RETURN TO MAIN INDEX
IM640-A
SAE400 & SAE400 WELD’N AIR -
May, 2004
DC ARC WELDING POWER SOURCE
For use with machines having Code Numbers: 10601, 10602, 10884, 10885
Safety Depends on You
Lincoln arc welding and cutting
equipment is designed and built with
safety in mind. However, your overall
safety can be increased by proper
installation ... and thoughtful opera-
tion on your part. DO NOT
INSTALL, OPERATE OR REPAIR
THIS EQUIPMENT WITHOUT
READING THIS MANUAL AND
THE SAFETY PRECAUTIONS
CONTAINED THROUGHOUT.
And, most importantly, think before
you act and be careful.
R
OPERATOR’S MANUAL
Copyright © 2004 Lincoln Global Inc.
� World's Leader in Welding and Cutting Products �
� Sales and Service through Subsidiaries and Distributors Worldwide �
Cleveland, Ohio 44117-1199 U.S.A. TEL: 216.481.8100 FAX: 216.486.1751 WEB SITE: www.lincolnelectric.com
i i
SAFETY
WARNING
CALIFORNIA PROPOSITION 65 WARNINGS
The engine exhaust from this product contains
Diesel engine exhaust and some of its constituents
chemicals known to the State of California to cause
are known to the State of California to cause can-
cancer, birth defects, or other reproductive harm.
cer, birth defects, and other reproductive harm.
The Above For Gasoline Engines
The Above For Diesel Engines
ARC WELDING CAN BE HAZARDOUS. PROTECT YOURSELF AND OTHERS FROM POSSIBLE SERIOUS INJURY OR DEATH.
KEEP CHILDREN AWAY. PACEMAKER WEARERS SHOULD CONSULT WITH THEIR DOCTOR BEFORE OPERATING.
Read and understand the following safety highlights. For additional safety information, it is strongly recommended that you
purchase a copy of “Safety in Welding & Cutting - ANSI Standard Z49.1� from the American Welding Society, P.O. Box 351040,
Miami, Florida 33135 or CSA Standard W117.2-1974. A Free copy of “Arc Welding Safety� booklet E205 is available from the
Lincoln Electric Company, 22801 St. Clair Avenue, Cleveland, Ohio 44117-1199.
BE SURE THAT ALL INSTALLATION, OPERATION, MAINTENANCE AND REPAIR PROCEDURES ARE
PERFORMED ONLY BY QUALIFIED INDIVIDUALS.
FOR ENGINE 1.h. To avoid scalding, do not remove the
radiator pressure cap when the engine is
powered equipment. hot.
1.a. Turn the engine off before troubleshooting and maintenance
work unless the maintenance work requires it to be running.
____________________________________________________
1.b. Operate engines in open, well-ventilated
areas or vent the engine exhaust fumes
outdoors.
ELECTRIC AND
MAGNETIC FIELDS
____________________________________________________
may be dangerous
1.c. Do not add the fuel near an open flame weld-
ing arc or when the engine is running. Stop
the engine and allow it to cool before refuel- 2.a. Electric current flowing through any conductor causes
ing to prevent spilled fuel from vaporizing on localized Electric and Magnetic Fields (EMF). Welding
contact with hot engine parts and igniting. Do current creates EMF fields around welding cables and
not spill fuel when filling tank. If fuel is spilled, welding machines
wipe it up and do not start engine until fumes
have been eliminated. 2.b. EMF fields may interfere with some pacemakers, and
____________________________________________________ welders having a pacemaker should consult their physician
1.d. Keep all equipment safety guards, covers and devices in posi- before welding.
tion and in good repair.Keep hands, hair, clothing and tools
away from V-belts, gears, fans and all other moving parts 2.c. Exposure to EMF fields in welding may have other health
when starting, operating or repairing equipment. effects which are now not known.
____________________________________________________
2.d. All welders should use the following procedures in order to
1.e. In some cases it may be necessary to remove safety
minimize exposure to EMF fields from the welding circuit:
guards to perform required maintenance. Remove
guards only when necessary and replace them when the
2.d.1. Route the electrode and work cables together - Secure
maintenance requiring their removal is complete.
them with tape when possible.
Always use the greatest care when working near moving
parts.
2.d.2. Never coil the electrode lead around your body.
___________________________________________________
1.f. Do not put your hands near the engine fan.
2.d.3. Do not place your body between the electrode and
Do not attempt to override the governor or
idler by pushing on the throttle control rods work cables. If the electrode cable is on your right
while the engine is running. side, the work cable should also be on your right side.
2.d.4. Connect the work cable to the workpiece as close as
possible to the area being welded.
___________________________________________________
1.g. To prevent accidentally starting gasoline engines while 2.d.5. Do not work next to welding power source.
turning the engine or welding generator during maintenance
work, disconnect the spark plug wires, distributor cap or
magneto wire as appropriate. Mar �95
ii ii
SAFETY
ARC RAYS can burn.
ELECTRIC SHOCK can kill.
3.a. The electrode and work (or ground) circuits 4.a. Use a shield with the proper filter and cover
are electrically “hot� when the welder is on. plates to protect your eyes from sparks and
Do not touch these “hot� parts with your bare the rays of the arc when welding or observing
skin or wet clothing. Wear dry, hole-free open arc welding. Headshield and filter lens
gloves to insulate hands. should conform to ANSI Z87. I standards.
4.b. Use suitable clothing made from durable flame-resistant
3.b. Insulate yourself from work and ground using dry insulation.
material to protect your skin and that of your helpers from
Make certain the insulation is large enough to cover your full
the arc rays.
area of physical contact with work and ground.
4.c. Protect other nearby personnel with suitable, non-flammable
In addition to the normal safety precautions, if welding
screening and/or warn them not to watch the arc nor expose
must be performed under electrically hazardous
themselves to the arc rays or to hot spatter or metal.
conditions (in damp locations or while wearing wet
clothing; on metal structures such as floors, gratings or
scaffolds; when in cramped positions such as sitting,
FUMES AND GASES
kneeling or lying, if there is a high risk of unavoidable or
accidental contact with the workpiece or ground) use
can be dangerous.
the following equipment:
5.a. Welding may produce fumes and gases
� Semiautomatic DC Constant Voltage (Wire) Welder.
hazardous to health. Avoid breathing these
� DC Manual (Stick) Welder.
fumes and gases.When welding, keep
� AC Welder with Reduced Voltage Control.
your head out of the fume. Use enough
ventilation and/or exhaust at the arc to keep
3.c. In semiautomatic or automatic wire welding, the electrode,
fumes and gases away from the breathing zone. When
electrode reel, welding head, nozzle or semiautomatic
welding with electrodes which require special
welding gun are also electrically “hot�.
ventilation such as stainless or hard facing (see
instructions on container or MSDS) or on lead or
3.d. Always be sure the work cable makes a good electrical
cadmium plated steel and other metals or coatings
connection with the metal being welded. The connection
which produce highly toxic fumes, keep exposure as
should be as close as possible to the area being welded.
low as possible and below Threshold Limit Values (TLV)
using local exhaust or mechanical ventilation. In
3.e. Ground the work or metal to be welded to a good electrical
confined spaces or in some circumstances, outdoors, a
(earth) ground.
respirator may be required. Additional precautions are
also required when welding on galvanized steel.
3.f. Maintain the electrode holder, work clamp, welding cable and
welding machine in good, safe operating condition. Replace
5.b. Do not weld in locations near chlorinated hydrocarbon vapors
damaged insulation.
coming from degreasing, cleaning or spraying operations.
The heat and rays of the arc can react with solvent vapors to
3.g. Never dip the electrode in water for cooling.
form phosgene, a highly toxic gas, and other irritating
products.
3.h. Never simultaneously touch electrically “hot� parts of
electrode holders connected to two welders because voltage
5.c. Shielding gases used for arc welding can displace air and
between the two can be the total of the open circuit voltage
cause injury or death. Always use enough ventilation,
of both welders.
especially in confined areas, to insure breathing air is safe.
3.i. When working above floor level, use a safety belt to protect
5.d. Read and understand the manufacturer’s instructions for this
yourself from a fall should you get a shock.
equipment and the consumables to be used, including the
material safety data sheet (MSDS) and follow your
3.j. Also see Items 6.c. and 8.
employer’s safety practices. MSDS forms are available from
your welding distributor or from the manufacturer.
5.e. Also see item 1.b.
Mar �95
iii iii
SAFETY
WELDING SPARKS can CYLINDER may explode
cause fire or explosion. if damaged.
6.a. Remove fire hazards from the welding area.
7.a. Use only compressed gas cylinders
If this is not possible, cover them to prevent
containing the correct shielding gas for the
the welding sparks from starting a fire.
process used and properly operating
Remember that welding sparks and hot
regulators designed for the gas and
materials from welding can easily go through small cracks
pressure used. All hoses, fittings, etc. should be suitable for
and openings to adjacent areas. Avoid welding near
the application and maintained in good condition.
hydraulic lines. Have a fire extinguisher readily available.
7.b. Always keep cylinders in an upright position securely
6.b. Where compressed gases are to be used at the job site,
chained to an undercarriage or fixed support.
special precautions should be used to prevent hazardous
situations. Refer to “Safety in Welding and Cutting� (ANSI
7.c. Cylinders should be located:
Standard Z49.1) and the operating information for the
� Away from areas where they may be struck or subjected to
equipment being used.
physical damage.
6.c. When not welding, make certain no part of the electrode
� A safe distance from arc welding or cutting operations and
circuit is touching the work or ground. Accidental contact can
any other source of heat, sparks, or flame.
cause overheating and create a fire hazard.
7.d. Never allow the electrode, electrode holder or any other
6.d. Do not heat, cut or weld tanks, drums or containers until the
electrically “hot� parts to touch a cylinder.
proper steps have been taken to insure that such procedures
will not cause flammable or toxic vapors from substances
7.e. Keep your head and face away from the cylinder valve outlet
inside. They can cause an explosion even though they have
when opening the cylinder valve.
been “cleaned�. For information, purchase “Recommended
Safe Practices for the Preparation for Welding and Cutting of
7.f. Valve protection caps should always be in place and hand
Containers and Piping That Have Held Hazardous
tight except when the cylinder is in use or connected for
Substances�, AWS F4.1 from the American Welding Society
use.
(see address above).
7.g. Read and follow the instructions on compressed gas
6.e. Vent hollow castings or containers before heating, cutting or
cylinders, associated equipment, and CGA publication P-l,
welding. They may explode.
“Precautions for Safe Handling of Compressed Gases in
Cylinders,� available from the Compressed Gas Association
6.f. Sparks and spatter are thrown from the welding arc. Wear oil
1235 Jefferson Davis Highway, Arlington, VA 22202.
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.
