RETURN TO MAIN MENU IM10066 ® AIR VANTAGE 500 (AU) For use with machine having Code Number: November, 2010 11656 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 READING THIS MANUAL AND THE SAFETY PRECAUTIONS CONTAINED THROUGHOUT.
i i SAFETY WARNING CALIFORNIA PROPOSITION 65 WARNINGS Diesel engine exhaust and some of its constituents are known to the State of California to cause cancer, birth defects, and other reproductive harm. The Above For Diesel Engines The engine exhaust from this product contains chemicals known to the State of California to cause cancer, birth defects, or other reproductive harm. The Above For Gasoline Engines ARC WELDING CAN bE HAzARDOUS.
ii ii SAFETY ELECTRIC SHOCK can kill. 3.a. The electrode and work (or ground) circuits are electrically “hot” when the welder is on. Do not touch these “hot” parts with your bare skin or wet clothing. Wear dry, hole-free gloves to insulate hands. 3.b. Insulate yourself from work and ground using dry insulation. Make certain the insulation is large enough to cover your full area of physical contact with work and ground.
iii iii SAFETY WELDING and CUTTING SPARKS can cause fire or explosion. 6.a. Remove fire hazards from the welding area. If this is not possible, cover them to prevent the welding sparks from starting a fire. Remember that welding sparks and hot materials from welding can easily go through small cracks and openings to adjacent areas. Avoid welding near hydraulic lines. Have a fire extinguisher readily available. 6.b.
iv SAFETY 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 suivantes: Sûreté Pour Soudage A L’Arc 1. Protegez-vous contre la secousse électrique: a. Les circuits à l’électrode et à la piéce sont sous tension quand la machine à souder est en marche.
v SAFETY Electromagnetic Compatibility (EMC) Conformance Products displaying the CE mark are in conformity with European Community Council Directive of 15 Dec 2004 on the approximation of the laws of the Member States relating to electromagnetic compatibility, 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.
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 recommendations.
vii vii Thank You 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! CUSTOMER ASSISTANCE POLICY The business of The Lincoln Electric Company is manufacturing and selling high quality welding equipment, consumables, and cutting equipment. Our challenge is to meet the needs of our customers and to exceed their expectations.
viii viii TAbLE OF CONTENTS Page Installation.......................................................................................................................Section A Technical Specifications .......................................................................................................A-1 Safety Precautions ........................................................................................................A-2 Location and Ventilation ....................................................
ix TAbLE OF CONTENTS Accessories........................................................................................................Section c Optional Field Installed Accessories......................................................................C-1 ________________________________________________________________________ Maintenance.......................................................................................................Section D Safety Precautions .......................................
A-1 A-1 INSTALLATION TECHNICAL SPECIFICATIONS - AIR VANTAGE® 500 (AU) (K32012-1) INPUT - DIESEL ENGINE Make/Model Cummins B3.3 Description Speed (RPM) Displacement cu. in. (ltrs.) Starting System 4 cylinder 56 HP (42kw) 1800 RPM Diesel Engine High Idle 1900 199(3.3) 12VDC Battery & starter Full Load 1800 Bore x Stroke inch (mm) Low Idle 1425 3.74 X 4.53 Capacities Fuel: 25 gal. (94.6 L) Oil: 2 gal. (7.5L) Radiator Coolant: 2.6gal. (9.
A-2 A-2 INSTALLATION SAFETY PRECAUTIONS LOCATION AND VENTILATION 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. • Do not touch electrically live parts or electrode with skin or wet clothing.
A-3 A-3 INSTALLATION LIFTING TOWING The AIR VANTAGE® 500 (AU) 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 (AU) the lift bale must be secured in a raised position. Secure the lift bale as follows: The recommended trailer for use with this equipment for road, in-plant and yard towing by a vehicle (1) is Lincoln’s K2636-1.
A-4 A-4 INSTALLATION PRE-OPERATION ENGINE AND COMPRESSOR SERVICE ENGINE COOLANT 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. • Stop engine and allow to cool before fuelling. • Do not smoke when fuelling.
