Vantage 500 Cummins 500

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

OPERATORS MANUAL

Copyright 2007 Lincoln Global Inc.

July, 2007

Safety Depends on You

Lincoln arc welding and cuttingequipment is designed andbuilt with safety in mind.However, your overall safetycan be increased by properinstallation . . . and thoughtfuloperation on your part. DONOT INSTALL, OPERATEOR REPAIR THIS EQUIP-MENT WITHOUT READINGTHIS MANUAL AND THESAFETY PRECAUTIONSCONTAINED THROUGHOUT.Most importantly, think beforeyou act and be careful.

IM873-A

For use with machines having Code Numbers: 11181, 11416

VANTAGE500CUMMINS

R

Downloaded from www.Manualslib.com manuals search engine

FOR ENGINEpowered equipment.

1.a. Turn the engine off before troubleshooting and maintenancework unless the maintenance work requires it to be running.

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1.b. Operate engines in open, well-ventilatedareas or vent the engine exhaust fumesoutdoors.

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1.c. Do not add the fuel near an open flamewelding arc or when the engine is running.Stop the engine and allow it to cool beforerefueling to prevent spilled fuel from vaporiz-ing on contact with hot engine parts andigniting. Do not spill fuel when filling tank. Iffuel is spilled, wipe it up and do not startengine until fumes have been eliminated.

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1.d. Keep all equipment safety guards, covers and devices inposition and in good repair.Keep hands, hair, clothing andtools away from V-belts, gears, fans and all other movingparts when starting, operating or repairing equipment.

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1.e. In some cases it may be necessary to remove safetyguards to perform required maintenance. Removeguards only when necessary and replace them when themaintenance requiring their removal is complete.Always use the greatest care when working near movingparts.

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1.f. Do not put your hands near the engine fan.Do not attempt to override the governor oridler by pushing on the throttle control rodswhile the engine is running.

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1.g. To prevent accidentally starting gasoline engines whileturning the engine or welding generator during maintenancework, disconnect the spark plug wires, distributor cap ormagneto wire as appropriate.

iSAFETYi

ARC WELDING CAN BE HAZARDOUS. PROTECT YOURSELF AND OTHERS FROM POSSIBLE SERIOUS INJURY OR DEATH.KEEP CHILDREN AWAY. PACEMAKER WEARERS SHOULD CONSULT WITH THEIR DOCTOR BEFORE OPERATING.

Read and understand the following safety highlights. For additional safety information, it is strongly recommended that youpurchase a copy of Safety in Welding & Cutting - ANSI Standard Z49.1 from the American Welding Society, P.O. Box351040, Miami, Florida 33135 or CSA Standard W117.2-1974. A Free copy of Arc Welding Safety booklet E205 is availablefrom the Lincoln Electric Company, 22801 St. Clair Avenue, Cleveland, Ohio 44117-1199.

BE SURE THAT ALL INSTALLATION, OPERATION, MAINTENANCE AND REPAIR PROCEDURES AREPERFORMED ONLY BY QUALIFIED INDIVIDUALS.

WARNING

Mar 95

ELECTRIC ANDMAGNETIC FIELDSmay be dangerous

2.a. Electric current flowing through any conductor causeslocalized Electric and Magnetic Fields (EMF). Weldingcurrent creates EMF fields around welding cables andwelding machines

2.b. EMF fields may interfere with some pacemakers, andwelders having a pacemaker should consult their physicianbefore welding.

2.c. Exposure to EMF fields in welding may have other healtheffects which are now not known.

2.d. All welders should use the following procedures in order tominimize exposure to EMF fields from the welding circuit:

2.d.1. Route the electrode and work cables together - Securethem with tape when possible.

2.d.2. Never coil the electrode lead around your body.

2.d.3. Do not place your body between the electrode andwork cables. If the electrode cable is on your rightside, the work cable should also be on your right side.

2.d.4. Connect the work cable to the workpiece as close aspossible to the area being welded.

2.d.5. Do not work next to welding power source.

1.h. To avoid scalding, do not remove theradiator pressure cap when the engine ishot.

CALIFORNIA PROPOSITION 65 WARNINGSDiesel engine exhaust and some of its constituentsare known to the State of California to cause can-cer, birth defects, and other reproductive harm.

The engine exhaust from this product containschemicals known to the State of California to causecancer, birth defects, or other reproductive harm.

The Above For Diesel Engines The Above For Gasoline Engines


iiSAFETYiiARC RAYS can burn.4.a. Use a shield with the proper filter and cover

plates to protect your eyes from sparks andthe rays of the arc when welding or observingopen arc welding. Headshield and filter lensshould conform to ANSI Z87. I standards.

4.b. Use suitable clothing made from durable flame-resistantmaterial to protect your skin and that of your helpers fromthe arc rays.

4.c. Protect other nearby personnel with suitable, non-flammablescreening and/or warn them not to watch the arc nor exposethemselves to the arc rays or to hot spatter or metal.

ELECTRIC SHOCK cankill.3.a. The electrode and work (or ground) circuits

are electrically hot when the welder is on.Do not touch these hot parts with your bareskin or wet clothing. Wear dry, hole-free

gloves to insulate hands.

3.b. Insulate yourself from work and ground using dry insulation.Make certain the insulation is large enough to cover your fullarea of physical contact with work and ground.

In addition to the normal safety precautions, if weldingmust be performed under electrically hazardousconditions (in damp locations or while wearing wetclothing; on metal structures such as floors, gratings orscaffolds; when in cramped positions such as sitting,kneeling or lying, if there is a high risk of unavoidable oraccidental contact with the workpiece or ground) usethe following equipment:

Semiautomatic DC Constant Voltage (Wire) Welder. DC Manual (Stick) Welder. AC Welder with Reduced Voltage Control.

3.c. In semiautomatic or automatic wire welding, the electrode,electrode reel, welding head, nozzle or semiautomaticwelding gun are also electrically hot.

3.d. Always be sure the work cable makes a good electricalconnection with the metal being welded. The connectionshould be as close as possible to the area being welded.

3.e. Ground the work or metal to be welded to a good electrical(earth) ground.

3.f. Maintain the electrode holder, work clamp, welding cable andwelding machine in good, safe operating condition. Replacedamaged insulation.

3.g. Never dip the electrode in water for cooling.

3.h. Never simultaneously touch electrically hot parts ofelectrode holders connected to two welders because voltagebetween the two can be the total of the open circuit voltageof both welders.

3.i. When working above floor level, use a safety belt to protectyourself from a fall should you get a shock.

3.j. Also see Items 6.c. and 8.

FUMES AND GASEScan be dangerous.5.a. Welding may produce fumes and gases

hazardous to health. Avoid breathing thesefumes and gases. When welding, keepyour head out of the fume. Use enoughventilation and/or exhaust at the arc to keep

fumes and gases away from the breathing zone. Whenwelding with electrodes which require specialventilation such as stainless or hard facing (seeinstructions on container or MSDS) or on lead orcadmium plated steel and other metals or coatingswhich produce highly toxic fumes, keep exposure aslow as possible and below Threshold Limit Values (TLV)using local exhaust or mechanical ventilation. Inconfined spaces or in some circumstances, outdoors, arespirator may be required. Additional precautions arealso required when welding on galvanized steel.

5. b. The operation of welding fume control equipment is affectedby various factors including proper use and positioning ofthe equipment, maintenance of the equipment and the spe-cific welding procedure and application involved. Workerexposure level should be checked upon installation andperiodically thereafter to be certain it is within applicableOSHA PEL and ACGIH TLV limits.

5.c. Do not weld in locations near chlorinated hydrocarbon vaporscoming from degreasing, cleaning or spraying operations.The heat and rays of the arc can react with solvent vapors toform phosgene, a highly toxic gas, and other irritating prod-ucts.

5.d. Shielding gases used for arc welding can displace air andcause injury or death. Always use enough ventilation,especially in confined areas, to insure breathing air is safe.

5.e. Read and understand the manufacturers instructions for thisequipment and the consumables to be used, including thematerial safety data sheet (MSDS) and follow youremployers safety practices. MSDS forms are available fromyour welding distributor or from the manufacturer.

5.f. Also see item 1.b.

AUG 06


iiiSAFETYiii

FOR ELECTRICALLYpowered equipment.

8.a. Turn off input power using the disconnectswitch at the fuse box before working onthe equipment.

8.b. Install equipment in accordance with the U.S. NationalElectrical Code, all local codes and the manufacturersrecommendations.

8.c. Ground the equipment in accordance with the U.S. NationalElectrical Code and the manufacturers recommendations.

CYLINDER may explodeif damaged.7.a. Use only compressed gas cylinders

containing the correct shielding gas for theprocess used and properly operatingregulators designed for the gas and

pressure used. All hoses, fittings, etc. should be suitable forthe application and maintained in good condition.

7.b. Always keep cylinders in an upright position securelychained to an undercarriage or fixed support.

7.c. Cylinders should be located: Away from areas where they may be struck or subjected tophysical damage.

A safe distance from arc welding or cutting operations andany other source of heat, sparks, or flame.

7.d. Never allow the electrode, electrode holder or any otherelectrically hot parts to touch a cylinder.

7.e. Keep your head and face away from the cylinder valve outletwhen opening the cylinder valve.

7.f. Valve protection caps should always be in place and handtight except when the cylinder is in use or connected foruse.

