally, welding is best if the “ARC CONTROL” is set to
SOFT for MIG and CRISP for INNERSHIELD. You may
however, want to start in the middle and adjust (as needed)
from there.

• Set the “IDLE” switch to the “AUTO” position. When not welding,
the Vantage engine will be at the low idle speed. If you are using
an LN-25 with an internal contactor, the electrode is not
energized until the gun trigger is closed.

antage.

CONNECTION OF PRINCE XL SPOOL GUN TO
THE VANTAGE

Connection of the Prince XL Spool Gun requires the use of the
K1849-1 Adapter Module.

• Shut the Welder off.

• For electrode Positive, connect the electrode cable to the "+"
terminal of the welder and work cable to the "-" terminal of the
welder. For electrode Negative, connect the electrode cable "­" terminal of the welder and work cable to the "+" terminal of
the welder.

• Connect the Control Cable of the Spool Gun to the Adapter
Module and connect the Control Cable of the Adapter Module
to the Welder.

• Connect the Gas Hose.

• Set the MODE switch to the "CV-WIRE " position.

• Set the "WELD TERMINALS" switch to "WELD TERMINALS
ON".

• Set the "ARC CONTROL" knob to "0" initially and adjust to suit.

• Set the "IDLE" switch to the "High" position

CAUTION

If you are using an LN-25 without an internal contactor, the
electrode will be energized when the Vantage is started.

--------------------------------------------------------------------------------------

• When the gun trigger is closed, the current sensing circuit will
cause the wire to begin to feed and the welding process is
started.

CONNECTION OF AN NA-3 AUTOMATIC
WELDING SYSTEM TO THE VANTAGE

For connection diagrams and instructions for connecting an NA-3
Welding System to the Vantage, refer to the NA-3 Welding
System instruction manual. The connection diagram for the LN-8
can be used for connecting the NA-3.

• Set the Wire Feeder Voltage Switch to 115V.

Vantage 500 CUMMINS

B-1 OPERATION B-1

SAFETY INSTRUCTIONS

Read and understand this entire section before operating
your Vantage.

WARNING

Do not attempt to use this equipment until you have
thoroughly read all operating and maintenance manuals
supplied with your machine. They include important safety
precautions, detailed engine starting, operating and
maintenance instructions and parts lists.

ELECTRIC SHOCK can kill.

• Do not touch electrically live parts such as
output terminals or internal wiring.

• Insulate yourself from the work and ground.

• Always wear dry insulating gloves.

-------------------------------------------------------------------------------------­ENGINE EXHAUST can kill.

• Use in open, well ventilated areas or vent

exhaust outside

• Do not stack anything near the engine.

-------------------------------------------------------------------------------------­MOVING PARTS can injure.

• Do not operate with doors open or guards off.

• Stop engine before servicing.

• Keep away from moving parts

--------------------------------------------------------------------------------------

Only qualified personnel should operate this equipment.

GENERAL DESCRIPTION

The Vantage is a diesel engine-driven welding power source. The
machine uses a brush type alternating current generator for DC
multi-purpose welding and for 120/240 VAC auxiliary standby
power. The welding control system uses state of the art Chopper

Technology™.

RECOMMENDED APPLICATIONS

WELDER

The Vantage provides excellent constant current DC welding
output for stick (SMAW) and TIG welding. The Vantage also
provides excellent constant voltage DC welding output for MIG
(GMAW), Innershield (FCAW), Outersield (FCAW-G) and Metal
Core welding. In addition the Vantage can be used for Arc
Gouging with carbons up to 3/8”(10mm) in diameter.

The Vantage is not recommended

GENERATOR

The Vantage provides smooth 120/240 VAC output for auxiliary power
and emergency standby power.

for pipe thawing.

ADDITIONAL SAFETY PRECAUTIONS

Always operate the welder with the hinged door closed and
the side panels in place as these provide maximum
protection from moving parts and insure proper cooling air
flow.

Vantage 500 CUMMINS

B-2 OPERATION B-2

CONTROLS AND SETTINGS

All welder and engine controls are located on the case front panel. Refer to Figure B.1 and the explanations that follow.

Figure B.1 Case Front Panel Controls

12

15

14

16

17

4

5

6

7

8

9

10

3

11

13

20

21

1

2

19

18

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.
started within that time or the fuel solenoid will deenergize, and
the switch must be toggled to reset the timer.

2. START PUSHBUTTON

Energizes the starter motor to crank the engine. With the engine
"Run / Stop" switch in the "Run" position, push and hold the Start
button to crank the engine; release as the engine starts. Do not
press while engine is running since this can cause damage to the
ring gear and/or starter motor

.

The engine must be

Vantage 500 CUMMINS

22

3. HOUR METER

The hour meter displays the total time that the engine has been
running. This meter is a useful indicator for scheduling preventive
maintenance.

4. FUEL LEVEL GAUGE

Displays the level of diesel fuel in the fuel tank.

The operator must watch the fuel level closely to prevent
running out of fuel and possibly having to bleed the system.

ENGINE TEMPERATURE GAUGE

5.

The gauge displays the engine coolant temperature.

B-3 OPERATION 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 temperatures. If the light
turns on, the engine protection system will stop the engine. Check
for proper oil level and add oil if necessary. Check for loose or
disconnected leads at the oil pressure sender located on the
engine. The light will remain on when the engine has been shut
down due to low oil pressure or over-temperature condition.

8. BATTERY CHARGING LIGHT

The yellow engine alternator light is off when battery charging
system is functioning normally
the voltage regulator may not be operating correctly. The light will
remain on when the engine is stopped and the run/stop switch is
in the run position.

9. IDLER SWITCH

Has two positions as follows:

A)

In the “High” position , the engine runs at the high idle
speed controlled by the governor.

B) In the “Auto” / position, the idler operates as

follows:

a. When switched from “High” to “Auto” or after starting the

engine, the engine will operate at full speed for
approximately 12 seconds and then go to low idle
speed.

b. When the electrode touches the work or power is drawn

for lights or tools (approximately 100 Watts minimum)
the engine accelerates and operates at full speed.

. If light turns on the alternator or

c. When welding ceases and the AC power load is turned

off, a fixed time delay of approximately 12 seconds
starts.

d. If the welding or AC power load is not restarted before

the end of the time delay, the idler reduces the engine
speed to low idle speed.

e. The engine will automatically return to high idle speed

when the welding load or A.C. power load is reapplied.

Idler Operational exceptions

When the WELDING TERMINALS switch is in the “Remotely
Controlled” position the idler will operate as follows:

a.

When the triggering device (Amptrol, Arc Start Switch, etc.) is
pressed the engine will accelerate and operate at full speed
provided a welding load is applied within approximately 12
seconds.

• If the triggering device remains pressed but no welding load is
applied within approximately 12 seconds the engine may return
to low idle speed.

• If the triggering device is released or welding ceases the engine
will return to low idle speed after approximately 12 seconds.

Vantage 500 CUMMINS

B-4 OPERATION B-4

WELDING CONTROLS (Items 10 through 19)

10. OUTPUT CONTROL: The OUTPUT dial is used to preset the

output voltage or current as displayed on the digital meters for the
four welding modes. When in the CC-STICK, DOWNHILL PIPE or
CV-WIRE modes and when a remote control is connected to the
6-Pin or 14-Pin Connector, the auto-sensing circuit automatically
switches the OUTPUT CONTROL from control at the welder to
the remote control. In the CV-WIRE mode, when the wire feeder
control cable is connected to the 14-Pin Connector, the auto­sensing circuit automatically makes OUTPUT CONTROL inactive
and the wire feeder voltage control active.

When in the TOUCH START TIG mode and when a Amptrol is
connected to the 6-Pin Connector, the OUTPUT dial is used to set
the maximum current range of the CURRENT CONTROL of the
Amptrol.

11. DIGITAL OUTPUT METERS: (Optional Kit)

The digital meters allow the output voltage (CV-WIRE mode) or
current (CC-STICK, DOWNHILL PIPE and TIG modes) to be set
prior to welding using the OUTPUT control knob. During welding,
the meters display the actual output voltage (VOLTS) and current
(AMPS). A memory feature holds the display of both meters on
the seven seconds after welding is stopped. This allows the
operator to read the actual current and voltage just prior to when
welding was ceased. While the display is being held the left-most
decimal point in each display will be flashing. The accuracy of the
meters is ± 3%.

