Page 2 - SAFETY; WARNING; CALIFORNIA PROPOSITION 65 WARNINGS; The Above For Diesel Engines
FOR ENGINEpowered equipment. 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....
Page 3 - ii; ELECTRIC SHOCK can kill.
ii SAFETY ii ARC RAYS can burn. 4.a. Use a shield with the proper filter and cover plates to protect your eyes from sparks andthe rays of the arc when welding or observingopen arc welding. Headshield and filter lensshould conform to ANSI Z87. I standards. 4.b. Use suitable clothing made from durable...
Page 4 - iii
iii SAFETY iii FOR ELECTRICALLYpowered equipment. 8.a. Turn off input power using the disconnect switch at the fuse box before working onthe equipment. 8.b. Install equipment in accordance with the U.S. National Electrical Code, all local codes and the manufacturer’srecommendations. 8.c. Ground the ...
Page 5 - iv; Assure that tank and compressor relief
iv SAFETY iv WARNING Assure that tank and compressor relief valves work properly, and are at correct pressure settings. NEVER move compressor with pressure in tank. DO NOT modify or repair air tank.
Page 7 - PRÉCAUTIONS DE SÛRETÉ
vi SAFETY vi SAE400 WELD’N AIR PRÉCAUTIONS DE SÛRETÉ Pour votre propre protection lire et observer toutes les instructions et les précautions de sûreté specifiques qui parraissent dans ce manuel aussi bien que les précautions de sûreté générales suiv- antes: Sûreté Pour Soudage A L’Arc 1. Protegez-v...
Page 8 - Thank You; Please Examine Carton and Equipment For Damage Immediately
SAE400 WELD’N AIR Thank You for selecting a QUALITY product by Lincoln Electric. We want youto take pride in operating this Lincoln Electric Company product •••as much pride as we have in bringing this product to you! Read this Operators Manual completely before attempting to use this equipment. Sav...
Page 9 - TABLE OF CONTENTS; viii
viii TABLE OF CONTENTS SAE400 WELD’N AIR viii Page Installation Instructions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Section A Technical Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .A-1In...
Page 10 - INSTALLATION; TECHNICAL SPECIFICATIONS - SAE400 WELD’N AIR; INPUT - DIESEL ENGINE
A-1 INSTALLATION SAE400 WELD’N AIR A-1 TECHNICAL SPECIFICATIONS - SAE400 WELD’N AIR 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...
Page 11 - SAFETY PRECAUTIONS; STACKING
A-2 INSTALLATION SAE400 WELD’N AIR A-2 Read this entire installation section before youstart installation. SAFETY PRECAUTIONS Do not attempt to use this equipment until you havethoroughly read all operating and maintenance man-uals supplied with your machine. They include impor-tant safety precautio...
Page 12 - HIGH ALTITUDE OPERATION
A-3 INSTALLATION SAE400 WELD’N AIR A-3 HIGH ALTITUDE OPERATION At higher altitudes, output derating may be necessary.As a rule of thumb, derate the welder output 5% forevery 500 meters (1640 ft.) above 1000 meters (3280ft.). Contact a Perkins Service Representative for anyengine adjustments that may...
Page 13 - ENGINE COOLING SYSTEM; WARNING: Use caution as the electrolyte is a strong; GASES FROM BATTERY can explode.; SPARK ARRESTER; CAUTION
A-4 INSTALLATION A-4 SAE400 WELD’N AIR ENGINE COOLING SYSTEM The cooling system has been filled at the factory witha 50-50 mixture of ethylene glycol antifreeze andwater. Check the radiator level and add a 50-50 solu-tion as needed. (See Engine Manual or antifreeze con-tainer for alternate antifreez...
Page 14 - WELDING OUTPUT CABLES; Table A.1 Combined Length of Electrode and Work; MACHINE GROUNDING
A-5 INSTALLATION SAE400 WELD’N AIR A-5 WELDING OUTPUT CABLES With the engine off, connect the electrode and workcables to the studs provided. These connections should be checked periodically and tightened if neces-sary. Listed in Table A.1 are copper cable sizes recom-mended for the rated current an...
Page 15 - OPERATION; GENERAL DESCRIPTION; RECOMMENDED APPLICATIONS; OPERATING INSTRUCTIONS; ADDITIONAL SAFETY PRECAUTIONS
B-1 OPERATION B-1 GENERAL DESCRIPTION The SAE400 WELD’N AIR is a diesel engine drivenwelding power source. The machine uses a DC gen-erator for DC stick electrode welding and an AC exciterfor 115/230 VAC auxiliary power. As a generator it cansupply up to 3,000 watts of 115/230 volt AC power. Asa wel...
