Lincoln Electric IM581 User's Manual
Contents
1. YJ HOLIMS N SSHHd TIO jo uee o eq ieureias end ue Aan iT rossardwog xeuee o 17e eurbug atqeeotazes ut queudtnbe TTY NOILOUIONd NIONS 53024002 92143 O13UO2 ayy a qybTq 13 D 410 pue epoii2e ATIYO jo HOLIMS NOILINSI SNOITLONYLSNI AONVNAINIVN WGELHWNV IVNIWHS3L NWO SLuvd IAO 185 pue Borger HOLVNHZITV eusqureu eui soueusqureu 440 remod eui uxni eoueuequreu uzogied ied T NINMSM HULINSI IHUVISONHSHI 1 ONIHSWT4 OL pm E pm pm pm HIV NOTAM 005 495 FHL 5 IVHNNS39 SIINN NO SuVduddV QV3T HALIN INTANT I IV N Q I4M 007 445 WVHOVIG SAE400 WELD N AIR LINCOLN E DIMENSION PRINT F 3 F 3 00 5410 VIG 69 SATOH VIG T8 6988lN V 00 8 gt 88 Mm BEER Ta2. ONTd Tao ILON ASTI uuMOd LESTA N3d SIOHNAS SWHIOVIdNONH HOLVNHHI IV aLIHM 5 ATOVIdHOAY NATAM O0 AVS HOLOH HOLVNHSWI IV SYOLSISHY WVHDOVIG MHHOS HOLISISSHH ONITHSVTA AOEC IVNIWHSI OL MOTTISA A ILIHM M Gqqu u NMOWGS N HOVTa 4 HO IOO SAE400 WELD N AIR F 2 WIRING DIAGRAMS F 2 Sjeued y euo uo eu episui pejsed si epoo 1e nonaed 10 au siy Aq paJ9A oo 5 10 9jenooe eq jou AjUO 89U918 91 10 S siu 3 ON dWnd NOIIOSDNI TANA rengen furieredo aes peppe SH lVHHdWul y eeg 1 3 st TTe3B1d se Tda SATVA 440 103 rengen SNISNS TT Lous TANA y ees HIOTO Ayme epu e BUT diTs 10 siojejnuuoo 1T einsseid eurqoeu y
3. CE Ne hoe T es A 2 SLACKING eet tuner foco Mie gast A 2 Angle of Operation siu sewer EE qu rRNA ETE E deb ai Awe A 2 Lifting s debi at WA ieee atur E wer A 2 High Altitude Operation A 3 TOWING s mbi Rowe eu wad athe io mee bid meet ewe ds A 3 Pre Operation Engine and Compressor Service A 3 Engine Oil o oia f tete pure sa Eee a eoe hgh ae de de ux A 3 Compressor Oll x IERI terere e RT RN eae A 3 a A 3 Engine Cooling System A 4 Battery Connection we ey SG eee ein nas ote ES watts A 4 Spark aise awe rb RR e eben ate he A ema evan hes A 4 Welding utput Cables 22350242 mex wer decode deed RO SEET A 5 Machine Grounding A 5 Operating Instructions Section B Safety Instr ctlons reti sem dba ee B 1 Additional Safety Precautions B 1 General Description ey due eos ir ens B 1 Recommended Applications B 1 WeId6r elu eae eoi CL eu uit RENE ewe B 1 Auxillary e EE eee ate B 1 Gompressed Air Poe we eas dette EE B 1 Design Features and Adv
4. RETURN TO MAIN MENU SAE400 WELD N AIR DL ARC WELDING POWER SOURCE AND 35 CFM AIR COMPRESSOR IM581 February 2000 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 most importantly think before you act and be careful This manual covers equipment which is obsolete and no longer in production by The Lincoln Electric Co Specifications and availability of optional features may have changed Date of Purchase Serial Number Code Number Model Where Purchased OPERATOR S MANUAL LINCOLN 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 SAFETY A WARNING CALIFORNIA PROPOSITION 65 WARNINGS A 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 defect
5. Code Quantity Cost Seminar Information ED 45 luames Lincoln Arc Welding Foundation Book Information JFLF 515 Educational Video Information ED 93 Procedure Handbook Twelfth Editor 1500 __ Howto Read Shop Drawings s50 H Incentive Management 590 i New Approach to Industrial Economics 5 00 Welding Preheat Calculator 93 00 WC 8 Pipe Weiding Chans 9450 oso _ CSCS OTT Aetna Shipping Costs if any a ee NA COS M qum gm eum mpeg pm um mm ua PE LINCOLN WARNING Spanish AVISO DE PRECAUCION French ATTENTION German WARNUNG Portuguese ATENC O Japanese it is BIR Korean Do not touch electrically live parts or electrode with skin or wet clothing Insulate yourself from work and ground No toque las partes los electrodos bajo carga con la piel ropa moja da Aislese del trabajo de la tierra Ne laissez ni la peau ni des v te ments mouill s entrer en contact avec des pi ces sous tension Isolez vous du travail et de la terre Ber hren Sie keine stromf hrenden Teile oder Elektroden mit Ihrem K rper oder feuchter Kleidung Isolieren Sie sich von den Elektroden und dem Erdboden toque partes el tricas e elec trodos com a pele ou
6. 40 Volts 7 27 L hr Auxiliary Power 96 gal hr 3000VA 3 63 L hr Air Compressor 1 04 gal hr 3 94 L hr 400 Amps 40 Volts Load 2 22 gal hr with Air Compressor ON 8 40 L hr Auxiliary Power 1 20 gal hr 3000 with 4 54 L hr Air Compressor ON SAE400 WELD N AIR LINCOLN P 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 for in plant and yard towing with E78 14 load range B tubeless tires Mounts directly to welder base K956 1 and 2 Trailer A 2 wheel trailer designed for road off road in plant and yard towing The K956 2 trailer is equipped with electric brakes Trailer mounts directly to welder base For highway use consult applicable federal state and local laws regarding possible requirements for brakes lights fenders etc Linc Thaw L2964 3 Includes meter and fuse to protect the welder when thawing frozen water pipes A WARNING Pipe Thawing IS NOT a CSA approved procedure If not done properly it can result in fire
7. ANSI Z87 standards Use suitable clothing made from durable flame resistant material to protect your skin and that of your helpers from the arc rays 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 3 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 Do not weld in locations near chlorinated hydrocarbon vapors coming from degreasing cleaning or spraying operations The heat and rays of the arc can react with solvent vapors to form phosgene a highly toxic gas and other irritating products Shielding gases used for arc welding can displace air and cause inju
8. 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 Model Name amp Number Code amp Serial Number Date of Purchase Whenever you request replacement parts for or information on this equipment always supply the information you have recorded above 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 A WARNING This statement appears where the information must be followed exactly to avoid serious personal injury or loss of life A CAUTION This statement appears where the information must be followed to avoid minor personal injury or damage to this equipment SAE400 WELD N AIR LINCOLN viii TABLE OF CONTENTS Page Installation Instructions Section A Technical Specifications A 1 Installation Precautions A 2 Location Ventilation sss eee qi ann GG
