Lincoln Electric SAE-300 Mode d'emploi

Marque: Lincoln Electric

Modèle: SAE-300

Catégorie: Système de soudage

Taper: Mode d'emploi

SAE-300

OPERATOR’S MANUAL

For Machines with Code Numbers 11645, 11916, 12090

IM10088-B

February 2013

Safety Depends on You

Lincoln arc welding and cutting

equipment is designed and built

with safety in mind. However,

your overall safety can be

increased by proper installation

... and thoughtful operation on

your part. DO NOT INSTALL,

OPERATE OR REPAIR THIS

EQUIPMENT WITHOUT READ-

ING THIS MANUAL AND THE

SAFETY PRECAUTIONS CON-

TAINED THROUGHOUT. And,

most importantly, think before

you act and be careful.

Cleveland, Ohio 44117-1199 U.S.A. TEL: 1.216.481.8100 For Service in U.S. and Canada: Call 1.888.935.3877

FAX: 1.216.486.1751 WEB SITE: lincolnelectric.com For Non-U.S. Service: Email [email protected]

• World's Leader in Welding and Cutting Products • • Sales and Service through Subsidiaries and Distributors Worldwide •

THANK YOU FOR SELECTING

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.

This statement appears where the information must be followed

exactly to avoid serious personal injury or loss of life.

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 Safety Data

Sheet (SDS) 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

AT ALL TIMES.

SPECIAL SITUATIONS

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.

Additional precautionary measures

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.

WARNING

CAUTION

Safety 01 of 04 - 5/16/2018

SECTION A:

WARNINGS

CALIFORNIA PROPOSITION 65 WARNINGS

WARNING: Breathing diesel engine exhaust

exposes you to chemicals known to the State

of California to cause cancer and birth defects,

or other reproductive harm.

• Always start and operate the engine in a

well-ventilated area.

• If in an exposed area, vent the exhaust to the outside.

• Do not modify or tamper with the exhaust system.

• Do not idle the engine except as necessary.

For more information go to

www.P65 warnings.ca.gov/diesel

WARNING: This product, when used for welding or

cutting, produces fumes or gases which contain

chemicals known to the State of California to cause

birth defects and, in some cases, cancer. (California

Health & Safety Code § 25249.5 et seq.)

WARNING: Cancer and Reproductive Harm

www.P65warnings.ca.gov

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.

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.

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

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 pos-

sible to the area being welded.

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

SAFETY

Safety 02 of 04 - 5/16/2018

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

between the

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.

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

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

hardfacing (see instructions on container or SDS)

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

unless exposure assessments indicate otherwise.

In confined spaces or in some circumstances,

outdoors, a respirator may also 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.

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

cause

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

Safety Data Sheet (SDS) and follow your employer’s safety

practices. SDS forms are available from your welding

distributor or from the manufacturer.

5.f. Also see item 1.b.

SAFETY

Safety 03 of 04 - 5/16/2018

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.

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.

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, 14501 George Carter Way

Chantilly, VA 20151.

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.

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.

SAFETY

Safety 04 of 04 - 5/16/2018

SAFETY

PRÉCAUTIONS DE SÛRETÉ

Pour votre propre protection lire et observer toutes les instructions

et les précautions de sûreté specifiques qui parraissent dans ce

manuel aussi bien que les précautions de sûreté générales suiv-

antes:

Sûreté Pour Soudage A LʼArc

1. Protegez-vous contre la secousse électrique:

a. 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.

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 ray-

onnement 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, pan-

talons 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.

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 lev-

age, 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.

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 debranch-

er à lʼinterrupteur à la boite de fusibles.

