Lincoln Electric SA-400I Operator's Manual
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Lincoln Electric SA-400I Operator's Manual

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Operator's Manual
SA-400I
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Date Purchased
Code: (ex: 10859)
Serial: (ex: U1060512345)
IM10192-A
| Issue D ate Nov-18
© Lincoln Global, Inc. All Rights Reserved.
®
For use with machines having Code Numbers:
12267, 12459, 12543
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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Summary of Contents for Lincoln Electric SA-400I

  • Page 1 Operator’s Manual SA-400I ® For use with machines having Code Numbers: 12267, 12459, 12543 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. thru Fri.
  • Page 2 THANK YOU FOR SELECTING A QUALITY PRODUCT BY KEEP YOUR HEAD OUT OF THE FUMES. DON’T get too close to the arc. LINCOLN ELEC TRIC. Use corrective lenses if necessary to stay a reasonable distance away from the arc. READ and obey the Safety Data PLEASE EXAMINE CARTON AND EQUIPMENT FOR Sheet (SDS) and the warning label DAMAGE IMMEDIATELY...
  • Page 3 MAGNETIC FIELDS MAY W117.2-1974. A Free copy of “Arc Welding Safety” booklet BE DANGEROUS E205 is available from the Lincoln Electric Company, 22801 St. Clair Avenue, Cleveland, Ohio 44117-1199. 2.a. Electric current flowing through any conductor BE SURE THAT ALL INSTALLATION, OPERATION, causes localized Electric and Magnetic Fields (EMF).
  • Page 4 S FETY 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 eyes from sparks and the rays of the arc when welding or not touch these “hot”...
  • Page 5 S FETY 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 welding sparks the gas and pressure used.
  • Page 6 SAFETY de la construction ou d’autres endroits éloignés de la zone de travail, on PRÉCAUTIONS DE SÛRETÉ 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 Pour votre propre protection lire et observer toutes les instructions et les pré- risques d’incendie ou d’echauffement des chaines et des câbles jusqu’à...

  • Page 7: Table Of Contents

    SA-400I TABLE OF CONTENTS ® Page ________________________________________________________________________________ Installation..........................Section A Technical Specifications.......................A-1 General Description........................A-2 Design Features...........................A-2 Pre-Operation Installation......................A-3 Safety Precautions........................A-3 Exhaust Spark Arrester......................A-3 Location/Ventilation ........................A-3 Angle of Operation........................A-4 Machine Grounding........................A-4 Lift Bail ............................A-4 Trailers ............................A-4 Vehicle Mounting........................A-5 Polarity Control and Cable Sizes....................A-5 Pre-Operation Service ........................A-5...
  • Page 8 SA-400I TABLE OF CONTENTS ® ________________________________________________________________________________ Diagrams..........................Section F Wiring Diagram ..........................F-1 Dimension Print..........................F-2 RCD Installation Instruction Print ....................F-3 ________________________________________________________________________________ Parts List ......................parts.lincolnelectric.com Content/details may be changed or updated without notice. For most current Instruction Manuals, go to parts.lincolnelectric.com.

  • Page 9: Installation

    ® has an Electronic Engine Protection System. In the Height 45.5 in (1156 mm) event of sudden low oil pressure or high coolant temperature, the engine immediately shuts down. The SA-400I ® has a current Width 24.3 in. (616 mm)

  • Page 10: Design Features

    All Copper Windings - For long life and dependable operation. detailed information on testing and resetting it. A GFCI should be properly tested at least once every month. Engine Idler - The SA-400I is equipped with an electronic auto- ®...

  • Page 11: Pre-Operation Installation

    SA-400I INSTALLATION ® Welder Enclosure - The complete welder is rubber mounted on WARNING a rugged steel “C” channel base. Do not attempt to use this equipment until you have The output terminals are placed at the side of the machines so thoroughly read the engine manufacturer’s manual supplied...

  • Page 12: Angle Of Operation

    SA-400I INSTALLATION ® ANGLE OF OPERATION WARNING Engines are designed to run in the level condition which is where the optimum performance is achieved. The maximum angle of • Lift only with equipment of adequate lifting continuous operation is 25º degrees in all directions, 35º...

  • Page 13: Vehicle Mounting

    SA-400I INSTALLATION ® VEHICLE MOUNTING PRE-OPERATION SERVICE WARNING CAUTION Improperly mounted concentrated loads may cause unstable READ the engine operating and maintenance instructions vehicle handling and tires or other components to fail. supplied with this machine. • Only transport this Equipment on serviceable vehicles which are rated and designed for such loads.

