Lincoln Electric IM10128 User Manual

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AIR VANTAGE 500(AU) KUBOTA
IM10128
June, 2012
For use with machine having Code Number:
Safety Depends on You
Lincoln arc welding and cutting equipment is designed and built with safety in mind. However, your overall safety can be increased by proper installation ... and thoughtful operation on your part. DO NOT INSTALL, OPER-
ATE OR REPAIR THIS EQUIP­MENT WITHOUT READING THIS MANUAL AND THE SAFETY PRECAUTIONS CON­TAINED THROUGHOUT. And,
most importantly, think before you act and be careful.
11858
• World's Leader in Welding and Cutting Products • • Sales and Service through Subsidiaries and Distributors Worldwide •
Cleveland, Ohio 44117-1199 U.S.A. TEL: 1.216.481.8100 For Service in U.S. and Canada: Call 1.888.935.3877
FAX: 1.216.486.1751 WEB SITE: lincolnelectric.com For Non-U.S. Service: Email globalservice@lincolnelectric.com
OPERATORʼS MANUAL
Copyright © Lincoln Global Inc.
i
SAFETY
i
WARNING
CALIFORNIA PROPOSITION 65 WARNINGS
Diesel engine exhaust and some of its constituents are known to the State of California to cause can­cer, birth defects, and other reproductive harm.
The Above For Diesel Engines
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.
The engine exhaust from this product contains chemicals known to the State of California to cause cancer, birth defects, or other reproductive harm.
The Above For Gasoline Engines
FOR ENGINE powered equipment.
1.a. Turn the engine off before troubleshooting and maintenance work unless the maintenance work requires it to be running.
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1.b. Operate engines in open, well-ventilated areas or vent the engine exhaust fumes outdoors.
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1.c. Do not add the fuel n ear 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.
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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.
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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.
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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.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.
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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.
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.
ii
SAFETY
ii
ELECTRIC SHOCK can kill.
3.a. The electrode and work (or ground) circuits are electrically “hot” when the welder is on. Do not touch these “hot” parts with your bare skin or wet clothing. Wear dry, hole-free
gloves to insulate hands.
3.b. Insulate yourself from work and ground using dry insulation. Make certain the insulation is large enough to cover your full area of physical contact with work and ground.
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 between the 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 Items 6.c. and 8.
ARC RAYS can burn.
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.
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 ma y produce fumes and gases hazardous to health. Avoid breathing these fumes and gases. When welding, keep your head out of the fume. Use enough ventilation and/or exhaust at the arc to keep
fumes and gases away from the breathing zone. When
welding with electrodes which require special ventilation such as stainless or hard facing (see instructions on container or MSDS) or on lead or cadmium plated steel and other metals or coatings which produce highly toxic fumes, keep exposure as
low as possible and within applicable OSHA PEL and ACGIH TLV limits using local exhaust or mechanical ventilation. In confined spaces or in some circum­stances, outdoors, a respirator may be required. Additional precautions are also required when welding on galvanized steel.
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 coming from degreasing, cleaning or spraying operations. The heat and rays of the arc can react with solvent vapors 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.
vapors
to
5.e. Read and understand the manufacturer’s instructions for this
equipment and the consumables to be used, including the material safety data sheet (MSDS) and follow your employer’s safety practices. MSDS forms are available from your welding distributor or from the manufacturer.
5.f. Also see item 1.b.
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SAFETY
iii
WELDING and CUTTING SPARKS can cause fire or explosion.
6.a.
Remove fire hazards from the welding area.
If this is not possible, cover them to prevent
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 been “cleaned”. For information, purchase “Recommended Safe Practices for the 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.
Sparks and spatter are thrown from the welding arc. Wear oil
6.f. 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.
the welding sparks from starting a fire.
though
they have
Preparation
for Welding and Cutting of
CYLINDER may explode if damaged.
7.a. Use on ly com pr essed ga s cyli nd ers 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. Alway s 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. Re ad and foll ow the inst ru ctions o n c ompressed gas cylinders, associated equipment, and CGA publication P-l, “Precautions for Safe Handling of Compressed Gases in Cylinders,” available from the Compressed Gas Association 1235 Jefferson Davis Highway, Arlington, VA 22202.
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. Ins tall 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.
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.
Refer to http://www.lincolnelectric.com/safety for additional safety information.
