Lincoln Electric IM10155 User Manual

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Operator’s Manual

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SAE-300 ® HE

For use with machines having Code Numbers:

11907

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Date Purchased

Code: (ex: 10859)

Serial: (ex: U1060512345)

IM10155 | Issue D ate Oct-13

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Page 2

THANK YOU FOR SELECTING

AT ALL

TIMES.

SPECIAL SITUATIONS

Additional precautionary measures

A QUALITY PRODUCT BY LINCOLN ELEC TRIC.

PLEASE EXAMINE CARTON AND EQUIPMENT FOR DAMAGE IMMEDIATELY

When this equipment is shipped, title passes to the purchaser upon receipt by the carrier. Consequently, Claims for material damaged in shipment must be made by the purchaser against the transportation company at the time the shipment is received.

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 READING THIS MANUAL AND THE SAFETY PRECAUTIONS CONTAINED THROUGHOUT. And, most importantly, think before you

act and be careful.

WARNING

This statement appears where the information must be followed exactly to avoid serious personal injury or loss of life.

CAUTION

This statement appears where the information must be followed to avoid minor personal injury or damage to this equipment.

KEEP YOUR HEAD OUT OF THE FUMES.

DON’T get too close to the arc. Use

corrective lenses if necessary to stay a reasonable distance away from the arc.

READ and obey the Material Safety

Data Sheet (MSDS) and the warning label that appears on all containers of welding materials.

USE ENOUGH VENTILATION or

exhaust at the arc, or both, to keep the fumes and gases from your breathing zone and the general area.

IN A LARGE ROOM OR OUTDOORS, natural ventilation may be

adequate if you keep your head out of the fumes (See below).

USE NATURAL DRAFTS or fans to keep the fumes away from your

face.

If you de velop unusual symptoms, see your supervisor. Perhaps the welding atmosphere and ventilation system should be checked.

WEAR CORRECT EYE, EAR & BODY PROTECTION

PROTECT your eyes and face with welding helmet

properly fitted and with proper grade of filter plate (See ANSI Z49.1).

PROTECT your body from welding spatter and arc

flash with protective clothing including woolen clothing, flame-proof apron and gloves, leather leggings, and high boots.

PROTECT others from splatter, flash, and glare with

protective screens or barriers.

IN SOME AREAS, protection from noise may be

appropriate.

BE SURE protective equipment is in good condition.

Also, wear safety glasses in work area

DO NOT WELD OR CUT containers or materials which previously had

been in contact with hazardous substances unless they are properly cleaned. This is extremely dangerous.

DO NOT WELD OR CUT painted or plated parts unless special

precautions with ventilation have been taken. They can release highly toxic fumes or gases.

PROTECT compressed gas cylinders from excessive heat, mechanical

shocks, and arcs; fasten cylinders so they cannot fall.

BE SURE cylinders are never grounded or part of an electrical circuit. REMOVE all potential fire hazards from welding area. ALWAYS HAVE FIRE FIGHTING EQUIPMENT READY FOR

IMMEDIATE USE AND KNOW HOW TO USE IT.

Page 3

SECTION A:

WARNINGS

CALIFORNIA PROPOSITION 65 WARNINGS

Diesel Engines

Diesel engine exhaust and some of its constituents are known to the State of California to cause cancer, birth defects, and other reproductive harm.

Gasoline Engines

The engine exhaust from this product contains chemicals known to the State of California to cause cancer, birth defects, or other reproductive harm.

ARC WELDING CAN BE HAZARDOUS. PROTECT YOURSELF AND OTHERS FROM POSSIBLE SERIOUS INJURY OR DEATH. KEEP CHILDREN AWAY. PACEMAKER WEARERS SHOULD CONSULT WITH THEIR DOCTOR BEFORE OPERATING.

Read and understand the following safety highlights. For additional safety information, it is strongly recommended that you purchase a copy of “Safety in Welding & Cutting - ANSI Standard Z49.1” from the American Welding Society, P.O. Box 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.

SAFETY

1.d. Keep all equipment safety guards, covers and devices in position and in good repair.Keep hands, hair, clothing and tools away from V-belts, gears, fans and all other moving parts when starting, operating or repairing equipment.

1.e. In some cases it may be necessary to remove safety guards to perform required maintenance. Remove guards only when necessary and replace them when the maintenance requiring their removal is complete. Always use the greatest care when working near moving parts.

1.f. Do not put your hands near the engine fan. Do not attempt to override the governor or idler by pushing on the throttle control rods while the engine is running.

1.g. To prevent accidentally starting gasoline engines while turning the engine or welding generator during maintenance work, disconnect the spark plug wires, distributor cap or magneto wire as appropriate.

1.h. To avoid scalding, do not remove the radiator pressure cap when the engine is

hot.

ELECTRIC AND MAGNETIC FIELDS MAY BE DANGEROUS

2.a. Electric current flowing through any conductor causes localized Electric and Magnetic Fields (EMF). Welding current creates EMF fields around welding cables and welding machines

FOR ENGINE POWERED 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.

1.c. Do not add the fuel near an open flame welding arc or when the engine is running. Stop the engine and allow it to cool before refueling to prevent spilled fuel from vaporizing on contact with hot engine parts and igniting. Do not spill fuel when filling tank. If fuel is spilled, wipe it up and do not start engine until fumes have been eliminated.

2.b. EMF fields may interfere with some pacemakers, and welders having a pacemaker should consult their physician before welding.

2.c. Exposure to EMF fields in welding may have other health effects which are now not known.

2.d. All welders should use the following procedures in order to minimize exposure to EMF fields from the welding circuit:

2.d.1. Route the electrode and work cables together - Secure them with tape when possible.

2.d.2. Never coil the electrode lead around your body.

2.d.3. Do not place your body between the electrode and work cables. If the electrode cable is on your right side, the work cable should also be on your right side.

2.d.4. Connect the work cable to the workpiece as close as possible to the area being welded.

2.d.5. Do not work next to welding power source.

Page 4

SAFETY

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.

3.b. Insulate yourself from work and ground using dry insulation. Make certain the insulation is large enough to cover your full area of physical contact with work and ground.

In addition to the normal safety precautions, if welding must be performed under electrically hazardous conditions (in damp locations or while wearing wet clothing; on metal structures such as floors, gratings or scaffolds; when in cramped positions such as sitting, kneeling or lying, if there is a high risk of unavoidable or accidental contact with the workpiece or ground) use the following equipment:

• Semiautomatic DC Constant Voltage (Wire) Welder.

• DC Manual (Stick) Welder.

• AC Welder with Reduced Voltage Control.

3.c. In semiautomatic or automatic wire welding, the electrode, electrode reel, welding head, nozzle or semiautomatic welding gun are also electrically “hot”.

3.d. Always be sure the work cable makes a good electrical connection with the metal being welded. The connection should be as close as possible to the area being welded.

3.e. Ground the work or metal to be welded to a good electrical (earth) ground.

3.f. Maintain the electrode holder, work clamp, welding cable and welding machine in good, safe operating condition. Replace damaged insulation.

3.g. Never dip the electrode in water for cooling.

3.h. Never simultaneously touch electrically “hot” parts of electrode holders connected to two welders because voltage

two can be the total of the open circuit voltage of both welders.

3.i. When working above floor level, use a safety belt to protect yourself from a fall should you get a shock.

between the

ARC RAYS CAN BURN.

4.a. Use a shield with the proper filter and cover plates to protect your eyes from sparks and the rays of the arc when welding or observing open arc welding. Headshield and filter lens should conform to ANSI Z87. I standards.

4.b. Use suitable clothing made from durable flame-resistant material to protect your skin and that of your helpers from the arc rays.

4.c. Protect other nearby personnel with suitable, non-flammable screening and/or warn them not to watch the arc nor expose themselves to the arc rays or to hot spatter or metal.

FUMES AND GASES CAN BE DANGEROUS.

5.a. Welding may produce fumes and gases hazardous to health. Avoid breathing these fumes and gases. When welding, keep your head out of the fume. Use enough ventilation and/or exhaust at the arc to keep fumes

and gases away from the breathing zone. When welding

with electrodes which require special ventilation such as stainless or hard facing (see instructions on container or MSDS) or on lead or cadmium plated steel and other metals or coatings which produce highly toxic fumes, keep exposure as low as possible and within applicable OSHA PEL and ACGIH TLV limits using local exhaust or mechanical ventilation. In confined spaces or in some circumstances, outdoors, a respirator may be required. Additional precautions are also required when welding on galvanized steel.

5. b. The operation of welding fume control equipment is affected by various factors including proper use and positioning of the equipment, maintenance of the equipment and the specific welding procedure and application involved. Worker exposure level should be checked upon installation and periodically thereafter to be certain it is within applicable OSHA PEL and ACGIH TLV limits.

5.c. Do not weld in locations near chlorinated hydrocarbon vapors coming from degreasing, cleaning or spraying operations. The heat and rays of the arc can react with solvent vapors to form phosgene, a highly toxic gas, and other irritating products.

3.j. Also see It ems 6.c. and 8.

5.d. Shielding gases used for arc welding can displace air and

injury or death. Always use enough ventilation, especially in confined areas, to insure breathing air is safe.

5.e. Read and understand the manufacturer’s instructions for this

equipment and the consumables to be used, including the material safety data sheet (MSDS) and follow your employer’s safety practices. MSDS forms are available from your welding distributor or from the manufacturer.

5.f. Also see item 1.b.

cause

Page 5

SAFETY

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 sparks and hot materials from welding can easily go through small cracks and openings to adjacent areas. Avoid welding near hydraulic lines. Have a fire extinguisher readily available.

6.b. Where compressed gases are to be used at the job site, special precautions should be used to prevent hazardous situations. Refer to “Safety in Welding and Cutting” (ANSI Standard Z49.1) and the operating information for the equipment being used.

6.c. When not welding, make certain no part of the electrode circuit is touching the work or ground. Accidental contact can cause overheating and create a fire hazard.

6.d. Do not heat, cut or weld tanks, drums or containers until the proper steps have been taken to insure that such procedures will not cause flammable or toxic vapors from substances inside. They can cause an explosion even though they have been “cleaned”. For information, purchase “Recommended Safe Practices for the Preparation for Welding and Cutting of Containers and Piping That Have Held Hazardous Substances”, AWS F4.1 from the American Welding Society (see address above).

6.e. Vent hollow castings or containers before heating, cutting or welding. They may explode.

6.f. Sparks and spatter are thrown from the welding arc. Wear oil free protective garments such as leather gloves, heavy shirt, cuffless trousers, high shoes and a cap over your hair. Wear ear plugs when welding out of position or in confined places. Always wear safety glasses with side shields when in a welding area.