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

place.

vi vi

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

Machine Grounding.........................................................................................A-3

Lift Bail ............................................................................................................A-3

Trailers ............................................................................................................A-3

Vehicle Mounting.............................................................................................A-4

Polarity Control and Cable Sizes ....................................................................A-4

Pre-Operation Service ...........................................................................................A-4

Oil....................................................................................................................A-4

Fuel .................................................................................................................A-4

Cooling System ...............................................................................................A-4

Battery Charging .............................................................................................A-5

Electrical Devices use with this Product..........................................................A-6

________________________________________________________________________

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

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

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

High Altitude Operation ...................................................................................B-1

Stopping the engine, Engine Break-In......................................................B-1,B-2

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

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

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

Idler Operation ................................................................................................B-3

Auxiliary Power, Fuel Consumption Data........................................................B-3

________________________________________________________________________

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

Optional Features (Field Installed)..................................................................C-1,C-2

________________________________________________________________________

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

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

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

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

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

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

Idler Maintenance..................................................................................................D-2

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, E-6, E-7

________________________________________________________________________

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

Wiring Diagrams .............................................................................................F-1, F-2

Dimension Print......................................................................................................F-3

________________________________________________________________________

Parts List.................................................................................................................P-665

________________________________________________________________________

A-1

INSTALLATION

SAE-300

A-1

TECHNICAL SPECIFICATIONS - SAE-300

Make/Model Description Speed (RPM) Displacement Starting Dry

System Capacities

4 Cylinder 135 cu. in

12VDC battery

Fuel: 16 gal.

4 Cycle (2.2 ltrs) (Group 24, 650 60.6 L.

Perkins Naturally Aspirated High Idle 1800 cold crank amps)

404D-22 Water-Cooled Low Idle 1400 Bore x Stroke

2.0 KW

Starter Oil: 11.2 Qts.

EPA Diesel Engine Full Load 1725 10.6 L.

Tier 4 interim Cast Iron Cylinder, 3.3” x 3.9”

Compliant Block/Crankcase (84mm x 100mm) Coolant: 9.5 Qts.

32.7HP @1800 RPM

9.0 L.

65 A. Alternator

w/ built in reg.

INPUT - DIESEL ENGINE

RATED OUTPUT @ 104°F(40°C) - WELDER

MODEL HEIGHT WIDTH DEPTH WEIGHT

(K3003-1, K3003-2, 45.5 in. 24.00 in. 65.0 in. 1453 lbs.

K3003-3) (1156 mm) (610 mm) (1651 mm ) (659 kg.)

CSA Without

Wire Feed Module

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

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 98V DC Max. OCV @ 1800RPM

Auxiliary Power

(1)

3,000 Watts Continuous, 60 Hz AC

26 Amps @ 115V

13 Amps @ 230V

PHYSICAL DIMENSIONS

(2)

* 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-2

INSTALLATION

SAE-300

A-2

GENERAL DESCRIPTION

The SAE-300

is a heavy duty, engine driven, DC arc weld-

ing power source, capable of providing constant current out-

put for stick welding or DC TIG welding. This welder is

wound with all copper coils, rated at 300 amps/32 Volts, and

provides other Classic

features such as improved door

latches and stainless hinges. With the addition of the option-

al K623-1 Wire Feed Module

™

, the SAE-300

will provide

constant voltage output for running the LN-7, LN-23P, or

LN-25 wire feeders. (The Wire Feed Module is factory

installed on the K1643-8). 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

has an Electronic Engine Protection System.

In the event of sudden low oil pressure or high coolant tem-

perature, the engine immediately shuts down. The SAE-

300

has a current range of 40-350 DC amps with output

ratings as follows:

These units are also capable of providing 3 KVA of 115/230

volts of 60 cycle AC auxiliary power.

The SAE-300

uses the Perkins 404D-22 industrial water-

cooled diesel engine.

DESIGN FEATURES

Control Panel

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 tempera-

ture gauge, a battery charging ammeter, an oil pressure

gauge, for auxiliary power consists of one 20 amp, 120VAC

(5-20R) duplex receptacle with GFCI protection and one 15

amp, 250VAC (6-15R) receptacle, protected by 2 pole, 15

Amp breaker.

All Copper Windings - For long life and dependable

operation.

Engine Idler - The SAE-300

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.

Auxiliary Power - 3.0 KVA of nominal 115/230V, 60Hz, AC.

Output voltage is maintained within ± 10% at all loads up to

rated capacity. (See Optional Features Section C for Power

Plug Kit.)

