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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 MANUAL

Copyright© 2004 Lincoln Global Inc.

• World’s Leader in Welding and Cutting Products •

• Sales and Service through Subsidiaries and Distributors Worldwide •
Cleveland, Ohio 44117-1199 USA Tel: 216.481.8100 Fax: 216.486.1751 Web Site: www.lincolnelectric.com
 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 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 you
purchase a copy of “Safety in Welding & Cutting - ANSI Standard Z49.1” from the American Welding Society, PO Box
351040, Miami, Florida 33135 or CSA Standard W117.2-1974 or WTIA (Welding Technology Institute of Australia), PO Box
6165, Silverwater, NSW, 2128. A free copy of “Arc Welding Safety” booklet E205 is available from the Lincoln Electrical
Company, 22801 St Clair Avenue, Cleveland, Ohio 44117-1199.

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

FOR ENGINE 1.h. To avoid scalding, do not remove the

radiator pressure cap when the engine is
powered equipment. hot.

1.a Turn the engine off before troubleshooting and maintenance

work unless the maintenance work requires it to be running.

1.b. Operate engines in open, well ventilated ELECTRIC AND

areas or vent the engine exhaust fumes
outdoors. MAGNETIC FIELDS
may be dangerous
1.c. Do not add fuel near an open flame, welding
arc or when the engine is running. Stop the 2.a.Electric current flowing through any conductor causes
engine and allow it to cool before refuelling localized Electric and Magnetic Fields (EMF). Welding
to prevent spilled fuel from vaporizing on current creates EMF fields around welding cables and
contact with hot engine parts and igniting. welding machines.
Do not spill fuel when filling tank. If fuel is 2.b.EMF fields may interfere with some pacemakers and welders
spilled, wipe it up and do not start engine having a pacemaker should consult their physician before
until fumes have been eliminated. welding.
2.c. Exposure to EMF fields in welding may have other health
1.d.Keep all equipment, safety guards, covers and devices in effects which are now not known.
position and in good repair. Keep hands, hair, clothing and
tools away from V-belts, gears, fans and all other moving 2.d.All welders should use the following procedures in order to
parts when starting, operating or repairing equipment. minimize exposure to EMF fields from the welding circuit:
2.d.1. Route the electrode and work cables together.
1.e.In some cases it may be necessary to remove safety guards Secure them with tape when possible.
to perform required maintenance. Remove guards only when
2.d.2. Never coil the electrode lead around your body.
necessary and replace them when the maintenance
requiring their removal is complete. Always use the greatest 2.d.3. Do not place your body between the electrode
care when working near moving parts. and work cables. If the electrode cable is on your
right side, the work cable should also be on your
right side.
1.f. Do not put your hands near the engine fan.
Do not attempt to override the governor or 2.d.4. Connect the work cable to the workplace as
idler by pushing on the throttle control rods close as possible to the area being welded.
while the engine is running.
2.d.5. Do not work next to welding power source.

1.g.To prevent accidentally starting petrol engines while turning

the engine or welding generator during maintenance work, Mar ‘95
disconnect the spark plug wires, distributor cap or magneto
wire as appropriate.
 ii SAFETY ii

ARC RAYS can burn.

ELECTRIC SHOCK 4a Use a shield with the proper filter and cover
can kill. plates to protect your eyes from sparks and
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 durable flame resistant
gloves to insulate hands. material to protect your skin and that of your helpers from the
arc rays.
3.b. Insulate yourself from work and ground using dry
insulation. Make certain the insulation is large enough to 4.c. Protect other nearby personnel with suitable non flammable
cover your full area of physical contact with work and screening and/or warn them not to watch the arc or expose
ground. themselves to the arc rays or to hot spatter or metal.
In addition to the normal safety precautions, if welding
must be performed under electrically hazardous
conditions (in damp locations or while wearing wet
clothing; on metal structures such as floors, gratings FUMES AND GASES
or scaffolds; when in cramped positions such as
sitting, kneeling or lying, if there is a high risk of can be dangerous
unavoidable or accidental contact with the workpiece 5.a. Welding may produce fumes and gases
or ground) use the following equipment: hazardous to health. Avoid breathing these
fumes and gases. When welding, keep your
• Semiautomatic DC Constant Voltage (Wire) Welder. head out of the fume. Use enough
ventilation and/or exhaust at the arc to
• DC Manual (Stick) Welder.
keep fumes and gases away from the breathing zone. When
• AC Welder with Reduced Voltage Control. welding with electrodes which require special ventilation
such as stainless or hard facing (see instructions on
3.c. In semi-automatic or automatic wire welding, the container or MSDS) or on lead or cadmium plated steel and
electrode, electrode reel, welding head, nozzle or semi- other metals or coatings which produce highly toxic fumes,
automatic welding gun are also electrically “hot”. keep exposure as low as possible and below Threshold
3.d. Always be sure the work cable makes a good electrical Limit values (TLV) using local exhaust or mechanical
connection with the metal being welded. The connection ventilation. In confined spaces or in some circumstances,
should be as close as possible to the area being welded. outdoors, a respirator may be required. Additional
precautions are also required when welding on galvanized
3.e. Ground the work or metal to be welded to a good electrical steel.
(earth) ground.
5.b.Do not weld in locations near chlorinated hydrocarbon
3.f. Maintain the electrode holder, work clamp, welding cable vapors coming from degreasing, cleaning or spraying
and welding machine in good, safe operating condition. operations. The heat and rays of the arc can react with
Replace damaged insulation. solvent vapors to form phosgene, a highly toxic gas, and
3.g. Never dip the electrode holder in water for cooling. other irritating products.

3.h. Never simultaneously touch electrically “hot” parts of 5.c. Shielding gases used for arc welding can displace air and
electrode holders connected to two welders because cause injury or death. Always use enough ventilation,
voltage between the two can be the total of the open circuit especially in confined areas, to ensure breathing air is safe.
voltage of both welders. 5.d.Read and understand the manufacturer’s instructions for this
3.i. When working above floor level, use a safety belt to equipment and the consumables to be used, including the
protect yourself from a fall should you get a shock. material safety data sheet (MSDS) and follow your
employer’s safety practices. MSDS forms are available from
3.j. Also see items 6c and 8. your welding distributor or from the manufacturer.
5.e. Also see Item 1b.

Mar ‘95
 iii SAFETY iii

WELDING SPARKS can CYLINDER may explode

cause fire or explosion if damaged
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 hot materials from
maintained in good condition.
welding can easily go through small cracks and openings to
7.b.Always keep cylinders in an upright position and securely
adjacent areas. Avoid welding near hydraulic lines. Have a fire
chained to an undercarriage or fixed support.
extinguisher readily available.
6.b.Where compressed gases are to be used at the job site, 7.c. Cylinders should be located :
special precautions should be used to prevent hazardous
situations. Refer to AS1674 Parts 1 & 2 “Safety in Welding • Away from areas where they may be struck or subjected to
and Cutting” (ANSI Standard Z49.1) and the operating physical damage.
information for the equipment being used. • A safe distance from arc welding or cutting operations and
6.c. When not welding, make certain no part of the electrode any other source of heat, sparks or flame.
circuit is touching the work or ground. Accidental contact can 7.d.Never allow the electrode, electrode holder, or any other
cause overheating and create a fire hazard. electrically “hot” parts to touch a cylinder.
6.d.Do not heat, cut or weld tanks, drums or containers until the 7.e.Keep your head and face away from the cylinder valve outlet
proper steps have been taken to insure that such procedures when opening the cylinder valve.
will not cause flammable or toxic vapors from substances
inside. These can cause an explosion even though the 7.f. Valve protection caps should always be in place and hand-
vessel has been “cleaned”. For information purchase tight except when the cylinder is in use or connected for use.
“Recommended Safe Practices for the Preparation for
7.g.Read and follow the instructions on compressed gas
Welding and Cutting of Containers and Piping that have held
cylinders, associated equipment, and CGA publication P-I,
Hazardous Substances”, AWS F4.1 from the American
“Precautions for Safe Handling of Compressed Gases in
Welding Society (see address above).
Cylinders”, available from the Compressed Gas Association
6.e.Vent hollow castings or containers before heating, cutting or 1235 Jefferson Davis Highway, Arlington, VA 22202.
welding. They may explode.
6.f. Sparks and spatter are thrown from the welding arc. Wear oil
free protective garments such as leather gloves, heavy shirt,
cuffless trousers, high shoes and a cap over your hair. Wear
ear plugs when welding out of position or in confined places.
Always wear safety glasses with side shields when in a
welding area.
FOR ELECTRICALLY
6.g.Connect the work cable to the work as close to the welding powered equipment.
area as possible. Work cables connected to the building 8.a. Turn off input power using the disconnect
framework or other locations away from the welding area switch at the fuse box before working on the
increase the possibility of the welding current passing equipment.
through lifting chains, crane cables or other alternate circuits.
This can create fire hazards or overheat lifting chains or 8.b.Install equipment in accordance with the National Electrical
cables until they fail. Code, all local codes and the manufacturer’s
recommendations.
6.h. Also see Item 1c.
8.c. Ground the equipment in accordance with the National
Electrical Code and the manufacturer’s recommendations.

Mar ‘95
 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
et les précautions de sûreté specifiques qui parraissent dans ce 7. Quand on ne soude pas, poser la pince à une endroit isolé de
manuel aussi bien que les précautions de sûreté générales la masse. Un court-circuit accidental peut provoquer un
suivantes: échauffement et un risque d’incendie.

Sûreté Pour Soudage A L’Arc 8. S’assurer que la masse est connectée le plus prés possible de
1. Protegez-vous contre la secousse électrique: la zone de travail qu’il est pratique de le faire. Si on place la
masse sur la charpente de la construction ou d’autres endroits
a. Les circuits à l’électrode et à la piéce sont sous tension éloignés de la zone de travail, on augmente le risque de voir
quand la machine à souder est en marche. Eviter toujours passer le courant de soudage par les chaines de levage,
tout contact entre les parties sous tension et la peau nue câbles de grue, ou autres circuits. Cela peut provoquer des
ou les vétements mouillés. Porter des gants secs et sans risques d’incendie ou d’echauffement des chaines et des
trous pour isoler les mains. câbles jusqu’à ce qu’ils se rompent.
b. Faire trés attention de bien s’isoler de la masse quand on
soude dans des endroits humides, ou sur un plancher 9. Assurer une ventilation suffisante dans la zone de soudage.
metallique ou des grilles metalliques, principalement dans Ceci est particuliérement important pour le soudage de tôles
les positions assis ou couché pour lesquelles une grande galvanisées plombées, ou cadmiées ou tout autre métal qui
partie du corps peut être en contact avec la masse. produit des fumeés toxiques.
c. Maintenir le porte-électrode, la pince de masse, le câble de
soudage et la machine à souder en bon et sûr état 10. Ne pas souder en présence de vapeurs de chlore provenant
defonctionnement. d’opérations de dégraissage, nettoyage ou pistolage. La
d.Ne jamais plonger le porte-électrode dans l’eau pour le chaleur ou les rayons de l’arc peuvent réagir avec les vapeurs
refroidir. du solvant pour produire du phosgéne (gas fortement toxique)
e. Ne jamais toucher simultanément les parties sous tension ou autres produits irritants.
des porte-électrodes connectés à deux machines à souder
parce que la tension entre les deux pinces peut être le total 11. Pour obtenir de plus amples renseignements sur la sûreté, voir
de la tension à vide des deux machines. le code “Code for safety in welding and cutting” CSA Standard
f. Si on utilise la machine à souder comme une source de W 117.2-1974.
courant pour soudage semi-automatique, ces precautions
pour le porte-électrode s’applicuent aussi au pistolet de
soudage.

