Lincoln Electric Welder IM10044 User Manual

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IM10044  
VANTAGE ®575 CUMMINS  
March, 2010  
For use with machine having Code Number:  
11686  
Safety Depends on You  
Lincoln arc welding and cutting  
equipment is designed and built  
with safety in mind. However,  
your overall safety can be  
increased by proper installation ...  
and thoughtful operation on your  
part. DO NOT INSTALL, OPER-  
ATE OR REPAIR THIS EQUIP-  
MENT WITHOUT READING  
THIS MANUAL AND THE SAFE-  
TY PRECAUTIONS CONTAINED  
THROUGHOUT. And, most  
importantly, think before you act  
and be careful.  
OPERATOR’S MANUAL  
Copyright © Lincoln Global Inc.  
• World's Leader in Welding and Cutting Products •  
• Sales and Service through Subsidiaries and Distributors Worldwide •  
Cleveland, Ohio 44117-1199 U.S.A. TEL: 216.481.8100 FAX: 216.486.1751 WEB SITE: www.lincolnelectric.com  
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SAFETY  
ARC RAYS can burn.  
ELECTRIC SHOCK can  
4.a. Use a shield with the proper filter and cover  
plates to protect your eyes from sparks and  
the rays of the arc when welding or observing  
open arc welding. Headshield and filter lens  
should conform to ANSI Z87. I standards.  
kill.  
3.a. The electrode and work (or ground) circuits  
are electrically “hot” when the welder is on.  
Do not touch these “hot” parts with your bare  
skin or wet clothing. Wear dry, hole-free  
gloves to insulate hands.  
4.b. Use suitable clothing made from durable flame-resistant  
material to protect your skin and that of your helpers from  
the arc rays.  
3.b. Insulate yourself from work and ground using dry insulation.  
Make certain the insulation is large enough to cover your full  
area of physical contact with work and ground.  
4.c. Protect other nearby personnel with suitable, non-flammable  
screening and/or warn them not to watch the arc nor expose  
themselves to the arc rays or to hot spatter or metal.  
In addition to the normal safety precautions, if welding  
must be performed under electrically hazardous  
conditions (in damp locations or while wearing wet  
clothing; on metal structures such as floors, gratings or  
scaffolds; when in cramped positions such as sitting,  
kneeling or lying, if there is a high risk of unavoidable or  
accidental contact with the workpiece or ground) use  
the following equipment:  
FUMES AND GASES  
can be dangerous.  
5.a. Welding may produce fumes and gases  
hazardous to health. Avoid breathing these  
• Semiautomatic DC Constant Voltage (Wire) Welder.  
• DC Manual (Stick) Welder.  
fumes and gases. When welding, keep  
your head out of the fume. Use enough  
ventilation and/or exhaust at the arc to keep  
• AC Welder with Reduced Voltage Control.  
fumes and gases away from the breathing zone. When  
welding with electrodes which require special  
ventilation such as stainless or hard facing (see  
instructions on container or MSDS) or on lead or  
cadmium plated steel and other metals or coatings  
which produce highly toxic fumes, keep exposure as  
low as possible and within applicable OSHA PEL and  
ACGIH TLV limits using local exhaust or mechanical  
ventilation. In confined spaces or in some circum-  
stances, outdoors, a respirator may be required.  
Additional precautions are also required when welding  
on galvanized steel.  
3.c. In semiautomatic or automatic wire welding, the electrode,  
electrode reel, welding head, nozzle or semiautomatic  
welding gun are also electrically “hot”.  
3.d. Always be sure the work cable makes a good electrical  
connection with the metal being welded. The connection  
should be as close as possible to the area being welded.  
3.e. Ground the work or metal to be welded to a good electrical  
(earth) ground.  
3.f. Maintain the electrode holder, work clamp, welding cable and  
welding machine in good, safe operating condition. Replace  
damaged insulation.  
5. b. The operation of welding fume control equipment is affected  
by various factors including proper use and positioning of  
the equipment, maintenance of the equipment and the spe-  
cific welding procedure and application involved. Worker  
exposure level should be checked upon installation and  
periodically thereafter to be certain it is within applicable  
OSHA PEL and ACGIH TLV limits.  
3.g. Never dip the electrode in water for cooling.  
3.h. Never simultaneously touch electrically “hot” parts of  
electrode holders connected to two welders because voltage  
between the 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 heat and rays of the arc can react with solvent vapors to  
form phosgene, a highly toxic gas, and other irritating prod-  
ucts.  
3.i. When working above floor level, use a safety belt to protect  
yourself from a fall should you get a shock.  
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  
material safety data sheet (MSDS) and follow your  
employer’s safety practices. MSDS forms are available from  
your welding distributor or from the manufacturer.  
5.f. Also see item 1.b.  
Jan ‘09  
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SAFETY  
WELDING and CUTTING  
CYLINDER may explode  
if damaged.  
SPARKS can  
cause fire or explosion.  
7.a. Use only compressed gas cylinders  
containing the correct shielding gas for the  
6.a. Remove fire hazards from the welding area.  
If this is not possible, cover them to prevent  
the welding sparks from starting a fire.  
process used and properly operating  
regulators designed for the gas and  
Remember that welding sparks and hot  
materials from welding can easily go through small cracks  
and openings to adjacent areas. Avoid welding near  
hydraulic lines. Have a fire extinguisher readily available.  
pressure used. All hoses, fittings, etc. should be suitable for  
the application and maintained in good condition.  
7.b. Always keep cylinders in an upright position securely  
chained to an undercarriage or fixed support.  
6.b. Where compressed gases are to be used at the job site,  
special precautions should be used to prevent hazardous  
situations. Refer to “Safety in Welding and Cutting” (ANSI  
Standard Z49.1) and the operating information for the  
equipment being used.  
7.c. Cylinders should be located:  
• Away from areas where they may be struck or subjected to  
physical damage.  
• A safe distance from arc welding or cutting operations and  
any other source of heat, sparks, or flame.  
6.c. When not welding, make certain no part of the electrode  
circuit is touching the work or ground. Accidental contact  
can cause overheating and create a fire hazard.  
7.d. Never allow the electrode, electrode holder or any other  
electrically “hot” parts to touch a cylinder.  
6.d. Do not heat, cut or weld tanks, drums or containers until the  
proper steps have been taken to insure that such procedures  
will not cause flammable or toxic vapors from substances  
inside. They can cause an explosion even though they have  
been “cleaned”. For information, purchase “Recommended  
Safe Practices for the Preparation for Welding and Cutting of  
Containers and Piping That Have Held Hazardous  
Substances”, AWS F4.1 from the American Welding Society  
(see address above).  
7.e. Keep your head and face away from the cylinder valve outlet  
when opening the cylinder valve.  
7.f. Valve protection caps should always be in place and hand  
tight except when the cylinder is in use or connected for  
use.  
7.g. Read and follow the instructions on compressed gas  
cylinders, associated equipment, and CGA publication P-l,  
“Precautions for Safe Handling of Compressed Gases in  
Cylinders,” available from the Compressed Gas Association  
1235 Jefferson Davis Highway, Arlington, VA 22202.  
6.e. Vent hollow castings or containers before heating, cutting or  
welding. They may explode.  
6.f. Sparks and spatter are thrown from the welding arc. Wear oil  
free protective garments such as leather gloves, heavy shirt,  
cuffless trousers, high shoes and a cap over your hair. Wear  
ear plugs when welding out of position or in confined places.  
Always wear safety glasses with side shields when in a  
welding area.  
FOR ELECTRICALLY  
powered equipment.  
8.a. Turn off input power using the disconnect  
switch at the fuse box before working on  
the equipment.  
6.g. Connect the work cable to the work as close to the welding  
area as practical. Work cables connected to the building  
framework or other locations away from the welding area  
increase the possibility of the welding current passing  
through lifting chains, crane cables or other alternate cir-  
cuits. This can create fire hazards or overheat lifting chains  
or cables until they fail.  
8.b. Install equipment in accordance with the U.S. National  
Electrical Code, all local codes and the manufacturer’s  
recommendations.  
8.c. Ground the equipment in accordance with the U.S. National  
Electrical Code and the manufacturer’s recommendations.  
6.h. Also see item 1.c.  
6.I. Read and follow NFPA 51B “ Standard for Fire Prevention  
During Welding, Cutting and Other Hot Work”, available  
from NFPA, 1 Batterymarch Park, PO box 9101, Quincy, Ma  
022690-9101.  
6.j. Do not use a welding power source for pipe thawing.  
Refer to http://www.lincolnelectric.com/safety for additional safety information.  
Jan ‘09  
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SAFETY  
PRÉCAUTIONS DE SÛRETÉ  
6. Eloigner les matériaux inflammables ou les recouvrir afin de  
prévenir tout risque d’incendie dû aux étincelles.  
Pour votre propre protection lire et observer toutes les instructions  
et les précautions de sûreté specifiques qui parraissent dans ce  
manuel aussi bien que les précautions de sûreté générales suiv-  
antes:  
7. Quand on ne soude pas, poser la pince à une endroit isolé de  
la masse. Un court-circuit accidental peut provoquer un  
échauffement et un risque d’incendie.  
Sûreté Pour Soudage A L’Arc  
8. S’assurer que la masse est connectée le plus prés possible  
de la zone de travail qu’il est pratique de le faire. Si on place  
la masse sur la charpente de la construction ou d’autres  
endroits éloignés de la zone de travail, on augmente le risque  
de voir passer le courant de soudage par les chaines de lev-  
age, câbles de grue, ou autres circuits. Cela peut provoquer  
des risques d’incendie ou d’echauffement des chaines et des  
câbles jusqu’à ce qu’ils se rompent.  
1. Protegez-vous contre la secousse électrique:  
a. Les circuits à l’électrode et à la piéce sont sous tension  
quand la machine à souder est en marche. Eviter toujours  
tout contact entre les parties sous tension et la peau nue  
ou les vétements mouillés. Porter des gants secs et sans  
trous pour isoler les mains.  
b. Faire trés attention de bien s’isoler de la masse quand on  
soude dans des endroits humides, ou sur un plancher  
metallique ou des grilles metalliques, principalement dans  
les positions assis ou couché pour lesquelles une grande  
partie du corps peut être en contact avec la masse.  
c. Maintenir le porte-électrode, la pince de masse, le câble  
de soudage et la machine à souder en bon et sûr état  
defonctionnement.  
9. Assurer une ventilation suffisante dans la zone de soudage.  
Ceci est particuliérement important pour le soudage de tôles  
galvanisées plombées, ou cadmiées ou tout autre métal qui  
produit des fumeés toxiques.  
10. Ne pas souder en présence de vapeurs de chlore provenant  
d’opérations de dégraissage, nettoyage ou pistolage. La  
chaleur ou les rayons de l’arc peuvent réagir avec les vapeurs  
du solvant pour produire du phosgéne (gas fortement toxique)  
ou autres produits irritants.  
d.Ne jamais plonger le porte-électrode dans l’eau pour le  
refroidir.  
e. Ne jamais toucher simultanément les parties sous tension  
des porte-électrodes connectés à deux machines à souder  
parce que la tension entre les deux pinces peut être le  
total de la tension à vide des deux machines.  
11. Pour obtenir de plus amples renseignements sur la sûreté,  
voir le code “Code for safety in welding and cutting” CSA  
Standard W 117.2-1974.  
f. Si on utilise la machine à souder comme une source de  
courant pour soudage semi-automatique, ces precautions  
pour le porte-électrode s’applicuent aussi au pistolet de  
soudage.  
2. Dans le cas de travail au dessus du niveau du sol, se protéger  
contre les chutes dans le cas ou on recoit un choc. Ne jamais  
enrouler le câble-électrode autour de n’importe quelle partie  
du corps.  
PRÉCAUTIONS DE SÛRETÉ POUR  
LES MACHINES À SOUDER À  
TRANSFORMATEUR ET À  
REDRESSEUR  
3. Un coup d’arc peut être plus sévère qu’un coup de soliel,  
donc:  
a. Utiliser un bon masque avec un verre filtrant approprié  
ainsi qu’un verre blanc afin de se protéger les yeux du ray-  
onnement de l’arc et des projections quand on soude ou  
quand on regarde l’arc.  
1. Relier à la terre le chassis du poste conformement au code de  
l’électricité et aux recommendations du fabricant. Le dispositif  
de montage ou la piece à souder doit être branché à une  
bonne mise à la terre.  
b. Porter des vêtements convenables afin de protéger la  
peau de soudeur et des aides contre le rayonnement de  
l‘arc.  
2. Autant que possible, I’installation et l’entretien du poste seront  
effectués par un électricien qualifié.  
c. Protéger l’autre personnel travaillant à proximité au  
soudage à l’aide d’écrans appropriés et non-inflammables.  
3. Avant de faires des travaux à l’interieur de poste, la debranch-  
er à l’interrupteur à la boite de fusibles.  
4. Des gouttes de laitier en fusion sont émises de l’arc de  
soudage. Se protéger avec des vêtements de protection libres  
de l’huile, tels que les gants en cuir, chemise épaisse, pan-  
talons sans revers, et chaussures montantes.  
4. Garder tous les couvercles et dispositifs de sûreté à leur  
place.  
5. Toujours porter des lunettes de sécurité dans la zone de  
soudage. Utiliser des lunettes avec écrans lateraux dans les  
zones où l’on pique le laitier.  
