Lincoln Electric Welding System IM640 A User Manual
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IM640-A  
SAE400 & SAE400 WELD’N AIR -  
DC ARC WELDING POWER SOURCE  
For use with machines having Code Numbers: 10601, 10602, 10884, 10885  
May, 2004  
Safety Depends on You  
Lincoln arc welding and cutting  
equipment is designed and built with  
safety in mind. However, your overall  
safety can be increased by proper  
installation ... and thoughtful opera-  
tion on your part. DO NOT  
INSTALL, OPERATE OR REPAIR  
THIS EQUIPMENT WITHOUT  
READING THIS MANUAL AND  
THE SAFETY PRECAUTIONS  
CONTAINED  
THROUGHOUT.  
And, most importantly, think before  
you act and be careful.  
R
OPERATOR’S MANUAL  
Copyright © 2004 Lincoln Global Inc.  
• World's Leader in Welding and Cutting Products •  
• Sales and Service through Subsidiaries and Distributors Worldwide •  
Cleveland, Ohio 44117-1199 U.S.A. TEL: 216.481.8100 FAX: 216.486.1751 WEB SITE: www.lincolnelectric.com  
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SAFETY  
ARC RAYS can burn.  
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.  
4.a. Use a shield with the proper filter and cover  
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 ANSI Z87. I standards.  
4.b. Use suitable clothing made from durable flame-resistant  
material to protect your skin and that of your helpers from  
the arc rays.  
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.  
4.c. 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.  
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,  
kneeling or lying, if there is a high risk of unavoidable or  
accidental contact with the workpiece or ground) use  
the following equipment:  
FUMES AND GASES  
can be dangerous.  
5.a. Welding may produce fumes and gases  
hazardous to health. Avoid breathing these  
• Semiautomatic DC Constant Voltage (Wire) Welder.  
• DC Manual (Stick) Welder.  
• AC Welder with Reduced Voltage Control.  
fumes and gases.When welding, keep  
your head out of the fume. Use enough  
ventilation and/or exhaust at the arc to keep  
3.c. In semiautomatic or automatic wire welding, the electrode,  
electrode reel, welding head, nozzle or semiautomatic  
welding gun are also electrically “hot”.  
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.  
3.d. 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.  
3.e. Ground the work or metal to be welded to a good electrical  
(earth) ground.  
3.f. Maintain the electrode holder, work clamp, welding cable and  
welding machine in good, safe operating condition. Replace  
damaged insulation.  
5.b. 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.  
3.g. Never dip the electrode in water for cooling.  
3.h. 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.  
5.c. Shielding gases used for arc welding can displace air and  
cause injury or death. Always use enough ventilation,  
especially in confined areas, to insure breathing air is safe.  
3.i. When working above floor level, use a safety belt to protect  
yourself from a fall should you get a shock.  
5.d. 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.  
3.j. Also see Items 6.c. and 8.  
5.e. Also see item 1.b.  
Mar ‘95  
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SAFETY  
WELDING SPARKS can  
cause fire or explosion.  
CYLINDER may explode  
if damaged.  
6.a. Remove fire hazards from the welding area.  
If this is not possible, cover them to prevent  
7.a. Use only compressed gas cylinders  
containing the correct shielding gas for the  
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.  
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.  
7.b. Always keep cylinders in an upright position securely  
chained to an undercarriage or fixed support.  
6.b. 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.  
7.c. Cylinders should be located:  
•Away from areas where they may be struck or subjected to  
physical damage.  
6.c. 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.  
•A safe distance from arc welding or cutting operations and  
any other source of heat, sparks, or flame.  
7.d. Never allow the electrode, electrode holder or any other  
electrically “hot” parts to touch a cylinder.  
6.d. 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 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).  
7.e. Keep your head and face away from the cylinder valve outlet  
when opening the cylinder valve.  
7.f. Valve protection caps should always be in place and hand  
tight except when the cylinder is in use or connected for  
use.  
7.g. Read and follow the instructions on compressed gas  
cylinders, associated equipment, and CGA publication P-l,  
“Precautions for Safe Handling of Compressed Gases in  
Cylinders,” available from the Compressed Gas Association  
1235 Jefferson Davis Highway, Arlington, VA 22202.  
6.e. Vent hollow castings or containers before heating, cutting or  
welding. They may explode.  
6.f. 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.  
FOR ELECTRICALLY  
powered equipment.  
6.g. 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.  
8.a. Turn off input power using the disconnect  
switch at the fuse box before working on  
the equipment.  
8.b. Install equipment in accordance with the U.S. National  
Electrical Code, all local codes and the manufacturer’s  
recommendations.  
6.h. Also see item 1.c.  
8.c. Ground the equipment in accordance with the U.S. National  
Electrical Code and the manufacturer’s recommendations.  
Mar ‘95  
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SAFETY  
zones où l’on pique le laitier.  
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  
manuel aussi bien que les précautions de sûreté générales suiv-  
antes:  
7. Quand on ne soude pas, poser la pince à une endroit isolé de  
la masse. Un court-circuit accidental peut provoquer un  
échauffement et un risque d’incendie.  
Sûreté Pour Soudage A L’Arc  
1. Protegez-vous contre la secousse électrique:  
8. S’assurer que la masse est connectée le plus prés 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  
éloignés de la zone de travail, on augmente le risque de voir  
passer le courant de soudage par les chaines de levage,  
câbles de grue, ou autres circuits. Cela peut provoquer des  
risques d’incendie ou d’echauffement des chaines et des  
câbles jusqu’à ce qu’ils se rompent.  
a. Les circuits à l’électrode et à la piéce sont sous tension  
quand la machine à souder est en marche. Eviter toujours  
tout contact entre les parties sous tension et la peau nue  
ou les vétements mouillés. Porter des gants secs et sans  
trous pour isoler les mains.  
b. Faire trés 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 couché pour lesquelles une grande  
partie du corps peut être en contact avec la masse.  
c. Maintenir le porte-électrode, la pince de masse, le câble de  
soudage et la machine à souder en bon et sûr état defonc-  
tionnement.  
9. Assurer une ventilation suffisante dans la zone de soudage.  
Ceci est particuliérement important pour le soudage de tôles  
galvanisées plombées, ou cadmiées ou tout autre métal qui  
produit des fumeés toxiques.  
10. Ne pas souder en présence de vapeurs de chlore provenant  
d’opérations de dégraissage, nettoyage ou pistolage. La  
chaleur ou les rayons de l’arc peuvent réagir avec les vapeurs  
du solvant pour produire du phosgéne (gas fortement toxique)  
ou autres produits irritants.  
d.Ne jamais plonger le porte-électrode dans l’eau pour le  
refroidir.  
e. Ne jamais toucher simultanément les parties sous tension  
des porte-électrodes connectés à deux machines à soud-  
er parce que la tension entre les deux pinces peut être le  
total de la tension à vide des deux machines.  
11. Pour obtenir de plus amples renseignements sur la sûreté, voir  
le code “Code for safety in welding and cutting” CSA Standard  
W 117.2-1974.  
f. Si on utilise la machine à souder comme une source de  
courant pour soudage semi-automatique, ces precautions  
pour le porte-électrode s’applicuent aussi au pistolet de  
soudage.  
