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Lincoln Electric IM869-D manual

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Table of contents for the manual

  • Page 1

    OPERA T ORʼS MANUAL S AE-400 DC ARC WELDING PO WER SOURCE IM869-D May , 2008 For use with machines having Code Numbers: 1 1 198, 1 1322, 1 1407, 1 1409,1 1509 Safety Depends on Y ou Lincoln arc welding and cutting equipment is designed a nd built with s afety in mind. Ho wever , your ov erall safety can be increased by pr oper instal latio n ... a[...]

  • Page 2

    FOR ENGINE powered equipment. 1.a. T urn 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. _______________________________________________[...]

  • Page 3

    ii SAFETY ii ARC RA YS 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[...]

  • Page 4

    iii SAFETY iii FOR ELECTRICALL Y powered equipment. 8.a. T urn 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 ʼs recommendations. 8.c. Ground the equipment in accordance with the U.S. Natio[...]

  • Page 5

    iv SAFETY iv Mar . ʻ93 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 suiv- antes: Sûreté Pour Soudage A L ʼArc 1. Protegez-vous contre la secousse électrique: a. Les[...]

  • Page 6

    v v Thank You for selecting a QUALITY product by Lincoln Electric. We want you to take pride in operating this Lincoln Electric Company product ••• as much pride as we have in bringing this product to you! Read this Operators Manual completely before attempting to use this equipment. Save this manual and keep it handy for quick reference. Pay[...]

  • Page 7

    vi T ABLE OF CONTENTS SAE-400 vi Page Installation Instructions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Section A T echnical Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .A-1 Installation Precautions . . . . . . . . . . . . . . . [...]

  • Page 8

    A-1 INST ALLA TION SAE-400 A-1 TECHNICAL SPECIFICA TIONS - SAE-400 (K1278-7, K1278-9) Make/Model Description Speed (RPM) Displacement Starting Capacities System K1278-7 Perkins 4 cylinder High Idle 1800 269 cu. in 12VDC batteries Fuel: 22.5 gal. 1 104C-44 Diesel 68.4 HP @ Low Idle 1 100 (4.4 L) (2 ) & Starter 85.1 L Engine 1725 RPM Full Load 17[...]

  • Page 9

    A-2 INST ALLA TION SAE-400 A-2 Read this entire installation section before you start installation. SAFETY PRECAUTIONS Do not attempt to use this equipment until you have thoroughly read all operating and maintenance man- uals supplied with your machine. They include impor- tant safety precautions, detailed engine starting, operating and maintenanc[...]

  • Page 10

    A-3 INST ALLA TION SAE-400 A-3 HIGH AL TITUDE OPERA TION At higher altitudes, output derating may be necessary . As a rule of thumb, derate the welder output 5% for every 500 meters (1640 ft.) above 1000 meters (3280 ft.). Contact a Perkins Service Representative for any engine adjustments that may be required for high alti- tude operation. TOWING [...]

  • Page 11

    A-4 INST ALLA TION A-4 SAE-400 • Stop engine while fueling. • Do not smoke when fueling. • Keep sparks and flame away from tank. • Do not leave unattended while fueling. • W ipe up spilled fuel and allow fumes to clear before starting engine. • Do not overfill tank, fuel expansion may cause over- flow . DIESEL FUEL ONL Y ---------------[...]

  • Page 12

    negative cable last. Keep well ven- tilated. ● USING A BOOSTER — connect positive lead to battery first then connect negative lead to negative battery lead at the lower control panel support. BA TTERY ACID can burn eyes and skin. ● Wear gloves and eye protection and be careful when working near battery . ● Follow instructions printed on bat[...]

  • Page 13

    B-1 OPERA TION B-1 both, to keep the fumes and gases from your br eathing zone and general area. WELDING SP ARKS can cause fire or explosion. • Do not weld near flammable material . • Do not weld on containers that have held flammable material. ----------------------------------------------------------- MOVING P ARTS can injure. • Keep away f[...]

