Operator’s Manual

®
SAE-400 DC ARC WELDING
POWER SOURCE
For use with machines having Code Numbers:
11808

Register your machine: Need Help? Call 1.888.935.3877

www.lincolnelectric.com/register to talk to a Service Representative
Authorized Service and Distributor Locator:
www.lincolnelectric.com/locator Hours of Operation:
8:00 AM to 6:00 PM (ET) Mon. thru Fri.
Save for future reference
After hours?
Use “Ask the Experts” at lincolnelectric.com
A Lincoln Service Representative will contact you
Date Purchased no later than the following business day.

For Service outside the USA:

Code: (ex: 10859) Email: globalservice@lincolnelectric.com

Serial: (ex: U1060512345)

IM10122 | Issue Date Sept- 13

© Lincoln Global, Inc. All Rights Reserved.
 THANK YOU FOR SELECTING
A QUALITY PRODUCT BY KEEP YOUR HEAD OUT OF THE FUMES.
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 Safety Data
PLEASE EXAMINE CARTON AND EQUIPMENT FOR Sheet (SDS) and the warning label
DAMAGE IMMEDIATELY that appears on all containers of
When this equipment is shipped, title passes to the purchaser welding materials.
upon receipt by the carrier. Consequently, claims for material USE ENOUGH VENTILATION or
damaged in shipment must be made by the purchaser against the exhaust at the arc, or both, to
transportation company at the time the shipment is received. keep the fumes and gases from
your breathing zone and the general area.
IN A LARGE ROOM OR OUTDOORS, natural ventilation may be
adequate if you keep your head out of the fumes (See below).
SAFETY DEPENDS ON YOU
USE NATURAL DRAFTS or fans to keep the fumes away
Lincoln arc welding and cutting equipment is designed and built
from your face.
with safety in mind. However, your overall safety can be increased
by proper installation ... and thoughtful operation on your part. If you develop unusual symptoms, see your supervisor.
DO NOT INSTALL, OPERATE OR REPAIR THIS EQUIPMENT Perhaps the welding atmosphere and ventilation system
WITHOUT READING THIS MANUAL AND THE SAFETY should be checked.
PRECAUTIONS CONTAINED THROUGHOUT. And, most importantly,
think before you act and be careful.
WEAR CORRECT EYE, EAR &
BODY PROTECTION
WARNING PROTECT your eyes and face with welding helmet
properly fitted and with proper grade of filter plate
(See ANSI Z49.1).
This statement appears where the information must be followed
exactly to avoid serious personal injury or loss of life. PROTECT your body from welding spatter and arc
flash with protective clothing including woolen
clothing, flame-proof apron and gloves, leather
CAUTION leggings, and high boots.
PROTECT others from splatter, flash, and glare
This statement appears where the information must be followed with protective screens or barriers.
to avoid minor personal injury or damage to this equipment.
IN SOME AREAS, protection from noise may be appropriate.
BE SURE protective equipment is in good condition.
Also, wear safety glasses in work area
AT ALL TIMES.

SPECIAL SITUATIONS
DO NOT WELD OR CUT containers or materials which previously
had been in contact with hazardous substances unless they are
properly cleaned. This is extremely dangerous.
DO NOT WELD OR CUT painted or plated parts unless special
precautions with ventilation have been taken. They can release
highly toxic fumes or gases.
Additional precautionary measures
PROTECT compressed gas cylinders from excessive heat,
mechanical shocks, and arcs; fasten cylinders so they cannot fall.
BE SURE cylinders are never grounded or part of an
electrical circuit.
REMOVE all potential fire hazards from welding area.
ALWAYS HAVE FIRE FIGHTING EQUIPMENT READY FOR
IMMEDIATE USE AND KNOW HOW TO USE IT.
Safety 01 of 04 - 5/16/2018
 SAFETY

SECTION A: 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

WARNINGS
fumes have been eliminated.
1.d. Keep all equipment safety guards, covers
and devices in position and in good repair.
CALIFORNIA PROPOSITION 65 WARNINGS Keep hands, hair, clothing and tools away
from V-belts, gears, fans and all other
moving parts when starting, operating or
WARNING: Breathing diesel engine exhaust repairing equipment.
exposes you to chemicals known to the State 1.e. In some cases it may be necessary to remove safety guards to
of California to cause cancer and birth defects, perform required maintenance. Remove guards only when
or other reproductive harm. necessary and replace them when the maintenance requiring
• Always start and operate the engine in a their removal is complete. Always use the greatest care when
well-ventilated area. working near moving parts.
• If in an exposed area, vent the exhaust to the outside. 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
• Do not modify or tamper with the exhaust system.
rods while the engine is running.
• Do not idle the engine except as necessary.
1.g. To prevent accidentally starting gasoline engines while turning
For more information go to the engine or welding generator during maintenance work,
www.P65 warnings.ca.gov/diesel disconnect the spark plug wires, distributor cap or magneto wire
as appropriate.
WARNING: This product, when used for welding or 1.h. To avoid scalding, do not remove the radiator
cutting, produces fumes or gases which contain pressure cap when the engine is hot.
chemicals known to the State of California to cause
birth defects and, in some cases, cancer. (California
Health & Safety Code § 25249.5 et seq.)

WARNING: Cancer and Reproductive Harm ELECTRIC AND

www.P65warnings.ca.gov MAGNETIC FIELDS MAY
BE DANGEROUS
ARC WELDING CAN BE HAZARDOUS. PROTECT
YOURSELF AND OTHERS FROM POSSIBLE SERIOUS 2.a. Electric current flowing through any conductor
INJURY OR DEATH. KEEP CHILDREN AWAY. causes localized Electric and Magnetic Fields (EMF).
PACEMAKER WEARERS SHOULD CONSULT WITH Welding current creates EMF fields around welding cables
THEIR DOCTOR BEFORE OPERATING. and welding machines
Read and understand the following safety highlights. For 2.b. EMF fields may interfere with some pacemakers, and
additional safety information, it is strongly recommended welders having a pacemaker should consult their physician
that you purchase a copy of “Safety in Welding & Cutting - before welding.
ANSI Standard Z49.1” from the American Welding Society,
2.c. Exposure to EMF fields in welding may have other health effects
P.O. Box 351040, Miami, Florida 33135 or CSA Standard
which are now not known.
W117.2-1974. A Free copy of “Arc Welding Safety” booklet
E205 is available from the Lincoln Electric Company, 2.d. All welders should use the following procedures in order to
22801 St. Clair Avenue, Cleveland, Ohio 44117-1199. minimize exposure to EMF fields from the welding circuit:
BE SURE THAT ALL INSTALLATION, OPERATION, 2.d.1. Route the electrode and work cables together - Secure
MAINTENANCE AND REPAIR PROCEDURES ARE them with tape when possible.
PERFORMED ONLY BY QUALIFIED INDIVIDUALS. 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
FOR ENGINE POWERED work cable should also be on your right side.

