Lincoln Electric SAE-300 HE Service Manual
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Lincoln Electric SAE-300 HE Service Manual

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SAE-300 ® HE
For use with machines having Code Numbers:
SAE-300 ® HE: 11907, 12683
SERVICE MANUAL
SVM290
| Issue D ate 18-Jul
© Lincoln Global, Inc. All Rights Reserved.

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Summary of Contents for Lincoln Electric SAE-300 HE

  • Page 1 SAE-300 ® HE For use with machines having Code Numbers: SAE-300 ® HE: 11907, 12683 SERVICE MANUAL SVM290 | Issue D ate 18-Jul © Lincoln Global, Inc. All Rights Reserved.
  • Page 2 THANK YOU FOR SELECTING A QUALITY PRODUCT BY KEEP YOUR HEAD OUT OF THE FUMES. DON’T get too close to the arc. LINCOLN ELEC TRIC. Use corrective lenses if necessary to stay a reasonable distance away from the arc. READ and obey the Safety Data PLEASE EXAMINE CARTON AND EQUIPMENT FOR Sheet (SDS) and the warning label DAMAGE IMMEDIATELY...
  • Page 3 MAGNETIC FIELDS MAY W117.2-1974. A Free copy of “Arc Welding Safety” booklet BE DANGEROUS E205 is available from the Lincoln Electric Company, 22801 St. Clair Avenue, Cleveland, Ohio 44117-1199. 2.a. Electric current flowing through any conductor BE SURE THAT ALL INSTALLATION, OPERATION, causes localized Electric and Magnetic Fields (EMF).
  • Page 4 S FETY ELECTRIC SHOCK ARC RAYS CAN BURN. CAN KILL. 3.a. The electrode and work (or ground) circuits are 4.a. Use a shield with the proper filter and cover plates to protect your electrically “hot” when the welder is on. Do eyes from sparks and the rays of the arc when welding or not touch these “hot”...
  • Page 5 S FETY WELDING AND CUTTING CYLINDER MAY EXPLODE IF SPARKS CAN CAUSE DAMAGED. FIRE OR EXPLOSION. 7.a. Use only compressed gas cylinders containing the correct shielding gas for the process used 6.a. Remove fire hazards from the welding area. If and properly operating regulators designed for this is not possible, cover them to prevent the welding sparks the gas and pressure used.

  • Page 6: Table Of Contents

    LINCOLN ELECTRIC SAE-300® HE Service Manual SAE-300® HE Service Manual Last update: 2018/07/01 SAE-300® HE ............................1 Service Manual ............................1 Theory of Operation ..........................3 AUTOMATIC ENGINE IDLE SYSTEM ......................5 EXCITER / AUXILIARY ALTERNATOR OPERATION ..................6 EXCITER / AUXILIARY ALTERNATOR OPERATION (Continued) ..............7 WELDER GENERATOR AND EXCITOR ......................
  • Page 7 LINCOLN ELECTRIC SAE-300® HE Service Manual DEAD SHORT, 1ST STEP AND OPEN REACTOR TEST PROCEDURES ............42 ROCKER ADJUSTMENT PROCEDURE ....................... 44 COARSE CURRENT CONTROL UNIT (VARIABLE REACTOR) INSPECTION AND SERVICE PROCEDURE ... 47 ENGINE GOVERNOR CONTROLLER (EGC) TEST PROCEDURE ..............51 ENGINE ALTERNATOR TEST PROCEDURE ....................

  • Page 8: Theory Of Operation

    LINCOLN ELECTRIC SAE-300® HE Service Manual Theory of Operation Figure F.1 – Block Diagram...
  • Page 9 LINCOLN ELECTRIC SAE-300® HE Service Manual ENGINE STARTING AND PROTECTION FIGURE F.2 – ENGINE START AND PROTECTION Turning on the run/stop switch supplies 12VDC power to The machine is equipped with a glow plug starting system idler/engine protection PC board and idle solenoid. During that is used for cold weather starting.