12. WELD MODE SELECTOR SWITCH:

(Provides four selectable welding modes)

CV

-WIRE

DOWNHILL PIPE

CC-STICK

TOUCH START TIG

13. ARC CONTROL:

The ARC CONTROL WIRE/STICK knob is active in the WIRE
and STICK modes, and has dif
This control is not active in the TIG mode.

CC-STICK mode: In this mode, the ARC CONTROL knob sets the
short circuit current (arc-force) during stick welding. Increasing
the number from -10(Soft) to +10(Crisp) increases the short
circuit current and prevents sticking of the electrode to the plate
while welding. This can also increase spatter. It is recommended
that the ARC CONTROL be set to the minimum number without
electrode sticking. Start with a setting at 0.

DOWNHILL PIPE mode: In this mode, the ARC CONTROL knob
sets the short circuit current (arc-force) during stick welding to
adjust for a soft or a more forceful digging arc (Crisp). Increasing
the number from -10 (Soft) to +10 (Crisp) increases the short
circuit current which results in a more forceful digging arc.
Typically a forceful digging arc is preferred for root and hot
passes. A softer arc is preferred for fill and cap passes where
weld puddle control and deposition (“stacking” of iron) are key to
fast travel speeds. It is recommended that the ARC CONTROL
be set initially at 0.

ferent functions in these modes.

CV-WIRE mode: In this mode, turning the ARC CONTROL knob
from -10(soft) to +10(crisp) changes the arc from soft and
washed-in to crisp and narrow. It acts as an inductance/pinch
control. The proper setting depends on the procedure and
operator preference. Start with a setting of 0.

14. WELDING TERMINALS SWITCH

In the WELD TERMINALS ON position, the output is electrically
hot all the time. In the REMOTEL
output is controlled by a wire feeder or amptrol device, and is
electrically off until a remote switch is depressed.

15. WIRE FEEDER VOLTMETER SWITCH:

Matches the polarity of the wire feeder voltmeter to the polarity of
the electrode.

16. 6 - PIN CONNECTOR

For attaching optional remote control equipment. Includes auto­sensing remote control circuit.

17. 14 - PIN CONNECTOR

For attaching wire feeder control cables. Includes contactor
closure circuit, auto-sensing remote control circuit, and 120V
and 42VAC power.

NOTE: When a wire feeder with a built in welding voltage control
is connected to the 14-pin connector, do not connect anything to
the 6-pin connector.

18. WELD OUTPUT TERMINALS + AND -

These 1/2 - 13 studs with flange nuts provide welding connection
points for the electrode and work cables. For positive polarity
welding the electrode cable connects to the “+” terminal and the
work cable connects to this “-” terminal. For negative polarity
welding the work cable connects to the “+” terminal and the
electrode cable connects to this “-” terminal.

Y CONTROLLED position, the

AC

AUXILIARY POWER CONTROLS

(Items 19-22)

19. 120/240 VAC RECEPTACLE

This is a 120/240VAC (14-50R) receptacle that provides 240VAC
or can be split for 120VAC single phase auxiliary power. This
receptacle has a 50 amp rating. Refer to the
RECEPTACLES section in the installation chapter for further
information about this receptacle. Also refer to the AUXILIARY
POWER OPERATION section later in this chapter.

AUXILIARY POWER

Vantage 500 CUMMINS

B-5 OPERATION B-5

20. CIRCUIT BREAKERS

These circuit breakers provide separate overload current
protection for each 120V circuit at the 240V receptacle, each
120V receptacle, the 120V
in the 14-Pin connector and battery circuit overload protection.

21. 120VAC RECEPTACLES

These two 120VAC (5-20R) receptacles with ground fault circuit
interruption protection provide 120V
receptacle has a 20 amp total rating. They are designed to protect
the user from the hazards of ground faults. When the GFCI has
tripped there will be no voltage available from the receptacle. If
the GFCI has tripped, any device plugged into the GFCI
receptacle should be unplugged and the reason for tripping the
GFCI should be determined. If the device is found to be damaged
or defective, it should be repaired or replaced before any further
use. The GFCI should be checked for proper operation prior to
each use by pressing the test button. The GFCI can be reset by
pushing the reset button. Refer to the AUXILIARY POWER
RECEPTACLES section in the installation chapter for further
information about these receptacles. Also refer to the AUXILIARY
POWER OPERATION section later in this chapter.

22. GROUND STUD

Provides a connection point for connecting the machine case to
earth ground. Refer to “MACHINE GROUNDING” in the
Installation chapter for proper machine grounding information.

AC in the 14-Pin connector, the 42VAC

AC for auxiliary power. Each

ENGINE OPERATION

STARTING THE ENGINE

1. Open the engine compartment door and check that the fuel

shutoff valve located to the left of the fuel filter housing is in the
open position (lever to be in line with the hose).

2. Check for proper oil level and coolant level. Close engine

compartment door.

3. Remove all plugs connected to the AC power receptacles.

4. Set IDLER switch to “AUTO”.

5. Set the RUN/STOP switch to “RUN”. Observe that the engine

protection and battery charging lights are on. After 10 seconds,
the engine protection light will turn off.

6. Within 30 seconds, press and hold the engine START button

until the engine starts.

7. Release the engine START button when the engine starts.

8. Check that the engine protection and battery charging lights

are off. The engine protection light is on after starting, the
engine will shutdown in a few seconds. Investigate any
indicated problem.

9. Allow the engine to warm up at low idle speed for several

minutes before applying a load and/or switching to high idle.
Allow a longer warm up time in cold weather.

COLD WEATHER STARTING

With a fully charged battery and the proper weight oil, the engine
should start satisfactorily even down to about -10°C. If the engine
must be frequently started below -40°C, it may be desirable to
install the optional ether start kit (K887-1). Installation and
operating instructions are included in the kit.

STOPPING THE ENGINE

1. Switch the RUN/STOP switch to “STOP”. This turns off the

voltage supplied to the shutdown solenoid. A backup shutdown
can be accomplished by shutting off the fuel valve located on
the fuel line.

Vantage 500 CUMMINS

B-6 OPERATION 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 break­in is accomplished. Check the oil level twice a day during the
break-in period. In general this takes 50 to 100 hours of
operation.

IMPORTANT
IN ORDER T

SHOULD BE SUBJECTED TO HEAVY LOADS, WITHIN THE
RATING OF THE MACHINE. AVOID LONG IDLE RUNNING
PERIODS.

O ACCOMPLISH THIS BREAK-IN, THE UNIT

ENGINE BREAK-IN

Lincoln Electric selects high quality, heavy-duty industrial engines
for the portable welding machines we offer. While it is normal to
see a small amount of crankcase oil consumption during initial
operation, excessive oil use, wetstacking (oil or tar like substance
at the exhaust port), or excessive smoke is not normal.

Larger machines with a capacity of 350 amperes and higher,
which are operated at low or no-load conditions for extended
periods of time are especially susceptible to the conditions
described above. To accomplish successful engine break-in,
most diesel-powered equipment needs only to be run at a
reasonably heavy load within the rating of the welder for some
period of time during the engine’s early life. However, if the
welder is subjected to extensive light loading, occasional
moderate to heavy loading of the engine may sometimes be
necessary. Caution must be observed in correctly loading a
diesel/generator unit.

1. Connect the welder output studs to a suitable
resistive load bank. Note that any attempt to short
the output studs by connecting the welding leads
together, direct shorting of the output studs, or
connecting the output leads to a length of steel will
result in catastrophic damage to the generator and
voids the warranty.

2. Set the welder controls for an output current and
voltage within the welder rating and duty cycle.
Note that any attempt to exceed the welder rating or
duty cycle for any period of time will result in
catastrophic damage to the generator and voids the
warranty.

3. Periodically shut off the engine and check the
crankcase oil level.

WELDER OPERATION

DUTY CYCLE

Duty Cycle is the ratio of the uninterrupted on-load duration to 10
minutes. The total time period of one complete on-load and no­load cycle is 10 minutes. For example, in the case of a 60% duty
cycle, load is applied continuously for 6 minutes followed by a no-

load period of 4 minutes.

