Lincoln Electric IM10027 User Manual

SAE-400 ®DC ARC WELDING POWER SOURCE

IM10027-B

RETURN TO MAIN MENU

For use with machines having Code Numbers: 11605, 11807, 11966

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 opera­tion 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.

January 2013

• World's Leader in Welding and Cutting Products • • Sales and Service through Subsidiaries and Distributors Worldwide •

Cleveland, Ohio 44117-1199 USA TEL: [phone]

For Service in the USA and Canada: Call 1.888.935.3877 For Service outside the USA: Email [e-mail]

OPERATOR’S MANUAL

Copyright © Lincoln Global Inc.

FAX: [phone] WEB SITE: lincolnelectric.com

i

SAFETY

WARNING

CALIFORNIA PROPOSITION 65 WARNINGS

Diesel engine exhaust and some of its constituents
are known to the State of California to cause can­cer, birth defects, and other reproductive harm.

The Above For Diesel 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
purchase 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.

The engine exhaust from this product contains
chemicals known to the State of California to cause
cancer, birth defects, or other reproductive harm.

The Above For Gasoline Engines

i

FOR ENGINE
powered equipment.

1.a. Turn the engine off before troubleshooting and maintenance
work unless the maintenance work requires it to be running.

____________________________________________________

____________________________________________________

____________________________________________________

1.d. Keep all equipment safety guards, covers and devices in posi-

tion and in good repair
away from V-belts, gears, fans and all other moving parts
when starting, operating or repairing equipment.

____________________________________________________

1.e. In some cases it may be necessary to remove safety
guards to perform required maintenance. Remove
guards only when necessary and replace them when the
maintenance requiring their removal is complete.
Always use the greatest care when working near moving
parts.

___________________________________________________

1.b. Operate engines in open, well-ventilated
areas or vent the engine exhaust fumes
outdoors.

1.c. Do not add the fuel near an open flame weld­ing arc or when the engine is running. Stop
the engine and allow it to cool before refuel­ing to prevent spilled fuel from vaporizing on
contact with hot engine parts and igniting. Do
not spill fuel when filling tank. If fuel is spilled,
wipe it up and do not start engine until fumes
have been eliminated.

.Keep hands, hair, clothing and tools

1.f. Do not put your hands near the engine fan.

Do not attempt to override the governor or
idler by pushing on the throttle control rods
while the engine is running.

1.h. To avoid scalding, do not remove the
radiator pressure cap when the engine is
hot.

ELECTRIC AND
MAGNETIC FIELDS
may be dangerous

2.a. Electric current flowing through any conductor causes
localized Electric and Magnetic Fields (EMF). Welding
current creates EMF fields around welding cables and
welding machines

2.b. EMF fields may interfere with some pacemakers, and
welders having a pacemaker should consult their physician
before welding.

2.c. Exposure to EMF fields in welding may have other health
effects which are now not known.

2.d. All welders should use the following procedures in order to
minimize exposure to EMF fields from the welding circuit:

2.d.1.

Route the electrode and work cables together - Secure
them with tape when possible.

2.d.2. Never coil the electrode lead around your body.

2.d.3. Do not place your body between the electrode and

work cables. If the electrode cable is on your right
side, the work cable should also be on your right side.

___________________________________________________

1.g. To prevent accidentally starting gasoline engines while
turning the engine or welding generator during maintenance
work, disconnect the spark plug wires, distributor cap or
magneto wire as appropriate.

2.d.4. Connect the work cable to the workpiece as close as
possible to the area being welded.

2.d.5. Do not work next to welding power source.

ii

SAFETY

ii

ELECTRIC SHOCK can kill.

3.a. The electrode and work (or ground) circuits
are electrically “hot” when the welder is on.
Do not touch these “hot” parts with your bare
skin or wet clothing. Wear dry, hole-free
gloves to insulate hands.

3.b. Insulate yourself from work and ground using dry insulation.
Make certain the insulation is large enough to cover your full
area of physical contact with work and ground.

In addition to the normal safety precautions, if welding
must be performed under electrically hazardous
conditions (in damp locations or while wearing wet
clothing; on metal structures such as floors, gratings or
scaffolds; when in cramped positions such as sitting,
kneeling or lying, if there is a high risk of unavoidable or
accidental contact with the workpiece or ground) use
the following equipment:

• Semiautomatic DC Constant Voltage (Wire) Welder.

• DC Manual (Stick) Welder.

• AC Welder with Reduced Voltage Control.

3.c. In semiautomatic or automatic wire welding, the electrode,
electrode reel, welding head, nozzle or semiautomatic
welding gun are also electrically “hot”.

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.

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.

3.i. When working above floor level, use a safety belt to protect
yourself from a fall should you get a shock.

3.j. Also see Items 6.c. and 8.

ARC RAYS can burn.

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.

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.

FUMES AND GASES
can be dangerous.

5.a. Welding may produce fumes and gases
hazardous to health. Avoid breathing these
fumes and gases. When welding, keep
your head out of the fume. Use enough
ventilation and/or exhaust at the arc to keep

fumes and gases away from the breathing zone. When

welding with electrodes which require special
ventilation such as stainless or hard facing (see
instructions on container or MSDS) or on lead or
cadmium plated steel and other metals or coatings
which produce highly toxic fumes, keep exposure as
low as possible and within applicable OSHA PEL and
ACGIH TLV limits 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.

5. b. The operation of welding fume control equipment is affected
by various factors including proper use and positioning of the
equipment, maintenance of the equipment and the specific
welding procedure and application involved. Worker expo­sure level should be checked upon installation and periodi­cally thereafter to be certain it is within applicable OSHA PEL
and ACGIH TLV limits.

5.c.

Do not weld in locations near chlorinated hydrocarbon
coming from degreasing, cleaning or spraying operations.
The heat and rays of the arc can react with solvent vapors
form phosgene, a highly toxic gas, and other irritating prod­ucts.

vapors

to

5.d. 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.

5.e. 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.

5.f. Also see item 1.b.

iii

SAFETY

iii

WELDING and CUTTING
SPARKS can
cause fire or explosion.

6.a.

Remove fire hazards from the welding area.

If this is not possible, cover them to prevent

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.

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.

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.

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
been “cleaned”. For information, purchase “Recommended
Safe Practices for the
Containers and Piping That Have Held Hazardous
Substances”, AWS F4.1 from the American Welding Society

(see address above).

6.e. Vent hollow castings or containers before heating, cutting or
welding. They may explode.

Sparks and spatter are thrown from the welding arc. Wear oil

6.f.
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.

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.

6.h. Also see item 1.c.

the welding sparks from starting a fire.

though

they have

Preparation

for Welding and Cutting of

CYLINDER may explode
if damaged.

7.a. Use only compressed gas cylinders
containing the correct shielding gas for the
process used and properly operating
regulators designed for the gas and

pressure used. All hoses, fittings, etc. should be suitable for
the application and maintained in good condition.

7.b. Always keep cylinders in an upright position securely
chained to an undercarriage or fixed support.

7.c. Cylinders should be located:

• Away from areas where they may be struck or subjected to

physical damage.

• 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.

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.

