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Lincoln 500 manual

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Table of contents for the manual

  • Page 1

    July, 2004 Safety Depends on Y ou Lincoln arc welding and cutting equipment is designed and built with safety in mind. However , your overall safety can be increased by proper installation . . . and thoughtful operation on your part. DO NOT INST ALL, OPERA TE OR REP AIR THIS EQUIPMENT WITHOUT READING THIS MANUAL AND THE SAFETY PRECAUTIONS CONT AINE[...]

  • Page 2

    ELECTRIC AND MAGNETIC FIELDS may be dangerous 2.a. Electric current flowing through any conductor causes localized Electric and Magnetic Fields (EMF). Welding current creates EMF fields around welding cables and welding machines. 2.b. EMF fields may interfere with some pacemakers and welders having a pacemaker should consult their physician before [...]

  • Page 3

    ELECTRIC SHOCK can kill. 3.a. The electrode and work (or ground) circuits are electrically “hot” when the welder is on. Do not touch these “hot” parts with your bare skin or wet clothing. Wear dry , hole-free gloves to insulate hands. 3.b. Insulate yourself from work and ground using dry insulation. Make certain the insulation is large enou[...]

  • Page 4

    FOR ELECTRICALL Y powered equipment. 8.a. Turn off input power using the disconnect switch at the fuse box before working on the equipment. 8.b. Install equipment in accordance with the National Electrical Code, all local codes and the manufacturer ’ s recommendations. 8.c. Ground the equipment in accordance with the National Electrical Code and [...]

  • Page 5

    iv SAFETY iv Mar . ‘93 PRÉCAUTIONS DE SÛRETÉ Pour votre propre protection lire et observer toutes les instructions et les précautions de sûreté specifiques qui parraissent dans ce manuel aussi bien que les précautions de sûreté générales suivantes: Sûreté Pour Soudage A L ’Arc 1. Protegez-vous contre la secousse électrique: a. Les[...]

  • Page 6

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

  • Page 7

    Page Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Section A T echnical Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .A-1 Safety Precautions . . . . . . . . . . .[...]

  • Page 8

    Accessories . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Section C Optional Field Installed Accessories . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .C-1 _____________________________________________________[...]

  • Page 9

    TECHNICAL SPECIFICA TIONS - V antage 500 CUMMINS (K2272-1) INPUT - DIESEL ENGINE Make /Model Description Speed (RPM) Displacement Starting Capacities System Cummins 4 cylinder High Idle 1900 199 cu. in 12VDC battery Fuel B3.3 56HP (42 kw) Low Idle 1425 (3.3L) & Starter (25 US gal) Diesel Engine @ 1800 RPM Full Load 1800 94.6L Bore x Stroke Oil:[...]

  • Page 10

    Read this entire installation section before you start installation. SAFETY PRECAUTIONS Do not attempt to use this equipment until you have thoroughly read all operating and maintenance manuals supplied with your machine. They include important safety precautions, detailed engine starting, operating and maintenance instructions and parts lists. ELE[...]

  • Page 11

    LIFTING The V antage lift bale should be used to lift the machine. The V antage is shipped with the lift bale retracted. Before attempting to lift the V antage the lift bale must be secured in a raised position. Secure the lift bale as follows: a. Open the engine compartment door . b. Locate the 2 access holes on the upper middle region of compartm[...]

  • Page 12

    PRE-OPERA TION ENGINE SERVICE READ the engine operating and maintenance instructions supplied with this machine. • Stop engine while fueling. • Do not smoke when fueling. • Keep sparks and flame away fr om tank. • Do not leave unattended while fueling. • Wipe up spilled fuel and allow fumes to clear before starting engine. • Do not over[...]

  • Page 13

    The V antage is shipped with the negative battery cable disconnected. Before you operate the machine, make sure the Engine Switch is in the OFF position and attach the disconnected cable securely to the negative (-) battery terminal. Remove the insulating cap from the negative battery terminal. Replace and tighten negative battery cable terminal. N[...]