2. Dans le cas de travail au dessus du niveau du sol, se protéger

PRÉCAUTIONS DE SÛRETÉ POUR
contre les chutes dans le cas ou on recoit un choc. Ne jamais LES MACHINES À SOUDER À
enrouler le câble-électrode autour de n’importe quelle partie du
corps. TRANSFORMATEUR ET À
REDRESSEUR
3. Un coup d’arc peut être plus sévère qu’un coup de soliel, donc:

a. Utiliser un bon masque avec un verre filtrant approprié ainsi 1. Relier à la terre le chassis du poste conformement au code de
qu’un verre blanc afin de se protéger les yeux du l’électricité et aux recommendations du fabricant. Le dispositif
rayonnement de l’arc et des projections quand on soude ou de montage ou la piece à souder doit être branché à une
quand on regarde l’arc. bonne mise à la terre.
b. Porter des vêtements convenables afin de protéger la peau
de soudeur et des aides contre le rayonnement de l‘arc. 2. Autant que possible, I’installation et l’entretien du poste seront
c. Protéger l’autre personnel travaillant à proximité au effectués par un électricien qualifié.
soudage à l’aide d’écrans appropriés et non-inflammables.
3. Avant de faires des travaux à l’interieur de poste, la
4. Des gouttes de laitier en fusion sont émises de l’arc de debrancher à l’interrupteur à la boite de fusibles.
soudage. Se protéger avec des vêtements de protection libres
de l’huile, tels que les gants en cuir, chemise épaisse, 4. Garder tous les couvercles et dispositifs de sûreté à leur place.
pantalons sans revers, et chaussures montantes.

5. Toujours porter des lunettes de sécurité dans la zone de

soudage. Utiliser des lunettes avec écrans lateraux dans les
zones où l’on pique le laitier.

Mar. ‘93
 v v
for selecting a QUALITY product by Lincoln Electric. We want you
Thank You to take pride in operating this Lincoln Electric Company product •••
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 is received.

Please record your equipment identification information below for future reference. This information can be found
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 you
have 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.

Read this Operators Manual completely before attempting to use this equipment. Save this manual and keep it
handy 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:

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

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

TABLE OF CONTENTS
Page
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Section A
Technical Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .A-1
Safety Precautions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .A-2
Location / Ventilation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .A-2
Storing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .A-2
Stacking . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .A-2
Angle of Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .A-2
Lifting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .A-3
High Altitude Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .A-3
High Temperature Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .A-3
Towing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .A-3
Pre-Operation Engine Service . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .A-4
Oil . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .A-4
Fuel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .A-4
Fuel Cap . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .A-4
Engine Cooling System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .A-4
Battery Connection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .A-4
Muffler Outlet Pipe . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .A-5
Spark Arrestor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .A-5
Radiator Cap Cover . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .A-5
Air Cleaner Inlet Hood . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .A-5
Welding Terminals . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .A-5
Welding Output Cables . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .A-5
Machine Grounding . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .A-5
Remote Control . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .A-6
Auxiliary Power Receptacles . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .A-6
Standby Power Connections . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .A-6
Connection of Vantage Premises Wiring . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .A-7
Connection of Lincoln Electric Wire Feeders . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .A-8, A-9

Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Section B
Safety Instructions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .B-1
General Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .B-1
Recommended Applications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .B-1
Controls and Settings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .B-2
Engine Controls . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .B-2, B-3
Welder Controls . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .B-4
Auxiliary Power Controls . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .B-4
Engine Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .B-5
Starting the Engine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .B-5
Stopping the Engine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .B-5
Break-In Period . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .B-6
Typical Fuel Consumption . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .B-6
Duty Cycle . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .B-6
Welding Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .B-6
Stick Welding Mode . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .B-6
CC-Stick Mode . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .B-6
Downhill Pipe Mode . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .B-6
Touch Start TIG Mode . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .B-6
Vantage Settings when using K930-2 TIG Module . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .B-7
Typical Current Ranges for Tungsten Electrodes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .B-7
CV-Wire Mode . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .B-8
Arc Gouging . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .B-8
Paralleling . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .B-8
Auxiliary Power Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .B-8
Simultaneous Welding and Auxiliary Power Loads . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .B-8
Simultaneous Welding and Power Loads, Extension Cord Length Recommendations . . . . . . . . . . .B-9

Vantage 500 CUMMINS

 vii vii

TABLE OF CONTENTS

Accessories . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Section C
Optional Field Installed Accessories . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .C-1
_________________________________________________________________________________________________

Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Section D
Safety Precautions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .D-1
Routine and Periodic Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .D-1
Engine Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .D-1
Air Filter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .D-1
Fuel Filters . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .D-2
Cooling System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .D-2
Battery Handling . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .D-2
Charging the Battery . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .D-2
Nameplate / Warning Decal Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .D-3
Welder / Generator Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .D-3
Engine Maintenance Components . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .D-3

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

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

Parts Lists . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .P-472 Series

Vantage 500 CUMMINS

 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 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

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

Welding Range
30 - 575 Amps CC/CV
20 - 250 Amps TIG

Open Circuit Voltage

60 Max OCV @ 1900 RPM

Auxiliary Power (1)

120/240 VAC
12,000 WATTS, 60 Hz.

PHYSICAL DIMENSIONS
Height (2)
Width Depth Weight

42.0 in 31.5 in. 63.1 in. 1605 lbs.

(1066.8 mm) (800.1mm) (1603mm) (728kg)
(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 8.8” (223.5mm) for exhaust.

Vantage 500 CUMMINS

 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
SAFETY PRECAUTIONS clean, cool air to the cooling air inlets and to avoid restricting the
cooling air outlets. Also, locate the welder so that the engine
exhaust fumes are properly vented to an outside area.
WARNING
Do not attempt to use this equipment until you have CAUTION
thoroughly read all operating and maintenance manuals
supplied with your machine. They include important safety
precautions, detailed engine starting, operating and DO NOT MOUNT OVER COMBUSTIBLE SURFACES
maintenance instructions and parts lists. Where there is a combustible surface directly under stationary or
fixed electrical equipment, that surface should be covered with a
ELECTRIC SHOCK can kill. steel plate at least .06”(1.6mm) thick, which should extend not
• Do not touch electrically live parts such as less than 5.90”(150mm) beyond the equipment on all sides.
output terminals or internal wiring. --------------------------------------------------------------------------------------
• Insulate yourself from the work and ground.
• Always wear dry insulating gloves.
STORING
-------------------------------------------------------------------------------------
1. Store the machine in a cool, dry place when it is not in use.
ENGINE EXHAUST can kill. Protect it from dust and dirt. Keep it where it can’t be
• Use in open, well ventilated areas or vent accidentally damaged from construction activities, moving
exhaust outside vehicles, and other hazards.
2. Drain the engine oil and refill with fresh 10W30 oil. Run the
engine for about five minutes to circulate oil to all the parts.
-------------------------------------------------------------------------------------
See the MAINTENANCE section of this manual for details
MOVING PARTS can injure. on changing oil.
• Do not operate with doors open or guards off. 3. Remove the battery, recharge it, and adjust the electrolyte
• Stop engine before servicing. level. Store the battery in a dry, dark place.

• Keep away from moving parts

------------------------------------------------------------------------------------- STACKING
Only qualified personnel should install, use or service this Vantage machines cannot be stacked.
equipment.

ANGLE OF OPERATION
To achieve optimum engine performance the Vantage should be
run in a level position. The maximum angle of operation for the
Cummins engine is 35 degrees in all directions. If the engine is to
be operated at an angle, provisions must be made for checking
and maintaining the oil level at the normal (FULL) oil capacity in
the crankcase. When operating the welder at an angle, the
effective fuel capacity will be slightly less than the specified 25
gallons.

Vantage 500 CUMMINS

 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 engine compartment door.
b. Locate the 2 access holes on the upper middle region
TOWING
of compartment wall just below the lift bale.
The recommended trailer for use with this equipment for road, in-
c. Use the lifting strap to raise the lift bale to the full upright
plant and yard towing by a vehicle (1) is Lincoln’s K953-1. If the
position. This will align the mounting holes on the lift
user adapts a non-Lincoln trailer, he must assume responsibility
bale with the access holes.
that the method of attachment and usage does not result in a
d. Secure the lift bale with 2 thread forming screws. The safety hazard nor damage the welding equipment. Some of the
screws are provided in the shipped loose parts bag. factors to be considered are as follows:
1. Design capacity of trailer vs. weight of Lincoln
WARNING equipment and likely additional attachments.
2. Proper support of, and attachment to, the base of the
welding equipment so that there will be no undue stress
• Lift only with equipment of to the trailer’s framework.
adequate lifting capacity. 3. Proper placement of the equipment on the trailer to
• Be sure machine is stable insure stability side to side and front to back when being
moved and when standing by itself.
when lifting.
• Do not lift this machine 4. Typical conditions of use, such as travel speed,
roughness of surface on which the trailer will be
using lift bail if it is operated, and environmental conditions.
equipped with a heavy 5. Proper preventative maintenance of trailer.
accessory such as
6. Conformance with federal, state and local laws (1) .
trailer or gas cylinder.
(1)
Consult applicable federal, state and local laws regarding
FALLING • Do not lift machine if specific requirements for use on public highways.
EQUIPMENT can lift bail isdamaged.
cause injury. • Do not operate machine VEHICLE MOUNTING
whilesuspended from lift Improperly mounted concentrated loads may cause unstable
vehicle handling and tires or other components to fail.
bail.

------------------------------------------------------------------------------------ WARNING
HIGH ALTITUDE OPERATION
At higher altitudes, output derating may be necessary. For • Only transport this Equipment on serviceable vehicles
maximum rating, derate the welder output 4% for every 300 which are rated and designed for such loads.
meters (984 ft.) above 1500 meters (4920 ft.). For output of 500A • Distribute, balance and secure loads so vehicle is stable
and below, derate the welder output 4% for every 300 meters under conditions of use.
(984 ft.) above 2100 meters (6888 ft.). • Do not exceed maximum rated loads for components such
as suspension, axles and tires.
Contact a Cummins Service Representative for any engine • Mount equipment base to metal bed or frame of vehicle.
adjustments that may be required. • Follow vehicle manufacturer’s instructions.
--------------------------------------------------------------------------------------

Vantage 500 CUMMINS

 A-4 INSTALLATION A-4

PRE-OPERATION ENGINE SERVICE ENGINE COOLANT

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 radiator filled with a
DIESEL FUEL • Wipe up spilled fuel and allow fumes to 50% mixture of ethylene glycol and water. See the
MAINTENANCE section and the engine Operator’s Manual for
can cause fire. clear before starting engine.
more information on coolant.
• Do not overfill tank, fuel expansion may
cause overflow.
DIESEL FUEL ONLY BATTERY CONNECTION
----------------------------------------------------------------------

WARNING
OIL GASES FROM BATTERY can explode.
The Vantage is shipped with the engine crankcase filled with high • Keep sparks, flame and cigarettes away from
quality SAE 10W-30 oil (API class CD or better). Check the oil battery.
level before starting the engine. If it is not up to the full mark on To prevent EXPLOSION when:
the dip stick, add oil as required. Check the oil level every four
hours of running time during the first 35 running hours. Refer to • INSTALLING A NEW BATTERY — disconnect
the engine Operator’s Manual for specific oil recommendations negative cable from old battery first and
and break-in information. The oil change interval is dependent on connect to new battery last.
the quality of the oil and the operating environment. Refer to the • CONNECTING A BATTERY CHARGER — remove battery
engine Operator’s Manual for the proper service and from welder by disconnecting negative cable first, then
maintenance intervals. positive cable and battery clamp. When reinstalling,
connect negative cable last. Keep well ventilated.
• USING A BOOSTER — connect positive lead to battery first
FUEL USE DIESEL FUEL ONLY then connect negative lead to negative battery lead at
Fill the fuel tank with clean, fresh diesel fuel. The capacity of the engine foot.
fuel tank is approx 95 liters. See engine Operator’s Manual for
specific fuel recommendations. Running out of fuel may
require bleeding the fuel injection pump. NOTE: Before BATTERY ACID can burn eyes and skin.
starting the engine, open the fuel shutoff valve (pointer to be in • Wear gloves and eye protection and be careful
line with hose). when working near battery.
• Follow instructions printed on battery.

