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IM727
SAE-400 SEVERE DUTY
January, 2005
DC ARC WELDING POWER SOURCE
For use with machines having Code Number: 10856
Safety Depends on You
Lincoln arc welding and cutting
equipment is designed and built with
safety in mind. However, your overall
safety can be increased by proper
installation ... and thoughtful opera-
tion on your part. DO NOT
INSTALL, OPERATE OR REPAIR
THIS EQUIPMENT WITHOUT
READING THIS MANUAL AND
THE SAFETY PRECAUTIONS
CONTAINED THROUGHOUT.
And, most importantly, think be
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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 SPARKS can CYLINDER may explode cause fire or explosion. if damaged. 6.a. Remove fire hazards from the welding area. 7.a.Use only compressed gas cylinders If this is not possible, cover them to prevent containing the correct shielding gas for the the welding sparks from starting a fire. process used and properly operating Remember that welding sparks and hot regulators designed for the gas and materials from welding can easily go through small cracks pressure used. All hos
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iv iv SAFETY zones où l’on pique le laitier. PRÉCAUTIONS DE SÛRETÉ 6. Eloigner les matériaux inflammables ou les recouvrir afin de Pour votre propre protection lire et observer toutes les instructions prévenir tout risque d’incendie dû aux étincelles. et les précautions de sûreté specifiques qui parraissent dans ce manuel aussi bien que les précautions de sûreté générales suiv- 7. Quand on ne soude pas, poser la pince à une endroit isolé de antes: la masse. Un court-circuit accidental peut provo
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v v 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! 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
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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 256 cu. in 12VDC batteries Fuel: 22.5 gal. 1004.42 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 (1) Duty Cycle Welding Output Volts at
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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 least .06”(1.6mm) WARNING 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 have thoroughly read all operatin
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A-3 A-3 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-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. excessi
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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 The muffler included with this welder has been modi- an earth ground, unless the machine is connected to fied and now qualifies as a spark arrestor. Mufflers on premises wiring (home, shop, etc.). WARNING To prevent dangerous electric shock, other equipment � Spark Arrestor and Muffler may be hot! powered by this engine driven wel
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B-1 B-1 OPERATION WELDING SPARKS can cause OPERATING INSTRUCTIONS fire or explosion. Read and understand this entire section before operat- � Do not weld near flammable material . ing your equipment. � Do not weld on containers that have held flammable material. SAFETY INSTRUCTIONS ----------------------------------------------------------- MOVING PARTS can injure. WARNING � Keep away from moving parts Do not attempt to use this equipment until you have � Do not operate with doors open or thorou
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B-2 B-2 OPERATION DESIGN FEATURES AND ADVANTAGES DUTY CYCLE FOR STICK WELDING Duty cycle is based on a ten minute period and opera- � Excellent DC constant current output for stick weld- tion in an ambient temperature of 104°F(40°C). ing applications. The SAE-400 SEVERE DUTY IS NEMA rated at 60% � Continuous adjustment of both voltage and current duty cycle. Duty cycle is based on a ten minute period. for unsurpassed welds on demanding jobs. Therefore, a 60% duty cycle welder can be operated at
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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” posi- close. tion, 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 manu
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B-4 B-4 OPERATION 4. If you want a little more current, turn the “Job WELDER CONTROLS POLARITY SWITCH Selector” up (counterclockwise) to increase cur- rent. If you want a little less current, turn the “Job Turn the Arc Polarity switch to electrode positive or Selector” down (clockwise) to decrease current. electrode negative as required for each particular application. 5. If dialing the desired current with the “Job Selector” moves the setting outside the black CONTROL OF WELDING CURRENT range c
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B-5 B-5 OPERATION BREAK-IN PERIOD ENGINE OPERATION CAUTION ENGINE Do not adjust the high idle engine speed (rpm) The engine used to supply power for your welder is a above the factory setting specification. heavy duty, industrial engine. It is designed and built ------------------------------------------------------------------------ for rugged use. It is very normal for any engine to use STARTING INSTRUCTIONS small quantities of oil until the break-in is accom- plished. Check the oil level t
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C-1 C-1 ACCESSORIES OPTIONAL FIELD INSTALLED ACCESSORIES K802-D Power Plug Kit - Kit includes male plugs for each auxiliary receptacle. K767-1 Trailer - A 4-wheel steerable trailer for in-plant (1) and yard towing with E78-14 load range (B) tubeless tires. Mounts directly to welder base. K956-1 and -2 Trailer - A 2-wheel trailer designed for (1) road , off road, in-plant and yard towing. The K956-2 trailer is equipped with electric brakes. Trailer mounts directly to welder base. 1 For highway us
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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 necessary. ELECTRIC SHOCK can kill. 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 vent
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D-2 D-2 MAINTENANCE BEARING MAINTENANCE To seat the slip ring brushes, position the brushes in place. Then slide one end of a piece of fine sandpaper This welder is equipped with a double-shielded ball bearing between slip rings and brushes with the coarse side having sufficient grease to last indefinitely under normal ser- against the brushes. Pull the sandpaper around the cir- vice. Where the welder is used constantly or in excessively cumference of the rings, in direction of rotation only -
