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Lincoln Electric IM826-A Welding System User Manual

1. 5 Break In Period rh eed ek nn ete ed 6 Typical Fuel Consumption 22 mx dame Ee d d B 6 Duty ss en alent 6 Welding cub me gale 6 Stick Welding ROSE algue 6 eee idees n dns 6 Downhill Pipe 6 Touch Start Mode ek qued E 6 AIR VANTAGE Settings when using K930 2 TIG Module B 7 Typical Current Ranges for Tungsten Electrodes B 7 CVEWireMOde Pru B 8 Precor E B 8 Paralleling sisi RM r eyed deb HM e RP TIAE E Ped B 8 Auxiliary Power Operation B 8 Simultaneous Welding and Auxiliary Power Loads B 8 Simultaneous Welding and Power Loads Extension Cord Length Recommendations B 9 LINCOLN vii vii TABLE OF CONTENTS AccessorleS aida nee EENE EIEE eee eue Section C Optional Field Installed Accessories C 1 Maintenance assis sue dans pacer ah RR EORR dates
2. 5 power off before servicing Desconectar el cable de alimentaci n de poder de la m quina antes de iniciar cualquier servicio D branchez le courant avant l entretien 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 e X2TTLA7Y UAINBUSD TTEAY LU FE e MN SIS AHS Aun Aj Jd i alll 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 e Anlage nie ohne Schuizgeh use oder Innenschutzverkleidung in Betrieb setzen e Mantenha se afastado das partes moventes opere com os paineis abertos ou guardas removidas e SIPH ERAL EE v e Ego Sel SEE ap S 42 Gils 13 oua Nhe y Chany WARNING Spanish AVISO DE PRECAUCION French ATTENTION German WARNUNG apanese LEIA E COMPREENDA AS INSTRUGOES DO FABRICANTE PARA ESTE EQUIPAMENTO E AS PARTES DE USO E SIGA AS PRATICAS DE SEGURAN A DO EMPREGADOR E gt MARPBHOA A OHRBEKK MA ETIMLTFEL EL TRHORSME RE TFE o
3. e 5 syed Aeme e 3ALIVO3N 1 euuoosiq e eoe d ul des e sjeued ejejedo jou oq e PT UD2 HDOHS 91419313 ONINHVM Y INVHOVIG NOILO3NNOO 8 98 H3aNVININOO AIR VANTAGE 500 CUMMINS LINCOLN E DIAGRAMS F 7 F 7 CONNECTION DIAGRAM V 182vCS 0002 22 01 4341 30 SV NOILISOd 3101 NI HOLIMS 44101 SOV 1d NOILISOd STIVNINYSL NI HOLIMS S IVNIWS3 L 9NIQT3M ADV Td NOILISOd JHL NI HOLIMS SCOW 39V ld 119V9 300819313 AHL JHL OL HOLIMS YALAWLIOA 830333 38IM AHL NOILISOd ALIAV 10d Q3slS30 SONLS 318V9 WANVA 9NILVel3dO 395 SNOILVOI adv 34N1N14 ANY 31VIQ3AAWI 41949 ALNG ANY JHL 803 ALIOVdVO 38 LSNW 531970 300819313 MYOM OL AYOM OL 4781 830334 38IM TOHLNO9 SLOWSY 198 TVNOILdO do jueuudinboe siu 2 JO syed ant A jeouioeje uono jou 5 pjnous jeuuosjed AIUO Buras e10J9q syed pee Meneg 3ALLVO3N 12euuoosig e goed ul uedo sjeued jou ONINHVM WV
4. SLOWSY 2987 1VNOILdO WVYSVId NOLLO3NNOO SSOMWODV GC N1 SS3Q 13M 3NISN3 TONSHdAIV AIR VANTAGE 500 CUMMINS LINCOLN E DIAGRAMS F 8 F 8 CONNECTION DIAGRAM 9 L82vcS 00027 L t NOILISOd HDIH NI HDLIMS H3 1dI 32Vld DN 37872 330812313 3 1 40 ALId V 10d JHL HOLVW OL HDLIMS YALAWLIOA 83033 38IM JHL NOILISOd ALI V TOd QH38IS3G 401 SANLS OLS318V2 ONIQTIM LOANNOD TN WANVW 5NILVH3dO 335 SNOILLV2l1ddV 34N1N1 ANY ALVIGAWWI 41249 ALNG LN388f12 JHL ALIDVd VOD 38 LSNW S318VD DNIQT3M IWANVW DNILVH34O H3QT3M 3NIDNH JHL 3151 SNOLLV2I3I23dS 3AO8V LSNFAV LON OG AHOLOV LV 135 444 SI DNILL3S HONH3AOD 3NION3 JHL LINDYID TOHLNOO JHL NYD HDIHM 39VLTOA 830333 DV JHL NI 25SV38DNI NV ASNWD 39 VANIT 31LLOSH L 5NIGIHH3AO HO 145 HONH3AOD JHL DNIDNVHO INdH 3NIDN3 9101 AHL 3SV3HDNI NOILQ VD LINN 1333 34M OL 31875 34041931 31875 IO4LNODS6S 31872 lON3HdAV LAdN 8 N1 OL Nid tl jueuudinbe 10 ses 10 syed Ajeoujoeje jou esn ejsui pjnoys jauuosied e Buas syed Aeme desye pes Aisyeg 1 euuoosiq e ui desye uedo sjoued ejeJedo jou oq e ONINHVM W WV49VIQ NOLL23NNOO 8 7 SH3Q 13M AIR VANTAGE
5. RR ea Section D Safety Precautioris vui nc eee bab RR ERE Dd Ee orca Re Rh P Y Rad D 1 Routine and Periodic Maintenance 2 2 D 1 Engine Maintenance 22220 een sien ae mare nel D 1 Dia lp crc m D 1 D 2 Fuel FilterS ocu eed ad doa by RID UR he Dante denses Pee eS here E pd pp Ae D 3 Gooling SYSTEMI decidi usce e neta ela UAE Eo D 3 B ttery Handlifg ur Ee gras tad We Ree oe Rob RA D 3 Charging Battery uix eee loges eme bos Ed mE des du ieee idee e e D 4 Nameplate Warning Decal Maintenance D 4 Welder Generator Maintenance D 4 Engine Maintenance Components D 4 GFCI Receptacle Testing and Resetting Procedure D 4 Troubleshootlhg sue sacs en see Section E Wiring Connection Diagrams and Dimension Print Section F Parts Lists ARR GR RR RR RAUS UN ER ea P 495 Series LINCOLN P A 1 INSTALLATION A 1 TECHNICAL SPECIFICATIONS AIR VANTAGE 500 CUMMINS K2325 1 INPUT DIESEL ENGINE Make Model Speed RPM Displacement Starting System Cummins 4 cylinder High Idle 1900 199 cu
6. 411934 T 980d TN M 3dsi431 4 LA Sg EM S ZM tac Ogg LJ J 2807 A1dHWassv P 1 LM LNdLNO NO anis oy slo 5902 Lm oC INVHOVIG ONIHIM 00S 39V LNVA AIR VANTAGE 500 CUMMINS LINCOLN E DIAGRAMS F 2 F 2 CONNECTION DIAGRAM 8 8 v7S 0002 22 01 NOILISOd 4101 H9IH NI HOLIMS 43101 NOILISOd Q3TIOS LNOO AT310IN38 OL HOLIMS S IVNINSH3 L 9NIGT3M 39V Id NOILISOd 38IM AO IHL NIHOLIMS SGOW 39Vld ALlav 10d 04341534 sanas S318v9 9NIQT3M LOANNOD NOILVO I ddY 40 319A9 ALNG ANY 803 Q3ZIS 38 LSNW S318V9 ONIGTAM WANVW 9NILVe3dO H3Q7T3M SHL NI 931511 SNOILVOISIOSdS 3AO8V 1SNFAY LON OG AHOLOV4 JHL LV 13S 3Md SI ONILL3S HONS3AO9 3NION3 JHL TONLNOD JHL NYO HOIHM 39V L10A 830334 3SIM OV JHL NI 3SV3SONI NV 2SNV9 39 VMNIT J1LLOSH L SHL ONIGISSIJAO ONILLAS HONH3AO9 Ad 3NION3 31GI SHL JO 35744 39unos YAMOd YO ANY 31000IN TOS LNOO OL 39VIAVQ NI L10S38 NOILISOd HOLIMS L938809NI 31000IN T1OHLNOOS ALVYAdO OL 9NILdW3LLV 3304338 NOILISOd 3805010
7. ui spienf deeye uedo sjeued jou ONINHVM WV NOLLO3NNOO 9IL SH30713M 3NISN3 NOILOVO AIR VANTAGE 500 CUMMINS LINCOLN E DIAGRAMS F 12 F 12 CONNECTION DIAGRAM 6 18 65 0002 22 01 41538 SV NOILISOd 7101 H9IH HO OLAV NI HOLIMS 44101 39VId TN NOILISOd ATALOWSY OL HOLIMS SIVNINYAL H3QT3M 39Vld NOILISOd AYIM AO JHL NI HOLIMS SGOW 3HL 39 1 300819313 JHL ALI V lOd JHL HOLVN OL HOLIMS YALAWLIOA 430333 SHIM AHL NOILISOd ALIHV 10d Q338 8S3Q 401 58715 LAdLNO 318V9 ONIGTAM LOANNOO WANVA 33S SNOILVONMddV AYALA ANY SLVIGSWWI 31949 ALNG ANY JHL ALIOVaVO 40 38 LSNW 53199 SNIGTJM WANVA 9NILVH3dO 83Q0 13M 3NISN3 SHL NI Q31ST1 SNOILVOISIOAdS 3AO8V LSNPAV LON OG AHOLOVJ JHL 13S 3Md SI ONLLL3S ANIONS JHL LINDYID 39 VIAVO HOIHM 39 VL 10A Y30334 38IM OV FHL NI 3SV3HONI NV 3Snv9 TIM 39 VMNIT3TLLOSH L JHL 9NIGIHSSAO 9NILE3S HONH3AO9 SHL A8 3NISN3 3 TII AHL 30 3SV38ONI LINN 0383 38IM OL NOILNVO 300819313 MYOM OL 1OH LNOO 2697 319 9 lt JON3HdNV CYZ NTOL Nid tl jueuudinbo siy 2 JO sued Ajeoujoeje jou esn ejsui pjnoys jeuu
8. SAFETY ii el CYLINDER may explode 796 if damaged 7 5 7 a Use only compressed gas cylinders containing the correct shielding gas for the process used and properly operating regulators designed for the gas and pressure used All hoses fittings etc should be suitable for the application and maintained in good condition 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 A 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 CGA publication P I Precautions for Safe Handling of Compressed Gases in Cylinders available from the Compressed Gas Association 1235 Jefferson Davis Highway Arlington VA 22202 FOR ELECTRICALLY powered equipment 8 a Turn off input power using the disconnect switch at the fuse box before working on the equipment Install equipment in accordance with the U S
9. Um Be Y 7 7 99 59 9 917 Lu 9 YE Y ZYG id 008 999 12091 psum 7 ose 0L 9 7 i 1 1 1 Es C is 016 C3 1 gt Y gt VN DE DE D DE 89901 DORE OO 0911 00 cv DD ag DE 2929 2929 19 Sv LE I LOEO COL DIE 2697 1 oa GE EET LL LL CE CE CE EE LUE m f Emm LL EIE EE LET LL LL LL 2 ad 1 y L 116 2510 _ 9 veel Seer 2S c8 Lo 58 i N 85 1111 AIR VANTAGE 500 CUMMINS LINCOLN E WARNING Spanish AVISO DE PRECAUCION French ATTENTION German WARNUNG SIR Chinese Korean Do not touch electrically live parts or electrode with skin or wet clothing e Insulate yourself from work and ground No toque las partes o los electrodos bajo carga con la piel o ropa mojada del trabajo y de la tierra Ne laissez ni la peau ni des v tements mouill s entrer en contact avec des pi ces sous tension Isolez vous du travail et de la terre e Ber hren Sie keine stromf
10. NOTE If desired the CV mode can be used for Arc Gouging Maximum current setting is limited to the AIR VANTAGE 500 maximum of 575 Amps 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 erratic outputs and large output imbalances between the units AUXILIARY POWER OPERATION If a GFCI receptacle is tripped See the MAINTENANCE section for detailed information on testing and resetting the GFCI receptacle 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 welding current is being drawn The auxiliary power of the AIR VANTAGE 500 consists of two 20 Amp 120VAC single phase 5 20R GFCI duplex receptacles one 50 Amp 120 240VAC single phase 14 50R receptacle and one 50 Amp 240VAC three phase 15 50R receptacle The 120 240VAC receptacle can be split for single phase 120 VAC operation The auxiliary power capacity is 12 000 watts of 60 Hz single phase power or 20 000 watts of 60Hz three phase power The auxiliary power capacity rating in watts is equivalent to volt amperes at unity power factor The maximum permissible current of the 240 VAC output is 50 A The 240 VAC single phase output can be split to provide
11. If all recommended possible areas 2 Open breakers may need to be reset of misadjustment have been 3 Faulty receptacle checked and the problem persists 4 Faulty auxiliary circuit wiring Contact your local Lincoln 5 GFCI tripped Authorized Field Service Facility 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 VANTAGE 500 CUMMINS LINCOLN P DIAGRAMS F 1 F 1 Sjeued eunso oue eui Jo euo uo eui pejsed si sened ano 2 eu jenueui siy Aq peJeAoo 10 eyeJnooe aq jou 3 AjUO 10 S SIUL ILON 88rvo TAN HOLVNH3LTV zez AN Le ea pa 00900 GION310S JOHINOO JO 305 1441 NO anis HOA SORTE W3luvis Nzez 58 Lez 2 L49d ag 4 L 9 5 pens HOLIMS YILINNV er 6 o 8 pop 299 wala An
12. K802N POWER PLUG KIT Provides four 120V plugs rated at 20 amps each and one dual voltage full KVA plug rated at 120 240V 50 amps 120V plug may not be compatible with NEMA common household receptacles K802 R POWER PLUG KIT Provides four 120V plugs rated 15 amps each and one dual voltage full KVA plug rated at 120 240V 50 amps 120V plug is compatible with NEMA common household receptacles K857 25 ft 7 5 m or K857 1 100 ft 30 4 m REMOTE CONTROL 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 CUMMINS is equipped with 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 headshield Filter plate work clamp and electrode holder Cable is rated at 500 amps 60 duty cycle K2641 2 FOUR WHEELED STEERABLE YARD TRAILER For in plant and yard towing Comes standard with a Duo HitchTM 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 federal state and local laws regarding possible additional requirements 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 am
