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Lincoln Electric IM869-D User's Manual

Contents

1. Section Technical Specifications A 1 Installation Precautions A 2 Location Ventilation dus on dan dd mandat SEA A 2 cud A 2 Angle of Operation A 2 LINO teva EROR A 2 High Altitude Operation A 3 Towing seem mmm efe nme eee ea cade or Rang Qu a A 3 Vehicle Mounting A 3 Pre Operation Engine and Compressor Service A 3 EE A 3 d 4 Engine Cooling System A 4 Break In Period NIE e TEE csser bee rwn bU ere ee A 4 Battery Connection A 4 Spark Arrester seas aude she ge eee DUX Re A 5 Welding Output Cables A 5 Machine Grounding A 5 Operating Instructions Section B Safety Instructions B 1 Additional Safety Precautions B 1 General Description
2. 7 5 s 1 907 ck 1034NOO SLOWSY KO 01201304 HOLIMS 9 dose vor 2 9 19 5 80 D 1 HOLIMS EI NOILINOI 3NI9N3 49 HOLIMS lp dis GION310S er S9N1d MOT 009 1905 Loos 8 9 9 L d HOLIMS lt 85 319v143934 amp TOHINO9 SLOWSY YOLSISSY ONY 30010 9NiHSY 1 H3 NHO3SNVH L ANSYYND OL H313INO LN31Od 00 64 310W3H 31IHWM NMOH amp N 4 ane n N3349 9 1H T NO 3874 A349 YO X9V 18 8 9 3009 9 qv31 ss HALHWOLNLOd t SUOLSISSY a TOYINOD SLOWSY Ca 9 OO 9 4 10 4 LH 9 TOUNO SLOWSY 308099 V8 JYLNIN W130 335 94 3NION3 H3T03NION3 OL Q3193NNOO SQV31 OL WHLNAN IMIA S
3. B 1 Recommended Applications B 2 er B 2 Auxiliary suse eee diriu e B 2 Product Application B 2 Design Features and Advantages B 2 D ty Pe B 2 Engine Controls Function Operation B 3 Welder Controls Function Operation B 3 Remote B 4 Auxiliary Power 5 B 4 Engine Operation B 5 Starting Instructions B 5 Typical Fuel Consumption B 6 AccessOrles 2254 2824 NIE EIERE ux RR EP eee eee Section C Maintenance ee ee ee Section 0 Routine D 1 Periodic Maintenance D 1 Pre Filter Washer D 2 Water Separator Element D 3 Engine Maintenance Components D 4 S
4. NMOH8 N aman N3349 9 038 4 A349 HOV19 4 3002 Qv31 fW 308029 JYLNIN 3NV41 OL TIVHLO3N HANHOASNVEL JIN3yddno OL MOT 98 d OO 4 0p 6x 81 L 9 VP gy Po E el 335 Od 3NION3 d3103NION3 OL GALOSNNOO SQV31 WOH GAMSA SY NMOHS SLN3NQHWOO T3NVd TDHLNOI Z0r VL 3803 HO NVA9DVIQ ONIAIM 500 AVS 00 AVS SAE400 LINCOLN WIRING DIAGRAM F 4 F 4 Sjeued JO euo UO SUIYOeW y episui paysed si epoo jejnomaed e 10 2 ou si Aq sauluoeui 10 eleJnooe eg jou 10 S SIUL 310 HOLMS ONISN3S JNayxno 3 9 8 Mo 300519919 OL ej oh ve oor vo 119VId3934 YOZ VOZ 00801 89 689 pro LU 3onvo t opa aiovldaoay M3ONSSIHOLMS res 90M YIMOd 0853 110 9 HOLIMS S WNINH3L DOM d IHYTOd 40 HoloWa OI ED IN 95 saan 002 MAA MOVE N S09 ESA gz 20 3onvo
5. Midi OL HOLIMS ANY 319V1d3934 TOHINO9 SLOWSY D dns 80104 YOLVNYSLIV ZC i YOLVNYSLTV 3anSS3yd Q 110 USON3S HOLIMS 853 10 eor 002 9 Jlo EE Eed V WON 4 VIS 8 5 ad 9 WELZ 65 vor o 95 M3ON3SIHOLIMS 89 3HnlLvd3dA3L HOLIMS 3N ENZ 8 HOLIMS EER NOILINOI 18 9 6 8 dcc OO OS NOILOSPNI 1903 0 6 uewe lt gt ANISNA 89 lt H8G We YOLSISSY ANY 30010 ONIHSV14 S9N1d MOT YALAWOLLNALOd OHINO9 SLOWSY HO 9frTd 3578 OL LOANNOO H XO SLOWSY X08 YALSWOLLNSLOd TOHINO9 SLOWSY SYOLSISSY 31IHWM NMOUE N EES YO 3474 A389 188 3009 40109 Qv31 AGYODOWY 38103N OL WHLNAN HANHOASNVAL JN3ydydno 01 0 64 8 Loa 9x4 99 VP gy l m eg C qdvog 9 d NOLLO31Od 3NION3 3 p D
6. 1 f Do not put your hands near the engine fan Do not attempt to override the governor or idler by pushing on the throttle control rods while the engine is running 2 d 3 Do not place your body between the electrode and work cables If the electrode cable is on your right side the work cable should also be on your right side 2 d 4 Connect the work cable to the workpiece as close as possible to the area being welded 1 g To prevent accidentally starting gasoline engines while turning the engine or welding generator during maintenance work disconnect the spark plug wires distributor cap or magneto wire as appropriate 2 d 5 Do not work next to welding power source Mar 95 LINCOLN i ELECTRIC SHOCK can kill 3 a The electrode and work or ground circuits are electrically hot when the welder is on Do not touch these hot parts with your bare skin or wet clothing Wear dry hole free gloves to insulate hands 3 b Insulate yourself from work and ground using dry insulation Make certain the insulation is large enough to cover your full area of physical contact with work and ground In addition to the normal safety precautions if welding must be performed under electrically hazardous conditions in damp locations or while wearing wet clothing on metal structures such as floors gratings or scaffolds when in cramped positions such as sitting kneeling or lying
7. Current Control A 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 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 SAE 400 LINCOLN P B 4 OPERATION 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 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 If 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 contro
8. Do not use AC welder if your clothing gloves work area is damp or if working on under or inside workpiece Use the following equipment e Semiautomatic DC constant voltage wire welder DC manual stick welder AC welder with reduced voltage control ARC RAYS injure eyes and burn skin 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 facurer 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 e Keep your head out of fumes e Use enough ventilation or exhaust at the arc or both to keep the fumes and gases TEK from your breathing zone and general area WELDING SPARKS can cause fire or explosion Do not weld near flammable material not weld on containers that have held flammable material 23 MOVING PARTS can injure Keep away from moving parts fr Do not operate with doors open guards off Stop engine before servicing ENGINE EXHAUST can kill Use in open well ventilated areas or vent exhaust outside ADDITIONAL SAFETY PRECAUTIONS Always operate the welder with the hinged doors closed a
9. eu episui paysed s epoo 10 5 si Aq peJeAoo 10 jou AIuo 104 S siu 310 OL9V34 IM 3MOd VI r4 3719193235 2890 AEZ w 200 vi X3 Mna TV STVNINYSL ALIHM d8 od EEN H313NOIN310d SLOWSY 91 Xo HOLIMS CNV 319v143934 OHINOO SLOWSY gt dis YJANIS H LIMS 853 110 9c OIM v YS 9 YOLVNYSL TV 3ynSS3yd 39nvo 10 EIER 002 9212 WON 39nv9 vy SYNLWYAdWAL Cd 96 amp lo APA M 9 YIANIS H LIMS JYNLYYJdNIL Oo ME HOLIMS EE GION310S IER And NOLLO3PNI 1904 NOILINOI L G AN9 6 9 uosuas dWAL ANION3 85 amp j4 e H313WOLLN310d l ONG 31034 To TOYINOD 31034 YOLSISAY ANY 30010 ONIHSV14