EQUIPMENT. 2.d.4. Connect the work cable to the workpiece as close as pos-
sible to the area being welded.
1.a. Turn the engine off before troubleshooting 2.d.5. Do not work next to welding power source.
and maintenance work unless the
maintenance work requires it to be running.
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 welding
arc or when the engine is running. Stop the
engine and allow it to cool before refueling to
prevent spilled fuel from vaporizing on contact Safety 02 of 04 - 5/16/2018
 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” parts with your bare skin or wet clothing. observing open arc welding. Headshield and filter lens should
Wear dry, hole-free gloves to insulate hands. conform to ANSI Z87. I standards.
3.b. Insulate yourself from work and ground using dry insulation. 4.b. Use suitable clothing made from durable flame-resistant material
Make certain the insulation is large enough to cover your full area to protect your skin and that of your helpers from the arc rays.
of physical contact with work and ground.
4.c. Protect other nearby personnel with suitable, non-flammable
In addition to the normal safety precautions, if screening and/or warn them not to watch the arc nor expose
welding must be performed under electrically themselves to the arc rays or to hot spatter or metal.
hazardous conditions (in damp locations or while
wearing wet clothing; on metal structures such as
floors, gratings or scaffolds; when in cramped FUMES AND GASES
positions such as sitting, kneeling or lying, if there CAN BE DANGEROUS.
is a high risk of unavoidable or accidental contact
with the workpiece or ground) use the following 5.a. Welding may produce fumes and gases
equipment: hazardous to health. Avoid breathing these
• Semiautomatic DC Constant Voltage (Wire) Welder. fumes and gases. When welding, keep your head out of the fume.
• DC Manual (Stick) Welder. Use enough ventilation and/or exhaust at the arc to keep fumes
and gases away from the breathing zone. When welding
• AC Welder with Reduced Voltage Control.
hardfacing (see instructions on container or SDS)
3.c. In semiautomatic or automatic wire welding, the electrode, or on lead or cadmium plated steel and other
electrode reel, welding head, nozzle or semiautomatic welding metals or coatings which produce highly toxic
gun are also electrically “hot”. fumes, keep exposure as low as possible and
3.d. Always be sure the work cable makes a good electrical within applicable OSHA PEL and ACGIH TLV limits
connection with the metal being welded. The connection should using local exhaust or mechanical ventilation
be as close as possible to the area being welded. unless exposure assessments indicate otherwise.
In confined spaces or in some circumstances,
3.e. Ground the work or metal to be welded to a good electrical (earth) outdoors, a respirator may also be required.
ground. Additional precautions are also required when
3.f. Maintain the electrode holder, work clamp, welding cable and welding
welding machine in good, safe operating condition. Replace on galvanized steel.
damaged insulation. 5. b. The operation of welding fume control equipment is affected by
3.g. Never dip the electrode in water for cooling. various factors including proper use and positioning of the
equipment, maintenance of the equipment and the specific
3.h. Never simultaneously touch electrically “hot” parts of electrode welding procedure and application involved. Worker exposure
holders connected to two welders because voltage between the level should be checked upon installation and periodically
two can be the total of the open circuit voltage of both thereafter to be certain it is within applicable OSHA PEL and
welders. ACGIH TLV limits.
3.i. When working above floor level, use a safety belt to protect 5.c. Do not weld in locations near chlorinated hydrocarbon vapors
yourself from a fall should you get a shock. coming from degreasing, cleaning or spraying operations. The
heat and rays of the arc can react with solvent vapors to form
3.j. Also see Items 6.c. and 8.
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.
5.e. Read and understand the manufacturer’s instructions for this
equipment and the consumables to be used, including the
Safety Data Sheet (SDS) and follow your employer’s safety
practices. SDS forms are available from your welding
distributor or from the manufacturer.
5.f. Also see item 1.b.

Safety 03 of 04 - 5/16/2018
 SAFETY

WELDING AND CUTTING CYLINDER MAY EXPLODE IF

SPARKS CAN CAUSE DAMAGED.
FIRE OR EXPLOSION. 7.a. Use only compressed gas cylinders containing
6.a. Remove fire hazards from the welding area. If the correct shielding gas for the process used
this is not possible, cover them to prevent the welding sparks and properly operating regulators designed for
from starting a fire. Remember that welding sparks and hot the gas and pressure used. All hoses, fittings,
materials from welding can easily go through small cracks and etc. should be suitable for the application and
openings to adjacent areas. Avoid welding near hydraulic lines. maintained in good condition.
Have a fire extinguisher readily available. 7.b. Always keep cylinders in an upright position securely chained to
6.b. Where compressed gases are to be used at the job site, special an undercarriage or fixed support.
precautions should be used to prevent hazardous situations. 7.c. Cylinders should be located:
Refer to “Safety in Welding and Cutting” (ANSI Standard Z49.1)
• Away from areas where they may be struck or subjected
and the operating information for the equipment being used.
to physical damage.
6.c. When not welding, make certain no part of the electrode circuit is • A safe distance from arc welding or cutting operations
touching the work or ground. Accidental contact can cause and any other source of heat, sparks, or flame.
overheating and create a fire hazard.
7.d. Never allow the electrode, electrode holder or any other
6.d. Do not heat, cut or weld tanks, drums or containers until the
electrically “hot” parts to touch a cylinder.
proper steps have been taken to insure that such procedures
will not cause flammable or toxic vapors from substances inside. 7.e. Keep your head and face away from the cylinder valve outlet
They can cause an explosion even though they have been when opening the cylinder valve.
“cleaned”. For information, purchase “Recommended Safe 7.f. Valve protection caps should always be in place and hand tight
Practices for the Preparation for Welding and Cutting of except when the cylinder is in use or connected for use.
Containers and Piping That Have Held Hazardous Substances”,
AWS F4.1 from the American Welding Society 7.g. Read and follow the instructions on compressed gas cylinders,
(see address above). associated equipment, and CGA publication P-l, “Precautions for
Safe Handling of Compressed Gases in Cylinders,” available from
6.e. Vent hollow castings or containers before heating, cutting or the Compressed Gas Association, 14501 George Carter Way
welding. They may explode.
Chantilly, VA 20151.
6.f. Sparks and spatter are thrown from the welding arc. Wear oil 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. FOR ELECTRICALLY
6.g. Connect the work cable to the work as close to the welding area POWERED EQUIPMENT.
as practical. Work cables connected to the building framework or
other locations away from the welding area increase the 8.a. Turn off input power using the disconnect
possibility of the welding current passing through lifting chains, switch at the fuse box before working on
crane cables or other alternate circuits. This can create fire the equipment.
hazards or overheat lifting chains or cables until they fail.
8.b. Install equipment in accordance with the U.S. National Electrical
6.h. Also see item 1.c. Code, all local codes and the manufacturer’s recommendations.
6.I. Read and follow NFPA 51B “Standard for Fire Prevention During 8.c. Ground the equipment in accordance with the U.S. National
Welding, Cutting and Other Hot Work”, available from NFPA, 1 Electrical Code and the manufacturer’s recommendations.
Batterymarch Park, PO box 9101, Quincy, MA 022690-9101.
6.j. Do not use a welding power source for pipe thawing.
Refer to
http://www.lincolnelectric.com/safety
for additional safety information.

