Sae400 Weld'N Air - DC Arc Welding Power Source and 35 CFM Air Compressor

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IM581
SAE400 WELD’N AIR - DC ARC WELDING POWER
February, 2000
SOURCE AND 35 CFM AIR COMPRESSOR
For use with machines having Code Number 10362
Safety Depends on You

Lincoln arc welding and cutting
equipment is designed and built with
safety in mind. However, your overall
safety can be increased by proper
installation ... and thoughtful opera-
tion on your part. DO NOT
INSTALL, OPERATE OR REPAIR
THIS EQUIPMENT WITHOUT
READING THIS MANUAL AND
THE SAFETY PRECAUTIONS
CONTAINED THROUGHOUT.
And, most importantly, think before
you act and be careful.
Date of Purchase:
Serial Number:
Code Number:
R
Model:
Where Purchased:
OPERATOR’S MANUAL
• World's Leader in Welding and Cutting Products •

• Sales and Service through Subsidiaries and Distributors Worldwide •
Cleveland, Ohio 44117-1199 U.S.A. TEL: 216.481.8100 FAX: 216.486.1751 WEB SITE: www.lincolnelectric.com
i i
SAFETY
WARNING
CALIFORNIA PROPOSITION 65 WARNINGS
Diesel engine exhaust and some of its constituents The engine exhaust from this product contains
are known to the State of California to cause can- chemicals known to the State of California to cause
cer, birth defects, and other reproductive harm. cancer, birth defects, or other reproductive harm.
The Above For Diesel Engines The Above For Gasoline Engines
ARC WELDING CAN BE HAZARDOUS. PROTECT YOURSELF AND OTHERS FROM POSSIBLE SERIOUS INJURY 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 & Cutting - ANSI Standard Z49.1” 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 1.h. To avoid scalding, do not remove the

radiator pressure cap when the engine is
powered equipment. hot.
1.a. Turn the engine off before troubleshooting and maintenance
work unless the maintenance work requires it to be running.
____________________________________________________
1.b. Operate engines in open, well-ventilated
areas or vent the engine exhaust fumes
outdoors.
ELECTRIC AND
MAGNETIC FIELDS
____________________________________________________
1.c. Do not add the fuel near an open flame weld- may be dangerous
ing arc or when the engine is running. Stop
the engine and allow it to cool before refuel- 2.a. Electric current flowing through any conductor causes
ing to prevent spilled fuel from vaporizing on localized Electric and Magnetic Fields (EMF). Welding
contact with hot engine parts and igniting. Do current creates EMF fields around welding cables and
not spill fuel when filling tank. If fuel is spilled, welding machines
wipe it up and do not start engine until fumes
have been eliminated. 2.b. EMF fields may interfere with some pacemakers, and
____________________________________________________ welders having a pacemaker should consult their physician
1.d. Keep all equipment safety guards, covers and devices in posi- before welding.
tion and in good repair.Keep hands, hair, clothing and tools
away from V-belts, gears, fans and all other moving parts 2.c. Exposure to EMF fields in welding may have other health
when starting, operating or repairing equipment. effects which are now not known.
____________________________________________________
1.e. In some cases it may be necessary to remove safety 2.d. All welders should use the following procedures in order to
guards to perform required maintenance. Remove minimize exposure to EMF fields from the welding circuit:
guards only when necessary and replace them when the
maintenance requiring their removal is complete. 2.d.1. Route the electrode and work cables together - Secure
Always use the greatest care when working near moving them with tape when possible.
parts.
___________________________________________________ 2.d.2. Never coil the electrode lead around your body.
1.f. Do not put your hands near the engine fan. Do
not attempt to override the governor or idler 2.d.3. Do not place your body between the electrode and
by pushing on the throttle control rods while work cables. If the electrode cable is on your right
the engine is running. side, the work cable should also be on your right side.
2.d.4. Connect the work cable to the workpiece as close as

possible to the area being welded.
___________________________________________________
1.g. To prevent accidentally starting gasoline engines while 2.d.5. Do not work next to welding power source.
turning the engine or welding generator during maintenance
work, disconnect the spark plug wires, distributor cap or
magneto wire as appropriate. Mar ‘95
ii SAFETY ii
ELECTRIC SHOCK can kill. ARC RAYS can burn.

3.a. The electrode and work (or ground) circuits 4.a. Use a shield with the proper filter and cover
are electrically “hot” when the welder is on. plates to protect your eyes from sparks and
Do not touch these “hot” parts with your bare the rays of the arc when welding or observing
skin or wet clothing. Wear dry, hole-free open arc welding. Headshield and filter lens
gloves to insulate hands. should conform to ANSI Z87. I standards.
3.b. Insulate yourself from work and ground using dry insulation. 4.b. Use suitable clothing made from durable flame-resistant
Make certain the insulation is large enough to cover your full material to protect your skin and that of your helpers from
area of physical contact with work and ground. the arc rays.
In addition to the normal safety precautions, if welding 4.c. Protect other nearby personnel with suitable, non-flammable
must be performed under electrically hazardous screening and/or warn them not to watch the arc nor expose
conditions (in damp locations or while wearing wet themselves to the arc rays or to hot spatter or metal.
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 FUMES AND GASES
accidental contact with the workpiece or ground) use
the following equipment: can be dangerous.
• Semiautomatic DC Constant Voltage (Wire) Welder. 5.a. Welding may produce fumes and gases
• DC Manual (Stick) Welder. hazardous to health. Avoid breathing these
• AC Welder with Reduced Voltage Control. fumes and gases.When welding, keep
your head out of the fume. Use enough
3.c. In semiautomatic or automatic wire welding, the electrode, ventilation and/or exhaust at the arc to keep
electrode reel, welding head, nozzle or semiautomatic fumes and gases away from the breathing zone. When
welding gun are also electrically “hot”. welding with electrodes which require special
ventilation such as stainless or hard facing (see
3.d. Always be sure the work cable makes a good electrical instructions on container or MSDS) or on lead or
connection with the metal being welded. The connection cadmium plated steel and other metals or coatings
should be as close as possible to the area being welded. which produce highly toxic fumes, keep exposure as
low as possible and below Threshold Limit Values (TLV)
3.e. Ground the work or metal to be welded to a good electrical using local exhaust or mechanical ventilation. In
(earth) ground. confined spaces or in some circumstances, outdoors, a
respirator may be required. Additional precautions are
3.f. Maintain the electrode holder, work clamp, welding cable and also required when welding on galvanized steel.
welding machine in good, safe operating condition. Replace
5.b. Do not weld in locations near chlorinated hydrocarbon vapors
damaged insulation.
coming from degreasing, cleaning or spraying operations.
The heat and rays of the arc can react with solvent vapors to
3.g. Never dip the electrode in water for cooling.
form phosgene, a highly toxic gas, and other irritating
products.
3.h. Never simultaneously touch electrically “hot” parts of
electrode holders connected to two welders because voltage
5.c. Shielding gases used for arc welding can displace air and
between the two can be the total of the open circuit voltage
cause injury or death. Always use enough ventilation,
of both welders.
especially in confined areas, to insure breathing air is safe.
3.i. When working above floor level, use a safety belt to protect
5.d. Read and understand the manufacturer’s instructions for this
yourself from a fall should you get a shock.
equipment and the consumables to be used, including the
material safety data sheet (MSDS) and follow your
3.j. Also see Items 6.c. and 8.
employer’s safety practices. MSDS forms are available from
your welding distributor or from the manufacturer.
5.e. Also see item 1.b.

