Lincoln Electric Welding System IM869 D User Manual
RETURN TO MAIN MENU  
IM869-D  
May, 2008  
SAE-400 DC ARC WELDING POWER SOURCE  
For use with machines having Code Numbers: 11198, 11322, 11407, 11409,11509  
Safety Depends on You  
Lincoln arc welding and cutting  
equipment is designed and built  
with safety in mind. However, your  
overall safety can be increased by  
proper installation ... and thoughtful  
operation on your part. DO NOT  
INSTALL, OPERATE OR REPAIR  
THIS EQUIPMENT WITHOUT  
READING THIS MANUAL AND  
THE SAFETY PRECAUTIONS  
CONTAINED  
THROUGHOUT.  
And, most importantly, think before  
you act and be careful.  
OPERATORʼS MANUAL  
Copyright © Lincoln Global Inc.  
• World's Leader in Welding and Cutting Products •  
• Sales and Service through Subsidiaries and Distributors Worldwide •  
Cleveland, Ohio 44117-1199 U.S.A. TEL: 216.481.8100 FAX: 216.486.1751 WEB SITE: www.lincolnelectric.com  
Download from Www.Somanuals.com. All Manuals Search And Download.  
ii  
ii  
SAFETY  
ARC RAYS can burn.  
ELECTRIC SHOCK can kill.  
4.a. Use a shield with the proper filter and cover  
plates to protect your eyes from sparks and  
the rays of the arc when welding or observing  
open arc welding. Headshield and filter lens  
should conform to ANSI Z87. I standards.  
3.a. The electrode and work (or ground) circuits  
are electrically “hot” when the welder is on.  
Do not touch these “hot” parts with your bare  
skin or wet clothing. Wear dry, hole-free  
gloves to insulate hands.  
4.b. Use suitable clothing made from durable flame-resistant  
material to protect your skin and that of your helpers from  
the arc rays.  
3.b. Insulate yourself from work and ground using dry insulation.  
Make certain the insulation is large enough to cover your full  
area of physical contact with work and ground.  
4.c. Protect other nearby personnel with suitable, non-flammable  
screening and/or warn them not to watch the arc nor expose  
themselves to the arc rays or to hot spatter or metal.  
In addition to the normal safety precautions, if welding  
must be performed under electrically hazardous  
conditions (in damp locations or while wearing wet  
clothing; on metal structures such as floors, gratings or  
scaffolds; when in cramped positions such as sitting,  
kneeling or lying, if there is a high risk of unavoidable or  
accidental contact with the workpiece or ground) use  
the following equipment:  
FUMES AND GASES  
can be dangerous.  
• Semiautomatic DC Constant Voltage (Wire) Welder.  
• DC Manual (Stick) Welder.  
5.a. Welding may produce fumes and gases  
hazardous to health. Avoid breathing these  
• AC Welder with Reduced Voltage Control.  
fumes and gases.When welding, keep  
your head out of the fume. Use enough  
3.c. In semiautomatic or automatic wire welding, the electrode,  
electrode reel, welding head, nozzle or semiautomatic  
welding gun are also electrically “hot”.  
ventilation and/or exhaust at the arc to keep  
fumes and gases away from the breathing zone. When  
welding with electrodes which require special  
ventilation such as stainless or hard facing (see  
instructions on container or MSDS) or on lead or  
cadmium plated steel and other metals or coatings  
which produce highly toxic fumes, keep exposure as  
low as possible and below Threshold Limit Values (TLV)  
using local exhaust or mechanical ventilation. In  
confined spaces or in some circumstances, outdoors, a  
respirator may be required. Additional precautions are  
also required when welding on galvanized steel.  
3.d. Always be sure the work cable makes a good electrical  
connection with the metal being welded. The connection  
should be as close as possible to the area being welded.  
3.e. Ground the work or metal to be welded to a good electrical  
(earth) ground.  
3.f. Maintain the electrode holder, work clamp, welding cable and  
welding machine in good, safe operating condition. Replace  
damaged insulation.  
5. b. The operation of welding fume control equipment is affected  
by various factors including proper use and positioning of the  
equipment, maintenance of the equipment and the specific  
welding procedure and application involved. Worker expo-  
sure level should be checked upon installation and periodi-  
cally thereafter to be certain it is within applicable OSHA PEL  
and ACGIH TLV limits.  
3.g. Never dip the electrode in water for cooling.  
3.h. Never simultaneously touch electrically “hot” parts of  
electrode holders connected to two welders because voltage  
between the two can be the total of the open circuit voltage  
of both welders.  
5.c. Do not weld in locations near chlorinated hydrocarbon vapors  
coming from degreasing, cleaning or spraying operations.  
The heat and rays of the arc can react with solvent vapors to  
form phosgene, a highly toxic gas, and other irritating prod-  
ucts.  
3.i. When working above floor level, use a safety belt to protect  
yourself from a fall should you get a shock.  
3.j. Also see Items 6.c. and 8.  
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 manufacturerʼs instructions for this  
equipment and the consumables to be used, including the  
material safety data sheet (MSDS) and follow your  
employerʼs safety practices. MSDS forms are available from  
your welding distributor or from the manufacturer.  
5.f. Also see item 1.b.  
AUG 06  
Download from Www.Somanuals.com. All Manuals Search And Download.  
iii  
iii  
SAFETY  
CYLINDER may explode  
if damaged.  
WELDING and CUTTING  
SPARKS can  
7.a. Use only compressed gas cylinders  
containing the correct shielding gas for the  
cause fire or explosion.  
6.a. Remove fire hazards from the welding area.  
If this is not possible, cover them to prevent  
the welding sparks from starting a fire.  
process used and properly operating  
regulators designed for the gas and  
pressure used. All hoses, fittings, etc. should be suitable for  
the application and maintained in good condition.  
Remember  
that  
welding  
sparks  
and  
hot  
materials from welding can easily go through small cracks  
and openings to adjacent areas. Avoid welding near  
hydraulic lines. Have a fire extinguisher readily available.  
7.b. Always keep cylinders in an upright position securely  
chained to an undercarriage or fixed support.  
6.b. Where compressed gases are to be used at the job site,  
special precautions should be used to prevent hazardous  
situations. Refer to “Safety in Welding and Cutting” (ANSI  
Standard Z49.1) and the operating information for the  
equipment being used.  
7.c. Cylinders should be located:  
•Away from areas where they may be struck or subjected to  
physical damage.  
•A safe distance from arc welding or cutting operations and  
any other source of heat, sparks, or flame.  
6.c. When not welding, make certain no part of the electrode  
circuit is touching the work or ground. Accidental contact can  
cause overheating and create a fire hazard.  
7.d. Never allow the electrode, electrode holder or any other  
electrically “hot” parts to touch a cylinder.  
6.d. Do not heat, cut or weld tanks, drums or containers until the  
proper steps have been taken to insure that such procedures  
will not cause flammable or toxic vapors from substances  
inside. They can cause an explosion even though they have  
been “cleaned”. For information, purchase “Recommended  
Safe Practices for the Preparation for Welding and Cutting of  
Containers and Piping That Have Held Hazardous  
Substances”, AWS F4.1 from the American Welding Society  
(see address above).  
7.e. Keep your head and face away from the cylinder valve outlet  
when opening the cylinder valve.  
7.f. Valve protection caps should always be in place and hand  
tight except when the cylinder is in use or connected for  
use.  
7.g. Read and follow the instructions on compressed gas  
cylinders, associated equipment, and CGA publication P-l,  
“Precautions for Safe Handling of Compressed Gases in  
Cylinders,” available from the Compressed Gas Association  
1235 Jefferson Davis Highway, Arlington, VA 22202.  
6.e. Vent hollow castings or containers before heating, cutting or  
welding. They may explode.  
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  
powered equipment.  
8.a. Turn off input power using the disconnect  
switch at the fuse box before working on  
the equipment.  
6.g. Connect the work cable to the work as close to the welding  
area as practical. Work cables connected to the building  
framework or other locations away from the welding area  
increase the possibility of the welding current passing  
through lifting chains, crane cables or other alternate circuits.  
This can create fire hazards or overheat lifting chains or  
cables until they fail.  
8.b. Install equipment in accordance with the U.S. National  
Electrical Code, all local codes and the manufacturerʼs  
recommendations.  
8.c. Ground the equipment in accordance with the U.S. National  
Electrical Code and the manufacturerʼs recommendations.  
6.h. Also see item 1.c.  
6.I. Read and folllow NFPA 51B “ Standard for Fire Prevention  
During Welding, Cutting and Other Hot Work”, available from  
NFPA, 1 Batterymarch Park,PO box 9101, Quincy, Ma  
022690-9101.  
Jan, 07  
6.j. Do not use a welding power source for pipe thawing.  