Mar. ‘93  
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SAFETY  
Electromagnetic Compatibility (EMC)  
Conformance  
Products displaying the CE mark are in conformity with European Community Council Directive of 3 May  
1989 on the approximation of the laws of the Member States relating to electromagnetic compatibility  
(89/336/EEC). It was manufactured in conformity with a national standard that implements a harmonized  
standard: EN 60974-10 Electromagnetic Compatibility (EMC) Product Standard for Arc Welding Equipment.  
It is for use with other Lincoln Electric equipment. It is designed for industrial and professional use.  
Introduction  
All electrical equipment generates small amounts of electromagnetic emission. Electrical emission may be  
transmitted through power lines or radiated through space, similar to a radio transmitter. When emissions  
are received by other equipment, electrical interference may result. Electrical emissions may affect many  
kinds of electrical equipment; other nearby welding equipment, radio and TV reception, numerical controlled  
machines, telephone systems, computers, etc. Be aware that interference may result and extra precautions  
may be required when a welding power source is used in a domestic establishment.  
Installation and Use  
The user is responsible for installing and using the welding equipment according to the manufacturer’s  
instructions. If electromagnetic disturbances are detected then it shall be the responsibility of the user of the  
welding equipment to resolve the situation with the technical assistance of the manufacturer. In some cases  
this remedial action may be as simple as earthing (grounding) the welding circuit, see Note. In other cases it  
could involve construction of an electromagnetic screen enclosing the power source and the work complete  
with associated input filters. In all cases electromagnetic disturbances must be reduced to the point where  
they are no longer troublesome.  
Note: The welding circuit may or may not be earthed for safety reasons according to national codes.  
Changing the earthing arrangements should only be authorized by a person who is compe-  
tent to access whether the changes will increase the risk of injury, e.g., by allowing parallel  
welding current return paths which may damage the earth circuits of other equipment.  
Assessment of Area  
Before installing welding equipment the user shall make an assessment of potential electromagnetic prob-  
lems in the surrounding area. The following shall be taken into account:  
a) other supply cables, control cables, signaling and telephone cables; above, below and adjacent to the  
welding equipment;  
b) radio and television transmitters and receivers;  
c) computer and other control equipment;  
d) safety critical equipment, e.g., guarding of industrial equipment;  
e) the health of the people around, e.g., the use of pacemakers and hearing aids;  
f) equipment used for calibration or measurement  
g) the immunity of other equipment in the environment. The user shall ensure that other equipment being  
used in the environment is compatible. This may require additional protection measures;  
h) the time of day that welding or other activities are to be carried out.  
L10093 3-1-96H  
VANTAGE® 575 CUMMINS  
Download from Www.Somanuals.com. All Manuals Search And Download.  
vi  
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SAFETY  
Electromagnetic Compatibility (EMC)  
The size of the surrounding area to be considered will depend on the structure of the building and other  
activities that are taking place. The surrounding area may extend beyond the boundaries of the premises.  
Methods of Reducing Emissions  
Mains Supply  
Welding equipment should be connected to the mains supply according to the manufacturer’s recommenda-  
tions. If interference occurs, it may be necessary to take additional precautions such as filtering of the mains  
supply. Consideration should be given to shielding the supply cable of permanently installed welding equip-  
ment, in metallic conduit or equivalent. Shielding should be electrically continuous throughout its length. The  
shielding should be connected to the welding power source so that good electrical contact is maintained  
between the conduit and the welding power source enclosure.  
Maintenance of the Welding Equipment  
The welding equipment should be routinely maintained according to the manufacturer’s recommendations.  
All access and service doors and covers should be closed and properly fastened when the welding equip-  
ment is in operation. The welding equipment should not be modified in any way except for those changes  
and adjustments covered in the manufacturers instructions. In particular, the spark gaps of arc striking and  
stabilizing devices should be adjusted and maintained according to the manufacturer’s recommendations.  
Welding Cables  
The welding cables should be kept as short as possible and should be positioned close together, running at  
or close to floor level.  
Equipotential Bonding  
Bonding of all metallic components in the welding installation and adjacent to it should be considered.  
However, metallic components bonded to the work piece will increase the risk that the operator could  
receive a shock by touching these metallic components and the electrode at the same time. The operator  
should be insulated from all such bonded metallic components.  
Earthing of the Workpiece  
Where the workpiece is not bonded to earth for electrical safety, not connected to earth because of its size  
and position, e.g., ships hull or building steelwork, a connection bonding the workpiece to earth may reduce  
emissions in some, but not all instances. Care should be taken to prevent the earthing of the workpiece  
increasing the risk of injury to users, or damage to other electrical equipment. Where necessary, the connec-  
tion of the workpiece to earth should be made by a direct connection to the workpiece, but in some countries  
where direct connection is not permitted, the bonding should be achieved by suitable capacitance, selected  
according to national regulations.  
Screening and Shielding  
Selective screening and shielding of other cables and equipment in the surrounding area may alleviate prob-  
lems of interference. Screening of the entire welding installation may be considered for special applications.  
1
_________________________  
1
Portions of the preceding text are contained in EN 60974-10: “Electromagnetic Compatibility (EMC) prod-  
uct standard for arc welding equipment.”  
L10093 3-1-96H  
VANTAGE® 575 CUMMINS  
Download from Www.Somanuals.com. All Manuals Search And Download.  
vii  
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for selecting a QUALITY product by Lincoln Electric. We want you  
to take pride in operating this Lincoln Electric Company product  
••• as much pride as we have in bringing this product to you!  
Thank You  
CUSTOMER ASSISTANCE POLICY  
The business of The Lincoln Electric Company is manufacturing and selling high quality welding equipment, consumables, and cutting equip-  
ment. 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 posses-  
sion at that time. Lincoln Electric is not in a position to warrant or guarantee such advice, and assumes no liability, with respect to such infor-  
mation 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.  
for any updated information.  
Please Examine Carton and Equipment For Damage Immediately  
When this equipment is shipped, title passes to the purchaser upon receipt by the carrier. Consequently, Claims  
for material damaged in shipment must be made by the purchaser against the transportation company at the  
time the shipment is received.  
Please record your equipment identification information below for future reference. This information can be  
found on your machine nameplate.  
Product _________________________________________________________________________________  
Model Number ___________________________________________________________________________  
Code Number or Date Code_________________________________________________________________  
Serial Number____________________________________________________________________________  
Date Purchased___________________________________________________________________________  
Where Purchased_________________________________________________________________________  
Whenever you request replacement parts or information on this equipment, always supply the information you  
have recorded above. The code number is especially important when identifying the correct replacement parts.  
On-Line Product Registration  
- Register your machine with Lincoln Electric either via fax or over the Internet.  
• For faxing: Complete the form on the back of the warranty statement included in the literature packet  
accompanying this machine and fax the form per the instructions printed on it.  
• For On-Line Registration: Go to our WEB SITE at www.lincolnelectric.com. Choose “Quick Links” and then  
“Product Registration”. Please complete the form and submit your registration.  
Read this Operators Manual completely before attempting to use this equipment. Save this manual and keep it  
handy for quick reference. Pay particular attention to the safety instructions we have provided for your protection.  
The level of seriousness to be applied to each is explained below:  
WARNING  
This statement appears where the information must be followed exactly to avoid serious personal injury or loss of life.  
CAUTION  
This statement appears where the information must be followed to avoid minor personal injury or damage to this equipment.  
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TABLE OF CONTENTS  
Page  
Installation.......................................................................................................................Section A  
Technical Specifications.......................................................................................................A-1  
Safety Precautions........................................................................................................A-2  
Location and Ventilation................................................................................................A-2  
Storing...........................................................................................................................A-2  
Stacking ........................................................................................................................A-2  
Angle of Operation ........................................................................................................A-2  
Lifting.............................................................................................................................A-3  
High Altitude Operation.................................................................................................A-3  
High Temperature Operation ........................................................................................A-3  
Towing...........................................................................................................................A-3  
Vehicle Mounting...........................................................................................................A-3  
Pre-Operation Engine Service..............................................................................................A-4  
Oil..................................................................................................................................A-4  
Fuel and Fuel Cap.........................................................................................................A-4  
Engine Coolant System.................................................................................................A-4  
Battery Connections......................................................................................................A-4  
Muffler Outlet Pipe ........................................................................................................A-5  
Spark Arrestor...............................................................................................................A-5  
Air Cleaner Inlet Hood..........................................................................................................A-5  
Welding Terminals................................................................................................................A-5  
Welding Output Cables .................................................................................................A-5  
Machine Grounding.......................................................................................................A-5  
Remote Control....................................................................................................................A-6  
Auxiliary Power Receptacles and Standby Power Connections ..........................................A-6  
Connection of Lincoln Electric Wire Feeders................................................................A-7, A-8  
________________________________________________________________________________  
Operation.........................................................................................................................Section B  
Safety Precautions ..............................................................................................................B-1  
General Description..............................................................................................................B-1  
Recommended Application, Generator ................................................................................B-1  
Controls and Settings ...........................................................................................................B-2  
Engine Controls ............................................................................................................B-2, B-3  
Welder Controls............................................................................................................B-3, B-4  
Auxiliary Power Controls...............................................................................................B-4, B-5  
Battery Jump Start Terminals...............................................................................................B-5  
What are VRD and ROCV Devices..................................................................................... B-6  
Welding Power Sources................................................................................................B-6  
Safety............................................................................................................................B-6  
VRD Operation Indicators .............................................................................................B-6  
Operation ......................................................................................................................B-6  
Starting Technique ...............................................................................................................B-7  
Break-In Period ....................................................................................................................B-7  
Typical Fuel Consumption....................................................................................................B-7  
Welding Operation................................................................................................................B-8  
Duty Cycle.....................................................................................................................B-8  
Stick Welding Mode ......................................................................................................B-8  
CC-Stick Mode..............................................................................................................B-8  
Touch Start TIG Mode...................................................................................................B-8  
VANTAGE® 575 Settings when using K930-2 TIG Module..........................................B-8  
Wire Welding-CV..................................................................................................................B-9  
Arc Gouging .........................................................................................................................B-9  
Typical Current Ranges for Tungsten Electrodes ................................................................B-9  
Paralleling...........................................................................................................................B-10  
Auxiliary Power Operation..................................................................................................B-10  
Simultaneous Welding and Auxiliary Power Loads............................................................B-10  
Simultaneous Welding and Power Loads, Extension Cord Length Recommendations.....B-10  
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TABLE OF CONTENTS  
Accessories........................................................................................................Section c  
Optional Field Installed Accessories......................................................................C-1  
________________________________________________________________________  
Maintenance.......................................................................................................Section D  
Safety Precautions ................................................................................................D-1  
Routine and Periodic Maintenance .......................................................................D-1  
Engine Maintenance..............................................................................................D-1  
Air Filter...................................................................................................D-1, D-2  
Fuel Filters ......................................................................................................D-3  
Cooling System...............................................................................................D-3  
Battery Handling .............................................................................................D-3  
Charging the Battery .............................................................................................D-4  
Nameplate / Warning Decal Maintenance.............................................................D-4  
Welder / Generator Maintenance ..........................................................................D-4  
Engine Maintenance Components ........................................................................D-4  
________________________________________________________________________  
Troubleshooting..............................................................................................Section E  
________________________________________________________________________  
Connection Diagrams, Wiring Diagrams and Dimension Print...................Section F  
________________________________________________________________________  
Parts List...................................................................................................P-639 Series  
________________________________________________________________________  
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A-1  
A-1  
INSTALLATION  
TECHNICAL SPECIFICATIONS - VANTAGE® 575 CUMMINS (K2170-2)  
INPUT - DIESEL ENGINE  
Make/Model  
Description  
Speed (RPM)  
Displacement  
cu. in. (ltrs.)  
Starting  
System  
Capacities  
4 cylinder  
High Idle 1590  
199(3.3)  
12VDC Battery &  
starter  
Fuel: 25 gal.  
(94.6 L)  
Oil: 2 gal. (7.5L)  
Cummins  
B3.3  
48 HP (36kw)  
1500 RPM  
Full Load 1500 Bore x Stroke inch (mm)  
Diesel Engine  
Low Idle 1300  
3.74 X 4.53  
(95 x 115mm)  
Radiator Coolant:  
2.6gal. (9.8L)  
RATED OUTPUT @ 104°F(40°C) - WELDER  
Duty Cycle  
Welding Output  
Volts at Rated Amps  
100%  
60%  
450 Amps (DC multi-purpose)  
500 Amps (DC multi-purpose)  
38 Volts  
40 volts  
OUTPUT @ 104°F(40°C) - WELDER AND GENERATOR  
Welding Range  
30 - 575 Amps CC/CV  
20 - 250 Amps TIG  
Open Circuit Voltage  
60 Max OCV @ 1590 RPM  
Auxiliary Power (1) (50 Hz)  
Outlets x Phase  
1 x 3ph  
Voltage  
415 Volts  
240 Volts  
Power  
20 Kva  
7.2 Kva  
Amps  
32 Amps  
15 Amps  
2 x 1ph  
PHYSICAL DIMENSIONS  
Height (2)  
Width  
Depth  
Weight  
42.0 in  
(1066.8 mm)  
32.7 in.  
(830.1mm)  
63.1 in.  
(1603mm)  
1625 lbs.  
(737kg)  
(Approx)  
1.  
2.  
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.  