FUEL CAP
IMPORTANT: To prevent ELECTRICAL DAMAGE WHEN:
Remove the plastic cap covering from the Fuel Tank Filler neck
and install the Fuel Cap. a) Installing new batteries.
b) Using a booster.
Use correct polarity — Negative Ground.

Vantage 500 CUMMINS

 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
Engine Switch is in the OFF position and attach the disconnected The Vantage is equipped with a toggle switch for selecting "hot"
cable securely to the negative (-) battery terminal. welding terminals when in the "WELD TERMINALS ON" position
or "cold" welding terminals when in the "REMOTELY
Remove the insulating cap from the negative battery terminal.
CONTROLLED" position.
Replace and tighten negative battery cable terminal. NOTE: This
machine is furnished with a wet charged battery; if unused for
several months, the battery may require a booster charge. Be
sure to use the correct polarity when charging the battery. WELDING OUTPUT CABLES
With the engine off, route the electrode and work cables thru the
strain relief bracket provided on the front of the base and connect
MUFFLER OUTLET PIPE to the terminals provided. These connections should be checked
periodically and tightened if necessary.
Remove the plastic plug covering the muffler outlet tube. Using
the clamp provided secure the outlet pipe extension to the outlet Listed in Table A.1 are copper cable sizes recommended for the
tube. Install the rain cap on the end of the outlet pipe extension. rated current and duty cycle. Lengths stipulated are the distance
from the welder to work and back to the welder again. Cable sizes
are increased for greater lengths primarily for the purpose of
SPARK ARRESTOR minimizing cable voltage drop.
Table A.1 Combined Length of Electrode and Work Cables.
Some federal, state or local laws may require that petrol or diesel
engines be equipped with exhaust spark arrestors when they are TOTAL COMBINED LENGTH OF
operated in certain locations where unarrested sparks may ELECTRODE AND WORK CABLES
present a fire hazard. The standard muffler included with this
welder does not qualify as a spark arrestor. When required by AMPS Up to 150ft 150-200ft 200-250ft
local regulations, a suitable spark arrestor, must be installed and @100%
properly maintained. Duty Cycle
500 3/0 AWG 3/0 AWG 4/0 AWG

CAUTION MACHINE GROUNDING

Because this portable engine driven welder creates its own
An incorrect arrestor may lead to damage to the engine or power, it is not necessary to connect its frame to an earth ground,
adversely affect performance. unless the machine is connected to premises wiring (home, shop,
-------------------------------------------------------------------------------------- etc.).
To prevent dangerous electric shock, other equipment powered
by this engine driven welder must:
RADIATOR CAP COVER a) be grounded to the frame of the welder using a
Install the radiator cap cover using the two screws which are grounded type plug,
taped to the radiator cap cover. or
b) be double insulated.
AIR CLEANER INLET HOOD When this welder is mounted on a truck or trailer, its frame must
be securely connected to the metal frame of the vehicle. When
Remove the plastic plug covering the air cleaner inlet. Install the this engine driven welder is connected to premises wiring such as
air cleaner inlet hood to the air cleaner. that in a home or shop, its frame must be connected to the system
earth ground. See further connection instructions in the section
entitled “Standby Power Connections” as well as
the article on grounding in the latest National Electrical Code and
the local codes.
In general, if the machine is to be grounded, it should be
connected with a #8 or larger copper wire to a solid earth ground
such as a metal ground stake going into the ground for at least 10
Feet or to the metal framework of a building which has been
effectively grounded. The National Electric Code lists a number of
alternate means of grounding electrical equipment. A machine
grounding stud marked with the symbol is provided on the
front of the welder.

Vantage 500 CUMMINS

 A-6 INSTALLATION A-6

REMOTE CONTROL STANDBY POWER CONNECTIONS

The Vantage is suitable for temporary, standby or emergency
OUTPUT power using the engine manufacturer’s recommended
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. Connections must be
hand Amptrol. When in the CC-STICK, DOWNHILL PIPE, or CV- made by a licensed electrician who can determine how the
WIRE modes and when a remote control is connected to the 6- 120/240 VAC power can be adapted to the particular installation
pin Connector, the auto-sensing circuit automatically switches the and comply with all applicable electrical codes. The following
OUTPUT control from control at the welder to remote control. information can be used as a guide by the electrician for most
applications. Refer to the connection diagram shown in Figure
A.2.
When in TOUCH START TIG mode and when a Amptrol is
connected to the 6-Pin Connector, the OUTPUT dial is used to set
1. Install the double-pole, double-throw switch between the power
the maximum current range of the CURRENT CONTROL of the
company meter and the premises disconnect.
Amptrol.
Switch rating must be the same or greater than the customer’s
premises disconnect and service over current protection.
The 14-pin connector is used to directly connect a wire feeder
control cable. In the CV-WIRE mode, when the control cable is
connected to the 14-pin connector, the auto-sensing circuit
automatically makes the Output Control inactive and the wire
feeder voltage control active

WARNING
NOTE: When a wire feeder with a built in welding voltage
control is connected to the 14-pin connector, do not connect
anything to the 6-pin connector.
--------------------------------------------------------------------------------------

AUXILIARY POWER RECEPTACLES

The auxiliary power capacity of the Vantage is 12,000 watts of 60
Hz, single phase power or 20,000 watts of 60Hz, three phase
power. The auxiliary power capacity rating in watts is equivalent
to volt-amperes at unity power factor. The maximum permissible
current of the 240 VAC single phase output is 50 A. The 240 VAC
output can be split to provide two separate 120 VAC outputs with
a maximum permissible current of 50 A per output to two separate
120 VAC branch circuits. The output voltage is within ± 10% at
all loads up to rated capacity.

The Vantage has two 20 Amp-120VAC single phase (5-20R)

GFCI duplex receptacles and one 50 Amp-120/240 VAC single
phase (14-50R) receptacle and one 240VAC three phase (15-
50R) receptacle. The 120/240 VAC receptacle can be split for
single phase 120 VAC operation. The auxiliary power receptacles
should only be used with three wire grounded type plugs or
approved double insulated tools with two wire plugs. The current
rating of any plug used with the system must be at least equal to
the current capacity of the associated receptacle.

NOTE: The two 120V GFCI receptacles and the two 120 volt
circuits of the 120/240V receptacle are connected to different
phases and can not be paralleled.

Vantage 500 CUMMINS

 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
circuit breaker. Maximum rated load for each leg of the 240 the desired length. (The 50 amp, 120/240 VAC plug is
VAC auxiliary is 50 amps. Loading above the rated output will available in the optional K802R plug kit.)
reduce output voltage below the allowable -10% of rated
voltage which may damage appliances or other motor-driven 4. Plug this cable into the 50 Amp 120/240 Volt receptacle on the
equipment and may result in overheating of the Vantage Vantage case front.
engine.

Figure A.2 Connection of the Vantage to Premises Wiring

240 VOLT

GROUNDED CONDUCTOR
240 Volt POWER
120 VOLT
60 Hz.
3-Wire COMPANY
120 VOLT
Service
METER

NEUTRAL
BUS
N
LOAD

DOUBLE POLE DOUBLE THROW

SWITCH RATING TO BE THE SAME
AS OR GREATER THAN PREMISES
SERVICE OVERCURRENT
PROTECTION.

PREMISES
DISCONNECT AND
SERVICE
GROUND OVERCURRENT
50AMP
240 VOLT PROTECTION

DOUBLE
POLE
50 AMP, 120/240 CIRCUIT
VOLT PLUG 240 VOLT BREAKER
NEMA TYPE 14-50

GND

50 AMP, 120/240 VOLT

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

Vantage 500 CUMMINS

 A-8 INSTALLATION A-8

CONNECTION OF LINCOLN ELECTRIC CONNECTION OF AN LN-23P WIRE FEEDER TO

WIRE FEEDERS THE VANTAGE
• 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
Shut off welder before making any electrical connections. must be used.
------------------------------------------------------------------------------------- • Set the “WIRE FEEDER VOLTMETER” switch to “-”.
CONNECTION OF LN-7, LN-8 OR LN-742 TO THE • Set the “SELECTOR” switch to “CV-WIRE” position.
VANTAGE
• Set the “WELDING TERMINALS” switch to “REMOTELY
• Shut the welder off. CONTROLLED”.

• Connect the LN-7, LN-8 OR LN-742 per instructions on the • Set the ARC CONTROL to desired crispness.
appropriate connection diagram in the DIAGRAMS section.
• Set the “IDLE” switch to the “HIGH” position. If you are using an
• Set the “WIRE FEEDER VOLTMETER” switch to either “+” or “- LN-23P with the K350-1 adapter kit, the electrode is not
” as required by the electrode being used. energized until the gun trigger is closed.

• Set the “SELECTOR” switch to the “CV-WIRE” position.

• Adjust the “ARC CONTROL” knob to desired Crispness. SOFT

for MIG and CRISP for INNERSHIELD.

• Set the “WELDING TERMINALS” switch to the “REMOTELY

CONTROLLED” position.

• Set the “IDLE” switch to the “HIGH” position.

CONNECTION OF LN-15 TO THE VANTAGE

These connections instructions apply to both the LN-15 Across-

The-Arc and Control Cable models. The LN-15 has an internal
contactor and the electrode is not energized until the gun trigger
is closed. When the gun trigger is closed the wire will begin to
feed and the welding process is started.

• Shut the welder off.

• For electrode Positive, connect the electrode cable to the "+"

terminal of the welder and work cable to the "-" terminal of the
welder. For electrode Negative, connect the electrode cable "-"
terminal of the welder and work cable to the "+" terminal of the
welder.

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

Control Cable Model:

Connect Control Cable between Engine Welder and Feeder.

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

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

Control Cable Model:

Set the "WELD TERMINALS" switch to "REMOTELY
CONTROLLED"

• Set the "WIRE FEEDER VOLTMETER" switch to either "+" or

"-" as required by the electrode polarity being used.

• Set the "ARC CONTROL" knob to "0" initially and adjust to suit.

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

Vantage 500 CUMMINS

 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
the Vantage. See the appropriate connection diagram in the CONNECTION OF PRINCE XL SPOOL GUN TO
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.

• For electrode Positive, connect the electrode cable from the LN-
25 to the “+” terminal of the welder and work cable to the “-” • For electrode Positive, connect the electrode cable to the "+"
terminal of the welder. For electrode Negative, connect the terminal of the welder and work cable to the "-" terminal of the
electrode cable from the LN-25 to the “-” terminal of the welder welder. For electrode Negative, connect the electrode cable "-
and work cable to the “+” terminal of the welder. " terminal of the welder and work cable to the "+" terminal of
the welder.
• Attach the single lead from the front of the LN-25 to work using
the spring clip at the end of the lead. This is a sense lead to • Connect the Control Cable of the Spool Gun to the Adapter
supply current to the wire feeder motor; it does not carry welding Module and connect the Control Cable of the Adapter Module
current. to the Welder.
• Set the SELECTOR switch to the “CV-WIRE” position.
• Connect the Gas Hose.
• Set the “WELDING TERMINALS” switch to “WELD
TERMINALS ON” • Set the MODE switch to the "CV-WIRE " position.
• Adjust the “ARC CONTROL” knob to desired crispness.
• Set the "WELD TERMINALS" switch to "WELD TERMINALS
Generally, welding is best if the “ARC CONTROL” is set to
ON".
SOFT for MIG and CRISP for INNERSHIELD. You may
however, want to start in the middle and adjust (as needed)
• Set the "ARC CONTROL" knob to "0" initially and adjust to suit.
from there.
• Set the "IDLE" switch to the "High" position
• Set the “IDLE” switch to the “AUTO” position. When not welding,
the Vantage engine will be at the low idle speed. If you are using
an LN-25 with an internal contactor, the electrode is not
energized until the gun trigger is closed.

CAUTION
If you are using an LN-25 without an internal contactor, the
electrode will be energized when the Vantage is started.
--------------------------------------------------------------------------------------
• When the gun trigger is closed, the current sensing circuit will
cause the wire to begin to feed and the welding process is
started.

