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ELECTRICAL DIAGRAMS

G-8

SAE-400 SEVERE DUTY

SCHEMATIC - COMPLETE MACHINE - CODE 11199 (G4924)

-1

G4924

SAE-400

MACHINE SCHEMATIC

NONE

DO NOT SCALE THIS DRAWING

EQUIPM

ENT TYPE:

SUBJECT:

SCALE:

CRM38346

PAGE ___ OF ___

ENGINEERING CONTROLLED
MANUFACTURER:

THIS DOCUMENT CONTAINS PROPRIETARY INFORMATION OWNED BY LINCOLN GLOBAL, INC. AND MAY NOT BE DUPLICATED, COMMUNICATED
TO OTHER PARTIES OR USED FOR ANY PURPOSE WITHOUT THE EXPRESS WRITTEN PERMISSION OF LINCOLN GLOBAL, INC.

PRO

PRIETARY & CONFIDENTIAL:

MATERIAL TOLERANCE (" ") TO AGREE

WITH PUBLISHED STANDARDS.

ON A

LL ANGLES IS ± .5 OF A DEGREE

ON 3 PLACE DECIMALS IS ± .002 in. (± 0.05 mm)

ON 2 PLACE DECIMALS IS ± .02 in. (± 0.5 mm)

UNLESS OTHERWISE SPECIFIED TOLERANCE:

MANUFACTURING TOLERANCE PER E2056

Revised

CHANGE DETAIL:

REFERENCE:

MATERIAL
DISPOSITION:

APPROVAL
DATE:

PROJECT
NUMBER:

DOCUMENT
NUMBER:

DOCUMENT
REVISION:

IF PRINTED

@ A1 SIZE

UNITS:

INCH

1/1/2000

Maglietta

D. BENDER

DRAWN BY:

ENGINEER:

CLEVELAND

APPROVED:

CONTROL:

G492

LEAD COLOR CODE:

B-BLACK OR GRAY
G-GREEN
O-ORANGE
R-RED OR PINK
U-BLUE
W-WHITE
Y-YELLOW

COMPONENT VALUE UNITS:

CAPACITOR: MFD/VOLTS
RESISTOR: OHMS/WATTS

CONNECTOR PIN NUMBERS:

VIEW OF CONNECTOR ON PC BOARD

1 2

EX. 12PIN CONNECTOR

LABELS

COMMON
FRAME

GROUND

EARTH

GROUND

AUXILIARY
WINDINGS

ALTERNATOR

ROTOR

EXCITER
WINDING

15A

20A

UPPER PANEL

GND SCREW

UPPER PANEL

GND SCREW

POLARITY

SWITCH

214

215

600A

P8-2

600

Y-TERMINAL

W-TERMINA

P8-3

602

P8-4

602

203

X-TERMINAL

n.c.

G-TERMINA

UPPER PANEL

GND SCREW

CAL / REMOTE

SWITCH

(SHOWN IN LOCAL

POSITION)

OPTIONAL REMOTE

CONTROL BOX

TO D1

AC POSTS

TO D1

AC POST

SHUNT

FIELD

SERIES FIELD

BRUSH POSITION SHOWN AS

VIEWED FROMCONTROL PANEL

ECTROD

WOR

2 CR

REED RELAY

POLARITY

SWITCH

ALTERNATOR

ROTOR

201

UPPER PANEL
GND SCREW

610

600

POWER
SUPPLY

+15VDC

608

J1-8

EXC. OVER-

VOLTAGE

PROTECTION

605

J1-7

J1-3

J1-4

600

606

J2-3

510

500

J2-2

2 AMP

PWM

J1-1

667

+140VDC

25V

1/8 AMP

J1-5

J1-6

J1-9

J1-2

77
76
75

521

+140VDC

+15VDC

J2-1

J2-5

J2-6

501

503

509

INPUTS

OUTPUTS

510

613

n.c.

602

SHUNT FIELD

DRIVE CIRCUIT

HOUR
METER

LOWER PANEL

GND SCREW

238

612

611

POSITIVE

NEG.

567

GENERATOR

666

622

25,000uf

75v

621

CR1

COI

CR1

CONTACTS

GENERATOR
SHUNT FIELD

30OHMS

100W

602

J2-3

TO PC BD

J1-10

229

203

600

S1C

500 OHMS

50W

500 OHMS

50W

AUXILIARY POWER

CIRCUIT

WELDCIRCUIT

BOARD

POWER

CR1 CONTACTOR

DRIVE RETURN

ARC

VOLTAGE

FEEDBACK

WELD C

OMMON

POWER OUTPUT

TO SHUNT

FIELD

CV SWITCH FOR

SHUNT FIELD

FLYWHEEL

DIODE

CV ADAPTER

CONTROL PCB

CHEM. # L6922)

ARMATURE

BRUSHES

2
3

5
6

2
3

5
6

8
9

CV ADAPTER

CONTROL PCB

TO D1

POST

n.c

POLES

/- 6.4, 150

max

/- 6.4

150 W

25OHM

50W

120 OHMS

2.5W

35A

800V

100 OHMS

50W

1000V

max

JOB

SELECTOR

HEOSTAT

VARIABLE

REACTOR

AUXILIARY OUTPUT

OCV

115/230 VAC + 10% @ 1800RPM

MAX LOAD

3KW @ 100% D.C.