Download from Www.Somanuals.com. All Manuals Search And Download.  
iv  
iv  
SAFETY  
6. Eloigner les matériaux inflammables ou les recouvrir afin de  
PRÉCAUTIONS DE SÛRETÉ  
prévenir tout risque dʼincendie dû aux étincelles.  
Pour votre propre protection lire et observer toutes les instructions  
et les précautions de sûreté specifiques qui parraissent dans ce  
manuel aussi bien que les précautions de sûreté générales suiv-  
antes:  
7. Quand on ne soude pas, poser la pince à une endroit isolé de  
la masse. Un court-circuit accidental peut provoquer un  
échauffement et un risque dʼincendie.  
8. Sʼassurer que la masse est connectée le plus prés possible de  
la zone de travail quʼil est pratique de le faire. Si on place la  
masse sur la charpente de la construction ou dʼautres endroits  
éloignés de la zone de travail, on augmente le risque de voir  
passer le courant de soudage par les chaines de levage,  
câbles de grue, ou autres circuits. Cela peut provoquer des  
risques dʼincendie ou dʼechauffement des chaines et des  
câbles jusquʼà ce quʼils se rompent.  
Sûreté Pour Soudage A LʼArc  
1. Protegez-vous contre la secousse électrique:  
a. Les circuits à lʼélectrode et à la piéce sont sous tension  
quand la machine à souder est en marche. Eviter toujours  
tout contact entre les parties sous tension et la peau nue  
ou les vétements mouillés. Porter des gants secs et sans  
trous pour isoler les mains.  
b. Faire trés attention de bien sʼisoler de la masse quand on  
soude dans des endroits humides, ou sur un plancher met-  
allique ou des grilles metalliques, principalement dans  
les positions assis ou couché pour lesquelles une grande  
partie du corps peut être en contact avec la masse.  
c. Maintenir le porte-électrode, la pince de masse, le câble de  
soudage et la machine à souder en bon et sûr état defonc-  
tionnement.  
9. Assurer une ventilation suffisante dans la zone de soudage.  
Ceci est particuliérement important pour le soudage de tôles  
galvanisées plombées, ou cadmiées ou tout autre métal qui  
produit des fumeés toxiques.  
10. Ne pas souder en présence de vapeurs de chlore provenant  
dʼopérations de dégraissage, nettoyage ou pistolage. La  
chaleur ou les rayons de lʼarc peuvent réagir avec les vapeurs  
du solvant pour produire du phosgéne (gas fortement toxique)  
ou autres produits irritants.  
d.Ne jamais plonger le porte-électrode dans lʼeau pour le  
refroidir.  
e. Ne jamais toucher simultanément les parties sous tension  
des porte-électrodes connectés à deux machines à souder  
parce que la tension entre les deux pinces peut être le total  
de la tension à vide des deux machines.  
f. Si on utilise la machine à souder comme une source de  
courant pour soudage semi-automatique, ces precautions  
pour le porte-électrode sʼapplicuent aussi au pistolet de  
soudage.  
11. Pour obtenir de plus amples renseignements sur la sûreté, voir  
le code “Code for safety in welding and cutting” CSA Standard  
W 117.2-1974.  
PRÉCAUTIONS DE SÛRETÉ POUR  
LES MACHINES À SOUDER À  
TRANSFORMATEUR ET À  
REDRESSEUR  
2. Dans le cas de travail au dessus du niveau du sol, se protéger  
contre les chutes dans le cas ou on recoit un choc. Ne jamais  
enrouler le câble-électrode autour de nʼimporte quelle partie du  
corps.  
3. Un coup dʼarc peut être plus sévère quʼun coup de soliel, donc:  
a. Utiliser un bon masque avec un verre filtrant approprié ainsi  
quʼun verre blanc afin de se protéger les yeux du rayon-  
nement de lʼarc et des projections quand on soude ou  
quand on regarde lʼarc.  
b. Porter des vêtements convenables afin de protéger la peau  
de soudeur et des aides contre le rayonnement de lʻarc.  
c. Protéger lʼautre personnel travaillant à proximité au  
soudage à lʼaide dʼécrans appropriés et non-inflammables.  
1. Relier à la terre le chassis du poste conformement au code de  
lʼélectricité et aux recommendations du fabricant. Le dispositif  
de montage ou la piece à souder doit être branché à une  
bonne mise à la terre.  
2. Autant que possible, Iʼinstallation et lʼentretien du poste seront  
effectués par un électricien qualifié.  
3. Avant de faires des travaux à lʼinterieur de poste, la debranch-  
er à lʼinterrupteur à la boite de fusibles.  
4. Des gouttes de laitier en fusion sont émises de lʼarc de  
soudage. Se protéger avec des vêtements de protection libres  
de lʼhuile, tels que les gants en cuir, chemise épaisse, pan-  
talons sans revers, et chaussures montantes.  
4. Garder tous les couvercles et dispositifs de sûreté à leur place.  
Mar. ʻ93  
5. Toujours porter des lunettes de sécurité dans la zone de  
soudage. Utiliser des lunettes avec écrans lateraux dans les  
zones où lʼon pique le laitier.  
Download from Www.Somanuals.com. All Manuals Search And Download.  
v
v
for selecting a QUALITY product by Lincoln Electric. We want you  
to take pride in operating this Lincoln Electric Company product •••  
as much pride as we have in bringing this product to you!  
Thank You  
CUSTOMER ASSISTANCE POLICY  
The business of The Lincoln Electric Company is manufacturing and selling high quality welding equipment, consumables, and cutting equip-  
ment. 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 customerʼs 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.  
Please Examine Carton and Equipment For Damage Immediately  
When this equipment is shipped, title passes to the purchaser upon receipt by the carrier. Consequently, Claims  
for material damaged in shipment must be made by the purchaser against the transportation company at the time  
the shipment is received.  
Please record your equipment identification information below for future reference. This information can be found  
on your machine nameplate.  
Product _________________________________________________________________________________  
Model Number ___________________________________________________________________________  
Code Number or Date Code_________________________________________________________________  
Serial Number____________________________________________________________________________  
Date Purchased___________________________________________________________________________  
Where Purchased_________________________________________________________________________  
Whenever you request replacement parts or information on this equipment, always supply the information you  
have recorded above. The code number is especially important when identifying the correct replacement parts.  
On-Line Product Registration  
- Register your machine with Lincoln Electric either via fax or over the Internet.  
• For faxing: Complete the form on the back of the warranty statement included in the literature packet  
accompanying this machine and fax the form per the instructions printed on it.  
• For On-Line Registration: Go to our WEB SITE at www.lincolnelectric.com. Choose “Quick Links” and then  
“Product Registration”. Please complete the form and submit your registration.  
Read this Operators Manual completely before attempting to use this equipment. Save this manual and keep it  
handy for quick reference. Pay particular attention to the safety instructions we have provided for your protection.  
The level of seriousness to be applied to each is explained below:  
WARNING  
This statement appears where the information must be followed exactly to avoid serious personal injury or loss of life.  
CAUTION  
This statement appears where the information must be followed to avoid minor personal injury or damage to this equipment.  
Download from Www.Somanuals.com. All Manuals Search And Download.  
vi  
vi  
TABLE OF CONTENTS  
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 and Compressor Service . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .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  
Product Application . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .B-2  
Design Features and Advantages . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .B-2  
Duty Cycle . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .B-2  
Engine Controls: Function/Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . B-3  
Welder Controls: Function/Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . B-3  
Remote Control . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .B-4  
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  
Water Separator Element . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .D-3  
Engine Maintenance Components . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .D-4  
Spark Arrester . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .D-4  
GFCI Receptacle Testing and Resetting Procedure (Accessory Kit Only) . . . . . . . . . . .D-4  
_____________________________________________________________________________________  
Troubleshooting Guide . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Section E  
_____________________________________________________________________________________  
Wiring Diagram and Dimension Print . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Section F  
____________________________________________________________________________________  
Parts List . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .P-530  
____________________________________________________________________________________  
SAE-400  
Download from Www.Somanuals.com. All Manuals Search And Download.  
A-1  
A-1  
INSTALLATION  
TECHNICAL SPECIFICATIONS - SAE-400 (K1278-7, K1278-9)  
INPUT - DIESEL ENGINE  
Make/Model  
Description  
Speed (RPM)  
Displacement  
Starting  
System  
Capacities  
K1278-7  
Perkins  
4 cylinder  
68.4 HP @  
1725 RPM  
High Idle 1800  
Low Idle 1100  
Full Load 1725  
269 cu. in  
(4.4 L)  
12VDC batteries Fuel: 22.5 gal.  
1104C-44 Diesel  
Engine  
(2) & Starter  
85.1 L  
EPA Tier II  
Compliant  
Bore x Stroke  
Oil: 10.1 Qts.  
