RETURN TO MAIN INDEX
IM662
SAE400
August, 2001
DC ARC WELDING POWER SOURCE
For use with machines having Code Number 10664, 10665
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.
Date of Purchase:
Serial Number:
Code Number: R
Model:
Where Purchased:
OPERATOR’S MANUAL
Copyright © 2001 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 pur-
chase 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. Do
not attempt to override the governor or idler 2.d.3. Do not place your body between the electrode and
by pushing on the throttle control rods while work cables. If the electrode cable is on your right
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
PRÉCAUTIONS DE SÛRETÉ 6. Eloigner les matériaux inflammables ou les recouvrir afin de
prévenir tout risque d’incendie dû aux étincelles.
Pour votre propre protection lire et observer toutes les instructions
et les précautions de sûreté specifiques qui parraissent dans ce
7. Quand on ne soude pas, poser la pince à une endroit isolé de
manuel aussi bien que les précautions de sûreté générales suiv-
la masse. Un court-circuit accidental peut provoquer un
antes:
échauffement et un risque d’incendie.
Sûreté Pour Soudage A L’Arc
8. S’assurer que la masse est connectée le plus prés possible de
1. Protegez-vous contre la secousse électrique:
la zone de travail qu’il est pratique de le faire. Si on place la
masse sur la charpente de la construction ou d’autres endroits
a. Les circuits à l’électrode et à la piéce sont sous tension
éloignés de la zone de travail, on augmente le risque de voir
quand la machine à souder est en marche. Eviter toujours
passer le courant de soudage par les chaines de levage,
tout contact entre les parties sous tension et la peau nue
câbles de grue, ou autres circuits. Cela peut provoquer des
ou les vétements mouillés. Porter des gants secs et sans
risques d’incendie ou d’echauffement des chaines et des
trous pour isoler les mains.
câbles jusqu’� ce qu’ils se rompent.
b. Faire trés attention de bien s’isoler de la masse quand on
soude dans des endroits humides, ou sur un plancher met-
9. Assurer une ventilation suffisante dans la zone de soudage.
allique ou des grilles metalliques, principalement dans
Ceci est particuliérement important pour le soudage de tôles
les positions assis ou couché pour lesquelles une grande
galvanisées plombées, ou cadmiées ou tout autre métal qui
partie du corps peut être en contact avec la masse.
produit des fumeés toxiques.
c. Maintenir le porte-électrode, la pince de masse, le câble de
soudage et la machine à souder en bon et sûr état defonc-
10. Ne pas souder en présence de vapeurs de chlore provenant
tionnement.
d’opérations de dégraissage, nettoyage ou pistolage. La
d.Ne jamais plonger le porte-électrode dans l’eau pour le
chaleur ou les rayons de l’arc peuvent réagir avec les vapeurs
refroidir.
du solvant pour produire du phosgéne (gas fortement toxique)
e. Ne jamais toucher simultanément les parties sous tension
ou autres produits irritants.
des porte-électrodes connectés à deux machines à soud-
er parce que la tension entre les deux pinces peut être le
11. Pour obtenir de plus amples renseignements sur la sûreté, voir
total de la tension à vide des deux machines.
le code “Code for safety in welding and cutting� CSA Standard
f. Si on utilise la machine à souder comme une source de
W 117.2-1974.
courant pour soudage semi-automatique, ces precautions
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
PRÉCAUTIONS DE SÛRETÉ POUR
contre les chutes dans le cas ou on recoit un choc. Ne jamais
LES MACHINES À SOUDER À
enrouler le câble-électrode autour de n’importe quelle partie
du corps.
TRANSFORMATEUR ET À
REDRESSEUR
3. Un coup d’arc peut être plus sévère qu’un coup de soliel,
donc:
a. Utiliser un bon masque avec un verre filtrant approprié 1. Relier à la terre le chassis du poste conformement au code de
ainsi qu’un verre blanc afin de se protéger les yeux du ray- l’électricité et aux recommendations du fabricant. Le dispositif
onnement de l’arc et des projections quand on soude ou de montage ou la piece à souder doit être branché à une
quand on regarde l’arc. bonne mise à la terre.
b. Porter des vêtements convenables afin de protéger la 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
zones où l’on pique le laitier.
SAE400
v v
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.
Model Name & Number _____________________________________
Code & Serial Number _____________________________________
Date of Purchase _____________________________________
Whenever you request replacement parts for or information on this equipment always supply the information you
have recorded above.
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.
SAE400
vi vi
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
Fuel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .A-3
Engine Cooling System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .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-1
Welder . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .B-1
Auxiliary Power . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .B-1
Compressed Air . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .B-1
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
Engine Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .B-5
Starting Instructions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .B-5
Break-In Period . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .B-5
Typical Fuel Consumption . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .B-5
Accessories . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Section C
Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Section D
Routine Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . D-1
Periodic Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . D-1
Troubleshooting Guide . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Section E
Wiring Diagrams and Dimension Print . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Section F
Parts Lists . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Appendix
SAE-400 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .P356 Series
SAE400
A-1 A-1
INSTALLATION
TECHNICAL SPECIFICATIONS - SAE400
INPUT - DIESEL ENGINE
Make/Model Description Speed (RPM) Displacement Starting Capacities
System
Perkins 4 cylinder High Idle 1800 236 cu. in 12VDC batteries Fuel: 22.5 gal.
4.236 Diesel 63 HP @ Low Idle 1100 (3.87 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. 2125 lbs.
1273.3 mm 711.2 mm 2108.2 mm 963.9 kg
Based on a 10 minute period.