STICK WELDING MODE

The Vantage can be used with a broad range of DC stick
electrodes.

The MODE switch provides two stick welding settings as follows:

CC-STICK MODE

The CC-STICK position of the MODE switch is designed for
horizontal, vertical-up and over head welding with all types of
electrodes, especially low hydrogen. The OUTPUT CONTROL
knob adjusts the full output range for stick welding.

The ARC CONTROL knob sets the short circuit (arc-force) current
during stick welding. Increasing the number from -10 (Soft) to +10
(Crisp) increases the short circuit current and prevents sticking of
the electrode to the plate while welding. This can also increase
spatter. It is recommended that the ARC CONTROL be set to the
minimum number without electrode sticking. Start with the knob

set at 0.

DOWNHILL PIPE MODE

This slope controlled setting is intended for “out-of-position” and
“down hill” pipe welding where the operator would like to control
the current level by changing the arc length. The OUTPUT
CONTROL knob adjusts the full output range for pipe welding.

The ARC CONTROL knob sets the short circuit current (arc-force)
during stick welding to adjust for a soft or a more forceful digging
arc (Crisp). Increasing the number from -10 (Soft) to +10 (Crisp)
increases the short circuit current which results in a more forceful
digging arc. Typically a forceful digging arc is preferred for root
and hot passes. A softer arc is preferred for fill and cap passes
where weld puddle control and deposition (“stacking” of iron) are
key to fast travel speeds. It is recommended that the ARC

CONTROL be set initially at 0.

TYPICAL FUEL CONSUMPTION

Refer to Table B.2 for typical fuel consumption of the Vantage’
Engine for various operating scenarios.

Table B.2

Cummins B3.3 Engine Fuel Consumption

Cummins B3.3 Running Time for

56HP(42Kw) 25GAL.(94.6L)
@1800 RPM (Hours)

Low Idle - .45 Gal./hour 55.6
no load 1425 RPM (1.7 Lts./hour)

High Idle - .81 Gal./hour 30.9
no load 1900 RPM (3.1 Lts./hour)

DC CC Weld 1.88 Gal./hour 13.3
Output 500 (7.1 Lts./hour)
Amps @ 40 Volts

Auxiliary Power 1.23 Gal./hour 20.3
12,000 VA (4.7 Lts./hour)

Vantage 500 CUMMINS

TOUCH START TIG MODE

The Vantage can be used in a wide variety of DC TIG welding
applications.

The TOUCH START TIG setting of the MODE switch is for DC
TIG (Tungsten Inert Gas) welding. To initiate a weld, the
OUTPUT CONTROL knob is first set to the desired current and
the tungsten is touched to the work. During the time the tungsten
is touching the work there is very little voltage or current and, in
general, avoids tungsten contamination. Then, the tungsten is
gently lifted off the work in a rocking motion, which establishes the
arc.

To stop the arc, simply lift the TIG torch away from the work piece.
When the arc voltage reaches approximately 30 volts, the arc will
go out and the machine will automatically reset to the touch start
current level. The tungsten may then be retouched to the work
piece to restrike the arc. The arc may also be started and stopped
with an Amptrol or Arc Start Switch.

The ARC CONTROL is not active in the TIG mode.

B-7 OPERATION B-7

n general the ‘Touch Start’ feature avoids tungsten contamination
without the use of a Hi-frequency unit. If the use of a high
frequency generator is desired, the K930-2 TIG Module can be
used with the Vantage. The settings are for reference.

The Vantage is equipped with the required R.F. bypass circuitry
for the connection of high frequency generating equipment.

The Vantage and any high frequency generating equipment must
be properly grounded. See the K930-2 TIG Module operating
manuals for complete instructions on installation, operation, and
maintenance.

When using the TIG Module, the OUTPUT control on the Vantage
is used to set the maximum range of the CURRENT CONTROL
on the TIG Module or an Amptrol if connected to the TIG Module.

Table B.3 TYPICAL CURRENT RANGES

FOR TUNGSTEN ELECTRODES

DCEN (-) DCEP (+) Approximate Argon Gas Flow Rate

Tungsten
Electrode 1%, 2% 1%, 2% TIG TORCH
Diameter Thoriated Thoriated Aluminium Stainless Steel Nozzle

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)

VANTAGE SETTINGS WHEN USING THE K930-2
TIG MODULE

• Set the WELD MODE switch to the “Touch Start Tig 20-250
Setting”.

• Set the IDLER switch to the “AUTO” position.

• Set the WELDING TERMINALS switch to the “Remotely
Controlled” position. This will keep the solid state contactor open
and provide a “cold” electrode until the triggering device
(Amptrol or Arc Start Switch) is pressed.

(1)

(2)

l/min (c.f.m.)

1.6 (1/16) 70-150 10-20 3-5 (5-10) 4-6 (9-13) #5, #6

2.4 (3/32) 150-250 15-30 6-8 (13-17) 5-7 (11-15) #6, #7, #8

3.2 (1/8) 250-400 25-40 7-11 (15-23) 5-7 (11-15)

4.0 (5/32) 400-500 40-55 10-12 (21-25) 6-8 (13-17) #8, #10

4.8 (3/16) 500-750 55-80 11-13 (23-27) 8-10 (18-22)

6.4 (1/4) 750-1000 80-125 13-15 (28-32) 11-13 (23-27)

(1) When used with argon gas. The current ranges shown must be reduced when using argon/helium or pure helium shielding gases.

(2) Tungsten electrodes are classified as follows by the American Welding Society (AWS):

Pure EWP
1% Thoriated EWTh-1

Though not yet recognized by the AWS, Ceriated Tungsten is now widely accepted as a substitute for 2% Thoriated Tungsten in
AC and DC applications.

(3) DCEP is not commonly used in these sizes.

(4) TIG torch nozzle “sizes” are in multiples of 1/16ths of an inch:

# 4 = 1/4 in. 6 mm
# 5 = 5/16 in. 8 mm
# 6 = 3/8 in. 10 mm
# 7 = 7/16 in. 11 mm
# 8 = 1/2 in. 12.5 mm
#10 = 5/8 in. 16 mm

(5) TIG torch nozzles are typically made from alumina ceramic. Special applications may require lava nozzles, which are less prone to

breakage, but cannot withstand high temperatures and high duty cycles.

2% Thoriated EWTh-2

Vantage 500 CUMMINS

B-8 OPERATION B-8

CV-WIRE MODE

Connect a wire feeder to the Vantage and set welder controls
according to the instructions listed earlier in this section.

The Vantage in the ”CV-WIRE” position, permits it to be used with
a broad range of flux cored wire (Innershield and Outershield)
electrodes and solid wires for MIG welding (gas metal arc
welding). Welding can be finely tuned using the “ARC
CONTROL”. Turning the ARC CONTROL clockwise from ­10(soft) to +10(crisp) changes the arc from soft and washed-in to
crisp and narrow. It acts as an inductance/pinch control. The
proper setting depends on the procedure and operator
preference. Start with the knob set at 0.

For any electrodes, including the above recommendations, the
procedures should be kept within the rating of the machine. For
additional electrode information, See www.lincolnelectric.com or
the appropriate Lincoln publication.

ARC GOUGING

For optimal performance when arc gouging, set the Vantage
“WELD MODE” switch to the “CC - STICK” position, and the
“ARC CONTROL” to 10.

Set the “OUTPUT” knob to adjust output current to the desired
level for the gouging electrode being used according to the
ratings in the following table:

* Maximum current setting is limited to the Vantage maximum of

575 Amps.

ELECTRODE CURRENT RANGE

DIAMETER (DC, electrode positive)

(1/8”) 30-60 Amps
(5/32”) 90-150 Amps
(3/16”) 200-250 Amps

(1/4”) 300-400 Amps
(5/16”) 350-450 Amps

(3/8”) 450-575 Amps*

NOTE: The two 120V GFCI receptacles and the two 120V circuits
of the 120/240V receptacle are connected to dif

be paralleled.

cannot

The auxiliary power receptacles should only be used with three
wire grounded type plugs or approved double insulated tools with
two wire plugs.