Safety 04 of 04 - 5/16/2018
vi TABLE OF CONTENTS vi

Page
Installation Instructions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Section A
Technical Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .A-1
Installation Precautions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A-2
Location / Ventilation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .A-2
Stacking . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .A-2
Angle of Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .A-2
Lifting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .A-2
High Altitude Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .A-3
Towing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .A-3
Vehicle Mounting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .A-3
Pre-Operation Engine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .A-3
Engine Oil . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .A-3
Fuel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .A-4
Engine Cooling System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .A-4
Break-In Period . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .A-4
Battery Connection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .A-4
Spark Arrester . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .A-5
Welding Output Cables . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .A-5
Machine Grounding . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .A-5
_____________________________________________________________________________________
Operating Instructions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Section B
Safety Instructions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . B-1
Additional Safety Precautions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . B-1
General Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .B-1
Recommended Applications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .B-2
Welder . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .B-2
Auxiliary Power . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .B-2
Design Features and Advantages . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .B-2
Duty Cycle . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .B-2
Engine Controls: Function/Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . B-2
Welder Controls: Function/Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . B-3
Remote Control . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .B-3
Auxiliary Power Controls . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .B-4
Engine Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .B-5
Starting Instructions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .B-5
Typical Fuel Consumption . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .B-6
_____________________________________________________________________________________
Accessories . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Section C
_____________________________________________________________________________________
Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Section D
Routine Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . D-1
Periodic Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . D-1
Pre Filter / Washer Separator . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .D-2
Engine Maintenance Components . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .D-3
Spark Arrester . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .D-3
_____________________________________________________________________________________
Troubleshooting Guide . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Section E
_____________________________________________________________________________________
Wiring Diagram and Dimension Print . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Section F
____________________________________________________________________________________
Parts List . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .P-692
____________________________________________________________________________________
A-1 INSTALLATION A-1

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.
Engine 64.4 HP @ Low Idle 1100 & Starter 9.6 L
Not EPA Tier 4 1710 RPM Full Load 1725
Compliant 4.13” x 5.00”
Export Only (105.0 mm x 127.0mm) Coolant: 3.4 gal.
12.8 L

RATED OUTPUT - WELDER

Duty Cycle (1)
Welding Output Volts at Rated Amps

60% (NEMA) 500 amps 40 volts

100% (NEMA) 400 amps 36 volts

100% (Lincoln Plus) 400 amps 40 volts

OUTPUT - WELDER AND GENERATOR

Welding Range Open Circuit Voltage Auxiliary Power
120/240 VAC
80 - 575 Amps 97 Max. OCV 10,000 Watts, 60 Hz., Single Phase
@ 1800 RPM 13,000 Watts, 3 Phase Auxiliary, 240V
100% Duty Cycle
RECEPTACLES AND CIRCUIT BREAKERS
RECEPTACLES AUXILIARY POWER CIRCUIT BREAKER

1 - 120VAC Duplex NEMA (5-20R) 2 - 20 amp for 120VAC Duplex NEMA

1 - 120VAC European (IEC-309) 1 - 15 amp for 120VAC European (IEC-309)
1 - 240VAC Duplex NEMA 1 - 15 amp (2 -pole) for 240 V Duplex and European (IEC-309)
1 - 240VAC European (IEC-309)
1 - 240VAC (15-50R) NEMA 3 Phase 1 - (30ma), (RCD) Residual Curret Detector
1 - 120VAC / 240VAC (14-50R) NEMA 1 Phase 1 - 50amp (3-pole), 240VAC Circuit Breaker
PHYSICAL DIMENSIONS
HEIGHT WIDTH DEPTH WEIGHT

49.80 in. 27.70 in. 83.10 in. 2286 lbs.

1,264.9 mm 703.6 mm 2,110.7 mm 1037 kg.

(1) Based on a 10 minute period.

SAE-400®
A-2 INSTALLATION A-2

Read this entire installation section before you

start installation. CAUTION
SAFETY PRECAUTIONS DO NOT MOUNT OVER COMBUSTIBLE SURFACES
Where there is a combustible surface directly under
WARNING stationary or fixed electrical equipment, that surface
should be covered with a steel plate at least
Do not attempt to use this equipment until you have .06”(1.6mm) thick, which should extend not less than
thoroughly read all operating and maintenance man- 5.90(150mm) beyond the equipment on all sides.
uals supplied with your machine. They include impor- ------------------------------------------------------------------------
tant safety precautions, detailed engine starting,
operating and maintenance instructions and parts STACKING
lists.
These machines cannot be stacked.
ELECTRIC SHOCK can kill.

•Do not touch electrically live parts such ANGLE OF OPERATION

as output terminals or internal wiring.
To achieve optimum engine performance the machine
•Insulate yourself from the work and should be run in a level position. The maximum angle
ground. of operation for the Perkins engine is 30 degrees in all
directions. If the engine is to be operated at an angle,
•Always wear dry insulating gloves. 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
ENGINE EXHAUST can kill. angle, the effective fuel capacity will be slightly less
than the specified 29.0 Gal.(109.8 ltr.).
•Use in open, well ventilated areas or
vent exhaust outside LIFTING

•Do not stack anything near the engine. The equipment lift bail should be used to lift the
------------------------------------------------------------------------ machine.

MOVING PARTS can injure. WARNING

•Do not operate with doors open or
guards off. • Lift only with equipment of adequate
lifting capacity.
•Stop engine before servicing. • Be sure machine is stable when lift-
ing.
•Keep away from moving parts
------------------------------------------------------------------------ • Do not lift this machine using lift bail if it is
Only qualified personnel should install, use or service equipped with a heavy accessory such as a trail-
this equipment er or gas cylinder.
FALLING • Do not lift machine if lift bail is
EQUIPMENT can damaged.
LOCATION / VENTILATION cause injury. • Do not operate machine while
suspended from lift bail.
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®
A-3 INSTALLATION A-3

HIGH ALTITUDE OPERATION VEHICLE MOUNTING

At higher altitudes, output derating may be necessary.

As a rule of thumb, derate the welder output 5% for
WARNING
every 500 meters (1640 ft.) above 1000 meters (3280
ft.). Improperly mounted concentrated loads may cause
unstable vehicle handling and tires or other compo-
Contact a Perkins Service Representative for any nents to fail.
engine adjustments that may be required for high alti- • Only transport this equipment on serviceable vehi-
cles which are rated and designed for such loads.
tude operation.
• Distribute, balance and secure loads so vehicle is
stable under conditions of use.
• Do not exceed maximum rated loads for compo-
TOWING nents such as suspension, axles and tires.
• Mount equipment base to metal bed or frame of
The recommended trailers for use with this equipment vehicle.
(1)
for in-plant and yard towing by a vehicle are Lincolnʼs • Follow vehicle manufacturerʼs instruction.
K2641-2 and K2637-2. The K2637-2 is also designed ------------------------------------------------------------------------
to be used at highway speeds(1). If the user adapts a PRE-OPERATION ENGINE SERVICE 
non-Lincoln trailer, he must assume responsibility that READ the engine operating and maintenance instruc-
the method of attachment and usage does not result in tions supplied with this machine.
a safety hazard nor damage the welding equipment.
Some of the factors to be considered are as follows:
ENGINE OIL
1. Design capacity of trailer vs. weight of Lincoln
The engine is shipped with the engine crankcase filled
equipment and likely additional attachments.
with high quality SAE 10W-30 oil (API class CD or bet-
ter). Check the oil level before starting the engine. If it is
2. Proper support of, and attachment to, the base of not up to the full mark on the dip stick, add oil as required.
the welding equipment so that there will be no Check the oil level every four hours of running time during
undue stress to the trailerʼs framework. the first 35 running hours. Refer to the engine Operatorʼs
Manual for specific oil recommendations and break-in
3. Proper placement of the equipment on the trailer to information. The oil change interval is dependent on the
insure stability side to side and front to back when quality of the oil and the operating environment. Refer to
being moved and when standing by itself. the engine Operatorʼs Manual for the proper service and
maintenance intervals.
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.

(1)
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, fend-
ers, etc.

