Lincoln Electric Air Vantage 566X Hydraulic Operator's Manual
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Lincoln Electric Air Vantage 566X Hydraulic Operator's Manual

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Operator's Manual
Air Vantage
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Date Purchased
Code: (ex: 10859)
Serial: (ex: U1060512345)
IM10559
| Issue D ate Apr - 20
© Lincoln Global, Inc. All Rights Reserved.
566X Hydraulic
®
For use with machines having Code Numbers:
12909
Need Help? Call 1.888.935.3877
to talk to a Service Representative
Hours of Operation:
8:00 AM to 6:00 PM (ET) Mon. thru Fri.
After hours?
Use "Ask the Experts" at lincolnelectric.com
A Lincoln Service Representative will contact you
no later than the following business day.
For Service outside the USA:
Email: globalservice@lincolnelectric.com

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Summary of Contents for Lincoln Electric Air Vantage 566X Hydraulic

  • Page 1 Operator’s Manual Air Vantage 566X Hydraulic ® For use with machines having Code Numbers: 12909 Need Help? Call 1.888.935.3877 Register your machine: to talk to a Service Representative www.lincolnelectric.com/register Authorized Service and Distributor Locator: Hours of Operation: www.lincolnelectric.com/locator 8:00 AM to 6:00 PM (ET) Mon. thru Fri. Save for future reference After hours? Use “Ask the Experts”...
  • Page 2 THANK YOU FOR SELECTING A QUALITY PRODUCT BY KEEP YOUR HEAD OUT OF THE FUMES. DON’T get too close to the arc. LINCOLN ELEC TRIC. Use corrective lenses if necessary to stay a reasonable distance away from the arc. READ and obey the Safety Data PLEASE EXAMINE CARTON AND EQUIPMENT FOR Sheet (SDS) and the warning label DAMAGE IMMEDIATELY...
  • Page 3 W117.2. A Free copy of “Arc Welding Safety” booklet E205 is available from the Lincoln Electric Company, 22801 2.d. All welders should use the following procedures in order to St. Clair Avenue, Cleveland, Ohio 44117-1199.
  • Page 4 SAFETY ELECTRIC SHOCK ARC RAYS CAN BURN. CAN KILL. 3.a. The electrode and work (or ground) circuits are 4.a. Use a shield with the proper filter and cover plates to protect your electrically “hot” when the welder is on. Do eyes from sparks and the rays of the arc when welding or not touch these “hot”...
  • Page 5 SAFETY WELDING AND CUTTING CYLINDER MAY EXPLODE IF SPARKS CAN CAUSE DAMAGED. FIRE OR EXPLOSION. 7.a. Use only compressed gas cylinders containing the correct shielding gas for the process used 6.a. Remove fire hazards from the welding area. If and properly operating regulators designed for this is not possible, cover them to prevent the welding sparks the gas and pressure used.
  • Page 6 TABLE OF CONTENTS...

