Page 2 - SAFETY; WARNING; ELECTRIC AND; CALIFORNIA PROPOSITION 65 WARNINGS; The Above For Diesel Engines
i SAFETY i FOR ENGINEpowered equipment. 1.a. Turn the engine off before troubleshooting and maintenance work unless the maintenance work requires it to be running. ____________________________________________________ 1.b. Operate engines in open, well-ventilated areas or vent the engine exhaust fume...
Page 4 - Refer to
iii SAFETY iii FOR ELECTRICALLYpowered equipment. 8.a. Turn off input power using the disconnect switch at the fuse box before working onthe equipment. 8.b. Install equipment in accordance with the U.S. National Electrical Code, all local codes and the manufacturer’srecommendations. 8.c. Ground the ...
Page 5 - PRÉCAUTIONS DE SÛRETÉ; PRÉCAUTIONS DE SÛRETÉ POUR
iv SAFETY iv Mar. ‘93 PRÉCAUTIONS DE SÛRETÉ Pour votre propre protection lire et observer toutes les instructions et les précautions de sûreté specifiques qui parraissent dans ce manuel aussi bien que les précautions de sûreté générales suiv- antes: Sûreté Pour Soudage A L’Arc 1. Protegez-vous contr...
Page 8 - TThhaannkk Y; Please Examine Carton and Equipment For Damage Immediately
vii vii TThhaannkk Y Yoouu for selecting a QUALITY product by Lincoln Electric. We want you to take pride in operating this Lincoln Electric Company product ••• as much pride as we have in bringing this product to you! Read this Operators Manual completely before attempting to use this equipment. Sa...
Page 9 - TABLE OF CONTENTS
viii viii TABLE OF CONTENTS Page Installation .......................................................................................................................Section A Technical Specifications .......................................................................................................
Page 11 - INSTALLATION; TECHNICAL SPECIFICATIONS - AIR VANTAGE® 500 CUMMINS (K32012); INPUT - DIESEL ENGINE
AIR VANTAGE® 500 CUMMINS A-1 INSTALLATION A-1 TECHNICAL SPECIFICATIONS - AIR VANTAGE® 500 CUMMINS (K32012) Make/Model Description Speed (RPM) Displacement Starting Capacities cu. in. (ltrs.) System 4 cylinder High Idle 1900 199(3.3) 12VDC Battery & Fuel: 25 gal. Cummins 56 HP (42kw) starter (94....
Page 12 - SAFETY PRECAUTIONS
A-2 INSTALLATION AIR VANTAGE® 500 CUMMINS A-2 SAFETY PRECAUTIONS Only qualified personnel should install, use, or service this equipment. Do not attempt to use this equipment until youhave thoroughly read the engine manufacturer’sm a n u a l s u p p l i e d w i t h y o u r w e l d e r . I t i n c l ...
Page 13 - LIFTING
A-3 INSTALLATION AIR VANTAGE® 500 CUMMINS A-3 LIFTING The AIR VANTAGE® 500 lift bale should be used to lift the machine. The Air Vantage 500 is shipped with the lift bale retracted. Before attempting to lift the AIR VAN- TAGE® 500 the lift bale must be secured in a raised position. Secure the lift b...
Page 15 - CAUTION
A-5 INSTALLATION AIR VANTAGE® 500 CUMMINS A-5 The AIR VANTAGE® 500 is shipped with the negative battery cable disconnected. Before you operate the machine, make sure the Engine Switch is in the OFF position and attach the disconnected cable securely to the negative (-) battery terminal. Remove the i...
Page 16 - REMOTE CONTROL; AUXILIARY POWER RECEPTACLES
A-6 INSTALLATION AIR VANTAGE® 500 CUMMINS A-6 REMOTE CONTROL The AIR VANTAGE® 500 is equipped with a 6-pin and a 14-pin connector. The 6-pin connector is for connecting the K857 or K857-1 Remote Control or for TIG welding, the K870 foot Amptrol or the K963-3 hand Amptrol. When in the CC-STICK or CV-...
