Page 2 - SAFETY; CALIFORNIA PROPOSITION 65 WARNINGS; WARNING
ELECTRIC ANDMAGNETIC FIELDSmay be dangerous 2.a. Electric current flowing through any conductor causes localized Electric and Magnetic Fields (EMF). Weldingcurrent creates EMF fields around welding cables andwelding machines. 2.b. EMF fields may interfere with some pacemakers and welders having a pa...
Page 3 - ii
ELECTRIC SHOCKcan kill. 3.a. The electrode and work (or ground) circuits are electrically “hot” when the welder is on.Do not touch these “hot” parts with your bareskin or wet clothing. Wear dry, hole-freegloves to insulate hands. 3.b. Insulate yourself from work and ground using dryinsulation. Make ...
Page 4 - iii; 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 - iv; PRÉCAUTIONS DE SÛRETÉ
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 suivantes: Sûreté Pour Soudage A L’Arc 1. Protegez-vous contre ...
Page 6 - Please Examine Carton and Equipment For Damage Immediately
v v TThhaannkk Y Yoouu for selecting a QUALITY product by Lincoln Electric. We want youto 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. Save thi...
Page 7 - TABLE OF CONTENTS
Page Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Section A Technical Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ...
Page 8 - vii
Accessories . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Section C Optional Field Installed Accessories . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .C-1 ___...
Page 9 - INPUT - DIESEL ENGINE; Cummins; PHYSICAL DIMENSIONS; INSTALLATION
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 Engi...
Page 10 - STORING; ANGLE OF OPERATION; AIR VANTAGE® 500 CUMMINS
Read this entire installation section before you startinstallation. SAFETY PRECAUTIONS Do not attempt to use this equipment until you havethoroughly read all operating and maintenance manualssupplied with your machine. They include important safetyprecautions, detailed engine starting, operating and...
Page 13 - WELDING TERMINALS
The AIR VANTAGE® 500 is shipped with the negative batterycable disconnected. Before you operate the machine, make surethe Engine Switch is in the OFF position and attach thedisconnected cable securely to the negative (-) battery terminal. Remove the insulating cap from the negative battery terminal....
Page 14 - REMOTE CONTROL; OUTPUT
REMOTE CONTROL OUTPUT The AIR VANTAGE® 500 is equipped with a 6-pin and a 14-pinconnector. The 6-pin connector is for connecting the K857 orK857-1 Remote Control or for TIG welding, the K870 foot Amptrolor the K936-2 hand Amptrol. When in the CC-STICK, DOWNHILLPIPE, or CV-WIRE modes and when a remot...
Page 15 - Figure A.2 Connection of the AIR VANTAGE® 500 to Premises Wiring
AIR VANTAGE® 500 CUMMINS A-7 INSTALLATION A-7 2. Take necessary steps to assure load is limited to the capacity of the AIR VANTAGE® 500 by installing a 50 amp, 240 VACdouble pole circuit breaker. Maximum rated load for each legof the 240 VAC auxiliary is 50 amps. Loading above the ratedoutput will r...
Page 17 - CAUTION
CONNECTION OF THE LN-25 TO THE AIRVANTAGE® 500 The LN-25 with or without an internal contactor may be used withthe AIR VANTAGE® 500. See the appropriate connectiondiagram in the DIAGRAMS section. NOTE: The LN-25 (K431) Remote Control Module and (K432)Remote Cable are not recommended for use with the...
Page 18 - OPERATION
SAFETY INSTRUCTIONS Read and understand this entire section before operating your AIR VANTAGE® 500. Do not attempt to use this equipment until you havethoroughly read all operating and maintenance manualssupplied with your machine. They include important safetyprecautions, detailed engine starting, ...
Page 19 - CONTROLS AND SETTINGS; Figure B.1 Case Front Panel Controls
ENGINE CONTROLS (Items 1 through 9) 1. RUN STOP SWITCH Toggling the switch to the RUN position energizes the fuelsolenoid for approximately 30 seconds. The engine must bestarted within that time or the fuel solenoid will deenergize, andthe switch must be toggled to reset the timer. 2. START PUSHBUTT...
Page 21 - AUXILIARY POWER CONTROLS
WELDING CONTROLS (Items 10 through 19) 10. OUTPUT CONTROL: The OUTPUT dial is used to preset theoutput voltage or current as displayed on the digital meters for thefour welding modes. When in the CC-STICK, DOWNHILL PIPE orCV-WIRE modes and when a remote control is connected to the6-Pin or 14-Pin Con...
Page 22 - ENGINE OPERATION; STARTING THE ENGINE
20. CIRCUIT BREAKERS These circuit breakers provide separate overload currentprotection for each 120V circuit at the 240V single phasereceptacle, each 120V single phase receptacle, the 240V threephase receptacle, the 120VAC in the 14-Pin connector, the42VAC in the 14-Pin connector and battery circui...
Page 23 - WELDER OPERATION
B-6 OPERATION B-6 AIR VANTAGE® 500 CUMMINS BREAK-IN PERIOD The engine used to supply power for your welder is a heavy duty,industrial engine. It is designed and built for rugged use. It is verynormal for any engine to use small quantities of oil until the break-in is accomplished. Check the oil leve...
Page 25 - AUXILIARY POWER OPERATION
CV-WIRE MODE Connect a wire feeder to the AIR VANTAGE® 500 and set weldercontrols according to the instructions listed earlier in this section. The AIR VANTAGE® 500 in the ”CV-WIRE” position, permits itto be used with a broad range of flux cored wire (Innershield andOutershield) electrodes and solid...
