English dropdown-ico

Lincoln Electric SEVERE DUTY SVM187-A manual

1
2
3
4
5
6
7
8
9
10
11
12
13
14
15
16
17
18
19
20
21
22
23
24
25
26
27
28
29
30
31
32
33
34
35
36
37
38
39
40
41
42
43
44
45
46
47
48
49
50
51
52
53
54
55
56
57
58
59
60
61
62
63
64
65
66
67
68
69
70
71
72
73
74
75
76
77
78
79
80
81
82
83
84
85
86
87
88
89
90
91
92
93
94
95
96
97
98
99
100
101
102
103
104
105
106
107
108
109
110
111
112
113
114
115
116
117
118
119
120
121
122
123
124
125
126
127
128
129
130
131
132
133
134
135
136
137
138
139
140
141
142

Go to page of

Similar user manuals

A good user manual

The rules should oblige the seller to give the purchaser an operating instrucion of Lincoln Electric SEVERE DUTY SVM187-A, along with an item. The lack of an instruction or false information given to customer shall constitute grounds to apply for a complaint because of nonconformity of goods with the contract. In accordance with the law, a customer can receive an instruction in non-paper form; lately graphic and electronic forms of the manuals, as well as instructional videos have been majorly used. A necessary precondition for this is the unmistakable, legible character of an instruction.

What is an instruction?

The term originates from the Latin word „instructio”, which means organizing. Therefore, in an instruction of Lincoln Electric SEVERE DUTY SVM187-A one could find a process description. An instruction's purpose is to teach, to ease the start-up and an item's use or performance of certain activities. An instruction is a compilation of information about an item/a service, it is a clue.

Unfortunately, only a few customers devote their time to read an instruction of Lincoln Electric SEVERE DUTY SVM187-A. A good user manual introduces us to a number of additional functionalities of the purchased item, and also helps us to avoid the formation of most of the defects.

What should a perfect user manual contain?

First and foremost, an user manual of Lincoln Electric SEVERE DUTY SVM187-A should contain:
- informations concerning technical data of Lincoln Electric SEVERE DUTY SVM187-A
- name of the manufacturer and a year of construction of the Lincoln Electric SEVERE DUTY SVM187-A item
- rules of operation, control and maintenance of the Lincoln Electric SEVERE DUTY SVM187-A item
- safety signs and mark certificates which confirm compatibility with appropriate standards

Why don't we read the manuals?

Usually it results from the lack of time and certainty about functionalities of purchased items. Unfortunately, networking and start-up of Lincoln Electric SEVERE DUTY SVM187-A alone are not enough. An instruction contains a number of clues concerning respective functionalities, safety rules, maintenance methods (what means should be used), eventual defects of Lincoln Electric SEVERE DUTY SVM187-A, and methods of problem resolution. Eventually, when one still can't find the answer to his problems, he will be directed to the Lincoln Electric service. Lately animated manuals and instructional videos are quite popular among customers. These kinds of user manuals are effective; they assure that a customer will familiarize himself with the whole material, and won't skip complicated, technical information of Lincoln Electric SEVERE DUTY SVM187-A.

Why one should read the manuals?

It is mostly in the manuals where we will find the details concerning construction and possibility of the Lincoln Electric SEVERE DUTY SVM187-A item, and its use of respective accessory, as well as information concerning all the functions and facilities.

After a successful purchase of an item one should find a moment and get to know with every part of an instruction. Currently the manuals are carefully prearranged and translated, so they could be fully understood by its users. The manuals will serve as an informational aid.

Table of contents for the manual

  • Page 1

    SVM187-A October , 2008 Safety Depends on Y ou Lincoln arc welding and cutting equipment is designed and built with safety in mind. However , your overall safety can be increased by pr oper installation . . . and thoughtful operation on your part. DO NOT INST ALL, OPERA TE OR REP AIR THIS EQUIPMENT WITHOUT READ- ING THIS MANUAL AND THE SAFETY PRECA[...]

  • Page 2

    SAFETY i i Return to Master T OC Return to Master T OC Return to Master T OC Return to Master T OC SAE-400 SEVERE DUTY FOR ENGINE powered equipment. 1.a. T urn the engine off before troubleshooting and maintenance work unless the maintenance work requires it to be running. ____________________________________________________ 1.b.Operate engines in [...]

  • Page 3

    SAFETY ii ii Return to Master T OC Return to Master T OC Return to Master T OC Return to Master T OC SAE-400 SEVERE DUTY 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 [...]

  • Page 4

    SAFETY iii iii Return to Master T OC Return to Master T OC Return to Master T OC Return to Master T OC SAE-400 SEVERE DUTY Jan ‘07 FOR ELECTRICALL Y powered equipment. 8.a. T urn 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,[...]

  • Page 5

    SAFETY iv iv Return to Master T OC Return to Master T OC Return to Master T OC Return to Master T OC SAE-400 SEVERE DUTY Mar ‘93 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 gén?[...]

  • Page 6

    SAFETY v v Return to Master T OC Return to Master T OC Return to Master T OC Return to Master T OC SAE-400 SEVERE DUTY Electromagnetic Compatibility (EMC) Conformance Products displaying the CE mark are in conformity with European Community Council Directive of 3 May 1989 on the approximation of the laws of the Member States relating to electromagn[...]

  • Page 7

    SAFETY vi vi Return to Master T OC Return to Master T OC Return to Master T OC Return to Master T OC SAE-400 SEVERE DUTY Electromagnetic Compatibility (EMC) The size of the surrounding area to be considered will depend on the structure of the building and other activities that are taking place. The surrounding area may extend beyond the boundaries [...]

  • Page 8

    - MASTER T ABLE OF CONTENTS FOR ALL SECTIONS - RETURN TO MAIN INDEX Page S a f e t y ........................................................................... i - i v I n s t a l l a t i o n .................................................................. S e c t i o nA O p e r a t i o n .........................................................[...]

  • Page 9

    A-1 A-1 SAE-400 SEVERE DUTY T ABLE OF CONTENTS - INST ALLA TION SECTION Return to Master T OC Return to Master T OC Return to Master T OC Return to Master T OC I n s t a l l a t i o n ............................................................................. A - 1 T e c h n i c a l S p e c i f i c a t i o n s ....................................[...]

  • Page 10

    INST ALLA TION A-2 A-2 SAE-400 SEVERE DUTY Return to Section T OC Return to Section T OC Return to Section T OC Return to Section T OC Return to Master T OC Return to Master T OC Return to Master T OC Return to Master T OC TECHNICAL SPECIFICA TIONS - SAE-400 SEVERE DUTY - Make/Model Description Speed (RPM) Displacement Starting Capacities System Pe[...]

  • Page 11

    INST ALLA TION A-3 A-3 SAE-400 SEVERE DUTY Return to Section T OC Return to Section T OC Return to Section T OC Return to Section T OC Return to Master T OC Return to Master T OC Return to Master T OC Return to Master T OC Read this entire installation section before you start installation. SAFETY PRECAUTIONS Do not attempt to use this equipment un[...]

  • Page 12

    INST ALLA TION A-4 A-4 SAE-400 SEVERE DUTY Return to Section T OC Return to Section T OC Return to Section T OC Return to Section T OC Return to Master T OC Return to Master T OC Return to Master T OC Return to Master T OC HIGH AL TITUDE OPERA TION At higher altitudes, output derating may be necessary . As a rule of thumb, derate the welder output [...]