FOR ELECTRICALLY
powered equipment.

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.

8.c. Ground the equipment in accordance with the U.S. National
Electrical Code and the manufacturer’s recommendations.

6.I. Read and follow NFPA 51B “ Standard for Fire Prevention
During Welding, Cutting and Other Hot Work”, available from
NFPA, 1 Batterymarch Park, PO box 9101, Quincy, Ma
022690-9101.

6.j. Do not use a welding power source for pipe thawing.

Refer to http://www.lincolnelectric.com/safety for additional safety information.

iv

SAFETY

iv

PRÉCAUTIONS DE SÛRETÉ

Pour votre propre protection lire et observer toutes les instructions
et les précautions de sûreté specifiques qui parraissent dans ce
manuel aussi bien que les précautions de sûreté générales suiv­antes:

Sûreté Pour Soudage A L’Arc

1. Protegez-vous contre la secousse électrique:

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 met­allique 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 defonc­tionnement.

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 souder
parce que la tension entre les deux pinces peut être le total
de la tension à vide des deux machines.

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.

6. Eloigner les matériaux inflammables ou les recouvrir afin de
prévenir tout risque d’incendie dû aux étincelles.

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.

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.

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.

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.

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 rayon­nement 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.

c. Protéger l’autre personnel travaillant à proximité au

soudage à l’aide d’écrans appropriés et non-inflammables.

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, pan­talons sans revers, et chaussures montantes.

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.

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.

3. Avant de faires des travaux à l’interieur de poste, la debranch­er à l’interrupteur à la boite de fusibles.

4. Garder tous les couvercles et dispositifs de sûreté à leur place.

Thank You

vv

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!

The business of The Lincoln Electric Company is manufacturing and selling high quality welding equipment, consumables, and cutting equip­ment. Our challenge is to meet the needs of our customers and to exceed their expectations. On occasion, purchasers may ask Lincoln Electric
for advice or information about their use of our products. We respond to our customers based on the best information in our possession at that
time. Lincoln Electric is not in a position to warrant or guarantee such advice, and assumes no liability, with respect to such information or
advice. We expressly disclaim any warranty of any kind, including any warranty of fitness for any customerʼs particular purpose, with respect
to such information or advice. As a matter of practical consideration, we also cannot assume any responsibility for updating or correcting any
such information or advice once it has been given, nor does the provision of information or advice create, expand or alter any warranty with
respect to the sale of our products.

Lincoln Electric is a responsive manufacturer, but the selection and use of specific products sold by Lincoln Electric is solely within the control
of, and remains the sole responsibility of the customer. Many variables beyond the control of Lincoln Electric affect the results obtained in
applying these types of fabrication methods and service requirements.

Subject to Change – This information is accurate to the best of our knowledge at the time of printing. Please refer to www.lincolnelectric.com
for any updated information.

CUSTOMER ASSISTANCE POLICY

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

Your Product”. 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:

WEB SITE at www.lincolnelectric.com. Choose “Support” and then “Register

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.

vi

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

Vehicle Mounting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .A-3

Pre-Operation Engine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .A-3

Engine Oil . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .A-3

Fuel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .A-4

Engine Cooling System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .A-4

Break-In Period . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .A-4

Battery Connection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .A-4

Spark Arrester . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .A-5

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

Product Application . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .B-2

Design Features and Advantages . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .B-2

Duty Cycle . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .B-2

Engine Controls: Function/Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . B-2

Welder Controls: Function/Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . B-3

Remote Control . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .B-3

Auxiliary Power 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

Engine Maintenance Components . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .D-4

Spark Arrester . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .D-4

GFCI Testing and Resetting Procedure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .D-4

_____________________________________________________________________________________

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

_____________________________________________________________________________________

Wiring Diagram and Dimension Print . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Section F

____________________________________________________________________________________

Parts List . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .P-621

____________________________________________________________________________________

TABLE OF CONTENTS

vi

Page

A-1

INSTALLATION

TECHNICAL SPECIFICATIONS - SAE-400® (K1278-14)

INPUT - DIESEL ENGINE

Make/Model Description Speed (RPM) Displacement Starting Capacities

System

269 cu. in Fuel: 22.5 gal.
(4.4 L) 85.1 L

K1278-14

Perkins
1104A-44 Diesel 4 cylinder High Idle 1800 Bore x Stroke
Engine 64.4 HP @ Low Idle 1100 & Starter 9.6 L
Not EPA Tier II 1710 RPM Full Load 1725
Compliant 4.13” x 5.00”
Export Only

(105.0 mm x 127.0mm) Coolant: 3.4 gal.

12VDC battery

Oil: 10.1 Qts.

12.8 L

A-1

Duty Cycle

35% (NEMA) 500 amps 40 volts

(1)

Welding Output Volts at Rated Amps

*60% (NEMA) 500 amps 40 volts

RATED OUTPUT - WELDER

100% (NEMA) 400 amps 36 volts

100% (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

RECEPTACLES AND CIRCUIT BREAKERS

RECEPTACLES AUXILIARY POWER CIRCUIT BREAKER

1 - 115VAC Duplex NEMA (5-20R)-GFCI protected 1 - 20 amp for 115VAC Duplex NEMA
1 - 115VAC European (IEC-309)-GFCI protected 1 - 15 amp for 115VAC European (IEC-309)
1 - 230VAC Duplex 1 - 15 amp (2 -pole) for 230 V Duplex and European (IEC-309)
1 - 230VAC European (IEC-309)

HEIGHT WIDTH DEPTH WEIGHT

50.13 in. 28.00 in. 83.00 in. 2157lbs.

1273.3 mm 711.2 mm 2108.2 mm 978.4kg

(1)

Based on a 10 minute period.

* For Codes 11807 and higher.

PHYSICAL DIMENSIONS

SAE-400®

A-2

Read this entire installation section before you
start installation.

INSTALLATION

A-2

CAUTION

SAFETY PRECAUTIONS

WARNING

Do not attempt to use this equipment until you have
thoroughly read all operating and maintenance man­uals supplied with your machine. They include impor­tant safety precautions, detailed engine starting,
operating and maintenance instructions and parts
lists.

ELECTRIC SHOCK can kill.

•Do not touch electrically live parts such
as output terminals or internal wiring.

•Insulate yourself from the work and
ground.

•Always wear dry insulating gloves.

------------------------------------------------------------------------

ENGINE EXHAUST can kill.

Use in open, well ventilated areas or

•
vent exhaust outside

DO NOT 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.

------------------------------------------------------------------------

STACKING

These machines cannot be stacked.

ANGLE OF OPERATION

To achieve optimum engine performance the machine
should be run in a level position. 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.

LIFTING

•Do not stack anything near the engine.

------------------------------------------------------------------------

MOVING PARTS can injure.

•

Do not operate with doors open or
guards off.

•Stop engine before servicing.

•Keep away from moving parts

------------------------------------------------------------------------

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.

The equipment lift bail should be used to lift the
machine.

WARNING

• Lift only with equipment of adequate
lifting capacity.

• Be sure machine is stable when lift­ing.

• Do not lift this machine using lift bail if it is
equipped with a heavy accessory such as a trail­er or gas cylinder.