  • Page 14: Battery Charging

    • To prevent BATTERY BUCKLING, tighten nuts on battery clamp until snug. BATTERY CHARGING The SA-400I is equipped with a wet charged battery. The ® charging current is automatically regulated when the battery is low (after starting the engine) to a trickle current when the bat- tery is fully charged.
  • Page 15 DO NOT USE THESE DEVICES WITH THIS PRODUCT. The Lincoln Electric Company is not responsible for any damage to electrical components improperly connected to this product.

  • Page 16: Operation

    If the fuel supply is cut off or runs out while the fuel pump is STARTING THE SA-400I PERKINS 404D-22 ®...

  • Page 17: Engine Break-In

    SA-400I OPERATION ® ENGINE BREAK-IN The NEMA output rating of the SA-400I is 300 amperes at 32 ® arc volts on a 60% duty cycle (consult Specifications in this Lincoln Electric selects high quality, heavy-duty industrial manual for alternate ratings). Duty cycle is based on a ten engines for the portable welding machines we offer.
  • Page 18 RESIDUAL CURRENT DEVICE READY (ONLY FOR 12459) The SA-400I is configured to allow for the addition of a Residual Current Device (RCD) to protect the 240V Single Phase Receptacle. The auxiliary power area on the front panel of the SA-400I has a hole sized and shaped to accept a typical 2-pole (RCD) along with a protective rubber boot.

  • Page 19: Accessories

    1. Go to www.lincolnelectric.com. 2. At the top of the screen in the Search field type E6.162 click on Search icon. 3. On the results screen click on SA-400I product information. ® 4. On the results screen which shows SA-400I sales literature ®...

  • Page 20: Maintenance

    MAINTENANCE ® SAFETY PRECAUTIONS COOLING SYSTEM The SA-400I® is equipped with a pressure radiator. Keep the WARNING radiator cap tight to prevent loss of coolant. Clean and flush the Have qualified personnel do the maintenance work. Turn cooling system periodically to prevent clogging the passage and the engine off before working inside the machine.

  • Page 21: Nameplates

    SA-400I MAINTENANCE ® Replace brushes when they wear within 1/4” of the pigtail. A complete set of replacement brushes should be kept on hand. Lincoln brushes have a curved face to fit the commutator. Have an experienced maintenance person seat these brushes by lightly stoning the commutator as the armature rotates at full speed until contact is made across the full face of the brushes.
  • Page 22 SA-400I MAINTENANCE ®...

  • Page 23: Gfci Testing And Resetting Procedure

    SA-400I MAINTENANCE ® GFCI TESTING AND RESETTING PROCEDURE The GFCI should be properly tested at least once every month or whenever it is tripped. To properly test and reset the GFCI: • If the GFCI has tripped, first carefully remove any load and check it for damage.

  • Page 24: Troubleshooting

    ® HOW TO USE TROUBLESHOOTING GUIDE WARNING Service and Repair should only be performed by Lincoln Electric Factory Trained Personnel. Unauthorized repairs performed on this equipment may result in danger to the technician and machine operator and will invalidate your factory warranty. For your safety and to avoid Electrical Shock, please observe all safety notes and precautions detailed throughout this manual.
  • Page 25 SA-400I TROUBLE SHOOTING ® Observe all Safety Guidelines detailed throughout this manual PROBLEMS POSSIBLE RECOMMENDED (SYMPTOMS) CAUSE COURSE OF ACTION Machine fails to hold the output (heat) Rough or dirty commutator. consistently. Brushes may be worn down to Limit. Field circuit may have variable resis-...
  • Page 26 SA-400I TROUBLE SHOOTING ® Observe all Safety Guidelines detailed throughout this manual PROBLEMS POSSIBLE RECOMMENDED (SYMPTOMS) CAUSE COURSE OF ACTION Welder starts but fails to generate cur- Generator or exciter brushes may be rent. loose or missing. Exciter may not be operating.