6.g. Connect the work cable to the work as close to the welding area as practical. Work cables connected to the building framework or other locations away from the welding area increase the possibility of the welding current passing through lifting chains, crane cables or other alternate circuits. This can create fire hazards or overheat lifting chains or cables until they fail.

6.h. Also see item 1.c.

CYLINDER MAY EXPLODE IF DAMAGED.

7.a. Use only compressed gas cylinders containing the correct shielding gas for the process used and properly operating regulators designed for the gas and pressure used. All hoses, fittings, etc. should be suitable for the application and maintained in good condition.

7.b. Always keep cylinders in an upright position securely chained to an undercarriage or fixed support.

7.c. Cylinders should be located:

• Away from areas where they may be struck or subjected to physical damage.

• A safe distance from arc welding or cutting operations and any other source of heat, sparks, or flame.

7.d. Never allow the electrode, electrode holder or any other electrically “hot” parts to touch a cylinder.

7.e. Keep your head and face away from the cylinder valve outlet when opening the cylinder valve.

7.f. Valve protection caps should always be in place and hand tight except when the cylinder is in use or connected for use.

7.g. Read and follow the instructions on compressed gas cylinders, associated equipment, and CGA publication P-l, “Precautions for Safe Handling of Compressed Gases in

Cylinders,” available from the Compressed Gas Association 1235 Jefferson Davis Highway, Arlington, VA 22202.

FOR ELECTRICALLY POWERED EQUIPMENT.

8.a. Turn off input power using the disconnect switch at the fuse box before working on the equipment.

8.b. Install equipment in accordance with the U.S. National Electrical Code, all local codes and the manufacturer’s recommendations.

6.I. Read and follow NFPA 51B “ Standard for Fire Prevention During Welding, Cutting and Other Hot Work”, available from NFPA, 1 Batterymarch Park, PO box 9101, Quincy, Ma 022690-9101.

6.j. Do not use a welding power source for pipe thawing.

8.c. Ground the equipment in accordance with the U.S. National Electrical Code and the manufacturer’s recommendations.

Refer to

http://www.lincolnelectric.com/safety

for additional safety information.

Welding Safety Interactive Web Guide for mobile devices

Page 6

3!&%49

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 suivantes:

Sûreté Pour Soudage A LʼArc

1. Protegez-vous contre la secousse électrique:

a. Les circuits à lʼélectrode et à la piéce sont sous tension

quand la machine à souder est en marche. Eviter toujours tout contact entre les parties sous tension et la peau nue ou les vétements mouillés. Porter des gants secs et sans trous pour isoler les mains.

b. Faire trés attention de bien sʼisoler de la masse quand on

soude dans des endroits humides, ou sur un plancher metallique ou des grilles metalliques, principalement dans les positions assis ou couché pour lesquelles une grande partie du corps peut être en contact avec la masse.

c. Maintenir le porte-électrode, la pince de masse, le câble

de soudage et la machine à souder en bon et sûr état defonctionnement.

d.Ne jamais plonger le porte-électrode dans lʼeau pour le

refroidir.

e. Ne jamais toucher simultanément les parties sous tension

des porte-électrodes connectés à deux machines à souder parce que la tension entre les deux pinces peut être le total de la tension à vide des deux machines.

f. Si on utilise la machine à souder comme une source de

courant pour soudage semi-automatique, ces precautions pour le porte-électrode sʼapplicuent aussi au pistolet de soudage.

6. Eloigner les matériaux inflammables ou les recouvrir afin de prévenir tout risque dʼincendie dû aux étincelles.

7. Quand on ne soude pas, poser la pince à une endroit isolé de la masse. Un court-circuit accidental peut provoquer un échauffement et un risque dʼincendie.

8. Sʼassurer que la masse est connectée le plus prés possible de la zone de travail quʼil est pratique de le faire. Si on place la masse sur la charpente de la construction ou dʼautres endroits éloignés de la zone de travail, on augmente le risque de voir passer le courant de soudage par les chaines de levage, câbles de grue, ou autres circuits. Cela peut provoquer des risques dʼincendie ou dʼechauffement des chaines et des câbles jusquʼà ce quʼils se rompent.

9. Assurer une ventilation suffisante dans la zone de soudage. Ceci est particuliérement important pour le soudage de tôles galvanisées plombées, ou cadmiées ou tout autre métal qui produit des fumeés toxiques.

10. Ne pas souder en présence de vapeurs de chlore provenant dʼopérations de dégraissage, nettoyage ou pistolage. La chaleur ou les rayons de lʼarc peuvent réagir avec les vapeurs du solvant pour produire du phosgéne (gas fortement toxique) ou autres produits irritants.

11. Pour obtenir de plus amples renseignements sur la sûreté, voir le code “Code for safety in welding and cutting” CSA Standard W 117.2-1974.

2. Dans le cas de travail au dessus du niveau du sol, se protéger contre les chutes dans le cas ou on recoit un choc. Ne jamais enrouler le câble-électrode autour de nʼimporte quelle partie du corps.

3. Un coup dʼarc peut être plus sévère quʼun coup de soliel, donc:

a. Utiliser un bon masque avec un verre filtrant approprié

ainsi quʼun verre blanc afin de se protéger les yeux du rayonnement de lʼarc et des projections quand on soude ou quand on regarde lʼarc.

b. Porter des vêtements convenables afin de protéger la

peau de soudeur et des aides contre le rayonnement de lʻarc.

c. Protéger lʼautre personnel travaillant à proximité au

soudage à lʼaide dʼécrans appropriés et non-inflammables.

4. Des gouttes de laitier en fusion sont émises de lʼarc de soudage. Se protéger avec des vêtements de protection libres de lʼhuile, tels que les gants en cuir, chemise épaisse, pantalons sans revers, et chaussures montantes.

5. Toujours porter des lunettes de sécurité dans la zone de soudage. Utiliser des lunettes avec écrans lateraux dans les zones où lʼon pique le laitier.

PRÉCAUTIONS DE SÛRETÉ POUR LES MACHINES À SOUDER À TRANSFORMATEUR ET À REDRESSEUR

1. Relier à la terre le chassis du poste conformement au code de lʼélectricité et aux recommendations du fabricant. Le dispositif de montage ou la piece à souder doit être branché à une bonne mise à la terre.

2. Autant que possible, Iʼinstallation et lʼentretien du poste seront effectués par un électricien qualifié.

3. Avant de faires des travaux à lʼinterieur de poste, la debrancher à lʼinterrupteur à la boite de fusibles.

4. Garder tous les couvercles et dispositifs de sûreté à leur place.

Page 7

SAE-300® HE

TABLE OF CONTENTS

Page

________________________________________________________________________

Installation .......................................................................................................Section A

Technical Specifications ........................................................................................A-1

General Description...............................................................................................A-2

Design Features ....................................................................................................A-2

Pre-Operation Installation......................................................................................A-3

Safety Precautions ..........................................................................................A-3

Exhaust Spark Arrester ...................................................................................A-3

Location/Ventilation.........................................................................................A-3

Angle of Operation ..........................................................................................A-4

Machine Grounding.........................................................................................A-4

Lift Bail ............................................................................................................A-4

Trailers ............................................................................................................A-4

Vehicle Mounting.............................................................................................A-5

Polarity Control and Cable Sizes ....................................................................A-5

Pre-Operation Service ...........................................................................................A-5

Oil, Fuel...........................................................................................................A-5

Cooling System ...............................................................................................A-5

Battery Charging .............................................................................................A-6

Electrical Devices use with this Product..........................................................A-7

________________________________________________________________________

Operation .........................................................................................................Section B

Engine Operation...................................................................................................B-1

Starting The Perkins Engine ...........................................................................B-1

High Altitude Operation, Stopping the engine .................................................B-1

Engine Break-In ..............................................................................................B-2

Welder Operation...................................................................................................B-2

Duty Cycle.......................................................................................................B-2

Current Control................................................................................................B-2

How to Set Controls for Stick Welding ............................................................B-3

Gas Shielding Flux Core Welding ...................................................................B-4

Idler Operation, Auxiliary Power, Fuel Consumption Data..............................B-4

________________________________________________________________________

Accessories.....................................................................................................Section C

Optional Features (Field Installed) ........................................................................C-1

________________________________________________________________________

Maintenance ....................................................................................................Section D

Safety Precautions ................................................................................................D-1

General Instructions ..............................................................................................D-1

Cooling System .....................................................................................................D-1

Bearings ................................................................................................................D-1

Commutator and Brushes .....................................................................................D-1

Nameplates ...........................................................................................................D-2

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 thru E-8

________________________________________________________________________

Diagrams ..........................................................................................................Section F

Wiring Diagrams ....................................................................................................F-1

Dimension Print......................................................................................................F-2

________________________________________________________________________

Parts List.................................................................................................................P-736

________________________________________________________________________

Page 8

INSTALLATIONSAE-300® HE

TECHNICAL SPECIFICATIONS - SAE-300®HE

INPUT - DIESEL ENGINE

Make/Model Description Speed (RPM) Displacement Starting Dry

System Capacities

3 Cylinder 91.47 cu. in

12VDC battery

Fuel: 16 gal.

24.7 HP(18.4kW) (1.5 ltrs) (Group 24, 650 60.6 L.

PERKINS TURBO High Idle 1800 cold crank amps) 403F-15T CHARGED Low Idle 1440 Bore x Stroke

EPA DIESEL Full Load 1800 6.0 L.

Tier 4 ENGINE 3.3” x 3.5”

Compliant (84mm x 90mm)

2.0 KW

Starter Oil: 6.34 Qtrs.

Coolant: 7.76 Qts.

65 A. Alternator

w/ built in reg.

RATED OUTPUT @ 104°F(40°C) - WELDER

DESCRIPTION RATED DC OUTPUT * Duty

VOLTS @ RATED AMPS CYCLE

300 Amp DC Welder 30V @ 250A 100% All Copper Windings 32V @ 300A 60%

Pure DC Power Generator 90V DC Max. OCV @ 1800RPM

RATED OUTPUT @ 104°F(40°C) - GENERATOR

Auxiliary Power

3,000 Watts Continuous, 60 Hz AC

26 Amps @ 120V 13 Amps @ 240V

PHYSICAL DIMENSIONS

MODEL HEIGHT WIDTH DEPTH WEIGHT

(1)

(2)

7.3 L.

K3202-1 45.5 in.

(2)

24.3 in. 62.8 in. 1419 lbs.

CSA Without (1156 mm) (616 mm) (1594 mm ) (644 kg.)

Wire Feed Module

* Based on a 10 min. period.

