Lincoln 500 - Manuals - manualsarea.com

Page 2 - SAFETY; CALIFORNIA PROPOSITION 65 WARNINGS; WARNING

ELECTRIC ANDMAGNETIC FIELDSmay be dangerous 2.a. Electric current flowing through any conductor causes localized Electric and Magnetic Fields (EMF). Weldingcurrent creates EMF fields around welding cables andwelding machines. 2.b. EMF fields may interfere with some pacemakers and welders having a pa...

Page 3 - ii

ELECTRIC SHOCKcan 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 bareskin or wet clothing. Wear dry, hole-freegloves to insulate hands. 3.b. Insulate yourself from work and ground using dryinsulation. Make ...

Page 4 - iii

F O R E L E C T R I C A L LYpowered equipment. 8.a. Turn off input power using the disconnect switch at the fuse box before working on theequipment. 8.b. Install equipment in accordance with the National Electrical Code, all local codes and the manufacturer ’srecommendations. 8.c. Ground the equipme...

Page 5 - iv; PRÉCAUTIONS DE SÛRETÉ

iv SAFETY iv Mar. ‘93 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 ...

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

Page Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Section A Technical Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ...

Page 8 - vii

Accessories . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Section C Optional Field Installed Accessories . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .C-1 ___...

Page 9 - INPUT - DIESEL ENGINE; Cummins; PHYSICAL DIMENSIONS; INSTALLATION

TECHNICAL SPECIFICATIONS - Vantage 500 CUMMINS (K2272-1) INPUT - DIESEL ENGINE Make /Model Description Speed (RPM) Displacement Starting Capacities System Cummins 4 cylinder High Idle 1900 199 cu. in 12VDC battery Fuel B3.3 56HP (42 kw) Low Idle 1425 (3.3L) & Starter (25 US gal) Diesel Engine @ ...

Page 10 - STORING; ANGLE OF OPERATION

Read this entire installation section before you startinstallation. SAFETY PRECAUTIONS Do not attempt to use this equipment until you havethoroughly read all operating and maintenance manualssupplied with your machine. They include important safetyprecautions, detailed engine starting, operating and...

Page 12 - PRE-OPERATION ENGINE SERVICE; OIL; FUEL CAP

PRE-OPERATION ENGINE SERVICE READ the engine operating and maintenance instructionssupplied with this machine. • Stop engine while fueling. • Do not smoke when fueling. • Keep sparks and flame away from tank. • Do not leave unattended while fueling. • Wipe up spilled fuel and allow fumes to clear be...

Page 13 - WELDING TERMINALS

The Vantage is shipped with the negative battery cabledisconnected. Before you operate the machine, make sure theEngine Switch is in the OFF position and attach the disconnectedcable securely to the negative (-) battery terminal. Remove the insulating cap from the negative battery terminal.Replace a...

Page 14 - REMOTE CONTROL; OUTPUT; STANDBY POWER CONNECTIONS

REMOTE CONTROL OUTPUT The Vantage is equipped with a 6-pin and a 14-pin connector. The6-pin connector is for connecting the K857 or K857-1 RemoteControl or for TIG welding, the K870 foot Amptrol or the K936-2hand Amptrol. When in the CC-STICK, DOWNHILL PIPE, or CV-WIRE modes and when a remote contro...

Page 15 - Figure A.2 Connection of the Vantage to Premises Wiring

Vantage 500 CUMMINS A-7 INSTALLATION A-7 2. Take necessary steps to assure load is limited to the capacity of the Vantage by installing a 50 amp, 240 VAC double polecircuit breaker. Maximum rated load for each leg of the 240VAC auxiliary is 50 amps. Loading above the rated output willreduce output v...

Page 16 - CONNECTION OF LN-15 TO THE VANTAGE

CONNECTION OF LINCOLN ELECTRICWIRE FEEDERS Shut off welder before making any electrical connections. ------------------------------------------------------------------------------------- CONNECTION OF LN-7, LN-8 OR LN-742 TO THEVANTAGE • Shut the welder off. • Connect the LN-7, LN-8 OR LN-742 per in...

