Air Vent Inc Welding System IM10065 User Manual
RETURN TO MAIN MENU  
IM10065  
November, 2010  
®
CUMMINS  
AIR VANTAGE 500  
For use with machine having Code Number:  
11651  
Safety Depends on You  
Lincoln arc welding and cutting  
equipment is designed and built  
with safety in mind. However,  
your overall safety can be  
increased by proper installation  
... and thoughtful operation on  
your part. DO NOT INSTALL,  
OPERATE OR REPAIR THIS  
EQUIPMENT WITHOUT READ-  
ING THIS MANUAL AND THE  
SAFETY PRECAUTIONS CON-  
TAINED THROUGHOUT. And,  
most importantly, think before  
you act and be careful.  
OPERATOR’SꢀMANUAL  
Copyright © Lincoln Global Inc.  
• World's Leader in Welding and Cutting Products •  
• Sales and Service through Subsidiaries and Distributors Worldwide •  
Cleveland, Ohio 44117-1199 U.S.A. TEL: 216.481.8100 FAX: 216.486.1751 WEBꢀSITE: www.lincolnelectric.com  
Download from Www.Somanuals.com. All Manuals Search And Download.  
ii  
ii  
SAFETY  
ARC RAYS can burn.  
ELECTRIC SHOCK can  
4.a. Use a shield with the proper filter and cover  
plates to protect your eyes from sparks and  
the rays of the arc when welding or observing  
open arc welding. Headshield and filter lens  
should conform to ANSI Z87. I standards.  
kill.  
3.a. The electrode and work (or ground) circuits  
are electrically “hot” when the welder is on.  
Do not touch these “hot” parts with your bare  
skin or wet clothing. Wear dry, hole-free  
gloves to insulate hands.  
4.b. Use suitable clothing made from durable flame-resistant  
material to protect your skin and that of your helpers from  
the arc rays.  
3.b. Insulate yourself from work and ground using dry insulation.  
Make certain the insulation is large enough to cover your full  
area of physical contact with work and ground.  
4.c. Protect other nearby personnel with suitable, non-flammable  
screening and/or warn them not to watch the arc nor expose  
themselves to the arc rays or to hot spatter or metal.  
In addition to the normal safety precautions, if welding  
must be performed under electrically hazardous  
conditions (in damp locations or while wearing wet  
clothing; on metal structures such as floors, gratings or  
scaffolds; when in cramped positions such as sitting,  
kneeling or lying, if there is a high risk of unavoidable or  
accidental contact with the workpiece or ground) use  
the following equipment:  
FUMES AND GASES  
can be dangerous.  
5.a. Welding may produce fumes and gases  
hazardous to health. Avoid breathing these  
• Semiautomatic DC Constant Voltage (Wire) Welder.  
• DC Manual (Stick) Welder.  
fumes and gases. When welding, keep  
your head out of the fume. Use enough  
ventilation and/or exhaust at the arc to keep  
• AC Welder with Reduced Voltage Control.  
fumes and gases away from the breathing zone. When  
welding with electrodes which require special  
ventilation such as stainless or hard facing (see  
instructions on container or MSDS) or on lead or  
cadmium plated steel and other metals or coatings  
which produce highly toxic fumes, keep exposure as  
low as possible and within applicable OSHA PEL and  
ACGIH TLV limits using local exhaust or mechanical  
ventilation. In confined spaces or in some circum-  
stances, outdoors, a respirator may be required.  
Additional precautions are also required when welding  
on galvanized steel.  
3.c. In semiautomatic or automatic wire welding, the electrode,  
electrode reel, welding head, nozzle or semiautomatic  
welding gun are also electrically “hot”.  
3.d. Always be sure the work cable makes a good electrical  
connection with the metal being welded. The connection  
should be as close as possible to the area being welded.  
3.e. Ground the work or metal to be welded to a good electrical  
(earth) ground.  
3.f. Maintain the electrode holder, work clamp, welding cable and  
welding machine in good, safe operating condition. Replace  
damaged insulation.  
5. b. The operation of welding fume control equipment is affected  
by various factors including proper use and positioning of  
the equipment, maintenance of the equipment and the spe-  
cific welding procedure and application involved. Worker  
exposure level should be checked upon installation and  
periodically thereafter to be certain it is within applicable  
OSHA PEL and ACGIH TLV limits.  
3.g. Never dip the electrode in water for cooling.  
3.h. Never simultaneously touch electrically “hot” parts of  
electrode holders connected to two welders because voltage  
between the two can be the total of the open circuit voltage  
of both welders.  
5.c. Do not weld in locations near chlorinated hydrocarbon vapors  
coming from degreasing, cleaning or spraying operations.  
The heat and rays of the arc can react with solvent vapors to  
form phosgene, a highly toxic gas, and other irritating prod-  
ucts.  
3.i. When working above floor level, use a safety belt to protect  
yourself from a fall should you get a shock.  
3.j. Also see Items 6.c. and 8.  
5.d. Shielding gases used for arc welding can displace air and  
cause injury or death. Always use enough ventilation,  
especially in confined areas, to insure breathing air is safe.  
5.e. Read and understand the manufacturer’s instructions for this  
equipment and the consumables to be used, including the  
material safety data sheet (MSDS) and follow your  
employer’s safety practices. MSDS forms are available from  
your welding distributor or from the manufacturer.  
5.f. Also see item 1.b.  
Download from Www.Somanuals.com. All Manuals Search And Download.  
iii  
iii  
SAFETY  
WELDING and CUTTING  
CYLINDER may explode  
if damaged.  
SPARKS can  
cause fire or explosion.  
7.a. Use only compressed gas cylinders  
containing the correct shielding gas for the  
6.a. Remove fire hazards from the welding area.  
If this is not possible, cover them to prevent  
the welding sparks from starting a fire.  
process used and properly operating  
regulators designed for the gas and  
Remember that welding sparks and hot  
materials from welding can easily go through small cracks  
and openings to adjacent areas. Avoid welding near  
hydraulic lines. Have a fire extinguisher readily available.  
pressure used. All hoses, fittings, etc. should be suitable for  
the application and maintained in good condition.  
7.b. Always keep cylinders in an upright position securely  
chained to an undercarriage or fixed support.  
6.b. Where compressed gases are to be used at the job site,  
special precautions should be used to prevent hazardous  
situations. Refer to “Safety in Welding and Cutting” (ANSI  
Standard Z49.1) and the operating information for the  
equipment being used.  
7.c. Cylinders should be located:  
•Away from areas where they may be struck or subjected to  
physical damage.  
•A safe distance from arc welding or cutting operations and  
any other source of heat, sparks, or flame.  
6.c. When not welding, make certain no part of the electrode  
circuit is touching the work or ground. Accidental contact  
can cause overheating and create a fire hazard.  
7.d. Never allow the electrode, electrode holder or any other  
electrically “hot” parts to touch a cylinder.  
6.d. Do not heat, cut or weld tanks, drums or containers until the  
proper steps have been taken to insure that such procedures  
will not cause flammable or toxic vapors from substances  
inside. They can cause an explosion even though they have  
been “cleaned”. For information, purchase “Recommended  
Safe Practices for the Preparation for Welding and Cutting of  
Containers and Piping That Have Held Hazardous  
Substances”, AWS F4.1 from the American Welding Society  
(see address above).  
7.e. Keep your head and face away from the cylinder valve outlet  
when opening the cylinder valve.  
7.f. Valve protection caps should always be in place and hand  
tight except when the cylinder is in use or connected for  
use.  
7.g. Read and follow the instructions on compressed gas  
cylinders, associated equipment, and CGA publication P-l,  
“Precautions for Safe Handling of Compressed Gases in  
Cylinders,” available from the Compressed Gas Association  
1235 Jefferson Davis Highway, Arlington, VA 22202.  
6.e. Vent hollow castings or containers before heating, cutting or  
welding. They may explode.  
6.f. Sparks and spatter are thrown from the welding arc. Wear oil  
free protective garments such as leather gloves, heavy shirt,  
cuffless trousers, high shoes and a cap over your hair. Wear  
ear plugs when welding out of position or in confined places.  
Always wear safety glasses with side shields when in a  
welding area.  
FOR ELECTRICALLY  
powered equipment.  
8.a. Turn off input power using the disconnect  
switch at the fuse box before working on  
the equipment.  
6.g. Connect the work cable to the work as close to the welding  
area as practical. Work cables connected to the building  
framework or other locations away from the welding area  
increase the possibility of the welding current passing  
through lifting chains, crane cables or other alternate cir-  
cuits. This can create fire hazards or overheat lifting chains  
or cables until they fail.  
8.b. Install equipment in accordance with the U.S. National  
Electrical Code, all local codes and the manufacturer’s  
recommendations.  
8.c. Ground the equipment in accordance with the U.S. National  
Electrical Code and the manufacturer’s recommendations.  
6.h. Also see item 1.c.  
6.I. Read and follow NFPA 51B “ Standard for Fire Prevention  
During Welding, Cutting and Other Hot Work”, available  
from NFPA, 1 Batterymarch Park, PO box 9101, Quincy, Ma  
022690-9101.  
6.j. Do not use a welding power source for pipe thawing.  
Refer to http://www.lincolnelectric.com/safety for additional safety information.  
Download from Www.Somanuals.com. All Manuals Search And Download.  
iv  
iv  
SAFETY  
PRÉCAUTIONS DE SÛRETÉ  
6. Eloigner les matériaux inflammables ou les recouvrir afin de  
prévenir tout risque d’incendie dû aux étincelles.  
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:  
7. Quand on ne soude pas, poser la pince à une endroit isolé de  
la masse. Un court-circuit accidental peut provoquer un  
échauffement et un risque d’incendie.  
Sûreté Pour Soudage A L’Arc  
8. S’assurer que la masse est connectée le plus prés possible  
de la zone de travail qu’il est pratique de le faire. Si on place  
la masse sur la charpente de la construction ou d’autres  
endroits éloignés de la zone de travail, on augmente le risque  
de voir passer le courant de soudage par les chaines de lev-  
age, câbles de grue, ou autres circuits. Cela peut provoquer  
des risques d’incendie ou d’echauffement des chaines et des  
câbles jusqu’à ce qu’ils se rompent.  
1. Protegez-vous contre la secousse électrique:  
a. Les circuits à l’électrode et à la piéce sont sous tension  
quand la machine à souder est en marche. Eviter toujours  
tout contact entre les parties sous tension et la peau nue  
ou les vétements mouillés. Porter des gants secs et sans  
trous pour isoler les mains.  
b. Faire trés attention de bien s’isoler de la masse quand on  
soude dans des endroits humides, ou sur un plancher  
metallique ou des grilles metalliques, principalement dans  
les positions assis ou couché pour lesquelles une grande  
partie du corps peut être en contact avec la masse.  
c. Maintenir le porte-électrode, la pince de masse, le câble  
de soudage et la machine à souder en bon et sûr état  
defonctionnement.  
9. Assurer une ventilation suffisante dans la zone de soudage.  
Ceci est particuliérement important pour le soudage de tôles  
galvanisées plombées, ou cadmiées ou tout autre métal qui  
produit des fumeés toxiques.  
10. Ne pas souder en présence de vapeurs de chlore provenant  
d’opérations de dégraissage, nettoyage ou pistolage. La  
chaleur ou les rayons de l’arc peuvent réagir avec les vapeurs  
du solvant pour produire du phosgéne (gas fortement toxique)  
ou autres produits irritants.  
d.Ne jamais plonger le porte-électrode dans l’eau pour le  
refroidir.  
e. Ne jamais toucher simultanément les parties sous tension  
des porte-électrodes connectés à deux machines à souder  
parce que la tension entre les deux pinces peut être le  
total de la tension à vide des deux machines.  
11. Pour obtenir de plus amples renseignements sur la sûreté,  
voir le code “Code for safety in welding and cutting” CSA  
Standard W 117.2-1974.  
f. Si on utilise la machine à souder comme une source de  
courant pour soudage semi-automatique, ces precautions  
pour le porte-électrode s’applicuent aussi au pistolet de  
soudage.  
2. Dans le cas de travail au dessus du niveau du sol, se protéger  
contre les chutes dans le cas ou on recoit un choc. Ne jamais  
enrouler le câble-électrode autour de n’importe quelle partie  
du corps.  
PRÉCAUTIONS DE SÛRETÉ POUR  
LES MACHINES À SOUDER À  
TRANSFORMATEUR ET À  
REDRESSEUR  
3. Un coup d’arc peut être plus sévère qu’un coup de soliel,  
donc:  
a. Utiliser un bon masque avec un verre filtrant approprié  
ainsi qu’un verre blanc afin de se protéger les yeux du ray-  
onnement de l’arc et des projections quand on soude ou  
quand on regarde l’arc.  
1. Relier à la terre le chassis du poste conformement au code de  
l’électricité et aux recommendations du fabricant. Le dispositif  
de montage ou la piece à souder doit être branché à une  
bonne mise à la terre.  
b. Porter des vêtements convenables afin de protéger la  
peau de soudeur et des aides contre le rayonnement de  
l‘arc.  
2. Autant que possible, I’installation et l’entretien du poste seront  
effectués par un électricien qualifié.  
c. Protéger l’autre personnel travaillant à proximité au  
soudage à l’aide d’écrans appropriés et non-inflammables.  
3. Avant de faires des travaux à l’interieur de poste, la debranch-  
er à l’interrupteur à la boite de fusibles.  
4. Des gouttes de laitier en fusion sont émises de l’arc de  
soudage. Se protéger avec des vêtements de protection libres  
de l’huile, tels que les gants en cuir, chemise épaisse, pan-  
talons sans revers, et chaussures montantes.  
4. Garder tous les couvercles et dispositifs de sûreté à leur  
place.  
5. Toujours porter des lunettes de sécurité dans la zone de  
soudage. Utiliser des lunettes avec écrans lateraux dans les  
zones où l’on pique le laitier.  