(1)

Output rating in watts is equivalent to volt-amperes at unity power factor. Output voltage is within ± 10% at all loads up to rated capacity. When welding, available auxiliary power will be reduced.

(2)

Height to top of exhaust elbow.

A-1

Page 9

INSTALLATIONSAE-300® HE

GENERAL DESCRIPTION

DESIGN FEATURES

Control Panel

All Copper Windings

Engine Idler

Auxiliary Pow er

GFCI Maintenance Section

120 V DUPLEX RECEP TACLE AND GFCI

The SAE-300®HE is a heavy duty, engine driven, DC arc welding power source, capable of providing constant current output for stick welding or DC TIG welding. This welder is wound with all copper coils, rated at 300 amps/32 Volts, and provides other

Classic hinges. With the addition of the optional K3964-1 Wire Feed

Module™, the SAE-300 for running the LN-7, LN-23P, or LN-25 wire feeders. The optional K924-5 Remote Control Kit, provides a remote control rheostat for remote fine current and open circuit voltage adjustment. See Section C for description.

The SAE-300 In the event of sudden low oil pressure or high coolant tempera-

ture, the engine immediately shuts down. The SAE-300 a current range of 40-350 DC amps with output ratings as follows: These units are also capable of providing 3 KVA of 120/240 volts of 60 cycle AC auxiliary power.

The SAE-300 diesel engine.

features such as improved door latches and stainless

HE will provide constant voltage output

HE has an Electronic Engine Protection System.

HE uses the Perkins 403F-15T Turbo Charge

RATED OUTPUT DUTY CYCLE

250A @ 30V 300A @ 32V

100%

60%

HE has

- For long life and dependable operation.

- The SAE-300

HE is equipped with an electronic automatic engine idler. It automatically increases and decreases engine speed when starting and stopping welding or using auxiliary power.

A built-in time delay permits changing electrodes before the engine slows to its low idle speed. The “Idler” control switch on the panel locks the idler in high idle position when desired.

- 3.0 KVA of nominal 120/240V, 60Hz, AC. Output voltage is maintained within ± 10% at all loads up to rated capacity. (See Optional Features Section C for Power Plug Kit.)

Protects the 20 amp, 120V duplex receptacle. See the

for detailed information on testing and

resetting of the GFCI.

A GFCI protects the 120V auxiliary power receptacle.

A GFCI (Ground Fault Circuit Interrupter) is a device to protect against electric shock should a piece of defective equipment connected to it develop a ground fault. If this situation should occur, the GFCI will trip, removing voltage from the output of the receptacle. If a GFCI is tripped see the MAINTENANCE section for detailed information on testing and resetting it. A GFCI should be properly tested at least once every month.

The 120 V auxiliary power receptacle should only be used with three wire grounded type plugs or approved double insulated tools with two wire plugs. The current rating of any plug used with the system must be at least equal to the current capacity of the associated receptacle.

The welder controls consist of a Reactor and a “Fine Current Adjustment” rheostat located on the upper control panel at the exciter end of the machine. The lower control panel welder is equipped with a “Start” button, an “Ignition” switch, an “Idler” control switch, and a “Glow Plug” button for easier cold weather starting.

The lower control panel also contains an engine temperature gauge, a battery charging fault indicator, an oil pressure gauge, a fuel / hour / LED indicator gauge, temperature gauge, for auxiliary power consists of one 20 amp, 120VAC (5-20R) duplex receptacle with GFCI protection and one 15 amp, 240VAC (6-15R) receptacle, protected by 2 pole, 15 Amp breaker.

A-2

Page 10

INSTALLATIONSAE-300® HE

Welder Enclosure

Cranking System

Air Cleaner

Muffler

Fuel / Hour / LED gauge

Engine Protection -

Bat tery Charging Light

NOTE

Oil Drain Valve -

Remote Control

PRE-OPERATION INSTALLATION

EXHAUST SPARK ARRESTER

Use of an incorrect arrester ma y l ead to engine damage or performance loss. Contact t he engine manufacturer for specific recommendations.

LOCATION / VENTILATION

Do not attempt to use this equipment until you have thoroughly read the engine manufacturer’s manual supplied with your welder. It includes impo rt ant safety pr ecautions, detailed engine st arting, operating and maintenance instructions, and parts list s.

ELECTRIC SHOCK can kill.

• Do not touch electrically live parts or electrode with skin or wet clothing.

• Insulate yourself from work and ground

• Always wear dry insulating gloves.

ENGI NE EXHAUST can kill.

• Use in open, w ell venti lated area s o r v ent exhaust outside.

MOVING PARTS ca n injure.

• Do not operate with doors open or gu ards off.

• Stop engine before servicing.

• Keep aw ay from moving parts.

See additional warning information at the front of

this operator’s manual.

a rugged steel “C” channel base.

The output terminals are placed at the side of the machines so that they are protected by the door. The output terminals are labeled (+) and (-).

standard.

show fuel status, battery charging fault LED and engine fault LED.

event of sudden low oil pressure or high coolant temperature. A warning light on the control panel will indicate such a fault. To reset the engine for restarting, turn the ignition switch off then on. Refer to Troubleshooting section for all warning light fault codes.

battery charge. The light is off when the systems are functioning properly. The light will come on if there is a Low/No battery condition but the machine will continue to run.

“ON” position. It will come on during cranking and stay on until the engine starts. After, starting the engine the light will go off unless a Low/No battery condition exists.

are standard.

- A muffler and stainless steel exhaust outlet elbow are

: The light will come on when the Run/Stop switch is in the

- The complete welder is rubber mounted on

- A 12 volt electric starter is standard.

- Heavy duty two stage dry type.

- A meter to record hours of operation,

The system shuts the engine down in the

- A warning indicator light for Low/No

A ball valve, hose and clamp are standard.

- The Remote / Local Switch and Receptacle

WARNING

Some federal, state or local laws may require that engines be equipped with exhaust spark arresters when they are operated in certain locations where unarrested sparks may present a fire hazard. The standard muffler included with this welder does not qualify as a spark arrester. When required by local regulations, a suitable spark arrester must be installed and properly maintained.

CAUTION

Always operate the welder with the doors closed. Leaving the doors open changes the designed air flow and may cause overheating.

The welder should be located to provide an unrestricted flow of clean, cool air. Also, locate the welder so that engine exhaust

fumes are properly vented to an outside area.

A-3

Page 11

INSTALLATIONSAE-300® HE

LIFT BAIL

TRAILER (SEE OPTIONAL FEATURES)

DO NOT MOUNT OVER COMBUSTIB LE SURFACES.

Where there is a combusti ble surface directly under stationary or fix ed electrical equipment, the surf ace shall be covered with a steel plate at least .06” (1.6m m) thick, w hich shall extend not more than 5.90”(150mm) beyond the equipment on all sides.

MACHINE GROUNDING

ANGLE OF OPERATION

Engines are designed to run in the level condition which is where the optimum performance is achieved. The maximum angle of continuous operation is 25º degrees in all directions, 35º intermittent (less than 10 minutes continuous) in all directions.

CAUTION

According to the United States National Electrical Code, the frame of this portable generator is not required to be grounded and is permitted to serve as the grounding means for cord connected equipment plugged into its receptacle.

Some state, local, or other codes or unusual operating circumstances may require the machine frame to be grounded. It is recommended that you determine the extent to which such requirements may apply to your particular situation and follow them explicitly. A machine grounding stud marked with the symbol is provided on the welding generator frame foot. In general, if the machine is to be grounded, it should be connected with a #8 or larger copper wire to a solid earth ground such as a metal water pipe going into the ground for at least ten feet and having no insulated joints, or to the metal framework of a building which has been effectively grounded. The U.S. National Code lists a number of alternate means of grounding electrical equipment.

A lift bail is provided for lifting with a hoist.

WARNING

• Lift only with equipment of adequate lifting capacity.

• Be sure machine is stable when lifting.

• Do not lift this machine using lift bail if it is equipped with a heavy accessory such as trailer or gas cylinder.

FALLING • Do not lift machine if lift bail is

EQUIPMENT can damaged.

cause injury. • Do not operate machine while

suspended from lift bail.

If the user adapts a non-Lincoln trailer, he must assume responsibility that the method of attachment and usage does not result in a safety hazard nor damage the welding equipment. Some of the factors to be considered are as follows:

1. Design capacity of trailer vs. weight of Lincoln equipment and likely additional attachments.

2. Proper support of, and attachment to, the base of the welding equipment so there will be no undue stress to the framework.

3. Proper placement of the equipment on the trailer to ensure stability side to side and front to back when being moved and when standing by itself while being operated or serviced.

4. Typical conditions of use, i.e., travel speed, roughness of surface on which the trailer will be operated; environmental conditions, likely maintenance.

5. Conformance with federal, state and local laws. (1)

(1)

Consult your federal, state and local laws regarding specific

requirements for use on public highways.

A-4

Page 12

INSTALLATIONSAE-300® HE

OIL

FUEL

COOLING SYSTEM

POLARITY CONTROL AND CABLE SIZES

positive

“+”

Negative

“-”

VEHICLE MOUNTING

Improperly mounted concentrated loads may cause unstable vehicle handling and tires or other components to fail.

• Only transport this Equipment on serviceable vehicles which are rated and designed for such loads.

• Distribute, balance and secure loads so vehicle is stable under conditions of use.

• Do not exceed maximum rated loads for components such as suspension, ax les and tires.

• Use appropriate nuts bolts and lockwashers to attach the equipment base to the metal bed or frame of vehicle.

• Follow vehicle manufacturer’s instr uctions.

• Stop engine while fueling.

• Do not smoke when fueling.

• Keep sparks and flame away from tank .

• Do not leave unattended while fueling.

• Wipe up spilled fuel and allow fumes to clear before starting engine.

• Do not overfill tank, fuel expansion may cause overflow.

DIES EL FUEL ONL Y -L ow sulphur f u e l or ul t ra l ow s ul p hu r fu e l in U . S . A . an d Canada.

WARNING

With the engine off, route the electrode and work cables through the strain relief bracket on the base and connect to the studs located below the fuel tank mounting rail. (See size recommendations below.) For cable to the terminal marked nect the electrode cable to the should be checked periodically and tightened if necessary.

polarity, connect the electrode

. For

stud. These connections

polarity, con-

PRE-OPERATION SERVICE

CAUTION

READ the engine operating and maintenance instructions supplied with this machine.

WARNING

DIESEL FUEL

can

cause fire

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

Amps Duty Cycle Up to 200ft.(61m) 200 to 250ft.

