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Lincoln Electric VANTAGE 500 CUMMINS 500 manual

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Table of contents for the manual

  • Page 1

    • Sales and Service through Subsidiaries and Distributors Worldwide • Cleveland, Ohio 44117-1199 U.S.A. TEL: 216.481.8100 FAX: 216.486.1751 WEB SITE: www.lincolnelectric.com • World's Leader in Welding and Cutting Products • OPERA TOR’S MANUAL Copyright © 2007 Lincoln Global Inc. July, 2007 Safety Depends on You Lincoln arc welding [...]

  • Page 2

    FOR ENGINE powered equipment. 1.a. Turn the engine off before troubleshooting and maintenance work unless the maintenance work requires it to be running. ____________________________________________________ 1.b. Operate engines in open, well-ventilated areas or vent the engine exhaust fumes outdoors. ________________________________________________[...]

  • Page 3

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

  • Page 4

    iii SAFETY 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 manufacturerʼs recommendations. 8.c. Ground the equipment in accordance with the U.S. Natio[...]

  • Page 5

    iv SAFETY iv Mar. ʻ93 PRÉCAUTIONS DE SÛRETÉ Pour votre propre protection lire et observer toutes les instructions et les précautions de sûreté specifiques qui parraissent dans ce manuel aussi bien que les précautions de sûreté générales suiv- antes: Sûreté Pour Soudage A LʼArc 1. Protegez-vous contre la secousse électrique: a. Les c[...]

  • Page 6

    v v Thank You for selecting a QUALITY product by Lincoln Electric. We want you to take pride in operating this Lincoln Electric Company product ••• as much pride as we have in bringing this product to you! Read this Operators Manual completely before attempting to use this equipment. Save this manual and keep it handy for quick reference. Pay[...]

  • Page 7

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

  • Page 8

    vii vii T ABLE OF CONTENTS Page Accessories . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Section C Optional Field Installed Accessories . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . C-1 ___________________[...]

  • Page 9

    A-1 INST ALLA TION VANTAGE 500 CUMMINS A-1 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 [...]

  • Page 10

    A-2 INST ALLA TION VANTAGE 500 CUMMINS A-2 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 [...]

  • Page 11

    A-3 INST ALLA TION VANTAGE 500 CUMMINS A-3 LIFTING The VANTAGE 500 CUMMINS lift bail should be used to lift the machine. The VANTAGE 500 CUMMINS is shipped with the lift bail retracted. Before attempting to lift the VANTAGE 500 CUMMINS the lift bail must be secured in a raised position. Secure the lift bail as follows: a. Open the engine compartmen[...]

  • Page 12

    ENGINE BREAK-IN Lincoln Electric selects high quality, heavy-duty indus- trial engines for the portable welding machines we offer. While it is normal to see a small amount of crankcase oil consumption during initial operation, excessive oil use, wet stacking (oil or tar like sub- stance at the exhaust port), or excessive smoke is not normal. Larger[...]

  • Page 13

    A-5 INST ALLA TION VANTAGE 500 CUMMINS A-5 • CONNECTING A BATTERY CHARGER — remove bat- tery from welder by disconnecting negative cable first, then positive cable and battery clamp. When rein- stalling, connect negative cable last. Keep well venti- lated. • USING A BOOSTER — connect positive lead to battery first then connect negative lead[...]

  • Page 14

    A-6 INST ALLA TION VANTAGE 500 CUMMINS A-6 REMOTE CONTROL OUTPUT The VANTAGE 500 CUMMINS is equipped with a 6- pin and a 14-pin connector. The 6-pin connector is for connecting the K857 or K857-1 Remote Control or for TIG welding, the K870 foot Amptrol or the K963-3 Hand Amptrol. When in the CC-STICK, DOWNHILL PIPE, or CV-WIRE modes and when a remo[...]

  • Page 15

    A-7 INST ALLA TION VANTAGE 500 CUMMINS A-7 2. Take necessary steps to assure load is limited to the capacity of the VANTAGE 500 CUMMINS by installing a 50 amp, 240 VAC double pole circuit breaker. Maximum rated load for each leg of the 240 VAC auxiliary is 50 amps. Loading above the rated output will reduce output voltage below the allowable -10% o[...]

