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IM869-D
May, 2008
SAE-400 DC ARC WELDING POWER SOURCE
For use with machines having Code Numbers: 11198, 11322, 11407, 11409,11509
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
operation on your part. DO NOT
INSTALL, OPERATE OR REPAIR
THIS EQUIPMENT WITHOUT
READING THIS MANUAL AND
THE SAFETY PRECAUTIONS
CONTAINED THROUGHOUT.
And, most importantly, th
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i i SAFETY WARNING CALIFORNIA PROPOSITION 65 WARNINGS Diesel engine exhaust and some of its constituents The engine exhaust from this product contains are known to the State of California to cause can- chemicals known to the State of California to cause cer, birth defects, and other reproductive harm. cancer, birth defects, or other reproductive harm. The Above For Diesel Engines The Above For Gasoline Engines ARC WELDING CAN BE HAZARDOUS. PROTECT YOURSELF AND OTHERS FROM POSSIBLE SERIOUS INJURY
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ii ii SAFETY ARC RAYS can burn. ELECTRIC SHOCK can kill. 3.a. The electrode and work (or ground) circuits 4.a. Use a shield with the proper filter and cover plates to protect your eyes from sparks and are electrically “hot” when the welder is on. the rays of the arc when welding or observing Do not touch these “hot” parts with your bare open arc welding. Headshield and filter lens skin or wet clothing. Wear dry, hole-free should conform to ANSI Z87. I standards. gloves to insulate hands. 4.b. Us
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iii iii SAFETY CYLINDER may explode WELDING and CUTTING SPARKS can if damaged. 7.a. Use only compressed gas cylinders cause fire or explosion. 6.a. Remove fire hazards from the welding area. containing the correct shielding gas for the If this is not possible, cover them to prevent process used and properly operating the welding sparks from starting a fire. regulators designed for the gas and pressure used. All hoses, fittings, etc. should be suitable for Remember that welding sparks and hot mat
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iv iv SAFETY 6. Eloigner les matériaux inflammables ou les recouvrir afin de PRÉCAUTIONS DE SÛRETÉ prévenir tout risque dʼincendie dû aux étincelles. Pour votre propre protection lire et observer toutes les instructions 7. Quand on ne soude pas, poser la pince à une endroit isolé de et les précautions de sûreté specifiques qui parraissent dans ce la masse. Un court-circuit accidental peut provoquer un manuel aussi bien que les précautions de sûreté générales suiv- échauffement et un risque dʼinc
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v v for selecting a QUALITY product by Lincoln Electric. We want you to take pride in operating this Lincoln Electric Company product ••• Thank You as much pride as we have in bringing this product to you! CUSTOMER ASSISTANCE POLICY The business of The Lincoln Electric Company is manufacturing and selling high quality welding equipment, consumables, and cutting equip- ment. Our challenge is to meet the needs of our customers and to exceed their expectations. On occasion, purchasers may ask Linco
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vi vi TABLE OF CONTENTS Page Installation Instructions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Section A Technical Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .A-1 Installation Precautions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A-2 Location / Ventilation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
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A-1 A-1 INSTALLATION TECHNICAL SPECIFICATIONS - SAE-400 (K1278-7, K1278-9) INPUT - DIESEL ENGINE Make/Model Description Speed (RPM) Displacement Starting Capacities System K1278-7 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) & Starter 85.1 L Engine 1725 RPM Full Load 1725 EPA Tier II Compliant Bore x Stroke Oil: 10.1 Qts. 9.6 L K1278-9 Perkins 4 cylinder 4.13” x 5.00” 1104A-44 Diesel 64.4 HP @ (105.0 mm x 1
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A-2 A-2 INSTALLATION Read this entire installation section before you start installation. CAUTION SAFETY PRECAUTIONS DO NOT MOUNT OVER COMBUSTIBLE SURFACES Where there is a combustible surface directly under stationary or fixed electrical equipment, that surface WARNING should be covered with a steel plate at least .06”(1.6mm) thick, which should extend not less than Do not attempt to use this equipment until you have 5.90(150mm) beyond the equipment on all sides. thoroughly read all operatin
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A-3 A-3 INSTALLATION HIGH ALTITUDE OPERATION VEHICLE MOUNTING At higher altitudes, output derating may be necessary. WARNING As a rule of thumb, derate the welder output 5% for every 500 meters (1640 ft.) above 1000 meters (3280 Improperly mounted concentrated loads may cause ft.). unstable vehicle handling and tires or other compo- nents to fail. Contact a Perkins Service Representative for any • Only transport this equipment on serviceable vehi- engine adjustments that may be required for hig