  • Page 7: Table Of Contents

    TABLE OF CONTENTS CV-WIRE MODE ...............................B-12 ARC GOUGING MODE ...............................B-12 ARCLINK MODE ...............................B-12 PULSE WELDING..............................B-13 CROSSLINC ................................B-14 PARALLELING ................................B-14 AUXILIARY POWER OPERATION..........................B-15 SIMULTANEOUS WELDING AND AUXILIARY POWER LOADS ..................B-15 TYPICAL FUEL CONSUMPTION ..........................B-16 ACCESSORIES ..............................SECTION C CROSSLINC ACCESSORIES ............................C-1 GENERAL ACCESSORIES............................C-1 TIG ACCESSORIES ..............................C-1 WIRE FEEDERS &...
  • Page 8 AIR VANTAGE 566X HYDRAULIC ® GRAPHIC SYMBOLS The following graphics appear on the machine or in the manual. Warning or Caution Engine Downhill Pipe welding Instructions Remote Fumes and Gases Oil Pressure Arc Control Explosion Engine Temperature Pulse Arc Rays Engine Hours Voltmeter Polarity Moving Parts...
  • Page 9 AIR VANTAGE 566X HYDRAULIC INSTALLATION ® GENERAL DESCRIPTION OUTPUT @ 104°F(40°C) - WELD ER AND GENERATOR Welding Mode Output Range The Air Vantage ® 566X Hydraulic is a diesel engine-driven welding power source. The machine uses a brush type alternating CC-Stick 30-600 Amps current generator for DC multi-purpose welding, for 120/240 VAC...
  • Page 10 AIR VANTAGE 566X HYDRAULIC INSTALLATION ® HYDRAULIC PUMP SPECIFICATIONS Outlet Fitting PTO Type Pump Description Output at High Idle Inlet Fitting Connection Connection Type: Cast Iron Gear Belt Driven 10 gal/min @3000 psi SAE12, 37° JIC SAE10, 37° JIC with 12 Volt Make: Casappa 37.9 L/min @ 20.7 Mpa) Male Flare...
  • Page 11 AIR VANTAGE 566X HYDRAULIC INSTALLATION ® INSTALLATION FIGURE A.1 ON / OFF VDR SWITCH SAFETY PRECAUTIONS WARNING 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.
  • Page 12 AIR VANTAGE 566X HYDRAULIC INSTALLATION ® STORING HIGH ALTITUDE OPERATION 1. Store the machine in a cool, dry place when it is not in use. At higher altitudes, output derating may be necessary. For Protect it from dust and dirt. Keep it where it can’t be maximum rating, derate the welder output in accordance with the accidentally damaged from construction activities, moving guidelines in Table A.1 below for this engine model from the...
  • Page 13 AIR VANTAGE 566X HYDRAULIC INSTALLATION ® READ the engine operation, compressor operation, and TOWING maintenance instructions supplied with this machine. Use a recommended trailer for use with this equipment for road, WARNING in-plant and yard towing by a vehicle . If the user adapts a non- Lincoln trailer, they must assume responsibility that the method of attachment and usage does not result in a safety hazard or •...
  • Page 14 AIR VANTAGE 566X HYDRAULIC INSTALLATION ® SPARK ARRESTOR BATTERY CONNECTION Some federal, state or local laws may require that gasoline or CAUTION diesel engines be equipped with exhaust spark arrestors when they are operated in certain locations where unarrested sparks may present a re hazard.
  • Page 15 AIR VANTAGE 566X HYDRAULIC INSTALLATION ® Hydraulic System Integration COMPRESSOR SYSTEM 1. Follow the tool component or system manufacturer’s The Air Vantage ® 566X Hydraulic has an integrated VMAC guidelines regarding the necessary equipment and safety compressor system installed on the machine. The compressor devices to be installed.
  • Page 16 AIR VANTAGE 566X HYDRAULIC INSTALLATION ® MACHINE GROUNDING The 120 VAC auxiliary power receptacles should only be used with three wire grounded type plugs or approved double insulated tools Because this portable engine driven welder creates its own power, with two wire plugs. The current rating of any plug used with the it is not necessary to connect its frame to an earth ground, unless system must be at least equal to the current capacity of the the machine is connected to premises wiring (home, shop, etc.).
  • Page 17 AIR VANTAGE 566X HYDRAULIC INSTALLATION ® STANDBY POWER CONNECTIONS 2. Take necessary steps to assure load is limited to the capacity of the Air Vantage ® 566X Hydraulic by installing a 50 amp, The Air Vantage 566X Hydraulic is suitable for temporary, ®...
  • Page 18 AIR VANTAGE 566X HYDRAULIC INSTALLATION ® CAUTION WELDING OUTPUT CABLES • Loose connections will cause the output terminals to With the engine off, route the electrode and work cables through overheat. The terminals may eventually melt. the strain relief bracket provided on the front of the base and connect to the terminals provided.
  • Page 19 The 5-pin ArcLink ® connection on the Air Vantage 566X Hydraulic is located on control panel. The ® control cable is keyed and polarized to prevent improper connection. To minimize inductance always use the appropriate size cables,...
  • Page 20 AIR VANTAGE 566X HYDRAULIC INSTALLATION ® REMOTE CONTROL CONNECTIONS WELDING TERMINALS The Air Vantage ® 566X Hydraulic is equipped with a 12-pin The Air Vantage ® 566X Hydraulic is equipped with a toggle and a 14-pin connector. To enable remote control capabilities, switch for selecting "hot"...
  • Page 21 AIR VANTAGE 566X HYDRAULIC INSTALLATION ® For electrode negative, connect the electrode cable “-” terminal of the welder and work cable to the “+” terminal of ACCESSORY CONNECTION DIAGRAMS the welder. Installation diagrams for common setups are included on the following pages. WARNING •...