  • Page 16

    A-8 INST ALLA TION VANTAGE 500 CUMMINS A-8 CONNECTION OF LINCOLN ELECTRIC WIRE FEEDERS Shut off welder before making any electrical con- nections. ------------------------------------------------------------------------ CONNECTION OF LN-7, LN-8 OR LN-742 TO THE V ANT AGE 500 CUMMINS • Shut the welder off. • Connect the LN-7, LN-8 OR LN-742 per [...]

  • Page 17

    A-9 INST ALLA TION VANTAGE 500 CUMMINS A-9 CONNECTION OF THE LN-25 TO THE V ANT AGE 500 CUMMINS The LN-25 with or without an internal contactor may be used with the VANTAGE 500 CUMMINS. See the appropriate connection diagram in the DIAGRAMS section. NOTE : The LN-25 (K431) Remote Control Module and (K432) Remote Cable are not recommended for use wi[...]

  • Page 18

    B-1 OPERA TION VANTAGE 500 CUMMINS B-1 SAFETY INSTRUCTIONS Read and understand this entire section before operating your VANTAGE 500 CUMMINS. 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, ope[...]

  • Page 19

    B-2 OPERA TION B-2 ENGINE CONTROLS (Items 1 through 9) 1. RUN STOP SWITCH Toggling the switch to the RUN position energizes the fuel solenoid for approximately 30 seconds. The engine must be started within that time or the fuel solenoid will denergize, and the switch must be tog- gled to reset the timer. 2. START PUSHBUTTON Energizes the starter mo[...]

  • Page 20

    B-3 OPERA TION B-3 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 coo[...]

  • Page 21

    B-4 OPERA TION B-4 WELDING CONTROLS (Items 10 through 19) 10. OUTPUT CONTROL: The OUTPUT dial is used to preset the output voltage or current as displayed on the digital meters for the four welding modes. When in the CC-STICK, DOWNHILL PIPE or CV-WIRE modes and when a remote control is connected to the 6-Pin or 14-Pin Connector, the auto-sensing ci[...]

  • Page 22

    B-5 OPERA TION B-5 20. CIRCUIT BREAKERS These circuit breakers provide separate overload current protection for each 120V circuit at the 240V single phase receptacle, each 120V single phase receptacle, the 240V three phase receptacle, the 120VAC in the 14-Pin connector, the 42VAC in the 14-Pin connector and battery circuit overload protec- tion. 21[...]

  • Page 23

    B-6 OPERA TION B-6 BREAK-IN PERIOD The engine used to supply power for your welder is a heavy duty, industrial engine. It is designed and built for rugged use. It is very normal for any engine to use small quantities of oil until the break-in is accomplished. Check the oil level twice a day during the break-in period. In general this takes 50 to 10[...]

  • Page 24

    B-7 OPERA TION B-7 The VANTAGE 500 CUMMINS and any high frequen- cy generating equipment must be properly grounded. See the K930-2 TIG Module operating manuals for complete instructions on installation, operation, and maintenance. When using the TIG Module, the OUTPUT control on the VANTAGE 500 CUMMINS is used to set the maxi- mum range of the CURR[...]

  • Page 25

    B-8 OPERA TION B-8 CV -WIRE MODE Connect a wire feeder to the VANTAGE 500 CUM- MINS and set welder controls according to the instruc- tions listed earlier in this section. The VANTAGE 500 CUMMINS in the ”CV-WIRE” position, permits it to be used with a broad range of flux cored wire (Innershield and Outershield) elec- trodes and solid wires for [...]

  • Page 26

    B-9 OPERA TION B-9 VANTAGE 500 CUMMINS TABLE B.5 VANTAGE 500 CUMMINS Extension Cord Length Recommendations Current (Amps) 15 15 20 20 25 30 38 50 Voltag e (Volts) 120 240 120 240 240 240 240 240 Load (Watts) 1800 3600 2400 4800 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) 125 2[...]

