Lincoln Electric SVM178-B manuel d'utilisation

SVM178-B April, 201 1 Safety Depends on Y ou 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 INST ALL, OPERA TE OR REP AIR THIS EQUIPMENT WITHOUT READ- ING THIS MANUAL AND THE SAFETY PRECAU[...]

V ANT AGE® 500 SAFETY i i FOR ENGINE powered equipment. 1.a. T urn 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. _____________________[...]

V ANT AGE® 500 SAFETY ii ii FUMES AND GASES can be dangerous. 5.a. Welding may produce fumes and gases hazardous to health. Avoid breathing these fumes and gases.When welding, keep your head out of the fume. Use enough ventilation and/or exhaust at the arc to keep fumes and gases away from the breathing zone. When welding with electrodes which req[...]

V ANT AGE® 500 SAFETY iii iii FOR ELECTRICALL Y powered 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 wit[...]

V ANT AGE® 500 SAFETY iv iv 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[...]

V ANT AGE® 500 SAFETY Electromagnetic Compatibility (EMC) Confor mance P roducts displaying the CE mark are in conformity with European Community Council Directive of 1 5 Dec 2004 on the appro ximation of the laws of the Member Stat es relating to electromagnetic compatibilit y , 2004/1 08/EC . It was manuf actured in conformit y with a national s[...]

V ANT AGE® 500 SAFETY 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 surr ounding ar ea ma y ext end bey ond the boundar ies of the premises. Methods of Reducing Emissions Mains Supply W elding equipment should be con[...]

- MASTER T ABLE OF CONTENTS FOR ALL SECTIONS - I I V ANT AGE® 500 Page Safety . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .i-iv Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . [...]

T ABLE OF CONTENTS - INST ALLA TION SECTION A1.1 A1.1 V ANT AGE® 500 Installation - V ANT AGE® 500 Deutz F3L912 (Code 10995) T echnical Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .A1.2 Safety Precautions . . . . . . . . . . . . . . . . . . . . . . . . [...]

INST ALLA TION A1.2 A1.2 V ANT AGE® 500 TECHNICAL SPECIFICA TIONS - V antage 500® DEUTZ (K2271-1) INPUT - DIESEL ENGINE Make /Model Description Speed (RPM) Displacement Starting Capacities System Deutz 3 cylinder High Idle 1900 173 cu. in 12VDC battery Fuel F3L 912 44HP (33 kw) (2.83L) & Starter (25 US gal Diesel Engine @ 1800 RPM Full Load 1[...]

INST ALLA TION A1.3 A1.3 V ANT AGE® 500 Read this entire installation section before you start installation. SAFETY PRECAUTIONS 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 ma[...]

INST ALLA TION A1.4 A1.4 V ANT AGE® 500 LIFTING The V antage® 500 lift bale should be used to lift the machine. The V antage® 500 is shipped with the lift bale retracted. Before attempting to lift the V antage® 500, secure the lift bale in a raised position. Secure the lift bale as follows: a. Open the engine compartment door . b. Locate the tw[...]

INST ALLA TION A1.5 A1.5 V ANT AGE® 500 PRE-OPERA TION ENGINE SERVICE READ the engine operating and maintenance instruc- tions supplied with this machine. • Keep hands away from the engine muffler or HOT engine parts. • Stop engine and allow to cool before fueling. • Do not smoke when fueling. • Fill fuel tank at a moderate rate and do n[...]

INST ALLA TION A1.6 A1.6 V ANT AGE® 500 IMPORT ANT : T o prevent ELECTRICAL DAMAGE WHEN: a) Installing new batteries b) Using a booster Use correct polarity — Negative Ground. The V antage® 500 is shipped with the negative battery cable disconnected. Before you operate the machine, make sure the Engine Switch is in the OFF position and attach t[...]

INST ALLA TION A1.7 A1.7 V ANT AGE® 500 WELDING OUTPUT CABLES With the engine off, route the electrode and work cables through the strain relief bracket provided on the front of the base and connect to the terminals provided. These connections should be checked periodically and tightened if necessary . Listed in T able A1.1 are copper cable sizes [...]

INST ALLA TION A1.8 A1.8 V ANT AGE® 500 Figure A1.1 Connection of the V antage® 500 to Premises Wiring 1. Install the double-pole, double-throw switch between the power company meter and the premises disconnect. Switch rating must be the same as or greater than the customer ’s premises disconnect and service over cur- rent protection. 2. T ake [...]

T ABLE OF CONTENTS - OPERA TION SECTION B1.1 B1.1 V ANT AGE® 500 Operation - V ANT AGE® 500 Deutz F3L912 (Code 10995) Operating Instructions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .B1.2 Safety Instructions . . . . . . . . . . . . . . . . . . . . . . . . . . . .[...]

OPERA TION B1.2 B1.2 V ANT AGE® 500 OPERA TING INSTRUCTIONS Read and understand this entire section before oper- ating your V antage® 500. SAFETY INSTRUCTIONS 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 e[...]

OPERA TION B1.3 B1.3 V ANT AGE® 500 RECOMMENDED APPLICA TIONS WELDER The V antage® 500 provides excellent constant current DC welding output for stick (SMA W) and TIG welding. The V antage® 500 also provides excellent constant voltage DC welding output for MIG (GMA W) and Innershield (FCA W) welding. GENERA TOR The V antage® 500 provides smooth[...]

OPERA TION B1.4 B1.4 V ANT AGE® 500 ENGINE CONTROLS (Items 1 through 9) 1 . R UN ST O P SW IT CH T oggling 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 denergize, and the switch must be tog- gled to reset the timer . 2. ST ART PUSHBUTT[...]

OPERA TION 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. Check for proper oil and coolan[...]

OPERA TION 13. WELDING TERMINALS SWITCH In the WELD TERMINALS ON position, the output is electrically hot all the time. In the REMOTEL Y CON- TROLLED position, the output is controlled by a wire feeder or amptrol device, and is electrically off until a remote switch is depressed. 14. WIRE FEEDER VOL TMETER SWITCH: Matches the polarity o[...]

OPERA TION ENGINE OPERA TION ST ARTING THE ENGINE 1. Open the engine compartment door and check that the fuel shutoff valve is in the open position (lever to be in line with the hose). 2. Check for proper oil level and coolant level. Close engine compartment door . 3. Remove all plugs connected to the AC power recep- tacles. 4. Set IDLER switch to [...]

WELDER OPERA TION DUTY CYCLE Duty Cycle is the the ratio of the uninterrupted on-load duration to 10 minutes. The total time period of one complete on-load and no-load cycle is 10 minutes. For example, in the case of a 60% duty cycle, load is applied continuously for 6 minutes followed by a no- load period of 4 minutes. STICK WELDING MODE The V ant[...]

OPERA TION B1.9 B1.9 V ANT AGE® 500 V ANT AGE 500 SETTINGS WHEN USING THE K799 HI-FREQ UNIT • Set the WELD MODE switch to the 20-250 setting (TIG). • Set the IDLER switch to the HIGH position. • Set the WELDING TERMINALS switch to the WELD TERMINALS ON position. This will close the solid state contactor and provide an always “hot” electr[...]

OPERA TION B1.10 B1.10 V ANT AGE® 500 WIRE FEED (CONST ANT VOL T AGE) WELDING Connect a wire feeder to the V antage® 500 and set welder controls according to the instructions listed ear- lier in this section. See the operator ’s manual for the wire feeder or the “ Diagrams ” section of this manual for connecting instructions of various Linc[...]

OPERA TION B1.11 B1.11 V ANT AGE® 500 T ABLE B1.4 – V ANT AGE 500 EXTENSION CORD LENGTH RECOMMENDA TIONS Current (Amps) 15 15 20 20 25 30 38 50 V oltage (V olts) 120 240 120 240 240 240 240 240 Load (W atts) 1800 3600 2400 48010 6000 7200 9000 12000 30 60 (9) (18) 40 75 30 60 (12) (23) (9) (18) 75 150 50 100 90 75 (23) (46) (15) (30) (27) (23) 1[...]

NOTES B1.12 B1.12 V ANT AGE® 500 Return to Section TOC Return to Section TOC Return to Section TOC Return to Section TOC Return to Master TOC Return to Master TOC Return to Master TOC Return to Master TOC[...]

T ABLE OF CONTENTS - ACCESSORIES SECTION C1.1 C1.1 V ANT AGE® 500 Accessories - V ANT AGE® 500 Deutz F3L912 (Code 10995) Options/Accessories . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .C1.1 Optional Field Installed Accessories . . . . . . . . . . . . . . . . . [...]

ACCESSORIES C1.2 C1.2 V ANT AGE® 500 K802N POWER PLUG KIT - Provides four 120V plugs rated at 20 amps each and one dual voltage, full KV A plug rated at 120/240V , 50 amps. The 20 amp/120V plug may not be compatible with NEMA common household receptacles. K802R POWER PLUG KIT - Provides four 120V plugs rated 15 amps each and one dual voltage, fu[...]

ACCESSORIES C1.3 C1.3 V ANT AGE® 500 TIG OPTIONS K1783-9 PT A-26V TIG T orch Air Cooled 200 amp torch (2 piece) equipped with valve for gas flow control. 25 ft. (7.6m) length. KP509 Magnum Parts Kit for PT A-26V TIG T orch Magnum Parts Kit provides all the torch accessories you need to start welding. Parts kit provides collets, collet bodies, a [...]

NOTES C1.4 C1.4 V ANT AGE® 500 Return to Section TOC Return to Section TOC Return to Section TOC Return to Section TOC Return to Master TOC Return to Master TOC Return to Master TOC Return to Master TOC[...]

T ABLE OF CONTENTS - MAINTENANCE SECTION D1.1 D1.1 V ANT AGE® 500 Maintenance - V ANT AGE® 500 Deutz F3L912 (Code 10995) Safety Precautions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .D1.2 Routine and Periodic Maintenance . . . . . . . . . . . . . . . . . . .[...]

MAINTENANCE D1.2 D1.2 V ANT AGE® 500 SAFETY PRECAUTIONS • Have qualified personnel do all maintenance and troubleshooting work. • T urn the engine off before working inside the machine. • Remove covers or guards only when necessary to perform maintenance and replace them when the maintenance requiring their removal is com- plete. • If cove[...]

MAINTENANCE D1.3 D1.3 V ANT AGE® 500 CHANGE THE OIL FIL TER: Change the oil filter the first time between 25 and 50 hours of operation. Then, under normal operating conditions, change the oil filter after every 250 hours of operation. If the engine is operated under heavy load or in high ambient tem - peratures, change the oil filter more frequent[...]

MAINTENANCE D1.4 D1.4 V ANT AGE® 500 FUEL FIL TERS: When working on the fuel system: • Keep naked lights away , do not smoke • Do not spill fuel The V antage® 500 is equipped with a Fuel Pre- Filter/W ater Separator Assembly located before the lift pump and a Secondary Fuel Filter located after the lift pump and before the fuel injectors. The[...]

MAINTENANCE D1.5 D1.5 V ANT AGE® 500 4. Slide the new element onto the grommet post on the bottom of the filter header until the element no longer easily moves up into the filter header . Now rotate the element (it may take almost 1 full turn) with a slight upward pressure until the element begins to further engage the header . With the prop- er o[...]

MAINTENANCE D1.6 D1.6 V ANT AGE® 500 BLEEDING THE FUEL SYSTEM: In the event the engine is operated until it runs out of fuel, you will need to bleed the fuel system in order to start the engine. Refer to the engine operation manual. AIR FIL TER Excessive air filter restriction will result in reduced engine life. The air filter element is a dry car[...]

MAINTENANCE D1.7 D1.7 V ANT AGE® 500 MAINTENANCE INSTRUCTIONS Return to Section TOC Return to Section TOC Return to Section TOC Return to Section TOC Return to Master TOC Return to Master TOC Return to Master TOC Return to Master TOC[...]

MAINTENANCE D1.8 D1.8 V ANT AGE® 500 COOLING SYSTEM The cooling system of the Deutz engine needs to be checked and cleaned periodically . Consult the engine Operation Manual for the proper frequency and proce- dure. COOLING BLOWER BEL T : The following procedure should be followed to replace the cooling blower belt: 1. Allow the machine to cool. 2[...]