120 OHMS

2.5W

1000V

35A

800V

35A

800V

35A

800V

74hz

CENTER OFF =NO WELD OUTPUT

12.8ms

5.2ms

50-250v

MAX POT/NO LOAD

50-250v

12.8ms

.5ms

MIN POT/NO LOAD

VOLTAGE WAVEFORM : J2-6 to J2-1 INCV MODE

360-440 OHMS @ 25C

23-24vdc

in CV

*SEE WAVEFORM
(J2-6 toJ2-1)

140vdc

(J2-3 toJ1-4)

*140vdc
(J1-8 to J1-4)

*12.9vdc
(J1-5 to J1-2)

*3.1vdc

(J1-9 to J1-2)

*NOTE : measurementmade in CV mode.

*0vdc

(J2-2 to J1-4)

140vdc (w/rheo- statat max)

140vdc

38.2-40.6 ohms
@ 25C

41.5 ohms +/- 1.0 @ 25C

MIN rheo=54vdc
MAX rheo=140vdc

MIN rheo=86vac
MAX rheo=0vac

located behind upper
control panel on
reactor box

alternator &rotor located at
end of generator

diodes located behind
upper control panel

located behind upper
control panel on
reactor box

located behind upper
control panel on reactor box

located behind

work stud

CVadapter box located on left fuel tank
rail (viewed from control panel end)

positive stud located on
right fuel tank rail (viewed
from control panel end)

201

201A

CURRENT

SENSE

TOROID

ROTOR FIELDAND

FLASH CIRCUIT

WELDING

GENERATOR

REMOTE

RECEPTACLE

AND PLUG

(SHOWN IN NEGATIVE POISTION)

flywheel
diode

GENERATO

BLOCK

output studs located on right fuel tank
rail (viewed from control panel end)
(electrode closest to control panel)

610

J2-3

+15VDC

CR1 CONTACTOR

DRIVE CIRCUIT

J2-3

S1D

CV VOLTAGE

CONTROL

POT

CR1 CONTACTOR

DRIVE INPUT

max

(NO AFFECT W/CV
ADAPTER HOOKED UP)

VVneg stud located on
right fuel tank rail
(viewed from control
panel end)

J2-3

SAE400 INTERFACE WITH

OPTIONAL CV ADAPTER

NOTE!! : WHEN INSTALLING CV ADAPTER,

"ELECTRODE" STUD BECOMES VV

"NEGATIVE"

STUD,& "TO WORK" STUD BECOMES

"POSITIVE"

STUD.

CVneg stud located on
adapter box mounted on left
fuel tank rail (viewed from
control panel end)

CV WELD OUTPUT

MIN TO MAX OCV

8-41vdc

WELD RANGE

15-35vdc

MAX LOAD

400A @ 35V @ 60% D.C.
500A @ 35V @ 35% D.C.

CC WELD OUTPUT

MIN TO MAX OCV 57-97VDC @ 1800 RPM
WELD RANGE

80-575 AMPS

MAX LOAD

400A @ 40V @ 100% D.C. (1725 RPM)

CV MODE – POWER UP SEQUENCE

Exciter rotor is flashed from 12v battery supply at
machine power up, exciter winding builds up power.
Exciter winding powers D2 bridge and CR1 contactor
drive circuit on PC board at J1 pins 4 & 8.
CR1 closes, applying power to PC board at J2 pins 2
& 3 and disconnecting flashing circuit.
PC Board PWM circuit regulates output voltage by
using voltage feedback from J1 pin 1 and control pot
at J1 pin 6 to control current thru the shunt fields.

Note!!:

Rheostat

Must

be set to max for CV operation.

VV MODE – POWER UP SEQUENCE

Exciter rotor is flashed from 12v battery supply at
machine power up, exciter winding builds up power.
CR1 contactor and PC board

DO NOT

power up.

Shunt fields receive power thru PC board.
Rheostat controls current thru the shunts.

TO D1AC

POST

TO P8-2

S2 large switch located on
face of CVadapter box

Capacitor bank and bleeder
resistor located inside CV
adapter box

located inside CV
adapter box

S1 small switch
located on face of
CVadapter box

CR1 located inside
CVadapter box

TO PC BD

844-TERMINA

LOWER PANEL

GND SCREW

top right of

generator frame

located upper Rt
hand side behind

control panel

located upper Lt
hand side behind
control panel

CR1 located inside

CVadapter box

S1 small switch
located on face of
CVadapter box

located on face of
CVadapter box

located lower center
of control panel

located lower middle
of control panel

OIL PRESSURE SWITCH /SENDER

TEMPERATURE SWITCH /SENDER

IDLER /ENGINE PROTECTION PC BOARD

J31-2
J31-1

J31-3

J31-6

J31-7

J31-8

J31-9

J31-5

J31-

RED ENGINE
PROTECTION
LIGHT

J32-1
J32-2
J32-3
J32-4

J31-1

ALTERNATOR

PICAL

CURRENT DRAW

IS 40

+/- 3 AMPS

PICAL CURRENT DRAW:

HOUR METER

PICAL CURRENT DRAW:

HOLD COIL - 1.1A

PULL COIL - 46A

SWITCH OPENS

AT 6

+/-2PSI

SENDER OPERATION:

0 PSI -> 10+/-5 OHMS

40PSI -> 105+/-5 OHMS

80 PSI -> 187+/-5 OHMS

SHOWN IN "AUTO

IDLE" POSITION

SWITCH CLOSES
AT 230

v+/-6vF

SENDER OPERATION:
140

vF -> 134+/-13.5 OHMS

194

vF -> 51.2+/-4.3 OHMS

212

vF -> 38.5+/-3 OHMS

12 VOLT - NORMALLY OFF

SHOWN IN

"OFF" POSITION

50B

51A

212D

212C

200

212A

212B

58H

238A

844A

-40 TO 40 AMPS

AMMETER SHOWS FULL

SCHARGE WHILE PRESSING

OW PLUG SWITCH

65AMP / 12VOLT

D+

GLOW PLUGS

N.C.

N.O.

ENGINE

SHUTDOWN

ENGINE

RUNNING

CR1

ENGINE

PROTECTION

AND

ALTERNATOR

FLASHING

DELAY TIMER

EE BELOW

R LOGIC)

IDLER DELAY TIMER CIRUITS

Q2ON FOR HIGH IDLE

INJECTION PUMP
SOLENOID

FUEL PUMP

UNUSED

USED FOR TOROID IN AC

AUXILIARY MACHINES

P. C. BD. L12400-2

SCHEMATIC G4828-2

FLYBACK

ODE

IDLE

SOLENOID

RIGHT SIDEOF ENGINE

(ASVIEWED FROM CONTROL PANEL)

RIGHT SIDE OF
ENGINE (AS
VIEWED FROM
CONTROL PANEL)

LOCATEDBEHINDLOWERPORTIONOF CONTROL PANEL

SENDER IS APPROX.
500 OHMS AT 70

HOLD COIL

PULL COIL

CB5

10A

212E

844

TO REED RELAY

TO HOUR
METER (+)

238

CENTEROF CONTROL
PANEL

CENTEROF CONTROL PANEL

RIGHT SIDEOF ENGINEBY
INJECTIONPUMP

PICAL CURRENT DRAW:

3.3A

RIGHT SIDEOF ENGINEBY
OIL FILLER

APPROXIMATE RESISTANCE:

3-4 OHMS

APPROXIMATE RESISTANCE:

3.3 OHMS

WINDING SPEC'S & RESISTANCES

EXCITER

WINDING

SPEC

RESISTANCE

POWER

ALT-214-3C .230 OHMS @ 25C

QUADRATURE

ALT-214-3B .560 OHMS @ 25C

AUXILIARY (TAIL) ALT-214-3D .424 OHMS @ 25C
ROTOR (4-POLE) ALT-214-3A 41.4+/-1.0 OHMS @ 25C
DIAGRAM

M14262

GENERATOR

INTERPOLE

S12261-25

N/A

SHUNT FIELD

FKL-5AJ

19.1-20.3 OHMS @ 25C

SERIES FIELD

FKL-420-U

N/A

ARMATURE

FKL-37.4N

N/A

DIAGRAM

M5570

STARTER
SOLENOID

TEMPERATURE

GAUGE

OIL PRESSURE

GAUGE

IGNITION

SWITCH

IDLER SWITCH

GENERATOR SHUNT

FIELDCIRCUIT

AMMETER

LATCH

SHOWN FOR REFERENCE ONLY-
NOT PART OF CV ADAPTER

UPPER PANEL

GND SCREW

UPPER PANEL

GND SCREW

OW PLUG

SWITCH

230V DUPLEX
RECEPTACLE

115V DUPLEX
RECEPTACLE

LEFT SIDEOF ENGINE

(ASVIEWED FROM CONTROL PANEL)

LOCATEDABOVEENGINE
ALTERNATOR.
RIGHT SIDEOF ENGINE
(ASVIEWED FROM CONTROL PANEL)

LOCATEDBEHIND FUEL FILTER,

LEFT SIDEOF ENGINE

(ASVIEWED FROM CONTROL PANEL)

ENGINE PROTECTION AND ALTERNATOR FLASHING DELAY TIMER LOGIC

UPON RECIEVEING POWER, CIRCUIT TO FLASH ALTERNATOR IS OPENED

AND ENGINE PROTECTION IS BYPASSED. AFTER TIME DELAY, ALTERNATOR

FLASHING CIRCUIT IS CLOSED AND ENGINE PORECTION IS ENABLED. NOTE:

AFTER TIME DELAY WHEN ENGINE PROTECTION IS ENABLED, IF THE ENGINE

IS NOT STARTED THE OIL PRESSURE WILL BE LOW AND THE MACHINE WILL

SHUT DOWN BECAUSE OF THE ENGINE PROTECTION CIRCUIT.