13. NI NMOHS HOLIMS TOHINOO TWNIWYSL ONIQT3M s 9L WOM HOVE Woui MOL H Fe N00 IOHLNOO LNd LNO az edo Ici 8 _HOLOVLNOO 4 lt aioWa YOM ovaz OVASLL 102 NOLIVNIAY13HL OL LS3HVEN 9Nhi 415 OL Q3193NNO9 HSNHE 3ALISOd 40 WOLLOS GNIS ANNOYS Asivrixnv LH 40 1 WOLLOS Noanis save eno 5 _ LN OA v Qoo di On up Lao TANVd TOHLNOO NO Qnis NI SWIL HONOUHL SSvd SQV31 33 MOd ANVITIXAY E 9 SONIGNIM ASVIIIXQV HOLVIS 3odms 1919 Had SIOSNAS 1V91H193713 V SC CM INVYSVIC ONIAIM 00S 39V LNVA ze nm Dane MEM 55 ONIGNIM HOLVLS HOLIMS 019313S 30ON M ANY TaM solvis lem Sod 2 VEZ 0 ll fa 28 9808 Sg w3ddoHo N 1HOlN HOLIMS ALINY 10d NOILISOd ALIS 10d NI NMOHS HOLIMS 8802
14. Aeme deey e peaj Meneg 3ALLVO3N 12euuoo siq e eoejd ui spienf deoye uedo sjoued jou ONINHVM WV NOLLO3NNOO 4 414V9 2987 OL SH3Q 13M 3NISN3 AIR VANTAGE 500 CUMMINS LINCOLN E DIAGRAMS F 6 F 6 CONNECTION DIAGRAM 68625 31V In SNI ANY SQV3139lr1dS GASNNN HOV3 31VINSNI 9NIGT3M 3HIM OL HOLIMS HO103 13S SHL NOILISOd ALINV1Od 3004193173 GAYISAG LOATAS OL HOLIMS ASN SN IWANVW SNIIJVH3dO 395 SNOILVOIAdY 34N11N14 ANY SLVIGAWWI 319A9 ALNA IN3HHNO JHL ALIOVdVO H3dOHd 38 LSNW 3 1HVO IVANVN 9NI1Vd3d0 ANIONS JHL NI 93151 SNOLLWOISIOAdS 3AO8V LSNPAV LON 3H L 145 4 SI ONILLAS HONH3AOO ANIONS SHL Q39VIAvQ 38 SLINDYIO TOHLNOO 430334 SHIM SLIOA 0r S309 39VETOA SIHL 41 39VET0A OV IHL IHL NI 3SY389NI 3S0 v9 FTLLOWHL 1 ONIGIHH3AO HO ONILLAS HONH3AO9 JHL ONIONVHO A8 3NION3 J101 IHL 30 3SV3HONI gt NOLLRVO LINN 0334 3HIM OL J18V9 300419413 OL ON1d d3ldvav 318V9 LNdNI IVSH3AIND 2987 961M HHOM OL 0218 430334 8 jueuudinbe siy 291A18 10 sed jou e esn eisui pjnous jauuosied
15. NOLLISOd 3HL NI HOLIMS SGOW AHL 39V 1d 318V9 300419313 IHL 40 ALINY Od JHL HOLVN OL HOLIMS H313INL0A 430334 IHM JHL NOLLISOd ALINW10d 028453 50015 114110 OL S318V2 LO3NNOO NOLLVOliddV 40 31942 ALNG 09715 38 LSNN S3 182 ONIGTAM JN WANVA S9NILVe3dO 3NISN3 JHL NI Q31ST1 SNOILVOISIOAdS Wd 3AO8V LSNPAV LON OG 7 AHOLOVJ 13S 3Md SI ONILL3S HONH3AO9 3NION3 JHL LINDYID TOHINOO JHL 39 VIVO HOIHM 830333 38IM OV JHL NI 3SV38ONI NV 3575 TIM 39 VXNIT 31LLOSH L JHL ONIGIHHTAO ONILLAS HONS3AO9 JHL ONIONVHI A8 Wd 3NISN3 SHL 30 ASVAYONI 0 91 NOILNYO LNdLNO ALOWSY ko 9 LINN 38IM OL 3782 300819313 MU ES 408005 JO TVNINYAL HHOM OL SLO3NNOO YOM OL NOLLO3NNOO YSLAWLIOA Y30334 38IM 0 NOLLO3NNOO ANVYS 0 QN9 CE OVAGEE 4 Le JN fo WAGY x TN 9NITTHM fo t m LO3NNCO a N3Lavav SHONNOS u3q13M 3NION3 NO LON 4 9 28 IVSSH3AIND 2985 T jueuudinbo siy eorues sued ant jou esn ejsui pjnous jeuuosied peyijenb AIUO BUIDIAJaS sued
16. hrenden Teile oder Elektroden mit Ihrem K rper oder feuchter Kleidung Isolieren Sie sich von den Elektroden und dem Erdboden toque partes el tricas e electrodos com a pele ou roupa molhada Isole se da e terra KARHE 7 5nfdcmn amp toc t 8 ATWSRIELT FSU ORRKAKDY 018 RETE ER 8 B BUBRET era Hg SE SML FS su ysa ij AAS ASAl niMAlg Gall pl ja gaai Y O pall aay 4 Usk stall AA olah JUS daa je Keep flammable materials away e Mantenga el material combustible fuera del rea de trabajo e Gardez l cart de tout mat riel inflammable Entfernen Sie brennbarres Material e Mantenha inflam veis bem guardados ORAPTUbEDOMtTOMEER TIZBWKHA e i 9 8 nio I LTA ug GIS ALUN gl Wear eye ear and body protection Prot jase los ojos los oidos y el cuerpo Prot gez vos yeux vos oreilles et votre corps Tragen Sie Augen Ohren und K r perschutz Use protec o para a vista ouvido e corpo HRUS CRBRELTE eEKR HRSHSEGSRR ec HS 200 due Jules A A J READ AND UNDERSTAND THE MANUFACTURER S INSTRUCTION FOR THIS EQUIPMENT AND THE CONSUMABLES TO BE USED AND FOLLO
17. the battery 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 does not qualify as a spark arrestor When required by local regulations a suitable spark arrestor must be installed and properly maintained An incorrect arrestor may lead to damage to the engine or adversely affect performance 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 is equipped with a toggle switch for selecting hot welding terminals when in the WELD TERMINALS ON position or cold welding terminals when in the REMOTELY CONTROLLED position WELDING OUTPUT CABLES With the engine off route the electrode and work cables thru the strain relief bracket provided on the front of the base and connect to the terminals provided These connections should be checked periodically and tightened
18. 500 CUMMINS LINCOLN E DIAGRAMS F 11 F 11 CONNECTION DIAGRAM 6 8 25 0002 22 01 Q38l 3 SV NOILISOd OLAV NI HOLIMS 44101 39 1 NOILISOd IOHLNO9 NI HOLIMS TOHLNO9 LAdLNO 39Vld JN NOILISOd 911 3H L NI HOLIMS SGOW 39Vld ALlsv lOd Q38lI 3G 58715 OL 318V9 9NIQT3M LO3NNOO WANVW ONILVYSdO 33 SNOILVON dd ANY 31VId3NMWI 40 319A9 ALNG ANY JHL ALIOVdVO 40 38 LSNW 3 18V9 WANVI 83Q T3M ANIONS JHL NI 931511 SNOILLV2I3IO3dS 3AO8V 5 LON Od AYOLOVA LV V N 13S 3Md SI 9NILL3S YONYSAOD 3NION3 SHL TOHLNOO SHL NVO HOIHM 39VL10A 830333 38IM OV JHL NI 3SV3HONI NV ASNVS TIM 39 VMNTT 3 TILLOSH L 3H L 9NIGIHSSAO ONILLAS HONS3AO9 3HL A8 3NISN3 7101 3SV3HONI MYOM OL HOLIMS LAVLS 7187 de TOULdNY QNVH 2967 Rd 3001 59184 OO JOULdWY 1003 0299 31875 926 ONILLIS LNdNI 579 OL 579 JONJHANY HALINMOT HOLVIN934 UN jueuudinbo si 2 10 sued Ajeouioeje uonoj jou esn ejsui pjnous jeuuosJed peyrjenb AIUO e urines sued e peaj 3ALLVO3N 128uu09sIQ e
19. A 1 Safety Pr cautions one RAE en URBE LR EC uix der ped A 2 Location Ventilation Pea E cv cete dig oves A 2 Re tp MAL RM ML EM IU E DE A 2 STACKING 2 Angle of Operation A 2 iunc TL A 3 High Altitude Operation A 3 High Temperature 54 eene Reo Rus sod RERO OR RES A 3 TOWING dede A 3 Vehicle Mounting erre omm ame nmn ER EX e P E Ea erus A 3 Pre Operation Engine and Compressor Service A 4 c EET A 4 RS DER __ _ ___ _ A 4 Fuel suse dE dcs A 4 Engine Cooling System A 4 Battery Connections cst sain ace dane te A 4 Muffler Outlet Pipe serras deals dd PR REY chewed ERR A 5 Spark Arrestol sales be Gand a isl Ru egre wur irn s pb exc thee eden A 5 Air Cleaner Inlet Hood A 5 Welding Termitials dpt exer emite t sure Patet hea Real ARR ROLE RUE UD A 5 Welding Output Cables A 5 Machine Grounding wit naseg beens bad a
20. ARAM REBAR BEER ERR 8 8 SE ER EST S28 HAS FHA ETMA weal Ai gli easly QUE al gti LINCOLN P LINCOLN amp World s Leader in Welding and Cutting Products Sales and Service through Subsidiaries and Distributors Worldwide Cleveland Ohio 44117 1199 USA Tel 216 481 8100 Fax 216 486 1751 Web Site www lincolnelectric com
21. Check the Engine and Compressor oil levels Refill the fuel tank to minimize moisture condensation in the tank Open the water drain valve located on the bottom of the water separator element 1 or 2 turns and allow to drain into a container suitable for diesel fuel for 2 to 3 seconds Repeat the above drainage procedure until diesel fuel is detected in the container 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 compressor oil level dipstick WEEKLY Blow out the machine with low pressure air periodically 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 VMAC rm 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 a Engine Oil and Filter b Air Cleaner c Fuel Filter and D
22. The AIR VANTAGE 500 has two 20 Amp 120VAC single phase 5 20R GFCI duplex receptacles one 50 Amp 120 240 single phase 14 50R receptacle and one 240VAC three phase 15 50R receptacle The auxiliary power receptacles should only be used with three wire grounded type plugs or approved double insulated tools with two wire plugs The current rating of any plug used with the system must be at least equal to the current capacity of the associated receptacle A 240VAC 3 phase plug is provided loose with the machine NOTE The two 120V GFCI receptacles and the two 120 volt circuits of the 120 240V receptacle are connected to different phases and can not be paralleled STANDBY POWER CONNECTIONS The AIR VANTAGEQ 500 is suitable for temporary standby or emergency power using the engine manufacturer s recommended maintenance schedule The AIR VANTAGE 500 can be permanently installed as a standby power unit for 240 volt 3 wire 50 amp service Connections must be made by a licensed electrician who can determine how the 120 240 VAC power can be adapted to the particular installation and comply with all applicable electrical codes The following information can be used as a guide by the electrician for most applications Refer to the connection diagram shown in Figure A 2 1 Install the double pole double throw switch between the power company meter and the premises disconnect Switch rating must be the same or greater than the custo
23. do not over fill Wipe up spilled fuel and allow fumes to clear before starting engine Keep sparks and flame away from tank Ts The AIR VANTAGEQ 500 is shipped with the engine crankcase filled with high quality SAE 10W 30 oil API class CD or better Check the engine and compressor oil levels before starting the engine If it is not up to the full mark on the dip stick add oil as required Check the oil level every four hours of running time during the first 35 running hours Refer to the engine and compressor Operator s Manuals for specific oil recommendations and break in information The oil change interval is dependent on the quality of the oil and the operating environment Refer to the engine and compressor Operators Manuals for the proper Service and maintenance intervals FUEL USE DIESEL FUEL ONLY Fill the fuel tank with clean fresh diesel fuel The capacity of the fuel tank is approximately 25 gallons 95 liters See engine Operator s Manual for specific fuel recommendations Running out of fuel may require bleeding the fuel injection pump NOTE Before starting the engine open the fuel shutoff valve pointer to be in line with hose FUEL CAP Remove the plastic cap covering from the Fuel Tank Filler neck and install the Fuel Cap ENGINE COOLANT The welder is shipped with the engine and radiator filled with a 50 mixture of ethylene glycol and water See the MAINTENANCE section and the engine Opera
24. exhaust fumes W outdoors Ir 1 c Do not add fuel near an open flame welding arc or when the engine is running Stop the engine and allow it to cool before refuelling to prevent spilled fuel from vaporizing on contact with hot engine parts and igniting Do not spill fuel when filling tank If fuel is spilled wipe it up and do not start engine until fumes have been eliminated 1 d Keep all equipment safety guards covers and devices in position and in good repair Keep hands hair clothing and tools away from V belts gears fans and all other moving parts when starting operating or repairing equipment 1 e In some cases it may be necessary to remove safety guards to perform required maintenance Remove guards only when necessary and replace them when the maintenance requiring their removal is complete Always use the greatest care when working near moving parts 14 Do not put your hands near the engine fan Do not attempt to override the governor or idler by pushing on the throttle control rods A while the engine is running 1 9 To prevent accidentally starting petrol engines while turning the engine or welding generator during maintenance work disconnect the spark plug wires distributor cap or magneto wire as appropriate ARC WELDING CAN BE HAZARDOUS PROTECT YOURSELF AND OTHERS FROM POSSIBLE SERIOUS INJURY OR DEATH KEEP CHILDREN AWAY PACEMAKER WEARERS SHOULD CONSULT WITH THEIR DOCTOR BEFORE OPERA