9. 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 position Push in the engine protection sys tem reset button 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 fac tory and should require no adjusting when received 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 A 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
10. Placing the ON OFF switch in the 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 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 SAE400 WELD N AIR LINCOLN B 5 OPERATION B 5 ENGINE OPERATION A 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
11. Porter des v tements convenables afin de prot ger la peau de soudeur et des aides contre le rayonnement de l arc c Prot ger l autre personnel travaillant proximit au soudage l aide d crans appropri s et non inflammables Des gouttes de laitier en fusion sont mises de l arc de soudage Se prot ger avec des v tements de protection libres de l huile tels que les gants en cuir chemise paisse pan talons sans revers et chaussures montantes Toujours porter des lunettes de s curit dans la zone de soudage Utiliser des lunettes avec crans lateraux dans les zones l on pique le laitier 6 Eloigner les mat riaux inflammables ou les recouvrir afin de pr venir tout risque d incendie aux tincelles Quand on ne soude pas poser la pince une endroit isol de la masse Un court circuit accidental peut provoquer un chauffement et un risque d incendie S assurer que la masse est connect e le plus pr s 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 loign s de la zone de travail on augmente le risque de voir passer le courant de soudage par les chaines de levage c bles de grue ou autres circuits Cela peut provoquer des risques d incendie ou d echauffement des chaines et des c bles jusqu ce qu ils se rompent Assurer une ventilation suffisante dans la zone de soudage Ceci est particuli rem
12. TOWING The recommended trailers for use with this equipment for in plant and yard towing by a vehicle are Lincoln s K767 1 K956 1 and K956 2 The K956 1 and K956 2 are also designed to be used at highway speeds If 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 consid ered 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 trailers 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 5 Proper preventative maintenance of trailer 6 Conformance with federal state and local laws For highway use consult applicable federal state and local laws regarding specific requirements for use on public highways such as brakes lights fend ers etc PRE OPERATION ENGINE AND COMPRESSOR SERVICE READ the engine and compressor operating and main tenance instructions supplied with this machine ENGINE OIL The WELD N AIR is shipped with the en
13. 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 com pressor instruction manuals GENERAL DESCRIPTION The SAE400 WELD N AIR is a diesel engine driven welding power source The machine uses a DC gen erator 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 provides 35 CFM at 100 PSI compressed air The engine is a 63 Hp 47kw 4 cylinder water cooled diesel made by Perkins RECOMMENDED APPLICATIONS WELDER The SAE400 WELD N AIR provides excellent constant current DC welding output for stick SMAW welding The field installed optional CV Adapter K385 1 pro vides up to 500 amps at 35 volts of constant voltage output for semiautomatic welding AUXILIARY POWER The SAE400 WELD N AIR provides 3 KW of 115 230 VAC output for auxiliary power and emergency stand by power COMPRESSED AIR The SAE400 WELD N AIR provides 35 CFM at 100 PSI compressed air for air arc gouging and air powered tools SAE400 WELD N AIR LINCOLN B 2 OPERATION B 2 DESIGN FEATURES AND ADVANTAGES FOR STICK WELDING Excellent DC constant current output for st
14. charged batteries and the proper weight oil the Thermostart system operates satisfactorily even down to about 0 F 18 C If the engine must be frequently started below 10 F 12 C it may be desirable to remove the Thermostart and install the optional ether starter kit Installation and operating instructions are included in the kit Use ether starting only when required because excessive use shortens engine life BREAK IN PERIOD ENGINE The engine used to supply power for your welder is a heavy duty industrial engine It is designed and built for rugged use It is very normal for any engine to use small quantities of oil until the break in is accom plished Check the oil level twice a day during the break in period about 100 running hours IMPORTANT IN ORDER TO ACCOMPLISH THIS BREAK IN THE UNIT SHOULD BE SUBJECTED TO HEAVY LOADS WITHIN THE RATING OF THE MACHINE AVOID LONG IDLE RUNNING PERIODS AIR COMPRESSOR 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 WELD N AIR for various operating scenarios is shown below Low ldle 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
15. generate high temperatures Do not touch or otherwise come in contact with A hot surfaces Doing so can cause Severe personal injury LINCOLN SAFETY PRECAUTIONS LISEZ CECI AVANT D OPERER VOTRE COMPRESSEUR DANGER UN RESERVOIR QUI EXPLOSE CAUSERA LA MORT BLESSURE SERIEUSE OU DES DOMMAGES DE MATERIAUX VIDER LE RESERVOIR A AIR APRES CHAQUE UTILISATION POUR PREVENIR UNE ACCUMULATION D HUMIDITE ET CORROSION QUI CAUSERA LA RUPTURE DU RESERVOIR S ASSURER QUE LES SOUPAPES DE PRESSION DE SURETE DU RESERVOIR SOIT REGLEES AUX NIVEAUX DE PRESSIONS APROPRIEES TAMAIS MODIFIER OU REPARER LE RESERVOIR A NE JAMAIS DEPLACER LE COMPRESSEUR AVEC UN RESERVOIR SOUS PRESSION NE PAS SUIVRE LES PROCEDURES D OPERATION ET D ENTRETIEN TELLES Q INDIQUEES DANS CE MANUEL POURRAIT RESULTER EN UN BRIS D EQUIPEMENT BLESSURE PERSONNELLE OU LA NE PAS UTILISER L AIR DU COMPRESSEUR POUR LA RESPIRATION OU LE TRAITEMENT D ALIMENTS L AIR DE CE COMPRESSEUR CAUSERA UNE SUIVEZ TOUTES LES PROCEDURES 4 D BLESSURE SEVERE OU LA MORT D ENTRETIEN AUX INTERVALLES S IL EST UTILISE POUR LA INDIQUEES RESPIRATION OU LE TRAITEMENT D ALIMENTS TOUTE OPERATION D ENTRETIEN DOIT ETRE EXECUTEE PAR UN PERSONNEL QUALIFIE UTILISANT LES OUTILS APPROPRIES LES TORQUES SPECIFIEES ET PIECES DE RECHANGE APPROUVEES L HUILE CHAUDE SOUS PRESSION PEUT CAUSER UNE BLESSURE SEVERE OU LA MORT ARRETEZ LE COMPRESSEUR LAISSEZ
