Lincoln Electric AIR VANTAGE IM10065 Operator's Manual
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Lincoln Electric AIR VANTAGE IM10065 Operator's Manual

Lincoln Electric AIR VANTAGE IM10065 Operator's Manual

Air vent inc. welding system user manual
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RETURN TO MAIN MENU
IM10065
®
AIR VANTAGE 500 CUMMINS
November, 2010
11651
For use with machine having Code Number:
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 READ-
ING THIS MANUAL AND THE
SAFETY PRECAUTIONS CON-
TAINED THROUGHOUT. And,
most importantly, think before
you act and be careful.
OPERATOR'S MANUAL
Copyright © Lincoln Global Inc.
• World's Leader in Welding and Cutting Products •
• Sales and Service through Subsidiaries and Distributors Worldwide •
Cleveland, Ohio 44117-1199 U.S.A. TEL: 216.481.8100 FAX: 216.486.1751 WEB SITE: www.lincolnelectric.com

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Summary of Contents for Lincoln Electric AIR VANTAGE IM10065

  • Page 1 RETURN TO MAIN MENU IM10065 ® AIR VANTAGE 500 CUMMINS November, 2010 11651 For use with machine having Code Number: 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 ...

  • Page 2: California Proposition 65 Warnings

    CALIFORNIA PROPOSITION 65 WARNINGS Diesel engine exhaust and some of its constituents are known to the State of California to cause can- cer, birth defects, and other reproductive harm. The Above For Diesel Engines ARC WELDING CAN bE HAzARDOUS. PROTECT YOURSELF AND OTHERS FROM POSSIbLE SERIOUS INJURY OR DEATH. KEEP CHILDREN AWAY.
  • Page 3 SAFETY...
  • Page 4 SAFETY...
  • Page 5 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.
  • Page 6 SAFETY AIR VANTAGE® 500 CUMMINS...
  • Page 7 SAFETY AIR VANTAGE® 500 CUMMINS...
  • Page 8 Thank You The business of The Lincoln Electric Company is manufacturing and selling high quality welding equipment, consumables, and cutting equip- ment. 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.

  • Page 9: Table Of Contents

    TAbLE OF CONTENTS Installation...Section A Technical Specifications ...A-1 Safety Precautions ...A-2 Location and Ventilation ...A-2 Storing ...A-2 Stacking ...A-2 Angle of Operation ...A-2 Lifting...A-3 High Altitude Operation ...A-3 High Temperature Operation ...A-3 Towing...A-3 Vehicle Mounting...A-3 Pre-Operation Engine and Compressor Service ...A-4 Oil ...A-4 Fuel and Fuel Cap...A-4 Engine Coolant System...A-4...
  • Page 10 Accessories...Section c Optional Field Installed Accessories...C-1 ________________________________________________________________________ Maintenance...Section D Safety Precautions ...D-1 Routine and Periodic Maintenance ...D-1 Compressor Maintenance ...D-1 Engine Maintenance...D-1 Air Filter...D-1, D-2 Fuel Filters ...D-3 Cooling System...D-3 Battery Handling ...D-3 Charging the Battery ...D-3 Nameplate / Warning Decal Maintenance ...D-4 Welder / Generator Maintenance ...D-4 GFCI Receptacle Testing and Reseting Procedure ...D-4 Engine Maintenance Components ...D-4...

  • Page 11: Technical Specifications

    TECHNICAL SPECIFICATIONS - AIR VANTAGE® 500 CUMMINS (K2325-3) Make/Model Description 4 cylinder Cummins 56 HP (42kw) B3.3 1800 RPM Diesel Engine RATED OUTPUT @ 104°F(40°C) - WELDER Duty Cycle 100% OUTPUT @ 104°F(40°C) - WELDER AND GENERATOR Compressor Model Description VMAC™...

  • Page 12: Safety Precautions

    SAFETY PRECAUTIONS WARNING 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 and maintenance instructions, and parts lists. ------------------------------------------------------------------------ ELECTRIC SHOCK can kill. •...

  • Page 13: Lifting

    LIFTING The AIR VANTAGE® 500 CUMMINS 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 VANTAGE® 500 CUMMINS the lift bale must be secured in a raised position. Secure the lift bale as follows: a.

  • Page 14: Pre-Operation Engine And Compressor Service

    PRE-OPERATION ENGINE AND COM- PRESSOR SERVICE READ the engine and compressor operating and maintenance instructions supplied with this machine. WARNING • Keep hands away from the engine muffler or HOT engine parts. • Stop engine and allow to cool before fuelling.

  • Page 15: Muffler Outlet Pipe

    The AIR VANTAGE® 500 CUMMINS 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.

  • Page 16: Remote Control

    REMOTE CONTROL The AIR VANTAGE® 500 CUMMINS 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 connected to the 6-pin Connector, the auto-sensing circuit automatically switches the OUTPUT control from control at the...
  • Page 17 2. Take necessary steps to assure load is limited to the capacity of the AIR VANTAGE® 500 CUMMINS by installing a 50 amp, 240 VAC double pole circuit breaker. Maximum rated load for each leg of the 240 VAC auxiliary is 50 amps. Loading above the rated output will reduce output voltage below the allowable -10% of rated voltage which may damage appliances or other motor-driven equipment and...

