Lincoln Electric SAE-500 User manual

Operator’s Manual
SAE-500TM & SEVERE DUTY TM
DC ARC WELDING POWER SOURCE
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IM10199-A | Issue D ate Apr-17
© Lincoln Global, Inc. All Rights Reserved.
For use with machines having Code Numbers:
12241, 12242, 12687, 12688
Save for future reference
Date Purchased
Code: (ex: 10859)
erial: (ex: U1060512345)
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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

Page
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Section A
Technical Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A-1
Safety 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
Pre-Operation Engine Service . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A-3
Engine Oil . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A-3
Fuel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A-3
Engine Break-In . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .A-4
Engine Cooling System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A-4
Battery Connection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A-4
Spark Arrestor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A-5
Welding Output Cables . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .A-5
Machine rounding . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .A-5
Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Section B
Operating Instructions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . B-1
Safety Instructions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . B-1
Additional Safety Precautions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . B-1
eneral Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . B-1
Recommended Applications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . B-1
Welder . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . B-1
Auxiliary Power . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . B-1
Design Features and Advantages . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .B-2
For Stick Welding . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . B-2
For Auxiliary Power . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . B-2
Duty Cycle . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .B-2
Engine Controls . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . B-3
Dashboard auge Features . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 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
Stopping the Engine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . B-5
Typical Fuel Consumption . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . B-6
Accessories . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Section C
Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Section D
Routine Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . D-1
Periodic Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . D-1
Engine Oil Change . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . D-1
Engine Air Filter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . D-1
Bearing Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . D-2
Commutator and Brush Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . D-2
Cooling System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .D-2
Fuel Filter, Secondary Fuel Filter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . D-2
FCI Receptacle Testing and Resetting Procedure . . . . . . . . . . . . . . . . . . . . . . . . . . . . .D-3
Replacement Service Items . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . D-3
Engine Air Cleaners Service Instructions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . D-4
2
TABLE OF CONTENTSSAE-500TM AND SAE-500TM SEVERE DUTYTM

3
TABLE OF CONTENTSSAE-500TM AND SAE-500TM SEVERE DUTYTM
Page
Troubleshooting Guide . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Section E
Safety Warning . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . E-1
How To Use Troubleshooting uide . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . E-1
Troubleshooting uide . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . E-2 thru E-5
Wiring Diagram and Dimension Print . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Section F
Parts List . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . parts.lincolnelectric.com
C ntent/details may be changed r updated with ut n tice. F r m st current Instructi n Manuals, g t
parts.linc lnelectric.c m.

A-1
INSTALLATIONSAE-500TM AND SAE-500TM SEVERE DUTYTM
TECHNICA SPECIFICATIONS - SAE-500™
Make/Model Description Speed (RPM) Displacement Starting Capacities
System
Deutz 4 cylinder High Idle 1800 176.9 in3
12VDC batteries Fuel: 29 gal.
TD 2.9 L 4 64 HP Low Idle 1180 (2.9 L) & Starter 109.8 L
Turbocharger (48 KW) @ Full Load 1800
Water cooled 1800 RPM Bore x Stroke Oil: 8.45 Qts.
Diesel Engine 8 L
EPA Tier 4 Final 3.62” x 4.33”
(92.0 mm x 110.0mm) Coolant: 2.40 gal.
9.06 L
INPUT - DIESE ENGINE
RATED OUTPUT - WE DER
HEIGHT WIDTH DEPTH WEIGHT
50.13 in. 28.00 in. 83.00 in. 2,111 lb
1273.3 mm 711.2 mm 2108.2 mm (957kg)
OUTPUT - WE DER 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
PHYSICA DIMENSIONS
(1) Based on a 10 minute period.

A-2
INSTALLATIONSAE-500TM AND SAE-500TM SEVERE DUTYTM
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.
E ECTRIC 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
OCATION/VENTI ATION
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.
DO NOT MOUNT OVER COMBUSTIB E 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.
ANG E OF OPERATION
To achieve optimum engine performance the machine
should be run in a level position. The maximum angle
of operation for the Deutz engine is 30 degrees con-
tinuous in all directions. 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.
IFTING
The equipment lift bail should be used to lift the
machine.
WARNING
CAUTION
• ift 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 trail-
er or gas cylinder.
FA ING • Do not lift machine if
EQUIPMENT can lift bail is damaged.
cause injury. • Do not operate machine while
suspended from lift bail.
------------------------------------------------------------------------
WARNING

