Lincoln Electric VANTAGE 500 User Manual 2

®

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VA NTAG E 5 00

IM957

April, 2009

For use with machine having Code Number:

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. And, most

importantly, think before you act
and be careful.

11467

Equipped with VRD (VOLTAGE REDUCTION DEVICE)
See Installation and Operation sections for an explanation.

OPERATOR’S MANUAL

Copyright © Lincoln Global Inc.

• World's Leader in Welding and Cutting Products •

• Sales and Service through Subsidiaries and Distributors Worldwide •

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

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 so me ca ses i t may b e neces sary to remove s
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.b. Operate engines in open, well-ventilated
areas or
outdoors.

1.c. Do not add the fuel near

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

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

vent the engine exhaust fumes

an open flame
welding arc or when the engine is running.
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.

afety

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
work, disconnect the spark plug wires, distributor cap or
magneto wire as appropriate.

engine or welding generator during maintenance

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 ‘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

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.

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

skin or wet clothing. Wear dry, hole-free

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

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 within applicable OSHA PEL and
ACGIH TLV limits 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.

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.

ventilation and/or exhaust at the arc to keep

vapors

to

5.e. 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.f. Also see item 1.b.

Jan ‘09

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. Us e 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 manufacturer’s
recommendations.

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

Refer to http://www.lincolnelectric.com/safety for additional safety information.

Jan ‘09

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

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 customer’s 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

Page

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

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

Machine Specification ...................................................................................................A-2

Safety Precautions ........................................................................................................A-3

VRD (Voltage Reduction Device)..................................................................................A-3

Location and Ventilation................................................................................................A-3

Stacking ........................................................................................................................A-3

Angle of Operation ........................................................................................................A-3

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

High Altitude Operation .................................................................................................A-4

High Temperature Operation ........................................................................................A-4

Cold Weather Operation ......................................................................................................A-4

Towing..................................................................................................................................A-4

Vehicle Mounting..................................................................................................................A-4

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

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

Fuel ...............................................................................................................................A-5

Engine Coolant..............................................................................................................A-5

Battery Connections......................................................................................................A-5

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

Spark Arrester ...............................................................................................................A-5

Remote Control .............................................................................................................A-5

Electrical Connections..........................................................................................................A-6

Machine Grounding ..............................................................................................................A-6

Welding Terminals................................................................................................................A-6

Welding Output Cables ........................................................................................................A-6

Cable Installation..................................................................................................................A-6

Auxiliary Power Receptacles and Plugs...............................................................................A-7

Standby Power Connections ................................................................................................A-7

Premises Wiring ...................................................................................................................A-8

Connection of Lincoln Electric Wire Feeders..............................................................A-9, A-10

________________________________________________________________________________

vi

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

Safety Precautions ..............................................................................................................B-1

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

For Auxiliary Power ..............................................................................................................B-1

Engine Operation..................................................................................................................B-1

Add Fuel ...............................................................................................................................B-1

Break in Period.....................................................................................................................B-1

Welder Controls .............................................................................................................B-2,B-3

Engine Controls....................................................................................................................B-4

Starting and Stopping the Engine...........................................................................B-4,B-5

Welding Operation................................................................................................................B-5

Duty Cycle and Electrode Information...........................................................................B-5

Constant Current (Stick) Welding.........................................................................................B-5

Downhill Pipe (Stick) Welding................................................................................B-5, B-6

Tig Welding ...................................................................................................................B-6

Typical Current Ranges for Tungsten Electrodes .........................................................B-6

Wire Welding-CV...........................................................................................................B-7

Arc Gouging ..................................................................................................................B-7

Auxiliary Power.....................................................................................................................B-7

Simultaneous Welding and Power Loads .....................................................................B-7

Extension Cord Recommendations...............................................................................B-7

________________________________________________________________________________

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

Field Installed

________________________________________________________________________________

Options / Accessories ...............................................................................C-1

vii

TABLE OF CONTENTS

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

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

Routine Maintenance ............................................................................................D-1

Engine Service Items.............................................................................................D-1

Engine Oil Change..........................................................................................D-2

Engine Oil Filter Change.................................................................................D-2

Air Cleaner .....................................................................................................D-2

Service Instructions And Installation Tips for Engine Air Filter .......................D-3

Cooling System .....................................................................................................D-4

Fan Belt...........................................................................................................D-4

Fuel .................................................................................................................D-4

Bleeding the Fuel System ...............................................................................D-4

Fuel Filter ........................................................................................................D-5

Engine Adjustment ..........................................................................................D-5

Battery Maintenance .......................................................................................D-5

Servicing Optional Spark Arrestor ...................................................................D-5

Welder / Generator Maintenance ........................................................................D-6

Storage ...........................................................................................................D-6

Cleaning..........................................................................................................D-6

Brush Removal and Replacement ..................................................................D-6

________________________________________________________________________

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

How to Use Troubleshooting Guide.......................................................................E-1

Troubleshooting Guide.............................................................................E-2 thru E-6

________________________________________________________________________

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

________________________________________________________________________

Parts List.....................................................................................................P-578 Series

________________________________________________________________________

vii

A-1

INSTALLATION

TECHNICAL SPECIFICATIONS - VANTAGE® 500 (K2686 -1)

INPUT - DIESEL ENGINE

Make/Model Description Speed (RPM) Displacement Starting Capacities

cu. in. (ltrs.) System

A-1

4 cylinder 135.6(2.2)

12VDC Battery &

Fuel: 20 gal.

43 HP High Idle 1850 starter (75.7 L)

PERKINS 1850 RPM

Bore x Stroke inch (mm)

(Group 34; 650

Oil: 8.45Qts. (8L)

404D-22T Turbo Charged Full Load 1850 cold crank amps)

water cooled
Diesel Engine Low Idle 1400

3.43 X 3.64

(87.1 x 92.5mm) W / Built in Regulator 11.5 Qts. (10.9L)

65 Amp Alternator Radiator Coolant:

RATED OUTPUT @ 104° F (40° C) - WELDER

Welding Process

DC Constant Current

DC Pipe Current

Touch-Start™TIG

DC Constant Voltage

Arc Gouging

Welding Output

Current/Voltage/Duty Cycle

500A / 40V / 100%

525A / 38V / 60%
300A / 32V / 100%
250A / 30V / 100%
500A / 40V / 100%

525A / 38V / 60%
500A / 40V / 100%

Output Range

30 TO 525 AMPS

40 TO 300 AMPS
20 TO 250 AMPS

14 TO 40 VOLTS

90 TO 500 AMPS

Max. Weld OCV

@Rated Load RPM

60 Volts

60 Volts

RATED OUTPUT @ 40° C (104° F).- GENERATOR

Auxiliary Power

13,000 Watts Peak / 12,000 Watts Continuous, 60 Hz 120/240 Volts Single Phase

22,000 Watts Peak / 20,000 Watts Continuous, 60 Hz 240 Volts 3 Phase

(1)

ENGINE

LUBRICATION EMISSIONS FUEL SYSTEM GOVERNOR

Full Pressure EPA Tier 4
with Full Flow Filter

Interim Compliant system, Electric shutoff solenoid, Indirect fuel injection.

Mechanical Fuel Pump, Auto air bleed Electronic

(2)

AIR CLEANER ENGINE IDLER MUFFLER ENGINE PROTECTION

Low noise Muffler: Shutdown on low oil

Single Element Automatic Idler Top outlet can be rotated. pressure & high engine

Made from long life, aluminized steel. coolant temperature

ENGINE WARRANTY: 2 years / 2000 hours, all non-electric components, 3 years major non-electric compo­nents . See Perkins warranty for details.

PHYSICAL DIMENSIONS

HEIGHT WIDTH DEPTH WEIGHT

(4)

35.94

913 mm 687 mm 1590 mm

(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) Reduced to less than 30V in the CC-stick Mode when VRD (VOLTAGE REDUCTION DEVICE) is on.

(3) Maximum per circuit breaker rating.

(4) To Top of enclosure. Add 7.35 (186.7mm) to top of exhaust. Add 3.87”(98.3mm) to top of Lift Bail.

in. 27.05 in 62.59 in.

VANTAGE®500

1290 lbs. (586kg.)

A-2

INSTALLATION

MACHINE SPECIFICATIONS

RECEPTACLES AUXILIARY POWER CIRCUIT Breaker OTHER CIRCUIT BREAKERS

A-2

(2)120VAC Duplex (5-20R) GFCI Protected

(1) 120/240 VAC Dual Voltage

Full KVA (14-50R)

(1) 240VAC 3-Phase (15-50R)

Two 20AMP for Two Duplex Receptacle

(1) 50AMP for Dual Voltage and for

10AMP for Battery Charging Circuit

10AMP for 42V Wire Feeder Power

3-Phase (3-pole)

VANTAGE®500

A-3

SAFETY PRECAUTIONS

INSTALLATION

A-3

FIGURE A.1

WARNING

Do not attempt to use this equipment until you
have thoroughly read the engine manufacturer’s
manual supplied with your welder. It includes
important safety precautions, detailed engine
starting, operating and maintenance instructions,
and parts lists.

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

ELECTRIC SHOCK can kill.

• Do not touch electrically live parts or

electrode with skin or wet clothing.

• Insulate yourself from 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.

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

See additional warning information at

front of this operator’s manual.

