Lincoln Electric SAE-300 HE Service Manual Download Page 23

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LINCOLN ELECTRIC

SAE-300® HE Service Manual

Observe Safety Guidelines

detailed in the beginning of this manual.

TROUBLESHOOTING GUIDE

PROBLEMS

(SYMPTOMS)

POSSIBLE AREAS OF

MISADJUSTMENT(S)

RECOMMENDED

COURSE OF ACTION

OUTPUT PROBLEMS

The weld output is considerably

higher than indicated on the

dials. Auxiliary voltage is

normal.

1. If a remote current control is

being used, try switching to

local control. The remote

current control may be faulty.

1. Verify that the rocker is

positioned correctly, according

to the factory drill mark.

2. Perform the

Dead Short, 1st

Step And Open Reactor Test

Procedures

3. Perform the

Exciter Rotor

Resistance And Ground Test

Procedure (Exciter / Auxiliary

Power Alternator)

4. Perform the

Shunt Field Coil

Resistance And Ground Test

Procedure

5. Perform the

Rocker

Adjustment Procedure

The welding arc is loud and

spatters excessively.

1. The weld current or voltage

settings may be incorrect.

2. The polarity may be

incorrect for the process in use.

3. If a remote current control is

being used, try switching to

local control. The remote

current control may be faulty.

1. The engine RPM may be

incorrect.

2. Perform the

Brush And Slip

Ring Service Procedure (Exciter

/ Auxiliary Power Alternator)

3. Perform the

Welding

Generator Brush And

Commutator Inspection And

Service Procedure

4. Perform the

Dead Short, 1st

Step And Open Reactor Test

Procedures

5. Perform the

Exciter Rotor

Resistance And Ground Test

Procedure (Exciter / Auxiliary

Power Alternator)

6. Perform the

Shunt Field Coil

Resistance And Ground Test

Procedure

7. Check that the rocker is

aligned to the factory drill mark

and perform the

Rocker

Adjustment Procedure

, if

necessary.

Summary of Contents for SAE-300 HE

Page 2: ...N 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 helmet properly fitted...

Page 3: ...ers 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 th...

Page 4: ...m 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 an...

Page 5: ...ent 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...

Page 6: ...OOTING GUIDE 11 PC BOARD TROUBLESHOOTING PROCEDURES 12 Troubleshooting guide 13 Test Procedures 26 BRUSH AND SLIP RING SERVICE PROCEDURE EXCITER AUXILIARY POWER ALTERNATOR 26 EXCITER ROTOR VOLTAGE TEST PROCEDURE 28 EXCITER ROTOR RESISTANCE AND GROUND TEST PROCEDURE EXCITER AUXILIARY POWER ALTERNATOR 30 FLASHING VOLTAGE TEST PROCEDURE 32 EXCITER STATOR SHORT CICUIT AND GROUND TEST PROCEDURE 34 WELD...

Page 7: ...RD TEST PROCEDURE 56 RHEOSTAT TEST PROCEDURE 58 Removal And Replacement Procedures 60 ALTERNATOR ROTOR REMOVAL AND REPLACEMENT PROCEDURE 60 ALTERNATOR STATOR REMOVAL AND REPLACEMENT PROCEDURE 64 GENERATOR FRAME REMOVAL AND REPLACEMENT PROCEDURE 67 GENERATOR ARMATURE REMOVAL AND REPLACEMENT PROCEDURE 69 CHOKE REMOVAL AND REPLACEMENT PROCEDURE 71 CURRENT SENSE BOARD REMOVAL AND REPLACEMENT PROCEDURE...

Page 8: ...LINCOLN ELECTRIC SAE 300 HE Service Manual 3 Theory of Operation Figure F 1 Block Diagram ...

Page 9: ...n and the engine will be shut down by shutting off the power to the fuel solenoid These systems signal a fault by connecting the sense lead to chassis ground If the engine fault light turns on the engine protection system must be reset by turning the run stop switch off then on again before attempting to restart the engine The machine is equipped with a glow plug starting system that is used for c...

Page 10: ...the specified high RPM setting The solenoid is supplied with 12VDC power and is activated when circuitry on the Idler engine shutdown PC board completes the solenoid s path to chassis ground The automatic idle circuitry on the PC board uses a magnetic reed switch to sense weld current and a toroidal current transformer to sense auxiliary current When weld current flows the reed switch closes conne...

