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Operator's Manual
SAE-500
DC ARC WELDING POWER SOURCE
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Date Purchased
Code: (ex: 10859)
Serial: (ex: U1060512345)
IM10199-A
| Issue D ate Apr-17
© Lincoln Global, Inc. All Rights Reserved.
& SEVERE DUTY
TM
For use with machines having Code Numbers:
12241, 12242, 12687, 12688
Need Help? Call 1.888.935.3877
to talk to a Service Representative
Hours of Operation:
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no later than the following business day.
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Summary of Contents for Lincoln Electric SAE-500
- Page 1 Operator’s Manual SAE-500 & SEVERE DUTY DC ARC WELDING POWER SOURCE For use with machines having Code Numbers: 12241, 12242, 12687, 12688 Register your machine: Need Help? Call 1.888.935.3877 www.lincolnelectric.com/register to talk to a Service Representative Authorized Service and Distributor Locator: www.lincolnelectric.com/locator...
- Page 2 THANK YOU FOR SELECTING A QUALITY PRODUCT BY KEEP YOUR HEAD OUT OF THE FUMES. DON’T get too close to the arc. LINCOLN ELEC TRIC. Use corrective lenses if necessary to stay a reasonable distance away from the arc. READ and obey the Safety Data PLEASE EXAMINE CARTON AND EQUIPMENT FOR Sheet (SDS) and the warning label DAMAGE IMMEDIATELY...
- Page 3 W117.2-1974. A Free copy of “Arc Welding Safety” booklet E205 is available from the Lincoln Electric Company, 2.d. All welders should use the following procedures in order to 22801 St. Clair Avenue, Cleveland, Ohio 44117-1199.
- Page 4 SAFETY ELECTRIC SHOCK ARC RAYS CAN BURN. CAN KILL. 3.a. The electrode and work (or ground) circuits are 4.a. Use a shield with the proper filter and cover plates to protect your electrically “hot” when the welder is on. Do eyes from sparks and the rays of the arc when welding or not touch these “hot”...
- Page 5 SAFETY WELDING AND CUTTING CYLINDER MAY EXPLODE IF SPARKS CAN CAUSE DAMAGED. FIRE OR EXPLOSION. 7.a. Use only compressed gas cylinders containing the correct shielding gas for the process used 6.a. Remove fire hazards from the welding area. If and properly operating regulators designed for this is not possible, cover them to prevent the welding sparks the gas and pressure used.
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Page 6: Table Of Contents
SAE-500 AND SAE-500 SEVERE DUTY TABLE OF CONTENTS Page Installation ............Section A Technical Specifications . - Page 7 SAE-500 AND SAE-500 SEVERE DUTY TABLE OF CONTENTS Page Troubleshooting Guide ..........Section E Safety Warning .
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Page 8: Tm And Sae-500
SAE-500 AND SAE-500 SEVERE DUTY INSTALLATION TECHNICAL SPECIFICATIONS - SAE-500™ INPUT - DIESEL ENGINE Make/Model Description Speed (RPM) Displacement Starting Capacities System Deutz 4 cylinder High Idle 1800 176.9 in 12VDC batteries Fuel: 29 gal. TD 2.9 L 4 64 HP Low Idle 1180 (2.9 L) -
Page 9: Safety Precautions
SAE-500 AND SAE-500 SEVERE DUTY 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, WARNING that surface shall be covered with a steel plate at least .06”(1.6mm) thick, which shall extend not... -
Page 10: High Altitude Operation
SAE-500 AND SAE-500 SEVERE DUTY INSTALLATION HIGH ALTITUDE OPERATION PRE-OPERATION ENGINE SERVICE At higher altitudes, output derating may be necessary. For maximum rating, derate the welder output in READ the engine operating and maintenance instruc- accordance with the following guidelines for this tions supplied with this machine. -
Page 11: Engine Break-In
BATTERY CONNECTION ENGINE BREAK-IN WARNING: Use caution as the electrolyte is a Lincoln Electric selects high quality, heavy-duty indus- strong acid that can burn skin and damage eyes. trial engines for the portable welding machines we offer. While it is normal to see a small amount of... -
