IM873-A RETURN TO MAIN MENU July, 2007 VANTAGE 500 CUMMINS For use with machines having Code Numbers: 11181, 11416 Safety Depends on You Lincoln arc welding and cutting equipment is designed and built with safety in mind. However, your overall safety can be increased by proper installation . . . and thoughtful operation on your part. DO NOT INSTALL, OPERATE OR REPAIR THIS EQUIPMENT WITHOUT READING THIS MANUAL AND THE SAFETY PRECAUTIONS CONTAINED THROUGHOUT.
i 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 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 ARC WELDING CAN BE HAZARDOUS.
ii ii SAFETY ARC RAYS can burn. ELECTRIC SHOCK can kill. 3.a. The electrode and work (or ground) circuits are electrically “hot” when the welder is on. Do not touch these “hot” parts with your bare skin or wet clothing. Wear dry, hole-free gloves to insulate hands. 3.b. Insulate yourself from work and ground using dry insulation. Make certain the insulation is large enough to cover your full area of physical contact with work and ground.
iii iii SAFETY 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 the welding sparks from starting a fire. Remember that welding sparks and hot materials from welding can easily go through small cracks and openings to adjacent areas. Avoid welding near hydraulic lines. Have a fire extinguisher readily available. 6.b.
iv iv SAFETY PRÉCAUTIONS DE SÛRETÉ Pour votre propre protection lire et observer toutes les instructions et les précautions de sûreté specifiques qui parraissent dans ce manuel aussi bien que les précautions de sûreté générales suivantes: Sûreté Pour Soudage A LʼArc 1. Protegez-vous contre la secousse électrique: a. Les circuits à lʼélectrode et à la piéce sont sous tension quand la machine à souder est en marche.
v v Thank You 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! CUSTOMER ASSISTANCE POLICY 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.
vi TABLE OF CONTENTS vi Page Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Section A Technical Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .A-1 Safety Precautions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .A-2 Location / Ventilation . . . . . . . . . . . . . . . . . . . . . . . . . .
vii vii TABLE OF CONTENTS Page Accessories . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Section C Optional Field Installed Accessories . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .C-1 _________________________________________________________________________________________________ Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
A-1 A-1 INSTALLATION TECHNICAL SPECIFICATIONS - VANTAGE 500 CUMMINS (K2406-1) INPUT - DIESEL ENGINE Make /Model Description Speed (RPM) Displacement Starting System CUMMINS B3.3 Diesel Engine 4 cylinder 53HP (40 kw) @ 1800 RPM High Idle 1890 Low Idle 1400 Full Load 1890 199 cu. in (3.3L) 12VDC battery & Starter Bore x Stroke 3.74” x 4.53” (95mm x 115mm) Capacities Fuel 25 US gal. (94.6L) Oil: 2 US gal. (7.6L) Coolant 2 US gal. (7.
A-2 A-2 INSTALLATION Read this entire installation section before you start installation. SAFETY PRECAUTIONS WARNING Do not attempt to use this equipment until you have thoroughly read all operating and maintenance manuals supplied with your machine. They include important safety precautions, detailed engine starting, operating and maintenance instructions and parts lists. ELECTRIC SHOCK can kill. • Do not touch electrically live parts such as output terminals or internal wiring.
A-3 A-3 INSTALLATION LIFTING TOWING The VANTAGE 500 CUMMINS lift bail should be used to lift the machine. The VANTAGE 500 CUMMINS is shipped with the lift bail retracted. Before attempting to lift the VANTAGE 500 CUMMINS the lift bail must be secured in a raised position. Secure the lift bail as follows: The recommended trailer for use with this equipment for road, in-plant and yard towing by a vehicle (1) is Lincolnʼs K953-1.
A-4 A-4 INSTALLATION PRE-OPERATION ENGINE ENGINE BREAK-IN READ the engine operating and maintenance instructions supplied with this machine. WARNING • Keep hands away from the engine muffler or HOT engine parts. • Stop engine and allow to cool before fuelling. • Do not smoke when fuelling. • Fill fuel tank at a moderate rate and do not over-fill. • Wipe up spilled fuel and allow fumes to clear before starting engine. • Keep sparks and flame away from tank.
