Lincoln Electric SAE-400 User's Manual
Contents
1. 4 Spark Arrestor 5 Welding Output Cables 5 Machine Grounding 5 Operating Instructions Section B Safety Instr ctions haved ae wee bead eed dda B 1 Additional Safety Precautions B 1 General Description NEEN a na RR he eg eem eius B 1 Recommended Applications B 1 Welder p EDT B 1 Auxiliary Power B 1 Design Features and Advantages B 2 D ty Cycle EE B 2 Engine Controls Function Operation B 3 Air Intake Shut Off hh B 3 Welder Controls Function Operation B 4 Remote Control B 4 Auxiliary Power Controls B 4 Engine Operation B 5 Starting Instructions B 5 Period he ERA ee bee pelle B 5 Typical Fuel Consumption B 5 ACCOSSONGS es NNN NEEN eee ee eee RR Section C Maintenance 22222000 2 c m rra ee eee dunes Section D Routine Maintenance Periodic Maintenance D 1 Engine Oil Chang2. e suonoeuuwo jqe e SMO3HO ATIVA SNOILONALSNI SONVNALNIVIN 10 99e dea pue p109 jo pjoy eJn2es 4997 e funfui snes ued spJo 5 1 100p Jo ONINYVM V 9 Jaye paoejdas spJen pue feme 1003 pue e 40 y HIOM 210pq 440 md Jo ay e NVO SL vd SNIAOW jeuucsJed e r YOSNAS Away 9333 1 11 kd en YALINSI lHVISOWHAH SADYNOS N3ATHO HOLOW 30d SNOILONALSNI SONVNALNIVIN IVH3N39 ONILYVLS NOLLO3fNI 7303 S3NIHOVW NO GNNOUD SI 39nv9 3iniVvi3adiWal 5575 39v9 az4niviadWal 330 lt 188 8 g ec 111 MAYIS ANNONO IBNVd IOHINOO OL 5 H2 LIMS 4 34 e ad lt ezz 9 gzz n 9 HOLIMS NOILINOI ozz 4 OOIONZIOS VO pez 9
3. 1 HOW TO USE TROUBLESHOOTING GUIDE WARNING Service and Repair should only be performed by Lincoln Electric Factory Trained Personnel Unauthorized repairs performed on this equipment may result in danger to the technician and machine operator and will invalidate your factory warranty For your safety and to avoid Electrical Shock please observe all safety notes and precautions detailed throughout this manual This Troubleshooting Guide is provided to help you locate and repair possible machine malfunctions Simply follow the three step procedure listed below Step 1 LOCATE PROBLEM SYMPTOM Look under the column labeled PROBLEM SYMP This column provides a course of action for the Possible Cause generally it states to contact your local Lincoln Authorized Field Service Facility If you do not understand or are unable to perform the Recommended Course of Action safely contact your TOMS This column describes possible symptoms that the machine may exhibit Find the listing that best describes the symptom that the machine is exhibiting 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 Step 3 RECOMMENDED COURSE OF ACTION A WARNING ELECTRIC SHOCK can kill Do not touch electrically live parts such as output terminals or internal wiring ENGI
4. 9 zzz n YOLVNYSLTV LET 8 LAVIiSONAIHL 69 80 ONIHSY 14 OL WALIN 3NISN3 SNIHA d 007 SVS SAE 400 SEVERE DUTY LINCOLN E 2 WIRING DIAGRAMS F 2 eunso ue y JO euo uo y 5 si 2p02 e 2 y Aq seulu2euu jou 92uasJ9JjaJ 51 siu 3 LON LEZGLIN 91007 Z HOLIMS ONISNAS IN3HHOD 3L MHOM OL 2004191313 SINT 431743 NO AVM SIHL HOLIMS SLOWSY HOLIMS ALRIV1Od 10 Ova OGM ASVIUIXOV 8 ovii M 49 33S 1 216919 H3d SIOEWAS 1951419573 310V 1d393H cdo IQ VSL 1 JO MAIA X114nQ M YOLVNYALIV 82095 M HOLIMS YYYA SIVNINYHAL 319v143934 Xd dna AVES 9 opie pe MOUISOd WOOTNI AlLlsdV lOd NMOHS 1OS LNOO SLOWSY 04 HOLIMS 7 H31AWOLLN3LOd OH1NOO 8d o lt H masya OL
5. in the MAINTENANCE section of this manual GFCI Receptacle is Optional Circuit Breakers open Faulty connections to auxiliary receptacles Faulty receptacles 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 SAE 400 SEVERE DUTY LINCOLN 1 WIRING DIAGRAMS F 1 Sjeued y JO euo uo euiuoeui y si epoo 4 ou siy 5 eq Jou AIUu0 104 S SIUL 3 LON 6090211 MOTI3A A SLIHM M N1449 9 HOMOV 18 8 3002 30102 aval suononugut 10 jenuejy Jo JO y sqreyBideuj eJojeqseusnuq 4 e suononagul 10 jenue y ees H10719 AYINI LON 1iededpies dis 10 s10jejnuuioo 2 e ainssaid ueo o e sv pue 949 jen pre juejooo e uopo 14 ui
6. 11 1 1 209 X v lt TEE lt lt M e GNNOYO H3MO1OL ANNONO WVSOVIG ONIAIAA KS 335 114 4 SHOLSIS3H 9 YS LAWOILNSLOd IOH LINOO SLOWSY ON Td HOLIMS ANY 310V1d3O3M TOHLNOO 51084 dl 7 90104 YOLVNYSL TV TEE SONIA MOTI3A A ko ALIHM M HOLISIS3H ANY ONIHSV14 amen HO 387 NMOHWS N N3dH9 9 ANE HO H9V18 4 3809 40109 1S N Q14M 8 00 1VS INVHOVIO ONIYIM TOHINOO SAE 400 SEVERE DUTY LINCOLN E DIMENSION PRINT F 3 F 3 69881 LO G 008 N 88 cz 18 00 00 2 SKI 92 69 m E gen 9 96 Kai TaN ON LN ANIONS S31VM HLIM ALIAVYS 30 33439 105 UND ELE 088 90 9 69 S110H VIC 69 VIG 18 VN zz mm nee nz a 00 8c SAE 400 SEVERE DUTY LINCOLN E NOTES SAE 400 SEVER DUTY LINCOLN WARNING Spanish AVISO DE PRECAUCION French ATTENTION Ge
7. Brush off 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 up Putting your fingers on the pull tabs push down evenly until the lower body of the pre filter screen contacts the floor of the upper cav ity 7 Re insert the large white volume plug into the upper cavity 8 Place the O ring onto the angled seal surface of the filter header and re install the plastic cap Make sure its flange rests on the O ring 9 Screw on the cap ring and tighten hand tight 10 Remember to open the fuel shutoff valve before starting the engine WATER SEPARATOR ELEMENT The water separator element is a two stage filter with a special filtration water separating media and an expanded water reservoir providing maximum protec tion against water in the fuel The recommended change interval for the water separator element is 1 000 hours The procedure for changing the element is as follows 1 Close the fuel shutoff valve located on the fuel strainer mounted to the under side of the fuel tank 2 Rotate the quick change ring located just below fil ter header clockwise approximately 1 2 turn and slide it down and off of the element 3 Grasp the element and pull down with a slight rock ing motion to remove the element from the grom met post on the bottom of the filter header 4 Slide the new element onto the grommet post o
8. j 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 e 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 e USING A BOOSTER connect positive lead to battery first then connect negative lead to neg ative battery lead at the lower control panel support BATTERY ACID can burn eyes and skin c e Wear gloves and eye protection and be careful when working near battery e Follow instructions printed on battery IMPORTANT To prevent ELECTRICAL DAMAGE WHEN a Installing new batteries b Using a booster Use correct polarity Negative Ground To prevent BATTERY BUCKLING tighten nuts on bat teries only until snug DO NOT OVERTIGHTEN SAE 400 SEVERE DUTY LINCOLN P 5 SPARK ARRESTOR The muffler included with this welder has been modi fied and now qualifies as a spark arrestor Mufflers on Spark Arrestor and Muffler may be hot Allow engine to cool before servicing spark arrestor Do not operate engine while servicing spark arrestor machines manufactured before this change do not qualify as spark arrestors and were shipped from the factory with an ad
9. stop the engine and consult the engine operating manual To stop the engine place the ignition toggle switch in the OFF position When an engine is started for the first time some of the oil will be needed to fill the passages of the lubri cating system Therefore on initial starting run the engine for about five minutes and then stop the engine and recheck the oil If the level is down fill to the full mark again The engine controls were properly set at the factory and should require no adjusting when received 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 or gener ator overheating Cold Weather Starting A WARNING Never use any other starting aids such as ether when using the Thermostart system When overnight temperatures are between 10 F 12 C and freezing use the standard Thermostart starting system installed on all engines Follow the instructions on the start panel nameplate and in the engine manu al shipped with the welder With fully charged batter ies and the proper weight oil the Thermostart system operates satisfactorily even down to about 0 F 18 C BREAK IN PERIOD ENGINE The engine used to supply power for your welder is a heavy duty industrial engine It is designed and built for rugged use It is very normal for any engine to use small quantities of oil until the bre
