Lincoln Electric E IM640-A User Manual

SAE400 & SAE400 WELD’N AIR -

R

RETURN TO MAIN MENU

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 opera­tion 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.

IM640-A

May, 2004

Cleveland, Ohio 44117-1199 U.S.A. TEL: [phone] FAX: [phone] WEB SITE: www.lincolnelectric.com

OPERATOR’S MANUAL

Copyright © 2004 Lincoln Global Inc.

• World's Leader in Welding and Cutting Products •

• Sales and Service through Subsidiaries and Distributors Worldwide •

i

SAFETY

WARNING

CALIFORNIA PROPOSITION 65 WARNINGS

Diesel engine exhaust and some of its constituents
are known to the State of California to cause can­cer, birth defects, and other reproductive harm.

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.

The engine exhaust from this product contains
chemicals known to the State of California to cause
cancer, birth defects, or other reproductive harm.

The Above For Gasoline Engines

i

FOR ENGINE
powered 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.

____________________________________________________

1.c. Do not add the fuel near an open flame weld­ing arc or when the engine is running. Stop
the engine and allow it to cool before refuel­ing to prevent spilled fuel from vaporizing on
contact with hot engine parts and igniting. Do
not spill fuel when filling tank. If fuel is spilled,
wipe it up and do not start engine until fumes
have been eliminated.

____________________________________________________

1.d. Keep all equipment safety guards, covers and devices in posi­tion and in good repair.Keep hands, hair, clothing and tools
away from V-belts, gears, fans and all other moving parts
when starting, operating or repairing equipment.

____________________________________________________

1.e. In some cases it may be necessary to remove safety

guards to perform required maintenance. Remove
guards only when necessary and replace them when the
maintenance requiring their removal is complete.
Always use the greatest care when working near moving
parts.

___________________________________________________

1.f. Do not put your hands near the engine fan.
Do not attempt to override the governor or
idler by pushing on the throttle control rods
while the engine is running.

1.h. To avoid scalding, do not remove the
radiator pressure cap when the engine is
hot.

ELECTRIC AND
MAGNETIC FIELDS
may be dangerous

2.a. Electric current flowing through any conductor causes
localized Electric and Magnetic Fields (EMF). Welding
current creates EMF fields around welding cables and
welding machines

2.b. EMF fields may interfere with some pacemakers, and
welders having a pacemaker should consult their physician
before welding.

2.c. Exposure to EMF fields in welding may have other health
effects which are now not known.

2.d. All welders should use the following procedures in order to
minimize exposure to EMF fields from the welding circuit:

2.d.1.

Route the electrode and work cables together - Secure
them with tape when possible.

2.d.2. Never coil the electrode lead around your body.

2.d.3. Do not place your body between the electrode and

work cables. If the electrode cable is on your right
side, the work cable should also be on your right side.

___________________________________________________

1.g. To prevent accidentally starting gasoline engines while
turning the engine or welding generator during maintenance
work, disconnect the spark plug wires, distributor cap or
magneto wire as appropriate.

2.d.4. Connect the work cable to the workpiece as close as
possible to the area being welded.

2.d.5. Do not work next to welding power source.

Mar ‘95

ii

SAFETY

ii

ELECTRIC SHOCK can kill.

3.a. The electrode and work (or ground) circuits
are electrically “hot” when the welder is on.
Do not touch these “hot” parts with your bare
skin or wet clothing. Wear dry, hole-free
gloves to insulate hands.

3.b. Insulate yourself from work and ground using dry insulation.
Make certain the insulation is large enough to cover your full
area of physical contact with work and ground.

In addition to the normal safety precautions, if welding
must be performed under electrically hazardous
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,
kneeling or lying, if there is a high risk of unavoidable or
accidental contact with the workpiece or ground) use
the following equipment:

• Semiautomatic DC Constant Voltage (Wire) Welder.

• DC Manual (Stick) Welder.

• AC Welder with Reduced Voltage Control.

3.c. In semiautomatic or automatic wire welding, the electrode,
electrode reel, welding head, nozzle or semiautomatic
welding gun are also electrically “hot”.

3.d. Always be sure the work cable makes a good electrical
connection with the metal being welded. The connection
should be as close as possible to the area being welded.

3.e. Ground the work or metal to be welded to a good electrical
(earth) ground.

3.f.

Maintain the electrode holder, work clamp, welding cable and
welding machine in good, safe operating condition. Replace
damaged insulation.

3.g. Never dip the electrode in water for cooling.

3.h. Never simultaneously touch electrically “hot” parts of
electrode holders connected to two welders because voltage
between the two can be the total of the open circuit voltage
of both welders.

3.i. When working above floor level, use a safety belt to protect
yourself from a fall should you get a shock.

3.j. Also see Items 6.c. and 8.

ARC RAYS can burn.

4.a. Use a shield with the proper filter and cover
plates to protect your eyes from sparks and
the rays of the arc when welding or observing
open arc welding. Headshield and filter lens
should conform to ANSI Z87. I standards.

4.b. Use suitable clothing made from durable flame-resistant
material to protect your skin and that of your helpers from
the arc rays.

4.c. Protect other nearby personnel with suitable, non-flammable
screening and/or warn them not to watch the arc nor expose
themselves to the arc rays or to hot spatter or metal.

FUMES AND GASES
can be dangerous.

5.a. Welding may produce fumes and gases
hazardous to health. Avoid breathing these
fumes and gases.When welding, keep
your head out of the fume. Use enough
ventilation and/or exhaust at the arc to keep

fumes and gases away from the breathing zone. When

welding with electrodes which require special
ventilation such as stainless or hard facing (see
instructions on container or MSDS) or on lead or
cadmium plated steel and other metals or coatings
which produce highly toxic fumes, keep exposure as
low as possible and below Threshold Limit Values (TLV)
using local exhaust or mechanical ventilation. In
confined spaces or in some circumstances, outdoors, a
respirator may be required. Additional precautions are
also required when welding on galvanized steel.

5.b.

Do not weld in locations near chlorinated hydrocarbon
coming from degreasing, cleaning or spraying operations.
The heat and rays of the arc can react with solvent vapors
form phosgene, a highly toxic gas, and other irritating
products.

5.c. Shielding gases used for arc welding can displace air and
cause injury or death. Always use enough ventilation,
especially in confined areas, to insure breathing air is safe.

5.d. Read and understand the manufacturer’s instructions for this

equipment and the consumables to be used, including the
material safety data sheet (MSDS) and follow your
employer’s safety practices. MSDS forms are available from
your welding distributor or from the manufacturer.

vapors

to

5.e. Also see item 1.b.

Mar ‘95

iii

SAFETY

iii

WELDING SPARKS can
cause fire or explosion.

6.a.

Remove fire hazards from the welding area.

If this is not possible, cover them to prevent

the welding sparks from starting a fire.

materials from welding can easily go through small cracks
and openings to adjacent areas. Avoid welding near
hydraulic lines. Have a fire extinguisher readily available.

6.b. Where compressed gases are to be used at the job site,
special precautions should be used to prevent hazardous
situations. Refer to “Safety in Welding and Cutting” (ANSI
Standard Z49.1) and the operating information for the
equipment being used.

6.c. When not welding, make certain no part of the electrode
circuit is touching the work or ground. Accidental contact can
cause overheating and create a fire hazard.

6.d. Do not heat, cut or weld tanks, drums or containers until the
proper steps have been taken to insure that such procedures
will not cause flammable or toxic vapors from substances
inside. They can cause an explosion even
been “cleaned”. For information, purchase “Recommended
Safe Practices for the
Containers and Piping That Have Held Hazardous
Substances”, AWS F4.1 from the American Welding Society

(see address above).

6.e. Vent hollow castings or containers before heating, cutting or
welding. They may explode.

Sparks and spatter are thrown from the welding arc. Wear oil

6.f.
free protective garments such as leather gloves, heavy shirt,
cuffless trousers, high shoes and a cap over your hair. Wear
ear plugs when welding out of position or in confined places.
Always wear safety glasses with side shields when in a
welding area.