A-5 A-5 INSTALLATION • CONNECTING A BATTERY CHARGER — remove battery from welder by disconnecting negative cable first, then positive cable and battery clamp. When reinstalling, connect negative cable last. Keep well ventilated. • USING A BOOSTER — connect positive lead to battery first then connect negative lead to negative battery lead at engine foot. BATTERY ACID can burn eyes and skin. • Wear gloves and eye protection and be careful when working near battery. • Follow instructions printed on battery.
A-6 INSTALLATION REMOTE CONTROL OUTPUT The VANTAGE 500 CUMMINS is equipped with a 6pin and a 14-pin connector. The 6-pin connector is for connecting the K857 or K857-1 Remote Control or for TIG welding, the K870 foot Amptrol or the K963-3 Hand Amptrol. When in the CC-STICK, DOWNHILL PIPE, or CV-WIRE modes and when a remote control is connected to the 6-pin Connector, the auto-sensing circuit automatically switches the OUTPUT control from control at the welder to remote control.
A-7 A-7 INSTALLATION 2. Take necessary steps to assure load is limited to the capacity of the VANTAGE 500 CUMMINS by installing a 50 amp, 240 VAC double pole circuit breaker. Maximum rated load for each leg of the 240 VAC auxiliary is 50 amps. Loading above the rated output will reduce output voltage below the allowable -10% of rated voltage which may damage appliances or other motor-driven equipment and may result in overheating of the VANTAGE 500 CUMMINS engine. 3.
A-8 INSTALLATION CONNECTION OF LINCOLN ELECTRIC WIRE FEEDERS WARNING Shut off welder before making any electrical connections. ------------------------------------------------------------------------ CONNECTION OF LN-7, LN-8 OR LN-742 TO THE VANTAGE 500 CUMMINS A-8 • Across The-Arc Model: Attach the single lead from the front of the LN-15 to work using the spring clip at the end of the lead. This is a control lead to supply current to the wire feeder motor; it does not carry welding current.
A-9 INSTALLATION CONNECTION OF THE LN-25 TO THE VANTAGE 500 CUMMINS The LN-25 with or without an internal contactor may be used with the VANTAGE 500 CUMMINS. See the appropriate connection diagram in the DIAGRAMS section. NOTE: The LN-25 (K431) Remote Control Module and (K432) Remote Cable are not recommended for use with the VANTAGE 500 CUMMINS.
B-1 OPERATION B-1 SAFETY INSTRUCTIONS GENERAL DESCRIPTION Read and understand this entire section before operating your VANTAGE 500 CUMMINS. The VANTAGE 500 CUMMINS is a diesel engine-driven welding power source. The machine uses a brush type alternating current generator for DC multi-purpose welding, for 120/240 VAC single phase and 240V three phase auxiliary standby power. The welding control system uses state of the art Chopper Technology™.
B-2 B-2 OPERATION CONTROLS AND SETTINGS All welder and engine controls are located on the case front panel. Refer to Figure B.1 and the explanations that follow. Figure B.1 Case Front Panel Controls 4 5 6 7 8 9 10 3 11 13 20 12 15 21 14 19 23 1 22 2 16 17 18 ENGINE CONTROLS (Items 1 through 9) 1. RUN STOP SWITCH Toggling the switch to the RUN position energizes the fuel solenoid for approximately 30 seconds.
B-3 OPERATION 6. OIL PRESSURE GAUGE The gauge displays the engine oil pressure when the engine is running. d. If the welding or AC power load is not restarted before the end of the time delay, the idler reduces the engine speed to low idle speed. e. The engine will automatically return to high idle speed when the welding load or A.C. power load is reapplied. 7. ENGINE PROTECTION The yellow engine protection light remains off with proper oil pressure and under normal operating temperatures.