7.g. Read and follow the instructions on compressed gascylinders, associated equipment, and CGA publication P-l,Precautions for Safe Handling of Compressed Gases inCylinders, available from the Compressed Gas Association1235 Jefferson Davis Highway, Arlington, VA 22202.

Jan, 07

WELDING and CUTTINGSPARKS cancause fire or explosion.6.a. Remove fire hazards from the welding area.

If this is not possible, cover them to preventthe welding sparks from starting a fire.

Remember that welding sparks and hotmaterials from welding can easily go through small cracksand openings to adjacent areas. Avoid welding nearhydraulic lines. Have a fire extinguisher readily available.

6.b. Where compressed gases are to be used at the job site,special precautions should be used to prevent hazardoussituations. Refer to Safety in Welding and Cutting (ANSIStandard Z49.1) and the operating information for theequipment being used.

6.c. When not welding, make certain no part of the electrodecircuit is touching the work or ground. Accidental contactcan cause overheating and create a fire hazard.

6.d. Do not heat, cut or weld tanks, drums or containers until theproper steps have been taken to insure that such procedureswill not cause flammable or toxic vapors from substancesinside. They can cause an explosion even though they havebeen cleaned. For information, purchase RecommendedSafe Practices for the Preparation for Welding and Cutting ofContainers and Piping That Have Held HazardousSubstances, AWS F4.1 from the American Welding Society(see address above).

6.e. Vent hollow castings or containers before heating, cutting orwelding. They may explode.

6.f. Sparks and spatter are thrown from the welding arc. Wear oilfree protective garments such as leather gloves, heavy shirt,cuffless trousers, high shoes and a cap over your hair. Wearear plugs when welding out of position or in confined places.Always wear safety glasses with side shields when in awelding area.

6.g. Connect the work cable to the work as close to the weldingarea as practical. Work cables connected to the buildingframework or other locations away from the welding areaincrease the possibility of the welding current passingthrough lifting chains, crane cables or other alternate cir-cuits. This can create fire hazards or overheat lifting chainsor cables until they fail.

6.h. Also see item 1.c.

6.I. Read and follow NFPA 51B Standard for Fire PreventionDuring Welding, Cutting and Other Hot Work, availablefrom NFPA, 1 Batterymarch Park,PO box 9101, Quincy, Ma022690-9101.

6.j. Do not use a welding power source for pipe thawing.


ivSAFETYiv

Mar. 93

PRCAUTIONS DE SRETPour votre propre protection lire et observer toutes les instructionset les prcautions de sret specifiques qui parraissent dans cemanuel aussi bien que les prcautions de sret gnrales suiv-antes:

Sret Pour Soudage A LArc1. Protegez-vous contre la secousse lectrique:

a. Les circuits llectrode et la pice sont sous tensionquand la machine souder est en marche. Eviter toujourstout contact entre les parties sous tension et la peau nueou les vtements mouills. Porter des gants secs et sanstrous pour isoler les mains.

b. Faire trs attention de bien sisoler de la masse quand onsoude dans des endroits humides, ou sur un planchermetallique ou des grilles metalliques, principalement dansles positions assis ou couch pour lesquelles une grandepartie du corps peut tre en contact avec la masse.

c. Maintenir le porte-lectrode, la pince de masse, le cblede soudage et la machine souder en bon et sr tatdefonctionnement.

d.Ne jamais plonger le porte-lectrode dans leau pour lerefroidir.

e. Ne jamais toucher simultanment les parties sous tensiondes porte-lectrodes connects deux machines souderparce que la tension entre les deux pinces peut tre letotal de la tension vide des deux machines.

f. Si on utilise la machine souder comme une source decourant pour soudage semi-automatique, ces precautionspour le porte-lectrode sapplicuent aussi au pistolet desoudage.

2. Dans le cas de travail au dessus du niveau du sol, se protgercontre les chutes dans le cas ou on recoit un choc. Ne jamaisenrouler le cble-lectrode autour de nimporte quelle partiedu corps.

3. Un coup darc peut tre plus svre quun coup de soliel,donc:

a. Utiliser un bon masque avec un verre filtrant appropriainsi quun verre blanc afin de se protger les yeux du ray-onnement de larc et des projections quand on soude ouquand on regarde larc.

b. Porter des vtements convenables afin de protger lapeau de soudeur et des aides contre le rayonnement delarc.

c. Protger lautre personnel travaillant proximit ausoudage laide dcrans appropris et non-inflammables.

4. Des gouttes de laitier en fusion sont mises de larc desoudage. Se protger avec des vtements de protection libresde lhuile, tels que les gants en cuir, chemise paisse, pan-talons sans revers, et chaussures montantes.

5. Toujours porter des lunettes de scurit dans la zone desoudage. Utiliser des lunettes avec crans lateraux dans leszones o lon pique le laitier.

6. Eloigner les matriaux inflammables ou les recouvrir afin deprvenir tout risque dincendie d aux tincelles.

7. Quand on ne soude pas, poser la pince une endroit isol dela masse. Un court-circuit accidental peut provoquer unchauffement et un risque dincendie.

8. Sassurer que la masse est connecte le plus prs possiblede la zone de travail quil est pratique de le faire. Si on placela masse sur la charpente de la construction ou dautresendroits loigns de la zone de travail, on augmente le risquede voir passer le courant de soudage par les chaines de lev-age, cbles de grue, ou autres circuits. Cela peut provoquerdes risques dincendie ou dechauffement des chaines et descbles jusqu ce quils se rompent.

9. Assurer une ventilation suffisante dans la zone de soudage.Ceci est particulirement important pour le soudage de tlesgalvanises plombes, ou cadmies ou tout autre mtal quiproduit des fumes toxiques.

10. Ne pas souder en prsence de vapeurs de chlore provenantdoprations de dgraissage, nettoyage ou pistolage. Lachaleur ou les rayons de larc peuvent ragir avec les vapeursdu solvant pour produire du phosgne (gas fortement toxique)ou autres produits irritants.

11. Pour obtenir de plus amples renseignements sur la sret,voir le code Code for safety in welding and cutting CSAStandard W 117.2-1974.

PRCAUTIONS DE SRET POURLES MACHINES SOUDER TRANSFORMATEUR ET REDRESSEUR

1. Relier la terre le chassis du poste conformement au code dellectricit et aux recommendations du fabricant. Le dispositifde montage ou la piece souder doit tre branch unebonne mise la terre.

2. Autant que possible, Iinstallation et lentretien du poste seronteffectus par un lectricien qualifi.

3. Avant de faires des travaux linterieur de poste, la debranch-er linterrupteur la boite de fusibles.

4. Garder tous les couvercles et dispositifs de sret leurplace.


vv

Thank You for selecting a QUALITY product by Lincoln Electric. We want youto 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 ithandy for quick reference. Pay particular attention to the safety instructions we have provided for your protection.The level of seriousness to be applied to each is explained below:

WARNINGThis statement appears where the information must be followed exactly to avoid serious personal injury or loss of life.

This statement appears where the information must be followed to avoid minor personal injury or damage to this equipment.CAUTION

Please Examine Carton and Equipment For Damage ImmediatelyWhen this equipment is shipped, title passes to the purchaser upon receipt by the carrier. Consequently, Claimsfor material damaged in shipment must be made by the purchaser against the transportation company at thetime the shipment is received.

Please record your equipment identification information below for future reference. This information can befound on your machine nameplate.

Product _________________________________________________________________________________

Model Number ___________________________________________________________________________

Code Number or Date Code_________________________________________________________________

Serial Number____________________________________________________________________________

Date Purchased___________________________________________________________________________

Where Purchased_________________________________________________________________________

Whenever you request replacement parts or information on this equipment, always supply the information youhave recorded above. The code number is especially important when identifying the correct replacement parts.

On-Line Product Registration- Register your machine with Lincoln Electric either via fax or over the Internet. For faxing: Complete the form on the back of the warranty statement included in the literature packet

accompanying this machine and fax the form per the instructions printed on it. For On-Line Registration: Go to our WEB SITE at www.lincolnelectric.com. Choose Quick Links and then

Product Registration. Please complete the form and submit your registration.

CUSTOMER ASSISTANCE POLICYThe business of The Lincoln Electric Company is manufacturing and selling high quality welding equipment, consumables, and cutting equip-ment. Our challenge is to meet the needs of our customers and to exceed their expectations. On occasion, purchasers may ask LincolnElectric for advice or information about their use of our products. We respond to our customers based on the best information in our posses-sion at that time. Lincoln Electric is not in a position to warrant or guarantee such advice, and assumes no liability, with respect to such infor-mation or advice. We expressly disclaim any warranty of any kind, including any warranty of fitness for any customers particular purpose,with respect to such information or advice. As a matter of practical consideration, we also cannot assume any responsibility for updating orcorrecting any such information or advice once it has been given, nor does the provision of information or advice create, expand or alter anywarranty with respect to the sale of our products.

Lincoln Electric is a responsive manufacturer, but the selection and use of specific products sold by Lincoln Electric is solely within the controlof, and remains the sole responsibility of the customer. Many variables beyond the control of Lincoln Electric affect the results obtained inapplying these types of fabrication methods and service requirements.