(1)
SAE400
A-2 A-2
INSTALLATION
Read this entire installation section before you STACKING
start installation.
These machines cannot be stacked.
SAFETY PRECAUTIONS
ANGLE OF OPERATION
WARNING
To achieve optimum engine performance the machine
should be run in a level position. The maximum angle
Do not attempt to use this equipment until you have
of operation for the Perkins engine is 40 degrees in all
thoroughly read all operating and maintenance man-
directions. If the engine is to be operated at an angle,
uals supplied with your machine. They include impor-
provisions must be made for checking and maintaining
tant safety precautions, detailed engine starting,
the oil level at the normal (FULL) oil capacity in the
operating and maintenance instructions and parts
engine crankcase. When operating the welder at an
lists.
angle, the effective fuel capacity will be slightly less
than the specified 22.5 gallons.
ELECTRIC SHOCK can kill.
•Do not touch electrically live parts such
as output terminals or internal wiring.
•Insulate yourself from the work and
ground.
LIFTING
•Always wear dry insulating gloves.
------------------------------------------------------------------------ The equipment lift bale should be used to lift the
machine.
ENGINE EXHAUST can kill.
•Use in open, well ventilated areas or
WARNING
vent exhaust outside
•Do not stack anything near the engine. FALLING EQUIPMENT can cause
------------------------------------------------------------------------ injury.
MOVING PARTS can injure. •Do not lift this machine using lift bale if
it is equipped with a heavy accessory
•Do not operate with doors open or such as a trailer or gas cylinder.
guards off.
•Lift only with equipment of adequate
•Stop engine before servicing. lifting capacity.
•Keep away from moving parts •Be sure machine is stable when lifting.
------------------------------------------------------------------------ ------------------------------------------------------------------------
Only qualified personnel should install, use or service
this equipment
LOCATION/VENTILATION
The welder should be located to provide an unrestricted
flow of clean, cool air to the cooling air inlets and to avoid
restricting the cooling air outlets. Also, locate the welder
so that the engine exhaust fumes are properly vented to
an outside area.
SAE400
A-3 A-3
INSTALLATION
HIGH ALTITUDE OPERATION ENGINE OIL
At higher altitudes, output derating may be necessary. The engine is shipped with the engine crankcase filled
with high quality SAE 10W-30 oil (API class CD or bet-
As a rule of thumb, derate the welder output 5% for
ter). Check the oil level before starting the engine. If it is
every 500 meters (1640 ft.) above 1000 meters (3280
not up to the full mark on the dip stick, add oil as required.
ft.).
Check the oil level every four hours of running time during
the first 35 running hours. Refer to the engine Operator’s
Contact a Perkins Service Representative for any
Manual for specific oil recommendations and break-in
engine adjustments that may be required for high alti-
information. The oil change interval is dependent on the
tude operation.
quality of the oil and the operating environment. Refer to
the engine Operator’s Manual for the proper service and
maintenance intervals.
TOWING
FUEL USE DIESEL FUEL ONLY
The recommended trailers for use with this equipment
(1)
for in-plant and yard towing by a vehicle are Lincoln’s
K767-1, K956-1 and K956-2. The K956-1 and K956-2
WARNING
are also designed to be used at highway speeds(1).If the
user adapts a non-Lincoln trailer, he must assume
•Stop engine and allow to cool before
responsibility that the method of attachment and usage
fueling.
does not result in a safety hazard nor damage the
•Do not smoke when fueling.
welding equipment. Some of the factors to be consid-
•Fill fuel tank at a moderate rate and do
ered are as follows:
not overfill.
•Wipe up spilled fuel and allow fumes to
1. Design capacity of trailer vs. weight of Lincoln
clear before starting engine.
equipment and likely additional attachments.
•Keep sparks and flame away from
tank.
2. Proper support of, and attachment to, the base of
------------------------------------------------------------------------
the welding equipment so that there will be no
undue stress to the trailer’s framework.
Fill the fuel tank with clean, fresh diesel fuel. The capac-
ity of the fuel tank is 22.5 gallons (85.1 liters). See engine
3. Proper placement of the equipment on the trailer to Operator’s Manual for specific fuel recommendations.
insure stability side to side and front to back when
being moved and when standing by itself. NOTE: Before starting the engine, be sure the fuel shut-
off valve on the sediment bowl is open by turning the han-
4. Typical conditions of use, such as travel speed, dle counterclockwise.
roughness of surface on which the trailer will be
operated, and environmental conditions.
5. Proper preventative maintenance of trailer.
6. Conformance with federal, state and local laws.1
(1)
For highway use, consult applicable federal, state
and local laws regarding specific requirements for
use on public highways, such as brakes, lights, fend-
ers, etc.
PRE-OPERATION ENGINE SERVICE
READ the engine operating and maintenance instruc-
tions supplied with this machine.
SAE400
A-4 A-4
INSTALLATION
ENGINE COOLING SYSTEM To prevent BATTERY BUCKLING, tighten nuts on bat-
teries only until snug. DO NOT OVERTIGHTEN.
