Lincoln Electric IM826-A manual

October , 2009 Safety Depends on Y ou 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 INST ALL, OPERA TE OR REP AIR THIS EQUIPMENT WITHOUT READING THIS MANUAL AND THE SAFETY PRECAUTIONS CONT [...]

E L E C T R I C A N D M A G N E T I C F I E L DS m a y b e d a ng er ou s 2.a . Electric current flowing through any conductor causes localized Electric and Magnetic Fields (EMF). Welding current creates EMF fields around welding cables and welding machines. 2.b. EMF fields may interfere with some pacemakers and welders having a pacemaker should co[...]

ELECTRIC SHOCK can kill. 3.a. The electrode and work (or ground) circuits are electrically “hot” when the welder is on. Do not touch these “hot” parts with your bare skin or wet clothing. Wear dry , hole-free gloves to insulate hands. 3. b. Insulate yourself from work and ground using dry insulation. Make certain the insulation is large eno[...]

iii SAFETY iii FOR ELECTRICALL Y powered equipment. 8.a. Turn off input power using the disconnect switch at the fuse box before working on the equipment. 8.b. Install equipment in accordance with the U.S. National Electrical Code, all local codes and the manufacturer ’s recommendations. 8.c. Ground the equipment in accordance with the U.S. Natio[...]

iv SAFETY iv Mar . ‘93 PRÉCAUTIONS DE SÛRETÉ Pour votre propre protection lire et observer toutes les instructions et les précautions de sûreté specifiques qui parraissent dans ce manuel aussi bien que les précautions de sûreté générales suivantes: Sûreté Pour Soudage A L ’Arc 1. Protegez-vous contre la secousse électrique: a. Les[...]

v v T T h h a a n n k k Y Y o o u u for selecting a QUALITY product by Lincoln Electric. We want you to take pride in operating this Lincoln Electric Company product ••• as much pride as we have in bringing this product to you! Read this Operators M anual completely before attempting to use this equipment. Save this manual and keep it handy f[...]

Page Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Section A T echnical Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .A-1 Safety Precautions . . . . . . . . . . .[...]

Accessories . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Section C Optional Field Installed Accessories . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .C-1 _____________________________________________________[...]

TECHNICAL SPECIFICA TIONS - AIR V ANT AGE® 500 CUMMINS (K2325-1) INPUT - DIESEL ENGINE Make /Model Description Speed (RPM) Displacement Starting Capacities System Cummins 4 cylinder High Idle 1900 199 cu. in 12VDC battery Fuel B3.3 56HP (42 kw) Low Idle 1425 (3.3L) & Starter (25 US gal) Diesel Engine @ 1800 RPM Full Load 1800 94.6L Bore x Stro[...]

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 parts lists. ELE[...]

LIFTING The AIR V ANT AGE® 500 lift bale should be used to lift the machine. The AIR V ANT AGE® 500 is shipped with the lift bale retracted. Before attempting to lift the AIR V ANT AGE® 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 th[...]

PRE-OPERA TION ENGINE AND COMPRESSOR SERVICE READ the engine and compressor operating and maintenance instructions supplied with this machine. • Keep hands away from the engine muffler or HOT engine parts. • Stop engine and allow to cool before fuelling. • Do not smoke when fuelling. • Fill fuel tank at a moderate rate and do not over-fill.[...]

The AIR V ANT AGE® 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 [...]

REMOTE CONTROL OUTPUT The AIR V ANT AGE® 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 Conne[...]

AIR V ANT AGE® 500 CUMMINS A-7 INST ALLA TION A-7 2. T ake necessary steps to assure load is limited to the capacity of the AIR V ANT AGE® 500 by installing a 50 amp, 240 V AC double pole circuit breaker . Maximum rated load for each leg of the 240 V AC auxiliary is 50 amps. Loading above the rated output will reduce output voltage below the allo[...]

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 V ANT AGE® 500 • Shut the welder off. • Connect the LN-7, LN-8 OR LN-742 per instructions on the appropriate co[...]

CONNECTION OF THE LN-25 TO THE AIR V ANT AGE® 500 The LN-25 with or without an internal contactor may be used with the AIR V ANT AGE® 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 V ANT AGE® 500. • Shut the weld[...]

SAFETY INSTRUCTIONS Read and understand this entire section before operating your AIR V ANT AGE® 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 p[...]