9.6 L  
K1278-9  
Perkins  
4 cylinder  
64.4 HP @  
1710 RPM  
4.13” x 5.00”  
1104A-44 Diesel  
Engine  
(105.0 mm x 127.0mm)  
Coolant: 3.4 gal.  
12.8 L  
Not EPA Tier II  
Compliant  
(Export Only)  
RATED OUTPUT - WELDER  
(1)  
Duty Cycle  
Welding Output  
Volts at Rated Amps  
35% (NEMA)  
100% (NEMA)  
500 amps  
40 volts  
36 volts  
40 volts  
400 amps  
100% (Lincoln Plus)  
400 amps  
OUTPUT - WELDER AND GENERATOR  
Welding Range  
Open Circuit Voltage  
Auxiliary Power  
80 - 575 Amps  
97 Max. OCV  
@ 1800 RPM  
115/230 VAC  
3000 Watts, 60 Hz.  
100% Duty Cycle  
PHYSICAL DIMENSIONS  
HEIGHT  
50.13 in.  
WIDTH  
DEPTH  
WEIGHT  
28.00 in.  
83.00 in.  
2108.2 mm  
2157lbs.  
978.4kg  
1273.3 mm  
711.2 mm  
(1) Based on a 10 minute period.  
SAE-400  
Download from Www.Somanuals.com. All Manuals Search And Download.  
A-2  
A-2  
INSTALLATION  
Read this entire installation section before you  
start installation.  
CAUTION  
SAFETY PRECAUTIONS  
WARNING  
Do not attempt to use this equipment until you have  
thoroughly read all operating and maintenance man-  
uals supplied with your machine. They include impor-  
tant safety precautions, detailed engine starting,  
operating and maintenance instructions and parts  
lists.  
DO NOT MOUNT OVER COMBUSTIBLE SURFACES  
Where there is a combustible surface directly under  
stationary or fixed electrical equipment, that surface  
should be covered with a steel plate at least  
.06”(1.6mm) thick, which should extend not less than  
5.90(150mm) beyond the equipment on all sides.  
-----------------------------------------------------------------------  
STACKING  
These machines cannot be stacked.  
ELECTRIC SHOCK can kill.  
ANGLE OF OPERATION  
•Do not touch electrically live parts such  
as output terminals or internal wiring.  
To achieve optimum engine performance the machine  
should be run in a level position. The maximum angle  
of operation for the Perkins engine is 30 degrees in all  
directions. If the engine is to be operated at an angle,  
provisions must be made for checking and maintaining  
the oil level at the normal (FULL) oil capacity in the  
engine crankcase. When operating the welder at an  
angle, the effective fuel capacity will be slightly less  
than the specified 22.5 gallons.  
•Insulate yourself from the work and  
ground.  
•Always wear dry insulating gloves.  
------------------------------------------------------------------------  
ENGINE EXHAUST can kill.  
•Use in open, well ventilated areas or  
vent exhaust outside  
LIFTING  
The equipment lift bail should be used to lift the  
machine.  
•Do not stack anything near the engine.  
------------------------------------------------------------------------  
MOVING PARTS can injure.  
WARNING  
•Do not operate with doors open or  
guards off.  
• Lift only with equipment of adequate  
lifting capacity.  
• Be sure machine is stable when lift-  
•Stop engine before servicing.  
ing.  
•Keep away from moving parts  
------------------------------------------------------------------------  
Only qualified personnel should install, use or service  
this equipment  
• Do not lift this machine using lift bail if it is  
equipped with a heavy accessory such as a trail-  
er or gas cylinder.  
FALLING  
EQUIPMENT can damaged.  
cause injury. • Do not operate machine while  
suspended from lift bail.  
------------------------------------------------------------------------  
• Do not lift machine if lift bail is  
LOCATION/VENTILATION  
The welder should be located to provide an unrestricted  
flow of clean, cool air to the cooling air inlets and to avoid  
restricting the cooling air outlets. Also, locate the welder  
so that the engine exhaust fumes are properly vented to  
an outside area.  
SAE-400  
Download from Www.Somanuals.com. All Manuals Search And Download.  
A-3  
A-3  
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.).  
WARNING  
Improperly mounted concentrated loads may cause  
unstable vehicle handling and tires or other compo-  
nents to fail.  
Contact a Perkins Service Representative for any  
engine adjustments that may be required for high alti-  
tude operation.  
• Only transport this equipment on serviceable vehi-  
cles which are rated and designed for such loads.  
• Distribute, balance and secure loads so vehicle is  
stable under conditions of use.  
• Do not exceed maximum rated loads for compo-  
nents such as suspension, axles and tires.  
• Mount equipment base to metal bed or frame of  
vehicle.  
TOWING  
The recommended trailers for use with this equipment  
for in-plant and yard towing by a vehicle(1) are Lincolnʼs  
K767-1 and K956-1. The K956-1 is also designed to be  
• Follow vehicle manufacturerʼs instruction.  
-P--R----E-----O----P--E---R----A---T--I-O----N----E---N----G---I-N---E-----S---E---R---V---I-C---E---  
(1)  
used at highway speeds .If the user adapts a non-  
Lincoln trailer, he must assume responsibility that the  
method of attachment and usage does not result in a  
safety hazard nor damage the welding equipment.  
Some of the factors to be considered are as follows:  
READ the engine operating and maintenance instruc-  
tions supplied with this machine.  
ENGINE OIL  
1. Design capacity of trailer vs. weight of Lincoln  
equipment and likely additional attachments.  
The engine is shipped with the engine crankcase filled  
with high quality SAE 10W-30 oil (API class CD or bet-  
ter). Check the oil level before starting the engine. If it is  
not up to the full mark on the dip stick, add oil as required.  
Check the oil level every four hours of running time during  
the first 35 running hours. Refer to the engine Operatorʼs  
Manual for specific oil recommendations and break-in  
information. The oil change interval is dependent on the  
quality of the oil and the operating environment. Refer to  
the engine Operatorʼs Manual for the proper service and  
maintenance intervals.  
2. Proper support of, and attachment to, the base of  
the welding equipment so that there will be no  
undue stress to the trailerʼs framework.  
3. Proper placement of the equipment on the trailer to  
insure stability side to side and front to back when  
being moved and when standing by itself.  
4. Typical conditions of use, such as travel speed,  
roughness of surface on which the trailer will be  
operated, and environmental conditions.  
5. Proper preventative maintenance of trailer.  
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  
Download from Www.Somanuals.com. All Manuals Search And Download.  
A-4  
A-4  
INSTALLATION  
WARNING  
• Stop engine while fueling.  
• Do not smoke when fueling.  
• Keep sparks and flame away from  
tank.  
• Do not leave unattended while  
fueling.  
1. Connect the welder output studs to a suitable resis-  
tive load bank. Note that any attempt to short the  
output studs by connecting the welding leads  
together, direct shorting of the output studs, or con-  
necting the output leads to a length of steel will  
result in catastrophic damage to the generator and  
voids the warranty.  
• Wipe up spilled fuel and allow  
fumes to clear before starting  
engine.  
DIESEL FUEL  
can cause fire.  
• Do not overfill tank, fuel  
expansion may cause over-  
flow.  
2. Set the welder controls for an output current and  
voltage within the welder rating and duty cycle.  
Note that any attempt to exceed the welder rating or  
duty cycle for any period of time will result in cata-  
strophic damage to the generator and voids the  
warranty.  
DIESEL FUEL ONLY  
------------------------------------------------------------------------  
Fill the fuel tank with clean, fresh diesel fuel.  
The capacity of the fuel tank is 22.5 gallons (85.1 liters).  
See engine Operatorʼs Manual for specific fuel recom-  
mendations.  
3. Periodically shut off the engine and check the  
crankcase oil level.  
Note: Before starting the engine, be sure the fuel shut-  
off valve is in the open position.  
WARNING  
BATTERY CONNECTION  
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  
water. Check the radiator level and add a 50-50 solu-  
tion as needed. (See Engine Manual or antifreeze  
container for alternate antifreeze recommendation.)  
Remove and discard the insulating caps from the  
negative  
battery  
terminals.  
Attach and tighten negative battery cable termi-  
nals.  
ENGINE BREAK-IN PERIOD  
NOTE: This machine is furnished with wet charged  
batteries; if unused for several months, the batteries  
Lincoln Electric selects high quality, heavy-duty indus-  
trial engines for the portable welding machines we  
offer. While it is normal to see a small amount of  
crankcase oil consumption during initial operation,  
excessive oil use, wet stacking (oil or tar like substance  
at the exhaust port), or excessive smoke is not normal.  
WARNING  
may require a booster charge. Be careful  
to charge the batteries with the correct  
polarity. Make sure that the batteries are  
level while charging.  
Larger machines with a capacity of 350 amperes and  
higher, which are operated at low or no-load conditions  
for extended periods of time are especially susceptible  
GASES FROM BATTERY can explode.  
