Page 2 - SAFETY; WARNING; CALIFORNIA PROPOSITION 65 WARNINGS; The Above For Diesel Engines
FOR ENGINEpowered equipment. 1.a. Turn the engine off before troubleshooting and maintenance work unless the maintenance work requires it to be running. ____________________________________________________ 1.b. Operate engines in open, well-ventilated areas or vent the engine exhaust fumesoutdoors. ...
Page 3 - ii
ii SAFETY ii ARC RAYS can burn. 4.a. Use a shield with the proper filter and cover plates to protect your eyes from sparks andthe rays of the arc when welding or observingopen arc welding. Headshield and filter lensshould conform to ANSI Z87. I standards. 4.b. Use suitable clothing made from durable...
Page 4 - iii
iii SAFETY iii FOR ELECTRICALLYpowered equipment. 8.a. Turn off input power using the disconnect switch at the fuse box before working onthe equipment. 8.b. Install equipment in accordance with the U.S. National Electrical Code, all local codes and the manufacturerʼsrecommendations. 8.c. Ground the ...
Page 5 - iv; PRÉCAUTIONS DE SÛRETÉ
iv SAFETY iv Mar. ʻ93 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 contr...
Page 6 - Thank You; Please Examine Carton and Equipment For Damage Immediately
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! Read this Operators Manual completely before attempting to use this equipment. Save this manual...
Page 7 - TABLE OF CONTENTS; Installation
vi vi TABLE OF CONTENTS Page Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Section A Technical Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .A...
Page 9 - INSTALLATION; INPUT - DIESEL ENGINE; PHYSICAL DIMENSIONS
A-1 INSTALLATION VANTAGE 500 CUMMINS A-1 TECHNICAL SPECIFICATIONS - VANTAGE 500 CUMMINS (K2406-1) INPUT - DIESEL ENGINE Make /Model Description Speed (RPM) Displacement Starting Capacities System CUMMINS 4 cylinder High Idle 1890 199 cu. in 12VDC battery Fuel B3.3 53HP (40 kw) Low Idle 1400 (3.3L) &...
Page 10 - SAFETY PRECAUTIONS
A-2 INSTALLATION VANTAGE 500 CUMMINS A-2 Read this entire installation section before youstart installation. SAFETY PRECAUTIONS Do not attempt to use this equipment until youhave thoroughly read all operating and mainte-nance manuals supplied with your machine. Theyinclude important safety precautio...
Page 11 - LIFTING
A-3 INSTALLATION VANTAGE 500 CUMMINS A-3 LIFTING The VANTAGE 500 CUMMINS lift bail should be usedto lift the machine. The VANTAGE 500 CUMMINS isshipped with the lift bail retracted. Before attemptingto lift the VANTAGE 500 CUMMINS the lift bail mustbe secured in a raised position. Secure the lift ba...
Page 13 - CAUTION
A-5 INSTALLATION VANTAGE 500 CUMMINS A-5 • 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 bat...
Page 14 - REMOTE CONTROL; OUTPUT; AUXILIARY POWER RECEPTACLES; STANDBY POWER CONNECTIONS
A-6 INSTALLATION VANTAGE 500 CUMMINS A-6 REMOTE CONTROL OUTPUT The VANTAGE 500 CUMMINS is equipped with a 6-pin and a 14-pin connector. The 6-pin connector is forconnecting the K857 or K857-1 Remote Control or forTIG welding, the K870 foot Amptrol or the K963-3Hand Amptrol. When in the CC-STICK, DOW...
Page 17 - NOTE
A-9 INSTALLATION VANTAGE 500 CUMMINS A-9 CONNECTION OF THE LN-25 TO THEVANTAGE 500 CUMMINS The LN-25 with or without an internal contactor maybe used with the VANTAGE 500 CUMMINS. See theappropriate connection diagram in the DIAGRAMSsection. NOTE : The LN-25 (K431) Remote Control Module and (K432) R...
