IM826-A
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October, 2009
AIR VANTAGE ®500 CUMMINS
For use with machines having Code Numbers: 11069, 11417
Safety Depends on You
Lincoln arc welding and cutting
equipment is designed and
built with safety in mind.
However, your overall safety
can be increased by proper
installation . . . and thoughtful
operation on your part. DO
NOT INSTALL, OPERATE OR
REPAIR THIS EQUIPMENT
WITHOUT READING THIS
MANUAL AND THE SAFETY
PRECAUTIONS CONTAINED
THROUGHOUT.
Most
importantly, think before you
act and be careful.
R
C
US
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 USA Tel: 216.481.8100 Fax: 216.486.1751 Web Site: www.lincolnelectric.com
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SAFETY
ii
ARC RAYS can burn.
ELECTRIC SHOCK
can kill.
3.a. The electrode and work (or ground) circuits
are electrically “hot” when the welder is on.
Do not touch these “hot” parts with your bare
skin or wet clothing. Wear dry, hole-free
gloves to insulate hands.
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
Z87.1 standards.
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 or 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
fumes and gases. When welding, keep
your head out of the fume. Use enough
ventilation and/or exhaust at the arc to keep
• Semiautomatic DC Constant Voltage (Wire) Welder.
• DC Manual (Stick) Welder.
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
circumstances, outdoors, a respirator may be required.
Additional precautions are also required when welding
on galvanized steel.
• AC Welder with Reduced Voltage Control.
3.c. In semi-automatic or automatic wire welding, the
electrode, electrode reel, welding head, nozzle or semi-
automatic 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 specific 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 holder 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.
3.i. When working above floor level, use a safety belt to
protect yourself from a fall should you get a shock.
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
products.
3.j.
Also see items 6c 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
iii
CYLINDER may explode
if damaged.
WELDING and CUTTING
SPARKS can
cause fire or explosion.
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.
7.a. Use only compressed gas cylinders
containing the correct shielding gas for the
process used and properly operating
regulators designed for the gas and
Remember
that
welding
sparks
and
hot
pressure used. All hoses, fittings, etc. should be suitable for
the application and maintained in good condition.
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.
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 circuits.
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.
Jan ‘09
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SAFETY
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6. Eloigner les matériaux inflammables ou les recouvrir afin de
prévenir tout risque d’incendie dû aux étincelles.
PRÉCAUTIONS DE SÛRETÉ
Pour votre propre protection lire et observer toutes les instructions
et les précautions de sûreté specifiques qui parraissent dans ce
manuel aussi bien que les précautions de sûreté générales
suivantes:
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.
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 levage,
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.
Sûreté Pour Soudage A L’Arc
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.
PRÉCAUTIONS DE SÛRETÉ POUR
LES MACHINES À SOUDER À
TRANSFORMATEUR ET À
REDRESSEUR
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.
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
rayonnement 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.
c. Protéger l’autre personnel travaillant à proximité au
soudage à l’aide d’écrans appropriés et non-inflammables.
2. Autant que possible, I’installation et l’entretien du poste seront
effectués par un électricien qualifié.
3. Avant de faires des travaux à l’interieur de poste, la
debrancher 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,
pantalons 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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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
equipment. Our challenge is to meet the needs of our customers and to exceed their expectations. On occasion, purchasers may ask
Lincoln Electric for advice or information about their use of our products. We respond to our customers based on the best information in
our possession at that time. Lincoln Electric is not in a position to warrant or guarantee such advice, and assumes no liability, with respect
to such information or advice. We expressly disclaim any warranty of any kind, including any warranty of fitness for any customer’s
particular purpose, with respect to such information or advice. As a matter of practical consideration, we also cannot assume any
responsibility for updating or correcting any such information or advice once it has been given, nor does the provision of information or
advice create, expand or alter any warranty with respect to the sale of our products.
Lincoln Electric is a responsive manufacturer, but the selection and use of specific products sold by Lincoln Electric is solely within the
control of, and remains the sole responsibility of the customer. Many variables beyond the control of Lincoln Electric affect the results
obtained in applying these types of fabrication methods and service requirements.
Subject to Change – This information is accurate to the best of our knowledge at the time of printing. Please refer to
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
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Section A
Installation
Technical Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .A-1
Safety Precautions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .A-2
Location / Ventilation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .A-2
Storing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .A-2
Stacking . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .A-2
Angle of Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .A-2
Lifting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .A-3
High Altitude Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .A-3
High Temperature Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .A-3
Towing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .A-3
Vehicle Mounting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .A-3
Pre-Operation Engine and Compressor Service . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .A-4
Oil . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .A-4
Fuel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .A-4
Fuel Cap . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .A-4
Engine Cooling System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .A-4
Battery Connection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .A-4
Muffler Outlet Pipe . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .A-5
Spark Arrestor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .A-5
Air Cleaner Inlet Hood . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .A-5
Welding Terminals . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .A-5
Welding Output Cables . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .A-5
Machine Grounding . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .A-5
Remote Control . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .A-6
Auxiliary Power Receptacles . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .A-6
Standby Power Connections . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .A-6
Connection of Vantage Premises Wiring . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .A-7
Connection of Lincoln Electric Wire Feeders . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .A-8, A-9
Operation
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Section B
Safety Instructions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .B-1
General Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .B-1
Recommended Applications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .B-1
Air Compressor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .B-1
Controls and Settings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .B-2
Engine Controls . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .B-2, B-3
Welder Controls . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .B-4
Auxiliary Power Controls . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .B-4
Air Compressor Controls . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .B-5
Battery Jump Start Terminals . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .B-5
Engine Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .B-5
Starting the Engine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .B-5
Stopping the Engine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .B-5
Break-In Period . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .B-6
Typical Fuel Consumption . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .B-6
Duty Cycle . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .B-6
Welding Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .B-6
Stick Welding Mode . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .B-6
CC-Stick Mode . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .B-6
Downhill Pipe Mode . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .B-6
Touch Start TIG Mode . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .B-6
AIR VANTAGE® Settings when using K930-2 TIG Module . . . . . . . . . . . . . . . . . . . . . . . . .B-7
Typical Current Ranges for Tungsten Electrodes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .B-7
CV-Wire Mode . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .B-8
Arc Gouging . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .B-8
Paralleling . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .B-8
Auxiliary Power Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .B-8
Simultaneous Welding and Auxiliary Power Loads . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .B-8
Simultaneous Welding and Power Loads, Extension Cord Length Recommendations . . . . . . . . . . .B-9
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vii
vii
TABLE OF CONTENTS
Accessories
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Section C
Optional Field Installed Accessories . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .C-1
_________________________________________________________________________________________________
Maintenance
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Section D
Safety Precautions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .D-1
Routine and Periodic Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .D-1
Engine Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .D-1
Air Filter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .D-1,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
GFCI Receptacle Testing and Resetting Procedure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .D-4
Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Section E
Wiring, Connection Diagrams and Dimension Print . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Section F
Parts Lists
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .P-495 Series
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A-1
INSTALLATION
A-1
TECHNICAL SPECIFICATIONS - AIR VANTAGE® 500 CUMMINS (K2325-1)
INPUT - DIESEL ENGINE
Make /Model
Description
Speed (RPM)
Displacement
Starting
System
Capacities
Cummins
B3.3
Diesel Engine
4 cylinder
56HP (42 kw)
@ 1800 RPM
High Idle 1900
Low Idle 1425
Full Load 1800
199 cu. in
(3.3L)
12VDC battery Fuel
& Starter (25 US gal)
94.6L
Oil:
Bore x Stroke
(2 US gal)
7.5L
3.74” x 4.53”
(95mm x 115mm)
Coolant:
(2.6 US gal)
9.8L
RATED OUTPUT @ 104°F(40°C) - WELDER
Duty Cycle
100%
Welding Output
Volts at Rated Amps
500 Amps (DC multi-purpose)
550 Amps (DC multi-purpose)
575 Amps (DC multi-purpose)
40 Volts
36 volts
35 volts
60%
50%
OUTPUT @ 104°F(40°C) - WELDER AND GENERATOR
Welding Range
30 - 575 Amps CC/CV
20 - 250 Amps TIG
Open Circuit Voltage
60 Max OCV @ 1900 RPM
(1)
Auxiliary Power
120/240 VAC
12,000 WATTS, 60 Hz., Single Phase
20,000 WATTS, 60 Hz., Three Phase
PHYSICAL DIMENSIONS
(2)
Height
Width
Depth
Weight
42.0 in
(1066.8 mm)
32.7 in.
(830.1mm)
63.1 in.
(1603mm)
1690 lbs.
(766kg)
(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.
AIR VANTAGE® 500 CUMMINS
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A-2
INSTALLATION
A-2
Read this entire installation section before you start
installation.
LOCATION / VENTILATION
The welder should be located to provide an unrestricted 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 properly vented to an outside area.