(61 to 76m)

250 100% 1 1/0

300 60% 1/0 2/0

This unit is supplied from the factory with the engine crankcase filled with a high quality SAE 10W/30 oil. This oil should be acceptable for most typical ambient temperatures. Consult the engine operation manual for specific engine manufacturer’s recommendations. Upon receipt of the welder, check the engine dipstick to be sure the oil is at the “full” mark. DO NOT overfill.

Fill the fuel tank with the grade of fuel recommended in the Engine Operator’s manual. Make sure the fuel valve on the water separator is in the open position.

The radiator has been filled at the factory with a 50-50 mixture of ethylene glycol antifreeze and water. Check the radiator level and add a 50-50 solution as needed (see engine manual or antifreeze container for alternate antifreeze recommendations).

A-5

Page 13

BATTERY CHARGING

NEGATIVE GROUND

GASES FROM BATTER Y can explode.

• Keep sparks, flame and cigarettes away.

BATTER Y ACID can burn eyes and skin.

• Wear gloves and eye protection and be careful when boosting, cha rging or working near battery.

To prevent EXPLOSION when:

a) Installing a new battery - disconnect

thenegative cable from the old battery first and connect the negative cable to the new battery last.

b) Connecting a battery charger - remove the battery from

the welder by disconnecting the negative cable first, then the positive cable and battery clamp. When reinstalling, connect the negative cable last.

c) Using a booster - connect the positive lead to the battery

first, then connect the negative lead to the ground lead on the base.

To prevent ELECTRICAL DAMAGE when:

a) Installing a new battery. b) Using a boo ster.

Use correct polarity - Negative Ground.

To prevent BATTERY DISCHARGE, if you have an ignition switch, turn it off when engine is not running.

• To prevent BATTERY BUCKLING, tighten nuts on battery clamp until snug.

WARNING

INSTALLATIONSAE-300® HE

The SAE-300®HE is equipped with a wet charged battery. The charging current is automatically regulated when the battery is low (after starting the engine) to a trickle current when the battery is fully charged.

When replacing, jumping or otherwise connecting the battery to the battery cables, the proper polarity must be observed. This system is

A-6

Page 14

CAUTION

Certain Electrical devices cannot be powered to this Product. See Table A.1

TABLE A.1

ELECTRICAL DEVICE USE WITH THIS PRODUCT

INSTALLATIONSAE-300® HE

Type

Resistive

Capacitive

Inductive

Common Electrical Devices

Heaters, toasters, incandescent light bulbs, electric range, hot pan, skillet, coffee maker.

TV sets, radios, microwaves, appliances with electrical control.

Single-phase induction motors, drills, well pumps, grinders, small refrigerators, weed and hedge trimmers.

Possible Concerns

NONE

Voltage spikes or high voltage regulation can cause the capacitative elements to fail. Surge protection, transient protection, and additional loading is recommended for 100% fail-safe operation. DO NOT RUN THESE DEVICES WITHOUT ADDITIONAL RESISTIVE TYPE LOADS.

These devices require large current inrush for starting. Some synchronous motors may be frequency sensitive to attain maximum output torque, but they SHOULD BE SAFE from any frequency induced failures.

Capacitive / Inductive

The Lincoln Electric Company is not responsible for any damage to electrical components improperly connected to this product.

Computers, high resolution TV sets, complicated electrical equipment.

A-7

An inductive type line conditioner along with transient and surge protection is required, and liabilities still exist. DO NOT USE THESE DEVICES WITH THIS PRODUCT.

Page 15

SAE-300® HE

ENGINE OPERATION

STARTING THE SAE-300®HE

PERKINS 403F-15T

DIESEL

ENGINE

COLD WEATHER STARTING:

Under NO

conditions should ether or other starting fluids

be used!

HIGH ALTITUDE OPERATION:

STOPPING THE ENGINE

OPERATION

WARNING

Do not attempt to use this equipment until you have thoroughly read the engine manufacturerʼs manual supplied with your welder. It includes important safety precautions, detailed engine starting, operating and maintenance instructions, and parts lists.

ELECTRIC SHOCK can kill.

• Do not touch electrically live parts or electrode with skin or wet clothing.

• Insulate yourself from work and ground

• Always wear dry insulating gloves.

ENGINE EXHAUST can kill.

• Use in open, well ventilated areas or vent exhaust outside.

MOVING PARTS can injure.

• Do not operate with doors open or guards off.

• Stop engine before servicing.

• Keep away from moving parts.

See additional warning information at the

front of this operatorʼs manual.

7. Allow the engine to run at high idle speed for several minutes to warm the engine. Stop the engine and recheck the oil level, after allowing sufficient time for the oil to drain into the pan. If the level is down, fill it to the full mark again. The engine controls were properly set at the factory and should require no adjusting when received.

With a fully charged battery and the proper weight oil, the engine should start satisfactorily even down to about -5°F (-20°C), it maybe desirable to install cold-starting aides.

Note: Extreme cold weather starting may require longer glow plug operation.

WARNING

At higher altitudes, output derating may be necessary. For maximum rating, derate the welder 2% for every 305 meters (1000 ft.) above 1524 meters (5000 ft.).

Contact a Perkins Service Representative for any engine adjustments that may be required.

Operate the welder with the doors closed. Leaving the doors open changes the designed air flow and can cause overheating.

1. Turn the “IDLER” switch to “HIGH”.

2. Turn the “IGNITION” switch to “ON”.

3. Press the Glow Plug button for 20 to 30 seconds. (maximum 60 seconds).

4. Press the Start button. When the engine starts running, release both buttons. If the engine fails to start in 20 seconds, wait 30 seconds and repeat the above procedure.

5. Observe the oil pressure. If no pressure shows within 30 seconds, stop the engine and consult the engine operating manual. To stop the engine, turn the “IGNITION” switch to “OFF”.

6. If the engine protection warning light comes on during cranking or after start up, the “IGNITION” switch must be turned “OFF” to reset the engine protection system.

1. Turn the “IGNITION” switch to “OFF”

At the end of each day’s welding, check the crankcase oil level, drain accumulated dirt and water from the water separator located on the fuel rail. Refill the fuel tank to minimize moisture condensation in the tank. Also, running out of fuel tends to draw dirt into the fuel system.

When hauling the welder between job sites, close the fuel feed valve on the separator located on the fuel rail.

If the fuel supply is cut off or runs out while the fuel pump is operating, air may be entrapped in the fuel distribution system. If this happens, bleeding of the fuel system may be necessary. Use qualified personnel to do this per the instructions in the MAINTENANCE section of this manual.

B-1

Page 16

SAE-300® HE

ENGI NE BREAK-IN

WELDER OPERATION

DUTY CYCLE

CURRENT CONTROL

Do not adjust the “Current Control” w hile welding because this can damage the control.

ELECTRIC SHOCK can kill.

• Do not touch electrically live parts or electrode with skin or wet clothing.

• Insulate yourself fr om work and ground.

FUMES & GASES ca n be dangerous.

• Keep your head out of the fumes.

• Use ventilation or exhaust to rem ove

fumes from breathing zone.

WELDING SPARKS can cause fire or explosio n.

• Keep flamma ble material away.

ARC RA YS can burn.

• Wear eye, ear, and body protection.

OPERATION

Lincoln Electric selects high quality, heavy-duty industrial 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 successful engine break-in, most diesel-powered equipment 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 moderate 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.

WARNING

The NEMA output rating of the SAE-300®HE is 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.

CAUTION

3. Periodically shut off the engine and check the crankcase oil level.

The “Coarse Current Control” is the main Current Adjuster and together with the “Fine Current Control” adjusts the current from minimum to maximum. Open circuit voltage is also controlled by the “Fine Current Control” permitting control of the arc characteristics.

A high open circuit voltage setting provides the soft “buttering” arc with best resistance to pop-outs preferred 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 techniques at lower end of the open circuit voltage range.

settings at the

B-2

Page 17

SAE-300® HE

HOW TO SET CONTROLS FOR STICK WELDING

Right Dial

Left Dial

Right Dial

K942-4

Right D i a l

STICK / TI G WELDI NG

SELF-SHI ELDED FLUX-CORED WELDING (WITH A

WIRE FEED MODULE INSTALLED)

OPERATION

1. Set the

2. Set the

(Fine Current and OCV) to 60.

(Coarse Current) to the Desired Current. Make a small increase in current when the weather warms up.

Remote Control unit can also be used as the

(Fine Control and

OCV).

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 markings 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.

K3964-1 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. Move the Coarse Current control to the left for a softer arc and to the right for a crisper arc.

3. Use

(Fine Current and OCV) to Make Changes to the

Arc Characteristics and Small Changes to the Output.

B-3

Page 18

SAE-300® HE

AUXI LIARY POWER

IDLER OPERATION

SAE-300®HE WITH PERKINS 403F-15F DIESEL ENGINE TYPICAL FUEL CONSUMPTION DATA

(WITH A K3964-1 WIRE FEED MODULE INSTALLED)

MIG WELDING (WITH A K3964-1 WIRE FEED MODULE INSTALLED)

CARBON ARC GOUGING

OPERATION

GAS-SHIELDED FLUX-CORED WELDING

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 220. Now move the Voltage Adjustment dial to the desired voltage. Move the Coarse Current control to the left for a softer arc and to the right for a crisper arc.

Set both the Coarse Current and Fine Current O.C.V controls to maximum for carbon arc gouging in the CC (constant current) mode. If a K3964-1 Wire Feed Module is installed and the CV (constant voltage) mode is desired, set the Wire (CV) / Stick (CC) toggle switch to the Wire (CV) position. Then set the left-side Coarse Current control to maximum output and the Voltage Adjustment dial to maximum output.

When welding or drawing power for lights or tools (approximately 100 watts minimum) from the receptacles, the idler solenoid deactivates and the engine operates at high idle speed.

When welding ceases or the power load is turned off, a preset time delay of about 15 seconds starts. This time delay cannot be adjusted.

If the welding or power load is not re-started before the end of the time delay, the idler solenoid activates and reduces the engine to low idle speed.

If GFCI is tripped, See the MAINTENANCE section for detailed information on testing and resetting the GFCI.

The AC auxiliary power, supplied as a standard, has a rating of

3.0 KVA of 120/240 VAC (60 hertz). Set fine current adjustment at 100 for maximum auxiliary power.

With the 3.0 KVA, 120/240 VAC auxiliary power, one 120V duplex protected by GFCI and one 240V duplex, grounding type receptacle with 2 pole, 15 amp circuit breaker.

Start the engine with the “Idler” switch in the “High” position. 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 positions as follows:

In the “High” position, the idler solenoid deactivates, and the engine goes to high idle speed. The speed is controlled by the governor.

