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RETURN TO MAIN MENU
SAE-300
®
July, 2011
For Machines with Code Numbers 11645
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 READ-
ING THIS MANUAL AND THE
SAFETY PRECAUTIONS CON-
TAINED THROUGHOUT. And,
most importantly, think before
you act and be careful.
OPERATOR'S MANUAL
Copyright © Lincoln Global Inc.
• World's Leader in Welding and Cutting Products •
• Sales and Service through Subsidiaries and Distributors Worldwide •
Cleveland, Ohio 44117-1199 U.S.A. TEL: 216.481.8100 FAX: 216.486.1751 WEB SITE: www.lincolnelectric.com
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Table of Contents
Troubleshooting
Related Manuals for Lincoln Electric SAE-300
Summary of Contents for Lincoln Electric SAE-300
- Page 1 RETURN TO MAIN MENU SAE-300 ® July, 2011 For Machines with Code Numbers 11645 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 ...
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Page 2: California Proposition 65 Warnings
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. -
Page 3: Electric Shock Can Kill
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. - Page 4 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 materials from welding can easily go through small cracks and openings to adjacent areas.
- Page 5 PRÉCAUTIONS DE SÛRETÉ Pour votre propre protection lire et observer toutes les instructions et les précautions de sûreté specifiques qui parraissent dans ce manuel aussi bien que les précautions de sûreté générales suiv- antes: Sûreté Pour Soudage A LʼArc 1. Protegez-vous contre la secousse électrique: a.
- Page 6 Electric for advice or information about their use of our products. We respond to our customers based on the best information in our posses- sion at that time. Lincoln Electric is not in a position to warrant or guarantee such advice, and assumes no liability, with respect to such infor- mation or advice.
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Page 7: Table Of Contents
Purging Air from Fuel System...D-2 Engine Service Chart ...D-3 GFCI Testing and Resetting Procedure ...D-4 ________________________________________________________________________ Troubleshooting ...Section E Safety Precautions...E-1 Welder Troubleshooting ...E-2 Electronic Idler Troubleshooting Guide...E-3,E-4 Engine Troubleshooting Guide ...E-5, E-6, E-7 ________________________________________________________________________ Diagrams ...Section F Wiring Diagrams ...F-1, F-2 Dimension Print...F-3... -
Page 8: Installation
TECHNICAL SPECIFICATIONS - SAE-300 Make/Model Description 4 Cylinder 4 Cycle Perkins Naturally Aspirated 404D-22 Water-Cooled Diesel Engine Cast Iron Cylinder, Tier 4 interim Block/Crankcase Compliant RATED OUTPUT @ 104°F(40°C) - WELDER DESCRIPTION 300 Amp DC Welder All Copper Windings Pure DC Power Generator RATED OUTPUT @ 104°F(40°C) - GENERATOR... -
Page 9: General Description
With the addition of the option- al K623-1 Wire Feed Module ™ , the SAE-300 constant voltage output for running the LN-7, LN-23P, or LN-25 wire feeders. (The Wire Feed Module is factory installed on the K1643-8). -
Page 10: Pre-Operation Installation
Leaving the doors open changes the designed air flow and may cause overheating. The welder should be located to provide an unrestrict- ed flow of clean, cool air. Also, locate the welder so that engine exhaust fumes are properly vented to an outside area. -
Page 11: Vehicle Mounting
When welding at a considerable distance from the welder, be sure you use ample sized welding cables. RECOMMENDED COPPER CABLE SIZES Cables Sizes for Combined Length of Electrode Plus Work Cable... -
Page 12: Battery Charging
Connecting a battery charger - remove the bat- tery from the welder by disconnecting the nega- tive cable first, then the positive cable and bat- tery clamp. When reinstalling, connect the neg- ative cable last. -
Page 13: Electrical Devices Use With This Product
Computers, high resolution TV sets, Capacitive / Inductive complicated electrical equipment. The Lincoln Electric Company is not responsible for any damage to electrical components improperly connected to this product. INSTALLATION CAUTION TABLE A.1 Possible Concerns... -
Page 14: Operation
------------------------------------------------------------------------ Operate the welder with the doors closed. Leaving the doors open changes the designed air flow and can cause overheating. STARTING THE SAE-300 ® 404D-22 DIESEL ENGINE Turn the “IDLER” switch to “HIGH”. Turn the “IGNITION” switch to “ON”. -
Page 15: Welder Operation
---------------------------------------------------------------------- OPERATION DUTY CYCLE The NEMA output rating of the SAE-300 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. -
Page 16: Idler Operation
Allow it to run at high idle speed for several minutes to warm the engine. See Specifications for operating speeds. The idler is controlled by the “Idler” toggle switch on the welder control panel. The switch has two posi- tions as follows: SAE-300 TYPICAL FUEL CONSUMPTION DATA Low Idle (1375 RPM)-No Load @ 45 Volts High Idle (1800 RPM)-No Load @ 96.6 Volts... -
Page 17: Accessories
(Field Installed) GENERAL OPTIONS WARNING Pipe Thawing with an arc welder can cause fire, explosion, damage to electric wiring or to the arc welder if done improperly. The use of an arc welder for pipe thawing is not approved by the CSA, nor is it recommended or supported by Lincoln Electric. - Page 18 Provides control of wire speed and gas flow. Input Cable K691-10 ( For SG Control Module) For Lincoln engine drives with 14-pin MS-type con- nection, separate 115V NEMA receptacle and output stud connections. 10 ft. length. K2652-2-10-45 SAE-300 ®...