  • Page 13

    INST ALLA TION A-5 A-5 SAE-400 SEVERE DUTY Return to Section T OC Return to Section T OC Return to Section T OC Return to Section T OC Return to Master T OC Return to Master T OC Return to Master T OC Return to Master T OC BA TTER Y CONNECTION W ARNING: Use caution as the electrolyte is a strong acid that can burn skin and damage eyes. Remove and d[...]

  • Page 14

    INST ALLA TION A-6 A-6 SAE-400 SEVERE DUTY Return to Section T OC Return to Section T OC Return to Section T OC Return to Section T OC Return to Master T OC Return to Master T OC Return to Master T OC Return to Master T OC WELDING OUTPUT CABLES With the engine off, connect the electrode and work cables to the studs provided. These connections shoul[...]

  • Page 15

    T ABLE OF CONTENTS - OPERA TION SECTION B-1 B-1 Return to Master T OC Return to Master T OC Return to Master T OC Return to Master T OC SAE-400 SEVERE DUTY O p e r a t i o n .............................................................................. B - 1 S a f e t y I n s t r u c t i o n s .......................................................[...]

  • Page 16

    OPERA TION B-2 B-2 SAE-400 SEVERE DUTY Return to Section T OC Return to Section T OC Return to Section T OC Return to Section T OC Return to Master T OC Return to Master T OC Return to Master T OC Return to Master T OC WELDING SP ARKS can cause fire or explosion. • Do not weld near flammable material . • Do not weld on containers that have held[...]

  • Page 17

    OPERA TION B-3 B-3 SAE-400 SEVERE DUTY Return to Section T OC Return to Section T OC Return to Section T OC Return to Section T OC Return to Master T OC Return to Master T OC Return to Master T OC Return to Master T OC DESIGN FEA TURES AND ADV ANT AGES FOR STICK WELDING • Excellent DC constant current output for stick weld- ing applications. • [...]

  • Page 18

    OPERA TION B-4 B-4 SAE-400 SEVERE DUTY Return to Section T OC Return to Section T OC Return to Section T OC Return to Section T OC Return to Master T OC Return to Master T OC Return to Master T OC Return to Master T OC ENGINE CONTROLS IGNITION SWITCH When placed in the “ON” position, this switch ener- gizes the fuel solenoid. When placed in the[...]

  • Page 19

    OPERA TION B-5 B-5 SAE-400 SEVERE DUTY Return to Section T OC Return to Section T OC Return to Section T OC Return to Section T OC Return to Master T OC Return to Master T OC Return to Master T OC Return to Master T OC WELDER CONTROLS POLARITY SWITCH T urn the Arc Polarity switch to electrode positive or electrode negative as required for each part[...]

  • Page 20

    OPERA TION B-6 B-6 SAE-400 SEVERE DUTY Return to Section T OC Return to Section T OC Return to Section T OC Return to Section T OC Return to Master T OC Return to Master T OC Return to Master T OC Return to Master T OC ENGINE OPERA TION For added safety always operate the welder with the doors closed. Further , leaving the doors open changes the de[...]

  • Page 21

    OPERA TION B-7 B-7 SAE-400 SEVERE DUTY Return to Section T OC Return to Section T OC Return to Section T OC Return to Section T OC Return to Master T OC Return to Master T OC Return to Master T OC Return to Master T OC TYPICAL FUEL CONSUMPTION The typical fuel consumption of the SAE-400 for various operat- ing scenarios is shown below: 1 1 199 + 1 [...]

  • Page 22

    Return to Section T OC Return to Section T OC Return to Section T OC Return to Section T OC Return to Master T OC Return to Master T OC Return to Master T OC Return to Master T OC NOTES B-8 B-8 SAE-400 SEVERE DUTY[...]

  • Page 23

    T ABLE OF CONTENTS - ACCESSORIES SECTION C-1 C-1 Return to Master T OC Return to Master T OC Return to Master T OC Return to Master T OC SAE-400 SEVERE DUTY A c c e s s o r i e s............................................................................ C - 1 O p t i o n a l F i e l d I n s t a l l e dA c c e s s o r i e s ........................[...]

  • Page 24

    ACCESSORIES C-2 C-2 SAE-400 SEVERE DUTY Return to Section T OC Return to Section T OC Return to Section T OC Return to Section T OC Return to Master T OC Return to Master T OC Return to Master T OC Return to Master T OC OPTIONAL FIELD INST ALLED ACCESSORIES K802-D Power Plug Kit - Kit includes male plugs for 20 Amp receptacle. K2641-1 T railer - A [...]

  • Page 25

    T ABLE OF CONTENTS - MAINTENANCE SECTION D-1 D-1 Return to Master T OC Return to Master T OC Return to Master T OC Return to Master T OC SAE-400 SEVERE DUTY M a i n t e n a n c e ........................................................................... D - 1 R o u t i n e M a i n t e n a n c e .....................................................[...]

  • Page 26

    MAINTENANCE D-2 D-2 SAE-400 SEVERE DUTY Return to Section T OC Return to Section T OC Return to Section T OC Return to Section T OC Return to Master T OC Return to Master T OC Return to Master T OC Return to Master T OC ELECTRIC SHOCK can kill. ● Do not touch electrically live parts such as output terminals or inter- nal wiring ENGINE EXHAUST can[...]

  • Page 27

    MAINTENANCE D-3 D-3 SAE-400 SEVERE DUTY Return to Section T OC Return to Section T OC Return to Section T OC Return to Section T OC Return to Master T OC Return to Master T OC Return to Master T OC Return to Master T OC BEARING MAINTENANCE This welder is equipped with a double-shielded ball bearing having sufficient grease to last indefinitely unde[...]

  • Page 28

    MAINTENANCE D-4 D-4 SAE-400 SEVERE DUTY Return to Section T OC Return to Section T OC Return to Section T OC Return to Section T OC Return to Master T OC Return to Master T OC Return to Master T OC Return to Master T OC 1. Close the fuel shutoff valve located under the fuel tank. (on code 10856 valve is located on the fuel strainer , which is mount[...]

  • Page 29

    MAINTENANCE D-5 D-5 SAE-400 SEVERE DUTY Return to Section T OC Return to Section T OC Return to Section T OC Return to Section T OC Return to Master T OC Return to Master T OC Return to Master T OC Return to Master T OC GFCI RECEPT ACLE TESTING AND RESET- TING PROCEDURE The GFCI receptacle should be properly tested at least once every month or when[...]

  • Page 30

    Return to Section T OC Return to Section T OC Return to Section T OC Return to Section T OC Return to Master T OC Return to Master T OC Return to Master T OC Return to Master T OC NOTES D-6 D-6 SAE-400 SEVERE DUTY[...]

  • Page 31

    T ABLE OF CONTENTS-THEOR Y OF OPERA TION SECTION E-1 E-1 Return to Master T OC Return to Master T OC Return to Master T OC Return to Master T OC SAE-400 SEVERE DUTY Theory of Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .E-1 Engine Starting and Prot[...]

