Lincoln Electric SVM187-A User Manual
SAE-400 SEVERE DUTY
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For use with machine code numbers 10856, 11199, 11408
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.
SVM187-A
October, 2008
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Cleveland, Ohio 44117-1199 U.S.A. TEL: 888-935-3877 FAX: 216.486.1751 WEB SITE: www.lincolnelectric.com
SERVICE MANUAL
Copyright © Lincoln Global Inc.
• World's Leader in Welding and Cutting Products •
• Sales and Service through Subsidiaries and Distributors Worldwide •
i 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
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
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
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 weldarc or when the engine is running. Stop
ing
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.
and in good repair.Keep hands, hair, clothing and tools
to perform required maintenance. Remove
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
maybedangerous
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.
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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.
Mar ‘95
SAE-400 SEVERE DUTY
ii ii
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
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 below Threshold Limit Values (TLV)
using local exhaust or mechanical ventilation. In
confined spaces or in some circumstances, outdoors, a
respirator may be required. Additional precautions are
also required when welding on galvanized steel.
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.
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.
vapors
to
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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.
Aug ‘06
SAE-400 SEVERE DUTY
iii iii
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
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.
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Jan ‘07
SAE-400 SEVERE DUTY
iv iv
SAFETY
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 LʼArc
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.
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.
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.
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.
PRÉCAUTIONS DE SÛRETÉ POUR
LES MACHINES À SOUDER À
TRANSFORMATEUR ET À
REDRESSEUR
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.
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Mar ‘93
SAE-400 SEVERE DUTY
v v
SAFETY
Electromagnetic Compatibility (EMC)
Conformance
Products displaying the CE mark are in conformity with European Community Council Directive of 3 May
1989 on the approximation of the laws of the Member States relating to electromagnetic compatibility
(89/336/EEC). It was manufactured in conformity with a national standard that implements a harmonized
standard: EN 60974-10 Electromagnetic Compatibility (EMC) Product Standard for Arc Welding Equipment.
It is for use with other Lincoln Electric equipment. It is designed for industrial and professional use.
Introduction
All electrical equipment generates small amounts of electromagnetic emission. Electrical emission may be
transmitted through power lines or radiated through space, similar to a radio transmitter. When emissions
are received by other equipment, electrical interference may result. Electrical emissions may affect many
kinds of electrical equipment; other nearby welding equipment, radio and TV reception, numerical controlled
machines, telephone systems, computers, etc. Be aware that interference may result and extra precautions
may be required when a welding power source is used in a domestic establishment.
Installation and Use
The user is responsible for installing and using the welding equipment according to the manufacturer’s
instructions. If electromagnetic disturbances are detected then it shall be the responsibility of the user of the
welding equipment to resolve the situation with the technical assistance of the manufacturer. In some cases
this remedial action may be as simple as earthing (grounding) the welding circuit, see Note. In other cases
it could involve construction of an electromagnetic screen enclosing the power source and the work complete with associated input filters. In all cases electromagnetic disturbances must be reduced to the point
where they are no longer troublesome.
Note: The welding circuit may or may not be earthed for safety reasons according to national
codes. Changing the earthing arrangements should only be authorized by a person who is
competent to access whether the changes will increase the risk of injury, e.g., by allowing
parallel welding current return paths which may damage the earth circuits of other equipment.
Assessment of Area
Before installing welding equipment the user shall make an assessment of potential electromagnetic problems in the surrounding area. The following shall be taken into account:
a) other supply cables, control cables, signaling and telephone cables; above, below and adjacent to the
welding equipment;
b) radio and television transmitters and receivers;
c) computer and other control equipment;
d) safety critical equipment, e.g., guarding of industrial equipment;
e) the health of the people around, e.g., the use of pacemakers and hearing aids;
f) equipment used for calibration or measurement
g) the immunity of other equipment in the environment. The user shall ensure that other equipment being
used in the environment is compatible. This may require additional protection measures;
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h) the time of day that welding or other activities are to be carried out.
