Lincoln Electric IM10155 User Manual
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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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.
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.
3
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.
4
cause
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
5
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.
6
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
________________________________________________________________________
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
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
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
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
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
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
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.
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
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
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
SAE-300® HE
a.
b.
c.
AUXI LIARY POWER
IDLER OPERATION
1.
2.
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.
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
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 .
Search
E6.162
Sear ch
SAE-300
®
HE
.
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.
on
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
SAE-300® HE
GENERAL INSTRUCTIONS
1.
2
.
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
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