Page 2 - SAFETY; WARNING; 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 3 - ii
ii SAFETY ii ARC RAYS can burn. 4.a. Use a shield with the proper filter and cover plates to protect your eyes from sparks andthe rays of the arc when welding or observingopen arc welding. Headshield and filter lensshould conform to ANSI Z87. I standards. 4.b. Use suitable clothing made from durable...
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 PRÉCAUTIONS DE SÛRETÉ Pour votre propre protection lire et observer toutes les instructionset les précautions de sûreté specifiques qui parraissent dans cemanuel aussi bien que les précautions de sûreté générales suiv-antes: Sûreté Pour Soudage A L’Arc 1. Protegez-vous contre la secouss...
Page 6 - Thank You; Please Examine Carton and Equipment For Damage Immediately
v v Thank You 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. Save this manual...
Page 7 - vi; TAbLE OF CONTENTS
vi vi TAbLE OF CONTENTS Page Installation .......................................................................................................................Section A Technical Specifications .......................................................................................................A...
Page 9 - INSTALLATION; INPUT - DIESEL ENGINE
AIR VANTAGE® 500 KUbOTA A-1 INSTALLATION A-1 TECHNICAL SPECIFICATIONS - AIR VANTAGE® 500 KUbOTA (K2325 -2) Make/Model Description Speed (RPM) Displacement Starting Capacities cu. in. (ltrs.) System 4 cylinder High Idle 1850 220.9(3.62) 12VDC Battery & Fuel: 25 gal. KUBOTA 58 HP (43.2kw) starter ...
Page 10 - SAFETY PRECAUTIONS
A-2 INSTALLATION AIR VANTAGE® 500 KUbOTA 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’smanual supplied with your welder. It includesi m p o r t a n t s a f e ...
Page 11 - LIFTING
A-3 INSTALLATION AIR VANTAGE® 500 KUbOTA A-3 LIFTING The AIR VANTAGE® 500 KUBOTA lift bale should beused to lift the machine. The Air Vantage 500 isshipped with the lift bale retracted. Before attemptingto lift the AIR VANTAGE® 500 KUBOTA the lift bale mustbe secured in a raised position. Secure the...
Page 12 - OIL
ENGINE COOLANT HOT COOLANT can burn skin. •Do not remove cap if radiator is hot. -------------------------------------------------------------------------------- The welder is shipped with the engine and radiatorfilled with a 50% mixture of ethylene glycol and water.S e e t h e M A I N T E N A N C E...
Page 13 - CAUTION
A-5 INSTALLATION AIR VANTAGE® 500 KUbOTA A-5 The AIR VANTAGE® 500 KUBOTA is shipped withthe negative battery cable disconnected. Before youoperate the machine, make sure the Engine Switch isin the OFF position and attach the disconnected cablesecurely to the negative (-) battery terminal. Remove the...
Page 14 - AIR VANTAGE® 500 KUbOTA; REMOTE CONTROL; AUXILIARY POWER RECEPTACLES
A-6 INSTALLATION AIR VANTAGE® 500 KUbOTA A-6 REMOTE CONTROL The AIR VANTAGE® 500 KUBOTA is equipped with a6-pin and a 14-pin connector. The 6-pin connector isfor connecting the K857 or K857-1 Remote Control orfor TIG welding, the K870 foot Amptrol or the K963-3hand Amptrol. When in the CC-STICK, ARC...
Page 15 - STANDbY POWER CONNECTIONS; • Only a licensed, certified, trained electrician
STANDbY POWER CONNECTIONS The AIR VANTAGE® 500 KUBOTA is suitable fortemporary, standby or emergency power using theengine manufacturer’s recommended maintenanceschedule. The AIR VANTAGE® 500 KUBOTA can be perma-nently installed as a standby power unit for 240 VAC,3 wire, single phase, 50 amp servic...
Page 16 - CONNECTION OF AIR VANTAGE® 500 KUbOTA 500 TO PREMISES WIRING
A-8 INSTALLATION AIR VANTAGE® 500 KUbOTA A-8 CONNECTION OF AIR VANTAGE® 500 KUbOTA 500 TO PREMISES WIRING WARNING • Only a licensed, certified, trained electrician should install the machine to a premises or residential electrical system. be certain that: • The installation complies with the Nationa...
