Lincoln Electric IM873 User Manual

VANTAGE 500 CUMMINS

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For use with machines having Code Numbers: 11181, 11416

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.

IM873-A

July, 2007

Cleveland, Ohio 44117-1199 U.S.A. TEL: [phone] FAX: [phone] WEB SITE: www.lincolnelectric.com

R

OPERATOR’S MANUAL

Copyright © 2007 Lincoln Global Inc.

• World's Leader in Welding and Cutting Products •

• Sales and Service through Subsidiaries and Distributors Worldwide •

i

SAFETY

WARNING

CALIFORNIA PROPOSITION 65 WARNINGS

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

The Above For Diesel Engines

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

Read and understand the following safety highlights. For additional safety information, it is strongly recommended that you
purchase a copy of “Safety in Welding & Cutting - ANSI Standard Z49.1” from the American Welding Society, P.O. Box
351040, Miami, Florida 33135 or CSA Standard W117.2-1974. A Free copy of “Arc Welding Safety” booklet E205 is available
from the Lincoln Electric 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.

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

The Above For Gasoline Engines

i

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.d. Keep all equipment safety guards, covers and devices in

position
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
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.b. Operate engines in open, well-ventilated
areas or vent the engine exhaust fumes
outdoors.

1.c. Do not add the fuel near an open flame
welding
Stop the engine and allow it to cool before
refueling 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.

and in good repair.Keep hands, hair, clothing and

to perform required maintenance. Remove

1.f. Do not put your hands near the engine fan.

Do
idler by pushing on the throttle control rods
while the engine is running.

arc or when the engine is running.

not attempt to override the governor or

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

ELECTRIC AND
MAGNETIC FIELDS
may be dangerous

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.

___________________________________________________

1.g. To prevent accidentally starting gasoline engines while
turning

the engine or welding generator during maintenance
work, disconnect the spark plug wires, distributor cap or
magneto wire as appropriate.

2.d.4. Connect the work cable to the workpiece as close as
possible to the area being welded.

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

Mar ʻ95

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 Voltage (Wire) Welder.

• DC Manual (Stick) Welder.

• AC Welder with Reduced Voltage Control.

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

3.d. Always be sure the work cable makes a good electrical
connection with the metal being welded. The connection
should be as close as possible to the area being welded.

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

3.f.

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

3.g. Never dip the electrode 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.

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. I 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 nor expose
themselves to the arc rays or to hot spatter or metal.

FUMES AND GASES
can be dangerous.

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

fumes and gases away from the breathing zone. When

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

5. b. The operation of welding fume control equipment is affected
by various factors including proper use and positioning of
the equipment, maintenance of the equipment and the spe­cific welding procedure and application involved. Worker
exposure level should be checked upon installation and
periodically thereafter to be certain it is within applicable
OSHA PEL and ACGIH TLV limits.

5.c.

Do not weld in locations near chlorinated hydrocarbon
coming from degreasing, cleaning or spraying operations.
The heat and rays of the arc can react with solvent vapors
form phosgene, a highly toxic gas, and other irritating prod­ucts.

vapors

to

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

5.d. Shielding gases used for arc welding can displace air and

cause injury or death. Always use enough ventilation,
especially in confined areas, to insure breathing air is safe.

5.e. Read and understand the manufacturerʼs instructions for this

equipment and the consumables to be used, including the
material safety data sheet (MSDS) and follow your
employerʼs safety practices. MSDS forms are available from
your welding distributor or from the manufacturer.

5.f. Also see item 1.b.

AUG 06

iii

SAFETY

iii

WELDING and CUTTING
SPARKS can
cause fire or explosion.

6.a.

Remove fire hazards from the welding area.

If this is not possible, cover them to prevent

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 “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. They can cause an explosion even
been “cleaned”. For information, purchase “Recommended
Safe Practices for the
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.

