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Lincoln Electric SAE-400 DC ARC, Operator'S Manual

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Lincoln Electric SAE-400 DC ARC Operator'S Manual Download Page 25

E-3

TROUBLE SHOOTING

Ifforanyreasonyoudonotunderstandthetestproceduresorareunabletoperformthetests/repairssafely,contactyour

Local  Lincoln Authorized Field Service Facility

fortechnicaltroubleshootingassistancebeforeyouproceed.

CAUTION

SAE-400™

FUNCTION PROBLEMS

PROBLEMS

(SYMPTOMS)

POSSIBLE 

CAUSE

RECOMMENDED

COURSE OF ACTION

Welderrunsbutfailstogenerate
current.

Weldingarcisloudandspatters
excessively.

1.Generatororexciterbrushesmay

belooseormissing.

2.Excitermaynotbeoperating.

3.Fieldcircuitofgeneratororexciter

maybeopen.

4.Polarityreversingswitchmaybe

intheneutralposition.

5.Excitermayhavelostexcitation.

1.Seriesfieldcircuitmaybeopen

circuited.

2.Currentsettingmaybetoohigh.

3.Polaritymaybewrong.

1.Besurethatallbrushesbearon

thecommutatorandhaveproper
springtension.

2.Checkexciteroutputvoltagewith

voltmeterorlamp.

3.Checkforopencircuitsinrheo-

stat,fieldleadsandfieldcoils.
Alsocheckresistors.

4.Puthandleinpositiveornegative

position.

5.Checkcomponentsandcontinuity

inflashingcircuit.

1.Checkcircuitwithringerorvolt-

meter.

2.Checksettingandcurrentoutput

withammeter.

3.Checkpolarity.Tryreversing

polarityortryanelectrodeofthe
oppositepolarity.

ObserveallSafetyGuidelinesdetailedthroughoutthismanual

Summary of Contents for SAE-400 DC ARC

Page 1: ...Code Numbers 11198 11322 11407 11409 11509 12250 Need Help Call 1 888 935 3877 to talk to a Service Representative Hours of Operation 8 00 AM to 6 00 PM ET Mon thru Fri After hours Use Ask the Experts at lincolnelectric com A Lincoln Service Representative will contact you no later than the following business day For Service outside the USA Email globalservice lincolnelectric com Save for future r...

Page 2: ...the general area IN A LARGE ROOM OR OUTDOORS natural ventilation may be adequate if you keep your head out of the fumes See below USE NATURAL DRAFTS or fans to keep the fumes away from your face If you develop unusual symptoms see your supervisor Perhaps the welding atmosphere and ventilation system should be checked wear CorreCt eye ear body ProteCtion PROTECT your eyes and face with welding helm...

Page 3: ...ty guards covers and devices in position and in good repair Keep hands hair clothing and tools away from V belts gears fans and all other moving parts when starting operating or repairing equipment 1 e In some cases it may be necessary to remove safety guards to perform required maintenance Remove guards only when necessary and replace them when the maintenance requiring their removal is complete ...

Page 4: ...o ANSI Z87 I standards 4 b Use suitable clothing made from durable flame resistant material to protect your skin and that of your helpers from the arc rays 4 c Protect other nearby personnel with suitable non flammable screening and or warn them not to watch the arc nor expose themselves to the arc rays or to hot spatter or metal FUMES AND GASES CAN BE DANGEROUS 5 a Welding may produce fumes and g...

Page 5: ...h lifting chains crane cables or other alternate circuits This can create fire hazards or overheat lifting chains or cables until they fail 6 h Also see item 1 c 6 I Read and follow NFPA 51B Standard for Fire Prevention During Welding Cutting and Other Hot Work available from NFPA 1 Batterymarch Park PO box 9101 Quincy Ma 022690 9101 6 j Do not use a welding power source for pipe thawing CYLINDER ...

Page 6: ... B 2 Remote Control B 3 Auxiliary Power Controls B 3 Engine Operation B 4 Starting Instructions B 4 Typical Fuel Consumption B 5 _____________________________________________________________________________________ Accessories Section C _____________________________________________________________________________________ Maintenance Section D Routine Maintenance D 1 Periodic Maintenance D 1 Pre Fi...

