Lincoln Electric IM870-A - Manuals

Lincoln Electric IM870-A – Manual in PDF format online.

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Manual

Manual Lincoln Electric IM870-A

Summary

Page 2 - SAFETY; WARNING; CALIFORNIA PROPOSITION 65 WARNINGS; The Above For Diesel Engines

FOR ENGINEpowered equipment. 1.a. Turn the engine off before troubleshooting and maintenance work unless the maintenance work requires it to be running. ____________________________________________________ 1.b. Operate engines in open, well-ventilated areas or vent the engine exhaust fumesoutdoors. ...

Page 5 - PRÉCAUTIONS DE SÛRETÉ

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 électriq...

Page 6 - Thank You; Please Examine Carton and Equipment For Damage Immediately

ix ix Thank You for selecting a QUALITY product by Lincoln Electric. We want you to take pride in operating this Lincoln Electric Company product••• as much pride as we have in bringing this product to you! Read this Operators Manual completely before attempting to use this equipment. Save this manu...

Page 7 - TABLE OF CONTENTS

vi TABLE OF CONTENTS SAE-400 SEVERE DUTY vi Page Installation Instructions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Section A Technical Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ...

Page 8 - INSTALLATION; TECHNICAL SPECIFICATIONS - SAE-400 SEVERE DUTY; INPUT - DIESEL ENGINE

A-1 INSTALLATION SAE-400 SEVERE DUTY A-1 TECHNICAL SPECIFICATIONS - SAE-400 SEVERE DUTY 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) & St...

Page 9 - SAFETY PRECAUTIONS; STACKING; ANGLE OF OPERATION

A-2 INSTALLATION SAE-400 SEVERE DUTY A-2 Read this entire installation section before youstart installation. SAFETY PRECAUTIONS Do not attempt to use this equipment until youhave thoroughly read all operating and mainte-nance manuals supplied with your machine. Theyinclude important safety precautio...

Page 10 - PRE-OPERATION ENGINE SERVICE; DIESEL FUEL ONLY

A-3 INSTALLATION SAE-400 SEVERE DUTY A-3 HIGH ALTITUDE OPERATION At higher altitudes, output derating may be necessary.As a rule of thumb, derate the welder output 5% forevery 500 meters (1640 ft.) above 1000 meters (3280ft.). Contact a Perkins Service Representative for anyengine adjustments that m...

Page 11 - BATTERY CONNECTION; ENGINE COOLING SYSTEM

A-4 INSTALLATION A-4 SAE-400 SEVERE DUTY BATTERY CONNECTION WARNING: Use caution as the electrolyte is a strong acid that can burn skin and damage eyes. Remove and discard the insulating caps from the neg-ative battery terminals. Attach and tighten negativebattery cable terminals. NOTE: This machine...

Page 12 - WELDING OUTPUT CABLES; MACHINE GROUNDING; CAUTION

A-5 INSTALLATION SAE-400 SEVERE DUTY A-5 WELDING OUTPUT CABLES With the engine off, connect the electrode and workc a b l e s t o t h e s t u d s p r o v i d e d . T h e s e c o n n e c t i o n sshould be checked periodically and tightened if neces-sary. Listed in Table A.1 are copper cable sizes re...

Page 13 - OPERATION; ADDITIONAL SAFETY PRECAUTIONS; GENERAL DESCRIPTION; RECOMMENDED APPLICATIONS; OPERATING INSTRUCTIONS

B-1 OPERATION B-1 WELDING SPARKS can cause fireor explosion. • Do not weld near flammable material . • Do not weld on containers that have held flammable material. -------------------------------------------------------------- MOVING PARTS can injure.• Keep away from moving parts• Do not operate wit...

Page 14 - DESIGN FEATURES AND ADVANTAGES; DUTY CYCLE

B-2 OPERATION B-2 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 • 3,000 w...

Page 15 - ENGINE CONTROLS

B-3 OPERATION B-3 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 isstopped to shut down the engine. “IDLER” SWITCH T h e i d l e r s w i t c h h a s t w o p o s i t i...