L10093 3-1-96H
SAE-400 SEVERE DUTY
vi vi
SAFETY
Electromagnetic Compatibility (EMC)
The size of the surrounding area to be considered will depend on the structure of the building and other
activities that are taking place. The surrounding area may extend beyond the boundaries of the premises.
Methods of Reducing Emissions
Mains Supply
Welding equipment should be connected to the mains supply according to the manufacturer’s recommendations. If interference occurs, it may be necessary to take additional precautions such as filtering of the
mains supply. Consideration should be given to shielding the supply cable of permanently installed welding
equipment, in metallic conduit or equivalent. Shielding should be electrically continuous throughout its
length. The shielding should be connected to the welding power source so that good electrical contact is
maintained between the conduit and the welding power source enclosure.
Maintenance of the Welding Equipment
The welding equipment should be routinely maintained according to the manufacturer’s recommendations.
All access and service doors and covers should be closed and properly fastened when the welding equipment is in operation. The welding equipment should not be modified in any way except for those changes
and adjustments covered in the manufacturers instructions. In particular, the spark gaps of arc striking and
stabilizing devices should be adjusted and maintained according to the manufacturer’s recommendations.
Welding Cables
The welding cables should be kept as short as possible and should be positioned close together, running at
or close to floor level.
Equipotential Bonding
Bonding of all metallic components in the welding installation and adjacent to it should be considered.
However, metallic components bonded to the work piece will increase the risk that the operator could
receive a shock by touching these metallic components and the electrode at the same time. The operator
should be insulated from all such bonded metallic components.
Earthing of the Workpiece
Where the workpiece is not bonded to earth for electrical safety, not connected to earth because of its size
and position, e.g., ships hull or building steelwork, a connection bonding the workpiece to earth may reduce
emissions in some, but not all instances. Care should be taken to prevent the earthing of the workpiece
increasing the risk of injury to users, or damage to other electrical equipment. Where necessary, the connection of the workpiece to earth should be made by a direct connection to the workpiece, but in some
countries where direct connection is not permitted, the bonding should be achieved by suitable capacitance, selected according to national regulations.
Screening and Shielding
Selective screening and shielding of other cables and equipment in the surrounding area may alleviate
problems of interference. Screening of the entire welding installation may be considered for special applica-
1
tions.
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_________________________
1
Portions of the preceding text are contained in EN 60974-10: “Electromagnetic Compatibility (EMC)
product standard for arc welding equipment.”
SAE-400 SEVERE DUTY
L10093 3-1-96H
vii vii
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- MASTER TABLE OF CONTENTS FOR ALL SECTIONS -
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Page
Safety ...........................................................................i-iv
Installation..................................................................SectionA
Operation ..................................................................SectionB
Accessories . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Section C
Maintenance ................................................................SectionD
TheoryofOperation ..........................................................SectionE
Troubleshooting and Repair . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Section F
ElectricalDiagrams ..........................................................SectionG
PartsManual ...................................................................P-530
SAE-400 SEVERE DUTY
A-1 A-1
Installation.............................................................................A-1
TechnicalSpecifications ................................................................A-2
Safety Precautions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .A-3
Location/Ventilation ..................................................................A-3
Stacking ............................................................................A-3
AngleOfOperation ...................................................................A-3
Lifting ..............................................................................A-3
High Altitude Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .A-4
Towing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .A-4
VehicleMounting .....................................................................A-4
TABLE OF CONTENTS - INSTALLATION SECTION
Pre-OperationEngineService ...........................................................A-4
EngineBreak-In ......................................................................A-5
Engine Cooling System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .A-5
BatteryConnection....................................................................A-5
Spark Arrestor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .A-6
Welding Output Cables . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .A-6
Machine Grounding . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ...............A-6
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SAE-400 SEVERE DUTY
A-2 A-2
INSTALLATION
TECHNICAL SPECIFICATIONS - SAE-400 SEVERE DUTY
INPUT - DIESEL ENGINE CODE 10856
-
Make/Model Description Speed (RPM) Displacement Starting Capacities
System
Perkins 4 cylinder High Idle 1800 256 cu. in
1104.42 Diesel 71 HP @ Low Idle 1100 (4.2 L)
Engine 1725 RPM Full Load 1725
Bore x Stroke Oil: 8.5 Qts.
