IM826-A
June, 2007
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AIR VANTAGE 500 CUMMINS
For use with machines having Code Numbers: 11069, 11417
Lincoln arc welding and cutting
Safety Depends on You
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.
C US
R
OPERATOR始S MANUAL
Copyright漏 2007 Lincoln Global Inc.
鈥? World始s Leader in Welding and Cutting Products 鈥?
鈥? Sales and Service through Subsidiaries and Distributors Worldwide 鈥?
Cleveland, Ohio 44117-1199 USA Tel: 216.481.8100 Fax: 216.486.1751 Web Site: www.lincolnelectric.com
SAFETY
i i
WARNING
CALIFORNIA PROPOSITION 65 WARNINGS
For Diesel Engines: diesel engine exhaust and For Gasoline Engines: The engine exhaust from this
some of its constituents are known to the State of product contains chemicals known to the State of
California to cause cancer, birth defects, and other California to cause cancer, birth defects, or other
reproductive harm. reproductive harm.
ARC WELDING CAN BE HAZARDOUS. PROTECT YOURSELF AND OTHERS FROM POSSIBLE SERIOUS INJURY OR DEATH.
KEEP CHILDREN AWAY. PACEMAKER WEARERS SHOULD CONSULT WITH THEIR DOCTOR BEFORE OPERATING.
Read and understand the following safety highlights. For additional safety information, it is strongly recommended that you
purchase a copy of 鈥淪afety in Welding & Cutting - ANSI Standard Z49.1鈥? from the American Welding Society, PO Box
351040, Miami, Florida 33135 or CSA Standard W117.2-1974 or WTIA (Welding Technology Institute of Australia), PO Box
6165, Silverwater, NSW, 2128. A free copy of 鈥淎rc Welding Safety鈥? booklet E205 is available from the Lincoln Electrical
Company, 22801 St Clair Avenue, Cleveland, Ohio 44117-1199.
BE SURE THAT ALL INSTALLATION, OPERATION, MAINTENANCE AND REPAIR PROCEDURES ARE
PERFORMED ONLY BY QUALIFIED INDIVIDUALS.
FOR ENGINE
powered equipment.
1.h. To avoid scalding, do not remove the
radiator pressure cap when the engine is
hot.
1.a Turn the engine off before troubleshooting and maintenance
work unless the maintenance work requires it to be running.
ELECTRIC AND
MAGNETIC FIELDS
1.b. Operate engines in open, well ventilated
areas or vent the engine exhaust fumes
may be dangerous
outdoors.
1.c. Do not add fuel near an open flame, welding
2.a.Electric current flowing through any conductor causes
arc or when the engine is running. Stop the
localized Electric and Magnetic Fields (EMF). Welding
engine and allow it to cool before refuelling
current creates EMF fields around welding cables and
to prevent spilled fuel from vaporizing on
welding machines.
contact with hot engine parts and igniting.
Do not spill fuel when filling tank. If fuel is 2.b.EMF fields may interfere with some pacemakers and welders
spilled, wipe it up and do not start engine having a pacemaker should consult their physician before
until fumes have been eliminated. welding.
2.c. Exposure to EMF fields in welding may have other health
1.d.Keep all equipment, safety guards, covers and devices in effects which are now not known.
position and in good repair. Keep hands, hair, clothing and
2.d.All welders should use the following procedures in order to
tools away from V-belts, gears, fans and all other moving
minimize exposure to EMF fields from the welding circuit:
parts when starting, operating or repairing equipment.
2.d.1. Route the electrode and work cables together.
Secure them with tape when possible.
1.e.In some cases it may be necessary to remove safety guards
to perform required maintenance. Remove guards only when
2.d.2. Never coil the electrode lead around your body.
necessary and replace them when the maintenance
requiring their removal is complete. Always use the greatest 2.d.3. Do not place your body between the electrode
care when working near moving parts. and work cables. If the electrode cable is on your
right side, the work cable should also be on your
right side.
1.f. Do not put your hands near the engine fan.
Do not attempt to override the governor or 2.d.4. Connect the work cable to the workplace as
idler by pushing on the throttle control rods close as possible to the area being welded.
while the engine is running.
2.d.5. Do not work next to welding power source.
1.g.To prevent accidentally starting petrol engines while turning
Mar 驶95
the engine or welding generator during maintenance work,
disconnect the spark plug wires, distributor cap or magneto
wire as appropriate.
SAFETY
ii ii
ARC RAYS can burn.
ELECTRIC SHOCK
can kill.
4a 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
3.a. The electrode and work (or ground) circuits
and filter lens should conform to ANSI
are electrically 鈥渉ot鈥? when the welder is on.
Z87.1 standards.
Do not touch these 鈥渉ot鈥? parts with your bare
skin or wet clothing. Wear dry, hole-free 4.b.Use suitable clothing made from durable flame resistant
gloves to insulate hands. 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 4.c. Protect other nearby personnel with suitable non flammable
cover your full area of physical contact with work and screening and/or warn them not to watch the arc or expose
ground. themselves to the arc rays or to hot spatter or metal.
In addition to the normal safety precautions, if welding
FUMES AND GASES
must be performed under electrically hazardous
conditions (in damp locations or while wearing wet
can be dangerous
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
5.a. Welding may produce fumes and gases
unavoidable or accidental contact with the workpiece
hazardous to health. Avoid breathing these
or ground) use the following equipment:
fumes and gases. When welding, keep your
鈥? Semiautomatic DC Constant Voltage (Wire) Welder. head out of the fume. Use enough
ventilation and/or exhaust at the arc to
鈥? DC Manual (Stick) Welder.
keep fumes and gases away from the breathing zone. When
welding with electrodes which require special ventilation
鈥? AC Welder with Reduced Voltage Control.
such as stainless or hard facing (see instructions on
3.c. In semi-automatic or automatic wire welding, the container or MSDS) or on lead or cadmium plated steel and
electrode, electrode reel, welding head, nozzle or semi- other metals or coatings which produce highly toxic fumes,
automatic welding gun are also electrically 鈥渉ot鈥?. keep exposure as low as possible and below Threshold
Limit values (TLV) using local exhaust or mechanical
3.d. Always be sure the work cable makes a good electrical
ventilation. In confined spaces or in some circumstances,
connection with the metal being welded. The connection
outdoors, a respirator may be required. Additional
should be as close as possible to the area being welded.
precautions are also required when welding on galvanized
3.e. Ground the work or metal to be welded to a good electrical steel.
(earth) ground.
5. b. The operation of welding fume control equipment is
3.f. Maintain the electrode holder, work clamp, welding cable affected by various factors including proper use and
and welding machine in good, safe operating condition. positioning of the equipment, maintenance of the
Replace damaged insulation. equipment and the specific welding procedure and
applicaiton involved. Worker exposure level should be
3.g. Never dip the electrode holder in water for cooling.
checked upon installation and periodically thereafter to be
3.h. Never simultaneously touch electrically 鈥渉ot鈥? parts of certain it is within applicable OSHA PEL and ACGIH TLV
electrode holders connected to two welders because limits.
voltage between the two can be the total of the open circuit
voltage of both welders.
5.c. Do not weld in locations near chlorinated hydrocarbon
vapors coming from degreasing, cleaning or spraying
3.i. When working above floor level, use a safety belt to
operations. The heat and rays of the arc can react with
protect yourself from a fall should you get a shock.
solvent vapors to form phosgene, a highly toxic gas, and
3.j. Also see items 6c and 8. other irritating products.
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始s instructions for
this equipment and the consumables to be used, including
the material safety data sheet (MSDS) and follow your
employer始s safety practices. MSDS forms are available
from your welding distributor or from the manufacturer.
5.f. Also see item 1.b.
AUG 06
SAFETY
iii iii
CYLINDER may explode
WELDING and CUTTING
SPARKS can if damaged.
cause fire or explosion. 7.a. Use only compressed gas cylinders
6.a. Remove fire hazards from the welding area. containing the correct shielding gas for the
If this is not possible, cover them to prevent process used and properly operating
the welding sparks from starting a fire. regulators designed for the gas and
Remember that welding sparks and hot pressure used. All hoses, fittings, etc. should be suitable for
materials from welding can easily go through small cracks the application and maintained in good condition.
and openings to 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 7.c. Cylinders should be located:
situations. Refer to 鈥淪afety in Welding and Cutting鈥? (ANSI 鈥? Away from areas where they may be struck or subjected to
Standard Z49.1) and the operating information for the physical damage.
equipment being used.
鈥? A safe distance from arc welding or cutting operations and
6.c. When not welding, make certain no part of the electrode any other source of heat, sparks, or flame.
circuit is touching the work or ground. Accidental contact can
cause overheating and create a fire hazard. 7.d. Never allow the electrode, electrode holder or any other
electrically 鈥渉ot鈥? parts to touch a cylinder.
6.d. Do not heat, cut or weld tanks, drums or containers until the
proper steps have been taken to insure that such procedures 7.e. Keep your head and face away from the cylinder valve outlet
will not cause flammable or toxic vapors from substances when opening the cylinder valve.
inside. They can cause an explosion even though they have
been 鈥渃leaned鈥?. For information, purchase 鈥淩ecommended 7.f. Valve protection caps should always be in place and hand
Safe Practices for the Preparation for Welding and Cutting of tight except when the cylinder is in use or connected for
Containers and Piping That Have Held Hazardous use.
Substances鈥?, AWS F4.1 from the American Welding Society
7.g. Read and follow the instructions on compressed gas
(see address above).
cylinders, associated equipment, and CGA publication P-l,
鈥淧recautions for Safe Handling of Compressed Gases in
6.e. Vent hollow castings or containers before heating, cutting or
Cylinders,鈥? available from the Compressed Gas Association
welding. They may explode.
1235 Jefferson Davis Highway, Arlington, VA 22202.
6.f. Sparks and spatter are thrown from the welding arc. Wear oil
FOR ELECTRICALLY
free protective garments such as leather gloves, heavy shirt,
cuffless trousers, high shoes and a cap over your hair. Wear
powered equipment.
ear plugs when welding out of position or in confined places.
Always wear safety glasses with side shields when in a
welding area.
8.a. Turn off input power using the disconnect
switch at the fuse box before working on
6.g. Connect the work cable to the work as close to the welding
the equipment.
area as practical. Work cables connected to the building
framework or other locations away from the welding area
8.b. Install equipment in accordance with the U.S. National
increase the possibility of the welding current passing
Electrical Code, all local codes and the manufacturer始s
through lifting chains, crane cables or other alternate circuits.
recommendations.
This can create fire hazards or overheat lifting chains or
cables until they fail.
8.c. Ground the equipment in accordance with the U.S. National
Electrical Code and the manufacturer始s recommendations.
6.h. Also see item 1.c.
Jan, 07
6.I. Read and follow NFPA 51B 鈥? Standard for Fire Prevention
During Welding, Cutting and Other Hot Work鈥?, 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.
