Lincoln Electric IM870-A Operator's Manual
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Lincoln Electric IM870-A Operator's Manual

Lincoln Electric IM870-A Operator's Manual

Severe duty dc arc welding power source
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SAE-400 SEVERE DUTY
DC ARC WELDING POWER SOURCE
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.
And, most impor-
tantly, think before you act and be
careful.
ISO 9001
ANSI RAB
QMS
Designed and Manufactured Under a
Quality Program Certified by
ABS Quality Evaluations, Inc.
to ISO 9001 Requirements.
CERTIFICATE NUMBER: 30273
• 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
RETURN TO MAIN MENU
For use with machines having Code Number: 11199, 11408
OPERATORʼS MANUAL
• World's Leader in Welding and Cutting Products •
R
Copyright © Lincoln Global Inc.
IM870-A
MAY, 2008

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  • Page 1 • 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 RETURN TO MAIN MENU Copyright © Lincoln Global Inc. IM870-A MAY, 2008...
  • Page 2 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.

  • 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 and CUTTING 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 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 LʼArc 1. Protegez-vous contre la secousse électrique: a.
  • Page 6 Electric for advice or information about their use of our products. We respond to our customers based on the best information in our posses- sion at that time. Lincoln Electric is not in a position to warrant or guarantee such advice, and assumes no liability, with respect to such infor- mation or advice.

  • 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 1104C-44 Diesel 68.4 HP @ Engine 1725 RPM Duty Cycle 35% (NEMA) 100% (NEMA) 100% (Lincoln Plus) OUTPUT - WELDER AND GENERATOR Welding Range 80 - 575 Amps HEIGHT WIDTH 50.13 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 mainte- nance manuals supplied with your machine. They include important 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 sub- stance at the exhaust port), or excessive smoke is not normal.

  • Page 12: Spark Arrestor

    SPARK ARRESTOR WARNING WARNING • Spark Arrestor and Muffler may be hot! Allow engine to cool before servicing spark arrestor! Do not operate engine while servicing spark arrestor! Some federal, state or local laws may require that diesel engines be equipped with exhaust spark arrestors when they are operated in certain locations where unarrested sparks may present a fire hazard.

  • Page 13: Operating Instructions

    OPERATING INSTRUCTIONS Read and understand this entire section before operating your equipment. SAFETY INSTRUCTIONS WARNING Do not attempt to use this equipment until you have thor- oughly read all operating and maintenance manuals sup- plied 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” position, 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 WARNING Do not attempt to use this equipment until you have thoroughly read the engine manufacturerʼs manual supplied with your welder. It includes important safety precautions, detailed engine starting, operating and maintenance instructions, and parts lists. ------------------------------------------------------------------------ ELECTRIC SHOCK can kill. •...

  • Page 18: Typical Fuel Consumption

    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.

  • Page 19: 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- 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”...

  • Page 20: 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 21 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 22 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- ring. 3. Remove the large white volume plug located directly under the center cap in the upper cavity of the filter header.

  • Page 23: Spark Arrestor

    SPARK ARRESTOR (for machines equipped with a separate spark arrest- ing unit) WARNING WARNING • Spark Arrestor and Muffler may be hot! Allow engine to cool before servicing spark arrestor! Do not operate engine while servicing spark arrestor! Service the spark arrestor every 100 hours of opera- tion or twice a year, which ever occurs first.Service as follows: 1.

  • Page 24: 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 25: Troubleshooting

    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 26 Observe all Safety Guidelines detailed throughout this manual PROBLEMS (SYMPTOMS) Welder runs but fails to generate cur- rent. 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 27 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 28 WIRING DIAGRAMS SAE-400 SEVERE DUTY...
  • Page 29 WIRING DIAGRAMS SAE-400 SEVERE DUTY...
  • Page 30 DIMENSION PRINT SAE-400 SEVERE DUTY...
  • Page 31 NOTES SAE-400 SEVERE DUTY...
  • Page 32 ● WARNING ● Spanish ● AVISO DE PRECAUCION ● French ● ATTENTION ● ● German WARNUNG ● Portuguese ● ATENÇÃO ● Japanese Chinese Korean Arabic ● ● ● ● ● ● ● ● ● ●...
  • Page 33 ● ● ● ● ● ● ● ● ● ● ● ● ● ● ● ● ● ● Spanish ● PRECAUCION French ● ATTENTION ● German WARNUNG Portuguese ● ● Japanese Chinese Korean Arabic WARNING AVISO DE ATENÇÃO...
  • Page 34 • 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...

This manual is also suitable for:

Sae-400

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