3.875” x 5.00”
(98.4 mm x 127.0mm) Coolant: 3.6 gal.
12VDC batteries
(2
) & Starter 85.1 L
Fuel: 22.5 gal.
8.04 L
13.63 L
RATED OUTPUT - WELDER CODES 10856
Duty Cycle
60% (NEMA) 400 amps 36 volts
60% (Lincoln Plus) 400 amps 40 volts
100% (Lincoln Plus) 400 amps 40 volts
(1)
Welding Output Volts at Rated Amps
INPUT - DIESEL ENGINE CODE 11199 &11408
Make/Model Description Speed (RPM) Displacement Starting Capacities
System
Perkins 4 cylinder High Idle 1800 269 cu. in
1104C-44 Diesel 68.4 HP @ Low Idle 1100 (4.2 L)
Engine 1725 RPM Full Load 1725
Bore x Stroke Oil: 10.1 Qts.
4.13” x 5.00”
(105 mm x 127mm) Coolant: 3.4 gal.
12VDC batteries
(2
) & Starter 85.1 L
Fuel: 22.5 gal.
9.6 L
12.8 L
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Duty Cycle
35% (NEMA) 500 amps 40 volts
100% (Lincoln Plus) 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 CODES 11199 &11408
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
PHYSICAL DIMENSIONS
HEIGHT WIDTH DEPTH WEIGHT
Codes
50.13 in. 28.00 in. 83.00 in. 11199 2,210 lbs.
11408 1002.4 kg
1273.3 mm 711.2 mm 2108.2 mm
10856 2178 lbs.
(1)
Based on a 10 minute period.
SAE-400 SEVERE DUTY
988.0 kg
A-3 A-3
Read this entire installation section before you
start installation.
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.
INSTALLATION
CAUTION
DO NOT MOUNT OVER COMBUSTIBLE SURFACES.
Where there is a combustible surface directly
under stationary or fixed electrical equipment, that
surface shall be covered with a steel plate at least
.06”(1.6mm) thick, which shall extend not less than
5.90”(150mm) beyond the equipment on all sides.
------------------------------------------------------------------------
STACKING
These machines cannot be stacked.
ANGLE OF OPERATION
ELECTRIC SHOCK can kill.
•Do not touch electrically live parts
such as output terminals or internal
wiring.
•Insulate yourself from the work and
ground.
•Always wear dry insulating gloves.
------------------------------------------------------------------------
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
ENGINE EXHAUST can kill.
The equipment lift bail should be used to lift the
•
Use in open, well ventilated areas or
vent exhaust outside
machine.
•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.
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 trailer or gas cylinder.
FALLING • Do not lift machine if lift bail is
damaged.
EQUIPMENT can • Do not operate machine while
cause injury. suspended from lift bail.
------------------------------------------------------------------------
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SAE-400 SEVERE DUTY
A-4 A-4
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.
INSTALLATION
• 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
TOWING
The recommended trailers for use with this equipment
for in-plant and yard towing by a vehicle
K767-1 and K956-1. The K956-1 is also designed to be
used at highway speeds
(1)
.If the user adapts a nonLincoln trailer, he must assume responsibility that the
method of attachment and usage does not result in a
safety hazard or 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 trailer’s 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.
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)
are Lincoln’s
1
VEHICLE MOUNTING
WARNING
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 Operator’s
Manual for specific oil recommendations and break-in
information. The oil change interval is dependent on the
quality of the oil and the operating environment. Refer to
the engine Operator’s Manual for the proper service and
maintenance intervals.
FUEL USE DIESEL FUEL ONLY
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 Operator’s Manual for specific fuel recommendations.
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Improperly mounted concentrated loads may cause
unstable vehicle handling and tires or other components to fail.
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NOTE:
fuel shutoff valve is open.
SAE-400 SEVERE DUTY
Before attemting to start the engine, be sure the
A-5 A-5
ENGINE BREAK-IN
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, wetstacking (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 engine’s 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.
