IMA 554C

September 1998

OPERATING MANUAL

SHIELD-ARC 400AS-50
WITH 12 VOLT ELECTRICS - KA1352

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.

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 WORLDS LEADER IN WELDING AND CUTTING PRODUCTS

PROTECT YOURSELF AND OTHERS FROM POSSIBLE SERIOUS INJURY OR DEATH. READ AND UNDERSTAND BOTH THE SPECIFIC INFORMATION GIVEN IN THE OPERATING MANUAL FOR THE WELDER AND/OR OTHER EQUIPMENT TO BE USED AS WELL AS THE FOLLOWING GENERAL INFORMATION.

ELECTRIC SHOCK can kill

ARC WELDING SAFETY PRECAUTIONS

ARC RAYS can burn

1. a. The electrode and work (or ground) circuits are electrically hot when the welder is on. Do not touch these hot parts with your bare skin or wet clothing. Wear dry, hole-free gloves to insulate hands. b. In semi-automatic and automatic wire welding, the electrode, electrode reel, welding head and nozzle or semi-automatic welding gun are also electrically hot. c. Insulate yourself from work and ground using dry insulation. When welding in damp locations, on metal framework such as floors, gratings or scaffolds, and when in positions such as sitting or Lying, make certain the insulation is large enough to cover your full area of physical contact with work and ground. d. Always be sure the work cable makes a good electrical connection with the metal being welded. The connection should be as close as possible to the area being welded. e. Ground the work or metal to be welded to a good electrical (earth) ground. f. Maintain the electrode holder, work clamp, welding cable and welding machine in good, safe operating condition. Replace damaged insulation. g. Never dip the electrode holder in water for cooling. h. Never simultaneously touch electrically hot parts of electrode holders connected to two welders because voltage between the two can be the total of the open circuit voltage of both welders. i. When working above floor level, protect yourself from a fall should you get a shock. j. Also see items 4c and 6.

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 1674.2-1990 standards. b. Use suitable clothing made from durable flame resistant material to protect your skin and that of your helpers from the arc rays. c. Protect other nearby personnel with suitable non flammable screening and/or warn them not to watch the arc or expose themselves to the arc rays or to hot spatter or metal.

WELDING SPARKS can cause fire or explosion

4. a. Remove fire hazards from the welding area. If this is not possible, cover them to prevent the welding sparks from starting a fire. Remember that welding sparks and hot materials from welding can easily go through small cracks and openings to adjacent areas. Have a fire extinguisher readily available. b. Where compressed gases are to be used at the job site, special precautions should be used to prevent hazardous situations. Refer to AS1674 Parts 1 & 2 Safety in Welding and Allied Processes, WTIA Technical Note 7 Health and Safety in Welding and the operating information for the equipment being used. c. When not welding, make certain no part of the electrode circuit is touching the work or ground. Accidental contact can cause overheating and create a fire hazard. d. Do not heat, cut or weld tanks, drums or containers until the proper steps have been taken to insure that such procedures will not cause flammable or toxic vapours from substances inside. These can cause an explosion even though the vessel has been cleaned. For information purchase AS 1674-1990. e. Vent hollow castings or containers before heating, cutting or welding. They may explode. f. Sparks and spatter are thrown from the welding arc. Wear oil free protective garments such as leather gloves, heavy shirt, cuffless trousers, high shoes and a cap over your hair. Wear ear plugs when welding out of position or in confined places. Always wear safety glasses with side shields when in a welding area.

FUMES AND GASES can be dangerous

2. a. Welding may produce fumes and gases hazardous to health. Avoid breathing these fumes and gases. When welding, keep your head out of the fume. Use enough ventilation and/or exhaust at the arc to keep fumes and gases away from the breathing zone. When welding on galvanised, lead or cadmium plated steel and other metals which produce toxic fumes, even greater care must be taken. b. Do not weld in locations near chlorinated hydrocarbon vapours coming from degreasing, cleaning or spraying operations. The heat and rays of the arc can react with solvent vapours to form phosgene, a highly toxic gas, and other irritating products. c. Shielding gases used for arc welding can displace air and cause injury or death. Always use enough ventilation, especially in confined areas, to ensure breathing air is safe. d. Read and understand the manufacturer s instructions for this equipment and the consumables to be used, including the material safety data sheet (MSDS) and follow your employers safety practices. e. Also see Item 7b.

g. Connect the work cable to the work as close to the welding area as possible. Work cables connected to the building framework or other locations away from the welding area increase the possibility of the welding current passing through lifting chains, crane cables or other alternate circuits. This can create fire hazards or overheat lifting chains or cables until they fail. h. Also see Item 7c.

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CYLINDER may explode if damaged

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. 7.

FOR ENGINE powered equipment

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.

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.

FOR ELECTRICALLY powered equipment

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 manufacturers recommendations. c. Ground the equipment in accordance with the SAA Wiring Rules and the manufacturers recommendations.

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.

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

For more detailed information it is strongly recommended that you purchase a copy of Safety in Welding and Cutting - ANSI Standard Z 49.1 and WTIA Technical Note 7. All WTIA publications and ANSI/AWS Standards 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.

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 companys 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

IMA 554C

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WELDING, EMF & PACEMAKERS

All welders should follow safe practices that minimise their exposure to electric and magnetic fields (EMF).

Welders with pacemakers

There is no question that the fields in arc welding 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 bipolar or designed to filter out such interference.

For welders wearing implanted pacemakers, safe welding practices are particularly important and additional procedures should be followed by those who have decided to continue to weld. (Hopefully in keeping with a doctors advice).

The following procedures will not eliminate exposure to EMF or the possibility of arc welding having an effect on a pacemaker, however if followed, they will significantly reduce exposure to electric and magnetic fields. Electric and magnetic fields are created any time electric current flows through a conductor, however it is not clear whether such exposure affects ones health.

For a welder or anyone working around electrical equipment the selection of a pacemaker is very important. Get a doctors advice about which pacemaker is the least sensitive to interference from welding while still being medically suitable.

Some researchers have reported that exposure to EMF may cause leukemia or other illnesses. These claims originally arose in relation to high voltage electric power lines and are very much in dispute in the medical and scientific arena, however the best advice is to minimise your exposure to EMF to protect your health should doctors eventually decide there is a risk.

In addition to the normal safety precautions, the following additional procedures should be adopted by welders with pacemakers. Use gas welding when the application is suitable. Use the lowest current setting appropriate for the application. Do not exceed 400 amps. Low current (75-200 amps) direct current (DC) welding should be used if arc welding is necessary. Do not TIG weld with high frequency. Do not use repeated, short welds. Wait about ten seconds between stopping one weld and starting the next. When having difficulty starting an electrode, do not re-strike the rod repeatedly. If you feel light headed, dizzy or faint, immediately stop welding. Lay the electrode holder down so that it does not contact the work and move away from any welding being performed. Arrange your work in advance so that, if you become dizzy and drop the electrode holder, the electrode holder will not fall on your body or strike the work. Do not work on a ladder or other elevated position or in a cramped, confined place. Do not work alone. Work only in the presence of an individual who understands these precautions and the possible effect welding may have on your pacemaker. Do not work near spot welding equipment. If you have a pacemaker and wish to continue arc welding, discuss this and any other questions you may have with your physician and follow his or her advice. The doctor may wish to contact the pacemaker manufacturer for a recommendation. As mentioned before, the design of the pacemaker significantly affects the degree to which it is subject to interference from a welding circuit. Do not rely on the fact that you know another welder with a pacemaker who has welded for years without experiencing a problem. That welder and his or her pacemaker may be quite different from you and your pacemaker.

There are four fundamental facts about EMF: With direct current (DC), the field strength is relatively constant and does not change. With alternating current (AC), the field strength constantly changes. The greater the current flow, i.e. the higher the amps, the stronger the field created by the current The closer the conductor or electrical device is to the body, the greater the exposure to the field.

