Linicolin Welding Machine

Operator’s Manual
VANTAGE ® 500-I
For use with machines having Code Numbers:
11576, 11954, 11961, 12304, 13180
Register your machine: Need Help? Call 1.888.935.3877

www.lincolnelectric.com/register to talk to a Service Representative
Authorized Service and Distributor Locator:
www.lincolnelectric.com/locator Hours of Operation:
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Use “Ask the Experts” at lincolnelectric.com
A Lincoln Service Representative will contact you
Date Purchased no later than the following business day.
For Service outside the USA:

Code: (ex: 10859) Email: [email protected]
Serial: (ex: U1060512345)
IM10003-C | Issue Date Apr-21

© Lincoln Global, Inc. All Rights Reserved.
THANK YOU FOR SELECTING
A QUALITY PRODUCT BY KEEP YOUR HEAD OUT OF THE FUMES.
LINCOLN ELECTRIC. DON’T get too close to the arc.
Use corrective lenses if necessary
to stay a reasonable distance
away from the arc.
READ and obey the Safety Data
PLEASE EXAMINE CARTON AND EQUIPMENT FOR Sheet (SDS) and the warning label
DAMAGE IMMEDIATELY that appears on all containers of
When this equipment is shipped, title passes to the purchaser welding materials.
upon receipt by the carrier. Consequently, claims for material USE ENOUGH VENTILATION or
damaged in shipment must be made by the purchaser against the exhaust at the arc, or both, to
transportation company at the time the shipment is received. keep the fumes and gases from
your breathing zone and the general area.
IN A LARGE ROOM OR OUTDOORS, natural ventilation may be
adequate if you keep your head out of the fumes (See below).
SAFETY DEPENDS ON YOU
USE NATURAL DRAFTS or fans to keep the fumes away
Lincoln arc welding and cutting equipment is designed and built
from your face.
with safety in mind. However, your overall safety can be increased
by proper installation ... and thoughtful operation on your part. If you develop unusual symptoms, see your supervisor.
DO NOT INSTALL, OPERATE OR REPAIR THIS EQUIPMENT Perhaps the welding atmosphere and ventilation system
WITHOUT READING THIS MANUAL AND THE SAFETY should be checked.
PRECAUTIONS CONTAINED THROUGHOUT. And, most importantly,
think before you act and be careful.
WEAR CORRECT EYE, EAR &
BODY PROTECTION
PROTECT your eyes and face with welding helmet
WARNING properly fitted and with proper grade of filter plate
(See ANSI Z49.1).
This statement appears where the information must be followed
exactly to avoid serious personal injury or loss of life. PROTECT your body from welding spatter and arc
flash with protective clothing including woolen
clothing, flame-proof apron and gloves, leather
CAUTION leggings, and high boots.
PROTECT others from splatter, flash, and glare
This statement appears where the information must be followed with protective screens or barriers.
to avoid minor personal injury or damage to this equipment.
IN SOME AREAS, protection from noise may be appropriate.
BE SURE protective equipment is in good condition.
Also, wear safety glasses in work area
AT ALL TIMES.
SPECIAL SITUATIONS
DO NOT WELD OR CUT containers or materials which previously
had been in contact with hazardous substances unless they are
properly cleaned. This is extremely dangerous.
DO NOT WELD OR CUT painted or plated parts unless special
precautions with ventilation have been taken. They can release
highly toxic fumes or gases.
Additional precautionary measures
PROTECT compressed gas cylinders from excessive heat,
mechanical shocks, and arcs; fasten cylinders so they cannot fall.
BE SURE cylinders are never grounded or part of an
electrical circuit.
REMOVE all potential fire hazards from welding area.
ALWAYS HAVE FIRE FIGHTING EQUIPMENT READY FOR
IMMEDIATE USE AND KNOW HOW TO USE IT.
Safety 01 of 04 - 06/15/2016
SAFETY
SECTION A: 1.d. Keep all equipment safety guards, covers

and devices in position and in good repair.
Keep hands, hair, clothing and tools away
WARNINGS from V-belts, gears, fans and all other
moving parts when starting, operating or
repairing equipment.
CALIFORNIA PROPOSITION 65 WARNINGS
Diesel Engines 1.e. In some cases it may be necessary to remove safety guards to
perform required maintenance. Remove guards only when
Diesel engine exhaust and some of its constituents are known necessary and replace them when the maintenance requiring
to the State of California to cause cancer, birth defects, and other their removal is complete. Always use the greatest care when
reproductive harm. working near moving parts.
Gasoline Engines 1.f. Do not put your hands near the engine fan. Do not attempt to
The engine exhaust from this product contains chemicals known override the governor or idler by pushing on the throttle control
to the State of California to cause cancer, birth defects, or other rods while the engine is running.
reproductive harm.
1.g. To prevent accidentally starting gasoline engines while turning
the engine or welding generator during maintenance work,
disconnect the spark plug wires, distributor cap or magneto wire
ARC WELDING CAN BE HAZARDOUS. PROTECT as appropriate.
YOURSELF AND OTHERS FROM POSSIBLE SERIOUS
1.h. To avoid scalding, do not remove the radiator
INJURY OR DEATH. KEEP CHILDREN AWAY. pressure cap when the engine is hot.
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, ELECTRIC AND
P.O. Box 351040, Miami, Florida 33135 or CSA Standard
W117.2-1974. A Free copy of “Arc Welding Safety” booklet MAGNETIC FIELDS MAY
E205 is available from the Lincoln Electric Company, BE DANGEROUS
22801 St. Clair Avenue, Cleveland, Ohio 44117-1199.
BE SURE THAT ALL INSTALLATION, OPERATION, 2.a. Electric current flowing through any conductor
MAINTENANCE AND REPAIR PROCEDURES ARE causes localized Electric and Magnetic Fields (EMF).
PERFORMED ONLY BY QUALIFIED INDIVIDUALS. Welding current creates EMF fields around welding cables
and welding machines
2.b. EMF fields may interfere with some pacemakers, and

welders having a pacemaker should consult their physician
before welding.
FOR ENGINE POWERED 2.c. Exposure to EMF fields in welding may have other health effects
EQUIPMENT. which are now not known.
1.a. Turn the engine off before troubleshooting 2.d. All welders should use the following procedures in order to
and maintenance work unless the minimize exposure to EMF fields from the welding circuit:
maintenance work requires it to be running. 2.d.1. Route the electrode and work cables together - Secure
them with tape when possible.
1.b. Operate engines in open, well-ventilated
2.d.2. Never coil the electrode lead around your body.
areas or vent the engine exhaust fumes outdoors.
2.d.3. Do not place your body between the electrode and work
1.c. Do not add the fuel near an open flame cables. If the electrode cable is on your right side, the
welding arc or when the engine is running. work cable should also be on your right side.
Stop the engine and allow it to cool before 2.d.4. Connect the work cable to the workpiece as close as pos-
refueling to prevent spilled fuel from sible to the area being welded.
vaporizing on contact with hot engine parts
2.d.5. Do not work next to welding power source.
and igniting. Do not spill fuel when filling
tank. If fuel is spilled, wipe it up and do not start engine until
fumes have been eliminated.
Safety 02 of 04 - 06/15/2016
SAFETY
ELECTRIC SHOCK ARC RAYS CAN BURN.

CAN KILL.
3.a. The electrode and work (or ground) circuits are 4.a. Use a shield with the proper filter and cover plates to protect your
electrically “hot” when the welder is on. Do eyes from sparks and the rays of the arc when welding or
not touch these “hot” parts with your bare skin or wet clothing. observing open arc welding. Headshield and filter lens should
Wear dry, hole-free gloves to insulate hands. 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 material
Make certain the insulation is large enough to cover your full area to protect your skin and that of your helpers from the arc rays.
of physical contact with work and ground.
4.c. Protect other nearby personnel with suitable, non-flammable
In addition to the normal safety precautions, if screening and/or warn them not to watch the arc nor expose
welding must be performed under electrically themselves to the arc rays or to hot spatter or metal.
hazardous conditions (in damp locations or while
wearing wet clothing; on metal structures such as
floors, gratings or scaffolds; when in cramped FUMES AND GASES
positions such as sitting, kneeling or lying, if there
is a high risk of unavoidable or accidental contact
CAN BE DANGEROUS.
with the workpiece or ground) use the following
5.a. Welding may produce fumes and gases
equipment:
hazardous to health. Avoid breathing these fumes and gases.
• Semiautomatic DC Constant Voltage (Wire) Welder. When welding, keep your head out of the fume. Use enough
• DC Manual (Stick) Welder. ventilation and/or exhaust at the arc to keep fumes and gases
• AC Welder with Reduced Voltage Control. away from the breathing zone. When welding hardfacing
(see instructions on container or SDS) or on lead
3.c. In semiautomatic or automatic wire welding, the electrode,
or cadmium plated steel and other metals or
electrode reel, welding head, nozzle or semiautomatic welding
coatings which produce highly toxic fumes, keep
gun are also electrically “hot”.
exposure as low as possible and within applicable
3.d. Always be sure the work cable makes a good electrical OSHA PEL and ACGIH TLV limits using local
connection with the metal being welded. The connection should exhaust or mechanical ventilation unless exposure
be as close as possible to the area being welded. assessments indicate otherwise. In confined
spaces or in some circumstances, outdoors, a
3.e. Ground the work or metal to be welded to a good electrical (earth) respirator may also be required. Additional
ground. precautions are also required when welding
on galvanized steel.
3.f. Maintain the electrode holder, work clamp, welding cable and
welding machine in good, safe operating condition. Replace 5. b. The operation of welding fume control equipment is affected by
damaged insulation. various factors including proper use and positioning of the
equipment, maintenance of the equipment and the specific
3.g. Never dip the electrode in water for cooling. welding procedure and application involved. Worker exposure
level should be checked upon installation and periodically
3.h. Never simultaneously touch electrically “hot” parts of electrode thereafter to be certain it is within applicable OSHA PEL and
holders connected to two welders because voltage between the ACGIH TLV limits.
two can be the total of the open circuit voltage of both
welders. 5.c. Do not weld in locations near chlorinated hydrocarbon vapors
coming from degreasing, cleaning or spraying operations. The
3.i. When working above floor level, use a safety belt to protect heat and rays of the arc can react with solvent vapors to form
yourself from a fall should you get a shock. phosgene, a highly toxic gas, and other irritating products.
3.j. Also see Items 6.c. and 8. 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 manufacturer’s instructions for this
equipment and the consumables to be used, including the
Safety Data Sheet (SDS) and follow your employer’s safety
practices. SDS forms are available from your welding
distributor or from the manufacturer.
5.f. Also see item 1.b.
Safety 03 of 04 - 06/15/2016
SAFETY
WELDING AND CUTTING CYLINDER MAY EXPLODE IF

SPARKS CAN CAUSE DAMAGED.
FIRE OR EXPLOSION. 7.a. Use only compressed gas cylinders containing
6.a. Remove fire hazards from the welding area. If the correct shielding gas for the process used
this is not possible, cover them to prevent the welding sparks and properly operating regulators designed for
from starting a fire. Remember that welding sparks and hot the gas and pressure used. All hoses, fittings,
materials from welding can easily go through small cracks and etc. should be suitable for the application and
openings to adjacent areas. Avoid welding near hydraulic lines. maintained in good condition.
Have a fire extinguisher readily available. 7.b. Always keep cylinders in an upright position securely chained to
6.b. Where compressed gases are to be used at the job site, special an undercarriage or fixed support.
precautions should be used to prevent hazardous situations. 7.c. Cylinders should be located:
Refer to “Safety in Welding and Cutting” (ANSI Standard Z49.1)
and the operating information for the equipment being used. • Away from areas where they may be struck or subjected
to physical damage.
6.c. When not welding, make certain no part of the electrode circuit is • A safe distance from arc welding or cutting operations
touching the work or ground. Accidental contact can cause and any other source of heat, sparks, or flame.
overheating and create a fire hazard.
7.d. Never allow the electrode, electrode holder or any other
6.d. Do not heat, cut or weld tanks, drums or containers until the electrically “hot” parts to touch a cylinder.
proper steps have been taken to insure that such procedures
will not cause flammable or toxic vapors from substances inside. 7.e. Keep your head and face away from the cylinder valve outlet
They can cause an explosion even though they have been when opening the cylinder valve.
“cleaned”. For information, purchase “Recommended Safe
Practices for the Preparation for Welding and Cutting of 7.f. Valve protection caps should always be in place and hand tight
Containers and Piping That Have Held Hazardous Substances”, except when the cylinder is in use or connected for use.
AWS F4.1 from the American Welding Society
7.g. Read and follow the instructions on compressed gas cylinders,
(see address above).
associated equipment, and CGA publication P-l, “Precautions for
6.e. Vent hollow castings or containers before heating, cutting or Safe Handling of Compressed Gases in Cylinders,” available from
welding. They may explode. the Compressed Gas Association, 14501 George Carter Way
Chantilly, VA 20151.
6.f. Sparks and spatter are thrown from the welding arc. Wear oil free
protective garments such as leather gloves, heavy shirt, cuffless
trousers, high shoes and a cap over your hair. Wear ear plugs
when welding out of position or in confined places. Always wear
safety glasses with side shields when in a welding area.
FOR ELECTRICALLY
6.g. Connect the work cable to the work as close to the welding area POWERED EQUIPMENT.
as practical. Work cables connected to the building framework or
other locations away from the welding area increase the 8.a. Turn off input power using the disconnect
possibility of the welding current passing through lifting chains, switch at the fuse box before working on
crane cables or other alternate circuits. This can create fire the equipment.
hazards or overheat lifting chains or cables until they fail.
8.b. Install equipment in accordance with the U.S. National Electrical
6.h. Also see item 1.c. Code, all local codes and the manufacturer’s recommendations.
6.I. Read and follow NFPA 51B “Standard for Fire Prevention During 8.c. Ground the equipment in accordance with the U.S. National
Welding, Cutting and Other Hot Work”, available from NFPA, 1 Electrical Code and the manufacturer’s recommendations.
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.
Safety 04 of 04 - 06/15/2016
vi TABLE OF CONTENTS vi
Page
Installation.......................................................................................................................Section A
Technical Specifications.......................................................................................................A-1
Safety Precautions ........................................................................................................A-2
Location and Ventilation................................................................................................A-2
Stacking ........................................................................................................................A-2
Angle of Operation ........................................................................................................A-2
Lifting.............................................................................................................................A-2
High Altitude Operation .................................................................................................A-3
Welder Output Ratings at Temperatires above 40Cº ....................................................A-3
Cold Weather Starting...................................................................................................A-3
Towing...........................................................................................................................A-3
Vehicle Mounting...........................................................................................................A-3
Pre-Operation Engine Service..............................................................................................A-3
Oil ..................................................................................................................................A-4
Fuel ...............................................................................................................................A-4
Engine Coolant..............................................................................................................A-4
Battery Connections ......................................................................................................A-4
Muffler Outlet Pipe ........................................................................................................A-4
Spark Arrester ...............................................................................................................A-4
Remote Control .............................................................................................................A-4
Electrical Connections ..........................................................................................................A-5
Machine Grounding.......................................................................................................A-5
Welding Terminals ........................................................................................................A-5
Welding Output Cables .................................................................................................A-5
Cable Installation...........................................................................................................A-5
Auxiliary Power Receptacles and Plugs...............................................................................A-6
Residual Current Device Ready ...........................................................................................A-6
Standby Power Connections ................................................................................................A-6
Connection of Lincoln Electric Wire Feeders .......................................................................A-7
________________________________________________________________________________
Operation.........................................................................................................................Section B
Safety Precautions ..............................................................................................................B-1
General Description..............................................................................................................B-1
For Auxiliary Power ..............................................................................................................B-1
Engine Operation..................................................................................................................B-1
Add Fuel ...............................................................................................................................B-1
Break in Period .....................................................................................................................B-1
Welder Controls .............................................................................................................B-2,B-3
Engine Controls .............................................................................................................B-3,B-4
Fuel Consumption .........................................................................................................B-3
Starting and Stopping the Engine .................................................................................B-4
Welding Operation................................................................................................................B-4
Duty Cycle and Electrode Information...........................................................................B-4
Constant Current (Stick) Welding..................................................................................B-4
Downhill Pipe (Stick) Welding .......................................................................................B-5
Wire Welding-CV...........................................................................................................B-5
Arc Gouging ..................................................................................................................B-5
Tig Welding ...................................................................................................................B-6
Typical Current Ranges for Tungsten Electrodes .........................................................B-6
Auxiliary Power.....................................................................................................................B-7
Simultaneous Welding and Power Loads .....................................................................B-7
Extension Cord Recommendations...............................................................................B-7
________________________________________________________________________________
Accessories .....................................................................................................Section C
Field Installed Options / Accessories ...............................................................................C-1
________________________________________________________________________________
vii TABLE OF CONTENTS vii
Maintenance......................................................................................................Section D
Safety Precautions ................................................................................................D-1
Routine Maintenance ............................................................................................D-1
Engine Service Items.............................................................................................D-1
Engine Oil Change..........................................................................................D-2
Engine Oil Filter Change.................................................................................D-2
Air Cleaner .....................................................................................................D-2
Service Instructions And Installation Tips for Engine Air Filter .......................D-3
Cooling System .....................................................................................................D-4
Fan Belt...........................................................................................................D-4
Fuel .................................................................................................................D-4
Bleeding the Fuel System ...............................................................................D-4
Fuel Filter ........................................................................................................D-5
Engine Adjustment ..........................................................................................D-5
Battery Maintenance .......................................................................................D-5
Servicing Optional Spark Arrestor ...................................................................D-5
Welder / Generator Maintenance ........................................................................D-6
Storage ...........................................................................................................D-6
Cleaning..........................................................................................................D-6
Brush Removal and Replacement ..................................................................D-6
GFCI Testing and Resetting Procedure..........................................................D-6
________________________________________________________________________
Troubleshooting ..............................................................................................Section E
How to Use Troubleshooting Guide.......................................................................E-1
Troubleshooting Guide ............................................................................E-2 thru E-6
________________________________________________________________________
Diagrams ..........................................................................................................Section F
Instructions for Installing a Residual Current Device......................................F-1, F-2
Connection Diagram with Optional Remote Control ..............................................F-3
Wiring Diagrams .............................................................................................F-4, F-5
Dimension Print......................................................................................................F-6
________________________________________________________________________
Parts List...................................................................................................P-608 SERIES
________________________________________________________________________
A-1 INSTALLATION A-1
TECHNICAL SPECIFICATIONS - VANTAGE® 500-I (K2805-1)
INPUT - DIESEL ENGINE
Make/Model Description Speed (RPM) Displacement Starting Capacities
PERKINS cu. in. (ltrs.) System
4 cylinder 135.6(2.2) 12VDC Battery & Fuel: 20 gal.

