Page 2 - SAFETY; WARNING; CALIFORNIA PROPOSITION 65 WARNINGS; The Above For Diesel Engines
FOR ENGINEpowered equipment. 1.a. Turn the engine off before troubleshooting and maintenance work unless the maintenance work requires it to be running. ____________________________________________________ 1.b. Operate engines in open, well-ventilated areas or vent the engine exhaust fumesoutdoors. ...
Page 3 - ii; ELECTRIC SHOCK can kill.
ii SAFETY ii ARC RAYS can burn. 4.a. Use a shield with the proper filter and cover plates to protect your eyes from sparks andthe rays of the arc when welding or observingopen arc welding. Headshield and filter lensshould conform to ANSI Z87. I standards. 4.b. Use suitable clothing made from durable...
Page 4 - iii
iii SAFETY iii FOR ELECTRICALLYpowered equipment. 8.a. Turn off input power using the disconnect switch at the fuse box before working onthe equipment. 8.b. Install equipment in accordance with the U.S. National Electrical Code, all local codes and the manufacturerʼsrecommendations. 8.c. Ground the ...
Page 5 - iv; PRÉCAUTIONS DE SÛRETÉ
iv SAFETY iv Mar. ʻ93 PRÉCAUTIONS DE SÛRETÉ 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: Sûreté Pour Soudage A LʼArc 1. Protegez-vous contr...
Page 6 - Thank You; Please Examine Carton and Equipment For Damage Immediately
v v Thank You 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! Read this Operators Manual completely before attempting to use this equipment. Save this manual...
Page 7 - TABLE OF CONTENTS
vi TABLE OF CONTENTS SAE-400 vi Page Installation Instructions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Section A Technical Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .A-1Installa...
Page 8 - INSTALLATION; INPUT - DIESEL ENGINE
A-1 INSTALLATION SAE-400 A-1 TECHNICAL SPECIFICATIONS - SAE-400 (K1278-7, K1278-9) Make/Model Description Speed (RPM) Displacement Starting Capacities System K1278-7 Perkins 4 cylinder High Idle 1800 269 cu. in 12VDC batteries Fuel: 22.5 gal. 1104C-44 Diesel 68.4 HP @ Low Idle 1100 (4.4 L) (2) &...
Page 9 - SAFETY PRECAUTIONS; STACKING
A-2 INSTALLATION SAE-400 A-2 Read this entire installation section before youstart installation. SAFETY PRECAUTIONS Do not attempt to use this equipment until you havethoroughly read all operating and maintenance man-uals supplied with your machine. They include impor-tant safety precautions, detail...
Page 10 - HIGH ALTITUDE OPERATION; VEHICLE MOUNTING; PRE-OPERATION ENGINE SERVICE; ENGINE OIL
A-3 INSTALLATION SAE-400 A-3 HIGH ALTITUDE OPERATION At higher altitudes, output derating may be necessary.As a rule of thumb, derate the welder output 5% forevery 500 meters (1640 ft.) above 1000 meters (3280ft.). Contact a Perkins Service Representative for anyengine adjustments that may be requir...
Page 11 - DIESEL FUEL ONLY; ENGINE COOLING SYSTEM; DIESEL FUEL
A-4 INSTALLATION A-4 SAE-400 • Stop engine while fueling.• Do not smoke when fueling.• Keep sparks and flame away from tank. • Do not leave unattended while fueling. • Wipe up spilled fuel and allow fumes to clear before startingengine. • Do not overfill tank, fuelexpansion may cause over-flow. DIES...
Page 12 - SPARK ARRESTER; WELDING OUTPUT CABLES
negative cable last. Keep well ven- tilated. ● USING A BOOSTER — connectpositive lead to battery first thenconnect negative lead to negativebattery lead at the lower controlpanel support. BATTERY ACID can burn eyes and skin. ● Wear gloves and eye protection and be carefulwhen working near battery. ●...
Page 13 - OPERATION; ADDITIONAL SAFETY PRECAUTIONS; GENERAL DESCRIPTION
B-1 OPERATION B-1 both, to keep the fumes and gases from your breathing zone and general area. WELDING SPARKS can cause fire orexplosion. • Do not weld near flammable material . • Do not weld on containers that have held flammable material. -----------------------------------------------------------...
Page 14 - RECOMMENDED APPLICATIONS; DESIGN FEATURES AND ADVANTAGES; DUTY CYCLE
B-2 OPERATION B-2 RECOMMENDED APPLICATIONS WELDER The SAE-400 provides excellent constant current DCwelding output for stick (SMAW) welding. The fieldinstalled optional CV Adapter (K385-[ ]) provides up to500 amps at 35 volts of constant voltage output forsemiautomatic welding. AUXILIARY POWER The S...
Page 15 - ENGINE CONTROLS; CAUTION
B-3 OPERATION B-3 ENGINE CONTROLS 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 toshut down the engine. “IDLER” SWITCH The idler switch has two positions, “HIGH” and“AU...
