Lincoln Electric IM10122 User Manual
Operator’s Manual
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SAE-400 ®DC ARC WELDING
POWER SOURCE
For use with machines having Code Numbers:
11808
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Save for future reference
Date Purchased
Code: (ex: 10859)
Serial: (ex: U1060512345)
IM10122 | Issue D ate Sept- 13
© Lincoln Global, Inc. All Rights Reserved.
Need Help? 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: globalservice@lincolnelectric.com
THANK YOU FOR SELECTING
AT ALL
TIMES.
SPECIAL SITUATIONS
Additional precautionary measures
A QUALITY PRODUCT BY
LINCOLN ELEC TRIC.
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.
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.
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.
KEEP YOUR HEAD OUT OF THE FUMES.
DON’T get too close to the arc. Use
corrective lenses if necessary to
stay a reasonable distance away
from the arc.
READ and obey the Material Safety
Data Sheet (MSDS) and the warning
label that appears on all containers
of welding materials.
USE ENOUGH VENTILATION or
exhaust at the arc, or both, to keep
the fumes and gases from your breathing zone and the general area.
IN A LARGE ROOM OR OUTDOORS, natural ventilation may be
adequate if you keep your head out of the fumes (See below).
USE NATURAL DRAFTSor fans to keep the fumes away from your
face.
If you de velop unusual symptoms, see your supervisor. Perhaps the
welding atmosphere and ventilation system should be checked.
WEAR CORRECT EYE, EAR & BODY PROTECTION
PROTECT your eyes and face with welding helmet
properly fitted and with proper grade of filter plate
(See ANSI Z49.1).
PROTECT your body from welding spatter and arc
flash with protective clothing including woolen
clothing, flame-proof apron and gloves, leather
leggings, and high boots.
PROTECT others from splatter, flash, and glare with
protective screens or barriers.
IN SOME AREAS, protection from noise may be
appropriate.
BE SURE protective equipment is in good condition.
Also, wear safety glasses in work area
DO NOT WELD OR CUT containers or materials which previously had
been in contact with hazardous substances unless they are properly
cleaned. This is extremely dangerous.
DO NOT WELD OR CUT painted or plated parts unless special
precautions with ventilation have been taken. They can release highly
toxic fumes or gases.
PROTECT compressed gas cylinders from excessive heat, mechanical
shocks, and arcs; fasten cylinders so they cannot fall.
BE SURE cylinders are never grounded or part of an electrical circuit.
REMOVE all potential fire hazards from welding area.
ALWAYS HAVE FIRE FIGHTING EQUIPMENT READY FOR IMMEDIATE
USE AND KNOW HOW TO USE IT.
SECTION A:
Diesel Engines
Gasoline Engines
WARNINGS
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 engine exhaust from this product contains chemicals known
to the State of California to cause cancer, birth defects, or other reproductive harm.
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.
SAFETY
1.d. Keep all equipment safety guards, covers and
devices in position and in good repair.Keep
hands, hair, clothing and tools away from
V-belts, gears, fans and all other moving parts
when starting, operating or repairing
equipment.
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.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.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.
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
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.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.
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.
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.
3
SAFETY
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
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.
between the
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 vapors
coming from degreasing, cleaning or spraying operations. The
heat and rays of the arc can react with solvent vapors to form
phosgene, a highly toxic gas, and other irritating products.
3.j. Also see It ems 6.c. and 8.
5.d. Shielding gases used for arc welding can displace air and
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.
4
cause
SAFETY
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 the
welding sparks from starting a fire. Remember that welding
sparks and hot materials from welding can easily go through
small cracks and openings to adjacent areas. Avoid welding near
hydraulic lines. Have a fire extinguisher readily available.
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 though they have been “cleaned”.
For information, purchase “Recommended Safe Practices for the
Preparation for Welding and Cutting of Containers and Piping That
Have Held Hazardous Substances”, AWS F4.1 from the American
Welding Society (see address above).
6.e. Vent hollow castings or containers before heating, cutting or
welding. They may explode.
