Lincoln Electric AIR VANTAGE 500 CUMMINS IM826-A User manual

October, 2009
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 NSTALL, OPERATE OR
REPA R TH S EQU PMENT
W THOUT READ NG TH S
MANUAL AND THE SAFETY
PRECAUT ONS CONTA NED
THROUGHOUT. Most
importantly, think before you
act and be careful.
OPERATOR’S MANUAL
opyright© Lincoln Global Inc.
• World’s Leader in Welding and utting Products •
• Sales and Service through Subsidiaries and Distributors Worldwide •
leveland, Ohio 44117-1199 USA Tel: [phone] Fax: [phone] Web Site: www.lincolnelectric.com
IM826-A
For use with machines having ode Numbers: 11069, 11417
AIR VANTAGE 500 CUMMINS
R
C US
®®

ELECTRC AND
MAGNETC F ELDS
may be dangerous
2.a.Electric current flowing through any conductor causes
localized Electric and Magnetic Fields (EMF). Welding
current creates EMF fields around welding cables and
welding machines.
2.b.EMF fields may interfere with some pacemakers and welders
having a pacemaker should consult their physician before
welding.
2.c.Exposure to EMF fields in welding may have other health
effects which are now not known.
2.d.All welders should use the following procedures in order to
minimize exposure to EMF fields from the welding circuit:
2.d.1. Route the electrode and work cables together.
Secure them with tape when possible.
2.d.2. Never coil the electrode lead around your body.
2.d.3. Do not place your body between the electrode
and work cables. If the electrode cable is on your
right side, the work cable should also be on your
right side.
2.d.4. onnect the work cable to the workplace as
close as possible to the area being welded.
2.d.5. Do not work next to welding power source.
1.h. To avoid scalding, do not remove the
radiator pressure cap when the engine is
hot.
For Diesel Engines: diesel engine exhaust and
some of its constituents are known to the State of
alifornia to cause cancer, birth defects, and other
reproductive harm.
For Gasoline Engines: The engine exhaust from this
product contains chemicals known to the State of
alifornia to cause cancer, birth defects, or other
reproductive harm.
ARC WELD NG CAN BE HAZARDOUS. PROTECT YOURSELF AND OTHERS FROM POSS BLE SER OUS NJURY OR DEATH.
KEEP CH LDREN AWAY. PACEMAKER WEARERS SHOULD CONSULT W TH THE R DOCTOR BEFORE OPERAT NG.
Read and understand the following safety highlights. For additional safety information, it is strongly recommended that you
purchase a copy of “Safety in Welding & utting - ANSI Standard Z49.1” from the American Welding Society, PO Box
351040, Miami, Florida 33135 or SA Standard W117.2-1974 or WTIA (Welding Technology Institute of Australia), PO Box
6165, Silverwater, NSW, 2128. A free copy of “Arc Welding Safety” booklet E205 is available from the Lincoln Electrical
ompany, 22801 St lair Avenue, leveland, Ohio 44117-1199.
BE SURE THAT ALL NSTALLAT ON, OPERAT ON, MA NTENANCE AND REPA R PROCEDURES ARE
PERFORMED ONLY BY QUAL F ED ND V DUALS.
1.a Turn the engine off before troubleshooting and maintenance
work unless the maintenance work requires it to be running.
1.b. Operate engines in open, well ventilated
areas or vent the engine exhaust fumes
outdoors.
1.c. Do not add fuel near an open flame, welding
arc or when the engine is running. Stop the
engine and allow it to cool before refuelling
to prevent spilled fuel from vaporizing on
contact with hot engine parts and igniting.
Do not spill fuel when filling tank. If fuel is
spilled, wipe it up and do not start engine
until fumes have been eliminated.
1.d.Keep all equipment, safety guards, covers and devices in
position and in good repair. Keep hands, hair, clothing and
tools away from V-belts, gears, fans and all other moving
parts when starting, operating or repairing equipment.
1.e.In some cases it may be necessary to remove safety guards
to perform required maintenance. Remove guards only when
necessary and replace them when the maintenance
requiring their removal is complete. Always use the greatest
care when working near moving parts.
1.f. Do not put your hands near the engine fan.
Do not attempt to override the governor or
idler by pushing on the throttle control rods
while the engine is running.
1.g.To prevent accidentally starting petrol engines while turning
the engine or welding generator during maintenance work,
disconnect the spark plug wires, distributor cap or magneto
wire as appropriate.
iSAFETY i
CAL FORN A PROPOS T ON 65 WARN NGS
WARN NG
FOR ENG NE
powered equipment.
Mar ‘95