Top of Enclosure, add 7.0” (177.8mm) for exhaust pipe.  
VANTAGE® 575 CUMMINS  
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A-2  
A-2  
INSTALLATION  
SAFETY PRECAUTIONS  
LOCATION AND VENTILATION  
WARNING  
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.  
Do not attempt to use this equipment until you  
have thoroughly read the engine manufacturer’s  
manual supplied with your welder. It includes  
important safety precautions, detailed engine  
starting, operating and maintenance instructions,  
and parts lists.  
CAUTION  
------------------------------------------------------------------------  
ELECTRIC SHOCK can kill.  
DO NOT MOUNT OVER COMBUSTIBLE SURFACES  
Where there is a combustible surface directly  
under stationary or fixed electrical equipment, that  
surface should be covered with a steel plate at  
least .06”(1.6mm) thick, which should extend not  
less than 5.90”(150mm) beyond the equipment on  
all sides.  
• Do not touch electrically live parts or  
electrode with skin or wet clothing.  
• Insulate yourself from work and  
ground  
• Always wear dry insulating gloves.  
------------------------------------------------------------------------  
ENGINE EXHAUST can kill.  
• Use in open, well ventilated areas or  
vent exhaust outside.  
------------------------------------------------------------------------  
STORING  
------------------------------------------------------------------------  
MOVING PARTS can injure.  
1. Store the machine in a cool, dry place when it is  
not in use. Protect it from dust and dirt. Keep it  
where it can’t be accidentally damaged from con-  
struction activities, moving vehicles, and other  
hazards.  
• Do not operate with doors open or  
guards off.  
• Stop engine before servicing.  
• Keep away from moving parts.  
------------------------------------------------------------------------  
See additional warning information at  
2. Drain the engine oil and refill with fresh 10W30  
oil. Run the engine for about five minutes to cir-  
culate oil to all the parts. See the MAINTE-  
NANCE section of this manual for details on  
changing oil.  
front of this operator’s manual.  
Only qualified personnel should install,  
use, or service this equipment.  
3. Remove the battery, recharge it, and adjust the  
electrolyte level. Store the battery in a dry, dark  
place.  
STACKING  
VANTAGE® 575 CUMMINS machines cannot be  
stacked.  
ANGLE OF OPERATION  
To achieve optimum engine performance the VAN-  
TAGE® 575 CUMMINS should be run in a level posi-  
tion. The maximum angle of operation for the VAN-  
TAGE® 575 CUMMINS engine is 20 degrees contin-  
ues in all directions and 30 degrees intermittent (less  
than 10 minutes). When operating the welder at an  
angle, provisions must be made for checking and  
maintaining the oil level at the normal (FULL) oil  
capacity. Also the effective fuel capacity will be slightly  
less than the specified 25 gal.(94.6 ltrs.).  
VANTAGE® 575 CUMMINS  
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A-3  
A-3  
INSTALLATION  
TOWING  
LIFTING  
The recommended trailer for use with this equipment  
for road, in-plant and yard towing by a vehicle is  
The VANTAGE® 575 CUMMINS lift bale should be  
used to lift the machine. The VANTAGE® 575 CUM-  
MINS is shipped with the lift bale retracted. Before  
attempting to lift the VANTAGE® 575 CUMMINS the  
lift bale must be secured in a raised position. Secure  
the lift bale as follows:  
(1)  
Lincoln’s K2636-1. 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 nor damage the welding equipment. Some of  
the factors to be considered are as follows:  
a. Open the engine compartment door.  
1. Design capacity of trailer vs. weight of Lincoln  
equipment and likely additional attachments.  
b. Locate the 2 access holes on the upper middle  
region of compartment wall just below the lift  
bale.  
2. Proper support of, and attachment to, the base of  
the welding equipment so that there will be no  
undue stress to the trailer’s framework.  
c. Use the lifting strap to raise the lift bale to the  
full upright position. This will align the mount-  
ing holes on the lift bale with the access holes.  
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.  
d. Secure the lift bale with 2 thread forming  
screws. The screws are provided in the  
shipped loose parts bag.  
4. Typical conditions of use, such as travel speed,  
roughness of surface on which the trailer will be  
operated, and environmental conditions.  
WARNING  
5. Proper preventative maintenance of trailer.  
6. Conformance with federal, state and local laws (1)  
.
• Lift only with equipment of ade-  
quate lifting capacity.  
(1)  
Consult applicable federal, state and local laws  
regarding specific requirements for use on public  
highways.  
• Be sure machine is stable when lift-  
ing.  
• Do not lift this machine using lift  
bail if it is equipped with a heavy  
accessory such as trailer or gas  
cylinder.  
VEHICLE MOUNTING  
FALLING  
• Do not lift machine if lift bail is  
damaged.  
WARNING  
EQUIPMENT can  
cause injury.  
• Do not operate machine while  
suspended from lift bail.  
Improperly mounted concentrated loads may  
cause unstable vehicle handling and tires or other  
components to fail.  
------------------------------------------------------------------------  
• Only transport this Equipment on serviceable  
vehicles which are rated and designed for such  
loads.  
• Distribute, balance and secure loads so vehicle  
is stable under conditions of use.  
• Do not exceed maximum rated loads for compo-  
nents such as suspension, axles and tires.  
• Mount equipment base to metal bed or frame of  
vehicle.  
• Follow vehicle manufacture’s instructions.  
------------------------------------------------------------------------  
HIGH ALTITUDE OPERATION  
At higher altitudes, output derating may be necessary.  
For maximum rating, derate the welder output 4% for  
every 300 meters (984 ft.) above 1500 meters (4920  
ft.). For output of 500A and below, derate the welder  
output 4% for every 300 meters (984 ft.) above 2100  
meters (6888 ft.).  
Contact a Cummins Service Representative for any  
engine adjustments that may be required.  
HIGH TEMPERATURE OPERATION  
At temperatures above 40°C (104°F), output voltage  
derating may be necessary. For maximum output cur-  
rent ratings, derate welder voltage rating 2 volts for  
every 10°C (21°F) above 40°C (104°F).  
VANTAGE® 575 CUMMINS  
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A-4  
A-4  
INSTALLATION  
PRE-OPERATION ENGINE AND COM-  
PRESSOR SERVICE  
ENGINE COOLANT  
WARNING  
READ the engine and compressor operating and  
maintenance instructions supplied with this machine.  
HOT COOLANT can burn skin.  
•Do not remove cap if radiator is hot.  
WARNING  
• Keep hands away from the engine  
muffler or HOT engine parts.  
------------------------------------------------------------------------  
The welder is shipped with the engine and radiator  
filled with a 50% mixture of ethylene glycol and water.  
See the MAINTENANCE section and the engine  
Operator’s Manual for more information on coolant.  
• Stop engine and allow to cool before  
fuelling.  
• Do not smoke when fuelling.  
• Fill fuel tank at a moderate rate and do not over-  
fill.  
BATTERY CONNECTION  
• Wipe up spilled fuel and allow fumes to clear  
before starting engine.  
WARNING  
GASES FROM BATTERY can explode.  
• Keep sparks and flame away from tank.  
------------------------------------------------------------------------  
• Keep sparks, flame and cigarettes  
away from battery.  
OIL  
To prevent EXPLOSION when:  
The VANTAGE® 575 CUMMINS is shipped with the  
engine crankcase filled with high quality SAE 10W-30  
oil (API class CD or better). Check the engine and  
compressor oil levels before starting the engine. If it is  
not up to the full mark on the dip stick, add oil as  
required. Check the oil level every four hours of run-  
ning time during the first 35 running hours. Refer to  
the engine Operator’s Manuals for specific oil recom-  
mendations and break-in information. The oil change  
interval is dependent on the quality of the oil and the  
operating environment. Refer to the engine Operator’s  
Manuals for the proper service and maintenance inter-  
vals.  
• INSTALLING A NEW BATTERY — disconnect  
negative cable from old battery first and connect  
to new battery last.  
• CONNECTING A BATTERY CHARGER — remove  
battery from welder by disconnecting negative  
cable first, then positive cable and battery clamp.  
When reinstalling, connect negative cable last.  
Keep well ventilated.  
• USING A BOOSTER — connect positive lead to  
battery first then connect negative lead to nega-  
tive battery lead at engine foot.  
BATTERY ACID can burn eyes and skin.  
FUEL USE DIESEL FUEL ONLY  
• Wear gloves and eye protection and  
be careful when working near battery.  
• Follow instructions printed on battery.  
Fill the fuel tank with clean, fresh diesel fuel. The  
capacity of the fuel tank is approximately 25 gallons  
(95 liters). See engine Operator’s Manual for specif-  
ic fuel recommendations. Running out of fuel may  
require bleeding the fuel injection pump.  
------------------------------------------------------------------------  
IMPORTANT: To prevent ELECTRICAL DAMAGE  
WHEN:  
NOTE: Before starting the engine, open the fuel shut-  
a) Installing new batteries.  
b) Using a booster.  
off valve (pointer to be in line with hose).  
FUEL CAP  
Use correct polarity — Negative Ground.  
Remove the plastic cap covering from the Fuel Tank  
Filler neck and install the Fuel Cap.  
VANTAGE® 575 CUMMINS  
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A-5  
A-5  
INSTALLATION  
The VANTAGE® 575 CUMMINS is shipped with the nega-  
tive battery cable disconnected. Before you operate the  
machine, make sure the Engine Switch is in the OFF posi-  
tion and attach the disconnected cable securely to the nega-  
tive (-) battery terminal.  
Listed in Table A.1 are copper cable sizes recom-  
mended for the rated current and duty cycle. Lengths  
stipulated are the distance from the welder to work  
and back to the welder again. Cable sizes are  
increased for greater lengths primarily for the purpose  
of minimizing cable voltage drop.  
Remove the insulating cap from the negative battery termi-  
nal. Replace and tighten negative battery cable terminal.  
NOTE: This machine is furnished with a wet charged bat-  
tery; if unused for several months, the battery may require a  
booster charge. Be sure to use the correct polarity when  
charging the battery.  
Table A.1 Combined Length of Electrode and  
Work Cables.  
TOTAL COMBINED LENGTH OF  
ELECTRODE AND WORK CABLES  
Cable Size for  
500 Amps  
Cable Length  
MUFFLER OUTLET PIPE  
100% Duty Cycle  
Remove the plastic plug covering the muffler outlet tube.  
Using the clamp provided secure the outlet pipe to the outlet  
tube with the pipe positioned such that it will direct the  
exhaust in the desired position.  
2)  
3/0 AWG (95mm  
0-150 Ft. (0-46 meters)  
150-200 Ft. (46-61 meters)  
200-250 Ft. (61-76 meters)  
2)  
3/0 AWG (95mm  
2)  
4/0 AWG(120mm  
MACHINE GROUNDING  
SPARK ARRESTOR  
Because this portable engine driven welder creates its  
own power, it is not necessary to connect its frame to  
an earth ground, unless the machine is connected to  
premises wiring (home, shop, etc.).  
Some federal, state or local laws may require that petrol or  
diesel engines be equipped with exhaust spark arrestors  
when they are operated in certain locations where unarrest-  
ed sparks may present a fire hazard. The standard muffler  
included with this welder has an internal spark arrestor.  
When required by local regulations, a suitable spark  
arrestor, must be installed and properly maintained.  
To prevent dangerous electric shock, other equipment  
to which this engine driven welder supplies power  
must:  
CAUTION  
WARNING  
An incorrect arrestor may lead to damage to the engine  
or adversely affect performance.  
------------------------------------------------------------------------------  
AIR CLEANER INLET HOOD  
Remove the plastic plug covering the air cleaner inlet. Install  
the air cleaner inlet hood to the air cleaner.  
• Be grounded to the frame of the welder using a  
grounded type plug or be double insulated.  
• Do not ground the machine to a pipe that carries  
explosive or combustible material.  
------------------------------------------------------------------------  
When this welder is mounted on a truck or trailer, its  
frame must be securely connected to the metal frame  
of the vehicle. When this engine driven welder is con-  
nected to premises wiring such as that in a home or  
shop, its frame must be connected to the system earth  
ground. See further connection instructions in the sec-  
tion entitled “Standby Power Connections” as well as  
the article on grounding in the latest National  
Electrical Code and the local codes.  
WELDING TERMINALS  
The VANTAGE® 575 CUMMINS is equipped with a toggle  
switch for selecting "hot" welding terminals when in the  
"WELD TERMINALS ON" position or "cold" welding termi-  
nals when in the "REMOTELY CONTROLLED" position.  
WARNING  
There is no VRD protection in the CV mode.  
In general, if the machine is to be grounded, it should  
be connected with a #8 or larger copper wire to a solid  
earth ground such as a metal ground stake going into  
the ground for at least 10 Feet or to the metal frame-  
work of a building which has been effectively ground-  
ed.  
With the toggle switch in the “WELD TERMINAL ON”  
position the voltage at the output terminal maybe up to  
60V. Only a LN-25 wire feeder with internal contactor  
should be used in this set up.  