ENGINE CONTROLS (Items 1 through 9) 1. RU N ST O P SW IT CH T oggling the switch to the RUN position energizes the fuel solenoid for approximately 30 seconds. The engine must be started within that time or the fuel solenoid will deenergize, and the switch must be toggled to reset the timer . 2. ST ART PUSHBUTTON Energizes the starter motor to crank[...]

6. OIL PRESSURE GAUGE 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 necessa[...]

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 automatical[...]

20. CIRCUIT BREAKERS These circuit breakers 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 120V AC in the 14-Pin connector , the 42V AC in the 14-Pin connector and battery circuit overload protection. 21. 120V AC SINGLE P[...]

B-6 OPERA TION B-6 AIR V ANT AGE® 500 CUMMINS 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. [...]

AIR V ANT AGE® 500 SETTINGS WHEN USING THE K930-2 TIG MODULE • Set the WELD MODE switch to the “T ouch 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[...]

CV -WIRE MODE Connect a wire feeder to the AIR V ANT AGE® 500 and set welder controls according to the instructions listed earlier in this section. The AIR V ANT AGE® 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 a[...]

B-9 OPERA TION B-9 AIR V ANT AGE® 500 CUMMINS T ABLE B.5 AIR V ANT AGE® 500 Extension Cord Length Recommendations Current (Amps) 15 15 20 20 25 30 38 50 V oltage (V olts) 120 240 120 240 240 240 240 240 Load (W atts) 1800 3600 2400 4800 6000 7200 9000 12000 30 60 (9) (18) 40 75 30 60 (12) (23) (9) (18) 75 150 50 100 90 75 (23) (46) (15) (30) (27)[...]

OPTIONAL FIELD INST ALLED ACCESSORIES K802N POWER PLUG KIT - Provides four 120V plugs rated at 20 amps each and one dual voltage, full KV A 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 KV A plug[...]

SAFETY PRECAUTIONS • 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. -----------------[...]

D-2 MAINTENANCE D-2 AIR V ANT AGE® 500 CUMMINS Service Instructions & Installation T ips For Engine Air Filter Release the 1 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 donít hinder filter removal/installation. Most latches are spring loaded to[...]

FUEL FIL TERS When working on the fuel system • Keep naked lights away , do not smoke ! • Do not spill fuel ! - ------------------------------------------------------------------------------------- The AIR V ANT AGE® 500 is equipped with a Fuel Filter located after the lift pump and before fuel injectors.The procedure for changing the filter i[...]

CHARGING THE BA TTER Y When you charge, jump, replace, or otherwise connect battery cables to the battery , be sure the polarity is correct. Improper polarity can damage the charging circuit. The AIR V ANT AGE® 500 positive (+) battery terminal has a red terminal cover. If you need to charge the battery with an external charger , disconnect the ne[...]

This T roubleshooting Guide is provided to help you locate and repair possible machine malfunctions. Simply follow the three- step procedure listed below . Step 1. LOCA TE PROBLEM (SYMPTOM). Look under the column labeled “PROBLEM (SYMPTOMS)”. This column describes possible symptoms that the machine may exhibit. Find the listing that best descri[...]

PROBLEMS (SYMPTOMS) Major Physical or Electrical Damage is Evident. Engine will not crank Engine will crank but not start. Engine shuts down shortly after starting. Engine shuts down while under a load. Engine runs rough. Engine will not shut off. POSSIBLE CAUSE 1. Contact your Local Lincoln Authorized Field Service Facility . 1. Battery low . 2. L[...]

CAUTION AIR V ANT AGE® 500 CUMMINS E-3 TROUBLESHOOTING E-3 PROBLEMS (SYMPTOMS) Battery does not stay charged. Engine will not idle down to low speed. Engine will not go to high idle when attempting to weld. Engine will not go to high idle when using auxiliary power. POSSIBLE CAUSE 1. Faulty battery . 2. Faulty engine alternator. 3. Loose or broken[...]

PROBLEMS (SYMPTOMS) Engine goes to low idle but does not stay at low idle. No welding output or auxiliary output. Welder has some/ no output and no control. Auxiliary output OK No welding output. Auxiliary output OK. No auxiliary power . POSSIBLE CAUSE 1. Faulty Peripheral PCB, Pull Coil/Battery PCB or Weld Control PCB. 1. Broken lead in rotor circ[...]

F-1 DIAGRAMS F-1 AIR V ANT AGE® 500 CUMMINS NOTE: This diagram is for reference only . It may not be accurate for all machines covered by this manual. The specific diagram for your particular machine is pasted inside the machine on one of the enclosure panels.[...]