MAINTENANCE D1.9 D1.9 V ANT AGE® 500 T ABLE D1.1 DEUTZ ENGINE MAINTENANCE SCHEDULE FREQUENCY MAINTENANCE REQUIRED Daily or Before Starting Engine • Fill fuel tank. •  Check oil level. • Check air cleaner for dirty , loose, or damaged parts. Replace if necessary . • Check air intake and cooling areas, clean as necessary . 1 First 50 Hours[...]

MAINTENANCE D1.10 D1.10 V ANT AGE® 500 BA TTER Y MAINTENANCE GASES FROM BA TTER Y can explode. • Keep sparks, flame, and cigarettes away from battery . BA TTERY ACID can burn eyes and skin. • Wear gloves and eye protection and be careful when working near a bat- tery . Follow the instructions printed on the battery . T o prevent EXPLOSION when[...]

MAINTENANCE D1.11 D1.11 V ANT AGE® 500 WELDER/GENERA TOR MAINTENANCE STORAGE: Store the V antage 500 in clean, dry , pro- tected areas. CLEANING: Blow out the generator and controls peri- odically with low pressure air . Do this at least once a week in particularly dirty areas. NAMEPLA TES: Whenever routine maintenance is performed on this machine[...]

MAINTENANCE D1.12 D1.12 V ANT AGE® 500 WARNING 1 2 4 3 5 7 8 6 9 10 OFF FIGURE D1.5 – MAJOR COMPONENT LOCA TIONS 1. CONTROL P ANEL ASSEMBL Y 2. CONTROL BOX & OUTPUT ASSEMBL Y 3. POWER MODULE ASSEMBL Y 4. BASE & LIFT BALE ASSEMBL Y 5. FUEL T ANK & MOUNTING 6. ENGINE ASSEMBL Y 7. GENERA TOR 8. SOLENOID ASSEMBL Y 9. CASEBACK 10. CASE TO[...]

T ABLE OF CONTENTS - INST ALLA TION SECTION A2.1 A2.1 V ANT AGE® 500 Installation - V ANT AGE® 500 Deutz F4L201 1 (Codes 1 1 180,1 1415) T echnical Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .A2.2 Safety Precautions . . . . . . . . . . . . . . . . . . [...]

INST ALLA TION A2.2 A2.2 V ANT AGE® 500 TECHNICAL SPECIFICA TIONS - V ANT AGE 500 DEUTZ (K2405-1) INPUT - DIESEL ENGINE Make /Model Description Speed (RPM) Displacement Starting Capacities System DEUTZ 4 cylinder High Idle 1890 190 cu. in 12VDC battery Fuel F4L201 1 48HP (36 kw) Low Idle 1425 (3.1L) & Starter 25 US gal. Diesel Engine @ 1800 RP[...]

INST ALLA TION A2.3 A2.3 V ANT AGE® 500 Read this entire installation section before you start installation. SAFETY PRECAUTIONS 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 m[...]

INST ALLA TION A2.4 A2.4 V ANT AGE® 500 LIFTING The V antage lift bale should be used to lift the machine. The V antage is shipped with the lift bale retracted. Before attempting to lift the V antage, secure the lift bale in a raised position. Secure the lift bale as follows: a. Open the engine compartment door . b. Locate the two access holes on [...]

INST ALLA TION A2.5 A2.5 V ANT AGE® 500 PRE-OPERA TION ENGINE SERVICE READ the engine operating and maintenance instruc- tions supplied with this machine. • Keep hands away from the engine muffler or HOT engine parts. • Stop engine and allow to cool before fueling. • Do not smoke when fueling. • Fill fuel tank at a moderate rate and do n[...]

INST ALLA TION A2.6 A2.6 V ANT AGE® 500 IMPORT ANT : T o prevent ELECTRICAL DAMAGE WHEN: a) Installing new batteries b) Using a booster Use correct polarity — Negative Ground. The V antage is shipped with the negative battery cable disconnected. Before you operate the machine, make sure the Engine Switch is in the OFF position and attach the dis[...]

INST ALLA TION A2.7 A2.7 V ANT AGE® 500 WELDING OUTPUT CABLES With the engine off, route the electrode and work cables through the strain relief bracket provided on the front of the base and connect to the terminals provided. These connections should be checked periodically and tightened if necessary . Listed in T able A2.1 are copper cable sizes [...]

INST ALLA TION A2.8 A2.8 V ANT AGE® 500 Figure A2.1 Connection of the V antage to Premises Wiring 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 cus- tomer ’s premises disconnect and service over current protection. 2. T ake necessary[...]

T ABLE OF CONTENTS - OPERA TION SECTION B2.1 B2.1 V ANT AGE® 500 Operation - V ANT AGE® 500 Deutz F4L201 1 (Codes 1 1 180,1 1415) Operating Instructions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .B2.2 Safety Instructions . . . . . . . . . . . . . . . . . . . . . .[...]

OPERA TION B2.2 B2.2 V ANT AGE® 500 OPERA TING INSTRUCTIONS Read and understand this entire section before oper- ating your V antage 500. SAFETY INSTRUCTIONS 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 eng[...]

OPERA TION B2.3 B2.3 V ANT AGE® 500 RECOMMENDED APPLICA TIONS WELDER The V antage 500 provides excellent constant current DC welding output for stick (SMA W) and TIG welding. The V antage 500 also provides excellent constant volt- age DC welding output for MIG (GMAW) and Innershield (FCA W) welding. GENERA TOR The V antage 500 provides smooth 120/[...]

OPERA TION B2.4 B2.4 V ANT AGE® 500 ENGINE CONTROLS (Items 1 through 9) 1 . R UN ST O P SW IT CH T oggling 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 denergize, and the switch must be tog- gled to reset the timer . 2. ST ART PUSHBUTT[...]

OPERA TION B2.5 B2.5 V ANT AGE® 500 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. Check[...]

OPERA TION B2.6 B2.6 V ANT AGE® 500 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, DOWN- HILL PIPE or CV -WIRE modes and when a remote control is connected to the 6-Pin or 14-Pin Connector[...]

OPERA TION B2.7 B2.7 V ANT AGE® 500 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 120V AC in the 14-Pin connector , the 42V AC in the 14-Pin connector and battery circuit over[...]

WELDER OPERA TION DUTY CYCLE Duty Cycle is the the ratio of the uninterrupted on-load duration to 10 minutes. The total time period of one complete on-load and no-load cycle is 10 minutes. For example, in the case of a 60% duty cycle, load is applied continuously for 6 minutes followed by a no- load period of 4 minutes. STICK WELDING MODE The V ant[...]

OPERA TION B2.9 B2.9 V ANT AGE® 500 V ANT AGE 500 SETTINGS WHEN USING THE K799 HI-FREQ UNIT • Set the WELD MODE switch to the 20-250 setting (TIG). • Set the IDLER switch to the HIGH position. • Set the WELDING TERMINALS switch to the WELD TERMINALS ON position. This will close the solid state contactor and provide an always “hot” electr[...]

OPERA TION B2.10 B2.10 V ANT AGE® 500 WIRE FEED (CONST ANT VOL T AGE) WELDING Connect a wire feeder to the V antage 500 and set welder controls according to the instructions listed ear- lier in this section. See the operator ’s manual for the wire feeder or the “Diagrams ” section of this manual for connecting instructions of various Lincoln[...]

OPERA TION B2.11 B2.11 V ANT AGE® 500 T ABLE B2.4 – V ANT AGE 500 EXTENSION CORD LENGTH RECOMMENDA TIONS Current (Amps) 15 15 20 20 25 30 38 50 V oltage (V olts) 120 240 120 240 240 240 240 240 Load (W atts) 1800 3600 2400 48010 6000 7200 9000 12000 30 60 (9) (18) 40 75 30 60 (12) (23) (9) (18) 75 150 50 100 90 75 (23) (46) (15) (30) (27) (23) 1[...]

NOTES B2.12 B2.12 V ANT AGE® 500 Return to Section TOC Return to Section TOC Return to Section TOC Return to Section TOC Return to Master TOC Return to Master TOC Return to Master TOC Return to Master TOC[...]

T ABLE OF CONTENTS - ACCESSORIES SECTION C2.1 C2.1 V ANT AGE® 500 Accessories - V ANT AGE® 500 Deutz F4L201 1 (Codes 1 1 180, 1 1415) Options/Accessories . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .C2.2 Optional Field Installed Accessories . . . . . . . . . . .[...]

ACCESSORIES C2.2 C2.2 V ANT AGE® 500 K802N POWER PLUG KIT - Provides four 120V plugs rated at 20 amps each and one dual voltage, full KV A plug rated at 120/240V , 50 amps. 120V plug may not be compatible with NEMA common household receptacles. K802R POWER PLUG KIT - Provides four 120V plugs rated 15 amps each and one dual voltage, full KV A plu[...]

ACCESSORIES C2.3 C2.3 V ANT AGE® 500 TIG OPTIONS K1783-9 PT A-26V TIG T orch Air Cooled 200 amp torch (2 piece) equipped with valve for gas flow control. 25 ft. (7.6m) length. KP509 Magnum Parts Kit for PT A-26V TIG T orch Magnum Parts Kit provides all the torch accessories you need to start welding. Parts kit provides collets, collet bodies, a [...]

NOTES C2.4 C2.4 V ANT AGE® 500 Return to Section TOC Return to Section TOC Return to Section TOC Return to Section TOC Return to Master TOC Return to Master TOC Return to Master TOC Return to Master TOC[...]

T ABLE OF CONTENTS - MAINTENANCE SECTION D2.1 D2.1 V ANT AGE® 500 Maintenance - V ANT AGE® 500 Deutz F4L201 1 (Codes 1 1 180,1 1415) Safety Precautions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .D2.2 Routine and Periodic Maintenance . . . . . . . . . . . . .[...]

MAINTENANCE D2.2 D2.2 V ANT AGE® 500 SAFETY PRECAUTIONS • Have qualified personnel do all maintenance and troubleshooting work. • T urn the engine off before working inside the machine. • Remove covers or guards only when necessary to perform maintenance and replace them when the maintenance requiring their removal is com- plete. • If cove[...]

MAINTENANCE D2.3 D2.3 V ANT AGE® 500 CHANGE THE OIL FIL TER Change the oil filter the first time between 25 and 50 hours of operation. Then, under normal operating con- ditions, change the oil filter after every 250 hours of operation. If the engine is operated under heavy load or in high ambient tem peratures, change the oil filter more frequentl[...]

MAINTENANCE D2.4 D2.4 V ANT AGE® 500 FUEL FIL TERS When working on the fuel system • Keep naked lights away , do not smoke ! • Do not spill fuel ! ------------------------------------------------------------------------ The V ANT AGE 500 DEUTZ is equipped with a Fuel Filter/W ater Separator located after the lift pump and before fuel injectors[...]

MAINTENANCE D2.5 D2.5 V ANT AGE® 500 AIR FIL TER: Excessive air filter restriction will result in reduced engine life. The air filter element is a dry cartridge type. It can be cleaned and reused. However , damaged elements should not be reused. Stop engine after 100 hours of running time and clean filter element. Replace the filter if necessary .[...]

MAINTENANCE D2.6 D2.6 V ANT AGE® 500 MAINTENANCE INSTRUCTIONS Return to Section TOC Return to Section TOC Return to Section TOC Return to Section TOC Return to Master TOC Return to Master TOC Return to Master TOC Return to Master TOC[...]

MAINTENANCE D2.7 D2.7 V ANT AGE® 500 COOLING SYSTEM The cooling system of the Deutz engine needs to be checked and cleaned periodically . Consult the engine Operation Manual for the proper frequency and proce- dures. COOLING BLOWER BEL T : The following procedure should be followed to replace the cooling blower belt: 1. Allow the machine to cool. [...]

MAINTENANCE D2.8 D2.8 V ANT AGE® 500 WELDER/GENERA TOR MAINTENANCE STORAGE: Store the V antage 500 in clean, dry , pro- tected areas. CLEANING: Blow out the generator and controls peri- odically with low pressure air . Do this at least once a week in particularly dirty areas. NAMEPLA TES: Whenever routine maintenance is per- formed on this machine[...]