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

VRD (VOLTAGE REDUCTION DEVICE)

(VRD)-VOLTAGE REDUCTION DEVICE
SWITCH IS LOCATED IN THIS AREA.

REMOVE 4 FRONT PANEL
SCREWS TO ACCESS
(VRD) SWITCH

LOCATION AND 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.

STACKING

VANTAGE® 500 machines cannot be stacked.

The VRD feature provides additional safety in the CC-Stick
mode especially in an environment with a higher risk of
electric shock such as wet areas and hot humid sweaty
conditions.

The VRD reduces the OCV (Open Circuit Voltage) at the
welding output terminals while not welding to less than 13V
DC when the resistance of the output circuit is above 200⏐
(ohms).

The VRD requires that the welding cable connections be
kept in good electrical condition because poor connections
will contribute to poor starting. Having good electrical con­nections also limits the possibility of other safety issues
such as heat-generated damage, burns and fires.

The machine is shipped with the VRD switch in the “Off”
position. To turn it “On” or “Off”.

• Turn the engine “Off”.

• Disconnect the negative battery cable.

• Lower the control panel by removing 4 front
panel screws.

• Place the VRD switch in the “On” or “Off” position.
(See Figure A.1)

With the VRD switch in the “On” position, the VRD lights
are enabled.

(See Figure A.1)

VANTAGE®500

ANGLE OF OPERATION

Engines are designed to run in the level condition
which is where the optimum performance is achieved.
The maximum angle of continuous operation is 25
degrees in all directions, 35 degrees Intermittent (less
than 10 minutes continuous) 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 amount
specified.

LIFTING

The VANTAGE® 500 weighs approximately 1460lbs.
(662kg.) with a full tank of fuel 1290lbs. (586kg) less
fuel. A lift bail is mounted to the machine and should
always be used when lifting the machine.

A-4

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

At higher altitudes, output derating may be necessary. For
maximum rating, derate the machine 1.0% for every 2000 ft.
(610m) up to 6000 ft. (1828m) and 2.0% for every 2000 ft.
(610m) over 6000 ft. (1828m). Due to new EPA and other
local emissions regulations, modifications to the engine for
high altitude are restricted within the United States. If
required contact an authorized Perkins engine field service
shop to determine if any adjustments can be made for oper­ation in higher elevations.

HIGH TEMPERATURE OPERATION

At temperatures above 104°F(40°C), Welder output derating
is necessary. For maximum output ratings, derate the
welder output 2 volts for every 18°F(10°C) above
104°F(40°C).

Cold weather starting:

With a fully charged battery and the proper oil, the
engine should start satisfactorily down to -15°F(­26C°). If the engine must be frequently started at or
below 0°F (-18°C), it may be desirable to install cold­starting aides. The use of No. 1D diesel fuel is recom­mended in place of No. 2D at temperatures below
23°F (-5°C). Allow the engine to warm up before
applying a load or switching to high idle.

Note: Extreme cold weather starting may require
longer glow plug operation.

WARNING

Under no conditions should ether or other starting
fluids be used with this engine!

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

TOWING

Use a recommended trailer for use with this equipment for road,
in-plant and yard towing by a vehicle(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 or damage the welding equipment. Some of the factors
to be considered are as follows:

INSTALLATION

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 there will be no undue stress to the 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 while being operated or serviced.

4. Typical conditions of use, i.e., travel speed; roughness of sur­face on which the trailer will be operated; environmental con­ditions; like maintenance.

5. Conformance with federal, state and local laws.

(1)

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

VEHICLE MOUNTING

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

• 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.

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

PRE-OPERATION ENGINE SERVICE

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

• Stop engine and allow to cool before fueling.

• Do not smoke when fueling.

• Fill fuel tank at a moderate rate and do not over­fill.

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

• Keep sparks and flame away from tank.

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

OIL

The VANTAGE® 500 is shipped with the engine crankcase filled
with high quality SAE 10W-30 Oil that meets classification CG-4 or
CH-4 for diesel engines. 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 50 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 more

details on the proper service and maintenance intervals.

A-4

(1)

WARNING

WARNING

VANTAGE®500

A-5

INSTALLATION

FUEL

USE DIESEL FUEL ONLY­Low Sulphur fuel or ultra low sulphur fuel in USA and

CANADA only.

WARNING

• Fill the fuel tank with clean, fresh fuel. The capacity of
the tank is 20 gals. (75.7 ltrs). When the fuel gauge
reads empty the tank contains approximately 2 gals.
(7.6ltrs.) of reserve fuel.

NOTE: A fuel shut off valve is located on the pre-fil-

ter/sediment filter. Which should be in the closed
position when the welder is not used for extend­ed periods of time.

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

ENGINE COOLING SYSTEM

WARNING

Air to cool the engine is drawn in the side and exhaust­ed through radiator & case back. It is important that the
intake and exhaust air is not restricted. Allow a mini­mum clearance of 1ft. (0.6m) from the case back and 16
in. (406mm) from either side of the base to a vertical
surface.

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

BATTERY CONNECTION

CAUTION

Use caution as the electrolyte is a strong acid that can
burn skin and damage eyes.

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

The VANTAGE® 500 is shipped with the negative battery
cable disconnected. Make certain that the RUN-STOP
switch is in the STOP position. Remove the two screws from
the battery tray using a screwdriver or a 3/8"(10mm) socket.
Attach the negative battery cable to the negative battery ter­minal and tighten using a 1/2"(13mm) socket or wrench.

NOTE: This machine is furnished with a wet charged
battery; if unused for several months, the battery may
require a booster charge. Be careful to charge the bat­tery with the correct polarity. (See Battery in
“Maintenance Section”)

MUFFLER OUTLET PIPE

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 direction. Tighten
using a 9/16"(14mm) socket or wrench.

SPARK ARRESTER

Some federal, state or local laws may require that
gasoline or diesel engines be equipped with exhaust
spark arresters when they are operated in certain
locations where unarrested sparks may present a fire
hazard.

A-5

The standard muffler included with this welder does
not qualify as a spark arrester. When required by local
regulations, a suitable spark arrester, such as the
K903-1 must be installed and properly maintained.

WARNING

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

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

REMOTE CONTROL

The VANTAGE® 500 is equipped with a 6-pin and a
14-pin connector. The 6-pin connector is for connect­ing the K857 or K857-1 Remote Control or for TIG
welding, the K870 foot Amptrol or the K963-3 hand
Amptrol. When in the CC-STICK, ARC GOUGING 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.

When in the DOWNHILL PIPE mode and when a
remote control is connected to the 6-Pin or 14-Pin
connector, the output control is used to set the max­imum current range of the remote.

EXAMPLE: When the OUTPUT CONTROL on the
welder is set to 200 amps the current range on the
remote control will be 40-200 amps, rather than the
full 40-300 amps. Any current range that is less than
the full range provides finer current resolution for more
fine tuning of the output.

In the CV-WIRE mode, if the feeder being used has a
voltage control when the wire feeder control cable is
connected to the 14-Pin Connector, the auto-sensing
circuit automatically makes OUTPUT CONTROL inac­tive and the wire feeder voltage control active.
Otherwise, the OUTPUT CONTROL is used to preset
the voltage.

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.

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

VANTAGE®500

A-6

INSTALLATION

ELECTRICAL CONNECTIONS

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
to which this engine driven welder supplies power
must:

A-6

WELDING OUTPUT CABLES

With the engine off connect the electrode and work
cables to the output studs. The welding process dic­tates the polarity of the electrode cable. These con­nections should be checked periodically and tightened
with a 3/4"(19mm) wrench.

Table A.1 lists recommended cable sizes and lengths
for rated current and duty cycle. Length refers to the
distance from the welder to the work and back to the
welder. Cable diameters are increased for long cable
lengths to reduce voltage drops.

WARNING

• Be grounded to the frame of the welder using a
grounded type plug or be double insulated.

• Do not ground the machine to a pipe that carries
explosive or combustible material.

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

When this welder is mounted on a truck or trailer, its
frame must be electrically bonded to the metal frame
of the vehicle. Use a #8 or larger copper wire connect­ed between the machine grounding stud and the
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 code.

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 water pipe going into
the ground for at least ten feet and having no insulat­ed joints, or to the metal framework of a building
which has been effectively grounded.

The National Electrical 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.

TOTAL COMBINED LENGTH OF

ELECTRODE AND WORK CABLES

Cable Length

0-100 Ft. (0-30 meters)

100-150 Ft. (30-46 meters)

150-200 Ft. (46-61 meters)

TABLE A.1

Cable Size for

400 Amps

60% Duty Cycle

2 / 0 AWG

2 / 0 AWG

3 / 0 AWG

CABLE INSTALLATION

Install the welding cables to your VANTAGE® 500 as
follows.

1. The engine must be OFF to install welding cables.

2. Remove the flanged nuts from the output terminals
.

3. Connect the electrode holder and work cables to
the weld output terminals. The terminals are identi­fied on the case front.

4. Tighten the flanged nuts securely.

5. Be certain that the metal piece you are welding (the
“work”) is properly connected to the work clamp and
cable.

WELDING TERMINALS

The VANTAGE® 500 is equipped with a toggle switch
for selecting "hot" welding terminal when in the
"WELD TERMINALS ON" position or "cold" welding
terminal when in the "REMOTELY CONTROLLED"
position.