-------------------------------------------------------------------------------  
WELDING OUTPUT CABLES  
The National Electric Code lists a number of alternate  
means of grounding electrical equipment. A machine  
With the engine off, route the electrode and work cables thru  
the strain relief bracket provided on the front of the base and  
connect to the terminals provided. These connections  
should be checked periodically and tightened if necessary.  
grounding stud marked with the symbol  
on the front of the welder.  
is provided  
VANTAGE® 575 CUMMINS  
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A-6  
A-6  
INSTALLATION  
REMOTE CONTROL  
The VANTAGE® 575 CUMMINS is equipped with a 6-  
pin and a 14-pin connector. The 6-pin connector is for  
connecting the K857 or K857-1 Remote Control or for  
TIG welding, the K870 foot Amptrol or the K963-3  
hand Amptrol. When in the CC-STICK or CV-WIRE  
modes and when a remote control is connected to the  
6-pin Connector, the auto-sensing circuit automatically  
switches the OUTPUT control from control at the  
welder to remote control.  
The auxiliary power receptacles should only be used  
with three or four wire earthed type plugs or approved  
double insulated tools. The current rating of any plug  
used with the system must be at least equal to the  
current capacity of the associated receptacle.  
STANDBY POWER CONNECTIONS  
The VANTAGE® 575 CUMMINS is suitable for tempo-  
rary, standby or emergency power using the engine  
manufacturer’s recommended maintenance schedule.  
When in TOUCH START TIG mode and when a  
Amptrol is connected to the 6-Pin Connector, the  
OUTPUT dial is used to set the maximum current  
range of the CURRENT CONTROL of the Amptrol.  
The VANTAGE® 575 CUMMINS can be permanently  
installed as a standby power unit for 415/240 volt (50  
Hz). Connections must be made by a licensed electri-  
cian who can determine how the 415/240 VAC power  
can be adapted to the particular installation and com-  
ply with all applicable electrical codes. The following  
information can be used as a guide by the electrician  
for most applications.  
In the CV-WIRE mode, if the feeder being used has a  
voltage control when the wire feeder control cable is  
connected to the 14-Pin Connector, the auto-sensing  
circuit automatically makes OUTPUT CONTROL inac-  
tive and the wire feeder voltage control active.  
Otherwise, the OUTPUT CONTROL is used to preset  
the voltage.  
1. Install an isolation switch between the power com-  
pany meter and the premises disconnect.(The  
VANTAGE® 575 CUMMINS and the power compa-  
ny supplies must not be connected together).  
The 14-pin connector is used to directly connect a  
wire feeder control cable. In the CV-WIRE mode,  
when the control cable is connected to the 14-pin con-  
nector, the auto-sensing circuit automatically makes  
the Output Control inactive and the wire feeder volt-  
age control active.  
Switch rating must be the same or greater than the  
customer’s premises disconnect and service over  
current protection.  
2. Take necessary steps to assure load is limited to  
the capacity of the VANTAGE® 575 CUMMINS by  
installing a 32 amp, 415 VAC three pole circuit  
breaker. Loading above the rated output will reduce  
output voltage below the allowable -10% of rated  
voltage which may damage appliances or other  
motor-driven equipment and may result in overheat-  
ing of the VANTAGE® 575 CUMMINS engine.  
WARNING  
NOTE: When a wire feeder with a built in welding  
voltage control is connected to the 14-pin connec-  
tor, do not connect anything to the 6-pin connec-  
tor.  
------------------------------------------------------------------------  
3. Install a 32 amp 3 phase plug to the triple-pole cir-  
cuit breaker using 6.02mm (minimum) x 4 conduc-  
tor cable of the desired length.(1 x 32 amp / 415 V  
& 2 x 15 amp / 240 V, plugs are available in the  
optional KA1373-2 plug kit).  
AUXILIARY POWER RECEPTACLES  
The auxiliary power capacity of the VANTAGE® 575  
CUMMINS is 20kVA of 50Hz three phase power pro-  
tected by an RCD (Residual Current Device) and a 3  
phase 32 amp circuit breaker. The auxiliary power  
capacity in watts equivalent to volt-amperes at unity  
power factor.  
4. Plug this cable into the 3 phase receptacle on the  
VANTAGE® 575 CUMMINS case front.  
This model has:  
1 x 3 phase and neutral Residual Current Device  
(RCD) protection (30mA)  
1 x 3 phase 32 amp Circuit Breaker  
1 x 3 phase 415 volt 32 amp  
2 x 1 phase 15 amp Circuit Breakers  
2 x 1 phase 240 volt 15 amp per outlet  
Note: The single-phase outlets are from different  
phases and cannot be paralleled.  
VANTAGE® 575 CUMMINS  
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A-7  
A-7  
INSTALLATION  
CONNECTION OF LINCOLN ELEC-  
TRIC WIRE FEEDERS  
• Set the "WELD TERMINALS" switch to "WELD  
TERMINALS ON".  
WARNING  
• When the gun trigger is closed, the current sens-  
ing circuit will cause the VANTAGE® 575 CUM-  
MINS engine to go to the high idle speed, the  
wire will begin to feed and the welding process  
started. When welding is stopped, the engine will  
revert to low idle speed after approximately 12  
seconds unless welding is resumed.  
Shut off welder before making any electrical con-  
nections.  
------------------------------------------------------------------------  
Connection of LN-7, LN-8 OR LN-742 to the VAN-  
TAGE® 575 CUMMINS  
1. Shut the welder off.  
4. Control Cable Model:  
2. Connect the LN-7, LN-8 OR LN-742 per instruc-  
tions on the appropriate connection diagram in  
Section F.  
• Connect Control Cable between Engine Welder  
and Feeder.  
• Set the "WELD TERMINALS" switch to  
"REMOTELY CONTROLLED"  
3. Set the "WIRE FEEDER VOLTMETER" switch to  
either "+" or "-" as required by the electrode being  
used.  
• Set the MODE switch to the "CV-WIRE " position.  
4. Set the "MODE" switch to the "CV WIRE " posi-  
• Set the "WIRE FEEDER VOLTMETER" switch to  
either "+" or "-" as required by the electrode polar-  
ity being used.  
tion.  
5. Set the "ARC CONTROL" knob to "0" initially and  
adjust to suit.  
• Set the "ARC CONTROL" knob to "0" initially and  
adjust to suit.  
6. Set the "WELD TERMINALS" switch to the  
"REMOTELY CONTROLLED" position.  
• Set the "IDLE" switch to the "AUTO" position.  
7. Set the "IDLE" switch to the "HIGH" position.  
• When the gun trigger is closed, the current sens-  
ing circuit will cause the VANTAGE® 575 CUM-  
MINS engine to go to the high idle speed, the  
wire will begin to feed and the welding process  
started. When welding is stopped, the engine will  
revert to low idle speed after approximately 12  
seconds unless welding is resumed.  
Connection of LN-15 to the VANTAGE® 575 CUM-  
MINS  
These connections instructions apply to both the LN-  
15 Across-The-Arc and Control Cable models. The  
LN-15 has an internal contactor and the electrode is  
not energized until the gun trigger is closed. When the  
gun trigger is closed the wire will begin to feed and the  
welding process is started.  
1. Shut the welder off.  
2. For electrode Positive, connect the electrode  
cable to the "+" terminal of the welder and work  
cable to the "-" terminal of the welder. For elec-  
trode Negative, connect the electrode cable to the  
"-" terminal of the welder and work cable to the "+"  
terminal of the welder.  
3. Across The-Arc Model:  
• Attach the single lead from the front of the LN-15  
to work using the spring clip at the end of the  
lead. This is a control lead to supply current to  
the wire feeder motor; it does not carry welding  
current.  
VANTAGE® 575 CUMMINS  
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A-8  
CONNECTION OF THE LN-25 TO THE VAN-  
TAGE® 575 CUMMINS  
A-8  
CONNECTION OF AN NA-3 AUTOMATIC  
WELDING SYSTEM TO THE VANTAGE®  
575 CUMMINS  
INSTALLATION  
.
WARNING  
For connection diagrams and instructions for connect-  
ing an NA-3 Welding System to the VANTAGE® 575  
CUMMINS, refer to the NA-3 Welding System instruc-  
tion manual. The connection diagram for the LN-8 can  
be used for connecting the NA-3.  
Shut off welder before making any electrical con-  
nections.  
--------------------------------------------------------------------------  
The LN-25 with or without an internal contactor may be  
used with the VANTAGE® 575 CUMMINS. 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  
• Set the Wire Feeder Voltage Switch to 115V.  
CONNECTION OF MAGNUM SC SPOOL  
GUN TO THE VANTAGE® 575 CUMMINS  
(SEE SECTION F)  
with the VANTAGE® 575 CUMMINS  
.
1. Shut the welder off.  
Spool Gun (K487-25) and Cobramatic to VAN-  
TAGE® 575 CUMMINS.  
2. For electrode Positive, connect the electrode cable  
from the LN-25 to the "+" terminal of the welder and  
work cable to the "-" terminal of the welder. For  
electrode Negative, connect the electrode cable  
from the LN-25 to the "-" terminal of the welder and  
work cable to the "+" terminal of the welder.  
• Shut the welder off.  
• Connect per instructions on the appropriate connec-  
tion diagram in Section F.  
3. Attach the single lead from the front of the LN-25 to  
work using the spring clip at the end of the lead.  
This is a control lead to supply current to the wire  
feeder motor; it does not carry welding current.  
4. Set the MODE switch to the "CV-WIRE " position.  
5. Set the "WELD TERMINALS" switch to "WELD  
TERMINALS ON"  
6. Set the "ARC CONTROL" knob to "0" initially and  
adjust to suit.  
7. Set the "IDLE" switch to the "AUTO" position. When  
not welding, the VANTAGE® 575 CUMMINS  
engine will be at the low idle speed. If you are using  
an LN-25 with an internal contactor, the electrode is  
not energized until the gun trigger is closed.  
8. When the gun trigger is closed, the current sensing  
circuit will cause the VANTAGE® 575 CUMMINS  
engine to go to the high idle speed, the wire will  
begin to feed and the welding process started.  
When welding is stopped, the engine will revert to  
low idle speed after approximately 12 seconds  
unless welding is resumed.  
CAUTION  
If you are using an LN-25 without an internal con-  
tactor, the electrode will be energized when the  
VANTAGE® 575 CUMMINS is started.  
--------------------------------------------------------------------------  
VANTAGE® 575 CUMMINS  
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B-1  
B-1  
OPERATION  
RECOMMENDED APPLICATIONS  
SAFETY PRECAUTIONS  
The VANTAGE® 575 CUMMINS provides excellent  
constant current DC welding output for stick (SMAW)  
and TIG welding. The VANTAGE® 575 CUMMINS  
also provides excellent constant voltage DC welding  
output for MIG (GMAW), Innershield (FCAW),  
Outershield (FCAW-G) and Metal Core welding. In  
addition the VANTAGE® 575 CUMMINS can be used  
for Arc Gouging with carbons up to 3/8”(10mm) in  
diameter.  
Read and understand this entire section before  
operating your VANTAGE® 575 CUMMINS.  
WARNING  
Do not attempt to use this equipment until you have  
thoroughly read the engine manufacturer’s manual  
supplied with your welder. It includes important  
safety precautions, detailed engine starting, operat-  
ing and maintenance instructions, and parts lists.  
------------------------------------------------------------------------  
ELECTRIC SHOCK can kill.  
The VANTAGE® 575 CUMMINS is not recommend-  
ed for pipe thawing.  
GENERATOR  
• Do not touch electrically live parts or  
electrode with skin or wet clothing.  
• Insulate yourself from work and  
ground  
The VANTAGE® 575 CUMMINS provides smooth  
output for auxiliary power and emergency standby  
power.  
• Always wear dry insulating gloves.  
--------------------------------------------------------------------------  
ENGINE EXHAUST can kill.  
• Use in open, well ventilated areas or  
vent exhaust outside  
• Do not stack anything near the engine.  
------------------------------------------------------------------------  
MOVING PARTS can injure.  
• Do not operate with doors open or  
guards off.  
• Stop engine before servicing.  
• Keep away from moving parts  
------------------------------------------------------------------------  
Only qualified personnel should operate this  
equipment.  
Always operate the welder with the sliding door  
closed and the side panels in place as these pro-  
vide maximum protection from moving parts and  
insure proper cooling air flow.  
GENERAL DESCRIPTION  
The VANTAGE® 575 CUMMINS is a diesel engine-dri-  
ven welding power source. The machine uses a brush  
type alternating current generator for DC multi-purpose  
welding. The DC welding control system uses state of  
the art Chopper Technology  
performance.  
for superior welding  
C
T
R
VANTAGE® 575 CUMMINS  
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B-2  
B-2  
OPERATION  
CONTROLS AND SETTINGS  
All welder and engine controls are located on the case front  
panel. Refer to Figure B.1 and the explanations that follow.  
FIGURE B.1  
6
7
4
5
12  
14  
8
9
10  
13  
16  
15  
11  
26  
21  
25  
21  
19  
2
C32  
6kA  
415V~ 50/60Hz  
23  
22  
1
17  
18  
20  
3
24  
27  
28  
29  
ENGINE CONTROLS (Items 1 through 9)  
1. RUN STOP SWITCH  
4. HOUR METER  
The hour meter displays the total time that the  
engine has been running. This meter is a useful  
indicator for scheduling preventive maintenance.  
Toggling the switch to the RUN position energizes  
the fuel solenoid for approximately 30 seconds.  
The engine must be started within that time or the  
fuel solenoid will deenergize, and the switch must  
be toggled to reset the timer.  
5. FUEL LEVEL GAUGE  
Displays the level of diesel fuel in the fuel tank.  
