IM10027

SAE-400 ™
DC ARC WELDING POWER SOURCE April, 2010

For use with machines having Code Numbers: 11605

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.

OPERATOR’S 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
i i
SAFETY
WARNING
CALIFORNIA PROPOSITION 65 WARNINGS
Diesel engine exhaust and some of its constituents The engine exhaust from this product contains
are known to the State of California to cause can- chemicals known to the State of California to cause
cer, birth defects, and other reproductive harm. cancer, birth defects, or other reproductive harm.
The Above For Diesel Engines The Above For Gasoline Engines
ARC WELDING CAN bE HAzARDOUS. PROTECT YOURSELF AND OTHERS FROM POSSIbLE SERIOUS INJURY OR DEATH.
KEEP CHILDREN AWAY. PACEMAKER WEARERS SHOULD CONSULT WITH THEIR DOCTOR bEFORE OPERATING.

Read and understand the following safety highlights. For additional safety information, it is strongly recommended that you
purchase a copy of “Safety in Welding & Cutting - ANSI Standard Z49.1” from the American Welding Society, P.O. Box 351040,
Miami, Florida 33135 or CSA Standard W117.2-1974. A Free copy of “Arc Welding Safety” booklet E205 is available from the
Lincoln Electric Company, 22801 St. Clair Avenue, Cleveland, Ohio 44117-1199.

bE SURE THAT ALL INSTALLATION, OPERATION, MAINTENANCE AND REPAIR PROCEDURES ARE
PERFORMED ONLY bY QUALIFIED INDIVIDUALS.

FOR ENGINE 1.h. To avoid scalding, do not remove the

radiator pressure cap when the engine is
powered equipment. hot.
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 fumes
outdoors.

ELECTRIC AND
MAGNETIC FIELDS
____________________________________________________
1.c. Do not add the fuel near an open flame weld- may be dangerous
ing arc or when the engine is running. Stop
the engine and allow it to cool before refuel- 2.a. Electric current flowing through any conductor causes
ing to prevent spilled fuel from vaporizing on localized Electric and Magnetic Fields (EMF). Welding
contact with hot engine parts and igniting. Do current creates EMF fields around welding cables and
not spill fuel when filling tank. If fuel is spilled, welding machines
wipe it up and do not start engine until fumes
have been eliminated. 2.b. EMF fields may interfere with some pacemakers, and
____________________________________________________ welders having a pacemaker should consult their physician
1.d. Keep all equipment safety guards, covers and devices in posi- before welding.
tion and in good repair.Keep hands, hair, clothing and tools
away from V-belts, gears, fans and all other moving parts 2.c. Exposure to EMF fields in welding may have other health
when starting, operating or repairing equipment. effects which are now not known.
____________________________________________________

1.e. In some cases it may be necessary to remove safety 2.d. All welders should use the following procedures in order to
guards to perform required maintenance. Remove minimize exposure to EMF fields from the welding circuit:
guards only when necessary and replace them when the
maintenance requiring their removal is complete. 2.d.1. Route the electrode and work cables together - Secure
Always use the greatest care when working near moving them with tape when possible.
parts.
___________________________________________________ 2.d.2. Never coil the electrode lead around your body.
1.f. Do not put your hands near the engine fan.
Do not attempt to override the governor or 2.d.3. Do not place your body between the electrode and
idler by pushing on the throttle control rods work cables. If the electrode cable is on your right
while the engine is running. side, the work cable should also be on your right side.

2.d.4. Connect the work cable to the workpiece as close as

possible to the area being welded.
___________________________________________________
1.g. To prevent accidentally starting gasoline engines while 2.d.5. Do not work next to welding power source.
turning the engine or welding generator during maintenance
work, disconnect the spark plug wires, distributor cap or
magneto wire as appropriate.
ii SAFETY ii

ELECTRIC SHOCK can kill. ARC RAYS can burn.

3.a. The electrode and work (or ground) circuits 4.a. Use a shield with the proper filter and cover
are electrically “hot” when the welder is on. plates to protect your eyes from sparks and
Do not touch these “hot” parts with your bare the rays of the arc when welding or observing
skin or wet clothing. Wear dry, hole-free open arc welding. Headshield and filter lens
gloves to insulate hands. should conform to ANSI Z87. I standards.

3.b. Insulate yourself from work and ground using dry insulation. 4.b. Use suitable clothing made from durable flame-resistant
Make certain the insulation is large enough to cover your full material to protect your skin and that of your helpers from
area of physical contact with work and ground. the arc rays.

In addition to the normal safety precautions, if welding 4.c. Protect other nearby personnel with suitable, non-flammable
must be performed under electrically hazardous screening and/or warn them not to watch the arc nor expose
conditions (in damp locations or while wearing wet themselves to the arc rays or to hot spatter or metal.
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 FUMES AND GASES
accidental contact with the workpiece or ground) use
the following equipment: can be dangerous.
• Semiautomatic DC Constant Voltage (Wire) Welder. 5.a. Welding may produce fumes and gases
• DC Manual (Stick) Welder. 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, ventilation and/or exhaust at the arc to keep
electrode reel, welding head, nozzle or semiautomatic fumes and gases away from the breathing zone. When
welding gun are also electrically “hot”. welding with electrodes which require special
ventilation such as stainless or hard facing (see
3.d. Always be sure the work cable makes a good electrical instructions on container or MSDS) or on lead or
connection with the metal being welded. The connection cadmium plated steel and other metals or coatings
should be as close as possible to the area being welded. which produce highly toxic fumes, keep exposure as
low as possible and within applicable OSHA PEL and
3.e. Ground the work or metal to be welded to a good electrical ACGIH TLV limits using local exhaust or mechanical ven-
(earth) ground. tilation. In confined spaces or in some circumstances,
outdoors, a respirator may be required. Additional pre-
3.f. Maintain the electrode holder, work clamp, welding cable cautions are also required when welding on galvanized
and welding machine in good, safe operating condition. Replace steel.
damaged insulation.
5. b. The operation of welding fume control equipment is affected
3.g. Never dip the electrode in water for cooling. by various factors including proper use and positioning of the
equipment, maintenance of the equipment and the specific
3.h. Never simultaneously touch electrically “hot” parts of welding procedure and application involved. Worker expo-
electrode holders connected to two welders because voltage sure level should be checked upon installation and periodi-
between the two can be the total of the open circuit voltage cally thereafter to be certain it is within applicable OSHA
of both welders. PEL and ACGIH TLV limits.

3.i. When working above floor level, use a safety belt to protect 5.c. Do not weld in locations near chlorinated hydrocarbon vapors
yourself from a fall should you get a shock. coming from degreasing, cleaning or spraying operations.
The heat and rays of the arc can react with solvent vapors to
3.j. Also see Items 6.c. and 8. form phosgene, a highly toxic gas, and other irritating prod-
ucts.

5.d. Shielding gases used for arc welding can displace air and
cause injury or death. Always use enough ventilation,
especially in confined areas, to insure breathing air is safe.

5.e. Read and understand the manufacturer’s instructions for this

equipment and the consumables to be used, including the
material safety data sheet (MSDS) and follow your
employer’s safety practices. MSDS forms are available from
your welding distributor or from the manufacturer.

5.f. Also see item 1.b.

iii SAFETY iii

WELDING and CUTTING CYLINDER may explode

SPARKS can if damaged.
cause fire or explosion. 7.a. Use only compressed gas cylinders
6.a. Remove fire hazards from the welding area. containing the correct shielding gas for the
If this is not possible, cover them to prevent process used and properly operating
the welding sparks from starting a fire. regulators designed for the gas and
Remember that welding sparks and hot pressure used. All hoses, fittings, etc. should be suitable for
materials from welding can easily go through small cracks the application and maintained in good condition.
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 7.c. Cylinders should be located:
situations. Refer to “Safety in Welding and Cutting” (ANSI • Away from areas where they may be struck or subjected to
Standard Z49.1) and the operating information for the physical damage.
equipment being used.
• A safe distance from arc welding or cutting operations and
6.c. When not welding, make certain no part of the electrode any other source of heat, sparks, or flame.
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 7.e. Keep your head and face away from the cylinder valve outlet
will not cause flammable or toxic vapors from substances when opening the cylinder valve.
inside. They can cause an explosion even though they have
been “cleaned”. For information, purchase “Recommended 7.f. Valve protection caps should always be in place and hand
Safe Practices for the Preparation for Welding and Cutting of tight except when the cylinder is in use or connected for
Containers and Piping That Have Held Hazardous use.
Substances”, AWS F4.1 from the American Welding Society
(see address above). 7.g. Read and follow the instructions on compressed gas
cylinders, associated equipment, and CGA publication P-l,
6.e. Vent hollow castings or containers before heating, cutting or “Precautions for Safe Handling of Compressed Gases in
welding. They may explode. Cylinders,” available from the Compressed Gas Association
1235 Jefferson Davis Highway, Arlington, VA 22202.
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.
FOR ELECTRICALLY
Always wear safety glasses with side shields when in a powered equipment.
welding area.
8.a. Turn off input power using the disconnect
6.g. Connect the work cable to the work as close to the welding switch at the fuse box before working on
area as practical. Work cables connected to the building the equipment.
framework or other locations away from the welding area
increase the possibility of the welding current passing 8.b. Install equipment in accordance with the U.S. National
through lifting chains, crane cables or other alternate circuits. Electrical Code, all local codes and the manufacturer’s
This can create fire hazards or overheat lifting chains or recommendations.
cables until they fail.
8.c. Ground the equipment in accordance with the U.S. National
6.h. Also see item 1.c. Electrical Code and the manufacturer’s recommendations.

6.I. Read and follow 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.

6.j. Do not use a welding power source for pipe thawing.

Refer to http://www.lincolnelectric.com/safety for additional safety information.

iv SAFETY iv

6. Eloigner les matériaux inflammables ou les recouvrir afin de

PRÉCAUTIONS DE SÛRETÉ 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 7. Quand on ne soude pas, poser la pince à une endroit isolé de
manuel aussi bien que les précautions de sûreté générales suiv- la masse. Un court-circuit accidental peut provoquer un
antes: échauffement et un risque d’incendie.

Sûreté Pour Soudage A L’Arc 8. S’assurer que la masse est connectée le plus prés possible de
1. Protegez-vous contre la secousse électrique: 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
a. Les circuits à l’électrode et à la piéce sont sous tension éloignés de la zone de travail, on augmente le risque de voir
quand la machine à souder est en marche. Eviter toujours passer le courant de soudage par les chaines de levage,
tout contact entre les parties sous tension et la peau nue câbles de grue, ou autres circuits. Cela peut provoquer des
ou les vétements mouillés. Porter des gants secs et sans risques d’incendie ou d’echauffement des chaines et des
trous pour isoler les mains. câbles jusqu’à ce qu’ils se rompent.
b. Faire trés attention de bien s’isoler de la masse quand on
soude dans des endroits humides, ou sur un plancher met- 9. Assurer une ventilation suffisante dans la zone de soudage.
allique ou des grilles metalliques, principalement dans Ceci est particuliérement important pour le soudage de tôles
les positions assis ou couché pour lesquelles une grande galvanisées plombées, ou cadmiées ou tout autre métal qui
partie du corps peut être en contact avec la masse. produit des fumeés toxiques.
c. Maintenir le porte-électrode, la pince de masse, le câble de
soudage et la machine à souder en bon et sûr état defonc- 10. Ne pas souder en présence de vapeurs de chlore provenant
tionnement. d’opérations de dégraissage, nettoyage ou pistolage. La
d.Ne jamais plonger le porte-électrode dans l’eau pour le chaleur ou les rayons de l’arc peuvent réagir avec les vapeurs
refroidir. du solvant pour produire du phosgéne (gas fortement toxique)
e. Ne jamais toucher simultanément les parties sous tension ou autres produits irritants.
des porte-électrodes connectés à deux machines à souder
parce que la tension entre les deux pinces peut être le total 11. Pour obtenir de plus amples renseignements sur la sûreté, voir
de la tension à vide des deux machines. le code “Code for safety in welding and cutting” CSA Standard
f. Si on utilise la machine à souder comme une source de W 117.2-1974.
courant pour soudage semi-automatique, ces precautions
pour le porte-électrode s’applicuent aussi au pistolet de
PRÉCAUTIONS DE SÛRETÉ POUR
soudage.
LES MACHINES À SOUDER À
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
TRANSFORMATEUR ET À
enrouler le câble-électrode autour de n’importe quelle partie du REDRESSEUR
corps.

