Lincoln Electric 11198 Operator's Manual
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Lincoln Electric 11198 Operator's Manual

Lincoln Electric 11198 Operator's Manual

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Operator's Manual
SAE-400
Register your machine:
www.lincolnelectric.com/register
Authorized Service and Distributor Locator:
www.lincolnelectric.com/locator
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Date Purchased
Code: (ex: 10859)
Serial: (ex: U1060512345)
IM869-E
| Issue Date Jan- 14
© Lincoln Global, Inc. All Rights Reserved.
™
DC ARC
For use with machines having Code Numbers:
11198, 11322, 11407, 11409,
11509, 12250
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 11198

  • Page 1 Operator’s Manual ™ SAE-400 DC ARC For use with machines having Code Numbers: 11198, 11322, 11407, 11409, 11509, 12250 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...
  • Page 2 THANK YOU FOR SELECTING KeeP your head out oF the Fumes. A QUALITY PRODUCT BY LINCOLN ELECTRIC. 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...

  • Page 3: California Proposition 65 Warnings

    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: Electric Shock Can Kill

    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 eyes from sparks and the rays of the arc when welding or not 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

    SAE-400™ TABLE OF CONTENTS Page General Description, Recommended Applications, Design Features and Advantages . . 7 Installation Instructions ..........Section A Technical Specifications .

  • Page 7: General Description

    SAE-400™ GENERAL DESCRIPTION GENERAL DESCRIPTION OTHER FEATURES The SAE-400 is a diesel engine driven welding power source. The machine uses a DC generator for DC stick electrode welding and • Perkins 4-cylinder, water cooled diesel engine. Designed for an AC exciter for 115/230 VAC auxiliary power. As a generator it long life, easy maintenance and excellent fuel economy.

  • Page 8: Technical Specifications

    SAE-400™ INSTALLATION TECHNICAL SPECIFICATIONS SAE-400™ (K1278-7, K1278-9) INPUT - DIESEL ENGINE OUTPUT- WELDER AND GENERATOR Description Welding Range 80-575 Amps 4 cylinder 68.4HP (48 kw) Open Circuit Voltage @ 1725 RPM 97 Max OCV @ 1800 RPM Auxiliary Power 4 cylinder 64.4HP (48 kw) @ 1710 RPM 115/230 VAC 3000 WATTS, 60 Hz...

  • Page 9: Location/Ventilation

    SAE-400™ INSTALLATION Read this entire installation section before you start installa- tion. SAFETY PRECAUTIONS CAUTION WARNING DO NOT MOUNT OVER COMBUSTIBLE SURFACES Where there is a combustible surface directly under station- Do not attempt to use this equipment until you have thor- ary or fixed electrical equipment, that surface should be cov- oughly read all operating and maintenance manuals sup- ered with a steel plate at least .06”(1.6mm) thick, which...

  • Page 10: High Altitude Operation

    SAE-400™ INSTALLATION HIGH ALTITUDE OPERATION VEHICLE MOUNTING 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.). Improperly mounted concentrated loads may cause unstable vehicle handling and tires or other components to fail.

  • Page 11: Fuel

    NOTE: This machine is furnished with wet charged batteries; if unused for several months, the batteries may require a booster Lincoln Electric selects high quality, heavy-duty industrial engines charge. Be careful to charge the batteries with the correct polari- for the portable welding machines we offer. While it is normal to ty.

  • Page 12: Spark Arrester

    SAE-400™ INSTALLATION • USING A BOOSTER — connect positive lead WELDING OUTPUT CABLES to battery first then connect negative lead to negative battery lead at the lower control With the engine off, connect the electrode and work cables to the panel support.

  • Page 13: Operating Instructions

    SAE-400™ OPERATION OPERATING INSTRUCTIONS ------------------------------------------------------ Read and understand this entire section before operating your WELDING SPARKS can cause fire or equipment. explosion. SAFETY INSTRUCTIONS • Do not weld near flammable material . • Do not weld on containers that have held WARNING flammable material.
  • Page 14 SAE-400™ OPERATION ENGINE CONTROLS ENGINE PROTECTION SYSTEM The engine protection system shuts down the engine under high IGNITION SWITCH coolant temperature or low engine oil pressure conditions by allowing the fuel solenoid valve to close. When placed in the “ON” position, this switch energizes the fuel solenoid.

  • Page 15: Remote Control

    SAE-400™ OPERATION How to Set the Controls AUXILIARY POWER CONTROLS Assume you want a normal soft arc and about 135 NOTE: GFCI receptacles our an option and if installed, amps, using a 5/32” (4.0 mm) electrode: see the MAINTENANCE section for detailed informa- tion on testing and resetting the GFCI receptacle.

