Manuals / Lincoln Electric / Power Tools / Welder

Lincoln Electric SVM187-A service manual SAE-400 Severe Duty

Models: SVM187-A

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E-10

NOTES

E-10

SAE-400 SEVERE DUTY

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Lincoln Electric SVM187-A service manual SAE-400 Severe Duty

Contents

SAE-400 Severe Duty ISAFETYi SAE-400 Severe DutySafety Electric Shock can killFumes and Gases Can be dangerousFor Electrically Powered equipmentIii Précautions DE Sûreté Sûreté Pour Soudage a LʼArcElectromagnetic Compatibility EMC Safety Vii Master Table of Contents for ALL Sections Table of Contents Installation Section Technical Specifications SAE-400 Severe Duty InstallationHeight Width Depth Weight Safety Precautions LOCATION/VENTILATIONStacking Angle of OperationPRE-OPERATION Engine Service Engine BREAK-IN Engine Cooling SystemWelding Output Cables Spark Arrestor Machine GroundingTable A.1 Combined Length of Electrode Work Cables Table of Contents Operation Section Safety Instructions OperationOperating Instructions General DescriptionDesign Features and Advantages Duty Cycle For Auxiliary PowerOther Features For Stick WeldingEngine Controls Remote Control Auxiliary Power ControlsPolarity Switch Welder ControlsEngine Operation Cold Weather StartingStarting Instructions Stopping the EngineTypical Fuel Consumption SAE-400 Severe Duty Table of Contents Accessories Section Accessories Optional Field Installed AccessoriesOrder K1690-1 Gfci Receptacle KITTable of Contents Maintenance Section Maintenance Routine MaintenancePeriodic Maintenance Engine OIL ChangeBearing Maintenance Fuel PRE-FILTER/WATER Separator AssemblyCooling System Fuel FiltersWater Separator Element Engine Maintenance ComponentsSecondary Fuel Filter Ting Procedure Spark ArrestorFor machines with separate spark arresting unit For machines with integral spark arresting muf- flersSAE-400 Severe Duty 1TABLE of CONTENTS-THEORY of Operation Section E-1 Theory of Operation Engine Starting and PROTEC- TionAutomatic Engine Idle System Figure E.2 Engine Starting and ProtectionFlashing EXCITER/AUXILIARY Alternator OperationBuilding output Operation EXCITER/AUXILIARY AlternatorAC Auxiliary Output Overview Excitation and field controlWelding Generator OPERA- Tion Producing weld currentReactor Assembly Series coils and reactorTion Welding Generator OperaInterpole coils SAE-400 Severe Duty 1TABLE of Contents Troubleshooting and Repair F-1 2TROUBLESHOOTING and Repair F-2 HOW to USE Troubleshooting GuideLocate Problem Symptom Course of ActionTroubleshooting and Repair PC Board Troubleshooting ProceduresAdjustment Test Troubleshooting and Repair Possible Areas Misadjustments Problems SymptomsRecommended Course of Action Possible Areas of Misadjustments Rocker Adjustment Procedure if necessaryTroubleshooting and Repair Adjustment Procedure Welding arc is loud and spatters excessively RPM Adjustment Test System Voltage Tests Protection System Test Perform the Engine Alternator Problems Symptoms Troubleshooting and Repair Low idle RPM may be too low. Perform the Engine Idle Troubleshooting and Repair Troubleshooting and Repair SAE-400 Severe Duty Test Description Engine RPM Adjustment TestMaterials Needed Test Procedure Engine RPM Adjustment TestStrobe-Tach Method Figure F.2 Engine Components Code 11199 Frequency counter methodHigh Idle Adjustment Engine RPM Adjustment ProcedureLow idle adjustment Code 10856 only Brush and Slip Ring Service Procedure Exciter / Auxiliary Power AlternatorProcedure