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 fumes outdoors....
Page 3 - ii; ELECTRIC SHOCK can kill.
ii SAFETY ii ARC RAYS can burn. 4.a. Use a shield with the proper filter and cover plates to protect your eyes from sparks andthe rays of the arc when welding or observingopen arc welding. Headshield and filter lensshould conform to ANSI Z87. I standards. 4.b. Use suitable clothing made from durable...
Page 4 - iii
iii SAFETY iii FOR ELECTRICALLYpowered equipment. 8.a. Turn off input power using the disconnect switch at the fuse box before working onthe equipment. 8.b. Install equipment in accordance with the U.S. National Electrical Code, all local codes and the manufacturer’srecommendations. 8.c. Ground the ...
Page 5 - iv; PRÉCAUTIONS DE SÛRETÉ
iv SAFETY iv Mar. ‘93 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 contr...
Page 6 - Thank You; Please Examine Carton and Equipment For Damage Immediately
v v 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 manual...
Page 7 - TABLE OF CONTENTS
vi TABLE OF CONTENTS SAE-400 SEVERE DUTY vi Page Installation Instructions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Section A Technical Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .A-1Inst...
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 256 cu. in 12VDC batteries Fuel: 22.5 gal. 1004.42 Diesel 71 HP @ Low Idle 1100 (4.2 L) (2) & Start...
Page 9 - SAFETY PRECAUTIONS; STACKING
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 you havethoroughly read all operating and maintenance man-uals supplied with your machine. They include impor-tant safety precaut...
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 workcables to the studs provided. These connectionsshould be checked periodically and tightened if neces-sary. Listed in Table A.1 are copper cable sizes recom-mended for the rated current a...
Page 13 - OPERATION; ADDITIONAL SAFETY PRECAUTIONS; GENERAL DESCRIPTION; RECOMMENDED APPLICATIONS; OPERATING INSTRUCTIONS
B-1 OPERATION B-1 WELDING SPARKS can causefire or explosion. • Do not weld near flammable material . • Do not weld on containers that haveheld flammable material. ----------------------------------------------------------- MOVING PARTS can injure.• Keep away from moving parts• Do not operate with do...
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 ” posi- tion, the flow of fuel to the injection pump is stopped toshut down the engine. “IDLER” SWITCH The idler switch has two positions, “ HIGH ...
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 current adjuster. The “ Job Selector ” is...
Page 17 - ENGINE OPERATION; STARTING INSTRUCTIONS; TYPICAL FUEL CONSUMPTION
B-5 OPERATION B-5 ENGINE OPERATION 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 sectio...
Page 18 - ACCESSORIES
C-1 ACCESSORIES C-1 OPTIONAL FIELD INSTALLEDACCESSORIES 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 (1) with E78-14 load range (B) tubeless tires. Mounts directly to welder base. K956-1 and -...
Page 19 - 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 20 - 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 21 - WATER SEPARATOR ELEMENT
D-3 MAINTENANCE D-3 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. 3. Remove the large white volume plug located direct- ly under th...
Page 22 - SPARK ARRESTOR
D-4 MAINTENANCE D-4 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. Service as follows: 1. Stop engine and allow to cool. 2. Loosen clamp and remove spark arrestor from machine. 3. Remo...
Page 23 - 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 24 - 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 27 - WIRING DIAGRAMS; RNI
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. SW IT C H PR OT EC T IO N P.C. B O A R D ID L...
Page 29 - DIMENSION PRINT
SAE-400 SEVERE DUTY F-3 DIMENSION PRINT F-3 M8869-23 5/01 28 .0 0 24 .5 0 27 .1 2 22 .0 0 22 .1 4 6.00 39.69 50.13 8.90 69 .7 5 77.00 81.2 5 83 .0 0 38 .5 0 63.06 .88 3.00 8.12 6.31 26.75 CENTER OF GRAVITY WITH OIL AND WATER IN ENGINE, BUT NO FUEL N. A. . 81 DI A. H OLES . N. B. . 69 DI A. HOLES. N....
Page 30 - NOTES
Page 31 - ÇÃ
WARNING AVISO DE PRECAUCION ATTENTION WARNUNG ATEN ÇÃ O Spanish French German Portuguese Japanese Chinese Korean Arabic READ AND UNDERSTAND THE MANUFACTURER’S INSTRUCTION FOR THIS EQUIPMENT AND THE CONSUMABLES TOBE USED AND FOLLOW YOUR EMPLOYER’S SAFETY PRACTICES. SE RECOMIENDA LEER Y ENTENDER LAS I...