  • Page 27: Electronic Idler Troubleshooting Guide

    SA-400I TROUBLE SHOOTING ® ELECTRONIC IDLER TROUBLESHOOTING GUIDE With Idler Control Switch in the Auto Position, Engine Will Not Return to Low Idle in Approximately 15 Seconds After Welding and Auxiliary Loads are Removed Set Idler Control Switch to the Auto Position...
  • Page 28 SA-400I TROUBLE SHOOTING ® ELECTRONIC IDLER TROUBLESHOOTING GUIDE With Idler Control Switch in the AUTO Position, Engine Will Not Pick Up Speed When: The Arc is Struck The Auxiliary Power Load is Turned ON Reed Switch in Weld Circuit Power Load Too Small...
  • Page 29 SA-400I TROUBLE SHOOTING ® Observe all Safety Guidelines detailed throughout this manual PROBLEMS POSSIBLE RECOMMENDED (SYMPTOMS) CAUSE COURSE OF ACTION Engine does not start. Lack of fuel. Air mixed in the fuel system. Clogged fuel filter. Irregular and faulty fuel supply (Injector pump trouble).
  • Page 30 SA-400I TROUBLE SHOOTING ® Observe all Safety Guidelines detailed throughout this manual PROBLEMS POSSIBLE RECOMMENDED (SYMPTOMS) CAUSE COURSE OF ACTION Engine stops during operation and 1. Overheat of the Engine. the Engine Protection light does turn Lack of Coolant Supply coolant.
  • Page 31 SA-400I TROUBLE SHOOTING ® Observe all Safety Guidelines detailed throughout this manual PROBLEMS POSSIBLE RECOMMENDED (SYMPTOMS) CAUSE COURSE OF ACTION White or Blue Smoke. Excess engine oil. Too low viscosity of the engine oil. Faulty injection timing. Dark Grey Smoke.
  • Page 32 SA-400I NOTES ®...
  • Page 33 SA-400I DIAGRAMS ®...
  • Page 34 SA-400I® DIAGRAMS WHITE > >...
  • Page 35 SA-400I DIMENSION PRINT ®...
  • Page 36 SA-400I® DIAGRAMS...
  • Page 37 SA-400I CCC - 12543...
  • Page 38 LOWER CONTROL PANEL P-981-E ENGINE ASSEMBLY P-981-F RADIATOR ASSEMBLY P-981-G FUEL TANK & MOUNTING P-981-H BASE & LIFT BALE ASSEMBLY P-981-J EXCITER & STATOR P-981-K WELDING GENERATOR & COUPLING P-981-L ROOF & DOORS P-981-M GENERATOR BRUSH HOLDER SA-400I CCC - 12543...
  • Page 39 Index of Sub Assemblies - 12543 P-981-A.jpg SA-400I CCC - 12543...
  • Page 40 CONTROL HANDLE 9SM25513 ANALOG METER ASSEMBLY 9SM25512 METER PLATE 9SM21003-1A DC AMMETER 9SM21002-3 VOLTMETER 9SS9262-39 PLAIN WASHER 9ST4291-B LOCKWASHER 9SCF000002 #4-40HN 9SS9262-175 PLAIN WASHER 9SCF000266 #10-32BR-HN 9SS9225-65 THREAD FORMING SCREW (ROLLING) 9SS24097-9 SHUNT & LEAD ASBLY SA-400I CCC - 12543...
  • Page 41 Upper Control Panel P-981-C.jpg SA-400I CCC - 12543...
  • Page 42 PLUG AND LEAD ASSEMBLY 9ST10800-56 SWITCHTOGGLEDPDT 9SS21012 RECEPTACLE 9SS9225-63 THREAD FORMING SCREW (CUTTING) 9ST11525-1 SPEED NUT#10-24 9SS22061-4 SEALING BOOT 9SM21760 RECEPTACLE COVER 9SS8025-97 SELF TAPPING SCREW 9ST12287-31 CIRCUIT BREAKER-20A250VAC32VDC 9SS22061-1 CIRCUIT BREAKER BOOT 9SS9225-36 THREAD FORMING SCREW (CUTTING) SA-400I CCC - 12543...
