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IM988
™
SAE -500
DC ARC WELDING POWER SOURCE
May, 2009
For use with machines having Code Numbers: 11476
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.
nd, 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
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Table of Contents
Troubleshooting
Related Manuals for Lincoln Electric SAE -500
Summary of Contents for Lincoln Electric SAE -500
- Page 1 IM988 ™ SAE -500 DC ARC WELDING POWER SOURCE May, 2009 For use with machines having Code Numbers: 11476 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 ...
- Page 2 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.
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Page 3: Electric Shock Can Kill
SAFETY ARC RAYS can burn. ELECTRIC SHOCK can kill. 4.a. Use a shield with the proper filter and cover 3.a. The electrode and work (or ground) circuits plates to protect your eyes from sparks and are electrically “hot” when the welder is on. the rays of the arc when welding or observing Do not touch these “hot”... - Page 4 SAFETY CYLINDER may explode WELDING and CUTTING SPARKS can if damaged. cause fire or explosion. 7.a. Use only compressed cylinders 6.a. Remove fire hazards from the welding area. containing the correct shielding gas for the process used and properly operating If this is not possible, cover them to prevent regulators designed for the gas and the welding sparks from starting a fire.
- Page 5 SAFETY 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 7. Quand on ne soude pas, poser la pince à une endroit isolé de et les précautions de sûreté...
- Page 6 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.
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Page 7: Table Of Contents
TABLE OF CONTENTS Page Installation Instructions ..........Section A Technical Specifications . -
Page 8: Technical Specifications
INSTALLATION TECHNICAL SPECIFICATIONS - SAE-500™ (K1278-11) INPUT - DIESEL ENGINE Make/Model Description Speed (RPM) Displacement Starting Capacities System K1278-11 Kubota 4 cylinder High Idle 1800 220.9 cu. in 12VDC batteries Fuel: 29.0 gal. V3600-T-E3BG 57.8 HP @ Low Idle 1100 (3.62 L) (2) &... -
Page 9: Location/Ventilation
INSTALLATION Read this entire installation section before you CAUTION start installation. DO NOT MOUNT OVER COMBUSTIBLE SURFACES SAFETY PRECAUTIONS Where there is a combustible surface directly under stationary or fixed electrical equipment, that WARNING surface should be covered with a steel plate at least .06”(1.6mm) thick, which should extend not Do not attempt to use this equipment until you less than 5.90(150mm) beyond the equipment on... -
Page 10: High Altitude Operation
INSTALLATION HIGH ALTITUDE OPERATION VEHICLE MOUNTING At higher altitudes, output derating may be necessary. WARNING For maximum rating, derate the welder output 5% for every 500 meters (1640 ft.) above 400 meters (1312 Improperly mounted concentrated loads may cause ft.). unstable vehicle handling and tires or other compo- nents to fail. -
Page 11: Fuel
WARNING ENGINE BREAK-IN PERIOD GASES FROM BATTERY can explode. Keep sparks, flame and cigarettes Lincoln Electric selects high quality, heavy-duty industrial away from battery. engines for the portable welding machines we offer. ------------------------------------------------------------------------ While it is normal to see a small amount of crankcase oil... -
Page 12: Spark Arrester
INSTALLATION USING A BOOSTER — connect 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. -
Page 13: Operating Instructions
OPERATION 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 SAFETY INSTRUCTIONS • Do not weld on containers that have held flam- WARNING mable material. -
Page 14: Design Features And Advantages
OPERATION RECOMMENDED APPLICATIONS OTHER FEATURES WELDER • Kubota 4-cylinder, water cooled diesel engine. The SAE-500™ 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 •... - Page 15 OPERATION ENGINE CONTROLS ENGINE PROTECTION SYSTEM The engine protection system shuts down the engine IGNITION SWITCH under high coolant temperature or low engine oil pres- sure conditions by allowing the fuel solenoid valve to When placed in the “ON” position, this switch ener- close.
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Page 16: Remote Control
OPERATION How to Set the Controls One 15 amp, 230 VAC duplex receptacle provides 230 VAC for auxiliary power. A total of 13 amps can be Assume you want a normal soft arc and about 135 drawn from this receptacle. amps, using a 5/32”... -
Page 17: Engine Operation
OPERATION Observe the oil pressure. If no pressure shows ENGINE OPERATION within 30 seconds, stop the engine and consult the WARNING engine operating manual. To stop the engine, turn the “IGNITION” switch to “OFF”. Do not attempt to use this equipment until you If the engine protection warning light comes on have thoroughly read the engine manufacturer’s during cranking or after start up, the “IGNITION”... -
Page 18: Typical Fuel Consumption
OPERATION TYPICAL FUEL CONSUMPTION The typical fuel consumption of the SAE-500™ for var- ious operating scenarios is shown below: KUBOTA V3600-T-E3BG Low Idle - No Load 0.31 gal./ hr. 1100 RPM ( 1.17 L./hr.) High Idle - No Load 0.69 gal./hr. 1800 RPM (2.61 L./hr.) Welding Load... -
Page 19: Accessories
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. -
Page 20: Maintenance
MAINTENANCE WARNING PERIODIC MAINTENANCE ELECTRIC SHOCK can kill. 1. Blow out the welder and controls with an air hose at least once every two months. In particularly dirty locations, this Do not touch electrically live parts cleaning may be necessary once a week. Use low pres- such as output terminals or inter- sure air to avoid driving dirt into the insulation. -
Page 21: Pre Filter / Washer Separator
MAINTENANCE COMMUTATOR AND BRUSH COOLING SYSTEM WARNING The SAE-500™ 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. -
Page 22: Spark Arrester
MAINTENANCE GFCI RECEPTACLE TESTING AND RESET- ENGINE AND COMPRESSOR MAINTENANCE COMPONENTS TING PROCEDURE ITEM MAKE PART NUMBER The GFCI receptacle should be properly tested at least once every month or whenever it is tripped. To proper- Engine Air Filter Donaldson P822768 ly test and reset the GFCI receptacle: Fan Belt... -
Page 23: How To Use Troubleshooting Guide
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. -
Page 24: Troubleshooting
TROUBLESHOOTING 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. - Page 25 TROUBLESHOOTING 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.
- Page 26 TROUBLESHOOTING 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 handle 1. With current control against the small compared to indication on the may have turned slightly in the minimum stop, set pointer to with- dial.
- Page 27 TROUBLESHOOTING 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.
- Page 28 WIRING DIAGRAMS SAE-500™...
- Page 29 DIMENSION PRINT SAE-500™...
- Page 30 NOTES SAE-500™...
- Page 31 NOTES SAE-500™...
- Page 32 Keep your head out of fumes. Turn power off before servicing. Do not operate with panel open or Use ventilation or exhaust to guards off. WARNING remove fumes from breathing zone. Spanish Los humos fuera de la zona de res- Desconectar el cable de ali- No operar con panel abierto o AVISO DE...
- Page 33 Do not touch electrically live parts or Keep flammable materials away. Wear eye, ear and body protection. WARNING electrode with skin or wet clothing. Insulate yourself from work and ground. Spanish No toque las partes o los electrodos Mantenga el material combustible Protéjase los ojos, los oídos y el AVISO DE bajo carga con la piel o ropa moja-...
- Page 34 • 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...