16. have been cleaned For information purchase Recommended Safe Practices for the Preparation for Welding and Cutting of Containers and Piping That Have Held Hazardous Substances AWS F4 1 from the American Welding Society see address above Vent hollow castings or containers before heating cutting or welding They may explode Sparks and spatter are thrown from the welding arc Wear oil 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 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 LINCOLN za 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 Always keep cylinders in an upright position securely cha
17. in 28 00 in 83 00 in 2294 lbs 1273 3 mm 711 2 mm 2108 2 mm 1040 6 kg Based on a 10 minute period SAE400 WELD N AIR LINCOLN 2 INSTALLATION A 2 Read this entire installation section before you start installation SAFETY PRECAUTIONS A 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 TX 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 MOVING PARTS can injure Do not operate with doors open or N guards off Stop engine before servicing Keep away from moving parts Only qualified personnel should install use 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 STACKING SAE400 WELD N AIR machines cannot be stacked ANGLE OF OPERATION To achie
18. on generator Field rheostat may be making poor contact and overheating Current Control may not be operat ing properly Current Control brushholder con tact springs may be worn out or missing Contact surface may be dirty rough and pitted Current Control brushholder sup port stud and mating contact sur faces may be dirty or pitted and burned Engine running at varying speeds 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 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 sur face 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 weld ing check engine rpm The engine should be running at full speed If indicator shows a significant differ ence consult your engine manual CAUTION If for any reason you do not understand the
19. roupa molha da Isole se da pe a e terra OBRPORARR XU HIE E OKIMPT AMPSSEPBBE NTWSHELTFSU e An 945 MAIER d ECH e Siss ae iss gr BAA nisle e Su AXE Ys ole Juil L gone ell el all Quali el ai 1 ASI d o El laits aal dua ule Yile woe Keep flammable materials away Mantenga el material combustible fuera del rea de trabajo Gardez l cart de tout mat riel inflammable Entfernen Sie brennbarres Material Mantenha inflam veis bem guarda dos e naedoe6oolcosiTEX e i DAMM Nu AI Am AL Aal ane e Wear eye ear and body protection Prot jase los ojos los o dos y el cuerpo Prot gez vos yeux vos oreilles et votre corps Tragen Sie Augen Ohren und K r perschutz Use prote o para a vista ouvido e corpo e BH HRUBS ISUCREREUCT e AUR ez 119 Sal Soave s ESSAI dii due Al 5 usas cil gah ce aua g 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 COM PRENEZ LES INSTRUCTIONS DU FABRICANT CE QUI
20. 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 WELD N AIR LINCOLN E 3 TROUBLESHOOTING E 3 Observe all Safety Guidelines detailed throughout this manual PROBLEMS RECOMMENDED SYMPTOMS POSSIBLE CAUSE COURSE OF ACTION FUNCTION PROBLEMS Welder runs but fails to generate Generator or exciter brushes may belBe sure that all brushes bear on the current loose or missing commutator and have proper spring tension Exciter may not be operating Check exciter output voltage with voltmeter or lamp Field circuit of generator or exciter Check for open circuits in rheostat may be open field leads and field coils Also check resistors Polarity reversing switch may be in Put handle in positive or negative the neutral position position Exciter may have lost excitation Check components and continuity in flashing circuit Welding arc is loud and spatters Series field circuit may be open cir Check circuit with ringer or volt excessively cuited meter Current setting may be too high Check setting and current output with ammeter Polarity may be wrong 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 Lo
21. 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 25 ft 7 6 m of 3 conductor cord for adjusting the OCV at the welding site Putting the switch in the REMOTE position allows fine current control at the remote con trol 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 AUXILIARY POWER CONTROLS 115 VAC Receptacle One 15 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 15 AMP Circuit Breakers These circuit breakers provide separate overload cur rent protection for each half of the 115 V duplex recep tacle The circuit breakers provide overload current pro tection 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 pro cedure refer to Machine Grounding in the INSTALLA TION section of this manual AIR COMPRESSOR CONTROLS COMPRESSOR ON OFF SWITCH
22. REFROIDIR ET RELACHER LA PRESSION AVANT TOUT ENTRETIEN TOUTES COMPOSANTES ELECTRIQUES CABLES ELECTRIQUES DOIVENT ETRE INSTALLES ET MIS A LA TERRE EN CONFORMANCE AVEC NFPA LES REGLEMENTS DE SECURITE ELECTRIQUE LUBRIFIANT DU MANUFACTURIER NATIONAUX ET TOUT REGLEMENT DE REPAREZ TOUTE FUITE ET NETTOYEZ SECURITE PROVINCIAL ET LOCAL TOUT DEGAT D HUILE APPLICABLE IMMEDIATEMENT AVANT D ENLEVER UNE PROTECTION OU DE TRAVAILLER SUR LE COMPRESSEUR DEBRANCHER TOUTE LIGNE DE NE JAMAIS TROP REMPLIR D HUILE LE COMPRESSEUR UTILISER LA QUANTITE APPROPRIEE DE LE COMPRESSEURS PRODUISENT DES TEMPERATURES ELEVEES NE PAS TOUCHER OU FAIRE CONTACT AVEC S ET COURANT ALIMENTANT LE COPA ACHE es DM PANNEAUX D ADVERTISSEMENT ET PERSONELLES BARRER LES CIRCUITS ELECTRIQUES TOUTES PROTECTIONS MECANIQUE ET ELECTRIQUE DOIVENT ETRE EN POSITION ET SECURES AVANT ET PENDANT L OPERATION LINCOLN vi SAFETY vi PR CAUTIONS DE S RET Pour votre propre protection lire et observer toutes les instructions et les pr cautions de s ret specifiques qui parraissent dans ce manuel aussi bien que les pr cautions de s ret g n rales suiv antes S ret Pour Soudage A L Arc 1 Protegez vous contre la secousse lectrique a Les circuits l lectrode et la pi ce sont sous tension quand la machine souder est en marche Eviter toujours tout contact entre les parties sous tension et la peau nue ou le
