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Lincoln Electric IM10066 User's Manual

1. ENGINE CONTROLS Items 1 through 9 1 RUN STOP SWITCH 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 ENGINE STOP SWITCH Shut s down engine 4 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 FUEL LEVEL GAUGE Displays the level of diesel fuel in the fuel tank The operator must watch the fuel level close ly to prevent running out of fuel and possibly having to bleed the system ENGINE TEMPERATURE GAUGE The gauge displays the engine coolant tempera ture E AIR 500 AU LINCOLN 3 7 OIL PRESSURE GAUGE En The gauge displays the engine oil pressure when the engine is running 8 ENGINE PROT
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4. 7 8 Section B Safety Precautions dendi ted ee adest e da ian B 1 General Descriptor EEN B 1 Recommended Application Welder Air Compressor and Generator B 1 Controls and Settings si B 2 Engine Controls seen enne enne nennen nennen nenne nnne B 2 B 3 Welder Controls 4 Auxiliary Power en te EE 4 Air Compressor 7 A KA KA A KRA ARA B 5 Battery Jump Start Terminals alal dl sial eiaeiiai B 5 Whatare VRD and Devices niet ee B 6 Welding Power Sources 6 SGU OLY HE B 6 VRD Operation Indicators eene nene nnne B 6 C antne Starting MCI GUC asi cies EET Break dioc Typical FuSl COMSUMPLION EE Welding Duty Cycle c epe t Ep Lr E Stick Welding Mode sin escudo N N NNDNnDMDI DMMMMMMMMMVMMMMNNENRNRNENn NH HRH III MD DNMDM EO Touch Start TIG Mode AIR VANTAGE Settings when using K930 2 TIG Module seeseeeeeeeeeeeereeserren B 8 Wire Welding CV sisi B 9 9 Typical Current Ranges for Tungsten Electrodes B 9 el Pare nea k peleke manen Mi b l oix ran B 10 Auxiliary Power Operation s
5. 38 AVIN SLINOHI9 103109 430334 3UIM SETOA 071 309 FOVLIOA SIHL 39VE10A OV JHL JHL 3SV389NI NY ASNVO TIM JOVANI 31LLOBHI SHL 9NIGIHH3AO ONILLAS HONH3AO9 A8 Wd ANIONS JHL 30 35 NOILOVO 318V9 LNdNI 961 30334 8 N1 ueuudinbe siy eaues esn ejsur pjnous jeuuosied e sued Aeme e eoe d ui spyen6 e up SLYVd ONIAOW LINN Q33H 3HIM OL 300419413 OL H3ldvav 2981 syed jou e BUIDIAIAS SALLVDAN 19euuoosiq e sjeued jou od e 4 15313 INVHO5VIG NOLLO3NNOO 8 N1 2985 SH3Q 13M 4 OL 3004193173 O AIR 500 AU LINCOLN E DIAGRAMS F 7 F 7 482906 0002 22 01 094 1538 SV NOILISOd 3 Ql OLAY NI HOLIMS 394 Id NOILISOd S IVNIWS3 L NI HOLIMS S IVNIINS3 L SHL 39V ld NOILISOd NI HOLIMS SCOW SHL ADV Id 318V9 330819313 40 AU 10d JHL HOLVIN OL HOLIMS YALAWLIOA 830334 NOILISOd ALIYV10d 0341530 50715 OL 31895
6. sued Aeme desye peg LI JALLVO3N 12euuoosiq e eoe d ui deey sjeued jou ode ONINHVM Y WV49VIQ NOILOANNOO Z N1 S83Q713M 3NI9N3 AIR 500 AU LINCOLN E 5 DIAGRAMS 1 18178 0002 22 01 1 IWRDINIXVIN TYNNVIN NOLLONHLSNI 304008 OL TN 439993 eem 335 2 50731 35070 OL AV THU JHM en NOILV1OSI ISN LNdLNO 9NIQT3M TVNOIS V NYNLIY 1 9830334 TN OL Leg ATIVNGIAIGN SaY31 GASNNN ALVINSNI NOILISOd IHL NI HOLIMS IQON JHL DA 319V9 3003110313 JHL JO IHL JN OL HOLIMS HALANL10A 830334 IHM JHL NOLLISOd AUDIO 9331534 sanis 114100 OL 5318 2 ONIGTAM LO3NNOO NOILVOMddV 40 11949 ALNG LNIHHNO 9371 38 LSNW 37890 ONIGTAM WANVW ONILVYAdO 3NION3 JHL 031511 SNOILVOISIOAdS 3409Y 15 LON OG IHL LV 135 344 SI 9NLLL3S 9 3NION3 UCI 1 00 JHL NYO HOIHM 39V L10A Y30334 OV IHL NI 3SV3SONI NV ASNVO TIM 39 VXNFI 31LLOSH 3HL 9NIGISHSSAO HO ONILLAS HONH3AOO 9NISNVHO 3NISN3 31 IHL 40 ASVIHONI SL NOILNVO 10105 LNdLNO ALOWSY w ai LINN
7. 500 AU LINCOLN B 1 OPERATION B 1 SAFETY PRECAUTIONS Read and understand this entire section before operating your AIR VANTAGE 500 AU WARNING Do not attempt to use this equipment until you have thoroughly read the engine manufacturer s manual supplied with your welder It includes important safety precautions detailed engine starting operat ing and maintenance instructions and parts lists e 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 3 Use in open well ventilated areas or vent exhaust outside Do not stack anything near the engine MOVING 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 Always operate the welder with the sliding door closed and the side panels in place as these pro vide maximum protection from moving parts and insure proper cooling air flow GENERAL DESCRIPTION The AIR VANTAGE 500 AU is a diesel engine driven welding power source The machine uses a brush type alternating current generator for DC multi purpose weld ing for 240 VAC single phase The AIR VANTAGE 500 AU also has a rotary screw 60 cfm air compressor built
8. Engine Oil and Filter b Air Cleaner C Fuel Filter and Delivery System d Alternator Belt e Battery f Cooling System Refer to Table D 1 at the end of this section for vari ous engine maintenance components AIR FILTER CAUTION Excessive air filter restriction result reduced engine life WARNING Never use gasoline or low flash point solvents for cleaning the air cleaner element A fire or explosion could result CAUTION Never run the engine without the air cleaner Rapid engine wear will result from contaminants such as dust and dirt being drawn into the engine The diesel engine is equipped with a dry type air filter Never apply oil to it Service the air cleaner as follows Replace the element as indicated by the service indi cator See Service Instructions and Installation Tips for Engine Air Filter AIR 500 AU LINCOLN D 2 MAINTENANCE D 2 Service Instructions Single and Two Stage Engine Air Cleaners 1 Remove the Filter Unfasten or unlatch the service cover Because the filter fits tightly over the outlet tube to create the critical seal there will be some initial resistance similar to breaking Rotate the filter while the seal on a jar Gently move the end of the filter pulling back and forth to break the seal then rotate while straight out pulling straight out Avoid knocking the filter against the housing
9. JHL NI 3SV3HONI NV ASNVO THM 31LLOSH L AHL 9NIGIHS3AO ONILLAS HONSH3AO9 JHL 9NISNVHO 4101 SHL 30 ASVAYONI NOUT OL HOLIMS 1391 8 ANVH 2 296 as 390510973 3189 CND 1003 0287 a L 9 6M ONILLIA 9 SV9 OL 579 HALINMOT HOLVIN934 uowudinbe 14 10 syed jou asn jeysul pjnous jeuuosied peyijenb e sued Aeme peaj Moyeg 3ALLVO3N 5 e goed ui deeye sjoued jou ode ONINHVM 77 Weieng NOLLO3NNOO 3 IndOW 9IL AIR 500 AU LINCOLN E 12 5 18 175 0002 22 01 8341540 SV NOILISOd 4101 HOI NI HOLIMS 41101 JN NOILISOd GSATIONLNOD ATALOWSY OL HOLIMS STVNINYSL Y3013M ON NOILISOd 3H L NI HOLIMS 300 39Vld ON 318v9 400419414 AHL ALI 10d JHL H LYW OL HOLIMS S313IAL OA 9349334 38IM JHL NOILISOd ALINV10d Q38IS30 401 58015 OL 318V9 SNIQT3M LOANNOO ON WANVW 9NILV380 33 SNOLLVOI dd 39113 ANY SLVIGSWWI 41949 ON LN388809 JHL ALIO VdVO HdO ld 38 LSNW S318V9 9NIQ I4M WANVW ONIL
10. 39 VIVO HOIHM 39 V LTOA 830334 38IM OV NI 3SV3SONI NV 2SNV9 39 VMNIT31LLOSHL 9NIQIHH3AO ONILLAS 9NI9NVHO A 3NISN3 SHL 30 3SV38ONI HHOM OL 9393 38IM OL 81875 39081913 A OWN 318V9 9297 DIAGRAMS 318 9 3 lt 9 Nid Pl ueuudinbe si 10 sued ed jou esn j ejsui jeuuosJed AIUO e u o es sued Aeme e Moneg 3ALLVO3N 12euuoosiq e goed ui sjeued jou oq e ONINHVM 7 NOLLO3NNOO 10 1 09 1NdINO 310IN38 L IOA V V C99 2 1 S830 13M 3NION3 F 9 AIR 500 AU LINCOLN E DIAGRAMS F 10 F 10 5 18 705 0002 22 01 Qd llS4Q SV NOILISOd 4101 HOH NI HOLIMS 43101 39VId NOILISOd S IVNIINSH3 LL QT3M SHL NI HOLIMS S IVNIWS3 L 9NIQT3M SHL NOILISOd 38IM AO AHL NI HOLIMS 39Vld 81875 300812313 AHL ALINY 10d JHL HOLVIN OL HOLIMS YSLANLIOA 3033 AHL NOILISOd ALIYV10d 9341 34 803 50 5 OL 318V9 ON DM LO3NNOO ON WANVW 9NILVH3dO 33 SNOILVOMddV 34N1N14 ANV 40 319A9 ANY JHL
11. If your air cleaner has a safety filter replace it every third primary filter change Remove the safety filter as you would the primary filter Make sure you cover the air cleaner outlet tube to avoid any unfiltered contaminant dropping into the engine Clean Both Surfaces of the Outlet Tube and Check the Vacuator Valve Use a clean cloth to wipe the filter sealing surface and the inside of the outlet tube Contaminant on the sealing surface could hinder an effective seal and cause leakage Make sure that all contaminant is removed before the new filter is inserted Dirt accidently transferred to the inside of the outlet tube will reach the engine and cause wear Engine manufacturers say that it takes only a few grams of dirt to dust an engine Be careful not to damage the sealing area on the tube Wipe both sides of the outlet tube clean Duter edge of the outlet tube Inner edge of the outlet tube If your air cleaner is equipped with a Vacuator Valve Visually check and physically squeeze to make sure the valve is flexible and not inverted damaged or plugged Inspect the Old Filter for Leak Clues Visually inspect the old filter for any signs of leaks A streak of dust on the clean side amp of the filter is telltale sign Remove any cause of leaks before installing new filter 4 Inspect the New Filter for Damage Inspect the new filter carefully paying attention to the inside of the open end which is
12. WANVW 0 YACTAM ANIONS JHL NI Q31ST1SNOILV2I3IO3dS Wd 3AO8V LSNPaV LON OG LV 13 3 SI ONILL3S YONYSAOS 3NION3 JHL LINOYIO 103109 NVO HOIHM JOVLIOA 830333 SHIM OV JHL NI 3SV3HONI NV ASNVS FILLOYHL AHL 9NIQIH HAO ONILLAS JHL Ad 4101 30 3SV4HONI 424005 FINGOW 1041 09 SHL OL 39VIAVG NI 110599 01102 NOILISOd HOLIMS L938809NI 310100 1041 09 3174340 OL ONILdWALLY 3804338 NOILISOd 3408019 LOVLNOD 102 11 IHL NI SI HOLIMS IAOW SINGOW TONLNOOD 1VHI SYNS 38 JINdON 1OWLNOO OL 51895 3008123 13 OL 1 310V1d393H 01 1699 31038 Nid 9 NN9 10085 GC 18V JINON TOMLNOO 5199 14393 OS G t Y30334 3MIM Nid FL 3199193933 jueuudinbe 14 2 10 sued Ajeoujoeje jou esn ejsui pjnous jeuuosied Bu o es syed deeye pes Aueneg JALLVO3N 19 9uuoos d e eoel d ui uedo sjeued jou ONINHVM W Weieng NOLL23NNOO NNO 1004 2877 8877 01 1699 SH3TT3M AIR 500 AU LINCOLN E 6586605 F 3 ALVINSNI ANY 30146 3 N ATIVnQIAIQNI GASNNN HOVA ALVINSNI ON JOULNOS 3 LOW3H OL GAHOLIMS ATIVOILVNOL
13. e Set CONTROL knob to O initially and adjust to suit N Set the IDLE switch to the AUTO position When not welding the AIR VANTAGE 500 AU engine will be at the low idle speed If you are using an LN 25 with an internal contactor the electrode is not energized until the gun trigger is closed 8 When the gun trigger is closed the current sensing circuit will cause the AIR VANTAGE 500 AU engine to go to the high idle speed the wire will begin to feed and the welding process started When welding is stopped the engine will revert to low idle speed after approximately 12 seconds unless welding is resumed A CAUTION you are using LN 25 without an internal con tactor the electrode will be energized when the AIR VANTAGE 500 AU is started CONNECTION OF AN NA 3 AUTOMATIC WELDING SYSTEM TO THE AIR VAN 500 AU For connection diagrams and instructions for connect ing an NA 3 Welding System to the AIR VANTAGE 500 AU refer to the NA 3 Welding System instruc tion manual The connection diagram for the LN 8 can be used for connecting the NA 3 Set the Wire Feeder Voltage Switch to 115V CONNECTION OF MAGNUM SC SPOOL GUN TO THE AIR VANTAGE 500 AU SEE SECTION F Spool Gun K487 25 and Cobramatic to AIR VAN 500 AU Shut the welder Connect per instructions on the appropriate connec tion diagram in Section F AIR
14. AIR 500 AU LINCOLN 8 0 4 CHARGING THE BATTERY When you charge jump replace or otherwise connect battery cables to the battery be sure the polarity is correct Improper polarity can damage the charging circuit The AIR VANTAGE 500 AU positive bat tery terminal has a red terminal cover If you need to charge the battery with an external charger disconnect the negative cable first then the positive cable before you attach the charger leads after the battery is charged reconnect the positive bat tery cable first and the negative cable last Failure to do so can result in damage to the internal charger components Follow the instructions of the battery charger manufac turer for proper charger settings and charging time NAMEPLATES WARNING DECALS MAIN TENANCE Whenever routine maintenance is performed on this machine or at least yearly inspect all nameplates and labels for legibility Replace those which are no longer clear Refer to the parts list for the replacement item number MAINTENANCE D 4 WELDER GENERATOR MAINTE NANCE STORAGE Store the AIR 500 AU in a clean dry protected areas CLEANING Blow out the generator and controls periodically with low pressure air Do this at least once a week in par ticularly dirty areas BRUSH REMOVAL AND REPLACEMENT It is normal for the brushes and slip rings to wear and darken slightly Inspect the brushes
