Operator’s Manual AIR VANTAGE 600 SD ® For use with machines having Code Numbers: 11984 Register your machine: www.lincolnelectric.com/register Authorized Service and Distributor Locator: www.lincolnelectric.com/locator 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. Save for future reference Date Purchased After hours? Use “Ask the Experts” at lincolnelectric.com A Lincoln Service Representative will contact you no later than the following business day. Code: (ex: 10859) For Service outside the USA: Email: [email protected] Serial: (ex: U1060512345) IM10179 | Issue Date Jun-16 © Lincoln Global, Inc. All Rights Reserved. THANK YOU FOR SELECTING A QUALITY PRODUCT BY LINCOLN ELECTRIC. Please examine Carton and equiPment For damage immediately When this equipment is shipped, title passes to the purchaser upon receipt by the carrier. Consequently, Claims for material damaged in shipment must be made by the purchaser against the transportation company at the time the shipment is received. 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. And, most importantly, think before you act and be careful. WARNING This statement appears where the information must be followed exactly to avoid serious personal injury or loss of life. CAUTION This statement appears where the information must be followed to avoid minor personal injury or damage to this equipment. KeeP your head out oF the Fumes. DON’T get too close to the arc. Use corrective lenses if necessary to stay a reasonable distance away from the arc. READ and obey the Material Safety Data Sheet (MSDS) and the warning label that appears on all containers of welding materials. USE ENOUGH VENTILATION or exhaust at the arc, or both, to keep the fumes and gases from your breathing zone and the general area. IN A LARGE ROOM OR OUTDOORS, natural ventilation may be adequate if you keep your head out of the fumes (See below). USE NATURAL DRAFTS or fans to keep the fumes away from your face. If you develop unusual symptoms, see your supervisor. Perhaps the welding atmosphere and ventilation system should be checked. wear CorreCt eye, ear & body ProteCtion PROTECT your eyes and face with welding helmet properly fitted and with proper grade of filter plate (See ANSI Z49.1). PROTECT your body from welding spatter and arc flash with protective clothing including woolen clothing, flame-proof apron and gloves, leather leggings, and high boots. PROTECT others from splatter, flash, and glare with protective screens or barriers. IN SOME AREAS, protection from noise may be appropriate. BE SURE protective equipment is in good condition. Also, wear safety glasses in work area AT ALL TIMES. SPECIAL SITUATIONS DO NOT WELD OR CUT containers or materials which previously had been in contact with hazardous substances unless they are properly cleaned. This is extremely dangerous. DO NOT WELD OR CUT painted or plated parts unless special precautions with ventilation have been taken. They can release highly toxic fumes or gases. Additional precautionary measures PROTECT compressed gas cylinders from excessive heat, mechanical shocks, and arcs; fasten cylinders so they cannot fall. BE SURE cylinders are never grounded or part of an electrical circuit. REMOVE all potential fire hazards from welding area. ALWAYS HAVE FIRE FIGHTING EQUIPMENT READY FOR IMMEDIATE USE AND KNOW HOW TO USE IT. SAFETY SECTION A: WARNINGS 1.d. Keep all equipment safety guards, covers and devices in position and in good repair.Keep hands, hair, clothing and tools away from V-belts, gears, fans and all other moving parts when starting, operating or repairing equipment. CALIFORNIA PROPOSITION 65 WARNINGS Diesel Engines 1.e. In some cases it may be necessary to remove safety guards to perform required maintenance. Remove guards only when necessary and replace them when the maintenance requiring their removal is complete. Always use the greatest care when working near moving parts. Diesel engine exhaust and some of its constituents are known to the State of California to cause cancer, birth defects, and other reproductive harm. Gasoline Engines 1.f. Do not put your hands near the engine fan. Do not attempt to override the governor or idler by pushing on the throttle control rods while the engine is running. The engine exhaust from this product contains chemicals known to the State of California to cause cancer, birth defects, or other reproductive harm. 1.g. To prevent accidentally starting gasoline engines while turning the engine or welding generator during maintenance work, disconnect the spark plug wires, distributor cap or magneto wire as appropriate. arC welding Can be hazardous. ProteCt yourselF and others From Possible serious inJury or death. KeeP Children away. PaCemaKer wearers should Consult with their doCtor beFore oPerating. Read and understand the following safety highlights. For additional safety information, it is strongly recommended that you purchase a copy of “Safety in Welding & Cutting - ANSI Standard Z49.1” from the American Welding Society, P.O. Box 351040, Miami, Florida 33135 or CSA Standard W117.2-1974. A Free copy of “Arc Welding Safety” booklet E205 is available from the Lincoln Electric Company, 22801 St. Clair Avenue, Cleveland, Ohio 44117-1199. BE SURE THAT ALL INSTALLATION, OPERATION, MAINTENANCE AND REPAIR PROCEDURES ARE PERFORMED ONLY BY QUALIFIED INDIVIDUALS. 1.h. To avoid scalding, do not remove the radiator pressure cap when the engine is hot. ELECTRIC AND MAGNETIC FIELDS MAY BE DANGEROUS 2.a. Electric current flowing through any conductor causes localized Electric and Magnetic Fields (EMF). Welding current creates EMF fields around welding cables and welding machines 2.b. EMF fields may interfere with some pacemakers, and welders having a pacemaker should consult their physician before welding. FOR ENGINE POWERED EQUIPMENT. 2.c. Exposure to EMF fields in welding may have other health effects which are now not known. 1.a. Turn the engine off before troubleshooting and maintenance work unless the maintenance work requires it to be running. 2.d. All welders should use the following procedures in order to minimize exposure to EMF fields from the welding circuit: 2.d.1. Route the electrode and work cables together - Secure them with tape when possible. 1.b. Operate engines in open, well-ventilated areas or vent the engine exhaust fumes outdoors. 2.d.2. Never coil the electrode lead around your body. 1.c. Do not add the fuel near an open flame welding arc or when the engine is running. Stop the engine and allow it to cool before refueling to prevent spilled fuel from vaporizing on contact with hot engine parts and igniting. Do not spill fuel when filling tank. If fuel is spilled, wipe it up and do not start engine until fumes have been eliminated. 2.d.3. Do not place your body between the electrode and work cables. If the electrode cable is on your right side, the work cable should also be on your right side. 2.d.4. Connect the work cable to the workpiece as close as possible to the area being welded. 2.d.5. Do not work next to welding power source. 3 SAFETY ELECTRIC SHOCK CAN KILL. ARC RAYS CAN BURN. 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. 4.a. Use a shield with the proper filter and cover plates to protect your eyes from sparks and the rays of the arc when welding or observing open arc welding. Headshield and filter lens should conform to ANSI Z87. I standards. 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. 4.b. Use suitable clothing made from durable flame-resistant material to protect your skin and that of your helpers from the arc rays. 4.c. Protect other nearby personnel with suitable, non-flammable screening and/or warn them not to watch the arc nor expose themselves to the arc rays or to hot spatter or metal. in addition to the normal safety precautions, if welding must be performed under electrically hazardous conditions (in damp locations or while wearing wet clothing; on metal structures such as floors, gratings or scaffolds; when in cramped positions such as sitting, kneeling or lying, if there is a high risk of unavoidable or accidental contact with the workpiece or ground) use the following equipment: • Semiautomatic DC Constant Voltage (Wire) Welder. FUMES AND GASES CAN BE DANGEROUS. 5.a. Welding may produce fumes and gases hazardous to health. Avoid breathing these fumes and gases. When welding, keep your head out of the fume. Use enough ventilation and/or exhaust at the arc to keep fumes and gases away from the breathing zone. when welding with electrodes which require special ventilation such as stainless or hard facing (see instructions on container or msds) or on lead or cadmium plated steel and other metals or coatings which produce highly toxic fumes, keep exposure as low as possible and within applicable osha Pel and aCgih tlV limits using local exhaust or mechanical ventilation. in confined spaces or in some circumstances, outdoors, a respirator may be required. additional precautions are also required when welding on galvanized steel. • DC Manual (Stick) Welder. • AC Welder with Reduced Voltage Control. 3.c. In semiautomatic or automatic wire welding, the electrode, electrode reel, welding head, nozzle or semiautomatic welding gun are also electrically “hot”. 3.d. Always be sure the work cable makes a good electrical connection with the metal being welded. The connection should be as close as possible to the area being welded. 3.e. Ground the work or metal to be welded to a good electrical (earth) ground. 3.f. Maintain the electrode holder, work clamp, welding cable and welding machine in good, safe operating condition. Replace damaged insulation. 5. b. The operation of welding fume control equipment is affected by various factors including proper use and positioning of the equipment, maintenance of the equipment and the specific welding procedure and application involved. Worker exposure level should be checked upon installation and periodically thereafter to be certain it is within applicable OSHA PEL and ACGIH TLV limits. 3.g. Never dip the electrode in water for cooling. 3.h. Never simultaneously touch electrically “hot” parts of electrode holders connected to two welders because voltage between the two can be the total of the open circuit voltage of both welders. 5.c. Do not weld in locations near chlorinated hydrocarbon vapors coming from degreasing, cleaning or spraying operations. The heat and rays of the arc can react with solvent vapors to form phosgene, a highly toxic gas, and other irritating products. 3.i. When working above floor level, use a safety belt to protect yourself from a fall should you get a shock. 3.j. Also see Items 6.c. and 8. 5.d. Shielding gases used for arc welding can displace air and cause injury or death. Always use enough ventilation, especially in confined areas, to insure breathing air is safe. 5.e. Read and understand the manufacturer’s instructions for this equipment and the consumables to be used, including the material safety data sheet (MSDS) and follow your employer’s safety practices. MSDS forms are available from your welding distributor or from the manufacturer. 5.f. Also see item 1.b. 4 SAFETY WELDING AND CUTTING SPARKS CAN CAUSE FIRE OR EXPLOSION. CYLINDER MAY EXPLODE IF DAMAGED. 7.a. Use only compressed gas cylinders containing the correct shielding gas for the process used and properly operating regulators designed for the gas and pressure used. All hoses, fittings, etc. should be suitable for the application and maintained in good condition. 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. 7.b. Always keep cylinders in an upright position securely chained to an undercarriage or fixed support. 6.b. Where compressed gases are to be used at the job site, special precautions should be used to prevent hazardous situations. Refer to “Safety in Welding and Cutting” (ANSI Standard Z49.1) and the operating information for the equipment being used. 7.c. Cylinders should be located: 6.c. When not welding, make certain no part of the electrode circuit is touching the work or ground. Accidental contact can cause overheating and create a fire hazard. • Away from areas where they may be struck or subjected to physical damage. • A safe distance from arc welding or cutting operations and any other source of heat, sparks, or flame. 7.d. Never allow the electrode, electrode holder or any other electrically “hot” parts to touch a cylinder. 6.d. Do not heat, cut or weld tanks, drums or containers until the proper steps have been taken to insure that such procedures will not cause flammable or toxic vapors from substances inside. They can cause an explosion even though they have been “cleaned”. For information, purchase “Recommended Safe Practices for the Preparation for Welding and Cutting of Containers and Piping That Have Held Hazardous Substances”, AWS F4.1 from the American Welding Society (see address above). 7.e. Keep your head and face away from the cylinder valve outlet when opening the cylinder valve. 7.f. Valve protection caps should always be in place and hand tight except when the cylinder is in use or connected for use. 7.g. Read and follow the instructions on compressed gas cylinders, associated equipment, and CGA publication P-l, “Precautions for Safe Handling of Compressed Gases in Cylinders,” available 6.e. Vent hollow castings or containers before heating, cutting or welding. They may explode. from the Compressed Gas Association 1235 Jefferson Davis Highway, Arlington, VA 22202. 6.f. Sparks and spatter are thrown from the welding arc. Wear oil free protective garments such as leather gloves, heavy shirt, cuffless trousers, high shoes and a cap over your hair. Wear ear plugs when welding out of position or in confined places. Always wear safety glasses with side shields when in a welding area. FOR ELECTRICALLY POWERED EQUIPMENT. 6.g. Connect the work cable to the work as close to the welding area as practical. Work cables connected to the building framework or other locations away from the welding area increase the possibility of the welding current passing through lifting chains, crane cables or other alternate circuits. This can create fire hazards or overheat lifting chains or cables until they fail. 8.a. Turn off input power using the disconnect switch at the fuse box before working on the equipment. 6.h. Also see item 1.c. 8.b. Install equipment in accordance with the U.S. National Electrical Code, all local codes and the manufacturer’s recommendations. 6.I. Read and follow NFPA 51B “ Standard for Fire Prevention During Welding, Cutting and Other Hot Work”, available from NFPA, 1 Batterymarch Park, PO box 9101, Quincy, Ma 022690-9101. 8.c. Ground the equipment in accordance with the U.S. National Electrical Code and the manufacturer’s recommendations. 6.j. Do not use a welding power source for pipe thawing. refer to http://www.lincolnelectric.com/safety for additional safety information. Welding Safety Interactive Web Guide for mobile devices 5 AIR VANTAGE® 600 SD TABLE OF CONTENTS Page Installation .......................................................................................................................................................................Section A General Description.................................................................................................................................................................A-1 Technical Specifications..........................................................................................................................................................A-1 Safety Precautions ..................................................................................................................................................................A-2 VRD (Voltage Reduction Device) ..............................................................................................................................................A-2 Location and Ventilation ..........................................................................................................................................................A-2 Storing .........................................................................................................................................................................A-2 Stacking.......................................................................................................................................................................A-2 Angle of Operation........................................................................................................................................................A-3 Lifting ..........................................................................................................................................................................A-3 High Altitude Operation ................................................................................................................................................A-3 High Temperature Operation ........................................................................................................................................A-3 Cold Weather Starting ..................................................................................................................................................A-3 Towing.........................................................................................................................................................................A-4 Vehicle Mounting..........................................................................................................................................................A-4 Pre-Operation Engine Service..................................................................................................................................................A-4 Fuel..............................................................................................................................................................................A-4 Engine Cooling System.................................................................................................................................................A-4 Battery Connection.......................................................................................................................................................A-5 Exhaust Outlet Pipe ......................................................................................................................................................A-5 Spark Arrestor..............................................................................................................................................................A-5 Air Cleaner Install .........................................................................................................................................................A-5 Pre-Operation Engine and Compressor Service .......................................................................................................................A-6 Oil ................................................................................................................................................................................A-6 Fuel Use Diesel Fuel.....................................................................................................................................................A-6 Fuel Cap.......................................................................................................................................................................A-6 Engine Coolant .............................................................................................................................................................A-6 Remote Control .......................................................................................................................................................................A-7 Welding Terminals ..................................................................................................................................................................A-7 Welding Output Cables............................................................................................................................................................A-7 Pulse Welding .........................................................................................................................................................................A-7 Cable Installation ....................................................................................................................................................................A-7 