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

6.h. Also see item 1.c.

Remember that welding sparks and hot

though

they have

Preparation

for Welding and Cutting of

CYLINDER may explode
if damaged.

7.a. Use only compressed gas cylinders
containing the correct shielding gas for the
process used and properly operating
regulators designed for the gas and

pressure used. All hoses, fittings, etc. should be suitable for
the application and maintained in good condition.

7.b. Always keep cylinders in an upright position securely
chained to an undercarriage or fixed support.

7.c. Cylinders should be located:

• Away from areas where they may be struck or subjected to

physical damage.

• A safe distance from arc welding or cutting operations and

any other source of heat, sparks, or flame.

7.d. Never allow the electrode, electrode holder or any other
electrically “hot” parts to touch a cylinder.

7.e. Keep your head and face away from the cylinder valve outlet
when opening the cylinder valve.

7.f. Valve protection caps should always be in place and hand
tight except when the cylinder is in use or connected for
use.

7.g. Read and follow the instructions on compressed gas
cylinders, associated equipment, and CGA publication P-l,
“Precautions for Safe Handling of Compressed Gases in
Cylinders,” available from the Compressed Gas Association
1235 Jefferson Davis Highway, Arlington, VA 22202.

FOR ELECTRICALLY
powered equipment.

8.a. Turn off input power using the disconnect
switch at the fuse box before working on
the equipment.

8.b. Install equipment in accordance with the U.S. National
Electrical Code, all local codes and the manufacturer’s
recommendations.

8.c. Ground the equipment in accordance with the U.S. National
Electrical Code and the manufacturer’s recommendations.

Mar ‘95

iv

SAFETY

iv

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 suiv­antes:

Sûreté Pour Soudage A L’Arc

1. Protegez-vous contre la secousse électrique:

a. Les circuits à l’électrode et à la piéce sont sous tension

quand la machine à souder est en marche. Eviter toujours
tout contact entre les parties sous tension et la peau nue
ou les vétements mouillés. Porter des gants secs et sans
trous pour isoler les mains.

b. Faire trés attention de bien s’isoler de la masse quand on

soude dans des endroits humides, ou sur un plancher met­allique ou des grilles metalliques, principalement dans
les positions assis ou couché pour lesquelles une grande
partie du corps peut être en contact avec la masse.

c. Maintenir le porte-électrode, la pince de masse, le câble de

soudage et la machine à souder en bon et sûr état defonc­tionnement.

d.Ne jamais plonger le porte-électrode dans l’eau pour le

refroidir.

e. Ne jamais toucher simultanément les parties sous tension

des porte-électrodes connectés à deux machines à soud­er parce que la tension entre les deux pinces peut être le
total de la tension à vide des deux machines.

f. Si on utilise la machine à souder comme une source de

courant pour soudage semi-automatique, ces precautions
pour le porte-électrode s’applicuent aussi au pistolet de
soudage.

zones où l’on pique le laitier.

6. Eloigner les matériaux inflammables ou les recouvrir afin de
prévenir tout risque d’incendie dû aux étincelles.

7. Quand on ne soude pas, poser la pince à une endroit isolé de
la masse. Un court-circuit accidental peut provoquer un
échauffement et un risque d’incendie.

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
masse sur la charpente de la construction ou d’autres endroits
éloignés de la zone de travail, on augmente le risque de voir
passer le courant de soudage par les chaines de levage,
câbles de grue, ou autres circuits. Cela peut provoquer des
risques d’incendie ou d’echauffement des chaines et des
câbles jusqu’à ce qu’ils se rompent.

9. Assurer une ventilation suffisante dans la zone de soudage.
Ceci est particuliérement important pour le soudage de tôles
galvanisées plombées, ou cadmiées ou tout autre métal qui
produit des fumeés toxiques.

10. Ne pas souder en présence de vapeurs de chlore provenant
d’opérations de dégraissage, nettoyage ou pistolage. La
chaleur ou les rayons de l’arc peuvent réagir avec les vapeurs
du solvant pour produire du phosgéne (gas fortement toxique)
ou autres produits irritants.

11. Pour obtenir de plus amples renseignements sur la sûreté, voir
le code “Code for safety in welding and cutting” CSA Standard
W 117.2-1974.

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
enrouler le câble-électrode autour de n’importe quelle partie
du corps.

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

ainsi qu’un verre blanc afin de se protéger les yeux du ray­onnement de l’arc et des projections quand on soude ou
quand on regarde l’arc.

b. Porter des vêtements convenables afin de protéger la

peau de soudeur et des aides contre le rayonnement de
l‘arc.

c. Protéger l’autre personnel travaillant à proximité au

soudage à l’aide d’écrans appropriés et non-inflammables.

4. Des gouttes de laitier en fusion sont émises de l’arc de
soudage. Se protéger avec des vêtements de protection libres
de l’huile, tels que les gants en cuir, chemise épaisse, pan­talons sans revers, et chaussures montantes.

5. Toujours porter des lunettes de sécurité dans la zone de
soudage. Utiliser des lunettes avec écrans lateraux dans les

PRÉCAUTIONS DE SÛRETÉ POUR
LES MACHINES À SOUDER À
TRANSFORMATEUR ET À
REDRESSEUR

1. Relier à la terre le chassis du poste conformement au code de
l’électricité et aux recommendations du fabricant. Le dispositif
de montage ou la piece à souder doit être branché à une
bonne mise à la terre.

2. Autant que possible, I’installation et l’entretien du poste seront
effectués par un électricien qualifié.

3. Avant de faires des travaux à l’interieur de poste, la debranch­er à l’interrupteur à la boite de fusibles.

4. Garder tous les couvercles et dispositifs de sûreté à leur
place.

Mar. ‘93

v

SAFETY

v

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

SAFETY

vi

for selecting a QUALITY product by Lincoln Electric. We want you

Thank You

to take pride in operating this Lincoln Electric Company product •••
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___________________________________________________________________________

viivii

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

“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:

WEB SITE at www.lincolnelectric.com. Choose “Quick Links” and then

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

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

viii

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

INSTALLATION

TECHNICAL SPECIFICATIONS - SAE400 & SAE400 WELD’N AIR

INPUT - DIESEL ENGINE

Make/Model Description Speed (RPM) Displacement Starting Capacities

System

A-1

Perkins 4 cylinder High Idle 1800 256 cu. in

1004.42 Diesel 71 HP @ Low Idle 1100 (4.2 L)

12VDC batteries
(2

) & Starter 85.1 L

Engine 1725 RPM Full Load 1725

Bore x Stroke Oil: 8.5 Qts.

3.875” x 5.00”

(98.4 mm x 127.0mm) Coolant: 3.6 gal.

RATED OUTPUT - WELDER

Duty Cycle

60% (NEMA) 400 amps 36 volts

60% (Lincoln Plus) 400 amps 40 volts

(1)

Welding Output Volts at Rated Amps

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

Fuel: 22.5 gal.

8.04 L

13.63 L

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/cm

Tooling/ Diamond Water Cooled, at 60% Maximum Allowable Unloads at 130 P.S.I. IMT’s

Air) Pressure Lubricated Duty Cycle

Aluminum Alloy 991 Liters/min. 150 PSI Compressor

Model Block with Cast- at 7.0 kg/cm

(1)

Working Pressure (9.1 kg/cm2) Synthetic

2

(10.5 kg/cm2) Oil

DA435ELW Iron sleeves

(1)

Based on a 10 minute period.

SAE400 & SAE400 WELD’N AIR

2

) (1.26 Liters)

A-2

Read this entire installation section before you
start installation.

INSTALLATION

A-2

CAUTION

SAFETY PRECAUTIONS

WARNING

Do not attempt to use this equipment until you have
thoroughly read all operating and maintenance man­uals supplied with your machine. They include impor­tant safety precautions, detailed engine starting,
operating and maintenance instructions and parts
lists.