A-5 A-5 INSTALLATION The AIR VANTAGE® 500 (AU) 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. Replace and tighten negative battery cable terminal.
A-6 INSTALLATION A-6 REMOTE CONTROL The AIR VANTAGE® 500 (AU) is equipped with a 6pin 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 welder to remote control.
A-7 INSTALLATION CONNECTION OF LINCOLN ELECTRIC WIRE FEEDERS WARNING Shut off welder before making any electrical connections. -----------------------------------------------------------------------Connection of LN-7, LN-8 OR LN-742 to the AIR VANTAGE® 500 (AU) 1. Shut the welder off. A-7 • Set the "WELD TERMINALS" switch to "WELD TERMINALS ON".
A-8 INSTALLATION CONNECTION OF THE LN-25 TO THE AIR VANTAGE® 500 (AU). WARNING Shut off welder before making any electrical connections. -------------------------------------------------------------------------The LN-25 with or without an internal contactor may be used with the AIR VANTAGE® 500 (AU). See the appropriate connection diagram in Section F. NOTE: The LN-25 (K431) Remote Control Module and (K432) Remote Cable are not recommended for use with the AIR VANTAGE® 500 (AU). 1. Shut the welder off.
b-1 OPERATION b-1 RECOMMENDED APPLICATIONS SAFETY PRECAUTIONS Read and understand this entire section before operating your AIR VANTAGE® 500 (AU). 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.
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 32 31 30 29 20 23 18 3 17 22 1 28 2 27 19 26 21 24 21 15 25 16 11 13 10 14 9 12 4 5 6 7 33 8 12 4 6 5 8 7 33 9 14 10 13 11 16 25 15 21 24 21 26 19 27 2 28 1 22 17 3 18 23 20 29 30 31 32 ENGINE CONTROLS (Items 1 through 9) 1.
b-3 OPERATION Idler Operational exceptions 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 operating temperatures. If the light turns on, the engine protection system will stop the engine. Check for proper oil level and add oil if necessary. Check for loose or disconnected leads at the oil pressure sender located on the engine.
b-4 OPERATION 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 CONTROL knob sets the short circuit current (arcforce) during stick welding.
b-5 b-5 OPERATION 23. GROUND STUD: Provides a connection point for connecting the machine case to earth ground. Refer to “MACHINE GROUNDING” in the Installation chapter for proper machine grounding information. 24. RCD: “Residual Current Device” provides protection from active to ground contact. RCD will not protect against electrical shock resulting from contact with active and neutral wires. bATTERY JUMP START TERMINAL (30-31) 30. POSITIVE bATTERY JUMP START TERMINAL. 31.
b-6 OPERATION WHAT 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 electric shock such as wet areas and hot humid sweaty conditions. VRD and ROCV are abbreviations for two different safety devices used in a welding power source to help protect the operator from electric shocks.
b-7 b-7 OPERATION Unlike other VRD’s Lincoln uses micro processor control to monitor and establish the arc without the sticking 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 between the metal core of the electrode and the job. Any damaged connection anywhere in the output circuit may limit the operation of the VRD.
b-8 OPERATION WELDER OPERATION b-8 The AIR VANTAGE® 500 (AU) is equipped with the required R.F. bypass circuitry for the connection of high frequency generating equipment. 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® 500 (AU) can be used with a broad range of DC stick electrodes.
b-9 b-9 OPERATION WIRE WELDING-CV ARC GOUGING Connect a wire feeder to the AIR VANTAGE® 500 (AU) (AU)according to the instructions in INSTALLATION INSTRUCTIONS Section. For optimal performance when arc gouging, set the AIR VANTAGE® 500 (AU) “WELD MODE” switch to the “CC - STICK” position, and the “ARC CONTROL” to 10.
b-10 b-10 OPERATION PARALLELING SIMULTANEOUS WELDING AND AUXILIARY POWER LOADS 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 erratic outputs, and large output imbalances between the units. It must be noted that the above auxiliary power ratings are with no welding load.