FOR ELECTRICALLY
Always wear safety glasses with side shields when in a
powered equipment.
welding area.
6.g. Connect the work cable to the work as close to the welding
8.a. Turn off input power using the disconnect
area as practical. Work cables connected to the building
switch at the fuse box before working on
framework or other locations away from the welding area
the equipment.
increase the possibility of the welding current passing
through lifting chains, crane cables or other alternate circuits.
8.b. Install equipment in accordance with the U.S. National
This can create fire hazards or overheat lifting chains or
Electrical Code, all local codes and the manufacturer’s
cables until they fail.
recommendations.
6.h. Also see item 1.c.
8.c. Ground the equipment in accordance with the U.S. National
Electrical Code and the manufacturer’s recommendations.
Mar �95
iv iv
SAFETY
zones où l’on pique le laitier.
PRÉCAUTIONS DE SÛRETÉ
6. Eloigner les matériaux inflammables ou les recouvrir afin de
Pour votre propre protection lire et observer toutes les instructions
prévenir tout risque d’incendie dû aux étincelles.
et les précautions de sûreté specifiques qui parraissent dans ce
manuel aussi bien que les précautions de sûreté générales suiv-
7. Quand on ne soude pas, poser la pince à une endroit isolé de
antes:
la masse. Un court-circuit accidental peut provoquer un
échauffement et un risque d’incendie.
Sûreté Pour Soudage A L’Arc
1. Protegez-vous contre la secousse électrique:
8. S’assurer que la masse est connectée le plus prés possible de
la zone de travail qu’il est pratique de le faire. Si on place la
a. Les circuits à l’électrode et à la piéce sont sous tension
masse sur la charpente de la construction ou d’autres endroits
quand la machine à souder est en marche. Eviter toujours
éloignés de la zone de travail, on augmente le risque de voir
tout contact entre les parties sous tension et la peau nue
passer le courant de soudage par les chaines de levage,
ou les vétements mouillés. Porter des gants secs et sans
câbles de grue, ou autres circuits. Cela peut provoquer des
trous pour isoler les mains.
risques d’incendie ou d’echauffement des chaines et des
b. Faire trés attention de bien s’isoler de la masse quand on
câbles jusqu’� ce qu’ils se rompent.
soude dans des endroits humides, ou sur un plancher met-
allique ou des grilles metalliques, principalement dans
9. Assurer une ventilation suffisante dans la zone de soudage.
les positions assis ou couché pour lesquelles une grande
Ceci est particuliérement important pour le soudage de tôles
partie du corps peut être en contact avec la masse.
galvanisées plombées, ou cadmiées ou tout autre métal qui
c. Maintenir le porte-électrode, la pince de masse, le câble de
produit des fumeés toxiques.
soudage et la machine à souder en bon et sûr état defonc-
tionnement.
10. Ne pas souder en présence de vapeurs de chlore provenant
d.Ne jamais plonger le porte-électrode dans l’eau pour le
d’opérations de dégraissage, nettoyage ou pistolage. La
refroidir.
chaleur ou les rayons de l’arc peuvent réagir avec les vapeurs
e. Ne jamais toucher simultanément les parties sous tension
du solvant pour produire du phosgéne (gas fortement toxique)
des porte-électrodes connectés à deux machines à soud-
ou autres produits irritants.
er parce que la tension entre les deux pinces peut être le
total de la tension à vide des deux machines.
11. Pour obtenir de plus amples renseignements sur la sûreté, voir
f. Si on utilise la machine à souder comme une source de
le code “Code for safety in welding and cutting� CSA Standard
courant pour soudage semi-automatique, ces precautions
W 117.2-1974.
pour le porte-électrode s’applicuent aussi au pistolet de
soudage.
2. Dans le cas de travail au dessus du niveau du sol, se protéger
contre les chutes dans le cas ou on recoit un choc. Ne jamais
PRÉCAUTIONS DE SÛRETÉ POUR
enrouler le câble-électrode autour de n’importe quelle partie
LES MACHINES À SOUDER À
du corps.
TRANSFORMATEUR ET À
3. Un coup d’arc peut être plus sévère qu’un coup de soliel,
REDRESSEUR
donc:
a. Utiliser un bon masque avec un verre filtrant approprié
ainsi qu’un verre blanc afin de se protéger les yeux du ray- 1. Relier à la terre le chassis du poste conformement au code de
onnement de l’arc et des projections quand on soude ou l’électricité et aux recommendations du fabricant. Le dispositif
quand on regarde l’arc. de montage ou la piece à souder doit être branché à une
b. Porter des vêtements convenables afin de protéger la bonne mise à la terre.
peau de soudeur et des aides contre le rayonnement de
l‘arc. 2. Autant que possible, I’installation et l’entretien du poste seront
c. Protéger l’autre personnel travaillant à proximité au effectués par un électricien qualifié.
soudage à l’aide d’écrans appropriés et non-inflammables.
3. Avant de faires des travaux à l’interieur de poste, la debranch-
4. Des gouttes de laitier en fusion sont émises de l’arc de er à l’interrupteur à la boite de fusibles.
soudage. Se protéger avec des vêtements de protection libres
de l’huile, tels que les gants en cuir, chemise épaisse, pan- 4. Garder tous les couvercles et dispositifs de sûreté à leur
talons sans revers, et chaussures montantes. place.
5. Toujours porter des lunettes de sécurité dans la zone de
soudage. Utiliser des lunettes avec écrans lateraux dans les
Mar. �93
v v
SAFETY
WARNING
Assure that tank and compressor relief
valves work properly, and are at correct
pressure settings.
DO NOT modify or repair air tank.
NEVER move compressor with pressure in
tank.
vi vi
SAFETY
vii vii
for selecting a QUALITY product by Lincoln Electric. We want you
Thank You to take pride in operating this Lincoln Electric Company product •â?¢â??
as much pride as we have in bringing this product to you!
Please Examine Carton and Equipment For Damage Immediately
When this equipment is shipped, title passes to the purchaser upon receipt by the carrier. Consequently, Claims
for material damaged in shipment must be made by the purchaser against the transportation company at the time
the shipment is received.
Please record your equipment identification information below for future reference. This information can be found
on your machine nameplate.
Product _________________________________________________________________________________
Model Number ___________________________________________________________________________
Code Number or Date Code_________________________________________________________________
Serial Number____________________________________________________________________________
Date Purchased___________________________________________________________________________
Where Purchased_________________________________________________________________________
Whenever you request replacement parts or information on this equipment, always supply the information you
have recorded above. The code number is especially important when identifying the correct replacement parts.
On-Line Product Registration
- Register your machine with Lincoln Electric either via fax or over the Internet.
� For faxing: Complete the form on the back of the warranty statement included in the literature packet
accompanying this machine and fax the form per the instructions printed on it.
� For On-Line Registration: Go to our WEB SITE at www.lincolnelectric.com. Choose “Quick Links� and then
“Product Registration�. Please complete the form and submit your registration.
Read this Operators Manual completely before attempting to use this equipment. Save this manual and keep it
handy for quick reference. Pay particular attention to the safety instructions we have provided for your protection.
The level of seriousness to be applied to each is explained below:
WARNING
This statement appears where the information must be followed exactly to avoid serious personal injury or
loss of life.
CAUTION
This statement appears where the information must be followed to avoid minor personal injury or damage to
this equipment.
viii viii
TABLE OF CONTENTS
Page
Installation Instructions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Section A
Technical Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .A-1
Installation Precautions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A-2
Location / Ventilation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .A-2
Stacking . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .A-2
Angle of Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .A-2
Lifting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .A-2
High Altitude Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .A-3
Towing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .A-3
Pre-Operation Engine and Compressor Service . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .A-3
Engine Oil . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .A-3
Compressor Oil . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .A-3
Fuel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .A-4
Engine Cooling System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .A-4
Break-In Period . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .A-4
Battery Connection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .A-4
Spark Arrester . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .A-4
Welding Output Cables . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .A-5
Machine Grounding . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .A-5
Operating Instructions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Section B
Safety Instructions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . B-1
Additional Safety Precautions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . B-1
General Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .B-1
Recommended Applications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .B-2
Welder . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .B-2
Auxiliary Power . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .B-2
Compressed Air . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .B-2
Product Application . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .B-2
Design Features and Advantages . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .B-2
Duty Cycle . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .B-2
Engine Controls: Function/Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . B-3
Welder Controls: Function/Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . B-3
Remote Control . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .B-4
Auxiliary Power Controls . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .B-4
Air Compressor Controls . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .B-4
Engine Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .B-5
Starting Instructions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .B-5
Typical Fuel Consumption . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .B-6
Accessories . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Section C
Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Section D
Routine Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . D-1
Periodic Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . D-1
Pre Filter / Washer Separator . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .D-2
Water Separator Element . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .D-3
Engine And Compressor Maintenance Components . . . . . . . . . . . . . . . . . . . . . . . . . . .D-4
Spark Arrester . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .D-4
Troubleshooting Guide . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Section E
Wiring Diagrams and Dimension Print . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Section F
Parts Lists . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Appendix
SAE-400 WELD’N AIR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .P303 Series
SAE-400 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .P339 Series
SAE400 & SAE400 WELD’N AIR
A-1 A-1
INSTALLATION
TECHNICAL SPECIFICATIONS - SAE400 & SAE400 WELD’N AIR
INPUT - DIESEL ENGINE
Make/Model Description Speed (RPM) Displacement Starting Capacities
System
Perkins 4 cylinder High Idle 1800 256 cu. in 12VDC batteries Fuel: 22.5 gal.
1004.42 Diesel 71 HP @ Low Idle 1100 (4.2 L) (2) & Starter 85.1 L
Engine 1725 RPM Full Load 1725
Bore x Stroke Oil: 8.5 Qts.
8.04 L
3.875� x 5.00�
Coolant: 3.6 gal.
(98.4 mm x 127.0mm)
13.63 L
RATED OUTPUT - WELDER
Duty Cycle Welding Output Volts at Rated Amps
(1)
60% (NEMA) 400 amps 36 volts
60% (Lincoln Plus) 400 amps 40 volts
OUTPUT - WELDER AND GENERATOR
Welding Range Open Circuit Voltage Auxiliary Power
80 - 575 Amps 97 Max. OCV 115/230 VAC
@ 1800 RPM 3000 Watts, 60 Hz.
100% Duty Cycle
PHYSICAL DIMENSIONS
HEIGHT WIDTH DEPTH WEIGHT
50.13 in. 28.00 in. 83.00 in. SAE400 2125 lbs.
963.9 kg
1273.3 mm 711.2 mm 2108.2 mm SAE400 2428 lbs.