  • Page 22 AIR VANTAGE 566X HYDRAULIC INSTALLATION ® CROSSLINC SETUP CV FIGURE A.7 Item Desc. Machine Air Vantage ® 566X Hydraulic K4343-3 Feeder LN-25X w/TVT K4267-2 K126 PRO Innershield ® ® 350A FCAW-SS Welding K126-12 Gun 15 ft 1/16-5/64 Weld Power Cable - Lug to Work Lug (3/0, 600A, 60%) - 35 K1842-35...
  • Page 23 AIR VANTAGE 566X HYDRAULIC INSTALLATION ® DUAL ARC SETUP Item Desc. FIGURE A.9 Machine Air Vantage ® 566X Hydraulic K4343-3 Feeder LN-25X w/TVT K4267-2 K126 PRO Innershield ® ® 350A FCAW-SS Welding K126-12 Gun 15 ft 1/16-5/64 Weld Power Cable - Lug to Work Lug (3/0, 600A, 60%) - 35 K1842-35...
  • Page 24 (2/0, 350A, 60%) - 15 ft (15.3 m) Adapter Lug to Tweco Style Receptacle Adapter K2487-1 SPOOL GUN MODULE Item Description FIGURE A.11 Machine Air Vantage 566X Hydraulic K4343-3 Accessory Spool Gun Module K488 Control Control Cable, Weld Cable, K691-10 Cable Gas Hose Magnum SG K487-25 Work Lead Work Lead - Lug &...
  • Page 25 AIR VANTAGE 566X HYDRAULIC OPERATION ® OPERATION RECOMMENDED APPLICATIONS WELDER - The Air Vantage 566X Hydraulic provides excellent ® SAFETY INSTRUCTIONS constant current DC welding output for stick (SMAW) and TIG Read and understand this entire section (GTAW) welding. The Air Vantage 566X Hydraulic also provides ®...
  • Page 26 AIR VANTAGE 566X HYDRAULIC OPERATION ® CAUTION ADD FUEL WARNING It is extremely important to have the compressor system power switch in the “OFF” position when starting the DIESEL FUEL can cause re. engine. Failure to observe this may result in loss of clutch •...
  • Page 27 AIR VANTAGE 566X HYDRAULIC OPERATION ® 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. 1D. FUEL LEVEL - Displays the level of diesel fuel in the fuel tank. SYSTEM CONTROLS The operator must watch the fuel level closely to prevent 1.
  • Page 28 AIR VANTAGE 566X HYDRAULIC OPERATION ® 3. CROSSLINC INDICATOR LIGHT - When a CrossLinc 8. 42V / 120V WIRE FEEDER VOLTAGE SWITCH enabled device is connected with the machine using the stan- Toggles output of 14-pin connector to voltage requirement of dard weld power cable and the device's sense lead is attached wire feeder.
  • Page 29 AIR VANTAGE 566X HYDRAULIC OPERATION ® 16. HIDDEN MENU BUTTON - The hidden setup menu can 11. START / GLOW PLUG SWITCH - Energizes the be accessed any time the machine is on with the engine run- starter motor to crank the engine. With the engine RUN / ning and not in a welding arc (arc off or OCV).
  • Page 30 AIR VANTAGE 566X HYDRAULIC OPERATION ® 26. 240 VAC THREE PHASE RECEPTACLE - This is a 32. DIAGNOSTIC PLUG - 240 VAC (15-50R) receptacle that provides 240 VAC three shops to connect and troubleshoot engine error codes, found phase auxiliary power. This receptacle has a 50 amp rating. FIGURE B.4 27.
  • Page 31 AIR VANTAGE 566X HYDRAULIC OPERATION ® 46. BATTERY ISOLATOR 37. NEGATIVE BATTERY JUMP START TERMINAL. When rotated clockwise, battery power is supplied to the front 38. POSITIVE BATTERY JUMP START TERMINAL. panel to start & run machine. When rotated counter clockwise, 12V battery jump start feature is standard.
  • Page 32 AIR VANTAGE 566X HYDRAULIC OPERATION ® ACTIVATING THE COMPRESSOR SYSTEM DEACTIVATING THE COMPRESSOR SYSTEM (See Figure B.14 and B.15) 1. Close the ball valve, Item 47, as shown in the Figure B.14. 1. The compressor can be activated in low or high idle. 2.
  • Page 33 AIR VANTAGE 566X HYDRAULIC OPERATION ® CONTROL SAFEGUARDS TO IMPROVE RELIABILITY CONTROL AND INDICATOR FUNCTIONALITY ON/OFF clutch safeguard (Numbers reference the preceding gures) • If the system is on and running and the power switch is pushed 1. The ball valve Item 47 to “OFF”...
  • Page 34 AIR VANTAGE 566X HYDRAULIC OPERATION ® e. Press the left end of the HYDRAULIC PUMP / AIR COMPRESSOR POWER SWITCH (A) to engage power to the HYDRAULIC SYSTEM PRE-START CHECKS AND clutch when the machine is started INITIAL START-UP 1. Ensure all connections are torqued in accordance with manufacturers recommendations.
  • Page 35 AIR VANTAGE 566X HYDRAULIC OPERATION ® FIGURE B.11 HIDDEN SETUP MENU FUNCTIONS HOT START CONTROL Hot start can be set based off weld mode. Non-applicable weld modes will not display hot start. The left display will show “Hot” and “Strt” alternately at 0.5 second intervals.
  • Page 36 AIR VANTAGE 566X HYDRAULIC OPERATION ® TEST MODES FOR GRID LOAD TESTING RESET BACK TO DEFAULT SETTINGS Pressing and holding the hidden reset push button for 5 seconds The left display will show “tESt” and “LoAd” alternately at 0.5 will cause certain stored values to be reset to defaults. The stored second intervals.
  • Page 37 They include important safety NOTE: The duty cycles for the IEC rated output and max output are precautions, detailed engine starting, operating and listed on the front nameplate of the Air Vantage 566X Hydraulic. maintenance instructions and parts lists. ELECTRIC SHOCK can kill.
  • Page 38 AIR VANTAGE 566X HYDRAULIC OPERATION ® WELDER OPERATION HIGH FREQUENCY TIG OPTIONS CC-STICK MODE In general the ‘Touch Start’ feature avoids tungsten contamination The Air Vantage ® 566X Hydraulic can be used with a broad range without the use of a high frequency unit. If the use of a high of DC stick electrodes.
  • Page 39 AIR VANTAGE 566X HYDRAULIC OPERATION ® SETTINGS WHEN USING THE K930-2 TIG MODULE • Set the WELD MODE switch to the TOUCH START TIG setting. • Set the RUN / STOP / IDLE switch to the AUTO IDLE / RUN position.