In the “Auto” / position, the idler operates as follows:

Low Idle-No Load

High Idle-No Load

3,000 Watts

150 Amps @ 26 Volts

The rating of 3.0 KVA permits a maximum continuous current of 13 amps to be drawn from the 240V duplex receptacle. 20 amps can be drawn from the 120V duplex receptacle. The total combined load of all receptacles is not to exceed 3.0 KVA.

An optional power plug kit is available. When this kit is specified, the customer is supplied with a plug for each receptacle.

0.22gal/hr ( 0.84 ltrs/hr)

0.35 gal/hr ( 1.33 ltrs/hr)

0.43 gal/hr ( 1.64 ltrs/hr)

0.53 gal/hr ( 2.01 ltrs/hr )

200 Amps @ 28 Volts

250 Amps @ 30 Volts

300 Amps @ 32 Volts

0.63 gal/hr ( 2.39 ltrs/hr )

0.94 gal/hr ( 3.55 ltrs/hr)

1.19 gal/hr ( 4.49 ltrs/hr)

B-4

Page 19

SAE-300® HE

OPTIONA L FEATURES

GENERAL OPTIONS

Pipe Thawing with an arc welder can cause fire, explosion, dam age to electric wiring or to the arc welder if done improperly. The use of an arc welder for pipe tha wing is not approved by the CSA, nor is it recommended or suppo rted by Lincoln Electric.

FIELD INSTALLED OPTIONAL ACCESSORI ES

www.lincolnelectric.com .

E6.162

Sear ch

SAE-300

SAE-300®HE

RECOM-

MENDED OPTIONS

ACCESSORIES

(Field Installed)

WARNING

Follow these steps:

1. Go to

2. At the top of the screen in the

3. On the results screen click on

icon.

tion

field type

product informa-

click

4. On the results screen which shows ture document, scroll down the beginning of the

page.

sales litera-

C-1

Page 20

SAE-300® HE

GENERAL INSTRUCTIONS

COOLING SY STEM

BEA RINGS

COMMUTATOR AND BRUSHES

Uncovered rotating equipment can be dangerous. Use care so your hands, hair, clothing or too ls do no t c atch in the rotating parts. Protect yourself from particles that may be throw n out by the rotating armature when stoning the commutator.

Have qualified personnel do the maintenance work. Turn the engine off before working inside the machine. In some cases, it may be nec essary to remove safety guards to perform required maintenance. Remove guards only when necessary and replace them w hen the maintenance requiring their rem oval is complete. Always use the greatest care when w orking near moving parts.

Do not put your ha nds near the engine cooling blower fan. If a problem cannot be corrected by following the instructions, take the machine to the nearest Lincoln Field Service Shop.

ELECTRIC SHOCK can kill.

• Do not touch electrica lly live parts or electrode with skin or wet clothing.

• Insulate yourself from work and ground

• Always wear dry insulating gloves.

ENGI NE EXHAUST can kill.

• Use in open, well ventilated areas or vent exhaust outside.

MOVING PA RTS can injure.

• Do not operate with doors open or guards off.

• Stop engine before servicing.

• Keep away from moving pa rts.

See additional w arning information at front of this

operator’s manual.

MAINTENANCE

SAFETY PRECAUTIONS

WARNING

The SAE-300®HE is equipped with a pressure radiator. Keep the radiator cap tight to prevent loss of coolant. Clean and flush the cooling system periodically to prevent clogging the passage and overheating the engine. When antifreeze is needed, always use the permanent type.

This welder is equipped with a double synthetic sealed ball bearing having sufficient grease to last indefinitely under normal service.

WARNING

Shifting of the commutator brushes may result in:

- Change in machine output

- Commutator damage

- Excessive brush wear

Periodically inspect the commutator, slip rings, and brushes by removing the covers. DO NOT remove or replace these covers while the machine is running. Commutators and slip rings require little attention. However, if they are black or appear uneven, have them cleaned by an experienced maintenance man using fine sandpaper or a commutator stone. Never use emery cloth or paper for this purpose.

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.

Follow the engine service schedule in this manual and the detailed maintenance and troubleshooting in the engine manufacturer’s manual.

D-1

Page 21

SAE-300® HE

NAMEPLATES

Replace brushes when they wear within 1/4” of the pigtail. A complete set of replacement brushes should be kept on hand. Lincoln brushes have a curved face to fit the commutator. Have an experienced maintenance person seat these brushes by lightly stoning the commutator as the armature rotates at full speed until contact is made across the full face of the brushes. After stoning, blow out the dust with low pressure air.

To seat slip ring brushes, position the brushes in place. Then slide one end of a piece of fine sandpaper between slip rings and brushes with the coarse side against the brushes. With slight additional finger pressure on top of the brushes, pull the sandpaper around the circumference of the rings - in direction of rotation only until brushes seat properly. In addition, stone slip ring with a fine stone. Brushes must be seated 100%.

Arcing or excessive exciter brush wear indicates a possible misaligned shaft. Have an authorized Field Service Shop check and realign the shaft.

Whenever routine maintenance is performed on this machine or at least yearly - inspect all nameplates and labels for legibility. Replace those which are no longer clear. Refer to the parts list for the replacement item number.

MAINTENANCE

D-2

Page 22

SAE-300® HE

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

I 50/ 50 Wate r/Ethyl e ne Gl ycol

R R 6.34 qrts., 6L (including ﬁlter) R R Pe rkins # 140517050

R Lincol n # M20840-A

R Perkins # 26561117 I I

R Donaldson # P821575

IContact Perkins

Notes:

1) Consult Engine Operator manual for oil recommendaons.

2) Consult Engine Operator manual for addional maintenance schedule informaon.

3) Fill Slowly ! Ensure correct quanty is used.

MAINTENANCE

EVERY 1000 HOURS

ENGINE SERVICE (NOTE 2)

MAINTENANCE ITEM

TYPE OR QUANTITY Coolant level Concentraon of anfreeze Coolant (NOTE 3)

R 7.76 qrts., 7.3L

Engine oil level (NOTE 1) Engine oil (NOTE 1 & 3) Engine oil ﬁlter Drain water separator & fuel straine Water separator element Fuel ﬁlter canister Tension of alternator drive belt Alternator drive belt wea Alternator drive belt

R Pe rkins # 080109080

Air ﬁlter (earlier check may be req'd) Air ﬁlter element Renew the engine breather

I Tighten cylinder head

Valve clearances

I Intake .008", Exhaust .008"

Electrical systems

All nuts and bolts for ghtness

Injector performance Leaks or engine damage Baery

I = Inspect R = Replace

C = Clean

Above operaons to be carried out by trained personnel with reference to the workshop manual where necessary.

These preventave maintenance periods apply to average condions of operaon. If necessary use shorter periods. S29909 VM

D-3

Page 23

SAE-300® HE

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.

• If the equipment has been shut down, it must be restarted.

• The equipment needs to be operating at high idle speed and any necessary adjustments made on the control panel so that the equipment is providing at least 80 volts to the receptacle input terminals.

• The circuit breaker for this receptacle must not be tripped. Reset if necessary.

• Push the "Reset" button located on the GFCI. This will assure normal GFCI operation.

• Plug a night-light (with an "ON/OFF" switch) or other product (such as a lamp) into the Duplex receptacle and turn the product "ON".

• Push the "Test" button located on the GFCI. The night-light or other product should go "OFF".

• Push the "Reset" button, again. The light or other product should go "ON" again.

MAINTENANCE

If the light or other product remains "ON" when the "Test" button is pushed, the GFCI is not working properly 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.

D-4

Page 24

SAE-300® HE

Step 1. LOCATE PROBLEM (SYMPTOM).

Step 2. POSSIBLE CAUSE.

Step 3. RECOMMENDED COURSE OF

ACTION

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.

This Troubleshooting Guide is provided to help you locate and repair possible machine malfunctions. Simply follow the three-step procedure listed below.

Look under the column labeled “PROBLEM (SYMPTOMS)”. This column describes possible symptoms that the machine may exhibit. Find the listing that best describes the symptom that the machine is exhibiting.

TROUBLE SHOOTING

WARNING

The second column labeled “POSSIBLE CAUSE” lists the obvious external possibilities that may contribute to the machine symptom.

This column provides a course of action for the Possible Cause, generally it states to contact your local Lincoln Authorized Field Service Facility.

If you do not understand or are unable to perform the Recommended Course of Action safely, contact your local Lincoln Authorized Field Service Facility.

Have qualified personnel do the troubleshooting work. Turn the engine off before working inside the machine. In some cases, it may be necessary to remove safety guards to perform required maintenance. Remove guards only when necessary and replace them when the maintenance requiring their removal is complete. Always use the greatest care when working near moving parts.

Do not put your hands near the engine cooling blower fan. If a problem cannot be corrected by following the instructions, take the machine to the nearest Lincoln Field Service Shop.

------------------------------------------------------------

CAUTION

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.

E-1

Page 25

SAE-300® HE

(SYMPTOMS)

PROBLEMS

Observe all Safety Guidelines detailed throughout this manual

POSSIBLE

CAUSE

RECOMMENDED

COURSE OF ACTION

TROUBLE SHOOTING

Machine fails to hold the output (heat) consistently.

1. Rough or dirty commutator.

2. Brushes may be worn down to Limit.

3. Field circuit may have variable resistance connection or intermittent open circuit due to loose connection or broken wire.

4. Electrode lead or work lead connection may be poor.

5. Wrong grade of brushes may have been installed on generator.

6. Field rheostat may be making poor contact and overheating.

7. “Current Control” may not be

operating properly.

8. “Current Control” brush holder

contact springs may be worn out or missing. Contact surface may be dirty, rough and pitted.

If all recommended possible areas of misadjustment have been checked and the problem persists, Contact

your local Lincoln Authorized Field Service Facility.

7. Check for loose or missing set screw in control handles.

8. Inspect. Replace needed parts. Clean internal contact surface of control device. Do not lubricate. Smooth rough surfaces.

9. “Current Control” brush holder support stud and mating contact surfaces may be dirty or pitted and burned.

9. If brush holder internal contact surface is pitted and burned, replace the brush holder and support stud. If the contact surface is dirty, clean off the brush holder stud and internal contact surface. Apply mixture of three parts silicone grease and one part zinc powder (by weight) to stud.

CAUTION

E-2

Page 26

SAE-300® HE

(SYMPTOMS)

PROBLEMS

Observe all Safety Guidelines detailed throughout this manual

POSSIBLE

CAUSE

RECOMMENDED

COURSE OF ACTION

TROUBLE SHOOTING

Welder starts but fails to generate current.

Welding arc is loud and spatters excessively.

