Lincoln Electric IM10041 manual

AIR V ANT A GE 500 CUMMINS OPERA TOR’S MANUAL IM10041 November, 2009 Safety Depends on You L i n c o l n a r c w e l d i n g a nd c u t t i n g 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, OPER- ATE OR REPAIR THI[...]

i SAFETY i FOR ENGINE powered equipment. 1.a. Turn the engine off before troubleshooting and maintenance work unless the maintenance work requires it to be running. ____________________________________________________ 1.b. Operate engines in open, well-ventilated areas or vent the engine exhaust fumes outdoors. _____________________________________[...]

ii SAFETY ii ARC R A Y S can b urn. 4.a. Use a shield with the proper filter and cover plates to protect your eyes from sparks and the rays of the arc when welding or observing open arc welding. Headshield and filter lens should conform to ANSI Z87. I standards. 4. b. Use suitable clothing made from durable flame-resistant material to protect your [...]

iii SAFETY iii FOR ELECTRIC ALL Y pow ered 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. Na[...]

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 suiv- antes: Sûreté Pour Soudage A L’Arc 1. Protegez-vous contre la secousse électrique: a. Les[...]

v SAFETY v AIR VANTAGE® 500 CUMMINS Electro magnetic Compatibility (EMC) Conformance Products displaying the CE mark are in conformity with European Community Council Directive of 3 May 1989 on the approximation of the laws of the Member States relating to electromagnetic compatibility (89/336/EEC). It was manufactured in conformity with a nationa[...]

vi SAFETY vi AIR VANTAGE® 500 CUMMINS Electro magnetic Compatibility (EMC) The size of the surrounding area to be considered will depend on the structure of the building and other activities that are taking place. The surrounding area may extend beyond the boundaries of the premises. Methods of Reducing Emissions Mains Supply Welding equipment sho[...]

vii vii 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 Manual completely before attempting to use this equipment. Save this manual and keep it hand[...]

viii viii T ABLE OF CONTENTS Page Installation .......................................................................................................................Section A Technical Specifications .......................................................................................................A-1 Safety Precautions .......................[...]

ix ix T ABLE OF CONTENTS Accessories ........................................................................................................Section c Optional Field Installed Accessories......................................................................C-1 ________________________________________________________________________ Maintenance ....[...]

AIR VANTAGE® 500 CUMMINS A-1 INST ALLA TION A-1 TECHNICAL SPECIFICA TIONS - AIR V ANT AGE® 500 CUMMINS (K32012) Make/Model Description Speed (RPM) Displacement Starting Capacities cu. in. (ltrs.) System 4 cylinder High Idle 1900 199(3.3) 12VDC Battery & Fuel: 25 gal. Cummins 56 HP (42kw) starter (94.6 L) B3.3 1800 RPM Full Load 1800 Bore x St[...]

A-2 INST ALLA TION AIR VANTAGE® 500 CUMMINS A-2 SAFETY PRECAUTIONS Only qualified personnel should install, use, or service this equipment. Do not attempt to use this equipment until you have thoroughly read the engine manufacturer’s manual supplied with your welder. It includes important safety precautions, detailed engine starting, operating a[...]

A-3 INST ALLA TION AIR VANTAGE® 500 CUMMINS 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 VAN- TAGE® 500 the lift bale must be secured in a raised position. Secure the lift bale as follows: a. Open the engine compartmen[...]

ENGINE COOLANT HOT COOLANT can burn skin. •Do not remove cap if radiator is hot. ------------------------------------------------------------------------ The welder is shipped with the engine and radiator filled with a 50% mixture of ethylene glycol and water. See the MAINTENANCE section and the engine Operator’s Manual for more information on [...]

A-5 INST ALLA TION AIR VANTAGE® 500 CUMMINS 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 termin[...]

A-6 INST ALLA TION AIR VANTAGE® 500 CUMMINS A-6 REMOTE CONTROL 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 K963-3 hand Amptrol. When in the CC-STICK or CV-WIRE modes and when a remote control is connec[...]

A-7 INST ALLA TION AIR VANTAGE® 500 CUMMINS A-7 CONNECTION OF LINCOLN ELEC- TRIC WIRE FEEDERS Shut off welder before making any electrical con- nections. ------------------------------------------------------------------------ Connection of LN-7, LN-8 OR LN-742 to the AIR VANTAGE® 500 1. Shut the welder off. 2. Connect the LN-7, LN-8 OR LN-742 pe[...]