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

the Maintenance Section for detailed information on testing

and resetting of the GFCI.

120 V DUPLEX RECEPTACLE AND 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.

Welder Enclosure - The complete welder is rubber mount-

ed on 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 (-).

Cranking System - A 12 volt electric starter is standard.

Air Cleaner - Heavy duty two stage dry type.

Muffler - A muffler and stainless steel exhaust outlet elbow

are standard.

Engine Hour Meter - A meter to record hours of operation.

Engine Protection - The system shuts the engine down in

the event of sudden low oil pressure or high coolant temper-

ature. 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.

Oil Drain Valve - A ball valve, hose and clamp are stan-

dard.

Remote Control - The Remote / Local Switch and

Receptacle are standard.

250A @ 30V

300A @ 32V

100%

60%

RATED OUTPUT DUTY CYCLE

A-3

INSTALLATION

SAE-300

A-3

PRE-OPERATION INSTALLATION

EXHAUST SPARK ARRESTER

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.

Use of an incorrect arrester may lead to engine damage

or performance loss. Contact the engine manufacturer

for specific recommendations.

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

LOCATION / VENTILATION

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 unrestrict-

ed flow of clean, cool air. Also, locate the welder so

that engine exhaust fumes are properly vented to an

outside area.

MACHINE GROUNDING

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 gen-

eral, 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 insulat-

ed 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.

LIFT BAIL

A lift bail is provided for lifting with a hoist.

TRAILER (SEE OPTIONAL FEATURES)

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 weld-

ing equipment. Some of the factors to be considered are

as follows:

1. Design capacity of trailer vs. weight of Lincoln equip-

ment and likely additional attachments.

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.

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

WARNING

CAUTION

• 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.

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

WARNING

DO NOT MOUNT OVER COMBUSTIBLE SURFACES.

Where there is a combustible surface directly under sta-

tionary or fixed electrical equipment, the surface shall

be covered with a steel plate at least .06”(1.6mm) thick,

which shall extend not more than 5.90”(150mm) beyond

the equipment on all sides.

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

CAUTION

PRE-OPERATION SERVICE

READ the engine operating and maintenance

instructions supplied with this machine.

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

OIL

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 manufacturerʼs recommendations.

Upon receipt of the welder, check the engine dipstick

to be sure the oil is at the “full” mark. DO NOT overfill.

FUEL

Fill the fuel tank with the grade of fuel recommended

in the Engine Operatorʼs manual. Make sure the fuel

valve on the water separator is in the open position.

COOLING SYSTEM

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).

CAUTION

A-4

INSTALLATION

SAE-300

A-4

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, rough-

ness of surface on which the trailer will be operat-

ed; environmental conditions, likely maintenance.

5. Conformance with federal, state and local laws.

(1)

Consult your federal, state and local laws regarding specific

requirements for use on public highways.

POLARITY CONTROL AND CABLE SIZES

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 positive polarity, connect the electrode cable to

the terminal marked “+”. For Negative polarity, con-

nect the electrode cable to the “-” stud. These con-

nections should be checked periodically and tightened

if necessary.

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

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 compo-

nents such as suspension, axles and tires.

• Use appropriate nuts bolts and lockwashers to

attach the equipment base to the metal bed or

frame of vehicle.

• Follow vehicle manufacturerʼs instructions.

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

WARNING

• 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 expan-

sion may cause overflow.

DIESEL FUEL ONLY-Low sulphur

fuel or ultra low sulphur fuel in U.S.A. and Canada.

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

WARNING

DIESEL FUEL

can

cause fire

A-5

INSTALLATION

SAE-300

A-5

BATTERY CHARGING

The SAE-300

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 NEGATIVE GROUND.

GASES FROM BATTERY can explode.

• Keep sparks, flame and cigarettes

away.

BATTERY ACID can burn eyes and

skin.

• Wear gloves and eye protection and

be careful when boosting, charging

or working near battery.

