Lincoln Electric VANTAGE 500 Operator's Manual
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Lincoln Electric VANTAGE 500 Operator's Manual

Lincoln Electric VANTAGE 500 Operator's Manual

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IM800
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July, 2004
Vantage 500 CUMMINS
10996
For use with machines having Code Numbers:
Safety Depends on You
Lincoln arc welding and cutting
equipment is designed and
built with safety in mind.
However, your overall safety
can be increased by proper
installation . . . and thoughtful
operation on your part. DO
NOT INSTALL, OPERATE OR
REPAIR THIS EQUIPMENT
WITHOUT READING THIS
MANUAL AND THE SAFETY
PRECAUTIONS CONTAINED
THROUGHOUT.
Most
importantly, think before you
act and be careful.
OPERATOR'S MANUAL
Copyright© 2004 Lincoln Global Inc.
• World's Leader in Welding and Cutting Products •
• Sales and Service through Subsidiaries and Distributors Worldwide •
Cleveland, Ohio 44117-1199 USA Tel: 216.481.8100 Fax: 216.486.1751 Web Site: www.lincolnelectric.com

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  • Page 1 July, 2004 Vantage 500 CUMMINS 10996 For use with machines having Code Numbers: 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 .

  • Page 2: California Proposition 65 Warnings

    351040, Miami, Florida 33135 or CSA Standard W117.2-1974 or WTIA (Welding Technology Institute of Australia), PO Box 6165, Silverwater, NSW, 2128. A free copy of “Arc Welding Safety” booklet E205 is available from the Lincoln Electrical Company, 22801 St Clair Avenue, Cleveland, Ohio 44117-1199.

  • Page 3: Electric Shock Can Kill

    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.
  • Page 4 WELDING SPARKS can cause fire or explosion 6 a Remove fire hazards from the welding area. If this is not possible, cover them to prevent the welding sparks from starting a fire. Remember that welding sparks and hot materials from welding can easily go through small cracks and openings to adjacent areas.
  • Page 5 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.
  • Page 6 The code number is especially important when identifying the correct replacement parts. - 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.

  • Page 7: Table Of Contents

    Connection of Lincoln Electric Wire Feeders ........
  • Page 8 ..............P-472 Series Vantage 500 CUMMINS...

  • Page 9: Installation

    TECHNICAL SPECIFICATIONS - Vantage 500 CUMMINS (K2272-1) Make /Model Description Cummins 4 cylinder B3.3 56HP (42 kw) Diesel Engine @ 1800 RPM RATED OUTPUT @ 104°F(40°C) - WELDER Duty Cycle 100% OUTPUT @ 104°F(40°C) - WELDER AND GENERATOR Height 42.0 in 31.5 in.

  • Page 10: Safety Precautions

    (FULL) oil capacity in the crankcase. When operating the welder at an angle, the effective fuel capacity will be slightly less than the specified 25 gallons. Vantage 500 CUMMINS...

  • Page 11: Lifting

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

  • Page 12: Pre-Operation Engine Service

    • Wear gloves and eye protection and be careful when working near battery. • Follow instructions printed on battery. IMPORTANT: To prevent ELECTRICAL DAMAGE WHEN: a) Installing new batteries. b) Using a booster. Use correct polarity — Negative Ground. Vantage 500 CUMMINS...

  • Page 13: Muffler Outlet Pipe

    Feet or to the metal framework of a building which has been effectively grounded. The National Electric Code lists a number of alternate means of grounding electrical equipment. A machine grounding stud marked with the symbol front of the welder. Vantage 500 CUMMINS 150-200ft 200-250ft 3/0 AWG 4/0 AWG Connections”...

