Lincoln Electric IM968 User Manual [en, de, es, fr]

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DC ARC WELDING POWER SOURCE

Safety Depends on You

Li nc ol n a rc welding an d c ut ti ng
equipment is designed an d buil t
with safety in mind. However, your
overall safety can be increased by
proper installation ... and thoughtful
operation on your part. DO NOT

INS T ALL , OPE R ATE O R
REP A IR THI S E Q UIP M ENT
WIT H OUT REA D ING THI S
MAN UAL AND THE SA F ETY
PRE CA UTI ONS CO NTA INE D
THROUGHOUT. And, most impor-

tantly, think before you act and be
careful.

IM968

May, 2009

For use with machines having Code Number: 11477

Cleveland, Ohio 44117-1199 U.S.A. TEL: [phone] FAX: [phone] WEB SITE: www.lincolnelectric.com

OPERATOR’S MANUAL

Copyright © Lincoln Global Inc.

• World's Leader in Welding and Cutting Products •

• Sales and Service through Subsidiaries and Distributors Worldwide •

i

SAFETY

WARNING

CALIFORNIA PROPOSITION 65 WARNINGS

Diesel engine exhaust and some of its constituents
are known to the State of California to cause can­cer, birth defects, and other reproductive harm.

The Above For Diesel Engines

ARC WELDING CAN BE HAZARDOUS. PROTECT YOURSELF AND OTHERS FROM POSSIBLE SERIOUS INJURY OR DEATH.
KEEP CHILDREN AWAY. PACEMAKER 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 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.

The engine exhaust from this product contains
chemicals known to the State of California to cause
cancer, birth defects, or other reproductive harm.

The Above For Gasoline Engines

i

FOR ENGINE
powered equipment.

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

____________________________________________________

1.b.Operate engines inopen, well-ventilated
areas or ventthe engine exhaust fumes
outdoors.

____________________________________________________

1.c. Do not add the fuel near an open flame
welding arc or when the engine is running.
Stop the engine and allow it to cool before
refueling to prevent spilled fuel from vaporiz­ing on contact with hot engine parts and
igniting. Do not spill fuel when filling tank. If
fuel is spilled, wipe it up and do not start
engine until fumeshave been eliminated.

____________________________________________________

1.d. Keep all equipment safety guards, covers and devices in
position and in good repair.Keep hands, hair, clothing and
tools away from V-belts, gears, fans and all other moving
parts when starting,operating or repairing equipment.

____________________________________________________

1.e. In some cases it may be necessary to remove safety

guards to perform required maintenance. Remove
guards only when necessary and replace them when the
maintenance requiring their removal is complete.
Always use the greatest care when working near moving
parts.

___________________________________________________

1.f. Do not put your hands near the engine fan.
Do not attempt to override the governor or
idler by pushing on the throttle control rods
while the engineis running.

1.h. To avoid scalding, do not remove the
radiator pressure cap when the engine is
hot.

ELECTRIC AND
MAGNETIC FIELDS
may be dangerous

2.a. Electric current flowing through any conductor causes
localized Electric and Magnetic Fields (EMF). Welding
current creates EMF fields around welding cables and
welding machines

2.b. EMF fields may interfere with some pacemakers, and
welders having a pacemaker should consult their physician
before welding.

2.c. Exposure to EMF fields in welding may have other health
effects which arenow not known.

2.d. All welders should use the following procedures in order to
minimize exposure to EMF fields from the welding circuit:

2.d.1.

Route the electrode and work cables together - Secure
them with tapewhen possible.

2.d.2. Never coil the electrode lead around your body.

2.d.3. Do not place your body between the electrode and

work cables. Ifthe electrode cable is on your right
side, the work cable should also be on your right side.

___________________________________________________

1.g. To prevent accidentallystarting gasoline engines while
turning the engine or welding generator during maintenance
work, disconnect the spark plug wires, distributor cap or
magneto wire asappropriate.

2.d.4. Connect the work cable to the workpiece as close as
possible to thearea being welded.

2.d.5. Donot work next to welding power source.

Mar ‘95

ii

SAFETY

ii

ELECTRIC SHOCK can
kill.

3.a. The electrode and work (or ground) circuits
are electrically “hot” when the welder is on.
Do not touch these “hot” parts with your bare
skin or wet clothing. Wear dry, hole-free

gloves to insulate hands.

3.b. Insulate yourself from work and ground using dry insulation.
Make certain the insulation is large enough to cover your full
area of physical contact with work and ground.

In addition to the normal safety precautions, if welding
must be performed under electrically hazardous
conditions (in damp locations or while wearing wet
clothing; on metal structures such as floors, gratings or
scaffolds; when in cramped positions such as sitting,
kneeling or lying, if there is a high risk of unavoidable or
accidental contact with the workpiece or ground) use
the following equipment:

• Semiautomatic DC Constant Voltage (Wire) Welder.

• DC Manual (Stick) Welder.

• AC Welder with Reduced Voltage Control.

3.c. In semiautomatic or automatic wire welding, the electrode,
electrode reel, welding head, nozzle or semiautomatic
welding gun are also electrically “hot”.

3.d. Always be sure the work cable makes a good electrical
connection with the metal being welded. The connection
should be as close as possible to the area being welded.

3.e. Ground the work or metal to be welded to a good electrical
(earth) ground.

ARC RAYS can burn.

4.a. Use a shield with the proper filter and cover
plates to protect your eyes from sparks and
the rays of the arc when welding or observing
open arc welding. Headshield and filter lens
should conform to ANSI Z87. I standards.

4.b. Use suitable clothing made from durable flame-resistant
material to protect your skin and that of your helpers from
the arc rays.

4.c. Protect other nearby personnel with suitable, non-flammable
screening and/or warn them not to watch the arc nor expose
themselves to the arc rays or to hot spatter or metal.

FUMES AND GASES
can be dangerous.

5.a.Welding may produce fumes and gases
hazardous to health. Avoid breathing these
fumes and gases. When welding, keep
your head out of the fume. Use enough
ventilation and/or exhaust at the arc to keep

fumes and gases away from the breathing zone. When

welding with electrodes which require special
ventilation such as stainless or hard facing (see
instructions on container or MSDS) or on lead or
cadmium plated steel and other metals or coatings
which produce highly toxic fumes, keep exposure as
low as possible and below Threshold Limit Values (TLV)
using local exhaust or mechanical ventilation. In
confined spaces or in some circumstances, outdoors, a
respirator may be required. Additional precautions are
also required when welding on galvanized steel.

3.f.

Maintain the electrode holder, work clamp, welding cable and
welding machine in good, safe operating condition. Replace
damaged insulation.

3.g. Never dip the electrode in water 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.

5. b. The operation of welding fume control equipment is affected
by various factors including proper use and positioning of
the equipment, maintenance of the equipment and the spe­cific welding procedure and application involved. Worker
exposure level should be checked upon installation and
periodically thereafter to be certain it is within applicable
OSHA PEL and ACGIH TLV limits.

5.c.

Do not weld in locations near chlorinated hydrocarbon
coming from degreasing, cleaning or spraying operations.
The heat and rays of the arc can react with solvent vapors
form phosgene, a highly toxic gas, and other irritating prod­ucts.

5.d. Shielding gases used for arc welding can displace air and

cause injury or death. Always use enough ventilation,
especially in confined areas, to insure breathing air is safe.

5.e. Read and understand the manufacturer’s instructions for this

equipment and the consumables to be used, including the
material safety data sheet (MSDS) and follow your
employer’s safety practices. MSDS forms are available from
your welding distributor or from the manufacturer.

5.f. Also see item 1.b.

vapors

AUG 06

to

iii

SAFETY

iii

WELDING and CUTTING
SPARKS can
cause fire or explosion.

6.a.

Remove fire hazards from the welding area.

If this is not possible, cover them to prevent

Remember that welding sparks and hot
materials from welding can 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 welding, make certain no part of the electrode
circuit is touching the work or ground. Accidental contact
can cause overheating and create a fire hazard.

6.d. Do not heat, cut or weld tanks, drums or containers until the
proper steps have been taken to insure that such procedures
will not cause flammable or toxic vapors from substances
inside. They can cause an explosion even
been “cleaned”. For information, purchase “Recommended
Safe Practices for the
Containers and Piping That Have Held Hazardous
Substances”, AWS F4.1 from the American Welding Society

(see address above).

6.e. Vent hollow castings or containers before heating, cutting or
welding. They may explode.