ELECTRIC SHOCK can kill.

•Do not touch electrically live parts such
as output terminals or internal wiring.

•Insulate yourself from the work and
ground.

•Always wear dry insulating gloves.

------------------------------------------------------------------------

ENGINE EXHAUST can kill.

•Use in open, well ventilated areas or
vent exhaust outside

•Do not stack anything near the engine.

------------------------------------------------------------------------

DO NOT MOUNT OVER COMBUSTIBLE SURFACES

Where there is a combustible surface directly under
stationary or fixed electrical equipment, that surface
should be covered with a steel plate at least
.06”(1.6mm) thick, which should extend not less than

5.90(150mm) beyond the equipment on all sides.

-----------------------------------------------------------------------

STACKING

These machines cannot be stacked.

ANGLE OF OPERATION

To achieve optimum engine performance the machine
should be run in a level position. The maximum angle
of operation for the air compressor is 20 degrees in all
directions. If the compressor is to be operated at an
angle, provisions must be made for checking and
maintaining the oil level at the normal (FULL) oil capac­ity in the compressor crankcase. The maximum angle
of operation for the Perkins engine is 30 degrees in all
directions. If the engine is to be operated at an angle,
provisions must be made for checking and maintaining
the oil level at the normal (FULL) oil capacity in the
engine crankcase. When operating the welder at an
angle, the effective fuel capacity will be slightly less
than the specified 22.5 gallons.

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 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.

LIFTING

The equipment lift bale should be used to lift the
machine.

WARNING

• Lift only with equipment of adequate
lifting capacity.

• Be sure machine is stable when lift-

ing.

• Do not lift this machine using lift
bale if it is equipped with a heavy
accessory such as trailer or gas
cylinder.

FALLING • Do not lift machine if lift bale is

EQUIPMENT can damaged.

cause injury. • Do not operate machine while

suspended from lift bale.

------------------------------------------------------------------------

SAE400 & SAE400 WELD’N AIR

A-3

INSTALLATION

A-3

HIGH ALTITUDE OPERATION

At higher altitudes, output derating may be necessary.
As a rule of thumb, derate the welder output 5% for
every 500 meters (1640 ft.) above 1000 meters (3280
ft.).

Contact a Perkins Service Representative for any
engine adjustments that may be required for high alti­tude operation.

TOWING

The recommended trailers for use with this equipment
for in-plant and yard towing by a vehicle
K767-1, K956-1 and K956-2. The K956-1 and K956-2
are also designed to be used at highway speeds
the user adapts a non-Lincoln trailer, he must assume
responsibility that the method of attachment and usage
does not result in a safety hazard nor damage the
welding equipment. Some of the factors to be consid­ered are as follows:

1. Design capacity of trailer vs. weight of Lincoln
equipment and likely additional attachments.

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.

3. Proper placement of the equipment on the trailer to
insure stability side to side and front to back when
being moved and when standing by itself.

4. Typical conditions of use, such as travel speed,
roughness of surface on which the trailer will be
operated, and environmental conditions.

(1)

are Lincoln’s

(1)

.If

• Only transport this equipment on serviceable vehi­cles which are rated and designed for such loads.

• Distribute, balance and secure loads so vehicle is
stable under conditions of use.

• Do not exceed maximum rated loads for compo­nents such as suspension, axles and tires.

• Mount equipment base to metal bed or frame of
vehicle.

• Follow vehicle manufacturer’s instruction.

----------------------------------------------------------------------------

PRE-OPERATION ENGINE AND
COMPRESSOR SERVICE

READ the engine and compressor operating and main­tenance instructions supplied with this machine.

ENGINE OIL

The engine is shipped with the engine crankcase filled
with high quality SAE 10W-30 oil (API class CD or bet­ter). 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.
Check the oil level every four hours of running time during
the first 35 running hours. Refer to the engine Operator’s
Manual for specific oil recommendations and break-in
information. The oil change interval is dependent on the
quality of the oil and the operating environment. Refer to
the engine Operator’s Manual for the proper service and
maintenance intervals.

AIR COMPRESSOR OIL (WELD’N AIR
Only)

The WELD’N AIR is shipped with the compressor filled
with a high quality synthetic compressor oil. If oil is
needed add only Iowa Mold Tooling Co., Inc. (IMT)
synthetic compressor oil until compressor is full.

CAUTION

5. Proper preventative maintenance of trailer.

6. Conformance with federal, state and local laws.

(1)

For highway use, consult applicable federal, state
and local laws regarding specific requirements for
use on public highways, such as brakes, lights, fend­ers, etc.

1

VEHICLE MOUNTING

WARNING

Improperly mounted concentrated loads may cause
unstable vehicle handling and tires or other compo­nents to fail.

SAE400 & SAE400 WELD’N AIR

The use of any other oil causes excessive carbon
build up, and will void the warranty on the com­pressor.

------------------------------------------------------------------------

Check the oil level daily. Refer to the compressor
Operator’s Manual for the proper service and mainte­nance intervals.

A-4

INSTALLATION

WARNING

• Stop engine while fueling.

• Do not smoke when fueling.

• Keep sparks and flame away from
tank.

• Do not leave unattended while
fueling.

DIESEL FUEL

can cause fire.

• Wipe up spilled fuel and allow
fumes to clear before starting
engine.

• Do not overfill tank, fuel
expansion may cause over­flow.

DIESEL FUEL ONLY

------------------------------------------------------------------------

Fill the fuel tank with clean, fresh diesel fuel. The capac­ity of the fuel tank is 22.5 gallons (85.1 liters). See engine
Operator’s Manual for specific fuel recommendations.

NOTE:

off valve on the sediment bowl is open by turning the han­dle counterclockwise.

ENGINE COOLING SYSTEM

The cooling system has been filled at the factory with
a 50-50 mixture of ethylene glycol antifreeze and
water. Check the radiator level and add a 50-50 solu­tion as needed. (See Engine Manual or antifreeze
container for alternate antifreeze recommendation.)

ENGINE BREAK-IN PERIOD

Before starting the engine, be sure the fuel shut-

A-4

1. Connect the welder output studs to a suitable resis­tive load bank. Note that any attempt to short the
output studs by connecting the welding leads
together, direct shorting of the output studs, or con­necting the output leads to a length of steel will
result in catastrophic damage to the generator and
voids the warranty.

2. Set the welder controls for an output current and
voltage within the welder rating and duty cycle.
Note that any attempt to exceed the welder rating or
duty cycle for any period of time will result in cata­strophic damage to the generator and voids the
warranty.

3. Periodically shut off the engine and check the
crankcase oil level.

BATTERY CONNECTION

WARNING

Use caution as the electrolyte is a strong acid that
can burn skin and damage eyes.

Remove and discard the insulating caps from the
negative battery terminals. Attach and tighten neg­ative battery cable terminals.

NOTE:

batteries; if unused for several months, the batteries
may require a booster charge. Be careful to charge the
batteries with the correct polarity. Make sure that the
batteries are level while charging.

This machine is furnished with wet charged

WARNING

Lincoln Electric selects high quality, heavy-duty indus­trial engines for the portable welding machines we
offer. While it is normal to see a small amount of
crankcase oil consumption during initial operation,
excessive oil use, wetstacking (oil or tar like substance
at the exhaust port), or excessive smoke is not normal.

Larger machines with a capacity of 350 amperes and
higher, which are operated at low or no-load conditions
for extended periods of time are especially susceptible
to the conditions described above. To accomplish suc­cessful engine break-in, most diesel-powered equip­ment needs only to be run at a reasonably heavy load
within the rating of the welder for some period of time
during the engine’s early life. However, if the welder is
subjected to extensive light loading, occasional moder­ate to heavy loading of the engine may sometimes be
necessary. Caution must be observed in correctly
loading a diesel/generator unit.

SAE400 & SAE400 WELD’N AIR

GASES FROM BATTERY can
explode.