The current rating of any plug used with the system must be at
least equal to the current capacity of the associated receptacle.

ferent phases and

SIMULTANEOUS WELDING AND AUXILIARY
POWER LOADS

It must be noted that the above auxiliary power ratings are with
no welding load. Simultaneous welding and power loads are
specified in table B.4. The permissible currents shown assume
that current is being drawn from either the 120 VAC or 240 VAC
supply (not both at the same time).

PARALLELING

When paralleling machines in order to combine their outputs, all
units must be operated in the CC-STICK mode only at the same
output settings. To achieve this, turn the WELD MODE switch to
the CC-STICK position. Operation in other modes may produce
erratic outputs, and large output imbalances between the units.

AUXILIARY POWER OPERATION

Start the engine and set the IDLER control switch to the desired
operating mode. Full power is available regardless of the welding
control settings, if no welding current is being drawn.

The auxiliary power of the Vantage consists of two 20 Amp­120VAC (5-20R) GFCI duplex receptacles and one 50 Amp­120/240 VAC (14-50R) receptacle. The 120/240VAC receptacle
can be split for single phase 120 VAC operation.

The auxiliary power capacity is 12,000 watts of 60 Hz, single
phase power. The auxiliary power capacity rating in watts is
equivalent to volt-amperes at unity power factor. The maximum
permissible current of the 240 VAC output is 50 A. The 240 VAC
output can be split to provide two separate 120 VAC outputs with
a maximum permissible current of 50 A per output to two separate
120 VAC branch circuits. Output voltage is within ± 10% at all
loads up to rated capacity.

Vantage 500 CUMMINS

B-9 OPERATION B-9

TABLE B.4 Vantage Simultaneous Welding and Power Loads

Welding Output Permissible Power Watts Permissible Auxiliary

at NEMA Voltage (Unity Power Factor) Current in Amperes

(V=.04I + 20) @ 120VAC * +/- 10% @ 240 VAC +/- 10%

0-250A/30V 12,000 100** 50
350A/34V 8,100 68** 34
400A/36V 5,600 46 23
450A/38V 2,900 24 12
500A/40V 0 0 0

* Each duplex receptacle is limited to 20 amps.

** Not to exceed 50A per 120 VAC branch circuit when splitting the 240 VAC output.

TABLE B.5 Vantage Extension Cord Length Recommendations

Current
(Amps)

15
15
20
20
25
30
38
50

Voltage

(Volts)

120
240
120
240
240
240
240
240

Load

(Watts)

1800
3600
2400
4800
6000
7200
9000

12000

Maximum Allowable Cord Length in ft. (m) for Conductor Size

14 AWG 12 AWG 10 AWG 8 AWG 6 AWG 4 AWG
30
60

(9)

(18)4075

Conductor size is based on maximum 2.0% voltage drop.

30
60

(12)
(23)

(9)

(18)

75

150

50

100

90
75

(23)
(46)
(15)
(30)
(27)
(23)

125
225

88
175
150
120
100

(38)
(69)
(27)
(53)
(46)
(37)
(30)

175
350
138
275
225
175
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)

Vantage 500 CUMMINS

C-1 ACCESSORIES C-1

OPTIONAL FIELD INSTALLED ACCESSORIES

K802N POWER PLUG KIT - Provides four 120V plugs rated at 20 amps each

and one dual voltage, full KVA plug rated at 120/240V, 50 amps. 120V plug may
not be compatible with NEMA common household receptacles.

K802-R POWER PLUG KIT - Provides four 120V plugs rated 15 amps each
and one dual voltage, full KVA plug rated at 120/240V, 50 amps, 120V plug is
compatible with NEMA common household receptacles.

K857 25 ft. (7.5 m) or K857-1 100 ft. (30.4 m) REMOTE CONTROL ­Portable control provides same dial range as the output control on the welder
from a location up to the specified length from the welder. Has convenient
plug for easy connection to the welder. The Vantage 500 CUMMINS is
equipped with a 6-pin connector for connecting the remote control.

K704 ACCESSORY SET - Includes 35 feet (10 m) of electrode
cable and 30 feet (9 m) of work cable, headshield, work clamp
and electrode holder. Cable is rated at 500 amps, 60% duty cycle.

K767-2 FOUR WHEELED STEERABLE YARD TRAILER

For in plant and yard towing.

K953-1 TRAILER - Two-wheeled trailer with optional fender and light
package. For highway use, consult applicable federal, state, and local laws
regarding possible additional requirements. There is a choice of 2 hitches,
a fender & a light package. Order:

K953-1 Trailer
K958-1 Ball Hitch
K958-2 Lunette Eye Hitch
K959-1 Fender & Light Kit
K965-1 Cable Rack

K887-1 ETHER START KIT - Provides maximum cold weather starting

assistance for frequent starting below 25
not provided with kit. (Cannot be used with K1858-1 Service Indicator Kit
at the same time.)

K1847-1 SPARK ARRESTOR KIT - Easily mounts to standard muffler.

K949-2 OIL DRAIN KIT - Includes ball valve, hose and clamp.

K1816-1 Full KVA Adapter Kit - Plugs into the 120/240V NEMA

14-50R receptacle on the case front (which accepts 4-prong
plugs) and converts it to a NEMA 6-50R receptacle (which
accepts 3-prong plugs) for connection to Lincoln Equipment with
a NEMA 6-50P plug,

K1858-1 Service Indicator Kit - Provides a GO / NO-GO visual indication of
air cleaner element useful service life. Filter service based on restriction
readings allows the longest life possible from the filter and best engine
protection.

(Cannot be used with K887-1 Ether Start Kit at the same time.)

o

F(-4 oC). Required Ether tank is

WARNING

Pipe Thawing with an arc welder can cause fire, explosion,
damage to electric wiring or to the arc welder if done
improperly. The use of an arc welder for pipe thawing is not
approved by the CSA, nor is it recommended or supported
by Lincoln Electric.

-------------------------------------------------------------------------------------

Vantage 500 CUMMINS

D-1 MAINTENANCE D-1

SAFETY PRECAUTIONS

WARNING

• Have a qualified technician do the maintenance and
troubleshooting work.

• Turn the engine off before working inside the machine.

• Remove guards only when necessary and replace them when
the maintenance requiring their removal is complete.

• Always use the greatest care when working near moving parts.

--------------------------------------------------------------------------------------

Read the Safety Precautions in front of this manual and the
engine instruction manual before working on this machine.

Keep all equipment safety guards, covers and devices in position
and in good repair. Keep hands, hair, clothing and tools away
from V-belts, gears, fans and all other moving parts when starting,
operating or repairing the equipment.

ROUTINE AND PERIODIC
MAINTENANCE

DAILY

• Check the crankcase oil level .

• Refill the fuel tank to minimize moisture condensation in the
tank.

• Open the water drain valve located on the bottom of the water
separator element 1 or 2 turns and allow to drain into a
container suitable for diesel fuel for 2 to 3 seconds. Repeat the
above drainage procedure until diesel fuel is detected in the
container.

• Check coolant level.

WEEKLY

Blow out the machine with low pressure air periodically. In
particularly dirty locations, this may be required once a week.

ENGINE MAINTENANCE

Refer to the “Periodic Checks” section of the Engine Operator’s
Manual for the recommended maintenance schedule of the
following:

a) Engine Oil and Filter
b) Air Cleaner
c) Fuel Filter - and Delivery System
d) Alternator Belt
e) Battery
f) Cooling System

Refer to Table D.1 at the end of this section for various engine
maintenance components.

AIR FILTER

CAUTION

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 ,
replace the filter if necessary. Service air cleaner regularly
according to Engine Operator’s Manual.

1. Locate the air filter canister located behind the engine door on
the top of the engine.

2. Remove air filter element.

3. Remove loose dirt from element with compressed air or water
hose directed from inside out.

Compressed Air: 100 psi maximum with nozzles at least

one inch away from element.

Water Hose: 40 psi maximum without nozzle.

4. Soak element in a mild detergent solution for 15 minutes. Do
not soak more than 24 hours. Swish element around in the
solution to help remove dirt.