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Page 19: Maintenance
----------------------------------------------------------- GENERAL INSTRUCTIONS 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. -
Page 20: Idler Maintenance
2. Idler solenoid is activated for low idle. 3. If desired, the welder can be used without automat- ic idling by setting the “Idler” switch to the “High” position. NAMEPLATES... -
Page 21: Engine Service Chart
MAINTENANCE ITEM TYPE OR QUANTITY 50/50 Water/Ethylene Glycol 9.5qt., 9.0L 8.45qt., 8L (refill amount) Perkins #140517050 Lincoln #M20840-A Perkins #130366120 Perkins #080109107 Donaldson #P821575 Intake .008”, exhaust .008” Contact P erkins C = Clean R = Replace SAE-300 ® S26354 VM... -
Page 22: Gfci Testing And Resetting Procedure
"Test" button is pushed, the GFCI is not working prop- erly or has been incorrectly installed (miswired). If your GFCI is not working properly, contact a qualified, certified electrician who can assess the situation, rewire the GFCI if necessary or replace the device. MAINTENANCE RESETTING SAE-300 ®... -
Page 23: Troubleshooting
HOW TO USE TROUBLESHOOTING GUIDE 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 24 9. “Current Control” brush holder support stud and mating contact surfaces may be dirty or pitted and burned. CAUTION SAE-300 ® RECOMMENDED COURSE OF ACTION If all recommended possible areas of misadjustment have been checked...
- Page 25 CAUTION SAE-300 ® RECOMMENDED COURSE OF ACTION If all recommended possible areas of misadjustment have been checked...
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Page 26: Electronic Idler Troubleshooting Guide
Local Lincoln Authorized Field Service Facility for technical troubleshooting assistance before you proceed. TROUBLESHOOTING Set Idler Control Switch to the Auto Position Check for Continuity through Idler Control Switch 12 VDC Check for Jamming of the Idler Solenoid Mechanism Closed Replace Reed Switch CAUTION SAE-300 ® Closed Replace Idler Control Switch... - Page 27 Solenoid Mechanism, or broken return spring. 2. Check for Continuity of Current Transformer (Toroid). Replace as Required. Speed 3. Check Idler Circuit Wiring and Repair as Required. 4. Replace Idler P.C. Board. CAUTION SAE-300 ® Power Load Too Small Try Load Above 150 Watts...
- Page 28 Engine itself defective. Lack of fuel in the fuel tank. Clogged fuel filter. Air mixed in the fuel system. Faulty function of the engine. CAUTION SAE-300 ® RECOMMENDED COURSE OF ACTION If all recommended possible areas of misadjustment have been...
- Page 29 Replace the switch. Oil leakage from the lubricating system Inspect and retighten. Clogged oil filter Replace with new one. Oil too light Drain and refill with proper grade. Faulty Idler/Engine Protection P.C. Board. Replace. CAUTION SAE-300 ® RECOMMENDED COURSE OF ACTION...
- Page 30 Resetting Procedure” in the Maintenace Section of this Manual. Faulty connections to auxiliary receptacles. Check connections CAUTION SAE-300 ® RECOMMENDED COURSE OF ACTION If all recommended possible areas of misadjustment have been checked and the problem persists, Contact your local Lincoln...
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Page 31: Diagrams
DIAGRAMS Enhanced Diagram SAE-300 ®... - Page 32 DIAGRAMS SAE-300 ®...
- Page 33 WARNING Spanish AVISO DE PRECAUCION French ATTENTION German WARNUNG Portuguese ATENÇÃO Japanese Chinese Korean Arabic...
- Page 34 Spanish PRECAUCION French ATTENTION German WARNUNG Portuguese Japanese Chinese Korean Arabic WARNING AVISO DE ATENÇÃO...
- Page 35 • World's Leader in Welding and Cutting Products • • Sales and Service through Subsidiaries and Distributors Worldwide • Cleveland, Ohio 44117-1199 U.S.A. TEL: 216.481.8100 FAX: 216.486.1751 WEB SITE: www.lincolnelectric.com...