A-8 INST ALLA TION AIR VANTAGE® 500 CUMMINS A-8 CONNECTION OF AN NA-3 AUTOMA TIC WELDING SYSTEM TO THE AIR V AN- T AGE® 500 For connection diagrams and instructions for connect- ing 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 for connecting t[...]

B-1 OPERA TION AIR VANTAGE® 500 CUMMINS B-1 SAFETY PRECAUTIONS Read and understan d this entire section before operating your AIR VANTAGE® 500. Do not attempt to use this equipment until you have thoroughly read the engine manufacturer’s manual supplied with your welder. It includes important safety precautions, detailed engine starting, operat[...]

B-2 OPERA TION B-2 ENGINE CONTROLS (Items 1 through 9) 1. RUN STOP SWITCH Toggling the switch to the RUN position energizes the fuel solenoid for approximately 30 seconds. The engine must be started within that time or the fuel solenoid will deenergize, and the switch must be toggled to reset the timer. 2. ST ART PUSHBUTTON Energizes the starter mo[...]

B-3 OPERA TION B-3 7. OIL PRESSURE GAUGE The gauge displays the engine oil pressure when the engine is running. 8. ENGINE PROTECTION The yellow engine protection light remains off with proper oil pressure and under normal oper- ating temperatures. If the light turns on, the engine protection system will stop the engine. Check for proper oil level a[...]

B-4 OPERA TION B-4 13. WELD MODE SELECTOR SWITCH: (Provides 3 selectable welding modes) CV-WIRE CC-STICK TOUCH START TIG 14. ARC CONTROL: The ARC CONTROL WIRE/STICK knob is active in the WIRE and STICK modes, and has different functions in these modes. This control is not active in the TIG mode. CC-STICK mode: In this mode, the ARC CON- TROL knob s[...]

B-5 OPERA TION B-5 23. GROUND STUD: Provides a connection point for connecting the machine case to earth ground. Refer to “MACHINE GROUNDI NG” in the Installation chapter for proper ma chine grounding informa- tion. 24. RCD: “ Residual Current Device” provides protection from active to ground contact. RCD will not protect against electrical[...]

B-6 OPERA TION B-6 WHA T ARE VRD AND ROCV DEVICES? VRD’s are gaining popularity as a “must have” safety accessory especially where welding applications are being carried out in an environment with a high-risk of e l e c t r i c s h o c k s u c h a s w e t a r e a s a n d h o t h u m i d sweaty conditions. VRD and R O CV are abbreviations for [...]

B-7 OPERA TION B-7 Unlike other VRD’s Lincoln uses micro processor con- trol to monitor and establish the arc without the stick- ing and shorting of the electrode to the job as seen in many other VRD installations. Due to the requirement of the resistance in the circuit to be low, for a VRD to operate, a good metal-to-metal contact must be made b[...]

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 inst allation, operation, and maintenance. When usi[...]

ARC GOUGING For optimal performance when arc gouging, set the AIR V ANT AG E® 500 “ WEL D MODE ” switc h to the “CC - STICK” position, and the “ARC CONTROL” t o 10. Set the “OUTPUT” knob to adjust output current to the desired level for the gouging electrode being used according to the ratings in the following Table B.2 NOTE: If de[...]

P ARALLELING When paralleling machines in order to combine their outputs, all units must be operated in the CC-STICK mode only at the same output settings. To achieve this, turn the WELD MODE switch to the CC-STICK position. Operation in other modes may produce errat- ic outputs, and large output imbalances between the units. AUXILIAR Y POWER OPERA[...]

K2354-1 Air Dryer Kit-Minimizes water content in sup- ply air. Avoids cold weather air hose ice up. K2356-1 Control Panel Cover Kit-Clear plexiglass cover to protect control panel from dirt and debris, and to visually monitor machine operation. Lockable to deter vandalism. K2340-1 Lockable Fuel Cap / Flash Arrester Kit-For use in loc ations where f[...]

D-1 MAINTENANCE D-1 AIR VANTAGE® 500 CUMMINS SAFETY PRECAUTIONS • Have qualified personnel do all maintenance and troubleshooting work. • Tu rn t he e ng in e off b ef or e wor ki ng ins id e the machine or servicing the engine. • Remove guar ds only w hen necessary to perform maintenance and replace them when the maintenance requiring their[...]