VANTAGE®500

6. Check and tighten the connections periodically.

CAUTION

• Loose connections will cause the output termi-

nals to overheat. The terminals may eventually
melt.

• Do not cross the welding cables at the output ter-

minal connection. Keep the cables isolated and
separate from one another.

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

A-7

INSTALLATION

AUXILIARY POWER RECEPTACLES

A-7

STANDBY POWER CONNECTIONS

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 module can be reset properly. See the
MAINTENANCE section for more detailed information on
testing and resetting the GFCI module.

The auxiliary power of the VANTAGE® 500 consists of
two 20 Amp-120 VAC (5-20R) duplex receptacles with
GFCI protection, one 50 Amp 120/240 VAC (14-50R)
receptacle and one 50 Amp 240VAC Three-Phase (15­50R) receptacle.

The auxiliary power capacity is 13,000 watts Peak,
12,000 Watts Continuous of 60 Hz, single phase power.
The auxiliary power capacity rating in watts is equivalent
to volt-amperes at unity power factor. The max permissi­ble current of the 240 VAC output is 50amps.

The 240 VAC output can be split to provide two separate
120 VAC outputs with a max permissible current of 50
Amps per output to two separate 120 VAC branch circuits
(these circuits cannot be paralleled). Output voltage is
within ± 10% at all loads up to rated capacity.

The Three-Phases auxiliary power capacity is 22,000
watts peak, 20,000 watts continuous. The maximum cur­rent is 45 amps.

120 V DUPLEX RECEPTACLES AND GFCI MODULES

A GFCI Module protects the two 120V auxiliary power
receptacles.

A GFCI (Ground Fault Circuit Interrupter) is a device to
protect against electric shock should a piece of defective
equipment connected to it develop a ground fault. If this
situation should occur, the GFCI module will trip, remov­ing voltage from the output of the receptacle. If a GFCI
module is tripped see the MAINTENANCE section for
detailed information on testing and resetting it. A GFCI
module should be properly tested at least once every
month.

The 120 V 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 240 V receptacle has two 120 V circuits, but
are of opposite polarities and cannot be paralleled.

All auxiliary power is protected by circuit breakers. The
120V has 20 Amp circuit breakers for each duplex recep­tacle. The 120/240V Single Phase and the 240V Three­Phases have a 50 Amp 3-pole Circuit Breaker that dis­connects both hot leads and all Three Phases simultane­ously.

VANTAGE®500

The VANTAGE® 500 is suitable for temporary, stand­by or emergency power using the engine manufactur­er’s recommended maintenance schedule.

The VANTAGE® 500 can be permanently installed as
a standby power unit for 240 VAC, 3 wire, single
phase, 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.

• 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.

• Take necessary steps to assure load is limited to
the capacity of the generator by installing a 50 amp,
240 VAC double pole circuit breaker. Maximum
rated load for each leg of the 240 VAC auxiliary is
50 amperes. 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 engine and/or alternator wind­ings.

• Install a 50 amp, 120/240 VAC plug (NEMA Type
14-50P) 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 or as part number T12153-9.)

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

WARNING

• Only a licensed, certified, trained electrician
should install the machine to a premises or resi­dential electrical system. Be certain that:

• The installation complies with the National
Electrical Code and all other applicable electri­cal codes.

• The premises is isolated and no feedback into
the utility system can occur. Certain laws require
the premises to be isolated before the generator
is linked to the premises. Check your local
requirements.

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

A-8

INSTALLATION

CONNECTION OF VANTAGE 500 TO PREMISES WIRING

A-8

WARNING

• Only a licensed, certified, trained electrician should install the machine to a premises or residential
electrical system. Be certain that:

• The installation complies with the National Electrical Code and all other applicable electrical codes.

• The premises is isolated and no feedback into the utility system can occur. Certain state and local

laws require the premises to be isolated before the generator is linked to the premises. Check your
state and local requirements.

• A double pole, double throw transfer switch in conjunction with the properly rated double throw

circuit breaker is connected between the generator power and the utility meter.

VANTAGE®500

A-9

INSTALLATION

CONNECTION OF LINCOLN ELECTRIC
WIRE FEEDERS

Connection of LN-7 or LN-8 to the VANTAGE® 500

1. Shut the welder off.

A-9

4. Control Cable Model:

• Connect Control Cable between Engine Welder
and Feeder.

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

2. Connect the LN-7 or LN-8 per instructions on the
appropriate connection diagram in Section F.

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

4. Set the "MODE" switch to the "CV WIRE " posi­tion.

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

6. Set the "WELD TERMINALS" switch to the
"REMOTELY CONTROLLED" position.

7. Set the "IDLE" switch to the "HIGH" position.

Connection of LN-15 to the VANTAGE® 500

1. Shut the welder off.

2. 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 to the
"-" terminal of the welder and work cable to the "+"
terminal of the welder.

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

• 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" position.

• When the gun trigger is closed, the current sens­ing circuit will cause the VANTAGE® 500 engine
to go to the high idle speed, the wire will begin to
feed and the welding process started. When
welding is stopped, the engine will revert to low
idle speed after approximately 12 seconds unless
welding is resumed.

3. 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.

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

• When the gun trigger is closed, the current sens­ing circuit will cause the VANTAGE® 500 engine
to go to the high idle speed, the wire will begin to
feed and the welding process started. When
welding is stopped, the engine will revert to low
idle speed after approximately 12 seconds
unless welding is resumed.

VANTAGE®500

A-10

WARNING

INSTALLATION

Spool Gun (K487-25) and Cobramatic to VAN­TAGE® 500

A-10

Connection of the LN-25 to the VANTAGE® 500
Shut off welder before making any electrical con­nections.

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

The LN-25 with or without an internal contactor may
be used with the VANTAGE® 500 . See the appropri­ate connection diagram in Section F.

1. Shut the welder off.

2.

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.

3. 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 control lead to supply current to the wire
feeder motor; it does not carry welding current.

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

• Shut the welder off.

• Connect per instructions on the appropriate connec­tion diagram in Section F.

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

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

7. Set the "IDLE" switch to the "AUTO" position.
When not welding, the VANTAGE® 500 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.

8. When the gun trigger is closed, the current sens­ing circuit will cause the VANTAGE® 500 engine
to go to the high idle speed, the wire will begin to
feed and the welding process started. When weld­ing is stopped, the engine will revert to low idle
speed after approximately 12 seconds unless
welding is resumed.

CAUTION

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

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

VANTAGE®500

B-1

OPERATION

SAFETY PRECAUTIONS

WARNING

Do not attempt to use this equipment until you
have thoroughly read the engine manufacturer’s
manual supplied with your welder. It includes
important safety precautions, detailed engine
starting, operating and maintenance instructions,
and parts lists.

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

ELECTRIC SHOCK can kill.

• Do not touch electrically live parts or
electrode with skin or wet clothing.

• Insulate yourself from work and
ground

• Always wear dry insulating gloves.

• Always operate the welder with the hinged door
closed and the side panels in place.

• Read carefully the Safety Precautions page
before operating this machine. Always follow
these and any other safety procedures included
in this manual and in the Engine Instruction
Manual.

GENERAL DESCRIPTION

The VANTAGE® 500 is a diesel engine powered DC
multi-process welding power source and AC power
generator. The engine drives a generator that supplies
three phase power for the DC welding circuit, single
phase and Three Phase power for the AC auxiliary
outlets. The DC welding control system uses state of
the art Chopper Technology for superior welding
performance.

C

R

T

B-1

• Add oil (if necessary) to bring the level up to the full
mark. Do not overfill. Close engine door.

• Check radiator for proper coolant level. (Fill if nec­essary).

• See Engine Owner’s Manual for specific oil and
coolant recommendations.

WARNING

ADD FUEL

• Stop engine while fueling.

• Do not smoke when fueling.

• Keep sparks and flame away
from tank.

• Do not leave unattended
while fueling.

DIESEL FUEL

can cause fire.

Diesel Fuel Only-Low Sulphur Fuel or Ultra Low
Sulphur in USA and Canada.

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

• Remove the fuel tank cap.

•

Fill the tank. DO NOT FILL THE TANK TO THE
POINT OF OVERFLOW.

• Replace the fuel cap and tighten securely.

• See Engine Owner’s Manual for specific fuel recom­mendations.

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

• Do not overfill tank, fuel
expansion may cause over­flow.

The VANTAGE® 500 is fitted with a selectable
VRD(Voltage Reduction Device). The VRD operates
in the CC-Stick mode reducing the OCV to <13 volts,
increasing operator safety when welding is performed
in environments with increased hazard of electric
shock such as wet areas and hot, humid sweaty con­ditions.

FOR AUXILIARY POWER:

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

ENGINE OPERATION

Before Starting the Engine:

• Be sure the machine is on a level surface.

• Open side engine door and remove the engine oil
dipstick and wipe it with a clean cloth. Reinsert the
dipstick and check the level on the dipstick.

VANTAGE®500

BREAK-IN PERIOD

The engine will use a small amount of oil during its
“break-in” period. The break-in period is about 50 run­ning hours.Check the oil every four hours during
break-in.

Change the oil after the first 50 hours of operation and
every 200 hours thereafter. Change the oil filter at
each oil change.

CAUTION

During break-in, subject the Welder to moderate
loads. Avoid long periods running at idle. Before
stopping the engine, remove all loads and allow
the engine to cool several minutes.

