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IM873-A
RETURN TO MAIN MENU
July, 2007
VANTAGE 500 CUMMINS
11181, 11416
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 EQUIP-
MENT WITHOUT READING
THIS MANUAL AND THE
SAFETY
PRECAUTIONS
CONTAINED THROUGHOUT.
Most importantly, think before
you act and be careful.
R
OPERATOR'S MANUAL
Copyright © 2007 Lincoln Global Inc.
• World's Leader in Welding and Cutting Products •
• Sales and Service through Subsidiaries and Distributors Worldwide •
Cleveland, Ohio 44117-1199 U.S.A. TEL: 216.481.8100 FAX: 216.486.1751 WEB SITE: www.lincolnelectric.com
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Table of Contents
Troubleshooting
Related Manuals for Lincoln Electric VANTAGE 500 CUMMINS 500
Summary of Contents for Lincoln Electric VANTAGE 500 CUMMINS 500
- Page 1 IM873-A RETURN TO MAIN MENU July, 2007 VANTAGE 500 CUMMINS 11181, 11416 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 .
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Page 2: California Proposition 65 Warnings
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. - Page 3 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 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 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 suiv- antes: Sûreté Pour Soudage A LʼArc 1. Protegez-vous contre la secousse électrique: a.
- Page 6 Electric for advice or information about their use of our products. We respond to our customers based on the best information in our posses- sion at that time. Lincoln Electric is not in a position to warrant or guarantee such advice, and assumes no liability, with respect to such infor- mation or advice.
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Page 7: Table Of Contents
Connection of Lincoln Electric Wire Feeders ........A-8,... - Page 8 Accessories ..............Section C Optional Field Installed Accessories .
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Page 9: Installation
TECHNICAL SPECIFICATIONS - VANTAGE 500 CUMMINS (K2406-1) Make /Model Description CUMMINS 4 cylinder B3.3 53HP (40 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 (1066.8 mm) (800.1mm) Output rating in watts is equivalent to volt-amperes at unity power factor. -
Page 10: Safety Precautions
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 mainte- nance manuals supplied with your machine. They include important safety precautions, detailed engine starting, operating and maintenance instructions and parts lists. -
Page 11: Lifting
LIFTING The VANTAGE 500 CUMMINS lift bail should be used to lift the machine. The VANTAGE 500 CUMMINS is shipped with the lift bail retracted. Before attempting to lift the VANTAGE 500 CUMMINS the lift bail must be secured in a raised position. Secure the lift bail as follows: a. -
Page 12: Oil
Manual for more information on coolant.) INSTALLATION ENGINE BREAK-IN Lincoln Electric selects high quality, heavy-duty indus- trial engines for the portable welding machines we offer. While it is normal to see a small amount of crankcase oil consumption during initial operation,... -
Page 13: Muffler Outlet Pipe
• CONNECTING A BATTERY CHARGER — remove bat- tery from welder by disconnecting negative cable first, then positive cable and battery clamp. When rein- stalling, connect negative cable last. Keep well venti- lated. • USING A BOOSTER — connect positive lead to battery first then connect negative lead to negative battery lead at engine foot. -
Page 14: Remote Control
REMOTE CONTROL OUTPUT The VANTAGE 500 CUMMINS 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. - Page 15 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...
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Page 16: Connection Of Lincoln Electric Wire Feeders
CONNECTION OF LINCOLN ELECTRIC WIRE FEEDERS WARNING Shut off welder before making any electrical con- nections. ------------------------------------------------------------------------ CONNECTION OF LN-7, LN-8 OR LN-742 TO THE VANTAGE 500 CUMMINS • Shut the welder off. • Connect the LN-7, LN-8 OR LN-742 per instructions on the appropriate connection diagram in the DIA- GRAMS section. - Page 17 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.
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Page 18: Operation
SAFETY INSTRUCTIONS Read and understand this entire section before operating your VANTAGE 500 CUMMINS. WARNING Do not attempt to use this equipment until you have thoroughly read all operating and mainte- nance manuals supplied with your machine. They include important safety precautions, detailed engine starting, operating and maintenance instructions and parts lists. -
Page 19: Controls And Settings
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. 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. - Page 20 6. OIL PRESSURE GAUGE The gauge displays the engine oil pressure when the engine is running. 7. ENGINE PROTECTION The yellow engine protection light remains off with proper oil pressure and under normal operating tem- peratures. If the light turns on, the engine protection system will stop the engine.
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Page 21: Auxiliary Power Controls
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. -
Page 22: Engine 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 protec- tion. -
Page 23: Break-In Period
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. -
Page 24: Typical Current Ranges For Tungsten Electrodes
The VANTAGE 500 CUMMINS and any high frequen- cy 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 maxi- mum range of the CURRENT CONTROL on the TIG Module or an Amptrol if connected to the TIG Module. -
Page 25: Cv-Wire Mode
CV-WIRE MODE Connect a wire feeder to the VANTAGE 500 CUM- MINS and set welder controls according to the instruc- tions listed earlier in this section. The VANTAGE 500 CUMMINS in the ”CV-WIRE” position, permits it to be used with a broad range of flux cored wire (Innershield and Outershield) elec- trodes and solid wires for MIG welding (gas metal arc welding). - Page 26 TABLE B.4 VANTAGE 500 CUMMINS SIMULTANEOUS WELDING AND POWER LOADS WELD 1 PHASE AMPS WATTS 12,000 12,000 PLUS 12,000 12,000 10,000 5,600 TABLE B.5 VANTAGE 500 CUMMINS Extension Cord Length Current Voltag (Amps) Load 14 AWG (Volts) (Watts) 1800 3600 (18) 2400 4800...