15. ALIO VaVO 93408 38 LSNW 318V9 318vo 390419573 OL OL 0 1 4412 4349393 38IM SCN1 OWLNOO 310 38 WNOILdO 9 TONHHdINV ueuudinbe 14 2 JO sued jou pjnous jeuuosied AIUO e Bu o es syed desye pes A e eg JALLVO3N 10901 0281 e ui e sjaued jou e ONINHVM WV 10 1 09 31034 TWNOILdO WV49VIQ NOLLO3NNOO 3H L SSOHOV 92 1 544014 ANIONS AIR 500 AU LINCOLN E DIAGRAMS F 11 F 11 6 8 705 0341530 SV NOILISOd 3101 NI HOLIMS 44101 39V1d TN NOLLISOd 10 1 09 3 10IN3H NI HOLIMS ON 911 SHL NI HOLIMS SGOW 39Vld 10d 9341534 58715 015318 2 ONIGTAM LOANNOO ON WANVW ONILVYSdO 3 5 310413 ANY 31vIg3WiI 319A9 ALNG ANY 145819 AHL ALIOVdVO HdO ld 30 38 LSNW 51899 ONIGTAM ONLLVeI3dO 4014 SHL NI 091511 SNOILVOISIOSdS 3409Y LSNPAV LON OG 7 AHOLOVA JHL LV 13S dHd SI ONILL3S 9 3NION3 1 LINDYID TOHLNOO 201 NYO 39 VL 10A 830334
16. IOWLNOO 170A 5 er Ar Sr e 9 lt s 9 san i HOLIMS tonn 7 170907 Fam ams wiel uonoury umop LAWA HOSNIS o rs B 9 FATANI O LaWA 29 WOH EI ieee Vous SEN 8 90 63 ANNOYS sez octo LLONA 2 Dees WE HOLS gera HOLIMS 34070 ann eh sh 8670 0 g ov No2 11 L t 8 HOSN3S azez Qus eee DEE OWA BunivusdWal INY1000 Ani 2 per Y 8 rn rad n Y3LINWLTOA TEE E pin 5 ez HOLIMS 3univusdWal a3unssaud 48 see jofa PI rol T 310N3H Nid 9 vez otras uosNas 4015 40 1005 2262 uossauanod moan J HOLMS S HOSNI HOSS3HdWOO HOSS3HdWOO EON MIS YE gunssaud V QN9 6 a um ee AS ap _ 29 09 Sao uzez 1 Wou4
17. Green cap color provides a visual reminder to use diesel when refueling K2359 1 Cold Weather Heater and Tarp Kit For extreme cold conditions where normal engine starting is not sufficient Includes oil pan heater engine water heater and radiator grill tarp TIG OPTIONS K870 Foot Amptrol Varies current while welding for making critical TIG welds and crater filling Depress pedal to increase current Depressing pedal fully achieves maximum set current Fully raising the pedal finishes the weld and starts the afterflow cycle on sys tems so equipped Includes 25 ft 7 6m control cable K963 3 Hand Amptrol amp Varies current for making criti cal TIG welds Fastens to the torch for convenient thumb control Comes with a 25 ft 7 6m cable for larger handle 18 or 26 series torches AIR 500 AU LINCOLN D 1 MAINTENANCE SAFETY PRECAUTIONS WARNING Have qualified personnel do maintenance and troubleshooting work Turn the engine off before working inside the machine or servicing the engine Remove guards only when necessary to perform maintenance and replace them when the maintenance requiring their removal is complete If guards are missing from the machine obtain replacements from a Lincoln Distributor See Operating Manual Parts List Read the Safety Precautions in the front of this manual and in the Engine Owner s Manual before working on this machine Keep all equipm
18. N o toque partes el tricas e electro dos com a pele ou roupa molhada sole se da pe a e terra gp CM 4A E n 380 Keep flammable materials away Mantenga el material combustible fuera del rea de trabajo Gardez l cart de tout mat riel inflammable Entfernen Sie brennbarres Material Mantenha inflam veis bem guarda dos ORAPCTUSDORTOBEER EA Wear eye ear and body protection Prot jase los ojos los oidos el cuerpo Prot gez vos yeux vos oreilles et votre corps Tragen Sie Augen Ohren und K r perschutz Use prote o para a vista ouvido e corpo HRUSHERMARELTF e Ri zk de kg ET ET IMM eRESR SESMSEGSEmA f B o RAT Korean e j4j AIX ex HEHA Syza Xe SH uu e AAS ien ui el al oaa y e 4l U d ay il oes badly All Gelak DA Aasch dis die le Lily dil jl READ AND UNDERSTAND THE MANUFACTURER S INSTRUCTION FOR THIS EQUIPMENT AND THE CONSUMABLES TO BE USED AND FOLLOW YOUR EMPLOYER S SAFETY PRACTICES SE RECOMIENDA LEER Y ENTENDER LAS INSTRUCCIONES DEL FABRICANTE PARA EL USO DE ESTE EQUIPO Y LOS CONSUMIB
19. PUT CONTROL inactive and the wire feeder volt age control active When in the TOUCH START TIG mode and when a Amptrol is connected to the 6 Pin Connector the OUTPUT dial is used to set the maximum current range of the CURRENT CON TROL of the Amptrol 12 DIGITAL OUTPUT METERS The digital meters allow the output voltage CV WIRE mode or current CC STICK and TIG modes to be set prior to welding using the OUT PUT control knob During welding the meters display the actual output voltage VOLTS and current AMPS A memory feature holds the dis play of both meters on the seven seconds after welding is stopped This allows the operator to read the actual current and voltage just prior to when welding was ceased While the display is being held the left most decimal point in each display will be flashing The accuracy of the meters is 3 AIR 500 AU LINCOLN OPERATION 13 WELD MODE SELECTOR SWITCH 17 Provides 3 selectable welding modes CV WIRE CC STICK TOUCH START TIG 14 ARC CONTROL The ARC CONTROL WIRE STICK knob is active in the WIRE and STICK modes and has different functions in these modes This control is not active in the TIG mode CC STICK mode In this mode the ARC CON TROL knob sets the short circuit current arc force during stick welding Increasing the num ber from 10 Soft to 10 Crisp increases the short circuit current and prevents sticking of the electrode
20. 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 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 Also see item 1 b SAFETY WELDING and CUTTING gt SPARKS 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 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 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 Do not heat cut or weld tanks drums or containers until the proper steps have been taken to insure that such procedures will n
21. The AIR VANTAGE 500 AU can be used with a broad range of DC stick electrodes The MODE switch provides two stick welding settings as follows CC STICK MODE The CC STICK position of the MODE switch is designed for horizontal vertical up and over head welding with all types of electrodes especially low hydrogen The OUTPUT CONTROL knob adjusts the full output range for stick welding The ARC CONTROL knob sets the short circuit arc force current during stick welding Increasing the number from 10 Soft to 10 Crisp increases the short circuit current and prevents sticking of the elec trode to the plate while welding This can also increase spatter It is recommended that the ARC CONTROL be set to the minimum number without electrode sticking Start with the knob set at O TOUCH START TIG MODE The AIR 500 AU can be used in a wide variety of DC TIG welding applications The TOUCH START TIG setting of the MODE switch is for DC TIG Tungsten Inert Gas welding To initiate a weld the OUTPUT CONTROL knob is first set to the desired current and the tungsten is touched to the work During the time the tungsten is touching the work there is very little voltage or current and in gen eral avoids tungsten contamination Then the tung sten is gently lifted off the work in a rocking motion which establishes the arc To stop the arc simply lift the TIG torch away from the work piece When the arc voltage reac
22. control circuit and 42VAC or 115VAC power The remote control circuit operates the same as the 6 Pin Connector 42V 115V WIRE FEEDER VOLTAGE SWITCH Toggles output of 14 pin connector to voltage requirement of Wire Feeder Located above 14 pin connector 20 WELD OUTPUT TERMINALS AND These 1 2 13 studs with flange nuts provide welding connection points for the electrode and work cables For positive polarity welding the electrode cable connects to the terminal and the work cable connects to this terminal For negative polarity welding the work cable con nects to the terminal and the electrode cable connects to this terminal AUXILIARY POWER CONTROLS Items 21 24 21 CIRCUIT BREAKERS These circuit breakers provide separate overload current protection for each 240V receptacles the 42VAC and 115VAC in the 14 Pin connector and battery circuit overload protection 22 240 VAC RECEPTACLES These two 240VAC receptacles provide up to 15 amp total rating each and are IP66 rated Refer to the AUXILIARY POWER RECEPTACLES section in the installation chapter for further infor mation about these receptacles Also refer to the AUXILIARY POWER OPERATION section later in this chapter AIR 500 AU LINCOLN 5 23 24 25 5 GROUND STUD Provides a connection point for connecting the machine cas
23. 0333 SHIM OL 318v9 300819313 304005 YAMOd 40 1 HHOM OL SLO3NNOO OL NOLLO3NNOO HALANLIOA Y30334 IC NOLLO3NNOO 4000S YIMOd 0 dN9 O Z Me d WASI OWA fe y x u3H1390L L93NNOO lo 2 an 0 daldvav JONJHANY 63284005 437 13M NO 180 LON 1 9 28 TWSYSAINN 298 L ueuudinbe 14 2 5 10 syed jou asn jeysul pjnous jeuuosied Ajuo e sued desye pee JALLVO3N 12euuoosid e ui desye uedo sjoued jou ONINHVM W INV 9VIQ NOLLO3NNOO 318V9 TOULNO 9 2987 OL SH3Q 13M 3NION3 AIR 500 AU LINCOLN E DIAGRAMS F 6 686625 ALVINSNI ANY SGV31 391195 1 ALVINSNI A9 SNITT3M 3HIM OL HOLIMS HOLOATAS AHL NOILISOd ALIHVTOd 3903419313 Q3HIS3Q 199135 OL HOLIMS H3 L3IALLTOA ASN WANVI ONILVH340 335 SNOIIVOIddV ANY ALVIGAWW 31949 ALNG ANY LNAYYND JHL ALIOVdVO H3dOHd HO LSNW 3199 ONIGTAM 031511 SNOLLVOISIOAdS 3AO8V LSNPAV LON OG HN WN TWANVIN ONI1V43d0 H3Q 3M ANIONS JHL AWOLOWS 145 4 SI ONILLAS HONYSAOS ANIONS JHL
24. 7 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 Always keep cylinders in an upright position securely chained to an undercarriage or fixed support Oylinders should be located Away from areas where they may be struck or subjected to physical damage safe distance from arc welding or cutting operations and any other source of heat sparks or flame Never allow the electrode electrode holder or any other electrically hot parts to touch a cylinder Keep your head and face away from the cylinder valve outlet when opening the cylinder valve Valve protection caps should always be in place and hand tight except when the cylinder is in use or connected for use Read and follow the instructions on compressed gas cylinders associated equipment and publication P I Precautions for Safe Handling of Compressed Gases in Oylinders 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 Install equipment in accordance with the U S National Electrical Code all local codes and the manufactur
25. BREAK IN THE UNIT SHOULD BE SUBJECTED TO HEAVY LOADS WITHIN THE RATING OF THE MACHINE AVOID LONG IDLE RUNNING PERIODS TYPICAL FUEL CONSUMPTION Refer to Table B 1 for typical fuel consumption of the AIR VANTAGE 500 AU Engine for various operat ing settings Table B 1 Cummins B3 3 Engine Fuel Consumption Cummins B3 3 Running Time for 56HP 42Kw 25GAL 94 6L 91800 RPM Hours Low Idle 59 Gal hour 42 4 no load 1425 RPM 2 2 L hour High Idle 87 Gal hour 28 7 no load 1900 RPM 3 3 L hour DC CC Weld 2 10 Gal hour 11 9 Output 500 7 9 L hour Amps 40 Volts Auxiliary Power 1 44 Gal hour 17 4 12 000 VA 5 5 L hour Air Compressor 1 29 Gal hour 19 4 60 CFM 100 PSI 4 9 L hour Air Compressor 60 100 PSI 2 46 Gal hour 10 2 and DC CC Weld 9 3 L hour Output 500 Amps 40 Volts Air Compressor 60 100 PSI 1 94 Gal hour 12 9 and Auxiliary Power 7 3 L hour 12 000 VA NOTE This data is for reference only Fuel consumption is approximate and can be influenced by many factors includ ing engine maintenance environmental conditions and fuel quality AIR VANTAGE 500 AU LINCOLN 8 OPERATION B 8 WELDER OPERATION DUTY CYCLE Duty Cycle is the percentage of time the load is being applied in a 10 minute period For example a 60 duty cycle represents 6 minutes of load and 4 minutes of no load in a 10 minute period STICK WELDING MODE
26. 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 amp Cutting ANSI Standard 749 1 from the American Welding Society 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 AN FOR ENGINE A H 1 h To avoid scalding do not remove the MI an OR n E a 9 00 gt radiator pressure when the engine is powered equipment Eug hot 1 Turn the engine off before troubleshooting and maintenance 5 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 3 outdoors AR ELECTRIC AND MAGNETIC FIELDS 1 c Do not add the fuel near an open flame may be dangerous welding arc or when the engine is running Stop the engine and allow it to cool before 2 a Electric current flowing through any conductor causes refueling to prevent spilled fuel from vaporiz localized Electric and Magnetic Fields EMF Welding ing on contact with hot engine parts and