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

B-2

12

OPERATION

B-2

FIGURE B.1

11

111

1

2

3

4

9

10

13

14

15

16

17

18

19

20

5

WELDING CONTROLS (Figure B.1)

1. OUTPUT CONTROL- The OUTPUT dial is

used to preset the output voltage or current as dis­played on the digital meters for the five welding
modes. When in the CC-STICK, ARC GOUGING or
CV-WIRE modes and when a remote control is con­nected to the 6-Pin or 14-Pin Connector, the auto­sensing circuit automatically switches the OUTPUT
CONTROL from control at the welder to the remote
control.

When in the DOWNHILL PIPE mode and when a
remote control is connected to the 6-Pin or 14-Pin

connector, the output control is used to set the max­imum current range of the remote.

EXAMPLE: When the OUTPUT CONTROL on the
welder is set to 200 amps the current range on the

remote control will be 40-200 amps, rather than the
full 40-300 amps. Any current range that is less than
the full range provides finer current resolution for
more fine tuning of the output.

8

7

21

22

6

When in the TOUCH START TIG mode and when
an 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.

2.

DIGITAL OUTPUT METERS-

The digital
meters allow the output voltage (CV-WIRE mode)
or current (CC-STICK, DOWNHILL PIPE, ARC
GOUGING and TIG modes) to be set prior to weld­ing using the OUTPUT control dial. During welding,
the meter display the actual output voltage
(VOLTS) and current (AMPS). A memory feature
holds the display of both meters on for 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%.

In the CV-WIRE mode, if the feeder being used has
a voltage control 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. Otherwise, the OUTPUT CONTROL is used
to preset the voltage

VANTAGE®500

3. WELD MODE SELECTOR SWITCH-

(Provides five selectable welding modes)

CV-WIRE

ARC GOUGING
DOWNHILL PIPE
CC-STICK
TOUCH START TIG

B-3

OPERATION

B-3

4. ARC CONTROL

- The ARC CONTROL dial is active in

10. WIRE FEEDER VOLTMETER SWITCH:

the CV-WIRE, CC-STICK and DOWNHILL PIPE modes,
and has different functions in these modes. This control is
not active in the TIG and ARC GOUGING mode.

11. VRD (Voltage Reduction Device) INDICA-

CC-STICK mode: In this mode, the ARC CONTROL dial

sets the short circuit current (arc-force) during stick welding
to adjust for a soft or crisp arc. Increasing the dial 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
dial 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.

CV-WIRE mode: In this mode, turning the ARC CONTROL
clock wise 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.

5. WELD OUTPUT TERMINALS WITH FLANGE

Provides a connection point for the electrode and

NUT-

work cables.

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

TOR LIGHTS-

On the front panel of the VAN­TAGE® 500 are two indicator lights. A red light when
lit indicates

OCV(Open Circuit Voltage) is equal to or

greater than 30V and a green light when lit indicates

OCV(Open Circuit Voltage)

is less than 30V.

The VRD “On/Off” switch inside the control panel
must be “On” for the VRD function to be active and
the lights to be enabled. When the machine is first
started with VRD enabled, both lights will illuminate
for 5 seconds.

These lights monitor the

OCV(Open Circuit Voltage)

and weld voltage at all times. In the CC-Stick mode
when not welding the green light will illuminate indi­cating that the VRD has reduced the OCV to less
than 30V. During welding the red light will illuminate
whenever the arc voltage is equal to or greater than
30V. This means that the red and green light may
alternate depending on the weld voltage. This is nor­mal operation.

If the red light remains illuminated when not welding
in the CC-stick mode, the VRD is not functioning
properly. Please refer to your local field service shop
for service.

If the VRD is turned “On” and the lights don’t come
“On”, refer to the trouble shooting section.

6. GROUND STUD-

Provides a connection point for

connecting the machine case to earth ground.

7. 14-PIN CONNECTOR-

For attaching wire feeder con­trol cables. Includes contactor closure circuit, auto-sensing
remote control circuit, and 42V power. The remote control
circuit operates the same as the 6 Pin Amphenol.

8. 6-PIN CONNECTOR-

For attaching optional remote
control equipment. Includes auto-sensing remote control
circuit.

9. WELD TERMINALS CONTROL SWITCH-

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

VANTAGE®500

TABLE B.1

MODE VRD "ON" VRD "OFF"

CC-STICK OCV Green (OCV Reduced)

CV-WIRE OCV Red (OCV Not Reduced)

PIPE OCV Green (No Output)

ARC GOUGING

TIG OCV Green (Process is Low Voltage)

*

It is normal for the lights to alternate between colors while welding.

While Red or Green
Welding (Depends on Weld Voltage) *

While Red or Green
Welding (Depends on Weld Voltage) *

While Not Applicable (No Output)
Welding

OCV Green (No Output)
While Not Applicable (No Output)

Welding

While Green (Process is Low Voltage)
Welding

VRD INDICATOR LIGHTS

Weld Terminals On
Red (OCV Not Reduced)
Weld Terminals Remotely Controlled
Gun Trigger Closed
Green (No OCV)
Weld Terminals Remotely Controlled
Gun Trigger Open No Lights

B-4

OPERATION

ENGINE CONTROLS:

12. RUN/STOP SWITCH

-RUN position energizes the engine prior to starting.
STOP position stops the engine. The oil pressure inter­lock switch prevents battery drain if the switch is left in
the RUN position and the engine is not operating.

-

18. ELECTRIC FUEL GAUGE-

gauge gives accurate and reliable indication as to how
much fuel is in the fuel tank.

19. COOLANT TEMPERATURE GAUGE-

tor of engine coolant temperature.

The electric fuel

A indica-

B-4

13. GLOW PLUG PUSH BUTTON

• When pushed activates the glow plugs. Glow plug

should not be activated for more than 20 seconds con­tinuously.

14. START PUSH BUTTON

motor to crank the engine.

15. IDLER SWITCH

1) In the HIGH position, the engine runs at the high idle

speed controlled by the engine governor.

2) In the AUTO position, the idler operates as follows:

• 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.

• 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.

• When welding ceases or the AC power load is turned
off, a fixed time delay of approximately 12 seconds
starts. 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.

• The engine will automatically return to high idle speed
when there is welding load or AC power load reapplied.

- Has two positions as follows:

16. ENGINE HOUR METER-

that the engine has been running. This meter is useful
for scheduling prescribed maintenance.

17. CIRCUIT BREAKER-

Charging Circuit.

TABLE B.2

For protection of Battery

-

- Energizes the starter

Displays the total time

TYPICAL VANTAGE® 500 FUEL CONSUMPTION

PERKINS 404D-22T

Gal./Hr (Liters/Hr)

Low Idle - No Load
1400 R.P.M.
High Idle - No Load
1850 R.P.M.
DC Weld Output
500 Amps @ 40Volts
20,000 Watts 3 Phase

12,000 Watts 1 Phase

NOTE: This data is for reference only. Fuel consumption is
approximate and can be influenced by many factors, including
engine maintenance, environmental conditions and fuel quality.

.38(1.44)

.59(2.23)

2.15(8.14)

1.91(7.23)

1.30 (4.92)

Running Time for

20 gallons / hours

52.63

33.90

9.30

10.47

15.38

VANTAGE®500

20. OIL PRESSURE GAUGE-

Oil Pressure.

21. ENGINE PROTECTION LIGHT-

cator light for Low Oil Pressure and/or Coolant Over
Temperature.The light is off when the systems are func­tioning properly. The light will come on and the engine
will shutdown when there is Low Oil Pressure and/or
the Coolant is Over Temperature.

Note: The light remains off when the RUN-STOP switch

is in the "ON" position prior to starting the
engine.However if the engine is not started within
60 seconds the light will come on. When this hap
pens the RUN-STOP switch must be returned to
the "OFF" position to reset the engine protection
system and light.

22. BATTERY CHARGING LIGHT-

tor light for Low/No battery charge. The light is off when
the systems are functioning properly. The light will
come on if there is a Low/No battery condition but the
machine will continue to run.

Note: The light may or may not come on when the

RUN-STOP switch is in the "ON" position. It will
come on during cranking and stay on until the
engine starts. After starting the engine the light will
go off unless a Low/No battery charge condition
exists.

A indicator of engine

A warning indi-

A warning indica-

STARTING THE ENGINE

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

2. Set IDLER switch to AUTO.

3. Press Glow Plug Button and hold 15 to 20 seconds.

4. Set the RUN/STOP switch to RUN.

5. Press START button until the engine starts or for up to 10
seconds. Continue to hold the glow plug button for up to
an additional 10 seconds.

6. Release the engine START button immediately when the
engine starts.

7. The engine will run at high idle speed for approximately
12 seconds and then drop to low idle speed. Allow the
engine to warm up at low idle for several minutes before
applying a load and/or switching to high idle. Allow a
longer warm up time in cold weather.

B-5

NOTE: If the unit fails to start turn Run/Stop switch

to off and repeat step 3 through step 7 after
waiting 30 seconds.

OPERATION

CAUTION

• Do not allow the starter motor to run continuously
for more than 20 seconds.

• Do not push the START button while the engine
is running because this can damage the ring
gear and/or the starter motor.

• IF the Engine Protection or Battery Charging
Lights do “not” turn off shortly after starting the
engine shut off the engine immediately and
determine the cause.