Page 12: Spark Arrestor
SAE-500 AND SAE-500 SEVERE DUTY INSTALLATION SPARK ARRESTOR MACHINE GROUNDING WARNING 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 diesel engines be equipped with exhaust spark premises wiring (home, shop, etc.). -
Page 13: Operation
• Keep your head out of fumes. • Use enough ventilation or exhaust at The SAE-500™ provides 3 KW of 115/230 VAC out- put for auxiliary power and emergency standby power. the arc, or both, to keep the fumes and gases from your breathing zone and general area. -
Page 14: Design Features And Advantages
SAE-500 AND SAE-500 SEVERE DUTY OPERATION DESIGN FEATURES AND ADVANTAGES DUTY CYCLE FOR STICK WELDING Duty cycle is the percentage of time the load is being • Excellent DC constant current output for stick weld- applied in a 10 minute period. For example a 60% ing applications. -
Page 15: Engine Controls
SAE-500 AND SAE-500 SEVERE DUTY OPERATION ENGINE CONTROLS BATTERY CHARGE VOLT METER Displays the voltage going from the charging alternator IGNITION SWITCH into the battery. It is normal for charging voltage to be high after starting or when the battery is low on charge. -
Page 16: Remote Control
SAE-500 AND SAE-500 SEVERE DUTY OPERATION WELDER CONTROLS 5. If dialing the desired current with the “Job Selector” moves the setting outside the black range causing POLARITY SWITCH undesirable arc characteristics, turn the “Job Selector” back to the center of the black range. Then Turn the Arc Polarity switch to electrode positive or turn the “Current Control”... -
Page 17: Engine Operation
SAE-500 AND SAE-500 SEVERE DUTY OPERATION ENGINE OPERATION If the engine fails to start in 60 seconds, wait 30 seconds and repeat the above procedure. Do not WARNING allow the starter motor to run continuously for more then 20 seconds. Do not attempt to use this equipment until you have Observe the oil pressure. -
Page 18: Typical Fuel Consumption
SAE-500 AND SAE-500 SEVERE DUTY OPERATION TYPICAL FUEL CONSUMPTION The typical fuel consumption of the SAE-500 for vari- ous operating scenarios is shown below: Low Idle - No Load 0.34 gal./ hr. 1180 RPM ( 1.30 L./hr.) High Idle - No Load 0.83 gal./hr. -
Page 19: Accessories
SAE-500 AND SAE-500 SEVERE DUTY ACCESSORIES OPTIONAL FIELD INSTALLED ACCESSORIES K802-D Power Plug Kit - Kit includes male plugs for 20 Amp receptacle. K2641-1 Trailer - A 4-wheel steerable trailer for in- plant and yard towing with E78-14 load range (B) tubeless tires. -
Page 20: Maintenance
ENGINE OIL CHANGE such as output terminals or inter- nal wiring The SAE-500™ SEVERE DUTY™ is equipped with a con- venient oil drain system. Drain the oil when the engine is ENGINE EXHAUST can kill. warm to assure rapid and complete draining. -
Page 21: Bearing Maintenance
• Do not spill fuel ! and slip rings more often. The SAE-500™ is equipped with a Fuel Filter located ----------------------------------------------------------------- after the lift pump and before fuel injectors.The proce- Replace brushes when they wear within 1/4" of the dure for changing the filter is as follows. -
Page 22: Gfci Receptacle Testing And Resetting Procedure
SAE-500 AND SAE-500 SEVERE DUTY MAINTENANCE GFCI RECEPTACLE TESTING AND • Push the "Reset" button located on the GFCI recep- RESETTING PROCEDURE tacle. This will assure normal GFCI operation. • Plug a night-light (with an "ON/OFF" switch) or other product (such as a lamp) into the GFCI receptacle The GFCI receptacle should be properly tested at and turn the product "ON". - Page 23 SAE-500 AND SAE-500 SEVERE DUTY MAINTENANCE Service Instructions Service Instructions Single- and Two-Stage Engine Air Cleaners Single- and Two-Stage Engine Air Cleaners Inspect the New Filter for Damage Inspect the New Filter for Damage Remove the Filter Remove the Filter...