B-4 OPERATION WELDING CONTROLS (Items 10 through 19) 10. OUTPUT CONTROL: The OUTPUT dial is used to preset the output voltage or current as displayed on the digital meters for the four welding modes. When in the CC-STICK, DOWNHILL PIPE or CV-WIRE modes and when a remote control is connected to the 6-Pin or 14-Pin Connector, the auto-sensing circuit automatically switches the OUTPUT CONTROL from control at the welder to the remote control.
B-5 OPERATION 20. CIRCUIT BREAKERS These circuit breakers provide separate overload current protection for each 120V circuit at the 240V single phase receptacle, each 120V single phase receptacle, the 240V three phase receptacle, the 120VAC in the 14-Pin connector, the 42VAC in the 14-Pin connector and battery circuit overload protection. 21. 120VAC SINGLE PHASE RECEPTACLES These two 120VAC (5-20R) receptacles with GFCI protection provide 120VAC single phase for auxiliary power.
B-6 OPERATION BREAK-IN PERIOD The engine used to supply power for your welder is a heavy duty, industrial engine. It is designed and built for rugged use. It is very normal for any engine to use small quantities of oil until the break-in is accomplished. Check the oil level twice a day during the break-in period. In general this takes 50 to 100 hours of operation. B-6 The ARC CONTROL knob sets the short circuit (arc-force) current during stick welding.
B-7 B-7 OPERATION The VANTAGE 500 CUMMINS and any high frequency generating equipment must be properly grounded. See the K930-2 TIG Module operating manuals for complete instructions on installation, operation, and maintenance. When using the TIG Module, the OUTPUT control on the VANTAGE 500 CUMMINS is used to set the maximum range of the CURRENT CONTROL on the TIG Module or an Amptrol if connected to the TIG Module.
B-8 OPERATION B-8 CV-WIRE MODE AUXILIARY POWER OPERATION Connect a wire feeder to the VANTAGE 500 CUMMINS and set welder controls according to the instructions listed earlier in this section. If a GFCI receptacle is tripped, See the MAINTENANCE section for detailed information on testing and resetting the GFCI receptacle.
B-9 B-9 OPERATION TABLE B.4 VANTAGE 500 CUMMINS SIMULTANEOUS WELDING AND POWER LOADS WELD 1 PHASE 3 PHASE BOTH 1 AND 3 PHASE AMPS WATTS AMPS WATTS AMPS WATTS AMPS 0 12,000 50 20,000 50 -----50 100 12,000 50 17,800 43 -----50 PLUS 12,000 OR 200 50 14,000 34 50 OR -----250 12,000 50 12,000 29 12,000 -----300 10,000 42 10,000 24 10,000 -----400 5,600 23 5,600 13 5,600 -----500 0 0 0 0 0 0 TABLE B.
C-1 C-1 ACCESSORIES OPTIONAL FIELD INSTALLED ACCESSORIES K802N POWER PLUG KIT - Provides four 120V plugs rated at 20 amps each and one dual voltage, full KVA plug rated at 120/240V, 50 amps. 120V plug may not be compatible with NEMA common household receptacles. K802R POWER PLUG KIT - Provides four 120V plugs rated 15 amps each and one dual voltage, full KVA plug rated at 120/240V, 50 amps, 120V plug is compatible with NEMA common household receptacles. K857 25 ft. (7.5 m) or K857-1 100 ft. (30.
C-2 ACCESSORIES C-2 TIG OPTIONS WIRE FEEDER OPTIONS K1783-9 PTA-26V TIG Torch Air Cooled 200 amp torch (2 piece) equipped with valve for gas flow control. 25 ft. (7.6m) length. K449 LN-25 Wire Feeder Portable CC/CV unit for flux-cored and MIG welding. Includes Gas Solenoid & Internal Contactor. KP509 Magnum Parts Kit for PTA-26V TIG Torch Magnum Parts Kit provides all the torch accessories you need to start welding.