The operator must watch the fuel level close-  
ly to prevent running out of fuel and possibly  
having to bleed the system.  
2. START PUSHBUTTON  
Energizes the starter motor to crank the engine.  
With the engine "Run / Stop" switch in the "Run"  
position, push and hold the Start button to crank  
the engine; release as the engine starts. Do not  
press while engine is running since this can  
cause damage to the ring gear and/or starter  
motor.  
6. ENGINE TEMPERATURE GAUGE  
The gauge displays the engine coolant tempera-  
ture.  
3. ENGINE STOP SWITCH  
Shut’s down engine.  
VANTAGE® 575 CUMMINS  
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B-3  
B-3  
OPERATION  
Idler Operational exceptions  
7. OIL PRESSURE GAUGE  
When the WELDING TERMINALS switch is in  
the “Remotely Controlled” position the idler will  
operate as follows:  
The gauge displays the engine oil pressure when  
the engine is running.  
a. When the triggering device (Amptrol, Arc Start  
Switch, etc.) is pressed the engine will acceler-  
ate and operate at full speed provided a weld-  
ing load is applied within approximately 12  
seconds.  
8. ENGINE PROTECTION  
The yellow engine protection light remains off  
with proper oil pressure and under normal oper-  
ating temperatures. If the light turns on, the  
engine protection system will stop the engine.  
Check for proper oil level and add oil if neces-  
sary. Check for loose or disconnected leads at  
the oil pressure sender located on the engine.  
The light will remain on when the engine has  
been shut down due to low oil pressure or over-  
temperature condition.  
• If the triggering device remains pressed but no  
welding load is applied within approximately 12  
seconds the engine may return to low idle  
speed.  
• If the triggering device is released or welding  
ceases the engine will return to low idle speed  
after approximately 12 seconds.  
WELDING CONTROLS (Items 11  
through 20)  
9. BATTERY CHARGING LIGHT  
The yellow engine alternator light is off when bat-  
tery charging system is functioning normally. If  
light turns on the alternator or the voltage regula-  
tor may not be operating correctly. The light will  
remain on when the engine is stopped and the  
run/stop switch is in the run position.  
11. OUTPUT CONTROL:  
The OUTPUT dial is used to preset the output  
voltage or current as displayed on the digital  
meters for the four welding modes. When in the  
CC-STICK or CV-WIRE modes and when a  
remote control is connected to the 6-Pin or 14-  
Pin Connector, the auto-sensing circuit automati-  
cally switches the OUTPUT CONTROL from con-  
trol at the welder to the remote control. In the  
CV-WIRE mode, when the wire feeder control  
cable is connected to the 14-Pin Connector, the  
auto-sensing circuit automatically makes OUT-  
PUT CONTROL inactive and the wire feeder volt-  
age control active.  
10. IDLER SWITCH  
Has two positions as follows:  
A) In the “High” position  
, the engine runs at  
the high idle speed controlled by the governor.  
B) In the “Auto” position, the  
/
idler operates as follows:  
a. When switched from “High” to “Auto” or after  
starting the engine, the engine will operate at  
full speed for approximately 12 seconds and  
then go to low idle speed.  
When in the TOUCH START TIG mode and  
when a Amptrol is connected to the 6-Pin  
Connector, the OUTPUT dial is used to set the  
maximum current range of the CURRENT CON-  
TROL of the Amptrol.  
b. When the electrode touches the work or power  
is drawn for lights or tools (approximately 100  
Watts minimum) the engine accelerates and  
operates at full speed.  
12. DIGITAL OUTPUT METERS:  
c. When welding ceases and the AC power load  
is turned off, a fixed time delay of approximate-  
ly 12 seconds starts.  
The digital meters allow the output voltage (CV-  
WIRE mode) or current (CC-STICK and TIG  
modes) to be set prior to welding using the OUT-  
PUT control knob. During welding, the meters  
display the actual output voltage (VOLTS) and  
current (AMPS). A memory feature holds the dis-  
play of both meters on the seven seconds after  
welding is stopped. This allows the operator to  
read the actual current and voltage just prior to  
when welding was ceased. While the display is  
being held the left-most decimal point in each  
display will be flashing. The accuracy of the  
meters is 3%.  
d. If the welding or AC power load is not restart-  
ed before the end of the time delay, the idler  
reduces the engine speed to low idle speed.  
e. The engine will automatically return to high  
idle speed when the welding load or A.C.  
power load is reapplied.  
VANTAGE® 575 CUMMINS  
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B-4  
B-4  
OPERATION  
17. 6 - PIN CONNECTOR:  
13. WELD MODE SELECTOR SWITCH:  
(Provides 3 selectable welding modes)  
CV-WIRE  
For attaching optional remote control equipment.  
When in the CC-STICK and CV-WIRE modes  
and when a remote control is connected to the  
Connector, the auto-sensing circuit automatically  
switches the OUTPUT control from control at the  
welder to remote control.  
CC-STICK  
TOUCH START TIG  
14. ARC CONTROL:  
18. 14-PIN CONNECTOR:  
The ARC CONTROL WIRE/STICK knob is active  
in the WIRE and STICK modes, and has different  
functions in these modes. This control is not  
active in the TIG mode.  
For attaching wire feeder control cable. Includes  
contactor closure circuit, auto-sensing remote  
control circuit, and 42VAC or 115VAC power.  
The remote control circuit operates the same as  
the 6-Pin Connector.  
CC-STICK mode: In this mode, the ARC CON-  
TROL knob sets the short circuit current (arc-  
force) during stick welding. Increasing the num-  
ber from -10(Soft) to +10(Crisp) increases the  
short circuit current and prevents sticking of the  
electrode to the plate while welding. This can  
also increase spatter. It is recommended that the  
ARC CONTROL be set to the minimum number  
without electrode sticking. Start with a setting at  
0.  
19. 42V / 115V WIRE FEEDER VOLTAGE  
SWITCH:  
Toggles output of 14-pin connector to voltage  
requirement of Wire Feeder. (Located above 14-  
pin connector.)  
CV-WIRE mode: In this mode, turning the ARC  
CONTROL knob from -10(soft) to +10(crisp)  
changes the arc from soft and washed-in to crisp  
and narrow. It acts as an inductance/pinch con-  
trol. The proper setting depends on the proce-  
dure and operator preference. Start with a setting  
of 0.  
20. WELD OUTPUT TERMINALS + AND -  
These 1/2” - 13 studs with flange nuts provide  
welding connection points for the electrode and  
work cables. For positive polarity welding the  
electrode cable connects to the “+” terminal and  
the work cable connects to this “-” terminal. For  
negative polarity welding the work cable con-  
nects to the “+” terminal and the electrode cable  
connects to this “-” terminal.  
15. WELDING TERMINALS SWITCH:  
In the WELD TERMINALS ON position, the out-  
put is electrically hot all the time. In the  
REMOTELY CONTROLLED position, the output  
is controlled by a wire feeder or amptrol device,  
and is electrically off until a remote switch is  
depressed.  
AUXILIARY POWER CONTROLS  
(Items 21-24)  
21. CIRCUIT BREAKERS  
These circuit breakers provide separate overload  
current protection for each 240V receptacles,  
415V 3 phase receptacle, the 42VAC and  
115VAC in the 14-Pin connector and battery cir-  
cuit overload protection.  
WARNING  
• There is no VRD protection in the CV Mode.  
• When the Toggle switch is in the “WELD  
TERMINAL ON” position the voltage at the  
output terminal maybe up to 60V.  
22. 240 VAC RECEPTACLES  
These two 240VAC receptacles provide up to 15  
amp total rating each and are IP66 rated. Refer  
to the AUXILIARY POWER RECEPTACLES  
section in the installation chapter for further infor-  
mation about these receptacles. Also refer to the  
AUXILIARY POWER OPERATION section later  
in this chapter.  
-----------------------------------------------------------------------  
16. WIRE FEEDER VOLTMETER SWITCH:  
Matches the polarity of the wire feeder volt-  
meter to the polarity of the electrode.  
VANTAGE® 575 CUMMINS  
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B-5  
B-5  
OPERATION  
23. 415 VAC RECEPTACLE  
BATTERY JUMP START TERMINAL  
(27-28)  
This is a 415VAC receptacle that provides auxil-  
iary power. This receptacle has 32 amp rating  
and IP66 rated. Refer to the AUXILIARY  
POWER RECEPTACLES section in the installa-  
tion chapter for further information about these  
receptacles. Also refer to the AUXILIARY  
POWER OPERATION section later in this chap-  
ter.  
27. POSITIVE BATTERY JUMP START  
TERMINAL.  
28. NEGATIVE BATTERY JUMP START  
TERMINAL.  
12V battery jump start feature is standard.  
Covered output studs for convenient access, and  
protection against accidental impact. can be used  
to jump-start a utility truck with up to 800 cold  
cranking amps. Can also be used to jump-start the  
VANTAGE® 575 CUMMINS.  
24. GROUND STUD:  
Provides a connection point for connecting the  
machine case to earth ground. Refer to  
“MACHINE GROUNDING” in the Installation  
chapter for proper machine grounding informa-  
tion.  
29. BATTERY DISCONNECT SWITCH  
25. RCD:  
Battery disconnect switch provides lockout/tagout  
capability. Switch is conveniently located on the  
front bottom of the machine.  
“Residual Current Device” provides protection  
from active to ground contact.  
RCD will not protect against electrical shock  
resulting from contact with active and neutral  
wires.  
30. AIR CLEANER SERVICE INDICATOR  
Air cleaner service indicator provides a Go/No-Go  
visual indication of useful filter service life. Also  
located inside the engine compartment. (SEE FIG-  
URE B.2)  
26. VRD INDICATOR LIGHTS:  
Indicates OCV voltage across the output termi-  
nals. Also indicates operation of VRD in CC  
mode. A Green light indicates OCV below 30V  
and a red light indicates OCV above 30V.  
FIGURE B.2  
During welding both lights will flash, depending on  
the type of Consumable being used.  
30  
VANTAGE® 575 CUMMINS  
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B-6  
B-6  
OPERATION  
VRD/ROCV’s are more commonly incorporated into  
the stick welding mode (CC) of the welding machines  
being used in environments with high-risk of electric  
shock.  
WHAT ARE VRD AND ROCV DEVICES?  
VRD’s are gaining popularity as a “must have” safety  
accessory especially where welding applications are  
being carried out in an environment with a high-risk of  
electric shock such as wet areas and hot humid  
sweaty conditions.  
SAFETY  
The reduction of the voltage supplies a safer level of  
voltage when an arc is not being struck or when an  
electrical resistance less than the welder’s body resis-  
tance have been detected. All VRD’s are only an aid  
to safety, personal protective equipment and safe  
working practices must be observed at all times. The  
risk of electric shock during welding from a correctly  
installed and maintained welding machine is negligi-  
ble, provided that sensible precautions are taken by  
the user and correct safe working procedures are fol-  
lowed. All of the welding output circuit should be con-  
sidered electrically active (hot) and the welder should  
make sure that they do not become a part of that cir-  
cuit to ground or they could receive a severe electric  
shock that could kill. Safe working procedures should  
always be followed whether a VRD is fitted or not.  
VRD and ROCV are abbreviations for two different  
safety devices used in a welding power source to help  
protect the operator from electric shocks.  
VRD stands for “Voltage Reduction Device” and  
ROCV stands for “Reduced Open Circuit Voltage”.  
Both devices are used as an after market addition or  
part of the integral design of a machine. VRD and  
ROCV reduce the voltage at the welding output termi-  
nals when not welding to a no load voltage of less  
than 35V for DC welding and for AC welding 35V peak  
25VAC RMS, when the resistance of the output circuit  
is in the range of 20-200 (ohms). The lower reactiva-  
tion resistance of the device, the higher the safety  
level and also requires that the welding cable connec-  
tions be kept in good electrical condition.  
VRD OPERATION INDICATOR  
Having good electrical connections also limits the pos-  
sibility of other safety issues such as heat-generated  
damage, burns and fires.  
On the front panel of the VANTAGE® 575 CUMMINS  
are two indicator lights. A red light when lit indicates  
voltage greater than >30V and a green light when lit  
indicates voltage less than <30V.  
WELDING POWER SOURCES  
Welding power sources generally have an Open  
Circuit Voltage (i.e. the voltage at the welding output  
terminals when not welding) in the range of 35-  
115VDC. Welding machines for stick welding  
(MMAW) and similar constant current (CC mode)  
processes supply a higher open circuit voltage  
between the electrode and the work when the welding  
machine is switched on and ready to commence weld-  
ing. These welding machines have high open circuit  
voltage (typically 60-80V) then when the arc is estab-  
lished and welding current is drawn the voltage drops  
to 20-35V.  
These lights monitor the OCV at all times. In the CC  
mode when the welding arc has stopped the green  
light will illuminate indicating that the VRD has  
reduced the OCV to less than 30V. During welding the  
red light will illuminate indicating that the OCV is  
greater than 30V. During welding the red and green  
light will flash on and off. This is normal operation as  
the welding voltage will produce less than 30V,  
depending on the process and type of electrode being  
used.  
If the red light remains illuminated after welding in the  
CC mode, please refer to your local field service shop  
for service.  
Consequently, the greatest danger occurs when han-  
dling the electrode and the electrode holder between  
welding operations, such as when changing elec-  
trodes.  