23. REGARDE CET EQUIPMENT ET LES PRODUITS ETRE EMPLOYES ET SUIVEZ LES PROCEDURES DE SECURITE DE VOTRE EMPLOYEUR LESEN SIE UND BEFOLGEN SIE DIE BETRIEBSANLEITUNG DER ANLAGE UND DEN ELEKTRODENEINSATZ DES HER STELLERS DIE UNFALLVERHUTUNGSVORSCHRIFTEN DES ARBEITGEBERS SIND EBENFALLS ZU BEACHTEN SAE400 WELD N AIR LINCOLN gui Keep your head out of fumes Use ventilation or exhaust to remove fumes from breathing zone Los humos fuera de la zona de res piraci n e Mantenga la cabeza fuera de los humos Utilice ventilaci n o aspiraci n para gases Gardez la t te l cart des fum es Utilisez un ventilateur ou un aspira teur pour les fum es des zones de travail Vermeiden Sie das Einatmen von Schweibrauch Sorgen Sie f r gute Be und Entl ftung des Arbeitsplatzes e Mantenha seu rosto da fuma a Use ventilac o e exhaust o para remover fumo da zona respirat ria E1 APSMERTLSCLT 9 fsPBHEILTABSESUCFEU e c EUR Fa fE ik MAH SUIAB BeleHlAlg SHAE AAS get Loi 587E Assis Clea oe lue dll ai gU Gall bacs ja d aach Jg Mall oe Quad us Turn power off before servicing Desconectar el cable de ali mentaci n de poder de la m quina antes de iniciar cualquier servicio D branchez le courant avant l entre tien Strom vor Wartungsarbeiten absc
24. Section F Parts Det ilf SP SER P303 Series P25 L amp P78 D SAE400 WELD N AIR LINCOLN viii 1 INSTALLATION 1 TECHNICAL SPECIFICATIONS SAE400 WELD N AIR INPUT DIESEL ENGINE Make Model Description Speed RPM Displacement Starting Capacities System 4 cylinder High Idle 1800 236 cu in 12VDC batteries Fuel 22 5 gal 63 HP Low Idle 1100 3 87 L 2 amp Starter 85 1 L 1725 RPM Full Load 1725 Bore x Stroke Oil 8 5 Qts 8 04 1 3 875 x 5 00 98 4 mm x 127 0mm Coolant 3 6 gal 13 63 L RATED OUTPUT WELDER 6096 NEMA 400 amps 36 volts 6096 Lincoln Plus 400 amps 40 volts 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 OUTPUT AIR COMPRESSOR Make Model Description Delivery Tank Capacity amp Rating Operating Pressure Oil Capacity IMT 4 cylinder 35 CFM 11 Gallons Loads at 95 P S I 1 33 Quarts lowa Mold Reciprocating at 100 PS I 41 6 Liters 6 7 kg cm 1 26 Liters Tooling Diamond Water Cooled at 6096 Maximum Allowable Unloads at 125 P S I IMT s Air Pressure Lubricated Duty Cycle Working Pressure 8 8 kg cm Synthetic Aluminum Alloy 991 Liters min 150 PSI Compressor Model Block with Cast at 7 0 kg cm 10 5 kg cm Oil DA435ELW Iron sleeves PHYSICAL DIMENSIONS HEIGHT WIDTH DEPTH WEIGHT 50 13
25. WELD N AIR LINCOLN E 5 TROUBLESHOOTING E 5 Observe all Safety Guidelines detailed throughout this manual PROBLEMS RECOMMENDED SYMPTOMS POSSE Hn 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 Faulty connections to auxiliary Check connections receptacles 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 WELD N AIR LINCOLN F 1 WIRING DIAGRAMS Sjeued y JO euo uo SUIYOeW y episui pejsed si epoo 1e nonjed 10 ojroeds y siu Aq 10 N eq Jou uo 89U918 91 10 S siu ALON A0Sc vert G31VH pao 9 Ca NOM OL HOLIMS ALIWHV IOd do MATA MNOVG N Cg HOLIMS ALIHV IOd NOILISOd 001 NI NMOHS SLONSH HO TWOOT HO4 HOLIMS LOTS INNIWHSI GINOOHD 5 SHIONSWH SVO OL 3 AVI IVNIWNHHI a IVNIWHUIL Huddoo
26. antages B 2 Duty OyCcle e euet sri er th re aout xr bre B 2 Engine Controls Function Operation B 3 Welder Controls Function Operation B 3 Remote Control do aca i Eet B 4 Auxiliary Power Controls buen heeded tee i ue Es B 4 Air Compressor Controls B 4 Engine Operation ik dans exer ENS Envie ed B 5 Starting Instrictloris Ee dE e B 5 Break InPertod ue tee eod dex vu rampe dde e E TRO ee ales B 5 Typical Fuel Consumption B 5 Starting Welders with Dead Batteries B 9 Auxiliary FOWE teer eu re PIOS LDALP E LEES A B 9 Duty Cy Mc EL ETT E B 9 Starting Instructions ins x25 ER Dee beer RC e Ada te ge E B 9 Bieak In P riodes eee E RERO MEX E EE EE B 9 Accessorles 1 clle E wa kl dee etal ERG es Section C Maintenance 55 ite tate E EIS eer RE NR RUE RE Section D Routine Mamenang 2 44 mat eee RENI xe iesu tant D 1 Periodic Maintenance D 1 Troubleshooting Guide Section E Wiring Diagrams and Dimension Print
27. assembly and welding information to shop personnel Practical exercises and examples develop the reader s ability to visualize mechanically drawn objects as they will appear in their assembled form 187 pages with more than 100 illustrations Size 8 1 2 x 11 Durable cloth covered board binding 4 50 postage paid U S A Mainland New Lessons in Arc Welding Lessons simply written cover manipulatory techniques machine and electrode characteristics related subjects such as distortion and supplemental information on arc welding applications speeds and costs Practice materials exercises questions and answers are suggested for each lesson 528 pages well illustrated 6 x 9 size bound in simulated gold embossed leather 5 00 postage paid U S A Mainland Need Welding Training The Lincoln Electric Company operates the oldest and most respected Arc Welding School in the United States at its corporate headquarters in Cleveland Ohio Over 100 000 students have graduated Tuition is low and the training is hands on Lincoln Welding School 22801 St Clair Ave Cleveland Ohio 44117 1199 For details write and ask for bulletin ED 80 or call 216 383 2259 and ask for the Welding School Registrar Lincoln Welding School BASIC COURSE 700 00 5 weeks of fundamentals There is a 10 discount on all orders of 50 00 or more for shipment at one time to one location lOrders of 50 or less before discount or orders ou
28. cal Lincoln Authorized Field Service Facility for technical troubleshooting assistance before you proceed SAE400 WELD N AIR LINCOLN TROUBLESHOOTING Observe all Safety Guidelines detailed throughout this manual PROBLEMS RECOMMENDED SYMPTOMS POSSIBLE CAUSE COURSE OF ACTION Welding current too great or too FUNCTION PROBLEMS Current Control shaft and handle small compared to indication on the may have turned slightly in the insu dial Welder has output and no control lated bushing of the current control brushholder caused by turning han dle too hard against one of the stops Exciter output low causing low out put 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 With current control against the min imum 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 con trol 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
