Lincoln Electric IM10065 User Manual

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AIR VANTAGE 500

CUMMINS

IM10065

May, 2012

For use with machine having Code Number:

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 READ­ING THIS MANUAL AND THE
SAFETY PRECAUTIONS CON­TAINED THROUGHOUT. And,

most importantly, think before
you act and be careful.

11651

• World's Leader in Welding and Cutting Products • • Sales and Service through Subsidiaries and Distributors Worldwide •

Cleveland, Ohio 44117-1199 U.S.A. TEL: [phone] For Service in U.S. and Canada: Call 1.888.935.3877

FAX: [phone] WEB SITE: lincolnelectric.com For Non-U.S. Service: Email [e-mail]

OPERATORʼS MANUAL

Copyright © Lincoln Global Inc.

i

SAFETY

i

WARNING

CALIFORNIA PROPOSITION 65 WARNINGS

Diesel engine exhaust and some of its constituents
are known to the State of California to cause can­cer, birth defects, and other reproductive harm.

The Above For Diesel Engines

ARC WELDING CAN BE HAZARDOUS. PROTECT YOURSELF AND OTHERS FROM POSSIBLE SERIOUS INJURY OR DEATH.
KEEP CHILDREN AWAY. PACEMAKER WEARERS SHOULD CONSULT WITH THEIR DOCTOR BEFORE OPERATING.

Read and understand the following safety highlights. For additional safety information, it is strongly recommended that you
purchase a copy of “Safety in Welding & Cutting - ANSI Standard Z49.1” from the American Welding Society, P.O. Box
351040, Miami, Florida 33135 or CSA Standard W117.2-1974. A Free copy of “Arc Welding Safety” booklet E205 is available
from the Lincoln Electric Company, 22801 St. Clair Avenue, Cleveland, Ohio 44117-1199.

BE SURE THAT ALL INSTALLATION, OPERATION, MAINTENANCE AND REPAIR PROCEDURES ARE
PERFORMED ONLY BY QUALIFIED INDIVIDUALS.

The engine exhaust from this product contains
chemicals known to the State of California to cause
cancer, birth defects, or other reproductive harm.

The Above For Gasoline Engines

FOR ENGINE
powered equipment.

1.a. Turn the engine off before troubleshooting and maintenance
work unless the maintenance work requires it to be running.

____________________________________________________

1.b. Operate engines in open, well-ventilated
areas or vent the engine exhaust fumes
outdoors.

____________________________________________________

1.c. Do not add the fuel n ear an open flame
welding arc or when the engine is running.
Stop the engine and allow it to cool before
refueling 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.h. To avoid scalding, do not remove the
radiator pressure cap when the engine is
hot.

ELECTRIC AND
MAGNETIC FIELDS
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.

___________________________________________________

1.g. To prevent accidentally starting gasoline engines while
turning the engine or welding generator during maintenance
work, disconnect the spark plug wires, distributor cap or
magneto wire as appropriate.

2.d.4. Connect the work cable to the workpiece as close as
possible to the area being welded.

2.d.5. Do not work next to welding power source.

ii

SAFETY

ii

ELECTRIC 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.

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:

• Semiautomatic DC Constant Voltage (Wire) Welder.

• DC Manual (Stick) Welder.

• AC Welder with Reduced Voltage Control.

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.

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.

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.

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. I 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 nor expose
themselves to the arc rays or to hot spatter or metal.

FUMES AND GASES
can be dangerous.

5.a. Welding ma y produce fumes and gases
hazardous to health. Avoid breathing these
fumes and gases. When welding, keep
your head out of the fume. Use enough
ventilation and/or exhaust at the arc to keep

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 circum­stances, outdoors, a respirator may be required.
Additional precautions are also required when welding
on galvanized steel.

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 spe­cific 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.

5.c.

Do not weld in locations near chlorinated hydrocarbon
coming from degreasing, cleaning or spraying operations.
The heat and rays of the arc can react with solvent vapors
form phosgene, a highly toxic gas, and other irritating prod­ucts.

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.

vapors

to

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.

iii

SAFETY

iii

WELDING and CUTTING
SPARKS can
cause fire or explosion.

6.a.

Remove fire hazards from the welding area.