  • Page 43 THREAD FORMING SCREW (ROLLING) 9SM24953-1 GUARD CASE FRONT LEFT 9SS9225-8 THREAD FORMING SCREW (ROLLING) 9SG8075 HARNESS ASSEMBLY 9SM20152-3 RECEPTACLE-230V 9SS9225-63 THREAD FORMING SCREW (CUTTING) 9SS28004-1 COVER PLATE 9SS25322-2 RCD STRAP 9SS9225-63 THREAD FORMING SCREW (CUTTING) 9SS31404 IEC RATING DECAL SA-400I CCC - 12543...
  • Page 44 Lower Control Panel P-981-D.jpg SA-400I CCC - 12543...
  • Page 45 SOLENOID ASSEMBLY 9SS9225-66 SELF TAPPING SCREW 9SS22070 IN-LINE SWIVEL 9SCF000060 1/4-28HJN As Req 9SS27287 IDLER LINKAGE 9SS26632 ROD END SWIVEL (FEMALE) 9SS9225-96 THREAD FORMING SCREW (CUTTING) 9SE106A-2 LOCKWASHER 9SCF000017 1/4-20HN 9SL13694 FAN GUARD (BOTTOM) 9ST10642-218 FLEX HOSE SA-400I CCC - 12543...
  • Page 46 9SS10888-33 HOSE CLAMP 9SM20358 AIR FILTER 9SM20359 AIR FILTER MTG BAND 9SE106A-3 LOCKWASHER 9SCF000028 5/16-18X1.25HHCS 9SS9262-121 PLAIN WASHER 9SCF000029 5/16-18HN 9SM8859-94 ENGINE MTG REF 9SCF000227 1/2X13X3.75HHCS 9SS14447 RUBBER MOUNT 9ST9072 RUBBER PAD 9ST9054 WASHER 9ST9187-4 LOCKNUT SA-400I CCC - 12543...
  • Page 47 Engine Assembly P-981-E.jpg SA-400I CCC - 12543...
  • Page 48 PLAIN WASHER 9SE106A-3 LOCKWASHER 9SCF000029 5/16-18HN 9SM8003 RADIATOR CAP COVER ASBLY 9SS8025-12 SELF TAPPING SCREW 9SM19051 FAN SHROUD ASBLY 9SCF000013 1/4-20X.625HHCS 9SE106A-2 LOCKWASHER 9SS9262-23 PLAIN WASHER 9SL13693 LEFT FAN GUARD 9SL13678 RIGHT FAN GUARD 9ST13086-235 WARNING DECAL SA-400I CCC - 12543...
  • Page 49 Radiator Assembly P-981-F.jpg SA-400I CCC - 12543...
  • Page 50 SELF TAPPING SCREW 9ST14166-9 OUTPUT TERMINAL KIT 9ST3960 FLANGE NUT 9SS9225-22 THREAD FORMING SCREW (ROLLING) 9ST9860-3 LOCKWASHER 9SCF000029 5/16-18HN 9ST12287-20 CIRCUIT BREAKER-10A250VAC 9SCF000020 1/2-13X.75HHCS 9SS9262-1 PLAIN WASHER 9SE106A-15 LOCKWASHER 9SM24836 COIL ASSEMBLY CHOKE 9SM25273 GUARD PC MOUNTING BRACKET SA-400I CCC - 12543...
  • Page 51 Fuel Tank & Mounting PART NUMBER DESCRIPTION 9SL12400-3V1 IDLER/ENGINE SHUTDOWN PC BD ASBLY 9SS9225-76 SELF TAPPING SCREW 9SS18250-397 PLUG & LEAD ASBLY 9SS16676-8 REED SWITCH & LEAD ASSEMBLY SA-400I CCC - 12543...
  • Page 52 Fuel Tank & Mounting P-981-G.jpg SA-400I CCC - 12543...
  • Page 53 HEX HD CAP SCREW 9SE106A-15 LOCKWASHER 9SCF000027 1/2-13HN 9SM15045-37 ACOUSTICAL FOAM 9SG3427 BASE ASBLY 9SS10918-82 SPACER 9SCF000127 #10-24X1.75RHS-FULL-GR2-1427 9ST9187-9 #10-24HLN 9SS20283 DECAL-CABLE ROUTING 9SS17851-3 DECAL CAUTION 9SM8237-15 REAR SUPPORT ASBLY 9SCF000019 3/8-16X1.00HHCS 10 9SS9262-120 PLAIN WASHER 9SE106A-16 LOCKWASHER SA-400I CCC - 12543...
  • Page 54 Base & Lift Bale Assembly PART NUMBER DESCRIPTION 9SCF000067 3/8-16HN 9SCF000029 5/16-18HN SA-400I CCC - 12543...
  • Page 55 Base & Lift Bale Assembly P-981-H.jpg SA-400I CCC - 12543...