  • Page 14

    REMOTE CONTROL OUTPUT The V antage is equipped with a 6-pin and a 14-pin connector . The 6-pin connector is for connecting the K857 or K857-1 Remote Control or for TIG welding, the K870 foot Amptrol or the K936-2 hand Amptrol. When in the CC-STICK, DOWNHILL PIPE, or CV - WIRE modes and when a remote control is connected to the 6- pin Connector , th[...]

  • Page 15

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

  • Page 16

    CONNECTION OF LINCOLN ELECTRIC WIRE FEEDERS Shut off welder before making any electrical connections. ------------------------------------------------------------------------------------- CONNECTION OF LN-7, LN-8 OR LN-742 TO THE V ANT AGE • Shut the welder off. • Connect the LN-7, LN-8 OR LN-742 per instructions on the appropriate connection d[...]

  • Page 17

    CONNECTION OF THE LN-25 TO THE V ANT AGE The LN-25 with or without an internal contactor may be used with the V antage. See the appropriate connection diagram in the DIAGRAMS section. NOTE : The LN-25 (K431) Remote Control Module and (K432) Remote Cable are not recommended for use with the V antage. • Shut the welder off. • For electrode Positi[...]

  • Page 18

    SAFETY INSTRUCTIONS Read and understand this entire section before operating your V antage. Do not attempt to use this equipment until you have thoroughly read all operating and maintenance manuals supplied with your machine. They include important safety precautions, detailed engine starting, operating and maintenance instructions and parts lists.[...]

  • Page 19

    ENGINE CONTROLS (Items 1 through 9) 1. RUN STOP SWITCH T oggling the switch to the RUN position energizes the fuel solenoid for approximately 30 seconds. The engine must be started within that time or the fuel solenoid will deenergize, and the switch must be toggled to reset the timer . 2. ST ART PUSHBUTTON Energizes the starter motor to crank the [...]

  • Page 20

    6. OIL PRESSURE GAUGE The gauge displays the engine oil pressure when the engine is running. 7. ENGINE PROTECTION The yellow engine protection light remains off with proper oil pressure and under normal operating temperatures. If the light turns on, the engine protection system will stop the engine. Check for proper oil level and add oil if necessa[...]

  • Page 21

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

  • Page 22

    20. CIRCUIT BREAKERS These circuit breakers provide separate overload current protection for each 120V circuit at the 240V receptacle, each 120V receptacle, the 120V AC in the 14-Pin connector , the 42V AC in the 14-Pin connector and battery circuit overload protection. 21. 120V AC RECEPT ACLES These two 120V AC (5-20R) receptacles with ground faul[...]

  • Page 23

    B-6 OPERA TION B-6 V antage 500 CUMMINS BREAK-IN PERIOD The engine used to supply power for your welder is a heavy duty , industrial engine. It is designed and built for rugged use. It is very normal for any engine to use small quantities of oil until the break- in is accomplished. Check the oil level twice a day during the break-in period. In gene[...]

  • Page 24

    n general the ‘T ouch Start’ feature avoids tungsten contamination without the use of a Hi-frequency unit. If the use of a high frequency generator is desired, the K930-2 TIG Module can be used with the V antage. The settings are for reference. The V antage is equipped with the required R.F . bypass circuitry for the connection of high frequenc[...]

  • Page 25

    CV -WIRE MODE Connect a wire feeder to the V antage and set welder controls according to the instructions listed earlier in this section. The V antage in the ”CV -WIRE” position, permits it to be used with a broad range of flux cored wire (Innershield and Outershield) electrodes and solid wires for MIG welding (gas metal arc welding). Welding c[...]

  • Page 26

    B-9 OPERA TION B-9 V antage 500 CUMMINS T ABLE B.5 V antage Extension Cord Length Recommendations Current (Amps) 15 15 20 20 25 30 38 50 V oltage (V olts) 120 240 120 240 240 240 240 240 Load (W atts) 1800 3600 2400 4800 6000 7200 9000 12000 30 60 (9) (18) 40 75 30 60 (12) (23) (9) (18) 75 150 50 100 90 75 (23) (46) (15) (30) (27) (23) 125 225 88 1[...]