2. Dans le cas de travail au dessus du niveau du sol, se protéger  
contre les chutes dans le cas ou on recoit un choc. Ne jamais  
enrouler le câble-électrode autour de n’importe quelle partie  
du corps.  
PRÉCAUTIONS DE SÛRETÉ POUR  
LES MACHINES À SOUDER À  
TRANSFORMATEUR ET À  
REDRESSEUR  
3. Un coup d’arc peut être plus sévère qu’un coup de soliel,  
donc:  
a. Utiliser un bon masque avec un verre filtrant approprié  
ainsi qu’un verre blanc afin de se protéger les yeux du ray-  
onnement de l’arc et des projections quand on soude ou  
quand on regarde l’arc.  
b. Porter des vêtements convenables afin de protéger la  
peau de soudeur et des aides contre le rayonnement de  
l‘arc.  
1. Relier à la terre le chassis du poste conformement au code de  
l’électricité et aux recommendations du fabricant. Le dispositif  
de montage ou la piece à souder doit être branché à une  
bonne mise à la terre.  
2. Autant que possible, I’installation et l’entretien du poste seront  
effectués par un électricien qualifié.  
c. Protéger l’autre personnel travaillant à proximité au  
soudage à l’aide d’écrans appropriés et non-inflammables.  
3. Avant de faires des travaux à l’interieur de poste, la debranch-  
er à l’interrupteur à la boite de fusibles.  
4. Des gouttes de laitier en fusion sont émises de l’arc de  
soudage. Se protéger avec des vêtements de protection libres  
de l’huile, tels que les gants en cuir, chemise épaisse, pan-  
talons sans revers, et chaussures montantes.  
4. Garder tous les couvercles et dispositifs de sûreté à leur  
place.  
5. Toujours porter des lunettes de sécurité dans la zone de  
soudage. Utiliser des lunettes avec écrans lateraux dans les  
Mar. ‘93  
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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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SAFETY  
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for selecting a QUALITY product by Lincoln Electric. We want you  
to take pride in operating this Lincoln Electric Company product •••  
as much pride as we have in bringing this product to you!  
Thank 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 shipment is received.  
Please record your equipment identification information below for future reference. This information can be found  
on your machine nameplate.  
Product _________________________________________________________________________________  
Model Number ___________________________________________________________________________  
Code Number or Date Code_________________________________________________________________  
Serial Number____________________________________________________________________________  
Date Purchased___________________________________________________________________________  
Where Purchased_________________________________________________________________________  
Whenever you request replacement parts or information on this equipment, always supply the information you  
have recorded above. The code number is especially important when identifying the correct replacement parts.  
On-Line Product Registration  
- Register your machine with Lincoln Electric either via fax or over the Internet.  
• For faxing: Complete the form on the back of the warranty statement included in the literature packet  
accompanying this machine and fax the form per the instructions printed on it.  
• For On-Line Registration: Go to our WEB SITE at www.lincolnelectric.com. Choose “Quick Links” and then  
“Product Registration”. Please complete the form and submit your registration.  
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:  
WARNING  
This statement appears where the information must be followed exactly to avoid serious personal injury or  
loss of life.  
CAUTION  
This statement appears where the information must be followed to avoid minor personal injury or damage to  
this equipment.  
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TABLE OF CONTENTS  
Page  
Installation Instructions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Section A  
Technical Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .A-1  
Installation Precautions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A-2  
Location / Ventilation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .A-2  
Stacking . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .A-2  
Angle of Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .A-2  
Lifting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .A-2  
High Altitude Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .A-3  
Towing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .A-3  
Pre-Operation Engine and Compressor Service . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .A-3  
Engine Oil . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .A-3  
Compressor Oil . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .A-3  
Fuel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .A-4  
Engine Cooling System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .A-4  
Break-In Period . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .A-4  
Battery Connection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .A-4  
Spark Arrester . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .A-4  
Welding Output Cables . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .A-5  
Machine Grounding . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .A-5  
Operating Instructions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Section B  
Safety Instructions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . B-1  
Additional Safety Precautions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . B-1  
General Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .B-1  
Recommended Applications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .B-2  
Welder . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .B-2  
Auxiliary Power . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .B-2  
Compressed Air . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .B-2  
Product Application . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .B-2  
Design Features and Advantages . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .B-2  
Duty Cycle . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .B-2  
Engine Controls: Function/Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . B-3  
Welder Controls: Function/Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . B-3  
Remote Control . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .B-4  
Auxiliary Power Controls . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .B-4  
Air Compressor Controls . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .B-4  
Engine Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .B-5  
Starting Instructions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .B-5  
Typical Fuel Consumption . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .B-6  
Accessories . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Section C  
Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Section D  
Routine Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . D-1  
Periodic Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . D-1  
Pre Filter / Washer Separator . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .D-2  
Water Separator Element . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .D-3  
Engine And Compressor Maintenance Components . . . . . . . . . . . . . . . . . . . . . . . . . . .D-4  
Spark Arrester . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .D-4  
Troubleshooting Guide . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Section E  
Wiring Diagrams and Dimension Print . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Section F  
Parts Lists . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Appendix  
SAE-400 WELD’N AIR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .P303 Series  
SAE-400 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .P339 Series  
SAE400 & SAE400 WELD’N AIR  
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A-1  
A-1  
INSTALLATION  
TECHNICAL SPECIFICATIONS - SAE400 & SAE400 WELD’N AIR  
INPUT - DIESEL ENGINE  
Make/Model  
Description  
Speed (RPM)  
Displacement  
Starting  
System  
Capacities  
Perkins  
1004.42 Diesel  
Engine  
4 cylinder  
71 HP @  
1725 RPM  
High Idle 1800  
Low Idle 1100  
Full Load 1725  
256 cu. in  
(4.2 L)  
12VDC batteries  
(2) & Starter  
Fuel: 22.5 gal.  
85.1 L  
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  
Welding Output  
(1)  
Duty Cycle  
Volts at Rated Amps  
60% (NEMA)  
400 amps  
400 amps  
36 volts  
40 volts  
60% (Lincoln Plus)  
OUTPUT - WELDER AND GENERATOR  
Welding Range  
Open Circuit Voltage  
Auxiliary Power  
80 - 575 Amps  
97 Max. OCV  
@ 1800 RPM  
115/230 VAC  
3000 Watts, 60 Hz.  
100% Duty Cycle  
PHYSICAL DIMENSIONS  
HEIGHT  
WIDTH  
DEPTH  
WEIGHT  
50.13 in.  
1273.3 mm  
28.00 in.  
83.00 in.  
SAE400 2125 lbs.  
963.9 kg  
SAE400 2428 lbs.  
WELD’N AIR 1101.3 kg  
711.2 mm  
2108.2 mm  
AIR COMPRESSOR OUTPUT - SAE400 WELD’N AIR ONLY  
Make/Model  
Description  
Delivery Tank Capacity & Rating Operating Pressure Oil Capacity  
IMT  
(Iowa Mold  
Tooling/ Diamond  
Air)  
4-cylinder  
35 CFM  
at 100 P.S.I.  
at 60%  
11 Gallons  
(41.6 Liters)  
Loads at 90 P.S.I.  