Machine Grounding.................................................................................................................................................................A-8 Auxiliary Power Receptacles ...................................................................................................................................................A-8 Standby Power Connections....................................................................................................................................................A-9 Connection to Premises Wiring................................................................................................................................................A-9 Connection of Lincoln Electric Wire Feeders .....................................................................................................................A-10 – A-11 Connection of Wire Feeders with Control Cable (14 Pin)...............................................................................................A-10 Connection of Across the Arc Wire Feeders .................................................................................................................A-11 Cable Inductance and its Effects on Welding ..........................................................................................................................A-11 Control Cable Connections .....................................................................................................................................................A-11 Operation..........................................................................................................................................................................Section B Safety Instructions ..................................................................................................................................................................B-1 Recommended Applications ....................................................................................................................................................B-1 Welder .........................................................................................................................................................................B-1 Generator.....................................................................................................................................................................B-1 Controls and Settings..............................................................................................................................................................B-2 Engine Controls ........................................................................................................................................................B-2, B-3 Welder Controls........................................................................................................................................................B-4, B-7 Activating & Deactivating the Compressor System ..................................................................................................................B-9 Control and Indicator Functionality .........................................................................................................................................B-10 Control Safeguards to Improve Reliability ...............................................................................................................................B-10 On/Off Clutch Safeguard..............................................................................................................................................B-10 Minimum Pressure Check Valve Clutch Safeguard.......................................................................................................B-10 Welder Operation ...................................................................................................................................................................B-11 Duty Cycle...................................................................................................................................................................B-11 Stick Welding Mode ....................................................................................................................................................B-11 CC-Stick Mode ............................................................................................................................................................B-11 Downhill Pipe Mode ....................................................................................................................................................B-11 Touch Start TIG Mode..................................................................................................................................................B-11 Typical Fuel Consumption ...........................................................................................................................................B-11 6 AIR VANTAGE® 600 SD TABLE OF CONTENTS Page Common Welding Procedures ................................................................................................................................................B-12 Making a Weld ............................................................................................................................................................B-12 Definition of Welding Modes...................................................................................................................................................B-12 Non-Synergic Welding Modes .....................................................................................................................................B-12 Synergic Welding Modes .............................................................................................................................................B-12 Basic Welding Controls ..........................................................................................................................................................B-12 Weld Mode..................................................................................................................................................................B-12 Wire Feed Speed.........................................................................................................................................................B-12 Amps ..........................................................................................................................................................................B-12 Volts............................................................................................................................................................................B-12 Trim ............................................................................................................................................................................B-12 UltimArc Control ..........................................................................................................................................................B-12 Pulse Welding ........................................................................................................................................................................B-12 AIR VANTAGE® 600 SD Settings when using K930-2 TIG Module...........................................................................................B-14 Typical Current Ranges for Tungsten Electrodes.....................................................................................................................B-14 CV-Wire Mode........................................................................................................................................................................B-15 Constant Voltage Welding ......................................................................................................................................................B-15 Synergic CV.................................................................................................................................................................B-15 Non-Synergic CV .........................................................................................................................................................B-15 Arc Gouging ...........................................................................................................................................................................B-15 Paralleling..............................................................................................................................................................................B-15 Auxiliary Power Operation ......................................................................................................................................................B-15 Simultaneous Welding and Auxiliary Power Loads ..................................................................................................................B-15 Simultaneous Welding and Power Loads Table.......................................................................................................................B-16 Extension Cord Length Recommendations Tables ..................................................................................................................B-16 Weld Set Reference Chart ......................................................................................................................................................B-17 Accessories......................................................................................................................................................................Section C Optional Field Installed Accessories.........................................................................................................................................C-1 Wire Feeder Options................................................................................................................................................................C-2 Maintenance ....................................................................................................................................................................Section D Safety Precautions ..................................................................................................................................................................D-1 Routine and Periodic Maintenance ..........................................................................................................................................D-1 Engine Maintenance ...............................................................................................................................................................D-1 Air Filter .......................................................................................................................................................................D-1 Service Instructions Air Cleaner...............................................................................................................................................D-2 Fuel Filters..............................................................................................................................................................................D-3 Cooling System.......................................................................................................................................................................D-3 Battery Handling .....................................................................................................................................................................D-3 Preventing Electrical Damage .................................................................................................................................................D-3 Charging the Battery ...............................................................................................................................................................D-4 Nameplates / Warning Decals Maintenance ............................................................................................................................D-4 Welder / Generator Maintenance.............................................................................................................................................D-4 Storage ........................................................................................................................................................................D-4 Cleaning.......................................................................................................................................................................D-4 Brush Removal and Replacement.................................................................................................................................D-4 Replacement Service Items.....................................................................................................................................................D-4 Troubleshooting ...............................................................................................................................................................Section E How to use Troubleshooting Guide ..........................................................................................................................................E-1 Troubleshooting Guide........................................................................................................................................................E-2 – E-4 Wiring, Connection Diagrams and Dimension Print .......................................................................................................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. 7 AIR VANTAGE® 600 SD INSTALLATION COMPRESSOR SPECIFICATIONS GENERAL DESCRIPTION The AIR VANTAGE® 600 SD is a diesel engine-driven welding power source. The machine uses a brush type alternating current generator for DC multi-purpose welding, for 120/240 VAC single phase and 240V three phase auxiliary standby power. The welding control system uses state of the art Chopper Technology™. The product also has a belt-driven 60 CFM rotary screw compressor. TECHNICAL SPECIFICATIONS INPUT - DIESEL ENGINE Make /Model DEUTZ Turbo Charged TD2.9L4 Diesel Engine EPA TIER 4 Final Compliant 4 cylinder 64HP (48 kw) Turbo Charged Water Cooled Diesel Engine Speed (RPM) Displacement High Idle 1800 Low Idle 1525 Full Load 178 cu. in. (2.9L) Bore x Stroke 3.62” x 4.33” 92mm x 110mm Starting System Fuel 25 US gal (94.6L) Oil: 2.25 US gal. (8.5L) Welding Output 575 Amps (DC multi-purpose) 43 Volts 60% 600 Amps (DC multi-purpose) 40 volts Delivery Maximum System Pressure High Idle Mode: 60 SCFM @ 100PSI (28.3 LTR/SEC. @ 7.0 KG/CM Compressor Protection 150 PSI (10.5 kg/cm2) Capacities 1.1 gal.(4.0 liters) Height (2) 42.0 in (1066.8 mm) Width (3) 32.9 in. (835.7mm) Depth 69.0 in. (1753mm) Weight 1737lbs. (787kg) (Approx.) (1) Output rating in watts is equivalent to volt-amperes at unity power factor. Output voltage is within +/- 10% at all loads up to rated capacity. When welding, available auxiliary power will be reduced. (2) Top of Enclosure. Add 16.8” (427mm) for exhaust and air cleaner. (3) Includes Door. Base is 31.6”(803mm) wide. Volts at Rated Amps 100% Belt-Drive Rotary Screw S700162 PHYSICAL DIMENSIONS RATED OUTPUT @ 104°F(40°C) - WELDER Duty Cycle (VMAC® ) S700162 High Temperature Automatic Shutdown 290° F (143°C) Capacities 12VDC battery and Starter with Automatic Glow Plugs Description Safety Relief Valve 200 PSI (14.1 kg/cm2) Description (K3242-1) Compressor Model OUTPUT @ 104°F(40°C) - WELDER AND GENERATOR Welding Range 30 - 600 Amps CC/CV 20 - 350 Amps TIG Open Circuit Voltage 60 Max OCV @ 1800 RPM Auxiliary Power (1) 120/240 VAC 12,000 WATTS, 60 Hz., Single Phase 20,000 WATTS, 60 Hz., Three Phase A-1 AIR VANTAGE® 600 SD SAFETY PRECAUTIONS INSTALLATION WARNING With the VRD switch in the “OFF” position, the VRD lights are non activated. FIGURE A.1 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. ON / OFF VDR SWITCH ELECTRIC SHOCK can kill. • Do not touch electrically live parts such as output terminals or internal wiring. • Insulate yourself from the work and ground. • Always wear dry insulating gloves. ------------------------------------------------------------------ REMOVE 4 SIDE PANEL SCREWS TO ACCESS (VRD) SWITCH ENGINE EXHAUST can kill. • Use in open, well ventilated areas or vent exhaust outside ------------------------------------------------------------------ FRONT PANEL ROTATES AWAY FROM THE FRONT PART OF WELDER MOVING PARTS can injure. • Do not operate with doors open or guards off. • Stop engine before servicing. • Keep away from moving parts LOCATION AND VENTILATION -----------------------------------------------------------------The welder should be located to provide an unrestricted flow of clean, cool air to the cooling air inlets and to avoid restricting the cooling air outlets. Also, locate the welder so that the engine exhaust fumes are properly vented to an outside area. Only qualified personnel should install, use or service this equipment. VRD (VOLTAGE REDUCTION DEVICE) The VRD reduces the OCV (Open Circuit Voltage) at the welding output terminals while not welding to less than 30VDC when the resistance of the output circuit is above 200Ω (ohms). The VRD requires that the welding cable connections be kept in good electrical condition because poor connections will contribute to poor starting. Having good electrical connections also limits the possibility of other safety issues such as heat-generated damage, burns and fires. The machine is shipped with the VRD switch in the “OFF” position. To turn it “On” or “Off”: • Turn the engine “Off”. • Disconnect the negative battery cable. • Lower the Front panel by removing 4 side panel screws. (See Figure A.1) • Place the VRD switch in the “On” or “Off” position. (See Figure A.1) DO NOT MOUNT OVER COMBUSTIBLE SURFACES Where there is a combustible surface directly under stationary or fixed electrical equipment, that surface should be covered with a steel plate at least .06”(1.6mm) thick, which should extend not less than 5.90”(150mm) beyond the equipment on all sides. --------------------------------------------------------------------- STORING 1. Store the machine in a cool, dry place when it is not in use. Protect it from dust and dirt. Keep it where it can’t be accidentally damaged from construction activities, moving vehicles, and other hazards. 2. Drain the engine oil and refill with fresh oil. Run the engine for about five minutes to circulate oil to all the parts. See the ENGINE OPERATION section manual for details on changing oil. 3. Remove the battery, recharge it, and adjust the electrolyte level. Store the battery in a dry, dark place. STACKING AIR VANTAGE® 600 SD machines cannot be stacked. A-2 AIR VANTAGE® 600 SD INSTALLATION ANGLE OF OPERATION HIGH TEMPERATURE OPERATION To achieve optimum engine performance the AIR VANTAGE® 600 SD At temperatures above 104°F (40°C), output voltage derating may should be run in a level position. The maximum angle of operation be necessary. For maximum output current ratings, derate welder for the Deutz engine is 30 degrees in all directions. When operatvoltage rating 2 volts for every 21°F (10°C) above 104°F (40°C). ing the welder at an angle, provisions must be made for checking and maintaining the oil level at the normal (FULL) oil capacity. Also Cold weather starting: the effective fuel capacity will be slightly less than the specified 25 gal.