● Keep sparks, flame and cigarettes away from  
battery.  
to  
the  
conditions  
described  
above.  
-----------------------------------------------------------------------  
To accomplish successful engine break-in, most  
diesel-powered equipment needs only to be run at a  
reasonably heavy load within the rating of the welder  
for some period of time during the engineʼs early life.  
However, if the welder is subjected to extensive light  
loading, occasional moderate to heavy loading of the  
engine may sometimes be necessary. Caution must  
be observed in correctly loading a diesel/generator  
unit.  
To prevent EXPLOSION when:  
● INSTALLING A NEW BATTERY — disconnect  
negative cable from old battery first and  
connect to new battery last.  
● CONNECTING A BATTERY CHARGER —  
remove battery from welder by disconnecting  
negative cable first, then positive cable and  
battery clamp. When reinstalling, connect  
SAE-400  
Download from Www.Somanuals.com. All Manuals Search And Download.  
A-5  
A-5  
INSTALLATION  
negative cable last. Keep well ven-  
tilated.  
WELDING OUTPUT CABLES  
With the engine off, connect the electrode and work  
cables to the studs provided. These connections  
should be checked periodically and tightened if neces-  
sary.  
● USING A BOOSTER — connect  
positive lead to battery first then  
connect negative lead to negative  
battery lead at the lower control  
panel support.  
Listed in Table A.1 are copper cable sizes recom-  
mended for the rated current and duty cycle. Lengths  
stipulated are the distance from the welder to work and  
back to the welder again. Cable sizes are increased  
for greater lengths primarily for the purpose of mini-  
mizing cable voltage drop.  
BATTERY ACID can burn eyes and skin.  
● Wear gloves and eye protection and be careful  
when working near battery.  
● Follow instructions printed on battery.  
IMPORTANT: To prevent ELECTRICAL DAMAGE  
Table A.1 Combined Length of Electrode and  
Work Cables.  
WHEN:  
a) Installing new batteries.  
TOTAL COMBINED LENGTH OF ELEC-  
TRODE AND WORK CABLES  
WARNING  
AMPS  
@60%  
Up to 100FT. 100-200FT. 200-250FT.  
b)  
Using a booster.  
Up to 31m  
31-61m  
61-76m  
Duty Cycle  
Use correct polarity — Negative Ground.  
To prevent BATTERY BUCKLING, tighten  
nuts on batteries only until snug. DO NOT  
400  
2/0 AWG  
3/0 AWG  
4/0 AWG  
OVERTIGHTEN.  
• Spark Arrester and Muffler may be  
MACHINE GROUNDING  
hot!  
• Allow engine to cool before servicing spark  
arrester!  
Because this portable engine driven welder creates its  
own power, it is not necessary to connect its frame to  
an earth ground, unless the machine is connected to  
premises wiring (home, shop, etc.).  
• Do not operate engine while servicing spark  
arrester!  
------------------------------------------------------------------------  
SPARK ARRESTER  
To prevent dangerous electric shock, other equipment  
powered by this engine driven welder must:  
Some federal, state or local laws may require that  
gasoline or diesel engines be equipped with exhaust  
spark arresters when they are operated in certain loca-  
tions where unarrested sparks may present a fire haz-  
ard. The muffler included with this welder has been  
a) be grounded to the frame of the welder using a  
grounded type plug,  
or  
b) be double insulated.  
When this welder is mounted on a truck or trailer, its  
frame must be securely connected to the metal frame  
of the vehicle. When this engine driven welder is con-  
nected to premises wiring such as that in a home or  
shop, its frame must be connected to the system earth  
ground. See the article on grounding in the latest U.S.  
National Electrical Code and the local code.  
CAUTION  
modified and now qualifies as a spark arrester. Spark  
arresting mufflers will have a clean out service plug  
and will have “USDA FS 5100-1c QUALIFIED SPARK  
ARRESTER” stamped on the muffler shell. Any spark  
arrester must be serviced and properly maintained.  
An incorrect arrester may lead to damage to the  
engine or adversely affect performance.  
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  
Download from Www.Somanuals.com. All Manuals Search And Download.  
B-1  
B-1  
OPERATION  
OPERATING INSTRUCTIONS  
both, to keep the fumes and gases  
from your breathing zone and general  
area.  
Read and understand this entire section before operat-  
ing your equipment.  
SAFETY INSTRUCTIONS  
WARNING  
WELDING SPARKS can cause fire or  
explosion.  
Do not attempt to use this equipment until you have  
thoroughly read all operating and maintenance manu-  
als supplied with your machine. They include important  
safety precautions, detailed engine starting, operating  
and maintenance instructions and parts lists.  
• Do not weld near flammable material  
.
• Do not weld on containers that have  
held flammable material.  
-----------------------------------------------------------  
MOVING PARTS can injure.  
ELECTRIC SHOCK can kill.  
• Do not touch electrically live parts or  
electrodes with your skin or wet cloth-  
ing.  
• Keep away from moving parts  
• Do not operate with doors open or  
guards off.  
• Stop engine before servicing.  
------------------------------------------------------------------------  
ENGINE EXHAUST can kill.  
• Insulate yourself from the work and  
ground.  
• Always wear dry insulating gloves.  
• Do not use AC welder if your clothing, gloves or  
work area is damp or if working on, under or  
inside workpiece.  
• Use in open, well ventilated areas or  
vent exhaust outside.  
------------------------------------------------------------------------  
Use the following equipment:  
• Semiautomatic DC constant voltage (wire)  
welder.  
ADDITIONAL SAFETY PRECAUTIONS  
• DC manual (stick) welder.  
Always operate the welder with the hinged doors  
closed as these provide maximum protection from  
moving parts and insure proper cooling air flow.  
• AC welder with reduced voltage control.  
------------------------------------------------------  
------------------  
ARC RAYS can injure eyes and  
Read carefully the Safety Precautions page in the  
Instruction Manual before operating this machine.  
Always follow these and any other safety procedures  
included in this manual and in the engine instruction  
manuals.  
burn skin.  
• Wear eye, ear, and body protection.  
----------------------------------------------------------  
• Only qualified personnel should install, use or  
service this equipment.  
GENERAL DESCRIPTION  
• Consult instruction manual before operating.  
----------------------------------------------------------------------  
Before operating, read and understand the manu-  
facurerʼs instructions for this equipment and the  
consumables to be used including the Material  
Safety Data Sheet (MSDS) and follow your  
employerʼs safety practices.  
The SAE-400 is a diesel engine driven welding power  
source. The machine uses a DC generator for DC stick  
electrode welding and an AC exciter for 115/230 VAC  
auxiliary power. As a generator it can supply up to  
3,000 watts of 115/230 volt AC power. As a welder it  
provides up to 575 amps of DC constant current out-  
put.  
-----------------------------------------------------  
-------------------  
The engine 1104C-44 is a 68.4 Hp @ 1725 RPM  
(51kw), 4-cylinder water cooled diesel made by  
Perkins.  
FUMES AND GASES can be  
dangerous to your health.  
• Keep your head out of fumes.  
The engine 1104A-44 is a 64.4 Hp @ 1710 RPM  
(48kw), 4-cylinder water cooled diesel made by  
Perkins.  
• Use enough ventilation or exhaust at the arc, or  
SAE-400  
Download from Www.Somanuals.com. All Manuals Search And Download.  
B-2  
B-2  
OPERATION  
RECOMMENDED APPLICATIONS  
OTHER FEATURES  
WELDER  
• Perkins 4-cylinder, water cooled diesel engine.  
Designed for long life, easy maintenance and excel-  
lent fuel economy.  
The SAE-400 provides excellent constant current DC  
welding output for stick (SMAW) welding. The field  
installed optional CV Adapter (K385-[ ]) provides up to  
500 amps at 35 volts of constant voltage output for  
semiautomatic welding.  
• Engine protection system shuts the engine down for  
low engine oil pressure or high coolant temperature.  
• Electronic Engine Idler. Engine automatically goes  
to low idle in 10 to 14 seconds after welding or use  
of auxiliary power stops. Includes high idle switch.  
• Gauges for engine oil pressure, coolant temperature  
and battery charging ammeter.  
AUXILIARY POWER  
The SAE-400 provides 3 KW of 115/230 VAC output  
for auxiliary power and emergency standby power.  
• Engine hour meter standard.  
DESIGN FEATURES AND ADVANTAGES  
• Extended range 22.5 gallon (85.1 L) fuel tank.  
FOR STICK WELDING  
DUTY CYCLE  
• Excellent DC constant current output for stick weld-  
ing applications.  
Duty cycle is the percentage of time the load is being  
applied in a 10 minute period. For example a 60% duty  
cycle, represents 6 minutes of load and 4 minutes of  
no load in a 10 minute period.  