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Page 27: Accessories
The use of an arc welder for pipe thawing is not approved by the CSA, nor is it recommended or supported by Lincoln Electric. ------------------------------------------------------------------------ K2356-1 Control Panel Cover Kit-Clear plexiglass cover to protect control panel from dirt and debris, and to visually monitor machine operation. - Page 28 TIG 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. KP509 Magnum Parts Kit for PTA-26V TIG Torch Magnum Parts Kit provides all the torch accessories you need to start welding.
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Page 29: Maintenance
SAFETY PRECAUTIONS WARNING • Have a qualified technician do the maintenance and troubleshooting work. • 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. •... - Page 30 Service Instructions & Installation Tips 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.
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Page 31: Fuel Filters
FUEL FILTERS WARNING When working on the fuel system • Keep naked lights away, do not smoke ! • Do not spill fuel ! ------------------------------------------------------------------------ The VANTAGE 500 CUMMINS is equipped with a Fuel Filter located after the lift pump and before fuel injectors.The procedure for changing the filter is as follows. -
Page 32: Charging The Battery
CHARGING THE BATTERY When you charge, jump, replace, or otherwise con- nect 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. 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. -
Page 33: Gfci Receptacle Testing And Restting Procedure
GFCI RECEPTACLE TESTING AND RESET- TING 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. -
Page 34: How To Use Troubleshooting Guide
HOW TO USE TROUBLESHOOTING GUIDE 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 35: Troubleshooting
Observe all Safety Guidelines detailed throughout this manual PROBLEMS (SYMPTOMS) Major Physical or Electrical Damage is Evident. Engine will not crank Engine will crank but not start. Engine shuts down shortly after starting. Engine shuts down while under a load. Engine runs rough. - Page 36 Observe all Safety Guidelines detailed throughout this manual PROBLEMS (SYMPTOMS) Battery does not stay charged. Engine will not idle down to low speed. Engine will not go to high idle when attempting to weld. Engine will not go to high idle when using auxiliary power.
- Page 37 Observe all Safety Guidelines detailed throughout this manual PROBLEMS (SYMPTOMS) Engine goes to low idle but does not stay at low idle. No welding output or auxiliary out- put. Welder has some/ no output and no control. Auxiliary output OK No welding output.
- Page 38 DIAGRAMS Enhanced Diagram VANTAGE 500 CUMMINS...
- Page 39 CONNECTION DIAGRAMS VANTAGE 500 CUMMINS...
- Page 40 CONNECTION DIAGRAMS VANTAGE 500 CUMMINS...
- Page 41 CONNECTION DIAGRAMS VANTAGE 500 CUMMINS...
- Page 42 CONNECTION DIAGRAMS VANTAGE 500 CUMMINS...
- Page 43 CONNECTION DIAGRAMS VANTAGE 500 CUMMINS...
- Page 44 CONNECTION DIAGRAMS VANTAGE 500 CUMMINS...
- Page 45 CONNECTION DIAGRAMS VANTAGE 500 CUMMINS...
- Page 46 CONNECTION DIAGRAMS VANTAGE 500 CUMMINS...
- Page 47 F-10 F-10 CONNECTION DIAGRAMS VANTAGE 500 CUMMINS...
- Page 48 F-11 F-11 CONNECTION DIAGRAMS VANTAGE 500 CUMMINS...
- Page 49 F-12 F-12 CONNECTION DIAGRAMS VANTAGE 500 CUMMINS...
- Page 50 F-13 F-13 DIMENSION PRINT VANTAGE 500 CUMMINS...
- Page 51 NOTES VANTAGE 500 CUMMINS...
- Page 52 ● WARNING ● Spanish ● AVISO DE PRECAUCION ● French ● ATTENTION ● ● German WARNUNG ● Portuguese ● ATENÇÃO ● Japanese Chinese Korean Arabic ● ● ● ● ● ● ● ● ● ●...
- Page 53 ● ● ● ● ● ● ● ● ● ● ● ● ● ● ● ● ● ● Spanish ● PRECAUCION French ● ATTENTION ● German WARNUNG Portuguese ● ● Japanese Chinese Korean Arabic WARNING AVISO DE ATENÇÃO...
- Page 54 • World's Leader in Welding and Cutting Products • • Sales and Service through Subsidiaries and Distributors Worldwide • Cleveland, Ohio 44117-1199 U.S.A. TEL: 216.481.8100 FAX: 216.486.1751 WEB SITE: www.lincolnelectric.com...