(94.6 ltrs.) will be slightly less than the amount specified. With a fully charged battery and OW40 oil, the engine should start satisfactorily down to -15°F(-26C°). If the engine must be freLIFTING quently started at or below 0°F (-18°C), it may be desirable to ® The AIR VANTAGE 600 weighs approximately 1911lbs. (866kg.) install cold-starting aides. For engines with common rail injection, with a full tank of fuel and 1737lbs. (787kg) less fuel. A lift bail is the mixing of petroleum or kerosene and adding of extra low addimounted to the machine and should always be used when lifting tives is not permissible. Fuels in accordance with ASTM S975 the machine. Grade 1D or DIN EN590-Arctic-Diesel may have no petroleum added. Allow the engine to warm up before applying a load or WARNING switching to high idle. WARNING • Lift only with equipment of adequate lifting capacity. • Be sure machine is stable when lifting. • Do not lift this machine using lift bale if it is equipped with a heavy accessory such as trailer or gas cylinder. FALLING • Do not lift machine if lift bale is EQUIPMENT can damaged. cause injury. • Do not operate machine while suspended from lift bale. ------------------------------------------------------------------ Under no conditions should ether or other starting fluids be used with this engine! ------------------------------------------------------------------ HIGH ALTITUDE OPERATION At higher altitudes, output derating may be necessary. For maximum rating, derate the welder output in accordance with the guidelines for this engine model from the manufacturer shown in Table A-1 below: TABLE A.1 DEUTZ D 2.9 L4 ALTITUDE MAXIMUM POWER METERS FEET AVAILABLE (%) 0-750 0-2461 99 1000 3281 95 2000 6562 95 3000 9842 93 4000 13123 88 5000 16404 74 6000 19685 60 A-3 AIR VANTAGE® 600 SD INSTALLATION TOWING FUEL USE DIESEL FUEL ONLY- Use a recommended trailer for use with this equipment for road, in-plant and yard towing by a vehicle(1). 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 damage the welding equipment. Some of the factors to be considered are as follows: Ultra low sulphur fuel only. WARNING • Fill the fuel tank with clean, fresh fuel. The capacity of the tank is 1. Design capacity of trailer vs. weight of Lincoln equipment and likely addi25 gals. (94.6 ltrs). When the fuel gauge reads empty the tank tional attachments. contains approximately 2 gals. (7.6 ltrs.) of reserve fuel. 2. Proper support of, and attachment to, the base of the welding equipment so NOTE: A fuel shut off valve is located just before the pre-filter/sedithere will be no undue stress to the framework. ment filter. Place the valve in the closed position when the 3. Proper placement of the equipment on the trailer to insure stability side to side and front to back when being moved and when standing by itself while welder is not used for extended periods of time. -----------------------------------------------------------------------being operated or serviced. 4. Typical conditions of use, i.e., travel speed; roughness of surface on which the trailer will be operated; environmental conditions; like maintenance. 5. Conformance with federal, state and local laws.(1) WARNING (1) Consult applicable federal, state and local laws regarding specific requirements for use on ENGINE COOLING SYSTEM public highways. VEHICLE MOUNTING Air to cool the engine is drawn in the side and exhausted through radiator and case back. It is important that the intake and exhaust air is not restricted. Allow a minimum clearance of 1ft. (0.6m) from the case back and 16 in. (406mm) from either side of the base to a vertical surface. (Failure to resolve these guidelines may result in an overtemp condition resulting in engine shut down). ------------------------------------------------------------------------ WARNING Improperly mounted concentrated loads may cause unstable vehicle handling and tires or other components to fail. • Only transport this Equipment on serviceable vehicles which are rated and designed for such loads. • Distribute, balance and secure loads so vehicle is stable under conditions of use. • Do not exceed maximum rated loads for components such as suspension, axles and tires. • Mount equipment base to metal bed or frame of vehicle. • Follow vehicle manufacturer’s instructions. ------------------------------------------------------------------ PRE-OPERATION ENGINE SERVICE READ the engine operating and maintenance instructions supplied with this machine. • • • • WARNING Stop engine and allow to cool before fueling. Do not smoke when fueling. Fill fuel tank at a moderate rate and do not overfill. Wipe up spilled fuel and allow fumes to clear before starting engine. • Keep sparks and flame away from tank. ------------------------------------------------------------------ A-4 AIR VANTAGE® 600 SD INSTALLATION SPARK ARRESTOR Some federal, state or local laws may require that gasoline or diesel engines be equipped with exhaust spark arresters when CAUTION they are operated in certain locations where unarrested sparks may present a fire hazard. Use caution as the electrolyte is a strong acid that can burn skin and damage eyes. The DOC (Diesel Oxidation Catalyst) unit included with this welder -----------------------------------------------------------------------not qualify as a spark arrester. When required by local regudoes ® The AIR VANTAGE 600 SD is shipped with the negative battery cable dislations, a suitable spark arrester, such as the K3985-1 must be connected. Make certain that the RUN-STOP switch is in the STOP posiinstalled and properly maintained. tion. Remove the two screws from the battery tray using a screwdriver or a 3/8"(10mm) socket. Attach the negative battery cable to the negative WARNING battery terminal and tighten using a 1/2"(13mm) socket or wrench. An incorrect spark arrestor may lead to damage to the engine NOTE: This machine is furnished with a wet charged battery; if or adversely affect performance. unused for several months, the battery may require a booster ----------------------------------------------------------------charge. Be careful to charge the battery with the correct polarity. (See Battery in “Maintenance Section”) BATTERY CONNECTION AIR CLEANER INSTALL WARNING All parts below are shipped with the machine in a separate box attached to the crate. (see Figure A.2) • Remove cap from air intake hose and DOC exhaust attached on machine. Insert air cleaner into bracket between the two ridges of a larger diameter. Position the vacuator at 3 or 6 o’clock. • Remove plug and install service indicator, use thread sealant or tape on pipe threads. • Tighten air hose clamp just below service indicator to hold clamp while pushing air cleaner onto hose, once hose is in place loosen air hose clamp slide down and tighten clamp. • Install 2 hex head screws, washers to mounting bracket securing air cleaner. GASES FROM BATTERY can explode. • Keep sparks, flame and cigarettes away from battery. To prevent EXPLOSION when: • INSTALLING A NEW BATTERY — disconnect negative cable from old battery first and connect to new battery last. • CONNECTING A BATTERY CHARGER — remove battery from welder by disconnecting negative cable first, then positive cable and battery clamp. When reinstalling, connect negative cable last. Keep well ventilated. • SERVICE INDICATOR • USING A BOOSTER — connect positive lead to battery first then connect negative lead to negative battery lead at engine foot. Air cleaner service indicator provides a Go/No-Go visual indication of useful filter service life. FIGURE A.2 BATTERY ACID can burn eyes and skin. (5/16-18x 1.25 HHCS) (2) • Wear gloves and eye protection and be careful when working near battery. INLET HOOD (LOCK WASHER) (2) (MAIN WASHER) (2) VACUATOR VALVE • Follow instructions printed on battery. ---------------------------------------------------------------- EXHAUST OUTLET IMPORTANT: To prevent ELECTRICAL DAMAGE WHEN: MOUNTING BRACKET a) Installing new batteries. SERVICE INDICATOR b) Using a booster. AIR HOSE CLAMP Use correct polarity — Negative Ground. EXHAUST OUTLET PIPE Remove cap from DOC pipe protruding from roof. Using the clamp provided secure the outlet pipe to the outlet tube with the pipe positioned such that it will direct the exhaust in the desired direction away from the air intake. Tighten using a 1/4"(6mm) internal socket or allen wrench. Torque to 106in.lbs.(9ft.-lbs.)(12N-M) A-5 CLAMP SEAL AIR VANTAGE® 600 SD INSTALLATION WARNING PRE-OPERATION ENGINE AND COMPRESSOR SERVICE READ the engine and compressor operating and maintenance instructions supplied with this machine. WARNING ENGINE COOLANT HOT COOLANT can burn skin. •Do not remove cap if radiator is hot. • Keep hands away from the engine muffler or HOT engine parts. ----------------------------------------------------------------- • Stop engine and allow to cool before fuelling. The welder is shipped with the engine and radiator filled with a 50% mixture of ethylene glycol and water. See the MAINTENANCE section and the engine Operator’s Manual for more information on coolant. • Do not smoke when fuelling. • Fill fuel tank at a moderate rate and do not over-fill. • Wipe up spilled fuel and allow fumes to clear before starting engine. • Keep sparks and flame away from tank. ----------------------------------------------------------------- OIL The AIR VANTAGE® 600 SD is shipped with the engine crankcase filled with high quality SAE 10W-30 oil that meets (API class CJ-4 or better) for diesel engines.. Check the engine and compressor oil levels before starting the engine. If it is not up to the full mark on the dip stick, add oil as required. Check the oil level every four hours of running time during the first 35 running hours. Refer to the engine and compressor Operator’s Manuals for specific oil recommendations and break-in information. The oil change interval is dependent on the quality of the oil and the operating environment. Refer to the engine and compressor Operator’s Manuals for the proper service and maintenance intervals. FUEL USE DIESEL FUEL ONLY • Fill the fuel tank with clean, fresh diesel fuel. The capacity of the fuel tank is approximately 25 gallons (95 liters). See engine Operator’s Manual for specific fuel recommendations. NOTE: Before starting the engine, open the fuel shutoff valve (pointer to be in line with hose). FUEL CAP Remove the plastic cap covering from the Fuel Tank Filler neck and install the Fuel Cap. A-6 AIR VANTAGE® 600 SD INSTALLATION REMOTE CONTROL WELDING OUTPUT CABLES The AIR VANTAGE® 600 SD is equipped with a 12-pin and a 14pin connector. To enable remote control capabilities, the LOCAL/REMOTE switch must be in the REMOTE position. For the DOWNHILL PIPE or CC-STICK weld mode selector switch positions, remote setting of the preset arc current is set through the 12 pin connector or the 14 pin connector depending on the setup menu setting (12 pin connector is the factory default setting). The OUTPUT CONTROL knob is used to set the maximum arc current preset range for the remote input. The left display will show the arc current preset. For the TOUCH START TIG weld mode selector switch position, remote setting of the preset arc current is set through the 12 pin connector (typically using a foot Amptrol). The OUTPUT CONTROL knob is used to set the maximum arc current preset range for the remote input. The left display will show the maximum setting for the arc current preset range as set by the OUTPUT CONTROL knob. With the engine off, route the electrode and work cables through the strain relief bracket provided on the front of the base and connect to the terminals provided. These connections should be checked periodically and tightened if necessary. Listed in Table A.2 are copper cable sizes recommended for the rated current and duty cycle. Lengths stipulated are the distance from the welder to work and back to the welder again. Cable sizes are increased for greater lengths primarily for the purpose of minimizing cable voltage drop. Table A.2 OUTPUT CABLE GUIDELINES Percent Duty Amperes Cycle EXAMPLE: When the OUTPUT CONTROL on the welder is set to 200 amps, the arc current preset range on the remote control will preset over the range from minimum to 200 amps, rather than the full minimum to maximum preset arc current range. Any preset arc current range that is less than the full range provides finer arc current preset resolution for more fine tuning of the output. For the ARC GOUGING weld mode selector switch position, remote setting of the preset arc current is set through the 12 pin connector. The remote input sets the arc current preset over the full range from minimum to maximum. The left display will show the arc current preset. CABLE SIZES FOR COMBINED LENGTHS OF ELECTRODE AND WORK CABLES [RUBBER COVERED COPPER - RATED 167°F (75°C)]** 0 to 50 Ft. 50 to 100 Ft. 100 to 150 Ft. 150 to 200 Ft. 200 to 250 Ft. 200 60 2 2 2 1 1/0 200 100 2 2 2 1 1/0 250 30 3 3 2 1 1/0 250 40 2 2 1 1 1/0 250 60 1 1 1 1 1/0 250 100 1 1 1 1 1/0 300 60 1 1 1 1/0 2/0 300 100 2/0 2/0 2/0 2/0 3/0 350 40 1/0 1/0 2/0 2/0 3/0 400 60 2/0 2/0 2/0 3/0 4/0 400 100 3/0 3/0 3/0 3/0 4/0 500 60 2/0 2/0 3/0 3/0 4/0 600 60 3/0 3/0 3/0 4/0 2-3/0 600 80 2-1/0 2-1/0 2-1/0 2-2/0 2-3/0 600 100 2-1/0 2-1/0 2-1/0 2-2/0 2-3/0 For operation with a control cable wire feeder: With the CV-WIRE weld mode selector switch position and the WELD TERMINALS ON switch in the REMOTE position, remote setting of the preset arc voltage is set through the 14 pin connector. The remote input sets the arc voltage preset range from 10.0V to 45.0V. The right display will show the arc voltage preset. PULSE WELDING For operation with an across the arc wire feeder (for example, an LN-25 PRO): With the CV-WIRE weld mode selector switch position and the WELD TERMINALS ON switch in the ON position, remote setting of the preset arc voltage is set through the 12 pin connector. The remote input sets the arc voltage preset range from 10.0V to 45.0V. The right display will show the arc voltage preset. CABLE INSTALLATION ** Tabled values are for operation at ambient temperatures of 104°F (40°C) and below. Applications above 104°F (40°C) may require cables larger than recommended, or cables rated higher than 167°F (75°C). When pulse welding, always use 4/0 cable. The cables must be sized based upon the peak current of the pulse waveform, not the average current. Do not coil the electrode or work cable. Limit the combined length of the electrode and work cable to 60 feet. Undersized cables, coiled cables and long lengths all increase cable inductance and lower pulse welding performance. Install the welding cables to your AIR VANTAGE® 600 SD as follows. For the ARCLINK weld mode selector switch position, remote capability is possible only with an ArcLink compatible digital remote control through the 12 pin connector. 1. The engine must be OFF to install welding cables. 2. Remove the flanged nuts from the output terminals NOTE: To connect accessories with a 6 pin connector, use the included 12-pin to 6-pin adaptor (K2909-1). 3. Connect the electrode holder and work cables to the weld output terminals. The terminals are identified on the case front. ----------------------------------------------------------------- WELDING TERMINALS 4. Tighten the flanged nuts securely. The AIR VANTAGE® 600 SD is equipped with a toggle switch for selecting "hot" welding terminals when in the "WELD TERMINALS ON" position or "cold" welding terminals when in the "REMOTELY CONTROLLED" position. This switch has no function in the Arclink mode. 5. Be certain that the metal piece you are welding (the “work”) is properly connected to the work clamp and cable. 6. Check and tighten the connections periodically. A-7 AIR VANTAGE® 600 SD INSTALLATION CAUTION FIGURE A.3 AUXILIARY POWER RECEPTACLES • Loose connections will cause the output terminals to overheat. The terminals may eventually melt. • Do not cross the welding cables at the output terminal connection. Keep the cables isolated and separate from one another. ------------------------------------------------------------------ 10A 42V/40V ARCLINK BREAKERS 20A 120V AUXILIARY BREAKERS BATTERY 20A BREAKER MACHINE GROUNDING Because this portable engine driven welder creates its own power, it is not necessary to connect its frame to an earth ground, unless the machine is connected to premises wiring (home, shop, etc.). To prevent dangerous electric shock, other equipment powered by this engine driven welder must: 240 VAC THREE PHASE RECEPTACLE a) be grounded to the frame of the welder using a grounded type plug, or IDLER SWITCH b) be double insulated. CIRCUIT BREAKERS When this welder is mounted on a truck or trailer, its frame must be securely connected to the metal frame of the vehicle. When this engine driven welder is connected to premises wiring such as that in a home or shop, its frame must be connected to the system earth ground. See further connection instructions in the section entitled “Standby Power Connections” as well as the article on grounding in the latest National Electrical Code and the local codes. In general, if the machine is to be grounded, it should be connected with a #8 or larger copper wire to a solid earth ground such as a metal ground stake going into the ground for at least 10Ft.(3.1m) or to the metal framework of a building which has been effectively grounded. The National Electric Code lists a number of alternate means of grounding electrical equipment. A machine grounding stud marked with the symbol is provided on the front of the welder. 120/240 VAC SINGLE PHASE RECEPTACLE 120 V DUPLEX RECEPTACLES AND GFCI A GFCI protects the two 120V auxiliary power receptacles. A GFCI (Ground Fault Circuit Interrupter) is a device to protect against electric shock should a piece of defective equipment connected to it develop a ground fault. If this situation should occur, the GFCI will trip, removing voltage from the output of the receptacle. If a GFCI is tripped see the MAINTENANCE section for detailed information on testing and resetting it. A GFCI should be properly tested at least once every month. The 120 V auxiliary power receptacles should only be used with three wire grounded type plugs or approved double insulated tools with two wire plugs. The current rating of any plug used with the system must be at least equal to the current capacity of the associated receptacle. NOTE: The 240 V receptacle has two 120 V circuits, but are of opposite polarities and cannot be paralleled. AUXILIARY POWER RECEPTACLES Start the engine and set the “IDLE/RUN/STOP” switch to the “High Idle” mode. Voltage is now correct at the receptacles for auxiliary power. This must be done before a tripped GFCI can be reset properly. See the MAINTENANCE section for more detailed information on testing and resetting the GFCI. All auxiliary power is protected by circuit breakers. The 120V has 20 Amp circuit breakers for each duplex receptacle. The 120/240V Single Phase and the 240V Three-Phases have a 50 Amp 3-pole Circuit Breaker that disconnects both hot leads and all Three Phases simultaneously. (See Figure A.3) The auxiliary power of the AIR VANTAGE® 600 SD consists of two 20 Amp-120 VAC (5-20R) duplex receptacles with GFCI protection, one 50 Amp 120/240 VAC (14-50R) receptacle and one 50 Amp 240VAC Three-Phase (15-50R) receptacle. The auxiliary power capacity is 12,000 Watts Continuous of 60 Hz, single phase power. The auxiliary power capacity rating in watts is equivalent to volt-amperes at unity power factor. The max permissible current of the 240 VAC output is 50 amps. The 240 VAC output can be split to provide two separate 120 VAC outputs with a max permissible current of 50 Amps per output to two separate 120 VAC branch circuits (these circuits cannot be paralleled). Output voltage is within ± 10% at all loads up to rated capacity. The Three-Phases auxiliary power capacity is 20,000 watts continuous. The maximum current is 50 amps. A-8 AIR VANTAGE® 600 SD INSTALLATION STANDBY POWER CONNECTIONS 2. Take necessary steps to assure load is limited to the capacity of the AIR VANTAGE® 600 SD 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 The AIR VANTAGE® 600 SD can be permanently installed as a and may result in overheating of the AIR VANTAGE® 600 SD standby power unit for 240 volt-3 wire, 50 amp service. engine and / or alternate windings. Connections must be made by a licensed electrician who can 3. Install a 50 amp 120/240 VAC plug (NEMA Type 14-50P) to the determine how the 120/240 VAC power can be adapted to the double-pole circuit breaker using No. 6, 4 conductor cable of particular installation and comply with all applicable electrical the desired length. codes. Refer to the connection diagram shown in Figure A.4. 4. Plug this cable into the 50 Amp 120/240 Volt receptacle on the AIR VANTAGE® 600 SD case front. 