D-1 D-1 MAINTENANCE AIR FILTER SAFETY PRECAUTIONS CAUTION WARNING • Have a qualified technician do the maintenance and troubleshooting work. • Excessive air filter restriction will result in reduced engine life. • Turn the engine off before working inside the machine. • Remove guards only when necessary and replace them when the maintenance requiring their removal is complete. WARNING • Never use gasoline or low flash point solvents for cleaning the air cleaner element.
D-2 D-2 MAINTENANCE Service Instructions & Installation Tips For Engine • Air Filter 1 Release the Seal Carefully Unlatch and remove the service cover of the air cleaner. Make certain the latches are folded back against the cover so that they don t hinder filter removal/installation. Most latches are spring loaded to fold back when open. The filter fits tightly over the outlet tube, creating the critical seal on the inside diameter of the filter endcap.
D-3 D-3 MAINTENANCE BATTERY HANDLING FUEL FILTERS GASES FROM BATTERY can explode. WARNING • Keep sparks, flame and cigarettes away from battery. When working on the fuel system • Keep naked lights away, do not smoke ! To prevent EXPLOSION when: • Do not spill fuel ! • INSTALLING A NEW BATTERY - disconnect negative cable from old battery first and connect to new battery last.
D-4 MAINTENANCE D-4 CHARGING THE BATTERY WELDER / GENERATOR MAINTENANCE 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 CUMMINS positive (+) battery terminal has a red terminal cover. STORAGE 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.
D-5 MAINTENANCE GFCI RECEPTACLE TESTING AND RESETTING PROCEDURE The GFCI receptacle should be properly tested at least once every month or whenever it is tripped. To properly test and reset the GFCI receptacle: • If the receptacle has tripped, first carefully remove any load and check it for damage. • If the equipment has been shut down, it must be restarted.
E-1 TROUBLESHOOTING E-1 HOW TO USE TROUBLESHOOTING GUIDE WARNING Service and Repair should only be performed by Lincoln Electric Factory Trained Personnel. Unauthorized repairs performed on this equipment may result in danger to the technician and machine operator and will invalidate your factory warranty. For your safety and to avoid Electrical Shock, please observe all safety notes and precautions detailed throughout this manual.
E-2 E-2 TROUBLESHOOTING Observe all Safety Guidelines detailed throughout this manual PROBLEMS (SYMPTOMS) POSSIBLE CAUSE RECOMMENDED COURSE OF ACTION ENGINE PROBLEMS Major Physical or Electrical Damage 1. Contact your Local Lincoln is Evident. Authorized Field Service Facility. Engine will not crank 1. Battery low. 2. Loose battery cable connections which may need Inspected, cleaned or tighten. 3. Faulty wiring in engine starting circuit. 4. Faulty engine starter.
E-3 E-3 TROUBLESHOOTING Observe all Safety Guidelines detailed throughout this manual PROBLEMS (SYMPTOMS) POSSIBLE CAUSE RECOMMENDED COURSE OF ACTION FUNCTION PROBLEMS Battery does not stay charged. 1. Faulty battery . 2. Faulty engine alternator. 3. Loose or broken lead in charging circuit. 4. Loose fan belt may need tightening. Engine will not idle down to low 1. Idler switch in HIGH idle position, speed. make sure switch is set to AUTO. 2. External load on welder or auxiliary power. 3.
E-4 E-4 TROUBLESHOOTING Observe all Safety Guidelines detailed throughout this manual PROBLEMS (SYMPTOMS) POSSIBLE CAUSE RECOMMENDED COURSE OF ACTION FUNCTION PROBLEMS Engine goes to low idle but does not 1. Weld Control PCB or electronic stay at low idle. governor controller. No welding output or auxiliary out- 1. put. 2. 3. 4. Broken lead in rotor circuit. Faulty field diode module. Faulty Weld Control PCB. Faulty rotor. Welder has some/ no output and no 1. Faulty remote kit. control.