Page 7: ...justment of both voltage and current for unsur passed welds on demanding jobs Remote control capability standard FOR AUXILIARY POWER 3 000 watts of 115 230 VAC 60 Hz auxiliary power One 20 amp 115 VAC duplex receptacle for up to 26 amps of 115 VAC power One 15 amp 230 VAC duplex receptacle for up to 13 amps of 230 VAC power Weld and AC auxiliary power at the same time within the limits shown on th...

Page 8: ...278 9 PERKINS 1104A 44 Diesel Engine EPA TIER II Compliant Description 4 cylinder 68 4HP 48 kw 1725 RPM 4 cylinder 64 4HP 48 kw 1710 RPM Speed RPM High Idle 1800 Low Idle 1100 Full Load 1725 Displacement 269 cu in 4 4L Bore x Stroke 4 13 x 5 00 105 0mm x 127mm Starting System 12VDC batteries 2 Starter Capacities Fuel 22 5 US gal 85 1L Oil 10 1 US gal 9 6L Coolant 3 4 gal 12 8L Welding Range 80 575...

Page 9: ...xhaust fumes are properly vented to an outside area DO NOT MOUNT OVER COMBUSTIBLE SURFACES Where there is a combustible surface directly under station ary or fixed electrical equipment that surface should be cov ered with a steel plate at least 06 1 6mm thick which should extend not less than 5 90 150mm beyond the equip ment on all sides STACKING These machines cannot be stacked ANGLE OF OPERATION...

Page 10: ... 5 Proper preventative maintenance of trailer 6 Conformance with federal state and local laws 1 1 For highway use consult applicable federal state and local laws regarding specific requirements for use on public highways such as brakes lights fenders etc VEHICLE MOUNTING Improperly mounted concentrated loads may cause unstable vehicle handling and tires or other components to fail Only transport t...

Page 11: ...lder is subjected to extensive light loading occasional moderate to heavy loading of the engine may sometimes be necessary Caution must be observed in correctly loading a diesel generator unit 1 Connect the welder output studs to a suitable resistive load bank Note that any attempt to short the output studs by con necting the welding leads together direct shorting of the out put studs or connectin...

Page 12: ...nded for the rated current and duty cycle Lengths stipulated are the distance from the welder to work and back to the welder again Cable sizes are increased for greater lengths primarily for the purpose of minimizing cable voltage drop Table A 1 Combined Length of Electrode and Work Cables MACHINE GROUNDING Because this portable engine driven welder creates its own power it is not necessary to con...

Page 13: ...protection Only qualified personnel should install use or service this equipment Consult instruction manual before operating Before operating read and understand the manufacurer s instructions for this equipment and the consumables to be used including the Material Safety Data Sheet MSDS and follow your employer s safety practices FUMES AND GASES can be dangerous to your health Keep your head out ...

Page 14: ...n charge ENGINE HOUR METER The engine hour meter records the total running time on the engine in hours It can be used to keep a record of maintenance on the engine and or welder ENGINE PROTECTION SYSTEM The engine protection system shuts down the engine under high coolant temperature or low engine oil pressure conditions by allowing the fuel solenoid valve to close WELDER CONTROLS POLARITY SWITCH ...

Page 15: ... REMOTE position allows fine current control at the remote control box while placing the switch in the LOCAL position allows fine current control at the Job Selector on the machine When using the optional field installed CV adapter K385 the Local Remote switch is only active in the VV mode AUXILIARY POWER CONTROLS NOTE GFCI receptacles our an option and if installed see the MAINTENANCE section for...

Page 16: ...ssure If no pressure shows within 30 seconds stop the engine and consult the engine operating manual To stop the engine turn the IGNITION switch to OFF 6 If the engine protection warning light comes on during cranking or after start up the IGNITION switch must be turned OFF to reset the engine protection system 7 Allow the engine to run at high idle speed for sev eral minutes to warm the engine St...

Page 17: ...RKINS 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 02 L hr Auxiliary Power 71 gal hr 79 gal hr 3000VA 3 68 L hr 2 98 L hr ...

Page 18: ... erly The use of an arc welder for pipe thawing is not approved by the CSA nor is it recommended or supported by Lincoln Electric K704 Standard Accessory Kit Includes electrode and work cables headshield work clamp and electrode holder K385 CV Adapter Provides constant voltage output for semi automatic welding Field installation only K1690 1 GFCI RECEPTACLE KIT Includes one UL approved 120V ground...