3. Un coup d’arc peut être plus sévère qu’un coup de soliel, donc: 1. Relier à la terre le chassis du poste conformement au code de
l’électricité et aux recommendations du fabricant. Le dispositif
a. Utiliser un bon masque avec un verre filtrant approprié ainsi de montage ou la piece à souder doit être branché à une
qu’un verre blanc afin de se protéger les yeux du rayon- bonne mise à la terre.
nement de l’arc et des projections quand on soude ou
quand on regarde l’arc. 2. Autant que possible, I’installation et l’entretien du poste seront
b. Porter des vêtements convenables afin de protéger la peau effectués par un électricien qualifié.
de soudeur et des aides contre le rayonnement de l‘arc.
c. Protéger l’autre personnel travaillant à proximité au 3. Avant de faires des travaux à l’interieur de poste, la debranch-
soudage à l’aide d’écrans appropriés et non-inflammables. er à l’interrupteur à la boite de fusibles.

4. Des gouttes de laitier en fusion sont émises de l’arc de 4. Garder tous les couvercles et dispositifs de sûreté à leur place.
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.

5. Toujours porter des lunettes de sécurité dans la zone de

soudage. Utiliser des lunettes avec écrans lateraux dans les
zones où l’on pique le laitier.
v v

for selecting a QUALITY product by Lincoln Electric. We want you

Thank You to take pride in operating this Lincoln Electric Company product •••
as much pride as we have in bringing this product to 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 customer’s particular purpose, with respect
to such information or advice. As a matter of practical consideration, we also cannot assume any responsibility for updating or correcting any
such information or advice once it has been given, nor does the provision of information or advice create, expand or alter any warranty with
respect to the sale of our products.

Lincoln Electric is a responsive manufacturer, but the selection and use of specific products sold by Lincoln Electric is solely within the control
of, and remains the sole responsibility of the customer. Many variables beyond the control of Lincoln Electric affect the results obtained in
applying these types of fabrication methods and service requirements.

Subject to Change – This information is accurate to the best of our knowledge at the time of printing. Please refer to www.lincolnelectric.com
for any updated information.

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.
vi TAbLE OF CONTENTS vi

Page
Installation Instructions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Section A
Technical Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .A-1
Installation Precautions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A-2
Location / Ventilation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .A-2
Stacking . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .A-2
Angle of Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .A-2
Lifting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .A-2
High Altitude Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .A-3
Towing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .A-3
Vehicle Mounting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .A-3
Pre-Operation Engine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .A-3
Engine Oil . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .A-3
Fuel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .A-4
Engine Cooling System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .A-4
Break-In Period . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .A-4
Battery Connection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .A-4
Spark Arrester . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .A-5
Welding Output Cables . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .A-5
Machine Grounding . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .A-5
_____________________________________________________________________________________
Operating Instructions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Section b
Safety Instructions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . B-1
Additional Safety Precautions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . B-1
General Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .B-1
Recommended Applications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .B-2
Welder . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .B-2
Auxiliary Power . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .B-2
Product Application . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .B-2
Design Features and Advantages . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .B-2
Duty Cycle . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .B-2
Engine Controls: Function/Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . B-2
Welder Controls: Function/Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . B-3
Remote Control . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .B-3
Auxiliary Power Controls . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .B-4
Engine Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .B-5
Starting Instructions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .B-5
Typical Fuel Consumption . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .B-6
_____________________________________________________________________________________
Accessories . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Section C
_____________________________________________________________________________________
Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Section D
Routine Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . D-1
Periodic Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . D-1
Pre Filter / Washer Separator . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .D-2
Engine Maintenance Components . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .D-4
Spark Arrester . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .D-4
GFCI ModuleTesting and Resetting Procedure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .D-4
_____________________________________________________________________________________
Troubleshooting Guide . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Section E
_____________________________________________________________________________________
Wiring Diagram and Dimension Print . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Section F
____________________________________________________________________________________
Parts List . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .P-621
____________________________________________________________________________________
A-1 INSTALLATION A-1

TECHNICAL SPECIFICATIONS - SAE-400™ (K1278-14)

INPUT - DIESEL ENGINE
Make/Model Description Speed (RPM) Displacement Starting Capacities
System

269 cu. in Fuel: 22.5 gal.

(4.4 L) 85.1 L
K1278-14
Perkins
1104A-44 Diesel 4 cylinder High Idle 1800 bore x Stroke 12VDC battery Oil: 10.1 Qts.
Engine 64.4 HP @ Low Idle 1100 & Starter 9.6 L
Not EPA Tier II 1710 RPM Full Load 1725
Compliant 4.13” x 5.00”
Export Only (105.0 mm x 127.0mm) Coolant: 3.4 gal.
12.8 L

RATED OUTPUT - WELDER

Duty Cycle (1)
Welding Output Volts at Rated Amps

35% (NEMA) 500 amps 40 volts

100% (NEMA) 400 amps 36 volts

100% (Lincoln Plus) 400 amps 40 volts

OUTPUT - WELDER AND GENERATOR

Welding Range Open Circuit Voltage Auxiliary Power

80 - 575 Amps 97 Max. OCV 115/230 VAC

@ 1800 RPM 3000 Watts, 60 Hz.
100% Duty Cycle
RECEPTACLES AND CIRCUIT bREAKERS
RECEPTACLES AUXILIARY POWER CIRCUIT bREAKER

1 - 115VAC Duplex NEMA (5-20R)-GFCI protected 1 - 20 amp for 115VAC Duplex NEMA
1 - 115VAC European (IEC-309)-GFCI protected 1 - 15 amp for 115VAC European (IEC-309)
1 - 230VAC Duplex 1 - 15 amp (2 -pole) for 230 V Duplex and European (IEC-309)
1 - 230VAC European (IEC-309)

PHYSICAL DIMENSIONS
HEIGHT WIDTH DEPTH WEIGHT

50.13 in. 28.00 in. 83.00 in. 2157lbs.

1273.3 mm 711.2 mm 2108.2 mm 978.4kg

(1) Based on a 10 minute period.

SAE-400™
A-2 INSTALLATION A-2

Read this entire installation section before you

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

•Do not touch electrically live parts such ANGLE OF OPERATION

as output terminals or internal wiring.
To achieve optimum engine performance the machine
•Insulate yourself from the work and should be run in a level position. The maximum angle
ground. of operation for the Perkins engine is 30 degrees in all
directions. If the engine is to be operated at an angle,
•Always wear dry insulating gloves. provisions must be made for checking and maintaining
------------------------------------------------------------------------ the oil level at the normal (FULL) oil capacity in the
engine crankcase. When operating the welder at an
ENGINE EXHAUST can kill. angle, the effective fuel capacity will be slightly less
than the specified 22.5 gallons.
•Use in open, well ventilated areas or
vent exhaust outside LIFTING

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

MOVING PARTS can injure. WARNING

•Do not operate with doors open or
guards off. • Lift only with equipment of adequate
lifting capacity.
•Stop engine before servicing. • be sure machine is stable when lift-
ing.
•Keep away from moving parts
------------------------------------------------------------------------ • Do not lift this machine using lift bail if it is
Only qualified personnel should install, use or service equipped with a heavy accessory such as a trail-
this equipment er or gas cylinder.
FALLING • Do not lift machine if lift bail is
EQUIPMENT can damaged.
LOCATION/VENTILATION cause injury. • Do not operate machine while
suspended from lift bail.
The welder should be located to provide an unrestricted
flow of clean, cool air to the cooling air inlets and to avoid
------------------------------------------------------------------------
restricting the cooling air outlets. Also, locate the welder
so that the engine exhaust fumes are properly vented to
an outside area.

SAE-400™
A-3 INSTALLATION A-3

HIGH ALTITUDE OPERATION VEHICLE MOUNTING

At higher altitudes, output derating may be necessary.

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

5. Proper preventative maintenance of trailer.

(1)
6. Conformance with federal, state and local laws.

(1)
For highway use, consult applicable federal, state
and local laws regarding specific requirements for
use on public highways, such as brakes, lights, fend-
ers, etc.

SAE-400™
A-4 INSTALLATION A-4

WARNING 1. Connect the welder output studs to a suitable resis-

• Stop engine while fueling. tive load bank. Note that any attempt to short the
• Do not smoke when fueling. output studs by connecting the welding leads
• Keep sparks and flame away from together, direct shorting of the output studs, or con-
necting the output leads to a length of steel will
tank.
result in catastrophic damage to the generator and
• Do not leave unattended while fuel-
voids the warranty.
ing.
• Wipe up spilled fuel and allow 2. Set the welder controls for an output current and
DIESEL FUEL fumes to clear before starting
can cause fire. voltage within the welder rating and duty cycle.
engine. Note that any attempt to exceed the welder rating or
• Do not overfill tank, fuel expan- duty cycle for any period of time will result in cata-
sion may cause overflow. strophic damage to the generator and voids the
DIESEL FUEL ONLY warranty.
------------------------------------------------------------------------
Fill the fuel tank with clean, fresh diesel fuel. The capac- 3. Periodically shut off the engine and check the
ity of the fuel tank is 22.5 gallons (85.1 liters). See engine crankcase oil level.
Operator’s Manual for specific fuel recommendations.
bATTERY CONNECTION
Note: Before starting the engine, be sure the fuel shut- Use caution as the electrolyte is a strong acid that
off valve is in the open position.
WARNING
ENGINE COOLING SYSTEM
can burn skin and damage eyes.
The cooling system has been filled at the factory with
a 50-50 mixture of ethylene glycol antifreeze and Remove and discard the insulating cap from the
water. Check the radiator level and add a 50-50 solu- negative battery terminal. Attach and tighten neg-
tion as needed. (See Engine Manual or antifreeze ative battery cable terminal.
container for alternate antifreeze recommendation.)
NOTE: This machine is furnished with a wet charged
ENGINE bREAK-IN PERIOD battery; if unused for several months, the battery may
require a booster charge. Be careful to charge the bat-
Lincoln Electric selects high quality, heavy-duty indus- tery with the correct polarity. Make sure that the battery
trial engines for the portable welding machines we is level while charging.
offer. While it is normal to see a small amount of
crankcase oil consumption during initial operation,
excessive oil use, wet stacking (oil or tar like substance
WARNING
at the exhaust port), or excessive smoke is not normal.
GASES FROM bATTERY can explode.
Larger machines with a capacity of 350 amperes and l Keep sparks, flame and cigarettes
higher, which are operated at low or no-load conditions away from battery.
for extended periods of time are especially susceptible -------------------------------------------------------
to the conditions described above. To accomplish suc- -----------------
cessful engine break-in, most diesel-powered equip- To prevent EXPLOSION when:
ment needs only to be run at a reasonably heavy load l INSTALLING A NEW bATTERY — disconnect
within the rating of the welder for some period of time negative cable from old battery first and
during the engine’s early life. However, if the welder is connect to new battery last.
subjected to extensive light loading, occasional moder-
ate to heavy loading of the engine may sometimes be l CONNECTING A bATTERY CHARGER —
necessary. Caution must be observed in correctly remove battery from welder by disconnecting
loading a diesel/generator unit. negative cable first, then positive cable and
battery clamp. When reinstalling, connect
negative cable last. Keep well ventilated.