32.7 HP High Idle 1880 starter (75.7 L)
(K2805-1) 1800 RPM Bore x Stroke inch (mm) (Group 34; 650 Oil: 8.45Qts. (8L)
404D-22 naturally aspirated Full Load 1800 cold crank amps)
water cooled 3.43 X 3.64 65 Amp Alternator Radiator Coolant:
Diesel Engine Low Idle 1400 (87.1 x 92.5mm) W/Built in Regulator 8.0 Qts. (7.6L)
RATED OUTPUT @ 104° F (40° C) - WELDER
Welding Process Welding Output Output Range Max. Weld OCV
Current/Voltage/Duty Cycle @Rated Load RPM
400A / 36V / 100%
DC Constant Current 450A / 34V / 60% 30 TO 500 AMPS
500A / 30V /40%
DC Pipe Current 300A / 32V / 100% 40 TO 300 AMPS
Touch-Start™TIG 250A / 30V / 100% 20 TO 250 AMPS 60 Volts
400A / 36V / 100%
DC Constant Voltage 450A / 34V / 60% 14 TO 36 VOLTS
500A / 30V / 40%
Arc Gouging 400A / 36V / 100% 90 to 450 Amps
RATED OUTPUT @ 104° F (40° C).- GENERATOR
Auxiliary Power (1)
19,000 Watts Peak, / 17,000 Watts Continuous, 60 Hz, 240 Volts 3-Phase
3600 Watts Peak(2), / 3600 Watts Continuous, 60 Hz, 240 Volts 1-Phase
PHYSICAL DIMENSIONS
HEIGHT WIDTH DEPTH WEIGHT
35.94* in. 25.30 in 60.00 in.
913 mm 643 mm 1524 mm 1230 lbs. (559kg.)
ENGINE
LUBRICATION EMISSIONS FUEL SYSTEM GOVERNOR
Full Pressure EPA Tier 4 Mechanical Fuel Pump, Auto air bleed Mechanical
with Full Flow Filter Interim Compliant system, Electric shutoff solenoid, Indirect fuel injector.
AIR CLEANER ENGINE IDLER MUFFLER ENGINE PROTECTION

Low noise Muffler: Shutdown on low oil
Single Element Automatic Idler Top outlet can be rotated. pressure & high engine
Made from long life, aluminized steel. coolant temperature
ENGINE WARRANTY: 2 years / 2000 hours, all non-electric components, 3 years major non-electric compo-
nents . See Perkins warranty for details.
MACHINE SPECIFICATIONS
RECEPTACLES AUXILIARY POWER CIRCUIT BREAKER OTHER CIRCUIT BREAKERS
1 - 120VAC Duplex NEMA (5-20R)-GFCI protected 1 - 20 amp for 120VAC Duplex (NEMA)
1 - 120VAC European (IEC 309)-GFCI protected 1 - 15 amp for 120VAC European (IEC 309) 10AMP for Battery Charging Circuit
1 - 240VAC European (IEC 309) 1 - 15 amp (2 -pole) for 240VAC European (IEC 309)
1 - 240VAC 3-Phase NEMA (15-50R) 1 - 50 amp (3-pole) for 240 VAC 3-Phase (NEMA)
(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.
* To Top of enclosure, add 10.28”(261.1mm) to top of exhaust pipe. Add 3.43”(87.1mm) to top of Lift Bail.
(2) Maximum per circuit breaker rating.
VANTAGE® 500-I
SAFETY PRECAUTIONS LIFTING
The VANTAGE® 500-I weighs approximately 1345lbs.
WARNING (611kg.) with a full tank of fuel 1230lbs.(559kg) less
fuel. A lift bail is mounted to the machine and should
Do not attempt to use this equipment until you always be used when lifting the machine.
have thoroughly read the engine manufacturer’s
manual supplied with your welder. It includes
important safety precautions, detailed engine WARNING
starting, operating and maintenance instructions,
and parts lists. • Lift only with equipment of ade-
------------------------------------------------------------------------ quate lifting capacity.
ELECTRIC SHOCK can kill. • Be sure machine is stable when lift-
• Do not touch electrically live parts or
ing.
electrode with skin or wet clothing.
• Do not lift this machine using lift
• Insulate yourself from work and
ground bail if it is equipped with a heavy
• Always wear dry insulating gloves. accessory such as trailer or gas
------------------------------------------------------------------------ cylinder.
ENGINE EXHAUST can kill. FALLING • Do not lift machine if lift bail is
• Use in open, well ventilated areas or EQUIPMENT can damaged.
vent exhaust outside.
cause injury. • Do not operate machine while
------------------------------------------------------------------------ suspended from lift bail.
MOVING PARTS can injure.
• Do not operate with doors open or ------------------------------------------------------------------------
guards off.
• Stop engine before servicing.
• Keep away from moving parts.
------------------------------------------------------------------------
See additional warning information at
front of this operator’s manual.
Only qualified personnel should install,
use, or service this equipment.
LOCATION AND VENTILATION
The welder should be located to provide an unrestrict-
ed flow of clean, cool air to the cooling air inlets and to
avoid restricting the cooling air outlets. Also, locate
the welder so that the engine exhaust fumes are prop-
erly vented to an outside area.
STACKING
VANTAGE® 500-I machines cannot be stacked.
ANGLE OF OPERATION
Engines are designed to run in the level condition
which is where the optimum performance is achieved.
The maximum angle of continuous operation is 25
degrees in all directions, 35 degrees Intermittent (less
than 10 minutes continuous) in all directions. If the
engine is to be operated at an angle, provisions must
be made for checking and maintaining the oil level at
the normal (FULL) oil capacity in the crankcase.
When operating the welder at an angle, the effective

fuel capacity will be slightly less than the amount
specified.
VANTAGE® 500-I
HIGH ALTITUDE OPERATION
At higher altitudes, output derating may be necessary. For max- VEHICLE MOUNTING
WARNING
imum rating, derate the machine 2.5% to 3.5% for every 1000 ft.
(305m). Due to new EPA and other local emissions regulations,
modifications to the engine for high altitude are restricted within Improperly mounted concentrated loads may
the United States. For use above 6000 ft.(1828 m) an autho- cause unstable vehicle handling and tires or other
rized Perkins engine field service shop should be contacted to components to fail.
determine if any adjustments can be made for operation in high-
er elevations. • Only transport this Equipment on serviceable
HIGH TEMPERATURE OPERATION vehicles which are rated and designed for such
Tested for extreme temperature operation up to 55°C. Output loads.
derated above 40°C. • Distribute, balance and secure loads so vehicle
is stable under conditions of use.
Cold weather starting: • Do not exceed maximum rated loads for compo-
nents such as suspension, axles and tires.
With a fully charged battery and the proper oil, the engine • Mount equipment base to metal bed or frame of
should start satisfactorily down to -15°F(-26°C). If the engine vehicle.
must be frequently started at or below 0°F (-18°C), it may be • Follow vehicle manufacturer’s instructions.
------------------------------------------------------------------------
desirable to install cold-starting aides. The use of No. 1D
diesel fuel is recommended in place of No. 2D at tempera- PRE-OPERATION ENGINE SERVICE
tures below 23°F (-5°C). Allow the engine to warm up before
READ the engine operating and maintenance instruc-
applying a load or switching to high idle.
tions supplied with this machine.
Note: Extreme cold weather starting may require
longer glow plug operation.
WARNING
Under no conditions should ether or other starting
• Stop engine and allow to cool before fueling
fluids be used with this engine!
• Do not smoke when fueling.
------------------------------------------------------------------------
• Fill fuel tank at a moderate rate and do not over-
TOWING
fill.
• Wipe up spilled fuel and allow fumes to clear
WARNING before starting engine.
• Keep sparks and flame away from tank.
------------------------------------------------------------------------
Use a recommended trailer for use with this equipment for road,
in-plant and yard towing by a vehicle(1). If the user adapts a
non-Lincoln trailer, he must assume responsibility that the
method of attachment and usage does not result in a safety
hazard or damage the welding equipment. Some of the factors
to be considered are as follows:
1. Design capacity of trailer vs. weight of Lincoln equipment and

likely additional attachments.
2. Proper support of, and attachment to, the base of the welding
equipment so there will be no undue stress to the framework.
3. Proper placement of the equipment on the trailer to insure
stability side to side and front to back when being moved and
when standing by itself while being operated or serviced.
4. Typical conditions of use, i.e., travel speed; roughness of sur-
face on which the trailer will be operated; environmental con-
ditions; like maintenance.
5. Conformance with federal, state and local laws.(1)
(1) Consult applicable federal, state and local laws regarding specific requirements for use on public high-
ways.
NOTE: This machine is furnished with a wet charged bat-

tery; if unused for several months, the battery may require a
booster charge. Be careful to charge the battery with the
correct polarity. (See Battery in “Maintenance Section”)
VANTAGE® 500-I
Because this portable engine driven welder creates its nections should be checked periodically and tightened
own power, it is not necessary to connect its with a 3/4" wrench.
frame to an earth ground, unless the machine
is connected to premises wiring (home, shop, etc.) Table A.1 lists recommended cable sizes and lengths
for rated current and duty cycle. Length refers to the
To prevent dangerous electric shock, other equipment distance from the welder to the work and back to the
to which this engine driven welder supplies power welder. Cable diameters are increased for long cable
must: lengths to reduce voltage drops.
• Be grounded to the frame of the welder using a
grounded type plug or be double insulated. TABLE A.1
• Do not ground the machine to a pipe that carries CABLE INSTALLATION
explosive or combustible material. Install the welding cables to your VANTAGE® 500-I as
follows.
WARNING
------------------------------------------------------------------------ TOTAL COMBINED LENGTH OF
ELECTRODE AND WORK CABLES
When this welder is mounted on a truck or trailer, its
frame must be electrically bonded to the metal frame Cable Size for
of the vehicle. Use a #8 or larger copper wire connect- Cable Length 400 Amps
ed between the machine grounding stud and the 60% Duty Cycle
frame of the vehicle. When this engine driven welder 0-100 Ft. (0-30 meters) 2 / 0 AWG
is connected to premises wiring such as that in a
home or shop, its frame must be connected to the 100-150 Ft. (30-46 meters) 2 / 0 AWG
system earth ground. See further connection instruc-
tions in the section entitled "Standby Power 150-200 Ft. (46-61 meters) 3 / 0 AWG
Connections" as well as the article on grounding in the
latest National Electrical Code and the local code.
1. The engine must be OFF to install welding cables.
2. Remove the flanged nuts from the output terminals
In general, if the machine is to be grounded, it should
3. Connect the electrode holder and work cables to
be connected with a #8 or larger copper wire to a solid
the weld output terminals. The terminals are identi-
earth ground such as a metal water pipe going into
fied on the case front.
the ground for at least ten feet and having no insulat-
4. Tighten the flanged nuts securely.
ed joints, or to the metal framework of a building
5. Be certain that the metal piece you are welding (the
which has been effectively grounded.
“work”) is properly connected to the work clamp and
cable.
The National Electrical Code lists a number of alter-
6. Check and tighten the connections periodically.
nate means of grounding electrical equipment. A
• Loose connections will cause the output termi-
machine grounding stud marked with the symbol
nals to overheat. The terminals may eventually
is provided on the front of the welder.
melt.
• Do not cross the welding cables at the output ter-
WELDING TERMINALS minal connection. Keep the cables isolated and
The VANTAGE® 500-I is equipped with a toggle
switch for selecting "hot" welding terminal when in CAUTION
the "WELD TERMINALS ON" position or "cold" weld- separate from one another.
ing terminal when in the "REMOTELY CON- ------------------------------------------------------------------------
TROLLED" position.
AUXILIARY POWER RECEPTACLES

WELDING OUTPUT CABLES
With the engine off connect the electrode and work Start the engine and set the “IDLER” control switch to
cables to the output studs. The welding process dic- the “High Idle” mode. Voltage is now correct at the
tates the polarity of the electrode cable. These con- receptacles for auxiliary power. This must be done
VANTAGE® 500-I
before a tripped GFCI can be reset properly. See the hole sized and shaped to accept a typical 2-pole
MAINTENANCE section for more detailed information (RCD). A coverplate with a label “RCD READY” cov-
on testing and resetting the GFCI. ers the hole and secures a mounting bracket on the
backside of the panel. See Section F Diagrams of this
The auxiliary power of the VANTAGE® 500-I consists Operator’s Manual for instructions on installing an
of Single Phase and Three Phase 60Hz Power. Out put (RCD).
Voltage is within +/- 10% at loads up to rated capacity.
Note: The (RCD) should be rated for 15 amps.
Single Phase:
One 120VAC NEMA (5-20R) 20 amp duplex receptacle STANDBY POWER CONNECTIONS
is protected by a 20 amp circuit breaker that provides
2400 watts Peak / 2400 watts Continuous power. The VANTAGE® 500-I is suitable for temporary,
Maximum current is 20 amps total. standby or emergency power using the engine manu-
facturer’s recommended maintenance schedule.
One 120VAC (IEC 309) 16 amp receptacle is protected
by a 15 amp circuit breaker that provides 1800 watts The VANTAGE® 500-I can be permanently installed
Peak / 1800 watts Continuous power. Maximum current as a standby power unit for 240 VAC, 3 wire, single
is 15 amps. phase, 50 amp service. Connections must be made
by a licensed electrician who can determine how the
One 240VAC (IEC 309) 16 amp receptacle is protected 120/240 VAC power can be adapted to the particular
by a 15 amp 2-pole circuit breaker that provides 3600 installation and comply with all applicable electrical
watts Peak / 3600 watts Continuous power. The 2-pole codes.
circuit breaker disconnects both hot leads at the same
time. Maximum current is 15 amps. Take necessary steps to assure load is limited to the
capacity of the VANTAGE® 500-I
Three-Phases:
One 240VAC NEMA (15-50R) 50 amp receptacle is • Only a licensed, certified, trained electrician
protected by a 50 amp 3-pole circuit breaker that pro- should install the machine to a premises or resi-
vides 19,000 watts Peak / 17,000 watts Continuous dential electrical system. Be certain that:
power. The 3-pole circuit breaker disconnects all 3
Phases at the same time. Maximum current is 41 • The installation complies with the National
amps. Electrical Code and all other applicable electrical
120 V RECEPTACLES WARNING
A GFCI protects, the two 120V Auxiliary Power recep- codes.
tacles. A GFCI (Ground Fault Circuit Interrupter) elec-
trical receptacle is a device to protect against electric • The premises is isolated and no feedback into
shock should a piece of defective equipment connected the utility system can occur. Certain state and
to it develop a ground fault. If this situation should local laws require the premises to be isolated
occur, the GFCI will trip, removing voltage from the out- before the generator is linked to the premises.
put of the receptacle. If a GFCI is tripped see the Check your state and local requirements.
MAINTENANCE section for detailed information on ------------------------------------------------------------------------
testing and resetting it. A GFCI should be properly test-
ed at least once every month.
The 120 V auxiliary power receptacles should only be

used with three wire grounded type plugs or approved
double insulated tools with two wire plugs. The current
rating of any plug used with the system must be at
least equal to the current capacity of the associated
receptacle.
RESIDUAL CURRENT DEVICE READY
The Vantage 500-I is configured to allow for the addi-

tion of a Residual Current Device (RCD) to protect the
240V Single Phase Receptacle. The auxiliary power
area on the front panel of the Vantage 500-I has a
VANTAGE® 500-I
CONNECTION OF LINCOLN ELECTRIC 1. Shut the welder off.