1.33 Quarts  
(1.26 Liters)  
IMT’s  
Synthetic  
Compressor  
Oil  
2
Reciprocating,  
Water Cooled,  
(6.3 kg/cm )  
Maximum Allowable  
Working Pressure  
150 PSI  
Unloads at 130 P.S.I.  
(1)  
2
Pressure Lubricated Duty Cycle  
(9.1 kg/cm )  
Aluminum Alloy  
Block with Cast-  
Iron sleeves  
991 Liters/min.  
2
2
Model  
DA435ELW  
at 7.0 kg/cm  
(10.5 kg/cm )  
(1)  
Based on a 10 minute period.  
SAE400 & SAE400 WELD’N AIR  
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A-2  
A-2  
INSTALLATION  
Read this entire installation section before you  
start installation.  
CAUTION  
SAFETY PRECAUTIONS  
WARNING  
DO NOT MOUNT OVER COMBUSTIBLE SURFACES  
Where there is a combustible surface directly under  
stationary or fixed electrical equipment, that surface  
should be covered with a steel plate at least  
.06”(1.6mm) thick, which should extend not less than  
5.90(150mm) beyond the equipment on all sides.  
-----------------------------------------------------------------------  
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.  
STACKING  
These machines cannot be stacked.  
ANGLE OF OPERATION  
ELECTRIC SHOCK can kill.  
•Do not touch electrically live parts such  
as output terminals or internal wiring.  
To achieve optimum engine performance the machine  
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 capac-  
ity in the compressor crankcase. The maximum angle  
of operation for the Perkins engine is 30 degrees in all  
directions. If the engine 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  
engine crankcase. When operating the welder at an  
angle, the effective fuel capacity will be slightly less  
than the specified 22.5 gallons.  
•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.  
------------------------------------------------------------------------  
LIFTING  
MOVING PARTS can injure.  
The equipment lift bale should be used to lift the  
machine.  
•Do not operate with doors open or  
guards off.  
•Stop engine before servicing.  
WARNING  
•Keep away from moving parts  
------------------------------------------------------------------------  
Only qualified personnel should install, use or service  
this equipment  
• Lift only with equipment of adequate  
lifting capacity.  
• Be sure machine is stable when lift-  
ing.  
• Do not lift this machine using lift  
bale if it is equipped with a heavy  
accessory such as trailer or gas  
cylinder.  
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.  
FALLING  
EQUIPMENT can damaged.  
cause injury. • Do not operate machine while  
suspended from lift bale.  
------------------------------------------------------------------------  
• Do not lift machine if lift bale is  
SAE400 & SAE400 WELD’N AIR  
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A-3  
A-3  
INSTALLATION  
• Only transport this equipment on serviceable vehi-  
cles which are rated and designed for such loads.  
• Distribute, balance and secure loads so vehicle is  
stable under conditions of use.  
• Do not exceed maximum rated loads for compo-  
nents such as suspension, axles and tires.  
• Mount equipment base to metal bed or frame of  
vehicle.  
HIGH ALTITUDE OPERATION  
At higher altitudes, output derating may be necessary.  
As a rule of thumb, derate the welder output 5% for  
every 500 meters (1640 ft.) above 1000 meters (3280  
ft.).  
Contact a Perkins Service Representative for any  
engine adjustments that may be required for high alti-  
tude operation.  
• Follow vehicle manufacturer’s instruction.  
----------------------------------------------------------------------------  
PRE-OPERATION ENGINE AND  
COMPRESSOR SERVICE  
TOWING  
READ the engine and compressor operating and main-  
tenance instructions supplied with this machine.  
The recommended trailers for use with this equipment  
for in-plant and yard towing by a vehicle(1) are Lincoln’s  
K767-1, K956-1 and K956-2. The K956-1 and K956-2  
ENGINE OIL  
(1)  
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:  
The engine is shipped with the engine crankcase filled  
with high quality SAE 10W-30 oil (API class CD or bet-  
ter). 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 Operator’s Manual for the proper service and  
maintenance intervals.  
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 trailer’s framework.  
AIR COMPRESSOR OIL (WELD’N AIR  
Only)  
The WELD’N AIR is shipped with the compressor filled  
with a high quality synthetic compressor oil. If oil is  
needed add only Iowa Mold Tooling Co., Inc. (IMT)  
synthetic compressor oil until compressor is full.  
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.  
CAUTION  
The use of any other oil causes excessive carbon  
build up, and will void the warranty on the com-  
pressor.  
5. Proper preventative maintenance of trailer.  
1
6. Conformance with federal, state and local laws.  
------------------------------------------------------------------------  
Check the oil level daily. Refer to the compressor  
Operator’s Manual for the proper service and mainte-  
nance intervals.  
(1) 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.  
VEHICLE MOUNTING  
WARNING  
Improperly mounted concentrated loads may cause  
unstable vehicle handling and tires or other compo-  
nents to fail.  
SAE400 & SAE400 WELD’N AIR  
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A-4  
A-4  
INSTALLATION  
1. Connect the welder output studs to a suitable resis-  
tive load bank. Note that any attempt to short the  
output studs by connecting the welding leads  
together, direct shorting of the output studs, or con-  
necting the output leads to a length of steel will  
result in catastrophic damage to the generator and  
voids the warranty.  
WARNING  
• Stop engine while fueling.  
• Do not smoke when fueling.  
• Keep sparks and flame away from  
tank.  
• Do not leave unattended while  
fueling.  
2. Set the welder controls for an output current and  
voltage within the welder rating and duty cycle.  
Note that any attempt to exceed the welder rating or  
duty cycle for any period of time will result in cata-  
strophic damage to the generator and voids the  
warranty.  
• Wipe up spilled fuel and allow  
fumes to clear before starting  
engine.  
• Do not overfill tank, fuel  
expansion may cause over-  
flow.  
DIESEL FUEL  
can cause fire.  
3. Periodically shut off the engine and check the  
crankcase oil level.  
DIESEL FUEL ONLY  
------------------------------------------------------------------------  
Fill the fuel tank with clean, fresh diesel fuel. The capac-  
ity of the fuel tank is 22.5 gallons (85.1 liters). See engine  
Operator’s Manual for specific fuel recommendations.  
BATTERY CONNECTION  
WARNING  
Use caution as the electrolyte is a strong acid that  
can burn skin and damage eyes.  
NOTE: Before starting the engine, be sure the fuel shut-  
off valve on the sediment bowl is open by turning the han-  
dle counterclockwise.  
Remove and discard the insulating caps from the  
negative battery terminals. Attach and tighten neg-  
ative battery cable terminals.  
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  
container for alternate antifreeze recommendation.)  
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.  
ENGINE BREAK-IN PERIOD  
WARNING  
Lincoln Electric selects high quality, heavy-duty indus-  
trial engines for the portable welding machines we  
offer. While it is normal to see a small amount of  
crankcase oil consumption during initial operation,  
excessive oil use, wetstacking (oil or tar like substance  
at the exhaust port), or excessive smoke is not normal.  
GASES FROM BATTERY can  
explode.  
● Keep sparks, flame and cigarettes  
away from battery.  