Mar ‘95
iii SAFETY iii
WELDING SPARKS can CYLINDER may explode

cause fire or explosion. 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
the welding sparks from starting a fire. containing the correct shielding gas for the
Remember that welding sparks and hot process used and properly operating
materials from welding can easily go through small cracks regulators designed for the gas and
and openings to adjacent areas. Avoid welding near pressure used. All hoses, fittings, etc. should be suitable for
hydraulic lines. Have a fire extinguisher readily available. the application and maintained in good condition.
6.b. Where compressed gases are to be used at the job site, 7.b. Always keep cylinders in an upright position securely
special precautions should be used to prevent hazardous chained to an undercarriage or fixed support.
situations. Refer to “Safety in Welding and Cutting” (ANSI
Standard Z49.1) and the operating information for the 7.c. Cylinders should be located:
equipment being used. • 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 • A safe distance from arc welding or cutting operations and
cause overheating and create a fire hazard. any other source of heat, sparks, or flame.
6.d. Do not heat, cut or weld tanks, drums or containers until the 7.d. Never allow the electrode, electrode holder or any other
proper steps have been taken to insure that such procedures electrically “hot” parts to touch a cylinder.
will not cause flammable or toxic vapors from substances
inside. They can cause an explosion even though they have 7.e. Keep your head and face away from the cylinder valve outlet
been “cleaned”. For information, purchase “Recommended when opening the cylinder valve.
Safe Practices for the Preparation for Welding and Cutting of
Containers and Piping That Have Held Hazardous 7.f. Valve protection caps should always be in place and hand
Substances”, AWS F4.1 from the American Welding Society tight except when the cylinder is in use or connected for
use.
(see address above).
7.g. Read and follow the instructions on compressed gas
6.e. Vent hollow castings or containers before heating, cutting or
cylinders, associated equipment, and CGA publication P-l,
welding. They may explode.
“Precautions for Safe Handling of Compressed Gases in
Cylinders,” available from the Compressed Gas Association
6.f. Sparks and spatter are thrown from the welding arc. Wear oil
1235 Jefferson Davis Highway, Arlington, VA 22202.
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 FOR ELECTRICALLY
welding area. powered equipment.
6.g. Connect the work cable to the work as close to the welding
8.a. Turn off input power using the disconnect
area as practical. Work cables connected to the building
switch at the fuse box before working on
framework or other locations away from the welding area
the equipment.
increase the possibility of the welding current passing
through lifting chains, crane cables or other alternate circuits.
8.b. Install equipment in accordance with the U.S. National
This can create fire hazards or overheat lifting chains or
Electrical Code, all local codes and the manufacturer’s
cables until they fail.
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
iv SAFETY iv
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.
v SAFETY v
vi SAFETY vi
PRÉCAUTIONS DE SÛRETÉ 6. Eloigner les matériaux inflammables ou les recouvrir afin de

Pour votre propre protection lire et observer toutes les instructions prévenir tout risque d’incendie dû aux étincelles.
et les précautions de sûreté specifiques qui parraissent dans ce
manuel aussi bien que les précautions de sûreté générales suiv- 7. Quand on ne soude pas, poser la pince à une endroit isolé de
antes: 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
a. Les circuits à l’électrode et à la piéce sont sous tension masse sur la charpente de la construction ou d’autres endroits
quand la machine à souder est en marche. Eviter toujours éloignés de la zone de travail, on augmente le risque de voir
tout contact entre les parties sous tension et la peau nue passer le courant de soudage par les chaines de levage,
ou les vétements mouillés. Porter des gants secs et sans câbles de grue, ou autres circuits. Cela peut provoquer des
trous pour isoler les mains. risques d’incendie ou d’echauffement des chaines et des
b. Faire trés attention de bien s’isoler de la masse quand on câbles jusqu’à ce qu’ils se rompent.
soude dans des endroits humides, ou sur un plancher met-
allique ou des grilles metalliques, principalement dans 9. Assurer une ventilation suffisante dans la zone de soudage.
les positions assis ou couché pour lesquelles une grande Ceci est particuliérement important pour le soudage de tôles
partie du corps peut être en contact avec la masse. galvanisées plombées, ou cadmiées ou tout autre métal qui
c. Maintenir le porte-électrode, la pince de masse, le câble de produit des fumeés toxiques.
soudage et la machine à souder en bon et sûr état defonc-
tionnement. 10. Ne pas souder en présence de vapeurs de chlore provenant
d.Ne jamais plonger le porte-électrode dans l’eau pour le d’opérations de dégraissage, nettoyage ou pistolage. La
refroidir. chaleur ou les rayons de l’arc peuvent réagir avec les vapeurs
e. Ne jamais toucher simultanément les parties sous tension du solvant pour produire du phosgéne (gas fortement toxique)
des porte-électrodes connectés à deux machines à soud- ou autres produits irritants.
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
f. Si on utilise la machine à souder comme une source de le code “Code for safety in welding and cutting” CSA Standard
courant pour soudage semi-automatique, ces precautions W 117.2-1974.
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
PRÉCAUTIONS DE SÛRETÉ POUR
enrouler le câble-électrode autour de n’importe quelle partie LES MACHINES À SOUDER À
du corps.
TRANSFORMATEUR ET À
3. Un coup d’arc peut être plus sévère qu’un coup de soliel, REDRESSEUR
donc:
a. Utiliser un bon masque avec un verre filtrant approprié 1. Relier à la terre le chassis du poste conformement au code de
ainsi qu’un verre blanc afin de se protéger les yeux du ray- l’électricité et aux recommendations du fabricant. Le dispositif
onnement de l’arc et des projections quand on soude ou de montage ou la piece à souder doit être branché à une
quand on regarde l’arc. bonne mise à la terre.
b. Porter des vêtements convenables afin de protéger la peau
de soudeur et des aides contre le rayonnement de l‘arc. 2. Autant que possible, I’installation et l’entretien du poste seront
c. Protéger l’autre personnel travaillant à proximité au effectués par un électricien qualifié.
soudage à l’aide d’écrans appropriés et non-inflammables.
3. Avant de faires des travaux à l’interieur de poste, la debranch-
4. Des gouttes de laitier en fusion sont émises de l’arc de er à l’interrupteur à la boite de fusibles.
soudage. Se protéger avec des vêtements de protection libres
de l’huile, tels que les gants en cuir, chemise épaisse, pan- 4. Garder tous les couvercles et dispositifs de sûreté à leur
talons sans revers, et chaussures montantes. place.
5. Toujours porter des lunettes de sécurité dans la zone de

soudage. Utiliser des lunettes avec écrans lateraux dans les
zones où l’on pique le laitier.
Mar. ‘93
SAE400 WELD’N AIR

vii vii
for selecting a QUALITY product by Lincoln Electric. We want you

Thank You to take pride in operating this Lincoln Electric Company product •••
as much pride as we have in bringing this product to you!
Please Examine Carton and Equipment For Damage Immediately

When this equipment is shipped, title passes to the purchaser upon receipt by the carrier. 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 & Number _____________________________________
Code & 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:
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.
SAE400 WELD’N AIR

viii TABLE OF CONTENTS viii
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-3
Engine Cooling System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .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-1
Welder . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .B-1
Auxiliary Power . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .B-1
Compressed Air . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .B-1
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
Break-In Period . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .B-5
Typical Fuel Consumption . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .B-5
Starting Welders with Dead Batteries . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .B-9

