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Operator's Manual
VANTAGE
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Date Purchased
Code: (ex: 10859)
Serial: (ex: U1060512345)
IM10003-B
| Issue D ate Jul-16
© Lincoln Global, Inc. All Rights Reserved.
®
500-I
For use with machines having Code Numbers:
11576, 11954, 11961, 12304
Need Help? Call 1.888.935.3877
to talk to a Service Representative
Hours of Operation:
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no later than the following business day.
For Service outside the USA:
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  • Page 1 Operator’s Manual VANTAGE ® 500-I For use with machines having Code Numbers: 11576, 11954, 11961, 12304 Need Help? Call 1.888.935.3877 Register your machine: to talk to a Service Representative www.lincolnelectric.com/register Authorized Service and Distributor Locator: Hours of Operation: www.lincolnelectric.com/locator 8:00 AM to 6:00 PM (ET) Mon. thru Fri. Save for future reference After hours? Use “Ask the Experts”...
  • Page 2 THANK YOU FOR SELECTING A QUALITY PRODUCT BY KEEP YOUR HEAD OUT OF THE FUMES. DON’T get too close to the arc. LINCOLN ELEC TRIC. Use corrective lenses if necessary to stay a reasonable distance away from the arc. READ and obey the Safety Data PLEASE EXAMINE CARTON AND EQUIPMENT FOR Sheet (SDS) and the warning label DAMAGE IMMEDIATELY...
  • Page 3 MAGNETIC FIELDS MAY W117.2-1974. A Free copy of “Arc Welding Safety” booklet BE DANGEROUS E205 is available from the Lincoln Electric Company, 22801 St. Clair Avenue, Cleveland, Ohio 44117-1199. 2.a. Electric current flowing through any conductor BE SURE THAT ALL INSTALLATION, OPERATION, causes localized Electric and Magnetic Fields (EMF).
  • Page 4: Electric Shock Can Kill

    S FETY ELECTRIC SHOCK ARC RAYS CAN BURN. CAN KILL. 3.a. The electrode and work (or ground) circuits are 4.a. Use a shield with the proper filter and cover plates to protect your electrically “hot” when the welder is on. Do eyes from sparks and the rays of the arc when welding or not touch these “hot”...
  • Page 5 S FETY WELDING AND CUTTING CYLINDER MAY EXPLODE IF SPARKS CAN CAUSE DAMAGED. FIRE OR EXPLOSION. 7.a. Use only compressed gas cylinders containing the correct shielding gas for the process used 6.a. Remove fire hazards from the welding area. If and properly operating regulators designed for this is not possible, cover them to prevent the welding sparks the gas and pressure used.
  • Page 6: Table Of Contents

    Welding Terminals ......................A-5 Welding Output Cables ....................A-5 Cable Installation......................A-5 Auxiliary Power Receptacles and Plugs................A-6 Residual Current Device Ready ...................A-6 Standby Power Connections ....................A-6 Connection of Lincoln Electric Wire Feeders ...............A-7 ________________________________________________________________________________ Operation.........................Section B Safety Precautions ......................B-1 General Description......................B-1 For Auxiliary Power ......................B-1 Engine Operation........................B-1...
  • Page 7 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...
  • Page 8: Installation

    INSTALLATION TECHNICAL SPECIFICATIONS - VANTAGE 500-I (K2805-1) ® INPUT - DIESEL ENGINE Make/Model Description Speed (RPM) Displacement Starting Capacities PERKINS cu. in. (ltrs.) System 4 cylinder 135.6(2.2) 12VDC Battery & Fuel: 20 gal. 32.7 HP High Idle 1880 starter (75.7 L) (K2805-1) 1800 RPM Bore x Stroke inch (mm)
  • Page 9: Safety Precautions

    INSTALLATION SAFETY PRECAUTIONS LIFTING The VANTAGE® 500-I weighs approximately 1345lbs. WARNING (611kg.) with a full tank of fuel 1230lbs.(559kg) less fuel. A lift bail is mounted to the machine and should always be used when lifting the machine. Do not attempt to use this equipment until you have thoroughly read the engine manufacturer’s manual supplied with your welder.
  • Page 10: High Altitude Operation