Page 18 - OPERATION; SAFETY INSTRUCTIONS; ADDITIONAL SAFETY PRECAUTIONS; GENERATOR
B-1 OPERATION VANTAGE 500 CUMMINS B-1 SAFETY INSTRUCTIONS Read and understand this entire section beforeoperating your VANTAGE 500 CUMMINS. Do not attempt to use this equipment until youhave thoroughly read all operating and mainte-nance manuals supplied with your machine. Theyinclude important safe...
Page 19 - ENGINE CONTROLS; RUN STOP SWITCH; ENGINE TEMPERATURE GAUGE; Figure B.1 Case Front Panel Controls; CONTROLS AND SETTINGS
B-2 OPERATION B-2 ENGINE CONTROLS (Items 1 through 9) 1. RUN STOP SWITCH Toggling the switch to the RUN position energizesthe fuel solenoid for approximately 30 seconds. Theengine must be started within that time or the fuelsolenoid will denergize, and the switch must be tog-gled to reset the timer....
Page 20 - OIL PRESSURE GAUGE
B-3 OPERATION B-3 6. OIL PRESSURE GAUGE The gauge displays the engine oil pressure whenthe engine is running. 7. ENGINE PROTECTION The yellow engine protection light remains off withproper oil pressure and under normal operating tem-peratures. If the light turns on, the engine protectionsystem will ...
Page 21 - WELDING TERMINALS SWITCH; AUXILIARY POWER CONTROLS
B-4 OPERATION B-4 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 digitalmeters for the four welding modes. When in the CC-STICK,DOWNHILL PIPE or CV-WIRE modes and when a remotecontrol is connected to the ...
Page 22 - 20VAC SINGLE PHASE RECEPTACLES; NGINE OPERATION; STARTING THE ENGINE
B-5 OPERATION B-5 20. CIRCUIT BREAKERS These circuit breakers provide separate overloadcurrent protection for each 120V circuit at the 240Vsingle phase receptacle, each 120V single phasereceptacle, the 240V three phase receptacle, the120VAC in the 14-Pin connector, the 42VAC in the14-Pin connector a...
Page 23 - IMPORTANT; TYPICAL FUEL CONSUMPTION; DUTY CYCLE
B-6 OPERATION B-6 BREAK-IN PERIOD The engine used to supply power for your welder is a heavyduty, industrial engine. It is designed and built for ruggeduse. It is very normal for any engine to use small quantitiesof oil until the break-in is accomplished. Check the oil leveltwice a day during the br...
Page 24 - Table B.3 TYPICAL CURRENT RANGES
B-7 OPERATION B-7 The VANTAGE 500 CUMMINS and any high frequen-cy generating equipment must be properly grounded.See the K930-2 TIG Module operating manuals forcomplete instructions on installation, operation, andmaintenance. When using the TIG Module, the OUTPUT control onthe VANTAGE 500 CUMMINS is...
Page 25 - ARC GOUGING; PARALLELING; ELECTRODE
B-8 OPERATION B-8 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 offlux cored wire (Innershield and Outers...
Page 26 - PLUS
B-9 OPERATION B-9 VANTAGE 500 CUMMINS TABLE B.5 VANTAGE 500 CUMMINS Extension Cord Length Recommendations Current (Amps) 1515202025303850 Voltag e (Volts) 120240120240240240240240 Load (Watts) 1800360024004800600072009000 12000 3060 (9) (18) 40753060 (12)(23) (9) (18) 75 150 50 100 9075 (23)(46)(15)...
Page 27 - ACCESSORIES; a m p s; K2359-1 Cold Weather Heater and Tarp Kit-
C-1 ACCESSORIES C-1 OPTIONAL FIELD INSTALLED ACCES-SORIES K802N POWER PLUG KIT - Provides four 120V plugs rated at 20 a m p s e a c h a n d o n e d u a l v o l t a g e , f u l l K V A p l u g r a t e d a t 120/240V, 50 amps. 120V plug may not be compatible with NEMAcommon household receptacles. K802...