-----------------------------------------------------------------------  
To prevent EXPLOSION when:  
Larger machines with a capacity of 350 amperes and  
higher, which are operated at low or no-load conditions  
for extended periods of time are especially susceptible  
to the conditions described above. To accomplish suc-  
cessful engine break-in, most diesel-powered equip-  
ment needs only to be run at a reasonably heavy load  
within the rating of the welder for some period of time  
during the engine’s early life. However, if the welder is  
subjected to extensive light loading, occasional moder-  
ate to heavy loading of the engine may sometimes be  
necessary. Caution must be observed in correctly  
loading a diesel/generator unit.  
● INSTALLING A NEW BATTERY — disconnect  
negative cable from old battery first and  
connect to new battery last.  
● CONNECTING A BATTERY CHARGER —  
remove battery from welder by disconnecting  
negative cable first, then positive cable and  
battery clamp. When reinstalling, connect  
negative cable last. Keep well ventilated.  
● USING A BOOSTER — connect positive lead to  
battery first then connect negative lead to neg-  
ative battery lead at the lower control panel  
support.  
SAE400 & SAE400 WELD’N AIR  
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A-5  
A-5  
INSTALLATION  
BATTERY ACID can burn eyes and  
skin.  
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.  
● Wear gloves and eye protection  
and be careful when working near  
battery.  
● Follow instructions printed on battery.  
IMPORTANT: To prevent ELECTRICAL DAMAGE  
WHEN:  
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. Cable sizes are increased  
for greater lengths primarily for the purpose of mini-  
mizing cable voltage drop.  
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.  
Table A.1 Combined Length of Electrode and  
Work Cables.  
WARNING  
• Spark Arrester and Muffler may be  
hot!  
TOTAL COMBINED LENGTH OF ELEC-  
TRODE AND WORK CABLES  
• Allow engine to cool before servicing  
spark arrester!  
• Do not operate engine while servicing  
spark arrester!  
AMPS  
@60%  
Duty Cycle  
Up to 100FT. 100-200FT. 200-250FT.  
Up to 31m  
31-61m  
61-76m  
400  
2/0 AWG  
3/0 AWG  
4/0 AWG  
SPARK ARRESTER  
MACHINE GROUNDING  
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 muffler included with this welder has been  
modified and now qualifies as a spark arrester.  
Mufflers on machines manufactured before this  
change do not qualify as spark arresters and when  
required by local regulations, a suitable spark arrestor  
must be installed. Spark arresting mufflers will have a  
clean out service plug and will have “USDA FS 5100-  
1c QUALIFIED SPARK ARRESTER” stamped on the  
muffler shell. Any spark arrester must be serviced and  
properly maintained.  
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.).  
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.  
CAUTION  
An incorrect arrester may lead to damage to the  
engine or adversely affect performance.  
------------------------------------------------------------------------  
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 having 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  
welding generator frame foot.  
SAE400 & SAE400 WELD’N AIR  
symbol is provided on the  
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B-1  
B-1  
WELDING SPARKS can cause  
OPERATION  
OPERATING INSTRUCTIONS  
Read and understand this entire section before operat-  
ing your equipment.  
fire or explosion.  
• Do not weld near flammable material .  
• Do not weld on containers that have  
held flammable material.  
SAFETY INSTRUCTIONS  
WARNING  
Do not attempt to use this equipment until you have  
thoroughly read all operating and maintenance manu-  
als supplied with your machine. They include important  
safety precautions, detailed engine starting, operating  
and maintenance instructions and parts lists.  
-----------------------------------------------------------  
MOVING PARTS can injure.  
• Keep away from moving parts  
• Do not operate with doors open or  
guards off.  
• Stop engine before servicing.  
------------------------------------------------------------------------  
ENGINE EXHAUST can kill.  
ELECTRIC SHOCK can kill.  
• Do not touch electrically live parts or  
electrodes with your skin or wet cloth-  
ing.  
• Use in open, well ventilated areas or  
vent exhaust outside.  
------------------------------------------------------------------------  
• Insulate yourself from the work and  
ground.  
ADDITIONAL SAFETY PRECAUTIONS  
• Always wear dry insulating gloves.  
• Do not use AC welder if your clothing, gloves or  
work area is damp or if working on, under or  
inside workpiece.  
Always operate the welder with the hinged doors  
closed as these provide maximum protection from  
moving parts and insure proper cooling air flow.  
Use the following equipment:  
• Semiautomatic DC constant voltage  
(wire) welder.  
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.  
• DC manual (stick) welder.  
• AC welder with reduced voltage con-  
trol.  
------------------------------------------------------------------------  
ARC RAYS can injure eyes and  
burn skin.  
GENERAL DESCRIPTION  
The SAE400 or SAE400 WELD’N AIR is a diesel  
engine driven welding power source. The machine  
uses a DC generator 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 com-  
pressor of the SAE400 WELD’N AIR provides 35 CFM  
at 100 PSI compressed air.  
• Wear eye, ear, and body protection.  
----------------------------------------------------------  
• Only qualified personnel should install, use or  
service this equipment.  
• Consult instruction manual before operating.  
----------------------------------------------------------------------  
Before operating, read and understand the manu-  
facurer’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.  
The engine is a 71 Hp (54kw), 4-cylinder water cooled  
diesel made by Perkins.  
------------------------------------------------------------------------  
FUMES AND GASES can be dangerous to  
your health.  
• Keep your head out of fumes.  
• Use enough ventilation or exhaust at the arc, or  
both, to keep the fumes and gases from your  
breathing zone and general area.  
SAE400 & SAE400 WELD’N AIR  
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B-2  
B-2  
OPERATION  
OTHER FEATURES  
RECOMMENDED APPLICATIONS  
• 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 engine oil pressure or high coolant temperature.  
• Electronic Engine Idler. Engine automatically goes  
to low idle in 10 to 14 seconds after welding or use  
of auxiliary power stops. Includes high idle switch.  
• Gauges for engine oil pressure, coolant temperature  
and battery charging ammeter.  
WELDER  
The SAE400 or SAE400 WELD’N AIR provides excel-  
lent constant current DC welding output for stick  
(SMAW) welding. The field installed optional CV  
Adapter (K385-1) provides up to 500 amps at 35 volts  
of constant voltage output for semiautomatic welding.  
AUXILIARY POWER  
The SAE400 or SAE400 WELD’N AIR provides 3 KW  
of 115/230 VAC output for auxiliary power and emer-  
gency standby power.  
• Engine hour meter standard.  
• Extended range 22.5 gallon (85.1 L) fuel tank.  
COMPRESSED AIR  
FOR COMPRESSED AIR (SAE400 WELD’N AIR only)  
The SAE400 WELD’N AIR only, provides 35 CFM at  
100 PSI compressed air for air arc gouging and air  
powered tools.  
• 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.  
• Indicator light for compressor operation.  
• Gauges for compressor air pressure and compres-  
sor oil pressure.  
• No welding output derating required at maximum  
compressor load.  
PRODUCT APPLICATION  
TOOL  
Arc Gouging, 3/8 in. (9.5)mm Electrode  
(Current Range, 350-600 amps DC)  
CFM - L/min  
16 453  
PSI - kg/cm2  
18  
1.27  
Grinder, 2 in.  
(50.8mm) wheel  
14-20 396-566 90  
28-30 793-850 90  
850  
2-20 57-566  
20-40 566-1133 90 6.33  
26 736 100 7.03  
6.33  
6.33  
6.33  
Chipping Hammer- Weight: 18lbs. (8.1kg.)  