If this is not possible, cover them to prevent

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 Cutting” (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
been “cleaned”. For information, purchase “Recommended
Safe Practices for the
Containers 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.

Sparks and spatter are thrown from the welding arc. Wear oil

6.f.
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. 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 cir­cuits. This can create fire hazards or overheat lifting chains
or cables until they fail.

6.h. Also see item 1.c.

the welding sparks from starting a fire.

though

they have

Preparation

for Welding and Cutting of

CYLINDER may explode
if damaged.

7.a. Use on ly com pr essed 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. 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.

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. Re ad and foll ow the inst ru ctions o n c ompressed 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.

FOR ELECTRICALLY
powered equipment.

8.a. Turn off input power using the disconnect
switch at the fuse box before working on
the equipment.

8.b. Ins tall 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.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.

iv

SAFETY

iv

PRÉCAUTIONS DE SÛRETÉ

Pour votre propre protection lire et observer toutes les instructions
et les précautions de sûreté specifiques qui parraissent dans ce
manuel aussi bien que les précautions de sûreté générales suiv­antes:

Sûreté Pour Soudage A LʼArc

1. Protegez-vous contre la secousse électrique:

a. Les circuits à lʼélectrode 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 sʼisoler 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 lʼeau 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 sʼapplicuent aussi au pistolet de
soudage.

6. Eloigner les matériaux inflammables ou les recouvrir afin de
prévenir tout risque dʼincendie 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 dʼincendie.

8. Sʼassurer que la masse est connectée le plus prés possible
de la zone de travail quʼil est pratique de le faire. Si on place
la masse sur la charpente de la construction ou dʼautres
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. Cela peut provoquer
des risques dʼincendie ou dʼechauffement des chaines et des
câbles jusquʼà ce quʼils se rompent.

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
dʼopérations de dégraissage, nettoyage ou pistolage. La
chaleur ou les rayons de lʼarc 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 “Code for safety in welding and cutting” CSA
Standard W 117.2-1974.

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 nʼimporte quelle partie
du corps.

3. Un coup dʼarc peut être plus sévère quʼun coup de soliel,
donc:

a. Utiliser un bon masque avec un verre filtrant approprié

ainsi quʼun verre blanc afin de se protéger les yeux du ray­onnement de lʼarc et des projections quand on soude ou
quand on regarde lʼarc.

b. Porter des vêtements convenables afin de protéger la

peau de soudeur et des aides contre le rayonnement de
lʻarc.

c. Protéger lʼautre personnel travaillant à proximité au

soudage à lʼaide dʼécrans appropriés et non-inflammables.

4. Des gouttes de laitier en fusion sont émises de lʼarc de
soudage. Se protéger avec des vêtements de protection libres
de lʼhuile, 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 lʼon pique le laitier.

PRÉCAUTIONS DE SÛRETÉ POUR
LES MACHINES À SOUDER À
TRANSFORMATEUR ET À
REDRESSEUR

1. Relier à la terre le chassis du poste conformement au code de
lʼélectricité 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, Iʼinstallation et lʼentretien du poste seront
effectués par un électricien qualifié.

3. Avant de faires des travaux à lʼinterieur de poste, la debranch­er à lʼinterrupteur à la boite de fusibles.

4. Garder tous les couvercles et dispositifs de sûreté à leur
place.

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.

v

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 compe­tent 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 prob­lems 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

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 recommenda­tions. 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 equip­ment, 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 equip­ment 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.

vi

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 connec­tion 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 prob­lems of interference. Screening of the entire welding installation may be considered for special

applications

1.

_________________________

1

Portions of the preceding text are contained in EN 60974-10: “Electromagnetic Compatibility (EMC) prod­uct standard for arc welding equipment.”

AIR VANTAGE®500 CUMMINS

Thank You

viivii

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!

The business of The Lincoln Electric Company 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 customerʼs 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.

CUSTOMER ASSISTANCE POLICY

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

Your Product”. 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:

WEB SITE at www.lincolnelectric.com. Choose “Support” and then “Register

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.