SAE-400™
A-5 INSTALLATION A-5

USING A bOOSTER — connect

l WELDING OUTPUT CAbLES
positive lead to battery first then
connect negative lead to negative With the engine off, connect the electrode and work
battery lead at the lower control cables to the studs provided. These connections
panel support. should be checked periodically and tightened if neces-
bATTERY ACID can burn eyes and skin. sary.
l Wear gloves and eye protection and be careful
when working near battery. Listed in Table A.1 are copper cable sizes recom-
l Follow instructions printed on battery.
mended for the rated current and duty cycle. Lengths
stipulated are the distance from the welder to work and
IMPORTANT: To prevent ELECTRICAL DAMAGE
back to the welder again. Cable sizes are increased
WHEN:
for greater lengths primarily for the purpose of mini-
a) Installing a new batterie. mizing cable voltage drop.
b) Using a booster.
Table A.1 Combined Length of Electrode and
Use correct polarity — Negative Ground.
Work Cables.
To prevent BATTERY BUCKLING, tighten the nuts on
battery until snug. DO NOT OVERTIGHTEN.
TOTAL COMBINED LENGTH OF ELEC-
WARNING TRODE AND WORK CABLES
AMPS Up to 100FT. 100-200FT. 200-250FT.
• Spark Arrester and Muffler may be @60% Up to 31m 31-61m 61-76m
hot! Duty Cycle
• Allow engine to cool before servicing
spark arrester! 400 2/0 AWG 3/0 AWG 4/0 AWG
• Do not operate engine while servicing
spark arrester! MACHINE GROUNDING
------------------------------------------------------------------------
SPARK ARRESTER Because this portable engine driven welder creates its
own power, it is not necessary to connect its frame to
Some federal, state or local laws may require that an earth ground, unless the machine is connected to
gasoline or diesel engines be equipped with exhaust premises wiring (home, shop, etc.).
spark arresters when they are operated in certain loca-
tions where unarrested sparks may present a fire haz- To prevent dangerous electric shock, other equipment
ard. The muffler included with this welder has been powered by this engine driven welder must:
modified and now qualifies as a spark arrester. Spark
arresting mufflers will have a clean out service plug
a) be grounded to the frame of the welder using a
and will have “USDA FS 5100-1c QUALIFIED SPARK
grounded type plug, or
ARRESTER” stamped on the muffler shell. Any spark
b) be double insulated.
arrester must be serviced and properly maintained.
When this welder is mounted on a truck or trailer, its
CAUTION frame must be securely connected to the metal frame
of the vehicle. When this engine driven welder is con-
An incorrect arrester may lead to damage to the
nected to premises wiring such as that in a home or
engine or adversely affect performance.
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.

In general, if the machine is to be grounded, it should

be connected with a #8 or larger copper wire to a solid
earth ground such as a metal water pipe going into the
ground for at least ten feet and having no insulated
joints, or to the metal framework of a building which
has been effectively grounded. The U.S. National
Electrical Code lists a number of alternate means of
grounding electrical equipment. A machine grounding
stud marked with the symbol is provided on the
welding generator frame foot.
SAE-400™
b-1 OPERATION b-1

OPERATING INSTRUCTIONS WELDING SPARKS can cause

Read and understand this entire section before operat-
fire or explosion.
ing your equipment. • Do not weld near flammable material .
• Do not weld on containers that have
SAFETY INSTRUCTIONS held flammable material.
------------------------------------------------------------------------
WARNING MOVING PARTS can injure.
• Keep away from moving parts
Do not attempt to use this equipment until you • Do not operate with doors open or
have thoroughly read all operating and mainte- guards off.
nance manuals supplied with your machine. They • Stop engine before servicing.
include important safety precautions, detailed ------------------------------------------------------------------------
engine starting, operating and maintenance ENGINE EXHAUST can kill.
instructions and parts lists. • Use in open, well ventilated areas or
vent exhaust outside.
ELECTRIC SHOCK can kill.
• Do not touch electrically live parts or ------------------------------------------------------------------------
electrodes with your skin or wet
clothing. ADDITIONAL SAFETY PRECAUTIONS
• Insulate yourself from the work and ground.
• Always wear dry insulating gloves. Always operate the welder with the hinged doors
• Do not use AC welder if your clothing, gloves or closed as these provide maximum protection from
work area is damp or if working on, under or moving parts and insure proper cooling air flow.
inside workpiece.
Use the following equipment: Read carefully the Safety Precautions page in the
• Semiautomatic DC constant voltage (wire) Instruction Manual before operating this machine.
welder. Always follow these and any other safety procedures
• DC manual (stick) welder. included in this manual and in the engine instruction
• AC welder with reduced voltage control. manuals.
------------------------------------------------------------------------
ARC RAYS can injure eyes and GENERAL DESCRIPTION
burn skin.
The SAE-400™ is a diesel engine driven welding
• Wear eye, ear, and body protection. power source. The machine uses a DC generator for
------------------------------------------------------------------------ DC stick electrode welding and an AC exciter for
• Only qualified personnel should install, use or 115/230 VAC auxiliary power. As a generator it can
service this equipment. supply up to 3,000 watts of 115/230 volt AC power. As
• Consult instruction manual before operating. a welder it provides up to 575 amps of DC constant
------------------------------------------------------------------------ current output.
before operating, read and understand the manu-
facurer’s instructions for this equipment and the The engine 1104A-44 is a 64.4 Hp @ 1710 RPM
consumables to be used including the Material (48kw), 4-cylinder water cooled diesel made by
Safety Data Sheet (MSDS) and follow your employ- Perkins.
er’s safety practices.
------------------------------------------------------------------------
FUMES AND GASES can be
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 breath-
ing zone and general area.

SAE-400™
b-2 OPERATION b-2

RECOMMENDED APPLICATIONS OTHER FEATURES

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

The SAE-400™ provides excellent constant current Designed for long life, easy maintenance and excel-
DC welding output for stick (SMAW) welding. The field lent fuel economy.
installed optional CV Adapter (K385-[ ]) provides up to • Engine protection system shuts the engine down for
500 amps at 35 volts of constant voltage output for low engine oil pressure or high coolant temperature.
semiautomatic welding. • Electronic Engine Idler. Engine automatically goes
to low idle in 10 to 14 seconds after welding or use
AUXILIARY POWER of auxiliary power stops. Includes high idle switch.
The SAE-400™ provides 3 KW of 115/230 VAC output • Gauges for engine oil pressure, coolant temperature
for auxiliary power and emergency standby power. and battery charging ammeter.
• 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
• Continuous adjustment of both voltage and current applied in a 10 minute period. For example a 60% duty
for unsurpassed welds on demanding jobs. cycle, represents 6 minutes of load and 4 minutes of
• Remote control capability standard. no load in a 10 minute period.

FOR AUXILIARY POWER ENGINE CONTROLS

• 3,000 watts of 115/230VAC, 60 Hz auxiliary power.
IGNITION SWITCH
• One 20 amp 115VAC duplex receptacle.
• One 15 amp, 230VAC duplex receptacle for up to 13 When placed in the “ON” position, this switch ener-
amps of 230VAC power. gizes the fuel solenoid. When placed in the “OFF” posi-
• One 115VAC (European IEC-309) 16 amp receptacle. tion, the flow of fuel to the injection pump is stopped to
• One 230VAC (European IEC-309) 15 amp receptacle. shut down the engine.
• Weld and AC auxiliary power at the same time (with-
in the limits shown on the chart below). “IDLER” SWITCH
The idler switch has two positions, “HIGH” and
Welding Using Only Using Only Total “AUTO”.
Current, Amps 115V Circuit, 230V Circuit, Aux.
@ NEMA Arc Amps Amps kVA When in “HIGH” ( ) position, the engine will run
Volts continuously at high idle.
0 26 13 3.0
When in “AUTO” ( / ) idle position, the idler
100 19.5 9.75 2.25 operates as follows:
200 13 6.5 1.5 a. Welding
300 6.5 3.25 0.75
When the electrode touches the work, the welding
400 0 0 0 arc is initiated and the engine accelerates to full
speed.
500 0 0 0
After welding ceases (and no auxiliary power is
being drawn), the engine will return to low idle after
approximately 10 to 14 seconds.

b. Auxiliary Power

With the engine running at low idle and auxiliary

power for lights or tools is drawn (approximately
100-150 watts or greater) from the receptacles, the
engine will accelerate to high speed. If no power is
being drawn from the receptacles ( and not weld-
ing) for 10-14 seconds, the idler reduces the engine
speed to low idle.

SAE-400™
b-3 OPERATION b-3

ENGINE TEMPERATURE GAUGE

“Current Control”
Displays the coolant temperature in the engine block.
CAUTION
ENGINE OIL PRESSURE GAUGE
Do not adjust the “Current Control” while welding
Displays the oil pressure to the engine. When the because this can damage the control.
engine starts running, watch for the oil pressure to ------------------------------------------------------------------------
build up. If no pressure shows within 30 seconds, stop The “Current Control” dial is calibrated in amperes on
the engine and consult the engine instruction manual. three separate colored dials corresponding to the
white, black and red ranges of the “Job Selector” dial.
bATTERY CHARGING AMMETER For example: when the “Job Selector” is set on the
black range, the approximate welding current is indi-
Displays the current going from the charging alternator cated on the black scale of the “Current Control” dial.
into the batteries. It is normal for charging current to be
high (above 15 amps) after starting or when the batter- How to Set the Controls
ies are ‘low’ on charge.
Assume you want a normal soft arc and about 135
ENGINE HOUR METER amps, using a 5/32” (4.0 mm) electrode:
The engine hour meter records the total running time
1. Set the “Job Selector” at the center of the black
on the engine in hours. It can be used to keep a record
of maintenance on the engine and or welder. range.
ENGINE PROTECTION SYSTEM
2. Set the “Current Control” to read 135 amps on the
The engine protection system shuts down the engine black dial.
under high coolant temperature or low engine oil pres-
sure conditions by allowing the fuel solenoid valve to 3. Start to weld.
close.
4. If you want a little more current, turn the “Job
WELDER CONTROLS Selector” up (counterclockwise) to increase cur-
POLARITY SWITCH rent. If you want a little less current, turn the “Job
Selector” down (clockwise) to decrease current.
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
CONTROL OF WELDING CURRENT range causing undesirable arc characteristics, turn
Purpose of Controls the “Job Selector” back to the center of the black
range. Then turn the “Current Control” up or down
The continuous “Current Control” is the main current a little as needed. Readjust the “Job Selector” for
adjuster. The “Job Selector” is both a fine current the exact characteristics and current desired.
adjuster and the continuous Open Circuit Voltage
adjuster. Open Circuit Voltage (OCV) controls the arc
characteristics.
REMOTE CONTROL

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

located on the lower front control panel. A remote con-
The “Job Selector” dial is divided into four colored sec- trol box with 100 ft. (30.5 m) of cord for adjusting the
tions providing OCV ranges as follows: OCV at the welding site is available. Putting the switch
in the “REMOTE” position allows fine current control at
Color Title OCV Range the remote control box while placing the switch in the
White Large Electrodes High OCV “LOCAL” position allows fine current control at the “Job
Black Normal Welding Medium OCV Selector” on the machine. When using the optional
Red Overhead & Vertical Low OCV
field installed CV adapter (K385-[ ]) the “Local/Remote”
Grey Special Applications Extra-Low OCV
switch is only active in the “VV” mode.
The “Job Selector” is usually set in the black range
because it provides a soft “Buttering “ arc desired for
most welding. Some operators prefer to set the “Job
Selector” in the red range for a snappy “Digging” arc
when welding vertical up or overhead.