29. e Operators Manual for specific fuel recommendations NOTE Before starting the engine be sure the fuel shut off valve on the sediment bowl is open by turning the han dle counterclockwise SAE400 WELD N AIR LINCOLN 4 INSTALLATION 4 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 acid that can burn skin and damage eyes Remove and discard the insulating caps from the neg ative battery terminals Attach and tighten negative battery cable terminals NOTE This machine is furnished with wet charged 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 A WARNING GASES FROM BATTERY can explode e Keep sparks flame and cigarettes away from battery To prevent EXPLOSION when e INSTALLING A NEW BATTERY disconnect negative cable from old battery first and connect to new battery last e CONNECTING A BATTERY CHARGER remove battery from welder by disconnecting negative cable first then positive cable and battery clamp When reinstalling connect negativ
30. e cable last Keep well ventilated e USING A BOOSTER connect positive lead to battery first then connect negative lead to neg ative battery lead at the lower control panel support BATTERY ACID can burn eyes and co skin e Wear gloves and eye protection and be careful when working near battery e 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 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 loca tions where unarrested sparks may present a fire haz ard The standard muffler included with this welder does not qualify as a spark arrester When required by local regulations a suitable spark arrester must be installed and properly maintained A CAUTION An incorrect arrester may lead to damage to the engine or adversely affect performance Contact the engine manufacturer for specific recommendations SAE400 WELD N AIR LINCOLN 5 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
31. el supply runs out while the fuel pump is oper ating air may be entrapped in the fuel distribution sys tem If this happens bleeding of the fuel system may be necessary See the engine instruction manual FUEL SYSTEM WATER SEPARATOR MAINTENANCE If the fuel system on the engine is equipped with a water separator the following maintenance proce dures must be followed Inspect the glass bowl for any accumulation of water on a daily basis If water is present 1 Insure the fuel shut off valve is in the open position 2 Loosen the drain screw on the bottom of the bowl one to two turns or until water begins to flow Do not remove the screw completely 3 Drain until the water has visibly drained from the bowl and only clear fuel starts to flow from the drain valve 4 Close the drain screw tightly by hand Note Water and fuel should be drained into a suit able container for proper disposal COMPRESSOR AIR RECEIVER TANKS 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 re used 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 runnin
32. engine and allow it to cool before refuel ing 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 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 EMF fields may interfere with some pacemakers and welders having a pacemaker should consult their physician before welding 1 d Keep all equipment safety guards covers and devices in posi tion 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 Exposure to EMF fields in welding may have other health effects which are now not known All welders should use the following procedures in order to 1 e In some cases it may be necessary to remove safety ME minimize exposure to EMF fields from the welding circuit 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 2 d 1 Route the electrode and work cables together Secure them with tape when possible 2 d 2 Never coil the elec
33. ent important pour le soudage de t les galvanis es plomb es ou cadmi es ou tout autre m tal qui produit des fume s toxiques 10 Ne pas souder en pr sence de vapeurs de chlore provenant d op rations de d graissage nettoyage ou pistolage La chaleur ou les rayons de l arc peuvent r agir avec les vapeurs du solvant pour produire du phosg ne gas fortement toxique ou autres produits irritants 11 Pour obtenir de plus amples renseignements sur la s ret voir le code Code for safety in welding and cutting CSA Standard W 117 2 1974 PR CAUTIONS DE S RET POUR LES MACHINES SOUDER TRANSFORMATEUR ET REDRESSEUR 1 Relier la terre le chassis du poste conformement au code de l lectricit et aux recommendations du fabricant Le dispositif de montage ou la piece souder doit tre branch une bonne mise la terre Autant que possible l installation et l entretien du poste seront effectu s par un lectricien qualifi Avant de faires des travaux l interieur de poste la debranch er l interrupteur la boite de fusibles Garder tous les couvercles et dispositifs de s ret leur place SAE400 WELD N AIR LINCOLN for selecting a QUALITY product by Lincoln Electric We want you kont 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
34. erly in pulley grooves SAE400 WELD N AIR LINCOLN 5 E 1 TROUBLESHOOTING E 1 HOW TO USE TROUBLESHOOTING GUIDE A 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 For Air Compressor trouble shooting see the air compressor operator s manual For Engine trouble shooting see the engine operator s guide For Generator trouble shooting follow this guide This Troubleshooting Guide is provided to help you locate and repair possible machine malfunctions Simply follow the three step procedure listed Step 1 LOCATE PROBLEM SYMPTOM Look under the column labeled PROBLEM SYMPTOMS This column describes pos sible symptoms that the machine may exhib it 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 possibili ties that may contribute to the machine symptom Step 3 RECOMMENDED COURSE OF ACTION This column provides a course of action for the Possible Cause If you do not understand or are unable to perform the Recommended Course of Action safely contact
35. explosion damage to wiring which may make it unsafe dam age to pipes burning up the welder or other haz ards IMPORTANT DO NOT USE A WELDER TO THAW 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 K385 1 CV Adapter Provides constant voltage output for semiautomatic welding Field installation only SAE400 WELD N AIR LINCOLN D 1 MAINTENANCE D 1 A WARNING e ELECTRIC SHOCK can kill e Do not touch electrically live parts such as output terminals or inter nal wiring ENGINE EXHAUST can kill e Use in open well ventilated areas or vent exhaust outside MOVING PARTS can injure e Do not operate with doors open or guards off e Stop engine before servicing e Keep away from moving parts e Remove guards only when necessary and replace when work requiring removal is com plete e 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 run ning out of fuel tends to draw dirt into the fuel system Check the engine crankcase and compressor oil levels If the fu