  • Page 27

    C-1 ACCESSORIES C-1 OPTIONAL FIELD INST ALLED ACCES- SORIES K802N POWER PLUG KIT - Provides four 120V plugs rated at 20 amps each and one dual voltage, full KVA plug rated at 120/240V, 50 amps. 120V plug may not be compatible with NEMA common household receptacles. K802R POWER PLUG KIT - Provides four 120V plugs rated 15 amps each and one dual volt[...]

  • Page 28

    C-2 ACCESSORIES C-2 TIG OPTIONS K1783-9 PTA-26V TIG Torch Air Cooled 200 amp torch (2 piece) equipped with valve for gas flow control. 25 ft. (7.6m) length. KP509 Magnum Parts Kit for PTA-26V TIG Torch Magnum Parts Kit provides all the torch accessories you need to start welding. Parts kit provides collets, collet bodies, a black cap, alumina nozzl[...]

  • Page 29

    D-1 MAINTENANCE D-1 VANTAGE 500 CUMMINS SAFETY PRECAUTIONS • Have a qualified technician do the maintenance and troubleshooting work. • Turn the engine off before working inside the machine. • Remove guards only when necessary and replace them when the maintenance requiring their removal is complete. • Always use the greatest care when work[...]

  • Page 30

    D-2 MAINTENANCE D-2 VANTAGE 500 CUMMINS Service Instructions & Installation T ips For Engine Air Filter • Release the 1 Seal Carefully Unlatch and remove the service cover of the air cleaner. Make certain the latches are folded back against the cover so that they don t hinder filter removal/installation. Most latches are spring loaded to fold[...]

  • Page 31

    D-3 MAINTENANCE D-3 FUEL FIL TERS When working on the fuel system • Keep naked lights away, do not smoke ! • Do not spill fuel ! ------------------------------------------------------------------------ The VANTAGE 500 CUMMINS is equipped with a Fuel Filter located after the lift pump and before fuel injectors.The procedure for changing the filt[...]

  • Page 32

    D-4 MAINTENANCE D-4 CHARGING THE BA TTER Y When you charge, jump, replace, or otherwise con- nect battery cables to the battery, be sure the polarity is correct. Improper polarity can damage the charging circuit. The VANTAGE 500 CUMMINS positive (+) battery terminal has a red terminal cover. If you need to charge the battery with an external charge[...]

  • Page 33

    D-5 MAINTENANCE D-5 GFCI RECEPT ACLE TESTING AND RESET- TING PROCEDURE The GFCI receptacle should be properly tested at least once every month or whenever it is tripped. To properly test and reset the GFCI receptacle: • If the receptacle has tripped, first carefully remove any load and check it for damage. • If the equipment has been shut down,[...]

  • Page 34

    E-1 TROUBLESHOOTING E-1 VANTAGE 500 CUMMINS If for any reason you do not understand the test procedures or are unable to perform the tests/repairs safely, contact your Local Lincoln Authorized Field Service Facility for technical troubleshooting assistance before you proceed. CAUTION This Troubleshooting Guide is provided to help you locate and rep[...]

  • Page 35

    E-2 TROUBLESHOOTING E-2 VANTAGE 500 CUMMINS Observe all Safety Guidelines detailed throughout this manual If for any reason you do not understand the test procedures or are unable to perform the tests/repairs safely, contact your Local Lincoln Authorized Field Service Facility for technical troubleshooting assistance before you proceed. CAUTION PRO[...]

  • Page 36

    E-3 TROUBLESHOOTING E-3 VANTAGE 500 CUMMINS Observe all Safety Guidelines detailed throughout this manual If for any reason you do not understand the test procedures or are unable to perform the tests/repairs safely, contact your Local Lincoln Authorized Field Service Facility for technical troubleshooting assistance before you proceed. CAUTION PRO[...]