    INSTALLATION HIGH ALTITUDE OPERATION VEHICLE MOUNTING At higher altitudes, output derating may be necessary. For max- WARNING imum rating, derate the machine 2.5% to 3.5% for every 1000 ft. (305m). Due to new EPA and other local emissions regulations, modifications to the engine for high altitude are restricted within Improperly mounted concentrated loads may the United States.
  • Page 11: Welding Terminals

    INSTALLATION nections should be checked periodically and tightened Because this portable engine driven welder creates its with a 3/4" wrench. own power, it is not necessary to connect its frame to an earth ground, unless the machine Table A.1 lists recommended cable sizes and lengths is connected to premises wiring (home, shop, etc.) for rated current and duty cycle.
  • Page 12: Residual Current Device Ready

    The Vantage 500-I is configured to allow for the addi- tion of a Residual Current Device (RCD) to protect the 240V Single Phase Receptacle. The auxiliary power area on the front panel of the Vantage 500-I has a VANTAGE® 500-I...
  • Page 13: Connection Of Lincoln Electric Wire Feeders

    INSTALLATION CONNECTION OF LINCOLN ELECTRIC 1. Shut the welder off. WIRE FEEDERS 2. For electrode Positive, connect the electrode WARNING cable from the Wire Feeder to the "+" terminal of the welder and work cable to the "-" terminal of the welder.
  • Page 14: Operation

    OPERATION SAFETY PRECAUTIONS WARNING WARNING ADD FUEL • Stop engine while fueling. Do not attempt to use this equipment until you have thoroughly read the engine manufacturer’s • Do not smoke when fueling. manual supplied with your welder. It includes •...
  • Page 15 OPERATION FIGURE B.1 WELDING CONTROLS (Figure B.1) When in the TOUCH START TIG mode and when an Amptrol is connected to the 6-Pin Connector, the OUT- PUT dial is used to set the maximum current range of the 1. OUTPUT CONTROL- The OUTPUT dial is used to CURRENT CONTROL of the Amptrol.
  • Page 16: Engine Controls

    OPERATION ENGINE CONTROLS: 4. ARC CONTROL - The ARC CONTROL dial is active 9. RUN/STOP SWITCH in the CV-WIRE, CC-STICK and DOWNHILL PIPE - RUN position energizes the modes, and has different functions in these modes. This engine prior to starting. STOP position stops the engine. control is not active in the TIG mode and ARC The oil pressure interlock switch prevents battery drain if GOUGING mode.
  • Page 17: Constant Current (Stick) Welding

    OPERATION 14. ENGINE HOUR METER- NOTE: If the unit fails to start turn Run/Stop switch Displays the total time to off and repeat step 3 through step 7 after that the engine has been running. This meter is useful waiting 30 seconds. for scheduling prescribed maintenance.
  • Page 18: Downhill Pipe (Stick) Welding

    OPERATION (arc-force) during stick welding to adjust for a soft ARC GOUGING or crisp arc. Increasing the number from -10(soft) to The VANTAGE® 500-I can be used for arc gouging. +10(crisp) increases the short circuit current and For optimal performance, set the MODE switch to prevents sticking of the electrode to the plate while ARC GOUGING.
  • Page 19 INSTALLATION MUFFLER OUTLET PIPE The VANTAGE® 500-I is shipped with the engine Using the clamp provided secure the outlet pipe to the outlet crankcase filled with high quality SAE 10W-30 Oil that tube with the pipe positioned such that it will direct the meets classification CG-4 or CH-4 for diesel engines.
  • Page 20: Tig Welding

    OPERATION TIG WELDING The VANTAGE® 500-I can be used in a wide variety of DC TIG welding applications. In general the ‘Touch Start’ feature allows contamination free starting with- The TOUCH START TIG setting of the MODE switch out the use of a Hi-frequency unit. If desired, the is for DC TIG (Tungsten Inert Gas) welding.
  • Page 21: Auxiliary Power