SAE-400®
A-4 INSTALLATION A-4

WARNING
• Stop engine while fueling. 1. Connect the welder output studs to a suitable resis-
• Do not smoke when fueling. tive load bank. Note that any attempt to short the
• Keep sparks and flame away from output studs by connecting the welding leads
together, direct shorting of the output studs, or con-
tank.
necting the output leads to a length of steel will
• Do not leave unattended while fuel-
result in catastrophic damage to the generator and
ing. voids the warranty.
• Wipe up spilled fuel and allow
DIESEL FUEL fumes to clear before starting
can cause fire. 2. Set the welder controls for an output current and
engine. voltage within the welder rating and duty cycle.
• Do not overfill tank, fuel expan- Note that any attempt to exceed the welder rating or
sion may cause overflow. duty cycle for any period of time will result in cata-
DIESEL FUEL ONLY strophic damage to the generator and voids the
------------------------------------------------------------------------ warranty.
Fill the fuel tank with clean, fresh diesel fuel. The capac-
ity of the fuel tank is 29.0 gallons (109.8 liters). See 3. Periodically shut off the engine and check the
engine Operatorʼs Manual for specific fuel recommenda- crankcase oil level.
tions.
BATTERY CONNECTION
Note: Before starting the engine, be sure the fuel shut-
off valve is in the open position.
WARNING
ENGINE COOLING SYSTEM Use caution as the electrolyte is a strong acid that
can burn skin and damage eyes.
The cooling system has been filled at the factory with
a 50-50 mixture of ethylene glycol antifreeze and Remove and discard the insulating cap from the
water. Check the radiator level and add a 50-50 solu- negative battery terminal. Attach and tighten neg-
tion as needed. (See Engine Manual or antifreeze ative battery cable terminal.
container for alternate antifreeze recommendation.)
NOTE: This machine is furnished with a wet charged
ENGINE BREAK-IN PERIOD battery; if unused for several months, the battery may
require a booster charge. Be careful to charge the bat-
Lincoln Electric selects high quality, heavy-duty indus- tery with the correct polarity. Make sure that the battery
trial engines for the portable welding machines we is level while charging.
offer. While it is normal to see a small amount of
crankcase oil consumption during initial operation,
excessive oil use, wet stacking (oil or tar like substance WARNING
at the exhaust port), or excessive smoke is not normal.
GASES FROM BATTERY can explode.
Larger machines with a capacity of 350 amperes and
Keep sparks, flame and cigarettes
higher, which are operated at low or no-load conditions away from battery.
for extended periods of time are especially susceptible
to the conditions described above. To accomplish suc- ------------------------------------------------------------------------
cessful engine break-in, most diesel-powered equip- To prevent EXPLOSION when:
ment needs only to be run at a reasonably heavy load
INSTALLING A NEW BATTERY — disconnect
within the rating of the welder for some period of time negative cable from old battery first and
during the engineʼs early life. However, if the welder is connect to new battery last.
subjected to extensive light loading, occasional moder-
ate to heavy loading of the engine may sometimes be

CONNECTING A BATTERY CHARGER —
necessary. Caution must be observed in correctly
remove battery from welder by disconnecting
loading a diesel/generator unit.
negative cable first, then positive cable and
battery clamp. When reinstalling, connect
negative cable last. Keep well ventilated.

SAE-400®
A-5 INSTALLATION A-5

WELDING OUTPUT CABLES

USING A BOOSTER — connect positive lead to
battery first then connect negative lead to neg- With the engine off, connect the electrode and work
ative battery lead at the lower control panel cables to the studs provided. These connections
support. should be checked periodically and tightened if neces-
BATTERY ACID can burn eyes and sary.
skin.

Wear gloves and eye protection Listed in Table A.1 are copper cable sizes recom-
and be careful when working near mended for the rated current and duty cycle. Lengths
battery. stipulated are the distance from the welder to work and

Follow instructions printed on battery. back to the welder again. Cable sizes are increased
for greater lengths primarily for the purpose of mini-
IMPORTANT: To prevent ELECTRICAL DAMAGE
mizing cable voltage drop.
WHEN:
a) Installing a new battery. Table A.1 Combined Length of Electrode and
b) Using a booster. Work Cables.
Use correct polarity — Negative Ground.
To prevent BATTERY BUCKLING, tighten the nuts on TOTAL COMBINED LENGTH OF ELEC-
battery until snug. DO NOT OVERTIGHTEN. TRODE AND WORK CABLES
AMPS Up to 100FT. 100-200FT. 200-250FT.
SPARK ARRESTER @60% Up to 31m 31-61m 61-76m
Duty Cycle
WARNING
400 2/0 AWG 3/0 AWG 4/0 AWG
• Spark Arrester and Muffler may be
hot! MACHINE GROUNDING
• Allow engine to cool before servicing
spark arrester! Because this portable engine driven welder creates its
• Do not operate engine while servicing own power, it is not necessary to connect its frame to
spark arrester! an earth ground, unless the machine is connected to
------------------------------------------------------------------------ premises wiring (home, shop, etc.).
Some federal, state or local laws may require that
gasoline or diesel engines be equipped with exhaust
To prevent dangerous electric shock, other equipment
spark arresters when they are operated in certain loca-
powered by this engine driven welder must:
tions where unarrested sparks may present a fire haz-
ard. The muffler included with this welder has been
modified and now qualifies as a spark arrester. Spark a) be grounded to the frame of the welder using a
arresting mufflers will have a clean out service plug grounded type plug, or
and will have “US FOREST SERVICE APPROVED” b) be double insulated.
stamped on the muffler shell. Any spark arrester must
be serviced and properly maintained. 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 con-
CAUTION nected to premises wiring such as that in a home or
An incorrect arrester may lead to damage to the shop, its frame must be connected to the system earth
engine or adversely affect performance. 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.
SAE-400®
B-1 OPERATION B-1

OPERATING INSTRUCTIONS WELDING SPARKS can cause

Read and understand this entire section before operat-
fire or explosion.
ing your equipment. • Do not weld near flammable material .
• Do not weld on containers that have
SAFETY INSTRUCTIONS held flammable material.
------------------------------------------------------------------------
WARNING MOVING PARTS can injure.
• Keep away from moving parts
Do not attempt to use this equipment until you • Do not operate with doors open or
have thoroughly read all operating and mainte- guards off.
nance manuals supplied with your machine. They • Stop engine before servicing.
include important safety precautions, detailed ------------------------------------------------------------------------
engine starting, operating and maintenance ENGINE EXHAUST can kill.
instructions and parts lists. • Use in open, well ventilated areas or
vent exhaust outside.
ELECTRIC SHOCK can kill.
• Do not touch electrically live parts or
electrodes with your skin or wet Pipe Thawing with an arc welder can cause fire,
clothing. explosion, damage to electric wiring or to the arc
• Insulate yourself from the work and ground. welder if done improperly. The use of an arc welder
• Always wear dry insulating gloves. for pipe thawing is not approved by the CSA, nor is
• Do not use AC welder if your clothing, gloves or it recommended or supported by Lincoln Electric.
work area is damp or if working on, under or ------------------------------------------------------------------------
inside workpiece.
Use the following equipment: ADDITIONAL SAFETY PRECAUTIONS
• Semiautomatic DC constant voltage (wire)
welder. Always operate the welder with the hinged doors
• DC manual (stick) welder. closed as these provide maximum protection from
• AC welder with reduced voltage control. moving parts and insure proper cooling air flow.
------------------------------------------------------------------------
Read carefully the Safety Precautions page in the
ARC RAYS can injure eyes and
Instruction Manual before operating this machine.
burn skin. Always follow these and any other safety procedures
included in this manual and in the engine instruction
• Wear eye, ear, and body protection.
manuals.
------------------------------------------------------------------------
• Only qualified personnel should install, use or
service this equipment.
GENERAL DESCRIPTION
• Consult instruction manual before operating.
------------------------------------------------------------------------ The SAE-400® is a diesel engine driven welding power
Before operating, read and understand the manu- source. The machine uses a DC generator for DC stick
facurerʼs instructions for this equipment and the electrode welding and an AC exciter for 10,000 watts
consumables to be used including the Material single phase auxiliary 120V/240V power, 13,000 watts
Safety Data Sheet (MSDS) and follow your employ- three phase auxiliary 240V power. As a welder it pro-
erʼs safety practices. vides up to 575 amps of DC constant current output.
------------------------------------------------------------------------
The engine 1104A-44 is a 64.4 Hp @ 1710 RPM
FUMES AND GASES can be (48kw), 4-cylinder water cooled diesel made by
dangerous to your health. Perkins.
• Keep your head out of fumes.
• Use enough ventilation or exhaust
at the arc, or both, to keep the
fumes and gases from your breath-
ing zone and general area.