  • Page 14: Remote Control

    Refer to the connection diagram shown in Figure A.2. 1. Install the double-pole, double-throw switch between the power company meter and the premises disconnect. Switch rating must be the same or greater than the customer’s premises disconnect and service over current protection. Vantage 500 CUMMINS manufacturer’s recommended...
  • Page 15 120 VOLT 50AMP 240 VOLT DOUBLE POLE CIRCUIT 240 VOLT BREAKER NOTE: No. 6 COPPER CONDUCTOR CABLE SEE NATIONAL ELECTRICAL CODE FOR ALTERNATE WIRE Vantage 500 CUMMINS GROUNDED CONDUCTOR NEUTRAL LOAD PREMISES DISCONNECT AND SERVICE GROUND OVERCURRENT PROTECTION SIZE RECOMMENDATIONS.

  • Page 16: Connection Of Lincoln Electric Wire Feeders

    CONNECTION OF LINCOLN ELECTRIC WIRE FEEDERS WARNING Shut off welder before making any electrical connections. ------------------------------------------------------------------------------------- CONNECTION OF LN-7, LN-8 OR LN-742 TO THE VANTAGE • Shut the welder off. • Connect the LN-7, LN-8 OR LN-742 per instructions on the appropriate connection diagram in the DIAGRAMS section.
  • Page 17 WELDING SYSTEM TO THE VANTAGE For connection diagrams and instructions for connecting an NA-3 Welding System to the Vantage, refer to the NA-3 Welding System instruction manual. The connection diagram for the LN-8 can be used for connecting the NA-3.

  • Page 18: Operation

    Core welding. In addition the Vantage can be used for Arc Gouging with carbons up to 3/8”(10mm) in diameter. The Vantage is not recommended for pipe thawing. GENERATOR The Vantage provides smooth 120/240 VAC output for auxiliary power and emergency standby power. Vantage 500 CUMMINS...

  • Page 19: Controls And Settings

    Displays the level of diesel fuel in the fuel tank. The operator must watch the fuel level closely to prevent running out of fuel and possibly having to bleed the system. 5. ENGINE TEMPERATURE GAUGE The gauge displays the engine coolant temperature. Vantage 500 CUMMINS...
  • Page 20 • If the triggering device remains pressed but no welding load is applied within approximately 12 seconds the engine may return to low idle speed. • If the triggering device is released or welding ceases the engine will return to low idle speed after approximately 12 seconds. Vantage 500 CUMMINS...

  • Page 21: Auxiliary Power Controls

    120VAC single phase auxiliary power. This receptacle has a 50 amp rating. Refer to the AUXILIARY POWER RECEPTACLES section in the installation chapter for further information about this receptacle. Also refer to the AUXILIARY POWER OPERATION section later in this chapter. Vantage 500 CUMMINS...

  • Page 22: Engine Operation

    STOPPING THE ENGINE 1. Switch the RUN/STOP switch to “STOP”. This turns off the voltage supplied to the shutdown solenoid. A backup shutdown can be accomplished by shutting off the fuel valve located on the fuel line. Vantage 500 CUMMINS...

  • Page 23: Break-In Period

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

  • Page 24: Typical Current Ranges For Tungsten Electrodes

    25-40 7-11 (15-23) 40-55 10-12 (21-25) 55-80 11-13 (23-27) 8-10 (18-22) 80-125 13-15 (28-32) 11-13 (23-27) Vantage 500 CUMMINS TIG TORCH Nozzle Size (4), (5) 2-4 (3-8) #4, #5, #6 3-5 (5-10) 3-5 (5-10) 4-6 (9-13) #5, #6 5-7 (11-15)

  • Page 25: Cv-Wire Mode

    For any electrodes, including the above recommendations, the procedures should be kept within the rating of the machine. For additional electrode information, See www.lincolnelectric.com or the appropriate Lincoln publication. ARC GOUGING For optimal performance when arc gouging, set the Vantage “WELD MODE”...
  • Page 26 Maximum Allowable Cord Length in ft. (m) for Conductor Size 12 AWG 10 AWG 8 AWG (12) (23) (23) (46) (15) (18) (30) (27) (23) Vantage 500 CUMMINS @ 240 VAC +/- 10% 6 AWG 4 AWG (38) (53) (91) (69) (107) (183) (27) (42) (69)

  • Page 27: Accessories

    Portable control provides same dial range as the output control on the welder from a location up to the specified length from the welder. Has convenient plug for easy connection to the welder. The Vantage 500 CUMMINS is equipped with a 6-pin connector for connecting the remote control.

