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IM870-A
SAE-400 SEVEREDUTY
MAY, 2008
DC ARC WELDING POWER SOURCE
For use with machines having Code Number: 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. DO NOT
INSTALL, OPERATE OR
REPAIR THIS EQUIPMENT
WITHOUT READING THIS
MANUAL AND THE SAFETY
PRECAUTIONS CONTAINED
THROUGHOUT. And, most impor-
tantly, think befo
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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 ARC RAYS can burn. 4.a. Use a shield with the proper filter and cover kill. plates to protect your eyes from sparks and 3.a. The electrode and work (or ground) circuits the rays of the arc when welding or observing are electrically “hot” when the welder is on. open arc welding. Headshield and filter lens Do not touch these “hot” parts with your bare should conform to ANSI Z87. I standards. skin or wet clothing. Wear dry, hole-free gloves to insulate hands. 4.b. Us
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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 5. Toujours porter des lunettes de sécurité dans la zone de PRÉCAUTIONS DE SÛRETÉ soudage. Utiliser des lunettes avec écrans lateraux dans les zones où lʼon pique le laitier. Pour votre propre protection lire et observer toutes les instructions et les précautions de sûreté specifiques qui parraissent dans ce 6. Eloigner les matériaux inflammables ou les recouvrir afin de manuel aussi bien que les précautions de sûreté générales suiv- prévenir tout risque dʼincendie dû aux étincelles
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ix ix for selecting a QUALITY product by Lincoln Electric. We want you to take pride in operating this Lincoln Electric Company product Thank You ••• 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 Lin
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vi vi TABLE OF CONTENTS Page Installation Instructions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Section A Technical Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .A-1 Installation Precautions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A-2 Location / Ventilation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
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A-1 A-1 INSTALLATION TECHNICAL SPECIFICATIONS - SAE-400 SEVERE DUTY INPUT - DIESEL ENGINE Make/Model Description Speed (RPM) Displacement Starting Capacities System Perkins 4 cylinder High Idle 1800 269 cu. in 12VDC batteries Fuel: 22.5 gal. 1104C-44 Diesel 68.4 HP @ Low Idle 1100 (4.4 L) (2) & Starter 85.1 L Engine 1725 RPM Full Load 1725 Bore x Stroke Oil: 10.1 Qts. 9.6 L 4.13” x 5.00” (105.0 mm x 127.0mm) Coolant: 3.4 gal. 12.8 L RATED OUTPUT - WELDER (1) Duty Cycle Welding Output Volts
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A-2 A-2 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 WARNING least .06”(1.6mm) thick, which shall extend not less than 5.90”(150mm) beyond the equipment on Do not attempt to use this equipment until you all sides. have thoroughly read all operatin
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A-3 A-3 INSTALLATION HIGH ALTITUDE OPERATION • Only transport this equipment on serviceable vehi- cles which are rated and designed for such loads. At higher altitudes, output derating may be necessary. • Distribute, balance and secure loads so vehicle is As a rule of thumb, derate the welder output 5% for stable under conditions of use. every 500 meters (1640 ft.) above 1000 meters (3280 • Do not exceed maximum rated loads for compo- ft.). nents such as suspension, axles and tires. • Mount equi
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A-4 A-4 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. exces
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A-5 A-5 INSTALLATION MACHINE GROUNDING Because this portable engine driven welder creates its SPARK ARRESTOR own power, it is not necessary to connect its frame to an earth ground, unless the machine is connected to WARNING premises wiring (home, shop, etc.). To prevent dangerous electric shock, other equipment WARNING powered by this engine driven welder must: • Spark Arrestor and Muffler may be hot! Allow engine to cool before servicing spark arrestor! a) be grounded to the frame of the we
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B-1 B-1 OPERATION OPERATING INSTRUCTIONS WELDING SPARKS can cause fire Read and understand this entire section before operating or explosion. your equipment. • Do not weld near flammable material . SAFETY INSTRUCTIONS • Do not weld on containers that have WARNING held flammable material. -------------------------------------------------------------- Do not attempt to use this equipment until you have thor- MOVING PARTS can injure. oughly read all operating and maintenance manuals sup- • Keep awa
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B-2 B-2 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% ing applications. duty cycle, represents 6 minutes of load and 4 min- utes 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
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B-3 B-3 OPERATION ENGINE CONTROLS ENGINE PROTECTION SYSTEM IGNITION SWITCH The engine protection system shuts down the engine under high coolant temperature or low engine oil pres- When placed in the “ON” position, this switch ener- sure conditions by allowing the fuel solenoid valve to gizes the fuel solenoid. When placed in the “OFF” close. position, the flow of fuel to the injection pump is stopped to shut down the engine. AIR INTAKE SHUT-OFF “IDLER” SWITCH The air intake shut-off is a automa
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B-4 B-4 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-5 B-5 OPERATION ENGINE OPERATION 5. Observe the oil pressure. If no pressure shows within 30 seconds, stop the engine and consult WARNING the engine operating manual. To stop the engine, Do not attempt to use this equipment until you turn the “IGNITION” switch to “OFF”. have thoroughly read the engine manufacturerʼs 6. If the engine protection warning light comes on manual supplied with your welder. It includes important safety precautions, detailed engine during cranking or after start up, th
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B-6 B-6 OPERATION TYPICAL FUEL CONSUMPTION The typical fuel consumption of the SAE-400 for vari- ous operating scenarios is shown below: Low Idle - No Load .30 gal./ hr. 1100 RPM (1.12 L./hr.) High Idle - No Load .69 gal./hr. 1800 RPM (2.61 L./hr.) Welding Load 1.79 gal./hr. 400 Amps, 40 Volts (6.76 L./hr.) Welding Load 2.43 gal./hr. 500 Amps, 40 Volts (9.19 L./hr.) Auxiliary Power .71 gal./hr. 3000VA (3.68 L./hr.) SAE-400 SEVERE DUTY
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C-1 C-1 ACCESSORIES OPTIONAL FIELD INSTALLED ACCESSORIES K802-D Power Plug Kit - Kit includes male plugs for 20 Amp receptacle. K2641-1 Trailer - A 4-wheel steerable trailer for in- (1) plant and yard towing with E78-14 load range (B) tubeless tires. Mounts directly to welder base.(Not for use on the highway.) Comes standard with a Duo-Hitch™, a 2” Ball and Lunette Eye combination Hitch. K2637-1 Trailer - A 2-wheel trailer designed for (1) road , off road, in-plant and yard towing. Trailer mount
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D-1 D-1 MAINTENANCE WARNING 4. Belts tend to loosen after the first 30 or 40 hours of oper- ation. Check the cooling fan belt and tighten if neces- ELECTRIC SHOCK can kill. sary. DO NOT OVER TIGHTEN. ● Do not touch electrically live parts ENGINE OIL CHANGE such as output terminals or inter- nal wiring The SAE-400 SEVERE DUTY is equipped with a convenient oil drain system. Drain the oil when the engine is warm to ENGINE EXHAUST can kill. assure rapid and complete draining. ● Use in open, well ve