  • Page 27

    OPTIONAL FIELD INST ALLED ACCESSORIES K802N POWER PLUG KIT - Provides four 120V plugs rated at 20 amps each and one dual voltage, full KV A plug rated at 120/240V , 50 amps. 120V plug may not be compatible with NEMA common household receptacles. K802-R POWER PLUG KIT - Provides four 120V plugs rated 15 amps each and one dual voltage, full KV A plug[...]

  • Page 28

    SAFETY PRECAUTIONS • Have a qualified technician do the maintenance and troubleshooting work. • T urn the engine off before working inside the machine. • Remove guards only when necessary and replace them when the maintenance requiring their removal is complete. • Always use the greatest care when working near moving parts. ----------------[...]

  • Page 29

    7. Inspect for holes and tears by looking through the element toward a bright light. Check for damaged gaskets or dented metal parts. Do not reuse damaged elements. Protect element from dust and damage during drying and storage. 8. Reinstall air filter element. After six cleanings replace air filter . A cleaned filter will have approximately 70% of[...]

  • Page 30

    CHARGING THE BA TTERY When you charge, jump, replace, or otherwise connect battery cables to the battery , be sure the polarity is correct. Improper polarity can damage the charging circuit. The V antage positive (+) battery terminal has a red terminal cover . If you need to charge the battery with an external charger , disconnect the negative cabl[...]

  • Page 31

    This T roubleshooting Guide is provided to help you locate and repair possible machine malfunctions. Simply follow the three- step procedure listed below . Step 1. LOCA TE PROBLEM (SYMPTOM). Look under the column labeled “PROBLEM (SYMPTOMS)”. This column describes possible symptoms that the machine may exhibit. Find the listing that best descri[...]

  • Page 32

    PROBLEMS (SYMPTOMS) Major Physical or Electrical Damage is Evident. Engine will not crank Engine will crank but not start. Engine shuts down shortly after starting. Engine shuts down while under a load. Engine runs rough. Engine will not shut off. POSSIBLE AREAS OF MISADJUSTMENT(S) 1. Contact your Local Lincoln Authorized Field Service Facility . 1[...]

  • Page 33

    CAUTION V antage 500 CUMMINS E-3 TROUBLESHOOTING E-3 PROBLEMS (SYMPTOMS) Battery does not stay charged. Engine will not idle down to low speed. Engine will not go to high idle when attempting to weld. Engine will not go to high idle when using auxiliary power . POSSIBLE AREAS OF MISADJUSTMENT(S) 1. Faulty battery . 2. Faulty engine alternator . 3. [...]

  • Page 34

    PROBLEMS (SYMPTOMS) Engine goes to low idle but does not stay at low idle. No welding output or auxiliary output. Welder has some/ no output and no control. Auxiliary output OK No welding output. Auxiliary output OK. No auxiliary power . POSSIBLE AREAS OF MISADJUSTMENT(S) 1. Faulty Peripheral PCB, Pull Coil/Battery PCB or Weld Control PCB. 1. Broke[...]

  • Page 35

    F-1 DIAGRAMS F-1 V antage 500 CUMMINS 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 the enclosure panels. CB6 10A 42A 42 RECTIFIER BRIDGE 238A 231 42A 41A 243 232 41 START BUTTON 238 222 MODE SELECTO[...]

  • Page 36

    V antage 500 CUMMINS F-2 DIAGRAMS F-2 CONNECTION DIAGRAM:[...]

