Lincoln Electric 11476 Manual de usuario

Operator’s Manual

SAE-500 TM DC ARC WELDING

POWER SOURCE

www.lin olnele tri . om/register

Authorized Service and Distributor Locator:

www.lin olnele tri . om/lo ator

IM988-A | Issue D ate Nov-15

For use with ma hines having Code Numbers:

11476, 12515

Save for future reference

Date Pur hased

Code: (ex: 10859)

Serial: (ex: U1060512345)

THANK YOU FOR SELECTING

A QUALITY PRODUCT BY

LINCOLN ELECTRIC.

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.

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 operation 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.

This statement appears where the information must be followed

exactly to avoid serious personal injury or loss of life.

This statement appears where the information must be followed

to avoid minor personal injury or damage to this equipment.

KEEP YOUR HEAD OUT OF THE FUMES.

DON’T get too close to the arc.

Use corrective lenses if necessary

to stay a reasonable distance

away from the arc.

READ and obey the Safety Data

Sheet (SDS) and the warning label

that appears on all containers of

welding materials.

USE ENOUGH VENTILATION or

exhaust at the arc, or both, to

keep the fumes and gases from

your breathing zone and the general area.

IN A LARGE ROOM OR OUTDOORS, natural ventilation may be

adequate if you keep your head out of the fumes (See below).

USE NATURAL DRAFTS or fans to keep the fumes away

from your face.

If you develop unusual symptoms, see your supervisor.

Perhaps the welding atmosphere and ventilation system

should be checked.

WEAR CORRECT EYE, EAR &

BODY PROTECTION

PROTECT your eyes and face with welding helmet

properly fitted and with proper grade of filter plate

(See ANSI Z49.1).

PROTECT your body from welding spatter and arc

flash with protective clothing including woolen

clothing, flame-proof apron and gloves, leather

leggings, and high boots.

PROTECT others from splatter, flash, and glare

with protective screens or barriers.

IN SOME AREAS, protection from noise may be appropriate.

BE SURE protective equipment is in good condition.

Also, wear safety glasses in work area

AT ALL TIMES.

SPECIAL SITUATIONS

DO NOT WELD OR CUT containers or materials which previously

had been in contact with hazardous substances unless they are

properly cleaned. This is extremely dangerous.

DO NOT WELD OR CUT painted or plated parts unless special

precautions with ventilation have been taken. They can release

highly toxic fumes or gases.

Additional precautionary measures

PROTECT compressed gas cylinders from excessive heat,

mechanical shocks, and arcs; fasten cylinders so they cannot fall.

BE SURE cylinders are never grounded or part of an

electrical circuit.

REMOVE all potential fire hazards from welding area.

ALWAYS HAVE FIRE FIGHTING EQUIPMENT READY FOR

IMMEDIATE USE AND KNOW HOW TO USE IT.

WARNING

CAUTION

Safety 01 of 04 - 5/16/2018

SECTION A:

WARNINGS

CALIFORNIA PROPOSITION 65 WARNINGS

WARNING: Breathing diesel engine exhaust

exposes you to chemicals known to the State

of California to cause cancer and birth defects,

or other reproductive harm.

• Always start and operate the engine in a

well-ventilated area.

• If in an exposed area, vent the exhaust to the outside.

• Do not modify or tamper with the exhaust system.

• Do not idle the engine except as necessary.

For more information go to

www.P65 warnings.ca.gov/diesel

WARNING: This product, when used for welding or

cutting, produces fumes or gases which contain

chemicals known to the State of California to cause

birth defects and, in some cases, cancer. (California

Health & Safety Code § 25249.5 et seq.)

WARNING: Cancer and Reproductive Harm

www.P65warnings.ca.gov

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.

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 in open, well-ventilated areas or vent the 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

fumes have 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 engine is running.

1.g. To prevent accidentally starting gasoline engines while turning

the engine or welding generator during maintenance work,

disconnect the spark plug wires, distributor cap or magneto wire

as appropriate.

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 are now 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 tape when 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. If the electrode cable is on your right side, the

work cable should also be on your right side.

2.d.4. Connect the work cable to the workpiece as close as pos-

sible to the area being welded.

2.d.5. Do not work next to welding power source.

SAFETY

Safety 02 of 04 - 5/16/2018

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.

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.

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

hardfacing (see instructions on container or SDS)

or on lead or cadmium plated steel and other

metals or coatings which produce highly toxic

fumes, keep exposure as low as possible and

within applicable OSHA PEL and ACGIH TLV limits

using local exhaust or mechanical ventilation

unless exposure assessments indicate otherwise.

In confined spaces or in some circumstances,

outdoors, a respirator may also be required.

Additional precautions are also required when

welding

on galvanized steel.

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 vapors

coming from degreasing, cleaning or spraying operations. The

heat and rays of the arc can react with solvent vapors to 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

Safety Data Sheet (SDS) and follow your employer’s safety

practices. SDS forms are available from your welding

distributor or from the manufacturer.

5.f. Also see item 1.b.

SAFETY

Safety 03 of 04 - 5/16/2018

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 the welding sparks

from starting a fire. 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 though they have been

“cleaned”. For information, purchase “Recommended Safe

Practices for the Preparation for Welding and Cutting of

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.

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

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.

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, 14501 George Carter Way

Chantilly, VA 20151.

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.

Refer to

http://www.lincolnelectric.com/safety

for additional safety information.