WELD’N AIR 1101.3 kg
AIR COMPRESSOR OUTPUT - SAE400 WELD’N AIR ONLY
Make/Model Description Delivery Tank Capacity & Rating Operating Pressure Oil Capacity
IMT 4-cylinder 35 CFM 11 Gallons Loads at 90 P.S.I. 1.33 Quarts
(Iowa Mold Reciprocating, at 100 P.S.I. (41.6 Liters) (6.3 kg/cm2) (1.26 Liters)
Tooling/ Diamond Water Cooled, at 60% Maximum Allowable Unloads at 130 P.S.I. IMT’s
Air) Pressure Lubricated Duty Cycle (1) Working Pressure (9.1 kg/cm2) Synthetic
Aluminum Alloy 991 Liters/min. 150 PSI Compressor
Model Block with Cast- at 7.0 kg/cm2 (10.5 kg/cm2) Oil
DA435ELW Iron sleeves
Based on a 10 minute period.
(1)
SAE400 & SAE400 WELD’N AIR
A-2 A-2
INSTALLATION
Read this entire installation section before you
CAUTION
start installation.
SAFETY PRECAUTIONS DO NOT MOUNT OVER COMBUSTIBLE SURFACES
Where there is a combustible surface directly under
stationary or fixed electrical equipment, that surface
WARNING
should be covered with a steel plate at least
.06�(1.6mm) thick, which should extend not less than
Do not attempt to use this equipment until you have
5.90(150mm) beyond the equipment on all sides.
thoroughly read all operating and maintenance man-
uals supplied with your machine. They include impor- -----------------------------------------------------------------------
tant safety precautions, detailed engine starting,
operating and maintenance instructions and parts STACKING
lists.
These machines cannot be stacked.
ELECTRIC SHOCK can kill.
ANGLE OF OPERATION
•Do not touch electrically live parts such
as output terminals or internal wiring.
To achieve optimum engine performance the machine
should be run in a level position. The maximum angle
•Insulate yourself from the work and
of operation for the air compressor is 20 degrees in all
ground.
directions. If the compressor is to be operated at an
angle, provisions must be made for checking and
•Always wear dry insulating gloves.
maintaining the oil level at the normal (FULL) oil capac-
------------------------------------------------------------------------
ity in the compressor crankcase. The maximum angle
of operation for the Perkins engine is 30 degrees in all
ENGINE EXHAUST can kill.
directions. If the engine is to be operated at an angle,
provisions must be made for checking and maintaining
•Use in open, well ventilated areas or
the oil level at the normal (FULL) oil capacity in the
vent exhaust outside
engine crankcase. When operating the welder at an
angle, the effective fuel capacity will be slightly less
•Do not stack anything near the engine.
than the specified 22.5 gallons.
------------------------------------------------------------------------
LIFTING
MOVING PARTS can injure.
The equipment lift bale should be used to lift the
•Do not operate with doors open or
machine.
guards off.
•Stop engine before servicing.
WARNING
•Keep away from moving parts � Lift only with equipment of adequate
------------------------------------------------------------------------ lifting capacity.
Only qualified personnel should install, use or service � Be sure machine is stable when lift-
this equipment ing.
� Do not lift this machine using lift
LOCATION/VENTILATION bale if it is equipped with a heavy
accessory such as trailer or gas
cylinder.
The welder should be located to provide an unrestricted
FALLING � Do not lift machine if lift bale is
flow of clean, cool air to the cooling air inlets and to avoid
restricting the cooling air outlets. Also, locate the welder EQUIPMENT can damaged.
so that the engine exhaust fumes are properly vented to cause injury. � Do not operate machine while
an outside area.
suspended from lift bale.
------------------------------------------------------------------------
SAE400 & SAE400 WELD’N AIR
A-3 A-3
INSTALLATION
� Only transport this equipment on serviceable vehi-
HIGH ALTITUDE OPERATION
cles which are rated and designed for such loads.
� Distribute, balance and secure loads so vehicle is
At higher altitudes, output derating may be necessary.
stable under conditions of use.
As a rule of thumb, derate the welder output 5% for
� Do not exceed maximum rated loads for compo-
every 500 meters (1640 ft.) above 1000 meters (3280
nents such as suspension, axles and tires.
ft.).
� Mount equipment base to metal bed or frame of
vehicle.
Contact a Perkins Service Representative for any � Follow vehicle manufacturer’s instruction.
engine adjustments that may be required for high alti- ----------------------------------------------------------------------------
tude operation.
PRE-OPERATION ENGINE AND
COMPRESSOR SERVICE
TOWING
READ the engine and compressor operating and main-
tenance instructions supplied with this machine.
The recommended trailers for use with this equipment
(1)
for in-plant and yard towing by a vehicle are Lincoln’s
ENGINE OIL
K767-1, K956-1 and K956-2. The K956-1 and K956-2
are also designed to be used at highway speeds(1).If
the user adapts a non-Lincoln trailer, he must assume The engine is shipped with the engine crankcase filled
responsibility that the method of attachment and usage with high quality SAE 10W-30 oil (API class CD or bet-
does not result in a safety hazard nor damage the ter). Check the oil level before starting the engine. If it is
not up to the full mark on the dip stick, add oil as required.
welding equipment. Some of the factors to be consid-
Check the oil level every four hours of running time during
ered are as follows:
the first 35 running hours. Refer to the engine Operator’s
Manual for specific oil recommendations and break-in
1. Design capacity of trailer vs. weight of Lincoln
information. The oil change interval is dependent on the
equipment and likely additional attachments.
quality of the oil and the operating environment. Refer to
the engine Operator’s Manual for the proper service and
2. Proper support of, and attachment to, the base of
maintenance intervals.
the welding equipment so that there will be no
undue stress to the trailer’s framework.
AIR COMPRESSOR OIL (WELD’N AIR
Only)
3. Proper placement of the equipment on the trailer to
The WELD’N AIR is shipped with the compressor filled
insure stability side to side and front to back when
with a high quality synthetic compressor oil. If oil is
being moved and when standing by itself.
needed add only Iowa Mold Tooling Co., Inc. (IMT)
synthetic compressor oil until compressor is full.
4. Typical conditions of use, such as travel speed,
roughness of surface on which the trailer will be
operated, and environmental conditions. CAUTION
The use of any other oil causes excessive carbon
5. Proper preventative maintenance of trailer.
build up, and will void the warranty on the com-
pressor.
6. Conformance with federal, state and local laws.1
------------------------------------------------------------------------
Check the oil level daily. Refer to the compressor
(1)
Operator’s Manual for the proper service and mainte-
For highway use, consult applicable federal, state
nance intervals.
and local laws regarding specific requirements for
use on public highways, such as brakes, lights, fend-
ers, etc.
VEHICLE MOUNTING
WARNING
Improperly mounted concentrated loads may cause
unstable vehicle handling and tires or other compo-
nents to fail.
SAE400 & SAE400 WELD’N AIR
A-4 A-4
INSTALLATION
1. Connect the welder output studs to a suitable resis-
WARNING tive load bank. Note that any attempt to short the
output studs by connecting the welding leads
� Stop engine while fueling.
together, direct shorting of the output studs, or con-
� Do not smoke when fueling.
necting the output leads to a length of steel will
� Keep sparks and flame away from
result in catastrophic damage to the generator and
tank.
voids the warranty.
� Do not leave unattended while
fueling. 2. Set the welder controls for an output current and
� Wipe up spilled fuel and allow voltage within the welder rating and duty cycle.
DIESEL FUEL fumes to clear before starting
Note that any attempt to exceed the welder rating or
can cause fire.
engine. duty cycle for any period of time will result in cata-
� Do not overfill tank, fuel strophic damage to the generator and voids the
warranty.
expansion may cause over-
flow.
3. Periodically shut off the engine and check the
DIESEL FUEL ONLY
crankcase oil level.
------------------------------------------------------------------------
Fill the fuel tank with clean, fresh diesel fuel. The capac-
BATTERY CONNECTION
ity of the fuel tank is 22.5 gallons (85.1 liters). See engine
Operator’s Manual for specific fuel recommendations.
WARNING
NOTE: Before starting the engine, be sure the fuel shut- Use caution as the electrolyte is a strong acid that
off valve on the sediment bowl is open by turning the han- can burn skin and damage eyes.
dle counterclockwise.
Remove and discard the insulating caps from the
ENGINE COOLING SYSTEM negative battery terminals. Attach and tighten neg-
ative battery cable terminals.
The cooling system has been filled at the factory with
a 50-50 mixture of ethylene glycol antifreeze and NOTE: This machine is furnished with wet charged
water. Check the radiator level and add a 50-50 solu- batteries; if unused for several months, the batteries
tion as needed. (See Engine Manual or antifreeze may require a booster charge. Be careful to charge the
container for alternate antifreeze recommendation.) batteries with the correct polarity. Make sure that the
batteries are level while charging.
ENGINE BREAK-IN PERIOD
WARNING
Lincoln Electric selects high quality, heavy-duty indus-
trial engines for the portable welding machines we GASES FROM BATTERY can
offer. While it is normal to see a small amount of explode.
crankcase oil consumption during initial operation,
G Keep sparks, flame and cigarettes
excessive oil use, wetstacking (oil or tar like substance
away from battery.
at the exhaust port), or excessive smoke is not normal.
-----------------------------------------------------------------------
To prevent EXPLOSION when:
Larger machines with a capacity of 350 amperes and
G INSTALLING A NEW BATTERY � disconnect
higher, which are operated at low or no-load conditions
negative cable from old battery first and
for extended periods of time are especially susceptible
connect to new battery last.
to the conditions described above. To accomplish suc-
cessful engine break-in, most diesel-powered equip-
ment needs only to be run at a reasonably heavy load G CONNECTING A BATTERY CHARGER �
within the rating of the welder for some period of time remove battery from welder by disconnecting
during the engine’s early life. However, if the welder is negative cable first, then positive cable and
subjected to extensive light loading, occasional moder- battery clamp. When reinstalling, connect
ate to heavy loading of the engine may sometimes be negative cable last. Keep well ventilated.
necessary. Caution must be observed in correctly
G USING A BOOSTER � connect positive lead to
loading a diesel/generator unit.
battery first then connect negative lead to neg-
ative battery lead at the lower control panel
support.
SAE400 & SAE400 WELD’N AIR
A-5 A-5
INSTALLATION
BATTERY ACID can burn eyes and WELDING OUTPUT CABLES
skin.
With the engine off, connect the electrode and work
G Wear gloves and eye protection
cables to the studs provided. These connections
and be careful when working near
should be checked periodically and tightened if neces-
battery.
sary.
G Follow instructions printed on battery.