Sparks and spatter are thrown from the welding arc. Wear oil

6.f.
free protective garments such as leather gloves, heavy shirt,
cuffless trousers, high shoes and a cap over your hair. Wear
ear plugs when welding out of position or in confined places.
Always wear safety glasses with side shields when in a
welding area.

6.g. Connect the work cable to the work as close to the welding
area as practical. Work cables connected to the building
framework or other locations away from the welding area
increase the possibility of the welding current passing
through lifting chains, crane cables or other alternate cir­cuits. This can create fire hazards or overheat lifting chains
or cables until they fail.

6.h. Also see item 1.c.

the welding sparks from starting a fire.

though

they have

Preparation

for Welding and Cutting of

CYLINDER may explode
if damaged.

7.a. Use only compressed gas cylinders
containing the correct shielding gas for the
process used and properly operating
regulators designed for the gas and

pressure used. All hoses, fittings, etc. should be suitable for
the application and maintained in good condition.

7.b. Always keep cylinders in an upright position securely
chained to an undercarriage or fixed support.

7.c. Cylinders should be located:

•Away from areas where they may be struck or subjected to

physical damage.

•A safe distance from arc welding or cutting operations and

any other source of heat, sparks, or flame.

7.d. Never allow the electrode, electrode holder or any other
electrically “hot” parts to touch a cylinder.

7.e. Keep your head and face away from the cylinder valve outlet
when opening the cylinder valve.

7.f. Valve protection caps should always be in place and hand
tight except when the cylinder is in use or connected for
use.

7.g. Read and follow the instructions on compressed gas
cylinders, associated equipment, and CGA publication P-l,
“Precautions for Safe Handling of Compressed Gases in
Cylinders,” available from the Compressed Gas Association
1235 Jefferson Davis Highway, Arlington, VA 22202.

FOR ELECTRICALLY
powered equipment.

8.a. Turn off input power using the disconnect
switch at the fuse box before working on
the equipment.

8.b. Install equipment in accordance with the U.S. National
Electrical Code, all local codes and the manufacturer’s
recommendations.

8.c. Ground the equipment in accordance with the U.S. National
Electrical Code and the manufacturer’s recommendations.

6.I. Read and follow NFPA 51B “ Standard for Fire Prevention
During Welding, Cutting and Other Hot Work”, available
from NFPA, 1 Batterymarch Park,PO box 9101, Quincy, Ma
022690-9101.

6.j. Do not use a welding power source for pipe thawing.

Jan, 07

iv

SAFETY

iv

PRÉCAUTIONS DE SÛRETÉ

Pour votre propre protection lire et observer toutes les instructions
et les précautions de sûreté specifiques qui parraissent dans ce
manuel aussi bien que les précautions de sûreté générales suiv­antes:

Sûreté Pour Soudage A L’Arc

1. Protegez-vous contre la secousse électrique:

a. Les circuits à l’électrode et à la piéce sont sous tension

quand la machine à souder est en marche. Eviter toujours
tout contact entre les parties sous tension et la peau nue
ou les vétements mouillés. Porter des gants secs et sans
trous pour isoler les mains.

b. Faire trés attention de bien s’isoler de la masse quand on

soude dans des endroits humides, ou sur un plancher
metallique ou des grilles metalliques, principalement dans
les positions assis ou couché pour lesquelles une grande
partie du corps peut être en contact avec la masse.

c. Maintenir le porte-électrode, la pince de masse, le câble

de soudage et la machine à souder en bon et sûr état
defonctionnement.

d.Ne jamais plonger le porte-électrode dans l’eau pour le

refroidir.

e. Ne jamais toucher simultanément les parties sous tension

des porte-électrodes connectés à deux machines à souder
parce que la tension entre les deux pinces peut être le
total de la tension à vide des deux machines.

f. Si on utilise la machine à souder comme une source de

courant pour soudage semi-automatique, ces precautions
pour le porte-électrode s’applicuent aussi au pistolet de
soudage.

2. Dans le cas de travail au dessus du niveau du sol, se protéger
contre les chutes dans le cas ou on recoit un choc. Ne jamais
enrouler le câble-électrode autour de n’importe quelle partie
du corps.

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.

6. Eloigner les matériaux inflammables ou les recouvrir afin de
prévenir tout risque d’incendie dû aux étincelles.

7. Quand on ne soude pas, poser la pince à une endroit isolé de
la masse. Un court-circuit accidental peut provoquer un
échauffement et un risque d’incendie.

8. S’assurer que la masse est connectée le plus prés possible
de la zone de travail qu’il est pratique de le faire. Si on place
la masse sur la charpente de la construction ou d’autres
endroits éloignés de la zone de travail, on augmente le risque
de voir passer le courant de soudage par les chaines de lev­age, câbles de grue, ou autres circuits. Cela peut provoquer
des risques d’incendie ou d’echauffement des chaines et des
câbles jusqu’à ce qu’ils se rompent.

9. Assurer une ventilation suffisante dans la zone de soudage.
Ceci est particuliérement important pour le soudage de tôles
galvanisées plombées, ou cadmiées ou tout autre métal qui
produit des fumeés toxiques.

10. Ne pas souder en présence de vapeurs de chlore provenant
d’opérations de dégraissage, nettoyage ou pistolage. La
chaleur ou les rayons de l’arc peuvent réagir avec les vapeurs
du solvant pour produire du phosgéne (gas fortement toxique)
ou autres produits irritants.

11. Pour obtenir de plus amples renseignements sur la sûreté,
voir le code “Code for safety in welding and cutting” CSA
Standard W 117.2-1974.

PRÉCAUTIONS DE SÛRETÉ POUR

3. Un coup d’arc peut être plus sévère qu’un coup de soliel,
donc:

a. Utiliser un bon masque avec un verre filtrant approprié

ainsi qu’un verre blanc afin de se protéger les yeux du ray­onnement de l’arc et des projections quand on soude ou
quand on regarde l’arc.

b. Porter des vêtements convenables afin de protéger la

peau de soudeur et des aides contre le rayonnement de
l‘arc.

c. Protéger l’autre personnel travaillant à proximité au

soudage à l’aide d’écrans appropriés 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, pan­talons sans revers, et chaussures montantes.

LES MACHINES À SOUDER À
TRANSFORMATEUR ET À
REDRESSEUR

1. Relier à la terre le chassis du poste conformement au code de
l’électricité et aux recommendations du fabricant. Le dispositif
de montage ou la piece à souder doit être branché à une
bonne mise à la terre.

2. Autant que possible, I’installation et l’entretien du poste seront
effectués par un électricien qualifié.

3. Avant de faires des travaux à l’interieur de poste, la debranch­er à l’interrupteur à la boite de fusibles.

4. Garder tous les couvercles et dispositifs de sûreté à leur
place.

Mar. ‘93

TThhaannkk YYoouu

vv

for selecting a QUALITY product by Lincoln Electric. We want you
to take pride in operating this Lincoln Electric Company product

••• as much pride as we have in bringing this product to you!

The business of The Lincoln Electric Company is manufacturing and selling high quality welding equipment, consumables, and cutting equip­ment. Our challenge is to meet the needs of our customers and to exceed their expectations. On occasion, purchasers may ask 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. We expressly disclaim any warranty of any kind, including any warranty of fitness for any customer’s particular purpose,
with respect to such information or advice. As a matter of practical consideration, we also cannot assume any responsibility for updating or
correcting any such information or advice once it has been given, nor does the provision of information or advice create, expand or alter any
warranty with respect to the sale of our products.

Lincoln Electric is a responsive manufacturer, but the selection and use of specific products sold by Lincoln Electric is solely within the control
of, and remains the sole responsibility of the customer. Many variables beyond the control of Lincoln Electric affect the results obtained in
applying these types of fabrication methods and service requirements.

Subject to Change – This information is accurate to the best of our knowledge at the time of printing. Please refer to www.lincolnelectric.com
for any updated information.

CUSTOMER ASSISTANCE POLICY

Please Examine Carton and Equipment For Damage Immediately

When this equipment is shipped, title passes to the purchaser upon receipt by the carrier. Consequently, Claims
for material damaged in shipment must be made by the purchaser against the transportation company at the
time the shipment is received.

Please record your equipment identification information below for future reference. This information can be
found on your machine nameplate.