Subject to Change This information is accurate to the best of our knowledge at the time of printing. Please refer to www.lincolnelectric.comfor any updated information.


vi vi TABLE OF CONTENTSPage

Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Section ATechnical Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .A-1Safety Precautions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .A-2Location / Ventilation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .A-2

Storing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .A-2Stacking . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .A-2Angle of Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .A-2Lifting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .A-3High Altitude Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .A-3High Temperature Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .A-3Towing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .A-3Vehicle Mounting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .A-3

Pre-Operation Engine and Compressor Service . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .A-4Oil . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .A-4Fuel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .A-4Fuel Cap . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .A-4Engine Coolant . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .A-4Battery Connection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .A-4Muffler Outlet Pipe . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .A-5Spark Arrestor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .A-5

Welding Terminals . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .A-5Welding Output Cables . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .A-5

Machine Grounding . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .A-5Remote Control . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .A-6Auxiliary Power Receptacles . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .A-6Standby Power Connections . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .A-6Connection of Vantage Premises Wiring . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .A-7Connection of Lincoln Electric Wire Feeders . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .A-8, A-9

Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Section BSafety Instructions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .B-1General Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .B-1

Recommended Applications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .B-1Controls and Settings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .B-2

Engine Controls . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .B-2, B-3Welder Controls . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .B-4Auxiliary Power Controls . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .B-4

Engine Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .B-5Starting the Engine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .B-5Stopping the Engine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .B-5

Break-In Period . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .B-6Typical Fuel Consumption . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .B-6Duty Cycle . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .B-6

Welding Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .B-6Stick Welding Mode . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .B-6CC-Stick Mode . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .B-6Downhill Pipe Mode . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .B-6Touch Start TIG Mode . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .B-6Vantage Settings when using K930-2 TIG Module . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .B-7

Typical Current Ranges for Tungsten Electrodes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .B-7CV-Wire Mode . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .B-8Arc Gouging . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .B-8Paralleling . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .B-8

Auxiliary Power Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .B-8Simultaneous Welding and Auxiliary Power Loads . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .B-8

Simultaneous Welding and Power Loads, Extension Cord Length Recommendations . . . . . . . . . . .B-9


vii viiTABLE OF CONTENTSPage

Accessories . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Section COptional Field Installed Accessories . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .C-1

_________________________________________________________________________________________________

Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Section DSafety Precautions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .D-1Routine and Periodic Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .D-1Engine Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .D-1

Air Filter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .D-1,D-2Fuel Filters . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .D-3Cooling System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .D-3Battery Handling . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .D-3

Charging the Battery . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .D-4Nameplate / Warning Decal Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .D-4Welder / Generator Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .D-4Engine Maintenance Components . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .D-4GFCI Receptacle Testing and Restting Procedure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .D-5

Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Section E

Wiring, Connection Diagrams and Dimension Print . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Section F

Parts Lists . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .P- 508


A-1INSTALLATION

VANTAGE 500 CUMMINS

A-1

TECHNICAL SPECIFICATIONS - VANTAGE 500 CUMMINS (K2406-1)INPUT - DIESEL ENGINE

Make /Model Description Speed (RPM) Displacement Starting CapacitiesSystem

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 RPM Full Load 1890 (94.6L)

Bore x Stroke Oil: 2 US gal.

3.74 x 4.53 (7.6L)(95mm x 115mm) Coolant

2 US gal. (7.6L)RATED OUTPUT @ 104F(40C) - WELDER

Duty Cycle Welding Output Volts at Rated Amps

100% 500 Amps (DC multi-purpose) 40 Volts

60% 550 Amps (DC multi-purpose) 36 volts

50% 575 Amps (DC multi-purpose) 35 volts

PHYSICAL DIMENSIONSHeight (2) Width Depth Weight

42.0 in 31.5 in. 63.1 in. 1443lbs.(1066.8 mm) (800.1mm) (1603mm) (655kg)

(Approx)1. Output rating in watts is equivalent to volt-amperes at unity power factor.

Output voltage is within +/- 10% at all loads up to rated capacity. When welding, available auxiliary power will be reduced.2. Top of Enclosure. Add 7.0 (177.8mm) for exhaust.

OUTPUT @ 104F(40C) - WELDER AND GENERATOR

Welding Range30 - 575 Amps CC/CV

20 - 250 Amps TIG

Open Circuit Voltage60 Max OCV @ 1900 RPM

Auxiliary Power (1)120/240 VAC

12,000 WATTS, 60 Hz., Single Phase20,000 WATTS, 60 Hz., Three Phase


A-2INSTALLATION

VANTAGE 500 CUMMINS

A-2

Read this entire installation section before youstart installation.SAFETY PRECAUTIONS

Do not attempt to use this equipment until youhave thoroughly read all operating and mainte-nance manuals supplied with your machine. Theyinclude important safety precautions, detailedengine starting, operating and maintenanceinstructions and parts lists.

ELECTRIC SHOCK can kill. Do not touch electrically live parts

such as output terminals or internalwiring.

Insulate yourself from the work andground.

Always wear dry insulating gloves.------------------------------------------------------------------------

ENGINE EXHAUST can kill. Use in open, well ventilated areas or

vent exhaust outside

------------------------------------------------------------------------

MOVING PARTS can injure. Do not operate with doors open or

guards off. Stop engine before servicing.

Keep away from moving parts------------------------------------------------------------------------

Only qualified personnel should install, use or ser-vice this equipment.------------------------------------------------------------------------

LOCATION / VENTILATIONThe welder should be located to provide an unrestrict-ed flow of clean, cool air to the cooling air inlets and toavoid restricting the cooling air outlets. Also, locatethe welder so that the engine exhaust fumes are prop-erly vented to an outside area.

DO NOT MOUNT OVER COMBUSTIBLE SUR-FACESWhere there is a combustible surface directlyunder stationary or fixed electrical equipment, thatsurface should be covered with a steel plate atleast .06(1.6mm) thick, which should extend notless than 5.90(150mm) beyond the equipment onall sides.------------------------------------------------------------------------STORING1. Store the machine in a cool, dry place when it is

not in use. Protect it from dust and dirt. Keep itwhere it cant be accidentally damaged from con-struction activities, moving vehicles, and otherhazards.

2. Drain the engine oil and refill with fresh 10W30oil. Run the engine for about five minutes to cir-culate oil to all the parts. See the MAINTE-NANCE section of this manual for details onchanging oil.

3. Remove the battery, recharge it, and adjust theelectrolyte level. Store the battery in a dry, darkplace.

STACKINGVANTAGE 500 CUMMINS machines cannot bestacked.

ANGLE OF OPERATIONTo achieve optimum engine performance the VAN-TAGE 500 CUMMINS should be run in a level posi-t ion. The maximum angle of operation for theCummins engine is 35 degrees in all directions. Whenoperating the welder at an angle, provisions must bemade for checking and maintaining the oil level at thenormal (FULL) oil capacity. Also the effective fuelcapacity will be slightly less than the specified 25gal.(94.6 ltrs.).

WARNING

CAUTION


A-3INSTALLATION

VANTAGE 500 CUMMINS

A-3

LIFTINGThe VANTAGE 500 CUMMINS lift bail should be usedto lift the machine. The VANTAGE 500 CUMMINS isshipped with the lift bail retracted. Before attemptingto lift the VANTAGE 500 CUMMINS the lift bail mustbe secured in a raised position. Secure the lift bail asfollows:

a. Open the engine compartment door.b. Locate the 2 access holes on the upper middle

region of compartment wall just below the liftbail.

c. Use the lifting strap to raise the lift bail to thefull upright position. This will align the mount-ing holes on the lift bail with the access holes.

d. Secure the lift bail with 2 thread formingscrews. The screws are provided in theshipped loose parts bag.

Lift only with equipment of ade-quate lifting capacity.

Be sure machine is stable whenlifting.

Do not lift this machine using liftbail if it is equipped with a heavyaccessory such as trailer or gascylinder.

FALLING Do not lift machine if lift bail is EQUIPMENT can damaged.

cause injury. Do not operate machine whilesuspended from lift bail.

------------------------------------------------------------------------

HIGH ALTITUDE OPERATION

At higher altitudes, output derating may be necessary.For maximum rating, derate the welder output 5% forevery 300 meters (984 ft.) above 1500 meters (4920ft.). For output of 500A and below, derate the welderoutput 5% for every 300 meters (984 ft.) above 2100meters (6888 ft.).Contact a Cummins Service Representative for anyengine adjustments that may be required.

TOWINGThe recommended trailer for use with this equipmentfor road, in-plant and yard towing by a vehicle (1) isLincolns K953-1. If the user adapts a non-Lincolntrailer, he must assume responsibility that the methodof attachment and usage does not result in a safetyhazard nor damage the welding equipment. Some ofthe factors to be considered are as follows:

1. Design capacity of trailer vs. weight of Lincolnequipment and likely additional attachments.

2. Proper support of, and attachment to, the baseof the welding equipment so that there will beno undue stress to the trailers framework.

3. Proper placement of the equipment on thetrailer to insure stability side to side and frontto back when being moved and when standingby itself.

4. Typical conditions of use, such as travelspeed, roughness of surface on which thetrailer will be operated, and environmentalconditions.

5. Proper preventative maintenance of trailer.6. Conformance with federal, state and local laws (1) .

(1) Consult applicable federal, state and local lawsregarding specific requirements for use on publichighways.

VEHICLE MOUNTING

Improperly mounted concentrated loads maycause unstable vehicle handling and tires or othercomponents to fail.

