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DC ARC WELDING POWER SOURCE
This manual covers equipment which is no
longer in production by The Lincoln Electric Co.
Speci cations and availability of optional
features may have changed.
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
INSTALL, OPERATE OR REPAIR
THIS EQUIPMENT WITHOUT
READING THIS MANUAL AND
THE SAFETY PRECAUTIONS
CONTAINED
THROUGHOUT.
And, most importantly, think before
you act and be careful.
Date of Purchase:
Serial Number:
Code Number:
Model:
Where Purchased:
• 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
SAE400
For use with machines having Code Number 10664, 10665
NOT
OPERATOR'S MANUAL
• World's Leader in Welding and Cutting Products •
R
Copyright © 2001 Lincoln Global Inc.
IM662
August, 2001
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Table of Contents
Troubleshooting
Related Manuals for Lincoln Electric IM662 SAE400
Summary of Contents for Lincoln Electric IM662 SAE400
- Page 1 DC ARC WELDING POWER SOURCE For use with machines having Code Number 10664, 10665 This manual covers equipment which is no longer in production by The Lincoln Electric Co. Speci cations and availability of optional features may have changed. Safety Depends on You...
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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
SAFETY ARC RAYS can burn. ELECTRIC SHOCK can kill. 3.a. The electrode and work (or ground) circuits 4.a. Use a shield with the proper filter and cover are electrically “hot” when the welder is on. plates to protect your eyes from sparks and Do not touch these “hot”... - Page 4 SAFETY WELDING SPARKS can CYLINDER may explode cause fire or explosion. if damaged. 6.a. Remove fire hazards from the welding area. 7.a. Use only compressed cylinders If this is not possible, cover them to prevent containing the correct shielding gas for the the welding sparks from starting a fire.
- Page 5 SAFETY PRÉCAUTIONS DE SÛRETÉ 6. Eloigner les matériaux inflammables ou les recouvrir afin de prévenir tout risque d’incendie dû aux étincelles. Pour votre propre protection lire et observer toutes les instructions et les précautions de sûreté specifiques qui parraissent dans ce 7.
- Page 6 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.
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Page 7: Table Of Contents
TABLE OF CONTENTS Page Installation Instructions ..........Section A Technical Specifications . -
Page 8: Technical Specifications
INSTALLATION TECHNICAL SPECIFICATIONS - SAE400 INPUT - DIESEL ENGINE Make/Model Description Speed (RPM) Displacement Starting Capacities System Perkins 4 cylinder High Idle 1800 236 cu. in 12VDC batteries Fuel: 22.5 gal. 4.236 Diesel 63 HP @ Low Idle 1100 (3.87 L) (2) &... -
Page 9: Location/Ventilation
INSTALLATION Read this entire installation section before you STACKING start installation. These machines cannot be stacked. SAFETY PRECAUTIONS ANGLE OF OPERATION WARNING To achieve optimum engine performance the machine should be run in a level position. The maximum angle Do not attempt to use this equipment until you have of operation for the Perkins engine is 40 degrees in all thoroughly read all operating and maintenance man- directions. -
Page 10: High Altitude Operation
INSTALLATION HIGH ALTITUDE OPERATION ENGINE OIL At higher altitudes, output derating may be necessary. The engine is shipped with the engine crankcase filled with high quality SAE 10W-30 oil (API class CD or bet- As a rule of thumb, derate the welder output 5% for ter). -
Page 11: Engine Cooling System
INSTALLATION ENGINE COOLING SYSTEM To prevent BATTERY BUCKLING, tighten nuts on bat- teries only until snug. DO NOT OVERTIGHTEN. The cooling system has been filled at the factory with SPARK ARRESTER a 50-50 mixture of ethylene glycol antifreeze and water. Check the radiator level and add a 50-50 solu- tion as needed. -
Page 12: Welding Output Cables
INSTALLATION WELDING OUTPUT CABLES To prevent dangerous electric shock, other equipment With the engine off, connect the electrode and work powered by this engine driven welder must: cables to the studs provided. These connections should be checked periodically and tightened if neces- sary. -
Page 13: Operating Instructions
OPERATION OPERATING INSTRUCTIONS GENERAL DESCRIPTION Read and understand this entire section before operat- The SAE400 is a diesel engine driven welding power ing your equipment. source. The machine uses a DC generator for DC stick electrode welding and an AC exciter for 115/230 VAC SAFETY INSTRUCTIONS auxiliary power. -
Page 14: Design Features And Advantages
OPERATION DESIGN FEATURES AND ADVANTAGES DUTY CYCLE FOR STICK WELDING Duty cycle is based on a ten minute period and opera- • Excellent DC constant current output for stick weld- tion in an ambient temperature of 104°F(40°C). ing applications. The SAE400 is NEMA rated at 60% duty cycle. Duty •... - Page 15 OPERATION ENGINE CONTROLS ENGINE PROTECTION SYSTEM The engine protection system shuts down the engine IGNITION SWITCH under high coolant temperature or low engine oil pres- sure conditions by allowing the fuel solenoid valve to When placed in the “ON” position, this switch energizes close.