  • Page 32

    THEOR Y OF OPERA TION E-2 E-2 SAE-400 SEVERE DUTY Return to Section T OC Return to Section T OC Return to Section T OC Return to Section T OC Return to Master T OC Return to Master T OC Return to Master T OC Return to Master T OC ENGINE ST ARTING AND PROTEC- TION T urning on the run/stop switch supplies 12VDC power to idler/engine protection PC boa[...]

  • Page 33

    THEOR Y OF OPERA TION E-3 E-3 SAE-400 SEVERE DUTY Return to Section T OC Return to Section T OC Return to Section T OC Return to Section T OC Return to Master T OC Return to Master T OC Return to Master T OC Return to Master T OC AUT OMA TIC ENGINE IDLE SYSTEM The automatic idle system reduces the engine RPM when there is no electrical demand on th[...]

  • Page 34

    THEOR Y OF OPERA TION E-4 E-4 SAE-400 SEVERE DUTY Return to Section T OC Return to Section T OC Return to Section T OC Return to Section T OC Return to Master T OC Return to Master T OC Return to Master T OC Return to Master T OC EXCITER/AUXILIAR Y AL TERNA TOR OPERA TION The exciter alternator is the smaller power generator that is located at the [...]

  • Page 35

    THEOR Y OF OPERA TION E-5 E-5 SAE-400 SEVERE DUTY Return to Section T OC Return to Section T OC Return to Section T OC Return to Section T OC Return to Master T OC Return to Master T OC Return to Master T OC Return to Master T OC EXCITER/AUXILIAR Y AL TERNA TOR OPERA TION (Continued) AC Auxiliary Output: The exciter alternator is now producing suff[...]

  • Page 36

    THEOR Y OF OPERA TION E-6 E-6 SAE-400 SEVERE DUTY Return to Section T OC Return to Section T OC Return to Section T OC Return to Section T OC Return to Master T OC Return to Master T OC Return to Master T OC Return to Master T OC WELDING GENERA T OR OPERA- TION Overview: The welding generator is coupled directly to the engine and produces the DC cu[...]

  • Page 37

    THEOR Y OF OPERA TION E-7 E-7 SAE-400 SEVERE DUTY Return to Section T OC Return to Section T OC Return to Section T OC Return to Section T OC Return to Master T OC Return to Master T OC Return to Master T OC Return to Master T OC WELDING GENERA T OR OPERA- TION (Continued) Producing weld current: Weld current is produced in the armature windings wh[...]

  • Page 38

    THEOR Y OF OPERA TION E-8 E-8 SAE-400 SEVERE DUTY Return to Section T OC Return to Section T OC Return to Section T OC Return to Section T OC Return to Master T OC Return to Master T OC Return to Master T OC Return to Master T OC WELDING GENERA T OR OPERA- TION (Continued) Current Control: The Current Control handle turns a rotor inside the reactor[...]

  • Page 39

    THEOR Y OF OPERA TION E-9 E-9 SAE-400 SEVERE DUTY Return to Section T OC Return to Section T OC Return to Section T OC Return to Section T OC Return to Master T OC Return to Master T OC Return to Master T OC Return to Master T OC WELDING GENERA T OR OPERA- TION (Continued) Interpole coils: Armature current from the remaining two sets of brush- es i[...]

  • Page 40

    Return to Section T OC Return to Section T OC Return to Section T OC Return to Section T OC Return to Master T OC Return to Master T OC Return to Master T OC Return to Master T OC NOTES E-10 E-10 SAE-400 SEVERE DUTY[...]

  • Page 41

    T ABLE OF CONTENTS - TROUBLESHOOTING AND REP AIR F-1 F-1 Return to Master T OC Return to Master T OC Return to Master T OC Return to Master T OC SAE-400 SEVERE DUTY T roubleshooting and Repair . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .F-1 How to Use T roubleshooting Gu[...]

  • Page 42

    TROUBLESHOOTING AND REP AIR F-2 F-2 SAE-400 SEVERE DUTY Return to Section T OC Return to Section T OC Return to Section T OC Return to Section T OC Return to Master T OC Return to Master T OC Return to Master T OC Return to Master T OC This T roubleshooting Guide is provided to help you locate and repair possible machine malfunctions. Simply follow[...]

  • Page 43

    TROUBLESHOOTING AND REP AIR F-3 F-3 SAE-400 SEVERE DUTY Return to Section T OC Return to Section T OC Return to Section T OC Return to Section T OC Return to Master T OC Return to Master T OC Return to Master T OC Return to Master T OC Sometimes machine failures appear to be due to PC board failures. These problems can sometimes be traced to poor e[...]

  • Page 44

    OUTPUT PROBLEMS Observe Safety Guidelines detailed in the beginning of this manual. PROBLEMS (SYMPTOMS) POSSIBLE AREAS OF MISADJUSTMENT(S) RECOMMENDED COURSE OF ACTION If for any reason you do not understand the test procedures or are unable to perform the tests/repairs safely , contact the Lincoln Electric Service Department for technical troubles[...]

  • Page 45

    OUTPUT PROBLEMS Observe Safety Guidelines detailed in the beginning of this manual. PROBLEMS (SYMPTOMS) POSSIBLE AREAS OF MISADJUSTMENT(S) RECOMMENDED COURSE OF ACTION If for any reason you do not understand the test procedures or are unable to perform the tests/repairs safely , contact the Lincoln Electric Service Department for technical troubles[...]

  • Page 46

    OUTPUT PROBLEMS Observe Safety Guidelines detailed in the beginning of this manual. PROBLEMS (SYMPTOMS) POSSIBLE AREAS OF MISADJUSTMENT(S) RECOMMENDED COURSE OF ACTION If for any reason you do not understand the test procedures or are unable to perform the tests/repairs safely , contact the Lincoln Electric Service Department for technical troubles[...]

  • Page 47

    OUTPUT PROBLEMS Observe Safety Guidelines detailed in the beginning of this manual. PROBLEMS (SYMPTOMS) POSSIBLE AREAS OF MISADJUSTMENT(S) RECOMMENDED COURSE OF ACTION If for any reason you do not understand the test procedures or are unable to perform the tests/repairs safely , contact the Lincoln Electric Service Department for technical troubles[...]

  • Page 48

    OUTPUT PROBLEMS Observe Safety Guidelines detailed in the beginning of this manual. PROBLEMS (SYMPTOMS) POSSIBLE AREAS OF MISADJUSTMENT(S) RECOMMENDED COURSE OF ACTION If for any reason you do not understand the test procedures or are unable to perform the tests/repairs safely , contact the Lincoln Electric Service Department for technical troubles[...]

  • Page 49

    OUTPUT PROBLEMS Observe Safety Guidelines detailed in the beginning of this manual. PROBLEMS (SYMPTOMS) POSSIBLE AREAS OF MISADJUSTMENT(S) RECOMMENDED COURSE OF ACTION If for any reason you do not understand the test procedures or are unable to perform the tests/repairs safely , contact the Lincoln Electric Service Department for technical troubles[...]

  • Page 50

    OUTPUT PROBLEMS Observe Safety Guidelines detailed in the beginning of this manual. PROBLEMS (SYMPTOMS) POSSIBLE AREAS OF MISADJUSTMENT(S) RECOMMENDED COURSE OF ACTION If for any reason you do not understand the test procedures or are unable to perform the tests/repairs safely , contact the Lincoln Electric Service Department for technical troubles[...]