Air or Impact Wrenches: 1/2 in. to 3/4 in. (12.7-19.1mm) 30  
Paint Sprayer  
Drills Capacity 3/8 in. (9.5mm)  
Sand Blaster - 1/8 in. (3.2 mm) Nozzle diameter  
90  
90 6.33  
DUTY CYCLE  
DESIGN FEATURES AND ADVANTAGES  
Duty cycle is based on a ten minute period and opera-  
tion in an ambient temperature of 104°F(40°C).  
FOR STICK WELDING  
• Excellent DC constant current output for stick weld-  
ing applications.  
• Continuous adjustment of both voltage and current  
for unsurpassed welds on demanding jobs.  
• Remote control capability standard.  
The SAE400 & SAE400 WELD’N AIR are 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.  
FOR AUXILIARY POWER  
• 3,000 watts of 115/230 VAC, 60 Hz auxiliary power.  
• One 20 amp 115 VAC duplex receptacle for up to 26  
amps of 115 VAC power.  
The auxiliary power can be used continuously (100%  
duty cycle) within its rated current capacities.  
• 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).  
The air compressor on the SAE400 WELD’N AIR is  
rated at a 60% duty cycle based on a ten minute peri-  
od as described above.  
Welding  
Current, Amps 115V Circuit,  
@ NEMA Arc  
Volts  
Using Only  
Using Only  
230V Circuit,  
Amps  
Total  
Aux.  
kVA  
Amps  
0
26  
19.5  
13  
13  
9.75  
6.5  
3.25  
0
3.0  
2.25  
1.5  
0.75  
0
100  
200  
300  
400  
6.5  
0
SAE400 & SAE400 WELD’N AIR  
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B-3  
B-3  
OPERATION  
ENGINE PROTECTION SYSTEM  
ENGINE CONTROLS  
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.  
IGNITION SWITCH  
When placed in the “ON” position, this switch ener-  
gizes the fuel solenoid. When placed in the “OFF” posi-  
tion, the flow of fuel to the injection pump is stopped to  
shut down the engine.  
WELDER CONTROLS  
POLARITY SWITCH  
“IDLER” SWITCH  
The idler switch has two positions, “HIGH” and  
“AUTO”.  
Turn the Arc Polarity switch to electrode positive or  
electrode negative as required for each particular  
application.  
When in “HIGH” (  
continuously at high idle.  
) position, the engine will run  
CONTROL OF WELDING CURRENT  
Purpose of Controls  
When in “AUTO” (  
/ ) idle position, the idler  
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.  
operates as follows:  
a. Welding  
When the electrode touches the work, the welding  
arc is initiated and the engine accelerates to full  
speed.  
“Job Selector”  
The “Job Selector” dial is divided into four colored sec-  
tions providing OCV ranges as follows:  
After welding ceases (and no auxiliary power is  
being drawn), the engine will return to low idle after  
approximately 10 to 14 seconds.  
Color  
Title  
OCV Range  
High OCV  
White  
Large Electrodes  
b. Auxiliary Power  
Black  
Red  
Normal Welding  
Medium OCV  
Overhead & Vertical Low OCV  
With the engine running at low idle and auxiliary  
power for lights or tools is drawn (approximately  
100-150 watts or greater) from the receptacles, the  
engine will accelerate to high speed. If no power is  
being drawn from the receptacles ( and not weld-  
ing) for 10-14 seconds, the idler reduces the engine  
speed to low idle.  
Grey  
Special Applications Extra-Low OCV  
The “Job Selector” is usually set in the black range  
because it provides a soft “Buttering “ 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.  
ENGINE TEMPERATURE GAUGE  
“Current Control”  
Displays the coolant temperature in the engine block.  
ENGINE OIL PRESSURE GAUGE  
CAUTION  
Do not adjust the “Current Control” while welding  
because this can damage the control.  
Displays the oil pressure to the engine. When the  
engine starts running, watch for the oil pressure to  
build up. If no pressure shows within 30 seconds, stop  
the engine and consult the engine instruction manual.  
------------------------------------------------------------------------  
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.  
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.  
SAE400 & SAE400 WELD’N AIR  
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B-4  
B-4  
OPERATION  
How to Set the Controls  
Circuit Breakers  
Assume you want a normal soft arc and about 135  
amps, using a 5/32” (4.0 mm) electrode:  
The circuit breakers provide separate overload current  
protection for each half of the 115 V duplex receptacle.  
The circuit breakers provide overload current protec-  
tion in both current carrying wires of the 230 V duplex  
receptacle.  
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.  
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.  
3. Start to weld.  
4. If 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.  
AIR COMPRESSOR CONTROLS -  
(SAE400 WELD’N AIR ONLY)  
5. If 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 “Job Selector” for  
the exact characteristics and current desired.  
COMPRESSOR ON/OFF SWITCH  
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  
switch” disengages the clutch and compressor.  
REMOTE CONTROL  
A receptacle and “Local/Remote” control switch on the  
lower front control panel and a remote control box with  
100 ft. (30.5 m) of cord for adjusting the OCV at the  
welding site are standard. Putting the switch in the  
“REMOTE” position allows fine current control at the  
remote control 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.  
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  
AUXILIARY POWER CONTROLS  
This light is on when the compressor “ON/OFF” switch  
is in the “ON” position.  
115 VAC Receptacle  
COMPRESSOR AIR PRESSURE GAUGE  
One 20 amp, 115 VAC duplex receptacle provides 115  
VAC for auxiliary power. A total of 26 amps can be  
drawn from this receptacle.  
This gauge displays the air pressure in the air receiver  
tanks.  
230 VAC Receptacle  
COMPRESSOR OIL PRESSURE GAUGE  
One 15 amp, 230 VAC duplex receptacle provides 230  
VAC for auxiliary power. A total of 13 amps can be  
drawn from this receptacle.  
This gauge displays the compressor oil pressure. Oil is  
under pressure only when the compressor clutch is  
engaged.  
SAE400 & SAE400 WELD’N AIR  
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B-5  
B-5  
OPERATION  
AIR COMPRESSOR (SAE400 WELD’N AIR only)  
ENGINE OPERATION  
CAUTION  
Do not adjust the high idle engine speed (rpm) above  
the factory setting specification as this will overspeed  
the air compressor and void it’s warranty.  
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.  
------------------------------------------------------------------------  
STARTING INSTRUCTIONS  
TYPICAL FUEL CONSUMPTION  
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, place ignition toggle  
switch in the “ON” position. 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 man-  
ual. To stop the engine, place the ignition toggle switch  
in the “OFF” position.  
The typical fuel consumption of the SAE400 and  
SAE400 WELD’N AIR for various operating scenarios  
is shown below:  
Low Idle - No Load  
1100 RPM  
.35 gal./ hr.  
(1.32 L./hr.)  
High Idle - No Load  
1800 RPM  
.75 gal./hr.  
(2.84 L./hr.)  
Welding Load  
400 Amps, 40 Volts  
1.92 gal./hr.  
(7.27 L./hr.)  
When an engine is started for the first time, some of  
the oil will be needed to fill the passages of the lubri-  
cating 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 factory and should require no adjusting when  
received.  