Page 16 - REMOTE CONTROL
B-4 OPERATION B-4 How to Set the Controls Assume you want a normal soft arc and about 135amps, using a 5/32” (4.0 mm) electrode: 1. Set the “Job Selector” at the center of the black range. 2. Set the “Current Control” to read 135 amps on the black dial. 3. Start to weld. 4. If you want a little more...
Page 17 - ENGINE OPERATION; STARTING INSTRUCTIONS; See additional warning information at the; STOPPING THE ENGINE
B-5 OPERATION B-5 SAE-400 ENGINE OPERATION For added safety always operate the welder with thedoors closed. Further, leaving the doors open changesthe designed air flow and may cause engine, genera-tor overheating. Do not adjust the high idle engine speed (rpm)above the factory setting specification...
Page 18 - TYPICAL FUEL CONSUMPTION
B-6 OPERATION B-6 SAE-400 TYPICAL FUEL CONSUMPTION The typical fuel consumption of the SAE-400 for various operating scenarios isshown below: PERKINS 1104C-44 PERKINS 1104A-44 Low Idle - No Load .30 gal./ hr. 26 gal./ hr. 1100 RPM (1.12 L./hr.) (.97 L./hr.) High Idle - No Load .69 gal./hr. .68 gal./...
Page 19 - ACCESSORIES
C-1 ACCESSORIES C-1 K930-2 TIG Module - Provides high frequency plus a gas valve for TIG welding. A water valve is available asan option. Requires 115 volt AC input. (Limited to 250A- 60% Duty Cycle). K802-D Power Plug Kit - Kit includes male plug for 20 amp receptacle. K2641-1 Trailer - A 4-wheel s...
Page 20 - MAINTENANCE; ROUTINE MAINTENANCE
D-1 MAINTENANCE D-1 ELECTRIC SHOCK can kill. ● Do not touch electrically live partssuch as output terminals or inter-nal wiring ENGINE EXHAUST can kill. ● Use in open, well ventilated areasor vent exhaust outside MOVING PARTS can injure. ● Do not operate with doors open orguards off ● Stop engine be...
Page 21 - PRE FILTER / WATER SEPARATOR
D-2 MAINTENANCE D-2 SAE-400 COMMUTATOR AND BRUSH MAINTENANCE Uncovered rotating equipment can be dangerous.Use care so your hands, hair, clothing or tools donot catch in the rotating parts. Protect yourselffrom particles that may be thrown out by the rotat-ing armature when stoning the commutator. -...
Page 22 - WATER SEPARATOR ELEMENT
D-3 MAINTENANCE D-3 SAE-400 4. Using a pair of pliers, gently tug on the pull tabs of the pre-filter screen in an alternating pattern togradually remove the pre-filter screen. 5. Brush off any debris and rinse in diesel fuel. 6. Re-install the pre-filter screen into the upper cavity of the filter he...
Page 23 - SPARK ARRESTOR
D-4 MAINTENANCE D-4 SAE-400 GFCI RECEPTACLE TESTING AND RESET-TING PROCEDURE The GFCI receptacle should be properly tested at leastonce every month or whenever it is tripped. To proper-ly test and reset the GFCI receptacle: • If the receptacle has tripped, first carefully remove any load and check i...
Page 24 - TROUBLESHOOTING; HOW TO USE TROUBLESHOOTING GUIDE
E-1 TROUBLESHOOTING E-1 SAE-400 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. CAUTION WARNING ELECTRIC SHOCK can ...
Page 25 - FUNCTION PROBLEMS
E-2 TROUBLESHOOTING E-2 SAE-400 Observe all Safety Guidelines detailed throughout this manual 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 assi...
Page 29 - WIRING DIAGRAMS; CODE
F-1 WIRING DIAGRAMS SAE-400 F-1 CODE NOTE: This diagram is for reference only . It may not be accurate for all machines covered by this manual. The specific diagram for a particular code is pasted inside the machine on one of the enclosure panels.
Page 30 - WIRING DIAGRAM
F-2 WIRING DIAGRAM F-2 SAE-400 NOTE: This diagram is for reference only . It may not be accurate for all machines covered by this manual. The specific diagram for a particular code is pasted inside the machine on one of the enclosure panels.
Page 33 - DIMENSION PRINT
SAE-400 F-5 DIMENSION PRINT F-5 M8 86 9 -3 6 AA N. A. .81 HO LES N. B. .69 HO LES 28. 00 22. 00 22. 14 24. 50 27. 12 6. 00 39. 69 47. 95 23. 00 26. 00 38. 50 63. 06 50. 13 21. 00 44. 00 8. 90 44. 50 69. 75 8. 12 77. 00 3. 00 81. 25 .8 8 83. 00 C E N T E R OF GR AVIT Y W IT H OIL AND W A TER I N ENG ...
Page 34 - NOTES
