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IM581
SAE400 WELDÕN AIR - DC ARC WELDING POWER
February, 2000
SOURCE AND 35 CFM AIR COMPRESSOR
For use with machines having Code Number 10362
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, m
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i i SAFETY WARNING CALIFORNIA PROPOSITION 65 WARNINGS Diesel engine exhaust and some of its constituents The engine exhaust from this product contains are known to the State of California to cause can- chemicals known to the State of California to cause cer, birth defects, and other reproductive harm. cancer, birth defects, or other reproductive harm. The Above For Diesel Engines The Above For Gasoline Engines ARC WELDING CAN BE HAZARDOUS. PROTECT YOURSELF AND OTHERS FROM POSSIBLE SERIOUS INJURY
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ii ii SAFETY ELECTRIC SHOCK can kill. ARC RAYS can burn. 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” parts with your bare the rays of the arc when welding or observing skin or wet clothing. Wear dry, hole-free open arc welding. Headshield and filter lens gloves to insulate hands. should conform to ANSI Z87. I standards. 3.b. In
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iii iii 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 gas cylinders If this is not possible, cover them to prevent containing the correct shielding gas for the the welding sparks from starting a fire. process used and properly operating Remember that welding sparks and hot regulators designed for the gas and materials from welding can easily go through small cracks pressure used. All hos
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iv iv 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.
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v v SAFETY
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vi vi 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. Quand on ne soude pas, poser la pince à une endroit isolé de manuel aussi bien que les précautions de sûreté générales suiv- la masse. Un court-circuit accidental peut provoquer un antes: échauffement et un risqu
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vii vii for selecting a QUALITY product by Lincoln Electric. We want you to take pride in operating this Lincoln Electric Company product ••• Thank You 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 ship
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viii viii TABLE OF CONTENTS Page Installation Instructions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Section A Technical Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .A-1 Installation Precautions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A-2 Location / Ventilation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
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A-1 A-1 INSTALLATION TECHNICAL SPECIFICATIONS - SAE400 WELD’N AIR 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) & Starter 85.1 L Engine 1725 RPM Full Load 1725 Bore x Stroke Oil: 8.5 Qts. 8.04 L 3.875” x 5.00” (98.4 mm x 127.0mm) Coolant: 3.6 gal. 13.63 L RATED OUTPUT - WELDER (1) Duty Cycle Welding Output Volts at Rat
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A-2 A-2 INSTALLATION Read this entire installation section before you STACKING start installation. SAE400 WELD’N AIR machines cannot be stacked. SAFETY PRECAUTIONS ANGLE OF OPERATION WARNING To achieve optimum engine performance the SAE400 Do not attempt to use this equipment until you have WELD’N AIR should be run in a level position. The thoroughly read all operating and maintenance man- maximum angle of operation for the air compressor is uals supplied with your machine. They include imp
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A-3 A-3 INSTALLATION HIGH ALTITUDE OPERATION ENGINE OIL At higher altitudes, output derating may be necessary. The WELD’N AIR is shipped with the engine crankcase filled with high quality SAE 10W-30 oil (API class CD or As a rule of thumb, derate the welder output 5% for better). Check the oil level before starting the engine. If it every 500 meters (1640 ft.) above 1000 meters (3280 is not up to the full mark on the dip stick, add oil as ft.). required. Check the oil level every four hours
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A-4 A-4 INSTALLATION To prevent BATTERY BUCKLING, tighten nuts on bat- ENGINE COOLING SYSTEM 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. (See Engine Manual or antifreeze con- Some federal, state or local laws may require that tainer for alternate antifreeze recommendation.) gasoline or diesel engines be equip
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A-5 A-5 INSTALLATION WELDING OUTPUT CABLES To prevent dangerous electric shock, other equipment With the engine off, connect the electrode and work cables to the studs provided. These connections powered by this engine driven welder must: should be checked periodically and tightened if neces- sary. a) be grounded to the frame of the welder using a grounded type plug, Listed in Table A.1 are copper cable sizes recom- or mended for the rated current and duty cycle. Lengths b) be double insul
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B-1 B-1 OPERATION OPERATING INSTRUCTIONS GENERAL DESCRIPTION Read and understand this entire section before operat- The SAE400 WELD’N AIR is a diesel engine driven ing your SAE400 WELD’N AIR. welding power source. The machine uses a DC gen- erator for DC stick electrode welding and an AC exciter SAFETY INSTRUCTIONS for 115/230 VAC auxiliary power. As a generator it can supply up to 3,000 watts of 115/230 volt AC power. As WARNING a welder it provides up to 575 amps of DC constant current output.
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B-2 B-2 OPERATION • Gauges for engine oil pressure, coolant temperature, DESIGN FEATURES AND ADVANTAGES battery charging ammeter, compressor air pressure and compressor oil pressure. FOR STICK WELDING • Excellent DC constant current output for stick weld- • Indicator light for compressor operation. ing applications. • Engine hour meter standard. • Continuous adjustment of both voltage and current for unsurpassed welds on demanding jobs. • Extended range 22.5 gallon (85.1 L) fuel tank. • Remote
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B-3 B-3 OPERATION ENGINE CONTROLS WELDER CONTROLS IGNITION SWITCH POLARITY SWITCH When placed in the “ON” position, this switch energizes Turn the Arc Polarity switch to electrode positive or the fuel solenoid. When placed in the “OFF” position, electrode negative as required for each particular the flow of fuel to the injection pump is stopped to shut application. down the engine. CONTROL OF WELDING CURRENT SPEED CONTROL LEVER Purpose of Controls Manually allows the engine to run at its high id
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B-4 B-4 OPERATION How to Set the Controls 15 AMP Circuit Breakers Assume you want a normal soft arc and about 135 These circuit breakers provide separate overload cur- amps, using a 5/32” (4.0 mm) electrode: rent protection for each half of the 115 V duplex recep- tacle. The circuit breakers provide overload current pro- 1. Set the “Job Selector” at the center of the black tection in both current carrying wires of the 230 V range. duplex receptacle. 2. Set the “Current Control” to read 135 amps
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B-5 B-5 OPERATION BREAK-IN PERIOD ENGINE OPERATION 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 as this will overspeed heavy duty, industrial engine. It is designed and built the air compressor and void it’s warranty. for rugged use. It is very normal for any engine to use ------------------------------------------------------------------------ small quantities of oil until the break-in
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C-1 C-1 ACCESSORIES K799 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-C Power Plug Kit - Kit includes male plugs for each auxiliary receptacle. K805-1 Ether Start Kit - Injects ether for starting aid. Recommended only when engines are frequently started at temperatures under 10°F (-12°C). Ether cylinder is not included. K767-1 Trailer - A 4-wheel steerable trailer