ELECTR C SHOCK
can 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.
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.
n 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:
• Semiautomatic DC Constant Voltage (Wire) Welder.
• DC Manual (Stick) Welder.
• AC Welder with Reduced Voltage Control.
3.c. In semi-automatic or automatic wire welding, the
electrode, electrode reel, welding head, nozzle or semi-
automatic 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.
3.g. Never dip the electrode holder 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.
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 6c and 8.
FUMES AND GASES
can be dangerous
5. . Welding m y produce fumes nd g ses
h z rdous to he lth. Avoid bre thing these
fumes nd g ses. When welding, keep
your he d out of the fume. Use enough
ventil tion nd/or exh ust t the rc to keep
fumes nd g ses w y from the bre thing zone. When
weld ng w th electrodes wh ch requ re spec al
vent lat on such as sta nless or hard fac ng (see
nstruct ons on conta ner or MSDS) or on lead or
cadm um plated steel and other metals or coat ngs
wh ch produce h ghly tox c fumes, keep exposure as
low as poss ble and w th n appl cable OSHA PEL and
ACGIH TLV l m ts us ng local exhaust or mechan cal
vent lat on. In conf ned spaces or n some
c rcumstances, outdoors, a resp rator may be requ red.
Add t onal precaut ons are also requ red when weld ng
on galvan zed steel.
5. b. The oper tion of welding fume control equipment is
ffected by v rious f ctors including proper use nd
positioning of the equipment, m inten nce of the
equipment nd the specific welding procedure nd
pplic tion involved. Worker exposure level should be
checked upon inst ll tion nd periodic lly there fter to be
cert in it is within pplic ble OSHA PEL nd ACGIH TLV
limits.
5.c.
Do not weld in loc tions ne r chlorin ted hydroc rbon v pors
coming from degre sing, cle ning or spr ying oper tions.
The he t nd r ys of the rc c n re ct with solvent v pors
to form phosgene, highly toxic g s, nd other irrit ting
products.
5.d. Shielding g ses used for rc welding c n displ ce ir nd
c use injury or de th. Alw ys use enough ventil tion,
especi lly in confined re s, to insure bre thing ir is s fe.
5.e. Re d nd underst nd the m nuf cturer’s instructions for
this equipment nd the consum bles to be used, including
the m teri l s fety d t sheet (MSDS) nd follow your
employer’s s fety pr ctices. MSDS forms re v il ble from
your welding distributor or from the m nuf cturer.
5.f. Also see item 1.b.
ARC RAYS can burn.
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
Z87.1 standards.
4.b.Use suitable clothing made from durable flame resistant
material to protect your skin and that of your helpers from the
arc rays.
4.c.Protect other nearby personnel with suitable non flammable
screening and/or warn them not to watch the arc or expose
themselves to the arc rays or to hot spatter or metal.
ii SAFETY ii
J n ‘09

iii SAFETY iii
FOR ELECTR CALLY
powered equipment.
8.a. Turn off input power using the disconnect
switch at the fuse box before working on
the equipment.
8.b. Install equipment in accordance with the U.S. National
Electrical ode, all local codes and the manufacturer’s
recommendations.
8.c. Ground the equipment in accordance with the U.S. National
Electrical ode and the manufacturer’s recommendations.
CYL NDER may explode
if damaged.
7.a. Use only compressed gas cylinders
containing the correct shielding gas for the
process used and properly operating
regulators designed for the gas and
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.
7.c. ylinders 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.
7.d. Never allow the electrode, electrode holder or any other
electrically “hot” parts to touch a cylinder.
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 GA publication P-l,
“Precautions for Safe Handling of ompressed Gases in
ylinders,” available from the ompressed Gas Association
1235 Jefferson Davis Highway, Arlington, VA 22202.
WELD NG and CUTT NG
SPARKS can
cause fire or explosion.
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.
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.
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 utting” (ANSI
Standard Z49.1) and the operating information for the
equipment being used.
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.
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 utting of
ontainers and Piping That Have Held Hazardous
Substances”, AWS F4.1 from the American Welding Society
(see address above).
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.
6.g. onnect 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 circuits.
This can create fire hazards or overheat lifting chains or
cables until they fail.
6.h. Also see item 1.c.
6.I. Read and follow NFPA 51B “ Standard for Fire Prevention
During Welding, utting 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.l ncolnelectr c.com/safety for ddition l s fety inform tion.
J n ‘09

iv SAFETY iv
Mar. ‘93
PRÉCAUT ONS DE SÛRETÉ
Pour votre propre protection lire et observer toutes les instructions
et les précautions de sûreté specifiques qui parraissent dans ce
manuel aussi bien que les précautions de sûreté générales
suivantes:
Sûreté Pour Soudage A L’Arc
1. Protegez-vous contre 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.
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.
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.
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
rayonnement de l’arc et des projections quand on soude ou
quand on regarde l’arc.
b. Porter des vêtements convenables afin de protéger la peau
de soudeur et des aides contre le rayonnement de l‘arc.
c. Protéger l’autre personnel travaillant à proximité au
soudage à l’aide d’écrans appropriés et non-inflammables.
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,
pantalons sans revers, et chaussures montantes.
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.
6. Eloigner les matériaux inflammables ou les recouvrir afin de
prévenir tout risque d’incendie dû aux étincelles.
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.
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 levage,
câbles de grue, ou autres circuits. ela peut provoquer des
risques d’incendie ou d’echauffement des chaines et des
câbles jusqu’à ce qu’ils se rompent.
9. Assurer une ventilation suffisante dans la zone de soudage.
eci 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.
11. Pour obtenir de plus amples renseignements sur la sûreté, voir
le code “ ode for safety in welding and cutting” SA Standard
W 117.2-1974.
PRÉCAUT ONS DE SÛRETÉ POUR
LES MACH NES À SOUDER À
TRANSFORMATEUR ET À
REDRESSEUR
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.
2. Autant que possible, I’installation et l’entretien du poste seront
effectués par un électricien qualifié.
3. Avant de faires des travaux à l’interieur de poste, la
debrancher à l’interrupteur à la boite de fusibles.
4. Garder tous les couvercles et dispositifs de sûreté à leur place.

