Lincoln Electric GENUINE SAE-300 Service Manual
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Lincoln Electric GENUINE SAE-300 Service Manual

Lincoln Electric GENUINE SAE-300 Service Manual

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SAE-300
®
For use with machines having Code Numbers:
11645, 11916, 12090, 11906, 12162, 12683
SERVICE MANUAL
SVM218-A
| Issue D ate 12-Apr
© Lincoln Global, Inc. All Rights Reserved.
NOTE: This manual will cover most of the troubleshooting and repair
procedures for the code numbers listed. Some variances may exist when
troubleshooting/repairing later code numbers.
Need Help? Call 1.888.935.3877
to talk to a Service Representative
Hours of Operation:
8:00 AM to 6:00 PM (ET) Mon. thru Fri.
After hours?
Use "Ask the Experts" at lincolnelectric.com
A Lincoln Service Representative will contact you
no later than the following business day.
For Service outside the USA:
Email: globalservice@lincolnelectric.com

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Summary of Contents for Lincoln Electric GENUINE SAE-300

  • Page 1 NOTE: This manual will cover most of the troubleshooting and repair procedures for the code numbers listed. Some variances may exist when troubleshooting/repairing later code numbers. SAE-300 ® For use with machines having Code Numbers: 11645, 11916, 12090, 11906, 12162, 12683 SERVICE MANUAL Need Help? Call 1.888.935.3877 to talk to a Service Representative...
  • Page 2 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.
  • Page 3 SAFETY ELECTRIC SHOCK can kill. ARC RAYS can burn. 3.a. The electrode and work (or ground) circuits 4.a. Use a shield with the proper filter and cover are electrically “hot” when the welder is on. plates to protect your eyes from sparks and Do not touch these “hot”...
  • Page 4 SAFETY WELDING and CUTTING CYLINDER may explode SPARKS can cause fire or if damaged. explosion. 7.a. Use only compressed cylinders containing the correct shielding gas for the 6.a. Remove fire hazards from the welding area.If process used and properly operating this is not possible, cover them to prevent the welding sparks regulators designed for the gas and from starting a fire.
  • Page 5 SAFETY 6. Eloigner les matériaux inflammables ou les recouvrir afin de PRÉCAUTIONS DE SÛRETÉ prévenir tout risque d’incendie dû aux étincelles. Pour votre propre protection lire et observer toutes les instructions 7. Quand on ne soude pas, poser la pince à une endroit isolé de et les précautions de sûreté...
  • Page 6 2004/108/EC. It was manufactured in conformity with a national standard that implements a harmonized standard: EN 60974-10 Electromagnetic Compatibility (EMC) Product Standard for Arc Welding Equipment. It is for use with other Lincoln Electric equipment. It is designed for industrial and professional use. Introduction All electrical equipment generates small amounts of electromagnetic emission.
  • Page 7 SAFETY Electromagnetic Compatibility (EMC) The size of the surrounding area to be considered will depend on the structure of the building and other activities that are taking place. The surrounding area may extend beyond the boundaries of the premises. Methods of Reducing Emissions Mains Supply Welding equipment should be connected to the mains supply according to the manufacturer’s recommen- dations.
  • Page 8 - MASTER TABLE OF CONTENTS FOR ALL SECTIONS - Page Safety ................i-vi Installation .

  • Page 9: Table Of Contents

    TABLE OF CONTENTS - INSTALLATION SECTION Installation ................A-1 Technical Specifications .
  • Page 10 INSTALLATION TECHNICAL SPECIFICATIONS - SAE-300 ® INPUT - DIESEL ENGINE Make/Model Description Speed (RPM) Displacement Starting System Capacities 4 Cylinder 135 cu. in 12VDC battery Fuel: 16 gal. 4 Cycle (2.2 ltrs) (Group 24, 650 60.6 L. Perkins Naturally Aspirated High Idle 1800 cold crank amps) 404D-22 Water-Cooled...

  • Page 11: Installation

    INSTALLATION GENERAL DESCRIPTION Engine Idler - The SAE-300 is equipped with an ® electronic automatic engine idler. It automatically The SAE-300 ® is a heavy duty, engine driven, DC arc increases and decreases engine speed when starting welding power source, capable of providing constant and stopping welding or using auxiliary power.

  • Page 12: Pre-Operation Installation

    INSTALLATION LOCATION / VENTILATION Oil Drain Valve - A ball valve, hose and clamp are standard. Always operate the welder with the doors closed. Remote Control - The Remote / Local Switch and Leaving the doors open changes the designed air flow Receptacle are standard.

  • Page 13: Trailer

    INSTALLATION TRAILER RECOMMENDED COPPER CABLE SIZES (SEE OPTIONAL FEATURES) Cables Sizes for Combined Length of Electrode Plus Work Cable If the user adapts a non-Lincoln trailer, he must assume responsibility that the method of attachment Amps Duty Cycle Up to 200ft.(61m) 200 to 250ft. and usage does not result in a safety hazard nor dam- (61 to 76m) 100%...