SAE-400™
b-4 OPERATION b-4

AUXILIARY POWER CONTROLS The 115V auxiliary power receptacles should only be
used with three wire grounded type plugs or approved
115 VAC Receptacle double insulated tools with two wire plugs. The current
rating of any plug used with the system must be at
One 20 amp, 115VAC (5-20R) NEMA duplex recepta- least equal to the current capacity of the associated
cle provides 115VAC for auxiliary power. Maximum receptacle.
current is 20 amps total.
RESIDUAL CURRENT DEVICE
One 115V (European IEC-309) 16 amp receptacle. IP44
rated. The SAE-400™ is configured to allow for the addition
of a Residual Current Device (RCD) to protect the
230VAC Receptacle 240V Single Phase Receptacle. The lower Control
Panel has a rectangular cut-out to accept a typical 2-
One 15 amp, 230VAC duplex receptacle provides 230 pole RCD along with a protective rubber boot. A cover
VAC for auxiliary power. A total of 13 amps can be plate a label “RCD READY” covers the rectangular cut-
drawn from this receptacle. out, and secures a mounting bracket on the backside
of the panel.
One 230V (European IEC-309) 15 amp receptacle. IP44
rated. Note: The (RCD) should be rated for at least 15 amps.

Circuit breakers There are many suppliers of RCD’s. One example is

Clipsal, part number 4RC225/30.
2 pole 15 amp rated provides overload protection for
the 230VAC (European IEC-309) receptacle and the The protective boot can be obtained from:
230VAC duplex receptacle. APM-Hexseal, part number HE-1035.

Single pole 15 amp rated provides overload protection See Section F Diagrams of this Operator’s Manual for
for the 115VAC (European IEC-309) receptacle. instructions on installing an RCD and protective rubber
boot.
Single pole 15 amp rated provides overload protection
for the 115VAC (5-20R) NEMA duplex receptacle. GROUND STUD
GFCI (Ground Fault Circuit Interrupter) module: Provides a connection point for connecting the
machine to earth ground. For the safest grounding pro-
• Protects both 115VAC auxiliary power receptacles. cedure refer to “Machine Grounding” in the INSTALLA-
TION section of this manual.
• If a GFCI module is tripped, see the Maintenence
Section for detailed information on testing and
resetting the GFCI module.

A GFCI (Ground Fault Circuit Interrupter) electrical

receptacle is a device to protect against electric shock
should a piece of defective equipment connected to it
develop a ground fault. If this situation should occur,
the GFCI module will trip, removing voltage from the
output of the receptacle. If a GFCI module is tripped
see the MAINTENANCE section for detailed informa-
tion on testing and resetting it. A GFCI module should
be properly tested at least once every month.

SAE-400™
b-5 OPERATION b-5

ENGINE OPERATION 5. Observe the oil pressure. If no pressure shows

within 30 seconds, stop the engine and consult the
WARNING engine operating manual. To stop the engine, turn
Do not attempt to use this equipment until you the “IGNITION” switch to “OFF”.
have thoroughly read the engine manufacturer’s 6. If the engine protection warning light comes on
manual supplied with your welder. It includes during cranking or after start up, the “IGNITION”
important safety precautions, detailed engine switch must be turned “OFF” to reset the engine
starting, operating and maintenance instructions,
and parts lists. protection system.
------------------------------------------------------------------------ 7. Allow the engine to run at high idle speed for sev-
ELECTRIC SHOCK can kill. eral minutes to warm the engine. Stop the engine
• Do not touch electrically live parts or and recheck the oil level, after allowing sufficient
electrode with skin or wet clothing. time for the oil to drain into the pan. If the level is
• Insulate yourself from work and down, fill it to the full mark again. The engine con-
ground trols were properly set at the factory and should
• Always wear dry insulating gloves.
------------------------------------------------------------------------ require no adjusting when received.
ENGINE EXHAUST can kill.
• Use in open, well ventilated areas or COLD WEATHER STARTING:
vent exhaust outside.
WARNING
------------------------------------------------------------------------ Under NO conditions should ether or other starting
MOVING PARTS can injure.
• Do not operate with doors open or fluids be used!
guards off. ------------------------------------------------------------------------
• Stop engine before servicing.
• Keep away from moving parts. With a fully charged battery and the proper weight oil,
------------------------------------------------------------------------ the engine should start satisfactorily even down to
about -5°F (-20°C), it maybe desirable to install cold-
See additional warning information at the starting aides.
front of this operator’s manual. Note: Extreme cold weather staring may require longer
glow plug operation.
For added safety always operate the welder with the
doors closed. Further, leaving the doors open changes
the designed air flow and may cause engine, genera- STOPPING THE ENGINE
tor overheating.
1. Turn the “IGNITION” switch to “OFF”
CAUTION At the end of each day’s welding, check the crankcase
Do not adjust the high idle engine speed (rpm) oil level, drain accumulated dirt and water from the
above the factory setting specification as this will water separator and refill the fuel tank to minimize
void warranty. moisture condensation in the tank. Also, running out of
----------------------------------------------------------------------- fuel tends to draw dirt into the fuel system.

STARTING INSTRUCTIONS When hauling the welder between job sites, close the
Be sure all Pre-Operation Maintenance has been fuel shut-off valve.
performed. (See INSTALLATION section of this
manual). If the fuel supply is cut off or runs out while the fuel
pump is operating, air may be entrapped in the fuel dis-
1. Turn the “IDLER” switch to “HIGH”. tribution system. If this happens, bleeding of the fuel
2. Turn the “IGNITION” switch to “ON”. system may be necessary. Use qualified personnel to
3. Press the Glow Plug button for 20 to 30 seconds. do this per the instructions in the MAINTENANCE sec-
(maximum 60 seconds). tion of this manual.
4. Press the Glow Plug and the Start button at the
same time. When the engine starts running,
release both buttons. If the engine fails to start in
20 seconds, wait 30 seconds and repeat the
above procedure.

SAE-400™
b-6 OPERATION b-6

TYPICAL FUEL CONSUMPTION

The typical fuel consumption of the SAE-400™ for various operating scenarios
is shown below:

PERKINS 1104A-44

Low Idle - No Load .26 gal./ hr.

1100 RPM (.97 L./hr.)

High Idle - No Load .68 gal./hr.

1800 RPM (2.56 L./hr.)

Welding Load 1.84 gal./hr.

400 Amps, 40 Volts (6.95 L./hr.)

Welding Load 2.38 gal./hr.

500 Amps, 40 Volts (9.02 L./hr.)

Auxiliary Power .79 gal./hr.

3000VA (2.98 L./hr.)

SAE-400™
C-1 ACCESSORIES C-1

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).

K802-D Power Plug Kit - Kit includes male plug for 20

amp receptacle.

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.

K2637-1 Trailer - A 2-wheel trailer designed for road(1),

off road, in-plant and yard towing. Trailer mounts
directly to welder base. Comes standard with a Duo-
Hitch™, a 2” Ball and Lunette Eye combination hitch.

Order:
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).

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

clamp.

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.

SAE-400™
D-1 MAINTENANCE D-1

PERIODIC MAINTENANCE
WARNING
1. Blow out the welder and controls with an air hose at least
ELECTRIC SHOCK can kill. once every two months. In particularly dirty locations, this
l Do not touch electrically live parts cleaning may be necessary once a week. Use low pres-
such as output terminals or inter- sure air to avoid driving dirt into the insulation.
nal wiring
2. The current control reactor brushes are self-lubricating
and should not be greased. Keep the contacts clean. This
ENGINE EXHAUST can kill. control should be moved from maximum to minimum daily
l Use in open, well ventilated areas to prevent the controls from sticking.
or vent exhaust outside
3. See the engine Instruction Manual for periodic engine
maintenance information. Change the crankcase oil at
regular intervals using the proper grade of oil as recom-
MOVING PARTS can injure.
mended in the engine operating manual. Change the oil
l Do not operate with doors open or filter in accordance with the instructions in the engine
guards off operating manual. When the oil filter is changed add one
l Stop engine before servicing quart of oil to the crankcase to replace the oil held in the
filter during operation.
l Keep away from moving parts
4. Belts tend to loosen after the first 30 or 40 hours of oper-
l Remove guards only when necessary and
ation. Check the cooling fan belt and tighten if necessary.
replace when work requiring removal is com-
DO NOT OVER TIGHTEN.
plete.
l Only qualified personnel should install, use, or bEARING MAINTENANCE
service this equipment.
This welder is equipped with a double-shielded ball bearing
ROUTINE MAINTENANCE having sufficient grease to last indefinitely under normal ser-
vice. Where the welder is used constantly or in excessively
At the end of each day’s welding, refill the fuel tank to dirty locations, it may be necessary to add one-half ounce of
minimize moisture condensation in the tank. Also, run- grease per year. A pad of grease one inch wide, one inch
ning out of fuel tends to draw dirt into the fuel system. long and one inch high weighs approximately one-half
Check the engine crankcase oil levels. ounce. Over greasing is far worse than insufficient greasing.

If the fuel supply runs out while the fuel pump is oper- When greasing the bearings, keep all dirt out of the area.
ating, air may be entrapped in the fuel distribution sys- Wipe the fittings completely clean and use clean equipment.
tem. If this happens, bleeding of the fuel system may More bearing failures are caused by dirt introduced during
be necessary. See the engine instruction manual. 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™
D-2 MAINTENANCE D-2

COMMUTATOR AND bRUSH MAINTENANCE COOLING SYSTEM

WARNING The SAE-400™ is equipped with a pressure radiator.

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

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

SPARK ARRESTOR
bottom of the filter header until the element no longer
easily moves up into the filter header. Now rotate the WARNING
element (may take almost 1 full turn) with a slight
upward pressure until the element begins to further • Spark Arrester and Muffler may be
engage the header. With the proper orientation now hot!
established apply additional pressure to seat the ele- • Allow engine to cool before servicing
ment in the filter header. You should feel the element spark arrester!
“pop” into place when properly seated. • Do not operate engine while servicing
Note: The element will only go on one way. Never spark arrester!
use excessive force when mounting the element to ------------------------------------------------------------------------
the header.
SAE-400™ with integral spark arresting mufflers:
5. Slide the quick change ring up over the element and Service spark arrester every 250 hours.
rotate counter clockwise until an audible click or pop is Service as follows:
heard. If you do not hear the click you have not rotated
the ring far enough and the element is not in the locked 1. Stop engine and allow to cool.
position. Another indication that the ring is in the locked
position is that one set (it doesn’t matter which one) of 2. Remove clean out plug from side of spark arrester.
arrows located on the outside of the ring should be
located directly under the air vent valve. 3. Without damaging the spark arrester, gently tap on the
arrester shell near the clean out plug.
6. Remove the see-through bowl from the old element
and install on the new element.
4. Once particles are removed, replace the clean out plug.
7. Open the fuel shutoff valve.

8. Open the air vent valve on the front of the filter header
until fuel emerges free of air bubbles and then close the
air vent valve.
Note: Consult your engine operation manual for
information on air bleeding the entire fuel system.

ENGINE AND MAINTENANCE COMPONENTS

ITEM MAKE PART NUMbER

Engine Air Filter Donaldson P822768

Fan Belt Perkins 2614B555 043

Fuel Filter Perkins 26560201

Engine Oil Filter Perkins 2654407

Pre-Filter/Water Lincoln M21584-B

Separator Element Stanadyne 39420 LE

SAE-400™
D-4 MAINTENANCE D-4

GFCI MODULE TESTING AND RESETTING

PROCEDURE

The GFCI module should be properly tested at least

once every month or whenever it is tripped. To proper-
ly test and reset the GFCI module:

• If the module has tripped, first carefully remove any

load and check it for damage.
• If the equipment has been shut down, it must be
restarted.
• 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 mod-
ule. This will assure normal GFCI operation.
• Plug a night-light (with an "ON/OFF" switch) or other
product (such as a lamp) into the Duplex receptacle
and turn the product "ON".
• Push the "Test" button located on the GFCI module.
The night-light or other product should go "OFF".
• Push the "Reset" button, again. The light or other
product should go "ON" again.

