SVM178

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SVM178-B
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April, 2011
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VANTAGE 500
For use with machine code numbers: 10995,10996,11180,11181
11415,11416,11468
Safety Depends on You

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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. DONOT INSTALL,
OPERATE OR REPAIR THIS
EQUIPMENT WITHOUT READ-
ING THIS MANUAL AND THE
SAFETY PRECAUTIONS CON-
TAINED THROUGHOUT. And,
most importantly, think before you
act and be careful.
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SERVICE MANUAL
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Copyright Lincoln Global Inc.
World's Leader in Welding and Cutting Products

Sales and Service through Subsidiaries and Distributors Worldwide
Cleveland, Ohio 44117-1199 U.S.A. TEL: 216.481.8100 FAX: 216.486.1751 WEBSITE: www.lincolnelectric.com
i SAFETY i
WARNING
CALIFORNIA PROPOSITION 65 WARNINGS

Diesel engine exhaust and some of its constituents The engine exhaust from this product contains
are known to the State of California to cause can- chemicals known to the State of California to cause
cer, birth defects, and other reproductive harm. cancer, birth defects, or other reproductive harm.
The Above For Diesel Engines The Above For Gasoline Engines
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, P.O. Box 351040,
Miami, Florida 33135 or CSA Standard W117.2-1974. A Free copy of Arc Welding Safety booklet E205 is available from the
Lincoln Electric 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
areas or vent the engine exhaust fumes
outdoors.
ELECTRIC AND
MAGNETIC FIELDS
____________________________________________________
1.c. Do not add the fuel near an open flame weld- may be dangerous
ing arc or when the engine is running. Stop
the engine and allow it to cool before refuel- 2.a. Electric current flowing through any conductor causes
ing to prevent spilled fuel from vaporizing on localized Electric and Magnetic Fields (EMF). Welding
contact with hot engine parts and igniting. Do current creates EMF fields around welding cables and
not spill fuel when filling tank. If fuel is spilled, welding machines
wipe it up and do not start engine until fumes
have been eliminated. 2.b. EMF fields may interfere with some pacemakers, and
____________________________________________________ welders having a pacemaker should consult their physician
1.d. Keep all equipment safety guards, covers and devices in posi- before welding.
tion and in good repair.Keep hands, hair, clothing and tools
away from V-belts, gears, fans and all other moving parts 2.c. Exposure to EMF fields in welding may have other health
when starting, operating or repairing equipment. effects which are now not known.
____________________________________________________
2.d. All welders should use the following procedures in order to
1.e. In some cases it may be necessary to remove safety
minimize exposure to EMF fields from the welding circuit:
guards to perform required maintenance. Remove
guards only when necessary and replace them when the
maintenance requiring their removal is complete. 2.d.1. Route the electrode and work cables together - Secure
Always use the greatest care when working near moving them with tape when possible.
parts.
___________________________________________________ 2.d.2. Never coil the electrode lead around your body.
1.f. Do not put your hands near the engine fan. 2.d.3. Do not place your body between the electrode and
Do not attempt to override the governor or work cables. If the electrode cable is on your right
side, the work cable should also be on your right side.
idler by pushing on the throttle control rods

while the engine is running.
2.d.4. Connect the work cable to the workpiece as close as
possible to the area being welded.
___________________________________________________
1.g. To prevent accidentally starting gasoline engines while 2.d.5. Do not work next to welding power source.
turning the engine or welding generator during maintenance
work, disconnect the spark plug wires, distributor cap or
magneto wire as appropriate.
VANTAGE 500
ii SAFETY ii
ELECTRIC SHOCK can kill. ARC RAYS can burn.

3.a. The electrode and work (or ground) circuits 4.a. Use a shield with the proper filter and cover
are electrically hot when the welder is on. plates to protect your eyes from sparks and
Do not touch these hot parts with your bare the rays of the arc when welding or observing
skin or wet clothing. Wear dry, hole-free open arc welding. Headshield and filter lens
gloves to insulate hands. should conform to ANSI Z87. I standards.
3.b. Insulate yourself from work and ground using dry insulation. 4.b. Use suitable clothing made from durable flame-resistant
Make certain the insulation is large enough to cover your full material to protect your skin and that of your helpers from
area of physical contact with work and ground. the arc rays.
In addition to the normal safety precautions, if welding 4.c. Protect other nearby personnel with suitable, non-flammable
must be performed under electrically hazardous screening and/or warn them not to watch the arc nor expose
conditions (in damp locations or while wearing wet themselves to the arc rays or to hot spatter or metal.
clothing; on metal structures such as floors, gratings or
scaffolds; when in cramped positions such as sitting,
kneeling or lying, if there is a high risk of unavoidable or FUMES AND GASES
accidental contact with the workpiece or ground) use
the following equipment: can be dangerous.
Semiautomatic DC Constant Voltage (Wire) Welder. 5.a. Welding may produce fumes and gases
DC Manual (Stick) Welder. hazardous to health. Avoid breathing these

AC Welder with Reduced Voltage Control. fumes and gases.When welding, keep
your head out of the fume. Use enough
3.c. In semiautomatic or automatic wire welding, the electrode, ventilation and/or exhaust at the arc to keep
electrode reel, welding head, nozzle or semiautomatic fumes and gases away from the breathing zone. When
welding gun are also electrically hot. welding with electrodes which require special
ventilation such as stainless or hard facing (see
3.d. Always be sure the work cable makes a good electrical instructions on container or MSDS) or on lead or
connection with the metal being welded. The connection cadmium plated steel and other metals or coatings
should be as close as possible to the area being welded. which produce highly toxic fumes, keep exposure as
low as possible and within applicable OSHA PEL and
3.e. Ground the work or metal to be welded to a good electrical ACGIH TLV limits using local exhaust or mechanical ven-
(earth) ground. tilation. In confined spaces or in some circumstances,
outdoors, a respirator may be required. Additional pre-
3.f. Maintain the electrode holder, work clamp, welding cable and cautions are also required when welding on galvanized
welding machine in good, safe operating condition. Replace steel.
damaged insulation.
5. b. The operation of welding fume control equipment is affected
by various factors including proper use and positioning of the
3.g. Never dip the electrode in water for cooling.
equipment, maintenance of the equipment and the specific
welding procedure and application involved. Worker expo-

3.h. Never simultaneously touch electrically hot parts of
sure level should be checked upon installation and periodi-
electrode holders connected to two welders because voltage
cally thereafter to be certain it is within applicable OSHA PEL
between the two can be the total of the open circuit voltage
and ACGIH TLV limits.
of both welders.
5.c. Do not weld in locations near chlorinated hydrocarbon vapors
3.i. When working above floor level, use a safety belt to protect
coming from degreasing, cleaning or spraying operations.
yourself from a fall should you get a shock.
The heat and rays of the arc can react with solvent vapors to
form phosgene, a highly toxic gas, and other irritating prod-
3.j. Also see Items 6.c. and 8.
ucts.
5.d. Shielding gases used for arc welding can displace air and
cause injury or death. Always use enough ventilation,
especially in confined areas, to insure breathing air is safe.
5.e. Read and understand the manufacturers instructions for this

equipment and the consumables to be used, including the
material safety data sheet (MSDS) and follow your
employers safety practices. MSDS forms are available from
your welding distributor or from the manufacturer.
5.f. Also see item 1.b.
VANTAGE 500
iii SAFETY iii
WELDING and CUTTING CYLINDER may explode

SPARKS can cause fire or if damaged.

explosion. 7.a. Use only compressed gas cylinders
containing the correct shielding gas for the
6.a. Remove fire hazards from the welding area.If process used and properly operating
this is not possible, cover them to prevent the welding sparks regulators designed for the gas and
from starting a fire. Remember that welding sparks and hot pressure used. All hoses, fittings, etc. should be suitable for
materials from welding can easily go through small cracks the application and maintained in good condition.
and openings to adjcent areas. Avoid welding near hydraulic
lines. Have a fire extinguisher readily available. 7.b. Always keep cylinders in an upright position securely
chained to an undercarriage or fixed support.
6.b. Where compressed gases are to be used at the job site,
special precautions should be used to prevent hazardous 7.c. Cylinders should be located:
situations. Refer to Safety in Welding and Cutting (ANSI Away from areas where they may be struck or subjected to
Standard Z49.1) and the operating information for the physical damage.
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
cause overheating and create a fire hazard. 7.d. Never allow the electrode, electrode holder or any other
electrically hot parts to touch a cylinder.

6.d. Do not heat, cut or weld tanks, drums or containers until the
proper steps have been taken to insure that such procedures 7.e. Keep your head and face away from the cylinder valve outlet
will not cause flammable or toxic vapors from substances when opening the cylinder valve.
inside. They can cause an explosion even though they have
been cleaned. For information, purchase Recommended 7.f. Valve protection caps should always be in place and hand
Safe Practices for the Preparation for Welding and Cutting of tight except when the cylinder is in use or connected for
Containers and Piping That Have Held Hazardous use.
Substances, AWS F4.1 from the American Welding Society
(see address above). 7.g. Read and follow the instructions on compressed gas
cylinders, associated equipment, and CGA publication P-l,
6.e. Vent hollow castings or containers before heating, cutting or Precautions for Safe Handling of Compressed Gases in
welding. They may explode. Cylinders, available from the Compressed Gas Association
1235 Jefferson Davis Highway, Arlington, VA 22202.
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.
FOR ELECTRICALLY
Always wear safety glasses with side shields when in a powered equipment.
welding area.
8.a. Turn off input power using the disconnect
6.g. Connect the work cable to the work as close to the welding switch at the fuse box before working on
area as practical. Work cables connected to the building the equipment.
framework or other locations away from the welding area
increase the possibility of the welding current passing through 8.b. Install equipment in accordance with the U.S. National
lifting chains, crane cables or other alternate circuits. This can Electrical Code, all local codes and the manufacturers
create fire hazards or overheat lifting chains or cables until recommendations.
they fail.
8.c. Ground the equipment in accordance with the U.S. National
6.h. Also see item 1.c. Electrical Code and the manufacturers recommendations.
6.I. Read and follow NFPA 51B Standard for Fire Prevention
During Welding, Cutting and Other Hot Work, available from
NFPA, 1 Batterymarch Park,PO box 9101, Quincy, Ma
022690-9101.
6.j. Do not use a welding power source for pipe thawing.

Refer to http://www.lincolnelectric.com/safety for additional safety information.
VANTAGE 500
iv SAFETY iv
6. Eloigner les matriaux inflammables ou les recouvrir afin de

PRCAUTIONS DE SRET
prvenir tout risque dincendie d aux tincelles.

Pour votre propre protection lire et observer toutes les instructions
et les prcautions de sret specifiques qui parraissent dans ce 7. Quand on ne soude pas, poser la pince une endroit isol de
manuel aussi bien que les prcautions de sret gnrales suiv- la masse. Un court-circuit accidental peut provoquer un
antes: chauffement et un risque dincendie.
Sret Pour Soudage A LArc 8. Sassurer que la masse est connecte le plus prs possible de
1. Protegez-vous contre la secousse lectrique: la zone de travail quil est pratique de le faire. Si on place la
masse sur la charpente de la construction ou dautres endroits
a. Les circuits llectrode et la pice sont sous tension loigns de la zone de travail, on augmente le risque de voir
quand la machine 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 cbles de grue, ou autres circuits. Cela peut provoquer des
ou les vtements mouills. Porter des gants secs et sans risques dincendie ou dechauffement des chaines et des
trous pour isoler les mains. cbles jusqu ce quils se rompent.
b. Faire trs attention de bien sisoler de la masse quand on
soude dans des endroits humides, ou sur un plancher met- 9. Assurer une ventilation suffisante dans la zone de soudage.
allique ou des grilles metalliques, principalement dans Ceci est particulirement important pour le soudage de tles
les positions assis ou couch pour lesquelles une grande galvanises plombes, ou cadmies ou tout autre mtal qui
partie du corps peut tre en contact avec la masse. produit des fumes toxiques.
c. Maintenir le porte-lectrode, la pince de masse, le cble de
soudage et la machine souder en bon et sr tat defonc- 10. Ne pas souder en prsence de vapeurs de chlore provenant
tionnement. doprations de dgraissage, nettoyage ou pistolage. La
d.Ne jamais plonger le porte-lectrode dans leau pour le chaleur ou les rayons de larc peuvent ragir avec les vapeurs
refroidir. du solvant pour produire du phosgne (gas fortement toxique)
e. Ne jamais toucher simultanment les parties sous tension ou autres produits irritants.
des porte-lectrodes connects deux machines souder
parce que la tension entre les deux pinces peut tre le total 11. Pour obtenir de plus amples renseignements sur la sret, voir
de la tension vide des deux machines. le code Code for safety in welding and cutting CSA Standard
f. Si on utilise la machine souder comme une source de W 117.2-1974.
courant pour soudage semi-automatique, ces precautions
pour le porte-lectrode sapplicuent aussi au pistolet de
soudage.
2. Dans le cas de travail au dessus du niveau du sol, se protger

PRCAUTIONS DE SRET POUR
contre les chutes dans le cas ou on recoit un choc. Ne jamais LES MACHINES SOUDER
enrouler le cble-lectrode autour de nimporte quelle partie du
corps.
TRANSFORMATEUR ET
REDRESSEUR
3. Un coup darc peut tre plus svre quun coup de soliel, donc:
a. Utiliser un bon masque avec un verre filtrant appropri ainsi 1. Relier la terre le chassis du poste conformement au code de
quun verre blanc afin de se protger les yeux du rayon- llectricit et aux recommendations du fabricant. Le dispositif
nement de larc et des projections quand on soude ou de montage ou la piece souder doit tre branch une
quand on regarde larc. bonne mise la terre.
b. Porter des vtements convenables afin de protger la peau
de soudeur et des aides contre le rayonnement de larc. 2. Autant que possible, Iinstallation et lentretien du poste seront
c. Protger lautre personnel travaillant proximit au effectus par un lectricien qualifi.
soudage laide dcrans appropris et non-inflammables.
3. Avant de faires des travaux linterieur de poste, la debranch-
4. Des gouttes de laitier en fusion sont mises de larc de er linterrupteur la boite de fusibles.
soudage. Se protger avec des vtements de protection libres
de lhuile, tels que les gants en cuir, chemise paisse, pan- 4. Garder tous les couvercles et dispositifs de sret leur place.
talons sans revers, et chaussures montantes.
5. Toujours porter des lunettes de scurit dans la zone de

soudage. Utiliser des lunettes avec crans lateraux dans les
zones o lon pique le laitier.
VANTAGE 500
Return to Master TOC v SAFETY v
Electromagnetic Compatibility (EMC)
Conformance
Products displaying the CE mark are in conformity with European Community Council Directive of 15 Dec
2004 on the approximation of the laws of the Member States relating to electromagnetic compatibility,
2004/108/EC. It was manufactured in conformity with a national standard that implements a harmonized
standard: EN 60974-10 Electromagnetic Compatibility (EMC) Product Standard for Arc Welding Equipment.
It is for use with other Lincoln Electric equipment. It is designed for industrial and professional use.
Introduction
All electrical equipment generates small amounts of electromagnetic emission. Electrical emission may be
transmitted through power lines or radiated through space, similar to a radio transmitter. When emissions
are received by other equipment, electrical interference may result. Electrical emissions may affect many
kinds of electrical equipment; other nearby welding equipment, radio and TV reception, numerical controlled
machines, telephone systems, computers, etc. Be aware that interference may result and extra precautions
may be required when a welding power source is used in a domestic establishment.
Installation and Use

The user is responsible for installing and using the welding equipment according to the manufacturers
instructions. If electromagnetic disturbances are detected then it shall be the responsibility of the user of the
welding equipment to resolve the situation with the technical assistance of the manufacturer. In some cases
this remedial action may be as simple as earthing (grounding) the welding circuit, see Note. In other cases
it could involve construction of an electromagnetic screen enclosing the power source and the work com-
plete with associated input filters. In all cases electromagnetic disturbances must be reduced to the point
where they are no longer troublesome.
Note: The welding circuit may or may not be earthed for safety reasons according to national
codes. Changing the earthing arrangements should only be authorized by a person who is
competent to access whether the changes will increase the risk of injury, e.g., by allowing
parallel welding current return paths which may damage the earth circuits of other equip-
ment.
Assessment of Area
Before installing welding equipment the user shall make an assessment of potential electromagnetic prob-
lems in the surrounding area. The following shall be taken into account:
a) other supply cables, control cables, signaling and telephone cables; above, below and adjacent to the
welding equipment;
b) radio and television transmitters and receivers;
c) computer and other control equipment;
d) safety critical equipment, e.g., guarding of industrial equipment;
e) the health of the people around, e.g., the use of pacemakers and hearing aids;
f) equipment used for calibration or measurement
g) the immunity of other equipment in the environment. The user shall ensure that other equipment being
used in the environment is compatible. This may require additional protection measures;
h) the time of day that welding or other activities are to be carried out.
VANTAGE 500
Return to Master TOC vi SAFETY vi
Electromagnetic Compatibility (EMC)
The size of the surrounding area to be considered will depend on the structure of the building and other
activities that are taking place. The surrounding area may extend beyond the boundaries of the premises.
Methods of Reducing Emissions
Mains Supply
Welding equipment should be connected to the mains supply according to the manufacturers recommenda-
tions. If interference occurs, it may be necessary to take additional precautions such as filtering of the mains
supply. Consideration should be given to shielding the supply cable of permanently installed welding equip-
ment, in metallic conduit or equivalent. Shielding should be electrically continuous throughout its length. The
shielding should be connected to the welding power source so that good electrical contact is maintained
between the conduit and the welding power source enclosure.
Maintenance of the Welding Equipment

The welding equipment should be routinely maintained according to the manufacturers recommendations.
All access and service doors and covers should be closed and properly fastened when the welding equip-
ment is in operation. The welding equipment should not be modified in any way except for those changes
and adjustments covered in the manufacturers instructions. In particular, the spark gaps of arc striking and
stabilizing devices should be adjusted and maintained according to the manufacturers recommendations.
Welding Cables
The welding cables should be kept as short as possible and should be positioned close together, running at
or close to floor level.
Equipotential Bonding
Bonding of all metallic components in the welding installation and adjacent to it should be considered.
However, metallic components bonded to the work piece will increase the risk that the operator could
receive a shock by touching these metallic components and the electrode at the same time. The operator
should be insulated from all such bonded metallic components.
Earthing of the Workpiece

Where the workpiece is not bonded to earth for electrical safety, not connected to earth because of its size
and position, e.g., ships hull or building steelwork, a connection bonding the workpiece to earth may reduce
emissions in some, but not all instances. Care should be taken to prevent the earthing of the workpiece
increasing the risk of injury to users, or damage to other electrical equipment. Where necessary, the con-
nection of the workpiece to earth should be made by a direct connection to the workpiece, but in some
countries where direct connection is not permitted, the bonding should be achieved by suitable capacitance,
selected according to national regulations.
Screening and Shielding

Selective screening and shielding of other cables and equipment in the surrounding area may alleviate
problems of interference. Screening of the entire welding installation may be considered for special applica-
tions. 1
_________________________
1 Portions of the preceding text are contained in EN 60974-10: Electromagnetic Compatibility (EMC) prod-
uct standard for arc welding equipment.
VANTAGE 500
I - MASTER TABLE OF CONTENTS FOR ALL SECTIONS - I
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Page
Safety . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .i-iv
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Section A
VANTAGE 500 Deutz F3L912 (Code 10995) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .A1
VANTAGE 500 Deutz F4L2011 (Code 11180, 11415) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .A2
VANTAGE 500 Deutz D2011L4i (Code 11468) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .A3
VANTAGE 500 Cummins B3.3 (Code 10996) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .A4
VANTAGE 500 Cummins B3.3 (Code 11181, 11416) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .A5
Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Section B
VANTAGE 500 Deutz F3L912 (Code 10995) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .B1

VANTAGE 500 Deutz F4L2011 (Code 11180, 11415) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .B2
VANTAGE 500 Deutz D2011L4i (Code 11468) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .B3
VANTAGE 500 Cummins B3.3 (Code 10996) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .B4
VANTAGE 500 Cummins B3.3 (Code 11181, 11416) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .B5
Accessories . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Section C
VANTAGE 500 Deutz F3L912 (Code 10995) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .C1
VANTAGE 500 Deutz F4L2011 (Code 11180, 11415) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .C2
VANTAGE 500 Deutz D2011L4i (Code 11468) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .C3
VANTAGE 500 Cummins B3.3 (Code 10996) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .C4
VANTAGE 500 Cummins B3.3 (Code 11181, 11416) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .C5
Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Section D
VANTAGE 500 Deutz F3L912 (Code 10995) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .D1
VANTAGE 500 Deutz F4L2011 (Code 11180, 11415) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .D2
VANTAGE 500 Deutz D2011L4i (Code 11468) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .D3
VANTAGE 500 Cummins B3.3 (Code 10996) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .D4
VANTAGE 500 Cummins B3.3 (Code 11181, 11416) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .D5
Theory of Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Section E
Troubleshooting and Repair . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Section F
Electrical Diagrams . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Section G
Parts Lists . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .P-472, P-508

VANTAGE 500 Deutz F3L912 (Code 10995) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .P-472
VANTAGE 500 Deutz F4L2011 (Code 11180, 11415) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .P-508
VANTAGE 500 Deutz D2011L4i (Code 11468) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .P-508
VANTAGE 500 Cummins B3.3 (Code 10996) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .P-472
VANTAGE 500 Cummins B3.3 (Code 11181, 11416) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .P-508
VANTAGE 500
A1.1 TABLE OF CONTENTS - INSTALLATION SECTION A1.1
Installation - VANTAGE 500 Deutz F3L912 (Code 10995)

Technical Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .A1.2
Safety Precautions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .A1.3
Location/Ventilation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .A1.3
Storing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .A1.3
Stacking . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .A1.3
Angle of Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .A1.3
Lifting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .A1.4
High Altitude Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .A1.4

High Temperature Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .A1.4
Towing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .A1.4
Vehicle Mounting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .A1.4
Pre-Operation Engine Service . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .A1.5
Oil . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .A1.5
Fuel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .A1.5
Fuel Cap . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .A1.5
Engine Cooling System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .A1.5

Battery Connection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .A1.5
Muffler Outlet Pipe . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .A1.6
Spark Arrester . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .A1.6
High Frequency Generators for TIG Applications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .A1.6
Electrical Connections . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .A1.6
Remote Control . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .A1.6
Welding Terminals . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .A1.6
Welding Output Cables . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .A1.7

Machine Grounding . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .A1.7
Auxiliary Power Receptacles . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .A1.7
Standby Power Connections . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .A1.7
VANTAGE 500
A1.2 INSTALLATION A1.2
TECHNICAL SPECIFICATIONS - Vantage 500 DEUTZ (K2271-1)

Return to Section TOC
INPUT - DIESEL ENGINE
Make /Model Description Speed (RPM) Displacement Starting Capacities

System
Deutz 3 cylinder High Idle 1900 173 cu. in 12VDC battery Fuel
F3L 912 44HP (33 kw) (2.83L) & Starter (25 US gal
Diesel Engine @ 1800 RPM Full Load 1800 94.6L)
Code 10995 Bore x Stroke Oil:
9.5 QTS.
3.94 x 4.72 9.0L
(100mm x 120mm)
RATED OUTPUT @ 104F(40C) - WELDER

Duty Cycle Welding Output Volts at Rated Amps
100% 500 Amps (DC multi-purpose) 40 Volts
60% 550 Amps (DC multi-purpose) 36 volts

OUTPUT @ 104F(40C) - 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. 1615 lbs.

(1066.8 mm) (800.1mm) (1603mm) (733kg)
(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 6.6 (167.6mm) for exhaust.
VANTAGE 500
Read this entire installation section before you LOCATION / VENTILATION

start installation.
The welder should be located to provide an unrestrict-
ed flow of clean, cool air to the cooling air inlets and to
SAFETY PRECAUTIONS avoid restricting the cooling air outlets. Also, locate the
welder so that the engine exhaust fumes are properly
WARNING vented to an outside area.
Do not attempt to use this equipment until you

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

STACKING
Do not operate with doors open or Vantage 500 machines cannot be stacked.
guards off.
Stop engine before servicing. ANGLE OF OPERATION
Keep away from moving parts 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
Only qualified personnel should install, use or ser- all directions. If the engine is to be operated at an
vice this equipment angle, provisions must be made for checking and main-
taining 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
LIFTING TOWING
The Vantage 500 lift bale should be used to lift the The recommended trailer for use with this equipment
machine. The Vantage 500 is shipped with the lift for road, in-plant and yard towing by a vehicle1 is
bale retracted. Before attempting to lift the Vantage Lincolns K2636-1. If the user adapts a non-Lincoln
500, secure the lift bale in a raised position. Secure the trailer, he must assume responsibility that the method
lift bale as follows: of attachment and usage does not result in a safety
hazard nor damage the welding equipment. Some of
a. Open the engine compartment door.
the factors to be considered are as follows:
b. Locate the two access holes on the upper mid-
1. Design capacity of the trailer vs. weight of the
dle region of the compartment wall just below
Lincoln equipment and likely additional attach-
the lift bale.
ments.
c. Use the lifting strap to raise the lift bale to the
2. Proper support of, and attachment to, the base of
full upright position. This will align the mounting
the welding equipment so that there will be no
holes on the lift bale with the access holes.
undue stress to the trailers framework.
d. Secure the lift bale with 2 thread forming
3. Proper placement of the equipment on the trailer to
screws. The screws are provided in the loose
insure stability side to side and front to back when

parts bag shipped with the machine.
being moved and when standing by itself.
4. Typical conditions of use, such as travel speed,
WARNING roughness of surface on which the trailer will be
operated, and environmental conditions.
5. Proper preventative maintenance of the trailer.
FALLING EQUIPMENT can cause injury.
6. Conformance with federal, state and local laws.1
Do not lift this machine using lift bale
if it is equipped with a heavy accesso-
ry such as a trailer or gas cylinder.
Consult applicable federal, state and local laws
1
Lift only with equipment of adequate regarding specific requirements for use on public high-
lifting capacity. ways.
Be sure machine is stable when lifting. VEHICLE MOUNTING
WARNING
HIGH ALTITUDE OPERATION
Improperly mounted concentrated loads may
At higher altitude, output derating may be necessary. cause unstable vehicle handling and tires or other
For maximum rating, derate the welder output 5% for components to fail.
every 300 meters (984 ft.) above 1500 meters (4920
ft.). For output of 500A and below, derate the welder Only transport this Equipment on serviceable
output 5% for every 300 meters (984 ft.) above 2100 vehicles which are rated and designed for such
meters (6888 ft.) loads.
Distribute, balance and secure loads so vehicle
Contact a Deutz Service Representative for any engine
is stable under conditions of use.
adjustments that may be required.
Do not exceed maximum rated loads for compo-
nents such as suspension, axles and tires.
HIGH TEMPERATURE OPERATION Mount equipment base to metal bed or frame of
At temperatures above 30C (86F), output voltage vehicle.
derating is necessary. For maximum output current rat- Follow vehicle manufacturers instructions.
ings, derate the welder voltage rating two volts for

every 10C (21F) above 30C (86F).
VANTAGE 500
PRE-OPERATION ENGINESERVICE ENGINE COOLING SYSTEM

READ the engine operating and maintenance instruc- The Deutz engine is air cooled by a belt-driven axial
tions supplied with this machine. blower. The oil cooler and engine cooling fins should
be blown out with compressed air or steam to maintain
proper cooling. (See the engine Operators Manual for
WARNING procedures and frequency.)
Keep hands away from the engine

muffler or HOT engine parts.
Stop engine and allow to cool before BATTERY CONNECTION
fueling.
WARNING
Do not smoke when fueling.
GASES FROM BATTERY can explode.
Fill fuel tank at a moderate rate and do not over-
Keep sparks, flame and cigarettes
fill.
away from battery.
Wipe up spilled fuel and allow fumes to clear
before starting engine.

To prevent EXPLOSION when:
Keep sparks and flame away from tank.
INSTALLING A NEW BATTERY disconnect neg-
ative cable from old battery first and connect to
OIL
new battery last.
The Vantage500 is shipped with the engine
CONNECTING A BATTERY CHARGER remove
crankcase filled with high quality SAE 10W-30 oil (API
battery from welder by disconnecting negative
class CD or better). Check the oil level before starting
cable first, then positive cable and battery clamp.
the engine. If it is not up to the full mark on the dip
When reinstalling, connect negative cable last.
stick, add oil as required. Check the oil level every four
Keep well ventilated.
hours of running time during the first 35 running hours.
Refer to the engine Operators Manual for specific oil USING A BOOSTER connect positive lead to
recommendations and break-in information. The oil battery first then connect negative lead to nega-
change interval is dependent on the quality of the oil tive battery lead at engine foot.
and the operating environment. Refer to the engine
BATTERY ACID can burn eyes and skin.
Operators Manual for the proper service and mainte-
nance intervals. Wear gloves and eye protection and

be careful when working near bat-
FUEL tery.
Follow instructions printed on bat-
NOTE: USE DIESEL FUEL ONLY.
tery.
Fill the fuel tank with clean, fresh diesel fuel. The
capacity of the fuel tank is approx 95 liters. See engine
Operators Manual for specific fuel recommendations.
Running out of fuel may require bleeding the fuel
injection pump.
NOTE: Before starting the engine, open the fuel shut-
off valve (pointer to be in line with hose).
FUEL CAP
Remove the plastic cap covering from the fuel tank filler
neck and install the fuel cap.
VANTAGE 500
IMPORTANT: To prevent ELECTRICAL DAMAGE HIGH FREQUENCY GENERATORS

WHEN:
FOR TIG APPLICATIONS
a) Installing new batteries
The K799 Hi-Freq Unit (obsolete) and the K930-1 or-2
b) Using a booster TIG Module are suitable for use with the Vantage
Use correct polarity Negative Ground. 500. The Vantage 500 is equipped with the required
R.F. bypass circuitry for the connection of high fre-
The Vantage 500 is shipped with the negative battery quency generating equipment. The high frequency
cable disconnected. Before you operate the machine, bypass network supplied with the K799 Hi-Freq Unit
make sure the Engine Switch is in the OFF position does NOT need to be installed into the Vantage 500.
and attach the disconnected cable securely to the neg-
ative (-) battery terminal. The Vantage 500 and any high frequency generating
equipment must be properly grounded. See the K799
Remove the insulating cap from the negative battery Hi-Freq Unit and the K930-1 or-2 TIG Module operat-
terminal. Replace and tighten the negative battery ing manuals for complete instructions on installation,
cable terminal. operation, and maintenance.
NOTE: This machine is furnished with a wet charged
battery; if unused for several months, the bat-

tery may require a booster charge. Be sure to ELECTRICAL CONNECTIONS

use the correct polarity when charging the bat-
tery.
REMOTE CONTROL
MUFFLER OUTLET PIPE The Vantage 500 is equipped with a 6-pin and a 14-
pin connector. The 6-pin connector is for connecting
Remove the plastic plug covering the muffler outlet the K857 or K857-1 Remote Control (optional) or, in the
tube. Using the clamp provided, secure the outlet pipe case of TIG welding applications, with the foot or hand
to the outlet tube with the pipe positioned to direct the Amptrol (K870 or K963-1 respectively).
exhaust in the desired direction.
The 14-pin connector is used to directly connect a wire
feeder or TIG Module (K930-1 or-2) control cable.
SPARK ARRESTER
NOTE: When using the 14-pin connector, if the wire
Some federal, state or local laws may require that feeder has a built-in power source output con-
gasoline or diesel engines be equipped with exhaust trol, do not connect anything to the 6-pin con-
spark arresters when they are operated in certain loca- nector.
tions where unarrested sparks may present a fire haz-

ard. The standard muffler included with this welder
does not qualify as a spark arrester. When required by WELDING TERMINALS
local regulations, a suitable spark arrester must be The Vantage 500 is equipped with a toggle switch for
installed and properly maintained. selecting "hot" welding terminals when in the "WELD
TERMINALS ON" position or "cold" welding terminals
when in the "WELDING TERMINALS REMOTELY
CAUTION CONTROLLED" position.
An incorrect arrester may lead to damage to the
engine or adversely affect performance.
VANTAGE 500
WELDING OUTPUT CABLES

With the engine off, route the electrode and work In general, if the machine is to be grounded, it should
cables through the strain relief bracket provided on the be connected with a #8 or larger copper wire to a solid
front of the base and connect to the terminals provided. earth ground such as a metal water pipe going into the
These connections should be checked periodically and ground for at least ten feet and having no insulated
tightened if necessary. joints, or to the metal framework of a building which has
been effectively grounded. The U.S. National Electrical
Listed in Table A1.1 are copper cable sizes recom-
Code lists a number of alternate means of grounding
mended for the rated current and duty cycle. Lengths
electrical equipment. A machine grounding stud
stipulated are the distance from the welder to work and
marked with the symbol is provided on the front of
back to the welder again. Cable sizes are increased for
the welder.
greater lengths primarily for the purpose of minimizing
cable voltage drop.
AUXILIARY POWER RECEPTACLES
The auxiliary power capacity of the Vantage 500 is
TABLE A1.1 COMBINED LENGTH OF
12,000 watts of 60 Hz, single-phase power. The auxil-
ELECTRODE AND WORK CABLES
iary power capacity rating in watts is equivalent to volt-
amperes at unity power factor. The maximum permis-

Total Combined Length of sible current of the 240 VAC output is 50 A. The 240
Electrode and Work Cables VAC output can be split to provide two separate 120
VAC outputs with a maximum permissible current of
Amps
50 A per output to two separate 120 VAC branch cir-
@ 100%
cuits. The output voltage is within 10% at all loads up
Duty Cycle Up to 150 ft. 150-200 ft. 200-250 ft.
to rated capacity.
500 3/0 AWG 3/0 AWG 4/0 AWG
NOTE: The 120/240V receptacle has two 120V outlets
of different phases and cannot be paralleled.
The Vantage 500 has two 20A-120VAC (5-20R)
MACHINE GROUNDING duplex receptacles and one 50A-120/240 VAC (14-
50R) receptacle. The 120/240 VAC receptacle can be
Because this portable engine driven welder creates its
split for single-phase 120 VAC operation. The auxiliary
own power, it is not necessary to connect its frame to
power receptacles should only be used with three-wire
an earth ground, unless the machine is connected to
grounded type plugs or approved double insulated
premises wiring (home, shop, etc.).
tools with two-wire plugs. The current rating of any plug

To prevent dangerous electric shock, other equipment used with the system must be at least equal to the cur-
powered by this engine driven welder must: rent capacity of the associated receptacle.
a) be grounded to the frame of the welder using a
grounded type plug, STANDBY POWER CONNECTIONS
or The Vantage 500 is suitable for temporary, standby or
emergency power using the engine manufacturers
b) be double insulated.
recommended maintenance schedule.
When this welder is mounted on a truck or trailer, its
The Vantage 500 can be permanently installed as a
frame must be securely connected to the metal frame
standby power unit for 240 volt, three-wire, 50 amp ser-
of the vehicle. When this engine driven welder is con-
vice. Connections must be made by a licensed electri-
nected to premises wiring such as that in a home or
cian who can determine how the 120/240 VAC power
shop, its frame must be connected to the system earth
can be adapted to the particular installation and com-
ground. See further connection instructions in the sec-
ply with all applicable electrical codes. The following
tion entitled Standby Power Connections as well as
information can be used as a guide by the electrician
the article on grounding in the latest U.S. National
for most applications. Refer to the connection diagram

Electrical Code and the local code.
shown in Figure A1.1.
VANTAGE 500
1. Install the double-pole, double-throw switch able -10% of rated voltage, which may damage
between the power company meter and the appliances or other motor-driven equipment and
premises disconnect. may result in overheating of the Vantage 500
engine.
Switch rating must be the same as or greater than the
customers premises disconnect and service over cur- 3. Install a 50 amp 120/240 VAC plug (NEMA Type
rent protection. 14-50) to the double-pole circuit breaker using
four-conductor cable of the proper size and desired
2. Take necessary steps to assure load is limited to
length. (The 50 amp, 120/240 VAC plug is avail-
the capacity of the Vantage by installing a 50 amp,
able in the optional K802R plug kit.)
240 VAC double-pole circuit breaker. Maximum
rated load for each leg of the 240 VAC auxiliary is 4. Plug this cable into the 50 amp 120/240 volt recep-
50 amperes. Loading above the rated output will tacle on the Vantage 500 case front.
reduce output voltage below the allow-
Figure A1.1 Connection of the Vantage 500 to Premises Wiring

240 VOLT
GROUNDED CONDUCTOR
240 Volt POWER
120 VOLT
60 Hz.
3-Wire COMPANY
Service 120 VOLT
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 4 CONDUCTOR COPPER CABLE
SEE NATIONAL ELECTRICAL CODE FOR
WIRE SIZE RECOMMENDATIONS.
VANTAGE 500
B1.1 TABLE OF CONTENTS - OPERATION SECTION B1.1
Operation - VANTAGE 500 Deutz F3L912 (Code 10995)

Operating Instructions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .B1.2
Safety Instructions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .B1.2
General Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .B1.2
Recommended Applications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .B1.3
Design Features and Advantages . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .B1.3
Controls andSettings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .B1.4
Engine Controls . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .B1.4
Welding Controls . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .B1.5

Auxiliary Power Controls . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .B1.6
Engine Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .B1.7
Starting the Engine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .B1.7
Stopping the Engine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .B1.7
Break-In Period . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .B1.7
Typical Fuel Consumption . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .B1.7
Welder Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .B1.8
Stick Welding . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .B1.8

Constant Current (CC)Welding . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .B1.8
Pipe Welding . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .B1.8
TIGWelding . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .B1.8
Wire Feed (Constant Voltage) Welding . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .B1.10
Auxiliary Power Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .B1.10
Arc Gouging . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .B1.10
Paralleling . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .B1.10
Simultaneous Welding and Auxiliary Power Loads . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .B1.11

Extension Cord Recommendations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .B1.11
VANTAGE 500
B1.2 OPERATION B1.2
OPERATING INSTRUCTIONS ENGINE EXHAUST can kill.

Read and understand this entire section before oper- Use in open, well ventilated areas or
ating your Vantage 500. vent exhaust outside
engine.
SAFETY INSTRUCTIONS
Do not operate with doors open or
WARNING guards off.
Do not attempt to use this equipment until you Stop engine before servicing.
Keep away from moving parts
include important safety precautions: detailed Only qualified personnel should operate this
engine starting, operating, and maintenance equipment.
ADDITIONAL SAFETY PRECAUTIONS

Always operate the welder with the hinged door closed
Do not touch electrically live parts or and the side panels in place, as these provide maxi-
electrodes with your skin or wet mum protection from moving parts and insure proper
clothing. cooling air flow.
Insulate yourself from the work and
ground.
GENERAL DESCRIPTION
Always wear dry insulating gloves.
The Vantage 500 is a diesel engine-driven welding
power source. The machine uses a brush type alter-
FUMES AND GASES CAN BE
nating current generator for DC multi-purpose welding
DANGEROUS. and for 120/240 VAC auxiliary standby power. The
Keep your head out of fumes. welding control system uses state of the art Chopper
Technology.
Use ventilation or exhaust to remove

fumes from breathing zone. The generator has a single sealed bearing for mainte-
nance free service. The rotor is a copper wound design
with two slip rings and brushes. The stator is wound
entirely with heavy gauge copper wire and insulated
WELDING SPARKS CAN CAUSE with NEMA class F insulation material. The stator is
FIRE OR EXPLOSION. then impregnated with three layers of high quality var-
nish. After the stator is assembled using tie bars, the
Keep flammable material away. entire assembly is covered with an environmental pro-
Do not weld on containers that have tective coating. These measures insure trouble-free
held combustibles. operation in the harshest environments.
The fuel tank is made from high density polyethylene
and holds 25 gallons (94.6 liters) of diesel fuel. This
will provide enough fuel to run for more than 12 hours
ARC RAYS CAN BURN. at full load.
Wear eye, ear, and body protection.
The Deutz F3L-912 engine is equipped with a stan-

dard, heavy duty, combination fuel filter/water separa-

tor element.
VANTAGE 500
B1.3 OPERATION B1.3
RECOMMENDED APPLICATIONS FOR AUXILIARY POWER

12,000 watts of 120/240 VAC, 60Hz auxiliary power.

WELDER
Power for tools, 120/240 VAC lights, electric pumps
The Vantage 500 provides excellent constant current and for standby emergency power.
DC welding output for stick (SMAW) and TIG welding.
Drive a 5 HP motor (provided it is started under no
The Vantage 500 also provides excellent constant
load).
voltage DC welding output for MIG (GMAW) and
Innershield (FCAW) welding. Two 20 amp 120 VAC duplex receptacles for up to 40
amps of 120 VAC power.
GENERATOR One 50 amp, 120/240 VAC dual voltage receptacle
The Vantage 500 provides smooth 120/240 VAC out- for up to 50 amps of 240 VAC, and up to 50 amps per
put for auxiliary power and emergency standby power. side to separate branch circuits (not in parallel) of
120 VAC single-phase auxiliary power. Allows easy
connection to premises wiring.
DESIGN FEATURES AND ADVANTAGES
Weld and AC auxiliary power at the same time (with-
K1639-2 VANTAGE 500 DELUXE MODEL
in machine total capacity).

FEATURES
OTHER FEATURES
FOR WELDING
Excellent DC multi-purpose welding for stick, MIG, Deutz 3-cylinder, air/oil cooled diesel engine.
TIG, cored wire and arc gouging applications. Designed for long life, easy maintenance, and
30 to 500 amps output in five slope-controlled ranges excellent fuel economy.
for out-of position and pipe electrodes, one constant Engine protection system shuts the engine down for
current output range for general purpose welding, low oil pressure, high oil temperature, or a broken
one constant voltage range for MIG wire and cored fan/engine alternator belt.
wire welding and one 20-250 amp range for Touch
Start TIG welding. Gauges for oil pressure, oil temperature, engine
alternator output, and fuel level.
100% duty cycle at 500 amps output and 50% duty
cycle at 575 amps output. Indicator lights for Engine Protection, and Battery
(engine alternator low output/broken belt).
Dual 3-digit output meters are provided (optional on
K1639-1) for presetting the weld amperage or volt- Engine hour meter standard on all models.
age and displaying the actual amperage and voltage Extended range 25 gallon (94.6 l) fuel tank.
during welding. The meters use superbrite L.E.D.'s
for improved readability in full sunlight. Automatic idler reduces engine speed when not
welding or drawing auxiliary power. This feature
LOOK-BACK FEATURE: After welding has stopped, reduces fuel consumption and extends engine life.
both displays will remain on for 7 seconds with the
last current and voltage value displayed. During this Compact size fits crosswise in full size pickup truck.
time, the left-most decimal point in each display will Single-side engine service.
be FLASHING.
Copper alternator windings and high temperature
Standard remote control capability with 14-pin and insulation for dependability and long life.
6-pin connectors for easy connection of Lincoln
remote control accessories. New paint system on case and base for outstanding
corrosion protection.
An internal "Solid State" contactor allows for the
selection of "hot" or "cold" output terminals with a
toggle switch on the control panel.
Arc Control potentiometer in Wire and Stick modes

for precise adjustment of arc characteristics.
Advanced circuitry to prevent pop-outs in the five
slope modes.
VANTAGE 500
B1.4 OPERATION B1.4
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 B1.1 Case Front Panel Controls
4 5 6 7 8 9
10
11
12
14
13 19
20
1
2
18
15
16
17 21
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
Toggling the switch to the RUN position energizes
scheduling preventive maintenance.
the fuel solenoid for approximately 30 seconds. The
engine must be started within that time or the fuel
solenoid will denergize, and the switch must be tog- 4. FUEL LEVEL GAUGE
gled to reset the timer.
Displays the level of diesel fuel in the fuel tank.
2. START PUSHBUTTON
The operator must watch the fuel level closely to
Energizes the starter motor to crank the engine. With prevent running out of fuel and possibly having to
the engine "Run / Stop" switch in the "Run" position, bleed the system.
push and hold the Start button to crank the engine;
5. ENGINE TEMPERATURE GAUGE
release as the engine starts. Do not press while
engine is running since this can cause damage to The gauge displays the engine coolant temperature.
the ring gear and/or starter motor
VANTAGE 500
B1.5 OPERATION B1.5
6. OIL PRESSURE GAUGE 10. DIGITAL OUTPUT METERS: (Optional)

The gauge displays the engine oil pressure when the The digital meters allow the output voltage (CV-WIRE
engine is running. mode) or current (CC-STICK, DOWNHILL PIPE and
TIG modes) to be set prior to welding using the OUT-
PUT control knob. During welding, the meters display
7. ENGINEPROTECTION the actual output voltage (VOLTS) and current (AMPS).
The yellow engine protection light remains off with A memory feature holds the display of both meters on
proper oil pressure and under normal operating tem- the seven seconds after welding is stopped. This
peratures. If the light turns on, the engine protection allows the operator to read the actual current and volt-
system will stop the engine. Check for proper oil and age just prior to when welding was ceased. While the
coolant levels and add oil and/or coolant if neces- display is being held the left-most decimal point in each
sary. Check for loose or disconnected leads at the oil display will be flashing. The accuracy of the meters is
pressure sender located on the engine. The light will 3%.
remain on when the engine has been shut down as
long as the Run/Stop switch is in the Run position.
11. WELDMODESELECTORSWITCH:
NOTE: This engine is equipped with an electronic
governor system. The engine speed ramps (Provides four selectable welding modes)
up during a warm up period. The complete CV-WIRE

cycle takes approximately 3 minutes. This DOWNHILL PIPE
allows the engine cylinder temperature to
build up slowly before going to full speed. CC-STICK
This feature is bypassed if the engine is TOUCH START TIG
already warm. The Engine may produce
White Smoke for a few minutes at low tem-
peratures. Do not apply a load to the 12. ARCCONTROL:
machine during the warm up period. The ARCCONTROL WIRE/STICK knob is active in the
WIRE and STICK modes, and has different functions in
these modes. This control is not active in the TIG
8. BATTERY CHARGING LIGHT mode.
The yellow engine alternator light is off when battery CC-STICK mode: In this mode, the ARC CONTROL
charging system is functioning normally. If light turns knob sets the short circuit current (arc-force) during
on the alternator or the voltage regulator may not be stick welding. Increasing the number from -10(Soft) to
operating correctly. The light will remain on when the +10 (Crisp) increases the short circuit current and pre-
engine is stopped and the Run/Stop switch is in the vents sticking of the electrode to the plate while weld-
Run position. ing. This can also increase spatter. It is recommended
WELDING CONTROLS (Items 9 through 17) that the ARCCONTROL be set to the minimum num-
ber without electrode sticking. Start with a setting at 0.
DOWNHILL PIPE mode: In this mode, the ARC CON-
9. OUTPUT CONTROL: The OUTPUT dial is used to TROL knob sets the short circuit current (arc-force)
preset the output voltage or current as displayed on the during stick welding to adjust for a soft or a more force-
digital meters for the four welding modes. When in the ful digging arc (Crisp). Increasing the number from -10
CC-STICK, DOWNHILL PIPE or CV-WIRE modes and (Soft) to +10 (Crisp) increases the short circuit current
when a remote control is connected to the 6-Pin or 14- which results in a more forceful digging arc. Typically a
Pin Connector, the auto-sensing circuit automatically forceful digging arc is preferred for root and hot pass-
switches the OUTPUT CONTROL from control at the es. A softer arc is preferred for fill and cap passes
welder to the remote control. In the CV-WIRE mode, where weld puddle control and deposition (stacking of
when the wire feeder control cable is connected to the iron) are key to fast travel speeds. It is recommended
14-pin connector the auto-sensing circuit automatically that the ARC CONTROL be set initially at 0.
makes OUTPUT CONTROL inactive and the wire feed-
CV-WIRE mode: In this mode, turning the ARCCON-

er voltage control (if present) active.

