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IM727
SAE-400 SEVERE DUTY
DC ARC WELDING POWER SOURCE
For use with machines having Code Number: 10856
January, 2005
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 opera-
tion 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.
R
OPERATOR’S MANUAL
Copyright © 2005 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
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SAFETY
ARC RAYS can burn.
ELECTRIC SHOCK can kill.
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.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.
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.
5.a. Welding may produce fumes and gases
hazardous to health. Avoid breathing these
• Semiautomatic DC Constant Voltage (Wire) Welder.
• DC Manual (Stick) Welder.
• AC Welder with Reduced Voltage Control.
fumes and gases.When welding, keep
your head out of the fume. Use enough
ventilation and/or exhaust at the arc to keep
3.c. In semiautomatic or automatic wire welding, the electrode,
electrode reel, welding head, nozzle or semiautomatic
welding gun are also electrically “hot”.
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. 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
products.
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. 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.
3.i. When working above floor level, use a safety belt to protect
yourself from a fall should you get a shock.
5.d. Read and understand the manufacturer’s instructions for this
equipment and the consumables to be used, including the
material safety data sheet (MSDS) and follow your
employer’s safety practices. MSDS forms are available from
your welding distributor or from the manufacturer.
3.j. Also see Items 6.c. and 8.
5.e. Also see item 1.b.
Mar ‘95
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SAFETY
WELDING SPARKS can
cause fire or explosion.
CYLINDER may explode
if damaged.
6.a. Remove fire hazards from the welding area.
If this is not possible, cover them to prevent
7.a. Use only compressed gas cylinders
containing the correct shielding gas for the
the welding sparks from starting a fire.
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.
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.
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.
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.
•A safe distance from arc welding or cutting operations and
any other source of heat, sparks, or flame.
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.
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.a. Turn off input power using the disconnect
switch at the fuse box before working on
the equipment.
8.b. Install equipment in accordance with the U.S. National
Electrical Code, all local codes and the manufacturer’s
recommendations.
6.h. Also see item 1.c.
8.c. Ground the equipment in accordance with the U.S. National
Electrical Code and the manufacturer’s recommendations.
Mar ‘95
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SAFETY
zones où l’on pique le laitier.
PRÉCAUTIONS DE SÛRETÉ
6. Eloigner les matériaux inflammables ou les recouvrir afin de
prévenir tout risque d’incendie 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 d’incendie.
Sûreté Pour Soudage A L’Arc
1. Protegez-vous contre la secousse électrique:
8. S’assurer que la masse est connectée le plus prés possible de
la zone de travail qu’il est pratique de le faire. Si on place la
masse sur la charpente de la construction ou d’autres 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 d’incendie ou d’echauffement des chaines et des
câbles jusqu’à ce qu’ils se rompent.
a. Les circuits à l’électrode 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 s’isoler 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
d’opérations de dégraissage, nettoyage ou pistolage. La
chaleur ou les rayons de l’arc 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 l’eau pour le
refroidir.
e. Ne jamais toucher simultanément les parties sous tension
des porte-électrodes connectés à deux machines à soud-
er parce que la tension entre les deux pinces peut être le
total de la tension à vide des deux machines.
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.
f. Si on utilise la machine à souder comme une source de
courant pour soudage semi-automatique, ces precautions
pour le porte-électrode s’applicuent aussi au pistolet de
soudage.
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 n’importe quelle partie
du corps.
PRÉCAUTIONS DE SÛRETÉ POUR
LES MACHINES À SOUDER À
TRANSFORMATEUR ET À
REDRESSEUR
3. Un coup d’arc peut être plus sévère qu’un coup de soliel,
donc:
a. Utiliser un bon masque avec un verre filtrant approprié
ainsi qu’un verre blanc afin de se protéger les yeux du ray-
onnement de l’arc et des projections quand on soude ou
quand on regarde l’arc.
b. Porter des vêtements convenables afin de protéger la
peau de soudeur et des aides contre le rayonnement de
l‘arc.
1. Relier à la terre le chassis du poste conformement au code de
l’électricité 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, I’installation et l’entretien du poste seront
effectués par un électricien qualifié.
c. Protéger l’autre personnel travaillant à proximité au
soudage à l’aide d’écrans appropriés et non-inflammables.
3. Avant de faires des travaux à l’interieur de poste, la debranch-
er à l’interrupteur à la boite de fusibles.
4. Des gouttes de laitier en fusion sont émises de l’arc de
soudage. Se protéger avec des vêtements de protection libres
de l’huile, 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.
