Lincoln Electric IM10044 manual

V ANT A GE 575 CUMMINS OPERA TOR’S MANUAL IM10044 March, 2010 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, OPER- ATE OR REPAIR THIS EQUIP- MENT WITHOUT READIN[...]

i SAFETY i FOR ENGINE powered 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 fumes outdoors. _____________________________________[...]

ii SAFETY ii ARC R A Y S can bur n. 4.a. Use a shield with the proper filter and cover plates to protect your eyes from sparks and the rays of the arc when welding or observing open arc welding. Headshield and filter lens should conform to ANSI Z87. I standards. 4.b. Us e suitable clothing made from durable flame-resistant material to protect your [...]

iii SAFETY iii FOR ELECTRIC ALL Y pow ered equipment. 8.a. Turn off input power using the disconnect switch at the fuse box before working on the equipment. 8.b. Install equipment in accordance with the U.S. National Electrical Code, all local codes and the manufacturer’s recommendations. 8.c. Ground the equipment in accordance with the U.S. Nati[...]

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 suiv- antes: Sûreté Pour Soudage A L’Arc 1. Protegez-vous contre la secousse électrique: a. Les[...]

v SAFETY v VANTAGE® 575 CUMMINS Electromagnetic Compatibility (EMC) Conformance Products displaying the CE mark are in conformity with European Community Council Directive of 3 May 1989 on the approximation of the laws of the Member States relating to electromagnetic compatibility (89/336/EEC). It was manufactured in conformity with a national sta[...]

vi SAFETY vi VANTAGE® 575 CUMMINS Electromagnetic Compatibility (EMC) The size of the surrounding area to be considered will depend on the structure of the building and other activities that are taking place. The surrounding area may extend beyond the boundaries of the premises. Methods of Reducing Emissions Mains Supply Welding equipment should b[...]

vii vii 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 and keep it handy for quick reference.[...]

viii viii T ABLE OF CONTENTS Page Installation ................................................................................................................... ....Section A Technical Specifications .......................................................................................................A-1 Safety Precautions ......................[...]

ix ix T ABLE OF CONTENTS Accessories ........................................................................................................Section c Optional Field Installed Accessories......................................................................C-1 ________________________________________________________________________ Maintenance ....[...]

VANTAGE® 575 CUMMINS A-1 INST ALLA TION A-1 TECHNICAL SPECIFICA TIONS - V ANT AGE® 575 CUMMINS (K2170-2) Make/Model Description Speed (RPM) Displacement Starting Capacities cu. in. (ltrs.) System 4 cylinder High Idle 1590 199(3.3) 12VDC Battery & Fuel: 25 gal. Cummins 48 HP (36kw) starter (94.6 L) B3.3 1500 RPM Full Load 1500 Bore x Stroke in[...]

A-2 INST ALLA TION VANTAGE® 575 CUMMINS A-2 SAFETY PRECAUTIONS Only qualified personnel should install, use, or service this equipment. Do not attempt to use this equipment until you have thoroughly read the engine manufacturer’s manual supplied with your welder. It includes important safety precautions, detailed engine starting, operating and m[...]

A-3 INST ALLA TION VANTAGE® 575 CUMMINS A-3 LIFTING The VANTAGE® 575 CUMMINS lift bale should be used to lift the machine. The VANTAGE® 575 CUM- MINS is shipped with the lift bale retracted. Before attempting to lift the VANTAGE® 575 CUMMINS the lift bale must be secured in a raised position. Secure the lift bale as follows: a. Open the engine [...]

ENGINE COOLANT HOT COOLANT can burn skin. •Do not remove cap if radiator is hot. ------------------------------------------------------------------------ The welder is shipped with the engine and radiator filled with a 50% mixture of ethylene glycol and water. See the MAINTENANCE section and the engine Operator’s Manual for more information on [...]

A-5 INST ALLA TION VANTAGE® 575 CUMMINS A-5 The VANTAGE® 575 CUMMINS is shipped with the nega- tive battery cable disconnected. Before you operate the machine, make sure the Engine Switch is in the OFF posi- tion and attach the disconnected cable securely to the nega- tive (-) battery terminal. Remove the insulating cap from the negative battery [...]

A-6 INST ALLA TION VANTAGE® 575 CUMMINS A-6 REMOTE CONTROL The VANTAGE® 575 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. When in the CC-STICK or CV-WIRE modes and when a remote control is conne[...]

A-7 INST ALLA TION VANTAGE® 575 CUMMINS A-7 CONNECTION OF LINCOLN ELEC- TRIC WIRE FEEDERS Shut off welder before making any electrical con- nections. ------------------------------------------------------------------------ Connection of LN-7, LN-8 OR LN-742 to the VAN- TAGE® 575 CUMMINS 1. Shut the welder off. 2. Connect the LN-7, LN-8 OR LN-742 [...]

