Lincoln Electric SAE -500 Operator'S Manual Download

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OPERATOR’S MANUAL

SAE -500

™

DC ARC WELDING POWER SOURCE

IM988

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

your

part.

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.

• 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

• World's Leader in Welding and Cutting Products •

Summary of Contents for SAE -500

Page 1: ...er 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 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...

Page 2: ...ER 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 avail...

Page 3: ...er for cooling 3 h Never simultaneously touch electrically hot parts of electrode holders connected to two welders because voltage between the two can be the total of the open circuit voltage of both welders 3 i When working above floor level use a safety belt to protect yourself from a fall should you get a shock 3 j Also see Items 6 c and 8 FUMES AND GASES can be dangerous 5 a Welding may produc...

Page 4: ... easily go through small cracks and openings to adjacent areas Avoid welding near hydraulic lines Have a fire extinguisher readily available 6 b Where compressed gases are to be used at the job site special precautions should be used to prevent hazardous situations Refer to Safety in Welding and Cutting ANSI Standard Z49 1 and the operating information for the equipment being used 6 c When not wel...

Page 5: ...ppropriés et non inflammables 4 Des gouttes de laitier en fusion sont émises de l arc de 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 ...

Page 6: ...pecially 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...

Page 7: ...Operation B 3 Welder Controls Function Operation B 3 Remote Control B 4 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...

Page 8: ...troke Oil 13 95 Qts 13 2 L 3 86 x 4 72 98 0 mm x 120 0mm Coolant 3 4 gal 12 8 L INPUT DIESEL ENGINE RATED OUTPUT WELDER HEIGHT WIDTH DEPTH WEIGHT 50 13 in 28 00 in 83 00 in 2048 lbs 1273 3 mm 711 2 mm 2108 2 mm 928 kg OUTPUT WELDER AND GENERATOR Duty Cycle 1 Welding Output Volts at Rated Amps 60 NEMA 500 amps 40 volts 100 NEMA 400 amps 36 volts 100 Lincoln Plus 400 amps 40 volts Welding Range Open...

Page 9: ...ted to an outside area DO NOT MOUNT OVER COMBUSTIBLE SURFACES Where there is a combustible surface directly under stationary or fixed electrical equipment that surface should be covered with a steel plate at least 06 1 6mm thick which should extend not less than 5 90 150mm beyond the equipment on all sides STACKING These machines cannot be stacked ANGLE OF OPERATION To achieve optimum engine perfo...

Page 10: ...5 Proper preventative maintenance of trailer 6 Conformance with federal state and local laws 1 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 VEHICLE MOUNTING Improperly mounted concentrated loads may cause unstable vehicle handling and tires or other compo nents to fail Only transport ...

Page 11: ...f the welder for some period of time during the engine s early life However if the welder is subjected to extensive light load ing occasional moderate to heavy loading of the engine may sometimes be necessary Caution must be observed in correctly loading a diesel generator unit 1 Connect the welder output studs to a suitable resistive load bank Note that any attempt to short the output studs by co...

Page 12: ...d for the rated current and duty cycle Lengths stipulated are the distance from the welder to work and back to the welder again Cable sizes are increased for greater lengths primarily for the purpose of mini mizing cable voltage drop Table A 1 Combined Length of Electrode and Work Cables MACHINE GROUNDING Because this portable engine driven welder creates its own power it is not necessary to conne...

Page 13: ...ONS Read and understand this entire section before operat ing your equipment SAFETY INSTRUCTIONS Do not attempt to use this equipment until you have thoroughly read all operating and maintenance manu als supplied 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 electrical...

Page 14: ...VAC power Weld and AC auxiliary power at the same time with in the limits shown on the chart below OTHER FEATURES Kubota 4 cylinder water cooled diesel engine Designed for long life easy maintenance and excel lent fuel economy Engine protection system shuts the engine down for low engine oil pressure or high coolant temperature Electronic Engine Idler Engine automatically goes to low idle in 10 to...

Page 15: ...ow on charge ENGINE HOUR METER The engine hour meter records the total running time on the engine in hours It can be used to keep a record of maintenance on the engine and or welder ENGINE PROTECTION SYSTEM The engine protection system shuts down the engine under high coolant temperature or low engine oil pres sure conditions by allowing the fuel solenoid valve to close WELDER CONTROLS POLARITY SW...

Page 16: ...remote control box while placing the switch in the LOCAL position allows fine current control at the Job Selector on the machine When using the optional field installed CV adapter K385 the Local Remote switch is only active in the VV mode AUXILIARY POWER CONTROLS NOTE GFCI receptacles are an option and if installed see the MAINTENANCE section for detailed informa tion on testing and resetting the ...

Page 17: ...ne and consult the engine operating manual To stop the engine turn the IGNITION switch to OFF 6 If the engine protection warning light comes on during cranking or after start up the IGNITION switch must be turned OFF to reset the engine protection system 7 Allow the engine to run at high idle speed for sev eral minutes to warm the engine Stop the engine and recheck the oil level after allowing suf...