  • Page 37

    E-4 TROUBLESHOOTING E-4 VANTAGE 500 CUMMINS Observe all Safety Guidelines detailed throughout this manual If for any reason you do not understand the test procedures or are unable to perform the tests/repairs safely, contact your Local Lincoln Authorized Field Service Facility for technical troubleshooting assistance before you proceed. CAUTION PRO[...]

  • Page 38

    F-1 DIAGRAMS F-1 VANTAGE 500 CUMMINS NOTE: This diagram is for reference only. It may not be accurate for all machines covered by this manual. The specific diagram for a particular code is pasted inside the machine on one of the enclosure panels. If the diagram is illegible, write to the Service Department for a replacement. Give the equipment code[...]

  • Page 39

    F-2 CONNECTION DIAGRAMS F-2 VANTAGE 500 CUMMINS[...]

  • Page 40

    F-3 CONNECTION DIAGRAMS F-3 VANTAGE 500 CUMMINS GND 75• 76 77 GREEN K291 OR K404 75 INPUT CABLE 76 N.E. 77 K775 OPTIONAL• REMOTE CONTR OL D AMAGED . THE ENGINE GO VERNOR SETTING IS PRE-SET A T THE F ACT ORY - DO NO T ADJUST ABOVE RPM SPECIFICA TIONS LISTED IN 81• 42 41 31 31 32 32 2 2 4 4 21 21 GND 82 N.D . LN-7• WIRE FEEDER Keep guards in [...]

  • Page 41

    F-4 CONNECTION DIAGRAMS F-4 VANTAGE 500 CUMMINS[...]

  • Page 42

    F-5 CONNECTION DIAGRAMS F-5 VANTAGE 500 CUMMINS[...]

  • Page 43

    F-6 CONNECTION DIAGRAMS F-6 VANTAGE 500 CUMMINS CA UTION : N.A. WELDING CABLE MUST BE OF PR OPER CAP ACITY FOR THE CURRENT AND DUTY CYCLE OF IMMEDIA TE AND FUTURE• APPICA TIONS. SEE OPERA TING MANUAL. 75 32 31 41 42 N.C. INSULA TE EACH UNUSED LEAD INDIVIDU ALL Y . N.D . SPLICE LEADS AND INSULA TE. THE ENGINE WELDER OPERA TING MANUAL. GND 31 4 21 [...]

  • Page 44

    F-7 CONNECTION DIAGRAMS F-7 VANTAGE 500 CUMMINS[...]

  • Page 45

    F-8 CONNECTION DIAGRAMS F-8 VANTAGE 500 CUMMINS[...]

  • Page 46

    F-9 CONNECTION DIAGRAMS F-9 VANTAGE 500 CUMMINS[...]

  • Page 47

    F-10 CONNECTION DIAGRAMS F-10 VANTAGE 500 CUMMINS[...]

  • Page 48

    F-11 CONNECTION DIAGRAMS F-11 VANTAGE 500 CUMMINS[...]

  • Page 49

    F-12 CONNECTION DIAGRAMS F-12 VANTAGE 500 CUMMINS[...]

  • Page 50

    F-13 DIMENSION PRINT F-13 VANTAGE 500 CUMMINS * * * * BOT TOM VI EW OF WELDER BASE. N.A. CENTER OF GRAVITY WITH OIL IN ENGINE, EM PTY F UEL TA NK AND CO OLANT IN RADIATO R. M18962-3 B 2.24 56.9 5.86 148.8 45.67 1160 31.50 800.1 42.00 1066.8 46.35 1177.3 32.08 814.8 33.53 851.7 42.35 1075.7 50.15 1273.8 16.85 428 63.10 1602.7 6.56 166.6 6.55 166.4 1[...]

  • Page 51

    NOTES VANTAGE 500 CUMMINS[...]

  • Page 52

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

  • Page 53

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

  • Page 54

    • Sales and Service through Subsidiaries and Distributors Worldwide • Cleveland, Ohio 44117-1199 U.S.A. TEL: 216.481.8100 FAX: 216.486.1751 WEB SITE: www.lincolnelectric.com • World's Leader in Welding and Cutting Products •[...]