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IM10041
®
November, 2009
AIR VANTAGE 500 CUMMINS
For use with machine having Code Number: 11679
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, OPER-
ATE OR REPAIR THIS EQUIP-
MENT WITHOUT READING
THIS MANUAL AND THE SAFE-
TY PRECAUTIONS CONTAINED
THROUGHOUT. And, most
importantly, think before you act
and be ca
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i i SAFETY WARNING CALIFORNIA PROPOSITION 65 WARNINGS Diesel engine exhaust and some of its constituents The engine exhaust from this product contains are known to the State of California to cause can- chemicals known to the State of California to cause cer, birth defects, and other reproductive harm. cancer, birth defects, or other reproductive harm. The Above For Diesel Engines The Above For Gasoline Engines ARC WELDING CAN BE HAZARDOUS. PROTECT YOURSELF AND OTHERS FROM POSSIBLE SERIOUS INJURY
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ii ii SAFETY ARC RAYS can burn. ELECTRIC SHOCK can 4.a. Use a shield with the proper filter and cover kill. plates to protect your eyes from sparks and 3.a. The electrode and work (or ground) circuits the rays of the arc when welding or observing are electrically “hot” when the welder is on. open arc welding. Headshield and filter lens Do not touch these “hot” parts with your bare should conform to ANSI Z87. I standards. skin or wet clothing. Wear dry, hole-free gloves to insulate hands. 4.b. Us
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iii iii SAFETY WELDING and CUTTING CYLINDER may explode SPARKS can if damaged. cause fire or explosion. 7.a. Use only compressed gas cylinders 6.a. Remove fire hazards from the welding area. containing the correct shielding gas for the If this is not possible, cover them to prevent process used and properly operating the welding sparks from starting a fire. regulators designed for the gas and Remember that welding sparks and hot pressure used. All hoses, fittings, etc. should be suitable for mat
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iv iv SAFETY PRÉCAUTIONS DE SÛRETÉ 6. Eloigner les matériaux inflammables ou les recouvrir afin de prévenir tout risque d’incendie dû aux étincelles. Pour votre propre protection lire et observer toutes les instructions et les précautions de sûreté specifiques qui parraissent dans ce 7. Quand on ne soude pas, poser la pince à une endroit isolé de manuel aussi bien que les précautions de sûreté générales suiv- la masse. Un court-circuit accidental peut provoquer un antes: échauffement et un risqu
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v v SAFETY Electromagnetic 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 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 El
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vi vi 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. If interference occurs, it may be necessary to take additional precautions such as filter
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vii vii for selecting a QUALITY product by Lincoln Electric. We want you to take pride in operating this Lincoln Electric Company product T Th ha an nk k Y Yo ou u ••• as much pride as we have in bringing this product to you! CUSTOMER ASSISTANCE POLICY 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, pur
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viii viii TABLE OF CONTENTS Page Installation.......................................................................................................................Section A Technical Specifications.......................................................................................................A-1 Safety Precautions ........................................................................................................A-2 Location and Ventilation...........................................
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ix ix TABLE OF CONTENTS Accessories........................................................................................................Section c Optional Field Installed Accessories......................................................................C-1 ________________________________________________________________________ Maintenance.......................................................................................................Section D Safety Precautions .........................