v v
TThhaannkk YYoouufor selecting a QUAL TY product by Lincoln Electric. We want you
to take pride in operating this Lincoln Electric ompany product •••
as much pride as we have in bringing this product to you!
Read this Operators Manual completely before attempting to use this equipment. Save this manual 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:
WARN NG
This statement appears where the information must be followed exactly to avoid serious personal injury
or loss of life.
This statement appears where the information must be followed to avoid minor personal injury or damage
to this equipment.
CAUT ON
Please Examine Carton and Equipment For Damage mmediately
When this equipment is shipped, title passes to the purchaser upon receipt by the carrier. onsequently,
laims 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 ____________________________________________________________________
ode Number or Date ode____________________________________________________________
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: omplete 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
WEB S TE at www.lincolnelectric.com. hoose “Quick Links” and then
“Product Registration”. Please complete the form and submit your registration.
CUSTOMER ASS STANCE POL CY
The business of The Lincoln Electric ompany is manufacturing and selling high quality welding equipment, consumables, and cutting
equipment. Our challenge is to meet the needs of our customers and to exceed their expectations. On occasion, purchasers may ask
Lincoln Electric for advice or information about their use of our products. We respond to our customers based on the best information in
our possession at that time. Lincoln Electric is not in a position to warrant or guarantee such advice, and assumes no liability, with respect
to such information or advice. We expressly disclaim any warranty of any kind, including any warranty of fitness for any customer’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 hange – 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.

Page
nstallation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Section A
Technical Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .A-1
Safety Precautions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .A-2
Location / Ventilation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .A-2
Storing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .A-2
Stacking . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .A-2
Angle of Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .A-2
Lifting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .A-3
High Altitude Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .A-3
High Temperature Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .A-3
Towing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .A-3
Vehicle Mounting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .A-3
Pre-Operation Engine and ompressor Service . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .A-4
Oil . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .A-4
Fuel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .A-4
Fuel ap . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .A-4
Engine ooling System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .A-4
Battery onnection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .A-4
Muffler Outlet Pipe . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .A-5
Spark Arrestor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .A-5
Air leaner Inlet Hood . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .A-5
Welding Terminals . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .A-5
Welding Output ables . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .A-5
Machine Grounding . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .A-5
Remote ontrol . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .A-6
Auxiliary Power Receptacles . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .A-6
Standby Power onnections . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .A-6
onnection of Vantage Premises Wiring . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .A-7
onnection of Lincoln Electric Wire Feeders . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .A-8, A-9
Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Section B
Safety Instructions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .B-1
General Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .B-1
Recommended Applications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .B-1
Air ompressor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .B-1
ontrols and Settings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .B-2
Engine ontrols . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .B-2, B-3
Welder ontrols . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .B-4
Auxiliary Power ontrols . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .B-4
Air ompressor ontrols . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .B-5
Battery Jump Start Terminals . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .B-5
Engine Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .B-5
Starting the Engine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .B-5
Stopping the Engine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .B-5
Break-In Period . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .B-6
Typical Fuel onsumption . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .B-6
Duty ycle . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .B-6
Welding Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .B-6
Stick Welding Mode . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .B-6
-Stick Mode . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .B-6
Downhill Pipe Mode . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .B-6
Touch Start TIG Mode . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .B-6
AIR VANTAGE® Settings when using K930-2 TIG Module . . . . . . . . . . . . . . . . . . . . . . . . .B-7
Typical urrent Ranges for Tungsten Electrodes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .B-7
V-Wire Mode . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .B-8
Arc Gouging . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .B-8
Paralleling . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .B-8
Auxiliary Power Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .B-8
Simultaneous Welding and Auxiliary Power Loads . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .B-8
Simultaneous Welding and Power Loads, Extension ord Length Recommendations . . . . . . . . . . .B-9
vi vi
TABLE OF CONTENTS