Auxiliary Power . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . B-9
Duty Cycle . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . B-9
Starting Instructions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . B-9
Break-In Period . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . B-9
Accessories . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Section C
Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Section D
Routine Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . D-1
Periodic Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . D-1
Troubleshooting Guide . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Section E
Wiring Diagrams and Dimension Print . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Section F
Parts List . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .P303 Series, P25-L & P78-D
SAE400 WELD’N AIR

A-1 INSTALLATION A-1
TECHNICAL SPECIFICATIONS - SAE400 WELD’N AIR
INPUT - DIESEL ENGINE

Make/Model Description Speed (RPM) Displacement Starting Capacities
System
Perkins 4 cylinder High Idle 1800 236 cu. in 12VDC batteries Fuel: 22.5 gal.
4.236 Diesel 63 HP @ Low Idle 1100 (3.87 L) (2) & Starter 85.1 L
Engine 1725 RPM Full Load 1725
Bore x Stroke Oil: 8.5 Qts.
8.04 L
3.875” x 5.00”
(98.4 mm x 127.0mm) Coolant: 3.6 gal.
13.63 L
RATED OUTPUT - WELDER

Duty Cycle (1)
Welding Output Volts at Rated Amps
60% (NEMA) 400 amps 36 volts
60% (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 & Rating Operating Pressure Oil Capacity
IMT 4-cylinder 35 CFM 11 Gallons Loads at 95 P.S.I. 1.33 Quarts
(Iowa Mold Reciprocating, at 100 P.S.I. (41.6 Liters) (6.7 kg/cm2) (1.26 Liters)
Tooling/ Diamond Water Cooled, at 60% Maximum Allowable Unloads at 125 P.S.I. IMT’s
Air) Pressure Lubricated Duty Cycle (1) Working Pressure (8.8 kg/cm2) Synthetic
Aluminum Alloy 991 Liters/min. 150 PSI Compressor
Model Block with Cast- at 7.0 kg/cm2 (10.5 kg/cm2) Oil
DA435ELW Iron sleeves
PHYSICAL DIMENSIONS
HEIGHT WIDTH DEPTH WEIGHT
50.13 in. 28.00 in. 83.00 in. 2294 lbs.
1273.3 mm 711.2 mm 2108.2 mm 1040.6 kg
(1)
Based on a 10 minute period.
SAE400 WELD’N AIR

Read this entire installation section before you STACKING

start installation.
SAE400 WELD’N AIR machines cannot be stacked.
SAFETY PRECAUTIONS
ANGLE OF OPERATION
WARNING
To achieve optimum engine performance the SAE400
Do not attempt to use this equipment until you have WELD’N AIR should be run in a level position. The
thoroughly read all operating and maintenance man- maximum angle of operation for the air compressor is
uals supplied with your machine. They include impor- 20 degrees in all directions. If the compressor is to be
tant safety precautions, detailed engine starting, operated at an angle, provisions must be made for
operating and maintenance instructions and parts checking and maintaining the oil level at the normal
lists. (FULL) oil capacity in the compressor crankcase. The
maximum angle of operation for the Perkins engine is
ELECTRIC SHOCK can kill. 45 degrees in all directions. If the engine is to be oper-
ated at an angle, provisions must be made for check-
•Do not touch electrically live parts such ing and maintaining the oil level at the normal (FULL)
as output terminals or internal wiring. oil capacity in the engine crankcase. When operating
the welder at an angle, the effective fuel capacity will
•Insulate yourself from the work and be slightly less than the specified 22.5 gallons.
ground.
LIFTING
•Always wear dry insulating gloves.
------------------------------------------------------------------------ The SAE400 WELD’N AIR lift bale should be used to
lift the machine.
ENGINE EXHAUST can kill.
•Use in open, well ventilated areas or

vent exhaust outside
WARNING
•Do not stack anything near the engine. FALLING EQUIPMENT can cause
------------------------------------------------------------------------ injury.
MOVING PARTS can injure. •Do not lift this machine using lift bale if
it is equipped with a heavy accessory
•Do not operate with doors open or such as a trailer or gas cylinder.
guards off.
•Lift only with equipment of adequate
•Stop engine before servicing. lifting capacity.
•Keep away from moving parts •Be sure machine is stable when lifting.
------------------------------------------------------------------------ ------------------------------------------------------------------------
Only qualified personnel should install, use or 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.
SAE400 WELD’N AIR

HIGH ALTITUDE OPERATION ENGINE OIL
At higher altitudes, output derating may be necessary. The WELD’N AIR is shipped with the engine crankcase
As a rule of thumb, derate the welder output 5% for filled with high quality SAE 10W-30 oil (API class CD or
every 500 meters (1640 ft.) above 1000 meters (3280 better). Check the oil level before starting the engine. If it
ft.). is not up to the full mark on the dip stick, add oil as
required. Check the oil level every four hours of running
Contact a Perkins Service Representative for any time during the first 35 running hours. Refer to the engine
engine adjustments that may be required for high alti- Operator’s Manual for specific oil recommendations and
tude operation. 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 ser-
vice and maintenance intervals.
TOWING
AIR COMPRESSOR OIL
The recommended trailers for use with this equipment
(1)
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 The WELD’N AIR is shipped with the compressor filled
are also designed to be used at highway speeds(1).If the with a high quality synthetic compressor oil. If oil is
user adapts a non-Lincoln trailer, he must assume needed add only Iowa Mold Tooling Co., Inc. (IMT) syn-
responsibility that the method of attachment and usage thetic compressor oil until compressor is full.
does not result in a safety hazard nor damage the
welding equipment. Some of the factors to be consid- CAUTION
ered are as follows:
The use of any other oil causes excessive carbon build
1. Design capacity of trailer vs. weight of Lincoln up, and will void the warranty on the compressor.
equipment and likely additional attachments. ------------------------------------------------------------------------
Check the oil level daily. Refer to the compressor
2. Proper support of, and attachment to, the base of Operator’s Manual for the proper service and mainte-
the welding equipment so that there will be no nance intervals.
undue stress to the trailer’s framework.
FUEL USE DIESEL FUEL ONLY
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. WARNING
4. Typical conditions of use, such as travel speed, •Stop engine and allow to cool before
roughness of surface on which the trailer will be fueling.
operated, and environmental conditions. •Do not smoke when fueling.
•Fill fuel tank at a moderate rate and do
5. Proper preventative maintenance of trailer. not overfill.
•Wipe up spilled fuel and allow fumes to
6. Conformance with federal, state and local laws.1 clear before starting engine.
•Keep sparks and flame away from
tank.
(1)
For highway use, consult applicable federal, state ------------------------------------------------------------------------
and local laws regarding specific requirements for
use on public highways, such as brakes, lights, fend- Fill the fuel tank with clean, fresh diesel fuel. The capac-
ers, etc. ity of the fuel tank is 22.5 gallons (85.1 liters). See engine
Operator’s 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-
PRE-OPERATION ENGINE AND dle counterclockwise.
COMPRESSOR SERVICE
READ the engine and compressor operating and main-
tenance instructions supplied with this machine.
SAE400 WELD’N AIR