Product _________________________________________________________________________________
Model Number ___________________________________________________________________________
Code Number or Date Code_________________________________________________________________
Serial Number____________________________________________________________________________
Date Purchased___________________________________________________________________________
Where Purchased_________________________________________________________________________
Whenever you request replacement parts or information on this equipment, always supply the information you

have recorded above. The code number is especially 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

“Product Registration”. Please complete the form and submit your registration.

Read this Operators Manual completely before attempting to use this equipment. Save this manual and keep it
handy for quick reference. Pay particular attention to the safety instructions we have provided for your protection.
The level of seriousness to be applied to each is explained below:

WEB SITE at www.lincolnelectric.com. Choose “Quick Links” and then

WARNING

This statement appears where the information must be followed exactly to avoid serious personal injury or loss of life.

CAUTION

This statement appears where the information must be followed to avoid minor personal injury or damage to this equipment.

vi

TABLE OF CONTENTS

Page

Installation Instructions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Section A

Technical Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .A-1

Installation Precautions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A-2

Location / Ventilation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .A-2

Stacking . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .A-2

Angle of Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .A-2

Lifting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .A-2

High Altitude Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .A-3

Towing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .A-3

Vehicle Mounting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .A-3

Pre-Operation Engine Service . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .A-3

Engine Oil . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .A-3

Fuel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .A-3

Engine Break-In, Engine Cooling System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .A-4

Battery Connection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .A-4

Spark Arrestor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .A-5

Welding Output Cables . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .A-5

Machine Grounding . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .A-5

______________________________________________________________________________

Operating Instructions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Section B

Safety Instructions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . B-1

Additional Safety Precautions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . B-1

General Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .B-1

Recommended Applications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .B-1

Welder . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .B-1

Auxiliary Power . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .B-1

Design Features and Advantages . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .B-2

Duty Cycle . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .B-2

Engine Controls: Function/Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . B-3

Air Intake Shut-Off . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . B-3

Welder Controls: Function/Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . B-4

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 Maintenance, Periodic Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . D-1

Engine Oil Change, Engine Air Filter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . D-1

Bearing, Commutator and Brush Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . D-2

Cooling System, Fuel Filter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . D-2

Water Separator, Secondary Fuel Filter and Engine Components . . . . . . . . . . . . . . . . . D-3

GFCI Receptacle Testing and Resetting Procedure . . . . . . . . . . . . . . . . . . . . . . . . . . . . .D-4

______________________________________________________________________________

Troubleshooting Guide . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Section E

______________________________________________________________________________

Wiring Diagram and Dimension Print . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Section F

______________________________________________________________________________

Parts Lists . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .P-601

vi

______________________________________________________________________________

SAE-500™ SEVERE DUTY™

A-1

INSTALLATION

TECHNICAL SPECIFICATIONS - SAE-500™ SEVERE DUTY™ (K1278-12)

INPUT - DIESEL ENGINE

Make/Model Description Speed (RPM) Displacement Starting Capacities

System

A-1

Kubota 4 cylinder High Idle 1800 220.9 cu. in
V3600-T-E3B 57.8 HP @ Low Idle 1100 (3.62 L)
Diesel Engine 1800 RPM Full Load 1725
EPA Tier 4i Bore x Stroke Oil: 13.95 Qts.
Compliant 13.2 L

3.86” x 4.72”

(98.0 mm x 120.0mm) Coolant: 3.4 gal.

12VDC batteries
(2

) & Starter 109.8 L

Fuel: 29 gal.

12.8 L

RATED OUTPUT - WELDER

Duty Cycle

60% (NEMA) 500 amps 40 volts
100% (NEMA) 400 amps 36 volts
100% (Lincoln Plus) 400 amps 40 volts

(1)

Welding Output Volts at Rated Amps

OUTPUT - WELDER AND GENERATOR

Welding Range Open Circuit Voltage Auxiliary Power

80 - 575 Amps 97 Max. OCV 115/230 VAC

@ 1800 RPM 3000 Watts, 60 Hz.

100% Duty Cycle

HEIGHT WIDTH DEPTH WEIGHT

50.13 in. 28.00 in. 83.00 in. 2048 lbs.

1273.3 mm 711.2 mm 2108.2 mm

(1)

Based on a 10 minute period.

PHYSICAL DIMENSIONS

929 kg

SAE-500™ SEVERE DUTY™

A-2

Read this entire installation section before you
start installation.

INSTALLATION

SAFETY PRECAUTIONS

WARNING

Do not attempt to use this equipment until you
have thoroughly read all operating and mainte­nance manuals supplied with your machine. They
include important safety precautions, detailed
engine starting, operating and maintenance
instructions and parts lists.

A-2

CAUTION

DO NOT MOUNT OVER COMBUSTIBLE SURFACES.

Where there is a combustible surface directly
under stationary or fixed electrical equipment,
that surface shall be covered with a steel plate at
least .06”(1.6mm) thick, which shall extend not
less than 5.90”(150mm) beyond the equipment on
all sides.

------------------------------------------------------------------------

STACKING

These machines cannot be stacked.

ELECTRIC SHOCK can kill.

•Do not touch electrically live parts
such as output terminals or internal
wiring.

•Insulate yourself from the work and
ground.

•Always wear dry insulating gloves.

------------------------------------------------------------------------

ENGINE EXHAUST can kill.

•Use in open, well ventilated areas or
vent exhaust outside

•Do not stack anything near the
engine.

------------------------------------------------------------------------

MOVING PARTS can injure.

•Do not operate with doors open or
guards off.

•Stop engine before servicing.

•Keep away from moving parts

------------------------------------------------------------------------

Only qualified personnel should install, use or
service this equipment

LOCATION/VENTILATION

ANGLE OF OPERATION

To achieve optimum engine performance the machine
should be run in a level position. The maximum angle
of operation for the Kubota engine is 20 degrees con­tinuous in all directions and 30 degeers intermittent
(less then 10 minutes). If the engine is to be operated
at an angle, provisions must be made for checking
and maintaining the oil level at the normal (FULL) oil
capacity in the engine crankcase. When operating the
welder at an angle, the effective fuel capacity will be
slightly less than the specified 29 gallons.

LIFTING

The equipment lift bail should be used to lift the
machine.

WARNING

• Lift only with equipment of ade­quate lifting capacity.

• Be sure machine is stable when lift­ing.

• Do not lift this machine using lift
bail if it is equipped with a heavy
accessory such as trailer or gas
cylinder.

FALLING • Do not lift machine if lift bail is

damaged.

EQUIPMENT can • Do not operate machine while

cause injury. suspended from lift bail.

------------------------------------------------------------------------

The welder should be located to provide an unrestricted
flow of clean, cool air to the cooling air inlets and to avoid
restricting the cooling air outlets. Also, locate the welder
so that the engine exhaust fumes are properly vented to
an outside area.

SAE-500™ SEVERE DUTY™

A-3

INSTALLATION

A-3

HIGH ALTITUDE OPERATION

At higher altitudes, output derating may be necessary.
For maximum rating, derate the welder output 5% for
every 500 meters (1640 ft.) above 400 meters (1312
ft.).

Contact a Kubota Service Representative for any
engine adjustments that may be required for high alti­tude operation.

TOWING

The recommended trailers for use with this equipment
for in-plant and yard towing by a vehicle
K2641-1 (4) wheel steerable trailer and K2637-1
wheel trailer. If the user adapts a non-Lincoln trailer,
he must assume responsibility that the method of
attachment and usage does not result in a safety haz­ard nor damage the welding equipment. Some of the
factors to be considered are as follows:

1. Design capacity of trailer vs. weight of Lincoln
equipment and likely additional attachments.

2. Proper support of, and attachment to, the base of
the welding equipment so that there will be no
undue stress to the trailer’s framework.

3. Proper placement of the equipment on the trailer
to insure stability side to side and front to back
when being moved and when standing by itself.

4. Typical conditions of use, such as travel speed,
roughness of surface on which the trailer will be
operated, and environmental conditions.

5. Proper preventative maintenance of trailer.

6. Conformance with federal, state and local laws.

(1)

are

Lincoln’s

(2)

VEHICLE MOUNTING

PRE-OPERATION ENGINE SERVICE

READ the engine operating and maintenance instruc­tions supplied with this machine.

ENGINE OIL

The engine is shipped with the engine crankcase filled
with high quality SAE 10W-30 oil (API class CD or bet­ter). Check the oil level before starting the engine. If it is
not up to the full mark on the dip stick, add oil as
required. Check the oil level every four hours of running
time during the first 35 running hours. Refer to the
engine Operator’s Manual for specific oil recommenda­tions and break-in information. The oil change interval is
dependent on the quality of the oil and the operating
environment. Refer to the engine Operator’s Manual for
the proper service and maintenance intervals.