INSTALLATION
BATTERY CONNECTION
WARNING: Use caution as the electrolyte is a strong
acid that can burn skin and damage eyes.
Remove and discard the insulating caps from the negative battery terminals. Attach and tighten negative
battery cable terminals.
NOTE:
batteries; if unused for several months, the batteries
may require a booster charge. Be careful to charge the
batteries with the correct polarity. Make sure that the
batteries are level while charging.
To prevent EXPLOSION when:
● INSTALLING A NEW BATTERY — disconnect
● CONNECTING A BATTERY CHARGER —
This machine is furnished with wet charged
negative cable from old battery first and
connect to new battery last.
remove battery from welder by disconnecting
negative cable first, then positive cable and
battery clamp. When reinstalling, connect
negative cable last. Keep well ventilated.
WARNING
GASES FROM BATTERY can explode.
● Keep sparks, flame and cigarettes
away from battery.
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.
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.)
● 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 new batteries.
b) Using a booster.
Use correct polarity — Negative Ground.
To prevent BATTERY BUCKLING, tighten nuts on batteries only until snug. DO NOT OVERTIGHTEN.
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SAE-400 SEVERE DUTY
A-6 A-6
SPARK ARRESTOR
INSTALLATION
MACHINE GROUNDING
WARNING
WARNING
Some federal, state or local laws may require that
diesel engines be equipped with exhaust spark
arrestors when they are operated in certain locations
where unarrested sparks may present a fire hazard.
SAE-400 Severe Duty machines are factory equipped
with either a muffler that qualifies as a spark arrestor or
with a separate Spark Arrestor Unit.
Qualified mufflers have a clean out service plug, and
will have “USDA FS 51001C QUALIFIED SPARK
ARRESTOR” stamped on the muffler shell. If a spark
arrestor is required, and the muffler is not stamped,
secure the separate spark arrestor to the outlet tube of
the muffler using the clamp provided.
Any type of spark arrestor must be serviced and properly maintained.
• Spark Arrestor and Muffler may be hot!
Allow engine to cool before
Do not operate engine while
servicing spark arrestor!
servicing spark arrestor!
CAUTION
An incorrect spark arrester may lead to damage to
the engine or adversely affect performance.
---------------------------------------------------------------------
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.
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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
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AMPS
@60%
Duty Cycle
400
Up to 100 FT.
(Up to 30m)
2/0 AWG
100-200 FT.
(30m-61m)
3/0 AWG
200-250 FT.
(61m-76m)
4/0 AWG
SAE-400 SEVERE DUTY
B-1 B-1
Operation..............................................................................B-1
Safety Instructions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .B-2
Additional Safety Precautions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .B-2
GeneralDescriptions ..................................................................B-2
Welder .............................................................................B-2
Auxiliary Power . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .B-2
DesignFeaturesAndAdvantages ........................................................B-3
Duty Cycle . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .....B-3
Engine Controls: Function / Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .B-4
TABLE OF CONTENTS - OPERATION SECTION
WelderControls:Function/Operation.....................................................B-5
RemoteControl ......................................................................B-5
Auxiliary Power Controls . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .B-5
Engine Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .B-6
StartingInstructions ...................................................................B-6
TypicalFuelConsumption ..............................................................B-7
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SAE-400 SEVERE DUTY
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B-2 B-2
OPERATION
OPERATING INSTRUCTIONS
WELDING SPARKS can cause
Read and understand this entire section before operating your equipment.
SAFETY INSTRUCTIONS
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.
WARNING
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 manufacturerʼs 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.
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------------------------------------------------------------------------
ADDITIONAL SAFETY PRECAUTIONS
Always operate the welder with the hinged doors
closed as these provide maximum protection from
moving parts and insure proper cooling air flow.
Read carefully the Safety Precautions page in the
Instruction Manual before operating this machine.
Always follow these and any other safety procedures
included in this manual and in the engine and compressor instruction manuals.
GENERAL DESCRIPTION
The SAE-400 SEVERE DUTY 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 is a 4-cylinder water cooled diesel made by
Perkins.
