Lincoln Electric SAE-400 SEVERE DUTY IM727 Operator's Manual
Severe duty dc arc welding power source
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- Specification sheet (168 pages)
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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 before
you act and be careful.
R
OPERATOR'S MANUAL
Copyright © 2005 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
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Related Manuals for Lincoln Electric SAE-400 SEVERE DUTY IM727
Summary of Contents for Lincoln Electric SAE-400 SEVERE DUTY IM727
- Page 1 RETURN TO MAIN MENU 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 ...
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Page 2: California Proposition 65 Warnings
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. -
Page 3: Electric Shock Can Kill
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. - Page 4 WELDING SPARKS can cause fire or explosion. 6.a. Remove fire hazards from the welding area. If this is not possible, cover them to prevent the welding sparks from starting a fire. Remember that welding sparks and hot materials from welding can easily go through small cracks and openings to adjacent areas.
- Page 5 PRÉCAUTIONS DE SÛRETÉ Pour votre propre protection lire et observer toutes les instructions et les précautions de sûreté specifiques qui parraissent dans ce manuel aussi bien que les précautions de sûreté générales suiv- antes: Sûreté Pour Soudage A L’Arc 1. Protegez-vous contre la secousse électrique: a.
- Page 6 The code number is especially important when identifying the correct replacement parts. - 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.
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Page 7: Table Of Contents
Installation Instructions ..........Section A Technical Specifications . -
Page 8: Technical Specifications
TECHNICAL SPECIFICATIONS - SAE-400 SEVERE DUTY Make/Model Description Perkins 4 cylinder 1004.42 Diesel 71 HP @ Engine 1725 RPM Duty Cycle Welding Output 60% (NEMA) 400 amps 60% (Lincoln Plus) 400 amps OUTPUT - WELDER AND GENERATOR Welding Range 80 - 575 Amps HEIGHT WIDTH 52.00 in. -
Page 9: Location/Ventilation
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. -
Page 10: High Altitude Operation
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 alti- tude operation. -
Page 11: Battery Connection
ENGINE BREAK-IN Lincoln Electric selects high quality, heavy-duty indus- trial engines for the portable welding machines we offer. While it is normal to see a small amount of crankcase oil consumption during initial operation, excessive oil use, wetstacking (oil or tar like substance at the exhaust port), or excessive smoke is not normal. -
Page 12: Spark Arrestor
SPARK ARRESTOR The muffler included with this welder has been modi- fied and now qualifies as a spark arrestor. Mufflers on WARNING • Spark Arrestor and Muffler may be hot! Allow engine to cool before servicing spark arrestor! Do not operate engine while servicing spark arrestor! machines manufactured before this change do not qualify as spark arrestors and were shipped from the... -
Page 13: Operating Instructions
OPERATING INSTRUCTIONS Read and understand this entire section before operat- ing your equipment. SAFETY INSTRUCTIONS WARNING Do not attempt to use this equipment until you have thoroughly read all operating and maintenance manu- als supplied with your machine. They include important safety precautions, detailed engine starting, operating and maintenance instructions and parts lists. -
Page 14: Design Features And Advantages
DESIGN FEATURES AND ADVANTAGES FOR STICK WELDING • Excellent DC constant current output for stick weld- ing applications. • Continuous adjustment of both voltage and current for unsurpassed welds on demanding jobs. • Remote control capability standard. FOR AUXILIARY POWER •... -
Page 15: Air Intake Shut-Off
ENGINE CONTROLS IGNITION SWITCH When placed in the “ON” position, this switch ener- gizes the fuel solenoid. When placed in the “OFF” posi- tion, the flow of fuel to the injection pump is stopped to shut down the engine. “IDLER” SWITCH The idler switch has two positions, “HIGH”... -
Page 16: Remote Control
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. -
Page 17: Engine Operation
ENGINE OPERATION CAUTION Do not adjust the high idle engine speed (rpm) above the factory setting specification. ------------------------------------------------------------------------ STARTING INSTRUCTIONS Be sure all Pre-Operation Maintenance has been per- formed. (See INSTALLATION section of this manual). To start the engine, place ignition toggle switch in the “ON”... -
Page 18: Accessories
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 and yard towing with E78-14 load range (B) tubeless tires. Mounts directly to welder base. K956-1 and -2 Trailer - A 2-wheel trailer designed for road , off road, in-plant and yard towing. -
Page 19: Maintenance
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 ●... - Page 20 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.
- Page 21 1. Close the fuel shutoff valve located on the fuel strainer mounted to the under side of the fuel tank. 2. Unscrew the cap ring located on the top of the filter header and remove the plastic center cap and O- ring.
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Page 22: Spark Arrestor
SPARK ARRESTOR WARNING • Spark Arrestor and Muffler may be hot! Allow engine to cool before servicing spark arrestor! Do not operate engine while servicing spark arrestor! For machines with separate spark arresting unit: Service the spark arrestor every 100 hours of opera- tion or twice a year, which ever occurs first. -
Page 23: How To Use Troubleshooting Guide
HOW TO USE TROUBLESHOOTING GUIDE Service and Repair should only be performed by Lincoln Electric Factory Trained Personnel. Unauthorized repairs performed on this equipment may result in danger to the technician and machine operator and will invalidate your factory warranty. For your safety and to avoid Electrical Shock, please observe all safety notes and precautions detailed throughout this manual. - Page 24 Observe all Safety Guidelines detailed throughout this manual PROBLEMS (SYMPTOMS) Engine will “crank” but not start. Machine fails to hold the “heat” constantly. 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.
- Page 25 Observe all Safety Guidelines detailed throughout this manual PROBLEMS (SYMPTOMS) Welder runs but fails to generate current. Welding arc is loud and spatters excessively. 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.
- Page 26 Observe all Safety Guidelines detailed throughout this manual PROBLEMS (SYMPTOMS) Welding current too great or too small compared to indication on the dial. Welder has output and no control No auxiliary power 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.
- Page 27 WIRING DIAGRAMS SAE-400 SEVERE DUTY...
- Page 28 WIRING DIAGRAMS SAE-400 SEVERE DUTY...
- Page 29 DIMENSION PRINT SAE-400 SEVERE DUTY...
- Page 30 NOTES SAE-400 SEVER DUTY...
- Page 31 ● WARNING ● Spanish ● AVISO DE PRECAUCION ● French ● ATTENTION ● ● German WARNUNG ● Portuguese ● ATENÇÃO ● Japanese Chinese Korean Arabic ● ● ● ● ● ● ● ● ● ●...
- Page 32 ● ● ● ● ● ● ● ● ● ● ● ● ● ● ● ● ● ● Spanish ● PRECAUCION French ● ATTENTION ● German Portuguese ● ● Japanese Chinese Korean Arabic WARNING AVISO DE WARNUNG ATENÇÃO...
- Page 33 • 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...