OPERATION  
The low voltage safety features of the VRD’s is to  
reduce the possibility of electric shock to the operator,  
a very slight delay during striking of the electrode may  
be experienced.  
Welding machines for MIG (GMAW & FCAW) have a  
flat constant voltage (CV) characteristic, generally with  
a lower open circuit voltage (30-50V). Also, the cur-  
rent is turned On and Off by a gun trigger, which also  
controls the wire feed. Therefore, the welder is not  
exposed to open circuit voltage unless the trigger is  
turned on and the wire is feeding. Also, electrodes are  
not changed as frequently as for stick welding  
(MMAW).  
The high voltage that is available on units without  
VRD’s allows them to penetrate and burn through  
dirty, painted and heavily mill scale plate. Units fitted  
with VRD’s cannot penetrate and are required to reg-  
ister the correct resistance, which switches the safety  
device into weld mode.  
VANTAGE® 575 CUMMINS  
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B-7  
B-7  
OPERATION  
TYPICAL FUEL CONSUMPTION  
Unlike other VRD’s Lincoln uses micro processor con-  
trol to monitor and establish the arc without the stick-  
ing and shorting of the electrode to the job as seen in  
many other VRD installations. Due to the requirement  
of the resistance in the circuit to be low, for a VRD to  
operate, a good metal-to-metal contact must be made  
between the metal core of the electrode and the job.  
Refer to Table B.1 for typical fuel consumption of the  
VANTAGE® 575 CUMMINS Engine for various oper-  
ating settings.  
Table B.1  
Cummins B3.3 Engine Fuel Consumption  
Cummins B3.3  
36Kw(48HP)  
@1500 RPM  
Running Time for  
94.6L(25GAL.)  
(Hours)  
Any damaged connection anywhere in the output cir-  
cuit may limit the operation of the VRD. This includes  
a good connection of the work return clamp and the  
job. The work return clamp should be connected close  
as practical to where the welding will be performed.  
Low Idle -  
no load 1300 RPM  
1.6 L/hour  
2.0 L/hour  
5.3 L/hour  
59.5  
47.3  
17.8  
High Idle -  
no load 1590 RPM  
Some electrodes form a cone at the end of the elec-  
trode after the welding arc has been broken, particu-  
larly iron powder and low hydrogen electrodes.  
DC CC Weld  
Output 450  
Amps @ 38 Volts  
Auxiliary Power  
12,000 V A  
4.2 L/hour  
8.0 L/hour  
21.0  
11.8  
This cone will need to be broken off in order to have  
the metal core of the electrode to make contact.  
20,000 V A  
STARTING TECHNIQUE  
The starting technique that has successfully overcome  
the problem is the push, twist, and peel technique.  
This technique requires the operator to push the elec-  
trode into the joint and twist.  
NOTE: This data is for reference only. Fuel consumption is  
approximate and can be influenced by many factors, includ-  
ing engine maintenance, environmental conditions and fuel  
quality.  
The Push and Twist breaks off the cone and allows  
the metal electrode to make contact.  
The peel and lift of the electrode establishes a con-  
trolled start to the welding arc. Normal welding tech-  
nique for the application is then used.  
BREAK-IN PERIOD  
The engine used to supply power for your welder is a  
heavy duty, industrial engine. It is designed and built  
for rugged use. It is very normal for any engine to use  
small quantities of oil until the break-in is accom-  
plished. Check the oil level twice a day during the  
break-in period. In general this takes 50 to 100 hours  
of operation.  
IMPORTANT  
IN ORDER TO ACCOMPLISH THIS BREAK-IN, THE  
UNIT SHOULD BE SUBJECTED TO HEAVY  
LOADS, WITHIN THE RATING OF THE MACHINE.  
AVOID LONG IDLE RUNNING PERIODS.  
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B-8  
B-8  
OPERATION  
The VANTAGE® 575 CUMMINS is equipped with the  
required R.F. bypass circuitry for the connection of  
high frequency generating equipment.  
WELDER OPERATION  
DUTY CYCLE  
Duty Cycle is the percentage of time the load is being  
applied in a 10 minute period. For example a 60%  
duty cycle, represents 6 minutes of load and 4  
minutes of no load in a 10 minute period.  
The VANTAGE® 575 CUMMINS and any high frequen-  
cy generating equipment must be properly grounded.  
See the K930-2 TIG Module operating manuals for  
complete instructions on installation, operation, and  
maintenance.  
STICK WELDING MODE  
When using the TIG Module, the OUTPUT control on  
the VANTAGE® 575 CUMMINS is used to set the max-  
imum range of the CURRENT CONTROL on the TIG  
Module or an Amptrol if connected to the TIG Module.  
The VANTAGE® 575 CUMMINS can be used with a  
broad range of DC stick electrodes. The MODE switch  
provides two stick welding settings as follows:  
CC-STICK MODE  
VANTAGE® 575 CUMMINS SETTINGS WHEN  
USING THE K930-2 TIG MODULE  
The CC-STICK position of the MODE switch is  
designed for horizontal, vertical-up and over head  
welding with all types of electrodes, especially low  
hydrogen. The OUTPUT CONTROL knob adjusts the  
full output range for stick welding.  
• Set the WELD MODE switch to the “Touch Start Tig 20-  
250 Setting”.  
• Set the IDLER switch to the “AUTO” position.  
• Set the WELDING TERMINALS switch to the “Remotely  
Controlled” position. This will keep the solid state contactor  
open and provide a “cold” electrode until the triggering  
device (Amptrol or Arc Start Switch) is pressed.  
The ARC CONTROL knob sets the short circuit (arc-  
force) current during stick welding. Increasing the  
number from -10(Soft) to +10 (Crisp) increases the  
short circuit current and prevents sticking of the elec-  
trode to the plate while welding. This can also  
increase spatter. It is recommended that the ARC  
CONTROL be set to the minimum number without  
electrode sticking. Start with the knob set at 0.  
TOUCH START TIG MODE  
The VANTAGE® 575 CUMMINS can be used in a wide  
variety of DC TIG welding applications.  
The TOUCH START TIG setting of the MODE switch  
is for DC TIG (Tungsten Inert Gas) welding. To initiate  
a weld, the OUTPUT CONTROL knob is first set to  
the desired current and the tungsten is touched to the  
work. During the time the tungsten is touching the  
work there is very little voltage or current and, in gen-  
eral, avoids tungsten contamination. Then, the tung-  
sten is gently lifted off the work in a rocking motion,  
which establishes the arc.  
To stop the arc, simply lift the TIG torch away from the  
work piece. When the arc voltage reaches approxi-  
mately 30 volts, the arc will go out and the machine  
will automatically reset to the touch start current level.  
The tungsten may then be retouched to the work  
piece to restrike the arc. The arc may also be started  
and stopped with an Amptrol or Arc Start Switch.  
The ARC CONTROL is not active in the TIG mode.  
In general the ‘Touch Start’ feature avoids tungsten  
contamination without the use of a Hi-frequency unit.  
If the use of a high frequency generator is desired, the  
K930-2 TIG Module can be used with the VANTAGE®  
575 CUMMINS. The settings are for reference.  
VANTAGE® 575 CUMMINS  
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B-9  
B-9  
OPERATION  
WIRE WELDING-CV  
ARC GOUGING  
For optimal performance when arc gouging, set the  
VANTAGE® 575 CUMMINS “WELD MODE” switch to  
the “CC - STICK” position, and the “ARC CONTROL”  
to 10.  
Connect a wire feeder to the VANTAGE® 575 CUM-  
MINS according to the instructions in INSTALLATION  
INSTRUCTIONS Section.  
The VANTAGE® 575 CUMMINS in the ”CV-WIRE”  
position, permits it to be used with a broad range of  
flux cored wire (Innershield and Outershield) elec-  
trodes and solid wires for MIG welding (gas metal arc  
welding). Welding can be finely tuned using the “ARC  
CONTROL”. 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.  
Set the “OUTPUT” knob to adjust output current to the  
desired level for the gouging electrode being used  
according to the ratings in the following Table B.2  
TABLE B.2  
Carbon Diameter  
Current Range (DC, elec-  
trode positive)  
30-60 Amps  
1/8"(3.2mm)  
5/32"(4.0mm)  
3/16"9(4.8mm)  
1/4"(6.4mm)  
5/16"(8.0mm)  
3/8"(10.0mm)  
90-150 Amps  
200-250 Amps  
300-400 Amps  
350-450 Amps  
The proper setting depends on the procedure and  
operator preference. Start with the knob set at 0.  
450-575 Amps*  
For any electrodes, including the above recommenda-  
tions, the procedures should be kept within the rating  
of the machine. For additional electrode information,  
Lincoln publication.  
NOTE: If desired the CV mode can be used for Arc Gouging.  
* Maximum current setting is limited to the VANTAGE® 575 CUMMINS maxi-  
mum of 575 Amps.  
Table B.3 TYPICAL CURRENT RANGES (1) FOR TUNGSTEN ELECTRODES (2)  
DCEN (-)  
DCEP (+)  
Approximate Argon Gas Flow Rate  
l/min (c.f.m.)  
Tungsten  
Electrode  
Diameter  
mm (in)  
1%, 2%  
Thoriated  
Tungsten  
1%, 2%  
Thoriated  
Tungsten  
TIG TORCH  
Nozzle  
Size (4), (5)  
Aluminium  
Stainless Steel  
.25 (0.010)  
.50 (0.020)  
1.0 (0.040)  
2-15  
5-20  
(3)  
(3)  
(3)  
2-4 (3-8)  
3-5 (5-10)  
3-5 (5-10)  
2-4 (3-8)  
3-5 (5-10)  
3-5 (5-10)  
#4, #5, #6  
15-80  
1.6 (1/16)  
70-150  
10-20  
3-5 (5-10)  
4-6 (9-13)  
#5, #6  
2.4 (3/32)  
3.2 (1/8)  
150-250  
250-400  
15-30  
25-40  
6-8 (13-17)  
7-11 (15-23)  
5-7 (11-15)  
5-7 (11-15)  
#6, #7, #8  
4.0 (5/32)  
4.8 (3/16)  
400-500  
500-750  
40-55  
55-80  
10-12 (21-25)  
11-13 (23-27)  
6-8 (13-17)  
8-10 (18-22)  
#8, #10  
6.4 (1/4)  
750-1000  
80-125  
13-15 (28-32)  
11-13 (23-27)  
(1)  
(2)  
When used with argon gas. The current ranges shown must be reduced when using argon/helium or pure helium shielding gases.  
Tungsten electrodes are classified as follows by the American Welding Society (AWS):  
Pure  
EWP  
1% Thoriated  
2% Thoriated  
EWTh-1  
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 applica-  
tions.  
(3)  
(4)  
DCEP is not commonly used in these sizes.  
TIG torch nozzle “sizes” are in multiples of 1/16ths of an inch:  
# 4 =  
# 5 =  
# 6 =  
# 7 =  
# 8 =  
#10 =  
1/4 in.  
5/16 in.  
3/8 in.  
7/16 in.  
1/2 in.  
5/8 in.  
6 mm  
8 mm  
10 mm  
11 mm  
12.5 mm  
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 can-  
not withstand high temperatures and high duty cycles.  
VANTAGE® 575 CUMMINS  
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B-10  
B-10  
OPERATION  
PARALLELING  
The auxiliary power receptacles should only be used  
with three wire, four wire or fire wire earth type plugs  
or approved double insulated tools with two wire  
plugs.  
When paralleling machines in order to combine their  
outputs, all units must be operated in the CC-STICK  
mode only at the same output settings. To achieve  
this, turn the WELD MODE switch to the CC-STICK  
position. Operation in other modes may produce errat-  
ic outputs, and large output imbalances between the  
units.  
The current rating of any plug used with the system  
must be at least equal to the current capacity of the  
associated receptacle.  
SIMULTANEOUS WELDING AND  
AUXILIARY POWER LOADS  
AUXILIARY POWER OPERATION  
Start the engine and set the IDLER control switch to  
the desired operating mode. Full power is available  
regardless of the welding control settings, if no weld-  
ing current is being drawn.  
It must be noted that the above auxiliary power ratings  
are with no welding load. Simultaneous welding and  
power loads are specified in table B.4. The permissi-  
ble currents shown assume that current is being  
drawn from either the 240 VAC or 415 VAC supply  
(not both at the same time).  
The auxiliary power of the VANTAGE® 575 CUM-  
MINS consists of two 15 Amp-240V single phase  
receptacles and one 32amp-415V 3 phase receptacle.  
The auxiliary power capacity is 7,200 watts of 50 Hz,  
single phase power or 20,000 watts of 50Hz, three  
phase power. The auxiliary power capacity rating in  
watts is equivalent to volt-amperes at unity power fac-  
tor. The maximum permissible current of the 415 VAC  
output is 32 A.Output voltage is within 10% at all  
loads up to rated capacity.  
NOTE: The 240V receptacles are connected to differ-  
ent phases and cannot be paralleled.  
TABLE B.4 VANTAGE® 575 CUMMINS SIMULTANEOUS WELDING AND POWER LOADS  
Permissible Auxiliary  
WELDING  
OUTPUT  
PERMISSIBLE  
POWER-WATTS  
Current in Amperes  
(Unity Power Factor)  
@ 415V 10%  
@ 240V 10%*  
500A/40V  
350A/34V  
200A/30V  
150A/26V  
90A/24V  
0
0
0
0
8,100  
14 amp/phase  
18.5 amp/phase  
23.6 amp/phase  
26.4 amp/phase  
32 amp/phase  
40*  
30*  
30*  
30*  
30*  
12,000  
16,000  
18,000  
20,000  
* Each receptacle is limited to 15 amps.  