IMPORTANT: To prevent ELECTRICAL DAMAGE
Listed in Table A.1 are copper cable sizes recom-
WHEN:
mended for the rated current and duty cycle. Lengths
a) Installing new batteries. stipulated are the distance from the welder to work and
back to the welder again. Cable sizes are increased
b) Using a booster.
for greater lengths primarily for the purpose of mini-
Use correct polarity � Negative Ground.
mizing cable voltage drop.
To prevent BATTERY BUCKLING, tighten nuts on bat-
teries only until snug. DO NOT OVERTIGHTEN.
Table A.1 Combined Length of Electrode and
Work Cables.
WARNING
� Spark Arrester and Muffler may be TOTAL COMBINED LENGTH OF ELEC-
hot! TRODE AND WORK CABLES
� Allow engine to cool before servicing AMPS Up to 100FT. 100-200FT. 200-250FT.
spark arrester! @60% Up to 31m 31-61m 61-76m
� Do not operate engine while servicing Duty Cycle
spark arrester!
400 2/0 AWG 3/0 AWG 4/0 AWG
SPARK ARRESTER
MACHINE GROUNDING
Some federal, state or local laws may require that
gasoline or diesel engines be equipped with exhaust Because this portable engine driven welder creates its
spark arresters when they are operated in certain loca- own power, it is not necessary to connect its frame to
tions where unarrested sparks may present a fire haz- an earth ground, unless the machine is connected to
ard. The muffler included with this welder has been premises wiring (home, shop, etc.).
modified and now qualifies as a spark arrester.
Mufflers on machines manufactured before this To prevent dangerous electric shock, other equipment
change do not qualify as spark arresters and when powered by this engine driven welder must:
required by local regulations, a suitable spark arrestor
must be installed. Spark arresting mufflers will have a a) be grounded to the frame of the welder using a
clean out service plug and will have “USDA FS 5100- grounded type plug, or
1c QUALIFIED SPARK ARRESTER� stamped on the b) be double insulated.
muffler shell. Any spark arrester must be serviced and
properly maintained. When this welder is mounted on a truck or trailer, its
frame must be securely connected to the metal frame
CAUTION of the vehicle. When this engine driven welder is con-
nected to premises wiring such as that in a home or
An incorrect arrester may lead to damage to the shop, its frame must be connected to the system earth
engine or adversely affect performance. ground. See the article on grounding in the latest U.S.
------------------------------------------------------------------------ National Electrical Code and the local code.
In general, if the machine is to be grounded, it should
be connected with a #8 or larger copper wire to a solid
earth ground such as a metal water pipe going into the
ground for at least ten feet and having no insulated
joints, or to the metal framework of a building which
has been effectively grounded. The U.S. National
Electrical Code lists a number of alternate means of
grounding electrical equipment. A machine grounding
stud marked with the symbol is provided on the
welding generator frame foot.
SAE400 & SAE400 WELD’N AIR
B-1 B-1
OPERATION
OPERATING INSTRUCTIONS WELDING SPARKS can cause
fire or explosion.
Read and understand this entire section before operat-
ing your equipment.
� Do not weld near flammable material .
� Do not weld on containers that have
SAFETY INSTRUCTIONS held flammable material.
-----------------------------------------------------------
WARNING
MOVING PARTS can injure.
Do not attempt to use this equipment until you have � Keep away from moving parts
thoroughly read all operating and maintenance manu- � Do not operate with doors open or
als supplied with your machine. They include important guards off.
safety precautions, detailed engine starting, operating � Stop engine before servicing.
and maintenance instructions and parts lists. ------------------------------------------------------------------------
ENGINE EXHAUST can kill.
ELECTRIC SHOCK can kill. � Use in open, well ventilated areas or
� Do not touch electrically live parts or vent exhaust outside.
electrodes with your skin or wet cloth-
ing. ------------------------------------------------------------------------
� Insulate yourself from the work and
ground. ADDITIONAL SAFETY PRECAUTIONS
� Always wear dry insulating gloves.
� Do not use AC welder if your clothing, gloves or Always operate the welder with the hinged doors
work area is damp or if working on, under or closed as these provide maximum protection from
inside workpiece. moving parts and insure proper cooling air flow.
Use the following equipment:
� Semiautomatic DC constant voltage Read carefully the Safety Precautions page in the
(wire) welder. Instruction Manual before operating this machine.
� DC manual (stick) welder. Always follow these and any other safety procedures
� AC welder with reduced voltage con- included in this manual and in the engine and com-
trol. pressor instruction manuals.
------------------------------------------------------------------------
ARC RAYS can injure eyes and
GENERAL DESCRIPTION
burn skin.
The SAE400 or SAE400 WELD’N AIR is a diesel
� Wear eye, ear, and body protection.
engine driven welding power source. The machine
----------------------------------------------------------
uses a DC generator for DC stick electrode welding
and an AC exciter for 115/230 VAC auxiliary power. As
� Only qualified personnel should install, use or
a generator it can supply up to 3,000 watts of 115/230
service this equipment.
volt AC power. As a welder it provides up to 575 amps
� Consult instruction manual before operating.
of DC constant current output. The belt driven air com-
----------------------------------------------------------------------
pressor of the SAE400 WELD’N AIR provides 35 CFM
Before operating, read and understand the manu-
at 100 PSI compressed air.
facurer’s instructions for this equipment and the
consumables to be used including the Material
The engine is a 71 Hp (54kw), 4-cylinder water cooled
Safety Data Sheet (MSDS) and follow your
diesel made by Perkins.
employer’s safety practices.
------------------------------------------------------------------------
FUMES AND GASES can be dangerous to
your health.
� Keep your head out of fumes.
� Use enough ventilation or exhaust at the arc, or
both, to keep the fumes and gases from your
breathing zone and general area.
SAE400 & SAE400 WELD’N AIR
B-2 B-2
OPERATION
OTHER FEATURES
RECOMMENDED APPLICATIONS
� Perkins 4-cylinder, water cooled diesel engine.
WELDER
Designed for long life, easy maintenance and excel-
The SAE400 or SAE400 WELD’N AIR provides excel-
lent fuel economy.
lent constant current DC welding output for stick
� Engine protection system shuts the engine down for
(SMAW) welding. The field installed optional CV
low engine oil pressure or high coolant temperature.
Adapter (K385-1) provides up to 500 amps at 35 volts
� Electronic Engine Idler. Engine automatically goes
of constant voltage output for semiautomatic welding.
to low idle in 10 to 14 seconds after welding or use
of auxiliary power stops. Includes high idle switch.
AUXILIARY POWER
� Gauges for engine oil pressure, coolant temperature
The SAE400 or SAE400 WELD’N AIR provides 3 KW
and battery charging ammeter.
of 115/230 VAC output for auxiliary power and emer-
� Engine hour meter standard.
gency standby power.
� Extended range 22.5 gallon (85.1 L) fuel tank.
COMPRESSED AIR
FOR COMPRESSED AIR (SAE400 WELD’N AIR only)
The SAE400 WELD’N AIR only, provides 35 CFM at
100 PSI compressed air for air arc gouging and air
� 35 CFM at 100 PSI for air arc gouging and air pow-
powered tools.
ered tools.
� 11 Gallon air receiver tank system with integral over-
PRODUCT APPLICATION
pressure relief valve for smooth air delivery.
PSI - kg/cm2 � Indicator light for compressor operation.
TOOL CFM - L/min
Arc Gouging, 3/8 in. (9.5)mm Electrode 16 453 18 1.27
� Gauges for compressor air pressure and compres-
(Current Range, 350-600 amps DC)
Grinder, 2 in. (50.8mm) wheel 14-20 396-566 90 6.33
sor oil pressure.
Chipping Hammer- Weight: 18lbs. (8.1kg.) 28-30 793-850 90 6.33
� No welding output derating required at maximum
Air or Impact Wrenches: 1/2 in. to 3/4 in. (12.7-19.1mm) 30 850 90 6.33
Paint Sprayer 2-20 57-566 90 6.33
compressor load.
Drills Capacity 3/8 in. (9.5mm) 20-40 566-1133 90 6.33
Sand Blaster - 1/8 in. (3.2 mm) Nozzle diameter 26 736 100 7.03
DUTY CYCLE
DESIGN FEATURES AND ADVANTAGES
Duty cycle is based on a ten minute period and opera-
FOR STICK WELDING
tion in an ambient temperature of 104°F(40°C).
� Excellent DC constant current output for stick weld-
ing applications.
The SAE400 & SAE400 WELD’N AIR are NEMA rated
� Continuous adjustment of both voltage and current
at 60% duty cycle. Duty cycle is based on a ten minute
for unsurpassed welds on demanding jobs.
period. Therefore, a 60% duty cycle welder can be
� Remote control capability standard.
operated at nameplate rated output for 6 minutes out of
every 10 minute period without overheating.
FOR AUXILIARY POWER
� 3,000 watts of 115/230 VAC, 60 Hz auxiliary power.
The auxiliary power can be used continuously (100%
� One 20 amp 115 VAC duplex receptacle for up to 26
duty cycle) within its rated current capacities.
amps of 115 VAC power.
� One 15 amp, 230 VAC duplex receptacle for up to 13
The air compressor on the SAE400 WELD’N AIR is
amps of 230 VAC power.
rated at a 60% duty cycle based on a ten minute peri-
� Weld and AC auxiliary power at the same time (with-
od as described above.
in the limits shown on the chart below).
Welding Using Only Using Only Total
Current, Amps 115V Circuit, 230V Circuit, Aux.
@ NEMA Arc Amps Amps kVA
Volts
0 26 13 3.0
100 19.5 9.75 2.25
200 13 6.5 1.5
300 6.5 3.25 0.75
400 0 0 0
SAE400 & SAE400 WELD’N AIR
B-3 B-3
OPERATION
ENGINE PROTECTION SYSTEM
ENGINE CONTROLS
The engine protection system shuts down the engine
IGNITION SWITCH
under high coolant temperature or low engine oil pres-
sure conditions by allowing the fuel solenoid valve to
When placed in the “ON� position, this switch ener-
close.
gizes the fuel solenoid. When placed in the “OFF� posi-
tion, the flow of fuel to the injection pump is stopped to
WELDER CONTROLS
shut down the engine.
POLARITY SWITCH
“IDLER� SWITCH
Turn the Arc Polarity switch to electrode positive or
The idler switch has two positions, “HIGH� and
electrode negative as required for each particular
“AUTO�.
application.
When in “HIGH� ( ) position, the engine will run
CONTROL OF WELDING CURRENT
continuously at high idle.