10. SAE 400 LINCOLN amp 2157105 978 4kg 2 INSTALLATION A 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 ELECTRIC SHOCK can kill Do not touch electrically live parts such as output terminals or internal wiring Insulate yourself from the work and ground Always wear dry insulating gloves ENGINE EXHAUST can kill Use in open well ventilated areas or vent exhaust outside Do not stack anything near the engine MOVING PARTS can injure Do not operate with doors open or N guards off Stop 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 A CAUTION DO NOT MOUNT OVER COMBUSTIBLE SURFACES Where there is a combustible surface directly under stationary or fixed electrical equipment that surface should be covered with a
11. rea de trabajo Gardez l cart de tout mat riel inflammable Entfernen Sie brennbarres Material e Mantenha inflam veis bem guarda dos edavo ve 008COSB amp TES EVA e 18 5 ftbi LIFE MT o ess Sais Aal Juni ALIM al gl e Wear eye ear and body protection 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 e BH eben HRSSUEGERR die de amp y ques cl el D 3 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 UNFALLVERH TUNGSVORSCHRIFTEN DES ARBEITGEBERS SIND EBENFALLS ZU BEACHTEN SAE 400 LINCOLN 5 gui LINCOLN World s Leader in Welding and Cutting Products Sales and Service through Sub
12. 11V130 395 Od 3NION3 H3TUSNION3 OL GALOSNNOO 50747 uva IMIA SY NMOHS SIN3NOJWOO TANVd TOHINOO 8611 33002 401 WVYSVIC 9NIHIM 5 AVS 00 AVS 400 2 Sjeued JO euo uo episui paysed si epoo 1e norued 10 5 ou siy Aq 10 eq jou uo 10 S 5141 310 LZVLLCIN 073M 300419313 OL gr WSL vo be 182 VOZ SECH 89 82 xsnana noez 39nv9 MWJONJSIHOLMS oss IM 43MOd z3lxandna AsLL 394055335410 9 10 HOLIMS SM ALBIY Od E HOLVNEL TV SMM Cor M L emm xovg 002 A woe masose oe er 9 vos 3Hnlvd3dN3l t 8 NEE HOLIMS DO NOUISOd WOOTNI ALIHY1Od 401901 HOLIMS 6 095 WIRING DIAGRAM F 2 Ww 009 0 HOLIMS ANY 3107198034 TOHINO9 3
13. 3 GFCI Receptacle if installed mayl3 Follow GFCI Receptacle Testing have tripped and Resetting Procedure in the MAINTENANCE section of this manual 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 LINCOLN P F 1 WIRING DIAGRAMS F 1 e VvSOcIN TWNIWYSL 300419413 YHOM OL HOLIMS ALISV Od 20 MOVE NOlISOd TWOOTNI ALINW1Od NMOHS TOHINO9 SLOWSY 01V901 401 HOLIMS Sjeued euo UO y episui paysed si epoo jejnomaed 10 2 UL siy Aq p918A09 Seuldoeu 10 eleJnooe eg jou AIuo 10 S 5141 3 LON 5 SOLO N IM f YOLVNYSLTV md 182 va 3719v143934 XIN Y K cao PT nor voz 0 8 y 90 p 131913933 c3 Xa ana ASIE STVNINYSL 31IHM 1VLSO3HH HOLIMS 8d 9 lt 94 a dd Od
14. Use suitable clothing made from durable flame resistant material to protect your skin and that of your helpers 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 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 9 The operation of welding fume control equipment is affected by various factors including proper use and positioning of the equipment maintenance of the equipment and the specific welding procedure and application involved Worker expo sure level should be checked upon installation and periodi cally thereafter to be certain it is within appl
15. any load and check it for damage If 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 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 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 SAE 400 LINCOLN E 1 TROUBLESHOOTING E 1 HOW TO USE TROUBLESHOOTING GUIDE A 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 you
16. clockwise approximately 1 2 turn andslide it down and off of the element 3 Grasp the element and pull down with a slight rocking motion to remove the element from the grommet post on the bottom of the filter header SAE 400 LINCOLN D 4 MAINTENANCE D 4 4 Slide the new element onto the grommet post on 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 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 rotated 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 Remove the see through bowl from the old element and install on the new element 7 Open the fuel shutoff valve Open the air vent valve on
17. if there is a high risk of unavoidable or accidental contact with the workpiece or ground use the following equipment Semiautomatic DC Constant Voltage Wire Welder DC Manual Stick Welder AC Welder with Reduced Voltage Control 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 5 5 f AUG 06 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 287 standards
18. negative cable from old battery first and connect to new battery last CONNECTING A BATTERY CHARGER remove battery from welder by disconnecting negative cable first then positive cable and battery clamp When reinstalling connect SAE 400 LINCOLN P A 5 negative cable last Keep well ven gt tilated e USING A BOOSTER connect positive lead to battery first then connect negative lead to negative battery lead at the lower control panel support BATTERY ACID can burn eyes and skin 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 A WARNING b Using a booster Use correct polarity Negative Ground To prevent BATTERY BUCKLING tighten nuts on batteries only until snug DO NOT OVERTIGHTEN e Spark Arrester and Muffler may be hot Allow engine to cool before servicing spark arrester Do not operate engine while servicing spark arrester SPARK ARRESTER U a Some federal state or local laws may require that gasoline or diesel engines be equipped with exhaust spark arresters when they are operated in certain loca tions where unarrested sparks may present a fire haz ard The muffler included with this welder has been A CAUTION modified and now qualifies as a spark arrester Spark arresting mufflers will have a clean out servic