FALLING • Do not lift machine if lift bail is

EQUIPMENT can damaged.

cause injury. • Do not operate machine while

suspended from lift bail.

------------------------------------------------------------------------

SAE-400®

A-3

INSTALLATION

A-3

HIGH ALTITUDE OPERATION

At higher altitudes, output derating may be necessary.
As a rule of thumb, derate the welder output 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 alti­tude operation.

TOWING

The recommended trailers for use with this equipment
for in-plant and yard towing by a vehicle
K2641-1 and K2637-1. The K2637-1 is also designed
to be used at highway speeds

(1)

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 considered are as follows:

1. Design capacity of trailer vs. weight of Lincoln
equipment and likely additional attachments.

2. Proper support of, and attachment to, the base of
the welding equipment so that there will be no
undue stress to the trailerʼs framework.

3. Proper placement of the equipment on the trailer to
insure stability side to side and front to back when
being moved and when standing by itself.

4. Typical conditions of use, such as travel speed,
roughness of surface on which the trailer will be
operated, and environmental conditions.

(1)

are Lincolnʼs

.If the user adapts a

VEHICLE MOUNTING

WARNING

Improperly mounted concentrated loads may cause
unstable vehicle handling and tires or other compo­nents to fail.

• Only transport this equipment on serviceable vehi­cles 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 compo­nents such as suspension, axles and tires.

• Mount equipment base to metal bed or frame of
vehicle.

• Follow vehicle manufacturerʼs instruction.

------------------------------------------------------------------------

PRE-OPERATION ENGINE SERVICE 

READ the engine operating and maintenance instruc­tions supplied with this machine.

ENGINE OIL

The engine is shipped with the engine crankcase filled
with high quality SAE 10W-30 oil (API class CD or bet­ter). Check the oil level before starting the engine. If it is
not up to the full mark on the dip stick, add oil as required.
Check the oil level every four hours of running time during
the first 35 running hours. Refer to the engine Operatorʼs
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 Operatorʼs Manual for the proper service and
maintenance intervals.

5. Proper preventative maintenance of trailer.

6. Conformance with federal, state and local laws.

(1)

For highway use, consult applicable federal, state
and local laws regarding specific requirements for
use on public highways, such as brakes, lights, fend­ers, etc.

(1)

SAE-400®

A-4

INSTALLATION

A-4

WARNING

• Stop engine while fueling.

• Do not smoke when fueling.

• Keep sparks and flame away from
tank.

• Do not leave unattended while fuel­ing.

DIESEL FUEL

can cause fire.

• Wipe up spilled fuel and allow
fumes to clear before starting
engine.

• Do not overfill tank, fuel expan­sion may cause overflow.

DIESEL FUEL ONLY

------------------------------------------------------------------------

Fill the fuel tank with clean, fresh diesel fuel. The capac­ity of the fuel tank is 22.5 gallons (85.1 liters). See engine
Operatorʼs Manual for specific fuel recommendations.

Note: Before starting the engine, be sure the fuel shut­off valve is in the open position.

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 solu­tion as needed. (See Engine Manual or antifreeze
container for alternate antifreeze recommendation.)

ENGINE BREAK-IN PERIOD

Lincoln Electric selects high quality, heavy-duty indus­trial 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, wet stacking (oil or tar like substance
at the exhaust port), or excessive smoke is not normal.

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 suc­cessful engine break-in, most diesel-powered equip­ment needs only to be run at a reasonably heavy load
within the rating of the welder for some period of time
during the engineʼs early life. However, if the welder is
subjected to extensive light loading, occasional moder­ate to heavy loading of the engine may sometimes be
necessary. Caution must be observed in correctly
loading a diesel/generator unit.

1. Connect the welder output studs to a suitable resis­tive load bank. Note that any attempt to short the
output studs by connecting the welding leads
together, direct shorting of the output studs, or con­necting the output leads to a length of steel will
result in catastrophic damage to the generator and
voids the warranty.

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 cata­strophic damage to the generator and voids the
warranty.

3. Periodically shut off the engine and check the
crankcase oil level.

BATTERY CONNECTION

WARNING

Use caution as the electrolyte is a strong acid that
can burn skin and damage eyes.

Remove and discard the insulating cap from the
negative battery terminal. Attach and tighten neg­ative battery cable terminal.

NOTE:

battery; if unused for several months, the battery may
require a booster charge. Be careful to charge the bat­tery with the correct polarity. Make sure that the battery
is level while charging.

This machine is furnished with a wet charged

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.

SAE-400®

A-5

INSTALLATION

A-5

 USING A BOOSTER — connect

positive lead to battery first then
connect negative lead to negative
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 a new batterie.

b) Using a booster.

Use correct polarity — Negative Ground.
To prevent BATTERY BUCKLING, tighten the nuts on
battery until snug. DO NOT OVERTIGHTEN.

WARNING

• Spark Arrester and Muffler may be
hot!

• Allow engine to cool before servicing
spark arrester!

• Do not operate engine while servicing
spark arrester!

------------------------------------------------------------------------

SPARK ARRESTER

Some federal, state or local laws may require that
gasoline or diesel engines be equipped with exhaust
spark arresters when they are operated in certain loca­tions where unarrested sparks may present a fire haz­ard. The muffler included with this welder has been
modified and now qualifies as a spark arrester. Spark
arresting mufflers will have a clean out service plug
and will have “USDA FS 5100-1c QUALIFIED SPARK
ARRESTER” or “US FOREST SERVICE APPROVED”
stamped on the muffler shell. Any spark arrester must
be serviced and properly maintained.

CAUTION

An incorrect arrester may lead to damage to the
engine or adversely affect performance.

------------------------------------------------------------------------

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 neces­sary.

Listed in Table A.1 are copper cable sizes recom­mended for the rated current and duty cycle. Lengths
stipulated are the distance from the welder to work and
back to the welder again. Cable sizes are increased
for greater lengths primarily for the purpose of mini­mizing cable voltage drop.

Table A.1 Combined Length of Electrode and

Work Cables.

TOTAL COMBINED LENGTH OF ELEC-

TRODE AND WORK CABLES

AMPS

@60%

Duty Cycle

400

Up to 100FT.

Up to 31m

2/0 AWG

100-200FT.

31-61m

3/0 AWG

200-250FT.

61-76m

4/0 AWG

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.).

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 con­nected to premises wiring such as that in a home or
shop, its frame must be connected to the system earth
ground. See the article on grounding in the latest U.S.
National Electrical Code and the local code.

In general, if the machine is to be grounded, it should
be connected with a #8 or larger copper wire to a solid
earth ground such as a metal water pipe going into the
ground for at least ten feet and 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 symbol is provided on the
welding generator frame foot.

SAE-400®

B-1

OPERATION

B-1

OPERATING INSTRUCTIONS

Read and understand this entire section before operat­ing your equipment.

SAFETY INSTRUCTIONS

WARNING

Do not attempt to use this equipment until you
have thoroughly read all operating and mainte­nance manuals supplied with your machine. They
include important safety precautions, detailed
engine starting, operating and maintenance
instructions and parts lists.

ELECTRIC SHOCK can kill.