RECOMMENDED APPLICATIONS
WELDER
The SAE-400 SEVERE DUTY provides excellent constant current DC welding output for stick (SMAW) welding.
AUXILIARY POWER
The SAE-400 SEVERE DUTY provides 3 KW of
115/230 VAC output for auxiliary power and emergency standby power.
SAE-400 SEVERE DUTY
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.
B-3 B-3
DESIGN FEATURES AND ADVANTAGES
OPERATION
DUTY CYCLE
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 115/230 VAC, 60 Hz auxiliary power.
• One 20 amp 115 VAC duplex receptacle for up to 26
amps of 115 VAC power.
• One 15 amp, 230 VAC duplex receptacle for up to 13
amps of 230 VAC power.
• Weld and AC auxiliary power at the same time (with-
in the limits shown on the chart below).
Welding Using Only Using Only Total
Current, Amps 115V Circuit, 230V Circuit, Aux.
@ NEMA Arc Amps Amps kVA
Vol ts
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.
026133.0
100 19.5 9.75 2.25
200 13 6.5 1.5
300 6.5 3.25 0.75
400 0 0 0
500• 0 0 0
* Codes 11199 and 11408
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,
alternator failure, or broken belt.
• 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.
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• 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.
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SAE-400 SEVERE DUTY
B-4 B-4
OPERATION
ENGINE CONTROLS
ENGINE PROTECTION SYSTEM
IGNITION SWITCH
The engine protection system shuts down the engine
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.
under high coolant temperature, low engine oil pres-
sure, broken belt or alternator failure conditions by
allowing the fuel solenoid valve to close.
AIR INTAKE SHUT-OFF
Code 10856:
This code uses an air intake shut-off device that is
manually engaged and blocks all intake air from enter-
ing the engine.
To shut down the engine, simply pull the emergency
stop handle on the lower control panel.
This air intake shut-off device must be reset manually
inside of the welder.
• Place the Ignition toggle switch in the “off” position.
• Manually turn the air intake shut-off reset handle such
that the handle is in-line with the air intake hoses. The
air intake shut-off is located on the top of the engine
between the muffler and the air filter.
Codes 11199 and 11408:
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.
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 ‘low’ on charge.
These codes have an automatic/manual device that
blocks all intake air from entering the engine.
The automatic feature of this shut-off device will
engage should excessive over speeding occur. The
valve is calibrated at the factory to shutdown before
damage occurs to the engine or generator.
To manually shut down the engine, simply pull the
emergency stop handle on the lower control panel.
This air intake shut-off device will reset automatically,
generally within one minute.
IMPORTANT: Before restarting engine, verify that the
air intake shut-off is in the open position. DO NOT
ATTEMPT TO START ENGINE WITH THE AIR
INTAKE SHUT-OFF IN THE CLOSED POSITION.
WARNING
•
Muffler and Engine may be hot!
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ENGINE HOUR METER
The engine hour meter records the total running time
on the engine in hours. It can be used to keep a record
of maintenance on the engine and or welder.
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This may cause severe damage to the engine.
SAE-400 SEVERE DUTY
B-5 B-5
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.
OPERATION
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
“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.
“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.
A receptacle and “Local/Remote” control switch on the
lower front control panel and a remote control box with
100 ft. (30.5 m) of cord for adjusting the OCV at the
welding site are standard. Putting the switch in the
“REMOTE” position allows fine current control at the
remote control box while placing the switch in the
“LOCAL” position allows fine current control at the “Job
Selector” on the machine.
AUXILIARY POWER CONTROLS
Note: GFCI receptacles are an option and if installed,
see the “MAINTENANCE SECTION” for detailed
information on testing and resetting the GFCI
receptacle.
115 VAC Receptacle
One 20 amp, 115 VAC duplex receptacle provides 115
VAC for auxiliary power. A total of 26 amps can be
drawn from this receptacle.
230 VAC Receptacle
One 15 amp, 230 VAC duplex receptacle provides 230
VAC for auxiliary power. A total of 13 amps can be
drawn from this receptacle.