  • Page 28: Maintenance

    5. Rinse elements from inside out with a gentle stream of water (less than 40 psi) to remove all suds and dirt. 6. Dry element before reuse with warm air at less than 160°F (71°C). Do not use a light bulb to dry the element. Vantage 500 CUMMINS...

  • Page 29: Fuel Filters

    When reconnecting the cables, connect the positive cable first and the negative cable last. PREVENTING BATTERY DISCHARGE Turn the RUN/STOP switch to stop when engine is not running. PREVENTING BATTERY BUCKLING Tighten nuts on battery clamp until snug. Vantage 500 CUMMINS...

  • Page 30: Charging The Battery

    Inspect and replace monthly, as FF5079 required. Replace annually. C6003112130 Replace every 500 hours or 6 months, FS19594 whichever is less. BCI GROUP 34 Inspect every 500 hours ----- Change every 750 hours or 3 months, whichever is less. Check daily. Vantage 500 CUMMINS...

  • Page 31: How To Use Troubleshooting Guide

    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.

  • Page 32: Troubleshooting

    Engine runs rough. Engine will not shut off. ºIf for any reason you do not understand the test procedures or are unable to perform the tests/repairs safely, contact your Local Lincoln Authorized Field Service Facility for technical troubleshooting assistance before you proceed.
  • Page 33 Engine will not go to high idle when using auxiliary power. 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.
  • Page 34 No welding output. Auxiliary output OK. No auxiliary power. 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.
  • Page 35 DIAGRAMS ENHANCED DIAGRAM Vantage 500 CUMMINS 405B 232F 405A 262A 208B 232D...
  • Page 36 DIAGRAMS CONNECTION DIAGRAM: Vantage 500 CUMMINS...
  • Page 37 DIAGRAMS CONNECTION DIAGRAM: Vantage 500 CUMMINS...
  • Page 38 DIAGRAMS CONNECTION DIAGRAM Vantage 500 CUMMINS...
  • Page 39 DIAGRAMS CONNECTION DIAGRAM Vantage 500 CUMMINS...
  • Page 40 DIAGRAMS CONNECTION DIAGRAM Vantage 500 CUMMINS...
  • Page 41 DIAGRAMS CONNECTION DIAGRAM Vantage 500 CUMMINS...
  • Page 42 DIAGRAMS CONNECTION DIAGRAM Vantage 500 CUMMINS...
  • Page 43 DIAGRAMS CONNECTION DIAGRAM Vantage 500 CUMMINS...
  • Page 44 DIAGRAMS F-10 F-10 CONNECTION DIAGRAM Vantage 500 CUMMINS...
  • Page 45 DIAGRAMS F-11 F-11 CONNECTION DIAGRAM Vantage 500 CUMMINS...
  • Page 46 DIAGRAMS F-12 F-12 CONNECTION DIAGRAM Vantage 500 CUMMINS...
  • Page 47 DIAGRAMS F-13 F-13 CONNECTION DIAGRAM Vantage 500 CUMMINS...
  • Page 48 DIAGRAMS F-14 F-14 DIMENSION PRINT Vantage 500 CUMMINS...
  • Page 49 WARNING Spanish AVISO DE PRECAUCION French ATTENTION German WARNUNG Portuguese ATENÇÃO Japanese Chinese Korean Arabic Vantage 500 CUMMINS...
  • Page 50 Vantage 500 CUMMINS WARNING Spanish AVISO DE PRECAUCION French ATTENTION German WARNUNG Portuguese ATENÇÃO Japanese Chinese Korean Arabic...
  • Page 51 World’s Leader in Welding and Cutting Products • Sales and Service through Subsidiaries and Distributors Worldwide • Cleveland, Ohio 44117-1199 USA Tel: 216.481.8100 Fax: 216.486.1751 Web Site: www.lincolnelectric.com...

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