Lincoln Electric SAE-300 MP K4089-2, Operator'S Manual

Page 1: ...hines having Code Numbers 12268 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 Pur...

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: ... 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 M...

Page 6: ...és et non 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 Eloig...

Page 7: ...How to Set Controls for Stick Welding B 3 Gas Shielding Flux Cored Welding B 4 Idler Operation Auxiliary Power Fuel Consumption Data B 4 Accessories Section C Optional Features Field Installed C 1 Maintenance Section D Safety Precautions D 1 General Instructions D 1 Cooling System D 1 Bearings D 1 Commutator and Brushes D 1 Nameplates D 2 Engine Service Chart D 3 GFCI Testing and Resetting Procedu...

Page 8: ...ED OUTPUT 104 F 40 C WELDER MODEL HEIGHT WIDTH DEPTH WEIGHT K4089 1 45 5 in 2 24 3 in 62 8 in 1419 lbs 1156 mm 616 mm 1594 mm 644 kg 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 DC Max OCV 1800RPM Auxiliary Power 1 3 000 Watts Continuous 60 Hz AC 26 Amps 120V 13 A...

Page 9: ...h has a battery charging fault indicator and engine fault indicator built in Auxiliary power consists of one 20 amp 120VAC 5 20R duplex receptacle with GFCI protection and one 15 amp 240VAC 6 15R receptacle protected by 2 pole 15 Amp breaker A 14 pin amphenol is included for voltage and output terminal control at wire feeder 42VAC not included Also included is a 6 pin amphenol to connect a remote ...

Page 10: ... connected to the 14 pin amphenol using a control cable the wire voltage control will automatically switch from either the control panel or remote if connected Cold Start Aid A block heater is included for extreme cold weather starting 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 o...

Page 11: ...nded from lift bail DO NOT MOUNT OVER COMBUSTIBLE SURFACES Where there is a combustible surface directly under stationary 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 this portab...

Page 12: ...connect the electrode cable to the terminal marked For Negative polarity con nect the electrode cable to the stud These connections 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...

Page 13: ...r battery To prevent EXPLOSION when a Installing a new battery disconnect thenegative cable from the old battery first and connect the negative cable to the new battery last b Connecting a battery charger remove the battery from the welder by disconnecting the negative cable first then the positive cable and battery clamp When reinstalling connect the negative cable last c Using a booster connect ...

Page 14: ...oncerns 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 outpu...

Page 15: ... front of this operator s manual 7 Allow the engine to run at high idle speed for several min utes to warm the engine Stop the engine and recheck the oil level after allowing sufficient time for the oil to drain into the pan If the level is down fill it to the full mark again The engine controls were properly set at the factory and should require no adjusting when received COLD WEATHER STARTING Wi...

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 MP 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: ...kings as an approximate guideline Arc characteristics and small changes in output can then be adjusted using the Fine Current and OCV control dial A K857 1 Remote Control or K2627 2 Remote with receptacle unit can also be used as the Fine Control and OCV control dial OCV Boost increases OCV at lower fine current settings and is recom mended for stick welding Position the OCV Boost switch to Classi...

Page 18: ...rating speeds The idler is controlled by the Idler toggle switch on the welder control panel The switch has two positions as follows 1 In the High position the idler solenoid deactivates and the engine goes to high idle speed The speed is con trolled by the governor 2 In the Auto position the idler operates as fol lows SAE 300 MP WITH PERKINS 403F 15F DIESEL ENGINE TYPICAL FUEL CONSUMPTION DATA GA...

Page 19: ... 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 MP product infor mation 4 On the results screen which shows SAE 300 MP sales liter ature document scroll down the b...

Page 20: ...dically 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 the commutator is a flat black color or the color appears uneven have the commutator cleaned by an experienced maintenance man using fine sandpaper or a commutator stone Never use emery cloth o...