  • Page 10: Automatic Engine Idle System

    LINCOLN ELECTRIC SAE-300® HE Service Manual AUTOMATIC ENGINE IDLE SYSTEM FIGURE F.3 – AUTOMATIC ENGINE IDLE SYSTEM The automatic idle system reduces the engine RPM The automatic idle circuitry on the PC board uses a when there is no electrical demand on the machine.

  • Page 11: Exciter / Auxiliary Alternator Operation

    LINCOLN ELECTRIC SAE-300® HE Service Manual EXCITER / AUXILIARY ALTERNATOR OPERATION FIGURE F.4 – EXCITER / AUXILIARY OPERATION The exciter alternator is the smaller power generator that is Building output: located at the end of the main welding generator. It...

  • Page 12: Exciter / Auxiliary Alternator Operation (Continued)

    LINCOLN ELECTRIC SAE-300® HE Service Manual EXCITER / AUXILIARY ALTERNATOR OPERATION (Continued) AC Auxiliary Output: The exciter alternator is now producing sufficient AC power from both the exciter winding and the 115/230 VAC auxiliary power winding. This 115/230 VAC, 60 Hz. auxiliary...

  • Page 13: Welder Generator And Excitor

    LINCOLN ELECTRIC SAE-300® HE Service Manual WELDER GENERATOR AND EXCITOR FIGURE F.5 – WELDING GENERATOR AND EXCITER Overview: The power used to excite the main welding generator is the same rectified DC current used to power the rotating field The welding generator is coupled directly to the engine of the exciter alternator.

  • Page 14: Welding Generator Operation (Continued)

    LINCOLN ELECTRIC SAE-300® HE Service Manual WELDING GENERATOR OPERATION (Continued) FIGURE F.6 – WELDING GENERATOR Producing weld current: The brushes contact the commutator at precise points around its circumference and are positioned so that they Weld current is produced in the armature windings when it will conduct current only from windings that are producing maximum output at the correct polarity.

  • Page 15: Welding Generator Operation (Continued)

    LINCOLN ELECTRIC SAE-300® HE Service Manual WELDING GENERATOR OPERATION (Continued) Reactor Assembly: Fine Current And O.C.V. Control: The reactor assembly functions like a specialized, high The fine current and O.C.V. control handle manipulates the 64 Ohm rheostat in the weld generator excitation circuit.

  • Page 16: Troubleshooting & Repair

    Troubleshooting & Repair HOW TO USE TROUBLESHOOTING GUIDE Service and repair should be performed by only Lincoln Electric Factory Trained Personnel. Unauthorized repairs performed on this equipment may result in danger to the technician and machine operator and will invalidate your factory warranty. For your safety and to avoid Electrical Shock, please observe all safety notes and precautions detailed throughout this manual.

  • Page 17: Pc Board Troubleshooting Procedures

    ELECTRIC SHOCK can kill. remove them until installation is complete. • If you return a PC board to The Lincoln Electric Company • Have an electrician install and service this for credit, it must be in the static-shielding bag. This will equipment.