5. Toujours porter des lunettes de sécurité dans la zone de
soudage. Utiliser des lunettes avec écrans lateraux dans les
Mar. ‘93
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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
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.
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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 Service . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .A-3
Engine Oil . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .A-3
Fuel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .A-3
Engine Break-In, Engine Cooling System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .A-4
Battery Connection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .A-4
Spark Arrestor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .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-1
Welder . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .B-1
Auxiliary Power . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .B-1
Design Features and Advantages . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .B-2
Duty Cycle . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .B-2
Engine Controls: Function/Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . B-3
Air Intake Shut-Off . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . B-3
Welder Controls: Function/Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . B-4
Remote Control . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .B-4
Auxiliary Power Controls . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .B-4
Engine Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .B-5
Starting Instructions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .B-5
Break-In Period . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .B-5
Typical Fuel Consumption . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .B-5
______________________________________________________________________________
Accessories . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Section C
______________________________________________________________________________
Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Section D
Routine Maintenance, Periodic Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . D-1
Engine Oil Change, Engine Air Filter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . D-1
Bearing, Commutator and Brush Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . D-2
Cooling System, Fuel Filter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . D-2
Water Separator, Secondary Fuel Filter and Engine Components . . . . . . . . . . . . . . . . D-3
Spark Arrestor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . D-4
GFCI Receptacle Testing and Resetting Procedure . . . . . . . . . . . . . . . . . . . . . . . . . . .D-4
______________________________________________________________________________
Troubleshooting Guide . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Section E
______________________________________________________________________________
Wiring Diagrams and Dimension Print . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Section F
______________________________________________________________________________
Parts Lists . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Appendix
SAE-400 SEVERE DUTY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .P399 Series
______________________________________________________________________________
SAE-400 SEVERE DUTY
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INSTALLATION
TECHNICAL SPECIFICATIONS - SAE-400 SEVERE DUTY
INPUT - DIESEL ENGINE
Make/Model
Description
Speed (RPM)
Displacement
Starting
System
Capacities
Perkins
1004.42 Diesel
Engine
4 cylinder
71 HP @
1725 RPM
High Idle 1800
Low Idle 1100
Full Load 1725
256 cu. in
(4.2 L)
12VDC batteries
(2) & Starter
Fuel: 22.5 gal.
85.1 L
Bore x Stroke
Oil: 8.5 Qts.
8.04 L
3.875” x 5.00”
(98.4 mm x 127.0mm)
Coolant: 3.6 gal.
13.63 L
RATED OUTPUT - WELDER
(1)
Duty Cycle
Welding Output
Volts at Rated Amps
60% (NEMA)
400 amps
36 volts
60% (Lincoln Plus)
400 amps
40 volts
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
WIDTH
DEPTH
WEIGHT
52.00 in.
1320.8 mm
28.00 in.
83.00 in.
2108.2 mm
2178 lbs.
988.0 kg
711.2 mm
(1)
Based on a 10 minute period.
SAE-400 SEVERE DUTY
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INSTALLATION
Read this entire installation section before you
start installation.
CAUTION
DO NOT MOUNT OVER COMBUSTIBLE SURFACES.
SAFETY PRECAUTIONS
WARNING
Where there is a combustible surface directly under
stationary or fixed electrical equipment, that surface
shall be covered with a steel plate at least .06”(1.6mm)
thick, which shall extend not less than 5.90”(150mm)
beyond the equipment on all sides.
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.
STACKING
These machines cannot be stacked.
ANGLE OF OPERATION
ELECTRIC SHOCK can kill.
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.
•Do not touch electrically live parts such
as output terminals or internal wiring.
•Insulate yourself from the work and
ground.
•Always wear dry insulating gloves.
------------------------------------------------------------------------
ENGINE EXHAUST can kill.
LIFTING
•Use in open, well ventilated areas or
vent exhaust outside
The equipment lift bale should be used to lift the
machine.
•Do not stack anything near the engine.
------------------------------------------------------------------------
WARNING
MOVING PARTS can injure.
• Lift only with equipment of
adequate lifting capacity.
•Do not operate with doors open or
guards off.
• Be sure machine is stable
when lifting.
• Do not lift this machine using
lift bale if it is equipped with a
heavy accessory such as trail-
er or gas cylinder.
•Stop engine before servicing.
•Keep away from moving parts
------------------------------------------------------------------------
Only qualified personnel should install, use or service
this equipment
FALLING
• Do not lift machine if lift bale
is damaged.
EQUIPMENT can • Do not operate machine while
cause injury. suspended from lift bale.
------------------------------------------------------------------------
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 SEVERE DUTY
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A-3
A-3
INSTALLATION
• 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.