To prevent EXPLOSION when:

a) Installing a new battery - disconnect thenega-

tive cable from the old battery first and connect

the negative cable to the new battery last.

b) Connecting a battery charger - remove the bat-

tery from the welder by disconnecting the nega-

tive cable first, then the positive cable and bat-

tery clamp. When reinstalling, connect the neg-

ative cable last.

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 booster.

Use correct polarity - Negative Ground.

To prevent BATTERY DISCHARGE, if you have an

ignition switch, turn it off when engine is not r u n -

ning.

• To prevent BATTERY BUCKLING, tighten nuts on

battery clamp until snug.

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

WARNING

A-6

INSTALLATION

SAE-300

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

Type

Resistive

Capacitive

Inductive

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.

Computers, high resolution TV sets,

complicated electrical equipment.

Possible Concerns

NONE

Voltage spikes or high voltage

regulation can cause the capac-

itative elements to fail. Surge

protection, transient protection,

and additional loading is recom-

mended 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.

An inductive type line condition-

er along with transient and

surge protection is required,

and liabilities still exist.

DO NOT USE THESE DEVICES

WITH THIS PRODUCT.

The Lincoln Electric Company is not responsible for any damage to electrical components

improperly connected to this product.

B-1

OPERATION

B-1

ENGINE OPERATION

Operate the welder with the doors closed. Leaving

the doors open changes the designed air flow and can

cause overheating.

STARTING THE SAE-300

404D-22 DIESEL

ENGINE

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.

SAE-300

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.

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

WARNING

7. Allow the engine to run at high idle speed for sev-

eral 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 con-

trols were properly set at the factory and should

require no adjusting when received.

COLD WEATHER STARTING:

With a fully charged battery and the proper weight oil,

the engine should start satisfactorily even down to

about -15°F (-26°C), it maybe desirable to install cold-

starting aides.

Note: Extreme cold weather starting may require

longer glow plug operation.

Under NO

conditions should ether or other

starting fluids be used!

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

HIGH ALTITUDE OPERATION:

The engine will run correctly up to an altitude of 600m

(2000ft.). If the engine is to be operated permanently

at an altitude above this, the fuel consumption and

exhaust emissions may be excessive.

Contact the Perkins Application Department for any

engine adjustments that may be required.

STOPPING THE ENGINE

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

At the end of each dayʼs 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 person-

nel to do this per the instructions in the MAINTE-

NANCE section of this manual.

WARNING

B-2

OPERATION

B-2

SAE-300

ENGINE BREAK-IN

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 success-

ful 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 engineʼs early life. However, if the welder is subject-

ed to extensive light loading, occasional moderate to

heavy loading of the engine may sometimes be neces-

sary. Caution must be observed in correctly loading a

diesel/generator unit.

1. Connect the welder output studs to a suitable resis-

tive load bank. Note that any attempt to short the

output studs by connecting the welding leads togeth-

er, direct shorting of the output studs, or connecting

the output leads to a length of steel will result in cat-

astrophic damage to the generator and voids the

warranty.

2. Set the welder controls for an output current and

voltage within the welder rating and duty cycle. Note

that any attempt to exceed the welder rating or duty

cycle for any period of time will result in catastrophic

damage to the generator and voids the warranty.

3. Periodically shut off the engine and check the

crankcase oil level.

WELDER OPERATION

DUTY CYCLE

The NEMA output rating of the SAE-300

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.

CURRENT CONTROL

Do not adjust the “Current Control” while welding

because this can damage the control.

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

The “Coarse Current Control” is the main Current Adjuster.

The “Fine Current Control” adjusts the current from mini-

mum to maximum. Open circuit voltage is also controlled by

the “Fine Current Control” permitting control of the arc char-

acteristics.

A high open circuit voltage setting provides the soft “butter-

ing” 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 elec-

trodes when trying to operate with long arc techniques at

settings at the lower end of the open circuit voltage range.

STICK / TIG WELDING

Start by setting the right-side Fine Current and OCV control

dial to 60, then set the left-side Coarse Current control dial

to the desired current using the dial markings as an approxi-

mate guideline. Arc characteristics and small changes in

output can then be adjusted using the Fine Current and

OCV control dial. A K924-4 Remote Control unit can also be

used as the Fine Control and OCV control dial.

