Lincoln Electric SHIELD-ARC 400AS-50 Operating Manual Download

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IMA 554C

September 1998

OPERATING MANUAL

THE LINCOLN ELECTRIC COMPANY

(AUSTRALIA) PTY. LTD.

A.B.N. 36 000 040 308

SYDNEY. AUSTRALIA

A Subsidiary of

THE LINCOLN ELECTRIC CO. U.S.A.

Associated Subsidiaries in Australasia, Asia, Canada, Europe, North and South America.

THE WORLD’S LEADER 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 you act and be careful.

SHIELD-ARC

400AS-50

WITH 12 VOLT ELECTRICS - KA1352

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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