A-3
INSTALLATIONSAE-500TM AND SAE-500TM SEVERE DUTYTM
HIGH A TITUDE OPERATION
At higher altitudes, output derating may be necessary.
For maximum rating, derate the welder output in
accordance with the following guidelines for this
engine model from the manufacturer:
TOWING
The recommended trailers for use with this equipment
for in-plant and yard towing by a vehicle(1) are Lincoln’s
K2641-1 (4) wheel steerable trailer and K2637-1 (2)
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 haz-
ard 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.
VEHIC E 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.
----------------------------------------------------------------------------
WARNING
PRE-OPERATION ENGINE SERVICE
READ the engine operating and maintenance instruc-
tions supplied with this machine.
ENGINE OI
The engine is shipped with the engine crankcase filled
with high quality SAE 10W-40 FE 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 50 running hours. Refer to the
engine Operator’s Manual for specific oil recommenda-
tions 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.
FUE USE DIESE FUE ON Y
ow 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 .
• 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 expan-
sion may cause ove flow.
DIESEL FUEL ONLY
------------------------------------------------------------------------
WARNING
DIESE FUE
can cause fire.
Deutz TD 2.9 L4
Altitude
Meters Feet Available(%)
0-1000
2000
3000
4000
5000
6000
0-3281
6562
9842
13123
16404
19685
100
95
90
84
79
74
Maximum Power

A-4
INSTALLATIONSAE-500TM AND SAE-500TM SEVERE DUTYTM
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: This machine is furnished with a wet charged
battery; if unused for several months, the battery may
require a booster charge. Be careful to charge the
battery with the correct polarity. Make sure that the
battery is level while charging.
GASES FROM BATTERY can
explode.
●Keep sparks, flame and cigarettes
away from battery.
To prevent EXP OSION when:
●INSTA ING A NEW BATTERY — disconnect
negative cable from old battery first and con-
nect 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 neg-
ative 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 DAMA E
WHEN:
a) Installing new battery.
b) Using a booster.
Use correct polarity — Negative Ground.
To prevent BATTERY BUCKLIN , tighten nuts on
battery only until snug. DO NOT OVERTIGHTEN.
WARNING
ENGINE BREAK-IN
Lincoln Electric selects high quality, heavy-duty indus-
trial 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 sub-
stance 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 condi-
tions for extended periods of time are especially sus-
ceptible to the conditions described above. To
accomplish successful engine break-in, most diesel-
powered equipment needs only to be run at a reason-
ably 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 suit-
able resistive load bank. Note that any
attempt to short the output studs by con-
necting 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 gener-
ator and voids the warranty.
2. Set the welder controls for an output cur-
rent 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 COO ING 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 solu-
tion as needed. (See Engine Manual or antifreeze
container for alternate antifreeze recommendation.)

A-5
INSTALLATIONSAE-500TM AND SAE-500TM SEVERE DUTYTM
WE DING OUTPUT CAB ES
With the engine off, connect the electrode and
work cables to the studs provided. These connec-
tions should be checked periodically and tightened
if necessary.
Listed in Table A.1 are copper cable sizes recom-
mended 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 ength of Electrode and
Work Cables.
EXHAUST OUT ET PIPE
Remove cap from DOC pipe protruding from roof.
Using the clamp & seal provided, secure the outlet
pipe to the outlet tube with the pipe positioned
such that it will direct the exhaust in the desired
direction. Tighten using a 1/4” (6mm) internal sock-
et or allen wrench. Torque to 106 in-lbs (9 ft-lbs)
(12N-m).
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 con-
nected 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 insulat-
ed 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 provid-
ed on the welding generator frame foot.
Up to 100 FT.
(Up to 30m)
2/0 AW
100-200 FT.
(30m-61m)
3/0 AW
200-250 FT.
(61m-76m)
4/0 AW
AMPS
@60%
Duty Cycle
400
TOTAL COMBINED LEN TH OF ELEC-
TRODE AND WORK CABLES
SPARK ARRESTOR
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.
An incorrect spark arrester may lead to damage to
the engine or adversely affect performance.
------------------------------------------------------------------------
CAUTION
WARNING