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A-1 A-1 INSTALLATION TECHNICAL SPECIFICATIONS - AIR VANTAGE® 500 CUMMINS (K32012) INPUT - DIESEL ENGINE 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 Stroke inch (mm) Oil: 2 gal. (7.5L) Diesel Engine Low Idle 1425 3.74 X 4.53 Radiator Coolant: (95 x 115mm) 2.6gal. (9.8L) RATED OUTPUT @ 104°F(40
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A-2 A-2 INSTALLATION SAFETY PRECAUTIONS LOCATION AND VENTILATION WARNING The welder should be located to provide an unrestrict- ed flow of clean, cool air to the cooling air inlets and to Do not attempt to use this equipment until you avoid restricting the cooling air outlets. Also, locate have thoroughly read the engine manufacturer’s the welder so that the engine exhaust fumes are prop- manual supplied with your welder. It includes erly vented to an outside area. important safety precaution
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A-3 A-3 INSTALLATION TOWING LIFTING The recommended trailer for use with this equipment The AIR VANTAGE® 500 lift bale should be used to lift (1) for road, in-plant and yard towing by a vehicle is the machine. The Air Vantage 500 is shipped with the Lincoln’s K2636-1. If the user adapts a non-Lincoln lift bale retracted. Before attempting to lift the AIR VAN- trailer, he must assume responsibility that the method TAGE® 500 the lift bale must be secured in a raised of attachment and usage does
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A-4 A-4 INSTALLATION PRE-OPERATION ENGINE AND COM- ENGINE COOLANT PRESSOR 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 • Keep hands away from the engine ------------------------------------------------------------------------ muffler or HOT engine parts. The welder is shipped with the engine and radiator • Stop engine and allow to cool before filled wi
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A-5 A-5 INSTALLATION The AIR VANTAGE® 500 is shipped with the negative Listed in Table A.1 are copper cable sizes recom- battery cable disconnected. Before you operate the mended for the rated current and duty cycle. Lengths machine, make sure the Engine Switch is in the OFF stipulated are the distance from the welder to work position and attach the disconnected cable securely to and back to the welder again. Cable sizes are the negative (-) battery terminal. increased for greater lengths pri
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A-6 A-6 INSTALLATION REMOTE CONTROL STANDBY POWER CONNECTIONS The AIR VANTAGE® 500 is equipped with a 6-pin and a 14-pin connector. The 6-pin connector is for The AIR VANTAGE® 500 is suitable for temporary, connecting the K857 or K857-1 Remote Control or for standby or emergency power using the engine manu- TIG welding, the K870 foot Amptrol or the K963-3 facturer’s recommended maintenance schedule. hand Amptrol. When in the CC-STICK or CV-WIRE modes and when a remote control is connected to
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A-7 A-7 INSTALLATION • Set the "WELD TERMINALS" switch to "WELD CONNECTION OF LINCOLN ELEC- TERMINALS ON". TRIC WIRE FEEDERS • When the gun trigger is closed, the current sens- WARNING ing circuit will cause the AIR VANTAGE® 500 engine to go to the high idle speed, the wire will Shut off welder before making any electrical con- begin to feed and the welding process started. nections. When welding is stopped, the engine will revert to low idle speed after approximately 12 seconds -------------
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A-8 A-8 INSTALLATION CONNECTION OF THE LN-25 TO THE AIR CONNECTION OF AN NA-3 AUTOMATIC VANTAGE® 500. WELDING SYSTEM TO THE AIR VAN- TAGE® 500 WARNING For connection diagrams and instructions for connect- ing an NA-3 Welding System to the AIR VANTAGE® Shut off welder before making any electrical con- 500, refer to the NA-3 Welding System instruction nections. manual. The connection diagram for the LN-8 can be -------------------------------------------------------------------------- used for
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B-1 B-1 OPERATION RECOMMENDED APPLICATIONS SAFETY PRECAUTIONS The AIR VANTAGE® 500 provides excellent constant Read and understand this entire section before current DC welding output for stick (SMAW) and TIG operating your AIR VANTAGE® 500. welding. The AIR VANTAGE® 500 also provides excellent constant voltage DC welding output for MIG WARNING (GMAW), Innershield (FCAW), Outershield (FCAW-G) and Metal Core welding. In addition the AIR VAN- TAGE® 500 can be used for Arc Gouging with car- Do not
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B-2 B-2 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. FIGURE B.1 6 4 5 7 12 14 8 9 10 13 11 16 25 15 21 24 21 19 26 2 27 1 22 17 3 18 23 20 28 29 30 31 ENGINE CONTROLS (Items 1 through 9) 4. HOUR METER 1. RUN STOP SWITCH The hour meter displays the total time that the engine has been running. This meter is a useful Toggling the switch to the RUN position energizes ind
