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Lincoln Electric SVM187-A TABLE OF CONTENTS - OPERATION SECTION

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TABLE OF CONTENTS - OPERATION SECTION

B-1 B-1

Return to Master TOC Return to Master TOC Return to Master TOC Return to Master TOC

SAE-400 SEVERE DUTY

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

SafetyInstructions ....................................................................B-2

AdditionalSafetyPrecautions ...........................................................B-2

GeneralDescriptions ..................................................................B-2

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

AuxiliaryPower.......................................................................B-2

DesignFeaturesAndAdvantages ........................................................B-3

DutyCycle..........................................................................B-3

EngineControls:Function/Operation ....................................................B-4

WelderControls:Function/Operation.....................................................B-5

RemoteControl ......................................................................B-5

AuxiliaryPowerControls...............................................................B-5

EngineOperation.....................................................................B-6

StartingInstructions ...................................................................B-6

TypicalFuelConsumption ..............................................................B-7

Contents

Main SVM187-A October, 2008 SERVICE MANUAL SAE-400 SEVERE DUTY i i FOR ENGINE powered equipment. Mar 95 WARNING ELECTRICAND MAGNETIC FIELDS maybedangerous ii ii FUMES AND GASES can be dangerous. Aug 06 ARC RAYS can burn. ELECTRIC SHOCK can kill. iii iii FOR ELECTRICALLY powered equipment. CYLINDER may explode if damaged. WELDING and CUTTING SPARKS can cause fire or explosion. iv iv Mar 93 PRCAUTIONS DE SRET PRCAUTIONS DE SRET POUR LES MACHINES SOUDER TRANSFORMATEUR ET REDRESSEUR Page Electromagnetic Compatibility (EMC) - MASTER TABLE OF CONTENTS FOR ALL SECTIONS - TABLE OF CONTENTS - INSTALLATION SECTION TECHNICAL SPECIFICATIONS - SAE-400 SEVERE DUTY INPUT - DIESEL ENGINE CODE 10856 PHYSICALDIMENSIONS OUTPUT - WELDER AND GENERATOR RATED OUTPUT - WELDER CODES 10856 SAFETYPRECAUTIONS LOCATION/VENTILATION STACKING ANGLE OF OPERATION LIFTING PRE-OPERATION ENGINE SERVICE ENGINE OIL FUEL USE DIESEL FUEL ONLY DIESEL FUEL ONLY DIESELFUEL BATTERYCONNECTION ENGINE BREAK-IN ENGINE COOLING SYSTEM WELDING OUTPUT CABLES MACHINE GROUNDING SPARKARRESTOR WARNING TABLE OF CONTENTS - OPERATION SECTION WELDING SPARKS can cause fire or explosion. ADDITIONALSAFETYPRECAUTIONS GENERALDESCRIPTION RECOMMENDEDAPPLICATIONS OPERATING INSTRUCTIONS SAFETYINSTRUCTIONS ARC RAYS can injure eyes and burn skin. DESIGN FEATURESAND ADVANTAGES DUTYCYCLE ENGINE CONTROLS WARNING WELDER CONTROLS REMOTE CONTROL AUXILIARY POWER CONTROLS ENGINEOPERATION WARNING STARTING INSTRUCTIONS See additional warning information at the front of this operators manual. COLD WEATHER STARTING TYPICALFUELCONSUMPTION Page Page ACCESSORIES OPTIONAL FIELD INSTALLED ACCESSORIES TABLE OF CONTENTS - MAINTENANCE SECTION ROUTINE MAINTENANCE PERIODIC MAINTENANCE ENGINE OIL CHANGE ENGINE AIR FILTER BEARING MAINTENANCE COMMUTATOR AND BRUSH MAINTENANCE COOLING SYSTEM FUEL FILTERS WATER