• Do not touch electrically live parts or

electrodes with your skin or wet
clothing.

• Insulate yourself from the work and ground.

• 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.

Use the following equipment:

• Semiautomatic DC constant voltage (wire)

welder.

• DC manual (stick) welder.

• AC welder with reduced voltage control.

------------------------------------------------------------------------

ARC RAYS can injure eyes and
burn skin.

• 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 manu­facturers instructions for this equipment and the
consumables to be used including the Material
Safety Data Sheet (MSDS) and follow your employ­erʼs safety practices.

------------------------------------------------------------------------

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.

WELDING SPARKS can cause
fire or explosion.

• Do not weld near flammable material .

• Do not weld on containers that have

held flammable material.

------------------------------------------------------------------------

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.

• Use in open, well ventilated areas or
vent exhaust outside.

------------------------------------------------------------------------

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 instruction
manuals.

GENERAL DESCRIPTION

The SAE-400® 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 engine 1104A-44 is a 64.4 Hp @ 1710 RPM
(48kw), 4-cylinder water cooled diesel made by
Perkins.

SAE-400®

B-2

OPERATION

B-2

RECOMMENDED APPLICATIONS

WELDER

The SAE-400® provides excellent constant current
DC welding output for stick (SMAW) welding. The field
installed optional CV Adapter (K385-[ ]) provides up to
500 amps at 35 volts of constant voltage output for
semiautomatic welding.

AUXILIARY POWER

The SAE-400® provides 3 KW of 115/230 VAC output
for auxiliary power and emergency standby power.

DESIGN FEATURES AND ADVANTAGES

FOR STICK WELDING

• Excellent DC constant current output for stick weld­ing applications.

• Continuous adjustment of both voltage and current
for unsurpassed welds on demanding jobs.

• Remote control capability standard.

FOR AUXILIARY POWER

• 3,000 watts of 115/230VAC, 60 Hz auxiliary power.

• One 20 amp 115VAC duplex receptacle.

• One 15 amp, 230VAC duplex receptacle for up to 13
amps of 230VAC power.

IEC-309

• One 115VAC (European

• One 230VAC (European

• Weld and AC auxiliary power at the same time (with­in the limits shown on the chart below).

Welding Using Only Using Only Total

Current, Amps 115V Circuit, 230V Circuit, Aux.

@ NEMA Arc Amps Amps kVA

Volts

026133.0

100 19.5 9.75 2.25

) 16 amp receptacle.

IEC-309

) 15 amp receptacle.

OTHER FEATURES

• Perkins 4-cylinder, water cooled diesel engine.
Designed for long life, easy maintenance and excel­lent 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.

• Engine hour meter standard.

• Extended range 22.5 gallon (85.1 L) fuel tank.

DUTY CYCLE

Duty cycle is the percentage of time the load is being
applied in a 10 minute period. For example a 60% duty
cycle, represents 6 minutes of load and 4 minutes of
no load in a 10 minute period.

ENGINE CONTROLS

IGNITION SWITCH

When placed in the “ON” position, this switch ener­gizes the fuel solenoid. When placed in the “OFF” posi­tion, the flow of fuel to the injection pump is stopped to
shut down the engine.

“IDLER” SWITCH

The idler switch has two positions, “HIGH” and
“AUTO”.

When in “HIGH” ( ) position, the engine will run
continuously at high idle.

When in “AUTO” ( / ) idle position, the idler
operates as follows:

200 13 6.5 1.5

300 6.5 3.25 0.75

400 0 0 0

500 0 0 0

a. Welding

When the electrode touches the work, the welding
arc is initiated and the engine accelerates to full
speed.

After welding ceases (and no auxiliary power is
being drawn), the engine will return to low idle after
approximately 10 to 14 seconds.

b. Auxiliary Power

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 weld­ing) for 10-14 seconds, the idler reduces the engine
speed to low idle.

SAE-400®

B-3

ENGINE TEMPERATURE GAUGE

Displays the coolant temperature in the engine block.

ENGINE OIL PRESSURE GAUGE

Displays the oil pressure to the engine. When the
engine starts running, watch for the oil pressure to
build up. If no pressure shows within 30 seconds, stop
the engine and consult the engine instruction manual.

BATTERY CHARGING AMMETER

Displays the current going from the charging alternator
into the batteries. It is normal for charging current to be
high (above 15 amps) after starting or when the batter­ies are ʻlowʼ on charge.

ENGINE HOUR METER

OPERATION

B-3

“CURRENT CONTROL”

CAUTION

Do not adjust the “Current Control” while welding
because this can damage the control.

------------------------------------------------------------------------

The “Current Control” dial is calibrated in amperes on
three separate colored dials corresponding to the
white, black and red ranges of the “Job Selector” dial.
For example: when the “Job Selector” is set on the
black range, the approximate welding current is indi­cated on the black scale of the “Current Control” dial.

How to Set the Controls

Assume you want a normal soft arc and about 135
amps, using a 5/32” (4.0 mm) electrode:

The engine hour meter records the total running time
on the engine in hours. It can be used to keep a record
of maintenance on the engine and or welder.

ENGINE PROTECTION SYSTEM

The engine protection system shuts down the engine
under high coolant temperature or low engine oil pres­sure conditions by allowing the fuel solenoid valve to
close.

WELDER CONTROLS

POLARITY SWITCH

Turn the Arc Polarity switch to electrode positive or
electrode negative as required for each particular
application.

CONTROL OF WELDING CURRENT
Purpose of Controls

The continuous “Current Control” is the main current
adjuster. The “Job Selector” is both a fine current
adjuster and the continuous Open Circuit Voltage
adjuster. Open Circuit Voltage (OCV) controls the arc
characteristics.

“Job Selector”

The “Job Selector” dial is divided into four colored sec­tions providing OCV ranges as follows:

Color Title OCV Range

White Large Electrodes High OCV
Black Normal Welding Medium OCV
Red Overhead & Vertical Low OCV
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.

1.

Set the “Job Selector” at the center of the black
range.

2. Set the “Current Control” to read 135 amps on the
black dial.

3. Start to weld.

4. If you want a little more current, turn the “Job
Selector” up (counterclockwise) to increase cur­rent. If you want a little less current, turn the “Job
Selector” down (clockwise) to decrease current.

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.

REMOTE CONTROL

A receptacle and “Local/Remote” control switch is
located on the lower front control panel. A remote con­trol box with 100 ft. (30.5 m) of cord for adjusting the
OCV at the welding site is available. 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-[ ]) the “Local/Remote”
switch is only active in the “VV” mode.

SAE-400®

B-4

OPERATION

B-4

AUXILIARY POWER CONTROLS

115 VAC Receptacle

One 20 amp, 115VAC (5-20R) NEMA duplex recepta­cle provides 115VAC for auxiliary power. Maximum
current is 20 amps total.

One 115V (European
rated.

230VAC Receptacle

One 15 amp, 230VAC duplex receptacle provides 230
VAC for auxiliary power. A total of 13 amps can be
drawn from this receptacle.

One 230V (European
rated.

Circuit Breakers

2 pole 15 amp rated provides overload protection for
the 230VAC (European
230VAC duplex receptacle.