Download from Www.Somanuals.com. All Manuals Search And Download.  
v
v
SAFETY  
Electromagnetic Compatibility (EMC)  
Conformance  
Products displaying the CE mark are in conformity with European Community Council Directive of 15 Dec  
2004 on the approximation of the laws of the Member States relating to electromagnetic compatibility,  
2004/108/EC. It was manufactured in conformity with a national standard that implements a harmonized  
standard: EN 60974-10 Electromagnetic Compatibility (EMC) Product Standard for Arc Welding Equipment.  
It is for use with other Lincoln Electric equipment. It is designed for industrial and professional use.  
Introduction  
All electrical equipment generates small amounts of electromagnetic emission. Electrical emission may be  
transmitted through power lines or radiated through space, similar to a radio transmitter. When emissions  
are received by other equipment, electrical interference may result. Electrical emissions may affect many  
kinds of electrical equipment; other nearby welding equipment, radio and TV reception, numerical controlled  
machines, telephone systems, computers, etc. Be aware that interference may result and extra precautions  
may be required when a welding power source is used in a domestic establishment.  
Installation and Use  
The user is responsible for installing and using the welding equipment according to the manufacturer’s  
instructions. If electromagnetic disturbances are detected then it shall be the responsibility of the user of the  
welding equipment to resolve the situation with the technical assistance of the manufacturer. In some cases  
this remedial action may be as simple as earthing (grounding) the welding circuit, see Note. In other cases it  
could involve construction of an electromagnetic screen enclosing the power source and the work complete  
with associated input filters. In all cases electromagnetic disturbances must be reduced to the point where  
they are no longer troublesome.  
Note: The welding circuit may or may not be earthed for safety reasons according to national codes.  
Changing the earthing arrangements should only be authorized by a person who is compe-  
tent to access whether the changes will increase the risk of injury, e.g., by allowing parallel  
welding current return paths which may damage the earth circuits of other equipment.  
Assessment of Area  
Before installing welding equipment the user shall make an assessment of potential electromagnetic prob-  
lems in the surrounding area. The following shall be taken into account:  
a) other supply cables, control cables, signaling and telephone cables; above, below and adjacent to the  
welding equipment;  
b) radio and television transmitters and receivers;  
c) computer and other control equipment;  
d) safety critical equipment, e.g., guarding of industrial equipment;  
e) the health of the people around, e.g., the use of pacemakers and hearing aids;  
f) equipment used for calibration or measurement  
g) the immunity of other equipment in the environment. The user shall ensure that other equipment being  
used in the environment is compatible. This may require additional protection measures;  
h) the time of day that welding or other activities are to be carried out.  
AIR VANTAGE® 500 CUMMINS  
Download from Www.Somanuals.com. All Manuals Search And Download.  
vi  
vi  
SAFETY  
Electromagnetic Compatibility (EMC)  
The size of the surrounding area to be considered will depend on the structure of the building and other  
activities that are taking place. The surrounding area may extend beyond the boundaries of the premises.  
Methods of Reducing Emissions  
Mains Supply  
Welding equipment should be connected to the mains supply according to the manufacturer’s recommenda-  
tions. If interference occurs, it may be necessary to take additional precautions such as filtering of the mains  
supply. Consideration should be given to shielding the supply cable of permanently installed welding equip-  
ment, in metallic conduit or equivalent. Shielding should be electrically continuous throughout its length. The  
shielding should be connected to the welding power source so that good electrical contact is maintained  
between the conduit and the welding power source enclosure.  
Maintenance of the Welding Equipment  
The welding equipment should be routinely maintained according to the manufacturer’s recommendations.  
All access and service doors and covers should be closed and properly fastened when the welding equip-  
ment is in operation. The welding equipment should not be modified in any way except for those changes  
and adjustments covered in the manufacturers instructions. In particular, the spark gaps of arc striking and  
stabilizing devices should be adjusted and maintained according to the manufacturer’s recommendations.  
Welding Cables  
The welding cables should be kept as short as possible and should be positioned close together, running at  
or close to floor level.  
Equipotential Bonding  
Bonding of all metallic components in the welding installation and adjacent to it should be considered.  
However, metallic components bonded to the work piece will increase the risk that the operator could  
receive a shock by touching these metallic components and the electrode at the same time. The operator  
should be insulated from all such bonded metallic components.  
Earthing of the Workpiece  
Where the workpiece is not bonded to earth for electrical safety, not connected to earth because of its size  
and position, e.g., ships hull or building steelwork, a connection bonding the workpiece to earth may reduce  
emissions in some, but not all instances. Care should be taken to prevent the earthing of the workpiece  
increasing the risk of injury to users, or damage to other electrical equipment. Where necessary, the connec-  
tion of the workpiece to earth should be made by a direct connection to the workpiece, but in some countries  
where direct connection is not permitted, the bonding should be achieved by suitable capacitance, selected  
according to national regulations.  
Screening and Shielding  
Selective screening and shielding of other cables and equipment in the surrounding area may alleviate prob-  
lems of interference. Screening of the entire welding installation may be considered for special  
1.  
applications  
_________________________  
1
Portions of the preceding text are contained in EN 60974-10: “Electromagnetic Compatibility (EMC) prod-  
uct standard for arc welding equipment.”  
AIR VANTAGE® 500 CUMMINS  
Download from Www.Somanuals.com. All Manuals Search And Download.  
vii  
vii  
for selecting a QUALITY product by Lincoln Electric. We want you  
to take pride in operating this Lincoln Electric Company product  
••• as much pride as we have in bringing this product to you!  
Thank You  
CUSTOMER ASSISTANCE POLICY  
The business of The Lincoln Electric Company is manufacturing and selling high quality welding equipment, consumables, and cutting equip-  
ment. 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 posses-  
sion at that time. Lincoln Electric is not in a position to warrant or guarantee such advice, and assumes no liability, with respect to such infor-  
mation or advice. We expressly disclaim any warranty of any kind, including any warranty of fitness for any customer’s particular purpose,  
with respect to such information or advice. As a matter of practical consideration, we also cannot assume any responsibility for updating or  
correcting any such information or advice once it has been given, nor does the provision of information or advice create, expand or alter any  
warranty with respect to the sale of our products.  
Lincoln Electric is a responsive manufacturer, but the selection and use of specific products sold by Lincoln Electric is solely within the control  
of, and remains the sole responsibility of the customer. Many variables beyond the control of Lincoln Electric affect the results obtained in  
applying these types of fabrication methods and service requirements.  
Subject to Change – This information is accurate to the best of our knowledge at the time of printing. Please refer to 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.  
• For faxing: Complete the form on the back of the warranty statement included in the literature packet  
accompanying this machine and fax the form per the instructions printed on it.  
• For On-Line Registration: Go to our WEbꢀSITE at www.lincolnelectric.com. Choose “Quick Links” and then  
“Product Registration”. Please complete the form and submit your registration.  
Read this Operators Manual completely before attempting to use this equipment. Save this manual and keep it  
handy for quick reference. Pay particular attention to the safety instructions we have provided for your protection.  
The level of seriousness to be applied to each is explained below:  
WARNING  
This statement appears where the information must be followed exactly to avoid serious personal injury or loss of life.  
CAUTION  
This statement appears where the information must be followed to avoid minor personal injury or damage to this equipment.  
Download from Www.Somanuals.com. All Manuals Search And Download.  
viii  
viii  
TAbLE OF CONTENTS  
Page  
Installation.......................................................................................................................Section A  
Technical Specifications.......................................................................................................A-1  
Safety Precautions........................................................................................................A-2  
Location and 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 and Fuel Cap.........................................................................................................A-4  
Engine Coolant System.................................................................................................A-4  
Battery Connections......................................................................................................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 and Standby Power Connections...................................A-6, A-7  
Connection of Lincoln Electric Wire Feeders................................................................A-8, A-9  
________________________________________________________________________________  
Operation.........................................................................................................................Section b  
Safety Precautions ..............................................................................................................B-1  
General Description..............................................................................................................B-1  
Recommended Application - Welder, Air Compressor and Generator.................................B-1  
Controls and Settings ...........................................................................................................B-2  
Engine Controls.....................................................................................................B-2, B-3  
Welder Controls.....................................................................................................B-3, B-4  
Auxiliary Power Controls...............................................................................................B-4  
Air Compressor Controls...............................................................................................B-5  
Battery Jump Start Terminals........................................................................................B-5  
Engine Operation .................................................................................................................B-6  
Engine the Engine.........................................................................................................B-6  
Cold Weather Starting...................................................................................................B-6  
Stopping the Engine......................................................................................................B-6  
Break-In Period .............................................................................................................B-6  
Typical Fuel Consumption.............................................................................................B-6  
Welding Operation................................................................................................................B-7  
Duty Cycle.....................................................................................................................B-7  
Stick Welding Mode ......................................................................................................B-7  
CC-Stick Mode..............................................................................................................B-7  
Downhill Pipe Mode ......................................................................................................B-7  
Touch Start TIG Mode...................................................................................................B-7  
AIR VANTAGE® Settings when using K930-2 TIG Module..........................................B-7  
Wire Welding-CV..................................................................................................................B-8  
Arc Gouging .........................................................................................................................B-8  
Typical Current Ranges for Tungsten Electrodes ................................................................B-8  
Paralleling.............................................................................................................................B-9  
Auxiliary Power Operation....................................................................................................B-9  
Simultaneous Welding and Auxiliary Power Loads..............................................................B-9  
Simultaneous Welding and Power Loads, Extension Cord Length Recommendations.......B-9  
Download from Www.Somanuals.com. All Manuals Search And Download.  
ix  
ix  
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  
Compressor 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-3  
Nameplate / Warning Decal Maintenance.............................................................D-4  
Welder / Generator Maintenance ..........................................................................D-4  
GFCI Receptacle Testing and Reseting Procedure ..............................................D-4  
Engine Maintenance Components ........................................................................D-4  
________________________________________________________________________  
Troubleshooting..............................................................................................Section E  
________________________________________________________________________  
Connection Diagrams, Wiring Diagrams and Dimension Print...................Section F  
________________________________________________________________________  
Parts List.....................................................................................................P-659 Series  
________________________________________________________________________  
Download from Www.Somanuals.com. All Manuals Search And Download.  
A-1  
A-1  
INSTALLATION  
TECHNICAL SPECIFICATIONS - AIR VANTAGE® 500 CUMMINS (K2325-3)  
INPUT - DIESEL ENGINE  
Displacement  
cu. in. (ltrs.)  
Make/Model  
Description  
Speed (RPM)  
Starting  
System  
Capacities  
4 cylinder  
56 HP (42kw)  
1800 RPM  
Diesel Engine  
High Idle 1900  
199(3.3)  
12VDC Battery &  
starter  
Fuel: 25 gal.  
(94.6 L)  
Oil: 2 gal. (7.5L)  
Cummins  
B3.3  
Full Load 1800 Bore x Stroke inch (mm)  
Low Idle 1425  
3.74 X 4.53  
(95 x 115mm)  
Radiator Coolant:  
2.6gal. (9.8L)  
RATED OUTPUT @ 104°F(40°C) - WELDER  
Welding Output  
Duty Cycle  
Volts at Rated Amps  
100%  
60%  
50%  
500 Amps (DC multi-purpose)  
550 Amps (DC multi-purpose)  
575 Amps (DC multi-purpose)  
40 Volts  
36 volts  
35 volts  
OUTPUT @ 104°F(40°C) - WELDER AND GENERATOR  
Welding Range  
30 - 575 Amps CC/CV  
20 - 250 Amps TIG  
Open Circuit Voltage  
60 Max OCV @ 1900 RPM  
Auxiliary Power (1)  
120/240 VAC  
12,000 WATTS, 60 Hz., Single Phase  
20,000 WATTS, 60 Hz., Three Phase  
COMPRESSOR SPECIFICATIONS  
Compressor Model  
Description  
Delivary  
Maximum System Compressor  
Pressure Profection  
150 PSI  
Capacities  
VMAC™  
S700157  
Belt-Drive Rotary  
High Idle Mode:  
Safety Relief Valve 1.3 gal.(5.0 ltrs)  
200 PSI  
2
Screw Air Compressor 60 CFM @ 100PSI  
(28.3 Ltr/sec. @  
(10.5 kg/cm )  
2
(10.5 kg/cm )  
7.0 kg/cm)  
Low Idle Mode:  
40 CFM @ 100PSI  
(18.9 Ltr/sec. @  
7.0 kg/cm)  
High Temperature  
Automatic Shutdown  
290° F (143°C)  
PHYSICAL DIMENSIONS  
Depth  
Height (2)  
Width  
Weight  
42.0 in  
(1066.8 mm)  
32.7 in.  
(830.1mm)  
63.1 in.  
(1603mm)  
1690 lbs.  
(766kg)  
(Approx)  
1.  
2.  
Output rating in watts is equivalent to volt-amperes at unity power factor.  
Output voltage is within +/- 10% at all loads up to rated capacity. When welding, available auxiliary power will be reduced.  
Top of Enclosure, add 7.0” (177.8mm) for exhaust pipe.  
AIR VANTAGE® 500 CUMMINS  
Download from Www.Somanuals.com. All Manuals Search And Download.  
A-2  
A-2  
INSTALLATION  
SAFETY PRECAUTIONS  
LOCATION AND VENTILATION  
WARNING  
The welder should be located to provide an unrestrict-  
ed flow of clean, cool air to the cooling air inlets and to  
avoid restricting the cooling air outlets. Also, locate  
the welder so that the engine exhaust fumes are prop-  
erly vented to an outside area.  
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 precautions, detailed engine  
starting, operating and maintenance instructions,  
and parts lists.  
CAUTION  
------------------------------------------------------------------------  
ELECTRIC SHOCK can kill.  
DO NOT MOUNT OVER COMbUSTIbLE SURFACES  
Where there is a combustible surface directly  
under stationary or fixed electrical equipment, that  
surface should be covered with a steel plate at  
least .06”(1.6mm) thick, which should extend not  
less than 5.90”(150mm) beyond the equipment on  
all sides.  