Only transport this Equipment on serviceablevehicles which are rated and designed for suchloads.

Distribute, balance and secure loads so vehicleis stable under conditions of use.

Do not exceed maximum rated loads for compo-nents such as suspension, axles and tires.

Mount equipment base to metal bed or frame ofvehicle.

Follow vehicle manufacturers instructions.------------------------------------------------------------------------

WARNING

WARNING


ENGINE BREAK-IN

Lincoln Electric selects high quality, heavy-duty indus-trial engines for the portable welding machines weoffer. While it is normal to see a small amount ofcrankcase oil consumption during initial operation,excessive oil use, wet stacking (oil or tar like sub-stance at the exhaust port), or excessive smoke is notnormal.

Larger machines with a capacity of 350 amperes andhigher, which are operated at low or no-load condi-tions for extended periods of time are especially sus-ceptible to the conditions described above. Toaccomplish successful engine break-in, most diesel-powered equipment needs only to be run at a reason-ably heavy load within the rating of the welder forsome period of time during the engines early life.However, if the welder is subjected to extensive lightloading, occasional moderate to heavy loading of theengine may sometimes be necessary. Caution mustbe observed in correctly loading a diesel/generatorunit.

1. Connect the welder output studs to a suitableresistive load bank. Note that any attempt to shortthe output studs by connecting the welding leadstogether, direct shorting of the output studs, or con-necting the output leads to a length of steel willresult in catastrophic damage to the generator andvoids the warranty.

2. Set the welder controls for an output current andvoltage within the welder rating and duty cycle.Note that any attempt to exceed the welder ratingor duty cycle for any period of time will result in cat-astrophic damage to the generator and voids thewarranty.

3. Periodically shut off the engine and check thecrankcase oil level.

BATTERY CONNECTION

GASES FROM BATTERY can explode. Keep sparks, flame and cigarettes

away from battery.To prevent EXPLOSION when: INSTALLING A NEW BATTERY

disconnect negative cable from oldbattery first and connect to new bat-tery last.

A-4INSTALLATION

VANTAGE 500 CUMMINS

A-4PRE-OPERATION ENGINE 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 beforefuelling.

Do not smoke when fuelling. Fill fuel tank at a moderate rate and do not over-fill. Wipe up spilled fuel and allow fumes to clear before

starting engine. Keep sparks and flame away from tank.------------------------------------------------------------------------

OILThe VANTAGE 500 CUMMINS is shipped with theengine crankcase filled with high quality SAE 10W-30 oil(API class CD or better). Check the engine oil levelbefore starting the engine. If it is not up to the full markon the dip stick, add oil as required. Check the oil levelevery four hours of running time during the first 35 run-ning hours. Refer to the engine Operators Manuals forspecific oil recommendations and break-in information.The oil change interval is dependent on the quality of theoil and the operating environment. Refer to the engineOperators Manuals for the proper service and mainte-nance intervals.

FUEL USE DIESEL FUEL ONLYFill the fuel tank with clean, fresh diesel fuel. The capaci-ty of the fuel tank is approximately 25 gallons (95 liters).See engine Operators Manual for specific fuel recom-mendations. Running out of fuel may require bleedingthe fuel injection pump. NOTE: Before starting theengine, open the fuel shutoff valve (pointer to be in linewith hose).FUEL CAPRemove the plastic cap covering from the Fuel TankFiller neck and install the Fuel Cap.

ENGINE COOLANT

HOT COOLANT can burn skin. Do not remove cap if radiator is hot.

----------------------------------------------------------------------------The welder is shipped with the engine and radiator filledwith a 50% mixture of ethylene glycol and water. (Seethe MAINTENANCE section and the engine OwnersManual for more information on coolant.)

WARNING

WARNING

WARNING


A-5INSTALLATION

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 batteryfirst then connect negative lead to negative batterylead at engine foot.

BATTERY ACID can burn eyes and skin. Wear gloves and eye protection and be

careful when working near battery. Follow instructions printed on battery.IMPORTANT : To prevent ELECTRICALDAMAGE WHEN:

a) Installing new batteries.b) Using a booster.

Use correct polarity Negative Ground.The VANTAGE 500 CUMMINS is shipped with the negativebattery cable disconnected. Before you operate themachine, make sure the Engine Switch is in the OFF posi-tion and attach the disconnected cable securely to the nega-tive (-) battery terminal.Remove the insulating cap from the negative battery termi-nal. Replace and tighten negative battery cable terminal.NOTE: This machine is furnished with a wet charged bat-tery; if unused for several months, the battery may require abooster charge. Be sure to use the correct polarity whencharging the battery.

MUFFLER OUTLET PIPERemove the plastic plug covering the muffler outlet tube.Using the clamp provided secure the outlet pipe to the outlettube with the pipe positioned such that it will direct theexhaust in the desired position.

SPARK ARRESTORSome federal, state or local laws may require that petrol ordiesel engines be equipped with exhaust spark arresterswhen they are operated in certain locations where unarrest-ed sparks may present a fire hazard. The standard mufflerincluded with this welder does not qualify as a sparkarrestor. When required by local regulations, a suitablespark arrestor, must be installed and properly maintained.

An incorrect arrestor may lead to damage to the engineor adversely affect performance.--------------------------------------------------------------------------------

AIR CLEANER INLET HOODRemove the plastic plug covering the air cleaner inlet. Installthe air cleaner inlet hood to the air cleaner.

WELDING TERMINALSThe VANTAGE 500 CUMMINS is equipped with a toggleswitch for selecting "hot" welding terminals when in the"WELD TERMINALS ON" position or "cold" welding termi-nals when in the "REMOTELY CONTROLLED" position.

WELDING OUTPUT CABLESWith the engine off, route the electrode and work cablesthru the strain relief bracket provided on the front of thebase and connect to the terminals provided. These con-nections should be checked periodically and tightened ifnecessary.Listed in Table A.1 are copper cable sizes recommendedfor the rated current and duty cycle. Lengths stipulated arethe distance from the welder to work and back to thewelder again. Cable sizes are increased for greater lengthsprimarily for the purpose of minimizing cable voltage drop.Table A.1 Combined Length of Electrode and WorkCables.

MACHINE GROUNDINGBecause this portable engine driven welder creates its ownpower, it is not necessary to connect its frame to an earthground, unless the machine is connected to premiseswiring (home, shop, etc.).To prevent dangerous electric shock, other equipmentpowered by this engine driven welder must:

a) be grounded to the frame of the welder using agrounded type plug, or

b) be double insulated.When this welder is mounted on a truck or trailer, its framemust be securely connected to the metal frame of the vehi-cle. When this engine driven welder is connected topremises wiring such as that in a home or shop, its framemust be connected to the system earth ground. See furtherconnection instructions in the section entitled StandbyPower Connections as well as the article on grounding inthe latest National Electrical Code and the local codes.In general, if the machine is to be grounded, it should beconnected with a #8 or larger copper wire to a solid earthground such as a metal ground stake going into the groundfor at least 10Ft.(3.1m) or to the metal framework of abuilding which has been effectively grounded. The NationalElectric Code lists a number of alternate means of ground-ing electrical equipment. A machine grounding studmarked with the symbol is provided on the front of thewelder.

CAUTION

AMPS Up to 200ft 1200-250ft@100% Up to 656m 656-820m

Duty Cycle500 3/0 AWG 4/0 AWG

TOTAL COMBINED LENGTH OF ELEC-TRODE AND WORK CABLES


A-6INSTALLATION

VANTAGE 500 CUMMINS

A-6

REMOTE CONTROLOUTPUTThe VANTAGE 500 CUMMINS is equipped with a 6-pin and a 14-pin connector. The 6-pin connector is forconnecting the K857 or K857-1 Remote Control or forTIG welding, the K870 foot Amptrol or the K963-3Hand Amptrol. When in the CC-STICK, DOWNHILLPIPE, or CV-WIRE modes and when a remote controlis connected to the 6-pin Connector, the auto-sensingcircuit automatically switches the OUTPUT controlfrom control at the welder to remote control.

When in TOUCH START TIG mode and when aAmptrol is connected to the 6-Pin Connector, theOUTPUT dial is used to set the maximum currentrange of the CURRENT CONTROL of the Amptrol.

The 14-pin connector is used to directly connect awire feeder control cable. In the CV-WIRE mode,when the control cable is connected to the 14-pin con-nector, the auto-sensing circuit automatically makesthe Output Control inactive and the wire feeder volt-age control activeNOTE: When a wire feeder with a built in welding volt-age control is connected to the 14-pin connector, donot connect anything to the 6-pin connector.

AUXILIARY POWER RECEPTACLESStart the engine and set the IDLER control switch tothe High Idle mode. Voltage is now correct at thereceptacles for auxiliary power. This must be donebefore a tripped GFCI receptacle can be reset proper-ly. See the MAINTENANCE section for detailed infor-mation on testing and resetting the GFCI receptacle.

The auxiliary power capacity of the VANTAGE 500CUMMINS is 12,000 watts of 60 Hz, single phase or20,000 watts of 60Hz, three phase power. The auxil-iary power capacity rating in watts is equivalent tovolt-amperes at unity power factor. The maximum per-missible current of the 240 VAC output is 50 A. The240 VAC single phase output can be split to providetwo separate 120 VAC outputs with a maximum per-missible current of 50 A per output to two separate120 VAC branch circuits. The output voltage is within 10% at all loads up to rated capacity.