CONNECTION OF AN NA-3 AUTOMATIC

WELDING SYSTEM TO THE VANTAGE
For connection diagrams and instructions for connecting an NA-3
Welding System to the Vantage, refer to the NA-3 Welding
System instruction manual. The connection diagram for the LN-8
can be used for connecting the NA-3.

• Set the Wire Feeder Voltage Switch to 115V.

Vantage 500 CUMMINS

 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
WARNING Technology™.

Do not attempt to use this equipment until you have RECOMMENDED APPLICATIONS
thoroughly read all operating and maintenance manuals
supplied with your machine. They include important safety WELDER
precautions, detailed engine starting, operating and
The Vantage provides excellent constant current DC welding
maintenance instructions and parts lists.
output for stick (SMAW) and TIG welding. The Vantage also
ELECTRIC SHOCK can kill. provides excellent constant voltage DC welding output for MIG
• Do not touch electrically live parts such as (GMAW), Innershield (FCAW), Outersield (FCAW-G) and Metal
output terminals or internal wiring. Core welding. In addition the Vantage can be used for Arc
Gouging with carbons up to 3/8”(10mm) in diameter.
• Insulate yourself from the work and ground.
The Vantage is not recommended for pipe thawing.
• Always wear dry insulating gloves.
--------------------------------------------------------------------------------------
ENGINE EXHAUST can kill.
GENERATOR
• Use in open, well ventilated areas or vent
exhaust outside The Vantage provides smooth 120/240 VAC output for auxiliary power
and emergency standby power.
• 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 this equipment.

ADDITIONAL SAFETY PRECAUTIONS

Always operate the welder with the hinged door closed and
the side panels in place as these provide maximum
protection from moving parts and insure proper cooling air
flow.

Vantage 500 CUMMINS

 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

4 5 6 7 8 9 10

11

12
13
15

14 20

21
1

2
19

16

17

18 22

ENGINE CONTROLS (Items 1 through 9) 3. HOUR METER

1. RUN STOP SWITCH The hour meter displays the total time that the engine has been
running. This meter is a useful indicator for scheduling preventive
Toggling the switch to the RUN position energizes the fuel maintenance.
solenoid for approximately 30 seconds. The engine must be
started within that time or the fuel solenoid will deenergize, and
the switch must be toggled to reset the timer. 4. FUEL LEVEL GAUGE
Displays the level of diesel fuel in the fuel tank.
2. START PUSHBUTTON The operator must watch the fuel level closely to prevent
Energizes the starter motor to crank the engine. With the engine running out of fuel and possibly having to bleed the system.
"Run / Stop" switch in the "Run" position, push and hold the Start
button to crank the engine; release as the engine starts. Do not
press while engine is running since this can cause damage to the 5. ENGINE TEMPERATURE GAUGE
ring gear and/or starter motor. The gauge displays the engine coolant temperature.

Vantage 500 CUMMINS

 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 idle speed
pressure and under normal operating temperatures. If the light when the welding load or A.C. power load is reapplied.
turns on, the engine protection system will stop the engine. Check
for proper oil level and add oil if necessary. Check for loose or
disconnected leads at the oil pressure sender located on the Idler Operational exceptions
engine. The light will remain on when the engine has been shut
When the WELDING TERMINALS switch is in the “Remotely
down due to low oil pressure or over-temperature condition.
Controlled” position the idler will operate as follows:
a. When the triggering device (Amptrol, Arc Start Switch, etc.) is
8. BATTERY CHARGING LIGHT pressed the engine will accelerate and operate at full speed
provided a welding load is applied within approximately 12
The yellow engine alternator light is off when battery charging
seconds.
system is functioning normally. If light turns on the alternator or
the voltage regulator may not be operating correctly. The light will • If the triggering device remains pressed but no welding load is
remain on when the engine is stopped and the run/stop switch is applied within approximately 12 seconds the engine may return
in the run position. to low idle speed.
• If the triggering device is released or welding ceases the engine
will return to low idle speed after approximately 12 seconds.
9. IDLER SWITCH
Has 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 at full speed for
approximately 12 seconds and then go to low idle
speed.
b. When the electrode touches the work or power is drawn
for lights or tools (approximately 100 Watts minimum)
the engine accelerates and operates at full speed.

Vantage 500 CUMMINS

 B-4 OPERATION B-4

WELDING CONTROLS (Items 10 through 19) CV-WIRE mode: In this mode, turning the ARC CONTROL knob
from -10(soft) to +10(crisp) changes the arc from soft and
washed-in to crisp and narrow. It acts as an inductance/pinch
10. OUTPUT CONTROL: The OUTPUT dial is used to preset the control. The proper setting depends on the procedure and
output voltage or current as displayed on the digital meters for the operator preference. Start with a setting of 0.
four welding modes. When in the CC-STICK, DOWNHILL PIPE or
CV-WIRE modes and when a remote control is connected to the
6-Pin or 14-Pin Connector, the auto-sensing circuit automatically 14. WELDING TERMINALS SWITCH
switches the OUTPUT CONTROL from control at the welder to In the WELD TERMINALS ON position, the output is electrically
the remote control. In the CV-WIRE mode, when the wire feeder hot all the time. In the REMOTELY CONTROLLED position, the
control cable is connected to the 14-Pin Connector, the auto- output is controlled by a wire feeder or amptrol device, and is
sensing circuit automatically makes OUTPUT CONTROL inactive electrically off until a remote switch is depressed.
and the wire feeder voltage control active.

When in the TOUCH START TIG mode and when a Amptrol is

connected to the 6-Pin Connector, the OUTPUT dial is used to set 15. WIRE FEEDER VOLTMETER SWITCH:
the maximum current range of the CURRENT CONTROL of the Matches the polarity of the wire feeder voltmeter to the polarity of
Amptrol. the electrode.
16. 6 - PIN CONNECTOR
11. DIGITAL OUTPUT METERS: (Optional Kit) For attaching optional remote control equipment. Includes auto-
The digital meters allow the output voltage (CV-WIRE mode) or sensing remote control circuit.
current (CC-STICK, DOWNHILL PIPE and TIG modes) to be set
prior to welding using the OUTPUT control knob. During welding,
17. 14 - PIN CONNECTOR
the meters display the actual output voltage (VOLTS) and current
(AMPS). A memory feature holds the display of both meters on For attaching wire feeder control cables. Includes contactor
the seven seconds after welding is stopped. This allows the closure circuit, auto-sensing remote control circuit, and 120VAC
operator to read the actual current and voltage just prior to when and 42VAC power.
welding was ceased. While the display is being held the left-most
decimal point in each display will be flashing. The accuracy of the
meters is ± 3%. NOTE: When a wire feeder with a built in welding voltage control
is connected to the 14-pin connector, do not connect anything to
the 6-pin connector.
12. WELD MODE SELECTOR SWITCH:
(Provides four selectable welding modes) 18. WELD OUTPUT TERMINALS + AND -
CV-WIRE These 1/2 - 13 studs with flange nuts provide welding connection
DOWNHILL PIPE points for the electrode and work cables. For positive polarity
welding the electrode cable connects to the “+” terminal and the
CC-STICK
work cable connects to this “-” terminal. For negative polarity
TOUCH START TIG welding the work cable connects to the “+” terminal and the
electrode cable connects to this “-” terminal.

13. ARC CONTROL:

The ARC CONTROL WIRE/STICK knob is active in the WIRE AUXILIARY POWER CONTROLS
and STICK modes, and has different functions in these modes. (Items 19-22)
This control is not active in the TIG mode.
CC-STICK mode: In this mode, the ARC CONTROL knob sets the
short circuit current (arc-force) during stick welding. Increasing 19. 120/240 VAC RECEPTACLE
the number from -10(Soft) to +10(Crisp) increases the short This is a 120/240VAC (14-50R) receptacle that provides 240VAC
circuit current and prevents sticking of the electrode to the plate or can be split for 120VAC single phase auxiliary power. This
while welding. This can also increase spatter. It is recommended receptacle has a 50 amp rating. Refer to the AUXILIARY POWER
that the ARC CONTROL be set to the minimum number without RECEPTACLES section in the installation chapter for further
electrode sticking. Start with a setting at 0. information about this receptacle. Also refer to the AUXILIARY
DOWNHILL PIPE mode: In this mode, the ARC CONTROL knob POWER OPERATION section later in this chapter.
sets the short circuit current (arc-force) during stick welding 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 more forceful digging arc.
Typically a forceful digging arc is preferred for root and hot
passes. A softer arc is preferred for fill and cap passes where
weld puddle control and deposition (“stacking” of iron) are key to
fast travel speeds. It is recommended that the ARC CONTROL
be set initially at 0.

Vantage 500 CUMMINS

 B-5 OPERATION B-5

20. CIRCUIT BREAKERS ENGINE OPERATION

These circuit breakers provide separate overload current
protection for each 120V circuit at the 240V receptacle, each STARTING THE ENGINE
120V receptacle, the 120VAC in the 14-Pin connector, the 42VAC
1. Open the engine compartment door and check that the fuel
in the 14-Pin connector and battery circuit overload protection.
shutoff valve located to the left of the fuel filter housing is in the
open position (lever to be in line with the hose).
21. 120VAC RECEPTACLES
2. Check for proper oil level and coolant level. Close engine
These two 120VAC (5-20R) receptacles with ground fault circuit compartment door.
interruption protection provide 120VAC for auxiliary power. Each
3. Remove all plugs connected to the AC power receptacles.
receptacle has a 20 amp total rating. They are designed to protect
the user from the hazards of ground faults. When the GFCI has 4. Set IDLER switch to “AUTO”.
tripped there will be no voltage available from the receptacle. If 5. Set the RUN/STOP switch to “RUN”. Observe that the engine
the GFCI has tripped, any device plugged into the GFCI protection and battery charging lights are on. After 10 seconds,
receptacle should be unplugged and the reason for tripping the the engine protection light will turn off.
GFCI should be determined. If the device is found to be damaged
or defective, it should be repaired or replaced before any further 6. Within 30 seconds, press and hold the engine START button
use. The GFCI should be checked for proper operation prior to until the engine starts.
each use by pressing the test button. The GFCI can be reset by 7. Release the engine START button when the engine starts.
pushing the reset button. Refer to the AUXILIARY POWER
RECEPTACLES section in the installation chapter for further 8. Check that the engine protection and battery charging lights
information about these receptacles. Also refer to the AUXILIARY are off. The engine protection light is on after starting, the
POWER OPERATION section later in this chapter. engine will shutdown in a few seconds. Investigate any
indicated problem.
9. Allow the engine to warm up at low idle speed for several
minutes before applying a load and/or switching to high idle.
22. GROUND STUD Allow a longer warm up time in cold weather.
Provides a connection point for connecting the machine case to
earth ground. Refer to “MACHINE GROUNDING” in the COLD WEATHER STARTING
Installation chapter for proper machine grounding information.
With a fully charged battery and the proper weight oil, the engine
should start satisfactorily even down to about -10°C. If the engine
must be frequently started below -40°C, it may be desirable to
install the optional ether start kit (K887-1). Installation and
operating instructions are included in the kit.

STOPPING THE ENGINE

1. Switch the RUN/STOP switch to “STOP”. This turns off the
voltage supplied to the shutdown solenoid. A backup shutdown
can be accomplished by shutting off the fuel valve located on
the fuel line.

Vantage 500 CUMMINS

 B-6 OPERATION B-6

BREAK-IN PERIOD WELDER OPERATION

The engine used to supply power for your welder is a heavy duty,
DUTY CYCLE
industrial engine. It is designed and built for rugged use. It is very
normal for any engine to use small quantities of oil until the break- Duty Cycle is the ratio of the uninterrupted on-load duration to 10
in is accomplished. Check the oil level twice a day during the minutes. The total time period of one complete on-load and no-
break-in period. In general this takes 50 to 100 hours of load cycle is 10 minutes. For example, in the case of a 60% duty
operation. cycle, load is applied continuously for 6 minutes followed by a no-
IMPORTANT load period of 4 minutes.