  • Page 14: Battery Charging

    INSTALLATION BATTERY CHARGING WARNING GASES FROM BATTERY can explode. • Keep sparks, flame and cigarettes away. BATTERY ACID can burn eyes and skin. • Wear gloves and eye protection and be careful when boosting, charging or working near battery. To prevent ExPLOSION when: a) Installing a new battery - disconnect the nega- tive cable from the old battery first and connect the negative cable to the new battery last.
  • Page 15 TABLE OF CONTENTS - OPERATION SECTION Operation ................B-1 Engine Operation .

  • Page 16: Operation

    OPERATION ENGINE OPERATION 7. Allow the engine to run at high idle speed for sev- eral minutes to warm the engine. Stop the engine WARNING and recheck the oil level, after allowing sufficient time for the oil to drain into the pan. If the level is Do not attempt to use this equipment until you down, fill it to the full mark again.

  • Page 17: Engine Break-In

    The NEMA output rating of the SAE-300 ® is 300 Lincoln Electric selects high quality, heavy-duty indus- amperes at 32 arc volts on a 60% duty cycle (consult trial engines for the portable welding machines we Specifications in this manual for alternate ratings).

  • Page 18: Gas-Shielded Flux-Cored Welding

    OPERATION GAS-SHIELDED FLUx-CORED 1. In the “High” position, the idler solenoid deac- tivates and the engine goes to high idle speed. The WELDING speed is controlled by the governor. (with a K623-1 Wire Feed Module installed) 2. In the “Auto” position, the idler oper- ates as follows: Start by setting the Wire (CV) / Stick (CC) toggle switch...
  • Page 19 TABLE OF CONTENTS - ACCESSORIES SECTION Accessories ................C-1 General Options .
  • Page 20 The use of an arc welder cable for adjusting the OCV at the welding site. for pipe thawing is not approved by the CSA, nor is it recommended or supported by Lincoln Electric. TIG OPTIONS ------------------------------------------------------------------------...
  • Page 21 ACCESSORIES WIRE FEEDER OPTIONS Input Cable K691-10 ( For SG Control Module) For Lincoln engine drives with 14-pin MS-type connec- Wire Feed Module K623-1 tion, separate 115V NEMA receptacle and output Provides constant voltage (CV) output with improved stud connections. 10 ft. length. arc stability for Innershield welding.
  • Page 22 NOTES SAE-300 ®...
  • Page 23 TABLE OF CONTENTS - MAINTENANCE SECTION Maintenance ................D-1 Service Instructions .

  • Page 24: Maintenance

    MAINTENANCE SAE-300 ®...

  • Page 25: Safety Precautions

    MAINTENANCE COOLING SYSTEM SAFETY PRECAUTIONS The SAE-300 ® is equipped with a pressure radiator. WARNING Keep the radiator cap tight to prevent loss of coolant. Have qualified personnel do the maintenance Clean and flush the cooling system periodically to pre- work.

  • Page 26: Idler Maintenance

    MAINTENANCE Replace brushes when they wear within 1/4” of the pig- PURGING AIR FROM FUEL tail. A complete set of replacement brushes should be SYSTEM kept on hand. Lincoln brushes have a curved face to fit the commutator. Have an experienced maintenance (Perkins 404D-22 Engine) man seat these brushes by lightly stoning the commu- tator as the armature rotates at full speed until contact...
  • Page 27 MAINTENANCE ENGINE SERVICE EVERY DAY OR EVERY 8 HOURS FIRST SERVICE - (20 / 50 HOURS) EVERY 100 HOURS OR 3 MONTHS EVERY 250 HOURS OR 6 MONTHS EVERY 500 HOURS OR 12 MONTHS EVERY 1000 HOURS ENGINE SERVICE (NOTE 2) MAINTENANCE ITEM TYPE OR QUANTITY Coolant level...