• Do not touch electrically live parts or  
electrode with skin or wet clothing.  
• Insulate yourself from work and  
ground  
• Always wear dry insulating gloves.  
------------------------------------------------------------------------  
ENGINEꢀEXHAUSTꢀcan kill.  
• Use in open, well ventilated areas or  
vent exhaust outside.  
------------------------------------------------------------------------  
STORING  
------------------------------------------------------------------------  
MOVING PARTSꢀcan injure.  
1. Store the machine in a cool, dry place when it is  
not in use. Protect it from dust and dirt. Keep it  
where it can’t be accidentally damaged from con-  
struction activities, moving vehicles, and other  
hazards.  
• Do not operate with doors open or  
guards off.  
• Stop engine before servicing.  
• Keep away from moving parts.  
------------------------------------------------------------------------  
See additional warning information at  
front of this operator’s manual.  
2. Drain the engine oil and refill with fresh 10W30  
oil. Run the engine for about five minutes to cir-  
culate oil to all the parts. See the MAINTE-  
NANCE section of this manual for details on  
changing oil.  
Only qualified personnel should install,  
use, or service this equipment.  
3. Remove the battery, recharge it, and adjust the  
electrolyte level. Store the battery in a dry, dark  
place.  
STACKING  
AIR VANTAGE® 500 CUMMINS machines cannot be  
stacked.  
ANGLE OF OPERATION  
To achieve optimum engine performance the Air  
Vantage 500 CUMMINS should be run in a level posi-  
tion. The maximum angle of operation for the VMAC  
Compressor and CUMMINS engine is 20 degrees  
continues in all directions and 30 degrees intermittent  
(less than 10 minutes). 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  
Download from Www.Somanuals.com. All Manuals Search And Download.  
A-3  
A-3  
INSTALLATION  
TOWING  
LIFTING  
The recommended trailer for use with this equipment  
(1)  
for road, in-plant and yard towing by a vehicle is  
The AIR VANTAGE® 500 CUMMINS lift bale should be  
used to lift the machine. The Air Vantage 500 is  
shipped with the lift bale retracted. Before attempting  
to lift the AIR VANTAGE® 500 CUMMINS the lift bale  
must be secured in a raised position. Secure the lift  
bale as follows:  
Lincoln’s K2636-1. If the user adapts a non-Lincoln  
trailer, he must assume responsibility that the method  
of attachment and usage does not result in a safety  
hazard nor damage the welding equipment. Some of  
the factors to be considered are as follows:  
a. Open the engine compartment door.  
1. Design capacity of trailer vs. weight of Lincoln  
equipment and likely additional attachments.  
b. Locate the 2 access holes on the upper middle  
region of compartment wall just below the lift  
bale.  
2. Proper support of, and attachment to, the base of  
the welding equipment so that there will be no  
undue stress to the trailer’s framework.  
c. Use the lifting strap to raise the lift bale to the  
full upright position. This will align the mount-  
ing holes on the lift bale with the access holes.  
3. Proper placement of the equipment on the trailer  
to insure stability side to side and front to back  
when being moved and when standing by itself.  
d. Secure the lift bale with 2 thread forming  
screws. The screws are provided in the  
shipped loose parts bag.  
4. Typical conditions of use, such as travel speed,  
roughness of surface on which the trailer will be  
operated, and environmental conditions.  
WARNING  
5. Proper preventative maintenance of trailer.  
6. Conformance with federal, state and local laws(1).  
• Lift only with equipment of ade-  
quate lifting capacity.  
(1) Consult applicable federal, state and local laws regarding  
specific requirements for use on public highways.  
• be sure machine is stable when lift-  
ing.  
• Do not lift this machine using lift  
bail if it is equipped with a heavy  
accessory such as trailer or gas  
cylinder.  
VEHICLE MOUNTING  
WARNING  
FALLING  
• Do not lift machine if lift bail is  
damaged.  
EQUIPMENT can  
cause injury.  
Improperly mounted concentrated loads may  
cause unstable vehicle handling and tires or other  
components to fail.  
• Do not operate machine while  
suspended from lift bail.  
------------------------------------------------------------------------  
• Only transport this Equipment on serviceable  
vehicles which are rated and designed for such  
loads.  
• Distribute, balance and secure loads so vehicle  
is stable under conditions of use.  
• Do not exceed maximum rated loads for compo-  
nents such as suspension, axles and tires.  
• Mount equipment base to metal bed or frame of  
vehicle.  
• Follow vehicle manufacture’s instructions.  
------------------------------------------------------------------------  
HIGH ALTITUDE OPERATION  
At higher altitudes, output derating may be necessary.  
For maximum rating, derate the welder output 4% for  
every 300 meters (984 ft.) above 1500 meters (4920  
ft.). For output of 500A and below, derate the welder  
output 4% for every 300 meters (984 ft.) above 2100  
meters (6888 ft.).  
Contact a Cummins Service Representative for any  
engine adjustments that may be required.  
HIGH TEMPERATURE OPERATION  
At temperatures above 40°C (104°F), output voltage  
derating may be necessary. For maximum output cur-  
rent ratings, derate welder voltage rating 2 volts for  
every 10°C (21°F) above 40°C (104°F).  
AIR VANTAGE® 500 CUMMINS  
Download from Www.Somanuals.com. All Manuals Search And Download.  
A-4  
A-4  
INSTALLATION  
PRE-OPERATION ENGINE AND COM-  
PRESSOR SERVICE  
ENGINE COOLANT  
WARNING  
READ the engine and compressor operating and  
maintenance instructions supplied with this machine.  
HOT COOLANT can burn skin.  
•Do not remove cap if radiator is hot.  
WARNING  
• Keep hands away from the engine  
muffler or HOT engine parts.  
------------------------------------------------------------------------  
The welder is shipped with the engine and radiator  
filled with a 50% mixture of ethylene glycol and water.  
See the MAINTENANCE section and the engine  
Operator’s Manual for more information on coolant.  
• Stop engine and allow to cool before  
fuelling.  
• Do not smoke when fuelling.  
• Fill fuel tank at a moderate rate and do not over-  
fill.  
bATTERY CONNECTION  
• Wipe up spilled fuel and allow fumes to clear  
before starting engine.  
WARNING  
GASES FROM bATTERY can explode.  
• Keep sparks and flame away from tank.  
------------------------------------------------------------------------  
• Keep sparks, flame and cigarettes  
away from battery.  
OIL  
To prevent EXPLOSION when:  
The AIR VANTAGE® 500 CUMMINS is shipped with  
the engine crankcase filled with high quality SAE  
10W-30 oil (API class CD or better). Check the engine  
and compressor oil levels before starting the engine. If  
it is not up to the full mark on the dip stick, add oil as  
required. Check the oil level every four hours of run-  
ning time during the first 35 running hours. Refer to  
the engine and compressor Operator’s Manuals for  
specific oil recommendations and break-in informa-  
tion. The oil change interval is dependent on the quali-  
ty of the oil and the operating environment. Refer to  
the engine and compressor Operator’s Manuals for  
the proper service and maintenance intervals.  
• INSTALLING A NEW bATTERY — disconnect  
negative cable from old battery first and connect  
to new battery last.  
• CONNECTING A bATTERY CHARGER — remove  
battery from welder by disconnecting negative  
cable first, then positive cable and battery clamp.  
When reinstalling, connect negative cable last.  
Keep well ventilated.  
• USING A bOOSTER — connect positive lead to  
battery first then connect negative lead to nega-  
tive battery lead at engine foot.  
bATTERY ACID can burn eyes and skin.  
FUEL USE DIESEL FUEL ONLY  
• Wear gloves and eye protection and  
be careful when working near battery.  
• Follow instructions printed on battery.  
• Fill the fuel tank with clean, fresh diesel fuel. The  
capacity of the fuel tank is approximately 25 gallons  
(95 liters). See engine Operator’s Manual for specif-  
ic fuel recommendations. Running out of fuel may  
require bleeding the fuel injection pump.  
------------------------------------------------------------------------  
IMPORTANT: To prevent ELECTRICAL DAMAGE  
WHEN:  
NOTE: Before starting the engine, open the fuel shut-  
off valve (pointer to be in line with hose).  
a) Installing new batteries.  
b) Using a booster.  
FUEL CAP  
Use correct polarity — Negative Ground.  
Remove the plastic cap covering from the Fuel Tank  
Filler neck and install the Fuel Cap.  
AIR VANTAGE® 500 CUMMINS  
Download from Www.Somanuals.com. All Manuals Search And Download.  
A-5  
A-5  
INSTALLATION  
The AIR VANTAGE® 500 CUMMINS 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.  
Listed in Table A.1 are copper cable sizes recom-  
mended for the rated current and duty cycle. Lengths  
stipulated are the distance from the welder to work  
and back to the welder again. Cable sizes are  
increased for greater lengths primarily for the purpose  
of minimizing cable voltage drop.  
Remove the insulating cap from the negative battery  
terminal. Replace and tighten negative battery cable  
terminal. NOTE: This machine is furnished with a wet  
charged battery; if unused for several months, the bat-  
tery may require a booster charge. Be sure to use the  
correct polarity when charging the battery.  
Table A.1 Combined Length of Electrode and  
Work Cables.  
TOTAL COMbINED LENGTH OF  
ELECTRODE AND WORK CAbLES  
Cable Size for  
500 Amps  
Cable Length  
MUFFLER OUTLET PIPE  
100% Duty Cycle  
2)  
Remove the plastic plug covering the muffler outlet  
tube. Using the clamp provided secure the outlet pipe  
to the outlet tube with the pipe positioned such that it  
will direct the exhaust in the desired position.  
0-150 Ft. (0-46 meters)  
150-200 Ft. (46-61 meters)  
200-250 Ft. (61-76 meters)  
3/0 AWG (95mm  
2)  
3/0 AWG (95mm  
2)  
4/0 AWG(120mm  
MACHINE GROUNDING  
SPARK ARRESTOR  
Because this portable engine driven welder creates its  
own power, it is not necessary to connect its frame to  
an earth ground, unless the machine is connected to  
premises wiring (home, shop, etc.).  
Some federal, state or local laws may require that  
petrol or diesel engines be equipped with exhaust  
spark arrestors when they are operated in certain  
locations where unarrested sparks may present a fire  
hazard. The standard muffler included with this welder  
has an internal spark arrestor. When required by local  
regulations, a suitable spark arrestor, must be  
installed and properly maintained.  
To prevent dangerous electric shock, other equipment  
to which this engine driven welder supplies power  
must:  
WARNING  
CAUTION  
• be grounded to the frame of the welder using a  
grounded type plug or be double insulated.  
• Do not ground the machine to a pipe that carries  
explosive or combustible material.  
An incorrect arrestor may lead to damage to the  
engine or adversely affect performance.  
------------------------------------------------------------------------  
AIR CLEANER INLET HOOD  
Remove the plastic plug covering the air cleaner inlet.  
Install the air cleaner inlet hood to the air cleaner.  
------------------------------------------------------------------------  
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 con-  
nected 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 sec-  
tion entitled “Standby Power Connections” as well as  
the article on grounding in the latest National  
Electrical Code and the local codes.  
WELDING TERMINALS  
The AIR VANTAGE® 500 CUMMINS is equipped with  
a toggle switch for selecting "hot" welding terminals  
when in the "WELD TERMINALS ON" position or  
"cold" welding terminals when in the "REMOTELY  
CONTROLLED" position.  
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 frame-  
work of a building which has been effectively ground-  
ed.  
WELDING OUTPUT CAbLES  
With the engine off, route the electrode and work  
cables thru the strain relief bracket provided on the  
front of the base and connect to the terminals provid-  
ed. These connections should be checked periodically  
and tightened if necessary.  
The National Electric Code lists a number of alternate  
means of grounding electrical equipment. A machine  
grounding stud marked with the symbol  
on the front of the welder.  
is provided  
AIR VANTAGE® 500 CUMMINS  
Download from Www.Somanuals.com. All Manuals Search And Download.  
A-6  
A-6  
INSTALLATION  
The AIR VANTAGE® 500 CUMMINS 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.  
REMOTE CONTROL  
The AIR VANTAGE® 500 CUMMINS 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-WIRE  
modes and when a remote control is connected to the  
6-pin Connector, the auto-sensing circuit automatically  
switches the OUTPUT control from control at the  
welder to remote control.  
When in the DOWNHILL PIPE mode and when a  
remote control is connected to the 6-Pin or 14-Pin  
connector, the output control is used to set the maxi-  
mum current range of the remote.  
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 con-  
nected to different phases and can not be paralleled.  
EXAMPLE: When the OUTPUT CONTROL on the  
welder is set to 200 amps the current range on the  
remote control will be 40-200 amps, rather than the  
full 40-300 amps. Any current range that is less than  
the full range provides finer current resolution for more  
fine tuning of the output.  
STANDbY POWER CONNECTIONS  
The AIR VANTAGE® 500 CUMMINS is suitable for  
temporary, standby or emergency power using the  
engine manufacturer’s recommended maintenance  
schedule.  
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 con-  
nector, the auto-sensing circuit automatically makes  
the Output Control inactive and the wire feeder volt-  
age control active.  
The AIR VANTAGE® 500 CUMMINS can be perma-  
nently installed as a standby power unit for 240 volt-3  
wire, 50 amp service. Connections must be made by a  
licensed electrician who can determine how the  
120/240 VAC power can be adapted to the particular  
installation and comply with all applicable electrical  
codes. The following information can be used as a  
guide by the electrician for most applications. Refer to  
the connection diagram shown in Figure A.1.  
WARNING  
NOTE: When a wire feeder with a built in welding  
voltage control is connected to the 14-pin connec-  
tor, do not connect anything to the 6-pin connec-  
tor.  
1. Install the double-pole, double-throw switch  
between the power company meter and the premis-  
es disconnect.  
