Engine Break-In; Welder Operation; Duty Cycle; Current Control - Lincoln Electric GENUINE SAE-300 Service Manual

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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, wet stacking (oil or tar like substance
at the exhaust port), or excessive smoke is not normal.
Larger machines with a capacity of 350 amperes and
higher, which are operated at low or no-load conditions
for extended periods of time are especially susceptible
to the conditions described above. To accomplish suc-
cessful engine break-in, most diesel-powered equip-
ment needs only to be run at a reasonably heavy load
within the rating of the welder for some period of time
during the engine's early life. However, if the welder is
subjected to extensive light loading, occasional moder-
ate to heavy loading of the engine may sometimes be
necessary. Caution must be observed in correctly
loading a diesel/generator unit.
1. Connect the welder output studs to a suitable
resistive load bank. Note that any attempt to short
the output studs by connecting the welding leads
together, direct shorting of the output studs, or
connecting the output leads to a length of steel will
result in catastrophic damage to the generator and
voids the warranty.
2. Set the welder controls for an output current and
voltage within the welder rating and duty cycle.
Note that any attempt to exceed the welder rating
or duty cycle for any period of time will result in
catastrophic damage to the generator and voids
the warranty.
3. Periodically shut off the engine and check the
crankcase oil level.

WELDER OPERATION

WARNING
ELECTRIC SHOCK can kill.
• Do not touch electrically live parts or
electrode with skin or wet clothing.
• Insulate yourself from work and ground.
------------------------------------------------------------------------
FUMES & GASES can be dangerous.
• Keep your head out of the fumes.
• Use ventilation or exhaust to remove
fumes from breathing zone.
------------------------------------------------------------------------
WELDING SPARKS can cause fire or
explosion.
• Keep flammable material away.
------------------------------------------------------------------------
ARC RAYS can burn.
• Wear eye, ear and body protection.
----------------------------------------------------------------------
OPERATION

DUTY CYCLE

The NEMA output rating of the SAE-300
amperes at 32 arc volts on a 60% duty cycle (consult
Specifications in this manual for alternate ratings).
Duty cycle is based on a ten minute period; thus, the
welder can be loaded at rated output for six minutes
out of every ten minute period.

CURRENT CONTROL

Do not adjust the "Current Control" while welding
because this can damage the control.
------------------------------------------------------------------------
The "Coarse Current Control" is the main Current
Adjuster. The "Fine Current Control" adjusts the cur-
rent from minimum to maximum. Open circuit voltage
is also controlled by the "Fine Current Control" permit-
ting control of the arc characteristics.
A high open circuit voltage setting provides the soft
"buttering" arc with best resistance to pop-outs pre-
ferred for most welding. To get this characteristic, set
the "Coarse Current Control" to the lowest setting that
still provides the current you need and set the "Fine
Current Control" near maximum.
When a forceful "digging" arc is required, usually for
vertical and overhead welding, use a higher "Coarse
Current Control" setting and lower open circuit voltage.
Some arc instability may be experienced with EXX10
electrodes when trying to operate with long arc tech-
niques at settings at the lower end of the open circuit
voltage range.

STICK / TIG WELDING

Start by setting the right-side Fine Current and OCV
control dial to 60, then set the left-side Coarse Current
control dial to the desired current using the dial mark-
ings as an approximate guideline. Arc characteristics
and small changes in output can then be adjusted
using the Fine Current and OCV control dial. A K924-4
Remote Control unit can also be used as the Fine
Control and OCV control dial.
SELF-SHIELDED FLUx-CORED
WELDING
(with a K623-1 Wire Feed Module installed)
Start by setting the Wire (CV) / Stick (CC) toggle switch
to the Wire (CV) position. Then set the left-side Coarse
Current control dial to 270. Now move the Voltage
Adjustment dial to the desired voltage.
Coarse Current control to the left for a softer arc and to
the right for a crisper arc.
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SAE-300 ®
®
CAUTION
Move the
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