Auxiliary Power  
3000VA  
.96 gal./hr.  
(3.63 L./hr.)  
Air Compressor  
(SAE400 WELD’N AIR Only)  
1.04 gal./hr.  
(3.94 L./hr.)  
400 Amps, 40 Volts Load  
with Air Compressor “ON”  
(SAE400 WELD’N AIR Only)  
2.22 gal./hr.  
(8.40 L./hr.)  
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, genera-  
tor or compressor overheating.  
Auxiliary Power  
3000 VA with  
1.20 gal./hr.  
(4.54 L./hr.)  
Air Compressor “ON”  
(SAE400 WELD’N AIR Only)  
COLD WEATHER STARTING  
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  
charged batteries and the proper weight oil, the  
“Thermostart” system operates satisfactorily even  
down to about 0°F (-18°C).  
SAE400 & SAE400 WELD’N AIR  
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C-1  
C-1  
ACCESSORIES  
K930-2 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).  
K2303-1 SHEET METAL KIT- For SAE400 model  
K1278-5.  
K802-D Power Plug Kit - Kit includes male plugs for  
each auxiliary receptacle.  
K767-1 Trailer - A 4-wheel steerable trailer for in-plant  
(1)  
and yard towing with E78-14 load range (B) tubeless  
tires. Mounts directly to welder base.  
(1)  
K956-1Trailer - A 2-wheel trailer designed for road ,  
off road, in-plant and yard towing. Trailer mounts  
directly to welder base.  
1For highway use, consult applicable federal, state and local laws regarding  
possible requirements for brakes, lights, fenders, etc.  
WARNING  
Pipe Thawing with an arc welder can cause fire,  
explosion, damage to electric wiring or to the arc  
welder if done improperly. The use of an arc  
welder for pipe thawing is not approved by the  
CSA, nor is it recommended or supported by  
Lincoln Electric.  
------------------------------------------------------------------------  
K704 Standard Accessory Kit - Includes electrode  
and work cables, headshield, work clamp and elec-  
trode holder.  
K385-1 CV Adapter - Provides constant voltage output  
for semiautomatic welding. (Field installation only).  
K2144-1 Oil Drain Kit - Includes ball valve, hose and  
clamp.  
K1847-1 Spark Arrestor Kit  
K1690-1 GFCI RECEPTACLE KIT  
Includes one UL approved 120V ground fault circuit  
interrupter duplex type receptacle with cover and  
installation instructions. Replaces the factory installed  
120V duplex receptacle. Each receptacle of the GFCI  
Duplex is rated at 20 Amps, the maximum total current  
from the GFCI Duplex is limited to the 20 Amps. Two  
kits are required.  
SAE400 & SAE400 WELD’N AIR  
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D-1  
D-1  
MAINTENANCE  
PERIODIC MAINTENANCE  
WARNING  
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.  
ELECTRIC SHOCK can kill.  
● Do not touch electrically live parts  
such as output terminals or inter-  
nal wiring  
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.  
ENGINE EXHAUST can kill.  
● Use in open, well ventilated areas  
or vent exhaust outside  
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.  
MOVING PARTS can injure.  
● Do not operate with doors open or  
guards off  
● Stop engine before servicing  
● Keep away from moving parts  
4. See the compressor operator’s manual for periodic com-  
pressor maintenance information. Change the compres-  
sor oil at regular intervals using only Iowa Mold Tooling  
Co., Inc. (IMT) synthetic compressor oil as recommended  
in the compressor operating manual.  
● Remove guards only when necessary and  
replace when work requiring removal is com-  
plete.  
● Only qualified personnel should install, use, or  
service this equipment.  
CAUTION  
ROUTINE MAINTENANCE  
The use of any other oil causes excessive carbon build up,  
and will void the warranty on the compressor.  
--------------------------------------------------------------------------------  
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 lev-  
els.  
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 adjustment.  
If the fuel 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.  
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.  
COMPRESSOR AIR RECEIVER TANKS -  
(SAE400 WELD’N AIR ONLY)  
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  
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.  
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 running.  
SAE400 & SAE400 WELD’N AIR  
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D-2  
D-2  
MAINTENANCE  
COMMUTATOR AND BRUSH MAINTENANCE  
COOLING SYSTEM  
WARNING  
The SAE400 and SAE400 WELD’N AIR are equipped  
with a pressure radiator. Keep the radiator cap tight to  
prevent loss of coolant. Clean and flush the cooling  
system periodically to prevent clogging the passage  
and overheating the engine. When antifreeze is need-  
ed, always use the permanent type.  
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.  
PRE FILTER / WASHER SEPARATOR  
WARNING  
When working on the fuel system  
Shifting of the brushes may result in:  
- Change in machine output  
- Commutator Damage  
• Keep unguarded lights away, do not  
smoke !  
- Excessive brush wear  
• Do not spill fuel !  
Periodically inspect the commutator, slip rings and  
brushes by removing the covers. DO NOT remove or  
replace these covers while the machine is running.  
------------------------------------------------------------------------  
The SAE-400 and SAE400 Weld”n Air machines with  
Codes 10884 and above are equipped with a Fuel Pre-  
Filter/Water Separator Assembly located before the  
lift pump mounted to the engine block.  
Commutators and slip rings 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.  
FUEL PRE-FILTER/WATER SEPARATOR ASSEMBLY  
The pre-filter is a 150 micron screen designed to pro-  
tect against gross fuel contamination of the water sep-  
arator element and the Secondary Fuel Filter. If the  
pre-filter becomes plugged it may be removed, inspect-  
ed, cleaned and reinstalled. In general this only needs  
to be done with each water separator element change  
(about every 1,000 hrs.) However if at any time exces-  
sive fuel contamination is suspected or a sudden fall-  
off in engine performance is detected the pre-filter  
screen should be inspected and cleaned. Follow the  
following procedure:  
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 ston-  
ing, blow out the dust with low pressure air.  
1. Close the fuel shutoff valve located on the fuel  
strainer mounted to the under side of the fuel tank.  
2. Unscrew the cap ring located on the top of the filter  
header and remove the plastic center cap and O-  
ring.  
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%.  
3. Remove the large white volume plug located direct-  
ly under the center cap in the upper cavity of the fil-  
ter header. Use a small screwdriver (or similar  
device) to lift the plug part way out of the cavity to  
assist with its removal.  
Arcing or excessive exciter brush wear indicates a pos-  
sible misaligned shaft. Have an authorized Field  
Service Shop check and realign the shaft.  
Be careful not to damage the pre-filter screen with  
the tool used to remove the plug.  
SAE400 & SAE400 WELD’N AIR  
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D-3  
D-3  
MAINTENANCE  
4. Using a pair of pliers, gently tug on the pull tabs of  
the pre-filter screen in an alternating pattern to  
gradually remove the pre-filter screen.  
5. Slide the quick change ring up over the element and  
rotate counter clockwise until an audible click or pop  
is heard. If you do not hear the click you have not rotat-  
ed the ring far enough and the element is not in the  
locked position. Another indication that the ring is in  
the locked position is that one set (it doesn’t matter  
which one) of arrows located on the outside of the ring  
should be located directly under the air vent valve.  