19. 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 and K956 1 The K956 1 is also designed to be used at highway speeds H the user adapts non Lincoln trailer he must assume responsibility that the method of attachment and usage does not result in a safety hazard nor damage the welding equipment Some of the factors to be considered are as follows 1 Design capacity of trailer vs weight of Lincoln equipment and likely additional attachments 2 Proper support of and attachment to the base of the welding equipment so that there will be no undue stress to the trailer s framework 3 Proper placement of the equipment on the trailer to insure stability side to side and front to back when being moved and when standing by itself 4 Typical conditions of use such as travel speed roughness of surface on which the trailer will be operated and environmental conditions 5 Proper preventative maintenance of trailer 6 Conformance with federal state and local laws 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 vehicle handling and tires or other compo nents to fail Only transport this equipment on serviceabl
20. attempt to use this equipment until you have thoroughly read the engine manufacturer s manual supplied with your welder It includes important safety precautions detailed engine starting operating and maintenance instructions and parts lists ELECTRIC SHOCK can kill Do not touch electrically live parts or electrode with skin or wet clothing Insulate yourself from work and ground Always wear dry insulating gloves ENGINE EXHAUST can kill Use in open well ventilated areas or vent exhaust outside MOVING PARTS can injure Do not operate with doors open guards off Stop engine before servicing Keep away from moving parts See additional warning information at the front of this operator s manual 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 A CAUTION Do not adjust the high idle engine speed rpm above the factory setting specification as this will void warranty STARTING INSTRUCTIONS Be sure all Pre Operation Maintenance has been performed See INSTALLATION section of this manual 1 Turn the IDLER switch to HIGH 2 Turn the IGNITION switch to ON 3 Press the Glow Plug button for 20 to 30 seconds maximum 60 seconds 4 Press the Glow Plug and the Start button at the same time When the engine starts running re
21. brushholder Inspect Replace needed parts contact springs may be worn out Clean internal contact surface of or missing Contact surface may control device Do not lubricate be dirty rough and pitted Smooth rough surfaces 10 Current Control brushholder 10 If brushholder internal contact support stud and mating contact surface is pitted and burned surfaces may be dirty or pitted replace the brushholder and and burned support stud If the contact sur face is dirty clean off the brush holder stud and internal contact surface Apply mixture of three parts silicone grease and one part zinc powder by weight to stud Engine running at varying Set welder controls for maximum speeds output and weld Then while welding check engine rpm The engine should be running at full speed If indicator shows a sig nificant difference consult your engine manual 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 LINCOLN E 3 TROUBLESHOOTING E 3 Observe all Safety Guidelines detailed throughout this manual PROBLEMS POSSIBLE RECOMMENDED SYMPTOMS CAUSE COURSE OF ACTION FUNCTION PROBLEMS Welder runs but fails to generate Generator or exciter brushes may 1 Be sure that all brushes bear on current be loose or mi
22. e Desconectar el cable de ali mentaci n de poder de la m quina 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 opere com as tampas removidas e Desligue a corrente antes de fazer servico e toque as partes el tricas nuas e X 7TTL7A Y5 UAUCBRUD FE LFM2TFS e 1SH AHS HHA SL J dall e 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 opere com os paineis abertos ou guardas removidas ex o2 amp WRU U7 do Gel Yee Sal OM AIS Gils 13 jlgall l a Ja Y e Cul AUI d Spanish AVISO DE PRECAUCION French ATTENTION German WARNUNG Chinese LEIA E COMPREENDA AS INSTRU ES DO FABRICANTE PARA ESTE EQUIPAMENTO E AS PARTES DE USO E SIGA AS PRATICAS DE SEGURANCA DO EMPREGADOR KE CEET EE CEA BEKI TRHORARMEK EDT FEU ER EE AR DO D RO BA LL FEE
23. item 1 c Read and folllow NFPA 51B Standard for Fire Prevention During Welding Cutting and Other Hot Work available from NFPA 1 Batterymarch Park PO box 9101 Quincy Ma 022690 9101 Do not use a welding power source for pipe thawing LINCOLN 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 from areas where they may be struck or subjected to physical damage 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 Ar
24. 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 SAE 400 LINCOLN D 3 MAINTENANCE D 3 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 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 For codes below 11409 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 inter
25. 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 PR CAUTIONS DE S RET POUR contre les chutes dans le cas ou on recoit un choc Ne jamais LES MACHINES SOUDER enrouler le c ble lectrode autour de n importe quelle partie du TRANSFORMATEU R ET 2 Dans le cas de travail au dessus du niveau du sol se prot ger corps REDRESSEUR Un coup d arc peut tre plus s v re qu un coup de soliel donc a Utiliser un bon masque avec un verre filtrant appropri ainsi 1 qu un verre blanc afin de se prot ger les yeux du rayon nement de l arc et des projections quand on soude ou quand on regarde l arc b Porter des v tements convenables afin de prot ger la peau de soudeur et des aides contre le rayonnement de l arc c Prot ger l autre personnel travaillant proximit au soudage l aide d crans appropri s et non inflammables 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 installati