10. DIMENSIONS 28 00 in 2178 lbs 988 0 kg 711 2 mm Based on a 10 minute period SAE 400 SEVERE DUTY LINCOLN 2 INSTALLATION 2 Read this entire installation section before you start installation SAFETY PRECAUTIONS WARNING 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 maintenance instructions and parts lists Le ELECTRIC SHOCK can kill Do not touch electrically live parts such as output terminals or internal wiring elnsulate yourself from the work and ground eAlways 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 N guards off eStop engine before servicing Keep away from moving parts Only qualified personnel should install use or service this equipment LOCATION 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 MOUNT OVER COMBUSTIBLE SURFACES Where there is a combustible surface directly un
11. Prot jase los ojos los o dos y el cuerpo Prot gez vos yeux vos oreilles et votre corps Tragen Sie Augen Ohren und K r perschutz Use protec o para a vista ouvido e corpo HRUGHICRBRELTE RRR HRARGHRBAR ez 12 59 6 dis due eleng al yal pi e t daags READ AND UNDERSTAND THE MANUFACTURER S INSTRUCTION FOR THIS EQUIPMENT AND THE CONSUMABLES TO BE USED AND FOLLOW YOUR EMPLOYER S SAFETY PRACTICES SE RECOMIENDA LEER Y ENTENDER LAS INSTRUCCIONES DEL FABRICANTE PARA EL USO DE ESTE EQUIPO Y LOS CONSUMIBLES QUE VA A UTILIZAR SIGA LAS MEDIDAS DE SEGURIDAD DE SU SUPERVISOR LISEZ ET COMPRENEZ LES INSTRUCTIONS DU FABRICANT EN CE QUI REGARDE CET EQUIPMENT ET LES PRODUITS A ETRE EMPLOYES ET SUIVEZ LES PROCEDURES DE SECURITE DE VOTRE EMPLOYEUR LESEN SIE UND BEFOLGEN SIE DIE BETRIEBSANLEITUNG DER ANLAGE UND DEN ELEKTRODENEINSATZ DES HER STELLERS DIE UNFALLVERHUTUNGSVORSCHRIFTEN DES ARBEITGEBERS SIND EBENFALLS ZU BEACHTEN Keep your head out of fumes Use ventilation or exhaust to remove fumes from breathing zone Los humos fuera de la zona de res piraci n Mantenga la cabeza fuera de los humos Utilice ventilaci n aspiraci n para gases Gardez la t te l cart des fum es e Utilisez un ventilateur ou un aspira teur pour ter les fum es des zones de travail e Vermeiden Sie das Einatmen von Schweibrauch Sorgen Si
12. failures are caused by dirt introduced during greasing than from insufficient grease COMMUTATOR AND BRUSH MAINTENANCE A WARNING 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 The generator brushes are properly adjusted when the welder is shipped They require no particular attention DO NOT SHIFT THE BRUSHES or adjust the rocker setting Shifting of the brushes may result in Change in machine output Commutator Damage Excessive brush wear Periodically inspect the commutator slip rings and brushes by removing the covers DO NOT remove or replace these covers while the machine is running Commutators and slip rings require little attention However if they are black or appear uneven have them cleaned by an experienced maintenance man using fine sandpaper or a commutator stone Never use emery cloth or paper for this purpose NOTE If the welder is used in dirty or dusty locations or if the welder is not used for prolonged periods of time it may be necessary to clean the commutator and slip rings more often Replace brushes when they wear within 1 4 of the pig tail A complete set of replacement brushes should be kept on hand Lincoln brushes have a curved face to fit the commutator Have an experienced maintenance man seat
13. intervals and element changing proce dures ENGINE MAINTENANCE COMPONENTS _____ Water Separator Lincoln Element Stanadyne Fuel Pre Filter Screen Lincoln Stanadyne Fuel Filter PART NUMBER P181052 2614B550 M16890 C 31572 M16890 B 29575 26560143 2654403 Engine Oil Filter SAE 400 SEVERE DUTY LINCOLN D 4 MAINTENANCE D 4 SPARK ARRESTOR GFCI RECEPTACLE TESTING AND RESET TING PROCEDURE Spark Arrestor and Muffler may be hot The GFCI receptacle should be properly tested at least once every month or whenever it is tripped To proper Do not operate engine while servicing spark arrestor ly test and reset the GFCI receptacle Allow engine to cool before servicing spark arrestor f the receptacle has tripped first carefully remove any load and check it for damage f the equipment has been shut down it must be restarted The equipment needs to be operating at high idle speed and any necessary adjustments made on the control panel so that the equipment is providing at least 80 volts to the receptacle input terminals The circuit breaker for this receptacle must not be tripped Reset if necessary Push the Reset button located on the GFCI recep tacle This will assure normal GFCI operation Plug a night light with an ON OFF switch or other product such as a lamp into the GFCI receptacle and turn the product ON Push the Test button
14. of Containers and Piping That Have Held Hazardous Substances AWS F4 1 from the American Welding Society see address above Vent hollow castings or containers before heating cutting or welding They may explode 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 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 LINCOLN CYLINDER may explode KI damaged 7 a Use only compressed gas cylinders containing the correct shielding gas for the process used and properly operating regulators designed for the gas and pressure used All hoses fittings etc should be suitable for the application and maintained in good condition Always keep cylinders in an upright position securely chained to an undercarriage or fixed support Cylinders should be located Away from areas where they may be s
15. 20V ground fault circuit interrupter duplex type receptacle with cover and installation instructions Replaces the factory installed 120V duplex receptacle Each receptacle of the Duplex is rated at 20 Amps the maximum total current from the GFCI Duplex is limited to the 20 Amps Two kits are required See the MAINTENANCE section for detailed information on testing and resetting the GFCI receptacle SAE 400 SEVERE DUTY LINCOLN P D 1 MAINTENANCE D 1 WARNING ELECTRIC SHOCK can kill Do not touch electrically live parts such as output terminals or inter nal wiring ENGINE EXHAUST can kill e Use in open well ventilated areas or vent exhaust outside MOVING PARTS can injure Do not operate with doors open or guards off AX Stop engine before servicing Keep away from moving parts Remove guards only when necessary and replace when work requiring removal is com plete Only qualified personnel should install use or service this equipment ROUTINE MAINTENANCE At the end of each day s welding refill the fuel tank to minimize moisture condensation in the tank Also run ning out of fuel tends to draw dirt into the fuel system Check the engine crankcase oil level If the fuel supply runs out while the fuel pump is oper ating air may be entrapped in the fuel distribution sys tem If this happens bleeding of the fuel system may be necessary See the engine instruction m