IN ORDER TO ACCOMPLISH THIS BREAK-IN, THE UNIT STICK WELDING MODE

SHOULD BE SUBJECTED TO HEAVY LOADS, WITHIN THE
RATING OF THE MACHINE. AVOID LONG IDLE RUNNING The Vantage can be used with a broad range of DC stick
PERIODS. electrodes.
The MODE switch provides two stick welding settings as follows:
ENGINE BREAK-IN
Lincoln Electric selects high quality, heavy-duty industrial engines CC-STICK MODE
for the portable welding machines we offer. While it is normal to
The CC-STICK position of the MODE switch is designed for
see a small amount of crankcase oil consumption during initial
horizontal, vertical-up and over head welding with all types of
operation, excessive oil use, wetstacking (oil or tar like substance
electrodes, especially low hydrogen. The OUTPUT CONTROL
at the exhaust port), or excessive smoke is not normal.
knob adjusts the full output range for stick welding.
Larger machines with a capacity of 350 amperes and higher, The ARC CONTROL knob sets the short circuit (arc-force) current
which are operated at low or no-load conditions for extended during stick welding. Increasing the number from -10 (Soft) to +10
periods of time are especially susceptible to the conditions (Crisp) increases the short circuit current and prevents sticking of
described above. To accomplish successful engine break-in, the electrode to the plate while welding. This can also increase
most diesel-powered equipment needs only to be run at a spatter. It is recommended that the ARC CONTROL be set to the
reasonably heavy load within the rating of the welder for some minimum number without electrode sticking. Start with the knob
period of time during the engine’s early life. However, if the set at 0.
welder is subjected to extensive light loading, occasional
moderate to heavy loading of the engine may sometimes be
necessary. Caution must be observed in correctly loading a DOWNHILL PIPE MODE
diesel/generator unit.
This slope controlled setting is intended for “out-of-position” and
1. Connect the welder output studs to a suitable “down hill” pipe welding where the operator would like to control
resistive load bank. Note that any attempt to short the current level by changing the arc length. The OUTPUT
the output studs by connecting the welding leads CONTROL knob adjusts the full output range for pipe welding.
together, direct shorting of the output studs, or
connecting the output leads to a length of steel will
result in catastrophic damage to the generator and
voids the warranty. The ARC CONTROL knob sets the short circuit current (arc-force)
2. Set the welder controls for an output current and during stick welding to adjust for a soft or a more forceful digging
voltage within the welder rating and duty cycle. arc (Crisp). Increasing the number from -10 (Soft) to +10 (Crisp)
Note that any attempt to exceed the welder rating or increases the short circuit current which results in a more forceful
duty cycle for any period of time will result in digging arc. Typically a forceful digging arc is preferred for root
catastrophic damage to the generator and voids the and hot passes. A softer arc is preferred for fill and cap passes
warranty. where weld puddle control and deposition (“stacking” of iron) are
3. Periodically shut off the engine and check the key to fast travel speeds. It is recommended that the ARC
crankcase oil level. CONTROL be set initially at 0.

TYPICAL FUEL CONSUMPTION

TOUCH START TIG MODE
Refer to Table B.2 for typical fuel consumption of the Vantage’
Engine for various operating scenarios. The Vantage can be used in a wide variety of DC TIG welding
applications.
Table B.2
Cummins B3.3 Engine Fuel Consumption The TOUCH START TIG setting of the MODE switch is for DC
TIG (Tungsten Inert Gas) welding. To initiate a weld, the
Cummins B3.3 Running Time for
OUTPUT CONTROL knob is first set to the desired current and
56HP(42Kw) 25GAL.(94.6L)
the tungsten is touched to the work. During the time the tungsten
@1800 RPM (Hours)
is touching the work there is very little voltage or current and, in
general, avoids tungsten contamination. Then, the tungsten is
Low Idle - .45 Gal./hour 55.6
gently lifted off the work in a rocking motion, which establishes the
no load 1425 RPM (1.7 Lts./hour)
arc.
High Idle - .81 Gal./hour 30.9 To stop the arc, simply lift the TIG torch away from the work piece.
no load 1900 RPM (3.1 Lts./hour) When the arc voltage reaches approximately 30 volts, the arc will
go out and the machine will automatically reset to the touch start
DC CC Weld 1.88 Gal./hour 13.3 current level. The tungsten may then be retouched to the work
Output 500 (7.1 Lts./hour) piece to restrike the arc. The arc may also be started and stopped
Amps @ 40 Volts with an Amptrol or Arc Start Switch.
The ARC CONTROL is not active in the TIG mode.
Auxiliary Power 1.23 Gal./hour 20.3
12,000 VA (4.7 Lts./hour)

Vantage 500 CUMMINS

 B-7 OPERATION B-7

n general the ‘Touch Start’ feature avoids tungsten contamination VANTAGE SETTINGS WHEN USING THE K930-2
without the use of a Hi-frequency unit. If the use of a high TIG MODULE
frequency generator is desired, the K930-2 TIG Module can be
used with the Vantage. The settings are for reference. • Set the WELD MODE switch to the “Touch Start Tig 20-250
Setting”.
The Vantage is equipped with the required R.F. bypass circuitry
for the connection of high frequency generating equipment. • Set the IDLER switch to the “AUTO” position.
The Vantage and any high frequency generating equipment must • Set the WELDING TERMINALS switch to the “Remotely
be properly grounded. See the K930-2 TIG Module operating Controlled” position. This will keep the solid state contactor open
manuals for complete instructions on installation, operation, and and provide a “cold” electrode until the triggering device
maintenance. (Amptrol or Arc Start Switch) is pressed.
When using the TIG Module, the OUTPUT control on the Vantage
is used to set the maximum range of the CURRENT CONTROL
on the TIG Module or an Amptrol if connected to the TIG Module.

Table B.3 TYPICAL CURRENT RANGES (1)

FOR TUNGSTEN ELECTRODES (2)

DCEN (-) DCEP (+) Approximate Argon Gas Flow Rate
l/min (c.f.m.)
Tungsten
Electrode 1%, 2% 1%, 2% TIG TORCH
Diameter Thoriated Thoriated Aluminium Stainless Steel Nozzle
mm (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, #8
3.2 (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, #10
4.8 (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 EWP
1% Thoriated EWTh-1
2% Thoriated EWTh-2
Though not yet recognized by the AWS, Ceriated Tungsten is now widely accepted as a substitute for 2% Thoriated Tungsten in
AC and 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 to
breakage, but cannot withstand high temperatures and high duty cycles.

Vantage 500 CUMMINS

 B-8 OPERATION B-8

CV-WIRE MODE NOTE: The two 120V GFCI receptacles and the two 120V circuits
of the 120/240V receptacle are connected to different phases and
Connect a wire feeder to the Vantage and set welder controls cannot be paralleled.
according to the instructions listed earlier in this section.
The auxiliary power receptacles should only be used with three
The Vantage in the ”CV-WIRE” position, permits it to be used with wire grounded type plugs or approved double insulated tools with
a broad range of flux cored wire (Innershield and Outershield) two wire plugs.
electrodes and solid wires for MIG welding (gas metal arc
welding). Welding can be finely tuned using the “ARC The current rating of any plug used with the system must be at
CONTROL”. Turning the ARC CONTROL clockwise from - least equal to the current capacity of the associated receptacle.
10(soft) to +10(crisp) changes the arc from soft and washed-in to
crisp and narrow. It acts as an inductance/pinch control. The
proper setting depends on the procedure and operator SIMULTANEOUS WELDING AND AUXILIARY
preference. Start with the knob set at 0. POWER LOADS
For any electrodes, including the above recommendations, the
It must be noted that the above auxiliary power ratings are with
procedures should be kept within the rating of the machine. For
no welding load. Simultaneous welding and power loads are
additional electrode information, See www.lincolnelectric.com or
specified in table B.4. The permissible currents shown assume
the appropriate Lincoln publication.
that current is being drawn from either the 120 VAC or 240 VAC
supply (not both at the same time).
ARC GOUGING
For optimal performance when arc gouging, set the Vantage
“WELD MODE” switch to the “CC - STICK” position, and the
“ARC CONTROL” to 10.
Set the “OUTPUT” knob to adjust output current to the desired
level for the gouging electrode being used according to the
ratings in the following table:
* Maximum current setting is limited to the Vantage maximum of
575 Amps.

ELECTRODE CURRENT RANGE

DIAMETER (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*

PARALLELING
When paralleling machines in order to combine their outputs, all
units must be operated in the CC-STICK mode only at the same
output settings. To achieve this, turn the WELD MODE switch to
the CC-STICK position. Operation in other modes may produce
erratic outputs, and large output imbalances between the units.

AUXILIARY POWER OPERATION

Start the engine and set the IDLER control switch to the desired
operating mode. Full power is available regardless of the welding
control settings, if no welding current is being drawn.

The auxiliary power of the Vantage consists of two 20 Amp-

120VAC (5-20R) GFCI duplex receptacles and one 50 Amp-
120/240 VAC (14-50R) receptacle. The 120/240VAC receptacle
can be split for single phase 120 VAC operation.

The auxiliary power capacity is 12,000 watts of 60 Hz, single

phase power. The auxiliary power capacity rating in watts is
equivalent to volt-amperes at unity power factor. The maximum
permissible current of the 240 VAC output is 50 A. The 240 VAC
output can be split to provide two separate 120 VAC outputs with
a maximum permissible current of 50 A per output to two separate
120 VAC branch circuits. Output voltage is within ± 10% at all
loads up to rated capacity.

Vantage 500 CUMMINS

 B-9 OPERATION B-9

TABLE B.4 Vantage Simultaneous Welding and Power Loads

Welding Output Permissible Power Watts Permissible Auxiliary

at NEMA Voltage (Unity Power Factor) Current in Amperes
(V=.04I + 20) @ 120VAC * +/- 10% @ 240 VAC +/- 10%

0-250A/30V 12,000 100** 50

350A/34V 8,100 68** 34
400A/36V 5,600 46 23
450A/38V 2,900 24 12
500A/40V 0 0 0

* Each duplex receptacle is limited to 20 amps.

** Not to exceed 50A per 120 VAC branch circuit when splitting the 240 VAC output.

TABLE B.5 Vantage Extension Cord Length Recommendations

Current Voltage Load Maximum Allowable Cord Length in ft. (m) for Conductor Size
(Amps) (Volts) (Watts) 14 AWG 12 AWG 10 AWG 8 AWG 6 AWG 4 AWG
15 120 1800 30 (9) 40 (12) 75 (23) 125 (38) 175 (53) 300 (91)
15 240 3600 60 (18) 75 (23) 150 (46) 225 (69) 350 (107) 600 (183)
20 120 2400 30 (9) 50 (15) 88 (27) 138 (42) 225 (69)
20 240 4800 60 (18) 100 (30) 175 (53) 275 (84) 450 (137)
25 240 6000 90 (27) 150 (46) 225 (69) 250 (76)
30 240 7200 75 (23) 120 (37) 175 (53) 300 (91)
38 240 9000 100 (30) 150 (46) 250 (76)
50 240 12000 125 (38) 200 (61)
Conductor size is based on maximum 2.0% voltage drop.

Vantage 500 CUMMINS

 C-1 ACCESSORIES C-1

OPTIONAL FIELD INSTALLED ACCESSORIES

K802N POWER PLUG KIT - Provides four 120V plugs rated at 20 amps each
and one dual voltage, full KVA plug rated at 120/240V, 50 amps. 120V plug may
not be compatible with NEMA common household receptacles.

K802-R POWER PLUG KIT - Provides four 120V plugs rated 15 amps each
and one dual voltage, full KVA plug rated at 120/240V, 50 amps, 120V plug is
compatible with NEMA common household receptacles.

K857 25 ft. (7.5 m) or K857-1 100 ft. (30.4 m) REMOTE CONTROL -

Portable control provides same dial range as the output control on the welder
from a location up to the specified length from the welder. Has convenient
plug for easy connection to the welder. The Vantage 500 CUMMINS is
equipped with a 6-pin connector for connecting the remote control.

K704 ACCESSORY SET - Includes 35 feet (10 m) of electrode

cable and 30 feet (9 m) of work cable, headshield, work clamp
and electrode holder. Cable is rated at 500 amps, 60% duty cycle.