WIRE FEEDERS
2. For electrode Positive, connect the electrode
WARNING
cable from the Wire Feeder to the "+" terminal of
the welder and work cable to the "-" terminal of the
welder. For electrode Negative, connect the elec-
Shut off welder before making any electrical con-
trode cable from the Wire Feeder to the "-" termi-
nections.
nal of the welder and work cable to the "+" termi-
------------------------------------------------------------------------
nal of the welder.
Connection of LN-15 Across The-Arc Model to the
VANTAGE® 500-I
3. Attach the single lead from the front of the Wire
Feeder to work using the spring clip at the end of
1. Shut the welder off.
the lead. This is a control lead to supply current to
the wire feeder motor; it does not carry welding
2. For electrode Positive, connect the electrode
current.
cable to the "+" terminal of the welder and work
cable to the "-" terminal of the welder. For elec-
4. Set the MODE switch to the "CV-WIRE " position.
trode Negative, connect the electrode cable to the
"-" terminal of the welder and work cable to the "+"
5. Set the "WELD TERMINALS" switch to "WELD
terminal of the welder.
TERMINALS ON"
3. Attach the single lead from the front of the LN-15
6. Set the "ARC CONTROL" knob to "0" initially and
to work using the spring clip at the end of the lead.
adjust to suit.
This is a control lead to supply current to the wire
feeder motor; it does not carry welding current.
7. Set the "IDLE" switch to the "AUTO" position.
When not welding, the VANTAGE® 500-I engine
4. Set the MODE switch to the "CV-WIRE " position.
will be at the low idle speed. If you are using an
LN-25 with an internal contactor, the electrode is
5. Set the "WELD TERMINALS" switch to "WELD
not energized until the gun trigger is closed.
TERMINALS ON".
8. When the gun trigger is closed, the current sens-
6. Set the "ARC CONTROL" knob to "0" initially and
ing circuit will cause the VANTAGE® 500-I engine
adjust to suit.
to go to the high idle speed, the wire will begin to
feed and the welding process started. When weld-
7. Set the "IDLE" switch to the "AUTO" position.
ing is stopped, the engine will revert to low idle
speed after approximately 12 seconds unless
8. When the gun trigger is closed, the current sens-
welding is resumed.
ing circuit will cause the VANTAGE® 500-I engine
CAUTION
to go to the high idle speed, the wire will begin to
feed and the welding process started. When weld-
ing is stopped, the engine will revert to low idle
If you are using an LN-25 without an internal con-
speed after approximately 12 seconds unless
tactor, the electrode will be energized when the
welding is resumed.
VANTAGE® 500-I is started.
------------------------------------------------------------------------
NOTE: LN-15 Control Cable Model will not work with
the Vantage 500-I.
Connection of the LN-25 PRO or LN-25 to the VAN-

TAGE® 500-I
The LN-25 PRO or LN-25 with or without an internal

contactor may be used with the VANTAGE® 500-I.
See the appropriate connection diagram in Section F.
NOTE: The LN-25 (K431) Remote Control Module

and (K432) Remote Cable are not recommended for
use with the VANTAGE® 500-I.
VANTAGE® 500-I
B-1 OPERATION B-1
SAFETY PRECAUTIONS
WARNING
WARNING
ADD FUEL
Do not attempt to use this equipment until you • Stop engine while fueling.
have thoroughly read the engine manufacturer’s • Do not smoke when fueling.
manual supplied with your welder. It includes • Keep sparks and flame away
important safety precautions, detailed engine
from tank.
starting, operating and maintenance instructions,
and parts lists. • Do not leave unattended while
------------------------------------------------------------------------ fueling.
ELECTRIC SHOCK can kill.
• Do not touch electrically live parts or DIESEL FUEL • Wipe up spilled fuel and allow
can cause fire. fumes to clear before starting
• Insulate yourself from work and engine.
ground • Do not overfill tank, fuel expan-
• Always wear dry insulating gloves. sion may cause overflow.
DIESEL FUEL ONLY
• Always operate the welder with the hinged door ------------------------------------------------------------------------
closed and the side panels in place. • Remove the fuel tank cap.
• Read carefully the Safety Precautions page
before operating this machine. Always follow • Fill the tank. DO NOT FILL THE TANK TO THE
these and any other safety procedures included POINT OF OVERFLOW.
in this manual and in the Engine Instruction
Manual. • Replace the fuel cap and tighten securely.
------------------------------------------------------------------------
• See Engine Owner’s Manual for specific fuel recom-
GENERAL DESCRIPTION mendations.
The VANTAGE® 500-I is a diesel engine powered DC
multi-process welding power source and 120 / 240 BREAK-IN PERIOD
volt AC power generator. The engine drives a genera-
tor that supplies three phase power for the DC weld- The engine will use a small amount of oil during its
ing circuit, single phase and Three Phase power for “break-in” period. The break-in period is about 50 run-
the AC auxiliary outlets. The DC welding control sys- ning hours.
tem uses state of the art Chopper Technology (CT™)
for superior welding performance. Check the oil every four hours during break-in.
Change the oil after the first 50 hours of operation and
every 200 hours thereafter. Change the oil filter at
FOR AUXILIARY POWER: each oil change.
Start the engine and set the IDLER control switch to
the desired operating mode. Full power is available During break-in, subject the Welder to moderate
regardless of the welding control settings providing no
welding current is being drawn. CAUTION
ENGINE OPERATION loads. Avoid long periods running at idle. Before
Before Starting the Engine: stopping the engine, remove all loads and allow
the engine to cool several minutes.
• Be sure the machine is on a level surface. ------------------------------------------------------------------------
• Open side engine door and remove the
engine oil dipstick and wipe it with a clean
cloth. Reinsert the dipstick and check the level on
the dipstick.
• Add oil (if necessary) to bring the level up to the full
mark. Do not overfill. Close engine door.
• Check radiator for proper coolant level. (Fill if nec-
essary).
• See Engine Owner’s Manual for specific oil and
coolant recommendations.
VANTAGE® 500-I
B-2 OPERATION B-2
FIGURE B.1
1
2
8
3
4
11
10
12
9
14 7
19
18
13
15
17
16
6
5
WELDING CONTROLS (Figure B.1) When in the TOUCH START TIG mode and when an
Amptrol is connected to the 6-Pin Connector, the OUT-
PUT dial is used to set the maximum current range of the
1. OUTPUT CONTROL- The OUTPUT dial is used to CURRENT CONTROL of the Amptrol.
preset the output voltage or current as displayed on the
digital meters for the five welding modes. When in the 2. DIGITAL OUTPUT METERS-The digital meters
ARC GOUGING or CV-WIRE modes and when a remote allow the output voltage (CV-WIRE mode) or current
control is connected to the 6-Pin or 14-Pin Connector, the (CC-STICK, DOWN HILL PIPE and TIG modes) to be set
auto-sensing circuit automatically switches the OUTPUT prior to welding using the OUTPUT control dial. During
CONTROL from control at the welder to the remote con- welding, the meter display the actual output voltage
trol. When in the CC-STICK or DOWNHILL PIPE mode (VOLTS) and current (AMPS). A memory feature holds
and when a remote control is connected to the 6-Pin or the display of both meters on for seven seconds after
14-Pin connector, the output control is used to set the welding is stopped. This allows the operator to read the
maximum current range of the remote. actual current and voltage just prior to when welding was
ceased.
EXAMPLE: When the OUTPUT CONTROL on the welder
is set to 200 amps the current range on the remote control While the display is being held the left-most decimal
will be Min-200 amps, rather than the full Min-Max amps. point in each display will be flashing. The accuracy of the
Any current range that is less than the full range provides meters is +/- 3%.
finer current resolution for more fine tuning of the output.
3. WELD MODE SELECTOR SWITCH-
In the CV-WIRE mode, if the feeder being used has a volt- (Provides Five selectable welding modes)
age control when the wire feeder control cable is connect- CV-WIRE
ed to the 14-Pin Connector, the auto-sensing circuit auto- ARC GOUGING
matically makes OUTPUT CONTROL inactive and the DOWNHILL PIPE
wire feeder voltage control active. Otherwise, the OUT- CC-STICK
PUT CONTROL is used to preset the voltage. TOUCH START TIG
VANTAGE® 500-I
B-3 OPERATION B-3
4. ARC CONTROL- The ARC CONTROL dial is active ENGINE CONTROLS:

in the CV-WIRE, CC-STICK and DOWNHILL PIPE 9. RUN/STOP SWITCH - RUN position energizes the
modes, and has different functions in these modes. This engine prior to starting. STOP position stops the engine.
control is not active in the TIG mode and ARC The oil pressure interlock switch prevents battery drain if
GOUGING mode. the switch is left in the RUN position and the engine is
not operating.
CC-STICK mode: In this mode, the ARC CONTROL dial
sets the short circuit current (arc-force) during stick weld-
ing to adjust for a soft or crisp arc. Increasing the dial
10. GLOW PLUG PUSH BUTTON -
from –10 (soft) to +10 (crisp) increases the short circuit • When pushed activates the glow plugs. Glow plug
current and prevents sticking of the electrode to the plate should not be activated for more than 20 seconds con-
while welding. This can also increase spatter. It is recom- tinuously.
mended that the ARC CONTROL be set to the minimum
number without electrode sticking. Start with a setting at 11. START PUSH BUTTON - Energizes the starter
0. motor to crank the engine.
DOWNHILL PIPE mode: In this mode, the ARC CON- 12. IDLER SWITCH- Has two positions as follows:
TROL dial sets the short circuit current (arc-force) during 1) In the HIGH position, the engine runs at the high
stick welding to adjust for a soft or a more forceful digging idle speed controlled by the engine governor.
arc (crisp). Increasing the number from –10 (soft) to +10 2) In the AUTO position, the idler operates
(crisp) increases the short circuit current which results in a as follows:
more forceful digging arc. Typically a forceful digging arc • When switched from HIGH to AUTO or after starting
is preferred for root and hot passes. A softer arc is pre- the engine, the engine will operate at full speed for
ferred for fill and cap passes where weld puddle control approximately 12 seconds and then go to low idle
and deposition ("stacking" of iron) are key to fast travel speed.
speeds. It is recommended that the ARC CONTROL be • When the electrode touches the work or power is
set initially at 0. drawn for lights or tools (approximately 100 Watts mini-
mum), the engine accelerates and operates at full
CV-WIRE mode: In this mode, turning the ARC CON- speed.
TROL clock wise from –10 (soft) to +10 (crisp) changes • When welding ceases or the AC power load is turned
the arc from soft and washed-in to crisp and narrow. It off, a fixed time delay of approximately 12 seconds
acts as an inductance/pinch control. The proper setting starts. If the welding or AC power load is not restarted
depends on the procedure and operator preference. Start before the end of the time delay, the idler reduces the
with a setting of 0. engine speed to low idle speed.
• The engine will automatically return to high idle speed
5. WELD OUTPUT TERMINALS WITH FLANGE when there is welding load or AC power load reapplied.
NUT- Provides a connection point for the electrode and
work cables. 13. ELECTRIC FUEL GAUGE- The electric fuel
gauge gives accurate and reliable indication as to how
much fuel is in the fuel tank.
6. GROUND STUD- Provides a connection point for
connecting the machine case to earth ground. TABLE B.1
TYPICAL VANTAGE® 500-I FUEL CONSUMPTION
7. 6-PIN CONNECTOR- For attaching optional remote PERKINS 404D-22 Running Time for
control equipment. Includes auto-sensing remote control Gal./Hr (Liters/Hr) 20 gallons / hours
circuit. Low Idle - No Load
.26 (.97) 76.92
1400 R.P.M.
8. WELD TERMINALS CONTROL SWITCH- In the High Idle - No Load
47.62
1880 R.P.M. .42 (1.57)
WELD TERMINALS ON position, the output is electrically
DC Weld Output
hot all the time. In the REMOTELY CONTROLLED posi- 1.18 (4.46) 16.95
400 Amps @ 36 Volts
tion, the output is controlled by a wire feeder or amptrol 16.13
17,000 Watts 3 Phase 1.24 (4.68)
device, and is electrically off until a remote switch is
depressed.
NOTE: This data is for reference only. Fuel consump-
tion is approximate and can be influenced by many
factors, including engine maintenance, environmental
conditions and fuel quality.
VANTAGE® 500-I
B-4 OPERATION B-4
14. ENGINE HOUR METER- Displays the total time NOTE: If the unit fails to start turn Run/Stop switch
that the engine has been running. This meter is useful to off and repeat step 3 through step 7 after
for scheduling prescribed maintenance. waiting 30 seconds.
15. ENGINE PROTECTION LIGHT- A warning indi- CAUTION

