Instruction/ maintenance manual of the product SAE-400 SEVERE DUTY IM727 Lincoln Electric
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OPERA T OR’S MANUAL S AE-400 SEVERE DUTY DC ARC WELDING PO WER SOURCE IM727 January , 2005 For use with machines having Code Number: 10856 Safety Depends on Y ou Lincoln arc welding and cutting equipment is designed and built with safety in mind. However , your overall safety can be increased by pr oper installation .
FOR ENGINE powered equipment. 1.a. T urn 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.
ii SAFETY ii ARC RA YS can burn. 4.a. Use a shield with the proper filter and cover plates to protect your eyes from sparks and the rays of the arc when welding or observing open arc welding. Headshield and filter lens should conform to ANSI Z87. I standards.
iii SAFETY iii FOR ELECTRICALL Y powered equipment. 8.a. T urn off input power using the disconnect switch at the fuse box before working on the equipment. 8.b. Install equipment in accordance with the U.S. National Electrical Code, all local codes and the manufacturer ’s recommendations.
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.
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.
vi T ABLE OF CONTENTS SAE-400 SEVERE DUTY vi Page Installation Instructions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Section A T echnical Specifications . . . . . . . . . . . . . . . . . . . . . . . . . .
A-1 INST ALLA TION SAE-400 SEVERE DUTY A-1 TECHNICAL SPECIFICA TIONS - 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 1 100 (4.
A-2 INST ALLA TION SAE-400 SEVERE DUTY A-2 Read this entire installation section before you start installation. SAFETY PRECAUTIONS Do not attempt to use this equipment until you have thoroughly read all operating and maintenance man- uals supplied with your machine.
A-3 INST ALLA TION SAE-400 SEVERE DUTY A-3 HIGH AL TITUDE OPERA TION At higher altitudes, output derating may be necessary . As a rule of thumb, derate the welder output 5% for every 500 meters (1640 ft.
A-4 INST ALLA TION A-4 SAE-400 SEVERE DUTY BA TTER Y CONNECTION W ARNING: 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 negative battery cable terminals.
A-5 INST ALLA TION SAE-400 SEVERE DUTY A-5 WELDING OUTPUT CABLES With the engine off, connect the electrode and work cables to the studs provided. These connections should be checked periodically and tightened if neces- sary . Listed in T able A.1 are copper cable sizes recom- mended for the rated current and duty cycle.
B-1 OPERA TION B-1 WELDING SP ARKS can cause fire or explosion. • Do not weld near flammable material . • Do not weld on containers that have held flammable material. ----------------------------------------------------------- MOVING P ARTS can injure.
B-2 OPERA TION B-2 DESIGN FEA TURES AND ADV ANT AGES 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.
B-3 OPERA TION 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 to shut down the engine.
B-4 OPERA TION B-4 WELDER CONTROLS POLARITY SWITCH T urn 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 .
B-5 OPERA TION B-5 ENGINE OPERA TION Do not adjust the high idle engine speed (rpm) above the factory setting specification. ------------------------------------------------------------------------ ST ARTING INSTRUCTIONS Be sure all Pre-Operation Maintenance has been per- formed.
C-1 ACCESSORIES C-1 OPTIONAL FIELD INST ALLED ACCESSORIES K802-D Power Plug Kit - Kit includes male plugs for each auxiliary receptacle. K767-1 T railer - A 4-wheel steerable trailer for in-plant and yard towing (1) with E78-14 load range (B) tubeless tires.
D-1 MAINTENANCE D-1 ELECTRIC SHOCK can kill. ● Do not touch electrically live parts such as output terminals or inter- nal wiring ENGINE EXHAUST can kill.
D-2 MAINTENANCE D-2 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 .
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.
D-4 MAINTENANCE D-4 SP ARK 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.
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.
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 troubleshooting assistance before you proceed.
E-3 TROUBLESHOOTING E-3 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 troubleshooting assistance before you proceed.
E-4 TROUBLESHOOTING E-4 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 troubleshooting assistance before you proceed.
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.
SAE-400 SEVERE DUTY F-2 WIRING DIAGRAMS F-2 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.
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 81.25 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 DIA.
SAE-400 SEVER DUTY NOTES.
W ARNING A VISO DE PRECAUCION A TTENTION W ARNUNG A TEN ÇÃ O Spanish French German Portuguese Japanese Chinese Korean Arabic READ AND UNDERST AND THE MANUF ACTURER’S INSTRUCTION FOR THIS EQUIPMENT AND THE CONSUMABLES TO BE USED AND FOLLOW YOUR EMPLOYER’S SAFETY PRACTICES.
W ARNING A VISO DE PRECAUCION A TTENTION W ARNUNG A TEN ÇÃ O Spanish French German Portuguese Japanese Chinese Korean Arabic LEIA E COMPREENDA AS INSTRUÇÕES DO F ABRICANTE PARA ESTE EQUIP AMENTO E AS P ARTES DE USO, E SIGA AS PRÁTICAS DE SEGURANÇA DO EMPREGADOR.
• Sales and Service through Subsidiaries and Distributors Worldwide • Cleveland, Ohio 441 17-1 199 U.S.A. TEL: 216.481.8100 F AX: 216.486.1751 WEB SITE: www .
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If you already are a holder of Lincoln Electric SAE-400 SEVERE DUTY IM727, but have not read the manual yet, you should do it for the reasons described above. You will learn then if you properly used the available features, and whether you have not made any mistakes, which can shorten the lifetime Lincoln Electric SAE-400 SEVERE DUTY IM727.
However, one of the most important roles played by the user manual is to help in solving problems with Lincoln Electric SAE-400 SEVERE DUTY IM727. Almost always you will find there Troubleshooting, which are the most frequently occurring failures and malfunctions of the device Lincoln Electric SAE-400 SEVERE DUTY IM727 along with tips on how to solve them. Even if you fail to solve the problem, the manual will show you a further procedure – contact to the customer service center or the nearest service center