Page 11: ...g diode and is applied to the rotor field winding through the exciter brushes and slip rings Building output The flashing current produces a weak magnetic field in the rotor which is coupled to the now running engine This rotating magnetic field begins to generate AC output from all of the stator windings Output from the exciter winding is rectified by a diode bridge and then fed back into the rot...

Page 12: ...lternator is now producing sufficient AC power from both the exciter winding and the 115 230 VAC auxiliary power winding This 115 230 VAC 60 Hz auxiliary power is made available for use through the receptacles on the front panel of the machine after passing through circuit breakers and the automatic idle system s current sensor ...

Page 13: ...mature can spin Creating this magnetic field is often described as exciting the generator and is accomplished by passing controlled DC current through two shunt coils in the generator stator The power used to excite the main welding generator is the same rectified DC current used to power the rotating field of the exciter alternator See the section EXCITER AUXILIARY ALTERNATOR OPERATION This DC cu...

Page 14: ...gh a commutator and a system of brushes The commutator is a cylindrical structure made up of copper conductor bars and insulating materials that keep each bar isolated from the other bars and from the armature shaft Each bar is connected to the end of an armature winding The brushes contact the commutator at precise points around its circumference and are positioned so that they will conduct curre...

Page 15: ...rrent and produce the drooping volt amp curve that is so important to a constant current welding source This current control has almost no effect on the OCV Series coils and reactor Current from the negative brushes is routed through the generator s series coils and the reactor assembly before being connected to the negative weld output terminal These series coils are wound and arranged in such a ...

Page 16: ...ibute to the machine symptom Perform these tests checks in the order listed In general these tests can be conducted without removing the case cover Step 3 PERFORM COMPONENT TESTS The last column labeled Recommended Course of Action lists the most likely components that may have failed in your machine It also specifies the appropriate test procedure to verify that the subject component is either go...

Page 17: ... board from the static shielding bag and place it directly into the equipment Don t set the PC board on or near paper plastic or cloth which could have a static charge If the PC board can t be installed immediately put it back in the static shielding bag If the PC board uses protective shorting jumpers don t remove them until installation is complete If you return a PC board to The Lincoln Electri...

Page 18: ...r Rotor Resistance And Ground Test Procedure Exciter Auxiliary Power Alternator There is no or very low weld output and no auxiliary output 1 Check that the remote local switch is in the local control position 2 Check that the auxiliary power circuit breakers and GFCIs if so equipped are not tripped NOTE GFCIs will not reliably reset unless engine is operating at high idle RPM 3 Check all leads an...

Page 19: ...ting these components 5 Perform the Weld Circuit Ground And Short Circuit Test Procedure 6 The armature may be faulty There is no auxiliary voltage at receptacles but weld output is normal 1 Check that the auxiliary power circuit breakers are not tripped 2 If the machine is equipped with a ground fault circuit interrupter GFCI it may be tripped or defective NOTE GFCIs will not reliably reset unles...

Page 20: ...Ring Service Procedure Exciter Auxiliary Power Alternator 2 Perform the Welding Generator Brush And Commutator Inspection And Service Procedure 3 Check all the large weld current carrying leads inside the machine for damaged conductors insulation and poor connections 4 Perform the Coarse Current Control Unit Variable Reactor Inspection And Service Procedure 5 Check the wiring that connects the exc...

Page 21: ...n 1 Perform the Welding Generator Brush And Commutator Inspection And Service Procedure 2 Perform the Brush And Slip Ring Service Procedure Exciter Auxiliary Power Alternator 3 Perform the Shunt Field Coil Resistance And Ground Test Procedure 4 Perform the Dead Short 1st Step and Open Reactor Test Procedures If necessary perform the Coarse Current Control Unit Variable Reactor Inspection And Servi...

Page 22: ...e Rocker Adjustment Procedure If for any reason you do not understand the test procedures or are unable to perform the test repairs safely contact the Lincoln Electric Service Department for electrical troubleshooting assistance before you proceed Call 1 888 935 3877 ...