If the light or other product remains "ON" when the

"Test" button is pushed, the GFCI module is not work-
ing properly or has been incorrectly installed (mis-
wired). If your GFCI module is not working properly,
contact a qualified, certified electrician who can assess
the situation, rewire the GFCI module if necessary or
replace the device.

SAE-400™
E-1 TROUbLESHOOTING E-1

HOW TO USE TROUbLESHOOTING GUIDE

WARNING
Service and Repair should only be performed by Lincoln Electric Factory Trained Personnel.
Unauthorized repairs performed on this equipment may result in danger to the technician and machine
operator and will invalidate your factory warranty. For your safety and to avoid Electrical Shock, please
observe all safety notes and precautions detailed throughout this manual.
__________________________________________________________________________
This Troubleshooting Guide is provided to help you Step 3. RECOMMENDED COURSE OF ACTION
locate and repair possible machine malfunctions. This column provides a course of action for the
Simply follow the three-step procedure listed below. Possible Cause, generally it states to contact your
local Lincoln Authorized Field Service Facility.
Step 1. LOCATE PROBLEM (SYMPTOM).
Look under the column labeled “PROBLEM (SYMP- If you do not understand or are unable to perform the
TOMS)”. This column describes possible symptoms Recommended Course of Action safely, contact your
that the machine may exhibit. Find the listing that best local Lincoln Authorized Field Service Facility.
describes the symptom that the machine is exhibiting.

Step 2. POSSIBLE CAUSE.

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

WARNING
ELECTRIC SHOCK can kill.
• Do not touch electrically live parts such as output
terminals or internal wiring.

ENGINE EXHAUST can kill.

• Use in open, well ventilated areas or vent exhaust
outside.

MOVING PARTS can injure.

• Do not operate with doors open or guards off.
• Stop engine before servicing.
• Keep away from moving parts.

• Remove guards only when necessary and replace when work

requiring removal is complete.
• Only qualified personnel should install, use or service this
equipment.

CAUTION
If for any reason you do not understand the test procedures or are unable to perform the tests/repairs safely, contact your Local
Lincoln Authorized Field Service Facility for technical troubleshooting assistance before you proceed.
SAE-400™
E-2 TROUbLESHOOTING E-2

Observe all Safety Guidelines detailed throughout this manual

PRObLEMS POSSIbLE RECOMMENDED

(SYMPTOMS) CAUSE COURSE OF ACTION
FUNCTION PRObLEMS
Machine fails to hold the “heat” 1. Rough or dirty commutator. 1. True and clean commutator.
constantly.
2. Brushes may be worn down to 2. Replace brushes.
limit of life.

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

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

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

tions may be poor.

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

installed on generator. Lincoln brushes.

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

poor contact and overheating.

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

operating properly. screw in control handles.

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

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

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

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

CAUTION
If for any reason you do not understand the test procedures or are unable to perform the tests/repairs safely, contact your Local
Lincoln Authorized Field Service Facility for technical troubleshooting assistance before you proceed.

SAE-400™
E-3 TROUbLESHOOTING E-3

Observe all Safety Guidelines detailed throughout this manual

PRObLEMS POSSIbLE RECOMMENDED

(SYMPTOMS) CAUSE COURSE OF ACTION
FUNCTION PRObLEMS
Welder runs but fails to generate 1. Generator or exciter brushes may 1. Be sure that all brushes bear on
current. be loose or missing. the commutator and have proper
spring tension.

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

voltmeter or lamp.

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

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

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

in the neutral position. position.

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

in flashing circuit.

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

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

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

polarity or try an electrode of the
opposite polarity.

CAUTION
If for any reason you do not understand the test procedures or are unable to perform the tests/repairs safely, contact your Local
Lincoln Authorized Field Service Facility for technical troubleshooting assistance before you proceed.

SAE-400™
E-4 TROUbLESHOOTING E-4

Observe all Safety Guidelines detailed throughout this manual

PRObLEMS POSSIbLE RECOMMENDED

(SYMPTOMS) CAUSE COURSE OF ACTION
FUNCTION PRObLEMS
Welding current too great or too 1. “Current Control” shaft and han- 1. With current control against the
small compared to indication on the dle may have turned slightly in minimum stop, set pointer to with-
dial. the insulated bushing of the cur- in 1/8” of the last scale division.
rent control brush holder, caused
by turning handle too hard against
one of the stops.

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

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

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

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

CAUTION
If for any reason you do not understand the test procedures or are unable to perform the tests/repairs safely, contact your Local
Lincoln Authorized Field Service Facility for technical troubleshooting assistance before you proceed.

SAE-400™
E-5 TROUbLESHOOTING E-5

Observe all Safety Guidelines detailed throughout this manual

PRObLEMS POSSIbLE RECOMMENDED

(SYMPTOMS) CAUSE COURSE OF ACTION
FUNCTION PRObLEMS
No auxiliary power 1. Circuit Breakers open. 1. Check and reset breakers. If
breakers keep tripping check con-
nections to auxiliary receptacles.
Also make sure load does nor
exceed receptacle’s current rating.

2. Faulty connections to auxiliary 2. Check connections.

receptacles.

3. GFCI module tripped. (See 3. Follow “GFCI Module Testing and

Maintenence Section). Resetting Procedure” in the MAIN-
TENANCE 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™
 F-1

SAE400
WIRING DIAGRAM

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

pasted inside the machine on one of the enclosure panels.

 60.36

05.83
DNA LIO HTI W YTIVARG FO RETNEC
LEUF ON TUB ,ENIGNE NI RETAW
00.32
00.62 00.82

31.05
00.44 96.93
59.74

00.12

00.6

09.8 05.44 00.22

21.8 57.96
.A.N
41.22
.B.N

00.3 00.77 05.42

.A.N

88. 52.18 21.72

00.38
.B.N

SELOH 96. .B.N

SELOH 18. .A.N

63-9688M
F-2

63.06

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

47.95 50.13
39.69 44.00

21.00

SAE-400™
6.00

22.00 44.50 8.90

N.B. N.A.
22.14 69.75 8.12
DIMENSION PRINT

N.A.
24.50 77.00 3.00

27.12 81.25 .88

N.B.
83.00

N.A. .81 HOLES

N.B. .69 HOLES

M8869-36
F-2
 F-3 DIAGRAM F-3

M22332
A.01

The unit is now ready for operation.

8. Reconnect the negative battery cable.

protecting the leads.
inserted in the opening on the side of the RCD cover box and is
set aside in step 3. Make sure the sleeving that is covering the leads is
7. Mount the RCD cover box to the lower control panel using the screws
in step 3 and the screws set aside in step 2.
Then insert the RCD. Mount the RCD by using the RCD bracket set aside
6. Insert the sealing boot through the RCD cut out in the lower control panel.
connect to RCD with a silicone rubber RTV sealant.
Figure 2 to insure proper operation of the RCD. Coat area where leads
2.4 NM (21 in-lb). Note: leads must be connected as shown in
black leads (6C &7C) into bottom teminals of RCD. Tighten leads to
5. Connect red leads (6A & 7A) into top terminals of the RCD and connect
lead ends to13mm (.50 in.).
4. Cut off existing insulated terminals from leads inside the box. Strip all 4
box for later use.
RCD cover box, and RCD mounting bracket that is inside RCD cover
3. Remove the RCD cover box from the lower control panel. Keep screws,
cover plate and keep the screws for later use.
the 230V euro receptacle on the outside of the machine. Discard the
2. Remove the RCD cover plate located on the lower control panel next to
1. Turn welder off, then disconnect the negative battery cable.

Do not touch electrically live parts. or service this equipment.

from ground before servicing. Only qualified personnel should install,use
Disconnect NEGATIVE (-) BATTERY LEAD(S) Keep away from moving parts.
Do not operate with panels open. Keep guards in place.
ELECTRIC SHOCK can kill
WARNING
MOVING PARTS can injure

DEVICE TO PROTECT THE 230V SINGLE PHASE RECEPTACLES.

INSTRUCTIONS FOR INSTALLING A 2-POLE RESIDUAL CURRENT

INSTRUCTIONS FOR INSTALLING A 2-POLE RESIDUAL CURRENT

DEVICE TO PROTECT THE 230V SINGLE PHASE RECEPTACLES.

WARNING
ELECTRIC SHOCK can kill MOVING PARTS can injure
Do not operate with panels open. Keep guards in place.
Disconnect NEGATIVE (-) BATTERY LEAD(S) Keep away from moving parts.
from ground before servicing. Only qualified personnel should install,use
Do not touch electrically live parts. or service this equipment.

1. Turn welder off, then disconnect the negative battery cable.

2. Remove the RCD cover plate located on the lower control panel next to
the 230V euro receptacle on the outside of the machine. Discard the
cover plate and keep the screws for later use.
3. Remove the RCD cover box from the lower control panel. Keep screws,
RCD cover box, and RCD mounting bracket that is inside RCD cover
box for later use.
4. Cut off existing insulated terminals from leads inside the box. Strip all 4
lead ends to13mm (.50 in.).
5. Connect red leads (6A & 7A) into top terminals of the RCD and connect
black leads (6C &7C) into bottom teminals of RCD. Tighten leads to
2.4 NM (21 in-lb). Note: leads must be connected as shown in
Figure 2 to insure proper operation of the RCD. Coat area where leads
connect to RCD with a silicone rubber RTV sealant.
6. Insert the sealing boot through the RCD cut out in the lower control panel.
Then insert the RCD. Mount the RCD by using the RCD bracket set aside
in step 3 and the screws set aside in step 2.
7. Mount the RCD cover box to the lower control panel using the screws
set aside in step 3. Make sure the sleeving that is covering the leads is
inserted in the opening on the side of the RCD cover box and is
protecting the leads.
8. Reconnect the negative battery cable.

The unit is now ready for operation.

A.01
M22332

SAE400
F-4 DIAGRAM F-4

FIGURE 1

Lower Control Panel

RCD
Cover Plate

230V
Euro Receptacle
FRONT PANEL

RED 7A
FIGURE 2
RED 6A

2-POLE RCD

RCD Mounting Strap

RCD SEALING BOOT

BLACK 6C Sleeving
BLACK 7C

FIGURE 3

Sleeving
(Route out of lower corner of RCD
cover box to upper control panel.)

RCD Cover Box

BACK PANEL A.01

M22332

SAE-400™
 P-621 P-621
Illustration of Sub Assemblies
RETURN TO MAIN INDEX
de o Sub sse b es

PARTS LIST FOR

SHIELD-ARC SAE-400 ®
Illustration of Sub Assemblies
de o Sub sse b es
Illustration of Sub Assemblies
de o Sub sse b es

This parts list is provided as an informative guide only.

Illustration of Sub Assemblies
de o Sub sse b es

It was accurate at the time of printing. These pages are only updated on the
Service Navigator DVD and in Lincoln Electricʼs official Parts Book (BK-34).

When ordering parts, always refer to Lincoln Electricʼs official Parts Book
(BK-34) for the latest pages.

SHIELD-ARC® SAE-400
 P-621-A.1 RETURN TO MAIN INDEX P-621-A.1
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SHIELD-ARC® SAE-400

For Code: 11605

Do Not use this Parts List for a machine if its code number is not listed. Contact the Service Department for any
code numbers not listed.