------------------------------------------------------------------------  
AUXILIARY POWER RECEPTACLES  
Start the engine and set the “IDLER” control switch to  
the “High Idle” mode. Voltage is now correct at the  
receptacles for auxiliary power. This must be done  
before a tripped GFCI receptacle can be reset proper-  
ly. See the MAINTENANCE section for detailed infor-  
mation on testing and resetting the GFCI receptacle.  
Switch rating must be the same or greater than the  
customer’s premises disconnect and service over cur-  
rent protection.  
The auxiliary power capacity of the AIR VANTAGE®  
500 CUMMINS 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 per-  
missible 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 per-  
missible current of 50 A per output to two separate  
120 VAC branch circuits. The output voltage is within  
± 10% at all loads up to rated capacity.  
AIR VANTAGE® 500 CUMMINS  
Download from Www.Somanuals.com. All Manuals Search And Download.  
A-7  
A-7  
INSTALLATION  
2. Take necessary steps to assure load is limited to  
the capacity of the AIR VANTAGE® 500 CUMMINS  
by installing a 50 amp, 240 VAC double pole circuit  
breaker. Maximum rated load for each leg of the  
240 VAC auxiliary is 50 amps. Loading above the  
rated output will reduce output voltage below the  
allowable -10% of rated voltage which may damage  
appliances or other motor-driven equipment and  
may result in overheating of the AIR VANTAGE®  
500 CUMMINS engine.  
3. Install a 50 amp 120/240 VAC plug (NEMA Type  
14-50) to the double-pole circuit breaker using No.  
6, 4 conductor cable of the desired length. (The 50  
amp, 120/240 VAC plug is available in the optional  
K802R plug kit.)  
4. Plug this cable into the 50 Amp 120/240 Volt recep-  
tacle on the AIR VANTAGE® 500 CUMMINS case  
front.  
Figure A.1 Connection of the AIR VANTAGE® 500 to Premises Wiring  
240 VOLT  
GROUNDED CONDUCTOR  
POWER  
240 Volt  
60 Hz.  
3-Wire  
Service  
120 VOLT  
COMPANY  
120 VOLT  
METER  
NEUTRAL  
BUS  
N
LOAD  
DOUBLE POLE DOUBLE THROW  
SWITCH RATING TO BE THE SAME  
AS OR GREATER THAN PREMISES  
SERVICE OVERCURRENT  
PROTECTION.  
PREMISES  
DISCONNECT AND  
SERVICE  
OVERCURRENT  
PROTECTION  
GROUND  
50AMP  
240 VOLT  
DOUBLE  
POLE  
CIRCUIT  
BREAKER  
50 AMP, 120/240  
VOLT PLUG  
NEMA TYPE 14-50  
240 VOLT  
GND  
N
50 AMP, 120/240 VOLT  
RECEPTACLE  
NOTE: No. 6 COPPER CONDUCTOR CABLE SEE  
NATIONAL ELECTRICAL CODE FOR ALTERNATE WIRE  
SIZE RECOMMENDATIONS.  
AIR VANTAGE® 500 CUMMINS  
Download from Www.Somanuals.com. All Manuals Search And Download.  
A-8  
A-8  
INSTALLATION  
CONNECTION OF LINCOLN ELEC-  
TRIC WIRE FEEDERS  
• Set the "WELD TERMINALS" switch to "WELD  
TERMINALS ON".  
WARNING  
• When the gun trigger is closed, the current sens-  
ing circuit will cause the AIR VANTAGE® 500  
CUMMINS engine to go to the high idle speed,  
the wire will begin to feed and the welding  
process started. When welding is stopped, the  
engine will revert to low idle speed after approxi-  
mately 12 seconds unless welding is resumed.  
Shut off welder before making any electrical con-  
nections.  
------------------------------------------------------------------------  
Connection of LN-7, LN-8 OR LN-742 to the AIR  
VANTAGE® 500 CUMMINS  
1. Shut the welder off.  
4. Control Cable Model:  
2. Connect the LN-7, LN-8 OR LN-742 per instruc-  
tions on the appropriate connection diagram in  
Section F.  
• Connect Control Cable between Engine Welder  
and Feeder.  
• Set the "WELD TERMINALS" switch to  
"REMOTELY CONTROLLED"  
3. Set the "WIRE FEEDER VOLTMETER" switch to  
either "+" or "-" as required by the electrode being  
used.  
• Set the MODE switch to the "CV-WIRE " position.  
4. Set the "MODE" switch to the "CV WIRE " posi-  
tion.  
5. Set the "ARC CONTROL" knob to "0" initially and  
adjust to suit.  
• Set the "WIRE FEEDER VOLTMETER" switch to  
either "+" or "-" as required by the electrode polar-  
ity being used.  
• Set the "ARC CONTROL" knob to "0" initially and  
adjust to suit.  
6. Set the "WELD TERMINALS" switch to the  
"REMOTELY CONTROLLED" position.  
• Set the "IDLE" switch to the "AUTO" position.  
7. Set the "IDLE" switch to the "HIGH" position.  
• When the gun trigger is closed, the current sens-  
ing circuit will cause the AIR VANTAGE® 500  
CUMMINS engine to go to the high idle speed,  
the wire will begin to feed and the welding  
process started. When welding is stopped, the  
engine will revert to low idle speed after approxi-  
mately 12 seconds unless welding is resumed.  
Connection of LN-15 to the AIR VANTAGE® 500  
CUMMINS  
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.  
1. Shut the welder off.  
2. For electrode Positive, connect the electrode  
cable to the "+" terminal of the welder and work  
cable to the "-" terminal of the welder. For elec-  
trode Negative, connect the electrode cable to the  
"-" terminal of the welder and work cable to the "+"  
terminal of the welder.  
3. 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.  
AIR VANTAGE® 500 CUMMINS  
Download from Www.Somanuals.com. All Manuals Search And Download.  
A-9  
A-9  
CONNECTION OF AN NA-3 AUTOMATIC  
WELDING SYSTEM TO THE AIR VAN-  
TAGE® 500 CUMMINS  
INSTALLATION  
CONNECTION OF THE LN-25 TO THE AIR  
VANTAGE® 500 CUMMINS.  
WARNING  
For connection diagrams and instructions for connect-  
ing an NA-3 Welding System to the AIR VANTAGE®  
500 CUMMINS, refer to the NA-3 Welding System  
instruction manual. The connection diagram for the  
LN-8 can be used for connecting the NA-3.  
Shut off welder before making any electrical con-  
nections.  
--------------------------------------------------------------------------  
The LN-25 with or without an internal contactor may be  
used with the AIR VANTAGE® 500 CUMMINS. See the  
appropriate connection diagram in Section F.  
NOTE: The LN-25 (K431) Remote Control Module and  
(K432) Remote Cable are not recommended for use  
with the AIR VANTAGE® 500 CUMMINS.  
• Set the Wire Feeder Voltage Switch to 115V.  
CONNECTION OF MAGNUM SC SPOOL  
GUN TO THE AIR VANTAGE® 500 CUM-  
MINS (SEE SECTION F)  
1. Shut the welder off.  
Spool Gun (K487-25) and Cobramatic to AIR VAN-  
TAGE® 500 CUMMINS  
2. For electrode Positive, connect the electrode cable  
from the LN-25 to the "+" terminal of the welder and  
work cable to the "-" terminal of the welder. For  
electrode Negative, connect the electrode cable  
from the LN-25 to the "-" terminal of the welder and  
work cable to the "+" terminal of the welder.  
• Shut the welder off.  
• Connect per instructions on the appropriate connec-  
tion diagram in Section F.  
3. Attach the single lead from the front of the LN-25 to  
work using the spring clip at the end of the lead.  
This is a control lead to supply current to the wire  
feeder motor; it does not carry welding current.  
4. Set the MODE switch to the "CV-WIRE " position.  
5. Set the "WELD TERMINALS" switch to "WELD  
TERMINALS ON"  
6. Set the "ARC CONTROL" knob to "0" initially and  
adjust to suit.  
7. Set the "IDLE" switch to the "AUTO" position. When  
not welding, the AIR VANTAGE® 500 CUMMINS  
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.  
8. When the gun trigger is closed, the current sensing  
circuit will cause the AIR VANTAGE® 500 CUM-  
MINS engine to go to the high idle speed, the wire  
will begin to feed and the welding process started.  
When welding is stopped, the engine will revert to  
low idle speed after approximately 12 seconds  
unless welding is resumed.  
CAUTION  
If you are using an LN-25 without an internal con-  
tactor, the electrode will be energized when the AIR  
VANTAGE® 500 CUMMINS is started.  
--------------------------------------------------------------------------  
AIR VANTAGE® 500 CUMMINS  
Download from Www.Somanuals.com. All Manuals Search And Download.  
b-1  
b-1  
OPERATION  
RECOMMENDED APPLICATIONS  
SAFETY PRECAUTIONS  
The AIR VANTAGE® 500 CUMMINS provides excel-  
lent constant current DC welding output for stick  
(SMAW) and TIG welding. The AIR VANTAGE® 500  
CUMMINS also provides excellent constant voltage  
DC welding output for MIG (GMAW), Innershield  
(FCAW), Outershield (FCAW-G) and Metal Core weld-  
ing. In addition the AIR VANTAGE® 500 CUMMINS  
can be used for Arc Gouging with carbons up to  
3/8”(10mm) in diameter.  
Read and understand this entire section before  
operating your AIR VANTAGE® 500 CUMMINS.  
WARNING  
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 precautions, detailed engine starting, operat-  
ing and maintenance instructions, and parts lists.  
------------------------------------------------------------------------  
ELECTRIC SHOCK can kill.  
The AIR VANTAGE® 500 CUMMINS is not recom-  
mended for pipe thawing.  
AIR COMPRESSOR  
The AIR VANTAGE® 500 CUMMINS provides 60 cfm  
at 100 psi.  
compressed air for Arc Gouging and Air powered  
tools.  
• Do not touch electrically live parts or  
electrode with skin or wet clothing.  
• Insulate yourself from work and  
ground  
• Always wear dry insulating gloves.  
--------------------------------------------------------------------------  
ENGINE EXHAUST can kill.  
GENERATOR  
• Use in open, well ventilated areas or  
vent exhaust outside  
• Do not stack anything near the engine.  
------------------------------------------------------------------------  
MOVING PARTS can injure.  
The AIR VANTAGE® 500 provides smooth 120/240 VAC  
single phase and 240V three phase output for auxiliary  
power and emergency standby power.  
• Do not operate with doors open or  
guards off.  
• Stop engine before servicing.  
• Keep away from moving parts  
------------------------------------------------------------------------  
•
Only qualified personnel should operate this  
equipment.  
•
Always operate the welder with the sliding door  
closed and the side panels in place as these pro-  
vide maximum protection from moving parts and  
insure proper cooling air flow.  
GENERAL DESCRIPTION  
The AIR VANTAGE® 500 CUMMINS is a diesel engine-  
driven welding power source. The machine uses a  
brush type alternating current generator for DC multi-  
purpose welding, for 240 VAC single phase. The AIR  
VANTAGE® 500 CUMMINS also has a rotary screw 60  
cfm air compressor built in. The DC welding control sys-  
tem uses state of the art Chopper Technology  
superior welding performance.  
for  
AIR VANTAGE® 500 CUMMINS  
Download from Www.Somanuals.com. All Manuals Search And Download.  
b-2  
b-2  
OPERATION  
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  
3
2
16  
2
14  
1
3
4
5
6
7
3
21  
6
31  
8
11  
3
4
5
13  
12  
7
9
10  
15  
14  
26  
25  
24  
20  
21  
2
1
23  
19  
16  
17  
18  
22  
27  
28  
29  
30  
ENGINE CONTROLS (Items 1 through 9)  
1. RUN STOP SWITCH  
3. HOUR METER  
The hour meter displays the total time that the  
engine has been running. This meter is a useful  
indicator for scheduling preventive maintenance.  
Toggling the switch to the RUN position energizes  
the fuel solenoid for approximately 30 seconds.  
The engine must be started within that time or the  
fuel solenoid will deenergize, and the switch must  
be toggled to reset the timer.  
4. FUEL LEVEL GAUGE  
Displays the level of diesel fuel in the fuel tank.  
The operator must watch the fuel level close-  
ly to prevent running out of fuel and possibly  
having to bleed the system.  
2. START PUSHbUTTON  
Energizes the starter motor to crank the engine.  
With the engine "Run / Stop" switch in the "Run"  
position, push and hold the Start button to crank  
the engine; release as the engine starts. Do not  
press while engine is running since this can  
cause damage to the ring gear and/or starter  
motor.  
5. ENGINE TEMPERATURE GAUGE  
The gauge displays the engine coolant tempera-  
ture.  
AIR VANTAGE® 500 CUMMINS  
Download from Www.Somanuals.com. All Manuals Search And Download.  
b-3  
b-3  
OPERATION  
Idler Operational exceptions  
6. OIL PRESSURE GAUGE  
When the WELDING TERMINALS switch is in  
the “Remotely Controlled” position the idler will  
operate as follows:  
The gauge displays the engine oil pressure when  
the engine is running.  
a. When the triggering device (Amptrol, Arc Start  
Switch, etc.) is pressed the engine will acceler-  
ate and operate at full speed provided a weld-  
ing load is applied within approximately 12  
seconds.  
7. ENGINEꢀPROTECTION  
The yellow engine protection light remains off  
with proper oil pressure and under normal oper-  
ating temperatures. If the light turns on, the  
engine protection system will stop the engine.  
Check for proper oil level and add oil if neces-  
sary. Check for loose or disconnected leads at  
the oil pressure sender located on the engine.  
The light will remain on when the engine has  
been shut down due to low oil pressure or over-  
temperature condition.  
• If the triggering device remains pressed but no  
welding load is applied within approximately 12  
seconds the engine may return to low idle  
speed.  
• If the triggering device is released or welding  
ceases the engine will return to low idle speed  
after approximately 12 seconds.  