27. ONIGTAM LO3NNOO TIV NVIN 0 33 5 34N1N1 ANY 31VIQ3AWI 40 319A9 ALNG ANY JHL 803 ALIOVaVO 93 03 30 38 LSAW 318V9 SNIQT3M 318v9 300819313 MYOM OL OL 4781 3033 SCHT 31 038 1584 INNOLLdO 3 Nid vb loON3HdAV jueuudinbe suit 2 5 10 sued A j eouioeje jou esn jje sul pjnous jeuuosied AIUO 5 sued e pee JALLVO3N 12euuoosiq e eoejd ui deeye uedo sjeued jou oq e ONINHVM Y TOULNOD 310 38 2589 TYNOILdO INV OVIQ NOLLO3NNOO 3H L 5504 mg SC N1 SH3Q0 13M 3NION3 AIR 500 AU LINCOLN E F 8 9 8 vcS 0002 F 1 y NOLLISOd NI HDLIMS 44141 2 N 318v2 390312313 AHL HOLVW HDLIMS YALAWLIOA 434333 38IM AHL NOLLISOd ALI V 10d 341530 401 SGNLS LAdLNO 31895 DNIQT3M LOANNOD ON IWANVW 5NILVH34O 335 SNOILVOlTddV 9404103 ANY SALVIGAWWI 31942 ALNG 134812 JHL ALIDVdV 434084 38 LSNW S318V2 DNIQTJM IWANVW DNILVdH3dO HO 13M 3NIDN3 NI Q31ST1SNOILV2I3I234dS Wd 3AO8V 15 LON Od AHOL9V4 13S 3Hd SI DNILLAS HONH3AOD 3NIDN3 TOHLNOO JHL NYD H2IHM 39V LL10A 830334 3HIM JHL NI 3SV3HDNI NV aSn
28. also controls the wire feed Therefore the welder is not exposed to open circuit voltage unless the trigger is turned on and the wire is feeding Also electrodes are not changed as frequently as for stick welding MMAW VRD ROCV s are more commonly incorporated into the stick welding mode CC of the welding machines being used in environments with high risk of electric shock SAFETY The reduction of the voltage supplies a safer level of voltage when an arc is not being struck or when an electrical resistance less than the welder s body resis tance have been detected All VRD s are only an aid to safety personal protective equipment and safe working practices must be observed at all times The risk of electric shock during welding from a correctly installed and maintained welding machine is negligi ble provided that sensible precautions are taken by the user and correct safe working procedures are fol lowed All of the welding output circuit should be con sidered electrically active hot and the welder should make sure that they do not become a part of that cir cuit to ground or they could receive a severe electric shock that could kill Safe working procedures should always be followed whether a VRD is fitted or not VRD OPERATION INDICATOR On the front panel of the Air Vantage 500 AU are two indicator lights A red light when lit indicates volt age greater than gt and a green light when lit indi cates voltage l
29. battery prevent EXPLOSION when INSTALLING A NEW BATTERY dis connect negative cable from old bat tery first and connect to new battery last CONNECTING A BATTERY CHARGER Remove battery from welder by dis connecting 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 nega tive lead to engine foot BATTERY ACID CAN BURN EYES AND SKIN Wear gloves and eye protection and be careful when working near battery Follow instructions printed on battery E PREVENTING ELECTRICAL DAMAGE 1 When replacing jumping or otherwise connecting the battery to the battery cables the proper polarity must be observed Failure to observe the proper polarity could result in damage to the charging cir cuit The positive battery cable has a red termi nal cover 2 If the battery requires charging from an external charger disconnect the negative battery cable first and then the positive battery cable before attaching the charger leads Failure to do so can result in damage to the internal charger components When reconnecting the cables connect the positive cable first and the negative cable last PREVENTING BATTERY DISCHARGE Turn the RUN STOP switch to stop when engine is not running PREVENTING BATTERY BUCKLING Tighten nuts on battery clamp until snug
30. dirt Keep it where it can t be accidentally damaged from con struction 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 cir culate oil to all the parts See the MAINTE NANCE 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 AU machines cannot be stacked ANGLE OF OPERATION To achieve optimum engine performance the Air Vantage 500 AU 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 500 AU LINCOLN A 3 INSTALLATION A 3 LIFTING The AIR 500 AU 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 500 AU 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
31. electrode electrode reel welding head nozzle or semiautomatic welding gun are also electrically hot 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 Ground the work or metal to be welded to a good electrical earth ground Maintain the electrode holder work clamp welding cable and welding machine in good safe operating condition Replace damaged insulation Never dip the electrode in water for cooling 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 When working above floor level use a safety belt to protect yourself from a fall should you get a shock 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 standards 4 b Use suitable clothing made from durable flame resistant 54 LINCOLN material to protect your skin and that of your helpers from the arc rays 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
32. is closed the current sens ing circuit will cause the AIR VANTAGE 500 AU engine to go to the high idle speed the wire will begin to feed and the welding process start ed When welding is stopped the engine will revert to low idle speed after approximately 12 seconds unless welding is resumed AIR 500 AU LINCOLN 8 INSTALLATION 8 CONNECTION OF THE LN 25 TO THE AIR VANTAGE 500 AU WARNING Shut off welder before making any electrical con nections The LN 25 with or without an internal contactor may be used with the AIR 500 AU See the appropriate connection diagram in Section F NOTE The LN 25 K431 Remote Control Module and K432 Remote Cable are not recommended for use with the AIR 500 AU 1 Shut the welder off 2 For electrode Positive connect the electrode cable from the LN 25 to the terminal of the welder and work cable to the terminal of the welder For electrode Negative connect the electrode cable from the LN 25 to the terminal of the welder and work cable to the terminal of the welder 3 Attach the single lead from the front of the LN 25 to work using the spring clip at the end of the lead This is a control lead to supply current to the wire feeder motor it does not carry welding current gt Set MODE switch to the CV WIRE position 5 Set the WELD TERMINALS switch to WELD TERMINALS ON
33. lated quil y lassa al glly l oig gal lata L LINCOLN World s Leader in Welding and Products 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
34. of our customers and to exceed their expectations On occasion purchasers may ask Lincoln Electric for advice or information about their use of our products We respond to our customers based on the best information in our posses sion at that time Lincoln Electric is not in a position to warrant or guarantee such advice and assumes no liability with respect to such infor mation or advice We expressly disclaim any warranty of any kind including any warranty of fitness for any customer s particular purpose with respect to such information or advice As a matter of practical consideration we also cannot assume any responsibility for updating or correcting any such information or advice once it has been given nor does the provision of information or advice create expand or alter any warranty with respect to the sale of our products Lincoln Electric is a responsive manufacturer but the selection and use of specific products sold by Lincoln Electric is solely within the control of and remains the sole responsibility of the customer Many variables beyond the control of Lincoln Electric affect the results obtained in applying these types of fabrication methods and service requirements Subject to Change This information is accurate to the best of our knowledge at the time of printing Please refer to www lincolnelectric com for any updated information Please Examine Carton and Equipment For Damage Immediately When this equipment is shipped titl
35. 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 mount ing 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 ZER only with equipment of ade quate lifting capacity Be sure machine is stable when lift ing Do not lift this machine using lift bail if it is equipped with a heavy accessory such as trailer or gas cylinder FALLING EQUIPMENT can cause injury Do not lift machine if lift bail is damaged 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 496 for every 300 meters 984 ft above 1500 meters 4920 ft For output of 500A and below derate the welder output 496 for every 300 meters 984 ft above 2100 meters 6888 ft Contact a Cummins Service Representative for any engine adjustments that may be required HIGH TEMPERATURE OPERATION At temperatures above 40 C 104 F output voltage derating may be necessary For maximum output cur rent ratings derate welder voltage rating 2 volts for every 10 C 21 F above 40 C 104 F TOWING The recommended trailer for use with this equipment for road in pla
36. or equivalent Shielding should be electrically continuous throughout its length The shielding should be connected to the welding power source so that good electrical contact is maintained between the conduit and the welding power source enclosure Maintenance of the Welding Equipment The welding equipment should be routinely maintained according to the manufacturer s recommendations All access and service doors and covers should be closed and properly fastened when the welding equip ment is in operation The welding equipment should not be modified in any way except for those changes and adjustments covered in the manufacturers instructions In particular the spark gaps of arc striking and stabilizing devices should be adjusted and maintained according to the manufacturer s recommendations Welding Cables The welding cables should be kept as short as possible and should be positioned close together running at or close to floor level Equipotential Bonding Bonding of all metallic components in the welding installation and adjacent to it should be considered However metallic components bonded to the work piece will increase the risk that the operator could receive a shock by touching these metallic components and the electrode at the same time The operator should be insulated from all such bonded metallic components Earthing of the Workpiece Where the workpiece is not bonded to earth for electrical safety not connected to earth because
37. souder parce que la tension entre les deux pinces peut tre le total de la tension vide des deux machines Si on utilise la machine souder comme une source de courant pour soudage semi automatique ces precautions pour le porte lectrode s applicuent aussi au pistolet de soudage Eloigner les mat riaux inflammables ou les recouvrir afin de pr venir tout risque d incendie d aux tincelles Quand on ne soude pas poser la pince une endroit isol de la masse Un court circuit accidental peut provoquer un chauffement et un risque d incendie S assurer que la masse est connect e le plus pr s 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 loign s de la zone de travail on augmente le risque de voir passer le courant de soudage par les chaines de lev age c bles de grue ou autres circuits Cela peut provoquer des risques d incendie ou d echauffement des chaines et des c bles jusqu ce qu ils se rompent Assurer une ventilation suffisante dans la zone de soudage Ceci est particuli rement important pour le soudage de t les galvanis es plomb es ou cadmi es ou tout autre m tal qui produit des fume s toxiques Ne pas souder en pr sence de vapeurs de chlore provenant d op rations de d graissage nettoyage ou pistolage La chaleur ou les rayons de l arc peuvent r agir avec les vapeurs du solvant pou
38. that all mounting bands clamps bolts and connections in the entire air cleaner system are tight Check for holes in piping and repair if needed Any leaks in your intake piping will send dust directly to the engine AIR 500 AU LINCOLN D 3 FUEL FILTERS WARNING iz When working on the fuel system 4 y Keep naked lights away do not smoke Do not spill fuel The AIR 500 AU is equipped with a Fuel Filter located after the lift pump and before fuel injec tors The procedure for changing the filter is as follows 1 Close the fuel shutoff valve 2 Clean the area around the fuel filter head Remove the filter Clean the gasket surface of the filter head and replace the o ring 3 Fill the clean filter with clean fuel and lubricate the o ring seal with clean lubricating oil 4 Install the filter as specified by the filter manufactur er WARNING Mechanical overtightening will distort the threads filter element seal or filter can COOLING SYSTEM The AIR VANTAGE 500 AU is equipped with a pressure radiator Keep the radiator cap tight to pre vent loss of coolant Clean and flush the coolant sys tem periodically to prevent clogging the passage and over heating the engine When antifreeze is needed always use the permanent type MAINTENANCE D 3 BATTERY HANDLING GASES FROM BATTERY can explode Keep sparks flame and cigarettes K away from