25. level Close engine compartment door 4 Remove all plugs connected to the AC power receptacles 5 Set IDLER switch to AUTO 6 Set the RUN STOP switch to RUN Observe that the engine protection and battery charging lights are on After 10 seconds the engine protection light will turn off 7 Within 30 seconds press and hold the engine START button until the engine starts 8 Release the engine START button when the engine starts 9 Check that the engine protection and battery charging lights are off The engine protection light is on after starting the engine will shutdown in a few seconds Investigate any indicated problem 10 Allow the engine to warm up at low idle speed for several minutes before applying a load and or switching to high idle Allow a longer warm up time in cold weather COLD WEATHER STARTING With a fully charged battery and the proper weight oil the engine should start satisfactorily even down to about 0 F 18 C If the engine must be frequently started below 10 12 it may be desirable to install the optional ether start kit K887 1 For extreme cold conditions it may be desirable to install the Cold Weather Heater and Tarp Kit K2359 1 Installation and operating instructions are included in the kits STOPPING THE ENGINE 1 Switch the RUN STOP switch to STOP This turns off the voltage supplied to the shutdown solenoid A backup shutdown can be accomplished by shutting off th
26. negative cable first then positive cable and battery clamp When reinstalling connect negative cable last Keep well ventilated USING A BOOSTER connect positive lead to battery first then connect negative lead to engine foot E BATTERY ACID CAN BURN EYES AND SKIN Wear gloves and eye protection and be careful when working near battery Follow instructions printed on battery 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 circuit The positive battery cable has a red terminal cover 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 AIR VANTAGE 500 CUMMINS LINCOLN P D 4 MAINTENANCE D 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 ch
27. oq ONINHVM WV NVYSVId NOLL23NNOO 3 INGOW 108 LNOO 1Nd1NO SLOWSY LIOA b 729M 1 SH3Q13M NOILOVO ON3HdlAV Nid vl AIR VANTAGE 500 CUMMINS LINCOLN E DIAGRAMS F 10 F 10 CONNECTION DIAGRAM C 18 vCS 0002 22 01 Q38I 3Q SV NOILISOd 4101 HOIH NI HOLIMS 44101 39V1d TN NOILISOd STYNIN Y3L SHL NI HOLIMS STVNINYSL 9NIQT3M SHL 39 Id ON NOILISOd 38IM7AO JHL NI HOLIMS SGOW SHL SOV 1d 119V9 3008129313 AHL 30 ALIV10d 3H L HOLVIN OL HOLIMS YSLAWLIOA 430334 38IM JHL NOILISOd ALIYV10d d38l S30 803 58015 LAdLAO 318V9 LO3NNOO AN WANVA 9NILVH340 335 SNOILVO I ddv SYNLAS ANY 31VIQ3AWI 40 41949 ANY SHL ALIO VdVO 38 LSNW SATEVO ONIGTAM 81875 300419313 AYOM OL 80M 830333 38IM SCN1 OW LNOO 310N3H TYNOILdO TON3HdMV Nld 9 7 jueuudinbo siy 2 10 sued jou esn ejsui e Buas sued deey e peg Moyeg JALLVO3N 12euuoosiq eoejd ui e uedo sjaued jou oq e ONINHVM WV 310IN38 VV TYNOILdO NOLL23NNOO SHL 5509 92 1 SH3Q 13M ANISNA AIR VANTAGE
28. or expose themselves to the arc rays or to hot spatter or metal FUMES AND GASES can be dangerous 5 a 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 circumstances outdoors a respirator may be required Additional precautions are also required when welding on galvanized steel 5 b The operation of welding fume control equipment is 5 0 affected by various factors including proper use and positioning of the equipment maintenance of the equipment and the specific welding procedure and application involved Worker exposure level should be checked upon installation and periodically thereafter to be certain it is within applicable OSHA PEL and ACGIH TLV limits 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
29. reset the GFCI receptacle f the receptacle has tripped first carefully remove any load and check it for damage If the equipment has been shut down it must be restarted The equipment needs to be operating at high idle speed and any necessary adjustments made on the control panel so that the equipment is providing at least 80 volts to the receptacle input terminals The circuit breaker for this receptacle must not be tripped Reset if necessary Push the Reset button located on the GFCI receptacle This will assure normal GFCI operation Plug a night light with an ON OFF switch or other product such as a lamp into the GFCI receptacle and turn the product ON Push the Test button located on the GFCI receptacle The night light or other product should go OFF Push the Reset button again The light or other product should go ON again If the light or other product remains ON when the Test button is pushed the GFCI is not working properly or has been incorrectly installed miswired If your is not working properly contact a qualified certified electrician who can assess the situation rewire the GFCI if necessary or replace the device 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
30. sous tension des porte lectrodes connect s deux machines 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 2 Dans le cas de travail au dessus du niveau du sol se prot ger contre les chutes dans le cas ou on recoit un choc Ne jamais enrouler le c ble lectrode autour de n importe quelle partie du corps Un coup d arc peut tre plus s v re qu un coup de soliel donc a Utiliser un bon masque avec un verre filtrant appropri ainsi qu un verre blanc afin de se prot ger les yeux du rayonnement de l arc et des projections quand on soude ou quand on regarde l arc b Porter des v tements convenables afin de prot ger la peau de soudeur et des aides contre le rayonnement de l arc c 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 pantalons 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 o l on pique le laitier 6
31. two separate 120 VAC outputs with a maximum permissible current of 50 A per output to two separate 120 VAC branch circuits Output voltage is within 10 at all loads up to rated capacity NOTE The two 120V GFCI receptacles and the two 120V circuits of the 120 240V receptacle are connected to different phases and cannot be paralleled The auxiliary power receptacles should only be used with three wire grounded type plugs or approved double insulated tools with two wire plugs The current rating of any plug used with the system must be at least equal to the current capacity of the associated receptacle SIMULTANEOUS WELDING AND AUXILIARY 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 The permissible currents shown assume that current is being drawn from either the 120 VAC or 240 VAC supply not both at the same time AIR VANTAGE 500 CUMMINS LINCOLN P B 9 OPERATION B 9 TABLE B 4 AIR VANTAGE 500 SIMULTANEOUS WELDING AND POWER LOADS TABLE B 5 AIR VANTAGE 500 Extension Cord Length Recommendations E Load Maximum Allowable Cord Length in ft m for Conductor Size ps Volts Watts 14 mec 212 ANS 10 AWG 8 AWG 6 awe 4 AWG 30 60 um Conductor size is based on maximum 2 096 voltage drop AIR VANTAGE 500 CUMMINS LINCOLN P C 1 ACCESSORIES C 1 OPTIONAL FIELD INSTALLED ACCESSORIES
32. when the engine has been shut down due to low oil pressure or over temperature condition 8 BATTERY CHARGING LIGHT E The yellow engine alternator light is off when battery charging system is functioning normally If light turns on the alternator or the voltage regulator may not be operating correctly The light will remain on when the engine is stopped and the run stop switch is in the run position 9 IDLER 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 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 position the idler operates as b When the electrode touches the work or power is drawn for lights or tools approximately 100 Watts minimum the engine accelerates and operates at full speed c When welding ceases and the AC power load is turned off a fixed time delay of approximately 12 seconds starts d If the welding or AC power load is not restarted before the end of the time delay the idler reduces the engine speed to low idle speed e The engine will automatically return to high idle speed when the welding load or A C power load is reapplied Idler Operational exceptions When the WELDING TERMINALS switch is in the Remotely Controlled position the idler will
33. wire feeder voltmeter to the polarity of the electrode 16 6 PIN CONNECTOR For attaching optional remote control equipment Includes auto sensing remote control circuit 17 14 PIN CONNECTOR For attaching wire feeder control cables Includes contactor closure circuit auto sensing remote control circuit and 120VAC and 42VAC power NOTE When a wire feeder with a built in welding voltage control is connected to the 14 pin connector do not connect anything to the 6 pin connector 18 WELD OUTPUT TERMINALS AND These 1 2 18 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 connects to the terminal and the electrode cable connects to this terminal AUXILIARY POWER CONTROLS Items 19 23 19 120 240 VAC SINGLE PHASE RECEPTACLE This is a 120 240VAC 14 50R receptacle that provides 240VAC or can be split for 120VAC single phase auxiliary power This receptacle has a 50 amp rating Refer to the AUXILIARY POWER RECEPTACLES section in the installation chapter for further information about this receptacle Also refer to the AUXILIARY POWER OPERATION section later in this chapter AIR VANTAGE 500 CUMMINS LINCOLN P B 5 OPERATION B 5 20 CIRCUIT BREAKERS 6 o These circuit breake
34. 500 CUMMINS LINCOLN E DIAGRAMS F 9 F 9 CONNECTION DIAGRAM 181v7S 0002 22 01 Q38l 3G SV NOILISOd 410 OLAY NI HOLIMS 414101 39 1 WANVW ONILVYAdO 33 SNOILVOlrTddav AFYALAS ANY 3 319A9 ALNG ANY SHL ALIO VdVO 38 LSNW S3 18V9 9NIQT3M 1149 300819313 ALIYV10d JHL HO1VIN OL HOLIMS YSLAWLIOA 830334 JHL NOILISOd ALII V TOd Q38IS30 SANLS OL S318V9 9NIQT3M LOANNOO NOLLISOd Q3TIOH LNOO AT310W38 OL HOLIMS S IVNIINS3 L 830 13M 39V Id NOILISOd IHL NI HOLIMS SCOW 39V ld WANVA ONILVYSdO 3G T3M ANIONS JHL NI 931511 5301191519395 3AO8V LSNPAV LON OG 7 LV 13S 3Md SI SNILL3S HONN3AO9 3NION3 1 39 VIAVO HOIHM SOVLIOA 30333 38IM OV JHL NI 3SV3HONI NV ASNVO 39YOINET 3 TLLOSH L SHL 9NIGISSSAO ONILLAS HONS3AO09 JHL Wd 3NISN3 JHL 30 3SV3HONI MYOM OL LINA 0333 38IM OL 319 3004192173 A T8N3SSV 3 18V XX 9C9H 41875 LAANI jueuudinbe 510 2 10 sued jou esn jeisui pjnous jeuuosied e unes sued deeye peg Moyeg JALLVO3N 129000251 e eoe d ui e uedo sjeued ejejedo jou