TROL knob from -10(soft) to +10(crisp) changes the
arc from soft and washed-in to crisp and narrow. It acts
When in the TOUCH START TIG mode and when a as an inductance/pinch control. The proper setting
Amptrol is connected to the 6-pin Connector, the OUT- depends on the procedure and operator preference.
PUT dial is used to set the maximum current range of Start with a setting of 0.
the CURRENT CONTROL of the Amptrol.
VANTAGE 500
B1.6 OPERATION B1.6
13. WELDING TERMINALS SWITCH 21. 120VAC SINGLE PHASE RECEPTACLES

In the WELDTERMINALSON position, the output is These two 120VAC (5-20R) receptacles with GFCI
electrically hot all the time. In the REMOTELYCON- protection provide 120VAC single phase for auxiliary
TROLLED position, the output is controlled by a wire power. Each receptacle has a 20 amp total rating.
feeder or amptrol device, and is electrically off until a They are designed to protect the user from the haz-
remote switch is depressed. ards of ground faults. When the GFCI has tripped
there will be no voltage available from the receptacle.
Refer to the AUXILIARY POWER RECEPTACLES
14. WIREFEEDERVOLTMETERSWITCH: section in the installation chapter for further informa-
Matches the polarity of the wire feeder voltmeter to the polari- tion about these receptacles. Also refer to the AUX-
ty of the electrode. ILIARY POWER OPERATION section later in this
chapter.
15. 6 - PIN CONNECTOR

22. GROUND STUD
For attaching optional remote control equipment. Includes
auto-sensing remote control circuit. Provides a connection point for connecting the
machine case to earth ground. Refer to MACHINE
GROUNDING in the Installation chapter for proper

16. 14 - PIN CONNECTOR machine grounding information.
For attaching wire feeder control cables. Includes contactor
closure circuit, auto-sensing remote control circuit, and
120VAC and 42VAC power.
NOTE: When a wire feeder with a built in welding voltage con-
trol is connected to the 14-pin connector, do not connect any-
thing to the 6-pin connector.
7. WELD OUTPUT TERMINALS + AND

These 1/2 - 13 studs with flange nuts provide welding con-
nection points for the electrode and work cables. For positive
polarity welding the electrode cable connects to the + termi-
nal and the work cable connects to this terminal. For nega-
tive polarity welding the work cable connects to the + termi-
nal and the electrode cable connects to this terminal.
AUXILIARY POWER CONTROLS (Items 18-21)
18. 120/240 VAC SINGLE PHASE RECEPTACLE

This is a 120/240VAC (14-50R) receptacle that provides
240VAC or can be split for 120VAC single phase auxiliary
power. This receptacle has a 50 amp rating. Refer to the AUX-
ILIARY POWER RECEPTACLES section in the installation
chapter for further information about this receptacle. Also refer
to the AUXILIARY POWER OPERATION section later in this
chapter.
20. CIRCUIT BREAKERS

These circuit breakers provide separate overload
current protection for each 120V circuit at the 240V

single phase receptacle, each 120V single phase
receptacle, the 240V three phase receptacle, the
120VAC in the 14-Pin connector, the 42VAC in the
14-Pin connector and battery circuit overload protec-
tion.
VANTAGE 500
B1.7 OPERATION B1.7
ENGINE OPERATION IMPORTANT

IN ORDER TO ACCOMPLISH THIS BREAK-IN, THE UNIT

STARTING THE ENGINE
SHOULD BE SUBJECTED TO HEAVY LOADS, WITHIN
1. Open the engine compartment door and check that THE RATING OF THE MACHINE. AVOID LONG IDLE RUN-
the fuel shutoff valve is in the open position (lever to NING PERIODS.
be in line with the hose).
2. Check for proper oil level and coolant level. Close
engine compartment door. TYPICAL FUEL CONSUMPTION
3. Remove all plugs connected to the AC power recep- Refer to Table B1.1 for typical fuel consumption of the VAN-
tacles. TAGE 500 Engine for various operating scenarios.
4. Set IDLER switch to AUTO.
5. Set the RUN/STOP switch to RUN. Observe that
Table B1.1 DEUTZ F3L 912
the engine protection and battery charging lights are
ENGINE FUEL CONSUMPTION
on. The engine protection light may turn off after 5
seconds or remain on until the engine is started. Deutz F3L 912 Running Time
6. Within 30 seconds, press and hold the engine 44.2 HP for 25 Gallons
START button until the engine starts. If the engine @1800 rpm (Hours)
does not start within 30 seconds the RUN/STOP High Idle .66 gallons/hour 37.9
switch must be returned to the STOP position, then No Load (2.50 liters/hour)
return to step 5. 1900 rpm
7. Release the engine START button when the engine DC-CC 1.94 gallons/hour 12.9
starts. Welding (7.34 liters/hour)
8. Check that the engine protection and battery charg- 500A @40V
ing lights are off. Investigate any indicated problem. Auxiliary Power 1.31 gallons/hour 19.1
NOTE: The engine will go through a 3 minute warm-up 12,000 VA (4.96 liters/hour)
cycle if cold. If the engine coolant is still warm
from recent operation, the engine will go imme-
diately to high idle and then to low idle if the idle
switch is in the AUTO position.
COLD WEATHER STARTING

With a fully charged battery and the proper weight oil,

the engine should start satisfactorily even down to
about 0F(-18C). If the engine must be frequently
started below 10(-12C), it may be desirable to install
the optional ether start kit (K887-1). Installation and
operating instructions are included in the kits.
STOPPING THE ENGINE

Switch the RUN/STOP switch to STOP. This turns off
the voltage supplied to the shutdown solenoid. A back-
up shutdown can be accomplished by shutting off the
fuel valve located on the fuel line.
BREAK-IN PERIOD
The engine used to supply power for your welder is a heavy
duty, industrial engine. It is designed and built for rugged use.
It is very normal for any engine to use small quantities of oil
until the break-in is accomplished. Check the oil level twice a
day during the break-in period. In general this takes 50 to 100
hours of operation.
VANTAGE 500
B1.8 OPERATION B1.8
WELDER OPERATION
DUTY CYCLE TOUCH START TIG MODE

Duty Cycle is the the ratio of the uninterrupted on-load The Vantage 500 can be used in a wide variety of DC
duration to 10 minutes. The total time period of one TIGwelding applications.
complete on-load and no-load cycle is 10 minutes. For
The TOUCHSTARTTIG setting of the MODE switch is
example, in the case of a 60% duty cycle, load is
for DC TIG (Tungsten Inert Gas) welding. To initiate a
applied continuously for 6 minutes followed by a no-
weld, the OUTPUT CONTROL knob is first set to the
load period of 4 minutes.
desired current and the tungsten is touched to the work.
STICK WELDING MODE During the time the tungsten is touching the work there
is very little voltage or current and, in general, avoids
The Vantage can be used with a broad range of DC
tungsten contamination. Then, the tungsten is gently lift-
stick electrodes.
ed off the work in a rocking motion, which establishes
The MODE switch provides two stick welding settings the arc.
as follows:
To stop the arc, simply lift the TIG torch away from the
work piece. When the arc voltage reaches approxi-
CC-STICK MODE mately 30 volts, the arc will go out and the machine will
automatically reset to the touch start current level. The
The CC-STICK position of the MODE switch is
tungsten may then be retouched to the work piece to
designed for horizontal, vertical-up and overhead weld-
restrike the arc. The arc may also be started and
ing with all types of electrodes, especially low hydrogen.
stopped with an Amptrol or Arc Start Switch.
The OUTPUT CONTROL knob adjusts the full output
range for stick welding. The ARCCONTROL is not active in the TIG mode.
The ARC CONTROL knob sets the short circuit (arc- In general the Touch Start feature avoids tungsten con-
force) current during stick welding. Increasing the num- tamination without the use of a Hi-frequency unit. If the
ber from -10 (Soft) to +10 (Crisp) increases the short use of a high frequency generator is desired, the K930-
circuit current and prevents sticking of the electrode to 2 TIG Module can be used with the Vantage. The set-
the plate while welding. This can also increase spatter. tings are for reference.
It is recommended that the ARC CONTROL be set to The Vantage is equipped with the required R.F. bypass
the minimum number without electrode sticking. Start circuitry for the connection of high frequency generat-
with the knob set at 0. ing equipment.
The Vantage and any high frequency generating equip-
DOWNHILL PIPE MODE ment must be properly grounded. See the K930-2 TIG
This slope controlled setting is intended for out-of-posi- Module operating manuals for complete instructions on
tion and down hill pipe welding where the operator installation, operation, and maintenance.
would like to control the current level by changing the When using the TIG Module, the OUTPUT control on
arc length. The OUTPUT CONTROL knob adjusts the the Vantage is used to set the maximum range of the
full output range for pipe welding. CURRENTCONTROL on the TIG Module or an Amptrol
The ARC CONTROL knob sets the short circuit current if connected to the TIG Module.
(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 pass-
es where weld puddle control and deposition (stacking
of iron) are key to fast travel speeds. It is recommend-
ed that the ARC CONTROL be set initially at 0.
VANTAGE 500
B1.9 OPERATION B1.9
TABLE B1.2 TYPICAL CURRENT RANGES1 FOR TUNGSTEN ELECTRODES2

Approximate Argon Gas Flow Rate

DCEN(-) DCEP(+) C.F.H. (l/min.)
Tungsten
Electrode 1%, 2% 1%, 2% TIGTORCH
Diameter Thoriated Thoriated Nozzle
in. (mm) Tungsten Tunsten Aluminum Stainless Steel Size4, 5
0.010 (.25) 2-15 3

3-8 (2-4) 3-8 (2-4) #4, #5, #6
0.020 (.50) 5-20 3
5-10 (3-5) 5-10 (3-5)
0.40 (1.0) 15-80 3
5-10 (3-5) 5-10 (3-5)
1/16 (1.6) 70-150 10-20 5-10 (3-5) 9-13 (4-6) #5, #6
3/32 (2.4) 150-250 15-30 13-17 (6-8) 11-15 (5-7) #6, #7, #8
1/8 (3.2) 250-400 25-40 15-23 (7-11) 11-15 (5-7)
5/32 (4.0) 400-500 40-55 21-25 (10-12) 13-17 (6-8) #8, #10
3/16 (4.8) 500-750 55-80 23-27 (11-13) 18-22 (8-10)
1/4 (6.4) 750-1000 80-125 28-32 (13-15) 23-27 (11-13)
When used with argon gas. The current ranges shown must be reduced when using argon/helium or pure helium shielding gases.
1
2
Tungsten electrodes are classified as follows by the American Welding Society (AWS):
Pure EWP
1% Thoriated EWTh-1
2% Thoriated EWTh-2
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.
DCEP is not commonly used in these sizes.
3
TIG torch nozzle sizes are in multiples of 1/16ths of an inch:

4
# 4 = 1/4 in. (6 mm) # 7 = 7/16 in. (11 mm)

# 5 = 5/16 in. (8 mm) # 8 = 1/2 in. (12.5 mm)
# 6 = 3/8 in. (10 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 break-
age, but cannot withstand high temperatures and high duty cycles.
VANTAGE 500 SETTINGS WHEN USING THE K799 VANTAGE 500 SETTINGS WHEN USING A K930-[ ]
HI-FREQ UNIT TIG MODULE
Set the WELD MODE switch to the 20-250 setting Set the WELD MODE switch to the 20-250 setting
(TIG). (TIG).
Set the IDLER switch to the HIGH position. Set the IDLER switch to the AUTO position.
Set the WELDING TERMINALS switch to the WELD Set the WELDING TERMINALS switch to the
TERMINALS ON position. This will close the solid REMOTELY CONTROLLED position. This will keep
state contactor and provide an always hot electrode. the solid state contactor open and provide a cold
electrode until the triggering device (Amptrol or Arc
NOTE: This is necessary because the K799 circuitry
Start Switch) is pressed.

does not provide the proper signal to open and close

the solid state contactor in the Vantage 500.
VANTAGE 500
B1.10 OPERATION B1.10
WIRE FEED (CONSTANT VOLTAGE) The auxiliary power receptacles should only be used
WELDING with three-wire grounded type plugs or approved dou-

ble insulated tools with two wire plugs.
Connect a wire feeder to the Vantage 500 and set
welder controls according to the instructions listed ear- The current rating of any plug used with the system
lier in this section. See the operators manual for the must be at least equal to the current capacity of the
wire feeder or the Diagrams section of this manual associated receptacle.
for connecting instructions of various Lincoln wire feed-
ers. SIMULTANEOUS WELDING AND
The Vantage 500 in the CV-WIRE position can be AUXILIARY POWER LOADS
used with a broad range of flux cored wire (Innershield It must be noted that the above auxiliary power ratings
and Outershield) electrodes and solid wires for MIG are with no welding load. Simultaneous welding and
welding (GMAW). Welding can be finely tuned using power loads are specified in Table B1.3. The permis-
the ARC CONTROL. sible currents shown assume that current is being
Some recommended Innershield electrodes are: NR- drawn from either the 120 VAC or 240 VAC supply (not
311, NS-3M, NR-207, NR-203 Ni 1%, NR-204-H. both at the same time).
Recommended Outershield electrodes are: 0S-70, 0S-

71M. ARC GOUGING
Some recommended solid wires for MIG welding are: For optimal performance when arc gouging, set the
.035 (0.9 mm), .045 (1.1 mm) and .052 (1.3 mm), L-50 Vantage 500 WELD MODE switch to the CC - STICK
and L-56, .035 (0.9 mm) and .045 (1.1 mm) Blue Max position, and the ARC CONTROL to 10.
MIG 308 LS. Set the OUTPUT knob to adjust output current to the
For any electrodes, including the above recommenda- desired level for the gouging electrode being used
tions, the procedures should be kept within the rating of according to the ratings in the following table:
the machine. For additional electrode information, see
Lincoln publications N-675, GS-100 and GS-210.
Electrode Current Range
Diameter (DC, electrode positive)
AUXILIARY POWER OPERATION 1/8 30-60 Amps
5/32 90-150 Amps
Full power is available regardless of the welding control 3/16 150-200 Amps
settings, if no welding current is being drawn.

1/4 200-400 Amps

The auxiliary power of the Vantage 500 consists of 5/16 250-400 Amps
two 20 Amp-120VAC (5-20R) duplex receptacles and 3/8 350-575 Amps*
one 50 Amp-120/240 VAC (14-50R) receptacle. The
120/240VAC receptacle can be split for single phase
120 VAC operation. * Maximum current setting is limited to the Vantage 500
maximum of 575 Amps.
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 PARALLELING
factor. The maximum permissible current of the 240 When paralleling machines in order to combine their
VAC output is 50 A. The 240 VAC output can be split to outputs, all units must be operated in the CC - STICK
provide two separate 120 VAC outputs with a maxi- mode only. To achieve this, turn the WELD MODE
mum permissible current of 50 A per output to two sep- switch to the CC - STICK position. Operation in other
arate 120 VAC branch circuits. Output voltage is within modes may produce erratic outputs and large output
10% at all loads up to rated capacity. iimbalances between the units.
NOTE: The 120/240V receptacle has two 120V out-

puts of different phases and cannot be paral-
leled.
VANTAGE 500
TABLE B1.3 Vantage 500 Duetz 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.
EXTENSION CORD
RECOMMENDATIONS
An extension cord can be used with the auxiliary power
outputs as long as it is of ample size. Table B1.4 lists
permissible extension cord lengths based on conduc-
tor size and auxiliary power output.
TABLE B1.4 VANTAGE 500 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 48010 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
Return to Section TOC Return to Section TOC Return to Section TOC Return to Section TOC
Return to Master TOC Return to Master TOC Return to Master TOC Return to Master TOC B1.12
NOTES
VANTAGE 500
B1.12
C1.1 TABLE OF CONTENTS - ACCESSORIES SECTION C1.1
Accessories - VANTAGE 500 Deutz F3L912 (Code 10995)

Options/Accessories . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .C1.1
Optional Field Installed Accessories . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .C1.2
Plasma Cutting Option . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .C1.2
TIG Welding Options . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .C1.3
High Frequency Generators for TIG Applications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .C1.3
Wire Feeder Options . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .C1.3

VANTAGE 500
C1.2 ACCESSORIES C1.2
OPTIONAL FIELD INSTALLED ACCESSORIES

K802N POWER PLUG KIT - Provides four 120V plugs rated at 20 T12153-9 Full-KVA Power Plug-One dual voltage
amps each and one dual voltage, full KVA plug rated at 120/240V, plug rated at 120/240V, 50 amps, single phase.
50 amps. The 20 amp/120V plug may not be compatible with NEMA
common household receptacles.
K2356-1 Control Panel Cover Kit-Clear plexiglass
cover to protect control panel from dirt and debris, and
K802R POWER PLUGKIT - Provides four 120V plugs rated 15 to visually monitor machine operation. Lockable to deter
amps each and one dual voltage, full KVA plug rated at 120/240V, vandalism.
50 amps. The 15 amp/120V plug is compatible with NEMA common
household receptacles. K2340-1 Lockable Fuel Cap / Flash Arrester Kit-For
use in locations where flash arrester safety is required.
Lockable fuel cap prevents tampering with fuel. Green
K857 25 ft. (7.5 m) or K857-1 100 ft. (30.4 m) REMOTE CON- cap color provides a visual reminder to use diesel when
TROL - Portable control provides same dial range as the output refueling.
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 is equipped with a 6-pin connector PLASMACUTTING
for connecting the remote control.

K1581-1 Pro-cut 80 - Cuts mild steel using the 3-phase
K704 ACCESSORY SET - Includes 35 feet (10 m) of ACgenerator power from the engine driven welder.
electrode cable and 30 feet (9 m) of work cable, head-
NOTE: Other Linclon plasma cutters, both single phase
shield, Filter plate, work clamp and electrode holder. and 3 phase can be used as long as the rating
Cable is rated at 500 amps, 60% duty cycle. of the receptacle is not exceeded
K2641-2 FOUR WHEELED STEERABLE YARD

TRAILER
For in plant and yard towing. Comes standard with a Duo-
WARNING
Hitch, a 2 Ball and Lunette Eye combination hitch.
Pipe Thawing with an arc welder can cause fire,
K2636-1 TRAILER - Two-wheeled trailer with optional fender explosion, damage to electric wiring or to the arc
and light package. For highway use, consult applicable federal, welder if done improperly. The use of an arc welder
state, and local laws regarding possible additional require- for pipe thawing is not approved by the CSA, nor is
ments. Comes standard with a Duo-Hitch, a 2 Ball and Lunette it recommended or supported by Lincoln Electric.
Eye combination hitch, a fender & a light package. Order: ------------------------------------------------------------------------
K2636-1 Trailer
K958-1 Ball Hitch
K958-2 Lunette Eye Hitch
K2639-1 Fender & Light Kit
K2640-1 Cable Rack
K887-1 ETHER START KIT - Provides maximum cold weather

starting assistance for frequent starting below 10(-12C).
Required Ether tank is not provided with kit.
K899-1 SPARK ARRESTOR KIT - Easily mounts to standard

muffler.
K949-1 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,
VANTAGE 500
TIG OPTIONS
K1783-9 PTA-26V TIGTorch KP653-3/32 Drive Roll and Guide Tube Kit (for LN-25)
Air Cooled 200 amp torch (2 piece) equipped with valve For .068-3/32 (1.8-2.4mm) cored or solid steel wire.
for gas flow control. 25 ft. (7.6m) length.
K1802-1 Magnum 300 MIGGun
KP509 Magnum Parts Kit for PTA-26V TIG Torch For .035-.045 (0.9-1.2mm) gas shielded wire. Includes
Magnum Parts Kit provides all the torch accessories 15 ft. gun and cable assembly and connector kit.
you need to start welding. Parts kit provides collets,
collet bodies, a black cap, alumina nozzles and tung- KP653-035S Drive Roll and Guide Tube Kit (for LN-25)
stens in a variety of sizes, all packaged in an easy to For .035-.040(0.9-1.0mm) solid steel wire.
carry reclosable sack.
K2613-1 LN-25 PRO PORTABLE WIRE FEEDER-The
K870 Foot Amptrol-Varies current while welding for MAXTRAC wire drive enhances performance, while the
making critical TIG welds and crater filling. Depress replacement case, and many other upgrade options that can
pedal to increase current. Depressing pedal fully be installed in less then five minutes aid in the serviceability.
achieves maximum set current. Fully raising the pedal
finishes the weld and starts the after flow cycle on sys- KP1697-5/64 Drive Roll Kit- Includes: 2 polished U
tems so equipped. Includes 25 ft. (7.6m) control cable. groove drive rolls, outer wire guide and inner wire guide
for solid core wire. (Used on LN-25 Pro)
K963-3 Hand Amptrol-Varies current for making crit-
ical TIG welds. Fastens to the torch for convenient

thumb control. Comes with a 25 ft. (7.6m) cable. (One KP1697-068 Drive Roll Kit- Includes: 2 polished U
size fits all Pro-Torch TIG Torches.) groove drive rolls, outer wire guide and inner wire guide
K2347-1 Precision TIG 185 Ready-Pak
For ACTIG Welding with square wave performance
use the ACgenerator of the Engine-Driven Welder to KP1696-1 Drive Roll Kit- Includes: 2 V groove drive
supply the power. Easy setup. Includes torch, foot rolls and inner wire guide for Steel Wires. (Used on LN-
amptrol, gas regulator and hose. Requires the K1816- 25 Pro)
1 Full KVA adapter kit.
K487-25 Magnum SGSpool Gun
K2350-1 Invertec V205-T AC/DC One-Pak Package Hand held semiautomatic wire feeder. Requires SG
For ACTIG welding with square wave performance, Control Module and Input Cable.
use the AC generator of the engine-driven welder to
supply the power. Easy setup. Includes torch, parts K488 SGControl Module
kit, regulator and hose kit, Twist-Mate torch adapter, The Interface between the power source and the spool
work cable with Twist-Mate end and foot Amptrol. gun. Provides control of the wire speed and gas flow.
For use with a spool gun.
HIGH FREQUENCY GENERATORS FOR K691-10 Input Cable (For SG Control Module)
For Lincoln engine power sources with 14-pin MS-type

TIG APPLICATIONS connection, separate 115VNEMAreceptacles and out-
The K799 Hi-Freq Unit (obsolete) and the K930- [ ] TIG put stud connections.
Modules are suitable for use with the Vantage 500.
The Vantage 500 is equipped with the required RF OTHER WIRE FEEDERS USABLE WITH
bypass circuitry for the connection of high frequency THE VANTAGE 500
generating equipment. The high frequency bypass net-
work supplied with the K799 Hi-Freq Unit does NOT NA-3 or LT-7 Automatic Wire Feeder
need to be installed into the Vantage 500.
LN-742 Semi-automatic Wire Feeder
The Vantage 500 and any high frequency-generating
LF-72/74 Semi-automatic Wire feeder
Hi-Freq Unit and the K930-AII TIG Module operating LN-7 Semi-automatic Wire Feeder
manuals for complete instructions on installation, oper-
ation, and maintenance.
LN-23P Semi-automatic Wire Feeder
WIRE FEEDER OPTIONS LN-15 Semi-automatic Wire Feeder

See the Wire Feeder Manual or the Diagrams section
K449 LN-25 Wire Feeder
Portable CC/CV unit for flux-cored and MIGwelding. of this manual for connection information of the various
Includes Gas Solenoid &Internal Contactor. feeders to the Vantage 500.
K126-2 Magnum 350 Innershield Gun (for LN-25)

For self-shielded wire with 15 ft. (4.5m) cable. For
.062-3/32 (1.6-2.4mm) wire.
VANTAGE 500
Return to Master TOC Return to Master TOC Return to Master TOC Return to Master TOC C1.4
NOTES
VANTAGE 500
C1.4
D1.1 TABLE OF CONTENTS - MAINTENANCE SECTION D1.1
Maintenance - VANTAGE 500 Deutz F3L912 (Code 10995)

Safety Precautions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .D1.2
Routine and Periodic Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .D1.2
Engine Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .D1.2
Change the Oil and Oil Filter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .D1.2
Fuel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .D1.3
Fuel Filters . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .D1.4
Bleeding the Fuel System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .D1.6

Air Filter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .D1.6
Cooling System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .D1.8
Cooling Blower Belt . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .D1.8
Engine Maintenance Schedules and Parts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .D1.9
Battery Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .D1.10
Cleaning the Battery . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .D1.10
Checking Specific Gravity . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .D1.10
Checking Electrolyte Level . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .D1.10

Charging the Battery . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .D1.10
Welder/Generator Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .D1.11
Storage . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .D1.11
Cleaning . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .D1.11
Nameplates . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .D1.11
Brush Removal and Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .D1.11
Bearings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .D1.11
Receptacles . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .D1.11
Cable Connections . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .D1.11
Major Component Locations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .D1.12
VANTAGE 500
D1.2 MAINTENANCE D1.2
SAFETY PRECAUTIONS
CAUTION
WARNING To prevent the engine from accidentally starting,

disconnect the negative battery cable before ser-
Have qualified personnel do all maintenance and vicing the engine.
troubleshooting work.
Turn the engine off before working inside the
machine. See Table D1.1 for a summary of maintenance inter-
vals for the items listed below. Follow either the hourly
Remove covers or guards only when necessary or the calendar intervals, whichever come first. More
to perform maintenance and replace them when frequent service may be required, depending on your
the maintenance requiring their removal is com- specific application and operating conditions.
plete.
OIL: Check the oil level after every 8 hours of operation
If covers or guards are missing from the or daily. BE SURE TO MAINTAIN THE OIL LEVEL.
machine, get replacements from a Lincoln
Distributor. Change the oil the first time between 25 and 50 hours
of operation. Then, under normal operating conditions,

change the oil as specified in Table D1.1. If the engine
Read the Safety Precautions in the front of this manu- is operated under heavy load or in high ambient tem-
al and in the instruction manual for the diesel engine peratures, change the oil more frequently.
used with your machine before working on the
Vantage 500.
CHANGE THE OIL AND FILTER
Keep all equipment safety guards, covers, and devices
in position and in good repair. Keep your hands, hair,
clothing, and tools away from the fans, and all other
CHANGE THE OIL: Change the oil, while the engine
moving parts when starting, operating, or repairing this
is still warm, as follows:
machine.
1 . Drain the oil from the drain plug located on the
engine bottom, as shown in Figure D1.1. Examine
ROUTINE AND PERIODIC the washer and replace it if it appears damaged.
MAINTENANCE 2. Replace the plug and washer and tighten firmly.
3. Remove the oil fill cap and add 9 quarts (8.5 L) of

ENGINE MAINTENANCE
oil. Check the dipstick and slowly add oil until the
DAILY level reaches the MAX mark on the dipstick. See
Figure D1.1. Use high quality oil viscosity grade
a. Check the crankcase oil level.
10W40. Consult the engine manual for oil specifi-
b. Refill the fuel tank to minimize moisture condensa- cations for various ambient temperatures. Always
tion in the tank. check the level with the dipstick before adding
more oil.
c. Open the water drain valve located on the bottom
of the water separator element one or two turns 4. Reinstall the oil fill cap and the dipstick.
and allow to drain into a container suitable for
5. If the oil filter has been changed, run the engine
diesel fuel for two to three seconds. Repeat the
and re-check the ilelel. Add oil as necessary until
above drainage procedure until diesel fuel is
the level reaches the MAX mark.
detected in the container.
NOTE: The K949-1 Oil Drain Kit can be installed to
WEEKLY
facilitate future oil changes.
Blow out the machine with low pressure air periodical-
ly. In particularly dirty locations, this may be required

once a week.
VANTAGE 500
FIGURE D1.1 OIL DRAIN AND REFILL

MAX
MIN
OIL FILL CAP
OIL FILTER DIPSTICK DRAIN PLUG
CHANGE THE OIL FILTER: Change the oil filter the 5. Refill the engine with the proper amount and type
first time between 25 and 50 hours of operation. Then, of oil as described in the Change the Oil section,
under normal operating conditions, change the oil filter above. Start the engine and check for leaks
after every 250 hours of operation. If the engine is around the filter element. Correct any leaks (usu-
operated under heavy load or in high ambient tem- ally by retightening the filter, but only enough to
peratures, change the oil filter more frequently. See stop leaks) before placing the Vantage 500 back in
Table D1.1 for recommended maintenance intervals. service.
See Table D1.2 for replacement oil filters.
6. If there are no leaks, stop the engine and recheck
Change the oil filter as follows: the oil level. If necessary, add oil to bring the level
up to the MAX mark, but do not overfill. See
1. Remove the oil drain plug. Drain the oil from the
Figure D1.1.
engine and allow the oil filter to drain. See Figure
D1.1. FUEL
2. Remove the old filter (spin it off) and discard it. At the end of each day's use, refill the fuel tank to min-
Wipe off the filter mounting surface and adapter. imize moisture condensation and dirt contamination in
See Figure D1.1. the fuel line. Do not overfill; leave room for the fuel to
3. Fill the new filter with fresh engine oil. Apply a thin expand.
coat of new oil to the rubber gasket on the new oil Refer to your engine operation manual for recom-
filter. mended grade of fuel.
4. Spin the new filter onto the mounting adapter finger

tight until the gasket is evenly seated. Then turn it
down another 1/2 turn. Do not overtighten the new
filter.
VANTAGE 500
FUEL FILTERS: 7. Re-insert the large white volume plug into the
upper cavity.
WARNING 8. Place the O-ring onto the angled seal surface of
When working on the fuel system: the filter header and re-install the plastic cap. Make
sure its flange rests on the O-ring.
Keep naked lights away, do not smoke
9. Screw on the cap ring and tighten hand tight.
Do not spill fuel
10. Remember to open the fuel shutoff valve (Lever in
line with the hose) before starting the engine.
The Vantage 500 is equipped with a Fuel Pre-
Water Separator Element: The water separator ele-
Filter/Water Separator Assembly located before the
ment is a two-stage filter with a special filtration/water
lift pump and a Secondary Fuel Filter located after the
separating media. An expanded water reservoir pro-
lift pump and before the fuel injectors. The Fuel Pre-
vides maximum protection against water in the fuel.
Filter/Water Separator is mounted to the engine block
The recommended change interval for the water sepa-
just below the lift pump (Figure D.2). The Secondary
rator element is 1,000 hours. See Figure D.2 and follow
Fuel Filter is mounted directly to the engine just above
this procedure.
the oil filter (Figure D1.3).
1. Close the fuel shutoff valve located on the side of

Fuel Pre-Filter/Water Separator Assembly:
the Fuel Pre-Filter/Water Separator Assembly. The
The pre-filter is a 150 micron screen designed to pro- lever should be perpendicular to the hose.
tect against gross fuel contamination of the water sep-
2. Rotate the quick change ring (located just below fil-
arator element and the Secondary Fuel Filter. If the
ter header) clockwise approximately 1/2 turn and
pre-filter becomes plugged, it may be removed,
slide it down and off the element.
inspected, cleaned and reinstalled. In general this only
needs to be done with each water separator element 3. Grasp the element and pull down with a slight rock-
change (about every 1,000 hrs). However, if at any ing motion to remove the element from the grommet
time excessive fuel contamination is suspected or a post on the bottom of the filter header.1
sudden fall-off in engine performance is detected the
pre-filter screen should be inspected and cleaned. See FIGURE D1.2 FUEL PRE-FILTER/WATER
Figure D.2 and follow this procedure: SEPARATOR ASSEMBLY
1. Close the fuel shutoff valve located on the side of
the Fuel Pre-Filter/Water Separator Assembly. The
lever should be perpendicular to the hose
2. Unscrew the cap ring located on the top of the filter

header and remove the plastic center cap and O-
ring.
3. Remove the large white volume plug located direct-
ly under the center cap in the upper cavity of the fil-
ter header. Use a small screwdriver (or similar
device) to lift the plug part way out of the cavity to
assist with its removal.
NOTE: Be careful not to damage the pre-filter screen
with the tool used to remove the plug.
4. Using a pair of pliers, gently tug on the pull tabs of
the pre-filter screen in an alternating pattern to
gradually remove the pre-filter screen.
5. Brush off any debris and rinse in diesel fuel.
FUEL FILTER QUICK CAP

6. Re-install the pre-filter screen into the upper cavity of SHUTOFF HEADER CHANGE RING
the filter header making sure the four pull tabs are VALVE RING
pointing up. Putting your fingers on the pull tabs,
push down evenly until the lower body of the pre-fil-
ter screen contacts the floor of the upper cavity.
VANTAGE 500
4. Slide the new element onto the grommet post on 5. Slide the quick change ring up over the element and
the bottom of the filter header until the element no rotate counter clockwise until an audible click or
longer easily moves up into the filter header. Now pop is heard. If you do not hear the click, you have
rotate the element (it may take almost 1 full turn) not rotated the ring far enough and the element is
with a slight upward pressure until the element not in the locked position. Another indication that
begins to further engage the header. With the prop- the ring is in the locked position is that one set (it
er orientation now established, apply additional doesnt matter which one) of arrows located on the
pressure to seat the element in the filter header. outside of the ring should be located directly under
You should feel the element pop into place when the air vent valve.
properly seated.
6 . Open the fuel shutoff valve (lever in line with the
NOTE: The element will only go on one way. Never use hose).
excessive force when mounting the element to the
7 . Open the air vent valve on the front of the filter
header.
header until fuel emerges free of air bubbles. Then
close the air vent valve.
Secondary Fuel Filter: The Secondary Fuel Filter is a
spin-on cartridge type mounted directly to the engine.
Consult your engine Operators Manual for complete

information on service intervals and element changing
procedures.
FIGURE D1.3 SECONDARY FUEL FILTER

SECONDARY
FUEL FILTER
OIL
FILTER
VANTAGE 500
BLEEDING THE FUEL SYSTEM: In the event the 3. Remove loose dirt from the element with com-
engine is operated until it runs out of fuel, you will need pressed air or a water hose directed from inside
to bleed the fuel system in order to start the engine. out.
Refer to the engine operation manual.
Compressed Air: 100 psi maximum with nozzles at
least one inch away from the ele-
AIR FILTER ment.
Water Hose: 40 psi maximum without nozzle.
CAUTION
4. Soak the element in a mild detergent solution for 15
minutes. Do not soak more than 24 hours. Swish
Excessive air filter restriction will result in
the element around in the solution to help remove
reduced engine life.
dirt.
5. Rinse elements from inside out with a gentle stream
The air filter element is a dry cartridge type. It can be of water (less than 40 psi) to remove all suds and
cleaned and reused. However, damaged elements dirt.
should not be reused. Stop engine after 100 hours of
6. Dry the element before reuse with warm air at less
running time and clean filter element. Replace the fil-
than 160F (71C). Do not use a light bulb to dry

ter if necessary. Service the air cleaner regularly
the element.
according to your engine operation manual.
7. Inspect for holes and tears by looking through the
1. Locate the air filter canister located behind the
element toward a bright light. Check for damaged
engine door on the top of the engine.
gaskets or dented metal parts. Do not reuse dam-
2. Remove the air filter element. aged elements. Protect the element from dust and
damage during drying and storage.
8. Reinstall the air filter element.
After six cleanings, replace the air filter. A cleaned
filter will have approximately 70% of the life of a
new filter element. A restricted filter element may
not appear excessively dirty.
VANTAGE 500
Return to Master TOC Return to Master TOC Return to Master TOC Return to Master TOC D1.7
VANTAGE 500
MAINTENANCE
MAINTENANCE INSTRUCTIONS
D1.7
COOLING SYSTEM
The cooling system of the Deutz engine needs to be 7. See Figure D1.4. Loosen the alternator mounting
checked and cleaned periodically. Consult the engine bolts (1, 2, 3) and rotate the alternator toward the
Operation Manual for the proper frequency and proce- engine.
dure. 8. Remove the old cooling blower belt and install a
COOLING BLOWER BELT: The following procedure new one.
should be followed to replace the cooling blower belt: 9 Push outward on the alternator (4) and adjust the
1. Allow the machine to cool. cold belt tension to 63-73 lbs (10-15 mm maximum
deflection) midway between any two pulleys.
2. Unfasten and slide the battery holder out from the Tighten bolts (1), (2), (3).
welder.
10. Reinstall the air cleaner hose, engine case side,
3. Disconnect the negative battery cable. and engine end panel. Reattach the negative bat-
4. Remove the engine case side. tery cable. Slide in and refasten the battery holder.
5. Loosen the air cleaner hose clamp and detach the 11. Check the cooling blower belt tension after 100
hose. hours of operation. (Follow steps 1-6; 9 and 10.)
6. Remove the engine end panel with air box and air
cleaner attached for access to the engine.
FIGURE D1.4 COOLING BLOWER BELT REPLACEMENT AND ADJUSTING
1
2
3
VANTAGE 500
TABLE D1.1
DEUTZ ENGINE MAINTENANCE SCHEDULE
FREQUENCY MAINTENANCE REQUIRED
Daily or Before Fill fuel tank.

Starting Engine Check oil level.
Check air cleaner for dirty, loose, or damaged parts. Replace if necessary.
Check air intake and cooling areas, clean as necessary.
1
First 50 Hours Change engine oil.
and Every 250 Change oil filter.
Hours Thereafter Change fuel filter.
Check fan belt.
Every 50 Hours Check fuel lines and clamps.
Every 100 Hours Check battery electrolyte level and connections.
Clean air filter.
Refer to your Deutz engine operation manual for periodic maintenance at 100 hours and beyond.
125 Hours for severe conditions.

1
TABLE D1.2
ENGINE MAINTENANCE PARTS
ITEM MANUFACTURER PART NUMBER
Air Cleaner Element Donaldson P181052

AC A302C
Cooling Blower Belt Lincoln T13536-3

Gates 7585
Oil Filter Element Deutz 1174418

Purolator PER2168
Napa 1820
Fram PH3776
Fuel Filter Element Deutz 1174423

Purolator PC42
Napa 3358
Fram P4102
Water Separator Element Lincoln M16890-C

Stanadyne 31572
Fuel Pre-Filter Screen Lincoln M16890-B

Stanadyne 29575
Battery BCI
Group
34
VANTAGE 500
BATTERY MAINTENANCE
CHECKING SPECIFIC GRAVITY: Check each battery

WARNING cell with a hydrometer. A fully charged battery will have
a specific gravity of 1.260. Charge the battery if the
GASES FROM BATTERY can explode. reading is below 1.215.
Keep sparks, flame, and cigarettes NOTE: Correct the specific gravity reading by adding
away from battery. four gravity points (0.004) for every five degrees the
electrolyte temperature is above 80 degrees F (27
degrees (C). Subtract four gravity points (.004) for
BATTERY ACID can burn eyes and every five degrees the electrolyte temperature is below
skin. 80 degrees F (27 degrees C).
Wear gloves and eye protection and

be careful when working near a bat- CHECKING ELECTROLYTE LEVEL: If battery cells
tery. Follow the instructions printed are low, fill them to the neck of the filler hole with dis-
on the battery. tilled water and recharge. If one cell is low, check for
leaks.

INSTALLING A NEW BATTERY -
Disconnect the negative cable from CHARGING THE BATTERY: The Vantage 500 is
the old battery first and connect to equipped with a wet charged battery. The charging
the new battery last. current is automatically regulated when the battery is
THE CORRECT POLARITY IS NEGATIVE low (after starting the engine) to a trickle current when
GROUND - Damage to the engine alternator and the battery is fully charged.
the printed circuit board can result from incor- When you charge, jump, replace, or otherwise connect
rect connection. battery cables to the battery, be sure the polarity is cor-
CONNECTING A BATTERY CHARGER - Remove rect. Improper polarity can damage the charging cir-
the battery from the welder by disconnecting the cuit. The Vantage 500 charging system is NEGA-
negative cable first, then the positive cable and TIVE GROUND. The positive (+) battery terminal has
battery clamp. When reinstalling, connect the a red terminal cover.
negative cable last. Keep the area well ventilated. If you need to charge the battery with an external
USING A BOOSTER - Connect the positive lead to charger, disconnect the negative cable first, then the
the battery first, then connect the negative lead positive cable before you attach the charger leads.
to the engine foot. After the battery is charged, reconnect the positive bat-
tery cable first and the negative cable last. Failure to
To prevent BATTERY BUCKLING, tighten the do so can result in damage to the internal charger com-
nuts on the battery clamp until snug. ponents.
Follow the instructions of the battery charger manufac-
CLEANING THE BATTERY: Keep the battery clean turer for proper charger settings and charging time.
by wiping it with a damp cloth when dirty. If the termi-
nals appear corroded, disconnect the battery cables
and wash the terminals with an ammonia solution or a
solution of 1/4 pound (0.113 kg) of baking soda and 1
quart (0.946 l) of water. Be sure the battery vent plugs
(if equipped) are tight so that none of the solution
enters the cells.
After cleaning, flush the outside of the battery, the bat-
tery compartment, and surrounding areas with clear

water. Coat the battery terminals lightly with petroleum
jelly or a non-conductive grease to retard corrosion.
Keep the battery clean and dry. Moisture accumulation
on the battery can lead to more rapid discharge and
early battery failure.
VANTAGE 500
WELDER/GENERATOR BEARINGS: The Vantage 500 is equipped with dou-

ble-shielded ball bearings having sufficient grease to

MAINTENANCE
last indefinitely under normal service. Where the
STORAGE: Store the Vantage 500 in clean, dry, pro- welder is used constantly or in excessively dirty loca-
tected areas. tions, it may be necessary to add one half ounce of
grease per year. A pad of grease one inch wide, one
CLEANING: Blow out the generator and controls peri- inch long, and one inch high weighs approximately one
odically with low pressure air. Do this at least once a half ounce. Over-greasing is far worse than insufficient
week in particularly dirty areas. greasing.
NAMEPLATES: Whenever routine maintenance is When greasing the bearings, keep all dirt out of the
performed on this machine - or at least yearly - inspect area. Wipe the fittings completely clean and use clean
all nameplates and labels for legibility. Replace those equipment. More bearing failures are caused by dirt
which are no longer clear. Refer to the parts list for the introduced during greasing than from insufficient
replacement item number. grease.
BRUSH REMOVAL AND REPLACEMENT: It is nor- RECEPTACLES: Keep the electrical receptacles in
mal for the brushes and slip rings to wear and darken good condition. Remove any dirt, oil, or other debris
slightly. Inspect the brushes when a generator over-
from their surfaces and holes.

haul is necessary.
CABLE CONNECTIONS: Check the welding cable
connections at the weld output terminals often. Be
WARNING sure that the connections are always tight.
Do not attempt to polish slip rings while the engine
is running.
VANTAGE 500
FIGURE D1.5 MAJOR COMPONENT LOCATIONS

1. CONTROL PANEL ASSEMBLY 6. ENGINE ASSEMBLY

2. CONTROL BOX & OUTPUT ASSEMBLY 7. GENERATOR
3. POWER MODULE ASSEMBLY 8. SOLENOID ASSEMBLY
4. BASE & LIFT BALE ASSEMBLY 9. CASEBACK
5. FUEL TANK & MOUNTING 10. CASE TOP AND SIDES
10
6
8
9
5 7
O
FF
ING
WARN
1
4
2
VANTAGE 500
Installation - VANTAGE 500 Deutz F4L2011 (Codes 11180,11415)

Location/Ventilation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .A.3
Storing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .A2.3
Stacking . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .A2.3
Lifting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .A2.4

Towing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .A2.4
Oil . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .A2.5
Fuel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .A2.5
Fuel Cap . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .A2.5

Spark Arrester . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .A2.6
Remote Control . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .A2.6

VANTAGE 500
TECHNICAL SPECIFICATIONS - VANTAGE 500 DEUTZ (K2405-1)


System
DEUTZ 4 cylinder High Idle 1890 190 cu. in 12VDC battery Fuel
F4L2011 48HP (36 kw) Low Idle 1425 (3.1L) & Starter 25 US gal.
Diesel Engine @ 1800 RPM Full Load 1800 (94.6L)
Bore x Stroke Oil:
2.5 US gal.
3.70 x 4.41 (9.5L)
(94mm x 112mm)


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

Auxiliary Power (1)
120/240 VAC
12,000 WATTS, 60 Hz., Single Phase
20,000 WATTS, 60 Hz., Three Phase
PHYSICAL DIMENSIONS
Height (2)
Width Depth Weight
42.0 in 31.5 in. 63.1 in. 1532lbs.

(1066.8 mm) (800.1mm) (1603mm) (695kg)
(Approx)
2. Top of Enclosure. Add 8.9 (226mm) for exhaust.
VANTAGE 500

start installation.
Do not attempt to use this equipment until you CAUTION

DO NOT MOUNT OVER COMBUSTIBLE SUR-
include important safety precautions, \detailed
FACES
all sides.
such as output terminals or internal ------------------------------------------------------------------------
wiring.
place.

STACKING
guards off.
VANTAGE 500
LIFTING TOWING
The Vantage lift bale should be used to lift the machine. The recommended trailer for use with this equipment
The Vantage is shipped with the lift bale retracted. for road, in-plant and yard towing by a vehicle1 is
Before attempting to lift the Vantage, secure the lift bale Lincolns K953-1. If the user adapts a non-Lincoln trail-
in a raised position. Secure the lift bale as follows: er, he must assume responsibility that the method of
attachment and usage does not result in a safety haz-
ard nor damage the welding equipment. Some of the
b. Locate the two access holes on the upper mid- factors to be considered are as follows:
the lift bale.
c. Use the lifting strap to raise the lift bale to the ments.
d. Secure the lift bale with 2 thread forming undue stress to the trailers framework.

FALLING EQUIPMENT can cause
injury.
if it is equipped with a heavy acces-
sory such as a trailer or gas cylinder.
1
Lift only with equipment of adequate regarding specific requirements for use on public high-
lifting capacity. ways.
Be sure machine is stable when lift- VEHICLE MOUNTING
ing.
WARNING
HIGH ALTITUDE OPERATION Improperly mounted concentrated loads may

cause unstable vehicle handling and tires or other
At higher altitude, output derating may be necessary. components to fail.
For maximum rating, derate the welder output 5% for
every 300 meters (984 ft.) above 1500 meters (4920 Only transport this Equipment on serviceable
ft.). For output of 500A and below, derate the welder vehicles which are rated and designed for such
output 5% for every 300 meters (984 ft.) above 2100 loads.
meters (6888 ft.) Distribute, balance and secure loads so vehicle
Mount equipment base to metal bed or frame of
HIGH TEMPERATURE OPERATION vehicle.
At temperatures above 30C (86F), output voltage Follow vehicle manufacturers instructions.
------------------------------------------------------------------------
derating is necessary. For maximum output current rat-

ings, derate the welder voltage rating two volts for
every 10C (21F) above 30C (86F).
VANTAGE 500
PRE-OPERATION ENGINESERVICE BATTERY CONNECTION

READ the engine operating and maintenance instruc- WARNING

tions supplied with this machine.
WARNING Keep sparks, flame and cigarettes away from bat-
Keep hands away from the engine tery.
Stop engine and allow to cool before
INSTALLING A NEW BATTERY dis-
fueling.
connect negative cable from old bat-
Do not smoke when fueling. tery first and connect to new battery
last.
fill. CONNECTING A BATTERY CHARGER remove
Wipe up spilled fuel and allow fumes to clear
Keep sparks and flame away from tank. Keep well ventilated.
USING A BOOSTER connect positive lead to
OIL battery first then connect negative lead to nega-
tive battery lead at engine foot.
The Vantage is shipped with the engine crankcase
filled with high quality SAE 10W-30 oil (API class CD BATTERY ACID can burn eyes and skin.
or better). Check the oil level before starting the
engine. If it is not up to the full mark on the dip stick,
add oil as required. Check the oil level every four
tery.
Refer to the engine Operators Manual for specific oil Follow instructions printed on bat-
recommendations and break-in information. The oil tery.
change interval is dependent on the quality of the oil
and the operating environment. Refer to the engine
nance intervals.
FUEL
NOTE: USE DIESEL FUEL ONLY. Fill the fuel tank
with clean, fresh diesel fuel. The capacity of the fuel
tank is approx 95 liters. See engine Operators Manual
for specific fuel recommendations. Running out of
fuel may require bleeding the fuel injection pump.
FUEL CAP
Remove the plastic cap covering from the fuel tank
filler neck and install the fuel cap.
ENGINE COOLING SYSTEM

The Deutz engine is air cooled by a belt-driven axial

blower. The oil cooler and engine cooling fins should
procedures and frequency.)
VANTAGE 500

WHEN:
b) Using a booster TIG Module are suitable for use with the Vantage 500.
Use correct polarity Negative Ground. The Vantage 500 is equipped with the required R.F.
bypass circuitry for the connection of high frequency
The Vantage is shipped with the negative battery cable generating equipment. The high frequency bypass net-
disconnected. Before you operate the machine, make work supplied with the K799 Hi-Freq Unit does NOT
sure the Engine Switch is in the OFF position and need to be installed into the Vantage 500.
attach the disconnected cable securely to the negative
(-) battery terminal. The Vantage 500 and any high frequency generating
battery; if unused for several months, the battery may

require a booster charge. Be sure to use the correct ELECTRICAL CONNECTIONS

polarity when charging the battery.
REMOTE CONTROL
MUFFLER OUTLET PIPE
The Vantage 500 is equipped with a 6-pin and a 14-pin
Remove the plastic plug covering the muffler outlet connector. The 6-pin connector is for connecting the
tube. Using the clamp provided, secure the outlet pipe K857 or K857-1 Remote Control (optional) or, in the
to the outlet tube with the pipe positioned to direct the case of TIG welding applications, with the foot or hand
exhaust in the desired direction. Amptrol (K870 or K963-1 respectively).
SPARK ARRESTER feeder or TIG Module (K930-1 or-2) control cable.
Some federal, state or local laws may require that NOTE: When using the 14-pin connector, if the wire
gasoline or diesel engines be equipped with exhaust feeder has a built-in power source output control, do
spark arresters when they are operated in certain loca- not connect anything to the 6-pin connector.

local regulations, a suitable spark arrester must be The Vantage is equipped with a toggle switch for
CAUTION when in the "WELDING TERMINALS REMOTELY
CONTROLLED" position.
VANTAGE 500

the welder.
cable voltage drop.