Minimising exposure

All welders should use the following procedures to minimise EMF exposure.

Route electrode or gun and work cables together. Secure them with tape if possible. Never coil the electrode lead around your body. Do not place your body between the electrode and work cables. If your electrode cable is on your right side the work cable should also be on your right side. Connect the work cable to the work piece as close as possible to the area being welded. (This is also a good practice to eliminate a common problem on welding - a poor work connection. Do not work next to the welding power source.

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INSTRUCTIONS FOR ELECTROMAGNETIC COMPATIBILITY

WARNING
g. This welding machine must be used by trained operators only. Read this manual carefully before attempting to use the welding machine. h.

The immunity of other equipment in the environment. The purchaser/user shall ensure that other equipment being used in the environment is compatible. This may require additional protection measures; The time of the day that welding or other activities are to be carried out.

Conformance
Products displaying the C-Tick mark are in conformity with Australian/New Zealand requirements for Electromagnetic Compatibility (EMC). They are: manufactured in conformity with Australian/New Zealand Standard (Emission):- AS/NZS 3652 Electromagnetic Compatibility - Arc Welding Equipment (Identical to and reproduced from British Standard EN 50199) for using with other Lincoln Electric/LiquidArc equipment. designed for industrial and professional use.

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 manufacturers recommendations.If interference occurs, it may be necessary to take additional precautions such as filtering the mains supply. Consideration should be given to shielding the supply cable of permanently installed welding equipment in metallic conduit or equivalent. Shielding should be electrically continuous throughout its length. The shielding should be connected to the welding power source so that good electrical contact is maintained between the conduit and the welding power source enclosure.

Introduction
All electrical equipment generates small amounts of electromagnetic emission. Electrical emission may be transmitted through power lines or radiated through space, similar to a radio transmitter. When emissions are received by other equipment, electrical interference may result. Electrical emissions may effect many kinds of electrical equipment: other nearby welding equipment, radio and TV transmitters and receivers, numerical controlled machines, telephone systems, computers, etc. Be aware that interference may result and extra precautions may be required when a welding power source is used in a domestic establishment.

Maintenance of the Welding Equipment

The welding equipment should be routinely maintained according to the manufacturers recommendations. All access and service doors and covers should be closed and properly fastened when the welding equipment is in operation. The welding equipment should not be modified in any way except for those changes and adjustment covered in the manufacturers instructions. In particular, the spark gaps of arc initiation and stabilising devices should be adjusted and maintained according to the manufacturers recommendations.

Installation and Use

The purchaser/user is responsible for installing and using the welding equipment according to the manufacturers instructions. If electromagnetic disturbances are detected then it shall be the responsibility of the purchaser/user of the welding equipment to resolve the situation with the technical assistance of the manufacturer. In some cases this remedial action may be as simple as earthing (grounding) the welding circuit (see note below). In other cases it could involve constructing an electromagnetic screen enclosing the power source and the work complete with associated input filters. In all cases electromagnetic disturbances must be reduced to the point where they are no longer troublesome. Note: The welding circuit may or may not be earthed for safety reasons according to national codes. Changing the earthing arrangements should only be authorised by a person who is competent to assess whether the changes increase the risk of injury, eg. by allowing parallel welding current return paths which may damage the earth circuits of other equipment.

Welding Cables
The welding cables should be kept as short as possible and should be positioned close together, running at or close to the floor level.

Equipotential Bonding
Bonding of all metallic components in the welding installation and adjacent to it should be considered. However, metallic components bonded to the work piece will increase the risk that the operator could receive a shock by touching these metallic components and the electrode at the same time. The operator should be insulated from all such bonded metallic components.

Earthing of the workpiece

Where the workpiece is not bonded to earth for electrical safety, nor connected to earth because of its size and position, eg. ships hull or building steelwork, a connection bonding the workpiece to earth may reduce emissions in some, but not all instances. Care should be taken to prevent the earthing of work pieces increasing the risk of injury to users, or damage to other electrical equipment. Where necessary, the connection of the workpiece to earth should be made by direct connection to the workpiece, but in some countries where direct connection is not permitted, the bonding should be achieved by suitable capacitance, selected according to national regulations.

Assessment of Area
Before installing welding equipment the purchaser/user shall make an assessment of potential problems in the surrounding area. The following shall be taken into account: a. Other supply cables, control cables, signalling and telephone cables above, below and adjacent to the welding equipment; Radio and television transmitters and receivers; Computer and other control equipment; Safety critical safety equipment, eg. guarding of industrial equipment; The health of people around, eg. the use of pacemakers and hearing aids;; Equipment used for calibration or measurement;

Screening and Shielding

Selective screening and shielding of other cables and equipment in the surrounding area may alleviate problems of interference. Screening of the entire welding installation may be considered for special applications.*
* Portions of the preceding text are contained in AS/NZS3652: Electromagnetic Compatibility - Arc Welding Equipment.

b. c. d. e. f.

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Batteries must not be filled or "topped up" whilst in normal operating position - always remove from machine. TO REMOVE BATTERIES 1. 2. 3. Remove the lower rear panel (radiator end.)

BATTERY INSTALLATION AND SERVICE INSTRUCTIONS INSTALLATION CAUTION 1. Inspect the battery tray and remove any foreign objects that
may be present. 2. 3. Place the battery in the tray. Connect the positive battery lead (marked with a red band), then connect the negative lead. Note: Always connect the negative lead last when installing a battery. 4. Refit the battery hold-down assembly. Do not over tighten this assembly as battery case damage is possible. Note: To prevent acid surge from bottle when filling, carefully pierce a small hole in the top of the acid bottle to allow bottle to breath.

Disconnect the battery leads. Always disconnect the negative lead first. Undo clamps and lift clear of machine.

COMMISSIONING AND RECHARGING 1. 2. 3. Always remove the battery from the machine before filling or recharging. Remove and retain vent plugs. Fill each cell of the battery to the top of the separators with the correct grade electrolyte* (ie. 1.260 specific gravity). Using higher or lower specific gravity electrolyte than recommended can impair the battery performance. Boost charge the battery at 15 amps until the specific gravity of the electrolyte is 1.250 or higher and the electrolyte temperature is at least 15C BOTH CONDITIONS MUST BE MET. If electrolyte bubbles violently while charging, reduce the charging rate until the excessive bubbling action subsides, then continue until both of the above conditions are achieved. If the ambient temperature is 10C or less, it is imperative that the above instructions be followed. 5. After boost charge check level of electrolyte in all cells. Add additional electrolyte to bring level to that shown on labelling. DO NOT OVERFILL. After the battery has been in service, add only approved water. DO NOT ADD ACID. Note: Depending on the age of the dry charged battery correct activation may take up to 48 hours. 6. Disconnect the battery from the charging source and refit the vent plugs ensuring they are screwed or pushed all the way home. Wash away any split electrolyte with water and dry the battery completely before installing it into the machine.

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 immediately with large quantities of clean drinking water. After use wash out empty electrolyte bottles with water and dispose of carefully - do not use empty electrolyte bottles for any other purpose. Always keep batteries and electrolyte out of reach of children. Dispose of old batteries carefully.

WARNING

4.

BATTERY MAINTENANCE 1. 2. 3. 4. 5. 6. Keep the electrolyte levels about 6mm above the plates and separators. Keep terminal posts free of corrosion. Keep battery clean and dry. Do not leave machine switched on without the engine running as this will discharge the battery. Do not fast charge any battery over 18 months old. Never add acid to a battery unless it has been lost through spillage.

7.