Accessories . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Section C
Optional Field Installed Accessories . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . -1
_________________________________________________________________________________________________
Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Section D
Safety Precautions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .D-1
Routine and Periodic Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .D-1
Engine Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .D-1
Air Filter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .D-1,D-2
Fuel Filters . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .D-3
ooling System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .D-3
Battery Handling . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .D-3
harging the Battery . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .D-4
Nameplate / Warning Decal Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .D-4
Welder / Generator Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .D-4
Engine Maintenance omponents . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .D-4
GF I Receptacle Testing and Resetting Procedure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .D-4
Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Section E
Wiring, Connection Diagrams and Dimension Print . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Section F
Parts Lists . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .P-495 Series
vii vii
TABLE OF CONTENTS

TECHN CAL SPEC F CAT ONS - A R VANTAGE® 500 CUMM NS (K2325-1)
NPUT - D ESEL ENG NE
Make /Model Description Speed (RPM) Displacement Starting Capacities
System
ummins 4 cylinder High Idle 1900 199 cu. in 12VD battery Fuel
B3.3 56HP (42 kw) Low Idle 1425 (3.3L) & Starter (25 US gal)
Diesel Engine @ 1800 RPM Full Load 1800 94.6L
Bore x Stroke Oil:
(2 US gal)
3.74” x 4.53” 7.5L
(95mm x 115mm) oolant:
(2.6 US gal)
9.8L
RATED OUTPUT @ 104°F(40°C) - WELDER
Duty Cycle Welding Output Volts at Rated Amps
100% 500 Amps (D multi-purpose) 40 Volts
60% 550 Amps (D multi-purpose) 36 volts
50% 575 Amps (D multi-purpose) 35 volts
PHYS CAL D MENS ONS
Height (2) Width Depth Weight
42.0 in 32.7 in. 63.1 in. 1690 lbs.
(1066.8 mm) (830.1mm) (1603mm) (766kg)
(Approx)
1. Output rating in watts is equivalent to volt-amperes at unity power factor.
Output voltage is within +/- 10% at all loads up to rated capacity. When welding, available auxiliary power will be reduced.
2. Top of Enclosure, add 7.0” (177.8mm) for exhaust pipe.
OUTPUT @ 104°F(40°C) - WELDER AND GENERATOR
Welding Range
30 - 575 Amps / V
20 - 250 Amps TIG
Open Circuit Voltage
60 Max O V @ 1900 RPM
Auxiliary Power (1)
120/240 VA
12,000 WATTS, 60 Hz., Single Phase
20,000 WATTS, 60 Hz., Three Phase
A-1 NSTALLAT ON A-1
A R VANTAGE® 500 CUMM NS

Read this entire installation section before you start
installation.
SAFETY PRECAUT ONS
Do not attempt to use this equipment until you have
thoroughly read all operating and maintenance manuals
supplied with your machine. They include important safety
precautions, detailed engine starting, operating and
maintenance instructions and parts lists.
ELECTR C SHOCK can kill.
• Do not touch electrically live parts such as
output terminals or internal wiring.
• nsulate yourself from the work and ground.
• Always wear dry insulating gloves.
-------------------------------------------------------------------------------------
ENG NE EXHAUST can kill.
• Use in open, well ventilated areas or vent
exhaust outside
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MOV NG PARTS can injure.
• Do not operate with doors open or guards off.
• Stop engine before servicing.
• Keep away from moving parts
-------------------------------------------------------------------------------------
Only qualified personnel should install, use or service this
equipment.
LOCAT ON / VENT LAT ON
The welder should be located to provide an unrestricted 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 properly vented to an outside area.
DO NOT MOUNT OVER COMBUST BLE 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.
--------------------------------------------------------------------------------------
STOR NG
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 construction activities, moving
vehicles, and other hazards.
2. Drain the engine oil and refill with fresh 10W30 oil. Run the
engine for about five minutes to circulate oil to all the parts.
See the MAINTENAN E section of this manual for details
on changing oil.
3. Remove the battery, recharge it, and adjust the electrolyte
level. Store the battery in a dry, dark place.
STACK NG
AIR VANTAGE® 500 machines cannot be stacked.
ANGLE OF OPERAT ON
To achieve optimum engine performance the AIR VANTAGE®
500 should be run in a level position. The maximum angle of
operation for the VMA ompressor and ummins engine is 35
degrees in all directions. When operating the welder at an angle,
provisions must be made for checking and maintaining the oil
level at the normal (FULL) oil capacity. Also the effective fuel
capacity will be slightly less than the specified 25 gal.(94.6 ltrs.).
A-2 NSTALLAT ON A-2
A R VANTAGE® 500 CUMM NS
WARN NG
CAUT ON