16. ILIARY POWER CONTROLS Note GFCI receptacles our an option and if installed see the MAINTENANCE SECTION for detailed information on testing and resetting the GFCI receptacle 115 VAC Receptacle One 20 amp 115 VAC duplex receptacle provides 115 VAC for auxiliary power A total of 26 amps can be drawn from this receptacle 230 VAC Receptacle One 15 amp 230 VAC duplex receptacle provides 230 VAC for auxiliary power A total of 18 amps can be drawn from this receptacle Circuit Breakers The circuit breakers provide separate overload current protection for each half of the 115 V duplex receptacle The circuit breakers provide overload current protec tion in both current carrying wires of the 230 V duplex receptacle Ground Stud Provides a connection point for connecting the machine to earth ground For the safest grounding pro cedure refer to Machine Grounding in the INSTALLA TION section of this manual SAE 400 SEVERE DUTY LINCOLN 5 5 ENGINE OPERATION CAUTION Do not adjust the high idle engine speed rpm above the factory setting specification STARTING INSTRUCTIONS Be sure all Pre Operation Maintenance has been per formed See INSTALLATION section of this manual To start the engine place ignition toggle switch in the ON position Engage the starter button When the engine starts running observe the engine oil pressure If no pressure shows within 30 seconds
17. NE EXHAUST can kill e Use in open well ventilated areas or vent exhaust outside Wi 4 MOVING PARTS can injure Do not operate with doors open or guards off Stop engine before servicing NY e Keep away from moving parts Remove guards only when necessary and replace when work requiring removal is complete Only qualified personnel should install use or service this equipment 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 SAE 400 SEVERE DUTY LINCOLN 2 TROUBLESHOOTING 2 Observe all Safety Guidelines detailed throughout this manual PROBLEMS POSSIBLE AREAS OF RECOMMENDED SYMPTOMS MISADJUSTMENT S COURSE OF ACTION Engine will crank but not start Air intake shut off is closed Manually reset inside machine Out of fuel Fill fuel tank Fuel shut off valve is in off posi tion Low battery voltage Machine fails to hold the heat Rough or dirty commutator constanily Brushes may be worn down to limit of life Brush springs may be broken Field circuit may have variable resistance connections or inter mittent open circuit due to loose connections or broken wire If all recommended possible areas Electrode or work lead connec of misadjustment
18. RETURN TO MAIN MENU 5 SEVERE DUTY DC ARC WELDING POWER SOURCE For use with machines having Code Number 10856 IM727 January 2005 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 opera tion 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 OPERATOR S MANUAL 150 9001 ANSI RABE 5 27 VE WE Designed and Manufactured Under a is CERTIFICATE NUMBER 30273 LINCOLN Copyright 2005 Lincoln Global Inc e World s Leader in Welding and Cutting Products e e Sales and Service through Subsidiaries and Distributors Worldwide e Cleveland Ohio 44117 1199 U S A 216 481 8100 FAX 216 486 1751 WEB SITE www lincolnelectric com l WARNING CALIFORNIA PROPOSITION 65 WARNINGS Diesel engine exhaust and some of its constituents The engine exhaust from this product contains are known to the State of California to cause can chemicals known to the State of California to cause cer birth defects and other reproductive harm cancer birth defects or other reproductive harm The Above For Diesel Engines The Above For Gaso
19. Y product by Lincoln Electric We want you ank You to take pride in operating this Lincoln Electric Company product ee as much pride as we have in bringing this product to you 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 WEB SITE at www lincolnelectric com Choose Quick Links and then Product Registration Please complete the form and submit your registration Read this Ope
20. ak in is accom plished Check the oil level twice a day during the break in period about 100 running hours IMPORTANT IN ORDER TO ACCOMPLISH THIS BREAK IN THE UNIT SHOULD BE SUBJECTED TO HEAVY LOADS WITHIN THE RATING OF THE MACHINE AVOID LONG IDLE RUNNING PERIODS TYPICAL FUEL CONSUMPTION The typical fuel consumption of the SAE 400 SEVERE DUTY for various operating scenarios is shown below Low Idle No Load 35 gal hr 1100 RPM 1 32 L hr High Idle No Load 75 gal hr 1800 RPM 2 84 L hr Welding Load 1 92 gal hr 400 Amps 40 Volts 7 27 L hr Auxiliary Power 96 gal hr 3000VA 3 63 L hr SAE 400 SEVERE DUTY LINCOLN P 1 ACCESSORIES OPTIONAL FIELD INSTALLED ACCESSORIES K802 D Power Plug Kit Kit includes male plugs for each auxiliary receptacle K767 1 Trailer 4 wheel steerable trailer for in plant and yard towing with E78 14 load range B tubeless tires Mounts directly to welder base K956 1 and 2 Trailer A 2 wheel trailer designed for road off road in plant and yard towing The K956 2 trailer is equipped with electric brakes Trailer mounts directly to welder base For highway use consult applicable federal state and local laws regarding possible requirements for brakes lights fenders etc K704 Standard Accessory Kit Includes electrode and work cables headshield work clamp and elec trode holder K1690 1 GFCI RECEPTACLE KIT Includes one UL approved 1
21. anual PERIODIC MAINTENANCE 1 Blow out the welder and controls with an air hose at least once every two months In particularly dirty locations this cleaning may be necessary once a week Use low pres sure air to avoid driving dirt into the insulation 2 The current control reactor brushes are self lubricating and should not be greased Keep the contacts clean This control should be moved from maximum to minimum daily to prevent the controls from sticking 3 See the engine Instruction Manual for periodic engine maintenance information Change the oil filter in accor dance with the instructions in the engine operating man ual When the oil filter is changed add one quart of oil to the crankcase to replace the oil held in the filter during operation 4 Belts tend to loosen after the first 30 or 40 hours of oper ation Check the cooling fan belt and tighten if necessary DO NOT OVER TIGHTEN ENGINE OIL CHANGE The SAE 400 SEVERE DUTY is equipped with a convenient oil drain system Drain the oil when the engine is warm to assure rapid and complete draining e Remove the oil filler cap and dipstick To open drain valve push handle away from valve and turn 90 e Drain oil into a suitable container To close drain valve turn handle 90 till handle snaps in the closed position Refill engine with the recommended oil to the appropriate level Replace dipstick and tighten the oil filler cap secure ly Chan
22. da Y e Aale Cut Al dl TERN WARNING Spanish AVISO DE PRECAUCION French ATTENTION German WARNUNG ATEN AO tm Chinese LEIA COMPREENDA AS INSTRU ES DO FABRICANTE PARA ESTE EQUIPAMENTO E AS PARTES DE USO E SIGA AS PR TICAS DE SEGURANCA DO EMPREGADOR HD RR PRU X A OHRBEE lt RA Eg EE AR BE CAE RE EE ER EXAMEN 5 Gei AMARA AR ziel Oka FAS ETA BHE aal gl Catia ail 9 laiul d ol ply Gail giall lala agi y L LINCOLN 5 World s Leader in Welding and Cutting Products Sales and Service through Subsidiaries and Distributors Worldwide Cleveland Ohio 44117 1199 U S A TEL 216 481 8100 FAX 216 486 1751 WEB SITE www lincolnelectric com
