Lincoln Electric AIR VANTAGE 800 (AU) CUMMINS Operator's Manual
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Lincoln Electric AIR VANTAGE 800 (AU) CUMMINS Operator's Manual

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Operator's Manual
AIR VANTAGE
Register your machine:
www.lincolnelectric.com/register
Authorized Service and Distributor Locator:
www.lincolnelectric.com/locator
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Date Purchased
Code: (ex: 10859)
Serial: (ex: U1060512345)
IM10339-A
| Issue D ate Aug-17
© Lincoln Global, Inc. All Rights Reserved.
®
800 (AU) CUMMINS
For use with machines having Code Numbers:
12557, 12762
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 800 (AU) CUMMINS

  • Page 1 Operator’s Manual AIR VANTAGE ® 800 (AU) CUMMINS For use with machines having Code Numbers: 12557, 12762 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.
  • 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 W117.2-1974. A Free copy of “Arc Welding Safety” booklet E205 is available from the Lincoln Electric Company, 2.d. All welders should use the following procedures in order to 22801 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 2004/108/EC. It was manufactured in conformity with a national standard that implements a harmonized standard: EN 60974-10 Electromagnetic Compatibility (EMC) Product Standard for Arc Welding Equipment. It is for use with other Lincoln Electric equipment. It is designed for industrial and professional use. Introduction All electrical equipment generates small amounts of electromagnetic emission.
  • Page 7 SAFETY Electromagnetic Compatibility (EMC) The size of the surrounding area to be considered will depend on the structure of the building and other activities that are taking place. The surrounding area may extend beyond the boundaries of the premises. Methods of Reducing Emissions Mains Supply Welding equipment should be connected to the mains supply according to the manufacturer’s recommenda- tions.

  • Page 8: Table Of Contents

    WELDING TERMINALS........................A-5 WELDING OUTPUT CABLES......................A-5 MACHINE GROUNDING........................A-5 REMOTE CONTROL......................... A-6 AUXILIARY POWER RECEPTACLES....................A-6 STANDBY POWER CONNECTIONS ....................A-6 CONNECTION OF LINCOLN ELECTRIC WIRE FEEDERS...............A-8 OPERATION..........................SECTION B GENERAL DESCRIPTION........................B-1 FOR AUXILIARY POWER:........................B-1 ENGINE OPERATION.........................B-1 ADD FUEL............................B-2 HAND PRIMER BUTTON........................B-2 BREAK-IN PERIOD..........................B-2...
  • Page 9 TABLE OF CONTENTS BATTERY HANDLING........................D-4 SERVICING MUFFLER WITH INTERNAL SPARK ARRESTOR..............D-4 NAMEPLATES / WARNING DECALS MAINTENANCE................D-5 WELDER / GENERATOR MAINTENANCE.................... D-5 TROUBLESHOOTING........................SECTION E DIAGRAMS ..........................SECTION F Parts List ......................parts.lincolnelectric.com Content/details may be changed or updated without notice. For most current Instruction Manuals, go to parts.lincolnelectric.com.

  • Page 10: Installation

    AIR VANTAGE ® 800 (AU) CUMMINS INSTALLATION TECHNICAL SPECIFICATIONS - AIR VANTAGE® 800 (AU) CUMMINS (K2961-3) INPUT - DIESEL ENGINE Make/Model Description Speed (RPM) Displacement Starting Dry Capacities cu. in. (ltrs.) System 4 cylinder High Idle 1860 199(3.3) 12VDC Battery & Fuel: 25 gal.

  • Page 11: Vrd (Voltage Reduction Device

    AIR VANTAGE ® 800 (AU) CUMMINS INSTALLATION SAFETY PRECAUTIONS enabled. LOCATION AND VENTILATION The welder should be located to provide an unrestricted flow of WARNING clean, cool air to the cooling air inlets and to avoid restricting the cooling air outlets. Also, locate the welder so that the engine Do not attempt to use this equipment until you have exhaust fumes are properly vented to an outside area.

