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Lincoln Electric POWER SOURCE IM640-A manual

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Table of contents for the manual

  • Page 1

    OPERA T OR’S MANUAL S AE400 & S AE400 WELD’N AIR - DC ARC WELDING PO WER SOURCE IM640-A May , 2004 For use with machines having Code Numbers: 10601, 10602, 10884, 10885 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 install[...]

  • Page 2

    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. _______________________________________________[...]

  • Page 3

    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. 4.b. Use suitable clothing made from durable flame-resistant material to protect your skin[...]

  • Page 4

    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. 8.c. Ground the equipment in accordance with the U.S. Nati[...]

  • Page 5

    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 contre la secousse électrique: a. L[...]

  • Page 6

    v SAFETY v W ARNING Assure that tank and compressor relief valves w ork properl y , and are at correct pressure settings. NEVER move compressor with pressure in tank. DO NO T modify or repair air tank.[...]

  • Page 7

    vi SAFETY vi[...]

  • Page 8

    vii vii 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 and keep it handy for quick reference.[...]

  • Page 9

    viii T ABLE OF CONTENTS SAE400 & SAE400 WELD ’ N AIR viii Page Installation Instructions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Section A T echnical Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .A-1 Installation Precautions . . . .[...]

  • Page 10

    A-1 INST ALLA TION SAE400 & SAE400 WELD ’ N AIR A-1 TECHNICAL SPECIFICA TIONS - SAE400 & SAE400 WELD ’ N AIR 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 (4.2 L) (2 ) & Starter 85.1 L Engin[...]

  • Page 11

    A-2 INST ALLA TION SAE400 & SAE400 WELD ’ N AIR 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. They include impor- tant safety precautions, detailed engine startin[...]

  • Page 12

    A-3 INST ALLA TION SAE400 & SAE400 WELD ’ N AIR 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.) above 1000 meters (3280 ft.). Contact a Perkins Service Representative for any engine adjustments that may be required for high al[...]

  • Page 13

    A-4 INST ALLA TION A-4 SAE400 & SAE400 WELD ’ N AIR • Stop engine while fueling. • Do not smoke when fueling. • Keep sparks and flame away from tank. • Do not leave unattended while fueling. • W ipe up spilled fuel and allow fumes to clear before starting engine. • Do not overfill tank, fuel expansion may cause over- flow . DIESEL[...]

  • Page 14

    BA TTERY ACID can burn eyes and skin. ● Wear gloves and eye protection and be careful when working near battery . ● Follow instructions printed on battery . IMPORT ANT : T o prevent ELECTRICAL DAMAGE WHEN: a) Installing new batteries. b) Using a booster . Use correct polarity — Negative Ground . T o prevent BA TTERY BUCKLING, tighten nuts on [...]

  • Page 15

    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. • Keep away from moving parts • Do not operate with doors open or guards off. • Stop en[...]

  • Page 16

    B-2 OPERA TION B-2 RECOMMENDED APPLICA TIONS WELDER The SAE400 or SAE400 WELD’N AIR provides excel- lent constant current DC welding output for stick (SMA W) welding. The field installed optional CV Adapter (K385-1) provides up to 500 amps at 35 volts of constant voltage output for semiautomatic welding. AUXILIAR Y POWER The SAE400 or SAE400 WELD[...]

  • Page 17

    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. “ IDLER ” SWITCH The idler switch has two positions, “HIGH” and “AUTO”. When in “HIGH”[...]

  • Page 18

    B-4 OPERA TION B-4 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. 3. Start to weld. 4. If you want a little more current, turn the “Job Selector” [...]

  • Page 19

    B-5 OPERA TION B-5 ENGINE OPERA TION Do not adjust the high idle engine speed (rpm) above the factory setting specification as this will overspeed the air compressor and void it’s warranty . ------------------------------------------------------------------------ ST ARTING INSTRUCTIONS Be sure all Pre-Operation Maintenance has been per- formed. ([...]

  • Page 20

    C-1 ACCESSORIES C-1 K930-2 Hi-Freq ™ - Provides high frequency plus a gas valve for TIG welding. A water valve is available as an option. Requires 1 15 volt AC input. (Limited to 250A - 60% Duty Cycle). 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 yar[...]

  • Page 21

    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. ● Use in open, well ventilated areas or vent exhaust outside MOVING P ARTS can injure. ● Do not operate with doors open or guards off ● Stop engine before servicing ● Keep away from mov[...]

