Lincoln Electric SAE-400 Operator's Manual
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Lincoln Electric SAE-400 Operator's Manual

Dc arc welding power source
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Operator's Manual
SAE-400
POWER SOURCE
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Date Purchased
Code: (ex: 10859)
Serial: (ex: U1060512345)
IM10122
| Issue D ate Sept- 13
© Lincoln Global, Inc. All Rights Reserved.
®
DC ARC WELDING
For use with machines having Code Numbers:
11808
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

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  • Page 1 Operator’s Manual ® SAE-400 DC ARC WELDING POWER SOURCE For use with machines having Code Numbers: 11808 Need Help? Call 1.888.935.3877 Register your machine: to talk to a Service Representative www.lincolnelectric.com/register Authorized Service and Distributor Locator: Hours of Operation: www.lincolnelectric.com/locator 8:00 AM to 6:00 PM (ET) Mon.
  • Page 2 THANK YOU FOR SELECTING A QUALITY PRODUCT BY KEEP YOUR HEAD OUT OF THE FUMES. LINCOLN ELEC TRIC. 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 PLEASE EXAMINE CARTON AND EQUIPMENT FOR Data Sheet (MSDS) and the warning DAMAGE IMMEDIATELY...
  • Page 3 American Welding Society, P.O. Box 351040, Miami, Florida 33135 or ELECTRIC AND CSA Standard W117.2-1974. A Free copy of “Arc Welding Safety” MAGNETIC FIELDS MAY booklet E205 is available from the Lincoln Electric Company, 22801 St. Clair Avenue, Cleveland, Ohio 44117-1199. BE DANGEROUS BE SURE THAT ALL INSTALLATION, OPERATION, 2.a.
  • Page 4 SAFETY ELECTRIC SHOCK ARC RAYS CAN BURN. CAN KILL. 3.a. The electrode and work (or ground) circuits are 4.a. Use a shield with the proper filter and cover plates to protect your electrically “hot” when the welder is on. Do not eyes from sparks and the rays of the arc when welding or touch these “hot”...
  • Page 5 SAFETY WELDING AND CUTTING CYLINDER MAY EXPLODE IF SPARKS CAN CAUSE DAMAGED. FIRE OR EXPLOSION. 7.a. Use only compressed gas cylinders containing the correct shielding gas for the process used 6.a. Remove fire hazards from the welding area. If and properly operating regulators designed for this is not possible, cover them to prevent the the gas and pressure used.

  • Page 6: Table Of Contents

    TABLE OF CONTENTS Page Installation Instructions ..........Section A Technical Specifications .

  • Page 7: Technical Specifications

    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 12VDC battery Oil: 10.1 Qts.

  • Page 8: 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. SAE-400 ®...

  • Page 9: High Altitude Operation

    5. Proper preventative maintenance of trailer. 6. Conformance with federal, state and local laws. For highway use, consult applicable federal, state and local laws regarding specific requirements for use on public highways, such as brakes, lights, fend- ers, etc. SAE-400 ®...

  • Page 10: Fuel

    Be careful to charge the bat- tery with the correct polarity. Make sure that the battery Lincoln Electric selects high quality, heavy-duty indus- is level while charging. trial engines for the portable welding machines we offer.

  • Page 11: Spark Arrester

    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 ®...

  • Page 12: Operating Instructions

    • Insulate yourself from the work and ground. for pipe thawing is not approved by the CSA, nor is • Always wear dry insulating gloves. it recommended or supported by Lincoln Electric. • Do not use AC welder if your clothing, gloves or ------------------------------------------------------------------------ work area is damp or if working on, under or inside workpiece.

  • Page 13: Auxiliary Power

    RECOMMENDED APPLICATIONS OTHER FEATURES • Perkins 4-cylinder, water cooled diesel engine. WELDER Designed for long life, easy maintenance and excel- The SAE-400 provides excellent constant current DC ® lent fuel economy. welding output for stick (SMAW) welding. The field • Engine protection system shuts the engine down for installed optional CV Adapter (K385-[ ]) provides up to low engine oil pressure or high coolant temperature.

  • Page 14: Remote Control

    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. SAE-400 ®...

  • Page 15: Auxiliary Power Controls

    OPERATION AUXILIARY POWER CONTROLS RESIDUAL CURRENT DEVICE 120 VAC Receptacles The SAE-400 is configured with a Residual Current ® Device (RCD) to protect all receptacles against current One 20 amp, (each side) 120VAC (5-20R) NEMA leakage (eg. to ground) from all receptacles.

  • Page 16: Engine Operation

    (maximum 60 seconds). 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 ®...

  • Page 17: Typical Fuel Consumption

    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...

  • Page 18: Accessories

    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 ®...

  • Page 19: Maintenance

    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. SAE-400 ®...
  • Page 20 MAINTENANCE COMMUTATOR AND BRUSH MAINTENANCE COOLING SYSTEM WARNING The SAE-400 ® is equipped with a pressure radiator. Keep the radiator cap tight to prevent loss of coolant. Uncovered rotating equipment can be dangerous. Clean and flush the cooling system periodically to pre- Use care so your hands, hair, clothing or tools do vent clogging the passage and overheating the engine.