FUEL USE DIESEL FUEL ONLY

WARNING

• Stop engine while fueling.

• Do not smoke when fueling.

• Ke ep sp arks and fla me a way
from tank.

• Do not leave unattended while

fueling.

DIESEL FUEL

can cause fire.

• Wipe up spilled fuel and allow
fumes to clear before starting
engine.

• Do no t o verfi l l tank , f uel
ex pansion may cause over­flow.

DIESEL FUEL ONLY

------------------------------------------------------------------------

Improperly mounted concentrated loads may cause
unstable vehicle handling and tires or other compo­nents to fail.

• Only transport this equipment on serviceable vehi-

WARNING

cles which are rated and designed for such loads.

• Distribute, balance and secure loads so vehicle is
stable under conditions of use.

• Do not exceed maximum rated loads for compo­nents such as suspension, axles and tires.

• Mount equipment base to metal bed or frame of
vehicle.

• Follow vehicle manufacturer’s instruction.

----------------------------------------------------------------------------

SAE-500™ SEVERE DUTY™

Low Sulphur fuel or ultra low sulphur fuel in USA and
CANADA only.

• Fill the fuel tank with clean, fresh diesel fuel.
The capacity of the fuel tank is approximately

29 Gal. (109.8 liters). See engine Operator’s

Manual for specific fuel recommendations.
Running out of fuel may require bleeding the
fuel injection pump. NOTE: Before starting the
engine, open the fuel shutoff valve (pointer to be
in line with hose).

------------------------------------------------------------------------

NOTE: Before starting the engine, be sure the fuel

shutoff valve is open on the fuel sedimenter .

A-4

INSTALLATION

A-4

ENGINE BREAK-IN

Lincoln Electric selects high quality, heavy-duty indus­trial engines for the portable welding machines we
offer. While it is normal to see a small amount of
crankcase oil consumption during initial operation,
excessive oil use, wetstacking (oil or tar like sub­stance at the exhaust port), or excessive smoke is not
normal.

Larger machines with a capacity of 350 amperes and
higher, which are operated at low or no-load condi­tions for extended periods of time are especially sus­ceptible to the conditions described above. To
accomplish successful engine break-in, most diesel­powered equipment needs only to be run at a reason­ably heavy load within the rating of the welder for
some period of time during the engine’s early life.
However, if the welder is subjected to extensive light
loading, 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 con­necting the welding leads together, direct
shorting of the output studs, or connecting
the output leads to a length of steel will
result in catastrophic damage to the gener­ator and voids the warranty.

2. Set the welder controls for an output cur­rent and voltage within the welder rating
and duty cycle. Note that any attempt to
exceed the welder rating or duty cycle for
any period of time will result in catastrophic
damage to the generator and voids the
warranty.

3. Periodically shut off the engine and check
the crankcase oil level.

ENGINE COOLING SYSTEM

The cooling system has been filled at the factory with
a 50-50 mixture of ethylene glycol antifreeze and
water. Check the radiator level and add a 50-50 solu­tion as needed. (See Engine Manual or antifreeze
container for alternate antifreeze recommendation.)

BATTERY CONNECTION

WARNING: Use caution as the electrolyte is a

strong acid that can burn skin and damage eyes.
Remove and discard the insulating caps from the neg-

ative battery terminals. Attach and tighten negative
battery cable terminals.

NOTE:

batteries; if unused for several months, the batteries
may require a booster charge. Be careful to charge
the batteries with the correct polarity. Make sure that
the batteries are level while charging.

This machine is furnished with wet charged

WARNING

GASES FROM BATTERY can explode.

● Keep sparks, flame and cigarettes

away from battery.

To prevent EXPLOSION when:

● INSTALLING A NEW BATTERY — disconnect

negative cable from old battery first and con­nect to new battery last.

● CONNECTING A BATTERY CHARGER —

remove battery from welder by disconnecting
negative cable first, then positive cable and
battery clamp. When reinstalling, connect
negative cable last. Keep well ventilated.

● USING A BOOSTER — connect positive lead to

battery first then connect negative lead to neg­ative battery lead at the lower control panel
support.

BATTERY ACID can burn eyes and
skin.

● Wear gloves and eye protection

and be careful when working near
battery.

● Follow instructions printed on battery.

IMPORTANT: To prevent ELECTRICAL DAMAGE
WHEN:

a) Installing new batteries.
b) Using a booster.

Use correct polarity — Negative Ground.
To prevent BATTERY BUCKLING, tighten nuts on
batteries only until snug. DO NOT OVERTIGHTEN.

SAE-500™ SEVERE DUTY™

A-5

WARNING

Allow engine to cool before
Do not operate engine while

servicing spark arrestor!

servicing spark arrestor!

• Spark Arrestor and Muffler may be hot!

INSTALLATION

A-5

SPARK ARRESTOR

WARNING

Some federal, state or local laws may require that
diesel engines be equipped with exhaust spark
arrestors when they are operated in certain locations
where unarrested sparks may present a fire hazard.

The muffler included with this welder has been modi­fied and now qualifies as a spark arrestor. Spark
arresting mufflers will have a clean out service plug
and will have “US FOREST SERVICE APPROVED”
stamped on the muffler shell. Any spark arrestor must
be serviced and properly maintained.

CAUTION

An incorrect spark arrester may lead to damage to
the engine or adversely affect performance.

------------------------------------------------------------------------

WELDING OUTPUT CABLES

With the engine off, connect the electrode and work
cables to the studs provided. These connections
should be checked periodically and tightened if neces­sary.

MACHINE GROUNDING

Because this portable engine driven welder creates its
own power, it is not necessary to connect its frame to
an earth ground, unless the machine is connected to
premises wiring (home, shop, etc.).

To prevent dangerous electric shock, other equipment
powered by this engine driven welder must:

a) be grounded to the frame of the welder using a

grounded type plug,

or

b) be double insulated.

When this welder is mounted on a truck or trailer, its
frame must be securely connected to the metal frame
of the vehicle. When this engine driven welder is con­nected to premises wiring such as that in a home or
shop, its frame must be connected to the system earth
ground. See the article on grounding in the latest U.S.
National Electrical Code and the local code.

In general, if the machine is to be grounded, it should
be connected with a #8 or larger copper wire to a solid
earth ground such as a metal water pipe going into
the ground for at least ten feet and having no insulat­ed joints, or to the metal framework of a building
which has been effectively grounded. The U.S.
National Electrical Code lists a number of alternate
means of grounding electrical equipment. A machine
grounding stud marked with the symbol is provid­ed on the welding generator frame foot.

Listed in Table A.1 are copper cable sizes recom­mended 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 minimizing cable voltage drop.

Table A.1 Combined Length of Electrode and

AMPS

@60%

Duty Cycle

400

Work Cables.

TOTAL COMBINED LENGTH OF ELEC-

TRODE AND WORK CABLES

Up to 100 FT.

(Up to 30m)

2/0 AWG

100-200 FT.

(30m-61m)

3/0 AWG

200-250 FT.

(61m-76m)

4/0 AWG

SAE-500™ SEVERE DUTY™

B-1

OPERATION

B-1

OPERATING INSTRUCTIONS

Read and understand this entire section before operating
your equipment.

SAFETY INSTRUCTIONS

WARNING

Do not attempt to use this equipment until you have thor­oughly read all operating and maintenance manuals 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 electrically live parts or

electrodes with your skin or wet cloth­ing.

• 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.

---------------------------------------------------------------------------

ARC RAYS can injure eyes and
burn skin.

• Wear eye, ear, and body protection.

--------------------------------------------------------------

• Only qualified personnel should install, use or ser­vice this equipment.

• Consult instruction manual before operating.

----------------------------------------------------------------------------

Before operating, read and understand the manufac­turer’s instructions for this equipment and the con­sumables to be used including the Material Safety
Data Sheet (MSDS) and follow your employer’s safety
practices.

---------------------------------------------------------------------------

FUMES AND GASES can be dan­gerous 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.

-------------------------------------------------------------

WELDING SPARKS can cause fire
or explosion.

• Do not weld near flammable material .

• Do not weld on containers that have

held flammable material.

--------------------------------------------------------------

MOVING PARTS can injure.

• Keep away from moving parts

• Do not operate with doors open or
guards off.