Page 23: ...d Coil Resistance And Ground Test Procedure 5 Perform the Rocker Adjustment Procedure The welding arc is loud and spatters excessively 1 The weld current or voltage settings may be incorrect 2 The polarity may be incorrect for the process in use 3 If a remote current control is being used try switching to local control The remote current control may be faulty 1 The engine RPM may be incorrect 2 Pe...

Page 24: ...coils for turn to turn shorts If for any reason you do not understand the test procedures or are unable to perform the test repairs safely contact the Lincoln Electric Service Department for electrical troubleshooting assistance before you proceed Call 1 888 935 3877 ...

Page 25: ...oo small or coiled Try using a set of short test cables of adequate size 1 Perform the Brush And Slip Ring Service Procedure Exciter Auxiliary Power Alternator 2 Perform the Welding Generator Brush And Commutator Inspection And Service Procedure 3 Perform the Coarse Current Control Unit Variable Reactor Inspection And Service Procedure 4 Perform the Exciter Rotor Voltage Test Procedure 5 Perform t...

Page 26: ...ects to the starter solenoid while holding in the start button If no voltage is present check the connections and wiring connecting the starter solenoid and the start push button switch See Wiring Diagram If the wiring and connections are good replace the push button switch If voltage is present check that the negative battery terminal is properly connected to the engine block If the battery is pr...

Page 27: ...n 3 If the machine is being used in a cold climate the thermostat or glow plug system may need to be used See the welder s operator manual and the engine operator s manual for detailed instructions 4 Check that there is an adequate supply of fresh clean fuel and that the fuel shut off valve is open 5 Check and if necessary replace the fuel filter 6 There may be air in the fuel system See the engin...

Page 28: ...m the Engine Governor Controller EGC Test Procedure The engine will not develop full power 1 Check that there is an adequate supply of fresh clean fuel and that the fuel shut off valve is fully open 2 Check the fuel and air filters replace if necessary 1 There may be internal problems with the engine Contact the engine manufacturer or a qualified engine repair technician The engine will not shut d...

Page 29: ...ormal weld and auxiliary output The engine starts and shuts down normally 1 Make sure there are no external loads on the weld terminals or the auxiliary power receptacles Disconnect the weld cables and unplug anything that may be connected to the auxiliary receptacles 1 The current sense board may be faulty Perform the Current Sense Board Test Procedure 2 Perform the Engine Governor Controller EGC...

Page 30: ...arts runs and shuts down normally 1 The load applied to the auxiliary receptacles may be too low A load of 100 Watts minimum is required for the idle system to operate reliably 2 Check that any power cords are in good condition and properly connected 3 Verify that any devices operating from the auxiliary AC power are operating correctly and are in good condition Try plugging the device into anothe...

Page 31: ...ine on the SAE 300 HE machine 2 Remove the covers from the exciter auxiliary power alternator by removing the screws securing it 3 Examine brushes slip rings and brush holder See Figure F 7 Brushes should be clean and free from oil or grease The brushes should be of sufficient length and have adequate spring tension Brushes should be making good continuous contact with the slip rings and should be...

Page 32: ...s have been replaced repositioned or are not making full contact with the slip rings it will be necessary to re seat them This can be done by placing a strip of 180 grit sandpaper between the slip rings and the brushes with the abrasive side against the brushes Pull the sandpaper strip around the circumference of the slip rings in the direction of rotor rotation only Repeat this procedure until th...

Page 33: ... Wiring Diagram NOTE On this machine and all other Lincoln Electric DC generator machines the black exciter lead is positive and the red lead is negative 5 Start the engine and place the idle switch in the HIGH position 6 Using a volt ohmmeter measure the voltage at the brush terminals See Wiring Diagram The voltage should be 135 to 145 VDC 7 Set the RUN STOP switch to STOP If the meter reading is...

Page 34: ...inched leads chafed insulation etc If necessary disconnect and insulate the stator output leads as close to the stator winding as possible If any leads were disconnected secure them to prevent damage from moving parts See Wiring Diagram 12 Re start the machine and measure the rotor voltage If the rotor voltage continues to read significantly lower than 124 VDC the stator is probably defective and ...