  • Page 40: Cv-Wire Mode

    AIR VANTAGE 566X HYDRAULIC OPERATION ® CV-WIRE MODE NOTE: If desired the CV-WIRE mode can be used for arc gouging applications. Connect a wire feeder to the Air Vantage ® 566X Hydraulic and set welder controls according to the instructions listed earlier in this section.

  • Page 41: Pulse Welding

    AIR VANTAGE 566X HYDRAULIC OPERATION ® PULSE WELDING UltimArc™ Control Pulse welding procedures are set by controlling an overall “arc UltimArc™ Control adjusts the focus or shape of the arc. length” variable. When pulse welding, the arc voltage is highly UltimArc™...

  • Page 42: Crosslinc

    AIR VANTAGE 566X HYDRAULIC OPERATION ® TABLE B.4 The following modes can be accessed via an ArcLink feeder: Synergic CV Modes Metal- Steel Stainless Flux C ore Alum inu m Cored Diameter Argon Argon Argon CO 2 Tri-M ix Argon M ix 4043 5356 M ix...

  • Page 43: Auxiliary Power Operation

    The current rating of any plug used with the system must be at least equal to the current capacity of the associated receptacle. TABLE B.5 AIR VANTAGE 566X HYDRAULIC SIMULTANEOUS WELDING AND POWER LOADS WELD 1 PHASE...

  • Page 44: Typical Fuel Consumption

    AIR VANTAGE 566X HYDRAULIC OPERATION ® TYPICAL FUEL CONSUMPTION Refer to Table B.7 for typical fuel consumption of the Air Vantage ® 566X Hydraulic Engine for various operating scenarios. TABLE B.7 (Deutz TD2.9L4) Fuel Consumption RUN TIME (HRS.) GAL. / HR. L / HR. WITH FULL TANK* High Idle...

  • Page 45: Accessories

    AIR VANTAGE 566X HYDRAULIC ACCESSORIES ® ACCESSORIES VMAC® Compressor Service Kits One easy-to-purchase kit including all the needed components to perform routine maintenance on the air compressor. CROSSLINC ACCESSORIES Order: KP3406-1 6 Month / 500 Hours LN-25X KP3408-1 12 Month / 1,000 Hours True Voltage Technology (TVT) is now included with the LN-25X Air Filter Kit portable wire feeder.

  • Page 46: Wire Feeders & Guns

    AIR VANTAGE 566X HYDRAULIC ACCESSORIES ® K3416-70 Tweco Style Plug (Male, 1/0 thru 2/0) Hand Amptrol K3416-90 Tweco Style Plug (Male, 3/0 thru 4/0) Remote output control hand control for TIG welding with a 25 ft. (7.6 m) cable featuring a 12-pin connector. Includes hook and K3417-70 Tweco Style Receptacle (Female, 1/0 thru 2/0) Torches.)