MAINTENANCE D2.9 D2.9 V ANT AGE® 500 BA TTER Y MAINTENANCE GASES FROM BA TTER Y can explode. • Keep sparks, flame, and cigarettes away from battery . BA TTERY ACID can burn eyes and skin. • Wear gloves and eye protection and be careful when working near a bat- tery . Follow the instructions printed on the battery . T o prevent EXPLOSION when: [...]

MAINTENANCE D2.10 D2.10 V ANT AGE® 500 WARNING W ARNING 1 1 2 2 4 4 6 6 3 3 5 5 7 7 10 10 9 9 FIGURE D2.6 – MAJOR COMPONENT LOCA TIONS 1. CONTROL P ANEL ASSEMBL Y 2. CONTROL BOX & OUTPUT ASSEMBL Y 3. POWER MODULE ASSEMBL Y 4. BASE & LIFT BALE ASSEMBL Y 5. FUEL T ANK & MOUNTING 6. ENGINE ASSEMBL Y 7. GENERA TOR 8. SOLENOID ASSEMBL Y 9[...]

T ABLE OF CONTENTS - INST ALLA TION SECTION A3.1 A3.1 V ANT AGE® 500 Installation - V ANT AGE® 500 Deutz D201 1L4i (Code1 1468) T echnical Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .A3.2 Safety Precautions . . . . . . . . . . . . . . . . . . . . . . .[...]

INST ALLA TION A3.2 A3.2 V ANT AGE® 500 TECHNICAL SPECIFICA TIONS - V ANT AGE® 500 DEUTZ (K2405-2) INPUT - DIESEL ENGINE Make /Model Description Speed (RPM) Displacement Starting Capacities System DEUTZ 4 cylinder High Idle 1890 190 cu. in 12VDC battery Fuel D 201 1 L4i 48HP (36 kw) Low Idle 1425 (3.1L) & Starter 25 US gal. Diesel Engine @ 18[...]

INST ALLA TION A3.3 A3.3 V ANT AGE® 500 Read this entire installation section before you start installation. SAFETY PRECAUTIONS 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 m[...]

INST ALLA TION A3.4 A3.4 V ANT AGE® 500 LIFTING The V antage lift bale should be used to lift the machine. The V antage is shipped with the lift bale retracted. Before attempting to lift the V antage, secure the lift bale in a raised position. Secure the lift bale as follows: a. Open the engine compartment door . b. Locate the two access holes on [...]

INST ALLA TION A3.5 A3.5 V ANT AGE® 500 PRE-OPERA TION ENGINE SERVICE READ the engine operating and maintenance instruc- tions supplied with this machine. • Keep hands away from the engine muffler or HOT engine parts. • Stop engine and allow to cool before fueling. • Do not smoke when fueling. • Fill fuel tank at a moderate rate and do n[...]

INST ALLA TION A3.6 A3.6 V ANT AGE® 500 IMPORT ANT : T o prevent ELECTRICAL DAMAGE WHEN: a) Installing new batteries b) Using a booster Use correct polarity — Negative Ground. The V antage is shipped with the negative battery cable disconnected. Before you operate the machine, make sure the Engine Switch is in the OFF position and attach the dis[...]

INST ALLA TION A3.7 A3.7 V ANT AGE® 500 WELDING OUTPUT CABLES With the engine off, route the electrode and work cables through the strain relief bracket provided on the front of the base and connect to the terminals provided. These connections should be checked periodically and tightened if necessary . Listed in T able A3.1 are copper cable sizes [...]

INST ALLA TION A3.8 A3.8 V ANT AGE® 500 Figure A3.1 Connection of the V antage to Premises Wiring 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 cus- tomer ’s premises disconnect and service over current protection. 2. T ake necessary[...]

T ABLE OF CONTENTS - OPERA TION SECTION B3.1 B3.1 V ANT AGE® 500 Operation - V ANT AGE® 500 Deutz D201 1L4i (Code 1 1468) Operating Instructions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .B3.2 Safety Instructions . . . . . . . . . . . . . . . . . . . . . . . . . .[...]

OPERA TION B3.2 B3.2 V ANT AGE® 500 OPERA TING INSTRUCTIONS Read and understand this entire section before oper- ating your V antage 500. SAFETY INSTRUCTIONS 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 eng[...]

OPERA TION B3.3 B3.3 V ANT AGE® 500 RECOMMENDED APPLICA TIONS WELDER The V antage 500 provides excellent constant current DC welding output for stick (SMA W) and TIG welding. The V antage 500 also provides excellent constant volt- age DC welding output for MIG (GMAW) and Innershield (FCA W) welding. GENERA TOR The V antage 500 provides smooth 120/[...]

OPERA TION B3.4 B3.4 V ANT AGE® 500 ENGINE CONTROLS (Items 1 through 9) 1 . R UN ST O P SW IT CH T oggling 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 denergize, and the switch must be tog- gled to reset the timer . 2. ST ART PUSHBUTT[...]

OPERA TION B3.5 B3.5 V ANT AGE® 500 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. Check[...]

OPERA TION B3.6 B3.6 V ANT AGE® 500 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, DOWN- HILL PIPE or CV -WIRE modes and when a remote control is connected to the 6-Pin or 14-Pin Connector[...]

OPERA TION B3.7 B3.7 V ANT AGE® 500 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 120V AC in the 14-Pin connector , the 42V AC in the 14-Pin connector and battery circuit over[...]

OPERA TION B3.8 B3.8 V ANT AGE® 500 WELDER OPERA TION DUTY CYCLE Duty Cycle is the the ratio of the uninterrupted on-load duration to 10 minutes. The total time period of one complete on-load and no-load cycle is 10 minutes. For example, in the case of a 60% duty cycle, load is applied continuously for 6 minutes followed by a no- load period of 4 [...]

OPERA TION B3.9 B3.9 V ANT AGE® 500 V ANT AGE 500 SETTINGS WHEN USING THE K799 HI-FREQ UNIT • Set the WELD MODE switch to the 20-250 setting (TIG). • Set the IDLER switch to the HIGH position. • Set the WELDING TERMINALS switch to the WELD TERMINALS ON position. This will close the solid state contactor and provide an always “hot” electr[...]

OPERA TION B3.10 B3.10 V ANT AGE® 500 WIRE FEED (CONST ANT VOL T AGE) WELDING Connect a wire feeder to the V antage 500 and set welder controls according to the instructions listed ear- lier in this section. See the operator ’s manual for the wire feeder or the “Diagrams ” section of this manual for connecting instructions of various Lincoln[...]

OPERA TION B3.11 B3.11 V ANT AGE® 500 T ABLE B3.4 – V ANT AGE 500 EXTENSION CORD LENGTH RECOMMENDA TIONS Current (Amps) 15 15 20 20 25 30 38 50 V oltage (V olts) 120 240 120 240 240 240 240 240 Load (W atts) 1800 3600 2400 48010 6000 7200 9000 12000 30 60 (9) (18) 40 75 30 60 (12) (23) (9) (18) 75 150 50 100 90 75 (23) (46) (15) (30) (27) (23) 1[...]

NOTES B3.12 B3.12 V ANT AGE® 500 Return to Section TOC Return to Section TOC Return to Section TOC Return to Section TOC Return to Master TOC Return to Master TOC Return to Master TOC Return to Master TOC[...]

T ABLE OF CONTENTS - ACCESSORIES SECTION C3.1 C3.1 V ANT AGE® 500 Accessories - V ANT AGE® 500 Deutz F4L201 1 (Codes 1 1 180, 1 1415) Options/Accessories . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .C3.2 Optional Field Installed Accessories . . . . . . . . . . .[...]

ACCESSORIES C3.2 C3.2 V ANT AGE® 500 K802N POWER PLUG KIT - Provides four 120V plugs rated at 20 amps each and one dual voltage, full KV A plug rated at 120/240V , 50 amps. 120V plug may not be compatible with NEMA common household receptacles. K802R POWER PLUG KIT - Provides four 120V plugs rated 15 amps each and one dual voltage, full KV A plu[...]

ACCESSORIES C3.3 C3.3 V ANT AGE® 500 TIG OPTIONS K1783-9 PT A-26V TIG T orch Air Cooled 200 amp torch (2 piece) equipped with valve for gas flow control. 25 ft. (7.6m) length. KP509 Magnum Parts Kit for PT A-26V TIG T orch Magnum Parts Kit provides all the torch accessories you need to start welding. Parts kit provides collets, collet bodies, a [...]

NOTES C3.4 C3.4 V ANT AGE® 500 Return to Section TOC Return to Section TOC Return to Section TOC Return to Section TOC Return to Master TOC Return to Master TOC Return to Master TOC Return to Master TOC[...]

T ABLE OF CONTENTS - MAINTENANCE SECTION D3.1 D3.1 V ANT AGE® 500 Maintenance - V ANT AGE® 500 Deutz D201 1L4i (Codes 1 1468) Safety Precautions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .D3.2 Routine and Periodic Maintenance . . . . . . . . . . . . . . . . [...]

MAINTENANCE D3.2 D3.2 V ANT AGE® 500 SAFETY PRECAUTIONS • Have qualified personnel do all maintenance and troubleshooting work. • T urn the engine off before working inside the machine. • Remove covers or guards only when necessary to perform maintenance and replace them when the maintenance requiring their removal is com- plete. • If cove[...]

MAINTENANCE D3.3 D3.3 V ANT AGE® 500 CHANGE THE OIL FIL TER Change the oil filter the first time between 25 and 50 hours of operation. Then, under normal operating con- ditions, change the oil filter after every 250 hours of operation. If the engine is operated under heavy load or in high ambient tem peratures, change the oil filter more frequentl[...]

MAINTENANCE D3.4 D3.4 V ANT AGE® 500 FUEL FIL TERS When working on the fuel system • Keep naked lights away , do not smoke ! • Do not spill fuel ! The V ANT AGE 500 DEUTZ is equipped with a Fuel Filter/W ater Separator located after the lift pump and before fuel injectors.The procedure for changing the fil- ter is as follows. See Figure D3.2 1[...]

MAINTENANCE D3.5 D3.5 V ANT AGE® 500 AIR FIL TER: Excessive air filter restriction will result in reduced engine life . The air filter element is a dry cartridge type. It can be cleaned and reused. However , damaged elements should not be reused. Stop engine after 100 hours of running time and clean filter element. Replace the filter if necessary [...]

MAINTENANCE D3.6 D3.6 V ANT AGE® 500 MAINTENANCE INSTRUCTIONS Return to Section TOC Return to Section TOC Return to Section TOC Return to Section TOC Return to Master TOC Return to Master TOC Return to Master TOC Return to Master TOC[...]

MAINTENANCE D3.7 D3.7 V ANT AGE® 500 COOLING SYSTEM The cooling system of the Deutz engine needs to be checked and cleaned periodically . Consult the engine Operation Manual for the proper frequency and proce- dures. COOLING BLOWER BEL T : The following procedure should be followed to replace the cooling blower belt: 1. Allow the machine to cool. [...]

MAINTENANCE D3.8 D3.8 V ANT AGE® 500 WELDER/GENERA TOR MAINTENANCE STORAGE: Store the V antage 500 in clean, dry , pro- tected areas. CLEANING: Blow out the generator and controls peri- odically with low pressure air . Do this at least once a week in particularly dirty areas. NAMEPLA TES: Whenever routine maintenance is per- formed on this machine[...]

MAINTENANCE D3.9 D3.9 V ANT AGE® 500 BA TTER Y MAINTENANCE GASES FROM BA TTER Y can explode. • Keep sparks, flame, and cigarettes away from battery . BA TTERY ACID can burn eyes and skin. • Wear gloves and eye protection and be careful when working near a bat- tery . Follow the instructions printed on the battery . T o prevent EXPLOSION when: [...]

MAINTENANCE D3.10 D3.10 V ANT AGE® 500 WARNING W ARNING 1 1 2 2 4 4 6 6 3 3 5 5 7 7 10 10 9 9 FIGURE D2.6 – MAJOR COMPONENT LOCA TIONS 1. CONTROL P ANEL ASSEMBL Y 2. CONTROL BOX & OUTPUT ASSEMBL Y 3. POWER MODULE ASSEMBL Y 4. BASE & LIFT BALE ASSEMBL Y 5. FUEL T ANK & MOUNTING 6. ENGINE ASSEMBL Y 7. GENERA TOR 8. SOLENOID ASSEMBL Y 9[...]