  • Page 51

    OUTPUT PROBLEMS Observe Safety Guidelines detailed in the beginning of this manual. PROBLEMS (SYMPTOMS) POSSIBLE AREAS OF MISADJUSTMENT(S) RECOMMENDED COURSE OF ACTION If for any reason you do not understand the test procedures or are unable to perform the tests/repairs safely , contact the Lincoln Electric Service Department for technical troubles[...]

  • Page 52

    OUTPUT PROBLEMS Observe Safety Guidelines detailed in the beginning of this manual. PROBLEMS (SYMPTOMS) POSSIBLE AREAS OF MISADJUSTMENT(S) RECOMMENDED COURSE OF ACTION If for any reason you do not understand the test procedures or are unable to perform the tests/repairs safely , contact the Lincoln Electric Service Department for technical troubles[...]

  • Page 53

    OUTPUT PROBLEMS Observe Safety Guidelines detailed in the beginning of this manual. PROBLEMS (SYMPTOMS) POSSIBLE AREAS OF MISADJUSTMENT(S) RECOMMENDED COURSE OF ACTION If for any reason you do not understand the test procedures or are unable to perform the tests/repairs safely , contact the Lincoln Electric Service Department for technical troubles[...]

  • Page 54

    OUTPUT PROBLEMS Observe Safety Guidelines detailed in the beginning of this manual. PROBLEMS (SYMPTOMS) POSSIBLE AREAS OF MISADJUSTMENT(S) RECOMMENDED COURSE OF ACTION If for any reason you do not understand the test procedures or are unable to perform the tests/repairs safely , contact the Lincoln Electric Service Department for technical troubles[...]

  • Page 55

    OUTPUT PROBLEMS Observe Safety Guidelines detailed in the beginning of this manual. PROBLEMS (SYMPTOMS) POSSIBLE AREAS OF MISADJUSTMENT(S) RECOMMENDED COURSE OF ACTION If for any reason you do not understand the test procedures or are unable to perform the tests/repairs safely , contact the Lincoln Electric Service Department for technical troubles[...]

  • Page 56

    OUTPUT PROBLEMS Observe Safety Guidelines detailed in the beginning of this manual. PROBLEMS (SYMPTOMS) POSSIBLE AREAS OF MISADJUSTMENT(S) RECOMMENDED COURSE OF ACTION If for any reason you do not understand the test procedures or are unable to perform the tests/repairs safely , contact the Lincoln Electric Service Department for technical troubles[...]

  • Page 57

    OUTPUT PROBLEMS Observe Safety Guidelines detailed in the beginning of this manual. PROBLEMS (SYMPTOMS) POSSIBLE AREAS OF MISADJUSTMENT(S) RECOMMENDED COURSE OF ACTION If for any reason you do not understand the test procedures or are unable to perform the tests/repairs safely , contact the Lincoln Electric Service Department for technical troubles[...]

  • Page 58

    OUTPUT PROBLEMS Observe Safety Guidelines detailed in the beginning of this manual. PROBLEMS (SYMPTOMS) POSSIBLE AREAS OF MISADJUSTMENT(S) RECOMMENDED COURSE OF ACTION If for any reason you do not understand the test procedures or are unable to perform the tests/repairs safely , contact the Lincoln Electric Service Department for technical troubles[...]

  • Page 59

    OUTPUT PROBLEMS Observe Safety Guidelines detailed in the beginning of this manual. PROBLEMS (SYMPTOMS) POSSIBLE AREAS OF MISADJUSTMENT(S) RECOMMENDED COURSE OF ACTION If for any reason you do not understand the test procedures or are unable to perform the tests/repairs safely , contact the Lincoln Electric Service Department for technical troubles[...]

  • Page 60

    Return to Section T OC Return to Section T OC Return to Section T OC Return to Section T OC Return to Master T OC Return to Master T OC Return to Master T OC Return to Master T OC NOTES F-20 F-20 SAE-400 SEVERE DUTY[...]

  • Page 61

    Service and repair should be performed by only Lincoln Electric factory trained personnel. Unauthorized repairs performed on this equipment may result in danger to the technician or machine operator and will invalidate your factory warranty . For your safety and to avoid electrical shock, please observe all safety notes and precautions detailed thr[...]

  • Page 62

    Idler Solenoid Spring Idler Rod Speed Control Lever Ball Joint Lock Nut Pulley Fan Blades Possible Strobe-T ach Mark Points FIGURE F .1 – ENGINE COMPONENTS (CODE 10856) ENGINE RPM ADJUSTMENT TEST (continued) TEST PROCEDURE 1. T urn the engine off 2. Open the left side door , on the engine end of the machine. W ARNING: Secure the door in the open [...]

  • Page 63

    SOLENOID BRACKET BALL JOINT LOCK NUT IDLER ROD FIGURE F .2 – ENGINE COMPONENTS (CODE 1 1 199 & 1 14080) ENGINE RPM ADJUSTMENT TEST (continued) Strobe-T ach Method (continued) 5. The tach should read between 1780 and 1810 RPM 6. Move the idle switch to the “AUTO IDLE” position and wait for the idle solenoid to energize, and the engine RPM [...]

  • Page 64

    ENGINE RPM ADJUSTMENT TEST (continued) ENGINE RPM ADJUSTMENT PROCEDURE High Idle Adjustment: IMPORT ANT : The high idle RPM is set by the engine manufacturer , and should not be changed. If the high idle RPM is not within the specified range, the engine should be serviced by a qualified engine technician. Low idle adjustment: Code 10856 only: 1. Ho[...]

  • Page 65

    Service and repair should be performed by only Lincoln Electric factory trained personnel. Unauthorized repairs performed on this equipment may result in danger to the technician or machine operator and will invalidate your factory warranty . For your safety and to avoid electrical shock, please observe all safety notes and precautions detailed thr[...]

  • Page 66

    EXC I TER COVER F I VE SCREWS (TWO ON OTHER S I DE) FIGURE F .3 – EXCITER COVER SCREW LOCA TIONS BRUSH AND SLIP RING SER VICE PROCEDURE (Exciter / Auxiliary Power Alternator) (continued) PROCEDURE 1. Open either , or both of the doors on the control panel end of the SAE-400 machine. W ARNING: Secure the doors in the open position using the door r[...]

  • Page 67

    BRUSHES FIGURE F .4 – BRUSH LOCA TIONS BRUSH AND SLIP RING SER VICE PROCEDURE (Exciter / Auxiliary Power Alternator) (continued) PROCEDURE (continued 5. Check for evidence of sticking brushes. Sticking brushes will normally result in the slip rings being pitted and discolored from excessive arcing. Another sign of sticking brushes is instability [...]

  • Page 68

    Return to Section T OC Return to Section T OC Return to Section T OC Return to Section T OC Return to Master T OC Return to Master T OC Return to Master T OC Return to Master T OC NOTES F-28 F-28 SAE-400 SEVERE DUTY[...]

  • Page 69

    Service and repair should be performed by only Lincoln Electric factory trained personnel. Unauthorized repairs performed on this equipment may result in danger to the technician or machine operator and will invalidate your factory warranty . For your safety and to avoid electrical shock, please observe all safety notes and precautions detailed thr[...]