WELDING CONTROLS (Items 10  
through 19)  
8. bATTERY CHARGING LIGHT  
The yellow engine alternator light is off when bat-  
tery charging system is functioning normally. If  
light turns on the alternator or the voltage regula-  
tor may not be operating correctly. The light will  
remain on when the engine is stopped and the  
run/stop switch is in the run position.  
10. OUTPUT CONTROL:  
The OUTPUT dial is used to preset the output  
voltage or current as displayed on the digital  
meters for the four welding modes. When in the  
CC-STICK, DOWNHILL PIPE or CV-WIRE  
modes and when a remote control is connected  
to the 6-Pin or 14-Pin Connector, the auto-sens-  
ing circuit automatically switches the OUTPUT  
CONTROL from control at the welder to the  
remote control.  
9. IDLER SWITCH  
Has two positions as follows:  
A) In the “High” position , the engine runs at  
the high idle speed controlled by the governor.  
B) In the “Auto” / position, the  
idler operates as follows:  
In the CV-WIRE mode, when the wire feeder  
control cable is connected to the 14-Pin  
Connector, the auto-sensing circuit automatically  
makes OUTPUT CONTROL inactive and the  
wire feeder voltage control active.  
a. When switched from “High” to “Auto” or after  
starting the engine, the engine will operate at  
full speed for approximately 12 seconds and  
then go to low idle speed.  
When in the DOWNHILL PIPE mode and when  
a remote control is connected to the 6-Pin or 14-  
Pin connector, the output control is used to set  
the maximum current range of the remote.  
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.  
EXAMPLE: When the OUTPUT CONTROL on  
the welder is set to 200 amps the current range  
on the remote control will be 40-200 amps,  
rather than the full 40-300 amps. Any current  
range that is less than the full range provides  
finer current resolution for more fine tuning of  
the output.  
c. When welding ceases and the AC power load  
is turned off, a fixed time delay of approximate-  
ly 12 seconds starts.  
d. If the welding or AC power load is not restart-  
ed before the end of the time delay, the idler  
reduces the engine speed to low idle speed.  
e. The engine will automatically return to high  
idle speed when the welding load or AC power  
load is reapplied.  
When in the TOUCH START TIG mode and  
when a Amptrol is connected to the 6-Pin  
Connector, the OUTPUT dial is used to set the  
maximum current range of the CURRENT CON-  
TROL of the Amptrol.  
AIR VANTAGE® 500 CUMMINS  
Download from Www.Somanuals.com. All Manuals Search And Download.  
b-4  
b-4  
OPERATION  
11. DIGITAL OUTPUT METERS:  
14. WELDING TERMINALS SWITCH  
The digital meters allow the output voltage (CV-WIRE  
mode) or current (CC-STICK, DOWNHILL PIPE and  
TIG modes) to be set prior to welding using the OUT-  
PUT control knob. During welding, the meters display  
the actual output voltage (VOLTS) and current  
(AMPS). A memory feature holds the display of both  
meters on the seven seconds after welding is  
stopped. This allows the operator to read the actual  
current and voltage just prior to when welding was  
ceased. While the display is being held the left-most  
decimal point in each display will be flashing. The  
accuracy of the meters is ± 3%.  
In the WELDꢀTERMINALSꢀON position, the output  
is electrically hot all the time. In the REMOTELY  
CONTROLLED position, the output is controlled by  
a wire feeder or amptrol device, and is electrically  
off until a remote switch is depressed.  
15. WIREꢀFEEDERꢀVOLTMETERꢀSWITCH:  
Matches the polarity of the wire feeder voltmeter to  
the polarity of the electrode.  
16. 6 - PIN CONNECTOR  
For attaching optional remote control equipment.  
Includes auto-sensing remote control circuit.  
12. WELDꢀMODEꢀSELECTORꢀSWITCH:  
(Provides four selectable welding modes)  
CV-WIRE  
17. 14 - PIN CONNECTOR  
For attaching wire feeder control cables. Includes  
contactor closure circuit, auto-sensing remote con-  
trol circuit, and 120VAC and 42VAC power.  
DOWNHILL PIPE  
CC-STICK  
TOUCH START TIG  
NOTE: When a wire feeder with a built in welding  
voltage control is connected to the 14-pin connec-  
tor, do not connect anything to the 6-pin connec-  
tor.  
13. ARCꢀCONTROL:  
The ARCꢀCONTROL WIRE/STICK knob is active in  
the WIRE and STICK modes, and has different func-  
tions in these modes. This control is not active in the  
TIG mode.  
18. WELD OUTPUT TERMINALS + AND -  
CC-STICK mode: In this mode, the ARC CONTROL  
knob sets the short circuit current (arc-force) during  
stick welding. Increasing the number from -10(Soft)  
to +10(Crisp) increases the short circuit current and  
prevents sticking of the electrode to the plate while  
welding. This can also increase spatter. It is recom-  
mended that the ARCꢀCONTROL be set to the mini-  
mum number without electrode sticking. Start with a  
setting at 0.  
These 1/2” - 13 studs with flange nuts provide  
welding connection points for the electrode and  
work cables. For positive polarity welding the elec-  
trode cable connects to the “+” terminal and the  
work cable connects to this “-” terminal. For nega-  
tive polarity welding the work cable connects to the  
“+” terminal and the electrode cable connects to  
this “-” terminal.  
DOWNHILL PIPE mode: In this mode, the ARC  
CONTROL knob sets the short circuit current (arc-  
force) during stick welding to adjust for a soft or a  
more forceful digging arc (Crisp). Increasing the num-  
ber 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 depo-  
sition (“stacking” of iron) are key to fast travel  
speeds. It is recommended that the ARC CONTROL  
be set initially at 0.  
AUXILIARY POWER CONTROLS  
(Items 19-23)  
19. 120/240 VAC SINGLE PHASE RECEPTACLE  
This is a 120/240VAC (14-50R) receptacle that  
provides 240VAC or can be split for 120VAC single  
phase auxiliary power. This receptacle has a 50  
amp rating. Refer to the AUXILIARY POWER  
RECEPTACLES section in the installation chapter  
for further information about this receptacle. Also  
refer to the AUXILIARY POWER OPERATION  
section later in this chapter.  
CV-WIRE mode: In this mode, turning the ARCꢀCON-  
TROL 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 set-  
ting depends on the procedure and operator prefer-  
ence. Start with a setting of 0.  
AIR VANTAGE® 500 CUMMINS  
Download from Www.Somanuals.com. All Manuals Search And Download.  
b-5  
b-5  
OPERATION  
26. COMPRESSOR HOUR METER  
20. CIRCUIT bREAKERS  
The compressor hour meter displays the total  
time that the compressor has been running (com-  
pressor switch must be on).  
These circuit breakers provide separate overload  
current protection for each 120V circuit at the  
240V single phase receptacle, each 120V single  
phase receptacle, the 240V three phase recepta-  
cle, the 120VAC in the 14-Pin connector, the  
42VAC in the 14-Pin connector and battery circuit  
overload protection.  
27. AIR DISCHARGE VALVE  
Controls flow of compressed air. A 3/4” NPT  
(National Pipe Thread) fitting is provided.  
21. 120VAC SINGLE PHASE RECEPTACLES  
These two 120VAC (5-20R) receptacles with  
ground fault circuit interruption protection provide  
120VAC single phase for auxiliary power. Each  
receptacle has a 20 amp total rating. They are  
designed to protect the user from the hazards of  
ground faults. When the GFCI has tripped there  
will be no voltage available from the receptacle.  
Refer to the AUXILIARY POWER RECEPTA-  
CLES section in the installation chapter for further  
information about these receptacles. Also refer to  
the AUXILIARY POWER OPERATION section  
later in this chapter.  
bATTERY JUMP START TERMINAL  
(28-31)  
28. POSITIVE bATTERY JUMP START  
TERMINAL.  
29. NEGATIVE bATTERY JUMP START  
TERMINAL.  
12V battery jump start feature is standard.  
Covered output studs for convenient access, and  
protection against accidental impact. can be used  
to jump-start a utility truck with up to 800 cold  
cranking amps. Can also be used to jump-start the  
AIR VANTAGE® 500 CUMMINS.  
22. GROUND STUD  
Provides a connection point for connecting the  
machine case to earth ground. Refer to  
“MACHINE GROUNDING” in the Installation chap-  
ter for proper machine grounding information.  
30. bATTERY DISCONNECT SWITCH  
Battery disconnect switch provides lockout/tagout  
capability. Switch is conveniently located on the  
front bottom of the machine.  
23. 240VAC THREE PHASE RECEPTACLE  
This is a 240VAC (15-50R) receptacle that pro-  
vides 240VAC three phase auxiliary power. This  
receptacle has a 50 amp rating.  
31. AIR CLEANER AND 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 FIG-  
URE B.2)  
AIR COMPRESSOR CONTROLS (24  
THRU 27)  
24. COMPRESSOR ON/OFF SWITCH  
FIGURE b.2  
Turns compressor on and off activating or deacti-  
vating the electromagnetic compressor clutch.  
31  
25. COMPRESSOR PROTECTION LIGHT  
The yellow compressor protection light remains  
off with proper compressor oil temperatures. If the  
lights turn on, the compressor protection system  
will deactivate the compressor clutch and put the  
system in standby mode until the temperature  
reaches allowable limits. Check for proper com-  
pressor oil level.  
AIR VANTAGE® 500 CUMMINS  
Download from Www.Somanuals.com. All Manuals Search And Download.  
b-6  
b-6  
OPERATION  
bREAK-IN PERIOD  
ENGINE OPERATION  
The engine used to supply power for your welder is a  
heavy duty, industrial engine. It is designed and built  
for rugged use. It is very normal for any engine to use  
small quantities of oil until the break-in is accom-  
plished. Check the oil level twice a day during the  
break-in period. In general this takes 50 to 100 hours  
of operation.  
STARTING THE ENGINE  
1. Open the engine compartment door and check that  
the fuel shutoff valve located to the left of the fuel  
filter housing is in the open position (lever to be in  
line with the hose).  
2. Make sure battery disconnect switch is in the on  
position.  
3. Check for proper oil level and coolant level. Close  
engine compartment door.  
IMPORTANT  
IN ORDER TO ACCOMPLISH THIS bREAK-IN, THE  
UNIT SHOULD bE SUbJECTED TO HEAVY  
LOADS, WITHIN THE RATING OF THE MACHINE.  
AVOID LONG IDLE RUNNING PERIODS.  
4. Remove all plugs connected to the AC power  
receptacles.  
5. Set IDLER switch to “AUTO”.  
6. Set the RUN/STOP switch to “RUN”. Observe that  
the engine protection and battery charging lights  
are on. After 10 seconds, the engine protection light  
will turn off.  
TYPICAL FUEL CONSUMPTION  
Refer to Table B.1 for typical fuel consumption of the  
AIR VANTAGE® 500 CUMMINS Engine for various  
operating settings.  
7. Within 30 seconds, press and hold the engine  
START button until the engine starts.  
8. Release the engine START button when the engine  
starts.  
Table b.1  
Cummins b3.3 Engine Fuel Consumption  
Cummins B3.3  
56HP(42Kw)  
@1800 RPM  
Running Time for  
25GAL.(94.6L)  
(Hours)  
9. Check that the engine protection and battery charg-  
ing lights are off. The engine protection light is on  
after starting, the engine will shutdown in a few sec-  
onds. Investigate any indicated problem.  
Low Idle -  
no load 1425 RPM  
.59 Gal./hour  
(2.2 L/hour)  
42.4  
28.7  
11.9  
10. Allow the engine to warm up at low idle speed for  
several minutes before applying a load and/or  
switching to high idle. Allow a longer warm up time  
in cold weather.  
High Idle -  
no load 1900 RPM  
.87 Gal./hour  
(3.3 L/hour)  
DC CC Weld  
Output 500  
Amps @ 40 Volts  
2.10 Gal./hour  
(7.9 L/hour)  
COLD WEATHER STARTING  
Auxiliary Power  
12,000 VA  
1.44 Gal./hour  
(5.5 L/hour)  
17.4  
19.4  
With a fully charged battery and the proper weight oil,  
the engine should start satisfactorily even down to  
about 0°F(-18°C). If the engine must be frequently  
started below 10°(-12°C), it may be desirable to install  
the optional ether start kit (K887-1). For extreme cold  
conditions it may be desirable to install the Cold  
Weather Heater and Tarp Kit (K2359-1). Installation  
and operating instructions are included in the kits.  
Air Compressor  
60 CFM @ 100 PSI  
1.29 Gal./hour  
(4.9 L/hour)  
Air Compressor  
60 CFM @ 100 PSI  
and DC, CC Weld  
Output 500 Amps  
@40 Volts  
2.46 Gal./hour  
(9.3 L/hour)  
10.2  
12.9  
Air Compressor  
60 CFM @ 100 PSI  
and Auxiliary Power  
12,000 VA  
1.94 Gal./hour  
(7.3 L/hour)  
STOPPING THE ENGINE  
1. Switch the RUN/STOP switch to “STOP”. This turns  
off the voltage supplied to the shutdown solenoid. A  
backup shutdown can be accomplished by shutting  
off the fuel valve located on the fuel line.  
NOTE: This data is for reference only. Fuel consumption is  
approximate and can be influenced by many factors, includ-  
ing engine maintenance, environmental conditions and fuel  
quality.  
AIR VANTAGE® 500 CUMMINS  
Download from Www.Somanuals.com. All Manuals Search And Download.  
b-7  
b-7  
OPERATION  
TOUCH START TIG MODE  
WELDER OPERATION  
The AIR VANTAGE® 500 CUMMINS can be used in a  
wide variety of DCꢀTIGꢀwelding applications.  
DUTY CYCLE  
Duty Cycle is the percentage of time the load is being  
applied in a 10 minute period. For example a 60% duty  
cycle, represents 6 minutes of load and 4 minutes of no  
load in a 10 minute period.  