  • Page 28: Gfci Testing And Resetting Procedure

    MAINTENANCE GFCI TESTING AND RESETTING PROCEDURE The GFCI should be properly tested at least once every month or whenever it is tripped. To properly test and reset the GFCI : • If the GFCI has tripped, first carefully remove any load and check it for damage.
  • Page 29 TABLE OF CONTENTS-THEORY OF OPERATION SECTION Theory of Operation ..............E-1 Engine Starting And Protection .
  • Page 30 THEORY OF OPERATION FIGURE E.2 - ENGINE START AND PROTECTION TERMINAL (–) OUTPUT CONTROL (OFF) FLYBACK DIODE REMOTE/LOCAL SW. (LOCAL POSITION) FLASHING DIODE REMOTE LOCAL RHEOSTAT RHEOSTAT TO GENERATOR (+) BRUSH GLOW PLUG BUTTON SHUNT COILS TO IDLE / ENGINE PROTECTION BOARD SERIES COILS INJECTION...
  • Page 31 THEORY OF OPERATION FIGURE E.3 - AUTOMATIC ENGINE IDLE SYSTEM TERMINAL (–) OUTPUT CONTROL (OFF) FLYBACK DIODE REMOTE/LOCAL SW. (LOCAL POSITION) FLASHING DIODE REMOTE LOCAL RHEOSTAT RHEOSTAT TO GENERATOR (+) BRUSH GLOW PLUG BUTTON SHUNT COILS TO IDLE / ENGINE PROTECTION BOARD SERIES COILS INJECTION...
  • Page 32 THEORY OF OPERATION FIGURE E.4 - ExCITER / AUxILIARY OPERATION TERMINAL (–) OUTPUT CONTROL (OFF) FLYBACK DIODE REMOTE/LOCAL SW. (LOCAL POSITION) FLASHING DIODE REMOTE LOCAL RHEOSTAT RHEOSTAT TO GENERATOR (+) BRUSH GLOW PLUG BUTTON SHUNT COILS TO IDLE / ENGINE PROTECTION BOARD SERIES COILS INJECTION...
  • Page 33 THEORY OF OPERATION ExCITER / AUxILIARY ALTERNA- TOR 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 power is made available for use through the receptacles on the front panel of the machine, after passing through circuit breakers and the automatic idle system’s current sensor.
  • Page 34 THEORY OF OPERATION FIGURE E.5 - WELDING GENERATOR AND ExCITER TERMINAL (–) OUTPUT CONTROL (OFF) FLYBACK DIODE REMOTE/LOCAL SW. (LOCAL POSITION) FLASHING DIODE REMOTE LOCAL RHEOSTAT RHEOSTAT TO GENERATOR (+) BRUSH GLOW PLUG BUTTON SHUNT COILS TO IDLE / ENGINE PROTECTION BOARD SERIES COILS INJECTION...
  • Page 35 THEORY OF OPERATION FIGURE E.6 - WELDING GENERATOR TERMINAL (–) OUTPUT CONTROL (OFF) FLYBACK DIODE REMOTE/LOCAL SW. (LOCAL POSITION) FLASHING DIODE REMOTE LOCAL RHEOSTAT RHEOSTAT TO GENERATOR (+) BRUSH GLOW PLUG BUTTON SHUNT COILS TO IDLE / ENGINE PROTECTION BOARD SERIES COILS INJECTION EXCITER...
  • Page 36 THEORY OF OPERATION WELDING GENERATOR OPERA- TION (Continued) Interpole coils: Reactor Assembly: Armature current from the positive brushes are routed The reactor assembly functions like a specialized, high through four interpole coils, before being connected to current rheostat and is connected in parallel with the the weld output terminal.
  • Page 37 TABLE OF CONTENTS - TROUBLESHOOTING AND REPAIR Troubleshooting and Repair ............. .F-1 How to Use Troubleshooting Guide .

  • Page 38: How To Use Troubleshooting Guide

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

  • Page 39: Pc Board Troubleshooting Procedures

    Do not touch electrically hot parts. - If you return a PC board to The Lincoln Electric Company for credit, it must be in the static-shielding bag. This will prevent further damage and allow prop- CAUTION er failure analysis.
  • Page 40 5. The Armature may be faulty. CAUTION If for any reason you do not understand the test procedures or are unable to perform the tests/repairs safely, contact the Lincoln Electric Service Department for technical troubleshooting assistance before you proceed. Call 1-888-935-3877. SAE-300...
  • Page 41 CAUTION If for any reason you do not understand the test procedures or are unable to perform the tests/repairs safely, contact the Lincoln Electric Service Department for technical troubleshooting assistance before you proceed. Call 1-888-935-3877. SAE-300 ®...
  • Page 42 Procedure if necessary. CAUTION If for any reason you do not understand the test procedures or are unable to perform the tests/repairs safely, contact the Lincoln Electric Service Department for technical troubleshooting assistance before you proceed. Call 1-888-935-3877. SAE-300 ®...
  • Page 43 Rocker Adjustment Procedure. CAUTION If for any reason you do not understand the test procedures or are unable to perform the tests/repairs safely, contact the Lincoln Electric Service Department for technical troubleshooting assistance before you proceed. Call 1-888-935-3877. SAE-300 ®...
  • Page 44 Procedure if necessary. CAUTION If for any reason you do not understand the test procedures or are unable to perform the tests/repairs safely, contact the Lincoln Electric Service Department for technical troubleshooting assistance before you proceed. Call 1-888-935-3877. SAE-300 ®...
  • Page 45 CAUTION If for any reason you do not understand the test procedures or are unable to perform the tests/repairs safely, contact the Lincoln Electric Service Department for technical troubleshooting assistance before you proceed. Call 1-888-935-3877. SAE-300 ®...
  • Page 46 CAUTION If for any reason you do not understand the test procedures or are unable to perform the tests/repairs safely, contact the Lincoln Electric Service Department for technical troubleshooting assistance before you proceed. Call 1-888-935-3877. SAE-300...
  • Page 47 CAUTION If for any reason you do not understand the test procedures or are unable to perform the tests/repairs safely, contact the Lincoln Electric Service Department for technical troubleshooting assistance before you proceed. Call 1-888-935-3877. SAE-300 ®...
  • Page 48 PC board. CAUTION If for any reason you do not understand the test procedures or are unable to perform the tests/repairs safely, contact the Lincoln Electric Service Department for technical troubleshooting assistance before you proceed. Call 1-888-935-3877. SAE-300...
  • Page 49 CAUTION If for any reason you do not understand the test procedures or are unable to perform the tests/repairs safely, contact the Lincoln Electric Service Department for technical troubleshooting assistance before you proceed. Call 1-888-935-3877. SAE-300...
  • Page 50 CAUTION If for any reason you do not understand the test procedures or are unable to perform the tests/repairs safely, contact the Lincoln Electric Service Department for technical troubleshooting assistance before you proceed. Call 1-888-935-3877. SAE-300...
  • Page 51 CAUTION If for any reason you do not understand the test procedures or are unable to perform the tests/repairs safely, contact the Lincoln Electric Service Department for technical troubleshooting assistance before you proceed. Call 1-888-935-3877. SAE-300...
  • Page 52 NOTES F-16 F-16 SAE-300 ®...