SAFETY PRECAUTIONS
WARNING
CAUTION
Do not attempt to use this equipment until you have
thoroughly read all operating and maintenance manuals
supplied with your machine. They include important safety
precautions, detailed engine starting, operating and
maintenance instructions and parts lists.
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.
ELECTRIC SHOCK can kill.
• Do not touch electrically live parts such as
output terminals or internal wiring.
--------------------------------------------------------------------------------------
• Insulate yourself from the work and ground.
• Always wear dry insulating gloves.
-------------------------------------------------------------------------------------
ENGINE EXHAUST can kill.
STORING
1.
2.
3.
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 construction activities, moving
vehicles, and other hazards.
• Use in open, well ventilated areas or vent
exhaust outside
Drain the engine oil and refill with fresh 10W30 oil. Run the
engine for about five minutes to circulate oil to all the parts.
See the MAINTENANCE section of this manual for details
on changing oil.
-------------------------------------------------------------------------------------
MOVING PARTS can injure.
• Do not operate with doors open or guards off.
• Stop engine before servicing.
Remove the battery, recharge it, and adjust the electrolyte
level. Store the battery in a dry, dark place.
• Keep away from moving parts
-------------------------------------------------------------------------------------
STACKING
Only qualified personnel should install, use or service this
equipment.
AIR VANTAGE® 500 machines cannot be stacked.
ANGLE OF OPERATION
To achieve optimum engine performance the AIR VANTAGE®
500 should be run in a level position. The maximum angle of
operation for the VMAC Compressor and Cummins engine is 35
degrees in all directions. 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.).
AIR VANTAGE® 500 CUMMINS
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A-3
INSTALLATION
A-3
LIFTING
HIGH TEMPERATURE OPERATION
The AIR VANTAGE® 500 lift bale should be used to lift the
machine. The AIR VANTAGE® 500 is shipped with the lift bale
retracted. Before attempting to lift the AIR VANTAGE® 500 the lift
bale must be secured in a raised position. Secure the lift bale as
follows:
At temperatures above 40°C (104°F), output voltage derating
may be necessary. For maximum output current ratings, derate
welder voltage rating 2 volts for every 10°C (21°F) above 40°C
(104°F).
a. Open the engine compartment door.
TOWING
b. Locate the 2 access holes on the upper middle region
of compartment wall just below the lift bale.
The recommended trailer for use with this equipment for road, in-
plant and yard towing by a vehicle is 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:
(1)
c. Use the lifting strap to raise the lift bale to the full upright
position. This will align the mounting holes on the lift
bale with the access holes.
d. Secure the lift bale with 2 thread forming screws. The
screws are provided in the shipped loose parts bag.
1. Design capacity of trailer vs. weight of Lincoln
equipment and likely additional attachments.
WARNING
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.
FALLING EQUIPMENT can cause injury.
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.
• Do not lift this machine using lift bale if it is
equipped with a heavy accessory such as a
trailer or gas cylinder.
4. Typical conditions of use, such as travel speed,
roughness of surface on which the trailer will be
operated, and environmental conditions.
• Lift only with equipment of adequate lifting
capacity.
•` Be sure machine is stable when lifting.
5. Proper preventative maintenance of trailer.
-------------------------------------------------------------------------------------
6. Conformance with federal, state and local laws (1)
.
(1)
Consult applicable federal, state and local laws regarding
specific requirements for use on public highways.
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.).
VEHICLE MOUNTING
WARNING
Contact a Cummins Service Representative for any engine
adjustments that may be required.
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 components such
as suspension, axles and tires.
• Mount equipment base to metal bed or frame of vehicle.
• Follow vehicle manufacture’s instructions.
--------------------------------------------------------------------------------------
AIR VANTAGE® 500 CUMMINS
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A-4
INSTALLATION
A-4
ENGINE COOLANT
PRE-OPERATION ENGINE AND
COMPRESSOR SERVICE
WARNING
WARNING
HOT COOLANT can burn skin.
READ the engine and compressor operating and maintenance
instructions supplied with this machine.
•Do not remove cap if radiator is hot.
• Keep hands away from the engine muffler or
HOT engine parts.
-------------------------------------------------------------------------------------
• Stop engine and allow to cool before fuelling.
• Do not smoke when fuelling.
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.
• Fill fuel tank at a moderate rate and do not over-fill.
• Wipe up spilled fuel and allow fumes to clear before
starting engine.
• Keep sparks and flame away from tank.
BATTERY CONNECTION
--------------------------------------------------------------------------------------
OIL
WARNING
The AIR VANTAGE® 500 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 running time
during the first 35 running hours. Refer to the engine and
compressor Operator’s Manuals for specific oil recommendations
and break-in information. The oil change interval is dependent on
the quality of the oil and the operating environment. Refer to the
engine and compressor Operator’s Manuals for the proper
service and maintenance intervals.
GASES FROM BATTERY can explode.
• Keep sparks, flame and cigarettes away from
battery.
To prevent EXPLOSION when:
• 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.
FUEL USE DIESEL FUEL ONLY
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 specific fuel recommendations. Running
out of fuel may require bleeding the fuel injection pump.
NOTE: Before starting the engine, open the fuel shutoff valve
(pointer to be in line with hose).
• USING A BOOSTER — connect positive lead to battery first
then connect negative lead to negative battery lead at
engine foot.
BATTERY ACID can burn eyes and skin.
• Wear gloves and eye protection and be careful
when working near battery.
FUEL CAP
• Follow instructions printed on battery.
Remove the plastic cap covering from the Fuel Tank Filler neck
and install the Fuel Cap.
IMPORTANT: To prevent ELECTRICAL DAMAGE WHEN:
a) Installing new batteries.
b) Using a booster.
Use correct polarity — Negative Ground.
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A-5
INSTALLATION
A-5
The AIR VANTAGE® 500 is shipped with the negative battery
cable disconnected. Before you operate the machine, make sure
the Engine Switch is in the OFF position and attach the
disconnected cable securely to the negative (-) battery terminal.
WELDING TERMINALS
The AIR VANTAGE® 500 is equipped with a toggle switch for
selecting "hot" welding terminals when in the "WELD
TERMINALS ON" position or "cold" welding terminals when in the
"REMOTELY CONTROLLED" position.
Remove the insulating cap from the negative battery terminal.
Replace and tighten negative battery cable terminal. NOTE: This
machine is furnished with a wet charged battery; if unused for
several months, the battery may require a booster charge. Be
sure to use the correct polarity when charging the battery.
WELDING OUTPUT CABLES
With the engine off, route the electrode and work cables thru the
strain relief bracket provided on the front of the base and connect
to the terminals provided. These connections should be checked
periodically and tightened if necessary.
MUFFLER OUTLET PIPE
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.
Listed in Table A.1 are copper cable sizes recommended 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.
SPARK ARRESTOR
Table A.1 Combined Length of Electrode and Work Cables.
Some federal, state or local laws may require that petrol or diesel
engines be equipped with exhaust spark arrestors when they are
operated in certain locations where unarrested sparks may
present a fire hazard. The standard muffler included with this
welder does not qualify as a spark arrestor. When required by
local regulations, a suitable spark arrestor, must be installed and
properly maintained.
TOTAL COMBINED LENGTH OF
ELECTRODE AND WORK CABLES
AMPS
@100%
Duty Cycle
Up to 150ft
150-200ft
200-250ft
Up to 45.7m
45.7-70.0m
70.0-76.2m
500
3/0 AWG
3/0 AWG
4/0 AWG
MACHINE GROUNDING
CAUTION
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.).
An incorrect arrestor may lead to damage to the engine or
adversely affect performance.
--------------------------------------------------------------------------------------
To prevent dangerous electric shock, other equipment powered
by this engine driven welder must:
AIR CLEANER INLET HOOD
a) be grounded to the frame of the welder using a
grounded type plug,
Remove the plastic plug covering the air cleaner inlet. Install the
air cleaner inlet hood to the air cleaner.
or
b) be double insulated.
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 connected 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 section
entitled “Standby Power Connections” as well as
the article on grounding in the latest National Electrical Code and
the local codes.
In general, if the machine is to be grounded, it should be
connected with a #8 or larger copper wire to a solid earth ground
such as a metal ground stake going into the ground for at least 10
Feet or to the metal framework of a building which has been
effectively grounded. The National Electric Code lists a number of
alternate means of grounding electrical equipment. A machine
grounding stud marked with the symbol
front of the welder.
is provided on the
AIR VANTAGE® 500 CUMMINS
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A-6
INSTALLATION
A-6
STANDBY POWER CONNECTIONS
REMOTE CONTROL
The AIR VANTAGE® 500 is suitable for temporary, standby or
emergency power using the engine manufacturer’s
recommended maintenance schedule.
