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IM640-A
SAE400 & SAE400 WELD'N AIR -
May, 2004
DC ARC WELDING POWER SOURCE
For use with machines having Code Numbers: 10601, 10602, 10884, 10885
Safety Depends on You
Lincoln arc welding and cutting
equipment is designed and built with
safety in mind. However, your overall
safety can be increased by proper
installation ... and thoughtful opera-
tion on your part. DO
NOT
INSTALL, OPERATE OR REPAIR
THIS EQUIPMENT WITHOUT
READING THIS MANUAL AND
THE SAFETY PRECAUTIONS
CONTAINED
THROUGHOUT.
And, most importantly, think before
you act and be careful.
R
OPERATOR'S MANUAL
Copyright © 2004 Lincoln Global Inc.
• World's Leader in Welding and Cutting Products •
• Sales and Service through Subsidiaries and Distributors Worldwide •
Cleveland, Ohio 44117-1199 U.S.A. TEL: 216.481.8100 FAX: 216.486.1751 WEB SITE: www.lincolnelectric.com
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Related Manuals for Lincoln Electric POWER SOURCE IM640-A
Summary of Contents for Lincoln Electric POWER SOURCE IM640-A
- Page 1 RETURN TO MAIN MENU IM640-A SAE400 & SAE400 WELD’N AIR - May, 2004 DC ARC WELDING POWER SOURCE For use with machines having Code Numbers: 10601, 10602, 10884, 10885 Safety Depends on You Lincoln arc welding and cutting equipment is designed and built with safety in mind.
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Page 2: California Proposition 65 Warnings
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. -
Page 3: Electric Shock Can Kill
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. - Page 4 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. Remember that welding sparks and hot materials from welding can easily go through small cracks and openings to adjacent areas.
- Page 5 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 contre la secousse électrique: a.
- Page 6 SAFETY WARNING Assure that tank and compressor relief valves work properly, and are at correct pressure settings. DO NOT modify or repair air tank. NEVER move compressor with pressure in tank.
- Page 7 SAFETY...
- Page 8 The code number is especially important when identifying the correct replacement parts. - 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.
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Page 9: Table Of Contents
viii Installation Instructions ..........Section A Technical Specifications . -
Page 10: Technical Specifications
TECHNICAL SPECIFICATIONS - SAE400 & SAE400 WELD’N AIR Make/Model Description Perkins 4 cylinder 1004.42 Diesel 71 HP @ Engine 1725 RPM Duty Cycle Welding Output 60% (NEMA) 400 amps 60% (Lincoln Plus) 400 amps OUTPUT - WELDER AND GENERATOR Welding Range 80 - 575 Amps HEIGHT WIDTH... -
Page 11: Location/Ventilation
Read this entire installation section before you start installation. SAFETY PRECAUTIONS WARNING Do not attempt to use this equipment until you have thoroughly read all operating and maintenance man- uals supplied with your machine. They include impor- tant safety precautions, detailed engine starting, operating and maintenance instructions and parts lists. -
Page 12: High Altitude Operation
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 alti- tude operation. -
Page 13: Fuel
(See Engine Manual or antifreeze container for alternate antifreeze recommendation.) ENGINE BREAK-IN PERIOD Lincoln Electric selects high quality, heavy-duty indus- trial engines for the portable welding machines we offer. While it is normal to see a small amount of... -
Page 14: Spark Arrester
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 —... -
Page 15: Operating Instructions
OPERATING INSTRUCTIONS Read and understand this entire section before operat- ing your equipment. SAFETY INSTRUCTIONS WARNING Do not attempt to use this equipment until you have thoroughly read all operating and maintenance manu- als supplied with your machine. They include important safety precautions, detailed engine starting, operating and maintenance instructions and parts lists. -
Page 16: Recommended Applications
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 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 emer-... - Page 17 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 to shut down the engine. “IDLER” SWITCH The idler switch has two positions, “HIGH”...