SAFETY
iv iv
PR脡CAUTIONS DE S脹RET脡 6. Eloigner les mat茅riaux inflammables ou les recouvrir afin de
pr茅venir tout risque d始incendie d没 aux 茅tincelles.
Pour votre propre protection lire et observer toutes les instructions
7. Quand on ne soude pas, poser la pince 脿 une endroit isol茅 de
et les pr茅cautions de s没ret茅 specifiques qui parraissent dans ce
la masse. Un court-circuit accidental peut provoquer un
manuel aussi bien que les pr茅cautions de s没ret茅 g茅n茅rales
茅chauffement et un risque d始incendie.
suivantes:
8. S始assurer que la masse est connect茅e le plus pr茅s possible de
S没ret茅 Pour Soudage A L始Arc
la zone de travail qu始il est pratique de le faire. Si on place la
1. Protegez-vous contre la secousse 茅lectrique:
masse sur la charpente de la construction ou d始autres endroits
茅loign茅s de la zone de travail, on augmente le risque de voir
a. Les circuits 脿 l始茅lectrode et 脿 la pi茅ce sont sous tension
passer le courant de soudage par les chaines de levage,
quand la machine 脿 souder est en marche. Eviter toujours
c芒bles de grue, ou autres circuits. Cela peut provoquer des
tout contact entre les parties sous tension et la peau nue
risques d始incendie ou d始echauffement des chaines et des
ou les v茅tements mouill茅s. Porter des gants secs et sans
c芒bles jusqu始脿 ce qu始ils se rompent.
trous pour isoler les mains.
b. Faire tr茅s attention de bien s始isoler de la masse quand on
9. Assurer une ventilation suffisante dans la zone de soudage.
soude dans des endroits humides, ou sur un plancher
Ceci est particuli茅rement important pour le soudage de t么les
metallique ou des grilles metalliques, principalement dans
galvanis茅es plomb茅es, ou cadmi茅es ou tout autre m茅tal qui
les positions assis ou couch茅 pour lesquelles une grande
produit des fume茅s toxiques.
partie du corps peut 锚tre en contact avec la masse.
c. Maintenir le porte-茅lectrode, la pince de masse, le c芒ble de
10. Ne pas souder en pr茅sence de vapeurs de chlore provenant
soudage et la machine 脿 souder en bon et s没r 茅tat
d始op茅rations de d茅graissage, nettoyage ou pistolage. La
defonctionnement.
chaleur ou les rayons de l始arc peuvent r茅agir avec les vapeurs
d.Ne jamais plonger le porte-茅lectrode dans l始eau pour le
du solvant pour produire du phosg茅ne (gas fortement toxique)
refroidir.
ou autres produits irritants.
e. Ne jamais toucher simultan茅ment les parties sous tension
des porte-茅lectrodes connect茅s 脿 deux machines 脿 souder
11. Pour obtenir de plus amples renseignements sur la s没ret茅, voir
parce que la tension entre les deux pinces peut 锚tre le total
le code 鈥淐ode for safety in welding and cutting鈥? CSA Standard
de la tension 脿 vide des deux machines.
W 117.2-1974.
f. Si on utilise la machine 脿 souder comme une source de
courant pour soudage semi-automatique, ces precautions
pour le porte-茅lectrode s始applicuent aussi au pistolet de
soudage.
PR脡CAUTIONS DE S脹RET脡 POUR
LES MACHINES 脌 SOUDER 脌
2. Dans le cas de travail au dessus du niveau du sol, se prot茅ger
contre les chutes dans le cas ou on recoit un choc. Ne jamais
TRANSFORMATEUR ET 脌
enrouler le c芒ble-茅lectrode autour de n始importe quelle partie du
REDRESSEUR
corps.
3. Un coup d始arc peut 锚tre plus s茅v猫re qu始un coup de soliel, donc:
a. Utiliser un bon masque avec un verre filtrant appropri茅 ainsi 1. Relier 脿 la terre le chassis du poste conformement au code de
qu始un verre blanc afin de se prot茅ger les yeux du l始茅lectricit茅 et aux recommendations du fabricant. Le dispositif
rayonnement de l始arc et des projections quand on soude ou de montage ou la piece 脿 souder doit 锚tre branch茅 脿 une
quand on regarde l始arc. bonne mise 脿 la terre.
b. Porter des v锚tements convenables afin de prot茅ger la peau
de soudeur et des aides contre le rayonnement de l驶arc. 2. Autant que possible, I始installation et l始entretien du poste seront
c. Prot茅ger l始autre personnel travaillant 脿 proximit茅 au effectu茅s par un 茅lectricien qualifi茅.
soudage 脿 l始aide d始茅crans appropri茅s et non-inflammables.
3. Avant de faires des travaux 脿 l始interieur de poste, la
4. Des gouttes de laitier en fusion sont 茅mises de l始arc de debrancher 脿 l始interrupteur 脿 la boite de fusibles.
soudage. Se prot茅ger avec des v锚tements de protection libres
de l始huile, tels que les gants en cuir, chemise 茅paisse, 4. Garder tous les couvercles et dispositifs de s没ret茅 脿 leur place.
pantalons sans revers, et chaussures montantes.
5. Toujours porter des lunettes de s茅curit茅 dans la zone de
soudage. Utiliser des lunettes avec 茅crans lateraux dans les
zones o霉 l始on pique le laitier.
Mar. 驶93
v v
for selecting a QUALITY product by Lincoln Electric. We want you
to take pride in operating this Lincoln Electric Company product 鈥⑩?⑩??
Thank You as much pride as we have in bringing this product to 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始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 鈥? This information is accurate to the best of our knowledge at the time of printing. Please refer to
www.lincolnelectric.com for any updated information.
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.
鈥? 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.
鈥? For On-Line Registration: Go to our WEB SITE at www.lincolnelectric.com. Choose 鈥淨uick Links鈥? and then
鈥淧roduct Registration鈥?. 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.
vi vi
TABLE OF CONTENTS
Page
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Section A
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
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
INSTALLATION
A-1 A-1
TECHNICAL SPECIFICATIONS - AIR VANTAGE 500 CUMMINS (K2325-1)
INPUT - DIESEL ENGINE
Make /Model Description Speed (RPM) Displacement Starting Capacities
System
Cummins 4 cylinder High Idle 1900 199 cu. in 12VDC battery Fuel
B3.3 56HP (42 kw) Low Idle 1425 (3.3L) & Starter (25 US gal)
Diesel Engine @ 1800 RPM Full Load 1800 94.6L
Bore x Stroke Oil:
(2 US gal)
3.74鈥? x 4.53鈥? 7.5L
(95mm x 115mm) Coolant:
(2.6 US gal)
9.8L
RATED OUTPUT @ 104掳F(40掳C) - WELDER
Duty Cycle Welding Output Volts at Rated Amps
100% 500 Amps (DC multi-purpose) 40 Volts
60% 550 Amps (DC multi-purpose) 36 volts
50% 575 Amps (DC multi-purpose) 35 volts
OUTPUT @ 104掳F(40掳C) - WELDER AND GENERATOR
Welding Range
30 - 575 Amps CC/CV
20 - 250 Amps TIG
Open Circuit Voltage
60 Max OCV @ 1900 RPM
Auxiliary Power (1)
120/240 VAC
12,000 WATTS, 60 Hz., Single Phase
20,000 WATTS, 60 Hz., Three Phase
PHYSICAL DIMENSIONS
Height Width Depth Weight
(2)
42.0 in 32.7 in. 63.1 in. 1690 lbs.
(1066.8 mm) (830.1mm) (1603mm) (766kg)
(Approx)
1. Output rating in watts is equivalent to volt-amperes at unity power factor.
Output voltage is within +/- 10% at all loads up to rated capacity. When welding, available auxiliary power will be reduced.
2. Top of Enclosure, add 7.0鈥? (177.8mm) for exhaust pipe.
AIR VANTAGE 500 CUMMINS
INSTALLATION
A-2 A-2
LOCATION / VENTILATION
Read this entire installation section before you start
installation.
SAFETY PRECAUTIONS
The welder should be located to provide an unrestricted flow of
clean, cool air to the cooling air inlets and to avoid restricting the
WARNING
cooling air outlets. Also, locate the welder so that the engine
exhaust fumes are properly vented to an outside area.
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
DO NOT MOUNT OVER COMBUSTIBLE SURFACES
precautions, detailed engine starting, operating and
Where there is a combustible surface directly under
maintenance instructions and parts lists.
stationary or fixed electrical equipment, that surface should
ELECTRIC SHOCK can kill. be covered with a steel plate at least .06鈥?(1.6mm) thick,
which should extend not less than 5.90鈥?(150mm) beyond the
鈥? Do not touch electrically live parts such as
equipment on all sides.
output terminals or internal wiring.
--------------------------------------------------------------------------------------
鈥? Insulate yourself from the work and ground.
鈥? Always wear dry insulating gloves.
STORING
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ENGINE EXHAUST can kill. 1. Store the machine in a cool, dry place when it is not in use.
鈥? Use in open, well ventilated areas or vent Protect it from dust and dirt. Keep it where it can始t be
exhaust outside accidentally damaged from construction activities, moving
vehicles, and other hazards.
2. Drain the engine oil and refill with fresh 10W30 oil. Run the
-------------------------------------------------------------------------------------
engine for about five minutes to circulate oil to all the parts.
MOVING PARTS can injure. See the MAINTENANCE section of this manual for details
on changing oil.
鈥? Do not operate with doors open or guards off.
3. Remove the battery, recharge it, and adjust the electrolyte
鈥? Stop engine before servicing.
level. Store the battery in a dry, dark place.
鈥? Keep away from moving parts
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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
INSTALLATION
A-3 A-3
LIFTING HIGH TEMPERATURE OPERATION
The Air Vantage 500 lift bale should be used to lift the machine. At temperatures above 40掳C (104掳F), output voltage derating
The Air Vantage 500 is shipped with the lift bale retracted. Before may be necessary. For maximum output current ratings, derate
attempting to lift the Air Vantage 500 the lift bale must be secured welder voltage rating 2 volts for every 10掳C (21掳F) above 40掳C
in a raised position. Secure the lift bale as follows: (104掳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-
c. Use the lifting strap to raise the lift bale to the full upright
plant and yard towing by a vehicle (1) is Lincoln始s K953-1. If the
position. This will align the mounting holes on the lift
user adapts a non-Lincoln trailer, he must assume responsibility
bale with the access holes.
that the method of attachment and usage does not result in a
d. Secure the lift bale with 2 thread forming screws. The safety hazard nor damage the welding equipment. Some of the
screws are provided in the shipped loose parts bag. factors to be considered are as follows:
1. Design capacity of trailer vs. weight of Lincoln
WARNING
equipment and likely additional attachments.
2. Proper support of, and attachment to, the base of the
welding equipment so that there will be no undue stress
to the trailer始s framework.