  • Page 18: Connection Of Lincoln Electric Wire Feeders

    CONNECTION OF LINCOLN ELEC- TRIC WIRE FEEDERS WARNING Shut off welder before making any electrical con- nections. ------------------------------------------------------------------------ Connection of LN-7, LN-8 OR LN-742 to the AIR VANTAGE® 500 CUMMINS 1. Shut the welder off. 2. Connect the LN-7, LN-8 OR LN-742 per instruc- tions on the appropriate connection diagram in Section F.
  • Page 19 CONNECTION OF THE LN-25 TO THE AIR VANTAGE® 500 CUMMINS. WARNING Shut off welder before making any electrical con- nections. -------------------------------------------------------------------------- The LN-25 with or without an internal contactor may be used with the AIR VANTAGE® 500 CUMMINS. See the appropriate connection diagram in Section F.

  • Page 20: Operation

    SAFETY PRECAUTIONS Read and understand this entire section before operating your AIR VANTAGE® 500 CUMMINS. WARNING 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- ing and maintenance instructions, and parts lists.

  • Page 21: Controls And Settings

    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. 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.

  • Page 22: Engine Protection

    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 oper- ating temperatures. If the light turns on, the engine protection system will stop the engine.

  • Page 23: Auxiliary Power Controls

    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 OUT- PUT control knob. During welding, the meters display the actual output voltage (VOLTS) and current (AMPS).

  • Page 24: Air Compressor Controls

    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 recepta- cle, the 120VAC in the 14-Pin connector, the 42VAC in the 14-Pin connector and battery circuit overload protection.

  • Page 25: Engine Operation

    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.

  • Page 26: Duty Cycle

    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®...

  • Page 27: Wire Welding-Cv

    WIRE WELDING-CV Connect a wire feeder to the AIR VANTAGE® 500 CUMMINS according to the instructions in INSTALLA- TION INSTRUCTIONS Section. The AIR VANTAGE® 500 CUMMINS 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).

  • Page 28: Paralleling

    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 errat- ic outputs, and large output imbalances between the units.

  • Page 29: Optional Field Installed Accessories

    OPTIONAL FIELD INSTALLED ACCESSORIES 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 house- hold receptacles.

  • Page 30: Maintenance

    SAFETY PRECAUTIONS WARNING • Have qualified personnel do all maintenance and troubleshooting work. • Turn the engine off before working inside the machine or servicing the engine. • Remove guards only when necessary to perform maintenance and replace them when the maintenance requiring their removal is complete.
  • Page 31 Single- and Two-Stage Engine Air Cleaners Single- and Two-Stage Engine Air Cleaners Remove the Filter Remove the Filter Unfasten or unlatch the service cover. Because the filter fits tightly over the outlet tube to create the critical seal, there will be some initial resistance, similar to breaking Rotate the the seal on a jar.

  • Page 32: Fuel Filters

    FUEL FILTERS WARNING When working on the fuel system: • Keep naked lights away, do not smoke ! • Do not spill fuel ! ------------------------------------------------------------------------- The AIR VANTAGE® 500 CUMMINS is equipped with a Fuel Filter located after the lift pump and before fuel injectors.The procedure for changing the filter is as fol- lows.

  • Page 33: Nameplate / Warning Decal Maintenance

    NAMEPLATES / WARNING DECALS MAIN- TENANCE 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 34: How To Use Troubleshooting Guide

    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.
  • Page 35 Observe all Safety Guidelines detailed throughout this manual 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.
  • Page 36 Observe all Safety Guidelines detailed throughout this manual 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.
  • Page 37 Observe all Safety Guidelines detailed throughout this manual 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 No auxiliary power.

  • Page 38: Wiring Diagram

    WIRING DIAGRAM AIR VANTAGE® 500 CUMMINS...
  • Page 39 DIAGRAMS AIR VANTAGE® 500 CUMMINS...
  • Page 40 DIAGRAMS AIR VANTAGE® 500 CUMMINS...
  • Page 41 DIAGRAMS AIR VANTAGE® 500 CUMMINS...
  • Page 42 DIAGRAMS AIR VANTAGE® 500 CUMMINS...
  • Page 43 DIAGRAMS AIR VANTAGE® 500 CUMMINS...
  • Page 44 DIAGRAMS AIR VANTAGE® 500 CUMMINS...
  • Page 45 DIAGRAMS AIR VANTAGE® 500 CUMMINS...
  • Page 46 DIAGRAMS AIR VANTAGE® 500 CUMMINS...
  • Page 47 F-10 F-10 DIAGRAMS AIR VANTAGE® 500 CUMMINS...
  • Page 48 F-11 F-11 DIAGRAMS AIR VANTAGE® 500 CUMMINS...
  • Page 49 F-12 F-12 DIAGRAMS AIR VANTAGE® 500 CUMMINS...

  • Page 50: Dimension Print

    F-13 F-13 DIMENSION PRINT AIR VANTAGE® 500 CUMMINS...
  • Page 51 NOTES AIR VANTAGE® 500 CUMMINS...
  • Page 54 • World's Leader in Welding and Cutting Products • • Sales and Service through Subsidiaries and Distributors Worldwide • Cleveland, Ohio 44117-1199 U.S.A. TEL: 216.481.8100 FAX: 216.486.1751 WEB SITE: www.lincolnelectric.com...

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