cator light for Low Oil Pressure and/or Coolant Over
• Do not allow the starter motor to run continuously
Temperature.The light is off when the systems are func-
for more than 20 seconds.
tioning properly. The light will come on and the engine
• Do not push the START button while the engine
will shutdown when there is Low Oil Pressure and/or
is running because this can damage the ring
the Coolant is Over Temperature.
gear and/or the starter motor.
• IF the Engine Protection or Battery Charging
Note: The light remains off when the RUN-STOP switch
Lights do “not” turn off shortly after starting the
is in the "ON" position prior to starting the engine.
engine shut off the engine immediately and
However if the engine is not started within 60 seconds
determine the cause.
the light will come on. When this happens the RUN- ------------------------------------------------------------------------
STOP switch must be returned to the "OFF" position to NOTE: When starting for the first time, or after and
reset the engine protection system and light. extended period of time of not operating, it will take
longer than normal to start because the fuel pump
16. BATTERY CHARGING LIGHT- A warning has to fill the fuel system. For best results, bleed the
fuel system as indicated in Maintenance Section of
indicator light for Low/No battery charge. The light is off
this manual.
when the systems are functioning properly. The light
will come on if there is a Low/No battery condition but
the machine will continue to run.
STOPPING THE ENGINE
Remove all welding and auxiliary power loads and
Note: allow the engine to run at low idle speed for a few
The light may or may not come on when the RUN- minutes to cool the engine.
STOP switch is in the "ON" position. It will come on dur-
ing cranking and stay on until the engine starts. After STOP the engine by placing the RUN-STOP switch in
starting the engine the light will go off unless a Low/No the STOP position.
battery charge condition exists. NOTE: A fuel shut off valve is located on the fuel pre-
filter.
17. COOLANT TEMPERATURE GAUGE-A indica-
tor of engine coolant temperature. WELDER OPERATION
DUTY CYCLE
18. OIL PRESSURE GAUGE- A indicator of engine Duty Cycle is the percentage of time the load is being
Oil Pressure. applied in a 10 minute period. For example a 60% duty
cycle, represents 6 minutes of load and 4 minutes of no
19. CIRCUIT BREAKER- For protection of Battery load in a 10 minute period.
Charging Circuit.
ELECTRODE INFORMATION
STARTING THE ENGINE For any electrode the procedures should be kept with-
1. Remove all plugs connected to the AC power recepta- in the rating of the machine. For information on elec-
cles. trodes and their proper application see (www.lincoln-
2. Set IDLER switch to AUTO. electric.com) or the appropriate Lincoln publication.
3. Press Glow Plug Button and hold 15 to 20 seconds.
4. Set the RUN/STOP switch to RUN. The VANTAGE® 500-I can be used with a broad range
5. Press START button until the engine starts or for up to of DC stick electrodes. The MODE switch provides two
10 seconds. Continue to hold the glow plug button for up stick welding settings as follows:
to an additional 10 seconds.
6. Release the engine START button immediately when the CONSTANT CURRENT (CC-STICK) WELDING
engine starts.
7. The engine will run at high idle speed for approximately The CC-STICK position of the MODE switch is designed
12 seconds and then drop to low idle speed. Allow the for horizontal and vertical-up welding with all types of
engine to warm up at low idle for several minutes before electrodes, especially low hydrogen. The OUTPUT CON-
applying a load and/or switching to high idle. Allow a TROL dial adjusts the full output range for stick welding.
longer warm up time in cold weather. The ARC CONTROL dial sets the short circuit current
VANTAGE® 500-I
B-5 OPERATION B-5
(arc-force) during stick welding to adjust for a soft
or crisp arc. Increasing the number from -10(soft) to ARC GOUGING
+10(crisp) increases the short circuit current and The VANTAGE® 500-I can be used for arc gouging.
prevents sticking of the electrode to the plate while For optimal performance, set the MODE switch to
welding. This can also increase spatter. It is recom- ARC GOUGING.
mended that the ARC CONTROL be set to the min-
imum number without electrode sticking. Start with Set the OUTPUT CONTROL knob to adjust output
the dial set at 0. current to the desired level for the gouging electrode
being used according to the ratings in the following
DOWNHILL PIPE WELDING Table B.2.
This slope controlled setting is intended for "out-of- TABLE B.2

position" and "down hill" pipe welding where the Carbon Diameter Current Range (DC, elec-
operator would like to control the current level by trode positive)
changing the arc length.
The OUTPUT CONTROL dial adjusts the full output 1/8"(3.2mm) 60-90 Amps
range for pipe welding.
5/32"(4.0mm) 90-150 Amps
The ARC CONTROL dial sets the short circuit cur-
rent (arc-force) during stick welding to adjust for a 3/16"9(4.8mm) 200-250 Amps
soft or more forceful digging arc (crisp). Increasing
the number from -10(soft) to +10(crisp) increases 1/4"(6.4mm) 300-400 Amps
the short circuit current which results in a more
forceful digging arc. 5/16"(8.0mm) 400-Max.Amps
Typically a forceful digging arc is preferred for root The ARC CONTROL is not active in the ARC GOUG-
and hot passes. A softer arc is preferred for fill and ING Mode. The ARC CONTROL is automatically set
cap passes where weld puddle control and deposi- to maximum when the ARC GOUGING mode is
tion (“stacking” of iron) are key to fast travel selected which provides the best ARC GOUGING per-
speeds. This can also increase spatter. formance.
It is recommended that the ARC CONTROL be set

to the minimum number without electrode sticking.
Start with the dial set at 0.
WIRE WELDING-CV
Connect a wire feeder to the VANTAGE® 500-I
according to the instructions in INSTALLATION
INSTRUCTIONS Section.
The VANTAGE® 500-I in the CV-WIRE mode, per-

mits it to be used with a broad range of flux cored
wire (Innershield and Outershield) electrodes and
solid wires for MIG welding (gas metal arc welding).
Welding can be finely tuned using the ARC CON-
TROL. Turning the ARC CONTROL clockwise from
–10 (soft) to +10 (crisp) changes the arc from soft
and washed-in to crisp and narrow. It acts as an
inductance/pinch control. The proper setting
depends on the procedure and operator prefer-
ence. Start with the dial set at 0.
VANTAGE® 500-I
B-6 INSTALLATION B-6
OIL
The VANTAGE® 500-I is shipped with the engine MUFFLER OUTLET PIPE
Using the clamp provided secure the outlet pipe to the outlet
crankcase filled with high quality SAE 10W-30 Oil that
tube with the pipe positioned such that it will direct the
meets classification CG-4 or CH-4 for diesel engines. exhaust in the desired direction. Tighten using a 9/16" sock-
Check the oil level before starting the engine. If it is not et or wrench.
up to the full mark on the dip stick, add oil as required.
Check the oil level every four hours of running time dur- SPARK ARRESTER
ing the first 50 running hours. Refer to the engine Some federal, state or local laws may require that gasoline
Operator’s Manual for specific oil recommendations and or diesel engines be equipped with exhaust spark arresters
break-in information. The oil change interval is depen- when they are operated in certain locations where unarrest-
ed sparks may present a fire hazard. The standard muffler
dent on the quality of the oil and the operating environ-
included with this welder does not qualify as a spark
ment. Refer to the Engine Operator’s Manual for more arrester. When required by local regulations, a suitable
details on the proper service and maintenance intervals. spark arrester, such as the K903-1 must be installed and
properly maintained.
FUEL An incorrect spark arrestor may lead to damage to the
USE DIESEL FUEL ONLY engine or adversely affect performance.
------------------------------------------------------------------------
REMOTE CONTROL
WARNING
• Fill the fuel tank with clean, fresh fuel. The WARNING
capacity of the tank is 20 gals. (75.7 ltrs). When
the fuel gauge reads empty the tank contains The VANTAGE® 500-I is equipped with a 6-pin connector.
approximately 2 gals. (7.6ltrs.) of reserve fuel. When in the ARC GOUGING or CV-WIRE modes and when a
NOTE: A fuel shut off valve is located on the pre- remote control is connected to the 6-pin Connector, the auto-
filter/sediment filter. Which should be in sensing circuit automatically switches the OUTPUT control from
the closed position when the welder is not control at the welder to remote control.
used for extended periods of time.
------------------------------------------------------------------------ When in TOUCH START TIG mode and when a Amptrol is con-
ENGINE COOLING SYSTEM nected to the 6-Pin Connector, the OUTPUT dial is used to set
the maximum current range of the CURRENT CONTROL of the
WARNING Amptrol.
When in the CC-STICK or DOWNHILL PIPE mode and when a
Air to cool the engine is drawn in the side and remote control is connected to the 6-Pin connector, the output
exhausted through radiator & case back. It is control is used to set the maximum current range of the remote.
important that the intake and exhaust air is not
restricted. Allow a minimum clearance of 1ft.
EXAMPLE: When the OUTPUT CONTROL on the welder is set
(0.6m) from the case back and 16in.(406mm) from
either side of the base to a vertical surface. to 200 amps the current range on the remote control will be
------------------------------------------------------------------------ Min-200 amps, rather than the full Min-Max amps. Any current
BATTERY CONNECTION range that is less than the full range provides finer current reso-
lution for more fine tuning of the output.
CAUTION
Use caution as the electrolyte is a strong acid that
can burn skin and damage eyes.
------------------------------------------------------------------------
The VANTAGE® 500-I is shipped with the negative

battery cable disconnected. Make certain that the
RUN-STOP switch is in the STOP position. Remove
the two screws from the battery tray using a screw-
driver or a 3/8" socket. Attach the negative battery
cable to the negative battery terminal and tighten
using a 1/2" socket or wrench. ELECTRICAL CONNECTIONS
MACHINE GROUNDING
VANTAGE® 500-I
B-7 OPERATION B-7
TIG WELDING The VANTAGE® 500-I can be used in a wide variety

of DC TIG welding applications. In general the ‘Touch
The TOUCH START TIG setting of the MODE switch Start’ feature allows contamination free starting with-
is for DC TIG (Tungsten Inert Gas) welding. To initiate out the use of a Hi-frequency unit. If desired, the
a weld, the OUTPUT CONTROL dial is first set to the K930-2 TIG Module can be used with the VANTAGE®
desired current and the tungsten is touched to the 500-I. The settings are for reference.
work. During the time the tungsten is touching the
work there is very little voltage or current and, in gen- VANTAGE® 500-I settings when using the K930-2
eral, no tungsten contamination. Then, the tungsten is TIG Module with an Amptrol or Arc Start Switch:
gently lifted off the work in a rocking motion, which
establishes the arc. • Set the MODE Switch to the TOUCH START TIG
setting.
When in the TOUCH START TIG mode and when a
Amptrol is connected to the 6-Pin connector the OUT- • Set the "IDLER" Switch to the "AUTO" position.
PUT CONTROL dial is used to set the maximum cur-
rent range of the current control of the Amptrol. • Set the "WELDING TERMINALS" switch to the
"REMOTELY CONTROLLED" position. This will
The ARC CONTROL is not active in the TIG mode. To keep the "Solid State" contactor open and provide a
STOP a weld, simply pull the TIG torch away from the "cold" electrode until the Amptrol or Arc Start
work. Switch is pressed.
When the arc voltage reaches approximately 30 Volts
the arc will go out and the machine will reset the cur- When using the TIG Module, the OUTPUT CONTROL
rent to the Touch Start level. on the VANTAGE® 500-I is used to set the maximum
range of the CURRENT CONTROL on the TIG
To reinitiate the arc, retouch the tungsten to the work Module or an Amptrol if connected to the TIG Module.
and lift. Alternatively, the weld can be stopped by
releasing the Amptrol or arc start switch.
TABLE B.3
TYPICAL CURRENT RANGES (1) FOR TUNGSTEN ELECTRODES(2)
Tungsten Electrode DCEN (-) DCEP (+) Approximate Argon Gas Flow TIG TORCH
Diameter in. (mm) Flow Rate C.F.H. ( l /min.) Nozzle Size (4), (5)
1%, 2% Thoriated 1%, 2% Thoriated Aluminum Stainless Steel

Tungsten Tungsten
.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)
0.040 (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) When used with argon gas. The current ranges shown must be reduced when using argon/helium or pure helium shielding gases.
(2) Tungsten electrodes are classified as follows by the American Welding Society (AWS):
Pure EWP
1% Thoriated EWTh-1
2% Thoriated EWTh-2
Though not yet recognized by the AWS, Ceriated Tungsten is now widely accepted as a substitute for 2% Thoriated Tungsten in AC and DC applications.
(3) DCEP is not commonly used in these sizes.
(4) TIG torch nozzle "sizes" are in multiples of 1/16ths of an inch:
# 4 = 1/4 in. (6 mm)
# 5 = 5/16 in. (8 mm)
# 6 = 3/8 in. (10 mm)
# 7 = 7/16 in. (11 mm)
# 8 = _ in. (12.5 mm)
#10 = 5/8 in. (16 mm)
(5) TIG torch nozzles are typically made from alumina ceramic. Special applications may require lava nozzles, which are less prone to breakage, but cannot withstand high temperatures
VANTAGE® 500-I
B-8 OPERATION B-8
AUXILIARY POWER:
Start the engine and set the IDLER control switch to
the desired operating mode. Full power is available
regardless of the welding control settings providing no
welding current is being drawn.
Simultaneous Welding and Auxiliary Power Loads

The auxiliary power ratings are with no welding load.
Simultaneous welding and power loads are specified
in the following Table B.4.
TABLE B.4
VANTAGE® 500-I Simultaneous Welding and Power Loads

Weld 1 PHASE (120V) 1 PHASE (240V) 3 PHASE BOTH 1 & 3 PHASE
Amps WATTS AMPS WATTS AMPS WATTS AMPS WATTS AMPS
0 4200 35 3600 15 17,000 41 - 50
100 4200 35 3600 15 15,400 37 - 50
200 PLUS OR OR OR
4200 35 3600 15 13,000 31 - 50
300 4200 35 3600 15 9400 23 4,700 -
400 1700 14 1700 7 3400 8 1,700 -
500 0 - 0 0 0 0 -
TABLE B.5
VANTAGE® 500-I Extension Cord Length Recommendations
(Use the shortest length extension cord possible sized per the following table.)
Current Voltag Load Maximum Allowable Cord Length in ft. (m) for Conductor Size
(Amps) e 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)
20 120 2400 30 (9) 50 (15) 88 (27) 138 (42) 225 (69)
15 240 3600 60 (18) 75 (23) 150 (46) 225 (69) 350 (107) 600 (183)
20 240 4800 60 (18) 100 (30) 175 (53) 275 (84) 450 (137)
44 240 9500 50 (15) 90 (27) 150 (46) 225 (69)
Conductor size is based on maximum 2.0% voltage drop.
VANTAGE® 500-I
C-1 ACCESSORIES C-1
FIELD INSTALLED OPTIONS / Invertec V275-S
Get a second arc for Stick or DC TIG welding from the
ACCESSORIES 3-phase AC generator power of the Vantage 500-I.
Run 200 amps from the V275-S and 200 amps from
the Vantage 500-I at the same time. Requires
K2641-2 FOUR WHEELED STEERABLE YARD T12153-10 Full-KVA 3-phase plug. See bulletin
TRAILER E2.161 for Invertec V275-S accessoies including plug
For in plant and yard towing. Comes standard with a options.
Duo-Hitch™, a 2” Ball and Lunette Eye combination Order K2269-1 (Accepts Twist-Mate™ Plugs)
Hitch. Order K2269-3 (Accepts Tweco®)
Tweco® is a registered trademark of Thermadyne.