FALLING EQUIPMENT can cause injury.
3. Proper placement of the equipment on the trailer to
鈥? Do not lift this machine using lift bale if it is
insure stability side to side and front to back when being
equipped with a heavy accessory such as a
moved and when standing by itself.
trailer or gas cylinder.
4. Typical conditions of use, such as travel speed,
鈥? Lift only with equipment of adequate lifting
roughness of surface on which the trailer will be
capacity.
operated, and environmental conditions.
鈥 Be sure machine is stable when lifting.
5. Proper preventative maintenance of trailer.
-------------------------------------------------------------------------------------
6. Conformance with federal, state and local laws (1) .
Consult applicable federal, state and local laws regarding
HIGH ALTITUDE OPERATION
(1)
specific requirements for use on public highways.
At higher altitudes, output derating may be necessary. For
VEHICLE MOUNTING
maximum rating, derate the welder output 4% for every 300
meters (984 ft.) above 1500 meters (4920 ft.). For output of 500A
WARNING
and below, derate the welder output 4% for every 300 meters
(984 ft.) above 2100 meters (6888 ft.).
Contact a Cummins Service Representative for any engine
Improperly mounted concentrated loads may cause unstable
adjustments that may be required.
vehicle handling and tires or other components to fail.
鈥? Only transport this Equipment on serviceable vehicles
which are rated and designed for such loads.
鈥? Distribute, balance and secure loads so vehicle is stable
under conditions of use.
鈥? Do not exceed maximum rated loads for components such
as suspension, axles and tires.
鈥? Mount equipment base to metal bed or frame of vehicle.
鈥? Follow vehicle manufacture始s instructions.
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AIR VANTAGE 500 CUMMINS
INSTALLATION
A-4 A-4
PRE-OPERATION ENGINE AND ENGINE COOLANT
COMPRESSOR SERVICE
WARNING
WARNING
HOT COOLANT can burn skin.
READ the engine and compressor operating and maintenance
instructions supplied with this machine. 鈥o not remove cap if radiator is hot.
鈥? Keep hands away from the engine muffler or
HOT engine parts.
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鈥? Stop engine and allow to cool before fuelling.
The welder is shipped with the engine and radiator filled with a
鈥? Do not smoke when fuelling. 50% mixture of ethylene glycol and water. See the
MAINTENANCE section and the engine Operator始s Manual for
鈥? Fill fuel tank at a moderate rate and do not over-fill.
more information on coolant.
鈥? Wipe up spilled fuel and allow fumes to clear before
starting engine.
BATTERY CONNECTION
鈥? Keep sparks and flame away from tank.
--------------------------------------------------------------------------------------
WARNING
OIL
The Air Vantage 500 is shipped with the engine crankcase filled
with high quality SAE 10W-30 oil (API class CD or better). Check
GASES FROM BATTERY can explode.
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. 鈥? Keep sparks, flame and cigarettes away from
Check the oil level every four hours of running time during the first battery.
35 running hours. Refer to the engine and compressor Operator始s
To prevent EXPLOSION when:
Manuals for specific oil recommendations and break-in
information. The oil change interval is dependent on the quality of 鈥? INSTALLING A NEW BATTERY 鈥? disconnect
the oil and the operating environment. Refer to the engine and negative cable from old battery first and
compressor Operator始s Manuals for the proper service and connect to new battery last.
maintenance intervals.
鈥? CONNECTING A BATTERY CHARGER 鈥? remove battery
from welder by disconnecting negative cable first, then
positive cable and battery clamp. When reinstalling,
FUEL USE DIESEL FUEL ONLY connect negative cable last. Keep well ventilated.
Fill the fuel tank with clean, fresh diesel fuel. The capacity of the 鈥? USING A BOOSTER 鈥? connect positive lead to battery first
fuel tank is approximately 25 gallons (95 liters). See engine then connect negative lead to negative battery lead at
Operator始s Manual for specific fuel recommendations. Running engine foot.
out of fuel may require bleeding the fuel injection pump.
NOTE: Before starting the engine, open the fuel shutoff valve
BATTERY ACID can burn eyes and skin.
(pointer to be in line with hose).
鈥? Wear gloves and eye protection and be careful
when working near battery.
FUEL CAP 鈥? 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 鈥? Negative Ground.
AIR VANTAGE 500 CUMMINS
INSTALLATION
A-5 A-5
WELDING TERMINALS
The Air Vantage 500 is shipped with the negative battery cable
disconnected. Before you operate the machine, make sure the
The Air Vantage 500 is equipped with a toggle switch for selecting
Engine Switch is in the OFF position and attach the disconnected
"hot" welding terminals when in the "WELD TERMINALS ON"
cable securely to the negative (-) battery terminal.
position or "cold" welding terminals when in the "REMOTELY
Remove the insulating cap from the negative battery terminal.
CONTROLLED" position.
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
WELDING OUTPUT CABLES
sure to use the correct polarity when charging the battery.
With the engine off, route the electrode and work cables thru the
strain relief bracket provided on the front of the base and connect
MUFFLER OUTLET PIPE to the terminals provided. These connections should be checked
periodically and tightened if necessary.
Remove the plastic plug covering the muffler outlet tube. Using
Listed in Table A.1 are copper cable sizes recommended for the
the clamp provided secure the outlet pipe to the outlet tube with
rated current and duty cycle. Lengths stipulated are the distance
the pipe positioned such that it will direct the exhaust in the
from the welder to work and back to the welder again. Cable sizes
desired position.
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 TOTAL COMBINED LENGTH OF
engines be equipped with exhaust spark arrestors when they are ELECTRODE AND WORK CABLES
operated in certain locations where unarrested sparks may
present a fire hazard. The standard muffler included with this AMPS Up to 150ft 150-200ft 200-250ft
welder does not qualify as a spark arrestor. When required by @100% Up to 492m 492-656m 656-820m
local regulations, a suitable spark arrestor, must be installed and Duty Cycle
properly maintained.
500 3/0 AWG 3/0 AWG 4/0 AWG
CAUTION MACHINE GROUNDING
Because this portable engine driven welder creates its own
power, it is not necessary to connect its frame to an earth ground,
An incorrect arrestor may lead to damage to the engine or unless the machine is connected to premises wiring (home, shop,
adversely affect performance. etc.).
-------------------------------------------------------------------------------------- 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
Remove the plastic plug covering the air cleaner inlet. Install the grounded type plug,
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 鈥淪tandby Power Connections鈥? 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 is provided on the
front of the welder.
AIR VANTAGE 500 CUMMINS
INSTALLATION
A-6 A-6
REMOTE CONTROL STANDBY POWER CONNECTIONS
The Air Vantage 500 is suitable for temporary, standby or
OUTPUT emergency power using the engine manufacturer始s
recommended maintenance schedule.
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 The Air Vantage 500 can be permanently installed as a standby
K857-1 Remote Control or for TIG welding, the K870 foot Amptrol power unit for 240 volt-3 wire, 50 amp service. Connections must
or the K936-2 hand Amptrol. When in the CC-STICK, DOWNHILL be made by a licensed electrician who can determine how the
PIPE, or CV-WIRE modes and when a remote control is 120/240 VAC power can be adapted to the particular installation
connected to the 6-pin Connector, the auto-sensing circuit and comply with all applicable electrical codes. The following
automatically switches the OUTPUT control from control at the information can be used as a guide by the electrician for most
welder to remote control. applications. Refer to the connection diagram shown in Figure
A.2.
When in TOUCH START TIG mode and when a Amptrol is
1. Install the double-pole, double-throw switch between the power
connected to the 6-Pin Connector, the OUTPUT dial is used to set
company meter and the premises disconnect.
the maximum current range of the CURRENT CONTROL of the
Amptrol.
Switch rating must be the same or greater than the customer始s
premises disconnect and service over current protection.
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.
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AUXILIARY POWER RECEPTACLES
Start the engine and set the 鈥淚DLER鈥? control switch to the 鈥淗igh
Idle鈥? 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 卤 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.
AIR VANTAGE 500 CUMMINS
INSTALLATION
A-7 A-7
3. Install a 50 amp 120/240 VAC plug (NEMA Type 14-50) to the
2. Take necessary steps to assure load is limited to the capacity
double-pole circuit breaker using No. 6, 4 conductor cable of
of the Air Vantage 500 by installing a 50 amp, 240 VAC double
the desired length. (The 50 amp, 120/240 VAC plug is
pole circuit breaker. Maximum rated load for each leg of the
available in the optional K802R plug kit.)
240 VAC auxiliary is 50 amps. Loading above the rated output
will reduce output voltage below the allowable -10% of rated
4. Plug this cable into the 50 Amp 120/240 Volt receptacle on the
voltage which may damage appliances or other motor-driven
Air Vantage 500 case front.
equipment and may result in overheating of the Air Vantage
500 engine.
Figure A.2 Connection of the Air Vantage 500 to Premises Wiring
240 VOLT
GROUNDED CONDUCTOR
POWER
240 Volt 120 VOLT
60 Hz.
COMPANY
3-Wire
120 VOLT
Service
METER
NEUTRAL
BUS
N
LOAD
DOUBLE POLE DOUBLE THROW
SWITCH RATING TO BE THE SAME
AS OR GREATER THAN PREMISES
SERVICE OVERCURRENT
PROTECTION.
PREMISES
DISCONNECT AND
SERVICE
GROUND OVERCURRENT
50AMP
PROTECTION
240 VOLT
DOUBLE
POLE
50 AMP, 120/240 CIRCUIT
VOLT PLUG 240 VOLT BREAKER
NEMA TYPE 14-50
GND
N
50 AMP, 120/240 VOLT
NOTE: No. 6 COPPER CONDUCTOR CABLE SEE
RECEPTACLE
NATIONAL ELECTRICAL CODE FOR ALTERNATE WIRE
SIZE RECOMMENDATIONS.
AIR VANTAGE 500 CUMMINS
INSTALLATION
A-8 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
鈥? Shut the welder off.
鈥? Connect the LN-7, LN-8 OR LN-742 per instructions on the
appropriate connection diagram in the DIAGRAMS section.
鈥? Set the 鈥淲IRE FEEDER VOLTMETER鈥? switch to either 鈥?+鈥? or 鈥?-
鈥? as required by the electrode being used.
鈥? Set the 鈥淪ELECTOR鈥? switch to the 鈥淐V-WIRE鈥? position.
鈥? Adjust the 鈥淎RC CONTROL鈥? knob to desired Crispness. SOFT
for MIG and CRISP for INNERSHIELD.
鈥? Set the 鈥淲ELDING TERMINALS鈥? switch to the 鈥淩EMOTELY
CONTROLLED鈥? position.
鈥? Set the 鈥淚DLE鈥? switch to the 鈥淗IGH鈥? 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.
鈥? Shut the welder off.
鈥? 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.
鈥? 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.
鈥? Set the MODE switch to the "CV-WIRE " position.