WELDER SPECIFICATIONS
Model Shield-Arc 400AS-50 Rated Output 400 amps at 36 arc volts and 80% duty cycle 300 amps at 32 arc volts and 100% duty cycle Welding Current Range 45-450 amps D.C. Speeds No Load 1500 r.p.m. Full Load 1450 r.p.m. Weight (dry, approx.) Without Trailer 800 kg. With Unsprung Trailer 895 kg. Auxiliary Power * 5000 watts, 240 volts, 50 Hz., 100% duty cycle 2500 watts, 115 volts, 50 Hz., 100% duty cycle
* Available while welding. (Refer table next page for welder/auxiliary power ratio.) N.B. If 240 volt and 115 volt supply are being used simultaneously the totalcurrent drawn should not exceed 20 amps.

ENGINE SPECIFICATIONS
Model Perkins D3.1524 Diesel Power 28kW @ 1500 r.p.m. Capacity 2.5 litres (152 cu.in.) Lubrication High pressure forced feed from rotary type oil pump Cooling Water Cooling with circulation by centrifugal pump Governor Mechanical, on injection pump Fuel Tank Capacity 64 litres (14 gallons). Sufficient for well over one days operation under severe conditions. Starting KA1351 24V starting and battery charging through special welder windings

24V starting KA1351 12V starting KA1352

KA1352 - 12V starter motor, battery and alternator

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OPERATING INSTRUCTIONS
IMPORTANT NOTE ABOUT RUNNING IN YOUR DIESEL ENGINE
All diesel engines require some additional care for about the first 50 hours operation. While maximum load can be applied to a new engine as soon as it is put into service and the coolant temperature has reached at least 60C, care should be taken that the engine is not run at very light loads (say less than 2.4 kVA, or a 10 amp radiator) for extended periods, as this can lead to glazing of the cylinder bores. Do not operate at high speeds without a load, and do not overload the engine. Cylinder glazing can lead to excessive oil consumption and smoky exhaust, while overloading during the first few hours can lead to excessive wear and shorten the life of the engine.

Engine Operation
On receipt of 400 AS-50, remove Gold Seal or Carecard label from engine, add ownership details, and mail to nearest Perkins Distributor. The Distributor will return a plastic Carecard which must be retained and presented should warranty service be required. Note that the Carecard is accepted world-wide. Before attempting to start the engine, the following should be carried out: 1. Ensure the crankcase oil level is at the Full mark on the dipstick. Use only the grade oil recommended by the engine manufacturer in accompanying Engine Manual. N.B.: Many oil companies market a product which meets the recommended MIL-L-46152 (SE CC) and the heavy duty and turbocharged engine specification MIL-L-2104C (SE CD). These oils are not recommended for use in this welder, particularly in the initial 50 hours of operation. 2. 3. Fill the fuel tank (always use clean fuel). Fill the radiator. Be sure to add Alfoc 2000 or equivalent to radiator as per container instructions. This is required for corrosion resistance. A water/glycol mixture is recommended for use in cold temperature conditions. In the case of a new engine or an engine which has been standing idle for any length of time, it is important to bleed the fuel system. Always use the manual primer on the lift pump to circulate fuel in the system. Extensive use of the electric starter for this purpose may lead to electrical component damage. Refer to the engine instruction manual for the correct procedure. Fill the dry charged battery. See page 6.

To Start the Welder

Turn the start switch to the H position for 15-20 seconds, then turn further in the clockwise direction to the start position. If the engine does not start after 30 seconds, return the switch to the H position for 10 seconds and then return to the start position. Then engage the starter motor again for a maximum period of 30 seconds. If the engine still does not start, allow at least 10 minutes for the starter motor and other electrical components to cool before repeating the starting procedure. As soon as the engine starts, the start switch should be released and allowed to return to the on position. If the engine is warm and has only been stopped for a short period, restart by turning switch directly on to the start position and releasing when the engine starts. Note: The H position is midway between the on position and the start position. A definite spring loaded location can be felt at the H position.

Failure to return the key switch to on position, or turning to start position while engine is running will cause electrical component damage. 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 sealed. This setting should not be altered, to do so will void the warranty. For normal running, lubricating and maintenance instructions, consult the engine instruction manual. For correct cooling air flow, the welder should be operated with the doors closed.

WARNING

4.

5.

FOR ENGINE powered equipment CAUTION

TO STOP THE ENGINE

Turn the key switch to off position.

Before Starting the Engine

FOR OPTIONAL ENGINE WATCHER OPERATION:

When an engine watcher option is fitted to a 400AS-12V, two (2) warning lights are mounted on the control panel. These are located in the area of the key switch. The light beside the key switch is the battery charge alternator light. If this light glows after the engine has reached operating speed there is a fault in the battery charge alternator and the battery is not being charged. The second light, mounted above the battery charge alternator light, is the engine watcher operation light. This light glows to indicate that the engine watcher is functioning correctly.

Operate internal combustion engine in open, well ventilated areas or vent the exhaust fumes outdoors. Whenever starting the engine, be sure any welding loads are removed and any A.C. auxiliary loads are either turned off or the plugs pulled. If the load is left connected it may prevent the generator from building up to full voltage.

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WELDER OPERATION

ELECTRIC SHOCK can kill

the approximate welding current is indicated by the Overhead and Vertical scale on the Current Control dial. Do not change the Current Control setting while welding.

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 marked Overhead and Vertical. 3. Strike the arc. 4. If the arc is too weak, move the Job Selector counter-clockwise to increase the current. If a still higher current is desired, turn up the Current Control 10 or 20 amps. In the final adjustment, be certain the Job Selector is still set in the same range to get the snappy arc recommended for vertical welding.

General
Connect the electrode and ground cables to the studs marked on the welder output panel. The studs are marked Positive and Negative. Some types of electrode require electrode positive and others negative. Therefore consult the instructions for the particular electrode being used to determine which lead is to be attached to the Positive and which to the Negative stud. When welding at a considerable distance from the machine, care should be taken that ample size welding cables are used. Small size cables for long distances reduce output at the point of welding.

Setting the Controls

The welder is equipped with Dual Continuous Control of the welding output. To meet the varied requirements of present day welding it is highly desirable to be able to vary the voltage and current separately. Dual Continuous Control means that it is possible to get the proper welding current throughout the range to the machine in two or more ways. There are two controls which determine the output of the generator: 1. 2. Continuous Current Control to vary the welding amperage Job Selector to vary the open circuit voltage of the generator.

FOR ELECTRICALLY powered equipment

Auxiliary Power
These machines are fitted with two standard 3 pin 240 volt 15 amp auxiliary power outlets and two 3 pin 115 volt auxiliary power outlets. Auxiliary power is available while welding - refer Table below for relative loadings. Both 240 volt and 115 volt supplies can be used simultaneously, provided the total current drawn does not exceed the current in the Table. The outlets are located on the control panel of the 400AS-50. Total power available is Welder Output (Amps) 300 or less 300-350 350-400 400-450 Maximum permissible Auxiliary Power Load (Amps) 20 15 10 5

Job Selector
The Job Selector is both the fine current adjustment and the voltage control of the welder. With this control it is possible to obtain the exact current necessary. Also by means of this control the open circuit voltage can be varied to suit different welding applications. The Job Selector dial is divided into four sections. The section marked Large Electrodes provides a high open circuit voltage. The section marked Normal Welding Range gives medium high open circuit voltage. The section marked Overhead and Vertical gives a medium low open circuit voltage. The section marked Special Applications provides a low open circuit voltage and is used with a minimum setting on the Continuous Current Control.

5,000 watts, 240 volt, 50 Hz. A.C. at 100% duty cycle or 2,500 watts, 115 volt, 50 Hz. A.C. at 100% duty cycle. Important: The 400AS-50 auxiliary power circuits are not connected to the welder frame, and earth leakage protection is not required (refer AS2790-1989, Clause 6.1.9.(a) and Comment 1), however connected equipment should be double insulated, or fitted with an effective earth wire.