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

6.f.
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 practical. 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 1.c.

the welding sparks from starting a fire.

though

they have

Preparation

for Welding and Cutting of

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 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 hand
tight 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-l,
“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 U.S. National
Electrical Code, all local codes and the manufacturerʼs
recommendations.

8.c. Ground the equipment in accordance with the U.S. National
Electrical Code and the manufacturerʼs recommendations.

6.I. Read and follow NFPA 51B “ Standard for Fire Prevention
During Welding, Cutting and Other Hot Work”, available
from NFPA, 1 Batterymarch Park,PO box 9101, Quincy, Ma
022690-9101.

6.j. Do not use a welding power source for pipe thawing.

Jan, 07

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 LʼArc

1. Protegez-vous contre la secousse électrique:

a. Les circuits à lʼélectrode 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 sʼisoler 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 lʼeau 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 sʼapplicuent aussi au pistolet de
soudage.

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

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

6. Eloigner les matériaux inflammables ou les recouvrir afin de
prévenir tout risque dʼincendie 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 dʼincendie.

8. Sʼassurer que la masse est connectée le plus prés possible
de la zone de travail quʼil est pratique de le faire. Si on place
la masse sur la charpente de la construction ou dʼautres
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 dʼincendie ou dʼechauffement des chaines et des
câbles jusquʼà ce quʼils 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
dʼopérations de dégraissage, nettoyage ou pistolage. La
chaleur ou les rayons de lʼarc peuvent réagir avec les vapeurs
du solvant pour produire du phosgéne (gas fortement toxique)
ou autres produits irritants.

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

PRÉCAUTIONS DE SÛRETÉ POUR

3. Un coup dʼarc peut être plus sévère quʼun coup de soliel,
donc:

a. Utiliser un bon masque avec un verre filtrant approprié

ainsi quʼun verre blanc afin de se protéger les yeux du ray­onnement de lʼarc et des projections quand on soude ou
quand on regarde lʼarc.

b. Porter des vêtements convenables afin de protéger la

peau de soudeur et des aides contre le rayonnement de
lʻarc.

c. Protéger lʼautre personnel travaillant à proximité au

soudage à lʼaide dʼécrans appropriés et non-inflammables.

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

LES MACHINES À SOUDER À
TRANSFORMATEUR ET À
REDRESSEUR

1. Relier à la terre le chassis du poste conformement au code de
lʼélectricité 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, Iʼinstallation et lʼentretien du poste seront
effectués par un électricien qualifié.

3. Avant de faires des travaux à lʼinterieur de poste, la debranch­er à lʼinterrupteur à la boite de fusibles.

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

Mar. ʻ93

Thank You

vv

for selecting a QUALITY product by Lincoln Electric. We want you
to take pride in operating this Lincoln Electric Company product

••• as much pride as we have in bringing this product to you!

The business of The Lincoln Electric Company is manufacturing and selling high quality welding equipment, consumables, and cutting equip­ment. Our challenge is to meet the needs of our customers and to exceed their expectations. On occasion, purchasers may ask Lincoln
Electric for advice or information about their use of our products. We respond to our customers based on the best information in our posses­sion at that time. Lincoln Electric is not in a position to warrant or guarantee such advice, and assumes no liability, with respect to such infor­mation or advice. We expressly disclaim any warranty of any kind, including any warranty of fitness for any customerʼs particular purpose,
with respect to such information or advice. As a matter of practical consideration, we also cannot assume any responsibility for updating or
correcting any such information or advice once it has been given, nor does the provision of information or advice create, expand or alter any
warranty with respect to the sale of our products.

Lincoln Electric is a responsive manufacturer, but the selection and use of specific products sold by Lincoln Electric is solely within the control
of, and remains the sole responsibility of the customer. Many variables beyond the control of Lincoln Electric affect the results obtained in
applying these types of fabrication methods and service requirements.

Subject to Change – This information is accurate to the best of our knowledge at the time of printing. Please refer to www.lincolnelectric.com
for any updated information.