26. the front of the filter header until fuel emerges free of air bubbles and then close the air vent valve Note Consult your engine operation manual for information on air bleeding the entire fuel system ENGINE AND COMPRESSOR MAINTENANCE COMPONENTS ITEM MAKE PART NUMBER Engine Air Filter P822768 Fuel Filter 26560201 Engine Oil Filter 2654407 Water Separator Element Codes Lincoln M16890 C below 11409 Fuel Pre Filter Screen Lincoln M16890 B Pre Filter Water Lincoln M21584 B Separator Element Codes Stanadyne 39420 LE 11409 and higher Note No Pre filter Screen required on codes 11409 and higher SPARK ARRESTOR A WARNING Spark Arrester and Muffler may be hot Allow engine to cool before servicing spark arrester not operate engine while servicing spark arrester Ea SAE 400 with integral spark arresting mufflers Service spark arrester every 250 hours Service as follows 1 Stop engine and allow to cool 2 Remove clean out plug from side of spark arrester 3 Without damaging the spark arrester gently tap on the arrester shell near the clean out plug 4 Once particles are removed replace the clean out plug GFCI RECEPTACLE TESTING AND RESET TING PROCEDURE The GFCI receptacle should be properly tested at least once every month or whenever it is tripped To proper ly test and reset the GFCI receptacle If the receptacle has tripped first carefully remove
27. yard towing with E78 14 load range B tube less tires Mounts directly to welder base Not for use on the road Comes standard with a Duo Hitch a 2 Ball and Lunette Eye combination hitch K2637 1 Trailer A 2 wheel trailer designed for road off road in plant and yard towing Trailer mounts directly to welder base Comes standard with a Duo Hitch 2 Ball and Lunette Eye combination hitch Order K2636 1 Trailer K2639 1 Fender amp Light Kit K2640 1 Cable Storage Rack 1For highway use consult applicable federal state and local laws regarding possible requirements for brakes lights fenders etc A WARNING Pipe Thawing with an arc welder can cause fire explosion damage to electric wiring or to the arc welder if done improperly The use of an arc welder for pipe thawing is not approved by the CSA nor is it recommended or supported by Lincoln Electric K704 Standard Accessory Kit Includes electrode and work cables headshield work clamp and elec trode holder K385 CV Adapter Provides constant voltage out put for semiautomatic welding Field installation only K1690 1 GFCI RECEPTACLE KIT Includes one UL approved 120V ground fault circuit interrupter duplex type receptacle with cover and installation instructions Replaces the factory installed 120V duplex receptacle Each receptacle of the GFCI Duplex is rated at 20 Amps the maximum total current from the GFCI Duplex is limited to the 20
28. 10W3H 3SV8 OL LOANNOO jew dis 80104 YOLVNYSLTV NMOHS TOYJNOD SLOWSY M iS in rara vol wi dm 3Hnlvd3dN3l HOLIMS NOILINS 3NI9N3 O 0 VVv8 HOLIMS EENG GION3IOS And NOILOSPNI 1904 YNOH 862 3NISN3 MOT YOLSISSY ANY 3010 ONIHSY14 Xog YSLAWOLNALOd OHINO9 SLOWSY 31IHWM NMOS8 N 3019 0 N3349 9 YO Q33 8 A349 H9V19 4 SYOLSISSY YILINWOLNILOd JOUINOD SLOWSY ON Id 9 xo TOYINOD SLOWSY 3009 40109 fW 338092908 JYLNIN AWVds OL Q3QNO8 TWHLNAN YAWYOSSNVYL JN OL 9 4 3NION3 H3 IGI 0b 64 8 1 9 SG II o Y x a4 at TIWL30 335 GYVOE Od 3NISN3 H3TOSNISN3 OL GALOSNNOO SQV31 GAMA SV NMOHS SIN3NQJIOO T3NVd TOHINOO 8 2ZELL 59005 WVYOVIC 007 AVS SAE 400 WIRING DIAGRAM F 3 F 3 oul E8Z EZIN IWNIWSDL 300319313 HHOM OL HOLIMS JO MAA MOVE NOllSOd 1VOO1NI ALIN NMOHS TOHINO9 31033 401V901 401 H Sleued eJnsoj oue eu JO euo uo
29. Amps Two kits are required See the MAINTENANCE section for detailed information on testing and resetting the GFCI receptacle K1735 1 MULTI WELD 350 For multiple arcs from the DC output of a welding power source See bulletin E5 300 for Multi Weld 350 and distribution system K2144 1 Oil Drain Kit Includes ball valve hose and clamp K1858 1 Service Indicator Kit Provides a GO NO GO visual indication of air cleaner element useful service life Filter service based on restriction readings allows the longest life possible from the filter and best engine protection SAE 400 LINCOLN 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 Use in open well ventilated areas or vent exhaust outside MOVING PARTS can injure Do not operate with doors open or guards off Stop engine before servicing Keep away from moving parts 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 levels If the fuel supply runs out while the fuel pump is o
30. ION 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 high idle When in AUTO idle position the idler operates as follows 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 the 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 altern
31. RETURN MAIN MENU IM869 D SAE 400 DC ARC WELDING POWER SOURCE May 2008 For use with machines having Code Numbers 11198 11322 11407 11409 11509 Safety Depends on You Lincoln arc welding and cutting equipment is designed built with safety in mind However your overall safety can be increased by proper installation and thoughtful operation on your part DO NOT INSTALL OPERATE OR REPAIR THIS EQUIPMENT WITHOUT READING THIS MANUAL AND THE SAFETY PRECAUTIONS CONTAINED THROUGHOUT And most importantly think before you act and be careful OPERATOR S MANUAL ISO 9001 ANS RAB m Om Designed and Manufactured Under a Quality Program Certified by ABS Quality Evaluations Inc to ISO 9001 Requirements CERTIFICATE NUMBER 30273 LI NCOLN Copyright Lincoln Global Inc 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 l SAFETY WARNING CALIFORNIA PROPOSITION 65 WARNINGS A 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 bir
32. S FR 9 SR I 0 SO 71 SES HYRAS SISAR HA ett t _ EPEA 425 ll Ss Jub Aal pag Gail cula S il 5 400 LINCOLN 5 Spanish AVISO DE PRECAUCION French ATTENTION German WARNUNG Chinese Korean Do not touch electrically live parts 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 de 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 OMRPORABA MARHE FRANDEACMHEUCE CU kg kakAEE EES ZE 1 E SS CRRACRHMALHER e 3544 Xe se ass a e 29 HIE Juan M gow uil pal 2 4 uio s all aua ule woe Keep flammable materials away Mantenga el material combustible fuera del
33. V NMOHS SIN3NOHIWOO TANVd TOHINOO 6091 3003 OH ONIAIM 00v AVS SAE400 LINCOLN DIMENSION PRINT F 5 5 9 6988lN Y ON 1 3NION3 NI H31VM HLIM A LIAVHO JO H31N3O 400 SAE LINCOLN E 5 400 LINCOLN 5 400 LINCOLN Keep your head out of fumes Use ventilation or exhaust to remove fumes from breathing zone Los humos fuera de la zona de res Mantenga cabeza fuera de los humos Utilice ventilaci n aspiraci n para gases e Gardez la t te l cart des fum es Utilisez un ventilateur ou un aspira teur pour ter les fum es des zones de travail e Vermeiden Sie das Einatmen von Schweibrauch Sorgen Sie f r gute Be und Entl ftung des Arbeitsplatzes e Mantenha seu rosto da fumaca Use ventilac o e exhaust o para remover fumo da zona respirat ria tar APSRMEBTESILT Feu ORAVHELCTIBELTTFEL e E fE Mak 2475 YHL 297148 Ash 7 217 7 amp ASA Qall Led Lal sui gal bic si gil e Ml ll Ge call ucl Turn power off before servicing