Continuous Current Control

The Current Control provides the major adjustment of welding current to suit any particular application. The dial reads continuously in a clockwise direction from maximum to minimum and has three graduated concentric dials corresponding to the respective sections of the Job Selector dial. When the Job Selector is set on the Overhead and Vertical section of its dial,

Notwithstanding the above, should a Residual Current Device (RCD) be fitted to this machine, it is imperative that the frame of the machine be earthed in accordance with AS3000, Clause 5.6. An effective earth is essential for the safe operation of machines fitted with RCD devices.

WARNING

FOR ELECTRICALLY powered equipment

USE OF WELDERS AS STAND-BY POWER UNITS

To avoid the possibility of electric shock and/or damage to the welding machine, connections and alterations must be made by a licensed electrician, who can determine how the machine can be adapted to the particular installation and comply with the local Supply Authority regulations. It is also important that an adequately rated isolation switch is used to ensure that the stand-by power unit and the Authorities Supply are not connected on parallel.

Welders with 240 volt, 50 Hz. auxiliary A.C. outlets can be used as stand-by power units.

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For instructions on lubrication and maintenance of the engine, refer to the engine instruction manual. Cylinder head nuts must be pulled down after 25 hours operation and no later - see Engine Manual. All internal and external connections should also be checked to make certain they are tight.

FOR ENGINE powered equipment

MAINTENANCE AND LUBRICATION

Communicator and Brushes

The commutator and brushes are inspected by opening the doors and removing generator covers. The brushes on the generator and alternator are properly adjusted before the machine leaves the factory. No particular attention is required to keep the brushes in good condition, however as the brushes wear out they must be replaced with new ones. One complete set of brushes should always be kept on hand. Before fitting replacement brushes, twist the brush pig tail at its entrance to the brush until the strands are tightly packed and no part of the pig tail protrudes beyond the brush surface in the pig tail slot. When the brush is placed in the holder, clear the pig tail from the side of the holder to allow free radial movement of the brush. New brushes must be bedded in before they can be used on the machine. This is accomplished by placing the new brush in position in the holder with a piece of medium sandpaper (never use emery cloth) placed under the brush. A second person should hold the brush in its normal position by a slight pressure of the fingers. The sandpaper then should be drawn in the direction of generator rotation under the brush with the back of the sandpaper held closely in contact with the commutator or slip ring. This will wear the end of the brush down to the proper curve. When the end of the brush has the proper curve, the operation is complete. Care should be taken to blow all carbon dust away from the commutator or slip rings. The commutator and slip rings require very little attention. They should be cleaned from time to time with a clean rag or, while running, with a piece of fine sandpaper. Never use emery cloth or paper or organic solvents for this purpose.

Running In
It is not necessary to gradually run in a new or factory rebuilt engine and any prolonged light load running during the early life of the engine can prove harmful to the bedding in of piston rings and liners.

SEE IMPORTANT NOTE ABOUT RUNNING IN YOUR DIESEL ENGINE ON PAGE 4.

WELDER
General
It is good practice to blow out the welder with compressed air and check all internal and external connections for tightness every 23 months. This welder is equipped with a double-seal ball bearing having sufficient grease to last the life of the bearing.

This procedure is only suitable for applications using DC mega testers up to 500V. 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. The insulation resistance values listed below are from Australian Standard AS1966.2. 1. 2 3. 4. 5. Ensure engine is stopped. Remove welding leads and disconnect any auxiliary equipment cables. Disconnect the leads from the battery charge alternator (mounted on the engine). Disconnect the negative and positive battery leads. Jumper together the positive, negative and both AC terminals of the two bridge rectifiers (one mounted on the rear of the control panel and the other is on the brush holder bracket). Place the key switch in the RUN position and the aux switch to the ON position. Remove the thermostart lead from terminal No 5 on the key switch. Remove the earth leads from: The bridge rectifier (mounted on the brush holder bracket). 15. 14. 11. 10.

WARNING

GROUND TEST PROCEDURE

The voltmeter.

The water temperature gauge and sender.

The stop solenoid (mounted in the engine fuel injector pump) The hour meter and engine watcher warning light (if fitted). 9. Auxiliary Circuit Test: Connect one lead of the mega tester to the frame of the machine and the other lead to the active terminal of one of the 240V aux. outlets. Apply the test. (Minimum resistance 1M) Welding Circuit Test: Connect one lead of the mega tester to the frame of the machine and the other lead to the positive output stud. Apply the test. (Minimum resistance 1M) Field Circuit Test: Connect one lead of the mega tester to the frame of the machine and the other lead to the positive output stud. Apply the test. (Minimum resistance 1M) Aux. to Weld Circuit Test: Connect one lead of the mega tester to the active terminal of one of the 240V aux. outlets and the other to the positive output stud. Apply the test. (Minimum resistance 10M) Aux. to Field Circuit Test: Connect one lead of the mega tester to the active terminal of one of the 240V aux. outlets and the other to one of the slip ring brush pig tails. Apply the test. (Minimum resistance 1M) Weld to Field Circuit Test: Connect one lead of the mega tester to the positive output stud and the other lead to one of the slip ring pig tails. Apply the test. (Minimum resistance 1M) Remove all jumper leads. Reconnect disconnected during this procedure. all leads

12.

13.

6. 7. 8.

IF ANY PROBLEMS ARE ENCOUNTERED REFER TO YOUR NEAREST AUTHORISED LINCOLN FIELD SERVICE SHOP

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Page 9

TROUBLESHOOTING
12V Starter - Read in conjunction with Wiring Diagram AM3062-E1, in this Manual. See page 18 Numbers in brackets key in to items on diagram.

TROUBLE
Machine fails to start

CAUSE
Check for: Flat battery and/or faulty terminal connections. Key switch (4) faulty connection and/or loose wires. Starter motor faulty (21).

WHAT TO DO

Charge battery and/or clean terminals Repair or replace Repair or replace

Machine starts, but has the following faults: Voltage at AC outlet, but no voltage or reduced voltage at welder output studs. Check DC voltage across bridge rectifier (8). If there is no voltage or half voltage, bridge rectifier may have open circuit in one or two diodes only. Replace

If the above is ok. then check: Rheostat (9) for open circuit. Shunt coil (9A) for open circuit. Bad connections. There is no output from either the AC outlet or the welder output studs Check fuse F4. If F4 is blown also check bridge rectifier (8).

Replace Repair or replace Repair Replace

If the above are ok., then check flashing circuit for faults. Check there is battery voltage across rotor brushes (12A) with key switch (4) turned midway between Run and Start position. If not, check for: Flashing diode (10) open circuit. Blocking diode (11) open circuit. Key Switch (4) faulty. Poor connections. If the above are ok., then check for: Bridge rectifier (8) open or short circuit. Rotor (12) open or short circuit. (Rotor resistance approx. 11 ohm.) Capacitors (13) faulty. Stator field windings (17) open or short circuit. Alternator brushes (12A) sticking or excessively worn. Dirty slip rings (12A). Poor connections. Machine has low welding output or fails to hold welding current constant. Rectifier bridge (8) may be open circuited on one or two diodes only. Main brushes excessively worn (7). Faulty capacitors (13). Rotor (12) or brushes (12A) may have a ground. Electrode lead or work lead connections may be poor Brush springs may be broken (7). Main brushholder rocker (7) moved position. Commutator may be dirty (7A). 2 segments on commutator burnt (7A) (open in that coil).

Replace Replace Replace Repair Replace Repair or replace Replace Repair or replace Free or replace Clean Repair Replace bridge

Replace brushes Replace capacitors Locate and remove ground Tighten all connections Replace brush springs Realign drilled marker points Refer maintenance section page 6 Repair or replace

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TROUBLE
Machine starts, but has the following faults: continued:

TROUBLESHOOTING (Cont)
CAUSE
Short circuit in armature (7A). (2 segments burnt in 4 locations 90 apart). Field rheostat may be making poor contact and overheating (9).