The cooling system has been filled at the factory with
SPARK ARRESTER
a 50-50 mixture of ethylene glycol antifreeze and
water. Check the radiator level and add a 50-50 solu-
tion as needed. (See Engine Manual or antifreeze con- Some federal, state or local laws may require that
tainer for alternate antifreeze recommendation.) gasoline or diesel engines be equipped with exhaust
spark arresters when they are operated in certain loca-
BATTERY CONNECTION tions where unarrested sparks may present a fire haz-
ard. The standard muffler included with this welder
WARNING: Use caution as the electrolyte is a strong
does not qualify as a spark arrester. When required by
acid that can burn skin and damage eyes.
local regulations, a suitable spark arrester must be
installed and properly maintained.
Remove and discard the insulating caps from the neg-
ative battery terminals. Attach and tighten negative
CAUTION
battery cable terminals.
An incorrect arrester may lead to damage to the engine
NOTE: This machine is furnished with wet charged
or adversely affect performance. Contact the engine
batteries; if unused for several months, the batteries
manufacturer for specific recommendations.
may require a booster charge. Be careful to charge the
------------------------------------------------------------------------
batteries with the correct polarity. Make sure that the
batteries are level while charging.
WARNING
GASES FROM BATTERY can explode.
q Keep sparks, flame and cigarettes
away from battery.
To prevent EXPLOSION when:
q INSTALLING A NEW BATTERY � disconnect
negative cable from old battery first and
connect to new battery last.
q CONNECTING A BATTERY CHARGER �
remove battery from welder by disconnecting
negative cable first, then positive cable and
battery clamp. When reinstalling, connect
negative cable last. Keep well ventilated.
USING A BOOSTER � connect positive lead to
q
battery first then connect negative lead to neg-
ative battery lead at the lower control panel
support.
BATTERY ACID can burn eyes and
skin.
q Wear gloves and eye protection
and be careful when working near
battery.
Follow instructions printed on battery.
q
IMPORTANT: To prevent ELECTRICAL DAMAGE
WHEN:
a) Installing new batteries.
b) Using a booster.
Use correct polarity � Negative Ground.
SAE400
A-5 A-5
INSTALLATION
WELDING OUTPUT CABLES
To prevent dangerous electric shock, other equipment
With the engine off, connect the electrode and work
powered by this engine driven welder must:
cables to the studs provided. These connections
should be checked periodically and tightened if neces-
sary. a) be grounded to the frame of the welder using a
grounded type plug,
Listed in Table A.1 are copper cable sizes recom- or
mended for the rated current and duty cycle. Lengths b) be double insulated.
stipulated are the distance from the welder to work and
back to the welder again. Cable sizes are increased for When this welder is mounted on a truck or trailer, its
greater lengths primarily for the purpose of minimizing frame must be securely connected to the metal frame
cable voltage drop. of the vehicle. When this engine driven welder is con-
nected to premises wiring such as that in a home or
shop, its frame must be connected to the system earth
Table A.1 Combined Length of Electrode and Work ground. See the article on grounding in the latest U.S.
Cables. National Electrical Code and the local code.
TOTAL COMBINED LENGTH OF ELEC-
In general, if the machine is to be grounded, it should
TRODE AND WORK CABLES
be connected with a #8 or larger copper wire to a solid
AMPS Up to 100 100-200 FT. 200-250 FT. earth ground such as a metal water pipe going into the
@60% FT. ground for at least ten feet and having no insulated
Duty Cycle joints, or to the metal framework of a building which
has been effectively grounded. The U.S. National
400 2/0 AWG 3/0 AWG 4/0 AWG 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.
MACHINE GROUNDING
Because this portable engine driven welder creates its
own power, it is not necessary to connect its frame to
an earth ground, unless the machine is connected to
premises wiring (home, shop, etc.).
SAE400
B-1 B-1
OPERATION
OPERATING INSTRUCTIONS GENERAL DESCRIPTION
Read and understand this entire section before operat- The SAE400 is a diesel engine driven welding power
ing your equipment. source. The machine uses a DC generator for DC stick
electrode welding and an AC exciter for 115/230 VAC
SAFETY INSTRUCTIONS auxiliary power. As a generator it can supply up to
3,000 watts of 115/230 volt AC power. As a welder it
WARNING provides up to 575 amps of DC constant current out-
put.
Do not attempt to use this equipment until you have
thoroughly read all operating and maintenance man-
The engine is a 63 Hp (47 kw), 4-cylinder water cooled
uals supplied with your machine. They include impor-
diesel made by Perkins.
tant safety precautions, detailed engine starting, oper-
ating and maintenance instructions and parts lists.
RECOMMENDED APPLICATIONS
ELECTRIC SHOCK can kill.
WELDER
•Do not touch electrically live parts such
as output terminals or internal wiring. The SAE400 provides excellent constant current DC
welding output for stick (SMAW) welding. The field
•Insulate yourself from the work and installed optional CV Adapter (K385-1) provides up to
ground. 500 amps at 35 volts of constant voltage output for
semiautomatic welding.
•Always wear dry insulating gloves.
------------------------------------------------------------------------ AUXILIARY POWER
ENGINE EXHAUST can kill.
The SAE400 provides 3 KW of 115/230 VAC output for
•Use in open, well ventilated areas or auxiliary power and emergency standby power.
vent exhaust outside
•Do not stack anything near the engine.
------------------------------------------------------------------------
MOVING PARTS can injure.
•Do not operate with doors open or
guards off.
•Stop engine before servicing.
•Keep away from moving parts
------------------------------------------------------------------------
Only qualified personnel should operate this equipment.
ADDITIONAL SAFETY PRECAUTIONS
Always operate the welder with the hinged doors
closed as these provide maximum protection from
moving parts and insure proper cooling air flow.