OUTPUT
The AIR VANTAGE® 500 is equipped with a 6-pin and a 14-pin
connector. The 6-pin connector is for connecting the K857 or
K857-1 Remote Control or for TIG welding, the K870 foot Amptrol
or the K936-2 hand Amptrol. When in the CC-STICK, DOWNHILL
PIPE, or CV-WIRE modes and when a remote control is
connected to the 6-pin Connector, the auto-sensing circuit
automatically switches the OUTPUT control from control at the
welder to remote control.
The AIR VANTAGE® 500 can be permanently installed as a
standby power unit for 240 volt-3 wire, 50 amp service.
Connections must be made by a licensed electrician who can
determine how the 120/240 VAC power can be adapted to the
particular installation and comply with all applicable electrical
codes. The following information can be used as a guide by the
electrician for most applications. Refer to the connection diagram
shown in Figure A.2.
When in TOUCH START TIG mode and when a Amptrol is
connected to the 6-Pin Connector, the OUTPUT dial is used to set
the maximum current range of the CURRENT CONTROL of the
Amptrol.
1. Install the double-pole, double-throw switch between the power
company meter and the premises disconnect.
When in the DOWNHILL PIPE mode and when a remote control is connected
to the 6-Pin or 14-Pin connector, the output control is used to set the
maximum current range of the remote.
Switch rating must be the same or greater than the customer’s
premises disconnect and service over current protection.
EXAMPLE: When the OUTPUT CONTROL on the welder is set to 200 amps
the current range on the remote control will be 40-200 amps, rather than the
full 40-300 amps. Any current range that is less than the full range provides
finer current resolution for more fine tuning of the output.
The 14-pin connector is used to directly connect a wire feeder
control cable. In the CV-WIRE mode, when the control cable is
connected to the 14-pin connector, the auto-sensing circuit
automatically makes the Output Control inactive and the wire
feeder voltage control active
WARNING
NOTE: When a wire feeder with a built in welding voltage
control is connected to the 14-pin connector, do not connect
anything to the 6-pin connector.
--------------------------------------------------------------------------------------
AUXILIARY POWER RECEPTACLES
Start the engine and set the “IDLER” control switch to the “High
Idle” mode. Voltage is now correct at the receptacles for auxiliary
power. This must be done before a tripped GFCI receptacle can
be reset properly. See the MAINTENANCE section for detailed
information on testing and resetting the GFCI receptacle.
The auxiliary power capacity of the AIR VANTAGE® 500 is
12,000 watts of 60 Hz, single phase or 20,000 watts of 60Hz,
three phase power. The auxiliary power capacity rating in watts
is equivalent to volt-amperes at unity power factor. The maximum
permissible current of the 240 VAC output is 50 A. The 240 VAC
single phase output can be split to provide two separate 120 VAC
outputs with a maximum permissible current of 50 A per output to
two separate 120 VAC branch circuits. The output voltage is
within ± 10% at all loads up to rated capacity.
The AIR VANTAGE® 500 has two 20 Amp-120VAC single
phase(5-20R) GFCI duplex receptacles, one 50 Amp-120/240
single phase VAC (14-50R) receptacle and one 240VAC three
phase (15-50R) receptacle. The auxiliary power receptacles
should only be used with three wire grounded type plugs or
approved double insulated tools with two wire plugs. The current
rating of any plug used with the system must be at least equal to
the current capacity of the associated receptacle.
A 240VAC 3 phase plug is provided loose with the machine.
NOTE: The two 120V GFCI receptacles and the two 120 volt
circuits of the 120/240V receptacle are connected to different
phases and can not be paralleled.
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A-7
INSTALLATION
A-7
2. Take necessary steps to assure load is limited to the capacity
of the AIR VANTAGE® 500 by installing a 50 amp, 240 VAC
double pole circuit breaker. Maximum rated load for each leg
of the 240 VAC auxiliary is 50 amps. 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 overheating of the AIR
VANTAGE® 500 engine.
3. Install a 50 amp 120/240 VAC plug (NEMA Type 14-50) to the
double-pole circuit breaker using No. 6, 4 conductor cable of
the desired length. (The 50 amp, 120/240 VAC plug is
available in the optional K802R plug kit.)
4. Plug this cable into the 50 Amp 120/240 Volt receptacle on the
AIR VANTAGE® 500 case front.
Figure A.2 Connection of the AIR VANTAGE® 500 to Premises Wiring
240 VOLT
GROUNDED CONDUCTOR
POWER
240 Volt
60 Hz.
3-Wire
Service
120 VOLT
COMPANY
120 VOLT
METER
NEUTRAL
BUS
N
LOAD
DOUBLE POLE DOUBLE THROW
SWITCH RATING TO BE THE SAME
AS OR GREATER THAN PREMISES
SERVICE OVERCURRENT
PROTECTION.
PREMISES
DISCONNECT AND
SERVICE
OVERCURRENT
PROTECTION
GROUND
50AMP
240 VOLT
DOUBLE
POLE
CIRCUIT
BREAKER
50 AMP, 120/240
VOLT PLUG
NEMA TYPE 14-50
240 VOLT
GND
N
50 AMP, 120/240 VOLT
RECEPTACLE
NOTE: No. 6 COPPER CONDUCTOR CABLE SEE
NATIONAL ELECTRICAL CODE FOR ALTERNATE WIRE
SIZE RECOMMENDATIONS.
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A-8
INSTALLATION
A-8
CONNECTION OF LINCOLN ELECTRIC
WIRE FEEDERS
WARNING
Shut off welder before making any electrical connections.
-------------------------------------------------------------------------------------
CONNECTION OF LN-7, LN-8 OR LN-742 TO THE
AIR VANTAGE® 500
• Shut the welder off.
• Connect the LN-7, LN-8 OR LN-742 per instructions on the
appropriate connection diagram in the DIAGRAMS section.
• Set the “WIRE FEEDER VOLTMETER” switch to either “+” or “-
” as required by the electrode being used.
• Set the “SELECTOR” switch to the “CV-WIRE” position.
• Adjust the “ARC CONTROL” knob to desired Crispness. SOFT
for MIG and CRISP for INNERSHIELD.
• Set the “WELDING TERMINALS” switch to the “REMOTELY
CONTROLLED” position.
• Set the “IDLE” switch to the “HIGH” position.
CONNECTION OF LN-15 TO THE AIR VANTAGE®
500
These connections instructions apply to both the LN-15 Across-
The-Arc and Control Cable models. The LN-15 has an internal
contactor and the electrode is not energized until the gun trigger
is closed. When the gun trigger is closed the wire will begin to
feed and the welding process is started.
• Shut the welder off.
• For electrode Positive, connect the electrode cable to the "+"
terminal of the welder and work cable to the "-" terminal of the
welder. For electrode Negative, connect the electrode cable "-"
terminal of the welder and work cable to the "+" terminal of the
welder.
• Across The-Arc Model:
Attach the single lead from the front of the LN-15 to work
using the spring clip at the end of the lead. This is a control
lead to supply current to the wire feeder motor; it does not
carry welding current.
Control Cable Model:
Connect Control Cable between Engine Welder and Feeder.
• Set the MODE switch to the "CV-WIRE " position.
• Across The-Arc Model:
Set the "WELD TERMINALS" switch to "WELD TERMINALS
ON"
Control Cable Model:
Set the "WELD TERMINALS" switch to "REMOTELY
CONTROLLED"
• Set the "WIRE FEEDER VOLTMETER" switch to either "+" or
"-" as required by the electrode polarity being used.
• Set the "ARC CONTROL" knob to "0" initially and adjust to suit.
• Set the "IDLE" switch to the "AUTO IDLE" position
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A-9
INSTALLATION
A-9
CONNECTION OF THE LN-25 TO THE AIR
VANTAGE® 500
CONNECTION OF MAGNUM SC SPOOL GUN TO
THE AIR VANTAGE® 500 (SEE SECTION F)
The LN-25 with or without an internal contactor may be used with
the AIR VANTAGE® 500. See the appropriate connection
diagram in the DIAGRAMS section.
NOTE: The LN-25 (K431) Remote Control Module and (K432)
Remote Cable are not recommended for use with the AIR
VANTAGE® 500.
• Shut the welder off.
• For electrode Positive, connect the electrode cable from the LN-
25 to the “+” terminal of the welder and work cable to the “-”
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.
• Attach the single lead from the front of the LN-25 to work using
the spring clip at the end of the lead. This is a sense lead to
supply current to the wire feeder motor; it does not carry welding
current.
• Set the SELECTOR switch to the “CV-WIRE” position.
• Set the “WELDING TERMINALS” switch to “WELD
TERMINALS ON”
• Adjust the “ARC CONTROL” knob to desired crispness.
Generally, welding is best if the “ARC CONTROL” is set to
SOFT for MIG and CRISP for INNERSHIELD. You may
however, want to start in the middle and adjust (as needed)
from there.
• Set the “IDLE” switch to the “AUTO” position. When not welding,
the AIR VANTAGE® 500 engine will be at the low idle speed. If
you are using an LN-25 with an internal contactor, the electrode
is not energized until the gun trigger is closed.