  • Page 70

    EXC I TER COVER F I VE SCREWS (TWO ON OTHER S I DE) FIGURE F .6 – EXCITER COVER SCREW LOCA TIONS EXCITER ROT OR VOL T AGE TEST(continued) PROCEDURE 1. T urn engine off. 2. Make sure that the battery is fully charged and in good condition, and the battery connections are clean and tight. The Engine and generator should be at normal operat- ing tem[...]

  • Page 71

    POSITIVE SLIP RING NEGA TIVE SLIP RING BRUSH HOLDER ASSEMBL Y BRUSHES VOL TMETER LEADS FIGURE F .7 – EXCITER ROTOR VOL T AGE TEST EXCITER ROT OR VOL T AGE TEST (continued) PROCEDURE (continued) 5. Connect the volt meter probes to the brush termi- nals. See the wiring diagram and Figure F .7 NOTE: On this machine, and all other Lincoln Electric DC[...]

  • Page 72

    EXCITER ROT OR VOL T AGE TEST (continued) PROCEDURE (continued) 9. Set the RUN/ST OP switch to “ST OP” If the meter reading is normal, this test is complete. If the voltage measures zero or very near zero, the rotor may be shorting or grounding while spinning. Perform the Exciter Rotor Resistance and Ground T est . If voltage is higher than spe[...]

  • Page 73

    Service and repair should be performed by only Lincoln Electric factory trained personnel. Unauthorized repairs performed on this equipment may result in danger to the technician or machine operator and will invalidate your factory warranty . For your safety and to avoid electrical shock, please observe all safety notes and precautions detailed thr[...]

  • Page 74

    EXC I TER COVER F I VE SCREWS (TWO ON OTHER S I DE) FIGURE F .8 – EXCITER COVER SCREW LOCA TIONS EXCITER ROT OR RESIST ANCE AND GROUND TEST (Exciter / Auxiliary Power Alternator) (continued) PROCEDURE “Static” T ests: 1. T urn the engine off. 2. Open either , or both of the doors on the control panel end of the SAE-400 machine. W ARNING: Secu[...]

  • Page 75

    POSITIVE SLIP RING NEGA TIVE SLIP RING BRUSH HOLDER ASSEMBL Y OHMMETER LEADS BRUSHES FIGURE F .9 – SLIP RING LOCA TIONS EXCITER ROT OR RESIST ANCE AND GROUND TEST (Exciter / Auxiliary Power Alternator) (continued) PROCEDURE (continued) 5. Using the ohmmeter , check the rotor winding resis- tance across the slip rings. Normal resistance is approxi[...]

  • Page 76

    POSITIVE SLIP RING NEGA TIVE SLIP RING BRUSH HOLDER ASSEMBL Y BRUSHES VOL TMETER LEADS FIGURE F .10 – SLIP RING LOCA TIONS EXCITER ROT OR RESIST ANCE AND GROUND TEST (Exciter / Auxiliary Power Alternator) (continued) PROCEDURE (continued) “Dynamic” T ests: (Also referred to as flying resistance test) This test checks for faults in the rotor w[...]

  • Page 77

    Service and repair should be performed by only Lincoln Electric factory trained personnel. Unauthorized repairs performed on this equipment may result in danger to the technician or machine operator and will invalidate your factory warranty . For your safety and to avoid electrical shock, please observe all safety notes and precautions detailed thr[...]

  • Page 78

    EXC I TER COVER F I VE SCREWS (TWO ON OTHER S I DE) FIGURE F .1 1 – EXCITER COVER SCREW LOCA TIONS FLASHING VOL T AGE TEST (Engine not running) (continued) PROCEDURE 1. Open either , or both of the doors on the control panel end of the SAE-400 machine. W ARNING: Secure the doors in the open position using the door restraint system. If the machine[...]

  • Page 79

    J1-1 (+) BA TTERY VOL T AGE J1-10, FLASHING AND HOUR METER OUTPUT J1-5, CHASSIS GROUND FIGURE F .13 – IDLER/ENGINE PROTECTION PC BOARD CODES 10856 FLASHING VOL T AGE TEST (Engine not running) (continued) PROCEDURE (continued) 7. If this voltage reading is correct, the test is com- plete. If the voltage is significantly higher than expected: There[...]

  • Page 80

    J31-1, (+) BA TTERY VOL T AGE I NPUT J31-10, FLASH I NG AND HOUR METER OUTPUT B-1 CHASS I S GROUND FIGURE F .14 – IDLER/ENGINE PROTECTION PC BOARD CODES 1 1 199 AND 1 1408 FLASHING VOL T AGE TEST (Engine not running (continued) PROCEDURE (continued) 10. Connect positive voltmeter probe to the Idler / Engine protection PC board J1 pin 10 for Code [...]

  • Page 81

    Service and repair should be performed by only Lincoln Electric factory trained personnel. Unauthorized repairs performed on this equipment may result in danger to the technician or machine operator and will invalidate your factory warranty . For your safety and to avoid electrical shock, please observe all safety notes and precautions detailed thr[...]

  • Page 82

    EXCITER ST A TOR SHORT CIRCUIT & GROUND TEST (continued) PROCEDURE 1. Open either , or both of the doors on the control panel end of the SAE-400 machine. W ARNING: Secure the doors in the open position using the door restraint system. If the machine does not have a door restraint system, remove the doors or securely restrain them to prevent the[...]

  • Page 83

    Service and repair should be performed by only Lincoln Electric factory trained personnel. Unauthorized repairs performed on this equipment may result in danger to the technician or machine operator and will invalidate your factory warranty . For your safety and to avoid electrical shock, please observe all safety notes and precautions detailed thr[...]

  • Page 84

    GENERA TOR COVER FOUR SCREWS T OT AL FIGURE F .15 – GENERA TOR COVER SCREW LOCA TIONS WELDING GENERA T OR BRUSH AND COMMUT A T OR INSPECTION AND SER VICE (continued) PROCEDURE 1. Shut off the engine. 2. Open either , or both of the doors on the control panel end of the SAE-400 machine. W ARNING: Secure the doors in the open position using the doo[...]

  • Page 85

    ARMA TURE COMMUT A TOR SPRINGS BRUSH HOLDER PLA TE BRUSHES BRUSH RET AINER BRUSH HOLDER INSULA TORS MOUNTING SCREW DRILL MARK ROCKER FIGURE F .16 – GENERA TOR COMPONENTS WELDING GENERA T OR BRUSH AND COMMUT A T OR INSPECTION AND SER VICE (continued) PROCEDURE 5. Examine the Commutator . Normal appearance: The commutator should appear smooth, and [...]

  • Page 86

    WELDING GENERA T OR BRUSH AND COMMUT A T OR INSPECTION AND SER VICE (continued) PROCEDURE (continued) Pitted and Arc Damaged Commutator: If pitting and arc damage to the commutator is evident, the machine may have been used with badly worn brushes. The brush spring tension may have been too low , or the brushes may have been sticking in the hold- e[...]

  • Page 87

    Service and repair should be performed by only Lincoln Electric factory trained personnel. Unauthorized repairs performed on this equipment may result in danger to the technician or machine operator and will invalidate your factory warranty . For your safety and to avoid electrical shock, please observe all safety notes and precautions detailed thr[...]