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

Electrical Device used with this Product.............................................................................A-10

________________________________________________________________________________

viii

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

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

®

Settings when using K930-2 TIG Module...........................................B-7

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 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

________________________________________________________________________

ix

A-1

INSTALLATION

TECHNICAL SPECIFICATIONS - AIR VANTAGE®500 CUMMINS (K2325-3)

INPUT - DIESEL ENGINE

Make/Model Description Speed (RPM) Displacement Starting Capacities

cu. in. (ltrs.) System

A-1

Cummins 56 HP (42kw) starter (94.6 L)
B3.3 1800 RPM Full Load 1800

4 cylinder High Idle 1900 199(3.3)

Bore x Stroke inch (mm)

Diesel Engine

Low Idle 1425

3.74 X 4.53

(95 x 115mm) 2.6gal. (9.8L)

12VDC Battery &

Fuel: 25 gal.

Oil: 2 gal. (7.5L)

Radiator Coolant:

RATED OUTPUT @ 104°F(40°C) - WELDER

Duty Cycle Welding Output Volts at Rated Amps

100% 500 Amps (DC multi-purpose) 40 Volts

60% 550 Amps (DC multi-purpose) 36 volts
50% 575 Amps (DC multi-purpose) 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

120/240 VAC

12,000 WATTS, 60 Hz., Single Phase

20,000 WATTS, 60 Hz., Three Phase

(1)

COMPRESSOR SPECIFICATIONS

Compressor Model

VMAC™

S700157

Description Delivary Maximum System Compressor Capacities

Belt-Drive Rotary

Screw Air Compressor 60 CFM @ 100PSI

High Idle Mode: 150 PSI

(28.3 Ltr/sec. @

7.0 kg/cm)

Low Idle Mode: High Temperature

40 CFM @ 100PSI Automatic Shutdown

(18.9 Ltr/sec. @ 290° F (143°C)

7.0 kg/cm)

Pressure Profection

Safety Relief Valve

(10.5 kg/cm2) 200 PSI

(10.5 kg/cm2)

PHYSICAL DIMENSIONS

Height

(1066.8 mm) (830.1mm) (1603mm) (766kg)

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.

(2)

42.0 in 32.7 in. 63.1 in. 1690 lbs.

Width Depth Weight

(Approx)

1.3 gal.(5.0 ltrs)

AIR VANTAGE®500 CUMMINS

A-2

INSTALLATION

A-2

SAFETY PRECAUTIONS

WARNING

Do not attempt to use this equipment until you
have thoroughly read the engine manufacturerʼs
manual supplied with your welder. It includes
important safety precautions, detailed engine
starting, operating and maintenance instructions,
and parts lists.

------------------------------------------------------------------------

ELECTRIC SHOCK can kill.

•

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.

•

Use in open, well ventilated areas or
vent exhaust outside.

------------------------------------------------------------------------

MOVING PARTS can injure.

•

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 operatorʼs manual.

Only qualified personnel should install,
use, or service this equipment.

LOCATION AND VENTILATION

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.

CAUTION

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.

------------------------------------------------------------------------

STORING

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 canʼt 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 MAINTE­NANCE 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.

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 posi­tion. 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

A-3

INSTALLATION

A-3

LIFTING

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:

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.

WARNING

• Lift only with equipment of ade­quate lifting capacity.

• Be sure machine is stable when lift­ing.

• Do not lift this machine using lift
bail if it is equipped with a heavy
accessory such as trailer or gas
cylinder.

FALLING • Do not lift machine if lift bail is

EQUIPMENT can damaged.

cause injury. • Do not operate machine while

suspended from lift bail.

------------------------------------------------------------------------

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.

TOWING

The recommended trailer for use with this equipment
for road, in-plant and yard towing by a vehicle
Lincolnʼs 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 trailerʼs 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. Conformance with federal, state and local laws

(1)

Consult applicable federal, state and local laws regarding
specific requirements for use on public highways.

(1)

(1)

.

VEHICLE MOUNTING

WARNING

Improperly 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 manufactureʼs instructions.

------------------------------------------------------------------------

is

HIGH TEMPERATURE OPERATION

At temperatures above 40°C (104°F), output voltage
derating may be necessary. For maximum output cur­rent ratings, derate welder voltage rating 2 volts for
every 10°C (21°F) above 40°C (104°F).

AIR VANTAGE®500 CUMMINS

A-4

INSTALLATION

PRE-OPERATION ENGINE AND COM­PRESSOR SERVICE

READ the engine and compressor operating and
maintenance instructions supplied with this machine.