    OPERATION 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.
  • Page 22: Accessories

    Invertec V275-S Get a second arc for Stick or DC TIG welding from the ACCESSORIES 3-phase AC generator power of the Vantage 500-I. Run 200 amps from the V275-S and 200 amps from the Vantage 500-I at the same time. Requires K2641-2 FOUR WHEELED STEERABLE YARD T12153-10 Full-KVA 3-phase plug.
  • Page 23: Maintenance

    MAINTENANCE SAFETY PRECAUTIONS Read the Safety Precautions in the front of this manual and in the Engine Owner’s Manual before WARNING working on this machine. • Have qualified personnel do all maintenance Keep all equipment safety guards, covers, and and troubleshooting work. devices in position and in good repair.
  • Page 24: Engine Oil Change

    MAINTENANCE ENGINE OIL CHANGE OIL FILTER CHANGE Drain the engine oil while the engine is warm to assure • Drain the oil. rapid and complete draining. It is recommended that each time the oil is changed the oil filter be changed as •...
  • Page 25 MAINTENANCE VANTAGE® 500-I...
  • Page 26: Cooling System

    MAINTENANCE FUEL COOLING SYSTEM WARNING At the end of each day’s use, refill the fuel tank to min- imize moisture condensation and dirt contamination in HOT COOLANT can burn skin. the fuel line. Do not overfill; leave room for the fuel to expand.
  • Page 27: Fuel Filter

    MAINTENANCE CLEANING THE BATTERY FUEL FILTER Keep the battery clean by wiping it with a damp cloth 1. Check the fuel filter and fuel pre-filter for water when dirty. If the terminals appear corroded, discon- accumulation or sediment. nect the battery cables and wash the terminals with an ammonia solution or a solution of 1/4 pound (0.1113 2.
  • Page 28: Welder / Generator Maintenance

    • Push the "Reset" button, again. The light or other product should go "ON" again. • Service and Repair should only be performed by Lincoln Electric Factory Trained Personnel. If the light or other product remains "ON" when the Unauthorized repairs performed on this equip- "Test"...
  • Page 29 NOTES VANTAGE® 500-I...
  • Page 30: 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.
  • Page 31 TROUBLESHOOTING Observe all Safety Guidelines detailed throughout this manual PROBLEMS POSSIBLE RECOMMENDED (SYMPTOMS) CAUSE COURSE OF ACTION 1. Contact your local Lincoln Major Physical or Electrical Damage Authorized Field Service is Evident. Facility. Engine will not "crank". 1. Battery is low, Charge Battery. 2.
  • Page 32 TROUBLESHOOTING Observe all Safety Guidelines detailed throughout this manual PROBLEMS POSSIBLE RECOMMENDED (SYMPTOMS) CAUSE COURSE OF ACTION Engine shuts down while under a 1. High radiator coolant tempera- load. ture. Reduce load if it is exceed- ing machine rating. Add coolant to system if low.
  • Page 33 TROUBLESHOOTING Observe all Safety Guidelines detailed throughout this manual PROBLEMS POSSIBLE RECOMMENDED (SYMPTOMS) CAUSE COURSE OF ACTION Engine will not go to high idle when 1. Auxiliary power load is less than using auxiliary power. 100 watts. Idler may not respond with less than a 100 watt load.
  • Page 34 TROUBLESHOOTING Observe all Safety Guidelines detailed throughout this manual PROBLEMS POSSIBLE RECOMMENDED (SYMPTOMS) CAUSE COURSE OF ACTION No welding power output. 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.
  • Page 35 TROUBLESHOOTING Observe all Safety Guidelines detailed throughout this manual PROBLEMS POSSIBLE RECOMMENDED (SYMPTOMS) CAUSE COURSE OF ACTION The welding arc is “cold.” The weld- 1. Make sure the MODE selector ing arc is not stable or is not satis- switch is in the correct position for factory.
  • Page 36 NOTES VANTAGE® 500-I...
  • Page 37: Diagrams