  • Page 53: Engine Rpm Adjustment Test Procedure

    ENGINE RPM ADJUSTMENT TEST PROCEDURE WARNING Service and repair should be performed only by Lincoln Electric factory trained personnel. Unauthorized repairs performed on this equipment may result in danger to the technician or 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 54 See the later in this section. strobe-tach manufacturer's instructions. NOTE: For Lincoln Electric 1800 RPM (4 Pole) The tach should read between 1790 and 1810 machines, that have 60 Hz AC auxiliary power; the engine RPM can be determined Move the idle switch to the "AUTO IDLE"...
  • Page 55 TROUBLESHOOTING AND REPAIR F-19 F-19 ENGINE RPM ADJUSTMENT TEST PROCEDURE (continued) FIGURE F.1 – ENGINE RPM ADJUSTMENT PROCEDURE HIGH IDLE ADJUSTMENT LOW IDLE ADJUSTMENT: IMPORTANT: The high idle RPM is set by the Put the idler switch in AUTO and allow the engine engine manufacturer and should not be changed.
  • Page 56 NOTES F-20 F-20 SAE-300 ®...

  • Page 57: Idle Solenoid Test

    IDLE SOLENOID TEST WARNING Service and repair should be performed only by Lincoln Electric factory trained personnel. Unauthorized repairs performed on this equipment may result in danger to the technician or 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 58 TROUBLESHOOTING AND REPAIR F-22 F-22 IDLE SOLENOID TEST (continued) PROCEDURE 1. Examine the idle linkage for damage, binding, or mis-alignment. 2. Check to be sure that the solenoid plunger can fully bottom-out in the solenoid coil housing. NOTE: When in the low idle position, the low idle stop screw on the injection pump should not come in contact with the engine speed control arm.

  • Page 59: Brush And Slip Ring Service Procedure

    (Exciter / Auxiliary Power Alternator) WARNING Service and repair should be performed only by Lincoln Electric factory trained personnel. Unauthorized repairs performed on this equipment may result in danger to the technician or 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 60 TROUBLESHOOTING AND REPAIR F-24 F-24 BRUSH AND SLIP RING SERVICE PROCEDURE (Exciter / Auxiliary Power Alternator) (continued) PROCEDURE 1. Remove the covers from the exciter / auxiliary power alternator by removing the screws secur- ing it. 2. Examine brushes, slip rings and brush holder. •...
  • Page 61 TROUBLESHOOTING AND REPAIR F-25 F-25 BRUSH AND SLIP RING SERVICE PROCEDURE (Exciter / Auxiliary Power Alternator) (continued) FIGURE F.2 – BRUSH LOCATIONS BRUSHES 4. Check for evidence of sticking brushes. Seating brushes: Sticking brushes will normally result in the slip If brushes have been replaced, repositioned, or are rings being pitted and discolored from exces- not making full contact with the slip rings, it will be...
  • Page 62 NOTES F-26 F-26 SAE-300 ®...

  • Page 63: Exciter Rotor Voltage Test

    ExCITER ROTOR VOLTAGE TEST WARNING Service and repair should be performed only by Lincoln Electric factory trained personnel. Unauthorized repairs performed on this equipment may result in danger to the technician or 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 64 TROUBLESHOOTING AND REPAIR F-28 F-28 ExCITER ROTOR VOLTAGE TEST (continued) FIGURE F.3 – ExCITER ROTOR VOLTAGE TEST BRUSH HOLDER ASSEMBLY VOLTMETER LEADS BRUSHES POSITIVE NEGATIVE SLIP RING SLIP RING PROCEDURE 1. Turn engine off. The Engine and generator should be at normal operating temperature for this test.