• Follow vehicle manufacturer’s instruction.
----------------------------------------------------------------------------
PRE-OPERATION ENGINE SERVICE
HIGH ALTITUDE OPERATION
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.).
Contact a Perkins Service Representative for any
engine adjustments that may be required for high alti-
tude operation.
READ the engine operating and maintenance instruc-
tions supplied with this machine.
TOWING
The recommended trailers for use with this equipment
for in-plant and yard towing by a vehicle(1) are Lincoln’s
K767-1, K956-1 and K956-2. The K956-1 and K956-2
ENGINE OIL
(1)
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 Operator’s
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 Operator’s Manual for the proper service and
maintenance intervals.
are also designed to be 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 consid-
ered are as follows:
1. Design capacity of trailer vs. weight of Lincoln
equipment and likely additional attachments.
2. Proper support of, and attachment to, the base of
the welding equipment so that there will be no
undue stress to the trailer’s framework.
FUEL USE DIESEL FUEL ONLY
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.
WARNING
• Stop engine while fueling.
• Do not smoke when fueling.
• Keep sparks and flame away
from tank.
4. Typical conditions of use, such as travel speed,
roughness of surface on which the trailer will be
operated, and environmental conditions.
• Do not leave unattended while
fueling.
5. Proper preventative maintenance of trailer.
• Wipe up spilled fuel and allow
fumes to clear before starting
engine.
DIESEL FUEL
can cause fire.
1
6. Conformance with federal, state and local laws.
• Do not overfill tank, fuel
expansion may cause over-
flow.
(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.
DIESEL FUEL ONLY
------------------------------------------------------------------------
Fill the fuel tank with clean, fresh diesel fuel. The capac-
ity of the fuel tank is 22.5 gallons (85.1 liters). See engine
Operator’s Manual for specific fuel recommendations.
VEHICLE MOUNTING
WARNING
NOTE: Before starting the engine, be sure the fuel shut-
off valve on the sediment bowl is open by turning the han-
dle counterclockwise.
Improperly mounted concentrated loads may cause
unstable vehicle handling and tires or other compo-
nents to fail.
SAE-400 SEVERE DUTY
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A-4
A-4
INSTALLATION
BATTERY CONNECTION
ENGINE BREAK-IN
WARNING: Use caution as the electrolyte is a strong
acid that can burn skin and damage eyes.
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, wetstacking (oil or tar like substance
at the exhaust port), or excessive smoke is not normal.
Remove and discard the insulating caps from the neg-
ative battery terminals. Attach and tighten negative
battery cable terminals.
NOTE: This machine is furnished with wet charged
batteries; if unused for several months, the batteries
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
to the conditions described above. To accomplish suc-
cessful engine break-in, most diesel-powered equip-
ment needs only to be run at a reasonably heavy load
within the rating of the welder for some period of time
during the engine’s early life. However, if the welder is
subjected to extensive light loading, occasional moder-
ate to heavy loading of the engine may sometimes be
necessary. Caution must be observed in correctly
loading a diesel/generator unit.
WARNING
GASES FROM BATTERY can explode.
● Keep sparks, flame and cigarettes
away from battery.
To prevent EXPLOSION when:
1. Connect the welder output studs to a suit-
able resistive load bank. Note that any
attempt to short the output studs by con-
necting the welding leads together, direct
shorting of the output studs, or connecting
the output leads to a length of steel will
result in catastrophic damage to the gener-
ator and voids the warranty.
● 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
negative cable last. Keep well ventilated.
● USING A BOOSTER — connect positive lead to
battery first then connect negative lead to neg-
ative battery lead at the lower control panel
support.
2. Set the welder controls for an output cur-
rent 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 catastrophic
damage to the generator and voids the
warranty.
BATTERY ACID can burn eyes and
skin.
● Wear gloves and eye protection
and be careful when working near
battery.
3. Periodically shut off the engine and check
the crankcase oil level.
● Follow instructions printed on battery.
ENGINE COOLING SYSTEM
IMPORTANT: To prevent ELECTRICAL DAMAGE
WHEN:
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.)
a) Installing new batteries.
b) Using a booster.
Use correct polarity — Negative Ground.
To prevent BATTERY BUCKLING, tighten nuts on bat-
teries only until snug. DO NOT OVERTIGHTEN.
SAE-400 SEVERE DUTY
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A-5
A-5
INSTALLATION
MACHINE GROUNDING
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.).