Purpose of Controls
When in “AUTO� ( / ) idle position, the idler
The continuous “Current Control� is the main current
operates as follows:
adjuster. The “Job Selector� is both a fine current
adjuster and the continuous Open Circuit Voltage
a. Welding
adjuster. Open Circuit Voltage (OCV) controls the arc
characteristics.
When the electrode touches the work, the welding
arc is initiated and the engine accelerates to full
“Job Selector�
speed.
The “Job Selector� dial is divided into four colored sec-
After welding ceases (and no auxiliary power is
tions providing OCV ranges as follows:
being drawn), the engine will return to low idle after
approximately 10 to 14 seconds.
Color Title OCV Range
White Large Electrodes High OCV
b. Auxiliary Power
Black Normal Welding Medium OCV
Red Overhead & Vertical Low OCV
With the engine running at low idle and auxiliary
Grey Special Applications Extra-Low OCV
power for lights or tools is drawn (approximately
100-150 watts or greater) from the receptacles, the
The “Job Selector� is usually set in the black range
engine will accelerate to high speed. If no power is
because it provides a soft “Buttering � arc desired for
being drawn from the receptacles ( and not weld-
most welding. Some operators prefer to set the “Job
ing) for 10-14 seconds, the idler reduces the engine
Selector� in the red range for a snappy “Digging� arc
speed to low idle.
when welding vertical up or overhead.
ENGINE TEMPERATURE GAUGE
“Current Control�
Displays the coolant temperature in the engine block.
CAUTION
ENGINE OIL PRESSURE GAUGE
Do not adjust the “Current Control� while welding
because this can damage the control.
Displays the oil pressure to the engine. When the
------------------------------------------------------------------------
engine starts running, watch for the oil pressure to
The “Current Control� dial is calibrated in amperes on
build up. If no pressure shows within 30 seconds, stop
three separate colored dials corresponding to the
the engine and consult the engine instruction manual.
white, black and red ranges of the “Job Selector� dial.
For example: when the “Job Selector� is set on the
BATTERY CHARGING AMMETER
black range, the approximate welding current is indi-
cated on the black scale of the “Current Control� dial.
Displays the current going from the charging alternator
into the batteries. It is normal for charging current to be
high (above 15 amps) after starting or when the batter-
ies are ‘low� on charge.
ENGINE HOUR METER
The engine hour meter records the total running time
on the engine in hours. It can be used to keep a record
of maintenance on the engine and or welder.
SAE400 & SAE400 WELD’N AIR
B-4 B-4
OPERATION
How to Set the Controls Circuit Breakers
Assume you want a normal soft arc and about 135 The circuit breakers provide separate overload current
amps, using a 5/32� (4.0 mm) electrode: protection for each half of the 115 V duplex receptacle.
The circuit breakers provide overload current protec-
1. Set the “Job Selector� at the center of the black tion in both current carrying wires of the 230 V duplex
range. receptacle.
2. Set the “Current Control� to read 135 amps on the Ground Stud
black dial.
Provides a connection point for connecting the
3. Start to weld. machine to earth ground. For the safest grounding pro-
cedure refer to “Machine Grounding� in the INSTALLA-
4. If you want a little more current, turn the “Job TION section of this manual.
Selector� up (counterclockwise) to increase cur-
rent. If you want a little less current, turn the “Job
Selector� down (clockwise) to decrease current. AIR COMPRESSOR CONTROLS -
(SAE400 WELD’N AIR ONLY)
5. If dialing the desired current with the “Job
Selector� moves the setting outside the black
range causing undesirable arc characteristics, turn COMPRESSOR ON/OFF SWITCH
the “Job Selector� back to the center of the black
range. Then turn the “Current Control� up or down Placing the “ON/OFF� switch in the “ON� position
a little as needed. Readjust the “Job Selector� for allows the “pressure switch� (factory preset) to control
the exact characteristics and current desired. the air compressor through an electric clutch. When
the system pressure falls below 90 psi, the “pressure
switch� engages the clutch and compressor. When the
REMOTE CONTROL system pressure goes above 130 psi, the “pressure
switch� disengages the clutch and compressor.
A receptacle and “Local/Remote� control switch on the
lower front control panel and a remote control box with The “ON/OFF� switch needs to be in the “ON� position
100 ft. (30.5 m) of cord for adjusting the OCV at the when using compressed air. When placed in the “OFF�
welding site are standard. Putting the switch in the position this switch does not allow the compressor
“REMOTE� position allows fine current control at the clutch to engage regardless of the tank pressure.
remote control box while placing the switch in the
“LOCAL� position allows fine current control at the “Job The “ON/OFF� switch should be in the “OFF� position
Selector� on the machine. When using the optional while starting the engine. This will minimize the load on
field installed CV adapter (K385-1) the “Local/Remote� the starter motor.
switch is only active in the “VV� mode.
COMPRESSOR OPERATING LIGHT
AUXILIARY POWER CONTROLS This light is on when the compressor “ON/OFF� switch
is in the “ON� position.
115 VAC Receptacle
COMPRESSOR AIR PRESSURE GAUGE
One 20 amp, 115 VAC duplex receptacle provides 115
VAC for auxiliary power. A total of 26 amps can be
This gauge displays the air pressure in the air receiver
drawn from this receptacle.
tanks.
230 VAC Receptacle
COMPRESSOR OIL PRESSURE GAUGE
One 15 amp, 230 VAC duplex receptacle provides 230
VAC for auxiliary power. A total of 13 amps can be This gauge displays the compressor oil pressure. Oil is
drawn from this receptacle. under pressure only when the compressor clutch is
engaged.
SAE400 & SAE400 WELD’N AIR
B-5 B-5
OPERATION
AIR COMPRESSOR (SAE400 WELD’N AIR only)
ENGINE OPERATION
CAUTION Cylinder head stud torque must be checked after initial
8 to 10 hours of operation. See compressor operator’s
Do not adjust the high idle engine speed (rpm) above
manual for details. Compressor mounting bolts should
the factory setting specification as this will overspeed
be checked for tightness after initial 8 to 10 hours of
the air compressor and void it’s warranty.
operation.
------------------------------------------------------------------------
STARTING INSTRUCTIONS
TYPICAL FUEL CONSUMPTION
Be sure all Pre-Operation Maintenance has been per-
The typical fuel consumption of the SAE400 and
formed. (See INSTALLATION section of this manual).
SAE400 WELD’N AIR for various operating scenarios
Set the air compressor “ON/OFF� switch in the “OFF�
is shown below:
position. To start the engine, place ignition toggle
switch in the “ON� position. Engage the starter button.
Low Idle - No Load .35 gal./ hr.
When the engine starts running, observe the engine oil
1100 RPM (1.32 L./hr.)
pressure. If no pressure shows within 30 seconds,
stop the engine and consult the engine operating man-
High Idle - No Load .75 gal./hr.
ual. To stop the engine, place the ignition toggle switch
1800 RPM (2.84 L./hr.)
in the “OFF� position.
Welding Load 1.92 gal./hr.
When an engine is started for the first time, some of
400 Amps, 40 Volts (7.27 L./hr.)
the oil will be needed to fill the passages of the lubri-
cating system. Therefore, on initial starting, run the
Auxiliary Power .96 gal./hr.
engine for about five minutes and then stop the engine
3000VA (3.63 L./hr.)
and recheck the oil. If the level is down, fill to the full
mark again. The engine controls were properly set at
Air Compressor 1.04 gal./hr.
the factory and should require no adjusting when
(SAE400 WELD’N AIR Only) (3.94 L./hr.)
received.
400 Amps, 40 Volts Load 2.22 gal./hr.
For added safety always operate the welder with the
with Air Compressor “ON� (8.40 L./hr.)
doors closed. Further, leaving the doors open changes
(SAE400 WELD’N AIR Only)
the designed air flow and may cause engine, genera-
tor or compressor overheating.
Auxiliary Power 1.20 gal./hr.
3000 VA with (4.54 L./hr.)
Air Compressor “ON�
(SAE400 WELD’N AIR Only)
COLD WEATHER STARTING
WARNING
Never use any other starting aids, such as ether,
when using the “Thermostart� system.
------------------------------------------------------------------------
When overnight temperatures are between 10°F (-
12°C) and freezing, use the standard “Thermostart�
starting system installed on all engines. Follow the
instructions on the start panel nameplate and in the
engine manual shipped with the welder. With fully
charged batteries and the proper weight oil, the
“Thermostart� system operates satisfactorily even
down to about 0°F (-18°C).
SAE400 & SAE400 WELD’N AIR
C-1 C-1
ACCESSORIES
K930-2 Hi-Freqâ„? - Provides high frequency plus a K2303-1 SHEET METAL KIT- For SAE400 model
gas valve for TIG welding. A water valve is available as K1278-5.
an option. Requires 115 volt AC input. (Limited to 250A
- 60% Duty Cycle).
K802-D Power Plug Kit - Kit includes male plugs for
each auxiliary receptacle.
K767-1 Trailer - A 4-wheel steerable trailer for in-plant
and yard towing(1) with E78-14 load range (B) tubeless
tires. Mounts directly to welder base.
K956-1Trailer - A 2-wheel trailer designed for road(1),
off road, in-plant and yard towing. Trailer mounts
directly to welder base.
1For highway use, consult applicable federal, state and local laws regarding
possible requirements for brakes, lights, fenders, etc.
WARNING
Pipe Thawing with an arc welder can cause fire,
explosion, damage to electric wiring or to the arc
welder if done improperly. The use of an arc
welder for pipe thawing is not approved by the
CSA, nor is it recommended or supported by
Lincoln Electric.
------------------------------------------------------------------------
K704 Standard Accessory Kit - Includes electrode
and work cables, headshield, work clamp and elec-
trode holder.
K385-1 CV Adapter - Provides constant voltage output
for semiautomatic welding. (Field installation only).
K2144-1 Oil Drain Kit - Includes ball valve, hose and
clamp.
K1847-1 Spark Arrestor Kit
K1690-1 GFCI RECEPTACLE KIT
Includes one UL approved 120V ground fault circuit
interrupter duplex type receptacle with cover and
installation instructions. Replaces the factory installed
120V duplex receptacle. Each receptacle of the GFCI
Duplex is rated at 20 Amps, the maximum total current
from the GFCI Duplex is limited to the 20 Amps. Two
kits are required.