36. g 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 pres sure 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 recom mended 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 com pressor maintenance information Change the compres sor oil at regular intervals using only lowa 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 oper ation Check the cooling fan belt and tighten if necessary DO NOT OVER TIGHTEN The compressor belt does not require any adjustme
37. gine 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 Operators Manual for the proper ser vice and maintenance intervals AIR COMPRESSOR OIL D The WELD N AIR is shipped with the compressor filled with a high quality synthetic compressor oil If oil is needed add only lowa Mold Tooling Co Inc IMT syn thetic compressor oil until compressor is full CAUTION 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 mainte nance intervals FUEL USE DIESEL FUEL ONLY m A WARNING Stop engine and allow to cool before fueling Do not smoke when fueling Fill fuel tank at a moderate rate and do not overfill Wipe up spilled fuel and allow fumes to clear before starting engine Keep sparks and flame away from tank Fill the fuel tank with clean fresh diesel fuel The capac ity of the fuel tank is 22 5 gallons 85 1 liters See engin
38. gs 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 pig tail 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 commu tator 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 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 pres sure 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 COOLING SYSTEM The SAE400 WELD N AIR i
39. halten Netzstrom v llig ff nen Maschine anhalten opere com as tampas removidas Desligue a corrente antes de fazer servico toque as partes el tricas nuas e X7TTLA UACNRUD PSB ETBRAL VY FE FAITE e HFA ER Au lt phd NM Jl ele Do not operate with panel open guards off No operar con panel abierto o guardas quitadas N op rez pas avec les panneaux ouverts ou avec les dispositifs de protection enlev s Anlage nie ohne Schutzgeh use oder Innenschutzverkleidung in Betrieb setzen Mantenha se afastado das partes moventes N o opere com os paineis abertos ou guardas removidas e RJAOLZ5S ERUALTE EE LKE KEN IE eggo gel HUE Gals D dali lin Jio de Aale Cut Al al Ayal Spanish AVISO DE PRECAUCION French ATTENTION German WARNUNG Portuguese ATENC O ZS BIR Chinese LEIA E COMPREENDA AS INSTRU ES DO FABRICANTE PARA ESTE EQUIPAMENTO E AS PARTES DE USO E SIGA AS PRATICAS DE SEGURANCA DO EMPREGADOR SRM OBO X A OBRBCE lt BA RT AL RES EE BA SR SE SEE ST 77 BO EL OR AO ool SASA HA Seil CRIS EPEAT HHCH eal canal ll Cat atl y d al SO ag l
40. ick weld ing 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 15 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 with in the limits shown on the chart below Welding Current Amps NEMA Arc Volts Using Only 230V Circuit Amps Using Only 115V Circuit Amps 0 26 13 100 9 75 200 6 5 FOR COMPRESSED AIR 35 CFM at 100 PSI for air arc gouging and air pow ered tools 11 Gallon air receiver tank system with integral over pressure relief valve for smooth air delivery No welding output derating required at maximum compressor load OTHER FEATURES Perkins 4 cylinder water cooled diesel engine Designed for long life easy maintenance and excel lent fuel economy Engine protection system shuts the engine down for low oil pressure or high coolant temperature Gauges for engine oil pressure coolant temperature battery charging ammeter compressor air pressure and compressor oil pressure Indicator light for compressor operation Engine hour meter standard Extended range 22 5 gallon 85 1 L fuel tank DUTY CYCLE Duty cycle is based on a ten minute per
41. ined to an undercarriage or fixed support Oylinders should be located Away from areas where they may be struck or subjected to physical damage safe distance from arc welding or cutting operations and any other source of heat sparks or flame Never allow the electrode electrode holder or any other electrically hot parts to touch a cylinder Keep your head and face away from the cylinder valve outlet when opening the cylinder valve Valve protection caps should always be in place and hand tight except when the cylinder is in use or connected for use Read and follow the instructions compressed gas cylinders associated equipment and CGA publication PL 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 Install equipment in accordance with the U S National Electrical Code all local codes and the manufacturer s recommendations Ground the equipment in accordance with the U S National Electrical Code and the manufacturer s recommendations SAFETY WARNING Read before operating your compressor Failure to follow operating and maintenance procedures as outlined in this manual could result in equipment damage pe
42. ing 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 WELD N AIR LINCOLN B 1 OPERATION B 1 OPERATING INSTRUCTIONS Read and understand this entire section before operat ing your SAE400 WEI DN AIR SAFETY INSTRUCTIONS 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 oper ating and maintenance instructions and parts lists e 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 9 CS x Do not operate with doors open or N guards off not stack anything near the engine MOVING PARTS can injure Stop engine before servicing Keep away from moving parts Only qualified personnel should operate this equipment ADDITIONAL SAFETY PRECAUTIONS Always operate the welder with the hinged doors closed as these provide maximum protection from moving parts
43. iod and opera tion in an ambient temperature of 104 F 40 C The SAE400 WELD N AIR is 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 10096 duty cycle within its rated current capacities The air compressor is rated at a 6096 duty cycle based on a ten minute period as described above SAE400 WELD N AIR LINCOLN 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 SPEED CONTROL LEVER 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 position To reduce the engine to low idle speed when not welding not using the compressor or not using auxiliary power place the speed control lever in the IDLE position notch 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 w
