Lincoln Electric SAE-400 User Manual

S AE-400 Severe Duty

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ENGINE DRIVEN WELDER

™

Great for the Off-Shore Salt Spray
and Other Corrosive Environments

For off-shore and other corrosive environments the SAE-400
Severe Duty™(The “Silver Bullet”) is the preferred choice with
its great arc performance, design simplicity, reliability and
ruggedness! Utilizing customer experience and input from
job-site use, it is an upgraded version of the workhorse
SAE-400 that you can count on!

Processes

Stick, Gouging

Advantage Lincoln

Output

Input

• Designed For The Off-Shore Salt Spray Environment

- Stainless steel and hot-dip galvanized case & internal sheet
metal parts.

- Stainless steel brushholder assemblies.

- All copper coils.

- Coated radiator, fuel tank, laminations and wire connections.

- Sealed switches.

• Rugged Construction

- Built in a heavy gauge steel case designed for durability on the job site.

- Withstands rough field handling.

• Includes Features Per Mineral Management Services Code

- Spark arrestor and engine air intake shutdown device are standard.

• High Duty Cycle Welding Output

- 100% duty cycle at 400amps for demanding applications. Also rated at
500 amps.

• Arc Gouging

- Arc gouging with up to 3/8" (10 mm) carbons.

• Heavy-Duty Industrial Diesel Engine

- Perkins 4-cylinder, water-cooled industrial diesel engine offers low
maintenance and long life.

• Three-Year Warranty

- Three-year Lincoln warranty on welder (engine is warranted separately
by the engine manufacturer).

• Dual Continuous Control

- Dual continuous control of both current and open circuit voltage lets
operator select the precise arc characteristics needed for each job.

TECHNICAL SPECIFICATIONS

Product Current/Voltage/ Output of of Speed H x W x D Weight

Name Duty Cycle Range Engine Cyl. (rpm) in. (mm) lbs (kg)

SAE-400 400A DC/40V/100% 80-575A DC Perkins 4 68.4 @ 1725 50 x 28 x 83 2,210
Severe Duty 500A DC/40V/35% 3000 watts 1104C-44 (1270 x 711 x 2109) (1,002)

Rated Output Type No. HP & Dimensions Net

Diesel

Publication E6.180.1 8/05

Web Update 8/07

www.lincolnelectric.com

A CLOSER LOOK

PERFORMANCE

• 400 amp rated output DC arc welding power source with
outstanding characteristics for pipe, construction and
maintenance stick welding. 575 amp maximum output.

• Dual continuous output control. Select either a soft “buttery”
arc or a snappy “digging” arc for fast, high-quality welding.

FEATURES

• Polarity switch for selecting DC+, DC- welding output.

• 100 ft. (30.5m) remote control included – not a separate kit.

• Powered by a heavy duty, industrial Perkins diesel engine.

• Pressure lubrication system with replaceable filter assures
lubrication to all critical areas of the engine.

• Engine gauges indicate oil pressure, temperature and battery
charging amps.

• All day welding with 22.5 gallon fuel capacity. Sediment bowl and
a filter in the fuel line help keep the fuel clean.

• Pushbutton starting is powered by two 12V batteries.

• Arc gouging with up to a 3/8" carbon.

• Delivers 3,000 watts of 115V/230V AC power for a grinder, lights
or other power tools.

• Glow plugs for starting the engine at low ambient temperatures,
32º F (0º C) to -5º F (-21º C).

• Combination muffler/spark arrestor manufactured from stainless
steel is standard on the machine. Spark arrestor included per
MMS (Mineral Management Services) code.

• Air intake Emergency Shutdown Device on engine per MMS
(Mineral Management Services) code.

• Single-side engine access for routine maintenance.

• Oil drain system includes ball valve, hose and clamp to direct oil
beyond the base of the machine.

• Engine hour meter for scheduling maintenance.