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SAFETY
iv
PRÉCAUTIONS DE SÛRETÉ
Pour votre propre protection lire et observer toutes les instructions et les précautions de sûreté specifiques qui parraissent dans ce manuel aussi bien que les précautions de sûreté générales suiv­antes:
Sûreté Pour Soudage A LʼArc
1. Protegez-vous contre la secousse électrique:
a. Les circuits à lʼélectrode et à la piéce sont sous tension
quand la machine à souder est en marche. Eviter toujours tout contact entre les parties sous tension et la peau nue ou les vétements mouillés. Porter des gants secs et sans trous pour isoler les mains.
b. Faire trés attention de bien sʼisoler de la masse quand on
soude dans des endroits humides, ou sur un plancher metallique ou des grilles metalliques, principalement dans les positions assis ou couché pour lesquelles une grande partie du corps peut être en contact avec la masse.
c. Maintenir le porte-électrode, la pince de masse, le câble
de soudage et la machine à souder en bon et sûr état defonctionnement.
d.Ne jamais plonger le porte-électrode dans lʼeau pour le
refroidir.
e. Ne jamais toucher simultanément les parties sous tension
des porte-électrodes connectés à deux machines à souder parce que la tension entre les deux pinces peut être le total de la tension à vide des deux machines.
f. Si on utilise la machine à souder comme une source de
courant pour soudage semi-automatique, ces precautions pour le porte-électrode sʼapplicuent aussi au pistolet de soudage.
6. Eloigner les matériaux inflammables ou les recouvrir afin de prévenir tout risque dʼincendie dû aux étincelles.
7. Quand on ne soude pas, poser la pince à une endroit isolé de la masse. Un court-circuit accidental peut provoquer un échauffement et un risque dʼincendie.
8. Sʼassurer que la masse est connectée le plus prés possible de la zone de travail quʼil est pratique de le faire. Si on place la masse sur la charpente de la construction ou dʼautres endroits éloignés de la zone de travail, on augmente le risque de voir passer le courant de soudage par les chaines de lev­age, câbles de grue, ou autres circuits. Cela peut provoquer des risques dʼincendie ou dʼechauffement des chaines et des câbles jusquʼà ce quʼils se rompent.
9. Assurer une ventilation suffisante dans la zone de soudage. Ceci est particuliérement important pour le soudage de tôles galvanisées plombées, ou cadmiées ou tout autre métal qui produit des fumeés toxiques.
10. Ne pas souder en présence de vapeurs de chlore provenant dʼopérations de dégraissage, nettoyage ou pistolage. La chaleur ou les rayons de lʼarc peuvent réagir avec les vapeurs du solvant pour produire du phosgéne (gas fortement toxique) ou autres produits irritants.
11. Pour obtenir de plus amples renseignements sur la sûreté, voir le code “Code for safety in welding and cutting” CSA Standard W 117.2-1974.
2. Dans le cas de travail au dessus du niveau du sol, se protéger contre les chutes dans le cas ou on recoit un choc. Ne jamais enrouler le câble-électrode autour de nʼimporte quelle partie du corps.
3. Un coup dʼarc peut être plus sévère quʼun coup de soliel, donc:
a. Utiliser un bon masque avec un verre filtrant approprié
ainsi quʼun verre blanc afin de se protéger les yeux du ray­onnement de lʼarc et des projections quand on soude ou quand on regarde lʼarc.
b. Porter des vêtements convenables afin de protéger la
peau de soudeur et des aides contre le rayonnement de lʻarc.
c. Protéger lʼautre personnel travaillant à proximité au
soudage à lʼaide dʼécrans appropriés et non-inflammables.
4. Des gouttes de laitier en fusion sont émises de lʼarc de soudage. Se protéger avec des vêtements de protection libres de lʼhuile, tels que les gants en cuir, chemise épaisse, pan­talons sans revers, et chaussures montantes.
5. Toujours porter des lunettes de sécurité dans la zone de soudage. Utiliser des lunettes avec écrans lateraux dans les
zones où lʼon pique le laitier.
PRÉCAUTIONS DE SÛRETÉ POUR LES MACHINES À SOUDER À TRANSFORMATEUR ET À REDRESSEUR
1. Relier à la terre le chassis du poste conformement au code de lʼélectricité et aux recommendations du fabricant. Le dispositif de montage ou la piece à souder doit être branché à une bonne mise à la terre.