Welding current too great or too small compared to indication on the dial.

1. Generator or exciter brushes may be loose or missing.

2. Exciter may not be operating.

3. Field circuit of generator or exciter may be open.

4. Exciter may have lost excitation.

5. Series field and armature circuit may be open-circuited.

1. Current setting may be too high.

2. Polarity may be wrong.

1. Exciter output low causing low output compared to dial indication.

2. Operating speed too low or too high.

If all recommended possible areas of misadjustment have been checked and the problem persists, Contact

your local Lincoln Authorized Field Service Facility.

3. “Current Control” shaft and handle may have turned slightly in the insulated bushing of the current control brush holder, caused by turning handle too hard against one of the stops.

3. With current control against the minimum stop, set pointer to within 1/8” of the last scale division.

CAUTION

E-3

Page 27

SAE-300® HE

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 through Idler

Control Switch

Open Closed

Check Voltage across Replace Idler

Idler Control switch Control Switch

12 VDC 0 VDC

TROUBLE SHOOTING

Contact Perkins Replace current

Engine Repair Sensing PCB Facility

CAUTION

E-4

Page 28

SAE-300® HE

TROUBLE SHOOTING

ELECTRONIC IDLER TROUBLESHOOTING GUIDE

With Idler Control Switch in the AUTO Position, Engine Will Not Pick Up Speed When:

The Arc is Struck Both Auxiliary Load

Check for loose or disconnected

wire running between weld

selector switch and output stud.

1. Check Idler circuit wiring. Possible Problems are wires from Current Sensing Board reversed at idler switch or wires connected incorrectly at Current Sensor Molex plug.

2. Check voltage across idler control switch.

12V 0V

Replace Current Contact Perkins Sensing PCB Engine Repair

Facility.

1. Load too small. Try load above 100 Watts.

2. Check for loose or disconnected wire running from black lead out of exciter to CB2 circuit breaker.

CAUTION

E-5

Page 29

SAE-300® HE

Observe all Safety Guidelines detailed throughout this manual

PROBLEMS

(SYMPTOMS)

POSSIBLE

CAUSE

TROUBLE SHOOTING

RECOMMENDED

COURSE OF ACTION

Engine does not start.

Engine does not turn over.

Irregular running of the engine.

1. Lack of fuel.

2. Air mixed in the fuel system.

3. Clogged fuel filter.

4. Irregular and faulty fuel supply (Injector pump trouble).

5. Glow plug not heated.

6. Clogged air cleaner.

7. No compression.

8. Engine protection light is ON.

1. Faulty Ignition switch and or Injector pump solenoid.

2. Insufficient charging or complete discharge of the battery.

3. Improper viscosity of the lubricating oil.

1. Air mixed in the fuel system.

If all recommended possible areas of misadjustment have been checked and the problem persists,

Contact your local Lincoln Authorized Field Service Facility.

2. Uneven fuel injection (Faulty fuel injector pump).

3. Clogged fuel filter.

4. Defective governor.

5. Engine itself defective.

Engine stops during operation and the Engine Protection light does not turn on.

Engine stops during operation and the Engine Protection light does turn on (Flashes Code)

1. Lack of fuel in the fuel tank.

2. Clogged fuel filter.

3. Air mixed in the fuel system.

4. Faulty function of the engine.

1. See light code diagnoses attached.

CAUTION

E-6

Page 30

SAE-300® HE

TROUBLE SHOOTING

Observe all Safety Guidelines detailed throughout this manual

* Count number of off pulses.

CAUTION

E-7

Page 31

SAE-300® HE

(SYMPTOMS)

PROBLEMS

Observe all Safety Guidelines detailed throughout this manual

POSSIBLE

CAUSE

RECOMMENDED

COURSE OF ACTION

TROUBLE SHOOTING

White or Blue Smoke.

Dark Grey Smoke.

Faulty Charging.

Starter Motor does not run.

Engine Protection Light not coming on.

1. Excess engine oil.

2. Too low viscosity of the engine oil.

3. Faulty injection timing.

1. Unsuitable fuel.

2. Excess injection.

3. Faulty function of the engine.

4. Overloading.

5. Clogged air cleaner.

1. Loose fan belt.

2. Faulty wiring.

3. Faulty battery.

4. Worn out alternator brush.

1. Loose or damaged wiring.

2. Drained voltage from battery.

3. Damaged starter motor (including solenoid).

1. Faulty light wiring.

2. Faulty Engine Control Unit.

3. Faulty LED indicator.

If all recommended possible areas of misadjustment have been checked and the problem persists,

Contact your local Lincoln Authorized Field Service Facility.

1. GFCI may have tripped.

No Auxiliary Power

Follow “GFCI Testing and Resetting Procedure” in the MAINTENANCE section of this manual.

2. Open breakers may need to be reset.

3. Faulty receptacle.

4. Faulty auxiliary circuit wiring.

CAUTION

E-8

Page 32

SAE-300® HE

NOTES

Page 33

SAE-300® HE

DIAGRAMS

F-1

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 a replacement. Give the equipment code number.

Page 34

SAE-300® HE

DIAGRAMS

F-2

Page 35

PARTS LIST FOR

SAE-300

P-736P-736

This parts list is provided as an informative guide only.

It was accurate at the time of printing. These pages are only updated on the Service Navigator DVD and in Lincoln Electricʼs ofﬁcial Parts Book (BK-34).

When ordering parts, always refer to Lincoln Electricʼs ofﬁcial Parts Book (BK-34) for the latest pages.

SAE-300

Page 36

ILLUSTRATION OF SUB-ASSEMBLIES

P-736-AP-736-A

SAE-300

Oct-13

Page 37

P-736-A.1P-736-A.1

SAE-300®HE

For Code: 11907

Do Not use this Parts List for a machine if its code number is not listed. Contact the Service Department for any code numbers not listed.

Use the Illustration of Sub-Assemblies page and the table below to determine which sub assembly page and column the desired part is located on for your particular code machine.

Sub Assembly Item

No.

SUB ASSEMBLY

PAGE NAME

PAGE NO .

CODE NO.

11907 111111111

Upper Control Panel

P-736-C

Lower Control Panel

P-736-D

Engine Assembly

P-736-E

Radiator Assembly

P-736-F

Fuel Tank, Mounting & Choke

Assembly

P-736-G

Base & Lift Bale Assembly

P-736-H

Exciter & Stator

P-736-J

Welding Generator & Coupling

P-736-K

Roof & Doors

P-736-L

SAE-300

Oct-13

Page 38

P-736-A.2P-736-A.2

SAE-300®HE

For Code: 11907

Do Not use this Parts List for a machine if its code number is not listed. Contact the Service Department for any code numbers not listed.

Use the Illustration of Sub-Assemblies page and the table below to determine which sub assembly page and column the desired part is located on for your particular code machine.

Sub Assembly Item

No.

SUB ASSEMBLY

PAGE NAME

PAGE NO .

CODE NO.

11907 1

Generator Brush Holder

P-736-M

SAE-300

Oct-13

Page 39

NOTES

SAE-300®HE

Page 40

Upper Control Panel

10A

15E

15C

15D

P-736-CP-736-C

10A

15E

15C

15D

SAE-300

Oct-13

Page 41

P-736-C.1

# Indicates a change this printing.

Use only the parts marked “x” in the column under the heading number called for in the model index page.

ITEM DESCRIPTION PART NO. QTY. 123456789

1 Upper Control Panel Asbly (L16355), Includes: NSS 1X 1A Reactor Box & Panel Assembly M25006 1 X 2A Rheostat M5090-C 1 X 2B Sems Screw (Not Shown) T10082-4 2 X 3A Brush Holder Stud Assembly T7852 1 X 3B Thread Forming Screw (Not Shown) S9225-8 2 X 4 Brush Holder Assembly (Not Shown) M6277 1 X 5 Reactor Spring Clip (Not Shown) S7297 1 X 6 Plain Washer (Not Shown) S9262-41 1 X 7 Spring (Not Shown) T8236 1 X 8A Cont. Control Assembly L2036-H 1 X 8B Thread Forming Screw (Not Shown) S9225-8 4 X 10A Reactor Lead Insulation T10576 1 X 10B #10 x .75 HHCS (SS) (Not Shown) S24739-7 2 X 15A Thread Forming Screw (Not Shown) S9225-26 5 X 15B Lock Washer (Not Shown) T9860-3 5 X 15C Reactor Control Handle S16664-16 1 X 15D Rheostat Handle S16664-13 1 X 15E Upper Control Nameplate L16306 1 X 15F Self Tapping Screw (Not Shown) S8025-92 8 X 17 Auxiliary Decal S28232-3 1 X 18 Reactor Shield (Not Shown) M22658 1 X 18A Self Tapping Screw (Not Shown) S8025-12 4 X

NSS - Not Sold Separately

SAE-300

Oct-13

Page 42

Lower Control Panel

34B

34A

12A

12B

20A

30A

30B

14F

30A

13A

13B

13D

13C

14B

14A

15A

15B

P-736-DP-736-D

30A

30B

30A

30B

34B

14F

34A

12B

12A

13B

13A

13C

13D

15A

15B

14A

20A

14B

SAE-300

Oct-13

Page 43

P-736-D.1

# Indicates a change this printing.

Use only the parts marked “x” in the column under the heading number called for in the model index page.