35. 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 CUMMINS LINCOLN amp E 1 TROUBLESHOOTING E 1 HOW TO USE TROUBLESHOOTING GUIDE 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 machine malfunctions Simply follow the three step procedure listed below Step 1 LOCATE PROBLEM SYMPTOM Look under the column labeled PROBLEM SYMPTOMS 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
36. 94 Gal hour 12 9 and Auxiliary Power 7 3 L hour 12 000 VA 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 The AIR VANTAGE 500 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 electrode 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 0 DOWNHILL PIPE MODE This slope controlled setting is intended for out of position and down hill pipe welding where the operator would like to control the current level by changing the arc length The OUTPUT CONTROL knob adjusts the full output range for pipe welding The ARC CONTROL knob sets the short circuit current arc force durin
37. B 8 OPERATION B 8 CV WIRE MODE Connect a wire feeder to the AIR VANTAGE 500 and set welder controls according to the instructions listed earlier in this section The AIR VANTAGE 500 in the CV WIRE position permits it to be used with a broad range of flux cored wire Innershield and Outershield electrodes 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 0 For any electrodes including the above recommendations the procedures should be kept within the rating of the machine For additional electrode information See www lincolnelectric com or the appropriate Lincoln publication ARC GOUGING For optimal performance when arc gouging set the AIR VANTAGE 500 WELD 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 ELECTRODE CURRENT RANGE DIAMETER DC electrode positive 1 8 30 60 Amps 5 32 90 150 3 16 200 250 Amps 1 4 300 400 Amps 5 16 350 450 Amps 3 8 450 575 Amps
38. 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 levage 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 pour produire du phosg ne gas fortement toxique ou autres produits irritants 11 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 PR CAUTIONS DE S RET POUR LES MACHINES SOUDER TRANSFORMATEUR ET
39. IONS 3HL d39VIAVG 38 AVN SLIN9HI9 TOH LNOO 430334 SETOA 0f 83 0 5309 SIHL 41 39VET0A IHL IHL NI 3SV38ONI NY ASNWO JOVANI 31LLOBH L JHL 9NIGIHH3AO ONILLAS HONH3AO9 3H L ONIONVHO 3NION3 4101 1 40 3SV38DNI SLOWSY HN NOILOVO TWNOILdO 9227 LINN 0334 OL 0O 300419414 94 MYOM OL 318VO HO 1627 IVSH3AIN 2987 HHOM OL 3004193173 Nid vb DIAGRAMS AIR VANTAGE 500 CUMMINS 8284334 LNI juewdinbe siy 3919S 10 syed jou od e esn ejsui jeuuosied AjuO e e10jeq sued feme e Qva 3ALIVO3N 1 euuoosia e eed ui e sjeued ui ejejedo jou e up SLAVd ODNIAOW UD5 HDOHS 91419313 ONINHVM Wf F 3 CONNECTION DIAGRAM INVHO9VIG Z NT 8Z22 2984 HH3aNVININOO DIAGRAMS F 4 F 4 CONNECTION DIAGRAM L8LVcS 0002 22 01 NOILISOd NI HOLIMS 44101 39V1d NOILISOd JHL NI HOLIMS 39 1 d18V9 3004191313 40 ALIS V lOd 3H L HOLVW OL HOLIMS YSLANLIOA 430333 NOILISOd ALII V 10d 4341 3Q 401 Sans OL 531979 SNIQT3M LO3NNOO WANVW ONILVH3d
40. LOVLNO9 NIOONI IHL NI SI HOLIMS SGOW JINON TOYLNOOD 1VH 33S 38 JINON OL 318V9 300819313 HHOM OL 31872 LNANI 119V1d1934 01 169M FLOWSY 9 L o NN9 100dS SC 187 FINGOW 10HLNO9 RTN 95 8815 43033 38IM Nid jueuidinbe siy 94195 10 syed AI 21199 9 jou esn esu pjnous jeuuo siad p eyjenb AO 5 20 syed oj Aeme deeye pee Aisne g 3AILVO3N PUU Siq eoejd 5 deeye uedo sjeued 9jejedo jou ONIN Y NOLLO3NNOO NN9 10085 2877 8873 01 1699 SHA TAM AIR VANTAGE 500 CUMMINS LINCOLN je 586825 3 ALVINSNI ANY 1 TN ATIVNGIAIGNI GASNNN 31VINSNI OL GAHOLIMS ATIVOILVNOLNY SI TOH LNOO Q3Sh SI IOHLNOO LAdLNO 310W3H dl NOILISOd 1OHLNOO H3Q33H 3HIM OL HOLIMS H3Q33H 32V Id AO 9NITTIM OL HOLIMS HOLO3T3S IHL NOLLISOd ALIHV10d 300419313 Q3HIS3Q 194145 OL HOLIMS HALAWLIOA ASN SN IWANVW SNIIVH3dO 33 3unina 40 371949 ALNA LNAYHND JHL ALIOVdVO AO 34 LSNW 318 VO VN IVANVIN 9NLIVH3d0 43073M 3NION3 JHL NI 03151 SNOI1V9141934S Wd 3408Y LSNPAY LON AHOLOV4 135 399 SI 9NLLL3S HONH3AO9 AN
41. National Electrical Code all local codes and the manufacturer 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 Jan 09 LINCOLN P 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 suivantes S ret Pour Soudage A 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
42. O 395 SNOILYONddY 38nln3 ANY 31VIQ3AMWI 30 41949 ALNG ANY JHL 803 ALIOVdVO 38 LSNN S318V9 9NIQT3M WANVW ONILVYSdO 83013M ANIONS SHL NI 931511 SNOI1V911193dS Wd 3AO8V LSAPAV LON OG 7 AHOLOV4J LV 13S 3Md SI S9NILL3S YONYSAOS 3NISN3 JHL TOHLNOO 39 VIVO NVO HOIHM 39VL10A 83033 38IM OV JHL NI 3SV3SONI NV 2SNV9 39 VXNIT3TLLOSHL 9NIGIHS3AO ONILLAS HONS3AOOS SHL 9NISNVHO Ad 3NISN3 310I SHL 30 3SV38ONI 0333 OL NOILNYVO 3004193173 HHOM OL 1041109 31084 Nid 9 IRL 318V2 1041 02 7869 LNdNI 21 OL m ueuudinbe si 95 JO sued Ajeoujoeje U9no jou esn esu pinoys jeuuosied peyenb e sued desye peg 3ALLVO3N 129000251 e eoe d e uedo sjaued jou ONINHVM WV NVYSVId NOILOANNOD 2 1 SHS30 13M AIR VANTAGE 500 CUMMINS LINCOLN E DIAGRAMS F 5 F 5 CONNECTION DIAGRAM 1484 05 0002 22 01 LNAYYND AYYITIXNY WRWIXVIN TWANV NOLLONYLSNI 398008 OL 3339 X40334 339 7 0731 35019 OL JHM NOILV1OSI 381 LNdLNO V NYNLIY LVHL SH30334 HO OL Loy ATIVAGIAIQNI SAV37 GASNNN HOV ALVINSNI
43. October 2009 AIR VANTAGE 500 CUMMINS For use with machines having Code Numbers 11069 11417 Safety Depends on You Lincoln arc welding and cutting equipment is designed and built with safety in mind However your overall safety can be increased by proper installation and thoughtful operation on your part DO NOT INSTALL OPERATE OR REPAIR THIS EQUIPMENT WITHOUT READING THIS MANUAL AND THE SAFETY PRECAUTIONS CONTAINED THROUGHOUT Most importantly think before you act and be careful amp OPERATOR S MANUAL Quality Pr Inder a 19150 9001 Requirements CERTIFICATE NUMBER 30273 LI N COLN Copyright Lincoln Global Inc World s Leader in Welding and Cutting Products Sales and Service through Subsidiaries and Distributors Worldwide Cleveland Ohio 44117 1199 USA Tel 216 481 8100 Fax 216 486 1751 Web Site www lincolnelectric com i SAFETY i A WARNING e CALIFORNIA PROPOSITION 65 WARNINGS Eor Diesel Engines diesel engine exhaust and some of its constituents are known to the State of California to cause cancer birth defects and other reproductive harm PERFORMED ONLY BY QUALIFIED INDIVIDUALS FOR ENGINE powered equipment 1 a Turn the engine off before troubleshooting and maintenance work unless the maintenance work requires it to be running 23 1 b Operate engines in open well ventilated E areas or vent the engine
44. POSSIBLE CAUSE lists the obvious external possibilities that may contribute to the machine symptom NOTE See VMAC owner s manual for compressor trouble shooting 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 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 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 VANTAGE 500 CUMMINS LINCOLN P E 2 TROUBLESHOOTING E 2 Observe all Safety Guidelines detailed throughout this manual PROBLEMS POSSIBLE RECOMMENDED SYMPTOMS CAUSE COURSE OF ACTION ENGINE PROBLEMS Major Physical or Electrical Damage is 1 Contact your Local Lincoln Authorized Evident Field Service Facility 1 Battery low 2 Loose battery cable connections which may need Inspected cleaned or tighten 3 Faulty wiring in engine starting circuit 4 Faulty engine starter Conta
45. QUIPMENT can cause injury Do not lift this machine using lift bale if it is equipped with a heavy accessory such as a trailer or gas cylinder Lift only with equipment of adequate lifting capacity Be sure machine is stable when lifting 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 current ratings derate welder voltage rating 2 volts for every 10 C 21 F above 40 C 1049 TOWING The recommended trailer for use with this equipment for road in plant 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
46. REDRESSEUR 1 Relier la terre le chassis 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 2 Autant que possible l installation et l entretien du poste seront effectu s par un lectricien qualifi 3 Avant de faires des travaux l interieur de poste la debrancher l interrupteur la boite de fusibles 4 Garder tous les couvercles et dispositifs de s ret leur place Mar 93 LINCOLN P V V for selecting a QUALITY product by Lincoln Electric We want you OU 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 equipment Our challenge is to meet the needs of our customers and to exceed their expectations On occasion purchasers may ask Lincoln Electric for advice or information about their use of our products We respond to our customers based on the best information in our possession at that time Lincoln Electric is not in a position to warrant or guarantee such advice and assumes no liability with respect to such information or advice We expressly disclaim any warranty of any kind including any warranty of fitness for any customer s pa
47. TE No 6 COPPER CONDUCTOR CABLE SEE RECEPTACLE NATIONAL ELECTRICAL CODE FOR ALTERNATE WIRE SIZE RECOMMENDATIONS AIR VANTAGE 500 CUMMINS LINCOLN P A 8 INSTALLATION CONNECTION OF LINCOLN ELECTRIC WIRE FEEDERS Shut off welder before making any electrical connections CONNECTION OF LN 7 LN 8 OR LN 742 TO THE AIR VANTAGE 500 Shut the welder off Connect the LN 7 LN 8 OR LN 742 per instructions on the appropriate connection diagram in the DIAGRAMS section Set the WIRE FEEDER VOLTMETER switch to either or as required by the electrode being used Set the SELECTOR switch to the CV WIRE position Adjust the ARC CONTROL knob to desired Crispness SOFT for MIG and CRISP for INNERSHIELD Set the WELDING TERMINALS switch to the REMOTELY CONTROLLED position Set the IDLE switch to the HIGH position CONNECTION OF LN 15 TO THE AIR VANTAGE 500 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 to feed and the welding process is started Shut the welder off For electrode Positive connect the electrode cable to the terminal of the welder and work cable to the terminal of the welder For electrode Negative connect the electrode cable terminal of
48. TING 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 Z49 1 from the American Welding Society PO Box 351040 Miami Florida 33135 or CSA Standard W117 2 1974 or WTIA Welding Technology Institute of Australia PO Box 6165 Silverwater NSW 2128 A free copy of Arc Welding Safety booklet E205 is available from the Lincoln Electrical Company 22801 St Clair Avenue Cleveland Ohio 44117 1199 BE SURE THAT ALL INSTALLATION OPERATION MAINTENANCE AND REPAIR PROCEDURES ARE For Gasoline Engines The engine exhaust from this product contains chemicals known to the State of California to cause cancer birth defects or other reproductive harm To avoid scalding do not remove the radiator pressure cap when the engine is hot _ ELECTRIC AND S9iR MAGNETIC FIELDS may be dangerous 2 a Electric current flowing through any conductor causes localized Electric and Magnetic Fields EMF Welding current creates EMF fields around welding cables and welding machines 2 6 EMF fields may interfere with some pacemakers and welders having a pacemaker should consult their physician before welding 2 c Exposure to EMF fields in welding may have other health effects which are now not known 2 d All welders should use the following procedures in order to minimize exposure to EMF field
