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Lincoln Electric IM869-D Operator's Manual

Dc arc welding power source for use with machines having code numbers: 11198, 11322, 11407, 11409,11509
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RETURN TO MAIN MENU
IM869-D
SAE-400 DC ARC WELDING POWER SOURCE
May, 2008
For use with machines having Code Numbers: 11198, 11322, 11407, 11409,11509
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 importantly, think before
you act and be careful.
OPERATORʼS MANUAL
Copyright © 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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  • Page 1 RETURN TO MAIN MENU IM869-D SAE-400 DC ARC WELDING POWER SOURCE May, 2008 For use with machines having Code Numbers: 11198, 11322, 11407, 11409,11509 Lincoln arc welding and cutting equipment is designed and built with safety in mind. However, your overall safety can be increased by proper installation ...

  • 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 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 We respond to our customers based on the best information in our possession at that time. Lincoln Electric is not in a position to warrant or guarantee such advice, and assumes no liability, with respect to such information or advice.

  • Page 7: Table Of Contents

    Installation Instructions ..........Section A Technical Specifications .

  • Page 8: Technical Specifications

    TECHNICAL SPECIFICATIONS - SAE-400 (K1278-7, K1278-9) Make/Model Description K1278-7 Perkins 4 cylinder 1104C-44 Diesel 68.4 HP @ Engine 1725 RPM EPA Tier II Compliant K1278-9 Perkins 4 cylinder 1104A-44 Diesel 64.4 HP @ Engine 1710 RPM Not EPA Tier II Compliant (Export Only) Duty Cycle...

  • 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: Fuel

    (See Engine Manual or antifreeze container for alternate antifreeze recommendation.) ENGINE BREAK-IN PERIOD 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...

  • Page 12: Spark Arrester

    negative cable last. Keep well ven- tilated. ● USING A BOOSTER — connect positive lead to battery first then connect negative lead to negative battery lead at the lower control panel support. BATTERY ACID can burn eyes and skin. ● Wear gloves and eye protection and be careful when working near battery.

  • 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: Auxiliary Power

    RECOMMENDED APPLICATIONS WELDER The SAE-400 provides excellent constant current DC welding output for stick (SMAW) welding. The field installed optional CV Adapter (K385-[ ]) provides up to 500 amps at 35 volts of constant voltage output for semiautomatic welding. AUXILIARY POWER The SAE-400 provides 3 KW of 115/230 VAC output for auxiliary power and emergency standby power.
  • Page 15 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

    How to Set the Controls Assume you want a normal soft arc and about 135 amps, using a 5/32” (4.0 mm) electrode: 1. Set the “Job Selector” at the center of the black range. 2. Set the “Current Control” to read 135 amps on the black dial.

  • 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 various operating scenarios is shown below: PERKINS 1104C-44 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

    The use of an arc welder for pipe thawing is not approved by the CSA, nor is it recommended or supported by Lincoln Electric. ------------------------------------------------------------------------ K704 Standard Accessory Kit - Includes electrode and work cables, headshield, work clamp and elec- trode holder.

  • 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: Pre Filter / Washer Separator

    COMMUTATOR AND BRUSH MAINTENANCE WARNING Uncovered rotating equipment can be dangerous. Use care so your hands, hair, clothing or tools do not catch in the rotating parts. Protect yourself from particles that may be thrown out by the rotat- ing armature when stoning the commutator. ------------------------------------------------------------------------ The generator brushes are properly adjusted when the welder is shipped.

  • Page 22: Water Separator Element

    4. Using a pair of pliers, gently tug on the pull tabs of the pre-filter screen in an alternating pattern to gradually remove the pre-filter screen. 5. Brush off any debris and rinse in diesel fuel. 6. Re-install the pre-filter screen into the upper cavity of the filter header making sure the four pull tabs are pointing up.

  • Page 23: Spark Arrester

    4. Slide the new element onto the grommet post on the bottom of the filter header until the element no longer easily moves up into the filter header. Now rotate the element (may take almost 1 full turn) with a slight upward pressure until the element begins to further engage the header.

  • 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) 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. TROUBLESHOOTING POSSIBLE CAUSE...
  • Page 26 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 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 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 Observe all Safety Guidelines detailed throughout this manual PROBLEMS (SYMPTOMS) 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. TROUBLESHOOTING POSSIBLE CAUSE...
  • Page 29 WIRING DIAGRAMS SAE-400...
  • Page 30 WIRING DIAGRAM SAE-400...
  • Page 31 WIRING DIAGRAM SAE400...
  • Page 32 WIRING DIAGRAM SAE400...
  • Page 33 DIMENSION PRINT SAE-400...
  • Page 34 NOTES SAE-400...
  • Page 35 NOTES SAE-400...
  • Page 36 ● ● ● ● ● ● ● ● ● ● ● ● ● ● ● ● ● ● ● ● ● ● ● SAE-400 WARNING Spanish AVISO DE PRECAUCION French ATTENTION German WARNUNG Portuguese ATENÇÃO Japanese Chinese Korean Arabic...
  • Page 37 ● WARNING ● Spanish ● AVISO DE PRECAUCION ● French ● ATTENTION ● ● German WARNUNG ● Portuguese ● ATENÇÃO ● Japanese Chinese Korean Arabic ● ● ● ● ● ● ● ● ● ● SAE-400...
  • Page 38 • 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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Sae-400

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