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

NOTE: When starting for the first time, or after and
extended period of time of not operating, it will take
longer than normal to start because the fuel pump has
to fill the fuel system. For best results, bleed the fuel
system as indicated in Maintenance Section of this
manual.

STOPPING THE ENGINE

Remove all welding and auxiliary power loads and
allow the engine to run at low idle speed for a few
minutes to cool the engine.

STOP the engine by placing the RUN-STOP switch in
the STOP position.

NOTE:

WELDER OPERATION

DUTY CYCLE

Duty Cycle is the percentage of time the load is being
applied in a 10 minute period. For example a 60% duty
cycle, represents 6 minutes of load and 4 minutes of no
load in a 10 minute period.

ELECTRODE INFORMATION

For any electrode the procedures should be kept with­in the rating of the machine. For information on elec­trodes and their proper application see
(www.lincolnelectric.com) or the appropriate Lincoln
publication.

The VANTAGE® 500 can be used with a broad range of
DC stick electrodes. The MODE switch provides two
stick welding settings as follows:

CONSTANT CURRENT (CC-STICK)
WELDING

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

A fuel shut off valve is located on the fuel pre-filter.

B-5

The ARC CONTROL dial sets the short circuit current
(arc-force) during stick welding to adjust for a soft or
crisp arc. 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 dial set at 0.

NOTE: Due to the low OCV with the VRD on, a
very slight delay during striking of the electrodes
may occur. Due to the requirement of the resis­tance in the circuit to be low for a VRD to operate, a
good metal-to-metal contact must be made
between the metal core of the electrode and the
job. A poor connection anywhere in the welding
output circuit may limit the operation of the VRD.
This includes a good connection of the work clamp
to the job. The work clamp should be connected as
close as practical to where the welding will be per­formed.

A. For New Electrodes

E6010 - Touch, Lift to Start the Arc
E7018, E7024 - Touch, Rock Back and Forth in

Joint, Lift .

Once the arc is started, normal welding technique
for the application is then used.

B. For Re-Striking Electrodes

Some electrodes form a cone at the end of the
electrode after the welding arc has been broken,
particularly iron powder and low hydrogen elec­trodes. This cone will need to be broken off in order
to have the metal core of the electrode make con­tact.

E6010 - Push, Twist in Joint, Lift
E7018, E7024 - Push, Rock Back and Forth in

Joint, Lift.

Once the arc is started, normal welding technique
for the application is then used.

For other electrodes the above techniques should
be tried first and varied as needed to suit operator
preference. The goal for successful starting is good
metal to metal contact.

For indicator light operation, see table B.1.

DOWNHILL PIPE Welding

This slope controlled setting is intended for "out-of­position" and "down hill" pipe welding where the oper­ator would like to control the current level by changing
the arc length.

VANTAGE®500

B-6

OPERATION

The OUTPUT CONTROL dial adjusts the full output
range for pipe welding.

The ARC CONTROL dial sets the short circuit current
(arc-force) during stick welding to adjust for a soft or
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. This can also
increase spatter.

It is recommended that the ARC CONTROL be set to the
minimum number without electrode sticking. Start with
the dial set at 0.

NOTE: With the VRD switch in the “ON” position there is
no output in the DOWNHILL PIPE mode.

For indicator

light operation, see table B.1.

TIG WELDING

B-6

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

The ARC CONTROL is not active in the TIG mode. To
STOP a weld, simply pull the TIG torch away from the
work.
When the arc voltage reaches approximately 30 Volts
the arc will go out and the machine will reset the cur­rent to the Touch Start level.

To reinitiate the arc, retouch the tungsten to the work
and lift. Alternatively, the weld can be stopped by
releasing the Amptrol or arc start switch.

The VANTAGE® 500 can be used in a wide variety of
DC TIG welding applications. In general the ‘Touch
Start’ feature allows contamination free starting with­out the use of a Hi-frequency unit. If desired, the
K930-2 TIG Module can be used with the VANTAGE®
500 . The settings are for reference.

The TOUCH START TIG setting of the MODE switch is
for DC TIG (Tungsten Inert Gas) welding. To initiate a
weld, the OUTPUT CONTROL dial 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, no tungsten
contamination. Then, the tungsten is gently lifted off the
work in a rocking motion, which establishes the arc.

VANTAGE® 500 settings when using the K930-2 TIG
Module with an Amptrol or Arc Start Switch:

• Set the MODE Switch to the TOUCH START TIG
setting.

• Set the "IDLER" Switch to the "AUTO" position.

• Set the "WELDING TERMINALS" switch to the
"REMOTELY CONTROLLED" position.

TABLE B.3

TYPICAL CURRENT RANGES

Tungsten Electrode DCEN (-) DCEP (+) Approximate Argon Gas Flow TIG TORCH

Diameter in. (mm) Flow Rate C.F.H. ( l /min.) Nozzle Size (4), (5)

1%, 2% Thoriated 1%, 2% Thoriated Aluminum Stainless Steel
Tungsten Tungsten

.010 (.25) 2-15 (3) 3-8 (2-4) 3-8 (2-4) #4, #5, #6

0.020 (.50) 5-20 (3) 5-10 (3-5) 5-10 (3-5)

0.040 (1.0) 15-80 (3) 5-10 (3-5) 5-10 (3-5)

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

3/32 (2.4) 150-250 15-30 13-17 (6-8) 11-15 (5-7) #6, #7, #8
1/8 (3.2) 250-400 25-40 15-23 (7-11) 11-15 (5-7)

5/32 (4.0) 400-500 40-55 21-25 (10-12) 13-17 (6-8) #8, #10
3/16 (4.8) 500-750 55-80 23-27 (11-13) 18-22 (8-10)
1/4 (6.4) 750-1000 80-125 28-32 (13-15) 23-27 (11-13)

(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

2% Thoriated EWTh-2

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:

(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

# 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)

and high duty cycles.

(1)

FOR TUNGSTEN ELECTRODES

(2)

VANTAGE®500

B-7

This will keep the "Solid State" contactor open and provide a
"cold" electrode until the Amptrol or Arc Start Switch is pressed.

OPERATION

Set the OUTPUT CONTROL knob to adjust output
current to the desired level for the gouging electrode
being used according to the ratings in the following

When using the TIG Module, the OUTPUT CONTROL on the

Table B.4.
VANTAGE® 500 is used to set the maximum range of the CUR­RENT CONTROL on the TIG Module or an Amptrol if connect­ed to the TIG Module.

Carbon Diameter

NOTE: The TIG process is to receive a low voltage welding

process. There is no difference in operation with the
VRD “On” or “Off” for this mode. For indicator light oper­ation, see table B.1.

WIRE WELDING-CV

Connect a wire feeder to the VANTAGE® 500 according to the
instructions in INSTALLATION INSTRUCTIONS Section.

The VANTAGE® 500 in the CV-WIRE mode, 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 dial set at 0.

NOTE: In the CV-Mode with VRD “On”, the OCV(Open Circuit

Voltage) is not reduced. For indicator light operation,
see table B.1.

ARC GOUGING

The VANTAGE® 500 can be used for arc gouging. For
optimal performance, set the MODE switch to ARC
GOUGING.

The ARC CONTROL is not active in the ARC GOUG-

ING Mode. The ARC CONTROL is automatically set

to maximum when the ARC GOUGING mode is

selected which provides the best ARC GOUGING per-

formance.

NOTE: With the VRD switch in the “ON” position there

is no output in the Arc Gouging Mode. For indicator

light operation, see table B.1.

AUXILIARY POWER:

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

Simultaneous Welding and Auxiliary Power Loads

The auxiliary power ratings are with no welding load.
Simultaneous welding and power loads are specified
in Table B.5.

B-7

TABLE B.4

Current Range (DC, electrode

positive)
1/8"(3.2mm) 60-90 Amps
5/32"(4.0mm) 90-150 Amps
3/16"9(4.8mm) 200-250 Amps
1/4"(6.4mm) 300-400 Amps
3/8"(10.0mm) 400-Max.Amps

WELD

AMPS

Current

(Amps)

15
20
15
20
44

TABLE B.5 VANTAGE® 500 PERKINS SIMULTANEOUS WELDING AND POWER LOADS

0
100
200
300
400
500

PLUS

1 PHASE

WATTS AMPS

13,000 50
11,100 50
10,900 50

OR

9,100 43
6,900 23
2,400 11

3 PHASE

WATTS AMPS

20,000 50
19,200 50
18,000 48
15,100 40
11,700 31

3,900 10

BOTH 1 AND 3 PHASE

WATTS AMPS

------ 50

------ 50

OR

------ 48
9,100 -----­6,900 -----­2,400 ------

TABLE B.6

VANTAGE® 500 Extension Cord Length Recommendations

(Use the shortest length extension cord possible sized per the following table.)

Voltage

Volts

120
120
240
240
240

Load

(Watts)

1800
2400
3600
4800
9500

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)

Conductor size is based on maximum 2.0% voltage drop.

40
30
75
60

(12)

(9)
(23)
(18)

75

50
150
100

50

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

125

88
225
175

90

(38)
(27)
(69)
(53)
(27)

175
138
350
275
150

(107)

VANTAGE®500

(53)
(42)

(84)
(46)

300
225
600
450
225

(91)

(69)
(183)
(137)

(69)

C-1

ACCESSORIES

FIELD INSTALLED OPTIONS /
ACCESSORIES are available at
www.lincolnelectric.com.