鈥? Across The-Arc Model:
Set the "WELD TERMINALS" switch to "WELD TERMINALS
ON"
Control Cable Model:
Set the "WELD TERMINALS" switch to "REMOTELY
CONTROLLED"
鈥? Set the "WIRE FEEDER VOLTMETER" switch to either "+" or
"-" as required by the electrode polarity being used.
鈥? Set the "ARC CONTROL" knob to "0" initially and adjust to suit.
鈥? Set the "IDLE" switch to the "AUTO IDLE" position
AIR VANTAGE 500 CUMMINS
INSTALLATION
A-9 A-9
CONNECTION OF THE LN-25 TO THE AIR CONNECTION OF MAGNUM SC SPOOL GUN TO
VANTAGE 500 THE AIR VANTAGE 500 (SEE SECTION F)
The LN-25 with or without an internal contactor may be used with
CONNECTION OF PRINCE XL SPOOL GUN TO
the Air Vantage 500. See the appropriate connection diagram in
THE AIR VANTAGE 500
the DIAGRAMS section.
NOTE: The LN-25 (K431) Remote Control Module and (K432)
Remote Cable are not recommended for use with the Air Vantage Connection of the Prince XL Spool Gun requires the use of the
500. K1849-1 Adapter Module.
鈥? Shut the Welder off.
鈥? Shut the welder off.
鈥? For electrode Positive, connect the electrode cable to the "+"
鈥? For electrode Positive, connect the electrode cable from the LN-
terminal of the welder and work cable to the "-" terminal of the
25 to the 鈥?+鈥? terminal of the welder and work cable to the 鈥?-鈥?
welder. For electrode Negative, connect the electrode cable "-
terminal of the welder. For electrode Negative, connect the
" terminal of the welder and work cable to the "+" terminal of
electrode cable from the LN-25 to the 鈥?-鈥? terminal of the welder
the welder.
and work cable to the 鈥?+鈥? terminal of the welder.
鈥? Attach the single lead from the front of the LN-25 to work using 鈥? Connect the Control Cable of the Spool Gun to the Adapter
the spring clip at the end of the lead. This is a sense lead to Module and connect the Control Cable of the Adapter Module
supply current to the wire feeder motor; it does not carry welding to the Welder.
current.
鈥? Connect the Gas Hose.
鈥? Set the SELECTOR switch to the 鈥淐V-WIRE鈥? position.
鈥? Set the MODE switch to the "CV-WIRE " position.
鈥? Set the 鈥淲ELDING TERMINALS鈥? switch to 鈥淲ELD
TERMINALS ON鈥?
鈥? Set the "WELD TERMINALS" switch to "WELD TERMINALS
鈥? Adjust the 鈥淎RC CONTROL鈥? knob to desired crispness.
ON".
Generally, welding is best if the 鈥淎RC CONTROL鈥? is set to
SOFT for MIG and CRISP for INNERSHIELD. You may
鈥? Set the "ARC CONTROL" knob to "0" initially and adjust to suit.
however, want to start in the middle and adjust (as needed)
from there.
鈥? Set the "IDLE" switch to the "High" position
鈥? Set the 鈥淚DLE鈥? switch to the 鈥淎UTO鈥? 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.
--------------------------------------------------------------------------------------
鈥? 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.
鈥? Set the Wire Feeder Voltage Switch to 115V.
AIR VANTAGE 500 CUMMINS
OPERATION
B-1 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
your Air Vantage 500.
generator for DC multi-purpose welding, for 120/240 VAC single
WARNING
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鈩?.
Do not attempt to use this equipment until you have
thoroughly read all operating and maintenance manuals
RECOMMENDED APPLICATIONS
supplied with your machine. They include important safety
precautions, detailed engine starting, operating and
WELDER
maintenance instructions and parts lists.
ELECTRIC SHOCK can kill. The Air Vantage 500 provides excellent constant current DC
welding output for stick (SMAW) and TIG welding. The Air
鈥? Do not touch electrically live parts such as
Vantage 500 also provides excellent constant voltage DC welding
output terminals or internal wiring.
output for MIG (GMAW), Innershield (FCAW), Outersield (FCAW-
鈥? Insulate yourself from the work and ground. G) and Metal Core welding. In addition the Air Vantage 500 can
be used for Arc Gouging with carbons up to 3/8鈥?(10mm) in
鈥? Always wear dry insulating gloves.
diameter.
--------------------------------------------------------------------------------------
The Air Vantage 500 is not recommended for pipe thawing.
ENGINE EXHAUST can kill.
AIR COMPRESSOR
鈥? Use in open, well ventilated areas or vent
exhaust outside
鈥? Do not stack anything near the engine. The Air Vantage 500 provides 60 cfm at 100 psi.
compressed air for Arc Gouging and Air powered tools.
--------------------------------------------------------------------------------------
MOVING PARTS can injure.
GENERATOR
鈥? Do not operate with doors open or guards off.
The Air Vantage 500 provides smooth 120/240 VAC single phase and
鈥? Stop engine before servicing.
240V three phase output for auxiliary power and emergency standby
鈥? Keep away from moving parts power.
--------------------------------------------------------------------------------------
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
OPERATION
B-2 B-2
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 9
5 7 8
4 10
3
11
13
20
12
21
15
14 19
24
25
23
1
22
2
16
18
17
26
27
28
ENGINE CONTROLS (Items 1 through 9) 3. HOUR METER
The hour meter displays the total time that the engine has been
1. RUN STOP SWITCH
running. This meter is a useful indicator for scheduling preventive
Toggling the switch to the RUN position energizes the fuel maintenance.
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
5. ENGINE TEMPERATURE GAUGE
press while engine is running since this can cause damage to the
ring gear and/or starter motor. The gauge displays the engine coolant temperature.
AIR VANTAGE 500 CUMMINS
OPERATION
B-3 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
The gauge displays the engine oil pressure when the engine is
starts.
running.
d. If the welding or AC power load is not restarted before
the end of the time delay, the idler reduces the engine
7. ENGINE PROTECTION speed to low idle speed.
The yellow engine protection light remains off with proper oil e. The engine will automatically return to high idle speed
pressure and under normal operating temperatures. If the light when the welding load or A.C. power load is reapplied.
turns on, the engine protection system will stop the engine. Check
for proper oil level and add oil if necessary. Check for loose or
Idler Operational exceptions
disconnected leads at the oil pressure sender located on the
engine. The light will remain on when the engine has been shut
When the WELDING TERMINALS switch is in the 鈥淩emotely
down due to low oil pressure or over-temperature condition.
Controlled鈥? position the idler will operate as follows:
a. When the triggering device (Amptrol, Arc Start Switch, etc.) is
8. BATTERY CHARGING LIGHT pressed the engine will accelerate and operate at full speed
provided a welding load is applied within approximately 12
The yellow engine alternator light is off when battery charging
seconds.
system is functioning normally. If light turns on the alternator or
the voltage regulator may not be operating correctly. The light will 鈥? If the triggering device remains pressed but no welding load is
remain on when the engine is stopped and the run/stop switch is applied within approximately 12 seconds the engine may return
in the run position. to low idle speed.
鈥? 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 鈥淗igh鈥? position , the engine runs at the high idle
speed controlled by the governor.
B) In the 鈥淎uto鈥? / position, the idler operates as
follows:
a. When switched from 鈥淗igh鈥? to 鈥淎uto鈥? 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.
AIR VANTAGE 500 CUMMINS
OPERATION
B-4 B-4
WELDING CONTROLS (Items 10 through 19) 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
10. OUTPUT CONTROL: The OUTPUT dial is used to preset the
operator preference. Start with a setting of 0.
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
14. WELDING TERMINALS SWITCH
6-Pin or 14-Pin Connector, the auto-sensing circuit automatically
switches the OUTPUT CONTROL from control at the welder to In the WELD TERMINALS ON position, the output is electrically
the remote control. In the CV-WIRE mode, when the wire feeder hot all the time. In the REMOTELY CONTROLLED position, the
control cable is connected to the 14-Pin Connector, the auto- output is controlled by a wire feeder or amptrol device, and is
sensing circuit automatically makes OUTPUT CONTROL inactive electrically off until a remote switch is depressed.
and the wire feeder voltage control active.
When in the TOUCH START TIG mode and when a Amptrol is
15. WIRE FEEDER VOLTMETER SWITCH:
connected to the 6-Pin Connector, the OUTPUT dial is used to set
the maximum current range of the CURRENT CONTROL of the Matches the polarity of the wire feeder voltmeter to the polarity of
Amptrol. the electrode.
11. DIGITAL OUTPUT METERS: 16. 6 - PIN CONNECTOR
The digital meters allow the output voltage (CV-WIRE mode) or For attaching optional remote control equipment. Includes auto-
current (CC-STICK, DOWNHILL PIPE and TIG modes) to be set sensing remote control circuit.
prior to welding using the OUTPUT control knob. During welding,
the meters display the actual output voltage (VOLTS) and current
17. 14 - PIN CONNECTOR
(AMPS). A memory feature holds the display of both meters on
the seven seconds after welding is stopped. This allows the For attaching wire feeder control cables. Includes contactor
operator to read the actual current and voltage just prior to when closure circuit, auto-sensing remote control circuit, and 120VAC
welding was ceased. While the display is being held the left-most and 42VAC power.
decimal point in each display will be flashing. The accuracy of the
meters is 卤 3%.
NOTE: When a wire feeder with a built in welding voltage control
is connected to the 14-pin connector, do not connect anything to
12. WELD MODE SELECTOR SWITCH: the 6-pin connector.
(Provides four selectable welding modes)
CV-WIRE 18. WELD OUTPUT TERMINALS + AND -
DOWNHILL PIPE These 1/2鈥? - 13 studs with flange nuts provide welding connection
points for the electrode and work cables. For positive polarity
CC-STICK
welding the electrode cable connects to the 鈥?+鈥? terminal and the
TOUCH START TIG
work cable connects to this 鈥?-鈥? terminal. For negative polarity
welding the work cable connects to the 鈥?+鈥? terminal and the
electrode cable connects to this 鈥?-鈥? terminal.
13. ARC CONTROL:
The ARC CONTROL WIRE/STICK knob is active in the WIRE
AUXILIARY POWER CONTROLS
and STICK modes, and has different functions in these modes.
This control is not active in the TIG mode.
(Items 19-23)
CC-STICK mode: In this mode, the ARC CONTROL knob sets the
short circuit current (arc-force) during stick welding. Increasing
19. 120/240 VAC SINGLE PHASE RECEPTACLE
the number from -10(Soft) to +10(Crisp) increases the short
circuit current and prevents sticking of the electrode to the plate
This is a 120/240VAC (14-50R) receptacle that provides 240VAC
while welding. This can also increase spatter. It is recommended
or can be split for 120VAC single phase auxiliary power. This
that the ARC CONTROL be set to the minimum number without
receptacle has a 50 amp rating. Refer to the AUXILIARY POWER
electrode sticking. Start with a setting at 0.
