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Lincoln Electric SAE-400 SEVERE DUTY IM727 manual

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Table of contents for the manual

  • Page 1

    OPERA T OR’S MANUAL S AE-400 SEVERE DUTY DC ARC WELDING PO WER SOURCE IM727 January , 2005 For use with machines having Code Number: 10856 Safety Depends on Y ou Lincoln arc welding and cutting equipment is designed and built with safety in mind. However , your overall safety can be increased by pr oper installation ... and thoughtful opera- tion[...]

  • 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 ’s recommendations. 8.c. Ground the equipment in accordance with the U.S. Nati[...]

  • Page 5

    iv SAFETY iv Mar . ‘93 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 ’Arc 1. Protegez-vous contre la secousse électrique: a. L[...]

  • 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 SEVERE DUTY vi Page Installation Instructions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Section A T echnical Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .A-1 Installation Precautions . . . . . . . . . . . . . [...]

  • Page 8

    A-1 INST ALLA TION SAE-400 SEVERE DUTY A-1 TECHNICAL SPECIFICA TIONS - SAE-400 SEVERE DUTY Make/Model Description Speed (RPM) Displacement Starting Capacities System Perkins 4 cylinder High Idle 1800 256 cu. in 12VDC batteries Fuel: 22.5 gal. 1004.42 Diesel 71 HP @ Low Idle 1 100 (4.2 L) (2 ) & Starter 85.1 L Engine 1725 RPM Full Load 1725 Bore[...]

  • Page 9

    A-2 INST ALLA TION SAE-400 SEVERE DUTY 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 an[...]

  • Page 10

    A-3 INST ALLA TION SAE-400 SEVERE DUTY 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 operat[...]

  • Page 11

    A-4 INST ALLA TION A-4 SAE-400 SEVERE DUTY BA TTER Y CONNECTION W ARNING: Use caution as the electrolyte is a strong acid that can burn skin and damage eyes. Remove and discard the insulating caps from the neg- ative battery terminals. Attach and tighten negative battery cable terminals. NOTE: This machine is furnished with wet charged batteries; i[...]

  • Page 12

    A-5 INST ALLA TION SAE-400 SEVERE DUTY A-5 WELDING OUTPUT CABLES With the engine off, connect the electrode and work cables to the studs provided. These connections should be checked periodically and tightened if neces- sary . Listed in T able A.1 are copper cable sizes recom- mended for the rated current and duty cycle. Lengths stipulated are the [...]

  • Page 13

    B-1 OPERA TION B-1 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 from moving parts • Do not operate with doors open or guards off. • Stop en[...]

  • Page 14

    B-2 OPERA TION B-2 DESIGN FEA TURES AND ADV ANT AGES FOR STICK WELDING • Excellent DC constant current output for stick weld- ing applications. • Continuous adjustment of both voltage and current for unsurpassed welds on demanding jobs. • Remote control capability standard. FOR AUXILIAR Y POWER • 3,000 watts of 1 15/230 V AC, 60 Hz auxiliar[...]

  • 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 “[...]

  • Page 16

    B-4 OPERA TION B-4 WELDER CONTROLS POLARITY SWITCH T urn the Arc Polarity switch to electrode positive or electrode negative as required for each particular application. CONTROL OF WELDING CURRENT Purpose of Controls The continuous “ Current Control ” is the main current adjuster . The “ Job Selector ” is both a fine current adjuster and th[...]

  • Page 17

    B-5 OPERA TION B-5 ENGINE OPERA TION Do not adjust the high idle engine speed (rpm) above the factory setting specification. ------------------------------------------------------------------------ ST ARTING INSTRUCTIONS Be sure all Pre-Operation Maintenance has been per- formed. (See INST ALLA TION section of this manual). T o start the engine, pl[...]

  • Page 18

    C-1 ACCESSORIES C-1 OPTIONAL FIELD INST ALLED ACCESSORIES K802-D Power Plug Kit - Kit includes male plugs for each auxiliary receptacle. K767-1 T railer - A 4-wheel steerable trailer for in-plant and yard towing (1) with E78-14 load range (B) tubeless tires. Mounts directly to welder base. K956-1 and -2 T railer - A 2-wheel trailer designed for roa[...]

  • Page 19

    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 20

    D-2 MAINTENANCE D-2 BEARING MAINTENANCE This welder is equipped with a double-shielded ball bearing having sufficient grease to last indefinitely under normal ser- vice. Where the welder is used constantly or in excessively dirty locations, it may be necessary to add one-half ounce of grease per year . A pad of grease one inch wide, one inch long a[...]

  • Page 21

    D-3 MAINTENANCE D-3 1. Close the fuel shutoff valve located on the fuel strainer mounted to the under side of the fuel tank. 2. Unscrew the cap ring located on the top of the filter header and remove the plastic center cap and O- ring. 3. Remove the large white volume plug located direct- ly under the center cap in the upper cavity of the fil- ter [...]

  • Page 22

    D-4 MAINTENANCE D-4 SP ARK ARRESTOR For machines with separate spark arresting unit: Service the spark arrestor every 100 hours of opera- tion or twice a year , which ever occurs first. Service as follows: 1. Stop engine and allow to cool. 2. Loosen clamp and remove spark arrestor from machine. 3. Remove locknut on top of spark arrestor housing and[...]

  • Page 23

    E-1 TROUBLESHOOTING E-1 SAE-400 SEVERE DUTY 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 [...]

  • Page 24

    E-2 TROUBLESHOOTING E-2 SAE-400 SEVERE DUTY 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 PR[...]

  • Page 25

    E-3 TROUBLESHOOTING E-3 SAE-400 SEVERE DUTY 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 PR[...]

  • Page 26

    E-4 TROUBLESHOOTING E-4 SAE-400 SEVERE DUTY 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 PR[...]

  • Page 27

    F-1 WIRING DIAGRAMS SAE-400 SEVERE DUTY F-1 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. SWITCH PROTECT I ON P.C. BOA RD IDL ER/E NGINE J1 + S W ITCH (N.C. ) OI L PR ES SUR E THER MOST[...]

  • Page 28

    SAE-400 SEVERE DUTY F-2 WIRING DIAGRAMS F-2 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. 7- 2 001G M192 37 COLOR CODE ALT ERNA TOR ROT OR AC + SLI P - RINGS (-) D2 FLA SHING D IODE B-B[...]

  • Page 29

    SAE-400 SEVERE DUTY F-3 DIMENSION PRINT F-3 M8869-23 5/01 28.0 0 24.5 0 27.1 2 22.0 0 22.1 4 6.00 39.69 50.13 8.90 69.7 5 77.00 81.25 83.0 0 38.5 0 63.06 .88 3.00 8.12 6.31 26.75 CENTER OF GRAVITY WITH OIL AND WATER IN ENGINE, BUT NO FUEL N.A. .81 DIA. HOLES. N.B. .6 9 DI A. HOLES. N.A. N.A. N.B. N.B. 43.7 5 44.50 23.13[...]

  • Page 30

    SAE-400 SEVER DUTY NOTES[...]

  • Page 31

    W ARNING A VISO DE PRECAUCION A TTENTION W ARNUNG A TEN ÇÃ O 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 ABRICANTE PARA EL[...]

  • Page 32

    W ARNING A VISO DE PRECAUCION A TTENTION W ARNUNG A TEN ÇÃ O 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 remove fumes f[...]

  • Page 33

    • 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 •[...]