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

DESIGN FEATURES AND ADVANTAGES
FOR STICK WE DING
• Excellent DC constant current output for stick weld-
ing applications.
• Continuous adjustment of both voltage and current
for unsurpassed welds on demanding jobs.
• Remote control capability standard.
FOR AUXI IARY 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) (Table B.1).
OTHER FEATURES
• Deutz 4-cylinder, water cooled diesel engine.
Designed for long life, easy maintenance and excel-
lent fuel economy.
• Engine protection system shuts the engine down for
low engine oil pressure or high coolant temperature.
• Electronic Engine Idler. Engine automatically goes
to low idle in 14 to 15 seconds after welding or use
of auxiliary power stops. Includes high idle switch.
• auges for engine oil pressure, coolant temperature,
fuel level, engine hour meter and battery charging
volt meter.
• Extended range 29 gallon (109.8 L) fuel tank.
DUTY CYC E
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 min-
utes of no load in a 10 minute period.
Welding Using Only Using Only Total
Current, Amps 115V Circuit, 230V Circuit, Aux.
@ NEMA Arc Amps Amps kVA
Volts
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
B-2
OPERATIONSAE-500TM AND SAE-500TM SEVERE DUTYTM
Table B.1

ENGINE CONTRO S
IGNITION SWITCH
When rocker switch is pressed in the “START” ( )
position, this switch starts the engine.
“AUTO/ID E/RUN” SWITCH
The idler switch has three positions,
“HI H/IDLE/RUN,” “AUTO/IDLE/RUN” and “STOP”.
When in “HI H/IDLE/RUN” ( ) position, the
engine will run continuously at high idle.
When in “AUTO/IDLE/RUN” ( / ) idle posi-
tion, the idler operates as follows:
When placed in the “STOP” ( ) position, the flow of
fuel to the injection pump is stopped to shut down the
engine.
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 14 to 16 seconds.
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 weld-
ing) for 14-16 seconds, the idler reduces the
engine speed to low idle.
DASHBOARD GAUGE FEATURES
ENGINE OI PRESSURE
Displays the oil pressure to the engine.
ENGINE TEMPERATURE
Displays the coolant temperature in the engine block.
ENGINE HOUR METER AND FAU T CODE DISP AY
When there is an active fault, the general code num-
ber is displayed for 2 seconds, followed by the engine
hours for 6 seconds. 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.
FUE EVE
Displays the fuel level in the fuel tank.
BATTERY CHARGE VO T METER
Displays the voltage going from the charging alternator
into the battery. It is normal for charging voltage to be
high after starting or when the battery is low on charge.
ENGINE PROTECTION SYSTEM
The engine protection system shuts down the engine
under high coolant temperature or low engine oil pres-
sure conditions by allowing the fuel solenoid valve to
close.
AIR INTAKE SHUT-OFF (Only on K3955-1)
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.
Avoid using on a regular basis to shut down machine.
The air intake shut-off device will reset automatically,
generally within one minute.
IMPORTANT: Before restarting engine, verify that the
air intake shut-off is in the open position. DO NOT
ATTEMPT TO START EN INE WITH THE AIR
INTAKE SHUT-OFF IN THE CLOSED POSITION.
This may cause severe damage to the engine.
WARNING
•Engine may be hot!
B-3
OPERATIONSAE-500TM AND SAE-500TM SEVERE DUTYTM

WE DER CONTRO S
PO ARITY SWITCH
Turn the Arc Polarity switch to electrode positive or
electrode negative as required for each particular
application.
CONTRO OF WE DING 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
rey 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”
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 indi-
cated on the black scale of the “Current Control” dial.
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.
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 CONTRO
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.
AUXI IARY POWER CONTRO S
Note: See the “MAINTENANCE SECTION” for detailed
information on testing and resetting the FCI
receptacle.
115 VAC Receptacle
One 20 amp, 115 VAC duplex receptacle with FCI pro-
tection provides 115 VAC for auxiliary power. A total of
20 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.
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 rounding” in the INSTALLATION section of
this manual.
Diagnostic Plug
This is used by Field Service shops to connect and trou-
bleshoot engine error codes and is found on a bracket
mounted to the liftbale on the service side.
Parts ocated in Current Box Mounted on iftbale
Glow Relay / Breaker (70A)
Fuel Relay / Breaker (20A)
Idle Time Delay Relay
ECU (Electronic Control Unit) Breaker (30A)
CAUTION
B-4
OPERATIONSAE-500TM AND SAE-500TM SEVERE DUTYTM