1. Install the double-pole, double-throw switch between the power company meter and the premises disconnect. Switch rating must be the same or greater than the customer’s premises disconnect and service over current protection. The AIR VANTAGE® 600 SD is suitable for temporary, standby or emergency power using the engine manufacturer’s recommended maintenance schedule. Figure A.4 Connection of the AIR VANTAGE® 600 SD to Premises Wiring 240 VOLT GROUNDED CONDUCTOR POWER 240 Volt 60 Hz. 3-Wire Service COMPANY METER 120 VOLT 120 VOLT NEUTRAL BUS N LOAD DOUBLE POLE DOUBLE THROW SWITCH RATING TO BE THE SAME AS OR GREATER THAN PREMISES SERVICE OVERCURRENT PROTECTION. GROUND 50AMP 240 VOLT 50 AMP, 120/240 VOLT PLUG NEMA TYPE 14-50 240 VOLT PREMISES DISCONNECT AND SERVICE OVERCURRENT PROTECTION DOUBLE POLE CIRCUIT BREAKER GND N 50 AMP, 120/240 VOLT RECEPTACLE NOTE: No. 6 COPPER CONDUCTOR CABLE SEE NATIONAL ELECTRICAL CODE FOR ALTERNATE WIRE SIZE RECOMMENDATIONS. A-9 AIR VANTAGE® 600 SD INSTALLATION FIGURE A.5 CONNECTION OF WIRE FEEDERS WITH CONTROL CABLE (14 PIN) WARNING Set Mode to CV Wire Set Weld Terminals to Remotely Controlled Shut off welder before making any electrical connections. Set Polarity to Match Electrode Polarity ------------------------------------------------------------------ CONNECTION OF LF-72, LF-74, FLEX FEED 74 HT, FLEX FEED 84, LN-25 PRO DUAL POWER TO THE AIR VANTAGE® 600 SD Set to Remote Set to 42V • Shut the welder off. • Set the “WIRE FEEDER VOLTMETER” switch to either “+” or “-” as required by the electrode being used (See Figure A.5). • For electrode Positive, connect the electrode cable to the "+" terminal of the welder and work cable to the "-" terminal of the welder. For electrode Negative, connect the electrode cable "-" terminal of the welder and work cable to the "+" terminal of the welder. • Set the “MODE” switch to the “CV-WIRE” position. • Adjust the “ARC CONTROL” knob to desired Crispness. SOFT for MIG and CRISP for Innershield. • Set the “WELDING TERMINALS” switch to the “REMOTELY CONTROLLED” position. • Set the wire feeder voltage switch to 42V. • Connect the 14 pin control cable from the wire feeder to the engine drive (See Figure A.6). • Set the “REMOTE/LOCAL” switch to “REMOTE” if the feeder is equipped with a remote output control knob. FIGURE A.6 ENGINE WELDER WIRE FEEDER K1797-xx CABLE A-10 AIR VANTAGE® 600 SD INSTALLATION FIGURE A.7 CONNECTION OF ACROSS THE ARC WIRE FEEDERS TO THE AIR VANTAGE® 600 SD These connections instructions apply to both the LN-25 Pro and Activ8 models. The feeders have an internal contactor and the electrode is not energized until the gun trigger is closed. When the gun trigger is closed the wire will begin to feed and the welding process is started. • Shut the welder off. Weld Terminals On Set Mode to CV Wire • For electrode Positive, connect the electrode cable to the "+" terminal of the welder and work cable to the "-" terminal of the welder. For electrode Negative, connect the electrode cable "-" terminal of the welder and work cable to the "+" terminal of the welder. • Attach the single lead from the front of the feeder to work using the spring clip at the end of the lead. This is a control lead to supply current to the wire feeder motor; it does not carry welding current (See Figure A.8). • Set the MODE switch to the "CV-WIRE" position (See Figure A.7). • Set the "WELD TERMINALS" switch to "WELD TERMINALS ON" • Set the "ARC CONTROL" knob to "0" initially and adjust to suit. • Set the “REMOTE/LOCAL” switch to “LOCAL” control. FIGURE A.8 A-11 Set to Local AIR VANTAGE® 600 SD INSTALLATION CABLE INDUCTANCE AND ITS EFFECTS ON WELDING CONTROL CABLE CONNECTIONS General Guidelines Excessive cable inductance will cause the welding performance to degrade. There are several factors that contribute to the overall inductance of the cabling system including cable size, and loop area. The loop area is defined by the separation distance between the electrode and work cables, and the overall welding loop length. The welding loop length is defined as the total of length of the electrode cable (A) + work cable (B) + work path (C) (See Figure A.9). Genuine Lincoln control cables should be used at all times (except where noted otherwise). Lincoln cables are specifically designed for the communication and power needs of the Engine Welder and Power Feed™ systems. Most are designed to be connected end to end for ease of extension. Generally, it is recommended that the total length not exceed 200ft. (60.960m). The use of non-standard cables, especially in lengths greater than 25 feet, can lead to communication problems (system shutdowns), poor motor accelTo minimize inductance always use the appropriate size cables, eration (poor arc starting), and low wire driving force (wire feeding and whenever possible, run the electrode and work cables in close problems). Always use the shortest length of control cable possiproximity to one another to minimize the loop area. Since the most ble, and DO NOT coil excess cable. significant factor in cable inductance is the welding loop length, avoid excessive lengths and do not coil excess cable. For long Regarding cable placement, best results will be obtained when work piece lengths, a sliding ground should be considered to keep control cables are routed separate from the weld cables. This minthe total welding loop length as short as possible. imizes the possibility of interference between the high currents flowing through the weld cables, and the low level signals in the control cables. Electrode Voltage Sensing The remote ELECTRODE sense lead (67) is built into the 5-pin ArcLink control cable and is always connected to the wire drive feed plate when an ArcLink wire feeder is present. Enabling or disabling electrode voltage sensing is application specific, and automatically configured by the active weld mode. Product specific Installation Instructions Voltage sense leads requirements are based on the weld process (See Table A.3) The 5-pin ArcLink® control cable connects the AIR VANTAGE® 600 SD to the wire feeder. The control cable consists of two power leads, one twisted pair for digital communication, and one lead for voltage sensing. The 5-pin ArcLink® connection on the AIR VANTAGE® 600 SD is located on control panel. The control cable is keyed and polarized to prevent improper connection. Best results will be obtained when control cables are routed separate from the weld cables, especially in long distance applications. The recommended combined length of the ArcLink® control cable network should not exceed 200ft. (60.960m). Process GMAW FCAW GTAW SMAW TABLE A.3 Electrode Voltage Sensing (1) 67 lead 67 lead 67 lead Voltage sense at studs Voltage sense at studs Connection Between AIR VANTAGE® 600 SD and ArcLink® Compatible Wire feeders (K1543, K2683 – ArcLink® Control Cable) (1) The electrode voltage sense lead (67) is automatically enabled by the weld process, and integral to the 5 pin ArcLink control cable (K1543-xx) or K2683-xx. FIGURE A.9 ® AIR A VANTAGE 600 SD A C WORK B A-12 AIR VANTAGE® 600 SD OPERATION SAFETY INSTRUCTIONS Read and understand this entire section before operating your AIR VANTAGE® 600 SD. 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. ELECTRIC SHOCK can kill. RECOMMENDED APPLICATIONS WELDER The AIR VANTAGE® 600 SD provides excellent constant current DC welding output for stick (SMAW) and TIG (GTAW) welding. The AIR VANTAGE® 600 SD also provides excellent constant voltage DC welding output for MIG (GMAW), Innershield (FCAW), Outershield (FCAW-G) and Metal Core (GMAW-C) welding. In addition the AIR VANTAGE® 600 SD can be used for Arc Gouging with carbons up to 1/2”(13mm) in diameter. The AIR VANTAGE® 600 SD is not recommended for pipe thaw• Do not touch electrically live parts such as ing. output terminals or internal wiring. • Insulate yourself from the work and ground. GENERATOR • Always wear dry insulating gloves. The AIR VANTAGE® 600 SD provides smooth 120/240 VAC single phase and 240V three phase output for auxiliary power and emergency standby power. ----------------------------------------------------------------ENGINE EXHAUST can kill. • Use in open, well ventilated areas or vent exhaust outside • Do not stack anything near the engine. ----------------------------------------------------------------MOVING PARTS can injure. • Do not operate with doors open or guards off. • Stop engine before servicing. • Keep away from moving parts ----------------------------------------------------------------Only qualified personnel should operate this equipment. ADDITIONAL SAFETY PRECAUTIONS Always operate the welder with the sliding door closed and the side panels in place as these provide maximum protection from moving parts and insure proper cooling air flow. B-1 AIR VANTAGE® 600 SD OPERATION CONTROLS AND SETTINGS All welder and engine controls are located on the case front panel. Refer to Figure B.3 and the explanations that follow. Figure B.3 Case Front Panel Controls 3 6 11 15 3c 3d 3e 34 35 36 5 6a 23 10 19 17 11a 20 12 21 22 1 18 24 14 25 31 33 32 ENGINE CONTROLS 37 16 8 9 13 3b 4 7 2 3a CAUTION 2) In the “Auto” follows: / position, the idler operates as a. When switched from “High” to “Auto” or after starting the engine, the engine will operate at full speed for approximately 12 seconds and then go to low idle speed. It is extremely important to have the compressor system power switch (Item 36) in the “OFF” position when starting the engine. Failure to observe this may result in loss of clutch life. b. When the electrode touches the work or power is drawn for lights or tools (approximately 100 Watts minimum) the engine accelerates and operates at full speed. ----------------------------------------------------------------- / (HIGH IDLE/RUN) c. When welding ceases and the AC power load is turned off, a fixed time delay of approximately 12 seconds starts. Toggling the switch to the RUN position energizes the fuel solenoid for approximately 30 seconds. The engine must be started within that time or the fuel solenoid will degenerize, and the switch must be toggled to reset the timer. d. If the welding or AC power load is not restarted before the end of the time delay, the idler reduces the engine speed to low idle speed. 1. STOP / (LOW IDLE/RUN) SWITCH Has two positions as follows: 1) In the “High” position , the engine runs at the high idle speed controlled by the governor. B-2 e. The engine will automatically return to high idle speed when the welding load or A.C. power load is reapplied. AIR VANTAGE® 600 SD OPERATION Idler Operational exceptions 4. OUTPUT CONTROL- The OUTPUT dial is used to preset the output voltage or current as displayed on the digital meters for the five welding modes. When the WELDING TERMINALS switch is in the “Remotely Controlled” position the idler will operate as follows: a. When the triggering device (Amptrol, Arc Start Switch, etc.) is pressed the engine will accelerate and operate at full speed provided a welding load is applied within approximately 12 seconds. 5. VRD (Voltage Reduction Device) INDICATOR LIGHTS- On the front panel of the AIR VANTAGE® 600 SD are two indicator lights. A red light when lit indicates OCV(Open Circuit Voltage) is equal to or greater than 30V and a green light when lit indicates OCV(Open Circuit Voltage) is less than 30V. • If the triggering device remains pressed but no welding load is applied within approximately 12 seconds the engine may return to low idle speed. • If the triggering device is released or welding ceases the engine will return to low idle speed after approximately 12 seconds. 2. START SWITCH Energizes the starter motor to crank the engine. With the engine "Run / Stop" switch in the "Run" position, push and release the Start button to start the engine: • this switch has an amber light (Top of switch) to indicate Glow light, this engine will automatically apply power to the glow circuit and indicator light will turn off when glow is completed. (Engine will crank but will not start until glow cycle is completed) • this switch also has a red light (Bottom of switch) it will light up when there are faults with the engine. (Check engine light comes on) Field Service Shop will need to connect to diagnostic plug to read error codes. 3. DASH BOARD GAUGE The dash board gauge displays 5 gauges: 3a. OIL PRESSURE The gauge displays the engine oil pressure when the engine is running. 3b. ENGINE TEMPERATURE The gauge displays the engine coolant temperature. 3c. HOUR METER The hour meter displays the total time that the engine has been running. This meter is a useful indicator for scheduling preventive maintenance. 3d. FUEL LEVEL Displays the level of diesel fuel in the fuel tank. The operator must watch the fuel level closely to prevent running out of fuel and possibly having to bleed the system. 3e. BATTERY VOLTAGE INDICATOR Displays the battery voltage and indicates that the charging system is functioning properly. B-3 The VRD “On/Off” switch inside the control panel must be “On” for the VRD function to be active and the lights to be enabled. When the machine is first started with VRD enabled, both lights will illuminate for 5 seconds. These lights monitor the OCV(Open Circuit Voltage) and weld voltage at all times. When not welding the green light will illuminate indicating that the VRD has reduced the OCV to less than 30V. During welding the red light will illuminate whenever the arc voltage is equal to or greater than 30V. This means that the red and green light may alternate depending on the weld voltage. This is normal operation. If the red light remains illuminated or both VRD lights flash when not welding, the VRD is not functioning properly. Please refer to your local field service shop for service. If the VRD is turned “On” and the lights don’t come “On”, refer to the trouble shooting section. AIR VANTAGE® 600 SD OPERATION 6. DIGITAL OUTPUT METERS-The digital meters allow the preset arc voltage (CV-WIRE mode) or preset arc current (CCSTICK, DOWNHILL PIPE, ARC GOUGING and TIG modes) to be set prior to welding using the OUTPUT control dial. During welding, the meter display the actual output voltage (VOLTS) and current (AMPS). A memory feature holds the display of both meters on for seven seconds after welding is stopped. This allows the operator to read the actual current and voltage just prior to when welding was ceased. HIDDEN SETUP MENU ACCESS PORT: INSERT TOOL OR PAPER CLIP TO ACCESS While the display is being held the left-most decimal point in each display will be flashing. The accuracy of the meters is +/- 3%. The meters will display all dashes for preset when ArcLink® mode is selected. 6a. HIDDEN MENU BUTTON: FIGURE B.4 The hidden setup menu can be accessed any time the machine is on with the engine running and not in a welding arc (arc off or OCV). To access, press the hidden setup menu push button (Figure B.4) with the appropriate tool or paper clip, if no tool is readily available. NOTE: The menu system will exit automatically if any of the following conditions are met: • If no settings are changed for 10 seconds. • If the mode selection switch position is changed. • If the arc status changes to arc or short. • If the entire setup menu sequence is cycled through. HIDDEN SETUP MENU FUNCTIONS • Hot start setting individually settable by mode. Hot start will not display if not applicable. The left display will show “Hot” and “Strt” alternately at 0.5 second intervals. The right display will show a number from 0.0 to 10.0. The default value will be 5, (Figure B.5). This setting will be stored in system memory and will be remembered between machine power cycles. FIGURE B.5 B-4 AIR VANTAGE® 600 SD OPERATION • Alternate CV mode selection. Default CV mode will be non-synergic FCAW-SS (mode 6). Alternate settings will be non-synergic GMAW (mode 5) and non-synergic FCAW-GS (mode 7). The left display will show “CV” and “type” alternately at 0.5 second intervals. The right display will show “FC.SS”(Figure B.6), “FC.gS”(Figure B.7) or “MIG”(Figure B.8). This setting will be stored in system memory and will be remembered between machine power cycles. This setting will only be visible if the process selection switch is in the CV Wire position. FIGURE B.6 FIGURE B.4 FIGURE B.7 FIGURE B.5 FIGURE B.8 FIGURE B.6 • Selection of the remote connector for stick (SMAW) modes. The customer can select between the 12-pin or the 14-pin connector for the remote potentiometer input when in the “remote” switch position for stick (SMAW) modes. The default from the factory will be the 12-pin connector. The left display will show “Pot”, “12P” (Figure B.9) and the right display will show “Pot”, “14P” (Figure B.10). This setting is stored in system memory and will be remembered between machine power cycles. This selection will only be visible for stick (SMAW) modes. FIGURE B.7 FIGURE B.9 FIGUREB.10 B.8 FIGURE B-5 AIR VANTAGE® 600 SD OPERATION • Test Modes for grid load testing. The left display will show “tESt” and “LoAd” alternately at 0.5 second intervals. The right display will show “CC” (mode 200)(Figure B.11), “CV” (mode 201) (Figure B.12) or “OFF” (normal operation)(Figure B.13). This setting is not remembered between machine power cycles and will default to OFF at each power on. Moving the position of the weld process selection rotary switch Item 10 will reset the setting back to OFF. FIGURE B.9B.11 FIGURE FIGURE B.10 FIGURE B.12 FIGURE B.13 FIGURE B.11 EXITING HIDDEN MENU BUTTON Pressing and holding the hidden reset push button for 5 seconds will cause certain stored values to be reset to defaults. The stored hot start values will return to a default setting of 5 on the display (0 at the attribute). The work point values will all be reset to the minimum from the weld table for each respective weld mode. The alternate CV mode selection will revert back to the Flux-Cored Arc Welding-Self Shielding (FCAW-SS) setting. The remote pot connector choice will revert back to the 12-pin connector. When the reset occurs, the left display will show “ deF”, and the right display will show “AuLt” for 3 seconds until the machine exits the menu system. B-6 AIR VANTAGE® 600 SD OPERATION 7. WELD TERMINALS ON SWITCH 13. 12-PIN CONNECTOR For attaching optional remote control equipment. The K2909-1 (12-pin to 6-pin) adapter cable is included for attaching to accessories requiring the 6-pin connector. Output is enabled when in the ON position. Output is remotely controlled when in the REMOTE position. This control is not active in ArcLink® modes. 8. DOOR LATCH 14. 14-PIN CONNECTOR For attaching wire feeder control cables. Includes contactor closure circuit, work sense leads, remote control circuit, and 120VAC and 42VAC power. 9. ARC CONTROL The ARC CONTROL knob is active in the CV-WIRE and CC-STICK modes, and has different functions in these modes. This control is not active in the TOUCH START TIG mode or in ArcLink® mode. 15. WELD OUTPUT TERMINALS “+” POSITIVE AND “-” NEGATIVE CC-STICK mode: In this mode, the ARC CONTROL knob sets the short circuit current (arc-force) during stick welding. Increasing the number from -10(Soft) to +10(Crisp) increases the short circuit current and prevents sticking of the electrode to the plate while welding. These 1/2” - 13 studs with flange nuts provide welding connection points for the electrode and work cables. For positive polarity welding the electrode cable connects to the “+” terminal and the work cable connects to this “-” terminal. For negative polarity welding the work cable connects to the “+” terminal and the electrode cable connects to this “-” terminal. This can also increase spatter. It is recommended that the ARC CONTROL be set to the minimum number without electrode sticking. Start with a setting at 0. DOWNHILL PIPE mode: In this mode, the ARC CONTROL knob sets the short circuit current (arc-force) during stick welding to adjust for a soft or a more forceful digging arc (Crisp). Increasing the number from -10(Soft) to +10(Crisp) increases the short circuit current which results in a more forceful digging arc. Typically a forceful digging arc is preferred for root and hot passes. A softer arc is preferred for fill and cap passes where weld puddle control and deposition (“stacking” of iron) are key to fast travel speeds. It is recommended that the ARC CONTROL be set initially at 0. 16. LOCAL/REMOTE SWITCH- In the LOCAL position, machine output control is set by the Output Control knob on the front of the machine. In the REMOTE position, the machine output control is set by the remote inputs. This control is not active in ArcLink® modes. 17. POLARITY SWITCH: Matches the polarity of the wire feeder voltmeter to the polarity of the electrode. 10. WELD MODE SELECTOR SWITCH: (Provides six selectable welding modes) CV-WIRE DOWNHILL PIPE CC-STICK TOUCH START TIG ARC GOUGES ARC LINK 11. 42V / 115V WIRE FEEDER VOLTAGE SWITCH: Toggles output of 14-pin connector to voltage requirement of Wire Feeder. (Located above 14-pin connector.) 11a. 42V and 115V WIRE FEEDER BREAKERS 12. 5-PIN CONNECTOR For attaching an ArcLink® Wire Feeder control cable. B-7 AIR VANTAGE® 600 SD OPERATION 18. 