  • Page 56 HEX HD CAP SCREW 9SM6964-2A BRUSH HOLDER ASBLY 9SM16158 BRUSH & BRUSH HOLDER ASBLY 9SG2114 BRUSH HOLDER CARTRIDGE 9SS19480 BRUSH ASBLY 9SM16157 BRUSH ASBLY RETAINER 9SM19896 BRUSH HOLDER BRACKET (SS) 9SCF000014 1/4-20X.75HHCS 9SS9262-23 PLAIN WASHER 9SE106A-2 LOCKWASHER 9SCF000017 1/4-20HN SA-400I CCC - 12543...
  • Page 57 Exciter & Stator PART NUMBER DESCRIPTION 9SS24739-7 #10 X .75 WASHER FACED SS HEX SCREW SA-400I CCC - 12543...
  • Page 58 Exciter & Stator P-981-J.jpg SA-400I CCC - 12543...
  • Page 59 COUPLING CLAMP RING-INSIDE 9SS14232 COUPLING CLAMP RING-OUTSIDE 9ST8833-2 HEX HD CAP SCREW 9SE106A-8 LOCKWASHER 9SCF000123 1/2-13X2.75HHCS 9SS9262-1 PLAIN WASHER 9ST8823 RUBBER PAD 9ST8822 RUBBER PAD 9ST9187-4 LOCKNUT 9SS9262-5 PLAIN WASHER 9SCF000067 3/8-16HN 9ST13260-4 DECAL-EARTH GROUND CONN SA-400I CCC - 12543...
  • Page 60 Welding Generator & Coupling P-981-K.jpg SA-400I CCC - 12543...
  • Page 61 SPRING CLIP 9ST9695-1 LOCKWASHER 9SCF000335 #10-24X.312 PPNHS 9ST9187-9 #10-24HLN 9SL5193-5 ROOF 9SS13593 ROOF MTG ANGLE 9SCF000258 5/16-18X1.50SQHS 9ST9187 LOCKNUT 9ST9428 ROOF MOUNTING ANGLE 9SCF000180 5/16-18X1.25SQHS-FULL-GR2-1817/1 9ST9187 LOCKNUT 9SM25546 DECAL-WIRING DIAGRAM 9SS27368-6 LOGO DECAL 9ST13086-237 FUEL WARNING DECAL SA-400I CCC - 12543...
  • Page 62 Roof & Doors PART NUMBER DESCRIPTION 9SM16197 DECAL-WARNING 9ST11030 DECAL-DOOROPEN-CLOSE 9SS26354 ENGINE SERVICE DECAL 9SM17238 INSTRUCTION TAG 9SS25896-4 DECAL WARNING 9SM21436 CARBON MONOXIDE WARNING DECAL 9SS28039-1 DECAL GREEN INITIATIVE 9SM25614 STACKING IRON DECAL SA-400I CCC - 12543...
  • Page 63 Roof & Doors P-981-L.jpg SA-400I CCC - 12543...
  • Page 64 SEMS SCREW 9SS27088-1 BRUSH HOLDER PLATE & RETAINER ASBLY 9SCF000040 5/16-18X.75HHCS 9SM6963-4 BRUSH HOLDER STUD 9ST9020 PLAIN WASHER 9ST4479 INSULATING WASHER 9SS13721-1 BRUSH HOLDER STUD INSULATION 9ST2414 CLAMPING WASHER 9SCF000019 3/8-16X1.00HHCS 10 9SE106A-16 LOCKWASHER 9ST2687 BRUSH SA-400I CCC - 12543...
  • Page 65 Generator Brush Holder P-981-M.jpg SA-400I CCC - 12543...
  • Page 66 WARNING Do not touch electrically live parts or Keep flammable materials away. Wear eye, ear and body protection. electrode with skin or wet clothing. Insulate yourself from work and AVISO DE ground. Spanish PRECAuCION No toque las partes o los electrodos Mantenga el material combustible Protéjase los ojos, los oídos y el bajo carga con la piel o ropa moja-...
  • Page 67 WARNING Keep your head out of fumes. Turn power off before servicing. Do not operate with panel open or Use ventilation or exhaust to guards off. remove fumes from breathing zone. AVISO DE Spanish PRECAuCION Los humos fuera de la zona de res- Desconectar el cable de ali- No operar con panel abierto o piración.
  • Page 68 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.

This manual is also suitable for:

122671245912543

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