ELECTRODE AND WORK CABLES The auxiliary power capacity of the Vantage 500 is

Total Combined Length of
Electrode and Work Cables
sible current of the 240 VAC output is 50 A. The 240
Amps VAC output can be split to provide two separate 120
@ 100% VAC outputs with a maximum permissible current of
Duty Cycle Up to 150 ft. 150-200 ft. 200-250 ft. 50 A per output to two separate 120 VAC branch cir-
500 3/0 AWG 3/0 AWG 4/0 AWG
to rated capacity.
MACHINE GROUNDING
The Vantage has two 20A-120VAC (5-20R) duplex
Because this portable engine driven welder creates its receptacles and one 50A-120/240 VAC (14-50R)
own power, it is not necessary to connect its frame to receptacle. The 120/240 VAC receptacle can be split
an earth ground, unless the machine is connected to for single-phase 120 VAC operation. The auxiliary
premises wiring (home, shop, etc.). power receptacles should only be used with three-wire

To prevent dangerous electric shock, other equipment
powered by this engine driven welder must:
used with the system must be at least equal to the cur-
a) be grounded to the frame of the welder using a rent capacity of the associated receptacle.
grounded type plug,
or STANDBY POWER CONNECTIONS
b) be double insulated. The Vantage 500 is suitable for temporary, standby or
of the vehicle. When this engine driven welder is con- The Vantage 500 can be permanently installed as a
nected to premises wiring such as that in a home or standby power unit for 240 volt, three-wire, 50 amp ser-
shop, its frame must be connected to the system earth vice. Connections must be made by a licensed electri-
ground. See further connection instructions in the sec- cian who can determine how the 120/240 VAC power
tion entitled Standby Power Connections as well as can be adapted to the particular installation and com-
the article on grounding in the latest U.S. National ply with all applicable electrical codes. The following
Electrical Code and the local code. information can be used as a guide by the electrician
VANTAGE 500
engine.
Switch rating must be the same or greater than the cus-
tomers premises disconnect and service over current 3. Install a 50 amp 120/240 VAC plug (NEMA Type
protection. 14-50) to the double-pole circuit breaker using
Figure A2.1 Connection of the Vantage to Premises Wiring

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

SERVICE OVERCURRENT
PROTECTION.
PREMISES
DISCONNECT AND
SERVICE
GROUND OVERCURRENT
50AMP
240 VOLT PROTECTION
DOUBLE
POLE
NEMA TYPE 14-50
GND
50 AMP, 120/240 VOLT

VANTAGE 500
Operation - VANTAGE 500 Deutz F4L2011 (Codes 11180,11415)


Break-In Period . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .B2.7
Stick Welding . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .B2.8

Pipe Welding . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .B2.8
TIGWelding . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .B2.8
Arc Gouging . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .B2.10
Paralleling . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .B2.10

VANTAGE 500
B2.2 OPERATION B2.2

engine.
SAFETY INSTRUCTIONS

WARNING
Do not attempt to use this equipment until you guards off.
Stop engine before servicing.
include important safety precautions: detailed Keep away from moving parts
engine starting, operating, and maintenance
Only qualified personnel should operate this

ELECTRIC SHOCK can kill. equipment.
or electrodes with your skin or wet ADDITIONAL SAFETY PRECAUTIONS
clothing.
Always operate the welder with the hinged door closed
Insulate yourself from the work and and the side panels in place, as these provide maxi-
ground. mum protection from moving parts and insure proper
Always wear dry insulating gloves. cooling air flow.
GENERAL DESCRIPTION
FUMES AND GASES CAN BE
DANGEROUS. The Vantage 500 is a diesel engine-driven welding
Keep your head out of fumes. nating current generator for DC multi-purpose welding
and for 120/240VAC single phase and 240VAC three


phase auxiliary standby power. The welding control
fumes from breathing zone.
system uses state of the art Chopper Technology.
The generator has a single sealed bearing for mainte-
WELDING SPARKS CAN CAUSE with two slip rings and brushes. The stator is wound
FIRE OR EXPLOSION. entirely with heavy gauge copper wire and insulated
with NEMA class F insulation material. The stator is
Keep flammable material away. then impregnated with three layers of high quality var-
Do not weld on containers that have nish. After the stator is assembled using tie bars, the
held combustibles. entire assembly is covered with an environmentally
protective coating. These measures insure trouble-free
operation in the harshest environments.
ARC RAYS CAN BURN.
Wear eye, ear, and body protection. will provide enough fuel to run for more than 12 hours
at full load.
tor element.
VANTAGE 500
B2.3 OPERATION B2.3


WELDER
The Vantage 500 also provides excellent constant volt-
load).
age DC welding output for MIG (GMAW) and
The Vantage 500 provides smooth 120/240 VAC output for up to 50 amps of 240 VAC, and up to 50 amps per
for auxiliary power and emergency standby power. side to separate branch circuits (not in parallel) of

FEATURES
OTHER FEATURES
FOR WELDING
Engine hour meter standard on all models.

K1639-1) for presetting the weld amperage or volt-

be FLASHING.

slope modes.
VANTAGE 500
B2.4 OPERATION B2.4

4 5 6 7 8 9 10
3
11
13
20
12
15 21
14 19
23
1
22
2
16
17 18

2. START PUSHBUTTON
VANTAGE 500
B2.5 OPERATION B2.5
6. OIL PRESSURE GAUGE

The gauge displays the engine oil pressure when the d. If the welding or AC power load is not restarted
engine is running. before the end of the time delay, the idler
reduces the engine speed to low idle speed.
7. ENGINEPROTECTION e. The engine will automatically return to high idle

speed when the welding load or A.C. power
The yellow engine protection light remains off with load is reapplied.
proper oil pressure and under normal operating tem-
peratures. If the light turns on, the engine protection Idler Operational exceptions
system will stop the engine. Check for proper oil and When the WELDING TERMINALS switch is in the
coolant levels and add oil and/or coolant if neces- Remotely Controlled position the idler will operate as
sary. Check for loose or disconnected leads at the oil follows:
pressure sender located on the engine. The light will a. When the triggering device (Amptrol, Arc Start
remain on when the engine has been shut down due Switch, etc.) is pressed the engine will acceler-
to low oil pressure or over-temperature condition. ate and operate at full speed provided a weld-
NOTE: This engine is equipped with an electronic ing load is applied within approximately 12 sec-
governor system. The engine speed ramps onds.
up during a warm up period. The complete If the triggering device remains pressed but no
cycle takes approximately 3 minutes. This welding load is applied within approximately 12
allows the engine cylinder temperature to seconds the engine may return to low idle
build up slowly before going to full speed. speed.
This feature is bypassed if the engine is
already warm. The Engine may produce If the triggering device is released or welding
White Smoke for a few minutes at low tem- ceases the engine will return to low idle speed
peratures. Do not apply a load to the after approximately 12 seconds.
machine during the warm up period.
8. BATTERY CHARGING LIGHT

The yellow engine alternator light is off when battery
charging system is functioning normally. If light turns
on the alternator or the voltage regulator may not be
operating correctly. The light will remain on when the
engine is stopped and the run/stop switch is in the

run position.
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.
c. When welding ceases and the AC power load is
turned off, a fixed time delay of approximately
12 seconds starts.
VANTAGE 500
B2.6 OPERATION B2.6
WELDING CONTROLS (Items 10 through 19)

10. OUTPUT CONTROL: The OUTPUT dial is used to preset the DOWNHILL PIPE mode: In this mode, the ARC CONTROL
output voltage or current as displayed on the digital meters knob sets the short circuit current (arc-force) during stick weld-
for the four welding modes. When in the CC-STICK, DOWN- ing to adjust for a soft or a more forceful digging arc (Crisp).
HILL PIPE or CV-WIRE modes and when a remote control is Increasing the number from -10(Soft) to +10(Crisp) increases
connected to the 6-Pin or 14-Pin Connector, the auto-sens- the short circuit current which results in a more forceful digging
ing circuit automatically switches the OUTPUT CONTROL arc. Typically a forceful digging arc is preferred for root and hot
from control at the welder to the remote control. In the CV- passes. A softer arc is preferred for fill and cap passes where
WIRE mode, when the wire feeder control cable is connect- weld puddle control and deposition (stacking of iron) are key
ed to the 14-Pin Connector, the auto-sensing circuit auto- to fast travel speeds. It is recommended that the ARC CON-
matically makes OUTPUT CONTROL inactive and the wire TROL be set initially at 0.
feeder voltage control active. CV-WIRE mode: In this mode, turning the ARCCONTROL
knob from -10(soft) to +10(crisp) changes the arc from soft
and washed-in to crisp and narrow. It acts as an
When in the TOUCH START TIG mode and when a Amptrol is
inductance/pinch control. The proper setting depends on the
connected to the 6-Pin Connector, the OUTPUT dial is used to
procedure and operator preference. Start with a setting of 0.
set the maximum current range of the CURRENT CONTROL
14. WELDING TERMINALS SWITCH

of the Amptrol.
11. DIGITAL OUTPUT METERS: In the WELDTERMINALSON position, the output is electri-
cally hot all the time. In the REMOTELYCONTROLLED posi-
The digital meters allow the output voltage (CV-WIRE mode)
tion, the output is controlled by a wire feeder or amptrol device,
or current (CC-STICK, DOWNHILL PIPE and TIG modes) to
and is electrically off until a remote switch is depressed.
be set prior to welding using the OUTPUT control knob.
During welding, the meters display the actual output voltage 15. WIREFEEDERVOLTMETERSWITCH:
(VOLTS) and current (AMPS). A memory feature holds the dis- Matches the polarity of the wire feeder voltmeter to the polari-
play of both meters on the seven seconds after welding is ty of the electrode.
stopped. This allows the operator to read the actual current
and voltage just prior to when welding was ceased. While the
display is being held the left-most decimal point in each dis- For attaching optional remote control equipment. Includes
play will be flashing. The accuracy of the meters is 3%. auto-sensing remote control circuit.
12. WELDMODESELECTORSWITCH: 17. 14 - PIN CONNECTOR
(Provides four selectable welding modes) For attaching wire feeder control cables. Includes contactor
CV-WIRE

DOWNHILL PIPE
CC-STICK trol is connected to the 14-pin connector, do not connect any-
TOUCH START TIG thing to the 6-pin connector.
13. ARCCONTROL: 18. WELD OUTPUT TERMINALS + AND -
The ARCCONTROL WIRE/STICK knob is active in the WIRE These 1/2 - 13 studs with flange nuts provide welding con-
and STICK modes, and has different functions in these modes. nection points for the electrode and work cables. For positive
This control is not active in the TIG mode. polarity welding the electrode cable connects to the + termi-
nal and the work cable connects to this - terminal. For nega-
CC-STICK mode: In this mode, the ARC CONTROL knob sets
the short circuit current (arc-force) during stick welding.
nal and the electrode cable connects to this - terminal.
Increasing the number from -10(Soft) to +10(Crisp) increases
the short circuit current and prevents sticking of the electrode AUXILIARY POWER CONTROLS
to the plate while welding. This can also increase spatter. It is (Items 19-23)
recommended that the ARCCONTROL be set to the minimum
number without electrode sticking. Start with a setting at 0. 19. 120/240 VAC SINGLE PHASE RECEPTACLE

chapter.
VANTAGE 500
B2.7 OPERATION B2.7

These circuit breakers provide separate overload 6. Within 30 seconds, press and hold the engine
current protection for each 120V circuit at the 240V START button until the engine starts. If the engine
single phase receptacle, each 120V single phase does not start within 30 seconds the RUN/STOP
receptacle, the 240V three phase receptacle, the switch must be returned to the STOP position, then
120VAC in the 14-Pin connector, the 42VAC in the return to step 5.
14-Pin connector and battery circuit overload protec- 7. Release the engine START button when the engine
tion. starts.
8. Check that the engine protection and battery charg-
21. 120VAC SINGLE PHASE RECEPTACLES ing lights are off. Investigate any indicated problem.
These two 120VAC (5-20R) receptacles with GFCI NOTE: The engine will go through a 3 minute warm-up
protection provide 120VAC single phase for auxiliary cycle if cold. If the engine coolant is still warm
power. Each receptacle has a 20 amp total rating. from recent operation, the engine will go imme-
They are designed to protect the user from the haz- diately to high idle and then to low idle if the idle
ards of ground faults. When the GFCI has tripped switch is in the AUTO position.

section in the installation chapter for further informa- COLD WEATHER STARTING
tion about these receptacles. Also refer to the AUX- With a fully charged battery and the proper weight oil,
ILIARY POWER OPERATION section later in this the engine should start satisfactorily even down to
chapter. about 0F(-18C). If the engine must be frequently
22. GROUND STUD the optional ether start kit (K887-1). Installation and
Provides a connection point for connecting the
GROUNDING in the Installation chapter for proper STOPPING THE ENGINE
machine grounding information.
1. Switch the RUN/STOP switch to STOP. This turns
23. 240VAC THREE PHASE RECEPTACLE off the voltage supplied to the shutdown solenoid. A
backup shutdown can be accomplished by shutting
This is a 240VAC (15-50R) receptacle that provides off the fuel valve located on the fuel line.
240VAC three phase auxiliary power. This receptacle
has a 50 amp rating. This receptacle in not present

on the models covered by this manual. BREAK-IN PERIOD

ENGINE OPERATION duty, industrial engine. It is designed and built for rugged use.
STARTING THE ENGINE until the break-in is accomplished. Check the oil level twice a
1. Open the engine compartment door and check that day during the break-in period. In general this takes 50 to 100
the fuel shutoff valve is in the open position (lever to hours of operation.
be in line with the hose). IMPORTANT
2. Check for proper oil level and coolant level. Close IN ORDER TO ACCOMPLISH THIS BREAK-IN, THE UNIT
engine compartment door. SHOULD BE SUBJECTED TO HEAVY LOADS, WITHIN
3. Remove all plugs connected to the AC power recep- THE RATING OF THE MACHINE. AVOID LONG IDLE RUN-
tacles. NING PERIODS.
5. Set the RUN/STOP switch to RUN. Observe that TYPICAL FUEL CONSUMPTION

on. The engine protection light may turn off after 5 Refer to Table B2.1 for typical fuel consumption of the VAN-
seconds or remain on until the engine is started. TAGE 500 Engine for various operating scenarios.
VANTAGE 500
B2.8 OPERATION B2.8
Table B2.1 DEUTZ F4L2011 DOWNHILL PIPE MODE

ENGINE FUEL CONSUMPTION This slope controlled setting is intended for out-of-posi-
tion and down hill pipe welding where the operator
Deutz F4L1022 Running Time
would like to control the current level by changing the
48 HP 25 Gal.(94.6L)
arc length. The OUTPUT CONTROL knob adjusts the
@1800 rpm (Hours)
full output range for pipe welding.
Low Idle .47 gallons/ hour 53
The ARC CONTROL knob sets the short circuit current
No Load (1.77 liters/hour)
1475 rpm
Hihg Idle .66 gallons/hour 40 from -10 (Soft) to +10 (Crisp) increases the short circuit
No Load (2.50 liters/hour) current which results in a more forceful digging arc.
1900 rpm Typically a forceful digging arc is preferred for root and
DC-CC 1.94 gallons/hour 12.6 hot passes. A softer arc is preferred for fill and cap pass-
Welding (7.34 liters/hour) es where weld puddle control and deposition (stacking
500A @40V of iron) are key to fast travel speeds. It is recommend-
Auxiliary Power 1.31 gallons/hour 20.0 ed that the ARC CONTROL be set initially at 0.
12,000 VA (4.96 liters/hour)
TOUCH START TIG MODE

Auxiliary Power 1.76 Gal./hour 14.2
The Vantage can be used in a wide variety of DCTIG
20,000VA (6.66L/hour)
welding applications.
WELDER OPERATION desired current and the tungsten is touched to the work.
DUTY CYCLE During the time the tungsten is touching the work there
Duty Cycle is the the ratio of the uninterrupted on-load tungsten contamination. Then, the tungsten is gently lift-
duration to 10 minutes. The total time period of one ed off the work in a rocking motion, which establishes
complete on-load and no-load cycle is 10 minutes. For the arc.
applied continuously for 6 minutes followed by a no- To stop the arc, simply lift the TIG torch away from the
load period of 4 minutes. work piece. When the arc voltage reaches approxi-
mately 30 volts, the arc will go out and the machine will
STICK WELDING MODE automatically reset to the touch start current level. The
The Vantage can be used with a broad range of DC tungsten may then be retouched to the work piece to
stick electrodes. restrike the arc. The arc may also be started and
The MODE switch provides two stick welding settings
as follows: The ARCCONTROL is not active in the TIG mode.
In general the Touch Start feature avoids tungsten con-
tamination without the use of a Hi-frequency unit. If the
CC-STICK MODE use of a high frequency generator is desired, the K930-
The CC-STICK position of the MODE switch is 2 TIG Module can be used with the Vantage. The set-
designed for horizontal, vertical-up and overhead weld- tings are for reference.
The Vantage is equipped with the required R.F. bypass
circuitry for the connection of high frequency generat-
range for stick welding.
ing equipment.
The ARC CONTROL knob sets the short circuit (arc-
force) current during stick welding. Increasing the num-
ment must be properly grounded. See the K930-2 TIG
ber from -10 (Soft) to +10 (Crisp) increases the short

Module operating manuals for complete instructions on
circuit current and prevents sticking of the electrode to
installation, operation, and maintenance.
the plate while welding. This can also increase spatter.
It is recommended that the ARC CONTROL be set to When using the TIG Module, the OUTPUT control on
the minimum number without electrode sticking. Start the Vantage is used to set the maximum range of the
with the knob set at 0. CURRENTCONTROL on the TIG Module or an Amptrol
if connected to the TIG Module.
VANTAGE 500
B2.9 OPERATION B2.9


Tungsten
0.010 (.25) 2-15 3

3-8 (2-4) 3-8 (2-4) #4, #5, #6
0.020 (.50) 5-20 3
5-10 (3-5) 5-10 (3-5)
0.40 (1.0) 15-80 3
5-10 (3-5) 5-10 (3-5)
1/16 (1.6) 70-150 10-20 5-10 (3-5) 9-13 (4-6) #5, #6
3/32 (2.4) 150-250 15-30 13-17 (6-8) 11-15 (5-7) #6, #7, #8
1/8 (3.2) 250-400 25-40 15-23 (7-11) 11-15 (5-7)
5/32 (4.0) 400-500 40-55 21-25 (10-12) 13-17 (6-8) #8, #10
3/16 (4.8) 500-750 55-80 23-27 (11-13) 18-22 (8-10)
1/4 (6.4) 750-1000 80-125 28-32 (13-15) 23-27 (11-13)
1
2
Pure EWP
1% Thoriated EWTh-1
2% Thoriated EWTh-2
2
applications.
3

4
# 4 = 1/4 in. (6 mm) # 7 = 7/16 in. (11 mm)

# 5 = 5/16 in. (8 mm) # 8 = 1/2 in. (12.5 mm)
# 6 = 3/8 in. (10 mm) #10 = 5/8 in. (16 mm)
5
(TIG). (TIG).
with respect to the #2 and #4 leads does not provide

the proper signal to open and close the solid state con-
tactor in the Vantage 500.
VANTAGE 500

The Vantage 500 in the CV-WIRE position can be used AUXILIARY POWER LOADS
with a broad range of flux cored wire (Innershield and It must be noted that the above auxiliary power ratings
Outershield) electrodes and solid wires for MIG weld- are with no welding load. Simultaneous welding and
ing (GMAW). Welding can be finely tuned using the power loads are specified in Table B2.3 or B2.4. The
ARC CONTROL. permissible currents shown assume that current is
Some recommended Innershield electrodes are: NR- being drawn from either the 120 VAC or 240 VAC sup-
311, NS-3M, NR-207, NR-203 Ni 1%, NR-204-H. ply (not both at the same time).

71M. ARC GOUGING
5/32 90-150 Amps
Start the engine and set the IDLER control switch to 3/16 150-200 Amps
the desired operating mode. Full power is available 1/4 200-400 Amps
regardless of the welding control settings, if no welding 5/16 250-400 Amps
current is being drawn. 3/8 350-575 Amps*
The auxiliary power of the Vantage consists of two 20
Amp-120VAC (5-20R) duplex receptacles and one 50
Amp-120/240 VAC (14-50R) receptacle. The * Maximum current setting is limited to the Vantage 500
120/240VAC receptacle can be split for single phase maximum of 575 Amps.
120 VAC operation.
The auxiliary power capacity is 12,000 watts of 60 Hz, PARALLELING
single phase power. The auxiliary power capacity rating When paralleling machines in order to combine their
in watts is equivalent to volt-amperes at unity power outputs, all units must be operated in the CC - STICK
factor. The maximum permissible current of the 240 mode only. To achieve this, turn the WELD MODE
VAC output is 50 A. The 240 VAC output can be split to switch to the CC - STICK position. Operation in other
provide two separate 120 VAC outputs with a maxi- modes may produce erratic outputs and large output
mum permissible current of 50 A per output to two sep- imbalances between the units.
arate 120 VAC branch circuits. Output voltage is within
10% at all loads up to rated capacity.

leled.
VANTAGE 500

(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

EXTENSION CORD
RECOMMENDATIONS
outputs as long as it is of ample size. Table B.5 lists
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 48010 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)

VANTAGE 500
NOTES
VANTAGE 500
B2.12
Accessories - VANTAGE 500 Deutz F4L2011 (Codes 11180, 11415)


VANTAGE 500

K802N POWER PLUG KIT - Provides four 120V plugs rated at 20 K2356-1 Control Panel Cover Kit-Clear plexiglass
amps each and one dual voltage, full KVA plug rated at 120/240V, cover to protect control panel from dirt and debris, and
50 amps. 120V plug may not be compatible with NEMA common to visually monitor machine operation. Lockable to deter
vandalism.
household receptacles.
K2340-1 Lockable Fuel Cap / Flash Arrester Kit-For
K802R POWER PLUGKIT - Provides four 120V plugs rated 15 use in locations where flash arrester safety is required.
amps each and one dual voltage, full KVA plug rated at 120/240V, Lockable fuel cap prevents tampering with fuel. Green
50 amps, 120V plug is compatible with NEMA common household cap color provides a visual reminder to use diesel when
refueling.
receptacles.
K857 25 ft. (7.5 m) or K857-1 100 ft. (30.4 m) REMOTE CON-

TROL - Portable control provides same dial range as the output PLASMACUTTING
from the welder. Has convenient plug for easy connection to the ACgenerator power from the engine driven welder.
welder. The VANTAGE 500 CUMMINS is equipped with a 6-pin
connector for connecting the remote control. NOTE: Other Linclon plasma cutters, both single phase
and 3 phase can be used as long as the rating

K704 ACCESSORY SET - Includes 35 feet (10 m) of of the receptacle is not exceeded
shield, Filter plate, work clamp and electrode holder.
Cable is rated at 500 amps, 60% duty cycle. WARNING
TRAILER
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.
K2636-1 TRAILER - Two-wheeled trailer with optional fender
------------------------------------------------------------------------
and light package. For highway use, consult applicable federal,
state, and local laws regarding possible additional require-
ments. Comes standard with a Duo-Hitch, a 2 Ball and Lunette
Eye combination hitch, a fender & a light package. Order:
K2636-1 Trailer
K958-1 Ball Hitch
K2640-1 Cable Rack


muffler.
50P plug,
T12153-9 Full-KVA Power Plug-One dual voltage

plug rated at 120/240V, 50 amps, single phase.
VANTAGE 500
TIG OPTIONS


The K799 Hi-Freq Unit and the K930- [ ] TIG Modules put stud connections.
are suitable for use with the Vantage 500. The Vantage
500 is equipped with the required RF bypass circuitry OTHER WIRE FEEDERS USABLE WITH
for the connection of high frequency generating equip- THE VANTAGE 500
ment. The high frequency bypass network supplied
with the K799 Hi-Freq Unit does NOT need to be NA-3 or LT-7 Automatic Wire Feeder
installed into the Vantage 500.


.062-3/32 (1.6-2.4mm) wire.
VANTAGE 500
NOTES
VANTAGE 500
C2.4
Maintenance - VANTAGE 500 Deutz F4L2011 (Codes 11180,11415)

Fuel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .D2.3
Fuel Filters . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .D2.4
Air Filter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .D2.6

Cooling System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .D2.7
Welder/Generator Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .D2.8
Storage . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .D2.8
Cleaning . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .D2.8
Nameplates . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .D2.8
Brush Removal and Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .D2.8

Bearings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .D2.8
Receptacles . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .D2.8
Battery Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .D2.9
Cleaning the Battery . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .D2.9
Checking Specific Gravity . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .D2.9
Checking Electrolyte Level . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .D2.9
Charging the Battery . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .D2.9

VANTAGE 500
SAFETY PRECAUTIONS CAUTION


machine. See the Service Plan section of the Engine Operation
Manual for a summary of maintenance intervals for the
Remove covers or guards only when necessary items listed below. Follow either the hourly or the cal-
to perform maintenance and replace them when endar intervals, whichever come first. More frequent
the maintenance requiring their removal is com- service may be required, depending on your specific
plete. application and operating conditions.
If covers or guards are missing from the OIL: Check the oil level after every 8 hours of operation
machine, get replacements from a Lincoln or daily. BE SURE TO MAINTAIN THE OIL LEVEL.
Distributor.
Change the oil the first time between 25 and 50 hours


Read the Safety Precautions in the front of this manu- change the oil as specified in Service Plan section of
al and in the instruction manual for the diesel engine the Engine Operation Manual. If the engine is operated
used with your machine before working on the Vantage under heavy load or in high ambient temperatures,
500. change the oil more frequently.

in position and in good repair. Keep your hands, hair, CHANGE THE OIL AND FILTER
machine.
CHANGE THE OIL
Change the oil, while the engine is still warm, as fol-
ROUTINE AND PERIODIC lows:
MAINTENANCE 1 . Route the Oil Drain hose through the access hol in
the frame. Drain the oil using the ball valve on the
ENGINE MAINTENANCE lower right side of the engine. See Figure D2.1.
DAILY 2. When the oil is drained, close the ball valve.
a. Check the crankcase oil level. 3. Remove the oil fill cap and pour in approximaterly
9 quarts (8.5 L) of oil. Check the dipstick and add
b. Refill the fuel tank to minimize moisture condensa-
oil until the level reaches the MAX mark. See
tion in the tank.
c. Open the water drain valve located on the bottom 10W40. Consult the engine manual for oil specifi-
of the water separator element one or two turns cations for various ambient temperatures. Always
and allow to drain into a container suitable for check the level with the dipstick before adding
diesel fuel for two to three seconds. Repeat the more oil. Do not overfill.
4. Reinstall the oil fill cap and the dipstick.
WEEKLY

once a week.
VANTAGE 500
FIGURE D2.1 ENGINE ASSEMBLY

Oil Fill
Cap
MAX
Oil Filter
MIN
Fuel Fuel
Shut-Off Dip Stick
Fuel Filter/ Pump
Water Separator
Oil Drain
Access Hole
CHANGE THE OIL FILTER
Change the oil filter the first time between 25 and 50 5. Refill the engine with the proper amount and type
hours of operation. Then, under normal operating con- of oil as described in the Change the Oil section.
ditions, change the oil filter after every 250 hours of Start the engine and check for leaks around the fil-
operation. If the engine is operated under heavy load ter element. Correct any leaks (usually by retight-
or in high ambient temperatures, change the oil filter ening the filter, but only enough to stop leaks)
more frequently. See Service Plan section of the before placing the Vantage 500 back in service.
Engine Operation Manual for recommended mainte-
nance intervals. See Table D2.1 for replacement oil fil-
the oil level. If necessary, add oil to bring the level
ters.
Change the oil filter as follows: Figure D2.1.
1. Drain the oil from the engine and allow the oil filter FUEL
to drain. See Figure D2.1.
At the end of each day's use, refill the fuel tank to min-
2. Remove the old filter (spin it off) and discard it. imize moisture condensation and dirt contamination in
Wipe off the filter mounting surface and adapter. the fuel line. Do not overfill; leave room for the fuel to
See Figure D2.1. expand.
3. Fill the new filter with fresh engine oil. Apply a thin Refer to your engine operation manual for recom-
coat of new oil to the rubber gasket on the new oil mended grade of fuel.
filter.
filter.
VANTAGE 500
FUEL FILTERS There is also a filter screen in the fuel pump that should
be checked whenever the Fuel Filter/Water Separator

WARNING maintenance is performed. See Figure D2.3
Close the fuel Shut-off valve.

When working on the fuel system
Keep naked lights away, do not smoke ! Remove the hex screw (1) on the top of the fuel
pump.
Do not spill fuel !
Remove the cover and stainer (2) and clean the
------------------------------------------------------------------------ strainer with diesel fuel (replace if necessary).
The VANTAGE 500 DEUTZ is equipped with a Fuel Make sure the seal (3) is in place. Replace the
Filter/Water Separator located after the lift pump and strainer and tighten the hex screw.
before fuel injectors.The procedure for changing the fil-
ter is as follows. See Figure D2.2 Open the fuel valve and check for leaks.
1. Close the fuel shutoff valve. FIGURE D2.3 - FUEL PUMP
2. Clean the area around the fuel filter head. Remove

the filter. Clean the gasket surface of the filter head
and replace the o-ring.
3. Fill the clean filter with clean fuel, and lubricate the o-
ring seal with clean lubricating oil.
4. Install the filter as specified by the filter manufactur-
er.
WARNING
Mechanical overtightening will distort the threads,
filter element seal or filter can.
------------------------------------------------------------------------
FIGURE D2.2 - ENGINE ASSEMBLY
Oil Fill
Cap
MAX
Oil Filter
MIN
Fuel Fuel Dip Stick
Shut-Off Fuel Filter/ Pump

Water Separator
Oil Drain
Access Hole
VANTAGE 500
AIR FILTER: 4. Soak the element in a mild detergent solution for 15


CAUTION the element around in the solution to help remove
Excessive air filter restriction will result in reduced dirt.
engine life. 5. Rinse elements from inside out with a gentle stream
of water (less than 40 psi) to remove all suds and
dirt.
The air filter element is a dry cartridge type. It can be
cleaned and reused. However, damaged elements 6. Dry the element before reuse with warm air at less
should not be reused. Stop engine after 100 hours of than 160F (71C). Do not use a light bulb to dry the
running time and clean filter element. Replace the filter element.
if necessary. Service the air cleaner regularly according 7. Inspect for holes and tears by looking through the
to your engine operation manual. element toward a bright light. Check for damaged
1. Locate the air filter canister located behind the gaskets or dented metal parts. Do not reuse dam-
engine door and mounted to the rear panel . aged elements. Protect the element from dust and
2. Remove the air filter element per the instructions on
8. Reinstall the air filter element per the Maintenance

the Maintenance Instructions located on the door.

(Also in this manual and the Operators Manual Decal.
3. Remove loose dirt from the element with com- After six cleanings, replace the air filter. See the
pressed air or a water hose directed from inside out. Maintenance Instructions. A cleaned filter will have
approximately 70% of the life of a new filter element.
Compressed Air: 100 psi maximum with nozzles at A restricted filter element may not appear exces-
least one inch away from the ele- sively dirty.
ment.
NOTE: If the entire cannister is removed or
Water Hose: 40 psi maximum without nozzle. replaced, the spring clamps should be tight-
ened to 15-20 in/lbs. See Figure D2.4
FIGURE D2.4 - AIR CLEANER

Spring Clamps
Torque to
15-20 in/lbs
Latch
VANTAGE 500
VANTAGE 500
MAINTENANCE
D2.6
COOLING SYSTEM
The cooling system of the Deutz engine needs to be 8. Remove the pulley gaurd - Note the placement of
checked and cleaned periodically. Consult the engine the flat washer at the uppper right mounting bolt of
Operation Manual for the proper frequency and proce- the pulley guard.
dures.
9. See Figure D3.5. Loosen the idler pulley mounting
COOLING BLOWER BELT: The following procedure bolt and move the pulley toward the engine.
should be followed to replace the cooling blower belt:
10. Remove the old cooling blower belt and install a
1. Allow the machine to cool. new one.
2. Unfasten and slide the battery holder out from the 11. Push outward on the idler pulley and adjust the cold
welder. belt tension for approximately 10-15 mm (.4-.6 in.)
maximum deflection) midway between any two pul-
3. Disconnect the negative battery cable.
leys and tighten the bolt.
4. Remove the engine case side.
5. Loosen the air cleaner hose clamp at the engine and engine end panel. Reattach the negative bat-
and detach the hose. tery cable. Slide in and refasten the battery holder.
6. Remove the engine end panel with air box and air 13. Run the engine for 15 minutes and reset the ten-
cleaner attached for access to the engine. sion per the Engine Operation Manual using a V-
belt tension gauge.
7 Remove the Idler solenoid from the pulley guard.
Air
Cleaner
Rear
Panel
Idler
Pulley
Idle
Solenoid
Pulley
Guard
VANTAGE 500
TABLE D2.1
WELDER/GENERATOR BEARINGS: The Vantage 500 is equipped with double-

shielded ball bearings having sufficient grease to last

MAINTENANCE indefinitely under normal service. Where the welder is
STORAGE: Store the Vantage 500 in clean, dry, pro- used constantly or in excessively dirty locations, it may
tected areas. be necessary to add one half ounce of grease per year.
A pad of grease one inch wide, one inch long, and one
CLEANING: Blow out the generator and controls peri- inch high weighs approximately one half ounce. Over-
odically with low pressure air. Do this at least once a greasing is far worse than insufficient greasing.
week in particularly dirty areas.
When greasing the bearings, keep all dirt out of the
NAMEPLATES: Whenever routine maintenance is per- area. Wipe the fittings completely clean and use clean
formed on this machine - or at least yearly - inspect all equipment. More bearing failures are caused by dirt
nameplates and labels for legibility. Replace those introduced during greasing than from insufficient
which are no longer clear. Refer to the parts list for the grease.
replacement item number.
RECEPTACLES: Keep the electrical receptacles in
BRUSH REMOVAL AND REPLACEMENT: It is normal good condition. Remove any dirt, oil, or other debris
for the brushes and slip rings to wear and darken slight- from their surfaces and holes.
ly. Inspect the brushes when a generator overhaul is
necessary. CABLE CONNECTIONS: Check the welding cable

connections at the weld output terminals often. Be sure
that the connections are always tight.
WARNING
is running.
VANTAGE 500
BATTERY MAINTENANCE
CHECKING SPECIFIC GRAVITY: Check each battery

WARNING cell with a hydrometer. A fully charged battery will have
GASES FROM BATTERY can explode. reading is below 1.215.
Keep sparks, flame, and cigarettes NOTE: Correct the specific gravity reading by adding
away from battery. four gravity points (0.004) for every five degrees the
electrolyte temperature is above 80 degrees F (27
degrees (C). Subtract four gravity points (.004) for
BATTERY ACID can burn eyes and every five degrees the electrolyte temperature is below
skin. 80 degrees F (27 degrees C).

be careful when working near a bat- CHECKING ELECTROLYTE LEVEL: If battery cells
tery. Follow the instructions printed are low, fill them to the neck of the filler hole with dis-
on the battery. tilled water and recharge. If one cell is low, check for
leaks.

INSTALLING A NEW BATTERY -
Disconnect the negative cable from CHARGING THE BATTERY: The Vantage 500 is
the old battery first and connect to equipped with a wet charged battery. The charging
the new battery last. current is automatically regulated when the battery is
GROUND - Damage to the engine alternator and the battery is fully charged.
the printed circuit board can result from incor- When you charge, jump, replace, or otherwise connect
rect connection. battery cables to the battery, be sure the polarity is cor-
CONNECTING A BATTERY CHARGER - Remove rect. Improper polarity can damage the charging cir-
the battery from the welder by disconnecting the cuit. The Vantage 500 charging system is NEGA-
negative cable first, then the positive cable and TIVE GROUND. The positive (+) battery terminal has
battery clamp. When reinstalling, connect the a red terminal cover.
negative cable last. Keep the area well ventilated. If you need to charge the battery with an external
USING A BOOSTER - Connect the positive lead to charger, disconnect the negative cable first, then the
the battery first, then connect the negative lead positive cable before you attach the charger leads.
to the engine foot. After the battery is charged, reconnect the positive bat-
tery cable first and the negative cable last. Failure to
To prevent BATTERY BUCKLING, tighten the do so can result in damage to the internal charger com-
nuts on the battery clamp until snug. ponents.
Follow the instructions of the battery charger manufac-
CLEANING THE BATTERY: Keep the battery clean turer for proper charger settings and charging time.
enters the cells.

VANTAGE 500


10
9
7
5 6
ING
WARN
4
VANTAGE 500
Installation - VANTAGE 500 Deutz D2011L4i (Code11468)

Storing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .A3.3
Stacking . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .A3.3
Lifting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .A3.4

Towing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .A3.4
Oil . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .A3.5
Fuel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .A3.5
Fuel Cap . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .A3.5

Spark Arrester . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .A3.6
Remote Control . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .A3.6

VANTAGE 500
TECHNICAL SPECIFICATIONS - VANTAGE 500 DEUTZ (K2405-2)


System
DEUTZ 4 cylinder High Idle 1890 190 cu. in 12VDC battery Fuel
D 2011 L4i 48HP (36 kw) Low Idle 1425 (3.1L) & Starter 25 US gal.
EPA Bore x Stroke Oil:
Tier 4 interim 2.5 US gal.
Compliant 3.70 x 4.41 (9.5L)
(94mm x 112mm)


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

Auxiliary Power (1)
120/240 VAC
PHYSICAL DIMENSIONS
Height (2)
Width Depth Weight
42.0 in 31.5 in. 63.1 in. 1532lbs.

(1066.8 mm) (800.1mm) (1603mm) (695kg)
(Approx)
2. Top of Enclosure. Add 8.9 (226mm) for exhaust.
VANTAGE 500

start installation.

FACES
all sides.
wiring.
place.

STACKING
guards off.
VANTAGE 500
LIFTING TOWING
Before attempting to lift the Vantage, secure the lift bale Lincolns K2636-1. If the user adapts a non-Lincoln
in a raised position. Secure the lift bale as follows: trailer, he must assume responsibility that the method
of attachment and usage does not result in a safety
hazard nor damage the welding equipment. Some of
b. Locate the two access holes on the upper mid- the factors to be considered are as follows:
the lift bale.

Lift only with equipment of adequate Consult applicable federal, state and local laws
1
lifting capacity. regarding specific requirements for use on public high-

ways.
Be sure machine is stable when lift-
ing. VEHICLE MOUNTING
WARNING

At higher altitude, output derating may be necessary. cause unstable vehicle handling and tires or other
meters (6888 ft.) loads.
Distribute, balance and secure loads so vehicle
derating may be necessary. For maximum output cur- Follow vehicle manufacturers instructions.
rent ratings, derate the welder voltage rating two volts

for every 10C (21F) above 40C (104F).
VANTAGE 500

READ the engine operating and maintenance instruc- The Deutz engine is air cooled by a belt-driven axial
tions supplied with this machine. blower. The oil cooler and engine cooling fins should
WARNING procedures and frequency.)

Stop engine and allow to cool before
fueling. BATTERY CONNECTION
Do not smoke when fueling. WARNING
Fill fuel tank at a moderate rate and do not over- GASES FROM BATTERY can explode.
fill.
Keep sparks, flame and cigarettes
Wipe up spilled fuel and allow fumes to clear away from battery.

INSTALLING A NEW BATTERY disconnect neg-
OIL
ative cable from old battery first and connect to
The Vantage is shipped with the engine crankcase new battery last.
filled with high quality SAE 10W-30 oil (API class CD
CONNECTING A BATTERY CHARGER remove
Keep well ventilated.
Refer to the engine Operators Manual for specific oil
recommendations and break-in information. The oil USING A BOOSTER connect positive lead to
change interval is dependent on the quality of the oil battery first then connect negative lead to nega-
and the operating environment. Refer to the engine tive battery lead at engine foot.
BATTERY ACID can burn eyes and
nance intervals.
skin.
FUEL Wear gloves and eye protection and

NOTE: USE DIESEL FUEL ONLY. tery.
Fill the fuel tank with clean, fresh diesel fuel. The Follow instructions printed on battery.
injection pump. NOTE: Before starting the engine,
open the fuel shutoff valve (pointer to be in line with
hose).

FUEL CAP
VANTAGE 500

WHEN:
The Vantage is shipped with the negative battery cable generating equipment. The high frequency bypass
disconnected. Before you operate the machine, make network supplied with the K799 Hi-Freq Unit does
sure the Engine Switch is in the OFF position and NOT need to be installed into the Vantage 500.


REMOTE CONTROL
MUFFLER OUTLET PIPE

VANTAGE 500

the welder.
cable voltage drop.


500 3/0 AWG 3/0 AWG 4/0 AWG
to rated capacity.
MACHINE GROUNDING

grounded type plug,
VANTAGE 500
engine.

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

SERVICE OVERCURRENT
PROTECTION.
PREMISES
DISCONNECT AND
SERVICE
GROUND OVERCURRENT
50AMP
240 VOLT PROTECTION
DOUBLE
POLE
NEMA TYPE 14-50
GND
50 AMP, 120/240 VOLT

VANTAGE 500
Operation - VANTAGE 500 Deutz D2011L4i (Code 11468)


Break-In Period . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .B3.7
Stick Welding . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .B3.8

Pipe Welding . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .B3.8
TIGWelding . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .B3.8
Arc Gouging . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .B3.10
Paralleling . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .B3.10

VANTAGE 500
B3.2 OPERATION B3.2

engine.
SAFETY INSTRUCTIONS
WARNING guards off.
Do not attempt to use this equipment until you Stop engine before servicing.
Keep away from moving parts
include important safety precautions: detailed
equipment.
ELECTRIC SHOCK can kill. ADDITIONAL SAFETY PRECAUTIONS

Do not touch electrically live parts or Always operate the welder with the hinged door closed
electrodes with your skin or wet and the side panels in place, as these provide maxi-
clothing. mum protection from moving parts and insure proper
cooling air flow.
Insulate yourself from the work and
ground.
Always wear dry insulating gloves. GENERAL DESCRIPTION
FUMES AND GASES CAN BE nating current generator for DC multi-purpose welding
DANGEROUS. and for 120/240VAC single phase and 240VAC three
phase auxiliary standby power. The welding control
Keep your head out of fumes. system uses state of the art Chopper Technology.
Use ventilation or exhaust to remove The generator has a single sealed bearing for mainte-
fumes from breathing zone. nance free service. The rotor is a copper wound design
WELDING SPARKS CAN CAUSE then impregnated with three layers of high quality var-
FIRE OR EXPLOSION. nish. After the stator is assembled using tie bars, the
entire assembly is covered with an environmentally
Keep flammable material away. protective coating. These measures insure trouble-free
Do not weld on containers that have operation in the harshest environments.
held combustibles. The fuel tank is made from high density polyethylene
at full load.
ARC RAYS CAN BURN.

tor element.
VANTAGE 500
B3.3 OPERATION B3.3


WELDER
load).