SELF-SHIELDED FLUX-CORED WELDING

(WITH A K623-1 WIRE FEED MODULE INSTALLED)

Start by setting the Wire (CV) / Stick (CC) toggle switch to

the Wire (CV) position. Then set the left-side Coarse

Current control dial to 270. Now move the Voltage

Adjustment dial to the desired voltage. Move the Coarse

Current control to the left for a softer arc and to the right for

a crisper arc.

ELECTRIC SHOCK can kill.

• Do not touch electrically live parts or

electrode with skin or wet clothing.

• Insulate yourself from work and ground.

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

FUMES & GASES can be dangerous.

• Keep your head out of the fumes.

• Use ventilation or exhaust to remove

fumes from breathing zone.

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

WELDING SPARKS can cause fire or

explosion.

• Keep flammable material away.

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

ARC RAYS can burn.

• Wear eye, ear, and body protection.

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

WARNING

CAUTION

B-3

OPERATION

B-3

1. In the “High” position, the idler solenoid

deactivates, and the engine goes to high idle

speed. The speed is controlled by the governor.

2. In the “Auto” / position, the idler oper-

ates as follows:

a. When welding or drawing power for lights or tools

(approximately 100 watts minimum) from the

receptacles, the idler solenoid deactivates and

the engine operates at high idle speed.

b. 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.

c. If the welding or power load is not re-started

before the end of the time delay, the idler sole-

noid activates and reduces the engine to low idle

speed.

AUXILIARY POWER

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 115/230 VAC (60 hertz). Set fine

current adjustment at 100 for maximum auxiliary

power.

With the 3.0 KVA, 115/230 VAC auxiliary power, one

120V duplex protected by GFCI and one 230V duplex,

grounding type receptacle with 2 pole, 15 amp circuit

breaker.

The rating of 3.0 KVA permits a maximum continuous

current of 13 amps to be drawn from the 230 volt

duplex receptacle. 20 amps can be drawn from the

120 volt 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.

SAE-300

IDLER OPERATION

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 posi-

tions as follows:

SAE-300

WITH PERKINS 404D-22 DIESEL ENGINE

TYPICAL FUEL CONSUMPTION DATA

Low Idle (1375 RPM)-No Load @ 45 Volts

High Idle (1800 RPM)-No Load @ 96.6 Volts

3000 Watts

250 Amps @ 30 Volts

300 Amps @ 32 Volts

0.28 gal/hr ( 1.06 ltrs/hr)

0.42 gal/hr ( 1.59 ltrs/hr)

0.59 gal/hr ( 2.23 ltrs/hr)

1.03 gal/hr ( 3.90 ltrs/hr)

1.37 gal/hr ( 5.19 ltrs/hr)

GAS-SHIELDED FLUX-CORED WELDING

(WITH A K623-1 WIRE FEED MODULE INSTALLED)

Start by setting the Wire (CV) / Stick (CC) toggle switch to

the Wire (CV) position. Then set the left-side Coarse

Current control dial to 150. 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.

MIG WELDING

(WITH A K623-1 WIRE FEED MODULE INSTALLED)

Start by setting the Wire (CV) / Stick (CC) toggle switch to

the Wire (CV) position. Then set the left-side Coarse

Current control dial to 150. 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.

CARBON ARC GOUGING

Set both the Coarse Current and Fine Current O.C.V con-

trols to maximum for carbon arc gouging in the CC (constant

current) mode. If a K623-1 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.

C-1

ACCESSORIES

C-1

SAE-300

OPTIONAL FEATURES (Field Installed)

GENERAL OPTIONS

Pipe Thawing with an arc welder can cause fire,

explosion, damage to electric wiring or to the arc

welder if done improperly. The use of an arc

welder for pipe thawing is not approved by the

CSA, nor is it recommended or supported by

Lincoln Electric.

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

Power Plug Kit K802D

A power plug kit for the auxiliary power receptacles is

available. (Provides a plug for each receptacle.)