CAUTION
If you are using an LN-25 without an internal contactor, the
electrode will be energized when the AIR VANTAGE® 500 is
started.
--------------------------------------------------------------------------------------
• When the gun trigger is closed, the current sensing circuit will
cause the wire to begin to feed and the welding process is
started.
CONNECTION OF AN NA-3 AUTOMATIC
WELDING SYSTEM TO THE AIR VANTAGE® 500
For connection diagrams and instructions for connecting an NA-3
Welding System to the AIR VANTAGE® 500, refer to the NA-3
Welding System instruction manual. The connection diagram for
the LN-8 can be used for connecting the NA-3.
• Set the Wire Feeder Voltage Switch to 115V.
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B-1
OPERATION
B-1
SAFETY INSTRUCTIONS
GENERAL DESCRIPTION
Read and understand this entire section before operating
The AIR VANTAGE® 500 is a diesel engine-driven welding power
source. The machine uses a brush type alternating current
generator for DC multi-purpose welding, for 120/240 VAC single
phase and 240V three phase auxiliary standby power. The AIR
VANTAGE® 500 also has a rotary screw 60 cfm air compressor
built in.The welding control system uses state of the art Chopper
Technology™.
your AIR VANTAGE® 500.
WARNING
Do not attempt to use this equipment until you have
thoroughly read all operating and maintenance manuals
supplied with your machine. They include important safety
precautions, detailed engine starting, operating and
maintenance instructions and parts lists.
RECOMMENDED APPLICATIONS
WELDER
ELECTRIC SHOCK can kill.
The AIR VANTAGE® 500 provides excellent constant current DC
welding output for stick (SMAW) and TIG welding. The AIR
VANTAGE® 500 also provides excellent constant voltage DC
welding output for MIG (GMAW), Innershield (FCAW), outershield
(FCAW-G) and Metal Core welding. In addition the AIR
VANTAGE® 500 can be used for Arc Gouging with carbons up to
3/8”(10mm) in diameter.
• Do not touch electrically live parts such as
output terminals or internal wiring.
• Insulate yourself from the work and ground.
• Always wear dry insulating gloves.
--------------------------------------------------------------------------------------
ENGINE EXHAUST can kill.
The AIR VANTAGE® 500 is not recommended for pipe thawing.
• Use in open, well ventilated areas or vent
exhaust outside
AIR COMPRESSOR
The AIR VANTAGE® 500 provides 60 cfm at 100 psi.
compressed air for Arc Gouging and Air powered tools.
• Do not stack anything near the engine.
--------------------------------------------------------------------------------------
MOVING PARTS can injure.
GENERATOR
• Do not operate with doors open or guards off.
• Stop engine before servicing.
The AIR VANTAGE® 500 provides smooth 120/240 VAC single phase
and 240V three phase output for auxiliary power and emergency standby
power.
• Keep away from moving parts
--------------------------------------------------------------------------------------
Only qualified personnel should operate this equipment.
ADDITIONAL SAFETY PRECAUTIONS
Always operate the welder with the sliding door closed and
the side panels in place as these provide maximum
protection from moving parts and insure proper cooling air
flow.
AIR VANTAGE® 500 CUMMINS
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B-2
OPERATION
B-2
10
CONTROLS AND SETTINGS
All welder and engine controls are located on the case front panel. Refer to Figure B.1 and the explanations that follow.
Figure B.1 Case Front Panel Controls
6
5
7
9
8
4
3
11
20
13
12
21
19
15
14
24
25
23
22
1
2
16
17
18
26
27
28
3. HOUR METER
ENGINE CONTROLS (Items 1 through 9)
The hour meter displays the total time that the engine has been
running. This meter is a useful indicator for scheduling preventive
maintenance.
1. RUN
STOP
SWITCH
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.
4. FUEL LEVEL GAUGE
Displays the level of diesel fuel in the fuel tank.
2. START PUSHBUTTON
The operator must watch the fuel level closely to prevent
running out of fuel and possibly having to bleed the system.
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.
5. ENGINE TEMPERATURE GAUGE
The gauge displays the engine coolant temperature.
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B-3
OPERATION
B-3
6. OIL PRESSURE GAUGE
c. When welding ceases and the AC power load is turned
off, a fixed time delay of approximately 12 seconds
starts.
The gauge displays the engine oil pressure when the engine is
running.
d. If the welding or AC power load is not restarted before
the end of the time delay, the idler reduces the engine
speed to low idle speed.
7. ENGINE PROTECTION
The yellow engine protection light remains off with proper oil
pressure and under normal operating temperatures. If the light
turns on, the engine protection system will stop the engine. Check
for proper oil level and add oil if necessary. 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.
e. The engine will automatically return to high idle speed
when the welding load or A.C. power load is reapplied.
Idler Operational exceptions
When the WELDING TERMINALS switch is in the “Remotely
Controlled” position the idler will operate as follows:
a. When the triggering device (Amptrol, Arc Start Switch, etc.) is
pressed the engine will accelerate and operate at full speed
provided a welding load is applied within approximately 12
seconds.
8. BATTERY CHARGING LIGHT
The yellow engine alternator light is off when battery charging
system is functioning normally. If light turns on the alternator or
the voltage regulator may not be operating correctly. The light will
remain on when the engine is stopped and the run/stop switch is
in the run position.
• 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.
9. IDLER SWITCH
Has two positions as follows:
A) In the “High” position
, the engine runs at the high idle
speed controlled by the governor.
B) In the “Auto”
follows:
/
position, the idler operates as
a. When switched from “High” to “Auto” or after starting the
engine, the engine will operate at full speed for
approximately 12 seconds and then go to low idle
speed.
b. When the electrode touches the work or power is drawn
for lights or tools (approximately 100 Watts minimum)
the engine accelerates and operates at full speed.
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B-4
OPERATION
B-4
WELDING CONTROLS (Items 10 through 19)
10. OUTPUT CONTROL: The OUTPUT dial is used to preset the
output voltage or current as displayed on the digital meters for the
four welding modes. When in the CC-STICK, DOWNHILL PIPE or
CV-WIRE modes and when a remote control is connected to the
6-Pin or 14-Pin Connector, the auto-sensing circuit automatically
switches the OUTPUT CONTROL from control at the welder to
the remote control.
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
control. The proper setting depends on the procedure and
operator preference. Start with a setting of 0.
In the CV-WIRE mode, when the wire feeder control cable is
connected to the 14-Pin Connector, the auto-sensing circuit
automatically makes OUTPUT CONTROL inactive and the wire
feeder voltage control active.
14. WELDING TERMINALS SWITCH
In the WELD TERMINALS ON position, the output 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.
When in the DOWNHILL PIPE mode and when a remote control is connected
to the 6-Pin or 14-Pin connector, the output control is used to set the
maximum current range of the remote.
EXAMPLE: When the OUTPUT CONTROL on the welder is set to 200 amps
the current range on the remote control will be 40-200 amps, rather than the
full 40-300 amps. Any current range that is less than the full range provides
finer current resolution for more fine tuning of the output.
15. WIRE FEEDER VOLTMETER SWITCH:
Matches the polarity of the wire feeder voltmeter to the polarity of
the electrode.
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 CONTROL of the
Amptrol.
16. 6 - PIN CONNECTOR
For attaching optional remote control equipment. Includes auto-
sensing remote control circuit.
11. DIGITAL OUTPUT METERS:
17. 14 - PIN CONNECTOR
The digital meters allow the output voltage (CV-WIRE mode) or
current (CC-STICK, DOWNHILL PIPE and TIG modes) to be set
prior to welding using the OUTPUT control knob. During welding,
the meters display the actual output voltage (VOLTS) and current
(AMPS). A memory feature holds the display 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%.
For attaching wire feeder control cables. Includes contactor
closure circuit, auto-sensing remote control circuit, and 120VAC
and 42VAC power.
NOTE: When a wire feeder with a built in welding voltage control
is connected to the 14-pin connector, do not connect anything to
the 6-pin connector.
18. WELD OUTPUT TERMINALS + AND -
12. WELD MODE SELECTOR SWITCH:
(Provides four selectable welding modes)
CV-WIRE
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 connects to the “+” terminal and the
electrode cable connects to this “-” terminal.
DOWNHILL PIPE
CC-STICK
TOUCH START TIG
AUXILIARY POWER CONTROLS
(Items 19-23)
13. ARC CONTROL:
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.
19. 120/240 VAC SINGLE PHASE RECEPTACLE
This is a 120/240VAC (14-50R) receptacle that provides 240VAC
or can be split for 120VAC single phase auxiliary power. This
receptacle has a 50 amp rating. Refer to the AUXILIARY POWER
RECEPTACLES section in the installation chapter for further
information about this receptacle. Also refer to the AUXILIARY
POWER OPERATION section later in this chapter.