• Continuous adjustment of both voltage and current  
for unsurpassed welds on demanding jobs.  
• Remote control capability standard.  
FOR AUXILIARY POWER  
• 3,000 watts of 115/230 VAC, 60 Hz auxiliary power.  
• One 20 amp 115 VAC duplex receptacle for up to 26  
amps of 115 VAC power.  
• One 15 amp, 230 VAC duplex receptacle for up to 13  
amps of 230 VAC power.  
• Weld and AC auxiliary power at the same time (with-  
in the limits shown on the chart below).  
Welding  
Using Only  
Using Only  
230V Circuit,  
Amps  
Total  
Aux.  
kVA  
Current, Amps 115V Circuit,  
@ NEMA Arc  
Volts  
Amps  
0
26  
19.5  
13  
6.5  
0
13  
9.75  
6.5  
3.25  
0
3.0  
2.25  
1.5  
0.75  
0
100  
200  
300  
400  
500  
0
0
0
SAE-400  
Download from Www.Somanuals.com. All Manuals Search And Download.  
B-3  
B-3  
OPERATION  
ENGINE PROTECTION SYSTEM  
ENGINE CONTROLS  
The engine protection system shuts down the engine  
under high coolant temperature or low engine oil pres-  
sure conditions by allowing the fuel solenoid valve to  
close.  
IGNITION SWITCH  
When placed in the “ON” position, this switch ener-  
gizes the fuel solenoid. When placed in the “OFF” posi-  
tion, the flow of fuel to the injection pump is stopped to  
shut down the engine.  
WELDER CONTROLS  
POLARITY SWITCH  
“IDLER” SWITCH  
Turn the Arc Polarity switch to electrode positive or  
electrode negative as required for each particular  
application.  
The idler switch has two positions, “HIGH” and  
“AUTO”.  
When in “HIGH” (  
) position, the engine will run  
CONTROL OF WELDING CURRENT  
Purpose of Controls  
continuously at high idle.  
When in “AUTO” (  
/ ) idle position, the idler  
The continuous “Current Control” is the main current  
adjuster. The “Job Selector” is both a fine current  
adjuster and the continuous Open Circuit Voltage  
adjuster. Open Circuit Voltage (OCV) controls the arc  
characteristics.  
operates as follows:  
a. Welding  
When the electrode touches the work, the welding  
arc is initiated and the engine accelerates to full  
speed.  
“Job Selector”  
The “Job Selector” dial is divided into four colored sec-  
tions providing OCV ranges as follows:  
After welding ceases (and no auxiliary power is  
being drawn), the engine will return to low idle after  
approximately 10 to 14 seconds.  
Color  
Title  
OCV Range  
High OCV  
White  
Large Electrodes  
Normal Welding  
b. Auxiliary Power  
Black  
Red  
Medium OCV  
Overhead & Vertical Low OCV  
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.  
Grey  
Special Applications Extra-Low OCV  
The “Job Selector” is usually set in the black range  
because it provides a soft “Buttering “ arc desired for  
most welding. Some operators prefer to set the “Job  
Selector” in the red range for a snappy “Digging” arc  
when welding vertical up or overhead.  
ENGINE TEMPERATURE GAUGE  
“Current Control”  
Displays the coolant temperature in the engine block.  
ENGINE OIL PRESSURE GAUGE  
CAUTION  
Do not adjust the “Current Control” while welding  
because this can damage the control.  
Displays the oil pressure to the engine. When the  
engine starts running, watch for the oil pressure to  
build up. If no pressure shows within 30 seconds, stop  
the engine and consult the engine instruction manual.  
------------------------------------------------------------------------  
The “Current Control” dial is calibrated in amperes on  
three separate colored dials corresponding to the  
white, black and red ranges of the “Job Selector” dial.  
For example: when the “Job Selector” is set on the  
black range, the approximate welding current is indi-  
cated on the black scale of the “Current Control” dial.  
BATTERY CHARGING AMMETER  
Displays the current going from the charging alternator  
into the batteries. It is normal for charging current to be  
high (above 15 amps) after starting or when the batter-  
ies are ʻlowʼ on charge.  
ENGINE HOUR METER  
The engine hour meter records the total running time  
on the engine in hours. It can be used to keep a record  
of maintenance on the engine and or welder.  
SAE-400  
Download from Www.Somanuals.com. All Manuals Search And Download.  
B-4  
B-4  
OPERATION  
How to Set the Controls  
230 VAC Receptacle  
Assume you want a normal soft arc and about 135  
amps, using a 5/32” (4.0 mm) electrode:  
One 15 amp, 230 VAC duplex receptacle provides 230  
VAC for auxiliary power. A total of 13 amps can be  
drawn from this receptacle.  
1. Set the “Job Selector” at the center of the black  
range.  
Circuit Breakers  
2. Set the “Current Control” to read 135 amps on the  
black dial.  
The circuit breakers provide separate overload current  
protection for each half of the 115 V duplex receptacle.  
The circuit breakers provide overload current protec-  
tion in both current carrying wires of the 230 V duplex  
receptacle.  
3. Start to weld.  
4. If you want a little more current, turn the “Job  
Selector” up (counterclockwise) to increase cur-  
rent. If you want a little less current, turn the “Job  
Selector” down (clockwise) to decrease current.  
Ground Stud  
Provides a connection point for connecting the  
machine to earth ground. For the safest grounding pro-  
cedure refer to “Machine Grounding” in the INSTALLA-  
TION section of this manual.  
5. If dialing the desired current with the “Job  
Selector” moves the setting outside the black  
range causing undesirable arc characteristics, turn  
the “Job Selector” back to the center of the black  
range. Then turn the “Current Control” up or down  
a little as needed. Readjust the “Job Selector” for  
the exact characteristics and current desired.  
REMOTE CONTROL  
A receptacle and “Local/Remote” control switch on the  
lower front control panel and a remote control box with  
100 ft. (30.5 m) of cord for adjusting the OCV at the  
welding site are standard. Putting the switch in the  
“REMOTE” position allows fine current control at the  
remote control box while placing the switch in the  
“LOCAL” position allows fine current control at the “Job  
Selector” on the machine. When using the optional  
field installed CV adapter (K385-[ ]) the “Local/Remote”  
switch is only active in the “VV” mode.  
AUXILIARY POWER CONTROLS  
NOTE: GFCI receptacles our an option and if installed,  
see the MAINTENANCE section for detailed informa-  
tion on testing and resetting the GFCI receptacle.  
115 VAC Receptacle  
One 20 amp, 115 VAC duplex receptacle provides 115  
VAC for auxiliary power. A total of 26 amps can be  
drawn from this receptacle.  
SAE-400  
Download from Www.Somanuals.com. All Manuals Search And Download.  
B-5  
B-5  
OPERATION  
ENGINE OPERATION  
5. Observe the oil pressure. If no pressure shows  
within 30 seconds, stop the engine and consult the  
engine operating manual. To stop the engine, turn  
the “IGNITION” switch to “OFF”.  
WARNING  
Do not attempt to use this equipment until you  
have thoroughly read the engine manufacturerʼs  
manual supplied with your welder. It includes  
important safety precautions, detailed engine  
starting, operating and maintenance instructions,  
and parts lists.  
6. If the engine protection warning light comes on  
during cranking or after start up, the “IGNITION”  
switch must be turned “OFF” to reset the engine  
protection system.  
7. Allow the engine to run at high idle speed for sev-  
eral minutes to warm the engine. Stop the engine  
and recheck the oil level, after allowing sufficient  
time for the oil to drain into the pan. If the level is  
down, fill it to the full mark again. The engine con-  
trols were properly set at the factory and should  
require no adjusting when received.  
------------------------------------------------------------------------  
ELECTRIC SHOCK can kill.  
• Do not touch electrically live parts or  
electrode with skin or wet clothing.  
• Insulate yourself from work and  
ground  
• Always wear dry insulating gloves.  
------------------------------------------------------------------------  
ENGINE EXHAUST can kill.  
COLD WEATHER STARTING:  
• Use in open, well ventilated areas or  
vent exhaust outside.  
WARNING  
------------------------------------------------------------------------  
MOVING PARTS can injure.  
Under NO conditions should ether or other starting  
fluids be used!  
• Do not operate with doors open or  
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-  
starting aides.  
See additional warning information at the  
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-  
tor overheating.  
STOPPING THE ENGINE  
1. Turn the “IGNITION” switch to “OFF”  
CAUTION  
At the end of each dayʼs welding, check the crankcase  
oil level, drain accumulated dirt and water from the  
water separator and refill the fuel tank to minimize  
moisture condensation in the tank. Also, running out of  
fuel tends to draw dirt into the fuel system.  
Do not adjust the high idle engine speed (rpm)  
above the factory setting specification as this will  
void warranty.  