IEC-309

) 16 amp receptacle. IP44

IEC-309

) 15 amp receptacle. IP44

IEC-309)

receptacle and the

The 115V auxiliary power receptacles should only be
used with three wire grounded type plugs or approved
double insulated tools with two wire plugs. The current
rating of any plug used with the system must be at
least equal to the current capacity of the associated
receptacle.

RESIDUAL CURRENT DEVICE

The SAE-400® is configured to allow for the addition
of a Residual Current Device (RCD) to protect the
240V Single Phase Receptacle. The lower Control
Panel has a rectangular cut-out to accept a typical 2­pole RCD along with a protective rubber boot. A cover
plate a label “RCD READY” covers the rectangular cut-
out, and secures a mounting bracket on the backside
of the panel.

Note: The (RCD) should be rated for at least 15 amps.

There are many suppliers of RCDʼs. One example is
Clipsal, part number 4RC225/30.

The protective boot can be obtained from:
APM-Hexseal, part number HE-1035.

Single pole 15 amp rated provides overload protection
for the 115VAC (European

Single pole 15 amp rated provides overload protection
for the 115VAC (5-20R) NEMA duplex receptacle.

GFCI (Ground Fault Circuit Interrupter):

• Protects both 115VAC auxiliary power receptacles.

• If the GFCI is tripped, see the Maintenence Section
for detailed information on testing and resetting the
GFCI.

The GFCI (Ground Fault Circuit Interrupter) electrical
receptacle is a device to protect against electric shock
should a piece of defective equipment connected to it
develop a ground fault. If this situation should occur,
the GFCI will trip, removing voltage from the output of
the receptacle. If the GFCI is tripped see the MAINTE­NANCE section for detailed information on testing and
resetting it. The GFCI should be properly tested at
least once every month.

IEC-309)

receptacle.

See Section F Diagrams of this Operatorʼs Manual for
instructions on installing an RCD and protective rubber
boot.

GROUND STUD

Provides a connection point for connecting the
machine to earth ground. For the safest grounding pro­cedure refer to “Machine Grounding” in the INSTALLA­TION section of this manual.

SAE-400®

B-5

OPERATION

B-5

ENGINE OPERATION

WARNING

Do not attempt to use this equipment until you
have thoroughly read the engine manufacturerʼs
manual supplied with your welder. It includes
important safety precautions, detailed engine
starting, operating and maintenance instructions,
and parts lists.

------------------------------------------------------------------------

ELECTRIC SHOCK can kill.

Do not touch electrically live parts or

•
electrode with skin or wet clothing.

• Insulate yourself from work and
ground

• Always wear dry insulating gloves.

------------------------------------------------------------------------

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.

------------------------------------------------------------------------

See additional warning information at the
front of this operatorʼs manual.

For added safety always operate the welder with the
doors closed. Further, leaving the doors open changes
the designed air flow and may cause engine, genera­tor overheating.

5. Observe the oil pressure. If no pressure shows
within 30 seconds, stop the engine and consult the
engine operating manual. To stop the engine, turn
the “IGNITION” switch to “OFF”.

6. If the engine protection warning light comes on
during cranking or after start up, the “IGNITION”
switch must be turned “OFF” to reset the engine
protection system.

7. Allow the engine to run at high idle speed for sev­eral minutes to warm the engine. Stop the engine
and recheck the oil level, after allowing sufficient
time for the oil to drain into the pan. If the level is
down, fill it to the full mark again. The engine con­trols were properly set at the factory and should
require no adjusting when received.

COLD WEATHER STARTING:

WARNING

Under NO conditions should ether or other starting
fluids be used!

------------------------------------------------------------------------

With a fully charged battery and the proper weight oil,
the engine should start satisfactorily even down to
about -5°F (-20°C), it maybe desirable to install cold­starting aides.

Note: Extreme cold weather staring may require longer
glow plug operation.

STOPPING THE ENGINE

1. Turn the “IGNITION” switch to “OFF”

CAUTION

Do not adjust the high idle engine speed (rpm)
above the factory setting specification as this will
void warranty.

-----------------------------------------------------------------------

STARTING INSTRUCTIONS

Be sure all Pre-Operation Maintenance has been
performed. (See INSTALLATION section of this
manual).

1. Turn the “IDLER” switch to “HIGH”.

2. Turn the “IGNITION” switch to “ON”.

3. Press the Glow Plug button for 20 to 30 seconds.
(maximum 60 seconds).

4. Press the Glow Plug and the Start button at the
same time. When the engine starts running,
release both buttons. If the engine fails to start in
20 seconds, wait 30 seconds and repeat the
above procedure.

SAE-400®

At the end of each dayʼs welding, check the crankcase
oil level, drain accumulated dirt and water from the
water separator and refill the fuel tank to minimize
moisture condensation in the tank. Also, running out of
fuel tends to draw dirt into the fuel system.

When hauling the welder between job sites, close the
fuel shut-off valve.

If the fuel supply is cut off or runs out while the fuel
pump is operating, air may be entrapped in the fuel dis­tribution system. If this happens, bleeding of the fuel
system may be necessary. Use qualified personnel to
do this per the instructions in the MAINTENANCE sec­tion of this manual.

B-6

OPERATION

TYPICAL FUEL CONSUMPTION

The typical fuel consumption of the SAE-400® for various operating scenarios
is shown below:

PERKINS 1104A-44

Low Idle - No Load .26 gal./ hr.
1100 RPM (.97 L./hr.)

High Idle - No Load .68 gal./hr.
1800 RPM (2.56 L./hr.)

Welding Load 1.84 gal./hr.
400 Amps, 40 Volts (6.95 L./hr.)

Welding Load 2.38 gal./hr.
500 Amps, 40 Volts (9.02 L./hr.)

Auxiliary Power .79 gal./hr.
3000VA (2.98 L./hr.)

B-6

SAE-400®

C-1

ACCESSORIES

C-1

K930-2 TIG Module - 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-D Power Plug Kit - Kit includes male plug for 20
amp receptacle.

K2641-2 Trailer - FOUR-WHEEL STEERABLE YARD
TRAILER WITH DUO-HITCH

• For off-road, plant and yard use with an overall width

of 55 in.

• Includes an automatically engaging drawbar lock

when the drawbar is raised to the vertical position.

• 13 in wheels with wheel bearings packed with high

viscosity, high pressure, low washout Lubriplate®
grease.

• Stiff 3/16 in welded rectangular steel frame construc-

tion is phosphate etched and powder coat painted for
superior rust and corrosion resistance.

• Also includes a Duo-Hitch™ - a 2 in Ball/Lunette Eye

combination hitch.

K2637-1 Trailer - A 2-wheel trailer designed for road

(1)

off road, in-plant and yard towing. Trailer mounts
directly to welder base. Comes standard with a Duo­Hitch™, a 2” Ball and Lunette Eye combination hitch.

K704 Standard Accessory Kit - Includes electrode
and work cables, headshield, work clamp and elec­trode holder.

K385-[ ] CV Adapter - Provides constant voltage out­put for semiautomatic welding. (Field installation only).