20A 120V AUXILIARY BREAKERS 26. DIAGNOSTIC PLUG This is used by Field Service shops to connect and troubleshoot engine error codes and is found on the firewall inside the machine on the service side. 19. 50A 240V 3 PHASE BREAKER 20. BATTERY 20A BREAKER 26 21. 240VAC THREE PHASE RECEPTACLE This is a 240VAC (15-50R) receptacle that provides 240VAC three phase auxiliary power. This receptacle has a 50 amp rating. Items 27 thru 30 are found inside the machine by removing the right side panel facing the front. 22. 120/240 VAC SINGLE PHASE RECEPTACLE This is a 120/240VAC (14-50R) receptacle that provides 240VAC or can be split for 120VAC single phase auxiliary power. This receptacle has a 50 amp rating. Refer to the AUXILIARY POWER RECEPTACLES section in the installation chapter for further information about this receptacle. Also refer to the AUXILIARY POWER OPERATION section later in this chapter. 27. GLOW RELAY / BREAKER (70A) 28. FUEL RELAY / BREAKER (20A) 29. IDLE RELAY 30. ECU (Electronic Control Unit) BREAKER (30A) 29 23. 10A 42V/40V ARCLINK BREAKERS 27 24. 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 receptacle, the 120VAC in the 14-Pin connector, the 42VAC in the 14-Pin connector and battery circuit overload protection. 30 25. 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. 28 31. NEGATIVE BATTERY JUMP START TERMINAL. 32. POSITIVE BATTERY JUMP START TERMINAL. 12V battery jump start feature is standard. Covered output studs for convenient access, and protection against accidental impact. These terminals can be used to jump-start a utility truck with up to 800 cold cranking amps. B-8 AIR VANTAGE® 600 SD OPERATION 33. ACTIVATING THE COMPRESSOR SYSTEM Figure B.14 (See Figure B.12 and B.13) 1. The compressor can be activated in low or high idle. 2. Close the ball valve, Item 33, as shown in the figure B.14. 3. Press the power switch, Item 36, to the “ON” position as shown in figure B.15. 4. Watch the pressure gage, Item 37, for an increase in pressure to approximately 150-160 psi, depending on the idle speed selected. 5. The hour meter, Item 34, will activate and show the total hours on the compressor system. 33 6. The amber fault light, Item 35, should not be illuminated when the system is functioning normally. • If the compressor system does not come on and/or the fault light is illuminated, turn off the compressor power switch, then turn off the machine (RUN/STOP to OFF) and go to the “TROUBLE SHOOTING” section to locate the cause of the problem. 7. The compressor system is ready to use after warming up for about one minute. 8. Connect up to the ball valve (3/4 NPT )and open fully to use the system air DEACTIVATING THE COMPRESSOR SYSTEM 1. Close the ball valve, Item 33, as shown in the figure B.12. 2. Press the power switch, Item 36, to the “OFF” position see figure B.15. 3. Watch the pressure gage, Item 37, for a decrease in pressure to approximately to 0 psi. This should take place in one minute or less. 34 35 Figure B.15 B-9 36 37 AIR VANTAGE® 600 SD OPERATION CONTROL AND INDICATOR FUNCTIONALITY (Letters reference the preceding figures) 1. The ball valve Item 33 controls the flow of air out of the system. The valve is fully closed when the handle is pointing to the left side of the machine (as shown in figure B.14). The valve is fully open when the handle is pointing away from the control panel. • Always turn the valve to the fully closed position before starting and stopping the system. 2. When the compressor system is running, the total hours on the system is displayed on the hour meter Item 34. This is the time interval used for servicing the system oil and filters and drive belt. 3. The amber fault light Item 35 on the lower right is normally off when the compressor system is functioning normally. If the light is illuminated it indicates a system malfunction and the system will automatically turn itself off by disengaging the magnetic clutch. The pressure gage should be reading 0 psi in this condition. • NOTE: It is acceptable to continue to use the machine for welding and auxiliary power without causing any further damage to the compressor system until it can be serviced. 4. The ON / OFF switch Item 36 controls power to the electromechanical clutch which mechanically couples and decouples the compressor to the engine. When the switch is pushed to the ON position, 12 volts DC is applied to the clutch, enabling the compressor to be driven by the engine. When the switch is pushed to the OFF position, the 12 volts DC is cut from the circuit thereby disengaging the clutch and stopping compressor rotation. 5. The air pressure gage Item 37 indicates that the system is on and functioning and reads the pressure at the filter manifold. The pressure at a tool attached to the system will be lower depending on the hose length and restrictions (lubricators, filters, regulators, tees, etc.) placed between the ball valve and the tool. Minimum pressure check valve clutch safeguard. • A minimum pressure check valve has been installed internal to the machine just ahead of the ball valve as a safeguard against starting and stopping the compressor with the ball valve open. This check valve will help to minimize damage to the clutch when the ball valve is not closed when starting and stopping the system over the coarse of the life of the machine. To ensure long term reliability the ball valve must be closed before starting and stopping the compressor. For informative purposes, this check valve has a cracking pressure of 60 psi. (FOR MORE DETAILS ON THE COMPRESSOR SYSTEM AND TROUBLESHOOTING CONSULT THE APPROPRIATE VMAC OWNERS MANUAL) CONTROL SAFEGUARDS TO IMPROVE RELIABILITY ON/OFF clutch safeguard • If the system is on and running and the power switch is pushed to “OFF” and then back “ON” before the system pressure reaches 2 psi, the following system behavior will be observed which is designed to prevent excessive wear or failure of the clutch: • The amber fault light will be illuminated. • The compressor clutch will not be engaged. • The air pressure gage will show a decrease in pressure until 2 psi is reached. • When the system reaches 2 psi a pressure switch will then allow 12V to go to the clutch reactivating the system. B-10 AIR VANTAGE® 600 SD OPERATION WELDER OPERATION TYPICAL FUEL CONSUMPTION DUTY CYCLE Refer to Table B.2 for typical fuel consumption of the AIR VANTAGE® 600 SD Engine for various operating scenarios. 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. TOUCH START TIG MODE The AIR VANTAGE® 600 SD can be used in a wide variety of DC TIG welding applications. STICK WELDING MODE The TOUCH START TIG setting of the MODE switch is for DC TIG (Tungsten Inert Gas) welding. To initiate a weld, the OUTPUT CONTROL knob is first set to the desired current and the tungsten is touched to the work. During The MODE switch provides two stick welding settings as follows: the time the tungsten is touching the work there is very little voltage or current and, in general, avoids tungsten contamination. Then, the tungCC-STICK MODE sten is gently lifted off the work in a rocking motion, which establishes The CC-STICK position of the MODE switch is designed for horizontal, ver- the arc. tical-up and over head welding with all types of electrodes, especially low To stop the arc, simply lift the TIG torch away from the work piece. When hydrogen. The OUTPUT CONTROL knob adjusts the full output range for the arc voltage reaches approximately 30 volts, the arc will go out and the stick welding. machine will automatically reset to the touch start current level. The The ARC CONTROL knob sets the short circuit (arc-force) current during tungsten may then be retouched to the work piece to restrike the arc. The stick welding. Increasing the number from -10(Soft) to +10 (Crisp) arc may also be started and stopped with an Amptrol or Arc Start Switch. increases the short circuit current and prevents sticking of the electrode The ARC CONTROL is not active in the TIG mode. to the plate while welding. This can also increase spatter. It is recommended that the ARC CONTROL be set to the minimum number without In general the ‘Touch Start’ feature avoids tungsten contamination without the use of a Hi-frequency unit. If the use of a high frequency generator is desired, electrode sticking. Start with the knob set at 0. the K930-2 TIG Module can be used with the AIR VANTAGE® 600 SD. The DOWNHILL PIPE MODE settings are for reference. This slope controlled setting is intended for “out-of-position” and “down The AIR VANTAGE® 600 SD is equipped with the required R.F. bypass hill” pipe welding where the operator would like to control the current circuitry for the connection of high frequency generating equipment. level by changing the arc length. The OUTPUT CONTROL knob adjusts the The AIR VANTAGE® 600 SD and any high frequency generating full output range for pipe welding. equipment must be properly grounded. See the K930-2 TIG The ARC CONTROL knob sets the short circuit current (arc-force) during Module operating manuals for complete instructions on installastick welding to adjust for a soft or a more forceful digging arc (Crisp). tion, operation, and maintenance. Increasing the number from -10(Soft) to +10(Crisp) increases the short When using the TIG Module, the OUTPUT control on the AIR VANTAGE® circuit current which results in a more forceful digging arc. Typically a 600 SD is used to set the maximum range of the CURRENT CONTROL forceful digging arc is preferred for root and hot passes. A softer arc is on the TIG Module Amptrol. preferred for fill and cap passes where weld puddle control and deposition (“stacking” of iron) are key to fast travel speeds. It is recommended that the ARC CONTROL be set initially at 0. The AIR VANTAGE® 600 SD can be used with a broad range of DC stick electrodes. Table B.2 (Deutz TD 2.9 L4) Fuel Consumption High Idle Low Idle 100A 24V 200A 28V 300A 32V 400A 36V 500A 40V Aux power 12,000VA single phase Aux power 20,000VA three phase GAL/HR 0.79 0.59 0.91 1.05 1.30 1.65 2.02 1.35 1.86 B-11 Liters/Hr 3.01 2.24 3.44 3.98 4.92 6.25 7.63 5.11 7.03 HRS @ 25 GAL(94.6L) 31.48 42.37 27.54 23.76 19.23 15.15 12.40 18.51 13.46 AIR VANTAGE® 600 SD OPERATION COMMON WELDING PROCEDURES WARNING AIR VANTAGE® 600 SD then uses the WFS setting to adjust the voltage and current according to settings contained in the AIR VANTAGE® 600 SD. MAKING A WELD The serviceability of a product or structure utilizing the welding programs is and must be the sole responsibility of the builder/user. Many variables beyond the control of The Lincoln Electric Company affect the results obtained in applying these programs. These variables include, but are not limited to, welding procedure, plate chemistry and temperature, weldment design, fabrication methods and service requirements. The available range of a welding program may not be suitable for all applications, and the build/user is and must be solely responsible for welding program selection. Choose the electrode material, electrode size, shielding gas, and process (GMAW, GMAW-P etc.) appropriate for the material to be welded. Select the weld mode that best matches the desired welding process. The standard weld set shipped with the AIR VANTAGE® 600 SD encompasses a wide range of common processes that will meet most needs. If a special weld mode is desired, contact the local Lincoln Electric sales representative. All adjustments are made through the user interface. Because of the different configuration options your system may not have all of the following adjustments. See Accessories Section for Kits and Options available to use with the AIR VANTAGE® 600 SD. DEFINITION OF WELDING MODES In non-synergic modes, the WFS control behaves like a conventional power source where WFS and voltage are independent adjustments. Therefore, to maintain proper arc characteristics, the operator must adjust the voltage to compensate for any changes made to the WFS. Amps In constant current modes, this control adjusts the welding amperage. Volts In constant voltage modes, this control adjusts the welding voltage. Trim In pulse synergic welding modes, the Trim setting adjusts the arc length. Trim is adjustable from 0.50 to 1.50. 1.00 is the nominal setting and is a good starting point for most conditions. UltimArc™ Control UltimArc™ Control allows the operator to vary the arc characteristics. UltimArc™ Control is adjustable from –10.0 to +10.0 with a nominal setting of 0.0. PULSE WELDING Pulse welding procedures are set by controlling an overall “arc length” variable. When pulse welding, the arc voltage is highly dependent upon the waveform. The peak current, back ground current, rise time, fall time and pulse frequency all affect the voltage. The exact voltage for a given wire feed speed can only be predicted when all the pulsing waveform parameters are known. Voltage or Trim can be adjusted. Trim adjusts the arc length and ranges from 0.50 to 1.50 with a nominal value of 1.00. Trim values greater than 1.00 increase the arc length, while values less than 1.00 decrease the arc length. (See Figure B.14) NON-SYNERGIC WELDING MODES • A Non-synergic welding mode requires all welding process variables to be set by the operator. SYNERGIC WELDING MODES • A Synergic welding mode offers the simplicity of single knob control. The machine will select the correct voltage and amperage based on the Wire Feed Speed (WFS) set by the operator. FIGURE B.14 BASIC WELDING CONTROLS Weld Mode Selecting a weld mode determines the output characteristics of the AIR VANTAGE® 600 SD power source. Weld modes are developed with a specific electrode material, electrode size, and shielding gas. For a more complete description of the weld modes programmed into the AIR VANTAGE® 600 SD at the factory, refer to the Weld Set Reference Guide supplied with the machine. Wire Feed Speed (WFS) In synergic welding modes (synergic CV, GMAW-P), WFS is the dominant control parameter. The user adjusts WFS according to factors such as wire size, penetration requirements, heat input, etc. The B-12 Trim .50 Arc Length Short Trim 1.00 Arc Length Medium Trim 1.50 Arc L ength Long AIR VANTAGE® 600 SD OPERATION Most pulse welding programs are synergic. As the wire feed speed is adjusted, the AIR VANTAGE® 600 SD will automatically recalculate the waveform parameters to maintain similar arc properties. The AIR VANTAGE® 600 SD utilizes “adaptive control” to compensate for changes in the electrical stick-out while welding. (Electrical stick-out is the distance from the contact tip to the work piece.) The AIR VANTAGE® 600 SD waveforms are optimized for a 0.75” stick-out. The adaptive behavior supports a range of stickouts from 0.50 to 1.25”. At very low or high wire feed speeds, the adaptive range may be less due to reaching physical limitations of the welding process. UltimArc™ Control adjusts the focus or shape of the arc. UltimArc™ Control is adjustable from -10.0 to +10.0 with a nominal setting of 0.0. Increasing the UltimArc™ Control increases the pulse frequency and background current while decreasing the peak current. This results in a tight, stiff arc used for high speed sheet metal welding. Decreasing the UltimArc™ Control decreases the pulse frequency and background current while increasing the peak current. This results in a soft arc good for out of position welding. (See Figure B.15) FIGURE B.15 UltimArc™ Control -10.0 Low Frequency, Wi de UltimArc™ Control OFF Med ium Fr equency and Wi dth B-13 UltimArc™ Control +10.0 Hi gh Frequency , Fo cu sed AIR VANTAGE® 600 SD OPERATION AIR VANTAGE® 600 SD SETTINGS WHEN USING THE K930-2 TIG MODULE • Set the WELD MODE switch to the “Touch Start TIG Setting”. • Set the STOP/AUTO IDLE/HIGH IDLE switch to the “AUTO/RUN” position. • Set the WELDING TERMINALS switch to the “Remotely Controlled” position. This will keep the solid state contactor open and provide a “cold” electrode until the triggering device (Amptrol or Arc Start Switch) is pressed. 1%, 2% Thoriated Tungsten .50 (0.020) 5-20 (3) 3-5 (5-10) 3-5 (5-10) 70-150 10-20 3-5 (5-10) 4-6 (9-13) #5, #6 400-500 500-750 40-55 55-80 6-8 (13-17) 8-10 (18-22) #8, #10 1.6 (1/16) (4) (5) 2-15 15-80 2.4 (3/32) 3.2 (1/8) 150-250 250-400 6.4 (1/4) 750-1000 4.0 (5/32) 4.8 (3/16) (3) Approximate Argon Gas Flow Rate l/min (c.f.m.) 1%, 2% Thoriated Tungsten 1.0 (0.040) (2) DCEP (+) Tungsten Electrode Diameter mm (in) .25 (0.010) (1) DCEN (-) Table B.3 TYPICAL CURRENT RANGES (1) FOR TUNGSTEN ELECTRODES (2) Aluminum (3) 2-4 (3-8) (3) 3-5 (5-10) 15-30 25-40 6-8 (13-17) 7-11 (15-23) 10-12 (21-25) 11-13 (23-27) 80-125 13-15 (28-32) Stainless Steel 2-4 (3-8) 3-5 (5-10) 5-7 (11-15) 5-7 (11-15) 11-13 (23-27) TIG TORCH Nozzle Size (4), (5) #4, #5, #6 #6, #7, #8 When used with argon gas. The current ranges shown must be reduced when using argon/helium or pure helium shielding gases. Tungsten electrodes are classified as follows by the American Welding Society (AWS): Pure EWP 1% Thoriated EWTh-1 2% Thoriated EWTh-2 Though not yet recognized by the AWS, Ceriated Tungsten is now widely accepted as a substitute for 2% Thoriated Tungsten in AC and DC applications. DCEP is not commonly used in these sizes. TIG torch nozzle “sizes” are in multiples of 1/16ths of an inch: #4= #5= #6= #7= #8= #10 = 1/4 in. 5/16 in. 3/8 in. 7/16 in. 1/2 in. 5/8 in. 6 mm 8 mm 10 mm 11 mm 12.5 mm 16 mm TIG torch nozzles are typically made from alumina ceramic. Special applications may require lava nozzles, which are less prone to breakage, but cannot withstand high temperatures and high duty cycles. B-14 AIR VANTAGE® 600 SD OPERATION CV-WIRE MODE PARALLELING Connect a wire feeder to the AIR VANTAGE® 600 SD and set welder When paralleling machines in order to combine their outputs, all controls according to the instructions listed earlier in this section. units must be operated in the CC-STICK mode at the same output ® The AIR VANTAGE 600 SD in the ”CV-WIRE” position, permits it to settings. To achieve this, turn the WELD MODE switch to the CCSTICK position. Operation in other modes may produce erratic outbe used with a broad range of flux cored wire (Innershield and and large output imbalances between the units. puts, Outershield) electrodes and solid wires for MIG welding (gas metal arc welding). Welding can be finely tuned using the “ARC CONTROL”. AUXILIARY POWER OPERATION Turning the ARC CONTROL clockwise from -10(soft) to +10(crisp) changes the arc from soft and washed-in to crisp and narrow. It acts Start the engine and set the IDLER control switch to the desired operating mode. Full power is available regardless of the welding as an inductance/pinch control. The proper setting depends on the control settings, if no welding current is being drawn. procedure and operator preference. Start with the knob set at 0. For any electrodes, including the above recommendations, the procedures should be kept within the rating of the machine. For additional electrode information, See www.lincolnelectric.com or the appropriate Lincoln publication. CONSTANT VOLTAGE WELDING The auxiliary power of the AIR VANTAGE® 600 SD consists of two 20 Amp-120VAC single phase (5-20R) GFCI duplex receptacles, one 50 Amp-120/240VAC single phase (14-50R) receptacle and one 50 Amp 240VAC three phase (15-50R) receptacle. The 120/240VAC receptacle can be split for single phase 120 VAC operation. Synergic CV For each wire feed speed, a corresponding voltage is preprogrammed into the machine through special software at the factory. The nominal preprogrammed voltage is the best average voltage for a given wire feed speed, but may be adjusted to preference. When the wire feed speed changes, the AIR VANTAGE® 600 SD automatically adjusts the voltage level correspondingly to maintain similar arc characteristics throughout the WFS range. The auxiliary power capacity is 12,000 watts of 60 Hz, single phase power or 20,000 watts of 60Hz, three phase power. The auxiliary power capacity rating in watts is equivalent to voltamperes at unity power factor. The maximum permissible current of the 240 VAC output is 50 A. The 240 VAC single phase output can be split to provide two separate 120 VAC outputs with a maximum permissible current of 50 A per output to two separate 120 VAC branch circuits. Output voltage is within ± 10% at all loads up to rated capacity. Non Synergic CV In non-synergic modes, the WFS control behaves more like a conventional CV power source where WFS and voltage are independent adjustments. Therefore to maintain the arc characteristics, the operator must adjust the voltage to compensate for any changes made to the WFS. ARC GOUGING For optimal performance when arc gouging, set the VANTAGE® 600 SD “WELD MODE” switch to the “Arc Gouging” position, and the “ARC CONTROL” to 10. Set the “OUTPUT” knob to adjust output current to the desired level for the gouging electrode being used according to the ratings in Table B.4 below. Due to available horsepower of engine at low idle, when gouging above 450 Amps it is recommended to set the machine for “High Idle.” NOTE: If desired the CV mode can be used for Arc Gouging*. Maximum current setting is limited to the AIR VANTAGE® 600 SD maximum of 600 Amps. ELECTRODE DIAMETER (1/8”) (5/32”) (3/16”) (1/4”) (5/16”) (3/8”) (1/2”) NOTE: The two 120V GFCI receptacles and the two 120V circuits of the 120/240V receptacle are connected to different phases and cannot be paralleled. The auxiliary power receptacles should only be used with three wire grounded type plugs or approved double insulated tools with two wire plugs. The current rating of any plug used with the system must be at least equal to the current capacity of the associated receptacle. SIMULTANEOUS WELDING AND AUXILIARY POWER LOADS It must be noted that the above auxiliary power ratings are with no welding load. Simultaneous welding and power loads are specified in table B.5. The permissible currents shown assume that current is being drawn from either the 120 VAC or 240 VAC supply (not both at the same time). TABLE B.4 CURRENT RANGE (DC, electrode positive) 30-60 Amps 90-150 Amps 200-250 Amps 300-400 Amps 350-450 Amps 450-600 Amps* 600 Amps B-15 AIR VANTAGE® 600 SD WELD AMPS 0 100 200 250 300 400 up to 600 OPERATION 1 PHASE WATTS AMPS 12,000 50 12,000 50 12,000 50 50 12,000 10,000 42 5,600 23 0 0 3 PHASE WATTS AMPS 20,000 50 17,800 43 14,000 34 29 12,000 10,000 24 5,600 13 0 0 TABLE B.5 AIR VANTAGE® 600 SD DEUTZ SIMULTANEOUS WELDING AND POWER LOADS PLUS OR OR BOTH 1 AND 3 PHASE WATTS AMPS 50 ----------50 -----50 12,000 -----10,000 -----5,600 -----0 0 TABLE B.6 AIR VANTAGE® 600 SD DEUTZ Extension Cord Length Recommendations Current Voltage Load (Amps) (Volts) (Watts) 15 15 20 20 25 30 38 50 120 240 120 240 240 240 240 240 1800 3600 2400 4800 6000 7200 9000 12000 14 AWG 30 60 (9) (18) Maximum Allowable Cord Length in ft. (m) for Conductor Size 12 AWG 10 AWG 8 AWG 6 AWG 40 75 30 60 (12) (23) (9) (18) 75 150 50 100 90 75 (23) (46) (15) (30) (27) (23) 125 225 88 175 150 120 100 (38) (69) (27) (53) (46) (37) (30) Conductor size is based on maximum 2.0% voltage drop. B-16 175 350 138 275 225 175 150 125 (53) (107) (42) (84) (69) (53) (46) (38) 4 AWG 300 600 225 450 250 300 250 200 (91) (183) (69) (137) (76) (91) (76) (61) AIR VANTAGE® 600 SD OPERATION The following additional modes can be accessed via an ArcLink feeder Dia. inches .030 .035 .040 .045 3/64 0.052 1/16 Dia. inches 0.035 0.045 3/64 0.052 1/16 Synergic CV Modes Metal Core Stainless Argon Tri-Mix Argon Mix Mix • • • • Steel Argon CO2 Mix • • • • • • • • • • • • • • • • Pulse Modes Steel Stainless Argon Argon Mix Mix • • • • • • • Aluminum 4043 5356 • • • • B-17 Flux Core Argon CO2 Mix • Aluminum 4043 5356 • • • • • AIR VANTAGE® 600 SD ACCESSORIES WARNING 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 household receptacles. 