------------------------------------------------------------------------  
STARTING INSTRUCTIONS  
Be sure all Pre-Operation Maintenance has been  
performed. (See INSTALLATION section of this  
manual).  
When hauling the welder between job sites, close the  
fuel shut-off valve.  
If the fuel supply is cut off or runs out while the fuel  
pump is operating, air may be entrapped in the fuel dis-  
tribution system. If this happens, bleeding of the fuel  
system may be necessary. Use qualified personnel to  
do this per the instructions in the MAINTENANCE sec-  
tion 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  
Download from Www.Somanuals.com. All Manuals Search And Download.  
B-6  
B-6  
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  
1100 RPM  
.30 gal./ hr.  
(1.12 L./hr.)  
26 gal./ hr.  
(.97 L./hr.)  
High Idle - No Load  
1800 RPM  
.69 gal./hr.  
(2.61 L./hr.)  
.68 gal./hr.  
(2.56 L./hr.)  
Welding Load  
1.79 gal./hr.  
(6.76 L./hr.)  
1.84 gal./hr.  
(6.95 L./hr.)  
400 Amps, 40 Volts  
Welding Load  
2.43 gal./hr.  
(9.19 L./hr.)  
2.38 gal./hr.  
(9.02 L./hr.)  
500 Amps, 40 Volts  
Auxiliary Power  
3000VA  
.71 gal./hr.  
(3.68 L./hr.)  
.79 gal./hr.  
(2.98 L./hr.)  
SAE-400  
Download from Www.Somanuals.com. All Manuals Search And Download.  
C-1  
C-1  
ACCESSORIES  
K930-2 TIG Module - Provides high frequency plus a  
gas valve for TIG welding. A water valve is available as  
an option. Requires 115 volt AC input. (Limited to 250A  
- 60% Duty Cycle).  
K1735-1 MULTI-WELD 350 - For multiple arcs from  
the DC output of a welding power source. See bulletin  
E5.300 for Multi-Weld 350 and distribution system.  
K2144-1 Oil Drain Kit- Includes ball valve, hose and  
K802-D Power Plug Kit - Kit includes male plug for 20  
clamp.  
amp receptacle.  
K1858-1 Service Indicator Kit- Provides a GO / NO-GO  
visual indication of air cleaner element useful service life.  
Filter service based on restriction readings allows the longest  
life possible from the filter and best engine protection.  
K2641-1 Trailer - A 4-wheel steerable trailer for in-  
plant and yard towing with E78-14 load range (B) tube-  
less tires. Mounts directly to welder base. (Not for use  
on the road.) Comes standard with a Duo-Hitch™, a 2”  
Ball and Lunette Eye combination hitch.  
(1)  
K2637-1 Trailer - A 2-wheel trailer designed for road ,  
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:  
K2636-1 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.  
------------------------------------------------------------------------  
K704 Standard Accessory Kit - Includes electrode  
and work cables, headshield, work clamp and elec-  
trode holder.  
K385-[ ] CV Adapter - Provides constant voltage out-  
put for semiautomatic welding. (Field installation only).  
K1690-1 GFCI RECEPTACLE KIT  
Includes one UL approved 120V ground fault circuit  
interrupter duplex type receptacle with cover and  
installation instructions. Replaces the factory installed  
120V duplex receptacle. Each receptacle of the GFCI  
Duplex is rated at 20 Amps, the maximum total current  
from the GFCI Duplex is limited to the 20 Amps. Two  
kits are required. See the MAINTENANCE section for  
detailed information on testing and resetting the GFCI  
receptacle.  
SAE-400  
Download from Www.Somanuals.com. All Manuals Search And Download.  
D-1  
D-1  
MAINTENANCE  
PERIODIC MAINTENANCE  
WARNING  
1. Blow out the welder and controls with an air hose at least  
once every two months. In particularly dirty locations, this  
cleaning may be necessary once a week. Use low pres-  
sure air to avoid driving dirt into the insulation.  
ELECTRIC SHOCK can kill.  
●
Do not touch electrically live parts  
such as output terminals or inter-  
nal wiring  
2. The current control reactor brushes are self-lubricating  
and should not be greased. Keep the contacts clean. This  
control should be moved from maximum to minimum daily  
to prevent the controls from sticking.  
ENGINE EXHAUST can kill.  
● Use in open, well ventilated areas  
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-  
mended in the engine operating manual. Change the oil  
filter in accordance with the instructions in the engine  
operating manual. When the oil filter is changed add one  
quart of oil to the crankcase to replace the oil held in the  
filter during operation.  
MOVING PARTS can injure.  
● Do not operate with doors open or  
guards off  
Stop engine before servicing  
●
● Keep away from moving parts  
4. Belts tend to loosen after the first 30 or 40 hours of oper-  
ation. Check the cooling fan belt and tighten if necessary.  
DO NOT OVER TIGHTEN.  
● Remove guards only when necessary and  
replace when work requiring removal is com-  
plete.  
●
Only qualified personnel should install, use, or  
BEARING MAINTENANCE  
service this equipment.  
This welder is equipped with a double-shielded ball bearing  
having sufficient grease to last indefinitely under normal ser-  
vice. Where the welder is used constantly or in excessively  
dirty locations, it may be necessary to add one-half ounce of  
grease per year. A pad of grease one inch wide, one inch  
long and one inch high weighs approximately one-half  
ounce. Over greasing is far worse than insufficient greasing.  
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.  
If the fuel supply runs out while the fuel pump is oper-  
ating, air may be entrapped in the fuel distribution sys-  
tem. If this happens, bleeding of the fuel system may  
be necessary. See the engine instruction manual.  
When greasing the bearings, keep all dirt out of the area.  
Wipe the fittings completely clean and use clean equipment.  
More bearing failures are caused by dirt introduced during  
greasing than from insufficient grease.  
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  
Download from Www.Somanuals.com. All Manuals Search And Download.  
D-2  
D-2  
MAINTENANCE  
COMMUTATOR AND BRUSH MAINTENANCE  
COOLING SYSTEM  
WARNING  
The SAE-400 is equipped with a pressure radiator.  
Keep the radiator cap tight to prevent loss of coolant.  
Clean and flush the cooling system periodically to pre-  
vent clogging the passage and overheating the engine.  
When antifreeze is needed, always use the permanent  
type.  
Uncovered rotating equipment can be dangerous.  
Use care so your hands, hair, clothing or tools do  
not catch in the rotating parts. Protect yourself  
from particles that may be thrown out by the rotat-  
ing armature when stoning the commutator.  
------------------------------------------------------------------------  
The generator brushes are properly adjusted when the  
welder is shipped. They require no particular attention.  
DO NOT SHIFT THE BRUSHES or adjust the rocker  
setting.  
PRE FILTER / WATER SEPARATOR  
WARNING  
When working on the fuel system  
Shifting of the brushes may result in:  
- Change in machine output  
- Commutator Damage  
• Keep unguarded lights away, do not  
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 pump  
mounted to the engine block.  
Commutators and slip rings require little attention.  
However, if they are black or appear uneven, have  
them cleaned by an experienced maintenance person  
using fine sandpaper or a commutator stone. Never  
use emery cloth or paper for this purpose.  
FUEL PRE-FILTER/WATER SEPARATOR ASSEMBLY  
(For codes below 11409)  
The pre-filter is a 150 micron screen designed to pro-  
tect against gross fuel contamination of the water sep-  
arator element and the Secondary Fuel Filter. If the  
pre-filter becomes plugged it may be removed, inspect-  
ed, cleaned and reinstalled. In general this only needs  
to be done with each water separator element change  
(about every 1,000 hrs.) However if at any time exces-  
sive fuel contamination is suspected or a sudden fall-  
off in engine performance is detected the pre-filter  
screen should be inspected and cleaned. Follow the  
following procedure:  
NOTE: If the welder is used in dirty or dusty locations,  
or if the welder is not used for prolonged periods of  
time, it may be necessary to clean the commutator and  
slip rings more often.  
Replace brushes when they wear within 1/4" of the pig-  
tail. 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 com-  
mutator as the armature rotates at full speed until con-  
tact is made across the full face of the brushes. After  
stoning, blow out the dust with low pressure air.  
1. Close the fuel shutoff valve located under the fuel  
tank.  
2. Unscrew the cap ring located on the top of the filter  
header and remove the plastic center cap and O-  
ring.  
To seat the slip ring brushes, position the brushes in  
place. Then slide one end of a piece of fine sandpaper  
between slip rings and brushes with the coarse side  
against the brushes. With slight additional finger pres-  
sure on top of the brushes, pull the sandpaper around  
the circumference of the rings, in direction of rotation  
only - until brushes seat properly. In addition, stone  
slip ring with a fine stone. Brushes must be seated  
100%.  