SAE-400®
B-2 OPERATION B-2

RECOMMENDED APPLICATIONS OTHER FEATURES

WELDER • Perkins 4-cylinder, water cooled diesel engine.

The SAE-400® provides excellent constant current DC Designed for long life, easy maintenance and excel-
welding output for stick (SMAW) welding. The field lent fuel economy.
installed optional CV Adapter (K385-[ ]) provides up to • Engine protection system shuts the engine down for
500 amps at 35 volts of constant voltage output for low engine oil pressure or high coolant temperature.
semiautomatic welding. • Electronic Engine Idler. Engine automatically goes
to low idle in 10 to 14 seconds after welding or use
AUXILIARY POWER of auxiliary power stops. Includes high idle switch.
The SAE-400® provides 10 KW of 120/240VAC Single • Gauges for engine oil pressure, coolant temperature
Phase 13kw 240V, 3 Phase output for auxiliary power and battery charging ammeter.
and emergency standby power. • Engine hour meter standard.
• Extended range 29.0 gallon (109.8 L) fuel tank.
DESIGN FEATURES AND ADVANTAGES
DUTY CYCLE
FOR STICK WELDING
• Excellent DC constant current output for stick weld- Duty cycle is the percentage of time the load is being
ing applications. applied in a 10 minute period. For example a 60% duty
• Continuous adjustment of both voltage and current cycle, represents 6 minutes of load and 4 minutes of
for unsurpassed welds on demanding jobs. no load in a 10 minute period.
• Remote control capability standard.
ENGINE CONTROLS
FOR AUXILIARY POWER
IGNITION SWITCH
• 10kVA of 120/240VAC, 13kVA for 240 3ph. 60 Hz
auxiliary power. When placed in the “ON” position, this switch ener-
• Two 20 amp 120VAC duplex receptacle. gizes the fuel solenoid. When placed in the “OFF” posi-
• One 15 amp, 240VAC duplex receptacle for up to 13 tion, the flow of fuel to the injection pump is stopped to
amps of 240VAC power. shut down the engine.
• One 120VAC (European IEC-309) 16 amp receptacle.
• One 240VAC (European IEC-309) 15 amp receptacle. “IDLER” SWITCH
• One 120/240V NEMA 50 amp receptacle. The idler switch has two positions, “HIGH” and
• One 240V3 phase NEMA 50 amp receptacle. “AUTO”.
• Weld and AC auxiliary power at the same time (with-
in the limits shown on the chart below). When in “HIGH” ( ) position, the engine will run
continuously at high idle.
Welding Using Only Using Only Total
Current, Amps 120V Circuit, 240V Circuit, Aux. When in “AUTO” ( / ) idle position, the idler
@ NEMA Arc Amps Amps 10kVA/ operates as follows:
Volts 1ph / 3ph 13kVA
a. Welding
0 84 42 / 31 10 / 13

100 81 40 / 30 10 / 12 When the electrode touches the work, the welding

arc is initiated and the engine accelerates to full
200 71 35 / 26 8 / 11 speed.
300 54 27 / 20 6/8
After welding ceases (and no auxiliary power is
400 30 15 / 11 4/5 being drawn), the engine will return to low idle after
approximately 10 to 14 seconds.
500 0 0/0 0/0
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 weld-
ing) for 10-14 seconds, the idler reduces the engine
speed to low idle.

SAE-400®
B-3 OPERATION B-3

ENGINE TEMPERATURE GAUGE

“CURRENT CONTROL”
Displays the coolant temperature in the engine block.
CAUTION
ENGINE OIL PRESSURE GAUGE
Do not adjust the “Current Control” while welding
Displays the oil pressure to the engine. When the engine because this can damage the control.
starts running, watch for the oil pressure to build up. If no ------------------------------------------------------------------------
pressure shows within 30 seconds, stop the engine and The “Current Control” dial is calibrated in amperes on
consult the engine instruction manual. three separate colored dials corresponding to the
white, black and red ranges of the “Job Selector” dial.
BATTERY CHARGING AMMETER For example: when the “Job Selector” is set on the
black range, the approximate welding current is indi-
Displays the current going from the charging alternator cated on the black scale of the “Current Control” dial.
into the batteries. It is normal for charging current to be
high (above 15 amps) after starting or when the batteries How to Set the Controls
are ʻlowʼ on charge.
Assume you want a normal soft arc and about 135
ENGINE HOUR METER amps, using a 5/32” (4.0 mm) electrode:
The engine hour meter records the total running time on
1. Set the “Job Selector” at the center of the black
the engine in hours. It can be used to keep a record of
maintenance on the engine and or welder. range.

ENGINE PROTECTION SYSTEM 2. Set the “Current Control” to read 135 amps on the
black dial.
The engine protection system shuts down the engine
under high coolant temperature or low engine oil pressure 3. Start to weld.
conditions by allowing the fuel solenoid valve to close.
4. If you want a little more current, turn the “Job
WELDER CONTROLS Selector” up (counterclockwise) to increase cur-
rent. If you want a little less current, turn the “Job
POLARITY SWITCH
Selector” down (clockwise) to decrease current.
Turn the Arc Polarity switch to electrode positive or elec-
trode negative as required for each particular application. 5. If dialing the desired current with the “Job
Selector” moves the setting outside the black
CONTROL OF WELDING CURRENT range causing undesirable arc characteristics, turn
the “Job Selector” back to the center of the black
Purpose of Controls range. Then turn the “Current Control” up or down
a little as needed. Readjust the “Job Selector” for
The continuous “Current Control” is the main current the exact characteristics and current desired.
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.
REMOTE CONTROL

“Job Selector” A receptacle and “Local/Remote” control switch is

located on the lower front control panel. A remote con-
The “Job Selector” dial is divided into four colored sec- trol box with 100 ft. (30.5 m) of cord for adjusting the
tions providing OCV ranges as follows: OCV at the welding site is available. Putting the switch
in the “REMOTE” position allows fine current control at
Color Title OCV Range the remote control box while placing the switch in the
White Large Electrodes High OCV “LOCAL” position allows fine current control at the “Job
Black Normal Welding Medium OCV Selector” on the machine. When using the optional
Red Overhead & Vertical Low OCV
field installed CV adapter (K385-[ ]) the “Local/Remote”
Grey Special Applications Extra-Low OCV
switch is only active in the “VV” mode.
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®
B-4 OPERATION B-4

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.
duplex receptacle provides 120VAC for auxiliary
power. GROUND STUD
One 120V (European IEC-309) 16 amp receptacle. IP44 Provides a connection point for connecting the
rated. machine to earth ground. For the safest grounding pro-
cedure refer to “Machine Grounding” in the INSTALLA-
One 120V/240V (14-50R) 1 phase 50 amp NEMA style TION section of this manual.
receptacle.