The VANTAGE 500 CUMMINS has two 20 Amp-120VAC single phase(5-20R) GFCI duplex recepta-cles, one 50 Amp-120/240 single phase VAC (14-50R) receptacle and one 240VAC three phase (15-50R) receptacle. The auxiliary power receptaclesshould only be used with three wire grounded typeplugs or approved double insulated tools with two wireplugs. The current rating of any plug used with thesystem must be at least equal to the current capacityof the associated receptacle.

A 240VAC 3 phase plug is provided loose with themachine.

Note: The two 120V GFCI receptacles and the two120 volt circuits of the 120/240V receptacle are con-nected to different phases and can not be paralleled.

STANDBY POWER CONNECTIONSThe VANTAGE 500 CUMMINS is suitable for tempo-rary, standby or emergency power using the enginemanufacturers recommended maintenance schedule.

The VANTAGE 500 CUMMINS can be permanentlyinstalled as a standby power unit for 240 volt-3 wire,50 amp service. Connections must be made by alicensed electrician who can determine how the120/240 VAC power can be adapted to the particularinstallation and comply with all applicable electricalcodes. The following information can be used as aguide by the electrician for most applications. Refer tothe connection diagram shown in Figure A.2.

1. Install the double-pole, double-throw switchbetween the power company meter and the premis-es disconnect.

Switch rating must be the same or greater than thecustomers premises disconnect and service over cur-rent protection.


A-7INSTALLATION

VANTAGE 500 CUMMINS

A-7

2. Take necessary steps to assure load is limited tothe capacity of the VANTAGE 500 CUMMINS byinstalling a 50 amp, 240 VAC double pole circuitbreaker. Maximum rated load for each leg of the240 VAC auxiliary is 50 amps. Loading above therated output will reduce output voltage below theallowable -10% of rated voltage which may damageappliances or other motor-driven equipment andmay result in overheating of the VANTAGE 500CUMMINS engine.

3. Install a 50 amp 120/240 VAC plug (NEMA Type14-50R) to the double-pole circuit breaker using #6or #4 conductor cable of the desired length. (The 50amp, 120/240 VAC plug is available in the optionalK802N or K802R plug kits or by itself as T12153-9.)

4. Plug this cable into the 50 Amp 120/240 Volt recep-tacle on the VANTAGE 500 CUMMINS case front.

Figure A.2 Connection of the VANTAGE 500 CUMMINS to Premises Wiring

240 Volt 60 Hz. 3-Wire Service

POWER

COMPANY

METER

240 VOLT

120 VOLT

120 VOLT

LOADN

NEUTRALBUS

GROUND

PREMISES DISCONNECT AND

SERVICE OVERCURRENT

PROTECTION

GND

N

NOTE: No. 6 COPPER CONDUCTOR CABLE SEE NATIONAL ELECTRICAL CODE FOR ALTERNATE WIRE

SIZE RECOMMENDATIONS.

240 VOLT

GROUNDED CONDUCTOR

50AMP 240 VOLT

DOUBLE POLE

CIRCUIT BREAKER

DOUBLE POLE DOUBLE THROWSWITCH RATING TO BE THE SAMEAS OR GREATER THAN PREMISESSERVICE OVERCURRENTPROTECTION.

50 AMP, 120/240 VOLT PLUG

NEMA TYPE 14-50

50 AMP, 120/240 VOLT RECEPTACLE


A-8INSTALLATION

VANTAGE 500 CUMMINS

A-8

CONNECTION OF LINCOLN ELECTRICWIRE FEEDERS

Shut off welder before making any electrical con-nections.------------------------------------------------------------------------CONNECTION OF LN-7, LN-8 OR LN-742TO THE VANTAGE 500 CUMMINS Shut the welder off.

Connect the LN-7, LN-8 OR LN-742 per instructionson the appropriate connection diagram in the DIA-GRAMS section.

Set the WIRE FEEDER VOLTMETER switch toeither + or - as required by the electrode beingused.

Set the SELECTOR switch to the CV-WIRE posi-tion.

Adjust the ARC CONTROL knob to desiredCrispness. SOFT for MIG and CRISP forInnershield.

Set the WELDING TERMINALS switch to theREMOTELY CONTROLLED position.

Set the IDLE switch to the HIGH position.

CONNECTION OF LN-15 TO THE VAN-TAGE 500 CUMMINSThese connections instructions apply to both the LN-15 Across-The-Arc and Control Cable models. TheLN-15 has an internal contactor and the electrode isnot energized until the gun trigger is closed. When thegun trigger is closed the wire will begin to feed and thewelding process is started.

Shut the welder off.

For electrode Positive, connect the electrode cableto the "+" terminal of the welder and work cable tothe "-" terminal of the welder. For electrodeNegative, connect the electrode cable "-" terminal ofthe welder and work cable to the "+" terminal of thewelder.

Across The-Arc Model:Attach the single lead from the front of the LN-15to work using the spring clip at the end of thelead. This is a control lead to supply current to thewire feeder motor; it does not carry welding cur-rent.

Control Cable Model:Connect Control Cable between Engine Welderand Feeder.

Set the MODE switch to the "CV-WIRE " position.

Across The-Arc Model:Set the "WELD TERMINALS" switch to "WELDTERMINALS ON"

Set the "WIRE FEEDER VOLTMETER" switch toeither "+" or "-" as required by the electrode polar-ity being used.

Set the "ARC CONTROL" knob to "0" initially andadjust to suit.

Set the "IDLE" switch to the "AUTO IDLE" posi-tion.

Control Cable Model:Set the "WELD TERMINALS" switch to"REMOTELY CONTROLLED"

Set the "WIRE FEEDER VOLTMETER" switch toeither "+" or "-" as required by the electrode polar-ity being used.


Set the "IDLE" switch to the "AUTO IDLE" posi-tion.

WARNING


A-9INSTALLATION

VANTAGE 500 CUMMINS

A-9

CONNECTION OF THE LN-25 TO THEVANTAGE 500 CUMMINSThe LN-25 with or without an internal contactor maybe used with the VANTAGE 500 CUMMINS. See theappropriate connection diagram in the DIAGRAMSsection.NOTE: The LN-25 (K431) Remote Control Moduleand (K432) Remote Cable are not recommended foruse with the VANTAGE 500 CUMMINS.

Shut the welder off. For electrode Positive, connect the electrode cable

from the LN-25 to the + terminal of the welder andwork cable to the - terminal of the welder. For elec-trode Negative, connect the electrode cable from theLN-25 to the - terminal of the welder and workcable to the + terminal of the welder.

Attach the single lead from the front of the LN-25 towork using the spring clip at the end of the lead. Thisis a sense lead to supply current to the wire feedermotor; it does not carry welding current.

Set the SELECTOR switch to the CV-WIRE posi-tion.

Set the WELDING TERMINALS switch to WELDTERMINALS ON

Adjust the ARC CONTROL knob to desired crisp-ness. Generally, welding is best if the ARC CON-TROL is set to SOFT for MIG and CRISP forINNERSHIELD. You may however, want to start inthe middle and adjust (as needed) from there.

Set the IDLE switch to the AUTO position. Whennot welding, the VANTAGE 500 CUMMINS enginewill be at the low idle speed. If you are using an LN-25 with an internal contactor, the electrode is notenergized until the gun trigger is closed.

If you are using an LN-25 without an internal con-tactor, the electrode will be energized when theVANTAGE 500 CUMMINS is started.------------------------------------------------------------------------ When the gun trigger is closed, the current sensing

circuit will cause the wire to begin to feed and thewelding process is started.

CONNECTION OF AN NA-3 AUTOMATICWELDING SYSTEM TO THE VANTAGE 500CUMMINSFor connection diagrams and instructions for connect-ing an NA-3 Welding System to the VANTAGE 500CUMMINS, refer to the NA-3 Welding System instruc-tion manual. The connection diagram for the LN-8 canbe used for connecting the NA-3.

Set the Wire Feeder voltmeter to the proper polarity of theelectrode.

CONNECTION OF MAGNUM SC SPOOLGUN TO THE VANTAGE 500 CUMMINS(SEE SECTION F)

CONNECTION OF PRINCE XL SPOOLGUN TO THE VANTAGE 500 CUMMINSConnection of the Prince XL Spool Gun requires theuse of the K1849-1 Adapter Module.

Shut the Welder off.

For electrode Positive, connect the electrode cableto the "+" terminal of the welder and work cable tothe "-" terminal of the welder. For electrodeNegative, connect the electrode cable "-" terminalof the welder and work cable to the "+" terminal ofthe welder.

Connect the Control Cable of the Spool Gun to theAdapter Module and connect the Control Cable ofthe Adapter Module to the Welder.

Connect the Gas Hose.

Set the MODE switch to the "CV-WIRE " position.

Set the "WELD TERMINALS" switch to "WELDTERMINALS ON".


Set the "IDLE" switch to the "High" position

CAUTION


B-1OPERATION

VANTAGE 500 CUMMINS

B-1

SAFETY INSTRUCTIONSRead and understand this entire section beforeoperating your VANTAGE 500 CUMMINS.

Do not attempt to use this equipment until youhave thoroughly read all operating and mainte-nance manuals supplied with your machine. Theyinclude important safety precautions, detailedengine starting, operating and maintenanceinstructions and parts lists.