• Stop engine before servicing.

---------------------------------------------------------------------------

ENGINE EXHAUST can kill.

• Use in open, well ventilated areas or

vent exhaust outside.

------------------------------------------------------------------------

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 com­pressor instruction manuals.

GENERAL DESCRIPTION

The SAE-500™ SEVERE DUTY™ 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
constant current output.

The engine is a 57.8 Hp (43.1kw), 4-cylinder water
cooled diesel made by Kubota.

RECOMMENDED APPLICATIONS

WELDER

The SAE-500™ SEVERE DUTY™ provides excellent
constant current DC welding output for stick (SMAW)
welding.

AUXILIARY POWER

The SAE-500™ SEVERE DUTY™ provides 3 KW of
115/230 VAC output for auxiliary power and emer­gency standby power.

SAE-500™ SEVERE DUTY™

B-2

OPERATION

B-2

DESIGN FEATURES AND ADVANTAGES

FOR STICK WELDING

• Excellent DC constant current output for stick weld­ing applications.

• Continuous adjustment of both voltage and current

for unsurpassed welds on demanding jobs.

• Remote control capability standard.

FOR AUXILIARY POWER

• 3,000 watts of 115/230 VAC, 60 Hz auxiliary power.

• One 20 amp 115 VAC duplex receptacle for up to 26

amps of 115 VAC power.

• One 15 amp, 230 VAC duplex receptacle for up to

13 amps of 230 VAC power.

• Weld and AC auxiliary power at the same time (with-

in the limits shown on the chart below).

Welding Using Only Using Only Total

Current, Amps 115V Circuit, 230V Circuit, Aux.

@ NEMA Arc Amps Amps kVA

Volts

DUTY CYCLE

Duty cycle is the percentage of time the load is being
applied in a 10 minute period. For example a 60%
duty cycle, represents 6 minutes of load and 4 min­utes of no load in a 10 minute period.

0 26 13 3.0
100 19.5 9.75 2.25
200 13 6.5 1.5
300 6.5 3.25 0.75
400 000
500 000

OTHER FEATURES

• Kubota 4-cylinder, water cooled diesel engine.
Designed for long life, easy maintenance and excel­lent 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 14 seconds after welding or use
of auxiliary power stops. Includes high idle switch.

• Gauges for engine oil pressure, coolant temperature
and battery charging ammeter.

• Engine hour meter standard.

• Extended range 29 gallon (109.8 L) fuel tank.

SAE-500™ SEVERE DUTY™

B-3

WARNING

• Muffler and Engine may be hot!

OPERATION

B-3

ENGINE CONTROLS

IGNITION SWITCH

When placed in the “ON” position, this switch ener­gizes the fuel solenoid. When placed in the “OFF”
position, the flow of fuel to the injection pump is
stopped to shut down the engine.

“IDLER” SWITCH

The idler switch has two positions, “HIGH” and
“AUTO”.

When in “HIGH” ( ) position, the engine will run
continuously at high idle.

When in “AUTO” ( / ) idle position, the idler
operates as follows:

a. Welding

When the electrode touches the work, the welding
arc is initiated and the engine accelerates to full
speed.

After welding ceases (and no auxiliary power is
being drawn), the engine will return to low idle after
approximately 10 to 14 seconds.

ENGINE PROTECTION SYSTEM

The engine protection system shuts down the engine
under high coolant temperature or low engine oil pres­sure conditions by allowing the fuel solenoid valve to
close.

AIR INTAKE SHUT-OFF

The air intake shut-off is a automatic/manually device
which blocks all intake air from entering the engine.

The automatic feature of the shut-off will engage
should excessive over speeding occur. The valve is
calibrated at the factory to shutdown within the safety
limits of the engine.

To manually shut down the engine, simply pull the
emergency stop handle on the lower control panel.

The air intake shut-off device will reset automatically,
generally within one minute.

b. Auxiliary Power

With the engine running at low idle and auxiliary
power for lights or tools is drawn (approximately
100-150 watts or greater) from the receptacles, the
engine will accelerate to high speed. If no power is
being drawn from the receptacles ( and not weld­ing) for 10-14 seconds, the idler reduces the
engine speed to low idle.

ENGINE TEMPERATURE GAUGE

Displays the coolant temperature in the engine block.

ENGINE OIL PRESSURE GAUGE

Displays the oil pressure to the engine. When the
engine starts running, watch for the oil pressure to
build up. If no pressure shows within 30 seconds, stop
the engine and consult the engine instruction manual.

BATTERY CHARGING AMMETER

Displays the current going from the charging alterna­tor into the batteries. It is normal for charging current
to be high (above 15 amps) after starting or when the
batteries are ‘low’ on charge.

IMPORTANT: Before restarting engine, verify that the
air intake shut-off is in the open position. DO NOT
ATTEMPT TO START ENGINE WITH THE AIR
INTAKE SHUT-OFF IN THE CLOSED POSITION.
This may cause severe damage to the engine.

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.

SAE-500™ SEVERE DUTY™

B-4

OPERATION

B-4

WELDER CONTROLS

POLARITY SWITCH

Turn the Arc Polarity switch to electrode positive or
electrode negative as required for each particular
application.

CONTROL OF WELDING CURRENT
Purpose of Controls

The continuous “Current Control” is the main current
adjuster. The “Job Selector” is both a fine current
adjuster and the continuous Open Circuit Voltage
adjuster. Open Circuit Voltage (OCV) controls the arc
characteristics.

“Job Selector”

The “Job Selector” dial is divided into four colored
sections providing OCV ranges as follows:

Color Title OCV Range

White Large Electrodes High OCV
Black Normal Welding Medium OCV
Red Overhead & Vertical Low OCV
Grey Special Applications Extra-Low OCV

The “Job Selector” is usually set in the black range
because it provides a soft “Buttering “ arc desired for
most welding. Some operators prefer to set the “Job
Selector” in the red range for a snappy “Digging” arc
when welding vertical up or overhead.

“Current Control”

CAUTION

Do not adjust the “Current Control” while welding
because this can damage the control.

------------------------------------------------------------------------

The “Current Control” dial is calibrated in amperes on
three separate colored dials corresponding to the
white, black and red ranges of the “Job Selector” dial.
For example: when the “Job Selector” is set on the
black range, the approximate welding current is indi­cated on the black scale of the “Current Control” dial.

4. If you want a little more current, turn the “Job
Selector” up (counterclockwise) to increase current.
If you want a little less current, turn the “Job
Selector” down (clockwise) to decrease current.

5. If dialing the desired current with the “Job Selector”
moves the setting outside the black range causing
undesirable arc characteristics, turn the “Job
Selector” back to the center of the black range. Then
turn the “Current Control” up or down a little as
needed. Readjust the “Job Selector” for the exact
characteristics and current desired.

REMOTE CONTROL

A receptacle and “Local/Remote” control switch on the
lower front control panel and a remote control box with
100 ft. (30.5 m) of cord for adjusting the OCV at the
welding site are standard. Putting the switch in the
“REMOTE” position allows fine current control at the
remote control box while placing the switch in the
“LOCAL” position allows fine current control at the “Job
Selector” on the machine.

AUXILIARY POWER CONTROLS

Note: GFCI receptacles are an option and if installed,

see the “MAINTENANCE SECTION” for detailed
information on testing and resetting the GFCI
receptacle.

115 VAC Receptacle

One 20 amp, 115 VAC duplex receptacle provides 115
VAC for auxiliary power. A total of 26 amps can be drawn
from this receptacle.

230 VAC Receptacle

One 15 amp, 230 VAC duplex receptacle provides 230
VAC for auxiliary power. A total of 13 amps can be drawn
from this receptacle.

How to Set the Controls

Assume you want a normal soft arc and about 135
amps, using a 5/32” (4.0 mm) electrode:

1. Set the “Job Selector” at the center of the black
range.

2. Set the “Current Control” to read 135 amps on the
black dial.

3. Start to weld.

SAE-500™ SEVERE DUTY™

Circuit Breakers

The circuit breakers provide separate overload current
protection for each half of the 115 V duplex receptacle.
The circuit breakers provide overload current protection
in both current carrying wires of the 230 V duplex recep­tacle.

Ground Stud

Provides a connection point for connecting the machine
to earth ground. For the safest grounding procedure refer
to “Machine Grounding” in the INSTALLATION section of
this manual.