23. dangerous electric shock other equipment powered by this engine driven welder must a be grounded to the frame of the welder using a grounded type plug or b be double insulated 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 con nected to premises wiring such as that in a home or shop its frame must be connected to the system earth ground See the article on grounding in the latest U S National Electrical Code and the local code 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 water pipe going into the ground for at least ten feet and having no insulated joints or to the metal framework of a building which has been effectively grounded The U S National Electrical Code lists a number of alternate means of grounding electrical equipment A machine grounding stud marked with the symbol is provided on the welding generator frame foot SAE 400 SEVERE DUTY LINCOLN amp 1 1 OPERATING INSTRUCTIONS Read and understand this entire section before operat ing your equipment SAFETY INSTRUCTIONS WARNING Do not attempt to use this equipment until you have thoroughly read all operating and maintenance manu als supplied with your machine They include important safety precautions detailed engi
24. der stationary or fixed electrical equipment that surface shall be covered with a steel plate at least 06 1 6mm thick which shall extend not less than 5 90 150mm beyond the equipment on all sides STACKING These machines cannot be stacked ANGLE OF OPERATION To achieve optimum engine performance the machine should be run in a level position The maximum angle of operation for the Perkins engine is 30 degrees in all directions If the engine is to be operated at an angle provisions must be made for checking and maintaining the oil level at the normal FULL oil capacity in the engine crankcase When operating the welder at an angle the effective fuel capacity will be slightly less than the specified 22 5 gallons LIFTING The equipment lift bale should be used to lift 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 bale if it is equipped with a heavy accessory such as trail er or gas cylinder Do not lift machine if lift bale is damaged Do not operate machine while suspended from lift bale FALLING EQUIPMENT can cause injury SAE 400 SEVERE DUTY LINCOLN 3 INSTALLATION HIGH ALTITUDE OPERATION 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 Perk
25. ditional spark arresting unit for that purpose Integral spark arresting mufflers will have a clean out service plug and will have USDA FS 51001C QUALIFIED SPARK ARRESTOR stamped on the muffler shell Any spark arrestor must be serviced and properly maintained For machines with separate spark arrestors secure the arrestor to the outlet tube on the muffler using the clamp provided An incorrect spark arrester may lead to damage to the engine or adversely affect performance CAUTION 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 Table A 1 are copper cable sizes recom mended 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 mini mizing cable voltage drop Table A 1 Combined Length of Electrode and Work Cables TOTAL COMBINED LENGTH OF ELEC TRODE AND WORK CABLES AMPS Up to 100 FT 100 200 FT 200 250 FT 60 to 30m 30m 61m 61m 76m Duty Cycle INSTALLATION A 5 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
26. e e Do not overfill tank fuel expansion may cause over flow DIESEL FUEL ONLY Fill the fuel tank with clean fresh diesel fuel The capac ity of the fuel tank is 22 5 gallons 85 1 liters See engine Operator s Manual for specific fuel recommendations NOTE Before starting the engine be sure the fuel shut off valve on the sediment bowl is open by turning the han dle counterclockwise SAE 400 SEVERE DUTY LINCOLN amp 4 INSTALLATION ENGINE BREAK IN Lincoln Electric selects high quality heavy duty indus trial engines for the portable welding machines we offer While it is normal to see a small amount of crankcase oil consumption during initial operation excessive oil use wetstacking oil or tar like substance at the exhaust port or excessive smoke is not normal Larger machines with a capacity of 350 amperes and higher which are operated at low or no load conditions for extended periods of time are especially susceptible to the conditions described above To accomplish suc cessful engine break in most diesel powered equip ment needs only to be run at a reasonably heavy load within the rating of the welder for some period of time during the engine s early life However if the welder is subjected to extensive light loading occasional moder ate to heavy loading of the engine may sometimes be necessary Caution must be observed in correctly loading a diesel generator unit 1 Connect the welder
27. e Engine Air Filter D 1 Bearing Commutator and Brush Maintenance D 2 Cooling System Fuel eee D 2 Water Separator Secondary Fuel Filter and Engine Components D 3 Spark Arrestor dd eidama RO K doe da E UR Roe ee ee D 4 GFCI Receptacle Testing and Resetting Procedure D 4 Troubleshooting Guide Section E Wiring Diagrams and Dimension Print Section F Parts LISIS ee De Se ele wre x Appendix SAE 400 SEVERE DUTY a C ea dd P399 Series SAE 400 SEVERE DUTY LINCOLN amp 1 INSTALLATION 1 TECHNICAL SPECIFICATIONS SAE 400 SEVERE DUTY INPUT DIESEL ENGINE Make Model Description Speed RPM Displacement Starting System Perkins 4 cylinder High Idle 1800 256 cu in 12VDC batteries Fuel 22 5 gal 1004 42 Diesel 71 HP Low Idle 1100 4 2 L 2 amp Starter 85 1 L Engine 1725 RPM Full Load 1725 Bore x Stroke Oil 8 5 Qts 8 04L 3 875 x 5 00 98 4 mm x 127 0mm Coolant 3 6 gal 13 63 L RATED OUTPUT WELDER 60 NEMA 400 amps 36 volts 60 Lincoln Plus 400 amps 40 volts OUTPUT WELDER AND GENERATOR 80 575 Amps 97 Max OCV 115 230 VAC 1800 RPM 3000 Watts 60 Hz 100 Duty Cycle PHYSICAL
28. e f r gute Be und Entl ftung des Arbeitsplatzes e Mantenha seu rosto da fuma a Use ventilac o e exhaust o para remover fumo da zona respirat ria eti AmP53U tRcocuc 9 fsUPBHEILTASESUCFEU e SH7IAE AAS AS 71974714 7 Q3 ge iua dL e c e Qa hia Ja d Aa qii e Lg Mail oe glaa uel Turn power off before servicing Desconectar el cable de ali mentaci n de poder de la maquina antes de iniciar cualquier servicio e D branchez le courant avant l entre tien Strom vor Wartungsarbeiten abschalten Netzstrom v llig ff nen Maschine anhalten e opere com as tampas removidas e Desligue a corrente antes de fazer servico e Nao toque as partes el tricas nuas XYVTFFYA H ERZKRU PY PRE ETBRATY FE DF I gt TKR e IE BIO BE Aia fl NM il gS jui ae Do not operate with panel open or guards off No operar con panel abierto o guardas quitadas N op rez pas avec les panneaux ouverts ou avec les dispositifs de protection enlev s Anlage nie ohne Schutzgeh use oder Innenschutzverkleidung in Betrieb setzen e Mantenha se afastado das partes moventes 20 opere com os paineis abertos ou guardas removidas e RJ L EUITFEL SERB 20 Sel E OAL Abiyi Gals D ali lin Ga
29. e lift pump The Secondary Fuel Filter is mounted directly to the engine just above the oil filter FUEL PRE FILTER WATER SEPARATOR ASSEMBLY The pre filter is a 150 micron screen designed to pro tect against gross fuel contamination of the water sep arator element and the Secondary Fuel Filter If the pre filter becomes plugged it may be removed inspect ed cleaned and reinstalled In general this only needs to be done with each water separator element change about every 1 000 hrs However if at any time exces sive fuel contamination is suspected or a sudden fall off in engine performance is detected the pre filter screen should be inspected and cleaned Follow the following procedure SAE 400 SEVERE DUTY LINCOLN 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 header Use a small screwdriver or similar device to lift the plug part way out of the cavity to assist with its removal Be careful not to damage the pre filter screen with the tool used to remove the plug 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