ELECTRIC SHOCK can kill. Do not touch electrically live parts

such as output terminals or internalwiring.

Insulate yourself from the work andground.

Always wear dry insulating gloves.------------------------------------------------------------------------

ENGINE EXHAUST can kill. Use in open, well ventilated areas or

vent exhaust outside Do not stack anything near the engine.

------------------------------------------------------------------------MOVING PARTS can injure. Do not operate with doors open or

guards off. Stop engine before servicing. Keep away from moving parts

------------------------------------------------------------------------Only qualified personnel should operate thisequipment.

ADDITIONAL SAFETY PRECAUTIONSAlways operate the welder with the Engine doorclosed and the side panels in place as these pro-vide maximum protection from moving parts andinsure proper cooling air flow.

GENERAL DESCRIPTIONThe VANTAGE 500 CUMMINS is a diesel engine-dri-ven welding power source. The machine uses a brushtype alternating current generator for DC multi-pur-pose welding, for 120/240 VAC single phase and240V three phase auxiliary standby power. The weld-ing control system uses state of the art ChopperTechnology.

RECOMMENDED APPLICATIONSWELDERThe VANTAGE 500 CUMMINS provides excellentconstant current DC welding output for stick (SMAW)and TIG welding. The VANTAGE 500 CUMMINS alsoprovides excellent constant voltage DC welding outputfor MIG (GMAW), Innershield (FCAW), Outershield(FCAW-G) and Metal Core welding. In addition theVANTAGE 500 CUMMINS can be used for ArcGouging with carbons up to 3/8(10mm) in diameter.The VANTAGE 500 CUMMINS is not recommendedfor pipe thawing.

GENERATORThe VANTAGE 500 CUMMINS provides smooth 120/240VAC single phase and 240V three phase output for auxiliarypower and emergency standby power.

WARNING


B-2OPERATIONB-2

ENGINE CONTROLS (Items 1 through 9)1. RUN STOP SWITCH

Toggling the switch to the RUN position energizesthe fuel solenoid for approximately 30 seconds. Theengine must be started within that time or the fuelsolenoid will denergize, and the switch must be tog-gled to reset the timer.

2. START PUSHBUTTONEnergizes the starter motor to crank the engine.With the engine "Run / Stop" switch in the "Run"position, push and hold the Start button to crank theengine; release as the engine starts. Do not presswhile engine is running since this can cause dam-age to the ring gear and/or starter motor

3. HOUR METERThe hour meter displays the total time that theengine has been running. This meter is a useful indi-cator for scheduling preventive maintenance.

4. FUEL LEVEL GAUGEDisplays the level of diesel fuel in the fuel tank.The operator must watch the fuel level closely toprevent running out of fuel and possibly havingto bleed the system.

5. ENGINE TEMPERATURE GAUGEThe gauge displays the engine coolant temperature.

VANTAGE 500 CUMMINS

Figure B.1 Case Front Panel Controls

3

4 5 6 7 8 9 10

11

12

15

14

13

1

2

17

21

16

18

22

23

19

20

CONTROLS AND SETTINGSAll welder and engine controls are located on the case front panel. Refer to Figure B.1 and the explanations that follow.


B-3OPERATIONB-36. OIL PRESSURE GAUGE

The gauge displays the engine oil pressure whenthe engine is running.

7. ENGINE PROTECTION The yellow engine protection light remains off withproper oil pressure and under normal operating tem-peratures. If the light turns on, the engine protectionsystem will stop the engine. Check for proper oil andcoolant levels and add oil and/or coolant if neces-sary. Check for loose or disconnected leads at theoil pressure sender located on the engine. The lightwill remain on when the engine has been shut downdue to low oil pressure or over-temperature condi-tion.NOTE: This engine is equipped with an electronic

governor system. The engine speed rampsup during a warm up period. The completecycle takes approximately 3 minutes. Thisallows the engine cylinder temperature tobuild up slowly before going to full speed.This feature is bypassed if the engine isalready warm. The Engine may produceWhite Smoke for a few minutes at low tem-peratures. Do not apply a load to themachine during the warm up period.

8. BATTERY CHARGING LIGHTThe yellow engine alternator light is off when batterycharging system is functioning normally. If light turnson the alternator or the voltage regulator may not beoperating correctly. The light will remain on whenthe engine is stopped and the run/stop switch is inthe run position.

9. IDLER SWITCHHas two positions as follows:A) In the High position , the engine runs at the

high idle speed controlled by the governor.B) In the Auto / position, the idler

operates as follows:a. When switched from High to Auto or after

starting the engine, the engine will operate atfull speed for approximately 12 seconds andthen go to low idle speed.

b. When the electrode touches the work or poweris drawn for lights or tools (approximately 100Watts minimum) the engine accelerates andoperates at full speed.

c. When welding ceases and the AC power loadis turned off, a fixed time delay of approximate-ly 12 seconds starts.

d. If the welding or AC power load is not restart-ed before the end of the time delay, the idlerreduces the engine speed to low idle speed.

e. The engine will automatically return to highidle speed when the welding load or A.C.power load is reapplied.

Idler Operational exceptionsWhen the WELDING TERMINALS switch is in theRemotely Controlled position the idler will operate asfollows:

a. When the triggering device (Amptrol, Arc StartSwitch, etc.) is pressed the engine will acceler-ate and operate at full speed provided a weld-ing load is applied within approximately 12 sec-onds.

If the triggering device remains pressed but nowelding load is applied within approximately 12seconds the engine may return to low idlespeed.

If the triggering device is released or weldingceases the engine will return to low idle speedafter approximately 12 seconds.

VANTAGE 500 CUMMINS


B-4OPERATIONB-4WELDING CONTROLS (Items 10 through 19)10. OUTPUT CONTROL: The OUTPUT dial is used to preset

the output voltage or current as displayed on the digitalmeters for the four welding modes. When in the CC-STICK,DOWNHILL PIPE or CV-WIRE modes and when a remotecontrol is connected to the 6-Pin or 14-Pin Connector, theauto-sensing circuit automatically switches the OUTPUTCONTROL from control at the welder to the remote control.In the CV-WIRE mode, when the wire feeder control cable isconnected to the 14-Pin Connector, the auto-sensing circuitautomatically makes OUTPUT CONTROL inactive and thewire feeder voltage control active.

When in the TOUCH START TIG mode and when a Amptrolis connected to the 6-Pin Connector, the OUTPUT dial isused to set the maximum current range of the CURRENTCONTROL of the Amptrol.

11. DIGITAL OUTPUT METERS: The digital meters allow the output voltage (CV-WIRE mode)or current (CC-STICK, DOWNHILL PIPE and TIG modes) tobe set prior to welding using the OUTPUT control knob.During welding, the meters display the actual output voltage(VOLTS) and current (AMPS). A memory feature holds thedisplay of both meters on the seven seconds after welding isstopped. This allows the operator to read the actual currentand voltage just prior to when welding was ceased. While thedisplay is being held the left-most decimal point in each dis-play will be flashing. The accuracy of the meters is 3%.

12. WELD MODE SELECTOR SWITCH:(Provides four selectable welding modes)CV-WIREDOWNHILL PIPECC-STICKTOUCH START TIG

13. ARC CONTROL:The ARC CONTROL WIRE/STICK knob is active in the WIREand STICK modes, and has different functions in thesemodes. This control is not active in the TIG mode.CC-STICK mode: In this mode, the ARC CONTROL knobsets the short circuit current (arc-force) during stick welding.Increasing the number from -10(Soft) to +10(Crisp) increasesthe short circuit current and prevents sticking of the electrodeto the plate while welding. This can also increase spatter. It isrecommended that the ARC CONTROL be set to the mini-mum number without electrode sticking. Start with a setting at0.

DOWNHILL PIPE mode: In this mode, the ARC CONTROLknob sets the short circuit current (arc-force) during stickwelding to adjust for a soft or a more forceful digging arc(Crisp). Increasing the number from -10(Soft) to +10(Crisp)increases the short circuit current which results in a moreforceful digging arc. Typically a forceful digging arc is pre-ferred for root and hot passes. A softer arc is preferred for filland cap passes where weld puddle control and deposition(stacking of iron) are key to fast travel speeds. It is recom-mended that the ARC CONTROL be set initially at 0.CV-WIRE mode: In this mode, turning the ARC CONTROLknob from -10(soft) to +10(crisp) changes the arc from softand washed-in to crisp and narrow. It acts as aninductance/pinch control. The proper setting depends on theprocedure and operator preference. Start with a setting of 0.

14. WELDING TERMINALS SWITCHIn the WELD TERMINALS ON position, the output is electri-cally hot all the time. In the REMOTELY CONTROLLED posi-tion, the output is controlled by a wire feeder or amptroldevice, and is electrically off until a remote switch isdepressed.

15. WIRE FEEDER VOLTMETER SWITCH:Matches the polarity of the wire feeder voltmeter to the polari-ty of the electrode.

16. 6 - PIN CONNECTORFor attaching optional remote control equipment. Includesauto-sensing remote control circuit.

17. 14 - PIN CONNECTORFor attaching wire feeder control cables. Includes contactorclosure circuit, auto-sensing remote control circuit, and120VAC and 42VAC power.NOTE: When a wire feeder with a built in welding voltage con-trol is connected to the 14-pin connector, do not connect any-thing to the 6-pin connector.