  • Page 47: Maintenance

    AIR VANTAGE 566X HYDRAULIC MAINTENANCE ® MAINTENANCE ROUTINE AND PERIODIC MAINTENANCE DAILY SAFETY PRECAUTIONS • Check the engine oil level. READ AND UNDERSTAND ENTIRE SECTION BEFORE • OPERATING MACHINE. tank. • Open the water drain valve located on the bottom of the water WARNING separator element 1 or 2 turns and allow to drain into a container suitable for diesel fuel for 2 to 3 seconds.

  • Page 48: Engine Maintenance

    AIR VANTAGE 566X HYDRAULIC MAINTENANCE ® ENGINE MAINTENANCE Refer to the SERVICE PLAN 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 Delivery System d) Alternator Belt e) Battery f) Cooling System...
  • Page 49 AIR VANTAGE 566X HYDRAULIC MAINTENANCE ® Service Instructions Single- and Two-Stage Engine Air Cleaners Inspect the New Filter for Damage Remove the Filter Inspect the new lter carefully, paying attention to Unfasten or unlatch the the inside of the open end, which is the service cover.

  • Page 50: Fuel Filters

    The coolant system is equipped with an internal expansion tank ------------------------------------------------------------------ located inside the top radiator tank. This allows for normal thermal The Air Vantage 566X Hydraulic is equipped with a fuel pre- lter ® expansion and contraction of the engine coolant. The system is / water separator before the electric lift pump and a fuel lter after the lift pump and before the injectors.

  • Page 51: Battery Handling

    AIR VANTAGE 566X HYDRAULIC MAINTENANCE ® BATTERY HANDLING ENGINE OIL CHANGE Drain the engine oil while the engine is warm to assure rapid and WARNING complete draining. It is recommended that each time the oil is GASES FROM BATTERY can •...

  • Page 52: Tightening The Fan Belt

    AIR VANTAGE 566X HYDRAULIC MAINTENANCE ® TIGHTENING THE FAN BELT If the fan belt is loose, the engine can overheat and the battery lose its charge. Check tightness by pressing on the belt midway between the pulleys. For tightness requirements, please refer to the Engine Owner's Manual.

  • Page 53: Gfci Maintenance

    AIR VANTAGE 566X HYDRAULIC MAINTENANCE ® GFCI MAINTENANCE WARNING • An electric shock can result in serious injury or death. • Always perform the GFCI test before using the generator. If the GFCI system fails the test, the machine must be repaired by an authorized service center.

  • Page 54: Troubleshooting

    AIR VANTAGE 566X HYDRAULIC TROUBLESHOOTING ® TROUBLESHOOTING HOW TO USE TROUBLESHOOTING GUIDE WARNING Service and Repair should only be performed by Lincoln Electric Factory Trained Personnel. Unauthorized repairs performed on this equipment may result in danger to the technician and machine operator and will invalidate your factory warranty.
  • Page 55 AIR VANTAGE 566X HYDRAULIC TROUBLESHOOTING ® Observe all Safety Guidelines detailed throughout this manual PROBLEMS POSSIBLE RECOMMENDED (SYMPTOMS) CAUSE COURSE OF ACTION ENGINE PROBLEMS Major Physical or Electrical Damage . Contact your Local Lincoln is Evident. Authorized Field Service Facility. 1.
  • Page 56 AIR VANTAGE 566X HYDRAULIC TROUBLESHOOTING ® Observe all Safety Guidelines detailed throughout this manual PROBLEMS POSSIBLE RECOMMENDED (SYMPTOMS) CAUSE COURSE OF ACTION FUNCTION PROBLEMS Battery does not stay charged. 1. Faulty battery. 2. Faulty engine alternator. 3. Loose or broken lead in charging circuit.
  • Page 57 AIR VANTAGE 566X HYDRAULIC TROUBLESHOOTING ® Observe all Safety Guidelines detailed throughout this manual PROBLEMS POSSIBLE RECOMMENDED (SYMPTOMS) CAUSE COURSE OF ACTION FUNCTION PROBLEMS Engine goes to low idle but does 1. Faulty Weld Control PCB or Idler not stay at low idle. relay.
  • Page 58 AIR VANTAGE 566X HYDRAULIC WIRING DIAGRAMS ®...
  • Page 59 AIR VANTAGE 566X HYDRAULIC DIMENSION PRINT ®...
  • Page 60 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.

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