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Lincoln Electric SAE-300 HE, Operator'S Manual, Page: 27 / 35

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Lincoln Electric SAE-300 HE Operator'S Manual Download Page 27

E-4

TROUBLESHOOTING

SAE-300

®

HE

E-4

ELECTRONIC  IDLER  TROUBLESHOOTING  GUIDE

Ifforanyreasonyoudonotunderstandthetestproceduresorareunabletoperformthetests/repairssafely,contactyour

Local  Lincoln Authorized Field Service Facility

fortechnicaltroubleshootingassistancebeforeyouproceed.

CAUTION

With Idler Control Switch in the Auto Position,

Engine Will Not Return to Low Idle in Approximately 15 Seconds

After Welding and Auxiliary Loads are Removed

Set Idler Control Switch

to the Auto Position

CheckforContinuitythroughIdler

ControlSwitch

Open

Closed

CheckVoltageacross

ReplaceIdler

IdlerControlswitch

ControlSwitch

12VDC

0VDC

ContactKubota

Replacecurrent

EngineRepair

SensingPCB

Facility

Summary of Contents for SAE-300 HE

Page 1: ...nes having Code Numbers 11906 12162 Need Help Call 1 888 935 3877 to talk to a Service Representative Hours of Operation 8 00 AM to 6 00 PM ET Mon thru Fri After hours Use Ask the Experts at lincolnelectric com A Lincoln Service Representative will contact you no later than the following business day For Service outside the USA Email globalservice lincolnelectric com Save for future reference Date...

Page 2: ...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 develop 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 helm...

Page 3: ...ty 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 ...

Page 4: ...o 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 g...

Page 5: ...h 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 ...

Page 6: ... inflammables 4 Des gouttes de laitier en fusion sont émises de l arc de soudage Se protéger avec des vêtements de protection libres de l huile 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 l on pique le laitier 6 Eloigner les m...

Page 7: ...ux 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...

Page 8: ...WIDTH DEPTH WEIGHT K3201 1 45 5 in 2 24 3 in 62 8 in 1432 lbs CSA Without 1156 mm 616 mm 1594 mm 650 kg Wire Feed Module K3201 2 45 5 in 2 24 3 in 62 8 in 1465 lbs CSA With 1156 mm 616 mm 1594 mm 665 kg 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 90V...

Page 9: ...sure gauge a fuel hour LED indicator gauge temperature gauge for auxiliary power con sists of one 20 amp 120VAC 5 20R duplex recepta cle with GFCI protection and one 15 amp 240VAC 6 15R receptacle protected by 2 pole 15 Amp break er All Copper Windings For long life and dependable operation Engine Idler The SAE 300 HE is equipped with an electronic automatic engine idler It automatically increases...

Page 10: ... and Receptacle are standard 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 suitabl...

Page 11: ...pended 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 MACHINE GROUNDING According to the United States National Electrical Code the frame of ...

Page 12: ...larity 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 ...

Page 13: ...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 conne...

Page 14: ...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 max...

Page 15: ... the front of this operator s 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 WEATHE...

Page 16: ...iodically shut off the engine and check the crankcase oil level WELDER OPERATION DUTY CYCLE 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 CURRENT CONTROL Do no...

Page 17: ...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 K3964 1 WIRE FEED MODULE INSTA...

Page 18: ...s The idler is controlled by the Idler toggle switch on the welder control panel The switch has two posi tions as follows 1 In the High position the idler solenoid deactivates and the engine goes to high idle speed The speed is controlled by the governor SAE 300 HE WITH KUBOTA D1503 DIESEL ENGINE TYPICAL FUEL CONSUMPTION DATA GAS SHIELDED FLUx CORED WELDING WITH A K3964 1 WIRE FEED MODULE INSTALLE...

Page 19: ...not approved by the CSA nor is it recommended or supported by Lincoln Electric FIELD INSTALLED OPTIONAL ACCESSORIES Follow these steps 1 Go to www lincolnelectric com 2 At the top of the screen in the Search field type E6 162 click on Search icon 3 On the results screen click on SAE 300 HE prod uct information 4 On the results screen which shows SAE 300 HE sales literature document scroll down the...

Page 20: ...sh 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 3...

Page 21: ...eated 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 po...

Page 22: ... EVERY 400 HOURS OR 12 MONTHS EVERY 500 HOURS OR 15 MONTHS EVERY 800 HOURS OR 24 MONTHS ENGINE SERVICE NOTE 2 TYPE OR QUANTITY I I 50 50 Water Ethylene Glycol R 7 82 qrts 7 4 L I R R 5 9 qrts 5 6 L including filter R R Kubota HH164 32430 C R Kubota 15221 43170 C Kubota 15831 43353 I I R Kubota 17480 97010 C R Donaldson P821575 I Intake 0071 0086 Exhaust 0071 0086 I I I I Fuel pre filter element Le...

Page 23: ...this receptacle must not be tripped Reset if necessary Push the Reset button located on the GFCI This will assure normal GFCI operation Plug a night light with an ON OFF switch or other product such as a lamp into the Duplex receptacle and turn the product ON Push the Test button located on the GFCI The night light or other product should go OFF Push the Reset button again The light or other produ...