Read carefully the Safety Precautions page in the
Instruction Manual before operating this machine.
Always follow these and any other safety procedures
included in this manual and in the engine and com-
pressor instruction manuals.
SAE400
B-2 B-2
OPERATION
DESIGN FEATURES AND ADVANTAGES DUTY CYCLE
FOR STICK WELDING Duty cycle is based on a ten minute period and opera-
� Excellent DC constant current output for stick weld- tion in an ambient temperature of 104°F(40°C).
ing applications.
The SAE400 is NEMA rated at 60% duty cycle. Duty
� Continuous adjustment of both voltage and current cycle is based on a ten minute period. Therefore, a
for unsurpassed welds on demanding jobs. 60% duty cycle welder can be operated at nameplate
rated output for 6 minutes out of every 10 minute peri-
� Remote control capability standard. od without overheating.
FOR AUXILIARY POWER The auxiliary power can be used continuously (100%
duty cycle) within its rated current capacities.
� 3,000 watts of 115/230 VAC, 60 Hz auxiliary power.
� One 20 amp 115 VAC duplex receptacle for up to 26
amps of 115 VAC power.
� One 15 amp, 230 VAC duplex receptacle for up to 13
amps of 230 VAC power.
� Weld and AC auxiliary power at the same time (with-
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
OTHER FEATURES
� Perkins 4-cylinder, water cooled diesel engine.
Designed for long life, easy maintenance and excel-
lent fuel economy.
� Engine protection system shuts the engine down for
low engine oil pressure or high coolant temperature.
� Gauges for engine oil pressure, coolant temperature
and battery charging ammeter.
� Engine hour meter standard.
� Extended range 22.5 gallon (85.1 L) fuel tank.
SAE400
B-3 B-3
OPERATION
ENGINE CONTROLS ENGINE PROTECTION SYSTEM
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 energizes
close.
the fuel solenoid. When placed in the “OFF� position,
the flow of fuel to the injection pump is stopped to shut
WELDER CONTROLS
down the engine.
POLARITY SWITCH
Turn the Arc Polarity switch to electrode positive or
electrode negative as required for each particular
SPEED CONTROL LEVER
application.
Manually allows the engine to run at its high idle speed
CONTROL OF WELDING CURRENT
controlled by the governor or at the factory set low idle
Purpose of Controls
speed. When welding or using auxiliary power the
speed control lever must be in the “RUN� position. To
The continuous “Current Control� is the main current
reduce the engine to low idle speed when not welding
adjuster. The “Job Selector� is both a fine current
or not using auxiliary power place the speed control
adjuster and the continuous Open Circuit Voltage
lever in the “IDLE� position notch.
adjuster. Open Circuit Voltage (OCV) controls the arc
characteristics.
“Job Selector�
ENGINE TEMPERATURE GAUGE
The “Job Selector� dial is divided into four colored sec-
Displays the coolant temperature in the engine block.
tions providing OCV ranges as follows:
Color Title OCV Range
White Large Electrodes High OCV
ENGINE OIL PRESSURE GAUGE
Black Normal Welding Medium OCV
Red Overhead & Vertical Low OCV
Displays the oil pressure to the engine. When the
Grey Special Applications Extra-Low OCV
engine starts running, watch for the oil pressure to
build up. If no pressure shows within 30 seconds, stop
The “Job Selector� is usually set in the black range
the engine and consult the engine instruction manual.
because it provides a soft “Buttering � arc desired for
most welding. Some operators prefer to set the “Job
Selector� in the red range for a snappy “Digging� arc
when welding vertical up or overhead.
BATTERY CHARGING AMMETER
“Current Control�
Displays the current going from the charging alternator
into the batteries. It is normal for charging current to be
CAUTION
high (above 15 amps) after starting or when the batter-
ies are ‘low� on charge.
Do not adjust the “Current Control� while welding
because this can damage the control.
------------------------------------------------------------------------
The “Current Control� dial is calibrated in amperes on
ENGINE HOUR METER
three separate colored dials corresponding to the
white, black and red ranges of the “Job Selector� dial.
The engine hour meter records the total running time
For example: when the “Job Selector� is set on the
on the engine in hours. It can be used to keep a record
black range, the approximate welding current is indi-
of maintenance on the engine and or welder.
cated on the black scale of the “Current Control� dial.
SAE400
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.
5. If dialing the desired current with the “Job
Selector� moves the setting outside the black
range causing undesirable arc characteristics, turn
the “Job Selector� back to the center of the black
range. Then turn the “Current Control� up or down
a little as needed. Readjust the “Job Selector� for
the exact characteristics and current desired.
REMOTE CONTROL (K1278-2 ONLY)
A receptacle and “Local/Remote� control switch on the
front control panel and a remote control box with 25 ft.
(7.6 m) of cord for adjusting the OCV at the welding
site are standard. Putting the switch in the “REMOTE�
position allows fine current control at the remote con-
trol box while placing the switch in the “LOCAL� position
allows fine current control at the “Job Selector� on the
machine. When using the optional field installed CV
adapter (K385-1) the “Local/Remote� switch is only
active in the “VV� mode.
AUXILIARY POWER CONTROLS
115 VAC Receptacle
One 20 amp, 115 VAC duplex receptacle provides 115
VAC for auxiliary power. A total of 26 amps can be
drawn from this receptacle.
230 VAC Receptacle
One 15 amp, 230 VAC duplex receptacle provides 230
VAC for auxiliary power. A total of 13 amps can be
drawn from this receptacle.