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 requirements. Comes standard WIRE FEEDER OPTIONS
with a Duo-Hitch™, a 2” Ball and Lunette Eye combi-
K2613-1 LN-25 PRO Wire Feeder- Portable CC/CV
nation hitch. Order:
unit for flux-cored and MIG welding with MAXTRAC®
K2636-1 Trailer
wire drive system. Includes gas solenoid and internal
K2639-1 Fender & Light Kit
contactor.
K2640-1 Cable Storage Rack
K1870-1 LN-15 Across the Arc Wire Feeder.
K903-1 SPARK ARRESTOR - Includes a heavy gage
Portable, lightweight, compact CC/CV unit for flux-
steel, approved spark arrestor, clamp and adapter for
cored and MIG welding. Includes Gas Solenoid,
mounting to the muffler exhaust pipe.
adjustable flow meter and internal contactor. For 10-
15 lb. (4.5-6.8kg) spools.
K704 ACCESSORY SET - Includes 35 ft. (10m) of
electrode cable and 30 ft. (9.1m) of work cable, head
Magnum Gun and Magnum Gun Connector Kit are
shield, work clamp electrode holder. Cables are rated
required for gas-shielded welding. Innershield Gun is
at 400 amps, 100% duty cycle.
required for gasless welding.
K857 25 ft (7.6m) or K857-1 100 ft. (30.4m)
K126-2 Magnum 350 Innershield Gun
REMOTE CONTROL
K1802-1 Magnum 300 MIG Gun (for LN-25)
Portable control provides same dial range as the out-
K470-2 Magnum 300 MIG Gun (for LN-15, Includes
put control on the welder. Has a convenient 6 pin plug
Connector Kit)
for easy connection to the welder.
K466-10 Connector Kit (for LN-15, K470-2)
K1500-1 Gun Receiver Bushing (for LN-15 & K126-2)
K2627-2 REMOTE OUTPUT CONTROL WITH 120V
AC RECEPTACLE-Remote output control box with Note: See Wire Feeder IM manuals for appropriate
two 120V AC receptacles having GFCI (Ground Fault Drive Roll and Guide Tubes.
Circuit Interruption) protection. One cord for both
remote and power. 100 ft. (30.5m) length. Permit TIG OPTIONS
remote adjustment of weld output and power for tools K1783-9 Pro -Torch® PTA-26V TIG Torch
(such as a grinder) at the work. 20 amp capacity. Air Cooled 200 amp torch (2 piece) equipped with
valve for gas flow control. 25 ft. (7.6m) length.
KP509 Magnum Parts Kit for PTA-26V TIG Torch

K1858-1 SERVICE INDICATOR KIT- Provides a GO / Magnum Parts Kit provides all the torch accessories
NO-GO visual indication of air cleaner element useful you need to start welding. Parts kit provides collets,
service life. Filter service based on restriction readings collet bodies, a black cap, alumina nozzles and tung-
allows the longest life possible from the filter and best stens in a variety of sizes, all packaged in an easy to
carry reclosable sack.
engine protection.
K870 Foot Amptrol®
K2679-1 COLD WEATHER HEATER AND TARP KIT K963-3 Hand Amptrol®
For engine starting and operation in extreme cold
weather conditions down to -40ºF / -40ºC (with the
use of OW40 synthetic oil and arctic diesel fuel),
PLASMA CUTTING
K1580-1 Pro-Cut 55
includes 120VAC engine block heater, and radiator Cuts metal using the 3-phase AC generator power
grill tarp. from the engine driven welder.
VANTAGE® 500-I
D-1 MAINTENANCE D-1
SAFETY PRECAUTIONS Read the Safety Precautions in the front of this

manual and in the Engine Owner’s Manual before
WARNING working on this machine.
• Have qualified personnel do all maintenance Keep all equipment safety guards, covers, and
and troubleshooting work. devices in position and in good repair. Keep
hands, hair, clothing, and tools away from the
• Turn the engine off before working inside the gears, fans, and all other moving parts when
machine or servicing the engine. starting, operating, or repairing the equipment.
------------------------------------------------------------------------
• Remove guards only when necessary to
perform maintenance and replace them when Routine Maintenance
the maintenance requiring their removal is
complete. If guards are missing from the At the end of each day’s use, refill the fuel tank to
machine, obtain replacements from a Lincoln minimize moisture condensation in the tank. Running
Distributor. (See Operating Manual Parts List.) out of fuel tends to draw dirt into the fuel system.
Also, check the crankcase oil level and add oil if
indicated.
ENGINE SERVICE
EVERY DAY OR EVERY 8 HOURS
FIRST SERVICE (20 / 50 HOURS)
EVERY 100 HOURS OR 3 MONTHS
EVERY 1000 HOURS OR ANNUALLY
ENGINE SERVICE (NOTE 2)
MAINTENANCE ITEM TYPE OR QUANTITY

I Coolant level
I Concentration of antifreeze 50/50 Water/Ethylene Glycol
R Coolant (NOTE 3) 9.5qt., 9.0L
I Engine oil level (NOTE 1)
R R Engine oil (NOTE 1 & 3) 8.45qt., 8L (including filter)
R R Engine oil filter Perkins #140517050
C Drain water separator & fuel strainer
R Water separator element Lincoln #M20840-A
R Fuel filter canister Perkins #130366120
I Tension of alternator drive belt
I Alternator drive belt wear
R Alternator drive belt Perkins #080109107
C Air filter (earlier check may be req’d)
R Air filter element Donaldson #P821575
R Renew the engine breather
I Tighten cylinder head
I Valve clearances Intake .008”, exhaust .008”
I Electrical systems
I All nuts and bolts for tightness
I Injector performance Contact Perkins
I Leaks or engine damage
I Battery
I = Inspect C = Clean R = Replace
Notes:
(1) Consult Engine Operators Manual for oil recommendations.
(2) Consult Engine Operators Manual for additional
maintenance schedule information.
(3) Fill slowly! Ensure correct quantity is used.
Above operations to be carried out by trained personnel with

reference to the workshop manual where necessary.
These preventative maintenance periods apply to average

conditions of operation. If necessary use shorter periods.
WARRANTY WORK PERFORMED ON THE ENGINE CONTAINED

IN THIS MACHINE, IF NOT BILLABLE TO THE ENGINE MANUFACTURER,
SHOULD BE PRE-APPROVED BY CALLING
THE LINCOLN ELECTRIC COMPANY AT 888-935-3877
S26354 VM
VANTAGE® 500-I
D-2 MAINTENANCE D-2
ENGINE OIL CHANGE OIL FILTER CHANGE
Drain the engine oil while the engine is warm to assure • Drain the oil.
rapid and complete draining. It is recommended that
each time the oil is changed the oil filter be changed as • Remove the oil filter with an oil filter wrench and
well. drain the oil into a suitable container. Discard the
used filter. Note: Care should be taken during filter
• Be sure the unit is off. Disconnect the negative bat- removal to not disrupt or damage in any way the fuel
tery cable to ensure safety. lines.
• Locate oil drain hose and valve in bottom of base • Clean the filter mounting base and coat the gasket
and pull through the hole in the battery access panel of the new filter with clean engine oil.
on the welder.
• Screw the new filter on by hand until the gasket con-
• Open oil drain valve by lifting up spring loaded lever tacts the mounting base. Using an oil filter wrench,
and rotate 90° counterclockwise. Pull to open and tighten the filter an additional 1/2 to 7/8 of a turn.
drain the oil into a suitable container for disposal. • Refill the crankcase with the specified amount of the
recommended engine oil. Reinstall the oil filler cap
• Close the drain valve by rotating lever 90° clockwise. and tighten securely.
• Re-fill the crankcase to the upper limit mark on the • Start the engine and check for oil filter leaks.
dipstick with the recommended oil (see engine oper-
ation manual OR engine service items decal OR • Stop the engine and check the oil level. If neces-
below). Replace and tighten the oil filler cap secure- sary, add oil to the upper limit mark on the dipstick.
ly.
• Push oil drain hose and valve back into unit, re-con-
nect negative battery cable, and close doors and
WARNING
engine top cover before restarting unit. Wash your
hands with soap and water after handling used motor • Never use gasoline or low flash point solvents
oil. Please dispose of used motor oil in a manner for cleaning the air cleaner element. A fire or
that is compatible with the environment. We suggest explosion could result.
you take it in a sealed container to your local service
station or recycling center for reclamation. DO NOT
throw it in the trash; pour it on the ground or down a
CAUTION
drain.
• Never run the engine without the air cleaner.
Use motor oil designed for diesel engines that meets Rapid engine wear will result from contaminants,
requirements for API service classification such as dust and dirt being drawn into the
CC/CD/CE/CF/CF-4/CG-4 or CH-4. engine.
------------------------------------------------------------------------
ACEA E1/E2/E3. Always check the API service label AIR CLEANER
on the oil container to be sure it includes the letters
indicated. (Note: An S-grade oil must not be used in a The diesel engine is equipped with a dry type air filter.
diesel engine or damage may result. It IS permissible Never apply oil to it. Service the air cleaner as follows:
to use an oil that meets S and C grade service classifi-
cations.) Replace the element every 500 hours of operation.
Under dusty conditions, replace sooner.
SAE 10W30 is recommended for general, all tempera-
ture use, 5F to 104F (-15C to 40C).
See engine owner’s manual for more specific informa-

tion on oil viscosity recommendations.
VANTAGE® 500-I
D-3 MAINTENANCE D-3
VANTAGE® 500-I
D-4 MAINTENANCE D-4
COOLING SYSTEM FUEL
WARNING At the end of each day’s use, refill the fuel tank to min-
imize moisture condensation and dirt contamination in
HOT COOLANT can burn skin. the fuel line. Do not overfill; leave room for the fuel to
expand.
• Do not remove cap if radiator is
hot. Use only fresh No. 2D diesel fuel, the use of No. 1D
diesel fuel is recommended in place of No. 2D at tem-
peratures below 23°F (-5°C). Do not use kerosene.
------------------------------------------------------------------------
Check the coolant level by observing the level in the See the Engine Operator's Manual for instructions on
radiator and recovery bottle. Add 50/50 antifreeze / replacing the fuel filter.
water solution if the level is close to or below the
"LOW" mark. Do not fill above the "FULL" mark.
BLEEDING THE FUEL SYSTEM
Remove radiator cap and add coolant to radiator. Fill
up to the top of the tube in the radiator filler neck
You may need to bleed air from the fuel system if the
which includes a connecting hose coming from the
fuel filter or fuel lines have been detached, the fuel
thermostat housing.
tank has been ran empty or after periods of long stor-
age. It is recommended that the fuel shutoff valve be
To drain the coolant, open the valve at the bottom of
closed during periods of non-use.
the radiator. Open the radiator cap to allow complete
drainage. (Tighten the valve and refill with a 50/50
antifreeze/water solution.) Use an automotive grade WARNING
(low silicate) ethylene glycol antifreeze. The cooling
system capacity is 8.0 quarts (7.6L.). Squeeze upper
To avoid personal injury, do not bleed a hot
and lower radiator hoses while filling to bleed air from
engine. This could cause fuel to spill onto a hot
system coolant. Replace and tighten the radiator cap.
exhaust manifold, creating a danger of fire.
------------------------------------------------------------------------
Bleed the fuel system as follows:
CAUTION
1. Fill the fuel tank with fuel.
Always premix the antifreeze and clean tap water 2. Open the fuel shut off valve.
before adding to the radiator. It is very important 3. Loosen bleed fitting on the fuel injector manifold.
that a precise 50/50 solution be used with this 4. Operate hand priming lever until fuel comes out the
engine year round. This gives proper cooling dur- bleed screw on the injector manifold. This could
ing hot weather and freezing protection to -34° F (- take 20-30 seconds of rapid operation of the prim-
37° C). ing lever. Tighten bleed fitting on injector manifold.
5. Follow normal STARTING procedures until engine
Cooling solution exceeding 50% ethylene glycol starts.
can result in engine overheating and damage to
the engine. Coolant solution must be premixed
before adding to radiator.
------------------------------------------------------------------------
Periodically remove the dirt from the radiator fins.

Periodically check the fan belt and radiator hoses.
Replace if signs of deterioration are found.
TIGHTENING THE FAN BELT
If the fan belt is loose, the engine can overheat and

the battery lose its charge. Check tightness by press-
ing on the belt midway between the pulleys. It should
deflect about .25 in.(6.4 mm) under a load of 20 lbs.(9
Kg).
VANTAGE® 500-I
D-5 MAINTENANCE D-5
CLEANING THE BATTERY
FUEL FILTER Keep the battery clean by wiping it with a damp cloth
1. Check the fuel filter and fuel pre-filter for water when dirty. If the terminals appear corroded, discon-
accumulation or sediment. nect the battery cables and wash the terminals with an
ammonia solution or a solution of 1/4 pound (0.1113
2. Replace the fuel filter if it is found with excessive kg) of baking soda and 1 quart (0.9461L) of water. Be
water accumulation or sediment. Empty fuel pre-fil- sure the battery vent plugs (if equipped) are tight so
ter. that none of the solution enters the cells.
After cleaning, flush the outside of the battery, the bat-
OVERSPEED IS HAZARDOUS tery compartment, and surrounding areas with clear
The maximum allowable high idle speed for this water. Coat the battery terminals lightly with petroleum
machine is 1890 RPM, no load. Do NOT tamper jelly or a non-conductive grease to retard corrosion.
with governor components or setting or make any Keep the battery clean and dry. Moisture accumula-
other adjustments to increase the maximum tion on the battery can lead to more rapid discharge
speed. Severe personal injury and damage to the and early battery failure.
machine can result if operated at speeds above
maximum.
CHECKING THE ELECTROLYTE LEVEL
ENGINE ADJUSTMENT If battery cells are low, fill them to the neck of the filler
Adjustments to the engine are to be made only by a hole with distilled water and recharge. If one cell is
Lincoln Service Center or an authorized Field Service low, check for leaks.
Shop.
CHARGING THE BATTERY

BATTERY MAINTENANCE When you charge, jump, replace, or otherwise con-
To access the battery, remove the battery tray from nect battery cables to the battery, be sure the polarity
the front of the machine with 3/8” nut driver or flat is correct. Improper polarity can damage the charging
head screw driver. Pull the tray out of machine far circuit. The VANTAGE® 500-I positive (+) battery ter-
enough to disconnect the negative and then positive minal has a red terminal cover.
battery cables. The tray can then be tilted and lifted to
remove the entire tray and battery from the machine If you need to charge the battery with an external
for easy service. charger, disconnect the negative cable first, then the
WARNING
positive cable before you attach the charger leads.
After the battery is charged, reconnect the positive
battery cable first and the negative cable last. Failure
GASES FROM BATTERY can explode. to do so can result in damage to the internal charger
Keep sparks, flame and cigarettes components.
away from battery. Follow the instructions of the battery charger manu-
l
facturer for proper charger settings and charging time.

To prevent EXPLOSION when:
SERVICING OPTIONAL SPARK

INSTALLING A NEW BATTERY — disconnect
negative cable from old battery first and con-
ARRESTOR
l
nect to new battery last.

CONNECTING A BATTERY CHARGER — Clean every 100 hours.
WARNING
remove battery from welder by disconnecting
l
negative cable first, then positive cable and

battery clamp. When reinstalling, connect
negative cable last. Keep well ventilated.
• MUFFLER MAY BE HOT
USING A BOOSTER — connect positive lead to
battery first then connect negative lead to neg- • ALLOW ENGINE TO COOL BEFORE INSTALLING
l
ative battery lead at engine foot. THE SPARK ARRESTER!

BATTERY ACID can burn eyes and
skin. • DO NOT OPERATE ENGINE WHILE INSTALLING
l Wear gloves and eye protection THE SPARK ARRESTER!
and be careful when working near
battery.
Follow instructions printed on battery.
VANTAGE® 500-I
l
D-6 MAINTENANCE D-6
WELDER / GENERATOR GFCI TESTING AND RESETTING

MAINTENANCE PROCEDURE
The GFCI should be properly tested at least once

STORAGE: Store in clean, dry protected areas. every month or whenever it is tripped. To properly test
and reset the GFCI:
CLEANING: Blow out the generator and controls peri-
odically with low pressure air. Do this at least once a • If the GFCI has tripped, first carefully remove any
week in particularly dirty areas. load and check it for damage.
• If the equipment has been shut down, it must be
BRUSH REMOVAL AND REPLACEMENT: It’s nor- restarted.
mal for the brushes and slip rings to wear and darken • The equipment needs to be operating at high idle
slightly. Inspect the brushes when a generator overspeed and any necessary adjustments made on the
haul is necessary. control panel so that the equipment is providing at
least 80 volts to the receptacle input terminals.
• The circuit breaker for this receptacle must not be
CAUTION tripped. Reset if necessary.
• Push the "Reset" button located on the GFCI. This
will assure normal GFCI operation.
• Do not attempt to polish slip rings while the • Plug a night-light (with an "ON/OFF" switch) or other
engine is running. product (such as a lamp) into the Duplex receptacle
and turn the product "ON".
• Push the "Test" button located on the GFCI. The
WARNING night-light or other product should go "OFF".
• Push the "Reset" button, again. The light or other
product should go "ON" again.
• Service and Repair should only be performed by
Lincoln Electric Factory Trained Personnel. If the light or other product remains "ON" when the
Unauthorized repairs performed on this equip- "Test" button is pushed, the GFCI is not working prop-
ment may result in danger to the technician and erly or has been incorrectly installed (miswired). If
machine operator and will invalidate your factory your GFCI is not working properly, contact a qualified,
warranty. For your safety and to avoid Electrical certified electrician who can assess the situation,
Shock, please observe all safety notes and pre- rewire the GFCI if necessary or replace the device.
cautions.
VANTAGE® 500-I
D-7 NOTES D-7
VANTAGE® 500-I
E-1 TROUBLESHOOTING E-1
HOW TO USE TROUBLESHOOTING GUIDE
WARNING
Service and Repair should only be performed by Lincoln Electric Factory Trained Personnel.
Unauthorized repairs performed on this equipment may result in danger to the technician and
machine operator and will invalidate your factory warranty. For your safety and to avoid Electrical
Shock, please observe all safety notes and precautions detailed throughout this manual.
__________________________________________________________________________
This Troubleshooting Guide is provided to help you Step 3. RECOMMENDED COURSE OF ACTION
locate and repair possible machine malfunctions. This column provides a course of action for the
Simply follow the three-step procedure listed below. Possible Cause, generally it states to contact your
local Lincoln Authorized Field Service Facility.
Step 1. LOCATE PROBLEM (SYMPTOM).
Look under the column labeled “PROBLEM (SYMP- If you do not understand or are unable to perform the
TOMS)”. This column describes possible symptoms Recommended Course of Action safely, contact your
that the machine may exhibit. Find the listing that local Lincoln Authorized Field Service Facility.
best describes the symptom that the machine is
exhibiting.
Step 2. POSSIBLE CAUSE.