2. Autant que possible, Iʼinstallation et lʼentretien du poste seront effectués par un électricien qualifié.
3. Avant de faires des travaux à lʼinterieur de poste, la debranch­er à lʼinterrupteur à la boite de fusibles.
4. Garder tous les couvercles et dispositifs de sûreté à leur place.
Thank You
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for selecting a QUALITY product by Lincoln Electric. We want you to take pride in operating this Lincoln Electric Company product
••• as much pride as we have in bringing this product to you!
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 customerʼs 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.
CUSTOMER ASSISTANCE POLICY
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.
Please record your equipment identification information below for future reference. This information can be found on your machine nameplate.
Product _________________________________________________________________________________
Model Number ___________________________________________________________________________
Code Number or Date Code_________________________________________________________________
Serial Number____________________________________________________________________________
Date Purchased___________________________________________________________________________
Where Purchased_________________________________________________________________________
Whenever you request replacement parts or information on this equipment, always supply the information you have recorded above. The code number is especially important when identifying the correct replacement parts.
On-Line Product Registration
- Register your machine with Lincoln Electric either via fax or over the Internet.
• For faxing: Complete the form on the back of the warranty statement included in the literature packet accompanying this machine and fax the form per the instructions printed on it.
• For On-Line Registration: Go to our
Your Product”. Please complete the form and submit your registration.
Read this Operators Manual completely before attempting to use this equipment. Save this manual and keep it handy for quick reference. Pay particular attention to the safety instructions we have provided for your protection. The level of seriousness to be applied to each is explained below:
WEB SITE at www.lincolnelectric.com. Choose “Support” and then “Register
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.
vi
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-2
Angle of Operation ........................................................................................................A-2
Lifting.............................................................................................................................A-3
High Altitude Operation .................................................................................................A-3
High Temperature Operation ........................................................................................A-3
Towing...........................................................................................................................A-3
Vehicle Mounting...........................................................................................................A-3
Pre-Operation Engine and Compressor Service ..................................................................A-4
Oil..................................................................................................................................A-4
Fuel and Fuel Cap.........................................................................................................A-4
Engine Coolant System.................................................................................................A-4
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 Plugs, Standby Power Connections ...............................A-6
Connection of Lincoln Electric Wire Feeders................................................................A-7, A-8
Electrical Device used with this Product...............................................................................A-9
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vi
Operation.........................................................................................................................Section B
Safety Precautions ..............................................................................................................B-1
General Description..............................................................................................................B-1
For Auxiliary Power ..............................................................................................................B-1
Engine Operation..................................................................................................................B-1
Add Fuel ...............................................................................................................................B-1
Break in Period.....................................................................................................................B-1
Recommended Application - Welder, Air Compressor and Generator.................................B-2
Welder Controls .............................................................................................................B-3,B-4
Engine Controls .............................................................................................................B-5,B-6
Starting and Stopping the Engine...........................................................................B-6,B-7
Welding Operation................................................................................................................B-7
Duty Cycle and Electrode Information...........................................................................B-7
Constant Current (Stick) Welding.........................................................................................B-7
Downhill Pipe (Stick) Welding ...................................................................................... B-8
TIG Welding ..................................................................................................................B-8
Wire Welding-CV...........................................................................................................B-9
Arc Gouging ..................................................................................................................B-9
Typical Current Ranges for Tungsten Electrodes .........................................................B-9
Paralleling...........................................................................................................................B-10
Auxiliary Power...................................................................................................................B-10
Simultaneous Welding and Power Loads ...................................................................B-10
Extension Cord Recommendations.............................................................................B-10
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Accessories.....................................................................................................Section C
Field Installed Options / Accessories ...............................................................................C-1
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vii
TABLE OF CONTENTS
Maintenance......................................................................................................Section D
Safety Precautions ................................................................................................D-1
Routine Maintenance, Daily and Weekly ..............................................................D-1
Compressor Maintenance .....................................................................................D-1
Vehicle Mounted Air Compressors........................................................................D-1
Engine Maintenance..............................................................................................D-1
Air Filter .................................................................................................................D-1
Service Instructions And Installation Tips for Engine Air Filter..............................D-2
Engine Oil Change..........................................................................................D-3
Engine Oil Filter Change.................................................................................D-3
Air Cleaner .....................................................................................................D-3
Cooling System .....................................................................................................D-4
Fan Belt...........................................................................................................D-4
Fuel .................................................................................................................D-4
Bleeding the Fuel System ...............................................................................D-4
Fuel Filter ........................................................................................................D-5
Engine Adjustment ..........................................................................................D-5
Battery Maintenance .......................................................................................D-5
Servicing Optional Spark Arrestor ...................................................................D-5
Welder / Generator Maintenance ........................................................................D-6
Storage ...........................................................................................................D-6
Cleaning..........................................................................................................D-6
Brush Removal and Replacement ..................................................................D-6
________________________________________________________________________
Troubleshooting..............................................................................................Section E
________________________________________________________________________
Connection Diagrams, Wiring Diagrams and Dimension Print...................Section F
________________________________________________________________________
Parts List.....................................................................................................P-714 Series
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vii
A-1
INSTALLATION
TECHNICAL SPECIFICATIONS - AIR VANTAGE®500(AU) KUBOTA (K3212-1 )
INPUT - DIESEL ENGINE
Make/Model Description Speed (RPM) Displacement Starting Capacities
cu. in. (ltrs.) System
A-1
KUBOTA 58 HP (43.2kw) starter (94.6 L) V3600-T 1850 RPM Full Load 1850
4 cylinder High Idle 1850 220.9(3.62)
Bore x Stroke inch (mm)
Diesel Engine
Low Idle 1425
3.86 X 4.72
(98 x 120mm) 2.6gal. (9.8L)
12VDC Battery &
Fuel: 25 gal.