ENGINE COOLING SYSTEM To prevent BATTERY BUCKLING, tighten nuts on bat-

teries only until snug. DO NOT OVERTIGHTEN.
The cooling system has been filled at the factory with
a 50-50 mixture of ethylene glycol antifreeze and SPARK ARRESTER
water. Check the radiator level and add a 50-50 solu-
tion as needed. (See Engine Manual or antifreeze con- Some federal, state or local laws may require that
tainer for alternate antifreeze recommendation.) gasoline or diesel engines be equipped with exhaust
spark arresters when they are operated in certain loca-
BATTERY CONNECTION tions where unarrested sparks may present a fire haz-
ard. The standard muffler included with this welder
WARNING: Use caution as the electrolyte is a strong
does not qualify as a spark arrester. When required by
acid that can burn skin and damage eyes.
local regulations, a suitable spark arrester must be
installed and properly maintained.
Remove and discard the insulating caps from the neg-
ative battery terminals. Attach and tighten negative
battery cable terminals. CAUTION
An incorrect arrester may lead to damage to the engine
NOTE: This machine is furnished with wet charged
or adversely affect performance. Contact the engine
batteries; if unused for several months, the batteries
manufacturer for specific recommendations.
may require a booster charge. Be careful to charge the
------------------------------------------------------------------------
batteries with the correct polarity. Make sure that the
batteries are level while charging.
WARNING
GASES FROM BATTERY can explode.
● Keep sparks, flame and cigarettes
away from battery.
To prevent EXPLOSION when:

● 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.
BATTERY ACID can burn eyes and
skin.
● Wear gloves and eye protection
and be careful when working near
battery.
● Follow instructions printed on battery.
IMPORTANT: To prevent ELECTRICAL DAMAGE

WHEN:
a) Installing new batteries.
b) Using a booster.
Use correct polarity — Negative Ground.
SAE400 WELD’N AIR

WELDING OUTPUT CABLES
With the engine off, connect the electrode and work To prevent dangerous electric shock, other equipment
cables to the studs provided. These connections powered by this engine driven welder must:
should be checked periodically and tightened if neces-
sary. a) be grounded to the frame of the welder using a
grounded type plug,
Listed in Table A.1 are copper cable sizes recom- or
mended for the rated current and duty cycle. Lengths b) be double insulated.
stipulated are the distance from the welder to work and
back to the welder again. Cable sizes are increased for When this welder is mounted on a truck or trailer, its
greater lengths primarily for the purpose of minimizing frame must be securely connected to the metal frame
cable voltage drop. 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
Table A.1 Combined Length of Electrode and Work ground. See the article on grounding in the latest U.S.
Cables. National Electrical Code and the local code.
TOTAL COMBINED LENGTH OF ELEC-
In general, if the machine is to be grounded, it should
TRODE AND WORK CABLES
be connected with a #8 or larger copper wire to a solid
AMPS Up to 100 100-200 FT. 200-250 FT. earth ground such as a metal water pipe going into the
@60% FT. ground for at least ten feet and having no insulated
Duty Cycle joints, or to the metal framework of a building which
has been effectively grounded. The U.S. National
400 2/0 AWG 3/0 AWG 4/0 AWG 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.
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.).
SAE400 WELD’N AIR

B-1 OPERATION B-1
OPERATING INSTRUCTIONS GENERAL DESCRIPTION

Read and understand this entire section before operat- The SAE400 WELD’N AIR is a diesel engine driven
ing your SAE400 WELD’N AIR. welding power source. The machine uses a DC gen-
erator for DC stick electrode welding and an AC exciter
SAFETY INSTRUCTIONS for 115/230 VAC auxiliary power. As a generator it can
supply up to 3,000 watts of 115/230 volt AC power. As
WARNING a welder it provides up to 575 amps of DC constant
Do not attempt to use this equipment until you have current output. The belt driven air compressor provides
thoroughly read all operating and maintenance man- 35 CFM at 100 PSI compressed air.
uals supplied with your machine. They include impor-
tant safety precautions, detailed engine starting, oper- The engine is a 63 Hp (47kw), 4-cylinder water cooled
ating and maintenance instructions and parts lists. diesel made by Perkins.
ELECTRIC SHOCK can kill. RECOMMENDED APPLICATIONS

•Do not touch electrically live parts such WELDER
as output terminals or internal wiring.
The SAE400 WELD’N AIR provides excellent constant
•Insulate yourself from the work and current DC welding output for stick (SMAW) welding.
ground. The field installed optional CV Adapter (K385-1) pro-
vides up to 500 amps at 35 volts of constant voltage
•Always wear dry insulating gloves. output for semiautomatic welding.
------------------------------------------------------------------------
ENGINE EXHAUST can kill. AUXILIARY POWER
•Use in open, well ventilated areas or The SAE400 WELD’N AIR provides 3 KW of 115/230
vent exhaust outside VAC output for auxiliary power and emergency stand-
by power.
•Do not stack anything near the engine.
------------------------------------------------------------------------ COMPRESSED AIR
MOVING PARTS can injure.
The SAE400 WELD’N AIR provides 35 CFM at 100
•Do not operate with doors open or PSI compressed air for air arc gouging and air powered
guards off. tools.
•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 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.
SAE400 WELD’N AIR

B-2 OPERATION B-2
DESIGN FEATURES AND ADVANTAGES • Gauges for engine oil pressure, coolant temperature,
battery charging ammeter, compressor air pressure
FOR STICK WELDING and compressor oil pressure.
• Excellent DC constant current output for stick weld-
ing applications. • Indicator light for compressor operation.
• Continuous adjustment of both voltage and current • Engine hour meter standard.
for unsurpassed welds on demanding jobs.
• Extended range 22.5 gallon (85.1 L) fuel tank.
• Remote control capability standard.
DUTY CYCLE
FOR AUXILIARY POWER
Duty cycle is based on a ten minute period and opera-
• 3,000 watts of 115/230 VAC, 60 Hz auxiliary power. tion in an ambient temperature of 104°F(40°C).
• One 15 amp 115 VAC duplex receptacle for up to 26 The SAE400 WELD’N AIR is NEMA rated at 60% duty
amps of 115 VAC power. cycle. Duty cycle is based on a ten minute period.
Therefore, a 60% duty cycle welder can be operated at
• One 15 amp, 230 VAC duplex receptacle for up to 13 nameplate rated output for 6 minutes out of every 10
amps of 230 VAC power. minute period without overheating.
• Weld and AC auxiliary power at the same time (with- The auxiliary power can be used continuously (100%
in the limits shown on the chart below). duty cycle) within its rated current capacities.
Welding Using Only Using Only Total The air compressor is rated at a 60% duty cycle based
Current, Amps 115V Circuit, 230V Circuit, Aux.
@ NEMA Arc Amps Amps kVA
on a ten minute period as described above.
Volts
0 26 13 3.0
100 19.5 9.75 2.25
200 13 6.5 1.5
300 6.5 3.25 0.75
400 0 0 0
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.
SAE400 WELD’N AIR