TABLE B.5  
VANTAGE® 575 CUMMINS Extension Cord Length Recommendations  
(Use the shortest length extension cord possible sized per the following table.)  
Maximum Allowable Cord Length in m (ft.) for Conductor Size  
2.52mm 14AWG 4.02mm 12AWG 6.02mm 10AWG 10.02mm 8AWG 16.02mm 6AWG 25.02mm 4AWG  
Current  
(Amps)  
Load  
(Watts)  
Voltage  
(Volts)  
15  
20  
3,600  
4,800  
240  
240  
18  
(60)  
23  
18  
(75)  
(60)  
46  
30  
(225)  
(175)  
107  
84  
(350)  
(275)  
183  
137  
(600)  
(450)  
(150)  
(100)  
69  
53  
Conductor size is based on maximum 2.0% voltage drop.  
VANTAGE® 575 CUMMINS  
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C-1  
C-1  
ACCESSORIES  
K2354-1 AIR DRYER KIT - Minimizes water content  
OPTIONAL FIELD INSTALLED  
ACCESSORIES  
in supply air. Avoids cold weather air hose ice up.  
K2356-1 CONTROL PANEL COVER KIT - Clear  
plexiglass cover to protect control panel from dirt and  
debris, and to visually monitor machine operation.  
Lockable to deter vandalism.  
K857 25 ft. (7.5 m) or K857-1 100 ft. (30.4 m)  
REMOTE CONTROL - Portable control provides  
same dial range as the output control on the welder  
from a location up to the specified length from the  
welder. Has convenient plug for easy connection to  
the welder. The VANTAGE® 575 CUMMINS is  
equipped with a 6-pin connector for connecting the  
remote control.  
K2340-1 LOCKABLE FUEL CAP / FLASH  
ARRESTER KIT - For use in locations where flash  
arrester safety is required. Lockable fuel cap prevents  
tampering with fuel. Green cap color provides a visual  
reminder to use diesel when refueling.  
K2359-1 COLD WEATHER HEATER AND TARP KIT  
- For extreme cold conditions where normal engine  
starting is not sufficient. Includes oil pan heater,  
engine water heater and radiator grill tarp.  
K704 ACCESSORY SET - Includes 35 feet (10 m) of  
electrode cable and 30 feet (9 m) of work cable, head-  
shield, filter plate, work clamp and electrode holder.  
Cable is rated at 500 amps, 60% duty cycle.  
TIG OPTIONS  
K2641-2 FOUR WHEELED STEERABLE YARD  
TRAILER  
For in plant and yard towing. Comes standard with a  
Duo-Hitch™, a 2” Ball and Lunette Eye combination  
Hitch.  
K870 FOOT AMPTROL® - Varies current while weld-  
ing for making critical TIG welds and crater filling.  
Depress pedal to increase current. Depressing pedal  
fully achieves maximum set current. Fully raising the  
pedal finishes the weld and starts the afterflow cycle  
on systems so equipped. Includes 25 ft. (7.6m) control  
cable.  
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  
with a Duo-Hitch™, a 2” Ball and Lunette Eye combi-  
nation hitch. A fender & a light package. Order:  
K2636-1 Trailer  
K963-3 HAND AMPTROL® - Varies current for mak-  
ing critical TIG welds. Fastens to the torch for conve-  
nient thumb control. Comes with a 25 ft. (7.6m) cable.  
(for larger handle 18 or 26 series torches)  
K2639-1 Fender & Light Kit  
K2640-1 Cable Storage Rack  
K887-1 ETHER START KIT - Provides maximum cold  
weather starting assistance for frequent starting below  
10°(-12°C). Required Ether tank is not provided with  
kit.  
K1847-1 SPARK ARRESTOR KIT - Easily mounts to  
standard muffler.  
WARNING  
Pipe Thawing with an arc welder can cause fire,  
explosion, damage to electric wiring or to the arc  
welder if done improperly. The use of an arc  
welder for pipe thawing is not approved by the  
CSA, nor is it recommended or supported by  
Lincoln Electric.  
------------------------------------------------------------------------  
VANTAGE® 575 CUMMINS  
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D-1  
D-1  
MAINTENANCE  
AIR FILTER  
SAFETY PRECAUTIONS  
CAUTION  
WARNING  
• Have qualified personnel do all maintenance  
and troubleshooting work.  
• Turn the engine off before working inside the  
machine or servicing the engine.  
• Remove guards only when necessary to  
perform maintenance and replace them when  
the maintenance requiring their removal is  
complete. If guards are missing from the  
machine, obtain replacements from a Lincoln  
Distributor. (See Operating Manual Parts List.)  
• Excessive air filter restriction will result in  
reduced engine life.  
WARNING  
• Never use gasoline or low flash point solvents  
for cleaning the air cleaner element. A fire or  
explosion could result.  
CAUTION  
Read the Safety Precautions in the front of this  
manual and in the Engine Owner’s Manual before  
working on this machine.  
• Never run the engine without the air cleaner.  
Rapid engine wear will result from contaminants,  
such as dust and dirt being drawn into the  
engine.  
Keep all equipment safety guards, covers, and  
devices in position and in good repair. Keep  
hands, hair, clothing, and tools away from the  
gears, fans, and all other moving parts when  
starting, operating, or repairing the equipment.  
------------------------------------------------------------  
---------------------------------------------------------------------  
The diesel engine is equipped with a dry type air filter.  
Never apply oil to it. Service the air cleaner as follows:  
Replace the element as indicated by the service indi-  
cator. (See Service Instructions and Installation Tips  
for Engine Air Filter.)  
ROUTINE AND PERIODIC MAINTENANCE  
DAILY  
• Check the Engine oil levels .  
• Refill the fuel tank to minimize moisture condensa-  
tion in the tank.  
• Check water separator for water and drain if neces-  
sary.  
• Check coolant level.  
WEEKLY  
Blow out the machine with low pressure air periodical-  
ly. In particularly dirty locations, this may be required  
once a week.  
ENGINE MAINTENANCE  
Refer to the “Periodic Checks” section of the Engine  
Operator’s Manual for the recommended maintenance  
schedule of the following:  
a) Engine Oil and Filter  
b) Air Cleaner  
c) Fuel Filter - and Delivery System  
d) Alternator Belt  
e) Battery  
f ) Cooling System  
Refer to Table D.1 at the end of this section for vari-  
ous engine maintenance components.  
VANTAGE® 575 CUMMINS  
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D-2  
D-2  
MAINTENANCE  
Service Instructions  
Single- annd Two-Staggee Enginne Airr Cleaners  
Inspect tthe New Fiilter foorr Damage  
Remove thhe Filter  
Inspect the new filter carefully, paying attention to  
the inside of the open end, which is the  
sealing area. NEVER install a damaged  
filter. A new Donaldson radial seal  
filter may have a dry lubricant on the  
seal to aid installation.  
Unfasten or unlatch the  
service cover. Because  
the filter fits tightly over the  
outlet tube to create the critical seal, there will  
be some initial resistance, similar to breaking  
the seal on a jar. Gently move the end of the filter  
back and forth to break the seal then rotate while  
pulling straight out. Avoid knocking the filter  
against the housing.  
Rotate the  
filter while  
pulling  
straight out.  
Insert the Neew Raddial SSeeal Filterr Propperly  
If you're servicing the safety filter, this should be seated into  
position before installing the primary filter.  
If your air cleaner has a safety filter, replace it every third primary  
filter change. Remove the safety filter as you would the primary  
filter. Make sure you cover the air cleaner outlet tube to avoid any  
unfiltered contaminant dropping into the engine.  
Insert the new filter carefully. Seat  
the filter by hand, making certain it is  
completely into the air cleaner housing  
before securing the cover in place.  
Clean Both Surfaces of the Outlet Tube  
and Check the Vacuator™ Valve  
The critical sealing area will stretch  
slightly, adjust itself and distribute the sealing pressure evenly. To  
complete a tight seal, apply pressure by hand at the outer rim of  
Use a clean cloth to wipe the filter sealing surface and the inside of  
the outlet tube. Contaminant on the sealing surface could hinder an  
effective seal and cause leakage. Make sure that all contaminant is  
removed before the new filter is inserted. Dirt accidently transferred  
to the inside of the outlet tube will reach the engine and cause  
wear. Engine manufacturers say that it takes only a few grams of  
dirt to "dust" an engine! Be careful not to damage the sealing area  
on the tube.  
the filter, not the flexible center. (Avoid pushing on the center of the  
urethane end cap.) No cover pressure is required to hold the seal.  
NEVER use the service cover to push the filter into place! Using the  
cover to push the filter in could cause damage to the housing, cover  
fasteners and will void the warranty.  
If the service cover hits the filter before it is fully in place, remove  
the cover and push the filter (by hand) further into the air cleaner  
and try again. The cover should go on with no extra force.  
Wipe both sides  
of the outlet  
tube clean.  
Once the filter is in place, secure the service cover.  
Outer edge of the  
Inner edge of the  
outlet tube  
Caution  
outlet tube  
NEVER uuse thee servviice cover to  
push the filter into place! Using  
the cover too push thhee filter iin could  
cause damage to the housing, cover  
fastenners and will void the warranty.  
If your air cleaner is equipped with a Vacuator Valve  
Visually check and physically squeeze to make sure the  
valve is flexible and not inverted, damaged or plugged.  
Inspect the Old  
Filter for Leeak Clues  
Check Connnectorrs for Tiight Fit  
Make sure that all mounting bands, clamps, bolts, and connections  
in the entire air cleaner system are tight. Check for holes in piping  
and repair if needed. Any leaks in your intake piping will send dust  
directly to the engine!  
Visually inspect the old filter for any signs  
of leaks. A streak of dust on the clean side  
of the filter is a telltale sign. Remove any  
cause of leaks before installing new filter.  
VANTAGE® 575 CUMMINS  
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D-3  
D-3  
MAINTENANCE  
FUEL FILTERS  
BATTERY HANDLING  
GASES FROM BATTERY can explode.  
WARNING  
• Keep sparks, flame and cigarettes  
away from battery.  
When working on the fuel system:  
• Keep naked lights away, do not smoke !  
• Do not spill fuel !  
To prevent EXPLOSION when:  
• INSTALLING A NEW BATTERY - dis-  
connect negative cable from old bat-  
tery first and connect to new battery  
last.  
-------------------------------------------------------------------------  
The VANTAGE® 575 CUMMINS is equipped with a  
Fuel Filter located after the lift pump and before fuel  
injectors.The procedure for changing the filter is as fol-  
lows.  
• CONNECTING A BATTERY CHARGER  
- Remove battery from welder by dis-  
connecting negative cable first, then  
positive cable and battery clamp.  
When reinstalling, connect negative  
cable last. Keep well ventilated.  
1. Close the fuel shutoff valve.  
2. Clean the area around the fuel filter head. Remove  
the filter. Clean the gasket surface of the filter head  
and replace the o-ring.  
3. Fill the clean filter with clean fuel, and lubricate the  
o-ring seal with clean lubricating oil.  
4. Install the filter as specified by the filter manufactur-  
er.  
• USING A BOOSTER - connect positive  
lead to battery first then connect nega-  
tive lead to engine foot.  
WARNING  
Mechanical overtightening will distort the threads,  
filter element seal or filter can.  
BATTERY ACID CAN BURN EYES AND  
SKIN.  
-------------------------------------------------------------------------  
• Wear gloves and eye protection and  
be careful when working near battery.  
Follow instructions printed on battery.  
COOLING SYSTEM  
The VANTAGE® 575 CUMMINS is equipped with a  
pressure radiator. Keep the radiator cap tight to pre-  
vent loss of coolant. Clean and flush the coolant sys-  
tem periodically to prevent clogging the passage and  
over-heating the engine. When antifreeze is needed,  
always use the permanent type.  
------------------------------------------------------------------------  
-PREVENTING ELECTRICAL DAMAGE  
1. When replacing, jumping, or otherwise connecting  
the battery to the battery cables, the proper polarity  
must be observed. Failure to observe the proper  
polarity could result in damage to the charging cir-  
cuit. The positive (+) battery cable has a red termi-  
nal cover.  
2. If the battery requires charging from an external  
charger, disconnect the negative battery cable first  
and then the positive battery cable before attaching  
the charger leads. Failure to do so can result in  
damage to the internal charger components. When  
reconnecting the cables, connect the positive cable  
first and the negative cable last.  
PREVENTING BATTERY DISCHARGE  
Turn the RUN/STOP switch to stop when engine is  
not running.  
PREVENTING BATTERY BUCKLING  
Tighten nuts on battery clamp until snug.  
VANTAGE® 575 CUMMINS  
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D-4  
D-4  
MAINTENANCE  
CHARGING THE BATTERY  
WELDER / GENERATOR MAINTE-  
When you charge, jump, replace, or otherwise connect  
battery cables to the battery, be sure the polarity is  
correct. Improper polarity can damage the charging  
circuit. The VANTAGE® 575 CUMMINS positive (+)  
battery terminal has a red terminal cover.  
NANCE  
STORAGE  
Store the VANTAGE® 575 CUMMINS in a clean, dry  
protected areas.  