  • Page 65: Exciter Rotor Resistance And Ground Test

    TROUBLESHOOTING AND REPAIR F-29 F-29 ExCITER ROTOR VOLTAGE TEST (continued) 5. Set the RUN/STOP switch to “STOP” 10. Re-start the machine and measure the rotor voltage. If the meter reading is normal, this test is complete. If the rotor voltage continues to read significantly If the voltage measures zero or very near zero, lower than 124VDC, the Stator is probably defec- Perform the Flashing Voltage Tests and the...
  • Page 66 NOTES F-30 F-30 SAE-300 ®...
  • Page 67 (Exciter / Auxiliary Power Alternator) WARNING Service and repair should be performed only by Lincoln Electric factory trained personnel. Unauthorized repairs performed on this equipment may result in danger to the technician or 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 68 TROUBLESHOOTING AND REPAIR F-32 F-32 ExCITER ROTOR RESISTANCE AND GROUND TEST (Exciter / Auxiliary Power Alternator) (continued) FIGURE F.4 – SLIP RING LOCATIONS BRUSHES BRUSH HOLDER ASSEMBLY OHMMETER LEADS POSITIVE NEGATIVE SLIP RING SLIP RING PROCEDURE “Static” Tests: 5. Measure the resistance to ground. Place one meter probe on either of the slip rings.
  • Page 69 TROUBLESHOOTING AND REPAIR F-33 F-33 ExCITER ROTOR RESISTANCE AND GROUND TEST (Exciter / Auxiliary Power Alternator) (continued) FIGURE F.5 – SLIP RING LOCATIONS BRUSH HOLDER ASSEMBLY VOLTMETER LEADS BRUSHES POSITIVE NEGATIVE SLIP RING SLIP RING “Dynamic” Tests: (Also referred to as flying resistance test) 2.
  • Page 70 NOTES F-34 F-34 SAE-300 ®...

  • Page 71: Flashing Voltage Test

    FLASHING VOLTAGE TEST WARNING Service and repair should be performed only by Lincoln Electric factory trained personnel. Unauthorized repairs performed on this equipment may result in danger to the technician or 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 72 TROUBLESHOOTING AND REPAIR F-36 F-36 FLASHING VOLTAGE TEST (continued) FIGURE F.6 – FLASHING VOLTAGE TEST BRUSH HOLDER ASSEMBLY VOLTMETER LEADS BRUSHES POSITIVE NEGATIVE SLIP RING SLIP RING PROCEDURE 1. Lift the left and right side covers and secure 9. If the voltage measures between 3 and 6 volts them with the hooks provided.

  • Page 73: Exciter Stator Short Circuit & Ground Test

    ExCITER STATOR SHORT CIRCUIT & GROUND TEST WARNING Service and repair should be performed only by Lincoln Electric factory trained personnel. Unauthorized repairs performed on this equipment may result in danger to the technician or 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 74 TROUBLESHOOTING AND REPAIR F-38 F-38 ExCITER STATOR SHORT CIRCUIT & GROUND TEST (continued) PROCEDURE 1. Open either, or both of the doors. • From chassis ground and one of the exciter winding leads. 2. Make sure that nothing is plugged into the aux- iliary receptacles.

  • Page 75: Welding Generator Brush And Commutator Inspection And Service

    INSPECTION AND SERVICE WARNING Service and repair should be performed only by Lincoln Electric factory trained personnel. Unauthorized repairs performed on this equipment may result in danger to the technician or 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 76 TROUBLESHOOTING AND REPAIR F-40 F-40 WELDING GENERATOR BRUSH AND COMMUTATOR INSPECTION AND SERVICE (continued) FIGURE F.7 – GENERATOR COMPONENTS SPRINGS BRUSH HOLDER PLATE BRUSH HOLDER INSULATORS MOUNTING SCREW DRILL MARK ROCKER COMMUTATOR ARMATURE BRUSHES BRUSH RETAINER PROCEDURE • Check the rocker position. Be certain that it is aligned with or very close to the factory drill 1.
  • Page 77 TROUBLESHOOTING AND REPAIR F-41 F-41 WELDING GENERATOR BRUSH AND COMMUTATOR INSPECTION AND SERVICE (continued) Pitted and Arc Damaged Commutator: Examine the brushes: If pitting and arc damage to the commutator is evi- The brushes and springs should all be in place and dent, the machine may have been used with badly not be excessively worn.
  • Page 78 NOTES F-42 F-42 SAE-300 ®...
  • Page 79 WELD CIRCUIT GROUND AND SHORT CIRCUIT TEST WARNING Service and repair should be performed only by Lincoln Electric factory trained personnel. Unauthorized repairs performed on this equipment may result in danger to the technician or 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 80 TROUBLESHOOTING AND REPAIR F-44 F-44 WELD CIRCUIT GROUND AND SHORT CIRCUIT TEST (continued) PROCEDURE 9. If the resistance measured at the negative ter- minal is low, examine the coarse current control 1. Turn the engine off. unit, the series coils and the heavy leads and brush holders connected to them.

  • Page 81: Shunt Field Coil Resistance And Ground Test

    SHUNT FIELD COIL RESISTANCE AND GROUND TEST WARNING Service and repair should be performed only by Lincoln Electric factory trained personnel. Unauthorized repairs performed on this equipment may result in danger to the technician or 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 82 TROUBLESHOOTING AND REPAIR F-46 F-46 SHUNT FIELD COIL RESISTANCE AND GROUND TEST (continued) PROCEDURE Shunt Coil Ground Test: 1. Measure the resistance between either the 1. Turn off the engine. brown or blue wires and a good clean chassis 2. Open one of the side doors and secure it with ground.