IDLE SOLENOID CIRCUIT LOGIC

1. WHEN THE ENGINE IS RUNNING IN HIGH IDLE OR UNDER LOAD, THE SOLENOID IS NOT ENERGIZED.

2. IF NO AUXILIARY CURRENT DRAW OR WELD LOAD IS SENSED FOR 15 SECONDS AND THE IDLER SWITCH IS

OPEN (AUTO), THE PULL AND HOLD COIL OF THE IDLER SOLENOID ARE ENERGIZED. THE PULL COIL IS
DE-ENERGIZED AFTER HALF A SECOND.

3. IF AN AUXILIARY CURRENT DRAW OR WELD LOAD IS SENSED OR THE IDLER SWITCH IS CLOSED (HIGH),

THE IDLE SOLENOID IS DE-ENERGIZED.

located generator
end of machine

located engine right side
(viewfrom control panel end)

FRAME

ENGINE BLOCK

ENGINE

STARTER

12 VOLT

BATTERY

235

ART SWITCH

50A

INJ

ECTION PUMP

TIMING SOLENOID

ENGINE

TEMPERATURE

SENSOR

212F

16 OHMS

0.9 AMPS

RIGHT SIDE OF ENGINE
ON INJECTION PUMP

INJ

ECTION PUMP TIMING

SOLENOID TYP. CURRENT

DRAW 0.9A APPROX.

RESISTANCE 16 OHMS

MAY NOT APPEAR ON ALL MODELS

212F

810

CB4

CB3

CB1

11A

400F

11B

202

203A

602C

G-8

NOTE:

This diagram is for reference only. It may not be accurate for all machines covered by this manual.

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Содержание SAE-400 SEVERE DUTY IM727

Страница 1: ...D THROUGHOUT And most importantly think before you act and be careful SERVICE MANUAL For use with machine code numbers 10856 11199 11408 Return to Master TOC Return to Master TOC Return to Master TOC Return to Master TOC View Safety Info View Safety Info View Safety Info View Safety Info Sales and Service through Subsidiaries and Distributors Worldwide Cleveland Ohio 44117 1199 U S A TEL 888 935 3...

Страница 2: ...E SERIOUS INJURY OR DEATH KEEP CHILDREN AWAY PACEMAKER WEARERS SHOULD CONSULT WITH THEIR DOCTOR BEFORE OPERATING Read and understand the following safety highlights For additional safety information it is strongly recommended that you purchase a copy of Safety in Welding Cutting ANSI Standard Z49 1 from the American Welding Society P O Box 351040 Miami Florida 33135 or CSA Standard W117 2 1974 A F...

Страница 3: ... your eyes from sparks and the rays of the arc when welding or observing open arc welding Headshield and filter lens should conform to ANSI Z87 I standards 4 b Use suitable clothing made from durable flame resistant material to protect your skin and that of your helpers from the arc rays 4 c Protect other nearby personnel with suitable non flammable screening and or warn them not to watch the arc ...

Страница 4: ...hat welding sparks and hot materials from welding can easily go through small cracks and openings to adjacent areas Avoid welding near hydraulic lines Have a fire extinguisher readily available 6 b Where compressed gases are to be used at the job site special precautions should be used to prevent hazardous situations Refer to Safety in Welding and Cutting ANSI Standard Z49 1 and the operating info...

Страница 5: ...availlant à proximité au soudage à l aide d écrans appropriés et non inflammables 4 Des gouttes de laitier en fusion sont émises de l arc de soudage Se protéger avec des vêtements de protection libres de l huile tels que les gants en cuir chemise épaisse pan talons sans revers et chaussures montantes 5 Toujours porter des lunettes de sécurité dans la zone de soudage Utiliser des lunettes avec écra...

Страница 6: ...e user of the welding equipment to resolve the situation with the technical assistance of the manufacturer In some cases this remedial action may be as simple as earthing grounding the welding circuit see Note In other cases it could involve construction of an electromagnetic screen enclosing the power source and the work com plete with associated input filters In all cases electromagnetic disturb...

Страница 7: ...ccording to the manufacturer s recommendations Welding Cables The welding cables should be kept as short as possible and should be positioned close together running at or close to floor level Equipotential Bonding Bonding of all metallic components in the welding installation and adjacent to it should be considered However metallic components bonded to the work piece will increase the risk that th...

Страница 8: ...IN INDEX Page Safety i iv Installation Section A Operation Section B Accessories Section C Maintenance Section D Theory of Operation Section E Troubleshooting and Repair Section F Electrical Diagrams Section G Parts Manual P 530 vii vii SAE 400 SEVERE DUTY ...

Страница 9: ...ion A 1 Technical Specifications A 2 Safety Precautions A 3 Location Ventilation A 3 Stacking A 3 Angle Of Operation A 3 Lifting A 3 High Altitude Operation A 4 Towing A 4 Vehicle Mounting A 4 Pre Operation Engine Service A 4 Engine Break In A 5 Engine Cooling System A 5 Battery Connection A 5 Spark Arrestor A 6 Welding Output Cables A 6 Machine Grounding A 6 ...