  • Page 12: Stacking

    AIR VANTAGE ® 800 (AU) CUMMINS INSTALLATION STACKING HIGH ALTITUDE OPERATION ® AIR VANTAGE 800 (AU) CUMMINS machines cannot be stacked. At higher altitudes, output derating may be necessary. For maximum rating, derate the welder output 4% for every 300 ANGLE OF OPERATION meters (984 ft.) above 1500 meters (4920 ft.).

  • Page 13: Pre-Operation Engine And Compressor Service

    AIR VANTAGE ® 800 (AU) CUMMINS INSTALLATION PRE-OPERATION ENGINE AND COMPRESSOR ENGINE COOLANT SERVICE WARNING READ the engine and compressor operating and maintenance instructions supplied with this machine. HOT COOLANT can burn skin. • Do not remove cap if radiator is hot. WARNING •...

  • Page 14: Muffler Outlet Pipe

    AIR VANTAGE ® 800 (AU) CUMMINS INSTALLATION The AIR VANTAGE ® 800 (AU) CUMMINS is shipped with the Listed in Table A.1 are copper cable sizes recommended for the negative battery cable disconnected. Before you operate the rated current and duty cycle. Lengths stipulated are the distance machine, make sure the Engine Switch is in the OFF position and from the welder to work and back to the welder again.

  • Page 15: Remote Control

    AIR VANTAGE ® 800 (AU) CUMMINS INSTALLATION REMOTE CONTROL AUXILIARY POWER RECEPTACLES The AIR VANTAGE ® 800 (AU) CUMMINS is equipped with a 6-pin The auxiliary power capacity of the AIR VANTAGE ® 800 (AU) and a 14-pin connector. The 6-pin connector is for connecting the CUMMINS is 20kVA of 60Hz three phase power protected by an K857 or K857-1 Remote Control or for TIG welding, the K870 foot RCD (Residual Current Device) and a 3 phase 32 amp circuit...
  • Page 16 AIR VANTAGE ® 800 (AU) CUMMINS INSTALLATION WARNING • Only a licensed, certified, trained electrician should install the machine to a premises or residential electrical system. Be certain that: • The installation complies with the National Electrical Code and all other applicable electrical codes. •...

  • Page 17: Connection Of Lincoln Electric Wire Feeders

    INSTALLATION Connection of LN-25 PRO to the AIR VANTAGE 800 (AU) CUMMINS ® CONNECTION OF LINCOLN ELECTRIC WIRE FEEDERS These connections instructions apply to both the LN-25 PRO Across-The-Arc and Control Cable models. The LN-25 PRO has an WARNING internal contactor and the electrode is not energized until the gun trigger is closed.
  • Page 18 AIR VANTAGE ® 800 (AU) CUMMINS INSTALLATION Connection of the LN-25 to the AIR VANTAGE CONNECTION OF AN NA-3 AUTOMATIC WELDING (AU) CUMMINS. SYSTEM TO THE AIR VANTAGE 800 (AU) CUM- ® MINS ® WARNING For connection diagrams and instructions for connecting an NA-3 Welding System to the AIR VANTAGE ®...
  • Page 19 DO NOT USE THESE DEVICES WITH THIS PRODUCT. The Lincoln Electric Company is not responsible for any damage to electrical components improperly connected to this product. A-10...

  • Page 20: Operation

    AIR VANTAGE ® 800 (AU) CUMMINS OPERATION OPERATION GENERAL DESCRIPTION The AIR VANTAGE ® 800 (AU) CUMMINS is a diesel engine-driven welding power source. The machine uses a brush type alternating SAFETY PRECAUTIONS current generator for DC multi-purpose welding, for 240 VAC single phase.

  • Page 21: Add Fuel

    AIR VANTAGE ® 800 (AU) CUMMINS OPERATION ADD FUEL BREAK-IN PERIOD No break in period is required for the Cummins engine. WARNING • Stop engine while fueling. RECOMMENDED APPLICATIONS • Do not smoke when fueling. The AIR VANTAGE ® 800 (AU) CUMMINS provides excellent •...