    DIAGRAMS INSTRUCTIONS FOR INSTALLING A RESIDUAL CURRENT DEVICE TO PROTECT THE 240V SINGLE PHASE RECEPTACLE WARNING Do not operate with covers removed Disconnect input power before servicing Do not touch electrically live parts Only qualified persons should install, ELECTRIC use or service this equipment SHOCK CAN KILL TURN OFF THE ENGINE AND DISCONNECT THE NEGATI VE BATTERY CABLE.
  • Page 38: The Lincoln Electric Company

    SECURE UPPER CONTROL PANEL IN PLACE. RECONNECT NEGATIVE BATTERY CABLE. THE UNI T IS NOW READY FOR OPERATION THE LINCOLN ELECTRIC COMPANY World's Leader in Welding and Cutting Products Sales and Service through Subsidiaries and Distributors Worldwide Cleveland, Ohio 44117-1199 U.S.A.
  • Page 39 DIAGRAMS VANTAGE® 500-I...
  • Page 40: Wiring Diagrams

    WIRING DIAGRAM VANTAGE® 500-I...
  • Page 41 DIAGRAMS VANTAGE® 500-I...
  • Page 42: Dimension Print

    DIMENSION PRINT VANTAGE® 500-I...
  • Page 43 Vantage 500-I - 12304...
  • Page 44 Contents Engine Driven Welders Vantage Vantage 500-I - 12304 Index of Sub Assemblies - 12304..................1 Case Front & Control Panel Assembly ................3 Output Panel Assembly .......................6 Power Module Panel Assembly ...................9 Generator & Rotor Assembly.....................11 Base, Fuel Tank & Battery Assembly ................13 Engine Assembly .......................17...
  • Page 45 THIS PAGE INTENTIONALLY LEFT BLANK...
  • Page 46: Vantage 500-I - 12304

    CASE FRONT & CONTROL PANEL ASSEMBLY P-608-D OUTPUT PANEL ASSEMBLY P-608-E POWER MODULE PANEL ASSEMBLY P-608-F GENERATOR & ROTOR ASSEMBLY P-608-G BASE FUEL TANK & BATTERY ASSEMBLY P-608-H ENGINE ASSEMBLY P-608-J_2 CASE BACK & RADIATOR ASBLY P-608-K ENCLOSURE COMPONENTS Vantage 500-I - 12304...
  • Page 47 Index of Sub Assemblies - 12304 P-608-A.jpg Vantage 500-I - 12304...
  • Page 48: Case Front & Control Panel Assembly

    SWITCH-PUSH BUTTON 9SS13146-1 START BUTTON 9ST10800-38 SWITCH-TOGGLE 9SS22061-4 SEALING BOOT 9SG7166 DECAL CARRIER 9SG5507-3 WELD CONTROL PC BD ASBLY 9SS8025-100 SELF TAPPING SCREW 9SL11924-1 PC BD MOUNTING BRKT 9ST9187-13 #10-24HLN-1817/1-NYLON INSERT 9SG6349 WIRING HARNESS 9ST13637-6 DIODE-BRIDGE35A400VF-W1-PH Vantage 500-I - 12304...
  • Page 49 SEALING BOOT 9SS22104-9 TOROID ASBLY 9SS9225-68 THREAD FORMING SCREW (CUTTING) 9SL13117 CASE FRONT & INSERT ASBLY 9SG4865 CASEFRONT 9SS9225-68 THREAD FORMING SCREW (CUTTING) 9SG4870 CASEFRONT INSERT 9SS9225-68 THREAD FORMING SCREW (CUTTING) 9SM17238 INSTRUCTION TAG 9SG6048 SHIELD Vantage 500-I - 12304...
  • Page 50 Case Front & Control Panel Assembly P-608-C.jpg Vantage 500-I - 12304...
  • Page 51: Output Panel Assembly

