Lincoln Electric Air Vantage 700 (AU) - 11655 Operator Manual

Operator’s Manual

AIR VANTAGE

®

700 (AU) CUMMINS

For use with machines having Code Numbers:

11655

, 12379

Register your machine: www.lincolnelectric.com/register

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Date Purchased

Code: (ex: 10859)

Serial: (ex: U1060512345)

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IM10103-A

| Issue D ate

Apr-16

© Lincoln Global, Inc. All Rights Reserved.

THANK YOU FOR SELECTING

A QUALITY PRODUCT BY

LINCOLN ELEC TRIC.

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.

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 Safety Data

Sheet (SDS) 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 de velop unusual symptoms, see your supervisor.

Perhaps the welding atmosphere and ventilation system should be checked.

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.

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 01 of 04 - 06/15/2016

SAFETY

SECTION A:

WARNINGS

CALIFORNIA PROPOSITION 65 WARNINGS

Diesel Engines

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

The engine exhaust from this product contains chemicals known to the State of California to cause cancer, birth defects, or other reproductive harm.

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.

FOR ENGINE POWERED

EQUIPMENT.

1.a. Turn the engine off before troubleshooting and maintenance work unless the maintenance work requires it to be running.

1.b. Operate engines in open, well-ventilated areas or vent the engine exhaust fumes outdoors.

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.

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.

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.

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.

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.

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.

2.c. Exposure to EMF fields in welding may have other health effects which are now not known.

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.

2.d.2. Never coil the electrode lead around your body.

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.

Safety 02 of 04 - 06/15/2016

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.

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.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.

4.b.

Use suitable clothing made from durable flame-resistant material to protect your skin and that of your helpers from the arc rays.

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.

• 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.

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 two can be the total of the open circuit voltage of both welders.

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 It ems 6.c. and 8.

between the

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.

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 hardfacing

(see instructions on container or SDS) 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 unless exposure assessments indicate otherwise. In confined spaces or in some circumstances, outdoors, a respirator may also be required. Additional precautions are also required when welding on galvanized steel.

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.

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.

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

Safety Data Sheet (SDS) and follow your employer’s safety practices. SDS forms are available from your welding distributor or from the manufacturer.

5.f. Also see item 1.b.

Safety 03 of 04 - 06/15/2016

SAFETY

WELDING AND CUTTING

SPARKS CAN CAUSE

FIRE OR EXPLOSION.

CYLINDER MAY EXPLODE IF

DAMAGED.

6.a. Remove fire hazards from the welding area. If this is not possible, cover them to prevent the welding sparks from starting a fire. Remember that welding sparks and hot materials from welding can easily go through small cracks and openings to adjacent areas. Avoid welding near hydraulic lines.

Have a fire extinguisher readily available.

6.b. 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.

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.

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).

6.e. Vent hollow castings or containers before heating, cutting or welding. They may explode.

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.

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.

6.h. Also see item 1.c.

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.

6.j. Do not use a welding power source for pipe thawing.

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.

7.b. Always keep cylinders in an upright position securely chained to an undercarriage or fixed support.

7.c. Cylinders should be located:

•

•

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.

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 from the Compressed Gas Association, 14501 George Carter Way

Chantilly, VA 20151.

FOR ELECTRICALLY

POWERED EQUIPMENT.

8.a. Turn off input power using the disconnect switch at the fuse box before working on the equipment.

8.b. Install equipment in accordance with the U.S. National Electrical

Code, all local codes and the manufacturer’s recommendations.

8.c. Ground the equipment in accordance with the U.S. National

Electrical Code and the manufacturer’s recommendations.

Refer to http://www.lincolnelectric.com/safety for additional safety information.

Safety 04 of 04 - 06/15/2016

SAFETY

Electromagnetic Compatibility (EMC)

Conformance

Products displaying the CE mark are in conformity with European Community Council Directive of 15 Dec

2004 on the approximation of the laws of the Member States relating to electromagnetic compatibility,

2004/108/EC. It was manufactured in conformity with a national standard that implements a harmonized standard: EN 60974-10 Electromagnetic Compatibility (EMC) Product Standard for Arc Welding Equipment.

It is for use with other Lincoln Electric equipment. It is designed for industrial and professional use.

Introduction

All electrical equipment generates small amounts of electromagnetic emission. Electrical emission may be transmitted through power lines or radiated through space, similar to a radio transmitter. When emissions are received by other equipment, electrical interference may result. Electrical emissions may affect many kinds of electrical equipment; other nearby welding equipment, radio and TV reception, numerical controlled machines, telephone systems, computers, etc. Be aware that interference may result and extra precautions may be required when a welding power source is used in a domestic establishment.

Installation and Use

The user is responsible for installing and using the welding equipment according to the manufacturer’s instructions. If electromagnetic disturbances are detected then it shall be the responsibility of the user of the welding equipment to resolve the situation with the technical assistance of the manufacturer. In some cases this remedial action may be as simple as earthing (grounding) the welding circuit, see Note. In other cases it could involve construction of an electromagnetic screen enclosing the power source and the work complete with associated input filters. In all cases electromagnetic disturbances must be reduced to the point where they are no longer troublesome.

Note: The welding circuit may or may not be earthed for safety reasons according to national codes. Changing the earthing arrangements should only be authorized by a person who is competent to access whether the changes will increase the risk of injury, e.g., by allowing parallel welding current return paths which may damage the earth circuits of other equipment.

Assessment of Area

Before installing welding equipment the user shall make an assessment of potential electromagnetic problems in the surrounding area. The following shall be taken into account: a) other supply cables, control cables, signaling and telephone cables; above, below and adjacent to the welding equipment; b) radio and television transmitters and receivers; c) computer and other control equipment; d) safety critical equipment, e.g., guarding of industrial equipment; e) the health of the people around, e.g., the use of pacemakers and hearing aids; f) equipment used for calibration or measurement g) the immunity of other equipment in the environment. The user shall ensure that other equipment being used in the environment is compatible. This may require additional protection measures; h) the time of day that welding or other activities are to be carried out.

6

SAFETY

Electromagnetic Compatibility (EMC)

The size of the surrounding area to be considered will depend on the structure of the building and other activities that are taking place. The surrounding area may extend beyond the boundaries of the premises.

Methods of Reducing Emissions

Mains Supply

Welding equipment should be connected to the mains supply according to the manufacturer’s recommendations. If interference occurs, it may be necessary to take additional precautions such as filtering of the mains supply. Consideration should be given to shielding the supply cable of permanently installed welding equipment, in metallic conduit or equivalent. Shielding should be electrically continuous throughout its length. The shielding should be connected to the welding power source so that good electrical contact is maintained between the conduit and the welding power source enclosure.

Maintenance of the Welding Equipment

The welding equipment should be routinely maintained according to the manufacturer’s recommendations.

All access and service doors and covers should be closed and properly fastened when the welding equipment is in operation. The welding equipment should not be modified in any way except for those changes and adjustments covered in the manufacturers instructions. In particular, the spark gaps of arc striking and stabilizing devices should be adjusted and maintained according to the manufacturer’s recommendations.

Welding Cables

The welding cables should be kept as short as possible and should be positioned close together, running at or close to floor level.

Equipotential Bonding

Bonding of all metallic components in the welding installation and adjacent to it should be considered.

However, metallic components bonded to the work piece will increase the risk that the operator could receive a shock by touching these metallic components and the electrode at the same time. The operator should be insulated from all such bonded metallic components.

Earthing of the Workpiece

Where the workpiece is not bonded to earth for electrical safety, not connected to earth because of its size and position, e.g., ships hull or building steelwork, a connection bonding the workpiece to earth may reduce emissions in some, but not all instances. Care should be taken to prevent the earthing of the workpiece increasing the risk of injury to users, or damage to other electrical equipment. Where necessary, the connection of the workpiece to earth should be made by a direct connection to the workpiece, but in some countries where direct connection is not permitted, the bonding should be achieved by suitable capacitance, selected according to national regulations.

Screening and Shielding

Selective screening and shielding of other cables and equipment in the surrounding area may alleviate problems of interference. Screening of the entire welding installation may be considered for special applications1.

_________________________

1 Portions of the preceding text are contained in EN 60974-10: “Electromagnetic Compatibility (EMC) product standard for arc welding equipment.”