  • Page 22: Welding Controls

    AIR VANTAGE ® 800 (AU) CUMMINS OPERATION FIGURE B.1 WELDING CONTROLS (FIGURE B.1) When in the TOUCH START TIG mode and when an Amptrol is connected to the 6-Pin Connector, the OUTPUT dial is used to 1. OUTPUT CONTROL- The OUTPUT dial is used to preset the set the maximum current range of the CURRENT CONTROL of output voltage or current as displayed on the digital meters the Amptrol.
  • Page 23 AIR VANTAGE ® 800 (AU) CUMMINS OPERATION 4. ARC CONTROL- The ARC CONTROL dial is active in the CV- enabled. When the machine is first started with VRD enabled, WIRE, CC-STICK and DOWNHILL PIPE modes, and has both lights will illuminate for 5 seconds. different functions in these modes.
  • Page 24 AIR VANTAGE ® 800 (AU) CUMMINS OPERATION ENGINE CONTROLS: When this happens the RUN-STOP switch must be returned to the "OFF" position to reset the engine protection system and 13. RUN/STOP SWITCH - light. -RUN position energizes the engine prior to starting. STOP 4.

  • Page 25: Engine Operation

    AIR VANTAGE ® 800 (AU) CUMMINS OPERATION STOPPING THE ENGINE ENGINE OPERATION STARTING THE ENGINE 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 the fuel valve located on the fuel TYPICAL FUEL CONSUMPTION 1.
  • Page 26 AIR VANTAGE ® 800 (AU) CUMMINS OPERATION B. For Re-Striking Electrodes WELDER OPERATION Some electrodes form a cone at the end of the electrode after the DUTY CYCLE welding arc has been broken, particularly iron powder and low hydrogen electrodes. This cone will need to be broken off in order to have the metal core of the electrode make contact.
  • Page 27 AIR VANTAGE ® 800 (AU) CUMMINS OPERATION TIG WELDING AIR VANTAGE ® 800 (AU) CUMMINS settings when using the K930- 2 TIG Module with an Amptrol or Arc Start Switch: The TOUCH START TIG setting of the MODE switch is for DC TIG •...
  • Page 28 AIR VANTAGE ® 800 (AU) CUMMINS OPERATION WIRE WELDING-CV PARALLELING Connect a wire feeder to the AIR VANTAGE ® 800 (AU) CUMMINS When paralleling machines in order to combine their outputs, all according to the instructions in INSTALLATION INSTRUCTIONS units must be operated in the CC-STICK mode only at the same Section.

  • Page 29: Auxiliary Power Operation

    AIR VANTAGE ® 800 (AU) CUMMINS OPERATION AUXILIARY POWER OPERATION Start the engine and set the IDLER control switch to the desired operating mode. Full power is available regardless of the welding control settings, if no welding current is being drawn. SIMULTANEOUS WELDING AND AUXILIARY POWER LOADS It must be noted that the above auxiliary power ratings are with no...

  • Page 30: Accessories

    AIR VANTAGE ® 800 (AU) CUMMINS ACCESSORIES ACCESSORIES OPTIONAL FIELD INSTALLED ACCESSORIES K2637-2 Medium Trailer K2639-1 Fender Kit K2640-1 Cable Rack K2641-2 Four Wheel Trailer K857 Remote Control K857-1 Remote Control K2642-1 Polarity Multiprocess Switch K2663-1 Docking Kit K2613-5A1 Ln-25 PRO with K126 PRO Gun K126-12 K126 PRO Gun KP1696-068 Drive Roll Kit K12038-2 Invertec PC610 Plasma...