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Page 16: Remote Control
OPERATION How to Set the Controls Circuit Breakers Assume you want a normal soft arc and about 135 The circuit breakers provide separate overload current amps, using a 5/32” (4.0 mm) electrode: protection for each half of the 115 V duplex receptacle. The circuit breakers provide overload current protec- 1. -
Page 17: Engine Operation
OPERATION ENGINE OPERATION BREAK-IN PERIOD CAUTION ENGINE Do not adjust the high idle engine speed (rpm) above The engine used to supply power for your welder is a the factory setting specification. heavy duty, industrial engine. It is designed and built ------------------------------------------------------------------------ for rugged use. -
Page 18: Accessories
A PIPE BEFORE REVIEWING LINCOLN BULLETIN E695.1 (dated October 1987 or later). This bulletin may be obtained from your local Lincoln distributor or by writing directly to Lincoln Electric at the address on the back of this manual. K704 Standard Accessory Kit - Includes electrode and work cables, headshield, work clamp and elec- trode holder. -
Page 19: Maintenance
MAINTENANCE Note: Water and fuel should be drained into a suit- WARNING able container for proper disposal. ENGINE AIR FILTER ELECTRIC SHOCK can kill. The engine air filter is an oil bath style filter. Inspect the ● Do not touch electrically live parts air filter daily, more often in dirty or dusty conditions. - Page 20 MAINTENANCE COMMUTATOR AND BRUSH MAINTENANCE COOLING SYSTEM WARNING The SAE400 is equipped with a pressure radiator. Keep the radiator cap tight to prevent loss of coolant. Uncovered rotating equipment can be dangerous. Clean and flush the cooling system periodically to pre- Use care so your hands, hair, clothing or tools do vent clogging the passage and overheating the engine.
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Page 21: How To Use Troubleshooting Guide
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. -
Page 22: Troubleshooting
TROUBLESHOOTING Observe all Safety Guidelines detailed throughout this manual PROBLEMS RECOMMENDED POSSIBLE CAUSE (SYMPTOMS) COURSE OF ACTION FUNCTION PROBLEMS Machine fails to hold the “heat” Rough or dirty commutator. True and clean commutator. constantly. Brushes may be worn down to limit Replace brushes. - Page 23 TROUBLESHOOTING Observe all Safety Guidelines detailed throughout this manual PROBLEMS RECOMMENDED POSSIBLE CAUSE (SYMPTOMS) COURSE OF ACTION FUNCTION PROBLEMS Welder runs but fails to generate Generator or exciter brushes may be Be sure that all brushes bear on the current. loose or missing.
- Page 24 TROUBLESHOOTING Observe all Safety Guidelines detailed throughout this manual PROBLEMS RECOMMENDED POSSIBLE CAUSE (SYMPTOMS) COURSE OF ACTION FUNCTION PROBLEMS Welding current too great or too “Current Control” shaft and handle With current control against the min- small compared to indication on the may have turned slightly in the insu- imum stop, set pointer to within 1/8”...
- Page 25 TROUBLESHOOTING Observe all Safety Guidelines detailed throughout this manual PROBLEMS RECOMMENDED POSSIBLE CAUSE (SYMPTOMS) COURSE OF ACTION FUNCTION PROBLEMS No auxiliary power Circuit Breakers open. Check and reset breakers. If breakers keep tripping check connections to auxiliary receptacles. Also make sure load does nor exceed receptacle’s current rating.
- Page 26 WIRING DIAGRAMS SAE400...
- Page 27 WIRING DIAGRAMS ENHANCED DIAGRAM SAE400...
- Page 28 WIRING DIAGRAMS SAE400...
- Page 29 DIMENSION PRINT SAE400...
- Page 30 NOTES SAE400...
- Page 31 Year AMERICAN EXPRESS USE THIS FORM TO ORDER: Order from: BOOK DIVISION, The Lincoln Electric Company, 22801 St. Clair Avenue, Cleveland, Ohio 44117-1199 for fastest service, FAX this completed form to: 216-361-5901 BOOKS OR FREE INFORMATIVE CATALOGS Telephone: 216-383-2211 or,...
- Page 32 ● ● ● Do not touch electrically live parts or Keep flammable materials away. Wear eye, ear and body protection. WARNING electrode with skin or wet clothing. ● Insulate yourself from work and ground. Spanish AVISO DE ● ● ● No toque las partes o los electrodos Mantenga el material combustible Protéjase los ojos, los oídos y el...
- Page 33 WARNING Spanish AVISO DE PRECAUCION French ATTENTION German WARNUNG Portuguese ATENÇÃO Japanese Chinese Korean Arabic LEIA E COMPREENDA AS INSTRUÇÕES DO FABRICANTE PARA ESTE EQUIPAMENTO E AS PARTES DE USO, E SIGA AS PRÁTICAS DE SEGURANÇA DO EMPREGADOR. SAE400...