The TOUCHꢀSTARTꢀTIG setting of the MODE switch  
is for DC TIG (Tungsten Inert Gas) welding. To initiate  
a weld, the OUTPUT CONTROL knob is first set to  
the desired current and the tungsten is touched to the  
work. During the time the tungsten is touching the  
work there is very little voltage or current and, in gen-  
eral, avoids tungsten contamination. Then, the tung-  
sten is gently lifted off the work in a rocking motion,  
which establishes the arc.  
STICK WELDING MODE  
The AIR VANTAGE® 500 CUMMINS can be used with a  
broad range of DC stick electrodes. The MODE switch  
provides two stick welding settings as follows:  
To stop the arc, simply lift the TIG torch away from the  
work piece. When the arc voltage reaches approxi-  
mately 30 volts, the arc will go out and the machine  
will automatically reset to the touch start current level.  
The tungsten may then be retouched to the work  
piece to restrike the arc. The arc may also be started  
and stopped with an Amptrol or Arc Start Switch.  
CC-STICK MODE  
The CC-STICK position of the MODE switch is  
designed for horizontal, vertical-up and over head  
welding with all types of electrodes, especially low  
hydrogen. The OUTPUT CONTROL knob adjusts the  
full output range for stick welding.  
The ARC CONTROL knob sets the short circuit (arc-  
force) current during stick welding. Increasing the  
number from -10(Soft) to +10(Crisp) increases the  
short circuit current and prevents sticking of the elec-  
trode to the plate while welding. This can also  
increase spatter. It is recommended that the ARC  
CONTROL be set to the minimum number without  
electrode sticking. Start with the knob set at 0.  
The ARCꢀCONTROL is not active in the TIG mode.  
In general the ‘Touch Start’ feature avoids tungsten  
contamination without the use of a Hi-frequency unit.  
If the use of a high frequency generator is desired, the  
K930-2 TIG Module can be used with the AIR VAN-  
TAGE® 500 CUMMINS. The settings are for refer-  
ence.  
The AIR VANTAGE® 500 CUMMINS is equipped with  
the required R.F. bypass circuitry for the connection of  
high frequency generating equipment.  
DOWNHILL PIPE MODE  
This slope controlled setting is intended for “out-of-  
position” and “down hill” pipe welding where the oper-  
ator would like to control the current level by changing  
the arc length. The OUTPUT CONTROL knob adjusts  
the full output range for pipe welding.  
The AIR VANTAGE® 500 CUMMINS and any high  
frequency generating equipment must be properly  
grounded. See the K930-2 TIG Module operating  
manuals for complete instructions on installation,  
operation, and maintenance.  
When using the TIG Module, the OUTPUT control on  
the AIR VANTAGE® 500 CUMMINS is used to set the  
maximum range of the CURRENTꢀCONTROL on the  
TIG Module or an Amptrol if connected to the TIG  
Module.  
The ARC CONTROL knob sets the short circuit cur-  
rent (arc-force) during stick welding to adjust for a soft  
or a more forceful digging arc (Crisp). Increasing the  
number from -10(Soft) to +10(Crisp) increases the  
short circuit current which results in a more forceful  
digging arc. Typically a forceful digging arc is pre-  
ferred for root and hot passes. A softer arc is pre-  
ferred for fill and cap passes where weld puddle con-  
trol and deposition (“stacking” of iron) are key to fast  
travel speeds. It is recommended that the ARC CON-  
TROL be set initially at 0.  
AIR VANTAGE® 500 CUMMINS SETTINGS  
WHEN USING THE K930-2 TIG MODULE  
• Set the WELD MODE switch to the “Touch Start Tig 20-  
250 Setting”.  
• Set the IDLER switch to the “AUTO” position.  
• Set the WELDING TERMINALS switch to the “Remotely  
Controlled” position. This will keep the solid state contactor  
open and provide a “cold” electrode until the triggering  
device (Amptrol or Arc Start Switch) is pressed.  
AIR VANTAGE® 500 CUMMINS  
Download from Www.Somanuals.com. All Manuals Search And Download.  
b-8  
b-8  
OPERATION  
WIRE WELDING-CV  
ARC GOUGING  
For optimal performance when arc gouging, set the  
AIR VANTAGE® 500 CUMMINS “WELD MODE”  
switch to the “CC - STICK” position, and the “ARC  
CONTROL” to 10.  
Connect a wire feeder to the AIR VANTAGE® 500  
CUMMINS according to the instructions in INSTALLA-  
TION INSTRUCTIONS Section.  
The AIR VANTAGE® 500 CUMMINS in the ”CV-  
WIRE” position, permits it to be used with a broad  
range of flux cored wire (Innershield and Outershield)  
electrodes and solid wires for MIG welding (gas metal  
arc welding). Welding can be finely tuned using the  
“ARC CONTROL”. Turning the ARC CONTROL clock-  
wise 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.  
Set the “OUTPUT” knob to adjust output current to the  
desired level for the gouging electrode being used  
according to the ratings in the following Table B.2.  
TAbLE b.2  
Carbon Diameter  
Current Range (DC, elec-  
trode positive)  
30-60 Amps  
1/8"(3.2mm)  
5/32"(4.0mm)  
3/16"9(4.8mm)  
1/4"(6.4mm)  
5/16"(8.0mm)  
3/8"(10.0mm)  
90-150 Amps  
200-250 Amps  
300-400 Amps  
350-450 Amps  
450-575 Amps*  
The proper setting depends on the procedure and  
operator preference. Start with the knob set at 0.  
For any electrodes, including the above recommenda-  
tions, the procedures should be kept within the rating  
of the machine. For additional electrode information,  
See www.lincolnelectric.com or the appropriate  
Lincoln publication.  
NOTE: If desired the CV mode can be used for Arc Gouging.  
* Maximum current setting is limited to the AIR VANTAGE® 500 CUMMINS  
maximum of 575 Amps.  
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  
Diameter  
mm (in)  
1%, 2%  
Thoriated  
Tungsten  
1%, 2%  
Thoriated  
Tungsten  
TIG TORCH  
Nozzle  
Size (4), (5)  
Aluminium  
Stainless Steel  
.25 (0.010)  
.50 (0.020)  
1.0 (0.040)  
2-15  
5-20  
(3)  
(3)  
(3)  
2-4 (3-8)  
3-5 (5-10)  
3-5 (5-10)  
2-4 (3-8)  
3-5 (5-10)  
3-5 (5-10)  
#4, #5, #6  
15-80  
1.6 (1/16)  
70-150  
10-20  
3-5 (5-10)  
4-6 (9-13)  
#5, #6  
2.4 (3/32)  
3.2 (1/8)  
150-250  
250-400  
15-30  
25-40  
6-8 (13-17)  
7-11 (15-23)  
5-7 (11-15)  
5-7 (11-15)  
#6, #7, #8  
4.0 (5/32)  
4.8 (3/16)  
400-500  
500-750  
40-55  
55-80  
10-12 (21-25)  
11-13 (23-27)  
6-8 (13-17)  
8-10 (18-22)  
#8, #10  
6.4 (1/4)  
750-1000  
80-125  
13-15 (28-32)  
11-13 (23-27)  
(1)  
(2)  
When used with argon gas. The current ranges shown must be reduced when using argon/helium or pure helium shielding gases.  
Tungsten electrodes are classified as follows by the American Welding Society (AWS):  
Pure  
1% Thoriated  
2% Thoriated  
EWP  
EWTh-1  
EWTh-2  
Though not yet recognized by the AWS, Ceriated Tungsten is now widely accepted as a substitute for 2% Thoriated Tungsten in AC and DC applica-  
tions.  
(3)  
(4)  
DCEP is not commonly used in these sizes.  
TIG torch nozzle “sizes” are in multiples of 1/16ths of an inch:  
# 4 =  
# 5 =  
# 6 =  
# 7 =  
# 8 =  
#10 =  
1/4 in.  
5/16 in.  
3/8 in.  
7/16 in.  
1/2 in.  
5/8 in.  
6 mm  
8 mm  
10 mm  
11 mm  
12.5 mm  
16 mm  
(5)  
TIG torch nozzles are typically made from alumina ceramic. Special applications may require lava nozzles, which are less prone to breakage, but can-  
not withstand high temperatures and high duty cycles.  
AIR VANTAGE® 500 CUMMINS  
Download from Www.Somanuals.com. All Manuals Search And Download.  
b-9  
b-9  
OPERATION  
PARALLELING  
The auxiliary power capacity rating in watts is equiva-  
lent to volt-amperes at unity power factor. The maxi-  
mum 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 maxi-  
mum permissible current of 50 A per output to two  
separate 120 VAC branch circuits. Output voltage is  
within ± 10% at all loads up to rated capacity.  
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 imbalances between the  
units.  
NOTE: The two 120V GFCI receptacles and the two  
120V circuits of the 120/240V receptacle are connect-  
ed to different phases and cannot be paralleled.  
AUXILIARY POWER OPERATION  
If a GFCI receptacle is tripped, See the MAINTE-  
NANCE section for detailed information on testing and  
resetting the GFCI receptacle.  
The auxiliary power receptacles should only be used  
with three wire grounded type plugs or approved dou-  
ble 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.  
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 weld-  
ing current is being drawn.  
SIMULTANEOUS WELDING AND AUXIL-  
IARY POWER LOADS  
The auxiliary power of the AIR VANTAGE® 500 con-  
sists 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.  
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 auxiliary power capacity is 12,000 watts of 60 Hz,  
single phase power or 20,000 watts of 60Hz, three  
phase power.  
TAbLE b.4 AIR VANTAGE® 500 CUMMINS SIMULTANEOUS WELDING AND POWER LOADS  
WELD  
AMPS  
0
100  
200  
250  
300  
400  
500  
1 PHASE  
WATTS  
3 PHASE  
WATTS  
bOTH 1 AND 3 PHASE  
AMPS  
50  
50  
50  
50  
42  
23  
0
AMPS  
50  
43  
34  
29  
24  
13  
0
WATTS  
AMPS  
50  
50  
12,000  
12,000  
12,000  
12,000  
10,000  
5,600  
0
20,000  
17,800  
14,000  
12,000  
10,000  
5,600  
0
------  
------  
------  
12,000  
10,000  
5,600  
0
PLUS  
OR  
50  
OR  
------  
------  
------  
0
TAbLE b.5  
AIR VANTAGE® 500 CUMMINS Extension Cord Length Recommendations  
(Use the shortest length extension cord possible sized per the following table.)  
Current Voltag  
Maximum Allowable Cord Length in ft. (m) for Conductor Size  
6 AWG  
(Amps)  
15  
15  
20  
20  
25  
30  
38  
50  
e
(Volts) (Watts)  
Load  
14 AWG  
12 AWG  
10 AWG  
8 AWG  
4 AWG  
120  
240  
120  
240  
240  
240  
240  
1800  
3600  
2400  
4800  
6000  
7200  
9000  
30  
60  
(9)  
(18)  
40  
(12)  
(23)  
(9)  
75  
(23)  
(46)  
(15)  
(30)  
(27)  
(23)  
125  
(38)  
(69)  
(27)  
(53)  
(46)  
(37)  
(30)  
175  
(53)  
(107)  
(42)  
(84)  
(69)  
(53)  
(46)  
(38)  
300  
600  
225  
450  
250  
300  
250  
200  
(91)  
(183)  
(69)  
(137)  
(76)  
(91)  
(76)  
(61)  
75  
30  
60  
150  
50  
100  
90  
225  
88  
175  
150  
120  
100  
350  
138  
275  
225  
175  
150  
125  
(18)  
75  
240 12000  
Conductor size is based on maximum 2.0% voltage drop.  
AIR VANTAGE® 500 CUMMINS  
Download from Www.Somanuals.com. All Manuals Search And Download.  
C-1  
C-1  
ACCESSORIES  
OPTIONAL FIELD INSTALLED  
ACCESSORIES  
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.  
K802N POWER PLUG KIT - Provides four 120V  
plugs rated at 20 amps each and one dual voltage,  
full KVA plug rated at 120/240V, 50 amps. 120V plug  
may not be compatible with NEMA common house-  
hold receptacles.  
K802-R POWER PLUGꢀKIT - Provides four 120V  
plugs rated 15 amps each and one dual voltage, full  
KVA plug rated at 120/240V, 50 amps, 120V plug is  
compatible with NEMA common household recepta-  
cles.  
------------------------------------------------------------------------  
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.  
K857 25 ft. (7.5 m) or K857-1 100 ft. (30.4 m) REMOTE CON-  
TROL - Portable control provides same dial range as the output  
control on the welder from a location up to the specified length  
from the welder. Has convenient plug for easy connection to the  
welder. The AIR VANTAGE® 500 CUMMINSis equipped with a  
6-pin connector for connecting the remote control.  
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.  
K704 ACCESSORY SET - Includes 35 feet (10 m) of  
electrode cable and 30 feet (9 m) of work cable, head-  
shield, filter plate, work clamp and electrode holder.  
Cable is rated at 500 amps, 60% duty cycle.  
K2359-1 Cold Weather Heater and Tarp Kit - For  
extreme cold conditions where normal engine starting  
is not sufficient. Includes oil pan heater, engine water  
heater and radiator grill tarp.  
K2641-2 FOUR WHEELED STEERAbLE YARD  
TRAILER  
TIG OPTIONS  
For in plant and yard towing. Comes standard with a  
Duo-Hitch™, a 2” Ball and Lunette Eye combination  
Hitch.  
K870 Foot Amptrol® - Varies current while welding  
for making critical TIG welds and crater filling.  
Depress pedal to increase current. Depressing pedal  
fully achieves maximum set current. Fully raising the  
pedal finishes the weld and starts the afterflow cycle  
on systems so equipped. Includes 25 ft. (7.6m) control  
cable.  