44. ithin 30 seconds stop the engine and consult the engine instruction manual BATTERY 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 batter ies are low on charge 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 ENGINE PROTECTION SYSTEM The engine protection system shuts down the engine under high coolant temperature or low engine oil pres sure 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 sec tions providing OCV ranges as follows Large Electrodes High OCV Medium OCV Low OCV Extra Low OCV Normal Welding Overhead amp Vertical Special Applications The Job Selector is usually set in the black range because it provides a soft Butte
45. mended 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 Up to 100 100 200 FT 200 250 FT 06096 FT 2 0 ANG 3 0 AWG 4 0 AWG Duty Cycle 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 INSTALLATION 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 con nected 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 hav
46. na ON Ing ANIONS NI TIO HLIM La OO LL ALIAWUD 40 cr da SL 69 P x nert Y 00 9 A ay i E os st Lei 8 6 69 6E ETOS l Y t sz heUZE xl SL Y gt 90 9 ra GW w CT EE SAE400 WELD N AIR LINCOLN E Now Available 12th Edition The Procedure Handbook of Arc Welding With over 500 000 copies of previous editions published since 1933 the Procedure Handbook is considered by many to be the Bible of the arc welding industry This printing will go fast so don t delay Place your order now using the coupon below The hardbound book contains over 750 pages of welding infor mation techniques and procedures Much of this material has never been included in any other book A must for all welders supervisors engineers and designers Many welding instructors will want to use the book as a reference for all students by taking advantage of the low quan tity discount prices which include shipping 4th class parcel post 15 00 postage paid U S A Mainland How To Read Shop Drawings The book contains the latest information and application data on the American Welding Society Standard Welding Symbols Detailed discussion tells how engineers and drafts men use the short cut language of symbols to pass on
47. neeling 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 In semiautomatic or automatic wire welding the electrode electrode reel welding head nozzle or semiautomatic welding gun are also electrically hot 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 Ground the work or metal to be welded to a good electrical earth ground Maintain the electrode holder work clamp welding cable and welding machine in good safe operating condition Replace damaged insulation Never dip the electrode in water for cooling 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 When working above floor level use a safety belt to protect yourself from a fall should you get a shock Also see Items 6 c and 8 LINCOLN Also see item 1 b ARC RAYS can burn 4 a Use a shield with the proper filter and cover 2 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
48. nt SAE400 WELD N AIR LINCOLN 5 D 2 MAINTENANCE D 2 BEARING MAINTENANCE This welder is equipped with a double shielded ball bearing having sufficient grease to last indefinitely under normal ser vice 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 COMMUTATOR AND BRUSH MAINTENANCE A 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 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 rin
49. ring 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 indi cated on the black scale of the Current Control dial SAE400 WELD N AIR LINCOLN 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 f you want a little more current turn the Job Selector up counterclockwise to increase cur rent If you want a little less current turn the Job Selector down clockwise to decrease current 5 f 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
50. rsonal injury or death Follow all maintenance procedures and intervals Maintenance must be performed only by trained and qualified personnel using correct tools specified torques and approved replacement parts All electrical components and cable wiring must be installed and grounded in accordance with NFPA national electrical codes and applicable state and local codes Before removing guards or servicing the compressor disconnect all power supplies Display warning signs and lock out electrical circuits All guards must be in position and secure before and during operation qe Ww wv P 4 DANGER EXPLODING TANK WILL CAUSE DEATH SERIOUS INJURY OR PROPERTY DAMAGE Drain air tank after each use to prevent moisture build up and corrosion which leads to tank failure 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 Do not use air from this compressor for breathing or food processing Air from this compressor will cause severe injury or death if used for breathing or food processing Hot oil under pressure can cause severe injury or death Shut down let cool and relieve pressure in compressor before servicing Do not overfill the compressor with oil Use correct quantity of manufacturer s lubricant Repair leaks and clean spills immediately Compressors
51. ry or death Always use enough ventilation especially in confined areas to insure breathing air is safe 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 Mar 95 SAFETY US WELDING SPARKS can lt gt 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 Avoid welding near hydraulic lines Have a fire extinguisher readily available 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 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 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 though they
52. s 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 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 pur chase a copy of Safety in Welding amp Cutting ANSI Standard 249 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 FOR ENGINE powered equipment 1 a Turn the engine off before troubleshooting and maintenance work unless the maintenance work requires it to be running 23 SX 1 h To avoid scalding do not remove the radiator pressure cap when the engine is hot 1 b Operate engines in open well ventilated areas or vent the engine exhaust fumes outdoors ELECTRIC AND 3 MAGNETIC FIELDS S may be dangerous 1 c Do not add the fuel near an open flame weld ing arc or when the engine is running Stop the