Page 35: ...move the cover from the exciter auxiliary power alternator by removing the screws securing it 4 Label and disconnect the leads connected to the rotor brush holder assembly See Wiring Diagram Remove the leads to electrically isolate the rotor windings 5 Using a volt ohmmeter measure the rotor winding resistance across the slip rings Normal resistance is approximately 40 ohms at 77 F 25 C See Figure...

Page 36: ...s at 77 deg F 25 deg C 9 Shut off engine and move one of the ohmmeter leads to a good clean chassis ground connection 10 Restart the engine and run it at high idle speed 1800 RPM The resistance should be very high at least 500 000 500k ohms 11 If the resistance readings differ significantly from the values indicated re check the brushes and the brush spring tension If the brushes and slip rings ar...

Page 37: ...6 Set the volt ohmmeter for DC volts and attach the leads to the brush terminals See Figure F 10 NOTE The negative brush is the one closest to the winding of the exciter and normally has a red wire attached 7 Place the idle switch in the High idle position start the engine and measure the voltage 8 If the voltage measures between 3 and 6 volts the flashing is normal and the test is complete 9 If t...

Page 38: ...AE 300 HE Service Manual 33 13 When testing is complete attach the previously removed exciter auxiliary power alternator cover and close the left and right side covers See Wiring Diagram Figure F 10 Flashing voltage test ...

Page 39: ...PROCEDURE 1 Turn off the engine on the SAE 300 HE machine 2 Lift the left and right side covers and secure them with the hooks provided 3 Make sure that nothing is plugged into the auxiliary receptacles 4 Disconnect and isolate the ground lead 820 connected to the neutral side of the 115 VAC auxiliary receptacle See the Wiring Diagram 5 Disconnect and isolate the exciter winding leads Leads 214 an...

Page 40: ...lves pressing an abrasive stone against a spinning commutator This procedure can be hazardous if done without proper training tools and protective equipment Consult the commutator stone manufacturer s instructions before attempting this procedure TEST PROCEDURE 1 Turn off the engine on the SAE 300 HE machine 2 Open either or both of the side covers and secure them with the hooks provided 3 Disconn...

Page 41: ...est Procedure If the brushes are worn out replace them and resurface or clean the commutator as needed If the brush springs appear weak discolored or damaged in any way replace them as well The brush holder plates and retainers should be clean smooth and undamaged so the brushes can move freely as they wear Check the rocker position Be certain that it is aligned with or very close to the factory d...

Page 42: ...rallel with the surface of the commutator and positioned 030 to 090 from the surface of the commutator The brush holder mounting screw should be tightened to a torque of 24 to 28 Ft Lbs The brush holder plate and retainer assembly must be clean and smooth nothing should prevent free movement of the brushes All electrical connections to the brush holders must be clean and tight The recommended torq...

Page 43: ... the engine on the SAE 300 HE machine 2 Open either or both of the side covers and secure them with the hooks provided 3 Remove the sheet metal cover protecting the welder generator brushes Weld circuit ground test 4 Rotate the coarse current control to the minimum output position 5 Using a volt ohmmeter measure the resistance between either of the two weld output terminals and a clean chassis gro...

Page 44: ...rement is too low check the heavy weld current carrying leads and connections for damaged insulation or dirt buildup between the negative series coils and positive interpole coils circuits If the low resistance point is between the stator coils the coils will require replacement or repair Field Flashing Procedure This procedure restores or corrects the residual magnetism in the welding generator T...

Page 45: ...e top of the welding generator frame and disconnect them See Wiring Diagram 4 Using a volt ohmmeter measure the resistance between the brown and blue wires that connect the shunt coils inside the generator frame See Wiring Diagram The resistance should measure about 50 to 54 Ohms at 77 F 25 C 5 If the resistance reading is correct proceed to the Shunt Coil Ground Test 6 If the resistance is signif...

Page 46: ...re is little or no output from the welding generator but auxiliary output is normal MATERIALS NEEDED Volt Ohmmeter Wiring Diagram TEST PROCEDURE 1 Turn off the engine on the SAE 300 HE machine 2 Locate the 12 pin Molex connector in the wire bundle that exits the welding generator fame See Wiring Diagram 3 Set the voltmeter for DC voltage and back probe pins 3 and 5 blue and brown wires of the 12 p...

