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IM800
July, 2004
Vantage 500 CUMMINS
For use with machines having Code Numbers: 10996
Safety Depends on You
Lincoln arc welding and cutting
equipment is designed and
built with safety in mind.
However, your overall safety
can be increased by proper
installation . . . and thoughtful
operation on your part. DO
NOT INSTALL, OPERATE OR
REPAIR THIS EQUIPMENT
WITHOUT READING THIS
MANUAL AND THE SAFETY
PRECAUTIONS CONTAINED
THROUGHOUT. Most
importantly, think before you
act and be careful.
OPERATOR’S M
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i SAFETY i WARNING CALIFORNIA PROPOSITION 65 WARNINGS For Diesel Engines: diesel engine exhaust and For Gasoline Engines: The engine exhaust from this some of its constituents are known to the State of product contains chemicals known to the State of California to cause cancer, birth defects, and other California to cause cancer, birth defects, or other reproductive harm. reproductive harm. ARC WELDING CAN BE HAZARDOUS. PROTECT YOURSELF AND OTHERS FROM POSSIBLE SERIOUS INJURY OR DEATH. KEEP CHIL
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ii SAFETY ii ARC RAYS can burn. ELECTRIC SHOCK 4 a Use a shield with the proper filter and cover plates to protect your eyes from sparks and can kill. the rays of the arc when welding or observing open arc welding. Headshield 3.a. The electrode and work (or ground) circuits and filter lens should conform to ANSI are electrically “hot” when the welder is on. Z87.1 standards. Do not touch these “hot” parts with your bare skin or wet clothing. Wear dry, hole-free 4.b.Use suitable clothing made from
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iii SAFETY iii CYLINDER may explode WELDING SPARKS can if damaged cause fire or explosion 7.a. Use only compressed gas cylinders containing the correct shielding gas for the process used 6 a Remove fire hazards from the welding area. If and properly operating regulators, designed this is not possible, cover them to prevent the for the gas and pressure used. All hoses, welding sparks from starting a fire. Remember fittings, etc. should be suitable for the application and that welding sparks and h
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iv SAFETY iv 6. Eloigner les matériaux inflammables ou les recouvrir afin de PRÉCAUTIONS DE SÛRETÉ prévenir tout risque d’incendie dû aux étincelles. Pour votre propre protection lire et observer toutes les instructions 7. Quand on ne soude pas, poser la pince à une endroit isolé de et les précautions de sûreté specifiques qui parraissent dans ce la masse. Un court-circuit accidental peut provoquer un manuel aussi bien que les précautions de sûreté générales échauffement et un risque d’incendie.
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v v for selecting a QUALITY product by Lincoln Electric. We want you to take pride in operating this Lincoln Electric Company product ��� Thank You as much pride as we have in bringing this product to you! Please Examine Carton and Equipment For Damage Immediately When this equipment is shipped, title passes to the purchaser upon receipt by the carrier. Consequently, Claims for material damaged in shipment must be made by the purchaser against the transportation company at the time the shipment
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vi vi TABLE OF CONTENTS Page Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Section A Technical Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .A-1 Safety Precautions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .A-2 Location / Ventilat
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vii vii TABLE OF CONTENTS Accessories . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Section C Optional Field Installed Accessories . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .C-1 _________________________________________________________________________________________________ Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
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A-1 INSTALLATION A-1 TECHNICAL SPECIFICATIONS - Vantage 500 CUMMINS (K2272-1) INPUT - DIESEL ENGINE Make /Model Description Speed (RPM) Displacement Starting Capacities System Cummins 4 cylinder High Idle 1900 199 cu. in 12VDC battery Fuel B3.3 56HP (42 kw) Low Idle 1425 (3.3L) & Starter (25 US gal) Diesel Engine @ 1800 RPM Full Load 1800 94.6L Bore x Stroke Oil: (2 US gal) 3.74” x 4.53” 7.5L (95mm x 115mm) Coolant: (2.6 US gal) 11.8L RATED OUTPUT @ 104°F(40°C) - WELDER Duty Cycle W
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A-2 INSTALLATION A-2 Read this entire installation section before you start LOCATION / VENTILATION installation. The welder should be located to provide an unrestricted flow of clean, cool air to the cooling air inlets and to avoid restricting the SAFETY PRECAUTIONS cooling air outlets. Also, locate the welder so that the engine exhaust fumes are properly vented to an outside area. WARNING CAUTION Do not attempt to use this equipment until you have thoroughly read all operating and maintenance m