- Page 24 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 25 SAE-500 AND SAE-500 SEVERE DUTY TROUBLESHOOTING Observe all Safety Guidelines detailed throughout this manual POSSIBLE PROBLEMS RECOMMENDED CAUSE (SYMPTOMS) COURSE OF ACTION Engine will “crank” but not start. 1. Out of fuel. 2. Fuel shut off valve is in the off posi-...
- Page 26 SAE-500 AND SAE-500 SEVERE DUTY TROUBLESHOOTING Observe all Safety Guidelines detailed throughout this manual PROBLEMS POSSIBLE RECOMMENDED (SYMPTOMS) CAUSE COURSE OF ACTION Major Physical or Electrical Damage . Contact your Local Lincoln is Evident. Authorized Field Service Facility. Engine will not crank 1.
- Page 27 SAE-500 AND SAE-500 SEVERE DUTY TROUBLESHOOTING Observe all Safety Guidelines detailed throughout this manual POSSIBLE PROBLEMS RECOMMENDED CAUSE (SYMPTOMS) COURSE OF ACTION 1. Generator or exciter brushes may Welder runs but fails to generate current. be loose or missing. 2. Exciter may not be operating.
- Page 28 SAE-500 AND SAE-500 SEVERE DUTY TROUBLESHOOTING PROBLEMS POSSIBLE RECOMMENDED (SYMPTOMS) CAUSE COURSE OF ACTION Battery does not stay charged. 1. Faulty battery. 2. Faulty engine alternator. 3. Loose or broken lead in charging circuit. 4. Loose fan belt may need tightening.
- Page 29 SAE-500 AND SAE-500 SEVERE DUTY TROUBLESHOOTING Error Code Description (code) Actuator error EGR-Valve (2.9;3.6) or Throttle-Valve (6.1,7.8); internal error Sensor error accelerator pedal; signal check either high or below the range Plausibility error between APP1 and APP2 or APP1 and idle switch Sensor error low fuel pressure;...
- Page 30 SAE-500 AND SAE-500 SEVERE DUTY TROUBLESHOOTING Error Code Description (code) Pressure Relief Valve (PRV) reached maximun allowed opening time count 523009 Injector cylinder-bank 1; short circuit 523350 Injector cylinder-bank 2; short circuit 523352 Injector powerstage output defect 523354 Pressure Relief Valve (PRV) forced to open by pressure increase or pressure shock 523470 Rail pressure out of tolerance range;...
- Page 31 SAE-500 AND SAE-500 SEVERE DUTY DIAGRAMS Code # 12241, 12242 SAE-500 & SAE-500SD T4 DEUTZ " WIRING DIAGRAM ELECTRICAL SYMBOLS PER E1537 " Ω GND. C %!& " &! &! " DASHBOARD GAUGE 3 TURNS 2 TURNS GND. C 75 R...
- Page 32 SAE-500 AND SAE-500 SEVERE DUTY DIAGRAMS Code # 12687, 12688 SAE-500 & SAE-500SD T4 DEUTZ " WIRING DIAGRAM ELECTRICAL SYMBOLS PER E1537 " Ω GND. C & & & " &! & '! (! & " DASHBOARD GAUGE & GND. C 75 R &...
- Page 33 SAE-500 AND SAE-500 SEVERE DUTY DIAGRAMS...
- Page 34 WARNING Do not touch electrically live parts or Keep flammable materials away. Wear eye, ear and body protection. electrode with skin or wet clothing. Insulate yourself from work and AVISO DE ground. Spanish PRECAuCION No toque las partes o los electrodos Mantenga el material combustible Protéjase los ojos, los oídos y el bajo carga con la piel o ropa moja-...
- Page 35 WARNING 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. remove fumes from breathing zone. AVISO DE Spanish PRECAuCION Los humos fuera de la zona de res- Desconectar el cable de ali- No operar con panel abierto o piración.
- Page 36 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.
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