B-3 OPERATION B-3
ENGINE CONTROLS WELDER CONTROLS
IGNITION SWITCH POLARITY SWITCH
When placed in the “ON” position, this switch energizes Turn the Arc Polarity switch to electrode positive or
the fuel solenoid. When placed in the “OFF” position, electrode negative as required for each particular
the flow of fuel to the injection pump is stopped to shut application.
down the engine.
CONTROL OF WELDING CURRENT
SPEED CONTROL LEVER
Purpose of Controls
Manually allows the engine to run at its high idle speed
controlled by the governor or at the factory set low idle The continuous “Current Control” is the main current
speed. When welding, using air compressor or using adjuster. The “Job Selector” is both a fine current
auxiliary power the speed control lever must be in the adjuster and the continuous Open Circuit Voltage
“RUN” position. To reduce the engine to low idle speed adjuster. Open Circuit Voltage (OCV) controls the arc
when not welding, not using the compressor or not characteristics.
using auxiliary power place the speed control lever in
the “IDLE” position notch. “Job Selector”
The “Job Selector” dial is divided into four colored sec-

ENGINE TEMPERATURE GAUGE tions providing OCV ranges as follows:
Displays the coolant temperature in the engine block. Color Title OCV Range
White Large Electrodes High OCV
ENGINE OIL PRESSURE GAUGE Black Normal Welding Medium OCV
Red Overhead & Vertical Low OCV
Displays the oil pressure to the engine. When the Grey Special Applications Extra-Low OCV
engine starts running, watch for the oil pressure to
build up. If no pressure shows within 30 seconds, stop The “Job Selector” is usually set in the black range
the engine and consult the engine instruction manual. 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
BATTERY CHARGING AMMETER when welding vertical up or overhead.
Displays the current going from the charging alternator “Current Control”
into the batteries. It is normal for charging current to be
high (above 15 amps) after starting or when the batter- CAUTION
ies are ‘low’ on charge.
Do not adjust the “Current Control” while welding
because this can damage the control.
ENGINE HOUR METER ------------------------------------------------------------------------
The “Current Control” dial is calibrated in amperes on
The engine hour meter records the total running time three separate colored dials corresponding to the
on the engine in hours. It can be used to keep a record white, black and red ranges of the “Job Selector” dial.
of maintenance on the engine and or welder. 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.
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.
SAE400 WELD’N AIR

B-4 OPERATION B-4
How to Set the Controls 15 AMP Circuit Breakers
Assume you want a normal soft arc and about 135 These circuit breakers provide separate overload cur-
amps, using a 5/32” (4.0 mm) electrode: rent protection for each half of the 115 V duplex recep-
tacle. The circuit breakers provide overload current pro-
1. Set the “Job Selector” at the center of the black tection in both current carrying wires of the 230 V
range. duplex receptacle.
2. Set the “Current Control” to read 135 amps on the Ground Stud
black dial.
Provides a connection point for connecting the
3. Start to weld. machine to earth ground. For the safest grounding pro-
cedure refer to “Machine Grounding” in the INSTALLA-
4. If you want a little more current, turn the “Job TION section of this manual.
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
5. If dialing the desired current with the “Job
Selector” moves the setting outside the black COMPRESSOR ON/OFF SWITCH
range causing undesirable arc characteristics, turn
the “Job Selector” back to the center of the black Placing the “ON/OFF” switch in the “ON” position
range. Then turn the “Current Control” up or down allows the “pressure switch” (factory preset) to control
a little as needed. Readjust the “Job Selector” for the air compressor through an electric clutch. When the
the exact characteristics and current desired. system pressure falls below 90 psi, the “pressure
switch” engages the clutch and compressor. When the
system pressure goes above 130 psi, the “pressure
REMOTE CONTROL switch” disengages the clutch and compressor.
A receptacle and “Local/Remote” control switch on the The “ON/OFF” switch needs to be in the “ON” position
lower front control panel and a remote control box with when using compressed air. When placed in the “OFF”
25 ft. (7.6 m) of 3-conductor cord for adjusting the OCV position this switch does not allow the compressor
at the welding site. Putting the switch in the “REMOTE” clutch to engage regardless of the tank pressure.
position allows fine current control at the remote con-
trol box while placing the switch in the “LOCAL” position The “ON/OFF” switch should be in the “OFF” position
allows fine current control at the “Job Selector” on the while starting the engine. This will minimize the load on
machine. When using the optional field installed CV the starter motor.
adapter (K385-1) the “Local/Remote” switch is only
active in the “VV” mode.
COMPRESSOR OPERATING LIGHT
AUXILIARY POWER CONTROLS This light is on when the compressor “ON/OFF” switch
is in the “ON” position.
115 VAC Receptacle
One 15 amp, 115 VAC duplex receptacle provides 115 COMPRESSOR AIR PRESSURE GAUGE
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
One 15 amp, 230 VAC duplex receptacle provides 230 COMPRESSOR OIL PRESSURE GAUGE
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 WELD’N AIR

B-5 OPERATION B-5
ENGINE OPERATION BREAK-IN PERIOD

CAUTION ENGINE
Do not adjust the high idle engine speed (rpm) above
the factory setting specification as this will overspeed The engine used to supply power for your welder is a
the air compressor and void it’s warranty. 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-
STARTING INSTRUCTIONS plished. Check the oil level twice a day during the
break-in period (about 100 running hours).
Be sure all Pre-Operation Maintenance has been per-
formed. (See INSTALLATION section of this manual). IMPORTANT: IN ORDER TO ACCOMPLISH THIS
Set the air compressor “ON/OFF” switch in the “OFF” BREAK-IN, THE UNIT SHOULD BE SUBJECTED TO
position. To start the engine, set the speed control lever HEAVY LOADS, WITHIN THE RATING OF THE
in the “RUN” position. Place ignition toggle switch in MACHINE. AVOID LONG IDLE RUNNING PERIODS.
the “ON” position. Push in the engine protection sys-
tem reset button. Engage the starter button. When the AIR COMPRESSOR
engine starts running, observe the engine oil pressure.
If no pressure shows within 30 seconds, stop the Cylinder head stud torque must be checked after initial
engine and consult the engine operating manual. To 8 to 10 hours of operation. See compressor operator’s
stop the engine, place the ignition toggle switch in the manual for details. Compressor mounting bolts should
“OFF” position. be checked for tightness after initial 8 to 10 hours of
operation.
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 TYPICAL FUEL CONSUMPTION
about five minutes and then stop the engine and
recheck the oil. If the level is down, fill to the full mark The typical fuel consumption of the SAE400 WELD’N
again. The engine controls were properly set at the fac- AIR for various operating scenarios is shown below:
tory and should require no adjusting when received.
Low Idle - No Load .35 gal./ hr.
For added safety always operate the welder with the 1100 RPM (1.32 L./hr.)
doors closed. Further, leaving the doors open changes
the designed air flow and may cause engine, generator High Idle - No Load .75 gal./hr.
or compressor overheating. 1800 RPM (2.84 L./hr.)
Cold Weather Starting Welding Load 1.92 gal./hr.