T ABLE OF CONTENTS - INST ALLA TION SECTION A4.1 A4.1 V ANT AGE® 500 Installation - V ANT AGE® 500 Cummins B3.3 (Code 10996) T echnical Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .A4.2 Safety Precautions . . . . . . . . . . . . . . . . . . . . . . . . [...]

INST ALLA TION A4.2 A4.2 V ANT AGE® 500 TECHNICAL SPECIFICA TIONS - V antage 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 @ 1800 RP[...]

INST ALLA TION A4.3 A4.3 V ANT AGE® 500 Read this entire installation section before you start installation. SAFETY PRECAUTIONS 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 m[...]

INST ALLA TION A4.4 A4.4 V ANT AGE® 500 LIFTING The V antage lift bale should be used to lift the machine. The V antage is shipped with the lift bale retracted. Before attempting to lift the V antage, secure the lift bale in a raised position. Secure the lift bale as follows: a. Open the engine compartment door . b. Locate the two access holes on [...]

INST ALLA TION A4.5 A4.5 V ANT AGE® 500 PRE-OPERA TION ENGINE SERVICE READ the engine operating and maintenance instruc- tions supplied with this machine. • Keep hands away from the engine muffler or HOT engine parts. • Stop engine and allow to cool before fueling. • Do not smoke when fueling. • Fill fuel tank at a moderate rate and do n[...]

INST ALLA TION A4.6 A4.6 V ANT AGE® 500 IMPORT ANT : T o prevent ELECTRICAL DAMAGE WHEN: a) Installing new batteries b) Using a booster Use correct polarity — Negative Ground. The V antage is shipped with the negative battery cable disconnected. Before you operate the machine, make sure the Engine Switch is in the OFF position and attach the dis[...]

INST ALLA TION A4.7 A4.7 V ANT AGE® 500 WELDING OUTPUT CABLES With the engine off, route the electrode and work cables through the strain relief bracket provided on the front of the base and connect to the terminals provided. These connections should be checked periodically and tightened if necessary . Listed in T able A4.1 are copper cable sizes [...]

INST ALLA TION A4.8 A4.8 V ANT AGE® 500 Figure A4.1 Connection of the V antage to Premises Wiring 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 cus- tomer ’s premises disconnect and service over current protection. 2. T ake necessary[...]

T ABLE OF CONTENTS - OPERA TION SECTION B4.1 B4.1 V ANT AGE® 500 Operation - V ANT AGE® 500 Cummins B3.3 (Code 10996) Operating Instructions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .B4.2 Safety Instructions . . . . . . . . . . . . . . . . . . . . . . . . . . . .[...]

OPERA TION B4.2 B4.2 V ANT AGE® 500 OPERA TING INSTRUCTIONS Read and understand this entire section before oper- ating your V antage 500. SAFETY INSTRUCTIONS 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 eng[...]

OPERA TION B4.3 B4.3 V ANT AGE® 500 RECOMMENDED APPLICA TIONS WELDER The V antage 500 provides excellent constant current DC welding output for stick (SMA W) and TIG welding. The V antage 500 also provides excellent constant volt- age DC welding output for MIG (GMAW) and Innershield (FCA W) welding. GENERA TOR The V antage 500 provides smooth 120/[...]

OPERA TION B4.4 B4.4 V ANT AGE® 500 ENGINE CONTROLS (Items 1 through 9) 1 . R UN ST O P SW IT CH T oggling 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 denergize, and the switch must be tog- gled to reset the timer . 2. ST ART PUSHBUTT[...]

OPERA TION B4.5 B4.5 V ANT AGE® 500 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. Check[...]

OPERA TION B4.6 B4.6 V ANT AGE® 500 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, DOWN- HILL PIPE or CV -WIRE modes and when a remote control is connected to the 6-Pin or 14-Pin Connector[...]

OPERA TION B4.7 B4.7 V ANT AGE® 500 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 120V AC in the 14-Pin connector , the 42V AC in the 14-Pin connector and battery circuit over[...]

OPERA TION B4.8 B4.8 V ANT AGE® 500 WELDER OPERA TION DUTY CYCLE Duty Cycle is the the ratio of the uninterrupted on-load duration to 10 minutes. The total time period of one complete on-load and no-load cycle is 10 minutes. For example, in the case of a 60% duty cycle, load is applied continuously for 6 minutes followed by a no- load period of 4 [...]

OPERA TION B4.9 B4.9 V ANT AGE® 500 V ANT AGE 500 SETTINGS WHEN USING THE K799 HI-FREQ UNIT • Set the WELD MODE switch to the 20-250 setting (TIG). • Set the IDLER switch to the HIGH position. • Set the WELDING TERMINALS switch to the WELD TERMINALS ON position. This will close the solid state contactor and provide an always “hot” electr[...]

OPERA TION B4.10 B4.10 V ANT AGE® 500 WIRE FEED (CONST ANT VOL T AGE) WELDING Connect a wire feeder to the V antage 500 and set welder controls according to the instructions listed ear- lier in this section. See the operator ’s manual for the wire feeder or the “Diagrams ” section of this manual for connecting instructions of various Lincoln[...]

OPERA TION B4.11 B4.11 V ANT AGE® 500 T ABLE B3.4 – V ANT AGE 500 EXTENSION CORD LENGTH RECOMMENDA TIONS Current (Amps) 15 15 20 20 25 30 38 50 V oltage (V olts) 120 240 120 240 240 240 240 240 Load (W atts) 1800 3600 2400 48010 6000 7200 9000 12000 30 60 (9) (18) 40 75 30 60 (12) (23) (9) (18) 75 150 50 100 90 75 (23) (46) (15) (30) (27) (23) 1[...]

NOTES B4.12 B4.12 V ANT AGE® 500 Return to Section TOC Return to Section TOC Return to Section TOC Return to Section TOC Return to Master TOC Return to Master TOC Return to Master TOC Return to Master TOC[...]

T ABLE OF CONTENTS - ACCESSORIES SECTION C4.1 C4.1 V ANT AGE® 500 Accessories - V ANT AGE® 500 Cummins B3.3 (Code 10996) Options/Accessories . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .C4.1 Optional Field Installed Accessories . . . . . . . . . . . . . . . . . [...]

ACCESSORIES C4.2 C4.2 V ANT AGE® 500 K802N POWER PLUG KIT - Provides four 120V plugs rated at 20 amps each and one dual voltage, full KV A plug rated at 120/240V , 50 amps. 120V plug may not be compatible with NEMA common household receptacles. K802R POWER PLUG KIT - Provides four 120V plugs rated 15 amps each and one dual voltage, full KV A plu[...]

ACCESSORIES C4.3 C4.3 V ANT AGE® 500 TIG OPTIONS K1783-9 PT A-26V TIG T orch Air Cooled 200 amp torch (2 piece) equipped with valve for gas flow control. 25 ft. (7.6m) length. KP509 Magnum Parts Kit for PT A-26V TIG T orch Magnum Parts Kit provides all the torch accessories you need to start welding. Parts kit provides collets, collet bodies, a [...]

NOTES C4.4 C4.4 V ANT AGE® 500 Return to Section TOC Return to Section TOC Return to Section TOC Return to Section TOC Return to Master TOC Return to Master TOC Return to Master TOC Return to Master TOC[...]

T ABLE OF CONTENTS - MAINTENANCE SECTION D4.1 D4.1 V ANT AGE® 500 Maintenance - V ANT AGE® 500 Cummins B3.3 (Code 10996) Safety Precautions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .D4.2 Routine and Periodic Maintenance . . . . . . . . . . . . . . . . . . .[...]

MAINTENANCE D4.2 D4.2 V ANT AGE® 500 SAFETY PRECAUTIONS • Have qualified personnel do all maintenance and troubleshooting work. • T urn the engine off before working inside the machine. • Remove covers or guards only when necessary to perform maintenance and replace them when the maintenance requiring their removal is com- plete. • If cove[...]

MAINTENANCE D4.3 D4.3 V ANT AGE® 500 3. Apply a thin coat of new oil to the rubber gasket on the new oil filter . 4. Spin the new filter onto the mounting adapter finger tight until the gasket is evenly seated. Then turn it down another 1/2 turn. Do not overtighten the new filter . 5. Refill the engine with the proper amount and type of oil as des[...]

MAINTENANCE D4.4 D4.4 V ANT AGE® 500 FUEL FIL TERS When working on the fuel system • Keep naked lights away , do not smoke ! • Do not spill fuel ! The V ANT AGE 500 Cummins is equipped with a Fuel Filter/W ater Separator located after the lift pump and before fuel injectors.The procedure for changing the fil- ter is as follows. See Figure D4.2[...]

MAINTENANCE D4.5 D4.5 V ANT AGE® 500 AIR FIL TER Excessive air filter restriction will result in reduced engine life. The air filter element is a dry cartridge type. It can be cleaned and reused. However , damaged elements should not be reused. Stop engine after 100 hours of running time and clean filter element. Replace the filter if necessary . [...]

MAINTENANCE D4.6 D4.6 V ANT AGE® 500 MAINTENANCE INSTRUCTIONS Return to Section TOC Return to Section TOC Return to Section TOC Return to Section TOC Return to Master TOC Return to Master TOC Return to Master TOC Return to Master TOC[...]

MAINTENANCE D4.7 D4.7 V ANT AGE® 500 WELDER/GENERA TOR MAINTENANCE STORAGE: Store the V antage 500 in clean, dry , pro- tected areas. CLEANING: Blow out the generator and controls peri- odically with low pressure air . Do this at least once a week in particularly dirty areas. NAMEPLA TES: Whenever routine maintenance is per- formed on this machine[...]

MAINTENANCE D4.8 D4.8 V ANT AGE® 500 BA TTER Y MAINTENANCE GASES FROM BA TTER Y can explode. • Keep sparks, flame, and cigarettes away from battery . BA TTERY ACID can burn eyes and skin. • Wear gloves and eye protection and be careful when working near a battery . Follow the instructions printed on the battery . T o prevent EXPLOSION when: ?[...]

MAINTENANCE D4.9 D4.9 V ANT AGE® 500 WARNING 1 2 4 3 5 7 6A 9 10 OFF FIGURE D.5 – MAJOR COMPONENT LOCA TIONS 1. CONTROL P ANEL ASSEMBL Y 2. CONTROL BOX & OUTPUT ASSEMBL Y 3. POWER MODULE ASSEMBL Y 4. BASE & LIFT BALE ASSEMBL Y 5. FUEL T ANK & MOUNTING 6A. ENGINE ASSEMBL Y 7. GENERA TOR FRAME 8. SOLENOID ASSEMBL Y 9. CASEBACK 10. CASE[...]

NOTES D4.10 D4.10 V ANT AGE® 500 Return to Section TOC Return to Section TOC Return to Section TOC Return to Section TOC Return to Master TOC Return to Master TOC Return to Master TOC Return to Master TOC[...]

T ABLE OF CONTENTS - INST ALLA TION SECTION A5.1 A5.1 V ANT AGE® 500 Installation - V ANT AGE® 500 Cummins B3.3 (Code 1 1 181, 1 1416) T echnical Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .A5.2 Safety Precautions . . . . . . . . . . . . . . . . . . . [...]

INST ALLA TION A5.2 A5.2 V ANT AGE® 500 TECHNICAL SPECIFICA TIONS - V ANT AGE 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) & Starter 25 US gal. Diesel Engine @ 1800 RP[...]

INST ALLA TION A5.3 A5.3 V ANT AGE® 500 Read this entire installation section before you start installation. SAFETY PRECAUTIONS 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 m[...]

INST ALLA TION A5.4 A5.4 V ANT AGE® 500 LIFTING The V antage lift bale should be used to lift the machine. The V antage is shipped with the lift bale retracted. Before attempting to lift the V antage, secure the lift bale in a raised position. Secure the lift bale as follows: a. Open the engine compartment door . b. Locate the two access holes on [...]

