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SVM187-A
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NOTES
B-8 B-8
SAE-400 SEVERE DUTY
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(