400 Amps, 40 Volts (7.27 L./hr.)
WARNING
Auxiliary Power .96 gal./hr.
Never use any other starting aids, such as ether, when 3000VA (3.63 L./hr.)
using the “Thermostart” system.
------------------------------------------------------------------------ Air Compressor 1.04 gal./hr.
When overnight temperatures are between 10°F (- (3.94 L./hr.)
12°C) and freezing, use the standard “Thermostart”
starting system installed on all engines. Follow the 400 Amps, 40 Volts Load 2.22 gal./hr.
instructions on the start panel nameplate and in the with Air Compressor “ON” (8.40 L./hr.)
engine manual shipped with the welder. With fully
charged batteries and the proper weight oil, the Auxiliary Power 1.20 gal./hr.
“Thermostart” system operates satisfactorily even 3000 VA with (4.54 L./hr.)
down to about 0°F (-18°C). Air Compressor “ON”
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.
SAE400 WELD’N AIR
C-1 ACCESSORIES C-1
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(1) 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(1), off road, in-plant and yard towing. The K956-2
trailer is equipped with electric brakes. Trailer mounts
directly to welder base.
1For 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.
WARNING
Pipe Thawing IS NOT a CSA approved procedure. If
not done properly, it can result in fire, 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

D-1 MAINTENANCE D-1
Note: Water and fuel should be drained into a suit-

WARNING able container for proper disposal.
ELECTRIC SHOCK can kill. COMPRESSOR AIR RECEIVER TANKS

● Do not touch electrically live parts
such as output terminals or inter- Drain the condensation from the tanks after each use
nal wiring by opening the drain valve located at the lower right
rear of the welder.
ENGINE EXHAUST can kill. ENGINE AIR FILTER

● Use in open, well ventilated areas
or vent exhaust outside 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
MOVING PARTS can injure. with compressed air or water hose directed from inside
● Do not operate with doors open or out. Compressed Air: 100 psi maximum. The filter
guards off should never be removed while the engine is running.
● Stop engine before servicing
● Keep away from moving parts
PERIODIC MAINTENANCE
1. Blow out the welder and controls with an air hose at least
● Remove guards only when necessary and
once every two months. In particularly dirty locations, this
replace when work requiring removal is com-
cleaning may be necessary once a week. Use low pres-
plete.
sure air to avoid driving dirt into the insulation.
● Only qualified personnel should install, use, or
service this equipment. 2. The current control reactor brushes are self-lubricating
and should not be greased. Keep the contacts clean. This
ROUTINE MAINTENANCE control should be moved from maximum to minimum daily
to prevent the controls from sticking.
At the end of each day’s welding, refill the fuel tank to
minimize moisture condensation in the tank. Also, run- 3. See the engine Instruction Manual for periodic engine
ning out of fuel tends to draw dirt into the fuel system. maintenance information. Change the crankcase oil at
Check the engine crankcase and compressor oil levels. regular intervals using the proper grade of oil as recom-
mended in the engine operating manual. Change the oil
If the fuel supply runs out while the fuel pump is oper- filter in accordance with the instructions in the engine
ating, air may be entrapped in the fuel distribution sys- operating manual. When the oil filter is changed add one
tem. If this happens, bleeding of the fuel system may quart of oil to the crankcase to replace the oil held in the
be necessary. See the engine instruction manual. filter during operation.
FUEL SYSTEM WATER SEPARATOR 4. See the compressor operator’s manual for periodic com-
MAINTENANCE pressor maintenance information. Change the compres-
sor oil at regular intervals using only Iowa Mold Tooling
If the fuel system on the engine is equipped with a Co., Inc. (IMT) synthetic compressor oil as recommended
water separator, the following maintenance proce- in the compressor operating manual.
dures must be followed.
Inspect the glass bowl for any accumulation of water CAUTION
on a daily basis. If water is present:
The use of any other oil causes excessive carbon build up,
and will void the warranty on the compressor.
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
5. Belts tend to loosen after the first 30 or 40 hours of oper-
not remove the screw completely.
ation. Check the cooling fan belt and tighten if necessary.
3. Drain until the water has visibly drained from the
DO NOT OVER TIGHTEN. The compressor belt does not
bowl and only clear fuel starts to flow from the
require any adjustment.
drain valve.
4. Close the drain screw tightly by hand.
SAE400 WELD’N AIR

D-2 MAINTENANCE D-2
BEARING MAINTENANCE between slip rings and brushes with the coarse side
against the brushes. With slight additional finger pres-
This welder is equipped with a double-shielded ball bearing sure on top of the brushes, pull the sandpaper around
having sufficient grease to last indefinitely under normal ser- the circumference of the rings, in direction of rotation
vice. Where the welder is used constantly or in excessively only - until brushes seat properly. In addition, stone
dirty locations, it may be necessary to add one-half ounce of slip ring with a fine stone. Brushes must be seated
grease per year. A pad of grease one inch wide, one inch 100%. Arcing or excessive exciter brush wear indicates
long and one inch high weighs approximately one-half a possible misaligned shaft. Have an authorized Field
ounce. Over greasing is far worse than insufficient greasing. Service Shop check and realign the shaft.
When greasing the bearings, keep all dirt out of the area.
Wipe the fittings completely clean and use clean equipment. COOLING SYSTEM
More bearing failures are caused by dirt introduced during The SAE400 WELD’N AIR is equipped with a pressure
greasing than from insufficient grease. radiator. Keep the radiator cap tight to prevent loss of
coolant. Clean and flush the cooling system periodi-
COMMUTATOR AND BRUSH MAINTENANCE cally to prevent clogging the passage and overheating
the engine. When antifreeze is needed, always use the
WARNING permanent type.
Uncovered rotating equipment can be dangerous. ENGINE AND COMPRESSOR MAINTENANCE

Use care so your hands, hair, clothing or tools do COMPONENTS
not catch in the rotating parts. Protect yourself ITEM MAKE PART NUMBER
from particles that may be thrown out by the rotat- Engine Air Filter Donaldson P181052
ing armature when stoning the commutator. Fan Belt Lincoln S19730
------------------------------------------------------------------------ Gates 8129
The generator brushes are properly adjusted when the Compressor Belt Lincoln S23887
welder is shipped. They require no particular attention. Gates 2/A40
DO NOT SHIFT THE BRUSHES or adjust the rocker Fuel Filter Perkins 26561117
setting. Engine Oil Filter Perkins 2654403
Shifting of the brushes may result in:
- Change in machine output
- Commutator Damage REPLACING AIR COMPRESSOR DRIVE BELT
- Excessive brush wear
Periodically inspect the commutator, slip rings and CAUTION
brushes by removing the covers. DO NOT remove or
replace these covers while the machine is running. Belt is tensioned using a automatic tensioning device.
Remove with care.
Commutators and slip rings require little attention. ------------------------------------------------------------------------
However, if they are black or appear uneven, have To remove compressor belt:
them cleaned by an experienced maintenance man 1. Remove nut and lock washer from lower locking
using fine sandpaper or a commutator stone. Never bolt on idler tension flange.
use emery cloth or paper for this purpose. 2. Loosen center mounting bolt on idler tensioner 1/2
turn or until it moves freely.
NOTE: If the welder is used in dirty or dusty locations, 3. Using a pipe wrench or equivalent tool, turn ten-
or if the welder is not used for prolonged periods of sioner body slightly to free locking bolt. Remove
time, it may be necessary to clean the commutator and locking bolt and slowly release tension on belt.
slip rings more often. Remove belt.
Replace brushes when they wear within 1/4" of the pig- Note: Do not loosen or remove compressor mounting
tail. A complete set of replacement brushes should be bolts. Pulley misalignment may result.
kept on hand. Lincoln brushes have a curved face to fit To install belt (after following above procedure):
the commutator. Have an experienced maintenance 1. Mount belt into pulley grooves and over idler pul-
man seat these brushes by lightly stoning the commu- ley.
tator as the armature rotates at full speed until contact 2. Using a pipe wrench or suitable tool, turn idler
is made across the full face of the brushes. body to realign locking slot in idler flange with lock-
After stoning, blow out the dust with low pressure air. ing hole. Insert locking bolt and tighten before
releasing idler body. Tighten center mounting bolt.
To seat the slip ring brushes, position the brushes in Note: Ensure that both belt strands are running prop-
place. Then slide one end of a piece of fine sandpaper erly in pulley grooves.
SAE400 WELD’N AIR