SPARK ARRESTOR
The muffler included with this welder has been modi-
fied and now qualifies as a spark arrestor. Mufflers on
WARNING
To prevent dangerous electric shock, other equipment
powered by this engine driven welder must:
• Spark Arrestor and Muffler may be hot!
Allow engine to cool before servicing spark arrestor!
Do not operate engine while servicing spark arrestor!
a) be grounded to the frame of the welder using a
grounded type plug,
or
b) be double insulated.
machines manufactured before this change do not
qualify as spark arrestors and were shipped from the
factory with an additional spark arresting unit for that
purpose. Integral spark arresting mufflers will have a
clean out service plug and will have “USDA FS 51001C
QUALIFIED SPARK ARRESTOR” stamped on the
muffler shell. Any spark arrestor must be serviced and
properly maintained. For machines with separate spark
arrestors, secure the arrestor to the outlet tube on the
muffler using the clamp provided.
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.
An incorrect spark 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
------------------------------------------------------------------------
CAUTION
stud marked with the
welding generator frame foot.
symbol is provided on the
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.
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.
Table A.1 Combined Length of Electrode and
Work Cables.
TOTAL COMBINED LENGTH OF ELEC-
TRODE AND WORK CABLES
AMPS
@60%
Up to 100 FT. 100-200 FT. 200-250 FT.
(Up to 30m) (30m-61m) (61m-76m)
Duty Cycle
400
2/0 AWG
3/0 AWG
4/0 AWG
SAE-400 SEVERE DUTY
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B-1
B-1
OPERATION
WELDING SPARKS can cause
OPERATING INSTRUCTIONS
fire or explosion.
Read and understand this entire section before operat-
ing your equipment.
• Do not weld near flammable material .
• Do not weld on containers that have
held flammable material.
SAFETY INSTRUCTIONS
WARNING
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.
-----------------------------------------------------------
MOVING PARTS can injure.
• Keep away from moving parts
• Do not operate with doors open or
guards off.
• Stop engine before servicing.
------------------------------------------------------------------------
ENGINE EXHAUST can kill.
• 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 cloth-
ing.
• 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 work-
piece.
Use the following equipment:
• Semiautomatic DC constant voltage
(wire) welder.
------------------------------------------------------------------------
ADDITIONAL SAFETY PRECAUTIONS
Always operate the welder with the hinged doors
closed as these provide maximum protection from
moving parts and insure proper cooling air flow.
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 and com-
pressor instruction manuals.
• DC manual (stick) welder.
• AC welder with reduced voltage con-
trol.
GENERAL DESCRIPTION
------------------------------------------------------------------------
ARC RAYS can injure eyes and
burn skin.
The SAE-400 SEVERE DUTY is a diesel engine driven
welding power source. The machine uses a DC gener-
ator 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 output.
• Wear eye, ear, and body protection.
----------------------------------------------------------
• Only qualified personnel should install, use or
service this equipment.
• Consult instruction manual before operating.
----------------------------------------------------------------------
Before operating, read and understand the manu-
facturer’s instructions for this equipment and the
consumables to be used including the Material
Safety Data Sheet (MSDS) and follow your
employer’s safety practices.
The engine is a 71 Hp (54kw), 4-cylinder water cooled
diesel made by Perkins.
RECOMMENDED APPLICATIONS
WELDER
------------------------------------------------------------------------
FUMES AND GASES can be
The SAE-400 SEVERE DUTY provides excellent con-
stant current DC welding output for stick (SMAW) weld-
ing.
dangerous to your health.
• Keep your head out of fumes.
• Use enough ventilation or exhaust at
the arc, or both, to keep the fumes
and gases from your breathing zone
and general area.
AUXILIARY POWER
The SAE-400 SEVERE DUTY provides 3 KW of
115/230 VAC output for auxiliary power and emer-
gency standby power.
SAE-400 SEVERE DUTY
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B-2
B-2
OPERATION
DESIGN FEATURES AND ADVANTAGES
DUTY CYCLE
FOR STICK WELDING
• Excellent DC constant current output for stick weld-
ing applications.
Duty cycle is based on a ten minute period and opera-
tion in an ambient temperature of 104°F(40°C).
The SAE-400 SEVERE DUTY IS NEMA rated at 60%
duty cycle. Duty cycle is based on a ten minute period.
Therefore, a 60% duty cycle welder can be operated at
nameplate rated output for 6 minutes out of every 10
minute period without overheating.
• Continuous adjustment of both voltage and current
for unsurpassed welds on demanding jobs.
• Remote control capability standard.
FOR AUXILIARY POWER
The auxiliary power can be used continuously (100%
duty cycle) within its rated current capacities.