  • Page 22

    D-2 MAINTENANCE D-2 COMMUT A TOR AND BRUSH MAINTENANCE 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 . ---------------------------------------------------[...]

  • Page 23

    D-3 MAINTENANCE D-3 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 of f 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. Put[...]

  • Page 24

    D-4 MAINTENANCE D-4 SP ARK ARRESTOR • Spark Arrester and Muffler may be hot! • Allow engine to cool before servicing spark arrester! • Do not operate engine while servicing spark arrester! For machines with separate spark arresting units: Service the spark arrestor every 100 hours of opera- tion or twice a year , which ever occurs first. Serv[...]

  • Page 25

    E-1 TROUBLESHOOTING E-1 SAE400 & SAE400 WELD ’ N AIR 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 W ARNING ELECTRIC SHOCK can kill. • Do not touc[...]

  • Page 26

    E-2 TROUBLESHOOTING E-2 SAE400 & SAE400 WELD ’ N AIR 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 proc[...]

  • Page 27

    E-3 TROUBLESHOOTING E-3 SAE400 & SAE400 WELD ’ N AIR 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 proc[...]

  • Page 28

    E-4 TROUBLESHOOTING E-4 SAE400 & SAE400 WELD ’ N AIR 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 proc[...]

  • Page 29

    E-5 TROUBLESHOOTING E-5 SAE400 & SAE400 WELD ’ N AIR 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 proc[...]

  • Page 30

    F-1 WIRING DIAGRAMS SAE400 & SAE400 WELD ’ N AIR F-1 B 239 Enable TERMINAL Compressor IGNITE R COLD B 233 THER MOSTART B B - START THER MOSTART 230 W 30 B B 229 B 234 220 B B IDLER SWITCH IND J2 PROTECTI ON P.C. BOA RD IDLER/ENGINE J1 + TO TORO ID 2 CR REED RELAY R GROUND SCREW B STARTING Pressure SW. TO CONTROL PA NEL B 232 G 243 B SWITCH 24[...]

  • Page 31

    SAE400 & SAE400 WELD ’ N AIR F-2 WIRING DIAGRAMS F-2 SWITCH PROTECTI ON P.C. BOA RD IDLER/ENGINE J1 + SW ITCH (N.C.) OIL PRESSUR E THERMOSTART COLD TERMINAL START B - THERMOSTART 5C B B + GROUND SCRE W TO CONTRO L PA NEL B G 223 W W R 4 3 2 5A 1 10 G 225 B 9 8 7 3 2 B SOLENOID 226 234 IDLER M19233 REED RELAY S R B - FUEL INJEC TION P U MP TEM[...]

  • Page 32

    SAE400 & SAE400 WELD ’ N AIR F-3 WIRING DIAGRAMS F-3 7- 01 M19 237 COLOR CODE ALTERNATOR ROTOR AC + SLIP - RINGS (-) D2 FLASHIN G DIODE B-BLACK OR GRAY G-GREEN N-BROWN R-RED OR PINK U-BLUE W-WHIT E Y-YELLOW AND RESISTOR 238 AC R SEE BATTERY W IRING DIAGR AM TO LOW ER PANEL GROU ND SCR EW 1 (+) AC 203 AC D1 W SEE BATTERY WIRING DIAGRAM A 1 2 2[...]

  • Page 33

    SAE400 & SAE400 WELD ’ N AIR F-4 DIMENSION PRINT F-4 18.50 22.14 22.00 27.12 24.50 8.12 3.00 .88 43.75 63.06 39.69 50.13 28.00 32.87 6.00 81.25 69.75 77.00 39.38 44.50 8.90 83.00 * = .81 DIA HOLES = .69 DIA HOLES * * CENTER OF GRAVITY WITH OIL AND WATER IN ENGINE, BUT NO FUEL. 1-98 M8869-33[...]

  • Page 34

    SAE400 & SAE400 WELD ’ N AIR NOTES[...]

  • Page 35

    SAE400 & SAE400 WELD ’ N AIR 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. ● Keep your head out of fumes. ● Use venti[...]

  • Page 36

    SAE400 & SAE400 WELD ’ N AIR 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. SE RECOMIENDA LEER Y ENTENDER LAS IN[...]

  • Page 37

    • 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 .lincolnelectric.com • World's Leader in W elding and Cutting Products •[...]