SAE400
B-5 B-5
OPERATION
ENGINE OPERATION BREAK-IN PERIOD
CAUTION ENGINE
Do not adjust the high idle engine speed (rpm) above
The engine used to supply power for your welder is a
the factory setting specification.
heavy duty, industrial engine. It is designed and built
------------------------------------------------------------------------
for rugged use. It is very normal for any engine to use
small quantities of oil until the break-in is accom-
STARTING INSTRUCTIONS plished. Check the oil level twice a day during the
break-in period (about 100 running hours).
Be sure all Pre-Operation Maintenance has been per-
formed. (See INSTALLATION section of this manual). IMPORTANT: IN ORDER TO ACCOMPLISH THIS
To start the engine, place ignition toggle switch in the BREAK-IN, THE UNIT SHOULD BE SUBJECTED TO
“ON� position. Engage the starter button. When the HEAVY LOADS, WITHIN THE RATING OF THE
engine starts running, observe the engine oil pressure. MACHINE. AVOID LONG IDLE RUNNING PERIODS.
If no pressure shows within 30 seconds, stop the
engine and consult the engine operating manual. To
stop the engine, place the ignition toggle switch in the
“OFF� position.
TYPICAL FUEL CONSUMPTION
When an engine is started for the first time, some of the
The typical fuel consumption of the SAE400 for various
oil will be needed to fill the passages of the lubricating
operating scenarios is shown below:
system. Therefore, on initial starting, run the engine for
about five minutes and then stop the engine and
Low Idle - No Load .35 gal./ hr.
recheck the oil. If the level is down, fill to the full mark
1100 RPM (1.32 L./hr.)
again. The engine controls were properly set at the fac-
tory and should require no adjusting when received.
High Idle - No Load .75 gal./hr.
1800 RPM (2.84 L./hr.)
For added safety always operate the welder with the
doors closed. Further, leaving the doors open changes
Welding Load 1.92 gal./hr.
the designed air flow and may cause engine or gener-
400 Amps, 40 Volts (7.27 L./hr.)
ator overheating.
Auxiliary Power .96 gal./hr.
Cold Weather Starting
3000VA (3.63 L./hr.)
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).
If the engine must be frequently started below 10°F
(-12°C), it may be desirable to remove the
“Thermostart� and install the optional ether starter kit.
Installation and operating instructions are included in
the kit. Use ether starting only when required because
excessive use shortens engine life.
SAE400
C-1 C-1
ACCESSORIES
K799 Hi-Freqâ„? - Provides high frequency plus a gas
valve for TIG welding. A water valve is available as an K2144-1 Oil Drain Kit - Includes Ball Vavle, hose and
option. Requires 115 volt AC input. (Limited to 250A - clamp.
60% Duty Cycle).
K802-D Power Plug Kit - Kit includes male plugs for
each auxiliary receptacle.
K805-1 Ether Start Kit - Injects ether for starting aid.
Recommended only when engines are frequently
started at temperatures under 10°F (-12°C). Ether
cylinder is not included.
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.
K956-1 and -2 Trailer - A 2-wheel trailer designed for
road(1), off road, in-plant and yard towing. The K956-2
trailer is equipped with electric brakes. Trailer mounts
directly to welder base.
1For highway use, consult applicable federal, state and local laws regarding
possible requirements for brakes, lights, fenders, etc.
Linc-Thawâ„? (L2964-3) - Includes meter and fuse to
protect the welder when thawing frozen water pipes.
WARNING
Pipe Thawing IS NOT a CSA approved procedure. If
not done properly, it can result in fire, explosion,
damage to wiring which may make it unsafe, dam-
age to pipes, burning up the welder or other haz-
ards.
IMPORTANT: DO NOT USE A WELDER TO THAW
A PIPE BEFORE REVIEWING LINCOLN BULLETIN
E695.1 (dated October 1987 or later). This bulletin
may be obtained from your local Lincoln distributor or
by writing directly to Lincoln Electric at the address on
the back of this manual.
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).
K1690-1 GFCI Receptacle Kit - Includes one UL
approved 20 amp, 120 volt ground fault circuit inter-
rupter receptacle (duplex type) and installation instruc-
tions.
SAE400
D-1 D-1
MAINTENANCE
Note: Water and fuel should be drained into a suit-
WARNING able container for proper disposal.
ENGINE AIR FILTER
ELECTRIC SHOCK can kill.
The engine air filter is an oil bath style filter. Inspect the
Do not touch electrically live parts
q
air filter daily, more often in dirty or dusty conditions.
such as output terminals or inter-
When necessary, clean the oil cup and replace the oil
nal wiring
in the cup (Fill cup to oil line with 10W - 30 oil).
ENGINE EXHAUST can kill.
CAUTION
Use in open, well ventilated areas
q
or vent exhaust outside
Never remove the oil cup while the engine is running.
Do not over fill the oil cup.
------------------------------------------------------------------------
MOVING PARTS can injure. PERIODIC MAINTENANCE
Do not operate with doors open or
q
guards off 1. Blow out the welder and controls with an air hose at least
once every two months. In particularly dirty locations, this
Stop engine before servicing
q
cleaning may be necessary once a week. Use low pres-
Keep away from moving parts
q
sure air to avoid driving dirt into the insulation.
Remove guards only when necessary and
q
2. The current control reactor brushes are self-lubricating
replace when work requiring removal is com-
and should not be greased. Keep the contacts clean. This
plete.
control should be moved from maximum to minimum daily
Only qualified personnel should install, use, or
q to prevent the controls from sticking.
service this equipment.