Page 16 - DESIGN FEATURES AND ADVANTAGES; FOR AUXILIARY POWER; DUTY CYCLE
B-2 OPERATION B-2 DESIGN FEATURES AND ADVANTAGES FOR STICK WELDING• Excellent DC constant current output for stick weld- ing applications. • Continuous adjustment of both voltage and current for unsurpassed welds on demanding jobs. • Remote control capability standard. FOR AUXILIARY POWER • 3,000 wa...
Page 17 - ENGINE CONTROLS
B-3 OPERATION B-3 ENGINE CONTROLS IGNITION SWITCH When placed in the “ON” position, this switch energizesthe fuel solenoid. When placed in the “OFF” position,the flow of fuel to the injection pump is stopped to shutdown the engine. SPEED CONTROL LEVER Manually allows the engine to run at its high id...
Page 18 - How to Set the Controls; 5 AMP Circuit Breakers; AIR COMPRESSOR CONTROLS
B-4 OPERATION B-4 How to Set the Controls Assume you want a normal soft arc and about 135amps, using a 5/32” (4.0 mm) electrode: 1. Set the “Job Selector” at the center of the black range. 2. Set the “Current Control” to read 135 amps on the black dial. 3. Start to weld. 4. If you want a little more...
Page 19 - ENGINE OPERATION; STARTING INSTRUCTIONS; Cold Weather Starting; TYPICAL FUEL CONSUMPTION
B-5 OPERATION B-5 ENGINE OPERATION Do not adjust the high idle engine speed (rpm) abovethe factory setting specification as this will overspeedthe air compressor and void it’s warranty. ------------------------------------------------------------------------ STARTING INSTRUCTIONS Be sure all Pre-Ope...
Page 20 - ACCESSORIES
C-1 ACCESSORIES C-1 K799 Hi-Freq™ - Provides high frequency plus a gasvalve for TIG welding. A water valve is available as anoption. Requires 115 volt AC input. (Limited to 250A -60% Duty Cycle). K802-C Power Plug Kit - Kit includes male plugs foreach auxiliary receptacle. K805-1 Ether Start Kit - I...
Page 21 - MAINTENANCE; ROUTINE MAINTENANCE; COMPRESSOR AIR RECEIVER TANKS; PERIODIC MAINTENANCE
D-1 MAINTENANCE D-1 ELECTRIC SHOCK can kill. ● Do not touch electrically live partssuch as output terminals or inter-nal wiring ENGINE EXHAUST can kill. ● Use in open, well ventilated areasor vent exhaust outside MOVING PARTS can injure. ● Do not operate with doors open orguards off ● Stop engine be...
Page 23 - TROUBLESHOOTING; terminals or internal wiring.
E-1 TROUBLESHOOTING E-1 SAE400 WELD’N AIR If for any reason you do not understand the test procedures or are unable to perform the tests/repairs safely, contact your LocalLincoln Authorized Field Service Facility for technical troubleshooting assistance before you proceed. CAUTION For Air Compressor...
Page 24 - FUNCTION PROBLEMS
E-2 TROUBLESHOOTING E-2 SAE400 WELD’N AIR Observe all Safety Guidelines detailed throughout this manual If for any reason you do not understand the test procedures or are unable to perform the tests/repairs safely, contact your LocalLincoln Authorized Field Service Facility for technical troubleshoo...
Page 28 - WIRING DIAGRAMS
F-1 WIRING DIAGRAMS SAE400 WELD’N AIR F-1 COLOR CODE RINGS FLASHING DIODE - (+) 1 3 TO ALT. EXC. TERMINAL ROTOR B AC AND RESISTOR AC B-BLACK G-GREEN N-BROWN R-RED U-BLUE W-WHITE Y-YELLOW ALTERNATOR SLIP ELECTRODE TO WORK BACK VIEW OF POLARITY SWITCH 5 4 1 B Y POLARITY SWITCH NOTE: CB1, CB2, CB3 &...
Page 30 - DIMENSION PRINT
SAE400 WELD’N AIR F-3 DIMENSION PRINT F-3 18.50 22.14 22.00 27.12 24.50 8.12 3.00 .88 43.75 63.06 39.69 50.13 28.00 32.87 6.00 81.25 69.75 77.00 39.38 44.50 8.90 83.00 * = .81 DIA HOLES = .69 DIA HOLES * * CENTER OF GRAVITY WITH OIL AND WATER IN ENGINE, BUT NO FUEL. A M8869-33
Page 31 - Lincoln Welding School; BASIC COURSE
Now Available...12th EditionThe Procedure Handbook of Arc Welding With over 500,000 copies of previous editions published since 1933, the Procedure Handbook is considered by many to be the “Bible” of the arc welding industry. This printing will go fast so don’t delay. Place your order now using the ...