Page 21: ... a piece of fine sandpaper between slip rings and brushes with the coarse side against the brushes With slight additional finger pressure on top of the brushes pull the sandpaper around the circumference of the rings in direction of rotation only until brushes seat properly In addition stone slip ring with a fine stone Brushes must be seated 100 Arcing or excessive exciter brush wear indicates a p...

Page 22: ...D 3 MAINTENANCE SAE 300 MP ...

Page 23: ...ker for this receptacle must not be tripped Reset if necessary Push the Reset button located on the GFCI This will assure normal GFCI operation Plug a night light with an ON OFF switch or other product such as a lamp into the Duplex receptacle and turn the prod uct 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 ot...

Page 24: ...ures or are unable to perform the tests repairs safely contact your Local Lincoln Authorized Field Service Facility for technical troubleshooting assistance before you proceed HOW TO USE TROUBLESHOOTING GUIDE Service and Repair should only be performed by Lincoln Electric Factory Trained Personnel Unauthorized repairs performed on this equipment may result in danger to the technician and machine o...

Page 25: ...ntrol Reactor coarse current bore may require cleaning 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 checked an...

Page 26: ... ly in the insulated bushing of the current control brush hold er caused by turning handle too hard against one of the stops If all recommended possible areas of misadjustment have been checked and the problem persists Contact your local Lincoln Authorized Field Service Facility 6 If auxiliary power is not present check connections to J12 flashing Check wiring continuity per wiring diagram Swap ou...

Page 27: ...P CAUTION ELECTRONIC IDLER TROUBLESHOOTING GUIDE With Idler Control Switch in the Auto Position Engine Will Not Return to Low Idle in Approximately 15 Seconds After Welding and Auxiliary Loads are Removed Set Idler Control Switch to the Auto Position Check for Continuity through Idler Control Switch Open Closed Check Voltage across Replace Idler Idler Control switch Control Switch 12 VDC 0 VDC Con...

Page 28: ...ick 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 Perkins Sensing PCB Engine Repair Facility Check for loose or disconnected wire running between weld...

Page 29: ...de 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 t...

Page 30: ...ual If for any reason you do not understand the test procedures or are unable to perform the tests repairs safely contact your Local Lincoln Authorized Field Service Facility for technical troubleshooting assistance before you proceed SAE 300 MP CAUTION Count number of off pulses ...

Page 31: ...iscosity 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: ...D Flash Codes LED tied in harness at control board Long Flash Short Flash Description 2 1 2 3 3 2 Negative armature in cvmode code 3 3 VArm 90V in cvmode code after CR2enable 4 2 Control board 18V Supply is under 16 2V 4 1 Control board 36V Supply is under 29 2V 5 1 Control board serial communication error 4 3 Control board 15V supply under code Field coil shorted fault can only be reset by restar...

Page 33: ... 3 4 5 6 7 2 3 4 11 12 8 9 10 5 6 1 7 J1 GREY J2 BLACK CONTROLLER ENGINE ECG NEGATIVE POSITIVE INTERPOLE COILS SHUNT FIELD SERIES FIELD BRUSH POSITION SHOWN AS VIEWED FROM CONTROL PANEL GENERATOR REACTOR 844A SPEED SENSOR J1 3 J1 10 57N 57 844 842 841 CHOKE 212D 844 GND B 51 J2 3 58N 58 212D J1 9 J2 7 66 57N 57 54 J2 9 212H 212 212J 61 844A D B ACTUATOR J1 8 J1 5 58N 58 212K J1 4 5D 5D G WK 59C 59...

Page 34: ...F 2 DIAGRAMS SAE 300 MP ...

Page 35: ...F 3 NOTES SAE 300 MP ...

Page 36: ...uch information or advice As a matter of practical consideration we also cannot assume any responsibility for updating or correcting any such information or advice once it has been given nor does the provision of information or advice create expand or alter any warranty with respect to the sale of our products Lincoln Electric is a responsive manufacturer but the selection and use of specific prod...