    RCD STRAP 9SS9225-63 THREAD FORMING SCREW (CUTTING) 9SS18907-3 RECEPTACLE 250v 50A 9SM18861 RECEPTACLE COVER 9ST9695-3 LOCKWASHER 9SCF000042 #8-32HN 9SM20586-1 CIRCUIT BREAKER50A3 POLE 9SS24911-4 CIRCUIT BREAKER COVER 9ST10082-30 SEMS SCREW 9ST4291-A LOCKWASHER 9SS26843-1 GFCI REWORK 9SS28464 GFCI COVER Vantage 500-I - 12304...
  • Page 52 9SM13900 OUTPUT TERMINAL ASBLY 9SS8025-91 SELF TAPPING SCREW 9SM20007 OUTPUT STUD COVER 9SS25669 OUTPUT STUD COVER PLATE 9SS9225-68 THREAD FORMING SCREW (CUTTING) 9ST9187-1 1/4-20HJLN 9SCF000017 1/4-20HN 9SS9225-68 THREAD FORMING SCREW (CUTTING) 9SS24097-2 SHUNT & LEAD ASBLY Vantage 500-I - 12304...
  • Page 53 Output Panel Assembly P-608-D.jpg Vantage 500-I - 12304...
  • Page 54: Power Module Panel Assembly

    LOCKWASHER 9SCF000010 #10-24HN 9SS22168 HEAT SINK HOLDER 9SS9225-45 THREAD FORMING SCREW 9SL11132-2 THREE PHASE BRIDGE RECTIFIER 9SS9262-121 PLAIN WASHER 9SE106A-14 LOCKWASHER 9SS9225-68 THREAD FORMING SCREW (CUTTING) 9SL12400-3V1 IDLER/ENGINE SHUTDOWN PC BD ASBLY 9SS8025-100 SELF TAPPING SCREW Vantage 500-I - 12304...
  • Page 55 Power Module Panel Assembly P-608-E.jpg Vantage 500-I - 12304...
  • Page 56: Generator & Rotor Assembly

    PLAIN WASHER 9SM21315 BRUSH HOLDER & BRACKET ASBLY 9SM18323 BRUSH HOLDER BRKT 9SM16158 BRUSH & BRUSH HOLDER ASBLY 9SG2114 BRUSH HOLDER CARTRIDGE 9SS19480 BRUSH ASBLY 9SM16157 BRUSH ASBLY RETAINER 9ST12380-4 BUSHING 9SS9225-8 THREAD FORMING SCREW (ROLLING) Vantage 500-I - 12304...
  • Page 57 Generator & Rotor Assembly P-608-F.jpg Vantage 500-I - 12304...
  • Page 58: Base, Fuel Tank & Battery Assembly

    FUEL TANK ASSEMBLY 9SG6058 FUEL TANK 9SL12505 FUEL SENDER 9SS19564-1 FUEL FITTING (PUSH-IN) 9SS19563 RUBBER PLUG 9SS20541 FUEL CAP 9SS19564-5 FUEL FITTINGPUSH-IN 9SM20547 CHOKE BRACKET 9SM19416-2 CHOKE ASBLY 9SCF000187 5/16-18X2.50HHCS 9SS9262-121 PLAIN WASHER 9SE106A-14 LOCKWASHER 9SCF000029 5/16-18HN Vantage 500-I - 12304...
  • Page 59 THREAD FORMING SCREW (CUTTING) 9SCF000014 1/4-20X.75HHCS 9SS9262-98 PLAIN WASHER 9SE106A-2 LOCKWASHER 9SCF000017 1/4-20HN 9SS13490-171A FILTER CAPACITOR 9SS22747 CAPACITOR BRKT ASBLY 9SS9225-68 THREAD FORMING SCREW (CUTTING) 9SS11604-65 SET SCREW 9SL12457 SUPPORT RAIL 9SS9225-68 THREAD FORMING SCREW (CUTTING) 9SM16197 DECAL-WARNING Vantage 500-I - 12304...
  • Page 60 Base, Fuel Tank & Battery Assembly PART NUMBER DESCRIPTION 9SS17851 DECAL-CAUTION 9SM20612 CONTAINER BRACKET 9SS9225-68 THREAD FORMING SCREW (CUTTING) 9SL12515-1 SIDE PANEL 9SS24739-27 1/4X.75 TEK SCREW 9ST14882-1 DOOR BUMPER Vantage 500-I - 12304...
  • Page 61 Base, Fuel Tank & Battery Assembly P-608-G.jpg Vantage 500-I - 12304...
  • Page 62: Engine Assembly

