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5.

a.

Use only compressed gas cylinders containing the
correct shielding gas for the process used and
properly operating regulators, designed for the gas
and pressure used. All hoses, fittings, etc. should be
suitable for the application and maintained in good
condition.

b.

Always keep cylinders in an upright position and
securely chained to an undercarriage or fixed support.

c.

Cylinders should be located :

Away from areas where they may be struck or
subjected to physical damage.

A safe distance from arc welding or cutting
operations and any other source of heat, sparks or
flame.

d.

Never allow the electrode, electrode holder, or any
other electrically “hot” parts to touch a cylinder.

e.

Keep your head and face away from the cylinder valve
outlet when opening the cylinder valve.

f.

Valve protection caps should always be in place and
hand-tight except when the cylinder is in use or
connected for use.

g.

Read and follow the instructions on compressed gas
cylinders and associated equipment, and AS 2030
Parts 1 & 2.

6.

a.

Turn off input power using the disconnect switch at the
fuse box before working on the equipment.

b.

Install equipment in accordance with the SAA Wiring
Rules, all local codes and the manufacturer’s
recommendations.

c.

Ground the equipment in accordance with the SAA
Wiring Rules and the manufacturer’s
recommendations.

7.

a.

Turn the engine off before troubleshooting
and maintenance work unless the
maintenance work requires it to be
running.

b.

Operate engines in open, well ventilated
areas or vent the engine exhaust fumes
outdoors.

c.

Do not add fuel near an open flame,
welding arc or when the engine is running.
Stop the engine and allow it to cool before
refuelling to prevent spilled fuel from
vaporizing on contact with hot engine
parts and igniting. Do not spill fuel when
filling tank. If fuel is spilled, wipe it up and
do not start engine until fumes have been
eliminated.

d.

Keep all equipment, safety 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.

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. Always use the greatest care
when working near moving parts.

f.

Do not put your hands near the engine fan.
Do not attempt to override the governor or
idler by pushing on the throttle control rods
while the engine is running.

g.

To prevent accidentally starting petrol
engines while turning the engine or
welding generator during maintenance
work, disconnect the spark plug wires,
distributor cap or magneto wire as
appropriate.

h.

To avoid scalding do not remove the
radiator pressure cap when the engine is
hot.

CYLINDER may explode if

damaged

FOR ELECTRICALLY

powered equipment

FOR ENGINE

powered equipment

HAVE ALL INSTALLATIONS, OPERATION, MAINTENANCE AND REPAIR WORK PERFORMED BY QUALIFIED PEOPLE

HOW TO ORDER REPLACEMENT PARTS

To ensure that you receive the correct replacement part the following procedure should be followed:

1. Quote Serial Number and Code Number.

2. Quote the Description, Item Number and Parts List Number of the desired part. When ordering parts for items carrying brand

names of other companies, such as fan motors, drive shafts, etc., be sure to include the other company’s name and part number
and other relevant information.

3. Should the primary cord be damaged, a special cord is required, and is available from Lincoln Electric.

4. Parts should be ordered from Lincoln, its offices or the nearest Authorised Field Service Shop. (The “Lincoln Service Directory”

listing these shops geographically is available on request.)

Note:

“Hardware” in the Lincoln Parts Lists are not Lincoln stock items but can be obtained via the Field Service Shop network.

Component parts of assemblies such as stator coils or armature coils, etc., which require electrical testing or locating fixtures are not
considered replaceable items. This is to ensure that the customer receives parts which will keep the welder in the best operating condition.

BUY ONLY GENUINE REPAIR PARTS 

For more detailed information it is strongly recommended that you purchase a copy of “Safety in Welding and Allied Processes AS1674
Parts 1 & 2” and WTIA Technical Note 7. All WTIA publications are available from the Welding Technology Institute of Australia, P.O. Box
6165, Silverwater NSW 2128. For copies of various Australian Standards contact your local S.A.A. office.

 

Summary of Contents for SHIELD-ARC 400AS-50

Page 1: ... IN WELDING AND CUTTING PRODUCTS SAFETY DEPENDS ON YOU Lincoln Electric welders are designed and built with safety in mind However your overall safety can be increased by proper installation and thoughtful operation on your part Read and observe the general safety precautions on page 2 and follow specific installation and operating instructions included in this manual Most importantly think before...

Page 2: ...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 e Also see Item 7b 3 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 AS 1674 2 2003 AS1337 19...

Page 3: ...s to perform required maintenance Remove guards only when necessary and replace them when the maintenance requiring their removal is complete Always use the greatest care when working near moving parts f Do not put your hands near the engine fan Do not attempt to override the governor or idler by pushing on the throttle control rods while the engine is running g To prevent accidentally starting pe...