L FT NG
The AIR VANTAGE® 500 lift bale should be used to lift the
machine. The AIR VANTAGE® 500 is shipped with the lift bale
retracted. Before attempting to lift the AIR VANTAGE® 500 the lift
bale must be secured in a raised position. Secure the lift bale as
follows:
a. Open the engine compartment door.
b. Locate the 2 access holes on the upper middle region
of compartment wall just below the lift bale.
c. Use the lifting strap to raise the lift bale to the full upright
position. This will align the mounting holes on the lift
bale with the access holes.
d. Secure the lift bale with 2 thread forming screws. The
screws are provided in the shipped loose parts bag.
FALL NG EQU PMENT can cause injury.
• Do not lift this machine using lift bale if it is
equipped with a heavy accessory such as a
trailer or gas cylinder.
• Lift only with equipment of adequate lifting
capacity.
•` Be sure machine is stable when lifting.
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H GH ALT TUDE OPERAT ON
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.).
ontact a ummins Service Representative for any engine
adjustments that may be required.
H GH TEMPERATURE OPERAT ON
At temperatures above 40° (104°F), output voltage derating
may be necessary. For maximum output current ratings, derate
welder voltage rating 2 volts for every 10° (21°F) above 40°
(104°F).
TOW NG
The recommended trailer for use with this equipment for road, in-
plant and yard towing by a vehicle (1) is 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:
1. Design capacity of trailer vs. weight of Lincoln
equipment and likely additional attachments.
2. Proper support of, and attachment to, the base of the
welding equipment so that there will be no undue stress
to the trailer’s framework.
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.
4. Typical conditions of use, such as travel speed,
roughness of surface on which the trailer will be
operated, and environmental conditions.
5. Proper preventative maintenance of trailer.
6. onformance with federal, state and local laws (1) .
(1) onsult applicable federal, state and local laws regarding
specific requirements for use on public highways.
VEH CLE MOUNT NG
mproperly mounted concentrated loads may cause unstable
vehicle handling and tires or other components to fail.
• 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 components such
as suspension, axles and tires.
• Mount equipment base to metal bed or frame of vehicle.
• Follow vehicle manufacture’s instructions.
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A-3 NSTALLAT ON A-3
A R VANTAGE® 500 CUMM NS
WARN NG
WARN NG

PRE-OPERAT ON ENG NE AND
COMPRESSOR SERV CE
READ the engine and compressor operating and maintenance
instructions supplied with this machine.
• Keep hands away from the engine muffler or
HOT engine parts.
• 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.
• Wipe up spilled fuel and allow fumes to clear before
starting engine.
• Keep sparks and flame away from tank.
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O L
The AIR VANTAGE® 500 is shipped with the engine crankcase
filled with high quality SAE 10W-30 oil (API class D or better).
heck 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. heck the oil level every four hours of running time
during the first 35 running hours. Refer to the engine and
compressor Operator’s Manuals for specific oil recommendations
and break-in information. The oil change interval is dependent on
the quality of the oil and the operating environment. Refer to the
engine and compressor Operator’s Manuals for the proper
service and maintenance intervals.
FUEL USE D ESEL FUEL ONLY
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 specific fuel recommendations. Running
out of fuel may require bleeding the fuel injection pump.
NOTE: Before starting the engine, open the fuel shutoff valve
(pointer to be in line with hose).
FUEL CAP
Remove the plastic cap covering from the Fuel Tank Filler neck
and install the Fuel ap.
ENG NE COOLANT
HOT COOLANT can burn skin.
•Do not remove cap if radiator is hot.
-------------------------------------------------------------------------------------
The welder is shipped with the engine and radiator filled with a
50% mixture of ethylene glycol and water. See the
MAINTENAN E section and the engine Operator’s Manual for
more information on coolant.
BATTERY CONNECT ON
GASES FROM BATTERY can explode.
• Keep sparks, flame and cigarettes away from
battery.
To prevent EXPLOS ON when:
• NSTALL NG A NEW BATTERY — disconnect
negative cable from old battery first and
connect to new battery last.
• CONNECT NG 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.
• US NG A BOOSTER — connect positive lead to battery first
then connect negative lead to negative battery lead at
engine foot.
BATTERY AC D can burn eyes and skin.
• Wear gloves and eye protection and be careful
when working near battery.
• Follow instructions printed on battery.
MPORTANT: To prevent ELE TRI AL DAMAGE WHEN:
a) Installing new batteries.
b) Using a booster.
Use correct polarity — Negative Ground.
A-4 NSTALLAT ON A-4
A R VANTAGE® 500 CUMM NS
WARN NG WARN NG
WARN NG