FEATURES
OTHER FEATURES
FOR WELDING


be FLASHING.

slope modes.
VANTAGE 500
B3.4 OPERATION B3.4

4 5 6 7 8 9 10
3
11
13
20
12
15 21
14 19
23
1
22
2
16
17 18

2. START PUSHBUTTON
VANTAGE 500
B3.5 OPERATION B3.5

The gauge displays the engine oil pressure when the d. If the welding or AC power load is not restarted
engine is running. before the end of the time delay, the idler

peratures. If the light turns on, the engine protection Idler Operational exceptions
system will stop the engine. Check for proper oil and When the WELDING TERMINALS switch is in the
coolant levels and add oil and/or coolant if neces- Remotely Controlled position the idler will operate as
sary. Check for loose or disconnected leads at the oil follows:
pressure sender located on the engine. The light will a. When the triggering device (Amptrol, Arc Start
remain on when the engine has been shut down due Switch, etc.) is pressed the engine will acceler-
to low oil pressure or over-temperature condition. ate and operate at full speed provided a weld-
NOTE: This engine is equipped with an electronic ing load is applied within approximately 12 sec-
governor system. The engine speed ramps onds.
up during a warm up period. The complete If the triggering device remains pressed but no
cycle takes approximately 3 minutes. This welding load is applied within approximately 12
allows the engine cylinder temperature to seconds the engine may return to low idle
build up slowly before going to full speed. speed.
This feature is bypassed if the engine is
already warm. The Engine may produce If the triggering device is released or welding
White Smoke for a few minutes at low tem- ceases the engine will return to low idle speed
peratures. Do not apply a load to the after approximately 12 seconds.
machine during the warm up period.


run position.
9. IDLER SWITCH

12 seconds starts.
VANTAGE 500
B3.6 OPERATION B3.6


of the Amptrol.
CV-WIRE

DOWNHILL PIPE

chapter.
VANTAGE 500
B3.7 OPERATION B3.7

These circuit breakers provide separate overload 6. Within 30 seconds, press and hold the engine
current protection for each 120V circuit at the 240V START button until the engine starts. If the engine
single phase receptacle, each 120V single phase does not start within 30 seconds the RUN/STOP
receptacle, the 240V three phase receptacle, the switch must be returned to the STOP position, then
120VAC in the 14-Pin connector, the 42VAC in the return to step 5.
14-Pin connector and battery circuit overload protec- 7. Release the engine START button when the engine
tion. starts.
21. 120VAC SINGLE PHASE RECEPTACLES ing lights are off. Investigate any indicated problem.
These two 120VAC (5-20R) receptacles with GFCI NOTE: The engine will go through a 3 minute warm-up
protection provide 120VAC single phase for auxiliary cycle if cold. If the engine coolant is still warm
power. Each receptacle has a 20 amp total rating. from recent operation, the engine will go imme-
They are designed to protect the user from the haz- diately to high idle and then to low idle if the idle
ards of ground faults. When the GFCI has tripped switch is in the AUTO position.

section in the installation chapter for further informa- COLD WEATHER STARTING
tion about these receptacles. Also refer to the AUX- With a fully charged battery and the proper weight oil,
ILIARY POWER OPERATION section later in this the engine should start satisfactorily even down to
chapter. about 0F(-18C). If the engine must be frequently
22. GROUND STUD the optional ether start kit (K887-1). Installation and
Provides a connection point for connecting the
GROUNDING in the Installation chapter for proper STOPPING THE ENGINE
23. 240VAC THREE PHASE RECEPTACLE off the voltage supplied to the shutdown solenoid. A
backup shutdown can be accomplished by shutting
This is a 240VAC (15-50R) receptacle that provides off the fuel valve located on the fuel line.
240VAC three phase auxiliary power. This receptacle
has a 50 amp rating. This receptacle in not present

on the models covered by this manual. BREAK-IN PERIOD

ENGINE OPERATION duty, industrial engine. It is designed and built for rugged use.
STARTING THE ENGINE until the break-in is accomplished. Check the oil level twice a
1. Open the engine compartment door and check that day during the break-in period. In general this takes 50 to 100
the fuel shutoff valve is in the open position (lever to hours of operation.
be in line with the hose). IMPORTANT
2. Check for proper oil level and coolant level. Close IN ORDER TO ACCOMPLISH THIS BREAK-IN, THE UNIT
engine compartment door. SHOULD BE SUBJECTED TO HEAVY LOADS, WITHIN
3. Remove all plugs connected to the AC power recep- THE RATING OF THE MACHINE. AVOID LONG IDLE RUN-
tacles. NING PERIODS.
5. Set the RUN/STOP switch to RUN. Observe that TYPICAL FUEL CONSUMPTION

on. The engine protection light may turn off after 5 Refer to Table B3.1 for typical fuel consumption of the VAN-
seconds or remain on until the engine is started. TAGE 500 Engine for various operating scenarios.
VANTAGE 500
B3.8 OPERATION B3.8
Table B3.1 DEUTZ F4L2011 DOWNHILL PIPE MODE

ENGINE FUEL CONSUMPTION This slope controlled setting is intended for out-of-posi-
Deutz D1022L4i Running Time
would like to control the current level by changing the
48 HP(36kw) 25 Gal.(94.6L)
arc length. The OUTPUT CONTROL knob adjusts the
@1800 rpm (Hours)
full output range for pipe welding.
Low Idle .47 gallons/ hour 53
No Load (1.77 liters/hour)
1475 rpm
Hihg Idle .66 gallons/hour 40 from -10 (Soft) to +10 (Crisp) increases the short circuit
No Load (2.50 liters/hour) current which results in a more forceful digging arc.
1900 rpm Typically a forceful digging arc is preferred for root and
DC-CC 1.99 gallons/hour 12.6 hot passes. A softer arc is preferred for fill and cap pass-
Welding (7.53 liters/hour) es where weld puddle control and deposition (stacking
500A @40V of iron) are key to fast travel speeds. It is recommend-
Auxiliary Power 1.25 gallons/hour 20.0 ed that the ARC CONTROL be set initially at 0.
12,000 VA (4.73 liters/hour)

20,000VA (6.66L/hour)
WELDER OPERATION desired current and the tungsten is touched to the work.
DUTY CYCLE During the time the tungsten is touching the work there
Duty Cycle is the the ratio of the uninterrupted on-load tungsten contamination. Then, the tungsten is gently lift-
duration to 10 minutes. The total time period of one ed off the work in a rocking motion, which establishes
complete on-load and no-load cycle is 10 minutes. For the arc.
applied continuously for 6 minutes followed by a no- To stop the arc, simply lift the TIG torch away from the
load period of 4 minutes. work piece. When the arc voltage reaches approxi-
STICK WELDING MODE automatically reset to the touch start current level. The
The Vantage can be used with a broad range of DC tungsten may then be retouched to the work piece to
stick electrodes. restrike the arc. The arc may also be started and
as follows: The ARCCONTROL is not active in the TIG mode.
CC-STICK MODE use of a high frequency generator is desired, the K930-
The CC-STICK position of the MODE switch is 2 TIG Module can be used with the Vantage. The set-
designed for horizontal, vertical-up and overhead weld- tings are for reference.
The Vantage is equipped with the required R.F. bypass
circuitry for the connection of high frequency generat-
ing equipment.

installation, operation, and maintenance.
It is recommended that the ARC CONTROL be set to When using the TIG Module, the OUTPUT control on
the minimum number without electrode sticking. Start the Vantage is used to set the maximum range of the
with the knob set at 0. CURRENTCONTROL on the TIG Module or an Amptrol
VANTAGE 500
B3.9 OPERATION B3.9


Tungsten
0.010 (.25) 2-15 3

3-8 (2-4) 3-8 (2-4) #4, #5, #6
0.020 (.50) 5-20 3
5-10 (3-5) 5-10 (3-5)
0.40 (1.0) 15-80 3
5-10 (3-5) 5-10 (3-5)
1/16 (1.6) 70-150 10-20 5-10 (3-5) 9-13 (4-6) #5, #6
3/32 (2.4) 150-250 15-30 13-17 (6-8) 11-15 (5-7) #6, #7, #8
1/8 (3.2) 250-400 25-40 15-23 (7-11) 11-15 (5-7)
5/32 (4.0) 400-500 40-55 21-25 (10-12) 13-17 (6-8) #8, #10
3/16 (4.8) 500-750 55-80 23-27 (11-13) 18-22 (8-10)
1/4 (6.4) 750-1000 80-125 28-32 (13-15) 23-27 (11-13)
1
2
Pure EWP
1% Thoriated EWTh-1
2% Thoriated EWTh-2
2
applications.
3

4
# 4 = 1/4 in. (6 mm) # 7 = 7/16 in. (11 mm)

# 5 = 5/16 in. (8 mm) # 8 = 1/2 in. (12.5 mm)
# 6 = 3/8 in. (10 mm) #10 = 5/8 in. (16 mm)
5
(TIG). (TIG).
with respect to the #2 and #4 leads does not provide

the proper signal to open and close the solid state con-
tactor in the Vantage 500.
VANTAGE 500


71M. ARC GOUGING
5/32 90-150 Amps
the desired operating mode. Full power is available 1/4 200-400 Amps
120 VAC operation.

leled.
VANTAGE 500

(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

EXTENSION CORD
RECOMMENDATIONS
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 48010 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)
VANTAGE 500
NOTES
VANTAGE 500
B3.12
Accessories - VANTAGE 500 Deutz F4L2011 (Codes 11180, 11415)


VANTAGE 500

K802N POWER PLUG KIT - Provides four 120V plugs rated at 20 K2356-1 Control Panel Cover Kit-Clear plexiglass
amps each and one dual voltage, full KVA plug rated at 120/240V, cover to protect control panel from dirt and debris, and
50 amps. 120V plug may not be compatible with NEMA common to visually monitor machine operation. Lockable to deter
vandalism.
household receptacles.
K2340-1 Lockable Fuel Cap / Flash Arrester Kit-For
K802R POWER PLUGKIT - Provides four 120V plugs rated 15 use in locations where flash arrester safety is required.
amps each and one dual voltage, full KVA plug rated at 120/240V, Lockable fuel cap prevents tampering with fuel. Green
50 amps, 120V plug is compatible with NEMA common household cap color provides a visual reminder to use diesel when
refueling.
receptacles.
K857 25 ft. (7.5 m) or K857-1 100 ft. (30.4 m) REMOTE CON-

TROL - Portable control provides same dial range as the output PLASMACUTTING
from the welder. Has convenient plug for easy connection to the ACgenerator power from the engine driven welder.
welder. The VANTAGE 500 CUMMINS is equipped with a 6-pin
connector for connecting the remote control. NOTE: Other Linclon plasma cutters, both single phase
and 3 phase can be used as long as the rating

K704 ACCESSORY SET - Includes 35 feet (10 m) of of the receptacle is not exceeded
shield, Filter plate, work clamp and electrode holder.
Cable is rated at 500 amps, 60% duty cycle. WARNING
TRAILER
K2636-1 TRAILER - Two-wheeled trailer with optional fender
------------------------------------------------------------------------
K2636-1 Trailer
K958-1 Ball Hitch
K2640-1 Cable Rack


muffler.
50P plug,
T12153-9 Full-KVA Power Plug-One dual voltage

VANTAGE 500
TIG OPTIONS
K1783-9 PTA-26V TIGTorch K126-2 Magnum 350 Innershield Gun (for LN-25)
Air Cooled 200 amp torch (2 piece) equipped with valve For self-shielded wire with 15 ft. (4.5m) cable. For
for gas flow control. 25 ft. (7.6m) length. .062-3/32 (1.6-2.4mm) wire.
KP509 Magnum Parts Kit for PTA-26V TIG Torch K1802-1 Magnum 300 MIGGun
Magnum Parts Kit provides all the torch accessories For .035-.045 (0.9-1.2mm) gas shielded wire. Includes
you need to start welding. Parts kit provides collets, 15 ft. gun and cable assembly and connector kit.
collet bodies, a black cap, alumina nozzles and tung-
stens in a variety of sizes, all packaged in an easy to KP653-035S Drive Roll and Guide Tube Kit (for LN-25)
carry reclosable sack. For .035-.040(0.9-1.0mm) solid steel wire.
K870 Foot Amptrol-Varies current while welding for K2613-1 LN-25 PRO PORTABLE WIRE FEEDER-The
making critical TIG welds and crater filling. Depress MAXTRAC wire drive enhances performance, while the
pedal to increase current. Depressing pedal fully replacement case, and many other upgrade options that can
achieves maximum set current. Fully raising the pedal be installed in less then five minutes aid in the serviceability.
finishes the weld and starts the after flow cycle on sys-
tems so equipped. Includes 25 ft. (7.6m) control cable. KP1697-5/64 Drive Roll Kit- Includes: 2 polished U
groove drive rolls, outer wire guide and inner wire guide
K963-3 Hand Amptrol-Varies current for making crit- for solid core wire. (Used on LN-25 Pro)

thumb control. Comes with a 25 ft. (7.6m) cable. (One
size fits all Pro-Torch TIG Torches.) KP1697-068 Drive Roll Kit- Includes: 2 polished U
groove drive rolls, outer wire guide and inner wire guide
K2347-1 Precision TIG 185 Ready-Pak for solid core wire. (Used on LN-25 Pro)
use the ACgenerator of the Engine-Driven Welder to
supply the power. Easy setup. Includes torch, foot KP1696-1 Drive Roll Kit- Includes: 2 V groove drive
amptrol, gas regulator and hose. Requires the K1816- rolls and inner wire guide for Steel Wires. (Used on LN-
1 Full KVA adapter kit. 25 Pro)
K2350-1 Invertec V205-T AC/DC One-Pak Package K487-25 Magnum SGSpool Gun
For ACTIG welding with square wave performance, Hand held semiautomatic wire feeder. Requires SG
use the AC generator of the engine-driven welder to Control Module and Input Cable.
supply the power. Easy setup. Includes torch, parts
kit, regulator and hose kit, Twist-Mate torch adapter, K488 SGControl Module
work cable with Twist-Mate end and foot Amptrol. The Interface between the power source and the spool
gun. Provides control of the wire speed and gas flow.
HIGH FREQUENCY GENERATORS FOR
K691-10 Input Cable (For SG Control Module)

TIG APPLICATIONS For Lincoln engine power sources with 14-pin MS-type
The K799 Hi-Freq Unit and the K930- [ ] TIG Modules connection, separate 115VNEMAreceptacles and out-
put stud connections.
500 is equipped with the required RF bypass circuitry
for the connection of high frequency generating equip- OTHER WIRE FEEDERS USABLE WITH
ment. The high frequency bypass network supplied THE VANTAGE 500
with the K799 Hi-Freq Unit does NOT need to be
installed into the Vantage 500. NA-3 or LT-7 Automatic Wire Feeder
The Vantage 500 and any high frequency-generating LN-742 Semi-automatic Wire Feeder
equipment must be properly grounded. See the K799 LF-72/74 Semi-automatic Wire feeder
Hi-Freq Unit and the K930-AII TIG Module operating
manuals for complete instructions on installation, oper- LN-7 Semi-automatic Wire Feeder
ation, and maintenance. LN-8 Semi-automatic Wire Feeder

K449 LN-25 Wire Feeder See the Wire Feeder Manual or the Diagrams section
Portable CC/CV unit for flux-cored and MIGwelding.
Includes Gas Solenoid &Internal Contactor. of this manual for connection information of the various
feeders to the Vantage 500.
KP653-3/32 Drive Roll and Guide Tube Kit (for LN-25)
For .068-3/32 (1.8-2.4mm) cored or solid steel wire.
VANTAGE 500
NOTES
VANTAGE 500
C3.4
Maintenance - VANTAGE 500 Deutz D2011L4i (Codes 11468)

Fuel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .D3.3
Fuel Filters . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .D3.4
Air Filter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .D3.6

Cooling System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .D3.7
Storage . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .D3.8
Cleaning . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .D3.8
Nameplates . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .D3.8

Bearings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .D3.8
Receptacles . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .D3.8
Cable Connections . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .D3.8

VANTAGE 500


machine. See the Service Plan section of the Engine Operation
Manual for a summary of maintenance intervals for the
Remove covers or guards only when necessary items listed below. Follow either the hourly or the cal-
to perform maintenance and replace them when endar intervals, whichever come first. More frequent
the maintenance requiring their removal is com- service may be required, depending on your specific
plete. application and operating conditions.
If covers or guards are missing from the OIL: Check the oil level after every 8 hours of operation
machine, get replacements from a Lincoln or daily. BE SURE TO MAINTAIN THE OIL LEVEL.
Distributor.


Read the Safety Precautions in the front of this manu- change the oil as specified in Service Plan section of

in position and in good repair. Keep your hands, hair, CHANGE THE OIL AND FILTER
machine.
CHANGE THE OIL
Change the oil, while the engine is still warm, as fol-
ROUTINE AND PERIODIC lows:
MAINTENANCE 1 . Route the Oil Drain hose through the access hol in
ENGINE MAINTENANCE lower right side of the engine. See Figure D3.1.
DAILY 2. When the oil is drained, close the ball valve.
a. Check the crankcase oil level. 3. Remove the oil fill cap and pour in approximaterly
9 quarts (8.5 L) of oil. Check the dipstick and add
oil until the level reaches the MAX mark. See
tion in the tank.
c. Open the water drain valve located on the bottom 10W40. Consult the engine manual for oil specifi-
of the water separator element one or two turns cations for various ambient temperatures. Always
and allow to drain into a container suitable for check the level with the dipstick before adding
diesel fuel for two to three seconds. Repeat the more oil. Do not overfill.
WEEKLY

once a week.
VANTAGE 500

Oil Fill
Cap
MAX
Oil Filter
MIN
Fuel Fuel
Shut-Off Dip Stick
Fuel Filter/ Pump
Water Separator
Oil Drain
Access Hole
CHANGE THE OIL FILTER
Change the oil filter the first time between 25 and 50 5. Refill the engine with the proper amount and type
hours of operation. Then, under normal operating con- of oil as described in the Change the Oil section.
ditions, change the oil filter after every 250 hours of Start the engine and check for leaks around the fil-
operation. If the engine is operated under heavy load ter element. Correct any leaks (usually by retight-
or in high ambient temperatures, change the oil filter ening the filter, but only enough to stop leaks)
more frequently. See Service Plan section of the before placing the Vantage 500 back in service.
Engine Operation Manual for recommended mainte-
nance intervals. See Table D3.1 for replacement oil fil-
ters.
Change the oil filter as follows: Figure D3.1.
1. Drain the oil from the engine and allow the oil filter FUEL
At the end of each day's use, refill the fuel tank to min-
2. Remove the old filter (spin it off) and discard it. imize moisture condensation and dirt contamination in
Wipe off the filter mounting surface and adapter. the fuel line. Do not overfill; leave room for the fuel to
See Figure D3.1. expand.
3. Fill the new filter with fresh engine oil. Apply a thin Refer to your engine operation manual for recom-
coat of new oil to the rubber gasket on the new oil mended grade of fuel.
filter.
filter.
VANTAGE 500
FUEL FILTERS
WARNING Close the fuel Shut-off valve.
Remove the hex screw (1) on the top of the fuel

pump.
Keep naked lights away, do not smoke !
Remove the cover and stainer (2) and clean the
Do not spill fuel !
strainer with diesel fuel (replace if necessary).
The VANTAGE 500 DEUTZ is equipped with a Fuel Make sure the seal (3) is in place. Replace the
Filter/Water Separator located after the lift pump and strainer and tighten the hex screw.
ter is as follows. See Figure D3.2 Open the fuel valve and check for leaks.
1. Close the fuel shutoff valve.

2. Clean the area around the fuel filter head. Remove FIGURE D3.3 - FUEL PUMP


er.
WARNING
Mechanical overtightening will distort the threads,
There is also a filter screen in the fuel pump that should

be checked whenever the Fuel Filter/Water Separator
maintenance is performed. See Figure D3.3

Oil Fill
Cap
MAX
Oil Filter
MIN
Fuel Fuel
Shut-Off Dip Stick
Fuel Filter/
Pump
Water Separator
Oil Drain
Access Hole
VANTAGE 500


dirt.
engine door and mounted to the rear panel . aged elements. Protect the element from dust and


ment.

Spring Clamps
Torque to
15-20 in/lbs
Latch
VANTAGE 500
VANTAGE 500
MAINTENANCE
D3.6
COOLING SYSTEM
The cooling system of the Deutz engine needs to be Note the placement of the flat washer at the uppper
checked and cleaned periodically. Consult the engine right mounting bolt of the pulley guard.
Operation Manual for the proper frequency and proce- 8. See Figure D3.5. Loosen the idler pulley mounting
dures. bolt and move the pulley toward the engine.
COOLING BLOWER BELT: The following procedure 9. Remove the old cooling blower belt and install a
should be followed to replace the cooling blower belt: new one.
1. Allow the machine to cool. 10. Push outward on the idler pulley and adjust the
2. Unfasten and slide the battery holder out from the cold belt tension for approximately 10-15 mm (.4-.6
welder. in.) maximum deflection) midway between any two
pulleys and tighten the bolt.
3. Disconnect the negative battery cable.
4. Remove the engine case side. and engine end panel. Reattach the negative bat-
5. Loosen the air cleaner hose clamp at the engine tery cable. Slide in and refasten the battery holder.
and detach the hose.
12. Run the engine for 15 minutes and reset the ten-
6. Remove the engine end panel with air box and air sion per the Engine Operation Manual using a V-
cleaner attached for access to the engine. belt tension gauge.
7 Remove the Idler solenoid and the pulley guard.
Air
Cleaner
Rear
Panel
Idler
Pulley
Idle
Solenoid
Pulley
Guard
VANTAGE 500
TABLE D3.1
WELDER/GENERATOR BEARINGS: The Vantage 500 is equipped with double-

shielded ball bearings having sufficient grease to last

MAINTENANCE indefinitely under normal service. Where the welder is
STORAGE: Store the Vantage 500 in clean, dry, pro- used constantly or in excessively dirty locations, it may
tected areas. be necessary to add one half ounce of grease per year.
A pad of grease one inch wide, one inch long, and one
CLEANING: Blow out the generator and controls peri- inch high weighs approximately one half ounce. Over-
odically with low pressure air. Do this at least once a greasing is far worse than insufficient greasing.
week in particularly dirty areas.
When greasing the bearings, keep all dirt out of the
NAMEPLATES: Whenever routine maintenance is per- area. Wipe the fittings completely clean and use clean
formed on this machine - or at least yearly - inspect all equipment. More bearing failures are caused by dirt
nameplates and labels for legibility. Replace those introduced during greasing than from insufficient
which are no longer clear. Refer to the parts list for the grease.
replacement item number.
RECEPTACLES: Keep the electrical receptacles in
BRUSH REMOVAL AND REPLACEMENT: It is normal good condition. Remove any dirt, oil, or other debris
for the brushes and slip rings to wear and darken slight- from their surfaces and holes.
ly. Inspect the brushes when a generator overhaul is
necessary. CABLE CONNECTIONS: Check the welding cable

WARNING
is running.
VANTAGE 500
BATTERY MAINTENANCE CHECKING SPECIFIC GRAVITY: Check each battery

cell with a hydrometer. A fully charged battery will have

WARNING reading is below 1.215.
GASES FROM BATTERY can explode. NOTE: Correct the specific gravity reading by adding
four gravity points (0.004) for every five degrees the
Keep sparks, flame, and cigarettes electrolyte temperature is above 80 degrees F (27
away from battery. degrees (C). Subtract four gravity points (.004) for
every five degrees the electrolyte temperature is below
80 degrees F (27 degrees C).
BATTERY ACID can burn eyes and
skin.
Wear gloves and eye protection and CHECKING ELECTROLYTE LEVEL: If battery cells
be careful when working near a bat- are low, fill them to the neck of the filler hole with dis-
tery. Follow the instructions printed tilled water and recharge. If one cell is low, check for
on the battery. leaks.

INSTALLING A NEW BATTERY - CHARGING THE BATTERY: The Vantage 500 is
Disconnect the negative cable from equipped with a wet charged battery. The charging
the old battery first and connect to current is automatically regulated when the battery is
the new battery last. low (after starting the engine) to a trickle current when
the battery is fully charged.
THE CORRECT POLARITY IS NEGATIVE
GROUND - Damage to the engine alternator and When you charge, jump, replace, or otherwise connect
the printed circuit board can result from incor- battery cables to the battery, be sure the polarity is cor-
rect connection. rect. Improper polarity can damage the charging cir-
cuit. The Vantage 500 charging system is NEGA-
CONNECTING A BATTERY CHARGER - Remove TIVE GROUND. The positive (+) battery terminal has
the battery from the welder by disconnecting the a red terminal cover.
negative cable first, then the positive cable and
battery clamp. When reinstalling, connect the If you need to charge the battery with an external
negative cable last. Keep the area well ventilated. charger, disconnect the negative cable first, then the
positive cable before you attach the charger leads.
USING A BOOSTER - Connect the positive lead to After the battery is charged, reconnect the positive bat-
the battery first, then connect the negative lead tery cable first and the negative cable last. Failure to
to the engine foot. do so can result in damage to the internal charger com-
To prevent BATTERY BUCKLING, tighten the ponents.
nuts on the battery clamp until snug. Follow the instructions of the battery charger manufac-
turer for proper charger settings and charging time.
CLEANING THE BATTERY: Keep the battery clean

enters the cells.

VANTAGE 500


10
9
7
5 6
ING
WARN
4
VANTAGE 500
Installation - VANTAGE 500 Cummins B3.3 (Code 10996)

Storing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .A4.3
Stacking . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .A4.3
Lifting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .A4.4

Towing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .A4.4
Vehicle Towing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .A4.4
Oil . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .A4.5
Fuel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .A4.5
Fuel Cap . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .A4.5

Spark Arrester . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .A4.6
Remote Control . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .A4.6

VANTAGE 500
TECHNICAL SPECIFICATIONS - Vantage 500 CUMMINS (K2272-1)


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

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

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)
VANTAGE 500

start installation.

FACES
all sides.
wiring.
place.

STACKING
guards off.
VANTAGE 500
LIFTING TOWING
the lift bale.

Lift only with equipment of adequate Consult applicable federal, state and local laws
1
lifting capacity. regarding specific requirements for use on public high-

ways.
Be sure machine is stable when lift-
ing. VEHICLE MOUNTING
WARNING
At higher altitudes, output derating may be necessary. cause unstable vehicle handling and tires or other
meters (6888 ft.). loads.
Contact a Cummins Service Representative for any Distribute, balance and secure loads so vehicle
engine adjustments that may be required. is stable under conditions of use.

VANTAGE 500


HOT COOLANT can burn skin.

WARNING
Do not remove cap if radiator is hot.
Stop engine and allow to cool before The welder is shipped with the engine and radiator
fueling. filled with a 50% mixture of ethylene glycol and water.
Do not smoke when fueling. See the MAINTENANCE section and the engine
Operators Manual for more information on coolant.
fill.
Wipe up spilled fuel and allow fumes to clear WARNING

Keep sparks and flame away from tank. BATTERY CONNECTION
OIL Keep sparks, flame and cigarettes
The Vantage is shipped with the engine crankcase away from battery.
filled with high quality SAE 10W-30 oil (API class CD
add oil as required. Check the oil level every four To prevent EXPLOSION when:
Refer to the engine Operators Manual for specific oil INSTALLING A NEW BATTERY disconnect nega-
recommendations and break-in information. The oil tive cable from old battery first and connect to new
change interval is dependent on the quality of the oil battery last.
and the operating environment. Refer to the engine CONNECTING A BATTERY CHARGER remove
Operators Manual for the proper service and mainte- battery from welder by disconnecting negative cable
nance intervals. first, then positive cable and battery clamp. When
reinstalling, connect negative cable last. Keep well
FUEL ventilated.
NOTE: USE DIESEL FUEL ONLY. USING A BOOSTER connect positive lead to
battery first then connect negative lead to negative
Fill the fuel tank with clean, fresh diesel fuel. The battery lead at engine foot.
Running out of fuel may require bleeding the fuel WARNING
injection pump. NOTE: Before starting the engine,
open the fuel shutoff valve (pointer to be in line with BATTERY ACID can burn eyes and
hose). skin.
NOTE: Before starting the engine, open the fuel shut- tery.
Follow instructions printed on battery.
FUEL CAP
VANTAGE 500

WHEN:


REMOTE CONTROL
MUFFLER OUTLET PIPE

VANTAGE 500

the welder.
cable voltage drop.


500 3/0 AWG 3/0 AWG 4/0 AWG
to rated capacity.
MACHINE GROUNDING

grounded type plug,
VANTAGE 500
engine.

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

SERVICE OVERCURRENT
PROTECTION.
PREMISES
DISCONNECT AND
SERVICE
GROUND OVERCURRENT
50AMP
240 VOLT PROTECTION
DOUBLE
POLE
NEMA TYPE 14-50
GND
50 AMP, 120/240 VOLT

VANTAGE 500
Operation - VANTAGE 500 Cummins B3.3 (Code 10996)


Stick Welding . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .B4.8

Pipe Welding . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .B4.8
TIGWelding . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .B4.8
Arc Gouging . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .B4.10
Paralleling . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .B4.10

VANTAGE 500
B4.2 OPERATION B4.2

Do not stack anything near the engine.
SAFETY INSTRUCTIONS
WARNING Do not operate with doors open or
guards off.
Do not attempt to use this equipment until you
nance manuals supplied with your machine. They Keep away from moving parts
include important safety precautions: detailed
instructions and parts lists. Only qualified personnel should operate this
equipment.
ELECTRIC SHOCK can kill. ADDITIONAL SAFETY PRECAUTIONS

Do not touch electrically live parts Always operate the welder with the hinged door closed
or electrodes with your skin or wet and the side panels in place, as these provide maxi-
clothing. mum protection from moving parts and insure proper
Insulate yourself from the work and cooling air flow.
ground.
GENERAL DESCRIPTION
FUMES AND GASES CAN BE nating current generator for DC multi-purpose welding
DANGEROUS. and for 120/240 VAC auxiliary standby power. The
welding control system uses state of the art Chopper

Keep your head out of fumes.

Technology.
WELDING SPARKS CAN with NEMA class F insulation material. The stator is
then impregnated with three layers of high quality var-
CAUSE FIRE OR EXPLOSION. nish. After the stator is assembled using tie bars, the
Keep flammable material away. entire assembly is covered with an environmentally
protective coating. These measures insure trouble-free
Do not weld on containers that have operation in the harshest environments.
held combustibles.
ARC RAYS CAN BURN. at full load.
VANTAGE 500
B4.3 OPERATION B4.3


WELDER
load).

FEATURES
OTHER FEATURES
FOR WELDING
Excellent DC multi-purpose welding for stick, MIG, Cummins 4 cylinder/4 cycle engine. Designed for
TIG, cored wire and arc gouging applications. long life, easy maintenance, and excellent fuel
30 to 500 amps output in five slope-controlled ranges economy.


be FLASHING.

slope modes.
VANTAGE 500
B4.4 OPERATION B4.4
All welder and engine controls are located on the case front. Refer to Figure B4.1 and the explanations that follow.
4 5 6 7 8 9 10
11
12
13
15
14 20
21
1
2
19
16
17
18 22

2. START PUSHBUTTON
VANTAGE 500
B4.5 OPERATION B4.5
6. OIL PRESSURE GAUGE Idler Operational exceptions

The gauge displays the engine oil pressure when the When the WELDING TERMINALS switch is in the
engine is running. Remotely Controlled position the idler will operate as
follows:
7. ENGINEPROTECTION a. When the triggering device (Amptrol, Arc Start

Switch, etc.) is pressed the engine will acceler-
The yellow engine protection light remains off with ate and operate at full speed provided a weld-
proper oil pressure and under normal operating tem- ing load is applied within approximately 12 sec-
peratures. If the light turns on, the engine protection onds.
system will stop the engine. Check for proper oil and
coolant levels and add oil and/or coolant if neces- If the triggering device remains pressed but no
sary. Check for loose or disconnected leads at the oil welding load is applied within approximately 12
pressure sender located on the engine. The light will seconds the engine may return to low idle
remain on when the engine has been shut down due speed.
to low oil pressure or over-temperature condition. If the triggering device is released or welding
ceases the engine will return to low idle speed
after approximately 12 seconds.

run position.
9. IDLER SWITCH

12 seconds starts.
d. If the welding or AC power load is not restarted

before the end of the time delay, the idler
e. The engine will automatically return to high idle

load is reapplied.
VANTAGE 500
B4.6 OPERATION B4.6


of the Amptrol.
CV-WIRE

DOWNHILL PIPE

chapter.
VANTAGE 500
B4.7 OPERATION B4.7
20. CIRCUIT BREAKERS NOTE: The engine will go through a 3 minute warm-up
These circuit breakers provide separate overload cycle if cold. If the engine coolant is still warm
current protection for each 120V circuit at the 240V from recent operation, the engine will go imme-
single phase receptacle, each 120V single phase diately to high idle and then to low idle if the idle
receptacle, the 240V three phase receptacle, the switch is in the AUTO position.
120VAC in the 14-Pin connector, the 42VAC in the
14-Pin connector and battery circuit overload protec- COLD WEATHER STARTING
tion.
With a fully charged battery and the proper weight oil,
the engine should start satisfactorily even down to
21. 120VAC SINGLE PHASE RECEPTACLES about 0F(-18C). If the engine must be frequently
These two 120VAC (5-20R) receptacles with GFCI started below 10(-12C), it may be desirable to install
protection provide 120VAC single phase for auxiliary the optional ether start kit (K887-1). Installation and
power. Each receptacle has a 20 amp total rating. operating instructions are included in the kits.
They are designed to protect the user from the haz-
ards of ground faults. When the GFCI has tripped
there will be no voltage available from the receptacle. STOPPING THE ENGINE


section in the installation chapter for further informa- off the voltage supplied to the shutdown solenoid. A
tion about these receptacles. Also refer to the AUX- backup shutdown can be accomplished by shutting
ILIARY POWER OPERATION section later in this off the fuel valve located on the fuel line.
chapter.
22. GROUND STUD TYPICAL FUEL CONSUMPTION

Provides a connection point for connecting the Refer to Table B4.2 for typical fuel consumption of the VAN-
machine case to earth ground. Refer to MACHINE TAGE 500 Engine for various operating scenarios.
Table B4.2
ENGINE OPERATION Cummins B3.3 Engine Fuel Consumption
Cummins B3.3 Running Time for
STARTING THE ENGINE 56HP(42Kw) 25GAL.(94.6L)
1. Open the engine compartment door and check that @1800 RPM (Hours)
the fuel shutoff valve is in the open position (lever to
Low Idle - .45 Gal./hour 55.6
be in line with the hose). no load 1425 RPM (1.7 Lts./hour)
2. Check for proper oil level and coolant level. Close
High Idle - .81 Gal./hour 30.9
engine compartment door. no load 1900 RPM (3.1 Lts./hour)
3. Remove all plugs connected to the AC power recep-
DC CC Weld 1.88 Gal./hour 13.3
tacles. Output 500 (7.1 Lts./hour)
4. Set IDLER switch to AUTO. Amps @ 40 Volts
5. Set the RUN/STOP switch to RUN. Observe that Auxiliary Power 1.23 Gal./hour 20.3
the engine protection and battery charging lights are 12,000 VA (4.7 Lts./hour)
seconds or remain on until the engine is started.
6. Within 30 seconds, press and hold the engine
START button until the engine starts. If the engine
does not start within 30 seconds the RUN/STOP
switch must be returned to the STOP position, then

return to step 5.
7. Release the engine START button when the engine
starts.
ing lights are off. Investigate any indicated problem.
VANTAGE 500
B4.8 OPERATION B4.8
WELDER OPERATION

DUTY CYCLE
Duty Cycle is the the ratio of the uninterrupted on-load
duration to 10 minutes. The total time period of one
complete on-load and no-load cycle is 10 minutes. For The TOUCHSTARTTIG setting of the MODE switch is
example, in the case of a 60% duty cycle, load is for DC TIG (Tungsten Inert Gas) welding. To initiate a
applied continuously for 6 minutes followed by a no- weld, the OUTPUT CONTROL knob is first set to the
load period of 4 minutes. desired current and the tungsten is touched to the work.
During the time the tungsten is touching the work there
STICK WELDING MODE is very little voltage or current and, in general, avoids
The Vantage can be used with a broad range of DC tungsten contamination. Then, the tungsten is gently lift-
stick electrodes. ed off the work in a rocking motion, which establishes
the arc.
as follows: To stop the arc, simply lift the TIG torch away from the
CC-STICK MODE automatically reset to the touch start current level. The
The CC-STICK position of the MODE switch is tungsten may then be retouched to the work piece to
designed for horizontal, vertical-up and overhead weld- restrike the arc. The arc may also be started and
ing with all types of electrodes, especially low hydrogen. stopped with an Amptrol or Arc Start Switch.
The OUTPUT CONTROL knob adjusts the full output The ARCCONTROL is not active in the TIG mode.
The ARC CONTROL knob sets the short circuit (arc- tamination without the use of a Hi-frequency unit. If the
force) current during stick welding. Increasing the num- use of a high frequency generator is desired, the K930-
ber from -10 (Soft) to +10 (Crisp) increases the short 2 TIG Module can be used with the Vantage. The set-
circuit current and prevents sticking of the electrode to tings are for reference.
DOWNHILL PIPE MODE Module operating manuals for complete instructions on

This slope controlled setting is intended for out-of-posi- installation, operation, and maintenance.
tion and down hill pipe welding where the operator When using the TIG Module, the OUTPUT control on
would like to control the current level by changing the the Vantage is used to set the maximum range of the
arc length. The OUTPUT CONTROL knob adjusts the CURRENTCONTROL on the TIG Module or an Amptrol
full output range for pipe welding. if connected to the TIG Module.
VANTAGE 500
B4.9 OPERATION B4.9


Tungsten
0.010 (.25) 2-15 3

3-8 (2-4) 3-8 (2-4) #4, #5, #6
0.020 (.50) 5-20 3
5-10 (3-5) 5-10 (3-5)
0.40 (1.0) 15-80 3
5-10 (3-5) 5-10 (3-5)
1/16 (1.6) 70-150 10-20 5-10 (3-5) 9-13 (4-6) #5, #6
3/32 (2.4) 150-250 15-30 13-17 (6-8) 11-15 (5-7) #6, #7, #8
1/8 (3.2) 250-400 25-40 15-23 (7-11) 11-15 (5-7)
5/32 (4.0) 400-500 40-55 21-25 (10-12) 13-17 (6-8) #8, #10
3/16 (4.8) 500-750 55-80 23-27 (11-13) 18-22 (8-10)
1/4 (6.4) 750-1000 80-125 28-32 (13-15) 23-27 (11-13)
1
2
Pure EWP
1% Thoriated EWTh-1
2% Thoriated EWTh-2
2
applications.
3

4
# 4 = 1/4 in. (6 mm) # 7 = 7/16 in. (11 mm)

# 5 = 5/16 in. (8 mm) # 8 = 1/2 in. (12.5 mm)
# 6 = 3/8 in. (10 mm) #10 = 5/8 in. (16 mm)
5
(TIG). (TIG).
with respect to the #2 and #4 leads does not

provide the proper signal to open and close the
solid state contactor in the Vantage 500.
VANTAGE 500


71M. ARC GOUGING
5/32 90-150 Amps
the desired operating mode. Full power is available
1/4 200-400 Amps


120 VAC operation.

leled.
VANTAGE 500

(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

EXTENSION CORD
RECOMMENDATIONS
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 48010 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)

VANTAGE 500
NOTES
VANTAGE 500
B4.12
Accessories - VANTAGE 500 Cummins B3.3 (Code 10996)


VANTAGE 500

K802N POWER PLUG KIT - Provides four 120V plugs rated at 20 K1858-1 Service Indicator Kit - Provides a GO / NO-GO visual
amps each and one dual voltage, full KVA plug rated at 120/240V, indication of air cleaner element useful service life. Filter service
50 amps. 120V plug may not be compatible with NEMA common based on restriction readings allows the longest life possible from
household receptacles. the filter and best engine protection. (Cannot be used with K887-
1 Ether Start Kit at the same time.)
K802R POWER PLUGKIT - Provides four 120V plugs rated 15
amps each and one dual voltage, full KVA plug rated at 120/240V, T12153-9 Full-KVA Power Plug-One dual voltage
50 amps, 120V plug is compatible with NEMA common household
receptacles. K2356-1 Control Panel Cover Kit-Clear plexiglass
K857 25 ft. (7.5 m) or K857-1 100 ft. (30.4 m) REMOTE CON- to visually monitor machine operation. Lockable to deter
TROL - Portable control provides same dial range as the output vandalism.
control on the welder from a location up to the specified length K2340-1 Lockable Fuel Cap / Flash Arrester Kit-For
from the welder. Has convenient plug for easy connection to the use in locations where flash arrester safety is required.
welder. The VANTAGE 500 CUMMINS is equipped with a 6-pin Lockable fuel cap prevents tampering with fuel. Green
connector for connecting the remote control. cap color provides a visual reminder to use diesel when
refueling.
K704 ACCESSORY SET - Includes 35 feet (10 m) of
shield, Filter plate, work clamp and electrode holder. PLASMACUTTING
Cable is rated at 500 amps, 60% duty cycle.
ACgenerator power from the engine driven welder.
TRAILER NOTE: Other Linclon plasma cutters, both single phase
For in plant and yard towing. Comes standard with a Duo- and 3 phase can be used as long as the rating
Hitch, a 2 Ball and Lunette Eye combination hitch. of the receptacle is not exceeded
K2636-1 TRAILER - Two-wheeled trailer with optional fender WARNING


K2636-1 Trailer
K958-1 Ball Hitch
K2640-1 Cable Rack


muffler.

50P plug,
VANTAGE 500
TIG OPTIONS




.062-3/32 (1.6-2.4mm) wire.
VANTAGE 500
NOTES
VANTAGE 500
C4.4
Maintenance - VANTAGE 500 Cummins B3.3 (Code 10996)

Fuel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .D4.3
Cooling System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .D4.3
Fuel Filters . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .D4.4

Air Filter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .D4.5
Storage . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .D4.7
Cleaning . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .D4.7
Nameplates . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .D4.7
Bearings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .D4.7
Receptacles . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .D4.7
Major Component Locations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .D4.9

VANTAGE 500


troubleshooting work. See the Service Plan section of the Engine Operation
Turn the engine off before working inside the Manual for a summary of maintenance intervals for the
machine. items listed below. Follow either the hourly or the cal-
endar intervals, whichever come first. More frequent
Remove covers or guards only when necessary service may be required, depending on your specific
to perform maintenance and replace them when application and operating conditions.
the maintenance requiring their removal is com-
plete. OIL: Check the oil level after every 8 hours of operation
or daily. BE SURE TO MAINTAIN THE OIL LEVEL.
If covers or guards are missing from the
machine, get replacements from a Lincoln Change the oil the first time between 25 and 50 hours
Distributor. of operation. Then, under normal operating conditions,
change the oil as specified in Service Plan section of

the Engine Operation Manual. If the engine is operated

Read the Safety Precautions in the front of this manu- under heavy load or in high ambient temperatures,
al and in the instruction manual for the diesel engine change the oil more frequently.
used with your machine before working on the Vantage CHANGE THE OIL AND FILTER
500.
clothing, and tools away from the fans, and all other 1 . Route the Oil Drain hose through the access hol in
moving parts when starting, operating, or repairing this the frame. Drain the oil using the ball valve on the
machine. lower right side of the engine. See Figure D4.1.
2. When the oil is drained, close the ball valve.
ROUTINE AND PERIODIC 3. Remove the oil fill cap and pour in approximaterly
7.5 quarts (8 L) of oil. Check the dipstick and add
MAINTENANCE oil until the level reaches the H mark. See

ENGINE MAINTENANCE
DAILY cations for various ambient temperatures. Always
check the level with the dipstick before adding
more oil. Do not overfill.
tion in the tank.
CHANGE THE OIL FILTER: Change the oil filter the
c. Open the water drain valve located on the bottom
first time between 25 and 50 hours of operation. Then,
of the water separator element one or two turns
under normal operating conditions, change the oil filter
after every 250 hours of operation. If the engine is
operated under heavy load or in high ambient tem-
peratures, change the oil filter more frequently. See
Service Plan section of the Engine Operation Manual
d. Check the coolant level. for recommended maintenance intervals. See Table
D4.1 for replacement oil filters.
Change the oil filter as follows:

WEEKLY
1. Drain the oil from the engine and allow the oil filter
once a week. 2. Remove the old filter (spin it off) and discard it.
Wipe off the filter mounting surface and adapter.
See Figure D4.1.
VANTAGE 500

Fuel
Strainer
H
Fuel
L
Shut-Off
Dip
Oil Filter Oil Fill Stick
Fuel Filter/
Water Separator Cap
3. Apply a thin coat of new oil to the rubber gasket on COOLINGSYSTEM

the new oil filter.
4. Spin the new filter onto the mounting adapter finger WARNING
down another 1/2 turn. Do not overtighten the new To avoid scalding, do not loosen or remove the
filter. radiator cap while the engine is hot.
5. Refill the engine with the proper amount and type
of oil as described in the Change the Oil section.
Start the engine and check for leaks around the fil- The VANTAGE 500 Cummins is equipped with a pres-
ter element. Correct any leaks (usually by retight- surized radiator. Keep the radiator cap tight to avoid
ening the filter, but only enough to stop leaks) loss of coolant. Clean and flush the coolant system
before placing the Vantage 500 back in service. periodically to prevent clogging the passages and over-
heating the engine. See the Engine Manual for mainte-
6. If there are no leaks, stop the engine and recheck nance schedule.
up to the MAX mark, but do not overfill. See If the coolant level is low, refill with a mixture of 50%
Figure D4.1. water and 50% ethylene-glycol based antifreeze. See
the Engine Manual for more information.
FUEL: At the end of each day's use, refill the fuel tank
to minimize moisture condensation and dirt contamina- DRIVEBELT

tion in the fuel line. Do not overfill; leave room for the Periodically check the Drive Belt tension and inspect
fuel to expand. the belt for cracks or other damage. See the Engine
Refer to your engine operation manual for recom- Manual for tension adjustment and/or belt replacement.
mended grade of fuel.
VANTAGE 500
FUEL FILTERS
WARNING
WARNING Mechanical overtightening will distort the threads,
Keep naked lights away, do not smoke ! There is also a Fuel Strainer mounted just above the
shut-off valve. See Figure D4.2. It is designed to pre-
Do not spill fuel ! vent larger particle from entering the fuel system. There
is no maintenance possible. If fuel flow seems restrict-
ed, replace the fuel strainer.
The VANTAGE 500 Cummins is equipped with a Fuel
Filter/Water Separator located after the lift pump and
ter is as follows. See Figure D4.2

er.
5. Open the fuel valve and check for leaks.

Fuel
Strainer
H
Fuel
L
Shut-Off
Dip
Fuel Filter/
Water Separator Cap
VANTAGE 500
AIR FILTER 4. Soak the element in a mild detergent solution for 15


dirt.
engine door and mounted to the roof . aged elements. Protect the element from dust and
the Maintenance Instructions located on the door. 8. Reinstall the air filter element per the Maintenance
Compressed Air: 100 psi maximum with nozzles at A restricted filter element may not appear excessively
least one inch away from the ele- dirty.
ment.
NOTE: If the entire cannister is removed or replaced,
Water Hose: 40 psi maximum without nozzle. the spring clamps should be tightened to 15-
20 in/lbs. See Figure D4.3
Spring Clamps
Torque to
15-20 in/lbs
Air Cleaner
(mounted
to roof)
Latch
VANTAGE 500
VANTAGE 500
MAINTENANCE
D4.6
TABLE D4.1
Cummins B3.3 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.
WELDER/GENERATOR
MAINTENANCE
STORAGE: Store the Vantage 500 in clean, dry, pro- BEARINGS: The Vantage 500 is equipped with double-
tected areas. shielded ball bearings having sufficient grease to last
indefinitely under normal service. Where the welder is
CLEANING: Blow out the generator and controls peri-
used constantly or in excessively dirty locations, it may

odically with low pressure air. Do this at least once a be necessary to add one half ounce of grease per year.
week in particularly dirty areas. A pad of grease one inch wide, one inch long, and one
NAMEPLATES: Whenever routine maintenance is per- inch high weighs approximately one half ounce. Over-
formed on this machine - or at least yearly - inspect all greasing is far worse than insufficient greasing.
nameplates and labels for legibility. Replace those When greasing the bearings, keep all dirt out of the
which are no longer clear. Refer to the parts list for the area. Wipe the fittings completely clean and use clean
replacement item number. equipment. More bearing failures are caused by dirt
BRUSH REMOVAL AND REPLACEMENT: It is normal introduced during greasing than from insufficient
for the brushes and slip rings to wear and darken slight- grease.
ly. Inspect the brushes when a generator overhaul is RECEPTACLES: Keep the electrical receptacles in
necessary. good condition. Remove any dirt, oil, or other debris
WARNING CABLE CONNECTIONS: Check the welding cable
Do not attempt to polish slip rings while the engine is


running.
VANTAGE 500


Wear gloves and eye protection and be
careful when working near a battery. CHECKING ELECTROLYTE LEVEL: If battery cells
Follow the instructions printed on the are low, fill them to the neck of the filler hole with dis-
battery. tilled water and recharge. If one cell is low, check for
leaks.
INSTALLING A NEW BATTERY - Disconnect the

negative cable from the old battery first and connect CHARGING THE BATTERY: The Vantage 500 is
to the new battery last. equipped with a wet charged battery. The charging
current is automatically regulated when the battery is
GROUND - Damage to the engine alternator and the the battery is fully charged.
printed circuit board can result from incorrect con-
nection. When you charge, jump, replace, or otherwise connect
battery cables to the battery, be sure the polarity is cor-
CONNECTING A BATTERY CHARGER rect. Improper polarity can damage the charging cir-
- Remove the battery from the welder by cuit. The Vantage 500 charging system is NEGA-
disconnecting the negative cable first, TIVE GROUND. The positive (+) battery terminal has
then the positive cable and battery a red terminal cover.
clamp. When reinstalling, connect the
negative cable last. Keep the area well If you need to charge the battery with an external
ventilated. charger, disconnect the negative cable first, then the
USING A BOOSTER - Connect the positive lead to

After the battery is charged, reconnect the positive bat-

the battery first, then connect the negative lead to the tery cable first and the negative cable last. Failure to
engine foot. do so can result in damage to the internal charger com-
To prevent BATTERY BUCKLING, tighten the nuts ponents.
on the battery clamp until snug. Follow the instructions of the battery charger manufac-

enters the cells.

VANTAGE 500
FIGURE D.5 MAJOR COMPONENT LOCATIONS

1. CONTROL PANEL ASSEMBLY 6A. ENGINE ASSEMBLY

2. CONTROL BOX & OUTPUT ASSEMBLY 7. GENERATOR FRAME
10
6A
5 7
O
FF
ING
WARN
1
4
2
VANTAGE 500
NOTES
VANTAGE 500
D4.10
Installation - VANTAGE 500 Cummins B3.3 (Code 11181, 11416)

Storing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .A5.3
Stacking . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .A5.3
Lifting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .A5.4

Towing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .A5.4
Oil . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .A5.5
Fuel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .A5.5
Fuel Cap . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .A5.5

Spark Arrester . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .A5.6
Remote Control . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .A5.6

VANTAGE 500
TECHNICAL SPECIFICATIONS - VANTAGE 500 CUMMINS (K2406-1)


System
CUMMINS 4 cylinder High Idle 1890 199 cu. in 12VDC battery Fuel
B3.3 53HP (40 kw) Low Idle 1400 (3.3L) & Starter 25 US gal.
Bore x Stroke Oil:
2 US gal.
3.74 x 4.53 (7.6L)
(95mm x 115mm) Coolant
2 US gal. (7.6L)


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

Auxiliary Power (1)
120/240 VAC
PHYSICAL DIMENSIONS
Height (2)
Width Depth Weight
42.0 in 31.5 in. 63.1 in. 1443lbs.

(1066.8 mm) (800.1mm) (1603mm) (655kg)
(Approx)

VANTAGE 500

start installation.

FACES
all sides.
such as output terminals or internal ------------------------------------------------------------------------
wiring.
place.

STACKING
guards off.
VANTAGE 500
LIFTING TOWING
the lift bale.