Page 17 - CONNECTION OF THE LN-25 TO THE VANTAGE; CAUTION

CONNECTION OF THE LN-25 TO THE VANTAGE The LN-25 with or without an internal contactor may be used withthe Vantage. See the appropriate connection diagram in theDIAGRAMS section. NOTE : The LN-25 (K431) Remote Control Module and (K432) Remote Cable are not recommended for use with the Vantage. • Shu...

Page 18 - SAFETY INSTRUCTIONS; ADDITIONAL SAFETY PRECAUTIONS; GENERAL DESCRIPTION; RECOMMENDED APPLICATIONS; GENERATOR; OPERATION

SAFETY INSTRUCTIONS Read and understand this entire section before operating your Vantage. Do not attempt to use this equipment until you havethoroughly read all operating and maintenance manualssupplied with your machine. They include important safetyprecautions, detailed engine starting, operating...

Page 19 - ENGINE CONTROLS; CONTROLS AND SETTINGS; Figure B.1 Case Front Panel Controls

ENGINE CONTROLS (Items 1 through 9) 1. RUN STOP SWITCH Toggling the switch to the RUN position energizes the fuelsolenoid for approximately 30 seconds. The engine must bestarted within that time or the fuel solenoid will deenergize, andthe switch must be toggled to reset the timer. 2. START PUSHBUTT...

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 thefour welding modes. When in the CC-STICK, DOWNHILL PIPE orCV-WIRE modes and when a remote control is connected to the6-Pin or 14-Pin Co...

Page 22 - ENGINE OPERATION; STARTING THE ENGINE; STOPPING THE ENGINE

20. CIRCUIT BREAKERS These circuit breakers provide separate overload currentprotection for each 120V circuit at the 240V receptacle, each120V receptacle, the 120VAC in the 14-Pin connector, the 42VACin the 14-Pin connector and battery circuit overload protection. 21. 120VAC RECEPTACLES These two 12...

Page 23 - TYPICAL FUEL CONSUMPTION; WELDER OPERATION; DUTY CYCLE

B-6 OPERATION B-6 Vantage 500 CUMMINS 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 verynormal for any engine to use small quantities of oil until the break-in is accomplished. Check the oil level twi...

Page 25 - ARC GOUGING; PARALLELING; AUXILIARY POWER OPERATION; ELECTRODE

CV-WIRE MODE Connect a wire feeder to the Vantage and set welder controlsaccording to the instructions listed earlier in this section. The Vantage in the ”CV-WIRE” position, permits it to be used witha broad range of flux cored wire (Innershield and Outershield)electrodes and solid wires for MIG wel...

Page 26 - * Each duplex receptacle is limited to 20 amps.

B-9 OPERATION B-9 Vantage 500 CUMMINS TABLE B.5 Vantage Extension Cord Length Recommendations Current (Amps) 1515202025303850 Voltage (Volts) 120240120240240240240240 Load (Watts) 1800360024004800600072009000 12000 3060 (9) (18) 40753060 (12)(23) (9) (18) 75 150 50 100 9075 (23)(46)(15)(30)(27)(23) ...

Page 27 - OPTIONAL FIELD INSTALLED ACCESSORIES; 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 maynot be compatible with NEMA common household receptacles. K802-R POWER PLUG KIT - Provides four 120V plugs rated 15 ...

Page 28 - SAFETY PRECAUTIONS; DAILY; ENGINE MAINTENANCE; AIR FILTER; MAINTENANCE

SAFETY PRECAUTIONS • Have a qualified technician do the maintenance andtroubleshooting 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. • Always use the greatest care when wor...

Page 31 - HOW TO USE TROUBLESHOOTING GUIDE; TROUBLESHOOTING

This Troubleshooting Guide is provided to help you locate andrepair possible machine malfunctions. Simply follow the three-step procedure listed below. Step 1. LOCATE PROBLEM (SYMPTOM). Look under the column labeled “PROBLEM (SYMPTOMS)”. Thiscolumn describes possible symptoms that the machine mayexh...