A-8 INST ALLA TION VANTAGE® 575 CUMMINS A-8 CONNECTION OF AN NA-3 AUT OMA TIC WELDING SYSTEM TO THE V ANT AGE® 575 CUMMINS For connection diagrams and instructions for connect- ing an NA-3 Welding System to the VANTAGE® 575 CUMMINS, refer to the NA-3 Welding System instruc- tion manual. The connection diagram for the LN-8 can be used for connect[...]

B-1 OPERA TION VANTAGE® 575 CUMMINS B-1 SAFETY PRECAUTIONS Read and understand this entire section before operating your VANTAGE® 575 CUMMINS. Do not attempt to use this equipment until you have thoroughly read the engine manufacturer’s manual supplied with your welder. It includes important safety precautions, detailed engine starting, operat-[...]

B-2 OPERA TION B-2 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. The engine must be started within that time or the fuel solenoid will deenergize, and the switch must be toggled to reset the timer. 2. ST ART PUSHBUTTON Energizes the starter mo[...]

B-3 OPERA TION B-3 7. OIL PRESSURE GAUGE The gauge displays the engine oil pressure when the engine is running. 8. ENGINE PROTECTION The yellow engine protection light remains off with proper oil pressure and under normal oper- ating temperatures. If the light turns on, the engine protection system will stop the engine. Check for proper oil level a[...]

B-4 OPERA TION B-4 13. WELD MODE SELECTOR SWITCH: (Provides 3 selectable welding modes) CV-WIRE CC-STICK TOUCH START TIG 14. ARC CONTROL: The ARC CONTROL WIRE/STICK knob is active in the WIRE and STICK modes, and has different functions in these modes. This control is not active in the TIG mode. CC-STICK mode: In this mode, the ARC CON- TROL knob s[...]

B-5 OPERA TION B-5 23. 415 V AC RECEPT ACLE This is a 415VAC receptacle that provides auxil- iary power. This receptacle has 32 amp rating and IP66 rated. Refer to the AUXILIARY POWER RECEPTACLES section in the installa- tion chapter for further information about these receptacles. Also refer to the AUXILIARY POWER OPERATION section later in this c[...]

B-6 OPERA TION B-6 WHA T ARE VRD AND ROCV DEVICES? VRD’s are gaining popularity as a “must have” safety accessory especially where welding applications are being carried out in an environment with a high-risk of electric shock such as wet areas and hot humid sweaty conditions. VRD and ROCV are abbreviations for two different safety devices us[...]

B-7 OPERA TION B-7 Unlike other VRD’s Lincoln uses micro processor con- trol to monitor and establish the arc without the stick- ing and shorting of the electrode to the job as seen in many other VRD installations. Due to the requirement of the resistance in the circuit to be low, for a VRD to operate, a good metal-to-metal contact must be made b[...]

The VANTAGE® 575 CUMMINS is equipped with the required R.F. bypass circuitry for the connection of high frequency generating equipment. The VANTAGE® 575 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.[...]

ARC GOUGING For optimal performance when arc gouging, set the VANTAGE® 575 CUMMINS “WELD MODE” switch to the “CC - STICK” position, and the “ARC CONTROL” to 10. Set the “OUTPUT” knob to adjust output current to the desired level for the gouging electrode being used according to the ratings in the following Table B.2 NOTE: If desire[...]

P ARALLELING When paralleling machines in order to combine their outputs, all units must be operated in the CC-STICK mode only at the same output settings. To achieve this, turn the WELD MODE switch to the CC-STICK position. Operation in other modes may produce errat- ic outputs, and large output imbalances between the units. AUXILIAR Y POWER OPERA[...]

K2354-1 AIR DRYER KIT - Minimizes water content in supply air. Avoids cold weather air hose ice up. K2356-1 CONTROL PANEL COVER KIT - Clear plexiglass cover to protect control panel from dirt and debris, and to visually monitor machine operation. Lockable to deter vandalism. K2340-1 LOCKABLE FUEL CAP / FLASH ARRESTER KIT - For use in locations wher[...]

D-1 MAINTENANCE D-1 VANTAGE® 575 CUMMINS SAFETY PRECAUTIONS • Have qualified personnel do all maintenance and troubleshooting work. • Turn the engine off before working inside the machine or servicing the engine. • Remove guards only when necessary to perform maintenance and replace them when the maintenance requiring their removal is comple[...]

D-2 MAINTENANCE D-2 VANTAGE® 575 CUMMINS Unfasten or unlatch the service cover . Because the filter fits tightly over the outlet tube to create the critical seal, there will be some initial resistance, similar to breaking the seal on a jar . Gently move the end of the filter back and forth to break the seal then rotate while pulling straight out. [...]

D-3 MAINTENANCE D-3 FUEL FIL TERS When working on the fuel system: • Keep naked lights away, do not smoke ! • Do not spill fuel ! ------------------------------------------------------------------------- The VANTAGE® 575 CUMMINS is equipped with a Fuel Filter located after the lift pump and before fuel injectors.The procedure for changing the [...]