CC-STICK mode: In this mode, the ARC CONTROL knob sets the
short circuit current (arc-force) during stick welding. Increasing
the number 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.
DOWNHILL PIPE mode: In this mode, the ARC CONTROL knob
sets the short circuit current (arc-force) during stick welding to
adjust for a soft or a more forceful digging arc (Crisp). Increasing
the number from -10(Soft) to +10(Crisp) increases the short
circuit current which results in a more forceful digging arc.
Typically a forceful digging arc is preferred for root and hot
passes. A softer arc is preferred for fill and cap passes where
weld puddle control and deposition (“stacking” of iron) are key to
fast travel speeds. It is recommended that the ARC CONTROL
be set initially at 0.
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B-5
OPERATION
B-5
20. CIRCUIT BREAKERS
ENGINE OPERATION
These circuit breakers provide separate overload current
protection for each 120V circuit at the 240V single phase
receptacle, each 120V single phase receptacle, the 240V three
phase receptacle, the 120VAC in the 14-Pin connector, the
42VAC in the 14-Pin connector and battery circuit overload
protection.
STARTING THE ENGINE
1. Open the engine compartment door and check that the fuel
shutoff valve located to the left of the fuel filter housing is in the
open position (lever to be in line with the hose).
2. Make sure battery disconnect switch is in the on position.
3. Check for proper oil level and coolant level. Close engine
compartment door.
21. 120VAC SINGLE PHASE RECEPTACLES
These two 120VAC (5-20R) receptacles with ground fault circuit
interruption protection provide 120VAC single phase for auxiliary
power. Each receptacle has a 20 amp total rating. They are
designed to protect the user from the hazards of ground faults.
When the GFCI has tripped there will be no voltage available
from the receptacle. Refer to the AUXILIARY POWER
RECEPTACLES section in the installation chapter for further
information about these receptacles. Also refer to the AUXILIARY
POWER OPERATION section later in this chapter.
4. Remove all plugs connected to the AC power receptacles.
5. Set IDLER switch to “AUTO”.
6. Set the RUN/STOP switch to “RUN”. Observe that the engine
protection and battery charging lights are on. After 10 seconds,
the engine protection light will turn off.
7. Within 30 seconds, press and hold the engine START button
until the engine starts.
8. Release the engine START button when the engine starts.
22. GROUND STUD
9. Check that the engine protection and battery charging lights
are off. The engine protection light is on after starting, the
engine will shutdown in a few seconds. Investigate any
indicated problem.
Provides a connection point for connecting the machine case to
earth ground. Refer to “MACHINE GROUNDING” in the
Installation chapter for proper machine grounding information.
10. Allow the engine to warm up at low idle speed for several
minutes before applying a load and/or switching to high idle.
Allow a longer warm up time in cold weather.
23. 240VAC THREE PHASE RECEPTACLE
This is a 240VAC (15-50R) receptacle that provides 240VAC
three phase auxiliary power. This receptacle has a 50 amp rating.
AIR COMPRESSOR CONTROLS (24 THRU 26)
COLD WEATHER STARTING
24. COMPRESSOR ON/OFF SWITCH
With a fully charged battery and the proper weight oil, the engine
should start satisfactorily even down to about 0°F(-18°C). If the
engine must be frequently started below 10°(-12°C), it may be
desirable to install the optional ether start kit (K887-1). For
extreme cold conditions it may be desirable to install the Cold
Weather Heater and Tarp Kit (K2359-1). Installation and operating
instructions are included in the kits.
Turns compressor on and off (standby) by opening and closing
the compressor inlet valve.
25. COMPRESSOR PROTECTION LIGHT
The yellow compressor protection light remains off with proper
compressor oil temperatures. If the lights turn on, the compressor
protection system will close the compressor inlet valve and put
the system in standby mode until the temperature reaches
allowable limits. Check for proper compressor oil level.
STOPPING THE ENGINE
26. AIR DISCHARGE VALVE
1. Switch the RUN/STOP switch to “STOP”. This turns off the
voltage supplied to the shutdown solenoid. A backup shutdown
can be accomplished by shutting off the fuel valve located on
the fuel line.
Controls flow of compressed air. A 3/4” NPT (National Pipe
Thread) fitting is provided.
BATTERY JUMP START TERMINAL (27-28)
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 AIR
VANTAGE® 500 Cummins.
FIGURE B.2
30
29. BATTERY DISCONNECT SWITCH
Battery disconnect switch provides lockout/tagout capability.
Switch is conveniently located inside the engine compartment.
(SEE FIGURE B.2)
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 FIGURE B.2)
29
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B-6
OPERATION
B-6
CC-STICK MODE
BREAK-IN PERIOD
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.
The engine used to supply power for your welder is a heavy duty,
industrial engine. It is designed and built for rugged use. It is very
normal for any engine to use small quantities of oil until the break-
in is accomplished. Check the oil level twice a day during the
break-in period. In general this takes 50 to 100 hours of
operation.
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 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 the knob
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.
set at 0.
DOWNHILL PIPE MODE
TYPICAL FUEL CONSUMPTION
This slope controlled setting is intended for “out-of-position” and
“down hill” pipe welding where the operator would like to control
the current level by changing the arc length. The OUTPUT
CONTROL knob adjusts the full output range for pipe welding.
Refer to Table B.2 for typical fuel consumption of the AIR
VANTAGE® 500 Engine for various operating scenarios.
Table B.2
Cummins B3.3 Engine Fuel Consumption
Cummins B3.3
56HP(42Kw)
@1800 RPM
Running Time for
25GAL.(94.6L)
(Hours)
The ARC CONTROL knob sets the short circuit current (arc-force)
during stick welding to adjust for a soft or a more forceful digging
arc (Crisp). Increasing the number from -10(Soft) to +10(Crisp)
increases the short circuit current which results in a more forceful
digging arc. Typically a forceful digging arc is preferred for root
and hot passes. A softer arc is preferred for fill and cap passes
where weld puddle control and deposition (“stacking” of iron) are
key to fast travel speeds. It is recommended that the ARC
Low Idle -
no load 1425 RPM
.59 Gal./hour
(2.2 L/hour)
42.4
28.7
11.9
High Idle -
no load 1900 RPM
.87 Gal./hour
(3.3 L/hour)
CONTROL be set initially at 0.
DC CC Weld
Output 500
Amps @ 40 Volts
2.10 Gal./hour
(7.9 L/hour)
TOUCH START TIG MODE
Auxiliary Power
12,000 VA
1.44 Gal./hour
(5.5 L/hour)
17.4
12.4
19.4
The AIR VANTAGE® 500 can be used in a wide variety of DC TIG
welding applications.
Auxiliary Power
20,000 VA
2.02 Gal./hour
(7.6 L/hour)
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
general, avoids tungsten contamination. Then, the tungsten is
gently lifted off the work in a rocking motion, which establishes the
arc.
Air Compressor
60 CFM @ 100 PSI
1.29 Gal./hour
(4.9 L/hour)
Air Compressor
60 CFM @ 100 PSI 2.46 Gal./hour
and DC, CC Weld
Output 500 Amps
@40 Volts
10.2
12.9
(9.3 L/hour)
To stop the arc, simply lift the TIG torch away from the work piece.
When the arc voltage reaches approximately 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.
Air Compressor
60 CFM @ 100 PSI 1.94 Gal./hour
and Auxiliary Power
12,000 VA
(7.3 L/hour)
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 AIR VANTAGE® 500. The settings are for
reference.
WELDER OPERATION
DUTY CYCLE
The AIR VANTAGE® 500 is equipped with the required R.F.
bypass circuitry for the connection of high frequency generating
equipment.
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 AIR VANTAGE® 500 and any high frequency 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
The AIR VANTAGE® 500 can be used with a broad range of DC
stick electrodes.
When using the TIG Module, the OUTPUT control on the AIR
VANTAGE® 500 is used to set the maximum range of the
CURRENT CONTROL on the TIG Module or an Amptrol if
connected to the TIG Module.
The MODE switch provides two stick welding settings as follows:
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B-7
OPERATION
B-7
AIR VANTAGE® 500 SETTINGS WHEN USING
THE K930-2 TIG MODULE
• 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.
(1)
Table B.3 TYPICAL CURRENT RANGES
(2)
FOR TUNGSTEN ELECTRODES
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 applications.
(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 cannot withstand high temperatures and high duty cycles.
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B-8
OPERATION
B-8
CV-WIRE MODE
The auxiliary power capacity is 12,000 watts of 60 Hz, single
phase power or 20,000 watts of 60Hz, three phase power. The
auxiliary power capacity rating in watts is equivalent to volt-
amperes at unity power factor. The maximum permissible current
of the 240 VAC output is 50 A. The 240 VAC single phase output
can be split to provide two separate 120 VAC outputs with a
maximum permissible current of 50 A per output to two separate
120 VAC branch circuits. Output voltage is within ± 10% at all
loads up to rated capacity.