Page 19 - OPERATION; GENERAL DESCRIPTION; ADD FUEL; DIESEL FUEL
b-1 OPERATION AIR VANTAGE® 500 KUbOTA b-1 SAFETY PRECAUTIONS Do not attempt to use this equipment until you havethoroughly read the engine manufacturer’s manualsupplied with your welder. It includes importantsafety precautions, detailed engine starting, operat-ing and maintenance instructions, and p...
Page 20 - RECOMMENDED APPLICATIONS; WELDER; mended; AIR COMPRESSOR
b-2 OPERATION b-2 RECOMMENDED APPLICATIONS WELDER The AIR VANTAGE® 500 KUBOTA provides excellentconstant current DC welding output for stick (SMAW)and TIG welding. The AIR VANTAGE® 500 KUBOTAalso provides excellent constant voltage DC weldingo u t p u t f o r M I G ( G M A W ) , I n n e r s h i e l ...
Page 21 - WELDING CONTROLS; D I G I TA L O U T P U T M E T E R S -
b-3 OPERATION b-3 WELDING CONTROLS (Figure b.1) 1. OUTPUT CONTROL- The OUTPUT dial is used to preset the output voltage or current as dis-played on the digital meters for the five weldingmodes. When in the CC-STICK, ARC GOUGING orCV-WIRE modes and when a remote control is con-nected to the 6-Pin or ...
Page 22 - WELD OUTPUT TERMINALS WITH FLANGE
b-4 OPERATION b-4 4. ARC CONTROL - The ARC CONTROL dial is active in the CV-WIRE, CC-STICK and DOWNHILL PIPE modes,and has different functions in these modes. This control isnot active in the TIG and ARC GOUGING mode. CC-STICK mode: In this mode, the ARC CONTROL dial sets the short circuit current (...
Page 23 - GLOW PLUG PUSH bUTTON
b-5 OPERATION b-5 ENGINE CONTROLS: 12. RUN/STOP SWITCH - -RUN position energizes the engine prior to starting.STOP position stops the engine. The oil pressure inter-lock switch prevents battery drain if the switch is left inthe RUN position and the engine is not operating. 13. GLOW PLUG PUSH bUTTON ...
Page 24 - COMPRESSOR PROTECTION LIGHT; STARTING THE ENGINE
b-6 OPERATION b-6 AIR COMPRESSOR CONTROLS (24THRU 26) 24. COMPRESSOR ON/OFF SWITCH Turns compressor on and off (standby) by openingand closing the compressor inlet valve. 25. COMPRESSOR PROTECTION LIGHT The yellow compressor protection light remains offwith proper compressor oil temperatures. If the...
Page 25 - WELDER OPERATION; TYPICAL AIR VANTAGE® 500 KUbOTA FUEL CONSUMPTION; STOPPING THE ENGINE
b-7 OPERATION b-7 AIR VANTAGE® 500 KUbOTA WELDER OPERATION DUTY CYCLE Duty Cycle is the percentage of time the load is beingapplied in a 10 minute period. For example a 60% dutycycle, represents 6 minutes of load and 4 minutes of noload in a 10 minute period. ELECTRODE INFORMATION For any electrode ...
Page 26 - DOWNHILL PIPE WELDING; TIG WELDING
E6010 - Touch, Lift to Start the ArcE7018, E7024 - Touch, Rock Back and Forth in Joint, Lift . Once the arc is started, normal welding technique forthe application is then used. b. For Re-Striking Electrodes Some electrodes form a cone at the end of the elec-trode after the welding arc has been brok...
Page 27 - ARC GOUGING
For optimal performance, set the MODE switch to ARCGOUGING. Set the OUTPUT CONTROL knob to adjust out-put current to the desired level for the gouging electrodebeing used according to the ratings in the following TableB.4 The ARC CONTROL is not active in the ARC GOUGINGMode. The ARC CONTROL is autom...
Page 28 - PARALLELING; AUXILIARY POWER OPERATION; PLUS
PARALLELING When paralleling machines in order to combine theiroutputs, all units must be operated in the CC-STICKmode only at the same output settings. To achievethis, turn the WELD MODE switch to the CC-STICKposition. Operation in other modes may produce errat-ic outputs, and large output imbalanc...
Page 29 - ACCESSORIES
C-1 ACCESSORIES C-1 AIR VANTAGE® 500 KUbOTA F I E L D I N S TA L L E D O P T I O N S /A C C E S S O R I E S a r e a v a i l a b l e a twww.lincolnelectric.com. Follow these steps: 1. Go to www.lincolnelectric.com 2. At the top of the screen in the Search field type E6.217 click on Search Icon. 3. O ...