D-4 MAINTENANCE D-4 CHARGING THE BA TTER Y When you charge, jump, replace, or otherwise connect battery cables to the battery, be sure the polarity is correct. Improper polarity can damage the charging circuit. The VANTAGE® 575 CUMMINS positive (+) battery terminal has a red terminal cover. If you need to charge the battery with an external charge[...]

E-1 TROUBLESHOOTING E-1 VANTAGE® 575 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 Troubleshooting Guide is provided to help you locate and r[...]

E-2 TROUBLESHOOTING E-2 VANTAGE® 575 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 troubleshooting assistance before you proceed. CAUTION P[...]

E-3 TROUBLESHOOTING E-3 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 troubleshooting assistance before you proceed. CAUTION PROBLEMS (SYMPTOMS) POS[...]

E-4 TROUBLESHOOTING E-4 VANTAGE® 575 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 troubleshooting assistance before you proceed. CAUTION P[...]

F-1 WIRING DIAGRAM F-1 VANTAGE® 575 CUMMINS NOTE: This diagram is for reference only. It may not be accurate for all machines covered by this manual. The specific diagram for a particular code is included with the machine. If the diagram is illegible, write to the Service Department for a replacement. Give the equipment code number.[...]

F-2 DIAGRAMS F-2 VANTAGE® 575 CUMMINS[...]

F-3 DIAGRAMS F-3 VANTAGE® 575 CUMMINS GND 75 76 77 GREEN K291 OR K404 75 INPUT CA BLE 76 N.E. 77 K775 OPTION A L REMOTE C ONTROL D A M A GED. T H E ENGINE GO V ERNOR SETTING IS PRE-SET A T T H E F AC TO RY - DO NOT A DJUST A BO V E RPM SPE C IFI CA TIONS LISTED IN 81 42 41 31 31 32 32 2 2 4 4 21 21 GND 82 N.D. LN-7 WIRE FEEDER Keep guards in place[...]

F-4 DIAGRAMS F-4 VANTAGE® 575 CUMMINS[...]

F-5 DIAGRAMS F-5 VANTAGE® 575 CUMMINS[...]

F-6 DIAGRAMS F-6 VANTAGE® 575 CUMMINS CA UTION : N. A . WELDING CA BLE MUST BE OF PROPER CA P AC ITY FOR T H E C URRENT A ND DUTY C Y C LE OF IMMEDI A TE A ND FUTURE A PPI CA TIONS. SEE OPER A TING M A NU A L. 75 32 31 41 42 N. C . INSUL A TE E ACH UNUSED LE A D INDI V IDU A LLY . N.D. SPLI C E LE A DS A ND INSUL A TE. T H E ENGINE WELDER OPER A T[...]

F-7 DIAGRAMS F-7 VANTAGE® 575 CUMMINS[...]

F-8 DIAGRAMS F-8 VANTAGE® 575 CUMMINS[...]

F-9 DIAGRAMS F-9 VANTAGE® 575 CUMMINS[...]

F-10 DIAGRAMS F-10 VANTAGE® 575 CUMMINS[...]

F-11 DIAGRAMS F-11 VANTAGE® 575 CUMMINS 2 9/03[...]

F-12 DIAGRAMS F-12 VANTAGE® 575 CUMMINS[...]

F-13 DIMENSION PRINT F-13 VANTAGE® 575 CUMMINS * * * * BO TT OM V V IE W O O F W W E LD E R B B AS E. N.A . . C C E N TE TE R O O F GR GR A VI TY TY W W IT H O O IL I I N E E N GI NE , E E M PT Y F F U EL TA TA N K K A A N D CO CO OL A N T T I I N R R A DI AT AT O R. M 18 9 6 2- 3 B 2.2 4 56 56 . 9 5.8 6 148 148 .8 45 45 . 67 116 116 0 31 31 . 50 [...]

W ARNING A VISO DE PRECAUCION A TTENTION W ARNUNG A TENÇÃO Spanish French German Portuguese Japanese Chinese Korean Arabic READ AND UNDERST AND THE MANUF ACTURER’S INSTRUCTION FOR THIS EQUIPMENT AND THE CONSUMABLES TO BE USED AND FOLLOW YOUR EMPLOYER’S SAFETY PRACTICES. SE RECOMIENDA LEER Y ENTENDER LAS INSTRUCCIONES DEL F ABRICANTE P ARA EL [...]

W ARNING A VISO DE PRECAUCION A TTENTION W ARNUNG A TENÇÃO Spanish French German Portuguese Japanese Chinese Korean Arabic LEIA E COMPREENDA AS INSTRUÇÕES DO F ABRICANTE P ARA ESTE EQUIP AMENTO E AS P ARTES DE USO, E SIGA AS PRÁTICAS DE SEGURANÇA DO EMPREGADOR. ● Keep your head out of fumes. ● Use ventilation or exhaust to remove fumes fr[...]

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