FALLING EQUIPMENT can cause
injury.
Do not lift this machine using lift bale if it
is equipped with a heavy accessory
such as a trailer or gas cylinder.
1
Lift only with equipment of adequate lift- regarding specific requirements for use on public high-
ing capacity. ways.
Be sure machine is stable when lifting. VEHICLE MOUNTING
WARNING
At higher altitudes, output derating may be necessary. cause unstable vehicle handling and tires or other
meters (6888 ft.). loads.
Contact a Cummins Service Representative for any Distribute, balance and secure loads so vehicle
engine adjustments that may be required. is stable under conditions of use.
------------------------------------------------------------------------

VANTAGE 500


HOT COOLANT can burn skin.

WARNING
Do not remove cap if radiator is hot.
Keep hands away from the engine muf-
fler or HOT engine parts.
Stop engine and allow to cool before The welder is shipped with the engine and radiator
fueling. filled with a 50% mixture of ethylene glycol and water.
Do not smoke when fueling. See the MAINTENANCE section and the engine
Operators Manual for more information on coolant.
Fill fuel tank at a moderate rate and do not overfill.
Wipe up spilled fuel and allow fumes to clear before
starting engine. WARNING

BATTERY CONNECTION
OIL GASES FROM BATTERY can explode.
The Vantage is shipped with the engine crankcase Keep sparks, flame and cigarettes away
filled with high quality SAE 10W-30 oil (API class CD from battery.
hours of running time during the first 35 running hours. To prevent EXPLOSION when:
Refer to the engine Operators Manual for specific oil
recommendations and break-in information. The oil INSTALLING A NEW BATTERY disconnect nega-
change interval is dependent on the quality of the oil tive cable from old battery first and connect to new
and the operating environment. Refer to the engine battery last.
Operators Manual for the proper service and mainte- CONNECTING A BATTERY CHARGER remove
nance intervals. battery from welder by disconnecting negative cable
first, then positive cable and battery clamp. When

FUEL reinstalling, connect negative cable last. Keep well
ventilated.
NOTE: USE DIESEL FUEL ONLY.
USING A BOOSTER connect positive lead to
Fill the fuel tank with clean, fresh diesel fuel. The battery first then connect negative lead to negative
capacity of the fuel tank is approx 95 liters. See engine battery lead at engine foot.
injection pump. NOTE: Before starting the engine, WARNING
open the fuel shutoff valve (pointer to be in line with
hose). BATTERY ACID can burn eyes and skin.
careful when working near battery.
off valve (pointer to be in line with hose). Follow instructions printed on battery.
FUEL CAP
VANTAGE 500

WHEN:

REMOTE CONTROL
MUFFLER OUTLET PIPE

VANTAGE 500

the welder.
cable voltage drop.


500 3/0 AWG 3/0 AWG 4/0 AWG
to rated capacity.
MACHINE GROUNDING

grounded type plug,
VANTAGE 500
engine.

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

SERVICE OVERCURRENT
PROTECTION.
PREMISES
DISCONNECT AND
SERVICE
GROUND OVERCURRENT
50AMP
240 VOLT PROTECTION
DOUBLE
POLE
NEMA TYPE 14-50
GND
50 AMP, 120/240 VOLT

VANTAGE 500
Operation - VANTAGE 500 Cummins B3.3 (Codes 11181 & 11416)


Stick Welding . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .B5.8

Pipe Welding . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .B5.8
TIGWelding . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .B5.8
Arc Gouging . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .B5.10
Paralleling . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .B5.10

VANTAGE 500
B5.2 OPERATION B5.2

Do not stack anything near the engine.
SAFETY INSTRUCTIONS
WARNING Do not operate with doors open or
guards off.
Do not attempt to use this equipment until you have
thoroughly read all operating and maintenance man-
uals supplied with your machine. They include impor- Keep away from moving parts
tant safety precautions: detailed engine starting, oper-
ating, and maintenance instructions and parts lists.
equipment.
Do not touch electrically live parts or ADDITIONAL SAFETY PRECAUTIONS
electrodes with your skin or wet cloth- Always operate the welder with the hinged door closed
ing. and the side panels in place, as these provide maxi-
Insulate yourself from the work and mum protection from moving parts and insure proper
ground. cooling air flow.

GENERAL DESCRIPTION
FUMES AND GASES CAN BE power source. The machine uses a brush type alter-
DANGEROUS. nating current generator for DC multi-purpose welding
and for 120/240 VAC auxiliary standby power. The
Keep your head out of fumes.
welding control system uses state of the art Chopper

Use ventilation or exhaust to remove Technology.
WELDING SPARKS CAN entirely with heavy gauge copper wire and insulated
CAUSE FIRE OR EXPLOSION. then impregnated with three layers of high quality var-
Keep flammable material away. nish. After the stator is assembled using tie bars, the
entire assembly is covered with an environmentally
Do not weld on containers that have protective coating. These measures insure trouble-free
held combustibles. operation in the harshest environments.
ARC RAYS CAN BURN. will provide enough fuel to run for more than 12 hours
at full load.
VANTAGE 500
B5.3 OPERATION B5.3


WELDER
20.000 watts of 240VAC,60Hz. 3 phase power.
The Vantage 500 provides excellent constant current
and for standby emergency power.
age DC welding output for MIG (GMAW) and Drive a 5 HP motor (provided it is started under no
Innershield (FCAW) welding. load).
Two 20 amp 120 VAC duplex receptacles for up to 40
GENERATOR amps of 120 VAC power.
The Vantage 500 provides smooth 120/240 VAC output One 50 amp, 120/240 VAC dual voltage receptacle
for auxiliary power and emergency standby power. for up to 50 amps of 240 VAC, and up to 50 amps per
side to separate branch circuits (not in parallel) of
DESIGN FEATURES AND ADVANTAGES 120 VAC single-phase auxiliary power. Allows easy
FEATURES Weld and AC auxiliary power at the same time (with-

FOR WELDING
OTHER FEATURES
Excellent DC multi-purpose welding for stick, MIG,
TIG, cored wire and arc gouging applications.
Cummins 4 cylinder/4 cycle engine. Designed for
30 to 500 amps output in five slope-controlled ranges long life, easy maintenance, and excellent fuel
for out-of position and pipe electrodes, one constant economy.
current output range for general purpose welding,
one constant voltage range for MIG wire and cored Engine protection system shuts the engine down for
wire welding and one 20-250 amp range for Touch low oil pressure, high oil temperature, or a broken
Start TIG welding. fan/engine alternator belt.
100% duty cycle at 500 amps output and 50% duty Gauges for oil pressure, oil temperature, engine
cycle at 575 amps output. alternator output, and fuel level.
Dual 3-digit output meters are provided (optional on Indicator lights for Engine Protection, and Battery


age and displaying the actual amperage and voltage Engine hour meter standard on all models.
for improved readability in full sunlight. Extended range 25 gallon (94.6 l) fuel tank.
LOOK-BACK FEATURE: After welding has stopped, Automatic idler reduces engine speed when not
both displays will remain on for 7 seconds with the welding or drawing auxiliary power. This feature
last current and voltage value displayed. During this reduces fuel consumption and extends engine life.
time, the left-most decimal point in each display will Compact size fits crosswise in full size pickup truck.
be FLASHING.
Single-side engine service.
Standard remote control capability with 14-pin and
6-pin connectors for easy connection of Lincoln Copper alternator windings and high temperature
remote control accessories. insulation for dependability and long life.
An internal "Solid State" contactor allows for the New paint system on case and base for outstanding
selection of "hot" or "cold" output terminals with a corrosion protection.

slope modes.
VANTAGE 500
B5.4 OPERATION B5.4

All welder and engine controls are located on the case front. Refer to Figure B5.1 and the explanations that follow.
4 5 6 7 8 9 10
3
11
13
20
12
15 21
14 19
23
1
22
2
16
18
17

2. START PUSHBUTTON
VANTAGE 500
B5.5 OPERATION B5.5

The gauge displays the engine oil pressure d. If the welding or AC power load is not restarted
when the engine is running. before the end of the time delay, the idler

peratures. If the light turns on, the engine protection
system will stop the engine. Check for proper oil and Idler Operational exceptions
coolant levels and add oil and/or coolant if neces- When the WELDING TERMINALS switch is in the
sary. Check for loose or disconnected leads at the oil Remotely Controlled position the idler will operate as
pressure sender located on the engine. The light will follows:
remain on when the engine has been shut down due
to low oil pressure or over-temperature condition. a. When the triggering device (Amptrol, Arc Start
Switch, etc.) is pressed the engine will acceler-
NOTE: This engine is equipped with an electronic ate and operate at full speed provided a weld-
governor system. The engine speed ramps
ing load is applied within approximately 12 sec-

up during a warm up period. The complete onds.
cycle takes approximately 3 minutes. This
allows the engine cylinder temperature to If the triggering device remains pressed but no
build up slowly before going to full speed. welding load is applied within approximately 12
This feature is bypassed if the engine is seconds the engine may return to low idle
already warm. The Engine may produce speed.
White Smoke for a few minutes at low tem- If the triggering device is released or welding
peratures. Do not apply a load to the ceases the engine will return to low idle speed
machine during the warm up period. after approximately 12 seconds.


run position.
9. IDLER SWITCH

12 seconds starts.
VANTAGE 500
B5.6 OPERATION B5.6


of the Amptrol.
CV-WIRE

DOWNHILL PIPE

chapter.
VANTAGE 500
B5.7 OPERATION B5.7
20. CIRCUIT BREAKERS 7. Release the engine START button when the engine
These circuit breakers provide separate overload starts.

current protection for each 120V circuit at the 240V 8. Check that the engine protection and battery charg-
single phase receptacle, each 120V single phase ing lights are off. Investigate any indicated problem.
receptacle, the 240V three phase receptacle, the NOTE: The engine will go through a 3 minute warm-up
120VAC in the 14-Pin connector, the 42VAC in the cycle if cold. If the engine coolant is still warm
14-Pin connector and battery circuit overload protec- from recent operation, the engine will go imme-
tion. diately to high idle and then to low idle if the idle
switch is in the AUTO position.
21. 120VAC SINGLE PHASE RECEPTACLES
These two 120VAC (5-20R) receptacles with GFCI COLD WEATHER STARTING
protection provide 120VAC single phase for auxiliary
power. Each receptacle has a 20 amp total rating. With a fully charged battery and the proper weight oil,
They are designed to protect the user from the haz- the engine should start satisfactorily even down to
ards of ground faults. When the GFCI has tripped about 0F(-18C). If the engine must be frequently
there will be no voltage available from the receptacle. started below 10(-12C), it may be desirable to install
the optional ether start kit (K887-1). Installation and

section in the installation chapter for further informa- operating instructions are included in the kits.
tion about these receptacles. Also refer to the AUX-
ILIARY POWER OPERATION section later in this
chapter. STOPPING THE ENGINE
off the voltage supplied to the shutdown solenoid. A
22. GROUND STUD backup shutdown can be accomplished by shutting
Provides a connection point for connecting the off the fuel valve located on the fuel line.
machine grounding information. TYPICAL FUEL CONSUMPTION
Refer to Table B5.1 for typical fuel consumption of the VAN-
23. 240VAC THREE PHASE RECEPTACLE
TAGE 500 Engine for various operating scenarios.
This is a 240VAC (15-50R) receptacle that provides
240VAC three phase auxiliary power. This receptacle Table B5.1
has a 50 amp rating. Cummins B3.3 Engine Fuel Consumption
Cummins B3.3 Running Time for

56HP(42Kw) 25GAL.(94.6L)
ENGINE OPERATION @1800 RPM (Hours)
STARTING THE ENGINE Low Idle - .45 Gal./hour 55.6

no load 1425 RPM (1.7 Lts./hour)
1. Open the engine compartment door and check that
the fuel shutoff valve is in the open position (lever to High Idle - .81 Gal./hour 30.9
no load 1900 RPM (3.1 Lts./hour)
be in line with the hose).
2. Check for proper oil level and coolant level. Close DC CC Weld 1.88 Gal./hour 13.3
Output 500 (7.1 Lts./hour)
engine compartment door. Amps @ 40 Volts
3. Remove all plugs connected to the AC power recep-
tacles. 12,000 VA (4.7 Lts./hour)
5. Set the RUN/STOP switch to RUN. Observe that

seconds or remain on until the engine is started.
6. Within 30 seconds, press and hold the engine
START button until the engine starts. If the engine
does not start within 30 seconds the RUN/STOP
switch must be returned to the STOP position, then
return to step 5.
VANTAGE 500
B5.8 OPERATION B5.8
WELDER OPERATION
DUTY CYCLE TOUCH START TIG MODE

Duty Cycle is the the ratio of the uninterrupted on-load The Vantage can be used in a wide variety of DCTIG
duration to 10 minutes. The total time period of one welding applications.
complete on-load and no-load cycle is 10 minutes. For The TOUCHSTARTTIG setting of the MODE switch is
example, in the case of a 60% duty cycle, load is for DC TIG (Tungsten Inert Gas) welding. To initiate a
applied continuously for 6 minutes followed by a no- weld, the OUTPUT CONTROL knob is first set to the
load period of 4 minutes. desired current and the tungsten is touched to the work.
During the time the tungsten is touching the work there
STICK WELDING MODE
The Vantage can be used with a broad range of DC tungsten contamination. Then, the tungsten is gently lift-
stick electrodes. ed off the work in a rocking motion, which establishes
The MODE switch provides two stick welding settings the arc.
as follows: To stop the arc, simply lift the TIG torch away from the
CC-STICK MODE
automatically reset to the touch start current level. The
The CC-STICK position of the MODE switch is tungsten may then be retouched to the work piece to
designed for horizontal, vertical-up and overhead weld- restrike the arc. The arc may also be started and
ing with all types of electrodes, especially low hydrogen. stopped with an Amptrol or Arc Start Switch.
The ARCCONTROL is not active in the TIG mode.
use of a high frequency generator is desired, the K930-
2 TIG Module can be used with the Vantage. The set-
tings are for reference.
DOWNHILL PIPE MODE

This slope controlled setting is intended for out-of-posi- installation, operation, and maintenance.
would like to control the current level by changing the When using the TIG Module, the OUTPUT control on
arc length. The OUTPUT CONTROL knob adjusts the the Vantage is used to set the maximum range of the
full output range for pipe welding. CURRENTCONTROL on the TIG Module or an Amptrol
VANTAGE 500
B5.9 OPERATION B5.9


Tungsten
0.010 (.25) 2-15 3

3-8 (2-4) 3-8 (2-4) #4, #5, #6
0.020 (.50) 5-20 3
5-10 (3-5) 5-10 (3-5)
0.40 (1.0) 15-80 3
5-10 (3-5) 5-10 (3-5)
1/16 (1.6) 70-150 10-20 5-10 (3-5) 9-13 (4-6) #5, #6
3/32 (2.4) 150-250 15-30 13-17 (6-8) 11-15 (5-7) #6, #7, #8
1/8 (3.2) 250-400 25-40 15-23 (7-11) 11-15 (5-7)
5/32 (4.0) 400-500 40-55 21-25 (10-12) 13-17 (6-8) #8, #10
3/16 (4.8) 500-750 55-80 23-27 (11-13) 18-22 (8-10)
1/4 (6.4) 750-1000 80-125 28-32 (13-15) 23-27 (11-13)
1
2
Pure EWP
1% Thoriated EWTh-1
2% Thoriated EWTh-2
2
applications.
3

4
# 4 = 1/4 in. (6 mm) # 7 = 7/16 in. (11 mm)

# 5 = 5/16 in. (8 mm) # 8 = 1/2 in. (12.5 mm)
# 6 = 3/8 in. (10 mm) #10 = 5/8 in. (16 mm)
5
(TIG). (TIG).
with respect to the #2 and #4 leads does not

provide the proper signal to open and close the
solid state contactor in the Vantage 500.
VANTAGE 500
WIRE FEED (CONSTANT VOLTAGE) PARALLELING

WELDING When paralleling machines in order to combine their

Connect a wire feeder to the Vantage 500 and set outputs, all units must be operated in the CC - STICK
welder controls according to the instructions listed ear- mode only. To achieve this, turn the WELD MODE
lier in this section. See the operators manual for the switch to the CC - STICK position. Operation in other
wire feeder or the Diagrams section of this manual modes may produce erratic outputs and large output
for connecting instructions of various Lincoln wire feed- imbalances between the units.
ers.
AUXILIARY POWER OPERATION
The Vantage 500 in the CV-WIRE position can be used
with a broad range of flux cored wire (Innershield and If a GFCI receptacle is tripped, See the MAINTE-
Outershield) electrodes and solid wires for MIG weld- NANCE section for detailed information on testing and
ing (GMAW). Welding can be finely tuned using the resetting the GFCI receptacle.
ARC CONTROL.
Start the engine and set the IDLER control switch to
Some recommended Innershield electrodes are: NR- the desired operating mode. Full power is available
311, NS-3M, NR-207, NR-203 Ni 1%, NR-204-H. regardless of the welding control settings, if no welding
current is being drawn.

71M.
The auxiliary power of the VANTAGE 500 CUMMINS
Some recommended solid wires for MIG welding are: consists of two 20 Amp-120VAC single phase (5-20R)
.035 (0.9 mm), .045 (1.1 mm) and .052 (1.3 mm), L-50 GFCI duplex receptacles, one 50 Amp-120/240VAC
and L-56, .035 (0.9 mm) and .045 (1.1 mm) Blue Max single phase (14-50R) receptacle and one 50 Amp
MIG 308 LS. 240VAC three phase (15-50R) receptacle. The
For any electrodes, including the above recommenda- 120/240VAC receptacle can be split for single phase
tions, the procedures should be kept within the rating of 120 VAC operation.
Lincoln publications N-675, GS-100 and GS-210. The auxiliary power capacity 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
ARC GOUGING watts is equivalent to volt-amperes at unity power fac-
For optimal performance when arc gouging, set the tor. The maximum permissible current of the 240 VAC
Vantage 500 WELD MODE switch to the CC - STICK output is 50 A. The 240 VAC single phase output can
position, and the ARC CONTROL to 10. be split to provide two separate 120 VAC outputs with
a maximum permissible current of 50 A per output to

Set the OUTPUT knob to adjust output current to the two separate 120 VAC branch circuits. Output voltage
desired level for the gouging electrode being used is within 10% at all loads up to rated capacity.
according to the ratings in the following table:
NOTE: The two 120V GFCI receptacles and the two
TABLE B5.3 120V circuits of the 120/240V receptacle are
connected to different phases and cannot be
Electrode Current Range paralleled.
The auxiliary power receptacles should only be used
1/8 30-60 Amps with three wire grounded type plugs or approved dou-
5/32 90-150 Amps ble insulated tools with two wire plugs.
3/16 150-200 Amps
The current rating of any plug used with the system
1/4 200-400 Amps
must be at least equal to the current capacity of the
5/16 250-400 Amps
associated receptacle.
3/8 350-575 Amps*
* Maximum current setting is limited to the Vantage 500

maximum of 575 Amps.
VANTAGE 500
SIMULTANEOUS WELDING AND AUXILIARY POWER LOADS

It must be noted that the auxiliary power ratings are with no welding load.
Simultaneous welding and power loads are specified in table B5.4. The permissible currents shown assume that
current is being drawn from either the 120 VAC or 240 VAC supply (not both at the same time).
TABLE B.4 VANTAGE 500 CUMMINS

SIMULTANEOUS WELDING AND POWER LOADS
WELD 1 PHASE 3 PHASE BOTH 1 AND 3 PHASE

AMPS WATTS AMPS WATTS AMPS WATTS AMPS
0 12,000 50 20,000 50 ------ 50
100 12,000 50 17,800 43 ------ 50
200 PLUS 12,000 50 OR 14,000 34 OR ------ 50
250 12,000 50 12,000 29 12,000 ------
300 10,000 42 10,000 24 10,000 ------
400 5,600 23 5,600 13 5,600 ------
500 0 0 0 0 0 0
TABLE B5.5 VANTAGE 500 CUMMINS

Extension Cord Length Recommendations
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)
15 120 2400 30 (9) 50 (15) 88 (27) 138 (42) 225 (69)
20 240 4800 60 (18) 100 (30) 175 (53) 275 (84) 450 (137)
20 240 6000 90 (27) 150 (46) 225 (69) 250 (76)
25 240 7200 75 (23) 120 (37) 175 (53) 300 (91)
30 240 9000 100 (30) 150 (46) 250 (76)
38 240 12000 125 (38) 200 (61)
50

VANTAGE 500
NOTES
VANTAGE 500
B5.12
Accessories - VANTAGE 500 Cummins B3.3 (Codes 11181 &11416)


VANTAGE 500

K802N POWER PLUG KIT - Provides four 120V plugs rated at 20 K1858-1 Service Indicator Kit - Provides a GO / NO-GO visual
amps each and one dual voltage, full KVA plug rated at 120/240V, indication of air cleaner element useful service life. Filter service
50 amps. 120V plug may not be compatible with NEMA common based on restriction readings allows the longest life possible from
household receptacles. the filter and best engine protection. (Cannot be used with K887-
1 Ether Start Kit at the same time.)
K802R POWER PLUGKIT - Provides four 120V plugs rated 15
amps each and one dual voltage, full KVA plug rated at 120/240V, T12153-9 Full-KVA Power Plug-One dual voltage
50 amps, 120V plug is compatible with NEMA common household
receptacles. K2356-1 Control Panel Cover Kit-Clear plexiglass
K857 25 ft. (7.5 m) or K857-1 100 ft. (30.4 m) REMOTE CON- to visually monitor machine operation. Lockable to deter
TROL - Portable control provides same dial range as the output vandalism.
control on the welder from a location up to the specified length K2340-1 Lockable Fuel Cap / Flash Arrester Kit-For
from the welder. Has convenient plug for easy connection to the use in locations where flash arrester safety is required.
welder. The VANTAGE 500 CUMMINS is equipped with a 6-pin Lockable fuel cap prevents tampering with fuel. Green
cap color provides a visual reminder to use diesel when
connector for connecting the remote control.

refueling.
K704 ACCESSORY SET - Includes 35 feet (10 m) of
shield, Filter plate, work clamp and electrode holder. PLASMACUTTING
Cable is rated at 500 amps, 60% duty cycle.
ACgenerator power from the engine driven welder.
TRAILER NOTE: Other Linclon plasma cutters, both single phase
For in plant and yard towing. Comes standard with a Duo- and 3 phase can be used as long as the rating
Hitch, a 2 Ball and Lunette Eye combination hitch. of the receptacle is not exceeded
K2636-1 TRAILER - Two-wheeled trailer with optional fender WARNING


K2636-1 Trailer
K958-1 Ball Hitch
------------------------------------------------------------------------
K2640-1 Cable Rack


muffler.

50P plug,
VANTAGE 500
TIG OPTIONS




.062-3/32 (1.6-2.4mm) wire.
VANTAGE 500
NOTES
VANTAGE 500
C5.4
Return to Master TOC D5.1 TABLE OF CONTENTS - MAINTENANCE SECTION D5.1
MAINTENANCE - VANTAGE 500 CUMMINS (CODE 11181 & 11416)
Routine Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .D5.2
Periodic Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .D5.2
Change Oil . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .D5.2
Change Oil Filter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .D5.2
Cooling System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .D5.3

Drive Belt . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .D5.3
Fuel Filters . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .D5.4
Air Filter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .D5.5
Storage . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .D5.7
Cleaning . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .D5.7
Nameplates . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .D5.7
Bearings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .D5.7
Receptacles . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .D5.7

Major Component Locations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .D5.9
VANTAGE 500

WARNING To prevent the engine from accidentally starting, dis-

connect the negative battery cable before servicing the
Have qualified personnel do all maintenance and engine.
troubleshooting work. See the Service Plan section of the Engine Operation
Turn the engine off before working inside the Manual for a summary of maintenance intervals for the
machine. items listed below. Follow either the hourly or the cal-
endar intervals, whichever come first. More frequent
Remove covers or guards only when necessary to service may be required, depending on your specific
perform maintenance and replace them when the application and operating conditions.
maintenance requiring their removal is complete.
OIL: Check the oil level after every 8 hours of operation
If covers or guards are missing from the machine, get or daily. BE SURE TO MAINTAIN THE OIL LEVEL.
replacements from a Lincoln Distributor.
change the oil as specified in Service Plan section of

Read the Safety Precautions in the front of this manu-

Keep all equipment safety guards, covers, and devices CHANGE THE OIL AND FILTER
machine. 1 . Route the Oil Drain hose through the access hol in
lower right side of the engine. See Figure D5.1.
ROUTINE AND PERIODIC 2. When the oil is drained, close the ball valve.
MAINTENANCE 3. Remove the oil fill cap and pour in approximaterly
7.5 quarts (8 L) of oil. Check the dipstick and add
ENGINE MAINTENANCE
oil until the level reaches the H mark. See
DAILY Figure D5.1. Use high quality oil viscosity grade

cations for various ambient temperatures. Always
b. Refill the fuel tank to minimize moisture condensa- check the level with the dipstick before adding
tion in the tank. more oil. Do not overfill.
c. Open the water drain valve located on the bottom 4. Reinstall the oil fill cap and the dipstick.
of the water separator element one or two turns
CHANGE THE OIL FILTER: Change the oil filter the
first time between 25 and 50 hours of operation. Then,
under normal operating conditions, change the oil filter
after every 250 hours of operation. If the engine is
operated under heavy load or in high ambient tem-
d. Check the coolant level. peratures, change the oil filter more frequently. See
Service Plan section of the Engine Operation Manual
for recommended maintenance intervals. See Table
WEEKLY D5.1 for replacement oil filters.
Blow out the machine with low pressure air periodical- Change the oil filter as follows:
1. Drain the oil from the engine and allow the oil filter
once a week.
2. Remove the old filter (spin it off) and discard it.
Wipe off the filter mounting surface and adapter.
See Figure D5.1.
VANTAGE 500

Fuel
Strainer
H
Fuel
L
Shut-Off
Dip
Fuel Filter/
Water Separator Cap
3. Apply a thin coat of new oil to the rubber gasket on COOLINGSYSTEM

the new oil filter.
4. Spin the new filter onto the mounting adapter finger WARNING
down another 1/2 turn. Do not overtighten the new To avoid scalding, do not loosen or remove the
filter. radiator cap while the engine is hot.
5. Refill the engine with the proper amount and type ------------------------------------------------------------------------
of oil as described in the Change the Oil section.
The VANTAGE 500 Cummins is equipped with a pres-
Start the engine and check for leaks around the fil-
surized radiator. Keep the radiator cap tight to avoid
ter element. Correct any leaks (usually by retight-
loss of coolant. Clean and flush the coolant system
ening the filter, but only enough to stop leaks)
periodically to prevent clogging the passages and over-
before placing the Vantage 500 back in service.
heating the engine. See the Engine Manual for mainte-
6. If there are no leaks, stop the engine and recheck nance schedule.
If the coolant level is low, refill with a mixture of 50%
water and 50% ethylene-glycol based antifreeze. See
Figure D5.1.
the Engine Manual for more information.
FUEL: At the end of each day's use, refill the fuel tank
DRIVEBELT
to minimize moisture condensation and dirt contamina-
tion in the fuel line. Do not overfill; leave room for the Periodically check the Drive Belt tension and inspect
fuel to expand. the belt for cracks or other damage. See the Engine
Manual for tension adjustment and/or belt replacement.
Refer to your engine operation manual for recom-
mended grade of fuel.
VANTAGE 500
FUEL FILTERS
WARNING
WARNING Mechanical overtightening will distort the threads,
When working on the fuel system ------------------------------------------------------------------------
Keep naked lights away, do not smoke ! There is also a Fuel Strainer mounted just above the
shut-off valve. See Figure D5.2. It is designed to pre-
Do not spill fuel !
vent larger particle from entering the fuel system. There
is no maintenance possible. If fuel flow seems restrict-
------------------------------------------------------------------------ ed, replace the fuel strainer.
The VANTAGE 500 Cummins is equipped with a Fuel
Filter/Water Separator located after the lift pump and
ter is as follows. See Figure D4.2

er.
5. Open the fuel valve and check for leaks.

Fuel
Strainer
H
Fuel
L
Shut-Off
Dip
Fuel Filter/
Water Separator Cap
VANTAGE 500


dirt.
Excessive air filter restriction will result in reduced 5. Rinse elements from inside out with a gentle stream
engine life. of water (less than 40 psi) to remove all suds and
dirt.
engine door and mounted to the roof . aged elements. Protect the element from dust and


ment.
Spring Clamps
Torque to
15-20 in/lbs
Air Cleaner
(mounted
to roof)
Latch
VANTAGE 500
VANTAGE 500
MAINTENANCE
D5.6
TABLE D5.1
Cummins B3.3 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.
WELDER/GENERATOR
MAINTENANCE
STORAGE: Store the Vantage 500 in clean, dry, pro- BEARINGS: The Vantage 500 is equipped with double-
tected areas. shielded ball bearings having sufficient grease to last
indefinitely under normal service. Where the welder is
CLEANING: Blow out the generator and controls peri-
used constantly or in excessively dirty locations, it may

odically with low pressure air. Do this at least once a be necessary to add one half ounce of grease per year.
week in particularly dirty areas. A pad of grease one inch wide, one inch long, and one
NAMEPLATES: Whenever routine maintenance is per- inch high weighs approximately one half ounce. Over-
formed on this machine - or at least yearly - inspect all greasing is far worse than insufficient greasing.
nameplates and labels for legibility. Replace those When greasing the bearings, keep all dirt out of the
which are no longer clear. Refer to the parts list for the area. Wipe the fittings completely clean and use clean
replacement item number. equipment. More bearing failures are caused by dirt
BRUSH REMOVAL AND REPLACEMENT: It is normal introduced during greasing than from insufficient
for the brushes and slip rings to wear and darken slight- grease.
ly. Inspect the brushes when a generator overhaul is RECEPTACLES: Keep the electrical receptacles in
necessary. good condition. Remove any dirt, oil, or other debris
WARNING CABLE CONNECTIONS: Check the welding cable
Do not attempt to polish slip rings while the engine is

running.
VANTAGE 500


careful when working near a battery. CHECKING ELECTROLYTE LEVEL: If battery cells
Follow the instructions printed on the are low, fill them to the neck of the filler hole with dis-
battery. tilled water and recharge. If one cell is low, check for
leaks.
INSTALLING A NEW BATTERY - Disconnect the

negative cable from the old battery first and connect CHARGING THE BATTERY: The Vantage 500 is
to the new battery last. equipped with a wet charged battery. The charging
current is automatically regulated when the battery is
GROUND - Damage to the engine alternator and the the battery is fully charged.
printed circuit board can result from incorrect con-
nection. When you charge, jump, replace, or otherwise connect
battery cables to the battery, be sure the polarity is cor-
CONNECTING A BATTERY CHARGER rect. Improper polarity can damage the charging cir-
- Remove the battery from the welder by cuit. The Vantage 500 charging system is NEGA-
disconnecting the negative cable first, TIVE GROUND. The positive (+) battery terminal has
then the positive cable and battery a red terminal cover.
clamp. When reinstalling, connect the
negative cable last. Keep the area well If you need to charge the battery with an external
ventilated. charger, disconnect the negative cable first, then the
USING A BOOSTER - Connect the positive lead to
After the battery is charged, reconnect the positive bat-

the battery first, then connect the negative lead to the tery cable first and the negative cable last. Failure to
engine foot. do so can result in damage to the internal charger com-
To prevent BATTERY BUCKLING, tighten the nuts ponents.
on the battery clamp until snug. Follow the instructions of the battery charger manufac-

enters the cells.

VANTAGE 500

1. CONTROL PANEL ASSEMBLY 6A. ENGINE ASSEMBLY

2. CONTROL BOX & OUTPUT ASSEMBLY 7. GENERATOR FRAME
10
6A
5 7
O
FF
ING
WARN
1
4
2
VANTAGE 500
NOTES
VANTAGE 500
D5.10
Return to Master TOC E-1 TABLE OF CONTENTS-THEORY OF OPERATION SECTION E-1
Theory of Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .E-1
General Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .E-2
Battery, Starter, Engine, Rotor, Stator, Pull Coil Board and Peripheral Board Engine Protection . . . . . .E-2
Weld Windings, Rectifier, Power Modules and Feedback . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .E-3
Weld Control Board . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .E-4
Insulated Gate Bipolar Transistor (IGBT)Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .E-5
Pulse Width Modulation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .E-6

Chopper Technology Fundamentals . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .E-7
FIGURE E.1 BLOCK LOGIC DIAGRAM
RECTIFIER
THREE-PHASE
SHUNT +
+ TO WELD
CONTROL
BOARD TO
CONTROL
PCB
_ IGBT
IGBT
CHOKE __
R4-50
80 VDC
2-POWER MODULES
W
D I
N
L D
PWM PWM
E SIGNAL SIGNAL
I
W
G +12VDC
RUN
WELD
CONTROL
VOLTMETER
MECHANICAL BOARD
ENGINE ROTATION
25
(COLD) ROTOR AMMETER
ALTERNATOR
SLIP
RINGS
AUX. POWER
+12 VDC USE SENSING ARC OUTPUT MODE
RUN STARTER CONTROL CONTROL SELECT
SWITCH
42 VAC and 120VAC
RUN/STOP
SWITCH
OIL
PRESSURE
WATER
TEMP.
STATOR to 14 Pin Amphenol
for Wire Feeder
(No 120 VAC on EURO Models)
ON
AUXILIARY WINDINGS
ENGINE
SENSORS 160VDC
START
BUTTON
+12 VDC
120VAC
RUN AC RECEPTACLES
+ Various combinations of
1 and 3 Outputs.
BATTERY See Techincal Specs.
PERIPHERAL
PCB
FLASHING
120VAC
120 VAC
HOLD
PULL RECEPTACLES
COIL (Not on EURO Machnes)
PCB
PULL PULL
IDLER FUEL
SOLENOID SOLENOID
LOW IDLER SIGNAL (TO SUPPLY PULL VOLTS)
HOLD VOLTS FROM CONTROL PCB
* On some codes the Peripheral Board, Pull Coil Board, Idler Solenoid & Fuel Solenoid are
replaced by an Electronic Governor Control module and components. See Wiring Diagram.
VANTAGE 500
E-2 THEORY OF OPERATION E-2
FIGURE E.2 - BATTERY, ENGINE, ROTOR, PULL COIL BOARD

AND PERIPHERAL BOARD (ENGINE PROTECTION

RECTIFIER
THREE-PHASE
SHUNT +
+ TO WELD
CONTROL
BOARD TO
CONTROL
PCB
_ IGBT
IGBT
CHOKE __
R4-50
80 VDC
2-POWER MODULES
W
D I
N
L D
PWM PWM
E SIGNAL SIGNAL
I
W
G +12VDC
RUN
WELD
CONTROL
VOLTMETER
MECHANICAL BOARD
ENGINE ROTATION
25
ALTERNATOR
SLIP
RINGS
AUX. POWER
SWITCH
42 VAC and 120VAC
RUN/STOP
SWITCH
OIL
PRESSURE
WATER
TEMP.
for Wire Feeder
ON
AUXILIARY WINDINGS
ENGINE
160VDC
SENSORS
START
BUTTON
+12 VDC
120VAC
RUN AC RECEPTACLES
1 and 3 Outputs.
PERIPHERAL
PCB
FLASHING
120VAC
120 VAC
HOLD
PULL RECEPTACLES
PCB
PULL PULL
IDLER FUEL
SOLENOID SOLENOID
GENERAL DESCRIPTION
The Vantage 500 is a diesel engine-driven welding This excitation or "flashing" voltage magnetizes the
power source capable of producing 500 amps at rotor lamination. This rotating magnet induces a volt-
40VDC at a 100% duty cycle. The engine is coupled to age in the stationary windings of the main alternator sta-
a brush-type alternating current generator. This AC out- tor. A 120VAC supply from the stator is fed through a
put is rectified and controlled by Chopper Technology rectifier and filter to supply the rotor with a steady DC
to produce DC current for multi-purpose welding appli- voltage. The stator also houses a three-phase weld
cations. The Vantage 500 also provides auxiliary power winding, a 120/240VAC single-phase auxiliary winding,
of various voltage and wattage levels depending on the In some codes, there is also a 3 phase auxiliary and a
Code number. See the appropriate Wiring Diagram or separate 120VAC and/or a 42VAC wire feeder power
Technical Specifications. supply that is routed to the 14 pin MS typel Connector.
The engine alternator supplies charging current for the
BATTERY, ENGINE, ROTOR, battery circuit. The Peripheral board monitors the
STATOR, PULL COIL BOARD AND engine sensors and will shut the engine off in the event
of low oil pressure, engine over temperature, malfunc-
PERIPHERAL BOARD ENGINE tion of the engines alternator system or a low fuel con-
PROTECTION dition. The idler solenoid, if present, is mechanically
connected to the engines throttle linkage. If no welding
The 12VDC battery powers the engine starter motor or auxiliary current is being drawn from the Vantage
and also supplies power to the Pull Coil PC board, 500, the Pull Coil board activates the idler solenoid,
Peripheral PC board and associated circuitry. When the
which then brings the engine to a low idle state. When

engine, which is mechanically coupled to the rotor, is output current is sensed (either weld or auxiliary), the
started and running, the 12 VDC battery voltage is fed Weld Control PC board deactivates the idler solenoid,
momentarily through the pull coil PC board to the rotor and the engine goes to high RPM.
field coil via a brush and slip ring configuration.
NOTE: Unshaded areas of Block Logic
Diagram are the subject of discussion
VANTAGE 500
FIGURE E.3 - WELD WINDINGS, RECTIFIER, POWER MODULES AND FEEDBACK

RECTIFIER
THREE-PHASE
SHUNT +
+ TO WELD
CONTROL
BOARD TO
CONTROL
PCB
_ IGBT
IGBT
CHOKE __
R4-50
80 VDC
2-POWER MODULES
W
D I
N
L D
PWM PWM
E SIGNAL SIGNAL
I
W
G +12VDC
RUN
WELD
CONTROL
VOLTMETER
MECHANICAL BOARD
ALTERNATOR
ENGINE ROTATION
25
SLIP
RINGS
AUX. POWER
SWITCH
42 VAC and 120VAC
RUN/STOP
SWITCH
OIL
PRESSURE
WATER
TEMP.
for Wire Feeder
ON
AUXILIARY WINDINGS
ENGINE
SENSORS 160VDC
START
BUTTON
+12 VDC
120VAC
RUN AC RECEPTACLES
1 and 3 Outputs.
PERIPHERAL
PCB
FLASHING
120VAC
120 VAC
HOLD
PULL RECEPTACLES
PCB
PULL PULL
IDLER FUEL
SOLENOID SOLENOID
WELD WINDINGS, RECTIFIER,

POWER MODULES AND
FEEDBACK
The three-phase stator weld windings are connected to a This chopped" DC output is applied through choke coils and
three-phase rectifier bridge. The resultant DC voltage is a shunt to the welding output terminals. The choke functions
applied to four paralleled capacitors incorporated within each as a current filter, and it helps to balance the outputs of the
of the two power modules. There are two capacitors in each two power modules. Free-wheeling diodes are incorporated
module. These capacitors function as filters and also as in the power modules to provide a current path for the stored
power supplies for the IGBTs. See IGBT Operation in this energy in the choke when the IGBTs are turned off. See the
section. The IGBTs act as high-speed switches operating at Chopper Technology discussion in this section.
20KHZ. These devices are switched on and off by the Weld Output voltage feedback from the output terminals and current
Control PC board through pulse width modulation circuitry. feedback from the shunt is fed to the Weld Control PC board
See Pulse Width Modulation discussion in this section. as a means of controlling the output.

VANTAGE 500
FIGURE E.4 - POWER MODULES AND WELD CONTROL BOARD

RECTIFIER
THREE-PHASE
SHUNT +
+ TO WELD
CONTROL
BOARD TO
CONTROL
PCB
_ IGBT
IGBT
CHOKE __
R4-50
80 VDC
2-POWER MODULES
W
D I
N
L D
PWM PWM
E SIGNAL SIGNAL
I
W
G +12VDC
RUN
WELD
CONTROL
VOLTMETER
MECHANICAL BOARD
ENGINE ROTATION
25
ALTERNATOR
SLIP
RINGS
AUX. POWER
SWITCH
42 VAC and 120VAC
RUN/STOP
SWITCH
OIL
PRESSURE
WATER
TEMP.
for Wire Feeder
ON
AUXILIARY WINDINGS
ENGINE
SENSORS 160VDC
START
BUTTON
+12 VDC
120VAC
RUN AC RECEPTACLES
1 and 3 Outputs.
PERIPHERAL
PCB
FLASHING
120VAC
120 VAC
HOLD
PULL RECEPTACLES
PCB
PULL PULL
IDLER FUEL
SOLENOID SOLENOID
WELD CONTROL BOARD
The 80 VDC derived from the filter capacitors on the The circuitry on the Weld Control PC board determines
Power Modules, supplies various regulated DC volt- how the output should be controlled to optimize welding
ages to operate the Weld Control PC board circuitry. It results, and it sends the correct PWM signals to the
also supplies two regulated DC voltages to operate the IGBT driver circuits. The Weld Control PC board also
IGBT driver circuitry on the two Power Modules. commands the thermal light and the voltmeter and
ammeter (some items may be optional).
The Weld Control PC board monitors the operator con-
trols (arc control, output, and process/range selector).
It compares these commands to the current and voltage
feedback information it receives from the shunt and out-
put terminal circuits.

VANTAGE 500
FIGURE E.5 IGBT OPERATION

POSITIVE
VOLTAGE
APPLIED
GATE GATE
SOURCE SOURCE
n+ n+ n+ n+
p BODY REGION p BODY REGION
n- DRAIN DRIFT REGION n- DRAIN DRIFT REGION
n+ BUFFER LAYER n+ BUFFER LAYER

p+ INJECTING LAYER p+ INJECTING LAYER
DRAIN DRAIN
A. PASSIVE B. ACTIVE
INSULATED GATE BIPOLAR

TRANSISTOR (IGBT) OPERATION
An IGBT is a type of transistor. IGBTs are semicon- Drawing B shows the IGBT in an active mode. When
ductors well suited for high frequency switching and the gate signal, a positive DC voltage relative to the
high current applications. source, is applied to the gate terminal of the IGBT, the
device is capable of conducting current. A voltage sup-

Drawing A in Figure E.5 shows an IGBT in a passive
ply connected to the drain terminal will allow the IGBT
mode. There is no gate signal, zero volts relative to the
to conduct and supply current to circuit components
source, and therefore, no current flow. The drain ter-
coupled to the source. Current will flow through the
minal of the IGBT may be connected to a voltage sup-
conducting IGBT to downstream components as long
ply; but since there is no conduction the circuit will not
as the positive gate signal is present. This is similar to
supply current to components connected to the source.
turning ON a light switch.
The circuit is turned off like a light switch in the OFF
position.
VANTAGE 500
FIGURE E.6 TYPICAL IGBT OUTPUTS

MINIMUM OUTPUT
(Dwell or Off Time)

2 sec 48 sec
50 sec
MAXIMUM OUTPUT
(Dwell or Off Time)

48 sec
50 sec
PULSE WIDTH MODULATION

The term PULSE WIDTH MODULATION is used to The positive portion of the signal represents one IGBT
describe how much time is devoted to conduction in the group conducting for 2 microsecond. The dwell time
cycle. Changing the pulse width is known as MODULA- (off time) is 48 microseconds. Since only 2 microsec-
TION. Pulse Width Modulation (PWM) is the varying of onds of the 50-microsecond time period is devoted to
the pulse width over the allowed range of a cycle to conducting, the output power is minimized.
affect the output of the machine.
MAXIMUM OUTPUT
MINIMUM OUTPUT
By holding the gate signals on for 48 microseconds and
By controlling the duration of the gate signal, the IGBT allowing only 2 microseconds of dwell time (off time)
is turned on and off for different durations during a cycle. during the 50-microsecond cycle, the output is maxi-
The top drawing shows the minimum output signal pos- mized. The darkened area under the top curve can be
sible over a 50-microsecond time period. compared to the area under the bottom curve. The
more darkened area under the curve, the more power is
present.
VANTAGE 500
CHOPPER TECHNOLOGY
FUNDAMENTALS
The new era of welding machines such as the Vantage Hence the name Chopper. The biggest advantage of
500, employ a technology whereby a DC source is chopper technology is the high-speed control of the
turned on and off (chopped up) at high speed, then arc, similar to the inverter machines. A block diagram
smoothed through an inductor to control an arc. for this is as follows:
EXTERNAL DC SOLID STATE INDUCTOR

ARC
SOURCE SWITCH AND DIODE
ARC
CONTROL
In this system, the engine drives a three-phase alter- turning the switch on and off, current in the inductor
nator, which generates power that is rectified and and the arc can be controlled. The following diagram
filtered to produce about 80VDC. The current is applied depicts the current flow in the system when the switch
through a solid state switch (IGBT) to an inductor. By is open and closed.
INDUCTOR
SWITCH
ARC
70-80VDC
DIODE
CURRENT WITH SWITCH OPEN
CURRENT WITH SWITCH CLOSED
When the switch is closed, current is applied through varying the ratio of on time versus off time of the switch
the inductor to the arc. When the switch opens, current (Duty Cycle), the current applied to the arc is con-
stored in the inductor sustains flow in the arc and trolled. This is the basis for Chopper Technology:
through the diode. The repetition rate of switch closure Controlling the switch in such a way as to produce
is 20Khz, which allows ultra-fast control of the arc. By superior welding.
VANTAGE 500
Return to Master TOC Return to Master TOC Return to Master TOC Return to Master TOC E-8
NOTES
VANTAGE 500
E-8
Return to Master TOC F-1 TABLE OF CONTENTS - TROUBLESHOOTING AND REPAIR F-1
Troubleshooting and Repair . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .F-1
How to Use Troubleshooting Guide . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .F-2
PC Board Troubleshooting Procedures . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .F-3
Troubleshooting Guide . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .F-4
Test Procedures . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .F-13
Case Cover Removal and Replacement Procedure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .F-13
Chopper Module Capacitor Discharge Procedure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .F-15
Chopper Module Resistance Test Procedure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .F-17
Idler Solenoid Test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .F-21

Shutdown Solenoid Test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .F-23
Engine Throttle Adjustment Test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .F-25
Rotor Resistance Test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .F-29
Flashing and Rotor Voltage Test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .F-31
Stator Voltage Test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .F-33
Output Rectifier Bridge Test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .F-37
Electronic Governor Test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .F-43
Charging Circuit Test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .F-45
Oscilloscope Waveforms . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .F-47
Normal Open Circuit Voltage Waveform (115VAC Supply) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .F-47

Normal Open Circuit Voltage Waveform (Stick) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .F-48
Normal Weld Voltage Waveform (Stick CC) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .F-49
Normal Weld Voltage Waveform (Wire CV) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .F-50
Normal TIG Mode Voltage Waveform . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .F-51
Normal Open Circuit Voltage Waveform (Wire CVTap) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .F-52
Replacement Procedures . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .F-53
Shutdown Solenoid Removal and Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .F-53
Output Rectifier Bridge Removal and Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .F-57
Stator/Rotor Removal and Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .F-59
Retest After Repair . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .F-68

VANTAGE 500
F-2 TROUBLESHOOTING AND REPAIR F-2
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 Step 3. RECOMMENDED
help you locate and repair possible machine COURSE OF ACTION
malfunctions. Simply follow the three-step The last column labeled Recommended
procedure listed below. Course of Action lists the most likely com-
ponents that may have failed in your
Step 1. LOCATE PROBLEM(SYMPTOM). machine. It also specifies the appropriate
Look under the column labeled PROBLEM test procedure to verify that the subject com-
(SYMPTOMS). This column describes pos- ponent is either good or bad. If there are a
sible symptoms that the machine may exhib- number of possible components, check the
it. Find the listing that best describes the components in the order listed to eliminate
symptom that the machine is exhibiting. one possibility at a time until you locate the
Symptoms are grouped into the following cause of your problem.
categories: output problems, function prob-
lems, wire feeding problems, and welding All of the referenced test procedures
problems. referred to in the Troubleshooting Guide are
described in detail at the end of this chapter.
Step 2. PERFORM EXTERNAL TESTS. Refer to the Troubleshooting and Repair
The second column labeled POSSIBLE Table of Contents to locate each specific
AREAS OF MISADJUSTMENT(S) lists the Test Procedure. All of the specified test
obvious external possibilities that may con- points, components, terminal strips, etc. can
tribute to the machine symptom. Perform be found on the referenced electrical wiring
these tests/checks in the order listed. In diagrams and schematics. Refer to the
general, these tests can be conducted with- Electrical Diagrams Section Table of
out removing the case wrap-around cover. Contents to locate the appropriate diagram.
CAUTION
If for any reason you do not understand the test procedures or are unable to perform the
tests/repairs safely, contact the Lincoln Electric Service Department for technical troubleshooting
assistance before you proceed. Call 1-888-935-3877.
-----------------------------------------------------------------------------------------------------------------------------------
VANTAGE 500
PC BOARD TROUBLESHOOTING PROCEDURES

- Remove the PC board from the static-shielding bag

WARNING and place it directly into the equipment. Dont set the
ELECTRIC SHOCK PC board on or near paper, plastic or cloth which
can kill. could have a static charge. If the PC board cant be
installed immediately, put it back in the static-shield-
Have an electrician install and ing bag.
service this equipment. Turn the
input power OFF at the fuse box - If the PC board uses protective shorting jumpers,
before working on equipment. Do dont remove them until installation is complete.
not touch electrically hot parts.
- If you return a PC board to The Lincoln Electric
Company for credit, it must be in the static-shielding
bag. This will prevent further damage and allow prop-
CAUTION er failure analysis.
Sometimes machine failures appear to be due to PC 4. Test the machine to determine if the failure
board failures. These problems can sometimes be symptom has been corrected by the
traced to poor electrical connections. To avoid prob- replacement PC board.

lems when troubleshooting and replacing PC boards,
please use the following procedure: NOTE: It is desirable to have a spare (known good)
PC board available for PC board troubleshooting.
1. Determine to the best of your technical ability
that the PC board is the most likely component NOTE: Allow the machine to heat up so that all
causing the failure symptom. electrical components can reach their operating
temperature.
2. Check for loose connections at the PC board
to assure that the PC board is properly 5. Remove the replacement PC board and
connected. substitute it with the original PC board to
recreate the original problem.
3. If the problem persists, replace the suspect PC
a. If the original problem does not reappear by
board using standard practices to avoid static
substituting the original board, then the PC
electrical damage and electrical shock. Read
board was not the problem. Continue to look
the warning inside the static resistant bag and
for bad connections in the control wiring
perform the following procedures:
harness, junction blocks, and terminal strips.
PC board can be damaged by static electricity. b. If the original problem is recreated by the
- Remove your bodys static substitution of the original board, then the PC
charge before opening the static- board was the problem. Reinstall the
shielding bag. Wear an anti-static replacement PC board and test the machine.
wrist strap. For safety, use a 1 6. Always indicate that this procedure was
Meg ohm resistive cord connected followed when warranty reports are to be
ATTENTION to a grounded part of the submitted.
Static-Sensitive equipment frame.
NOTE: Following this procedure and writing on the
Devices - If you dont have a wrist strap, warranty report, INSTALLED AND SWITCHED PC
Handle only at touch an un-painted, grounded,
BOARDS TO VERIFY PROBLEM, will help avoid
Static-Safe part of the equipment frame. Keep denial of legitimate PC board warranty claims.
Workstations touching the frame to prevent
static build-up. Be sure not to
touch any electrically live parts at
the same time.
- Tools which come in contact with the PC board must

be either conductive, anti-static or static-dissipative.
VANTAGE 500
Observe Safety Guidelines detailed in the beginning of this manual.

