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SVM187-A
October, 2008
SAE-400SEVERE DUTY
For use with machine code numbers 10856, 11199, 11408
Safety Depends on You
Lincoln arc welding and cutting
equipment is designed and built
with safety in mind. However,
your overall safety can be
increased by proper installation
. . . and thoughtful operation on
your part. DONOT INSTALL,
OPERATE OR REPAIR THIS
EQUIPMENT WITHOUT READ-
ING THIS MANUAL AND THE
SAFETY PRECAUTIONS CON-
TAINED THROUGHOUT. And,
most importantly, think before
you act and be car
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i i SAFETY 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 Gasoline Engines ARC WELDING can be hazardous. PROTECT YOURSELF AND OTHERS FROM POSSIBLE SERIOUS INJURY
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ii ii SAFETY ELECTRIC SHOCK can kill. ARC RAYS can burn. 3.a. The electrode and work (or ground) circuits 4.a. Use a shield with the proper filter and cover are electrically “hot” when the welder is on. plates to protect your eyes from sparks and Do not touch these “hot” parts with your bare the rays of the arc when welding or observing skin or wet clothing. Wear dry, hole-free open arc welding. Headshield and filter lens gloves to insulate hands. should conform to ANSI Z87. I standards. 3.b. In
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iii iii SAFETY WELDING and CUTTING CYLINDER may explode SPARKS can if damaged. cause fire or explosion. 7.a. Use only compressed gas cylinders 6.a. Remove fire hazards from the welding area. containing the correct shielding gas for the If this is not possible, cover them to prevent process used and properly operating the welding sparks from starting a fire. regulators designed for the gas and Remember that welding sparks and hot pressure used. All hoses, fittings, etc. should be suitable for mat
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iv iv SAFETY 6. Eloigner les matériaux inflammables ou les recouvrir afin de PRÉCAUTIONS DE SÛRETÉ prévenir tout risque d’incendie dû aux étincelles. Pour votre propre protection lire et observer toutes les instructions 7. Quand on ne soude pas, poser la pince à une endroit isolé de et les précautions de sûreté specifiques qui parraissent dans ce la masse. Un court-circuit accidental peut provoquer un manuel aussi bien que les précautions de sûreté générales suiv- échauffement et un risque d’inc
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v v SAFETY Electromagnetic Compatibility (EMC) Conformance Products displaying the CE mark are in conformity with European Community Council Directive of 3 May 1989 on the approximation of the laws of the Member States relating to electromagnetic compatibility (89/336/EEC). It was manufactured in conformity with a national standard that implements a harmonized standard: EN 60974-10 Electromagnetic Compatibility (EMC) Product Standard for Arc Welding Equipment. It is for use with other Lincoln El
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vi vi SAFETY Electromagnetic Compatibility (EMC) The size of the surrounding area to be considered will depend on the structure of the building and other activities that are taking place. The surrounding area may extend beyond the boundaries of the premises. Methods of Reducing Emissions Mains Supply Welding equipment should be connected to the mains supply according to the manufacturer’s recommen- dations. If interference occurs, it may be necessary to take additional precautions such as filter
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vii vii - MASTER TABLE OF CONTENTS FOR ALL SECTIONS - RETURN TO MAIN INDEX Page Safety ...........................................................................i-iv Installation ..................................................................SectionA Operation ..................................................................Section B Accessories . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Section C Maintenanc
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A-1 A-1 TABLE OF CONTENTS - INSTALLATION SECTION Installation .............................................................................A-1 Technical Specifications ................................................................A-2 Safety Precautions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .A-3 Location / Ventilation ..................................................................A-3 Stacking ....