7

TABLE OF CONTENTS

Page

Installation ................................................................................................................................................Section A

Technical Specifications................................................................................................................................A-1

Safety Precautions...................................................................................................................................A-2

VRD (Voltage Reduction Device) ............................................................................................................A-2

Location and Ventilation........................................................................................................................A-2

Storing .................................................................................................................................................A-2

Stacking ...............................................................................................................................................A-3

Angle of Operation ................................................................................................................................A-3

Lifting......................................................................................................................................................A-3

High Altitude Operation .........................................................................................................................A-3

High Temperature Operation .................................................................................................................A-3

Towing .................................................................................................................................................A-3

Vehicle Mounting ..................................................................................................................................A-3

Pre-Operation Engine and Compressor Service .............................................................................................A-4

Oil ........................................................................................................................................................A-4

Fuel and Fuel Cap.................................................................................................................................A-4

Engine Coolant System .........................................................................................................................A-4

Battery Connections..............................................................................................................................A-4

Muffler Outlet Pipe................................................................................................................................A-5

Spark Arrestor ......................................................................................................................................A-5

Air Cleaner Inlet Hood ...................................................................................................................................A-5

Welding Terminals ........................................................................................................................................A-5

Welding Output Cables..................................................................................................................................A-5

Machine Grounding...............................................................................................................................A-5

Remote Control...............................................................................................................................................A-6

Auxiliary Power Receptacles and Standby Power Connections ...............................................................A-6, A-7

Connection of Lincoln Electric Wire Feeders ............................................................................................A-8, A-9

Electrical Device used with this Product ......................................................................................................A-10

________________________________________________________________________________

Operation Section B

Safety Precautions .......................................................................................................................................B-1

General Description.......................................................................................................................................B-1

Auxiliary Power ....................................................................................................................................B-1

Engine Operation ..................................................................................................................................B-1

Add Fuel .......................................................................................................................................................B-2

Hand Primer Button.......................................................................................................................................B-2

Recommended Applications ..........................................................................................................................B-2

Air Compressor .............................................................................................................................................B-2

Generator......................................................................................................................................................B-2

Welder Controls...............................................................................................................................B-3 thru B-4

Engine Controls.............................................................................................................................................B-5

Engine Operations.........................................................................................................................................B-7

Welder Operations.........................................................................................................................B-8 thru B-10

Auxiliary Power Operation ...........................................................................................................................B-11

Simultaneous Welding and Auxiliary Power Loads...............................................................................B-11

Accessories .................................................................................................................................Section c

Optional Field Installed Accessories .............................................................................................C-1

________________________________________________________________________

8

TABLE OF CONTENTS

Maintenance ..............................................................................................................................Section D

Safety Precautions.......................................................................................................................D-1

Routine and Periodic Maintenance ................................................................................................D-1

Compressor Maintenance ............................................................................................................D-1

Engine Maintenance ....................................................................................................................D-1

Air Filter ...............................................................................................................................D-1

Service Instructions for Engine Air Cleaner...................................................................................D-2

Fuel Filters ...........................................................................................................................D-3

Cooling System ....................................................................................................................D-3

Battery Handling...................................................................................................................D-4

Charging the Battery .....................................................................................................................D-4

Servicing Muffler with Internal Spark Arrester ..............................................................................D-4

Nameplate / Warning Decal Maintenance.....................................................................................D-5

Welder / Generator Maintenance..................................................................................................D-5

Engine Maintenance Components ................................................................................................D-5

________________________________________________________________________

Troubleshooting.......................................................................................................................Section E

________________________________________________________________________

Connection Diagrams, Wiring 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.

________________________________________________________________________

9

AIR VANTAGE ® 700 (AU) CUMMINS NOTES

10

AIR VANTAGE ® 700 (AU) CUMMINS INSTALLATION

TECHNICAL SPECIFICATIONS - AIR VANTAGE

®

700 (AU) CUMMINS (K2961-2)

INPUT - DIESEL ENGINE

Make/Model Description Speed (RPM) Displacement Starting Dry Capacities

cu. in. (ltrs.) System

4 cylinder High Idle 1860 199(3.3) 12VDC Battery & Fuel: 25 gal.

Cummins ® 69 HP (51.4kw) starter (94.6 L)

B3.3T 1800 RPM Full Load 1860 Bore x Stroke inch (mm) Oil: 2 gal. (7.6L)

Turbo Charged

Diesel Engine Low Idle 1500 3.74 X 4.53 Radiator Coolant:

(95 x 115mm) 4.0gal. (15.1L)

RATED OUTPUT @ 104°F(40°C) - WELDER

Duty Cycle Welding Output Volts at Rated Amps

100% 600 Amps (DC multi-purpose)



OUTPUT @ 104°F(40°C) - WELDER AND GENERATOR

44 Volts

40 volts

38 volts

Welding Range

30 - 700 Amps CC/CV

20 - 250 Amps TIG

Open Circuit Voltage

60 Max OCV @ 1860 RPM

Auxiliary Power (1)

240 VAC 2 x 3600 WATTS, 60 Hz., Single Phase

415 VAC 20,000 WATTS, 60 Hz., Three Phase

COMPRESSOR SPECIFICATIONS

Compressor Model Description Delivery Maximum System Compressor Capacities

Pressure Protection

VMAC ® Belt-Drive Rotary High Idle Mode: 150 PSI Safety Relief Valve 1.3 gal.(5.0 ltrs)

S700159 Screw Air Compressor 60 SCFM @ 100PSI (10.5 kg/cm 2 ) 200 PSI

(28.3 Ltr/sec. @ (14.1 kg/cm 2 )

7.0 kg/cm)

High Temperature

Automatic Shutdown

290° F (143°C)

PHYSICAL DIMENSIONS

Height (2) Width (3) Depth Weight

36.9 in 28.5 in. 77.0 in. 2018 lbs.

(937 mm) (724 mm) (1956 mm) (915 kg)

(Approx.)

Lift Bail weight rating 2500 lbs. (1134 kg.) Maximum.

(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 8.3” (211mm) for exhaust pipe, also add 3.65”(93mm) for metal skid.

(3) Without metal skid.

A-1

AIR VANTAGE ® 700 (AU) CUMMINS

SAFETY PRECAUTIONS

WARNING

Do not attempt to use this equipment until you have thoroughly read the engine manufacturer’s manual supplied with your welder. It includes important safety precautions, detailed engine starting, operating and maintenance instructions, and parts lists.

--------------------------------------------------------------------

ELECTRIC SHOCK can kill.

• Do not touch electrically live parts or electrode with skin or wet clothing.

• Insulate yourself from work and ground

• Always wear dry insulating gloves.

--------------------------------------------------------------------

ENGINE EXHAUST can kill.

• Use in open, well ventilated areas or vent exhaust outside.

--------------------------------------------------------------------

MOVING PARTS can injure.

• Do not operate with doors open or guards off.

• Stop engine before servicing.

• Keep away from moving parts.

--------------------------------------------------------------------

See additional warning information at front of this operator’s manual.

Only qualified personnel should install, use, or service this equipment.

VRD (VOLTAGE REDUCTION DEVICE)

The VRD feature provides additional safety in the CC-Stick mode especially in an environment with a higher risk of electric shock such as wet areas and hot humid sweaty conditions.

The VRD reduces the OCV (Open Circuit Voltage) at the welding output terminals while not welding to less than 30V DC 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 control panel by removing 4 front panel screws.

(See Figure A.1)

• Place the VRD switch in the “On or “Off” position. (See

Figure A.1)

With the VRD switch in the “On” position, the VRD lights are enabled.

FIGURE A.1

REMOVE 4 FRONT PANEL

SCREWS TO ACCESS

(VRD) SWITCH

INSTALLATION

(VRD)-VOLTAGE REDUCTION DEVICE

SWITCH IS LOCATED IN THIS AREA.

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.

CAUTION

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 10W30 oil. Run the engine for about five minutes to circulate oil to all the parts. See the MAINTENANCE section of this 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.

A-2


STACKING

AIR VANTAGE ® 700 (AU) CUMMINS machines cannot be stacked.

ANGLE OF OPERATION

To achieve optimum engine performance the AIR VANTAGE ® 700

(AU) CUMMINS should be run in a level position.

The maximum angle of operation for the machine with the compressor running is 25 degrees continuous in all directions.

The maximum angle of operation for the machine with the compressor not running is 35 degrees continuous in all directions.

When operating the welder at an angle, provisions must be made for checking and maintaining the oil level at the normal

(FULL) oil capacity. Also the effective fuel capacity will be slightly less than the specified 25 gal.(94.6 ltrs.).

LIFTING

The AIR VANTAGE ® 700 (AU) CUMMINS weighs approximately 2188 lbs.(992 kg) with a full tank of fuel, 2018 lbs.(915kg) less fuel. A lift bail is mounted to the machine and should always be used when lifting the machine.

WARNING

• Lift only with equipment of adequate lifting capacity.

• Be sure machine is stable when lifting.

• Do not lift this machine using lift bail if it is equipped with a heavy accessory such as trailer or gas cylinder.

FALLING • Do not lift machine if lift bail is

EQUIPMENT can damaged.

cause injury. • Do not operate machine while suspended from lift bail.

• DO NOT EXCEED MAXIMUM LIFT BAIL WEIGHT RATING.

( SEE TECHNICAL SPECIFICATIONS PAGE)

--------------------------------------------------------------------

INSTALLATION

HIGH ALTITUDE OPERATION

At higher altitudes, output derating may be necessary. For maximum rating, derate the welder output 4% for every 300 meters (984 ft.) above 1500 meters

(4920 ft.). For output of 500A and below, derate the welder output 4% for every

300 meters (984 ft.) above 2100 meters (6888 ft.).

Contact a Cummins Service Representative for any engine adjustments that may be required.

HIGH TEMPERATURE OPERATION

At temperatures above 40°C (104°F), output voltage derating may be necessary.

For maximum output current ratings, derate welder voltage rating 2 volts for every 10°C (21°F) above 40°C (104°F).

TOWING

The recommended trailer for use with this equipment for road, in-plant and yard towing by a vehicle (1) is Lincoln’s K2637-2. If the user adapts a non-Lincoln trailer, he must assume responsibility that the method of attachment and usage does not result in a safety hazard nor damage the welding equipment. Some of the factors to be considered are as follows:

1. Design capacity of trailer vs. weight of Lincoln equipment and likely additional attachments.

2. Proper support of, and attachment to, the base of the welding equipment so that there will be no undue stress to the trailer’s framework.

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.

4. Typical conditions of use, such as travel speed, roughness of surface on which the trailer will be operated, and environmental conditions.

5. Proper preventative maintenance of trailer.

6. Conformance with federal, state and local laws (1) .

(1) Consult applicable federal, state and local laws regarding specific requirements for use on public highways.

VEHICLE MOUNTING

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.

WARNING

• 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 manufacture’s instructions.