Page 4: ...elding can interfere with a pacemakers function Generally the interference does not permanently damage the pacemaker Once the wearer leaves the arc welding environment or stops welding the pacemaker returns to normal functioning The welding arc has little or no effect on the operation of some pacemakers especially designs that are bi polar or designed to filter out such interference For a welder o...

Page 5: ...t welding or other activities are to be carried out The size of the surrounding area to be considered will depend on the structure of the building and other activities that are taking place The surrounding area may extend beyond the boundaries of the premises Methods of Reducing Emissions Mains Supply Welding equipment should be connected to the mains supply according to the manufacturer s recomme...

Page 6: ...he acid bottle to allow bottle to breath Battery electrolyte contains sulphuric acid which is corrosive to skin and clothing Batteries also contain explosive gasses When charging provide adequate ventilation to allow the safe escape of explosive gases Do not do anything to cause sparks near a battery Keep naked flames and cigarettes away from batteries If acid contacts eyes or skin flush immediate...

Page 7: ...sition is midway between the on position and the start position A definite spring loaded location can be felt at the H position If the oil pressure gauge does not show normal oil pressure 200 420kPa 10 seconds after starting stop the engine and consult the engine instruction manual The engine speed has been pre set in the factory for optimum welder performance and the fuel pump and governor then s...

Page 8: ...lding How to Set the Controls Assume you want to make a vertical up weld using a 4 0mm electrode at about 135 amps A snappy digging arc medium low open circuit voltage is required to give the best control of the arc in the whipping technique that must be used 1 Set the Job Selector to the section of the dial marked Overhead and Vertical 2 Set the Current Control to read 135 amps on the scale marke...

Page 9: ...use emery cloth or paper or organic solvents for this purpose MAINTENANCE AND LUBRICATION FOR ENGINE powered equipment Note This procedure is for machines as built many modifications could have taken place over the life of a particular machine so details of this procedure may need to be adjusted to suit these modifications For prompt service contact your local authorised Lincoln field service shop...

Page 10: ...ge across rotor brushes 12A with key switch 4 turned midway between Run and Start position If not check for Flashing diode 10 open circuit Replace Blocking diode 11 open circuit Replace Key Switch 4 faulty Replace Poor connections Repair If the above are ok then check for Bridge rectifier 8 open or short circuit Replace Rotor 12 open or short circuit Repair or replace Rotor resistance approx 11 oh...

Page 11: ...rushes generator 7 Welding is loud and Series field 5 and armature circuit may be open Check circuit with voltmeter spatters excessively circuited 7A Current setting may be too high Check setting and current output with ammeter Polarity may be wrong Check polarity Try reversing polarity or try an electrode of the opposite polarity Maximum welding Open in series coil 5 Repair or replace output all ...

Page 12: ... 1 19 Water Outlet 1 20 Flat Washer 2 Quote AP 33 C plus Machine Code No and Serial No No Item Part Name and Description Req 21 Governor Adjust Pad Assembly 1 23 Hex Head Screw 5 16 Whit x 3 4 4 24 Hex Head Nut 5 16 Whit 4 25 Flat Washer 5 16 dia 4 25A Lockwasher 5 16 dia 4 26 Rear Lower Panel Assembly 1 34 Transfer Not Shown 1 40 Battery Not Shown 1 41 Positive Lead Not Shown 1 42 Negative Lead N...

Page 13: ...Spire J Nuts 12 Quote AP 33 C plus Item No Description Machine Code No and Serial No No Item Part Name and Description Req 76 Hex Head Bolt 1 4 x 23 4 Not Shown 2 Spire J Nuts 2 Lockwasher 2 76A Hex Head Screw 1 4 x 3 4 Not Shown 2 Hex Nut 1 4 Not Shown 2 Lockwasher 1 4 Not Shown 2 78 Reactor Handle 1 79 Half Dog Point Socket Set Screw 1 80 R H Door Lower Panel Assy Not Shown 1 81 L H Door Lower P...

Page 14: ... 2 Washer 1 Spring Clip 1 Spring 1 Quote AP 33 E plus Machine Code No and Serial No No Item Part Name and Description Req 11 Stud Assembly includes 1 Brush Holder Stud 1 Reactor Brush Holder Bracket Assembly 1 Insulation Bush 1 Insulation Washer 2 Brass Jam Nut 1 Washer 1 Lockwasher 1 12 S T Screw Mounting Stud Assembly 2 14 Air Cleaner Clamp Band 1 15 S T Screws Clamp Band to Frame 2 Air Cleaner ...