Страница 10: ...73 3 mm 711 2 mm 2108 2 mm 10856 2178 lbs 988 0 kg OUTPUT WELDER AND GENERATOR Duty Cycle 1 Welding Output Volts at Rated Amps 60 NEMA 400 amps 36 volts 60 Lincoln Plus 400 amps 40 volts 100 Lincoln Plus 400 amps 40 volts Welding Range Open Circuit Voltage Auxiliary Power 80 575 Amps 97 Max OCV 115 230 VAC 1800 RPM 3000 Watts 60 Hz 100 Duty Cycle PHYSICAL DIMENSIONS Make Model Description Speed RP...

Страница 11: ...ts and to avoid restricting the cooling air outlets Also locate the welder so that the engine exhaust fumes are properly vented to an outside area DO NOT MOUNT OVER COMBUSTIBLE SURFACES Where there is a combustible surface directly under stationary or fixed electrical equipment that surface shall be covered with a steel plate at least 06 1 6mm thick which shall extend not less than 5 90 150mm beyo...

Страница 12: ...e on public highways such as brakes lights fend ers etc VEHICLE MOUNTING Improperly mounted concentrated loads may cause unstable vehicle handling and tires or other compo nents to fail Only transport this equipment on serviceable vehi cles which are rated and designed for such loads Distribute balance and secure loads so vehicle is stable under conditions of use Do not exceed maximum rated loads ...

Страница 13: ...ectric selects high quality heavy duty indus trial engines for the portable welding machines we offer While it is normal to see a small amount of crankcase oil consumption during initial operation excessive oil use wetstacking oil or tar like substance at the exhaust port or excessive smoke is not normal Larger machines with a capacity of 350 amperes and higher which are operated at low or no load...

Страница 14: ...ical Code and the local code In general if the machine is to be grounded it should be connected with a 8 or larger copper wire to a solid earth ground such as a metal water pipe going into the ground for at least ten feet and having no insulated joints or to the metal framework of a building which has been effectively grounded The U S National Electrical Code lists a number of alternate means of g...

Страница 15: ...afety Instructions B 2 Additional Safety Precautions B 2 General Descriptions B 2 Welder B 2 Auxiliary Power B 2 Design Features And Advantages B 3 Duty Cycle B 3 Engine Controls Function Operation B 4 Welder Controls Function Operation B 5 Remote Control B 5 Auxiliary Power Controls B 5 Engine Operation B 6 Starting Instructions B 6 Typical Fuel Consumption B 7 ...

Страница 16: ...ERE DUTY provides excellent con stant current DC welding output for stick SMAW weld ing AUXILIARY POWER The SAE 400 SEVERE DUTY provides 3 KW of 115 230 VAC output for auxiliary power and emer gency standby power OPERATING INSTRUCTIONS Read and understand this entire section before operat ing your equipment SAFETY INSTRUCTIONS Do not attempt to use this equipment until you have thoroughly read all...

Страница 17: ...d 11408 OTHER FEATURES Perkins 4 cylinder water cooled diesel engine Designed for long life easy maintenance and excel lent fuel economy Engine protection system shuts the engine down for low engine oil pressure or high coolant temperature alternator failure or broken belt Electronic Engine Idler Engine automatically goes to low idle in 10 to 14 seconds after welding or use of auxiliary power stop...

Страница 18: ...harging current to be high above 15 amps after starting or when the batter ies are low on charge ENGINE HOUR METER The engine hour meter records the total running time on the engine in hours It can be used to keep a record of maintenance on the engine and or welder ENGINE PROTECTION SYSTEM The engine protection system shuts down the engine under high coolant temperature low engine oil pres sure br...

Страница 19: ...Current Control to read 135 amps on the black dial 3 Start to weld 4 If you want a little more current turn the Job Selector up counterclockwise to increase cur rent If you want a little less current turn the Job Selector down clockwise to decrease current 5 If dialing the desired current with the Job Selector moves the setting outside the black range causing undesirable arc characteristics turn t...

Страница 20: ...lt the engine operating manual To stop the engine turn the IGNITION switch to OFF 6 If the engine protection warning light comes on during cranking or after start up the IGNITION switch must be turned OFF to reset the engine protection system 7 Allow the engine to run at high idle speed for sev eral minutes to warm the engine Stop the engine and recheck the oil level after allowing sufficient time...

Страница 21: ...N The typical fuel consumption of the SAE 400 for various operat ing scenarios is shown below 11199 11408 10856 Low Idle No Load 30 gal hr 35 gal hr 1100 RPM 1 12 L hr 1 32 L hr High Idle No Load 69 gal hr 75 gal hr 1800 RPM 2 61 L hr 2 84 L hr Welding Load 1 79 gal hr 1 92 gal hr 400 Amps 40 Volts 6 76 L hr 7 27 L hr Welding Load 2 43 gal hr 500 Amps 40 Volts 9 19 L hr Auxiliary Power 71 gal hr 9...