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A-3 INSTALLATION A-3 LIFTING HIGH TEMPERATURE OPERATION The Vantage lift bale should be used to lift the machine. The At temperatures above 40°C (104°F), output voltage derating Vantage is shipped with the lift bale retracted. Before attempting may be necessary. For maximum output current ratings, derate to lift the Vantage the lift bale must be secured in a raised welder voltage rating 2 volts for every 10°C (21°F) above 40°C position. Secure the lift bale as follows: (104°F). a. Open the engin
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A-4 INSTALLATION A-4 ENGINE COOLANT PRE-OPERATION ENGINE SERVICE READ the engine operating and maintenance instructions supplied with this machine. WARNING WARNING HOT COOLANT can burn skin. • Stop engine while fueling. �Do not remove cap if radiator is hot. • Do not smoke when fueling. • Keep sparks and flame away from tank. ------------------------------------------------------------------------------------- • Do not leave unattended while fueling. The welder is shipped with the engine and r
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A-5 INSTALLATION A-5 The Vantage is shipped with the negative battery cable WELDING TERMINALS disconnected. Before you operate the machine, make sure the The Vantage is equipped with a toggle switch for selecting "hot" Engine Switch is in the OFF position and attach the disconnected welding terminals when in the "WELD TERMINALS ON" position cable securely to the negative (-) battery terminal. or "cold" welding terminals when in the "REMOTELY Remove the insulating cap from the negative battery te
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A-6 INSTALLATION A-6 STANDBY POWER CONNECTIONS REMOTE CONTROL The Vantage is suitable for temporary, standby or emergency power using the engine manufacturer’s recommended OUTPUT maintenance schedule. The Vantage is equipped with a 6-pin and a 14-pin connector. The 6-pin connector is for connecting the K857 or K857-1 Remote The Vantage can be permanently installed as a standby power Control or for TIG welding, the K870 foot Amptrol or the K936-2 unit for 240 volt-3 wire, 50 amp service. Connecti
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A-7 INSTALLATION A-7 2. Take necessary steps to assure load is limited to the capacity 3. Install a 50 amp 120/240 VAC plug (NEMA Type 14-50) to the of the Vantage by installing a 50 amp, 240 VAC double pole double-pole circuit breaker using No. 6, 4 conductor cable of the desired length. (The 50 amp, 120/240 VAC plug is circuit breaker. Maximum rated load for each leg of the 240 available in the optional K802R plug kit.) VAC auxiliary is 50 amps. Loading above the rated output will reduce outpu
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A-8 INSTALLATION A-8 CONNECTION OF AN LN-23P WIRE FEEDER TO CONNECTION OF LINCOLN ELECTRIC THE VANTAGE WIRE FEEDERS � Shut the welder off. � Connect the LN-23P per instructions on the appropriate WARNING connection diagram in the DIAGRAMS section. (NOTE): When connecting an LN-23P to the Vantage, a K350-1 adapter kit must be used. Shut off welder before making any electrical connections. � Set the “WIRE FEEDER VOLTMETER” switch to “-”. ------------------------------------------------------------
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A-9 INSTALLATION A-9 CONNECTION OF THE LN-25 TO THE VANTAGE The LN-25 with or without an internal contactor may be used with CONNECTION OF PRINCE XL SPOOL GUN TO the Vantage. See the appropriate connection diagram in the DIAGRAMS section. THE VANTAGE NOTE: The LN-25 (K431) Remote Control Module and (K432) Remote Cable are not recommended for use with the Vantage. Connection of the Prince XL Spool Gun requires the use of the K1849-1 Adapter Module. � Shut the welder off. � Shut the Welder off. �
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B-1 OPERATION B-1 SAFETY INSTRUCTIONS GENERAL DESCRIPTION Read and understand this entire section before operating The Vantage is a diesel engine-driven welding power source. The machine uses a brush type alternating current generator for DC your Vantage. multi-purpose welding and for 120/240 VAC auxiliary standby power. The welding control system uses state of the art Chopper Technology™. WARNING Do not attempt to use this equipment until you have RECOMMENDED APPLICATIONS thoroughly read all
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B-2 OPERATION B-2 CONTROLS AND SETTINGS All welder and engine controls are located on the case front panel. Refer to Figure B.1 and the explanations that follow. Figure B.1 Case Front Panel Controls 5 6 7 8 9 4 10 3 11 12 13 15 14 20 21 1 2 19 16 17 18 22 3. HOUR METER ENGINE CONTROLS (Items 1 through 9) The hour meter displays the total time that the engine has been 1. RUN STOP SWITCH running. This meter is a useful indicator for scheduling preventive Toggling the switch to the RUN po
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B-3 OPERATION B-3 6. OIL PRESSURE GAUGE c. When welding ceases and the AC power load is turned off, a fixed time delay of approximately 12 seconds The gauge displays the engine oil pressure when the engine is starts. running. d. If the welding or AC power load is not restarted before the end of the time delay, the idler reduces the engine 7. ENGINE PROTECTION speed to low idle speed. The yellow engine protection light remains off with proper oil e. The engine will automatically return to high id