If you need to charge the battery with an external  
charger, disconnect the negative cable first, then the  
positive cable before you attach the charger leads.  
after the battery is charged, reconnect the positive bat-  
tery cable first and the negative cable last. Failure to  
do so can result in damage to the internal charger  
components.  
CLEANING  
Blow out the generator and controls periodically with  
low pressure air. Do this at least once a week in par-  
ticularly dirty areas.  
BRUSH REMOVAL AND REPLACEMENT  
It is normal for the brushes and slip rings to wear and  
darken slightly. Inspect the brushes when a generator  
overhaul is necessary.  
Follow the instructions of the battery charger manufac-  
turer for proper charger settings and charging time.  
NAMEPLATES / WARNING DECALS MAIN-  
TENANCE  
WARNING  
Whenever routine maintenance is performed on this  
machine - or at least yearly - inspect all nameplates  
and labels for legibility. Replace those which are no  
longer clear. Refer to the parts list for the replacement  
item number.  
Do not attempt to polish slip rings while the  
engine is running.  
------------------------------------------------------------------------  
Table D.1 Engine Maintenance Components  
ITEM  
MAKE  
PART NUMBER  
P822768  
SERVICE INTERVAL  
Air Cleaner Element  
Donaldson  
Fleetguard  
Replace as indicated by  
Service Indicator  
AF25436  
Oil Filer  
Fan Belt  
Cummins  
Fleetguard  
C6002112110  
LF16011  
Replace every 750 hours or 3 months,  
whichever is less.  
Cummins  
C0412021749  
Inspect every 1000 hours or 12 months,  
whichever is less.  
Fuel Strainer  
Cummins  
Fleetguard  
3826094  
FF5079  
Inspect and replace monthly as  
required. Replace annually.  
Fuel Filter /  
Water Separator  
Fleetguard  
FS19594  
Replace every 500 hours or 6 months,  
whichever is less.  
Battery  
-----  
BCI GROUP 34  
-----  
Inspect every 500 hours  
Engine Oil Change  
See Manual  
Change every 750 hours or 3 months,  
whichever is less. Check daily.  
VANTAGE® 575 CUMMINS  
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E-1  
E-1  
TROUBLESHOOTING  
HOW TO USE TROUBLESHOOTING GUIDE  
WARNING  
Service and Repair should only be performed by Lincoln Electric Factory Trained Personnel.  
Unauthorized repairs performed on this equipment may result in danger to the technician and  
machine operator and will invalidate your factory warranty. For your safety and to avoid Electrical  
Shock, please observe all safety notes and precautions detailed throughout this manual.  
__________________________________________________________________________  
This Troubleshooting Guide is provided to help you  
locate and repair possible machine malfunctions.  
Simply follow the three-step procedure listed below.  
Step 3. RECOMMENDED COURSE OF ACTION  
This column provides a course of action for the  
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-  
TOMS)”. This column describes possible symptoms  
that the machine may exhibit. Find the listing that  
best describes the symptom that the machine is  
exhibiting.  
If you do not understand or are unable to perform the  
Recommended Course of Action safely, contact your  
local Lincoln Authorized Field Service Facility.  
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® 575 CUMMINS  
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E-2  
E-2  
TROUBLESHOOTING  
Observe all Safety Guidelines detailed throughout this manual  
PROBLEMS  
(SYMPTOMS)  
POSSIBLE  
CAUSE  
RECOMMENDED  
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 low.  
2. Loose battery cable connections  
which may need Inspected, cleaned  
or tighten.  
3. Faulty wiring in engine starting circuit.  
4. Faulty engine starter. Contact autho-  
rized local Engine Service Shop.  
5. Battery disconnect switch is in the off  
position.  
Engine will crank but not start.  
1. Out of fuel.  
2. Fuel shut off valve is in the off posi-  
tion make sure the valve lever is in a  
vertical direction.  
3. Engine shut down solenoid not pulling  
in.  
4. On/Off switch on for more than 30  
sec. before starting, the On/Off switch  
will need to be switch off and turned  
back on.  
I
f all recommended possible areas  
of misadjustment have been  
checked and the problem persists,  
Contact your local Lincoln  
Authorized Field Service Facility.  
5. Fuel Filters dirty/clogged, main filter  
element and/or In-line Fuel Filter may  
need to be replaced.  
6. High water temperature or low oil  
pressure. (engine protection light lit)  
1. Low oil pressure (engine protection  
light lit). Check oil level (Consult  
engine service dealer).  
Engine shuts down shortly after starting.  
2. High water temperature. Check  
engine cooling system. (engine pro-  
tection light lit).  
3. Faulty oil pressure switch.  
4. Faulty water temperature switch.  
Contact authorized local Engine  
Service Shop.  
1. High water temperature.  
Engine shuts down while under a load.  
Engine runs rough.  
1. Dirty fuel or air filters may need  
cleaned/replaced.  
2. Water in fuel.  
Engine will not shut off.  
1. Fuel Shutdown solenoid not function-  
ing properly / linkage binding.  
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® 575 CUMMINS  
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E-3  
E-3  
TROUBLESHOOTING  
Observe all Safety Guidelines detailed throughout this manual  
PROBLEMS  
(SYMPTOMS)  
POSSIBLE  
CAUSE  
RECOMMENDED  
COURSE OF ACTION  
Battery does not stay charged.  
1. Faulty battery .  
2. Faulty engine alternator.  
3. Loose or broken lead in charging  
circuit.  
4. Loose fan belt may need tighten-  
ing.  
Engine will not idle down to low 1. Idler switch in HIGH idle position,  
speed.  
make sure switch is set to AUTO.  
2. External load on welder or auxil-  
iary power.  
3. Mechanical problem in idler sole-  
noid linkage.  
4. Faulty wiring in solenoid circuit.  
5. No or low voltage @ idle solenoid  
6. Faulty idler solenoid.  
7. Faulty, Weld Control PCB  
(Printed Circuit Board), Pull Coil  
/Battery PCB  
Engine will not go to high idle when 1. Poor work lead connection to  
attempting to weld.  
work.  
If all recommended possible areas of  
misadjustment have been checked  
and the problem persists, Contact  
your local Lincoln Authorized  
Field Service Facility.  
2. Broken idler solenoid spring.  
3. Welding Terminals switch in  
wrong position.  
4. No open circuit voltage at output  
studs.  
5. Faulty, Pull Coil/Battery PCB or  
Weld Control PCB.  
Engine will not go to high idle when 1. Broken wire in auxiliary current  
using auxiliary power.  
sensor wiring.  
2. Auxiliary power load is less than  
100 watts.  
3. Faulty Pull Coil/Battery PCB or  
Weld Control PCB.  
CAUTION  
If for any reason you do not understand the test procedures or are unable to perform the tests/repairs safely, contact your  
Local Lincoln Authorized Field Service Facility for technical troubleshooting assistance before you proceed.  
VANTAGE® 575 CUMMINS  
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E-4  
E-4  
TROUBLESHOOTING  
Observe all Safety Guidelines detailed throughout this manual  
PROBLEMS  
(SYMPTOMS)  
POSSIBLE  
CAUSE  
RECOMMENDED  
COURSE OF ACTION  
Engine goes to low idle but does not  
stay at low idle.  
1. Faulty Peripheral PCB, Pull  
Coil/Battery PCB or Weld  
Control PCB.  
No welding output or auxiliary output.  
1. Broken lead in rotor circuit.  
2. Faulty field diode module.  
3. Faulty Weld Control PCB.  
4. Faulty rotor.  
Welder has some/ no output and no  
control. Auxiliary output OK  
1. Faulty remote kit.  
2. Faulty output control potentiome-  
ter.  
3. Faulty output control wiring.  
4. Faulty Weld Control PCB, Pull  
Coil/Battery PCB or Chopper  
PCB.  
No welding output. Auxiliary output  
OK.  
1. WELDING TERMINALS switch  
in wrong position, be sure switch  
is in WELDING TERMINALS  
ALWAYS ON position.  
2. Faulty Weld Control PCB, Pull  
Coil/Battery PCB or Chopper  
PCB.  
I
f all recommended possible areas  
of misadjustment have been  
checked and the problem persists,  
Contact your local Lincoln  
No auxiliary power.  
1. RCD may have tripped.  
2. Open breakers may need to be Authorized Field Service Facility.  
reset.  
3. Faulty receptacle.  
4. Faulty auxiliary circuit wiring.  
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® 575 CUMMINS  
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F-1  
F-1  
WIRING DIAGRAM  
VANTAGE® 575 CUMMINS  
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F-2  
F-2  
DIAGRAMS  
VANTAGE® 575 CUMMINS  
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F-3  
F-3  
DIAGRAMS  
}
VANTAGE® 575 CUMMINS  
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F-4  
F-4  
DIAGRAMS  
VANTAGE® 575 CUMMINS  
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F-5  
F-5  
DIAGRAMS  
VANTAGE® 575 CUMMINS  
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F-6  
F-6  
DIAGRAMS  
}
VANTAGE® 575 CUMMINS  
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F-7  
F-7  
DIAGRAMS  
VANTAGE® 575 CUMMINS  
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F-8  
F-8  
DIAGRAMS  
VANTAGE® 575 CUMMINS  
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F-9  
F-9  
DIAGRAMS  
VANTAGE® 575 CUMMINS  
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F-10  
F-10  
DIAGRAMS  
VANTAGE® 575 CUMMINS  
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F-11  
F-11  
DIAGRAMS  
VANTAGE® 575 CUMMINS  
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F-12  
F-12  
DIAGRAMS  
VANTAGE® 575 CUMMINS  
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F-13  
F-13  
DIMENSION PRINT  
VANTAGE® 575 CUMMINS  
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Do not touch electrically live parts or  
electrode with skin or wet clothing.  
Insulate yourself from work and  
ground.  
Keep flammable materials away.  
Wear eye, ear and body protection.  
WARNING  
Spanish  
No toque las partes o los electrodos Mantenga el material combustible  
Protéjase los ojos, los oídos y el  
bajo carga con la piel o ropa moja-  
da.  
Aislese del trabajo y de la tierra.  
fuera del área de trabajo.  
cuerpo.  
AVISO DE  
PRECAUCION  
French  
Ne laissez ni la peau ni des vête-  
ments mouillés entrer en contact  
avec des pièces sous tension.  
Gardez à l’écart de tout matériel  
inflammable.  
Protégez vos yeux, vos oreilles et  
votre corps.  
ATTENTION  
Isolez-vous du travail et de la terre.  
German  
Berühren Sie keine stromführenden  
Teile oder Elektroden mit Ihrem  
Körper oder feuchter Kleidung!  
Isolieren Sie sich von den  
Entfernen Sie brennbarres Material! Tragen Sie Augen-, Ohren- und Kör-  
perschutz!  
WARNUNG  
Elektroden und dem Erdboden!  
Portuguese  
Não toque partes elétricas e elec-  
trodos com a pele ou roupa molha-  
da.  
Mantenha inflamáveis bem guarda- Use proteção para a vista, ouvido e  
dos.  
corpo.  
ATENÇÃO  
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.  
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Keep your head out of fumes.  
Use ventilation or exhaust to  
remove fumes from breathing zone.  
Turn power off before servicing.  
Do not operate with panel open or  
guards off.  
WARNING  
Spanish  
Los humos fuera de la zona de res-  
piración.  
Mantenga la cabeza fuera de los  
humos. Utilice ventilación o  
aspiración para gases.  
Desconectar el cable de ali-  
mentación de poder de la máquina  
antes de iniciar cualquier servicio.  
No operar con panel abierto o  
guardas quitadas.  
AVISO DE  
PRECAUCION  
French  
Débranchez le courant avant l’entre- N’opérez pas avec les panneaux  
tien.  
Gardez la tête à l’écart des fumées.  
Utilisez un ventilateur ou un aspira-  
teur pour ôter les fumées des zones  
de travail.  
ouverts ou avec les dispositifs de  
protection enlevés.  
ATTENTION  
German  
Strom vor Wartungsarbeiten  
abschalten! (Netzstrom völlig öff-  
nen; Maschine anhalten!)  
Anlage nie ohne Schutzgehäuse  
oder Innenschutzverkleidung in  
Betrieb setzen!  
Vermeiden Sie das Einatmen von  
Schweibrauch!  
Sorgen Sie für gute Be- und  
Entlüftung des Arbeitsplatzes!  
WARNUNG  
Portuguese  
Não opere com as tampas removidas.  
Desligue a corrente antes de fazer  
serviço.  
Mantenha-se afastado das partes  
moventes.  
Não opere com os paineis abertos  
ou guardas removidas.  
Mantenha seu rosto da fumaça.  
Use ventilação e exhaustão para  
remover fumo da zona respiratória.  
ATENÇÃO  
Não toque as partes elétricas nuas.  
Japanese  
Chinese  
Korean  
Arabic  
LEIA E COMPREENDA AS INSTRUÇÕES DO FABRICANTE PARA ESTE EQUIPAMENTO E AS PARTES DE USO, E SIGA AS  
PRÁTICAS DE SEGURANÇA DO EMPREGADOR.  
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• World's Leader in Welding and Cutting Products •  
• Sales and Service through Subsidiaries and Distributors Worldwide •  
Cleveland, Ohio 44117-1199 U.S.A. TEL: 216.481.8100 FAX: 216.486.1751 WEB SITE: www.lincolnelectric.com  
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