Spark Arrestor Kit K903-1

Includes a heavy gage steel, approved spark arrestor,

clamp and adapter for mounting to the muffler exhaust

pipe.

TRAILER K2636-1

For heavy-duty road, off-road, plant and yard use.

Includes pivoting jack stand, safety chains, and 13 in.

(330.2 mm) wheels. Stiff .120 in. (3.0 mm) welded rec-

tangular steel tube frame construction is phosphate

etched and powder coat painted for superior rust and

corrosion resistance. Low sway suspension gives out-

standing stability with manageable tongue

weight.Wheel bearings are packed with high viscosity,

high pressure, low washout Lubriplate

grease.

Includes a Duo-Hitch™– a 2 in. (50.8 mm)

Ball/Lunette

Eye combination hitch. Overall width: 60 in. (1.5 m)

K2639-1 Fender & Light Kit

K2640-1 Cable Rack

Stainless Steel Sheet Metal Kit K2423-1

Stainless steel roof and doors. Also includes decals

(mounted), door latches, door hooks, bumpers and all-

required mounting hardware. Fits K6090-9 and -10

Pipeliner

200D and K1643-1 thru -10 Classic

300D

STICK OPTIONS

ACCESSORY SET K704

Includes 35 feet (10 m) of electrode cable and 30 feet

(9 m) of work cable, headshield, work clamp and elec-

trode holder. Cable is rated at 500 amps, 60% duty

cycle.

Remote Control Kit K924-4

Contains remote control rheostat and 100 ft. (30.5 m)

cable for adjusting the OCV at the welding site.

TIG OPTIONS

TIG Module K930-2

Provides high frequency and shielding gas control for

AC and DC GTAW (TIG) welding applications. Its

compact case is designed for easy carrying, complete

with a handle. High frequency bypass is built in.

Additionally, the K936-3 control cable is required if

remote control is used. If remote control is not used

the K936-4 control cable is required.

PTA-26V TIG Torch K1783-9

Air cooled 200 amp torch equipped with valve for gas

flow control. 25Ft. length.

Magnum Parts Kit For PTA-26V TIG Torch KP509

Control Cable K936-4 (required for TIG Module)

Control cable for connecting the K930-2 TIG Module.

Arc Start Switch K814 (required for TIG Module)

Comes with a 25ft.(7.6m) cable.

Attaches to the TIG torch for convenient finger control.

Contactor Kit K938-1 (required for TIG Module)

Provide “Cold” tungsten Tip when welding with the

TIG Module.

Control Cable Extension K937-45

Allows the TIG Module to be operated at distances up

to 200 ft. from the power source.Available in 45 ft.

(13.7m).

WARNING

C-2

ACCESSORIES

C-2

WIRE FEEDER OPTIONS

Wire Feed Module K623-1

Provides constant voltage (CV) output with improved

arc stability for Innershield welding. Excellent for MIG

welding. Recommended wire feeders are the LN-7,

LN-23P and LN-25.

Remote Control Kit K2464-1

(Stick & Wire)

For machines that have the wire feed module.

Contains a rheostat for stick output, a potentiometer

for wire output and 100 ft. (30 m) of control cable.

LN-25 PRO Wire Feeder K2613-1

Portable CC/CV unit for flux-cored and MIG welding

with MAXTRAC

wire drive system. Includes Gas

Solenoid & Internal Contactor. Requires Wire Feed

Module.

Magnum

350 Innershield Gun for LN-25 K126-12

For self-shielded wire with 15 ft. (4.5m) cable. For

.072”(1.9mm) (5/64” (2.0mm) wire.

Magnum

PRO 350 Ready-Pak

K2652-2-10-45

15 ft., .035-5/64 in.

Magnum

PRO MIG/flux-cored welding guns are rated

100% duty cycle. The guns are designed for high

amperage, high duty cycle applications in extreme

environments where heat-resistance and fast service-

ability are key.

Drive Roll and Guide Tube Kit (for LN-25 PRO)

KP1697-068 for .068-.072 in. (1.8 mm)

KP1697-5/64 for 5/64 in. (2.0 mm)

For cored or solid steel wire.