-------------------------------------------------------------------------------------

A-3


PRE-OPERATION ENGINE AND COMPRESSOR

SERVICE

READ the engine and compressor operating and maintenance instructions supplied with this machine.

WARNING

• Keep hands away from the engine muffler or

HOT engine parts.

• Stop engine and allow to cool before fuelling.

• 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 ® 700 (AU) CUMMINS is shipped with the engine crankcase filled with high quality SAE 10W-30 oil (API class CD or better). 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.

INSTALLATION

ENGINE COOLANT

WARNING

HOT COOLANT can burn skin.

•Do not remove cap if radiator is hot.

------------------------------------------------------

The welder is shipped with the engine and radiator filled with a

50% mixture of ethylene glycol and water. See the MAINTE-

NANCE section and the engine Operator’s Manual for more information on coolant.

BATTERY CONNECTION

WARNING

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.

• USING A BOOSTER — connect positive lead to battery first then connect negative lead to negative battery lead at engine foot.

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.

Running out of fuel may require bleeding the fuel injection pump.

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.

BATTERY ACID can burn eyes and skin.

• Wear gloves and eye protection and be careful when working near battery.

• Follow instructions printed on battery.

------------------------------------------------------

IMPORTANT: To prevent ELECTRICAL DAMAGE WHEN:

a) Installing new batteries.

b) Using a booster.

Use correct polarity — Negative Ground.

A-4


The AIR VANTAGE ® 700 (AU) CUMMINS is shipped with the negative battery cable disconnected. Before you operate the machine, make sure the Engine Switch is in the OFF position and attach the disconnected cable securely to the negative (-) battery terminal.

INSTALLATION

Listed in Table A.1 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.

Remove the insulating cap from the negative battery terminal.

Replace and tighten negative battery cable terminal. NOTE: This machine is furnished with a wet charged battery; if unused for several months, the battery may require a booster charge. Be sure to use the correct polarity when charging the battery.

MUFFLER OUTLET PIPE

Remove the plastic plug covering the muffler outlet tube. 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 position.

Table A.1 Combined Length of Electrode and Work Cables.

TOTAL COMBINED LENGTH OF

ELECTRODE AND WORK CABLES

Cable Parallel

Length Cables

Lengths up to 150 ft. (46m)

150 ft. (46m) to 200 ft. (61m) 2

200 ft. (61m) to 250 ft. (76m)

Cable Size for

600 Amps

100% Duty Cycle

1/0 AWG (53mm2)

2/0 AWG (67mm2)

3/0 AWG(85mm2)

SPARK ARRESTOR

Some federal, state or local laws may require that petrol or diesel engines be equipped with exhaust spark arrestors when they are operated in certain locations where unarrested sparks may present a fire hazard. The standard muffler included with this welder has an internal spark arrestor. When required by local regulations, a suitable spark arrestor, must be installed and properly maintained.

An incorrect arrestor may lead to damage to the engine or adversely affect performance.

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 to which this engine driven welder supplies power must:

WARNING

CAUTION

--------------------------------------------------------------------

AIR CLEANER INLET HOOD

Remove the plastic plug covering the air cleaner inlet. Install the air cleaner inlet hood to the air cleaner.

WELDING TERMINALS

The AIR VANTAGE ® 700 (AU) CUMMINS 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.

• Be grounded to the frame of the welder using a grounded type plug or be double insulated.

• Do not ground the machine to a pipe that carries explosive or combustible material.

--------------------------------------------------------------------

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.

WELDING OUTPUT CABLES

With the engine off, route the electrode and work cables thru 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.

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

10 Feet 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.

A-5


REMOTE CONTROL

The AIR VANTAGE ® 700 (AU) CUMMINS is equipped with a 6-pin and a 14-pin connector. The 6-pin connector is for connecting the K857 or K857-1 Remote Control or for TIG welding, the K870 foot Amptrol or the K963-3 hand Amptrol. When in the CC-STICK,

ARC GOUGING or CV-WIRE modes and when a remote control is connected to the 6-pin Connector, the auto-sensing circuit automatically switches the OUTPUT control from control at the welder to remote control.

When in TOUCH START TIG mode and when a Amptrol is connected to the 6-Pin Connector, the OUTPUT dial is used to set the maximum current range of the CURRENT CONTROL of the

Amptrol.

When in the DOWNHILL PIPE mode and when a remote control is connected to the 6-Pin or 14-Pin connector, the output control is used to set the maximum current range of the remote.

INSTALLATION

AUXILIARY POWER RECEPTACLES

The auxiliary power capacity of the AIR VANTAGE ® 700 (AU)

CUMMINS is 20kVA of 60Hz three phase power protected by an

RCD (Residual Current Device) and a 3 phase 32 amp circuit breaker. The auxiliary power capacity in watts equivalent to voltamperes at unity power factor.

This model has:

1 x 3 phase and neutral Residual Current Device ( R C D ) protection (30mA)

1 x 3 phase 32 amp Circuit Breaker

1 x 3 phase 415 volt 28 amp

2 x 1 phase 15 amp Circuit Breakers

2 x 1 phase 240 volt 15 amp per outlet

Note: The single-phase outlets are from different phases and cannot be paralleled.

EXAMPLE: When the OUTPUT CONTROL on the welder is set to

200 amps the current range on the remote control will be 40-

200 amps, rather than the full 40-300 amps. Any current range that is less than the full range provides finer current resolution for more fine tuning of the output.

The auxiliary power receptacles should only be used with three or four wire earthed type plugs or approved double insulated tools. The current rating of any plug used with the system must be at least equal to the current capacity of the associated receptacle.

In the CV-WIRE mode, if the feeder being used has a voltage control when the wire feeder control cable is connected to the

14-Pin Connector, the auto-sensing circuit automatically makes

OUTPUT CONTROL inactive and the wire feeder voltage control active. Otherwise, the OUTPUT CONTROL is used to preset the voltage.

The 14-pin connector is used to directly connect a wire feeder control cable. In the CV-WIRE mode, when the control cable is connected to the 14-pin connector, the auto-sensing circuit automatically makes the Output Control inactive and the wire feeder voltage control active.

WARNING

NOTE: When a wire feeder with a built in welding voltage control is connected to the 14-pin connector, do not connect anything to the 6-pin connector.

--------------------------------------------------------------------

STANDBY POWER CONNECTIONS

The AIR VANTAGE ® 700 (AU) CUMMINS is suitable for temporary, standby or emergency power using the engine manufacturer’s recommended maintenance schedule.

The AIR VANTAGE ® 700 (AU) CUMMINS can be permanently installed as a standby power unit for 415/240 volt (60 Hz).

Connections must be made by a licensed electrician who can determine how the 415/240 VAC power can be adapted to the particular installation and comply with all applicable electrical codes. The following information can be used as a guide by the electrician for most applications.

1. Install an isolation switch between the power company meter and the premises disconnect.(The AIR VANTAGE ® 700 (AU)

CUMMINS and the power company supplies must not be connected together).

Switch rating must be the same or greater than the customer’s premises disconnect and service over current protection.

A-6


2. Take necessary steps to assure load is limited to the capacity of the AIR VANTAGE ® 700 (AU) CUMMINS by installing a 32 amp, 415 VAC three pole circuit breaker. Loading above the rated output will reduce output voltage below the allowable -

10% of rated voltage which may damage appliances or other motor-driven equipment and may result in overheating of the

AIR VANTAGE ® 700 (AU) CUMMINS engine.

3. Install a 32 amp 3 phase plug to the triple-pole circuit breaker using 6.02mm (minimum) x 4 conductor cable of the desired length.(1 x 32 amp / 415 V & 2 x 15 amp / 240 V, plugs are available in the optional KA1373-2 plug kit).

4. Plug this cable into the 3 phase receptacle on the AIR VAN-

TAGE ® 700 (AU) CUMMINS case front.

WARNING

• Only a licensed, certified, trained electrician should install the machine to a premises or residential electrical system.

Be certain that:

• The installation complies with the National Electrical Code and all other applicable electrical codes.

• The premises is isolated and no feedback into the utility system can occur. Certain laws require the premises to be isolated before the generator is linked to the premises.

Check your local requirements.

--------------------------------------------------------------------

INSTALLATION

A-7


CONNECTION OF LINCOLN ELECTRIC WIRE

FEEDERS

WARNING

Shut off welder before making any electrical connections.

--------------------------------------------------------------------

Connection of LN-7, LN-8 OR LN-742 to the


1. Shut the welder off.

2. Connect the LN-7, LN-8 OR LN-742 per instructions on the appropriate connection diagram in Section F.

3. Set the "WIRE FEEDER VOLTMETER" switch to either "+" or

"-" as required by the electrode being used.

4. Set the "MODE" switch to the "CV WIRE " position.

5. Set the "ARC CONTROL" knob to "0" initially and adjust to suit.

6. Set the "WELD TERMINALS" switch to the "REMOTELY CON-

TROLLED" position.

7. Set the "IDLE" switch to the "HIGH" position.

Connection of LN-15 to the AIR VANTAGE ® 700 (AU)

CUMMINS

These connections instructions apply to both the LN-15 Across-

The-Arc and Control Cable models. The LN-15 has 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.


2. 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 to the "-" terminal of the welder and work cable to the

"+" terminal of the welder.

3. Across The-Arc Model:

• Attach the single lead from the front of the LN-15 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.

• Set the "WELD TERMINALS" switch to "WELD TERMINALS

ON".

INSTALLATION

• When the gun trigger is closed and an arc has been struck, the current sensing circuit will cause the AIR VANTAGE ®

700 (AU) CUMMINS engine to go to the high idle speed, the wire will begin to feed and the welding process started.