34. ank Also running out of fuel tends to draw dirt into the fuel system When hauling the welder between job sites close the fuel shut off valve If the fuel supply is cut off or runs out while the fuel pump is operating air may be entrapped in the fuel dis tribution system If this happens bleeding of the fuel system may be necessary Use qualified personnel to do this per the instructions in the MAINTENANCE sec tion of this manual SAE 400 LINCOLN P B 6 OPERATION TYPICAL FUEL CONSUMPTION The typical fuel consumption of the SAE 400 for various operating scenarios is shown below PERKINS 1104C 44 PERKINS 1104A 44 30 gal hr 26 gal hr 1 12 Lhr 97 L hr 69 gal hr 68 gal hr 2 61 L hr 2 56 L hr Low Idle No Load 1100 RPM High Idle No Load 1800 RPM Welding Load 400 Amps 40 Volts Welding Load 500 Amps 40 Volts Auxiliary Power 3000VA 1 79 gal hr 1 84 gal hr 6 76 L hr 6 95 L hr 2 43 gal hr 2 38 gal hr 9 19 L hr 9 02 L hr 71 gal hr 79 gal hr 3 68 L hr 2 98 L hr SAE 400 LINCOLN P 1 ACCESSORIES 1 K930 2 Module Provides high frequency plus gas valve for TIG welding A water valve is available as an option Requires 115 volt AC input Limited to 250A 60 Duty Cycle K802 D Power Plug Kit Kit includes male plug for 20 amp receptacle K2641 1 Trailer A 4 wheel steerable trailer for in plant and
35. ator 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 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 Large Electrodes High OCV Medium OCV Low OCV Extra Low OCV Normal Welding 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
36. ay sometimes be necessary Caution must be observed in correctly loading a diesel generator unit 1 Connect the welder output studs to a suitable resis tive load bank Note that any attempt to short the output studs by connecting the welding leads together direct shorting of the output studs or con necting the output leads to a length of steel will result in catastrophic damage to the generator and voids the warranty 2 Set the welder controls for an output current 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 cata strophic damage to the generator and voids the warranty 3 Periodically shut off the engine and check the crankcase oil level WARNING BATTERY CONNECTION Use caution as the electrolyte is a strong acid that can burn skin and damage eyes Remove and discard the insulating caps from the negative battery terminals Attach and tighten negative battery cable termi nals NOTE This machine is furnished with wet charged batteries if unused for several months the batteries WARNING Wwe may require a booster charge Be careful to charge the batteries with the correct polarity Make sure that the batteries are level while charging GASES FROM BATTERY can explode Keep sparks flame and cigarettes away from battery To prevent EXPLOSION when INSTALLING A NEW BATTERY disconnect
37. d replace when work requiring removal is complete Only qualified personnel should install use or service this equipment 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 LINCOLN 2 TROUBLESHOOTING E 2 Observe all Safety Guidelines detailed throughout this manual PROBLEMS POSSIBLE RECOMMENDED SYMPTOMS CAUSE COURSE OF ACTION FUNCTION PROBLEMS Machine fails to hold the heat Rough or dirty commutator True and clean commutator constantly Brushes may be worn down to Replace brushes limit of life Brush springs may be broken Replace brush springs Field circuit may have variable Check field current with ammeter resistance connections or inter to discover varying current This mittent open circuit due to loose applies to both the main genera connections or broken wire tor and exciter Electrode or work lead connec Tighten all connections tions may be poor Wrong grade of brushes may be Use only the recommended installed on generator Lincoln brushes Field rheostat may be making Inspect and clean rheostat poor contact and overheating Current Control may not be Check for loose or missing set operating properly screw in control handles Current Control
38. d shaft Have an authorized Field Service Shop check and realign the shaft COOLING SYSTEM The SAE 400 is equipped with a pressure radiator Keep the radiator cap tight to prevent loss of coolant Clean and flush the cooling system periodically to pre vent clogging the passage and overheating the engine When antifreeze is needed always use the permanent type PRE FILTER WATER SEPARATOR A When working on the fuel system H Keep unguarded lights away do not smoke Do not spill fuel The SAE 400 is equipped with a Fuel Pre Filter Water Separator Assembly located before the lift pump mounted to the engine block FUEL PRE FILTER WATER SEPARATOR ASSEMBLY For codes below 11409 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 1 Close the fuel shutoff valve located under the fuel tank 2 Unscrew the cap ring located on the top of the filter header and remove the plastic center cap and O
39. e plug and will have USDA FS 5100 1 QUALIFIED SPARK ARRESTER stamped on the muffler shell Any spark arrester must be serviced and properly maintained An incorrect arrester may lead to damage to the engine or adversely affect performance INSTALLATION 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 100FT 100 200FT 200 250FT 60 Up to 31m 31 61m 61 76m Duty Cycle 2 0 AWG 3 0 AWG 4 0 AWG MACHINE GROUNDING Because this portable engine driven welder creates its own power it is not necessary to connect its frame to an earth ground unless the machine is connected to premises wiring home shop etc To prevent dangerous electric shock other equipment powered by this engine driven welder must a be grounded to the frame of the welder using a grounded type plug b be double insulated When this welder is mounted on a truck or trailer its frame mu
