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Lincoln Electric AIR VANTAGE 500 User Manual

Lincoln Electric AIR VANTAGE 500
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AIR VANTAGE 500 (AU)
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November, 2010
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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. % $%* $)*""
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)*/ &(+*%$) %$
*$ *(%+%+* And,
most importantly, think before
you act and be careful.
For use with machine having Code Number:

• Sales and Service through Subsidiaries and Distributors Worldwide •
Cleveland, Ohio 44117-1199 U.S.A. TEL: 216.481.8100 FAX: 216.486.1751 WEB SITE: www.lincolnelectric.com
• World's Leader in Welding and Cutting Products •
Copyright © Lincoln Global Inc.
Q

Table of Contents

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Lincoln Electric AIR VANTAGE 500 Specifications

General IconGeneral
Max Output500 Amps
Engine Power24.8 HP
Fuel TypeDiesel
Duty Cycle100%
Generator Output120/240V AC
ProcessesStick, TIG, MIG, Flux-Cored
TypeEngine Driven Welder/Generator
Rated Output500A/40V/100%

Summary

Safety Information

Proposition 65 Warnings

Warnings about diesel engine exhaust constituents known to cause cancer, birth defects, or reproductive harm.

Electric Shock Hazards

Precautions against electric shock, emphasizing insulation and dry gloves.

Fumes and Gases Hazards

Warnings about breathing hazardous fumes and gases produced during welding.

Fire and Explosion Hazards

Precautions to prevent fires and explosions from welding sparks and compressed gases.

Cylinder Safety

Safety measures for handling compressed gas cylinders to prevent explosions.

Installation Guide

Technical Specifications

Detailed technical data for the AIR VANTAGE® 500 (AU) welder.

Location and Ventilation

Guidelines for placing the welder to ensure proper airflow and exhaust venting.

Lifting and Handling

Instructions for safely lifting and moving the welding machine.

Pre-Operation Checks

Steps for checking engine oil, coolant, fuel, and battery before operation.

Welding Terminals and Cables

Guidance on connecting welding terminals and output cables.

Remote Control and Wire Feeder Connections

Instructions for connecting remote controls and wire feeders.

Operating the Welder

General Description

Overview of the AIR VANTAGE® 500 (AU) diesel engine welder's features.

Engine Controls

Explanation of the switches and gauges for engine operation and monitoring.

Welding Controls and Settings

Details on adjusting output, mode selection, and arc control for welding.

Welding Modes

How to use Stick, CC-Stick, and Touch Start TIG welding modes.

Wire Welding and Arc Gouging

Procedures for CV wire welding and arc gouging operations.

Maintenance Procedures

Safety Precautions

Essential safety rules for performing maintenance tasks on the equipment.

Routine and Periodic Maintenance

Daily and weekly checks for engine, compressor, and fuel systems.

Engine Air Filter Service

Instructions for inspecting, cleaning, and replacing the engine air filter.

Battery Handling and Charging

Guidelines for safely handling, connecting, and charging the battery.

Troubleshooting Guide

How to Use the Guide

Steps for diagnosing and resolving machine malfunctions using the guide.

Engine Starting Issues

Troubleshooting common problems related to engine cranking and starting.

Engine Operation Problems

Diagnosing issues like engine shutdown, rough running, or failure to stop.

Output and Control Issues

Resolving problems with welding output, control, or auxiliary power.

Connection Diagrams

Wiring Diagram

Overall electrical schematic for the AIR VANTAGE® 500 (AU).

Spool Gun Connection

Diagram for connecting spool guns to the welder.

LN-7/K775/K867 Connection

Diagram for connecting LN-7, K775, or K867 wire feeders.

K930 TIG Module Connection

Diagram for connecting the K930 TIG Module.

LN-742 Connection

Diagram for connecting the LN-742 wire feeder.

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