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® 600 SD is equipped with a 12-pin connector for connecting the remote control and 12pin to 6-pin adapter. Pipe Thawing with an arc welder can cause fire, explosion, damage to electric wiring or to the arc welder if done improperly. The use of an arc welder for pipe thawing is not approved by the CSA, nor is it recommended or supported by Lincoln Electric. -----------------------------------------------------------------REMOTE OUTPUT CONTROL WITH 120V AC RECEPTACLES Remote weld output control box with two 120V AC receptacles having GFCI (Ground Fault Circuit Interrupter) protection. One cord for both remote and power. 100 ft. (30.5 m) length. Permits remote adjustment of weld output and power for tools (such as a grinder) at the work. 20 amp capacity. K2627-2 K704 ACCESSORY SET - Includes 35 feet (10 m) of electrode cable and 30ft. (9m) of work cable, headshield, Filter plate, work DOCKING KIT clamp and electrode holder. Cable is rated at 500 amps, 60% duty Secures the K2642-1 Polarity/Multi- Process Switch to the enginedriven welder roof. Release latch permits removal of K2642-1 cycle. Polarity/Multi- Process Switch. Made from stainless steel for rustfree operation. For all Lincoln Electric Chopper Technology® K2641-2 FOUR WHEELED STEERABLE YARD TRAILER engine-driven welders. For in plant and yard towing. Comes standard with a Duo-Hitch™, a 2” K2663-1 Ball and Lunette Eye combination hitch. TIG OPTIONS MEDIUM WELDER TRAILER For heavy-duty road, off-road, plant and yard use. Includes pivoting jack stand, safety chains, and 13 in. (330 mm) wheels. Stiff .120 in. (3.0 mm) welded rectangular steel tube frame construction is phosphate etched and powder coat painted for superior rust and corrosion resistance. Low sway suspension gives outstanding stability with manageable tongue weight. Wheel bearings are packed with high viscosity, high pressure, low washout Lubriplate® grease. Includes a Duo-Hitch® – a 2 in. (51 mm) Ball/Lunette Eye combination hitch. Overall width 60 in. (1524 mm). Overall length 124 in. (3150 mm). K2636-1 Trailer K2639-1 Fender & Light Kit K2640-1 Cable Rack POLARITY/MULTI-PROCESS SWITCH For easy polarity switching. Example: DC-stick root pass on pipe and DC+ stick for hot, fill and cap passes. Also for an easy process change. Example: DC+ stick root pass on pipe and DC- Innershield® self-shielded flux-cored wire for hot, fill and cap passes. 6 and 14-pin remote connections can be made to this unit. For all Lincoln Electric Chopper Technology® engine-driven welders. Mounts on roof with K2663-1 Docking Kit. K2642-1 K1783-9 PTA-26V TIG Torch Air Cooled 200 amp torch (2 piece) equipped with valve for gas flow control. 25 ft. (7.6m) length. KP509 Magnum Parts Kit for PTA-26V TIG Torch Magnum Parts Kit provides all the torch accessories you need to start welding. Parts kit provides collets, collet bodies, a black cap, alumina nozzles and tungstens in a variety of sizes, all packaged in an easy to carry reclosable sack. K870 Foot Amptrol® - Varies current while welding for making critical TIG welds and crater filling. Depress pedal to increase current. Depressing pedal fully achieves maximum set current. Fully raising the pedal finishes the weld and starts the after flow cycle on systems so equipped. Includes 25 ft. (7.6m) control cable. K963-3 Hand Amptrol® - Provides 25 ft. (7.6 m) of remote current control for TIG welding. (6-pin plug connection). Velcro straps secure torch. (one size fits all Pro-Torch™ TIG Torches) K3985-1 SPARK ARRESTOR KIT - Easily mounts to D.O.C. unit in place of the exhaust outlet pipe. Square Wave™ TIG 175 For AC TIG Welding with square wave performance, use the AC generator of the engine-driven welder to supply the power (full rated output may not be available). Easy setup. Includes torch, foot Amptrol™ and gas regulator and hose. Requires the K1816-1 Full KVA Adapter Kit. K1478-5 K1816-1 Full KVA Adapter Kit - Plugs into the 120/240V NEMA 14-50R receptacle on the case front (which accepts 4-prong plugs) and converts it to a NEMA 6-50R receptacle (which accepts 3-prong plugs) for connection to Lincoln Equipment with a NEMA 6-50P plug, K2350-2 Invertec® V205-T AC/DC One-Pak™ Package For AC TIG welding with square wave performance, use the AC generator of the engine-driven welder to supply the power. Easy setup. Includes torch, parts kit, regulator and hose kit, TwistMate™ torch adapter, work cable with Twist-Mate end and foot Amptrol® . T12153-9 Full-KVA Power Plug - One dual voltage plug rated at 120/240V, 50 amps, single phase. C-1 AIR VANTAGE® 600 SD ACCESSORIES WIRE FEEDER OPTIONS LN-25 IRONWORKER™ WIRE FEEDER Portable CV unit for flux-cored and mig welding with maxtrac® wire drive system. includes digital meters for wire feed speed/amperage and voltage, gas solenoid, internal contactor and 5/64 in. (2.0 mm) drive roll kit for cored wire. has 83% reduced wire feed speed capability for 6 o’clock pipe welding with Innershield® wire. K2614-9 K126™ PRO Innershield® Gun For self-shielded wire with 15 ft. (4.5 m) cable. For .062-5/64 in. (1.6-2.0 mm) wire. Includes K466-10 Connector Kit. K126-12 KP1696-1 Drive Roll Kit - Includes: 2 V groove drive rolls and inner wire guide for Steel Wires. (Used on LN-25 Pro) Drive Roll and Guide Tube Kit For .068-.072 in. (1.7-1.8 mm) cored or solid steel wire. KP1697-068 Magnum® PRO 350 Ready-Pak® 15 ft., .035-5/64 in. Magnum® PRO MIG/flux-cored welding guns are rated 100% duty cycle. The guns are designed for high amperage, high duty cycle applications in extreme environments where heat-resistance and fast serviceability are key. K2652-2-10-45 K487-25 Magnum SG Spool Gun Hand held semiautomatic wire feeder. Requires SG Control Module and Input Cable. K488 SG Control Module The Interface between the power source and the spool gun. Provides control of the wire speed and gas flow. For use with a spool gun. K691-10 Input Cable (For SG Control Module) For Lincoln engine power sources with 14-pin MS-type connection, separate 115V NEMA receptacles and output stud connections. POWER FEED 25M This compact shop or construction wire feeder is push-pull capable for premium aluminum welding. Featuring our MAXTRAC® drive system, full controls and procedural memory presets, the Power Feed® 25M is ready for advanced process welding on almost any application. PLASMA CUTTING Tomahawk® 1000 Cuts metal using the AC generator power from the engine-driven welder. Requires the T12153-9 Full-KVA Power Plug (1-Phase). K2808-1 C-2 AIR VANTAGE® 600 SD NOTES C-3 AIR VANTAGE® 600 SD NOTES C-4 AIR VANTAGE® 600 SD SAFETY PRECAUTIONS MAINTENANCE AIR FILTER WARNING • Have a qualified technician do the maintenance and troubleshooting work. CAUTION • Excessive air filter restriction will result in reduced engine life. WARNING • Turn the engine off before working inside the machine. • Remove guards only when necessary and replace them when the maintenance requiring their removal is complete. • Never use gasoline or low flash point solvents for cleaning the air cleaner element. A fire or explosion could result. • Always use the greatest care when working near moving parts. CAUTION -----------------------------------------------------------------Read the Safety Precautions in front of this manual and the engine instruction manual before working on this machine. • Never run the engine without the air cleaner. Rapid engine wear will result from contaminants, such as dust and dirt being drawn into the engine. ------------------------------------------------------------------ Keep all equipment safety guards, covers and devices in position and in good repair. Keep hands, hair, clothing and tools away from The diesel engine is equipped with a dry type air filter. Never V-belts, gears, fans and all other moving parts when starting, apply oil to it. Service the air cleaner as follows: operating or repairing the equipment. ROUTINE AND PERIODIC MAINTENANCE DAILY Replace the element as indicated by the service indicator. (See Service Instructions and Installation Tips for Engine Air Filter.) • Check the Engine oil level. • Refill the fuel tank to minimize moisture condensation in the tank. • Open the water drain valve located on the bottom of the water separator element 1 or 2 turns and allow to drain into a container suitable for diesel fuel for 2 to 3 seconds. Repeat the above drainage procedure until diesel fuel is detected in the container. WEEKLY Blow out the machine with low pressure air periodically. In particularly dirty locations, this may be required once a week. 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 Refer to Table D.1 at the end of this section for various engine maintenance components. D-1 AIR VANTAGE® 600 SD 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. Avoid knocking the filter against the housing. If your air cleaner has a safety filter, replace it every third primary filter change. Remove the safety filter as you would the primary filter. Make sure you cover the air cleaner outlet tube to avoid any unfiltered contaminant dropping into the engine. Insert the New Radial Seal Filter Properly If you're servicing the safety filter, this should be seated into position before installing the primary filter. Insert the new filter carefully. Seat the filter by hand, making certain it is completely into the air cleaner housing before securing the cover in place. Clean Both Surfaces of the Outlet Tube and Check the Vacuator™ Valve The critical sealing area will stretch slightly, adjust itself and distribute the sealing pressure evenly. To complete a tight seal, apply pressure by hand at the outer rim of the filter, not the flexible center. (Avoid pushing on the center of the urethane end cap.) No cover pressure is required to hold the seal. NEVER use the service cover to push the filter into place! Using the cover to push the filter in could cause damage to the housing, cover fasteners and will void the warranty. Use a clean cloth to wipe the filter sealing surface and the inside of the outlet tube. Contaminant on the sealing surface could hinder an effective seal and cause leakage. Make sure that all contaminant is removed before the new filter is inserted. Dirt accidently transferred to the inside of the outlet tube will reach the engine and cause wear. Engine manufacturers say that it takes only a few grams of dirt to "dust" an engine! Be careful not to damage the sealing area on the tube. If the service cover hits the filter before it is fully in place, remove the cover and push the filter (by hand) further into the air cleaner and try again. The cover should go on with no extra force. Wipe both sides of the outlet tube clean. Outer edge of the outlet tube Inspect the new filter carefully, paying attention to the inside of the open end, which is the sealing area. NEVER install a damaged filter. A new Donaldson radial seal filter may have a dry lubricant on the seal to aid installation. Once the filter is in place, secure the service cover. Inner edge of the outlet tube Caution NEVER use the service cover to push the filter into place! Using the cover to push the filter in could cause damage to the housing, cover fasteners and will void the warranty. If your air cleaner is equipped with a Vacuator Valve Visually check and physically squeeze to make sure the valve is flexible and not inverted, damaged or plugged. Inspect the Old Filter for Leak Clues Check Connectors for Tight Fit Visually inspect the old filter for any signs of leaks. A streak of dust on the clean side of the filter is a telltale sign. Remove any cause of leaks before installing new filter. Make sure that all mounting bands, clamps, bolts, and connections in the entire air cleaner system are tight. Check for holes in piping and repair if needed. Any leaks in your intake piping will send dust directly to the engine! D-2 AIR VANTAGE® 600 SD MAINTENANCE FUEL FILTERS WARNING BATTERY HANDLING GASES FROM BATTERY can explode. • Keep sparks, flame and cigarettes away from battery. When working on the fuel system • Keep naked lights away, do not smoke ! To prevent EXPLOSION when: • Do not spill fuel ! • INSTALLING A NEW BATTERY - disconnect negative cable from old battery first and connect to new battery last. -----------------------------------------------------------------The AIR VANTAGE® 600 SD is equipped with a Fuel Filter located after the lift pump and before fuel injectors.The procedure for changing the filter is as follows. • CONNECTING A BATTERY CHARGER - Remove battery from welder by disconnecting negative cable first, then positive cable and battery clamp. When reinstalling, connect negative cable last. Keep well ventilated. 1. Close the fuel shutoff valve. 2. Clean the area around the fuel filter head. Remove the filter. Clean the gasket surface of the filter head and replace the oring. 3. Fill the clean filter with clean fuel, and lubricate the o-ring seal with clean lubricating oil. • USING A BOOSTER - connect positive lead to battery first then connect negative lead to engine foot. WARNING 4. Install the filter as specified by the filter manufacturer. BATTERY ACID CAN BURN EYES AND SKIN. Mechanical over tightened will distort the threads, filter element seal or filter can. • Wear gloves and eye protection and be careful when working near battery. Follow instructions printed on battery. ------------------------------------------------------------------ COOLING SYSTEM -----------------------------------------------------------------The cooling system of the Deutz engine needs to be checked and cleaned periodically. (Consult the engine Owners Manual for the PREVENTING ELECTRICAL DAMAGE proper procedures and frequency). 1. When replacing, jumping, or otherwise connecting the battery to the battery cables, the proper polarity must be observed. Failure to observe the proper polarity could result in damage to Coolant needs to be added at the radiator filler neck after removthe charging circuit. The positive (+) battery cable has a red tering cap when system is cool. Fill to top of filler neck. Engine will minal cover. not start if coolant level is too low. 2. If the battery requires charging from an external charger, disconnect the negative battery cable first and then the positive battery cable before attaching the charger leads. Failure to do The coolant system is equipped with an internal expansion tank so can result in damage to the internal charger components. located inside the top radiator tank. This allows for normal thermal When reconnecting the cables, connect the positive cable first expansion and contraction of the engine coolant. The system is fitand the negative cable last. ted with a “catch only” reservoir to keep any rejected or excess coolant from entering the environment. Check periodically and empty as required. Do not fill with coolant. PREVENTING BATTERY DISCHARGE Turn the RUN/STOP switch to stop when engine is not running. PREVENTING BATTERY BUCKLING Tighten nuts on battery clamp until snug. D-3 AIR VANTAGE® 600 SD MAINTENANCE CHARGING THE BATTERY WELDER / GENERATOR MAINTENANCE 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® 600 SD positive (+) battery terminal has a red terminal cover. STORAGE Store the AIR VANTAGE® 600 SD in a clean, dry protected areas. 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. after the battery is charged, reconnect the positive battery cable first and the negative cable last. Failure to do so can result in damage to the internal charger components. CLEANING Blow out the generator and controls periodically with low pressure air. do this at least once a week in particularly dirty areas. BRUSH REMOVAL AND REPLACEMENT It is normal for the brushes and slip rings to wear and darken slightly. Inspect the brushes when a generator overhaul is necessary. Follow the instructions of the battery charger manufacturer for proper charger settings and charging time. WARNING 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. Do not attempt to polish slip rings while the engine is running. ------------------------------------------------------------------ REPLACEMENT SERVICE ITEMS ITEM MAKE PART NUMBER P822768 SERVICE INTERVAL (WITH SERVICE INDICATOR) CLEAN AS NEEDED, REPLACE AS INDICATED BY THE SERVICE INDICATOR (WITHOUT SERVICE INDICATOR) CLEAN AS NEEDED, REPLACE EVERY 200 HOURS. AIR CLEANER ELEMENT DONALDSON FLEETGUARD AF25553 OIL FILTER DEUTZ 01174416 REPLACE EVERY 500 HOURS OR 12 MONTHS, WHICHEVER IS LESS FAN BELT DEUTZ 04131488 REPLACE EVERY 1500 HOURS FUEL FILTER DEUTZ 04131532 REPLACE EVERY 500 HOURS OR 24 MONTHS, WHICHEVER IS LESS FUEL FILTER/ WATER SEPARATOR DEUTZ 04130241 CLEAN AS NEEDED, REPLACE EVERY 1000 HOURS BATTERY —— BCI GROUP 34 INSPECT EVERY 500 HOURS ENGINE OIL CHANGE SEE MANUAL —— D-4 CHANGE EVERY 500 HOURS OR 6 MONTHS, WHICHEVER IS LESS. CHECK DAILY. S29926 AIR VANTAGE® 600 SD 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. This Troubleshooting Guide is provided to help you locate and repair possible machine malfunctions. Simply follow the three-step procedure listed below. Step 1. LOCATE PROBLEM (SYMPTOM). Look under the column labeled “PROBLEM (SYMPTOMS)”. This column describes possible symptoms that the machine may exhibit. Find the listing that best describes the symptom that the machine is exhibiting. Step 2. POSSIBLE CAUSE. The second column labeled “POSSIBLE CAUSE” lists the obvious external possibilities that may contribute to the machine symptom. Step 3. RECOMMENDED COURSE OF ACTION This column provides a course of action for the Possible Cause, generally it states to contact your local Lincoln Authorized Field Service Facility. If you do not understand or are unable to perform the Recommended Course of Action safely, contact your local Lincoln Authorized Field Service Facility. CAUTION If for any reason you do not understand the test procedures or are unable to perform the tests/repairs safely, contact your Lincoln Authorized Service Facility for technical troubleshooting assistance before you proceed. WWW.LINCOLNELECTRIC.COM/LOCATOR E-1 TROUBLE SHOOTING AIR VANTAGE® 600 SD Observe all Safety Guidelines detailed throughout this manual PROBLEMS (SYMPTOMS) POSSIBLE CAUSE ENGINE PROBLEMS 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. If check engine light is on contact your Field Service Facility. 