Page 47: ... 300 HE machine 2 If possible bring the machine to normal temperature by connecting a load bank and operating the machine at 100 output 250 amps 30 volts for about 30 minutes 3 Remove the load turn the Fine Current O C V Rheostat to MAXIMUM and the Coarse Current Control to MINIMUM Contacts on the insulated steel filler or Open Reactor 4 Short the output terminals and check that the machine output...

Page 48: ...Procedure or an open in the cables connecting to it See Wiring Diagram and perform the Coarse Current Control Unit Variable Reactor Inspection and Service Procedure These values will be accurate if machine is operating at normal temperature If the machine is cold the values will be higher Figure F 12 Course current control unit ...

Page 49: ...f the Rocker may be beneficial if the machine is operating within the specified limits but the arc characteristics are unsatisfactory for the desired application CAUTION Improper Rocker adjustment can result in poor performance reduced Brush life and damage to the Welding Generator This adjustment should only be attempted by an experienced professional MATERIALS NEEDED Resistive Load Bank Capable ...

Page 50: ...the direction of the armature rotation will reduce sparking 9 Continue running the machine under load for at least 30 minutes to bring the machine up to normal operating temperature and to fully seat the brushes Check for Max output 10 Remove the load set the output control and rheostat to maximum re apply the load and adjust the load bank to apply a 300 Amp load to the machine WARNING Do not move...

Page 51: ...LINCOLN ELECTRIC SAE 300 HE Service Manual 46 Figure F 13 Rocker w marks ...

Page 52: ...a visual inspection of the unit indicates excessive wear dirt or damage It should also be performed if the Coarse Current control unit fails a ground test or if called for in the dead short 1st step or open reactor tests It should also be done if the weld output is low or erratic and the auxiliary output is normal MATERIALS NEEDED 400 to 600 Grit Sandpaper Volt Ohmmeter Wiring Diagram TEST PROCEDU...

Page 53: ...blies See Figure F 16 Replace any that are worn damaged or missing If the shaft insulation tube requires replacement position the shaft and tube per Figure F 17 and torque the two 5 16 18 Hex head screws to 8 Ft Lbs 13 Disassemble the output stud assembly and check the insulating washers and tube Replace them if they are damaged or worn and re assemble the output stud assembly See Figure F 16 14 C...

Page 54: ...LINCOLN ELECTRIC SAE 300 HE Service Manual 49 Figure F 14 Brush spring Figure F 15 Windings insulated wedge ...

Page 55: ...LINCOLN ELECTRIC SAE 300 HE Service Manual 50 Figure F 1 Insulator spring locations Figure F 2 Shaft tube ...

Page 56: ...This test will determine if the Engine Governor Controller EGC is functioning properly MATERIALS NEEDED Volt Ohmmeter Wiring Diagram TEST PROCEDURE 1 Turn off the engine on the SAE 300 HE machine 2 Open the side covers and secure them with the hooks provided 3 Locate the engine governor controller EGC on the left rear side of the front panel See Figure F 18 See Wiring Diagram 4 Place the Run Stop ...

Page 57: ...H IN THE RUN POSITION PLUG J2 PIN 7 CHASSIS GROUND 4 OHMS IDLER SWITCH IN THE HIGH IDLE POSITION RUN STOP SWITCH IN THE RUN POSITION MACHINE OFF PLUG J1 PIN 5 PLUG J1 PIN 8 4 7 VDC IDLER SWITCH IN THE HIGH IDLE POSITION MACHINE RUNNING PLUG J1 PIN 5 PLUG J1 PIN 8 4 7 OHMS IDLER SWITCH IN THE HIGH IDLE POSITION RUN STOP SWITCH IN THE RUN POSITION MACHINE OFF PLUG J1 PIN 3 PLUG J1 PIN 10 2 6 KHZ IDL...

Page 58: ...LINCOLN ELECTRIC SAE 300 HE Service Manual 53 Figure F 3 Engine governor controller EGC location Figure F 4 Engine governor controller EGC plug and pin locations ...

Page 59: ...ack left side of the engine See Wiring Diagram 4 Using a volt ohmmeter perform the tests outlined below See Wiring Diagram 5 Place the Run Stop switch into the Stop position and test the following points Chassis ground to the B terminal of the alternator Lead 51 the meter should read battery voltage Chassis ground to the alternator flash sense lead Lead 59 The meter should read 0 volts 6 Place the...