RECEPTACLES section in the installation chapter for further
DOWNHILL PIPE mode: In this mode, the ARC CONTROL knob information about this receptacle. Also refer to the AUXILIARY
sets the short circuit current (arc-force) during stick welding to POWER OPERATION section later in this chapter.
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 (鈥渟tacking鈥? of iron) are key to
fast travel speeds. It is recommended that the ARC CONTROL
be set initially at 0.
AIR VANTAGE 500 CUMMINS
OPERATION
B-5 B-5
ENGINE OPERATION
20. CIRCUIT BREAKERS
These circuit breakers provide separate overload current
STARTING THE ENGINE
protection for each 120V circuit at the 240V single phase
receptacle, each 120V single phase receptacle, the 240V three
1. Open the engine compartment door and check that the fuel
phase receptacle, the 120VAC in the 14-Pin connector, the
shutoff valve located to the left of the fuel filter housing is in the
42VAC in the 14-Pin connector and battery circuit overload
open position (lever to be in line with the hose).
protection.
2. Make sure battery disconnect switch is in the on position.
21. 120VAC SINGLE PHASE RECEPTACLES 3. Check for proper oil level and coolant level. Close engine
compartment door.
These two 120VAC (5-20R) receptacles with ground fault circuit
4. Remove all plugs connected to the AC power receptacles.
interruption protection provide 120VAC single phase for auxiliary
power. Each receptacle has a 20 amp total rating. They are 5. Set IDLER switch to 鈥淎UTO鈥?.
designed to protect the user from the hazards of ground faults.
6. Set the RUN/STOP switch to 鈥淩UN鈥?. Observe that the engine
When the GFCI has tripped there will be no voltage available
protection and battery charging lights are on. After 10 seconds,
from the receptacle. Refer to the AUXILIARY POWER
the engine protection light will turn off.
RECEPTACLES section in the installation chapter for further
information about these receptacles. Also refer to the AUXILIARY 7. Within 30 seconds, press and hold the engine START button
POWER OPERATION section later in this chapter. 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
Provides a connection point for connecting the machine case to are off. The engine protection light is on after starting, the
earth ground. Refer to 鈥淢ACHINE GROUNDING鈥? in the engine will shutdown in a few seconds. Investigate any
Installation chapter for proper machine grounding information. indicated problem.
10. Allow the engine to warm up at low idle speed for several
23. 240VAC THREE PHASE RECEPTACLE
minutes before applying a load and/or switching to high idle.
This is a 240VAC (15-50R) receptacle that provides 240VAC Allow a longer warm up time in cold weather.
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
Turns compressor on and off (standby) by opening and closing should start satisfactorily even down to about 0掳F(-18掳C). If the
the compressor inlet valve. engine must be frequently started below 10掳(-12掳C), it may be
desirable to install the optional ether start kit (K887-1). For
25. COMPRESSOR PROTECTION LIGHT extreme cold conditions it may be desirable to install the Cold
Weather Heater and Tarp Kit (K2359-1). Installation and operating
The yellow compressor protection light remains off with proper
instructions are included in the kits.
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
STOPPING THE ENGINE
allowable limits. Check for proper compressor oil level.
26. AIR DISCHARGE VALVE 1. Switch the RUN/STOP switch to 鈥淪TOP鈥?. This turns off the
voltage supplied to the shutdown solenoid. A backup shutdown
Controls flow of compressed air. A 3/4鈥? NPT (National Pipe
can be accomplished by shutting off the fuel valve located on
Thread) fitting is provided.
the fuel line.
BATTERY JUMP START TERMINAL (27-28)
27. POSITIVE BATTERY JUMP START TERMINAL.
28. NEGATIVE BATTERY JUMP START TERMINAL.
FIGURE B.2
12V battery jump start feature is standard. Covered output studs
30
for convenient access, and protection against accidental impact.
Canbe used to jump-start a utility truck with up to 800 cold
cranking amps. Can also be used to junp-start the Air Vantage
500 Cummins.
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
AIR VANTAGE 500 CUMMINS
OPERATION
B-6 B-6
BREAK-IN PERIOD CC-STICK MODE
The CC-STICK position of the MODE switch is designed for
The engine used to supply power for your welder is a heavy duty,
horizontal, vertical-up and over head welding with all types of
industrial engine. It is designed and built for rugged use. It is very
electrodes, especially low hydrogen. The OUTPUT CONTROL
normal for any engine to use small quantities of oil until the break-
knob adjusts the full output range for stick welding.
in is accomplished. Check the oil level twice a day during the
break-in period. In general this takes 50 to 100 hours of The ARC CONTROL knob sets the short circuit (arc-force) current
operation. during stick welding. Increasing the number from -10(Soft) to +10
(Crisp) increases the short circuit current and prevents sticking of
IMPORTANT
the electrode to the plate while welding. This can also increase
IN ORDER TO ACCOMPLISH THIS BREAK-IN, THE UNIT spatter. It is recommended that the ARC CONTROL be set to the
SHOULD BE SUBJECTED TO HEAVY LOADS, WITHIN THE minimum number without electrode sticking. Start with the knob
RATING OF THE MACHINE. AVOID LONG IDLE RUNNING
set at 0.
PERIODS.
DOWNHILL PIPE MODE
TYPICAL FUEL CONSUMPTION
This slope controlled setting is intended for 鈥渙ut-of-position鈥? and
Refer to Table B.2 for typical fuel consumption of the Air Vantage
鈥渄own hill鈥? pipe welding where the operator would like to control
500 Engine for various operating scenarios.
the current level by changing the arc length. The OUTPUT
Table B.2 CONTROL knob adjusts the full output range for pipe welding.
Cummins B3.3 Engine Fuel Consumption
Cummins B3.3 Running Time for
56HP(42Kw) 25GAL.(94.6L)
The ARC CONTROL knob sets the short circuit current (arc-force)
@1800 RPM (Hours)
during stick welding to adjust for a soft or a more forceful digging
arc (Crisp). Increasing the number from -10(Soft) to +10(Crisp)
Low Idle - .59 Gal./hour 42.4
increases the short circuit current which results in a more forceful
no load 1425 RPM (2.2 L/hour)
digging arc. Typically a forceful digging arc is preferred for root
and hot passes. A softer arc is preferred for fill and cap passes
High Idle - .87 Gal./hour 28.7
where weld puddle control and deposition (鈥渟tacking鈥? of iron) are
no load 1900 RPM (3.3 L/hour)
key to fast travel speeds. It is recommended that the ARC
CONTROL be set initially at 0.
DC CC Weld 2.10 Gal./hour 11.9
Output 500 (7.9 L/hour)
Amps @ 40 Volts
TOUCH START TIG MODE
Auxiliary Power 1.44 Gal./hour 17.4
The Air Vantage 500 can be used in a wide variety of DC TIG
12,000 VA (5.5 L/hour)
welding applications.
Auxiliary Power 2.02 Gal./hour 12.4 The TOUCH START TIG setting of the MODE switch is for DC
20,000 VA (7.6 L/hour) TIG (Tungsten Inert Gas) welding. To initiate a weld, the
OUTPUT CONTROL knob is first set to the desired current and
Air Compressor 1.29 Gal./hour 19.4 the tungsten is touched to the work. During the time the tungsten
60 CFM @ 100 PSI (4.9 L/hour) is touching the work there is very little voltage or current and, in
general, avoids tungsten contamination. Then, the tungsten is
Air Compressor gently lifted off the work in a rocking motion, which establishes the
60 CFM @ 100 PSI 2.46 Gal./hour 10.2 arc.
and DC, CC Weld (9.3 L/hour)
To stop the arc, simply lift the TIG torch away from the work piece.
Output 500 Amps
When the arc voltage reaches approximately 30 volts, the arc will
@40 Volts
go out and the machine will automatically reset to the touch start
current level. The tungsten may then be retouched to the work
Air Compressor
piece to restrike the arc. The arc may also be started and stopped
60 CFM @ 100 PSI 1.94 Gal./hour 12.9
with an Amptrol or Arc Start Switch.
and Auxiliary Power (7.3 L/hour)
12,000 VA The ARC CONTROL is not active in the TIG mode.
In general the 驶Touch Start始 feature avoids tungsten contamination
WELDER OPERATION
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.
DUTY CYCLE The Air Vantage 500 is equipped with the required R.F. bypass
circuitry for the connection of high frequency generating
Duty cycle is the percentage of time the load is being applied in a
equipment.
10 minute period. For example, a 60% duty cycle represents 6
The Air Vantage 500 and any high frequency generating
minutes of load and 4 minutes of no load in a 10 minute period.
equipment must be properly grounded. See the K930-2 TIG
STICK WELDING MODE Module operating manuals for complete instructions on
installation, operation, and maintenance.
The Air Vantage 500 can be used with a broad range of DC stick
When using the TIG Module, the OUTPUT control on the Air
electrodes.
Vantage 500 is used to set the maximum range of the CURRENT
The MODE switch provides two stick welding settings as follows:
CONTROL on the TIG Module or an Amptrol if connected to the
TIG Module.
AIR VANTAGE 500 CUMMINS
OPERATION
B-7 B-7
AIR VANTAGE 500 SETTINGS WHEN USING
THE K930-2 TIG MODULE
鈥? Set the WELD MODE switch to the 鈥淭ouch Start Tig 20-250
Setting鈥?.
鈥? Set the IDLER switch to the 鈥淎UTO鈥? position.
鈥? Set the WELDING TERMINALS switch to the 鈥淩emotely
Controlled鈥? position. This will keep the solid state contactor open
and provide a 鈥渃old鈥? electrode until the triggering device
(Amptrol or Arc Start Switch) is pressed.
Table B.3 TYPICAL CURRENT RANGES (1)
FOR TUNGSTEN ELECTRODES (2)
DCEN (-) DCEP (+) Approximate Argon Gas Flow Rate
l/min (c.f.m.)
Tungsten
Electrode 1%, 2% 1%, 2% TIG TORCH
Diameter Thoriated Thoriated Aluminium Stainless Steel Nozzle
mm (in) Tungsten Tungsten Size (4), (5)
.25 (0.010) 2-15 (3) 2-4 (3-8) 2-4 (3-8) #4, #5, #6
.50 (0.020) 5-20 (3) 3-5 (5-10) 3-5 (5-10)
1.0 (0.040) 15-80 (3) 3-5 (5-10) 3-5 (5-10)
1.6 (1/16) 70-150 10-20 3-5 (5-10) 4-6 (9-13) #5, #6
2.4 (3/32) 150-250 15-30 6-8 (13-17) 5-7 (11-15) #6, #7, #8
3.2 (1/8) 250-400 25-40 7-11 (15-23) 5-7 (11-15)
4.0 (5/32) 400-500 40-55 10-12 (21-25) 6-8 (13-17) #8, #10
4.8 (3/16) 500-750 55-80 11-13 (23-27) 8-10 (18-22)
6.4 (1/4) 750-1000 80-125 13-15 (28-32) 11-13 (23-27)
(1) When used with argon gas. The current ranges shown must be reduced when using argon/helium or pure helium shielding gases.
