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; PRÉCAUTIONS DE SÛRETÉ
iv SAFETY iv Mar. ‘93 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-vous contr...
Page 6 - Assure that tank and compressor relief
v SAFETY v 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 8 - Thank You; Please Examine Carton and Equipment For Damage Immediately
vii vii Thank You for selecting a QUALITY product by Lincoln Electric. We want you to 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. Save this ma...
Page 9 - TABLE OF CONTENTS; viii
viii TABLE OF CONTENTS SAE400 & SAE400 WELD ’ N AIR viii Page Installation Instructions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Section A Technical Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ....
Page 10 - INSTALLATION; TECHNICAL SPECIFICATIONS - SAE400 & SAE400 WELD
A-1 INSTALLATION SAE400 & SAE400 WELD ’ N AIR A-1 TECHNICAL SPECIFICATIONS - SAE400 & SAE400 WELD ’ N AIR 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 11...
Page 11 - SAFETY PRECAUTIONS; STACKING
A-2 INSTALLATION SAE400 & 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 s...
Page 13 - DIESEL FUEL ONLY; ENGINE COOLING SYSTEM; BATTERY CONNECTION; DIESEL FUEL
A-4 INSTALLATION A-4 SAE400 & SAE400 WELD ’ N AIR • Stop engine while fueling.• Do not smoke when fueling.• Keep sparks and flame away from tank. • Do not leave unattended while fueling. • Wipe up spilled fuel and allow fumes to clear before startingengine. • Do not overfill tank, fuelexpansion ...
Page 14 - SPARK ARRESTER; WELDING OUTPUT CABLES
BATTERY ACID can burn eyes andskin. ● Wear gloves and eye protectionand be careful when working nearbattery. ● Follow instructions printed on battery. IMPORTANT: To prevent ELECTRICAL DAMAGE WHEN: a) Installing new batteries. b) Using a booster. Use correct polarity — Negative Ground . To prevent BA...
Page 15 - OPERATION; ADDITIONAL SAFETY PRECAUTIONS; GENERAL DESCRIPTION
B-1 OPERATION B-1 WELDING SPARKS can causefire or explosion. • Do not weld near flammable material . • Do not weld on containers that haveheld flammable material. ----------------------------------------------------------- MOVING PARTS can injure. • Keep away from moving parts • Do not operate with ...
Page 16 - RECOMMENDED APPLICATIONS; DESIGN FEATURES AND ADVANTAGES
B-2 OPERATION B-2 RECOMMENDED APPLICATIONS WELDER The SAE400 or SAE400 WELD’N AIR provides excel-lent constant current DC welding output for stick(SMAW) welding. The field installed optional CVAdapter (K385-1) provides up to 500 amps at 35 voltsof constant voltage output for semiautomatic welding. A...
Page 17 - ENGINE CONTROLS; CAUTION
B-3 OPERATION B-3 ENGINE CONTROLS IGNITION SWITCH When placed in the “ON” position, this switch ener-gizes the fuel solenoid. When placed in the “OFF” posi-tion, the flow of fuel to the injection pump is stopped toshut down the engine. “ IDLER ” SWITCH The idler switch has two positions, “HIGH” and“...
Page 19 - ENGINE OPERATION; STARTING INSTRUCTIONS; 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 K930-2 Hi-Freq ™ - Provides high frequency plus a gas valve for TIG welding. A water valve is available asan 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-...
Page 21 - MAINTENANCE; ROUTINE 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 22 - PRE FILTER / WASHER SEPARATOR
D-2 MAINTENANCE D-2 COMMUTATOR AND BRUSH MAINTENANCE Uncovered rotating equipment can be dangerous.Use care so your hands, hair, clothing or tools donot catch in the rotating parts. Protect yourselffrom particles that may be thrown out by the rotat-ing armature when stoning the commutator. ---------...
Page 23 - WATER SEPARATOR ELEMENT
D-3 MAINTENANCE D-3 4. Using a pair of pliers, gently tug on the pull tabs of the pre-filter screen in an alternating pattern togradually remove the pre-filter screen. 5. Brush off any debris and rinse in diesel fuel. 6. Re-install the pre-filter screen into the upper cavity of the filter header mak...
Page 24 - SPARK ARRESTOR
D-4 MAINTENANCE D-4 SPARK ARRESTOR • Spark Arrester and Muffler may be hot! • Allow engine to cool before servicing spark arrester! • Do not operate engine while servicing spark arrester! For machines with separate spark arresting units: Service the spark arrestor every 100 hours of opera-tion or tw...
Page 25 - TROUBLESHOOTING; HOW TO USE TROUBLESHOOTING GUIDE
E-1 TROUBLESHOOTING E-1 SAE400 & 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 Local Lincoln Authorized Field Service Facility for technical troubleshooting assistance before you proceed. CAUTION WA...
Page 26 - FUNCTION PROBLEMS
E-2 TROUBLESHOOTING E-2 SAE400 & 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 Local Lincoln Authorized Field Service Facility for techn...
Page 30 - WIRING DIAGRAMS; WA
F-1 WIRING DIAGRAMS SAE400 & SAE400 WELD ’ N AIR F-1 B 239 En a b le TER M INA L C o m p re sso r IG N ITE R CO LD B 233 T H ER MOST A R T B B - ST A R T T H ER MOST A R T 230 W 30 B B 229 B 234 220 B B ID L E R SW IT C H IN D J2 PROTECTI ON P.C. BOA R D IDLER/ENGINE J1 + TO TO RO ID 2 C R R EED...
Page 31 - IR
SAE400 & SAE400 WELD ’ N AIR F-2 WIRING DIAGRAMS F-2 SW IT C H PROTECTI ON P.C. BOA R D IDLER/ENGINE J1 + S W ITC H ( N .C .) OI L PR ESSUR E THE R M O STA RT CO LD TE R M IN A L ST A R T B - THER M O S T A R T 5C B B + G R O UND S C RE W TO CO NTRO L P A NE L B G 223 W W R 4 3 2 5A 1 10 G 225 B...
Page 33 - DIMENSION PRINT
SAE400 & SAE400 WELD ’ N AIR F-4 DIMENSION PRINT F-4 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. 1-98 M8869-33
Page 34 - NOTES
Page 35 - ÇÃ
SAE400 & SAE400 WELD ’ N AIR WARNING AVISO DE PRECAUCION ATTENTION WARNUNG ATEN ÇÃ O Spanish French German Portuguese Japanese Chinese Korean Arabic LEIA E COMPREENDA AS INSTRUÇÕES DO FABRICANTE PARA ESTE EQUIPAMENTO E AS PARTES DE USO, E SIGA ASPRÁTICAS DE SEGURANÇA DO EMPREGADOR. ● Keep your h...