  • Page 18: Troubleshooting Guide

    Short Circuit And Ground Test connections. Procedure. If for any reason you do not understand the test procedures or are unable to perform the test/repairs safely, contact the Lincoln Electric Service Department for electrical troubleshooting assistance before you proceed. Call 1-888-935-3877.
  • Page 19 Repair or replace any defective parts or wiring. If for any reason you do not understand the test procedures or are unable to perform the test/repairs safely, contact the Lincoln Electric Service Department for electrical troubleshooting assistance before you proceed. Call 1-888-935-3877.
  • Page 20 Rocker Adjustment Procedure, if necessary. If for any reason you do not understand the test procedures or are unable to perform the test/repairs safely, contact the Lincoln Electric Service Department for electrical troubleshooting assistance before you proceed. Call 1-888-935-3877.
  • Page 21 LINCOLN ELECTRIC SAE-300® HE Service Manual Observe Safety Guidelines TROUBLESHOOTING GUIDE detailed in the beginning of this manual. PROBLEMS POSSIBLE AREAS OF RECOMMENDED (SYMPTOMS) MISADJUSTMENT(S) COURSE OF ACTION OUTPUT PROBLEMS The weld output is considerably 1. Check welding cables for 1.
  • Page 22 Rocker Adjustment Procedure. If for any reason you do not understand the test procedures or are unable to perform the test/repairs safely, contact the Lincoln Electric Service Department for electrical troubleshooting assistance before you proceed. Call 1-888-935-3877.
  • Page 23 LINCOLN ELECTRIC SAE-300® HE Service Manual Observe Safety Guidelines TROUBLESHOOTING GUIDE detailed in the beginning of this manual. PROBLEMS POSSIBLE AREAS OF RECOMMENDED (SYMPTOMS) MISADJUSTMENT(S) COURSE OF ACTION OUTPUT PROBLEMS The weld output is considerably 1. If a remote current control is 1.
  • Page 24 8. Check the series coils for turn to turn shorts. If for any reason you do not understand the test procedures or are unable to perform the test/repairs safely, contact the Lincoln Electric Service Department for electrical troubleshooting assistance before you proceed. Call 1-888-935-3877.
  • Page 25 Rocker Adjustment Procedure, if necessary. If for any reason you do not understand the test procedures or are unable to perform the test/repairs safely, contact the Lincoln Electric Service Department for electrical troubleshooting assistance before you proceed. Call 1-888-935-3877.
  • Page 26 If for any reason you do not understand the test procedures or are unable to perform the test/repairs safely, contact the Lincoln Electric Service Department for electrical troubleshooting assistance before you proceed. Call 1-888-935-3877.
  • Page 27 If for any reason you do not understand the test procedures or are unable to perform the test/repairs safely, contact the Lincoln Electric Service Department for electrical troubleshooting assistance before you proceed. Call 1-888-935-3877.
  • Page 28 Replace and/or adjust the belt tension. If for any reason you do not understand the test procedures or are unable to perform the test/repairs safely, contact the Lincoln Electric Service Department for electrical troubleshooting assistance before you proceed. Call 1-888-935-3877.
  • Page 29 If for any reason you do not understand the test procedures or are unable to perform the test/repairs safely, contact the Lincoln Electric Service Department for electrical troubleshooting assistance before you proceed. Call 1-888-935-3877.
  • Page 30 If for any reason you do not understand the test procedures or are unable to perform the test/repairs safely, contact the Lincoln Electric Service Department for electrical troubleshooting assistance before you proceed. Call 1-888-935-3877.

  • Page 31: Test Procedures

    If for any reason you do not understand the test procedures or are unable to perform the test/repairs safely, contact the Lincoln Electric Service Department for electrical troubleshooting assistance before you proceed. Call 1-888-935-3877.
  • Page 32 LINCOLN ELECTRIC SAE-300® HE Service Manual 6. If there is any evidence that the brushes may have been sticking in the brush holders, a new brush holder and brush assembly should be installed. Cleaning slip rings: In the event that the slip rings have become dirty, discolored or mildly pitted, it will be necessary to clean them using very fine (500 or 600 grit) emery cloth or a 220 or 320 grit commutator stone.

  • Page 33: Exciter Rotor Voltage Test Procedure

    3. Remove the covers from the exciter/auxiliary power alternator by removing the screws securing it. 4. Connect the voltmeter probes to the brush terminals. See Figure F.8. See Wiring Diagram. NOTE: On this machine and all other Lincoln Electric DC generator machines, the black exciter lead is positive and the red lead is negative.

  • Page 34: Alternator)

    LINCOLN ELECTRIC SAE-300® HE Service Manual 9. Check the wiring, fuse and terminals connecting the field bridge rectifier to the exciter stator winding. See Wiring Diagram. 10. Perform the Exciter Stator Short Circuit and Ground Test Procedure. 11. Perform the Exciter Rotor Resistance and Ground Test Procedure (Exciter / Auxiliary Power Alternator).
  • Page 35 If for any reason you do not understand the test procedures or are unable to perform the test/repairs safely, contact the Lincoln Electric Service Department for electrical troubleshooting assistance before you proceed. Call 1-888-935-3877.
  • Page 36 LINCOLN ELECTRIC SAE-300® HE Service Manual seated. Perform the Brush and Slip Ring Service Procedure (Exciter / Auxiliary Power Alternator), if necessary. 7. Insulate the lead wires that had been disconnected from the brushes during the static rotor resistance test. Position and secure them so they cannot become damaged by the spinning rotor.