K1735-1 MULTI-WELD 350 - For multiple arcs from
the DC output of a welding power source. See bulletin
E5.300 for Multi-Weld 350 and distribution system.

K2144-1 Oil Drain Kit- Includes ball valve, hose and
clamp.

,

Order:
K2636-1 Trailer
K2639-1 Fender & Light Kit
K2640-1 Cable Storage Rack

1

For 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.

------------------------------------------------------------------------

SAE-400®

D-1















MAINTENANCE

D-1

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.

PERIODIC MAINTENANCE

1. Blow out the welder and controls with an air hose at least
once every two months. In particularly dirty locations, this
cleaning may be necessary once a week. Use low pres­sure air to avoid driving dirt into the insulation.

2. The current control reactor brushes are self-lubricating
and should not be greased. Keep the contacts clean. This
control should be moved from maximum to minimum daily
to prevent the controls from sticking.

3. See the engine Instruction Manual for periodic engine
maintenance information. Change the crankcase oil at
regular intervals using the proper grade of oil as recom­mended in the engine operating manual. Change the oil
filter in accordance with the instructions in the engine
operating manual. When the oil filter is changed add one
quart of oil to the crankcase to replace the oil held in the
filter during operation.

4. Belts tend to loosen after the first 30 or 40 hours of oper­ation. Check the cooling fan belt and tighten if necessary.
DO NOT OVER TIGHTEN.

BEARING MAINTENANCE
(For Code 11605 only)

ROUTINE MAINTENANCE

At the end of each dayʼs welding, refill the fuel tank to
minimize moisture condensation in the tank. Also, run­ning out of fuel tends to draw dirt into the fuel system.
Check the engine crankcase oil levels.

If the fuel supply runs out while the fuel pump is oper­ating, air may be entrapped in the fuel distribution sys­tem. If this happens, bleeding of the fuel system may
be necessary. See the engine instruction manual.

ENGINE AIR FILTER

The engine air filter element is a dry cartridge type. It
is located above the engine. It can be cleaned and re­used; 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.

This welder is equipped with a double-shielded ball bearing
having sufficient grease to last indefinitely under normal ser­vice. Where the welder is used constantly or in excessively
dirty locations, it may be necessary to add one-half ounce of
grease per year. A pad of grease one inch wide, one inch
long and one inch high weighs approximately one-half
ounce. Over greasing is far worse than insufficient greasing.

When greasing the bearings, keep all dirt out of the area.
Wipe the fittings completely clean and use clean equipment.
More bearing failures are caused by dirt introduced during
greasing than from insufficient grease.

SAE-400®

D-2

MAINTENANCE

D-2

COMMUTATOR AND BRUSH MAINTENANCE

WARNING

Uncovered rotating equipment can be dangerous.
Use care so your hands, hair, clothing or tools do
not catch in the rotating parts. Protect yourself
from particles that may be thrown out by the rotat­ing armature when stoning the commutator.

------------------------------------------------------------------------

The generator brushes are properly adjusted when the
welder is shipped.
DO NOT SHIFT THE BRUSHES or adjust the rocker
setting.

Shifting of the brushes may result in:

- Change in machine output

- Commutator Damage

- Excessive brush wear

Periodically inspect the commutator, slip rings and
brushes by removing the covers. DO NOT remove or
replace these covers while the machine is running.

Commutators and slip rings require little attention.
However, if they are black or appear uneven, have
them cleaned by an experienced maintenance person
using fine sandpaper or a commutator stone. Never
use emery cloth or paper for this purpose.

NOTE: If the welder is used in dirty or dusty locations,
or if the welder is not used for prolonged periods of
time, it may be necessary to clean the commutator and
slip rings more often.

Replace brushes when they wear within 1/4" of the pig­tail. 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
person seat these brushes by lightly stoning the com­mutator as the armature rotates at full speed until con­tact is made across the full face of the brushes. After
stoning, blow out the dust with low pressure air.

To seat the slip ring brushes, position the brushes in
place. Then slide one end of a piece of fine sandpaper
between slip rings and brushes with the coarse side
against the brushes. With slight additional finger pres­sure on top of the brushes, pull the sandpaper around
the circumference of the rings, in direction of rotation
only - until brushes seat properly. In addition, stone
slip ring with a fine stone. Brushes must be seated
100%.

Arcing or excessive exciter brush wear indicates a pos­sible misaligned shaft. Have an authorized Field
Service Shop check and realign the shaft.

They require no particular attention.

SAE-400®

COOLING SYSTEM

The SAE-400® is 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 needed, always use the permanent
type.

PRE FILTER / WATER SEPARATOR

WARNING

When working on the fuel system

• Keep unguarded lights away, do not
smoke !

• Do not spill fuel !

------------------------------------------------------------------------

The SAE-400® is equipped with a Fuel Pre-

Filter/W

lift pump mounted to the engine block.

FUEL PRE-FILTER/WATER SEPARATOR
ASSEMBLY

The assembly uses a 30 micron pre-filter/water separator
element that is designed to protect against gross contam­ination of the final fuel filter. Using chemically treated
paper media the element also provides maximum protec­tion against water in the fuel. The assembly is also
equipped with a see-through bowl for easy visual check­ing for water. The recommended change interval for the
pre-filter/water separator element is 1,000 hours. See
below for information on the see-through bowl and for the
procedure for changing the element.

See-Through Bowl:

• Check the see-through bowl for water regularly. Water

1. Close the fuel shut-off valve.

2. Drain by opening the self venting drain valve and allow-

3. Close the drain valve and open the fuel shut-off valve.

Pre-Filter/Water Separator Element:

1. Close the fuel shutoff valve located under the fuel tank.

2. Rotate the quick change ring (located just below filter-

3. Grasp the element and pull down with a slight rocking

ater Separator Assembly located before the

will collect at the bottom of the bowl and appears differ­ent from the fuel.
Note: The see-through bowl is re-usable.

ing all water to escape.

header) clockwise approximately 1/2 turn and slide it
down and off of the element.

motion to remove the element from the grommet post
on the bottom of the filter header.

D-3

MAINTENANCE

D-3

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 ele­ment 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.

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 rotated
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 doesnʼt matter which one) of
arrows located on the outside of the ring should be
located directly under the air vent valve.

6. Remove the see-through bowl from the old element
and install on the new element.

7. Open the fuel shutoff valve.

SPARK ARRESTOR

WARNING

• Spark Arrester and Muffler may be
hot!

• Allow engine to cool before servicing
spark arrester!

• Do not operate engine while servicing

spark arrester!

------------------------------------------------------------------------

SAE-400® with integral spark arresting mufflers:

Service spark arrester every 250 hours.
Service as follows:

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.

8. Open the air vent valve on the front of the filter header
until fuel emerges free of air bubbles and then close the
air vent valve.

Note: Consult your engine operation manual for
information on air bleeding the entire fuel system.