Key Controls

1. Polarity Switch

2. Current Control

3. 115V Receptacles with Covers

4. Engine Hour Meter

5. Air Intake Emergency Shutdown
Handle

6. Remote Control Receptacle

7. Local/Remote Control

8. Engine Protection Light

9. Engine Idler

10. Glow Plug Button

11. Pushbutton Start

12. On/Off Switch

13. Oil Pressure, Temperature, and
Battery Charging Amps Gauges

14. Circuit Breakers

15. 230V Receptacles with Covers

16. Job Selector

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SAE-400 Severe Duty

[2]

www.lincolnelectric.com

A CLOSER LOOK

QUALITY AND RELIABILITY

Designed And Built For The Off-Shore Salt Spray And Other Corrosive Environments

Assembled on a heavy gauge galvanized steel frame. Designed for
durability on the job site. Rugged construction withstands rough field
handling, protecting internal parts.

Stainless steel roof, doors, control panel and
remote control box.

Fuel tank coated inside and out with plastisol.
Material does not interact with diesel fuel.

Lexan™ nameplates - printing will
not wash out from salt spray.

Weather protective covers
on all receptacles.

All toggle switches sealed to
protect against moisture.

All switch and wire connections are coated for
corrosion protection and to prevent electrical
"tracking" between contacts.

Radiator - phenolic (plastic) dip­coated for corrosion protection.

All copper coil windings. Improved
coil insulation for
increased durability.

Generator, armature and exciter
lamination stacks are dipped in
E-Coat for a tough, completely
bonded coating.

Brushholder assemblies are stainless
steel and non-metallic materials to
avoid corrosion.

Hot-dip galvanized base, radiator shroud
and internal steel components.

• Most fasteners are stainless steel. Assembled with anti-seize
compound.

• Perkins 4-cylinder, water-cooled industrial diesel engine offers low
maintenance and long life. Water separator on engine to filter
water from diesel fuel.

• Automatic shutdown protection for low oil pressure or high
coolant temperature.

• Two 12 volt batteries paralleled for 1130 cold cranking amps of
engine starting.

• Printed circuit board for idler and engine protection is potted to
provide a robust environmental shield.

• Manufactured under a quality system certified to ISO 9001
requirements and ISO 14001 environmental standards.

• Approved by the Canadian Standards Association (CSA).

• Three-year Lincoln warranty. (Engine is warranted separately
by the manufacturer.)

[3]

SAE-400 Severe Duty

www.lincolnelectric.com

A CLOSER LOOK

MACHINE SPECIFICATIONS

imensions

Product Ordering CC Rated Output (1) Generator HxWxL (3) Weight

ame Information Description Current/Voltage/Duty Cycle AC Power (2) in (mm) lbs (kg)

N

AE-400 K1278-8 400 Amp DC Lincoln Rating 3,000 Watts 50 x 28 x 83 2,210

S

Severe Duty

1) Based on 10 minute period. High Altitude: For maximum rating, derate the output 5% for every 1,650 ft (500 m) above 3,300 ft. (1,000 m).

(

2) 115V will operate either 60 Hz or 50/60 Hz power tools, lights, etc.

(
(3) Height is to top of lift bale; 46 in. (1168mm) case height.

Arc Welder with 400A/40V/100% 60 Hz, AC

,000 Watts of 500A/40V/35%

3

C Power and 26 Amps @

A

100 ft. (30.5m) 80-575 Amps 115V

emote Control

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ontinuous Adjustment of 230V

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Voltage and Current

13 Amps @

2)

(

D

(1270 x 711 x 2109) (1,002)

ENGINE SPECIFICATIONS

ngine Model Description Displacement Capacities Speeds Consumption

E

Perkins 4 Cylinder, 4 Cycle 68.4 HP @ Fuel: Full Load: 1,725 RPM 1.8 gals/hr

iesel (4) Water-cooled Diesel 1,725 RPM 22.5 gals (85.1 ltrs) (400A) (6.8 ltrs/hr)

D
1104C-44 Engine with Dry

(4) Engine warranty is 2 years/3,000 hours.