  • Page 31: Maintenance

    AIR VANTAGE ® 800 (AU) CUMMINS MAINTENANCE MAINTENANCE a. Compressor oil and filter. b. Compressor air filter. Safety Precautions c. Compressor coalescing filter. VMAC ™ WARNING (VEHICLE MOUNTED AIR COMPRESSORS) www.vmac.ca/index.php?airvantagemanuals • Have qualified personnel do all maintenance and troubleshooting work. 1333 Kipp Road •...
  • Page 32 AIR VANTAGE ® 800 (AU) CUMMINS MAINTENANCE Service Instructions Service Instructions Single- and Two-Stage Engine Air Cleaners Single- and Two-Stage Engine Air Cleaners Inspect the New Filter for Damage Inspect the New Filter for Damage Remove the Filter Remove the Filter Inspect the new filter carefully, paying attention to Unfasten or unlatch the the inside of the open end, which is the...

  • Page 33: Fuel Filters

    AIR VANTAGE ® 800 (AU) CUMMINS MAINTENANCE FUEL FILTERS FILL COOLANT HERE. REPLACE CAP COMPLETELY WHEN FINISHED. WARNING When working on the fuel system: • Keep naked lights away, do not smoke ! • Do not spill fuel ! The AIR VANTAGE ®...

  • Page 34: Battery Handling

    AIR VANTAGE ® 800 (AU) CUMMINS MAINTENANCE CHARGING THE BATTERY BATTERY HANDLING When you charge, jump, replace, or otherwise connect battery cables to the battery, be sure the polarity is correct. Improper WARNING polarity can damage the charging circuit. The AIR VANTAGE ®...

  • Page 35: Nameplates / Warning Decals Maintenance

    AIR VANTAGE ® 800 (AU) CUMMINS MAINTENANCE 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.

  • Page 36: Troubleshooting

    HOW TO USE TROUBLESHOOTING GUIDE WARNING Service and Repair should only be performed by Lincoln Electric Factory Trained Personnel. Unauthorized repairs per- formed on this equipment may result in danger to the technician and machine operator and will invalidate your factory warranty.
  • Page 37 AIR VANTAGE ® 800 (AU) CUMMINS TROUBLESHOOTING Observe all Safety Guidelines detailed throughout this manual PROBLEMS POSSIBLE RECOMMENDED (SYMPTOMS) CAUSE COURSE OF ACTION Major Physical or Electrical Damage is 1. Contact your local Lincoln Authorized Evident. Field Service Facility. Engine will not crank 1.
  • Page 38 AIR VANTAGE ® 800 (AU) CUMMINS TROUBLESHOOTING Observe all Safety Guidelines detailed throughout this manual PROBLEMS POSSIBLE RECOMMENDED (SYMPTOMS) CAUSE COURSE OF ACTION Battery does not stay charged. 1. Faulty battery . 2. Faulty engine alternator. 3. Loose or broken lead in charging circuit. 4.
  • Page 39 AIR VANTAGE ® 800 (AU) CUMMINS TROUBLESHOOTING Observe all Safety Guidelines detailed throughout this manual PROBLEMS POSSIBLE RECOMMENDED (SYMPTOMS) CAUSE COURSE OF ACTION Welder has some/ no output and no control. 1. Faulty remote kit. Auxiliary output OK. 2. Faulty output control potentiometer. 3.
  • Page 40 AIR VANTAGE ® 800 (AU) CUMMINS DIAGRAMS...
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  • Page 52 AIR VANTAGE ® 800 (AU) CUMMINS DIAGRAMS F-13...
  • Page 54 WARNING Do not touch electrically live parts or Keep flammable materials away. Wear eye, ear and body protection. electrode with skin or wet clothing. Insulate yourself from work and AVISO DE ground. Spanish PRECAuCION No toque las partes o los electrodos Mantenga el material combustible Protéjase los ojos, los oídos y el bajo carga con la piel o ropa moja-...
  • Page 55 WARNING Keep your head out of fumes. Turn power off before servicing. Do not operate with panel open or Use ventilation or exhaust to guards off. remove fumes from breathing zone. AVISO DE Spanish PRECAuCION Los humos fuera de la zona de res- Desconectar el cable de ali- No operar con panel abierto o piración.

  • Page 56: Diagrams

    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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