39. when a generator overhaul is necessary WARNING Do not attempt to polish slip rings while the engine is running Table D 1 Engine Maintenance Components ITEM MAKE PART NUMBER SERVICE INTERVAL Air Cleaner Element Donaldson P822768 Replace as indicated by Service Indicator Fleetguard AF25436 Oil Filer Cummins C6002112110 Replace every 750 hours or 3 months Fleetguard LF16011 whichever is less Fan Belt Cummins C0412021749 Inspect every 1000 hours or 12 months whichever is less Fuel Strainer Cummins 3826094 Inspect and replace monthly as Fleetguard FF5079 required Replace annually Fuel Filter Fleetguard FS19594 Replace every 500 hours or 6 months Water Separator whichever is less Battery BCI GROUP 34 Inspect every 500 hours Engine Oil Change See Manual Change every 750 hours or 3 months whichever is less Check daily AIR VANTAGE 500 AU LINCOLN 8 1 TROUBLESHOOTING 1 HOW USE TROUBLESHOOTING GUIDE WARNING Service and Repair should only be performed by Lincoln Electric Factory Trained Personnel Unauthorized repairs performed on this equipment may result in danger to the technician and machine operator and will invalidate your factory warranty For your safety and to avoid Electrical Shock please observe all safety notes and precautions detailed throughout this manual This Troubleshooting Guide is provided to help you locate and repair possible mac
40. A 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 UECHT Section Technical Specifications issues A 1 Safety p tri titine A 2 Ventilati n rier e a E R A 2 A 2 ee le gt a Are k y ekl ew A 2 nie EE Re TEE 2 Bulle DEE A 3 High Altitude Operation sise A 3 High Temperature Operation sise A 3 EE A 3 Mlle A 3 Pre Operation Engine and Compressor Service 4 4 Fuel andi Fuel HT T 4 ErigireCoolant System eire erre he en 4 Battery ss A 4 Muffler Outlet Pipe nina y hekan H k b k k bek a ke beb hen n n A 5 Spark le E 5 Air Cleaner Inlet Rood ces 5 Welding ME ES Lu LL ANS s ee akan berdo A 5 Welding Output Cables initiales 5 Machine Grounding TT A 5 Remote COMMON t DAL A 6 Auxiliary Power Receptacles and Standby Power Connections A 6 Connection of Lincoln Electric Wire Feeders
41. AIR VANTAGE 500 AU November 2010 For use with machine having Code Number 11656 Safety Depends on You Lincoln arc welding and cutting equipment is designed and built with safety in mind However your overall safety can be increased by proper installation and thoughtful operation on your part DO NOT INSTALL OPERATE OR REPAIR THIS EQUIPMENT WITHOUT READ ING THIS MANUAL AND THE SAFETY PRECAUTIONS CON TAINED THROUGHOUT And most importantly think before you act and be careful OPERATOR S MANUAL EEE DEDE E ISO 9001 J RI 4 A Quality ufactured Under a m by LI NCOLN Copyright Lincoln Global Inc World s Leader in Welding and Cutting Products Sales and Service through Subsidiaries and Distributors Worldwide Cleveland Ohio 44117 1199 U S A TEL 216 481 8100 FAX 216 486 1751 WEB SITE www lincolnelectric com SAFETY WARNING CALIFORNIA PROPOSITION 65 WARNINGS A Diesel engine exhaust and some of its constituents The engine exhaust from this product contains are known to the State of California to cause can chemicals known to the State of California to cause cer birth defects and other reproductive harm cancer birth defects or other reproductive harm The Above For Diesel Engines The Above For Gasoline Engines ARC WELDING CAN BE HAZARDOUS PROTECT YOURSELF AND OTHERS FROM POSSIBLE SERIOUS INJURY OR
42. AUTION 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 AU is equipped with a tog gle switch for selecting hot welding terminals when in the WELD TERMINALS ON position or cold welding terminals when in the REMOTELY CON TROLLED position WELDING OUTPUT CABLES With the engine off route the electrode and work cables thru the strain relief bracket provided on the front of the base and connect to the terminals provid ed These connections should be checked periodically and tightened if necessary Listed in Table A 1 are copper cable sizes recom mended for the rated current and duty cycle Lengths stipulated are the distance from the welder to work and back to the welder again Cable sizes are increased for greater lengths primarily for the purpose of minimizing cable voltage drop Table A 1 Combined Length of Electrode and Work Cables TOTAL COMBINED LENGTH OF ELECTRODE AND WORK CABLES Cable Size for 500 Amps 100 Duty Cycle 3 0 AWG 95mm 3 0 AWG 95mm 4 0 AWG 120mm Cable Length 0 150 Ft 0 46 meters 150 200 Ft 46 61 meters 200 250 Ft 61 76 meters MACHINE GROUNDING Because this portable engine driven welder creates its own power it is not necessary to connect its frame to
43. DLER SWITCH Has two positions as follows A In the High position the engine runs at the high idle speed controlled by the governor B In the Auto lt gt 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 When welding ceases and the power load is turned off a fixed time delay of approximate ly 12 seconds starts If the welding or AC power load is not restart ed before the end of the time delay the idler reduces the engine speed to low idle speed e The engine will automatically return to high idle speed when the welding load or AC power load is reapplied 11 OUTPUT CONTROL The OUTPUT dial is used to preset the output voltage or current as displayed on the digital meters for the four welding modes When in the CC STICK or CV WIRE modes and when a remote control is connected to the 6 Pin or 14 Pin Connector the auto sensing circuit automati cally switches the OUTPUT CONTROL from con trol at the welder to the remote control In the CV WIRE mode when the wire feeder control cable is connected to the 14 Pin Connector the auto sensing circuit automatically makes OUT
44. ECTION The yellow engine protection light remains off with proper oil pressure and under normal oper ating temperatures If the light turns on the engine protection system will stop the engine Check for proper oil level and add oil if neces sary Check for loose or disconnected leads at the oil pressure sender located on the engine The light will remain on when the engine has been shut down due to low oil pressure or over temperature condition Idler Operational exceptions When the WELDING TERMINALS switch is in the Remotely Controlled position the idler will operate as follows a When the triggering device Amptrol Arc Start Switch etc is pressed the engine will acceler ate and operate at full speed provided a weld ing load is applied within approximately 12 seconds If the triggering device remains pressed but welding load is applied within approximately 12 seconds the engine may return to low idle speed If the triggering device is released or welding ceases the engine will return to low idle speed after approximately 12 seconds WELDING CONTROLS Items 11 through 20 9 BATTERY CHARGING LIGHT The yellow engine alternator light is off when bat tery charging system is functioning normally If light turns on the alternator or the voltage regula tor may not be operating correctly The light will remain on when the engine is stopped and the run stop switch is in the run position 10 I
45. JUMP START TERMINAL 31 NEGATIVE BATTERY JUMP START TERMINAL 12V battery jump start feature is standard Covered output studs for convenient access and protection against accidental impact can be used to jump start a utility truck with up to 800 cold cranking amps Can also be used to jump start the AIR 500 AU Cummins 32 BATTERY DISCONNECT SWITCH Battery disconnect switch provides lockout tagout capability Switch is conveniently located on the front bottom of the machine 33 AIR CLEANER AND SERVICE INDICATOR Air cleaner service indicator provides a Go No Go visual indication of useful filter service life Also located inside the engine compartment SEE FIG URE B2 FIGURE B 2 AIR 500 AU LINCOLN 6 6 WHAT ARE VRD ROCV DEVICES VRD s are gaining popularity as a must have safety accessory especially where welding applications are being carried out in an environment with a high risk of electric shock such as wet areas and hot humid Sweaty conditions VRD and are abbreviations for two different safety devices used in a welding power source to help protect the operator from electric shocks VRD stands for Voltage Reduction Device and ROCV stands for Reduced Open Circuit Voltage Both devices are used as an after market addition or part of the integral design of a machine VRD and ROCV reduce the voltage at the welding outpu
46. L 109 6982 9 867 596 1 i T B 1 CL F i i J O s SNOILLVOO1 ONILNNOW HATIVEL y X 6 vo O 9 6682 JO OL IINA ALANI o B oc YOLVIGVY NI LNV1009 HOSS3HdWOO NI TIO 3NION3 NI TIO ALIAVHO JO H31N3O s 7 99 469 91 6 9 vH 7276 25 7 eco 999 272091 d gt 959 OL E9 fy LLI 0 6 U 7 H H 1 gogo VN 241 002 aset 42 26 8v i i a 1 111 13 AIR 500 AU LINCOLN E AIR 500 AU LINCOLN Spanish AVISO DE PRECAUCION French ATTENTION German WARNUNG ATENCAO tim BR Chinese Do not touch electrically live parts or electrode with skin or wet clothing Insulate yourself from work and ground No toque las partes los electrodos bajo carga con la piel ropa moja da Aislese del trabajo de la tierra Nelaissez ni la peau ni des v te ments mouill s entrer en contact avec des pi ces sous tension solez vous du travail et de la terre Ber hren Sie keine stromf hrenden Teile oder Elektroden mit Ihrem K rper oder feuchter Kleidung solieren Sie sich von den Elektroden und dem Erdboden
47. LES QUE VA A UTILIZAR SIGA LAS MEDIDAS DE SEGURIDAD DE SU SUPERVISOR LISEZ ET COMPRENEZ LES INSTRUCTIONS DU FABRICANT EN CE QUI REGARDE CET EQUIPMENT ET LES PRODUITS A ETRE EMPLOYES ET SUIVEZ LES PROCEDURES DE SECURITE DE VOTRE EMPLOYEUR LESEN SIE UND BEFOLGEN SIE DIE BETRIEBSANLEITUNG DER ANLAGE UND DEN ELEKTRO DENEINSATZ DES HERSTELLERS DIE UNFALLVERHUTUNGSVORSCHRIFTEN DES ARBEITGEBERS SIND EBENFALLS ZU BEACHTEN Keep your head out of fumes Use ventilation or exhaust to remove fumes from breathing zone Los humos fuera de la zona de res piraci n Mantenga la cabeza fuera de los humos Utilice ventilaci n o aspiraci n para gases Gardez la t te l cart des fum es Utilisez un ventilateur ou un aspira teur pour ter les fum es des zones de travail Vermeiden Sie das Einatmen von Schweibrauch Sorgen Sie f r gute Be und Entl ftung des Arbeitsplatzes Mantenha seu rosto da fumaca Use ventila o e exhaust o para remover fumo da zona respirat ria t Fats RACVHEL SBELT FEU 71050108 OPK E 5 JE Y Bok HF CH 87 8 HAPI Ash 7129471 27 amp HSHM Lan ui e Ja gaal e Ju Al Mail pe us Turn power off before servicing Desconectar el cable de ali mentaci n de poder de la m quina antes de iniciar cualquier servicio D branchez le cou
48. NY SI TOHLNOO Q3Sh SI TOHLNOO LAdLNO 310W3H 41 NOILISOd 3 18VO 1OH LNOO 430334 SHIM OL HOLIMS 430334 SHIM 39V ld AO 9NIQT3M OL HOLIMS HOLZ IS AHL NOILISOd ALIHV10d 300819313 Q3HIS3Q 193 13S OL HOLIMS HALAWLIOA ASN ON IWANVW 9NILVH3dO 335 SNOLLWONMIddV SYNLNA ANY ALVIGAWWI 319A9 ALNG ANY LNSYYND JHL ALIOVdVO H3dOHd 40 LSNW d THVO ONIGTAM IVANYN ONILV43d0 83Q13M ANIONS NI 931511 SNOI1V914193dS LSAPAY LON OG 145 4 SI ONILLAS HONH3AOO ANIONS 38 AVIN SLINDHIO TOHLNOO 339333 SLIOA DpL 309 FOVITOA SIHL 41 OV JHL NI SSVSHONI NY ASNVO TIM TILLOHHL JHL ONIGIHH3AO ONILLAS JHL A8 ANIONS 31011 40 ASVSYONI 031409 3LOWSY TWNOLLdO 5 23 LINN 9333 3HIM OL 18 0 300419773 a O S O HOM OL d3ldvav 318V9 LNdNI mc 0 HO 1623 IVSH3AIND 2987 MHOM OL 390319373 TONSHdWY DIAGRAMS 430333 LNT jueuudinbe siy 2 5 10 syed jou e esn eisul pjnous jauuosied e Bulo Jes sued 9957 e 3ALLVO3N 1 euuoosiq e ui des e
49. TEERABLE YARD TRAILER For in plant and yard towing Comes standard with a Duo Hitch a 2 Ball and Lunette Eye combination Hitch K2636 1 TRAILER Two wheeled trailer with optional fender and light package For highway use consult applicable feder al state and local laws regarding possible additional require ments Comes standard with a Duo Hitch 2 Ball and Lunette Eye combination hitch A fender amp a light package Order K2636 1 Trailer K2639 1 Fender amp Light Kit K2640 1 Cable Storage Rack K887 1 ETHER START KIT Provides maximum cold weath er starting assistance for frequent starting below 10 12 Required Ether tank is not provided with kit K1847 1 SPARK ARRESTOR KIT Easily mounts to stan dard muffler WARNING Pipe Thawing with an arc welder can cause fire explosion damage to electric wiring or to the arc welder if done improperly The use of an arc welder for pipe thawing is not approved by the CSA nor is it recommended or supported by Lincoln Electric K2354 1 Air Dryer Kit Minimizes water content in sup ply air Avoids cold weather air hose ice up K2356 1 Control Panel Cover Kit Clear plexiglass cover to protect control panel from dirt and debris and to visually monitor machine operation Lockable to deter vandalism K2340 1 Lockable Fuel Cap Flash Arrester Kit For use in locations where flash arrester safety is required Lockable fuel cap prevents tampering with fuel