B-5
OPERATIONSAE-500TM AND SAE-500TM SEVERE DUTYTM
ENGINE OPERATION
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.
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. Press the “IDLER” switch to “RUN”.
2. Push (For 2 Seconds) & release the “START” but-
ton to start the engine. This switch has an amber
light to indicate glow. This engine will automatically
apply power to the glow circuit & indicator light will
turn off when is complete. This switch also has a
red light (Bottom of Switch) that will light up when
there are faults with the engine (Check engine light
comes on). Field Service shop will need to connect
to diagnostic plug to read detailed error codes.
eneral fault code numbers are displayed on dash
board gauge.
CAUTION
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, operat-
ing and maintenance instructions, and parts lists.
------------------------------------------------------------------------
E ECTRIC 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.
WARNING
3. 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.
4. 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 “IDLER” switch to “STOP”.
5. If the engine protection warning light comes on
during cranking or after start up, the “IDLER”
switch must be turned “STOP” to reset the engine
protection system.
6. Allow the engine to run at high idle speed for sev-
eral minutes to warm the engine. Stop the engine
and recheck the oil level, after allowing sufficient
time for the oil to drain into the pan. If the level is
down, fill it to the full mark again. The engine con-
trols were properly set at the factory and should
require no adjusting when received.
CO D WEATHER STARTING:
Under NO conditions should ether or other start-
ing fluids be used!
------------------------------------------------------------------------
With a fully charged battery and the proper weight oil,
the engine should start satisfactorily even down to
about -15°F (-26°C), it maybe desirable to install cold-
starting aides.
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 “IDLER” switch to “STOP”
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 person-
WARNING

B-6
OPERATIONSAE-500TM AND SAE-500TM SEVERE DUTYTM
TYPICA FUE CONSUMPTION
The typical fuel consumption of the SAE-500 for vari-
ous operating scenarios is shown below:
Low Idle - No Load 0.34 gal./ hr.
1180 RPM ( 1.30 L./hr.)
High Idle - No Load 0.83 gal./hr.
1800 RPM ( 3.13 L./hr.)
Welding Load 2.07 gal./hr.
400 Amps, 40 Volts ( 7.85 L./hr.)
Welding Load 2.50 gal./hr.
500 Amps, 40 Volts ( 9.46 L./hr.)
Auxiliary Power 0.87 gal./hr.
3000VA ( 3.30 L./hr.)

OPTIONA FIE D INSTA ED
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.)
Comes standard with a Duo-Hitch™, a
2” Ball and Lunette Eye combination Hitch.
K2637-1 Trailer - A 2-wheel trailer designed for
road(1), off road, in-plant and yard towing. Trailer
mounts directly to welder base. Comes standard with a
Duo-Hitch™, a 2” Ball and Lunette Eye combination Hitch.
Order:
K2637-1 Trailer
K2639-1 Fender & Light Kit.
K2640-1 Cable Storage Rack
1For highway use, consult applicable federal, state and local laws regarding
possible requirements for brakes, lights, fenders, etc.
K704 Standard Accessory Kit - Includes electrode
and work cables, headshield, work clamp and elec-
trode holder.
C-1
ACCESSORIESSAE-500TM AND SAE-500TM SEVERE DUTYTM

D-1
MAINTENANCESAE-500TM AND SAE-500TM SEVERE DUTYTM
E ECTRIC SHOCK can kill.
●Do not touch electrically live parts
such as output terminals or inter-
nal 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 ser-
vice this equipment.
ROUTINE MAINTENANCE
At the end of each day’s welding, refill the fuel tank to mini-
mize moisture condensation in the tank. Also, running out of
fuel tends to draw dirt into the fuel system. Check the
engine crankcase oil level.
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 mini-
mum daily to prevent the controls from sticking.
3. See the engine Instruction Manual for periodic engine
maintenance information. Change the oil filter in accor-
dance with the instructions in the engine operating man-
ual. When the oil filter is changed add one quart of oil to
the crankcase to replace the oil held in the filter during
operation.
4. Belts tend to loosen after the first 30 or 40 hours of oper-
ation. Check the cooling fan belt and tighten if neces-
sary. DO NOT OVER TI HTEN.
ENGINE OI CHANGE
The SAE-500™ SEVERE DUTY™ is equipped with a con-
venient 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 prop-
er grade of oil as recommended in the Engine Operating
Manual. Wash your hands with soap and water after han-
dling 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.
ENGINE AIR FI TER
The engine air filter element is a dry cartridge type. It
is located above the engine. It can be cleaned and re-
used; 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 fil-
ter should never be removed while the engine is run-
ning.
WARNING