NOTE: This diagram is for reference only. It may not be accurate for all machines covered by this manual. The specific diagram for a particular code is pasted inside the machine on one of the enclosure panels. If the diagram is illegible, write to the Service Department for a replacement. Give the equipment code number.
F-2 CONNECTION DIAGRAMS VANTAGE 500 CUMMINS F-2
VANTAGE 500 CUMMINS TO WORK K867 UNIVERSAL ADAPTER PLUG 77 76 75• GND 21 4 2 32 31 41 42 81• 82 SPARE } N.E. 21 4 2 32 31 77 76 75 GND N.D. GREEN or service this equipment. Only qualified personnel should install,use Keep away from moving parts. Keep guards in place. N.E. SPLICE LEADS AND INSULATE. N.D. INSULATE EACH UNUSED LEAD INDIVIDUALLY.• N.C. IF OPTIONAL REMOTE OUTPUT CONTROL IS USED,CONTROL IS AUTOMATICALLY SWITCHED TO REMOTE CONTROL.
F-4 CONNECTION DIAGRAMS VANTAGE 500 CUMMINS F-4
F-5 CONNECTION DIAGRAMS VANTAGE 500 CUMMINS F-5
VANTAGE 500 CUMMINS TO WORK ADAPTER PLUG K867 UNIVERSAL 77 76• 75 GND 21 4 2 32 31 41 42 81 82 SPARE } N.D. N.C. C B A GND 21 4 2 32 31 or service this equipment. Only qualified personnel should install,use Keep away from moving parts. Keep guards in place. N.D. SPLICE LEADS AND INSULATE. N.C. INSULATE EACH UNUSED LEAD INDIVIDUALLY. N.A. WELDING CABLE MUST BE OF PROPER CAPACITY FOR THE CURRENT AND DUTY CYCLE OF IMMEDIATE AND FUTURE• APPICATIONS. SEE OPERATING MANUAL. N.B.
F-7 CONNECTION DIAGRAMS VANTAGE 500 CUMMINS F-7
F-8 CONNECTION DIAGRAMS VANTAGE 500 CUMMINS F-8
F-9 CONNECTION DIAGRAMS VANTAGE 500 CUMMINS F-9
F-10 CONNECTION DIAGRAMS VANTAGE 500 CUMMINS F-10
F-11 CONNECTION DIAGRAMS VANTAGE 500 CUMMINS F-11
F-12 CONNECTION DIAGRAMS VANTAGE 500 CUMMINS F-12
VANTAGE 500 CUMMINS 28.99 736.3 16.85 428 23.69 601.7 42.35 1075.7 * 50.38 1279.7 54.44 1382.8 63.10 1602.7 45.38 1152.7 BOTTOM VIEW OF WELDER BASE. 19.63 498.6 33.53 32.08 851.7 814.8 50.15 1273.8 37.30 947.4 14.63 371.6 * 6.55 166.4 6.53 165.9 * 24.97 634.2 6.56 166.6 * 46.35 42.00 1177.3 1066.8 48.92 1242.6 31.50 800.1 5.86 148.8 B DIMENSION PRINT M18962-3 N.A. CENTER OF GRAVITY WITH OIL IN ENGINE, EMPTY FUEL TANK AND COOLANT IN RADIATOR. *TRAILER MOUNTING HOLE LOCATIONS. 45.
NOTES VANTAGE 500 CUMMINS
● Do not touch electrically live parts or WARNING Spanish AVISO DE PRECAUCION French ATTENTION German WARNUNG Portuguese ATENÇÃO ● Keep flammable materials away. ● Wear eye, ear and body protection. ● Mantenga el material combustible ● Protéjase los ojos, los oídos y el 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 your head out of fumes. ● Use ventilation or exhaust to ● Turn power off before servicing. ● Do not operate with panel open or guards off. remove fumes from breathing zone. ● 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- ● Desconectar el cable de ali- mentación de poder de la máquina antes de iniciar cualquier servicio.
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