(2) Tungsten electrodes are classified as follows by the American Welding Society (AWS):
Pure EWP
1% Thoriated EWTh-1
2% Thoriated EWTh-2
Though not yet recognized by the AWS, Ceriated Tungsten is now widely accepted as a substitute for 2% Thoriated Tungsten in
AC and DC applications.
(3) DCEP is not commonly used in these sizes.
(4) TIG torch nozzle 鈥渟izes鈥? are in multiples of 1/16ths of an inch:
#4= 1/4 in. 6 mm
#5= 5/16 in. 8 mm
#6= 3/8 in. 10 mm
#7= 7/16 in. 11 mm
#8= 1/2 in. 12.5 mm
#10 = 5/8 in. 16 mm
(5) TIG torch nozzles are typically made from alumina ceramic. Special applications may require lava nozzles, which are less prone to
breakage, but cannot withstand high temperatures and high duty cycles.
AIR VANTAGE 500 CUMMINS
OPERATION
B-8 B-8
CV-WIRE MODE
The auxiliary power capacity is 12,000 watts of 60 Hz, single
Connect a wire feeder to the Air Vantage 500 and set welder phase power or 20,000 watts of 60Hz, three phase power. The
controls according to the instructions listed earlier in this section. auxiliary power capacity rating in watts is equivalent to volt-
amperes at unity power factor. The maximum permissible current
The Air Vantage 500 in the 鈥滳V-WIRE鈥? position, permits it to be
of the 240 VAC output is 50 A. The 240 VAC single phase output
used with a broad range of flux cored wire (Innershield and
can be split to provide two separate 120 VAC outputs with a
Outershield) electrodes and solid wires for MIG welding (gas
maximum permissible current of 50 A per output to two separate
metal arc welding). Welding can be finely tuned using the 鈥淎RC
120 VAC branch circuits. Output voltage is within 卤 10% at all
CONTROL鈥?. Turning the ARC CONTROL clockwise from -
loads up to rated capacity.
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
NOTE: The two 120V GFCI receptacles and the two 120V circuits
proper setting depends on the procedure and operator
of the 120/240V receptacle are connected to different phases and
preference. Start with the knob set at 0.
cannot be paralleled.
For any electrodes, including the above recommendations, the
procedures should be kept within the rating of the machine. For
The auxiliary power receptacles should only be used with three
additional electrode information, See www.lincolnelectric.com or
wire grounded type plugs or approved double insulated tools with
the appropriate Lincoln publication.
two wire plugs.
ARC GOUGING The current rating of any plug used with the system must be at
least equal to the current capacity of the associated receptacle.
For optimal performance when arc gouging, set the Air Vantage
500 鈥淲ELD MODE鈥? switch to the 鈥淐C - STICK鈥? position, and the
鈥淎RC CONTROL鈥? to 10.
SIMULTANEOUS WELDING AND AUXILIARY
POWER LOADS
Set the 鈥淥UTPUT鈥? 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
ELECTRODE CURRENT RANGE drawn from either the 120 VAC or 240 VAC supply (not both at the
DIAMETER (DC, electrode positive) same time).
(1/8鈥?) 30-60 Amps
(5/32鈥?) 90-150 Amps
(3/16鈥?) 200-250 Amps
(1/4鈥?) 300-400 Amps
(5/16鈥?) 350-450 Amps
(3/8鈥?) 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.
AIR VANTAGE 500 CUMMINS
OPERATION
B-9 B-9
TABLE B.4 AIR VANTAGE 500 SIMULTANEOUS WELDING AND POWER LOADS
WELD 1 PHASE 3 PHASE BOTH 1 AND 3 PHASE
AMPS WATTS AMPS WATTS AMPS WATTS AMPS
0 12,000 50 20,000 50 ------ 50
100 12,000 50 17,800 43 ------ 50
PLUS 12,000 OR 14,000 OR ------
200 50 34 50
250 12,000 50 12,000 29 12,000 ------
300 10,000 42 10,000 24 10,000 ------
400 5,600 23 5,600 13 5,600 ------
500 0 0 0 0 0 0
TABLE B.5 Air Vantage 500 Extension Cord Length
Recommendations
Current Voltage Load Maximum Allowable Cord Length in ft. (m) for Conductor Size
(Amps) (Volts) (Watts) 14 AWG 12 AWG 10 AWG 8 AWG 6 AWG 4 AWG
15 120 1800 30 (9) 40 (12) 75 (23) 125 (38) 175 (53) 300 (91)
15 240 3600 60 (18) 75 (23) 150 (46) 225 (69) 350 (107) 600 (183)
20 120 2400 30 (9) 50 (15) 88 (27) 138 (42) 225 (69)
20 240 4800 60 (18) 100 (30) 175 (53) 275 (84) 450 (137)
25 240 6000 90 (27) 150 (46) 225 (69) 250 (76)
30 240 7200 75 (23) 120 (37) 175 (53) 300 (91)
38 240 9000 100 (30) 150 (46) 250 (76)
50 240 12000 125 (38) 200 (61)
Conductor size is based on maximum 2.0% voltage drop.
AIR VANTAGE 500 CUMMINS
ACCESSORIES
C-1 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.
K802N POWER PLUG KIT - Provides four 120V plugs rated at 20 amps each
Includes oil pan heater, engine water heater and radiator grill
and one dual voltage, full KVA plug rated at 120/240V, 50 amps. 120V plug may
tarp.
not be compatible with NEMA common household receptacles.
K802-R POWER PLUG KIT - Provides four 120V plugs rated 15 amps each
TIG OPTIONS
and one dual voltage, full KVA plug rated at 120/240V, 50 amps, 120V plug is
compatible with NEMA common household receptacles.
K870 Foot Amptrol庐-Varies current while welding for making
critical TIG welds and crater filling. Depress pedal to increase
K857 25 ft. (7.5 m) or K857-1 100 ft. (30.4 m) REMOTE CONTROL -
current. Depressing pedal fully achieves maximum set current.
Portable control provides same dial range as the output control on the welder
Fully raising the pedal finishes the weld and starts the afterflow
from a location up to the specified length from the welder. Has convenient
cycle on systems so equipped. Includes 25 ft. (7.6m) control
plug for easy connection to the welder. The AIR VANTAGE 500 CUMMINS is
cable.
equipped with a 6-pin connector for connecting the remote control.
K704 ACCESSORY SET - Includes 35 feet (10 m) of electrode K963-3 Hand Amptrol庐-Varies current for making critical TIG
cable and 30 feet (9 m) of work cable, headshield, Filterplate, welds. Fastens to the torch for convenient thumb control. Comes
work clamp and electrode holder. Cable is rated at 500 amps, with a 25 ft. (7.6m) cable. (for larger handle 18 or 26 series
60% duty cycle. torches)
K2641-2 FOUR WHEELED STEERABLE YARD TRAILER
For in plant and yard towing. Comes standard with a Duo-Hitch鈩?,
a 2鈥? 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鈩?, a 2鈥? 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掳(-12掳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.
AIR VANTAGE 500 CUMMINS
MAINTENANCE
D-1 D-1
SAFETY PRECAUTIONS COMPRESSOR MAINTENANCE
Refer to the 鈥淩outine Maintenance鈥? section of the compressor
WARNING
owner始s manual for the recommended maintenance schedule of
the following:
a. Compressor oil and filter.
鈥? Have a qualified technician do the maintenance and
b. Compressor air filter.
troubleshooting work.
c. Compressor coalescing filter.
鈥? Turn the engine off before working inside the machine.
VMAC鈩?
鈥? Remove guards only when necessary and replace them when
VEHICLE MOUNTED AIR COMPRESSORS
the maintenance requiring their removal is complete.
www.VMAC.ca
鈥? Always use the greatest care when working near moving parts.
-------------------------------------------------------------------------------------- 1333 Kipp Road
Nanamino
Read the Safety Precautions in front of this manual and the
British Columbia
engine instruction manual before working on this machine.
Canada, V9X1R3
Keep all equipment safety guards, covers and devices in position
and in good repair. Keep hands, hair, clothing and tools away Telephone: (250) 740-3200
from V-belts, gears, fans and all other moving parts when starting, Facsimile: (250) 740-3201
operating or repairing the equipment. Toll Free: 800-738-8622
ENGINE MAINTENANCE
ROUTINE AND PERIODIC
MAINTENANCE Refer to the 鈥淧eriodic Checks鈥? section of the Engine Operator始s
Manual for the recommended maintenance schedule of the
following:
a) Engine Oil and Filter
DAILY b) Air Cleaner
c) Fuel Filter - and Delivery System
鈥? Check the Engine and Compressor oil levels .
d) Alternator Belt
鈥? Refill the fuel tank to minimize moisture condensation in the e) Battery
tank. f) Cooling System
鈥? Open the water drain valve located on the bottom of the water
Refer to Table D.1 at the end of this section for various engine
separator element 1 or 2 turns and allow to drain into a
maintenance components.
container suitable for diesel fuel for 2 to 3 seconds. Repeat the
above drainage procedure until diesel fuel is detected in the
container.
AIR FILTER
鈥? Check coolant level.
WARNING CAUTION
鈥? Only Vmac certified and approved synthetic
鈥? Excessive air filter restriction will result in
oil MUST be used. Shut down the
reduced engine life.
Welder/Compressor for 3 minutes, open the
pressure supply valve to ensure the system is
WARNING
depressurized prior to removing the
compressor oil level dipstick.
鈥? Never use gasoline or low flash point solvents
--------------------------------------------------------------------
for cleaning the air cleaner element. A fire or
WEEKLY explosion could result.
Blow out the machine with low pressure air periodically. In
CAUTION
particularly dirty locations, this may be required once a week.
鈥? 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.)
AIR VANTAGE 500 CUMMINS
MAINTENANCE
D-2 D-2
Service Instructions & Installation Tips
For Engine Air Filter
Donaldson filters with RadialSeal鈩? Sealing
5Filter
1Seal Check the Old
Release the
Technology are self-aligning, self-centering,
for Leak Clues
Carefully and self-sealing. A new filter has a dry
Visually inspect the old filter for any signs
Unlatch and remove the service
lubricant to aid installation. The critical
of leaks. A streak of dust on
cover of the air cleaner. Make
sealing area will stretch slightly, adjust
the clean side of the filter
certain the latches are folded
itself and distribute the sealing pressure
is a telltale sign.
back against the cover so that
evenly. To complete a tight seal, apply
Remove any cause
they don铆t hinder filter
pressure by hand at the outer rim of the
of leaks before
removal/installation. Most latches
filter, not the flexible center. (Avoid
installing new
are spring loaded to fold back when open.
pushing on the center of the urethane end
The filter fits tightly over the outlet tube, filter. cap.) No cover pressure is required to hold
creating the critical seal on the inside
the seal. Again, do NOT use the service
diameter of the filter endcap. The filter
6Filter
Inspect the New cover to push the filter into place!
should be removed gently to reduce the
for Damage
amount of dust dislodged. There will be When the filter in is place, put the service
Inspect the new filter carefully,
some initial resistance, similar to breaking cover back on, making sure the Vacuator鈩?
paying attention to the inside of
the seal on a jar. Gently move the end of the Valve points down. Inspect the Vacuator 鈩?
the open end,
filter back and forth to break the seal. Valve for cracks or dust hang-ups to insure
which is the
that it is functioning properly. Re-fasten
sealing area. the latches.