Oil: 3.5gal. (13.2L)
Radiator Coolant:
RATED OUTPUT @ 104°F(40°C) - WELDER
Duty Cycle Welding Output Volts at Rated Amps
100% 500 Amps (DC multi-purpose) 40 Volts
60% 550 Amps (DC multi-purpose) 36 volts 50% 575 Amps (DC multi-purpose) 35 volts
OUTPUT @ 104°F(40°C) - WELDER AND GENERATOR
Welding Range
30 - 575 Amps CC/CV
20 - 250 Amps TIG
Open Circuit Voltage
60 Max OCV @ 1850 RPM
Auxiliary Power
2 x 240 VAC Receptacles
2 x 3600 WATTS, 60 Hz., Single Phase
(1)
COMPRESSOR SPECIFICATIONS
Compressor Model
VMAC™
S700066
Height
42.0 in 32.7 in. 63.1 in. 1730 lbs.
(1066.8 mm) (830.1mm) (1603mm) (785kg)
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 7.0” (177.8mm) for exhaust pipe.
Description Delivery Maximum System Compressor Capacities
Direct-Drive Rotary
Screw Air Compressor 60 CFM @ 100PSI
(2)
High Idle Mode: 150 PSI
(28.3 Ltr/sec. @
7.0 kg/cm)
Low Idle Mode: High Temperature
40 CFM @ 100PSI Automatic Shutdown
(18.9 Ltr/sec. @ 290° F (143°C)
7.0 kg/cm)
PHYSICAL DIMENSIONS
Width Depth Weight
Pressure Profection
Safety Relief Valve
(10.5 kg/cm2) 200 PSI
(10.5 kg/cm2)
(Approx)
1.3 gal.(5.0 ltrs)
AIR VANTAGE®500(AU) KUBOTA
A-2
INSTALLATION
A-2
SAFETY PRECAUTIONS
WARNING
Do not attempt to use this equipment until you have thoroughly read the engine manufacturerʼs 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
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 operatorʼs 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 13V 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.
• 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.
(See Figure A.1)
 can injure.
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.
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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 canʼt 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.
STACKING
AIR VANTAGE®500(AU) KUBOTA machines cannot be stacked.
ANGLE OF OPERATION
To achieve optimum engine performance the TAGE®500(AU) KUBOTA tion. The maximum angle of operation for the VMAC Compressor and KUBOTA engine is 20 degrees con­tinues in all directions and 30 degrees intermittent (less than 10 minutes). 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.).
should be run in a level posi-
AIR VAN-
AIR VANTAGE®500(AU) KUBOTA
A-3
INSTALLATION
A-3
LIFTING
The
AIR VANTAGE®500(AU) KUBOTA
lift bale should be used to lift the machine. The Air Vantage 500 is shipped with the lift bale retracted. Before attempting to lift the
AIR VANTAGE®500(AU) KUBOTA
the lift bale must be secured in a raised position. Secure the lift bale as follows:
a. Open the engine compartment door.
b. Locate the 2 access holes on the upper middle
region of compartment wall just below the lift bale.
c. Use the lifting strap to raise the lift bale to the
full upright position. This will align the mount­ing holes on the lift bale with the access holes.
d. Secure the lift bale with 2 thread forming
screws. The screws are provided in the shipped loose parts bag.