SAE400 & SAE400 WELD’N AIR
D-1 D-1
MAINTENANCE
PERIODIC MAINTENANCE
WARNING
1. Blow out the welder and controls with an air hose at least
ELECTRIC SHOCK can kill. once every two months. In particularly dirty locations, this
cleaning may be necessary once a week. Use low pres-
G Do not touch electrically live parts
sure air to avoid driving dirt into the insulation.
such as output terminals or inter-
nal wiring
2. The current control reactor brushes are self-lubricating
and should not be greased. Keep the contacts clean. This
ENGINE EXHAUST can kill. control should be moved from maximum to minimum daily
G Use in open, well ventilated areas to prevent the controls from sticking.
or vent exhaust outside
3. See the engine Instruction Manual for periodic engine
maintenance information. Change the crankcase oil at
regular intervals using the proper grade of oil as recom-
MOVING PARTS can injure.
mended in the engine operating manual. Change the oil
G Do not operate with doors open or filter in accordance with the instructions in the engine
guards off operating manual. When the oil filter is changed add one
quart of oil to the crankcase to replace the oil held in the
G Stop engine before servicing
filter during operation.
G Keep away from moving parts
4. See the compressor operator’s manual for periodic com-
G Remove guards only when necessary and
pressor maintenance information. Change the compres-
replace when work requiring removal is com-
sor oil at regular intervals using only Iowa Mold Tooling
plete.
Co., Inc. (IMT) synthetic compressor oil as recommended
G Only qualified personnel should install, use, or in the compressor operating manual.
service this equipment.
CAUTION
ROUTINE MAINTENANCE
The use of any other oil causes excessive carbon build up,
At the end of each day’s welding, refill the fuel tank to and will void the warranty on the compressor.
minimize moisture condensation in the tank. Also, run- --------------------------------------------------------------------------------
ning out of fuel tends to draw dirt into the fuel system.
Check the engine crankcase and compressor oil lev- 5. Belts tend to loosen after the first 30 or 40 hours of oper-
els. ation. Check the cooling fan belt and tighten if necessary.
DO NOT OVER TIGHTEN. The compressor belt does not
If the fuel supply runs out while the fuel pump is oper- require any adjustment.
ating, air may be entrapped in the fuel distribution sys-
tem. If this happens, bleeding of the fuel system may
be necessary. See the engine instruction manual. BEARING MAINTENANCE
This welder is equipped with a double-shielded ball bearing
COMPRESSOR AIR RECEIVER TANKS - having sufficient grease to last indefinitely under normal ser-
(SAE400 WELD’N AIR ONLY) vice. Where the welder is used constantly or in excessively
dirty locations, it may be necessary to add one-half ounce of
Drain the condensation from the tanks after each use grease per year. A pad of grease one inch wide, one inch
by opening the drain valve located at the lower right long and one inch high weighs approximately one-half
rear of the welder. ounce. Over greasing is far worse than insufficient greasing.
ENGINE AIR FILTER When greasing the bearings, keep all dirt out of the area.
Wipe the fittings completely clean and use clean equipment.
The engine air filter element is a dry cartridge type. It More bearing failures are caused by dirt introduced during
is located above the engine. It can be cleaned and re- greasing than from insufficient grease.
used; however, damaged elements should not be
washed or re-used. Remove loose dirt from element
with compressed air or water hose directed from inside
out. Compressed Air: 100 psi maximum. The filter
should never be removed while the engine is running.
SAE400 & SAE400 WELD’N AIR
D-2 D-2
MAINTENANCE
COMMUTATOR AND BRUSH MAINTENANCE COOLING SYSTEM
WARNING The SAE400 and SAE400 WELD’N AIR are equipped
with a pressure radiator. Keep the radiator cap tight to
Uncovered rotating equipment can be dangerous.
prevent loss of coolant. Clean and flush the cooling
Use care so your hands, hair, clothing or tools do
system periodically to prevent clogging the passage
not catch in the rotating parts. Protect yourself
and overheating the engine. When antifreeze is need-
from particles that may be thrown out by the rotat-
ed, always use the permanent type.
ing armature when stoning the commutator.
------------------------------------------------------------------------
PRE FILTER / WASHER SEPARATOR
The generator brushes are properly adjusted when the
welder is shipped. They require no particular attention.
WARNING
DO NOT SHIFT THE BRUSHES or adjust the rocker
setting.
When working on the fuel system
Shifting of the brushes may result in:
� Keep unguarded lights away, do not
- Change in machine output
smoke !
- Commutator Damage
- Excessive brush wear
� Do not spill fuel !
Periodically inspect the commutator, slip rings and
------------------------------------------------------------------------
brushes by removing the covers. DO NOT remove or
The SAE-400 and SAE400 Weldâ€n Air machines with
replace these covers while the machine is running.
Codes 10884 and above are equipped with a Fuel Pre-
Filter/Water Separator Assembly located before the
Commutators and slip rings require little attention.
lift pump mounted to the engine block.
However, if they are black or appear uneven, have
them cleaned by an experienced maintenance man
FUEL PRE-FILTER/WATER SEPARATOR ASSEMBLY
using fine sandpaper or a commutator stone. Never
use emery cloth or paper for this purpose.
The pre-filter is a 150 micron screen designed to pro-
tect against gross fuel contamination of the water sep-
NOTE: If the welder is used in dirty or dusty locations,
arator element and the Secondary Fuel Filter. If the
or if the welder is not used for prolonged periods of
pre-filter becomes plugged it may be removed, inspect-
time, it may be necessary to clean the commutator and
ed, cleaned and reinstalled. In general this only needs
slip rings more often.
to be done with each water separator element change
(about every 1,000 hrs.) However if at any time exces-
Replace brushes when they wear within 1/4" of the pig-
sive fuel contamination is suspected or a sudden fall-
tail. A complete set of replacement brushes should be
off in engine performance is detected the pre-filter
kept on hand. Lincoln brushes have a curved face to fit
screen should be inspected and cleaned. Follow the
the commutator. Have an experienced maintenance
following procedure:
man seat these brushes by lightly stoning the commu-
tator as the armature rotates at full speed until contact
1. Close the fuel shutoff valve located on the fuel
is made across the full face of the brushes. After ston-
strainer mounted to the under side of the fuel tank.
ing, blow out the dust with low pressure air.
2. Unscrew the cap ring located on the top of the filter
To seat the slip ring brushes, position the brushes in
header and remove the plastic center cap and O-
place. Then slide one end of a piece of fine sandpaper
ring.
between slip rings and brushes with the coarse side
against the brushes. With slight additional finger pres-
3. Remove the large white volume plug located direct-
sure on top of the brushes, pull the sandpaper around
ly under the center cap in the upper cavity of the fil-
the circumference of the rings, in direction of rotation
ter header. Use a small screwdriver (or similar
only - until brushes seat properly. In addition, stone
device) to lift the plug part way out of the cavity to
slip ring with a fine stone. Brushes must be seated
assist with its removal.
100%.
Arcing or excessive exciter brush wear indicates a pos-
Be careful not to damage the pre-filter screen with
sible misaligned shaft. Have an authorized Field
the tool used to remove the plug.
Service Shop check and realign the shaft.
SAE400 & SAE400 WELD’N AIR
D-3 D-3
MAINTENANCE
4. Using a pair of pliers, gently tug on the pull tabs of 5. Slide the quick change ring up over the element and
the pre-filter screen in an alternating pattern to rotate counter clockwise until an audible click or pop
gradually remove the pre-filter screen. is heard. If you do not hear the click you have not rotat-
ed the ring far enough and the element is not in the
5. Brush off any debris and rinse in diesel fuel. locked position. Another indication that the ring is in
the locked position is that one set (it doesn’t matter
6. Re-install the pre-filter screen into the upper cavity which one) of arrows located on the outside of the ring
of the filter header making sure the four pull tabs should be located directly under the air vent valve.
are pointing up. Putting your fingers on the pull
6. Open the fuel shutoff valve.
tabs, push down evenly until the lower body of the
pre-filter screen contacts the floor of the upper cav- 7. Open the air vent valve on the front of the filter head-
ity. er until fuel emerges free of air bubbles and then close
the air vent valve.
7. Re-insert the large white volume plug into the upper
Note : Consult your engine operation manual for infor-
cavity.
mation on air bleeding the entire fuel system
8. Place the O-ring onto the angled seal surface of the
filter header and re-install the plastic cap. Make
sure its flange rests on the O-ring.
9. Screw on the cap ring and tighten hand tight.
10. Remember to open the fuel shutoff valve before
starting the engine.
WATER SEPARATOR ELEMENT
The water separator element is a two stage filter with a
special filtration/water separating media, and an
expanded water reservoir providing maximum protec-
tion against water in the fuel. The recommended
change interval for the water separator element is
1,000 hours. The procedure for changing the element
is as follows:
1. Close the fuel shutoff valve located on the fuel
strainer mounted to the under side of the fuel tank.
2. Rotate the quick change ring (located just below fil-
ter header) clockwise approximately 1/2 turn and
slide it down and off of the element.
3. Grasp the element and pull down with a slight rock-
ing motion to remove the element from the grom-
met post on the bottom of the filter header.
4. Slide the new element onto the grommet post on the
bottom of the filter header until the element no longer
easily moves up into the filter header. Now rotate the
element (may take almost 1 full turn) with a slight
upward pressure until the element begins to further
engage the header. With the proper orientation now
established apply additional pressure to seat the ele-
ment in the filter header. You should feel the element
“pop� into place when properly seated.
Note: The element will only go on one way. Never use
excessive force when mounting the element to the
header.
SAE400 & SAE400 WELD’N AIR
D-4 D-4
MAINTENANCE
SPARK ARRESTOR
ENGINE AND COMPRESSOR MAINTENANCE
COMPONENTS
WARNING
ITEM MAKE PART NUMBER
� Spark Arrester and Muffler may be
Engine Air Filter Donaldson P181052 hot!
� Allow engine to cool before servicing
Fan Belt Perkins 2614B550 spark arrester!
� Do not operate engine while servicing
spark arrester!
Compressor Belt Lincoln S23887
Gates 2/A40
(SAE400 WELD’N AIR only) For machines with separate spark arresting units:
Service the spark arrestor every 100 hours of opera-
Fuel Filter Perkins 26560143 tion or twice a year, which ever occurs first.
Service as follows:
Engine Oil Filter Perkins 2654403 1. Stop engine and allow to cool.
2. Loosen clamp and remove spark arrestor from
(Codes 10884 & Above)
Water Separator Lincoln M16890-C machine.
Element Stanadyne 31572
3. Remove locknut on top of spark arrestor housing
(Codes 10884 & Above) and lift off cap.
Fuel Pre-Filter Screen Lincoln M16890-B
Stanadyne 29575 4. Separate plates and clean if necessary.
5. Inspect plates and housing for holes or cracks.
Replace spark arrestor if damaged.
REPLACING AIR COMPRESSOR DRIVE BELT
(SAE400 WELD’N AIR only) 6. Assemble spark arrestor using reverse order: step
3, then step 2.