C-1 ACCESSORIES OPTIONAL FIELD ACCESSORIES INSTALLED K857 25 ft. (7.5 m) or K857-1 100 ft. (30.4 m) REMOTE CONTROL - Portable control provides same dial range as the output control on the welder from a location up to the specified length from the welder. Has convenient plug for easy connection to the welder. The AIR VANTAGE® 500 (AU)is equipped with a 6-pin connector for connecting the remote control.
D-1 D-1 MAINTENANCE SAFETY PRECAUTIONS VMAC™ WARNING (VEHICLE MOUNTED AIR COMPRESSORS) • 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. If guards are missing from the machine, obtain replacements from a Lincoln Distributor. (See Operating Manual Parts List.) WWW.
D-2 D-2 MAINTENANCE Service Instructions Single- and Two-Stage Engine Air Cleaners Inspect the New Filter for Damage Remove the Filter Rotate the filter while pulling straight out. 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 the seal on a jar. Gently move the end of the filter back and forth to break the seal then rotate while pulling straight out.
D-3 D-3 MAINTENANCE FUEL FILTERS bATTERY HANDLING GASES FROM bATTERY can explode. WARNING When working on the fuel system: • Keep sparks, flame and cigarettes away from battery. • Keep naked lights away, do not smoke ! To prevent EXPLOSION when: • Do not spill fuel ! ------------------------------------------------------------------------The AIR VANTAGE® 500 (AU) is equipped with a Fuel Filter located after the lift pump and before fuel injectors.The procedure for changing the filter is as follows.
D-4 D-4 MAINTENANCE CHARGING THE bATTERY When you charge, jump, replace, or otherwise connect battery cables to the battery, be sure the polarity is correct. Improper polarity can damage the charging circuit. The AIR VANTAGE® 500 (AU) positive (+) battery terminal has a red terminal cover. If you need to charge the battery with an external charger, disconnect the negative cable first, then the positive cable before you attach the charger leads.
E-1 TROUbLESHOOTING E-1 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. For your safety and to avoid Electrical Shock, please observe all safety notes and precautions detailed throughout this manual.
E-2 E-2 TROUbLESHOOTING Observe all Safety Guidelines detailed throughout this manual PRObLEMS (SYMPTOMS) POSSIbLE CAUSE RECOMMENDED COURSE OF ACTION Major Physical or Electrical Damage 1. Contact your local Lincoln is Evident. Authorized Field Service Facility. Engine will not crank 1. Battery low. 2. Loose battery cable connections which may need Inspected, cleaned or tighten. 3. Faulty wiring in engine starting circuit. 4. Faulty engine starter. Contact authorized local Engine Service Shop. 5.
E-3 E-3 TROUbLESHOOTING Observe all Safety Guidelines detailed throughout this manual PRObLEMS (SYMPTOMS) Battery does not stay charged. POSSIbLE CAUSE RECOMMENDED COURSE OF ACTION 1. Faulty battery . 2. Faulty engine alternator. 3. Loose or broken lead in charging circuit. 4. Loose fan belt may need tightening. Engine will not idle down to low 1. Idler switch in HIGH idle position, speed. make sure switch is set to AUTO. 2. External load on welder or auxiliary power. 3.
E-4 E-4 TROUbLESHOOTING Observe all Safety Guidelines detailed throughout this manual PRObLEMS (SYMPTOMS) POSSIbLE CAUSE RECOMMENDED COURSE OF ACTION Engine goes to low idle but does not 1. Faulty Peripheral PCB, Pull stay at low idle. Coil/Battery PCB or Weld Control PCB. No welding output or auxiliary output. 1. 2. 3. 4. Broken lead in rotor circuit. Faulty field diode module. Faulty Weld Control PCB. Faulty rotor. Welder has some/ no output and no 1. Faulty remote kit. control.