WHAT TO DO

Locate fault using growler and repair or replace Inspect rheostat. Clean out and if necessary increase finger tension on contact arm by bending arm. Check field current with ammeter to discover varying current. This applies to both the main generator and alternator. If brushholder internal contact surface is pitted and burned, replace the brushholder and support stud. If the contact tact surface is dirty, clean off the brushholder stud and internal contact surface. Apply mixture of three parts silicone grease and one part zinc powder (by weight) to stud. Inspect. Replace needed parts. Clean internal contact surface of control device. Do not Iubricate. Smooth up roughened surface. Check for loose or missing set screw in control handles. Check nameplate for desired speed and reset. (Refer engine instruction manual.) Fit correct Lincoln brushes

Field circuit may have variable resistance connections or intermittent open circuit, due to loose connections or broken wires (17), (8), (9) or (9A). Current control brushholder support stud and mating contact surfaces may be dirty or pitted and burned (5A).

Current control brushholder contact springs may be worn out or missing. Contact surface may be dirty, rough or pitted (5A).

Current-adjusting mechanism may not be operating properly (5A). Engine speed low.

Wrong grade of brushes may have been installed on generator (7). Welding is loud and spatters excessively Series field (5) and armature circuit may be open circuited (7A). Current setting may be too high. Polarity may be wrong. Maximum welding output all the time Battery not charging Open in series coil (5).

Check circuit with voltmeter Check setting and current output with ammeter Check polarity. Try reversing polarity or try an electrode of the opposite polarity Repair or replace

Faulty battery charge alternator (22) Faulty meter (14) Battery may be fully charged. Faulty battery charge alternator (22). Capacitors faulty (13).

Repair or replace Repair or replace meter

Battery over-charging Auxiliary power fails under load Welding current too great or too small ompared to indication on dial.

Repair or replace Replace capacitors

Current control shaft and handle (5) may have turned slightly in the insulated bushing of the current control brushholder, caused by turning handle too hard against one of the stops. Alternator low causing low output compared to dial indication. Current control set to minimum and welder output so great that the engine stalls when arc is struck. Engine running at incorrect speed.

With current control against the minimum stop, set the pointer to within 3mm of last scale division.

Check for faulty rotor circuits

Check to see that the series field is properly connected & not shorted. Set welder controls for maximum output and weld. Then, while welding, check engine R.P.M. The engine should be running at full load speed. If indicator shows a significant difference, consult your engine instruction manual. Reset Repair or replace Repair or replace stator

Welding output ok., but no auxiliary output.

Aux power circuit breaker tripped. Broken wires. Open circuit in auxiliary power (18) windings

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GENERAL ASSEMBLY AP-33-C

68A

67

63A

64

18A 18, 23, 24, 25,25A

14

Note: In all Parts Lists, left and right hand side should be determined while standing facing the Generator end of the Welder. These illustrations show the 24 volt unit which differs from the 12volt

100

104

95

5,6,9,10 11, 11A

103 43, 44, 45 97

16,17

19, 20

66

109

5, 7, 8 9, 11A, 12

13

26

BATTERIES UNDER RADIATOR (NOT SHOWN)

97A 48, 49, 50 21 15, 17

AG-1236 4/2/87

29 A
Quote AP-33-C plus Machine Code No. and Serial No. Item 1 2 3 4 5 6 7 8 9 10 11 11A 12 13 14 15 16 17 18 18A 19 20 Part Name and Description Lift Bale Assembly Rear End Frame Assembly Front End Frame Assembly Chassis Assembly Hex. Head Bolt (1/2 UNC x31/4) Washer Rubber Mount - Engine Rubber Mount - Engine (Top) Nyloc Nut (1/2 UNC) Rubber Mount - Generator Rubber Mount - Generator (Top) Washer (9/16 I.D. x 33/8 O.D). Engine Mounting Spacer Engine Foot Engine Fan (Perkins Parts) Bottom Radiator Hose Top Radiator Hose Radiator Hose Clamp Radiator Radiator Shroud Water Outlet Flat Washer No. Req 1 1 1 1 4 2 2 2 4 2 2 12 4 2 1 1 1 4 1 1 1 2 Item 21 23 24 25 25A 26 34 40 41 42 43 44 45 48 49 50 51 52 53 Part Name and Description Governor Adjust Pad Assembly Hex. Head Screw (5/16 Whit. x 3/4) Hex. Head Nut (5/16 Whit.) Flat Washer (5/16 dia.) Lockwasher (5/16 dia.) Rear Lower Panel Assembly Transfer (Not Shown) Battery (Not Shown) Positive Lead (Not Shown) Negative Lead (Not Shown) Hex. Head Bolt (1/2 UNC x 11/4) Lockwasher (1/2 dia.) Hex. Nut (1/2 UNC) Hex. Head Screw (5/16 Whit. x 3/4) Hex. Nut (5/16 Whit.) Lockwasher (5/16 dia.) Hex. Head Screw (5/16 x 3/4) Lockwasher (5/16 dia.) Self Tapping Screw No. Req 1 4 4 4 4 1 1 1 1 1 4 4 4 2 2 2 4 4 16

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53 99

82 51, 52 52A 93

74A 78

90 41

42 107

Quote AP-33-C plus Item No, Description, Machine Code No. and Serial No. Item 57 58 59 60 60B 61 61A 62 63 63A 64 66 Part Name and Description Self Tapping Screw (Not Shown) (Lower Door Panel to Machine) Heat Shrink Tubing (1/2 x 1/2)(Not Shown) Cable Tie (Oil Gauge Line)(Not Shown) Fuel Tank Union (Male Adaptor)(Not Shown) Perkins Nut #33533112 Sleeve Syco Radiator Cap Cover Assy. (Not Shown) Radiator Cap (Not Shown) Self Tapping Screw (Not Shown) (Radiator Cap Hinge to Rear End Frame) Exhaust Pipe Assembly (Not Shown) Exhaust Pipe Clamp Hose Clamp Air Cleaner (Hose to Manifold) Air Cleaner Clamp Assy. includes: Air Cleaner Support Air Cleaner Clamp Self Tapping Screws Air Cleaner Hose Air Cleaner Hose Clamp Door Handle (Not Shown) Door Handle Latch Assy. (Not Shown) Split Pin 1/8 x 3/4 (Not Shown) Countersunk Screw (3/16 x 1/2) (Not Shown) Lockwasher 3/16 (Not Shown) Hex. Nut (Not Shown) Rubber Seal (Lift Bale)(Not Shown) Canopy* (Not Shown) Canopy Support Plate (Not Shown) Thread Forming Screw (Not Shown) Spire J Nuts No. Req 16 2 8 2 1 2 1 1 2 1 1 1 1 1 1 2 1 1 2 2 2 4 4 4 1 1 1 12 12 No. Req 2 2 2 2 2 2 1 1 1 1 1 2 1 1 2 1 2 2 1 1 1 1 1 1 1 1 1 1 4 1 5 1