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HowtoSettheControls
Assume you want a normal soft arc and about 135
amps, using a 5/32” (4.0 mm) electrode:
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.
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Circuit Breakers
The circuit breakers provide separate overload current
protection for each half of the 115 V duplex receptacle.
The circuit breakers provide overload current protection in both current carrying wires of the 230 V duplex
receptacle.
Ground Stud
Provides a connection point for connecting the
machine to earth ground. For the safest grounding procedure refer to “Machine Grounding” in the INSTAL-
LATION section of this manual.
SAE-400 SEVERE DUTY
B-6 B-6
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.
OPERATION
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
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-----------------------------------------------------------------------MOVING PARTS can injure.
• Do not operate with doors open or
guards off.
• Stop engine before servicing.
•Keepawayfrommovingparts.
------------------------------------------------------------------------
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.
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). (codes 11199 and 11408
only).
4. Press the Glow Plug and the Start buttons at the
same time. When the engine starts running,
release buttons. If the engine fails to start in 20
seconds, wait 30 seconds and repeat the above
procedure. Press the Start button only for code
10856.
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Under NO conditions should ether or other starting
fluids be used!
-----------------------------------------------------------------------Code 10856
When overnight temperatures are between 10oF(12oC)
and freezing, use the standard “Thermostart” starting
system installed on all engines. Follow the instructions
on the start panel nameplate and in the engine manual shipped with the welder. With fully charged batteries
and the proper weight oil, the “Themostart” system
operates satisfactorially even down to about 0
o
C).
18
Codes 11199 and 11408
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 at lower temperatures.
Note: Extreme cold weather staring may require longer
glow plug operation.
STOPPING THE ENGINE
1. Turn the “IGNITION” switch to “OFF”
At the end of each day’s 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.
SAE-400 SEVERE DUTY
o
F(-
B-7 B-7
OPERATION
TYPICAL FUEL CONSUMPTION
The typical fuel consumption of the SAE-400 for various operating scenarios is shown below:
11199 + 11408 10856
Low Idle - No Load .30 gal./ hr. .35 gal./hr
1100 RPM (1.12 L./hr.) (1.32 L/hr)
High Idle - No Load .69 gal./hr. .75 gal./hr
1800 RPM (2.61 L./hr.) (2.84 L/hr)
Welding Load 1.79 gal./hr. 1.92 gal./hr
400 Amps, 40 Volts (6.76 L./hr.) (7.27 L/hr)
Welding Load 2.43 gal./hr.
500 Amps, 40 Volts (9.19 L./hr.)
Auxiliary Power .71 gal./hr. .96 gal./hr
3000VA (3.68 L./hr.) (3.63 L/hr)
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SAE-400 SEVERE DUTY
B-8 B-8
NOTES
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SAE-400 SEVERE DUTY
C-1 C-1
Accessories . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .C-1
Optional Field Installed Accessories . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .C-2
TABLE OF CONTENTS - ACCESSORIES SECTION
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SAE-400 SEVERE DUTY
C-2 C-2
ACCESSORIES
OPTIONAL FIELD INSTALLED
ACCESSORIES
K802-D Power Plug Kit - Kit includes male plugs for
20 Amp receptacle.
K2641-1 Trailer - A 4-wheel steerable trailer for in-
(1)
plant and yard towing
with E78-14 load range (B)
tubeless tires. Mounts directly to welder base.(Not for
use on the highway.)
Comes standard with a Duo-Hitch™, a
2” Ball and 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 Duo-Hitch™,
a 2” Ball and Lunette Eye combination Hitch.
Order:
K2637-1 Trailer
K958-1 Ball Hitch
K958-2 Lunette Eye Hitch
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.
K704 Standard Accessory Kit - Includes electrode
and work cables, headshield, work clamp and electrode holder.
K1690-1 GFCI RECEPTACLE KIT
Includes one UL approved 120V ground fault circuit
interrupter duplex type receptacle with cover and
installation instructions. Replaces the factory installed
120V duplex receptacle. Each receptacle of the GFCI
Duplex is rated at 20 Amps, the maximum total current
from the GFCI Duplex is limited to the 20 Amps. See
the MAINTENANCE section for detailed information on
testing and resetting the GFCI receptacle.