Page 60: ...00 HE machine 2 Open the side covers and secure them with the hooks provided 3 Locate the choke assembly attached to the rear of the front panel and perform the following tests See Wiring Diagram 4 Open No weld output Using a volt ohmmeter test the resistance from the top choke terminal to the negative output terminal See Wiring Diagram Typical resistance is less than one ohm 5 Turn To Turn Short ...

Page 61: ...SAE 300 HE machine 2 Open the side covers and secure them with the hooks provided 3 Locate the current sense board on the left rear side of the front panel See Figure F 20 See Wiring Diagram 4 Place the Run Stop switch into the Run position See Wiring Diagram 5 Using a volt ohmmeter measure the voltage from current sensor board plug pin 1 to pin 2 Normal reading is 12 VDC See Figure F 21 See Wirin...

Page 62: ...LINCOLN ELECTRIC SAE 300 HE Service Manual 57 Figure F 20 Current sense board location Figure F 21 Current sense board pin locations ...

Page 63: ...Ohmmeter Wiring Diagram TEST PROCEDURE 1 Turn off the engine on the SAE 300 HE machine 2 Open the side covers and secure them with the hooks provided 3 Locate the rheostat on the rear of the upper control panel See Figure F 22 See Wiring Diagram 4 Label and disconnect leads from the rheostat terminals See Wiring Diagram 5 Using a volt ohmmeter measure the resistance from the top rheostat terminal ...

Page 64: ...LINCOLN ELECTRIC SAE 300 HE Service Manual 59 Figure F 22 Rheostat terminal locations ...

Page 65: ...ATERIALS NEEDED 7 16 Wrench 1 2 Wrench 3 8 Wrench 5 16 Wrench 1 5 8 Socket Wrench Small Gear Puller Wiring Diagram REMOVAL PROCEDURE 1 Turn off the engine on the SAE 300 HE machine 2 Open the side covers and secure them with the hooks provided 3 Remove the roof panel 4 Using a 7 16 wrench remove the two bolts and washers and partially slide out the battery mounting panel See Figure F 23 5 Using a ...

Page 66: ...7 minimum is allowed 3 Mount the brush holder assembly to the stator frame using two bolts washers and nuts Installing and Seating Exciter Slip Ring Brushes a Make sure the slip rings are clean and free from oil and grease b With the brushes in place insert one end of a minimum 24 long piece of 180 grit sandpaper between the slip rings and brushes abrasive against brushes Pull the paper around the...

Page 67: ...LINCOLN ELECTRIC SAE 300 HE Service Manual 62 Figure F 23 Battery panel removal Figure F 24 Alternator cover and wraparound removal ...

Page 68: ...LINCOLN ELECTRIC SAE 300 HE Service Manual 63 Figure F 25 Rotor removal ...

Page 69: ...cover protecting the welding generator brushes and commutator See Figure F 26 5 Use the wiring diagram to identify all of the wires connected to the alternator stator winding Carefully mark these leads for later reassembly and then disconnect them Cut cable ties as necessary 6 Lift the eight welding generator brushes from the commutator Note the position of the brushes for later reassembly 7 To as...

Page 70: ... between the two mating parts Carefully and evenly tighten the four mounting bolts 5 Check the armature air gap At the smallest point the gap should be wide enough to allow a 035 thick Ч wide feeler gage to fit between the armature and stator through the entire length 6 Position the rocker tightly against the hub align the drill mark and tighten the rocker lock screw to 70 to 75 Inch Lbs DO NOT OV...

Page 71: ...LINCOLN ELECTRIC SAE 300 HE Service Manual 66 Figure F 26 Generator cover removal Figure F 27 Rocker mark locations ...

Page 72: ...edure 4 Label and disconnect all of the wires and cables that connect to the stator frame assembly See Wiring Diagram 5 Remove the mounting bolts from the generator feet 6 Using a hoist and sling very carefully lift the generator only enough so the generator frame will clear the welder frame and can be removed The sling should be positioned near the center of the generator frame Carefully watch th...