50. VYSdO Y3013M ANIONS 415 1 SNOILVOISIOSdS 3AO08V LSNPAV LON OG AHOLOV4J 13S 3Md SI 9NILL3S HONN3AO9 3NION3 LINDYIO NYO HOIHM 39V L10A 830334 2014 OV IHL NI 3SV3SONI NV ASNVO TIM ATLLOYHL 9NIGIHSH3AO ONILLAS JHL 9NISNVHO Ad 3NISN3 3SV38ONI ANV 333 38IM OL NOU AO 300819313 OL DIAGRAMS F 12 103105 069 318V9 1 CYZNT OL jueuudinbe 141 sued any jou esn eisur pjnous jeuuosied AIUO e e ojeq sued deey peaj 3ALLVO3N 12euuoosiq e eoe d ui deey uedo sjeued jou og e ONINHVM 7 NVYSVIC NOLLO3NNOO CtZ N 1 SH3Q713M 3NION3 TONZHdINV 500 0 LINCOLN E 13 3Sv8 IWOLLOS ECH Gei vv vS 76721 EENG
51. 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 con nected to premises wiring such as that in a home or shop its frame must be connected to the system earth ground See further connection instructions in the sec tion entitled Standby Power Connections as well as the article on grounding in the latest National Electrical Code and the local codes In general if the machine is to be grounded it should be connected with a 8 or larger copper wire to a solid earth ground such as a metal ground stake going into the ground for at least 10 Feet or to the metal frame work of a building which has been effectively ground ed 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 AIR VANTAGE 500 AU LINCOLN 5 6 INSTALLATION A 6 REMOTE CONTROL The AIR 500 AU is equipped with a 6 pin a
52. ctions printed on battery IMPORTANT To prevent ELECTRICAL DAMAGE WHEN Installing new batteries b Using a booster Use correct polarity Negative Ground AIR 500 AU LINCOLN A 5 INSTALLATION A 5 The AIR 500 AU is shipped with the negative battery cable disconnected Before you oper ate 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 bat tery may require a booster charge Be sure to use the correct polarity when charging the battery 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 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 C
53. ctor open and provide a cold electrode until the triggering device Amptrol or Arc Start Switch is pressed AIR 500 AU LINCOLN 9 WIRE WELDING CV Connect a wire feeder to the AIR VANTAGEG 500 AU AU according to the instructions in INSTALLA TION INSTRUCTIONS Section The AIR VANTAGE 500 AU in the CV WIRE position permits it to be used with a broad range of flux cored wire Innershield and Outershield elec trodes and solid wires for MIG welding gas metal arc welding Welding can be finely tuned using the ARC CONTROL Turning the ARC CONTROL clockwise from 10 soft to 10 crisp changes the arc from soft and washed in to crisp and narrow It acts as an inductance pinch control The proper setting depends on the procedure and operator preference Start with the knob set at O For any electrodes including the above recommenda tions the procedures should be kept within the rating of the machine For additional electrode information See www lincolnelectric com or the appropriate Lincoln publication OPERATION B 9 ARC GOUGING For optimal performance when arc gouging set the AIR VANTAGE 500 AU WELD MODE switch to the CC STICK position and the ARC CONTROL to 10 Set the OUTPUT knob to adjust output current to the desired level for the gouging electrode being used according to the ratings in the following Table B 2 TABLE B 2 Carbon Diameter Curren
54. current creates EMF fields around welding cables and igniting Do not spill fuel when filling tank If welding machines fuel is spilled wipe it up and do not start engine until fumes have been eliminated EMF fields may interfere with some pacemakers and welders having a pacemaker should consult their physician 1 d Keep all equipment safety guards covers and devices in before welding position and in good repair Keep hands hair clothing and tools away from V belts gears fans and all other moving ji Exposure to EMF fields in welding may have other health parts when starting operating or repairing equipment effects which are now not known welders should use the following procedures in order to In some cases it may be necessary to remove safety D i dd minimize exposure to EMF fields from the welding circuit guards to perform required maintenance Remove guards only when necessary and replace them when the maintenance requiring their removal is complete 2 d 1 Route the electrode and work cables together Secure Always use the greatest care when working near moving them with tape when possible parts 2 d 2 Never coil the electrode lead around your body 1 f Do not put your hands near the engine fan Do not attempt to override the governor or 2 d 3 Do not place your body between the electrode and idler by pushing on the throttle control rods work cables If the electrode cable is on your right w
55. e 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 WEB SITE at www lincolnelectric com Choose Quick Links and then Product Registration Please complete the form and submit your registration Read this Operators Manual completely before attempting to use this equipment Save this manual and keep it handy for quick reference Pay particular attention to the safety instructions we have provided for your protection The level of seriousness to be applied to each is explained below
56. e to earth ground Refer to MACHINE GROUNDING in the Installation chapter for proper machine grounding informa tion RCD Residual Current Device provides protection from active to ground contact RCD will not protect against electrical shock resulting from contact with active and neutral wires VRD INDICATOR LIGHTS Indicates OCV voltage across the output termi nals Also indicates operation of VRD in CC mode A Green light indicates OCV below 30V and a red light indicates OCV above 30V During welding both lights will flash depending on the type of Consumable being used AIR COMPRESSOR CONTROLS 26 THRU 29 26 27 28 29 COMPRESSOR HOUR METER The compressor hour meter displays the total time that the compressor has been running com pressor switch must be on COMPRESSOR ON OFF SWITCH Turns compressor on and off activating or deacti vating the electromagnetic compressor clutch COMPRESSOR PROTECTION LIGHT The yellow compressor protection light remains off with proper compressor oil temperatures If the lights turn on the compressor protection system will deactivate the compressor clutch and put the system in standby mode until the temperature reaches allowable limits Check for proper com pressor oil level AIR DISCHARGE VALVE Controls flow of compressed air A 3 4 NPT National Pipe Thread fitting is provided BATTERY JUMP START TERMINAL 30 31 30 POSITIVE BATTERY
57. emises disconnect and service over cur rent protection 2 Take necessary steps to assure load is limited to the capacity of the AIR 500 AU Loading above the rated output will reduce output voltage below the allowable 1096 of rated voltage which may damage appliances or other motor dri ven equipment and may result in overheating of the AIR VANTAGE 500 AU engine AIR 500 AU LINCOLN 7 INSTALLATION 7 CONNECTION OF LINCOLN ELEC TRIC WIRE FEEDERS WARNING Shut off welder before making any electrical con nections Connection of LN 7 LN 8 OR LN 742 to the AIR VANTAGE 500 AU 1 Shut the welder off 2 Connect the LN 7 LN 8 OR LN 742 per instruc tions on the appropriate connection diagram in Section F 3 Set the WIRE FEEDER VOLTMETER switch to either or as required by the electrode being used 4 Set the switch to the CV WIRE posi tion 5 Set the CONTROL knob to O initially and adjust to suit 6 Set the WELD TERMINALS switch to the REMOTELY CONTROLLED position 7 Set the IDLE switch to the HIGH position Connection of LN 15 to the AIR VANTAGE 500 AU These connections instructions apply to both the LN 15 Across The Arc and Control Cable models The LN 15 has an internal contactor and the electrode is not energized until the gun trigger is closed When the gun trigger is closed the wire will begin t
58. en is now widely accepted as a substitute for 2 Thoriated Tungsten in AC and DC applica tions 3 DCEP is not commonly used in these sizes 4 TIG torch nozzle sizes are in multiples of 1 16ths of an inch 4 1 4 in 6 mm 252 5 16 in 8 6 3 8 in 10 mm 7 7 16 in 11mm 8 1 2 in 12 5 mm 10 5 8 in 16 5 TIG torch nozzles are typically made from alumina ceramic Special applications may require lava nozzles which are less prone to breakage but can not withstand high temperatures and high duty cycles AIR 500 AU LINCOLN 10 PARALLELING When paralleling machines in order to combine their outputs all units must be operated in the CC STICK mode only at the same output settings To achieve this turn the WELD MODE switch to the CC STICK position Operation in other modes may produce errat ic outputs and large output imbalances between the units AUXILIARY POWER OPERATION Start the engine and set the IDLER control switch to the desired operating mode Full power is available regardless of the welding control settings if no weld ing current is being drawn The auxiliary power of the AIR VANTAGE 500 sists of two 15Amp 240VAC single phase receptacles The auxiliary power receptacles should only be used with three wire grounded type plugs or approved dou ble insulated tools with two wire plugs The current rating of any plug used with the system must be at leas
59. ent radio and TV reception numerical controlled machines telephone systems computers etc Be aware that interference may result and extra precautions may be required when a welding power source is used in a domestic establishment Installation and Use The user is responsible for installing and using the welding equipment according to the manufacturer s instructions If electromagnetic disturbances are detected then it shall be the responsibility of the user of the welding equipment to resolve the situation with the technical assistance of the manufacturer In some cases this remedial action may be as simple as earthing grounding the welding circuit see Note In other cases it could involve construction of an electromagnetic screen enclosing the power source and the work complete with associated input filters In all cases electromagnetic disturbances must be reduced to the point where they are no longer troublesome Note The welding circuit may or may not be earthed for safety reasons according to national codes Changing the earthing arrangements should only be authorized by a person who is compe tent to access whether the changes will increase the risk of injury e g by allowing parallel welding current return paths which may damage the earth circuits of other equipment Assessment of Area Before installing welding equipment the user shall make an assessment of potential electromagnetic prob lems in the surrounding area The following sha
60. ent safety guards covers and devices in position and in good repair Keep hands hair clothing and tools away from the gears fans and all other moving parts when starting operating or repairing the equipment ROUTINE AND PERIODIC MAINTENANCE DAILY Check the Engine and Compressor oil levels Refill the fuel tank to minimize moisture condensa tion in the tank Check water separator for water and drain if neces sary Check coolant level WARNING Only VMAC certified and approved synthetic oil MUST be used Shut down the Welder Compressor for 3 minutes open the pressure supply valve to ensure the system is depressurized prior to removing the compres sor oil level dipstick WEEKLY Blow out the machine with low pressure air periodical ly In particularly dirty locations this may be required once a week COMPRESSOR MAINTENANCE Refer to the Routine Maintenance section of the compressor owner s manual for the recommended maintenance schedule of the following a Compressor oil and filter b Compressor air filter c Compressor coalescing filter VEHICLE MOUNTED AIR COMPRESSORS WWW VMAC CA 1333 Kipp Road Nanamino British Columbia Canada V9X1R3 Telephone 250 740 3200 Facsimile 250 740 3201 Toll Free 800 738 8622 ENGINE MAINTENANCE Refer to the Periodic Checks section of the Engine Operator s Manual for the recommended maintenance schedule of the following