The AIR VANTAGE® 500 is shipped with the negative battery
cable disconnected. Before you operate the machine, make sure
the Engine Switch is in the OFF position and attach the
disconnected cable securely to the negative (-) battery terminal.
Remove the 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 battery may require a booster charge. Be
sure to use the correct polarity when charging the battery.
MUFFLER OUTLET P PE
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.
SPARK ARRESTOR
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 does not qualify as a spark arrestor. When required by
local regulations, a suitable spark arrestor, must be installed and
properly maintained.
An incorrect arrestor may lead to damage to the engine or
adversely affect performance.
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A R CLEANER NLET HOOD
Remove the plastic plug covering the air cleaner inlet. Install the
air cleaner inlet hood to the air cleaner.
WELD NG TERM NALS
The AIR VANTAGE® 500 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 ONTROLLED" position.
WELD NG 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 provided. These connections should be checked
periodically and tightened if necessary.
Listed in Table A.1 are copper cable sizes recommended for the
rated current and duty cycle. Lengths stipulated are the distance
from the welder to work and back to the welder again. able sizes
are increased for greater lengths primarily for the purpose of
minimizing cable voltage drop.
Table A.1 Combined Length of Electrode and Work Cables.
MACH NE GROUND NG
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.).
To prevent dangerous electric shock, other equipment powered
by this engine driven welder must:
a) be grounded to the frame of the welder using a
grounded type plug,
or
b) be double insulated.
When this welder is mounted on a truck or trailer, its frame must
be securely connected to the metal frame of the vehicle. When
this engine driven welder is connected to premises wiring such as
that in a home or shop, its frame must be connected to the system
earth ground. See further connection instructions in the section
entitled “Standby Power onnections” as well as
the article on grounding in the latest National Electrical ode and
the local codes.
In general, if the machine is to be grounded, it should be
connected with a #8 or larger copper wire to a solid earth ground
such as a metal ground stake going into the ground for at least 10
Feet or to the metal framework of a building which has been
effectively grounded. The National Electric ode lists a number of
alternate means of grounding electrical equipment. A machine
grounding stud marked with the symbol is provided on the
front of the welder.
A-5 NSTALLAT ON A-5
A R VANTAGE® 500 CUMM NS
CAUT ON
AMPS Up to 150ft 150-200ft 200-250ft
@100% Up to 45.7m 45.7-70.0m 70.0-76.2m
Duty ycle
500 3/0 AWG 3/0 AWG 4/0 AWG
TOTAL OMBINED LENGTH OF
ELE TRODE AND WORK ABLES

REMOTE CONTROL
OUTPUT
The AIR VANTAGE® 500 is equipped with a 6-pin and a 14-pin
connector. The 6-pin connector is for connecting the K857 or
K857-1 Remote ontrol or for TIG welding, the K870 foot Amptrol
or the K936-2 hand Amptrol. When in the -STI K, DOWNHILL
PIPE, or V-WIRE modes and when a remote control is
connected to the 6-pin onnector, the auto-sensing circuit
automatically switches the OUTPUT control from control at the
welder to remote control.
When in TOU H START TIG mode and when a Amptrol is
connected to the 6-Pin onnector, the OUTPUT dial is used to set
the maximum current range of the URRENT ONTROL of the
Amptrol.
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.
EXAMPLE: When the OUTPUT ONTROL 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.
The 14-pin connector is used to directly connect a wire feeder
control cable. In the V-WIRE mode, when the control cable is
connected to the 14-pin connector, the auto-sensing circuit
automatically makes the Output ontrol inactive and the wire
feeder voltage control active
NOTE: When a wire feeder with a built in welding voltage
control is connected to the 14-pin connector, do not connect
anything to the 6-pin connector.
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AUX L ARY 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 GF I receptacle can
be reset properly. See the MAINTENAN E section for detailed
information on testing and resetting the GF I receptacle.
The auxiliary power capacity of the AIR VANTAGE® 500 is
12,000 watts of 60 Hz, single phase or 20,000 watts of 60Hz,
three phase power. The auxiliary power capacity rating in watts
is equivalent to volt-amperes at unity power factor. The maximum
permissible current of the 240 VA output is 50 A. The 240 VA
single phase output can be split to provide two separate 120 VA
outputs with a maximum permissible current of 50 A per output to
two separate 120 VA branch circuits. The output voltage is
within ± 10% at all loads up to rated capacity.
The AIR VANTAGE® 500 has two 20 Amp-120VA single
phase(5-20R) GF I duplex receptacles, one 50 Amp-120/240
single phase VA (14-50R) receptacle and one 240VA three
phase (15-50R) receptacle. The auxiliary power receptacles
should only be used with three wire grounded type plugs or
approved double insulated tools with two wire plugs. The current
rating of any plug used with the system must be at least equal to
the current capacity of the associated receptacle.
A 240VA 3 phase plug is provided loose with the machine.
NOTE: The two 120V GF I receptacles and the two 120 volt
circuits of the 120/240V receptacle are connected to different
phases and can not be paralleled.
STANDBY POWER CONNECT ONS
The AIR VANTAGE® 500 is suitable for temporary, standby or
emergency power using the engine manufacturer’s
recommended maintenance schedule.
The AIR VANTAGE® 500 can be permanently installed as a
standby power unit for 240 volt-3 wire, 50 amp service.
onnections must be made by a licensed electrician who can
determine how the 120/240 VA 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.2.
1. Install the double-pole, double-throw switch between the power
company meter and the premises disconnect.
Switch rating must be the same or greater than the customer’s
premises disconnect and service over current protection.
A-6 NSTALLAT ON A-6
A R VANTAGE® 500 CUMM NS
WARN NG