Magnum

300 MIG Gun and Cable Package LN-25

PRO K1802-1 (includes K466-1 Connector Kit)

For .035-.045 in. (0.9-1.2 mm) gas-shielded wire with

15 ft. (4.5 m) cable.

Drive Roll and Guide Tube Kit (for LN-25 PRO)

KP1696-1

For .035 in. and .045 in. (0.9 mm and 1.1 mm) solid

steel wire.

Magnum Spool Gun K487-25

Hand held semiautomatic wire feeder requires SG

Control Module. 25 ft. length.

SG Control Module K488 (For Magnum Spool Gun)

The interface between the power source and the

spool gun. Provides control of wire speed and gas

flow.

Input Cable K691-10 ( For SG Control Module)

For Lincoln engine drives with 14-pin MS-type con-

nection, separate 115V NEMA receptacle and output

stud connections. 10 ft. length.

SAE-300

D-1

MAINTENANCE

D-1

SAFETY PRECAUTIONS

GENERAL INSTRUCTIONS

1. Blow out the welder and controls with an air hose at

least once every two months. In particularly dirty

locations, this cleaning may be necessary once a

week. Use low pressure air to avoid driving dirt into

the insulation.

Follow the engine service schedule in this manual

and the detailed maintenance and troubleshooting

in the engine manufacturerʼs manual.

COOLING SYSTEM

The SAE-300

is equipped with a pressure radiator.

Keep the radiator cap tight to prevent loss of coolant.

Clean and flush the cooling system periodically to pre-

vent clogging the passage and overheating the

engine. When antifreeze is needed, always use the

permanent type.

BEARINGS

This welder is equipped with a double synthetic

sealed ball bearing having sufficient grease to last

indefinitely under normal service.

COMMUTATOR AND BRUSHES

Uncovered rotating equipment can be dangerous.

Use care so your hands, hair, clothing or tools do

not catch in the rotating parts. Protect yourself

from particles that may be thrown out by the rotat-

ing armature when stoning the commutator.

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

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.

SAE-300

Have qualified personnel do the maintenance

work. Turn the engine off before working inside

the machine. In some cases, it may be neces-

sary to remove safety guards to perform

required maintenance. Remove guards only

when necessary and replace them when the

maintenance requiring their removal is com-

plete. Always use the greatest care when work-

ing 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.

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

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

front of this operatorʼs manual.

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

WARNING

D-2

MAINTENANCE

D-2

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 mainte-

nance man 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 pres-

sure 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.

IDLER MAINTENANCE

Before doing electrical work on the idler printed

circuit board, disconnect the battery.

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

When installing a new battery or using a jumper bat-

tery to start the engine, be sure the battery polarity is

connected properly. The correct polarity is negative

ground. Damage to the engine alternator and the

printed circuit board can result from incorrect connec-

tion.

1. Proper operation of the idler requires good ground-

ing of the printed circuit board, reed switch, and

battery.

2. Idler solenoid is activated for low idle.

3. If desired, the welder can be used without automat-

ic idling by setting the “Idler” switch to the “High”

position.

NAMEPLATES

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 replace-

ment item number.

PURGING AIR FROM FUEL SYSTEM

(PERKINS 404D-22 ENGINE)

Keep fuel clear of open flames or arcs, allow

engine to cool before working on the fuel system.

Wipe up any spilled fuel and do not start engine

until fumes clear.

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

If the engine is running rough and you suspect air has

been trapped in the fuel system, (e.g. the engine was

allowed to run out of fuel) perform the following steps

using qualified personnel:

. Loosen by two or three turns, the vent screw

(Figure D.1) on the fuel inlet connection.

FIGURE D.1

2. Operate the electric fuel pump by turning the

“Ignition” switch “ON” until fuel, free of air, flows

from the vent point. Tighten the vent screw.

3. Contact your Perkins Engine repair facility if prob-

lems persist.

SAE-300

CAUTION

WARNING

Vent Screw

Priming

Lever

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