  • Page 14

    B-2 OPERA TION B-2 RECOMMENDED APPLICA TIONS WELDER The SAE-400 provides excellent constant current DC welding output for stick (SMA W) welding. The field installed optional CV Adapter (K385-[ ]) provides up to 500 amps at 35 volts of constant voltage output for semiautomatic welding. AUXILIAR Y POWER The SAE-400 provides 3 KW of 1 15/230 V AC outp[...]

  • Page 15

    B-3 OPERA TION B-3 ENGINE CONTROLS IGNITION SWITCH When placed in the “ON” position, this switch ener- gizes the fuel solenoid. When placed in the “OFF” posi- tion, the flow of fuel to the injection pump is stopped to shut down the engine. “IDLER” SWITCH The idler switch has two positions, “HIGH” and “AUTO”. When in “HIGH” ([...]

  • Page 16

    B-4 OPERA TION B-4 How to Set the Controls Assume you want a normal soft arc and about 135 amps, using a 5/32” (4.0 mm) electrode: 1. Set the “Job Selector” at the center of the black range. 2. Set the “Current Control” to read 135 amps on the black dial. 3. Start to weld. 4. If you want a little more current, turn the “Job Selector” [...]

  • Page 17

    B-5 OPERA TION B-5 SAE-400 ENGINE OPERA TION For added safety always operate the welder with the doors closed. Further , leaving the doors open changes the designed air flow and may cause engine, genera- tor overheating. Do not adjust the high idle engine speed (rpm) above the factory setting specification as this will void warranty . -------------[...]

  • Page 18

    B-6 OPERA TION B-6 SAE-400 TYPICAL FUEL CONSUMPTION The typical fuel consumption of the SAE-400 for various operating scenarios is shown below: PERKINS 1 104C-44 PERKINS 1 104A-44 Low Idle - No Load .30 gal./ hr . 26 gal./ hr . 1 100 RPM (1.12 L./hr .) (.97 L./hr .) High Idle - No Load .69 gal./hr . .68 gal./hr . 1800 RPM (2.61 L./hr .) (2.56 L./hr[...]

  • Page 19

    C-1 ACCESSORIES C-1 K930-2 TIG Module - Provides high frequency plus a gas valve for TIG welding. A water valve is available as an option. Requires 1 15 volt AC input. (Limited to 250A - 60% Duty Cycle). K802-D Power Plug Kit - Kit includes male plug for 20 amp receptacle. K2641-1 T railer - A 4-wheel steerable trailer for in- plant and yard towing[...]

  • Page 20

    D-1 MAINTENANCE D-1 ELECTRIC SHOCK can kill. ● Do not touch electrically live parts such as output terminals or inter- nal wiring ENGINE EXHAUST can kill. ● Use in open, well ventilated areas or vent exhaust outside MOVING P ARTS can injure. ● Do not operate with doors open or guards off ● Stop engine before servicing ● Keep away from mov[...]

  • Page 21

    D-2 MAINTENANCE D-2 SAE-400 COMMUT A TOR AND BRUSH MAINTENANCE Uncovered rotating equipment can be dangerous. Use care so your hands, hair , clothing or tools do not catch in the rotating parts. Protect yourself from particles that may be thrown out by the rotat- ing armature when stoning the commutator . -------------------------------------------[...]

  • Page 22

    D-3 MAINTENANCE D-3 SAE-400 4. Using a pair of pliers, gently tug on the pull tabs of the pre-filter screen in an alternating pattern to gradually remove the pre-filter screen. 5. Brush of f any debris and rinse in diesel fuel. 6. Re-install the pre-filter screen into the upper cavity of the filter header making sure the four pull tabs are pointing[...]

  • Page 23

    D-4 MAINTENANCE D-4 SAE-400 GFCI RECEPT ACLE TESTING AND RESET- TING PROCEDURE The GFCI receptacle should be properly tested at least once every month or whenever it is tripped. T o proper- ly test and reset the GFCI receptacle: • If the receptacle has tripped, first carefully remove any load and check it for damage. • If the equipment has been[...]