30. emiautomatic DC Constant Voltage Wire Welder DC Manual Stick Welder AC Welder with Reduced Voltage Control In semiautomatic or automatic wire welding the electrode electrode reel welding head nozzle or semiautomatic welding gun are also electrically hot 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 Ground the work or metal to be welded to a good electrical earth ground Maintain the electrode holder work clamp welding cable and welding machine in good safe operating condition Replace damaged insulation Never dip the electrode in water for cooling 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 When working above floor level use a safety belt to protect yourself from a fall should you get a shock Also see Items 6 c and 8 LINCOLN L Also see item 1 b 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 standards Use suitable clothing made from durable flame resistant material to protect your skin and that of your hel
31. er by pushing on the throttle control rods while the engine is running 2 4 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 SD Connect the work cable to the workpiece as close as possible to the area being welded 1 9 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 Do not work next to welding power source Mar 95 LINCOLN 5 3 b SAFETY e 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 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 S
32. ge the crankcase oil at regular intervals using the prop er grade of oil as recommended in the Engine Operating Manual Wash your hands with soap and water after handling used oil Please dispose of used motor oil in a manner that is compatible with the environment We suggest you take it in sealed container to your local service station or recycling center for reclamation Do not throw it in the trash pour it on the ground or down a drain ENGINE AIR FILTER The engine air filter element is a dry cartridge type It is located above the engine It can be cleaned and re used however damaged elements should not be washed or re used Remove loose dirt from element with compressed air or water hose directed from inside out Compressed Air 100 psi maximum The filter should never be removed while the engine is running SAE 400 SEVERE DUTY LINCOLN 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 pad of grease one inch wide one inch long and one inch high weighs approximately one half ounce Over greasing is far worse than insufficient greasing When greasing the bearings keep all dirt out of the area Wipe the fittings completely clean and use clean equipment More bearing
33. have been tions may be poor checked and the problem persists Contact your local Lincoln Wrong grade of brushes may be Authorized Field Service Facility installed on generator Field rheostat may be making poor contact and overheating Current Control may not be operating properly Current Control brushholder contact springs may be worn out or missing Contact surface may be dirty rough and pitted 10 Current Control brushholder support stud and mating contact surfaces may be dirty or pitted and burned Engine running at varying speeds A 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 SAE 400 SEVERE DUTY LINCOLN E 3 TROUBLESHOOTING E 3 Observe all Safety Guidelines detailed throughout this manual PROBLEMS POSSIBLE AREAS OF RECOMMENDED SYMPTOMS MISADJUSTMENT S COURSE OF ACTION Welder runs but fails to generate 1 Generator or exciter brushes may current be loose or missing Exciter may not be operating Field circuit of generator or exciter may be open Polarity reversing switch may be in the neutral position Exciter may have lost excitation If all recommended possible areas of misadjustment have been checked and the problem persists Welding arc is loud and s
34. he engine When the engine starts running watch for the oil pressure to build up If no pressure shows within 30 seconds stop the engine and consult the engine instruction manual BATTERY CHARGING AMMETER Displays the current going from the charging alternator into the batteries It is normal for charging current to be high above 15 amps after starting or when the batter ies are low on charge ENGINE HOUR METER The engine hour meter records the total running time on the engine in hours It can be used to keep a record of maintenance on the engine and or welder ENGINE PROTECTION SYSTEM The engine protection system shuts down the engine under high coolant temperature or low engine oil pres sure conditions by allowing the fuel solenoid valve to close AIR INTAKE SHUT OFF The air intake shut off is a manually engaged device that blocks all intake air from entering the engine To shut down the engine simply pull the emergency stop handle on the lower control panel The air intake shut off device must be reset manually inside the welder Place the ignition toggle switch in the OFF position Manually turn the air intake shut off reset handle such that the handle is in line with the air intake hoses The air intake shut off is located on the top of the engine between the muffler and air filter AWARNING Muffler and Engine may be hot IMPORTANT Before restarting engine verify that the air intake
35. ins Service Representative for any engine adjustments that may be required for high alti tude operation TOWING The recommended trailers for use with this equipment for in plant and yard towing by a vehicle are Lincoln s K767 1 K956 1 and K956 2 The K956 1 and K956 2 are also designed to be used at highway speeds 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 consid ered 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 highway use consult applicable federal state and local laws regarding specific requirements for use on public highways such as brakes lights fend ers etc VEHICLE MOUNTING A WARNING Improperly mounted concentrated loads may cause unstable vehic
36. le handling and tires or other compo nents to fail A 3 e Only transport this equipment on serviceable vehi cles which are rated and designed for such loads e Distribute balance and secure loads so vehicle is stable under conditions of use Do not exceed maximum rated loads for compo nents such as suspension axles and tires Mount equipment base to metal bed or frame of vehicle Follow vehicle manufacturer s instruction PRE OPERATION ENGINE SERVICE READ the engine operating and maintenance instruc tions supplied with this machine qe The engine is shipped with the engine crankcase filled with high quality SAE 10W 30 oil API class CD or bet ter Check the oil level 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 Operator s Manual 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 Operator s Manual for the proper service and maintenance intervals ENGINE OIL FUEL USE DIESEL FUEL ONLY e Stop engine while fueling Do not smoke when fueling Keep sparks and flame away from tank Do not leave unattended while fueling DIESEL FUEL e Wipe up spilled fuel and allow can cause fire fumes to clear before starting engin
37. line 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 amp Cutting ANSI Standard 249 1 from the American Welding Society 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 A A h To avoid scalding do not remove the powered equipment 9 0 radiator pressure when the engine is hot 1 Turn the engine off before troubleshooting and maintenance work unless the maintenance work requires it to be running 3 SX 1 b Operate engines in open well ventilated areas or vent the engine exhaust fumes outdoors ELECTRIC AND 3 mm MAGNETIC FIELDS 1 may be dangerous 1 c Do not add the fuel near an open flame weld ing arc or when the engine is running Stop the engine and allow it to cool before refuel ing to prevent spilled fuel from vaporizing on contact with hot engine pa