Page 73: ...re not damaged 4 Align the bolt holes and install the screws that had been removed earlier Carefully and evenly tighten them making sure that the mating surfaces come together cleanly all the way around Tighten the screws 5 Remove the supports from the engine and carefully lower the generator frame Install the rubber mounts 6 Reverse the removal procedure to reassemble the machine Be sure to secur...

Page 74: ...rform the Alternator Stator Removal Procedure 4 Perform the Generator Frame Removal Procedure 5 Using the rope sling support the armature Position the sling at the center of gravity of the armature assembly See Figure F 28 6 Remove the eight screws securing the blower paddle segments and the outer diameter of the flexible coupling disk to the flywheel 7 With the armature securely supported in the ...

Page 75: ...LINCOLN ELECTRIC SAE 300 HE Service Manual 70 Figure F 28 Sling lift ...

Page 76: ...e SAE 300 HE machine 2 Remove the roof and side covers 3 Remove the lower control panel to gain access to the choke leads 4 Using a 1 2 open end wrench and a 1 2 socket remove the bolt nut and lock washer securing leads to the top choke terminal Label and disconnect leads See Figure F 29 See Wiring Diagram 5 Using a 1 2 open end wrench and a 1 2 socket remove the bolt nut and lock washer securing ...

Page 77: ...eads to the bottom choke terminal See Wiring Diagram 5 Using a 1 2 open end wrench and a 1 2 socket attach the bolt nut and lock washer securing leads to the top choke terminal See Figure F X See Wiring Diagram 6 Attach the roof and side covers to the machine 7 Perform the Retest After Repair Procedure Figure F 29 Choke terminal locations ...

Page 78: ...e Board MATERIALS NEEDED Phillips Screwdriver Wiring Diagram REMOVAL PROCEDURE 1 Turn off the engine on the SAE 300 HE machine 2 Open the left side cover 3 Label and disconnect the plug from the current sense board See Figure F 30 See Wiring Diagram 4 Label and disconnect the four quick connect terminals securing leads to the current sense board See Wiring Diagram 5 Using a Phillips screwdriver re...

Page 79: ...LINCOLN ELECTRIC SAE 300 HE Service Manual 74 Figure F 30 Current sense board plug location ...

Page 80: ...cian in the removal and replacement of the Engine Governor Controller EGC MATERIALS NEEDED Slotted Screwdriver Wiring Diagram REMOVAL PROCEDURE 1 Turn off the engine on the SAE 300 HE machine 2 Open the left side cover 3 Label and disconnect plugs J1 and J2 from the engine governor controller See Figure F 31 See Wiring Diagram 4 Using a slotted screwdriver remove the two screws standoffs nuts and ...

Page 81: ...LINCOLN ELECTRIC SAE 300 HE Service Manual 76 Figure F 31 Engine governor controller EGC plug and mounting hardware locations ...

Page 82: ...ST DESCRIPTION This procedure will aid the technician in the removal and replacement of the Rheostat MATERIALS NEEDED 11 32 Nutdriver 3 32 Allen Wrench Wiring Diagram REMOVAL PROCEDURE 1 Turn off the engine on the SAE 300 HE machine 2 Open the side covers and secure them with the hooks provided 3 Using an 11 32 nutdriver remove the two nuts securing the leads to the rheostat terminals See Figure F...

Page 83: ...LINCOLN ELECTRIC SAE 300 HE Service Manual 78 Figure F 32 Rheostat terminal locations ...

Page 84: ...replace any electrical components ENGINE OUTPUT IDLE RPM FULL LOAD RPM HIGH IDLE 1800 1800 LOW IDLE 1440 N A RATED OUTPUT 104 F 40 C WELDER WELDING PROCESS WELDING OUTPUT CURRENT VOLTAGE DUTY CYCLE OUTPUT RANGE AMPS MAX WELD OCV FULL LOAD RPM DC CONSTANT CURRENT 250A 30V 100 300A 32V 60 30A TO 300A 90 VOLTS RATED OUTPUT 104 F 40 C GENERATOR AUXILIARY POWER SINGLE PHASE 60 HZ AC VOLTS AMPS POWER 12...

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Summary of Contents for SAE-300 HE

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Lincoln Electric SAE-300 HE, Service Manual, Page: 23 / 84

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Summary of Contents for SAE-300 HE

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