Connect a wire feeder to the AIR VANTAGE® 500 and set welder
controls according to the instructions listed earlier in this section.
The AIR VANTAGE® 500 in the ”CV-WIRE” position, permits it
to be used with a broad range of flux cored wire (Innershield and
Outershield) electrodes and solid wires for MIG welding (gas
metal arc welding). Welding 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. The
proper setting depends on the procedure and operator
preference. Start with the knob set at 0.
NOTE: The two 120V GFCI receptacles and the two 120V circuits
of the 120/240V receptacle are connected to different phases and
cannot be paralleled.
For any electrodes, including the above recommendations, the
procedures should be kept within the rating of the machine. For
the appropriate Lincoln publication.
The auxiliary power receptacles should only be used with three
wire grounded type plugs or approved double insulated tools with
two wire plugs.
The current rating of any plug used with the system must be at
least equal to the current capacity of the associated receptacle.
ARC GOUGING
For optimal performance when arc gouging, set the AIR
VANTAGE® 500 “WELD MODE” switch to the “CC - STICK”
position, and the “ARC CONTROL” to 10.
SIMULTANEOUS WELDING AND AUXILIARY
POWER LOADS
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:
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 permissible currents shown assume that current is being
drawn from either the 120 VAC or 240 VAC supply (not both at the
same time).
ELECTRODE
DIAMETER
(1/8”)
CURRENT RANGE
(DC, electrode positive)
30-60 Amps
(5/32”)
90-150 Amps
(3/16”)
200-250 Amps
(1/4”)
300-400 Amps
(5/16”)
350-450 Amps
(3/8”)
450-575 Amps*
NOTE: If desired the CV mode can be used for Arc Gouging.
* Maximum current setting is limited to the AIR VANTAGE® 500
maximum of 575 Amps.
PARALLELING
When paralleling machines in order to combine their outputs, all
units must be operated in the CC-STICK mode only at the same
output settings. To achieve this, turn the WELD MODE switch to
the CC-STICK position. Operation in other modes may produce
erratic outputs, and large output imbalances between the units.
AUXILIARY POWER OPERATION
If a GFCI receptacle is tripped, See the MAINTENANCE section
for detailed information on testing and resetting the GFCI
receptacle.
Start the engine and set the IDLER control switch to the desired
operating mode. Full power is available regardless of the welding
control settings, if no welding current is being drawn.
The auxiliary power of the AIR VANTAGE® 500 consists of two 20
Amp-120VAC single phase (5-20R) GFCI duplex receptacles,
one 50 Amp-120/240VAC single phase (14-50R) receptacle and
one 50 Amp 240VAC three phase (15-50R) receptacle. The
120/240VAC receptacle can be split for single phase 120 VAC
operation.
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B-9
OPERATION
B-9
TABLE B.4 AIR VANTAGE® 500 SIMULTANEOUS WELDING AND POWER LOADS
WELD
AMPS
0
100
200
250
300
400
500
1 PHASE
WATTS
3 PHASE
WATTS
BOTH 1 AND 3 PHASE
AMPS
50
50
50
50
42
23
0
AMPS
50
43
34
29
24
13
0
WATTS
------
AMPS
50
12,000
12,000
12,000
12,000
10,000
5,600
0
20,000
17,800
14,000
12,000
10,000
5,600
0
------
50
PLUS
OR
------
50
OR
12,000
10,000
5,600
0
------
------
------
0
TABLE B.5 AIR VANTAGE® 500 Extension Cord Length
Recommendations
Current Voltage Load
(Amps) (Volts) (Watts)
Maximum Allowable Cord Length in ft. (m) for Conductor Size
14 AWG
12 AWG
10 AWG
8 AWG
6 AWG
4 AWG
15
15
20
20
25
30
38
50
120
240
120
240
240
240
240
1800
3600
2400
4800
6000
7200
9000
30
60
(9)
(18)
40
(12)
(23)
(9)
75
150
50
100
90
75
(23)
(46)
(15)
(30)
(27)
(23)
125
225
88
175
150
120
100
(38)
(69)
(27)
(53)
(46)
(37)
(30)
175
(53)
(107)
(42)
(84)
(69)
(53)
(46)
(38)
300
600
225
450
250
300
250
200
(91)
(183)
(69)
(137)
(76)
(91)
(76)
(61)
75
30
60
350
138
275
225
175
150
125
(18)
240 12000
Conductor size is based on maximum 2.0% voltage drop.
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C-1
ACCESSORIES
C-1
OPTIONAL FIELD INSTALLED ACCESSORIES
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.
K802N POWER PLUG KIT - Provides four 120V plugs rated at 20 amps each
and one dual voltage, full KVA plug rated at 120/240V, 50 amps. 120V plug may
not be compatible with NEMA common household receptacles.
K802-R POWER PLUG KIT - Provides four 120V plugs rated 15 amps each
and one dual voltage, full KVA plug rated at 120/240V, 50 amps, 120V plug is
compatible with NEMA common household receptacles.
TIG OPTIONS
K870 Foot Amptrol®-Varies current while welding 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 after flow
cycle on systems so equipped. Includes 25 ft. (7.6m) control
cable.
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 AIR VANTAGE® 500 CUMMINS
is equipped with a 6-pin connector for connecting the remote control.
K704 ACCESSORY SET - Includes 35 feet (10 m) of electrode
cable and 30 feet (9 m) of work cable, headshield, Filter plate,
work clamp and electrode holder. Cable is rated at 500 amps,
60% duty cycle.
K963-3 Hand Amptrol®-Varies current for making critical TIG
welds. Fastens to the torch for convenient thumb control. Comes
with a 25 ft. (7.6m) cable. (for larger handle 18 or 26 series
torches)
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.
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 combination hitch. A fender
& a light package. Order:
K2636-1 Trailer
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.
K1816-1 Full KVA Adapter Kit - Plugs into the 120/240V NEMA
14-50R receptacle on the case front (which accepts 4-prong
plugs) and converts it to a NEMA 6-50R receptacle (which
accepts 3-prong plugs) for connection to Lincoln Equipment with
a NEMA 6-50P plug,
T12153-9 Full-KVA Power Plug-One dual voltage plug rated at
120/240V, 50 amps, single phase.
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.
-------------------------------------------------------------------------------------
K2354-1 Air Dryer Kit-Minimizes water content 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.
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.
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D-1
MAINTENANCE
D-1
COMPRESSOR MAINTENANCE
SAFETY PRECAUTIONS
Refer to the “Routine Maintenance” section of the compressor
owner’s manual for the recommended maintenance schedule of
the following:
WARNING
a. Compressor oil and filter.
b. Compressor air filter.
• Have
troubleshooting work.
a
qualified technician do the maintenance and
c. Compressor coalescing filter.
• Turn the engine off before working inside the machine.
VMAC
™
• Remove guards only when necessary and replace them when
the maintenance requiring their removal is complete.
VEHICLE MOUNTED AIR COMPRESSORS
• Always use the greatest care when working near moving parts.
--------------------------------------------------------------------------------------
1333 Kipp Road
Nanamino
British Columbia
Canada, V9X1R3
Read the Safety Precautions in front of this manual and the
engine instruction manual before working on this machine.
Keep all equipment safety guards, covers and devices in position
and in good repair. Keep hands, hair, clothing and tools away
from V-belts, gears, fans and all other moving parts when starting,
operating or repairing the equipment.
Telephone: (250) 740-3200
Facsimile: (250) 740-3201
Toll Free:
800-738-8622
ENGINE MAINTENANCE
Refer to the “Periodic Checks” section of the Engine Operator’s
Manual for the recommended maintenance schedule of the
following:
ROUTINE AND PERIODIC
MAINTENANCE
a) Engine Oil and Filter
b) Air Cleaner
DAILY
c) Fuel Filter - and Delivery System
d) Alternator Belt
e) Battery
• Check the Engine and Compressor oil levels .
• Refill the fuel tank to minimize moisture condensation in the
tank.
f) Cooling System
• Open the water drain valve located on the bottom of the water
separator element 1 or 2 turns and allow to drain into a
container suitable for diesel fuel for 2 to 3 seconds. Repeat the
above drainage procedure until diesel fuel is detected in the
container.
Refer to Table D.1 at the end of this section for various engine
maintenance components.
AIR FILTER
• Check coolant level.
WARNING
CAUTION
• Only Vmac certified and approved synthetic
oil MUST be used. Shut down the
Welder/Compressor for 3 minutes, open the
pressure supply valve to ensure the system is
depressurized prior to removing the
compressor oil level dipstick.
• 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.
--------------------------------------------------------------------
WEEKLY
Blow out the machine with low pressure air periodically. In
particularly dirty locations, this may be required once a week.
CAUTION
• 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.
---------------------------------------------------------------------
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
indicator. (See Service Instructions and Installation
Tips for Engine Air Filter.)