PROBLEMS POSSIBLE AREAS OF RECOMMENDED

(SYMPTOMS) MISADJUSTMENT(S) COURSE OF ACTION
OUTPUT PROBLEMS
Major physical or electrical damage 1. Contact your local Lincoln 1. Contact the Lincoln Electric
is evident. Authorized Field Service Service Department at 1-888-
Facility. 935-3877.
No welding output in neither Stick or 1. Place the Welding Terminals 1. Check for loose or faulty con-
CV modes. The engine operates Switch in the "ALWAYS ON" nections on the heavy current
normally. The auxiliary output is position. If the problem is carrying leads between the out-
normal solved, the fault may be in the put bridge, the power modules,
external control cable (if used), the choke and the output termi-
leads #2 and #4. See the nals.
Wiring Diagram.
2. Check the Welding Terminals

2. With the engine at high idle Switch and associated leads.
(1900RPM), the machine in the See the Wiring Diagram.
Stick mode and the OUTPUT
3. Check gate leads #23, #23A,
CONTROL at maximum, check
#25 and #25A for loose or faulty
for the presence of approxi-
connections. See the Wiring
mately 87VDC (open circuit volt-
Diagram.
age) at the output terminals.
4. Perform the Stator Voltage
3. If the correct OCV is present at
Test.
the welding output terminals
check the welding cables, 5. Perform the Output Rectifier
clamps and electrode holder for Bridge Test.
loose or faulty connections.
6. Perform the Chopper Module
Test.
7. The Weld Control PC Board
may be faulty.
CAUTION
If for any reason you do not understand the test procedures or are unable to perform the tests/repairs safely,
contact the Lincoln Electric Service Department for technical troubleshooting assistance before you proceed.
Call 1-888-935-3877.
VANTAGE 500


OUTPUT PROBLEMS
No welding output in either Stick or 1. Check the brushes for wear and 1. Perform the Rotor Resistance
CV modes. Also no auxiliary power. proper contact to the rotor slip Test.
rings.
The engine operates normally. 2. Perform the Flashing and
2. Make sure the engine is operat- Rotor Voltage Test. If the
ing at the correct high idle speed "flashing" voltage is not pre-
(1900RPM). sent the leads 6,5H,200B,
#201 or #200 may be faulty.
3. Check for loose or faulty con-
See the Wiring Diagram. Also
nections or leads on the auxil-
make sure that lead #5P has
iary power studs in the control
continuity (zero ohms) to
box. See the Wiring Diagram.
ground.
3. Check the field diode bridge

and capacitor. Replace if nec-
essary.
Test.
No auxiliary power at the recepta- 1. The circuit breakers may be 1. Check the wiring between the
cles. The welding output is normal tripped. Reset if necessary. auxiliary receptacles, the con-
and the engine operates normally. nection studs in the control box,
2. Check for loose or faulty con-
and the main stator. See the
nections at the auxiliary recepta-
Wiring Diagram.
cles.
Test.
3. Check GFCI receptacles.
NOTE: The machine must be at
high idle to reset the GFCI
receptacles
CAUTION
Call 1-888-935-3877.
VANTAGE 500


OUTPUT PROBLEMS
The machine has welding output 1. If a remote control unit is con- 1. Check the OUTPUT control
but no control of output. The auxil- nected to the machine, check potentiometer and related
iary power is normal. the remote control and related leads. See the Wiring
cable. Diagram.
2. Check the welding and work 2. Check the shunt and associat-
cables for loose or faulty con- ed feedback leads. See the
nections. Wiring Diagram.
3. Check the voltage feedback
leads for loose or faulty con-
nections. See the Wiring
Diagram.
Test.
5. The Weld Control PC board
may be faulty.
6. Pull coil board may be faulty.
Except tier II Cummins code
11181.
The machine has low welding out- 1. Check the brushes for wear and 1. If the engine high idle speed is
put and low auxiliary output proper contact to the slip rings. low, perform the Throttle Ad -
2. The engine RPM may be low. justment Test.
2. Perform the Rotor Resistance
Test.
3. Perform the Flashing and
Rotor Voltage Test. If the rotor
voltage is low, the field capaci-
tor or field bridge may be faulty.
Test and replace if necessary.
See the Wiring Diagram.
4. If the engine high idle RPM is
OK, then the engine may have
lost horsepower and be in need
of major repair.
5. Tier II Cummins - See EGC test
and adjustment.
CAUTION
Call 1-888-935-3877.
VANTAGE 500


FUNCTION PROBLEMS
The machine control is still active 1. This is normal in TIG mode. 1. Check Plug J11 on the Weld
when the remote control unit is Control PC board for loose or
2. The remote control unit may be
attached. faulty connections.
defective.
3. Check the Amphenol connec-
may be faulty.
tions and associated wiring.
The machine seems locked into the 1. Check the position of the MODE 1. Check the MODE SELECTOR
CC mode of operation (Stick mode). SELECTOR switch. It must be switch and associated leads.
in the correct position for the See the Wiring Diagram.
process being used.
may be faulty.
CAUTION
Call 1-888-935-3877.
VANTAGE 500


FUNCTION PROBLEMS
The wire feeder does not work 1. Check the appropriate circuit 1. Check for the presence of
when connected to the welder breaker (CB1 or CB6). Reset if appropriate source voltage at
amphenol. tripped. the 14-pin amphenol.
2. The wire feeder control cable 2. If the appropriate voltage (42
may be faulty. VAC or 115 VAC) is NOT pre-
sent at the 14-pin amphenol,
3. The wire feeder may be faulty.
check for loose or faulty con-
nections. See the Wiring
Diagram.
Test.
The battery does not stay charged. 1. Check for loose or faulty con- 1. The battery charging circuit
nections at the battery and may be faulty. Perform the
engine charging system. Charging Circuit Test.
2. The battery may be faulty.
Check or replace.
3. Loosen fan belt
CAUTION
Call 1-888-935-3877.
VANTAGE 500


ENGINE PROBLEMS
The engine will not crank when the 1. Check for loose or faulty battery 1. The starter motor or starter
start button is push cable connections. solenoid may be faulty.
2. The battery may be low or faulty. 2. The engine may be hard to
crank due to a mechanical fail-
3. The START button may be
ure in the engine.
faulty.
The engine cranks but will not 1. Check for adequate fuel supply 1. The shutdown solenoid may be
start. (Check fuel filters). faulty. Perform the Shutdown
Solenoid Test.
2. Make sure the fuel shut off valve
is in the open position. 2. The Peripheral PC board may
be faulty. With the RUN/STOP
3. The engine oil temperature may
switch in the "RUN" position,
be too high. Check cooling sys-
the Peripheral PC board should
tem.
normally supply 10VDC to the
4. The battery voltage may be too shutdown solenoid via leads
low. #232 and #262. See the Wiring
Diagram.
5. ON/OFF switch has been on for

more than 30 seconds before 3. The Pull Coil PC board may be
starting (cycle switch OFF then faulty. Pull Coil Board supplies
ON.) 12VDC for 3/4 second after
Run Stop switch is activated.
(Except tier II Cummins code
11181)
4. The engine may be in need of
mechanical repair.
5. Tier II Cummins - check code
11181 governor control linkage
for proper adjustment See EGC
test and adjustment
6. Tier II Cummins electronic gov-
ernor control board may be
faulty.
CAUTION
Call 1-888-935-3877.
VANTAGE 500


ENGINE PROBLEMS
The engine shuts down shortly after 1. Check for adequate fuel supply. 1. Check the RUN/STOP switch
starting. and associated leads for loose
2. If any indicator light is lit when
or faulty connections.
the engine shuts down, that par-
ticular system has faulted. 2. Perform the Shutdown
Check system. Solenoid Test. (except tier II
Cummins
3. Check the battery cables for
loose or faulty connections. 3. The Peripheral PC board may
be faulty. With the RUN/STOP
switch in the "RUN" position,
the Peripheral PC board should
normally supply 10VDC to the

shutdown solenoid via leads
#252 and #262. See the Wiring
Diagram. (except tier II
Cummins code 11181.
4. Tier II Cummins electronic gov-
ernor control board may be
faulty misadjusted governor
linkage see EGC test + adjust-
ments.
The engine will not idle down to low 1. Make sure the IDLER switch is 1. Perform the Idler Solenoid
speed. The machine has normal in the "AUTO" position. Test.
weld output and auxiliary power.
2. Make sure there is NOT an 2. Check leads #227, #232L,
external load on the weld termi- #232M and #226A for loose or
nals nor the auxiliary power faulty connections. See the
receptacles. Wiring Diagram.
3. Check for mechanical restric- 3. The Pull Coil PC board may be
tions in the solenoid linkage. faulty. (Except tier II Cummins).
4. Tier II Cummins electronic con-
trol board may be faulty - mis-
adjusted governor linkage see
EGC test & adjustment.
CAUTION
Call 1-888-935-3877.
VANTAGE 500


ENGINE PROBLEMS
The engine will not go to high idle 1. Make sure the auxiliary power 1. Check the current sensing
when using the auxiliary power. leads are tight. toroid for loose or faulty con-
Auxiliary power is normal when the nections. See the Wiring
2. The automatic idler may not
IDLER switch is in the "HIGH" posi- Diagram.
function if the auxiliary power is
tion. Automatic idle function works
loaded to less than 150 watts. 2. Make sure leads #3 and #6A
properly when the welding termi-
pass through the toroid twice in
nals are loaded
opposite directions.
3. The current sensing toroid may
be faulty.
4. Pull coil board may be faulty

may be faulty.
6. Tier II Cummins governor con-
trol board may be faulty- mis-
adjusted governor linkage see
EGC test & adjustment
The engine will not go to high idle 1. Make sure the welding cables 1. The Weld Control PC board
when attempting to weld or when and auxiliary power lead con- may be faulty.
the auxiliary power is loaded. nections are tight.

Welding output and auxiliary power
outputs are normal when IDLER 3. Tier II Cummins Governor
switch is in the " HIGH" position Control may be faulty.
CAUTION
Call 1-888-935-3877.
VANTAGE 500


ENGINE PROBLEMS
The machine goes to low idle but 1. Make sure there is NOT an 1. The idler solenoid linkage may
does not stay at low idle. external load (auxiliary or weld) be misadjusted or damaged.
connected to the Vantage 500.
2. The idler solenoid lead connec-
tions may be loose or dam-
aged. See the Wiring Diagram.
3. Perform the Idler Solenoid
Test.
except tier II Cummins code
11181.

may be faulty.
6. Tier II Cummins governor con-
trol board may be faulty see
EGC test & adjustment.
WELDING PROBLEMS
The welding arc is "cold." The 1. Check for loose or faulty con- 1. Check for the correct OCV at
engine runs normally. The auxiliary nections at the weld output ter- the welding output terminals. If
power is normal. minals and welding cable con- the correct voltage is present
nections. at the output terminals, check
for loose connection on the

2. The welding cables may be too

heavy current carrying leads
long or coiled, causing an
inside the Vantage 500. See
excessive voltage drop.
the Wiring Diagram.
3. Make sure the electrode (wire,
2. If the OCV is low at the welder
gas, voltage, current etc.) is cor-
output terminals, perform the
rect for the process being used.
Engine Throttle Adjustment
Test.
3. Perform the Output Rectifier
Bridge Test.
Test.
Test.

may be faulty.
CAUTION
Call 1-888-935-3877.
VANTAGE 500
CASE COVER REMOVAL AND REPLACEMENT PROCEDURE

WARNING
Service and repair should be performed by only Lincoln Electric factory trained personnel.
Unauthorized repairs performed on this equipment may result in danger to the technician
or 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.
test/repairs safely, contact the Lincoln Electric Service Department for electrical trou-
bleshooting assistance before you proceed. Call 1-888-935-3877.
TEST DESCRIPTION
This procedure will aid the technician in the removal and replacement of the case sheet
metal covers.
MATERIALS NEEDED
3/8" wrench
7/16" wrench
1/2" wrench
3/4" wrench
NOTE: Because the Vantage 500 uses several different models of both Cummins and
Deutz engines, the removal and replacement procedures may vary from the
descriptions in this manual. Refer to the engine manufacturers manuals for more
specific information.
VANTAGE 500
CASE COVER REMOVAL AND REPLACEMENT PROCEDURE (continued)

FIGURE F.1 DOOR REMOVAL

PROCEDURE
1. Turn the engine off. 6. With the 9/16" wrench, remove the exhaust pipe
rain cap.
2. Using the 3/8" wrench, remove the battery cover.
Slide the battery out and disconnect the negative 7. Remove the fuel tank cap, gasket, and the lift bail
battery cable. cover seal.
3. Unlatch and open the engine service access door. 8. With the help of an assistant, carefully remove the
roof. The door assembly remains attached to the
4. Support the door assembly. Using the 3/8" wrench, roof. Replace the fuel cap.
remove the #10-24 round head screw, lock washer,
flat washer, and nut from the top corner of the door 9. With 3/8" wrench, remove the left rear panel and
hinge assembly where it attaches to the roof. the right and left front panels.
Remove the support rod.
5. Using the 3/8" wrench, remove the screws from the
top front of the roof assembly and the screws from
the sides of the control box. Carefully lower the

front control panel.
VANTAGE 500
CHOPPER MODULE CAPACITOR DISCHARGE PROCEDURE

WARNING
manual.
TEST DESCRIPTION
This procedure will insure that the large capacitors in the chopper modules have been dis-
charged. This procedure should be performed whenever work is to be attempted on or
near the chopper modules.
MATERIALS NEEDED
Miscellaneous Hand Tools
Volt/Ohmmeter
Resistor (25-1000 ohms and 25 watts minimum)
Jumper leads
Wiring diagram
VANTAGE 500
CHOPPER MODULE CAPACITOR DISCHARGE PROCEDURE (CONTINUED)

FIGURE F.2 CHOPPER MODULE CAPACITOR TERMINAL DISCHARGE
B8 B7
B1 B4
B2
B5
INSULATED
GLOVE B3 B6
POWER
RESISTOR
PROCEDURE
1. Turn engine off. 4. Discharge Capacitors.
2. Perform the Case Cover Removal Procedure. If the Lincoln recommended resistor, or an equivalent
resistor is used, the capacitors can be discharged by
Note: It is necessary to remove the fuel cap in order to holding the resistor with insulated pliers and using the
take the case cover off the machine. Be sure resistor terminals to bridge chopper module terminals
the fuel cap is ON when discharging the chop- B1 to B2, and B4 to B5. DO NOT TOUCH THE TER-
per module capacitors. MINALS OR METAL PARTS OF THE PLIERS WITH
3. Locate the chopper module on the inner machine YOUR BARE HANDS. Hold the resistor in place for
baffle. See Figure F.2 and the Wiring Diagram. about 10 seconds.
If another type of resistor is used, jumper leads may
need to be attached to the resistor. The leads can then
be used to connect terminals B1 to B2, and B4 to B5.
5. Using the volt/ohmmeter, check the voltage across
B1 and B2 then B4 and B5. It should be zero volts

in both cases. See Figure F.2.
VANTAGE 500
CHOPPER MODULE RESISTANCE TEST PROCEDURE

WARNING
manual.
TEST DESCRIPTION
This test will help determine if the chopper module is shorted. This test can only detect
some problems in the Power section of the module. Problems in some other PC board
components may not be detected.
MATERIALS NEEDED
Miscellaneous hand tools
Digital Ohmmeter
Wiring Diagram
VANTAGE 500
CHOPPER MODULE RESISTANCE TEST (CONTINUED)

FIGURE F.3 LEADS & TERMINALS

88
87 PWM Input Present
W7 NOTE: Early design P C

W8 LEAD Boards did not have LEDs.
LEAD
Board orientation may be dif-
ferent than what is shown.
B1 LXXXXX-X
B4
LED1
POS POS
LEAD LEAD
B2 B5
LED2 LED3
NEG NEG
LEAD LEAD
B3 B6
Chopper Operating Power at Recitifier Bridge

PROCEDURE
1. Turn the engine off. 6. Check resistance with analog ohmmeter per the
Chopper Test Table F.1.
2. Perform the Case Cover Removal procedure.
Note: Make sure the bolts do not fall back against the
3. Perform the Capacitor Discharge procedure. heat sink.
4. Use a 7/16 wrench, label and disconnect the six 7. Reconnect all leads.
heavy black flex leads W8, positive, negative W7,
positive , negative from the Power Module PC Note: The chopper module screw connections should
Board. be tightened to 50-60 inch-pounds.
5. Using the 7/16 wrench, remove the negative
jumper strap attaching the power capacitors to the 8. Perform the Case Cover Replacement
Power Module PC Board. Procedure.
VANTAGE 500
CHOPPER MODULE RESISTANCE TEST (CONTINUED)

TABLE F.1 CHOPPER TEST TABLE
CHOPPER TEST
OHMMETER
OHMMETER
CHOPPER TERMINAL CONNECTIONS
(+) Lead (-) Lead READING
B5 B6 6k to 9k
B6 B5 6k to 9k
B4 B5 200k or higher
B2 B3 6k to 9k
B3 B2 6k to 9k
VANTAGE 500
Return to Master TOC Return to Master TOC Return to Master TOC Return to Master TOC F-20
NOTES
VANTAGE 500
F-20
IDLER SOLENOID TEST PROCEDURE

(CUMMINS ENGINE ONLY)
WARNING
manual.
TEST DESCRIPTION
This test will determine if the idler solenoid is capable of functioning when it is energized
with 12VDC.
MATERIALS NEEDED
External 12VDC supply ( 30 amps required)
Wiring Diagram
Volt/Ohmmeter
VANTAGE 500
IDLER SOLENOID TEST PROCEDURE (CONTINUED)

FIGURE F.4 IDLER SOLENOID LEAD TERMINALS
Cummins Engine
Shutdown Solenoid
Idler Solenoid
COMMON (BLACK)
PULL (WHITE)
HOLD (RED)
COMMON (BLACK) [232]
3 4 PULL (WHITE) [227]
1 2 HOLD (RED) [226]
TEST PROCEDURE
1. Turn the engine off.
CAUTION
2. Unlatch, lift, and secure the right side engine ser-
vice access door. When the solenoid activates, remove the voltage sup-
ply immediately. Leaving the external supply con-
3. Locate and separate J55/P55 connector that nected to terminals #232M and #265 for longer than
attaches the idler solenoid leads to the wiring har- three seconds will damage the coil.
ness leads (#226, #227 and #232L). See Figure
F.4 and the Wiring Diagram. Remove and replace The solenoid should deactivate when the 12VDC is
necessary wire wraps. removed.
4. Check the pull-in coil resistance (White to Black 6. If the solenoid does not operate properly, check for a
#227 to #232L). The normal resistance is approx- mechanical restriction in the linkage.
imately 0.2 ohms. 7. Using the external 12VDC supply, apply 12VDC to the
Check the hold-in coil resistance (Red to Black hold idler solenoid terminals for the hold-in coil (#226
#226A to #232S). Normal coil resistance is to #232 +). Push in the solenoid plunger. With 12
approximately 11 ohms. VDC applied to the hold-in coil, the plunger should
stay in until the 12 VDC is removed.
If either coil resistance is not correct, the solenoid
may be faulty. Replace. 8. If the linkage is intact and the solenoid does not oper-
ate correctly when the 12VDC is applied, the solenoid
5. Using the external 12VDC supply, apply 12VDC to may be faulty. Replace.
the pull coil terminals (#227 to #232L +). The sole-
noid should activate. 9. Replace harness connectors. See Figure F.4 and
the Wiring Diagram. Replace any previously
removed wire wraps.
10. Close and secure the right side engine service access
door.
VANTAGE 500
SHUTDOWN SOLENOID TEST PROCEDURE

WARNING
manual.
TEST DESCRIPTION
This test will determine if the shutdown solenoid is capable of functioning when it is ener-
gized with 12VDC.
MATERIALS NEEDED
External 12VDC supply ( 30 amps required)
Wiring Diagram
Volt/Ohmmeter
VANTAGE 500
SHUTDOWN SOLENOID TEST PROCEDURE

FIGURE F.5 SHUTDOWN SOLENOID
Common (Black) [232]

Cummins Engine Pull (White) [265]
Hold (Red) [262]
Shutdown Solenoid
Idler Solenoid
Deutz Engine
TEST PROCEDURE
1. Turn the engine off. CAUTION
2. Unlatch, lift, and secure the right side engine ser-
vice access door. When the solenoid activates, remove the voltage sup-
ply immediately. Leaving the external supply con-
3. Locate and separate J54 / P54 connector that
nected to terminals #232M and #265 for longer than
attaches the shutdown solenoid leads to the wiring
three seconds will damage the coil.
harness leads ( #262, #232 and #265). See Figure
F.5 and the Wiring Diagram. Remove any neces- The solenoid should deactivate when the 12VDC is
sary wire wraps. removed.

4. Check the pull-in coil resistance (Black to White 6. If the solenoid does not operate properly, check for a
#232 to #265). The normal resistance is approxi- mechanical restriction in the linkage.
mately 0.2 ohms.
7. Using the external 12VDC supply, apply 12VDC to the
Check the hold-in coil resistance (Black to Red hold coil solenoid terminals for the hold-in coil (#262-
#232 to #262). Normal coil resistance is approxi- to #232+). Push in the solenoid plunger. With 12
mately 11 ohms. VDC applied to the hold-in coil, the plunger should
stay in until the 12 VDC is removed.
If either coil resistance is not correct, the solenoid
may be faulty. Replace. 8. If the linkage is intact and the solenoid does not oper-
ate correctly when the 12VDC is applied, the solenoid
5. Using the external 12VDC supply, apply 12VDC to
may be faulty. Replace.
the pull coil shutdown solenoid terminals (#232M+
to #265-). The solenoid should activate. 9. Replace harness connector. See Figure F.5 and the
Wiring Diagram. Replace any previously removed
wire wraps.
10. Close and secure the right side engine service access
door.
VANTAGE 500
ENGINE THROTTLE ADJUSTMENT TEST PROCEDURE

(CUMMINS ENGINE ONLY)
WARNING
manual.
TEST DESCRIPTION
If the machine output is low or high, this test will determine whether the engine is operat-
ing at the correct speed (RPM) during both HIGH and LOW idle conditions. Directions for
adjusting the throttle to the correct RPM are given.
MATERIALS NEEDED
Slot head screw driver
10mm Wrench
White or red marking pencil
Strobe-tach, frequency counter, or oscilloscope
VANTAGE 500
ENGINE THROTTLE ADJUSTMENT TEST PROCEDURE (CONTINUED)

FIGURE F.6 STROBE MARK LOCATION

O
FF
MARK BLOWER
PADDLE HERE
PROCEDURE
Strobe-tach Method
1. Conduct this procedure with the engine OFF. 6. If either of the readings is incorrect, adjust the
throttle as follows:
2. Unlatch, lift and secure the right side engine ser-
vice access door. Perform the Case Cover Adjust HIGH IDLE: Use the 10mm wrench to
Removal and Replacement Procedure. (For loosen the locking nut. See Figure F.7 for location
Strobe-Tach method only.) of the adjusting screw and locking nut. Turn the
threaded screw counter-clockwise to increase the
3. With a white or red marking pencil, place a mark on HIGH IDLE speed. Adjust the speed until the tach
one of the blower paddles. See Figure F.6 for loca- reads between 1890 and 1910 RPM. Retighten
tion. the locking nut.
4. Connect the strobe-tach according to the manufac- Adjust LOW IDLE: First make sure there is no load
turer's instructions. on the machine. Set the IDLE switch to AUTO and
5. Start the engine and direct the strobe-tach light on wait for the engine to change to low idle speed.
the blower. Synchronize it to the rotating mark. Use the 10mm wrench to loosen the solenoid lever
arm locking nut. See Figure F.7. Adjust the collar,

With the machine at HIGH IDLE the tach should to change the amount of throw in the lever arm,
read between 1890 and 1910 RPM. until the tach reads between 1450 and 1500 RPM.
With the machine at LOW IDLE the tach should Retighten the locking nut.
read between 1450 and 1500 RPM. (Cummins
1425).
VANTAGE 500

FIGURE F.7 HIGH AND LOW IDLE ADJUSTMENTS - CUMMINS ENGINE ONLY
Shutdown Solenoid
Idler Solenoid
Adjusting Collar
Locking Nut
Adjusting Screw
Locking Nut
LEFT SIDE
PROCEDURE
Frequency Counter Method

1. Plug the frequency counter into one of the 115 VAC Adjust LOW IDLE: First make sure there is no load
auxiliary receptacles. on the machine. Set the IDLE switch to AUTO and
wait for the engine to change to low idle speed.
2. Start the engine and check the frequency counter.
Use the 10mm wrench to loosen the solenoid lever
At HIGH IDLE (1900 RPM), the counter should
arm locking nut. See Figure F.7. Adjust the collar,
read 63 Hz. At LOW IDLE (1475 RPM), the
to change the amount of throw in the lever arm,
counter should read 49 Hz. Note that these are
until the frequency reads 49 Hz. Retighten the
median measurements; hertz readings may vary
locking nut.
slightly above or below.
3. If either of the readings is incorrect, adjust the
throttle as follows:
Adjust HIGH IDLE: Use the 10mm wrench to
loosen the locking nut. See Figure F.7 for location
of the adjusting screw and locking nut. Turn the

HIGH IDLE speed. Adjust the speed until the fre-
quency reads 63 Hz. Retighten the locking nut.
VANTAGE 500

PROCEDURE
Adjust HIGH IDLE: Use the 10mm wrench to
Oscilloscope Method loosen the locking nut. See Figure F.7 for location
of the adjusting screw and locking nut. Turn the
1. Connect the oscilloscope to the 115 VAC recepta-
cle, according to the manufacturers instructions.
HIGH IDLE speed. Adjust the speed until the peri-
At HIGH IDLE (1900 RPM), the waveform should
od is 15.8 milliseconds. Retighten the locking nut.
exhibit a period of 15.8 milliseconds. At LOW IDLE
(1475 RPM), the waveform should exhibit a period Adjust LOW IDLE: First make sure there is no load
of 20.3 milliseconds. Refer to the NORMAL OPEN on the machine. Set the IDLE switch to AUTO and
CIRCUIT VOLTAGE WAVEFORM (115 VAC SUP- wait for the engine to change to low idle speed.
PLY) HIGH IDLE - NO LOAD below. Use the 10mm wrench to loosen the solenoid lever
arm locking nut. See Figure F.7 Adjust the collar,
2. If either of these waveform periods is incorrect,
to change the amount of throw in the lever arm,
adjust the throttle as follows:

until the period is 20.3 milliseconds. Retighten the

locking nut.
NORMAL OPEN CIRCUIT VOLTAGE WAVEFORM (115VAC SUPPLY)

HIGH IDLE NO LOAD
15.8 ms
0 volts
50V 5ms
This is the typical auxiliary output voltage generated from a properly operating
machine.
Note that each vertical division represents 50 volts and that each horizontal divi-
sion represents 5 milliseconds in time.
Note: Scope probes are connected at machine 115VAC receptacle.
VANTAGE 500
ROTOR RESISTANCE TEST

WARNING
manual.
TEST DESCRIPTION
This test will determine if there is a shorted winding in the rotor or if the rotor is grounded.
MATERIALS NEEDED
Ohmmeter
3/8" Wrench or socket wrench
VANTAGE 500
ROTOR RESISTANCE TEST (CONTINUED)

FIGURE F.8 ROTOR BRUSH LEADS
SLIP
RINGS
BRUSH
HOLDER
ASSEMBLY
ACCESS PANEL
PROCEDURE
1. Conduct this test with the engine off. 7. If the test does not meet the resistance specifica-
tions, then the rotor may be faulty. Replace.
2. Using the 3/8" wrench, remove the right front case
side. 8. Position the brush holder assembly and attach it
with two screws previously removed. Make certain
3. Using the 3/8" wrench, remove the brush holder
the brushes are centered and seated properly on
access panel. See Figure F.10.
the slip rings. Adjust if necessary.
9. Replace the brush holder access panel.
assembly. See Figure F.10.
10. Replace the right front case cover.
5. Using the ohmmeter, check the rotor winding resis-
tance across the slip rings. Normal resistance is
approximately 27.0 ohms.
6. Measure the resistance to ground. Place one
meter probe on either of the slip rings. Place the

other probe on any good unpainted ground. The
resistance should be very high, at least 500,000
ohms.
VANTAGE 500
FLASHING AND ROTOR VOLTAGE TEST

WARNING
manual.
TEST DESCRIPTION
This test will determine if the correct DC voltage is being applied to the rotor at the maxi-
mum engine speed (1900 RPM). This information will aid the technician in determining if
the generator field is operating properly.
MATERIALS NEEDED
Volt/Ohmmeter
3/8" Wrench
Wiring Diagram
VANTAGE 500
FLASHING AND ROTOR VOLTAGE TEST(CONTINUED)

FIGURE F.9 ROTOR BRUSH LOCATION
#200A
#200B
#201
PROCEDURE
1. Using the 3/8" wrench, remove the sheet metal 7. If the voltage reading is low or not present, the gen-
screws from the right front case side. erator field is not functioning properly. Perform the
Rotor Resistance Test. Also check the field diode
2. Carefully remove the right case side. rectifier bridge, filter capacitor, and associated
3. Set the volt/ohmmeter to the DC volts position. leads and connections. See the Wiring Diagram.
4. Locate leads #200A and #201A at the rotor brush- NOTE: The normal flashing voltage is approximately
es. 9VDC. This is battery voltage, which is
processed through the Pull Coil PC Board.
NOTE: Cut any cable ties necessary to perform the This voltage must be present during start-up to
test. "flash" the rotor field.
5. Connect the positive meter probe to lead #200B 8. If the rotor voltage readings are normal, the field
and the negative meter probe to lead #201. circuit is functioning properly. Replace any cable
6. Start the engine and run it at high idle speed (1900 ties cut during the test. Install the right case side.
RPM). Check the voltage reading on the meter. It

should read approximately 120 VDC.
VANTAGE 500
STATOR VOLTAGE TEST

WARNING
manual.
TEST DESCRIPTION
This test will determine if the correct AC voltages are being generated from the stator
windings.
MATERIALS NEEDED
Volt/Ohmmeter
3/8" wrench
3/4" Wrench
VANTAGE 500
STATOR VOLTAGE TEST (CONTINUED)

FIGURE F.10 FRONT CONTROL PANEL REMOVAL

PROCEDURE AUXILIARY POWER AND WELD WIND-

1. Turn the engine off. INGS TEST
2. Using the 3/8" wrench, remove the screws holding Start the engine and run at high idle (1900 RPM). Do
the front control panel to the case top and sides. not load welding or auxiliary power. See Figure F11
and the appropriate Wiring Diagram for test points.
3. Carefully lower the front control panel.
Single Phase Auxiliary Machines
4. Using the 3/8" wrench, remove the front left and
right side panels. 1. Check for 115-132VAC from:
5. Using the 3/4" wrench, remove the internal leads Lead 6B on CB4 to lead 5B at Receptacle J12.
from the output terminals. Insulate the leads. Leads 3A on CB3 to Lead 5B at ReceptacleJ12.
6. Using the 3/8" wrench, remove the screws holding 2. Check for 230 to 264VAC from lead 3A on CB3 to
the lower front panel (output panel) to the case lead 6B on CB4.
front assembly. Then remove the front two screws
Three Phase Auxiliary Machines
holding the top of the panel. These are accessed in

the control box, on the bottom at each side of the 1. Check for 230 to 246VAC from lead 3 to 6 on CB1.
box. See Figure F.10. Carefully move the lower
front panel to the right side. Note the green ground 2. Check for 230 to 246VAC from lead 3 to 4 on CB1.
lead will still be attached. 3. Check for 230 to 246VAC from lead 4 to 6 on CB1.
4. Check for 115 to 132C from leads 3, 4, & 6 at CB1
to lead 5B at Receptacle J12.
VANTAGE 500

FIGURE F.11 AUXILIARY LEAD TEST LOCATIONS ON BACKOFCONTROLPANEL
3A
Back of Control Panel
Typical 1 Auxiliary Machine
236A
238B
CB3 CB5 CB1

32A
32
CB4 CB6 CB2
42B
12 6B
GND-C
11 42A 9
8
J10 J11 J12
GND-D GND-E
5E 5B
5C
Back of Control Panel

STATOR LEADS
236A Typical 3 Auxiliary Machine
3 4 6
CB1 238B
32A
CB5
CB2
42B 32
CB6 CB3
42A
3D
GND-L GND-C
3A
4A 3C
6B 6D
6E
J13 J10 J12 J11

5B GND-E
3B GND-D 5E
5C
6C
VANTAGE 500

FIGURE F.12 OUTPUT RECTIFIER DIODE BRIDGE

WELD WINDING
LEAD CONNECTIONS
W1 W6
W3 W2
W5 W4
1. Locate the weld winding leads connected to the 5. If the tests in Steps 6 and 7 are OK and the stator
three-phase output rectifier diode bridge. See voltages are low or missing, the stator may be
Figure F.12. faulty.
2. Check for approximately 68VAC from: 6. Replace the lower front panel and output leads.
W1/W6 to W2/W3. 7. Replace the upper control panel and secure.
W1/W6 to W4/W5 8. Replace the front left and right case sides.
W2/W3 to W4/W5
3. If any of these voltages are low or missing perform
the Flashing and Rotor Voltage Test and also the
Rotor Resistance Test.
4. Also check leads #6F and #5P for loose or faulty
connections to the field bridge. See the Wiring
Diagram.
VANTAGE 500
OUTPUT RECTIFIER BRIDGE TEST

WARNING
manual.
TEST DESCRIPTION
This test will determine if the rectifier is grounded, or if there are any failed diode groups.
NOTE: This test will not be able to detect individual open diodes within a group.
MATERIALS NEEDED
Miscellaneous hand tools
Analog Ohmmeter or diode tester (For testing diodes)
Ohm meter (any type for ground test)
VANTAGE 500
OUTPUT RECTIFIER BRIDGE TEST(CONTINUED)


PROCEDURE
1. Turn the engine off. Mark leads W1, W2, and W3 so they can be prop-
erly reconnected after the test is complete.
2. Perform Case Cover Removal Procedure. Remove these leads and position them so they do
3. Perform Chopper Module Capacitor Discharge not come in contact with any part of the rectifier.
Procedure. See the wiring diagram.
4. Using the 3/8" wrench, remove the three screws 7. Electrically isolate the DC output terminals of
holding the lower front panel (output panel) to the the rectifier:
case front assembly. Then remove the front two Mark the leads connected to the positive and neg-
screws holding the top of the panel. These are ative terminals of the output bridge rectifier to
accessed in the control box, on the bottom at each assure that they can be reconnected properly. See
side of the box. Using the 7/16" wrench, discon- Figure F.14.
nect the green ground lead. See Figure F.13.
Carefully move the lower front panel to the right 8. Remove leads W4, W5, and W10 from the positive
terminal of the rectifier, and remove leads W6 and
side.
W11 from the negative terminal. Position these
5. Disconnect Bypass PC board leads #206B and leads so they do not come in contact with any part
#208 from their in-line connectors. of the rectifier. See the wiring diagram and Figure
6. Electrically isolate the three-phase input termi- F.14.
nals of the output bridge rectifier as follows:
VANTAGE 500

FIGURE F.14 DIODE LEAD REMOVAL

WELD WINDING
LEAD CONNECTIONS
W1 W6
W3 W2
W5 W4
9. Using the 7/16 wrench, remove the stator leads 15. Replace the lower front panel and output leads.
from the three AC terminals. Label leads for
16. Replace the upper control panel and secure.
reassembly. Note leads and AC terminals place-
ment for reassembly. See Figure F.15. 17. Replace the front left and right case sides.
10. Electronically isolate the 3 AC terminals leads by * One open diode will not be detected.
carefully bending them out into free air
11. With an ohmmeter or diode tester, check each of
the 3 AC terminals to their respective heat sinks.
12. Reverse the tester leads and check the diodes
again. Diodes should have a low resistance in one
polarity and very high resistance in the opposite
polarity. See diode test Table F.2.
* One open diode will not be detected.
13. Replace rectifier bridge if any shorted or open

diode as tests indicate.
14. Replace the AC terminals and stator leads.
Assemble the washers and nuts.
VANTAGE 500
2
1
3
2
AC
1
AC 1,2,3
AC 1
+
DC+
VANTAGE 500
D.C.+
FIGURE F.15 DIODE LEAD REMOVAL
D.C.-
-
TROUBLESHOOTING AND REPAIR
DC-
F-40

TABLE F.2 DIODE TEST TABLE
DIODE TEST
TEST INSTRUMENT DIODE BIAS
RECTIFIER TERMINAL CONNECTIONS
& EXPECTED
(+) Lead (-) Lead TEST RESULT
AC1 DC(+) Forward Bias

(Low Resistance)

(Low Resistance)

(Low Resistance)
DC(-) AC1 Forward Bias

(Low Resistance)

(Low Resistance)

(Low Resistance)
AC1 DC(-) ReverseBias

(High Resistance)

(High Resistance)

(High Resistance)
DC(+) AC1 ReverseBias

(High Resistance)

(High Resistance)

(High Resistance)
18. Reconnect all leads.
19. Perform the Case Cover Replacement Procedure.
VANTAGE 500
NOTES
VANTAGE 500
F-42
ELECTRONIC GOVERNOR TEST

WARNING
manual.
TEST DESCRIPTION
This test will help determine if the Electronic Governor is operating properly.
MATERIALS NEEDED
Volt/Ohmmeter (Analog)
Miscellaneous Hand Tools
VANTAGE 500
ELECTRONIC GOVERNOR TEST (CONTINUED)

TEST PROCEDURE
CHECK CONTROLLER CHECK AND ADJUST FUEL CONTROL LEVER AND

ACTUATOR LINKAGE
1. Turn the Run/Stop switch to Run. Do not start
engine. 1. Disconnect actuator linkage rod from fuel control
lever at injection pump.
2. The engine protection light should be ON for 5 sec-
onds then go out. 2. Loosen lock nut on fuel lever off stop screw.
3. After 30 additional seconds the light should come 3. Adjust fuel lever stop screw clockwise (down) until
back on. engine will just start and run slowly while holding
fuel lever against stop screw. CAUTION: DO NOT
4. If a-c or 1-3 are OK then the controller is probably
ALLOW FUEL LEVER TO GO FULL ON AS
good.
ENGINE OVERSPEED WILL OCCUR.
5. If the engine protection light stays ON, controller

4. While holding fuel lever against the stop screw
may be defective.
slowly turn stop screw counterclockwise (up) until
6. Turn the Run/Stop switch to Stop. engine just stops. Adjust additional 1/2 turn up and
tighten lock nut.
5. Check actuator for freedom of movement and
CHECK FUEL CONTROL LEVER ACTUATOR
proper return spring operation. Linkage should not
1. Disconnect leads 270 and 271 from actuator leads. bind or rub on anything.
2. Measure 2 to 2.5 ohms between actuator leads. 6. Adjust actuator rod length so that at rest the attach-
ment hole lines up with the hole in the fuel control
3. Reconnect leads 270 and 271 to the actuator lever when it is against the off stop. Shorten the
leads. rod by 1 to 2 turns of the adjustment clevis and
reattach to the fuel control lever.
CHECK MAG PICK-UP 7. At rest the actuator should just hold the fuel con-
trol lever against the off stop.
1. Disconnect shielded cable leads from the magnet-
ic pick-up leads. 8. If the rod is too long engine speed regulation can
be sluggish, overspeeding can occur and engine
2. Measure 200-220 Ohms between the mag pick-up protection function may not work.
leads.
9. If the rod is too short, engine starting may be diffi-
3. Set the voltmeter for VAC with a max scale of 4 cult or impossible.
volts.
10. Repeat steps until engine starts and stops proper-
4. Disconnect leads 262 from the fuel solenoid so the ly.
engine cannot start.
11. For a final check of the linkage while engine is run-
5. Measure 1 to 2 VAC while engine is cranking. ning manually push and hold actuator linkage
6. If ohms and volts are OKmag pick-up is working against fuel lever off stop and verify engine does
properly. stop.
7. If ohms are OK, but the voltage is less than 1 volt

mag pick-up may be defective or need adjustment.
8. Correct adjustment of pick-up is .015 to .020 inch

gap from flywheel teeth (approx. 1/2 turn from just
touching the teeth).
9. Reconnect shielding cable leads to mag pick-up
leads and lead 262 to engine fuel solenoid.
VANTAGE 500
CHARGING CIRCUIT TEST

WARNING
manual.
TEST DESCRIPTION
This test will determine if the engine alternator and associated circuitry are functioning
properly.
MATERIALS NEEDED
3/8" Wrench
Volt/Ohmmeter
Wiring Diagram
VANTAGE 500
CHARGING CIRCUIT TEST (CONTINUED)

FIGURE F.16 ENGINE ALTERNATOR LOCATION (DEUTZ 10995)
#239 #281
#238
PROCEDURE
1. Turn engine off. 7. Set the voltmeter for DC volts and measure the DC
volts at lead #281 (#232 Cummins) to engine
2. Using the 3/8" wrench, remove the left rear case
ground. See the Wiring Diagram. Normal is 13.2
cover. (remove right rear case cover for Cummins
to 14.5 VDC.
engine 10996)
NOTE: Lead #281 (#232 Cummins) carries the flash-
3. Locate the engine alternator. See Figure F.16.
ing voltage for the engine alternator. Battery voltage
4. Start the engine and run it at high idle (1900 RPM). should be present whenever the engine is off. See the
Wiring Diagram.
5. Set the voltmeter for DC volts and measure the DC
volts at lead #239 (Deutz) to engine ground. See 8. If the correct flashing voltage is present and the
the Wiring Diagram. Normal is 13.2 to 14.5VDC. charging output voltage is low or missing, the
engine alternator may be faulty.
6. Set the voltmeter for DC volts and measure the DC
volts at lead #238 to engine ground. See the Wiring 9. Stop the engine and check the alternator V-belt for
Diagram. Normal is 13.2 to 14.5VDC. proper tension. See the engine operation manual.
10. Replace the left rear case cover.
VANTAGE 500
NORMAL OPEN CIRCUIT VOLTAGE WAVEFORM (115VAC SUPPLY)

HIGH IDLE NO LOAD
15.8 ms
0 volts
50V 5ms
This is the typical auxiliary output volt-
age generated from a properly operat-
ing machine. Note that each vertical

division represents 50 volts and that
each horizontal division represents 5
milliseconds in time.
Note: Scope probes connected at

machine 115VAC receptacle.
SCOPE SETTINGS
Volts/Div.....................50V/Div.
Horizontal Sweep .....5 ms/Div.
Coupling.............................DC
Trigger.........................Internal
VANTAGE 500
NORMAL OPEN CIRCUIT VOLTAGE WAVEFORM (STICK)

MAX TAP MAX CONTROL POT HIGH IDLE NO LOAD
0 volts
50V 5ms
This is the typical DC open circuit out-

put voltage generated from a properly
operating machine in the Constant

Current (CC)mode.
Note that each vertical division repre-
sents 50 volts and that each horizon-
tal division represents 5 milliseconds
in time.
SCOPE SETTINGS
Volts/Div.....................50V/Div.
Coupling.............................DC
VANTAGE 500
NORMAL WELD VOLTAGE WAVEFORM (STICKCC)

MACHINE LOADED TO 500 AMPS AT 40 VOLTS
0 volts
20V 0.1ms
This is the typical DC output voltage

generated from a properly operating
machine in the Constant Current (CC)

mode.
tal division represents 0.1 millisec-
onds in time.
The machine was loaded with a
resistance grid bank to 500 amps at
40 volts.
SCOPE SETTINGS
Volts/Div.....................20V/Div.
Horizontal Sweep ..0.1 ms/Div.
Coupling.............................DC
VANTAGE 500
NORMAL TIG MODE VOLTAGE WAVEFORM

LOADED TO 200A 16 VOLTS
0 volts
10V 5 s
This is the typical output voltage gen-

erated from a properly operating
machine in the TIG Mode.

sents 10 volts and that each horizontal
division represents 50 microseconds
in time.
The machine was loaded with a resis-
tance grid bank to 200 amps at 16
VDC.
SCOPE SETTINGS
Volts/Div.....................10V/Div.
Horizontal Sweep....05 ms/Div.
Coupling.............................DC
VANTAGE 500
NORMAL OPEN CIRCUIT VOLTAGE WAVEFORM (WIRE CV)

HIGHIDLE - NOLOAD
0 volts
50V 5MS
This is the typical auxiliary output volt-

age generated from a properly operat-
ing machine in the CV mode.

sents 50 volts and that each horizontal
division represents 5 milliseconds in
time.
SCOPE SETTINGS
Volts/Div.....................50V/Div.
Coupling.............................DC
VANTAGE 500
NORMAL WELD VOLTAGE WAVEFORM (WIRECV)

MACHINE LOADED TO 500 AMPS AT 40 VOLTS
0 volts
20V 0.1ms
This is the typical DC output voltage

generated from a properly operating
machine in the Constant Voltage (CV)

mode.
tal division represents 5 milliseconds
in time.
The machine was loaded with a
resistance grid bank to 500 amps at
40 volts.
SCOPE SETTINGS
Volts/Div.....................20V/Div.
Horizontal Sweep ...0.1ms/Div.
Coupling.............................DC
VANTAGE 500
SHUTDOWNSOLENOID REMOVAL AND REPLACEMENT