INST ALLA TION A5.5 A5.5 V ANT AGE® 500 PRE-OPERA TION ENGINE SERVICE READ the engine operating and maintenance instruc- tions supplied with this machine. • Keep hands away from the engine muf- fler or HOT engine parts. • Stop engine and allow to cool before fueling. • Do not smoke when fueling. • Fill fuel tank at a moderate rate and do[...]

INST ALLA TION A5.6 A5.6 V ANT AGE® 500 IMPORT ANT : T o prevent ELECTRICAL DAMAGE WHEN: a) Installing new batteries b) Using a booster Use correct polarity — Negative Ground. The V antage is shipped with the negative battery cable disconnected. Before you operate the machine, make sure the Engine Switch is in the OFF position and attach the dis[...]

INST ALLA TION A5.7 A5.7 V ANT AGE® 500 WELDING OUTPUT CABLES With the engine off, route the electrode and work cables through the strain relief bracket provided on the front of the base and connect to the terminals provided. These connections should be checked periodically and tightened if necessary . Listed in T able A5.1 are copper cable sizes [...]

INST ALLA TION A5.8 A5.8 V ANT AGE® 500 Figure A5.1 Connection of the V antage to Premises Wiring 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 cus- tomer ’s premises disconnect and service over current protection. 2. T ake necessary[...]

T ABLE OF CONTENTS - OPERA TION SECTION B5.1 B5.1 V ANT AGE® 500 Operation - V ANT AGE® 500 Cummins B3.3 (Codes 1 1 181 & 1 1416) Operating Instructions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .B5.2 Safety Instructions . . . . . . . . . . . . . . . . . . . .[...]

OPERA TION B5.2 B5.2 V ANT AGE® 500 OPERA TING INSTRUCTIONS Read and understand this entire section before oper- ating your V antage 500. SAFETY INSTRUCTIONS Do not attempt to use this equipment until you have thoroughly read all operating and maintenance man- uals supplied with your machine. They include impor- tant safety precautions: detailed e[...]

OPERA TION B5.3 B5.3 V ANT AGE® 500 RECOMMENDED APPLICA TIONS WELDER The V antage 500 provides excellent constant current DC welding output for stick (SMA W) and TIG welding. The V antage 500 also provides excellent constant volt- age DC welding output for MIG (GMAW) and Innershield (FCA W) welding. GENERA TOR The V antage 500 provides smooth 120/[...]

OPERA TION B5.4 B5.4 V ANT AGE® 500 ENGINE CONTROLS (Items 1 through 9) 1 . R UN ST O P SW IT CH T oggling 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 denergize, and the switch must be tog- gled to reset the timer . 2. ST ART PUSHBUTT[...]

OPERA TION B5.5 B5.5 V ANT AGE® 500 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. Check[...]

OPERA TION B5.6 B5.6 V ANT AGE® 500 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, DOWN- HILL PIPE or CV -WIRE modes and when a remote control is connected to the 6-Pin or 14-Pin Connector[...]

OPERA TION B5.7 B5.7 V ANT AGE® 500 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 120V AC in the 14-Pin connector , the 42V AC in the 14-Pin connector and battery circuit over[...]

OPERA TION B5.8 B5.8 V ANT AGE® 500 WELDER OPERA TION DUTY CYCLE Duty Cycle is the the ratio of the uninterrupted on-load duration to 10 minutes. The total time period of one complete on-load and no-load cycle is 10 minutes. For example, in the case of a 60% duty cycle, load is applied continuously for 6 minutes followed by a no- load period of 4 [...]

OPERA TION B5.9 B5.9 V ANT AGE® 500 V ANT AGE 500 SETTINGS WHEN USING THE K799 HI-FREQ UNIT • Set the WELD MODE switch to the 20-250 setting (TIG). • Set the IDLER switch to the HIGH position. • Set the WELDING TERMINALS switch to the WELD TERMINALS ON position. This will close the solid state contactor and provide an always “hot” electr[...]

OPERA TION B5.10 B5.10 V ANT AGE® 500 WIRE FEED (CONST ANT VOL T AGE) WELDING Connect a wire feeder to the V antage 500 and set welder controls according to the instructions listed ear- lier in this section. See the operator ’s manual for the wire feeder or the “Diagrams ” section of this manual for connecting instructions of various Lincoln[...]

OPERA TION B5.11 B5.11 V ANT AGE® 500 SIMUL T ANEOUS WELDING AND AUXILIAR Y POWER LOADS It must be noted that the auxiliary power ratings are with no welding load. Simultaneous welding and power loads are specified in table B5.4. The permissible currents shown assume that current is being drawn from either the 120 V AC or 240 V AC supply (not both[...]

NOTES B5.12 B5.12 V ANT AGE® 500 Return to Section TOC Return to Section TOC Return to Section TOC Return to Section TOC Return to Master TOC Return to Master TOC Return to Master TOC Return to Master TOC[...]

T ABLE OF CONTENTS - ACCESSORIES SECTION C5.1 C5.1 V ANT AGE® 500 Accessories - V ANT AGE® 500 Cummins B3.3 (Codes 1 1 181 &1 1416) Options/Accessories . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .C5.1 Optional Field Installed Accessories . . . . . . . . . .[...]

ACCESSORIES C5.2 C5.2 V ANT AGE® 500 K802N POWER PLUG KIT - Provides four 120V plugs rated at 20 amps each and one dual voltage, full KV A plug rated at 120/240V , 50 amps. 120V plug may not be compatible with NEMA common household receptacles. K802R POWER PLUG KIT - Provides four 120V plugs rated 15 amps each and one dual voltage, full KV A plu[...]

ACCESSORIES C5.3 C5.3 V ANT AGE® 500 TIG OPTIONS K1783-9 PT A-26V TIG T orch Air Cooled 200 amp torch (2 piece) equipped with valve for gas flow control. 25 ft. (7.6m) length. KP509 Magnum Parts Kit for PT A-26V TIG T orch Magnum Parts Kit provides all the torch accessories you need to start welding. Parts kit provides collets, collet bodies, a [...]

NOTES C5.4 C5.4 V ANT AGE® 500 Return to Section TOC Return to Section TOC Return to Section TOC Return to Section TOC Return to Master TOC Return to Master TOC Return to Master TOC Return to Master TOC[...]

T ABLE OF CONTENTS - MAINTENANCE SECTION D5.1 D5.1 V ANT AGE® 500 MAINTENANCE - V ANT AGE 500 CUMMINS (CODE 1 1 181 & 1 1416) Safety Precautions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .D5.2 Routine Maintenance . . . . . . . . . . . . . . . . . . . . . [...]

MAINTENANCE D5.2 D5.2 V ANT AGE® 500 SAFETY PRECAUTIONS • Have qualified personnel do all maintenance and troubleshooting work. • T urn the engine off before working inside the machine. • Remove covers or guards only when necessary to perform maintenance and replace them when the maintenance requiring their removal is complete. • If covers[...]

MAINTENANCE D5.3 D5.3 V ANT AGE® 500 3. Apply a thin coat of new oil to the rubber gasket on the new oil filter . 4. Spin the new filter onto the mounting adapter finger tight until the gasket is evenly seated. Then turn it down another 1/2 turn. Do not overtighten the new filter . 5. Refill the engine with the proper amount and type of oil as des[...]

MAINTENANCE D5.4 D5.4 V ANT AGE® 500 FUEL FIL TERS When working on the fuel system • Keep naked lights away , do not smoke ! • Do not spill fuel ! ------------------------------------------------------------------------ The V ANT AGE 500 Cummins is equipped with a Fuel Filter/W ater Separator located after the lift pump and before fuel injecto[...]

MAINTENANCE D5.5 D5.5 V ANT AGE® 500 AIR FIL TER: Excessive air filter restriction will result in reduced engine life. The air filter element is a dry cartridge type. It can be cleaned and reused. However , damaged elements should not be reused. Stop engine after 100 hours of running time and clean filter element. Replace the filter if necessary .[...]

MAINTENANCE D5.6 D5.6 V ANT AGE® 500 MAINTENANCE INSTRUCTIONS Return to Section TOC Return to Section TOC Return to Section TOC Return to Section TOC Return to Master TOC Return to Master TOC Return to Master TOC Return to Master TOC[...]

MAINTENANCE D5.7 D5.7 V ANT AGE® 500 WELDER/GENERA TOR MAINTENANCE STORAGE: Store the V antage 500 in clean, dry , pro- tected areas. CLEANING: Blow out the generator and controls peri- odically with low pressure air . Do this at least once a week in particularly dirty areas. NAMEPLA TES: Whenever routine maintenance is per- formed on this machine[...]

MAINTENANCE D5.8 D5.8 V ANT AGE® 500 BA TTER Y MAINTENANCE GASES FROM BA TTER Y can explode. • Keep sparks, flame, and cigarettes away from battery . BA TTERY ACID can burn eyes and skin. • Wear gloves and eye protection and be careful when working near a battery . Follow the instructions printed on the battery . T o prevent EXPLOSION when: ?[...]

MAINTENANCE D5.9 D5.9 V ANT AGE® 500 WARNING 1 2 4 3 5 7 6A 9 10 OFF FIGURE D5.4 – MAJOR COMPONENT LOCA TIONS 1. CONTROL P ANEL ASSEMBL Y 2. CONTROL BOX & OUTPUT ASSEMBL Y 3. POWER MODULE ASSEMBL Y 4. BASE & LIFT BALE ASSEMBL Y 5. FUEL T ANK & MOUNTING 6A. ENGINE ASSEMBL Y 7. GENERA TOR FRAME 8. SOLENOID ASSEMBL Y 9. CASEBACK 10. CAS[...]

NOTES D5.10 D5.10 V ANT AGE® 500 Return to Section TOC Return to Section TOC Return to Section TOC Return to Section TOC Return to Master TOC Return to Master TOC Return to Master TOC Return to Master TOC[...]

T ABLE OF CONTENTS-THEOR Y OF OPERA TION SECTION E-1 E-1 V ANT AGE® 500 Theory of Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .E-1 General Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . [...]

THEOR Y OF OPERA TION E-2 E-2 V ANT AGE® 500 FIGURE E.2 - BA TTER Y , ENGINE, ROTOR, PULL COIL BOARD AND PERIPHERAL BOARD (ENGINE PROTECTION NOTE: Unshaded areas of Block Logic Diagram are the subject of discussion GENERAL DESCRIPTION The V antage 500 is a diesel engine-driven welding power source capable of producing 500 amps at 40VDC at a 100% d[...]

THEOR Y OF OPERA TION E-3 E-3 V ANT AGE® 500 FIGURE E.3 - WELD WINDINGS, RECTIFIER, POWER MODULES AND FEEDBACK WELD WINDINGS, RECTIFIER, POWER MODULES AND FEEDBACK The three-phase stator weld windings are connected to a three-phase rectifier bridge. The resultant DC voltage is applied to four paralleled capacitors incorporated within each of the t[...]

THEOR Y OF OPERA TION E-4 E-4 V ANT AGE® 500 FIGURE E.4 - POWER MODULES AND WELD CONTROL BOARD WELD CONTROL BOARD The 80 VDC derived from the filter capacitors on the Power Modules, supplies various regulated DC volt- ages to operate the Weld Control PC board circuitry . It also supplies two regulated DC voltages to operate the IGBT driver circuit[...]

THEOR Y OF OPERA TION E-5 E-5 V ANT AGE® 500 INSULA TED GA TE BIPOLAR TRANSIST OR (IGBT) OPERA TION An IGBT is a type of transistor . IGBT s are semicon- ductors well suited for high frequency switching and high current applications. Drawing A in Figure E.5 shows an IGBT in a passive mode. There is no gate signal, zero volts relative to the source[...]

THEOR Y OF OPERA TION E-6 E-6 V ANT AGE® 500 PULSE WIDTH MODULA TION The term PULSE WIDTH MODULA TION is used to describe how much time is devoted to conduction in the cycle. Changing the pulse width is known as MODULA- TION. Pulse Width Modulation (PWM) is the varying of the pulse width over the allowed range of a cycle to affect the output of th[...]