5. Brush off any debris and rinse in diesel fuel.  
6. Re-install the pre-filter screen into the upper cavity  
of the filter header making sure the four pull tabs  
are pointing up. Putting your fingers on the pull  
tabs, push down evenly until the lower body of the  
pre-filter screen contacts the floor of the upper cav-  
ity.  
6. Open the fuel shutoff valve.  
7. Open the air vent valve on the front of the filter head-  
er until fuel emerges free of air bubbles and then close  
the air vent valve.  
7. Re-insert the large white volume plug into the upper  
cavity.  
Note : Consult your engine operation manual for infor-  
mation on air bleeding the entire fuel system  
8. Place the O-ring onto the angled seal surface of the  
filter header and re-install the plastic cap. Make  
sure its flange rests on the O-ring.  
9. Screw on the cap ring and tighten hand tight.  
10. Remember to open the fuel shutoff valve before  
starting the engine.  
WATER SEPARATOR ELEMENT  
The water separator element is a two stage filter with a  
special filtration/water separating media, and an  
expanded water reservoir providing maximum protec-  
tion against water in the fuel. The recommended  
change interval for the water separator element is  
1,000 hours. The procedure for changing the element  
is as follows:  
1. Close the fuel shutoff valve located on the fuel  
strainer mounted to the under side of the fuel tank.  
2. Rotate the quick change ring (located just below fil-  
ter header) clockwise approximately 1/2 turn and  
slide it down and off of the element.  
3. Grasp the element and pull down with a slight rock-  
ing motion to remove the element from the grom-  
met post on the bottom of the filter header.  
4. Slide the new element onto the grommet post on the  
bottom of the filter header until the element no longer  
easily moves up into the filter header. Now rotate the  
element (may take almost 1 full turn) with a slight  
upward pressure until the element begins to further  
engage the header. With the proper orientation now  
established apply additional pressure to seat the ele-  
ment in the filter header. You should feel the element  
“pop” into place when properly seated.  
Note: The element will only go on one way. Never use  
excessive force when mounting the element to the  
header.  
SAE400 & SAE400 WELD’N AIR  
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D-4  
D-4  
MAINTENANCE  
ENGINE AND COMPRESSOR MAINTENANCE  
COMPONENTS  
SPARK ARRESTOR  
WARNING  
• Spark Arrester and Muffler may be  
hot!  
• Allow engine to cool before servicing  
spark arrester!  
ITEM  
Engine Air Filter  
Fan Belt  
MAKE  
Donaldson  
Perkins  
PART NUMBER  
P181052  
2614B550  
• Do not operate engine while servicing  
spark arrester!  
Compressor Belt  
(SAE400 WELD’N AIR only) Gates  
Lincoln  
S23887  
2/A40  
For machines with separate spark arresting units:  
Service the spark arrestor every 100 hours of opera-  
tion or twice a year, which ever occurs first.  
Service as follows:  
Fuel Filter  
Perkins  
Perkins  
26560143  
Engine Oil Filter  
2654403  
1. Stop engine and allow to cool.  
(Codes 10884 & Above)  
Water Separator  
Element  
2. Loosen clamp and remove spark arrestor from  
machine.  
Lincoln  
Stanadyne  
M16890-C  
31572  
3. Remove locknut on top of spark arrestor housing  
and lift off cap.  
(Codes 10884 & Above)  
Fuel Pre-Filter Screen Lincoln  
M16890-B  
29575  
Stanadyne  
4. Separate plates and clean if necessary.  
5. Inspect plates and housing for holes or cracks.  
Replace spark arrestor if damaged.  
REPLACING AIR COMPRESSOR DRIVE BELT  
(SAE400 WELD’N AIR only)  
6. Assemble spark arrestor using reverse order: step  
3, then step 2.  
CAUTION  
For machines with integral spark arresting mufflers:  
Service spark arrester every 250 hours.  
Service as follows:  
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.  
1. Stop engine and allow to cool.  
2. Remove clean out plug from side of spark arrester.  
3. Without damaging the spark arrester, gently tap on the  
arrester shell near the clean out plug.  
4. Once particles are removed, replace the clean out plug.  
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  
locking hole. Insert locking bolt and tighten before  
releasing idler body. Tighten center mounting bolt.  
Note: Ensure that both belt strands are running prop-  
erly in pulley grooves.  
SAE400 & SAE400 WELD’N AIR  
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E-1  
E-1  
TROUBLESHOOTING  
HOW TO USE TROUBLESHOOTING GUIDE  
WARNING  
Service and Repair should only be performed by Lincoln Electric Factory Trained Personnel.  
Unauthorized repairs performed on this equipment may result in danger to the technician and machine  
operator and will invalidate your factory warranty. For your safety and to avoid Electrical Shock, please  
observe all safety notes and precautions detailed throughout this manual.  
__________________________________________________________________________  
This Troubleshooting Guide is provided to help you  
locate and repair possible machine malfunctions.  
Simply follow the three-step procedure listed below.  
This column provides a course of action for the  
Possible Cause, generally it states to contact your  
local Lincoln Authorized Field Service Facility.  
Step 1. LOCATE PROBLEM (SYMPTOM).  
If you do not understand or are unable to perform the  
Recommended Course of Action safely, contact your  
local Lincoln Authorized Field Service Facility.  
Look under the column labeled “PROBLEM (SYMP-  
TOMS)”. This column describes possible symptoms  
that the machine may exhibit. 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 possibilities that may contribute to  
the machine symptom.  
Step 3. RECOMMENDED COURSE OF ACTION  
WARNING  
ELECTRIC SHOCK can kill.  
• Do not touch electrically live parts such as output  
terminals or internal 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.  
• 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 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 & SAE400 WELD’N AIR  
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E-2  
E-2  
TROUBLESHOOTING  
Observe all Safety Guidelines detailed throughout this manual  
PROBLEMS  
(SYMPTOMS)  
RECOMMENDED  
COURSE OF ACTION  
POSSIBLE CAUSE  
FUNCTION PROBLEMS  
Machine fails to hold the “heat”  
constantly.  
Rough or dirty commutator.  
True and clean commutator.  
Brushes may be worn down to limit Replace brushes.  
of life.  
Brush springs may be broken.  
Replace brush springs.  
Field circuit may have variable resis- Check field current with ammeter to  
tance connections or intermittent  
open circuit, due to loose connec-  
tions or broken wire.  
discover varying current. This  
applies to both the main generator  
and exciter.  
Electrode or work lead connections Tighten all connections.  
may be poor.  
Wrong grade of brushes may be  
installed on generator.  
Use only the recommended Lincoln  
brushes.  
Field rheostat may be making poor Inspect and clean rheostat.  
contact and overheating.  
“Current Control” may not be operat- Check for loose or missing set  
ing properly.  
screw in control handles.  
“Current Control” brushholder con- Inspect. Replace needed parts.  
tact springs may be worn out or  
missing. Contact surface may be  
dirty, rough and pitted.  
Clean internal contact surface of  
control device. Do not lubricate.  
Smooth rough surfaces.  
“Current Control” brushholder sup- If brushholder internal contact sur-  
port stud and mating contact sur-  
faces may be dirty or pitted and  
burned.  
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.  
Engine running at varying speeds.  