The auxiliary power receptacles should only be used

with three or four wire grounded type plugs or
approved double insulated tools. The current rating of
any plug used with the system must be at least equal
to the current capacity of the associated receptacle.

240VAC Receptacles

One 15 amp, 240VAC duplex receptacle provides 240

VAC for auxiliary power.

One 240V (European IEC-309) 15 amp receptacle. IP44

rated.

One 240V (15-50R) 3 phase 50 amp NEMA style

receptacle.

Circuit Breakers

2 pole 15 amp rated provides overload protection for

the 240VAC (European IEC-309) receptacle and the
240VAC duplex receptacle.

2 Single pole 20 amp rated circuit breakers provides

overload protection for the 120VAC (5-20R NEMA)
duplex receptacle.

Single pole 15 amp rated provides overload protection

for the 120VAC (European IEC-309) receptacle.

3 pole, 50 amp circuit breaker provides overload pro-

tection to 240V, 3 phase and 120/240 1 phase NEMA
(15-50R and 14-50R) plugs.

SAE-400®
B-5 OPERATION B-5

ENGINE OPERATION 5. 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
Do not attempt to use this equipment until you the “IGNITION” switch to “OFF”.
have thoroughly read the engine manufacturerʼs 6. If the engine protection warning light comes on
manual supplied with your welder. It includes during cranking or after start up, the “IGNITION”
important safety precautions, detailed engine switch must be turned “OFF” to reset the engine
starting, operating and maintenance instructions,
and parts lists. protection system.
------------------------------------------------------------------------ 7. Allow the engine to run at high idle speed for sev-
ELECTRIC SHOCK can kill. eral minutes to warm the engine. Stop the engine
• Do not touch electrically live parts or and recheck the oil level, after allowing sufficient
electrode with skin or wet clothing. time for the oil to drain into the pan. If the level is
• Insulate yourself from work and down, fill it to the full mark again. The engine con-
ground trols were properly set at the factory and should
• Always wear dry insulating gloves.
------------------------------------------------------------------------ require no adjusting when received.
ENGINE EXHAUST can kill.
• Use in open, well ventilated areas or COLD WEATHER STARTING:
vent exhaust outside.
WARNING
------------------------------------------------------------------------ Under NO conditions should ether or other starting
MOVING PARTS can injure.
• Do not operate with doors open or fluids be used!
guards off. ------------------------------------------------------------------------
• Stop engine before servicing.
• Keep away from moving parts. 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 cold-
See additional warning information at the starting aides.
front of this operatorʼs manual. Note: Extreme cold weather staring may require longer
glow plug operation.
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, genera- STOPPING THE ENGINE
tor overheating.
1. Turn the “IGNITION” switch to “OFF”
CAUTION At the end of each dayʼs welding, check the crankcase
Do not adjust the high idle engine speed (rpm) oil level, drain accumulated dirt and water from the
above the factory setting specification as this will water separator and refill the fuel tank to minimize
void warranty. moisture condensation in the tank. Also, running out of
----------------------------------------------------------------------- fuel tends to draw dirt into the fuel system.

STARTING INSTRUCTIONS When hauling the welder between job sites, close the
fuel shut-off valve.
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).
4. 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®
B-6 OPERATION B-6

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 4.61

Auxiliary 13KVA 1.39 5.27

Weld 400A 40V, Auxiliary 10KVA 2.33 8.28

Weld 400A 40V, Auxiliary 13KVA 2.24 8.47

SAE-400®
C-1 ACCESSORIES C-1

K930-2 TIG Module - Provides high frequency plus a K704 Standard Accessory Kit - Includes electrode
gas valve for TIG welding. A water valve is available as and work cables, headshield, work clamp and elec-
an option. Requires 115 volt AC input. (Limited to 250A trode holder.
- 60% Duty Cycle).
K385-2 CV Adapter - Provides constant voltage output
K802D Power Plug Kit - Kit includes male plug for 20 for semiautomatic welding. (Field installation only).
amp receptacle.
K1735-1 MULTI-WELD 350 - For multiple arcs from
K2641-2 Trailer - FOUR-WHEEL STEERABLE YARD the DC output of a welding power source. See bulletin
TRAILER WITH DUO-HITCH E5.300 for Multi-Weld 350 and distribution system.
• For off-road, plant and yard use with an overall width
of 55 in. K2144-1 Oil Drain Kit- Includes ball valve, hose and
• Includes an automatically engaging drawbar lock clamp.
when the drawbar is raised to the vertical position.
• 13 in wheels with wheel bearings packed with high
viscosity, high pressure, low washout Lubriplate®
grease.
• Stiff 3/16 in welded rectangular steel frame construc-
tion is phosphate etched and powder coat painted for
superior rust and corrosion resistance.
• Also includes a Duo-Hitch™ - a 2 in Ball/Lunette Eye
combination hitch.

K2637-2 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:
K2637-2 Trailer
K2639-1 Fender & Light Kit
K2640-1 Cable Storage Rack

1For highway use, consult applicable federal, state and local laws regarding

possible requirements for brakes, lights, fenders, etc.

WARNING
Pipe Thawing with an arc welder can cause fire,
explosion, damage to electric wiring or to the arc
welder if done improperly. 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®
D-1 MAINTENANCE D-1

PERIODIC MAINTENANCE
WARNING
1. Blow out the welder and controls with an air hose at least
ELECTRIC SHOCK can kill. once every two months. In particularly dirty locations, this

Do not touch electrically live parts cleaning may be necessary once a week. Use low pres-
such as output terminals or inter- sure air to avoid driving dirt into the insulation.
nal wiring
2. The current control reactor brushes are self-lubricating
and should not be greased. Keep the contacts clean. This
ENGINE EXHAUST can kill. control should be moved from maximum to minimum daily

Use in open, well ventilated areas to prevent the controls from sticking.
or vent exhaust outside
3. See the engine Instruction Manual for periodic engine
maintenance information. Change the crankcase oil at
regular intervals using the proper grade of oil as recom-
MOVING PARTS can injure.
mended in the engine operating manual. Change the oil

Do not operate with doors open or filter in accordance with the instructions in the engine
guards off operating manual. When the oil filter is changed add one

Stop engine before servicing quart of oil to the crankcase to replace the oil held in the
filter during operation.

Keep away from moving parts
4. Belts tend to loosen after the first 30 or 40 hours of oper-

Remove guards only when necessary and
ation. Check the cooling fan belt and tighten if necessary.
replace when work requiring removal is com-
DO NOT OVER TIGHTEN.
plete.

Only qualified personnel should install, use, or
service this equipment.

ROUTINE MAINTENANCE
At the end of each dayʼs welding, refill the fuel tank to
minimize moisture condensation in the tank. Also, run-
ning out of fuel tends to draw dirt into the fuel system.
Check the engine crankcase oil levels.

ENGINE AIR FILTER

The engine air filter element is a dry cartridge type. It
is located above the engine. It can be cleaned and re-
used; 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.