  • Page 88

    WELD CIRCUIT GROUND AND SHORT CIRCUIT TEST (continued) PROCEDURE 1. T urn the engine off. Weld circuit ground test: 1. Rotate the output control to the minimum output position. 2. Measure the resistance between either of the two weld output terminals and a clean chassis ground connection. 3. The resistance measurement should be very high 500,000 (5[...]

  • Page 89

    Service and repair should be performed by only Lincoln Electric factory trained personnel. Unauthorized repairs performed on this equipment may result in danger to the technician or machine operator and will invalidate your factory warranty . For your safety and to avoid electrical shock, please observe all safety notes and precautions detailed thr[...]

  • Page 90

    SHUNT FIELD COIL RESIST ANCE AND GROUND TEST (continued) PROCEDURE 1. T urn the engine off. 2 . Open both of the doors on the control panel end of the SAE-400 machine. The roof may also need to be removed on some models. W ARNING: Secure the doors in the open position using the door restraint system. If the machine does not have a door restraint sy[...]

  • Page 91

    Service and repair should be performed by only Lincoln Electric factory trained personnel. Unauthorized repairs performed on this equipment may result in danger to the technician or machine operator and will invalidate your factory warranty . For your safety and to avoid electrical shock, please observe all safety notes and precautions detailed thr[...]

  • Page 92

    SHUNT FIELD CIRCUIT VOL T AGE TEST (continued) PROCEDURE 1. T urn the engine off. 2. Open both of the doors on the control panel end of the SAE-400 machine. The roof may need to be removed on some models. W ARNING: Secure the doors in the open position using the door restraint system. If the machine does not have a door restraint system, remove the[...]

  • Page 93

    Service and repair should be performed by only Lincoln Electric factory trained personnel. Unauthorized repairs performed on this equipment may result in danger to the technician or machine operator and will invalidate your factory warranty . For your safety and to avoid electrical shock, please observe all safety notes and precautions detailed thr[...]

  • Page 94

    WINDING CONT ACT SPRINGS MOV ABLE CONT ACTS Min. (open) Position FIRST STEP CONT ACT POSITION ROTOR INSULA TED FILLER FIGURE F .17 – OUTPUT CONTROL UNIT DEAD SHORT , 1ST STEP , AND OPEN REACTOR TESTS (continued) PROCEDURE 1. If possible, bring the machine to normal tempera- ture by connecting a load bank and operating the machine at 100% output ([...]

  • Page 95

    Service and repair should be performed by only Lincoln Electric factory trained personnel. Unauthorized repairs performed on this equipment may result in danger to the technician or machine operator and will invalidate your factory warranty . For your safety and to avoid electrical shock, please observe all safety notes and precautions detailed thr[...]

  • Page 96

    ARMA TURE COMMUT A TOR SPRINGS BRUSH HOLDER PLA TE BRUSHES BRUSH RET AINER BRUSH HOLDER INSULA TORS MOUNTING SCREW DRILL MARK ROCKER FIGURE F .18 – ROCKER W/MARKS ROCKER ADJUSTMENT PROCEDURE (continued) PROCEDURE The factory set point drill marks: 1. When the rocker is set for the first time at the facto- ry , a 1/8” drill is used to mark the p[...]

  • Page 97

    ROCKER ADJUSTMENT PROCEDURE (continued) PROCEDURE (continued) Initial rocker placement: 1. The rocker should be initially positioned so the center of brushes visually lines up with the center of the main poles. Lining up the four brush holder studs with the four exciter brack- et mounting bolts is acceptable for initial place- ment. The rocker shou[...]

  • Page 98

    Return to Section T OC Return to Section T OC Return to Section T OC Return to Section T OC Return to Master T OC Return to Master T OC Return to Master T OC Return to Master T OC NOTES F-58 F-58 SAE-400 SEVERE DUTY[...]

  • Page 99

    Service and repair should be performed by only Lincoln Electric factory trained personnel. Unauthorized repairs performed on this equipment may result in danger to the technician or machine operator and will invalidate your factory warranty . For your safety and to avoid electrical shock, please observe all safety notes and precautions detailed thr[...]

  • Page 100

    WINDING Contacts & Springs Output Stud Assembly Brush Holder Assembly FIGURE F .19 – BRUSH & SPRING OUTPUT CONTROL UNIT (V ARIABLE REACT OR) INSPECTION AND SERVICE PROCEDURE (continued) PROCEDURE 1. Turn the engine of f, open the doors on the control panel end of the machine and disconnect the nega- tive battery cable. The doors must be s[...]

  • Page 101

    WINDING INSULA TED WEDGE FIGURE F .20 – BRUSH & SPRING OUTPUT CONTROL UNIT (V ARIABLE REACT OR) INSPECTION AND SERVICE PROCEDURE (continued) PROCEDURE (continued) Servicing the continuous control unit: 8. Clean the continuous output control unit by using low pressure air to remove any excess dust and dirt. If the unit is greasy or oily , a mo[...]

  • Page 102

    Steel Shaft Coil Spring Spring Clip Flat W asher Insulator Tu b e Springs Contacts Insulator (Short Insulator T ube Not Shown) Output Stud Output Stud Bracket Brush Holder FIGURE F .21 – INSULA TOR & SPRING LOCA TIONS OUTPUT CONTROL UNIT (V ARIABLE REACT OR) INSPECTION AND SERVICE PROCEDURE (continued) PROCEDURE Servicing the rotating brush h[...]

  • Page 103

    FIGURE F .22 – SHAFT & TUBE OUTPUT CONTROL UNIT (V ARIABLE REACT OR) INSPECTION AND SERVICE PROCEDURE (continued) PROCEDURE (continued) The shaft spring will need to be compressed and the bracket drawn close to the back of the output control before the screws can be started and tightened. Locking type pliers and a drift punch can be used to m[...]

  • Page 104

    Return to Section T OC Return to Section T OC Return to Section T OC Return to Section T OC Return to Master T OC Return to Master T OC Return to Master T OC Return to Master T OC NOTES F-64 F-64 SAE-400 SEVERE DUTY[...]

  • Page 105

    Service and repair should be performed by only Lincoln Electric factory trained personnel. Unauthorized repairs performed on this equipment may result in danger to the technician or machine operator and will invalidate your factory warranty . For your safety and to avoid electrical shock, please observe all safety notes and precautions detailed thr[...]

  • Page 106

    #237 #224 GROUND FIGURE F .23 – ENGINE AL TERNA TOR CODE 10856 ENGINE PROTECTION SYSTEM CIRCUIT TEST (continued) PROCEDURE IMPORT ANT : Before proceeding with this test, verify that the engine has normal oil pressure, is not overheated, and the alternator drive belt is in place and properly ten- sioned. Open all of the doors on the SAE-400 machin[...]

  • Page 107

    #59 #51 FIGURE F .24 – ENGINE AL TERNA TOR CODE 1 1 199 &1 1408 ENGINE PROTECTION SYSTEM CIRCUIT TEST (continued) PROCEDURE (continued) 4. Insulate and/or position these leads so they cannot touch chassis ground, any other electrical conduc- tor , or be damaged by any moving parts. 5. Start the engine and allow it to run. 6. If the engine sti[...]

  • Page 108

    Return to Section T OC Return to Section T OC Return to Section T OC Return to Section T OC Return to Master T OC Return to Master T OC Return to Master T OC Return to Master T OC NOTES F-68 F-68 SAE-400 SEVERE DUTY[...]