E-1 TROUBLESHOOTING E-1
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.
__________________________________________________________________________
For Air Compressor trouble shooting see the Step 1. LOCATE PROBLEM (SYMPTOM).
air compressor operator’s manual. Look under the column labeled “PROBLEM
(SYMPTOMS)”. This column describes pos-
For Engine trouble shooting see the engine sible symptoms that the machine may exhib-
operator’s guide. it. Find the listing that best describes the
symptom that the machine is exhibiting.
For Generator trouble shooting follow this Step 2. POSSIBLE CAUSE.
guide. The second column labeled “POSSIBLE
CAUSE” lists the obvious external possibili-
This Troubleshooting Guide is provided to ties that may contribute to the machine
help you locate and repair possible machine symptom.
malfunctions. Simply follow the three-step Step 3. RECOMMENDED COURSE OF
procedure listed. 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 you local Lincoln
Authorized Field Service Facility.
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 WELD’N AIR
Observe all Safety Guidelines detailed throughout this manual
PROBLEMS RECOMMENDED
POSSIBLE CAUSE
(SYMPTOMS) COURSE OF ACTION
FUNCTION PROBLEMS
Machine fails to hold the “heat” Rough or dirty commutator. True and clean commutator.
constantly.
Brushes may be worn down to limit Replace brushes.
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 discover varying current. This
open circuit, due to loose connec- applies to both the main generator
tions or broken wire. and exciter.
Electrode or work lead connections Tighten all connections.

may be poor.
Wrong grade of brushes may be Use only the recommended Lincoln

installed on generator. 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 screw
ing properly. in control handles.
“Current Control” brushholder con- Inspect. Replace needed parts.

tact springs may be worn out or Clean internal contact surface of
missing. Contact surface may be control device. Do not lubricate.
dirty, rough and pitted. Smooth rough surfaces.
“Current Control” brushholder sup- If brushholder internal contact sur-

port stud and mating contact surface is pitted and burned, replace
faces may be dirty or pitted and the brushholder and support stud. If
burned. 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
SAE400 WELD’N AIR

POSSIBLE CAUSE
FUNCTION PROBLEMS
Welder runs but fails to generate Generator or exciter brushes may be Be sure that all brushes bear on the
current. loose or missing. 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
SAE400 WELD’N AIR

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 Check to see that series field is

and welder output so great that properly connected and not shorted.
engine stalls when arc is struck.
Welder has output and no control Local/Remote switch is in wrong Place switch in “LOCAL” position to
position. control output at the welder. Place
switch in “REMOTE” position to con-
trol output remotely.
CAUTION
SAE400 WELD’N AIR

POSSIBLE CAUSE
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
SAE400 WELD’N AIR

CONTROL WIRING DIAGRAM - SAE-400 WELD’N AIR
F-1
PLUG FOR
COLOR CODE RECEPTACLE FOR REMOTE
RESISTORS REMOTE CONTROL
CONTROL RHEOSTAT W
B-BLACK
COPPER
ALTERNATOR
G-GREEN TERMINAL
ROTOR
N-BROWN + - B
SLIP GROUND
R-RED
RINGS TERMINAL
FLASHING DIODE G (WIDE TAB)
U-BLUE
AND RESISTOR W
W-WHITE G
B G
Y-YELLOW CONNECT TO CASE
G
W REMOTE CONTROL
NEG RHEOSTAT BOX
POS
TO ALT. EXC. B GROUND TERMINAL
B
TERMINAL (WIDE SLOT)
R
G
GROUND 1 4
3 2
SCREW (+)
SWITCH FOR LOCAL OR
REMOTE CONTROL (SHOWN
AC AC 500 Y IN LOCAL POSITION)
G POLARITY
G G (-) 1
U SWITCH
2
4 3
230V DUPLEX N
WHITE 4 5
RECEPTACLE TERMINALS REACTOR
U
ALTERNATOR
SAE400 WELD’N AIR

R
AUXILIARY N
BACK VIEW
B POWER WDG. OF POLARITY
SWITCH
WIRING DIAGRAMS
F
E
A 2
1
FRONT VIEW
OF RECEPTACLES B 3
ELECTRODE
115V DUPLEX TO WORK

CB1 CB2 CB3 CB4 RECEPTACLE
B
NOTE:
CB1, CB2, CB3 & CB4 - RATED 15A,
250V
ELECTRICAL SYMBOLS PER E1537 C-RW
M18827
NOTE: This diagram is for reference only. It may not be accurate for all machines covered by this manual. The
F-1
specific diagram for a particular code is pasted inside the machine on one of the enclosure panels.
ENGINE WIRING DIAGRAM - SAE-400 WELD’N AIR
F-2
LEAD APPEARS ON EARLIER UNITS ONLY

ENGINE HOUR METER
GENERAL MAINTENANCE INSTRUCTIONS FOR

THE SAE-400 WELD’N AIR
TO FLASHING DIODE
+
-
Y THERMOSTART
EXC IGNITER
THERMOSTART WARNING: - Have only qualified personnel perform

maintenance work.
+
Y B
- Turn the engine or input power OFF before
B maintenance work unless the maintenance work
B requires it to be running.
START
ALTERNATOR - Keep hands, hair, clothing and tools away
+
- MOVING
from moving parts, and insure all guards or
PARTS covers are replaced after servicing.
COLD CAN INJURE
G B TERMINAL
85
U Compressor
AMMETER
Enable 30
Y Y 87a
87 MAINTENANCE INSTRUCTIONS
G
86
B
G
B
IGNITION
SWITCH Fuse (10A) DAILY CHECKS:
- Electrode and work connections are tight.

ENGINE B B
Compressor
- Rotate the current control twice to clean
PROTECTION Pressure SW.
Clutch contacts.
RELAY
- All equipment in serviceable condition.
Y
R - Coolant, Engine & Compressor oil to be at
SAE400 WELD’N AIR

proper operating levels. (Use only IMT
FUSE Synthetic Compressor oil.
(SFE 14) - Engine air cleaner, Compressor air filter and
S
+
+
Fuel strainer to be clean of contamination

WIRING DIAGRAMS
OIL PRESSURE G N O NC S B
SWITCH (N.C.)
STARTING AS REQUIRED:
MOTOR - -
- Blow dust from the machine using clean low
B
pressure air.
- Clean commutators or slip rings with fine
G
sandpaper-
NOT EMERY CLOTH. See the
ENGINE GROUND Operating Manual for instructions.
FUEL SHUT
Y OFF VALVE - Replace brushes before the pigtail is within
1/4" of the commutator. See the Operating
Manual for instructions.
TEMPERATURE GAGE
- Grease may be added to bearings no more than
once a year. See instructions in the
Operating Manual.
FUEL INJECTION PUMP
C-RW
M18777
NOTE: This diagram is for reference only. It may not be accurate for all machines covered by this manual. The
F-2
specific diagram for a particular code is pasted inside the machine on one of the enclosure panels.
F-3
63.06
28.00 43.75
32.87
50.13 39.69 39.38
18.50
SAE400 WELD’N AIR