Страница 22: ...turn to Section TOC Return to Section TOC Return to Section TOC Return to Section TOC Return to Master TOC Return to Master TOC Return to Master TOC Return to Master TOC NOTES B 8 B 8 SAE 400 SEVERE DUTY ...

Страница 23: ...BLE OF CONTENTS ACCESSORIES SECTION C 1 C 1 Return to Master TOC Return to Master TOC Return to Master TOC Return to Master TOC SAE 400 SEVERE DUTY Accessories C 1 Optional Field Installed Accessories C 2 ...

Страница 24: ...y to welder base Comes standard with a Duo Hitch a 2 Ball and Lunette Eye combination Hitch Order K2637 1 Trailer K958 1 Ball Hitch K958 2 Lunette Eye Hitch K2639 1 Fender Light Kit K2640 1 Cable Storage Rack 1For highway use consult applicable federal state and local laws regarding possible requirements for brakes lights fenders etc K704 Standard Accessory Kit Includes electrode and work cables h...

Страница 25: ...EVERE DUTY Maintenance D 1 Routine Maintenance D 2 Periodic Maintenance D 2 Engine Oil Change Engine Air Filter D 2 Bearing Commutator And Brush Maintenance D 3 Cooling System Fuel Filter D 3 Water Seperator D 4 Secondary Fuel Filter D 4 Engine Maintenance Components D 4 Spark Arrestor D 5 GFCI Receptacle Testing And Reseting Procedure D 5 ...

Страница 26: ...ng 3 See the engine Instruction Manual for periodic engine maintenance information Change the oil filter in accor dance with the instructions in the engine operating man ual When the oil filter is changed add one quart of oil to the crankcase to replace the oil held in the filter during operation 4 Belts tend to loosen after the first 30 or 40 hours of oper ation Check the cooling fan belt and tig...

Страница 27: ... of replacement brushes should be kept on hand Lincoln brushes have a curved face to fit the commutator Have an experienced maintenance man seat these brushes by lightly stoning the commu tator as the armature rotates at full speed until contact is made across the full face of the brushes After ston ing blow out the dust with low pressure air To seat the slip ring brushes position the brushes in p...

Страница 28: ...he quick change ring located just below fil ter header clockwise approximately 1 2 turn and slide it down and off of the element 3 Grasp the element and pull down with a slight rock ing motion to remove the element from the grommet post on the bottom of the filter header 4 Slide the new element onto the grommet post on the bottom of the filter header until the element no longer easily moves up int...

Страница 29: ...light or other product should go ON again If the light or other product remains ON when the Test button is pushed the GFCI is not working prop erly or has been incorrectly installed miswired If your GFCI is not working properly contact a qualified certi fied electrician who can assess the situation rewire the GFCI if necessary or replace the device SPARK ARRESTOR For machines with separate spark a...

Страница 30: ...turn to Section TOC Return to Section TOC Return to Section TOC Return to Section TOC Return to Master TOC Return to Master TOC Return to Master TOC Return to Master TOC NOTES D 6 D 6 SAE 400 SEVERE DUTY ...

Страница 31: ...DLE 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 WINDIN...

Страница 32: ...is equipped with either a Thermostart or a glow plug starting system that is used for cold weath er starting Pressing the Thermostart or Glow Plug button activates this system See the machine name plate and engine manual for operating instructions and service information Pressing the start button activates the starter motor which cranks the engine The start button is a momen tary contact switch th...

Страница 33: ...t When weld current flows the reed switch closes con necting the sense lead to chassis ground When suffi cient AC current flows the toroidal current transformer sends a signal to the PC board When the idle switch is in the high position power to the solenoid is shut off deactivating it and causing the engine to operate at high rpm The idle circuitry on the PC board continues to sense if there is a...

Страница 34: ...e stator windings Output from the exciter winding is rectified by a diode bridge and then fed back into the rotating field winding through the brushes making the magnetic field stronger This stronger magnetic field then produces higher voltage from the stator windings which feeds back to the rotor making its magnetic field even stronger This process of strengthening the magnetic field through feed...

Страница 35: ... TOC EXCITER AUXILIARY ALTERNATOR OPERATION Continued AC Auxiliary Output The exciter alternator is now producing sufficient AC power from both the exciter winding and the 115 230 VAC auxiliary power winding This 115 230 VAC 60 Hz auxiliary power is made available for use through the receptacles on the front panel of the machine after passing through circuit breakers and the automatic idle system ...

Страница 36: ...d 64 Ohm rheostat The now controlled AC current is then converted to direct current DC by a full wave bridge rectifier The DC output from the rectifier then passes through a polarity reversing switch and is then applied to the two series connected shunt coils in the generator stator Reversing the polarity of the field also reverses the polarity of the weld current When the polarity switch is moved...

Страница 37: ...ngs that are producing maximum output at the correct polarity With the armature spinning at about 1800 RPM wind ings are coming in contact with the brushes many times per second producing a continuous flow of DC current at the generator brushes Controlling the weld output The SAE 400 utilizes a dual continuous control system for weld output These controls are the Job Selector and the Current Contr...