CUSTOMER ASSISTANCE POLICY

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

TABLE OF CONTENTS

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

Vehicle Mounting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .A-3

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

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

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

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

Engine Coolant . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .A-4

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

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

Spark Arrestor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .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

vi

Page

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

vii vii

TABLE OF CONTENTS

Page

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,D-2

Fuel Filters . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .D-3

Cooling System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .D-3

Battery Handling . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .D-3

Charging the Battery . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .D-4

Nameplate / Warning Decal Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .D-4

Welder / Generator Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .D-4

Engine Maintenance Components . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .D-4

GFCI Receptacle Testing and Restting Procedure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .D-5

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

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

Parts Lists . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .P- 508

A-1

INSTALLATION

TECHNICAL SPECIFICATIONS - VANTAGE 500 CUMMINS (K2406-1)

INPUT - DIESEL ENGINE

Make /Model Description Speed (RPM) Displacement Starting Capacities

System

CUMMINS 4 cylinder High Idle 1890 199 cu. in 12VDC battery Fuel
B3.3 53HP (40 kw) Low Idle 1400 (3.3L) & Starter 25 US gal.
Diesel Engine @ 1800 RPM Full Load 1890 (94.6L)

Bore x Stroke Oil:

2 US gal.

3.74” x 4.53” (7.6L)

(95mm x 115mm) Coolant

2 US gal. (7.6L)

RATED OUTPUT @ 104°F(40°C) - WELDER

Duty Cycle Welding Output Volts at Rated Amps

A-1

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

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

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

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

Welding Range

30 - 575 Amps CC/CV

20 - 250 Amps TIG

Open Circuit Voltage

60 Max OCV @ 1900 RPM

Auxiliary Power

120/240 VAC

12,000 WATTS, 60 Hz., Single Phase

20,000 WATTS, 60 Hz., Three Phase

(1)

PHYSICAL DIMENSIONS

Height

(2)

Width Depth Weight

42.0 in 31.5 in. 63.1 in. 1443lbs.

(1066.8 mm) (800.1mm) (1603mm) (655kg)

(Approx)

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 7.0” (177.8mm) for exhaust.

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 canʼt 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 500 CUMMINS machines cannot be
stacked.

ANGLE OF OPERATION

To achieve optimum engine performance the VAN­TAGE 500 CUMMINS should be run in a level posi­tion. The maximum angle of operation for the
Cummins engine is 35 degrees in all directions. When
operating the welder at an angle, provisions must be
made for checking and maintaining the oil level at the
normal (FULL) oil capacity. Also the effective fuel
capacity will be slightly less than the specified 25
gal.(94.6 ltrs.).

VANTAGE 500 CUMMINS

A-3

INSTALLATION

A-3

LIFTING

The VANTAGE 500 CUMMINS lift bail should be used
to lift the machine. The VANTAGE 500 CUMMINS is
shipped with the lift bail retracted. Before attempting
to lift the VANTAGE 500 CUMMINS the lift bail must
be secured in a raised position. Secure the lift bail 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
bail.

c. Use the lifting strap to raise the lift bail to the

full upright position. This will align the mount­ing holes on the lift bail with the access holes.

d. Secure the lift bail 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 lift bail is

EQUIPMENT can damaged.

cause injury. • Do not operate machine while

suspended from lift bail.

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

HIGH ALTITUDE OPERATION

TOWING

The recommended trailer for use with this equipment
for road, in-plant and yard towing by a vehicle
Lincolnʼs K953-1. If the user adapts a non-Lincoln
trailer, he must assume responsibility that the method
of attachment and usage does not result in a safety
hazard nor damage the welding equipment. Some of
the factors to be considered are as follows:

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

2. Proper support of, and attachment to, the base
of the welding equipment so that there will be
no undue stress to the trailerʼs 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)

(1)

VEHICLE MOUNTING

WARNING

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

is

.