61. er s recommendations Ground the equipment in accordance with the U S National Electrical Code and the manufacturer s recommendations Refer to http www lincolnelectric com safety for additional safety information LINCOLN iv SAFETY iv PR CAUTIONS DE S RET Pour votre propre protection lire et observer toutes les instructions et les pr cautions de s ret specifiques qui parraissent dans ce manuel aussi bien que les pr cautions de s ret g n rales suiv antes 6 S ret Pour Soudage L Arc 1 Protegez vous contre la secousse lectrique a Les circuits l lectrode et la pi ce sont sous tension quand la machine souder est en marche Eviter toujours tout contact entre les parties sous tension et la peau nue ou les v tements mouill s Porter des gants secs et sans trous pour isoler les mains Faire tr s 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 couch pour lesquelles une grande partie du corps peut tre en contact avec la masse Maintenir le porte lectrode la pince de masse le c ble de soudage et la machine souder en bon et s r tat defonctionnement d Ne jamais plonger le porte lectrode dans l eau pour le refroidir Ne jamais toucher simultan ment les parties sous tension des porte lectrodes connect s deux machines
62. ess than 30V These lights monitor the OCV at all times In the CC mode when the welding arc has stopped the green light will illuminate indicating that the VRD has reduced the OCV to less than 30V During welding the red light will illuminate indicating that the OCV is greater than 30V During welding the red and green light will flash on and off This is normal operation as the welding voltage will produce less than 30V depending on the process and type of electrode being used If the red light remains illuminated after welding in the CC mode please refer to your local field service shop for service OPERATION The low voltage safety features of the VRD s is to reduce the possibility of electric shock to the operator a very slight delay during striking of the electrode may be experienced The high voltage that is available on units without VRD s allows them to penetrate and burn through dirty painted and heavily mill scale plate Units fitted with VRD s cannot penetrate and are required to reg ister the correct resistance which switches the safety device into weld mode AIR 500 AU LINCOLN 7 OPERATION B 7 Unlike other VRD s Lincoln uses micro processor con trol to monitor and establish the arc without the stick ing and shorting of the electrode to the job as seen in many other VRD installations Due to the requirement of the resistance in the circuit to be low for a VRD to operate a good m
63. etal to metal contact must be made between the metal core of the electrode and the job Any damaged connection anywhere in the output cir cuit may limit the operation of the VRD This includes a good connection of the work return clamp and the job The work return clamp should be connected close as practical to where the welding will be performed Some electrodes form a cone at the end of the elec trode after the welding arc has been broken particu larly iron powder and low hydrogen electrodes This cone will need to be broken off in order to have the metal core of the electrode to make contact STARTING TECHNIQUE The starting technique that has successfully overcome the problem is the push twist and peel technique This technique requires the operator to push the elec trode into the joint and twist The Push and Twist breaks off the cone and allows the metal electrode to make contact The peel and lift of the electrode establishes a con trolled start to the welding arc Normal welding tech nique for the application is then used BREAK IN PERIOD The engine used to supply power for your welder is a heavy duty industrial engine It is designed and built for rugged use It is very normal for any engine to use small quantities of oil until the break in is accom plished Check the oil level twice a day during the break in period In general this takes 50 to 100 hours of operation IMPORTANT IN ORDER TO ACCOMPLISH THIS
64. have been Open breakers may need to be checked and the problem persists reset Contact your local Lincoln Faulty receptacle Authorized Field Service Facility Faulty auxiliary circuit wiring CAUTION If for any reason you do not understand the test procedures or are unable to perform the tests repairs safely contact your Local Lincoln Authorized Field Service Facility for technical troubleshooting assistance before you proceed AIR 500 AU LINCOLN 8 WIRING DIAGRAM F 1 Jequunu eu 10 2914199 9U O 91M SI si e 10 siy je eq you U 10 SI 141 1431 1HOddns E N 105 Tlnd usage ud 8 10H1NOO ar 6 Sr s HOLVNH3LTV 1431NO ONUS 894 54 LIOA 4 ILONA id QUA Bee ooo GION310S Ws e n it ent 135 300W
65. hes approxi mately 30 volts the arc will go out and the machine will automatically reset to the touch start current level The tungsten may then be retouched to the work piece to restrike the arc The arc may also be started and stopped with an Amptrol or Arc Start Switch The ARC CONTROL is not active in the TIG mode In general the Touch Start feature avoids tungsten contamination without the use of a Hi frequency unit If the use of a high frequency generator is desired the K930 2 TIG Module can be used with the AIR VAN 500 AU The settings are for reference The AIR 500 AU is equipped with the required R F bypass circuitry for the connection of high frequency generating equipment The AIR 500 AU and any high frequen cy generating equipment must be properly grounded See the K930 2 TIG Module operating manuals for complete instructions on installation operation and maintenance When using the TIG Module the OUTPUT control on the AIR VANTAGE 500 AU is used to set the maxi mum range of the CURRENT CONTROL on the TIG Module or an Amptrol if connected to the TIG Module AIR VANTAGE 500 AU SETTINGS WHEN USING THE K930 2 TIG MODULE Set the WELD MODE switch to the Touch Start Tig 20 250 Setting Set the IDLER switch to the AUTO position Set the WELDING TERMINALS switch to the Remotely Controlled position This will keep the solid state conta
66. hile the engine is running Side the work cable should also be on your right side 2 4 4 Connect the work cable to the workpiece as close as possible to the area being welded 1 9 To prevent accidentally starting gasoline engines while 2 d 5 Do not work next to welding power source turning the engine or welding generator during maintenance work disconnect the spark plug wires distributor cap or magneto wire as appropriate LINCOLN SAFETY 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 In semiautomatic or automatic wire welding the
67. hine malfunctions Simply follow the three step procedure listed below Step 1 LOCATE PROBLEM SYMPTOM Look under the column labeled PROBLEM SYMP TOMS This column describes possible symptoms that the machine may exhibit Find the listing that best describes the symptom that the machine is exhibiting Step 2 POSSIBLE CAUSE The second column labeled POSSIBLE CAUSE lists the obvious external possibilities that may contribute to the machine symptom Step 3 RECOMMENDED COURSE OF ACTION This column provides a course of action for the Possible Cause generally it states to contact your local Lincoln Authorized Field Service Facility If you do not understand or are unable to perform the Recommended Course of Action safely contact your local Lincoln Authorized Field Service Facility NOTE See VMAC owner s manual for compressor trouble shooting VMAC VEHICLE MOUNTED AIR COMPRESSORS WWW VMAC CA 1333 Kipp Road Nanamino British Columbia Canada V9X1R3 Telephone 250 740 3200 Facsimile 250 740 3201 Toll Free 800 738 8622 CAUTION If for any reason you do not understand the test procedures or are unable to perform the tests repairs safely contact your Local Lincoln Authorized Field Service Facility for technical troubleshooting assistance before you proceed AIR 500 AU LINCOLN 8 TROUBLESHOOTING E 2 Observe all Safety Guidelines detailed throughout this manual Eng
68. imately 25 gallons 95 liters See engine Operator s Manual for ic fuel recommendations Running out of fuel may require bleeding the fuel injection pump FUEL USE DIESEL FUEL ONLY 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 INSTALLATION 4 ENGINE COOLANT WARNING 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 5096 mixture of ethylene glycol and water See the MAINTENANCE section and the engine Operator s Manual for more information on coolant GASES FROM BATTERY can explode To prevent EXPLOSION when to new battery last cable first then positive cable and battery clamp USING A BOOSTER connect positive lead to BATTERY CONNECTION WARNING Keep sparks flame and cigarettes away from battery INSTALLING A NEW BATTERY disconnect negative cable from old battery first and connect CONNECTING A BATTERY CHARGER remove battery from welder by disconnecting negative When reinstalling connect negative cable last Keep well ventilated battery first then connect negative lead to nega tive battery lead at engine foot BATTERY ACID can burn eyes and skin Wear gloves and eye protection and de be careful when working near battery Follow instru
69. in The DC welding control system uses state of the art Chopper Technology for superior welding performance RECOMMENDED APPLICATIONS The AIR 500 AU provides excellent con stant current DC welding output for stick SMAW and TIG welding The AIR 500 AU also pro vides excellent constant voltage DC welding output for MIG GMAW Innershield FCAW Outershield FCAW G and Metal Core welding In addition the AIR VANTAGE 500 AU can be used for Arc Gouging with carbons up to 3 8 10mm in diameter The AIR 500 AU is not recommended for pipe thawing AIR COMPRESSOR The AIR VANTAGE 500 AU provides 60 cfm at 100 psi compressed air for Arc Gouging and Air powered tools GENERATOR The AIR 500 AU provides smooth 240 VAC single phase output for auxiliary power and emergency standby power AIR 500 AU LINCOLN 5 2 CONTROLS AND SETTINGS All welder and engine controls are located on the case front panel Refer to Figure B 1 and the explanations that follow OPERATION FIGURE 1 12 4 8 14 3 10 12 1 16 5 15 21 24 27 28 geg 22 17 3 E EE 23
70. ine will not crank Engine will crank but not start Engine shuts down shortly after starting Engine shuts down while under a load Engine runs rough Engine will not shut off Contact your local Lincoln Authorized Field Service Facility Battery low Loose battery cable connections which may need Inspected cleaned or tighten Faulty wiring in engine starting circuit Faulty engine starter Contact autho rized local Engine Service Shop Battery disconnect switch is in the off position Out of fuel Fuel shut off valve is in the off posi tion make sure the valve lever is in a vertical direction Engine shut down solenoid not pulling In On Off switch on for more than 30 sec before starting the On Off switch will need to be switch off and all recommended possible areas back on of misadjustment have been Fuel Filters dirty clogged main fiiter Checked and the problem persists element and or In line Fuel Filter may Contact your local Lincoln need to be replaced Authorized Field Service Facility High water temperature or low oil pressure engine protection light lit Low oil pressure engine protection light lit Check oil level Consult engine service dealer High water temperature Check engine cooling system engine pro tection light lit Faulty oil pressure switch Faulty water temperature switch Contact authorized local E
71. is B 10 Simultaneous Welding and Auxiliary Power Loade B 10 Simultaneous Welding and Power Loads Extension Cord Length Recommendations 8 10 viii ix TABLE OF CONTENTS J CO gn ERE Section c Optional Field Installed Accessories C 1 P Section D Safety Pr cautions nn ele ee D 1 Routine and Periodic D 1 Engine MaInt nance occ rs eq ed Rs E D 1 EE EET EL UII LEM D 1 D 2 i um D 3 ell RE EE D 3 Battery r rg D 3 Charging the Battery s k D 4 Nameplate Warning Decal Maintenance D 4 Welder Generator Maintenance D 4 Engine Maintenance Components sess D 4 Troubleshooting ss eene nnne nennen tnn EKA Ak kK Section E Connection Diagrams Wiring Diagrams and Dimension Print Section F Parts MPO M 661 Series an INSTALLATION 1 TECHNICAL SPECIFICATIONS AIR 500 AU K32012 1 INPUT DIESEL ENGINE Make Model Description Speed RPM Displacement Starting Capacities cu in US System 4 cylinder High Idle 1900 12VDC Battery amp Fuel 25 gal Cummins 56 HP 42kw starter 94 6 L B3 3 1800 RPM Full Load 1800 inch mm Cil 2 gal 7 5L Diesel Engine Low Idle 1425 3 74 X 4 53 Radiator Coolant 95 x 115mm 2 6ga
