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SAE400 WELD'N AIR - DC ARC WELDING POWER
SOURCE AND 35 CFM AIR COMPRESSOR
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
RETURN TO MAIN MENU
For use with machines having Code Number 10362
NOT
OPERATOR'S MANUAL
• World's Leader in Welding and Cutting Products •
R
IM581
February, 2000
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Summary of Contents for Lincoln Electric IM581
- Page 1 Where Purchased: OPERATOR’S MANUAL • 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 RETURN TO MAIN MENU IM581 February, 2000...
- Page 2 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. 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 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 6 SAFETY...
- Page 7 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 8 This statement appears where the information must be followed to avoid minor personal injury or damage to this equipment. for selecting a QUALITY product by Lincoln Electric. We want you to take pride in operating this Lincoln Electric Company product •••...
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Page 9: Table Of Contents
Air Compressor Controls ........ -
Page 10: Technical Specifications
Open Circuit Voltage Auxiliary Power 97 Max. OCV 115/230 VAC @ 1800 RPM 3000 Watts, 60 Hz. 100% Duty Cycle OUTPUT - AIR COMPRESSOR Delivery Tank Capacity & Rating 35 CFM 11 Gallons at 100 P.S.I. (41.6 Liters) at 60%... -
Page 11: Location/Ventilation
To achieve optimum engine performance the SAE400 WELD’N AIR 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. -
Page 12: High Altitude Operation
Refer to the engine Operator’s Manual for the proper ser- vice and maintenance intervals. AIR COMPRESSOR OIL are Lincoln’s The WELD’N AIR is shipped with the compressor filled with a high quality synthetic compressor oil. If oil is .If the... -
Page 13: Engine Cooling System
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 solu- tion as needed. (See Engine Manual or antifreeze con- tainer for alternate antifreeze recommendation.) BATTERY CONNECTION WARNING: Use caution as the electrolyte is a strong... -
Page 14: Welding Output Cables
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 neces- sary. Listed in Table A.1 are copper cable sizes recom- mended for the rated current and duty cycle. Lengths stipulated are the distance from the welder to work and back to the welder again. -
Page 15: Operating Instructions
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 provides 35 CFM at 100 PSI compressed air. The engine is a 63 Hp (47kw), 4-cylinder water cooled diesel made by Perkins. -
Page 16: Design Features And Advantages
The auxiliary power can be used continuously (100% duty cycle) within its rated current capacities. Total The air compressor is rated at a 60% duty cycle based Aux. on a ten minute period as described above. 2.25 0.75... - Page 17 Manually allows the engine to run at its high idle speed controlled by the governor or at the factory set low idle speed. When welding, using air compressor or using auxiliary power the speed control lever must be in the “RUN”...
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Page 18: Remote Control
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... -
Page 19: Engine Operation
Be sure all Pre-Operation Maintenance has been per- formed. (See INSTALLATION section of this manual). Set the air compressor “ON/OFF” switch in the “OFF” position. To start the engine, set the speed control lever in the “RUN” position. Place ignition toggle switch in the “ON”... -
Page 20: Duty Cycle
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 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 Stop engine before servicing Keep away from moving parts... - Page 22 Engine Air Filter Fan Belt Compressor Belt Fuel Filter Engine Oil Filter REPLACING AIR COMPRESSOR DRIVE BELT 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.
- Page 23 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.
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Page 24: Troubleshooting
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 25 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 26 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 27 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 28 WIRING DIAGRAMS SAE400 WELD’N AIR...
- Page 29 WIRING DIAGRAMS SAE400 WELD’N AIR...
- Page 30 DIMENSION PRINT SAE400 WELD’N AIR...
- Page 31 ® ® |_|_|_|_|_|_|_|_|_|_|_|_|_|_|_|_|_|_|_|_|_| Account No. USE THIS FORM TO ORDER: Order from: BOOK DIVISION, The Lincoln Electric Company, 22801 St. Clair Avenue, Cleveland, Ohio 44117-1199 BOOKS OR FREE INFORMATIVE CATALOGS Lincoln Welding School Titles: (ED-80) New Lessons in Arc Welding Seminar Information Procedure Handbook “Twelfth Edition”...
- Page 32 Do not touch electrically live parts or WARNING electrode with skin or wet clothing. Insulate yourself from work and ground. Spanish No toque las partes o los electrodos AVISO DE bajo carga con la piel o ropa moja- PRECAUCION Aislese del trabajo y de la tierra. French Ne laissez ni la peau ni des vête- ments mouillés entrer en contact...
- Page 33 Keep your head out of fumes. Turn power off before servicing. Use ventilation or exhaust to remove fumes from breathing zone. Los humos fuera de la zona de res- Desconectar el cable de ali- piración. mentación de poder de la máquina Mantenga la cabeza fuera de los antes de iniciar cualquier servicio.
- Page 34 • 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...