6.f. Sparks and spatter are thrown from the welding arc. Wear oil free
protective garments such as leather gloves, heavy shirt, cuffless
trousers, high shoes and a cap over your hair. Wear ear plugs
when welding out of position or in confined places. Always wear
safety glasses with side shields when in a welding area.
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
from the Compressed Gas Association 1235 Jefferson Davis
Highway, Arlington, VA 22202.
Cylinders,” available
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.
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.
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.
Refer to
http://www.lincolnelectric.com/safety
for additional safety information.
Welding Safety
Interactive Web Guide
for mobile devices
5
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
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-3
Spark Arrester . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .D-3
_____________________________________________________________________________________
Troubleshooting Guide . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Section E
_____________________________________________________________________________________
Wiring Diagram and Dimension Print . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Section F
____________________________________________________________________________________
Parts List . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .P-692
____________________________________________________________________________________
TABLE OF CONTENTS
vi
Page
A-1
INSTALLATION
TECHNICAL SPECIFICATIONS - SAE-400®(K1278-15)
INPUT - DIESEL ENGINE
Make/Model Description Speed (RPM) Displacement Starting Capacities
System
269 cu. in Fuel: 29.0 gal.
(4.4 L) 109.8 L
K1278-15
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 4 1710 RPM Full Load 1725
Compliant 4.13” x 5.00”
Export Only
(105.0 mm x 127.0mm)
12VDC battery
Oil: 10.1 Qts.
Coolant: 3.4 gal.
12.8 L
A-1
Duty Cycle
60% (NEMA) 500 amps 40 volts
100% (NEMA) 400 amps 36 volts
100% (Lincoln Plus) 400 amps 40 volts
(1)
Welding Output Volts at Rated Amps
OUTPUT - WELDER AND GENERATOR
RATED OUTPUT - WELDER
Welding Range Open Circuit Voltage Auxiliary Power
120/240 VAC
80 - 575 Amps 97 Max. OCV 10,000 Watts, 60 Hz., Single Phase
@ 1800 RPM 13,000 Watts, 3 Phase Auxiliary, 240V
100% Duty Cycle
RECEPTACLES AND CIRCUIT BREAKERS
RECEPTACLES AUXILIARY POWER CIRCUIT BREAKER
1 - 120VAC Duplex NEMA (5-20R) 2 - 20 amp for 120VAC Duplex NEMA
1 - 120VAC European (IEC-309) 1 - 15 amp for 120VAC European (IEC-309)
1 - 240VAC Duplex NEMA 1 - 15 amp (2 -pole) for 240 V Duplex and European (IEC-309)
1 - 240VAC European (IEC-309)
1 - 240VAC (15-50R) NEMA 3 Phase 1 - (30ma), (RCD) Residual Curret Detector
1 - 120VAC / 240VAC (14-50R) NEMA 1 Phase 1 - 50amp (3-pole), 240VAC Circuit Breaker
HEIGHT WIDTH DEPTH WEIGHT
49.80 in. 27.70 in. 83.10 in. 2286 lbs.
1,264.9 mm 703.6 mm 2,110.7 mm 1037 kg.
(1)
Based on a 10 minute period.
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 29.0 Gal.(109.8 ltr.).
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
K2641-2 and K2637-2. The K2637-2 is also designed
(1)
to be used at highway speeds
. If the user adapts a
non-Lincoln trailer, he must assume responsibility that
the method of attachment and usage does not result in
a safety hazard nor damage the welding equipment.
Some of the factors to be 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
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
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 29.0 gallons (109.8 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.
A-4
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
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.
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 battery.
b) Using a booster.
Use correct polarity — Negative Ground.
To prevent BATTERY BUCKLING, tighten the nuts on
battery until snug. DO NOT OVERTIGHTEN.
SPARK ARRESTER
WARNING
• Spark Arrester and Muffler may be
hot!
• Allow engine to cool before servicing
spark arrester!