3. Remove the large white volume plug located direct-  
ly under the center cap in the upper cavity of the fil-  
ter header. Use a small screwdriver (or similar  
device) to lift the plug part way out of the cavity to  
assist with its removal.  
Arcing or excessive exciter brush wear indicates a pos-  
sible misaligned shaft. Have an authorized Field  
Service Shop check and realign the shaft.  
Be careful not to damage the pre-filter screen with  
the tool used to remove the plug.  
SAE-400  
Download from Www.Somanuals.com. All Manuals Search And Download.  
D-3  
D-3  
MAINTENANCE  
4. Using a pair of pliers, gently tug on the pull tabs of  
the pre-filter screen in an alternating pattern to  
gradually remove the pre-filter screen.  
Note: The element will only go on one way. Never use  
excessive force when mounting the element to the  
header.  
5. Slide the quick change ring up over the element and  
rotate counter clockwise until an audible click or pop  
is heard. If you do not hear the click you have not rotat-  
ed the ring far enough and the element is not in the  
locked position. Another indication that the ring is in  
the locked position is that one set (it doesnʼt matter  
which one) of arrows located on the outside of the ring  
should be located directly under the air vent valve.  
5. Brush off any debris and rinse in diesel fuel.  
6. Re-install the pre-filter screen into the upper cavity  
of the filter header making sure the four pull tabs  
are pointing up. Putting your fingers on the pull  
tabs, push down evenly until the lower body of the  
pre-filter screen contacts the floor of the upper cav-  
ity.  
6. Open the fuel shutoff valve.  
7. Re-insert the large white volume plug into the upper  
cavity.  
7. Open the air vent valve on the front of the filter head-  
er until fuel emerges free of air bubbles and then close  
the air vent valve.  
8. Place the O-ring onto the angled seal surface of the  
filter header and re-install the plastic cap. Make  
sure its flange rests on the O-ring.  
Note : Consult your engine operation manual for infor-  
mation on air bleeding the entire fuel system  
9. Screw on the cap ring and tighten hand tight.  
FUEL PRE-FILTER/WATER SEPARATOR  
ASSEMBLY  
10. Remember to open the fuel shutoff valve before  
starting the engine.  
(For codes 11409 and above)  
The assembly uses a 30 micron pre-filter/water separator  
element that is designed to protect against gross contam-  
ination of the final fuel filter. Using chemically treated  
paper media the element also provides maximum protec-  
tion against water in the fuel. The assembly is also  
equipped with a see-through bowl for easy visual check-  
ing for water. The recommended change interval for the  
pre-filter/water separator element is 1,000 hours. See  
below for information on the see-through bowl and for the  
procedure for changing the element.  
WATER SEPARATOR ELEMENT  
(For codes below 11409)  
The water separator element is a two stage filter with a  
special filtration/water separating media, and an  
expanded water reservoir providing maximum protec-  
tion against water in the fuel. The recommended  
change interval for the water separator element is  
1,000 hours. The procedure for changing the element  
is as follows:  
See-Through Bowl:  
• Check the see-through bowl for water regularly. Water  
will collect at the bottom of the bowl and appears differ-  
ent from the fuel.  
1. Close the fuel shutoff valve located under the fuel  
tank.  
Note: The see-through bowl is re-usable.  
2. Rotate the quick change ring (located just below fil-  
ter header) clockwise approximately 1/2 turn and  
slide it down and off of the element.  
1. Close the fuel shut-off valve.  
2. Drain by opening the self venting drain valve and allow-  
ing all water to escape.  
3. Grasp the element and pull down with a slight rock-  
ing motion to remove the element from the grom-  
met post on the bottom of the filter header.  
3. Close the drain valve and open the fuel shut-off valve.  
Pre-Filter/Water Separator Element:  
4. Slide the new element onto the grommet post on the  
bottom of the filter header until the element no longer  
easily moves up into the filter header. Now rotate the  
element (may take almost 1 full turn) with a slight  
upward pressure until the element begins to further  
engage the header. With the proper orientation now  
established apply additional pressure to seat the ele-  
ment in the filter header. You should feel the element  
“pop” into place when properly seated.  
1. Close the fuel shutoff valve located under the fuel tank.  
2. Rotate the quick change ring (located just below filter-  
header) clockwise approximately 1/2 turn andslide it  
down and off of the element.  
3. Grasp the element and pull down with a slight rocking-  
motion to remove the element from the grommet post  
on the bottom of the filter header.  
SAE-400  
Download from Www.Somanuals.com. All Manuals Search And Download.  
D-4  
D-4  
MAINTENANCE  
4. Slide the new element onto the grommet post on the  
bottom of the filter header until the element no longer  
easily moves up into the filter header. Now rotate the  
element (may take almost 1 full turn) with a slight  
upward pressure until the element begins to further  
engage the header. With the proper orientation now  
established apply additional pressure to seat the ele-  
ment in the filter header. You should feel the element  
“pop” into place when properly seated.  
SPARK ARRESTOR  
WARNING  
• Spark Arrester and Muffler may be  
hot!  
• Allow engine to cool before servicing  
spark arrester!  
• Do not operate engine while servicing  
spark arrester!  
Note: The element will only go on one way. Never  
use excessive force when mounting the element to  
the header.  
------------------------------------------------------------------------  
SAE-400 with integral spark arresting mufflers:  
Service spark arrester every 250 hours.  
Service as follows:  
5. Slide the quick change ring up over the element and  
rotate counter clockwise until an audible click or pop is  
heard. If you do not hear the click you have not rotated  
the ring far enough and the element is not in the locked  
position. Another indication that the ring is in the locked  
position is that one set (it doesnʼt matter which one) of  
arrows located on the outside of the ring should be  
located directly under the air vent valve.  
1. Stop engine and allow to cool.  
2. Remove clean out plug from side of spark arrester.  
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.  
GFCI RECEPTACLE TESTING AND RESET-  
TING PROCEDURE  
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.  
The GFCI receptacle should be properly tested at least  
once every month or whenever it is tripped. To proper-  
ly test and reset the GFCI receptacle:  
Note: Consult your engine operation manual for  
information on air bleeding the entire fuel system.  
• If the receptacle has tripped, first carefully remove  
any load and check it for damage.  
ENGINE AND COMPRESSOR MAINTENANCE  
COMPONENTS  
• If the equipment has been shut down, it must be  
restarted.  
ITEM  
Engine Air Filter  
Fan Belt  
MAKE  
Donaldson  
Perkins  
PART NUMBER  
P822768  
• The equipment needs to be operating at high idle  
speed and any necessary adjustments made on the  
control panel so that the equipment is providing at  
least 80 volts to the receptacle input terminals.  
• The circuit breaker for this receptacle must not be  
tripped. Reset if necessary.  
2614B555 043  
26560201  
Fuel Filter  
Perkins  
• Push the "Reset" button located on the GFCI recep-  
tacle. This will assure normal GFCI operation.  
• Plug a night-light (with an "ON/OFF" switch) or other  
product (such as a lamp) into the GFCI receptacle  
and turn the product "ON".  
Engine Oil Filter  
Perkins  
2654407  
Water Separator  
Element (Codes  
below 11409)  
Lincoln  
M16890-C  
31572  
Stanadyne  
• Push the "Test" button located on the GFCI recepta-  
cle. The night-light or other product should go "OFF".  
• Push the "Reset" button, again. The light or other  
product should go "ON" again.  
Fuel Pre-Filter Screen Lincoln  
M16890-B  
29575  
(Codes below 11409)  
Stanadyne  
Pre-Filter/Water  
Lincoln  
M21584-B  
39420 LE  
If the light or other product remains "ON" when the  
"Test" button is pushed, the GFCI is not working prop-  
erly or has been incorrectly installed (miswired). If your  
GFCI is not working properly, contact a qualified, certi-  
fied electrician who can assess the situation, rewire the  
GFCI if necessary or replace the device.  
Separator Element (Codes Stanadyne  
11409 and higher)  
Note: No Pre-filter Screen required on codes 11409  
and higher.  
SAE-400  
Download from Www.Somanuals.com. All Manuals Search And Download.  
E-1  
E-1  
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.  
__________________________________________________________________________  
This Troubleshooting Guide is provided to help you  
locate and repair possible machine malfunctions.  
Simply follow the three-step procedure listed below.  
Step 3. RECOMMENDED COURSE OF ACTION  
This column provides a course of action for the  
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-  
TOMS)”. This column describes possible symptoms  
that the machine may exhibit. Find the listing that best  
describes the symptom that the machine is exhibiting.  
If you do not understand or are unable to perform the  
Recommended Course of Action safely, contact your  
local Lincoln Authorized Field Service Facility.  
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  
Download from Www.Somanuals.com. All Manuals Search And Download.  