  • Page 109

    Service and repair should be performed by only Lincoln Electric factory trained personnel. Unauthorized repairs performed on this equipment may result in danger to the technician or machine operator and will invalidate your factory warranty . For your safety and to avoid electrical shock, please observe all safety notes and precautions detailed thr[...]

  • Page 110

    #237 #224 GROUND FIGURE F .25 – AL TERNA TOR CODE 10856 ENGINE AL TERNA T OR TEST (continued) PROCEDURE 1. Open the right side cover , on the radiator end of the SAE-400 machine. W ARNING: Secure the door in the open position using the door restraint system. If the machine does not have a door restraint system, remove the door(s) or securely rest[...]

  • Page 111

    #59 #51 FIGURE F .26 – AL TERNA TOR CODE 1 1 199 & 1 1408 ENGINE AL TERNA T OR TEST (continued) PROCEDURE (continued) Engine running: • Chassis ground to the B+ terminal of the alterna- tor , (Lead #237 for code 10856) (Lead #51 for codes 1 1 199 and 1 1408) the meter should read about 13.5 to 14.2 VDC. • Chassis ground to the alternator [...]

  • Page 112

    Return to Section T OC Return to Section T OC Return to Section T OC Return to Section T OC Return to Master T OC Return to Master T OC Return to Master T OC Return to Master T OC NOTES F-72 F-72 SAE-400 SEVERE DUTY[...]

  • Page 113

    Service and repair should be performed by only Lincoln Electric factory trained personnel. Unauthorized repairs performed on this equipment may result in danger to the technician or machine operator and will invalidate your factory warranty . For your safety and to avoid electrical shock, please observe all safety notes and precautions detailed thr[...]

  • Page 114

    J1-5 (-), CHASSIS GROUND J1-9 (+), 1 1 T O 13 VOL TS TO FUEL SOLENOIDS J1-1 (+), BA TTERY VOL T AGE INPUT T O PC BOARD FIGURE F .27 – PC BOARD ENGINE FUEL SYSTEM VOL T AGE TESTS (continued) PROCEDURE 1. Open the doors on the SAE-400 machine. W ARNING: Secure the doors in the open position using the door restraint system. If the machine does not h[...]

  • Page 115

    J31-1, (+) BA TTERY VOL T AGE I NPUT J31-9 (+) OUTPUT T O FUEL SOLENO I DS AND PUMP B-1 (-) CHASS I S GROUND FIGURE F .28 – PC BOARD ENGINE FUEL SYSTEM VOL T AGE TESTS (continued) PROCEDURE For Code 10856: 1. Place the run/stop switch in the “RUN” position and within 30 seconds, check for battery voltage between terminal J1-9 (+) and terminal[...]

  • Page 116

    ENGINE FUEL SYSTEM VOL T AGE TESTS (continued) PROCEDURE For Codes 1 1 199 and 1 1408 1. Place the run/stop switch in the “RUN” position and within 30 seconds, check for 1 1 to 13 VDC between terminal J31-9 (+) and terminal B-1 (-). 2. Check for battery voltage between terminal J31-1 (+) and terminal B-1 (-). 3. Check for positive battery volta[...]

  • Page 117

    Service and repair should be performed by only Lincoln Electric factory trained personnel. Unauthorized repairs performed on this equipment may result in danger to the technician or machine operator and will invalidate your factory warranty . For your safety and to avoid electrical shock, please observe all safety notes and precautions detailed thr[...]

  • Page 118

    EXCITER ROTOR BRUSH HOLDER ASSEMBL Y NUT WA S H E R SLEEVE COLLAR BRUSH HOLDER BRACKET FIGURE F .29 – ROTOR REMOV AL AL TERNA TOR ROT OR REMOV AL AND REPLACEMENT (continued) PROCEDURE Rotor Removal 1. T urn off the engine. 2. Open either , or both of the doors on the control panel end of the SAE-400 machine. W ARNING: Secure the doors in the open[...]

  • Page 119

    AL TERNA TOR ROT OR REMOV AL AND REPLACEMENT (continued) Rotor Replacement: 1. Clean and inspect the armature shaft, the exciter rotor and slip rings. Replace the rotor if it is dam- aged, or if the slip rings are excessively worn. 2. Carefully slide the rotor onto the armature shaft. NOTE: It is recommended that a new sleeve collar , washer and lo[...]

  • Page 120

    Return to Section T OC Return to Section T OC Return to Section T OC Return to Section T OC Return to Master T OC Return to Master T OC Return to Master T OC Return to Master T OC NOTES F-80 F-80 SAE-400 SEVERE DUTY[...]

  • Page 121

    Service and repair should be performed by only Lincoln Electric factory trained personnel. Unauthorized repairs performed on this equipment may result in danger to the technician or machine operator and will invalidate your factory warranty . For your safety and to avoid electrical shock, please observe all safety notes and precautions detailed thr[...]

  • Page 122

    GENERA TOR COVER FOUR SCREWS T OT AL FIGURE F .30 – GENERA TOR COVER REMOV AL AL TERNA TOR ST A TOR REMOV AL AND REPLACEMENT (continued) PROCEDURE 1. T urn off the engine. 2. Perform the Alternator Rotor Removal Procedure. 3. Remove the roof and doors. 4. Remove the four covers protecting the welding gen- erator brushes. See Figure F .30 5. Use t[...]

  • Page 123

    ARMA TURE COMMUT A TOR SPRINGS BRUSH HOLDER PLA TE BRUSHES BRUSH RET AINER BRUSH HOLDER INSULA TORS MOUNTING SCREW DRILL MARK ROCKER FIGURE F .31 – ROCKER & MARK LOCA TIONS AL TERNA TOR ST A TOR REMOV AL AND REPLACEMENT (continued) PROCEDURE (continued) 9. Drain the fuel and store it in an approved container . Disconnect the fuel line from th[...]

  • Page 124

    AL TERNA TOR ST A TOR REMOV AL AND REPLACEMENT (continued) Replacing the Exciter Alternator Stator: 1. During reassembly , anti-seize compound should be applied to the screw threads. 2. Inspect the mating surfaces of the generator frame and the exciter bracket assembly . These surfaces must mate together completely so it is very impor- tant that th[...]

  • Page 125

    Service and repair should be performed by only Lincoln Electric factory trained personnel. Unauthorized repairs performed on this equipment may result in danger to the technician or machine operator and will invalidate your factory warranty . For your safety and to avoid electrical shock, please observe all safety notes and precautions detailed thr[...]

  • Page 126

    GENERA T OR FRAME REMOV AL AND REPLACEMENT (continued) PROCEDURE Remove the generator frame 1. T urn off Engine. 2. Perform the Alternator Rotor Removal Procedure . 3. Perform the Alternator Stator Removal Procedure. 4. Disconnect all of the wires and cables that connect to the stator/frame assembly . Carefully mark them for reassembly . 5. Remove [...]

  • Page 127

    Service and repair should be performed by only Lincoln Electric factory trained personnel. Unauthorized repairs performed on this equipment may result in danger to the technician or machine operator and will invalidate your factory warranty . For your safety and to avoid electrical shock, please observe all safety notes and precautions detailed thr[...]