Page 32 - Observe all Safety Guidelines detailed throughout this manual

PROBLEMS (SYMPTOMS) Major Physical or Electrical Damage isEvident. 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. Engine will not shut off. POSSIBLE AREAS OF MISADJUSTMENT(S) 1. Contact your Lo...

Page 33 - PROBLEMS

CAUTION Vantage 500 CUMMINS E-3 TROUBLESHOOTING E-3 PROBLEMS (SYMPTOMS) Battery does not stay charged. Engine will not idle down to lowspeed. Engine will not go to high idle whenattempting to weld. Engine will not go to high idle when usingauxiliary power. POSSIBLE AREAS OF MISADJUSTMENT(S) 1. Fault...

Page 34 - POSSIBLE AREAS OF; RECOMMENDED; FUNCTION PROBLEMS

PROBLEMS (SYMPTOMS) Engine goes to low idle but does not stay atlow idle. No welding output or auxiliary output. Welder has some/ no output and no control.Auxiliary output OK No welding output. Auxiliary output OK. No auxiliary power. POSSIBLE AREAS OF MISADJUSTMENT(S) 1. Faulty Peripheral PCB, Pull...

Page 35 - 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 dia- gram for your particular machine is pasted inside the machine on one of the enclosure panels. CB6 10A 42A 42 R E CTI F IE R BR ID GE 238A ...

Page 37 - COMMANDER; ARNING

F-3 DIAGRAMS F-3 Vantage 500 CUMMINS CONNECTION DIAGRAM: GND 75 76 77 GREEN K291 OR K404 75 INPUT C ABLE 76 N.E. 77 K775 OPTIONAL REMO TE CONTR O L D AMA GED .THE E NGINE G O VERNOR SETTING IS P RE-SET AT THE FA C TO R Y - D O N O T ADJUST ABO VE RPM SPECIFICA TIONS LISTED IN 81 42 41 31 31 32 32 2 ...

Page 38 - CONNECTION DIAGRAM

F-4 DIAGRAMS F-4 Vantage 500 CUMMINS CONNECTION DIAGRAM

Page 43 - WA; THE ENGINE GOVERNOR SETTING IS PRE-SET

Vantage 500 CUMMINS F-9 DIAGRAMS F-9 CONNECTION DIAGRAM o r s e rvice this e q u ip m e n t. O n ly qualified p ers onne l s hou ld ins tall, u s e Keep aw ay from m ovi n g p a rt s . Keep gua rd s in p lac e. MO VING PART S ca n injure WA R N IN G Do n o t to u ch e le ctricall y liv e p a rts . b...

Page 48 - DIMENSION PRINT

Vantage 500 CUMMINS F-14 DIAGRAMS F-14 DIMENSION PRINT TR AI LE R MOUN TI NG HOL E LOCAT IONS. * 28.9 9 19.6 3 6.55 23.6 9 50.3 8 54.4 4 14.6 3 37.3 0 45.3 8 63.1 0 6.56 42.0 0 50.8 1 16.8 5 33.5 3 32.0 8 42.3 5 31.5 0 45.6 7 2.24 50.1 5 5.86 46.3 5 * * * * BO TT OM VI EW OF W E LD ER BAS E. N. A. C...

Page 50 - AVISO DE; ATTENTION

Vantage 500 CUMMINS WARNING AVISO DE PRECAUCION ATTENTION WARNUNG ATENÇÃO Spanish French German Portuguese Japanese Chinese Korean Arabic LEIA E COMPREENDA AS INSTRUÇÕES DO FABRICANTE PARA ESTE EQUIPAMENTO E AS PARTES DE USO, E SIGA AS PRÁTICAS DE SEGURANÇA DO EMPREGADOR. l Keep your head out of fum...

Page 51 - World’s Leader in Welding and Cutting Products

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