6.00
DIMENSION PRINT
22.00 44.50 * 8.90
22.14 * 69.75 8.12
CENTER OF GRAVITY
24.50 77.00 3.00
WITH OIL AND
WATER IN ENGINE,
27.12 BUT NO FUEL. 81.25 .88
83.00
= .81 DIA HOLES
* A
M8869-33
= .69 DIA HOLES
F-3
Now Available...12th Edition New Lessons in Arc Welding
The Procedure Handbook of Arc Welding Lessons, simply written, cover manipulatory techniques;
With over 500,000 copies of previous editions published machine and electrode characteristics; related subjects, such
since 1933, the Procedure Handbook is considered by many to as distortion; and supplemental information on arc welding
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This printing will go fast so don’t delay. Place your questions and answers are suggested for each
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The hardbound book contains over 750 pages of welding infor- 528 pages, well illustrated, 6” x 9” size, bound in simulated,
mation, techniques and procedures. Much of this material gold embossed leather.
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a reference for all students by taking advantage of the low quan-
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men use the “short-cut” language of symbols to pass on 22801 St. Clair Ave.
assembly and welding information to shop personnel. Cleveland, Ohio 44117-1199.
Practical exercises and examples develop the reader’s ability and ask for bulletin ED-80 or call 216-383-2259 and ask for the
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● Do not touch electrically live parts or ● Keep flammable materials away. ● Wear eye, ear and body protection.
WARNING electrode with skin or wet clothing.

● Insulate yourself from work and
ground.
Spanish
● No toque las partes o los electrodos ● Mantenga el material combustible ● Protéjase los ojos, los oídos y el
AVISO DE bajo carga con la piel o ropa moja-
da.
fuera del área de trabajo. cuerpo.
PRECAUCION ● Aislese del trabajo y de la tierra.
French ● Ne laissez ni la peau ni des vête- ● Gardez à l’écart de tout matériel ● Protégez vos yeux, vos oreilles et
ments mouillés entrer en contact inflammable. votre corps.
ATTENTION avec des pièces sous tension.
● Isolez-vous du travail et de la terre.
German ● Berühren Sie keine stromführenden ● Entfernen Sie brennbarres Material! ● Tragen Sie Augen-, Ohren- und Kör-
Teile oder Elektroden mit Ihrem perschutz!
WARNUNG Körper oder feuchter Kleidung!
● Isolieren Sie sich von den
Elektroden und dem Erdboden!
Portuguese
● Não toque partes elétricas e elec- ● Mantenha inflamáveis bem guarda- ● Use proteção para a vista, ouvido e
trodos com a pele ou roupa molha- dos. corpo.
ATENÇÃO da.
● 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 WELD’N AIR

● Keep your head out of fumes. ● Turn power off before servicing. ● Do not operate with panel open or
● Use ventilation or exhaust to
remove fumes from breathing zone.
guards off.
WARNING
● Los humos fuera de la zona de res- Spanish
● Desconectar el cable de ali- ● No operar con panel abierto o
piración.
● Mantenga la cabeza fuera de los
mentación de poder de la máquina
antes de iniciar cualquier servicio.
guardas quitadas. AVISO DE
humos. Utilice ventilación o
aspiración para gases.
PRECAUCION
● Gardez la tête à l’écart des fumées. ● Débranchez le courant avant l’entre- ● N’opérez pas avec les panneaux French
● Utilisez un ventilateur ou un aspira- tien. ouverts ou avec les dispositifs de
teur pour ôter les fumées des zones
de travail.
protection enlevés. ATTENTION
● Vermeiden Sie das Einatmen von ● Strom vor Wartungsarbeiten ● Anlage nie ohne Schutzgehäuse German
Schweibrauch! abschalten! (Netzstrom völlig öff- oder Innenschutzverkleidung in
● Sorgen Sie für gute Be- und
Entlüftung des Arbeitsplatzes!
nen; Maschine anhalten!) Betrieb setzen! WARNUNG
Portuguese
● Mantenha seu rosto da fumaça. ● Não opere com as tampas removidas. ● Mantenha-se afastado das partes
● Use ventilação e exhaustão para ● Desligue a corrente antes de fazer moventes.
remover fumo da zona respiratória. serviço. ● Não opere com os paineis abertos ATENÇÃO
● Não toque as partes elétricas nuas. ou guardas removidas.
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 WELD’N AIR

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• 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 Depends on You

• World's Leader in Welding and Cutting Products •

FOR ENGINE 1.h. To avoid scalding, do not remove the

2.d.4. Connect the work cable to the workpiece as close as

ELECTRIC SHOCK can kill. ARC RAYS can burn.

5.e. Also see item 1.b.

WELDING SPARKS can CYLINDER may explode

Assure that tank and compressor relief

PRÉCAUTIONS DE SÛRETÉ 6. Eloigner les matériaux inflammables ou les recouvrir afin de

2. Dans le cas de travail au dessus du niveau du sol, se protéger

5. Toujours porter des lunettes de sécurité dans la zone de

SAE400 WELD’N AIR

for selecting a QUALITY product by Lincoln Electric. We want you

Please Examine Carton and Equipment For Damage Immediately

Code & Serial Number _____________________________________

Date of Purchase _____________________________________

SAE400 WELD’N AIR

Operating Instructions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Section B

Starting Welders with Dead Batteries . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .B-9

Troubleshooting Guide . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Section E

Wiring Diagrams and Dimension Print . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Section F

Parts List . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .P303 Series, P25-L & P78-D

SAE400 WELD’N AIR

TECHNICAL SPECIFICATIONS - SAE400 WELD’N AIR

INPUT - DIESEL ENGINE

RATED OUTPUT - WELDER

60% (NEMA) 400 amps 36 volts

60% (Lincoln Plus) 400 amps 40 volts

80 - 575 Amps 97 Max. OCV 115/230 VAC

OUTPUT - AIR COMPRESSOR

50.13 in. 28.00 in. 83.00 in. 2294 lbs.

1273.3 mm 711.2 mm 2108.2 mm 1040.6 kg

SAE400 WELD’N AIR

Read this entire installation section before you STACKING

•Use in open, well ventilated areas or

SAE400 WELD’N AIR

HIGH ALTITUDE OPERATION ENGINE OIL

NOTE: Before starting the engine, be sure the fuel shut-

SAE400 WELD’N AIR

ENGINE COOLING SYSTEM To prevent BATTERY BUCKLING, tighten nuts on bat-

To prevent EXPLOSION when:

IMPORTANT: To prevent ELECTRICAL DAMAGE

SAE400 WELD’N AIR

WELDING OUTPUT CABLES

Because this portable engine driven welder creates its

SAE400 WELD’N AIR

OPERATING INSTRUCTIONS GENERAL DESCRIPTION

ELECTRIC SHOCK can kill. RECOMMENDED APPLICATIONS

•Stop engine before servicing.

•Keep away from moving parts

ADDITIONAL SAFETY PRECAUTIONS

Always operate the welder with the hinged doors

Read carefully the Safety Precautions page in the

SAE400 WELD’N AIR

100 19.5 9.75 2.25

200 13 6.5 1.5

300 6.5 3.25 0.75

FOR COMPRESSED AIR