Page 26 - PLUS
B-9 OPERATION B-9 AIR VANTAGE® 500 CUMMINS TABLE B.5 AIR VANTAGE® 500 Extension Cord Length Recommendations Current (Amps) 1515202025303850 Voltage (Volts) 120240120240240240240240 Load (Watts) 1800360024004800600072009000 12000 3060 (9) (18) 40753060 (12)(23) (9) (18) 75 150 50 100 9075 (23)(46)(15...
Page 27 - OPTIONAL FIELD INSTALLED ACCESSORIES; TIG OPTIONS; ACCESSORIES
OPTIONAL FIELD INSTALLED ACCESSORIES K802N POWER PLUG KIT - Provides four 120V plugs rated at 20 amps eachand one dual voltage, full KVA plug rated at 120/240V, 50 amps. 120V plug maynot be compatible with NEMA common household receptacles. K802-R POWER PLUG KIT - Provides four 120V plugs rated 15 a...
Page 28 - MAINTENANCE
SAFETY PRECAUTIONS • Have a qualified technician do the maintenance and troubleshooting work. • Turn the engine off before working inside the machine. • Remove guards only when necessary and replace them when the maintenance requiring their removal is complete. • Always use the greatest care when wo...
Page 29 - Service Instructions & Installation Tips; For Engine Air Filter
D-2 MAINTENANCE D-2 AIR VANTAGE® 500 CUMMINS Service Instructions & Installation Tips For Engine Air Filter Release the 1 Seal Carefully Unlatch and remove the service cover of the air cleaner. Make certain the latches are folded back against the cover so that they donít hinder filter removal/in...
Page 32 - HOW TO USE TROUBLESHOOTING GUIDE; TROUBLESHOOTING
This Troubleshooting Guide is provided to help you locate andrepair possible machine malfunctions. Simply follow the three-step procedure listed below. Step 1. LOCATE PROBLEM (SYMPTOM). Look under the column labeled “PROBLEM (SYMPTOMS)”. Thiscolumn describes possible symptoms that the machine mayexh...
Page 33 - Observe all Safety Guidelines detailed throughout this manual
PROBLEMS (SYMPTOMS) Major Physical or Electrical Damage isEvident. Engine will not crank Engine will crank but not start. Engine shuts down shortly after starting. Engine shuts down while under a load. Engine runs rough. Engine will not shut off. POSSIBLE CAUSE 1. Contact your Local Lincoln Authoriz...
Page 34 - PROBLEMS
CAUTION AIR VANTAGE® 500 CUMMINS E-3 TROUBLESHOOTING E-3 PROBLEMS (SYMPTOMS) Battery does not stay charged. Engine will not idle down to lowspeed. Engine will not go to high idle whenattempting to weld. Engine will not go to high idle when usingauxiliary power. POSSIBLE CAUSE 1. Faulty battery . 2. ...
Page 35 - FUNCTION PROBLEMS
PROBLEMS (SYMPTOMS) Engine goes to low idle but does not stay atlow idle. No welding output or auxiliary output. Welder has some/ no output and no control.Auxiliary output OK No welding output. Auxiliary output OK. No auxiliary power. POSSIBLE CAUSE 1. Faulty Peripheral PCB, Pull Coil/Battery PCB or...
Page 36 - DIAGRAMS
F-1 DIAGRAMS 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 diagram for your particular machine is pasted inside the machine on one of the enclosure panels.
Page 38 - IN
F-3 DIAGRAMS F-3 AIR VANTAGE® 500 CUMMINS CONNECTION DIAGRAM: G N D 7 5 7 6 7 7 G R E E N K 2 9 1 O R K 4 0 4 7 5 IN P U T C A B L E 7 6 N .E . 7 7 K 7 7 5 O P T IO N A L R E M O T E C O N T R O L D A M A G E D . T H E E N G IN E G O V E R N O R S E TT IN G IS P R E -S E T AT T H E F A C TO R Y - D ...
Page 40 - CONNECTION DIAGRAM
AIR VANTAGE® 500 CUMMINS F-5 DIAGRAMS F-5 CONNECTION DIAGRAM
Page 48 - DIMENSION PRINT
AIR VANTAGE® 500 CUMMINS F-13 DIAGRAMS F-13 DIMENSION PRINT M 1 8 9 6 2 -4 B T R A IL E R M O U N T IN G H O L E L O C A T IO N S . * 2 8 .9 9 7 3 6 .3 1 9 .6 3 4 9 8 .6 6 .5 5 1 6 6 .4 2 3 .6 9 6 0 1 .7 5 0 .3 8 1 2 7 9 .7 5 4 .4 4 1 3 8 2 .8 1 4 .6 3 3 7 1 .6 3 7 .3 0 9 4 7 .4 4 5 .3 8 1 1 5 2 .7 ...
Page 50 - AVISO DE; ATTENTION
WARNING AVISO DE PRECAUCION ATTENTION WARNUNG ATENÇÃO Spanish French German Portuguese Japanese Chinese Korean Arabic LEIA E COMPREENDA AS INSTRUÇÕES DO FABRICANTE PARA ESTE EQUIPAMENTO E AS PARTES DE USO, E SIGA AS PRÁTICAS DE SEGURANÇA DO EMPREGADOR. ● Keep your head out of fumes. ● Use ventilatio...
Page 51 - World’s Leader in Welding and Cutting Products
World’s Leader in Welding and Cutting Products • Sales and Service through Subsidiaries and Distributors Worldwide • Cleveland, Ohio 44117-1199 USA Tel: 216.481.8100 Fax: 216.486.1751 Web Site: www.lincolnelectric.com