Item 76

76A

78 79 80 81 82 85 86 88 89 90 91 92 93 94 95 97 97A 99 100 106 107 109 110

67 68A 69 69A 70 70A 71 71A 72 73 73A 74 74A

111 Nut, bolt and washer sizes are given so that they may be procured locally.

Part Name and Description Hex. Head Bolt (1/4 x 23/4)(Not Shown) Spire J Nuts Lockwasher Hex. Head Screw (1/4 x 3/4) (Not Shown) Hex. Nut (1/4) (Not Shown) Lockwasher (1/4) (Not Shown) Reactor Handle Half Dog Point Socket Set Screw R.H. Door & Lower Panel Assy. (Not Shown) L.H. Door & Lower Panel Assy. (Not Shown) Rheostat Handle Lock Rod Assembly (Not Shown) Rubber Gasket (Not Shown) (Fuel Tank Neck to Air Cleaner) Filler Pipe Cap (Not Shown) Logo Doors (Not Shown) Hex. Nut (lead to Reactor) Hex. Nut (Not Shown) Hex. Head Bolt (1/2 UNCx1-1/4)(Not Shown) Control Panel Assy. (See AP-33-D) Fuel Tank, Reactor & Air Cleaner Assy. (See AP-33-E) Alternator Assy. (See AP-33-G) Fuel Line (Lift Pump to Tank) Fuel Line (Tank Return) Oil Pressure Line Pulley Fan Belt Rain Cap Assy. (Not Shown) Front Louvre Panel Air Cleaner Brass Rod (3/16 x 9/16)(Not Shown) Support Plate (Oil Line) (Not Shown) Saddles (Mounts Fuel lines) (Not Shown) Supports Oil Pressure Line on Fuel Tank Rail Main Generator Cover (220mm wide) (N/S) *Specify if Sound Reduced

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FRAME, FUEL, TANK AND REACTOR AP-33-E

(plan view)

Quote AP-33-E plus Machine Code No. and Serial No. Item 1 2 3 3A 3B 5 6 7 7A 7B 8 8A 10 Part Name and Description Frame Assembly Fuel Tank Assembly Hex. Hd. Screw Fuel Tank Hex. Nut to Rails Not Shown Lockwasher Reactor Assembly Rear Reactor Support (Not Used) Hex. Hd. Screw Hex. Hd. Screw Reactor Base to Frame Lockwasher Hex. Hd. Screw Reactor Base to Rear Reactor Support Lockwasher Reactor Brush Holder Assembly, includes Brush Holder Spring Contact Spring Rd. Hd. Screw Lockwasher Shaft Tube Hex. Hd. Screw Washer Spring Clip Spring No. Req 1 1 4 4 4 1 1 1 2 3 2 2 1 1 3 3 3 3 1 1 2 1 1 1 Item 11 Part Name and Description Stud Assembly, includes Brush Holder Stud Reactor Brush Holder Bracket Assembly Insulation Bush Insulation Washer Brass Jam Nut Washer Lockwasher S/T Screw (Mounting Stud Assembly) Air Cleaner Clamp Band* S/T Screws (Clamp Band to Frame)* *Air Cleaner is mounted on Lift Bale under Canopy No. Req 1 1 1 1 2 1 1 1 2 1 2

12 14 15

Nut, bolt and washer sizes are given so that they may be procured locally.

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IMA 554C

WELDING GENERATOR AND COUPLING AP-27-F

FOR ALTERNATOR PARTS SEE AP-33-G

Quote AP-27-F plus Machine Code No. and Serial No. Item 1 2 2A 3 4 5 6 8 9 10 10A 11 12 19 19A 20 21 Part Name and Description D.C. Frame Interpole Coil Assembly Interpole Pole Pieces Series Coil Shunt Coil Armature Assembly Generator Brush Holder Assembly (See AP-9-G for parts) Inner Dust Cap Rocker Bearing Bearing Spacer O Ring (Not Shown) (between bearing and spacer) Outer Dust Cap H/H Bolt Dust Cap (5/16-18 x 31/2) Flywheel H/H Screw H/T (1/2 UNF x 1) (Flywheel to Crankshaft) Backplate Coupling Disc (Small Engine side) No. Req 1 4 4 2 2 1 4 1 1 1 1 1 1 2 1 6 1 1 Item 22 22A 23 23B Part Name and Description Hex. Head Screw H/T (1/2 UNC x 1) (Backplate to Frame) Springwasher (Backplate to Frame) Hex. Head Screw (3/8 - 24 UNF x 1) (Backplate to Engine) Starwasher (3/8) (Backplate to Engine) Blower Kit Assembly, includes: H/H H/T Screw (7/16 UNC x 11/2) (Coupling to Armature) Coupling Lock Tab H/H H/T Screw (7/16 UNC x 1) (Coupling to Flywheel) Spring Washer (7/16) Dowel (Not Shown) Blower Segments Coupling Disc (Large Stainless Steel) Backing Disc (71/2 dia. Armature side) Generator Brush Main Pole No. Req 5 5 10 10 1 8 4 8 8 2 4 1 1 8 4

24 24A 25 25A 26 27 27B 27C 29 31

ALTERNATOR ASSEMBLY AP-33-G

Quote AP-33-G plus Machine Code No. and Serial No. Item 1 2 3
Fillet Weld

4 5 6 7 8 9 10

AL2328

AM 2373 24/10/90 AM3228

11

Part Name and Description Stator and Baffle Assembly Alternator Bracket Hex Head Screw, High Tensile (1/2-20 UNF x 13/4) Spring Washer 1/2 Stator Cover ( Not Shown) Rotor Assembly Rotor Locating Collar (Not Shown) Rotor Locknut Washer (Not Shown) Rotor Locknut (Not Shown) Rotor Brush Holder Assembly (Not Shown) (See AP -1-D) Capacitor Assembly, includes: (Not Shown) (See AP -1-D) Slip Ring Brush Holder Support Bracket Capacitors (200 MFD) Bridge Rectifier (fitted on S/ring B/hold Bkt)

No. Req 1 1 4 4 1 1 1 1 1 1 1 2 2 2 1

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SLIP RING BRUSH HOLDER ASSEMBLY AP-1-D

FACE OF STATOR LAM

66mm ref.

AM 3229

Quote AP-1-D.2 plus Machine Code No. & Serial No.

Item 1 2 3 4 5 6 7 Part Name and Description Slip Ring Brush Holder Assembly (Less Item 10) Mounting Bracket Brushholder Bracket 5 16 Whit. x 3/4 Hex. Hd. Bolt etc. Insulation Left Hand Brush Holder Right Hand Brush Holder Insulating Washer No. Req 1 1 1 2 2 1 1 2 Item 8 Part Name and Description 316 Z/P Flat Washer 316 Z/P Lock Washer 316 Z/P Hex. Nut 316 x 11/4 Z/P Rd. Hd. Screw Spring Brush Insulating Tube No. Req 4 2 2 2 2 2 2

9 10 11

GENERATOR BRUSH HOLDER AP-9-G

Parts List AP-9 AP-9-G

Note: When ordering give No. Part Name, Parts List No. Welder Code and Serial Number.

Item 1 2 3 4 5 6 7 8 9 10 11 12 13 14

Part Name and Description Brushhloder Assy, includes Brushholder Stud Retainer Assembly Washer Insulating Washer Insulating Tube Washer Spring Clip Spring Lockwasher Hex. Head Bolt Hex. Head Bolt Round Head Screw Round Head Screw Lockwasher

No. Req 4 1 1 1 2 1 1 2 2 1 1 1 1 2 2

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Shield-Arc 400AS-50

IMA 554C

CONTROL PANEL AP-33-D

AL2398 A1.6.94M

AM3034-2 A29-3-95M

Quote AP-33-D plus Machine Code No. and Serial No. Item 1 2 3 4 5 7 8 10 12 13 14 16 19 20 Part Name and Description Control Panel Nameplate Fastener Button Rheostat Oil Pressure Gauge Voltmeter Key Switch Moulded Output Stud 3 Pin Plug Receptacle 240V Cork Gasket 3 Pin Plug Receptacle 115V Bridge Rectifier Lockwasher Truss Head Screw Hex Nut Starwasher Rd Head Screw Hex Nut Springwasher Round Head Screw No. Req 1 1 4 1 1 1 1 2 2 2 1 1 2 2 1 1 1 4 4 4

Quote AP-33-D plus Machine Code No. and Serial No. Item 23 Part Name and Description Hex Nut Springwasher Round Head Screw Hex Nut Starwasher Round Head Screw Aux Switch Decal Code & Serial Number Decal (N/S) Hex Nut (Mounts Leads to Rheostat) (N/S) Starwasher (Mounts Leads to Rheostat) (N/S) Rd Hd Screw (Mts Leads to Rheostat) (N/S) Outlet Panel Switch Flange Nut Connector 3 Pin Self Tapping Screw Handle Red Indicator Lamp Temperature Gauge Warning Decal No. Req 2 2 2 2 2 1 1 1 3 3 2 1 1 2 1 4 1 1 1 1 1

29

31 32 33

22

34 35 36 37 38 39 40 41 42 43

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Page 17

Page 18
This diagram is typical of the machines 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 machines serial number and code number from the nameplate.