SAE-400®
D-2 MAINTENANCE D-2

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.
not catch in the rotating parts. Protect yourself
When antifreeze is needed, always use the permanent
from particles that may be thrown out by the rotat-
type.
ing armature when stoning the commutator.
------------------------------------------------------------------------
The generator brushes are properly adjusted when the FUEL PRE FILTER / WATER SEPARATOR
welder is shipped. They require no particular attention.
DO NOT SHIFT THE BRUSHES or adjust the rocker WARNING
setting.
When working on the fuel system
Shifting of the brushes may result in:
- Change in machine output • Keep unguarded lights away, do not
- Commutator Damage smoke !
- Excessive brush wear
• Do not spill fuel !
Periodically inspect the commutator, slip rings and
brushes by removing the covers. DO NOT remove or ------------------------------------------------------------------------
replace these covers while the machine is running. The SAE-400® is equipped with a Fuel Pre-Filter /
Water Separator Assembly located before the lift
Commutators and slip rings require little attention. pump mounted to the engine block.
However, if they are black or appear uneven, have
them cleaned by an experienced maintenance person FUEL PRE-FILTER / WATER SEPARATOR
using fine sandpaper or a commutator stone. Never ASSEMBLY
use emery cloth or paper for this purpose.
The assembly uses a 30 micron pre-filter/water separator
NOTE: If the welder is used in dirty or dusty locations, element that is designed to protect against gross contam-
or if the welder is not used for prolonged periods of ination of the final fuel filter. Using chemically treated
time, it may be necessary to clean the commutator and paper media the element also provides maximum protec-
slip rings more often. tion against water in the fuel. The assembly is also
equipped with a see-through bowl for easy visual check-
Replace brushes when they wear within 1/4" of the pig- ing for water. The recommended change interval for the
tail. A complete set of replacement brushes should be pre-filter/water separator element is 1,000 hours. See
kept on hand. Lincoln brushes have a curved face to fit below for information on the see-through bowl and for the
procedure for changing the element.
the commutator. Have an experienced maintenance
person seat these brushes by lightly stoning the com-
See-Through Bowl:
mutator as the armature rotates at full speed until con- • Check the see-through bowl for water regularly. Water
tact is made across the full face of the brushes. After will collect at the bottom of the bowl and appears differ-
stoning, blow out the dust with low pressure air. ent from the fuel.
Note: The see-through bowl is re-usable.
To seat the slip ring brushes, position the brushes in
place. Then slide one end of a piece of fine sandpaper 1. Close the fuel shut-off valve.
between slip rings and brushes with the coarse side 2. Drain by opening the self venting drain valve and allow-
against the brushes. With slight additional finger pres- ing all water to escape.
sure on top of the brushes, pull the sandpaper around 3. Close the drain valve and open the fuel shut-off valve.
the circumference of the rings, in direction of rotation
only - until brushes seat properly. In addition, stone Pre-Filter/Water Separator Element:
slip ring with a fine stone. Brushes must be seated 1. Close the fuel shutoff valve located under the fuel tank.
100%. 2. Rotate the quick change ring (located just below filter-
header) clockwise approximately 1/2 turn and slide it
Arcing or excessive exciter brush wear indicates a pos- down and off of the element.
sible misaligned shaft. Have an authorized Field 3. Grasp the element and pull down with a slight rocking
Service Shop check and realign the shaft. motion to remove the element from the grommet post
on the bottom of the filter header.
SAE-400®
D-3 MAINTENANCE D-3

4. Slide the new element onto the grommet post on the

SPARK ARRESTOR
bottom of the filter header until the element no longer
easily moves up into the filter header. Now rotate the WARNING
element (may take almost 1 full turn) with a slight
upward pressure until the element begins to further • Spark Arrester and Muffler may be
engage the header. With the proper orientation now hot!
established apply additional pressure to seat the ele- • Allow engine to cool before servicing
ment in the filter header. You should feel the element spark arrester!
“pop” into place when properly seated. • Do not operate engine while servicing
Note: The element will only go on one way. Never spark arrester!
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.
rotate counter clockwise until an audible click or pop is Service as follows:
heard. If you do not hear the click you have not rotated
the ring far enough and the element is not in the locked 1. Stop engine and allow to cool.
position. Another indication that the ring is in the locked
position is that one set (it doesnʼt matter which one) of 2. Remove clean out plug from side of spark arrester.
arrows located on the outside of the ring should be
located directly under the air vent valve. 3. Without damaging the spark arrester, gently tap on the
arrester shell near the clean out plug.
6. Remove the see-through bowl from the old element
and install on the new element.
4. Once particles are removed, replace the clean out plug.
7. Open the fuel shutoff valve.

8. 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
information on air bleeding the entire fuel system.

ENGINE AND MAINTENANCE COMPONENTS

ITEM MAKE PART NUMBER

Engine Air Filter Donaldson P822768

Fan Belt Perkins 2614B655

Fuel Filter Perkins 26560201

Engine Oil Filter Perkins 2654407

Pre-Filter/Water Lincoln M21584-B

Separator Element Stanadyne 39420 LE

SAE-400®
E-1 TROUBLESHOOTING E-1

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.
__________________________________________________________________________
This Troubleshooting Guide is provided to help you Step 3. RECOMMENDED COURSE OF ACTION
locate and repair possible machine malfunctions. This column provides a course of action for the
Simply follow the three-step procedure listed below. Possible Cause, generally it states to contact your
local Lincoln Authorized Field Service Facility.
Step 1. LOCATE PROBLEM (SYMPTOM).
Look under the column labeled “PROBLEM (SYMP- If you do not understand or are unable to perform the
TOMS)”. This column describes possible symptoms Recommended Course of Action safely, contact your
that the machine may exhibit. Find the listing that best local Lincoln Authorized Field Service Facility.
describes the symptom that the machine is exhibiting.

Step 2. POSSIBLE CAUSE.

The second column labeled “POSSIBLE CAUSE” lists
the obvious external possibilities that may contribute to
the machine symptom.

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.

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®
E-2 TROUBLESHOOTING E-2

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. Replace brushes.
limit of life.

3. Brush springs may be broken. 3. Replace brush springs.

4. Field circuit may have variable 4. Check field current with ammeter
resistance connections or inter- to discover varying current. This
mittent open circuit, due to loose applies to both the main genera-
connections or broken wire. tor and exciter.

5. Electrode or work lead connec- 5. Tighten all connections.

tions may be poor.

6. Wrong grade of brushes may be 6. Use only the recommended

installed on generator. Lincoln brushes.

7. Field rheostat may be making 7. Inspect and clean rheostat.

poor contact and overheating.

8. “Current Control” may not be 8. Check for loose or missing set

operating properly. screw in control handles.

9. “Current Control” brush holder 9. Inspect. Replace needed parts.

contact springs may be worn out Clean internal contact surface of
or missing. Contact surface may control device. Do not lubricate.
be dirty, rough and pitted. Smooth rough surfaces.

10. “Current Control” brush holder 10. If brush holder internal contact
support stud and mating contact surface is pitted and burned,
surfaces may be dirty or pitted replace the brush holder and
and burned. support stud. If the contact sur-
face is dirty, clean off the brush
holder stud and internal contact
surface. Apply mixture of three
parts silicone grease and one
part zinc powder (by weight) to
stud.

11. Engine running at varying 11. Set welder controls for maximum
speeds. output and weld. Then, while
welding, check engine rpm. The
engine should be running at full
speed. If indicator shows a sig-
nificant difference, consult your
engine manual.

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®
E-3 TROUBLESHOOTING E-3

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. be loose or missing. the commutator and have proper
spring tension.

2. Exciter may not be operating. 2. Check exciter output voltage with

voltmeter or lamp.

3. Field circuit of generator or exciter 3. Check for open circuits in rheo-

may be open. stat, field leads and field coils.
Also check resistors.

4. Polarity reversing switch may be 4. Put handle in positive or negative

in the neutral position. position.

5. Exciter may have lost excitation. 5. Check components and continuity

in flashing circuit.

Welding arc is loud and spatters 1. Series field circuit may be open 1. Check circuit with ringer or volt-
excessively. circuited. meter.

2. Current setting may be too high. 2. Check setting and current output
with ammeter.

3. Polarity may be wrong. 3. Check polarity. Try reversing

polarity or try an electrode of the
opposite polarity.