38. located on the GFCI recepta cle The night light or other product should go OFF Push the Reset button again The light or other product should go ON again 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 lift off cap 4 Separate plates and clean if necessary 5 Inspect plates and housing for holes or cracks Replace spark arrestor if damaged 6 Assemble spark arrestor using reverse order step 3 then step 2 If the light or other product remains ON when the Test button is pushed the GFCI is not working prop erly or has been incorrectly installed miswired If your GFCI is not working properly contact a qualified certi fied electrician who can assess the situation rewire the GFCI if necessary or replace the device For machines with integral spark arresting muf flers Service spark arrestor every 250 hours Service as follows 1 Stop engine and allow to cool 2 Remove clean out plug from the side of the spark arrestor 3 Without damaging the spark arrestor gently tap on the shell near the clean out plug 4 Once particles are removed replace the clean out plug SAE 400 SEVERE DUTY LINCOLN 1 TROUBLESHOOTING
39. 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 Mar 95 SAFETY 7 WELDING SPARKS gt cause fire or explosion 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 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 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 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
40. n the bottom of the filter header until the element no longer easily moves up into the filter header Now rotate the element may take almost 1 full turn with a slight upward pressure until the element begins to further engage the header With the proper orientation now established apply additional pressure to seat the ele ment in the filter header You should feel the element pop into place when properly seated Note The element will only go on one way Never use excessive force when mounting the element to the header 5 Slide the quick change ring up over the element and rotate counter clockwise until an audible click or pop is heard If you do not hear the click you have not rotat ed the ring far enough and the element is not in the locked position Another indication that the ring is in the locked position is that one set it doesn t matter which one of arrows located on the outside of the ring should be located directly under the air vent valve Open the fuel shutoff valve N Open the air vent valve on the front of the filter head er until fuel emerges free of air bubbles and then close the air vent valve Note Consult your engine operation manual for infor mation on air bleeding the entire fuel system SECONDARY FUEL FILTER The Secondary Fuel Filter has a quick change element mounted to the engine similar to the Water Separator Consult your engine operation manual for complete infor mation on service
41. nc REDRESSEUR Un coup d arc peut tre plus s v re qu un coup de soliel a Utiliser un bon masque avec un verre filtrant appropri ainsi qu un verre blanc afin de se prot ger les yeux du ray 1 onnement de et des projections quand on soude ou quand on regarde Porter des v tements convenables afin de prot ger la peau de soudeur et des aides contre le rayonnement de l arc Prot ger l autre personnel travaillant proximit au soudage l aide d crans appropri s et non inflammables Des gouttes de laitier en fusion sont mises de l arc de soudage Se prot ger avec des v tements de protection libres de l huile tels que les gants en cuir chemise paisse pan talons sans revers et chaussures montantes Toujours porter des lunettes de s curit dans la zone de soudage Utiliser des lunettes avec crans lateraux dans les LINCOLN Relier la terre le chassis du poste conformement au code de l lectricit et aux recommendations du fabricant Le dispositif de montage ou la piece souder doit tre branch une bonne mise la terre Autant que possible l installation et l entretien du poste seront effectu s par un lectricien qualifi Avant de faires des travaux l interieur de poste la debranch er l interrupteur la boite de fusibles Garder tous les couvercles et dispositifs de s ret leur place V V h mE for selecting a QUALIT
42. ne starting operating and maintenance instructions and parts lists e ELECTRIC SHOCK can kill Do not touch electrically live parts or electrodes with your skin or wet cloth ing Insulate yourself from the work and ground Always wear dry insulating gloves Do not use AC welder if your clothing gloves or work area is damp or if working on under or inside work piece Use the following equipment Semiautomatic DC constant voltage wire welder DC manual stick welder AC welder with reduced voltage con trol J ARC RAYS can injure eyes and J ini skin 2 e Wear eye ear and body protection Only qualified personnel should install use or service this equipment Consult instruction manual before operating Before operating read and understand the manu facturer 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 FUMES AND GASES can be dangerous to your health Keep your head out of fumes 40 Use enough ventilation or exhaust at the arc or both to keep the fumes and gases from your breathing zone and general area T WELDING SPARKS can cause X5 fire or explosion Do not weld near flammable material Do not weld on containers that have held flammable material MOVING PARTS can injure Keep away from moving parts Do not operate with doors open or guard
43. of the Job Selector dial For example when the Job Selector is set on the black range the approximate welding current is indi cated on the black scale of the Current Control dial 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 f you want a little more current turn the Job Selector up counterclockwise to increase cur rent If you want a little less current turn the Job Selector down clockwise to decrease current 5 f dialing the desired current with the Job Selector moves the setting outside the black range causing undesirable arc characteristics turn the Job Selector back to the center of the black range Then turn the Current Control up or down a little as needed Readjust the Job Selector for the exact characteristics and current desired REMOTE CONTROL A receptacle and Local Remote control switch on the lower front control panel and a remote control box with 100 ft 30 5 m of cord for adjusting the OCV at the welding site are standard Putting the switch in the REMOTE position allows fine current control at the remote control box while placing the switch in the LOCAL position allows fine current control at the Job Selector on the machine AUX
44. ous adjustment of both voltage and current for unsurpassed welds on demanding jobs Remote control capability standard FOR AUXILIARY POWER 3 000 watts of 115 230 VAC 60 Hz auxiliary power One 20 amp 115 VAC duplex receptacle for up to 26 amps of 115 VAC power One 15 amp 230 VAC duplex receptacle for up to 13 amps of 230 VAC power Weld and AC auxiliary power at the same time with in the limits shown on the chart below Welding Current Amps NEMA Arc Volts Using Only 115V Circuit Amps Using Only 230V Circuit Amps 26 OTHER FEATURES e Perkins 4 cylinder water cooled diesel engine Designed for long life easy maintenance and excel lent fuel economy Engine protection system shuts the engine down for low engine oil pressure or high coolant temperature Electronic Engine Idler Engine automatically goes to low idle in 10 to 14 seconds after welding or use of auxiliary power stops Includes high idle switch Gauges for engine oil pressure coolant temperature and battery charging ammeter Engine hour meter standard Extended range 22 5 gallon 85 1 L fuel tank DUTY CYCLE Duty cycle is based on a ten minute period and opera tion in an ambient temperature of 104 F 40 C The SAE 400 SEVERE DUTY IS NEMA rated at 6096 duty cycle Duty cycle is based on a ten minute period Therefore a 6096 duty cycle welder can be operated at nameplate rated output for 6 minu