Страница 38: ...current flowing from the armature to pass through the series coils This setting will produce the lowest weld current that can be set with this control Moving the current control off of the minimum setting closes the circuit in the reactor and allows some of the current to bypass the series coils Continuing to move the control to the higher settings reduces the resis tance of the reactor and causes...

Страница 39: ...nected and arranged to counteract this magnetic distortion If not corrected the distortion would cause reduced output and 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 PRO...

Страница 40: ...urn to Section TOC Return to Section TOC Return to Section TOC Return to Section TOC Return to Master TOC Return to Master TOC Return to Master TOC Return to Master TOC NOTES E 10 E 10 SAE 400 SEVERE DUTY ...

Страница 41: ...ing F 37 Exciter Stator Short Circuit Ground Test F 41 Welding Generator Brush And Commutator Inspection And Service F 43 Weld Circuit Ground And Short Circuit Test F 47 Shunt Field Coil Resistance And Ground Test F 49 Shunt Field Circuit Voltage Test F 51 Dead Short 1st Step And Open Reactor Test F 53 Rocker Adjustment Procedure F 55 Output Control Unit Variable Reactor Inspection And Service Pro...

Страница 42: ...machine It also specifies the appropriate test procedure to verify that the subject com ponent is either good or bad If there are a number of possible components check the components in the order listed to eliminate one possibility at a time until you locate the cause of your problem All of the referenced test procedures referred to in the Troubleshooting Guide are described in detail at the end o...

Страница 43: ... on equipment Do not touch electrically hot parts Remove the PC board from the static shielding bag and place it directly into the equipment Don t set the PC board on or near paper plastic or cloth which could have a static charge If the PC board can t be installed immediately put it back in the static shield ing bag If the PC board uses protective shorting jumpers don t remove them until installa...

Страница 44: ...or damaged or poor connections Check the polarity switch make sure it is not in the off position Check that the remote local switch is positioned correctly If a remote current control is being used try switching to local control The remote current control may be faulty Check all leads and cables for damaged or poor connections Perform the Engine RPM Adjustment Test Perform the Brush and Slip Ring ...

Страница 45: ...eset unless engine is operating at high idle RPM Check all leads and cables for damaged or poor connections Check for auxiliary voltage at the receptacle input terminals if normal voltage is present replace receptacle Check for auxiliary voltage at the connections closest to the exciter stator windings See wiring diagram If normal voltage is present check the wiring and circuit breakers between th...

Страница 46: ...is an adequate supply of clean fresh fuel Replace fuel filters if necessary Have engine serviced by a qualified engine technician Check and if necessary perform the Brush and Slip Ring Service Procedure Perform the Welding Generator Brush and Commutator Inspection and Service Procedure Perform the Engine RPM Adjustment Test Check all the large weld current carrying leads inside the machine for dam...

Страница 47: ...ary voltage is normal continued Examine polarity switch for poor electrical connections and damaged or burned contacts Replace if necessary If polarity switch contacts have excessive arc damage check the 500 Ohm resistor Perform the Exciter Rotor Resistance and Ground Test Perform the Shunt Field Coil Resistance and Ground Test Check the Generator brush rocker position perform the Rocker Adjustmen...

Страница 48: ...ave engine serviced by a qualified engine technician Perform the Engine RPM Adjustment Test Perform the Welding Generator Brush and Commutator Inspection and Service Procedure Perform the Brush and Slip Ring Service Procedure Perform the Shunt Field Coil Resistance and Ground Test Perform the Dead Short First Step and Open Reactor Tests If necessary perform the Output Control Unit Inspection and S...

Страница 49: ... The remote current control may be faulty Examine polarity switch for poor electrical connections and damaged or burned contacts Replace if necessary If polarity switch contacts have excessive arc damage check the 500 Ohm resistor Verify that the rocker is positioned correctly according to the factory drill mark If necessary perform the Rocker Adjustment Procedure Verify that the rocker is positio...

Страница 50: ...witch indicates If a remote current control is being used try switching to local control The remote current control may be faulty The engine RPM may be incorrect perform the Engine RPM Adjustment Test Perform the Brush and Slip Ring Service Procedure Perform the Welding generator Brush and Commutator Inspection and Service Procedure Perform the Dead Short First Step and Open Reactor Tests Perform ...

Страница 51: ...or replace the batteries The battery cables or battery connections may be loose or corroded Service the battery terminals The engine RPM may be incorrect perform the Engine RPM Adjustment Test Perform the Brush and Slip Ring Service Procedure Perform the Welding Generator Brush and Commutator Inspection and Service Procedure Perform the Output control unit Inspection and Service Procedure Perform ...

Страница 52: ... move it back to the run position If the machine is being used in a cold climate the thermostart or glow plug system may need to be used See the welder operators manual and the engine operator s manual for detailed instructions Check that there is an adequate supply of fresh clean fuel and that the fuel shut off valve is open Check and if necessary replace the fuel filter There may be air in the f...

Страница 53: ...turer or a qualified engine specialist to determine the cause of the overheat condition and make any required adjustments or repairs Check that there is an adequate supply of fresh clean fuel and that the fuel shut off valve is fully open Check the fuel and air filters replace if necessary The idle engine protection PC board alternator oil pressure switch or engine coolant temperature switch may b...