  • Page 83: Shunt Field Circuit Voltage Test

    SHUNT FIELD CIRCUIT VOLTAGE TEST WARNING Service and repair should be performed only by Lincoln Electric factory trained personnel. Unauthorized repairs performed on this equipment may result in danger to the technician or 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 84 TROUBLESHOOTING AND REPAIR F-48 F-48 SHUNT FIELD CIRCUIT VOLTAGE TEST (continued) PROCEDURE 1. Turn the engine off. 2. Locate the 12 pin molex connector in the wire bundle that exits the welding generator fame. See the Wiring Diagram. 3. Set the voltmeter for DC voltage and back- probe pins #3 and #5, (Blue and brown wires) of the 12 pin Molex connector.

  • Page 85: Dead Short, 1St Step And Open Reactor Tests

    DEAD SHORT, 1ST STEP AND OPEN REACTOR TESTS WARNING Service and repair should be performed only by Lincoln Electric factory trained personnel. Unauthorized repairs performed on this equipment may result in danger to the technician or 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 86 TROUBLESHOOTING AND REPAIR F-50 F-50 DEAD SHORT, 1ST STEP AND OPEN REACTOR TESTS (continued) FIGURE F.8 – COARSE CONTROL UNIT ROTOR WINDING MOVABLE CONTACTS Min. (open) Position FIRST STEP CONTACT CONTACT SPRINGS POSITION INSULATED FILLER PROCEDURE 1. If possible, bring the machine to normal tem- 4.

  • Page 87: Rocker Adjustment Procedure

    ROCKER ADJUSTMENT PROCEDURE WARNING Service and repair should be performed only by Lincoln Electric factory trained personnel. Unauthorized repairs performed on this equipment may result in danger to the technician or 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 88 TROUBLESHOOTING AND REPAIR F-52 F-52 ROCKER ADJUSTMENT PROCEDURE (continued) FIGURE F.9 – ROCKER W/MARKS SPRINGS BRUSH HOLDER PLATE BRUSH HOLDER INSULATORS MOUNTING SCREW DRILL MARK ROCKER COMMUTATOR ARMATURE BRUSHES BRUSH RETAINER PROCEDURE The factory set point drill marks: Setting the Rocker - if the factory drill mark is missing or invalid due to component replacement.
  • Page 89 TROUBLESHOOTING AND REPAIR F-53 F-53 ROCKER ADJUSTMENT PROCEDURE (continued) PROCEDURE Initial rocker placement: Check for Max output. 1. The rocker should be initially positioned so the 6. Remove the load, set the output control and center of brushes visually lines up with the cen- rheostat to maximum, re-apply the load and ter of the main poles.
  • Page 90 NOTES F-54 F-54 SAE-300 ®...

  • Page 91: Coarse Current Control Unit (Variable Reactor) Inspection And Service Procedure

    INSPECTION AND SERVICE PROCEDURE WARNING Service and repair should be performed only by Lincoln Electric factory trained personnel. Unauthorized repairs performed on this equipment may result in danger to the technician or 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 92 TROUBLESHOOTING AND REPAIR F-56 F-56 COARSE CURRENT CONTROL UNIT (VARIABLE REACTOR) INSPECTION AND SERVICE PROCEDURE (continued) FIGURE F.10 – BRUSH & SPRING WINDING Output Stud Brush Assembly Holder Assembly Contacts & Springs PROCEDURE 1. Turn the engine off, open the doors and discon- 5.
  • Page 93 TROUBLESHOOTING AND REPAIR F-57 F-57 COARSE CURRENT CONTROL UNIT (VARIABLE REACTOR) INSPECTION AND SERVICE PROCEDURE (continued) FIGURE F.11 – BRUSH & SPRING WINDING INSULATED WEDGE Servicing the continuous control unit: 8. Clean the continuous output control unit by The resistance should be very high, 500,000 using low pressure air to remove any excess (500k) Ohms min.
  • Page 94 TROUBLESHOOTING AND REPAIR F-58 F-58 COARSE CURRENT CONTROL UNIT (VARIABLE REACTOR) INSPECTION AND SERVICE PROCEDURE (continued) FIGURE F.12 – INSULATOR & SPRING LOCATIONS Steel Coil Insulator Output Shaft Contacts Spring Tube Stud Springs Insulator (Short Insulator Tube Not Shown) Brush Spring Flat Holder...
  • Page 95 TROUBLESHOOTING AND REPAIR F-59 F-59 COARSE CURRENT CONTROL UNIT (VARIABLE REACTOR) INSPECTION AND SERVICE PROCEDURE (continued) FIGURE F.13 – SHAFT & TUBE CHAMFERED END OF SHAFT AT THIS END 5/8” 1/4” The shaft spring will need to be compressed and the bracket drawn close to the back of the output control before the screws can be started and tight- ened.
  • Page 96 NOTES F-60 F-60 SAE-300 ®...