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.
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HIGH ALTITUDE OPERATION
At higher altitudes, output derating may be necessary. For maximum rating, derate the welder output 5% for every 500 meters (1640ft.) above 400 meters (1312 ft.).
Contact a KUBOTA 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 Lincolnʼs K2641-2. 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 trailerʼs 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)
Consult applicable federal, state and local laws regarding specific requirements for use on public highways.
(1)
(1)
VEHICLE MOUNTING
WARNING
Improperly mounted concentrated loads may cause unstable vehicle handling and tires or other components to fail.
• Only transport this Equipment on serviceable vehicles which are rated and designed for such loads.
• Distribute, balance and secure loads so vehicle is stable under conditions of use.
• Do not exceed maximum rated loads for compo­nents such as suspension, axles and tires.
• Mount equipment base to metal bed or frame of vehicle.
• Follow vehicle manufactureʼs instructions.
--------------------------------------------------------------------------------
is
.
AIR VANTAGE®500(AU) KUBOTA
A-4
INSTALLATION
PRE-OPERATION ENGINE AND COM­PRESSOR SERVICE
READ the engine and compressor operating and maintenance instructions supplied with this machine.
WARNING
A-4
ENGINE COOLANT
WARNING
HOT COOLANT can burn skin.
•Do not remove cap if radiator is hot.
• Keep hands away from the engine muffler or HOT engine parts.
• Stop engine and allow to cool before fuelling.
• Do not smoke when fuelling.
• Fill fuel tank at a moderate rate and do not over­fill.
• Wipe up spilled fuel and allow fumes to clear before starting engine.
• Keep sparks and flame away from tank.
--------------------------------------------------------------------------------
OIL
The AIR VANTAGE®500(AU) KUBOTA 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 Operatorʼs 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 Operatorʼs Manuals for the proper service and maintenance intervals.
FUEL
USE DIESEL FUEL ONLY Low Sulphur fuel or ultra low sulphur fuel in USA and
CANADA only.
• Fill the fuel tank with clean, fresh diesel fuel. The capacity of the fuel tank is approximately 25 gallons (95 liters). See engine Operatorʼs 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).
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FUEL CAP
--------------------------------------------------------------------------------
The welder is shipped with the engine and radiator filled with a 50% mixture of ethylene glycol and water. See the MAINTENANCE section and the engine Operatorʼs Manual for more information on coolant.
BATTERY CONNECTION
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.
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.
Remove the plastic cap covering from the Fuel Tank Filler neck and install the Fuel Cap.
AIR VANTAGE®500(AU) KUBOTA
A-5
The AIR VANTAGE®500(AU) KUBOTA is shipped with the negative battery cable disconnected. Before you operate the machine, make sure the Engine Switch is in the OFF position and attach the discon­nected cable securely to the negative (-) battery termi­nal.
Remove the insulating cap from the negative battery terminal. Replace and tighten negative battery cable terminal. 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.
INSTALLATION
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.
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.
CAUTION
An incorrect arrestor may lead to damage to the engine or adversely affect performance.
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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®500(AU) KUBOTA 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.
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.
A-5
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.
Table A.1 Combined Length of Electrode and
Work Cables.
TOTAL COMBINED LENGTH OF
ELECTRODE AND WORK CABLES
Cable Length
0-150 Ft. (0-46 meters) 150-200 Ft. (46-61 meters) 200-250 Ft. (61-76 meters)
Cable Size for
500 Amps
100% Duty Cycle
3 / 0 AWG 3 / 0 AWG 4 / 0 AWG
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
• 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.
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When this welder is mounted on a truck or trailer, its frame must be securely connected to the metal frame of the vehicle. When this engine driven welder is con­nected to premises wiring such as that in a home or shop, its frame must be connected to the system earth ground. See further connection instructions in the sec­tion entitled “Standby Power Connections” as well as the article on grounding in the latest National Electrical Code and the local codes.
In general, if the machine is to be grounded, it should be connected with a #8 or larger copper wire to a solid earth ground such as a metal ground stake going into the ground for at least 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.
AIR VANTAGE®500(AU) KUBOTA
A-6
INSTALLATION
A-6
REMOTE CONTROL
The AIR VANTAGE®500(AU) KUBOTA 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.
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.