ITEM DESCRIPTION PART NO. QTY. 123456789

1 Lower Control Panel (G7526), Includes: NSS 1X 1A Rear Lower Panel L15842-3 1 X 2 Fuel/Hour/LED Gauge M22209-3 1 X 3 Temperature Gauge S25154-2 1 X 4 Oil Gauge S20206-2 1 X 6A Duplex Receptacle S14377 1 X 6B Thread Forming Screw (Not Shown) S9225-63 2 X 6C Speed Nut (Not Shown) T11525-1 2 X 7A Receptacle (20 Amp) S20184 1 X 7B GFCI Receptacle Cover L13286 1 X 7C Mounting Bracket (Not Shown) S27167 1 X 7D Thermoplastic Screw (Not Shown) S24738-3 2 X 7E Foam Receptacle Seal (Not Shown) S27176 1 X 8A Switch T10800-55 2 X 8B Sealing Boot S22061-4 2 X 9 Start Button S13146-1 1 X 10 Glow Plug Button S13146-4 1 X 12A Circuit Breaker (2 Pole) M20585-3 1 X 12B Circuit Breaker Boot S24911-2 1 X 12C Sems Screw (Not Shown) T10082-30 4 X 13A GFCI Blank Face Receptacle S26843-1 1 X 13B GFCI Cover S28464 1 X 13C GFCI Receptacle Cover L13286 1 X 13D Mounting Bracket S27167 1 X 13E Thermpolastic Screw (Not Shown) S24738-3 2 X 14 Switch & Receptacle Assembly, Includes: M19120-5 1 X 14A Toggle Switch T10800-56 1 X 14B Receptacle S21012 1 X 14C Thread Forming Screw (Not Shown) S9225-63 2 X 14D Speed Nut (Not Shown) T11525-1 2 X 14E Sealing Boot (Not Shown) S22061-4 1 X 14F Receptacle Cover M21760 1 X 14G Self Tapping Screw S8025-97 4 X 15A Circuit Breaker (20 Amp) T12287-31 1 X 15B Sealing Boot S22061-1 1 X 16A Thread Forming Screw (Not Shown) S9225-36 2 X 16B Lock Washer (Not Shown) T9695-1 2 X 16C #10-24 HN (Not Shown) CF000010 4 X 19A Diode Bridge (Not Shown) T13637-5 2 X 19B #8-32 x .875 RHS (Not Shown) CF000059 2 X 19C Plain Washer (Not Shown) S9262-3 2 X 19D Lock Washer (Not Shown) T4291-A 2 X 19E #8-32 HN (Not Shown) CF000042 2 X 20A Fuse Holder T15011-1 1 X 20B Fuse (Not Shown) T10728-8 1 X 20C #4-40 x .375 RHS (Not Shown) CF000001 1 X 20D Plain Washer (Not Shown) S9262-39 1 X 20E Lock Washer (Not Shown) T4291-B 1 X 20F #4-40 HN (Not Shown) CF000002 1 X 22 Receptacle & Lead Assembly (Not Shown) S14165-472 1 X 23 Plug & Lead Assembly (Not Shown) S14165-473 1 X

NSS - Not Sold Separately

SAE-300

Oct-13

Page 44

P-736-D.2

# Indicates a change this printing.

Use only the parts marked “x” in the column under the heading number called for in the model index page.

ITEM DESCRIPTION PART NO. QTY. 123456789

29A Thread Forming Screw (Not Shown) S9225-26 4 X 29B Lock Washer (Not Shown) T9860-3 4 X 30A Receptacle Cover M16996 2 X 30B Receptacle Gasket S21088 2 X 31 3 Year Warranty Decal (Not Shown) S22127-3 1 X 32 Electronic Governor Controller (Not Shown) * 1X

Plain Washer S9262-27 4 X Lock Washer T9695-1 2 X #10-24 HN CF000010 2 X Spacer S10918-69 2 X

#10-24 x 1.75 RHS CF000127 2 X 33 Current Sensor P.C. Board (Not Shown) S25590-2 1 X 34A Lower Control Nameplate L16333 1 X 34B Fastener Button T14659-2 2 X 35 Right Side Case Front Guard (Not Shown) M24952 1 X 36 Left Side Case Front Guard (Not Shown) M24953 1 X 37 Harness (Not Shown) G7519 1 X 38 Terminal Block (Not Shown) S29970 1 X

510 Ohm Resistor S10400-5100 1 X

1.5K Ohm Resistor S10404-1501 1 X

Note: When ordering new printed circuit boards indicate the dash number [ ] of the “Old” board

that is to be replaced. This will aid Lincoln in supplying the correct and latest board along with any necessary jumpers or adapters. The dash number brackets [ ] have purposely been left blank so as to eliminate errors, confusion and updates.

* Contact Engine Manufacturer

SAE-300

Oct-13

Page 45

NOTES

SAE-300®HE

Page 46

P-736-EP-736-E

Engine Assembly

SAE-300

Oct-13

Page 47

P-736-E.1

# Indicates a change this printing.

Use only the parts marked “x” in the column under the heading number called for in the model index page.

ITEM DESCRIPTION PART NO. QTY. 123456789

Perkins Diesel Engine Asbly (L16311), Includes: NSS 1X 1 Engine (Perkins 403F-T Diesel) (M24738) NSS 1X 2 Fuel Filter (Supplied w/Engine) * 1X

M10-1.50x35 HHS w/Lock Washer (Supplied w/Engine)

* 2X

3 Air Filter Mounting Bracket L16328 1 X

M8-1.25x16HHS w/Lock Washer (Supplied w/Engine)

* 2X

Air Filter Vertical Brace S29527 1 X Thread Forming Screw S9225-26 1 X M8-1.25x20mm SHCS T14731-3 1 X Lock Washer E106A-3 1 X Air Filter Mounting Band M20359 1 X 5/16-18x1.25 HHCS CF000028 2 X 5/16-18 HN CF000029 2 X Lock Washer E106A-3 2 X Plain Washer S9262-121 4 X Hose M24773 1 X Hose Clamp S10888-33 2 X

4 Starter (Supplied w/Engine) * 1X

3/8-16x1.00 HHCS CF000019 1 X Lock Washer E106A-4 1 X M6 LOCK WASHER S17400-3 1 X M6 X 1.0 HN T14815-3 1 X

5 Muffler L16324 1 X

Exhaust Gasket (Supplied w/Engine) * 1X M8-1.25x25HHS w/Lock Washer (Supplied w/Engine)

* 4X

6 Flex Hose (Oil Drain) T10642-218 1 X

Clamp S10888-27 1 X

7 Engine Mounting Foot S29473 2 X

M14-1.5x25 HHS T14731-48 8 X

Lock Washer S17400-5 8 X 9 Bottom Fan Guard L16329 1 X 10 Hose, Breather T10642-354 1 X

Fitting S26600 1 X

Hose Clamp S10888-27 2 X 11 Bracket - Speed Sensor S29649 1 X

Speed Sensor S29889 1 X 12 Flywheel Lock Stud S29603 4 X 14 Upper Radiator Hose L16326 1 X

Hose Clamp S10888-8 1 X

Hose Clamp S10888-44 1 X 15 Lower Radiator Hose L16327 1 X

Hose Clamp S10888-8 1 X

Hose Clamp S10888-44 1 X

NSS - Not Sold Separately

* Contact Engine Manufacturer

SAE-300

Oct-13

Page 48

Radiator Assembly

{

P-736-FP-736-F

SAE-300

Oct-13

Page 49

P-736-F.1

# Indicates a change this printing.

Use only the parts marked “x” in the column under the heading number called for in the model index page.

ITEM DESCRIPTION PART NO. QTY. 123456789

1 Radiator (Includes Cap) G3432 1 X 1A Filler Cap S9970 1 X 1B Lock Washer E106A-15 2 X 1C Plain Washer S9262-5 2 X 1D 1/2-13 HN CF000027 2 X 1E Drain Cock (Mounts in Radiator) T9956 1 X 2A Radiator Shell L5163-2 1 X 2B Thread Forming Screw (Not Shown) S9225-8 4 X 2C 5/16-18 x 1.50 HHCS CF000081 2 X 2D Plain Washer S9262-121 4 X 2E Lock Washer E106A-3 2 X 2F 5/16-18 HN CF000029 2 X 2G Radiator Cap Cover M8003 1 X 2H Self Tapping Screw S8025-12 2 X 4A Shroud Assembly (Includes Rubber Channels) M24776 1 X 4B 1/4-20 x .625 HHCS CF000013 6 X 4C Lock Washer E106A-2 6 X 4D Plain Washer S9262-23 6 X 7A Fan Guard L16331 1 X 7B Fan Guard (Alternator Side) L16332 1 X 9 Warning Decal T13086-62 2 X

SAE-300

Oct-13

Page 50

P-736-G

1C 1D

Fuel Tank, Mounting & Choke Assembly

P-736-G

1C 1D

SAE-300

Oct-13

Page 51

P-736-G.1

# Indicates a change this printing.

Use only the parts marked “x” in the column under the heading number called for in the model index page.

ITEM DESCRIPTION PART NO. QTY. 123456789

1 Fuel Tank & Support Assembly, Includes: L16336 1 X 1B Fuel Cap S20541 1 X 1C 3/8-16 x 1.00 HHCS (Not Shown) CF000019 4 X 1D Plain Washer (Not Shown) S9262-120 8 X 1E Lock Washer (Not Shown) E106A-16 4 X 1F 3/8-16 HN (Not Shown) CF000067 4 X 1G Fuel Sender (Not Shown) L16341 1 X 2 Gasket S10437-G 1 X 5A Fuel Return Line (Not Shown) T10642-231 1 X 5B Hose Clamp (Not Shown) T13777-6 1 X 6A Fuel Feed Line (Not Shown) T10642-86 1 X 6B Hose Clamp (Not Shown) T13777-1 1 X 7A Fuel Tank Rail M12479-1 1 X 7B Thread Forming Screw S9225-22 2 X 7C Lock Washer T9860-3 2 X 7D 5/16-18 HN CF000029 2 X

Output Panel Asbly, Includes: M13942-9 1 X 8A Output Rail M13946-1 1 X 8B Self Tapping Screw (Not Shown) S8025-91 4 X 8C Output Terminal (Includes Output Stud Nut) T14166-9 2 X 8D Output Stud Nut T3960 2 X 8F Thread Forming Screw (Not Shown) S9225-22 2 X 8G Lock Washer (Not Shown) T9860-3 2 X 8H 5/16-18 HN (Not Shown) CF000029 2 X 9A 1/2-13 x .75 HHCS (Not Shown) CF000020 2 X 9B Plain Washer (Not Shown) S9262-1 1 X 9C Lock Washer (Not Shown) E106A-15 1 X 10 Choke Assembly M24836 1 X

SAE-300

Oct-13

Page 52

Base & Lift Bale Assembly

10A

P-736-HP-736-H

10A

SAE-300

Oct-13

Page 53

P-736-H.1

# Indicates a change this printing.

Use only the parts marked “x” in the column under the heading number called for in the model index page.