5. Rinse elements from inside out with a gentle stream of water
(less than 40 psi) to remove all suds and dirt.

6. Dry element before reuse with warm air at less than 160°F
(71°C). Do not use a light bulb to dry the element.

Vantage 500 CUMMINS

D-2 MAINTENANCE D-2

7. Inspect for holes and tears by looking through the element
toward a bright light. Check for damaged gaskets or dented
metal parts. Do not reuse damaged elements. Protect element
from dust and damage during drying and storage.

8. Reinstall air filter element.

After six cleanings replace air filter. A cleaned filter will have
approximately 70% of the life of a new filter element. A restricted
filter element may not appear excessively dirty.

FUEL FILTERS

WARNING

When working on the fuel system

• Keep naked lights away, do not smoke !

• Do not spill fuel !

--------------------------------------------------------------------------------------

The Vantage is equipped with a Fuel Filter located after the lift
pump and before fuel injectors.The procedure for changing the
filter is as follows.

1. Close the fuel shutof

2. Clean the area around the fuel filter head. Remove the filter.
Clean the gasket surface of the filter head and replace the o­ring.

3. Fill the clean filter with clean fuel, and lubricate the o-ring seal
with clean lubricating oil.

4. Install the filter as specified by the filter manufacturer.

f valve.

WARNING

Mechanical overtightening will distort the threads, filter
element seal or filter can.

--------------------------------------------------------------------------------------

COOLING SYSTEM

The Vantage is equipped with a pressure radiator. Keep the
radiator cap tight to prevent loss of coolant. Clean and flush the
coolant system periodically to prevent clogging the passage and
over-heating the engine. When antifreeze is needed, always use
the permanent type.

BATTERY HANDLING

GASES FROM BATTERY can explode.

• Keep sparks, flame and cigarettes away from
battery.

To prevent EXPLOSION when:

• INSTALLING A NEW BATTERY - disconnect
negative cable from old battery first and
connect to new battery last.

• CONNECTING A BATTERY CHARGER ­Remove battery from welder by disconnecting
negative cable first, then positive cable and
battery clamp. When reinstalling, connect
negative cable last. Keep well ventilated.

• USING A BOOSTER - connect positive lead to
battery first then connect negative lead to
engine foot.

BATTERY ACID CAN BURN EYES AND SKIN.

• Wear gloves and eye protection and be careful

when working near battery. Follow instructions
printed on battery.

--------------------------------------------------------------------------------------

PREVENTING ELECTRICAL DAMAGE

1. When replacing, jumping, or otherwise connecting the battery
to the battery cables, the proper polarity must be observed.
Failure to observe the proper polarity could result in damage to
the charging circuit. The positive (+) battery cable has a red
terminal cover.

2. If the battery requires charging from an external charger
disconnect the negative battery cable first and then the positive
battery cable before attaching the charger leads. Failure to do
so can result in damage to the internal charger components.
When reconnecting the cables, connect the positive cable first
and the negative cable last.

PREVENTING BATTERY DISCHARGE

Turn the RUN/STOP switch to stop when engine is not running.

PREVENTING BATTERY BUCKLING

Tighten nuts on battery clamp until snug.

,

Vantage 500 CUMMINS

D-3 MAINTENANCE D-3

CHARGING THE BATTERY

When you charge, jump, replace, or otherwise connect battery
cables to the battery, be sure the polarity is correct. Improper
polarity can damage the charging circuit. The Vantage positive (+)
battery terminal has a red terminal cover.

If you need to charge the battery with an external charger,
disconnect the negative cable first, then the positive cable before
you attach the charger leads. after the battery is charged,
reconnect the positive battery cable first and the negative cable
last. Failure to do so can result in damage to the internal charger

components.

Follow the instructions of the battery charger manufacturer for
proper charger settings and charging time.

NAMEPLATES / WARNING DECALS
MAINTENANCE

Whenever routine maintenance is performed on this machine - or
at least yearly - inspect all nameplates and labels for legibility.
Replace those which are no longer clear. Refer to the parts list for
the replacement item number.

WELDER / GENERATOR
MAINTENANCE

STORAGE

Store the Vantage in a clean, dry protected areas.

CLEANING

Blow out the generator and controls periodically with low pressure
air. do this at least once a week in particularly dirty areas.

BRUSH REMOVAL AND REPLACEMENT

It is normal for the brushes and slip rings to wear and darken
slightly. Inspect the brushes when a generator overhaul is
necessary.

WARNING

Do not attempt to polish slip rings while the engine is
running.

--------------------------------------------------------------------------------------

Table D.1 Engine Maintenance Components

ITEM MAKE PART NUMBER SERVICE INTERVAL

Air Cleaner Element Donaldson P181052 Replace every 200 hours. (Replace more

Oil Filer Cummins C6002112110 Replace every 750 hours or 12 months,

Fan Belt Cummins C0412021748 Inspect every 1000 hours or 12 months,

Fuel Strainer Cummins 3826094 Inspect and replace monthly, as

Fuel Filter / Cummins C6003112130 Replace every 500 hours or 6 months,

Water Separator Fleetguard FS19594 whichever is less.

.

Battery ----- BCI GROUP 34 Inspect every 500 hours

Engine Oil Change See Manual ----- Change every 750 hours or 3 months,

AC A302C often when used in dusty and / or

Fleetguard AF437K high ambient temperature conditions)

Fleetguard LF3855 whichever is less.

whichever is less.

Fleetguard FF5079 required. Replace annually.

whichever is less. Check daily.

Vantage 500 CUMMINS

E-1 TROUBLESHOOTING E-1

HOW TO USE TROUBLESHOOTING GUIDE

WARNING

Service and Repair should only be performed by Lincoln Electric Factory Trained Personnel. Unauthorized repairs
performed on this equipment may result in danger to the technician and machine operator and will invalidate your factory
warranty. For your safety and to avoid Electrical Shock, please observe all safety notes and precautions detailed
throughout this manual.

_______________________________________________________________________________________________

This Troubleshooting Guide is provided to help you locate and
repair possible machine malfunctions. Simply follow the three­step procedure listed below.

Step 1. LOCATE PROBLEM (SYMPTOM).

Look under the column labeled “PROBLEM (SYMPTOMS)”. This
column describes possible symptoms that the machine may
exhibit. Find the listing that best describes the symptom that the
machine is exhibiting.

Step 2. POSSIBLE CAUSE.

The second column labeled “POSSIBLE CAUSE” lists the
obvious external possibilities that may contribute to the machine
symptom.

Step 3. RECOMMENDED COURSE OF ACTION

This column provides a course of action for the Possible Cause,
generally it states to contact your local Lincoln
Service Facility.

If you do not understand or are unable to perform the
Recommended Course of Action safely, contact your local Lincoln
Authorized Field Service Facility.

Authorized Field

CAUTION

If for any reason you do not understand the test procedures or are unable to perform the tests/repairs safely, contact your Local Lincoln
Authorized Field Service Facility for technical troubleshooting assistance before you proceed.

Vantage 500 CUMMINS

E-2 TROUBLESHOOTING E-2

Observe all Safety Guidelines detailed throughout this manual

PROBLEMS

(SYMPTOMS)

Major Physical or Electrical Damage is
Evident.

Engine will not crank

Engine will crank but not start.

Engine shuts down shortly after starting.

POSSIBLE AREAS OF

MISADJUSTMENT(S)

ENGINE PROBLEMS

1. Contact your Local Lincoln Authorized
Field Service Facility.

1. Battery low.

2. Loose battery cable connections which

may need Inspected, cleaned or tighten.

3. Faulty wiring in engine starting circuit.

4. Faulty engine starter. Contact authorized

local Engine Service Shop.

1. Out of fuel.

2. Fuel shut off valve is in the off position

make sure the valve lever is in a vertical
direction.

3. Engine shut down solenoid not pulling in.

4. On/Off switch on for more than 30 sec.

before starting, the On/Off switch will
need to be switch off and turned back on.

5. Fuel Filters dirty/clogged, main filter

element and/or Inline Fuel Filter may
need to be replaced.

6. High water temperature or low oil

pressure. (engine protection light lit)

1. Low oil pressure (engine protection light

lit). Check oil level (Consult engine
service dealer).