ENGINE AND MAINTENANCE COMPONENTS

ITEM MAKE PART NUMBER

Engine Air Filter Donaldson P822768

Fan Belt Perkins 2614B555 043

Fuel Filter Perkins 26560201

Engine Oil Filter Perkins 2654407

Pre-Filter/Water Lincoln M21584-B
Separator Element

Stanadyne 39420 LE

SAE-400®

D-4

MAINTENANCE

GFCI TESTING AND RESETTING
PROCEDURE

The GFCI should be properly tested at least once every
month or whenever it is tripped. To properly test and
reset the GFCI:

• If the GFCI has tripped, first carefully remove any

load and check it for damage.

• If the equipment has been shut down, it must be

restarted.

• The equipment needs to be operating at high idle

speed and any necessary adjustments made on the
control panel so that the equipment is providing at
least 80 volts to the receptacle input terminals.

• The circuit breaker for this receptacle must not be

tripped. Reset if necessary.

• Push the "Reset" button located on the GFCI. This

will assure normal GFCI operation.

• Plug a night-light (with an "ON/OFF" switch) or other

product (such as a lamp) into the Duplex receptacle
and turn the product "ON".

• Push the "Test" button located on the GFCI. The

night-light or other product should go "OFF".

• Push the "Reset" button, again. The light or other

product should go "ON" again.

D-4

If the light or other product remains "ON" when the
"Test" button is pushed, the GFCI is not working prop­erly or has been incorrectly installed (miswired). If your
GFCI is not working properly, contact a qualified, certi­fied electrician who can assess the situation, rewire the
GFCI if necessary or replace the device.

SAE-400®

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.

__________________________________________________________________________

E-1

This Troubleshooting Guide is provided to help you
locate and repair possible machine malfunctions.
Simply follow the three-step procedure listed below.

Step 1. LOCATE PROBLEM (SYMPTOM).

Look under the column labeled “PROBLEM (SYMP­TOMS)”. 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.

ELECTRIC SHOCK can kill.

• Do not touch electrically live parts such as output
terminals or internal wiring.

Step 3. RECOMMENDED COURSE OF ACTION

This column provides a course of action for the
Possible Cause, generally it states to contact your
local Lincoln Authorized Field Service Facility.

If you do not understand or are unable to perform the
Recommended Course of Action safely, contact your
local Lincoln Authorized Field Service Facility.

WARNING

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.

SAE-400®

E-2

TROUBLESHOOTING

Observe all Safety Guidelines detailed throughout this manual

E-2

PROBLEMS

(SYMPTOMS)

Machine fails to hold the “heat”
constantly.

POSSIBLE

CAUSE

FUNCTION PROBLEMS

1. Rough or dirty commutator.

2. Brushes may be worn down to
limit of life.

3. Brush springs may be broken.

4. Field circuit may have variable
resistance connections or inter­mittent open circuit, due to loose
connections or broken wire.

5. Electrode or work lead connec­tions may be poor.

6. Wrong grade of brushes may be
installed on generator.

7. Field rheostat may be making
poor contact and overheating.

RECOMMENDED

COURSE OF ACTION

1. True and clean commutator.

2. Replace brushes.

3. Replace brush springs.

4. Check field current with ammeter
to discover varying current. This
applies to both the main genera­tor and exciter.

5. Tighten all connections.

6. Use only the recommended
Lincoln brushes.

7. Inspect and clean rheostat.

8. “Current Control” may not be
operating properly.

9. “Current Control” brush holder
contact springs may be worn out
or missing. Contact surface may
be dirty, rough and pitted.

10. “Current Control” brush holder

support stud and mating contact
surfaces may be dirty or pitted
and burned.

11. Engine running at varying

speeds.

8. Check for loose or missing set
screw in control handles.

9. Inspect. Replace needed parts.
Clean internal contact surface of
control device. Do not lubricate.
Smooth rough surfaces.

10. If brush holder internal contact

surface is pitted and burned,
replace the brush holder and
support stud. If the contact sur­face is dirty, clean off the brush
holder stud and internal contact
surface. Apply mixture of three
parts silicone grease and one
part zinc powder (by weight) to
stud.

11. Set welder controls for maximum

output and weld. Then, while
welding, check engine rpm. The
engine should be running at full
speed. If indicator shows a sig­nificant difference, 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.

SAE-400®

E-3

TROUBLESHOOTING

Observe all Safety Guidelines detailed throughout this manual

E-3

PROBLEMS

(SYMPTOMS)

Welder runs but fails to generate
current.

POSSIBLE

CAUSE

FUNCTION PROBLEMS

1. Generator or exciter brushes may
be loose or missing.

2. Exciter may not be operating.

3. Field circuit of generator or exciter
may be open.

4. Polarity reversing switch may be
in the neutral position.

5. Exciter may have lost excitation.

RECOMMENDED

COURSE OF ACTION

1. Be sure that all brushes bear on
the commutator and have proper
spring tension.

2. Check exciter output voltage with
voltmeter or lamp.

3. Check for open circuits in rheo­stat, field leads and field coils.
Also check resistors.

4. Put handle in positive or negative
position.

5. Check components and continuity
in flashing circuit.

Welding arc is loud and spatters
excessively.

1. Series field circuit may be open
circuited.

2. Current setting may be too high.

3. Polarity may be wrong.

1. Check circuit with ringer or volt­meter.

2. Check setting and current output
with ammeter.

3. 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.

SAE-400®

E-4

TROUBLESHOOTING

Observe all Safety Guidelines detailed throughout this manual

E-4

PROBLEMS

(SYMPTOMS)

Welding current too great or too
small compared to indication on the
dial.

Welder has output and no control

POSSIBLE

CAUSE

FUNCTION PROBLEMS

1. “Current Control” shaft and han­dle may have turned slightly in
the insulated bushing of the cur­rent control brush holder, caused
by turning handle too hard against
one of the stops.

2. Exciter output low causing low
output compared to dial indica­tion.

3. “Current Control” set to minimum
and welder output so great that
engine stalls when arc is struck.

1. Local/Remote switch is in wrong
position.

RECOMMENDED

COURSE OF ACTION

1. With current control against the
minimum stop, set pointer to with­in 1/8” of the last scale division.

2. Check for shorts in exciter arma­ture with growler.

3. Check to see that series field is
properly connected and not short­ed.

1. Place switch in “LOCAL” position
to control output at the welder.
Place switch in “REMOTE” posi­tion to control 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.

SAE-400®

E-5

TROUBLESHOOTING

Observe all Safety Guidelines detailed throughout this manual

E-5

PROBLEMS

(SYMPTOMS)

POSSIBLE

CAUSE

FUNCTION PROBLEMS

No auxiliary power 1. Circuit Breakers open.

2. Faulty connections to auxiliary
receptacles.

3. If the GFCI tripped. (See
Maintenence Section).

RECOMMENDED

COURSE OF ACTION

1. Check and reset breakers. If
breakers keep tripping check con­nections to auxiliary receptacles.
Also make sure load does nor
exceed receptacleʼs current rating.

2. Check connections.

3. Follow “GFCI Testing and
Resetting Procedure” in the MAIN­TENANCE section of this 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.

SAE-400®

F-1

Enhanced Diagram

WIRING DIAGRAM

F-1

pasted inside the machine on one of the enclosure panels.

NOTE: This diagram is for reference only. It may not be accurate for all machines covered by this manual. The specific diagram for a particular code is

SAE-400®

F-2

WIRING DIAGRAM

F-2

SAE-400®

pasted inside the machine on one of the enclosure panels.