Page 28 - TIG OPTIONS; KP509 Magnum Parts Kit for PTA-26V TIG Torch; WIRE FEEDER OPTIONS; K488 SG Control Module; PLASMA CUTTING
C-2 ACCESSORIES C-2 TIG OPTIONS K1783-9 PTA-26V TIG Torch Air Cooled 200 amp torch (2 piece) equipped withvalve 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 accessoriesyou need to start welding. Parts kit provides co...
Page 29 - MAINTENANCE; ROUTINE AND PERIODIC MAINTENANCE
D-1 MAINTENANCE D-1 VANTAGE 500 CUMMINS SAFETY PRECAUTIONS • Have a qualified technician do the maintenance and troubleshooting work. • T u r n t h e e n g i n e o f f b e f o r e w o r k i n g i n s i d e t h e machine. • Remove guards only when necessary and replace them when the maintenance requi...
Page 30 - Service Instructions & Installation Tips; For Engine Air Filter
D-2 MAINTENANCE D-2 VANTAGE 500 CUMMINS Service Instructions & Installation Tips For Engine Air Filter • Release the 1 Seal Carefully Unlatch and remove the servicecover of the air cleaner. Makecertain the latches are foldedback against the cover so thatthey don t hinder filterremoval/installati...
Page 31 - FUEL FILTERS
D-3 MAINTENANCE D-3 FUEL FILTERS 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 ...
Page 32 - CHARGING THE BATTERY; CLEANING
D-4 MAINTENANCE D-4 CHARGING THE BATTERY When you charge, jump, replace, or otherwise con-nect battery cables to the battery, be sure the polarityis correct. Improper polarity can damage the chargingcircuit. The VANTAGE 500 CUMMINS positive (+)battery terminal has a red terminal cover. If you need t...
Page 34 - TROUBLESHOOTING; Local Lincoln Authorized Field Service Facility; Step 3. RECOMMENDED COURSE OF ACTION; HOW TO USE TROUBLESHOOTING GUIDE
E-1 TROUBLESHOOTING E-1 VANTAGE 500 CUMMINS 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. CAUTION This Troublesho...
Page 35 - Observe all Safety Guidelines detailed throughout this manual; PROBLEMS
E-2 TROUBLESHOOTING E-2 VANTAGE 500 CUMMINS Observe all Safety Guidelines detailed throughout this manual 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 troubles...
Page 36 - Contact; FUNCTION PROBLEMS
E-3 TROUBLESHOOTING E-3 VANTAGE 500 CUMMINS Observe all Safety Guidelines detailed throughout this manual 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 troubles...
Page 38 - DIAGRAMS; Enhanced Diagram
F-1 DIAGRAMS F-1 VANTAGE 500 CUMMINS NOTE: This diagram is for reference only. It may not be accurate for all machines covered by this manual. The specific diag ram for a particular code is pasted inside the machine on one of the enclosure panels. If the diagram is illegible, write to the Service De...
Page 39 - CONNECTION DIAGRAMS
Page 40 - RNING
F-3 CONNECTION DIAGRAMS F-3 VANTAGE 500 CUMMINS GND 75• 76 77 GREEN K291 OR K404 75 INPUT CABLE 76 N.E. 77 K775 OPTIONAL• REMO TE CONTR O L D AMA GED . THE ENGINE GO VERNOR SETTING IS PRE-SET A T THE F A CT OR Y - DO NO T ADJUST ABO VE RPM SPECIFICA TIONS LISTED IN 81• 42 41 31 31 32 32 2 2 4 4 21 2...
Page 50 - DIMENSION PRINT
F-13 DIMENSION PRINT F-13 VANTAGE 500 CUMMINS * * * * B O T T O M VI EW O F W EL D ER BA SE . N. A. C E NT E R OF G R A VI TY W IT H OI L IN E N GI N E , EM PT Y FU E L T A N K A N D C O O LA NT I N R A DI ATO R. M1 89 62 -3 B 2. 24 56. 9 5. 86 148. 8 45. 67 1160 31. 50 800. 1 42. 00 1066. 8 46. 35 ...
Page 51 - NOTES