  • Page 21: Engine Maintenance Components

    Note: The element will only go on one way. Never use excessive force when mounting the element to ------------------------------------------------------------------------ the header. SAE-400 with integral spark arresting mufflers: ® 5. Slide the quick change ring up over the element and Service spark arrester every 250 hours.

  • Page 22: Troubleshooting Guide

    HOW TO USE TROUBLESHOOTING GUIDE WARNING Service and Repair should only be performed by Lincoln Electric Factory Trained Personnel. Unauthorized repairs performed on this equipment may result in danger to the technician and machine operator and will invalidate your factory warranty. For your safety and to avoid Electrical Shock, please observe all safety notes and precautions detailed throughout this manual.

  • Page 23: Troubleshooting

    CAUTION If for any reason you do not understand the test procedures or are unable to perform the tests/repairs safely, contact your Local Lincoln Authorized Field Service Facility for technical troubleshooting assistance before you proceed. SAE-400 ®...
  • Page 24 CAUTION If for any reason you do not understand the test procedures or are unable to perform the tests/repairs safely, contact your Local Lincoln Authorized Field Service Facility for technical troubleshooting assistance before you proceed. SAE-400 ®...
  • Page 25 CAUTION If for any reason you do not understand the test procedures or are unable to perform the tests/repairs safely, contact your Local Lincoln Authorized Field Service Facility for technical troubleshooting assistance before you proceed. SAE-400 ®...
  • Page 26 RCD circuit by pressing “Reset” button. CAUTION If for any reason you do not understand the test procedures or are unable to perform the tests/repairs safely, contact your Local Lincoln Authorized Field Service Facility for technical troubleshooting assistance before you proceed. SAE-400 ®...
  • Page 27 WIRING DIAGRAM SAE-400 ®...
  • Page 28 DIMENSION PRINT SAE-400 ®...
  • Page 29 This parts list is provided as an informative guide only. It was accurate at the time of printing. These pages are only updated on the Service Navigator DVD and in Lincoln Electricʼs official Parts Book (BK-34). When ordering parts, always refer to Lincoln Electricʼs official Parts Book (BK-34) for the latest pages.
  • Page 30 P-692-A.1 P-692-A.1 SAE-400 ® For Code: 11808 Do Not use this Parts List for a machine if its code number is not listed. Contact the Service Department for any code numbers not listed. Use the Illustration of Sub-Assemblies page and the table below to determine which sub assembly page and column the desired part is located on for your particular code machine.
  • Page 31 P-692-A.2 P-692-A.2 SAE-400 ® For Code: 11808 Do Not use this Parts List for a machine if its code number is not listed. Contact the Service Department for any code numbers not listed. Use the Illustration of Sub-Assemblies page and the table below to determine which sub assembly page and column the desired part is located on for your particular code machine.
  • Page 32 DESCRIPTION ...............PART NUMBER For SAE-400: CV Adapter .
  • Page 33 Earth Ground Connection Decal T13260-4 Door Catch Decal T11030 Warning Decal M16197 Engine Instruction Tag M17238 Warning Decal S25896 Service Decal S26005 Wiring Diagram L16159 CO Warning Decal M21436 Nameplate L16028 Fastener Button T14659-2 Lower Nameplate L12645 Fastener Button T14659-2 04-03-2012 SAE-400 ®...
  • Page 34 P-692-C P-692-C Final Assembly N.C. N.C. 11 11 47 19 04-03-2012 SAE-400 ®...
  • Page 35 CF000027 Circuit Breaker T12287-20 Fuel Tank Rail & Output Panel See P-692-H 1/2-13 x 1.25 HHCS CF000030 Lock Washer E106A-15 1/2-13 HN CF000027 Plain Washer S9262-1 Lock Washer E106A-15 1/2-13 HN CF000027 NSS - Not Sold Separately 01-22-2013 SAE-400 ®...
  • Page 36 Door Restraint Assembly (Not Shown) S25475 Reed Switch & Lead Assembly S17472-1 Remote Control Box Assembly (Not Shown) See P-692-K Breaker & Receptacle Guard Assembly M18959-2 Thread Forming Screw S9225-68 Door Latch Bracket S27545-1 Thread Forming Screw S9225-8 10-23-2012 SAE-400 ®...