  • Page 97: Engine Protection System Circuit Test

    ENGINE PROTECTION SYSTEM CIRCUIT TEST WARNING Service and repair should be performed only by Lincoln Electric factory trained personnel. Unauthorized repairs performed on this equipment may result in danger to the technician or 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 98 TROUBLESHOOTING AND REPAIR F-62 F-62 ENGINE PROTECTION SYSTEM CIRCUIT TEST (continued) FIGURE F.14 – ENGINE ALTERNATOR PROCEDURE IMPORTANT: Before proceeding with this test, 1. Disconnect the lead from the engine coolant verify that the engine has normal oil temperature switch, lead #44. pressure, is not overheated and the 2.
  • Page 99 TROUBLESHOOTING AND REPAIR F-63 F-63 ENGINE PROTECTION SYSTEM CIRCUIT TEST (continued) 4. Insulate and/or position these leads so they 8. If the engine continues to run with these wires cannot touch chassis ground, any other electri- disconnected, one of the engine protection cal conductor, or be damaged by any moving switches is faulty or the engine alternator is parts.
  • Page 100 NOTES F-64 F-64 SAE-300 ®...

  • Page 101: Engine Alternator Test

    ENGINE ALTERNATOR TEST WARNING Service and repair should be performed only by Lincoln Electric factory trained personnel. Unauthorized repairs performed on this equipment may result in danger to the technician or 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 102 TROUBLESHOOTING AND REPAIR F-66 F-66 ENGINE ALTERNATOR TEST (continued) FIGURE F.15 – ENGINE ALTERNATOR PROCEDURE 1. Locate the engine alternator (See Figure F.15) Engine running: 2. Check voltage as follows: • Chassis ground to the B+ terminal of the alternator, (Lead #51). The meter should 3.

  • Page 103: Engine Fuel System Voltage Tests

    ENGINE FUEL SYSTEM VOLTAGE TESTS WARNING Service and repair should be performed only by Lincoln Electric factory trained personnel. Unauthorized repairs performed on this equipment may result in danger to the technician or 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 104 TROUBLESHOOTING AND REPAIR F-68 F-68 ENGINE FUEL SYSTEM VOLTAGE TESTS (continued) FIGURE F.16 – PC BOARD B-1 (-) CHASSIS GROUND J31-9 (+) OUTPUT TO FUEL SOLENOID J31-1, (+) BATTERY VOLTAGE INPUT PROCEDURE 1. Open the doors on the SAE-300 ® machine and If battery voltage is present at the solenoids and secure them using the hooks provided.
  • Page 105 TROUBLESHOOTING AND REPAIR F-69 F-69 ENGINE FUEL SYSTEM VOLTAGE TESTS (continued) 1. Place the run/stop switch in the “RUN” position and within 30 seconds, check for 11 to 13 VDC between terminal J31-9(+) and terminal B-1(-). 2. Check for battery voltage between terminal J31-1(+) and terminal B-1(-).
  • Page 106 NOTES F-70 F-70 SAE-300 ®...

  • Page 107: Alternator Rotor Removal And Replacement Procedure

    REMOVAL AND REPLACEMENT PROCEDURE WARNING Service and repair should be performed only by Lincoln Electric factory trained personnel. Unauthorized repairs performed on this equipment may result in danger to the technician or 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 108 TROUBLESHOOTING AND REPAIR F-72 F-72 ALTERNATOR ROTOR REMOVAL AND REPLACEMENT PROCEDURE (continued) FIGURE F.17 – BATTERY PANEL REMOVAL NEGATIVE BATTERY CABLE BATTERY MOUNTING PANEL PROCEDURE 1. Turn the engine off. 2. Using the 7/16” wrench, remove the two bolts and washers and partially slide out the battery mounting panel.
  • Page 109 TROUBLESHOOTING AND REPAIR F-73 F-73 ALTERNATOR ROTOR REMOVAL AND REPLACEMENT PROCEDURE (continued) FIGURE F.18 – ALTERNATOR COVER AND WRAPAROUND REMOVAL WRAPAROUND SLIP RINGS ALTERNATOR COVER BRUSHES See Figure F.18 for steps 3 - 5. 3. With the 3/8" wrench, loosen the screws on the left and right sides and bottom of the alternator wrap-around.
  • Page 110 TROUBLESHOOTING AND REPAIR F-74 F-74 ALTERNATOR ROTOR REMOVAL AND REPLACEMENT PROCEDURE (continued) FIGURE F.19 – ROTOR REMOVAL "BENT" WASHER STATOR FRAME SLEEVE BRUSH COLLAR HOLDER BRACKET BRUSH HOLDER CARTRIDGE ASSEMBLY See Figure F.19 for steps 6 - 8. 6. With the 7/16" wrench, remove the two bolts, 8.
  • Page 111 TROUBLESHOOTING AND REPAIR F-75 F-75 ALTERNATOR ROTOR REMOVAL AND REPLACEMENT PROCEDURE (continued) Replacement 9. Carefully mount the rotor onto the generator shaft. Install a new sleeve collar (part number T14337), washer and rotor locking nut. NOTE: Be careful not to damage or deform the new sleeve collar.
  • Page 112 NOTES F-76 F-76 SAE-300 ®...

