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WELDING SPARKS can cause fire
or explosion.
•
Do not weld near flammable material .
•
Do not weld on containers that have
held flammable material.
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MOVING PARTS can injure.
• Keep away from moving parts
• Do not operate with doors open or
guards off.
• Stop engine before servicing.
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ENGINE EXHAUST can kill.
•
Use in open, well ventilated areas or
vent exhaust outside.
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ADDITIONAL SAFETY PRECAUTIONS
Always operate the welder with the hinged doors
closed as these provide maximum protection from
moving parts and insure proper cooling air flow.
Read carefully the Safety Precautions page in the
Instruction Manual before operating this machine.
Always follow these and any other safety procedures
included in this manual and in the engine and com-
pressor instruction manuals.
GENERAL DESCRIPTION
The SAE-500™ is a diesel engine driven welding
power source. The machine uses a DC generator for
DC stick electrode welding and an AC exciter for
115/230 VAC auxiliary power. As a generator it can
supply up to 3,000 watts of 115/230 volt AC power.
As a welder it provides up to 575 amps of DC con-
stant current output.
The engine is a 64 Hp (48kw), 4-cylinder water cooled
diesel made by Deutz.
RECOMMENDED APPLICATIONS
WELDER
The SAE-500™ provides excellent constant current
DC welding output for stick (SMAW) welding.
AUXILIARY POWER
The SAE-500™ provides 3 KW of 115/230 VAC out-
put for auxiliary power and emergency standby power.
B-1
OPERATION
SAE-500
TM
AND SAE-500
TM
SEVERE DUTY
TM
OPERATING INSTRUCTIONS
Read and understand this entire section before operating
your equipment.
SAFETY INSTRUCTIONS
Do not attempt to use this equipment until you have thor-
oughly read all operating and maintenance manuals sup-
plied with your machine. They include important safety
precautions, detailed engine starting, operating and
maintenance instructions and parts lists.
ELECTRIC SHOCK can kill.
•
Do not touch electrically live parts or
electrodes with your skin or wet cloth-
ing.
•
Insulate yourself from the work and
ground.
• Always wear dry insulating gloves.
• Do not use AC welder if your clothing, gloves or
work area is damp or if working on, under or inside
workpiece.
Use the following equipment:
• Semiautomatic DC constant voltage
(wire) welder.
• DC manual (stick) welder.
• AC welder with reduced voltage control.
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ARC RAYS can injure eyes and
burn skin.
• Wear eye, ear, and body protection.
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• Only qualified personnel should install, use or ser-
vice this equipment.
• Consult instruction manual before operating.
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Before operating, read and understand the manufac-
turer’s instructions for this equipment and the con-
sumables to be used including the Material Safety
Data Sheet (MSDS) and follow your employer’s safe-
ty practices.
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FUMES AND GASES can be dan-
gerous to your health.
• Keep your head out of fumes.
• Use enough ventilation or exhaust at
the arc, or both, to keep the fumes and
gases from your breathing zone and
general area.
WARNING