  • Page 37 NOTES SAE-400 ®...
  • Page 38 P-692-D P-692-D Engine Assembly 04-03-2012 SAE-400 ®...
  • Page 39 Starter (Not Shown) G2127 3/8-16 x 1.25 HHCS T8833-10 3/8-16 x 1.50 HHCS CF000066 Lock Washer E106A-4 3/8-16 HN CF000067 Top Hose L12349 Hose Clamp S10888-8 Hose Clamp S10888-29 Lower Hose L12350 Hose Clamp S10888-8 Hose Clamp S10888-33 10-23-2012 SAE-400 ®...
  • Page 40 M21584-B M8 x 1.25 Metric HHCS T14731-4 Plain Washer S9262-121 Lock Washer E106A-3 Temperature Switch/Sender S25162 Oil Filler Spacer (Not Shown) S25992 M8 x 1.25 SHCS T14731-3 Gasket S26001 Lock Washer E106A-24 Amp to Lucar Adapter S26426 04-03-2012 SAE-400 ®...
  • Page 41 NOTES SAE-400 ®...
  • Page 42 P-692-E P-692-E Generator-Alternator Assembly 11 11 04-03-2012 SAE-400 ®...
  • Page 43 3/8-16 HN CF000067 #10-24 HN CF000010 Armature L2667-34 Exciter Wraparound L15921 Speed Nut T11525-5 Thread Forming Screw S9225-8 Exciter End Cap M22605 Speed Nut T11525-5 Thread Forming Screw S9225-8 Exciter Brush Mount S28545 Thread Forming Screw S9225-26 Oct-13 SAE-400 ®...
  • Page 44 P-692-F P-692-F Lower Control Panel Assembly 11 11 04-03-2012 SAE-400 ®...
  • Page 45 M18861 #8-32 x .875 RHS CF000059 Plain Washer S9262-3 Lock Washer T4291-A #8-32 HN CF000042 120V Receptacle (1 Phase) S18907-2 Receptacle Cover M18861 #8-32 x .875 RHS CF000059 Plain Washer S9262-3 Lock Washer T4291-A #8-32 HN CF000042 04-03-2012 SAE-400 ®...
  • Page 46 This will aid Lincoln in supplying the correct and latest board along with any necessary jumpers or adapters. The dash number brackets [ ] have purposely been left blank so as to eliminate errors, confusion and updates. 04-03-2012 SAE-400 ®...
  • Page 47 NOTES SAE-400 ®...
  • Page 48 P-692-G P-692-G Control Panel Assembly 20 22 10 11 11 12 12 13 04-03-2012 SAE-400 ®...
  • Page 49 Instruction Decal S28232-2 Receptacle Cover M16996 Receptacle Gasket S21088 Thread Forming Screw S9225-63 Speed Nut T11525-1 Receptacle (240V) S14377 Reactor Lead Insulation T10576 Clamp (Lead Clip) T12563-12 Self Tapping Screw S8025-22 Circuit Breaker (20A) T12287-31 Sealing Boot S22061-1 04-03-2012 SAE-400 ®...
  • Page 50 1 2 3 4 5 6 7 8 9 ITEM DESCRIPTION PART NO. QTY. Circuit Breaker (15A - 2 Pole), Includes: M20585-3 Circuit Breaker Cover Seal S24911-2 Sems Screw T10082-30 Lock Washer T4291-A Spark Arrester Decal S26606 04-03-2012 SAE-400 ®...
  • Page 51 NOTES SAE-400 ®...
  • Page 52 P-692-H P-692-H Left Gas Tank Rail & Output Panel ELECTRODE ELECTRODE TO WORK TO WORK 9 11 11 04-03-2012 SAE-400 ®...
  • Page 53 Plain Washer (Not Shown) S9262-1 1/2-13 x .75 HHCS (Work) CF000020 1/2-13 x .875 HHCS CF000344 Plain Washer S9262-1 Lock Washer E106A-15 1/2-13 Hex Flange Nut T3960 Decal, “Electrode” S25371 Decal, “To Work” S25372 NSS - Not Sold Separately 04-03-2012 SAE-400 ®...
  • Page 54 P-692-J P-692-J Radiator Assembly 11 11 10-23-2012 SAE-400 ®...
  • Page 55 Radiator L3102-9 Radiator Shroud L12191-1 Radiator Cap Assembly M8003 Self Tapping Screw S8025-12 Isolation Mount S29451 Thread Forming Screw S9225-76 Plain Washer S9262-187 Socket Head Cap Screw T9447-53 Plain Washer S9262-69 Lock Washer E106A-2 1/4-20 HN CF000017 10-23-2012 SAE-400 ®...
  • Page 56 P-692-K P-692-K Remote Control 11 11 04-03-2012 SAE-400 ®...
  • Page 57 Resistor Bank Assembly, Includes: M17285 Resistor Mounting Bracket S21009 Resistor S10404-22 #10-24 x 5.00 RHS CF000045 Insulating Washer T4479-A Lock Washer E106A-1 #10-24 HN CF000010 #8-32 x .50 BR RHS CF000102 #8-32 BR HN CF000103 Self Tapping Screw S8025-92 04-03-2012 SAE-400 ®...
  • Page 58 P-692-L P-692-L Generator Brush Holder 11 11 04-03-2012 SAE-400 ®...
  • Page 59 Brush Holder Washer Brush Holder Stud Retainer Assembly S27088-1 Lock Washer E106A-3 5/16-18 x .75 HHCS CF000040 Brush Holder Spring T8495 Brush Holder Spring Clip Lock Washer E106A-3 5/16-18 x .75 HHCS T10082-29 NSS - Not Sold Separately 04-03-2012 SAE-400 ®...
  • Page 60 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.

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