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D-2
MAINTENANCE
D-2
Service Instructions & Installation Tips
For Engine Air Filter
Donaldson filters with RadialSeal™ Sealing
Technology are self-aligning, self-centering,
and self-sealing. A new filter has a dry
lubricant to aid installation. 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 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. Again, do NOT use the service
cover to push the filter into place!
Check the Old
Release the
5Filter for Leak Clues
Visually inspect the old filter for any signs
of leaks. A streak of dust on
the clean side of the fi
is a telltale sign.
1Seal Carefully
Unlatch and remove the service
cover of the air cleaner. Make
certain the latches are folded
back against the cover so that
they donít hinder filter
Remove any cause
of leaks before
installing new
removal/installation. Most latches
are spring loaded to fold back when open.
The filter fits tightly over the outlet tube,
creating the critical seal on the inside
diameter of the filter endcap. The filter
should be removed gently to reduce the
amount of dust dislodged. 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.
filter.
Inspect the New
6Filter for Damage
Inspect the new filter carefully,
n to the inside of
the open end,
When the filter in is place, put the service
cover back on, making sure the Vacuator™
™
Valve points down. Inspect the Vacuator
Valve for cracks or dust hang-ups to insure
that it is functioning properly. Re-fasten
the latches.
which is the
sealing area.
NEVER install
a damaged filter.
Avoid Dislodging
2Dust from the Filter
Gently pull the
Check Connections
filter off the outlet
8for Tight Fit
tube and out of the
Make sure that all clamps, bolts, and
connections in the entire air intake system
are tight. Check for holes in piping, and
repair if needed.
Insert the New
housing. Avoid
knocking the filter
against the housing.
7RadialSealô Filter
by Hand
Insert carefully. Seat the new filter by hand,
making certain it is completely into the air
cleaner housing before latching the cover in
place. If the cover hits the filter before it is
fully in place, remove the cover and push
(by hand) the
Clean Sealing Surface
3of the Outlet Tube
Use a clean cloth to wipe the sealing
surface. Dust on the outside diameter of the
outlet tube could hinder
an effective seal
filter further into
the air cleaner
and try again.
The cover
should go on
with no extra force.
and cause leakage.
Make sure that all
contaminant is
removed before the
new filter is inserted.
Never use the latches on the cover to force
the filter into the air cleaner! It is tempting
to assume the cover will do the job of
seating the filter ñ but it will not! Using the
latches to push the filter in could cause
damage to the housing and will void the
warranty.
Clean the Inside of
4the Outlet Tube
Carefully wipe the inside
of the outlet tube
with a clean cloth.
Dirt accidently
transferred to the
inside of the outlet
tube will reach the
engine and cause wear.
(Engine manufacturers says that it takes
only a few grams of dirt to ëdustí an
engine!) Be careful not to damage the
sealing area on the tube.
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D-3
MAINTENANCE
D-3
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 - 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.
The AIR VANTAGE® 500 is equipped with a Fuel Filter located
after the lift pump and before fuel injectors.The procedure for
changing the filter is as follows.
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.
• USING A BOOSTER - connect positive lead to
battery first then connect negative lead to
engine foot.
3. Fill the clean filter with clean fuel, and lubricate the o-ring seal
with clean lubricating oil.
BATTERY ACID CAN BURN EYES AND SKIN.
• Wear gloves and eye protection and be careful
4. Install the filter as specified by the filter manufacturer.
when
working
near
battery.
Follow
instructions printed on battery.
WARNING
--------------------------------------------------------------------------------------
PREVENTING ELECTRICAL DAMAGE
Mechanical overtightening will distort the threads, filter
element seal or filter can.
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 circuit. The positive (+) battery cable has a red
terminal cover.
--------------------------------------------------------------------------------------
COOLING SYSTEM
The AIR VANTAGE® 500 is equipped with a pressure radiator.
Keep the radiator cap tight to prevent loss of coolant. Clean and
flush the coolant system periodically to prevent clogging the
passage and over-heating the engine. When antifreeze is
needed, always use the permanent type.
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.
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D-4
MAINTENANCE
D-4
CHARGING THE BATTERY
GFCI RECEPTACLE TESTING AND RESETTING
PROCEDURE
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 AIR VANTAGE®
500 positive (+) battery terminal has a red terminal cover.
The GFCI receptacle should be properly tested at least once
every month or whenever it is tripped. To properly test and reset
the GFCI receptacle:
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 battery cable first and the negative cable
last. Failure to do so can result in damage to the internal charger
• If the receptacle has tripped, first carefully remove any load and
check it for damage.
• If the equipment has been shut down, it must be restarted.
• The equipment needs to be operating at high idle speed and
any necessary adjustments made on the control panel so that
the equipment is providing at least 80 volts to the receptacle
input terminals.
• The circuit breaker for this receptacle must not be tripped.
Reset if necessary.
• Push the "Reset" button located on the GFCI receptacle. This
will assure normal GFCI operation.
components.
Follow the instructions of the battery charger manufacturer for
proper charger settings and charging time.
NAMEPLATES / WARNING DECALS
MAINTENANCE
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.
• Plug a night-light (with an "ON/OFF" switch) or other product
(such as a lamp) into the GFCI receptacle and turn the product
"ON".
• Push the "Test" button located on the GFCI receptacle. The
night-light or other product should go "OFF".
• Push the "Reset" button, again. The light or other product
should go "ON" again.
WELDER / GENERATOR
MAINTENANCE
If the light or other product remains "ON" when the "Test" button
is pushed, the GFCI is not working properly or has been
incorrectly installed (miswired). If your GFCI is not working
properly, contact a qualified, certified electrician who can assess
the situation, rewire the GFCI if necessary or replace the device.
STORAGE
Store the AIR VANTAGE® in a clean, dry protected areas.
CLEANING
Blow out the generator and controls periodically with low pressure
air. Do this at least once a week in particularly 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.
WARNING
Do not attempt to polish slip rings while the engine is
running.
--------------------------------------------------------------------------------------
Table D.1 Engine Maintenance Components
ITEM
MAKE
PART NUMBER
SERVICE INTERVAL
Air Cleaner Element
Donaldson
Fleetguard
P822768
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.
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E-1
TROUBLESHOOTING
E-1
HOW TO USE TROUBLESHOOTING GUIDE
WARNING
Service and Repair should only be performed by Lincoln Electric Factory Trained Personnel. Unauthorized repairs
performed on this equipment may result in danger to the technician and machine operator and will invalidate your factory
warranty. For your safety and to avoid Electrical Shock, please observe all safety notes and precautions detailed
throughout this manual.
_______________________________________________________________________________________________
This Troubleshooting Guide is provided to help you locate and
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 (SYMPTOMS)”. 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.
NOTE: See VMAC owner’s manual for compressor trouble shooting.
VMAC
™
VEHICLE MOUNTED AIR COMPRESSORS
1333 Kipp Road
Nanamino
British Columbia
Canada, V9X1R3
Telephone: (250) 740-3200
Facsimile: (250) 740-3201
Toll Free:
800-738-8622
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.
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E-2
TROUBLESHOOTING
Observe all Safety Guidelines detailed throughout this manual
E-2
RECOMMENDED
COURSE OF ACTION
POSSIBLE
CAUSE
PROBLEMS
(SYMPTOMS)
ENGINE PROBLEMS
1. Contact your Local Lincoln Authorized
Field Service Facility.
Major Physical or Electrical Damage is
Evident.
1. Battery low.
Engine will not crank
2. Loose battery cable connections which
may need Inspected, cleaned or tighten.
3. Faulty wiring in engine starting circuit.
4. Faulty engine starter. Contact authorized
local Engine Service Shop.
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 position
make sure the valve lever is in a vertical
direction.
3. Engine shut down solenoid not pulling in.
4. On/Off switch on for more than 30 sec.
before starting, the On/Off switch will
need to be switch off and turned back on.
If all recommended possible areas
of misadjustment have been
checked and the problem persists,
Contact your local Lincoln
5. Fuel Filters dirty/clogged, main filter
element and/or Inline Fuel Filter may
need to be replaced.
6. High water temperature or low oil
pressure. (engine protection light lit)
Authorized Field Service Facility.
Engine shuts down shortly after starting.
1. Low oil pressure (engine protection light
lit). Check oil level (Consult engine
service dealer).
2. High water temperature. Check engine
cooling system. (engine protection light
lit).
3. Faulty oil pressure switch.
4. Faulty water temperature switch. Contact
authorized local Engine Service Shop.
Engine shuts down while under a load.
Engine runs rough.
1. High water temperature.
1. Dirty fuel or air filters may need
cleaned/replaced.
2. Water in fuel.
Engine will not shut off.
1. Fuel Shutdown solenoid not functioning
properly / linkage binding.