At higher altitudes, output derating may be necessary.
For maximum rating, derate the welder output 5% for
every 300 meters (984 ft.) above 1500 meters (4920
ft.). For output of 500A and below, derate the welder
output 5% for every 300 meters (984 ft.) above 2100
meters (6888 ft.).

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

VANTAGE 500 CUMMINS

• 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 manufacturerʼs instructions.

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

A-4

INSTALLATION

A-4

PRE-OPERATION ENGINE

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

WARNING

• Keep hands away from the engine muf­fler or HOT engine parts.

• Stop engine and allow to cool before
fuelling.

• Do not smoke when fuelling.

• Fill fuel tank at a moderate rate and do not over-fill.

• Wipe up spilled fuel and allow fumes to clear before
starting engine.

• Keep sparks and flame away from tank.

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

OIL

The VANTAGE 500 CUMMINS is shipped with the
engine crankcase filled with high quality SAE 10W-30 oil
(API class CD or better). Check the engine 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 Operatorʼs Manuals 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
Operatorʼs Manuals for the proper service and mainte­nance intervals.

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, wet stacking (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 diesel­powered equipment needs only to be run at a reason­ably heavy load within the rating of the welder for
some period of time during the engineʼs 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.

FUEL USE DIESEL FUEL ONLY

Fill the fuel tank with clean, fresh diesel fuel. The capaci­ty of the fuel tank is approximately 25 gallons (95 liters).
See engine Operatorʼs 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).

FUEL CAP

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

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. (See
the MAINTENANCE section and the engine Owners
Manual for more information on coolant.)

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.

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.

VANTAGE 500 CUMMINS

A-5

• 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.

IMPORTANT: To prevent ELECTRICAL

DAMAGE WHEN:

a) Installing new batteries.

b) Using a booster.

Use correct polarity — Negative Ground.

The VANTAGE 500 CUMMINS 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.

INSTALLATION

MUFFLER OUTLET PIPE

Remove the plastic plug covering the muffler outlet tube.
Using the clamp provided secure the outlet pipe to the outlet
tube with the pipe positioned such that it will direct the
exhaust in the desired position.

SPARK ARRESTOR

Some federal, state or local laws may require that petrol or
diesel engines be equipped with exhaust spark arresters
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.

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

AIR CLEANER INLET HOOD

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

A-5

WELDING TERMINALS

The VANTAGE 500 CUMMINS is equipped with a toggle
switch for selecting "hot" welding terminals when in the
"WELD TERMINALS ON" position or "cold" welding 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 ELEC-

TRODE AND WORK CABLES

AMPS Up to 200ft 1200-250ft

@100% Up to 656m 656-820m

Duty Cycle

500 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 10Ft.(3.1m) 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 500 CUMMINS is equipped with a 6­pin and a 14-pin connector. The 6-pin connector is for
connecting the K857 or K857-1 Remote Control or for
TIG welding, the K870 foot Amptrol or the K963-3
Hand Amptrol. When in the CC-STICK, DOWNHILL
PIPE, or CV-WIRE modes and when a remote control
is connected to the 6-pin 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

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

AUXILIARY POWER RECEPTACLES

Start the engine and set the “IDLER” control switch to
the “High Idle” mode. Voltage is now correct at the
receptacles for auxiliary power. This must be done
before a tripped GFCI receptacle can be reset proper­ly. See the MAINTENANCE section for detailed infor­mation on testing and resetting the GFCI receptacle.

The VANTAGE 500 CUMMINS has two 20 Amp­120VAC single phase(5-20R) GFCI duplex recepta­cles, one 50 Amp-120/240 single phase VAC (14­50R) receptacle and one 240VAC three phase (15­50R) receptacle. 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.

A 240VAC 3 phase plug is provided loose with the
machine.

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.

STANDBY POWER CONNECTIONS

The VANTAGE 500 CUMMINS is suitable for tempo­rary, standby or emergency power using the engine
manufacturerʼs recommended maintenance schedule.

