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Lincoln Electric AIR VANTAGE 500 (AU) User Manual

Lincoln Electric AIR VANTAGE 500 (AU)
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Operator’s Manual
AIR VANTAGE
®
500 (AU)
Register your machine:
www.lincolnelectric.com/registration
Authorized Service and Distributor Locator:
www.lincolnelectric.com/locator
IM10066-A | Issue D ate May-12
© Lincoln Global, Inc. All Rights Reserved.
For use with machines having Code Numbers:
11656, 11661
Save for future reference
Date Purchased
Code: (ex: 10859)
Serial: (ex: U1060512345)
Need Help? Call 1.888.935.3877
to talk to a Service Representative
Hours of Operation:
8:00 AM to 6:00 PM (ET) Mon. thru Fri.
After hours?
Use “Ask the Experts” at lincolnelectric.com
A Lincoln Service Representative will contact you
no later than the following business day.
For Service outside the USA:
Email: globalservice@lincolnelectric.com
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Lincoln Electric AIR VANTAGE 500 (AU) Specifications

General IconGeneral
ModelAIR VANTAGE 500 (AU)
Output Current Range20 - 500 Amps
FuelDiesel
Power Factor1.0
Protection ClassIP23
TypeEngine Driven Welding Generator
ProcessesStick, TIG, MIG, Flux-Cored
Rated Output500 Amps
Input PowerN/A (Engine-Driven)
Engine Power24.8 HP
Frequency50 Hz

Summary

Safety Information

General Safety Precautions and Warnings

Covers essential safety advice, warnings, and cautions for operating the equipment.

Proposition 65 and Engine Exhaust Warnings

Details California Proposition 65 warnings and hazards related to engine exhaust.

Arc Welding and EMF Hazards

Highlights hazards of arc welding and exposure to electric and magnetic fields.

Electric Shock and Arc Ray Hazards

Addresses electric shock risks and protection from arc rays, with recommended safety measures.

Fumes, Gases, and Fire Prevention

Covers hazards from fumes and gases, and precautions against fire and explosion risks.

Cylinder Safety and EMC

Outlines precautions for cylinder safety and Electromagnetic Compatibility (EMC).

Installation

Technical Specifications

Provides detailed specifications for the engine, welder, compressor, and physical dimensions.

Location, Ventilation, and Storage

Covers requirements for unit placement, ventilation, and proper storage procedures.

Lifting, Altitude, and Towing Procedures

Details procedures for lifting, towing, and considerations for high altitude operation.

Pre-Operation Service (Engine, Compressor, Battery)

Details pre-operation checks for the engine, compressor, fuel, and battery connection.

Component Installation (Muffler, Air Cleaner, Terminals)

Describes installation of muffler, spark arrestor, and air cleaner components.

Cable Connections and Grounding

Details routing and connecting welding output cables and machine grounding procedures.

Remote Control and Power Connections

Explains connections for remote controls and setting up standby power systems.

Wire Feeder Connection Procedures

Details the procedure for connecting LN-7, LN-8, LN-742, and LN-15 wire feeders.

System Connection (LN-25, NA-3, Spool Gun)

Covers connecting the LN-25, NA-3 welding system, and spool guns.

Operation

Operation Overview and Applications

Provides a general description of the unit, its applications, and its compressor/generator functions.

Engine Controls

Details the engine controls including the run/stop switch, start button, hour meter, and gauges.

Welding Controls (Mode, Arc, Terminals)

Explains welding mode selector, arc control knob, and output terminals for welding operations.

Auxiliary Power Controls

Describes the controls for auxiliary power, including circuit breakers and receptacles.

VRD/ROCV Safety Devices

Explains Voltage Reduction Devices (VRD) and Reduced Open Circuit Voltage (ROCV) and their operation indicators.

Starting Technique and Break-in Period

Covers the recommended starting technique and the engine break-in period.

Welder Operation Modes (Stick, TIG)

Details operation in Stick and Touch Start TIG modes, including settings.

Wire Welding and Arc Gouging

Details operation for wire welding (CV-WIRE) and arc gouging applications.

Paralleling and Load Management

Explains how to parallel machines and manage simultaneous welding and auxiliary power loads.

Accessories

Optional Field Installed Accessories

Lists various optional accessories available for enhancing the unit's functionality.

Maintenance

Safety, Routine Checks, and Compressor Maintenance

Covers safety, routine checks, and recommended maintenance for the engine and compressor.

Air Filter Service Instructions

Provides detailed instructions for inspecting, cleaning, and replacing engine air cleaner elements.

Fluid System and Battery Maintenance

Details maintenance procedures for fuel filters, cooling system, and safe battery handling.

Battery Charging and Welder Maintenance

Covers battery charging procedures and maintenance for the welder and generator components.

Troubleshooting

How to Use the Troubleshooting Guide

Explains the three-step process for using the troubleshooting guide effectively.

Engine Starting and Running Issues

Addresses common engine problems such as not cranking, not starting, or shutting down unexpectedly.

Idle Speed and Output Control Issues

Covers troubleshooting issues related to engine idle speed and output control.

Output and Power Troubleshooting

Addresses problems with no welding output, loss of control, or lack of auxiliary power.

Diagrams

Wiring Diagrams (Codes 11656 & 11661)

Presents wiring diagrams for specific machine codes and electrical symbols.

Spool Gun Connection Diagram

Illustrates the connection diagram for spool guns (K487-25) to the engine welder.

LN-7 Wire Feeder Connection Diagram

Shows the connection diagram for LN-7 wire feeders and related accessories.

LN-8 Wire Feeder Connection Diagram

Shows the connection diagram for LN-8 wire feeders.

LN-25 with K857 Remote Connection Diagram

Illustrates connection diagrams for LN-25 wire feeders with optional K857 remote control.

K930 TIG Module Connection Diagram

Details the connection diagram for the K930 TIG module with the engine welder.

LN-742 Wire Feeder Connection Diagram

Shows the connection diagram for LN-742 wire feeders.

Dimension Print

Machine Dimensions and Specifications

Provides a detailed dimension print of the welder, including trailer mounting locations and center of gravity.

Customer Assistance Policy

Lincoln Electric Support Information

Outlines Lincoln Electric's policy on providing advice and support for their products.

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