Use the Illustration of Sub-Assemblies page and the table below to determine which sub assembly page and
column the desired part is located on for your particular code machine.

Sub Assembly Item

No.

Generator-Alternator Assembly

Lower Control Panel Assembly

Left Gas Tank Rail & Output

Optional Equipment Listing
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Control Panel Assembly

Miscellaneous Items

Engine Assembly
SUB ASSEMBLY

Remote Control
Final Assembly

PAGE NAME

Panel
PAGE NO. P-621-B.1 P-621-B.2 P-621-C P-621-D P-621-E P-621-F P-621-G P-621-H P-621-J
CODE NO.

11605 (Export) 1 1 1 1 1 1 1 1
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SHIELD-ARC® SAE-400 08-05-2009

 P-621-A.2 RETURN TO MAIN INDEX P-621-A.2
us a o o Sub sse b es

SAE-400

For Code: 11605

Do Not use this Parts List for a machine if its code number is not listed. Contact the Service Department for any
code numbers not listed.

Use the Illustration of Sub-Assemblies page and the table below to determine which sub assembly page and
column the desired part is located on for your particular code machine.

Sub Assembly Item

No.
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Generator Brush Holder

SUB ASSEMBLY
PAGE NAME

PAGE NO. P-621-K

CODE NO.

11605 (Export) 1
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SHIELD-ARC® SAE-400 08-05-2009

 P-621-B.1 P-621-B.1
OPTIONAL EQUIPMENT LISTING
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Miscellaneous Options Available for your machine are listed below:

# Indicates a change this printing.
DESCRIPTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .PART NUMBER

For SAE-400:

CV Adapter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Order K385-2

Accessory Kit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Order K704
4 Wheel Steerable Trailer . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Order K2641-1
TIG Module . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Order K930-2
Auxiliary Power Plug Kit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Order K802D
Large Welder Trailer, Heavy Duty . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Order K2637-1
Fender & Light Kit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Order K2639-1
Cable Storage Rack . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Order K2640-1
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Multi-Weld 350 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Order K1735-1

Remote Control Box . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Order L9303-1
Oil Drain Kit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Order K2144-1
Service Indicator Kit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Order K1858-1
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SHIELD-ARC® SAE-400 09-08-2009

 MISCELLANEOUS ITEMS
P-621-B.2 (THESE ITEMS ARE NOT ILLUSTRATED) P-621-B.2
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# Indicates a change this printing. Use only the parts marked “x” in the column under the
heading number called for in the model index page.

DESCRIPTION PART NO. QTY. 1 2 3 4 5 6 7 8 9

Coupling Clamp Ring (Outside) S14232 1 X

Coupling Clamp Ring (Inside) S14233 1 X
Coupling Disc M6730 1 X
Disc Backing Plate S8042 2 X
7/16-14 x 1.50 HHCS T8833-2 8 X
Lock Washer E106A-8 8 X
Blower Paddle M10840 4 X #
Plain Washer S9262-180 8 X
7/16-14 x 1.00 HHCS T8833-1 8 X
Lock Washer E106A-8 8 X
Lead L2286-34 1 X
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1/2-13 x 1.00 HHCS CF000021 2 X

Lock Washer E106A-15 2 X
1/2-13 HN CF000027 2 X
Hex Jam Nut (Brass) T10114 1 X
Reed Switch & Lead Assembly S17472-1 1 X
Ground Lead (Engine Foot to Base) L2286-272 1 X
Plain Washer S9262-4 2 X
Lock Washer E106A-4 1 X
3/8-16 HN CF000067 1 X
Logo Decal S11893-6 2 X
Warning Decal T13086-62 2 X
Caution Decal M16679 1 X
Fuel Warning Decal T13086-26 1 X
Earth Ground Connection Decal T13260-4 1 X
Door Catch Decal T11030 2 X
Warning Decal M16197 1 X
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Engine Instruction Tag M17238 1 X

Warning Decal S25896 1 X
Service Decal S26005 1 X
Wiring Diagram M22241 1 X
CO Warning Decal M21436 1 X
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SHIELD-ARC® SAE-400 04-22-2010

 P-621-C P-621-C
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Final Assembly
Part Numbers
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3
Part Numbers

30 17 15 21
31 37 20
23 40
42 13

39 18
38 19
11
12
25
27 N.A.N.

+.09
.75 -.13
4

9
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10
54
Part Numbers

1 41 41
26
2
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Part Numbers

SHIELD-ARC® SAE-400 08-05-2009

 P-621-C.1 P-621-C.1
Sub Assembly Illustration
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# Indicates a change this printing. Use only the parts marked “x” in the column under the
heading number called for in the model index page.

ITEM DESCRIPTION PART NO. QTY. 1 2 3 4 5 6 7 8 9

1 Base Welded Assembly L5519-1 1 X

2 Engine Assembly See P-621-D 1 X
3 Rain Cap S9563-4 1 X
4 Generator Assembly See P-621-E 1 X
Generator Mounting (See Item 21) P-621-D.1 X
1/2-13 x 2.75 HHCS T8833-33 6 X
Lock Washer E106A-5 6 X
8 Cable (Solenoid to Battery Positive) S17187-8 1 X
Metric Hex Nut (M10) T14815-5 1 X
Metric Hex Nut (M5) T14815-4 1 X
Metric Lock Washer S18385-1 1 X
Sub Assembly Illustration
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9 Cable (Battery Negative to Base) S17187-9 1 X

3/8-16 x .75 HHCS CF000034 1 X
Lock Washer E106A-16 1 X
3/8-16 HN CF000067 1 X
10 Battery M9399-4 1 X
Cap T14654 1 X
Battery Clamp Bracket S16931-2 1 X
Battery Hook T8818-3 2 X
Lock Washer E106A-3 2 X
5/16-18 HN CF000029 2 X
11 Rear Support Assembly M8237-13 1 X
Lock Washer T9860-4 4 X
3/8-16 X .75 Thread Forming Screw S9225-28 4 X
12 Lower Control Panel Assembly See P-621-F 1 X
Lock Washer T9860-3 6 X
Thread Forming Screw S9225-26 6 X
Sub Assembly Illustration
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13 Control Panel Assembly See P-621-G 1 X

Lock Washer T9860-3 5 X
Thread Forming Screw S9225-26 5 X
15 Lift Bale Assembly M8889-3 1 X
1/2-13 x 1.25 HHCS T8833-24 4 X
Lock Washer E106A-15 4 X
1/2-13 HN CF000027 4 X
17 Cover Seal S12934-2 1 X
18 Fuel Tank Rail M12005-6 1 X
1/2-13 x 1.25 HHCS CF000030 1 X
Plain Washer S9262-1 1 X
Lock Washer E106A-15 1 X
1/2-13 HN CF000027 1 X
1/2-13 x 1.25 HHCS CF000030 1 X
Lock Washer E106A-15 1 X
1/2-13 HN CF000027 1 X
Circuit Breaker T12287-20 1 X
Sub Assembly Illustration
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19 Fuel Tank Rail & Output Panel See P-621-H 1 X

1/2-13 x 1.25 HHCS CF000030 1 X
Lock Washer E106A-15 1 X
1/2-13 HN CF000027 1 X
Plain Washer S9262-1 1 X
Lock Washer E106A-15 1 X
1/2-13 HN CF000027 1 X

SHIELD-ARC® SAE-400 08-05-2009

 P-621-C.2 P-621-C.2
Sub Assembly Illustration
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# Indicates a change this printing. Use only the parts marked “x” in the column under the
heading number called for in the model index page.

ITEM DESCRIPTION PART NO. QTY. 1 2 3 4 5 6 7 8 9

20 Fuel Tank Assembly (Plastic Tank) L12684-1 1 X

3/8-16 x 2.00 HHCS CF000071 4 X
Plain Washer S9262-120 8 X
Lock Washer E106A-16 4 X
3/8-16 HN CF000067 4 X
21 Fuel Gauge/Cap (For Plastic Tank) M21278 1 X
Fuel Tank Gasket (For Plastic Tank) S10437-G 1 X
23 Hose Clamp T13777-5 1 X
25 Elbow Fitting S25908 1 X
Hose Connector T13595 1 X
26 Hose Clamp T13777-1 1 X
Sub Assembly Illustration
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27 Radiator & Shell Assembly, Includes: M8567-23 1 X

Radiator Shell Assembly L3095 1 X
Radiator (Includes Radiator Cap) L3102-5 1 X
Radiator Cap S9970-1 1 X
Rubber Washer T10355-3 1 X
Hex Lock Nut T9187 6 X
Plain Washer S9262-121 6 X
Radiator Cap Cover Assembly M8003 1 X
Self Tapping Screw S8025-12 2 X
5/16-18 x .62 Thread Forming Screw S9225-26 6 X
28 Fan Guard (Fuel Pump Side) M20542-1 1 X
Fan Guard (Alternator Side) M20811-1 1 X
Fan Guard (Top) M20897-1 1 X
Acoustical Foam M15045-37 1 X
Self Tapping Screw S8025-12 10 X
Self Tapping Screw S8025-79 2 X
Sub Assembly Illustration
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M10 x 1.5 x 16 Metric HHCS T14731-13 1 X

Lock Washer S17400-1 1 X
30 Air Cleaner M20281 1 X
Mounting Band M20282 1 X
5/16-18 x 1.25 HHCS CF000028 2 X
Lock Washer E106A-3 2 X
Plain Washer S9262-121 4 X
5/16-18 HN CF000029 2 X
31 Air Intake Hose L12351 1 X
Hose Clamp S10888-20 1 X
Hose Clamp S10888-33 1 X
37 Roof L3448-27 1 X
38 Roof Mounting Angle (Rear) T9428 2 X
5/16-18 x 1.25 SQHS CF000180 2 X
5/16-18 HLN T9187 2 X
39 Roof Hook (Front) T8818 2 X
5/16-18 HLN T9187 2 X
Sub Assembly Illustration
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40 Door Bumper (Mounts in Roof) (Not Shown) T15154 8 X

41 Door L3319-C 4 X
42 Door Hinge Pin S20295 8 X
Retaining Ring S9776-62 16 X

SHIELD-ARC® SAE-400 08-05-2009

 P-621-C.3 P-621-C.3
Sub Assembly Illustration
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# Indicates a change this printing. Use only the parts marked “x” in the column under the
heading number called for in the model index page.

ITEM DESCRIPTION PART NO. QTY. 1 2 3 4 5 6 7 8 9

43 Door Bumper (Mounts in Door) (Not Shown) S21463 12 X
Plain Washer S9262-98 12 X
Rivet M8834-1 12 X
Speed Clip T10982-7 12 X
44 Door Hook Assembly (Not Shown) S10656-1 4 X
Washer T10878 4 X
Self Tapping Screw S8025-92 8 X
45 Door Hook Assembly (Not Shown) S10656-2 4 X
Washer T10878 4 X
Self Tapping Screw S8025-92 8 X
53 Remote Control Box Assembly See P-621-J 1 X
54 Door Restraint Assembly S25474 1 X
Sub Assembly Illustration
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#10-24 x .50 HHCS S24739-2 2 X

Plain Washer S9262-174 4 X
Lock Washer E106A-22 2 X
#10-24 HN CF000393 2 X
Spring Clip (Not Shown) S20290 1 X
#10-24 x .38 RHS (Not Shown) S24739-29 1 X
Plain Washer (Not Shown) S9262-174 2 X
Lock Washer (Not Shown) E106A-22 1 X
#10-24 HN (Not Shown) CF000393 1 X
62 Breaker & Receptacle Guard Assembly (Not Shown) M18959-2 1 X
Thread Forming Screw S9225-68 2 X
Sub Assembly Illustration
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Sub Assembly Illustration
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SHIELD-ARC® SAE-400 08-05-2009

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Part Numbers Part Numbers Part Numbers Part Numbers
P-621-D

Engine Assembly

24
3

23
5
2

27

17
8

SHIELD-ARC® SAE-400
12
4A
4B
4C

26

6
25
P-621-D

08-05-2009
 P-621-D.1 P-621-D.1
Sub Assembly Illustration
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# Indicates a change this printing. Use only the parts marked “x” in the column under the
heading number called for in the model index page.