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®
E-4 TROUBLESHOOTING E-4

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 han- 1. With current control against the
small compared to indication on the dle may have turned slightly in minimum stop, set pointer to with-
dial. the insulated bushing of the cur- in 1/8” of the last scale division.
rent control brush holder, caused
by turning handle too hard against
one of the stops.

2. Exciter output low causing low 2. Check for shorts in exciter arma-
output compared to dial indica- ture with growler.
tion.

3. “Current Control” set to minimum 3. Check to see that series field is

and welder output so great that properly connected and not short-
engine stalls when arc is struck. ed.

Welder has output and no control 1. Local/Remote switch is in wrong 1. Place switch in “LOCAL” position
position. to control output at the welder.
Place switch in “REMOTE” posi-
tion to control output remotely.

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®
E-5 TROUBLESHOOTING E-5

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 receptacleʼs current rating.

2. Faulty connections to auxiliary 2. Check connections.

receptacles.

3. RCD tripped. 3. Clear any ground fault and reset

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®
 F-1

SAE-400®
WIRING DIAGRAM

NOTE: This diagram is for reference only. It may not be accurate for all machines covered by this manual. The specific diagram for a particular code is
F-1

pasted inside the machine on one of the enclosure panels.

 F-2

63.06

38.50
23.00 CENTER OF GRAVITY WITH OIL AND
28.00 26.00 WATER IN ENGINE, BUT NO FUEL

47.95 50.13
39.69 43.00

22.00

SAE-400®
6.00

22.00 44.50 8.90

N.B. N.A.
DIMENSION PRINT

22.14 69.75 8.12

N.A.
24.50 77.00 3.00

27.12 81.25 .88

N.B.
83.00

N.A. .81 HOLES

N.B. .69 HOLES

A.02

M8869-39
F-2
 WARNING
l Do not touch electrically live parts or l Keep flammable materials away. l Wear eye, ear and body protection.
electrode with skin or wet clothing.
l Insulate yourself from work and

AVISO DE
ground.
Spanish
l No toque las partes o los electrodos l Mantenga el material combustible l Protéjase los ojos, los oídos y el

PRECAuCION
bajo carga con la piel o ropa moja- fuera del área de trabajo. cuerpo.
da.
l Aislese del trabajo y de la tierra.

French

ATTENTION
l Ne laissez ni la peau ni des vête- l Gardez à l’écart de tout matériel l Protégez vos yeux, vos oreilles et
ments mouillés entrer en contact inflammable. votre corps.
avec des pièces sous tension.
l Isolez-vous du travail et de la terre.

German

WARNuNG
l Berühren Sie keine stromführenden l Entfernen Sie brennbarres Material! l Tragen Sie Augen-, Ohren- und Kör-
Teile oder Elektroden mit Ihrem perschutz!
Körper oder feuchter Kleidung!
l Isolieren Sie sich von den
Elektroden und dem Erdboden!
Portuguese

ATENÇÃO
l Não toque partes elétricas e elec- l Mantenha inflamáveis bem guarda- l Use proteção para a vista, ouvido e
trodos com a pele ou roupa molha- dos. corpo.
da.
l Isole-se da peça e terra.

Japanese

Chinese

Korean

Arabic

READ AND UNDERSTAND THE MANUFACTURER’S INSTRUCTION FOR THIS EQUIPMENT AND THE CONSUMABLES TO BE
USED AND FOLLOW YOUR EMPLOYER’S SAFETY PRACTICES.

SE RECOMIENDA LEER Y ENTENDER LAS INSTRUCCIONES DEL FABRICANTE PARA EL USO DE ESTE EQUIPO Y LOS
CONSUMIBLES QUE VA A UTILIZAR, SIGA LAS MEDIDAS DE SEGURIDAD DE SU SUPERVISOR.

LISEZ ET COMPRENEZ LES INSTRUCTIONS DU FABRICANT EN CE QUI REGARDE CET EQUIPMENT ET LES PRODUITS A
ETRE EMPLOYES ET SUIVEZ LES PROCEDURES DE SECURITE DE VOTRE EMPLOYEUR.

LESEN SIE UND BEFOLGEN SIE DIE BETRIEBSANLEITUNG DER ANLAGE UND DEN ELEKTRODENEINSATZ DES HER-
STELLERS. DIE UNFALLVERHÜTUNGSVORSCHRIFTEN DES ARBEITGEBERS SIND EBENFALLS ZU BEACHTEN.
 WARNING
l Keep your head out of fumes. l Turn power off before servicing. l Do not operate with panel open or
l Use ventilation or exhaust to guards off.
remove fumes from breathing zone.

AVISO DE
l Los humos fuera de la zona de res- Spanish
l Desconectar el cable de ali- l No operar con panel abierto o

PRECAuCION
piración. mentación de poder de la máquina guardas quitadas.
l Mantenga la cabeza fuera de los antes de iniciar cualquier servicio.
humos. Utilice ventilación o
aspiración para gases.
French

ATTENTION
l Gardez la tête à l’écart des fumées. l Débranchez le courant avant l’entre- l N’opérez pas avec les panneaux
l Utilisez un ventilateur ou un aspira- tien. ouverts ou avec les dispositifs de
teur pour ôter les fumées des zones protection enlevés.
de travail.

German

WARNuNG
l Vermeiden Sie das Einatmen von l Strom vor Wartungsarbeiten l Anlage nie ohne Schutzgehäuse
Schweibrauch! abschalten! (Netzstrom völlig öff- oder Innenschutzverkleidung in
l Sorgen Sie für gute Be- und nen; Maschine anhalten!) Betrieb setzen!
Entlüftung des Arbeitsplatzes!

Portuguese

ATENÇÃO
l Mantenha seu rosto da fumaça. l Não opere com as tampas removidas. l Mantenha-se afastado das partes
l Use ventilação e exhaustão para l Desligue a corrente antes de fazer moventes.
remover fumo da zona respiratória. serviço. l Não opere com os paineis abertos
l Não toque as partes elétricas nuas. ou guardas removidas.

Japanese

Chinese

Korean

Arabic

LEIA E COMPREENDA AS INSTRUÇÕES DO FABRICANTE PARA ESTE EQUIPAMENTO E AS PARTES DE USO, E SIGA AS
PRÁTICAS DE SEGURANÇA DO EMPREGADOR.
CUSTOMER ASSISTANCE POLICY
The business of The Lincoln Electric Company is manufacturing and
selling high quality welding equipment, consumables, and cutting
equipment. Our challenge is to meet the needs of our customers and
to exceed their expectations. On occasion, purchasers may ask
Lincoln Electric for advice or information about their use of our
products. We respond to our customers based on the best information
in our possession at that time. Lincoln Electric is not in a position to
warrant or guarantee such advice, and assumes no liability, with
respect to such information or advice. We expressly disclaim any
warranty of any kind, including any warranty of fitness for any
customer’s particular purpose, with respect to such information or
advice. As a matter of practical consideration, we also cannot assume
any responsibility for updating or correcting any such information or
advice once it has been given, nor does the provision of information or
advice create, expand or alter any warranty with respect to the sale of
our products.
Lincoln Electric is a responsive manufacturer, but the selection and
use of specific products sold by Lincoln Electric is solely within the
control of, and remains the sole responsibility of the customer. Many
variables beyond the control of Lincoln Electric affect the results
obtained in applying these types of fabrication methods and service
requirements.
Subject to Change – This information is accurate to the best of our
knowledge at the time of printing. Please refer to
www.lincolnelectric.com for any updated information.