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A-4 A-4 INSTALLATION WARNING • Stop engine while fueling. • Do not smoke when fueling. 1. Connect the welder output studs to a suitable resis- • Keep sparks and flame away from tive load bank. Note that any attempt to short the tank. output studs by connecting the welding leads • Do not leave unattended while together, direct shorting of the output studs, or con- fueling. necting the output leads to a length of steel will • Wipe up spilled fuel and allow result in catastrophic damage to the g
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A-5 A-5 INSTALLATION negative cable last. Keep well ven- WELDING OUTPUT CABLES tilated. With the engine off, connect the electrode and work cables to the studs provided. These connections should be checked periodically and tightened if neces- ● USING A BOOSTER — connect sary. positive lead to battery first then connect negative lead to negative Listed in Table A.1 are copper cable sizes recom- battery lead at the lower control mended for the rated current and duty cycle. Lengths panel sup
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B-1 B-1 OPERATION OPERATING INSTRUCTIONS both, to keep the fumes and gases Read and understand this entire section before operat- from your breathing zone and general ing your equipment. area. SAFETY INSTRUCTIONS WELDING SPARKS can cause fire or WARNING explosion. Do not attempt to use this equipment until you have • Do not weld near flammable material thoroughly read all operating and maintenance manu- . als supplied with your machine. They include important safety precautions, detailed engine
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B-2 B-2 OPERATION RECOMMENDED APPLICATIONS OTHER FEATURES WELDER • Perkins 4-cylinder, water cooled diesel engine. The SAE-400 provides excellent constant current DC Designed for long life, easy maintenance and excel- welding output for stick (SMAW) welding. The field lent fuel economy. installed optional CV Adapter (K385-[ ]) provides up to • Engine protection system shuts the engine down for 500 amps at 35 volts of constant voltage output for low engine oil pressure or high coolant temperature
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B-3 B-3 OPERATION ENGINE PROTECTION SYSTEM ENGINE CONTROLS The engine protection system shuts down the engine IGNITION SWITCH under high coolant temperature or low engine oil pres- sure conditions by allowing the fuel solenoid valve to When placed in the “ON” position, this switch ener- close. gizes the fuel solenoid. When placed in the “OFF” posi- tion, the flow of fuel to the injection pump is stopped to WELDER CONTROLS shut down the engine. POLARITY SWITCH “IDLER” SWITCH Turn the Arc Polarity
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B-4 B-4 OPERATION How to Set the Controls 230 VAC Receptacle Assume you want a normal soft arc and about 135 One 15 amp, 230 VAC duplex receptacle provides 230 amps, using a 5/32” (4.0 mm) electrode: VAC for auxiliary power. A total of 13 amps can be drawn from this receptacle. 1. Set the “Job Selector” at the center of the black range. Circuit Breakers 2. Set the “Current Control” to read 135 amps on the The circuit breakers provide separate overload current black dial. protection for each half
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B-5 B-5 OPERATION ENGINE OPERATION 5. Observe the oil pressure. If no pressure shows within 30 seconds, stop the engine and consult the WARNING engine operating manual. To stop the engine, turn Do not attempt to use this equipment until you the “IGNITION” switch to “OFF”. have thoroughly read the engine manufacturerʼs 6. If the engine protection warning light comes on manual supplied with your welder. It includes during cranking or after start up, the “IGNITION” important safety precautions, det
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B-6 B-6 OPERATION TYPICAL FUEL CONSUMPTION The typical fuel consumption of the SAE-400 for various operating scenarios is shown below: PERKINS 1104C-44 PERKINS 1104A-44 Low Idle - No Load .30 gal./ hr. 26 gal./ hr. 1100 RPM (1.12 L./hr.) (.97 L./hr.) High Idle - No Load .69 gal./hr. .68 gal./hr. 1800 RPM (2.61 L./hr.) (2.56 L./hr.) Welding Load 1.79 gal./hr. 1.84 gal./hr. 400 Amps, 40 Volts (6.76 L./hr.) (6.95 L./hr.) Welding Load 2.43 gal./hr. 2.38 gal./hr. 500 Amps, 40 Volts (9.19 L./hr.) (9.0
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C-1 C-1 ACCESSORIES K930-2 TIG Module - Provides high frequency plus a K1735-1 MULTI-WELD 350 - For multiple arcs from gas valve for TIG welding. A water valve is available as the DC output of a welding power source. See bulletin an option. Requires 115 volt AC input. (Limited to 250A E5.300 for Multi-Weld 350 and distribution system. - 60% Duty Cycle). K2144-1 Oil Drain Kit- Includes ball valve, hose and K802-D Power Plug Kit - Kit includes male plug for 20 clamp. amp receptacle. K1858-1 Servic
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D-1 D-1 MAINTENANCE PERIODIC MAINTENANCE WARNING 1. Blow out the welder and controls with an air hose at least ELECTRIC SHOCK can kill. once every two months. In particularly dirty locations, this cleaning may be necessary once a week. Use low pres- ● Do not touch electrically live parts sure air to avoid driving dirt into the insulation. such as output terminals or inter- nal wiring 2. The current control reactor brushes are self-lubricating and should not be greased. Keep the contacts clean. T