WARNING
manual.
TEST DESCRIPTION
This procedure will aid the technician in the removal and replacement of the shutdown
solenoid.
MATERIALS NEEDED
7/16" Wrench, 10mm wrench
Long slot head screwdriver
Needle nose pliers
VANTAGE 500
SHUTDOWN SOLENOID REMOVAL AND REPLACEMENT (DEUTZ)

FIGURE F.17 SHUTDOWN SOLENOID LEAD CONNECTIONS
Leads 262, 232M, 265

PROCEDURE REASSEMBLY
1. Turn engine off. 1. Reassemble the pivot pin and retaining ring to the
linkage assembly
2. Unlatch, lift and secure the engine access door.
2. Remount the shutdown solenoid assembly to the
3. Locate and remove the spade connectors that
engine.
attach the shutdown solenoid terminals to the
wiring harness leads. Cut the cable tie. 3. Reattach the spade connectors from the wiring
harness to the shutdown solenoid assembly.
4. Remove the bolts that mount shutdown solenoid
Replace the cable tie.
assembly to engine.
4. Close the engine access door.
5. Remove the pivot pin retaining ring and pivot pin
from the solenoid linkage assembly.
6. Remove the solenoid assembly.
7. Replace any faulty or worn parts and reassemble
the solenoid assembly.
VANTAGE 500
SHUTDOWN SOLENOID REMOVAL AND REPLACEMENT (CUMMINS)

FIGURE F.18 SHUTDOWN SOLENOID LINKAGE ARM ASSEMBLY
LEADS
262 232M 265
Shutdwn
Solenoid
Idler
Solenoid
PROCEDURE REASSEMBLY
1. Turn engine off. 1. Reassemble the pivot pin and retaining ring to the
linkage assembly.
2. Unlatch. lift and secure engine access door.
2. Remount the shutdown solenoid assembly to the
3. Locate and remove the spade connectors that
engine.
attach the shutdown solenoid terminals to the
wiring harness leads. Cut the cable tie. 3. Reattach the spade connectors from the wiring har-
ness to the shutdown solenoid assembly. Replace
4. Remove the bolts that mount shutdown solenoid
the cable tie.
assembly to engine.
4. Close the engine access door.
5. Remove the pivot pin retaining ring and pivot pin
from the solenoid linkage assembly.
6. Remove the solenoid assembly.
7. Replace any faulty or worn parts and reassemble
the solenoid assembly.
VANTAGE 500
NOTES
VANTAGE 500
F-56
OUTPUTRECTIFIER REMOVAL AND REPLACEMENT PROCEDURE

WARNING
manual.
TEST DESCRIPTION
The following procedure will aid the technician in removing and replacing stud type diodes
to the aluminum heat sinks on the Vantage 500.
MATERIALS NEEDED
7/16 socket & ratchet
1/2 socket & ratchet
VANTAGE 500
OUTPUTRECTIFIER REMOVAL AND

REPLACEMENT PROCEDURE (continued)

CHOPPER
MODULES (2)
HEATSINKS
2 7/16"
BOLTS
OUTPUT
RECTIFIER
BRIDGE
2 1/2"
NUTS
2 7/16"
BOLTS
PROCEDURE
1. Turn the engine off. 7. Using 1/2 socket, remove output rectifier assem-
bly and replace.
2. Perform the output panel removal as described in
the Case Cover Removal procedure. 8. Reverse procedure for assembly.
3. Perform the Chopper Module Capacitor

Discharge procedure.
4. Using the 7/16" wrench, remove the appropriate
stator leads and AC terminals leads. Refer to
Figure F.19. Label the leads for reassembly.
5. Using 7/16 socket remove 4 bolts holding power
module assembly to base.
6. Remove power module assembly.
VANTAGE 500
STATOR/ROTOR REMOVAL AND REPLACEMENT

WARNING
manual.
TEST DESCRIPTION
The following procedure will aid the technician in removing and replacing the Vantage 500
stator and rotor.
MATERIALS NEEDED
5/16" Wrench
3/8" Wrench Slot head screw driver
7/16" Wrench Phillips head screw driver
1/2" Wrench Gear puller (small)
3/4" Wrench Hoist
1" Open end wrench Feeler gauge (for air gap check)
1 1/8" Wrench
9/16" Deep socket wrench
17mm Wrench
VANTAGE 500
STATOR/ROTOR REMOVAL AND REPLACEMENT (CONTINUED)

FIGURE F.20 FUEL TANK REMOVAL DETAILS
LEADS #229
AND #242D
PLUG
FUEL
LINES
U-BOLTS (2)
{
PROCEDURE
Refer to Figure F.20.
1. Turn the engine off and disconnect battery leads 7. Turn the fuel off at the shutoff valve. Remove and
and drain fuel. plug the fuel return line.
2. Perform the Case Cover Removal procedure, 8. Remove and plug the lower fuel line. Pull it
including removing the output panel. through the firewall.
3. Perform the Chopper Module / Output Rectifier 9. Using the 9/16" deep socket wrench, remove the
Bridge Assembly Removal Procedure. four lock nuts, washers, and rubber washers from
the fuel tank mounting U-bolts.
4. Perform the Chopper Module Capacitor
Discharge Procedure. 10. Carefully remove the U-bolts and lift the fuel tank
from the machine.
5. Disconnect Battery.
6. Using the 3/8" wrench, remove leads #229 (white)
and #242D from the fuel level sensor. Label the

leads for reassembly.
VANTAGE 500

FIGURE F.21 PLUG J52/FILTER CAPACITOR/FIELD RECTIFIER BRIDGE DISCONNECTION
#200D
#4
6
#201A
FILTER FIELD DIODE

CAPACITOR RECTIFIER BRIDGE
11. See Figure F.21. Using the slot head screw driver,
disconnect leads #200A, #200B(+) and #201A(-) or
remove screw cap bracket and remove cap from
the filter capacitor.
12. Label and remove leads #5H, and #201A, #200A,
and #6A from the field diode rectifier bridge.
VANTAGE 500

FIGURE F.22 BRUSH HOLDER AND LEAD REMOVAL
Refer to Figure F.22 for Steps 13-15.

access panel.
#200A
assembly.
#200B
15. Cut the cable tie and then label and remove brush
leads #201(-) and piggy-backed leads #200A(+)
and #200B(+) from the brush holder assembly.
#201 (The piggy-backed leads connect closest to the
stator laminations.)
FIGURE F.23 CONTROL BOX CONNECTIONS
CONTROL BOX
PULL COIL PC BOARD

(LEADS #265 & #227
12 VDC STUD
LEADS #232L
& #232M
PROCEDURE
1. Turn the engine off. 4. Support the door assembly. Using the 3/8" wrench,
remove the #10-24 round head screw, lock washer,

2. Using the 3/8" wrench, remove the battery cover.
flat washer, and nut from the top corner of the door
Slide the battery out and disconnect the negative
hinge assembly, where it attaches to the roof.
battery cable.
Remove the support rod.
3. Unlatch and open the engine service access door.
See Figure F.1.
VANTAGE 500

6 SCREWS
SHROUD
ACOUSTICAL
FOAM
18. See Figure F.24. With the 5/16" wrench, remove 19. With the 7/16" wrench, remove the two nuts, lock
the six screws that hold the top and bottom of the washers and flat washers that hold the bottom of
alternator shroud together. the shroud to the machine base. Remove the
shroud.
VANTAGE 500

FIGURE F.25 LIFT FRAME AND ASSOCIATED COMPONENT REMOVAL
LIFT FRAME
WELDMENT
CENTER PANEL
FUEL TANK
SUPPORTS
FAN BAFFLE
BASE
In steps 20 24, the lift frame weldment, fuel tank sup- 22. With the 3/8" wrench, remove the nuts, lock wash-
ports, and fan baffle are removed as a unit. See Figure ers, and flat washers from the two studs that hold
F.25. the fan baffle to the machine base.
20. Using the 3/8" wrench, remove the two bolts (at 23. Using the 3/4" wrench, remove the four bolts, lock
top) that hold the center panel to the lift frame washers, and nuts from the bottom of the lift frame
weldment. weldment.
21. Using the 1/2" wrench, remove the two bolts (at 24. Carefully remove the lift frame weldment, fuel tank
bottom) that hold the center panel to the lift frame supports, and attached fan baffle. You will need to
weldment. lift the fan baffle off the two studs on the machine
base, then cock it slightly to remove it.
VANTAGE 500

FIGURE F.26 STATOR REMOVAL
STATOR / ENGINE
MOUNTING BOLTS &
LOCK WASHERS
BEARING FLYWHEEL
SPLASH
FAN HUB PLATE
BOLTS
(4)
FAN
NUT MOUNTING
FOOT
PROCEDURE
First, cut any necessary cable ties in order to free the 4. Using two air impact from bottom wrench on top,
stator leads from the bundle of leads running to the remove the nut, lock washer, and carriage bolt
control box. Refer to Figure F.39 for stator removal. holding the alternator mounting foot to the machine
base. Do this on each side.
1. Using the 1 1/8" wrench, remove the fan nut.
Remove the fan, noting its direction for reassem- 5. Using the 3/8" wrench, remove the three bolts from
bly. the flywheel splash plate. Remove the plate.
2. Using the gear puller, remove the fan hub. 6. Support the stator with the hoist. Place wooden
blocks under the engine to support it when the sta-
3. Using the 3/8" wrench, remove the two bolts and tor is removed.
flat washers holding the bearing in place.
7. Using the 17mm" wrench, remove the bolts and
lock washers holding the stator to the engine.
8. Remove the stator from the engine. It may be nec-
essary to pry and slide it free.
VANTAGE 500

FIGURE F.27 ROTOR REMOVAL
FLEX PLATE
ROTOR
BLOWER
SEGMENT (4)
PROCEDURE
Refer to Figure F.27 for rotor removal. INSTALL ROTOR: Support the rotor with the hoist.
Install the blower segments and flex plate to the engine
1. Support the rotor with the hoist.
flywheel.
2. Using the 5/8" wrench, remove the flex plate bolts,
INSTALL STATOR: Be sure the engine is blocked
lock washers, and four blower segments.
securely and the stator is supported with the hoist.
WARNING Watch bearing housing, install tolerance ring and install
bearing cover plate. When stator is bolted to engine
The rotor will be free to fall when the bolts are inspect ball bearing and make sure it is seated fully in
removed. the mount. Using a dead blow hammer or 2X4 and
hammer hit the bearing mount to relieve and tension
bearing. Install the stator to the engine with the bolts
3. Using the hoist, carefully remove the rotor and flex and lock washers. Install the fan blade, making sure
plate assembly. that it faces the proper direction, with the fan nut and
four cap screws.

REASSEMBLY NOTES
Check the air gap for .010" minimum.
Reassemble the rotor and stator to the Vantage 500 by
carefully retracing the disassembly procedure steps in Install the brush holder assembly. Be sure the brush-
reverse order. Keep the following special points in es are centered and properly seated on the slip rings.
mind as you proceed. Lead Reconnection Checklists
Install the flywheel splash plate.
are provided here as an aid to reassembly.
VANTAGE 500

LEAD RECONNECTION CHECKLIST

ENGINE OUTPUT PANEL AND CONTROL BOX
n Leads #5I and #229 to fuel level sensor n Leads #232N and #227 to Pull Coil PC board
n Brush leads #201(-) and #200B(+) n Leads #232L and #232N to 12 VDC insulated
stud
n Leads #5H, and #201A, #200, #200A, and #6A
to the field bridge rectifier n Leads #200A, #200B(+), and #201(-) and
#201A(-) to the field capacitor.
VANTAGE 500
RETEST AFTER REPAIR

Retest a machine:
If it is rejected under test for any reason that requires you to remove any mechanical part which could affect the
machines electrical characteristics. OR
If you repair or replace any electrical components.
ENGINE RPM
Mode No Load RPM Load RPM

Low Idle 1400 - 1450 NA
High Idle 1890 - 1910 1750 - 1890
WELDER DC (STICK) OUTPUT
Mode Selector Open Circuit

Switch Fine Control Voltage Load Volts Load Amps
30-575 Setting Maximum 55 - 60 39.5 - 42.0 565 - 585
WELDER CV (WIRE) OUTPUT
Mode Selector Open Circuit

Switch Fine Control Voltage Load Volts Load Amps
CV - Wire Maximum 55 - 60 39 - 42 520 - 535
CV - Wire Maximum NA 48 - 49 20
CV - Wire Minimum 55 - 60 13 - 14 20
VANTAGE 500
RETEST AFTER REPAIR (CONTINUED)

TOUCH START TIG MODE OUTPUT
Mode Selector Open Circuit Short Circuit

Switch Fine Control Voltage Current
TIG 20 - 250 A Maximum 10 - 15 18 - 28
TIG 20 - 250 A Minimum 10 - 15 18 - 28
AUXILIARY POWER OUTPUT
230 Volt Receptacle 115 Volt Receptacles

Open Circuit Open Circuit

Voltage Load Volts Load Amps Voltage Load Volts Load Amps
230 - 264 216 - 252 50 115 - 132 108 - 126 20

VANTAGE 500
NOTES
VANTAGE 500
F-70
Return to Master TOC G-1 TABLE OF CONTENTS - DIAGRAM SECTION G-1
Electrical Diagrams . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .G-1
Wiring Diagram (G4342 Code 10995 Deutz) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .G-2
Wiring Diagram (G4329 Code 10996 Cummins) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .G-3
Wiring Diagram (G4847 Codes 11180, 11415 &11468 Deutz) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .G-4
Wiring Diagram (G4971 Codes 11181 & 11416 Cummins) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .G-5
Schematic Complete Machine (G4363 Code 10995 Deutz) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .G-6, G-7
Schematic Complete Machine (G4442 Code 10996 Cummins) . . . . . . . . . . . . . . . . . . . . . . . . . . .G-8, G-9

Schematic Complete Machine (G4848 Codes 11180, 11415 &11468 Deutz) . . . . . . . . . . . . . . .G-10, G-11
Schematic Complete Machine (G4791 Codes 11181 & 1416 Cummins) . . . . . . . . . . . . . . . . . . . . . . . .G-12
Schematic Weld Control PC Board* (G4108-1) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .G-13 thru G-17
Schematic - Chopper PCBoard* (M19792-1) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .G-18
Schematic - Peripheral PCBoard* (G3663) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .G-19
Schematic - Pull Coil / Battery PCBoard* (G4117-1) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .G-20
* NOTE: Many PC Board Assemblies are now totally encapsulated, surface mounted and/or multi-layered
and are therefore considered to be unserviceable. Assembly drawings of these boards are no
longer provided.
VANTAGE 500
G-2 ELEcTricaL DiaGramS G-2
WiriNG DiaGram - vaNTaGE500 - G4342 (cODE 11095 DEuTz)
POS
POS
VANTAGE 500 WIRING DIAGRAM STATOR AUXILIARY WINDINGS
W7
POS
POS W4 & W5 W2 & W3
K2271-1 6A 3
W1 & W6
W8 CB1 6 5 5A
20A
206C NEG RECTIFIER 9
B6 B3 NEG BRIDGE
+ 204S LEFT SIDE NEG 3 3A
32A
CHOPPER NEG 50A

50MV=400AMPS
B5 PCB6 B2 12 5AINSULATED
+ - 206S
B4
B8 B7
CB3 9
HOT
GND-C
5B
5C
NEUTRAL
STUD ON
BOTTOM
B1
W3 W2 J12 115/230V 12
RIGHT OF
W3 W2 LINE TERMINAL 5E CONTROL
31 5H BOX
R4 B7 23
WHITE
20A 11
B8 25 GND-E 5B J10
206A 206B STATOR HOT
POS POS WELD 8
5C
GROUND STUD W4
W4 WINDINGS W1
W1 GROUND STUD ON CB2 J11
ON OUTPUT PANEL NEG NEG CONTROL PANEL 6A
W5 W6 6BCB4
GND-K W6 50A WHITE
W5 GND-F GND-D
W9
11
W10
208C MODE SELECTOR GND-E 5E
BYPASS GND-J SWITCH STATOR 42V WINDING GND-A GND-D
208
FILTER L1 CHOKE S5 10A GND-B GND-C
B6 B3 CV
ASSEMBLY 214 1 42 GND-J 5
RIGHT SIDE 218 2 CB6
I
208B CHOPPER PIPE

A 42B 32A
3
208A
B5 PCB5 B2 CC
41
220 4 AUXILIARY GROUND STUD, BOTTOM
TIG CENTER OF CONTROL BOX
B8 B7 222 42A
B4 B1 32
SWITCH SHOWN IN 6
B7 23A
POSITIVE POLARITY 14A 41A
POSITION 13A B8 25A
POS POS 201
- 200B 200A 200
+
13 14
POLARITY NEG NEG BRUSH BRUSH SHUTDOWN SOLENOID
+
21 5H
SWITCH 32 3200MFD
-
- 41A
42A
ROTOR
300V
6
HOLD
COIL
PULL
COIL
POSITIVE BRUSH CONNECTED RED WHT

206A TO SLIP RING NEAREST BLK
208B TO THE LAMINATION P54
1 2 3 4
J 31 32 201 201A J54
115VAC
A 32 WELDING TERMINAL - 232M
OUTPUT CONTROL PINCH POT
+
42VAC I 41A
CCW
CONTROL SWITCH 262 265
K 42A SHOWN IN "ALWAYS ON" POSITION 4
WORK H 21
R1 10K 4A
VIEWED VIEWED FROM BACK HOUR METER
E
77B FROM 2A 2
REMOTE 232R 262A
CONTROL F 76B BACK
CONTACTOR
G 75B 77 76 75 277 278 279 262 START BUTTON
D 4B
C 2B 20A
GROUND B GND-A 238B OIL PRESSURE
CB5 231 SENSOR & SWITCH
AMPHENOL 1 238A SWITCH
234
AMPHENOL 2 OIL OIL 228 SENSOR 235
77A AMMETER VOLTMETER PRESSURE TEMPERATURE FUEL 236A 236B
G WK
A 77B 232R
REMOTE 76A
CONTROL B 76B
75A 4 1 4 1 4 1 RUN OIL TEMPERATURE
C 75B
J53 J51 RUN/STOP SWITCH SENSOR & SWITCH
CONTACTOR 2A M1 M3 M5 M9 M1 M3 M5 M9 243 247 J52 SHOWN IN "RUN" POSITION
STOP
D 2B M2 M4 M6 M10 M2 M4 M6 M10 SWITCH
4A GOLD GOLD 232H
E 4B 12VDC 232B SENSOR 235
241
GROUND F GND-B ALT
ENG INSULATED 232C 232A 232F
PROT
STUD 232K 232B 5M 232C 5L 232K 5K
SILVER 228 241 229 229 FUEL LVL.
SILVER 5J SENSOR
405B 232M
405B 232A
405A
214
M10
218
220
222
208B
M10
232N
25A
23A
M9
M6
M9
M3
M1
25
23
14
238A
231
M2
M6
M4
M5
M2
M3
M1
M4
M5
279
278
277
77
260
256
76
75
250
250
13
1 5 1 5
1 8 1 8
6 10
9 16
6 10
9 16 PERIPHERAL BD
PCB1
5T
5M
5L
5K
5J
5S
5S
265
232N
281
238
STARTER
SOLENOID
+
J5 J4 J3 PROGRAMMING
J7 STARTING
VOLT METER CONTROL, MODE SEL. AMMETER CHOPPER,POWER,PWM,THERMAL 1 3 MOTOR 12V BATTERY
232F
B4 B3 B2 B1
270
271
243
403
247
239
234
262A
5T
-
405A
12 VOLT GROUND
405
PULL COIL BD 239
405
403
270
4 6 STUD ON LEFT SIDE SENSE EXC
WELD BOARD J30
281
271
BACK OF CONTROL BOX
200
PCB3 12 7 ALTERNATOR ENGINE SUPPORT
75A
76A
77A
16 9 PCB8 POS NEG RIGHT SIDE

5N
+-
500
1 4
5F
4
2
J6 16 9 J2 12 7 6 1
206S 2 J1 8 J31 1 J32 281
AMPHENOL,I.D. ENGINE,PERIPHERAL
204S 1 SHUNT 5 8
8 6 1 J43
1 5N ENGINE BLOCK
LEFT SIDE
ENGINE SUPPORT
LEFT SIDE A
G4342
NOTE: This diagram is for reference only. It may not be accurate for all machines covered by this manual. The wiring diagram specific to your code is pasted inside one of the enclosure panels of your machine.
vaNTaGE 500
WiriNG DiaGram - vaNTaGE 500 - G4329 (cODE 10996)
POS STATOR AUXILIARY WINDINGS

POS VANTAGE 500 WIRING DIAGRAM 6A 3
POS
W7
W8
POS W4 & W5 W2 & W3 W1 & W6 K2272-1 AUXILIARY POWER LEADS PASS THROUGH
TOROID TWICE IN DIRECTION INDICATED
6 5 5A
20A
RECTIFIER 260 CB1
206C NEG BRIDGE 261 9
B6 B3
+ 204S LEFT SIDE
NEG
NEG 3A
32A
50MV=400AMPS
CHOPPER NEG 50A
B5 PCB6 B2 3 12 5A INSULATED
206S
+ - B8 B7
CB3 9
HOT
GND-C
5B
5C
NEUTRAL
STUD ON
BOTTOM
B4 B1 W3 W2 J12 115/230V 12
RIGHT OF
W3 W2 LINE TERMINAL
J10 5E CONTROL
WHITE 31 5H BOX
R4 B7 23 CB2
20A 11
B8 25 GND-E 5B
206A 206B STATOR HOT
POS POS WELD 8
W4 W1 5C
GROUND STUD
W4
WINDINGS
W1 GROUND STUD ON J11
ON OUTPUT PANEL NEG NEG CONTROL PANEL
W5 W6 6BCB4
GND-K W6 50A WHITE
W5 GND-F GND-D
W9
6A 11
W10
208C GND-E 5E
BYPASS GND-J MODE SELECTOR GND-A GND-D
208
FILTER L1 CHOKE B6 B3 SWITCH GND-B GND-C
ASSEMBLY STATOR 42V WINDING 10A GND-J 5
RIGHT SIDE S5
CV
I
214 1 42
208B CHOPPER 218 2 CB6
32A
208A
B5 PCB5 B2 PIPE
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 B7 6
23A
POSITIVE POLARITY
POSITION 13A 14A B8 25A
POS 41A 201 200B 200A 200
POS -
+ SHUTDOWN
+
IDLER
13 14 BRUSH BRUSH
POLARITY NEG NEG SOLENOID SOLENOID
+
21 5H
SWITCH 3200MFD
-
- 41A
ROTOR
300V
6
HOLD
COIL
PULL
COIL
HOLD
COIL
PULL
COIL
42A
POSITIVE BRUSH CONNECTED RED WHT RED WHT
206A TO SLIP RING NEAREST BLK BLK
208B TO THE LAMINATION P54 J55
1 2 3 4 1 2 3 4
J 31 32 32 201 201A P55
115VAC J54
A 32 WELDING TERMINAL 256 SHOWN IN
232M 232L
I 41A
OUTPUT CONTROL PINCH POT CONTROL SWITCH - "HIGH" POSITION
42VAC CCW HIGH 262 265 226 227
+
K 42A SHOWN IN "ALWAYS ON" POSITION 4 IDLER
R1 10K 4A
WORK H 21
VIEWED AUTO CONTROL
VIEWED FROM BACK

E 77B FROM 2A 2
REMOTE
F 76B BACK HOUR METER
CONTROL 257
G 75B 232R 262A
77 76 75 277 278 279 START BUTTON
CONTACTOR 232E
D 4B
262
C 2B 20A
GROUND B GND-A
238B
OIL PRESSURE
CB5 231 SENSOR & SWITCH
AMPHENOL 1 238A SWITCH
234
AMPHENOL 2 OIL COOLANT 228 SENSOR 235
77A AMMETER VOLTMETER PRESSURE TEMPERATURE FUEL 236A 236B G WK
A 77B 232R
REMOTE 76A
CONTROL B 76B
75A 1
RUN/STOP RUN COOLANT TEMPERATURE
4 1 4 1 4
CONTACTOR
C 75B
2A M1 M3 M5 M9 M1 M3 M5 M9 243 247 J53 J52 J51 SWITCH STOP SENSOR & SWITCH
D 2B M2 M4 M6 M10 M2 M4 M6 M10 232B SHOWN IN "RUN" POSITION SWITCH
4A GOLD 232D 232H
E 4B 232C 241 SENSOR 235
12VDC
GROUND F GND-B ALT
ENG INSULATED 232K 232A 232F
PROT
STUD 232M 232B 5M 232C 5L 232K 5K
232
SILVER
232L
228 241 229 229 FUEL LVL.
5J SENSOR
232A
232E 405B 232N
405A
214
222
M10
218
220
208B
M10
25A
23A
257
M9
M6
M9
M3
M1
25
23
14
238A
231
M2
M6
M4
M5
M2
M3
M1
M4
M5
279
278
277
77
261
260
256
76
75
250
250
13
1 5 1 1 5 1 8
8 STARTER
6 10 9 16 6 10 9 16
PERIPHERAL BD
PCB1
5G
5T
5M
5L
5K
5J
5S
5S
265 227
232N
238
SOLENOID +
PROGRAMMING
J5 J7 J3 STARTING
J4 12V BATTERY
VOLT METER CONTROL, MODE SEL. AMMETER CHOPPER, POWER, PWM, THERMAL 1 3 MOTOR
405B
232F
B4 B3 B2 B1
262A
270
271
234
403
247
5T
-
405A
12 VOLT GROUND
405
PULL COIL BD B
405
403
404
270
232
WELD BOARD 4 6 STUD ON LEFT SIDE P L
J30
271
BACK OF CONTROL BOX 243
200
PCB3 7
75A
76A
12
77A
16 9 PCB8 IG
232D
404
ALTERNATOR
226
5N
5G
500
1 4
ENGINE BLOCK
4
2
J6 16 9 J2 12 7
206S 2 J1 8 J31 1 6 1
ENGINE,PERIPHERAL J32
204S 1 SHUNT AMPHENOL,I.D. 5
6 1 J43 8 5N ENGINE
8 1 SUPPORT
LEFT SIDE
A
G4329
vaNTaGE 500
WiriNG DiaGram - vaNTaGE 500 - G4847 (cODES 11180,11415 & 11468)
POS
STATOR AUXILIARY WINDINGS
POS
POS
VANTAGE 500 WIRING DIAGRAM
W7 POS W2 & W3 W1 & W6 6 3
W4 & W5
W8 ELECTRICAL SYMBOLS PER E1537
AUXILIARY POWER LEADS PASS THROUGH
TOROID THREE TIMES IN DIRECTION INDICATED 6A
206C NEG 5 5A
B6 B3
RECTIFIER 260
+ 204S LEFT SIDE
NEG
NEG
BRIDGE 261
50MV=400AMPS
CHOPPER NEG
4
B5 PCB6 B2
W3 W2
W3 W2
+ - 206S
B8 B7
3 4 6
CB1
6D
B4 B1 3C
STATOR
50A
3 POLE
20A CB2 20A CB3
WELD
W4 WINDINGS W1
4A 6B LINE TERMINALS
R4 B7 23 W4 W1
GND-C
3D 6E
B8 25 3A GND-L 32A
206A 206B W5 W6 HOT
POS POS W5 W6 J13 240V
120/240V 6D HOT
3PH
GROUND STUD
J10 J12 J11
ON OUTPUT PANEL NEG NEG X Z
X Y
GND-K GND-C Y
3B W WHITE WHITE
W9 6C
GROUND STUD ON
3B 3C
W10 6B
CONTROL PANEL GND-D 5B GND-E 5E
208C MODE SELECTOR GND-L
6C
BYPASS GND-J SWITCH GND-F
FILTER STATOR 42V WINDING 5C
208 L1 CHOKE B6 B3 S5 10A INSULATED
ASSEMBLY 214
CV
1 42 GND-A 5
5A NEUTRAL
RIGHT SIDE STUD ON
CB6
I
218 2 GND-B GND-E 5E BOTTOM

208B CHOPPER PIPE
42B GND-D 5B RIGHT OF
CC 3 A GND-J
208A
B5 PCB5 B2
41 5C CONTROL
220 4 BOX
TIG AUXILIARY GROUND STUD, BOTTOM 32A
B8 B7 222 42A 31 5H
B1 CENTER OF CONTROL BOX
B4
SWITCH SHOWN IN 32 6A
B7 23A
POSITIVE POLARITY
POSITION 13A 14A B8 25A
POS 41A 201 200B 200A 200
POS -
+ SHUTDOWN
+
IDLER
13 14
+
BRUSH BRUSH
POLARITY NEG NEG SOLENOID SOLENOID
21 5H
SWITCH 3200MFD
-
- 41A
ROTOR
300V
6A BLK
COIL
RED
HOLD
COIL
PULL
COIL
42A
POSITIVE BRUSH CONNECTED RED WHT
206A TO SLIP RING NEAREST BLK
256
208B TO THE LAMINATION J54 J55
201 201A IDLER 2 1 2 3
J 31 32 32 HIGH P54 P55 1 4
115VAC WELDING TERMINAL CONTROL
A 32 232M 232L
SHOWN IN
42VAC
I 41A
OUTPUT CONTROL PINCH POT CONTROL SWITCH - AUTO
"HIGH" POSITION 262 226 227
+
K 42A SHOWN IN "ALWAYS ON" POSITION
CCW 257
WORK H 21 4
R1 10K 4A
E 77B
REMOTE
F 76B
VIEWED VIEWED FROM BACK HOUR METER
CONTROL FROM 2A 2
BACK 232R 262A CB5
CONTACTOR
G 75B
20A START BUTTON
D 4B 77 76 75 277 278 279 262
C 2B 238B
GROUND B GND-A OIL PRESSURE
RUN/STOP
231 SENSOR & SWITCH
AMPHENOL 1 SWITCH 238A SWITCH
SHOWN IN "RUN" POSITION 234
AMPHENOL 2 OIL COOLANT 228 SENSOR 235
77A AMMETER VOLTMETER PRESSURE TEMPERATURE FUEL 236A 236B G WK
A 77B
REMOTE 76A 12VDC
CONTROL B 76B
75A INSULATED 1 RUN COOLANT TEMPERATURE
232R 4 1 4 1 4
CONTACTOR
C 75B
2A M1 M3 M5 M9 M1 M3 M5 M9
243 247 STUD
J53 J52 J51 232D STOP SENSOR & SWITCH
D 2B M2 M4 M6 M10 M2 M4 M6 M10 232B SWITCH
4A GOLD GOLD
E 4B 232C 232H 235
ENG
241 SENSOR
GROUND F GND-B ALT PROT 232K 232A 232F
232M 231
232B 5M 232C 5L 232K 5K
SILVER SILVER 238A
232L
228 241 229 229 FUEL LVL.
5J SENSOR
232A
405B 405B 232N
405A
214
222
M10
218
220
208B
M10
25A
23A
257
M9
M6
M9
M3
M1
25
23
14
STARTER
SOLENOID +
M2
M6
M4
M5
M3
M2
M1
M5
M4
279
278
277
77
261
260
256
76
75
250
250
13
227
1 5 1 1 1 5S 232N 12V
8 5 8 STARTING
5G 5M 5K
5J
5S MOTOR BATTERY
6 10 9 16 6 10 9 16
PERIPHERAL BD 5T 5L
281
PCB1 B4 B3 B2 B1
-
PROGRAMMING
J5 J7 J4 J3
D+
405
404
270
VOLT METER CONTROL, MODE SEL. AMMETER CHOPPER, POWER, PWM, THERMAL 1 3 W
232F
262A
239
270
271
234
247
239
243
5T
271
281
200
PULL COIL BD
+ - B-
405A
WELD BOARD
405
4 6
1 4 PCB8 B+
J30 12 VOLT GROUND
PCB3 7 STUD ON LEFT SIDE ALTERNATOR
75A
76A
12
77A
16 9
232D
404
226
5N
5G
500
BACK OF CONTROL BOX

5 8
4
2
J43
J6 16 9 J2 12 7
206S 2 J1 8 J31 1 6 1
ENGINE,PERIPHERAL J32 5N
204S 1 SHUNT AMPHENOL,I.D.
8 6 1
1 ENGINE SUPPORT
ENGINE SUPPORT ENGINE BLOCK RIGHT SIDE
LEFT SIDE LEFT SIDE B
G4847
vaNTaGE 500
WiriNG DiaGram - vaNTaGE 500 - G4971 (cODES 11181 &11416)
206C
POS VANTAGE 500 WIRING DIAGRAM
POS
POS K2406-1 STATOR AUXILIARY WINDINGS
W7 POS W4 & W5 W2 & W3 W1 & W6
W8 ELECTRICAL SYMBOLS PER E1537 6 3
206C AUXILIARY POWER LEADS PASS THROUGH

B6 B3
RECTIFIER TOROID THREE TIMES IN DIRECTION INDICATED
+ 204S LEFT SIDE
NEG
NEG
BRIDGE
261
6A 5 5A
50MV=400AMPS
CHOPPER NEG 260
B5 PCB6 B2
NEG W3 W2
W3 W2
-
R4
206S 4
B8 B7
+
B4 B1
STATOR 3 4 6 6D
WELD 3C
W4 WINDINGS W1 CB1 32A CB2 CB3
POS POS W4 W1 50A 20A 20A
4A 6B 3 POLE
206A 206B W5 W6 3D 6E
NEG B8 B7 NEG W5 W6 GND-L GND-C
3A LINE TERMINALS
GROUND STUD
ON OUTPUT PANEL 23
J13 240V
3PH
120/240V J10 6D HOT HOT
GND-K 208C 25
J12 J11
X Z
W9 GROUND STUD ON X Y
CONTROL PANEL
W10 GND-C 3B Y W WHITE WHITE

BYPASS MODE SELECTOR GND-F GND-L 6B 3B 3C 6C
FILTER GND-J SWITCH GND-D 5B GND-E 5E
B6 STATOR 42V WINDING 6C
208 ASSEMBLY L1 CHOKE B3
S5 10A
5A
CV 5C
RIGHT SIDE 214 1 41 42 GND-A 5 INSULATED
CB6 NEUTRAL
I
218 2 GND-B GND-E 5E

208B
CHOPPER PIPE STUD ON
A 42B GND-J GND-D 5B
B5 PCB5 B2 CC 3
5C
BOTTOM
208A RIGHT OF
220 4
CONTROL
B8 B7 TIG AUXILIARY GROUND STUD, BOTTOM
41A 42A 31 5H BOX
B4 B1 CENTER OF CONTROL BOX 32A
222
SWITCH SHOWN IN POS POS 32 6A
POSITIVE POLARITY
POSITION -
NEG B8 B7 NEG 201 200B 200A 200
+
+ 23A
BRUSH BRUSH
200
POLARITY 13A 14A 5H
+
21 25A
SWITCH 14
3200MFD
- 202 R3
- 13
ROTOR
POSITIVE BRUSH CONNECTED
300V
6A
41A
TO SLIP RING NEAREST
206A 42A TO THE LAMINATION
201 201A
J 31
115VAC 256 SHOWN IN
A 32 32 HOUR METER "HIGH" POSITION
42VAC
I 41A
OUTPUT CONTROL ARC CONTROL WELDING TERMINAL - HIGH
+
K 42A
CCW CCW CONTROL SWITCH IDLER
WORK H 21
R1 R2 SHOWN IN "ALWAYS ON" POSITION CONTROL
AUTO
E 77B 10K 4
REMOTE VIEWED 10K VIEWED
CONTROL F 76B 4A 257
FROM FROM 262B 5S
G 75B 208B
CONTACTOR BACK BACK
262 262A 5R
D 4B 77 76 75 277 278 279 2A
C 2B 2 OIL PRESSURE
GROUND B GND-A SENSOR & SWITCH
SWITCH 234
AMPHENOL 1
228 SENSOR 235
AMPHENOL 2 G WK
77A AMMETER VOLTMETER 243 247
CB5 START
REMOTE
A 77B
76A 20A
BUTTON
CONTROL B 76B
75A
COOLANT TEMPERATURE
C 75B M1 M3 M5 M9 M1 M3 M5 M9
OIL COOLANT 238B SENSOR & SWITCH
CONTACTOR 2A
D 2B M2 M4 M6 M10 M2 M4 M6 M10 PRESSURE TEMPERATURE FUEL RUN/STOP 236B
241A SWITCH
4A 236A
E 4B SWITCH 241 SENSOR 235
ENG
GROUND F GND-B ALT PROT 4 1 4 1 4 1 RUN
SHOWN IN "RUN" POSITION 231
12VDC J53 J52 J51 STOP 238A
INSULATED STUD
229 FUEL LVL.
232H 232
5J SENSOR
232B 5M 232C 5L 232K 5K
232E 5S 232E 232C 232K 232L 228 241 229
214
222
218
220
208B
M10
25A
23A
257
M10
M1
M9
M3
M9
M3
M1
25
23
14
232A 232F
232D 232A 232B 232M
M2
M6
M4
M5
M6
M2
M4
M5
279
278
277
77
261
260
256
76
+12V
75
250
250
13
1 5 1 8 1 5 1 8 SHLD 238
247A 247 405 280
5G 5M
5L
5K 5J STARTER STARTING
BLACK 270 271 5T 5R
6 10 6 9
GOVERNOR 232L 262A 262 247A 232L 405 262A SOLENOID MOTOR BATT
9 16 10 16
CONTROL WHITE 247 232M
-
232M 30
J5 J7 J4 J3 232
BLACK
VOLT METER CONTROL, MODE SEL. CHOPPER, POWER, PWM, THERMAL MODULE 85 86
241A
AMMETER
247A
232F
404
270
87a NO NO B
NO 87 280
CONNECTION CONNECTION P L
SHLD
WHITE
CONNECTION 12 VOLT GROUND

405
243
271
ALTERNATOR
5T
5N
234
WELD BOARD STUD ON LEFT SIDE IG

GOVERNOR BACK OF CONTROL BOX
PCB3 7 ALTERNATE WIRING
75A
76A
12
77A
262B
ENGINE
232D
CONTROL
202
404
5G
500
WITHOUT RELAY
4
FUEL
2
J6 9 J2 12 7 FUEL RELAY 5N
206S 2 16 J1 6 1
AMPHENOL,I.D. ENGINE,PERIPHERAL J31
MAGNETIC LEVER SOLENOID
204S 1 SHUNT 1
6
8 1 PICK-UP ACTUATOR ENGINE
SUPPORT
ENGINE
BLOCK
LEFT SIDE A
G4971
vaNTaGE 500
SchEmaTic - cOmpLETE machiNE - G4363 (cODE 10995 DEuTz) paGE 1
G4363 ENGINEERING CONTROLLED CHANGE DETAIL: RELEASED FROM X A.01

MANUFACTURER: No
+12 VOLTS RUN
OIL
LEFT CHOPPER PC BOARD IGBT'S, FLYBACK DIODES AND FUEL PRESS. TEMP.
R4 is located on top of p/n L11845-1
chopper power module FILTER CAPACITORS ARE INTEGRAL
assembly. TO CHOPPER MODULES AND NOT 4 1 4 1 4 1
FUEL LVL.
+COM INDIVIDUALLY REPLACEABLE.
SENSOR
B2 B5 Chopper modules are located on power Rectifier is located on
10,000uF x4 power module 229
module assembly behind output terminal
panel. assemblybehind output 241
+ control panel. 5J 230 OHMS EMPTY
FLYBACK 30 OHMS FULL 228
R4
Shunt on back of positive 50 OHM
DIODES (6) RIGHT CHOPPPPER PC BOARD
p/n L11845-1 THREE PHASE Oil Pressure Switch
output terminal 100 W FILTER 60 TO 65 VAC PHASE TO PHASE
RECTIFIER closes on low 10 OHMS @ 0 PSI
CAPACITORS (4) AT HIGH IDLE
SHUNT oil pressure. 100 OHMS @ 75PS1
POSITIVE 50MV=400 AMPS +COM PERIPHERAL Located on rear
IGBT (8) W1 W6 OIL PRESSURE
OUTPUT of control panel
B3 C E B1 W1 W6 PCBOARD left side.
B2 B5 (J32-6) 234
TERMINAL 204S CURRENT LEVEL B6 B4 10,000uF x4 243 (J32-4)
Low oil
206S FEED BACK SIGNAL 247 (J32-1) SWITCH SENDER
206B + pressure or
206A B7 B8 GATE SIGNAL FLYBACK high
DIODES (6) W2 STATOR Engine protection
BY-PASS WIREFEEDER W2 temperature
DC BUS VOLTAGE WELD
FOUR POLE 1800 RPM ALTERNATOR circuit. Lamp test

PC BOARD FILTER YELLOW ENG. YELLOW shutdown

Located on back of VOLTMETER LEFT CHOKE 90+/-10VDC @ HI IDLE W3 WINDINGS ALT.
LED PROT. LED TEMPERATURE
21 PWM Signal to Chopper CAPACITORS (4) W3 and 30second
output panel 208 POLARITY delay onengine
SWITCH 15 volt @ 20 kHz No alternator Temperature Switch
between terminals start.
208A IGBT (8) B1 B4 output shutdown (SIMPLIFIED closes on high SWITCH SENDER
B3 C E
NEGATIVE W4 W5 (fan belt breakage) BOARD temperature. 500-600 OHMS COLD
B6 W4 W5 SCHEMATIC) 50-100 OHMS HOT
OUTPUT RIGHT CHOKE 239 (J32-8)
TERMINAL Chokes are mounted on
power module assembly B7 B8 GATE SIGNAL 405A (J31-12) +12 VOLTS RUN
41 +10 Volts
Open Circuit Volts: behind output terminal panel. Field capacitor and diode bridge
14A 13A 405 (J31-11)
Max Min 42 VOLT AC ROTOR FIELD located on lower rear of fan baffle
CC 58 58 WIRE FEEDER SLIP RINGS on right side of machine.
CV 58 POWER 403 (J31-3)
58 (J31-4) 232F
Pipe 58 26 200
Tig 12 12 42 200A 271 (J32-7)
Power Supply +
to Control 160 VDC
3 3200uf 270 (J31-8) +20Volts from pull
14 13 Board
300vdc coil board
(J31-6) 262A
120 V AC
TWISTED TWISTED TWISTED TWISTED AC AUX. 201
PAIR PAIR PAIR PAIR POWER
240 V AC 5 REVOLVING FIELD
23A(J3-12)
25A(J3-11)
23 (J3-10)
25 (J3-9)
13 (J3-8)
14 (J3-16)
RESISTANCE APPROX.
204S (J6-1) 5A (J31-9) 5T
25 OHMS @ 75F
206S (J6-2) 120 V AC
ARC VOLTAGE FEEDBACK SIGNAL

208B (J3-15) Control board common is
at welder positive output 6A
10 V 120 VOLT AC
77 (J7-1) and shunt
OUTPUT POWER FOR
0-10 V
CONTROL 10K R1 76 (J7-4) ROTOR FIELD CIRCUIT PULL COIL Located on lower left
2A (TO AMPHENOL) (SIMPLIFIED BOARD
0V
WELDCONTROL 15 V
6 side of control
75 (J7-5) (J1-4) 2 5H PCBOARD compartment
SCHEMATIC)
PCBOARD WELD TERM. SW.
10 V P/N G4107-1 (J1-3) 4
77A (J1-11) 0V (TO AMPHENOL) 232N (B2) HOUR
4A Voltage
(TO AMPHENOL) REMOTE -15 V (W/O POT.)
76A (J1-14) Regulators
METER
+ _
CONTROL 10K
0V 75A (J1-10) Located on back of (J7-9) 214 CV
control panel. PIPE
(J7-14) 218
MODE +10 Volts

279 (J7-6) CC
ARC (SEE SHEET 2 FOR SWITCH
(J7-15) 220 TIG +20 Volts
CONTROL 10K R2 278 (J7-7) SIMPLIFIED +12 VOLTS RUN
CONTROL BOARD (J7-16) 222
277 (J7-8) SCHEMATIC)
260 (J3-4)
+12V FROM RUN/STOP SWITCH SHUT DOWN SHUT DOWN
Jumpers replace idle torroid 260 (J3-3) (J2-6) 232D 270 (J43-6) PULL COIL HOLD COIL
and idle selector switch. 256 (J3-7)
271 (J43-4) 265 (B3)
256 (J3-14) +12 VOLTS RUN 403 (J43-7)
0.2 OHM 11 OHMS
250 (J3-5) 405 (J43-5)
(J1-5) 500
Jumper required for output. 250 (J3-1)
(J1-13) 500
5G (J2-3) 3/4 Second
Control board circuits associated with J2 are part (J4-1 to 10) (J5-1 to 10) Timer 5S (B4)
of engine electrical system and are common to 500 I.D. JUMPER (Part 232D RUN-STOP SWITCH ALTERNATOR FLASHING 281 (J43-2)
frame ground (negative battery terminal. WELD AMMETER WELD VOLTMETER of amphenol plug and SHOWN IN RUN POS. ROTOR FLASHING 200 (J43-3)
lead assembly.) 236B
Meters display setpoint volts or amps when not welding.
Meters display actual volts and amps when welding. CB 15A
Hold function displays actual volts and amps for
approximately 5 seconds after welding stops.
During this hold display the right most decimal point will 236A 238B
blink.
232H START BUTTON SWITCH
J 31
115VAC Rotor Flashing: +12 volts
A 32
@ 0.5 amps
I 41A 238A until generator builds up
42VAC SENSE EXC. 231
K 42A then +160 volts @ 0 amps.
WORK H 21 238
A 77B POS NEG
REMOTE E 77A
CONTROL B 76B REMOTE 77B ENGINE
ALTERNATOR
+ LEAD COLOR CODE: COMPONENT VALUE UNITS:
75B
CONTROL F 76A
76B
C 75A INPUT TO B-BLACK OR GRAY CAPACITOR: MFD/VOLTS
G 75B ENGINE
D 2B CONTACTOR AMPHENOL + G-GREEN RESISTOR: OHMS/WATTS
D 4A STARTER O-ORANGE
E 4B 4B Battery voltage:
C 2A 12 VOLT SOLENOID R-RED OR PINK
GROUND F GND-B 2B 12.6 volts at rest CONNECTOR PIN NUMBERS:
GROUND B GND-A
14 volts engine BATTERY U-BLUE
W-WHITE EX. 12 PINCONNECTOR
running ENGINE
AMPHENOL AMPHENOL Y-YELLOW

STARTER 1 2 6
FRAME LABELS:
GROUND
COMMON
7 12
FRAME GROUND LATCH
EARTH GROUND VIEWOF CONNECTORONPCBOARD
PROPRIETARY & CONFIDENTIAL: THIS DOCUMENT CONTAINS PROPRIETARY INFORMATION OWNED BY LINCOLN GLOBAL, INC. AND MAY NOT BE DUPLICATED, COMMUNICATED
TO OTHER PARTIES OR USED FOR ANY PURPOSE WITHOUT THE EXPRESS WRITTEN PERMISSION OF LINCOLN GLOBAL, INC.
DESIGN INFORMATION REFERENCE:
THE INFORMATION ON THIS
PRINT IS FOR REFERENCE
EQUIPMENT TYPE: VANTAGE500 (DEUTZ) 2
1 OF ___
PAGE ___
DRAWN BY: bmuter Reference DOCUMENT DOCUMENT
ONLY. COMPONENTS AND
CIRCUITRY MAY BE DIFFERENT ENGINEER: SCALE:
SUBJECT: MACHINESCHEMATIC NUMBER: REVISION:
FROM AN ACTUAL MACHINE. APPROVED: NONE

MATERIAL
DISPOSITION:
UF APPROVAL
DATE: 03/19/2003
PROJECT
NUMBER:
CRM35043 G4363 A
NOTE: This diagram is for reference only. It may not be accurate for all machines covered by this manual.
vaNTaGE 500
SchEmaTic - cOmpLETE machiNE - G4363 (cODE 10995 DEuTz) paGE 2

MANUFACTURER: No
SIMPLIFIEDCONTROL BOARDSCHEMATIC
+15V
TRANSFORMER
+5V
+3.3V
WELDING + J3-8
TERMINAL +15V CONTROL BOARD
POWERFROM 40-100VDC
CONTROL (2)
J1-4 INPUT
SWITCH CHOPPERBOARD
SHOWN IN "ALWAYS (4) 2-4 SENSE - J3-16 -15V
+12VISOLATEDCIRCUITRYFORENGINEFUNCTIONS
ON" POSITION J1-3
+ STUD
+15V COM Circuits associated with connector J2
+ STUD not used on Deutz engine models
FRAME IS COMMON FOR