B-5

OPERATION

B-5

ENGINE OPERATION

WARNING

Do not attempt to use this equipment until you
have thoroughly read the engine manufacturer’s
manual supplied with your welder. It includes
important safety precautions, detailed engine
starting, operating and maintenance instructions,
and parts lists.

-----------------------------------------------------------------------­ELECTRIC SHOCK can kill.

• Do not touch electrically live parts or

electrode with skin or wet clothing.

• Insulate yourself from work and

ground

• Always wear dry insulating gloves.

-----------------------------------------------------------------------­ENGINE EXHAUST can kill.

• Use in open, well ventilated areas or

vent exhaust outside.

-----------------------------------------------------------------------­MOVING PARTS can injure.

• Do not operate with doors open or

guards off.

• Stop engine before servicing.

• Keep away from moving parts.

------------------------------------------------------------------------

See additional warning information at the

front of this operator’s manual.

5. Observe the oil pressure. If no pressure shows
within 20 seconds, stop the engine 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 sev­eral minutes to warm the engine. Stop the engine
and recheck the oil level, after allowing sufficient
time for the oil to drain into the pan. If the level is
down, fill it to the full mark again. The engine con­trols were properly set at the factory and should
require no adjusting when received.

COLD WEATHER STARTING:

WARNING

Under NO
ing fluids be used!

------------------------------------------------------------------------

With a fully charged battery and the proper weight oil,
the engine should start satisfactorily even down to
about -5°F (-20°C), it maybe desirable to install cold­starting aides.

conditions should ether or other start-

For added safety always operate the welder with the
doors closed. Further, leaving the doors open
changes the designed air flow and may cause engine,
generator overheating.

CAUTION

Do not adjust the high idle engine speed (rpm)
above the factory setting specification as this will
void warranty.

------------------------------------------------------------------------

STARTING INSTRUCTIONS

Be sure all Pre-Operation Maintenance has been
performed. (See INSTALLATION section of this
manual).

1. Turn the “IDLER” switch to “HIGH”.

2. Turn the “IGNITION” switch to “ON”.

3. Press the Glow Plug button for 15-20 seconds.

4. Press the Glow Plug and the Start button at the
same time. When the engine starts running,
release both buttons. If the engine fails to start in
60 seconds, wait 30 seconds and repeat the
above procedure. Do not allow the starter motor
to run continuously for more then 20 seconds.

Note: Extreme cold weather staring may require
longer glow plug operation.

STOPPING THE ENGINE

1. Important:
Run the engine under low idle for 5 minutes
before shutting it off after a full load operation.
Note: Failure to do so may lead to turbo charger

trouble.

2. Turn the “IGNITION” switch to “OFF”

At the end of each day’s welding, check the crankcase
oil level, drain accumulated dirt and water from the
water separator and refill the fuel tank to minimize
moisture condensation in the tank. Also, running out
of fuel tends to draw dirt into the fuel system.

When hauling the welder between job sites, close the
fuel shut-off valve.

If the fuel supply is cut off or runs out while the fuel
pump is operating, air may be entrapped in the fuel
distribution system. If this happens, bleeding of the
fuel system may be necessary. Use qualified person­nel to do this per the instructions in the MAINTE­NANCE section of this manual.

SAE-500™ SEVERE DUTY™

B-6

OPERATION

TYPICAL FUEL CONSUMPTION

The typical fuel consumption of the SAE-500 for vari­ous operating scenarios is shown below:

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.)

B-6

SAE-500™ SEVERE DUTY™

C-1

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. Mounts directly to welder base.(Not for
use on the highway.)
2” Ball and Lunette Eye combination Hitch.

K2637-1 Trailer - A 2-wheel trailer designed for

(1)

road

, off road, in-plant and yard towing. Trailer
mounts directly to welder base.
Duo-Hitch™, a 2” Ball and Lunette Eye combination Hitch.

Order:

K2637-1 Trailer
K2639-1 Fender & Light Kit.
K2640-1 Cable Storage Rack

1

For highway use, consult applicable federal, state and local laws regarding

possible requirements for brakes, lights, fenders, etc.

Comes standard with a Duo-Hitch™, a

Comes standard with a

C-1

K704 Standard Accessory Kit - Includes electrode

and work cables, headshield, work clamp and elec­trode holder.

K1690-1 GFCI RECEPTACLE KIT

Includes one UL approved 120V ground fault circuit
interrupter duplex type receptacle with cover and
installation instructions. Replaces the factory installed

120V duplex receptacle. Each receptacle of the GFCI
Duplex is rated at 20 Amps, the maximum total cur-

rent from the GFCI Duplex is limited to the 20 Amps.
Two kits are required. See the MAINTENANCE sec-

tion for detailed information on testing and resetting
the GFCI receptacle.

SAE-500™ SEVERE DUTY™

D-1

MAINTENANCE

D-1

WARNING

ELECTRIC SHOCK can kill.

●●

Do not touch electrically live parts
such as output terminals or inter­nal wiring

ENGINE EXHAUST can kill.

●●

Use in open, well ventilated areas
or vent exhaust outside

MOVING PARTS can injure.

●●

Do not operate with doors open or
guards off

●●

Stop engine before servicing

●●

Keep away from moving parts

●●

Remove guards only when necessary and replace
when work requiring removal is complete.

●●

Only qualified personnel should install, use, or ser­vice this equipment.

ROUTINE MAINTENANCE

At the end of each day’s welding, refill the fuel tank to mini­mize moisture condensation in the tank. Also, running out of
fuel tends to draw dirt into the fuel system. Check the
engine crankcase oil level.

4. Belts tend to loosen after the first 30 or 40 hours of oper­ation. Check the cooling fan belt and tighten if neces­sary. DO NOT OVER TIGHTEN.

ENGINE OIL CHANGE

The SAE-500™ SEVERE DUTY™ is equipped with a con­venient oil drain system. Drain the oil when the engine is
warm to assure rapid and complete draining.

• Remove the oil filler cap and dipstick.

• To open drain valve, push handle away from valve and

turn 90°.

• Drain oil into a suitable container.

• To close drain valve, turn handle 90° till handle snaps in

the closed position.

• Refill engine with the recommended oil to the appropriate

level. Replace dipstick and tighten the oil filler cap secure­ly.

Change the crankcase oil at regular intervals using the prop­er grade of oil as recommended in the Engine Operating
Manual. Wash your hands with soap and water after han­dling used oil. Please dispose of used motor oil in a manner
that is compatible with the environment. We suggest you
take it in a sealed container to your local service station or
recycling center for reclamation. Do not throw it in the trash,
pour it on the ground or down a drain.

If the fuel supply runs out while the fuel pump is operating,
air may be entrapped in the fuel distribution system. If this
happens, bleeding of the fuel system may be necessary.
See the engine instruction manual.

PERIODIC MAINTENANCE

1. Blow out the welder and controls with an air hose at least
once every two months. In particularly dirty locations,
this cleaning may be necessary once a week. Use low
pressure 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 Manual for periodic engine
maintenance information. Change the oil filter in accor­dance with the instructions in the engine operating man­ual. When the oil filter is changed add one quart of oil to
the crankcase to replace the oil held in the filter during
operation.

SAE-500™ SEVERE DUTY™

ENGINE AIR FILTER

The engine air filter element is a dry cartridge type. It
is located above the engine. It can be cleaned and re­used; however, damaged elements should not be
washed or re-used. Remove loose dirt from element
with compressed air or water hose directed from
inside out. Compressed Air: 100 psi maximum. The fil­ter should never be removed while the engine is run­ning.

D-2

MAINTENANCE

BEARING MAINTENANCE

This welder is equipped with a double-shielded ball bearing
having sufficient grease to last indefinitely under normal ser­vice. Where the welder is used constantly or in excessively
dirty locations, it may be necessary to add one-half ounce of
grease per year. A pad of grease one inch wide, one inch
long and one inch high weighs approximately one-half
ounce. Over greasing is far worse than insufficient greasing.

D-2

To seat the slip ring brushes, position the brushes in
place. Then slide one end of a piece of fine sandpa­per between slip rings and brushes with the coarse
side against 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%.

When greasing the bearings, keep all dirt out of the area.
Wipe the fittings completely clean and use clean equipment.
More bearing failures are caused by dirt introduced during
greasing than from insufficient grease.

COMMUTATOR AND BRUSH MAINTENANCE

WARNING

Uncovered rotating equipment can be dangerous.
Use care so your hands, hair, clothing or tools do
not catch in the rotating parts. Protect yourself
from particles that may be thrown out by the rotat­ing armature when stoning the commutator.