• 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
13
9.75
6.5
3.25
0
3.0
2.25
1.5
0.75
0
100
200
300
400
6.5
0
OTHER FEATURES
• Perkins 4-cylinder, water cooled diesel engine.
Designed for long life, easy maintenance and excel-
lent fuel economy.
• 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.
• Engine hour meter standard.
• Extended range 22.5 gallon (85.1 L) fuel tank.
SAE-400 SEVERE DUTY
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B-3
B-3
OPERATION
ENGINE CONTROLS
ENGINE PROTECTION SYSTEM
IGNITION SWITCH
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.
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.
AIR INTAKE SHUT-OFF
“IDLER” SWITCH
The air intake shut-off is a manually engaged device
that blocks all intake air from entering the engine.
The idler switch has two positions, “HIGH” and
“AUTO”.
To shut down the engine, simply pull the emergency
stop handle on the lower control panel.
When in “HIGH” (
continuously at high idle.
) position, the engine will run
/ ) idle position, the idler
The air intake shut-off device must be reset manually
inside the welder.
When in “AUTO” (
operates as follows:
• Place the ignition toggle switch in the "OFF" position
a. Welding
• Manually turn the air intake shut-off reset handle such
that the handle is in-line with the air intake hoses.
The air intake shut-off is located on the top of the
engine between the muffler and air filter.
When the electrode touches the work, the welding
arc is initiated and the engine accelerates to full
speed.
WARNING
After welding ceases (and no auxiliary power is
being drawn), the engine will return to low idle after
approximately 10 to 14 seconds.
• Muffler and Engine may be hot!
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.
IMPORTANT: Before restarting engine, verify that the
air intake shut-off is in the open position. DO NOT
ATTEMPT TO START ENGINE WITH THE AIR
INTAKE SHUT-OFF IN THE CLOSED POSITION.
This may cause severe damage to the engine.
ENGINE TEMPERATURE GAUGE
Displays the coolant temperature in the engine block.
ENGINE OIL PRESSURE GAUGE
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.
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 ‘low’ 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 SEVERE DUTY
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B-4
B-4
OPERATION
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.
WELDER CONTROLS
POLARITY SWITCH
Turn the Arc Polarity switch to electrode positive or
electrode negative as required for each particular
application.
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.
CONTROL OF WELDING CURRENT
Purpose of Controls
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.
REMOTE CONTROL
“Job Selector”
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.
The “Job Selector” dial is divided into four colored sec-
tions providing OCV ranges as follows:
Color
White
Black
Red
Title
OCV Range
High OCV
Medium OCV
Large Electrodes
Normal Welding
Overhead & Vertical Low OCV
Grey
Special Applications Extra-Low OCV
AUXILIARY POWER CONTROLS
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.
Note: GFCI receptacles our an option and if installed,
see the “MAINTENANCE SECTION” for detailed
information on testing and resetting the GFCI
receptacle.
“Current Control”
115 VAC Receptacle
CAUTION
One 20 amp, 115 VAC duplex receptacle provides 115
VAC for auxiliary power. A total of 26 amps can be
drawn from this receptacle.
Do not adjust the “Current Control” while welding
because this can damage the control.
------------------------------------------------------------------------
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.
230 VAC Receptacle
One 15 amp, 230 VAC duplex receptacle provides 230
VAC for auxiliary power. A total of 13 amps can be
drawn from this receptacle.
How to Set the Controls
Circuit Breakers
Assume you want a normal soft arc and about 135
amps, using a 5/32” (4.0 mm) electrode:
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.
1. Set the “Job Selector” at the center of the black
range.
2. Set the “Current Control” to read 135 amps on the
Ground Stud
black dial.
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.
3. Start to weld.
SAE-400 SEVERE DUTY
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B-5
B-5
OPERATION
BREAK-IN PERIOD
ENGINE OPERATION
CAUTION
ENGINE
Do not adjust the high idle engine speed (rpm)
The engine used to supply power for your welder is a
heavy duty, industrial engine. It is designed and built
for rugged use. It is very normal for any engine to use
small quantities of oil until the break-in is accom-
plished. Check the oil level twice a day during the
break-in period (about 100 running hours).
above the factory setting specification.
------------------------------------------------------------------------
STARTING INSTRUCTIONS
Be sure all Pre-Operation Maintenance has been per-
formed. (See INSTALLATION section of this manual).
To start the engine, place ignition toggle switch in the
“ON” position. Engage the starter button. When the
engine starts running, observe the engine oil pressure.