NOTE: This diagram is for reference only. It may not be accurate for all machines covered by this manual. The specific diagram for a particular code is

F-3

A

DIMENSION PRINT

F-3

A

M8869-36

50.13

21.00

CENTER OF GRAVITY WITH OIL AND

WATER IN ENGINE, BUT NO FUEL

44.00

63.06

38.50

23.00

26.00

6.00

39.69

47.95

8.12

8.9044.50

69.75

77.00 3.00

N.A.

83.00

81.25 .88

N.B.

22.14

24.50

28.00

22.00

N.B.

27.12

N.A.

 .69 HOLES

 .81 HOLES

N.B.

N.A.

SAE-400®

F-4

DIAGRAM

INSTRUCTIONS FOR INSTALLING A 2-POLE RESIDUAL CURRENT

F-4

DEVICE TO PROTECT THE 230V SINGLE PHASE RECEPTACLE

WARNING

ELECTRIC SHOCK can kill

Do not operate with panels open.
Disconnect NEGATIVE (-) BATTERY LEAD(S)
from ground before servicing.
Do not touch electrically live parts.

1. Turn welder off, then disconnect the negative battery cable.

2. Remove the RCD cover plate located on the lower control panel next to
the 230V euro receptacle on the outside of the machine. Discard the

cover plate and keep the screws for later use.

3. Remove the RCD cover box from the lower control panel. Keep screws,
RCD cover box, and RCD mounting bracket that is inside RCD cover
box for later use.

4. Cut off existing insulated terminals from leads inside the box. Strip all 4
lead ends to13mm (.50 in.).

5. Connect red leads (6A & 7A) into top terminals of the RCD and connect

black leads (6C &7C) into bottom teminals of R

2.4 NM (21 in-lb). Note: leads must be connected as shown in

Figure 2 to insure proper operation of the RCD. Coat area where leads
connect to RCD with a silicone rubber RTV seal

MOVING PARTS can injure

Keep guards in place.
Keep away from moving parts.

Only qualified personnel should install,use
or service this equipment.

CD. Tighten leads to

ant.

S.

6. Insert the sealing boot through the RCD cut out in the lower control panel.

Then insert the RCD. Mount the RCD by using the RCD bracket set aside

in step 3 and the screws set aside in step 2.

7. Mount the RCD cover box to the lower control panel using the screws
set aside in step 3. Make sure the sleeving that is covering the leads is

inserted in the opening on the side of the RCD cover box and is
protecting the leads.

8. Reconnect the negative battery cable.

The unit is now ready for operation.

A.01

M22332

SAE-400®

F-5

Lower Control Panel

RED

RED

6A

7A

DIAGRAM

FIGURE 1

FRONT PANEL

FIGURE 2

F-5

RCD
Cover Plate

230V
Euro Receptacle

2-POLE RCD

RCD Mounting Strap

RCD SEALING BOOT

BLACK

(Route out of lower corner of RCD
cover box to upper control panel.)

RCD Cover Box

6C

BLACK

Sleeving

7C

Sleeving

FIGURE 3

BACK PANEL

SAE-400®

A.01

M22332

NOTES

SAE-400®

NOTES

SAE-400®

 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

 Los humos fuera de la zona de res-

piración.

 Mantenga la cabeza fuera de los

humos. Utilice ventilación o
aspiración para gases.

 Gardez la tête à l’écart des fumées.
 Utilisez un ventilateur ou un aspira-

teur pour ôter les fumées des zones
de travail.

 Vermeiden Sie das Einatmen von

Schweibrauch!

 Sorgen Sie für gute Be- und

Entlüftung des Arbeitsplatzes!

 Mantenha seu rosto da fumaça.
 Use ventilação e exhaustão para

remover fumo da zona respiratória.

 Desconectar el cable de ali-

mentación de poder de la máquina
antes de iniciar cualquier servicio.

 Débranchez le courant avant l’entre-

tien.

 Strom vor Wartungsarbeiten

abschalten! (Netzstrom völlig öff­nen; Maschine anhalten!)

 Não opere com as tampas removidas.
 Desligue a corrente antes de fazer

serviço.

 Não toque as partes elétricas nuas.

 No operar con panel abierto o

guardas quitadas.

 N’opérez pas avec les panneaux

ouverts ou avec les dispositifs de
protection enlevés.

 Anlage nie ohne Schutzgehäuse

oder Innenschutzverkleidung in
Betrieb setzen!

 Mantenha-se afastado das partes

moventes.

 Não opere com os paineis abertos

ou guardas removidas.

Spanish

AVISO DE

PRECAUCION

French

ATTENTION

German

WARNUNG

Portuguese

ATENÇÃO

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.

WARNING

Spanish

AVISO DE

PRECAUCION

 Do not touch electrically live parts or

electrode with skin or wet clothing.

 Insulate yourself from work and

ground.

 No toque las partes o los electrodos

bajo carga con la piel o ropa moja­da.

 Aislese del trabajo y de la tierra.

 Keep flammable materials away.

 Mantenga el material combustible

fuera del área de trabajo.

 Wear eye, ear and body protection.

 Protéjase los ojos, los oídos y el

cuerpo.

French

ATTENTION

German

WARNUNG

Portuguese

ATENÇÃO

Japanese

Chinese

Korean

Arabic

 Ne laissez ni la peau ni des vête-

ments mouillés entrer en contact
avec des pièces sous tension.

 Isolez-vous du travail et de la terre.

 Berühren Sie keine stromführenden

Teile oder Elektroden mit Ihrem
Körper oder feuchter Kleidung!

 Isolieren Sie sich von den

Elektroden und dem Erdboden!

 Não toque partes elétricas e elec-

trodos com a pele ou roupa molha­da.

 Isole-se da peça e terra.

 Gardez à l’écart de tout matériel

inflammable.

 Entfernen Sie brennbarres Material!

 Mantenha inflamáveis bem guarda-

dos.

 Protégez vos yeux, vos oreilles et

votre corps.

 Tragen Sie Augen-, Ohren- und Kör-

perschutz!

 Use proteção para a vista, ouvido e

corpo.

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 HER­STELLERS. DIE UNFALLVERHÜTUNGSVORSCHRIFTEN DES ARBEITGEBERS SIND EBENFALLS ZU BEACHTEN.

Need Help?

Lincoln Electric “Rapid Response” Service!

Call 1.888.935.3877 to talk to a Service Representative

Hours of Operation: 8:00 AM to 6:00 PM (ET) Mon. thru Fri.

After hours? Use “Ask the Experts” at lincolnelectric.com

A Lincoln Service Representative will contact you no later than the following business
day.

• For Service outside the USA: Email [e-mail]

Copyright © Lincoln Global Inc.

• World's Leader in Welding and Cutting Products • • Sales and Service through Subsidiaries and Distributors Worldwide •

Cleveland, Ohio 44117-1199 USA TEL: [phone]

For Service in the USA and Canada: Call 1.888.935.3877 For Service outside the USA: Email [e-mail]

FAX: [phone] WEB SITE: lincolnelectric.com