Page 18: ...ous 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 2 00 gal hr 400 Amps 40 Volts 7 57 L hr Welding Load 2 45 gal hr 500 Amps 40 Volts 9 27 L hr Auxiliary Power 0 65 gal hr 3000VA 2 46 L hr ...

Page 19: ...lder 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 K1690 1 GFCI RECEPTACLE KIT Includes one UL a...

Page 20: ...once every two months In particularly dirty locations this cleaning may be necessary once a week Use low pres sure air to avoid driving dirt into the insulation 2 The current control reactor brushes are self lubricating and should not be greased Keep the contacts clean This control should be moved from maximum to minimum daily to prevent the controls from sticking 3 See the engine Instruction Manu...

Page 21: ... of a piece of fine sandpaper between slip rings and brushes with the coarse side against the brushes With slight additional finger pres sure on top of the brushes pull the sandpaper around the circumference of the rings in direction of rotation only until brushes seat properly In addition stone slip ring with a fine stone Brushes must be seated 100 Arcing or excessive exciter brush wear indicates...

Page 22: ...ther 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 is not working prop erly or has been incorrectly installed miswired If your GFCI is not working properly contact a qualified certi fied electrician who can assess the situation rewire the GFCI if necessary or replace t...

Page 23: ...column labeled PROBLEM SYMP TOMS This column describes possible symptoms that the machine may exhibit Find the listing that best 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 Step 3 RECOMMENDED COURSE OF ACTION This column provides a course of ac...

Page 24: ...rn out or missing Contact surface may be dirty rough and pitted 10 Current Control brushholder support stud and mating contact surfaces may be dirty or pitted and burned 11 Engine running at varying speeds 1 True and clean commutator 2 Replace brushes 3 Replace brush springs 4 Check field current with ammeter to discover varying current This applies to both the main generator and exciter 5 Tighten...

Page 25: ...may not be operating 3 Field circuit of generator or exciter may be open 4 Polarity reversing switch may be in the neutral position 5 Exciter may have lost excitation 1 Series field circuit may be open circuited 2 Current setting may be too high 3 Polarity may be wrong 1 Be sure that all brushes bear on the commutator and have proper spring tension 2 Check exciter output voltage with voltmeter or ...

Page 26: ... Control shaft and handle may have turned slightly in the insulated bushing of the current control brushholder caused by turning handle too hard against one of the stops 2 Exciter output low causing low output compared to dial indica tion 3 Current Control set to minimum and welder output so great that engine stalls when arc is struck 1 Local Remote switch is in wrong position 1 With current contr...

Page 27: ...ou proceed CAUTION FUNCTION PROBLEMS PROBLEMS SYMPTOMS POSSIBLE CAUSE RECOMMENDED COURSE OF ACTION No auxiliary power 1 Circuit Breakers open 2 Faulty connections to auxiliary receptacles 3 GFCI Receptacle if installed may have tripped 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 C...

Page 28: ...WER WDG WELD CURRENT SWITCH FOR LOCAL OR REMOTE CONTROL SHOWN IN LOCAL POSITION BACK VIEW OF POLARITY SWITCH POLARITY SWITCH PLUG FOR REMOTE CONTROL POTENTIOMETER REMOTE CONTROL POTENTIOMETER BOX RESISTORS Y X U G W G 11B 820 810 REMOTE CONTROL GND C GND T GND S GND R 602C 203A CONNECT TO BASE STARTING MOTOR B BLACK OR GREY R RED OR PINK G GREEN U BLUE N BROWN W WHITE LEAD COLOR CODE 238 TO WORK T...

Page 29: ...N PRINT F 5 M8869 38 A 01 27 27 22 50 38 63 63 13 45 83 6 00 24 50 28 14 83 01 43 01 23 50 49 77 CENTER OF GRAVITY WITH OIL IN ENGINE BUT NO FUEL 77 02 N A 0 32 DIA N B 0 81 DIA N A 20 00 N B 2 13 73 88 14 03 44 50 N B N A ...

Page 30: ...NOTES SAE 500 ...

Page 31: ...NOTES SAE 500 ...

Page 32: ...für gute Be und Entlüftung des Arbeitsplatzes Mantenha seu rosto da fumaça Use ventilação e exhaustão para remover fumo da zona respiratória Turn power off before servicing Desconectar el cable de ali mentación de poder de la máquina antes de iniciar cualquier servicio Débranchez le courant avant l entre tien Strom vor Wartungsarbeiten abschalten Netzstrom völlig öff nen Maschine anhalten Não oper...

Page 33: ...uch electrically live parts or electrode with skin or wet clothing Insulate yourself from work and ground No toque las partes o los electrodos bajo carga con la piel o ropa moja da Aislese del trabajo y de la tierra Ne laissez ni la peau ni des vête ments mouillés entrer en contact avec des pièces sous tension Isolez vous du travail et de la terre Berühren Sie keine stromführenden Teile oder Elekt...

Page 34: ...s 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 World s Leader in Welding and Cutting Products ...

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