● Keep sparks, flame and cigarettes

away from battery.

-----------------------------------------------------------------------

To prevent EXPLOSION when:

● INSTALLING A NEW BATTERY — disconnect

negative cable from old battery first and
connect to new battery last.

● 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

battery first then connect negative lead to neg­ative battery lead at the lower control panel
support.

A-5

INSTALLATION

A-5

BATTERY ACID can burn eyes and
skin.

● Wear gloves and eye protection

and be careful when working near
battery.

● 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 BATTERY BUCKLING, tighten nuts on bat-

teries only until snug. DO NOT OVERTIGHTEN.

WARNING

• Spark Arrester and Muffler may be
hot!

• Allow engine to cool before servicing
spark arrester!

• Do not operate engine while servicing
spark arrester!

SPARK ARRESTER

Some federal, state or local laws may require that
gasoline or diesel engines be equipped with exhaust
spark arresters when they are operated in certain loca­tions where unarrested sparks may present a fire haz­ard. The muffler included with this welder has been
modified and now qualifies as a spark arrester.
Mufflers on machines manufactured before this
change do not qualify as spark arresters and when
required by local regulations, a suitable spark arrestor
must be installed. Spark arresting mufflers will have a
clean out service plug and will have “USDA FS 5100­1c QUALIFIED SPARK ARRESTER” stamped on the
muffler shell. Any spark arrester must be serviced and
properly maintained.

CAUTION

An incorrect arrester may lead to damage to the
engine or adversely affect performance.

------------------------------------------------------------------------

WELDING OUTPUT CABLES

With the engine off, connect the electrode and work
cables to the studs provided. These connections
should be checked periodically and tightened if neces­sary.

Listed in Table A.1 are copper cable sizes recom­mended for the rated current and duty cycle. Lengths
stipulated are the distance from the welder to work and
back to the welder again. Cable sizes are increased
for greater lengths primarily for the purpose of mini­mizing cable voltage drop.

Table A.1 Combined Length of Electrode and

Work Cables.

TOTAL COMBINED LENGTH OF ELEC-

TRODE AND WORK CABLES

AMPS

@60%

Duty Cycle

400

Up to 100FT.

Up to 31m

2/0 AWG

100-200FT.

31-61m

3/0 AWG

200-250FT.

61-76m

4/0 AWG

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.).

To prevent dangerous electric shock, other equipment
powered by this engine driven welder must:

a) be grounded to the frame of the welder using a

grounded type plug, or

b) be double insulated.

When this welder is mounted on a truck or trailer, its
frame must be securely connected to the metal frame
of the vehicle. When this engine driven welder is con­nected to premises wiring such as that in a home or
shop, its frame must be connected to the system earth
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

OPERATION

B-1

OPERATING INSTRUCTIONS

Read and understand this entire section before operat­ing your equipment.

SAFETY INSTRUCTIONS

WARNING

Do not attempt to use this equipment until you have
thoroughly read all operating and maintenance manu­als supplied with your machine. They include important
safety precautions, detailed engine starting, operating
and maintenance instructions and parts lists.

ELECTRIC SHOCK can kill.

• Do not touch electrically live parts or

electrodes with your skin or wet cloth­ing.

• Insulate yourself from the work and

ground.

• Always wear dry insulating gloves.

• Do not use AC welder if your clothing, gloves or

work area is damp or if working on, under or
inside workpiece.

Use the following equipment:

• Semiautomatic DC constant voltage
(wire) welder.

• DC manual (stick) welder.

• AC welder with reduced voltage con-

trol.

------------------------------------------------------------------------

ARC RAYS can injure eyes and
burn skin.

WELDING SPARKS can cause
fire or explosion.

• Do not weld near flammable material .

• Do not weld on containers that have

held flammable material.

-----------------------------------------------------------

MOVING PARTS can injure.

• Keep away from moving parts

• Do not operate with doors open or

guards off.

• Stop engine before servicing.

-----------------------------------------------------------------------­ENGINE EXHAUST can kill.

• Use in open, well ventilated areas or

vent exhaust outside.

------------------------------------------------------------------------

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 com­pressor instruction manuals.

GENERAL DESCRIPTION

• Wear eye, ear, and body protection.

----------------------------------------------------------

• Only qualified personnel should install, use or
service this equipment.

• Consult instruction manual before operating.

----------------------------------------------------------------------

Before operating, read and understand the manu­facurer’s instructions for this equipment and the
consumables to be used including the Material
Safety Data Sheet (MSDS) and follow your
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.

The SAE400 or SAE400 WELD’N AIR is a diesel
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
a generator it can supply up to 3,000 watts of 115/230
volt AC power. As a welder it provides up to 575 amps
of DC constant current output. The belt driven air com­pressor of the SAE400 WELD’N AIR provides 35 CFM
at 100 PSI compressed air.

The engine is a 71 Hp (54kw), 4-cylinder water cooled
diesel made by Perkins.

SAE400 & SAE400 WELD’N AIR

B-2

OPERATION

B-2

RECOMMENDED APPLICATIONS

WELDER

The SAE400 or SAE400 WELD’N AIR provides excel­lent constant current DC welding output for stick
(SMAW) welding. The field installed optional CV
Adapter (K385-1) provides up to 500 amps at 35 volts
of constant voltage output for semiautomatic welding.

AUXILIARY POWER

The SAE400 or SAE400 WELD’N AIR provides 3 KW
of 115/230 VAC output for auxiliary power and emer­gency standby power.

COMPRESSED AIR

The SAE400 WELD’N AIR only, provides 35 CFM at
100 PSI compressed air for air arc gouging and air
powered tools.

PRODUCT APPLICA TION

Arc Gouging, 3/8 in. (9.5)mm Electrode 16 453 18 1.27

(Current Range, 350-600 amps DC)
Grinder, 2 in. (50.8mm) wheel 14-20 396-566 90 6.33
Chipping Hammer- Weight: 18lbs. (8.1kg.) 28-30 793-850 90 6.33
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
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

TOOL CFM - L/min PSI - kg/cm

OTHER FEATURES

• Perkins 4-cylinder, water cooled diesel engine.
Designed for long life, easy maintenance and excel­lent fuel economy.

• Engine protection system shuts the engine down for
low engine oil pressure or high coolant temperature.

• Electronic Engine Idler. Engine automatically goes

to low idle in 10 to 14 seconds after welding or use
of auxiliary power stops. Includes high idle switch.

• 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.

FOR COMPRESSED AIR (SAE400 WELD’N AIR only)

• 35 CFM at 100 PSI for air arc gouging and air pow­ered tools.

• 11 Gallon air receiver tank system with integral over-

2

pressure relief valve for smooth air delivery.

• Indicator light for compressor operation.

• Gauges for compressor air pressure and compres-

sor oil pressure.

• No welding output derating required at maximum

compressor load.

DESIGN FEATURES AND ADVANTAGES

FOR STICK WELDING

• Excellent DC constant current output for stick weld­ing applications.

• Continuous adjustment of both voltage and current
for unsurpassed welds on demanding jobs.

• Remote control capability standard.

FOR AUXILIARY POWER

• 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 (with­in 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

DUTY CYCLE

Duty cycle is based on a ten minute period and opera­tion in an ambient temperature of 104°F(40°C).

The SAE400 & SAE400 WELD’N AIR are NEMA rated
at 60% duty cycle. Duty cycle is based on a ten minute
period. Therefore, a 60% duty cycle welder can be
operated at nameplate rated output for 6 minutes out of
every 10 minute period without overheating.

The auxiliary power can be used continuously (100%
duty cycle) within its rated current capacities.

The air compressor on the SAE400 WELD’N AIR is
rated at a 60% duty cycle based on a ten minute peri­od as described above.