  • Page 37: Flashing Voltage Test Procedure

    If for any reason you do not understand the test procedures or are unable to perform the test/repairs safely, contact the Lincoln Electric Service Department for electrical troubleshooting assistance before you proceed. Call 1-888-935-3877.
  • Page 38 LINCOLN ELECTRIC SAE-300® HE Service Manual 13. When testing is complete, attach the previously removed exciter / auxiliary power alternator cover and close the left and right side covers. See Wiring Diagram. Figure F.10 – Flashing voltage test...

  • Page 39: Exciter Stator Short Cicuit And Ground Test Procedure

    If for any reason you do not understand the test procedures or are unable to perform the test/repairs safely, contact the Lincoln Electric Service Department for electrical troubleshooting assistance before you proceed. Call 1-888-935-3877.

  • Page 40: Welding Generator Brush And Commutator Inspection And Service Procedure

    If for any reason you do not understand the test procedures or are unable to perform the test/repairs safely, contact the Lincoln Electric Service Department for electrical troubleshooting assistance before you proceed. Call 1-888-935-3877.
  • Page 41 LINCOLN ELECTRIC SAE-300® HE Service Manual tightening can destroy the rocker. • Perform the Weld Circuit Ground and Short Circuit Test Procedure. • If the weld circuit is not grounded or shorted and poor brush quality or contamination is suspected, replace the brushes and seat them with a commutator stone or sandpaper.
  • Page 42 LINCOLN ELECTRIC SAE-300® HE Service Manual Examine the brush holders: The brush holder insulators must be clean and in good condition and all of the hardware must be in place. See Figure F.11. Replace any insulators that are cracked or damaged in any way.

  • Page 43: Weld Circuit Ground And Short Circuit Test Procedure

    If for any reason you do not understand the test procedures or are unable to perform the test/repairs safely, contact the Lincoln Electric Service Department for electrical troubleshooting assistance before you proceed. Call 1-888-935-3877.
  • Page 44 16. Turn off the engine on the SAE-300 HE machine. 17. Place the fine current / OCV control to the maximum setting.

  • Page 45: Shunt Field Coil Resistance And Ground Test Procedure

    If for any reason you do not understand the test procedures or are unable to perform the test/repairs safely, contact the Lincoln Electric Service Department for electrical troubleshooting assistance before you proceed. Call 1-888-935-3877.

  • Page 46: Shunt Field Circuit Voltage Test Procedure

    If for any reason you do not understand the test procedures or are unable to perform the test/repairs safely, contact the Lincoln Electric Service Department for electrical troubleshooting assistance before you proceed. Call 1-888-935-3877.

  • Page 47: Dead Short, 1St Step And Open Reactor Test Procedures

    If for any reason you do not understand the test procedures or are unable to perform the test/repairs safely, contact the Lincoln Electric Service Department for electrical troubleshooting assistance before you proceed. Call 1-888-935-3877.
  • Page 48 LINCOLN ELECTRIC SAE-300® HE Service Manual indicate an open coarse current control unit, an open choke (perform the Choke Test Procedure) or an open in the cables connecting to it. See Wiring Diagram and perform the Coarse Current Control Unit (Variable Reactor) Inspection and Service Procedure.

  • Page 49: Rocker Adjustment Procedure

    If for any reason you do not understand the test procedures or are unable to perform the test/repairs safely, contact the Lincoln Electric Service Department for electrical troubleshooting assistance before you proceed. Call 1-888-935-3877.
  • Page 50 LINCOLN ELECTRIC SAE-300® HE Service Manual Setting the Rocker - If the factory drill mark is missing or invalid due to component replacement. IMPORTANT: The following procedures should only be attempted if all the other systems have been thoroughly checked and are functioning normally.
  • Page 51 LINCOLN ELECTRIC SAE-300® HE Service Manual Figure F.13 – Rocker w/marks...