When welding is stopped, the engine will revert to low idle speed after approximately 12 seconds unless welding is resumed.

4. Control Cable Model:

• Connect Control Cable between Engine Welder and Feeder.

• Set the "WELD TERMINALS" switch to "REMOTELY CON-

TROLLED"

• Set the MODE switch to the "CV-WIRE " position.

• Set the "WIRE FEEDER VOLTMETER" switch to either "+" or

"-" as required by the electrode polarity being used.

• Set the "ARC CONTROL" knob to "0" initially and adjust to suit.

• Set the "IDLE" switch to the "AUTO" position.

• When the gun trigger is closed and an arc has been struck, the current sensing circuit will cause the AIR VANTAGE ®

700 (AU) CUMMINS engine to go to the high idle speed, the wire will begin to feed and the welding process started.

When welding is stopped, the engine will revert to low idle speed after approximately 12 seconds unless welding is resumed.

A-8


CONNECTION OF THE LN-25 TO THE AIR VANTAGE

®

700 (AU) CUMMINS.

WARNING

Shut off welder before making any electrical connections.

----------------------------------------------------------------------

The LN-25 with or without an internal contactor may be used with the AIR VANTAGE ® 700 (AU) CUMMINS. See the appropriate connection diagram in Section F.

NOTE: The LN-25 (K431) Remote Control Module and (K432)

Remote Cable are not recommended for use with the AIR VAN-

TAGE ® 700 (AU) CUMMINS.


2. For electrode Positive, connect the electrode cable from the

LN-25 to the "+" terminal of the welder and work cable to the

"-" terminal of the welder. For electrode Negative, connect the electrode cable from the LN-25 to the "-" terminal of the welder and work cable to the "+" terminal of the welder.

3. Attach the single lead from the front of the LN-25 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.

4. Set the MODE switch to the "CV-WIRE " position.

5. Set the "WELD TERMINALS" switch to "WELD TERMINALS ON"

6. Set the "ARC CONTROL" knob to "0" initially and adjust to suit.

7. Set the "IDLE" switch to the "AUTO" position. When not welding, the AIR VANTAGE ® 700 (AU) CUMMINS engine will be at the low idle speed. If you are using an LN-25 with an internal contactor, the electrode is not energized until the gun trigger is closed.

8. When the gun trigger is closed and an arc has been struck, the current sensing circuit will cause the AIR VANTAGE ® 700

(AU) CUMMINS engine to go to the high idle speed, the wire will begin to feed and the welding process started. When welding is stopped, the engine will revert to low idle speed after approximately 12 seconds unless welding is resumed.

CAUTION

If you are using an LN-25 without an internal contactor, the electrode will be energized when the AIR VANTAGE ® 700 (AU)

CUMMINS is started.

----------------------------------------------------------------------

INSTALLATION

CONNECTION OF AN NA-3 AUTOMATIC WELDING

SYSTEM TO THE AIR VANTAGE

®

700 (AU) CUMMINS

For connection diagrams and instructions for connecting an NA-3

Welding System to the AIR VANTAGE ® 700 (AU) CUMMINS, refer to the NA-3 Welding System instruction manual. The connection diagram for the LN-8 in Section F can be used for connecting the

NA-3.

• Set the Wire Feeder Voltage Switch to 115V.

CONNECTION OF MAGNUM SC SPOOL GUN TO THE

AIR VANTAGE

®

700 (AU) CUMMINS (SEE SECTION F)

Spool Gun (K487-25) and Cobramatic to AIR VANTAGE ® 700

(AU) CUMMINS

• Shut the welder off.

• Connect per instructions on the appropriate connection diagram in Section F.

A-9


CAUTION

Certain electrical devices cannot be powered by this product. See Table A.2

TABLE A.2

ELECTRICAL DEVICE USE WITH THIS PRODUCT

INSTALLATION

Type

Resistive

Common Electrical Devices

Heaters, toasters, incandescent light bulbs, electric range, hot pan, skillet, coffee maker.

TV sets, radios, microwaves, appliances with electrical control.

Possible Concerns

NONE

Capacitive

Inductive

Capacitive / Inductive

Single-phase induction motors, drills, well pumps, grinders, small refrigerators, weed and hedge trimmers.

Computers, high resolution TV sets, complicated electrical equipment.

Voltage spikes or high voltage regulation can cause the capacitative elements to fail. Surge protection, transient protection, and additional loading is recommended for 100% fail-safe operation.

DO NOT RUN

THESE DEVICES WITHOUT

ADDITIONAL RESISTIVE TYPE

LOADS.

These devices require large current inrush for starting.

Some synchronous motors may be frequency sensitive to attain maximum output torque, but they SHOULD BE SAFE from any frequency induced failures.

An inductive type line conditioner along with transient and surge protection is required, and liabilities still exist.

DO NOT USE THESE DEVICES

WITH THIS PRODUCT.

The Lincoln Electric Company is not responsible for any damage to electrical components improperly connected to this product.

A-10



Read and understand this entire section before operating your AIR VANTAGE ® 700 (AU) CUMMINS.

WARNING

• Do not attempt to use this equipment until you have thoroughly read the engine manufacturer’s manual supplied with your welder. It includes important safety precautions, detailed engine starting, operating and maintenance instructions, and parts lists.

----------------------------------------------------------------------

ELECTRIC SHOCK can kill.

• Do not touch electrically live parts or electrode with skin or wet clothing.

• Insulate yourself from work and ground

• Always wear dry insulating gloves.

----------------------------------------------------------------------

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.

• 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.

----------------------------------------------------------------------

GENERAL DESCRIPTION

The AIR VANTAGE ® 700 (AU) CUMMINS is a diesel engine-driven welding power source. The machine uses a brush type alternating current generator for DC multi-purpose welding, for 240 VAC single phase. The AIR VANTAGE ® 700 (AU) CUMMINS also has a rotary screw 60 SCFM air compressor built in. The DC welding control system uses state of the art Chopper Technology for superior welding performance.

OPERATION

The AIR VANTAGE ® 700 (AU) CUMMINS is fitted with a selectable

VRD(Voltage Reduction Device). The VRD operates in the CC-

Stick mode reducing the OCV to <13 volts, increasing operator safety when welding is performed in environments with increased hazard of electric shock such as wet areas and hot, humid sweaty conditions.

FOR AUXILIARY POWER:

Start the engine and set the IDLER control switch to the desired operating mode. Full power is available regardless of the welding control settings providing no welding current is being drawn.

ENGINE OPERATION

Before Starting the Engine:

• Be sure the machine is on a level surface.

• Open side engine door and remove the engine oil dipstick and wipe it with a clean cloth. Reinsert the dipstick and check the level on the dipstick.

• Add oil (if necessary) to bring the level up to the full mark. Do not overfill. Close engine door.

• Check radiator for proper coolant level. (Fill if necessary).

• Check oil in the compressor for proper level. (Fill if necessary).

• See Engine Owner’s Manual for specific oil and coolant recommendations.

B-1


WARNING

ADD FUEL

• Stop engine while fueling.

• Do not smoke when fueling.

• Keep sparks and flame away from tank.

• Do not leave unattended while fueling.

• Wipe up spilled fuel and allow fumes to clear before starting engine.

DIESEL FUEL

can cause fire.

• Do not overfill tank, fuel expansion may cause overflow.

DIESEL FUEL ONLY-Low sulphur fuel or ultra low sulphur fuel in U.S.A. and

Canada.

--------------------------------------------------------------------

• Remove the fuel tank cap.

• Fill the tank. DO NOT FILL THE TANK TO THE POINT OF OVER-

FLOW.

• Replace the fuel cap and tighten securely.

• See Engine Owner’s Manual for specific fuel recommendations.

HAND PRIMER BUTTON

Air in the fuel system will cause the following engine problems:

• Hard to start

• Run rough

• Misfire

• Fuel knock

For faster air purge, a small amount of air can be vented from the system by pumping the hand primer button on the fuel filter head. (See Engine Service Side View)

OPERATION

BREAK-IN PERIOD

No break in period is required for the Cummins engine.

RECOMMENDED APPLICATIONS

The AIR VANTAGE ® 700 (AU) CUMMINS provides excellent constant current DC welding output for stick (SMAW) and TIG welding. The AIR VANTAGE ® 700 (AU) CUMMINS also provides excellent constant voltage DC welding output for MIG (GMAW),

Innershield (FCAW), Outershield (FCAW-G) and Metal Core welding. In addition the AIR VANTAGE ® 700 (AU) CUMMINS can be used for Arc Gouging with carbons up to 1/2”(13mm) in diameter.

The AIR VANTAGE ® 700 (AU) CUMMINS is not recommended for pipe thawing.

AIR COMPRESSOR

The AIR VANTAGE ® 700 (AU) CUMMINS provides 60 scfm at 100 psi. compressed air for Arc Gouging and Air powered tools.

GENERATOR

The AIR VANTAGE ® 700 (AU) CUMMINS provides smooth 240 VAC single phase and 415V three phase output for auxiliary power and emergency standby power.

Engine Service Side View

HAND PRIMER BUTTON

B-2

AIR VANTAGE ® 700 (AU) CUMMINS OPERATION

2

17

14

15

13

19

20

21

3

4

5

25

26

1

FIGURE B.1

12

10

11

18

8A

22

8

9

7

23

16

6

24

WELDING CONTROLS

(Figure B.1)

1. 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 in the ARC GOUGING or CV-

WIRE modes and when a remote control is connected to the 6-

Pin or 14-Pin Connector, the auto-sensing circuit automatically switches the OUTPUT CONTROL from control at the welder to the remote control.