Follow these steps:

1. Go to www.lincolnelectric.com

2. At the top of the screen in the Search field type
E6.214 click on Search Icon.

3. On the results screen click on Engine Driven

Welders: Vantage 500

4. On this results screen which shows Vantage 500
sales literature document, scroll down to the begin­nig of the RECOMMENDED OPTIONS page.

C-1

VANTAGE®500

D-1

MAINTENANCE

D-1

SAFETY PRECAUTIONS

WARNING

• Have qualified personnel do all maintenance
and troubleshooting work.

• Turn the engine off before working inside the
machine or servicing the engine.

• Remove guards only when necessary to
perform maintenance and replace them when
the maintenance requiring their removal is
complete. If guards are missing from the
machine, obtain replacements from a Lincoln
Distributor. (See Operating Manual Parts List.)

Read the Safety Precautions in the front of this
manual and in the Engine Owner’s 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 the
gears, fans, and all other moving parts when
starting, operating, or repairing the equipment.

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

Routine Maintenance

At the end of each day’s use, refill the fuel tank to
minimize moisture condensation in the tank. Running
out of fuel tends to draw dirt into the fuel system.
Also, check the crankcase oil level and add oil if
indicated.

VANTAGE®500

D-2

MAINTENANCE

D-2

ENGINE OIL CHANGE

Drain the engine oil while the engine is warm to assure
rapid and complete draining. It is recommended that
each time the oil is changed the oil filter be changed as
well.

• Be sure the unit is off. Disconnect the negative bat-

tery cable to ensure safety.

• Locate oil drain hose and valve in bottom of base

and pull through the hole in the battery access panel
on the welder.

• Open oil drain valve by lifting up spring loaded lever

and rotate 90
drain the oil into a suitable container for disposal.

• Close the drain valve by rotating lever 90

• Re-fill the crankcase to the upper limit mark on the

dipstick with the recommended oil (see engine oper­ation manual OR engine service items decal OR
below). Replace and tighten the oil filler cap secure­ly.

counterclockwise. Pull to open and

°

clockwise.

°

OIL FILTER CHANGE

• Drain the oil.

• Remove the oil filter with an oil filter wrench and
drain the oil into a suitable container. Discard the
used filter. Note: Care should be taken during filter
removal to not disrupt or damage in any way the fuel
lines.

• Clean the filter mounting base and coat the gasket

of the new filter with clean engine oil.

• Screw the new filter on by hand until the gasket con-

tacts the mounting base. Using an oil filter wrench,
tighten the filter an additional 1/2 to 7/8 of a turn.

• Refill the crankcase with the specified amount of the

recommended engine oil. Reinstall the oil filler cap
and tighten securely.

• Start the engine and check for oil filter leaks.

• Stop the engine and check the oil level. If neces-

sary, add oil to the upper limit mark on the dipstick.

• Push oil drain hose and valve back into unit, re-con­nect negative battery cable, and close doors and
engine top cover before restarting unit.Wash your
hands with soap and water after handling used motor
oil. Please dispose of used motor oil in a manner that
is compatible with the environment. We suggest you
take it in a sealed container to your local service sta­tion or recycling center for reclamation. DO NOT
throw it in the trash; pour it on the ground or down a
drain.

Use motor oil designed for diesel engines that meets
requirements for API service classification
CC/CD/CE/CF/CF-4/CG-4 or CH-4.

ACEA E1/E2/E3. Always check the API service label
on the oil container to be sure it includes the letters
indicated. (Note: An S-grade oil must not be used in a
diesel engine or damage may result. It IS permissible
to use an oil that meets S and C grade service classifi­cations.)

SAE 10W30 is recommended for general, all tempera­ture use, 5F to 104F (-15C to 40C).

WARNING

• Never use gasoline or low flash point solvents
for cleaning the air cleaner element. A fire or
explosion could result.

CAUTION

• Never run the engine without the air cleaner.
Rapid engine wear will result from contaminants,
such as dust and dirt being drawn into the
engine.

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

AIR CLEANER

The diesel engine is equipped with a dry type air filter.
Never apply oil to it. Service the air cleaner as follows:

Replace the element every 500 hours of operation.
Under dusty conditions, replace sooner.

See engine owner’s manual for more specific informa­tion on oil viscosity recommendations.

VANTAGE®500

D-3

Remove the Filter

Clean Both Surfaces of the Outlet Tube
and Check the Vacuator™ Valve

Inspect the Old
Filter for Leak Clues

Inspect the New Filter for Damage

Insert the New Radial Seal Filter Properly

Check Connectors for Tight Fit

NEVER use the service cover to
push the filter into place! Using
the cover to push the filter in could
cause damage to the housing, cover
fasteners and will void the warranty.

Caution

Service Instructions

Single- and Two-Stage Engine Air Cleaners

MAINTENANCE

Service Instructions

Single- and Two-Stage Engine Air Cleaners

D-3

Remove the Filter

Unfasten or unlatch the
service cover. Because
the filter fits tightly over the
outlet tube to create the critical seal, there will

Rotate the
filter while
pulling
straight out.

If your air cleaner has a safety filter, replace it every third primary
filter change. Remove the safety filter as you would the primary
filter. Make sure you cover the air cleaner outlet tube to avoid any
unfiltered contaminant dropping into the engine.

Clean Both Surfaces of the Outlet Tube
and Check the Vacuator™ Valve

Use a clean cloth to wipe the filter sealing surface and the inside of
the outlet tube. Contaminant on the sealing surface could hinder an
effective seal and cause leakage. Make sure that all contaminant is
removed before the new filter is inserted. Dirt accidently transferred
to the inside of the outlet tube will reach the engine and cause
wear. Engine manufacturers say that it takes only a few grams of
dirt to "dust" an engine! Be careful not to damage the sealing area
on the tube.

be some initial resistance, similar to breaking
the seal on a jar. Gently move the end of the filter
back and forth to break the seal then rotate while
pulling straight out. Avoid knocking the filter
against the housing.

Wipe both sides
of the outlet
tube clean.

Inspect the New Filter for Damage

Inspect the new filter carefully, paying attention to
the inside of the open end, which is the
sealing area. NEVER install a damaged
filter. A new Donaldson radial seal
filter may have a dry lubricant on the
seal to aid installation.

Insert the New Radial Seal Filter Properly

If you're servicing the safety filter, this should be seated into
position before installing the primary filter.

Insert the new filter carefully. Seat
the filter by hand, making certain it is
completely into the air cleaner housing
before securing the cover in place.

The critical sealing area will stretch
slightly, adjust itself and distribute the sealing pressure evenly. To
complete a tight seal, apply pressure by hand at the outer rim of
the filter, not the flexible center. (Avoid pushing on the center of the
urethane end cap.) No cover pressure is required to hold the seal.
NEVER use the service cover to push the filter into place! Using the
cover to push the filter in could cause damage to the housing, cover
fasteners and will void the warranty.

If the service cover hits the filter before it is fully in place, remove
the cover and push the filter (by hand) further into the air cleaner
and try again. The cover should go on with no extra force.

Once the filter is in place, secure the service cover.

Outer edge of the
outlet tube

If your air cleaner is equipped with a Vacuator Valve

Visually check and physically squeeze to make sure the
valve is flexible and not inverted, damaged or plugged.

Inner edge of the
outlet tube

Inspect the Old
Filter for Leak Clues

Visually inspect the old filter for any signs
of leaks. A streak of dust on the clean side
of the filter is a telltale sign. Remove any
cause of leaks before installing new filter.

NEVER use the service cover to
push the filter into place! Using
the cover to push the filter in could
cause damage to the housing, cover
fasteners and will void the warranty.

Check Connectors for Tight Fit

Make sure that all mounting bands, clamps, bolts, and connections
in the entire air cleaner system are tight. Check for holes in piping
and repair if needed. Any leaks in your intake piping will send dust
directly to the engine!

VANTAGE®500

Caution

D-4
COOLING SYSTEM

WARNING

MAINTENANCE

FUEL: Diesel Fuel Only - Low Sulphur Fuel

or Ultra Low Sulphur Fuel in U.S.A. and

CANADA only.

D-4

HOT COOLANT

• Do not remove cap if radiator is
hot.

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

Check the coolant level by observing the level in the
radiator and recovery bottle. Add 50/50 antifreeze /
water solution if the level is close to or below the
"LOW" mark. do not fill above the "FULL" mark.
Remove radiator cap and add coolant to radiator. Fill
up to the top of the tube in the radiator filler neck
which includes a connecting hose coming from the
thermostat housing.

To drain the coolant, open the valve at the bottom of
the radiator. Open the radiator cap to allow complete
drainage. (Tighten the valve and refill with a 50/50
antifreeze/water solution.) Use an automotive grade
(low silicate) ethylene glycol antifreeze. The cooling
system capacity is11.5 quarts (10.9L). Squeeze upper
and lower radiator hoses while filling to bleed air from
system coolant. Replace and tighten the radiator cap.

can burn skin.

CAUTION

Always premix the antifreeze and clean tap water
before adding to the radiator. It is very important
that a precise 50/50 solution be used with this
engine year round. This gives proper cooling dur­ing hot weather and freezing protection to -34° F (­37° C).

Cooling solution exceeding 50% ethylene glycol
can result in engine overheating and damage to
the engine. Coolant solution must be premixed
before adding to radiator.