  • Page 16: Engine Operation

    SAE-400™ OPERATION ENGINE OPERATION Observe the oil pressure. If no pressure shows within 30 seconds, stop the engine and consult the WARNING engine operating manual. To stop the engine, turn the “IGNITION” switch to “OFF”. Do not attempt to use this equipment until you If the engine protection warning light comes on have thoroughly read the engine manufacturer’s during cranking or after start up, the “IGNITION”...

  • Page 17: Typical Fuel Consumption

    SAE-400™ OPERATION TYPICAL FUEL CONSUMPTION The typical fuel consumption of the SAE-400 for various operating scenarios is shown below: PERKINS 1104C-44 PERKINS 1104A-44 Low Idle - No Load .30 gal./ hr. 26 gal./ hr. 1100 RPM (1.12 L./hr.) (.97 L./hr.) High Idle - No Load .69 gal./hr.

  • 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. ------------------------------------------------------------------ K704 Standard Accessory Kit - Includes electrode and work cables, headshield, work clamp and electrode holder.

  • Page 19: Maintenance

    SAE-400™ MAINTENANCE saFety PreCautions WARNING PERIODIC MAINTENANCE ELECTRIC SHOCK can kill. 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 nec- Do not touch electrically live parts such as •...

  • Page 20: Pre Filter / Washer Separator

    SAE-400™ MAINTENANCE COMMUTATOR AND BRUSH MAINTENANCE COOLING SYSTEM WARNING The SAE-400 is equipped with a pressure radiator. Keep the radia- tor cap tight to prevent loss of coolant. Clean and flush the cooling Uncovered rotating equipment can be dangerous. Use care so system periodically to prevent clogging the passage and overheat- your hands, hair, clothing or tools do not catch in the rotating ing the engine.

  • Page 21: Water Separator Element

    SAE-400™ MAINTENANCE 4. Using a pair of pliers, gently tug on the pull tabs of the pre-filter Note: The element will only go on one way. Never use excessive force when mounting the element to the header. screen in an alternating pattern to gradually remove the pre-fil- ter screen.

  • Page 22: Spark Arrester

    SAE-400™ MAINTENANCE . Slide the new element onto the grommet post on the bottom of the SPARK ARRESTOR filter header until the element no longer easily moves up into the fil- • WARNING ter header. Now rotate the element (may take almost 1 full turn) with a slight upward pressure until the element begins to further engage Spark Arrester and Muffler may be hot! the header.

  • Page 23: How To Use 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.

  • Page 24: Troubleshooting

    SAE-400™ TROUBLE SHOOTING Observe all Safety Guidelines detailed throughout this manual PROBLEMS POSSIBLE RECOMMENDED (SYMPTOMS) CAUSE COURSE OF ACTION FUNCTION PROBLEMS Machine fails to hold the “heat” 1. Rough or dirty commutator. 1. True and clean commutator. constantly. 2. Brushes may be worn down to 2.
  • Page 25 SAE-400™ TROUBLE SHOOTING Observe all Safety Guidelines detailed throughout this manual PROBLEMS POSSIBLE RECOMMENDED (SYMPTOMS) CAUSE COURSE OF ACTION FUNCTION PROBLEMS Welder runs but fails to generate 1. Generator or exciter brushes may 1. Be sure that all brushes bear on current.
  • Page 26 SAE-400™ TROUBLE SHOOTING Observe all Safety Guidelines detailed throughout this manual PROBLEMS POSSIBLE RECOMMENDED (SYMPTOMS) CAUSE COURSE OF ACTION FUNCTION PROBLEMS Welding current too great or too 1. “Current Control” shaft and handle 1. With current control against the small compared to indication on the may have turned slightly in the minimum stop, set pointer to with- dial.
  • Page 27 SAE-400™ TROUBLE SHOOTING Observe all Safety Guidelines detailed throughout this manual PROBLEMS POSSIBLE RECOMMENDED (SYMPTOMS) CAUSE COURSE OF ACTION FUNCTION PROBLEMS No auxiliary power 1. Circuit Breakers open. 1. Check and reset breakers. If breakers keep tripping check con- nections to auxiliary receptacles. Also make sure load does nor exceed receptacle’s current rating.
  • Page 28 SAE-400™ DIAGRAMS...
  • Page 29 SAE-400™ DIAGRAMS...
  • Page 30 SAE-400™ DIAGRAMS...
  • Page 31 SAE-400™ DIAGRAMS...
  • Page 32 SAE-400™ DIAGRAMS...
  • Page 33 SAE-400™ DIAGRAMS...
  • Page 34 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.

This manual is also suitable for:

113221140711591225011409Sae-400 dc arc

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