The second column labeled “POSSIBLE CAUSE” lists
the obvious external possibilities that may contribute
to the machine symptom.
CAUTION
If for any reason you do not understand the test procedures or are unable to perform the tests/repairs safely, contact your
Local Lincoln Authorized Field Service Facility for technical troubleshooting assistance before you proceed.
VANTAGE® 500-I
Observe all Safety Guidelines detailed throughout this manual
PROBLEMS POSSIBLE RECOMMENDED
(SYMPTOMS) CAUSE COURSE OF ACTION
Major Physical or Electrical Damage 1. Contact your local Lincoln
is Evident. Authorized Field Service
Facility.
Engine will not "crank". 1. Battery is low, Charge Battery.

2. Loose battery cable connections.
Inspect, clean and tighten terminals.
3. Faulty engine starter motor.
Contact authorized local Engine
Service Shop.
Engine will "crank" but not start. 1. Fuel shut off valve on Main Fuel
Filter in the OFF position. Open
valve (vertical) position of handle.
2. Fuel Filters dirty/clogged. Check
and replace main filter element
and/or Inline Fuel Filter.
3. Out of fuel. Fill tank and bleed fuel
system.
4. High coolant temperature or low
oil pressure. (indictor lights lit) If all recommended possible areas
Check oil and coolant levels. Fill if of misadjustment have been
required. Check for loose or bro- checked and the problem persists,
ken fan belt. Contact your local Lincoln
5. Faulty fuel shutdown solenoid. Authorized Field Service Facility.
Check that shutdown solenoid is
functioning properly and not bind-
ing/ contact authorized engine
service shop.
6. Faulty fuel pump. Check for fuel
flow through filters. Contact autho-
rized local Engine Service Shop.
Engine shuts down shortly after 1. High coolant temperature or low

starting. oil pressure. (indictor light lit)
Change oil and oil filters and fill to
proper level. Check and fill coolant
level. Check for loose or broken
fan belt. Start engine and look for
leaks.
2. Faulty oil pressure switch or other
engine component. Contact
authorized local Engine Service
Shop.
3. Faulty Idler/Protection Board.
CAUTION
VANTAGE® 500-I
Engine shuts down while under a 1. High radiator coolant tempera-
load. ture. Reduce load if it is exceed-
ing machine rating. Add coolant
to system if low. Clean fins on
radiator if dirty. Tighten fan belt if
loose. Remove objects blocking
or close to intake openings on
both sides of base and exhaust
end (case back).
Engine runs rough. 1. Dirty fuel or air filters. Inspect and

clean/replace filters as needed.
Inspect and clean/replace filters
as needed.
2. Water in fuel. If water found in
tank. Empty fuel tank and refill
then purge fuel lines.
Battery does not stay charged. 1. Faulty battery. Replace.

Engine alternator trouble light is on 2. Loose connections at battery or
while machine is running. alternator. Clean and tighten con-
nections. If all recommended possible areas of
3. Faulty engine alternator or charg- misadjustment have been checked
er module. Consult authorized and the problem persists, Contact
Engine Service Shop. your local Lincoln Authorized
Field Service Facility.
Engine will not idle down to low 1. Idler switch in High idle position.
speed. Set switch to Auto.
2. External load on welder or auxil-
iary power. Remove all external
loads.
3. Faulty PC board or idler sole-
noid.
Engine will not go to high idle when 1. Poor work lead connection to
attempting to weld. work. Make sure work clamp is
tightly connected to clean base
metal.
2. "Contactor" switch is in wrong
position. Set to "Welding On" when
welding without a control cable.
Refer to Operations chapter for prop-
er use of this switch.
3. Faulty PC board. Low idle speed
set to low.
CAUTION
VANTAGE® 500-I
Engine will not go to high idle when 1. Auxiliary power load is less than
using auxiliary power. 100 watts. Idler may not respond
with less than a 100 watt load. Set
idler to "High".
2. Faulty PC board.(Control or Idler).
Engine will not go to high idle 1. Faulty idler solenoid. Check for
under weld or auxiliary loading. bent linkage or broken spring.
2. Faulty PC board.(Control or Idler).
Engine does not develop full 1. Fuel filter clogged, Replace.

power. Engine runs rough. 2. Air filter clogged, clean or replace.
3. High idle setting incorrect, check
and adjust if required.
4. Valves out of adjustment.
5. Fuel contaminated with water or
sediment. Check fuel pre-filter
and empty of water, bleed fuel
system. Replace fuel in tank if
needed.
Engine will not go to high idle when 1. Broken spring on Idle Solenoid,
attempting to weld or using auxil- solenoid linkage binding, Faulty If all recommended possible areas
iary power. Switching to manual PC board (Control or Idler), low of misadjustment have been
high idle does not work. idle speed set too low on idle checked and the problem persists,
solenoid. Contact your local Lincoln
Authorized Field Service Facility.
Engine will not shut off. 1. Fuel Shutdown solenoid not func-
tioning properly / linkage binding.
Stop engine by shutting off valve
located on main fuel filter. Contact
Shop.
Engine does not develop full power. 1. Fuel filter dirty/clogged. Replace.
Low weld and auxiliary output. 2. Air filter dirty/clogged. Replace Air
Engine runs rough. Filter Element.
3. Fouled fuel injector(s). Contact
authorized Engine Service Shop.
4. Fuel contaminated with water.
Check water separator for water.
Clean and replace as needed.
Replace fuel in tank.
5. Cracked or loose fuel hose.
Replace hose and tighten clamps.
6. Valves out of adjustment. Contact
Shop.
CAUTION
VANTAGE® 500-I
No welding power output. 1. Poor work lead connection to
work. Make sure work clamp is
metal.
2. "Weld Terminals" switch in wrong
position. Place switch in "Weld
Terminals On" position when
welding without control cable.
3. Faulty PC board or welder alterna-
tor.
Welder has output but no control. 1. Poor remote/control cable connec-

tion to 6-pin or 14-pin connector.
Check connections.
2. Faulty remote cable or faulty wire
feeder or wire feeder cable.
Replace if necessary.
3. Faulty control potentiometer or PC
board.
If all recommended possible areas

No auxiliary power. 1. Open circuit breakers. Reset of misadjustment have been
breakers. If breakers keep tripping checked and the problem persists,
reduce power draw. Contact your local Lincoln
2. GFCI may have tripped. Authorized Field Service Facility.
Follow “GFCI Testing and
Resetting Procedure” in the MAIN-
TENANCE section of this manual.
3. Faulty connections to auxiliary
receptacles. Check connections.
tor.
CAUTION
VANTAGE® 500-I
The welding arc is “cold.” The weld- 1. Make sure the MODE selector
ing arc is not stable or is not satis- switch is in the correct position for
factory. the engine runs normally. the process being used. (For exam-
The auxiliary power is normal. ple, CV-WIRE, PIPE, CC-STICK.)
2. Make sure the electrode (wire, gas,
voltage, current etc.) is correct for
the process being used.
3. Check for loose or faulty connec-
tions at the weld output terminals
and welding cable connections.
4. The welding cables may be too long
or coiled, causing an excessive
voltage drop. If all recommended possible areas of
5. Faulty Control Board. misadjustment have been checked
and the problem persists, Contact
your local Lincoln Authorized
No output in Pipe Mode. 1. Poor work lead connection to Field Service Facility.
work. Make sure work clamp is
metal.
2. "Weld Terminals" switch in wrong
position. Place switch in "Weld
Terminals On" position when
welding without control cable.
tor
CAUTION
VANTAGE® 500-I
E-7 NOTES E-7
VANTAGE® 500-I
F-1 DIAGRAMS F-1
INSTRUCTIONS FOR INSTALLING A RESIDUAL CURRENT DEVICE

TO PROTECT THE 240V SINGLE PHASE RECEPTACLE
WARNING
Do not operate with covers removed
Disconnect input power before servicing
Do not touch electrically live parts
Only qualified persons should install,
ELECTRIC use or service this equipment
SHOCK
CAN KILL
1. TURN OFF THE ENGINE AND DISCONNECT THE NEGATI VE BATTERY CABLE.
2. REMOVE THE FOUR SCREWS THAT SECURE THE UPPER CONTROL PANEL AND
OPEN THE PANEL.
3. WHILE HOLDING THE RCD MOUNTI NG BRACKET REMOVE THE TWO SCREWS
SECURING THE COVER PLATE AND RCD MOUNTING BRACKET. SET THE RCD
MOUNTING BRACKET AND SCREWS ASIDE AND DISCARD COVER PLATE.
(SEE FIGURE 1).
UPPER CONTROL
PANEL
RCD MOUNTING
BRACKET
COVER PLATE FIGURE 1

A
M22156
VANTAGE® 500-I
F-2 DIAGRAMS F-2
4. ROUTE LEADS 3C & 6D THROUGH RCD O PENING AS SHOWN

(SEE FIGURE 2). CUT BO TH LEADS AS SHOWN.
5. STRIP ALL FOUR LEADS 13MM (.50”).
RCD OPENING
6D
3C
6D 3C
CUT LEAD
FIGURE 2
6. CONNECT LEADS FROM CIRCUIT BREAKERS TO RCD AS SHOWN

(SEE FIGURE 3). NOTE LEAD CONFIG URATIO N.
7. TIGHTEN LEADS TO 2.4NM (21 IN. LBS.) MOUNT RCD TO PANEL USING
MOUNTING BRACKET AND SCREWS SET ASIDE IN STEP 3.
CIRCUIT BREAKERS
6D
3C
6D
3C
FIGURE 3 RCD
8. SECURE UPPER CONTROL PANEL IN PLACE.
9. RECONNECT NEGATIVE BATTERY CABLE.
THE UNI T IS NOW READY FOR OPERATION
R
THE LINCOLN ELECTRIC COMPANY
World's Leader in Welding and Cutting Products
Sales and Service through Subsidiaries and Distributors Worldwide
Cleveland, Ohio 44117-1199 U.S.A. A
M22156
VANTAGE® 500-I
ENGINE WELDERS /LN-25 PRO, LN-25 OR LN-15 ACROSS THE ARC CONNECTION DIAGRAM WITH OPTIONAL REMOTE CONTROL
F-3
WARNING
ELECTRIC SHOCK can kill MOVING PARTS can injure
Do not operate with panels open. Keep guards in place.
Disconnect NEGATIVE (-) Battery lead Keep away from moving parts.
before servicing. Only qualified personnel should install,use
Do not touch electrically live parts. or service this equipment.
14 PIN 6 PIN
ENGINE OPTIONAL
CONNECTOR CONNECTOR
(MAY NOT WELDER REMOTE CONTROL
BE ON ALL
MACHINES)
LN-25 PRO, LN-25 OR LN-15
_ WIRE FEEDER
+ WORK CLIP LEAD
TO WORK
VANTAGE® 500-I
DIAGRAMS
TO WORK
ELECTRODE CABLE
N.A. WELDING CABLES MUST BE OF PROPER CAPACITY FOR THE CURRENT AND DUTY CYCLE OF IMMEDIATE
AND FUTURE APPLICATIONS. SEE OPERATING MANUAL.
N.B. CONNECT WELDING CABLES TO OUTPUT STUDS FOR DESIRED POLARITY. POSITION THE WIRE FEEDER
VOLTMETER SWITCH TO MATCH THE POLARITY OF THE ELECTRODE CABLE.
N.C. PLACE THE MODE SWITCH IN THE “CV-WIRE” POSITION.
N.D. PLACE THE WELDING TERMINALS SWITCH IN THE “WELD TERMINALS ON” POSITION.
N.E. PLACE IDLER SWITCH IN “AUTO” OR “HIGH” IDLE POSITION AS DESIRED.
A
F-3
S24787-1
F-4
VANTAGE® 500-I
WIRING DIAGRAM
NOTE: This diagram is for reference only. It may not be accurate for all machines covered by this manual. The specific diagram for a particular code is included
F-4
with the machine. If the diagram is illegible, write to the Service Department for a replacement. Give the equipment code number.
VANTAGE 500-I WIRING DIAGRAM FOR CODES 11954, 11961. 12304
F-5
VANTAGE® 500-I
DIAGRAMS
NOTE: This diagram is for reference only. It may not be accurate for all machines covered by this manual. The specific diagram for a particular code is included with the
F-5
machine. If the diagram is illegible, write to the Service Department for a replacement. Give the equipment code number.
VANTAGE 500-I WIRING DIAGRAM FOR CODES 13180
F-6
AUXILIARY POWER LEADS PASS THROUGH STATOR AUXILIARY WINDINGS

VANTAGE 500-I WIRING DIAGRAM TOROID THREE TIMES IN DIRECTION INDICATED
6 3
ELECTRICAL SYMBOLS PER E1537
ALL CASEFRONT COMPONENTS SHOWN VIEWED FROM REAR
5
RECTIFIER BRIDGE 3 6 261 6A 5A
260
-
B1-NEG
B4-NEG
POS-SHUNT POS-SHUNT
4
B1-NEG B4-NEG
+ 204S CB3
B2-POS 20A
50MV=400AMPS CB2 6E
B5-POS
W4 & W5 15A
206S W2 & W3 W1 & W6
+
14 14C
- B2-POS B5-POS
B4 3E 6F 6K
+
WELDING OUTPUT B1 W3 W2
TERMINAL W3 W2 3 4 6 GND-L 3D 6J 6L
3D 6J
206C
B5 CB4 5B 6G
B2 J10 J11
J13 15A
206 B7B8 CHOPPER X Z 240V/15A J12
CB1 240V NA
GROUNDED BY STATOR 1 PHASE 120V/16A
13 PCB3 3PH (BLUE) E NA
MOUNTING 13A WELD Y 1 PHASE SILVER
13C W4 W1 E
B6 W4 WINDINGS W1 3B 4A 3C 6D (YELLOW) GND-E
B3 GND-D
GND-M 23 25 3B 4A 6C 5D
W5 W6 6C GND-G
3E 3C 6D
R4
W5 W6
6E
BYPASS FILTER
208D GROUND STUD ON
ASSEMBLY 15
6G
AUXILIARY POWER
6F 6K RECEPTACLE PANEL
208 6L
B3 CHOKE HOT HOT
I
B6 CHOKE GND-D
MODE SELECTOR SWITCH GFCI GFCI 5
LINE
LINE
GND-E
LOAD
LOAD
13C 13 23 25 S5 5A 5H WHITE WHITE

