Page 2 - SAFETY; WARNING; CALIFORNIA PROPOSITION 65 WARNINGS; The Above For Diesel Engines
FOR ENGINEpowered 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....
Page 3 - ii
ARC RAYS can burn. 4.a. Use a shield with the proper filter and cover plates to protect your eyes from sparks andthe rays of the arc when welding or observingopen arc welding. Headshield and filter lensshould conform to ANSI Z87. I standards. 4.b. Use suitable clothing made from durable flame-resist...
Page 4 - iii; Refer to
FOR ELECTRICALLYpowered equipment. 8.a. Turn off input power using the disconnect switch at the fuse box before working onthe equipment. 8.b. Install equipment in accordance with the U.S. National Electrical Code, all local codes and the manufacturer’srecommendations. 8.c. Ground the equipment in ac...
Page 5 - iv; PRÉCAuTIONS DE SÛRETÉ
iv SAFETY iv Mar ‘93 PRÉCAuTIONS DE SÛRETÉ Pour votre propre protection lire et observer toutes les instructionset les précautions de sûreté specifiques qui parraissent dans cemanuel aussi bien que les précautions de sûreté générales suiv-antes: Sûreté Pour Soudage A L’Arc 1. Protegez-vous contre la...
Page 6 - Thank You; Please Examine Carton and Equipment For Damage Immediately
v v Thank You for selecting a QuALITY product by Lincoln Electric. We want you to take pride in operating this Lincoln Electric Company product••• as much pride as we have in bringing this product to you! Read this Operators Manual completely before attempting to use this equipment. Save this manual...
Page 7 - TAbLE OF CONTENTS
vi vi TAbLE OF CONTENTS Page Installation .......................................................................................................Section A Technical Specifications ........................................................................................A-1General Description ............
Page 8 - INSTALLATION; INPuT - DIESEL ENGINE
A-1 INSTALLATION SAE-300® A-1 TEChNICAL SPECIFICATIONS - SAE-300® Make/Model Description Speed (RPM) Displacement Starting Dry 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) 404...
Page 9 - GENERAL DESCRIPTION; DESIGN FEATuRES
A-2 INSTALLATION SAE-300® A-2 GENERAL DESCRIPTION The SAE-300® is a heavy duty, engine driven, DC arc weld-ing power source, capable of providing constant current out-put for stick welding or DC TIG welding. This welder iswound with all copper coils, rated at 300 amps/32 Volts, andprovides other Cla...
Page 10 - P R E - O P E R AT I O N I N S TA L L AT I O N
A-3 INSTALLATION SAE-300® A-3 P R E - O P E R AT I O N I N S TA L L AT I O N ExhAuST SPARK ARRESTER Some federal, state or local laws may require thatengines be equipped with exhaust spark arresterswhen they are operated in certain locations whereunarrested sparks may present a fire hazard. Thestand...
Page 12 - bATTERY ChARGING; NEGATIVE GROuND; To prevent ExPLOSION when:; c) using a booster - connect the positive lead to; To prevent ELECTRICAL DAMAGE when:; • To prevent bATTERY buCKLING, tighten nuts on
A-5 INSTALLATION SAE-300® A-5 bATTERY ChARGING The SAE-300® is equipped with a wet charged bat-tery. The charging current is automatically regulatedwhen the battery is low (after starting the engine) to atrickle current when the battery is fully charged. When replacing, jumping or otherwise connecti...
Page 13 - OPERATION; ENGINE OPERATION; See additional warning information at the
b-1 OPERATION b-1 ENGINE OPERATION Operate the welder with the doors closed. Leavingthe doors open changes the designed air flow and cancause overheating. STARTING ThE SAE-300® 404D-22 DIESELENGINE 1. Turn the “IDLER” switch to “HIGH”. 2. Turn the “IGNITION” switch to “ON”. 3. Press the Glow Plug bu...
Page 14 - WELDER OPERATION; DuTY CYCLE
b-2 OPERATION b-2 SAE-300® ENGINE bREAK-IN Lincoln Electric selects high quality, heavy-duty industrialengines for the portable welding machines we offer.While it is normal to see a small amount of crankcase oilconsumption during initial operation, excessive oil use,wet stacking (oil or tar like sub...