6. Check 30A Breaker (ECU). Engine will crank but not start. 1. Out of fuel. 2. Fuel shut off valve is in the off position make sure the valve lever is in the open position (lever in-line with the Hose). 3. Engine shut down solenoid not pulling in. 4. On/Off switch on for more than 30 sec. before starting, the On/Off switch will need to be switch off and turned back on. 5. Fuel Filters dirty/clogged, main filter element and/or Inline Fuel Filter may need to be replaced. 6. High oil temperature or low oil pressure. (engine protection light lit) RECOMMENDED COURSE OF ACTION If all recommended possible areas of misadjustment have been checked and the problem persists, Contact your local Lincoln Authorized Field Service Facility. Engine shuts down shortly after starting. 1. Low oil pressure (engine protection light lit). Check oil level (Consult engine service dealer). 2. High oil temperature. Check engine cooling system. (engine protection light lit). 3. Faulty oil pressure switch. 4. Faulty oil temperature switch. Contact authorized local Engine Service Shop. 5. Check coolant level. Engine shuts down while under a load. 1. High oil temperature. Engine runs rough. 1. Dirty fuel or air filters may need cleaned/replaced. 2. Water in fuel. Engine will not shut off. 1. Fuel Shutdown solenoid not functioning properly. CAUTION If for any reason you do not understand the test procedures or are unable to perform the tests/repairs safely, contact your Lincoln Authorized Service Facility for technical troubleshooting assistance before you proceed. WWW.LINCOLNELECTRIC.COM/LOCATOR E-2 TROUBLE SHOOTING AIR VANTAGE® 600 SD Observe all Safety Guidelines detailed throughout this manual PROBLEMS (SYMPTOMS) Battery does not stay charged. POSSIBLE CAUSE FUNCTION PROBLEMS TROUBLE SHOOTING 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. Faulty relay. 3. Faulty Weld Control PCB (Printed Circuit Board) Engine will not go to high idle when 1. Poor work lead connection to attempting to weld. work. 2. Welding Terminals switch in wrong position. 3. No open circuit voltage at output studs. 4. Faulty Weld Control PCB. If all recommended possible areas of misadjustment have been checked and the problem persists, Contact your local Lincoln Authorized Field Service Facility. Engine will not go to high idle when 1. Broken wire in auxiliary current using auxiliary power. sensor wiring. 2. Auxiliary power load is less than 100 watts. 3. Faulty Weld Control PCB. CAUTION If for any reason you do not understand the test procedures or are unable to perform the tests/repairs safely, contact your Lincoln Authorized Service Facility for technical troubleshooting assistance before you proceed. WWW.LINCOLNELECTRIC.COM/LOCATOR E-3 AIR VANTAGE® 600 SD Observe all Safety Guidelines detailed throughout this manual PROBLEMS (SYMPTOMS) POSSIBLE CAUSE FUNCTION PROBLEMS TROUBLE SHOOTING RECOMMENDED COURSE OF ACTION Engine goes to low idle but does not 1. Faulty Weld Control PCB or Idler stay at low idle. relay. No welding output or auxiliary out- 1. put. 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. Auxiliary output OK 2. Faulty output control potentiometer. 3. Faulty output control wiring. 4. Faulty Weld Control PCB, Idler/Engine Protection PCB or Chopper PCB. No welding output. Auxiliary output 1. WELDING TERMINALS switch in wrong position, be sure switch is OK. in WELDING TERMINALS ALWAYS ON position. 2. Faulty Weld Control PCB, Idler/Engine Protection PCB or Chopper PCB. No auxiliary power. If all recommended possible areas of misadjustment have been checked and the problem persists, Contact your local Lincoln Authorized Field Service Facility. 1. Open breakers may need to be reset. 2. Faulty receptacle. 3. Faulty auxiliary circuit wiring. 4. GFCI tripped. CAUTION If for any reason you do not understand the test procedures or are unable to perform the tests/repairs safely, contact your Lincoln Authorized Service Facility for technical troubleshooting assistance before you proceed. WWW.LINCOLNELECTRIC.COM/LOCATOR E-4 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 pasted inside the machine on one of the enclosure panels. If the diagram is illegible, write to the Service Department for a replacement. Give the equipment code number. AIR VANTAGE® 600 SD WIRING DIAGRAMS F-1 F-2 TO WORK ELECTRODE CABLE TO WIRE FEED UNIT TO WORK K867 UNIVERSAL ADAPTER PLUG 77 76 75 GND 21 4 2 N.E. } 77 76 75 GND 21 4 2 32 31 GREEN 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. PLACE WIRE FEEDER SWITCH TO "WIRE FEEDER WITH CONTROL CABLE POSITION. N.B. USE VOLTMETER SWITCH TO SELECT DESIRED ELECTRODE POLARITY. POSITION THE "SELECTOR" SWITCH TO "WIRE WELDING CV". N.A. WELDING CABLE MUST BE OF PROPER CAPACITY FOR THE CURRENT AND DUTY CYCLE OF IMMEDIATE AND FUTURE APPILICATIONS. SEE OPERATING MANUAL. ANY INCREASE OF THE HIGH IDLE ENGINE RPM BY CHANGING THE GOVERNOR SETTING OR OVERRIDING THE THROTTLE LINKAGE WILL CAUSE AN INCREASE IN THE THE AC AUXILIARY VOLTAGE. IF THIS VOLTAGE GOES OVER 140 VOLTS, WIRE FEEDER CONTROL CIRCUITS MAY BE DAMAGED. THE ENGINE GOVERNOR SETTING IS PRE-SET AT THE FACTORY - DO NOT ADJUST ABOVE RPM SPECIFICATIONS LISTED IN THE ENGINE WELDER OPERATING MANUAL. CAUTION : ELECTRODE 14 PIN AMPHENOL 32 31 41 42 81 } or service this equipment. N.D. Only qualified personnel should install,use Do not touch electrically live parts. 82 Keep away from moving parts. before servicing. SPARE Keep guards in place. Do not operate with panels open. Disconnect NEGATIVE (-) BATTERY LEAD WARNING VANTAGE / K867 / K775 / LN-7 CONNECTION DIAGRAM K775 OPTIONAL REMOTE CONTROL K291 OR K404 INPUT CABLE LN-7 WIRE FEEDER S23983 7-2000 AIR VANTAGE® 600 SD CONNECTION DIAGRAMS AIR VANTAGE® 600 SD CONNECTION DIAGRAMS F-3 F-4 TO WORK ELECTRODE CABLE TO WIRE FEED UNIT TO WORK ADAPTER PLUG K867 UNIVERSAL 77 76 75 GND 21 4 2 N.C. N.D. } C B A GND 21 4 2 32 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. USE VOLTMETER SWITCH TO SELECT DESIRED ELECTRODE POLARITY. POSITION THE SELECTOR SWITCH TO "WIRE WELDING CV". ANY INCREASE OF THE HIGH IDLE ENGINE RPM BY CHANGING THE GOVERNOR SETTING OR OVERRIDING THE THROTTLE LINKAGE WILL CAUSE AN INCREASE IN THE THE AC AUXILIARY VOLTAGE. IF THIS VOLTAGE GOES OVER 140 VOLTS, WIRE FEEDER CONTROL CIRCUITS MAY BE DAMAGED. THE ENGINE GOVERNOR SETTING IS PRE-SET AT THE FACTORY - DO NOT ADJUST ABOVE RPM SPECIFICATIONS LISTED IN THE ENGINE WELDER OPERATING MANUAL. CAUTION : ELECTRODE 14 PIN AMPHENOL 32 31 41 42 81 31 or service this equipment. } Only qualified personnel should install,use Do not touch electrically live parts. 82 Keep away from moving parts. before servicing. SPARE Keep guards in place. Do not operate with panels open. Disconnect NEGATIVE (-) BATTERY LEAD WARNING VANTAGE / K867 / LN-8 CONNECTION DIAGRAM INPUT CABLE K196 FEEDER WIRE LN-8 S23989 7-2000 AIR VANTAGE® 600 SD CONNECTION DIAGRAMS F-5 + _ ELELCTRODE CABLE TO WIRE FEED UNIT K595 CONTROL CABLE LN-8 INPUT CABLE PLUG TO WORK Keep guards in place. Keep away from moving parts. Only qualified personnel should install,use or service this equipment. MOVING PARTS can injure S24787-6 4-14-2000 N.A. WELDING CABLES MUST BE OF PROPER CAPACITY FOR THE CURRENT AND DUTY CYCLE OF IMMEDIATE AND FUTURE APPLICATIONS. SEE OPERATING MANUAL. N.B. CONNECT WELDING CABLES TO OUTPUT STUDS FOR DESIRED POLARITY. POSITION THE WIRE FEEDER VOLTMETER SWITCH TO MATCH THE POLARITY OF THE ELECTRODE CABLE. N.C. PLACE IDLER SWITCH IN “HIGH” POSITION. ANY INCREASE OF THE HIGH IDLE ENGINE RPM BY CHANGING THE GOVERNOR SETTING OR OVERRIDING THE THROTTLE LINKAGE WILL CAUSE AN INCREASE IN THE AC WIRE FEEDER VOLTAGE, WHICH CAN DAMAGE THE CONTROL CIRCUIT. THE ENGINE GOVERNOR SETTING IS PRE-SET AT THE FACTORY – DO NOT ADJUST ABOVE RPM SPECIFICATIONS LISTED IN THE ENGINE WELDER OPERATING MANUAL. CAUTION 14 PIN AMPHENOL Do not operate with panels open. Disconnect NEGATIVE (-) Battery lead before servicing. Do not touch electrically live parts. ELECTRIC SHOCK can kill WARNING ENGINE WELDERS / LN-8 CONNECTION DIAGRAM AIR VANTAGE® 600 SD CONNECTION DIAGRAMS AIR VANTAGE® 600 SD CONNECTION DIAGRAMS F-6 AIR VANTAGE® 600 SD CONNECTION DIAGRAMS F-7 AIR VANTAGE® 600 SD CONNECTION DIAGRAMS F-8 AIR VANTAGE® 600 SD CONNECTION DIAGRAMS F-9 F-10 + _ ENGINE WELDER TO WORK 12 PIN CONNECTOR ELECTRODE CABLE S24787-16 A.01 TO WORK WORK CLIP LEAD OPTIONAL K444-1 REMOTE CONTROL LN-25 WIRE FEEDER K2909-1 12 PIN TO 6 PIN ADAPTER CABLE Keep guards in place. Keep away from moving parts. Only qualified personnel should install,use or service this equipment. MOVING PARTS can injure N.A. WELDING CABLES MUST BE OF PROPER CAPACITY FOR THE CURRENT AND DUTY CYCLE OF IMMEDIATE & FUTURE APPLICATIONS. SEE OPERATING MANUAL. N.B. CONNECT WELDING CABLES TO OUTPUT STUDS FOR DESIRED POLARITY. POSITION THE WIRE FEEDER VOLTMETER SWITCH TO MATCH THE POLARITY OF THE ELECTRODE CABLE. N.C. PLACE THE MODE SWITCH IN THE “CV-WIRE” POSITION. N.D. PLACE THE WELDING TERMINALS SWITCH IN THE “WELD TERMINALS ON” POSITION. N.E. PLACE IDLER SWITCH IN “AUTO” OR “HIGH” IDLE POSITION AS DESIRED. 14 PIN CONNECTOR (MAY NOT BE ON ALL MACHINES) Do not operate with panels open. Disconnect NEGATIVE (-) Battery lead before servicing. Do not touch electrically live parts. ELECTRIC SHOCK can kill WARNING TIER 4 FINAL ENGINE WELDERS /LN-25 ACROSS THE ARC CONNECTION DIAGRAM WITH OPTIONAL K444-1 REMOTE CONTROL AIR VANTAGE® 600 SD CONNECTION DIAGRAMS F-11 + _ ELECTRODE CABLE TO WIRE FEED UNIT K2909-1 12 PIN TO 6 PIN ADAPTER CABLE K584 CONTROL CABLE TO LN-7 INPUT CABLE PLUG TO WORK OPTIONAL K857 REMOTE CONTROL Keep guards in place. Keep away from moving parts. Only qualified personnel should install,use or service this equipment. MOVING PARTS can injure N.A. WELDING CABLES MUST BE OF PROPER CAPACITY FOR THE CURRENT AND DUTY CYCLE OF IMMEDIATE AND FUTURE APPLICATIONS. SEE OPERATING MANUAL. N.B. CONNECT WELDING CABLES TO OUTPUT STUDS FOR DESIRED POLARITY. POSITION THE WIRE FEEDER VOLTMETER SWITCH TO MATCH THE POLARITY OF THE ELECTRODE CABLE. N.C. PLACE THE MODE SWITCH IN THE “CV-WIRE” POSITION. N.D. PLACE IDLER SWITCH IN “HIGH” POSITION. A.01 S24787-17 CAUTION: ANY INCREASE OF THE HIGH IDLE ENGINE RPM BY CHANGING THE GOVERNOR SETTING OR OVERRIDING THE THROTTLE LINKAGE WILL CAUSE AN INCREASE IN THE AC WIRE FEEDER VOLTAGE, WHICH CAN DAMAGE THE CONTROL CIRCUIT. THE ENGINE GOVERNOR SETTING IS PRE-SET AT THE FACTORY – DO NOT ADJUST ABOVE RPM SPECIFICATIONS LISTED IN THE ENGINE WELDER OPERATING MANUAL. 12 PIN CONNECTOR 14 PIN CONNECTOR (MAY NOT BE ON ALL MACHINES) Do not operate with panels open. Disconnect NEGATIVE (-) Battery lead before servicing. Do not touch electrically live parts. ELECTRIC SHOCK can kill WARNING TIER 4 FINAL ENGINE WELDERS /LN-7 CONNECTION DIAGRAM AIR VANTAGE® 600 SD CONNECTION DIAGRAMS F-12 12 PIN REMOTE RECEPTACLE TO WORK ELECTRODE CABLE TO CONTROL MODULE _ 14 PIN WIRE FEEDER RECEPTACLE K691-10 INPUT CABLE K487-25 SPOOL GUN K488 SG CONTROL MODULE Keep guards in place. Keep away from moving parts. Only qualified personnel should install,use or service this equipment. MOVING PARTS can injure A.01 S24787-18 N.A. WELDING CABLES MUST BE SIZED FOR CURRENT AND DUTY CYCLE OF APPLICATION. N.B. CONNECT WELDING CABLES TO OUTPUT STUDS FOR DESIRED POLARITY. N.C. PLACE THE MODE SWITCH IN THE “CV-WIRE” POSITION. PLACE WELDING TERMINALS SWITCH TO “REMOTELY CONTROLLED” POSITION. N.D. PLACE IDLER SWITCH IN “HIGH” IDLE POSITION. ANY INCREASE OF THE HIGH IDLE ENGINE RPM BY CHANGING THE GOVERNOR SETTING OR OVERRIDING THE THROTTLE LINKAGE WILL CAUSE AN INCREASE IN THE AC WIRE FEEDER VOLTAGE, WHICH CAN DAMAGE THE CONTROL CIRCUIT. THE ENGINE GOVERNOR SETTING IS PRE-SET AT THE FACTORY – DO NOT ADJUST ABOVE RPM SPECIFICATIONS LISTED IN THE ENGINE WELDER OPERATING MANUAL. CAUTION: BE SURE THAT CONTROL MODULE MODE SWITCH IS IN THE “LINCOLN” (CONTACT CLOSURE) POSITION BEFORE ATTEMPTING TO OPERATE CONTROL MODULE. INCORRECT SWITCH POSITION COULD RESULT IN DAMAGE TO THE CONTROL MODULE AND/OR POWER SOURCE. + RANGER 115V RECEPTACLE Do not operate with panels open. Disconnect NEGATIVE (-) Battery lead before servicing. Do not touch electrically live parts. ELECTRIC SHOCK can kill WARNING TIER 4 FINAL ENGINE WELDERS / K691-10 / K488 / K487 SPOOL GUN CONNECTION DIAGRAM AIR VANTAGE® 600 SD CONNECTION DIAGRAMS R F-13 + _ TO WORK 5 PIN AMPHENOL ELECTRODE CABLE R POWER FEED 25M WIRE FEEDER TO WORK WORK CLIP LEAD Keep guards in place. Keep away from moving parts. Only qualified personnel should install,use or service this equipment. MOVING PARTS can injure S24787-19 A.01 N.A. WELDING CABLES MUST BE OF PROPER CAPACITY FOR THE CURRENT AND DUTY CYCLE OF IMMEDIATE & FUTURE APPLICATIONS. SEE OPERATING MANUAL. N.B. CONNECT WELDING CABLES TO OUTPUT STUDS FOR DESIRED POLARITY. N.C. PLACE THE MODE SWITCH IN THE “ARC-LINK” POSITION. N.D. PLACE IDLER SWITCH IN “AUTO” OR “HIGH” IDLE POSITION AS DESIRED. 14 PIN AMPHENOL Do not operate with panels open. Disconnect NEGATIVE (-) Battery lead before servicing. Do not touch electrically live parts. ELECTRIC SHOCK can kill WARNING TIER 4 FINAL ENGINE WELDERS / POWER FEED 25M WIRE FEEDER AIR VANTAGE® 600 SD CONNECTION DIAGRAMS F-14 28.99 736.2 N.C. N.D. 18.50 469.9 11.50 292.1 45.22 1148.5 58.78 1493 N.D. N.C. 69.00 1752.6 51.44 1306.5 19.63 498.6 23.96 608.6 50.38 1279.6 54.44 1382.9 15.43 391.8 39.49 1003.1 36.00 34.88 914.4 32.03 886 22.92 813.6 582.2 43.36 1101.2 N.A. * 20.69 525.5 * 12.61 320.3 * 24.47 621.4 7.03 178.5 41.97 1066.1 * 51.72 1313.6 45.59 1157.9 31.62 803.1 32.93 836.3 3.82 97.1 * TRAILER MOUNTING HOLE LOCATIONS. A.02 M18962-9 N.A. CENTER OF GRAVITY WITH OIL IN ENGINE, OIL IN COMPRESSOR, IF PRESENT, COOLANT IN RADIATOR & EMPTY FUEL TANK. N.B. AIR CLEANER INSTALLED BY END USER. N.C. VANTAGE 600 N.D. AIR VANTAGE 600 45.59 1157.9 8.95 227.3 AIR VANTAGE® 600 SD DIMENSION PRINT Air Vantage 600 T4F 11984 Contents Engine Driven Welders Air Vantage Air Vantage 600 T4F - 11984 Index of Sub Assemblies - 11984........................................................................................1 Miscellaneous Items ............................................................................................................3 Control Panel Assembly ......................................................................................................5 Control Box Assembly .........................................................................................................8 Output Panel Assembly .....................................................................................................11 Power Module Assembly ...................................................................................................14 Base & Lift Bale Assembly ................................................................................................17 Fuel Tank & Mounting .......................................................................................................21 Engine Assembly ...............................................................................................................24 Generator Assembly ..........................................................................................................26 Radiator & Case Back Assembly.......................................................................................29 Covers ................................................................................................................................31 Air Compressor ..................................................................................................................34 i THIS PAGE INTENTIONALLY LEFT BLANK ii Index of Sub Assemblies - 11984 KEY PART NUMBER DESCRIPTION QTY INDEX OF SUB ASSEMBLIES AR P-756-B.2 MISCELLANEOUS ITEMS AR 1 P-756-C CONTROL PANEL ASSEMBLY AR 2 P-756-D CONTROL BOX ASSEMBLY AR 3 P-756-E OUTPUT PANEL ASSEMBLY AR 4 P-756-F POWER MODULE ASSEMBLY AR 5 P-756-G BASE & LIFT BALE ASSEMBLY AR 6 P-756-H FUEL TANK & MOUNTING AR 7 P-756-J ENGINE ASSEMBLY AR 8 P-756-K GENERATOR ASSEMBLY AR 9 P-756-L RADIATOR & CASE BACK ASSEMBLY AR 10 P-756-M COVERS AR 11 P-756-N AIR COMPRESSOR AR Printed 06/24/2016 at 13:49:02. Produced by Enigma. P-756-A Air Vantage 600 T4F - 11984 1 Printed 06/24/2016 at 13:49:02. Produced by Enigma. Index of Sub Assemblies - 11984 P-756-A.jpg 2 Air Vantage 600 T4F - 11984 Miscellaneous Items PART NUMBER DESCRIPTION QTY 9SG7638 CONTROL HARNESS 1 9ST12153-10 PLUG 4 WIRE GROUNDING 1 K2909-1 12 PIN TO 6 PIN CABLE ADAPTER 1 K3985-1 SPARK ARRESTOR KIT 1 Printed 06/24/2016 at 13:49:02. Produced by Enigma. KEY Air Vantage 600 T4F - 11984 3 Printed 06/24/2016 at 13:49:02. Produced by Enigma. Miscellaneous Items No Image 4 Air Vantage 600 T4F - 11984 Control Panel Assembly KEY DESCRIPTION QTY 9SG4852-2 CONTROL PANEL ASSEMBLY 1 1 9SG4467-5 CONTROL PANEL 1 2A 9SS11668-2 RECEPTACLE DUPLEX 120VAC 20A 2 2B 9SS27290 COVER RECEPTACLE DUPLEX 2 2C 9SL13286 GFCI HOUSING 2 2D 9SS27167 MOUNTING BRACKET 2 9SS24738-3 THERMOPLASTIC SCREW 4 9SS18907-2 RECEPTACLE-SINGLE 1 9ST9695-3 LOCKWASHER 4 9SCF000042 #8-32HN 4 3D 9SM18861 RECEPTACLE COVER 1 4A 9SS18907-3 RECEPTACLE 250v 50A 1 9ST9695-3 LOCKWASHER 4 9SCF000042 #8-32HN 4 9SM18861 RECEPTACLE COVER 1 5 9ST10800-72 ROCKER SWITCH 3 6A 9SS17062-12 CONNECTOR CAP 1 9SCF000389 #4-40X.375SS-PPNHS-FULL-GR2-3147 4 9SCF000002 #4-40HN 4 9ST9695-2 LOCKWASHER 4 9SS17062-11 CABLE CONNECTOR CAP 1 9SS8025-96 SELF TAPPING SCREW 4 8 9ST10800-80 ROCKER SWITCH 1 9 9ST10800-74 ROCKER SWITCH 1 10A 9SM20586-1 CIRCUIT BREAKER50A3 POLE 1 10B 9SS24911-4 CIRCUIT BREAKER COVER 1 9ST10082-30 SEMS SCREW 6 9ST4291-A LOCKWASHER 6 11 9SM22778-2 KNOB 1.5" 2 12 9SG7492 NAMEPLATE 1 13 9ST10800-70 ROCKER SWITCH 2 14 9SM22859 DASHBOARD GAUGE 1 15A 9SG7220-1 CHOPPER UI PC BD ASBLY 1 9ST9187-13 #10-24HLN-1817/1-NYLON INSERT 4 3A 4D 7A Printed 06/24/2016 at 13:49:02. Produced by Enigma. PART NUMBER Air Vantage 600 T4F - 11984 5 Control Panel Assembly 16A DESCRIPTION QTY 9ST12287-20 CIRCUIT BREAKER-10A250VAC 2 9SS22061-3 SEALING BOOT 2 9ST12287-31 CIRCUIT BREAKER-20A250VAC32VDC 1 9SS22061-1 CIRCUIT BREAKER BOOT 1 9ST12287-38 CIRCUIT BREAKER 2 9SS22061-2 SEALING BOOT 2 9SS28844-1 MODE SWITCH P.C. BOARD ASSEMBLY 1 9SM21328-24 DOOR DECAL & LATCH ASSEMBLY 1 20A 9SM24106 CONTROL PANEL DOOR ASSEMBLY 1 20B 9SG7555 FRONT DOOR NAMEPLATE 1 20C 9SS25569 DOOR PADDLE LATCH 1 9SG7338-2 RATING PLATE 1 9SS8025-92 SELF TAPPING SCREW 4 9SS24659 CATCH BRACKET 1 9SS8025-98 SELF TAPPING SCREW 2 9SM19685-41 CONNECTOR & LEAD ASSEMBLY 1 9SM19685-39 CONNECTOR & LEAD ASSEMBLY 1 9SM19685-37 CONNECTOR & LEAD ASSEMBLY 1 25A 9SS12021-70 BOX RECEPTACLE SOLID SHELL 1 25B 9SS12021-73 BOX RECEPTACLE SOLID SHELL 1 25C 9SS12021-78 CABLE CONNECTOR 1 9SS21440-1 TOROID ASBLY 1 9ST11577-58 CAPACITOR-CERAMIC DISC 1 9SS13100-279 CONNECTOR & LEAD ASSEMBLY 1 28 9ST13483-7 O RING 011 2 29 9SM22778-3 KNOB 1 30A 9SS17062-10 CABLE CONNECTOR CAP 1 9SS9225-62 THREAD FORMING SCREW (ROLLING) 4 31 9SM22209-2 HOUR METER/LED 1 32 9SM25046 PRESSURE GAUGE 1 9ST14659-2 FASTENER BUTTON 2 17A 18A 19 21A 6 PART NUMBER Air Vantage 600 T4F - 11984 Printed 06/24/2016 at 13:49:02. Produced by Enigma. KEY Printed 06/24/2016 at 13:49:02. Produced by Enigma. Control Panel Assembly P-756-C.jpg Air Vantage 600 T4F - 11984 7 Control Box Assembly DESCRIPTION QTY 9SM24622 CONTROL BOX ASSEMBLY 1 9SL8893-7 CONTROL BOX 1 2 9ST12380-12 BUSHING 3 3 9ST12380-4 BUSHING 1 4 9ST11525-5 SPEED NUT1/4-20 6 9SS18922-5 GROUND SCREW ASSEMBLY 1 9SS9225-76 SELF TAPPING SCREW 1 9SS9262-27 PLAIN WASHER 2 9SCF000017 1/4-20HN 2 9SE106A-2 LOCKWASHER 1 9ST9695-1 LOCKWASHER 1 6 9SCF000356 1/4-20X1.50HHB-FULL-GR2-E1817/1 2 7 9ST11267-A INSULATOR 2 8 9ST11267-B INSULATOR 2 9 9SS9262-98 PLAIN WASHER 4 10 9SE106A-2 LOCKWASHER 2 11 9SCF000017 1/4-20HN 2 13A 9SL11832-3 40V DC BUS PC BD ASBLY 1 9ST9187-13 #10-24HLN-1817/1-NYLON INSERT 4 14A 9SS10404-136 RESISTOR-WW25W2510% 1 14B 9ST4479-A INSULATING WASHER 2 14C 9SCF000009 #10-24X3.00RHS 1 14D 9SS9262-27 PLAIN WASHER 1 14E 9SE106A-1 LOCKWASHER 1 14F 9SCF000010 #10-24HN 1 15A 9SS13490-171A FILTER CAPACITOR 1 15B 9SS11604-65 SET SCREW 2 16A 9SM22747-1 CAPACITOR BRACKET 1 9ST9187-13 #10-24HLN-1817/1-NYLON INSERT 4 9SS22436 CAPACITOR BRACKET 1 9SS22747 CAPACITOR BRKT ASBLY 1 9SS8025-94 SELF TAPPING SCREW 1 19A 9SM20007 OUTPUT STUD COVER 1 19B 9SS25669 OUTPUT STUD COVER PLATE 1 1A 5A 18A 8 PART NUMBER Air Vantage 600 T4F - 11984 Printed 06/24/2016 at 13:49:02. Produced by Enigma. KEY Control Box Assembly KEY PART NUMBER DESCRIPTION QTY 9SS9225-68 THREAD FORMING SCREW (CUTTING) 2 20A 9ST13637-5 DIODE-BRIDGE35A800VF-W1-PH 1 9SS10773-7 INSULATING WASHER 1 9SS9262-3 PLAIN WASHER 1 9SE106A-1 LOCKWASHER 1 20E 9SCF000010 #10-24HN 1 21A 9SS9262-98 PLAIN WASHER 2 21B 9SE106A-2 LOCKWASHER 2 21C 9SCF000198 1/4-28HN 2 9SS13100-278 CONNECTOR & LEAD ASBLY 1 Printed 06/24/2016 at 13:49:02. Produced by Enigma. 