E-2  
E-2  
TROUBLESHOOTING  
Observe all Safety Guidelines detailed throughout this manual  
PROBLEMS  
(SYMPTOMS)  
POSSIBLE  
RECOMMENDED  
CAUSE  
COURSE OF ACTION  
FUNCTION PROBLEMS  
Machine fails to hold the “heat”  
constantly.  
1. Rough or dirty commutator.  
1. True and clean commutator.  
2. Replace brushes.  
2. Brushes may be worn down to  
limit of life.  
3. Brush springs may be broken.  
3. Replace brush springs.  
4. Field circuit may have variable  
resistance connections or inter-  
mittent open circuit, due to loose  
connections or broken wire.  
4. Check field current with ammeter  
to discover varying current. This  
applies to both the main genera-  
tor and exciter.  
5. Electrode or work lead connec-  
tions may be poor.  
5. Tighten all connections.  
6. Wrong grade of brushes may be 6. Use only the recommended  
installed on generator.  
Lincoln brushes.  
7. Field rheostat may be making  
poor contact and overheating.  
7. Inspect and clean rheostat.  
8. “Current Control” may not be  
operating properly.  
8. Check for loose or missing set  
screw in control handles.  
9. “Current Control” brushholder  
contact springs may be worn out  
or missing. Contact surface may  
be dirty, rough and pitted.  
9. Inspect. Replace needed parts.  
Clean internal contact surface of  
control device. Do not lubricate.  
Smooth rough surfaces.  
10. “Current Control” brushholder  
support stud and mating contact  
surfaces may be dirty or pitted  
and burned.  
10. If brushholder internal contact  
surface is pitted and burned,  
replace the brushholder and  
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  
speeds.  
11. Set welder controls for maximum  
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  
Download from Www.Somanuals.com. All Manuals Search And Download.  
E-3  
E-3  
TROUBLESHOOTING  
Observe all Safety Guidelines detailed throughout this manual  
PROBLEMS  
(SYMPTOMS)  
POSSIBLE  
RECOMMENDED  
COURSE OF ACTION  
CAUSE  
FUNCTION PROBLEMS  
Welder runs but fails to generate  
current.  
1. Generator or exciter brushes may 1. Be sure that all brushes bear on  
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  
excessively.  
1. Series field circuit may be open  
circuited.  
1. Check circuit with ringer or volt-  
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  
Download from Www.Somanuals.com. All Manuals Search And Download.  
E-4  
E-4  
TROUBLESHOOTING  
Observe all Safety Guidelines detailed throughout this manual  
PROBLEMS  
(SYMPTOMS)  
POSSIBLE  
RECOMMENDED  
COURSE OF ACTION  
CAUSE  
FUNCTION PROBLEMS  
Welding current too great or too  
small compared to indication on the  
dial.  
1. “Current Control” shaft and han- 1. With current control against the  
dle may have turned slightly in  
the insulated bushing of the cur-  
rent control brushholder, caused  
by turning handle too hard against  
one of the stops.  
minimum stop, set pointer to with-  
in 1/8” of the last scale division.  
2. Exciter output low causing low  
output compared to dial indica-  
tion.  
2. Check for shorts in exciter arma-  
ture with growler.  
3. “Current Control” set to minimum 3. Check to see that series field is  
and welder output so great that  
engine stalls when arc is struck.  
properly connected and not short-  
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  
Download from Www.Somanuals.com. All Manuals Search And Download.  
E-5  
E-5  
TROUBLESHOOTING  
Observe all Safety Guidelines detailed throughout this manual  
PROBLEMS  
(SYMPTOMS)  
POSSIBLE  
RECOMMENDED  
COURSE OF ACTION  
CAUSE  
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  
receptacles.  
2. Check connections.  
3. GFCI Receptacle (if installed) may 3. Follow “GFCI Receptacle Testing  
have tripped.  
and Resetting Procedure” in the  
MAINTENANCE section of this  
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  
Download from Www.Somanuals.com. All Manuals Search And Download.  
F-1  
F-1  
WIRING DIAGRAMS  
SAE-400  
Download from Www.Somanuals.com. All Manuals Search And Download.  
F-2  
F-2  
WIRING DIAGRAM  
SAE-400  
Download from Www.Somanuals.com. All Manuals Search And Download.  
F-3  
F-3  
WIRING DIAGRAM  
SAE400  
Download from Www.Somanuals.com. All Manuals Search And Download.  
F-4  
F-4  
WIRING DIAGRAM  
SAE400  
Download from Www.Somanuals.com. All Manuals Search And Download.  
F-5  
F-5  
DIMENSION PRINT  
SAE-400  
Download from Www.Somanuals.com. All Manuals Search And Download.  
NOTES  
SAE-400  
Download from Www.Somanuals.com. All Manuals Search And Download.  
NOTES  
SAE-400  
Download from Www.Somanuals.com. All Manuals Search And Download.  
● Keep your head out of fumes.  
● Use ventilation or exhaust to  
remove fumes from breathing zone.  
● Turn power off before servicing.  
● Do not operate with panel open or  
guards off.  
WARNING  
Spanish  
● Los humos fuera de la zona de res-  
piración.  
● Mantenga la cabeza fuera de los  
humos. Utilice ventilación o  
aspiración para gases.  
● Desconectar el cable de ali-  
mentación de poder de la máquina  
antes de iniciar cualquier servicio.  
● No operar con panel abierto o  
guardas quitadas.  
AVISO DE  
PRECAUCION  
French  
● N’opérez pas avec les panneaux  
ouverts ou avec les dispositifs de  
protection enlevés.  
● Gardez la tête à l’écart des fumées. ● Débranchez le courant avant l’entre-  
● Utilisez un ventilateur ou un aspira-  
teur pour ôter les fumées des zones  
de travail.  
tien.  
ATTENTION  
German  
● Anlage nie ohne Schutzgehäuse  
oder Innenschutzverkleidung in  
Betrieb setzen!  
● Vermeiden Sie das Einatmen von  
Schweibrauch!  
● Sorgen Sie für gute Be- und  
Entlüftung des Arbeitsplatzes!  
● Strom vor Wartungsarbeiten  
abschalten! (Netzstrom völlig öff-  
nen; Maschine anhalten!)  
WARNUNG  
Portuguese  
● Não opere com as tampas removidas.  
● Desligue a corrente antes de fazer  
serviço.  
● Mantenha-se afastado das partes  
moventes.  
● Não opere com os paineis abertos  
ou guardas removidas.  
● Mantenha seu rosto da fumaça.  
● Use ventilação e exhaustão para  
remover fumo da zona respiratória.  
ATENÇÃO  
● Não toque as partes elétricas nuas.  
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.  
SAE-400  
Download from Www.Somanuals.com. All Manuals Search And Download.  
● 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  
ground.  
WARNING  
Spanish  
● 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-  
da.  
● Aislese del trabajo y de la tierra.  
fuera del área de trabajo.  
cuerpo.  
AVISO DE  
PRECAUCION  
French  
● Ne laissez ni la peau ni des vête-  
ments mouillés entrer en contact  
avec des pièces sous tension.  
● Gardez à l’écart de tout matériel  
inflammable.  
● Protégez vos yeux, vos oreilles et  
votre corps.  
ATTENTION  
● Isolez-vous du travail et de la terre.  
German  
● Berühren Sie keine stromführenden  
Teile oder Elektroden mit Ihrem  
Körper oder feuchter Kleidung!  
● Isolieren Sie sich von den  
● Entfernen Sie brennbarres Material! ● Tragen Sie Augen-, Ohren- und Kör-  
perschutz!  
WARNUNG  
Elektroden und dem Erdboden!  
Portuguese  
● Não toque partes elétricas e elec-  
trodos com a pele ou roupa molha-  
da.  
● Mantenha inflamáveis bem guarda- ● Use proteção para a vista, ouvido e  
dos.  
corpo.  
ATENÇÃO  
● 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.  
SAE-400  
Download from Www.Somanuals.com. All Manuals Search And Download.  
• World's Leader in Welding and Cutting Products •  
• Sales and Service through Subsidiaries and Distributors Worldwide •  
Cleveland, Ohio 44117-1199 U.S.A. TEL: 216.481.8100 FAX: 216.486.1751 WEB SITE: www.lincolnelectric.com  
Download from Www.Somanuals.com. All Manuals Search And Download.  

La Crosse Technology Clock WT 8008U User Manual
Leica Laser Level E7500i User Manual
Lennox Hearth Indoor Fireplace MPRCVDE User Manual
Lenovo Personal Computer 9949 User Manual
LevelOne Switch IFE 0501 User Manual
Lincoln Electric Portable Generator IM511 D User Manual
Makita Power Hammer HM1140C User Manual
M Audio Musical Instrument I O User Manual
Maytag Clothes Dryer W10557650B User Manual
Mercury Automobile 2006 Mariner User Manual