If no pressure shows within 30 seconds, stop the
engine and consult the engine operating manual. To
stop the engine, place the ignition toggle switch in the
“OFF” position.
IMPORTANT: IN ORDER TO ACCOMPLISH THIS
BREAK-IN, THE UNIT SHOULD BE SUBJECTED TO
HEAVY LOADS, WITHIN THE RATING OF THE
MACHINE. AVOID LONG IDLE RUNNING PERIODS.
TYPICAL FUEL CONSUMPTION
When an engine is started for the first time, some of
the oil will be needed to fill the passages of the lubri-
cating system. Therefore, on initial starting, run the
engine for about five minutes and then stop the engine
and recheck the oil. If the level is down, fill to the full
mark again. The engine controls were properly set at
the factory and should require no adjusting when
received.
The typical fuel consumption of the SAE-400 SEVERE
DUTY for various operating scenarios is shown below:
Low Idle - No Load
1100 RPM
.35 gal./ hr.
(1.32 L./hr.)
High Idle - No Load
1800 RPM
.75 gal./hr.
(2.84 L./hr.)
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 or gener-
ator overheating.
Welding Load
400 Amps, 40 Volts
1.92 gal./hr.
(7.27 L./hr.)
Auxiliary Power
3000VA
.96 gal./hr.
(3.63 L./hr.)
Cold Weather Starting
WARNING
Never use any other starting aids, such as ether,
when using the “Thermostart” system.
------------------------------------------------------------------------
When overnight temperatures are between 10°F(12°C)
and freezing, use the standard “Thermostart” starting
system installed on all engines. Follow the instructions
on the start panel nameplate and in the engine manu-
al shipped with the welder. With fully charged batter-
ies and the proper weight oil, the “Thermostart” system
operates satisfactorily even down to about 0°F (-18°C).
SAE-400 SEVERE DUTY
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C-1
C-1
ACCESSORIES
OPTIONAL FIELD INSTALLED
ACCESSORIES
K802-D Power Plug Kit - Kit includes male plugs for
each auxiliary receptacle.
K767-1 Trailer - A 4-wheel steerable trailer for in-plant
and yard towing(1) with E78-14 load range (B) tubeless
tires. Mounts directly to welder base.
K956-1 and -2 Trailer - A 2-wheel trailer designed for
road(1), off road, in-plant and yard towing. The K956-2
trailer is equipped with electric brakes. Trailer mounts
directly to welder base.
1For highway use, consult applicable federal, state and local laws regarding
possible requirements for brakes, lights, fenders, etc.
K704 Standard Accessory Kit - Includes electrode
and work cables, headshield, work clamp and elec-
trode holder.
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 SEVERE DUTY
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D-1
D-1
MAINTENANCE
WARNING
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.
ELECTRIC SHOCK can kill.
● Do not touch electrically live parts
such as output terminals or inter-
nal wiring
ENGINE OIL CHANGE
The SAE-400 SEVERE DUTY is equipped with a convenient
oil drain system. Drain the oil when the engine is warm to
assure rapid and complete draining.
ENGINE EXHAUST can kill.
● Use in open, well ventilated areas
• Remove the oil filler cap and dipstick.
or vent exhaust outside
• To open drain valve, push handle away from valve and turn
90°.
MOVING PARTS can injure.
● Do not operate with doors open or
• Drain oil into a suitable container.
guards off
• To close drain valve, turn handle 90° till handle snaps in the
closed position.
● Stop engine before servicing
● Keep away from moving parts
• Refill engine with the recommended oil to the appropriate
level. Replace dipstick and tighten the oil filler cap secure-
ly.
● Remove guards only when necessary and
replace when work requiring removal is com-
plete.
● Only qualified personnel should install, use, or
Change the crankcase oil at regular intervals using the prop-
er grade of oil as recommended in the Engine Operating
Manual. Wash your hands with soap and water after handling
used oil. Please dispose of used motor oil in a manner that is
compatible with the environment. We suggest you take it in a
sealed container to your local service station or recycling
center for reclamation. Do not throw it in the trash, pour it on
the ground or down a drain.
service this equipment.
ROUTINE MAINTENANCE
At the end of each day’s 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 level.
ENGINE AIR FILTER
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.
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.
PERIODIC MAINTENANCE
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.
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.
3. See the engine Instruction Manual for periodic engine
maintenance information. Change the oil filter in accor-
dance with the instructions in the engine operating man-
ual. When the oil filter is changed add one quart of oil to
the crankcase to replace the oil held in the filter during
operation.
SAE-400 SEVERE DUTY
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D-2
D-2
MAINTENANCE
BEARING MAINTENANCE
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. Pull the sandpaper around the cir-
cumference 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%.