  • Page 24

    E-1 TROUBLESHOOTING E-1 SAE-400 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. CAUTION W ARNING ELECTRIC SHOCK can kill. • Do not touch electrically live parts s[...]

  • Page 25

    E-2 TROUBLESHOOTING E-2 SAE-400 Observe all Safety Guidelines detailed throughout this manual 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. CAUTION FUNCTION PROBL[...]

  • Page 26

    E-3 TROUBLESHOOTING E-3 SAE-400 Observe all Safety Guidelines detailed throughout this manual 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. CAUTION FUNCTION PROBL[...]

  • Page 27

    E-4 TROUBLESHOOTING E-4 SAE-400 Observe all Safety Guidelines detailed throughout this manual 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. CAUTION FUNCTION PROBL[...]

  • Page 28

    E-5 TROUBLESHOOTING E-5 SAE-400 Observe all Safety Guidelines detailed throughout this manual 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. CAUTION FUNCTION PROBL[...]

  • Page 29

    F-1 WIRING DIAGRAMS SAE-400 F-1 CODE NOTE: This diagram is for reference only . It may not be accurate for all machines covered by this manual. The specific diagram for a particular code is pasted inside the machine on one of the enclosure panels.[...]

  • Page 30

    F-2 WIRING DIAGRAM F-2 SAE-400 NOTE: This diagram is for reference only . It may not be accurate for all machines covered by this manual. The specific diagram for a particular code is pasted inside the machine on one of the enclosure panels.[...]

  • Page 31

    SAE400 F-3 WIRING DIAGRAM F-3 NOTE: This diagram is for reference only . It may not be accurate for all machines covered by this manual. The specific diagram for a particular code is pasted inside the machine on one of the enclosure panels.[...]

  • Page 32

    SAE400 F-4 WIRING DIAGRAM F-4 NOTE: This diagram is for reference only . It may not be accurate for all machines covered by this manual. The specific diagram for a particular code is pasted inside the machine on one of the enclosure panels.[...]

  • Page 33

    SAE-400 F-5 DIMENSION PRINT F-5 M8869-36 A A N.A.  .81 HOLES N.B.  .69 HOLES 28.00 22.00 22.14 24.50 27.12 6.00 39.69 47.95 23.00 26.00 38.50 63.06 50.13 21.00 44.00 8.90 44.50 69.75 8.12 77.00 3.00 81.25 .88 83.00 CENTER OF GRAVITY W IT H OIL AND W ATER IN ENGINE, BUT NO F UEL N.A. N.A. N.B. N.B.[...]

  • Page 34

    NOTES SAE-400[...]

  • Page 35

    NOTES SAE-400[...]

  • Page 36

    SAE-400 W ARNING AV I S O D E PRECAUCION A TTENTION W ARNUNG A TENÇÃO Spanish French German Portuguese Japanese Chinese Korean Arabic LEIA E COMPREENDA AS INSTRUÇÕES DO F ABRICANTE PARA ESTE EQUIP AMENTO E AS P ARTES DE USO, E SIGA AS PRÁTICAS DE SEGURANÇA DO EMPREGADOR. ● Keep your head out of fumes. ● Use ventilation or exhaust to remov[...]

  • Page 37

    SAE-400 W ARNING AV I S O D E PRECAUCION A TTENTION W ARNUNG A TENÇÃO Spanish French German Portuguese Japanese Chinese Korean Arabic READ AND UNDERST AND THE MANUF ACTURER’S INSTRUCTION FOR THIS EQUIPMENT AND THE CONSUMABLES TO BE USED AND FOLLOW YOUR EMPLOYER’S SAFETY PRACTICES. SE RECOMIENDA LEER Y ENTENDER LAS INSTRUCCIONES DEL F ABRICANT[...]

  • Page 38

    • Sales and Service through Subsidiaries and Distributors Worldwide • Cleveland, Ohio 441 17-1 199 U.S.A. TEL: 216.481.8100 F AX: 216.486.1751 WEB SITE: www .lincolnelectric.com • World's Leader in W elding and Cutting Products •[...]