ITEM DESCRIPTION PART NO. QTY. 123456789

1A Battery Mounting Panel S15639-1 1 X 1B 1/4-20 x .50 HHCS CF000012 2 X 1C Lock Washer E106A-2 2 X 1D Plain Washer S9262-23 2 X 2A Battery (M9399-4) NSS 1X 2B Cap (Insulates Neg. Terminal) T14654 1 X 2C Battery Bracket S12128 1 X 2D Carriage Bolt T11888 2 X 2E Plain Washer S9262-169 2 X 2F Lock Washer E106A-20 2 X 2G 1/4-20 HN CF000395 4 X 3A Positive Battery Cable S8070-29 1 X 3B Lead Clip (Not Shown) S24469 1 X 3C Speed Nut (Not Shown) T11525-5 1 X 3D Thread Forming Screw (Not Shown) S9225-8 1 X 3E M6 x 100 HN (Not Shown) T14815-3 1 X 3F M8 x 1.25 HN (Not Shown) T14815-2 1 X 4A Battery Cable & Ground Strap S14922-1 1 X 4B Thread Forming Screw (Not Shown) S9225-26 2 X 5A Lift Bale & Hook Assembly L9084 1 X 5B Hex Head Cap Screw T8833-24 4 X 5C Lock Washer E106A-15 4 X 5D 1/2-13 HN CF000027 4 X 5E Foam M15045-37 1 X 6 Base G7568 1 X 6A Tube S10918-82 2 X 6B #10-24 x 1.75 RHS (Not Shown) CF000127 2 X 6C #10-24 HLN (Not Shown) T9187-9 2 X 8 Cable Routing Decal S20283 1 X 9 Caution Decal S17851 2 X 10A Rear Support Assembly M8237-15 1 X 10B 3/8-16 x 1.00 HHCS (Not Shown) CF000019 4 X 10C Plain Washer (Not Shown) S9262-120 4 X 10D Lock Washer (Not Shown) E106A-16 4 X 10E 3/8-16 HN (Not Shown) CF000067 4 X 10F 5/16-18 HN (Not Shown) CF000029 4 X

NSS - Not Sold Separately

SAE-300

Oct-13

Page 54

Exciter & Stator

11A

11B

11C

17A

17B

17C

P-736-JP-736-J

11C

11B

17C

11A

17B

17A

SAE-300

Oct-13

Page 55

P-736-J.1

P-736J.1

# Indicates a change this printing.

Use only the parts marked “x” in the column under the heading number called for in the model index page.

ITEM DESCRIPTION PART NO. QTY. 123456789

1A Exciter End Bracket L6061-7 1 X 1C 7/16-14 x 1.50 HHCS T8833-2 4 X 1D Lock Washer E106A-8 4 X 2A Baffle M13683 1 X 2B Thread Forming Screw (Not Shown) S9225-8 4 X 2C Plain Washer (Not Shown) S9262-23 4 X 2D Lock Washer (Not Shown) T9860-6 4 X 3A Bracket Cover L3391-46 1 X 3B 1/4-20 x 2.00 RHS CF000143 2 X 3C Lock Washer E106A-2 2 X 3D 1/4-20 HN CF000017 2 X 4 Rotor Assembly M13641-4 1 X 5 Armature Sleeve Collar T14337 1 X 6 Exciter Nut Washer T7090-1 1 X 7 Exciter Nut T6225-1 1 X 8A Exciter Shroud L8254 1 X 8B Lock Washer T9860-6 3 X 8C Thread Forming Screw S9225-8 3 X 9A Blower Shroud L6129-1 1 X 9B Self Tapping Screw S8025-91 4 X 11 Rocker Assembly, Includes: S16986-1 1 X 11A Rocker M9857-1 1 X 11B Lock Washer E106A-2 1 X 11C 1/4-20 x 2.00 HHCS T8833-22 1 X 13 Generator Brush Holder See P-736-M 4 X 17A Alternator Brush Holder Asbly, Includes: M16158 1 X

Brush Holder Cartridge G2114 1 X Brush Assembly S19480 2 X Brush Assembly Retainer M16157 1 X

17B Brush Holder Bracket M19896 1 X

(Items 17C thru F Mount Brush Holder Bracket to Alternator Frame) 17C 1/4-20 x .75 HHCS CF000014 2 X 17D Plain Washer (Not Shown) S9262-23 2 X 17E Lock Washer (Not Shown) E106A-2 2 X 17F 1/4-20 HN (Not Shown) CF000017 2 X

(Item 17G Mounts Brush Holder Asbly to Brush Holder Bracket) 17G Self Tapping Screw (Not Shown) S24739-7 2 X

SAE-300

Oct-13

Page 56

Welding Generator & Coupling

13B

13A

20C

20F

20H

20G

20A

20B

P-736-KP-736-K

13A

13B

20A

20B

20G

20C

20F

20H

SAE-300

Oct-13

Page 57

P-736-K.1

# Indicates a change this printing.

Use only the parts marked “x” in the column under the heading number called for in the model index page.

ITEM DESCRIPTION PART NO. QTY. 123456789

Generator Frame Assembly, Includes: L8576-12 1 X 1 Frame L9137-4 1 X

Interpole Coil & Pole, Includes: S12261-26 4 X 2 Interpole Coil S12261-26A 4 X 2A Interpole Piece S12260-8 4 X 3 Shunt Coils (Top) L1741-82 1 X

Shunt Coils (Bottom) L1741-83 1 X

Series Coil (Bottom) L16319-4 1 X

Series Coil (Top) L16319-3 1 X 4 Main Poles S10745-14 4 X 5 Armature Assembly M7014-14 1 X 6A Bearing M9300-180 1 X 6B Bearing Shoulder Ring S18541 1 X 7 Blower Segments (Sold in Set of 4 Only) M14361 1 X

7/16-14 x .75 HHCS

(Blower Segments to Engine Coupling)

T8833-44 8 X 8B Lock Washer E106A-8 8 X 9 Disc Backing Plate S8042 2 X 10 Coupling Disc M6730 1 X 11 Coupling Ring (Inside) S14233 1 X 12 Coupling Ring (Outside-Closest to Engine) S14232 1 X 13A 7/16-14 x 1.50 HHCS

(Coupling Rings to Armature Hub) T8833-2 8 X

13B Lock Washer E106A-8 8 X 20A 1/2-13 x 2.75 HHCS CF000123 1 X 20B Plain Washer S9262-1 1 X 20C Welder Foot Support Rubber T8823 1 X 20F Rubber Pad T8822 1 X 20G 1/2-13 HLN T9187-4 1 X 20H Plain Washer S9262-5 1 X 21 3/8-16 HN CF000067 1 X 22 Ground Decal T13260-4 1 X

NSS - Not Sold Separately

SAE-300

Oct-13

Page 58

Roof & Doors

10A

13A

10B

10D

10C

{

10A

P-736-LP-736-L

10C

10B

13A

10D

SAE-300

Oct-13

Page 59

P-736-L.1

# Indicates a change this printing.

Use only the parts marked “x” in the column under the heading number called for in the model index page.

ITEM DESCRIPTION PART NO. QTY. 123456789

1A Door L6659-G 2 X 1B Door Hinge Pin S20295 4 X 1C Retaining Ring S9776-62 8 X 2 Door Bumper (Mounts in Roof) T15154 4 X 3 Door Hook Assembly S10656-3 2 X 4 Door Hook Assembly S10656-4 2 X 5A Door Hook Washer T10878 4 X 5B Self Tapping Screw S8025-92 8 X 6A Door Support Rod M16696 2 X 6B Speed Clip T10982-7 2 X 7A Door Support Bracket S20289 2 X 7B 1/4-20 x RHS CF000012 4 X 7C Lock Washer E106A-2 4 X 7D 1/4-20 HN CF000017 4 X 8A Door Bumper (Mounts to Door) S21463 8 X 8B Plain Washer S9262-98 8 X 8C Rivet M8834-1 8 X 8D Speed Clip T10982-7 8 X 9A Spring Clip S20290 2 X 9B Lock Washer T9695-1 2 X 9C #10-24 x .312 PPHS CF000335 2 X 9D #10-24 HLN T9187-9 2 X 10A Roof L5193-5 1 X 10B Roof Mounting Angle (Radiator End) S13593 2 X 10C 5/16-18 x 1.50 SQHS CF000258 2 X 10D 5/16-18 HLN T9187 2 X 10E

Roof Mounting Angle (Control Panel End) (Not Shown)

T9428 2 X 10F 5/16-18 x 1.25 SQHS (Not Shown) CF000180 2 X 10G 5/16-18 HLN (Not Shown) T9187 2 X 11 Wiring Diagram M24751 1 X 12 Logo Decal S27368-6 2 X 13A Fuel Warning Decal T13086-205 1 X 14 Warning Decal M16197 1 X 15 Door Catch Decal T11030 2 X 16 Engine Service Decal S29902 1 X 17 Engine Instruction Tag (Not Shown) M17238 1 X 18 Warning Decal S25896 1 X 19 CO Warning Decal M21436 1 X 20 Family Logo Decal - SAE S28596 2 X 21 Green Initiative Decal S28039-4 1 X

SAE-300

Oct-13

Page 60

Generator Brush Holder

{

}

P-736-MP-736-M

SAE-300

Oct-13

Page 61

P-736-M.1

# Indicates a change this printing.

Use only the parts marked “x” in the column under the heading number called for in the model index page.

ITEM DESCRIPTION PART NO. QTY. 123456789

Brush Holder Assembly Includes: M6964-2A 4 X 1 Spring and Clip Assembly T8495 2 X 2 Round Head Screw & Lock Washer T10082-20 2 X 3 Plate & Retainer Assembly S27088-1 1 X 5 5/16-18 x 5/8 HHCS CF000040 2 X 6 Stud M6963-4 1 X 7 Clamping Washer T9020 1 X 8 Insulating Washer T4479 2 X 9 Insulating Tube S13721-1 1 X 10 Clamping Washer T2414 1 X 11 3/8-16 x 1.00 HHCS CF000019 1 X

Lock Washer E106A-16 1 X

12 Generator Brush T2687 8 X

SAE-300

Oct-13

Page 62

NOTES

SAE-300®HE

Page 63

SAE-300® HE

NOTES

F-3

Page 64

CUSTOMER ASSISTANCE POLICY

The business of The Lincoln Electric Company is manufacturing and selling high quality welding equipment, consumables, and cutting equipment. Our challenge is to meet the needs of our customers and to exceed their expectations. On occasion, purchasers may ask Lincoln Electric for advice or information about their use of our products. We respond to our customers based on the best information in our possession at that time. Lincoln Electric is not in a position to warrant or guarantee such advice, and assumes no liability, with respect to such information or advice. We expressly disclaim any warranty of any kind, including any warranty of fitness for any customer’s particular purpose, with respect to such information or advice. As a matter of practical consideration, we also cannot assume any responsibility for updating or correcting any such information or advice once it has been given, nor does the provision of information or advice create, expand or alter any warranty with respect to the sale of our products.

Lincoln Electric is a responsive manufacturer, but the selection and use of specific products sold by Lincoln Electric is solely within the control of, and remains the sole responsibility of the customer. Many variables beyond the control of Lincoln Electric affect the results obtained in applying these types of fabrication methods and service requirements.

Subject to Change – This information is accurate to the best of our knowledge at the time of printing. Please refer to www.lincolnelectric.com for any updated information.

Lincoln Electric IM10155 User Manual

Specifications and Main Features

Frequently Asked Questions

User Manual