40. e vehi cles which are rated and designed for such loads Distribute balance and secure loads so vehicle is stable under conditions of use Do not exceed maximum rated loads for compo nents such as suspension axles and tires e 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 ENGINE OIL 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 SAE 400 LINCOLN amp A 4 INSTALLATION A 4 A WARNING Stop engine while fueling Do not smoke when fueling Keep sparks and flame away from tank e Do not leave unattended while fueling DIESEL FUEL E up spilled fuel and allow ean caus fire umes to clear before starting engine Do not overfill tank fuel expansion may cause over
41. el 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 Operators Manual completely before attempting to use this equipment Save this manual and keep it handy for quick reference Pay particular attention to the safety instructions we have provided for your protection The level of seriousness to be applied to each is explained below A WARNING This statement appears where the information must be followed exactly to avoid serious personal injury or loss of life A CAUTION This statement appears where the information must be followed to avoid minor personal injury or damage to this equipment TABLE OF CONTENTS Page Installation Instructions
42. flow DIESEL FUEL ONLY Fill the fuel tank with clean fresh diesel fuel The capacity of the fuel tank is 22 5 gallons 85 1 liters See engine Operator s Manual for specific fuel recom mendations Note Before starting the engine be sure the fuel shut off valve is in the open position 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 ENGINE BREAK IN PERIOD 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 wet stacking 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 successful engine break in most diesel powered equipment 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 moderate to heavy loading of the engine m
43. fore refuel ing to prevent spilled fuel from vaporizing on contact with hot engine parts and igniting Do not spill fuel when filling tank If fuel is spilled wipe it up and do not start engine until fumes have been eliminated 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 1 d Keep all equipment safety guards covers and devices in posi before welding tion and in good repair Keep hands hair clothing and tools away from V belts gears fans and all other moving parts when starting operating or repairing equipment Exposure to EMF fields in welding may have other health effects which are now not known All welders should use the following procedures in order to 1 some cases it may be necessary to remove safety His 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
44. icable OSHA PEL and ACGIH TLV limits 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 prod ucts 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 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 Also see item 1 b WELDING and CUTTING SPARKS 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 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 be
45. ing 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 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 Also see
46. l 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 When using the optional field installed CV adapter K385 the Local Remote Switch is only active in the VV mode AUXILIARY POWER CONTROLS NOTE GFCI receptacles our an option and if installed see the MAINTENANCE section for detailed informa tion 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 LINCOLN P B 5 OPERATION B 5 ENGINE OPERATION A WARNING Do not
47. lease both buttons If the engine fails to start in 20 seconds wait 30 seconds and repeat the above procedure 5 ObDserve the oil pressure If no pressure shows within 30 seconds stop the engine and consult the engine operating manual To stop the engine turn the IGNITION switch to OFF 6 If the engine protection warning light comes on during cranking or after start up the IGNITION switch must be turned OFF to reset the engine protection system 7 Allow the engine to run at high idle speed for sev eral minutes to warm the engine Stop the engine and recheck the oil level after allowing sufficient time for the oil to drain into the pan If the level is down fill it to the full mark again The engine con trols were properly set at the factory and should require no adjusting when received COLD WEATHER STARTING A WARNING Under NO conditions should ether or other starting fluids be used With a fully charged battery and the proper weight oil the engine should start satisfactorily even down to about 5 F 20 C it maybe desirable to install cold starting aides Note Extreme cold weather staring may require longer glow plug operation STOPPING THE ENGINE 1 Turn the IGNITION switch to OFF At the end of each day s welding check the crankcase oil level drain accumulated dirt and water from the water separator and refill the fuel tank to minimize moisture condensation in the t
48. lington 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 iv PRECAUTIONS DE SURETE 5 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 vous 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 ja
49. mais 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 souder 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 Eloigner les mat riaux inflammables ou les recouvrir afin de pr venir tout risque d incendie d aux tincelles Quand on ne soude pas poser la pince une endroit isol de 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
50. ng 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 person 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 person seat these brushes by lightly stoning the com mutator as the armature rotates at full speed until con tact is made across the full face of the brushes After stoning 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 With slight additional finger pres sure on top of the brushes pull the sandpaper around the circumference 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 misaligne