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 AIR VANTAGE® 500 (AU) F-2
AIR VANTAGE® 500 (AU) TO WORK K867 UNIVERSAL ADAPTER PLUG 77 76 75 GND 21 4 2 32 31 41 42 81 82 SPARE } N.E. 21 4 2 32 31 77 76 75 GND N.D. GREEN or service this equipment. Only qualified personnel should install,use Keep away from moving parts. Keep guards in place. N.E. SPLICE LEADS AND INSULATE. N.D. INSULATE EACH UNUSED LEAD INDIVIDUALLY. N.C. IF OPTIONAL REMOTE OUTPUT CONTROL IS USED,CONTROL IS AUTOMATICALLY SWITCHED TO REMOTE CONTROL.
F-4 DIAGRAMS AIR VANTAGE® 500 (AU) F-4
F-5 DIAGRAMS AIR VANTAGE® 500 (AU) F-5
AIR VANTAGE® 500 (AU) TO WORK ADAPTER PLUG K867 UNIVERSAL 77 76 75 GND 21 4 2 32 31 41 42 81 82 SPARE } N.D. N.C. C B A GND 21 4 2 32 31 or service this equipment. Only qualified personnel should install,use Keep away from moving parts. Keep guards in place. N.D. SPLICE LEADS AND INSULATE. N.C. INSULATE EACH UNUSED LEAD INDIVIDUALLY. N.A. WELDING CABLE MUST BE OF PROPER CAPACITY FOR THE CURRENT AND DUTY CYCLE OF IMMEDIATE AND FUTURE APPICATIONS. SEE OPERATING MANUAL. N.B.
F-7 DIAGRAMS AIR VANTAGE® 500 (AU) F-7
F-8 DIAGRAMS AIR VANTAGE® 500 (AU) F-8
F-9 DIAGRAMS AIR VANTAGE® 500 (AU) F-9
F-10 DIAGRAMS AIR VANTAGE® 500 (AU) F-10
F-11 DIAGRAMS 2 9/03 30/9 2 F-11 AIR VANTAGE® 500 (AU)
F-12 DIAGRAMS AIR VANTAGE® 500 (AU) F-12
AIR VANTAGE® 500 (AU) 28.99 736.3 9.10 231.1 63.10 1602.7 50.38 1279.7 54.44 1382.8 BOTTOM VIEW OF WELDER BASE. 19.63 498.6 23.69 601.7 32.08 814.8 36.13 917.7 52.52 42.35 1334 1075.7 45.38 1152.7 37.30 947.4 * 14.63 371.6 * * 6.53 165.9 * 24.97 634.2 6.55 166.4 6.56 166.6 N.A. 48.92 1242.6 45.67 1160 31.50 800.1 * TRAILER MOUNTING HOLE LOCATIONS. B 05.13 1.008 81.3 8.08 42.2 9.65 76.54 0611 .SNOITACOL ELOH GNITNUOM RELIART * 29.84 6.2421 65.6 6.661 .A.N 55.6 4.661 35.6 9.
NOTES AIR VANTAGE® 500 (AU)
• Do not touch electrically live parts or WARNING Spanish AVISO DE PRECAUCION French ATTENTION German WARNUNG Portuguese ATENÇÃO • Keep flammable materials away. • Wear eye, ear and body protection. • Mantenga el material combustible • Protéjase los ojos, los oídos y el electrode with skin or wet clothing. • Insulate yourself from work and ground. • No toque las partes o los electrodos bajo carga con la piel o ropa mojada. • Aislese del trabajo y de la tierra.
• Keep your head out of fumes. • Use ventilation or exhaust to • Turn power off before servicing. • Do not operate with panel open or guards off. remove fumes from breathing zone. • Los humos fuera de la zona de res- piración. • Mantenga la cabeza fuera de los humos. Utilice ventilación o aspiración para gases. • Gardez la tête à l’écart des fumées. • Utilisez un ventilateur ou un aspira- • Desconectar el cable de ali- mentación de poder de la máquina antes de iniciar cualquier servicio.
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