ITEM DESCRIPTION PART NO. QTY. 1 2 3 4 5 6 7 8 9

Engine Asbly, Includes: L13352 1 X

1 Perkins 1104A-44 Engine M21146 1 X
2 Housing Plate Assembly L7342 1 X
M10 x 1.5 HHCS T14731-5 1 X
Lock Washer S17400-1 6 X
Dowel Pin T13942 2 X
3 Flywheel & Ring Gear Assembly M14343-5 1 X
1/2-20 x 1.00 HHCS T8833-36 6 X
Lock Washer E106A-15 6 X
4A Fan Blade L9815 1 X
4C Lock Washer E106A-3 4 X
Sub Assembly Illustration
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5 Hose Clamp T13777-1 2 X

Flex Tube (Engine to Tank) T10642-103 1 X
6 Hose Clamp T13777-1 6 X
Fuel Shut Off S24068 1 X
Flex Tube (Shut Off to Water Sep.) T10642-91 1 X
Flex Tube (Water Sep. to Filter) T10642-228 1 X
7 Oil Pressure Switch/Sender S17026-3 1 X
Pipe Adapter S24464-2 1 X
M4-0.7 HN T14815-6 2 X
8 Muffler L12426-1 1 X
9 Solenoid & Bracket Asbly, Includes: (Not Shown) M21158 1 X
Solenoid Assembly S20140-8 1 X
Idler Solenoid Bracket M20527-1 1 X
Speed Nut T11525-5 2 X
Thread Forming Screw S9225-66 2 X
Lock Washer E106A-2 3 X
Sub Assembly Illustration
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In Line Swivel S22070 1 X

Idler Linkage S26643 1 X
1/4-28 HJN CF000060 1 X
Rod End Swivel S22232 1 X
1/4-20 x 1.00 HHCS CF000015 1 X
Lock Washer E106A-2 1 X
1/4-20 HN CF000017 1 X
12 Air Filter Bracket M20532-1 1 X
M10 x 1.5 HHCS T14731-5 2 X
Lock Washer S17400-1 2 X
21 Generator & Engine Mtg Kit Includes: (Not Shown)
(2) Generator Mounts & (2) Engine Mounts S25632 1 X
22 Starter (Not Shown) G2127 1 X
3/8-16 x 1.25 HHCS T8833-10 2 X
3/8-16 x 1.50 HHCS CF000066 1 X
Lock Washer E106A-4 3 X
3/8-16 HN CF000067 1 X
Sub Assembly Illustration
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23 Top Hose L12349 1 X

Hose Clamp S10888-8 1 X
Hose Clamp S10888-29 1 X
24 Lower Hose L12350 1 X
Hose Clamp S10888-8 1 X
Hose Clamp S10888-33 1 X

SHIELD-ARC® SAE-400 08-05-2009

 P-621-D.2 P-621-D.2
Sub Assembly Illustration
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# Indicates a change this printing. Use only the parts marked “x” in the column under the
heading number called for in the model index page.

ITEM DESCRIPTION PART NO. QTY. 1 2 3 4 5 6 7 8 9

25 Filter Assembly (Not Shown) M17494-2 1 X

M8 x 1.25 Metric HHCS T14731-4 2 X
Plain Washer S9262-121 2 X
Lock Washer E106A-3 2 X
26 Temperature Switch/Sender S25162 1 X
28 Oil Filler Spacer (Not Shown) S25992 1 X
M8 x 1.25 SHCS T14731-3 2 X
Gasket S26001 1 X
Lock Washer E106A-24 2 X
30 Amp to Lucar Adapter S26426 1 X
Sub Assembly Illustration
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Sub Assembly Illustration
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Sub Assembly Illustration
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SHIELD-ARC® SAE-400 08-05-2009

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NOTES

SHIELD-ARC® SAE-400
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Part Numbers Part Numbers Part Numbers Part Numbers

15
P-621-E

1
Generator-Alternator Assembly

SHIELD-ARC® SAE-400
3
4
5
6
7

14
8

13
P-621-E

10

12

08-05-2009
11
 P-621-E.1 P-621-E.1
Sub Assembly Illustration
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# Indicates a change this printing. Use only the parts marked “x” in the column under the
heading number called for in the model index page.

ITEM DESCRIPTION PART NO. QTY. 1 2 3 4 5 6 7 8 9

Generator-Alternator Asbly, Includes: G1709-11 1 X

1 Generator Frame Asbly, Includes: M15077-4 1 X
Shunt Coils (L1741-64 & L1741-63 - Set of 2) FKL-5AG 1 X
Series Coils (L4660-2 & L4660-1 - Set of 2) FKL-420T 1 X
Main Pole Lamination (Not Shown) S10745-1 4 X
Interpole Coils & Lamination (Not Shown) S12261-3 4 X
Interpole Coil (Set of 4) (Not Shown) S12261-3A 1 X
Interpole Lamination (Not Shown) S12260-3 4 X
2 Armature L2667-31 1 X
3 Rocker & Brush Holder Assembly, Includes: S13247-12 1 X
Brush Holder Assembly M6964-10 4 X
Sub Assembly Illustration
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Brushes T12564-1 8 X
5/16-18 x .50 HHCS CF000074 4 X
4 Bracket Guard M5583 2 X
Thread Forming Screw S9225-8 4 X
5 Bearing M9300-22 1 X
6 End Bracket L6795-1 1 X
Pipe Plug S10780-4 1 X
1/2-13 x 1.75 HHCS CF000277 4 X
7 Rotor M13641-4 1 X
8 Brush & Brush Holder Asbly, Includes: M16158 1 X
Brush Holder Cartridge G2114 1 X
Brush Assembly S19480 2 X
Brush Holder Retainer M16157 1 X
Brush Holder Bracket M19896 1 X
1/4-20 x .75 HHCS CF000014 2 X
Plain Washer S9262-23 2 X
Sub Assembly Illustration
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Lock Washer E106A-2 2 X

1/4-20 HN CF000017 2 X
10 Top Exciter Cover M13690-1 1 X
Lock Washer T9860-6 1 X
Thread Forming Screw S9225-8 1 X
11 Rotor Lock Nut T6225-1 1 X
12 Rotor Nut Washer T7090-1 1 X
13 Armature Sleeve Collar T14337 1 X
14 Bottom Exciter Cover M13686 1 X
Lock Washer T9860-6 4 X
Thread Forming Screw S9225-8 4 X
15 3/8-16 HN CF000067 1 X
Sub Assembly Illustration
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SHIELD-ARC® SAE-400 08-05-2009

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Part Numbers Part Numbers Part Numbers Part Numbers

20

26
10

11

25
1
P-621-F

2
3
4
Lower Control Panel Assembly

13
5

14
15

SHIELD-ARC® SAE-400
12 6
P-621-F

27
29
28

08-05-2009
 P-621-F.1 P-621-F.1
Sub Assembly Illustration
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# Indicates a change this printing. Use only the parts marked “x” in the column under the
heading number called for in the model index page.

ITEM DESCRIPTION PART NO. QTY. 1 2 3 4 5 6 7 8 9

Lower Control Panel Assembly, Includes: G4895-4 1 X

1 Rear Lower Panel L10886-5 1 X
2 Rear Panel Nameplate L12645 1 X
Fastener Button T14659-2 4 X
3 Oil Gauge S20206 1 X
4 Temperature Gage (Water) S25154 1 X
5 Ammeter S7514-7 1 X
6 Hour Meter (Engine) S17475-6 1 X
9 Switch (Ignition) T10800-55 1 X
9A Sealing Boot (Not Shown) S22061-4 1 X
10 Switch (Push Button) S13146-4 1 X
Sub Assembly Illustration
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11 Pilot Light T13534-3 1 X

12 Switch & Receptacle Assembly, Includes: M19120 1 X
Switch, Toggle, DPDT T10800-56 1 X
Receptacle S21012 1 X
Thread Forming Screw S9225-63 2 X
Speed Nut T11525-1 2 X
Sealing Boot S22061-4 1 X
13 Start Button S13146-1 1 X
14 Switch (Idler) T10800-55 1 X
14A Sealing Boot S22061-4 1 X
15 Thread Forming Screw S9225-36 1 X
Lock Washer T9695-1 1 X
#10-24 HN CF000010 2 X
20 Idler Engine P.C. Board L12400-[ ] 1 X
#10-24 x 1.25 RHS CF000149 4 X
Plain Washer S9262-27 4 X
Sub Assembly Illustration
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Lock Washer E106A-1 4 X

#10-24 HN CF000010 4 X
23 Plug & Lead Assembly (Not Shown) S18250-397 1 X
24 Harness (Not Shown) G4935 1 X
25 Fastener Button T14659-1 4 X
26 GFCI Module M21586-3 1 X
27 Euro Receptacle (115V) (Yellow) M20152-2 1 X
Thread Forming Screw S9225-63 4 X
28 Euro Receptacle (230V) (Blue) M20152-3 1 X
Thread Forming Screw S9226-63 4 X
29 RCD Cover Plate S28004-2 1 X
Thread Forming Screw S9225-63 2 X
30 Receptacle Guard M22328 1 X
Thread Forming Screw S9225-63 4 X

Note: When ordering new printed circuit boards indicate the dash number [ ] of the “Old” board
Sub Assembly Illustration
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that is to be replaced. This will aid Lincoln in supplying the correct and latest board along
with any necessary jumpers or adapters. The dash number brackets [ ] have purposely
been left blank so as to eliminate errors, confusion and updates.

SHIELD-ARC® SAE-400 08-05-2009

 P-621-G P-621-G
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Control Panel Assembly

Part Numbers

17
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Part Numbers

6
7 5 2
8
16
3
4
1

19 18
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Part Numbers

24 23
22 14
20 34 10 11 12 13
15 27B 25 27
21
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Part Numbers

SHIELD-ARC® SAE-400 08-05-2009

 P-621-G.1 P-621-G.1
Sub Assembly Illustration
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# Indicates a change this printing. Use only the parts marked “x” in the column under the
heading number called for in the model index page.