49. W YOUR EMPLOYER S SAFETY PRACTICES SE RECOMIENDA LEER Y ENTENDER LAS INSTRUCCIONES DEL FABRICANTE PARA EL USO DE ESTE EQUIPO Y LOS CONSUMIBLES 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 ELEKTRODENEINSATZ DES HERSTELLERS DIE UNFALLVERHUTUNGSVORSCHRIFTEN DES ARBEITGEBERS SIND EBENFALLS ZU BEACHTEN LINCOLN Keep your head out of fumes Use ventilation or exhaust to remove fumes from breathing zone Los humos fuera de la zona de respiraci n e Mantenga la cabeza fuera de los humos Utilice ventilaci n o aspiraci n para gases e Gardez la t te l cart des fum es Utilisez un ventilateur ou un aspirateur pour ter les fum es des zones de travail e Vermeiden Sie das Einatmen von Schweibrauch Sorgen Sie f r gute Be und Entl ftung des Arbeitsplatzes e Mantenha seu rosto da fumaca Use ventilac o e exhaust o para remover fumo da zona respirat ria 207 e OPER E e Fi S BK 2882 18 e 20258 SATACEFE SUISSES MASH Ash 71271714 SSE HSHM dal ge yay dui say gaal bie ualde AU
50. arging circuit The AIR VANTAGEG 500 positive battery 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 battery 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 manufacturer for proper charger settings and charging time NAMEPLATES WARNING DECALS MAINTENANCE 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 WELDER GENERATOR MAINTENANCE STORAGE Store the AIR 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 particularly dirty areas BRUSH REMOVAL AND REPLACEMENT It is normal for the brushes and slip rings to wear and darken slightly Inspect the brushes when a generator overhaul is necessary Do not attempt to polish slip rings while the engine is running GFCI RECEPTACLE TESTING AND RESETTING PROCEDURE The GFCI receptacle should be properly tested at least once every month or whenever it is tripped To properly test and
51. ately 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 ARA oit 3 HOUR METER The hour meter displays the total time that the engine has been running This meter is a useful indicator for scheduling preventive maintenance 4 FUEL LEVEL GAUGE Displays the level of diesel fuel in the fuel tank The operator must watch the fuel level closely to prevent running out of fuel and possibly having to bleed the system 5 ENGINE TEMPERATURE GAUGE E The gauge displays the engine coolant temperature AIR VANTAGE 500 CUMMINS LINCOLN B 3 OPERATION B 3 6 OIL PRESSURE GAUGE Em The gauge displays the engine oil pressure when the engine is running 7 ENGINE PROTECTION The yellow engine protection light remains off with proper oil pressure and under normal operating temperatures If the light turns on the engine protection system will stop the engine Check for proper oil level and add oil if necessary Check for loose or disconnected leads at the oil pressure sender located on the engine The light will remain on
52. ating current generator for DC multi purpose welding for 120 240 VAC single phase and 240V three phase auxiliary standby power The AIR VANTAGE 500 also has a rotary screw 60 cfm air compressor built in The welding control system uses state of the art Chopper Technology RECOMMENDED APPLICATIONS WELDER The AIR VANTAGE 500 provides excellent constant current DC welding output for stick SMAW and TIG welding The AIR VANTAGE 500 also provides excellent constant voltage DC welding output for MIG GMAW Innershield FCAW outershield FCAW G and Metal Core welding In addition the AIR VANTAGE 500 can be used for Arc Gouging with carbons up to 3 8 10mm in diameter The AIR VANTAGE 500 is not recommended for pipe thawing AIR COMPRESSOR The AIR VANTAGE 500 provides 60 cfm at 100 psi compressed air for Arc Gouging and Air powered tools GENERATOR The AIR VANTAGE 500 provides smooth 120 240 VAC single phase and 240V three phase output for auxiliary power and emergency standby power AIR VANTAGE 500 CUMMINS LINCOLN P B 2 OPERATION B 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 Figure B 1 Case Front Panel Controls EAP E ENGINE CONTROLS Items 1 through 9 1 RUN STOP 3 SWITCH Toggling the switch to the RUN position energizes the fuel solenoid for approxim
53. cause damage to the housing and will void the warranty AIR VANTAGE 500 CUMMINS LINCOLN P D 3 MAINTENANCE D 3 FUEL FILTERS When working on the fuel system Keep naked lights away do not smoke f y Do not spill fuel The AIR VANTAGEQ 500 is equipped with a Fuel Filter located after the lift pump and before fuel injectors 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 manufacturer Mechanical overtightening will distort the threads filter element seal or filter can COOLING SYSTEM The AIR VANTAGE 500 is equipped with a pressure radiator Keep the radiator cap tight to prevent loss of coolant Clean and flush the coolant system periodically to prevent clogging the passage and over heating the engine When antifreeze is needed always use the permanent type BATTERY HANDLING GASES FROM BATTERY can explode Keep sparks flame and cigarettes away from battery To prevent EXPLOSION when INSTALLING A NEW BATTERY disconnect negative cable from old battery first and connect to new battery last CONNECTING A BATTERY CHARGER Remove battery from welder by disconnecting
54. ct authorized local Engine Service Shop 5 Battery disconnect switch is in the off position Engine will not crank Engine will crank but not start 1 Out of fuel 2 Fuel shut off valve is in the off position make sure the valve lever is in a vertical direction 3 Engine shut down solenoid not pulling in 4 On Off switch on for more than 30 sec before starting the On Off switch will need to be switch off and turned back on 5 Fuel Filters dirty clogged main filter element and or Inline Fuel Filter may need to be replaced If all recommended possible areas of misadjustment have been checked and the problem persists Contact your local Lincoln 6 High water temperature or low oil Authorized Field Service Facility pressure engine protection light lit Engine shuts down shortly after starting 1 Low oil pressure engine protection light lit Check oil level Consult engine Service dealer 2 High water temperature Check engine cooling system engine protection light lit 3 Faulty oil pressure switch 4 Faulty water temperature switch Contact authorized local Engine Service Shop Engine shuts down while under a load 1 High water temperature Engine runs rough 1 Dirty fuel or air filters may need cleaned replaced 2 Water in fuel Engine will not shut off 1 Fuel Shutdown solenoid not functioning properly linkage binding elf for any reason you do not unders
55. dd Gd eine nes a a A 5 Remote Controle Meme AERE D Rn NE dear o tre A A 6 Auxiliary Power Receptacles 2o EE bene Ged weed heed bp P RE REM A 6 Standby Power Connections 2 A 6 Connection of Vantage Premises Wiring A 7 Connection of Lincoln Electric Wire Feeders A 8 A 9 Operation ERA tite nd eda eae Due dignes Section B Satety Instructiors o fest Aust ash dan OI Ale een E B 1 General Description ha db baie Dade Dh B 1 Recommended Applications ees mrs Ex yx e mr deere B 1 AIL COMPRESSOR LEE since nine dd SuSE B 1 Controls and Settings espe ninga manne ane eau E RH ue Rd ses B 2 Engine Controls e RP pede XU equa B 2 B 3 Welder Controls cree rires me buse ambre d menti yes B 4 Auxiliary Power Controls B 4 Air Compressor Controls B 5 Battery Jump Start Terminals B 5 Engine Operation disant eee Pd eee Lae Pa __ B 5 Starting Ihe t cR bak Ie Gon E nine B 5 Stopping thie ENGINE
56. e full 40 300 amps Any current range that is less than the full range provides finer current resolution for more fine tuning of the output The 14 pin connector is used to directly connect a wire feeder control cable In the CV WIRE mode when the control cable is connected to the 14 pin connector the auto sensing circuit automatically makes the Output Control inactive and the wire feeder voltage control active NOTE When a wire feeder with a built in welding voltage control is connected to the 14 pin connector do not connect anything to the 6 pin connector AUXILIARY POWER RECEPTACLES Start the engine and set the IDLER control switch to the High Idle mode Voltage is now correct at the receptacles for auxiliary power This must be done before a tripped GFCI receptacle can be reset properly See the MAINTENANCE section for detailed information on testing and resetting the GFCI receptacle The auxiliary power capacity of the AIR VANTAGE 500 is 12 000 watts of 60 Hz single phase or 20 000 watts of 60Hz three phase power The auxiliary power capacity rating in watts is equivalent to volt amperes at unity power factor The maximum permissible current of the 240 VAC output is 50 A The 240 VAC single phase output can be split to provide two separate 120 VAC outputs with a maximum permissible current of 50 A per output to two separate 120 VAC branch circuits The output voltage is within 10 at all loads up to rated capacity
57. e fuel valve located on the fuel line FIGURE B 2 AIR VANTAGE 500 CUMMINS LINCOLN P B 6 OPERATION B 6 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 accomplished 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 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 2 for typical fuel consumption of the AIR VANTAGE 500 Engine for various operating scenarios Table B 2 Cummins B3 3 Engine Fuel Consumption Cummins B3 3 Running Time for 56HP 42Kw 25GAL 94 6L 01800 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 Auxiliary Power 2 02 Gal hour 12 4 20 000 VA 7 6 L hour Air Compressor 1 29 Gal hour 19 4 60 CFM 100 PSI 4 9 L hour Air Compressor 60 CFM 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
58. ed 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 When used with argon gas The current ranges shown must be reduced when using argon helium or pure helium shielding gases 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 Tungsten is now widely accepted as a substitute for 2 Thoriated Tungsten in AC and DC applications DCEP is not commonly used in these sizes TIG torch nozzle sizes are in multiples of 1 16ths of an inch 4 1 4 in 6 mm 5 5 16 8 mm 6 3 8 10 7 7 16 11 8 1 2 12 5 10 5 8 16 TIG torch nozzles typically made from alumina ceramic Special applications may require lava nozzles which are less prone to breakage but cannot withstand high temperatures and high duty cycles AIR VANTAGE 500 CUMMINS LINCOLN P