  • Page 52: Coarse Current Control Unit (Variable Reactor) Inspection And Service Procedure

    If for any reason you do not understand the test procedures or are unable to perform the test/repairs safely, contact the Lincoln Electric Service Department for electrical troubleshooting assistance before you proceed. Call 1-888-935-3877.
  • Page 53 LINCOLN ELECTRIC SAE-300® HE Service Manual 9. Remove the two screws holding the brush holder stud assembly. Use caution, the shaft is under spring tension. The stud assembly and the rotating brush holder/contact assembly can now be removed through the back of the unit. See Figures F.14 and F.15.
  • Page 54 LINCOLN ELECTRIC SAE-300® HE Service Manual Figure F.14 – Brush & spring Figure F.15 – Windings & insulated wedge...
  • Page 55 LINCOLN ELECTRIC SAE-300® HE Service Manual Figure F.1 – Insulator & spring locations Figure F.2 – Shaft & tube...

  • Page 56: Engine Governor Controller (Egc) Test Procedure

    If for any reason you do not understand the test procedures or are unable to perform the test/repairs safely, contact the Lincoln Electric Service Department for electrical troubleshooting assistance before you proceed. Call 1-888-935-3877.
  • Page 57 LINCOLN ELECTRIC SAE-300® HE Service Manual Table F.1 – Electronic governor control (EGC) tests (POS) TEST POINT (NEG) TEST POINT EXPECTED READING MACHINE CONDITION RUN/STOP SWITCH IN THE RUN PLUG J1 PIN 9 CHASSIS GROUND 12 VDC POSITION. IDLER SWITCH IN THE LOW IDLE...
  • Page 58 LINCOLN ELECTRIC SAE-300® HE Service Manual Figure F.3 – Engine governor controller (EGC) location Figure F.4 – Engine governor controller (EGC) plug and pin locations...

  • Page 59: Engine Alternator Test Procedure

    If for any reason you do not understand the test procedures or are unable to perform the test/repairs safely, contact the Lincoln Electric Service Department for electrical troubleshooting assistance before you proceed. Call 1-888-935-3877.

  • Page 60: Choke Test Procedure

    If for any reason you do not understand the test procedures or are unable to perform the test/repairs safely, contact the Lincoln Electric Service Department for electrical troubleshooting assistance before you proceed. Call 1-888-935-3877.

  • Page 61: Current Sense Board Test Procedure

    If for any reason you do not understand the test procedures or are unable to perform the test/repairs safely, contact the Lincoln Electric Service Department for electrical troubleshooting assistance before you proceed. Call 1-888-935-3877.
  • Page 62 LINCOLN ELECTRIC SAE-300® HE Service Manual Figure F.20 – Current sense board location Figure F.21 – Current sense board pin locations...

  • Page 63: Rheostat Test Procedure

    If for any reason you do not understand the test procedures or are unable to perform the test/repairs safely, contact the Lincoln Electric Service Department for electrical troubleshooting assistance before you proceed. Call 1-888-935-3877.
  • Page 64 LINCOLN ELECTRIC SAE-300® HE Service Manual Figure F.22 – Rheostat terminal locations...

  • Page 65: Removal And Replacement Procedures

    If for any reason you do not understand the test procedures or are unable to perform the test/repairs safely, contact the Lincoln Electric Service Department for electrical troubleshooting assistance before you proceed. Call 1-888-935-3877.
  • Page 66 LINCOLN ELECTRIC SAE-300® HE Service Manual NOTE: The sleeve collar will have to be removed with a gear puller. Be careful not to damage the rotor slip ring assembly. 12. Remove the rotor by pulling it free of the generator shaft.
  • Page 67 LINCOLN ELECTRIC SAE-300® HE Service Manual Figure F.23 – Battery panel removal Figure F.24 – Alternator cover and wraparound removal...
  • Page 68 LINCOLN ELECTRIC SAE-300® HE Service Manual Figure F.25 – Rotor removal...