Page 30 - MAINTENANCE; ROUTINE AND PERIODIC MAINTENANCE; WEEKLY; COMPRESSOR MAINTENANCE; ENGINE MAINTENANCE
D-1 MAINTENANCE D-1 AIR VANTAGE® 500 KUbOTA 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 - Clean Both Surfaces of the Outlet Tube; 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 KUbOTA Unfasten or unlatch the service cover. Because the filter fits tightly over the outlet tube to create the critical seal, there will be some initial resistance, similar to breaking the seal on a jar. Gently move the end of the filter back and forth to break...
Page 32 - ENGINE OIL CHANGE; • Never use gasoline or low flash point solvents; AIR CLEANER
D-3 MAINTENANCE D-3 ENGINE OIL CHANGE Drain the engine oil while the engine is warm to assurerapid and complete draining. It is recommended thateach time the oil is changed the oil filter be changed aswell. • Be sure the unit is off. Disconnect the negative bat- tery cable to ensure safety. • Locate...
Page 33 - COOLING SYSTEM; • Do not remove cap if radiator is; TIGHTENING THE FAN bELT; bleed the fuel system as follows:; FUEL FILTER
D-4 MAINTENANCE D-4 COOLING SYSTEM HOT COOLANT can burn skin. • Do not remove cap if radiator is hot. ------------------------------------------------------------------------ Check the coolant level by observing the level in theradiator and recovery bottle. Add 50/50 antifreeze /water solution if th...
Page 34 - ENGINE ADJUSTMENT; CLEANING THE bATTERY; • MUFFLER MAY bE HOT
D-5 MAINTENANCE D-5 ENGINE ADJUSTMENT Adjustments to the engine are to be made only by aLincoln Service Center or an authorized Field ServiceShop. bATTERY MAINTENANCE To access the battery, remove the battery tray fromthe front of the machine with 3/8” nut driver or flathead screw driver. Pull the t...
Page 35 - • Service and Repair should only be performed by; REPLACEMENT SERVICE ITEMS; TAbLE D.1 ENGINE MAINTENANCE COMPONENTS
D-6 MAINTENANCE D-6 AIR VANTAGE® 500 KUbOTA GFCI MODULE TESTING AND RESETTINGPROCEDURE The GFCI module should be properly tested at leastonce every month or whenever it is tripped. To properlytest and reset the GFCI module: • If the module has tripped, first carefully remove any load and check it fo...
Page 36 - TROUbLESHOOTING; HOW TO USE TROUbLESHOOTING GUIDE
E-1 TROUbLESHOOTING E-1 AIR VANTAGE® 500 KUbOTA 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 Troubl...
Page 37 - PRObLEMS; C o n t a c t y o u r l o c a l L i n c o l n
E-2 TROUbLESHOOTING E-2 AIR VANTAGE® 500 KUbOTA 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 trou...
Page 38 - Local Lincoln Authorized Field Service Facility; Contact
E-3 TROUbLESHOOTING E-3 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 troubleshooting assistance b...
Page 42 - DIAGRAMS; IN; IN
F-1 DIAGRAMS F-1 AIR VANTAGE® 500 KUbOTA G N D 75 76 77 G R E E N K 29 1 O R K 40 4 75 IN P U T C A B LE 76 N .E . 77 K 77 5 O P TIO N A L R E M O TE C O N TR O L DA M AG ED . T HE EN GIN E G OV ER NO R S ET TIN G IS PR E-S ET AT TH E F AC TO RY - D O N OT AD JU ST AB OV E R PM SP EC IFIC AT IO NS L...
Page 53 - WIRING DIAGRAM; Enhanced Diagram
F-12 WIRING DIAGRAM F-12 AIR VANTAGE® 500 KUbOTA 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 repl...
Page 54 - DIMENSION PRINT
F-13 DIMENSION PRINT F-13 AIR VANTAGE® 500 KUbOTA M 18 96 2-7 A.0 1 BO TT OM VIE W O F W EL DE R B AS E TR AIL ER M O U N TIN G H O LE L O C AT IO N S. * 28.9 9 736 .3 19.6 3 498 .6 6.5 5 166 .4 23.6 9 601 .7 50.3 8 127 9.7 54.4 4 138 2.8 14.6 3 371 .6 37.3 0 947 .4 45.3 8 115 2.7 31.5 0 800 .1 45.6...
Page 55 - NOTES