59. elivery System d Alternator Belt e Battery f Cooling System Refer to Table D 1 at the end of this section for various engine maintenance components AIR FILTER CAUTION Excessive air filter restriction will result in 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 indicator See Service Instructions and Installation Tips for Engine Air Filter AIR VANTAGE 500 CUMMINS LINCOLN P D 2 MAINTENANCE D 2 Service Instructions amp Installation Tips Release the Seal Carefully Unlatch and remove the service cover of the air cleaner Make certain the latches are folded back against the cover so that they donit hinder filter removal installation Most latches are spring loaded to fold back when open The filter fits tightly over the outlet tube creating the critical seal on the inside diameter of the filter endcap The filter should be removed gently to reduce the amount of dust dislodged There will be some initial resistance similar to breaking the seal on a jar Gent
60. est 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 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 vi TABLE OF CONTENTS Page Installation mue ae ko earn a ng cR xd aka n hh mac Ro o EK RC Section A Technical Specifications Rr Rede aha hele PURE Arden e teg
61. g stick welding to adjust for a soft or a more forceful digging arc Crisp Increasing the number from 10 Soft to 10 Crisp increases the short circuit current which results in a more forceful digging arc Typically a forceful digging arc is preferred for root and hot passes A softer arc is preferred for fill and cap passes where weld puddle control and deposition stacking of iron are key to fast travel speeds It is recommended that the ARC CONTROL be set initially at 0 TOUCH START TIG MODE The AIR VANTAGE 500 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 general avoids tungsten contamination Then the tungsten 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 reaches approximately 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 ge
62. ge Control In semi automatic or automatic wire welding the electrode electrode reel welding head nozzle or semi automatic 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 holder 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 6c and 8 LINCOLN P 4 b 4 ARC RAYS can burn Use shield with the proper filter and cover plates to protect your eyes from sparks and the rays of the arc when welding or observing open arc welding Headshield and filter lens should conform to ANSI Z87 1 standards Use suitable clothing made from durable flame resistant 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
63. h proper compressor oil temperatures If the lights turn on the compressor protection system will close the compressor inlet valve and put the system in standby mode until the temperature reaches allowable limits Check for proper compressor oil level 26 AIR DISCHARGE VALVE Controls flow of compressed air A 3 4 NPT National Pipe Thread fitting is provided BATTERY JUMP START TERMINAL 27 28 27 POSITIVE BATTERY JUMP START TERMINAL 28 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 VANTAGE 500 Cummins 29 BATTERY DISCONNECT SWITCH Battery disconnect switch provides lockout tagout capability Switch is conveniently located inside the engine compartment SEE FIGURE B 2 30 AIR CLEANER 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 FIGURE B 2 ENGINE OPERATION STARTING THE ENGINE 1 Open the engine compartment door and check that the fuel shutoff valve located to the left of the fuel filter housing is in the open position lever to be in line with the hose 2 Make sure battery disconnect switch is in the on position 3 Check for proper oil level and coolant
64. if necessary Listed in Table A 1 are copper cable sizes recommended for the rated current and duty cycle Lengths stipulated are the distance from the welder to work and back to the welder again 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 AMPS Up to 150ft 150 200ft 200 250ft 100 Up to 45 7m 45 7 70 0m 70 0 76 2m Duty Cycle 500 3 0 ANG 3 0 ANG 4 0 AWG MACHINE GROUNDING Because this portable engine driven welder creates its own power it is not necessary to connect its frame to an earth ground unless the machine is connected to premises wiring home shop etc To prevent dangerous electric shock other equipment powered by this engine driven welder must a be grounded to the frame of the welder using a grounded type plug or b be double insulated When this welder is mounted on a truck or trailer its frame must be securely connected to the metal frame of the vehicle When this engine driven welder is connected to premises wiring such as that in a home or shop its frame must be connected to the system earth ground See further connection instructions in the section entitled Standby Power Connections as well as the article on grounding in the latest National Electrical Code and the local codes In general if the machine is t
65. in 12VDC battery Fuel B3 3 56HP 42 kw Low Idle 1425 3 3L amp Starter 25 US gal Diesel Engine 1800 RPM Full Load 1800 94 6L Bore x Stroke Oil 2 US gal 3 74 x 4 53 7 5L 95mm x 115mm Coolant 2 6 US gal 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 Max OCV 1900 RPM Auxiliary Power 120 240 VAC 12 000 WATTS 60 Hz Single Phase 20 000 WATTS 60 Hz Three Phase PHYSICAL DIMENSIONS Height Width Depth Weight 42 0 in 1690 lbs 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 8mm for exhaust pipe AIR VANTAGE 500 CUMMINS LINCOLN P A 2 INSTALLATION A 2 Read this entire installation section before you start installation SAFETY PRECAUTIONS Do not attempt to use this equipment until you have thoroughly read all operating and maintenance manuals supplied with your machine They include important safety precautions detailed engine starting operating and maintenance instructions and
66. is less than 100 Contact your local Lincoln watts Authorized Field Service Facility 3 Faulty Pull Coil Battery PCB or Weld Control PCB 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 VANTAGE 500 CUMMINS LINCOLN P E 4 TROUBLESHOOTING E 4 PROBLEMS POSSIBLE RECOMMENDED SYMPTOMS CAUSE COURSE OF ACTION FUNCTION PROBLEMS Engine goes to low idle but does not stay at 1 Faulty Peripheral PCB Pull Coil Battery low idle PCB or Weld Control PCB 1 Broken lead in rotor circuit 2 Faulty field diode module 3 Faulty Weld Control PCB 4 Faulty rotor No welding output or auxiliary output Welder has some no output and no control Auxiliary output OK 1 Faulty remote kit 2 Faulty output control potentiometer 3 Faulty output control wiring 4 Faulty Weld Control PCB Pull Coil Battery PCB or Chopper PCB No welding output Auxiliary output OK 1 WELDING TERMINALS switch in wrong position be sure switch is in WELDING TERMINALS ALWAYS ON position 2 Faulty Weld Control PCB Pull Coil Battery PCB or Chopper PCB No auxiliary power 1 GFCI Receptacle may have tripped Follow GFCI Receptacle Testing and Resetting Procedure in the MAINTENANCE section of this manual
67. ly move the end of the filter back and forth to break the seal Avoid Dislodging Dust from the Filter Gently pull the filter off the outlet tube and out of the a housing Avoid knocking the filter against the housing iuh Sealing Surface of the Outlet Tube Use a clean cloth to wipe the sealing surface Dust on the outside diameter of the outlet tube could hinder an effective seal and cause leakage Make sure that all contaminant is removed before the new filter is inserted Clean the Inside of the Outlet Tube Carefully wipe the inside of the outlet tube with a clean cloth Dirt accidently transferred to the inside of the outlet tube will reach the engine and cause wear Engine manufacturers says that it takes only a few grams of dirt to dust an engine Be careful not to damage the sealing area on the tube For Engine Air Filter Check the Old Filter for Leak Clues Visually inspect the old filter for any signs of leaks A streak of dust on the clean side of the filter is a telltale sign Donaldson filters with RadialSeal Sealing Technology are self aligning self centering and self sealing A new filter has a dry lubricant to aid installation The critical sealing area will stretch slightly adjust itself and distribute the sealing pressure evenly To complete a tight seal apply Removeany cause pressure by hand at the outer rim of the ot leaks filter not the flexible ce
68. mer s premises disconnect and service over current protection AIR VANTAGE 500 CUMMINS LINCOLN P A 7 INSTALLATION A 7 2 Take necessary steps to assure load is limited to the capacity 3 Install a 50 amp 120 240 VAC plug NEMA Type 14 50 to the of the AIR VANTAGE 500 by installing a 50 amp 240 VAC double pole circuit breaker using No 6 4 conductor cable of double pole circuit breaker Maximum rated load for each leg the desired length The 50 amp 120 240 VAC plug is of the 240 VAC auxiliary is 50 amps Loading above the rated available in the optional K802R plug kit output will reduce output voltage below the allowable 10 of rated voltage which may damage appliances or other motor 4 Plug this cable into the 50 Amp 120 240 Volt receptacle on the driven equipment and may result in overheating of the AIR AIR VANTAGE 500 case front VANTAGE 500 engine Figure A 2 Connection of the AIR VANTAGE 500 to Premises Wiring 240 VOLT GROUNDED CONDUCTOR 240 Volt POWER 120 VOLT 60 Hz 3 Wire COMPANY Service METER NEUTRAL LOAD DOUBLE POLE DOUBLE THROW SWITCH RATING TO BE THE SAME AS OR GREATER THAN PREMISES SERVICE OVERCURRENT PROTECTION gt PREMISES DISCONNECT AND SERVICE GROUND OVERCURRENT 240 VOLT PROTECTION DOUBLE POLE 50 AMP 120 240 VOLT PLUG NEMA TYPE 14 50 240 VOLT BREAKER N nn 50 AMP 120 240 VOLT T Pa c D NO
69. ncreases the short circuit current and prevents sticking of the electrode 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 DOWNHILL PIPE mode In this mode the ARC CONTROL knob sets the short circuit current arc force during stick welding to adjust for a soft or a more forceful digging arc Crisp Increasing the number from 10 Soft to 10 Crisp increases the short circuit current which results in a more forceful digging arc Typically a forceful digging arc is preferred for root and hot passes A softer arc is preferred for fill and cap passes where weld puddle control and deposition stacking of iron are key to fast travel speeds It is recommended that the ARC CONTROL be set initially at O CV WIRE mode In this mode turning the ARC CONTROL knob from 10 soft to 10 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 a setting of 0 14 WELDING TERMINALS SWITCH In the WELD TERMINALS ON position the output 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 15 WIRE FEEDER VOLTMETER SWITCH Matches the polarity of the