  • Page 69: Alternator Stator Removal And Replacement Procedure

    If for any reason you do not understand the test procedures or are unable to perform the test/repairs safely, contact the Lincoln Electric Service Department for electrical troubleshooting assistance before you proceed. Call 1-888-935-3877.
  • Page 70 LINCOLN ELECTRIC SAE-300® HE Service Manual that these marks be precisely aligned during reassembly. See Figure F.27. NOTE: If these drill marks cannot be found, the positions of the rocker and exciter bracket should be clearly marked so these parts can be precisely aligned when the machine is reassembled.
  • Page 71 LINCOLN ELECTRIC SAE-300® HE Service Manual Figure F.26 – Generator cover removal Figure F.27 – Rocker & mark locations...

  • Page 72: Generator Frame Removal And Replacement Procedure

    If for any reason you do not understand the test procedures or are unable to perform the test/repairs safely, contact the Lincoln Electric Service Department for electrical troubleshooting assistance before you proceed. Call 1-888-935-3877.
  • Page 73 LINCOLN ELECTRIC SAE-300® HE Service Manual REPLACEMENT PROCEDURE 1. During reassembly, anti-seize compound should be applied to the screw threads. 2. Carefully inspect the mating surfaces of the engine adapter plate and the generator frame. The mating surfaces must be clean and undamaged.

  • Page 74: Generator Armature Removal And Replacement Procedure

    If for any reason you do not understand the test procedures or are unable to perform the test/repairs safely, contact the Lincoln Electric Service Department for electrical troubleshooting assistance before you proceed. Call 1-888-935-3877.
  • Page 75 LINCOLN ELECTRIC SAE-300® HE Service Manual Figure F.28 – Sling lift...

  • Page 76: Choke Removal And Replacement Procedure

    If for any reason you do not understand the test procedures or are unable to perform the test/repairs safely, contact the Lincoln Electric Service Department for electrical troubleshooting assistance before you proceed. Call 1-888-935-3877.
  • Page 77 LINCOLN ELECTRIC SAE-300® HE Service Manual 4. Using a 1/2” open-end wrench and a 1/2” socket, attach the bolt, nut and lock washer securing leads to the bottom choke terminal. See Wiring Diagram. 5. Using a 1/2” open-end wrench and a 1/2”socket, attach the bolt, nut and lock washer securing leads to the top choke terminal.

  • Page 78: Current Sense Board Removal And Replacement Procedure

    If for any reason you do not understand the test procedures or are unable to perform the test/repairs safely, contact the Lincoln Electric Service Department for electrical troubleshooting assistance before you proceed. Call 1-888-935-3877.
  • Page 79 LINCOLN ELECTRIC SAE-300® HE Service Manual Figure F.30 – Current sense board plug location...

  • Page 80: Engine Governor Controller (Egc) Removal And Replacement Procedure

    If for any reason you do not understand the test procedures or are unable to perform the test/repairs safely, contact the Lincoln Electric Service Department for electrical troubleshooting assistance before you proceed. Call 1-888-935-3877.
  • Page 81 LINCOLN ELECTRIC SAE-300® HE Service Manual Figure F.31 – Engine governor controller (EGC) plug and mounting hardware locations...

  • Page 82: Rheostat Removal And Replacement Procedure

    If for any reason you do not understand the test procedures or are unable to perform the test/repairs safely, contact the Lincoln Electric Service Department for electrical troubleshooting assistance before you proceed. Call 1-888-935-3877.
  • Page 83 LINCOLN ELECTRIC SAE-300® HE Service Manual Figure F.32 – Rheostat terminal locations...

  • Page 84: Retest After Repair

    LINCOLN ELECTRIC SAE-300® HE Service Manual RETEST AFTER REPAIR Retest a machine: • If it is rejected under test for any reason that requires you to remove any part which could affect the machine’s electrical characteristics. • If you repair or replace any electrical components.

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