SAFETY

Safety 04 of 04 - 5/16/2018

TABLE OF CONTENTS

SAE-500™

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 and Compressor Service . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .A-3

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

Fuel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .A-4

Engine Cooling System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .A-4

Break-In Period . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .A-4

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

Spark Arrester . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .A-5

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

Machine rounding . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .A-5

_____________________________________________________________________________________

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

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

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

eneral Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .B-1

Recommended Applications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .B-2

Welder . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .B-2

Auxiliary Power . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .B-2

Product Application . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .B-2

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

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

Engine Controls: Function/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 Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . D-1

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

Pre Filter / Washer Separator . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .D-2

Engine Maintenance Components . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .D-3

Spark Arrester . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .D-3

FCI Receptacle Testing and Resetting Procedure (Accessory Kit Only) . . . . . . . . . . . .D-3

_____________________________________________________________________________________

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

_____________________________________________________________________________________

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

___________________________________________________________________________________

Parts List . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .parts. inco ne ectric.com

Content/details may be changed or updated without notice. For most current Operator’s Manual, go to

parts.lincolnelectric.com.

A-1

INSTALLATION

SAE-500™

A-1

TECHNICAL SPECIFICATIONS - SAE-500™ ( 1278-11)

Make/Model Description Speed (RPM) Displacement Starting Capacities

System

1278-11

Kubota 4 cylinder High Idle 1800 220.9 cu. in

12VDC batteries

Fuel: 29.0 gal.

V3600-T-E3B 57.8 HP @ Low Idle 1100 (3.62 L)

) & Starter 109.8 L

Diesel Engine 1800 RPM Full Load 1725

EPA Tier 4i

Compliant Bore x Stroke Oil: 13.95 Qts.

13.2 L

1278-16

Kubota

V3600-T-E3B 3.86” x 4.72”

Diesel Engine

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

EPA Tier 4i

12.8 L

Compliant

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 Circuit Voltage Auxiliary Power

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

@ 1800 RPM 3000 Watts, 60 Hz.

100% Duty Cycle

PHYSICAL DIMENSIONS

(1) Based on a 10 minute period.

A-2

INSTALLATION

SAE-500™

A-2

Read this entire installation section before you

start installation.

SAFETY PRECAUTIONS

Do not attempt to use this equipment until you

have thoroughly read all operating and mainte-

nance manuals supplied with your machine. They

include important safety precautions, detailed

engine starting, operating and maintenance

instructions and parts lists.

ELECTRIC SHOC 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.

• eep away from moving parts

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

Only qualified personnel should install, use or

service this equipment

LOCATION/VENTILATION

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.

This equipment is for industrial use only and it is not

intended for use in residential locations where the electri-

cal power is provided by the public low-voltage supply

system. There can be potential difficulties in residential

locations due to conducted as well as radiated radio-fre-

quency disturbances. The EMC or RF classification of this

equipment is Class A.

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.

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

STAC ING

These machines cannot be stacked.

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 con-

tinuous in all directions and 30 degrees intermittent

(less than 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 capac-

ity 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.

• 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 a

trailer or gas cylinder.

FALLING • Do not lift machine if lift bail is

EQUIPMENT can damaged.

Cause injury. • Do not operate machine while

Suspended from lift bail.

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

WARNING

CAUTION

A-3

INSTALLATION

SAE-500™

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 alti-

tude operation.

TOWING

The recommended trailers for use with this equipment

for in-plant and yard towing by a vehicle(1) are Lincoln’s

K2641-1 and K2637-1. The K2637-1 is also designed

to be used at highway speeds(1).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)

(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 this equipment on serviceable vehi-

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 compo-

nents such as suspension, axles and tires.

• Mount equipment base to metal bed or frame of

vehicle.

• Follow vehicle manufacturer’s instruction.

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

PRE-OPERATION ENGINE SERVICE

READ the engine operating and maintenance instruc-

tions 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 bet-

ter). 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.

WARNING

A-4

INSTALLATION

A-4

SAE-500™

• Stop engine while fueling.

• Do not smoke when fueling.

• Keep spa ks and flame away f om

tank.

• Do not leave unattended while

fueling.

• Wipe up spilled fuel and allow

fumes to clea befo e sta ting

engine.

• Do not ove fill tank, fuel

expansion may cause ove -

flow.

DIESEL FUEL ONLY

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

FUEL

USE DIESEL FUEL ONLY

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).

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

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.)

ENGINE BREA -IN PERIOD

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,

wet stacking (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 diesel-powered equipment needs

only to be run at a reasonably heavy load within the rat-

ing of 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 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 volt-

age 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 dam-

age to the generator and voids the warranty.

3. Periodically shut off the engine and check the

crankcase oil level.

BATTERY CONNECTION

Use caution as the electrolyte is a strong acid that

can burn skin and damage eyes.

Remove and discard the insulating caps from the

negative battery terminals. Attach and tighten nega-

tive battery cable terminals.

NOTE: This machine is furnished with wet charged bat-

teries; if unused for several months, the batteries may

require a booster charge. Be careful to charge the bat-

teries with the correct polarity. Make sure

that the batteries are level while charging.

GASES FROM BATTERY can explode.

leep sparks, flame and cigarettes away from bat-

tery.

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

To prevent EXPLOSION when:

lINSTALLING A NEW BATTERY — disconnect neg-

ative cable from old battery first and connect

to new battery last.

lCONNECTING A BATTERY CHARGER — remove

battery from welder by disconnecting negative

cable first, then positive cable and battery clamp.

When reinstalling, connect

negative cable last. eep well ventilated.

DIESEL FUEL

can cause fire.

WARNING

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