45. output studs to a suit able resistive load bank Note that any attempt to short the output studs by con necting the welding leads together direct shorting of the output studs or connecting the output leads to a length of steel will result in catastrophic damage to the gener ator and voids the warranty 2 Set the welder controls for an output cur rent and voltage within the welder rating and duty cycle Note that any attempt to exceed the welder rating or duty cycle for any period of time will result in catastrophic damage to the generator and voids the warranty 3 Periodically shut off the engine and check the crankcase oil level ENGINE COOLING SYSTEM The cooling system has been filled at the factory with a 50 50 mixture of ethylene glycol antifreeze and water Check the radiator level and add a 50 50 solu tion as needed See Engine Manual or antifreeze container for alternate antifreeze recommendation A 4 BATTERY CONNECTION WARNING 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 if unused for several months the batteries may require a booster charge Be careful to charge the batteries with the correct polarity Make sure that the batteries are level while charging A WARNING 4
46. patters Series field circuit may be open Contact your local Lincoln excessively circuited Authorized Field Service Facility 2 Current setting may be too high 3 Polarity may be wrong 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 SAE 400 SEVERE DUTY LINCOLN 4 TROUBLESHOOTING E 4 Observe all Safety Guidelines detailed throughout this manual PROBLEMS POSSIBLE AREAS OF RECOMMENDED SYMPTOMS MISADJUSTMENT S COURSE OF ACTION Welding current too great or too Current Control shaft and han small compared to indication on the dle may have turned slightly in dial the insulated bushing of the cur rent control brushholder caused by turning handle too hard against one of the stops Exciter output low causing low output compared to dial indica tion Current Control set to minimum and welder output so great that engine stalls when arc is struck Welder has output and no control Local Remote switch is in wrong If all recommended possible areas position of misadjustment have been checked and the problem persists Contact your local Lincoln Authorized Field Service Facility No auxiliary power GFCI Receptacle may have tripped Follow GFCI Receptacle Testing and Resetting Procedure
47. pers from the arc rays 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 23 FUMES AND GASES can be dangerous 5 a Welding may produce fumes and gases hazardous to health Avoid breathing these fumes and gases When welding keep your head out of the fume Use enough ventilation and or exhaust at the arc to keep fumes and gases away from the breathing zone When welding with electrodes which require special ventilation such as stainless or hard facing see instructions on container or MSDS or on lead or cadmium plated steel and other metals or coatings which produce highly toxic fumes keep exposure as low as possible and below Threshold Limit Values TLV 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 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 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 Read and understand the
48. rators 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 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 LINCOLN TABLE OF CONTENTS Page Installation Instructions Section A Technical Specifications A 1 Installation Precautions A 2 Location Ventilation A 2 Stacking PC PITT A 2 Angle of A 2 ut waar eure oy eMedia ee A 2 High Altitude Operation A 3 TOWING 2 cc datas oe seed whee edi A 3 Vehicle Mounting A 3 Pre Operation Engine Service A 3 Engine Me Mae MO A 3 d PC A 3 Engine Break In Engine Cooling System 4 Battery Connection
49. rman WARNUNG ATEN AO BIR Chinese Korean Do not touch electrically live parts or electrode with skin or wet clothing Insulate yourself from work and ground No toque las partes los electrodos bajo carga con la piel o ropa moja da Aislese del trabajo y de la tierra Ne laissez ni la peau ni des v te ments mouill s entrer en contact avec des pi ces sous tension Isolez vous du travail et de la terre e Ber hren Sie keine stromf hrenden Teile oder Elektroden mit Ihrem K rper oder feuchter Kleidung Isolieren Sie sich von den Elektroden und dem Erdboden e toque partes el tricas e elec trodos com a pele ou roupa molha da Isole se da e terra eod EmBOBaum ELE het EE LATE 7 EECH E SE O amp 5B C EXEAT PETER Saiss Xe uc iss AU ne e Ss Hz B Au W Git ell quali Y O el ai ay zial DS dan moe Keep flammable materials away Mantenga el material combustible fuera del rea de trabajo Gardez l cart de tout mat riel inflammable Entfernen Sie brennbarres Material Mantenha inflamaveis bem guarda dos CORRES MMIC UTHEW ECA ein OSTEN LS Aal ule Am Aal Wear eye ear and body protection
50. rts and igniting Do not spill fuel when filling tank If fuel is spilled wipe it up and do not start engine until fumes have been eliminated 2 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 EMF fields may interfere with some pacemakers and welders having a pacemaker should consult their physician before welding 1 d Keep all equipment safety guards covers and devices in posi tion and in good repair Keep hands hair clothing and tools away from V belts gears fans and all other moving parts 3 f Exposure to fields welding may have other health when starting operating or repairing equipment effects which are now not known All welders should use the following procedures in order to 1 In some cases it may be necessary to remove safety dd px minimize exposure to EMF fields from the welding circuit 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 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 1 f Do not put your hands near the engine fan Do not attempt to override the idl
51. s off Stop engine before servicing ENGINE EXHAUST can kill Use in open well ventilated areas or f e vent exhaust outside ADDITIONAL SAFETY PRECAUTIONS Always operate the welder with the hinged doors closed as these provide maximum protection from moving parts and insure proper cooling air flow Read carefully the Safety Precautions page in the Instruction Manual before operating this machine Always follow these and any other safety procedures included in this manual and in the engine and com pressor instruction manuals GENERAL DESCRIPTION The SAE 400 SEVERE DUTY is a diesel engine driven welding power source The machine uses a DC gener ator for DC stick electrode welding and an AC exciter for 115 230 VAC auxiliary power As a generator it can supply up to 3 000 watts of 115 230 volt AC power As a welder it provides up to 575 amps of DC constant current output The engine is a 71 Hp 54kw 4 cylinder water cooled diesel made by Perkins RECOMMENDED APPLICATIONS WELDER The SAE 400 SEVERE DUTY provides excellent con stant current DC welding output for stick SMAW weld ing AUXILIARY POWER The SAE 400 SEVERE DUTY provides 3 KW of 115 230 VAC output for auxiliary power and emer genoy standby power SAE 400 SEVERE DUTY LINCOLN P 2 2 DESIGN FEATURES AND ADVANTAGES FOR STICK WELDING Excellent DC constant current output for stick weld ing applications Continu