WELDING OUTPUT L1 CHOKE GND-G
TERMINAL NEUTRAL STUD ON 5C 5C 5B 5D
CV GND-L
208A 214 10 AUXILIARY POWER 5E
RECEPTACLE PANEL 5E GND-J
217 GOUGE 1 STATOR 42V WINDING
FERRITE 218 PIPE 2 GND-K
CC 3 A 201 200B 200A 200
42
+
-
220 4 BRUSH BRUSH SHUTDOWN IDLER
TIG
+
222 41 5H 6A GLOW GLOW PLUG SOLENOID SOLENOID
4200MFD
300V PLUGS BUTTON
COIL HOLD PULL
-
ROTOR 6A 239 COIL COIL
208C NOT USED POSITIVE BRUSH CONNECTED TO
SLIP RING NEAREST TO THE RED WHT
LAMINATION BLK
201 201A
P56 P55
SHOWN IN J56 J55
256
5N HOUR METER "HIGH" POSITION 1 4
262 5P 232L
GND-J OUTPUT CONTROL ARC CONTROL WELDING TERMINAL HIGH IDLER 238C 226 227
+
-
GROUND STUD IN UPPER CONTROL PANEL CCW CCW CONTROL SWITCH CONTROL
GND-M
R1 R2 SHOWN IN "ALWAYS ON" POSITION AUTO SWITCH
GND-B 10K 4
VIEWED 10K VIEWED
FROM FROM 4A 257 CB5
263 5T 5U
BACK BACK 10A START BUTTON
77 76 75 277 278 279 2A
2 236A 238B
OIL PRESSURE
NOT USED 238A SENSOR & SWITCH
VANTAGE® 500-I
231 SWITCH
NOTE:
DIAGRAMS
234
FERRITE ON 6 PIN REMOTE 228 SENSOR 235
LEADS 75A & 76A 244 247 13C 14C
77A VOLTMETER AMMETER G WK
(3 TURNS) A RUN/STOP
REMOTE 76A
CONTROL B
75A OIL COOLANT SWITCH COOLANT TEMPERATURE
C M1 M3 M5 M9 SHOWN IN "RUN" POSITION SENSOR & SWITCH
CONTACTOR 2A M1 M3 M5 M9 PRESSURE TEMPERATURE FUEL 236B
D M2 M4 M6 M10 M2 M4 M6 M10 236A SWITCH
4A
E 215 241 SENSOR 235
216 ALT ENG 1 RUN
GROUND F GND-B 4 1 4 1 4
PROT
1 3 J53 J52 J51 STOP 232L
J60 229 FUEL LEVEL
FERRITE FERRITE 6 5J SENSOR
5U 4
232B 5M 238A
5R 232C 5L 232K 5K 232B 232K 232
5R 231
228 241 229
NOT USED 232C 232F
214
216
217
222
218
220
M6
M9
M10
25
M9
M3
M1
23
M10
257
14
208C
M2
M6
M4
M5
M2
M3
STARTER
M1
M4
M5
77
76
75
215
279
278
277
+
261
260
256
13
250
250
1 5 1 1 5 1 8 5S 227 SOLENOID
8 238 STARTING
5S 5T 5L 5J MOTOR
12V BATTERY
5G 5M 5K 5P
FERRITE ON 6 10 9 16 6 10 9 16 B1
TWISTED PAIR J5 J7 J3
405
243
J4
244
200
4 TURNS VOLT METER CONTROL, MODE SEL. CHOPPER, POWER, PWM, THERMAL 5 10 B3
ALTERNATOR -
AMMETER 12 VOLT GROUND STUD
263 ON UPPER CONTROL PANEL +
247 D+
VRD WELD BOARD 262 5N
B4 243
J31 226 GENERATOR SUPPORT
PCB1 232F
1 3 1 2 GND-K
76A
232 B2
400
75A
77A
234 ENGINE BLOCK
5G
405
4
J32
2
J33
400
1 6
J6 16 9 J1 J2 12 7 4 6 3 4
206S 2
AMPHENOL,I.D. ENGINE,PERIPHERAL IDLER/ENGINE SHUTDOWN PCB2 271
204S 1 SHUNT
8 6 1
1 A
B1
G7633-1PRINT
R
CLEVELAND, OHIO, U.S.A.
NOTE: This diagram is for reference only. It may not be accurate for all machines covered by this manual. The specific diagram for a particular code is included with the
F-6
machine. If the diagram is illegible, write to the Service Department for a replacement. Give the equipment code number.
F-7 DIMENSION PRINT F-7
VANTAGE® 500-I
Vantage 500-I - 12304
Contents
Engine Driven Welders

Vantage
Vantage 500-I - 12304
Index of Sub Assemblies - 12304........................................................................................1
Case Front & Control Panel Assembly ................................................................................3
Output Panel Assembly .......................................................................................................6
Power Module Panel Assembly ...........................................................................................9
Generator & Rotor Assembly.............................................................................................11
Base, Fuel Tank & Battery Assembly ................................................................................13
Engine Assembly ...............................................................................................................17
Case Back & Radiator Asbly .............................................................................................20
Enclosure Components......................................................................................................22
i
THIS PAGE INTENTIONALLY LEFT BLANK
ii
Index of Sub Assemblies - 12304
KEY PART NUMBER DESCRIPTION QTY
P-608-A INDEX OF SUB ASSEMBLIES AR
1 P-608-C CASE FRONT & CONTROL PANEL ASSEMBLY AR
2 P-608-D OUTPUT PANEL ASSEMBLY AR
3 P-608-E POWER MODULE PANEL ASSEMBLY AR
4 P-608-F GENERATOR & ROTOR ASSEMBLY AR
5 P-608-G BASE FUEL TANK & BATTERY ASSEMBLY AR
6 P-608-H ENGINE ASSEMBLY AR
7 P-608-J_2 CASE BACK & RADIATOR ASBLY AR
8 P-608-K ENCLOSURE COMPONENTS AR
Printed 07/11/2016 at 11:31:21. Produced by Enigma.
Vantage 500-I - 12304 1

Index of Sub Assemblies - 12304
P-608-A.jpg
2 Vantage 500-I - 12304

Case Front & Control Panel Assembly
9SG4982-36 CONTROL PANEL ASBLY 1
1 9SG4867-1 CONTROL PANEL 1
9SS9262-27 PLAIN WASHER 2
9SCF000010 #10-24HN 4
9SE106A-1 LOCKWASHER 2
9SM19685-17 CONNECTOR & LEAD ASBLY 1
5B 9ST10491-1 KNOB 1
5C 9ST10491 KNOB 2
5D 9ST13483-7 O RING 011 3
9SM19685-23 CONNECTOR & LEAD ASBLY 1
6A 9SS12021-68 CONNECTOR 1
6B 9SS17062-10 CABLE CONNECTOR CAP 1
6C 9SS28004 COVER PLATE 1
6D 9SS8025-96 SELF TAPPING SCREW 8
7 9SS17585-1 FUEL GAUGE 1
8 9SS25154-2 WATER TEMPERATURE GAUGE 1
9 9SS20206-2 OIL PRESSURE GAUGE 1
10 9ST13534-11 PILOT LIGHT 2
11A 9SS24659 CATCH BRACKET 1
9SS8025-98 SELF TAPPING SCREW 2
13 9SS17475-3 HOURMETER 1
14A 9ST10800-36 SWITCH-TOGGLEDPDT 1
9SS22061-4 SEALING BOOT 1
15 9SS13146-4 SWITCH-PUSH BUTTON 1
16 9SS13146-1 START BUTTON 1
17A 9ST10800-38 SWITCH-TOGGLE 2

19 9SG7166 DECAL CARRIER 1
20A 9SG5507-3 WELD CONTROL PC BD ASBLY 1
20C 9SL11924-1 PC BD MOUNTING BRKT 1
9ST9187-13 #10-24HLN-1817/1-NYLON INSERT 4
9SG6349 WIRING HARNESS 1
22A 9ST13637-6 DIODE-BRIDGE35A400VF-W1-PH 1
Vantage 500-I - 12304 3

9SS10773-7 INSULATING WASHER 1
9SCF000010 #10-24HN 1
24 9ST14659-1 FASTENER BUTTON 1
K2467-1 DIGITAL WELD METER KIT 1
31A 9SL11160 METER HOUSING ASBLY 2
9SS24630 METER HOUSING SEAL 2
31E 9SM19368 METER BEZEL 2
31F 9ST14807-9 FILTER LENS 2
31G 9SCF000389 #4-40X.375SS-PPNHS-FULL-GR2-3147 4
9SCF000005 #6-32HN 4
9SM21328-21 DOOR DECAL & LATCH ASBLY 1
35A 9SL12440 FLIP DOWN DOOR ASBLY 1
35B 9SG7166 DECAL CARRIER 1
35C 9SS25569 DOOR PADDLE LATCH 1
9SS9225-68 THREAD FORMING SCREW (CUTTING) 4
38A 9ST12287-20 CIRCUIT BREAKER-10A250VAC 1
9SS22104-9 TOROID ASBLY 1
9SL13117 CASE FRONT & INSERT ASBLY 1
48A 9SG4865 CASEFRONT 1

48C 9SG4870 CASEFRONT INSERT 1
9SM17238 INSTRUCTION TAG 1
50 9SG6048 SHIELD 1
4 Vantage 500-I - 12304

P-608-C.jpg
Vantage 500-I - 12304 5

Output Panel Assembly
9SG4983-31 OUTPUT PANEL ASSEMBLY 1
1A 9SG4866-13 WELD OUTPUT PANEL 1
9SCF000010 #10-24HN 4
5A 9SS11668-2 RECEPTACLE DUPLEX 120VAC 20A 1
5B 9SS27290 COVER RECEPTACLE DUPLEX 1
5C 9SL13286 GFCI HOUSING 1
5D 9SS27167 MOUNTING BRACKET 1
5E 9SS24738-3 THERMOPLASTIC SCREW 2
6A 9ST12287-38 CIRCUIT BREAKER 1
6B 9SS22061-2 SEALING BOOT 1
7A 9SM20152-2 RECEPTACLE-115V 1
8A 9ST12287-22 CIRCUIT BREAKER-15A 1
8B 9SS22061-1 CIRCUIT BREAKER BOOT 1
9A 9SM20152-3 RECEPTACLE-230V 1
10A 9SM20585-3 CIRCUIT BREAKER 2 POLE 1
10B 9SS24911-2 COVER CIRCUIT BREAKER 2 POLE 1
9ST10082-30 SEMS SCREW 4
11A 9SS28004-1 COVER PLATE 1
11B 9SS25322-2 RCD STRAP 1
12A 9SS18907-3 RECEPTACLE 250v 50A 1

12B 9SM18861 RECEPTACLE COVER 1
9ST9695-3 LOCKWASHER 4
9SCF000042 #8-32HN 4
13A 9SM20586-1 CIRCUIT BREAKER50A3 POLE 1
13B 9SS24911-4 CIRCUIT BREAKER COVER 1
9ST10082-30 SEMS SCREW 6
9ST4291-A LOCKWASHER 6
14E 9SS26843-1 GFCI REWORK 2
14F 9SS28464 GFCI COVER 2
6 Vantage 500-I - 12304

14G 9SL13286 GFCI HOUSING 2
14H 9SS27167 MOUNTING BRACKET 2
9SS24738-3 THERMOPLASTIC SCREW 4
20A 9SM13900 OUTPUT TERMINAL ASBLY 2
21A 9SM20007 OUTPUT STUD COVER 2
21B 9SS25669 OUTPUT STUD COVER PLATE 2
21C 9SS9225-68 THREAD FORMING SCREW (CUTTING) 4
22A 9ST9187-1 1/4-20HJLN 1
22B 9SCF000017 1/4-20HN 1
9SS24097-2 SHUNT & LEAD ASBLY 1
Vantage 500-I - 12304 7

P-608-D.jpg
8 Vantage 500-I - 12304

Power Module Panel Assembly
9SG5011-4 POWER MODULE PANEL ASBLY 1
1 9SG4930-1 POWER MODULE PANEL 1
2A 9SG4932-1 FUEL TANK FRONT PANEL 1
2B 9SS9225-68 THREAD FORMING SCREW (CUTTING) 1
3 9ST12380-4 BUSHING 1
4A 9SS26006-1 CHOPPER BRACKET 2
5A 9SL12683-1 CHOPPER HEAT SINK 1
9SS25930-6 TORX BUTTON HEAD SCREW 1/4-20X.62 4
7A 9SS10404-138 RESISTOR-WW100W505% 1
7B 9SCF000191 #10-24X7.50RHS 1
7C 9SS9262-27 PLAIN WASHER 2
7E 9SCF000010 #10-24HN 1
8A 9SS22168 HEAT SINK HOLDER 2
8B 9SS9225-45 THREAD FORMING SCREW 2
9A 9SL11132-2 THREE PHASE BRIDGE RECTIFIER 1
15A 9SL12400-3V1 IDLER/ENGINE SHUTDOWN PC BD ASBLY 1
15B 9SS8025-100 SELF TAPPING SCREW 4
Vantage 500-I - 12304 9

Power Module Panel Assembly
P-608-E.jpg
10 Vantage 500-I - 12304

Generator & Rotor Assembly
9SL10742-15 GENERATOR ASBLY 1
1 9SG3088-16 STATOR TIE BAR ASBLY 1
9SL13110-3 ROTOR & COUPLING DISC ASBLY 1
2A 9SL10501-5 ROTOR & SHAFT ASBLY 1
2B 9SM19796 COUPLING DISC 1
9SS8042 COUPLING DISC BACKING PLATE 2
2D 9SS14233 COUPLING CLAMP RING-INSIDE 1
2E 9ST8833-2 HEX HD CAP SCREW 8
2F 9SE106A-8 LOCKWASHER 8
3A 9SS22657 FAN COUPLE 1
3B 9SCF000025 3/4-10HN 1
3C 9SE106A-7 LOCKWASHER 1
4A 9SL9551 FAN BLADE 1
4B 9SS9225-22 THREAD FORMING SCREW (ROLLING) 4
4C 9SE106A-14 LOCKWASHER 4
5A 9SM9300-85 BEARING 1
5B 9SS18044-5 TOLERANCE RING 1
9A 9SS11868-1 BLOWER SEGMENT 4
9B 9ST14731-61 METRIC SOCKET HD SCREW-M10 X 1.25 SS 8
9C 9SS17400-1 LOCKWASHER-METRIC 8
9ST8833-10 HEX HD CAP SCREW 8
15A 9ST8833-86 HEX HD CAP SCREW 2
15B 9SE106A-16 LOCKWASHER 2
15C 9SS9262-120 PLAIN WASHER 2
9SM21315 BRUSH HOLDER & BRACKET ASBLY 1

18A 9SM18323 BRUSH HOLDER BRKT 1
18B 9SM16158 BRUSH & BRUSH HOLDER ASBLY 1
9SG2114 BRUSH HOLDER CARTRIDGE 1
9SS19480 BRUSH ASBLY 2
9SM16157 BRUSH ASBLY RETAINER 1
18C 9ST12380-4 BUSHING 1
9SS9225-8 THREAD FORMING SCREW (ROLLING) 2
Vantage 500-I - 12304 11

Generator & Rotor Assembly
P-608-F.jpg
12 Vantage 500-I - 12304

Base, Fuel Tank & Battery Assembly
1 9SG4900-4 BASE 1
2A 9SM20610 MOUNTING BRACKET 4
2B 9SS9225-64 SELF TAPPING SCREW 8
3A 9SL12454-11 STATOR SUPPORT 1
3C 9SL12454-12 SUPPORT 1
5A 9ST11991-2 RUBBER MOUNTING 4
6A 9SM9399-11 BATTERY 1
6B 9SS8070-51 BATTERY CABLE (NEGATIVE) 1
6C 9SS8070-47 BATTERY CABLE 1
9ST14815-2 METRIC HEX NUT-M8 X 1.25 BRASS 1
6E 9SM20535 BATTERY TRAY 1
6F 9SS22018 BATTERY BRKT 1
6G 9ST11827-31 CARRIAGE BOLT 2
6H 9ST9187-6 LOCKNUT 2
6J 9ST14654 CAP-PLASTIC 1
7 9SS20191-1 BATTERY TERMINAL COVER 1
9SG6071 FUEL TANK ASSEMBLY 1
11A 9SG6058 FUEL TANK 1
11B 9SL12505 FUEL SENDER 1
11C 9SS19564-1 FUEL FITTING (PUSH-IN) 1
11D 9SS19563 RUBBER PLUG 2

11E 9SS20541 FUEL CAP 1
11F 9SS19564-5 FUEL FITTINGPUSH-IN 1
14A 9SM20547 CHOKE BRACKET 1
14B 9SM19416-2 CHOKE ASBLY 1
14C 9SCF000187 5/16-18X2.50HHCS 2
14D 9SS9262-121 PLAIN WASHER 2
14E 9SE106A-14 LOCKWASHER 2
14F 9SCF000029 5/16-18HN 2
Vantage 500-I - 12304 13