When in DOWNHILL PIPE and CC-STICK modes if a remote control is connected to the 6-Pin or 14 Pin Connectors, the output is controlled by the remote and the output control on the machine is used to set the maximum current range for the remote.

EXAMPLE: When the OUTPUT CONTROL on the welder is set to

200 amps the current range on the remote control will be MIN-

200 amps, rather than the full MIN-MAX amps. Any current range that is less than the full range provides finer current resolution for more fine tuning of the output.

3. WELD MODE SELECTOR SWITCH-

(Provides five selectable welding modes)

CV-WIRE

ARC GOUGING

DOWNHILL PIPE

CC-STICK

TOUCH START TIG

In the CV-WIRE mode, if the feeder being used has a voltage control when the wire feeder control cable is connected to the

14-Pin Connector, the auto-sensing circuit automatically makes OUTPUT CONTROL inactive and the wire feeder voltage control active. Otherwise, the OUTPUT CONTROL is used to preset the voltage

When in the TOUCH START TIG mode and when an

Amptrol is connected to the 6-Pin Connector, the OUTPUT dial is used to set the maximum current range of the CURRENT

CONTROL of the Amptrol.

2. DIGITAL OUTPUT METERS-

The digital meters allow the output voltage (CV-WIRE mode) or current (CC-STICK, DOWN-

HILL 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.

While the display is being held the left-most decimal point in each display will be flashing. The accuracy of the meters is

+/- 3%.

B-3


4. ARC CONTROL

- The ARC CONTROL dial is active in the CV-WIRE,

CC-STICK and DOWNHILL PIPE modes, and has different functions in these modes. This control is not active in the TIG and ARC GOUGING mode.

CC-STICK mode: In this mode, the ARC CONTROL dial sets the short circuit current (arc-force) during stick welding to adjust for a soft or crisp arc. Increasing the dial from –10 (soft) to +10 (crisp) increases the short circuit current and prevents sticking of the electrode to the plate while welding. 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 dial 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.

CV-WIRE mode: In this mode, turning the ARC CONTROL clock wise from –10 (soft) to +10 (crisp) changes the arc from soft and washed-in to crisp and narrow. It acts as an inductance/pinch control. The proper setting depends on the procedure and operator preference. Start with a setting of 0.

5. WELD OUTPUT TERMINALS WITH FLANGE NUT-

Provides a connection point for the electrode and work cables.

6. GROUND STUD-

Provides a connection point for connecting the machine case to earth ground.

7. 14-PIN CONNECTOR-

For attaching wire feeder control cables.

Includes contactor closure circuit, auto-sensing remote control circuit, and 42V power. The remote control circuit operates the same as the 6

Pin Amphenol.

8. 42V / 115V WIRE FEEDER VOLTAGE SWITCH:

Toggles output of 14-pin connector to voltage requirement of Wire

Feeder. (Located above 14-pin connector.)

8A. 42V and 115V WIRE FEEDER BREAKERS

OPERATION

11. WIRE FEEDER VOLTMETER SWITCH:

Matches the polarity of the wire feeder voltmeter to the polarity of the electrode.

12. VRD (Voltage Reduction Device) INDICATOR LIGHTS-

On the front panel of the AIR VANTAGE ® 700 (AU) CUMMINS 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.

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. In the CC-Stick mode 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 when not welding in the CCstick mode, 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.

TABLE B.1

MODE

CC-STICK OCV

VRD INDICATOR LIGHTS

VRD "ON"

Green (OCV Reduced)

While Red or Green

Welding (Depends on Weld Voltage) *

CV-WIRE OCV Green (OCV Reduced)

Green (No OCV)

Weld Terminals Remotely Controlled

PIPE

While

Gun Trigger Open

Red or Green

Welding (Depends on Weld Voltage) *

OCV Green (No Output)

While Not Applicable (No Output)

VRD "OFF"

No Lights

Welding

ARC GOUGING OCV Green (OCV Reduced)

TIG

While

Welding

OCV

While

Welding

(Depends on Weld Voltage) *

Green (Process is Low Voltage)

Green (Process is Low Voltage)

* It is normal for the lights to alternate between colors while welding.

9. 6-PIN CONNECTOR-

For attaching optional remote control equipment. Includes auto-sensing remote control circuit.

10. WELD TERMINALS CONTROL SWITCH-

In the WELD TERMINALS ON position, the output is electrically hot all the time. In the REMOTELY CONTROLLED position, the output is controlled by a wire feeder or amptrol device, and is electrically off until a remote switch is depressed.

B-4


ENGINE CONTROLS:

13. RUN/STOP SWITCH

-

-RUN position energizes the engine prior to starting. STOP position stops the engine. The oil pressure interlock switch prevents battery drain if the switch is left in the RUN position and the engine is not operating.

14. GLOW PLUG PUSH BUTTON

-

• When pushed activates the glow plugs. Glow plug should not be activated for more than 20 seconds continuously.

15. CIRCUIT BREAKER-

For protection of Battery Charging

Circuit.

16. ENGINE STOP BUTTON

Shuts down engine

17. START PUSH BUTTON

- Energizes the starter motor to crank the engine.

18. IDLER SWITCH

- Has two positions as follows:

1) In the HIGH position, the engine runs at the high idle speed controlled by the engine governor.

2) In the AUTO position, the idler operates as follows:

• 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.

• 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.

• When welding ceases or the AC power load is turned off, a fixed time delay of approximately 12 seconds starts. 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.

• The engine will automatically return to high idle speed when there is welding load or AC power load reapplied.

19. COMBINATION METER GAUGE

(4 FUNCTIONS)

1. ENGINE HOUR METER

-

When the RUN-STOP switch is in the "ON" position the hour meter displays the total time that the engine has been running. If the engine is not started within 60 seconds the hour meter is turned off automatically. This meter is useful for scheduling prescribed maintenance.

OPERATION

2. ELECTRIC FUEL GAUGE

-

When the RUN-STOP switch is in the "ON" position the electric fuel gauge displays accurate and reliable indication as to how much fuel is in the fuel tank. If the engine is not started within 60 seconds the fuel gauge is turned off automatically.

3. ENGINE PROTECTION LIGHT

-

A warning indicator light for

Low Oil Pressure and/or Coolant Over Temperature.The light is off when the systems are functioning properly. The light will come on and the engine will shutdown when there is

Low Oil Pressure and/or the Coolant is Over Temperature.

Note: The light remains off when the RUN-STOP switch is in the "ON" position prior to starting the engine. However if the engine is not started within 60 seconds the light will come on. When this happens the RUN-STOP switch must be returned to the "OFF" position to reset the engine protection system and light.

4. BATTERY CHARGING LIGHT

-

A warning indicator light for

Low/No battery charge. The light is off when the systems are functioning properly. The light will come on if there is a

Low/No battery condition but the machine will continue to run.

Note: The light may or may not come on when the RUN-

STOP switch is in the "ON" position. It will come on during cranking and stay on until the engine starts. After starting the engine the light will go off unless a Low/No battery charge condition exists.

20. COOLANT TEMPERATURE GAUGE-

An indicator of engine coolant temperature.

21. OIL PRESSURE GAUGE-

An indicator of engine Oil

Pressure.

ENGINE PROTECTION LIGHT-

A warning indicator light for Low Oil Pressure and/or Coolant Over Temperature.The

light is off when the systems are functioning properly. The light will come on and the engine will shutdown when there is Low

Oil Pressure and/or the Coolant is Over Temperature.

Note: The light remains off when the RUN-STOP switch is in the

"ON" position prior to starting the engine. However if the engine is not started within 60 seconds the light will come on. When this happens the RUN-STOP switch must be returned to the

"OFF" position to reset the engine protection system and light.

B-5


AIR COMPRESSOR CONTROLS (22 THRU 24)

22. COMPRESSOR ON/OFF SWITCH

Turns compressor on and off by activating or deactivating the electromagnetic compressor clutch.

23. COMBINED GAUGE (2 FUNCTIONS)

1. COMPRESSOR PROTECTION LIGHT

The yellow compressor protection light remains off with proper compressor oil temperatures. If the lights turn on, the compressor protection system will deactivate the compressor clutch and put the system in standby mode until the temperature reaches allowable limits. Check for proper compressor oil level.

2. COMPRESSOR HOUR METER

The compressor hour meter displays the total time that the compressor has been running (compressor switch must be on).

24. AIR DISCHARGE VALVE

Controls flow of compressed air. A 3/4” NPT (National Pipe

Thread) fitting is provided.

25. BATTERY DISCONNECT SWITCH

Battery disconnect switch provides lockout/tagout capability.

Switch is conveniently located on the front bottom of the machine.

26. THERMAL LIGHT

This status light indicates the Power Source has been driven into thermal overload. Welding output shuts off to protect the welding system components and resets when the overload condition is resolved. The Engine and Air

Compressor will continue to operate.

B-6

OPERATION


ENGINE OPERATION

STARTING THE ENGINE

1. Open the engine compartment door and check that the fuel shutoff valve located to the left of the fuel filter housing is in the open position (lever to be in line with the hose).

2. Make sure battery disconnect switch is in the on position.

3. Check for proper oil level and coolant level. Close engine compartment door.

4. Remove all plugs connected to the AC power receptacles.

5. Set IDLER switch to “AUTO”.

6. Set the RUN/STOP switch to “RUN”. Observe that the engine protection and battery charging lights are on.

6a. Press Glow Plug Button and hold 15 to 20 seconds.

7. Press START button until the engine starts or for up to 10 seconds.

8. Release the engine START button when the engine starts.

9. Check that the engine protection and battery charging lights are off. If the engine protection light is on after starting, the engine will shutdown in a few seconds. Investigate any indicated problem.