The VANTAGE 500 CUMMINS 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.

The auxiliary power capacity of the VANTAGE 500
CUMMINS is 12,000 watts of 60 Hz, single phase 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 output is 50 A. The
240 VAC single phase 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.

VANTAGE 500 CUMMINS

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

A-7

2

S

AD

RE

INSTALLATION

A-7

2. Take necessary steps to assure load is limited to
the capacity of the VANTAGE 500 CUMMINS by
installing a 50 amp, 240 VAC double pole circuit
breaker. Maximum rated load for each leg of the
240 VAC auxiliary is 50 amps. Loading above the

3. Install a 50 amp 120/240 VAC plug (NEMA Type
14-50R) to the double-pole circuit breaker using #6
or #4 conductor cable of the desired length. (The 50
amp, 120/240 VAC plug is available in the optional
K802N or K802R plug kits or by itself as T12153-9.)

rated output will reduce output voltage below the
allowable -10% of rated voltage which may damage
appliances or other motor-driven equipment and

4. Plug this cable into the 50 Amp 120/240 Volt recep­tacle on the VANTAGE 500 CUMMINS case front.

may result in overheating of the VANTAGE 500
CUMMINS engine.

Figure A.2 Connection of the VANTAGE 500 CUMMINS to Premises Wiring

240 VOLT

40 Volt
60 Hz.

3-Wire

ervice

POWER

COMPANY

METER

120 VOLT

120 VOLT

GROUNDED CONDUCTOR

NEUTRAL
BUS

N

LO

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

50 AMP, 120/240

VOLT PLUG

NEMA TYPE 14-50

240 VOLT

50AMP

240 VOLT

DOUBLE

POLE

CIRCUIT

BREAKER

GND

PREMISES

DISCONNECT AND

GROUND

N

SERVICE

OVERCURRENT

PROTECTION

50 AMP, 120/240 VOLT

RECEPTACLE

VANTAGE 500 CUMMINS

NOTE: No. 6 COPPER CONDUCTOR CABLE SEE

NATIONAL ELECTRICAL CODE FOR ALTERNATE WI

SIZE RECOMMENDATIONS.

A-8

INSTALLATION

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 500 CUMMINS

• Shut the welder off.

A-8

• 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.

• 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 500 CUMMINS

These connections instructions apply to both the LN­15 Across-The-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.

• Across The-Arc Model:

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

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 "AUTO IDLE" posi­tion.

• 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 "AUTO IDLE" posi­tion.

• 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.

VANTAGE 500 CUMMINS

A-9

INSTALLATION

A-9

CONNECTION OF THE LN-25 TO THE
VANTAGE 500 CUMMINS

The LN-25 with or without an internal contactor may
be used with the VANTAGE 500 CUMMINS. See the
appropriate connection diagram in the DIAGRAMS
section.

NOTE: The LN-25 (K431) Remote Control Module
and (K432) Remote Cable are not recommended for
use with the VANTAGE 500 CUMMINS.

• Shut the welder off.

• For electrode Positive, connect the electrode cable

from the LN-25 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 500 CUMMINS engine
will be at the low idle speed. If you are using an LN­25 with an internal contactor, the electrode is not
energized until the gun trigger is closed.

CAUTION

If you are using an LN-25 without an internal con­tactor, the electrode will be energized when the
VANTAGE 500 CUMMINS 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 500
CUMMINS

For connection diagrams and instructions for connect­ing an NA-3 Welding System to the VANTAGE 500
CUMMINS, 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 voltmeter to the proper polarity of the
electrode.

CONNECTION OF MAGNUM SC SPOOL
GUN TO THE VANTAGE 500 CUMMINS
(SEE SECTION F)

CONNECTION OF PRINCE XL SPOOL
GUN TO THE VANTAGE 500 CUMMINS

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

VANTAGE 500 CUMMINS