15A 9ST10642-231 FLEX TUBE 1
15B 9SS10888-35 HOSE CLAMP 2
16A 9ST10642-111 FLEX TUBE 1
16B 9SS10888-35 HOSE CLAMP 2
19A 9SG6084 LIFT BALE FRAME 1
9SCF000027 1/2-13HN 4
20A 9SS10227-61 LIFT BALE 1
9SCF000027 1/2-13HN 4
9SL13304 FUEL TANK TRAY 1
22A 9SL12458-1 FAN GUARD 1
22B 9SL12485 STATOR FAN SHROUD 1
22D 9SL10121-1 BYPASS/STABILIZER PC BD ASBLY 1
22E 9SS14020-3 PLASTIC EXPANSION NUT 3
22F 9SS8025-97 SELF TAPPING SCREW 3
22G 9SM20007 OUTPUT STUD COVER 1
22H 9SS25669 OUTPUT STUD COVER PLATE 1
22J 9SS9225-68 THREAD FORMING SCREW (CUTTING) 2
23A 9SCF000014 1/4-20X.75HHCS 2
23B 9SS9262-98 PLAIN WASHER 2

23D 9SE106A-2 LOCKWASHER 2
23E 9SCF000017 1/4-20HN 2
25A 9SS13490-171A FILTER CAPACITOR 1
25B 9SS22747 CAPACITOR BRKT ASBLY 1
9SS11604-65 SET SCREW 2
26A 9SL12457 SUPPORT RAIL 2
27 9SM16197 DECAL-WARNING 1
14 Vantage 500-I - 12304

9SS17851 DECAL-CAUTION 1
30A 9SM20612 CONTAINER BRACKET 1
31A 9SL12515-1 SIDE PANEL 1
9SS24739-27 1/4X.75 TEK SCREW 3
9ST14882-1 DOOR BUMPER 2
Vantage 500-I - 12304 15

P-608-G.jpg
16 Vantage 500-I - 12304

Engine Assembly
9SG6063-2 ENGINE ASSEMBLY 1
1 9SM25280 ENGINE 1
2B 9SM20808 SOLENOID BRACKET 1
9ST14731-31 METRIC HEX HD SCREW-M8 X1.25 2
9ST10642-86 FLEX TUBE 1
9ST13777-1 HOSE CLAMP 2
4A 9SM20840 FUEL PRE-FILTER/WATER SEPARATOR 1
9SM20840-A WATER SEPARATOR ELEMENT SET 1
9SCF000073 5/16-18X2.75HHCS 1
9SCF000029 5/16-18HN 1
6A 9SL10878-2 MUFFLER ASBLY 1
7A 9SS24739-31 1/4-20 STAINLESS STEEL SCREW 1
7B 9SE106A-2 LOCKWASHER 1
8A 9SS20140-2 SOLENOID ASBLY 1
8C 9SS22070 IN-LINE SWIVEL 1
8D 9SCF000060 1/4-28HJN 4
8E 9SS22232 ROD END SWIVEL 1
8F 9SE106A-2 LOCKWASHER 5
8G 9SS26305-1 SOLENOID LINKAGE 1
9A 9ST10642-278 FLEX TUBE 1

9SS10888-27 HOSE CLAMP 1
10A 9SM25295 ENGINE FOOT WELDED ASBLY 2
12A 9SM20827 UPPER RADIATOR HOSE 1
9SM20828 LOWER RADIATOR HOSE 1
13A 9SM20501 AIR INTAKE HOSE 1
14A 9SS26772 LIFT EYE 1
Vantage 500-I - 12304 17

Engine Assembly
16A 9SM20358 AIR FILTER 1
16B 9SM20359 AIR FILTER MTG BAND 1
9SM20807 AIR CLEANER BRACKET 1
9SCF000028 5/16-18X1.25HHCS 2
9SCF000029 5/16-18HN 2
9SS24739-31 1/4-20 STAINLESS STEEL SCREW 3
18 Vantage 500-I - 12304

Vantage 500-I - 12304

P-608-H.jpg
Engine Assembly
19
Case Back & Radiator Asbly
1A 9SL13118-9 CASE BACK & RADIATOR ASBLY 1
9SG4901-10 CASE BACK 1
9SG3115-6 RADIATOR 1
9SM15045-80 ACOUSTICAL FOAM 2
9SG6916-2 FAN SHROUD 1
9SS9225-26 THREAD FORMING SCREW (ROLLING) 4
9ST11827-71 CARRIAGE BOLT 4
9SS30690 SPACER 4
9SS30686 ISOLATOR 4
9SM25275 MOUNTING BRACKET 2
9ST9187-10 3/8-16HLN-1817/1-NYLON INSERT 4
9ST10642-218 FLEX HOSE 1
9SS24068 FUEL SHUT-OFF 1
9ST10642-333 FLEX TUBE 1
9SM15045-89 ACOUSTICAL FOAM 1
10A 9SG4058-10 LEFT FAN GUARD 1
11A 9SG4060-10 FAN GUARD 1
12 9SS26354 ENGINE SERVICE DECAL 1

13 9ST13086-62 DECAL-WARNING 1
9ST14882 DOOR BUMPER 1
20 Vantage 500-I - 12304

Case Back & Radiator Asbly
P-608-J_2.jpg
Vantage 500-I - 12304 21

Enclosure Components
1A 9SG4902-1 ROOF 1
1B 9SS24739-27 1/4X.75 TEK SCREW 13
1C 9SL12084 FUEL TROUGH 1
9SM20278 RADIATOR CAP COVER ASSEMBLY 1
2A 9SS25717 RADIATOR CAP COVER 1
2B 9SS21250-19 HINGE - STAINLESS STEEL 1
2C 9SS24694 LATCH 1
9ST12584-12 BLIND RIVET 2
2E 9ST14882 DOOR BUMPER 2
9ST12584-6 RIVET 2
3A 9SG4903 LEFT CASE SIDE 1
9SS24739-27 1/4X.75 TEK SCREW 11
4A 9SG4904 RIGHT CASE SIDE 1
4B 9SS24739-27 1/4X.75 TEK SCREW 7
7A 9SL12516-1 DOOR SLIDE 1
7B 9SS24739-27 1/4X.75 TEK SCREW 12
7C 9SS25719-2 EDGE GUARD 2
9SL13813 DOOR ASBLY 1
8A 9SL12513-1 DOOR 1
8B 9SS25698 DOOR HOOK 2
8C 9SM20241 DOOR LATCH 1
8D 9ST12584-6 RIVET 6
8E 9ST14882-2 DOOR BUMPER 2
8F 9ST14882 DOOR BUMPER 2
8G 9SS27368-6 LOGO DECAL 1

8H 9SM21801 FAMILY NAME LOGO 1
10 9ST13086-205 FUEL WARNING DECAL 1
11 9SS12934-1 COVER SEAL 1
12 9SS25896 DECAL-WARNING 1
13 9SS27368-6 LOGO DECAL 1
15 9ST14882-1 DOOR BUMPER 2
17 9SM21801 FAMILY NAME LOGO 1
20 9SM21436 CARBON MONOXIDE WARNING DECAL 1
22 Vantage 500-I - 12304

22 9SS28039-1 DECAL GREEN INITIATIVE 1
Vantage 500-I - 12304 23

P-608-K.jpg
24 Vantage 500-I - 12304

WARNING
l Do not touch electrically live parts or l Keep flammable materials away. l Wear eye, ear and body protection.
l Insulate yourself from work and
AVISO DE
ground.
Spanish
l No toque las partes o los electrodos l Mantenga el material combustible l Protéjase los ojos, los oídos y el
PRECAuCION
bajo carga con la piel o ropa moja- fuera del área de trabajo. cuerpo.
da.
l Aislese del trabajo y de la tierra.
French
ATTENTION
l Ne laissez ni la peau ni des vête- l Gardez à l’écart de tout matériel l Protégez vos yeux, vos oreilles et
ments mouillés entrer en contact inflammable. votre corps.
avec des pièces sous tension.
l Isolez-vous du travail et de la terre.
German
WARNuNG
l Berühren Sie keine stromführenden l Entfernen Sie brennbarres Material! l Tragen Sie Augen-, Ohren- und Kör-
Teile oder Elektroden mit Ihrem perschutz!
Körper oder feuchter Kleidung!
l Isolieren Sie sich von den
Elektroden und dem Erdboden!
Portuguese
ATENÇÃO
l Não toque partes elétricas e elec- l Mantenha inflamáveis bem guarda- l Use proteção para a vista, ouvido e
trodos com a pele ou roupa molha- dos. corpo.
da.
l Isole-se da peça e terra.
Japanese
Chinese
Korean
Arabic
READ AND UNDERSTAND THE MANUFACTURER’S INSTRUCTION FOR THIS EQUIPMENT AND THE CONSUMABLES TO BE
USED AND FOLLOW YOUR EMPLOYER’S SAFETY PRACTICES.
SE RECOMIENDA LEER Y ENTENDER LAS INSTRUCCIONES DEL FABRICANTE PARA EL USO DE ESTE EQUIPO Y LOS
CONSUMIBLES QUE VA A UTILIZAR, SIGA LAS MEDIDAS DE SEGURIDAD DE SU SUPERVISOR.
LISEZ ET COMPRENEZ LES INSTRUCTIONS DU FABRICANT EN CE QUI REGARDE CET EQUIPMENT ET LES PRODUITS A
ETRE EMPLOYES ET SUIVEZ LES PROCEDURES DE SECURITE DE VOTRE EMPLOYEUR.
LESEN SIE UND BEFOLGEN SIE DIE BETRIEBSANLEITUNG DER ANLAGE UND DEN ELEKTRODENEINSATZ DES HER-
STELLERS. DIE UNFALLVERHÜTUNGSVORSCHRIFTEN DES ARBEITGEBERS SIND EBENFALLS ZU BEACHTEN.
WARNING
l Keep your head out of fumes. l Turn power off before servicing. l Do not operate with panel open or
l Use ventilation or exhaust to guards off.
remove fumes from breathing zone.
AVISO DE
l Los humos fuera de la zona de res- Spanish
l Desconectar el cable de ali- l No operar con panel abierto o
PRECAuCION
piración. mentación de poder de la máquina guardas quitadas.
l Mantenga la cabeza fuera de los antes de iniciar cualquier servicio.
humos. Utilice ventilación o
aspiración para gases.
French
ATTENTION
l Gardez la tête à l’écart des fumées. l Débranchez le courant avant l’entre- l N’opérez pas avec les panneaux
l Utilisez un ventilateur ou un aspira- tien. ouverts ou avec les dispositifs de
teur pour ôter les fumées des zones protection enlevés.
de travail.
German
WARNuNG
l Vermeiden Sie das Einatmen von l Strom vor Wartungsarbeiten l Anlage nie ohne Schutzgehäuse
Schweibrauch! abschalten! (Netzstrom völlig öff- oder Innenschutzverkleidung in
l Sorgen Sie für gute Be- und nen; Maschine anhalten!) Betrieb setzen!
Entlüftung des Arbeitsplatzes!
Portuguese
ATENÇÃO
l Mantenha seu rosto da fumaça. l Não opere com as tampas removidas. l Mantenha-se afastado das partes
l Use ventilação e exhaustão para l Desligue a corrente antes de fazer moventes.
remover fumo da zona respiratória. serviço. l Não opere com os paineis abertos
l Não toque as partes elétricas nuas. ou guardas removidas.
Japanese
Chinese
Korean
Arabic
LEIA E COMPREENDA AS INSTRUÇÕES DO FABRICANTE PARA ESTE EQUIPAMENTO E AS PARTES DE USO, E SIGA AS
PRÁTICAS DE SEGURANÇA DO EMPREGADOR.
CUSTOMER ASSISTANCE POLICY
The business of The Lincoln Electric Company is manufacturing and
selling high quality welding equipment, consumables, and cutting
equipment. Our challenge is to meet the needs of our customers and
to exceed their expectations. On occasion, purchasers may ask
Lincoln Electric for advice or information about their use of our
products. We respond to our customers based on the best information
in our possession at that time. Lincoln Electric is not in a position to
warrant or guarantee such advice, and assumes no liability, with
respect to such information or advice. We expressly disclaim any
warranty of any kind, including any warranty of fitness for any
customer’s particular purpose, with respect to such information or
advice. As a matter of practical consideration, we also cannot assume
any responsibility for updating or correcting any such information or
advice once it has been given, nor does the provision of information
or advice create, expand or alter any warranty with respect to the sale
of our products.
Lincoln Electric is a responsive manufacturer, but the selection and
use of specific products sold by Lincoln Electric is solely within the
control of, and remains the sole responsibility of the customer. Many
variables beyond the control of Lincoln Electric affect the results
obtained in applying these types of fabrication methods and service
requirements.
Subject to Change – This information is accurate to the best of our
knowledge at the time of printing. Please refer to
www.lincolnelectric.com for any updated information.
TABLE OF CONTENTS
INSTALLATION
OPERATION
ACCESSORIES
MAINTENANCE
TROUBLESHOOTING
DIAGRAMS

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Operator’s Manual

Register your machine: Need Help? Call 1.888.935.3877

For Service outside the USA:

Serial: (ex: U1060512345)

IM10003-C | Issue Date Apr-21

SECTION A: 1.d. Keep all equipment safety guards, covers

2.b. EMF fields may interfere with some pacemakers, and

ELECTRIC SHOCK ARC RAYS CAN BURN.

WELDING AND CUTTING CYLINDER MAY EXPLODE IF

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

4 cylinder 135.6(2.2) 12VDC Battery & Fuel: 20 gal.

AIR CLEANER ENGINE IDLER MUFFLER ENGINE PROTECTION

When operating the welder at an angle, the effective

1. Design capacity of trailer vs. weight of Lincoln equipment and

NOTE: This machine is furnished with a wet charged bat-

AUXILIARY POWER RECEPTACLES

The 120 V auxiliary power receptacles should only be

The Vantage 500-I is configured to allow for the addi-

CONNECTION OF LINCOLN ELECTRIC 1. Shut the welder off.

Connection of the LN-25 PRO or LN-25 to the VAN-

The LN-25 PRO or LN-25 with or without an internal

NOTE: The LN-25 (K431) Remote Control Module

4. ARC CONTROL- The ARC CONTROL dial is active ENGINE CONTROLS:

15. ENGINE PROTECTION LIGHT- A warning indi- CAUTION

This slope controlled setting is intended for "out-of- TABLE B.2

It is recommended that the ARC CONTROL be set

The VANTAGE® 500-I in the CV-WIRE mode, per-

The VANTAGE® 500-I is shipped with the negative

TIG WELDING The VANTAGE® 500-I can be used in a wide variety

1%, 2% Thoriated 1%, 2% Thoriated Aluminum Stainless Steel

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

Simultaneous Welding and Auxiliary Power Loads

VANTAGE® 500-I Simultaneous Welding and Power Loads

Tweco® is a registered trademark of Thermadyne.

KP509 Magnum Parts Kit for PTA-26V TIG Torch

SAFETY PRECAUTIONS Read the Safety Precautions in the front of this

MAINTENANCE ITEM TYPE OR QUANTITY

Above operations to be carried out by trained personnel with

These preventative maintenance periods apply to average

WARRANTY WORK PERFORMED ON THE ENGINE CONTAINED

See engine owner’s manual for more specific informa-

Periodically remove the dirt from the radiator fins.

TIGHTENING THE FAN BELT

If the fan belt is loose, the engine can overheat and

CHARGING THE BATTERY

facturer for proper charger settings and charging time.

SERVICING OPTIONAL SPARK

nect to new battery last.

negative cable first, then positive cable and

ative battery lead at engine foot. THE SPARK ARRESTER!

WELDER / GENERATOR GFCI TESTING AND RESETTING

The GFCI should be properly tested at least once

HOW TO USE TROUBLESHOOTING GUIDE

Step 2. POSSIBLE CAUSE.

Engine will not "crank". 1. Battery is low, Charge Battery.

Engine shuts down shortly after 1. High coolant temperature or low

Engine runs rough. 1. Dirty fuel or air filters. Inspect and

Battery does not stay charged. 1. Faulty battery. Replace.

Engine does not develop full 1. Fuel filter clogged, Replace.

Welder has output but no control. 1. Poor remote/control cable connec-