72. is du poste conformement au code de l lectricit et aux recommendations du fabricant Le dispositif de montage ou la piece souder doit tre branch une bonne mise la terre Autant que possible l installation et l entretien du poste seront effectu s par un lectricien qualifi Avant de faires des travaux l interieur de poste la debranch er l interrupteur la boite de fusibles Garder tous les couvercles et dispositifs de s ret leur place 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 equipm
73. l 9 8L RATED OUTPUT 104 F 40 C WELDER Duty Cycle Welding Output Volts at Rated Amps 500 Amps DC multi purpose 40 Volts 550 Amps DC multi purpose 36 volts 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 1900 RPM Auxiliary Power 2 x 240 VAC Receptacles 2 x 3600 Watts 60Hz Single Phase COMPRESSOR SPECIFICATIONS Geng Model Description Delivary Maximum System Compressor Capacities Pressure Protection Belt Drive Rotary High Idle Mode 150 PSI Safety Relief Valve 1 3 gal 5 0 ltrs Screw Air 60 100PSI 10 5 kg cm 200 PSI 28 3 Ltr sec 10 5 kg cm 7 0 kg cm Low Idle Mode High Temperature 40 100PSI Automatic Shutdown 18 9 Ltr sec 290 F 143 C 7 0 kg cm PHYSICAL DIMENSIONS Deph 42 0 in 7 in 1690 165 1066 8 mm 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 8 for exhaust pipe AIR 500 AU LINCOLN 5 2 SAFETY PRECAUTIONS WARNING Do not attempt to use this equipment until you have thoroughly read the engine manufacturer s man
74. ll 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 9 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 5 the time of day that welding or other activities are to be carried out AIR 500 AU LINCOLN vi SAFETY vi Electromagnetic Compatibility EMC The size of the surrounding area to be considered will depend on the structure of the building and other activities that are taking place The surrounding area may extend beyond the boundaries of the premises Methods of Reducing Emissions Mains Supply Welding equipment should be connected to the mains supply according to the manufacturer s recommenda tions If interference occurs it may be necessary to take additional precautions such as filtering of the mains supply Consideration should be given to shielding the supply cable of permanently installed welding equip ment in metallic conduit
75. metal FUMES AND GASES can be dangerous 5 Welding may 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 circum stances outdoors a respirator may be required Additional precautions are also required when welding on galvanized steel The operation of welding fume control equipment is affected by various factors including proper use and positioning of the equipment maintenance of the equipment and the spe cific welding procedure and application involved Worker exposure level should be checked upon installation and periodically thereafter to be certain it is within applicable OSHA PEL and ACGIH TLV limits Do not weld in locations near chlorinated hydrocarbon vapors coming from degreasing cleaning or spraying operations The heat and rays of the arc can react with solvent vapors to form phosgene a highly toxic gas and other irritating prod ucts
76. nd 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 TOUCH START TIG mode and when a Amptrol is connected to the 6 Pin Connector the OUTPUT dial is used to set the maximum current range of the CURRENT CONTROL of the Amptrol In the CV WIRE mode if the feeder being used has a voltage control when the wire feeder control cable is connected to the 14 Pin Connector the auto sensing circuit automatically makes OUTPUT CONTROL inac tive and the wire feeder voltage control active Otherwise the OUTPUT CONTROL is used to preset the voltage The 14 pin connector is used to directly connect a wire feeder control cable In the CV WIRE mode when the control cable is connected to the 14 pin con nector the auto sensing circuit automatically makes the Output Control inactive and the wire feeder volt age control active WARNING NOTE When a wire feeder with a built in welding voltage control is connected to the 14 pin connec tor do not connect anything to the 6 pin connec tor AUXILIARY POWER RECEPTACLES The auxiliary power capacity of the AIR VANTAGE 500 AU is 7 2KW of 60Hz single phase power
77. ngine Service Shop High water temperature Dirty fuel or air filters may need cleaned replaced Water in fuel Fuel Shutdown solenoid not function ing properly linkage binding CAUTION If for any reason you do not understand the test procedures are unable to perform the tests repairs safely contact your Local Lincoln Authorized Field Service Facility for technical troubleshooting assistance before you proceed AIR 500 AU LINCOLN 5 E 3 TROUBLESHOOTING E 3 Observe all Safety Guidelines detailed throughout this manual Battery does not stay charged Faulty battery Faulty engine alternator Loose or broken lead in charging circuit Loose fan belt may need tighten ing Engine will not idle down to low 1 Idler switch in HIGH idle position Speed make sure switch is set to AUTO External load on welder or auxil iary power Mechanical problem in idler sole noid linkage Faulty wiring in solenoid circuit No or low voltage idle solenoid Faulty idler solenoid Faulty Weld Control PCB Printed Circuit Board Pull Coil Battery PCB Engine will not go to high idle when 1 Poor work lead connection to attempting to weld Work If all recommended possible areas of Broken idler solenoid spring misadjustment have been checked Welding Terminals switch inland the problem persists Contact wrong position your local Lincoln Authorized No open ci
78. nt and yard towing by a vehicle 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 Conformance with federal state and local laws Consult applicable federal state and local laws regarding specific requirements for use on public highways 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 compo nents such as suspension axles and
79. o feed and the welding process is started 1 Shut the welder off 2 For electrode Positive connect the electrode cable to the terminal of the welder and work cable to the terminal of the welder For elec trode Negative connect the electrode cable to the terminal of the welder and work cable to the terminal of the welder 3 Across The Arc Model Attach the single lead from the front of the LN 15 to work using the spring clip at the end of the lead This is a control lead to supply current to the wire feeder motor it does not carry welding current Set the WELD TERMINALS switch to WELD TERMINALS ON When the gun trigger is closed the current sens ing circuit will cause the AIR 500 AU engine to go to the high idle speed the wire will begin to feed and the welding process start ed When welding is stopped the engine will revert to low idle speed after approximately 12 seconds unless welding is resumed 4 Control Cable Model Connect Control Cable between Engine Welder and Feeder the WELD TERMINALS switch to REMOTELY CONTROLLED Set the MODE switch to the CV WIRE position Set the WIRE FEEDER VOLTMETER switch to either or as required by the electrode polar ity being used Set the ARC CONTROL knob to O initially and adjust to suit Set the IDLE switch to the AUTO position When the gun trigger
80. of its size and position e g ships hull or building steelwork a connection bonding the workpiece to earth may reduce emissions in some but not all instances Care should be taken to prevent the earthing of the workpiece increasing the risk of injury to users or damage to other electrical equipment Where necessary the connec tion of the workpiece to earth should be made by a direct connection to the workpiece but in some countries where direct connection is not permitted the bonding should be achieved by suitable capacitance selected according to national regulations Screening and Shielding Selective screening and shielding of other cables and equipment in the surrounding area may alleviate prob lems of interference Screening of the entire welding installation may be considered for special applications i 1 Portions of the preceding text are contained in EN 60974 10 Electromagnetic Compatibility EMC prod uct standard for arc welding equipment AIR 500 AU LINCOLN vii vii for selecting a QUALITY product by Lincoln Electric We want you Thank You to take pride in operating this Lincoln Electric Company product as much pride as we have in bringing this product to you CUSTOMER ASSISTANCE POLICY The business of The Lincoln Electric Company is manufacturing and selling high quality welding equipment consumables and cutting equip ment Our challenge is to meet the needs
81. ot cause flammable or toxic vapors from substances inside They can cause an explosion even though they have been cleaned For information purchase Recommended Safe Practices for the Preparation for Welding and Cutting of Containers and Piping That Have Held Hazardous Substances AWS F4 1 from the American Welding Society see address above Vent hollow castings or containers before heating cutting or welding They may explode 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 Connect the work cable to the work as close to the welding area as practical Work cables connected to the building framework or other locations away from the welding area increase the possibility of the welding current passing through lifting chains crane cables or other alternate cir cuits This can create fire hazards or overheat lifting chains or cables until they fail Also see item 1 c Read and follow 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 Do not use a welding power source for pipe thawing CYLINDER may explode if damaged
82. r produire du phosg ne gas fortement toxique ou autres produits irritants Pour obtenir de plus amples renseignements sur la s ret 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 prot ger PR CAUTIONS DE S RET POU R contre les chutes dans le cas ou on recoit un choc Ne jamais enrouler le c ble lectrode autour de n importe quelle partie LES MACHINES SOUDER TRANSFORMATEUR Un coup d arc peut tre plus s v re qu un coup soliel REDRESSEUR donc a Utiliser un bon masque avec un verre filtrant appropri 1 ainsi qu un verre blanc afin de se prot ger les yeux du ray onnement de l arc et des projections quand on soude ou quand on regarde l arc Porter des v tements convenables afin de prot ger la peau de soudeur et des aides contre le rayonnement de l arc Prot ger l autre personnel travaillant proximit au soudage l aide d crans appropri s et non inflammables Des gouttes de laitier en fusion sont mises de l arc de soudage Se prot ger avec des v tements de protection libres de l huile tels que les gants en cuir chemise paisse pan talons sans revers et chaussures montantes Toujours porter des lunettes de s curit dans la zone de soudage Utiliser des lunettes avec crans lateraux dans les zones l on pique le laitier LINCOLN Relier la terre le chass
83. rant avant l entre tien Strom vor Wartungsarbeiten abschalten Netzstrom v llig ffnen Maschine anhalten opere com as tampas removidas Desligue a corrente antes de fazer servico toque as partes el tricas nuas gt 57 gt 2 YEAR 5 79 521 7 e HN RIS e AHS HAHAE luca A ch gl dell e Do not operate with panel open or guards off No operar con panel abierto o guardas quitadas N op rez pas avec les panneaux ouverts ou avec les dispositifs de protection enlev s Anlage nie ohne Schutzgeh use oder Innenschutzverkleidung in Betrieb setzen Mantenha se afastado das partes moventes N o opere com os paineis abertos ou guardas removidas ORERTMN ARS SET E gdo Bel Age cols 13 Uu Jat Ye Ale carl Spanish AVISO DE PRECAUCION French ATTENTION German WARNUNG Chinese LEIA E COMPREENDA AS INSTRU ES DO FABRICANTE PARA ESTE EQUIPAMENTO E AS PARTES DE USO E SIGA AS PRATICAS DE SEGURANCA DO EMPREGADOR 5 ETERMUCTSU ELTRHOREMELR SU EHRE WR t RE PA RI HEHE 00 II CER 8 8 BUR BI 25 Bji SSS HYHA Gel g Eros sal gll
84. rcuit voltage at Service Facility studs Faulty Pull Coil Battery PCB or Weld Control PCB Engine will not go to high idle when 1 Broken wire in auxiliary current using auxiliary power sensor wiring Auxiliary power load is less than 100 watts Faulty Pull Coil Battery PCB or Weld Control PCB CAUTION If for any reason you do not understand the test procedures are unable to perform the tests repairs safely contact your Local Lincoln Authorized Field Service Facility for technical troubleshooting assistance before you proceed AIR 500 AU LINCOLN 4 TROUBLESHOOTING 4 Observe all Safety Guidelines detailed throughout this manual Engine goes to low idle but does not 1 Faulty Peripheral PCB Pull i Coil Battery PCB or Weld Conirol PCB No welding output or auxiliary output 1 Broken lead in rotor circuit Faulty field diode module Faulty Weld Control PCB Faulty rotor Welder has some no output and nol Faulty remote kit control Auxiliary output OK Faulty output control potentiome ter Faulty output control wiring Faulty Weld Control PCB Pull Coil Battery PCB or Chopper PCB WELDING TERMINALS switch in wrong position be sure switch is in WELDING TERMINALS ALWAYS ON position Faulty Weld Control PCB Pull Coil Battery PCB or Chopper PCB If all recommended possible areas No auxiliary power RCD may have tripped of misadjustment