200 13 6.5 1.5

300 6.5 3.25 0.75

400 0 0 0

SAE400 & SAE400 WELD’N AIR

B-3

OPERATION

B-3

ENGINE CONTROLS

IGNITION SWITCH

When placed in the “ON” position, this switch ener­gizes the fuel solenoid. When placed in the “OFF” posi­tion, the flow of fuel to the injection pump is stopped to
shut down the engine.

“IDLER” SWITCH

The idler switch has two positions, “HIGH” and
“AUTO”.

When in “HIGH” ( ) position, the engine will run
continuously at high idle.

When in “AUTO” ( / ) idle position, the idler
operates as follows:

a. Welding

When the electrode touches the work, the welding
arc is initiated and the engine accelerates to full
speed.

After welding ceases (and no auxiliary power is
being drawn), the engine will return to low idle after
approximately 10 to 14 seconds.

b. Auxiliary Power

With the engine running at low idle and auxiliary
power for lights or tools is drawn (approximately
100-150 watts or greater) from the receptacles, the
engine will accelerate to high speed. If no power is
being drawn from the receptacles ( and not weld­ing) for 10-14 seconds, the idler reduces the engine
speed to low idle.

ENGINE TEMPERATURE GAUGE

Displays the coolant temperature in the engine block.

ENGINE OIL PRESSURE GAUGE

Displays the oil pressure to the engine. When the
engine starts running, watch for the oil pressure to
build up. If no pressure shows within 30 seconds, stop
the engine and consult the engine instruction manual.

BA TTERY CHARGING AMMETER

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 batter­ies are ‘low’ on charge.

ENGINE PROTECTION SYSTEM

The engine protection system shuts down the engine
under high coolant temperature or low engine oil pres­sure conditions by allowing the fuel solenoid valve to
close.

WELDER CONTROLS

POLARITY SWITCH

Turn the Arc Polarity switch to electrode positive or
electrode negative as required for each particular
application.

CONTROL OF WELDING CURRENT
Purpose of Controls

The continuous “Current Control” is the main current
adjuster. The “Job Selector” is both a fine current
adjuster and the continuous Open Circuit Voltage
adjuster. Open Circuit Voltage (OCV) controls the arc
characteristics.

“Job Selector”

The “Job Selector” dial is divided into four colored sec­tions providing OCV ranges as follows:

Color Title OCV Range

White Large Electrodes High OCV
Black Normal Welding Medium OCV
Red Overhead & Vertical Low OCV
Grey Special Applications Extra-Low OCV

The “Job Selector” is usually set in the black range
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.

“Current Control”

CAUTION

Do not adjust the “Current Control” while welding
because this can damage the control.

------------------------------------------------------------------------

The “Current Control” dial is calibrated in amperes on
three separate colored dials corresponding to the
white, black and red ranges of the “Job Selector” dial.
For example: when the “Job Selector” is set on the
black range, the approximate welding current is indi­cated on the black scale of the “Current Control” dial.

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

OPERATION

B-4

How to Set the Controls

Assume you want a normal soft arc and about 135
amps, 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 current, turn the “Job
Selector” up (counterclockwise) to increase cur­rent. 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

A receptacle and “Local/Remote” control switch on the
lower front control panel and a remote control box with
100 ft. (30.5 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 control 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.

Circuit Breakers

The circuit breakers provide separate overload current
protection for each half of the 115 V duplex receptacle.
The circuit breakers provide overload current protec­tion in both current carrying wires of the 230 V duplex
receptacle.

Ground Stud

Provides a connection point for connecting the
machine to earth ground. For the safest grounding pro­cedure refer to “Machine Grounding” in the INSTALLA­TION section of this manual.

AIR COMPRESSOR CONTROLS ­(SAE400 WELD’N AIR ONL Y)

COMPRESSOR ON/OFF SWITCH

Placing the “ON/OFF” switch in the “ON” position
allows the “pressure switch” (factory preset) to control
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
system pressure goes above 130 psi, the “pressure
switch” disengages the clutch and compressor.

The “ON/OFF” switch needs to be in the “ON” position
when using compressed air. When placed in the “OFF”
position this switch does not allow the compressor
clutch to engage regardless of the tank pressure.

The “ON/OFF” switch should be in the “OFF” position
while starting the engine. This will minimize the load on
the starter motor.

COMPRESSOR OPERATING LIGHT

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 & SAE400 WELD’N AIR

This light is on when the compressor “ON/OFF” switch
is in the “ON” position.

COMPRESSOR AIR PRESSURE GAUGE

This gauge displays the air pressure in the air receiver
tanks.

COMPRESSOR OIL PRESSURE GAUGE

This gauge displays the compressor oil pressure. Oil is
under pressure only when the compressor clutch is
engaged.

B-5

OPERATION

B-5

ENGINE OPERATION

CAUTION

Do not adjust the high idle engine speed (rpm) above
the factory setting specification as this will overspeed
the air compressor and void it’s warranty.

------------------------------------------------------------------------

STARTING INSTRUCTIONS

Be sure all Pre-Operation Maintenance has been per­formed. (See INSTALLATION section of this manual).
Set the air compressor “ON/OFF” switch in the “OFF”
position. To start the engine, place ignition toggle
switch in the “ON” position. Engage the starter button.
When the engine starts running, observe the engine oil
pressure. 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.

When an engine is started for the first time, some of
the oil will be needed to fill the passages of the lubri­cating system. Therefore, on initial starting, run the
engine for about five minutes and then stop the engine
and recheck the oil. If the level is down, fill to the full
mark again. The engine controls were properly set at
the factory and should require no adjusting when
received.

AIR COMPRESSOR (SAE400 WELD’N AIR only)

Cylinder head stud torque must be checked after initial
8 to 10 hours of operation. See compressor operator’s
manual for details. Compressor mounting bolts should
be checked for tightness after initial 8 to 10 hours of
operation.

TYPICAL FUEL CONSUMPTION

The typical fuel consumption of the SAE400 and
SAE400 WELD’N AIR for various operating scenarios
is shown below:

Low Idle - No Load .35 gal./ hr.
1100 RPM (1.32 L./hr.)

High Idle - No Load .75 gal./hr.
1800 RPM (2.84 L./hr.)

Welding Load 1.92 gal./hr.
400 Amps, 40 Volts (7.27 L./hr.)

Auxiliary Power .96 gal./hr.
3000VA (3.63 L./hr.)

Air Compressor 1.04 gal./hr.
(SAE400 WELD’N AIR Only) (3.94 L./hr.)

For added safety always operate the welder with the
doors closed. Further, leaving the doors open changes
the designed air flow and may cause engine, genera­tor or compressor overheating.

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).

400 Amps, 40 Volts Load 2.22 gal./hr.
with Air Compressor “ON” (8.40 L./hr.)
(SAE400 WELD’N AIR Only)

Auxiliary Power 1.20 gal./hr.
3000 VA with (4.54 L./hr.)
Air Compressor “ON”
(SAE400 WELD’N AIR Only)

SAE400 & SAE400 WELD’N AIR

C-1

ACCESSORIES

C-1

K930-2 Hi-Freq™ - Provides high frequency plus a

gas valve for TIG welding. A water valve is available as
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.

1

For 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 elec­trode holder.

K2303-1 SHEET METAL KIT- For SAE400 model

K1278-5.

,

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

MAINTENANCE

D-1

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.

ROUTINE MAINTENANCE

At the end of each day’s welding, refill the fuel tank to
minimize moisture condensation in the tank. Also, run­ning out of fuel tends to draw dirt into the fuel system.
Check the engine crankcase and compressor oil lev­els.

If the fuel supply runs out while the fuel pump is oper­ating, air may be entrapped in the fuel distribution sys­tem. If this happens, bleeding of the fuel system may
be necessary. See the engine instruction manual.

PERIODIC MAINTENANCE

1. Blow out the welder and controls with an air hose at least
once every two months. In particularly dirty locations, this
cleaning may be necessary once a week. Use low pres­sure air to avoid driving dirt into the insulation.

2. The current control reactor brushes are self-lubricating
and should not be greased. Keep the contacts clean. This
control should be moved from maximum to minimum daily
to prevent the controls from sticking.