,
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SAE-400 SEVERE DUTY
D-1 D-1
Maintenance ...........................................................................D-1
RoutineMaintenance ..................................................................D-2
PeriodicMaintenance..................................................................D-2
EngineOilChange,EngineAirFilter ......................................................D-2
BearingCommutatorAndBrushMaintenance ..............................................D-3
Cooling System, Fuel Filter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .D-3
WaterSeperator......................................................................D-4
SecondaryFuelFilter..................................................................D-4
Engine Maintenance Components . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .......D-4
TABLE OF CONTENTS - MAINTENANCE SECTION
Spark Arrestor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .D-5
GFCIReceptacleTestingAndResetingProcedure...........................................D-5
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SAE-400 SEVERE DUTY
D-2 D-2
●
●
●
●
●
●
●
MAINTENANCE
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.
ROUTINE MAINTENANCE
At the end of each day’s 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 level.
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.
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.
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.
ENGINE OIL CHANGE
The SAE-400 SEVERE DUTY is equipped with a convenient
oil drain system. Drain the oil when the engine is warm to
assure rapid and complete draining.
• Remove the oil filler cap and dipstick.
• To open drain valve, push handle away from valve and turn
90°.
• Drain oil into a suitable container.
• To close drain valve, turn handle 90° till handle snaps in the
closed position.
• Refill engine with the recommended oil to the appropriate
level. Replace dipstick and tighten the oil filler cap securely.
Change the crankcase oil at regular intervals using the proper grade of oil as recommended in the Engine Operating
Manual. Wash your hands with soap and water after handling
used oil. Please dispose of used motor oil in a manner that is
compatible with the environment. We suggest you take it in a
sealed container to your local service station or recycling
center for reclamation. Do not throw it in the trash, pour it on
the ground or down a drain.
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.
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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 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.
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SAE-400 SEVERE DUTY
D-3 D-3
MAINTENANCE
BEARING MAINTENANCE
To seat the slip ring brushes, position the brushes in
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.
place. Then slide one end of a piece of fine sandpaper
between slip rings and brushes with the coarse side
against 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.
COOLING SYSTEM
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
man 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.
They require no particular attention.
The SAE-400 SEVERE DUTY 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.
FUEL FILTERS
WARNING
When working on the fuel system
• Keep ungrounded lights away, do not
smoke !
• Do not spill fuel !
-----------------------------------------------------------------------The SAE-400 SEVERE DUTY is equipped with a Fuel
Pre-Filter/Water Separator Assembly located before
the lift pump and a Secondary Fuel Filter located after
the lift pump and before the fuel injectors. The Fuel
Pre-Filter/Water Separator is mounted to the engine
block just below the lift pump.
The Secondary Fuel Filter is mounted directly to the
engine just above the oil filter.
FUEL PRE-FILTER/WATER SEPARATOR ASSEMBLY
The pre-filter is a 150 micron screen designed to protect against gross fuel contamination of the water separator element and the Secondary Fuel Filter. If the
pre-filter becomes plugged it may be removed, inspected, cleaned and reinstalled. In general this only needs
to be done with each water separator element change
(about every 1,000 hrs.) However if at any time excessive fuel contamination is suspected or a sudden falloff in engine performance is detected the pre-filter
screen should be inspected and cleaned. Follow the
following procedure:
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SAE-400 SEVERE DUTY
D-4 D-4
1. Close the fuel shutoff valve located under the fuel
tank. (on code 10856 valve is located on the fuel
strainer, which is mounted on tank)
MAINTENANCE
3. Grasp the element and pull down with a slight rocking motion to remove the element from the grommet
post on the bottom of the filter header.
2. Unscrew the cap ring located on the top of the filter
header and remove the plastic center cap and Oring.
3. Remove the large white volume plug located directly under the center cap in the upper cavity of the filter header. Use a small screwdriver (or similar
device) to lift the plug part way out of the cavity to
assist with its removal.