  • Page 113: Alternator Stator Removal And Replacement Procedure

    REMOVAL AND REPLACEMENT PROCEDURE WARNING Service and repair should be performed only by Lincoln Electric factory trained personnel. Unauthorized repairs performed on this equipment may result in danger to the technician or 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 114 TROUBLESHOOTING AND REPAIR F-78 F-78 ALTERNATOR STATOR REMOVAL AND REPLACEMENT PROCEDURE (continued) FIGURE F.20 – GENERATOR COVER REMOVAL COMMUTATOR WRAPAROUND PROCEDURE 1. Turn off the engine. 6. Lift the eight welding generator brushes from the commutator. Note the position of the brush- 2.
  • Page 115 TROUBLESHOOTING AND REPAIR F-79 F-79 ALTERNATOR STATOR REMOVAL AND REPLACEMENT PROCEDURE (continued) FIGURE F.21 – ROCKER & MARK LOCATIONS SPRINGS BRUSH HOLDER PLATE BRUSH HOLDER INSULATORS MOUNTING SCREW DRILL MARK ROCKER COMMUTATOR ARMATURE BRUSHES BRUSH RETAINER 9. Drain the fuel and store it in an approved con- 10.
  • Page 116 TROUBLESHOOTING AND REPAIR F-80 F-80 ALTERNATOR STATOR REMOVAL AND REPLACEMENT PROCEDURE (continued) Replacing the Exciter Alternator Stator: 1. During reassembly, anti-seize compound 8. Re-attach the heavy generator leads to the should be applied to the screw threads. brush holders. Use the notes made during dis- assembly to assure that the leads are connect- 2.

  • Page 117: Generator Frame Removal And Replacement Procedure

    REMOVAL AND REPLACEMENT PROCEDURE WARNING Service and repair should be performed only by Lincoln Electric factory trained personnel. Unauthorized repairs performed on this equipment may result in danger to the technician or 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 118 TROUBLESHOOTING AND REPAIR F-82 F-82 GENERATOR FRAME REMOVAL AND REPLACEMENT PROCEDURE (continued) Remove the generator frame Replacing the Generator Frame 1. Turn off Engine. 1. During reassembly, anti-seize compound should be applied to the screw threads. 2. Perform the Alternator Rotor Removal Procedure.

  • Page 119: Generator Armature Removal And Replacement

    REMOVAL AND REPLACEMENT PROCEDURE WARNING Service and repair should be performed only by Lincoln Electric factory trained personnel. Unauthorized repairs performed on this equipment may result in danger to the technician or 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 120 TROUBLESHOOTING AND REPAIR F-84 F-84 GENERATOR ARMATURE REMOVAL AND REPLACEMENT PROCEDURE (continued) FIGURE F.22 – SLING LIFT ROPE SLING BLOWER PADDLE BLOWER PADDLE/ARMATURE MOUNTING BOLTS (8) PROCEDURE Removing the Armature Replacing the armature 1. Turn off the engine 1. Carefully inspect the mating surfaces of the fly- wheel and armature coupling parts.

  • Page 121: Retest After Repair

    RETEST AFTER REPAIR F-85 F-85 Retest after repair The machine should be retested if any parts are replaced that could affect the machine’s electrical characteristics. Engine output: Perform the Engine RPM Adjustment Test Welder DC Output: Maximum Output: Bring the machine to normal temperature by connecting a load bank and operating the machine at 100% output (250 amps @ 30 volts) for about 30 minutes.
  • Page 122 NOTES F-86 F-86 SAE-300 ®...
  • Page 123 TABLE OF CONTENTS - DIAGRAM SECTION Electrical Diagrams ..............G-1 Wiring Diagram (M22535) .

  • Page 124: Electrical Diagrams

    ELECTriCaL DiaGramS WiriNG DiaGram - (m22535) SAE-300 - PERKINS WIRING DIAGRAM CONTROL PANEL COMPONENTS SHOWN AS VIEWED FROM REAR. LEADS CONNECTED TO ENGINE IDLER/ENGINE P.C. BOARD, SEE DETAIL NEUTRAL BONDED TO FRAME. NEUTRE RACCORDE AU BATI. IDLER/ENGINE PROTECTION P.C. Bd. 400D LEAD COLOR CODE TO CURRENT...

  • Page 125: Schematic - Complete Machine (L15879

    ELECTriCaL DiaGramS SChEmaTiC - COmpLETE maChiNE (L15879) ENGINEERING CONTROLLED CHANGE DETAIL: CHANGED DC EXCITER TO AC EXCITER MANUFACTURER: AMMETER SHOWS FULL THIS LEAD PROVIDES FLASH K924-4 REMOTE CONTROL BACK, LEFT SIDE OF ENGINE IDLER / ENGINE PROTECTION PC BOARD DISCHARGE WHILE PRESSING FOR ALTERNATOR AND 65 AMP / 12 VOLT GLOW PLUG...

  • Page 126: Schematic - Idler Pc Board (G4828

    ELECTriCaL DiaGramS SChEmaTiC - iDLEr pC bOarD (G4828) NOTE: This diagram is for reference only. It may not be accurate for all machines covered by this manual. SaE-300 ®...

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