WARNING

A-4

ENGINE COOLANT

WARNING

HOT COOLANT can burn skin.

•Do not remove cap if radiator is hot.

• 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 over­fill.

• Wipe up spilled fuel and allow fumes to clear
before starting engine.

• Keep sparks and flame away from tank.

------------------------------------------------------------------------

OIL

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 run­ning time during the first 35 running hours. Refer to
the engine and compressor Operatorʼs 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 Operatorʼs Manuals for
the proper service and maintenance intervals.

------------------------------------------------------------------------

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
Operatorʼs Manual for more information on coolant.

BATTERY CONNECTION

WARNING

GASES FROM BATTERY can explode.

• Keep sparks, flame and cigarettes
away from battery.

To prevent EXPLOSION when:

• 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 nega­tive battery lead at engine foot.

FUEL USE DIESEL 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 Operatorʼs Manual for specif­ic fuel recommendations. Running out of fuel may

require bleeding the fuel injection pump.

NOTE: Before starting the engine, open the fuel shut-

off 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 Cap.

AIR VANTAGE®500 CUMMINS

BATTERY ACID can burn eyes and skin.

• Wear gloves and eye protection and
be careful when working near battery.

• Follow instructions printed on battery.

------------------------------------------------------------------------

IMPORTANT: To prevent ELECTRICAL DAMAGE
WHEN:

a) Installing new batteries.

b) Using a booster.

Use correct polarity — Negative Ground.

A-5

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.

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.

INSTALLATION

MUFFLER OUTLET PIPE

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.

A-5

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. Cable 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.

TOTAL COMBINED LENGTH OF

ELECTRODE AND WORK CABLES

Cable Length

0-150 Ft. (0-46 meters)
150-200 Ft. (46-61 meters)
200-250 Ft. (61-76 meters)

Cable Size for

500 Amps

100% Duty Cycle

3/0 AWG (95mm
3/0 AWG (95mm

4/0 AWG(120mm

2)

2)

2)

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
has an internal spark arrestor. When required by local
regulations, a suitable spark arrestor, must be
installed and properly maintained.

CAUTION

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.

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.

MACHINE GROUNDING

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
to which this engine driven welder supplies power
must:

WARNING

• 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.

------------------------------------------------------------------------

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 Connections” as well as
the article on grounding in the latest National
Electrical Code and the local codes.

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 provid­ed. These connections should be checked periodically
and tightened if necessary.

AIR VANTAGE®500 CUMMINS

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 Code 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-6

INSTALLATION

A-6

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 maxi­mum current range of the remote.

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.

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 con­nector, the auto-sensing circuit automatically makes
the Output Control inactive and the wire feeder volt­age control active.

WARNING

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.

------------------------------------------------------------------------

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 can be reset properly. See the
MAINTENANCE section for detailed information on
testing and resetting the GFCI.

The AIR VANTAGE®500 CUMMINS has two 20 Amp­120VAC single phase(5-20R) GFCI duplex recepta­cles, one 50 Amp-120/240 single phase VAC (14­50R) receptacle and one 240VAC three phase (15­50R) 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 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 con­nected to different phases and can not be paralleled.

STANDBY POWER CONNECTIONS

The AIR VANTAGE®500 CUMMINS is suitable for
temporary, standby or emergency power using the
engine manufacturerʼs recommended maintenance
schedule.

The AIR VANTAGE
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.

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
customerʼs premises disconnect and service over cur­rent protection.

®

500 CUMMINS can be perma-

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 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 maximum per­missible 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

®

A-7

INSTALLATION

A-7

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.

Figure A.1 Connection of the AIR VANTAGE®500 to Premises Wiring

240 VOLT

240 Volt

60 Hz.

3-Wire

Service

POWER



COMPANY



METER

120 VOLT

120 VOLT

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 recep­tacle on the AIR VANTAGE

®

front.

GROUNDED CONDUCTOR

®

500 CUMMINS case

NEUTRAL
BUS

N

LOAD

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

240 VOLT

50AMP

240 VOLT

DOUBLE

POLE

CIRCUIT

BREAKER

GND

PREMISES

DISCONNECT AND

GROUND

N

SERVICE

OVERCURRENT

PROTECTION

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