  • Page 128

    BLOWER PADDLE/ARMATURE MOUNTING BOLTS ( 8 ) BLOWER PADDLE ROPE SLING FIGURE F .32 – SLING LIFT GENERA T OR ARMA TURE REMOV AL AND REPLACEMENT (continued) PROCEDURE Removing the Armature 1. T urn off the engine 2. Perform the Alternator Rotor Removal Procedure. 3. Perform the Alternator Stator Removal Procedure . 4. Perform the Generator Frame Rem[...]

  • Page 129

    RETEST AFTER REP AIR F-89 F-89 SAE-400 SEVERE DUTY Return to Section T OC Return to Section T OC Return to Section T OC Return to Section T OC Return to Master T OC Return to Master T OC Return to Master T OC Return to Master T OC Retest after repair The machine should be retested if any parts are replaced that could affect the machine’ s electri[...]

  • Page 130

    T ABLE OF CONTENTS - DIAGRAM SECTION G-1 G-1 Return to Master T OC Return to Master T OC Return to Master T OC Return to Master T OC SAE-400 SEVERE DUTY Electrical Diagrams . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .G-1 Wiring Diagram - Control - Code 1085[...]

  • Page 131

    ELECTRICAL DIAGRAMS G-2 SAE-400 SEVERE DUTY ® WIRING DIAGRAM - CONTROL - CODE 10856 (M19237) M19237 EN G I N E W EL D ERS W I RI N G D IA G RA M NONE M 18827 FEI - U NLESS OT HERW I SE SPE C I F I ED T OLE RANCE MAN UFA CT UR I NG TOLE RA N CE PER E2056 ON 2 PLACE DEC I MALS I S ± .0 2 ON 3 PLA CE DE C I MA LS I S ±. 0 0 2 ON ALL AN GLES I S ± [...]

  • Page 132

    ELECTRICAL DIAGRAMS G-3 SAE-400 SEVERE DUTY ® WIRING DIAGRAM - ENGINE - CODE 10856 (M20609) SW ITC H PR OT EC TI ON P.C. B OARD IDLER /EN G INE J1 + SW ITCH (N. C.) O IL PRESS UR E TH ERMOS TART CO LD TERM IN AL S TART B - TH ERMOS TART 5C B B + GRO UND S CR EW TO C O NTR O L P AN EL B G 223 W W R 4 3 2 5A 1 10 G 225 B 9 8 7 3 2 B SOLENO ID 226 23[...]

  • Page 133

    ELECTRICAL DIAGRAMS G-4 SAE-400 SEVERE DUTY ® WIRING DIAGRAM - CODE 1 1 199 (M20544) AC (-) D2 238 AC 202 1 (+ ) AC 203 AC D1 A 1 2 2CR E *844 GN D-E 602B (-) NE G POS TOR OI D 201 W 3 500 602A - 22 600A Y 4 3 1 X 4 2 P8 215 + W 2 7A 11A 11 4A 400F 6A (+ ) REA CTO R N U F 5 4 ELE CTRO D E B 600 R R 41A 214 G 602 5 6 42 4 3 41 2 1 42A 21 CB1 CB2 CB[...]

  • Page 134

    ELECTRICAL DIAGRAMS G-5 SAE-400 SEVERE DUTY ® WIRING DIAGRAM - CODE 1 1408 (M21283) AC (-) D2 238 AC 202 1 (+ ) AC 203 AC D1 A 1 2 2CR E *844 GN D-E 602B (-) NE G POS TOR OI D 201 W 3 500 602A - 22 600A Y 4 3 1 X 4 2 P8 215 + W 2 7A 11A 11 4A 400F 6A (+ ) REA CT O R N U F 5 4 ELEC TRO DE B 600 R R 41A 214 G 602 5 6 42 4 3 41 2 1 42A 21 201A STA RT[...]

  • Page 135

    ELECTRICAL DIAGRAMS G-6 SAE-400 SEVERE DUTY ® WIRING DIAGRAM - GENERA TOR FRAME (M5570) G-6 NOTE: This diagram is for reference only . It may not be accurate for all machines covered by this manual. The wiring diagram specific to your code is pasted ins ide one of the enclosure panels of your machine. Return to Section TOC Return to Section TOC Re[...]

  • Page 136

    Return to Section TOC Return to Section TOC Return to Section TOC Return to Section TOC Return to Master TOC Return to Master TOC Return to Master TOC Return to Master TOC ELECTRICAL DIAGRAMS G-7 SAE-400 SEVERE DUTY ® SCHEMA TIC - COMPLETE MACHINE - CODE 10856 (G5351) EN-170 S O L ID E D G E G5351 SAE-400 MAC HI N ES C HEM ATIC NONE - DO NO T SC A[...]

  • Page 137

    ELECTRICAL DIAGRAMS G-8 SAE-400 SEVERE DUTY ® SCHEMA TIC - COMPLETE MACHINE - CODE 11 199 (G4924) EN-170 S O L ID E D G E G4924 SAE-400 MAC HI N ES C HEM ATIC NONE - DO NO T SC AL E T HIS DR A WING EQ UIP M ENT TYPE: SUBJECT: SCA L E: NA CRM38346 1 PAGE ___ OF ___ 1 E NGI N EE RI NG CO NT RO LLE D MA NU FA CT URE R: No THIS DOCUMENT CONTAINS PROPR[...]

  • Page 138

    Return to Section TOC Return to Section TOC Return to Section TOC Return to Section TOC Return to Master TOC Return to Master TOC Return to Master TOC Return to Master TOC ELECTRICAL DIAGRAMS G-9 SAE-400 SEVERE DUTY ® SCHEMA TIC - COMPLETE MACHINE - CODE 11408 (G5827) EN-170 S O L ID E D G E G5827 SAE-400 MAC HI N ES C HEM ATIC NONE - DO NO T SC A[...]

  • Page 139

    NOTE: Lincoln Electric assumes no responsibility for liablilities resulting from board level troubleshooting. PC Board repairs will invalidate your factory warranty . Individual Printed Circuit Board Components are not available from Lincoln Electric. This information is pro- vided for reference only . Lincoln Electric discourages board level troub[...]

  • Page 140

    ELECTRICAL DIAGRAMS G-1 1 SAE-400 SEVERE DUTY ® SCHEMA TIC - IDLER/ENGINE SHUTDOWN PC BOARD - CODE 10856 (L11006-2) G-1 1 NOTE: This diagram is for reference only . It may not be accurate for all machines covered by this manual. Return to Section TOC Return to Section TOC Return to Section TOC Return to Section TOC Return to Master TOC Return to M[...]

  • Page 141

    NOTE: Lincoln Electric assumes no responsibility for liablilities resulting from board level troubleshooting. PC Board repairs will invalidate your factory warranty . Individual Printed Circuit Board Components are not available from Lincoln Electric. This information is pro- vided for reference only . Lincoln Electric discourages board level troub[...]

  • Page 142

    Return to Section TOC Return to Section TOC Return to Section TOC Return to Section TOC Return to Master TOC Return to Master TOC Return to Master TOC Return to Master TOC ELECTRICAL DIAGRAMS G-13 SAE-400 SEVERE DUTY ® SCHEMA TIC - IDLER/ENGINE SHUTDOWN PC BOARD (G4828-2) G-13 NOTE: This diagram is for reference only . It may not be accurate for a[...]