70. neral 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 VANTAGE 500 The settings are for reference The AIR VANTAGE 500 is equipped with the required R F bypass circuitry for the connection of high frequency generating equipment The AIR VANTAGE 500 and any high frequency 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 is used to set the maximum range of the CURRENT CONTROL on the TIG Module or an Amptrol if connected to the TIG Module AIR VANTAGE 500 CUMMINS LINCOLN P B 7 OPERATION B 7 AIR VANTAGE 500 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 contactor open and provide a cold electrode until the triggering device Amptrol or Arc Start Switch is pressed Table TYPICAL CURRENT RANGES FOR TUNGSTEN ELECTRODES DCEN DCEP Approximate Argon Gas Flow Rate l min c f m Tungsten Electrode 196 296 1 2 TIG TORCH Diameter Thoriat
71. ns 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 after flow cycle on systems so equipped Includes 25 ft 7 6m control cable K963 3 Hand Amptrol Varies current for making critical 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 VANTAGE 500 CUMMINS LINCOLN P D 1 MAINTENANCE D 1 SAFETY PRECAUTIONS A WARNING Have a qualified technician do the maintenance and troubleshooting work Turn the engine off before working inside the machine Remove guards only when necessary and replace them when the maintenance requiring their removal is complete Always use the greatest care when working near moving parts Read the Safety Precautions in front of this manual and the engine instruction manual before working on this machine Keep all equipment safety guards covers and devices in position and in good repair Keep hands hair clothing and tools away from V belts gears fans and all other moving parts when starting operating or repairing the equipment ROUTINE AND PERIODIC MAINTENANCE DAILY
72. nter Avoid installing new pushing on the center of the urethane end filter cap No cover pressure is required to hold the seal Again do NOT use the service Inspect the New Filter for Damage Inspect the new filter carefully cover to push the filter into place When the filter in is place put the service cover back on making sure the Vacuator paying attention to the inside of B 5 E Valve points down Inspect the Vacuator Valve for cracks or dust hang ups to insure that it is functioning properly Re fasten the latches the open end which is the sealing area NEVER install a damaged filter Check Connections for Tight Fit Make sure that all clamps bolts and connections in the entire air intake system Insert the New RadialSeal Filter by Hand Insert carefully Seat the new filter by hand are tight Check for holes in piping and repair if needed making certain it is completely into the air cleaner housing before latching the cover in place If the cover hits the filter before it is fully in place remove the cover and push by hand the filter further into the air cleaner and try again The cover should go on with no extra force Never use the latches on the cover to force the filter into the air cleaner It is tempting to assume the cover will do the job of seating the filter ii but it will not Using the latches to push the filter in could
73. nus 5822 2107 8902 2854 or s YOSN3 1304 zez 4 ose HOLIMS mpm 5 HOLIMS 8 HOSN3S qunivsadWal lNviooo E 192 azez Here EE 40154 HOLIMS P 5 8 E dOLS NNX4 voez HOTTMS HOLIMS 8 HOSNIS 3unssaud see 2 4 822 02 622 NS 4 esr Nea 3univsdWal 131009 a 3HNSSTUd BEDV Qv313llHM S HO LIMS ABQNVIS NO P HOSS3HdMWOO Eus NOLLNG LYVLS TOYNLNOD NOLLISOd NI NMOHS Y oy Y ny rs es 102 1109 ing go GION310S GION310S NMOGLNHS SN l en l un id oin vw n en we H313AL 10A amp QN9 e 4 Z lt ez YILIN YNOH b NOLLISOd
74. o be grounded it should be connected with a 8 or larger copper wire to a solid earth ground Such as a metal ground stake going into the ground for at least 10 Feet or to the metal framework of a building which has been effectively grounded The National Electric Code lists a number of alternate means of grounding electrical equipment A machine grounding stud marked with the symbol is provided on the front of the welder AIR VANTAGE 500 CUMMINS LINCOLN P A 6 INSTALLATION A 6 REMOTE CONTROL OUTPUT The AIR VANTAGE 500 is equipped with a 6 pin and a 14 pin connector The 6 pin connector is for connecting the K857 or K857 1 Remote Control or for TIG welding the K870 foot Amptrol or the K936 2 hand Amptrol When in the CC STICK DOWNHILL PIPE 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 When in the DOWNHILL PIPE mode and when a remote control is connected to the 6 Pin or 14 Pin connector the output control is used to set the maximum current range of the remote EXAMPLE When the OUTPUT CONTROL on the welder is set to 200 amps the current range on the remote control will be 40 200 amps rather than th
75. operate as follows a When the triggering device Amptrol Arc Start Switch etc is pressed the engine will accelerate and operate at full speed provided a welding load is applied within approximately 12 seconds If the triggering device remains pressed but no welding load is applied within approximately 12 seconds the engine may return to low idle speed If the triggering device is released or welding ceases the engine will return to low idle speed after approximately 12 seconds AIR VANTAGE 500 CUMMINS LINCOLN P B 4 OPERATION B 4 WELDING CONTROLS Items 10 through 19 10 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 DOWNHILL PIPE or CV WIRE modes and when a remote control is connected to the 6 Pin or 14 Pin Connector the auto sensing circuit automatically switches the OUTPUT CONTROL from control 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 OUTPUT CONTROL inactive and the wire feeder voltage control active When in the DOWNHILL PIPE mode and when a remote control is connected to the 6 Pin or 14 Pin connector the output control is used to set the maximum current range of the remote EXAMPLE When the OUTPUT CONTROL on the welder is set to 200 amps the current range on
76. or connecting the NA 3 Set the Wire Feeder Voltage Switch to 115V CONNECTION OF MAGNUM SC SPOOL GUN TO THE AIR VANTAGE 500 SEE SECTION F AIR VANTAGE 500 CUMMINS LINCOLN P B 1 OPERATION B 1 SAFETY INSTRUCTIONS Read and understand this entire section before operating your AIR VANTAGE 500 Do not attempt to use this equipment until you have thoroughly read all operating and maintenance manuals supplied with your machine They include important safety precautions detailed engine starting operating and maintenance instructions and parts lists ELECTRIC SHOCK can kill e Do not touch electrically live parts such as output terminals or internal wiring Insulate yourself from the work and ground Always wear dry insulating gloves ENGINE EXHAUST can kill 3 Use in open well ventilated areas or vent 2 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 ADDITIONAL SAFETY PRECAUTIONS Always operate the welder with the sliding door closed and the side panels in place as these provide maximum protection from moving parts and insure proper cooling air flow GENERAL DESCRIPTION The AIR VANTAGEQ 500 is a diesel engine driven welding power Source The machine uses a brush type altern
77. osied e sued Aeme e peaj Msyeg J3ALLVO3N 12euuoosiq e ui desye uedo sjaued ejejedo jou og ONINHVM Y WNV49VIQ NOLLO3NNOO 272 7 SH3Q013M ANISNA AIR VANTAGE 500 CUMMINS LINCOLN E DIAGRAMS F 13 DIMENSION PRINT F 13 Jequunu epoo jueuudinbe y SAID e JO jueuruedeq 2919S eu 0 si eui sjaued eu JO euo uo eui episui pejsed si epoo e 10 eu siy Aq peJeAoo 104 eq jou 104 S 51 3 LON 968 H3G 13M NIA WOLLOS T 97861 vv YS 16 21 8 09 Lu 2109 l 69 9967 9 6l ETUR RU cp cR 99 Ir 5 E i feb SNOILVOOT1 3 1OH ONILNNON H3 TI VH L Z v 9 X46 vc 9 O 66 82 o ALANG m O HOLVIQVH HOSS3HdIlWOO NI 110 3NION3 NI TIO ALIAVHO H31N3O9
78. p Light Kit K2640 1 Cable Storage Rack K887 1 ETHER START KIT Provides maximum cold weather starting assistance for frequent starting below 10 12 C Required Ether tank is not provided with kit K1847 1 SPARK ARRESTOR KIT Easily mounts to standard muffler K1816 1 Full KVA Adapter Kit Plugs into the 120 240V NEMA 14 50R receptacle on the case front which accepts 4 prong plugs and converts it to a NEMA 6 50R receptacle which accepts 3 prong plugs for connection to Lincoln Equipment with a NEMA 6 50P plug T12153 9 Full KVA Power Plug One dual voltage plug rated at 120 240V 50 amps single phase 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 supply 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 Green cap color provides a visual reminder to use diesel when refueling K2359 1 Cold Weather Heater and Tarp Kit For extreme cold conditio
79. parts See the MAINTENANCE section of this manual for details on changing oil 3 Remove the battery recharge it and adjust the electrolyte level Store the battery in a dry dark place STACKING AIR VANTAGE 500 machines cannot be stacked ANGLE OF OPERATION To achieve optimum engine performance the AIR VANTAGEG 500 should be run in a level position The maximum angle of operation for the VMAC Compressor and Cummins engine is 35 degrees in all directions When operating the welder at an angle provisions must be made for checking and maintaining the oil level at the normal FULL oil capacity Also the effective fuel capacity will be slightly less than the specified 25 gal 94 6 ltrs AIR VANTAGE 500 CUMMINS LINCOLN P A 3 INSTALLATION A 3 LIFTING The AIR VANTAGE 500 lift bale should be used to lift the machine The AIR VANTAGE 500 is shipped with the lift bale retracted Before attempting to lift the AIR VANTAGEQ 500 the lift bale must be secured in a raised position Secure the lift bale as follows a Open the engine compartment door b Locate the 2 access holes on the upper middle region of compartment wall just below the lift bale Use the lifting strap to raise the lift bale to the full upright position This will align the mounting holes on the lift bale with the access holes d Secure the lift bale with 2 thread forming screws The Screws are provided in the shipped loose parts bag FALLING E
80. parts lists ELECTRIC SHOCK can kill Do not touch electrically live parts such as output terminals or internal wiring Insulate yourself from the work and ground Always wear dry insulating gloves ENGINE EXHAUST can kill 3 Use in open well ventilated areas or vent exhaust outside T MOVING PARTS can injure e Do not operate with doors open or guards off Stop engine before servicing Keep away from moving parts Only qualified personnel should install use or service this equipment LOCATION VENTILATION The welder should be located to provide an unrestricted flow of clean cool air to the cooling air inlets and to avoid restricting the cooling air outlets Also locate the welder so that the engine exhaust fumes are properly vented to an outside area DO NOT MOUNT OVER COMBUSTIBLE SURFACES Where there is a combustible surface directly under stationary or fixed electrical equipment that surface should be covered with a steel plate at least 06 1 6mm thick which should extend not less than 5 90 150mm beyond the equipment on all sides STORING 1 Store the machine in a cool dry place when it is not in use Protect it from dust and dirt Keep it where it can t be accidentally damaged from construction activities moving vehicles and other hazards 2 Drain the engine oil and refill with fresh 10W30 oil Run the engine for about five minutes to circulate oil to all the