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

At the end of each day’s use, refill the fuel tank to min­imize moisture condensation and dirt contamination in
the fuel line. Do not overfill; leave room for the fuel to
expand.

Use only fresh No. 2D diesel fuel, the use of No. 1D
diesel fuel is recommended in place of No. 2D at tem­peratures below 23°F (-5°C). Do not use kerosene.

See the Engine Operator's Manual for instructions on
replacing the fuel filter.

BLEEDING THE FUEL SYSTEM

You may need to bleed air from the fuel system if the
fuel filter or fuel lines have been detached, the fuel
tank has been ran empty or after periods of long stor­age. It is recommended that the fuel shutoff valve be
closed during periods of non-use.

WARNING

To avoid personal injury, do not bleed a hot
engine. This could cause fuel to spill onto a hot
exhaust manifold, creating a danger of fire.

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

Bleed the fuel system as follows:

1. Fill the fuel tank with fuel.

2. Open the fuel shut off valve.

3. Loosen bleed fitting on the fuel injector manifold.
Operate hand priming lever until fuel comes out the

4.
bleed screw on the injector manifold. This could
take 20-30 seconds of rapid operation of the prim­ing lever. Tighten bleed fitting on injector manifold.

5. Follow normal STARTING procedures until engine
starts.

Periodically remove the dirt from the radiator fins.
Periodically check the fan belt and radiator hoses.
Replace if signs of deterioration are found.

TIGHTENING THE FAN BELT

If the fan belt is loose, the engine can overheat and
the battery lose its charge. Check tightness by press­ing on the belt midway between the pulleys. It should
deflect about .25 in.(6.4 mm) under a load of 20 lbs.(9
Kg).

VANTAGE®500

D-5

●

●

●

●

●

●

MAINTENANCE

D-5

FUEL FILTER

1. Check the fuel filter and fuel pre-filter for water
accumulation or sediment.

2. Replace the fuel filter if it is found with excessive
water accumulation or sediment. Empty fuel pre-fil-

ter.

OVERSPEED IS HAZARDOUS

The maximum allowable high idle speed for this
machine is 1850 RPM, no load. Do NOT tamper
with governor components or setting or make any
other adjustments to increase the maximum
speed. Severe personal injury and damage to the
machine can result if operated at speeds above
maximum.

ENGINE ADJUSTMENT

Adjustments to the engine are to be made only by a
Lincoln Service Center or an authorized Field Service
Shop.

BATTERY MAINTENANCE

To access the battery, remove the battery tray from
the front of the machine with 3/8” nut driver or flat
head screw driver. Pull the tray out of machine far
enough to disconnect the negative and then positive
battery cables. The tray can then be tilted and lifted to
remove the entire tray and battery from the machine
for easy service.

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.

CLEANING THE BATTERY

Keep the battery clean by wiping it with a damp cloth
when dirty. If the terminals appear corroded, discon­nect the battery cables and wash the terminals with an
ammonia solution or a solution of 1/4 pound (0.1113
kg) of baking soda and 1 quart (0.9461L) of water. Be
sure the battery vent plugs (if equipped) are tight so
that none of the solution enters the cells.
After cleaning, flush the outside of the battery, the bat­tery compartment, and surrounding areas with clear
water. Coat the battery terminals lightly with petroleum
jelly or a non-conductive grease to retard corrosion.
Keep the battery clean and dry. Moisture accumula­tion on the battery can lead to more rapid discharge
and early battery failure.

CHECKING THE ELECTROLYTE LEVEL

If battery cells are low, fill them to the neck of the filler
hole with distilled water and recharge. If one cell is
low, check for leaks.

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® 500 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.

SERVICING OPTIONAL SPARK
ARRESTOR

Clean every 100 hours.

WARNING

USING A BOOSTER — connect positive lead to
battery first then connect negative lead to neg-

ative 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.

• MUFFLER MAY BE HOT

• ALLOW ENGINE TO COOL BEFORE INSTALLING
THE SPARK ARRESTER!

• DO NOT OPERATE ENGINE WHILE INSTALLING
THE SPARK ARRESTER!

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

VANTAGE®500

D-6

MAINTENANCE

D-6

WELDER / GENERATOR
MAINTENANCE

STORAGE: Store in clean, dry protected areas.

CLEANING: Blow out the generator and controls peri-

odically with low pressure air. Do this at least once a
week in particularly dirty areas.

BRUSH REMOVAL AND REPLACEMENT: It’s nor­mal for the brushes and slip rings to wear and darken
slightly. Inspect the brushes when a generator over­haul is necessary.

CAUTION

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

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.

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

GFCI MODULE TESTING AND RESETTING
PROCEDURE

The GFCI module should be properly tested at least
once every month or whenever it is tripped. To properly
test and reset the GFCI module:

• If the module has tripped, first carefully remove any
load and check it for damage.

• If the equipment has been shut down, it must be
restarted.

• The equipment needs to be operating at high idle
speed and any necessary adjustments made on the
control panel so that the equipment is providing at
least 80 volts to the receptacle input terminals.

• The circuit breaker for this receptacle must not be
tripped. Reset if necessary.

• Push the "Reset" button located on the GFCI module.
This will assure normal GFCI operation.

• Plug a night-light (with an "ON/OFF" switch) or other
product (such as a lamp) into the Duplex receptacle
and turn the product "ON".

• Push the "Test" button located on the GFCI module.
The night-light or other product should go "OFF".

• Push the "Reset" button, again. The light or other
product should go "ON" again.

If the light or other product remains "ON" when the
"Test" button is pushed, the GFCI module is not work­ing properly or has been incorrectly installed (miswired).
If your GFCI module is not working properly, contact a
qualified, certified electrician who can assess the situa­tion, rewire the GFCI module if necessary or replace
the device.

VANTAGE®500

E-1

TROUBLESHOOTING

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.

__________________________________________________________________________

E-1

This Troubleshooting Guide is provided to help you
locate and repair possible machine malfunctions.
Simply follow the three-step 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 Authorized Field 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.

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

E-2

Observe all Safety Guidelines detailed throughout this manual

PROBLEMS

(SYMPTOMS)

TROUBLESHOOTING

POSSIBLE

CAUSE

E-2

RECOMMENDED

COURSE OF ACTION

Major Physical or Electrical Damage
is Evident.

Engine will not "crank".

Engine will "crank" but not start.

1. Contact your local Lincoln
Authorized Field Service
Facility.

1. Battery is low,

2. Loose battery cable connections.
Inspect, clean and tighten terminals.

3. Faulty engine starter motor.
Contact authorized local Engine
Service Shop.

1. Fuel shut off valve on Main Fuel
Filter in the OFF position. Open
valve (vertical) position of handle.

2. Fuel Filters dirty/clogged. Check
and replace main filter element
and/or Inline Fuel Filter.

3. Out of fuel. Fill tank and bleed fuel
system.

4. High coolant temperature or low
oil pressure. (indictor lights lit)
Check oil and coolant levels. Fill if
required. Check for loose or bro­ken fan belt.

5. Faulty fuel shutdown solenoid.
Check that shutdown solenoid is
functioning properly and not bind­ing/ contact authorized engine
service shop.

6. Faulty fuel pump. Check for fuel
flow through filters. Contact autho­rized local Engine Service Shop.

Charge Battery.

I

f all recommended possible areas
of misadjustment have been
checked and the problem persists,

Contact your local Lincoln
Authorized Field Service Facility.

Engine shuts down shortly after
starting.

1. High coolant temperature or low
oil pressure. (indictor light lit)
Change oil and oil filters and fill to
proper level. Check and fill coolant
level. Check for loose or broken
fan belt. Start engine and look for
leaks.

2. Faulty oil pressure switch or other
engine component. Contact
authorized local Engine Service
Shop.

3. Faulty Idler/Protection Board.

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

E-3

Observe all Safety Guidelines detailed throughout this manual

PROBLEMS

(SYMPTOMS)

TROUBLESHOOTING

POSSIBLE

CAUSE

E-3

RECOMMENDED

COURSE OF ACTION

Engine shuts down while under a
load.

Engine runs rough.

Battery does not stay charged.
Engine alternator trouble light is on
while machine is running.

Engine will not idle down to low
speed.

1. High radiator coolant tempera­ture. Reduce load if it is exceed­ing machine rating. Add coolant
to system if low. Clean fins on
radiator if dirty. Tighten fan belt if
loose. Remove objects blocking
or close to intake openings on
both sides of base and exhaust
end (case back).

1. Dirty fuel or air filters. Inspect and
clean/replace filters as needed.
Inspect and clean/replace filters
as needed.

2. Water in fuel. If water found in
tank. Empty fuel tank and refill
then purge fuel lines.

1. Faulty battery. Replace.

2. Loose connections at battery or
alternator. Clean and tighten con­nections.

3. Faulty engine alternator or charg­er module. Consult authorized
Engine Service Shop.

1. Idler switch in High idle position.
Set switch to Auto.

2. External load on welder or auxil­iary power.
loads.

3. Faulty PC board or idler sole­noid.

Remove all external

If all recommended possible areas of
misadjustment have been checked
and the problem persists, Contact

your local Lincoln Authorized
Field Service Facility.

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

1. Poor work lead connection to
work. Make sure work clamp is
tightly
metal.

2. "Contactor" switch is in wrong
position.
welding without a control cable.
Refer to Operations chapter for prop­er use of this switch.