CAUTION
For machines with integral spark arresting mufflers:
Belt is tensioned using a automatic tensioning Service spark arrester every 250 hours.
device. Remove with care. Service as follows:
------------------------------------------------------------------------
To remove compressor belt: 1. Stop engine and allow to cool.
1. Remove nut and lock washer from lower locking
bolt on idler tension flange. 2. Remove clean out plug from side of spark arrester.
2. Loosen center mounting bolt on idler tensioner 1/2
turn or until it moves freely. 3. Without damaging the spark arrester, gently tap on the
3. Using a pipe wrench or equivalent tool, turn ten- arrester shell near the clean out plug.
sioner body slightly to free locking bolt. Remove
locking bolt and slowly release tension on belt. 4. Once particles are removed, replace the clean out plug.
Remove belt.
Note: Do not loosen or remove compressor mounting
bolts. Pulley misalignment may result.
To install belt (after following above procedure):
1. Mount belt into pulley grooves and over idler pul-
ley.
2. Using a pipe wrench or suitable tool, turn idler
body to realign locking slot in idler flange with
locking hole. Insert locking bolt and tighten before
releasing idler body. Tighten center mounting bolt.
Note: Ensure that both belt strands are running prop-
erly in pulley grooves.
SAE400 & SAE400 WELD’N AIR
E-1 E-1
TROUBLESHOOTING
HOW TO USE TROUBLESHOOTING GUIDE
WARNING
Service and Repair should only be performed by Lincoln Electric Factory Trained Personnel.
Unauthorized repairs performed on this equipment may result in danger to the technician and machine
operator and will invalidate your factory warranty. For your safety and to avoid Electrical Shock, please
observe all safety notes and precautions detailed throughout this manual.
__________________________________________________________________________
This Troubleshooting Guide is provided to help you This column provides a course of action for the
locate and repair possible machine malfunctions. Possible Cause, generally it states to contact your
Simply follow the three-step procedure listed below. local Lincoln Authorized Field Service Facility.
Step 1. LOCATE PROBLEM (SYMPTOM). If you do not understand or are unable to perform the
Look under the column labeled “PROBLEM (SYMP- Recommended Course of Action safely, contact your
TOMS)�. This column describes possible symptoms local Lincoln Authorized Field Service Facility.
that the machine may exhibit. Find the listing that best
describes the symptom that the machine is exhibiting.
Step 2. POSSIBLE CAUSE.
The second column labeled “POSSIBLE CAUSE� lists
the obvious external possibilities that may contribute to
the machine symptom.
Step 3. RECOMMENDED COURSE OF ACTION
WARNING
ELECTRIC SHOCK can kill.
� Do not touch electrically live parts such as output
terminals or internal wiring.
ENGINE EXHAUST can kill.
� Use in open, well ventilated areas or vent exhaust
outside.
MOVING PARTS can injure.
� Do not operate with doors open or guards off.
� Stop engine before servicing.
� Keep away from moving parts.
� Remove guards only when necessary and replace when work
requiring removal is complete.
� Only qualified personnel should install, use or service this
equipment.
CAUTION
If for any reason you do not understand the test procedures or are unable to perform the tests/repairs safely, contact your Local
Lincoln Authorized Field Service Facility for technical troubleshooting assistance before you proceed.
SAE400 & SAE400 WELD’N AIR
E-2 E-2
TROUBLESHOOTING
Observe all Safety Guidelines detailed throughout this manual
PROBLEMS RECOMMENDED
POSSIBLE CAUSE
(SYMPTOMS) COURSE OF ACTION
FUNCTION PROBLEMS
Machine fails to hold the “heat� Rough or dirty commutator. True and clean commutator.
constantly.
Brushes may be worn down to limit Replace brushes.
of life.
Brush springs may be broken. Replace brush springs.
Field circuit may have variable resis- Check field current with ammeter to
tance connections or intermittent discover varying current. This
open circuit, due to loose connec- applies to both the main generator
tions or broken wire. and exciter.
Electrode or work lead connections Tighten all connections.
may be poor.
Wrong grade of brushes may be Use only the recommended Lincoln
installed on generator. brushes.
Field rheostat may be making poor Inspect and clean rheostat.
contact and overheating.
“Current Control� may not be operat- Check for loose or missing set
ing properly. screw in control handles.
“Current Control� brushholder con- Inspect. Replace needed parts.
tact springs may be worn out or Clean internal contact surface of
missing. Contact surface may be control device. Do not lubricate.
dirty, rough and pitted. Smooth rough surfaces.
“Current Control� brushholder sup- If brushholder internal contact sur-
port stud and mating contact sur- face is pitted and burned, replace
faces may be dirty or pitted and the brushholder and support stud. If
burned. the contact 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.
Engine running at varying speeds. Set welder controls for maximum
output and weld. Then, while weld-
ing, check engine rpm. The engine
should be running at full speed. If
indicator shows a significant differ-
ence, consult your engine manual.
CAUTION
If for any reason you do not understand the test procedures or are unable to perform the tests/repairs safely, contact your Local
Lincoln Authorized Field Service Facility for technical troubleshooting assistance before you proceed.
SAE400 & SAE400 WELD’N AIR
E-3 E-3
TROUBLESHOOTING
Observe all Safety Guidelines detailed throughout this manual
PROBLEMS RECOMMENDED
POSSIBLE CAUSE
(SYMPTOMS) COURSE OF ACTION
FUNCTION PROBLEMS
Welder runs but fails to generate Generator or exciter brushes may Be sure that all brushes bear on the
current. be loose or missing. commutator and have proper spring
tension.
Exciter may not be operating. Check exciter output voltage with
voltmeter or lamp.
Field circuit of generator or exciter Check for open circuits in rheostat,
may be open. field leads and field coils. Also check
resistors.
Polarity reversing switch may be in Put handle in positive or negative
the neutral position. position.
Exciter may have lost excitation. Check components and continuity in
flashing circuit.
Welding arc is loud and spatters Series field circuit may be open cir- Check circuit with ringer or volt-
excessively. cuited. meter.
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.
CAUTION
If for any reason you do not understand the test procedures or are unable to perform the tests/repairs safely, contact your Local
Lincoln Authorized Field Service Facility for technical troubleshooting assistance before you proceed.
SAE400 & SAE400 WELD’N AIR
E-4 E-4
TROUBLESHOOTING
Observe all Safety Guidelines detailed throughout this manual
PROBLEMS RECOMMENDED
POSSIBLE CAUSE
(SYMPTOMS) COURSE OF ACTION
FUNCTION PROBLEMS
Welding current too great or too “Current Control� shaft and handle With current control against the min-
small compared to indication on the may have turned slightly in the insu- imum stop, set pointer to within 1/8�
dial. lated bushing of the current control of the last scale division.
brushholder, caused by turning han-
dle too hard against one of the
stops.
Exciter output low causing low out- Check for shorts in exciter armature
put compared to dial indication. with growler.
“Current Control� set to minimum Check to see that series field is
and welder output so great that properly connected and not shorted.
engine stalls when arc is struck.
Welder has output and no control Local/Remote switch is in wrong Place switch in “LOCAL� position to
position. control output at the welder. Place
switch in “REMOTE� position to con-
trol output remotely.
CAUTION
If for any reason you do not understand the test procedures or are unable to perform the tests/repairs safely, contact your Local
Lincoln Authorized Field Service Facility for technical troubleshooting assistance before you proceed.
SAE400 & SAE400 WELD’N AIR
E-5 E-5
TROUBLESHOOTING
Observe all Safety Guidelines detailed throughout this manual
PROBLEMS RECOMMENDED
POSSIBLE CAUSE
(SYMPTOMS) COURSE OF ACTION
FUNCTION PROBLEMS
No auxiliary power Circuit Breakers open. Check and reset breakers. If break-
ers keep tripping check connections
to auxiliary receptacles. Also make
sure load does nor exceed recepta-
cle’s current rating.
Faulty connections to auxiliary Check connections.
receptacles.
CAUTION
If for any reason you do not understand the test procedures or are unable to perform the tests/repairs safely, contact your Local
Lincoln Authorized Field Service Facility for technical troubleshooting assistance before you proceed.
SAE400 & SAE400 WELD’N AIR
F-1
WIRING DIAGRAM - SAE-400 WELD'N AIR
ENGINE HOUR METER
GENERAL MAINTENANCE INSTRUCTIONS FOR ENGINE
AND MOTOR DRIVEN ARC WELDING POWER SOURCES.
W
TO FLASHING DIODE
238
+
-
THERMOSTART WARNING: Have only qualified personnel perform
IGNITER maintenance work.
THERMOSTART Turn the engine or input power OFF before
+
IND maintenance work unless the maintenance work
233
B requires it to be running.
W
Keep hands, hair, clothing and tools away
B MOVING from moving parts, and insure all guards or
237
B PARTS
START covers are replaced after servicing.
230 CAN INJURE
+
ALTERNATOR -
B
AMMETER
222
U COLD WARNING
IDLER G TERMINAL
IDLER 234
B SWITCH Compressor
SOLENOID Enable Uncontrolled release of door restraint cords can cause injury.
B
5B
B 220 Keep secure hold of cord, and keep face away
85
226
U Y
240
B
from cord when hooking or releasing hook.
239 B 30
229
B
231 87a
Fuse
IGNITION
G 5A B (10A) 87
SWITCH B MAINTENANCE INSTRUCTIONS
86
235
B DAILY CHECKS:
236
B
1
Welding cable connections are tight.
242
1 2 3 4 5 6 7 8 9 10 2 B
3
J1 R G
J2 All equipment in serviceable condition.
IDLER/ENGINE R
4
PROTECTION 243
B B
P.C. BOARD 241
B
R Engine oil, coolant, air cleaner and fuel
Compressor
G
G Pressure SW.
strainer are at proper operating level and clean.
Clutch
G
AS REQUIRED:
Blow dust from machine using clean low pressure air.
5C
+
+
S
W Clean commutators or slip rings with fine sandpaper-
NOT EMERY CLOTH. See Operating Manual for instructions.
W
OIL PRESSURE
SAE400 & SAE400 WELD’N AIR
WIRING DIAGRAMS
STARTING Replace brushes before the pigtails are within 1/4"of
B
SWITCH (N.C.) - -
MOTOR
G the commutator. See Operating Manual for instructions.
TO CONTROL PANEL
GROUND SCREW
228 B
LEAD COLOR CODE
TO TOROID
B-BLACK OR GRAY
R
G-GREEN
232
B B N-BROWN
2 CR
221 B R-RED OR PINK
FUEL SHUT
U-BLUE
REED RELAY
OFF VALVE W-WHITE
TEMPERATURE GAGE Y-YELLOW
G
ENGINE TEMP.