Page 15 - AuxILIARY POWER; TYPICAL FuEL CONSuMPTION DATA; CARbON ARC GOuGING
b-3 OPERATION b-3 1. In the “High” position, the idler solenoidd e a c t i v a t e s , a n d t h e e n g i n e g o e s t o h i g h i d l espeed. The speed is controlled by the governor. 2. In the “Auto” / position, the idler oper-ates as follows: a. When welding or drawing power for lights or tools(...
Page 16 - ACCESSORIES; OPTIONAL FEATuRES
C-1 ACCESSORIES C-1 SAE-300® OPTIONAL FEATuRES (Field Installed) GENERAL OPTIONS Pipe Thawing with an arc welder can cause fire,explosion, damage to electric wiring or to the arcw e l d e r i f d o n e i m p r o p e r l y . T h e u s e o f a n a r cwelder for pipe thawing is not approved by theC S A...
Page 17 - WIRE FEEDER OPTIONS; Magnum® PRO 350 Ready-Pak®; SG Control Module K488 (For Magnum Spool Gun)
C-2 ACCESSORIES C-2 WIRE FEEDER OPTIONS Wire Feed Module K623-1 Provides constant voltage (CV) output with improvedarc stability for Innershield welding. Excellent for MIGwelding. Recommended wire feeders are the LN-7,LN-23P and LN-25. Remote Control Kit K2464-1 (Stick & Wire) For Classic® and P...
Page 18 - MAINTENANCE; SAFETY PRECAuTIONS; S e e a d d i t i o n a l w a r n i n g i n f o r m a t i o n a t
D-1 MAINTENANCE D-1 SAFETY PRECAuTIONS GENERAL INSTRuCTIONS 1. Blow out the welder and controls with an air hose atleast once every two months. In particularly dirtylocations, this cleaning may be necessary once aweek. Use low pressure air to avoid driving dirt intothe insulation. 2 . Follow the eng...
Page 19 - IDLER MAINTENANCE; negative; NAMEPLATES; CAuTION; Vent Screw
D-2 MAINTENANCE D-2 Replace brushes when they wear within 1/4” of thepigtail. A complete set of replacement brushes shouldbe kept on hand. Lincoln brushes have a curved faceto fit the commutator. Have an experienced mainte-nance man seat these brushes by lightly stoning thecommutator as the armature...
Page 21 - G F C I
D-4 MAINTENANCE D-4 G F C I T E S T I N G A N D R E S E T T I N G PROCEDuRE The GFCI should be properly tested at least onceevery month or whenever it is tripped. To properly testand reset the GFCI : • If the GFCI has tripped, first carefully remove any load and check it for damage. • If the equipme...
Page 22 - TROubLEShOOTING; Local Lincoln Authorized Field Service Facility; hOW TO uSE TROubLEShOOTING GuIDE
E-1 TROubLEShOOTING SAE-300® E-1 If for any reason you do not understand the test procedures or are unable to perform the tests/repairs safely, contact your Local Lincoln Authorized Field Service Facility for technical troubleshooting assistance before you proceed. CAuTION have qualified personnel d...
Page 23 - PRObLEMS; Contact
SAE-300® E-2 TROubLEShOOTING E-2 Observe all Safety Guidelines detailed throughout this manual If for any reason you do not understand the test procedures or are unable to perform the tests/repairs safely, contact your Local Lincoln Authorized Field Service Facility for technical troubleshooting ass...
Page 25 - ELECTRONIC IDLER TROubLEShOOTING GuIDE
E-3 TROubLEShOOTING SAE-300® E-3 ELECTRONIC IDLER TROubLEShOOTING GuIDE With Idler Control Switch in the Auto Position, Engine Will Not Return to Low Idle in Approximately 15 Seconds After Welding and Auxiliary Loads are Removed Set Idler Control Switch to the Auto Position Check for Continuity thro...
Page 27 - does
E-5 TROubLEShOOTING SAE-300® E-5 If for any reason you do not understand the test procedures or are unable to perform the tests/repairs safely, contact your Local Lincoln Authorized Field Service Facility for technical troubleshooting assistance before you proceed. CAuTION Observe all Safety Guideli...
Page 30 - DIAGRAMS
F-1 DIAGRAMS F-1 SAE-300® NOTE: This diagram is for reference only. It may not be accurate for all machines covered by this manual. The specific diagram for a particular code is pasted inside the machine on one of the enclosure panels. If the diagram is illegible, write to the Service Department for...