K2636-1 TRAILER - Two-wheeled trailer with optional fender  
and light package. For highway use, consult applicable feder-  
al, state, and local laws regarding possible additional require-  
ments. Comes standard with a Duo-Hitch™, a 2” Ball  
and Lunette Eye combination hitch. A fender & a light  
package. Order:  
K963-3 Hand Amptrol® - Varies current for making  
critical TIG welds. Fastens to the torch for convenient  
thumb control. Comes with a 25 ft. (7.6m) cable. (for  
larger handle 18 or 26 series torches)  
K2636-1 Trailer  
K2639-1 Fender & Light Kit  
K2640-1 Cable Storage Rack  
K887-1 ETHER START KIT - Provides maximum cold weath-  
er starting assistance for frequent starting below 10°(-12°C)  
.
Required Ether tank is not provided with kit.  
K1847-1 SPARK ARRESTOR KIT - Easily mounts to stan-  
dard muffler.  
AIR VANTAGE® 500 CUMMINS  
Download from Www.Somanuals.com. All Manuals Search And Download.  
D-1  
D-1  
MAINTENANCE  
a. Compressor oil and filter.  
b. Compressor air filter.  
c. Compressor coalescing filter.  
SAFETY PRECAUTIONS  
WARNING  
• Have qualified personnel do all maintenance  
and troubleshooting work.  
• Turn the engine off before working inside the  
machine or servicing the engine.  
VMAC  
™
(VEHICLE MOUNTED AIR COMPRESSORS)  
WWW.VMAC.CA  
• Remove guards only when necessary to  
perform maintenance and replace them when  
the maintenance requiring their removal is  
complete. If guards are missing from the  
machine, obtain replacements from a Lincoln  
Distributor. (See Operating Manual Parts List.)  
1333 Kipp Road  
Nanamino  
British Columbia  
Canada, V9X1R3  
Telephone: (250) 740-3200  
Facsimile: (250) 740-3201  
Toll Free: 800-738-8622  
Read the Safety Precautions in the front of this  
manual and in the Engine Owner’s Manual before  
working on this machine.  
ENGINE MAINTENANCE  
Keep all equipment safety guards, covers, and  
devices in position and in good repair. Keep  
hands, hair, clothing, and tools away from the  
gears, fans, and all other moving parts when  
starting, operating, or repairing the equipment.  
------------------------------------------------------------------------  
ROUTINE AND PERIODIC MAINTENANCE  
Refer to the “Periodic Checks” section of the Engine  
Operator’s Manual for the recommended maintenance  
schedule of the following:  
a) Engine Oil and Filter  
b) Air Cleaner  
c) Fuel Filter - and Delivery System  
d) Alternator Belt  
e) Battery  
f ) Cooling System  
Refer to Table D.1 at the end of this section for vari-  
ous engine maintenance components.  
DAILY  
• Check the Engine and Compressor oil levels .  
• Refill the fuel tank to minimize moisture condensa-  
tion in the tank.  
• Open the water drain valve located on the bottom of  
the water separator element 1 or 2 turns and allow  
to drain into a container suitable for diesel fuel for 2  
to 3 seconds. Repeat the above drainage procedure  
until diesel fuel is detected in the container.  
AIR FILTER  
CAUTION  
• Excessive air filter restriction will result in  
reduced engine life.  
• Check coolant level.  
WARNING  
WARNING  
• Only VMAC certified and approved synthetic oil  
• Never use gasoline or low flash point solvents  
for cleaning the air cleaner element. A fire or  
explosion could result.  
MUST  
be  
used.  
Shut  
down  
the  
Welder/Compressor for 3 minutes, open the  
pressure supply valve to ensure the system is  
depressurized prior to removing the compres-  
sor oil level dipstick.  
CAUTION  
------------------------------------------------------------------------  
• Never run the engine without the air cleaner.  
Rapid engine wear will result from contaminants,  
such as dust and dirt being drawn into the  
engine.  
------------------------------------------------------------------------  
The diesel engine is equipped with a dry type air filter.  
Never apply oil to it. Service the air cleaner as follows:  
WEEKLY  
Blow out the machine with low pressure air periodical-  
ly. In particularly dirty locations, this may be required  
once a week.  
COMPRESSOR MAINTENANCE  
Refer to the “Routine Maintenance” section of the  
compressor owner’s manual for the recommended  
maintenance schedule of the following:  
Replace the element as indicated by the service indi-  
cator. (See Service Instructions and Installation Tips  
for Engine Air Filter.)  
AIR VANTAGE® 500 CUMMINS  
Download from Www.Somanuals.com. All Manuals Search And Download.  
D-2  
D-2  
MAINTENANCE  
Service Instructions  
Single- and Two-Sttage Engine Air Cleaners  
Inspect the New Filter for Damage  
Removve the Filter  
Inspect the new filter carefully, paying attention to  
the inside of the open end, which is the  
sealing area. NEVER install a damaged  
filter. A new Donaldson radial seal  
filter may have a dry lubricant on the  
seal to aid installation.  
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 the seal then rotate while  
pulling straight out. Avoid knocking the filter  
against the housing.  
Rotate the  
filter while  
pulling  
straight out.  
Insert the New Radial Seal Filter Properly  
If you're servicing the safety filter, this should be seated into  
position before installing the primary filter.  
If your air cleaner has a safety filter, replace it every third primary  
filter change. Remove the safety filter as you would the primary  
filter. Make sure you cover the air cleaner outlet tube to avoid any  
unfiltered contaminant dropping into the engine.  
Insert the new filter carefully. Seat  
the filter by hand, making certain it is  
completely into the air cleaner housing  
before securing the cover in place.  
Clean Booth Surfaces oof the Outtllet Tube  
and Check the Vacuaator™ VValve  
The critical sealing area will stretch  
slightly, adjust itself and distribute the sealing pressure evenly. To  
complete a tight seal, apply pressure by hand at the outer rim of  
Use a clean cloth to wipe the filter sealing surface and the inside of  
the outlet tube. Contaminant on the sealing surface could hinder an  
effective seal and cause leakage. Make sure that all contaminant is  
removed before the new filter is inserted. Dirt accidently transferred  
to the inside of the outlet tube will reach the engine and cause  
wear. Engine manufacturers say that it takes only a few grams of  
dirt to "dust" an engine! Be careful not to damage the sealing area  
on the tube.  
the filter, not the flexible center. (Avoid pushing on the center of the  
urethane end cap.) No cover pressure is required to hold the seal.  
NEVER use the service cover to push the filter into place! Using the  
cover to push the filter in could cause damage to the housing, cover  
fasteners and will void the warranty.  
If the service cover hits the filter before it is fully in place, remove  
the cover and push the filter (by hand) further into the air cleaner  
and try again. The cover should go on with no extra force.  
Wipe both sides  
of the outlet  
tube clean.  
Once the filter is in place, secure the service cover.  
Outer edge of the  
Inner edge of the  
outlet tube  
Caution  
outlet tube  
NEVER use tthe serrvvice coover to  
push the fillter intoo place!! Using  
the coverr to push thee filterr iin could  
cause damaage to thhee housingg, cover  
fastenerrs and will vvooid the waarranty.  
If your air cleaner is equipped with a Vacuator Valve  
Visually check and physically squeeze to make sure the  
valve is flexible and not inverted, damaged or plugged.  
Inspect the Old  
Filter for Leak Clues  
Check Connectors for Tight Fit  
Make sure that all mounting bands, clamps, bolts, and connections  
in the entire air cleaner system are tight. Check for holes in piping  
and repair if needed. Any leaks in your intake piping will send dust  
directly to the engine!  
Visually inspect the old filter for any signs  
of leaks. A streak of dust on the clean side  
of the filter is a telltale sign. Remove any  
cause of leaks before installing new filter.  
AIR VANTAGE® 500 CUMMINS  
Download from Www.Somanuals.com. All Manuals Search And Download.  
D-3  
D-3  
MAINTENANCE  
FUEL FILTERS  
• USING A bOOSTER - connect positive lead to  
battery first then connect negative lead to engine  
foot.  
WARNING  
When working on the fuel system:  
• Keep naked lights away, do not smoke !  
• Do not spill fuel !  
bATTERY ACID CAN bURN EYES AND  
SKIN.  
• Wear gloves and eye protection and  
be careful when working near battery.  
Follow instructions printed on battery.  
-------------------------------------------------------------------------  
The AIR VANTAGE® 500 CUMMINS is equipped with  
a Fuel Filter located after the lift pump and before fuel  
injectors.The procedure for changing the filter is as fol-  
lows.  
------------------------------------------------------------------------  
-PREVENTING ELECTRICAL DAMAGE  
1. When replacing, jumping, or otherwise connecting  
the battery to the battery cables, the proper polarity  
must be observed. Failure to observe the proper  
polarity could result in damage to the charging cir-  
cuit. The positive (+) battery cable has a red termi-  
nal cover.  
1. Close the fuel shutoff valve.  
2. Clean the area around the fuel filter head. Remove  
the filter. Clean the gasket surface of the filter head  
and replace the o-ring.  
3. Fill the clean filter with clean fuel, and lubricate the  
o-ring seal with clean lubricating oil.  
2. If the battery requires charging from an external  
charger, disconnect the negative battery cable first  
and then the positive battery cable before attaching  
the charger leads. Failure to do so can result in  
damage to the internal charger components. When  
reconnecting the cables, connect the positive cable  
first and the negative cable last.  
4. Install the filter as specified by the filter manufactur-  
er.  
WARNING  
Mechanical overtightening will distort the threads,  
filter element seal or filter can.  
-------------------------------------------------------------------------  
PREVENTING bATTERY DISCHARGE  
Turn the RUN/STOP switch to stop when engine is  
not running.  
COOLING SYSTEM  
The AIR VANTAGE® 500 CUMMINS is equipped with  
a pressure radiator. Keep the radiator cap tight to pre-  
vent loss of coolant. Clean and flush the coolant sys-  
tem periodically to prevent clogging the passage and  
over-heating the engine. When antifreeze is needed,  
always use the permanent type.  
PREVENTING bATTERY bUCKLING  
Tighten nuts on battery clamp until snug.  
CHARGING THE bATTERY  
bATTERY HANDLING  
When you charge, jump, replace, or otherwise con-  
nect battery cables to the battery, be sure the polarity  
is correct. Improper polarity can damage the charging  
circuit. The AIR VANTAGE® 500 CUMMINS positive  
(+) battery terminal has a red terminal cover.  
GASES FROM bATTERY can explode.  
• Keep sparks, flame and cigarettes away  
from battery.  
If you need to charge the battery with an external  
charger, disconnect the negative cable first, then the  
positive cable before you attach the charger leads.  
after the battery is charged, reconnect the positive  
battery cable first and the negative cable last. Failure  
to do so can result in damage to the internal charger  
components.  
To prevent EXPLOSION when:  
• INSTALLING A NEW bATTERY - dis-  
connect negative cable from old battery  
first and connect to new battery last.  
• CONNECTING A bATTERY CHARGER -  
Remove battery from welder by discon-  
necting negative cable first, then posi-  
tive cable and battery clamp. When  
reinstalling, connect negative cable  
last. Keep well ventilated.  
Follow the instructions of the battery charger manu-  
facturer for proper charger settings and charging time.  
AIR VANTAGE® 500 CUMMINS  
Download from Www.Somanuals.com. All Manuals Search And Download.  
D-4  
D-4  
MAINTENANCE  
GFCI RECEPTACLE TESTING AND RESET-  
TING PROCEDURE  
NAMEPLATES / WARNING DECALS MAIN-  
TENANCE  
Whenever routine maintenance is performed on this  
machine - or at least yearly - inspect all nameplates  
and labels for legibility. Replace those which are no  
longer clear. Refer to the parts list for the replacement  
item number.  
The GFCI receptacle should be properly tested at  
least once every month or whenever it is tripped. To  
properly test and reset the GFCI receptacle:  
• If the receptacle has tripped, first carefully remove  
any load and check it for damage.  
• If the equipment has been shut down, it must be  
restarted.  
WELDER / GENERATOR MAINTE-  
NANCE  
• The equipment needs to be operating at high idle  
speed and any necessary adjustments made on the  
control panel so that the equipment is providing at  
least 80 volts to the receptacle input terminals.  
• The circuit breaker for this receptacle must not be  
tripped. Reset if necessary.  
STORAGE  
Store the AIR VANTAGE® 500 CUMMINS in a clean,  
dry protected areas.  
• Push the "Reset" button located on the GFCI recep-  
tacle. This will assure normal GFCI operation.  
• Plug a night-light (with an "ON/OFF" switch) or other  
product (such as a lamp) into the GFCI receptacle  
and turn the product "ON".  
• Push the "Test" button located on the GFCI recepta-  
cle. The night-light or other product should go  
"OFF".  
CLEANING  
Blow out the generator and controls periodically with  
low pressure air. Do this at least once a week in par-  
ticularly dirty areas.  
bRUSH REMOVAL AND REPLACEMENT  
• Push the "Reset" button, again. The light or other  
product should go "ON" again.  
It is normal for the brushes and slip rings to wear and  
darken slightly. Inspect the brushes when a generator  
overhaul is necessary.  
If the light or other product remains "ON" when the  
"Test" button is pushed, the GFCI is not working prop-  
erly or has been incorrectly installed (miswired). If  
your GFCI is not working properly, contact a qualified,  
certified electrician who can assess the situation,  
rewire the GFCI if necessary or replace the device.  
WARNING  
Do not attempt to polish slip rings while the  
engine is running.  
------------------------------------------------------------------------  
Table D.1 Engine Maintenance Components  
ITEM  
MAKE  
PART NUMbER  
P822768  
SERVICE INTERVAL  
Air Cleaner Element  
Donaldson  
Fleetguard  
Replace as indicated by  
Service Indicator  
AF25436  
Oil Filer  
Fan Belt  
Cummins  
Fleetguard  
C6002112110  
LF16011  
Replace every 750 hours or 3 months,  
whichever is less.  
Cummins  
C0412021749  
Inspect every 1000 hours or 12 months,  
whichever is less.  
Fuel Strainer  
Cummins  
Fleetguard  
3826094  
FF5079  
Inspect and replace monthly as  
required. Replace annually.  