Be careful not to damage the pre-filter screen with the
tool used to remove the plug.
4. Using a pair of pliers, gently tug on the pull tabs of
the pre-filter screen in an alternating pattern to
gradually remove the pre-filter screen.
5. Brush off any debris and rinse in diesel fuel.
6. Re-install the pre-filter screen into the upper cavity
of the filter header making sure the four pull tabs
are pointing up. Putting your fingers on the pull
tabs, push down evenly until the lower body of the
pre-filter screen contacts the floor of the upper cavity.
7. Re-insert the large white volume plug into the upper
cavity.
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 doesn’t matter
which one) of arrows located on the outside of the ring
should be located directly under the air vent valve.
6. Open the fuel shutoff valve.
7. 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 informa-
tion on air bleeding the entire fuel system.
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8. Place the O-ring onto the angled seal surface of the
filter header and re-install the plastic cap. Make
sure its flange rests on the O-ring.
9. Screw on the cap ring and tighten hand tight.
10. Remember to open the fuel shutoff valve before
starting the engine.
WATER SEPARATOR ELEMENT
The water separator element is a two stage filter with a
special filtration/water separating media, and an
expanded water reservoir providing maximum protection against water in the fuel. The recommended
change interval for the water separator element is
1,000 hours. The procedure for changing the element
is as follows:
1. Close the fuel shutoff valve located under the fuel
tank.
2. Rotate the quick change ring (located just below filter header) clockwise approximately 1/2 turn and
slide it down and off of the element.
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SECONDARY FUEL FILTER
The Secondary Fuel Filter has a quick change element
mounted to the engine similar to the Water Separator.
Consult your engine operation manual for complete information on service intervals and element changing procedures.
ENGINE MAINTENANCE COMPONENTS
ITEM MAKE PART NUMBER PART NUMBER
Engine Air Filter Donaldson P822768 P181052
Fan Belt Perkins 26148555043 2614B550
Water Seperator
Element
Fuel Pre-Filter Screen
Fuel Filter Perkins 26560201 26560143
Engin Oil Filter Perkins 2654407 2654403
SAE-400 SEVERE DUTY
Lincoln
Stanadyne
Lincoln
Stanadyne
11199 & 11408 10856
M16890-C
31572
B
M1689029575
M16890-C
31572
M16890-B
29575
D-5 D-5
SPARK ARRESTOR
MAINTENANCE
GFCI RECEPTACLE TESTING AND RESETTING PROCEDURE
WARNING
The GFCI receptacle should be properly tested at least
WARNING
For machines with separate spark arresting unit:
Service the spark arrestor every 100 hours of operation or twice a year, which ever occurs first.
Service as follows:
1. Stop engine and allow to cool.
2. Loosen clamp and remove spark arrestor from
machine.
3. Remove locknut on top of spark arrestor housing
and lift off cap.
4. Seperate plates and clean if necessary.
5. Inspect plates and housing for holes or cracks.
Replace spark arrestor if damaged.
6. Assemble spark arrestor using reverse order:
step 3, then step 2.
For machines with integral spark arresting mufflers:
•
Spark Arrestor and Muffler may be hot!
Allow engine to cool before
Do not operate engine while
servicing spark arrestor!
servicing spark arrestor!
once every month or whenever it is tripped. To properly test and reset the GFCI receptacle:
• If the receptacle 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 receptacle. This will assure normal GFCI operation.
• Plug a night-light (with an "ON/OFF" switch) or other
product (such as a lamp) into the GFCI receptacle
and turn the product "ON".
• Push the "Test" button located on the GFCI receptacle. The night-light or other product should go "OFF".
• Push the "Reset" button, again. The light or other
product should go "ON" again.
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.
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Service spark arrestor every 250 hours.
Service as follows:
1. Stop engine and allow to cool.
2. Remove clean out plug from the side of the spark
arrestor.
3. Without damaging the spark arrestor, gently tap on
the shell near the clean out plug.
4. Once particles are removed, replace the clean out
plug.
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SAE-400 SEVERE DUTY
D-6 D-6
NOTES
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SAE-400 SEVERE DUTY
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