81. phosgene a highly toxic gas and other irritating products 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 Jan 09 Z WELDING and CUTTING gt SPARKS can cause fire or explosion 6 a Remove fire hazards from the welding area If this is not possible cover them to prevent the welding sparks from starting a fire Remember that welding sparks 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 s
82. rs provide separate overload current protection for each 120V circuit at the 240V single phase receptacle each 120V single phase receptacle the 240V three phase receptacle the 120VAC in the 14 Pin connector the 42VAC in the 14 Pin connector and battery circuit overload protection 21 120VAC SINGLE PHASE RECEPTACLES These two 120VAC 5 20R receptacles with ground fault circuit interruption protection provide 120VAC single phase for auxiliary power Each receptacle has a 20 amp total rating They are designed to protect the user from the hazards of ground faults When the GFCI has tripped there will be no voltage available from the receptacle Refer to the AUXILIARY POWER RECEPTACLES section in the installation chapter for further information about these receptacles Also refer to the AUXILIARY POWER OPERATION section later in this chapter 22 GROUND STUD D Provides a connection point for connecting the machine case to earth ground Refer to MACHINE GROUNDING in the Installation chapter for proper machine grounding information 23 240VAC THREE PHASE RECEPTACLE This is a 240VAC 15 50R receptacle that provides 240VAC three phase auxiliary power This receptacle has a 50 amp rating AIR COMPRESSOR CONTROLS 24 THRU 26 24 COMPRESSOR ON OFF SWITCH Turns compressor on and off standby by opening and closing the compressor inlet valve 25 COMPRESSOR PROTECTION LIGHT The yellow compressor protection light remains off wit
83. rticular 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 title passes to the purchaser upon receipt by the carrier Consequently Claims for material damaged in shipment must be made by the purchaser against the transportation company at the time the shipment is received Please record your equipment identification information below for future reference This information can be found on your machine nameplate Product Model Number Code Number or Date Code Serial Number Date Purchased Where Purchased Whenever you requ
84. s from the welding circuit 2 d 1 Route the electrode and work cables together Secure them with tape when possible 2 d 2 Never coil the electrode lead around your body 2 d 3 Do not place your body between the electrode and work cables If the electrode cable is on your right side the work cable should also be on your right side 2 d 4 Connect the work cable to the workplace as close as possible to the area being welded 2 d 5 Do not work next to welding power source Mar 95 LINCOLN P 3 b 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 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 Volta
85. tand 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 VANTAGE 500 CUMMINS LINCOLN P E 3 TROUBLESHOOTING E 3 PROBLEMS POSSIBLE RECOMMENDED SYMPTOMS CAUSE COURSE OF ACTION FUNCTION PROBLEMS Battery does not stay charged Faulty battery Faulty engine alternator 1 2 3 Loose or broken lead in charging circuit 4 Loose fan belt may need tightening Engine will not idle down to low 1 Idler switch in HIGH idle position make speed sure switch is set to AUTO External load on welder or auxiliary power Mechanical problem in idler solenoid 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 m e Nous Engine will not go to high idle when 1 Poor work lead connection to work attempting to weld Broken idler solenoid spring Welding Terminals switch in wrong position No open circuit voltage at output studs Faulty Pull Coil Battery PCB or Weld Control PCB ns If all recommended possible areas Engine will not go to high idle when using 1 Broken wire in auxiliary current sensor of misadjustment have been auxiliary power wiring checked and the problem persists 2 Auxiliary power load
86. teps have been taken to insure that such procedures will not cause flammable or toxic vapors from substances inside They can cause an explosion even though they have been cleaned For information purchase Recommended Safe Practices for the Preparation for Welding and 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 circuits This can create fire hazards or overheat lifting chains or cables until they fail Also see item 1 c Read and follow 518 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
87. the remote control will be 40 200 amps rather than the full 40 300 amps Any current range that is less than the full range provides finer current resolution for more fine tuning of the output 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 CONTROL of the Amptrol 11 DIGITAL OUTPUT METERS The digital meters allow the output voltage CV WIRE mode or current CC STICK DOWNHILL PIPE and TIG modes to be set prior to welding using the OUTPUT control knob During welding the meters display the actual output voltage VOLTS and current AMPS A memory feature holds the display 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 12 WELD MODE SELECTOR SWITCH Provides four selectable welding modes CV WIRE DOWNHILL PIPE CC STICK TOUCH START TIG 13 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 CONTROL knob sets the short circuit current arc force during stick welding Increasing the number from 10 Soft to 10 Crisp i
88. the welder and work cable to the terminal of the welder Across The Arc Model Attach the single lead from the front of the LN 15 to work using the spring clip at the end of the lead This is a control lead to supply current to the wire feeder motor it does not carry welding current Control Cable Model Connect Control Cable between Engine Welder and Feeder Set the MODE switch to the CV WIRE position Across The Arc Model Set the WELD TERMINALS switch to WELD TERMINALS ON Control Cable Model Set the WELD TERMINALS switch to REMOTELY CONTROLLED Set the WIRE FEEDER VOLTMETER switch to either or as required by the electrode polarity being used Set the ARC CONTROL knob to 0 initially and adjust to suit Set the IDLE switch to the AUTO IDLE position AIR VANTAGE 500 CUMMINS LINCOLN P A 9 INSTALLATION A 9 CONNECTION OF THE LN 25 TO THE AIR VANTAGE 500 The LN 25 with or without an internal contactor may be used with the AIR VANTAGE 500 See the appropriate connection diagram in the DIAGRAMS section NOTE The LN 25 K431 Remote Control Module and K432 Remote Cable are not recommended for use with the AIR VANTAGE 500 Shut the welder off For electrode Positive connect the electrode cable from the LN 25 to the terminal of the welder and work cable to the terminal of the welder For electrode Negative connect the electrode cable from the LN 25
89. to the terminal of the welder and work cable to the terminal of the welder Attach the single lead from the front of the LN 25 to work using the spring clip at the end of the lead This is a sense lead to supply current to the wire feeder motor it does not carry welding current Set the SELECTOR switch to the CV WIRE position Set the WELDING TERMINALS switch to WELD TERMINALS ON Adjust the ARC CONTROL knob to desired crispness Generally welding is best if the ARC CONTROL is set to SOFT for MIG and CRISP for INNERSHIELD You may however want to start in the middle and adjust as needed from there Set the IDLE switch to the AUTO position When not welding the AIR VANTAGE 500 engine will be at the low idle speed If you are using an LN 25 with an internal contactor the electrode is not energized until the gun trigger is closed A CAUTION If you are using an LN 25 without an internal contactor the electrode will be energized when the AIR VANTAGE 500 is started When the gun trigger is closed the current sensing circuit will cause the wire to begin to feed and the welding process is started CONNECTION OF AN NA 3 AUTOMATIC WELDING SYSTEM TO THE AIR VANTAGE 500 For connection diagrams and instructions for connecting an NA 3 Welding System to the AIR VANTAGE 500 refer to the NA 3 Welding System instruction manual The connection diagram for the LN 8 can be used f
90. 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 Improperly mounted concentrated loads may cause unstable vehicle handling and tires or other components to fail Only transport this Equipment on serviceable vehicles which are rated and designed for such loads Distribute balance and secure loads so vehicle is stable under conditions of use Do not exceed maximum rated loads for components such as suspension axles and tires Mount equipment base to metal bed or frame of vehicle Follow vehicle manufacture s instructions AIR VANTAGE 500 CUMMINS LINCOLN P A 4 INSTALLATION A 4 PRE OPERATION ENGINE AND COMPRESSOR SERVICE READ the engine and compressor operating and maintenance instructions supplied with this machine 4 Keep hands away from the engine muffler HOT engine parts Stop engine and allow to cool before fuelling Do not smoke when fuelling Fill fuel tank at a moderate rate and
91. tor s Manual for more information on coolant BATTERY CONNECTION GASES FROM BATTERY can explode Keep sparks flame and cigarettes away from battery To prevent EXPLOSION when INSTALLING A NEW BATTERY disconnect negative cable from old battery first and connect to new battery last CONNECTING A BATTERY CHARGER remove battery from welder by disconnecting negative cable first then positive cable and battery clamp When reinstalling connect negative cable last Keep well ventilated USING A BOOSTER connect positive lead to battery first then connect negative lead to negative battery lead at engine foot BATTERY ACID can burn eyes and skin Wear gloves and eye protection and be careful when working near battery Follow instructions printed on battery IMPORTANT To prevent ELECTRICAL DAMAGE WHEN a Installing new batteries b Using a booster Use correct polarity Negative Ground AIR VANTAGE 500 CUMMINS LINCOLN P A 5 INSTALLATION A 5 The AIR VANTAGE 500 is shipped with the negative battery cable disconnected Before you operate the machine make sure the Engine Switch is in the OFF position and attach the disconnected cable securely to the negative battery terminal Remove the insulating cap from the negative battery terminal Replace and tighten negative battery cable terminal NOTE This machine is furnished with a wet charged battery if unused for several months

Lincoln Electric IM826-A Welding System User Manual

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