ITEM DESCRIPTION PART NO. QTY. 1 2 3 4 5 6 7 8 9

Control Panel Asbly, Includes: L13089-3 1 X

1 Reactor Box & Panel Asbly M17602-7 1 X
2 Handle (Selector) S16664-16 1 X
3 Nameplate L12707 1 X
4 Fastener Button T14659-2 4 X
5 Reversing Switch Assembly M7057-1 1 X
Self Tapping Screw S8025-22 2 X
6 Rheostat M5090-C 1 X
7 Sems Screw T10082-4 2 X
8 Handle (Rheostat) S16664-13 1 X
9 Brush Holder Stud Assembly T7852 1 X
Sub Assembly Illustration
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Thread Forming Screw S9225-8 2 X

10 Brush Holder Assembly, Includes: M6277 1 X
Brush Holder - 4 Brush M6264 1 X
Brush Holder Contact Spring T6985 4 X
Lock Washer E106A-1 4 X
#10-24 x 3/8 RHS CF000061 4 X
Brush Contact Spring Assembly T7494 4 X
Brush Holder Shaft T8218 1 X
Insulating Tube T8219 1 X
5/16-18 x 1.00 HHCS CF000062 2 X
11 Reactor Spring Clip S7297 1 X
12 Plain Washer S9262-41 1 X
13 Spring T8236 1 X
14 Continuous Control Assembly L2036-B 1 X
Thread Forming Screw S9225-8 4 X
15 Resistor T8280 1 X
Sub Assembly Illustration
de o Sub sse b es

#10-24 x 5.00 RHS CF000045 1 X

Lock Washer E106A-1 1 X
#10-24 HN CF000010 1 X
16 Caution Decal T13339 1 X
17 Silicon Bridge Assembly T13637 3 X
#8-32 x .875 RHS CF000059 3 X
Plain Washer S9262-3 4 X
Lock Washer T4291-A 3 X
#8-32 HN CF000042 3 X
18 Diode Assembly T13622-1 1 X
19 Resistor Assembly S24403 1 X
20 Receptacle S20184 1 X
21 Instruction Decal S28232 1 X
22 Receptacle Cover M16996 2 X
Receptacle Gasket S21088 2 X
Thread Forming Screw S9225-63 4 X
Speed Nut T11525-1 4 X
Sub Assembly Illustration
de o Sub sse b es

23 Receptacle S14377 1 X
24 Reactor Lead Insulation T10576 1 X
Clamp (Lead Clip) T12563-12 1 X
Self Tapping Screw S8025-22 2 X
25 Circuit Breaker (15A) T12287-22 1 X
27 Circuit Breaker (20A) T12287-31 1 X
Sealing Boot S22061-1 2 X

SHIELD-ARC® SAE-400 08-05-2009

 P-621-G.2 P-621-G.2
Sub Assembly Illustration
de o Sub sse b es

# Indicates a change this printing. Use only the parts marked “x” in the column under the
heading number called for in the model index page.

ITEM DESCRIPTION PART NO. QTY. 1 2 3 4 5 6 7 8 9

27B Circuit Breaker (15A - 2 Pole), Includes: M20585-3 1 X

Circuit Breaker Cover Seal S24911-2 1 X
Sems Screw T10082-30 4 X
Lock Washer T4291-A 4 X
32 Receptacle & Lead Assembly (Not Shown) S14165-463 1 X
34 Spark Arrester Decal S26606 1 X
Sub Assembly Illustration
de o Sub sse b es
Sub Assembly Illustration
de o Sub sse b es
Sub Assembly Illustration
de o Sub sse b es

SHIELD-ARC® SAE-400 08-05-2009

 de o Sub sse b es de o Sub sse b es de o Sub sse b es de o Sub sse b es

NOTES

SHIELD-ARC® SAE-400
 de o Sub sse b es de o Sub sse b es de o Sub sse b es de o Sub sse b es
Part Numbers Part Numbers Part Numbers Part Numbers
P-621-H

13

ELECTRODE
1
Left Gas Tank Rail & Output Panel

9 11
TO WORK

SHIELD-ARC® SAE-400
14

12
P-621-H

08-05-2009
 P-621-H.1 P-621-H.1
Sub Assembly Illustration
de o Sub sse b es

# Indicates a change this printing. Use only the parts marked “x” in the column under the
heading number called for in the model index page.

ITEM DESCRIPTION PART NO. QTY. 1 2 3 4 5 6 7 8 9

Left Gas Tank Rail & Output Panel, Includes: NSS 1 X

1 Rail & Output Panel Assembly M9735-11 1 X
6 Output Terminal Asbly (Does NOT Include Stainless T14166-9 2 X
Steel Flange Nut. It Must be Ordered Separately.)
(Item 8 Is Used to Mount Rail to Lift Bale.)
8 1/2-13 x 1.25 HHCS CF000030 2 X
Lock Washer (Not Shown) E106A-5 2 X
1/2-13 HN CF000027 2 X
Plain Washer (Not Shown) S9262-1 1 X
9 1/2-13 x .75 HHCS (Work) CF000020 1 X
1/2-13 x .875 HHCS CF000344 1 X
Sub Assembly Illustration
de o Sub sse b es

Plain Washer S9262-1 1 X

Lock Washer E106A-15 1 X
12 1/2-13 Hex Flange Nut T3960 2 X
13 Decal, “Electrode” S25371 1 X
14 Decal, “To Work” S25372 1 X
Sub Assembly Illustration
de o Sub sse b es
Sub Assembly Illustration
de o Sub sse b es

NSS - Not Sold Separately SHIELD-ARC® SAE-400 08-05-2009

 de o Sub sse b es de o Sub sse b es de o Sub sse b es de o Sub sse b es
Part Numbers Part Numbers Part Numbers Part Numbers

9
10
P-621-J

3
Remote Control

5
4

711

SHIELD-ARC® SAE-400
1
6
P-621-J

08-05-2009
2
 P-621-J.1 P-621-J.1
Sub Assembly Illustration
de o Sub sse b es

# Indicates a change this printing. Use only the parts marked “x” in the column under the
heading number called for in the model index page.

ITEM DESCRIPTION PART NO. QTY. 1 2 3 4 5 6 7 8 9

Remote Control, Includes: L9303-1 1 X

1 Control Box L9253 1 X
2 Wraparound L9252 1 X
Self Tapping Screw S8025-91 8 X
3 Handle Mounting Bracket L9254 1 X
Self Tapping Screw S8025-91 4 X
4 Handle M15446 1 X
Thread Forming Screw S9225-53 2 X
5 Rheostat M5090-C 1 X
1/4-20 x .375 HHB CF000170 2 X
Lock Washer E106A-2 1 X
Sub Assembly Illustration
de o Sub sse b es

6 Rheostat Handle S16664-13 1 X

7 Nameplate M17267 1 X
8 Thread Forming Screw S9225-30 1 X
Lock Washer (Not Shown) T9695-1 1 X
#10-24 HN CF000010 2 X
9 Box Connector T9639-2 1 X
10 Cable Assembly S21007 1 X
#8-32 x .50 BR RHS CF000102 2 X
#8-32 BR HN CF000103 4 X
11 Resistor Bank Assembly, Includes: M17285 1 X
Resistor Mounting Bracket S21009 2 X
Resistor S10404-22 3 X
#10-24 x 5.00 RHS CF000045 3 X
Insulating Washer T4479-A 3 X
Lock Washer E106A-1 3 X
#10-24 HN CF000010 3 X
Sub Assembly Illustration
de o Sub sse b es

#8-32 x .50 BR RHS CF000102 6 X

#8-32 BR HN CF000103 12 X
Self Tapping Screw S8025-92 2 X
Sub Assembly Illustration
de o Sub sse b es

SHIELD-ARC® SAE-400 08-05-2009

 de o Sub sse b es de o Sub sse b es de o Sub sse b es de o Sub sse b es
Part Numbers Part Numbers Part Numbers Part Numbers

1
P-621-K

2
3
4
5
Generator Brush Holder

4
6
9

7
8
10

SHIELD-ARC® SAE-400
10

11

12
9

13

14
P-621-K

08-05-2009
 P-621-K.1 P-621-K.1
Sub Assembly Illustration
de o Sub sse b es

# Indicates a change this printing. Use only the parts marked “x” in the column under the
heading number called for in the model index page.

ITEM DESCRIPTION PART NO. QTY. 1 2 3 4 5 6 7 8 9

Brush Holder Assembly, Includes: M6964-10 1 X

1 3/8-16 x .625 HHCS CF000018 1 X
2 Lock Washer E106A-16 1 X
3 Clamping Washer (SS) NSS 1 X
4 Brush Holder Insulating Washer T4479 2 X
5 Stud Insulator S13721-2 1 X
6 Brush Holder Washer NSS 1 X
7 Brush Holder Stud NSS 1 X
8 Retainer Assembly M6304-2B 1 X
9 Lock Washer E106A-3 2 X
10 5/16-18 x .75 HHCS CF000040 2 X
Sub Assembly Illustration
de o Sub sse b es

11 Brush Holder Spring T8495 2 X

12 Brush Holder Spring Clip NSS 2 X
13 Lock Washer E106A-3 2 X
14 5/16-18 x .75 HHCS CF000040 2 X
Sub Assembly Illustration
de o Sub sse b es
Sub Assembly Illustration
de o Sub sse b es

NSS - Not Sold Separately SHIELD-ARC® SAE-400 08-05-2009

 de o Sub sse b es de o Sub sse b es de o Sub sse b es de o Sub sse b es

NOTES

SHIELD-ARC® SAE-400
NOTES

SAE-400
l Keep your head out of fumes. l Turn power off before servicing. l Do not operate with panel open or
l Use ventilation or exhaust to
remove fumes from breathing zone.
guards off.
WARNING
l Los humos fuera de la zona de res- Spanish
l Desconectar el cable de ali- l No operar con panel abierto o
piración.
l Mantenga la cabeza fuera de los
mentación de poder de la máquina
antes de iniciar cualquier servicio.
guardas quitadas. AVISO DE
humos. Utilice ventilación o
aspiración para gases.
PRECAUCION
l Gardez la tête à l’écart des fumées. l Débranchez le courant avant l’entre- l N’opérez pas avec les panneaux French
l Utilisez un ventilateur ou un aspira- tien. ouverts ou avec les dispositifs de
teur pour ôter les fumées des zones
de travail.
protection enlevés. ATTENTION
l Vermeiden Sie das Einatmen von l Strom vor Wartungsarbeiten l Anlage nie ohne Schutzgehäuse German
Schweibrauch! abschalten! (Netzstrom völlig öff- oder Innenschutzverkleidung in
l Sorgen Sie für gute Be- und
Entlüftung des Arbeitsplatzes!
nen; Maschine anhalten!) Betrieb setzen! WARNUNG
Portuguese
l Mantenha seu rosto da fumaça. l Não opere com as tampas removidas. l Mantenha-se afastado das partes
l Desligue a corrente antes de fazer
l Use ventilação e exhaustão para
remover fumo da zona respiratória. serviço.
moventes.
l Não opere com os paineis abertos ATENÇÃO
l Não toque as partes elétricas nuas. ou guardas removidas.

Japanese

Chinese

Korean

Arabic

LEIA E COMPREENDA AS INSTRUÇÕES DO FABRICANTE PARA ESTE EQUIPAMENTO E AS PARTES DE USO, E SIGA AS
PRÁTICAS DE SEGURANÇA DO EMPREGADOR.

SAE-400™
 l Do not touch electrically live parts or l Keep flammable materials away. l Wear eye, ear and body protection.

WARNING electrode with skin or wet clothing.

l Insulate yourself from work and
ground.
Spanish
l No toque las partes o los electrodos l Mantenga el material combustible l Protéjase los ojos, los oídos y el
AVISO DE bajo carga con la piel o ropa moja-
da.
fuera del área de trabajo. cuerpo.

PRECAUCION l Aislese del trabajo y de la tierra.

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

German l Berühren Sie keine stromführenden l Entfernen Sie brennbarres Material! l Tragen Sie Augen-, Ohren- und Kör-
Teile oder Elektroden mit Ihrem perschutz!
WARNUNG Körper oder feuchter Kleidung!
l Isolieren Sie sich von den
Elektroden und dem Erdboden!
Portuguese
l Não toque partes elétricas e elec- l Mantenha inflamáveis bem guarda- l Use proteção para a vista, ouvido e
trodos com a pele ou roupa molha-
ATENÇÃO da.
dos. corpo.

l Isole-se da peça e terra.

Japanese

Chinese

Korean

Arabic

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

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

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

LESEN SIE UND BEFOLGEN SIE DIE BETRIEBSANLEITUNG DER ANLAGE UND DEN ELEKTRODENEINSATZ DES HER-
STELLERS. DIE UNFALLVERHÜTUNGSVORSCHRIFTEN DES ARBEITGEBERS SIND EBENFALLS ZU BEACHTEN.

SAE-400™
 • 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