------------------------------------------------------------------------

The generator brushes are properly adjusted when
the welder is shipped. They require no particular
attention. DO NOT SHIFT THE BRUSHES or adjust
the rocker setting.

Shifting of the brushes may result in:

- Change in machine output

- Commutator Damage

- Excessive brush wear

Periodically inspect the commutator, slip rings and
brushes by removing the covers. DO NOT remove or
replace these covers while the machine is running.
Commutators and slip rings require little attention.
However, if they are black or appear uneven, have
them cleaned by an experienced maintenance man
using fine sandpaper or a commutator stone. Never
use emery cloth or paper for this purpose.

NOTE: If the welder is used in dirty or dusty locations,
or if the welder is not used for prolonged periods of
time, it may be necessary to clean the commutator
and slip rings more often.

Arcing or excessive exciter brush wear indicates a
possible misaligned shaft. Have an authorized Field
Service Shop check and realign the shaft.

COOLING SYSTEM

The SAE-500™ SEVERE DUTY™ is equipped with a
pressure radiator. Keep the radiator cap tight to pre­vent loss of coolant. Clean and flush the cooling sys­tem periodically to prevent clogging the passage and
overheating the engine. When antifreeze is needed,
always use the permanent type.

WARNING

FUEL FILTERS

When working on the fuel system

• Keep ungrounded lights away, do not
smoke !

• Do not spill fuel !

------------------------------------------------------------------------

The SAE-500™ SEVERE DUTY™ is equipped with a
Fuel Pre-Filter/Water Separator Assembly is
mounted to the engine block just below the oil filter.

The Secondary Fuel Filter is mounted directly to the
engine just above the oil filter.

FUEL PRE-FILTER/WATER SEPARATOR ASSEMBLY

The pre-filter is a 30 micron screen designed to pro­tect against gross fuel contamination of the water sep­arator element and the Secondary Fuel Filter.

Replace brushes when they wear within 1/4" of the
pigtail. A complete set of replacement brushes should
be kept on hand. Lincoln brushes have a curved face
to fit the commutator. Have an experienced mainte­nance man seat these brushes by lightly stoning the
commutator as the armature rotates at full speed until
contact is made across the full face of the brushes.
After stoning, blow out the dust with low pressure air.

SAE-500™ SEVERE DUTY™

D-3

MAINTENANCE

D-3

The water separator element is a two stage filter with
a special filtration/water separating media, and an
expanded water reservoir providing maximum protec­tion against water in the fuel. The recommended
change interval for the water separator element is
1,000 hours. The procedure for changing the element
is as follows:

Note : Consult your engine operation manual for infor­mation on air bleeding the entire fuel system.

ENGINE MAINTENANCE COMPONENTS

ITEM MAKE PART NUMBER

Engine Air Filter Donaldson P822768
Fan Belt Kubota 1G517-97011

Fuel Filter Element Racor R60P
Engine Oil Filter Kubota 1C020-32435

GFCI RECEPTACLE TESTING AND RESET­TING PROCEDURE

The GFCI receptacle should be properly tested at
least once every month or whenever it is tripped. To
properly test and reset the GFCI receptacle:

• If the receptacle has tripped, first carefully remove
any load and check it for damage.

• If the equipment has been shut down, it must be
restarted.

• The equipment needs to be operating at high idle
speed and any necessary adjustments made on the
control panel so that the equipment is providing at
least 80 volts to the receptacle input terminals.

• The circuit breaker for this receptacle must not be
tripped. Reset if necessary.

• Push the "Reset" button located on the GFCI recep­tacle. 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
and turn the product "ON".

• Push the "Test" button located on the GFCI recepta­cle. The night-light or other 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 prop­erly or has been incorrectly installed (miswired). If
your GFCI is not working properly, contact a qualified,
certified electrician who can assess the situation,
rewire the GFCI if necessary or replace the device.

SAE-500™ SEVERE DUTY™

E-1

TROUBLESHOOTING

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.

__________________________________________________________________________

This Troubleshooting Guide is provided to help you
locate and repair possible machine malfunctions.
Simply follow the three-step procedure listed below.

Step 1. LOCATE PROBLEM (SYMPTOM).

Look under the column labeled “PROBLEM (SYMP­TOMS)”. This column describes possible symptoms
that the machine may exhibit. Find the listing that
best describes the symptom that the machine is
exhibiting.

Step 3. RECOMMENDED COURSE OF ACTION

This column provides a course of action for the
Possible Cause, generally it states to contact your
local Lincoln Authorized Field Service Facility.

If you do not understand or are unable to perform the
Recommended Course of Action safely, contact your
local Lincoln Authorized Field Service Facility.

E-1

Step 2. POSSIBLE CAUSE.

The second column labeled “POSSIBLE CAUSE” lists
the obvious external possibilities that may contribute
to the machine symptom.

ELECTRIC SHOCK can kill.

• Do not touch electrically live parts such as output
terminals or internal wiring.

ENGINE EXHAUST can kill.

• Use in open, well ventilated areas or vent exhaust
outside.

MOVING PARTS can injure.

• Do not operate with doors open or guards off.

• Stop engine before servicing.

• Keep away from moving parts.

• Remove guards only when necessary and replace when work
requiring removal is complete.

• Only qualified personnel should install, use or service this
equipment.

WARNING

CAUTION

If for any reason you do not understand the test procedures or are unable to perform the tests/repairs safely, contact your

Local Lincoln Authorized Field Service Facility for technical troubleshooting assistance before you proceed.

SAE-500™ SEVERE DUTY™

E-2

TROUBLESHOOTING

Observe all Safety Guidelines detailed throughout this manual

E-2

PROBLEMS

(SYMPTOMS)

Engine will “crank” but not start.

Machine fails to hold the “heat”
constantly.

POSSIBLE

CAUSE

1. Air intake shut-off is closed.
Manually reset inside machine.

2. Out of fuel. Fill fuel tank.

3. Fuel shut off valve is in off posi­tion.

4. Low battery voltage.

1. Rough or dirty commutator.

2. Brushes may be worn down to
limit of life.

3. Brush springs may be broken.

4. Field circuit may have variable
resistance connections or intermit­tent open circuit, due to loose con­nections or broken wire.

5. Electrode or work lead connec­tions may be poor.

6. Wrong grade of brushes may be
installed on generator.

RECOMMENDED

COURSE OF ACTION

If all recommended possible areas
of misadjustment have been
checked and the problem persists,

Contact your local Lincoln
Authorized Field Service Facility.

7. Field rheostat may be making
poor contact and overheating.

8. “Current Control” may not be
operating properly.

9. “Current Control” brushholder con­tact springs may be worn 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.

CAUTION

If for any reason you do not understand the test procedures or are unable to perform the tests/repairs safely, contact your

Local Lincoln Authorized Field Service Facility for technical troubleshooting assistance before you proceed.

SAE-500™ SEVERE DUTY™

E-3

TROUBLESHOOTING

Observe all Safety Guidelines detailed throughout this manual

E-3

PROBLEMS

(SYMPTOMS)

Welder runs but fails to generate cur­rent.

Welding arc is loud and spatters
excessively.

POSSIBLE

CAUSE

1. Generator or exciter brushes may
be loose or missing.

2. Exciter 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.

RECOMMENDED

COURSE OF ACTION

If all recommended possible areas
of misadjustment have been
checked and the problem persists,

Contact your local Lincoln
Authorized Field Service Facility.

2. Current setting may be too high.

3. Polarity may be wrong.

CAUTION

If for any reason you do not understand the test procedures or are unable to perform the tests/repairs safely, contact your

Local Lincoln Authorized Field Service Facility for technical troubleshooting assistance before you proceed.

SAE-500™ SEVERE DUTY™

E-4

TROUBLESHOOTING

Observe all Safety Guidelines detailed throughout this manual

E-4

PROBLEMS

(SYMPTOMS)

Welding current too great or too
small compared to indication on the
dial.

Welder has output and no control

POSSIBLE

CAUSE

1. “Current 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 indication.

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.

RECOMMENDED

COURSE OF ACTION

If all recommended possible areas
of misadjustment have been
checked and the problem persists,

Contact your local Lincoln
Authorized Field Service Facility.