FRAME ENGINE CONTROL CIRCUITS
+15V
CURRENT LIMITS
J1-13 REGULATION MODE

J1-12
MACHINE IDENTITY TABLE: MACH SEL 1 ON / OFF (+5V=ON)
J1-8 J4-1
PINS JUMPERED TO SELECT MACHINE HOLD (+5V=HOLD)
J1-5 J1-6 J1-7 J1-8 MACHINE J4-2
RANGER 250 G&D J1-7 MACH SEL 2 MACHINE/ J4-3
J1-13 RANGER 305 G&D
J1-13 VANTAGE 500
MACH SEL 3
MODE BLINK (PULLED LOW AND HIGH J4-4
J1-6 IN LOOKBACK TO FLASH J4-5
J1-13
J1-13
VANTAGE 575
AIR VANTAGE 500
LOGIC DECIMAL POINT)
J4-6 AMMETER
J1-5 MACH SEL 4 (CPU) J4-7 DISPLAY
J4-8
+15V
J4-9 METER (+) INPUT (0 - 2V) 1V = 1000 ON METER
+ STUD
J7-16 J4-10 METER (-) INPUT
+ STUD METERSOPTIONAL ONVANTAGE

TIG MODE
J7-15 ON / OFF (+5V=ON) NOJ4 ORJ5 ONRANGER250
J5-1
HOLD(+5V=HOLD)
TIG PIPE MODE J5-2
J7-14 (NOT AVAILABLE ON AUSTRALIAN
4 VANTAGE 575) J5-3
CC N/A J5-4
MODE J7-13 BLINK (PULLED LOW AND HIGH
3 IN LOOKBACK TO FLASH
SELECTOR J5-5
DECIMAL POINT)
SWITCH A J5-6
(AUSTRAILIAN J7-12
N/A VOLTMETER
VANTAGE 575 USES A J5-7 DISPLAY
3 POSITION TOGGLE 2
SWITCH) N/A J5-8
PIPE J7-11
1 J5-9 METER (+) INPUT (0 - 2V) 1V = 100.0 ON METER
CV CV MODE J5-10 METER (-) INPUT
J7-9
+ STUD
CURRENT
SELECT CONTROL POINT LIMITS,
ROCV ENABLE
J7-10 (FOR AUSTRALIAN VANTAGE 575) CURRENT FEEDBACK AVERAGE,
+15V ABSOLUTE,
CURRENTFEEDBACK DISPLAY WELD AMPS & FOLDBACK
J7-2
+
+ STUD
+STUD G4107
(ONLY)
PRESET DISPLAY
PRESET
(206S) J6-2 - VALUE
- G4109
VOLTAGE
(ONLY) + CURRENTFEEDBACK
SHUNT 50mV = 400 AMPS 47.5 ohms FEEDBACK
#1
x80 47.5 ohm
+ (204S)
DISPLAY WELD VOLTS PWM SIGNAL (+12V ON MULTIMETER) CHOPPER
J6-1 FEEDBACK J3-9
+ STUD is COMMON BOARD
+ STUD FOR WELD CONTROL PWM 47.5 ohm
PWM SIGNAL (+12V)
J3-11 (ALL MACHINES)
CHOPPER
-
CIRCUITS
(208B) REGULATING
VOLTAGE FEEDBACK
- STUD J3-15 AMPLIFIER
CONTROL 47.5 ohm
PWM COMMON
CONTROL POINT J3-10
#2
CIRCUIT 47.5 ohm CHOPPER
+5V +5V PWM COMMON
J3-12
+ STUD BOARD
+ STUD
(277) (VANTAGE ONLY)
J7-8 + STUD
(278) ARC
10K J7-7
ARCCONTROL POT
CONTROL
CIRCUITRY
(279)
J7-6
+10V
+ STUD + STUD
OCV
(77)
J7-1 TOUCH START
VARIABLE PINCH
OUTPUT 10K (76)
CONTROL POT J7-4 PIPE ARC FORCE CONTROL
VARIABLE ARC FORCE POINT
(75)
J7-5 LOCAL SELECT SEESPECIFICMACHINESCHEMATICFORDETAILSON
FIXED ARC FORCE
THE TOP END OF THE REMOTE POT IN WHATPARTSOF THEG4107/G4109 AREUSED INEACH LEAD COLOR CODE: COMPONENT VALUE UNITS:
TIG MODE IS THE SETTING OF THE LOCAL PRESET PRESET CONNECTORS
OUTPUT CONTROL POT. APPLICATION. NOT ALL CIRCUITSAREUSEDALL THETIME. B-BLACK CAPACITOR: MFD/VOLTS
+ STUD
TIG MODE +10V
FIXED HOT START J1 AMPHENOL &MACHINEIDJUMPER G-GREEN
IN EVERY OTHER MODE, THE REMOTE
REMOTE +5V O-ORANGE RESISTOR: OHMS/WATTS
POT WILL SET MACHINE TO MAX OUTPUT. J2 ENGINE12VCONTROL FUNCTIONS
(77B) R-RED
J1-11 J3 CHOPPERPWM, POWERIN, (THERMAL OVERLOADIFUSED), VOLTAGEFEEDBACK U-BLUE CONNECTOR PIN NUMBERS:
J4 AMMETER (NOCONNECTORONRANGER250)
+ STUD W-WHITE EX. 12 PIN CONNECTOR

REMOTE 10K (76B) ALL OTHER MODES J5 VOLTMETER (NOCONNECTORONRANGER250) Y-YELLOW
J1-14 1 2 6
CONTROL POT J6 SHUNT/CURRENTFEEDBACK LABELS:
J7 OUTPUTCONTROL, ARCFORCE, MODESELECT COMMON
(75B)
J1-10 7 12
FRAME GROUND LATCH
EARTH GROUND VIEW OF CONNECTOR ON PC BOARD
+ STUD + STUD
EQUIPMENT TYPE: VANTAGE500 (DEUTZ) 2
2 OF ___
PAGE ___
ONLY. COMPONENTS AND SUBJECT: MACHINESCHEMATIC NUMBER: REVISION:
EN-170

MATERIAL
DISPOSITION:
UF APPROVAL
DATE: 03/19/2003
PROJECT
NUMBER:
CRM35043 G4363 A
vaNTaGE 500
SchEmaTic - cOmpLETE machiNE - G4442 (cODE 10996 cummiNS) paGE1

MANUFACTURER: No
+12 VOLTS RUN
OIL
LEFT CHOPPER PC BOARD IGBT'S, FLYBACK DIODES AND FUEL PRESS. TEMP.
R4 is located on top of p/n L11845-1
chopper power module FILTER CAPACITORS ARE INTEGRAL
assembly. TO CHOPPER MODULES AND NOT 4 1 4 1 4 1
FUEL LVL.
+COM INDIVIDUALLY REPLACEABLE.
SENSOR
B2 B5 Chopper modules are located on power
10,000uF x4 229
module assembly behind output terminal Rectifier is located on power module
panel. assembly behind output control panel. 241
+ 5J 230 OHMS EMPTY
R4
DIODES (6) RIGHT CHOPPPPER PC BOARD
p/n L11845-1 THREE PHASE Oil Pressure Switch
POSITIVE 50MV=400 AMPS +COM PERIPHERAL Located on rear
IGBT (8) W1 W6 OIL PRESSURE
OUTPUT of control panel
B3 C E B1 W1 W6 PCBOARD left side.
B2 B5 (J32-6) 234
TERMINAL 204S CURRENT LEVEL B6 B4 10,000uF x4 247 (J32-1)
Low oil SWITCH SENDER
206S FEED BACK SIGNAL pressure or
206B +
206A B7 B8 GATE SIGNAL FLYBACK high
DIODES (6) W2 STATOR Engine protection
BY-PASS WIREFEEDER W2 temperature
DC BUS VOLTAGE WELD
FOUR POLE 1800 RPM ALTERNATOR circuit. Lamp test

PC BOARD FILTER ENG. YELLOW shutdown

Located on back of VOLTMETER LEFT CHOKE 90+/-10VDC @ HI IDLE W3 WINDINGS PROT. LED TEMPERATURE
21 PWM Signal to Chopper CAPACITORS (4) W3 and 30second
output panel 208 POLARITY delay onengine
SWITCH 15 volt @ 20 kHz Temperature Switch
208A IGBT (8) B1 B4 (SIMPLIFIED closes on high SWITCH SENDER
B3 C E
NEGATIVE W4 W5 BOARD temperature. 500-600 OHMS COLD
B6 W4 W5 SCHEMATIC) 50-100 OHMS HOT
OUTPUT RIGHT CHOKE 405B (J32-8)
41 +10 Volts
Open Circuit Volts: behind output terminal panel. Field capacitor and diode bridge
14A 13A 405 (J31-11)
Max Min 42 VOLT AC ROTOR FIELD located on lower rear of fan baffle
CC 58 58 WIRE FEEDER SLIP RINGS on right side of machine.
CV 58 POWER 403 (J31-3)
58 (J31-4) 232F
Pipe 58 26 200
Tig 12 12 42 200A 271 (J32-7)
Power Supply +
to Control 160 VDC
3 3200uf 270 (J31-8) +20Volts from pull
14 13 Board
300vdc coil board
(J31-6) 262A
120 V AC
TWISTED TWISTED TWISTED TWISTED AC AUX. 201
PAIR PAIR PAIR PAIR POWER
240 V AC 5 REVOLVING FIELD
23A(J3-12)
25A(J3-11)
23 (J3-10)
25 (J3-9)
13 (J3-8)
14 (J3-16)
RESISTANCE APPROX.
204S (J6-1) 5A (J31-9) 5T
25 OHMS @ 75F
206S (J6-2) 120 V AC
+15V @ LOW IDLE TO PULL COIL BOARD
ARC VOLTAGE FEEDBACK SIGNAL (J2-4) 404
208B (J3-15) Control board common is
at welder positive output 6A
10 V LOW IDLE SOLENOID HOLD COIL (0V @ LOW IDLE) 120 VOLT AC
77 (J7-1) and shunt (J2-5) 226
OUTPUT POWER FOR
0-10 V
CONTROL 10K R1 76 (J7-4) 0V Swich closed for high idle. ROTOR FIELD CIRCUIT PULL COIL Located on lower left
(J3-14) 257 (SIMPLIFIED BOARD
0V
WELDCONTROL IDLER SWITCH 6 side of control
75 (J7-5) (J3-7) 256 15 V 5H PCBOARD compartment
SCHEMATIC)
PCBOARD
10 V 2A (TO AMPHENOL)
77A (J1-11) P/N G4107-1 15 V 232N (B2) HOUR
(J1-4) 2 Voltage
76A (J1-14)
WELD TERM. SW.
Regulators
METER
(J1-3) 4
+ _
CONTROL 10K 0V
0V Located on back of 4A (TO AMPHENOL)
75A (J1-10)
control panel. +10 Volts
CV
279 (J7-6) (J7-9) 214

PIPE 0.2 OHM 11 OHMS
ARC (SEE SHEET 2 FOR (J7-14) 218 MODE +20 Volts
CC IDLE SOL. IDLE SOL.
CONTROL 10K R2 278 (J7-7) SIMPLIFIED SWITCH +12 VOLTS RUN
CONTROL BOARD TIG PULL COIL HOLD COIL
(J7-15) 220
277 (J7-8) SCHEMATIC) 227 (B1)
TOROID- (J7-16) 222
SENSES AC 260 (J3-4) SHUT DOWN SHUT DOWN
+12V FROM RUN/STOP SWITCH
POWER TO (J2-6) 232D 270 (J43-6) PULL COIL HOLD COIL
ACTIVATE 261 (J3-3)
IDLER 271 (J43-4) 265 (B3)
250 (J3-5) +12 VOLTS RUN 403 (J43-7)
Located on wiring behind 0.2 OHM 11 OHMS
receptacles. 250 (J3-1) (J1-5) 500 405 (J43-5)
Jumper required for output.
(J1-13) 500
5G (J2-3) 3/4 Second
Control board circuits associated with J2 are part (J4-1 to 10) (J5-1 to 10) Timer 5S (B4)
of engine electrical system and are common to 500 I.D. JUMPER (Part 232D RUN-STOP SWITCH 3/4 Second
frame ground (negative battery terminal. WELD AMMETER WELD VOLTMETER of amphenol plug and 404 (J43-8)
SHOWN IN RUN POS. ROTOR FLASHING Timer
lead assembly.) 200 (J43-3)
236B
Meters display setpoint volts or amps when not welding.
Meters display actual volts and amps when welding. CB 15A
Hold function displays actual volts and amps for
approximately 5 seconds after welding stops.
During this hold display the right most decimal point will 236A 238B
blink.
232H START BUTTON SWITCH
J 31 ALT.
YELLOW
115VAC LAMP Rotor Flashing: +12 volts
A 32
@ 0.5 amps
I 41A 238A until generator builds up
42VAC 231
K 42A then +160 volts @ 0 amps.
WORK H 21 238
B
A 77B
E 77A P L
REMOTE COMPONENT VALUE UNITS:
B 76B REMOTE 77B LEAD COLOR CODE:
CONTROL CONTROL F 76A IG
C 75B 76B B-BLACK OR GRAY CAPACITOR: MFD/VOLTS
G 75A INPUT TO
2B CONTACTOR 75B ENGINE ENGINE G-GREEN
D D 4A AMPHENOL + STARTER RESISTOR: OHMS/WATTS
4B ALTERNATOR O-ORANGE
E 4B Battery voltage:
C 2A 12 VOLT SOLENOID R-RED OR PINK
GROUND F GND-B 2B 12.6 volts at rest CONNECTOR PIN NUMBERS:
GROUND B GND-A
14 volts engine BATTERY U-BLUE
running ENGINE
AMPHENOL AMPHENOL Y-YELLOW

STARTER 1 2 6
FRAME LABELS:
GROUND
COMMON
7 12
FRAME GROUND LATCH
EQUIPMENT TYPE: VANTAGE500 (CUMMINS) 2
1 OF ___
PAGE ___

MATERIAL
DISPOSITION:
UF APPROVAL
DATE: 03/20/2003
PROJECT
NUMBER:
CRM35043 G4442 A
vaNTaGE 500
SchEmaTic - cOmpLETE machiNE - G4442 (cODE 10996 cummiNS) paGE 2

MANUFACTURER: No
+15V
TRANSFORMER
J3-3 AUXILLARY
AUXILIARY CURRENT
SENSE SENSE
TOROID +5V
+ STUD +3.3V
WELDING J3-4 + J3-8
POWERFROM 40-100VDC
CONTROL (2)
J1-4 INPUT
SWITCH CHOPPERBOARD
ON" POSITION J1-3
+ STUD (ALL CIRCUITSON CONNECTOR J2) +12V Battery Supply
+15V +15V COM
IDLER J3-7 + STUD
CONTROL IDLE SWITCH SENSE
SHOWN IN "HIGH" POSITION J3-14
IDLE
J2-6 1
IDLE HOLD COIL
SOLENOID
+ STUD
J2-5
FRAME IS COMMON FOR DIODE ONLY ON -E 0 Volts 2 RED HOLD
+15V +15V COM VERSION AND ABOVE Hold Coil COIL
Energized
IDLE CONTROL IDLE CONTROL
3 BLK +12 Volt
THERMAL SHUTDOWN (if used)
+15V
CURRENT LIMITS
4 WHT PULL
TO IDLE PULL COIL BOARD COIL
J1-12 HIGH = PULL TO LOW IDLE
J1-8 J4-1 J2-4
J1-5 J1-6 J1-7 J1-8 MACHINE J4-2 0 Volts
RANGER 250 G&D J1-7 MACH SEL 2 MACHINE/ J4-3 FRAME
Pull Coil
Energized
PULL COIL
J1-13 RANGER 305 G&D
J1-13 VANTAGE 500
MACH SEL 3
+ STUD
BOARD
J1-13
J1-13
VANTAGE 575
AIR VANTAGE 500
J4-6 AMMETER
J2-3
J4-8 FRAME FRAME

+15V
+ STUD

TIG MODE
J5-1
HOLD(+5V=HOLD)
TIG PIPE MODE J5-2
4 VANTAGE 575) J5-3
CC N/A J5-4
SELECTOR J5-5
DECIMAL POINT)
SWITCH A J5-6
(AUSTRAILIAN J7-12
N/A VOLTMETER
3 POSITION TOGGLE 2
SWITCH) N/A J5-8
PIPE J7-11
J7-9
+ STUD
CURRENT
ROCV ENABLE
J7-10 (FOR AUSTRALIAN VANTAGE 575) CURRENT FEEDBACK AVERAGE,
ABSOLUTE,
THERMAL SHUTDOWN
+15V
CURRENTFEEDBACK DISPLAY WELD AMPS & FOLDBACK
J7-2
+
+ STUD
+STUD G4107
(ONLY)
PRESET DISPLAY
PRESET
(206S) J6-2 - VALUE
- G4109
VOLTAGE
(ONLY) + CURRENTFEEDBACK
#1
x80 47.5 ohm
+ (204S)
J6-1 FEEDBACK J3-9
PWM SIGNAL (+12V)
CHOPPER
-
CIRCUITS
(208B) REGULATING
VOLTAGE FEEDBACK
CONTROL 47.5 ohm
PWM COMMON
CONTROL POINT J3-10
#2
+5V +5V PWM COMMON
J3-12
+ STUD BOARD
+ STUD
J7-8 + STUD
(278) ARC
10K J7-7
ARCCONTROL POT
CONTROL
CIRCUITRY
(279)
J7-6
+10V
+ STUD + STUD
OCV
(77)
J7-1 TOUCH START
VARIABLE PINCH
OUTPUT 10K (76)
(75)
FIXED ARC FORCE
THE TOP END OF THE REMOTE POT IN WHATPARTSOF THEG4107/G4109 AREUSED INEACH LEAD COLOR CODE: COMPONENT VALUE UNITS:
TIG MODE IS THE SETTING OF THE LOCAL PRESET PRESET CONNECTORS
OUTPUT CONTROL POT. APPLICATION. NOT ALL CIRCUITSAREUSEDALL THETIME. B-BLACK CAPACITOR: MFD/VOLTS
+ STUD
TIG MODE +10V
FIXED HOT START J1 AMPHENOL &MACHINEIDJUMPER G-GREEN
REMOTE +5V O-ORANGE RESISTOR: OHMS/WATTS
POT WILL SET MACHINE TO MAX OUTPUT. J2 ENGINE12VCONTROL FUNCTIONS
(77B) R-RED
J1-11 J3 CHOPPERPWM, POWERIN, (THERMAL OVERLOADIFUSED), VOLTAGEFEEDBACK U-BLUE CONNECTOR PIN NUMBERS:
J4 AMMETER (NOCONNECTORONRANGER250)
+ STUD W-WHITE EX. 12 PIN CONNECTOR

J1-14 1 2 6
J7 OUTPUTCONTROL, ARCFORCE, MODESELECT COMMON
(75B)
J1-10 7 12
FRAME GROUND LATCH
EARTH GROUND VIEW OF CONNECTOR ON PC BOARD
+ STUD + STUD
EQUIPMENT TYPE: VANTAGE500 (CUMMINS) 2
2 OF ___
PAGE ___

MATERIAL
DISPOSITION:
UF APPROVAL
DATE: 03/20/2003
PROJECT
NUMBER:
CRM35043 G4442 A
vaNTaGE 500
SchEmaTic - cOmpLETE machiNE - G4848 (cODES 11180, 11415 & 11468 DEuTz) paGE 1
G4848 ENGINEERING CONTROLLED CHANGE DETAIL: Released A.01 from X

MANUFACTURER: No
+12 VOLTS RUN
OIL
IGBT'S, FLYBACK DIODES AND FUEL PRESS. TEMP.
LEFT CHOPPER PC BOARD p/n L11845-1
FILTER CAPACITORS ARE INTEGRAL Located in top of fuel tank
R4 is located on top of TO CHOPPER MODULES AND NOT 4 1 4 1 4 1
FUEL LVL.
chopper power module +COM INDIVIDUALLY REPLACEABLE.
SENSOR
assembly. Located in engine block
B2 B5 10,000uF x4 Right side, rear
229
Chopper modules are located on power Rectifier is located on power module
assembly behind output control panel. 241
+ module assembly behind output terminal 5J 230 OHMS EMPTY
R4 panel.
DIODES (6)
RIGHT CHOPPPPER PC BOARD p/n L11845-1 THREE PHASE Oil Pressure Switch
POSITIVE 50MV=400 AMPS +COM Located on front panel PERIPHERAL Located on rear
IGBT (8) W1 W6 of control panel OIL PRESSURE
OUTPUT B3 C E B1 W1 W6 PCBOARD left side.
B2 B5 239 (J32-8) (J32-6) 234
TERMINAL 204S
CURRENT LEVEL B6 B4 10,000uF x4
243 (J32-4)
FEED BACK SIGNAL Low oil SWITCH SENDER
206S pressure or
206B B8 +
206A B7 GATE SIGNAL FLYBACK high
DIODES (6) W2 STATOR 247 (J32-1) Engine protection
WIREFEEDER W2 temperature
BY-PASS DC BUS VOLTAGE WELD FOUR POLE 1800 RPM ALTERNATOR circuit. Lamp test
VOLTMETER LEFT CHOKE FILTER W3 shutdown TEMPERATURE
Located on back of PC BOARD 21 90+/-10VDC @ HI IDLE W3 WINDINGS and 30second
POLARITY PWM Signal to Chopper CAPACITORS (4)
output panel delay onengine
208 SWITCH 15 volt @ 20 kHz Temperature Switch
208A IGBT (8) B1 B4 (SIMPLIFIED closes on high SWITCH SENDER
B3 E
NEGATIVE C W4 W5 BOARD temperature. 500-600 OHMS COLD

YELLOW
ALT. ENG. YELLOW
B6 W4 W5 LED PROT. LED SCHEMATIC) 50-100 OHMS HOT
OUTPUT RIGHT CHOKE
Located in engine thermostat housing
behind output terminal panel. Field capacitor and diode bridge +10 Volts
Open Circuit Volts: 41 405 (J31-11)
14A 13A located on lower rear of fan baffle
Max Min ROTOR FIELD on right side of machine.
CC 58 58 42 VOLT AC
58 WIRE FEEDER SLIP RINGS
CV 58 200 (J31-4) 232F
Pipe 58 26 POWER
Tig 12 12 200A
271 (J32-7)
Power Supply 42 +
to Control 160 VDC 270 (J31-8) +20Volts from pull
Board 3 3200uf
14 13 coil board
300vdc (J31-6) 262A
6 5H
201
5
4 REVOLVING FIELD
TWISTED TWISTED TWISTED TWISTED AC AUX. POWER RESISTANCE APPROX.
3 TO 5 - 120 VAC 1 PHASE 5A (J31-9) 5T
PAIR PAIR PAIR PAIR 25 OHMS @ 75F
6A TO 5 -120 VAC 1 PHASE
3 TO 6A - 240 VAC 1 PHASE 120 VOLT AC
23A(J3-12)
25A(J3-11)
23 (J3-10)
25 (J3-9)
13 (J3-8)
14 (J3-16)
3, 4 AND 6A - 240 VAC 3 PHASE POWER FOR
204S (J6-1) 6A ROTOR FIELD CIRCUIT
206S (J6-2) 6
ARC VOLTAGE FEEDBACK SIGNAL 5H
208B (J3-15) Control board common is (J2-4) 404 +15V @ LOW IDLE TO PULL COIL BOARD PULL COIL Located on lower left
(SIMPLIFIED BOARD
at welder positive output side of control
10 V
77 (J7-1) and shunt (J2-5) 226
LOW IDLE SOLENOID HOLD COIL (0V @ LOW IDLE) PCBOARD compartment
SCHEMATIC)
OUTPUT 0-10 V
CONTROL 10K R1 76 (J7-4)
(J3-14) 257
0V Swich closed for high idle.
Voltage
232N (B2) HOUR
0V
WELDCONTROL IDLER SWITCH METER
75 (J7-5) (J3-7) 256 15 V Regulators
10 V
PCBOARD
2A (TO AMPHENOL) + _
77A (J1-11) P/N G4107-1 15 V +20 Volts +10 Volts
(J1-4) 2
76A (J1-14)
WELD TERM. SW. J54-1 J55-3
CONTROL 10K (J1-3) 4 0.2 OHM 11 OHMS
0V (TO AMPHENOL)
0V Located on back of 4A IDLE SOL. IDLE SOL.
75A (J1-10) PULL COIL J55-2
control panel. J55-4 HOLD COIL
CV
(J7-9) 214
279 (J7-6) PIPE 227 (B1)

ARC (SEE SHEET 2 FOR (J7-14) 218 MODE 270 (J43-6)
CC
CONTROL 10K R2 278 (J7-7) SIMPLIFIED SWITCH +12 VOLTS RUN 271 (J43-4)
CONTROL BOARD (J7-15) 220 TIG SHUT DOWN COIL J54-2
277 (J7-8) 405 (J43-5)
SCHEMATIC)
TOROID- (J7-16) 222 281 (J43-2)
SENSES AC FIELD FLASHING ALTERNATOR
260 (J3-4) +12V FROM RUN/STOP SWITCH 3.5 OHMS
POWER TO (J2-6) 232D
ACTIVATE 261 (J3-3) +12 VOLTS RUN
IDLER
250 (J3-5) Solenoids located on right front of engine
Located on wiring behind RUN-STOP SWITCH
receptacles. 250 (J3-1) (J1-5) 500 SHOWN IN RUN POS. 5S (B4)
Jumper required for output. 236B Located on front panel 404 (J43-8) 3/4 Second Timer
(J1-13) 500 ROTOR FLASHING
5G (J2-3) CB 15A 200 (J43-3)
Control board circuits associated with J2 are part (J4-1 to 10) (J5-1 to 10)
232D
of engine electrical system and are common to 500 I.D. JUMPER (Part
frame ground (negative battery terminal. WELD AMMETER WELD VOLTMETER of amphenol plug and 236A 238B
lead assembly.) D+ W
Meters display setpoint volts or amps when not welding. 232H
ALTERNATOR START BUTTON SWITCH
Meters display actual volts and amps when welding. B+ B-
Hold function displays actual volts and amps for Rotor Flashing: +12 volts
approximately 5 seconds after welding stops. Located inside engine blower housing LOCKOUT @ 0.5 amps
During this hold display the right most decimal point will blink. SWITCH 238A until generator builds up
231
then +160 volts @ 0 amps.
115VAC
J 31
A 32
41A ENGINE
I
42VAC STARTER
K 42A SOLENOID
WORK H 21 Battery voltage:
A 77B
E 77A 12.6 volts at rest
REMOTE ENGINE
CONTROL B 76B REMOTE 77B 14 volts engine LEAD COLOR CODE: COMPONENT VALUE UNITS:
CONTROL F 76A STARTER
75B 76B running
C 75A INPUT TO B-BLACK OR GRAY CAPACITOR: MFD/VOLTS
G 75B
D 2B CONTACTOR AMPHENOL G-GREEN
D 4A
+ RESISTOR: OHMS/WATTS
E 4B 4B O-ORANGE
C 2A
GROUND F GND-B 2B 12 VOLT R-RED OR PINK CONNECTOR PIN NUMBERS:
GROUND B GND-A
U-BLUE
BATTERY
AMPHENOL
AMPHENOL Y-YELLOW 1 2 6
FRAME LABELS:
GROUND
COMMON
7 12
FRAME GROUND LATCH
THIS DOCUMENT CONTAINS PROPRIETARY INFORMATION OWNED BY LINCOLN GLOBAL, INC. AND MAY NOT BE DUPLICATED, COMMUNICATED
PROPRIETARY & CONFIDENTIAL: TO OTHER PARTIES OR USED FOR ANY PURPOSE WITHOUT THE EXPRESS WRITTEN PERMISSION OF LINCOLN GLOBAL, INC.
MANUFACTURING TOLERANCE PER E2056
UNLESS OTHERWISE SPECIFIED TOLERANCE: DESIGN INFORMATION REFERENCE:
ON 2 PLACE DECIMALS IS .02
EQUIPMENT TYPE: VANTAGE 500 DEUTZ 2
1 OF ___
PAGE ___
ON 3 PLACE DECIMALS IS .002 DRAWN BY: B. MUTER G4487 DOCUMENT DOCUMENT
ON ALL ANGLES IS .5 OF A DEGREE
MATERIAL TOLERANCE (" t ") TO AGREE ENGINEER: N.S. SCALE:
SUBJECT: MACHINE SCHEMATIC NUMBER: REVISION:
WITH PUBLISHED STANDARDS.

DO NOT SCALE THIS DRAWING APPROVED: NONE
MATERIAL
DISPOSITION: UF APPROVAL
DATE:
08/03/2004 PROJECT
NUMBER: CRM36466 G4848 A
vaNTaGE 500
SchEmaTic - cOmpLETE machiNE - G4848 (cODES 11180, 11415 & 11468 DEuTz) paGE 2
G4848 ENGINEERING CONTROLLED CHANGE DETAIL: Released A.01 from X

MANUFACTURER: No
AUXILIARY
SENSE +15V
TOROID
TRANSFORMER
J3-3 AUXILLARY
CURRENT
SENSE +5V
+ STUD +3.3V
WELDING J3-4 + J3-8
POWERFROM 40-100VDC
CONTROL (2)
J1-4 INPUT
SWITCH CHOPPERBOARD
ON" POSITION J1-3
+ STUD (ALL CIRCUITS ON CONNECTOR J2) +12V Battery Supply
+15V +15V COM
IDLER J3-7 + STUD
CONTROL IDLE SWITCH SENSE
SHOWN IN "HIGH" POSITION J3-14
IDLE
J2-6 1
IDLE HOLD COIL
SOLENOID
+ STUD
J2-5
FRAME IS COMMON FOR DIODE ONLY ON -E 0 Volts 2 RED HOLD
+15V +15V COM VERSION AND ABOVE Hold Coil COIL
Energized
IDLE CONTROL IDLE CONTROL
3 BLK +12 Volt
THERMAL SHUTDOWN (if used)
+15V
CURRENT LIMITS
4 PULL
WHT

TO IDLE PULL COIL BOARD COIL
J1-12 HIGH = PULL TO LOW IDLE
J1-8 J4-1 J2-4
J1-5 J1-6 J1-7 J1-8 MACHINE J4-2 0 Volts
RANGER 250 G&D J1-7 MACH SEL 2 MACHINE/ J4-3 FRAME
Pull Coil
Energized
PULL COIL
J1-13 RANGER 305 G&D BOARD
J1-13 VANTAGE 500
MACH SEL 3
+ STUD
J1-13
J1-13
VANTAGE 575
AIR VANTAGE 500
J4-6 AMMETER
J2-3
J4-8 FRAME FRAME

+15V
+ STUD

TIG MODE
J5-1
HOLD(+5V=HOLD)
TIG PIPE MODE J5-2
4 VANTAGE 575) J5-3
CC N/A J5-4
SELECTOR J5-5
DECIMAL POINT)
SWITCH A J5-6
(AUSTRAILIAN J7-12
N/A VOLTMETER
3 POSITION TOGGLE 2
SWITCH) N/A J5-8
PIPE J7-11
J7-9
+ STUD
CURRENT
ROCV ENABLE
J7-10 (FOR AUSTRALIAN VANTAGE 575) CURRENTFEEDBACK AVERAGE,
ABSOLUTE,
THERMALSHUTDOWN
+15V
CURRENT FEEDBACK DISPLAY WELD AMPS & FOLDBACK
J7-2
+
+ STUD
+STUD
G4107
(ONLY)
PRESET DISPLAY
PRESET
(206S) J6-2 - VALUE
- G4109
VOLTAGE
(ONLY) + CURRENT FEEDBACK
#1
x80
47.5 ohm
+ (204S)
J6-1 FEEDBACK J3-9
PWM SIGNAL (+12V)
CHOPPER
-
CIRCUITS
(208B) REGULATING
VOLTAGE FEEDBACK
CONTROL 47.5 ohm
PWM COMMON
CONTROL POINT J3-10
#2
+5V +5V PWM COMMON
J3-12
+ STUD BOARD
+ STUD
J7-8 + STUD
(278) ARC
10K J7-7
ARCCONTROL POT
CONTROL
CIRCUITRY
(279)
J7-6
+10V
+ STUD + STUD
OCV
(77)
J7-1 TOUCH START
VARIABLE PINCH
OUTPUT 10K (76)
(75)
FIXED ARC FORCE LEAD COLOR CODE: COMPONENT VALUE UNITS:
THE TOP END OF THE REMOTE POT IN WHAT PARTSOFTHEG4107/G4109 AREUSED INEACH
TIG MODE IS THE SETTING OF THE LOCAL PRESET PRESET B-BLACK CAPACITOR: MFD/VOLTS
OUTPUT CONTROL POT.
CONNECTORS APPLICATION. NOTALL CIRCUITSAREUSEDALL THETIME. G-GREEN
+ STUD
TIG MODE +10V
FIXED HOT START J1 AMPHENOL &MACHINEIDJUMPER O-ORANGE RESISTOR: OHMS/WATTS
POT WILL SET MACHINE TO MAX OUTPUT.
REMOTE +5V J2 ENGINE12VCONTROL FUNCTIONS R-RED
(77B) J3 CHOPPERPWM, POWERIN, (THERMAL OVERLOADIFUSED), VOLTAGEFEEDBACK CONNECTOR PIN NUMBERS:
J1-11 U-BLUE
+ STUD J4 AMMETER (NOCONNECTORONRANGER250) W-WHITE EX. 12 PINCONNECTOR

J1-14 1 2 6
J7 OUTPUTCONTROL, ARCFORCE, MODESELECT
(75B) COMMON
J1-10 7 12
FRAME GROUND LATCH

+ STUD + STUD
PROPRIETARY & CONFIDENTIAL: TO OTHER PARTIES OR USED FOR ANY PURPOSE WITHOUT THE EXPRESS WRITTEN PERMISSION OF LINCOLN GLOBAL, INC.
MANUFACTURING TOLERANCE PER E2056
UNLESS OTHERWISE SPECIFIED TOLERANCE: DESIGN INFORMATION REFERENCE:
ON 2 PLACE DECIMALS IS .02
EQUIPMENT TYPE: VANTAGE 500 DEUTZ 2
2 OF ___
PAGE ___
ON 3 PLACE DECIMALS IS .002 DRAWN BY: B. MUTER G4487 DOCUMENT DOCUMENT
ON ALL ANGLES IS .5 OF A DEGREE
MATERIAL TOLERANCE (" t ") TO AGREE ENGINEER: N.S. SCALE:
SUBJECT: MACHINE SCHEMATIC NUMBER: REVISION:
WITH PUBLISHED STANDARDS.

DO NOT SCALE THIS DRAWING APPROVED: NONE
MATERIAL
DISPOSITION: UF APPROVAL
DATE:
08/03/2004 PROJECT
NUMBER: CRM36466 G4848 A
vaNTaGE 500
SchEmaTic - cOmpLETE machiNE - G4791 (cODES 11181 & 11416 cummiNS) paGE 1
FIRING CIRCUIT TRIGGER CIRCUIT

(ALTERNATE CONNECTION)
204 D14 1A C37 0.022uF
400V R264 DZ4
8.25K 50V
50/25W R262 Q7
10K 1A
R166 J7 A A J7 100V 10V
1A D21 1A 1A
R205
R231
D3 619 D34
1 J8 5W
1.5K
1.5K
R165 1 8 DZ12 DZ13 400V
1000V 1000V 619
15V 15V
R265
9 J5
2.21K
D18 1A
R263
16 J5 1W 1W 4 R144 R145
10K
204 R18 R269 CW
R183
R181
D69 1A 1.5K 5W 1.5K 5W
100K
1000V
1.5K
51 5W 51 5W R90 R98 OCI3
200 200 R285 R286
R44
1000V R267 R268 10K R89 R97 DZ3 CNY17-3 1
C38 C39 200 200 1.5K 5W 1.5K 5W
51 5W 51 5W 2 4 J5
R230
32VAC 0.0047uF 0.05uF R88 R96 GND R37
2K
3000V 600V 200 200 R287 R288
D20 1A R87 R95 700 5W
R195
LED7 D1 SCR1 SCR2 1.5K 5W 1.5K 5W 2
10K
200 200 Q6
D70 1A R270 R271 1A 8A R86 8A R94 DZ2 1A R289 R290 20V
1000V 400V 200 400V 200 DZ1 5W
51 5W 51 5W 400V R85 R93 D31 1A 100V D64 1A D16 1A OCI2
203 15 J5
1000V
R36 R272 .05A D17 1A D11 200 D12 200
400V 301 3 J5 1.5K 5W 1.5K 5W 3023 1 J5 11
0.022uF 0.022uF QU1 D32 1A 400V 5.1V 1000V R233 309
51 5W 51 5W 1000V 1A 400V 1A 400V 20V 2N6027 R162 400V THERMOSTATIC FAN/ 1W
D2 1A C1 C3 D24 SNUBBER PCB 39.2
2 J8 1W 2.67K C32
50V LED1 50V LED2
R252
3.32K
2
R194
1000V DZ9 22uF
33.2
R84 R92 1A 5.1V D22 63V
C5 C6 5.1K
R158
1K .05A 50V C2 1K .05A 50V C4 400V 1A
1W OCI1
10
10
10
10
50/25W C7 5W TO CONTROL BOARD
1000V 1 CNY17-3 5
C8 C9 LED10 2 & 4 CLOSEURE
R140
R136
R138
R142
R141
0.33uF 0.15uF
R135
R137
R139
R182
0.33uF
2 J5
0.022uF
0.022uF
R83
D28 D33
R91
R161
41
267
267
475
150
150
150
150
332K
50V 50V 100V 0.15uF 0.022uF CONTROL SIGINAL
R160
1A
267
100V 50V T.S.2 1A
203 400V 400V 2 6 4 ACTIVATOR
.05A
(ALTERNATE CONNECTION) D27 1A
1 J5
D15 J4 D36
1A J4 41A
1 G1 2 G2 400V
R234
1A GND
100K
400V 400V CHOKE THERMOSTAT
J6 2 N.B.
R232 J5 10 310
39.2
1A C35 0.022uF
206 D35 R260
400V 8.25K 50V
50/25W R258 Q5
10K
R192 B B J7 1A
D42 1A 619 J7 100V
D9 1A R193 2 4
3 J8 1000V 619 DZ11
15V DZ14
2.21K
1000V 15V
R259
R261
D40 1A CW 1W
10K
1W
R199
R201
100K
1.5K
1000V R180
206 7 J5 R64 R275 R173
200 R179
200
D67 1A 51 5W 51 5W R172 200
200 R178
R171 200 GND
R45
1000V R273 R274 10K 200 R177
R227
C40 C41 R170 SCR4 200 Q4
10K
51 5W 51 5W SCR3 200 8A R176 1A
32VAC 0.0047uF
3000V
0.05uF
600V 8A R169
200 400V 200 DZ5 100V
LED8 D41 1A 400V R168 R175 D63 1A
D68 1A D4 200 200 D43 1A
R276 R277 D29 D30
1A 1000V 0.022uF 400V 400V QU2 D44 1A 214 CONNECTED TO R3 30 OHM 100 WATT LATCHING RESISTOR ON DC-600/MULTI-SOURCE
1000V 51 5W 51 5W 400V 0.022uF 1A 400V C13 1A R198 400V
D39 1A C12 2N6027 400V
205 8 J5 R82 R278 .05A
50V LED4 20V
1W D38 2.67K
1000V 50V LED3
R226
R200
51 5W 51 5W R174 14 J5
33.2
475
D8 1A R167 1A 214
4 J8 1K C14
.05A 50V
1K .05A C15 400V
10
10
10
10
1000V C10 50V
C11 C20 C18 C16
R197
R164
R163
R184
R185
R187
R189
0.15uF
R186
R188
R190
R191
0.022uF
332K
R196
267
267
50/25W 0.33uF 0.022uF
150
150
150
150
0.022uF
100V C17 C19
267
50V 0.33uF 0.15uF 50V
R203
50V 100V 0.022uF 0.022uF
LATCHING
150
400V 400V
205 D52 RESISTOR D71
1A D59 ENABLE 3A
400V J4 3 1A J4 4 GND OCI2 1000V
(ALTERNATE CONNECTION) G3 G4
400V 3023 6
J6 1 N.B. SCR7
12A
R217
TP1
39.2
4 400V 130V
R204 90J
100
R218
68
0.75W GND
208 D51 1A C34 0.022uF
R256
400V 8.25K 50V
R254 C30
R241
50/25W
100K
10K Q3
1A 10uF
R240 J7 C C 100V 150V
D6 1A D57 1A 619
5 J7
5 J8 R239 6 DZ10 DZ15
1000V 1000V 619 15V
R255
R257
2.21K
D55 1A 1W
10K
208 5 J5 R116 R281 CW
R244
100K
15V GND
1000V
R242
D65 1A 51 5W 51 5W
1.5K
R225 1W
R46
1000V R279 R280 10K 200 R213 GND

R224 200
R251
C42 51 5W 51 5W C43 R212
10K
200 200
32VAC 0.0047uF
3000V
0.05uF
600V
R223
200 R211 Q2
R229
D58 1A 200 1A
10K
LED9 D7 SCR5 R222 R210 DZ7 100V

D66 1A R282 R283 1A 200 SCR6 200 D62
1000V 8A R221 8A R209 D53 1A
1000V 51 5W 51 5W 400V 400V 200 200
.05A D56 1A R220 400V
207 6 J5 R134 R284 D49 200 R208
200 400V QU3 D54 1A 1A 400V
J5 231
1000V 0.022uF D47 20V 2N6027 R216 13 FIRING SIGNAL
51 5W 51 5W 1A 400V 0.022uF 1W FROM CONTROL BOARD
D5 1A C26 50V 1A 400V 2.67K 400V
6 J8 C23 50V D50 J8
R243
R228
R143 R266 7 MULTI-SOURCE

33.2
475
1000V LED5 LED6 1A OCI3 FIRING ENABLE

R219 400V CNY17-3 5 200 200
GND C29 R207
50/25W 1K .05A 50V C22 C28
R248 10
DZ6
R247 10
1K .05A
R238 10
R237 10
50V C31 5.1V

C21 C24 1W
R246
R245
R206
0.33uF C25 FIRING CIRCUIT

0.022uF
6 4
R249
R214
R202
R250
R215
267
0.15uF
150
150
0.022uF
332K
50V
267
R235
267
0.022uF
150
150
207 0.33uF 100V ENABLE
100
50V 0.15uF 50V R253 Q1
100V 10 4A GENERAL INFORMATION LAST NO. USED
(ALTERNATE CONNECTION) DZ8 C44 100V R- 290 Q-7 LED-10

0.022uF
R159
D60
100K
ELECTRICAL SYMBOLS PER E1537
R236
15V C- 44 QU-3 SCR-7
50V
20K
1A C33 CAPACITORS = MFD ( .022/50V UNLESS OTHERWISE SPECIFIED)
400V J4 J4 1W 0.15uF RESISTORS = Ohms ( 1/4W UNLESS OTHERWISE SPECIFIED) LABELS D- 71 Z-15 OCI-3
5 G5 D61 6 G6 GND 100V
215
1A DIODES = 1A,400V (UNLESS OTHERWISE SPECIFIED)

400V J5 12 TO OUTPUT SUPPLY VOLTAGE NET
RECTIFIER POWER SUPPLY SOURCE POINT
COMMON CONNECTION
J6 3 N.B. FRAME CONNECTION
EARTH GROUND CONNECTION
NOTES: PROPRIETARY & CONFIDENTIAL: TO OTHER PARTIES, OR USED FOR ANY PURPOSE WITHOUT THE EXPRESS WRITTEN PERMISSION OF LINCOLN GLOBAL, INC.
N.A. SINCE COMPONENTS OR CIRCUITRY ON A PRINTED CIRCUIT BOARD MAY CHANGE WITHOUT AFFECTING THE
INTERCHANGEABILITY OF A COMPLETE BOARD, THIS DIAGRAM MAY NOT SHOW THE EXACT COMPONENTS
CIRCUITRY OF CONTROLS HAVING A COMMON CODE NUMBER.
OR
SINCE COMPONENTS OR CIRCUITRY ON A
PRINTED CIRCUIT BOARD MAY CHANGE DESIGN INFORMATION EQUIPMENT TYPE: DC-600 / MULTI-SOURCE PAGE 01 OF 01
WITHOUT AFFECTING THE INTERCHANGE- DRAWN BY: FM 6-17-2008 DOCUMENT DOCUMENT
N.B. J6 IS USED TO CONNECT THE FIRING PCBS IN TWO LIKE MACHINES TO PARELLEL THEIR OUTPUTS.
J7 REMAINS IN THE MASTER FIRING PCB.
ABILITY OF A COMPLETE BOARD, THIS
DIAGRAM MAY NOT SHOW THE EXACT ENGINEER: NGM REFERENCE:
SUBJECT: SCHEMATIC, FIRING PCB NUMBER: REVISION:
NUMBER: CRM39604 G 4791-1A0 A.01
J7 IS REMOVED FROM THE SLAVE FIRING PCB. MATERIAL APPROVAL PROJECT
DISPOSITION: NA DATE:
COMPONENTS OR CIRCUITRY OF CONTROLS
HAVING A COMMON CODE NUMBER. APPROVED: --------- -------
vaNTaGE 500
SchEmaTic - WELD cONTrOL BOarD - G4108 paGE 1
vaNTaGE 500
SchEmaTic - WELD cONTrOL BOarD - G4801-1 paGE 2
vaNTaGE 500
vaNTaGE 500
vaNTaGE 500
SchEmaTic - WELD cONTrOL BOarD - paGE 5
vaNTaGE 500
SchEmaTic - chOppEr pc BOarD - m19792-1
vaNTaGE 500
SchEmaTic - pEriphEraL BOarD - G3663
vaNTaGE 500
SchEmaTic puLL cOiL/BaTTEry BOarD - G4117-1
vaNTaGE 500

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Safety Depends on You

Lincoln arc welding and cutting

Copyright Lincoln Global Inc.

World's Leader in Welding and Cutting Products

CALIFORNIA PROPOSITION 65 WARNINGS

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

idler by pushing on the throttle control rods

ELECTRIC SHOCK can kill. ARC RAYS can burn.

DC Manual (Stick) Welder. hazardous to health. Avoid breathing these

welding procedure and application involved. Worker expo-

5.e. Read and understand the manufacturers instructions for this

5.f. Also see item 1.b.

WELDING and CUTTING CYLINDER may explode

SPARKS can cause fire or if damaged.

electrically hot parts to touch a cylinder.

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

Refer to http://www.lincolnelectric.com/safety for additional safety information.

6. Eloigner les matriaux inflammables ou les recouvrir afin de

prvenir tout risque dincendie d aux tincelles.

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

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

Electromagnetic Compatibility (EMC)

Installation and Use

b) radio and television transmitters and receivers;

c) computer and other control equipment;

d) safety critical equipment, e.g., guarding of industrial equipment;

f) equipment used for calibration or measurement

Electromagnetic Compatibility (EMC)

Methods of Reducing Emissions

Maintenance of the Welding Equipment

Earthing of the Workpiece

Screening and Shielding

RETURN TO MAIN MENU

VANTAGE 500 Deutz F3L912 (Code 10995) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .B1

Theory of Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Section E

Troubleshooting and Repair . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Section F

Electrical Diagrams . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Section G

Parts Lists . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .P-472, P-508

Installation - VANTAGE 500 Deutz F3L912 (Code 10995)

Technical Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .A1.2

Safety Precautions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .A1.3

Angle of Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .A1.3

High Altitude Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .A1.4

High Temperature Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .A1.4

Vehicle Mounting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .A1.4

Pre-Operation Engine Service . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .A1.5

Fuel Cap . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .A1.5

Engine Cooling System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .A1.5

Battery Connection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .A1.5

Muffler Outlet Pipe . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .A1.6

Spark Arrester . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .A1.6

High Frequency Generators for TIG Applications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .A1.6

Electrical Connections . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .A1.6

Remote Control . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .A1.6

Welding Terminals . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .A1.6

Welding Output Cables . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .A1.7

Machine Grounding . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .A1.7

Auxiliary Power Receptacles . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .A1.7

Standby Power Connections . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .A1.7

TECHNICAL SPECIFICATIONS - Vantage 500 DEUTZ (K2271-1)

INPUT - DIESEL ENGINE

Make /Model Description Speed (RPM) Displacement Starting Capacities

RATED OUTPUT @ 104F(40C) - WELDER