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 recom­mended in the engine operating manual. Change the oil
filter in accordance with the instructions in the engine
operating manual. When the oil filter is changed add one
quart of oil to the crankcase to replace the oil held in the
filter during operation.

4. See the compressor operator’s manual for periodic com­pressor maintenance information. Change the compres­sor oil at regular intervals using only Iowa Mold Tooling
Co., Inc. (IMT) synthetic compressor oil as recommended
in the compressor operating manual.

CAUTION

The use of any other oil causes excessive carbon build up,
and will void the warranty on the compressor.

--------------------------------------------------------------------------------

5. Belts tend to loosen after the first 30 or 40 hours of oper­ation. Check the cooling fan belt and tighten if necessary.
DO NOT OVER TIGHTEN. The compressor belt does not
require any adjustment.

BEARING MAINTENANCE

COMPRESSOR AIR RECEIVER TANKS ­(SAE400 WELD’N AIR ONLY)

Drain the condensation from the tanks after each use
by opening the drain valve located at the lower right
rear of the welder.

ENGINE AIR FILTER

The engine air filter element is a dry cartridge type. It
is located above the engine. It can be cleaned and re­used; 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

This welder is equipped with a double-shielded ball bearing
having sufficient grease to last indefinitely under normal ser­vice. Where the welder is used constantly or in excessively
dirty locations, it may be necessary to add one-half ounce of
grease per year. A pad of grease one inch wide, one inch
long and one inch high weighs approximately one-half
ounce. Over greasing is far worse than insufficient greasing.

When greasing the bearings, keep all dirt out of the area.
Wipe the fittings completely clean and use clean equipment.
More bearing failures are caused by dirt introduced during
greasing than from insufficient grease.

D-2

MAINTENANCE

D-2

COMMUTATOR AND BRUSH MAINTENANCE

WARNING

Uncovered rotating equipment can be dangerous.
Use care so your hands, hair, clothing or tools do
not catch in the rotating parts. Protect yourself
from particles that may be thrown out by the rotat­ing 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 pig­tail. 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 commu­tator as the armature rotates at full speed until contact
is made across the full face of the brushes. After ston­ing, blow out the dust with low pressure air.

COOLING SYSTEM

The SAE400 and SAE400 WELD’N AIR are equipped
with a pressure radiator. Keep the radiator cap tight to
prevent loss of coolant. Clean and flush the cooling
system periodically to prevent clogging the passage
and overheating the engine. When antifreeze is need­ed, always use the permanent type.

PRE FILTER / WASHER SEPARATOR

WARNING

When working on the fuel system

• Keep unguarded lights away, do not
smoke !

• Do not spill fuel !

------------------------------------------------------------------------

The SAE-400 and SAE400 Weld”n Air machines with

Codes 10884 and above are equipped with a Fuel Pre-
Filter/Water Separator Assembly located before the

lift pump mounted to the engine block.

FUEL PRE-FILTER/WATER SEPARATOR ASSEMBLY

The pre-filter is a 150 micron screen designed to pro­tect against gross fuel contamination of the water sep­arator element and the Secondary Fuel Filter. If the
pre-filter becomes plugged it may be removed, inspect­ed, cleaned and reinstalled. In general this only needs
to be done with each water separator element change
(about every 1,000 hrs.) However if at any time exces­sive fuel contamination is suspected or a sudden fall­off in engine performance is detected the pre-filter
screen should be inspected and cleaned. Follow the
following procedure:

1. Close the fuel shutoff valve located on the fuel
strainer mounted to the under side of the fuel tank.

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 pres­sure 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 pos­sible misaligned shaft. Have an authorized Field
Service Shop check and realign the shaft.

SAE400 & SAE400 WELD’N AIR

2. Unscrew the cap ring located on the top of the filter
header and remove the plastic center cap and O­ring.

3. Remove the large white volume plug located direct­ly under the center cap in the upper cavity of the fil­ter header. Use a small screwdriver (or similar
device) to lift the plug part way out of the cavity to
assist with its removal.

Be careful not to damage the pre-filter screen with
the tool used to remove the plug.

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 to
gradually 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 making sure the four pull tabs
are pointing up. Putting your fingers on the pull
tabs, push down evenly until the lower body of the
pre-filter screen contacts the floor of the upper cav­ity.

7. Re-insert the large white volume plug into the upper
cavity.

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.

5. Slide the quick change ring up over the element and
rotate counter clockwise until an audible click or pop
is heard. If you do not hear the click you have not rotat­ed the ring far enough and the element is not in the
locked position. Another indication that the ring is in
the locked position is that one set (it doesn’t matter
which one) of arrows located on the outside of the ring
should be located directly under the air vent valve.

6. Open the fuel shutoff valve.

7. Open the air vent valve on the front of the filter head­er until fuel emerges free of air bubbles and then close
the air vent valve.

Note : Consult your engine operation manual for infor­mation on air bleeding the entire fuel system

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 protec­tion 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 fil­ter 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 rock­ing motion to remove the element from the grom­met 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 ele­ment 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

MAINTENANCE

D-4

ENGINE AND COMPRESSOR MAINTENANCE
COMPONENTS

ITEM MAKE PART NUMBER

Engine Air Filter Donaldson P181052

Fan Belt Perkins 2614B550

Compressor Belt Lincoln S23887

(SAE400 WELD’N AIR only) Gates 2/A40

Fuel Filter Perkins 26560143

Engine Oil Filter Perkins 2654403

(Codes 10884 & Above)
Water Separator Lincoln M16890-C

Element Stanadyne 31572

(Codes 10884 & Above)
Fuel Pre-Filter Screen Lincoln M16890-B

Stanadyne 29575

SPARK ARRESTOR

WARNING

• 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 opera­tion or twice a year, which ever occurs first.
Service as follows:

1. Stop engine and allow to cool.

2. Loosen clamp and remove spark arrestor from
machine.

3. Remove locknut on top of spark arrestor housing
and lift off cap.

4. Separate plates and clean if necessary.

REPLACING AIR COMPRESSOR DRIVE BELT
(SAE400 WELD’N AIR only)

CAUTION

Belt is tensioned using a automatic tensioning
device. Remove with care.

------------------------------------------------------------------------

To remove compressor belt:

1. Remove nut and lock washer from lower locking
bolt on idler tension flange.

2. Loosen center mounting bolt on idler tensioner 1/2
turn or until it moves freely.

3. Using a pipe wrench or equivalent tool, turn ten­sioner body slightly to free locking bolt. Remove
locking bolt and slowly release tension on belt.
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 pul­ley.

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.

5. Inspect plates and housing for holes or cracks.
Replace spark arrestor if damaged.

6. Assemble spark arrestor using reverse order: step
3, then step 2.

For machines with integral spark arresting mufflers:

Service spark arrester every 250 hours.
Service as follows:

1. Stop engine and allow to cool.

2. Remove clean out plug from side of spark arrester.

3. Without damaging the spark arrester, gently tap on the
arrester shell near the clean out plug.

4. Once particles are removed, replace the clean out plug.

SAE400 & SAE400 WELD’N AIR

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.

__________________________________________________________________________

E-1

This Troubleshooting Guide is provided to help you
locate and repair possible machine malfunctions.
Simply follow the three-step procedure listed below.

Step 1. LOCATE PROBLEM (SYMPTOM).

Look under the column labeled “PROBLEM (SYMP­TOMS)”. This column describes possible symptoms
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

ELECTRIC SHOCK can kill.

• Do not touch electrically live parts such as output
terminals or internal wiring.

This column provides a course of action for the
Possible Cause, generally it states to contact your
local Lincoln Authorized Field Service Facility.

If you do not understand or are unable to perform the
Recommended Course of Action safely, contact your
local Lincoln Authorized Field Service Facility.