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 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 & SAE400 WELD’N AIR  
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E-3  
E-3  
TROUBLESHOOTING  
Observe all Safety Guidelines detailed throughout this manual  
PROBLEMS  
(SYMPTOMS)  
RECOMMENDED  
COURSE OF ACTION  
POSSIBLE CAUSE  
FUNCTION PROBLEMS  
Welder runs but fails to generate  
current.  
Generator or exciter brushes may  
be loose or missing.  
Be sure that all brushes bear on the  
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  
may be open.  
Check for open circuits in rheostat,  
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  
excessively.  
Series field circuit may be open cir- Check circuit with ringer or volt-  
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 Local  
Lincoln Authorized Field Service Facility for technical troubleshooting assistance before you proceed.  
SAE400 & SAE400 WELD’N AIR  
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E-4  
E-4  
TROUBLESHOOTING  
Observe all Safety Guidelines detailed throughout this manual  
PROBLEMS  
(SYMPTOMS)  
RECOMMENDED  
COURSE OF ACTION  
POSSIBLE CAUSE  
FUNCTION PROBLEMS  
Welding current too great or too  
“Current Control” shaft and handle  
With current control against the min-  
small compared to indication on the may have turned slightly in the insu- imum stop, set pointer to within 1/8”  
dial.  
lated bushing of the current control of the last scale division.  
brushholder, caused by turning han-  
dle too hard against one of the  
stops.  
Exciter output low causing low out- Check for shorts in exciter armature  
put compared to dial indication.  
with growler.  
“Current Control” set to minimum  
and welder output so great that  
engine stalls when arc is struck.  
Check to see that series field is  
properly connected and not shorted.  
Welder has output and no control  
Local/Remote switch is in wrong  
position.  
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 & SAE400 WELD’N AIR  
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E-5  
E-5  
TROUBLESHOOTING  
Observe all Safety Guidelines detailed throughout this manual  
PROBLEMS  
(SYMPTOMS)  
RECOMMENDED  
COURSE OF ACTION  
POSSIBLE CAUSE  
FUNCTION PROBLEMS  
No auxiliary power  
Circuit Breakers open.  
Check and reset breakers. If break-  
ers keep tripping check connections  
to auxiliary receptacles. Also make  
sure load does nor exceed recepta-  
cle’s current rating.  
Faulty connections to auxiliary  
receptacles.  
Check connections.  
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 & SAE400 WELD’N AIR  
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F-1  
F-1  
WIRING DIAGRAMS  
+
+
+
+
+
SAE400 & SAE400 WELD’N AIR  
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F-2  
F-2  
WIRING DIAGRAMS  
+
+
+
+
+
SAE400 & SAE400 WELD’N AIR  
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F-3  
F-3  
WIRING DIAGRAMS  
SAE400 & SAE400 WELD’N AIR  
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F-4  
F-4  
DIMENSION PRINT  
SAE400 & SAE400 WELD’N AIR  
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NOTES  
SAE400 & SAE400 WELD’N AIR  
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● Keep your head out of fumes.  
● Use ventilation or exhaust to  
remove fumes from breathing zone.  
● Turn power off before servicing.  
● Do not operate with panel open or  
guards off.  
WARNING  
Spanish  
● Los humos fuera de la zona de res-  
piración.  
● Mantenga la cabeza fuera de los  
humos. Utilice ventilación o  
aspiración para gases.  
● Desconectar el cable de ali-  
mentación de poder de la máquina  
antes de iniciar cualquier servicio.  
● No operar con panel abierto o  
guardas quitadas.  
AVISO DE  
PRECAUCION  
French  
● N’opérez pas avec les panneaux  
ouverts ou avec les dispositifs de  
protection enlevés.  
● Gardez la tête à l’écart des fumées. ● Débranchez le courant avant l’entre-  
● Utilisez un ventilateur ou un aspira-  
teur pour ôter les fumées des zones  
de travail.  
tien.  
ATTENTION  
German  
● Anlage nie ohne Schutzgehäuse  
oder Innenschutzverkleidung in  
Betrieb setzen!  
● Vermeiden Sie das Einatmen von  
Schweibrauch!  
● Sorgen Sie für gute Be- und  
Entlüftung des Arbeitsplatzes!  
● Strom vor Wartungsarbeiten  
abschalten! (Netzstrom völlig öff-  
nen; Maschine anhalten!)  
WARNUNG  
Portuguese  
● Não opere com as tampas removidas.  
● Desligue a corrente antes de fazer  
serviço.  
● Mantenha-se afastado das partes  
moventes.  
● Não opere com os paineis abertos  
ou guardas removidas.  
● Mantenha seu rosto da fumaça.  
● Use ventilação e exhaustão para  
remover fumo da zona respiratória.  
ATENÇÃO  
● Não toque as partes elétricas nuas.  
Japanese  
Chinese  
Korean  
Arabic  
LEIA E COMPREENDA AS INSTRUÇÕES DO FABRICANTE PARA ESTE EQUIPAMENTO E AS PARTES DE USO, E SIGA AS  
PRÁTICAS DE SEGURANÇA DO EMPREGADOR.  
SAE400 & SAE400 WELD’N AIR  
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● Do not touch electrically live parts or ● Keep flammable materials away.  
● Wear eye, ear and body protection.  
electrode with skin or wet clothing.  
● Insulate yourself from work and  
ground.  
WARNING  
Spanish  
● No toque las partes o los electrodos ● Mantenga el material combustible  
● Protéjase los ojos, los oídos y el  
bajo carga con la piel o ropa moja-  
da.  
● Aislese del trabajo y de la tierra.  
fuera del área de trabajo.  
cuerpo.  
AVISO DE  
PRECAUCION  
French  
● Ne laissez ni la peau ni des vête-  
ments mouillés entrer en contact  
avec des pièces sous tension.  
● Gardez à l’écart de tout matériel  
inflammable.  
● Protégez vos yeux, vos oreilles et  
votre corps.  
ATTENTION  
● Isolez-vous du travail et de la terre.  
German  
● Berühren Sie keine stromführenden  
Teile oder Elektroden mit Ihrem  
Körper oder feuchter Kleidung!  
● Isolieren Sie sich von den  
● Entfernen Sie brennbarres Material! ● Tragen Sie Augen-, Ohren- und Kör-  
perschutz!  
WARNUNG  
Elektroden und dem Erdboden!  
Portuguese  
● Não toque partes elétricas e elec-  
trodos com a pele ou roupa molha-  
da.  
● Mantenha inflamáveis bem guarda- ● Use proteção para a vista, ouvido e  
dos.  
corpo.  
ATENÇÃO  
● Isole-se da peça e terra.  
Japanese  
Chinese  
Korean  
Arabic  
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 COMPRENEZ LES INSTRUCTIONS DU FABRICANT EN CE QUI REGARDE CET EQUIPMENT ET LES PRODUITS A  
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 UNFALLVERHÜTUNGSVORSCHRIFTEN DES ARBEITGEBERS SIND EBENFALLS ZU BEACHTEN.  
SAE400 & SAE400 WELD’N AIR  
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• World's Leader in Welding and Cutting Products •  
• Sales and Service through Subsidiaries and Distributors Worldwide •  
Cleveland, Ohio 44117-1199 U.S.A. TEL: 216.481.8100 FAX: 216.486.1751 WEB SITE: www.lincolnelectric.com  
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