1. GFCI Receptacle may have

No auxiliary power

tripped. Follow “GFCI Receptacle
Testing and Resetting Procedure”
in the MAINTENANCE section of
this manual. (GFCI Receptacle is
Optional)

2. Circuit Breakers open.

3. Faulty connections to auxiliary
receptacles.

4. Faulty receptacles.

CAUTION

If for any reason you do not understand the test procedures or are unable to perform the tests/repairs safely, contact your

Local Lincoln Authorized Field Service Facility for technical troubleshooting assistance before you proceed.

SAE-500™ SEVERE DUTY™

F-1

AC

(-)

D2

238

AC

202

1

(+)

AC

203

AC

D1

A

1

2

2CR

E

*844

GND-E

602B

(-)

NEG

POS

TOROID

201

W

3

500

Ω

602A

-

22

600A

Y

4

3

1

X

4

2

P8

215

+

W

2

7A

11A

11

4A

400F

6A

(+)

REACTOR

N

U

F

5

4

ELECTRODE

B

600

R

R

41A

214

G

602

5

6

42

4

3

41

2

1

42A

21

201A

START

+

52

+

AMMETER

IDLER

SOLENOID

-

-

51

D+

ALTERNATOR

B+

50

50B

53

S

B

5C

50A

WK

S

S

G

G

I

I

G

ENGINE

FAILURE

LAMP

TEMPERATURE

SENDER

OIL PRESSURE

SWITCH/SENDER

OIL PRESSURE

GAUGE

WATER

TEMPERATURE

GAUGE

GLOW

PLUG

ENGINE

HOUR

METER

IGNITION

SWITCH

R

W

B

*57

*55

*238A

51A

212A

212B

GND-M

200

*54

43

GND-N

*61

*59

10A

CB5

56

*58

NEUTRAL BONDED TO FRAME.

NEUTRE RACCORDE AU BATI.

CONTROL PANEL COMPONENTS SHOWN AS VIEWED FROM REAR.

GLOW PLUGS

58P

*GND-A

212E

*212C

*212D

*844A

GND-B

GND-C

GND-E

TO IDLER

P.C. BD.

FLASHING DIODE

AND RESISTOR

SLIP RINGS

ALTERNATOR

ROTOR

REMOTE CONTROL

RECEPTACLE

AND SWITCH

WHITE

TERMINALS

ALTERNATOR

AUXILIARY

POWER WDG.

WELD CU

R

R

E

NT

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-WHIT E

LEAD COLOR CODE

238

TO WORK

TERMINAL

5C

GND-B

IDLER

SWITCH

115V DUPLEX

RECEPTACLE

230V DUPLEX

RECEPTACLE

5B

41A

-

+

-

+

602A

FUEL

PUMP

RHEOSTAT

*

LEADS CONNECTED TO ENGINE IDLER/ENGINE P.C. BOARD,

SEE DETAIL

1 2

3

4

J33

6

5

1 2 3 4

1

234

5

6

7

8

9

10

J31

J32

B2

B3

B4

212D

212C

59

61

445457

58

238A

55

TO CURRENT

TRANSFORMER

IDLER/ENGINE PROTECTION P.C. BOARD

B1GND-A

844

844A

CB3

20A

CB2

20A

8107A

CB1

15A

11A

(+)

AC

D3

(-)

202A

AC

41B

44*44*44*44*44

*

TEMP. SWITCH

44*44

*

GND

-

N

5B

SAE 500 / SAE 500 SD WIRING DIAGRAM

M21929

A

Enhanced Diagram

WIRING DIAGRAMS

F-1

SAE-500™ SEVERE DUTY™

pasted inside the machine on one of the enclosure panels.

NOTE: This diagram is for reference only. It may not be accurate for all machines covered by this manual. The specific diagram for a particular code is

F-2

M8869-36

A

N.A.

 .81 HOLES

N.B.

 .69 HOLES

28.00

22.00

22.14

24.50

27.12

6.00

39.69

47.95

23.00

26.00

38.50

63.06

50.13

21.00

44.00

8.9044.50

69.75 8.12

77.00 3.00

81.25 .88

83.00

CENTER OF GRAVITY WITH OIL AND

WATER IN ENGINE, BUT NO FUEL

N.A.

N.A.

N.B.

N.B.

DIMENSION PRINT

F-2

SAE-500™ SEVERE DUTY™

WARNING

Spanish

AVISO DE

PRECAUCION

● Do not touch 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 moja­da.

● Aislese del trabajo y de la tierra.

● Keep flammable materials away.

● Mantenga el material combustible

fuera del área de trabajo.

● Wear eye, ear and body protection.

● Protéjase los ojos, los oídos y el

cuerpo.

French

ATTENTION

German

WARNUNG

Portuguese

ATENÇÃO

Japanese

Chinese

Korean

Arabic

● 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 Elektroden mit Ihrem
Körper oder feuchter Kleidung!

● Isolieren Sie sich von den

Elektroden und dem Erdboden!

● Não toque partes elétricas e elec-

trodos com a pele ou roupa molha­da.

● Isole-se da peça e terra.

● Gardez à l’écart de tout matériel

inflammable.

● Entfernen Sie brennbarres Material!

● Mantenha inflamáveis bem guarda-

dos.

● Protégez vos yeux, vos oreilles et

votre corps.

● Tragen Sie Augen-, Ohren- und Kör-

perschutz!

● Use proteção para a vista, ouvido e

corpo.

READ AND UNDERSTAND THE MANUFACTURER’S INSTRUCTION FOR THIS EQUIPMENT AND THE CONSUMABLES TO BE
USED AND FOLLOW YOUR EMPLOYER’S SAFETY PRACTICES.

SE RECOMIENDA LEER Y ENTENDER LAS INSTRUCCIONES DEL FABRICANTE PARA EL USO DE ESTE EQUIPO Y LOS
CONSUMIBLES QUE VA A UTILIZAR, SIGA LAS MEDIDAS DE SEGURIDAD DE SU SUPERVISOR.

LISEZ ET COMPRENEZ LES INSTRUCTIONS DU FABRICANT EN CE QUI REGARDE CET EQUIPMENT ET LES PRODUITS A
ETRE EMPLOYES ET SUIVEZ LES PROCEDURES DE SECURITE DE VOTRE EMPLOYEUR.

LESEN SIE UND BEFOLGEN SIE DIE BETRIEBSANLEITUNG DER ANLAGE UND DEN ELEKTRODENEINSATZ DES HER­STELLERS. DIE UNFALLVERHÜTUNGSVORSCHRIFTEN DES ARBEITGEBERS SIND EBENFALLS ZU BEACHTEN.

● Keep your head out of fumes.

● Use ventilation or exhaust to

remove fumes from breathing zone.

● Turn power off before servicing.

● Do not operate with panel open or

guards off.

WARNING

● Los humos fuera de la zona de res-

piración.

● Mantenga la cabeza fuera de los

humos. Utilice ventilación o
aspiración para gases.

● Gardez la tête à l’écart des fumées.

● Utilisez un ventilateur ou un aspira-

teur pour ôter les fumées des zones
de travail.

● Vermeiden Sie das Einatmen von

Schweibrauch!

● Sorgen Sie für gute Be- und

Entlüftung des Arbeitsplatzes!

● Mantenha seu rosto da fumaça.

● Use ventilação e exhaustão para

remover fumo da zona respiratória.

● 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 öff­nen; Maschine anhalten!)

● Não opere com as tampas removidas.

● Desligue a corrente antes de fazer

serviço.

● Não toque as partes elétricas nuas.

● No operar con panel abierto o

guardas quitadas.

● N’opérez pas avec les panneaux

ouverts ou avec les dispositifs de
protection enlevés.

● Anlage nie ohne Schutzgehäuse

oder Innenschutzverkleidung in
Betrieb setzen!

● Mantenha-se afastado das partes

moventes.

● Não opere com os paineis abertos

ou guardas removidas.

Spanish

AVISO DE

PRECAUCION

French

ATTENTION

German

WARNUNG

Portuguese

ATENÇÃO

Japanese

Chinese

Korean

Arabic

LEIA E COMPREENDA AS INSTRUÇÕES DO FABRICANTE PARA ESTE EQUIPAMENTO E AS PARTES DE USO, E SIGA AS
PRÁTICAS DE SEGURANÇA DO EMPREGADOR.

• World's Leader in Welding and Cutting Products •

• Sales and Service through Subsidiaries and Distributors Worldwide •

Cleveland, Ohio 44117-1199 U.S.A. TEL: [phone] FAX: [phone] WEB SITE: www.lincolnelectric.com