F-2 DIAGRAMS F-2 AIR V ANT AGE® 500 CUMMINS CONNECTION DIAGRAM:[...]

F-3 DIAGRAMS F-3 AIR V ANT AGE® 500 CUMMINS CONNECTION DIAGRAM: GND 75 76 77 GREEN K291 OR K40 4 75 INPUT CABLE 76 N.E. 77 K775 OPTIO NAL REMOTE CONTROL D AMAGED . THE ENGINE GOVERNOR SETTING IS PRE-SET A T THE F ACT OR Y - DO NOT ADJUST ABO VE RPM SPECIFICA TIONS LISTED IN 81 42 41 31 31 32 32 2 2 4 4 21 21 GND 82 N.D . LN -7 WIRE FEE[...]

F-4 DIAGRAMS F-4 AIR V ANT AGE® 500 CUMMINS CONNECTION DIAGRAM[...]

AIR V ANT AGE® 500 CUMMINS F-5 DIAGRAMS F-5 CONNECTION DIAGRAM[...]

AIR V ANT AGE® 500 CUMMINS F-6 DIAGRAMS F-6 CONNECTION DIAGRAM CA UTION : N.A. WELDING CABLE MUST BE OF PROPER CAP ACITY FOR THE CURRENT AND DUTY CYCLE OF IMMEDIA TE AND FUTURE APPICA TIONS. SEE OPERA TING MANUAL. 75 32 31 41 42 N.C. INSULA TE EACH UNUSED LEAD INDIVIDUALL Y . N.D . SPLICE LEADS AND INSULA TE. THE ENGINE WELDER OPERA TING MANUAL[...]

AIR V ANT AGE® 500 CUMMINS F-7 DIAGRAMS F-7 CONNECTION DIAGRAM[...]

AIR V ANT AGE® 500 CUMMINS F-8 DIAGRAMS F-8 CONNECTION DIAGRAM[...]

AIR V ANT AGE® 500 CUMMINS F-9 DIAGRAMS F-9 CONNECTION DIAGRAM[...]

AIR V ANT AGE® 500 CUMMINS F-10 DIAGRAMS F-10 CONNECTION DIAGRAM[...]

AIR V ANT AGE® 500 CUMMINS F-1 1 DIAGRAMS F-1 1 CONNECTION DIAGRAM[...]

AIR V ANT AGE® 500 CUMMINS F-12 DIAGRAMS F-12 CONNECTION DIAGRAM[...]

AIR V ANT AGE® 500 CUMMINS F-13 DIAGRAMS F-13 DIMENSION PRINT M 18 96 2- 4 B TRAILER MOUNTING H OLE LOCATIONS. * 28.99 736.3 19.63 498.6 6.55 166.4 23.69 601.7 50.38 1279.7 54.44 1382.8 14.63 371.6 37.30 947.4 45.38 1152.7 31.50 800.1 45.67 1160 2.24 56.9 3.18 80.8 * * * * BOTTOM VIEW OF WEL DER BASE. N.A. CENTER OF GRAVI TY W ITH OIL IN ENGINE, O[...]

W ARNING A VISO DE PRECAUCION A TTENTION W ARNUNG A TENÇÃO Spanish French German Portuguese Japanese Chinese Korean Arabic READ AND UNDERST AND THE MANUF ACTURER’S INSTRUCTION FOR THIS EQUIPMENT AND THE CONSUMABLES TO BE USED AND FOLLOW YOUR EMPLOYER’S SAFETY PRACTICES. SE RECOMIENDA LEER Y ENTENDER LAS INSTRUCCIONES DEL F ABRICANTE P ARA EL [...]

W ARNING A VISO DE PRECAUCION A TTENTION W ARNUNG A TENÇÃO Spanish French German Portuguese Japanese Chinese Korean Arabic LEIA E COMPREENDA AS INSTRUÇÕES DO F ABRICANTE PARA ESTE EQUIP AMENTO E AS P ARTES DE USO, E SIGA AS PRÁTICAS DE SEGURANÇA DO EMPREGADOR. ● Keep your head out of fume s. ● Use ve ntil ation or exh aust to remo ve fume[...]

World’ s Leader in Welding and Cutting Products • Sales and Service through Subsidiaries and Distributors Worldwide • Cleveland, Ohio 441 17-1 199 USA T el: 216.481.8100 Fax: 216.486.1751 Web Site: www .lincolnelectric.com[...]