2DustAvoid Dislodging NEVER install
from the Filter a damaged filter.
8for
Gently pull the Check Connections
filter off the outlet
Tight Fit
tube and out of the
Make sure that all clamps, bolts, and
7RadialSeal
Insert the New
housing. Avoid
connections in the entire air intake system
么
Filter
knocking the filter
are tight. Check for holes in piping, and
against the housing. by Hand repair if needed.
Insert carefully. Seat the new filter by hand,
3of Clean Sealing Surface making certain it is completely into the air
the Outlet Tube cleaner housing before latching the cover in
place. If the cover hits the filter before it is
Use a clean cloth to wipe the sealing
fully in place, remove the cover and push
surface. Dust on the outside diameter of the
(by hand) the
outlet tube could hinder
filter further into
an effective seal
the air cleaner
and cause leakage.
and try again.
Make sure that all
The cover
contaminant is
should go on
removed before the
with no extra force.
new filter is inserted.
Never use the latches on the cover to force
4the Clean the Inside of the filter into the air cleaner! It is tempting
Outlet Tube to assume the cover will do the job of
Carefully wipe the inside seating the filter 帽 but it will not! Using the
of the outlet tube latches to push the filter in could cause
with a clean cloth. damage to the housing and will void the
Dirt accidently warranty.
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 毛dust铆 an
engine!) Be careful not to damage the
sealing area on the tube.
AIR VANTAGE 500 CUMMINS
MAINTENANCE
D-3 D-3
FUEL FILTERS BATTERY HANDLING
WARNING
GASES FROM BATTERY can explode.
鈥? Keep sparks, flame and cigarettes away from
battery.
When working on the fuel system
To prevent EXPLOSION when:
鈥? Keep naked lights away, do not smoke !
鈥? INSTALLING A NEW BATTERY - disconnect
鈥? Do not spill fuel !
negative cable from old battery first and
connect to new battery last.
鈥? CONNECTING A BATTERY CHARGER -
--------------------------------------------------------------------------------------
Remove battery from welder by disconnecting
The Air Vantage 500 is equipped with a Fuel Filter located after
negative cable first, then positive cable and
the lift pump and before fuel injectors.The procedure for changing
battery clamp. When reinstalling, connect
the filter is as follows.
negative cable last. Keep well ventilated.
1. Close the fuel shutoff valve.
2. Clean the area around the fuel filter head. Remove the filter.
鈥? USING A BOOSTER - connect positive lead to
Clean the gasket surface of the filter head and replace the o-
battery first then connect negative lead to
ring.
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.
4. Install the filter as specified by the filter manufacturer.
鈥? Wear gloves and eye protection and be careful
WARNING
when working near battery. Follow
instructions printed on battery.
--------------------------------------------------------------------------------------
PREVENTING ELECTRICAL DAMAGE
Mechanical overtightening will distort the threads, filter
1. When replacing, jumping, or otherwise connecting the battery
element seal or filter can.
to the battery cables, the proper polarity must be observed.
--------------------------------------------------------------------------------------
Failure to observe the proper polarity could result in damage to
COOLING SYSTEM the charging circuit. The positive (+) battery cable has a red
terminal cover.
The Air Vantage 500 is equipped with a pressure radiator. Keep
2. If the battery requires charging from an external charger,
the radiator cap tight to prevent loss of coolant. Clean and flush
disconnect the negative battery cable first and then the positive
the coolant system periodically to prevent clogging the passage
battery cable before attaching the charger leads. Failure to do
and over-heating the engine. When antifreeze is needed, always
so can result in damage to the internal charger components.
use the permanent type.
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.
AIR VANTAGE 500 CUMMINS
MAINTENANCE
D-4 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 The GFCI receptacle should be properly tested at least once
positive (+) battery terminal has a red terminal cover. 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
鈥? If the receptacle has tripped, first carefully remove any load and
you attach the charger leads. after the battery is charged,
check it for damage.
reconnect the positive battery cable first and the negative cable
鈥? If the equipment has been shut down, it must be restarted.
last. Failure to do so can result in damage to the internal charger
鈥? The equipment needs to be operating at high idle speed and
components. any necessary adjustments made on the control panel so that
the equipment is providing at least 80 volts to the receptacle
Follow the instructions of the battery charger manufacturer for
input terminals.
proper charger settings and charging time.
鈥? The circuit breaker for this receptacle must not be tripped.
NAMEPLATES / WARNING DECALS Reset if necessary.
MAINTENANCE 鈥? Push the "Reset" button located on the GFCI receptacle. This
will assure normal GFCI operation.
Whenever routine maintenance is performed on this machine - or 鈥? Plug a night-light (with an "ON/OFF" switch) or other product
at least yearly - inspect all nameplates and labels for legibility. (such as a lamp) into the GFCI receptacle and turn the product
Replace those which are no longer clear. Refer to the parts list for "ON".
the replacement item number. 鈥? Push the "Test" button located on the GFCI receptacle. The
WELDER / GENERATOR
night-light or other product should go "OFF".
鈥? Push the "Reset" button, again. The light or other product
MAINTENANCE should go "ON" again.
STORAGE
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
Store the Air Vantage in a clean, dry protected areas.
properly, contact a qualified, certified electrician who can assess
the situation, rewire the GFCI if necessary or replace the device.
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 P822768 Replace as indicated by
Service Indicator
Fleetguard AF25436
Oil Filer Cummins C6002112110 Replace every 750 hours or 3 months,
Fleetguard LF16011 whichever is less.
Fan Belt Cummins C0412021749 Inspect every 1000 hours or 12 months,
whichever is less.
Fuel Strainer Cummins 3826094 Inspect and replace monthly as
Fleetguard FF5079 required. Replace annually.
Fuel Filter / Fleetguard FS19594 Replace every 500 hours or 6 months,
Water Separator 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.
AIR VANTAGE 500 CUMMINS
TROUBLESHOOTING
E-1 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.
_______________________________________________________________________________________________
Step 3. RECOMMENDED COURSE OF ACTION
This Troubleshooting Guide is provided to help you locate and
repair possible machine malfunctions. Simply follow the three-
This column provides a course of action for the Possible Cause,
step procedure listed below.
generally it states to contact your local Lincoln Authorized Field
Step 1. LOCATE PROBLEM (SYMPTOM). Service Facility.
Look under the column labeled 鈥淧ROBLEM (SYMPTOMS)鈥?. This If you do not understand or are unable to perform the
column describes possible symptoms that the machine may Recommended Course of Action safely, contact your local Lincoln
exhibit. Find the listing that best describes the symptom that the Authorized Field Service Facility.
machine is exhibiting.
Step 2. POSSIBLE CAUSE.
The second column labeled 鈥淧OSSIBLE CAUSE鈥? lists the
obvious external possibilities that may contribute to the machine
symptom.
NOTE: See VMAC owner始s manual for compressor trouble shooting.
VMAC鈩?
VEHICLE MOUNTED AIR COMPRESSORS
www.VMAC.ca
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.
AIR VANTAGE 500 CUMMINS
TROUBLESHOOTING
E-2 E-2
Observe all Safety Guidelines detailed throughout this manual
RECOMMENDED
POSSIBLE
PROBLEMS
COURSE OF ACTION
CAUSE
(SYMPTOMS)
ENGINE PROBLEMS
Major Physical or Electrical Damage is 1. Contact your Local Lincoln Authorized
Field Service Facility.
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
5. Fuel Filters dirty/clogged, main filter
of misadjustment have been
element and/or Inline Fuel Filter may
checked and the problem persists,
need to be replaced.
Contact your local Lincoln
6. High water temperature or low oil Authorized Field Service Facility.
pressure. (engine protection light lit)
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. 1. High water temperature.
Engine runs rough. 1. Dirty fuel or air filters may need
cleaned/replaced.
2. Water in fuel.
Engine will not shut off. 1. Fuel Shutdown solenoid not functioning
properly / linkage binding.
CAUTION
潞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
TROUBLESHOOTING
E-3 E-3
PROBLEMS POSSIBLE RECOMMENDED
(SYMPTOMS) CAUSE COURSE OF ACTION
FUNCTION PROBLEMS
1. Faulty battery .
Battery does not stay charged.
2. Faulty engine alternator.
3. Loose or broken lead in charging circuit.
4. Loose fan belt may need tightening.
low 1. Idler switch in HIGH idle position, make
Engine will not idle down to
sure switch is set to AUTO.
speed.
2. External load on welder or auxiliary
power.
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
Engine will not go to high idle when 1. Poor work lead connection to work.
2. Broken idler solenoid spring.
attempting to weld.
3. Welding Terminals switch in wrong
position.
4. No open circuit voltage at output studs.
5. Faulty, Pull Coil/Battery PCB or Weld
Control PCB.
If all recommended possible areas
of misadjustment have been
Engine will not go to high idle when using 1. Broken wire in auxiliary current sensor
checked and the problem persists,
wiring.
auxiliary power.
Contact your local Lincoln
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
TROUBLESHOOTING
E-4 E-4
PROBLEMS RECOMMENDED
POSSIBLE
(SYMPTOMS) COURSE OF ACTION
CAUSE
FUNCTION PROBLEMS
Engine goes to low idle but does not stay at 1. Faulty Peripheral PCB, Pull Coil/Battery
low idle. 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. 1. Faulty remote kit.
Auxiliary output OK 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 鈥淕FCI Receptacle Testing and
Resetting Procedure鈥? in the
If all recommended possible areas
MAINTENANCE section of this manual.
of misadjustment have been
2. Open breakers may need to be reset.
checked and the problem persists,
3. Faulty receptacle.
Contact your local Lincoln
4. Faulty auxiliary circuit wiring.
Authorized Field Service Facility.
5. GFCI tripped.
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
F-1
DIAGRAMS
AIR VANTAGE 500 CUMMINS
NOTE: This diagram is for reference only. It may not be accurate for all machines covered by this manual. The specific diagram for your particular machine is pasted inside the machine on one of
F-1
the enclosure panels.
DIAGRAMS
F-2 F-2
CONNECTION DIAGRAM:
AIR VANTAGE 500 CUMMINS
COMMANDER / K867 / K775 / LN-7 CONNECTION DIAGRAM F-3
WARNING
Do not operate with panels open. Keep guards in place.