3. Faulty PC board. Low idle speed
set to low.

connected to clean base

Set to "Welding On" when

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

E-4

Observe all Safety Guidelines detailed throughout this manual

PROBLEMS

(SYMPTOMS)

TROUBLESHOOTING

POSSIBLE

CAUSE

E-4

RECOMMENDED

COURSE OF ACTION

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

Engine will not go to high idle
under weld or auxiliary loading.

Engine does not develop full
power. Engine runs rough.

Engine will not go to high idle when
attempting to weld or using auxil­iary power. Switching to manual
high idle does not work.

Engine will not shut off.

1. Auxiliary power load is less than
100 watts.
with less than a 100 watt load. Set
idler to "High".

2. Faulty PC board.(Control or Idler).

1. Faulty idler solenoid. Check for
bent linkage or broken spring.

2. Faulty PC board.(Control or Idler).

1. Fuel filter clogged,

2. Air filter clogged,

3. High idle setting incorrect, check
and adjust if required.

4. Valves out of adjustment.

5. Fuel contaminated with water or
sediment. Check fuel pre-filter
and empty of water, bleed fuel
system. Replace fuel in tank if
needed.

1. Broken spring on Idle Solenoid,
solenoid linkage binding, Faulty
PC board (Control or Idler), low
idle speed set too low on idle
solenoid.

1. Fuel Shutdown solenoid not func­tioning properly / linkage binding.
Stop engine by shutting off valve
located on main fuel filter. Contact
authorized local Engine Service
Shop.

Idler may not respond

Replace.

clean or replace.

I

f all recommended possible areas
of misadjustment have been
checked and the problem persists,

Contact your local Lincoln
Authorized Field Service Facility.

Engine does not develop full power.
Low weld and auxiliary output.
Engine runs rough.

1. Fuel filter dirty/clogged. Replace.

2. Air filter dirty/clogged. Replace Air
Filter Element.

3. Fouled fuel injector(s). Contact
authorized Engine Service Shop.

4. Fuel contaminated with water.
Check water separator for water.
Clean and replace as needed.
Replace fuel in tank.

5. Cracked or loose fuel hose.
Replace hose and tighten clamps.

6. Valves out of adjustment. Contact
authorized local Engine Service
Shop.

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

E-5

Observe all Safety Guidelines detailed throughout this manual

PROBLEMS

(SYMPTOMS)

TROUBLESHOOTING

POSSIBLE

CAUSE

E-5

RECOMMENDED

COURSE OF ACTION

No welding power output.

Welder has output but no control.

Wire feeder does not work when
control cable is connected to 14 pin
connector.

No auxiliary power.

1. Poor work lead connection to
work. Make sure work clamp is
tightly connected to clean base
metal.

2. "Weld Terminals" switch in wrong
position. Place switch in "Weld
Terminals On" position when
welding without control cable.

3. Faulty PC board or welder alterna­tor.

1. Poor remote/control cable connec­tion to 6-pin or 14-pin connector.
Check connections.

2. Faulty remote cable or faulty wire
feeder or wire feeder cable.
Replace if necessary.

3. Faulty control potentiometer or PC
board.

1. Wire Feeder Power circuit breaker
open. Check 42V beaker and
reset if tripped.

2. Faulty control cable. Repair or
replace cable.

3. Faulty wire feeder. Replace wire
feeder.

1. Open circuit breakers. Reset
breakers. If breakers keep tripping
reduce power draw.

2. GFCI module may have tripped.
Follow “GFCI Module Testing and
Resetting Procedure” in the MAIN­TENANCE section of this manual.

3. Faulty connections to auxiliary
receptacles. Check connections.

4. Faulty PC board or welder alterna­tor.

I

f 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

E-6

Observe all Safety Guidelines detailed throughout this manual

PROBLEMS

(SYMPTOMS)

TROUBLESHOOTING

POSSIBLE

CAUSE

E-6

RECOMMENDED

COURSE OF ACTION

The welding arc is “cold.” The weld­ing arc is not stable or is not satis­factory. the engine runs normally.
The auxiliary power is normal.

No output in Pipe Mode.

1. Make sure the MODE selector
switch is in the correct position for
the process being used. (For exam­ple, CV-WIRE, PIPE, CC-STICK.)

2. Make sure the electrode (wire, gas,
voltage, current etc.) is correct for
the process being used.

3. Check for loose or faulty connec­tions at the weld output terminals
and welding cable connections.

4. The welding cables may be too long
or coiled, causing an excessive
voltage drop.

5. Faulty Control Board.

1. Make sure VRD ON/OFF toggle
switch is in the “OFF” position.

2. Poor work lead connection to

work. Make sure work clamp is
tightly connected to clean base
metal.

3. "Weld Terminals" switch in wrong

position. Place switch in "Weld
Terminals On" position when
welding without control cable.

4. Faulty PC board or welder alterna-

tor.

If all recommended possible areas of
misadjustment have been checked
and the problem persists, Contact

your local Lincoln Authorized
Field Service Facility.

VRD Lights don’t light up.

1. Ensure VRD ON/OFF switch is in

the “ON” position.

2. If light is burned out, replace both

VRD lights.

3. Faulty OCV indicator PC board.

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

F-1

DIAGRAMS

F-1

VANTAGE®500

F-2

DIAGRAMS

F-2

VANTAGE®500

F-3

DIAGRAMS

F-3

VANTAGE®500

F-4

DIAGRAMS

F-4

VANTAGE®500

F-5

DIAGRAMS

F-5

VANTAGE® 500

F-6

DIAGRAMS

F-6

VANTAGE® 500

F-7

DIAGRAMS

F-7

VANTAGE® 500

F-8

DIAGRAMS

2

F-8

9/03

VANTAGE® 500

F-9

DIAGRAMS

F-9

VANTAGE® 500

F-10

WIRING DIAGRAM

F-10

VANTAGE®500

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 included

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

F-11

DIMENSION PRINT

46.62

2.25

57.2

1184.15

N.A.

F-11

B

L13699

55.50

1409.7

36.06

915.9

28.95

735.3

523.3

20.60

655.8

25.82

27.00

685.8

39.41

1001

913.0

35.94

5.75

146.0

425.4

16.75

32.3

1.27

60.00

1524.0

30.69

779.5

24.00

609.6

NOTES:

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

VANTAGE®500

NOTES

VANTAGE®500

NOTES

VANTAGE® 500

WARNING

Spanish

AVISO DE

PRECAUCION

● Do not touch electrically live parts or

electrode with skin or wet clothing.

● Insulate yourself from work and

ground.

● No toque las partes o los electrodos

bajo carga con la piel o ropa moja­da.

● Aislese del trabajo y de la tierra.

● Keep flammable materials away.

● Mantenga el material combustible

fuera del área de trabajo.

● Wear eye, ear and body protection.

● Protéjase los ojos, los oídos y el

cuerpo.

French

ATTENTION

German

WARNUNG

Portuguese

ATENÇÃO

Japanese

Chinese

Korean

Arabic

● Ne laissez ni la peau ni des vête-

ments mouillés entrer en contact
avec des pièces sous tension.

● Isolez-vous du travail et de la terre.

● Berühren Sie keine stromführenden

Teile oder Elektroden mit Ihrem
Körper oder feuchter Kleidung!

● Isolieren Sie sich von den

Elektroden und dem Erdboden!

● Não toque partes elétricas e elec-

trodos com a pele ou roupa molha­da.

● Isole-se da peça e terra.

● Gardez à l’écart de tout matériel

inflammable.

● Entfernen Sie brennbarres Material!

● Mantenha inflamáveis bem guarda-

dos.

● Protégez vos yeux, vos oreilles et

votre corps.

● Tragen Sie Augen-, Ohren- und Kör-

perschutz!

● 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.

● Keep your head out of fumes.

● Use ventilation or exhaust to

remove fumes from breathing zone.

● Turn power off before servicing.

● Do not operate with panel open or

guards off.

WARNING

● Los humos fuera de la zona de res-

piración.

● Mantenga la cabeza fuera de los

humos. Utilice ventilación o
aspiración para gases.

● Gardez la tête à l’écart des fumées.

● Utilisez un ventilateur ou un aspira-

teur pour ôter les fumées des zones
de travail.

● Vermeiden Sie das Einatmen von

Schweibrauch!

● Sorgen Sie für gute Be- und

Entlüftung des Arbeitsplatzes!

● Mantenha seu rosto da fumaça.

● Use ventilação e exhaustão para

remover fumo da zona respiratória.

● Desconectar el cable de ali-

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

● Débranchez le courant avant l’entre-

tien.

● Strom vor Wartungsarbeiten

abschalten! (Netzstrom völlig öff­nen; Maschine anhalten!)

● Não opere com as tampas removidas.

● Desligue a corrente antes de fazer

serviço.

● Não toque as partes elétricas nuas.

● No operar con panel abierto o

guardas quitadas.

● N’opérez pas avec les panneaux

ouverts ou avec les dispositifs de
protection enlevés.

● Anlage nie ohne Schutzgehäuse

oder Innenschutzverkleidung in
Betrieb setzen!

● Mantenha-se afastado das partes

moventes.

● 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.

• World's Leader in Welding and Cutting Products •

• Sales and Service through Subsidiaries and Distributors Worldwide •

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