BEARING MAINTENANCE
This welder is equipped with a double-shielded ball bearing hav-
ing sufficient grease to last indefinitely under normal service.
COMMUTATOR AND BRUSH MAINTENANCE
Uncovered rotating equipment can be dangerous.
Use care so your hands, hair, clothing or tools do
not catch in the rotating parts. Protect yourself
from particles that may be thrown out by the rotat-
ing armature when stoning the commutator.
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The generator brushes are properly adjusted when
the welder is shipped. They require no particular
attention. DO NOT SHIFT THE BRUSHES or adjust
the rocker setting.
Shifting of the brushes may result in:
- Change in machine output
- Commutator Damage
- Excessive brush wear
Periodically inspect the commutator, slip rings and
brushes by removing the covers. DO NOT remove or
replace these covers while the machine is running.
Commutators and slip rings require little attention.
However, if they are black or appear uneven, have
them cleaned by an experienced maintenance man
using fine sandpaper or a commutator stone. Never
use emery cloth or paper for this purpose.
NOTE:
If the welder is used in dirty or dusty locations,
or if the welder is not used for prolonged periods of
time, it may be necessary to clean the commutator
and slip rings more often.
Replace brushes when they wear within 1/4" of the
pigtail. A complete set of replacement brushes should
be kept on hand. Lincoln brushes have a curved face
to fit the commutator. Have an experienced mainte-
nance man seat these brushes by lightly stoning the
commutator as the armature rotates at full speed until
contact is made across the full face of the brushes.
After stoning, blow out the dust with low pressure air.
To seat the slip ring brushes, position the brushes in
place. Then slide one end of a piece of fine sandpaper
between slip rings and brushes with the coarse side
against the brushes. Pull the sandpaper around the cir-
cumference of the rings, in direction of rotation only -
until brushes seat properly. In addition, stone slip ring
with a fine stone. Brushes must be seated 100%.
Arcing or excessive exciter brush wear indicates a
possible misaligned shaft. Have an authorized Field
Service Shop check and realign the shaft.
WARNING
COOLING SYSTEM
The SAE-500™ is equipped with a pressure radiator.
Keep the radiator cap tight to prevent loss of coolant.
Clean and flush the cooling system periodically to pre-
vent clogging the passage and overheating the
engine. When antifreeze is needed, always use the
permanent type.
FUEL FILTERS
When working on the fuel system
• Keep ungrounded lights away, do not
smoke !
• Do not spill fuel !
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The SAE-500™ is equipped with a
Fuel Pre-
Filter/Water Separator Assembly
mounted by the
fuel tank on the engine service side.
The Secondary Fuel Filter is mounted directly to the
engine just below the high pressure pump.
FUEL FILTERS
When working on the fuel system
• Keep naked lights away, do not smoke !
• Do not spill fuel !
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The SAE-500™ is equipped with a
Fuel Filter
located
after the lift pump and before fuel injectors.The proce-
dure for changing the filter is as follows.
1. Close the fuel shutoff valve.
2. Clean the area around the fuel filter head. Remove
the filter. Clean the gasket surface of the filter head
and replace the o-ring.
3. Fill the clean filter with clean fuel, and lubricate the
o-ring seal with clean lubricating oil.
4. Install the filter as specified by the filter manufacturer.
Mechanical over tightened will distort the threads, filter ele-
ment seal or filter can.
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WARNING
WARNING
WARNING
D-2
MAINTENANCE
SAE-500
TM
AND SAE-500
TM
SEVERE DUTY
TM