A R VANTAGE® 500 CUMM NS
A-7 NSTALLAT ON A-7
2. Take necessary steps to assure load is limited to the capacity
of the AIR VANTAGE® 500 by installing a 50 amp, 240 VA
double pole circuit breaker. Maximum rated load for each leg
of the 240 VA 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 engine.
3. Install a 50 amp 120/240 VA 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 VA plug is
available in the optional K802R plug kit.)
4. Plug this cable into the 50 Amp 120/240 Volt receptacle on the
AIR VANTAGE® 500 case front.
Figure A.2 Connection of the A R VANTAGE® 500 to Premises Wiring
240 Volt
60 Hz.
3-Wire
Service
POWER

COMPANY

METER
240 VOLT
120 VOLT
120 VOLT
LOAD
N
NEUTRAL
BUS
GROUND
PREMISES
DISCONNECT AND
SERVICE
OVERCURRENT
PROTECTION
GND
N
NOTE: No. 6 COPPER CONDUCTOR CABLE SEE
NATIONAL ELECTRICAL CODE FOR ALTERNATE WIRE
SIZE RECOMMENDATIONS.
240 VOLT
GROUNDED CONDUCTOR
50AMP
240 VOLT
DOUBLE
POLE
CIRCUIT
BREAKER
DOUBLE POLE DOUBLE THROW
SWITCH RATING TO BE THE SAME
AS OR GREATER THAN PREMISES
SERVICE OVERCURRENT
PROTECTION.
50 AMP, 120/240
VOLT PLUG
NEMA TYPE 14-50
50 AMP, 120/240 VOLT
RECEPTACLE

CONNECT ON OF L NCOLN ELECTR C
W RE FEEDERS
Shut off welder before making any electrical connections.
-------------------------------------------------------------------------------------
CONNECT ON OF LN-7, LN-8 OR LN-742 TO THE
A R VANTAGE® 500
• Shut the welder off.
• onnect the LN-7, LN-8 OR LN-742 per instructions on the
appropriate connection diagram in the DIAGRAMS section.
• Set the “WIRE FEEDER VOLTMETER” switch to either “+” or “-
” as required by the electrode being used.
• Set the “SELE TOR” switch to the “ V-WIRE” position.
• Adjust the “AR ONTROL” knob to desired rispness. SOFT
for MIG and RISP for INNERSHIELD.
• Set the “WELDING TERMINALS” switch to the “REMOTELY
ONTROLLED” position.
• Set the “IDLE” switch to the “HIGH” position.
CONNECT ON OF LN-15 TO THE A R VANTAGE®
500
These connections instructions apply to both the LN-15 Across-
The-Arc and ontrol able 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.
• Shut the welder off.
• For electrode Positive, connect the electrode cable to the "+"
terminal of the welder and work cable to the "-" terminal of the
welder. For electrode Negative, connect the electrode cable "-"
terminal of the welder and work cable to the "+" terminal of the
welder.
• Across The-Arc Model:
Attach the single lead from the front of the LN-15 to work
using the spring clip at the end of the lead. This is a control
lead to supply current to the wire feeder motor; it does not
carry welding current.
Control Cable Model:
onnect ontrol able between Engine Welder and Feeder.
• Set the MODE switch to the " V-WIRE " position.
• Across The-Arc Model:
Set the "WELD TERMINALS" switch to "WELD TERMINALS
ON"
Control Cable Model:
Set the "WELD TERMINALS" switch to "REMOTELY
ONTROLLED"
• Set the "WIRE FEEDER VOLTMETER" switch to either "+" or
"-" as required by the electrode polarity being used.
• Set the "AR ONTROL" knob to "0" initially and adjust to suit.
• Set the "IDLE" switch to the "AUTO IDLE" position
A-8 NSTALLAT ON A-8
A R VANTAGE® 500 CUMM NS
WARN NG

CONNECT ON OF THE LN-25 TO THE A R
VANTAGE® 500
The LN-25 with or without an internal contactor may be used with
the AIR VANTAGE® 500. See the appropriate connection
diagram in the DIAGRAMS section.
NOTE: The LN-25 (K431) Remote ontrol Module and (K432)
Remote able are not recommended for use with the AIR
VANTAGE® 500.
• Shut the welder off.
• 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.
• 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 sense lead to
supply current to the wire feeder motor; it does not carry welding
current.
• Set the SELE TOR switch to the “ V-WIRE” position.
• Set the “WELDING TERMINALS” switch to “WELD
TERMINALS ON”
• Adjust the “AR ONTROL” knob to desired crispness.
Generally, welding is best if the “AR ONTROL” is set to
SOFT for MIG and RISP for INNERSHIELD. You may
however, want to start in the middle and adjust (as needed)
from there.
• Set the “IDLE” switch to the “AUTO” position. When not welding,
the AIR VANTAGE® 500 engine will be at the low idle speed. If
you are using an LN-25 with an internal contactor, the electrode
is not energized until the gun trigger is closed.
f you are using an LN-25 without an internal contactor, the
electrode will be energized when the A R VANTAGE® 500 is
started.
--------------------------------------------------------------------------------------
• When the gun trigger is closed, the current sensing circuit will
cause the wire to begin to feed and the welding process is
started.
CONNECT ON OF AN NA-3 AUTOMAT C
WELD NG SYSTEM TO THE A R VANTAGE® 500
For connection diagrams and instructions for connecting an NA-3
Welding System to the AIR VANTAGE® 500, refer to the NA-3
Welding System instruction manual. The connection diagram for
the LN-8 can be used for connecting the NA-3.
• Set the Wire Feeder Voltage Switch to 115V.
CONNECT ON OF MAGNUM SC SPOOL GUN TO
THE A R VANTAGE® 500 (SEE SECT ON F)
A-9 NSTALLAT ON A-9
A R VANTAGE® 500 CUMM NS
CAUT ON