WARNING

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

TROUBLESHOOTING

Observe all Safety Guidelines detailed throughout this manual

E-2

PROBLEMS

(SYMPTOMS)

Machine fails to hold the “heat”
constantly.

POSSIBLE CAUSE

FUNCTION PROBLEMS

Rough or dirty commutator.

Brushes may be worn down to limit
of life.

Brush springs may be broken.

Field circuit may have variable resis­tance connections or intermittent
open circuit, due to loose connec­tions or broken wire.

Electrode or work lead connections
may be poor.

Wrong grade of brushes may be
installed on generator.

Field rheostat may be making poor
contact and overheating.

RECOMMENDED

COURSE OF ACTION

True and clean commutator.

Replace brushes.

Replace brush springs.

Check field current with ammeter to
discover varying current. This
applies to both the main generator
and exciter.

Tighten all connections.

Use only the recommended Lincoln
brushes.

Inspect and clean rheostat.

“Current Control” may not be operat­ing properly.

“Current Control” brushholder con­tact springs may be worn out or
missing. Contact surface may be
dirty, rough and pitted.

“Current Control” brushholder sup­port stud and mating contact sur­faces may be dirty or pitted and
burned.

Engine running at varying speeds.

Check for loose or missing set
screw in control handles.

Inspect. Replace needed parts.
Clean internal contact surface of
control device. Do not lubricate.
Smooth rough surfaces.

If brushholder internal contact sur­face is pitted and burned, replace
the brushholder and support stud. If
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.

Set welder controls for maximum
output and weld. Then, while weld­ing, check engine rpm. The engine
should be running at full speed. If
indicator shows a significant differ­ence, 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

TROUBLESHOOTING

Observe all Safety Guidelines detailed throughout this manual

E-3

PROBLEMS

(SYMPTOMS)

Welder runs but fails to generate
current.

POSSIBLE CAUSE

FUNCTION PROBLEMS

Generator or exciter brushes may
be loose or missing.

Exciter may not be operating.

Field circuit of generator or exciter
may be open.

Polarity reversing switch may be in
the neutral position.

Exciter may have lost excitation.

RECOMMENDED

COURSE OF ACTION

Be sure that all brushes bear on the
commutator and have proper spring
tension.

Check exciter output voltage with
voltmeter or lamp.

Check for open circuits in rheostat,
field leads and field coils. Also check
resistors.

Put handle in positive or negative
position.

Check components and continuity in
flashing circuit.

Welding arc is loud and spatters
excessively.

Series field circuit may be open cir­cuited.

Current setting may be too high.

Polarity may be wrong.

Check circuit with ringer or volt­meter.

Check setting and current output
with ammeter.

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

TROUBLESHOOTING

Observe all Safety Guidelines detailed throughout this manual

E-4

PROBLEMS

(SYMPTOMS)

Welding current too great or too
small compared to indication on the
dial.

Welder has output and no control

POSSIBLE CAUSE

FUNCTION PROBLEMS

“Current Control” shaft and handle
may have turned slightly in the insu­lated bushing of the current control
brushholder, caused by turning han­dle too hard against one of the
stops.

Exciter output low causing low out­put compared to dial indication.

“Current Control” set to minimum
and welder output so great that
engine stalls when arc is struck.

Local/Remote switch is in wrong
position.

RECOMMENDED

COURSE OF ACTION

With current control against the min­imum stop, set pointer to within 1/8”
of the last scale division.

Check for shorts in exciter armature
with growler.

Check to see that series field is
properly connected and not shorted.

Place switch in “LOCAL” position to
control output at the welder. Place
switch in “REMOTE” position to con­trol 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

TROUBLESHOOTING

Observe all Safety Guidelines detailed throughout this manual

E-5

PROBLEMS

POSSIBLE CAUSE

(SYMPTOMS)

FUNCTION PROBLEMS

No auxiliary power Circuit Breakers open.

Faulty connections to auxiliary
receptacles.

RECOMMENDED

COURSE OF ACTION

Check and reset breakers. If break­ers keep tripping check connections
to auxiliary receptacles. Also make
sure load does nor exceed recepta­cle’s current rating.

Check connections.

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

WIRING DIAGRAMS

01
11-

F-1

M19232

WARNING

maintenance work.

maintenance work unless the maintenance work

Keep hands, hair, clothing and tools away

covers are replaced after servicing.

from moving parts, and insure all guards or

Turn the engine or input power OFF before

Have only qualified personnel perform

requires it to be running.

Welding cable connections are tight.

All equipment in serviceable condition.

strainer are at proper operating level and clean.

236

B

1

242

2

10
9
8
7
6
5

4
3
2
1

B

Engine oil, coolant, air cleaner and fuel

Compressor

B

243

B

G

R

241

B

R

R

4

3

J2

P.C. BOARD

PROTECTION

IDLER/ENGINE

J1

Clutch

Pressure SW.

G

G

G

DAILY CHECKS:

MAINTENANCE INSTRUCTIONS

from cord when hooking or releasing hook.

WARNING:

GENERAL MAINTENANCE INSTRUCTIONS FOR ENGINE

AND MOTOR DRIVEN ARC WELDING POWER SOURCES.

IGNITER

THERMOSTART

233

PARTS

MOVING

CAN INJURE

COLD

B

START

B

THERMOSTART

-

+

B

Keep secure hold of cord, and keep face away

Uncontrolled release of door restraint cords can cause injury.

30

868587

87a

B

B

Y

TERMINAL

Enable

Compressor

B

239

Fuse

B

(10A)

235

240

-

238

+

AMMETER

G

5B

SWITCH

B

IGNITION

W

237

IDLER

B

SWITCH

ENGINE HOUR METER

IND

+

TO FLASHING DIODE

234

ALTERNATOR

B

222

U

IDLER

W

230

229

5A

B

226

G

U

B

231

220

B

SOLENOID

Clean commutators or slip rings with fine sandpaper-

Blow dust from machine using clean low pressure air.

AS REQUIRED:

Replace brushes before the pigtails are within 1/4"of

NOT EMERY CLOTH. See Operating Manual for instructions.

the commutator. See Operating Manual for instructions.

LEAD COLOR CODE

B-BLACK OR GRAY

G-GREEN

N-BROWN

R-RED OR PINK

U-BLUE

W-WHI TE

Y-YELLOW

-

+

-

+

S

STARTING

TO TOROID

2 CR

REED RELAY

ENGINE TEMP.

SENSOR

MOTOR

R

B

B

G

G

FUEL INJECTION PUMP

specific diagram for a particular code is pasted inside the machine on one of the enclosure panels.

5C

B

FUEL SHUT

OFF VALVE

TO CONTROL PANEL

GROUND SCREW

B

228

232

B

B

221

TEMPERATURE GAGE

G

W

W

NOTE: This diagram is for reference only. It may not be accurate for all machines covered by this manual. The

SWITCH (N.C.)

OIL PRESSURE

SAE400 & SAE400 WELD’N AIR

F-2

Have only qualified personnel perform

WIRING DIAGRAMS

01

­11

F-2

M19233

WARNING

Welding cable connections are tight.

All equipment in serviceable condition.

strainer are at proper operating level and clean.

maintenance work.

maintenance work unless the maintenance work

Keep hands, hair, clothing and tools away

covers are replaced after servicing.

from moving parts, and insure all guards or

Turn the engine or input power OFF before

requires it to be running.

DAILY CHECKS:

MAINTENANCE INSTRUCTIONS

Engine oil, coolant, air cleaner and fuel

Clean commutators or slip rings with fine sandpaper-

Blow dust from machine using clean low pressure air.

AS REQUIRED:

Replace brushes before the pigtails are within 1/4"of

NOT EMERY CLOTH. See Operating Manual for instructions.

1/4" of the commutator. See Operating Manual for instructions.

LEAD COLOR CODE

B-BLACK OR GRAY

G-GREEN

N-BROWN

R-RED OR PINK

U-BLUE

W-WHI TE

Y-YELLOW

WIRING DIAGRAM - SAE-400 PERKINS

from cord when hooking or releasing hook.