  • Page 37

    F-3 DIAGRAMS F-3 V antage 500 CUMMINS CONNECTION DIAGRAM: GND 75 76 77 GREEN K291 OR K404 75 INPUT CABLE 76 N.E. 77 K775 OPTIONAL REMOTE CONTR OL D AMAGED . THE ENGINE GO VERNOR SETTING IS PRE-SET A T THE F ACT OR Y - DO NOT ADJUST ABO VE RPM SPECIFICA TIONS LISTED IN 81 42 41 31 31 32 32 2 2 4 4 21 21 GND 82 N.D . LN-7 WIRE FEEDER Keep guards in p[...]

  • Page 38

    F-4 DIAGRAMS F-4 V antage 500 CUMMINS CONNECTION DIAGRAM[...]

  • Page 39

    V antage 500 CUMMINS F-5 DIAGRAMS F-5 CONNECTION DIAGRAM[...]

  • Page 40

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

  • Page 41

    V antage 500 CUMMINS F-7 DIAGRAMS F-7 CONNECTION DIAGRAM[...]

  • Page 42

    V antage 500 CUMMINS F-8 DIAGRAMS F-8 CONNECTION DIAGRAM[...]

  • Page 43

    V antage 500 CUMMINS F-9 DIAGRAMS F-9 CONNECTION DIAGRAM or service t his equip men t. Only qualified personnel should install,use Keep away from m oving parts. Keep guards in place. MOVING PART S can injure WA R N I N G Do no t touch el ectrically live parts . before servicing. Disconnect NEGATI VE (-) Battery lead Do not operate with panels open.[...]

  • Page 44

    V antage 500 CUMMINS F-10 DIAGRAMS F-10 CONNECTION DIAGRAM[...]

  • Page 45

    V antage 500 CUMMINS F-1 1 DIAGRAMS F-1 1 CONNECTION DIAGRAM[...]

  • Page 46

    V antage 500 CUMMINS F-12 DIAGRAMS F-12 CONNECTION DIAGRAM[...]

  • Page 47

    V antage 500 CUMMINS F-13 DIAGRAMS F-13 CONNECTION DIAGRAM[...]

  • Page 48

    V antage 500 CUMMINS F-14 DIAGRAMS F-14 DIMENSION PRINT TRAI LER MOUNT ING HOLE LOCATIONS. * 28.9 9 19.6 3 6.55 23.6 9 50.38 54.4 4 14.6 3 37.3 0 45.3 8 63.1 0 6.56 42.0 0 50.8 1 16.8 5 33.5 3 32.0 8 42.3 5 31.5 0 45.6 7 2.24 50.1 5 5.86 46.3 5 * * * * BOTTOM VI EW OF W E LDER BASE. N.A. CE NTER OF GRA VITY W ITH OIL IN ENG INE, EM PTY FUEL TAN K A[...]

  • Page 49

    V antage 500 CUMMINS W ARNING A VISO DE PRECAUCION A TTENTION W ARNUNG A TENÇÃO Spanish French German Portuguese Japanese Chinese Korean Arabic READ AND UNDERST AND THE MANUF ACTURER’S INSTRUCTION FOR THIS EQUIPMENT AND THE CONSUMABLES TO BE USED AND FOLLOW YOUR EMPLOYER’S SAFETY PRACTICES. SE RECOMIENDA LEER Y ENTENDER LAS INSTRUCCIONES DEL [...]

  • Page 50

    V antage 500 CUMMINS W ARNING A VISO DE PRECAUCION A TTENTION W ARNUNG A TENÇÃO Spanish French German Portuguese Japanese Chinese Korean Arabic LEIA E COMPREENDA AS INSTRUÇÕES DO F ABRICANTE P ARA ESTE EQUIPAMENTO E AS P ARTES DE USO, E SIGA AS PRÁTICAS DE SEGURANÇA DO EMPREGADOR. l Keep your head out of fumes. l Use ventilation or exhaust to[...]

  • Page 51

    World’ s Leader in Welding and Cutting Products • Sales and Service through Subsidiaries and Distributors Worldwide • Cleveland, Ohio 441 17-1 199 USA T el: 216.481.8100 Fax: 216.486.1751 W eb Site: www .lincolnelectric.com[...]