K767-2 FOUR WHEELED STEERABLE YARD TRAILER

For in plant and yard towing.

K953-1 TRAILER - Two-wheeled trailer with optional fender and light

package. For highway use, consult applicable federal, state, and local laws
regarding possible additional requirements. There is a choice of 2 hitches,
a fender & a light package. Order:
K953-1 Trailer
K958-1 Ball Hitch
K958-2 Lunette Eye Hitch
K959-1 Fender & Light Kit
K965-1 Cable Rack

K887-1 ETHER START KIT - Provides maximum cold weather starting

assistance for frequent starting below 25 oF(-4 oC). Required Ether tank is
not provided with kit. (Cannot be used with K1858-1 Service Indicator Kit
at the same time.)

K1847-1 SPARK ARRESTOR KIT - Easily mounts to standard muffler.

K949-2 OIL DRAIN KIT - Includes ball valve, hose and clamp.

K1816-1 Full KVA Adapter Kit - Plugs into the 120/240V NEMA
14-50R receptacle on the case front (which accepts 4-prong
plugs) and converts it to a NEMA 6-50R receptacle (which
accepts 3-prong plugs) for connection to Lincoln Equipment with
a NEMA 6-50P plug,

K1858-1 Service Indicator Kit - Provides a GO / NO-GO visual indication of

air cleaner element useful service life. Filter service based on restriction
readings allows the longest life possible from the filter and best engine
protection. (Cannot be used with K887-1 Ether Start Kit at the same time.)

WARNING
Pipe Thawing with an arc welder can cause fire, explosion,
damage to electric wiring or to the arc welder if done
improperly. The use of an arc welder for pipe thawing is not
approved by the CSA, nor is it recommended or supported
by Lincoln Electric.

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

Vantage 500 CUMMINS

 D-1 MAINTENANCE D-1

SAFETY PRECAUTIONS ENGINE MAINTENANCE

Refer to the “Periodic Checks” section of the Engine Operator’s
WARNING Manual for the recommended maintenance schedule of the
following:
a) Engine Oil and Filter
• Have a qualified technician do the maintenance and
b) Air Cleaner
troubleshooting work.
c) Fuel Filter - and Delivery System
• Turn the engine off before working inside the machine. d) Alternator Belt
e) Battery
• Remove guards only when necessary and replace them when
f) Cooling System
the maintenance requiring their removal is complete.
• Always use the greatest care when working near moving parts. Refer to Table D.1 at the end of this section for various engine
-------------------------------------------------------------------------------------- maintenance components.

Read the Safety Precautions in front of this manual and the

engine instruction manual before working on this machine.
AIR FILTER
Keep all equipment safety guards, covers and devices in position
and in good repair. Keep hands, hair, clothing and tools away
from V-belts, gears, fans and all other moving parts when starting,
operating or repairing the equipment.
CAUTION
EXCESSIVE AIR FILTER RESTRICTION WILL RESULT IN
REDUCED ENGINE LIFE.
ROUTINE AND PERIODIC --------------------------------------------------------------------------------------
MAINTENANCE The air filter element is a dry cartridge type. It can be cleaned and
reused; however, damaged elements should not be reused. Stop
engine after 100 hours of running time and clean filter element ,
DAILY replace the filter if necessary. Service air cleaner regularly
according to Engine Operator’s Manual.
• Check the crankcase oil level .
1. Locate the air filter canister located behind the engine door on
• Refill the fuel tank to minimize moisture condensation in the
the top of the engine.
tank.
2. Remove air filter element.
• Open the water drain valve located on the bottom of the water
separator element 1 or 2 turns and allow to drain into a 3. Remove loose dirt from element with compressed air or water
container suitable for diesel fuel for 2 to 3 seconds. Repeat the hose directed from inside out.
above drainage procedure until diesel fuel is detected in the Compressed Air: 100 psi maximum with nozzles at least
container. one inch away from element.
• Check coolant level. Water Hose: 40 psi maximum without nozzle.
4. Soak element in a mild detergent solution for 15 minutes. Do
not soak more than 24 hours. Swish element around in the
WEEKLY solution to help remove dirt.
Blow out the machine with low pressure air periodically. In 5. Rinse elements from inside out with a gentle stream of water
particularly dirty locations, this may be required once a week. (less than 40 psi) to remove all suds and dirt.
6. Dry element before reuse with warm air at less than 160°F
(71°C). Do not use a light bulb to dry the element.

Vantage 500 CUMMINS

 D-2 MAINTENANCE D-2

7. Inspect for holes and tears by looking through the element BATTERY HANDLING
toward a bright light. Check for damaged gaskets or dented
metal parts. Do not reuse damaged elements. Protect element GASES FROM BATTERY can explode.
from dust and damage during drying and storage. • Keep sparks, flame and cigarettes away from
8. Reinstall air filter element. battery.

After six cleanings replace air filter. A cleaned filter will have
approximately 70% of the life of a new filter element. A restricted To prevent EXPLOSION when:
filter element may not appear excessively dirty.
• INSTALLING A NEW BATTERY - disconnect
negative cable from old battery first and
connect to new battery last.
FUEL FILTERS

• CONNECTING A BATTERY CHARGER -

WARNING Remove battery from welder by disconnecting
negative cable first, then positive cable and
When working on the fuel system battery clamp. When reinstalling, connect
negative cable last. Keep well ventilated.
• Keep naked lights away, do not smoke !
• Do not spill fuel ! • USING A BOOSTER - connect positive lead to
battery first then connect negative lead to
engine foot.

--------------------------------------------------------------------------------------
BATTERY ACID CAN BURN EYES AND SKIN.
The Vantage is equipped with a Fuel Filter located after the lift
pump and before fuel injectors.The procedure for changing the • Wear gloves and eye protection and be careful
filter is as follows. when working near battery. Follow instructions
printed on battery.
1. Close the fuel shutoff valve.
--------------------------------------------------------------------------------------
2. Clean the area around the fuel filter head. Remove the filter.
Clean the gasket surface of the filter head and replace the o- PREVENTING ELECTRICAL DAMAGE
ring. 1. When replacing, jumping, or otherwise connecting the battery
3. Fill the clean filter with clean fuel, and lubricate the o-ring seal to the battery cables, the proper polarity must be observed.
with clean lubricating oil. Failure to observe the proper polarity could result in damage to
the charging circuit. The positive (+) battery cable has a red
4. Install the filter as specified by the filter manufacturer. terminal cover.
2. If the battery requires charging from an external charger,
disconnect the negative battery cable first and then the positive
WARNING battery cable before attaching the charger leads. Failure to do
so can result in damage to the internal charger components.
When reconnecting the cables, connect the positive cable first
Mechanical overtightening will distort the threads, filter and the negative cable last.
element seal or filter can.
--------------------------------------------------------------------------------------
PREVENTING BATTERY DISCHARGE
COOLING SYSTEM Turn the RUN/STOP switch to stop when engine is not running.
The Vantage is equipped with a pressure radiator. Keep the
radiator cap tight to prevent loss of coolant. Clean and flush the
coolant system periodically to prevent clogging the passage and PREVENTING BATTERY BUCKLING
over-heating the engine. When antifreeze is needed, always use Tighten nuts on battery clamp until snug.
the permanent type.

Vantage 500 CUMMINS

 D-3 MAINTENANCE D-3

CHARGING THE BATTERY WELDER / GENERATOR

When you charge, jump, replace, or otherwise connect battery MAINTENANCE
cables to the battery, be sure the polarity is correct. Improper
polarity can damage the charging circuit. The Vantage positive (+)
battery terminal has a red terminal cover.
STORAGE
If you need to charge the battery with an external charger,
disconnect the negative cable first, then the positive cable before Store the Vantage in a clean, dry protected areas.
you attach the charger leads. after the battery is charged,
reconnect the positive battery cable first and the negative cable
last. Failure to do so can result in damage to the internal charger CLEANING
components. Blow out the generator and controls periodically with low pressure
Follow the instructions of the battery charger manufacturer for air. do this at least once a week in particularly dirty areas.
proper charger settings and charging time.

BRUSH REMOVAL AND REPLACEMENT

NAMEPLATES / WARNING DECALS It is normal for the brushes and slip rings to wear and darken
MAINTENANCE slightly. Inspect the brushes when a generator overhaul is
necessary.
Whenever routine maintenance is performed on this machine - or
at least yearly - inspect all nameplates and labels for legibility.
Replace those which are no longer clear. Refer to the parts list for
the replacement item number.
WARNING
Do not attempt to polish slip rings while the engine is
running.
--------------------------------------------------------------------------------------

Table D.1 Engine Maintenance Components

ITEM MAKE PART NUMBER SERVICE INTERVAL

Air Cleaner Element Donaldson P181052 Replace every 200 hours. (Replace more
AC A302C often when used in dusty and / or
Fleetguard AF437K high ambient temperature conditions)

Oil Filer Cummins C6002112110 Replace every 750 hours or 12 months,

Fleetguard LF3855 whichever is less.

Fan Belt Cummins C0412021748 Inspect every 1000 hours or 12 months,

whichever is less.

Fuel Strainer Cummins 3826094 Inspect and replace monthly, as

Fleetguard FF5079 required. Replace annually.

Fuel Filter / Cummins C6003112130 Replace every 500 hours or 6 months,

Water Separator Fleetguard FS19594 whichever is less.
.
Battery ----- BCI GROUP 34 Inspect every 500 hours

Engine Oil Change See Manual ----- Change every 750 hours or 3 months,
whichever is less. Check daily.

Vantage 500 CUMMINS

 E-1 TROUBLESHOOTING E-1

HOW TO USE TROUBLESHOOTING GUIDE

WARNING
Service and Repair should only be performed by Lincoln Electric Factory Trained Personnel. Unauthorized repairs
performed on this equipment may result in danger to the technician and machine operator and will invalidate your factory
warranty. For your safety and to avoid Electrical Shock, please observe all safety notes and precautions detailed
throughout this manual.
_______________________________________________________________________________________________

This Troubleshooting Guide is provided to help you locate and Step 3. RECOMMENDED COURSE OF ACTION
repair possible machine malfunctions. Simply follow the three-
This column provides a course of action for the Possible Cause,
step procedure listed below.
generally it states to contact your local Lincoln Authorized Field
Step 1. LOCATE PROBLEM (SYMPTOM). Service Facility.
Look under the column labeled “PROBLEM (SYMPTOMS)”. This If you do not understand or are unable to perform the
column describes possible symptoms that the machine may Recommended Course of Action safely, contact your local Lincoln
exhibit. Find the listing that best describes the symptom that the Authorized Field Service Facility.
machine is exhibiting.

Step 2. POSSIBLE CAUSE.

The second column labeled “POSSIBLE CAUSE” lists the
obvious external possibilities that may contribute to the machine
symptom.

CAUTION
If for any reason you do not understand the test procedures or are unable to perform the tests/repairs safely, contact your Local Lincoln
Authorized Field Service Facility for technical troubleshooting assistance before you proceed.

Vantage 500 CUMMINS

 E-2 TROUBLESHOOTING E-2
Observe all Safety Guidelines detailed throughout this manual

PROBLEMS POSSIBLE AREAS OF RECOMMENDED

(SYMPTOMS) MISADJUSTMENT(S) COURSE OF ACTION
ENGINE PROBLEMS
Major Physical or Electrical Damage is 1. Contact your Local Lincoln Authorized
Evident. Field Service Facility.
Engine will not crank 1. Battery low.
2. Loose battery cable connections which
may need Inspected, cleaned or tighten.
3. Faulty wiring in engine starting circuit.
4. Faulty engine starter. Contact authorized
local Engine Service Shop.
Engine will crank but not start. 1. Out of fuel.
2. Fuel shut off valve is in the off position
make sure the valve lever is in a vertical
direction.
3. Engine shut down solenoid not pulling in.
4. On/Off switch on for more than 30 sec.
before starting, the On/Off switch will
need to be switch off and turned back on.
5. Fuel Filters dirty/clogged, main filter
element and/or Inline Fuel Filter may
need to be replaced.
6. High water temperature or low oil
pressure. (engine protection light lit) If all recommended possible areas
of misadjustment have been
checked and the problem persists,
Engine shuts down shortly after starting. 1. Low oil pressure (engine protection light
Contact your local Lincoln
lit). Check oil level (Consult engine
Authorized Field Service Facility.
service dealer).
2. High water temperature. Check engine
cooling system. (engine protection light
lit).
3. Faulty oil pressure switch.
4. Faulty water temperature switch. Contact
authorized local Engine Service Shop.