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.
Arcing or excessive exciter brush wear indicates a pos-
sible misaligned shaft. Have an authorized Field
Service Shop check and realign the shaft.
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.
COOLING SYSTEM
COMMUTATOR AND BRUSH MAINTENANCE
The SAE-400 SEVERE DUTY is equipped with a pres-
sure radiator. Keep the radiator cap tight to prevent
loss of coolant. Clean and flush the cooling system
periodically to prevent clogging the passage and over-
heating the engine. When antifreeze is needed, always
use the permanent type.
WARNING
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.
FUEL FILTERS
WARNING
When working on the fuel system
• Keep ungrounded lights away, do not
smoke !
Shifting of the brushes may result in:
- Change in machine output
- Commutator Damage
• Do not spill fuel !
- Excessive brush wear
------------------------------------------------------------------------
The SAE-400 SEVERE DUTY is equipped with a Fuel
Pre-Filter/Water Separator Assembly located before
the lift pump and a Secondary Fuel Filter located after
the lift pump and before the fuel injectors. The Fuel
Pre-Filter/Water Separator is mounted to the engine
block just below the lift pump.
Periodically inspect the commutator, slip rings and
brushes by removing the covers. DO NOT remove or
replace these covers while the machine is running.
Commutators and slip rings require little attention.
However, if they are black or appear uneven, have
them cleaned by an experienced maintenance man
using fine sandpaper or a commutator stone. Never
use emery cloth or paper for this purpose.
The Secondary Fuel Filter is mounted directly to the
engine just above the oil filter.
FUEL PRE-FILTER/WATER SEPARATOR ASSEMBLY
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.
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:
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
man seat these brushes by lightly stoning the commu-
tator as the armature rotates at full speed until contact
is made across the full face of the brushes. After ston-
ing, blow out the dust with low pressure air.
SAE-400 SEVERE DUTY
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D-3
D-3
MAINTENANCE
1. Close the fuel shutoff valve located on the fuel
strainer mounted to the under side of the fuel tank.
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.
2. Unscrew the cap ring located on the top of the filter
header and remove the plastic center cap and O-
ring.
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.
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.
Be careful not to damage the pre-filter screen with
the tool used to remove the plug.
Note: The element will only go on one way. Never use
excessive force when mounting the element to the
header.
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.
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 doesn’t 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. 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.
7. Re-insert the large white volume plug into the upper
cavity.
Note : Consult your engine operation manual for infor-
mation on air bleeding the entire fuel system.
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.
SECONDARY FUEL FILTER
The Secondary Fuel Filter has a quick change element
mounted to the engine similar to the Water Separator.
Consult your engine operation manual for complete infor-
mation on service intervals and element changing proce-
dures.
9. Screw on the cap ring and tighten hand tight.
10. Remember to open the fuel shutoff valve before
starting the engine.
ENGINE MAINTENANCE COMPONENTS
WATER SEPARATOR ELEMENT
ITEM
MAKE
PART NUMBER
P181052
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:
Engine Air Filter
Fan Belt
Donaldson
Perkins
2614B550
Water Separator
Element
Lincoln
Stanadyne
M16890-C
31572
1. Close the fuel shutoff valve located on the fuel
strainer mounted to the under side of the fuel tank.
Fuel Pre-Filter Screen Lincoln
Stanadyne
M16890-B
29575
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.
Fuel Filter
Perkins
Perkins
26560143
2654403
Engine Oil Filter
SAE-400 SEVERE DUTY
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D-4
D-4
MAINTENANCE
SPARK ARRESTOR
GFCI RECEPTACLE TESTING AND RESET-
TING PROCEDURE
WARNING
• Spark Arrestor and Muffler may be hot!
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:
Allow engine to cool before servicing spark arrestor!
Do not operate engine while servicing spark arrestor!
• If the receptacle has tripped, first carefully remove
any load and check it for damage.
For machines with separate spark arresting unit:
• If the equipment has been shut down, it must be
restarted.
Service the spark arrestor every 100 hours of opera-
tion or twice a year, which ever occurs first.
Service as follows:
• 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.
• 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".
1. Stop engine and allow to cool.
2. Loosen clamp and remove spark arrestor from
machine.
3. Remove locknut on top of spark arrestor housing
and lift off cap.
4. Separate plates and clean if necessary.
• 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.
5. Inspect plates and housing for holes or cracks.
Replace spark arrestor if damaged.
6. Assemble spark arrestor using reverse order: step
3, then step 2.
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.
