Lincoln-electric IM988 SAE500 User Manual

OPERATOR’S MANUALSAE -500™DC ARC WELDING POWER SOURCEIM988May, 2009For use with machines having Code Numbers: 11476Safety Depends on YouLincoln arc we

A-3INSTALLATIONSAE-500™A-3HIGH ALTITUDE OPERATIONAt higher altitudes, output derating may be necessary.For maximum rating, derate the welder output 5%

A-4INSTALLATIONA-4SAE-500™• Stop engine while fueling.• Do not smoke when fueling.• Keep sparks and flame away fromtank.• Do not leave unattended

● USING A BOOSTER — connectpositive lead to battery first thenconnect negative lead to negativebattery lead at the lower controlpanel support.BATTERY

B-1OPERATIONB-1WELDING SPARKS can causefire or explosion.• Do not weld near flammable material.• Do not weld on containers that have held flam

B-2OPERATIONB-2RECOMMENDED APPLICATIONSWELDERThe SAE-500™ provides excellent constant currentDC welding output for stick (SMAW) welding. The fiel

B-3OPERATIONB-3ENGINE CONTROLSIGNITION SWITCHWhen placed in the “ON” position, this switch ener-gizes the fuel solenoid. When placed in the “O

B-4OPERATIONB-4How to Set the ControlsAssume you want a normal soft arc and about 135amps, using a 5/32” (4.0 mm) electrode:1. Set the “Job

B-5OPERATIONB-5SAE-500™ENGINE OPERATIONFor added safety always operate the welder with thedoors closed. Further, leaving the doors open changesthe de

B-6OPERATIONB-6SAE-500™ TYPICAL FUEL CONSUMPTIONThe typical fuel consumption of the SAE-500™ for var-ious operating scenarios is shown below:KUBOTA V3

C-1ACCESSORIESC-1K930-2 TIG Module - Provides high frequency plus agas valve for TIG welding. A water valve is available asan option. Requires 115 vol

FOR ENGINEpowered equipment.1.a. Turn the engine off before troubleshooting and maintenancework unless the maintenance work requires it to be running.

D-1MAINTENANCED-1ELECTRIC SHOCK can kill.●●Do not touch electrically live partssuch as output terminals or inter-nal wiringENGINE EXHAUST can kill.●●U

D-2MAINTENANCED-2SAE-500™COMMUTATOR AND BRUSH Uncovered rotating equipment can be dangerous.Use care so your hands, hair, clothing or tools donot cat

D-3MAINTENANCED-3SAE-500™GFCI RECEPTACLE TESTING AND RESET-TING PROCEDUREThe GFCI receptacle should be properly tested at leastonce every month or

E-1TROUBLESHOOTINGE-1SAE-500™If for any reason you do not understand the test procedures or are unable to perform the tests/repairs safely, contact yo

E-2TROUBLESHOOTINGE-2SAE-500™Observe all Safety Guidelines detailed throughout this manualIf for any reason you do not understand the test procedures

E-3TROUBLESHOOTINGE-3SAE-500™Observe all Safety Guidelines detailed throughout this manualIf for any reason you do not understand the test procedures

E-4TROUBLESHOOTINGE-4SAE-500™Observe all Safety Guidelines detailed throughout this manualIf for any reason you do not understand the test procedures

E-5TROUBLESHOOTINGE-5SAE-500™Observe all Safety Guidelines detailed throughout this manualIf for any reason you do not understand the test procedures

F-1WIRING DIAGRAMSSAE-500™F-1AC(-)D2238AC2021(+)AC203ACD1A122CRE*844GND-E602B(-)NEGPOSTOROID201W3500Ω602A-22600AY431X42P8215+W27A11A114A400F6A(+)REACT

SAE-500™F-5DIMENSION PRINTF-5M8869-38A.0127.2722.5038.6363.1345.836.0024.5028.1483.0143.0123.5049.77CENTER OF GRAVITY WITH OIL IN ENGINE, BUT NO FUEL7

iiSAFETYiiARC RAYS can burn.4.a. Use a shield with the proper filter and coverplates to protect your eyes from sparks andthe rays of the arc when weld

NOTES SAE-500™

NOTES SAE-500™

SAE-500™WARNINGAVISO DEPRECAUCIONATTENTIONWARNUNGATENÇÃOSpanishFrenchGermanPortugueseJapaneseChineseKoreanArabicLEIA E COMPREENDA AS INSTRUÇÕES DO FAB

SAE-500™WARNINGAVISO DEPRECAUCIONATTENTIONWARNUNGATENÇÃOSpanishFrenchGermanPortugueseJapaneseChineseKoreanArabicREAD AND UNDERSTAND THE MANUFACTURER’S

• Sales and Service through Subsidiaries and Distributors Worldwide •Cleveland, Ohio 44117-1199 U.S.A. TEL: 216.481.8100 FAX: 216.486.1751 WEB

iiiSAFETYiiiFOR ELECTRICALLYpowered equipment.8.a. Turn off input power using the disconnectswitch at the fuse box before working onthe equipment.8.b.

ivSAFETYivMar. ‘93PRÉCAUTIONS DE SÛRETÉPour votre propre protection lire et observer toutes les instructionset les précautions de sûreté specifiques q

vvTThhaannkk YYoouufor selecting a QUALITY product by Lincoln Electric. We want youto take pride in operating this Lincoln Electric Company product •

viTABLE OF CONTENTSSAE-500™viPageInstallation Instructions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

A-1INSTALLATION SAE-500™A-1TECHNICAL SPECIFICATIONS - SAE-500™ (K1278-11)Make/Model Description Speed (RPM) Displacement Starting CapacitiesSystemK

A-2INSTALLATION SAE-500™A-2Read this entire installation section before youstart installation.SAFETY PRECAUTIONSDo not attempt to use this equipment