SAFETY NSTRUCT ONS
Read and understand this entire section before operating
your A R VANTAGE® 500.
Do not attempt to use this equipment until you have
thoroughly read all operating and maintenance manuals
supplied with your machine. They include important safety
precautions, detailed engine starting, operating and
maintenance instructions and parts lists.
ELECTR C SHOCK can kill.
• Do not touch electrically live parts such as
output terminals or internal wiring.
• nsulate yourself from the work and ground.
• Always wear dry insulating gloves.
--------------------------------------------------------------------------------------
ENG NE EXHAUST can kill.
• Use in open, well ventilated areas or vent
exhaust outside
• Do not stack anything near the engine.
--------------------------------------------------------------------------------------
MOV NG PARTS can injure.
• 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.
ADD T ONAL SAFETY PRECAUT ONS
Always operate the welder with the sliding door closed and
the side panels in place as these provide maximum
protection from moving parts and insure proper cooling air
flow.
GENERAL DESCR PT ON
The AIR VANTAGE® 500 is a diesel engine-driven welding power
source. The machine uses a brush type alternating current
generator for D multi-purpose welding, for 120/240 VA single
phase and 240V three phase auxiliary standby power. The AIR
VANTAGE® 500 also has a rotary screw 60 cfm air compressor
built in.The welding control system uses state of the art Chopper
Technology™.
RECOMMENDED APPL CAT ONS
WELDER
The AIR VANTAGE® 500 provides excellent constant current D
welding output for stick (SMAW) and TIG welding. The AIR
VANTAGE® 500 also provides excellent constant voltage D
welding output for MIG (GMAW), Innershield (F AW), outershield
(F AW-G) and Metal ore welding. In addition the AIR
VANTAGE® 500 can be used for Arc Gouging with carbons up to
3/8”(10mm) in diameter.
The AIR VANTAGE® 500 is not recommended for pipe thawing.
A R COMPRESSOR
The AIR VANTAGE® 500 provides 60 cfm at 100 psi.
compressed air for Arc Gouging and Air powered tools.
GENERATOR
The AIR VANTAGE® 500 provides smooth 120/240 VA single phase
and 240V three phase output for auxiliary power and emergency standby
power.
B-1 OPERAT ON B-1
A R VANTAGE® 500 CUMM NS
WARN NG

ENG NE CONTROLS (Items 1 through 9)
1. RUN STOP SW TCH
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.
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.
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.
4. FUEL LEVEL GAUGE
Displays the level of diesel fuel in the fuel tank.
The operator must watch the fuel level closely to prevent
running out of fuel and possibly having to bleed the system.
5. ENG NE TEMPERATURE GAUGE
The gauge displays the engine coolant temperature.
B-2 OPERAT ON B-2
A R VANTAGE® 500 CUMM NS
CONTROLS AND SETT NGS
All welder and engine controls are located on the case front panel. Refer to Figure B.1 and the explanations that follow.
Figure B.1 Case Front Panel Controls
3
45678910
11
12
15
14
24
25
13
1
2
17
21
16
18
27
28
22
26
23
19
20

6. O L PRESSURE GAUGE
The gauge displays the engine oil pressure when the engine is
running.
7. ENG NE PROTECT ON
The yellow engine protection light remains off with proper oil
pressure and under normal operating temperatures. If the light
turns on, the engine protection system will stop the engine. heck
for proper oil level and add oil if necessary. heck 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.
8. BATTERY CHARG NG L GHT
The yellow engine alternator light is off when battery charging
system is functioning normally. If light turns on the alternator or
the voltage regulator 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.
9. DLER SW TCH
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:
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.
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.
c. When welding ceases and the A power load is turned
off, a fixed time delay of approximately 12 seconds
starts.
d. If the welding or A power load is not restarted 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 A. . power load is reapplied.
dler Operational exceptions
When the WELDING TERMINALS switch is in the “Remotely
ontrolled” position the idler will operate as follows:
a. When the triggering device (Amptrol, Arc Start Switch, etc.) is
pressed the engine will accelerate and operate at full speed
provided a welding load is applied within approximately 12
seconds.
• 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.
B-3 OPERAT ON B-3
A R VANTAGE® 500 CUMM NS