Page 19: ... least once every two months In particularly dirty locations this cleaning may be nec essary once a week Use low pressure air to avoid driving dirt into the insulation 2 The current control reactor brushes are self lubricating and should not be greased Keep the contacts clean This control should be moved from maximum to minimum daily to prevent the controls from sticking 3 See the engine Instructi...

Page 20: ...shes pull the sandpa per around the circumference of the rings in direction of rotation only until brushes seat properly In addition stone slip ring with a fine stone Brushes must be seated 100 Arcing or excessive exciter brush wear indicates a possible mis aligned shaft Have an authorized Field Service Shop check and realign the shaft COOLING SYSTEM The SAE 400 is equipped with a pressure radiato...

Page 21: ...prop erly seated Note The element will only go on one way Never use excessive force when mounting the element to the header 5 Slide the quick change ring up over the element and rotate counter clockwise until an audible click or pop is heard If you do not hear the click you have not rotated the ring far enough and the element is not in the locked position Another indication that the ring is in the...

Page 22: ...ster gently tap on the arrester shell near the clean out plug 4 Once particles are removed replace the clean out plug GFCI RECEPTACLE TESTING AND RESETTING PROCEDURE The GFCI receptacle should be properly tested at least once every month or whenever it is tripped To properly test and reset the GFCI receptacle If the receptacle has tripped first carefully remove any load and check it for damage If ...

Page 23: ... 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 HOW TO USE TROUBLESHOOTING GUIDE Service and Repair should only be performed by Lincoln Electric Factory Trained Personnel Unauthorized repairs performed on this equipment may re...

Page 24: ...n out or missing Contact surface may be dirty rough and pitted 10 Current Control brushholder support stud and mating contact surfaces may be dirty or pitted and burned 11 Engine running at varying speeds 1 True and clean commutator 2 Replace brushes 3 Replace brush springs 4 Check field current with ammeter to discover varying current This applies to both the main generator and exciter 5 Tighten ...

Page 25: ... be open 4 Polarity reversing switch may be in the neutral position 5 Exciter may have lost excitation 1 Series field circuit may be open circuited 2 Current setting may be too high 3 Polarity may be wrong 1 Be sure that all brushes bear on the commutator and have proper spring tension 2 Check exciter output voltage with voltmeter or lamp 3 Check for open circuits in rheo stat field leads and fiel...

Page 26: ...Control shaft and handle may have turned slightly in the insulated bushing of the current control brushholder caused by turning handle too hard against one of the stops 2 Exciter output low causing low output compared to dial indication 3 Current Control set to minimum and welder output so great that engine stalls when arc is struck 1 Local Remote switch is in wrong position 1 With current control...

Page 27: ...d CAUTION SAE 400 FUNCTION PROBLEMS PROBLEMS SYMPTOMS POSSIBLE CAUSE RECOMMENDED COURSE OF ACTION No auxiliary power 1 Circuit Breakers open 2 Faulty connections to auxiliary receptacles 3 GFCI Receptacle if installed may have tripped 1 Check and reset breakers If breakers keep tripping check con nections to auxiliary receptacles Also make sure load does nor exceed receptacle s current rating 2 Ch...

Page 28: ...t 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 pan els If the diagram is illegible write to the Service Department for a replacement Give the equipment code number CODE ...

Page 29: ... 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 If the diagram is illegible write to the Service Department for a replacement Give the equipment code number ...

Page 30: ... 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 If the diagram is illegible write to the Service Department for a replacement Give the equipment code number ...

Page 31: ... 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 If the diagram is illegible write to the Service Department for a replacement Give the equipment code number ...

Page 32: ... 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 If the diagram is illegible write to the Service Department for a replacement Give the equipment code number ...

Page 33: ... A 81 HOLES N B 69 HOLES 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 88 83 00 CENTER OF GRAVITY WITH OIL AND WATER IN ENGINE BUT NO FUEL N A N A N B N B ...

Page 34: ...stomer s particular purpose with respect to such information or advice As a matter of practical consideration we also cannot assume any responsibility for updating or correcting any such information or advice once it has been given nor does the provision of information or advice create expand or alter any warranty with respect to the sale of our products Lincoln Electric is a responsive manufactur...

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