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A-2 A-2 INSTALLATION TECHNICAL SPECIFICATIONS - SAE-400 SEVERE DUTY INPUT - DIESEL ENGINE CODE 10856 - Make/Model Description Speed (RPM) Displacement Starting Capacities System Perkins 4 cylinder High Idle 1800 256 cu. in 12VDC batteries Fuel: 22.5 gal. 1104.42 Diesel 71 HP @ Low Idle 1100 (4.2 L) (2) & Starter 85.1 L Engine 1725 RPM Full Load 1725 Bore x Stroke Oil: 8.5 Qts. 8.04 L 3.875” x 5.00” (98.4 mm x 127.0mm) Coolant: 3.6 gal. 13.63 L RATED OUTPUT - WELDER CODES 10856 (1) Duty Cycle Wel
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A-3 A-3 INSTALLATION Read this entire installation section before you CAUTION start installation. DO NOT MOUNT OVER COMBUSTIBLE SURFACES. SAFETY PRECAUTIONS Where there is a combustible surface directly under stationary or fixed electrical equipment, that surface shall be covered with a steel plate at least WARNING .06”(1.6mm) thick, which shall extend not less than 5.90”(150mm) beyond the equipment on all sides. Do not attempt to use this equipment until you ------------------------------------
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A-4 A-4 INSTALLATION • Only transport this equipment on serviceable vehi- HIGH ALTITUDE OPERATION cles which are rated and designed for such loads. • Distribute, balance and secure loads so vehicle is At higher altitudes, output derating may be necessary. stable under conditions of use. As a rule of thumb, derate the welder output 5% for • Do not exceed maximum rated loads for compo- every 500 meters (1640 ft.) above 1000 meters (3280 nents such as suspension, axles and tires. ft.). • Mount equi
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A-5 A-5 INSTALLATION BATTERY CONNECTION ENGINE BREAK-IN WARNING: Use caution as the electrolyte is a strong acid that can burn skin and damage eyes. Lincoln Electric selects high quality, heavy-duty indus- trial engines for the portable welding machines we Remove and discard the insulating caps from the neg- offer. While it is normal to see a small amount of ative battery terminals. Attach and tighten negative crankcase oil consumption during initial operation, battery cable terminals. excessive
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A-6 A-6 INSTALLATION SPARK ARRESTOR MACHINE GROUNDING WARNING Because this portable engine driven welder creates its own power, it is not necessary to connect its frame to WARNING an earth ground, unless the machine is connected to • Spark Arrestor and Muffler may be hot! premises wiring (home, shop, etc.). Allow engine to cool before servicing spark arrestor! Do not operate engine while servicing spark arrestor! To prevent dangerous electric shock, other equipment powered by this engine driven
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B-1 B-1 TABLE OF CONTENTS - OPERATION SECTION Operation ..............................................................................B-1 Safety Instructions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .B-2 Additional Safety Precautions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .B-2 General Descriptions ...............................
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B-2 B-2 OPERATION OPERATING INSTRUCTIONS WELDING SPARKS can cause Read and understand this entire section before operat- fire or explosion. ing your equipment. •Donotweldnearflammablematerial. SAFETY INSTRUCTIONS • Do not weld on containers that have Do not attempt to use this equipment until you have held flammable material. thoroughly read all operating and maintenance manu- --------------------------------------------- als supplied with your machine. They include important MOVING PARTS can in
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B-3 B-3 OPERATION DESIGN FEATURES AND ADVANTAGES DUTY CYCLE FOR STICK WELDING Duty cycle is the percentage of time the load is being • Excellent DC constant current output for stick weld- applied in a 10 minute period. For example a 60% duty ing applications. cycle, represents 6 minutes of load and 4 minutes of no load in a 10 minute period. • Continuous adjustment of both voltage and current for unsurpassed welds on demanding jobs. • Remote control capability standard. FOR AUXILIARY POWER • 3,0
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B-4 B-4 OPERATION ENGINE CONTROLS ENGINE PROTECTION SYSTEM IGNITION SWITCH The engine protection system shuts down the engine When placed in the “ON” position, this switch ener- under high coolant temperature, low engine oil pres- gizes the fuel solenoid. When placed in the “OFF” posi- sure, broken belt or alternator failure conditions by tion, the flow of fuel to the injection pump is stopped to allowing the fuel solenoid valve to close. shut down the engine. AIR INTAKE SHUT-OFF “IDLER” SWITCH
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B-5 B-5 OPERATION 4. If you want a little more current, turn the “Job WELDER CONTROLS Selector” up (counterclockwise) to increase cur- POLARITY SWITCH rent. If you want a little less current, turn the “Job Selector” down (clockwise) to decrease current. Turn the Arc Polarity switch to electrode positive or electrode negative as required for each particular 5. If dialing the desired current with the “Job application. Selector” moves the setting outside the black CONTROL OF WELDING CURRENT range c
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B-6 B-6 OPERATION 5. Observe the oil pressure. If no pressure shows ENGINE OPERATION within 30 seconds, stop the engine and consult the WARNING engine operating manual. To stop the engine, turn the “IGNITION” switch to “OFF”. Do not attempt to use this equipment until you 6. If the engine protection warning light comes on have thoroughly read the engine manufacturerʼs manual supplied with your welder. It includes during cranking or after start up, the “IGNITION” important safety precautions, det