(Ref: AM3062E1 A28-4-93)

Wiring Diagram 12v Starter

Wiring Diagram

Shield-Arc 400AS-50

IMA 554C

400AS-50 OPTIONAL PARTS

Quote AP-33-J plus Machine Code No. and Serial No. Item A 9 10 11 12 12 13 14 15 16 17 19 20 21 B 1 2 C 1 2 3 4 5 6 7 8 Part Name and Description SOUND REDUCTION OPTION Door Assembly Canopy Bolt Kit End Frame (Low Fan Radiator) End Frame (Front End Muffler) Door Handle (Locking Type) Radiator Shroud Assembly Base Plate Hex. Hd. Bolt & Lock Washer (1/2" UNC 1") Nyloc Nut (Base Plate) (1/2 UNC) Muffler (Dome Shaped 3 Hole Flange) Muffler Pipe Pipe Clamps HOUR METER OPTION Hour Meter Diode & Lead Assembly REMOTE CONTROL OPTION Remote Field Control Packs, includes: Plug (3 Pin) Plug Base (3 Pin) Clamp Rheostat (64 ohm) Rheostat Handle Remote Control Box Nameplate Mounting Plate (21/2 x 25/8) No. Req 2 1 1 1 1 2 1 1 4 4 1 1 2 1 1 1 1 1 1 1 1 1 1 1 ENGINE WATCHER Quote AP-43-B plus Machine Code No. and Serial No. Item 10 11 12 13A 14 15 17A 18 20 22 Part Name and Description Oil Pressure Switch Female Tee Hex Nipple Engine Temperature Sensor Assembly Engine Temperature Sensor Plug only Engine Temperature Sensor Switch only Stop Button Switch Red Indicator Light Instruction Decal Assembly Instructions No. Req 1 1 1 1 1 1 1 1 1 1

Nut, bolt and washer sizes are given so that you may procure locally.

UNDERCARRIAGE (2-wheel type)

Item 1

2 3 4 6 7 8 9 10 11

Part Name and Description Assembly (Unsprung), Includes: Axle Assembly (Sprung), Includes: Axle Grease Cup Axle Cup Small Cone (Bearing) Seal Large Cone Large Cup Small Cup Hub and Stud Assy. (AS-2959) each assembly includes: Stud (7/16 UNF-2A x 17/8 LG) Drawbar (Standard) Drawbar (Sprung Trailers with Brakes) Chain (3/8 - 18) Registration only Nyloc Nuts (1/2) Wheel and Tyre, Includes: Wheel (14) Mudguard Supports Nyloc Nuts (1/2) Mudguard U Bolts Turnbuckle (5/16) (Hooks each and Tail Lamp to Trafficator)

No. Req 1 1 1 2 2 2 2 2 2 2 2 5 1 1 2 8 2 2 4 6 2 4 1

Item 16 17

17

18 19 20* 21* 22 23 26 27 30

Part Name and Description Cable Tie Drawbar Stand, includes Handle and Shaft Spring Jockey Wheel Assy. (optional) includes: Wheel Spring Hanger Plate Hex. Nuts 12mm (U Bolt) Left Hand Spring Assy. Right Hand Spring Assy. Brake Cable Connector Brake Cable Wheel Nuts (7/16 UNF) Wheel Studs (7/16 UNF-2A x 1 5/8) Override Brake Assembly (not shown)

No. Req 6 1 1 1 1 1 1 16 1 1 1 1 10 10 1

Notes: * Each Spring Assembly includes the following parts. 2 Shackle Assemblies 4 Shackle Bolts 2 Shackle Bolts with grease hole 6 Nyloc Nuts

Nut, bolt and washer sizes are given so that you may procure locally.

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Page 19

UNDERCARRIAGE (4-wheel type)

AL-1695 (5/10/83)

Quote AP-22-B plus Machine Code No. and Serial No. No. Item Part Name and Description Req 1 Front Axle 1 Rear Axle 1 2 3 Front Spring 3 leaf 2 2 Rear Spring 4 leaf 4 5 Wheel and Tyre 4 6 Drawbar 1 20 Wheel Nut 60 7 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) 4 sets Shackle Bolts and Nuts 10 32 Hex Nuts (U-Bolt) 11 12 Hanger Plate 4 13 U-Bolt 8 1 Grease Nipple (Not Shown) 14 15 Shackle Bolt and Nut 1 set 8 Shackle 16

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IMA 554C

RECOMMENDED SPARE PARTS 1.10.97 (revised 22.9.98)

If working at remote sites, the highlighted items should be carried to support one 400AS machine for a period of one year. Other items are optional and could assist in minimising potential down time and delay.

Lincoln Shield-Arc 400AS-50 (KA1352)

For codes 1297 & up
Description Radiator Bottom radiator hose Top radiator hose Bottom series coil Top series coil Blower segment assy Rotor assy Moulded output stud Muffler assy Brush holder assy Capacitor & lead assy Temperature gauge Red light assy Oil pressure gauge Fuel tank cap Hose clamp Carbon brush Volt meter Switch Bottom coil assy Top coil assy Reactor assy Armature assy Rheostat Reactor brush holder assy Brush holder assy Bearing Air cleaner element Oil filter Fuel filter Key start switch Mail pole lamination Interpole coil assy Rheostat handle Rocker Fuse 15A 250V 3GA Carbon brush Diode 35A 1000V Temperature sender unit Engine foot Engine foot spacer Engine & generator mounting kit Coupling disk Backing disk

Part No. AG1165-1 AL1834 AL1835 AL2224A1 AL2224A2 AM2338 AM2373-1E AM2464-1 AM2548 AM3229 AS3289-3 AS4302 AT2996-2 AT3002-1 AT3024 AT3061-6 AT3081 AT3639 AT3919 L1741-14B L1741-15B L2036CA2 L2667-21C M5090C M6277A1Z M6964-10X M9300-22 P26510192 P2654403 P26561117 P28461230 S10745-1 S12261-12 S16664-4 S5960 T10728-8A T12564 T13637 T14129-1 AS2654-2 AT2226-1 AT3443 M6730 AS 3021

Qty. 1 1 1 1 1 1 1 2 1 1 1 1 1 1 2 2 4 1 1 1 1 1 1 1 1 1 1 4 4 4 1 1 4 1 1 4 8 2 1 2 4 1 1 2