3. See the engine Instruction Manual for periodic engine
ROUTINE MAINTENANCE maintenance information. Change the crankcase oil at
regular intervals using the proper grade of oil as recom-
At the end of each day’s welding, refill the fuel tank to mended in the engine operating manual. Change the oil
minimize moisture condensation in the tank. Also, run- filter in accordance with the instructions in the engine
ning out of fuel tends to draw dirt into the fuel system. operating manual. When the oil filter is changed add one
Check the engine crankcase oil level. quart of oil to the crankcase to replace the oil held in the
filter during operation.
If the fuel supply runs out while the fuel pump is oper-
ating, air may be entrapped in the fuel distribution sys- 4. Belts tend to loosen after the first 30 or 40 hours of oper-
tem. If this happens, bleeding of the fuel system may ation. Check the cooling fan belt and tighten if necessary.
be necessary. See the engine instruction manual. DO NOT OVER TIGHTEN.
FUEL SYSTEM WATER SEPARATOR MAIN- BEARING MAINTENANCE
TENANCE
This welder is equipped with a double-shielded ball bear-
ing having sufficient grease to last indefinitely under nor-
If the fuel system on the engine is equipped with a
mal service. Where the welder is used constantly or in
water separator, the following maintenance procedures
excessively dirty locations, it may be necessary to add
must be followed.
one-half ounce of grease per year. A pad of grease one
Inspect the glass bowl for any accumulation of water
inch wide, one inch long and one inch high weighs
on a daily basis. If water is present:
approximately one-half ounce. Over greasing is far worse
than insufficient greasing.
1. Insure the fuel shut off valve is in the "open" position.
2. Loosen the drain screw on the bottom of the bowl When greasing the bearings, keep all dirt out of the area.
one to two turns or until water begins to flow. Do not Wipe the fittings completely clean and use clean equip-
remove the screw completely. ment. More bearing failures are caused by dirt introduced
3. Drain until the water has visibly drained from the during greasing than from insufficient grease.
bowl and only clear fuel starts to flow from the drain
valve.
4. Close the drain screw tightly by hand.
SAE400
D-2 D-2
MAINTENANCE
COMMUTATOR AND BRUSH MAINTENANCE COOLING SYSTEM
WARNING The SAE400 is equipped with a pressure radiator.
Keep the radiator cap tight to prevent loss of coolant.
Uncovered rotating equipment can be dangerous. Clean and flush the cooling system periodically to pre-
Use care so your hands, hair, clothing or tools do vent clogging the passage and overheating the engine.
not catch in the rotating parts. Protect yourself When antifreeze is needed, always use the permanent
from particles that may be thrown out by the rotat- type.
ing armature when stoning the commutator.
------------------------------------------------------------------------
The generator brushes are properly adjusted when the
welder is shipped. They require no particular attention.
DO NOT SHIFT THE BRUSHES or adjust the rocker
setting.
Shifting of the brushes may result in:
- Change in machine output
- Commutator Damage
- Excessive brush wear
Periodically inspect the commutator, slip rings and
brushes by removing the covers. DO NOT remove or
replace these covers while the machine is running.
Commutators and slip rings require little attention.
However, if they are black or appear uneven, have
them cleaned by an experienced maintenance man
using fine sandpaper or a commutator stone. Never
use emery cloth or paper for this purpose.
NOTE: If the welder is used in dirty or dusty locations,
or if the welder is not used for prolonged periods of
time, it may be necessary to clean the commutator and
slip rings more often.
Replace brushes when they wear within 1/4" of the pig-
tail. A complete set of replacement brushes should be
kept on hand. Lincoln brushes have a curved face to fit
the commutator. Have an experienced maintenance
man seat these brushes by lightly stoning the commu-
tator as the armature rotates at full speed until contact
is made across the full face of the brushes. After ston-
ing, blow out the dust with low pressure air.
To seat the slip ring brushes, position the brushes in
place. Then slide one end of a piece of fine sandpaper
between slip rings and brushes with the coarse side
against the brushes. With slight additional finger pres-
sure on top of the brushes, pull the sandpaper around
the circumference of the rings, in direction of rotation
only - until brushes seat properly. In addition, stone
slip ring with a fine stone. Brushes must be seated
100%.
Arcing or excessive exciter brush wear indicates a pos-
sible misaligned shaft. Have an authorized Field
Service Shop check and realign the shaft.
SAE400
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 local
Simply follow the three-step procedure listed below. 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
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 screw
ing properly. 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
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 Be sure that all brushes bear on the
current. 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
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
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 breakers
keep tripping check connections to
auxiliary receptacles. Also make sure
load does nor exceed receptacle’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
PERKINS ENGINE WELDERS WIRING DIAGRAM (BATTERY CIRCUIT #1)
F-1
LEAD APPEARS ON EARLIER UNITS ONLY
ENGINE HOUR METER
GENERAL MAINTENANCE INSTRUCTIONS FOR ENGINE
TO FLASHING DIODE
AND MOTOR DRIVEN ARC WELDING POWER SOURCES
(SAE UNITS ONLY)
+
-
THERMOSTART
IGNITER
EXC
WARNING: - Have only qualified personnel perform
THERMOSTART
maintenance work.
+
Y
- Turn the engine or input power OFF before
maintenance work unless the maintenance work
requires it to be running.