Engine shuts down while under a load. 1. High water temperature.

Engine runs rough. 1. Dirty fuel or air filters may need

cleaned/replaced.
2. Water in fuel.

Engine will not shut off. 1. Fuel Shutdown solenoid not functioning
properly / linkage binding.

CAUTION
ºIf for any reason you do not understand the test procedures or are unable to perform the tests/repairs safely, contact your Local Lincoln
Authorized Field Service Facility for technical troubleshooting assistance before you proceed.
______________________________________________________________________________________________________________

Vantage 500 CUMMINS

 E-3 TROUBLESHOOTING E-3

PROBLEMS POSSIBLE AREAS OF RECOMMENDED

(SYMPTOMS) MISADJUSTMENT(S) COURSE OF ACTION
FUNCTION PROBLEMS
Battery does not stay charged. 1. Faulty battery .
2. Faulty engine alternator.
3. Loose or broken lead in charging circuit.
4. Loose fan belt may need tightening.

Engine will not idle down to low 1. Idler switch in HIGH idle position, make
speed. sure switch is set to AUTO.
2. External load on welder or auxiliary
power.
3. Mechanical problem in idler solenoid
linkage.
4. Faulty wiring in solenoid circuit.
5. No or low voltage @ idle solenoid
6. Faulty idler solenoid.
7. Faulty, Weld Control PCB, Pull Coil
/Battery PCB

Engine will not go to high idle when 1. Poor work lead connection to work.
attempting to weld. If all recommended possible areas
2. Broken idler solenoid spring. of misadjustment have been
checked and the problem persists,
3. Welding Terminals switch in wrong
Contact your local Lincoln
position.
Authorized Field Service Facility.
4. No open circuit voltage at output studs.
5. Faulty, Pull Coil/Battery PCB or Weld
Control PCB.
Engine will not go to high idle when using 1. Broken wire in auxiliary current sensor
auxiliary power. wiring.
2. Auxiliary power load is less than 100
watts.
3. Faulty Pull Coil/Battery PCB or Weld
Control PCB.

CAUTION
If for any reason you do not understand the test procedures or are unable to perform the tests/repairs safely, contact your Local Lincoln
Authorized Field Service Facility for technical troubleshooting assistance before you proceed.
______________________________________________________________________________________________________________

Vantage 500 CUMMINS

 E-4 TROUBLESHOOTING E-4

PROBLEMS POSSIBLE AREAS OF RECOMMENDED

(SYMPTOMS) MISADJUSTMENT(S) COURSE OF ACTION
FUNCTION PROBLEMS
Engine goes to low idle but does not stay at 1. Faulty Peripheral PCB, Pull Coil/Battery
low idle. PCB or Weld Control PCB.

No welding output or auxiliary output. 1. Broken lead in rotor circuit.

2. Faulty field diode module.
3. Faulty Weld Control P.C. Board.
4. Faulty rotor.

Welder has some/ no output and no control. 1. Faulty remote kit.

Auxiliary output OK 2. Faulty output control potentiometer.
3. Faulty output control wiring.
4. Faulty Weld Control PCB, Pull
Coil/Battery PCB or Chopper PCB.

No welding output. Auxiliary output OK. 1. WELDING TERMINALS switch in wrong

position, be sure switch is in WELDING
TERMINALS ALWAYS ON position.
If all recommended possible areas
2. Faulty Weld Control PCB, Pull
of misadjustment have been
Coil/Battery PCB or Chopper PCB.
checked and the problem persists,
Contact your local Lincoln
Authorized Field Service Facility.
No auxiliary power. 1. Open breakers may need to be reset.
2. Faulty receptacle.
3. Faulty auxiliary circuit wiring.
4. GFCI tripped.

CAUTION
If for any reason you do not understand the test procedures or are unable to perform the tests/repairs safely, contact your Local Lincoln
Authorized Field Service Facility for technical troubleshooting assistance before you proceed.
______________________________________________________________________________________________________________

Vantage 500 CUMMINS

 VANGAGE 500 CUMMINS WIRING DIAGRAM
F-1

POS STATOR AUXILIARY WINDINGS

POS
POS 6A 3
W7 AUXILIARY POWER LEADS PASS THROUGH
POS W4 & W5 W2 & W3 W1 & W6 TOROID TWICE IN DIRECTION INDICATED
W8 6 5 5A
20A
RECTIFIER 260 CB1
206C NEG BRIDGE 261 9
B6 B3 NEG 32A
+ 204S LEFT SIDE NEG 3A
CHOPPER NEG 50A
50MV=400AMPS
B5 PCB6 B2 3 12 5A INSULATED
206S SILVER
CB3 5B 5B NEUTRAL
- J12 GND-C STUD ON
B8 B7 5C
BOTTOM

+
B4 B1 W3 W2 115/230V 12
W3 W2 RIGHT OF
J10 5E CONTROL
20A 9 HOT (GOLD) GND-E 31 5H BOX
R4 B7 23
SILVER 11
B8 25 8 5E
206A 206B STATOR
POS POS WELD
CB2 J11
GROUND STUD W4 WINDINGS W1 5C
W4 W1 GROUND STUD ON GROUND STUD ON 6B
ON OUTPUT PANEL NEG NEG CONTROL PANEL RECEPTACLE PANEL 50A
8
GND-K W5 W6 HOT (GOLD)
W5 W6 GND-F GND-H 6A 11
W9 GND-D
CB4
W10
208C GND-D
BYPASS GND-J MODE SELECTOR GND-A GND-E
208
FILTER L1 CHOKE B6 B3 SWITCH GND-B GND-C
ASSEMBLY STATOR 42V WINDING 10A GND-J 5
RIGHT SIDE S5

I
CV
214 1 42 32A
208B CHOPPER 218 2 CB6
B5 PCB5 B2 PIPE
208A A 42B
CC 3 AUXILIARY GROUND STUD, BOTTOM
41 CENTER OF CONTROL BOX
B8 B7 220 4
B4 B1 TIG 32
222 42A

SWITCH SHOWN IN 6
B7 23A
POSITIVE POLARITY
POSITION 13A 14A B8 25A
POS 41A 201 200B 200A 200
POS
SHUTDOWN

+
+ IDLER
-
13 14 BRUSH BRUSH
NEG NEG SOLENOID SOLENOID
POLARITY

+
21 5H
SWITCH 3200MFD
300V HOLD PULL HOLD PULL
- 41A COIL COIL COIL COIL
-
42A
ROTOR 6
POSITIVE BRUSH CONNECTED RED WHT RED WHT
206A TO SLIP RING NEAREST BLK BLK
208B TO THE LAMINATION J54 P55
1 2 3 4 1 2 3 4
J 31 32 32 201 201A J55
115VAC SHOWN IN P54
A 32 WELDING TERMINAL 256
"HIGH" POSITION 232M 232L
I 41A
OUTPUT CONTROL PINCH POT CONTROL SWITCH
42VAC CCW HIGH 262 265 226 227
K 42A SHOWN IN "ALWAYS ON" POSITION 4
+

IDLER
-
R1 10K 4A
WORK H 21 AUTO CONTROL
VIEWED VIEWED FROM BACK
E 77B FROM
REMOTE 2A 2
F 76B BACK HOUR METER
CONTROL 257
G 75B 232R 262A
77 76 75 277 278 279
CONTACTOR 232E START BUTTON
D 4B
262
C 2B 20A
DIAGRAMS

GROUND B GND-A OIL PRESSURE

238B
231 SENSOR & SWITCH
AMPHENOL 1 CB5 238A SWITCH
234

Vantage 500 CUMMINS

AMPHENOL 2 OIL COOLANT 228 SENSOR 235
PRESSURE TEMPERATURE FUEL 236A 236B G
77A AMMETER VOLTMETER WK
A 77B 232R
REMOTE 76A
CONTROL B 76B RUN/STOP RUN COOLANT TEMPERATURE
75A 4 1 4 1 4 1
C 75B M1 M3 M5 M9 SWITCH STOP SENSOR & SWITCH
CONTACTOR 2A M1 M3 M5 M9 243 247 J53 J52 J51
D 2B M2 M4 M6 M10 M2 M4 M6 M10 232B SHOWN IN "RUN" POSITION SWITCH
4A GOLD 232D 232H
E 4B 232C SENSOR 235
12VDC 241
GROUND F GND-B ENG INSULATED 232K
ALT PROT 232A 232F
STUD 232M 232B 5M 232C 5L 232K 5K
232
SILVER 228 241 229 229 FUEL LVL.
5J SENSOR
232N
232E 405B 232A
405A

214
222

218
220

M9

M6
M10
25

M9

M3

M1
23

M10
257

25A
14

23A
208B
238A
231

M2

M6
M4
M5

M2
M3

M1
M5
M4
77
76
75
279
278
277
261
260
256
13

250
250
1 5 1 8 1 5 1 8
5M 5K 5S 265 227
STARTER
PERIPHERAL BD 5T 5L 5J 5S 232N SOLENOID +
6 10 9 1 6 6 10 9 16 238
J7 J3
PCB1 PROGRAMMING STARTING
J5 J4
VOLT METER CONTROL, MODE SEL. AMMETER CHOPPER, POWER, PWM, THERMAL 1 3 MOTOR 12V BATTERY
3 TURNS B4 B3 B2 B1
3 TURNS
271

270
234
247

403
5T
405B

232F
THRU

262A
THRU
TOROID 12 VOLT GROUND 232 B
TOROID PULL COIL BD

405
405

6
403
270

4 STUD ON LEFT SIDE

405A
WELD BOARD P L -
J30 BACK OF CONTROL BOX 243
7
281
271
200

PCB3 16 9 12 IG
5N PCB8

75A

76A
77A
ALTERNATOR

5G
1 4

404
226

500
2
232D
ENGINE BLOCK
J6 16 9 J2 12 7
206S 2 J1 8 J31 1 6 1
ENGINE,PERIPHERAL J32
204S 1 SHUNT AMPHENOL,I.D.
6 1 5 8 5N
8 J43 ENGINE
1 SUPPORT
LEFT SIDE
A.02
ENHANCED DIAGRAM

G4329
NOTE: This diagram is for reference only. It may not be accurate for all machines covered by this manual. The specific dia- gram for your particular machine is pasted inside the machine on one of
F-1

the enclosure panels.

 F-2 DIAGRAMS F-2
CONNECTION DIAGRAM:

Vantage 500 CUMMINS

 COMMANDER / K867 / K775 / LN-7 CONNECTION DIAGRAM
F-3

WARNING
Do not operate with panels open. Keep guards in place.
Disconnect NEGATIVE (-) BATTERY LEAD Keep away from moving parts.
before servicing. Only qualified personnel should install,use
Do not touch electrically live parts. or service this equipment.
CONNECTION DIAGRAM:

SPARE

82

81 LN-7
N.D.
WIRE
42 FEEDER
41
}
31 31

32 32

14 PIN 2 2
AMPHENOL
4 4
ELECTRODE TO WORK 21 21
K291 OR K404
K867 UNIVERSAL
GND GND INPUT CABLE
ADAPTER PLUG
DIAGRAMS

GREEN

Vantage 500 CUMMINS

TO WORK 75 75

76 76
ELECTRODE CABLE 77 77
TO WIRE FEED UNIT
}
K775 OPTIONAL
CAUTION : N.E. REMOTE CONTROL

ANY INCREASE OF THE HIGH IDLE ENGINE RPM BY CHANGING THE GOVERNOR SETTING OR OVERRIDING THE THROTTLE LINKAGE WILL CAUSE
AN INCREASE IN THE THE AC AUXILIARY VOLTAGE. IF THIS VOLTAGE GOES OVER 140 VOLTS, WIRE FEEDER CONTROL CIRCUITS MAY BE
DAMAGED. THE ENGINE GOVERNOR SETTING IS PRE-SET AT THE FACTORY - DO NOT ADJUST ABOVE RPM SPECIFICATIONS LISTED IN
THE ENGINE WELDER OPERATING MANUAL.