THEOR Y OF OPERA TION E-7 E-7 V ANT AGE® 500 CHOPPER TECHNOLOGY FUNDAMENT ALS The new era of welding machines such as the V antage 500, employ a technology whereby a DC source is turned on and off (chopped up) at high speed, then smoothed through an inductor to control an arc. Hence the name “Chopper .” The biggest advantage of chopper technol[...]

NOTES E-8 E-8 V ANT AGE® 500 Return to Section TOC Return to Section TOC Return to Section TOC Return to Section TOC Return to Master TOC Return to Master TOC Return to Master TOC Return to Master TOC[...]

T ABLE OF CONTENTS - TROUBLESHOOTING AND REP AIR F-1 F-1 V ANT AGE® 500 T roubleshooting and Repair . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .F-1 How to Use T roubleshooting Guide . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . [...]

TROUBLESHOOTING AND REP AIR F-2 F-2 V ANT AGE® 500 This T roubleshooting Guide is provided to help you locate and repair possible machine malfunctions. Simply follow the three-step procedure listed below . Step 1. LOCA TE PROBLEM (SYMPTOM). Look under the column labeled “PROBLEM (SYMPTOMS)”. This column describes pos- sible symptoms that the[...]

TROUBLESHOOTING AND REP AIR F-3 F-3 V ANT AGE® 500 Sometimes machine failures appear to be due to PC board failures. These problems can sometimes be traced to poor electrical connections. T o avoid prob- lems when troubleshooting and replacing PC boards, please use the following procedure: 1. Determine to the best of your technical ability that th[...]

OUTPUT PROBLEMS Observe Safety Guidelines detailed in the beginning of this manual. PROBLEMS (SYMPTOMS) POSSIBLE AREAS OF MISADJUSTMENT(S) RECOMMENDED COURSE OF ACTION If for any reason you do not understand the test procedures or are unable to perform the tests/repairs safely , contact the Lincoln Electric Service Department for technical troubles[...]

OUTPUT PROBLEMS Observe Safety Guidelines detailed in the beginning of this manual. PROBLEMS (SYMPTOMS) POSSIBLE AREAS OF MISADJUSTMENT(S) RECOMMENDED COURSE OF ACTION If for any reason you do not understand the test procedures or are unable to perform the tests/repairs safely , contact the Lincoln Electric Service Department for technical troubles[...]

OUTPUT PROBLEMS Observe Safety Guidelines detailed in the beginning of this manual. PROBLEMS (SYMPTOMS) POSSIBLE AREAS OF MISADJUSTMENT(S) RECOMMENDED COURSE OF ACTION If for any reason you do not understand the test procedures or are unable to perform the tests/repairs safely , contact the Lincoln Electric Service Department for technical troubles[...]

FUNCTION PROBLEMS Observe Safety Guidelines detailed in the beginning of this manual. PROBLEMS (SYMPTOMS) POSSIBLE AREAS OF MISADJUSTMENT(S) RECOMMENDED COURSE OF ACTION If for any reason you do not understand the test procedures or are unable to perform the tests/repairs safely , contact the Lincoln Electric Service Department for technical troubl[...]

FUNCTION PROBLEMS Observe Safety Guidelines detailed in the beginning of this manual. PROBLEMS (SYMPTOMS) POSSIBLE AREAS OF MISADJUSTMENT(S) RECOMMENDED COURSE OF ACTION If for any reason you do not understand the test procedures or are unable to perform the tests/repairs safely , contact the Lincoln Electric Service Department for technical troubl[...]

ENGINE PROBLEMS Observe Safety Guidelines detailed in the beginning of this manual. PROBLEMS (SYMPTOMS) POSSIBLE AREAS OF MISADJUSTMENT(S) RECOMMENDED COURSE OF ACTION If for any reason you do not understand the test procedures or are unable to perform the tests/repairs safely , contact the Lincoln Electric Service Department for technical troubles[...]

ENGINE PROBLEMS Observe Safety Guidelines detailed in the beginning of this manual. PROBLEMS (SYMPTOMS) POSSIBLE AREAS OF MISADJUSTMENT(S) RECOMMENDED COURSE OF ACTION If for any reason you do not understand the test procedures or are unable to perform the tests/repairs safely , contact the Lincoln Electric Service Department for technical troubles[...]

ENGINE PROBLEMS Observe Safety Guidelines detailed in the beginning of this manual. PROBLEMS (SYMPTOMS) POSSIBLE AREAS OF MISADJUSTMENT(S) RECOMMENDED COURSE OF ACTION If for any reason you do not understand the test procedures or are unable to perform the tests/repairs safely , contact the Lincoln Electric Service Department for technical troubles[...]

WELDING PROBLEMS Observe Safety Guidelines detailed in the beginning of this manual. PROBLEMS (SYMPTOMS) POSSIBLE AREAS OF MISADJUSTMENT(S) RECOMMENDED COURSE OF ACTION If for any reason you do not understand the test procedures or are unable to perform the tests/repairs safely , contact the Lincoln Electric Service Department for technical trouble[...]

Service and repair should be performed by only Lincoln Electric factory trained personnel. Unauthorized repairs performed on this equipment may result in danger to the technician or machine operator and will invalidate your factory warranty . For your safety and to avoid electrical shock, please observe all safety notes and precautions detailed thr[...]

FIGURE F .1 – DOOR REMOV AL CASE COVER REMOV AL AND REPLACEMENT PROCEDURE (continued) PROCEDURE 1. T urn the engine off. 2. Using the 3/8" wrench, remove the battery cover . Slide the battery out and disconnect the negative battery cable. 3. Unlatch and open the engine service access door . 4. Support the door assembly . Using the 3/8" [...]

Service and repair should be performed by only Lincoln Electric factory trained personnel. Unauthorized repairs performed on this equipment may result in danger to the technician or machine operator and will invalidate your factory warranty . For your safety and to avoid electrical shock, please observe all safety notes and precautions detailed thr[...]

B1 B2 B3 B4 B5 B6 B7 B8 POWER RESIST OR INSULA TED GLOVE FIGURE F .2 – CHOPPER MODULE CAP ACITOR TERMINAL DISCHARGE CHOPPER MODULE CAP ACIT OR DISCHARGE PROCEDURE (CONTINUED) PROCEDURE 1. Turn engine off. 2. Perform the Case Cover Removal Procedure. Note: It is necessary to remove the fuel cap in order to take the case cover off the machine. Be s[...]

Service and repair should be performed by only Lincoln Electric factory trained personnel. Unauthorized repairs performed on this equipment may result in danger to the technician or machine operator and will invalidate your factory warranty . For your safety and to avoid electrical shock, please observe all safety notes and precautions detailed thr[...]

B1 B4 B5 B6 B2 B3 87 W8 LEAD W7 LEAD POS LEAD POS LEAD NEG LEAD NEG LEAD 88 PWM Input Present Power at Recitifier Bridge Chopper Operating LED3 LED2 LED1 LXX XX X- X FIGURE F .3 – LEADS & TERMINALS CHOPPER MODULE RESIST ANCE TEST (CONTINUED) PROCEDURE 1. T urn the engine off. 2. Perform the Case Cover Removal procedure. 3. Perform the Capacit[...]

T ABLE F .1 – CHOPPER TEST T ABLE CHOPPER MODULE RESIST ANCE TEST (CONTINUED) TROUBLESHOOTING AND REP AIR F-19 F-19 V ANT AGE® 500 B5 B6 6k to 9k B6 B5 6k to 9k B4 B5 200k or higher B5 B4 400k or higher B4 B6 200k or higher B6 B4 400k or higher B2 B3 6k to 9k B3 B2 6k to 9k B4 B2 200k or higher B2 B4 400k or higher B4 B3 200k or higher B3 B4 400[...]

NOTES F-20 F-20 V ANT AGE® 500 Return to Section TOC Return to Section TOC Return to Section TOC Return to Section TOC Return to Master TOC Return to Master TOC Return to Master TOC Return to Master TOC[...]

Service and repair should be performed by only Lincoln Electric factory trained personnel. Unauthorized repairs performed on this equipment may result in danger to the technician or machine operator and will invalidate your factory warranty . For your safety and to avoid electrical shock, please observe all safety notes and precautions detailed thr[...]

Shutdown Solenoid Idler Solenoid FIGURE F .4 – IDLER SOLENOID LEAD TERMINALS IDLER SOLENOID TEST PROCEDURE (CONTINUED) TEST PROCEDURE 1. T urn the engine off. 2. Unlatch, lift, and secure the right side engine ser- vice access door . 3. Locate and separate J55/P55 connector that attaches the idler solenoid leads to the wiring har- ness leads (#22[...]

Service and repair should be performed by only Lincoln Electric factory trained personnel. Unauthorized repairs performed on this equipment may result in danger to the technician or machine operator and will invalidate your factory warranty . For your safety and to avoid electrical shock, please observe all safety notes and precautions detailed thr[...]

Shutdown Solenoid Idler Solenoid FIGURE F .5 – SHUTDOWN SOLENOID SHUTDOWN SOLENOID TEST PROCEDURE TEST PROCEDURE 1. T urn the engine off. 2. Unlatch, lift, and secure the right side engine ser- vice access door . 3. Locate and separate J54 / P54 connector that attaches the shutdown solenoid leads to the wiring harness leads ( #262, #232 and #265)[...]

Service and repair should be performed by only Lincoln Electric factory trained personnel. Unauthorized repairs performed on this equipment may result in danger to the technician or machine operator and will invalidate your factory warranty . For your safety and to avoid electrical shock, please observe all safety notes and precautions detailed thr[...]

OFF MARK BLOWER PADDLE HERE FIGURE F .6 – STROBE MARK LOCA TION ENGINE THROTTLE ADJUSTMENT TEST PROCEDURE (CONTINUED) PROCEDURE Strobe-tach Method 1. Conduct this procedure with the engine OFF . 2. Unlatch, lift and secure the right side engine ser- vice access door . Perform the Case Cover Removal and Replacement Procedure . (For Strobe-T ach me[...]

Shutdown Solenoid LEFT SIDE Idler Solenoid Adjusting Collar Locking Nut Adjusting Screw Locking Nut FIGURE F .7 – HIGH AND LOW IDLE ADJUSTMENTS - CUMMINS ENGINE ONL Y ENGINE THROTTLE ADJUSTMENT TEST PROCEDURE (CONTINUED) PROCEDURE Frequency Counter Method 1. Plug the frequency counter into one of the 1 15 V AC auxiliary receptacles. 2. Start the [...]

ENGINE THROTTLE ADJUSTMENT TEST PROCEDURE (CONTINUED) PROCEDURE Oscilloscope Method 1. Connect the oscilloscope to the 1 15 V AC recepta- cle, according to the manufacturer ’s instructions. At HIGH IDLE (1900 RPM), the waveform should exhibit a period of 15.8 milliseconds. At LOW IDLE (1475 RPM), the waveform should exhibit a period of 20.3 milli[...]

Service and repair should be performed by only Lincoln Electric factory trained personnel. Unauthorized repairs performed on this equipment may result in danger to the technician or machine operator and will invalidate your factory warranty . For your safety and to avoid electrical shock, please observe all safety notes and precautions detailed thr[...]

SLIP RINGS BRUSH HOLDER ASSEMBL Y ACCESS P ANEL FIGURE F .8 – ROTOR BRUSH LEADS ROT OR RESIST ANCE TEST (CONTINUED) PROCEDURE 1. Conduct this test with the engine off. 2. Using the 3/8" wrench, remove the right front case side. 3. Using the 3/8" wrench, remove the brush holder access panel. See Figure F .10. 4. Using the 3/8" wrenc[...]

Service and repair should be performed by only Lincoln Electric factory trained personnel. Unauthorized repairs performed on this equipment may result in danger to the technician or machine operator and will invalidate your factory warranty . For your safety and to avoid electrical shock, please observe all safety notes and precautions detailed thr[...]

#200A #200B #201 FIGURE F .9 – ROTOR BRUSH LOCA TION FLASHING AND ROT OR VOL T AGE TEST (CONTINUED) PROCEDURE 1. Using the 3/8" wrench, remove the sheet metal screws from the right front case side. 2. Carefully remove the right case side. 3. Set the volt/ohmmeter to the DC volts position. 4. Locate leads #200A and #201A at the rotor brush- e[...]