B
START
- Keep hands, hair, clothing and tools away
ALTERNATOR
+
MOVING
- from moving parts, and insure all guards or
PARTS covers are replaced after servicing.
COLD CAN INJURE
G TERMINAL
MAINTENANCE INSTRUCTIONS
AMMETER
TO CR7
(SAM UNITS
LEAD DOES NOT ONLY)
} DAILY CHECKS:
APPEAR ON
EARLIER UNITS - Electrode and work connections are tight.
- - - Rotate the current control twice to clean
contacts.
IGNITION
- All equipment in serviceable condition.
SWITCH
- Engine oil, coolant, air cleaner and fuel
strainer are at proper operating level and
+
+
SAE400
ENGINE clean.
PROTECTION
RELAY
AS REQUIRED:
FUSE
WIRING DIAGRAMS
(SFE 14) - Blow dust from the machine using clean low
S
pressure air.
OIL PRESSURE B
G N O NC S - Clean commutators or slip rings with fine
SWITCH (N.C.) sandpaper- NOT EMERY CLOTH. See the
STARTING
Operating Manual for instructions.
MOTOR
- Replace brushes before the pigtail is within
1/4" of the commutator. See the Operating
Manual for instructions.
- Grease may be added to bearings no more than
G
once a year. See instructions in the
ENGINE GROUND
FUEL SHUT Operating Manual.
OFF VALVE
9-30-94D
TEMPERATURE GAGE
M 16522
FUEL INJECTION PUMP
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.
FKL - 214 ENGINE WELDER WIRING DIAGRAM
F-2
LEAD COLOR CODE
ALTERNATOR
U-BLUE
ROTOR
N-BROWN
Y-YELLOW
+ -
B-BLACK OR GREY
SLIP RINGS
R-RED
FLASHING DIODE
G-GREEN
&
W-WHITE
B
RESISTOR
R
REVERSING SWITCH
+
B
W
-
G
GROUND
(+)
SEE BATTERY VOLT AMMETER
SCREW
(OPTIONAL)
WIRING DIAGRAM
R
MV
AC
AC 500
Y
G -
+
Y
G (-)
G 4 R
230 VOLT DUPLEX
5
WHITE
RECEPTACLE
REACTOR
TERMINALS
R
SAE400
B
ALTERNATOR N
AUXILIARY
POWER
U
115 VOLT WINDING
DUPLEX PANEL
W
WIRING DIAGRAMS
RECEPTACLE
E F
FRONT VIEW OF
1
A
RECEPTACLES 2
B
B
B
15A
15A 20A 20A
B
ELECTRODE
ENGINE IDLER
SHUNT
CB4
CB3
CB1 CB2
(OPTIONAL)
ENGINE IDLER DOES
B
B
NOT APPEAR ON
TO WORK
ENHANCED
DIESEL ENGINE WELDERS
WIRING DIAGRAM
ELECTRICAL SYMBOLS PER E1537
3-12-99J
M19489
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.
FKL-214 ENGINE WELDER WIRING DIAGRAM WITH REMOTE CONTROL
F-3
PLUG FOR
RESISTORS RECEPTACLE FOR REMOTE
COLOR CODE REMOTE CONTROL
CONTROL RHEOSTAT W
B-BLACK OR GREY COPPER
ALTERNATOR
TERMINAL
ROTOR
G-GREEN
B
+ -
N-BROWN
SLIP GROUND
R-RED RINGS TERMINAL
G
FLASHING DIODE (WIDE TAB)
U-BLUE
AND RESISTOR W
G
W-WHITE
B G
Y-YELLOW CONNECT TO CASE
G
REMOTE CONTROL
W
RHEOSTAT BOX
SEE BATTERY B GROUND TERMINAL
B
(WIDE SLOT)
WIRING DIAGRAM
R
G
GROUND
(+)
SCREW
SWITCH FOR LOCAL OR
Y
REMOTE CONTROL (SHOWN
500
AC IN LOCAL POSITION)
MV
AC
+
Y
G G G (-) VOLT AMMETER
U -
(OPTIONAL)
SAE400
R
N Y
WHITE
4 5
TERMINALS
REACTOR
230V DUPLEX
U
RECEPTACLE ALTERNATOR B
R
AUXILIARY
N
POWER WDG.
B
WIRING DIAGRAMS
W SHUNT
(OPTIONAL)
115V DUPLEX
F
E
RECEPTACLE
A 2
1 ELECTRODE
FRONT VIEW
OF RECEPTACLES B
B
15A 20A 20A
15A
B
B
PANEL
ENGINE IDLER
(DOES NOT APPEAR TO WORK
CB4
CB2 CB3 ON DIESEL ENGINE
CB1
B B WELDERS)
NOTES:
ELECTRICAL SYMBOLS PER E1537
N.A. CENTER TERMINAL OF FUSE HOLDER.
3-12-99J
M19490
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
SAE400
18.50
6.00
DIMENSION PRINT
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!
A
* M8869-33
= .69 DIA HOLES
F-4
NOTES
SAE400
Now Available...12th Edition New Lessons in Arc Welding
The Procedure Handbook of Arc Welding Lessons, simply written, cover manipulatory techniques;
With over 500,000 copies of previous editions published machine and electrode characteristics; related subjects, such
since 1933, the Procedure Handbook is considered by many to as distortion; and supplemental information on arc welding
be the “Bible� of the arc welding industry. applications, speeds and costs. Practice materials, exercises,
questions and answers are suggested for each
This printing will go fast so don’t delay. Place your
lesson.
order now using the coupon below.