52. ser la pince une endroit isol de la masse Un court circuit accidental peut provoquer un chauffement et un risque d incendie S assurer que la masse est connect e le plus pr s possible de la zone de travail qu il est pratique de le faire Si on place la masse sur la charpente de la construction ou d autres endroits loign s de la zone de travail on augmente le risque de voir passer le courant de soudage par les chaines de levage c bles de grue ou autres circuits Cela peut provoquer des risques d incendie ou d echauffement des chaines et des c bles jusqu ce qu ils se rompent Assurer une ventilation suffisante dans la zone de soudage Ceci est particuli rement important pour le soudage de t les galvanis es plomb es ou cadmi es ou tout autre m tal qui produit des fume s toxiques Ne pas souder en pr sence de vapeurs de chlore provenant d op rations de d graissage nettoyage ou pistolage La chaleur ou les rayons de l arc peuvent r agir avec les vapeurs du solvant pour produire du phosg ne gas fortement toxique ou autres produits irritants 11 Pour obtenir de plus amples renseignements sur la s ret voir le code Code for safety in welding and cutting CSA Standard W 117 2 1974 contre les chutes dans le cas ou on recoit un choc Ne jamais PR CAUTIONS DE S RET POUR enrouler le c ble lectrode autour de n importe quelle partie pes LES MACHINES SOUDER TRANSFORMATEUR ET do
53. shut off is in the open position DO NOT ATTEMPT TO START ENGINE WITH THE AIR INTAKE SHUT OFF IN THE CLOSED POSITION This may cause severe damage to the engine SAE 400 SEVERE DUTY LINCOLN P B 4 OPERATION B 4 WELDER CONTROLS POLARITY SWITCH Turn 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 the continuous Open Circuit Voltage adjuster Open Circuit Voltage OCV controls the arc characteristics Job Selector The Job Selector dial is divided into four colored sec tions providing OCV ranges as follows OCV Range Large Electrodes Normal Welding High OCV Medium OCV Low OCV Extra Low OCV Overhead amp Vertical Special Applications The Job Selector is usually set in the black range because it provides a soft Buttering arc desired for most welding Some operators prefer to set the Job Selector in the red range for a snappy Digging arc when welding vertical up or overhead Current Control CAUTION Do not adjust the Current Control while welding because this can damage the control The Current Control dial is calibrated in amperes on three separate colored dials corresponding to the white black and red ranges
54. tes out of every 10 minute period without overheating The auxiliary power can be used continuously 10096 duty cycle within its rated current capacities SAE 400 SEVERE DUTY LINCOLN P 3 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 position the engine will run continuously at hig idle lt gt When in AUTO operates as follows idle position the idler a Welding When the electrode touches the work the welding arc is initiated and the engine accelerates to full speed After welding ceases and no auxiliary power is being drawn the engine will return to low idle after approximately 10 to 14 seconds b Auxiliary Power With the engine running at low idle and auxiliary power for lights or tools is drawn approximately 100 150 watts or greater from the receptacles the engine will accelerate to high speed If no power is being drawn from the receptacles and not weld ing for 10 14 seconds the idler reduces the engine speed to low idle ENGINE TEMPERATURE GAUGE Displays the coolant temperature in the engine block ENGINE OIL PRESSURE GAUGE Displays the oil pressure to t
55. these brushes by lightly stoning the commu tator as the armature rotates at full speed until contact is made across the full face of the brushes After ston ing blow out the dust with low pressure air To seat the slip ring brushes position the brushes in place Then slide one end of a piece of fine sandpaper between slip rings and brushes with the coarse side against the brushes Pull the sandpaper around the cir cumference of the rings in direction of rotation only until brushes seat properly In addition stone slip ring with a fine stone Brushes must be seated 100 Arcing or excessive exciter brush wear indicates a pos sible misaligned shaft Have an authorized Field Service Shop check and realign the shaft COOLING SYSTEM The SAE 400 SEVERE DUTY is equipped with a pres sure radiator Keep the radiator cap tight to prevent loss of coolant Clean and flush the cooling system periodically to prevent clogging the passage and over heating the engine When antifreeze is needed always use the permanent type FUEL FILTERS WARNING When working on the fuel system H e Keep ungrounded lights away do not 4 smoke e Do not spill fuel The SAE 400 SEVERE DUTY is equipped with a Fuel Pre Filter Water Separator Assembly located before the lift pump and a Secondary Fuel Filter located after the lift pump and before the fuel injectors The Fuel Pre Filter Water Separator is mounted to the engine block just below th
56. truck or subjected to physical damage e A safe distance from arc welding or cutting operations and any other source of heat sparks or flame Never allow the electrode electrode holder or any other electrically hot parts to touch a cylinder Keep your head and face away from the cylinder valve outlet when opening the cylinder valve Valve protection caps should always be in place and hand tight except when the cylinder is in use or connected for use Read and follow the instructions on compressed gas cylinders associated equipment and CGA publication 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 Install equipment in accordance with the U S National Electrical Code all local codes and the manufacturer s recommendations Ground the equipment in accordance with the U S National Electrical Code and the manufacturer s recommendations iv SAFETY PR CAUTIONS DE S RET Pour votre propre protection lire et observer toutes les instructions et les pr cautions de s ret specifiques qui parraissent dans ce manuel aussi bien que les pr cautions de s ret g n rales suiv antes S ret Pour Soudage A L Arc 1 Protegez vo
57. us contre la secousse lectrique a Les circuits l lectrode et la pi ce sont sous tension quand la machine souder est en marche Eviter toujours tout contact entre les parties sous tension et la peau nue ou les v tements mouill s Porter des gants secs et sans trous pour isoler les mains Faire tr s attention de bien s isoler de la masse quand on soude dans des endroits humides ou sur un plancher met allique ou des grilles metalliques principalement dans les positions assis ou couch pour lesquelles une grande partie du corps peut tre en contact avec la masse Maintenir le porte lectrode la pince de masse le c ble de soudage et la machine souder en bon et s r tat defonc tionnement d Ne jamais plonger le porte lectrode dans l eau pour le refroidir Ne jamais toucher simultan ment les parties sous tension des porte lectrodes connect s deux machines soud er parce que la tension entre les deux pinces peut tre le total de la tension vide des deux machines Si on utilise la machine souder comme une source de courant pour soudage semi automatique ces precautions pour le porte lectrode s applicuent aussi au pistolet de soudage 2 Dans le cas de travail au dessus du niveau du sol se prot ger 6 zones l on pique le laitier Eloigner les mat riaux inflammables ou les recouvrir afin de pr venir tout risque d incendie aux tincelles Quand on ne soude pas po
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