Page 17 - CONNECTION OF LINCOLN ELEC-
A-7 INSTALLATION AIR VANTAGE® 500 CUMMINS A-7 CONNECTION OF LINCOLN ELEC- TRIC WIRE FEEDERS Shut off welder before making any electrical con- nections. ------------------------------------------------------------------------ Connection of LN-7, LN-8 OR LN-742 to the AIR VANTAGE® 500 1. Shut the weld...
Page 18 - CONNECTION OF AN NA-3 AUTOMATIC
A-8 INSTALLATION AIR VANTAGE® 500 CUMMINS A-8 CONNECTION OF AN NA-3 AUTOMATIC WELDING SYSTEM TO THE AIR VAN- TAGE® 500 For connection diagrams and instructions for connect- ing an NA-3 Welding System to the AIR VANTAGE® 500, refer to the NA-3 Welding System instruction manual. The connection diagram...
Page 19 - OPERATION; GENERAL DESCRIPTION; RECOMMENDED APPLICATIONS
B-1 OPERATION AIR VANTAGE® 500 CUMMINS B-1 SAFETY PRECAUTIONS Read and understand this entire section before operating your AIR VANTAGE® 500. Do not attempt to use this equipment until you have thoroughly read the engine manufacturer’s manual supplied with your welder. It includes important safety p...
Page 20 - ENGINE CONTROLS; RUN STOP SWITCH; ENGINE TEMPERATURE GAUGE; CONTROLS AND SETTINGS
B-2 OPERATION B-2 ENGINE CONTROLS (Items 1 through 9) 1. RUN STOP SWITCH Toggling the switch to the RUN position energizes the fuel solenoid for approximately 30 seconds. The engine must be started within that time or the fuel solenoid will deenergize, and the switch must be toggled to reset the tim...
Page 21 - OIL PRESSURE GAUGE; WELDING CONTROLS (Items 11
B-3 OPERATION B-3 7. OIL PRESSURE GAUGE The gauge displays the engine oil pressure when the engine is running. 8. ENGINE PROTECTION The yellow engine protection light remains off with proper oil pressure and under normal oper- a t i n g t e m p e r a t u r e s . I f t h e l i g h t t u r n s o n , t...
Page 22 - AUXILIARY POWER CONTROLS
B-4 OPERATION B-4 13. WELD MODE SELECTOR SWITCH: (Provides 3 selectable welding modes) CV-WIRE CC-STICK TOUCH START TIG 14. ARC CONTROL: The ARC CONTROL WIRE/STICK knob is active in the WIRE and STICK modes, and has different f u n c t i o n s i n t h e s e m o d e s . T h i s c o n t r o l i s n o ...
Page 23 - AIR COMPRESSOR CONTROLS (26
B-5 OPERATION B-5 23. GROUND STUD: Provides a connection point for connecting the m a c h i n e c a s e t o e a r t h g r o u n d . R e f e r t o “ M A C H I N E G R O U N D I N G ” i n t h e I n s t a l l a t i o n chapter for proper machine grounding informa- tion. 24. RCD: “Residual Current Devic...
Page 24 - WHAT ARE VRD AND ROCV DEVICES?
B-6 OPERATION B-6 WHAT ARE VRD AND ROCV DEVICES? VRD’s are gaining popularity as a “must have” safety accessory especially where welding applications are being carried out in an environment with a high-risk of e l e c t r i c s h o c k s u c h a s w e t a r e a s a n d h o t h u m i d sweaty conditi...
Page 25 - STARTING TECHNIQUE
B-7 OPERATION B-7 Unlike other VRD’s Lincoln uses micro processor con- trol to monitor and establish the arc without the stick- ing and shorting of the electrode to the job as seen in many other VRD installations. Due to the requirement of the resistance in the circuit to be low, for a VRD to operat...
Page 26 - AIR VANTAGE® 500 SETTINGS WHEN USING; WELDER OPERATION; DUTY CYCLE
T h e A I R V A N T A G E ® 5 0 0 i s e q u i p p e d w i t h t h e required R.F. bypass circuitry for the connection of high frequency generating equipment. The AIR VANTAGE® 500 and any high frequency generating equipment must be properly grounded. See the K930-2 TIG Module operating manuals for co...