51. nimum stop set pointer to with dial the insulated bushing of the cur in 1 8 of the last scale division rent control brushholder caused by turning handle too hard against one of the stops Exciter output low causing low Check for shorts in exciter arma output compared to dial indica ture with growler tion Current Control set to minimum 13 Check to see that series field is and welder output so great that properly connected and not short engine stalls when arc is struck ed Welder has output and no control Local Remote switch is in wrong Place switch in LOCAL position position to control output at the welder Place switch in posi tion to control output remotely 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 LINCOLN P 5 TROUBLESHOOTING 5 Observe all Safety Guidelines detailed throughout this manual PROBLEMS POSSIBLE RECOMMENDED SYMPTOMS CAUSE COURSE OF ACTION FUNCTION PROBLEMS No auxiliary power 1 Circuit Breakers open 1 Check and reset breakers If breakers keep tripping check con nections to auxiliary receptacles Also make sure load does nor exceed receptacle s current rating 2 Faulty connections to auxiliary Check connections receptacles
52. on et l entretien du poste seront effectu s par un lectricien qualifi Avant de faires des travaux l interieur de poste la debranch 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 zones ou l on pique le laitier LINCOLN P er l interrupteur la boite de fusibles Garder tous les couvercles et dispositifs de s ret leur place for selecting a QUALITY product by Lincoln Electric We want you TL You to take pride in operating this Lincoln Electric Company product as much pride as we have in bringing this product to you CUSTOMER ASSISTANCE POLICY The business of The Lincoln Electric Company is manufacturing and selling high quality welding equipment consumables and cutting equip ment Our challenge is to meet the needs of our customers and to exceed their expectations On occasion purchasers may ask Lincoln Electric for advice or information about their use of our products We respond to our customers based on the best information in our possession at that time Lincoln Electric is not in a position to warrant or guarantee such advice and assumes no liability with respect to such inf
53. ormation or advice We expressly disclaim any warranty of any kind including any warranty of fitness for any customer s particular purpose with respect to such information or advice As a matter of practical consideration we also cannot assume any responsibility for updating or correcting any such information or advice once it has been given nor does the provision of information or advice create expand or alter any warranty with respect to the sale of our products Lincoln Electric is a responsive manufacturer but the selection and use of specific products sold by Lincoln Electric is solely within the control of and remains the sole responsibility of the customer Many variables beyond the control of Lincoln Electric affect the results obtained in applying these types of fabrication methods and service requirements Subject to Change This information is accurate to the best of our knowledge at the time of printing Please refer to www lincolnelectric com for any updated information 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 Mod
54. park Arrester SR D 4 GFCI Receptacle Testing and Resetting Procedure Accessory Kit Only D 4 Troubleshooting Guide Section E Wiring Diagram and Dimension Print Section F Parts List Se ee hee ee eae ee deed P 530 SAE 400 LINCOLN 1 INSTALLATION 1 TECHNICAL SPECIFICATIONS SAE 400 1278 7 1278 9 INPUT DIESEL ENGINE Make Model Speed RPM Displacement Description Starting System Fuel 22 5 gal 85 1 L K1278 7 Perkins 1104C 44 Diesel Engine EPA Tier Compliant 4 cylinder 68 4 HP 1725 RPM High Idle 1800 Low Idle 1100 Full Load 1725 269 cu in 4 4 L 12VDC batteries 2 amp Starter Bore x Stroke Oil 10 1 Qts 9 6L K1278 9 Perkins 1104A 44 Diesel Engine Not EPA Tier II Compliant Export Only 4 cylinder 64 4 HP 1710 RPM 4 13 x 5 00 105 0 mm x 127 0mm Coolant 3 4 gal 12 8L RATED OUTPUT WELDER Volts at Rated Amps 3596 NEMA 500 amps 40 volts 10096 NEMA 400 amps 36 volts 100 Lincoln Plus 400 amps OUTPUT WELDER AND GENERATOR 80 575 Amps 40 volts 97 Max 1800 RPM 115 230 VAC 3000 Watts 60 Hz 100 Duty Cycle PHYSICAL DIMENSIONS HEIGHT WIDTH DEPTH WEIGHT 50 13 in 1273 3 mm 28 00 in 711 2 mm 1 Based on a 10 minute period 83 00 in 2108 2 mm
55. per 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 manual 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 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 crankcase oil at regular intervals using the proper grade of oil as recom mended in the engine operating manual Change the oil filter in accordance with the instructions in the engine operating manual 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 af
56. r 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 TOMS This column describes possible symptoms that the machine may exhibit Find the listing that best describes the symptom that the machine is exhibiting 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 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 local Lincoln Authorized Field Service Facility A WARNING _ ELECTRIC SHOCK can kill Do not touch electrically live parts such as output terminals or internal wiring ENGINE EXHAUST can kill outside Use in open well ventilated areas vent exhaust Stop engine before servicing MOVING PARTS can injure 26 Do not operate with doors open or guards off LAN Keep away from moving parts Remove guards only when necessary an
57. s 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 instruction manuals GENERAL DESCRIPTION The SAE 400 is a diesel engine driven welding power source The machine uses a DC generator 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 out put The engine 1104C 44 is a 68 4 Hp 1725 RPM 51kw 4 cylinder water cooled diesel made by Perkins The engine 1104A 44 is a 64 4 Hp 1710 RPM 48kw 4 cylinder water cooled diesel made by Perkins SAE 400 LINCOLN P B 2 OPERATION B 2 RECOMMENDED APPLICATIONS WELDER The SAE 400 provides excellent constant current DC welding output for stick SMAW welding The field installed optional CV Adapter K385 provides up to 500 amps at 35 volts of constant voltage output for semiautomatic welding AUXILIARY POWER The SAE 400 provides 3 KW of 115 230 VAC output for auxiliary power and emergency standby power DESIGN FEATURES AND ADVANTAGES FOR STICK WELDING Excellent DC constant current output for stick weld ing applications Continuous adjustment of both voltage and curren