Keep away from moving parts.
Disconnect NEGATIVE (-) BATTERY LEAD
before servicing. Only qualified personnel should install,use
or service this equipment.
Do not touch electrically live parts.
CONNECTION DIAGRAM:
SPARE
82
LN-7
81 N.D.
WIRE
42 FEEDER
41
31 31
32 32
}
14 PIN 2 2
AMPHENOL
4 4
ELECTRODE TO WORK 21 21
K291 OR K404
K867 UNIVERSAL
GND INPUT CABLE
GND
ADAPTER PLUG
DIAGRAMS
GREEN
75 75
TO WORK
76
AIR VANTAGE 500 CUMMINS
76
ELECTRODE CABLE 77 77
}
TO WIRE FEED UNIT K775 OPTIONAL
N.E. REMOTE CONTROL
CAUTION :
ANY INCREASE OF THE HIGH IDLE ENGINE RPM BY CHANGING THE GOVERNOR SETTING OR OVERRIDING THE THROTTLE LINKAGE WILL CAUSE
AN INCREASE IN THE THE AC AUXILIARY VOLTAGE. IF THIS VOLTAGE GOES OVER 140 VOLTS, WIRE FEEDER CONTROL CIRCUITS MAY BE
DAMAGED. THE ENGINE GOVERNOR SETTING IS PRE-SET AT THE FACTORY - DO NOT ADJUST ABOVE RPM SPECIFICATIONS LISTED IN
THE ENGINE WELDER OPERATING MANUAL.
N.A. WELDING CABLE MUST BE OF PROPER CAPACITY FOR THE CURRENT AND DUTY CYCLE OF IMMEDIATE AND FUTURE
APPILICATIONS. SEE OPERATING MANUAL.
N.B. USE VOLTMETER SWITCH TO SELECT DESIRED ELECTRODE POLARITY. POSITION THE "SELECTOR" SWITCH TO "WIRE WELDING CV".
PLACE WIRE FEEDER SWITCH TO "WIRE FEEDER WITH CONTROL CABLE POSITION.
N.C. IF OPTIONAL REMOTE OUTPUT CONTROL IS USED,CONTROL IS AUTOMATICALLY SWITCHED TO REMOTE CONTROL.
N.D. INSULATE EACH UNUSED LEAD INDIVIDUALLY.
N.E. SPLICE LEADS AND INSULATE.
7-2000
F-3
S23983
DIAGRAMS
F-4 F-4
CONNECTION DIAGRAM
AIR VANTAGE 500 CUMMINS
DIAGRAMS
F-5 F-5
CONNECTION DIAGRAM
AIR VANTAGE 500 CUMMINS
COMMANDER / K867 / LN-8 CONNECTION DIAGRAM
F-6
WARNING
Do not operate with panels open. Keep guards in place.
Keep away from moving parts.
Disconnect NEGATIVE (-) BATTERY LEAD
before servicing. Only qualified personnel should install,use
CONNECTION DIAGRAM
or service this equipment.
Do not touch electrically live parts.
SPARE
82 LN-8
WIRE
81 N.C.
FEEDER
42
41
31 31
32 32
14 PIN
}
AMPHENOL
2 2
4 4
ELECTRODE TO WORK 21 21 K196
K867 UNIVERSAL
GND INPUT CABLE
GND
ADAPTER PLUG
DIAGRAMS
75 A
TO WORK
76 B
ELECTRODE CABLE
AIR VANTAGE 500 CUMMINS
77 C
}
TO WIRE FEED UNIT
CAUTION : N.D.
ANY INCREASE OF THE HIGH IDLE ENGINE RPM BY CHANGING THE GOVERNOR SETTING OR OVERRIDING THE THROTTLE LINKAGE WILL CAUSE
AN INCREASE IN THE THE AC AUXILIARY VOLTAGE. IF THIS VOLTAGE GOES OVER 140 VOLTS, WIRE FEEDER CONTROL CIRCUITS MAY BE
DAMAGED. THE ENGINE GOVERNOR SETTING IS PRE-SET AT THE FACTORY - DO NOT ADJUST ABOVE RPM SPECIFICATIONS LISTED IN
THE ENGINE WELDER OPERATING MANUAL.
N.A. WELDING CABLE MUST BE OF PROPER CAPACITY FOR THE CURRENT AND DUTY CYCLE OF IMMEDIATE AND FUTURE
APPICATIONS. SEE OPERATING MANUAL.
N.B. USE VOLTMETER SWITCH TO SELECT DESIRED ELECTRODE POLARITY. POSITION THE SELECTOR SWITCH TO "WIRE WELDING CV".
N.C. INSULATE EACH UNUSED LEAD INDIVIDUALLY.
N.D. SPLICE LEADS AND INSULATE.
7-2000
F-6
S23989
DIAGRAMS
F-7 F-7
CONNECTION DIAGRAM
AIR VANTAGE 500 CUMMINS
DIAGRAMS
F-8 F-8
CONNECTION DIAGRAM
AIR VANTAGE 500 CUMMINS
DIAGRAMS
F-9 F-9
CONNECTION DIAGRAM
AIR VANTAGE 500 CUMMINS
DIAGRAMS
F-10 F-10
CONNECTION DIAGRAM
AIR VANTAGE 500 CUMMINS
DIAGRAMS
F-11 F-11
CONNECTION DIAGRAM
AIR VANTAGE 500 CUMMINS
DIAGRAMS
F-12 F-12
CONNECTION DIAGRAM
AIR VANTAGE 500 CUMMINS
3.18
80.8
52.52 2.24
1334
42.35 56.9
1075.7
36.13
F-13
917.7
32.08
814.8
48.92
1242.6 45.67
46.35
1160
42.00 1177.3
1066.8
N.A.
9.10
231.1
63.10 6.56 31.50
1602.7 166.6 800.1
45.38
1152.7
*
37.30
947.4 14.63
371.6 * 6.55
166.4
N.A. CENTER OF GRAVITY WITH OIL IN ENGINE, OIL IN COMPRESSOR, COOLANT IN RADIATOR,
DIAGRAMS
DIMENSION PRINT
AND EMPTY FUEL TANK.
AIR VANTAGE 500 CUMMINS
28.99
736.3
24.97
634.2
* TRAILER MOUNTING HOLE LOCATIONS.
*
6.53
*
165.9
19.63
498.6 23.69
601.7 50.38
1279.7 54.44
1382.8
BOTTOM VIEW OF WELDER BASE.
B
M18962-4
F-13
NOTE: This diagram is for reference only. It may not be accurate for all machines covered by this manual. The specific diagram for a particular code is pasted inside the machine on one of the enclosure
panels. If the diagram is illegible, write to the Service Department for a replacement. Give the equipment code number.
WARNING
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.
AVISO DE
G Insulate yourself from work and
ground.
Spanish
PRECAUCION
G No toque las partes o los electrodos G Mantenga el material combustible G Prot茅jase los ojos, los o铆dos y el
bajo carga con la piel o ropa fuera del 谩rea de trabajo. cuerpo.
mojada.
G Aislese del trabajo y de la tierra.
ATTENTION
French G Ne laissez ni la peau ni des G Gardez 脿 l鈥櫭ヽart de tout mat茅riel G Prot茅gez vos yeux, vos oreilles et
v锚tements mouill茅s entrer en contact inflammable. votre corps.
avec des pi猫ces sous tension.
G Isolez-vous du travail et de la terre.
WARNUNG
German G Ber眉hren Sie keine stromf眉hrenden G Entfernen Sie brennbarres Material! G Tragen Sie Augen-, Ohren- und K枚r-
Teile oder Elektroden mit Ihrem perschutz!
K枚rper oder feuchter Kleidung!
G Isolieren Sie sich von den
ATEN脟脙O
Portuguese
Elektroden und dem Erdboden!
G N茫o toque partes el茅tricas e G Mantenha inflam谩veis bem G Use prote莽茫o para a vista, ouvido e
electrodos com a pele ou roupa guardados. corpo.
molhada.
G Isole-se da pe莽a e terra.
Japanese
Chinese
Korean
Arabic
READ AND UNDERSTAND THE MANUFACTURER鈥橲 INSTRUCTION FOR THIS EQUIPMENT AND THE CONSUMABLES TO
BE USED AND FOLLOW YOUR EMPLOYER鈥橲 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 UNFALLVERH脺TUNGSVORSCHRIFTEN DES ARBEITGEBERS SIND EBENFALLS ZU BEACHTEN.
WARNING
G Keep your head out of fumes. G Turn power off before servicing. G Do not operate with panel open or
G Use ventilation or exhaust to guards off.
remove fumes from breathing zone.
AVISO DE
Spanish
PRECAUCION
G Los humos fuera de la zona de G Desconectar el cable de G No operar con panel abierto o
respiraci贸n. alimentaci贸n de poder de la guardas quitadas.
G Mantenga la cabeza fuera de los m谩quina antes de iniciar cualquier
humos. Utilice ventilaci贸n o servicio.
ATTENTION
French
aspiraci贸n para gases.
G N鈥檕p茅rez pas avec les panneaux
G Gardez la t锚te 脿 l鈥櫭ヽart des fum茅es.
G D茅branchez le courant avant ouverts ou avec les dispositifs de
G Utilisez un ventilateur ou un
l鈥檈ntretien. protection enlev茅s.
aspirateur pour 么ter les fum茅es des
WARNUNG
zones de travail.
German
G Anlage nie ohne Schutzgeh盲use
G Vermeiden Sie das Einatmen von
G Strom vor Wartungsarbeiten oder Innenschutzverkleidung in
Schweibrauch!
abschalten! (Netzstrom v枚llig Betrieb setzen!
G Sorgen Sie f眉r gute Be- und
枚ffnen; Maschine anhalten!)
Entl眉ftung des Arbeitsplatzes!
ATEN脟脙O
Portuguese
G Mantenha-se afastado das partes
G Mantenha seu rosto da fuma莽a.
G N茫o opere com as tampas removidas. moventes.
G Use ventila莽茫o e exhaust茫o para
G Desligue a corrente antes de fazer G N茫o opere com os paineis abertos
remover fumo da zona respirat贸ria.
servi莽o. ou guardas removidas.
Japanese
G N茫o toque as partes el茅tricas nuas.
Chinese
Korean
Arabic
LEIA E COMPREENDA AS INSTRU脟脮ES DO FABRICANTE PARA ESTE EQUIPAMENTO E AS PARTES DE USO,
E SIGA AS PR脕TICAS DE SEGURAN脟A DO EMPREGADOR.
World始s Leader in Welding and Cutting Products
鈥? Sales and Service through Subsidiaries and Distributors Worldwide 鈥?
Cleveland, Ohio 44117-1199 USA Tel: 216.481.8100 Fax: 216.486.1751 Web Site: www.lincolnelectric.com
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