528 pages, well illustrated, 6� x 9� size, bound in simulated,
The hardbound book contains over 750 pages of welding infor-
gold embossed leather.
mation, techniques and procedures. Much of this material
$5.00 postage paid U.S.A. Mainland
has never been included in any other book.
A must for all welders, supervisors, engineers and
designers. Many welding instructors will want to use the book as
a reference for all students by taking advantage of the low quan-
tity discount prices which include shipping by
4th class parcel post.
$15.00 postage paid U.S.A. Mainland
Need Welding Training?
The Lincoln Electric Company operates the oldest and
most respected Arc Welding School in the United States at its
How To Read Shop Drawings
corporate headquarters in Cleveland, Ohio. Over 100,000 students
have graduated. Tuition is low and the training is
The book contains the latest information and application
“hands on�
data on the American Welding Society Standard Welding
For details write: Lincoln Welding School
Symbols. Detailed discussion tells how engineers and drafts-
22801 St. Clair Ave.
men use the “short-cut� language of symbols to pass on
assembly and welding information to shop personnel. Cleveland, Ohio 44117-1199.
Practical exercises and examples develop the reader’s ability and ask for bulletin ED-80 or call 216-383-2259 and ask for the
to visualize mechanically drawn objects as they will appear in Welding School Registrar.
their assembled form.
187 pages with more than 100 illustrations. Size 8-1/2� x 11� Lincoln Welding School
Durable, cloth-covered board binding. BASIC COURSE $700.00
$4.50 postage paid U.S.A. Mainland 5 weeks of fundamentals
There is a 10% discount on all orders of $50.00 or more for shipment at one time to one location.
Orders of $50 or less before discount or orders outside of North America must be prepaid with charge, check or money order in U.S. Funds Only.
Prices include shipment by 4 th Class Book Rate for U.S.A. Mainland Only. Please allow up to 4 weeks for delivery.
UPS Shipping for North America Only. All prepaid orders that request UPS shipment please add:
$5.00 For order value up to $49.99
$10.00 For order value between $50.00 & $99.99
$15.00 For order value between $100.00 & $149.00
For North America invoiced orders over $50.00 & credit card orders, if UPS is requested, it will be invoiced or charged to you at cost.
Outside U.S.A. Mainland order must be prepaid in U.S. Funds. Please add $2.00 per book for surface mail or $15.00 per book for air parcel post shipment.
METHOD OF PAYMENT: (Sorry, No C.O.D. Orders) Name: _______________________________________________
CHECK ONE:
Address: _______________________________________________
Please Invoice (only if order is over $50.00)
_______________________________________________
Check or Money Order Enclosed, U.S. Funds only
Credit Card - Telephone: _______________________________________________
VISA MasterCard
®
®
Signature as it appears on Charge Card:
|_|_|_|_|_|_|_|_|_|_|_|_|_|_|_|_|_|_|_|_|_| |_|_| |_|_|
Account No. Exp Date
______________________
AMERICAN EXPRESS
MasterCard
Month Year
AMERICAN EXPRESS
USE THIS FORM TO ORDER: Order from: BOOK DIVISION, The Lincoln Electric Company, 22801 St. Clair Avenue, Cleveland, Ohio 44117-1199
Telephone: 216-383-2211 or, for fastest service, FAX this completed form to: 216-361-5901.
BOOKS OR FREE INFORMATIVE CATALOGS
Lincoln Welding School Titles: Price Code Quantity Cost
(ED-80) New Lessons in Arc Welding $5.00 L
Seminar Information Procedure Handbook “Twelfth Edition� $15.00 PH
(ED-45) How to Read Shop Drawings $4.50 H
Educational Video Information Incentive Management $5.00 IM
(ED-93) A New Approach to Industrial Economics $5.00 NA
James F. Lincoln Arc Welding The American Century of John C. Lincoln $5.00 AC
Foundation Book Information Welding Preheat Calculator $3.00 WC-8
(JFLF-515) Pipe Welding Charts $4.50 ED-89
SUB TOTAL
Additional Shipping Costs if any
TOTAL COST
q Do not touch electrically live parts or q Keep flammable materials away. q Wear eye, ear and body protection.
WARNING electrode with skin or wet clothing.
q Insulate yourself from work and
ground.
Spanish
q No toque las partes o los electrodos q Mantenga el material combustible q 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 q Aislese del trabajo y de la tierra.
French q Ne laissez ni la peau ni des vête- q Gardez à l’écart de tout matériel q Protégez vos yeux, vos oreilles et
ments mouillés entrer en contact inflammable. votre corps.
ATTENTION avec des pièces sous tension.
q Isolez-vous du travail et de la terre.
German q Berühren Sie keine stromführenden q Entfernen Sie brennbarres Material! q Tragen Sie Augen-, Ohren- und Kör-
Teile oder Elektroden mit Ihrem perschutz!
WARNUNG Körper oder feuchter Kleidung!
q Isolieren Sie sich von den
Elektroden und dem Erdboden!
Portuguese
q Não toque partes elétricas e elec- q Mantenha inflamáveis bem guarda- q Use proteção para a vista, ouvido e
trodos com a pele ou roupa molha- dos. corpo.
ATENÇÃO da.
q 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
WARNING
Spanish
AVISO DE
PRECAUCION
French
ATTENTION
German
WARNUNG
Portuguese
ATENÇÃO
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
|