CAUTION
ºIf for any reason you do not understand the test procedures or are unable to perform the tests/repairs safely, contact your Local Lincoln
Authorized Field Service Facility for technical troubleshooting assistance before you proceed.
______________________________________________________________________________________________________________
AIR VANTAGE® 500 CUMMINS
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E-3
TROUBLESHOOTING
E-3
PROBLEMS
(SYMPTOMS)
POSSIBLE
CAUSE
RECOMMENDED
COURSE OF ACTION
FUNCTION PROBLEMS
1. Faulty battery .
2. Faulty engine alternator.
Battery does not stay charged.
3. Loose or broken lead in charging circuit.
4. Loose fan belt may need tightening.
1. Idler switch in HIGH idle position, make
sure switch is set to AUTO.
2. External load on welder or auxiliary
power.
Engine will not idle down to low
speed.
3. Mechanical problem in idler solenoid
linkage.
4. Faulty wiring in solenoid circuit.
5. No or low voltage @ idle solenoid
6. Faulty idler solenoid.
7. Faulty, Weld Control PCB (Printed Circuit
Board), Pull Coil /Battery PCB
1. Poor work lead connection to work.
2. Broken idler solenoid spring.
3. Welding Terminals switch in wrong
position.
Engine will not go to high idle when
attempting to weld.
4. No open circuit voltage at output studs.
5. Faulty, Pull Coil/Battery PCB or Weld
Control PCB.
If all recommended possible areas
of misadjustment have been
checked and the problem persists,
Contact your local Lincoln
1. Broken wire in auxiliary current sensor
Engine will not go to high idle when using
auxiliary power.
wiring.
2. Auxiliary power load is less than 100
Authorized Field Service Facility.
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.
______________________________________________________________________________________________________________
AIR VANTAGE® 500 CUMMINS
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E-4
TROUBLESHOOTING
E-4
PROBLEMS
(SYMPTOMS)
RECOMMENDED
COURSE OF ACTION
POSSIBLE
CAUSE
FUNCTION PROBLEMS
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 potentiometer.
3. Faulty output control wiring.
4. Faulty Weld Control PCB, Pull
Coil/Battery PCB or Chopper PCB.
No welding output. Auxiliary output OK.
1. WELDING TERMINALS switch in wrong
position, be sure switch is in WELDING
TERMINALS ALWAYS ON position.
2. Faulty Weld Control PCB, Pull
Coil/Battery PCB or Chopper PCB.
No auxiliary power.
1. GFCI Receptacle may have tripped.
Follow “GFCI Receptacle Testing and
Resetting
Procedure”
in
the
If all recommended possible areas
of misadjustment have been
checked and the problem persists,
Contact your local Lincoln
MAINTENANCE section of this manual.
2. Open breakers may need to be reset.
3. Faulty receptacle.
4. Faulty auxiliary circuit wiring.
5. GFCI tripped.
Authorized Field Service Facility.
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.
______________________________________________________________________________________________________________
AIR VANTAGE® 500 CUMMINS
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F-1
DIAGRAMS
F-1
AIR VANTAGE® 500 CUMMINS
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F-2
DIAGRAMS
F-2
CONNECTION DIAGRAM:
AIR VANTAGE® 500 CUMMINS
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F-3
DIAGRAMS
F-3
CONNECTION DIAGRAM:
}
AIR VANTAGE® 500 CUMMINS
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F-4
DIAGRAMS
F-4
CONNECTION DIAGRAM
AIR VANTAGE® 500 CUMMINS
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F-5
DIAGRAMS
F-5
CONNECTION DIAGRAM
AIR VANTAGE® 500 CUMMINS
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F-6
DIAGRAMS
F-6
CONNECTION DIAGRAM
}
AIR VANTAGE® 500 CUMMINS
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F-7
DIAGRAMS
F-7
CONNECTION DIAGRAM
AIR VANTAGE® 500 CUMMINS
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F-8
DIAGRAMS
F-8
CONNECTION DIAGRAM
AIR VANTAGE® 500 CUMMINS
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F-9
DIAGRAMS
F-9
CONNECTION DIAGRAM
AIR VANTAGE® 500 CUMMINS
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F-10
DIAGRAMS
F-10
CONNECTION DIAGRAM
AIR VANTAGE® 500 CUMMINS
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F-11
DIAGRAMS
F-11
CONNECTION DIAGRAM
AIR VANTAGE® 500 CUMMINS
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F-12
DIAGRAMS
F-12
CONNECTION DIAGRAM
AIR VANTAGE® 500 CUMMINS
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F-13
DIAGRAMS
F-13
DIMENSION PRINT
AIR VANTAGE® 500 CUMMINS
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G Do not touch electrically live parts or G Keep flammable materials away.
G Wear eye, ear and body protection.
electrode with skin or wet clothing.
G Insulate yourself from work and
ground.
WARNING
Spanish
G No toque las partes o los electrodos G Mantenga el material combustible
G Protéjase los ojos, los oídos y el
bajo carga con la piel o ropa
mojada.
G Aislese del trabajo y de la tierra.
fuera del área de trabajo.
cuerpo.
AVISO DE
PRECAUCION
French
G Ne laissez ni la peau ni des
G Gardez à l’écart de tout matériel
inflammable.
G Protégez vos yeux, vos oreilles et
votre corps.
vêtements mouillés entrer en contact
avec des pièces sous tension.
ATTENTION
G Isolez-vous du travail et de la terre.
German
G Berühren Sie keine stromführenden
Teile oder Elektroden mit Ihrem
Körper oder feuchter Kleidung!
G Isolieren Sie sich von den
G Entfernen Sie brennbarres Material! G Tragen Sie Augen-, Ohren- und Kör-
perschutz!
WARNUNG
Elektroden und dem Erdboden!
Portuguese
G Não toque partes elétricas e
electrodos com a pele ou roupa
molhada.
G Mantenha inflamáveis bem
guardados.
G Use proteção para a vista, ouvido e
corpo.
ATENÇÃO
G Isole-se da peça e terra.
Japanese
Chinese
Korean
Arabic
READ AND UNDERSTAND THE MANUFACTURER’S INSTRUCTION FOR THIS EQUIPMENT AND THE CONSUMABLES TO
BE USED AND FOLLOW YOUR EMPLOYER’S SAFETY PRACTICES.
SE RECOMIENDA LEER Y ENTENDER LAS INSTRUCCIONES DEL FABRICANTE PARA EL USO DE ESTE EQUIPO Y LOS
CONSUMIBLES QUE VA A UTILIZAR, SIGA LAS MEDIDAS DE SEGURIDAD DE SU SUPERVISOR.
LISEZ ET COMPRENEZ LES INSTRUCTIONS DU FABRICANT EN CE QUI REGARDE CET EQUIPMENT ET LES PRODUITS A
ETRE EMPLOYES ET SUIVEZ LES PROCEDURES DE SECURITE DE VOTRE EMPLOYEUR.
LESEN SIE UND BEFOLGEN SIE DIE BETRIEBSANLEITUNG DER ANLAGE UND DEN ELEKTRODENEINSATZ DES
HERSTELLERS. DIE UNFALLVERHÜTUNGSVORSCHRIFTEN DES ARBEITGEBERS SIND EBENFALLS ZU BEACHTEN.
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G Keep your head out of fumes.
G Use ventilation or exhaust to
remove fumes from breathing zone.
G Turn power off before servicing.
G Do not operate with panel open or
guards off.
WARNING
Spanish
G Los humos fuera de la zona de
respiración.
G Mantenga la cabeza fuera de los
humos. Utilice ventilación o
aspiración para gases.
G Desconectar el cable de
alimentación de poder de la
máquina antes de iniciar cualquier
servicio.
G No operar con panel abierto o
guardas quitadas.
AVISO DE
PRECAUCION
French
G N’opérez pas avec les panneaux
ouverts ou avec les dispositifs de
protection enlevés.
G Gardez la tête à l’écart des fumées.
G Utilisez un ventilateur ou un
aspirateur pour ôter les fumées des
zones de travail.
G Débranchez le courant avant
l’entretien.
ATTENTION
German
G Anlage nie ohne Schutzgehäuse
oder Innenschutzverkleidung in
Betrieb setzen!
G Vermeiden Sie das Einatmen von
Schweibrauch!
G Sorgen Sie für gute Be- und
Entlüftung des Arbeitsplatzes!
G Strom vor Wartungsarbeiten
abschalten! (Netzstrom völlig
öffnen; Maschine anhalten!)
WARNUNG
Portuguese
G Mantenha-se afastado das partes
moventes.
G Não opere com os paineis abertos
ou guardas removidas.
G Mantenha seu rosto da fumaça.
G Use ventilação e exhaustão para
remover fumo da zona respiratória.
G Não opere com as tampas removidas.
G Desligue a corrente antes de fazer
serviço.
ATENÇÃO
G 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 USA Tel: 216.481.8100 Fax: 216.486.1751 Web Site: www.lincolnelectric.com
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