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Page 18: Remote Control
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. -
Page 19: Engine Operation
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 per- formed. (See INSTALLATION section of this manual). Set the air compressor “ON/OFF”... -
Page 20: Accessories
The use of an arc welder for pipe thawing is not approved by the CSA, nor is it recommended or supported by Lincoln Electric. ------------------------------------------------------------------------ K704 Standard Accessory Kit - Includes electrode and work cables, headshield, work clamp and elec- trode holder. -
Page 21: Maintenance
WARNING ELECTRIC SHOCK can kill. ● Do not touch electrically live parts such as output terminals or inter- nal 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 ●... -
Page 22: Pre Filter / Washer Separator
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 rotat- ing armature when stoning the commutator. ------------------------------------------------------------------------ The generator brushes are properly adjusted when the welder is shipped. -
Page 23: Water Separator Element
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. -
Page 24: Engine And Compressor Maintenance Components
ENGINE AND COMPRESSOR MAINTENANCE COMPONENTS ITEM MAKE Engine Air Filter Donaldson Fan Belt Perkins Compressor Belt Lincoln Gates (SAE400 WELD’N AIR only) Fuel Filter Perkins Engine Oil Filter Perkins (Codes 10884 & Above) Water Separator Lincoln Element Stanadyne (Codes 10884 & Above) Fuel Pre-Filter Screen Lincoln Stanadyne REPLACING AIR COMPRESSOR DRIVE BELT... -
Page 25: How To Use Troubleshooting Guide
HOW TO USE TROUBLESHOOTING GUIDE 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. - Page 26 Observe all Safety Guidelines detailed throughout this manual PROBLEMS (SYMPTOMS) Machine fails to hold the “heat” constantly. 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. TROUBLESHOOTING POSSIBLE CAUSE FUNCTION PROBLEMS...
- Page 27 Observe all Safety Guidelines detailed throughout this manual PROBLEMS (SYMPTOMS) Welder runs but fails to generate current. Welding arc is loud and spatters excessively. 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.
- Page 28 Observe all Safety Guidelines detailed throughout this manual PROBLEMS (SYMPTOMS) Welding current too great or too small compared to indication on the dial. Welder has output and no control 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.
- Page 29 Observe all Safety Guidelines detailed throughout this manual PROBLEMS (SYMPTOMS) No auxiliary power 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. TROUBLESHOOTING POSSIBLE CAUSE FUNCTION PROBLEMS...
- Page 30 WIRING DIAGRAMS SAE400 & SAE400 WELD’N AIR...
- Page 31 WIRING DIAGRAMS SAE400 & SAE400 WELD’N AIR...
- Page 32 WIRING DIAGRAMS SAE400 & SAE400 WELD’N AIR...
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Page 33: Sae400 & Sae400 Weld'n Air
DIMENSION PRINT SAE400 & SAE400 WELD’N AIR... - Page 34 NOTES SAE400 & SAE400 WELD’N AIR...
- Page 35 ● ● ● ● ● ● ● ● ● ● ● ● ● ● ● ● ● ● ● ● ● ● ● SAE400 & SAE400 WELD’N AIR WARNING Spanish AVISO DE PRECAUCION French ATTENTION German WARNUNG Portuguese ATENÇÃO Japanese Chinese Korean Arabic...
- Page 36 ● WARNING ● Spanish ● AVISO DE PRECAUCION ● French ● ATTENTION ● ● German WARNUNG ● Portuguese ● ATENÇÃO ● Japanese Chinese Korean Arabic ● ● ● ● ● SAE400 & SAE400 WELD’N AIR ● ● ● ● ●...
- Page 37 • World's Leader in Welding and Cutting Products • • Sales and Service through Subsidiaries and Distributors Worldwide • Cleveland, Ohio 44117-1199 U.S.A. TEL: 216.481.8100 FAX: 216.486.1751 WEB SITE: www.lincolnelectric.com...