19C Air Vantage 600 T4F - 11984 9 Printed 06/24/2016 at 13:49:02. Produced by Enigma. Control Box Assembly P-756-D.jpg 10 Air Vantage 600 T4F - 11984 Output Panel Assembly Printed 06/24/2016 at 13:49:02. Produced by Enigma. KEY PART NUMBER DESCRIPTION QTY 9SL16346 OUTPUT PANEL ASSEMBLY 1 1A 9SL10649-8 OUTPUT PANEL 1 2A 9SS28839 INSULATION 2 2B 9ST10082-3 SEMS SCREW 4 2C 9SCF000010 #10-24HN 4 2D 9ST8141-7 CONNECTION STRAP 2 2E 9ST6931-11 STUD 2 2F 9ST3960 FLANGE NUT 2 2G 9SCF000054 1/2-13HJN 4 2H 9ST14374 INSULATING BUSHING 2 2J 9SS10773-9 INSULATING WASHER 2 2K 9SS9262-80 PLAIN WASHER 2 2L 9SE106A-15 LOCKWASHER 2 2M 9SS9262-1 PLAIN WASHER 4 3A 9SS24097-8 SHUNT ASBLY 1 3B 9SCF000021 1/2-13X1.00HHCS 1 3C 9SS9262-1 PLAIN WASHER 1 3D 9SE106A-15 LOCKWASHER 1 3E 9SCF000027 1/2-13HN 1 4A 9SL15862-1 MEGA BYPASS/VRD STABILIZER PC BD ASBLY 1 4B 9SCF000033 #8-32X.50RHS 3 4C 9SS9262-3 PLAIN WASHER 6 4D 9SE106A-1 LOCKWASHER 3 4E 9SCF000014 1/4-20X.75HHCS 2 9SS9262-98 PLAIN WASHER 2 9SE106A-2 LOCKWASHER 2 9SCF000017 1/4-20HN 2 9SCF000017 1/4-20HN 2 9ST9187-1 1/4-20HJLN 2 7A 9SM20007 OUTPUT STUD COVER 2 7B 9SS25669 OUTPUT STUD COVER PLATE 2 7C 9SS9225-68 THREAD FORMING SCREW (CUTTING) 4 8 9SG3343-2 OUTPUT PANEL NAMEPLATE 1 9SS28840 SUPPRESSOR ASBLY 3 Air Vantage 600 T4F - 11984 11 Output Panel Assembly PART NUMBER DESCRIPTION QTY 9SS9262-27 PLAIN WASHER 2 9SE106A-1 LOCKWASHER 2 9SCF000010 #10-24HN 4 9SS13100-280 CONNECTOR & LEAD ASSEMBLY 1 9ST14659-1 FASTENER BUTTON 2 Printed 06/24/2016 at 13:49:02. Produced by Enigma. KEY 12 Air Vantage 600 T4F - 11984 Printed 06/24/2016 at 13:49:02. Produced by Enigma. Output Panel Assembly P-756-E.jpg Air Vantage 600 T4F - 11984 13 Power Module Assembly 1 14 PART NUMBER DESCRIPTION QTY 9SG7428 POWER MODULE ASSEMBLY 1 1A 9SM19139-3 POWER MODULE BRACKET 1 2A 9SL15882-1 CHOKE ASSEMBLY 2 2B 9SCF000013 1/4-20X.625HHCS 4 2C 9SS9262-98 PLAIN WASHER 8 2D 9SE106A-2 LOCKWASHER 4 2E 9SCF000017 1/4-20HN 4 2F 9SCF000069 1/4-20X1.25HHCS 4 2G 9SS9262-98 PLAIN WASHER 4 3 9SL11132-8 RECTIFIER 1 4A 9SL11497-1 CHOPPER HEAT SINK ASBLY 1 4B 9SCF000014 1/4-20X.75HHCS 4 4C 9SE106A-2 LOCKWASHER 4 4D 9SG7218-1 CHOPPER HEATSINK ASSEMBLY 1 9SCF000014 1/4-20X.75HHCS 4 9SE106A-2 LOCKWASHER 4 5A 9SM19140-3 POWER MODULE TOP BRACKET 1 5B 9ST12380-1 BUSHING 4 6A 9SS10404-138 RESISTOR-WW100W505% 1 6B 9SS22168 HEAT SINK HOLDER 2 9ST9187-16 1/4-20 HLN 2 6D 9SCF000191 #10-24X7.50RHS 1 6E 9SS9262-27 PLAIN WASHER 2 6F 9SE106A-1 LOCKWASHER 1 6G 9SCF000010 #10-24HN 1 9SCF000040 5/16-18X.75HHCS 2 9SCF000029 5/16-18HN 2 9SE106A-14 LOCKWASHER 2 9SS9262-121 PLAIN WASHER 2 9SM19685-42 CONNECTOR & LEAD ASSEMBLY 1 9SS9225-66 SELF TAPPING SCREW 4 9SS9262-98 PLAIN WASHER 6 9SE106A-2 LOCKWASHER 3 9SCF000017 1/4-20HN 3 Air Vantage 600 T4F - 11984 Printed 06/24/2016 at 13:49:02. Produced by Enigma. KEY Power Module Assembly KEY DESCRIPTION QTY 9SCF000015 1/4-20X1.00HHCS 3 9ST13359-15 THERMOSTAT 1 9SS8025-80 SELF TAPPING SCREW 2 Printed 06/24/2016 at 13:49:02. Produced by Enigma. 9A PART NUMBER Air Vantage 600 T4F - 11984 15 Printed 06/24/2016 at 13:49:02. Produced by Enigma. Power Module Assembly P-756-F.jpg 16 Air Vantage 600 T4F - 11984 Base & Lift Bale Assembly KEY Printed 06/24/2016 at 13:49:02. Produced by Enigma. 1 PART NUMBER DESCRIPTION QTY 9SG3473-7 BASE WELDED ASSEMBLY 1 9SL8904-6 BATTERY & HOLD DOWN ASBLY 1 2A 9SM17798-3 BATTERY PANEL 1 2B 9SS22018 BATTERY BRKT 1 9ST9187-6 LOCKNUT 2 2D 9ST11827-31 CARRIAGE BOLT 2 2E 9SM9399-15 BATTERY 1 4 9SS8070-54 BATTERY CABLE 1 4A 9SS20191-1 BATTERY TERMINAL COVER 1 5 9SS8070-49 BATTERY CABLE (NEGATIVE) 1 9SS20191-3 BATTERY TERMINAL COVER 1 9SS9225-53 THREAD FORMING SCREW 1 9SS9262-4 PLAIN WASHER 1 9SE106A-16 LOCKWASHER 1 9SS9225-66 SELF TAPPING SCREW 4 9ST11525-5 SPEED NUT1/4-20 4 9SS9262-98 PLAIN WASHER 4 9SE106A-2 LOCKWASHER 4 9SG3098-7 LIFT FRAME ASSEMBLY 1 7A 9SL16143 LIFT FRAME WELDMENT 1 7B 9SM16888 LIFT BALE ASBLY 1 7C 9SG7273 FIRE WALL 1 7D 9SS9225-68 THREAD FORMING SCREW (CUTTING) 2 7F 9ST12380-12 BUSHING 1 9SS20689 BALE SUPPORT BRACKET 1 7H 9SS9225-45 THREAD FORMING SCREW 2 7J 9ST11525-5 SPEED NUT1/4-20 8 7K 9ST12380-8 BUSHING 2 7L 9ST13086-62 DECAL-WARNING 2 7M 9ST12380-1 BUSHING 2 7N 9SS25760 REMOTE JUMP-START TERMINAL(POSITIVE) 1 7P 9SS29557-1 DUST CAP 1 7Q 9SL16229 ECU MOUNTING BRACKET 1 7R 9SL16317 DOC MOUNTING BRACKET 1 Air Vantage 600 T4F - 11984 17 Base & Lift Bale Assembly 8 DESCRIPTION QTY 9SS23736-1 STRAIN RELIEF 2 9ST8833-24 HEX HD CAP SCREW 4 9SE106A-15 LOCKWASHER 4 9SCF000027 1/2-13HN 4 9SS15017-16 GROUND STRAP 1 9ST14731-14 METRIC HEX HD SCREW-M8 X1.25 1 9SS9262-121 PLAIN WASHER 1 11A 9SS27497 VALVE MOUNTING BRACKET ASBLY 1 11B 9SS9225-66 SELF TAPPING SCREW 2 12 9SL16360 CIRCUIT BREAKER BOX ASSEMBLY 1 12A 9SL16364 CIRCUIT BREAKER BOX ASBLY 1 9ST12287-38 CIRCUIT BREAKER 1 12C 9SS22061-2 SEALING BOOT 1 12D 9ST12287-12 CIRCUIT BREAKER-30A250VAC24VDC 1 12E 9SS22061-5 SEALING BOOT 1 12F 9ST12287-41 70A CIRCUIT BREAKER 1 12G 9SS22061-1 CIRCUIT BREAKER BOOT 1 9SS13100-274 CONNECTOR & LEAD ASSEMBLY 1 9SS13100-275 CONNECTOR & LEAD ASSEMBLY 1 9SS8025-96 SELF TAPPING SCREW 2 12K 9SS14293-20 RELAY HEAVY DUTY 12VDC SPDT 2 12L 9SS14293-24 RELAY 1 12M 9SS19999-1 CORD GRIP CONNECTOR 1 12N 9ST14370-2 CONDUIT LOCKNUT 1 9SS13100-276 CONNECTOR & LEAD ASSEMBLY 1 9SCF000010 #10-24HN 2 9SS8025-96 SELF TAPPING SCREW 2 12R 9SS28115 MOUNTING STRAP ASSEMBLY 1 12S 9SCF000010 #10-24HN 2 12T 9SCF000017 1/4-20HN 1 12U 9SE106A-2 LOCKWASHER 1 12V 9SS9262-98 PLAIN WASHER 1 9SS13100-277 CONNECTOR & LEAD ASSEMBLY 1 9SS25760 REMOTE JUMP-START TERMINAL(POSITIVE) 1 13 18 PART NUMBER Air Vantage 600 T4F - 11984 Printed 06/24/2016 at 13:49:02. Produced by Enigma. KEY Base & Lift Bale Assembly KEY 9SS25761 DESCRIPTION REMOTE JUMP-START TERMINAL(NEGATIVE) QTY 1 Printed 06/24/2016 at 13:49:02. Produced by Enigma. 14 PART NUMBER Air Vantage 600 T4F - 11984 19 Printed 06/24/2016 at 13:49:02. Produced by Enigma. Base & Lift Bale Assembly P-756-G.jpg 20 Air Vantage 600 T4F - 11984 Fuel Tank & Mounting Printed 06/24/2016 at 13:49:02. Produced by Enigma. KEY PART NUMBER DESCRIPTION QTY 1A 9SG3568-1 FAN BAFFLE 1 1B 9ST13086-62 DECAL-WARNING 2 1C 9SS18543-5 GROMMET 2 1D 9SM19177 LOWER STATOR BAFFLE 1 1E 9SL10999-1 UPPER STATOR BAFFLE 1 1F 9SS8025-92 SELF TAPPING SCREW 6 1G 9SS24327 BRUSH COVER 1 1H 9SS9225-66 SELF TAPPING SCREW 1 9SS18543-2 INPUT CABLE GROMMET 1 1K 9SM15045-77 ACOUSTICAL FOAM 2 1L 9ST11525-5 SPEED NUT1/4-20 1 1M 9SS9262-98 PLAIN WASHER 2 1N 9SE106A-2 LOCKWASHER 2 1P 9SCF000017 1/4-20HN 2 3A 9ST13637-5 DIODE-BRIDGE35A800VF-W1-PH 1 3B 9SCF000072 #10-24X.75RHS 1 3C 9SS9262-27 PLAIN WASHER 1 3D 9SE106A-1 LOCKWASHER 1 3E 9SCF000010 #10-24HN 1 4A 9SS13490-171A FILTER CAPACITOR 1 4B 9SS9225-66 SELF TAPPING SCREW 1 4C 9SS22747 CAPACITOR BRKT ASBLY 1 4D 9SS9262-98 PLAIN WASHER 2 4E 9SE106A-2 LOCKWASHER 2 4F 9SS11604-65 SET SCREW 2 4G 9SCF000198 1/4-28HN 2 5A 9SM16889-1 FUEL TANK SUPPORT 1 5B 9SM16889-2 FUEL TANK SUPPORT 1 5C 9SS9225-26 THREAD FORMING SCREW (ROLLING) 4 6A 9SS20746 FUEL TANK STRAP 2 6B 9ST11135-18 RUBBER WASHER 4 6C 9SS9262-120 PLAIN WASHER 4 6D 9ST9187-10 3/8-16HLN-1817/1-NYLON INSERT 4 9SG2500-1 FUEL TANK ASBLY 1 Air Vantage 600 T4F - 11984 21 Fuel Tank & Mounting KEY PART NUMBER DESCRIPTION QTY 7A 9SG2499-1 FUEL TANK 1 7B 9SM16893 FUEL LEVER SENDER 1 7C 9ST10082-4 SEMS SCREW 5 7D 9SS19563 RUBBER PLUG 2 7E 9SS19564-1 FUEL FITTING (PUSH-IN) 2 7F 9SS20541 FUEL CAP 1 8 9ST12380-1 BUSHING 1 10 9ST10642-187 FLEX TUBE 2 11 9ST13777-7 HOSE CLAMP 1 12 9SG7935-1 FUEL TANK GUARD 1 9SS10404-132 RESISTORWW25W105% 1 9SCF000009 #10-24X3.00RHS 1 9ST4479-A INSULATING WASHER 2 13D 9SS9262-27 PLAIN WASHER 1 13E 9SE106A-1 LOCKWASHER 1 13F 9SCF000010 #10-24HN 1 14 9SM20007 OUTPUT STUD COVER 1 15 9SS9225-66 SELF TAPPING SCREW 2 16 9SS25669 OUTPUT STUD COVER PLATE 1 Printed 06/24/2016 at 13:49:02. Produced by Enigma. 13A 22 Air Vantage 600 T4F - 11984 Printed 06/24/2016 at 13:49:02. Produced by Enigma. Fuel Tank & Mounting P-756-H.jpg Air Vantage 600 T4F - 11984 23 Engine Assembly DESCRIPTION QTY 9SG7213-1 ENGINE ASSEMBLY 1 9SM22791 ENGINE 1 9SM24913-1 ENGINE FOOT WELDMENT 1 9ST14731-76 METRIC SCREW 2 9SS17400-2 LOCKWASHER-METRIC M12 2 9SM24913-2 ENGINE FOOT WELDMENT 1 9ST14731-76 METRIC SCREW 2 9SS17400-2 LOCKWASHER-METRIC M12 2 4 9SM22803 FAN SPACER 1 5 9SL16309 FAN 1 9SM22803-2B METRIC SCREW 4 9SM22803-2C LOCK WASHER 4 9SG7362 COOLANT HOSE 1 9SS10888-44 HOSE CLAMP 2 9SG7540 OVERFLOW HOSE 1 9SS10888-31 HOSE CLAMP 2 9SG7561 AIR INTAKE HOSE 1 9SS10888-44 HOSE CLAMP 2 9SL16180-1 AIR INTAKE HOSE 1 9SS10888-33 HOSE CLAMP 1 9SL16345-2 AIR INTAKE HOSE TEE 1 9SS10888-33 HOSE CLAMP 1 9SS29517 FILTER BRACKET 1 9ST14731-76 METRIC SCREW 1 9SS17400-2 LOCKWASHER-METRIC M12 1 9ST14731-78 METRIC SCREW 1 9SE106A-12 LOCKWASHER 1 9ST10642-91 FLUX TUBE 1 9SS10888-35 HOSE CLAMP 2 9ST10642-218 FLEX HOSE 1 9SS10888-35 HOSE CLAMP 1 9SS23024 OIL DRAIN VALVE 2 1 3 6 7 8 9 12 13 14 24 PART NUMBER Air Vantage 600 T4F - 11984 Printed 06/24/2016 at 13:49:02. Produced by Enigma. KEY Printed 06/24/2016 at 13:49:02. Produced by Enigma. Engine Assembly P-756-J.jpg Air Vantage 600 T4F - 11984 25 Generator Assembly 1 DESCRIPTION QTY 9SG3088-27 STATOR TIE WELDED ASSEMBLY 1 9SL13110-3 ROTOR & COUPLING DISC ASBLY 1 9SL10501-5 ROTOR & SHAFT ASBLY 1 3 9SS22657 FAN COUPLE 1 4 9SL9551 FAN BLADE 1 5A 9SCF000025 3/4-10HN 1 5B 9SE106A-7 LOCKWASHER 1 6A 9SS9225-22 THREAD FORMING SCREW (ROLLING) 4 6B 9SE106A-14 LOCKWASHER 4 7A 9SM9300-85 BEARING 1 7B 9SS18044-5 TOLERANCE RING 1 7C 9SL11614 STATOR COWLING 1 7D 9SS9225-8 THREAD FORMING SCREW (ROLLING) 8 7E 9SS22415-4 TRIM SEAL 2 7F 9SM15045-64 ACOUSTICAL FOAM 2 7G 9SL11614-1 STATOR COWLING 1 8A 9SS11868-1 BLOWER SEGMENT 4 8B 9SS17400-1 LOCKWASHER-METRIC 8 8C 9ST14731-5 METRIC HEX HD SCREW-M10 X 1.5 8 8D 9SM19796 COUPLING DISC 1 8E 9SS8042 COUPLING DISC BACKING PLATE 2 8F 9SS14233 COUPLING CLAMP RING-INSIDE 1 8G 9ST8833-2 HEX HD CAP SCREW 8 8H 9SE106A-8 LOCKWASHER 8 8J 9ST14731-5 METRIC HEX HD SCREW-M10 X 1.5 8 8K 9SS17400-1 LOCKWASHER-METRIC 8 9SM21315-8 BRUSH HOLDER & BRACKET ASBLY 1 9A 9SM18323-1 BRUSH HOLDER BRKT 1 9B 9SM16158 BRUSH & BRUSH HOLDER ASBLY 1 9SG2114 BRUSH HOLDER CARTRIDGE 1 9SS19480 BRUSH ASBLY 2 9SM16157 BRUSH ASBLY RETAINER 1 9C 9SS8025-91 SELF TAPPING SCREW 2 9D 9ST12380-4 BUSHING 1 2A 26 PART NUMBER Air Vantage 600 T4F - 11984 Printed 06/24/2016 at 13:49:02. Produced by Enigma. KEY Generator Assembly KEY PART NUMBER DESCRIPTION QTY 9SS9225-8 THREAD FORMING SCREW (ROLLING) 2 14A 9SS24485 RUBBER MOUNT 4 14B 9SS9225-26 THREAD FORMING SCREW (ROLLING) 8 14C 9SCF000123 1/2-13X2.75HHCS 4 14D 9ST9054 WASHER 4 14E 9SS9262-5 PLAIN WASHER 4 14F 9ST9187-4 LOCKNUT 4 Printed 06/24/2016 at 13:49:02. Produced by Enigma. 9E Air Vantage 600 T4F - 11984 27 Printed 06/24/2016 at 13:49:02. Produced by Enigma. Generator Assembly P-756-K.jpg 28 Air Vantage 600 T4F - 11984 Radiator & Case Back Assembly Printed 06/24/2016 at 13:49:02. Produced by Enigma. KEY PART NUMBER DESCRIPTION QTY 9SG7341-1 RADIATOR & CASE BACK ASSEMBLY 1 1 9SL8912-6 CASE BACK 1 2 9ST13086-62 DECAL-WARNING 2 9SM15045-64 ACOUSTICAL FOAM 2 4A 9SM25275-2 LEFT MOUNTING BRACKET 1 4B 9ST11827-71 CARRIAGE BOLT 6 4C 9SS30690 SPACER 6 4D 9SS30686 ISOLATOR 6 4E 9SS9262-47 PLAIN WASHER 6 4F 9ST9187-10 3/8-16HLN-1817/1-NYLON INSERT 6 5A 9SM25275-3 RIGHT MOUNTING BRACKET 1 6A 9SG7340-1 FAN SHROUD 1 6B 9SCF000062 5/16-18X1.00HHCS 6 6C 9SE106A-3 LOCKWASHER 6 6D 9SS9262-121 PLAIN WASHER 6 7 9SG7333-1 RADIATOR 1 8 9ST10642-218 FLEX HOSE 1 9 9ST10642-333 FLEX TUBE 1 9SS10888-35 HOSE CLAMP 3 11 9SS24068 FUEL SHUT-OFF 1 12A 9SG7360-1 RIGHT FAN GUARD 1 9SS9225-68 THREAD FORMING SCREW (CUTTING) 4 13A 9SG7361-1 LEFT FAN GUARD 1 13B 9SS9225-68 THREAD FORMING SCREW (CUTTING) 5 14 9SS9225-66 SELF TAPPING SCREW 6 Air Vantage 600 T4F - 11984 29 Printed 06/24/2016 at 13:49:02. Produced by Enigma. Radiator & Case Back Assembly P-756-L.jpg 30 Air Vantage 600 T4F - 11984 Covers KEY DESCRIPTION QTY 9SL13116-8 ROOF ASSEMBLY 1 1A 9SG3998-5 ROOF 1 2 9ST14882-1 DOOR BUMPER 2 9SM20278 RADIATOR CAP COVER ASSEMBLY 1 9ST12584-6 RIVET 2 9ST11525-7 SPEED NUT 2 5A 9SL16589 AIR CLEANER BRACKET 1 5B 9SS24739-40 STAINLESS STEEL SCREW 2 9SS24739-31 1/4-20 STAINLESS STEEL SCREW 18 9SL10648-4 LEFT SIDE PANEL 1 9SS24739-31 1/4-20 STAINLESS STEEL SCREW 10 9ST11525-5 SPEED NUT1/4-20 2 9SM15045-77 ACOUSTICAL FOAM 1 9SL12093-3 ENGINE CASE SIDE ASBLY 1 9SS24739-31 1/4-20 STAINLESS STEEL SCREW 6 9ST11525-5 SPEED NUT1/4-20 3 9SL12115-3 DOOR SLIDE 1 9SS24739-31 1/4-20 STAINLESS STEEL SCREW 7 9SS25719-5 EDGE GUARD 1 9SL16173 DOOR ASBLY 1 9SL16172 DOOR WELDED ASSEMBLY 1 9SM20241 DOOR LATCH 1 9ST12584-6 RIVET 4 9ST14882-2 DOOR BUMPER 2 9ST12584-16 RIVET 2 9SS27368-6 LOGO DECAL 1 9SL16174 SIDE PANEL 1 9SS24739-5 1/4-20 STAINLESS STEEL SCREW 3 9SL10646-4 RIGHT SIDE PANEL 1 9SS24739-31 1/4-20 STAINLESS STEEL SCREW 10 9ST11525-5 SPEED NUT1/4-20 3 9SM15045-77 ACOUSTICAL FOAM 1 16 9SS12934-1 COVER SEAL 1 17 9SM21436 CARBON MONOXIDE WARNING DECAL 1 3A 4 10A 11A 12A 12D 12F Printed 06/24/2016 at 13:49:02. Produced by Enigma. PART NUMBER 12K 13A Air Vantage 600 T4F - 11984 31 Covers KEY PART NUMBER DESCRIPTION QTY 9ST13086-221 WARNING DECAL 1 19 9SS25896 DECAL-WARNING 1 20 9SS10437-F GASKET 1 21 9SL13737-1 BACK PANEL 1 22 9SG8108 SIDE DECAL 2 23 9SM16197 DECAL-WARNING 1 24 9SS28039-4 DECAL GREEN INITIATIVE 1 25 9SM21908 FAMILY NAME LOGO 1 9SS27368-6 LOGO DECAL 1 Printed 06/24/2016 at 13:49:02. Produced by Enigma. 18 32 Air Vantage 600 T4F - 11984 Printed 06/24/2016 at 13:49:02. Produced by Enigma. Covers P-756-M.jpg Air Vantage 600 T4F - 11984 33 Air Compressor 34 PART NUMBER DESCRIPTION QTY 1 9SG7444-6 Belt K060465 46.5 1 2 9SG7444-3 Main Bracket Assembly 1 3 9SG7444-7 Crank Pulley 1 4 9SG7444-4 Manifold Assembly 1 5 9SG6911-16 SOLENOID ASBLY 1 6 9SG7444-8 Pressure Switch Assembly 1 9SS30275 PROTECTIVE BOOT 1 7 9SG6204-11 DISCHARGE VALVE ASBLY 1 8 9SG7444-24 Minimum Pressure Check Valve Assembly 1 9 9SG6204-16 OIL SEPARATOR TANK MOUNTING BRACKET 1 10 9SG6984-2 LINCOLN LABEL 1 11 9SG6984-3 Warning Label 1 12 9SG7444-1 Compressor Assembly 1 13 9SG7444-5 Oil Cooler 1 14 9SG7444-9 Tank Assembly 1 15 9SG7444-10 Harness S700162 1 16 9SG7444-11 HOSE CRIMPED 17 9SG6204-5 HOSE ASBLY 49" COOLER TO MANIFOLD 1 18 9SG7444-12 Hose crimped 1 19 9SG7444-13 Hose crimped x57 (Compressor - Tank) 1 21 9SG6984-30 COOLER FILTER CRIMPED HOSE 1/2X65" 1 23 9SG7444-25 HOSECRIMPED X26 CHECK VALVE-BALL VALVE 1 24 9SG7444-14 HOSECRIMPED X17 (MANIFOLD-CHECK VALVE) 1 9SS28937-1 OIL FILTER 1 9SS28937-2 1 LITER COMPRESSOR OIL 1 9SS28937-3 4 LITER COMPRESSOR OIL 1 9SS28937-5 COALESCING FILTER 1 9SG4481-16 PRESSURE RELIEF VALVE 1 9SG6911-4 CLUTCH 1 1-888-241-2289 FOR VMAC QUESTIONS PLEASE CALL 1 X 49 (TANK - MANIFOLD) x 20 (Cooler - Filter) 1 Air Vantage 600 T4F - 11984 Printed 06/24/2016 at 13:49:02. Produced by Enigma. KEY Printed 06/24/2016 at 13:49:02. Produced by Enigma. Air Compressor P-756-N.jpg Air Vantage 600 T4F - 11984 35 WARNING AVISO DE PRECAuCION Spanish l Do not touch electrically live parts or l No toque las partes o los electrodos bajo carga con la piel o ropa mojada. l Aislese del trabajo y de la tierra. French l Ne laissez ni la peau ni des vête- German l Berühren Sie keine stromführenden ATTENTION WARNuNG Portuguese ATENÇÃO Japanese l Keep flammable materials away. l Wear eye, ear and body protection. l Mantenga el material combustible l Protéjase los ojos, los oídos y el electrode with skin or wet clothing. l Insulate yourself from work and ground. ments mouillés entrer en contact avec des pièces sous tension. l Isolez-vous du travail et de la terre. fuera del área de trabajo. l Gardez à l’écart de tout matériel inflammable. l Entfernen Sie brennbarres Material! Teile oder Elektroden mit Ihrem Körper oder feuchter Kleidung! l Isolieren Sie sich von den Elektroden und dem Erdboden! l Não toque partes elétricas e elec- trodos com a pele ou roupa molhada. l Isole-se da peça e terra. cuerpo. l Protégez vos yeux, vos oreilles et votre corps. l Tragen Sie Augen-, Ohren- und Kör- perschutz! l Mantenha inflamáveis bem guarda- dos. l Use proteção para a vista, ouvido e corpo. Chinese Korean Arabic READ AND UNDERSTAND THE MANUFACTURER’S INSTRUCTION FOR THIS EQUIPMENT AND THE CONSUMABLES TO BE USED AND FOLLOW YOUR EMPLOYER’S SAFETY PRACTICES. SE RECOMIENDA LEER Y ENTENDER LAS INSTRUCCIONES DEL FABRICANTE PARA EL USO DE ESTE EQUIPO Y LOS CONSUMIBLES QUE VA A UTILIZAR, SIGA LAS MEDIDAS DE SEGURIDAD DE SU SUPERVISOR. LISEZ ET COMPRENEZ LES INSTRUCTIONS DU FABRICANT EN CE QUI REGARDE CET EQUIPMENT ET LES PRODUITS A ETRE EMPLOYES ET SUIVEZ LES PROCEDURES DE SECURITE DE VOTRE EMPLOYEUR. LESEN SIE UND BEFOLGEN SIE DIE BETRIEBSANLEITUNG DER ANLAGE UND DEN ELEKTRODENEINSATZ DES HERSTELLERS. DIE UNFALLVERHÜTUNGSVORSCHRIFTEN DES ARBEITGEBERS SIND EBENFALLS ZU BEACHTEN. l Keep your head out of fumes. l Use ventilation or exhaust to l Turn power off before servicing. l Do not operate with panel open or guards off. remove fumes from breathing zone. l Los humos fuera de la zona de res- piración. l Mantenga la cabeza fuera de los humos. Utilice ventilación o aspiración para gases. l Gardez la tête à l’écart des fumées. l Utilisez un ventilateur ou un aspira- l Desconectar el cable de ali- mentación de poder de la máquina antes de iniciar cualquier servicio. l Débranchez le courant avant l’entre- tien. teur pour ôter les fumées des zones de travail. l Vermeiden Sie das Einatmen von Schweibrauch! l Sorgen Sie für gute Be- und Entlüftung des Arbeitsplatzes! l Mantenha seu rosto da fumaça. l Use ventilação e exhaustão para remover fumo da zona respiratória. l Strom vor Wartungsarbeiten l No operar con panel abierto o guardas quitadas. l N’opérez pas avec les panneaux ouverts ou avec les dispositifs de protection enlevés. l Anlage nie ohne Schutzgehäuse abschalten! (Netzstrom völlig öffnen; Maschine anhalten!) oder Innenschutzverkleidung in Betrieb setzen! l Não opere com as tampas removidas. l Desligue a corrente antes de fazer l Mantenha-se afastado das partes serviço. l Não toque as partes elétricas nuas. moventes. l Não opere com os paineis abertos ou guardas removidas. WARNING AVISO DE PRECAuCION Spanish French ATTENTION German WARNuNG Portuguese ATENÇÃO Japanese Chinese Korean Arabic LEIA E COMPREENDA AS INSTRUÇÕES DO FABRICANTE PARA ESTE EQUIPAMENTO E AS PARTES DE USO, E SIGA AS PRÁTICAS DE SEGURANÇA DO EMPREGADOR. 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. On occasion, purchasers may ask Lincoln Electric for advice or information about their use of our products. 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. We expressly disclaim any warranty of any kind, including any warranty of fitness for any customer’s particular purpose, with respect to such information or advice. As a matter of practical consideration, we also cannot assume any responsibility for updating or correcting any such information or advice once it has been given, nor does the provision of information or advice create, expand or alter any warranty with respect to the sale of our products. Lincoln Electric is a responsive manufacturer, but the selection and use of specific products sold by Lincoln Electric is solely within the control of, and remains the sole responsibility of the customer. Many variables beyond the control of Lincoln Electric affect the results obtained in applying these types of fabrication methods and service requirements. Subject to Change – This information is accurate to the best of our knowledge at the time of printing. Please refer to www.lincolnelectric.com for any updated information. TABLE OF CONTENTS INSTALLATION OPERATION ACCESSORIES MAINTENANCE TROUBLE SHOOTING WIRING DIAGRAMS CONNECTION DIAGRAMS
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