2. High water temperature. Check engine

cooling system. (engine protection light
lit).

3. Faulty oil pressure switch.

4. Faulty water temperature switch. Contact

authorized local Engine Service Shop.

RECOMMENDED

COURSE OF ACTION

If all recommended possible areas
of misadjustment have been
checked and the problem persists,
Contact your local Lincoln
Authorized Field Service Facility.

Engine shuts down while under a load.

Engine runs rough.

Engine will not shut off.

1. High water temperature.

1. Dirty fuel or air filters may need

cleaned/replaced.

2. Water in fuel.

1. Fuel Shutdown solenoid not functioning

properly / linkage binding.

CAUTION

ºIf for any reason you do not understand the test procedures or are unable to perform the tests/repairs safely, contact your Local Lincoln
Authorized Field Service Facility for technical troubleshooting assistance before you proceed.

______________________________________________________________________________________________________________

Vantage 500 CUMMINS

E-3 TROUBLESHOOTING E-3

PROBLEMS

(SYMPTOMS)

Battery does not stay charged.

Engine will not idle down to low
speed.

Engine will not go to high idle when
attempting to weld.

Engine will not go to high idle when using
auxiliary power.

POSSIBLE AREAS OF

MISADJUSTMENT(S)

FUNCTION PROBLEMS

1. Faulty battery .

2. Faulty engine alternator.

3. Loose or broken lead in charging circuit.

4. Loose fan belt may need tightening.

1. Idler switch in HIGH idle position, make
sure switch is set to AUTO.

2. External load on welder or auxiliary
power.

3. Mechanical problem in idler solenoid
linkage.

4. Faulty wiring in solenoid circuit.

5. No or low voltage @ idle solenoid

6. Faulty idler solenoid.

7. Faulty, Weld Control PCB, Pull Coil
/Battery PCB

1. Poor work lead connection to work.

2. Broken idler solenoid spring.

3. Welding Terminals switch in wrong
position.

4. No open circuit voltage at output studs.

5. Faulty, Pull Coil/Battery PCB or Weld
Control PCB.

1. Broken wire in auxiliary current sensor
wiring.

2. Auxiliary power load is less than 100
watts.

3. Faulty Pull Coil/Battery PCB or Weld
Control PCB.

RECOMMENDED

COURSE OF ACTION

If all recommended possible areas
of misadjustment have been
checked and the problem persists,
Contact your local Lincoln
Authorized Field Service Facility.

CAUTION

If for any reason you do not understand the test procedures or are unable to perform the tests/repairs safely, contact your Local Lincoln
Authorized Field Service Facility for technical troubleshooting assistance before you proceed.

______________________________________________________________________________________________________________

Vantage 500 CUMMINS

E-4 TROUBLESHOOTING E-4

PROBLEMS

(SYMPTOMS)

Engine goes to low idle but does not stay at
low idle.

No welding output or auxiliary output.

Welder has some/ no output and no control.
Auxiliary output OK

No welding output. Auxiliary output OK.

No auxiliary power.

POSSIBLE AREAS OF

MISADJUSTMENT(S)

FUNCTION PROBLEMS

1. Faulty Peripheral PCB, Pull Coil/Battery
PCB or Weld Control PCB.

1. Broken lead in rotor circuit.

2. Faulty field diode module.

3. Faulty Weld Control P.C. Board.

4. Faulty rotor.

1. Faulty remote kit.

2. Faulty output control potentiometer.

3. Faulty output control wiring.

4. Faulty Weld Control PCB, Pull
Coil/Battery PCB or Chopper PCB.

1. WELDING TERMINALS switch in wrong
position, be sure switch is in WELDING
TERMINALS ALWAYS ON position.

2. Faulty Weld Control PCB, Pull
Coil/Battery PCB or Chopper PCB.

1. Open breakers may need to be reset.

2. Faulty receptacle.

3. Faulty auxiliary circuit wiring.

4. GFCI tripped.

RECOMMENDED

COURSE OF ACTION

If all recommended possible areas
of misadjustment have been
checked and the problem persists,
Contact your local Lincoln
Authorized Field Service Facility.

CAUTION

If for any reason you do not understand the test procedures or are unable to perform the tests/repairs safely, contact your Local Lincoln
Authorized Field Service Facility for technical troubleshooting assistance before you proceed.

______________________________________________________________________________________________________________

Vantage 500 CUMMINS

F-1 DIAGRAMS F-1

ENHANCED DIAGRAM

A.02

3

6A

STATOR AUXILIARY WINDINGS

AUXILIARY POWER LEADS PASS THROUGH

WIRING DIAGRAM

W1 & W6

VANGAGE 500 CUMMINS

W2 & W3

POS

POS

POS

POS

INSULATED

NEUTRAL

STUD ON

BOTTOM

RIGHT OF

CONTROL

BOX

5H

5A

31

5E

CB1

260

RECTIFIER

5C

5B

12

5C

GND-C

115/230V

J10

11

GND-E

5E

5B

J12

SILVER

9

12

32A

50A

CB3

3A

3

261

GND-D

J11

SILVER

HOT (GOLD)

HOT (GOLD)

8

9

8

11

20A

50A

CB4

CB2

6B

6A

GROUND STUD ON

RECEPTACLE PANEL

5

GND-H

GND-D

GND-E

GND-C

GND-B

GND-A

GND-J

GND-F

GROUND STUD ON

CONTROL PANEL

10A

BRIDGE

W6

W1

W6

W1

W2

W2

WELD

W3

STATOR

W3

WINDINGS

W4

NEG

NEG

NEG

NEG

STATOR 42V WINDING

W4

CV

W5

W5

S5

MODE SELECTOR

SWITCH

6

IDLER

SHUTDOWN

32

32A

200

200A

+

200B

-

AUXILIARY GROUNDSTUD, BOTTOM

CENTER OF CONTROL BOX

201

42B

42A

CB6

42

41

41A

A

222

1

4

2

3

TIG

214

PIPE

CC

220

218

SOLENOID

SOLENOID

5H

+

BRUSH

BRUSH

4

227

COIL

WHT

PULL

3

BLK

232L

21

226

RED

COIL

HOLD

J55

P55

4

265

COIL

WHT

PULL

3

BLK

232M

2

262

RED

COIL

HOLD

1

J54

P54

SHOWN IN

"HIGH" POSITION

IDLER

CONTROL

256

HIGH

AUTO

-

+

6

-

201A

300V

3200MFD

201

4

2

ROTOR

POSITIVE BRUSH CONNECTED

TO SLIP RING NEAREST

TO THE LAMINATION

2A

4A

CONTROL SWITCH

WELDING TERMINAL

SHOWN IN "ALWAYS ON" POSITION

VIEWED FROM BACK

32

10K

PINCH POT

R1

CCW

FROM

VIEWED

OUTPUT CONTROL

5A
5

6

20A

TOROID TWICE IN DIRECTION INDICATED

W4 & W5

234

235

235

WK

SWITCH

SWITCH

FUEL LVL.