D-2 MAINTENANCE D-2 AIR VANTAGE® 500 CUMMINS Unfasten or unlatch the s ervice cover . Because the filter fits tightly over the outlet tube to create the critical seal, there will be some initial resistance, similar to breaking the seal on a jar . Gently move the end of the filter back and forth to break the seal then rotate while pulling straight [...]

D-3 MAINTENANCE D-3 FUEL FIL TERS When working on the fuel system: • Keep naked lights away, do not smoke ! • Do not spill fuel ! ------------------------------------------------------------------------- The AIR VANTAGE® 500 is equipped with a Fuel Filter located after the lift pump and before fuel injec- tors.The procedure for changing the fi[...]

D-4 MAINTENANCE D-4 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 t he charging circuit. The AIR VANTAGE® 500 positive (+) battery terminal has a red terminal cover. If you need to charge the battery with an external charger, [...]

E-1 TROUBLESHOOTING E-1 AIR VANTAGE® 500 CUMMINS 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. CAUTION This Troubleshooting Guide is provided to help you locate a[...]

E-2 TROUBLESHOOTING E-2 AIR VANTAGE® 500 CUMMINS Observe all Safety Guidelines detailed throughout this manual 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. CAUTI[...]

E-3 TROUBLESHOOTING E-3 Observe all Safety Guidelines detailed throughout this manual 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. CAUTION PROBLEMS (SYMPTOMS) POS[...]

E-4 TROUBLESHOOTING E-4 AIR VANTAGE® 500 CUMMINS Observe all Safety Guidelines detailed throughout this manual 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. CAUTI[...]

F-1 WIRING DIAGRAM F-1 AIR VANTAGE® 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 a particular code is included with the machine. If the diagram is illegible, write to the Service Department for a replacement. Give the equipment code number.[...]

F-2 DIAGRAMS F-2 AIR VANTAGE® 500 CUMMINS[...]

F-3 DIAGRAMS F-3 AIR VANTAGE® 500 CUMMINS GND 75 76 77 GREEN K291 OR K40 4 75 INPUT CABLE 76 N.E. 77 K775 OPTION AL REMOTE CONT ROL DAMAGED. THE ENGINE GO VERNOR SE TTING IS PRE-SET A T THE F ACTORY - DO NO T ADJUST A BOVE RPM SPECIFICA T IONS LIST ED IN 81 42 41 31 31 32 32 2 2 4 4 21 21 GND 82 N.D. LN-7 WIRE FEEDER Keep guard s in place. E NGINE[...]

F-4 DIAGRAMS F-4 AIR VANTAGE® 500 CUMMINS[...]

F-5 DIAGRAMS F-5 AIR VANTAGE® 500 CUMMINS[...]

F-6 DIAGRAMS F-6 AIR VANTAGE® 500 CUMMINS CAUTION : N.A. WELDI NG CABLE MUST BE OF PROPER CAPACITY FOR THE CURRENT AND DUTY CYCLE O F IMMEDIA TE AND FUTURE APPICA TIONS . SEE OPERATING MANUAL. 75 32 31 41 42 N.C. INSUL A TE EAC H UNUSED LEA D INDIVIDUALLY . N.D. SPLIC E LEADS AND INSULA TE. THE ENGI NE WELDER OPERA TING MANUAL. GND 31 4 21 B C A 1[...]

F-7 DIAGRAMS F-7 AIR VANTAGE® 500 CUMMINS[...]

F-8 DIAGRAMS F-8 AIR VANTAGE® 500 CUMMINS[...]

F-9 DIAGRAMS F-9 AIR VANTAGE® 500 CUMMINS[...]

F-10 DIAGRAMS F-10 AIR VANTAGE® 500 CUMMINS[...]

F-11 DIAGRAMS F-11 AIR VANTAGE® 500 CUMMINS 2 9/03[...]

F-12 DIAGRAMS F-12 AIR VANTAGE® 500 CUMMINS[...]

F-13 DIMENSION PRINT F-13 AIR VANTAGE® 500 CUMMINS M 18 96 2- 4 B TRAILER MOUNTING HOLE 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 W ELDER BASE. N.A. CENTER OF GRAVI TY W ITH OIL IN ENGINE, OIL IN COM PR[...]

NOTES AIR VANTAGE® 500 CUMMINS[...]

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 P ARA ESTE EQUIP AMENTO E AS PAR TES DE USO, E SIGA AS PRÁTICAS DE SEGURANÇA DO EMPREGADOR. ● Keep your h ead out of fum es. ● Use ventila tio n or ex haus t t o remo ve [...]

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