WARNING:

GENERAL MAINTENANCE INSTRUCTIONS FOR ENGINE

AND MOTOR DRIVEN ARC WELDING POWER SOURCES.

PARTS

MOVING

CAN INJURE

Keep secure hold of cord, and keep face away

Uncontrolled release of door restraint cords can cause injury.

+

+

IGNITER

THERMOSTART

TERMINAL

233

B

THERMOSTART

-

+

238

W

ENGINE HOUR METER

IND

+

TO FLASHING DIODE

W

COLD

B

START

B

-

+

B

B

235

B

236

SWITCH

B

5B

IGNITION

R

G

5C

5A

237

B

AMMETER

G

IDLER

SWITCH

G

226

220

B

229

U

B

B

225

1

10
9
8
73
6
5

4

2
1

J1

R

432

J2

P.C. BOARD

PROTECTION

IDLER/ENGINE

ALTERNATOR

224

222

U

234

B

IDLER

SOLENOID

-

-

S

STARTING

TO TOROID

2 CR

REED RELAY

ENGINE TEMP.

SENSOR

MOTOR

R

B

B

B

FUEL SHUT

OFF VALVE

TO CONTROL PANEL

GROUND SCREW

G

W

W

227

B

G

G

specific diagram for a particular code is pasted inside the machine on one of the enclosure panels.

B

223

SWITCH (N.C.)

OIL PRESSURE

B

221

TEMPERATURE GAGE

FUEL INJECTION PUMP

NOTE: This diagram is for reference only. It may not be accurate for all machines covered by this manual. The

SAE400 & SAE400 WELD’N AIR

F-3

G

PLUG FOR REMOTE CONTROL

POTENTIOMETER

X

Y

G

RESISTORS

WIRING DIAGRAMS

W

U

W

R

01
7-

F-3

M19237

W

G

CONNECT

TO BASE

REMOTE CONTROL

POTENTIOMETER BOX

R

REMOTE SWITCH WIRED THIS

602

WAY ON EARLIER UNITS

ELECTRODE

Y

G

X

B

REMOTE CONTROL RECEPTACLE

AND SWITCH

(+)

AC

D2

203

(-)

W

-

ROTOR

+

ALTERNATOR

R

RINGS

SLIP

R

W

AC

41

600

FLASHING DIODE

AND RESISTOR

3

1

4

W

42

602

600A

R

1

41A

G

5

2

R

3

42A

238

6

4

W

+

POS

-

NEG

B

B

R

W

SWITCH FOR LOCAL OR

REMOTE CONTROL SHOWN

IN LOCAL POSITION.

2

P8

4

2

3

1

Y

U

AC

SWITCH

POLARITY

602A

U

D1

500

W

(-)

(+)

AC

201

B

G

G

SCREW

GROUND

602B

G

G

5

4

WHITE

TERMINALS

230V DUPLEX

RECEPTACLE

BACK VIEW

OF POLARITY

SWITCH

REACTOR

N

U

AUXILIARY

POWER WDG.

ALTERNATOR

R

B

F

1

2

E

A

W

115V DUPLEX

RECEPTACLE

FRONT VIEW

OF RECEPTACLES

TO WORK TERMINAL

2CR

WELD CURRENT

SENSING SWITCH

R

B

SEE BATTERY

WIRING DIAGRAM

W

3

B

20A

B

20A

15A

15A

W

TOROID

CB4

B

B

CB3

CB2

B

B

CB1

specific diagram for a particular code is pasted inside the machine on one of the enclosure panels.

NOTE: This diagram is for reference only. It may not be accurate for all machines covered by this manual. The

CONTROL WIRING DIAGRAM - SAE-400 & WELD'N AIR

B-BLACK OR GRAY

G-GREEN

N-BROWN

COLOR CODE

R-RED OR PINK

U-BLUE

W-WHITE

Y-YELLOW

SEE BATTERY

WIRING DIAGRAM

TO LOWER PANEL

GROUND SCREW

SAE400 & SAE400 WELD’N AIR

ELECTRICAL SYMBOLS PER E1537

F-4

DIMENSION PRINT

F-4

3.00

63.06

43.75

32.87

39.38

18.50

*

44.50 8.90

8.12

69.75

77.00

.88

81.25

83.00

1-98

M8869-33

28.00

39.69

50.13

6.00

22.00

CENTER OF GRAVITY

WITH OIL AND

WATER IN ENGINE,

BUT NO FUEL.

*

24.50

27.12

22.14

= .81 DIA HOLES

= .69 DIA HOLES

*

SAE400 & SAE400 WELD’N AIR

NOTES

SAE400 & SAE400 WELD’N AIR

● Keep your head out of fumes.

● Use ventilation or exhaust to

remove fumes from breathing zone.

● Turn power off before servicing.

● Do not operate with panel open or

guards off.

WARNING

● Los humos fuera de la zona de res-

piración.

● Mantenga la cabeza fuera de los

humos. Utilice ventilación o
aspiración para gases.

● Gardez la tête à l’écart des fumées.

● Utilisez un ventilateur ou un aspira-

teur pour ôter les fumées des zones
de travail.

● Vermeiden Sie das Einatmen von

Schweibrauch!

● Sorgen Sie für gute Be- und

Entlüftung des Arbeitsplatzes!

● Mantenha seu rosto da fumaça.

● Use ventilação e exhaustão para

remover fumo da zona respiratória.

● Desconectar el cable de ali-

mentación de poder de la máquina
antes de iniciar cualquier servicio.

● Débranchez le courant avant l’entre-

tien.

● Strom vor Wartungsarbeiten

abschalten! (Netzstrom völlig öff­nen; Maschine anhalten!)

● Não opere com as tampas removidas.

● Desligue a corrente antes de fazer

serviço.

● Não toque as partes elétricas nuas.

● No operar con panel abierto o

guardas quitadas.

● N’opérez pas avec les panneaux

ouverts ou avec les dispositifs de
protection enlevés.

● Anlage nie ohne Schutzgehäuse

oder Innenschutzverkleidung in
Betrieb setzen!

● Mantenha-se afastado das partes

moventes.

● Não opere com os paineis abertos

ou guardas removidas.

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
PRÁTICAS DE SEGURANÇA DO EMPREGADOR.

SAE400 & SAE400 WELD’N AIR

WARNING

Spanish

AVISO DE

PRECAUCION

● Do not touch electrically live parts or

electrode with skin or wet clothing.

● Insulate yourself from work and

ground.

● No toque las partes o los electrodos

bajo carga con la piel o ropa moja­da.

● Aislese del trabajo y de la tierra.

● Keep flammable materials away.

● Mantenga el material combustible

fuera del área de trabajo.

● Wear eye, ear and body protection.

● Protéjase los ojos, los oídos y el

cuerpo.

French

ATTENTION

German

WARNUNG

Portuguese

ATENÇÃO

Japanese

Chinese

Korean

Arabic

● Ne laissez ni la peau ni des vête-

ments mouillés entrer en contact
avec des pièces sous tension.

● Isolez-vous du travail et de la terre.

● Berühren Sie keine stromführenden

Teile oder Elektroden mit Ihrem
Körper oder feuchter Kleidung!

● Isolieren Sie sich von den

Elektroden und dem Erdboden!

● Não toque partes elétricas e elec-

trodos com a pele ou roupa molha­da.

● Isole-se da peça e terra.

● Gardez à l’écart de tout matériel

inflammable.

● Entfernen Sie brennbarres Material!

● Mantenha inflamáveis bem guarda-

dos.

● Protégez vos yeux, vos oreilles et

votre corps.

● Tragen Sie Augen-, Ohren- und Kör-

perschutz!

● Use proteção para a vista, ouvido e

corpo.

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 HER­STELLERS. DIE UNFALLVERHÜTUNGSVORSCHRIFTEN 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: [phone] FAX: [phone] WEB SITE: www.lincolnelectric.com