    HEX HD CAP SCREW 9ST10642-278 FLEX TUBE 9SS10888-27 HOSE CLAMP 9SM25295 ENGINE FOOT WELDED ASBLY 9SM20827 UPPER RADIATOR HOSE 9SM20828 LOWER RADIATOR HOSE 9SS10888-44 HOSE CLAMP 9SM20501 AIR INTAKE HOSE 9SS10888-29 HOSE CLAMP 9SS26772 LIFT EYE Vantage 500-I - 12304...
  • Page 63 9ST8833-86 HEX HD CAP SCREW 9SE106A-16 LOCKWASHER 9SS9262-120 PLAIN WASHER 9SM20358 AIR FILTER 9SM20359 AIR FILTER MTG BAND 9SM20807 AIR CLEANER BRACKET 9SCF000028 5/16-18X1.25HHCS 9SS9262-121 PLAIN WASHER 9SE106A-14 LOCKWASHER 9SCF000029 5/16-18HN 9SS24739-31 1/4-20 STAINLESS STEEL SCREW Vantage 500-I - 12304...
  • Page 64 Engine Assembly P-608-H.jpg Vantage 500-I - 12304...
  • Page 65: Case Back & Radiator Asbly

    ACOUSTICAL FOAM 9SS9225-68 THREAD FORMING SCREW (CUTTING) 9SG7166 DECAL CARRIER 9SG4058-10 LEFT FAN GUARD 9SS9225-68 THREAD FORMING SCREW (CUTTING) 9SG4060-10 FAN GUARD 9SS9225-68 THREAD FORMING SCREW (CUTTING) 9SS26354 ENGINE SERVICE DECAL 9ST13086-62 DECAL-WARNING 9ST14882 DOOR BUMPER Vantage 500-I - 12304...
  • Page 66 Case Back & Radiator Asbly P-608-J_2.jpg Vantage 500-I - 12304...
  • Page 67: Enclosure Components

    DOOR BUMPER 9SS27368-6 LOGO DECAL 9SM21801 FAMILY NAME LOGO 9ST13086-205 FUEL WARNING DECAL 9SS12934-1 COVER SEAL 9SS25896 DECAL-WARNING 9SS27368-6 LOGO DECAL 9ST14882-1 DOOR BUMPER 9SM21801 FAMILY NAME LOGO 9SM21436 CARBON MONOXIDE WARNING DECAL 9SG7166 DECAL CARRIER Vantage 500-I - 12304...
  • Page 68 Enclosure Components PART NUMBER DESCRIPTION 9SS28039-1 DECAL GREEN INITIATIVE Vantage 500-I - 12304...
  • Page 69 Enclosure Components P-608-K.jpg Vantage 500-I - 12304...
  • Page 70 WARNING Do not touch electrically live parts or Keep flammable materials away. Wear eye, ear and body protection. electrode with skin or wet clothing. Insulate yourself from work and AVISO DE ground. Spanish PRECAuCION No toque las partes o los electrodos Mantenga el material combustible Protéjase los ojos, los oídos y el bajo carga con la piel o ropa moja-...
  • Page 71 WARNING Keep your head out of fumes. Turn power off before servicing. Do not operate with panel open or Use ventilation or exhaust to guards off. remove fumes from breathing zone. AVISO DE Spanish PRECAuCION Los humos fuera de la zona de res- Desconectar el cable de ali- No operar con panel abierto o piración.
  • Page 72 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.

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