Page 16 - WELDER CONTROLS

B-4 OPERATION B-4 WELDER CONTROLS POLARITY SWITCH Turn the Arc Polarity switch to electrode positive orelectrode negative as required for each particularapplication. CONTROL OF WELDING CURRENTPurpose of Controls The continuous “Current Control” is the main currentadjuster. The “Job Selector” is both...

Page 17 - ENGINE OPERATION; STARTING INSTRUCTIONS; See additional warning information at the; STOPPING THE ENGINE

B-5 OPERATION B-5 SAE-400 SEVERE DUTY ENGINE OPERATION For added safety always operate the welder with thed o o r s c l o s e d . F u r t h e r , l e a v i n g t h e d o o r s o p e nchanges the designed air flow and may cause engine,generator overheating. Do not adjust the high idle engine speed (r...

Page 18 - TYPICAL FUEL CONSUMPTION

B-6 OPERATION B-6 SAE-400 SEVERE DUTY 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 A...

Page 19 - ACCESSORIES

C-1 ACCESSORIES C-1 OPTIONAL FIELD INSTALLEDACCESSORIES 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 (1) with E78-14 load range (B) tubeless tires. Mounts directly to welder base.(Not foruse on the ...

Page 20 - MAINTENANCE; ROUTINE MAINTENANCE

D-1 MAINTENANCE D-1 ELECTRIC SHOCK can kill. ● Do not touch electrically live partssuch as output terminals or inter-nal wiring ENGINE EXHAUST can kill. ● Use in open, well ventilated areasor vent exhaust outside MOVING PARTS can injure. ● Do not operate with doors open orguards off ● Stop engine be...

Page 21 - BEARING MAINTENANCE

D-2 MAINTENANCE D-2 BEARING MAINTENANCE This welder is equipped with a double-shielded ball bearinghaving sufficient grease to last indefinitely under normal ser-vice. Where the welder is used constantly or in excessivelydirty locations, it may be necessary to add one-half ounce ofgrease per year. A...

Page 22 - WATER SEPARATOR ELEMENT; SECONDARY FUEL FILTER

D-3 MAINTENANCE D-3 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. R e m o v e t h e l a r g e w h i t e v o l u m e p l u g l o c a t e d directly under the center cap in t...

Page 23 - SPARK ARRESTOR

D-4 MAINTENANCE D-4 GFCI RECEPTACLE TESTING AND RESET-TING PROCEDURE The GFCI receptacle should be properly tested atleast once every month or whenever it is tripped. Toproperly test and reset the GFCI receptacle: • If the receptacle has tripped, first carefully remove any load and check it for dama...

Page 24 - TROUBLESHOOTING; HOW TO USE TROUBLESHOOTING GUIDE

E-1 TROUBLESHOOTING E-1 SAE-400 SEVERE DUTY 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. CAUTION WARNING ELECTRI...

Page 25 - PROBLEMS

E-2 TROUBLESHOOTING E-2 SAE-400 SEVERE DUTY Observe all Safety Guidelines detailed throughout this manual 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 troubles...

Page 28 - WIRING DIAGRAMS

F-1 WIRING DIAGRAMS SAE-400 SEVERE DUTY F-1 NOTE: This diagram is for reference only. It may not be accurate for all machines covered by this manual. The specific diagram for a particular code is pasted inside the machine on one of the enclosure panels.

Page 30 - DIMENSION PRINT

SAE-400 SEVERE DUTY F-3 DIMENSION PRINT F-3 M8 86 9 -3 6 A N. A. .81 HO LES N. B. .69 HO LES 28. 00 22. 00 22. 14 24. 50 27. 12 6. 00 39. 69 47. 95 23. 00 26. 00 38. 50 63. 06 50. 13 21. 00 44. 00 8. 90 44. 50 69. 75 8. 12 77. 00 3. 00 81. 25 .8 8 83. 00 C E N T E R OF GR AVIT Y W IT H OIL AND W A T...

Page 31 - NOTES