58. sidiaries and Distributors Worldwide Cleveland Ohio 44117 1199 U S A TEL 216 481 8100 216 486 1751 WEB SITE www lincolnelectric com
59. ssing the commutator and have proper spring tension Exciter may not be operating Check exciter output voltage with voltmeter or lamp Field circuit of generator or Check for open circuits in rheo may be open stat field leads and field coils Also check resistors Polarity reversing switch may be Put handle in positive or negative in the neutral position position Exciter may have lost excitation Check components and continuity in flashing circuit Welding arc is loud and spatters Series field circuit may be open Check circuit with ringer or volt excessively circuited meter Current setting may be too high Check setting and current output with ammeter Polarity may be wrong Check polarity Try reversing polarity or try an electrode of the opposite polarity 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 LINCOLN 4 TROUBLESHOOTING E 4 Observe all Safety Guidelines detailed throughout this manual PROBLEMS POSSIBLE RECOMMENDED SYMPTOMS CAUSE COURSE OF ACTION FUNCTION PROBLEMS Welding current too great or too 1 Current Control shaft and han 1 With current control against the small compared to indication on the dle may have turned slightly in mi
60. st 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 LINCOLN amp B 1 OPERATION B 1 OPERATING INSTRUCTIONS Read and understand this entire section before operat ing your equipment SAFETY INSTRUCTIONS A 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 engine starting operating and maintenance instructions and parts lists ELECTRIC SHOCK can kill Do not touch electrically live parts or electrodes with your skin or wet cloth ing e Insulate yourself from the work and ground Always wear dry insulating gloves
61. steel plate at least 06 1 6mm thick which should 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 bail should be used to lift the machine A WARNING only with equipment of adequate lifting capacity sure machine is stable when lift ing Do not lift this machine using lift bail if it is equipped with a heavy accessory such as a trail er or gas cylinder FALLING Do not lift machine if lift bail is EQUIPMENT can damaged cause injury not operate machine while suspended from lift bail SAE 400 LINCOLN amp 3 INSTALLATION A 3 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 Perkins Service Representative for any engine adjustments that may be required for high
62. t 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 20 115 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 0 26 13 100 19 5 9 75 200 13 6 5 300 400 500 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 the percentage of time the load is being applied in a 10 minute period For example a 60 duty cycle represents 6 minutes of load and 4 minutes of no load in a 10 minute period SAE 400 LINCOLN P B 3 OPERATION B 3 ENGINE CONTROLS IGNIT
63. ter the first 30 or 40 hours of oper ation Check the cooling fan belt and tighten if necessary DO NOT OVER TIGHTEN 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 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 failures are caused by dirt introduced during greasing than from insufficient grease SAE 400 LINCOLN D 2 MAINTENANCE D 2 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 removi
64. th defects or other reproductive harm The Above For Diesel Engines The Above For Gasoline 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 P O Box 351040 Miami Florida 33135 or CSA Standard W117 2 1974 A Free copy of Arc Welding Safety booklet E205 is available from the Lincoln Electric Company 22801 St Clair Avenue Cleveland Ohio 44117 1199 BE SURE THAT ALL INSTALLATION OPERATION MAINTENANCE AND REPAIR PROCEDURES ARE PERFORMED ONLY BY QUALIFIED INDIVIDUALS powered equipment 1 Turn the engine off before troubleshooting and maintenance work unless the maintenance work requires it to be running 3 SX 1 h To avoid scalding do not remove the radiator pressure cap when the engine is hot 1 b Operate engines in open well ventilated areas or vent the engine exhaust fumes outdoors ELECTRIC AND 3 mmm MAGNETIC FIELDS 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 be
65. under the air vent valve 6 Open the fuel shutoff valve 7 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 FUEL PRE FILTER WATER SEPARATOR ASSEMBLY For codes 11409 and above The assembly uses 30 micron pre filter water separator element that is designed to protect against gross contam ination of the final fuel filter Using chemically treated paper media the element also provides maximum protec tion against water in the fuel The assembly is also equipped with a see through bowl for easy visual check ing for water The recommended change interval for the pre filter water separator element is 1 000 hours See below for information on the see through bowl and for the procedure for changing the element See Through e Check the see through bowl for water regularly Water will collect at the bottom of the bowl and appears differ ent from the fuel Note The see through bowl is re usable 1 Close the fuel shut off valve 2 Drain by opening the self venting drain valve and allow ing all water to escape 3 Close the drain valve and open the fuel shut off valve Pre Filter Water Separator Element 1 Close the fuel shutoff valve located under the fuel tank 2 Rotate the quick change ring located just below filter header
66. val 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 under 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 on 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

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