SEPARATOR ELEMENT SECONDARY FUEL FILTER GFCI RECEPTACLE TESTING AND RESET- TING PROCEDURE SPARK ARRESTOR WARNING Page TABLE OF CONTENTS-THEORY OF OPERATION SECTION E-1 E-1 (+) FIGURE E.1 BLOCK LOGIC DIAGRAM DIESEL ENGINE ENGINE STARTING AND PROTEC- TION --- AUTOMATIC ENGINE IDLE SYSTEM --- EXCITER/AUXILIARY ALTERNATOR OPERATION EXCITER/AUXILIARY ALTERNATOR OPERATION (Continued) TION Page Page E-9 E-9 Return to Section TOC Return to Section TOC Return to Section TOC Return to Section TOC FIGURE E.2 - GENERAL DESCRIPTION (+) DIESEL ENGINE Page TABLE OF CONTENTS - TROUBLESHOOTING AND REPAIR HOW TO USE TROUBLESHOOTING GUIDE PC BOARD TROUBLESHOOTING PROCEDURES Page Page Page Page Page Page Page Page Page Page Page Page Page Page Page Page Page ENGINE RPM ADJUSTMENT TEST TEST PROCEDURE Strobe-Tach Method (continued) Page (Exciter / Auxiliary Power Alternator) Page BRUSHES PROCEDURE (continued Page EXCITER ROTOR VOLTAGE TEST EXCITER ROTOR VOLTAGE TEST(continued) Page EXCITER ROTOR VOLTAGE TEST (continued) (Exciter / Auxiliary Power Alternator) Static Tests: Page Page (Engine not running) (Engine not running) (continued) (Engine not running) (continued) (Engine not running (continued) EXCITER STATOR SHORT CIRCUIT & GROUND TEST EXCITER STATOR SHORT CIRCUIT & GROUND TEST (continued) SERVICE GENERATOR COVER FOUR SCREWS TOTAL SERVICE (continued) Page SERVICE (continued) WELD CIRCUIT GROUND AND SHORT CIRCUIT TEST WELD CIRCUIT GROUND AND SHORT CIRCUIT TEST (continued) SHUNT FIELD COIL RESISTANCE AND GROUND TEST SHUNT FIELD COIL RESISTANCE AND GROUND TEST (continued) SHUNT FIELD CIRCUIT VOLTAGE TEST SHUNT FIELD CIRCUIT VOLTAGE TEST (continued) DEAD SHORT, 1ST STEP, AND OPEN REACTOR TESTS DEAD SHORT, 1ST STEP, AND OPEN REACTOR TESTS (continued) ROCKER ADJUSTMENT PROCEDURE Page ROCKER ADJUSTMENT PROCEDURE (continued) Page OUTPUT CONTROL UNIT (VARIABLE REACTOR) INSPECTION AND SERVICE PROCEDURE WINDING Contacts & Springs Output Stud Assembly Brush Holder Assembly Page OUTPUT CONTROL UNIT (VARIABLE REACTOR) INSPECTION AND SERVICE PROCEDURE (continued) Page Page ENGINE PROTECTION SYSTEM CIRCUIT TEST #237 #224 ENGINE PROTECTION SYSTEM CIRCUIT TEST (continued) #59 #51 Page ENGINE ALTERNATOR TEST #237 #224 ENGINE ALTERNATOR TEST (continued) #59 #51 Page ENGINE FUEL SYSTEM VOLTAGE TESTS Page Page Page ALTERNATOR ROTOR REMOVAL AND REPLACEMENT Page ALTERNATOR ROTOR REMOVAL AND REPLACEMENT (continued) Page ALTERNATOR STATOR REMOVAL AND REPLACEMENT GENERATOR COVER FOUR SCREWS TOTAL Page Page GENERATOR FRAME REMOVAL AND REPLACEMENT GENERATOR FRAME REMOVAL AND REPLACEMENT (continued) GENERATOR ARMATURE REMOVAL AND REPLACEMENT BLOWER PADDLE/ARMATURE MOUNTING BOLTS ROPE SLING BLOWER PADDLE ( GENERATOR ARMATURE REMOVAL AND REPLACEMENT (continued) RETEST AFTER REPAIR Retest after repair Engine output: Welder DC Output: AC Auxiliary Output: TABLE OF CONTENTS - DIAGRAM SECTION * NOTE: ELECTRICAL DIAGRAMS CO MI CEPTACLE UPLE WIRING DIAGRAM- SAE-400 PERKINS VE 227 221 ENG EMP. SENSOR ENGINEWELDERS WIRINGDIAGRAM(BATTERYCIRCUIT#1) - PROPRIETARY& CONFIDENTIAL: E NI MMU - 10/05/2006 INC. , AL Page ELECTRICAL DIAGRAMS SCHEMATIC- COMPLETE MACHINE - CODE 10856 (G5351) 41 CTI N=A ELECTRICAL DIAGRAMS SCHEMATIC- COMPLETE MACHINE - CODE 11199 (G4924) NI 12V 3. ELECTRICAL DIAGRAMS SCHEMATIC- COMPLETE MACHINE - CODE 11408 (G5827) NI EL FILT U ELECTRICAL DIAGRAMS NT S24586PRI 13 3- Page ELECTRICAL DIAGRAMS N.C. 11 12 E. CONNECTORSMUSTBEGREASEDWITHITEM(