N.A. WELDING CABLE MUST BE OF PROPER CAPACITY FOR THE CURRENT AND DUTY CYCLE OF IMMEDIATE AND FUTURE
APPILICATIONS. SEE OPERATING MANUAL.
N.B. USE VOLTMETER SWITCH TO SELECT DESIRED ELECTRODE POLARITY. POSITION THE "SELECTOR" SWITCH TO "WIRE WELDING CV".
PLACE WIRE FEEDER SWITCH TO "WIRE FEEDER WITH CONTROL CABLE POSITION.
N.C. IF OPTIONAL REMOTE OUTPUT CONTROL IS USED,CONTROL IS AUTOMATICALLY SWITCHED TO REMOTE CONTROL.
N.D. INSULATE EACH UNUSED LEAD INDIVIDUALLY.
N.E. SPLICE LEADS AND INSULATE.

7-2000
F-3

S23983
 F-4 DIAGRAMS F-4

CONNECTION DIAGRAM

Vantage 500 CUMMINS

 F-5 DIAGRAMS F-5

CONNECTION DIAGRAM

Vantage 500 CUMMINS

 COMMANDER / K867 / LN-8 CONNECTION DIAGRAM
F-6

WARNING
Do not operate with panels open. Keep guards in place.
Disconnect NEGATIVE (-) BATTERY LEAD Keep away from moving parts.
before servicing. Only qualified personnel should install,use
Do not touch electrically live parts. or service this equipment.
CONNECTION DIAGRAM

SPARE

82 LN-8
81 N.C. WIRE
FEEDER
42

41
}
31 31

32 32
14 PIN
AMPHENOL
2 2

4 4
ELECTRODE TO WORK 21 21 K196
K867 UNIVERSAL
GND GND INPUT CABLE
ADAPTER PLUG
DIAGRAMS

Vantage 500 CUMMINS

TO WORK 75 A

76 B
ELECTRODE CABLE
TO WIRE FEED UNIT 77 C
}
CAUTION : N.D.
ANY INCREASE OF THE HIGH IDLE ENGINE RPM BY CHANGING THE GOVERNOR SETTING OR OVERRIDING THE THROTTLE LINKAGE WILL CAUSE
AN INCREASE IN THE THE AC AUXILIARY VOLTAGE. IF THIS VOLTAGE GOES OVER 140 VOLTS, WIRE FEEDER CONTROL CIRCUITS MAY BE
DAMAGED. THE ENGINE GOVERNOR SETTING IS PRE-SET AT THE FACTORY - DO NOT ADJUST ABOVE RPM SPECIFICATIONS LISTED IN
THE ENGINE WELDER OPERATING MANUAL.

N.A. WELDING CABLE MUST BE OF PROPER CAPACITY FOR THE CURRENT AND DUTY CYCLE OF IMMEDIATE AND FUTURE
APPICATIONS. SEE OPERATING MANUAL.
N.B. USE VOLTMETER SWITCH TO SELECT DESIRED ELECTRODE POLARITY. POSITION THE SELECTOR SWITCH TO "WIRE WELDING CV".

N.C. INSULATE EACH UNUSED LEAD INDIVIDUALLY.

N.D. SPLICE LEADS AND INSULATE.

7-2000
F-6

S23989
 F-7 DIAGRAMS F-7

CONNECTION DIAGRAM

Vantage 500 CUMMINS

 F-8 DIAGRAMS F-8

CONNECTION DIAGRAM

Vantage 500 CUMMINS

 ENGINE WELDERS /LN-8 CONNECTION DIAGRAM
F-9

WARNING
ELECTRIC SHOCK can kill MOVING PARTS can injure
Do not operate with panels open. Keep guards in place.
Disconnect NEGATIVE (-) Battery lead Keep away from moving parts.
CONNECTION DIAGRAM

before servicing. Only qualified personnel should install,use

Do not touch electrically live parts. or service this equipment.

14 PIN
AMPHENOL TO LN-8 INPUT
CABLE PLUG

K595 CONTROL CABLE

+ _
TO WORK
DIAGRAMS

ELECTRODE CABLE

Vantage 500 CUMMINS

TO WIRE FEED UNIT

CAUTION:

ANY INCREASE OF THE HIGH IDLE ENGINE RPM BY CHANGING THE GOVERNOR SETTING OR OVERRIDING THE THROTTLE LINKAGE WILL CAUSE
AN INCREASE IN THE AC WIRE FEEDER VOLTAGE, WHICH CAN DAMAGE THE CONTROL CIRCUIT. THE ENGINE GOVERNOR SETTING IS PRE-SET
AT THE FACTORY – DO NOT ADJUST ABOVE RPM SPECIFICATIONS LISTED IN THE ENGINE WELDER OPERATING MANUAL.

N.A. WELDING CABLES MUST BE OF PROPER CAPACITY FOR THE CURRENT AND DUTY CYCLE OF IMMEDIATE AND FUTURE
APPLICATIONS. SEE OPERATING MANUAL.
N.B. CONNECT WELDING CABLES TO OUTPUT STUDS FOR DESIRED POLARITY. POSITION THE WIRE FEEDER VOLTMETER SWITCH TO
MATCH THE POLARITY OF THE ELECTRODE CABLE.
N.C. PLACE IDLER SWITCH IN “HIGH” POSITION.

4-14-2000
F-9

S24787-6
 F-10 DIAGRAMS F-10

CONNECTION DIAGRAM

Vantage 500 CUMMINS

 F-11 DIAGRAMS F-11

CONNECTION DIAGRAM

Vantage 500 CUMMINS

 F-12 DIAGRAMS F-12

CONNECTION DIAGRAM

Vantage 500 CUMMINS

 F-13 DIAGRAMS F-13

CONNECTION DIAGRAM

Vantage 500 CUMMINS

 ENGINEERING CONTROLLED CHANGE DETAIL: Revised overall height dimension.
5.86
MANUFACTURER: No
F-14

50.15 2.24
42.35
33.53
32.08

N.A.

50.81
46.35 45.67
42.00

16.85

63.10 6.56 31.50

45.38 * 37.30
14.63
* 6.55
N.A. CENTER OF GRAVITY WITH OIL IN ENGINE, EMPTY FUEL TANK AND COOLANT IN RADIATOR.
DIAGRAMS
DIMENSION PRINT

Vantage 500 CUMMINS

28.99
24.97
*
* TRAILER MOUNTING HOLE LOCATIONS.
6.53
*
19.63
23.69
50.38
54.44

BOTTOM VIEW OF WELDER BASE.

A. 0 2

M18962-3 Ref.
NOTE: This diagram is for reference only. It may not be accurate for all machines covered by this manual. The specific diagram for a particular code is pasted inside the machine on one of the enclosure
F-14

panels. If the diagram is illegible, write to the Service Department for a replacement. Give the equipment code number.
 l Do not touch electrically live parts or l Keep flammable materials away. l Wear eye, ear and body protection.

WARNING electrode with skin or wet clothing.

l Insulate yourself from work and
ground.
Spanish
l No toque las partes o los electrodos l Mantenga el material combustible l Protéjase los ojos, los oídos y el
AVISO DE bajo carga con la piel o ropa
mojada.
fuera del área de trabajo. cuerpo.

PRECAUCION l Aislese del trabajo y de la tierra.

French l Ne laissez ni la peau ni des l Gardez à l’écart de tout matériel l Protégez vos yeux, vos oreilles et
vêtements mouillés entrer en contact inflammable. votre corps.
ATTENTION avec des pièces sous tension.
l Isolez-vous du travail et de la terre.

German l Berühren Sie keine stromführenden l Entfernen Sie brennbarres Material! l Tragen Sie Augen-, Ohren- und Kör-
Teile oder Elektroden mit Ihrem perschutz!
WARNUNG Körper oder feuchter Kleidung!
l Isolieren Sie sich von den
Elektroden und dem Erdboden!
Portuguese
l Não toque partes elétricas e l Mantenha inflamáveis bem l Use proteção para a vista, ouvido e
electrodos com a pele ou roupa guardados. corpo.
ATENÇÃO molhada.
l Isole-se da peça e terra.

Japanese

Chinese

Korean

Arabic

READ AND UNDERSTAND THE MANUFACTURER’S INSTRUCTION FOR THIS EQUIPMENT AND THE CONSUMABLES TO
BE USED AND FOLLOW YOUR EMPLOYER’S SAFETY PRACTICES.

SE RECOMIENDA LEER Y ENTENDER LAS INSTRUCCIONES DEL FABRICANTE PARA EL USO DE ESTE EQUIPO Y LOS
CONSUMIBLES QUE VA A UTILIZAR, SIGA LAS MEDIDAS DE SEGURIDAD DE SU SUPERVISOR.

LISEZ ET COMPRENEZ LES INSTRUCTIONS DU FABRICANT EN CE QUI REGARDE CET EQUIPMENT ET LES PRODUITS A
ETRE EMPLOYES ET SUIVEZ LES PROCEDURES DE SECURITE DE VOTRE EMPLOYEUR.

LESEN SIE UND BEFOLGEN SIE DIE BETRIEBSANLEITUNG DER ANLAGE UND DEN ELEKTRODENEINSATZ DES
HERSTELLERS. DIE UNFALLVERHÜTUNGSVORSCHRIFTEN DES ARBEITGEBERS SIND EBENFALLS ZU BEACHTEN.

Vantage 500 CUMMINS

l Keep your head out of fumes. l Turn power off before servicing. l Do not operate with panel open or
l Use ventilation or exhaust to
remove fumes from breathing zone.
guards off.
WARNING
Spanish
l Los humos fuera de la zona de l Desconectar el cable de l No operar con panel abierto o
respiración.
l Mantenga la cabeza fuera de los
alimentación de poder de la guardas quitadas. AVISO DE
máquina antes de iniciar cualquier
humos. Utilice ventilación o
aspiración para gases.
servicio. PRECAUCION
French
l Gardez la tête à l’écart des fumées. l N’opérez pas avec les panneaux
l Utilisez un ventilateur ou un l Débranchez le courant avant ouverts ou avec les dispositifs de
aspirateur pour ôter les fumées des l’entretien. protection enlevés. ATTENTION
zones de travail.

German
l Vermeiden Sie das Einatmen von l Anlage nie ohne Schutzgehäuse
Schweibrauch! l Strom vor Wartungsarbeiten oder Innenschutzverkleidung in
l Sorgen Sie für gute Be- und
Entlüftung des Arbeitsplatzes!
abschalten! (Netzstrom völlig
öffnen; Maschine anhalten!)
Betrieb setzen! WARNUNG
Portuguese
l Mantenha seu rosto da fumaça. l Mantenha-se afastado das partes
l Não opere com as tampas removidas.
l Use ventilação e exhaustão para
remover fumo da zona respiratória. l Desligue a corrente antes de fazer
moventes.
l Não opere com os paineis abertos ATENÇÃO
serviço. ou guardas removidas.
l Não toque as partes elétricas nuas.
Japanese

Chinese

Korean

Arabic

LEIA E COMPREENDA AS INSTRUÇÕES DO FABRICANTE PARA ESTE EQUIPAMENTO E AS PARTES DE USO,

E SIGA AS PRÁTICAS DE SEGURANÇA DO EMPREGADOR.

Vantage 500 CUMMINS

 World’s Leader in Welding and Cutting Products
• Sales and Service through Subsidiaries and Distributors Worldwide •
Cleveland, Ohio 44117-1199 USA Tel: 216.481.8100 Fax: 216.486.1751 Web Site: www.lincolnelectric.com