Figure F.3 Exciter Cover Screw LocationsBrushes Cleaning slip ringsSeating brushes SAE-400 Severe Duty Exciter Rotor Voltage Test Test DescriptionExciter Rotor Voltage Test Figure F.6 Exciter Cover Screw LocationsFigure F.7 Exciter Rotor Voltage Test Circuit and Ground Test Exciter / Auxiliary Power Alternator Exciter Rotor Resistance and Ground TestStatic Tests Figure F.9 Slip Ring Locations Figure F.10 Slip Ring Locations Dynamic TestsFlashing Voltage Test Engine not runningFlashing Voltage Test Figure F.13 IDLER/ENGINE Protection PC Board Codes If battery voltage is detected Figure F.14 IDLER/ENGINE Protection PC Board Codes 11199Exciter Stator Short Circuit & Ground Test Test DescriptionExciter Stator Short Circuit & Ground Test Welding Generator Brush and Commutator Inspection Service Service Figure F.15 Generator Cover Screw LocationsNormal appearance Blackened CommutatorWelding Generator Brush and Commutator Inspection Pitted and Arc Damaged CommutatorUneven Commutator appearance Examine the brushesWeld Circuit Ground and Short Circuit Test Weld circuit ground test If the resistance is lower than 500k OhmsShunt Field Coil Resistance and Ground Test Shunt Coil Resistance Test Shunt Field Coil Resistance and Ground TestShunt Coil Ground Test Shunt Field Circuit Voltage Test Shunt Field Circuit Voltage Test Dead SHORT, 1ST STEP, and Open Reactor Tests Rotor Winding Movable Contacts Min. open PositionFirst Step Contact Contact Springs Position Insulated FillerRocker Adjustment Procedure Figure F.18 Rocker W/MARKS Factory set point drill marksInitial rocker placement Rocker Adjustment ProcedureCheck for Max output SAE-400 Severe Duty Test Description Inspection and Service Procedure Output Control Unit Variable ReactorFigure F.20 Brush & Spring Winding Insulated Wedge Servicing the continuous control unitSteel Coil Insulator Contacts Figure F.22 Shaft & Tube Chamfered END of Shaft AT this ENDSAE-400 Severe Duty Engine Protection System Circuit Test Test Description66TROUBLESHOOTING and Repair F-66 Engine Protection System Circuit Test67TROUBLESHOOTING and Repair F-67 Figure F.24 Engine Alternator Code 11199 &11408SAE-400 Severe Duty Troubleshooting and Repair Engine Alternator TestRun/stop switch on Engine Alternator Test#59 #51 SAE-400 Severe Duty Engine Fuel System Voltage Tests Test DescriptionEngine Fuel System Voltage Tests Engine Fuel System Voltage Tests Figure F.28 PC BoardFor Codes 11199 Alternator Rotor Removal and Replacement Test DescriptionAlternator Rotor Removal and Replacement Rotor RemovalRotor Replacement SAE-400 Severe Duty Alternator Stator Removal and Replacement Test DescriptionAlternator Stator Removal and Replacement Alternator Stator Removal and Replacement Figure F.31 Rocker & Mark LocationsReplacing the Exciter Alternator Stator Generator Frame Removal and Replacement Test DescriptionRemove the generator frame Generator Frame Removal and ReplacementReplacing the Generator Frame Generator Armature Removal and Replacement Removing the Armature Generator Armature Removal and ReplacementReplacing the armature Retest After Repair Table of Contents Diagram Section Electrical Diagrams Wiring Diagram SAE-400 Perkins M20544 M21283 Wiring Diagram Generator Frame M5570 Electrical Diagrams Schematic Complete Machine Code 11199 G4924 Schematic Complete Machine Code 11408 G5827 Section TOC Schematic IDLER/ENGINE Shutdown PC Board Code 10856 L11006-2 PC Board Assembly IDLER/ENGINE Shutdown PC Board L12400-2 Schematic IDLER/ENGINE Shutdown PC Board G4828-2