10. Allow the engine to warm up at low idle speed for several minutes before applying a load and/or switching to high idle.

Allow a longer warm up time in cold weather.

COLD WEATHER STARTING

With a fully charged battery and the proper weight oil, the engine should start satisfactorily even down to about 0°F(-18°C). If the engine must be frequently started below 10°(-12°C), it may be desirable to install the optional ether start kit (K887-1). For extreme cold conditions it may be desirable to install additional equipment such as a block heater or oil pan pad heater, etcetera.

NOTE: Extreme cold weather starting may require longer glow plug operations.

OPERATION

STOPPING THE ENGINE

1. Switch the RUN/STOP switch to “STOP”. This turns off the voltage supplied to the shutdown solenoid. A backup shutdown can be accomplished by shutting off the fuel valve located on the fuel line.

TYPICAL FUEL CONSUMPTION

Refer to Table B.1 for typical fuel consumption of the AIR VAN-

TAGE ® 700 (AU) CUMMINS Engine for various operating settings.

Table B.1

Cummins B3.3T Engine Fuel Consumption

Cummins B3.3T Running Time for

69HP 25GAL.(94.6L)

(Hours)

High Idle No load 1.10 Gal./hour 22.7

1860 RPM (4.17 L/hour)

Low Idle No load 0.72 Gal./hour 34.83

1500 RPM (2.72 L/hour)

DC CC Weld Output 2.37 Gal./hour 10.56

500A 100% Duty Cycle (8.96 L/hour)


500A with Compressor (11.74 L/hour)

100% Duty Cycle





100% Duty Cycle





60% Duty Cycle





40% Duty Cycle

Aux. 7.2kva 1.28 Gal./hour 19.55

(4.84 L/hour)

Aux. 12kva 1.63 Gal./hour 15.3

(6.18 L/hour)

Aux. 20kva 2.18 Gal./hour 11.48

(8.25 L/hour)

NOTE: This data is for reference only. Fuel consumption is approximate and can be influenced by many factors, including engine maintenance, environmental conditions and fuel quality.

B-7


WELDER OPERATION

DUTY CYCLE

Duty Cycle is the percentage of time the load is being applied in a 10 minute period. For example a 60% duty cycle, represents 6 minutes of load and 4 minutes of no load in a 10 minute period.

ELECTRODE INFORMATION

For any electrode the procedures should be kept within the rating of the machine. For information on electrodes and their proper application see (www.lincolnelectric.com) or the appropriate

Lincoln publication.

The AIR VANTAGE ® 700 (AU) CUMMINS can be used with a broad range of DC stick electrodes. The MODE switch provides two stick welding settings as follows:

CONSTANT CURRENT (CC-STICK) WELDING

The CC-STICK position of the MODE switch is designed for horizontal and vertical-up welding with all types of electrodes, especially low hydrogen.

The ARC CONTROL dial sets the short circuit current (arc-force) during stick welding to adjust for a soft or crisp arc. 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. This can also increase spatter. It is recommended that the ARC CONTROL be set to the minimum number without electrode sticking. Start with the dial set at 0.

NOTE: Due to the low OCV with the VRD on, a very slight delay during striking of the electrodes may occur. Due to the requirement of the resistance in the circuit to be low for a VRD to operate, a good metal-to-metal contact must be made between the metal core of the electrode and the job. A poor connection anywhere in the welding output circuit may limit the operation of the

VRD. This includes a good connection of the work clamp to the job. The work clamp should be connected as close as practical to where the welding will be performed.

A. For New Electrodes

E6010 - Touch, Lift to Start the Arc.

E7018, E7024 - Touch, Rock Back and Forth in Joint, Lift.

Once the arc is started, normal welding technique for the application is then used.

OPERATION

B. For Re-Striking Electrodes

Some electrodes form a cone at the end of the electrode after the welding arc has been broken, particularly iron powder and low hydrogen electrodes. This cone will need to be broken off in order to have the metal core of the electrode make contact.

E6010 - Push, Twist in Joint, Lift

E7018, E7024 - Touch, Rock Back and Forth in Joint, Lift.

Once the arc is started, normal welding technique for the application is then used.

For other electrodes the above techniques should be tried first and varied as needed to suit operator preference. The goal for successful starting is good metal to metal contact.

For indicator light operation, see Table B.1.

DOWNHILL PIPE Welding

This slope controlled setting is intended for "out-of-position" and

"down hill" pipe welding where the operator would like to control the current level by changing the arc length.

The ARC CONTROL dial sets the short circuit current (arc-force) during stick welding to adjust for a soft or 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. This can also increase spatter.

It is recommended that the ARC CONTROL be set to the minimum number without electrode sticking. Start with the dial set at 0.

NOTE: With the VRD switch in the “ON” position (See figure A.1 for location) there is no output in the DOWNHILL PIPE mode. For indicator light operation, see Table B.1.

B-8


TIG WELDING

OPERATION

The TOUCH START TIG setting of the MODE switch is for DC TIG

(Tungsten Inert Gas) welding. To initiate a weld, the OUTPUT

CONTROL dial is first set to the desired current and the tungsten is touched to the work. During the time the tungsten is touching the work there is very little voltage or current and, in general, no tungsten contamination. Then, the tungsten is gently lifted off the work in a rocking motion, which establishes the arc.

AIR VANTAGE ® 700 (AU) CUMMINS settings when using the

K930-2 TIG Module with an Amptrol or Arc Start Switch:

• Set the MODE Switch to the TOUCH START TIG setting.

• Set the "IDLER" Switch to the "AUTO" position.

• Set the "WELDING TERMINALS" switch to the "REMOTELY

CONTROLLED" position.

When in the TOUCH START TIG mode and when a Amptrol is connected to the 6-Pin connector the OUTPUT CONTROL dial is used to set the maximum current range of the current control of the Amptrol.

This will keep the "Solid State" contactor open and provide a

"cold" electrode until the Amptrol or Arc Start Switch is pressed.

The ARC CONTROL is not active in the TIG mode. To STOP a weld, simply pull the TIG torch away from the work.

When using the TIG Module, the OUTPUT CONTROL on the AIR

VANTAGE ® 700 (AU) CUMMINS is used to set the maximum range of the CURRENT CONTROL on the TIG Module or an

Amptrol if connected to the TIG Module.

When the arc voltage reaches approximately 30 Volts the arc will go out and the machine will reset the current to the Touch Start level.

NOTE: The TIG process is to receive a low voltage welding process. There is no difference in operation with the VRD

“On” or “Off” for this mode. For indicator light operation, see Table B.1.

To reinitiate the arc, retouch the tungsten to the work and lift.

Alternatively, the weld can be stopped by releasing the Amptrol or arc start switch.

The AIR VANTAGE ® 700 (AU) CUMMINS an be used in a wide variety of DC TIG welding applications. In general the ‘Touch

Start’ feature allows contamination free starting without the use of a Hi-frequency unit.

If desired, the K930-2 TIG Module can be used with the AIR VAN-

TAGE ® 700 (AU) CUMMINS. The settings are for reference.

TABLE B.3

TYPICAL CURRENT RANGES

(1)

FOR TUNGSTEN ELECTRODES

(2)

Tungsten Electrode DCEN (-)

Diameter in. (mm)

DCEP (+) Approximate Argon Gas Flow

Flow Rate C.F.H. ( l /min.)

Stainless Steel

3/32

1/8

5/32

3/16

1/4

1/16

1%, 2% Thoriated 1%, 2% Thoriated Aluminum

Tungsten Tungsten

.010 (.25) 2-15

0.020

(.50) 5-20

0.040 (1.0) 15-80

(1.6) 70-150

(3)

(3)

(3)

10-20

3-8

5-10

5-10

5-10

(2.4) 150-250

(3.2) 250-400

(4.0) 400-500

(4.8) 500-750

(6.4) 750-1000

15-30

25-40

40-55

55-80

80-125

(2-4)

(3-5)

(3-5)

(3-5)

13-17 (6-8)

15-23 (7-11)

21-25

28-32

(10-12)

23-27 (11-13)

(13-15)

3-8

5-10

5-10

9-13

11-15

11-15

13-17

18-22

23-27

(2-4)

(3-5)

(3-5)

(4-6)

(5-7)

(5-7)

(6-8)

(8-10)

(11-13)

TIG TORCH

Nozzle Size (4), (5)

#4, #5, #6

#5, #6

#6, #7, #8

#8, #10

(1) When used with argon gas. The current ranges shown must be reduced when using argon/helium or pure helium shielding gases.

(2) Tungsten electrodes are classified as follows by the American Welding Society (AWS):

Pure

1% Thoriated

EWP

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.

(3) DCEP is not commonly used in these sizes.

(4) TIG torch nozzle "sizes" are in multiples of 1/16ths of an inch:

# 4 = 1/4 in.

# 5 = 5/16 in.

(6 mm)

(8 mm)

# 6 = 3/8 in.

# 7 = 7/16 in.

(10 mm)

(11 mm)

# 8 = 1/2 in.

(12.5 mm)

#10 = 5/8 in.

(16 mm)

(5) 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-9


WIRE WELDING-CV

Connect a wire feeder to the AIR VANTAGE ® 700 (AU) CUMMINS according to the instructions in INSTALLATION INSTRUCTIONS

Section.

The AIR VANTAGE ® 700 (AU) CUMMINS in the CV-WIRE mode, permits it to be used with a broad range of flux cored wire

(Innershield and Outershield) electrodes and solid wires for MIG welding (gas metal arc welding). Welding can be finely tuned using the ARC CONTROL. 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 as an inductance/pinch control. The proper setting depends on the procedure and operator preference. Start with the dial set at 0.