For machines with integral spark arresting muf-
flers:
Service spark arrestor every 250 hours.
Service as follows:
1. Stop engine and allow to cool.
2. Remove clean out plug from the side of the spark
arrestor.
3. Without damaging the spark arrestor, gently tap on
the shell near the clean out plug.
4. Once particles are removed, replace the clean out
plug.
SAE-400 SEVERE DUTY
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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.
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).
If you do not understand or are unable to perform the
Recommended Course of Action safely, contact your
local Lincoln Authorized Field Service Facility.
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.
Step 2. POSSIBLE CAUSE.
The second column labeled “POSSIBLE CAUSE” lists
the obvious external possibilities that may contribute to
the machine symptom.
Step 3. RECOMMENDED COURSE OF ACTION
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 SEVERE DUTY
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E-2
E-2
TROUBLESHOOTING
Observe all Safety Guidelines detailed throughout this manual
POSSIBLE AREAS OF
MISADJUSTMENT(S)
PROBLEMS
(SYMPTOMS)
RECOMMENDED
COURSE OF ACTION
Engine will “crank” but not start.
1. Air intake shut-off is closed.
Manually reset inside machine.
2. Out of fuel. Fill fuel tank.
3. Fuel shut off valve is in off posi-
tion.
4. Low battery voltage.
Machine fails to hold the “heat”
1. Rough or dirty commutator.
constantly.
2. Brushes may be worn down to
limit of life.
3. Brush springs may be broken.
4. Field circuit may have variable
resistance connections or inter-
mittent open circuit, due to loose
connections or broken wire.
If all recommended possible areas
of misadjustment have been
checked and the problem persists,
Contact your local Lincoln
5. Electrode or work lead connec-
tions may be poor.
6. Wrong grade of brushes may be Authorized Field Service Facility.
installed on generator.
7. Field rheostat may be making
poor contact and overheating.
8. “Current Control” may not be
operating properly.
9. “Current Control” brushholder
contact springs may be worn out
or missing. Contact surface may
be dirty, rough and pitted.
10. “Current Control” brushholder
support stud and mating contact
surfaces may be dirty or pitted
and burned.
11. Engine running at varying
speeds.
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 SEVERE DUTY
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E-3
E-3
TROUBLESHOOTING
Observe all Safety Guidelines detailed throughout this manual
POSSIBLE AREAS OF
MISADJUSTMENT(S)
PROBLEMS
(SYMPTOMS)
RECOMMENDED
COURSE OF ACTION
Welder runs but fails to generate
current.
1. Generator or exciter brushes may
be loose or missing.
2. Exciter may not be operating.
3. Field circuit of generator or exciter
may be open.
4. Polarity reversing switch may be
in the neutral position.
5. Exciter may have lost excitation.
If all recommended possible areas
of misadjustment have been
checked and the problem persists,
Contact your local Lincoln
Authorized Field Service Facility.
Welding arc is loud and spatters
excessively.
1. Series field circuit may be open
circuited.
2. Current setting may be too high.
3. Polarity may be wrong.
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 SEVERE DUTY
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E-4
E-4
TROUBLESHOOTING
Observe all Safety Guidelines detailed throughout this manual
POSSIBLE AREAS OF
MISADJUSTMENT(S)
PROBLEMS
(SYMPTOMS)
RECOMMENDED
COURSE OF ACTION
Welding current too great or too
small compared to indication on the
dial.
1. “Current Control” shaft and han-
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.
2. Exciter output low causing low
output compared to dial indica-
tion.
3. “Current Control” set to minimum
and welder output so great that
engine stalls when arc is struck.
Welder has output and no control
1. Local/Remote switch is in wrong If all recommended possible areas
position.
of misadjustment have been
checked and the problem persists,
Contact your local Lincoln
Authorized Field Service Facility.
No auxiliary power
1. GFCI Receptacle may have
tripped. Follow “GFCI Receptacle
Testing and Resetting Procedure”
in the MAINTENANCE section of
this manual. (GFCI Receptacle is
Optional)
2. Circuit Breakers open.
3. Faulty connections to auxiliary
receptacles.
4. Faulty receptacles.
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 SEVERE DUTY
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F-1
F-1
WIRING DIAGRAMS
+
+
+
+
+
SAE-400 SEVERE DUTY
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F-2
F-2
WIRING DIAGRAMS
SAE-400 SEVERE DUTY
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F-3
F-3
DIMENSION PRINT
SAE-400 SEVERE DUTY
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NOTES
SAE-400 SEVER DUTY
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● 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.
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● 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.
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• 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
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