53. s equipped with a pressure radiator Keep the radiator cap tight to prevent loss of coolant Clean and flush the cooling system periodi cally to prevent clogging the passage and overheating the engine When antifreeze is needed always use the permanent type ENGINE AND COMPRESSOR MAINTENANCE COMPONENTS ITEM MAKE PART NUMBER P181052 Engine Air Filter Fan Belt 519730 Compressor Belt Lincoln 523887 Gates 2 A40 Perkins 26561117 Perkins 2654403 Fuel Filter Engine Oil Filter REPLACING AIR COMPRESSOR DRIVE BELT 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 ten sioner 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 pul ley 2 Using a pipe wrench or suitable tool turn idler body to realign locking slot in idler flange with lock ing hole Insert locking bolt and tighten before releasing idler body Tighten center mounting bolt Note Ensure that both belt strands are running prop
54. s gaai SAE400 WELD N AIR LINCOLN gui LINCOLN World s Leader Welding and Cutting Products Sales and Service through Subsidiaries and Distributors Worldwide Cleveland Ohio 44117 1199 U S A TEL 216 481 8100 216 486 1751 WEB SITE www lincolnelectric com
55. s v tements mouill s Porter des gants secs et sans trous pour isoler les mains Faire tr s attention de bien s isoler de la masse quand on soude dans des endroits humides ou sur un plancher met allique ou des grilles metalliques principalement dans les positions assis ou couch pour lesquelles une grande partie du corps peut tre en contact avec la masse Maintenir le porte lectrode la pince de masse le c ble de soudage et la machine souder en bon et s r tat defonc tionnement d Ne jamais plonger le porte lectrode dans l eau pour le refroidir Ne jamais toucher simultan ment les parties sous tension des porte lectrodes connect s deux machines soud er parce que la tension entre les deux pinces peut tre le total de la tension vide des deux machines Si on utilise la machine souder comme une source de courant pour soudage semi automatique ces precautions pour le porte lectrode s applicuent aussi au pistolet de soudage 2 Dans le cas de travail au dessus du niveau du sol se prot ger contre les chutes dans le cas ou on recoit un choc Ne jamais enrouler le c ble lectrode autour de n importe quelle partie du corps Un coup d arc peut tre plus s v re qu un coup de soliel donc a Utiliser un bon masque avec un verre filtrant appropri ainsi qu un verre blanc afin de se prot ger les yeux du ray onnement de l arc et des projections quand on soude ou quand on regarde l arc b
56. trode lead around your body 1 f Do not put your hands near the engine fan Do e not attempt to override the governor or idler by pushing on the throttle control rods while the engine is running 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 2 4 4 Connect the work cable to the workpiece as close as possible to the area being welded 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 5 Do not work next to welding power source Mar 95 LINCOLN 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 k
57. tside of North America must be prepaid with charge check or money order in U S Funds Only l IPrices include shipment by 4thClass Book Rate for U S A Mainland Only Please allow up to 4 weeks for delivery IUPS Shipping for North America Only All prepaid orders that request UPS shipment please add 5 00 For order value up to 49 99 10 00 15 00 For North America invoiced orders over 550 00 amp credit card orders if UPS is requested it will be invoiced charged to you at cost Outside U S A Mainland order must be prepaid in U S Funds Please add 2 00 per book for surface mail or 15 00 per book for air parcel post shipment METHOD OF PAYMENT Sorry No C O D Orders Name CHECKONE Andes Please Invoice only if order is over 50 00 Check or Money Order Enclosed U S Funds only 1 Credit Card ww oS Telephone Kg No Eil E qe p en sp spen OP Exp Date Wd mE Signature as it appears on Charge Card onth Year USE THIS FORM TO ORDER nos OR FREE INFORMATIVE CATALOGS li Welding School Titles ED 80 For order value between 50 00 amp 99 99 For order value between 100 00 amp 149 00 Order from BOOK DIVISION The Lincoln Electric Company 22801 St Clair Avenue Cleveland Ohio 44117 1199 Telephone 216 383 2211 or for fastest service FAX this completed form to 216 361 5901 New Lessons in Arc Welding 5 00 Price
58. ve 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 The maximum angle of operation for the Perkins engine is 45 degrees in all directions If the engine is to be oper ated at an angle provisions must be made for check ing 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 LIFTING The SAE400 WELD N AIR lift bale should be used to lift the machine A WARNING FALLING EQUIPMENT can cause injury Do not lift this machine using lift bale if itis equipped with a heavy accessory such as a trailer or gas cylinder Lift only with equipment of adequate lifting capacity Be sure machine is stable when lifting SAE400 WELD N AIR LINCOLN 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 596 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
59. you local Lincoln Authorized Field Service Facility A WARNING 0 ELECTRIC SHOCK can kill e Do not touch electrically live parts such as output terminals or internal wiring amp ENGINE EXHAUST can kill qA Use in open well ventilated areas or vent exhaust outside i Stop engine before servicing 4 MOVING PARTS can injure x Do not operate with doors open or guards off NY gt Keep away from moving parts e 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 are unable to perform the tests repairs safely contact your Local Lincoln Authorized Field Service Facility for technical troubleshooting assistance before you proceed SAE400 WELD N AIR LINCOLN 5 2 TROUBLESHOOTING E 2 Observe all Safety Guidelines detailed throughout this manual PROBLEMS RECOMMENDED SYMPTOMS POSSIBLE CAUSE COURSE OF ACTION Machine fails to hold the heat constantly 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 resis tance connections or intermittent open circuit due to loose connec tions or broken wire Electrode or work lead connections may be poor Wrong grade of brushes may be installed
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