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Lincoln Electric SVM187-A 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, NOTE: Unshaded areas of Block Logic Diagram are the subject of discussion

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THEORY OF OPERATION

E-9 E-9

SAE-400 SEVERE DUTY

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WELDING GENERATOR OPERA-

TION (Continued)

Interpole coils:Armature current from the remaining two sets of brush-es is routed through four interpole coils, before beingconnected to the weld output terminal. These coils arenarrower than the shunt and series coils, and are locat-ed in the generator stator between them. Their purposeis to reduce distortion of the magnetic field.The magnetic field generated by the the shunt coils willbecome distorted when current is drawn from thearmature. This distortion will increase as the currentflow increases. The interpole coils are connected andarranged to counteract this magnetic distortion. If notcorrected, the distortion would cause reduced outputand excessive sparking on the commutator.FIGURE E.2 - GENERAL DESCRIPTION

DIESEL

ENGINE

THERMOSTAT

INJECTION

PUMP

SOLENOID

SYSTEM

THERMOSTART

BUTTON

IDLE SWITCH

IDLE

SOLENOID

IDLE / ENGINE

PROTECTION BOARD

TO IDLE / ENGINE

PROTECTION BOARD

RUN/STOP

SWITCH

S

T

A

R

T

E

R

TO IDLE/ENGINE

PROT. BOARD

OIL

PRESSURE

SWITCH

TEMP

SWITCH

STARTER

SOLENOID

AMMETER

START

BUTTON

ENGINE

FAULT

LIGHT

HOUR

METER

TO

FLASHING

RESISTOR

AND

DIODE

INTERPOLE COILS

GENERATOR

ARMATURE

SERIES COILS

SHUNT COILS

115 VAC

RECEPTACLES

230 VAC

RECEPTACLES

AUXILIARY

POWER

WINDINGS

EXCITER

WINDING

EXCITER

ROTOR

MIN

(OFF)

MAX

OUTPUT

CONTROL

ELECTRODE

TERMINAL

RESISTOR

POLARITY

SWITCH

REMOTE

RHEOSTAT

LOCAL

RHEOSTAT

(JOB SELECTOR)

TO HOUR METER

FLASHING

RESISTOR AND

DIODE

(+)

(+)

(-)

(-)

AC

AC

(-) (+)

WORK

TERMINAL

TO ALTERNATOR

FLASH/SENSE

TO INJECTION

PUMP SOLENOID

NOTE: Unshaded areas of Block LogicDiagram are the subject of discussion

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(