18. WELD OUTPUT TERMINALS + AND -These 1/2 - 13 studs with flange nuts provide welding con-nection points for the electrode and work cables. For positivepolarity welding the electrode cable connects to the + termi-nal and the work cable connects to this - terminal. For nega-tive polarity welding the work cable connects to the + termi-nal and the electrode cable connects to this - terminal.

AUXILIARY POWER CONTROLS(Items 19-23)19. 120/240 VAC SINGLE PHASE RECEPTACLE

This is a 120/240VAC (14-50R) receptacle that provides240VAC or can be split for 120VAC single phase auxiliarypower. This receptacle has a 50 amp rating. Refer to theAUXILIARY POWER RECEPTACLES section in the installa-tion chapter for further information about this receptacle. Alsorefer to the AUXILIARY POWER OPERATION section later inthis chapter.

VANTAGE 500 CUMMINS


B-5OPERATIONB-520. CIRCUIT BREAKERS

These circuit breakers provide separate overloadcurrent protection for each 120V circuit at the 240Vsingle phase receptacle, each 120V single phasereceptacle, the 240V three phase receptacle, the120VAC in the 14-Pin connector, the 42VAC in the14-Pin connector and battery circuit overload protec-tion.

21. 120VAC SINGLE PHASE RECEPTACLESThese two 120VAC (5-20R) receptacles with GFCIprotection provide 120VAC single phase for auxiliarypower. Each receptacle has a 20 amp total rating.They are designed to protect the user from the haz-ards of ground faults. When the GFCI has trippedthere will be no voltage available from the recepta-cle. Refer to the AUXILIARY POWER RECEPTA-CLES section in the installation chapter for furtherinformation about these receptacles. Also refer tothe AUXILIARY POWER OPERATION section laterin this chapter.

22. GROUND STUDProvides a connection point for connecting themachine case to earth ground. Refer to MACHINEGROUNDING in the Installation chapter for propermachine grounding information.

23. 240VAC THREE PHASE RECEPTACLEThis is a 240VAC (15-50R) receptacle that provides240VAC three phase auxiliary power. This recepta-cle has a 50 amp rating.

ENGINE OPERATIONSTARTING THE ENGINE1. Open the engine compartment door and check that

the fuel shutoff valve is in the open position (leverto be in line with the hose).

2. Check for proper oil level and coolant level. Closeengine compartment door.

3. Remove all plugs connected to the AC powerreceptacles.

4. Set IDLER switch to AUTO.5. Set the RUN/STOP switch to RUN. Observe that

the engine protection and battery charging lightsare on. The engine protection light may turn offafter 5 seconds or remain on until the engine isstarted.

6. Within 30 seconds, press and hold the engineSTART button until the engine starts. If the enginedoes not start within 30 seconds the RUN/STOPswitch must be returned to the STOP position, thenreturn to step 5.

7. Release the engine START button when the enginestarts.

8. Check that the engine protection and battery charg-ing lights are off. Investigate any indicated problem.

NOTE: The engine will go through a 3 minute warm-up cycle if cold. If the engine coolant is stillwarm from recent operation, the engine will goimmediately to high idle and then to low idle ifthe idle switch is in the AUTO position.

COLD WEATHER STARTINGWith a fully charged battery and the proper weight oil,the engine should start satisfactorily even down toabout 0F(-18C). If the engine must be frequentlystarted below 10(-12C), it may be desirable to installthe optional ether start kit (K887-1). Installation andoperating instructions are included in the kits.

STOPPING THE ENGINE1. Switch the RUN/STOP switch to STOP. This turns

off the voltage supplied to the shutdown solenoid. Abackup shutdown can be accomplished by shuttingoff the fuel valve located on the fuel line.

VANTAGE 500 CUMMINS


B-6OPERATIONB-6BREAK-IN PERIODThe engine used to supply power for your welder is a heavyduty, industrial engine. It is designed and built for ruggeduse. It is very normal for any engine to use small quantitiesof oil until the break-in is accomplished. Check the oil leveltwice a day during the break-in period. In general this takes50 to 100 hours of operation.IMPORTANTIN ORDER TO ACCOMPLISH THIS BREAK-IN, THE UNITSHOULD BE SUBJECTED TO HEAVY LOADS, WITHINTHE RATING OF THE MACHINE. AVOID LONG IDLERUNNING PERIODS. TYPICAL FUEL CONSUMPTIONRefer to Table B.2 for typical fuel consumption of the VAN-TAGE 500 CUMMINS Engine for various operating scenar-ios.

WELDER OPERATIONDUTY CYCLEDuty cycle is the percentage of time the load is beingapplied in a 10 minute period. For example, a 60% dutycycle represents 6 minutes of load and 4 minutes of no loadin a 10 minute period.

STICK WELDING MODEThe VANTAGE 500 CUMMINS can be used with a broadrange of DC stick electrodes.The MODE switch provides two stick welding settings as fol-lows:CC-STICK MODEThe CC-STICK position of the MODE switch is designed forhorizontal, vertical-up and over head welding with all typesof electrodes, especially low hydrogen. The OUTPUT CON-TROL knob adjusts the full output range for stick welding.

The ARC CONTROL knob sets the short circuit (arc-force)current during stick welding. Increasing the number from -10(Soft) to +10 (Crisp) increases the short circuit currentand prevents sticking of the electrode to the plate whilewelding. This can also increase spatter. It is recommendedthat the ARC CONTROL be set to the minimum numberwithout electrode sticking. Start with the knob set at 0.DOWNHILL PIPE MODEThis slope controlled setting is intended for out-of-positionand down hill pipe welding where the operator would liketo control the current level by changing the arc length. TheOUTPUT CONTROL knob adjusts the full output range forpipe welding. The ARC CONTROL knob sets the short circuit current (arc-force) during stick welding to adjust for a soft or a moreforceful digging arc (Crisp). Increasing the number from -10(Soft) to +10(Crisp) increases the short circuit currentwhich results in a more forceful digging arc. Typically aforceful digging arc is preferred for root and hot passes. Asofter arc is preferred for fill and cap passes where weldpuddle control and deposition (stacking of iron) are key tofast travel speeds. It is recommended that the ARC CON-TROL be set initially at 0.TOUCH START TIG MODEThe VANTAGE 500 CUMMINS can be used in a wide vari-ety of DC TIG welding applications.The TOUCH START TIG setting of the MODE switch is forDC TIG (Tungsten Inert Gas) welding. To initiate a weld, theOUTPUT CONTROL knob is first set to the desired currentand the tungsten is touched to the work. During the time thetungsten is touching the work there is very little voltage orcurrent and, in general, avoids tungsten contamination.Then, the tungsten is gently lifted off the work in a rockingmotion, which establishes the arc.To stop the arc, simply lift the TIG torch away from the workpiece. When the arc voltage reaches approximately 30 volts,the arc will go out and the machine will automatically resetto the touch start current level. The tungsten may then beretouched to the work piece to restrike the arc. The arc mayalso be started and stopped with an Amptrol or Arc StartSwitch. The ARC CONTROL is not active in the TIG mode.In general the Touch Start feature avoids tungsten contam-ination without the use of a Hi-frequency unit. If the use of ahigh frequency generator is desired, the K930-2 TIG Modulecan be used with the VANTAGE 500 CUMMINS. The set-tings are for reference.The VANTAGE 500 CUMMINS is equipped with therequired R.F. bypass circuitry for the connection of high fre-quency generating equipment.

VANTAGE 500 CUMMINS

Table B.2CUMMINS B3.3 Engine Fuel Consumption

CUMMINS B3.3 Running Time for53HP(40Kw) 25GAL.(94.6L)@1800 RPM (Hours)

Low Idle - .43 Gal./hour 58no load 1400 RPM (1.62 L/hour)

High Idle - .66 Gal./hour 38no load 1890 RPM (2.5 L/hour)

DC CC Weld 1.96 Gal./hour 12.8Output 500 (7.40 L/hour)Amps @ 40 Volts

Auxiliary Power 1.32 Gal./hour 18.912,000 VA ( 5.00 L/hour)

Auxiliary Power 1.84 Gal./hour 13.620,000 VA (6.97 L/hour)


B-7OPERATIONB-7The VANTAGE 500 CUMMINS and any high frequen-cy generating equipment must be properly grounded.See the K930-2 TIG Module operating manuals forcomplete instructions on installation, operation, andmaintenance.When using the TIG Module, the OUTPUT control onthe VANTAGE 500 CUMMINS is used to set the maxi-mum range of the CURRENT CONTROL on the TIGModule or an Amptrol if connected to the TIG Module.

VANTAGE 500 CUMMINS SETTINGS WHEN USINGTHE K930-2 TIG MODULE Set the WELD MODE switch to the Touch Start Tig

20-250 Setting. Set the IDLER switch to the AUTO position. Set the WELDING TERMINALS switch to the

Remotely Controlled position. This will keep thesolid state contactor open and provide a cold elec-trode until the triggering device (Amptrol or Arc StartSwitch) is pressed.

VANTAGE 500 CUMMINS

Table B.3 TYPICAL CURRENT RANGES (1)FOR TUNGSTEN ELECTRODES (2)

DCEN (-) DCEP (+) Approximate Argon Gas Flow Ratel/min (c.f.m.)