Service and repair should be performed by only Lincoln Electric factory trained personnel. Unauthorized repairs performed on this equipment may result in danger to the technician or machine operator and will invalidate your factory warranty . For your safety and to avoid electrical shock, please observe all safety notes and precautions detailed thr[...]

FIGURE F .10 – FRONT CONTROL P ANEL REMOV AL ST A T OR VOL T AGE TEST (CONTINUED) PROCEDURE 1. T urn the engine off. 2. Using the 3/8" wrench, remove the screws holding the front control panel to the case top and sides. 3. Carefully lower the front control panel. 4. Using the 3/8" wrench, remove the front left and right side panels. 5. [...]

32 32A 42A 42B 236A CB6 CB5 CB3 CB2 J13 CB1 3C 6D 3D 6 4 3 5C 5E 6B 6C 3B 4A GND-L STATOR LEADS 3A GND-C GND-D 6E 5B J12 J10 GND-E J11 238B Back of Control Panel T ypical 3Ø Auxiliary Machine FIGURE F .1 1 – AUXILIAR Y LEAD TEST LOCA TIONS ON BACK OF CONTROL P ANEL ST A T OR VOL T AGE TEST (CONTINUED) TROUBLESHOOTING AND REP AIR F-35 F-35 [...]

WELD WINDING LEAD CONNECTIONS W1 W6 W3 W2 W5 W4 FIGURE F .12 – OUTPUT RECTIFIER DIODE BRIDGE ST A T OR VOL T AGE TEST (CONTINUED) 1. Locate the weld winding leads connected to the three-phase output rectifier diode bridge. See Figure F .12. 2. Check for approximately 68V AC from: W1/W6 to W2/W3. W1/W6 to W4/W5 W2/W3 to W4/W5 3. If any of these vo[...]

Service and repair should be performed by only Lincoln Electric factory trained personnel. Unauthorized repairs performed on this equipment may result in danger to the technician or machine operator and will invalidate your factory warranty . For your safety and to avoid electrical shock, please observe all safety notes and precautions detailed thr[...]

FIGURE F .13 – DOOR REMOV AL OUTPUT RECTIFIER BRIDGE TEST (CONTINUED) PROCEDURE 1. T urn the engine off. 2. Perform Case Cover Removal Procedure . 3. Perform Chopper Module Capacitor Discharge Procedure . 4. Using the 3/8" wrench, remove the three screws holding the lower front panel (output panel) to the case front assembly . Then remove th[...]

WELD WINDING LEAD CONNECTIONS W1 W6 W3 W2 W5 W4 FIGURE F .14 – DIODE LEAD REMOV AL OUTPUT RECTIFIER BRIDGE TEST (CONTINUED) 9. Using the 7/16” wrench, remove the stator leads from the three AC terminals. Label leads for reassembly . Note leads and AC terminals place- ment for reassembly . See Figure F .15 . 10. Electronically isolate the 3 AC t[...]

OUTPUT RECTIFIER BRIDGE TEST (CONTINUED) TROUBLESHOOTING AND REP AIR F-40 F-40 V ANT AGE® 500 FIGURE F .15 – DIODE LEAD REMOV AL AC 1 + - D.C. D.C. 1 2 3 AC DC+ DC- + - AC 1,2,3 1 2 3 Return to Section TOC Return to Section TOC Return to Section TOC Return to Section TOC Return to Master TOC Return to Master TOC Return to Master TOC Return to Ma[...]

OUTPUT RECTIFIER BRIDGE TEST (CONTINUED) TROUBLESHOOTING AND REP AIR F-41 F-41 V ANT AGE® 500 T ABLE F .2 – DIODE TEST T ABLE AC1 DC(+) Forward Bias (Low Resistance) AC2 DC(+) Forward Bias (Low Resistance) AC3 DC(+) Forward Bias (Low Resistance) DC(-) AC1 Forward Bias (Low Resistance) DC(-) AC2 Forward Bias (Low Resistance) DC(-) AC3 Forward Bia[...]

NOTES F-42 F-42 V ANT AGE® 500 Return to Section TOC Return to Section TOC Return to Section TOC Return to Section TOC Return to Master TOC Return to Master TOC Return to Master TOC Return to Master TOC[...]

Service and repair should be performed by only Lincoln Electric factory trained personnel. Unauthorized repairs performed on this equipment may result in danger to the technician or machine operator and will invalidate your factory warranty . For your safety and to avoid electrical shock, please observe all safety notes and precautions detailed thr[...]

ELECTRONIC GOVERNOR TEST (CONTINUED) TEST PROCEDURE CHECK CONTROLLER 1. T urn the Run/Stop switch to Run. Do not start engine. 2. The engine protection light should be ON for 5 sec- onds then go out. 3. After 30 additional seconds the light should come back on. 4. If a-c or 1-3 are OK then the controller is probably good. 5. If the engine protectio[...]

Service and repair should be performed by only Lincoln Electric factory trained personnel. Unauthorized repairs performed on this equipment may result in danger to the technician or machine operator and will invalidate your factory warranty . For your safety and to avoid electrical shock, please observe all safety notes and precautions detailed thr[...]

#239 #281 #238 FIGURE F .16 – ENGINE AL TERNA TOR LOCA TION (DEUTZ 10995) CHARGING CIRCUIT TEST (CONTINUED) PROCEDURE 1. T urn engine off. 2. Using the 3/8" wrench, remove the left rear case cover . (remove right rear case cover for Cummins engine 10996) 3. Locate the engine alternator . See Figure F .16. 4. Start the engine and run it at hi[...]

This is the typical auxiliary output volt- age generated from a properly operat- ing machine. Note that each vertical division represents 50 volts and that each horizontal division represents 5 milliseconds in time. Note: Scope probes connected at machine 1 15V AC receptacle. SCOPE SETTINGS V olts/Div .....................50V/Div . Horizontal Sweep[...]

0 volts 50V 5ms This is the typical DC open circuit out- put voltage generated from a properly operating machine in the Constant Current (CC)mode. Note that each vertical division repre- sents 50 volts and that each horizon- tal division represents 5 milliseconds in time. SCOPE SETTINGS V olts/Div .....................50V/Div . Horizontal Sweep ...[...]

0 volts 20V 0.1ms This is the typical DC output voltage generated from a properly operating machine in the Constant Current (CC) mode. Note that each vertical division repre- sents 20 volts and that each horizon- tal division represents 0.1 millisec- onds in time. The machine was loaded with a resistance grid bank to 500 amps at 40 volts. SCOPE SET[...]

0 volts 10V 5 µs This is the typical output voltage gen- erated from a properly operating machine in the TIG Mode. Note that each vertical division repre- sents 10 volts and that each horizontal division represents 50 microseconds in time. The machine was loaded with a resis- tance grid bank to 200 amps at 16 VDC. SCOPE SETTINGS V olts/Div .......[...]

0 volts 50V 5MS This is the typical auxiliary output volt- age generated from a properly operat- ing machine in the CV mode. Note that each vertical division repre- sents 50 volts and that each horizontal division represents 5 milliseconds in time. SCOPE SETTINGS V olts/Div .....................50V/Div . Horizontal Sweep .....5 ms/Div . Coupling ..[...]

0 volts 20V 0.1ms This is the typical DC output voltage generated from a properly operating machine in the Constant V oltage (CV) mode. Note that each vertical division repre- sents 20 volts and that each horizon- tal division represents 5 milliseconds in time. The machine was loaded with a resistance grid bank to 500 amps at 40 volts. SCOPE SETTIN[...]

Service and repair should be performed by only Lincoln Electric factory trained personnel. Unauthorized repairs performed on this equipment may result in danger to the technician or machine operator and will invalidate your factory warranty . For your safety and to avoid electrical shock, please observe all safety notes and precautions detailed thr[...]

Leads 262, 232M, 265 FIGURE F .17 – SHUTDOWN SOLENOID LEAD CONNECTIONS SHUTDOWN SOLENOID REMOV AL AND REPLACEMENT (DEUTZ) PROCEDURE 1. T urn engine off. 2. Unlatch, lift and secure the engine access door . 3. Locate and remove the spade connectors that attach the shutdown solenoid terminals to the wiring harness leads. Cut the cable tie. 4. Remov[...]

Shutdwn Solenoid Idler Solenoid LEADS 262 232M 265 FIGURE F .18 – SHUTDOWN SOLENOID LINKAGE ARM ASSEMBL Y SHUTDOWN SOLENOID REMOV AL AND REPLACEMENT (CUMMINS) PROCEDURE 1. T urn engine off. 2. Unlatch. lift and secure engine access door . 3. Locate and remove the spade connectors that attach the shutdown solenoid terminals to the wiring harness l[...]

NOTES F-56 F-56 V ANT AGE® 500 Return to Section TOC Return to Section TOC Return to Section TOC Return to Section TOC Return to Master TOC Return to Master TOC Return to Master TOC Return to Master TOC[...]

Service and repair should be performed by only Lincoln Electric factory trained personnel. Unauthorized repairs performed on this equipment may result in danger to the technician or machine operator and will invalidate your factory warranty . For your safety and to avoid electrical shock, please observe all safety notes and precautions detailed thr[...]

OUTPUT RECTIFIER BRIDGE 2 7/16" BOL TS 2 7/16" BOL TS 2 1/2" NUTS CHOPPER MODULES (2) HEA TSINKS FIGURE F .19 – DOOR REMOV AL OUTPUT RECTIFIER REMOV AL AND REPLACEMENT PROCEDURE (continued) PROCEDURE 1. T urn the engine off. 2. Perform the output panel removal as described in the Case Cover Removal procedure. 3. Perform the Chopp[...]

Service and repair should be performed by only Lincoln Electric factory trained personnel. Unauthorized repairs performed on this equipment may result in danger to the technician or machine operator and will invalidate your factory warranty . For your safety and to avoid electrical shock, please observe all safety notes and precautions detailed thr[...]

PLUG FUEL LINES U-BOL TS (2 ) LEADS #229 AND #242D { FIGURE F .20 – FUEL T ANK REMOV AL DET AILS ST A T OR/ROTOR REMOV AL AND REPLACEMENT (CONTINUED) PROCEDURE Refer to Figure F .20. 1. T urn the engine off and disconnect battery leads and drain fuel. 2. Perform the Case Cover Removal procedure, including removing the output panel. 3. Perform the[...]

#201A 6 #200D #4 FIL TER CAP ACITOR FIELD DIODE RECTIFIER BRIDGE FIGURE F .21 – PLUG J52/FIL TER CAP ACITOR/FIELD RECTIFIER BRIDGE DISCONNECTION ST A T OR/ROTOR REMOV AL AND REPLACEMENT (CONTINUED) 1 1. See Figure F .21. Using the slot head screw driver , disconnect leads #200A, #200B(+) and #201A(-) or remove screw cap bracket and remove cap fro[...]

CONTROL BOX PULL COIL PC BOARD (LEADS #265 & #227 12 VDC STUD LEADS #232L & #232M FIGURE F .22 – BRUSH HOLDER AND LEAD REMOV AL ST A T OR/ROTOR REMOV AL AND REPLACEMENT (CONTINUED) PROCEDURE 1. T urn the engine off. 2. Using the 3/8" wrench, remove the battery cover . Slide the battery out and disconnect the negative battery cable. 3[...]

6 SCREWS SHROUD ACOUSTICAL FOAM FIGURE F .24 – DOOR REMOV AL ST A T OR/ROTOR REMOV AL AND REPLACEMENT (CONTINUED) 18. See Figure F .24. With the 5/16" wrench, remove the six screws that hold the top and bottom of the alternator shroud together . 19. With the 7/16" wrench, remove the two nuts, lock washers and flat washers that hold the [...]

CENTER P ANEL LIFT FRAME WELDMENT BASE FUEL T ANK SUPPORTS F AN BAFFLE FIGURE F .25 – LIFT FRAME AND ASSOCIA TED COMPONENT REMOV AL ST A T OR/ROTOR REMOV AL AND REPLACEMENT (CONTINUED) In steps 20 – 24, the lift frame weldment, fuel tank sup- ports, and fan baffle are removed as a unit. See Figure F .25. 20. Using the 3/8" wrench, remove t[...]