Page 15: ...udes 1 24 H H H T Screw 7 16 UNC x 11 2 8 Coupling to Armature 24A Coupling Lock Tab 4 25 H H H T Screw 7 16 UNC x 1 8 Coupling to Flywheel 25A Spring Washer 7 16 8 26 Dowel Not Shown 2 27 Blower Segments 4 27B Coupling Disc Large Stainless Steel 1 27C Backing Disc 71 2 dia Armature side 1 29 Generator Brush 8 31 Main Pole 4 WELDING GENERATOR AND COUPLING AP 27 F No Item Part Name and Description ...

Page 16: ...asher 2 3 16 Z P Hex Nut 2 3 16 x 11 4 Z P Rd Hd Screw 2 9 Spring 2 10 Brush 2 11 Insulating Tube 2 No Item Part Name and Description Req Brushhloder Assy includes 4 1 Brushholder Stud 1 2 Retainer Assembly 1 3 Washer 1 4 Insulating Washer 2 5 Insulating Tube 1 6 Washer 1 7 Spring Clip 2 8 Spring 2 9 Lockwasher 1 10 Hex Head Bolt 1 11 Hex Head Bolt 1 12 Round Head Screw 1 13 Round Head Screw 2 14 ...

Page 17: ...sher 4 Round Head Screw 4 Quote AP 33 D plus Machine Code No and Serial No No Item Part Name and Description Req 23 Hex Nut 2 Springwasher 2 Round Head Screw 2 29 Hex Nut 2 Starwasher 2 Round Head Screw 1 31 Aux Switch Decal 1 32 Code Serial Number Decal N S 1 33 Hex Nut Mounts Leads to Rheostat N S 3 Starwasher Mounts Leads to Rheostat N S 3 Rd Hd Screw Mts Leads to Rheostat N S 2 34 Outlet Panel...

Page 18: ... wiring For specific detail refer to the diagram attached to the machine itself If the diagram has been destroyed or defaced contact the factory quoting the machine s serial number and code number from the nameplate Ref AM3062E1 A28 4 93 Wiring Diagram 12v Starter Wiring Diagram ...

Page 19: ...er sizes are given so that you may procure locally ENGINE WATCHER Quote AP 43 B plus Machine Code No and Serial No UNDERCARRIAGE 2 wheel type No Item Part Name and Description Req 1 Assembly Unsprung Includes 1 Axle Assembly Sprung Includes 1 Axle 1 Grease Cup 2 Axle Cup 2 Small Cone Bearing 2 Seal 2 Large Cone 2 Large Cup 2 Small Cup 2 Hub and Stud Assy AS 2959 2 each assembly includes Stud 7 16 ...

Page 20: ... Nut 60 20 8 Hex Screw Washer and Nyloc Nut 16 sets 2 x 1 2 UNC 9 Hex Bolt Flatwasher and Nyloc Nut 4 sets 31 4 x 1 2 UNC 10 Shackle Bolts and Nuts 4 sets 11 Hex Nuts U Bolt 32 12 Hanger Plate 4 13 U Bolt 8 14 Grease Nipple Not Shown 1 15 Shackle Bolt and Nut 1 set 16 Shackle 8 Quote AP 22 B plus Machine Code No and Serial No AL 1695 5 10 83 Page 20 Shield Arc 400AS 50 IMA 554C ...

Page 21: ...96 2 Red light assy 1 AT3002 1 Oil pressure gauge 1 AT3024 Fuel tank cap 2 AT3061 6 Hose clamp 2 AT3081 Carbon brush 4 AT3639 Volt meter 1 AT3919 Switch 1 L1741 14B Bottom coil assy 1 L1741 15B Top coil assy 1 L2036CA2 Reactor assy 1 L2667 21C Armature assy 1 M5090C Rheostat 1 M6277A1Z Reactor brush holder assy 1 M6964 10X Brush holder assy 1 M9300 22 Bearing 1 P26510192 Air cleaner element 4 P265...

Page 22: ...Page 22 Shield Arc 400AS 50 IMA 554C NOTES ...

Page 23: ...IMA 554C Shield Arc 400AS 50 Page 23 NOTES ...

Page 24: ...for the operation non operation or malfunction of any such battery CONDITION OF WARRANTY TO OBTAIN WARRANTY COVERAGE The purchaser must contact Lincoln or Lincoln s Authorised Service Facility about any defect claimed under Lincoln s warranty Determination of warranty on welding and cutting equipment will be made by Lincoln or Lincoln s Authorised Service Facility WARRANTY REPAIR If Lincoln or Lin...

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