Page 24: ... 1 LOCATE PROBLEM SYMPTOM Look under the column labeled PROBLEM SYMP TOMS This column describes possible symptoms that the machine may exhibit Find the listing that best describes the symptom that the machine is exhibiting Step 2 POSSIBLE CAUSE The second column labeled POSSIBLE CAUSE lists the obvious external possibilities that may contribute to the machine symptom Step 3 RECOMMENDED COURSE OF A...

Page 25: ... 6 Field rheostat may be making poor contact and overheating 7 Current Control may not be operating properly 8 Current Control brush holder contact springs may be worn out or missing Contact surface may be dirty rough and pitted 9 Current Control brush holder support stud and mating contact surfaces may be dirty or pitted and burned If all recommended possible areas of misadjustment have been chec...

Page 26: ...hes may be loose or missing 2 Exciter may not be operating 3 Field circuit of generator or exciter may be open 4 Exciter may have lost excita tion 5 Series field and armature cir cuit may be open circuited 1 Current setting may be too high 2 Polarity may be wrong 1 Exciter output low causing low output compared to dial indica tion 2 Operating speed too low or too high 3 Current Control shaft and h...

Page 27: ...ubleshooting assistance before you proceed CAUTION With Idler Control Switch in the Auto Position Engine Will Not Return to Low Idle in Approximately 15 Seconds After Welding and Auxiliary Loads are Removed Set Idler Control Switch to the Auto Position Check for Continuity through Idler Control Switch Open Closed Check Voltage across Replace Idler Idler Control switch Control Switch 12 VDC 0 VDC C...

Page 28: ... Pick Up Speed When The Arc is Struck Both Auxiliary Load 1 Check Idler circuit wiring Possible Problems are wires from Current Sensing Board reversed at idler switch or wires connected incorrectly at Current Sensor Molex plug 2 Check voltage across idler control switch 12V 0V Replace Current Contact Kubota Sensing PCB Engine Repair Facility Check for loose or disconnected wire running between wel...

Page 29: ...ode 1 Lack of fuel 2 Air mixed in the fuel system 3 Clogged fuel filter 4 Irregular and faulty fuel supply Injector pump trouble 5 Glow plug not heated 6 Clogged air cleaner 7 No compression 8 Engine protection light is ON 1 Faulty Ignition switch and or Injector pump solenoid 2 Insufficient charging or com plete discharge of the battery 3 Improper viscosity of the lubri cating oil 1 Air mixed in ...

Page 30: ...TER TEMPERATURE SWITCH MAY BE GROUNDED CHECK LONG 1 SHORT 5 NOT ENABLED FOR LINCOLN PRODUCTS LONG 2 SHORT 1 0 RPM IS DETECTED AND 12V IS DETECTED FAULTY RPM SENSOR CHECK FOR GOOD CONNECTION FROM L TERMINAL ON ALTERNATOR FAULTY ECU CHECK FOR 12 VOLTS ON SUPPLY LEAD TO RPM SENSOR FROM ECU LONG 2 SHORT 2 CURRENT TO ACTUATOR IS OUT OF LIMIT FAULTY ACTUATOR CHECK FOR PROPER COIL RESISTANCE LEADS TO ACT...

Page 31: ...viscosity of the engine oil 3 Faulty injection timing 1 Unsuitable fuel 2 Excess injection 3 Faulty function of the engine 4 Overloading 5 Clogged air cleaner 1 Loose fan belt 2 Faulty wiring 3 Faulty battery 4 Worn out alternator brush 1 Loose or damaged wiring 2 Drained voltage from battery 3 Damaged starter motor including solenoid 1 Faulty light wiring 2 Faulty Engine Control Unit 3 Faulty LED...

Page 32: ... CONTROL POTENTIOMETER CONNECT TO CASE REMOTE CONTOL POTENTIOMETER BOX RESISTORS REMOTE CONTROL OPTIONAL Y X B G W N U Y W LEADS CONNECTED TO ENGINE CONTROL UNIT SEE DETAIL NEUTRAL BONDED TO FRAME NEUTRE RACCORDE AU BATI CONTROL PANEL COMPONENTS SHOWN AS VIEWED FROM REAR LEAD COLOR CODE G GREEN N BROWN U BLUE W WHITE Y YELLOW B BLACK OR GRAY R RED OR PINK 56 57 ACTUATOR 844A IDLER SWITCH 844 60E 6...

Page 33: ... 62 75 4 00 4 00 23 00 8 70 41 66 3 35 57 80 O 56 SKID MOUNTING HOLE O 56 SKID MOUNTING HOLE N B N B N A NOTES N A CENTER OF GRAVITY WITH OIL AND WATER IN ENGINE BUT NO FUEL N B Ø 56 TRAILER MOUNTING HOLES 20 62 18 50 40 75 45 50 25 80 13 50 CONTROL PANEL ...

Page 34: ...SAE 300 HE NOTES ...

Page 35: ...stomer s particular purpose with respect to such information or advice As a matter of practical consideration we also cannot assume any responsibility for updating or correcting any such information or advice once it has been given nor does the provision of information or advice create expand or alter any warranty with respect to the sale of our products Lincoln Electric is a responsive manufactur...

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