85. t Range DC elec trode positive 1 8 3 2mm 30 60 Amps 5 82 4 0mm 90 150 Amps 3 16 9 4 8mm 200 250 Amps 1 4 6 4mm 300 400 Amps 5 16 8 0mm 350 450 Amps 3 8 10 0mm 450 575 Amps NOTE If desired the CV mode can be used for Arc Gouging Maximum current setting is limited to the AIR 500 AU maximum of 575 Amps Table TYPICAL CURRENT RANGES gt FOR TUNGSTEN ELECTRODES DCEN Approximate Argon Gas Flow Rate l min c f m Tungsten Electrode 196 296 196 296 TIG TORCH Diameter Thoriated Thoriated Aluminium Stainless Steel Nozzle mm in Tungsten Tungsten Size 4 5 25 0 010 2 15 3 2 4 3 8 2 4 3 8 4 5 6 50 0 020 5 20 3 3 5 5 10 3 5 5 10 1 0 0 040 15 80 3 3 5 5 10 3 5 5 10 1 6 1 16 70 150 10 20 3 5 5 10 4 6 9 13 5 6 2 4 3 32 150 250 15 30 6 8 13 17 5 7 11 15 6 7 8 3 2 1 8 250 400 25 40 7 11 15 23 5 7 11 15 4 0 5 32 400 500 40 55 10 12 21 25 6 8 13 17 8 10 4 8 3 16 500 750 55 80 11 13 23 27 8 10 18 22 6 4 1 4 750 1000 80 125 13 15 28 32 11 13 23 27 1 When used with argon gas The current ranges shown must reduced when using argon helium or pure helium shielding gases 2 Tungsten electrodes are classified as follows by the American Welding Society AWS Pure EWP 196 Thoriated EWTh 1 296 Thoriated EWTh 2 Though not yet recognized by the AWS Ceriated Tungst
86. t equal to the current capacity of the associated receptacle OPERATION B 10 SIMULTANEOUS WELDING AND AUXIL IARY POWER LOADS It must be noted that the above auxiliary power ratings are with no welding load Simultaneous welding and power loads are specified in table B 4 TABLE B 4 AIR 500 SIMULTANEOUS WELDING AND POWER LOADS TABLE B 5 AIR VANTAGE 500 AU Extension Cord Length Recommendations Use the shortest length extension cord possible sized per the following table rrent Voltage Load Maximum Allowable Cord Length in ft m for Conductor Size mps Volts 14AWG 2 52 12AWG 4 02 10AWG 6 0 mm 8AWG 10 02 6AWG 16 02 4AWG 25 02mm Conductor size is based on maximum 2 096 voltage drop AIR 500 AU LINCOLN 1 ACCESSORIES 1 OPTIONAL FIELD ACCESSORIES INSTALLED K857 25 ft 7 5 m or K857 1 100 ft 30 4 m REMOTE CON TROL Portable control provides same dial range as the output control on the welder from a location up to the specified length from the welder Has convenient plug for easy connection to the welder The AIR VANTAGE 500 AU is equipped with a 6 pin connector for connecting the remote control K704 ACCESSORY SET Includes 35 feet 10 m of electrode cable and 30 feet 9 m of work cable head shield filter plate work clamp and electrode holder Cable is rated at 500 amps 60 duty cycle K2641 2 FOUR WHEELED S
87. t termi nals when not welding to a no load voltage of less than 35V for DC welding and for AC welding 35V peak 25VAC RMS when the resistance of the output circuit is in the range of 20 200 ohms The lower reactiva tion resistance of the device the higher the safety level and also requires that the welding cable connec tions be kept in good electrical condition Having good electrical connections also limits the pos sibility of other safety issues such as heat generated damage burns and fires WELDING POWER SOURCES Welding power sources generally have an Open Circuit Voltage i e the voltage at the welding output terminals when not welding in the range of 35 115VDC Welding machines for stick welding MMAW and similar constant current CC mode processes supply a higher open circuit voltage between the electrode and the work when the welding machine is switched on and ready to commence weld ing These welding machines have high open circuit voltage typically 60 80V then when the arc is estab lished and welding current is drawn the voltage drops to 20 35V Consequently the greatest danger occurs when han dling the electrode and the electrode holder between welding operations such as when changing elec trodes Welding machines for MIG GMAW amp FCAW have a flat constant voltage CV characteristic generally with a lower open circuit voltage 30 50V Also the cur rent is turned On and Off by a gun trigger which
88. tected by an RCD Residual Current Device and 2 single phase 15 amp circuit breakers The auxiliary power capacity in watts equivalent to volt amperes at unity power factor This model has 1 Residual Current Device RCD protection 30mA 2 x 1 phase 15 amp Circuit Breakers 2 x 1 phase 240 volt 15 amp per outlet Note The single phase outlets are from different phases and cannot be paralleled The auxiliary power receptacles should only be used with three grounded type plugs or approved double insulated tools The current rating of any plug used with the system must be at least equal to the current capacity of the associated receptacle STANDBY POWER CONNECTIONS The AIR VANTAGE 500 AU is suitable for tempo rary standby or emergency power using the engine manufacturer s recommended maintenance schedule The AIR VANTAGE 500 AU can be permanently installed as a standby power unit for 240 volt 60 Connections must be made by a licensed electrician who can determine how the 240 VAC power can be adapted to the particular installation and comply with all applicable electrical codes The following informa tion can be used as a guide by the electrician for most applications 1 Install an isolation switch between the power com pany meter and the premises disconnect The AIR VANTAGE 500 AU and the power company supplies must not be connected together Switch rating must be the same or greater than the customer s pr
89. the sealing area NEVER install a damaged filter new Donaldson radial seal filter may have a dry lubricant on the seal to aid installation 5 Insert the New Radial Seal Filter Properly If you re servicing the safety filter this should be seated into position before installing the primary filter Insert the new filter carefully Seat the filter by hand making certain it is completely into the air cleaner housing before securing the cover in place The critical sealing area will stretch slightly adjust itself and distribute the sealing pressure evenly To complete a tight seal apply pressure by hand at the outer rim of the filter not the flexible center Avoid pushing on the center of the urethane end cap No cover pressure is required to hold the seal NEVER use the service cover to push the filter into place Using the cover to push the filter in could cause damage to the housing cover fasteners and will void the warranty If the service cover hits the filter before it is fully in place remove the cover and push the filter by hand further into the air cleaner and try again The cover should go on with no extra force Once the filter is in place secure the service cover Caution NEVER use the service cover to push the filter into place Using the cover to push the filter in could cause damage to the housing cover fasteners and will void the warranty 6 Check Connectors for Tight Fit Make sure
90. tires Mount equipment base to metal bed or frame of vehicle Follow vehicle manufacture s instructions AIR 500 AU LINCOLN 4 PRE OPERATION ENGINE AND COM PRESSOR SERVICE READ the engine and compressor operating and maintenance instructions supplied with this machine e Keep hands away from the engine 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 OIL mer The AIR 500 AU is shipped with the engine crankcase filled with high quality 10W 30 oil API class CD or better Check the engine and compressor oil levels before starting the engine If it is not up to the full mark on the dip stick add oil as required Check the oil level every four hours of run ning time during the first 35 running hours Refer to the engine and compressor Operator s Manuals for specific oil recommendations and break in informa tion The oil change interval is dependent on the quali ty of the oil and the operating environment Refer to the engine and compressor Operator s Manuals for the proper service and maintenance intervals Fill the fuel tank with clean fresh diesel fuel The capacity of the fuel tank is approx
91. to the plate while welding This can also increase spatter It is recommended that the ARC CONTROL be set to the minimum number without electrode sticking Start with a setting at 0 CV WIRE mode In this mode turning the ARC CONTROL knob from 10 soft to 10 crisp changes the arc from soft and washed in to crisp and narrow It acts as an inductance pinch con trol The proper setting depends on the proce dure and operator preference Start with a setting of 0 15 WELDING TERMINALS SWITCH In the WELD TERMINALS ON position the out put is electrically hot all the time In the REMOTELY CONTROLLED position the output is controlled by a wire feeder or amptrol device and is electrically off until a remote switch is depressed WARNING There is no VRD protection in the CV Mode When the Toggle switch is in the WELD TERMINAL ON position the voltage at the output terminal maybe up to 60V 16 WIRE FEEDER VOLTMETER SWITCH Matches the polarity of the wire feeder volt meter to the polarity of the electrode 18 19 6 PIN CONNECTOR For attaching optional remote control equipment When in the CC STICK and CV WIRE modes and when a remote control is connected to the Connector the auto sensing circuit automatically Switches the OUTPUT control from control at the welder to remote control 14 PIN CONNECTOR For attaching wire feeder control cable Includes contactor closure circuit auto sensing remote
92. ual supplied with your welder It includes important safety precautions detailed engine starting operating and maintenance instructions and parts lists ELECTRIC SHOCK can kill Ti e Do not touch electrically live parts or electrode with skin or wet clothing e Insulate yourself from work and ground Always wear dry insulating gloves ENGINE EXHAUST can kill Use in open well ventilated areas or CR vent exhaust outside MOVING PARTS can injure Do not operate with doors open or guards off AM Stop engine before servicing Keep away from moving parts See additional warning information at front of this operator s manual Only qualified personnel should install use or service this equipment INSTALLATION LOCATION AND VENTILATION The welder should be located to provide an unrestrict ed flow of clean cool air to the cooling air inlets and to avoid restricting the cooling air outlets Also locate the welder so that the engine exhaust fumes are prop erly vented to an outside area 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
93. uedo sjeued jou e UBD 4494 ONIAOW D ONINHVM Wf F 3 INVHOVIG NOILO3NNOO Z N1 273 2983 SH3Q 13M AIR 500 AU LINCOLN E 7 1817565 F 4 0002 22 01 DIAGRAMS F 4 NOILISOd NI HOLIMS 44101 39 1 NOILISOd AHL NI HOLIMS 39V ld 4199 300819313 ALIS V 10d JHL HOLVW OL HOLIMS YALSWLIOA 30333 38IM NOLLISOd ALI V TOd 38 830 303 50115 LAdLNO S318V9 ONIGTAM LO3NNOO ON WANVW 9NILVel3dO 335 39113 ANY 31949 ANY AHL ALIO VdVO 38 LSNN 57895 SNIQT3SM IVONVIA ONLLVS3dO 3NION3 JHL NI 03151 SNOLLWOISIDAdS 3AO8V 15 LON OG 30193 LY l3S 3td SI ONILLAS HONS3AO9 3NION3 LINDYIO TOHLNOO JHL 39VINVO HOIHM 39 V L 10A 830334 OV FHL NI 3SV3ONI NV 3600 TIM 31LL08H L IHL 9NIGIHS3AO 35 NONH3AO9 JHL ONIONVHO Wd 3NION3 IHL 40 3SV38ONI LINN 1333 38IM OL Mm 51890 300819313 OL JOULNOO SLOWSY Nid 9 318V2 1031109 7869 N Md 319V9 LNdNI 27 OL 14 2 5 Jo syed jou esn je su peyrjenb AIUO
94. v2 TIIM AHL DNIGISH3AO DNILI3S HONH3AOD Ad Wd 3NIDN3 7 1GI 1 HO 3SV3HDNI LINN 93933 34M OL 31875 390312913 DIAGRAMS 3182 IOuLNOD 693 31872 E LAdN 8 N1 OL Nid Fl jueuudinbe siy Jo syed jou esn ejsui pnoys jeuuosied peyijenb Ajuo e sued Aeme dose pee JALLVOJN 1 euuoosiq e ui dose uedo sjeued uy jou ONINHVM 77 NOLLO3NNOO 8 1 SYA 13M F 8 AIR 500 AU LINCOLN E 18 1758 9 0002 22 01 1341540 SV NOILISOd 4101 OLAV NI HOLIMS 44101 39V1Id ON ONILVYAdO 33S 5 330403 ANY ALVIGSWWI 319A9 ALNG LNSYYND JHL ALIOVdVO 40 38 LSNW S318V9 ON OM 21875 300819373 AHL 40 ALIS 10d 3H L HOLVIN HOLIMS YSLAWLIOA 830334 38IM JHL NOLLISOd ALI V TOd 341830 303 SANLS S318v9 ONIGTAM LO3NNOO ON NOILISOd Q3TIOH LNOO AT31OW38 OL HOLIMS S IVNIINS3 L 83QT3M 39V Id NOLLISOd A4IM A9 JHL NI HOLIMS 39V ld WANVW 3 0 83013M JHL NI GSLSIT SNOILVOISIOSdS 3AO8V 5 LON OQ AHOLOV3 155 184 SI ONILL3S HONS3AO9 3NION3 LINDYID TOHLNOO

Lincoln Electric IM10066 User's Manual

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