SENSOR

SENSOR

241

COOLANT TEMPERATURE

SENSOR & SWITCH

232F

RUN

232H

STOP

232A

232D

RUN/STOP

SWITCH

SHOWN IN "RUN" POSITION

1

J51

4

1

J52

14

J53

4

5J

229

232

5K

229

232K

5L

241

232C

5M

228

232B

SENSOR

G

OIL PRESSURE

SENSOR & SWITCH

228

231

238A

START BUTTON

238B

20A

236B

CB5

236A

257

262A

262

232E

232R

FUEL

HOUR METER

COOLANT

TEMPERATURE

OIL

PRESSURE

232A

232C

232B

279

278

277

75

76

BACK

77

232K

232M

232R

232N

12VDC

INSULATED

STUD

SILVER

GOLD

405B

ENG

PROT

247

243

405A

ALT

232E

12V BATTERY

+

STARTER

SOLENOID

231

238A

238

227

232N

265

5S

5S

5K

5L

5M

5T 5J

PERIPHERAL BD

STARTING

PROGRAMMING

PCB1

ENGINE BLOCK

-

243

ALTERNATOR

B

L

IG

P

MOTOR

232

B1

B2

B3

PCB8

B4

4

271

PULL COIL BD

403

200

270

281

405

1

1

5N

12 VOLT GROUND

STUD ON LEFT SIDE

BACK OF CONTROL BOX

3

6

J30

4

1

247

7

1

271
405B

234

6

12

9

1

5T

403

405

232F

405A

262A

270

16

G4329

ENGINE

SUPPORT

LEFT SIDE

5N

8

J43

5

J32

J31

8

8

14

16

13

208B

256

25

23

B2

B3

PCB6

CHOPPER

LEFT SIDE

B5

B6

W7

W8

POS

B1

B7

B8

B7

B8

POS

B4

B3

NEG

CHOPPER

NEG

RIGHT SIDE

B6

W9

W10

R4

206C

204S

206S

-

+

50MV=400AMPS

206B

+

206A

L1 CHOKE

208C

GND-J

GROUND STUD

ON OUTPUT PANEL

GND-K

BYPASS

208B

FILTER

ASSEMBLY

I

208

25A

23A

B2

PCB5

B5

POS

NEG

B1

B7

B8

B7

B8

POS

B4

NEG

14

14A

13

13A

42A

41A

208B

32

21

31

21

32

4B

2B

41A

42A

76B

GND-A

77B

75B

K

I

J

A

DCH

B

-

+

POLARITY

SWITCH

SWITCH SHOWN IN

POSITIVE POLARITY

POSITION

208A

EFG

206A

42VAC

WORK

115VAC

REMOTE

GROUND

CONTACTOR

CONTROL

AMPHENOL 1

VOLTMETER

AMMETER

77A

AMPHENOL 2

M9

M5

M3

M1

M9

M5

M3

M1

2A

75A

76A

76B

75B

77B

ABCDE

REMOTE

CONTACTOR

CONTROL

M10

M6

M4

M2

M10

M6

M4

M2

4A

4B

2B

257

250

23A

261

J3

25A

260

23

25

250

1

9

CHOPPER, POWER, PWM, THERMAL

5

M10

10

M5

M9

M4

M3

J4

M2

M6

1

8

277

278
279
75

76

77

1

5

M5
M4

M3
M2
M1

1

AMMETER

6

J7

CONTROL, MODE SEL.

916

10

J5

VOLT METER

6

3 TURNS

M1

222

220
218

214

M10

M9

GND-B

M6

F

GROUND

1

7

5G

404
226

232D

6

12

J2

ENGINE,PERIPHERAL

J1

AMPHENOL,I.D.

9

1

75A

4

77A

2

500

76A

3 TURNS

THRU

TOROID

8

16

J6

SHUNT

2

1

PCB3

WELD BOARD

206S

204S

the enclosure panels.

THRU

TOROID

NOTE: This diagram is for reference only. It may not be accurate for all machines covered by this manual. The specific dia- gram for your particular machine is pasted inside the machine on one of

Vantage 500 CUMMINS

F-2 DIAGRAMS F-2

CONNECTION DIAGRAM:

Vantage 500 CUMMINS

F-3 DIAGRAMS F-3

CONNECTION DIAGRAM:

LN-7

WIRE

FEEDER

K775 OPTIONAL

K291 OR K40475INPUT CABLE

REMOTE CONTROL

7-2000

S23983

Only qualified personnel should install,use

Keep guards in place.

or service this equipment.

Keep away from moving parts.

WARNING

Do not operate with panels open.

Disconnect NEGATIVE (-) BATTERY LEAD

before servicing.

Do not touch electrically live parts.

N.D.

81424131313232

82

SPARE

}

224

4

21

GND

21

GND

K867 UNIVERSAL

ADAPTER PLUG

GREEN

757677

77

76

N.E.

}

TO WORK

COMMANDER / K867 / K775 / LN-7 CONNECTION DIAGRAM

14 PIN

AMPHENOL

TO WORK

ELECTRODE

Vantage 500 CUMMINS

TO WIRE FEED UNIT

ELECTRODE CABLE

PLACE WIRE FEEDER SWITCH TO "WIRE FEEDER WITH CONTROL CABLE POSITION.

APPILICATIONS. SEE OPERATING MANUAL.

N.E. SPLICE LEADS AND INSULATE.

N.C. IF OPTIONAL REMOTE OUTPUT CONTROL IS USED,CONTROL IS AUTOMATICALLY SWITCHED TO REMOTE CONTROL.

N.D. INSULATE EACH UNUSED LEAD INDIVIDUALLY.

N.B. USE VOLTMETER SWITCH TO SELECT DESIRED ELECTRODE POLARITY. POSITION THE "SELECTOR" SWITCH TO "WIRE WELDING CV".

N.A. WELDING CABLE MUST BE OF PROPER CAPACITY FOR THE CURRENT AND DUTY CYCLE OF IMMEDIATE AND FUTURE

ANY INCREASE OF THE HIGH IDLE ENGINE RPM BY CHANGING THE GOVERNOR SETTING OR OVERRIDING THE THROTTLE LINKAGE WILL CAUSE

AN INCREASE IN THE THE AC AUXILIARY VOLTAGE. IF THIS VOLTAGE GOES OVER 140 VOLTS, WIRE FEEDER CONTROL CIRCUITS MAY BE

THE ENGINE WELDER OPERATING MANUAL.

CAUTION :

DAMAGED. THE ENGINE GOVERNOR SETTING IS PRE-SET AT THE FACTORY - DO NOT ADJUST ABOVE RPM SPECIFICATIONS LISTED IN

F-4 DIAGRAMS F-4

CONNECTION DIAGRAM

Vantage 500 CUMMINS

F-5 DIAGRAMS F-5

CONNECTION DIAGRAM

Vantage 500 CUMMINS

F-6 DIAGRAMS F-6

CONNECTION DIAGRAM

WIRE

FEEDER

LN-8

K196

INPUT CABLE

C

GND

A

B

N.D.

}

4

2

31

32

Only qualified personnel should install,use

or service this equipment.

Keep away from moving parts.

Keep guards in place.

N.C.

21

}

7-2000

S23989

COMMANDER / K867 / LN-8 CONNECTION DIAGRAM

WARNING

Do not operate with panels open.

before servicing.

Disconnect NEGATIVE (-) BATTERY LEAD

Do not touch electrically live parts.

SPARE

2

82

81

42

31

41

32

14 PIN

AMPHENOL

4

21

K867 UNIVERSAL

TO WORK

ELECTRODE

GND

ADAPTER PLUG

76

77

75

TO WORK

TO WIRE FEED UNIT

ELECTRODE CABLE

APPICATIONS. SEE OPERATING MANUAL.

N.A. WELDING CABLE MUST BE OF PROPER CAPACITY FOR THE CURRENT AND DUTY CYCLE OF IMMEDIATE AND FUTURE

N.B. USE VOLTMETER SWITCH TO SELECT DESIRED ELECTRODE POLARITY. POSITION THE SELECTOR SWITCH TO "WIRE WELDING CV".

N.C. INSULATE EACH UNUSED LEAD INDIVIDUALLY.

N.D. SPLICE LEADS AND INSULATE.

THE ENGINE WELDER OPERATING MANUAL.

ANY INCREASE OF THE HIGH IDLE ENGINE RPM BY CHANGING THE GOVERNOR SETTING OR OVERRIDING THE THROTTLE LINKAGE WILL CAUSE

AN INCREASE IN THE THE AC AUXILIARY VOLTAGE. IF THIS VOLTAGE GOES OVER 140 VOLTS, WIRE FEEDER CONTROL CIRCUITS MAY BE

CAUTION :

DAMAGED. THE ENGINE GOVERNOR SETTING IS PRE-SET AT THE FACTORY - DO NOT ADJUST ABOVE RPM SPECIFICATIONS LISTED IN

Vantage 500 CUMMINS

F-7 DIAGRAMS F-7

CONNECTION DIAGRAM

Vantage 500 CUMMINS

F-8 DIAGRAMS F-8

CONNECTION DIAGRAM

Vantage 500 CUMMINS

F-9 DIAGRAMS F-9

ENGINE WELDERS /LN-8 CONNECTION DIAGRAM

CAUTION:

CONNECTION DIAGRAM

TO WORK

4-14-2000

S24787-6

MOVING PARTS can injure

WARNING

ELECTRIC SHOCK can kill

Keep away from moving parts.