BOL TS (4) F AN HUB MOUNTING FOOT FL YWHEEL SPLASH PLA TE F AN NU T ST A TOR / ENGINE MOUNTING BOL TS & LOCK W ASHERS BEARING FIGURE F .26 – ST A TOR REMOV AL ST A T OR/ROTOR REMOV AL AND REPLACEMENT (CONTINUED) PROCEDURE First, cut any necessary cable ties in order to free the stator leads from the bundle of leads running to the control box.[...]

FLEX PLA TE BLOWER SEGMENT (4) ROT OR FIGURE F .27 – ROTOR REMOV AL ST A T OR/ROTOR REMOV AL AND REPLACEMENT (CONTINUED) PROCEDURE Refer to Figure F .27 for rotor removal. 1. Support the rotor with the hoist. 2. Using the 5/8" wrench, remove the flex plate bolts, lock washers, and four blower segments. The rotor will be free to fall when the[...]

ST A T OR/ROTOR REMOV AL AND REPLACEMENT (CONTINUED) LEAD RECONNECTION CHECKLIST ENGINE n Leads #5I and #229 to fuel level sensor n Brush leads #201(-) and #200B(+) n Leads #5H, and #201A, #200, #200A, and #6A to the field bridge rectifier OUTPUT P ANEL AND CONTROL BOX n Leads #232N and #227 to Pull Coil PC board n Leads #232L and #232N to 12 VDC i[...]

TROUBLESHOOTING AND REP AIR F-68 F-68 V ANT AGE® 500 RETEST AFTER REP AIR Retest a machine: • If it is rejected under test for any reason that requires you to remove any mechanical part which could af fect the machine’s electrical characteristics. OR • If you repair or replace any electrical components. ENGINE RPM Mode No Load RPM Load RPM L[...]

TROUBLESHOOTING AND REP AIR F-69 F-69 V ANT AGE® 500 RETEST AFTER REP AIR (CONTINUED) TOUCH ST ART TIG MODE OUTPUT Mode Selector Open Circuit Short Circuit Switch Fine Control V oltage Current TIG 20 - 250 A Maximum 10 - 15 18 - 28 TIG 20 - 250 A Minimum 10 - 15 18 - 28 AUXILIAR Y POWER OUTPUT 230 V olt Receptacle 1 15 V olt Receptacles Open Circu[...]

NOTES F-70 F-70 V ANT AGE® 500 Return to Section TOC Return to Section TOC Return to Section TOC Return to Section TOC Return to Master TOC Return to Master TOC Return to Master TOC Return to Master TOC[...]

T ABLE OF CONTENTS - DIAGRAM SECTION G-1 G-1 V ANT AGE® 500 Electrical Diagrams . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .G-1 Wiring Diagram (G4342 Code 10995 Deutz) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . [...]

ELEcTricaL DiaGramS G-2 v aNT aGE® 500 WiriNG DiaGram - v aNT aGE®500 - G4342 (cODE 1 1095 DEuTz) O UTP UT CO NT R OL C CW RE CTI FIE R B RI D GE HOU R M ETER ALT 75 PIN C H P OT 278 SILVER - 232 R 238A 231 42A 41A 405A + 232 C FU EL OIL PR ESS URE 241 228 START B UTT ON 5L 229 232B 5M 247 OIL TE M PE R ATU RE 243 222 MOD E SELECTO R SW ITC H 206[...]

ELEcTricaL DiaGramS G-3 v aNT aGE® 500 WiriNG DiaGram - v aNT aGE® 500 - G4329 (cODE 10996) C B6 10A 42A 42 RE CTI FIE R B RI D GE 238A 231 42A 41A 243 232 41 START B UTT ON 238 222 MOD E SELECTO R SW ITC H 206A + 206A W2 W2 W3 W3 W5 W4 W5 W4 W1 W1 W6 W6 214 S5 218 1 2 3 220 A 4 - 206S 208B 208A 208B + 50MV= 400AMPS W4 & W5 W2 & W3 W1 &am[...]

ELEcTricaL DiaGramS G-4 v aNT aGE® 500 WiriNG DiaGram - v aNT aGE® 500 - G4847 (cODES 1 1 180,1 1415 & 1 1468) C B6 10A 42A 42 RE CTI FIE R B RI D GE 42A 41A 41 222 MOD E SELECTO R SW ITC H 206A + 206A 214 S5 218 1 2 3 220 A 4 - 206S 208B 208A 208B + 50MV= 400AMPS W4 & W5 W2 & W3 W1 & W6 204S 23 2D STATO R 42V W INDI NG G48 47 B 2[...]

ELEcTricaL DiaGramS G-5 v aNT aGE® 500 WiriNG DiaGram - v aNT aGE® 500 - G4971 (cODES 1 1 181 &1 1416) C B6 10A 42A 42 RE CTI FIE R B RI D GE 42A 41A 243 232 41 START B UTT ON 238 222 M OD E SELECTO R SW ITC H 206A + 206A 214 S5 218 1 2 3 220 A 4 - 206S 208B 208A 208B + 50MV= 400AMPS W4 & W5 W2 & W3 W1 & W6 204S STATO R 42V W INDI[...]

ELEcTricaL DiaGramS G-6 v aNT aGE® 500 SchEma Tic - cOmpLETE machiNE - G4363 (cODE 10995 DEuTz) p aGE 1 G 4363 E NGI N EE RI NG CO NT RO LLE D MA NU FA CT U RE R: No R EL EASE D F R OM X A.01 G4363 VANTAGE 5 0 0 ( DEUT Z) MAC HI NE S CHE MAT I C NONE Reference bmuter D RAWN BY: DESIG N I NFO RMATI ON ENG I NEER: AP PRO VED : REFERE NCE: EQ UIP M E[...]

ELEcTricaL DiaGramS G-7 v aNT aGE® 500 SchEma Tic - cOmpLETE machiNE - G4363 (cODE 10995 DEuTz) p aGE 2 E N -1 7 0 G 4363 E NGI N EE RI NG CO NT RO LLE D MA NU FA CT U RE R: No R EL EASE D F R OM X A.01 G4363 VANTAGE 5 0 0 ( DEUT Z) MAC HI NE S CHE MAT I C NONE Reference bmuter D RAWN BY: DESIG N I NFO RMATI ON ENG I NEER: AP PRO VED : REFERE NCE:[...]

ELEcTricaL DiaGramS G-8 v aNT aGE® 500 SchEma Tic - cOmpLETE machiNE - G4442 (cODE 10996 cummiNS) p aGE1 G 4442 E NGI N EE RI NG CO NT RO LLE D MA NU FA CT U RE R: No R EL EASE D F R OM X A.01 G4442 VANTAGE 500 ( CUMM I NS) MAC HI NE S CHE MAT I C NONE Reference bmuter D RAWN BY: DESIG N I NFO RMATI ON ENG I NEER: AP PRO VED : REFERE NCE: EQ UIP M[...]

ELEcTricaL DiaGramS G-9 v aNT aGE® 500 SchEma Tic - cOmpLETE machiNE - G4442 (cODE 10996 cummiNS) p aGE 2 G 4442 E NGI N EE RI NG CO NT RO LLE D MA NU FA CT U RE R: No R EL EASE D F R OM X A.01 G4442 VANTAGE 500 ( CUMM I NS) MAC HI NE S CHE MAT I C NONE Reference bmuter D RAWN BY: DESIG N I NFO RMATI ON ENG I NEER: AP PRO VED : REFERE NCE: EQ UIP [...]

ELEcTricaL DiaGramS G-10 v aNT aGE® 500 SchEma Tic - cOmpLETE machiNE - G4848 (cODES 1 1 180, 1 1415 & 1 1468 DEuTz) p aGE 1 G4848 VA NTA GE 500 DE UT Z MAC HI N E SC HEM ATIC NONE G4487 B. M UTER N.S. DO NO T SC AL E T HIS DR A WING D RAWN BY: DESIG N I NFO RMATI ON ENG I NEER: AP PRO VED : EQ UIP M ENT TYPE: SUBJECT: SCA L E: UF CRM36466 1 P[...]

ELEcTricaL DiaGramS G-11 v aNT aGE® 500 SchEma Tic - cOmpLETE machiNE - G4848 (cODES 1 1 180, 1 1415 & 1 1468 DEuTz) p aGE 2 G4848 VA NTA GE 500 DE UT Z MAC HI N E SC HEM ATIC NONE G4487 B. M UTER N.S. DO NO T SC AL E T HIS DR A WING D RAWN BY: DESIG N I NFO RMATI ON ENG I NEER: AP PRO VED : EQ UIP M ENT TYPE: SUBJECT: SCA L E: UF CRM36466 2 P[...]

ELEcTricaL DiaGramS G-12 v aNT aGE® 500 SchEma Tic - cOmpLETE machiNE - G4791 (cODES 1 1 181 & 1 1416 cummiNS) p aGE 1 G-12 NOTE: This diagram is for reference only . It may not be accurate for all machines covered by this manual. Return to Section TOC Return to Section TOC Return to Section TOC Return to Section TOC Return to Master TOC Retur[...]

ELEcTricaL DiaGramS G-13 v aNT aGE® 500 SchEma Tic - WELD cONTrOL BOarD - G4108 p aGE 1 G-13 NOTE: This diagram is for reference only . It may not be accurate for all machines covered by this manual. Return to Section TOC Return to Section TOC Return to Section TOC Return to Section TOC Return to Master TOC Return to Master TOC Return to Master TO[...]

ELEcTricaL DiaGramS G-14 v aNT aGE® 500 SchEma Tic - WELD cONTrOL BOarD - G4801-1 p aGE 2 G-14 NOTE: This diagram is for reference only . It may not be accurate for all machines covered by this manual. Return to Section TOC Return to Section TOC Return to Section TOC Return to Section TOC Return to Master TOC Return to Master TOC Return to Master [...]

ELEcTricaL DiaGramS G-15 v aNT aGE® 500 SchEma Tic - WELD cONTrOL BOarD - G4801-1 p aGE 3 G-15 NOTE: This diagram is for reference only . It may not be accurate for all machines covered by this manual. Return to Section TOC Return to Section TOC Return to Section TOC Return to Section TOC Return to Master TOC Return to Master TOC Return to Master [...]

ELEcTricaL DiaGramS G-16 v aNT aGE® 500 SchEma Tic - WELD cONTrOL BOarD - G4801-1 p aGE 4 G-16 NOTE: This diagram is for reference only . It may not be accurate for all machines covered by this manual. Return to Section TOC Return to Section TOC Return to Section TOC Return to Section TOC Return to Master TOC Return to Master TOC Return to Master [...]

ELEcTricaL DiaGramS G-17 v aNT aGE® 500 SchEma Tic - WELD cONTrOL BOarD - p aGE 5 G-17 NOTE: This diagram is for reference only . It may not be accurate for all machines covered by this manual. Return to Section TOC Return to Section TOC Return to Section TOC Return to Section TOC Return to Master TOC Return to Master TOC Return to Master TOC Retu[...]

ELEcTricaL DiaGramS G-18 v aNT aGE® 500 SchEma Tic - chOppEr pc BOarD - m19792-1 G-18 NOTE: This diagram is for reference only . It may not be accurate for all machines covered by this manual. Return to Section TOC Return to Section TOC Return to Section TOC Return to Section TOC Return to Master TOC Return to Master TOC Return to Master TOC Retur[...]

ELEcTricaL DiaGramS G-19 v aNT aGE® 500 SchEma Tic - pEriphEraL BOarD - G3663 G-19 NOTE: This diagram is for reference only . It may not be accurate for all machines covered by this manual. Return to Section TOC Return to Section TOC Return to Section TOC Return to Section TOC Return to Master TOC Return to Master TOC Return to Master TOC Return t[...]

ELEcTricaL DiaGramS G-20 v aNT aGE® 500 SchEma Tic puLL cOiL/Ba TTEr y BOarD - G41 17-1 G-20 NOTE: This diagram is for reference only . It may not be accurate for all machines covered by this manual. Return to Section TOC Return to Section TOC Return to Section TOC Return to Section TOC Return to Master TOC Return to Master TOC Return to Master TO[...]