IMA 554C

Shield-Arc 400AS-50

Page 21

NOTES

Page 22

Shield-Arc 400AS-50

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NOTES

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LIMITED WARRANTY
STATEMENT OF LIMITED WARRANTY The Lincoln Electric Company (Australia) Pty Limited ("Lincoln") warrants all new machinery and equipment ("goods") manufactured by Lincoln against defects in workmanship and material subject to certain limitations hereinafter provided. This warranty is void if Lincoln or its Authorised Service Facility finds that the equipment has been subjected to improper installation, improper care or abnormal operations. PERIOD OF WARRANTY "LINCOLN BRANDED GOODS" The period from the commencement of the warranty in respect of goods covered by this warranty shall be as follows: Three Years All Lincoln welding machines, wire feeders and plasma cutting machines unless listed below. Two Years All Weldanpowers, Rangers and Italian Invertec welders. One Year Italian Plasmas. All water coolers (internal and external). Arc welding and cutting robots and robotic controllers. All stick electrodes, welding wires and fluxes. All Environmental Systems equipment, including portable units, central units and accessories. (Does not include consumable items listed under 30-day warranty). All welding and cutting accessories including wire feed modules, undercarriages, field installed options that are sold separately, unattached options, welding supplies, standard accessory sets, replacement parts. (Does not include expendable parts and guns/torches listed under 90 and 30 day warranties) All Pro Torch TIG torches. 90 Days All Gun and Cable Assemblies (manufactured by Lincoln) and Spool guns. All MIG, TIG and Plasma Torches 30 Days All consumable items that may be used with the environmental systems described above. This includes hoses, filters, belts and hose adapters. Expendable Parts - Lincoln is not responsible for the replacement of any expendable part that is required due to normal wear. ENGINE WARRANTY To the extent permitted by law Lincoln shall be entitled to in its absolute discretion repair all engines and engine accessories however Lincoln shall not be held responsible for any such repair which shall be the sole responsibility of the engine manufacturer which provides for warranties for the period and subject to any limitations provided for by those manufacturers of the respective engines and engine accessories. Three Years* Deutz 912 Engine and Accessories (Warranty service can only be carried out an authorised Deutz service dealer) Cummins B3.3 Engine and Accessories (Warranty service can only be carried out an authorised Cummins service dealer) Two Years Perkins Engines and Accessories (The Perkins Distributor Organisation provides all warranty service (accessories included) for the Perkins Engines powering goods manufactured by Lincoln. Briggs & Stratton Vanguard Engines and Accessories. (Warranty service can only be carried out by an authorised Briggs & Stratton service dealer). Kubota Engines and Accessories (Warranty service can only be carried out an authorised Kubota service dealer) One Year* Ruggerini Engines and Accessories (Warranty service can only be carried out by authorised Lincoln Field Service Shop or the engine distributors authorised by the Lincoln branch office). BATTERY WARRANTY Lincoln supplies certain batteries in connection with its supply of goods and the purchaser acknowledges that any such battery is warranted by its manufacturer and any claim in respect of such a battery whether as to a defect in the battery or as to damage consequential upon a defect in a battery shall be made by the purchaser to the manufacturer of the battery and the purchaser shall not hold Lincoln in any way liable for the operation, non-operation or malfunction of any such battery. *Subject to conditions imposed by Deutz. *Subject to conditions imposed by Cummins CONDITION OF WARRANTY

IMAWS1 (1/06)

TO OBTAIN WARRANTY COVERAGE: The purchaser must contact Lincoln or Lincolns Authorised Service Facility about any defect claimed under Lincolns warranty. Determination of warranty on welding and cutting equipment will be made by Lincoln or Lincolns Authorised Service Facility. WARRANTY REPAIR If Lincoln or Lincolns Authorised Service Facility confirms the existence of a defect covered by this warranty, the defect will be corrected by repair or replacement at Lincolns option. At Lincolns request, the purchaser must return, to Lincoln or its Authorised Service Facility, any "Goods" claimed defective under Lincolns warranty. FREIGHT COSTS The purchaser is responsible for shipment to and from the Lincoln Authorised Service Facility. WARRANTY LIMITATIONS Certain conditions warranties and obligations are implied by law (for example under the Trade Practices Act 1974) and cannot be excluded or modified ("the statutory warranties"). Where the statutory warranties do apply then any express warranties given by Lincoln (the "express warranties") are given in addition and without derogation from the statutory warranties. Apart from the express warranties and (in cases where they apply by law but not otherwise) the statutory warranties Lincoln gives no warranties whether express or implied by operation of law or otherwise in respect of any goods manufactured or supplied by Lincoln or by its authorised distributor. Any warranty whether express or statutory and the term of any such warranty as set out herein commences on the date Lincoln or Lincolns authorised distributorship forwards the goods from the premises of Lincoln or Lincolns authorised distributor to the purchaser. In respect of any claim under the warranty herein provided a purchaser must furnish Lincoln with written notice of any claim under the warranty within the time period of the warranty as further specified herein. The extent of Lincolns warranty whether express or statutory is limited to a liability to repair, replace or pay to the purchaser an amount equal to: a) b) c) The cost of replacing the goods; The cost of obtaining equivalent goods; or The cost of having the goods repaired whichever remedy in its absolute discretion Lincoln chooses.

Upon request by Lincoln the purchaser must permit Lincoln to inspect the goods the subject of any claim under this warranty and Lincoln may at its absolute discretion repair or replace the goods F.O.B. at its own premises or at such other premises as Lincoln may designate provided that all freight charges to and from Lincolns premises or such other premises as Lincoln may designate shall be paid by the purchaser. Subject to the express and statutory warranties hereinbefore provided Lincoln provides no other warranties in respect of the manufacture or sale of goods and in particular Lincoln shall have no responsibility or liability in respect of: a) Repairs done to Lincolns goods and undertaken by the purchaser outside Lincolns premises without written authority from Lincoln obtained prior to any such repair; Any damage or failure of the goods as a result of normal wear and tear or the neglect misuse abuse or failure to properly service goods by any purchaser.

*Subject to conditions imposed by Perkins

b)

*The Magnetron ignition system is warranted by Briggs & Stratton for 5 years. *Subject to conditions imposed by Kubota.

The liability of Lincoln is limited as hereinbefore provided and Lincoln shall not be liable for any incidental special or consequential damage suffered by a purchaser whether or not arising out of circumstances known or foreseeable known by Lincoln and in particular arising out of the supply of goods to a purchaser or the use of goods by a purchaser whether based on breach of contract negligence or tort. CUSTOMER ASSISTANCE POLICY The business of The Lincoln Electric Company is manufacturing and selling high quality welding equipment, consumables, and cutting equipment. Our challenge is to meet the needs of our customers and to exceed their expectations. On occasion, purchasers may ask Lincoln Electric for advice or information about their use of our products. We respond to our customers based on the best information in our possession at that time. Lincoln Electric is not in a position to warrant or guarantee such advice and assumes no liability, with respect to such information or advice. We expressly disclaim any warranty of any kind, including any warranty of fitness for any customers 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 manufacturer, but the selection and use of specific products sold by Lincoln Electric is solely within the control of, and remains the sole responsibility of the customer. Many variables beyond the control of Lincoln Electric affect the results obtained in applying this type of fabrication methods and service requirements.

In Australia, Lincoln Technical Sales Representatives are located in, Mackay, Brisbane, Newcastle, Sydney, Melbourne, Adelaide and Perth. To contact your local Lincoln Technical Sales Representative, call 1300 728

The Lincoln Electric Company (Australia) Pty. Ltd. A.B.N. 36 000 040 308
35 Bryant Street, Padstow, Sydney 2211, Australia
Telephone: International: (02) 9772 7222 Fax: (02) 9792 2420 Ph: +61 2 9772 7222 Fax: +61 2 9792 2420

720

(for the cost of a local call). Lincoln products are sold primarily

through its distributors. Our Regional Office locations are: Northern Region: Unit 1/15 Westgate St, Wacol, QLD, 4076 (07) 3271 3000 (02) 9772 7222 Central Region: 35 Bryant Street, Padstow, NSW, 2211 Southern Region: 52b Winterton Road, Clayton, VIC, 3168 (03) 9543 9399 Western Region: 25 Barker Street, Belmont, WA, 6104 (08) 9277 8744 New Zealand: 7B/761 Great South Road, Penrose, Auckland (9) 580 4008 (65) 6773 6689 Singapore: 11 Pandan Crescent, Singapore

THE LINCOLN ELECTRIC CO. Cleveland, Ohio, U.S.A. - Subsidiary companies established in Australasia, Asia, Canada, Europe, North and South America.