Keep guards in place.

Do not operate with panels open.

Disconnect NEGATIVE (-) Battery lead

Only qualified personnel should install,use

before servicing.

or service this equipment.

CABLE PLUG

TO LN-8 INPUT

K595 CONTROL CA BL E

ELECTRODE C ABLE

TO WIRE FEE D U NIT

_

Do not touch electrically live parts.

+

14 PIN

AMPHE NOL

Vantage 500 CUMMINS

APPLICATIONS. SEE OPERATING MANUAL.

ANY INCREASE OF THE HIGH IDLE ENGINE RPM BY CHANGING THE GOVERNOR SETTING OR OVERRIDING THE THROTTLE LINKAGE WILL CAUSE

AN INCREASE IN THE AC WIRE FEEDER VOLTAGE, WHICH CAN DAMAGE THE CONTROL CIRCUIT. THE ENGINE GOVERNOR SETTING IS PRE-SET

AT THE FACTORY – DO NOT ADJUST ABOVE RPM SPECIFICATIONS LISTED IN THE ENGINE WELDER OPERATING MANUAL.

N.A. WELDING CABLES MUST BE OF PROPER CAPACITY FOR THE CURRENT AND DUTY CYCLE OF IMMEDIATE AND FUTURE

N.B. CONNECT WELDING CABLES TO OUTPUT STUDS FOR DESIRED POLARITY. POSITION THE WIRE FEEDER VOLTMETER SWITCH TO

MATCH THE POLARITY OF THE ELECTRODE CABLE.

N.C. PLACE IDLER SWITCH IN “HIGH” POSITION.

F-10 DIAGRAMS F-10

CONNECTION DIAGRAM

Vantage 500 CUMMINS

F-11 DIAGRAMS F-11

CONNECTION DIAGRAM

Vantage 500 CUMMINS

F-12 DIAGRAMS F-12

CONNECTION DIAGRAM

Vantage 500 CUMMINS

F-13 DIAGRAMS F-13

CONNECTION DIAGRAM

Vantage 500 CUMMINS

F-14 DIAGRAMS F-14

DIMENSION PRINT

Ref.

A. 0 2

M18962-3

5.86

31.50

2.24

45.67

Revised overall height dimension.

50.15

CHANGE DETAIL:

42.35

33.53

No

N.A. CENTER OF GRAVITY WITH OIL IN ENGINE, EMPTY FUEL TANK AND COOLANT IN RADIATOR.

50.81

46.35

42.00

6.55

TRAILER MOUNTING HOLE LOCATIONS.

*

*

24.97

*

6.53

*

14.63

37.30

*

45.38

63.10 6.56

54.44

50.38

32.08

23.69

19.63

ENGINEERING CONTROLLED

MANUFACTURER:

BOTTOM VIEW OF WELDER BASE.

N.A.

16.85

Vantage 500 CUMMINS

28.99

NOTE: This diagram is for reference only. It may not be accurate for all machines covered by this manual. The specific diagram for a particular code is pasted inside the machine on one of the enclosure

panels. If the diagram is illegible, write to the Service Department for a replacement. Give the equipment code number.

WARNING

Spanish

AVISO DE

PRECAUCION

l Do not touch electrically live parts or

electrode with skin or wet clothing.

l Insulate yourself from work and

ground.

l No toque las partes o los electrodos

bajo carga con la piel o ropa
mojada.

l Aislese del trabajo y de la tierra.

l Keep flammable materials away.

l Mantenga el material combustible

fuera del área de trabajo.

l Wear eye, ear and body protection.

l Protéjase los ojos, los oídos y el

cuerpo.

French

ATTENTION

German

WARNUNG

Portuguese

ATENÇÃO

Japanese

Chinese

Korean

Arabic

l Ne laissez ni la peau ni des

vêtements mouillés entrer en contact
avec des pièces sous tension.

l Isolez-vous du travail et de la terre.

l Berühren Sie keine stromführenden

Teile oder Elektroden mit Ihrem
Körper oder feuchter Kleidung!

l Isolieren Sie sich von den

Elektroden und dem Erdboden!

l Não toque partes elétricas e

electrodos com a pele ou roupa
molhada.

l Isole-se da peça e terra.

l Gardez à l’écart de tout matériel

inflammable.

l Entfernen Sie brennbarres Material!

l Mantenha inflamáveis bem

guardados.

l Protégez vos yeux, vos oreilles et

votre corps.

l Tragen Sie Augen-, Ohren- und Kör-

perschutz!

l Use proteção para a vista, ouvido e

corpo.

READ AND UNDERSTAND THE MANUFACTURER’S INSTRUCTION FOR THIS EQUIPMENT AND THE CONSUMABLES TO
BE USED AND FOLLOW YOUR EMPLOYER’S SAFETY PRACTICES.

SE RECOMIENDA LEER Y ENTENDER LAS INSTRUCCIONES DEL FABRICANTE PARA EL USO DE ESTE EQUIPO Y LOS
CONSUMIBLES QUE VA A UTILIZAR, SIGA LAS MEDIDAS DE SEGURIDAD DE SU SUPERVISOR.

LISEZ ET COMPRENEZ LES INSTRUCTIONS DU FABRICANT EN CE QUI REGARDE CET EQUIPMENT ET LES PRODUITS A
ETRE EMPLOYES ET SUIVEZ LES PROCEDURES DE SECURITE DE VOTRE EMPLOYEUR.

LESEN SIE UND BEFOLGEN SIE DIE BETRIEBSANLEITUNG DER ANLAGE UND DEN ELEKTRODENEINSATZ DES
HERSTELLERS. DIE UNFALLVERHÜTUNGSVORSCHRIFTEN DES ARBEITGEBERS SIND EBENFALLS ZU BEACHTEN.

Vantage 500 CUMMINS

l Keep your head out of fumes.
l Use ventilation or exhaust to

remove fumes from breathing zone.

l Turn power off before servicing.

l Do not operate with panel open or

guards off.

WARNING

l Los humos fuera de la zona de

respiración.

l Mantenga la cabeza fuera de los

humos. Utilice ventilación o
aspiración para gases.

l Gardez la tête à l’écart des fumées.
l Utilisez un ventilateur ou un

aspirateur pour ôter les fumées des
zones de travail.

l Vermeiden Sie das Einatmen von

Schweibrauch!

l Sorgen Sie für gute Be- und

Entlüftung des Arbeitsplatzes!

l Mantenha seu rosto da fumaça.
l Use ventilação e exhaustão para

remover fumo da zona respiratória.

l Desconectar el cable de

alimentación de poder de la
máquina antes de iniciar cualquier
servicio.

l Débranchez le courant avant

l’entretien.

l Strom vor Wartungsarbeiten

abschalten! (Netzstrom völlig
öffnen; Maschine anhalten!)

l Não opere com as tampas removidas.
l Desligue a corrente antes de fazer

serviço.

l Não toque as partes elétricas nuas.

l No operar con panel abierto o

guardas quitadas.

l N’opérez pas avec les panneaux

ouverts ou avec les dispositifs de
protection enlevés.

l Anlage nie ohne Schutzgehäuse

oder Innenschutzverkleidung in
Betrieb setzen!

l Mantenha-se afastado das partes

moventes.

l Não opere com os paineis abertos

ou guardas removidas.

Spanish

AVISO DE

PRECAUCION

French

ATTENTION

German

WARNUNG

Portuguese

ATENÇÃO

Japanese

Chinese

Korean

Arabic

LEIA E COMPREENDA AS INSTRUÇÕES DO FABRICANTE PARA ESTE EQUIPAMENTO E AS PARTES DE USO,
E SIGA AS PRÁTICAS DE SEGURANÇA DO EMPREGADOR.

Vantage 500 CUMMINS

World’s Leader in Welding and Cutting Products

• Sales and Service through Subsidiaries and Distributors Worldwide •

Cleveland, Ohio 44117-1199 USA Tel: [phone] Fax: [phone] Web Site: www.lincolnelectric.com