AUXILIARY POWER RECEPTACLES
The auxiliary power capacity of the AIR VANTAGE® 500(AU) KUBOTA is 7.2KW of 60Hz single phase power protected by an RCD (Residual Current Device) and 2 single phase 15 amp circuit breakers.
The auxiliary power capacity in watts equivalent to volt-amperes at unity power factor. This model has:
1 Residual Current Device (RCD) protection (30mA).
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.
The auxiliary power receptacles should only be used with three grounded 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.
STANDBY POWER CONNECTIONS
The AIR VANTAGE® 500(AU) KUBOTA is suitable for temporary, standby or emergency power using the engine manufacturerʼs recommended maintenance schedule.
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.
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The AIR VANTAGE® 500(AU) KUBOTA can be per­manently installed as a standby power unit for 240 volt (60Hz). Connections must be made by a licensed electrician who can determine how the 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 com-
pany meter and the premises disconnect. (The AIR VANTAGE® 500(AU) KUBOTA and the power company supplies must not be connected togeth­er).
Switch rating must be the same or greater than the customerʼs premises disconnect and service over cur­rent protection.
2. Take necessary steps to assure load is limited to
the capacity of the AIR VANTAGE® 500(AU) KUBOTA. 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® 500(AU) KUB­OTA engine.
AIR VANTAGE®500(AU) KUBOTA
A-7
INSTALLATION
CONNECTION OF LINCOLN ELEC­TRIC WIRE FEEDERS
A-7
4. Control Cable Model:
Connection of LN-7, LN-8 OR LN-742 to the AIR VANTAGE
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 CONTROLLED" position.
7. Set the "IDLE" switch to the "HIGH" position.
Connection of LN-15 to the AIR VANTAGE 500(AU) KUBOTA
®
500(AU) KUBOTA
• Connect Control Cable between Engine Welder and Feeder.
• Set the "WELD TERMINALS" switch to "REMOTELY CONTROLLED"
• 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, the current sens-
®
ing circuit will cause the AIR VANTAGE KUBOTA 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.
500(AU)
1. Shut the welder off.
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".
• When the gun trigger is closed, the current sens­ing circuit will cause the AIR VANTAGE 500(AU) KUBOTA 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.
®
AIR VANTAGE®500(AU) KUBOTA
A-8
INSTALLATION
A-8
CONNECTION OF THE LN-25 TO THE AIR
®
VANTAGE
500(AU) KUBOTA.
WARNING
Shut off welder before making any electrical con­nections.
--------------------------------------------------------------------------------
The LN-25 with or without an internal contactor may be used with the AIR VANTAGE®500(AU) KUBOTA . See the appropriate connection diagram in Section F.
1. Shut the welder off.
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.
CONNECTION OF AN NA-3 AUTOMATIC WELDING SYSTEM TO THE AIR VAN­TAGE®500(AU) KUBOTA
For connection diagrams and instructions for connect­ing an NA-3 Welding System to the AIR VANTAGE 500(AU) KUBOTA, refer to the NA-3 Welding System instruction manual. The connection diagram for the LN-8 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®500(AU) KUBOTA (SEE SECTION F)
®
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 KUBOTA 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, the current sens­ing circuit will cause the AIR VANTAGE KUBOTA 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.
500(AU)
®
500(AU)
CAUTION
If you are using an LN-25 without an internal con­tactor, the electrode will be energized when the AIR VANTAGE
------------------------------------------------------------------------
®
500(AU) KUBOTA is started.
AIR VANTAGE®500(AU) KUBOTA
A-9
INSTALLATION
CAUTION
Certain Electrical devices cannot be powered to this Product. See Table A.2
TABLE A.2
ELECTRICAL DEVICE USE WITH THIS PRODUCT
A-9
Type
Resistive
Capacitive
Inductive
Common Electrical Devices
Heaters, toasters, incandescent light bulbs, electric range, hot pan, skillet, coffee maker.
TV sets, radios, microwaves, appliances with electrical control.
Single-phase induction motors, drills, well pumps, grinders, small refrigerators, weed and hedge trimmers.
Possible Concerns
NONE
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. (See Some synchronous motors may be frequency sensitive to attain maximum output torque, but they SHOULD BE SAFE from any frequency induced failures.
Capacitive / Inductive
The Lincoln Electric Company is not responsible for any damage to electrical components improperly connected to this product.
Computers, high resolution TV sets, complicated electrical equipment.
AIR VANTAGE®500(AU) KUBOTA
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.
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