Fuel Filter /  
Water Separator  
Fleetguard  
FS19594  
Replace every 500 hours or 6 months,  
whichever is less.  
Battery  
-----  
BCI GROUP 34  
-----  
Inspect every 500 hours  
Engine Oil Change  
See Manual  
Change every 750 hours or 3 months,  
whichever is less. Check daily.  
AIR VANTAGE® 500 CUMMINS  
Download from Www.Somanuals.com. All Manuals Search And Download.  
E-1  
E-1  
TROUbLESHOOTING  
HOW TO USE TROUbLESHOOTING GUIDE  
WARNING  
Service and Repair should only be performed by Lincoln Electric Factory Trained Personnel.  
Unauthorized repairs performed on this equipment may result in danger to the technician and  
machine operator and will invalidate your factory warranty. For your safety and to avoid Electrical  
Shock, please observe all safety notes and precautions detailed throughout this manual.  
__________________________________________________________________________  
This Troubleshooting Guide is provided to help you  
locate and repair possible machine malfunctions.  
Simply follow the three-step procedure listed below.  
Step 3. RECOMMENDED COURSE OF ACTION  
This column provides a course of action for the  
Possible Cause, generally it states to contact your  
local Lincoln Authorized Field Service Facility.  
Step 1. LOCATE PROBLEMꢀ(SYMPTOM).  
Look under the column labeled “PROBLEM (SYMP-  
TOMS)”. This column describes possible symptoms  
that the machine may exhibit. Find the listing that  
best describes the symptom that the machine is  
exhibiting.  
If you do not understand or are unable to perform the  
Recommended Course of Action safely, contact your  
local Lincoln Authorized Field Service Facility.  
Step 2. POSSIBLE CAUSE.  
The second column labeled “POSSIBLE CAUSE” lists  
the obvious external possibilities that may contribute  
to the machine symptom.  
NOTE: See VMAC owner’s manual for compressor trouble shooting.  
VMAC  
™
VEHICLE MOUNTED AIR COMPRESSORS  
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  
Download from Www.Somanuals.com. All Manuals Search And Download.  
E-2  
E-2  
TROUbLESHOOTING  
Observe all Safety Guidelines detailed throughout this manual  
PRObLEMS  
(SYMPTOMS)  
POSSIbLE  
CAUSE  
RECOMMENDED  
COURSE OF ACTION  
Major Physical or Electrical Damage 1. Contact your local Lincoln  
is Evident.  
Authorized Field Service  
Facility.  
Engine will not crank  
1. Battery low.  
2. Loose battery cable connections  
which may need Inspected, cleaned  
or tighten.  
3. Faulty wiring in engine starting circuit.  
4. Faulty engine starter. Contact autho-  
rized 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 posi-  
tion 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.  
I
f all recommended possible areas  
of misadjustment have been  
checked and the problem persists,  
Contact your local Lincoln  
Authorized Field Service Facility.  
5. Fuel Filters dirty/clogged, main filter  
element and/or In-line Fuel Filter may  
need to be replaced.  
6. High water temperature or low oil  
pressure. (engine protection light lit)  
1. Low oil pressure (engine protection  
light lit). Check oil level (Consult  
engine service dealer).  
Engine shuts down shortly after starting.  
2. High water temperature. Check  
engine cooling system. (engine pro-  
tection light lit).  
3. Faulty oil pressure switch.  
4. Faulty water temperature switch.  
Contact authorized local Engine  
Service Shop.  
1. High water temperature.  
Engine shuts down while under a load.  
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 function-  
ing properly / linkage binding.  
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  
Download from Www.Somanuals.com. All Manuals Search And Download.  
E-3  
E-3  
TROUbLESHOOTING  
Observe all Safety Guidelines detailed throughout this manual  
PRObLEMS  
(SYMPTOMS)  
POSSIbLE  
CAUSE  
RECOMMENDED  
COURSE OF ACTION  
Battery does not stay charged.  
1. Faulty battery .  
2. Faulty engine alternator.  
3. Loose or broken lead in charging  
circuit.  
4. Loose fan belt may need tighten-  
ing.  
Engine will not idle down to low 1. Idler switch in HIGH idle position,  
speed.  
make sure switch is set to AUTO.  
2. External load on welder or auxil-  
iary power.  
3. Mechanical problem in idler sole-  
noid 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  
attempting to weld.  
work.  
If all recommended possible areas of  
misadjustment have been checked  
and the problem persists, Contact  
your local Lincoln Authorized  
Field Service Facility.  
2. Broken idler solenoid spring.  
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.  
Engine will not go to high idle when 1. Broken wire in auxiliary current  
using auxiliary power.  
sensor wiring.  
2. Auxiliary power load is less than  
100 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  
Download from Www.Somanuals.com. All Manuals Search And Download.  
E-4  
E-4  
TROUbLESHOOTING  
Observe all Safety Guidelines detailed throughout this manual  
PRObLEMS  
(SYMPTOMS)  
POSSIbLE  
CAUSE  
RECOMMENDED  
COURSE OF ACTION  
Engine goes to low idle but does not 1. Faulty Peripheral PCB, Pull  
Coil/Battery PCB or Weld Control  
PCB.  
stay at low idle.  
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 1. Faulty remote kit.  
control. Auxiliary output OK  
2. Faulty output control potentiome-  
ter.  
3. Faulty output control wiring.  
4. Faulty Weld Control PCB, Pull  
Coil/Battery PCB or Chopper PCB.  
No welding output. Auxiliary output 1. WELDING TERMINALS switch in  
OK.  
wrong position, be sure switch is  
in WELDING TERMINALS  
ALWAYS ON position.  
2. Faulty Weld Control PCB, Pull  
Coil/Battery PCB or Chopper PCB.  
If all recommended possible areas  
No auxiliary power.  
1. GFCI Receptacle may have of misadjustment have been  
tripped. Follow “GFCI Receptacle checked and the problem persists,  
Testing and Resetting Procedure” Contact your local Lincoln  
in the MAINTENANCE section of Authorized Field Service Facility.  
this manual.  
2. Open breakers may need to be  
reset.  
3. Faulty receptacle.  
4. Faulty auxiliary circuit wiring.  
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  
Download from Www.Somanuals.com. All Manuals Search And Download.  
F-1  
F-1  
WIRING DIAGRAM  
AIR VANTAGE® 500 CUMMINS  
Download from Www.Somanuals.com. All Manuals Search And Download.  
F-2  
F-2  
DIAGRAMS  
AIR VANTAGE® 500 CUMMINS  
Download from Www.Somanuals.com. All Manuals Search And Download.  
F-3  
F-3  
DIAGRAMS  
}
}
AIR VANTAGE® 500 CUMMINS  
Download from Www.Somanuals.com. All Manuals Search And Download.  
F-4  
F-4  
DIAGRAMS  
AIR VANTAGE® 500 CUMMINS  
Download from Www.Somanuals.com. All Manuals Search And Download.  
F-5  
F-5  
DIAGRAMS  
AIR VANTAGE® 500 CUMMINS  
Download from Www.Somanuals.com. All Manuals Search And Download.  
F-6  
F-6  
DIAGRAMS  
}
}
AIR VANTAGE® 500 CUMMINS  
Download from Www.Somanuals.com. All Manuals Search And Download.  
F-7  
F-7  
DIAGRAMS  
AIR VANTAGE® 500 CUMMINS  
Download from Www.Somanuals.com. All Manuals Search And Download.  
F-8  
F-8  
DIAGRAMS  
AIR VANTAGE® 500 CUMMINS  
Download from Www.Somanuals.com. All Manuals Search And Download.  
F-9  
F-9  
DIAGRAMS  
AIR VANTAGE® 500 CUMMINS  
Download from Www.Somanuals.com. All Manuals Search And Download.  
F-10  
F-10  
DIAGRAMS  
AIR VANTAGE® 500 CUMMINS  
Download from Www.Somanuals.com. All Manuals Search And Download.  
F-11  
F-11  
DIAGRAMS  
AIR VANTAGE® 500 CUMMINS  
Download from Www.Somanuals.com. All Manuals Search And Download.  
F-12  
F-12  
DIAGRAMS  
AIR VANTAGE® 500 CUMMINS  
Download from Www.Somanuals.com. All Manuals Search And Download.  
F-13  
F-13  
DIMENSION PRINT  
AIR VANTAGE® 500 CUMMINS  
Download from Www.Somanuals.com. All Manuals Search And Download.  
NOTES  
AIR VANTAGE® 500 CUMMINS  
Download from Www.Somanuals.com. All Manuals Search And Download.  
•
•
Do not touch electrically live parts or  
electrode with skin or wet clothing.  
Insulate yourself from work and  
ground.  
•
•
Keep flammable materials away.  
•
•
Wear eye, ear and body protection.  
WARNING  
Spanish  
•
No toque las partes o los electrodos  
bajo carga con la piel o ropa moja-  
da.  
Mantenga el material combustible  
fuera del área de trabajo.  
Protéjase los ojos, los oídos y el  
cuerpo.  
AVISO DE  
PRECAUCION  
French  
•
•
Aislese del trabajo y de la tierra.  
Ne laissez ni la peau ni des vête-  
ments mouillés entrer en contact  
avec des pièces sous tension.  
Isolez-vous du travail et de la terre.  
•
•
Gardez à l’écart de tout matériel  
inflammable.  
•
•
Protégez vos yeux, vos oreilles et  
votre corps.  
ATTENTION  
•
•
German  
Berühren Sie keine stromführenden  
Teile oder Elektroden mit Ihrem  
Körper oder feuchter Kleidung!  
Isolieren Sie sich von den  
Entfernen Sie brennbarres Material!  
Tragen Sie Augen-, Ohren- und Kör-  
perschutz!  
WARNUNG  
•
Elektroden und dem Erdboden!  
Portuguese  
•
•
Não toque partes elétricas e electro-  
dos com a pele ou roupa molhada.  
Isole-se da peça e terra.  
•
Mantenha inflamáveis bem guarda-  
dos.  
•
Use proteção para a vista, ouvido e  
corpo.  
ATENÇÃO  
Japanese  
Chinese  
Korean  
Arabic  
READ AND UNDERSTAND THE MANUFACTURER’S INSTRUCTION FOR THIS EQUIPMENT AND THE  
CONSUMABLES TO BE USED AND FOLLOWYOUR EMPLOYER’S SAFETY PRACTICES.  
SE RECOMIENDA LEERY ENTENDER LAS INSTRUCCIONES DEL FABRICANTE PARA EL USO DE  
ESTE EQUIPOY 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 ELEKTRO-  
DENEINSATZ DES HERSTELLERS. DIE UNFALLVERHÜTUNGSVORSCHRIFTEN DES ARBEITGEBERS  
SIND EBENFALLS ZU BEACHTEN.  
Download from Www.Somanuals.com. All Manuals Search And Download.  
•
•
Keep your head out of fumes.  
Use ventilation or exhaust to  
remove fumes from breathing zone.  
•
•
Turn power off before servicing.  
•
•
Do not operate with panel open or  
guards off.  
WARNING  
Spanish  
•
•
Los humos fuera de la zona de res-  
piración.  
Mantenga la cabeza fuera de los  
humos. Utilice ventilación o  
aspiración para gases.  
Desconectar el cable de ali-  
mentación de poder de la máquina  
antes de iniciar cualquier servicio.  
No operar con panel abierto o  
guardas quitadas.  
AVISO DE  
PRECAUCION  
French  
•
•
Débranchez le courant avant l’entre-  
tien.  
•
•
N’opérez pas avec les panneaux  
ouverts ou avec les dispositifs de  
protection enlevés.  
•
•
Gardez la tête à l’écart des fumées.  
Utilisez un ventilateur ou un aspira-  
teur pour ôter les fumées des zones  
de travail.  
ATTENTION  
German  
Strom vor Wartungsarbeiten  
abschalten! (Netzstrom völlig öffnen;  
Maschine anhalten!)  
Anlage nie ohne Schutzgehäuse  
oder Innenschutzverkleidung in  
Betrieb setzen!  
•
•
Vermeiden Sie das Einatmen von  
Schweibrauch!  
Sorgen Sie für gute Be- und  
Entlüftung des Arbeitsplatzes!  
WARNUNG  
Portuguese  
•
•
Não opere com as tampas removidas.  
Desligue a corrente antes de fazer  
serviço.  
•
•
Mantenha-se afastado das partes  
moventes.  
Não opere com os paineis abertos  
ou guardas removidas.  
•
•
Mantenha seu rosto da fumaça.  
Use ventilação e exhaustão para  
remover fumo da zona respiratória.  
ATENÇÃO  
•
Não toque as partes elétricas nuas.  
Japanese  
Chinese  
Korean  
Arabic  
LEIA E COMPREENDA AS INSTRUÇÕES DO FABRICANTE PARA ESTE EQUIPAMENTO E AS PARTES  
DE USO, E SIGA AS PRÁTICAS DE SEGURANÇA DO EMPREGADOR.  
Download from Www.Somanuals.com. All Manuals Search And Download.  
• World's Leader in Welding and Cutting Products •  
• Sales and Service through Subsidiaries and Distributors Worldwide •  
Cleveland, Ohio 44117-1199 U.S.A. TEL: 216.481.8100 FAX: 216.486.1751 WEBꢀSITE: www.lincolnelectric.com  
Download from Www.Somanuals.com. All Manuals Search And Download.  

3D Innovations Dishwasher 68417800000 User Manual
Abocom Network Card RE450 User Manual
ADIC Life Jacket FileServ Version 441601363 User Manual
AEG Oven BP5013001M User Manual
Aiphone Intercom System 0311 A OI User Manual
Airlink101 Computer Drive AWLL5088 User Manual
Ask Proxima Projector C2 COMPACT User Manual
Avet Reels Fishing Equipment MXJ 581 User Manual
Barco Car Video System MDCC 6230 User Manual
Beko Flat Panel Television Plasma TV User Manual