ARC GOUGING

The AIR VANTAGE ® 700 (AU) CUMMINS can be used for arc gouging. The minimum output in the arc gouging mode is 200

Amps. For arc gouging below 200 Amps use the CC-Stick Mode.

For optimal performance, set the MODE per Table B.4.

The maximum output control range setting is automatically increased in the gouging mode, when the compressor is not turned on. The maximum preset readout on the weld ammeter will increase from approximately 700 Amps to 800 Amps. This feature provides extra capacity by taking advantage of the available engine HP when the internal compressor is not on and an external air supply is used for gouging.

Set the OUTPUT CONTROL knob to adjust output current to the desired level for the gouging electrode being used according to the ratings in the following Table B.4.

OPERATION

PARALLELING

When paralleling machines in order to combine their outputs, all units must be operated in the CC-STICK mode only at the same output settings. To achieve this, turn the WELD MODE switch to the CC-STICK position. Operation in other modes may produce erratic outputs, and large output imbalances between the units.

Carbon Diameter

1/8"(3.2mm)

5/32"(4.0mm)

3/16"9(4.8mm)

1/4"(6.4mm)

3/8"(10.0mm)

1/2"(13.0mm)

TABLE B.4

Current Range (DC, electrode positive)

60-90 Amps

90-150 Amps

200-250 Amps

300-400 Amps

400-600 Amps

600-MAX. Amps

Mode

CC-STICK

CC-STICK

ARC GOUGE

ARC GOUGE

ARC GOUGE

ARC GOUGE

The ARC CONTROL is not active in the ARC GOUGING Mode. The

ARC CONTROL is automatically set to maximum when the ARC

GOUGING mode is selected which provides the best ARC GOUG-

ING performance.

B-10


AUXILIARY POWER OPERATION

Start the engine and set the IDLER control switch to the desired operating mode. Full power is available regardless of the welding control settings, if no welding current is being drawn.

SIMULTANEOUS WELDING AND AUXILIARY POWER

LOADS

It must be noted that the above auxiliary power ratings are with no welding load.

Simultaneous welding and power loads are specified in table

B.5.

OPERATION

WELD

AMPS

0

100

200

300

400

500

600

TABLE B.5 AIR VANTAGE ® 700 (AU) CUMMINS SIMULTANEOUS WELDING AND POWER LOADS

PLUS

1 PHASE

WATTS AMPS

7,200 30

7,200 30

7,200 30

7,200 30

7,200 30

6,400 26

0 0

OR

3 PHASE

WATTS AMPS

20,000 28

20,000 28

20,000 28

16,800 23

12,000 16

6,400 9

0 0

OR

WATTS

------

------

------

BOTH 1 AND 3 PHASE

AMPS

28

28

28

------ 23

7,200 ------

6,400 ------

0 ------

Current

(Amps)

Voltage

(Volts)

Load

(Watts)

15 240 3,600

AIR VANTAGE ® 700 (AU) CUMMINS Extension Cord Length Recommendations

(Use the shortest length extension cord possible sized per the following table.)

18 (60)

Maximum Allowable Cord Length in m (ft.) for Conductor Size

2.5

2 mm 14AWG 4.0

2 mm 12AWG 6.0

2 mm

23 (75) 46 (150) 69 (225) 107 (350)

Conductor size is based on maximum 2.0% voltage drop.

183 (600)

B-11


OPTIONAL FIELD INSTALLED ACCESSORIES

K2637-2 Medium Trailer

K2639-1 Fender Kit

K2640-1 Cable Rack

K2641-2 Four Wheel Trailer

K857 Remote Control

K857-1 Remote Control

K2642-1 Polarity Multiprocess Switch

K2663-1 Docking Kit

K2613-5A1 Ln-25 PRO with K126 PRO Gun

K126-12 K126 PRO Gun

KP1696-068 Drive Roll Kit

K12038-2 Invertec PC610 Plasma

K12048-1 Tomahawk 1025 Plasma

KA1452-12 Pigtail

KA1452-4 Extension Lead 10m

KA1452-13 Extension Lead 20m

KA1452-9 Work Return Lead 9m

KA1452-10 Electrode Lead 10mRoll Frame/Spill Tray Air Dryer

Kit

ACCESSORIES

C-1



WARNING

• Have qualified personnel do all maintenance and troubleshooting work.

• Turn the engine off before working inside the machine or servicing the engine.

• Remove guards only when necessary to perform maintenance and replace them when the maintenance requiring their removal is complete. If guards are missing from the machine, obtain replacements from a Lincoln

Distributor. (See Operating Manual Parts List.)

Read the Safety Precautions in the front of this manual and in the Engine Owner’s Manual before working on this machine.

Keep all equipment safety guards, covers, and devices in position and in good repair. Keep hands, hair, clothing, and tools away from the gears, fans, and all other moving parts when starting, operating, or repairing the equipment.

--------------------------------------------------------------------

ROUTINE AND PERIODIC MAINTENANCE

DAILY

• Check the Engine and Compressor oil levels .

• 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.

• Check coolant level.

• Only VMAC certified and approved synthetic oil MUST be

WARNING used. Shut down the Welder/Compressor for 3 minutes, open the pressure supply valve to ensure the system is depressurized prior to removing the compressor oil level dipstick.

--------------------------------------------------------------------

WEEKLY

Blow out the machine with low pressure air periodically. In particularly dirty locations, this may be required once a week.

COMPRESSOR MAINTENANCE

Refer to the “Routine Maintenance” section of the compressor owner’s manual for the recommended maintenance schedule of the following: a. Compressor oil and filter.

b. Compressor air filter.

c. Compressor coalescing filter.

VMAC™

(VEHICLE MOUNTED AIR COMPRESSORS)

www.vmac.ca/index.php?airvantagemanuals

MAINTENANCE

1333 Kipp Road

Nanamino

British Columbia

Canada, V9X1R3

Telephone: (250) 740-3200

Facsimile: (250) 740-3201

Toll Free: 800-738-8622

ENGINE MAINTENANCE

Refer to the “Periodic Checks” 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.

AIR FILTER

CAUTION

• Excessive air filter restriction will result in reduced engine life.

WARNING

• Never use gasoline or low flash point solvents for cleaning the air cleaner element. A fire or explosion could result.

CAUTION

• 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.

--------------------------------------------------------------------

The diesel engine is equipped with a dry type air filter. Never apply oil to it. Service the air cleaner as follows:

Replace the element as indicated by the service indicator. (See

Service Instructions and Installation Tips for Engine Air Filter.)

D-1


Service Instructions

Single- and Two-Stage Engine Air Cleaners

MAINTENANCE

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.

Clean Both Surfaces of the Outlet Tube and Check the Vacuator™ Valve

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.

Inspect the New Filter for Damage

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.

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.

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.

Wipe both sides of the outlet tube clean.

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.

Once the filter is in place, secure the service cover.

Outer edge of the outlet tube

Inner edge of the outlet tube

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

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.

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.

Check Connectors for Tight Fit

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


FUEL FILTERS

WARNING

When working on the fuel system:

• Keep naked lights away, do not smoke !

• Do not spill fuel !

---------------------------------------------------------------------

The AIR VANTAGE ® 700 (AU) CUMMINS is equipped with a Fuel

Filter located after the lift pump and before fuel injectors.The procedure for changing the filter is as follows.

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.

4. Install the filter as specified by the filter manufacturer.

Mechanical overtightening will distort the threads, filter ele-

WARNING

SHUT

OFF ment seal or filter can.

---------------------------------------------------------------------

COOLING SYSTEM

The AIR VANTAGE ® 700 (AU) CUMMINS is equipped with a pressure radiator. Keep the radiator cap tight to prevent loss of coolant. Clean and flush the coolant system periodically to prevent clogging the passage and over-heating the engine. When antifreeze is needed, always use the permanent type.

• When draining the entire contents of the system, remove radiator cap and open vent cock on top of tank (counter clockwise).

Next, pull both drain hoses through the access hole in the base and open both valves until system is empty.

• When refilling, close both valves on drain hoses and open vent cock on top of tank to vent air from system fully. Close vent cock when done. (See Figure D.1)

S29260 VM

ON

OPEN

MAINTENANCE

FILL COOLANT HERE.

REPLACE CAP COMPLETELY

WHEN FINISHED.

*IF PRESENT

OPEN (COUNTER-CLOCKWISE)

THIS VENT FITTING WHEN

FILLING SYSTEM.

CLOSE WHEN FINISHED.

OPEN BOTH DRAIN VALVES TO

DRAIN SYSTEM COMPLETELY.

CLOSE WHEN FINISHED.

D-3


BATTERY HANDLING

WARNING

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.

• USING A BOOSTER - connect positive lead to battery first then connect negative lead to engine foot.

BATTERY ACID CAN BURN EYES AND SKIN.

• Wear gloves and eye protection and be careful when working near battery. Follow instructions printed on battery.

--------------------------------------------------------------------

PREVENTING ELECTRICAL DAMAGE

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 the charging circuit. The positive (+) battery cable has a red terminal cover.

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 so can result in damage to the internal charger components.

When reconnecting the cables, connect the positive cable first and the negative cable last.

PREVENTING BATTERY DISCHARGE

Turn the RUN/STOP switch to stop when engine is not running.

MAINTENANCE

CHARGING THE BATTERY

When you charge, jump, replace, or otherwise connect battery cables to the battery, be sure the polarity is correct. Improper polarity can damage the charging circuit. The AIR VANTAGE ®

700 (AU) CUMMINS positive (+) battery terminal has a red terminal cover.