SENSOR
FUEL INJECTION PUMP
G
B
11-01
M19232
NOTE: This diagram is for reference only. It may not be accurate for all machines covered by this manual. The
F-1
specific diagram for a particular code is pasted inside the machine on one of the enclosure panels.
F-2
WIRING DIAGRAM - SAE-400 PERKINS
ENGINE HOUR METER
GENERAL MAINTENANCE INSTRUCTIONS FOR ENGINE
AND MOTOR DRIVEN ARC WELDING POWER SOURCES.
TO FLASHING DIODE W
238
+
-
THERMOSTART
IGNITER
WARNING: Have only qualified personnel perform
THERMOSTART
maintenance work.
+
IND
B 233 Turn the engine or input power OFF before
W maintenance work unless the maintenance work
B requires it to be running.
237
B START Keep hands, hair, clothing and tools away
224 ALTERNATOR MOVING
+
from moving parts, and insure all guards or
-
PARTS
B covers are replaced after servicing.
AMMETER
222
U CAN INJURE
COLD
TERMINAL
IDLER
IDLER 234
B G
SWITCH
SOLENOID B WARNING
220
B 5B
226
U Uncontrolled release of door restraint cords can cause injury.
B
225 229
B Keep secure hold of cord, and keep face away
IGNITION
5A
G
SWITCH from cord when hooking or releasing hook.
235
B
MAINTENANCE INSTRUCTIONS
236
B
1
1 2 3 4 5 6 7 8 9 10 2 B DAILY CHECKS:
3
J1 R
J2
IDLER/ENGINE 4 Welding cable connections are tight.
PROTECTION
P.C. BOARD R
G All equipment in serviceable condition.
Engine oil, coolant, air cleaner and fuel
5C strainer are at proper operating level and clean.
+
+
S AS REQUIRED:
W
Blow dust from machine using clean low pressure air.
W
OIL PRESSURE
SAE400 & SAE400 WELD’N AIR
WIRING DIAGRAMS
STARTING Clean commutators or slip rings with fine sandpaper-
SWITCH (N.C.) B - -
G MOTOR
NOT EMERY CLOTH. See Operating Manual for instructions.
TO CONTROL PANEL
GROUND SCREW Replace brushes before the pigtails are within 1/4"of
B
223
1/4" of the commutator. See Operating Manual for instructions.
TO TOROID
R
227
B LEAD COLOR CODE
B
2 CR
221 B FUEL SHUT
B-BLACK OR GRAY
REED RELAY
OFF VALVE
G-GREEN
TEMPERATURE GAGE N-BROWN
R-RED OR PINK
G
U-BLUE
ENGINE TEMP.
W-WHITE
SENSOR
Y-YELLOW
FUEL INJECTION PUMP
G
B
11- 01
M19233
NOTE: This diagram is for reference only. It may not be accurate for all machines covered by this manual. The
F-2
specific diagram for a particular code is pasted inside the machine on one of the enclosure panels.
F-3
CONTROL WIRING DIAGRAM - SAE-400 & WELD'N AIR
PLUG FOR REMOTE CONTROL
REMOTE CONTROL RECEPTACLE
POTENTIOMETER
AC
COLOR CODE AND SWITCH G
W 203 G
ALTERNATOR
B-BLACK OR GRAY
ROTOR X
G Y
X
G-GREEN RESISTORS
+ D2
- B Y
(-) (+)
SLIP
N-BROWN
RINGS R W
W
R-RED OR PINK AC
R U
600
FLASHING DIODE
U-BLUE
AND RESISTOR
W-WHIT E 41 W
600A
R
1
41A
Y-YELLOW G
R W
2
G
42
3
238 42A
602
4
POS
B NEG W
SEE BATTERY W - 5
+ CONNECT
B
WIRING DIAGRAM TO BASE
6
R
4
1
GROUND REMOTE CONTROL
B 2
3 P8 POTENTIOMETER BOX
SCREW (+)
TO LOWER PANEL 201
G SWITCH FOR LOCAL OR
GROUND SCREW
Y REMOTE CONTROL SHOWN
U
AC
AC
IN LOCAL POSITION.
POLARITY
D1 602A
U
SWITCH
500
1
R
G 2
(-) 3
4
W
R
G G 602B
4
WHITE
230V DUPLEX 5
TERMINALS
RECEPTACLE 602
U BACK VIEW
ALTERNATOR REACTOR
R W
OF POLARITY
AUXILIARY N
B SWITCH REMOTE SWITCH WIRED THIS
POWER WDG.
WAY ON EARLIER UNITS
SAE400 & SAE400 WELD’N AIR
WIRING DIAGRAMS
W
115V DUPLEX F
E
RECEPTACLE
A2
FRONT VIEW 1
OF RECEPTACLES B
B3
15A 15A 20A 20A
B B ELECTRODE
TOROID
2CR TO WORK TERMINAL
W R
SEE BATTERY
WIRING DIAGRAM
CB1 CB3 CB4
CB2 B
W
WELD CURRENT
B B
SENSING SWITCH
ENHANCED
WIRING DIAGRAM
ELECTRICAL SYMBOLS PER E1537 7- 01
M19237
NOTE: This diagram is for reference only. It may not be accurate for all machines covered by this manual. The
F-3
specific diagram for a particular code is pasted inside the machine on one of the enclosure panels.
F-4
63.06
28.00 43.75
32.87
50.13 39.69 39.38
18.50
6.00
DIMENSION PRINT
SAE400 & SAE400 WELD’N AIR
22.00 44.50 8.90
*
22.14 8.12
69.75
* CENTER OF GRAVITY
3.00
77.00
24.50
WITH OIL AND
WATER IN ENGINE,
.88
81.25
27.12 BUT NO FUEL.
83.00
= .81 DIA HOLES
1-98
M8869-33
* = .69 DIA HOLES
F-4
NOTES
SAE400 & SAE400 WELD’N AIR
G Keep your head out of fumes. G Turn power off before servicing. G Do not operate with panel open or
G Use ventilation or exhaust to
WARNING
guards off.
remove fumes from breathing zone.
Spanish
G Los humos fuera de la zona de res- G Desconectar el cable de ali- G No operar con panel abierto o
AVISO DE
piración. mentación de poder de la máquina guardas quitadas.
G Mantenga la cabeza fuera de los antes de iniciar cualquier servicio.
PRECAUCION
humos. Utilice ventilación o
aspiración para gases.
French
G N’opérez pas avec les panneaux
G Gardez la tête à l’écart des fumées. G Débranchez le courant avant l’entre-
G Utilisez un ventilateur ou un aspira- ouverts ou avec les dispositifs de
tien.
ATTENTION
protection enlevés.
teur pour ôter les fumées des zones
de travail.
German
G Anlage nie ohne Schutzgehäuse
G Vermeiden Sie das Einatmen von G Strom vor Wartungsarbeiten
oder Innenschutzverkleidung in
Schweibrauch! abschalten! (Netzstrom völlig öff-
WARNUNG
G Sorgen Sie für gute Be- und Betrieb setzen!
nen; Maschine anhalten!)
Entlüftung des Arbeitsplatzes!
Portuguese
G Não opere com as tampas removidas. G Mantenha-se afastado das partes
G Mantenha seu rosto da fumaça.
G Desligue a corrente antes de fazer
G Use ventilação e exhaustão para moventes.
ATENÇÃO
serviço. G Não opere com os paineis abertos
remover fumo da zona respiratória.
G Não toque as partes elétricas nuas. ou guardas removidas.
Japanese
Chinese
Korean
Arabic
LEIA E COMPREENDA AS INSTRUÇÕES DO FABRICANTE PARA ESTE EQUIPAMENTO E AS PARTES DE USO, E SIGA AS
PRÃTICAS DE SEGURANÇA DO EMPREGADOR.
SAE400 & SAE400 WELD’N AIR
G Do not touch electrically live parts or G Keep flammable materials away. G Wear eye, ear and body protection.
WARNING electrode with skin or wet clothing.
G Insulate yourself from work and
ground.
Spanish
G No toque las partes o los electrodos G Mantenga el material combustible G Protéjase los ojos, los oÃdos y el
AVISO DE bajo carga con la piel o ropa moja- fuera del área de trabajo. cuerpo.
da.
PRECAUCION G Aislese del trabajo y de la tierra.
French G Ne laissez ni la peau ni des vête- G Gardez à l’écart de tout matériel G Protégez vos yeux, vos oreilles et
ments mouillés entrer en contact inflammable. votre corps.
ATTENTION avec des pièces sous tension.
G Isolez-vous du travail et de la terre.
G Berühren Sie keine stromführenden
German G Entfernen Sie brennbarres Material! G Tragen Sie Augen-, Ohren- und Kör-
Teile oder Elektroden mit Ihrem perschutz!
WARNUNG Körper oder feuchter Kleidung!
G Isolieren Sie sich von den
Elektroden und dem Erdboden!
Portuguese
G Não toque partes elétricas e elec- G Mantenha inflamáveis bem guarda- G Use proteção para a vista, ouvido e
trodos com a pele ou roupa molha- dos. corpo.
ATENÇÃO da.
G Isole-se da peça e terra.
Japanese
Chinese
Korean
Arabic
READ AND UNDERSTAND THE MANUFACTURER’S INSTRUCTION FOR THIS EQUIPMENT AND THE CONSUMABLES TO
BE USED AND FOLLOW YOUR EMPLOYER’S SAFETY PRACTICES.
SE RECOMIENDA LEER Y ENTENDER LAS INSTRUCCIONES DEL FABRICANTE PARA EL USO DE ESTE EQUIPO Y LOS
CONSUMIBLES QUE VA A UTILIZAR, SIGA LAS MEDIDAS DE SEGURIDAD DE SU SUPERVISOR.
LISEZ ET COMPRENEZ LES INSTRUCTIONS DU FABRICANT EN CE QUI REGARDE CET EQUIPMENT ET LES PRODUITS A
ETRE EMPLOYES ET SUIVEZ LES PROCEDURES DE SECURITE DE VOTRE EMPLOYEUR.
LESEN SIE UND BEFOLGEN SIE DIE BETRIEBSANLEITUNG DER ANLAGE UND DEN ELEKTRODENEINSATZ DES HER-
STELLERS. DIE UNFALLVERHÃœTUNGSVORSCHRIFTEN DES ARBEITGEBERS SIND EBENFALLS ZU BEACHTEN.
SAE400 & SAE400 WELD’N AIR
� World's Leader in Welding and Cutting Products �
� Sales and Service through Subsidiaries and Distributors Worldwide �
Cleveland, Ohio 44117-1199 U.S.A. TEL: 216.481.8100 FAX: 216.486.1751 WEB SITE: www.lincolnelectric.com
|