TungstenElectrode 1%, 2% 1%, 2% TIG TORCHDiameter Thoriated Thoriated Aluminum Stainless Steel Nozzlemm (in) Tungsten Tungsten Size (4), (5)

.25 (0.010) 2-15 (3) 2-4 (3-8) 2-4 (3-8) #4, #5, #6

.50 (0.020) 5-20 (3) 3-5 (5-10) 3-5 (5-10)1.0 (0.040) 15-80 (3) 3-5 (5-10) 3-5 (5-10)

1.6 (1/16) 70-150 10-20 3-5 (5-10) 4-6 (9-13) #5, #6

2.4 (3/32) 150-250 15-30 6-8 (13-17) 5-7 (11-15) #6, #7, #83.2 (1/8) 250-400 25-40 7-11 (15-23) 5-7 (11-15)

4.0 (5/32) 400-500 40-55 10-12 (21-25) 6-8 (13-17) #8, #104.8 (3/16) 500-750 55-80 11-13 (23-27) 8-10 (18-22)6.4 (1/4) 750-1000 80-125 13-15 (28-32) 11-13 (23-27)

(1) When used with argon gas. The current ranges shown must be reduced when using argon/helium or pure helium shielding gases.(2) Tungsten electrodes are classified as follows by the American Welding Society (AWS):

Pure EWP1% Thoriated EWTh-12% Thoriated EWTh-2

Though not yet recognized by the AWS, Ceriated Tungsten is now widely accepted as a substitute for 2% Thoriated Tungsten in ACand DC applications.

(3) DCEP is not commonly used in these sizes.(4) TIG torch nozzle sizes are in multiples of 1/16ths of an inch:

# 4 = 1/4 in. 6 mm# 5 = 5/16 in. 8 mm# 6 = 3/8 in. 10 mm# 7 = 7/16 in. 11 mm# 8 = 1/2 in. 12.5 mm#10 = 5/8 in. 16 mm

(5) TIG torch nozzles are typically made from alumina ceramic. Special applications may require lava nozzles, which are less prone tobreakage, but cannot withstand high temperatures and high duty cycles.


B-8OPERATIONB-8CV-WIRE MODEConnect 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-WIREposition, permits it to be used with a broad range offlux cored wire (Innershield and Outershield) elec-trodes and solid wires for MIG welding (gas metal arcwelding). Welding can be finely tuned using the ARCCONTROL. Turning the ARC CONTROL clockwisefrom -10(soft) to +10(crisp) changes the arc from softand washed-in to crisp and narrow. It acts as aninductance/pinch control. The proper setting dependson the procedure and operator preference. Start withthe knob set at 0.For any electrodes, including the above recommenda-tions, the procedures should be kept within the ratingof the machine. For additional electrode information,See www.lincolnelectric.com or the appropriateLincoln publication.

ARC GOUGINGFor optimal performance when arc gouging, set theVANTAGE 500 CUMMINS WELD MODE switch tothe CC - STICK position, and the ARC CONTROLto 10.Set the OUTPUT knob to adjust output current to thedesired level for the gouging electrode being usedaccording to the ratings in the following table:

NOTE: If desired the CV mode can be used for ArcGouging.* Maximum current setting is limited to the VANTAGE

500 CUMMINS maximum of 575 Amps.

PARALLELINGWhen paralleling machines in order to combine theiroutputs, all units must be operated in the CC-STICKmode only at the same output settings. To achievethis, turn the WELD MODE switch to the CC-STICKposition. Operation in other modes may produce errat-ic outputs, and large output imbalances between theunits.

AUXILIARY POWER OPERATIONIf a GFCI receptacle is tripped, See the MAINTE-NANCE section for detailed information on testing andresetting the GFCI receptacle.

Start the engine and set the IDLER control switch tothe desired operating mode. Full power is availableregardless of the welding control settings, if no weld-ing current is being drawn.

The auxiliary power of the VANTAGE 500 CUMMINSconsists of two 20 Amp-120VAC single phase (5-20R)GFCI duplex receptacles, one 50 Amp-120/240VACsingle phase (14-50R) receptacle and one 50 Amp240VAC three phase (15-50R) receptacle. The120/240VAC receptacle can be split for single phase120 VAC operation.

The auxiliary power capacity is 12,000 watts of 60 Hz,single phase power or 20,000 watts of 60Hz, threephase power. The auxiliary power capacity rating inwatts is equivalent to volt-amperes at unity power fac-tor. The maximum permissible current of the 240 VACoutput is 50 A. The 240 VAC single phase output canbe split to provide two separate 120 VAC outputs witha maximum permissible current of 50 A per output totwo separate 120 VAC branch circuits. Output voltageis within 10% at all loads up to rated capacity.

NOTE: The two 120V GFCI receptacles and the two120V circuits of the 120/240V receptacle are connect-ed to different phases and cannot be paralleled.

The auxiliary power receptacles should only be usedwith three wire grounded type plugs or approved dou-ble insulated tools with two wire plugs.The current rating of any plug used with the systemmust be at least equal to the current capacity of theassociated receptacle.

SIMULTANEOUS WELDING AND AUXIL-IARY POWER LOADSIt must be noted that the above auxiliary power ratingsare with no welding load.Simultaneous welding and power loads are specifiedin table B.4. The permissible currents shown assumethat current is being drawn from either the 120 VAC or240 VAC supply (not both at the same time).

VANTAGE 500 CUMMINS

ELECTRODE CURRENT RANGEDIAMETER (DC, electrode positive)

(1/8) 30-60 Amps(5/32) 90-150 Amps(3/16) 200-250 Amps(1/4) 300-400 Amps(5/16) 350-450 Amps(3/8) 450-575 Amps*


B-9OPERATIONB-9

VANTAGE 500 CUMMINS

TABLE B.5 VANTAGE 500 CUMMINS Extension Cord LengthRecommendations

Current(Amps)

1515202025303850

Voltage

(Volts)120240120240240240240240

Load(Watts)180036002400480060007200900012000

3060

(9)(18)

40753060

(12)(23)(9)

(18)

7515050

1009075

(23)(46)(15)(30)(27)(23)

12522588

175150120100

(38)(69)(27)(53)(46)(37)(30)

175350138275225175150125

(53)(107)(42)(84)(69)(53)(46)(38)

300600225450250300250200

(91)(183)(69)

(137)(76)(91)(76)(61)

Maximum Allowable Cord Length in ft. (m) for Conductor Size

Conductor size is based on maximum 2.0% voltage drop.

14 AWG 12 AWG 10 AWG 8 AWG 6 AWG 4 AWG

TABLE B.4 VANTAGE 500 CUMMINS SIMULTANEOUS WELDING AND POWER LOADSWELDAMPS

0100200250300400500

1 PHASEWATTS AMPS

12,000 5012,000 5012,000 5012,000 5010,000 425,600 23

0 0

3 PHASEWATTS AMPS

20,000 5017,800 4314,000 3412,000 2910,000 245,600 13

0 0

BOTH 1 AND 3 PHASEWATTS AMPS------ 50------ 50------ 5012,000 ------10,000 ------5,600 ------0 0

PLUS OR OR


C-1ACCESSORIESC-1OPTIONAL FIELD INSTALLED ACCES-SORIESK802N POWER PLUG KIT - Provides four 120V plugs rated at 20amps each and one dual voltage, full KVA plug rated at120/240V, 50 amps. 120V plug may not be compatible with NEMAcommon household receptacles.

K802R POWER PLUG KIT - Provides four 120V plugs rated 15amps each and one dual voltage, full KVA plug rated at120/240V, 50 amps, 120V plug is compatible with NEMA commonhousehold receptacles.

K857 25 ft. (7.5 m) or K857-1 100 ft. (30.4 m) REMOTE CON-TROL - Portable control provides same dial range as the outputcontrol on the welder from a location up to the specified lengthfrom the welder. Has convenient plug for easy connection to thewelder. The VANTAGE 500 CUMMINS is equipped with a 6-pinconnector for connecting the remote control.

K704 ACCESSORY SET - Includes 35 feet (10 m) ofelectrode cable and 30 feet (9 m) of work cable, head-shield, Filter plate, work clamp and electrode holder.Cable is rated at 500 amps, 60% duty cycle.

K2641-2 FOUR WHEELED STEERABLE YARDTRAILERFor in plant and yard towing. Comes standard with a Duo-Hitch, a 2 Ball and Lunette Eye combination hitch.

K2636-1 TRAILER - Two-wheeled trailer with optional fenderand light package. For highway use, consult applicable feder-al, state, and local laws regarding possible additional require-ments. Comes standard with a Duo-Hitch, a 2 Ball andLunette Eye combination hitch, a fender & a light package.Order:K2636-1 TrailerK958-1 Ball HitchK958-2 Lunette Eye Hitch K2639-1 Fender & Light KitK2640-1 Cable Rack

K887-1 ETHER START KIT - Provides maximum cold weath-er starting assistance for frequent starting below 10(-12C).Required Ether tank is not provided with kit.

K1847-1 SPARK ARRESTOR KIT - Easily mounts to stan-dard muffler.

K1816-1 Full KVA Adapter Kit - Plugs into the120/240V NEMA

Vantage 500 Cummins 500

Documents

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copy of safety

isafetyiarc welding

welding generator

youlincoln arc welding

manuals search engine

engine exhaust fumesoutdoors

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