If you need to charge the battery with an external charger, disconnect the negative cable first, then the positive cable before you attach the charger leads.

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.

Follow the instructions of the battery charger manufacturer for proper charger settings and charging time.

SERVICING MUFFLER WITH INTERNAL

SPARK ARRESTOR

CAUTION

• Wear suitable personal protective equipment.

----------------------------------------------------------------------------

Clean every 100 hours. Remove screw plug on muffler body.

Place a metallic container under the plug boss and run the machine until no more debris comes out.

WARNING

• MUFFLER MAY BE HOT

• ALLOW ENGINE TO COOL BEFORE INSTALLING THE SPARK

ARRESTER!

• DO NOT OPERATE ENGINE WHILE INSTALLING THE SPARK

ARRESTOR!

--------------------------------------------------------------------

PREVENTING BATTERY BUCKLING

Tighten nuts on battery clamp until snug.

D-4


NAMEPLATES / WARNING DECALS MAINTE-

NANCE

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.

WELDER / GENERATOR MAINTENANCE

STORAGE

Store the AIR VANTAGE ® 700 (AU) CUMMINS in clean, dry, protected areas.

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.

WARNING

Do not attempt to polish slip rings while the engine is running.

--------------------------------------------------------------------

MAINTENANCE

Table D.1 Engine Maintenance Components

ITEM MAKE PART NUMBER SERVICE INTERVAL

Air Cleaner Element Donaldson P822768 (With Service Indicator) Clean as Needed,

(Engine) Replace as indicated by Service Indicator.

Air Cleaner Element Donaldson

(Compressor)

P821575 (Without Service Indicator) Clean as Needed,

Replace every 200 Hours.

Oil Filter Cummins C6002112110 Replace every 250 hours or 3 months,

Fleetguard LF16011 whichever is less.

Fan Belt Cummins C0412021749 Inspect every 1000 hours or 12 months, whichever is less.

Fuel Strainer Cummins 3826094 Inspect and Replace monthly as required.

Fleetguard FF5079 Replace annually.

Fuel Filter / Fleetguard FS19594 Replace every 500 hours or 6 months,

Water Separator whichever is less.

Battery ----- BCI GROUP 34 Inspect every 500 hours

Engine Oil Change See Manual ----- Change every 250 hours or 3 months, whichever is less. Check daily.

D-5


HOW TO USE TROUBLESHOOTING GUIDE

TROUBLESHOOTING

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 threestep procedure listed below.

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.

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.

If you do not understand or are unable to perform the

Recommended Course of Action safely, contact your local

Lincoln Authorized Field Service Facility.

Step 2. POSSIBLE CAUSE.

The second column labeled “POSSIBLE CAUSE” lists the obvious external possibilities that may contribute to the machine symptom.

NOTE: See VMAC owner’s manual for compressor trouble shooting.

VMAC™

VEHICLE MOUNTED AIR COMPRESSORS www.vmac.ca/index.php?airvantage500manuals

1333 Kipp Road

Nanamino

British Columbia

Canada, V9X1R3

Telephone: (250) 740-3200

Facsimile: (250) 740-3201

Toll Free: 800-738-8622

CAUTION

If for any reason you do not understand the test procedures or are unable to perform the tests/repairs safely, contact your Local Lincoln Authorized

Field Service Facility for technical troubleshooting assistance before you proceed.

E-1

AIR VANTAGE ® 700 (AU) CUMMINS TROUBLESHOOTING

PROBLEMS

(SYMPTOMS)

Observe all Safety Guidelines detailed throughout this manual

POSSIBLE

CAUSE

Major Physical or Electrical Damage is

Evident.

1. Contact your local Lincoln Authorized

Field Service Facility.

RECOMMENDED

COURSE OF ACTION

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. Battery disconnect switch is in the off position.

Engine will crank but not start.

Engine shuts down shortly after starting.

1. Out of fuel.

2. Fuel shut off valve is in the off position make sure the valve lever is in a vertical direction.

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 In-line Fuel Filter may need to be replaced.

6. High water temperature or low oil pressure.

(engine protection light lit)

1. Low oil pressure (engine protection light lit).

Check oil level (Consult engine service dealer).

If all recommended possible areas of misadjustment have been checked and the problem persists, Contact your local

Lincoln Authorized Field Service Facility.

2. High water temperature. Check engine cooling system. (engine protection light lit).

3. Faulty oil pressure switch.

4. Faulty water temperature switch. Contact authorized local Engine Service Shop.

Engine shuts down while under a load.

1. High water temperature.

Engine runs rough.

Engine will not shut off.

1. Dirty fuel or air filters may need cleaned/replaced.

2. Water in fuel.

1. Fuel Shutdown solenoid not functioning properly / linkage binding.

CAUTION



E-2


PROBLEMS

(SYMPTOMS)

Battery does not stay charged.

TROUBLESHOOTING


POSSIBLE

CAUSE

1. Faulty battery .

2. Faulty engine alternator.

3. Loose or broken lead in charging circuit.

4. Loose fan belt may need tightening.

RECOMMENDED


Engine will not idle down to low speed.

1. Idler switch in HIGH idle position, make sure switch is set to AUTO.

2. External load on welder or auxiliary power.

3. Mechanical problem in idler solenoid linkage.

4. Faulty wiring in solenoid circuit.

5. No or low voltage @ idle solenoid

6. Faulty idler solenoid.

7. Faulty Weld Control PCB (Printed Circuit

Board) or Engine Control Units.

Engine will not go to high idle when attempting to weld.

1. Poor work lead connection to work.

2. Broken idler solenoid spring.

3. Welding Terminals switch in wrong position.

4. No open circuit voltage at output studs.

5. Faulty Engine Control Units or Weld

Control PCB.



Engine will not go to high idle when using auxiliary power.

1. Broken wire in auxiliary current sensor wiring.

2. Auxiliary power load is less than 100 watts.

3. Faulty Engine Control Units or Weld

Control PCB.

Engine goes to low idle but does not stay at low idle.

1. Faulty Idler / Engine Shutdown PCB or

Weld Control PCB.

No welding output or auxiliary output.

1. Broken lead in one of the rotor circuits.

2. One of the field diode modules are faulty.

3. Faulty Weld Control PCB.

4. One of the rotors are faulty.

CAUTION



E-3


PROBLEMS

(SYMPTOMS)


POSSIBLE

CAUSE

Welder has some/ no output and no control.

Auxiliary output OK.

1. Faulty remote kit.

2. Faulty output control potentiometer.

3. Faulty output control wiring.

4. Faulty Weld Control PCB, Engine Control Units or

Chopper PCB.

TROUBLESHOOTING

RECOMMENDED


No welding output. Auxiliary output OK.

No auxiliary power.

1. WELDING TERMINALS switch in wrong position, be sure switch is in WELDING TERMINALS

ALWAYS ON position.

2. Faulty Weld Control PCB, Engine Control Units or

Chopper PCB.

1. RCD may have tripped.

2. Open breakers may need to be reset.

3. Faulty receptacle.

4. Faulty auxiliary circuit wiring.

Welder load drops off.

VRD Lights don’t light up.

1. Check thermostat on each of the chopper module.

2. Check fan operation in power electronic component.

Wire feeder does not work when control cable is connected to 14 pin connector.

1. Wire Feeder Power circuit breaker open. Check

42V or 115V breaker and reset if tripped.

2. Faulty control cable. Repair or replace cable.

3. Faulty wire feeder. Replace wire feeder.



No output in Pipe Mode.

1. Make sure VRD ON/OFF toggle switch is in the

“OFF” position.

2. Poor work lead connection to work. Make sure work clamp is tightly connected to clean base metal.

3. "Weld Terminals" switch in wrong position.

Place switch in "Weld Terminals On" position when welding without control cable.

4. Faulty PC board or welder alternator.

1. Ensure VRD ON/OFF switch is in the “ON” position.

2. If light is burned out, replace both VRD lights.

3. Faulty OCV indicator PC board.

CAUTION



E-4


LIFT PU

JUMP STAR

ENGINE BLOC

ENGINE SUPP

NIFOLD PRESSURE OPEN 5 - 7 PSI

N E

C GND-

COLD STAR

ENGINE STOP

GLOW PLUG

RUN STOP

5K

D

5TA

243

262

5U

229 232

247

+

STARTING MO

+

+

B 228

RECTIFIER BRIDGE

+

CHOKE A-B

WB2

WB3

WB2

WB3

STATOR WE

WA2

WA3

WA2

WA3

STATOR WE

25A 25B

I

SELECTOR SW

ITCH S5

POLARITY SW

+

+

FROM BACK

42V / 115V SW

FROM BACK

ON/OFF SW

OVER TE

HOUR ME

COMPRESSOR

AIR

295 (SI

E F

B

25

23

294

257

25A

23A

208

14

B

260

261

295

256

13

250

250

M9

M10

M6

M2

M3

M1

M4

M5

M2

M6

M4

M5

M9

M10

M3

M1

214

215

76

220

218

213

222

216

77

217

278

279

75

277

R5

BLK

232N

270

5S

271

WHT

SHLD

A

N

F

262

200

232

5G

405

291

76A

290

2

4

75A

77A

A

A

650

650

A 650

F-1

DIAGRAMS

AIR VANTAGE ® 700 (AU) CUMMINS DIAGRAMS

F-2


}

F-3

N.B. USE VOL


F-4


F-5


}

F-6


F-7


F-8


F-9


F-10


F-11


F-12


F-13

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

TROUBLESHOOTING

DIAGRAMS

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