Cartridge Air Filter 269 cu in Oil: High Idle: 1,800 RPM 0.7 gals/hr

and Water Separator (4.4 ltrs) 10.1 qts (9.6 ltrs) (2.6 ltrs/hr)

EPA Tier 2

Horsepower & Operating Fuel

Radiator Coolant: Low Idle: 1,100 RPM 0.3 gals/hr

3.4 gals (12.8 ltrs) (1.1 ltrs/hr)

[4]

SAE-400 Severe Duty

www.lincolnelectric.com

RECOMMENDED OPTIONS

GENERAL OPTIONS

Power Plug Kit

Provides two 115V plugs rated at
20 amps each, and two 230V plugs
rated at 15 amps each. 120V plug
may not be compatible with
common household receptacles.

Order K802D

GFCI Receptacle Kit

Includes one UL approved 115V
ground fault circuit interrupter
duplex type receptacle and
installation instructions. Replaces
the factory installed 115V duplex
receptacle. Each receptacle of the
GFCI duplex is rated at 20 amps.
Maximum total current from the
GFCI duplex is limited to 20 amps.
Order K1690-1

Large Welder Trailer

For heavy-duty road, off-road,
plant and yard use. Includes
pivoting jack stand, safety chains,
and 14" wheels. Stiff .120" welded
rectangular steel tube frame
construction is phosphate etched
and powder coat painted for
superior rust and corrosion
resistance. Low sway suspension
gives outstanding stability with
manageable tongue weight. Wheel
bearings are packed with high
viscosity, high pressure, low
washout Lubriplate
Includes a Duo-Hitch™– a 2"
Ball/Lunette Eye combination
hitch. Overall width: 60".
Order:
K2637-1 Trailer
K2639-1 Fender & Light Kit
K2640-1 Cable Rack

®

grease.

TICK OPTIONS

S

Accessory Kit

For stick welding. Includes 35 ft.
(10.7m)) 2/0 electrode cable with
lug, 30 ft. (9.1m) 2/0 work cable
with lugs, headshield, filter plate,
work clamp and electrode holder.
400 amp capacity.

Order K704

Four-Wheeled Steerable
Yard Trailer

For off-road, plant and yard use.
Includes an automatically engaging
drawbar lock when the drawbar is
raised to the verticle position. 13"
wheels. Wheel bearings are packed
with high viscosity, high pressure,
low washout Lubriplate
Assembles directly to the base of
the SAE-400 or SAE-400 Severe
Duty welder. Also includes a Duo-

™

Hitch

–a2" Ball/Lunette Eye
combination hitch. Overall width:
55".

Order K2641-1

®

grease.

[5]

SAE-400 Severe Duty

www.lincolnelectric.com

AE-400 SEVERE DUTY ORDER FORM

S

PRODUCT DESCRIPTION ORDER NUMBER QUANTITY PRICE

SAE-400 SEVERE DUTY K1278-8

ECOMMENDED GENERAL OPTIONS

R

ower Plug Kit K802D

P
GFCI Receptacle Kit K1690-1

arge Welder Trailer with Duo-Hitch

L

Fender and Light Kit K2639-1

-

- Cable Rack K2640-1
Four-Wheeled Yard Trailer with Duo-Hitch™: 2" Ball/Lunette Eye Hitch K2641-1

ccessory Kit K704

A

™

2"Ball/Lunette Eye Hitch K2637-1

:

TOTAL:

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 customer’s 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 responsible 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.

C U S T O M E R A S S I S T A N C E P O L I C Y

THE LI NCO LN ELE CTR IC COMPANY

®

22801 St. Clair Ave., Cleveland, OH 44117-1199 • 216.481.8100 • www.lincolnelectric.com