• Do not operate engine while servicing
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 haz-
The muffler included with this welder has been
ard.
modified and now qualifies as a spark arrester. Spark
arresting mufflers will have a clean out service plug
and will have “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 manufacurerʼs 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.
Pipe Thawing with an arc welder can cause fire,
explosion, damage to electric wiring or to the arc
welder if done improperly
for pipe thawing is not approved by the CSA, nor is
it recommended or supported by Lincoln Electric.
------------------------------------------------------------------------
. The use of an arc welder
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 10,000 watts
single phase auxiliary 120V/240V power, 13,000 watts
three phase auxiliary 240V 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
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
Phase 13kw 240V, 3 Phase output for auxiliary power
and emergency standby power.
®
provides excellent constant current DC
®
provides 10 KW of 120/240VAC Single
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
• 10kVA of 120/240VAC, 13kVA for 240 3ph. 60 Hz
auxiliary power.
• Two 20 amp 120VAC duplex receptacle.
• One 15 amp, 240VAC duplex receptacle for up to 13
amps of 240VAC power.
• One 120VAC (European
• One 240VAC (European
• One 120/240V NEMA 50 amp receptacle.
• One 240V3 phase NEMA 50 amp receptacle.
• 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 120V Circuit, 240V Circuit, Aux.
@ NEMA Arc Amps Amps 10kVA/
Volts 1ph / 3ph 13kVA
0 84 42 / 31 10 / 13
100 81 40 / 30 10 / 12
200 71 35 / 26 8 / 11
300 54 27 / 20 6 / 8
400 30 15 / 11 4 / 5
500 0 0 / 0 0 / 0
IEC-309
) 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 29.0 gallon (109.8 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:
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
SAE-400
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.
®
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.
Set the “Job Selector” at the center of the black
1.
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
120 VAC Receptacles
One 20 amp, (each side) 120VAC (5-20R) NEMA
duplex receptacle provides 120VAC for auxiliary
power.
One 120V (European IEC-309) 16 amp receptacle. IP44
rated.
One 120V/240V (14-50R) 1 phase 50 amp NEMA style
receptacle.
The auxiliary power receptacles should only be used
with three or four wire grounded type plugs or
approved double insulated tools. The current rating of
any plug used with the system must be at least equal
to the current capacity of the associated receptacle.
240VAC Receptacles
One 15 amp, 240VAC duplex receptacle provides 240
VAC for auxiliary power.
RESIDUAL CURRENT DEVICE
The SAE-400®is configured with a Residual Current
Device (RCD) to protect all receptacles against current
leakage (eg. to ground) from all receptacles.
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.
IEC-309
One 240V (European
rated.
One 240V (15-50R) 3 phase 50 amp NEMA style
receptacle.
Circuit Breakers
2 pole 15 amp rated provides overload protection for
the 240VAC (European IEC-309) receptacle and the
240VAC duplex receptacle.
2 Single pole 20 amp rated circuit breakers provides
overload protection for the 120VAC (5-20R NEMA)
duplex receptacle.
Single pole 15 amp rated provides overload protection
for the 120VAC (European IEC-309) receptacle.
3 pole, 50 amp circuit breaker provides overload protection to 240V, 3 phase and 120/240 1 phase NEMA
(15-50R and 14-50R) plugs.
) 15 amp receptacle. IP44
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
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”
conditions should ether or other starting
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.
®
B-6
OPERATION
TYPICAL FUEL CONSUMPTION
SAE-400® 10KVA
TEST CONDITION FUEL CONSUMPTION
US gal./ hr. liters/ hr.
Low Idle, No Load 0.54 2.04
High Idle, No Load 0.79 2.99
Welding 400A 40V 1.84 6.95
Welding 500A 40V 2.01 7.60
Auxiliary 10KVA 1.22 4.61
Auxiliary 13KVA 1.39 5.27
Weld 400A 40V, Auxiliary 10KVA 2.33 8.28
B-6
Weld 400A 40V, Auxiliary 13KVA 2.24 8.47
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).
K802D 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 construction 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.
K2637-2 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.
K385-2 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:
K2637-2 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
®
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