Page 27 - ARC GOUGING
ARC GOUGING For optimal performance when arc gouging, set the AIR VANTAGE® 500 “WELD MODE” switch to the “CC - STICK” position, and the “ARC CONTROL” to 10. Set the “OUTPUT” knob to adjust output current to the desired level for the gouging electrode being used according to the ratings in the follow...
Page 28 - PARALLELING; AUXILIARY POWER OPERATION; SIMULTANEOUS WELDING AND AUXIL-; PLUS
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 errat- ic outputs, and large output imb...
Page 29 - TIG OPTIONS; ACCESSORIES; O P T I O N A L F I E L D I N S TA L L E D
K2354-1 Air Dryer Kit-Minimizes water content in sup-ply air. Avoids cold weather air hose ice up. K2356-1 Control Panel Cover Kit-Clear plexiglasscover to protect control panel from dirt and debris, andto visually monitor machine operation. Lockable todeter vandalism. K2340-1 Lockable Fuel Cap / Fl...
Page 30 - MAINTENANCE; ROUTINE AND PERIODIC MAINTENANCE; COMPRESSOR MAINTENANCE; ENGINE MAINTENANCE
D-1 MAINTENANCE D-1 AIR VANTAGE® 500 CUMMINS SAFETY PRECAUTIONS • Have qualified personnel do all maintenance and troubleshooting work. • Turn the engine off before working inside the machine or servicing the engine. • R e m o v e g u a r d s o n l y w h e n n e c e s s a r y t o perform maintenance...
Page 31 - Caution; S e r v i c e I n s t r u c t i o n s; S i n g l e - a n d Tw o - S t a g e E n g i n e A i r C l e a n e r s
D-2 MAINTENANCE D-2 AIR VANTAGE® 500 CUMMINS Unfasten or unlatch theservice cover. Becausethe filter fits tightly over theoutlet tube to create the critical seal, there willbe some initial resistance, similar to breakingthe seal on a jar. Gently move the end of the filterback and forth to break the ...
Page 33 - CHARGING THE BATTERY; W E L D E R / G E N E R ATO R M A I N T E -; STORAGE
D-4 MAINTENANCE D-4 CHARGING THE BATTERY When you charge, jump, replace, or otherwise connect battery cables to the battery, be sure the polarity is correct. Improper polarity can damage the charging circuit. The AIR VANTAGE® 500 positive (+) battery terminal has a red terminal cover. If you need to...
Page 34 - TROUBLESHOOTING; HOW TO USE TROUBLESHOOTING GUIDE
E-1 TROUBLESHOOTING E-1 AIR VANTAGE® 500 CUMMINS 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. CAUTION This Troub...
Page 35 - PROBLEMS
E-2 TROUBLESHOOTING E-2 AIR VANTAGE® 500 CUMMINS Observe all Safety Guidelines detailed throughout this manual 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 tro...
Page 38 - WIRING DIAGRAM
F-1 WIRING DIAGRAM F-1 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 diag ram for a particular code is included with the machine. If the diagram is illegible, write to the Service Department for a repla...
Page 39 - DIAGRAMS
Page 40 - IN
F-3 DIAGRAMS F-3 AIR VANTAGE® 500 CUMMINS G N D 75 76 77 G R EE N K2 91 O R K 40 4 75 IN PU T C AB LE 76 N .E . 77 K7 75 O PT IO N AL R EM O TE C O N TR O L DA MA GE D. TH E E NG IN E G OV ER NO R SE TT IN G IS PR E- SE T A T T HE FA CT OR Y - D O NO T A DJ US T A BO VE R PM SP EC IFI CA TIO NS LI S...
Page 50 - DIMENSION PRINT
F-13 DIMENSION PRINT F-13 AIR VANTAGE® 500 CUMMINS M 18 96 2- 4 B TR AI LE R M O UN TI NG H O LE L O CA TI O NS . * 28 .9 9 73 6. 3 19 .6 3 49 8. 6 6. 55 16 6. 4 23 .6 9 60 1. 7 50 .3 8 12 79 .7 54 .4 4 13 82 .8 14 .6 3 37 1. 6 37 .3 0 94 7. 4 45 .3 8 11 52 .7 31 .5 0 80 0. 1 45 .6 7 11 60 2. 24 56 ...
Page 51 - NOTES