Страница 54: ...erminals or the auxiliary power receptacles Disconnect the weld cables and unplug anything that may be connected to the auxiliary receptacles Check for mechanical restrictions in the idler solenoid linkage Perform the Engine Alternator Test The idle solenoid linkage may be bent or out of adjustment Check that the linkage moves freely and that the plunger does not bind in any way Check that the sol...

Страница 55: ... operating normally For code 10856 the solenoid should pull in and hold firmly when battery voltage is applied For codes 11199 and 11408 apply battery voltage for only an instant to the black and white leads The solenoid should pull in immediately WARNING Do not allow the black and white leads to remain connected to battery Serious damage can result Apply battery voltage to the black and red leads...

Страница 56: ...d Unplug J2 for code 10856 and J32 for codes 11119 and 11408 If the machine idles down after the sensor is unplugged check the wiring between the PC board and toroidal current sensor for damaged insulation and electrical contact with other electrically live components See the wiring diagram If the wiring is good there is likely a load on the auxiliary circuit Check all wiring and components in the...

Страница 57: ... of adjustment Check that the linkage moves freely and that the plunger is not binding in any way Check that the solenoid can freely pull in and solidly seat against its internal stop The idle solenoid may have failed Disconnect the solenoid leads and check the resistance of the solenoid coil It should be about 8 8 Ohms at 77 Deg F 25 Deg C Check the solenoid for a grounded coil the resistance bet...

Страница 58: ...bles and the auxiliary power lead connections are tight and in good condition Check that the welding cables electrode holder and work clamp are tight and in good condition This may be normal operation if the machine has a Constant Voltage adapter and is operating in CV mode See the operator s manual for the Constant Voltage Adapter For code 10856 The Idle switch may be defective or the insulation ...

Страница 59: ...ondition and properly connected Verify that any devices operating from the auxiliary AC power are operating correctly and are in good condition Try plugging the device into another source of AC power to be sure it is functioning properly Some devices may test the input power for correct voltage and frequency before they will operate If such a device is being used the idle switch will need to be pl...

Страница 60: ...urn to Section TOC Return to Section TOC Return to Section TOC Return to Section TOC Return to Master TOC Return to Master TOC Return to Master TOC Return to Master TOC NOTES F 20 F 20 SAE 400 SEVERE DUTY ...

Страница 61: ...tact the Lincoln Electric Service Department for electrical trou bleshooting assistance before you proceed Call 1 888 935 3877 TEST DESCRIPTION This test will determine if the engine is operating at the correct RPM for both high and low idle positions MATERIALS NEEDED Miscellaneous hand tools Strobe Tachometer Frequency Counter or Multimeter with frequency counter function Bright colored marking p...

Страница 62: ...hly visible mark on the engine crankshaft pulley or another rotating component connected to the engine crankshaft See Figure F 1 2 Connect the strobe tach according to the manufac turer s instructions 3 Start the engine and place the idle switch in the HIGH IDLE position Apply a resistive load operat ing the machine at 100 output 400 amps 36 volts for about 30 minutes to get the machine up to oper...

Страница 63: ...rt the engine and place the idle switch in the HIGH IDLE position Apply a resistive load of about 300 amps long enough to get the machine up to operating temperature and the RPM to stabilize CAUTION Do Not Short the Output Studs Together as a means of loading the machine Serious damage can result that will not be covered by Warranty The frequency should read between 59 3 and 60 3 Hz Move the idle ...

Страница 64: ...ge moves freely and does not bind When the solenoid is energized the plunger must fully seat against the stop inside the solenoid coil assembly Codes 11199 and 11408 4 Hold the idle rod with a wrench and loosen the lock nut Adjust the length of the idle rod by turning it onto or out of the ball joint on the injection pump 5 Recheck the low idle RPM and adjust as needed when the low idle RPM is cor...

Страница 65: ...e Lincoln Electric Service Department for electrical trou bleshooting assistance before you proceed Call 1 888 935 3877 TEST DESCRIPTION This procedure provides guidance in testing and maintaining the brush and slip ring sys tem of the Exciter auxiliary power alternator MATERIALS NEEDED 500 or 600 grit emery cloth 180 grit sand paper 220 or 320 grit commutator stone Optional BRUSH AND SLIP RING SE...

Страница 66: ...om oil or grease The brushes should be of sufficient length and have adequate spring tension Brushes should be making good continuous contact with the slip rings and should be riding near the center of the slip rings The brush holder bracket may need to be slightly bent to achieve acceptable alignment Generally the brushes should be replaced if either brush has less than 1 4 remaining before it re...

Страница 67: ...ienced technicians who have the knowledge and equipment necessary to use them safely Seating brushes If brushes have been replaced repositioned or are not making full contact with the slip rings it will be neces sary to re seat them This can be done by placing a strip of 180 grit sandpaper between the slip rings and the brushes with the abrasive side against the brush es Pull the sandpaper strip a...

Страница 68: ...urn to Section TOC Return to Section TOC Return to Section TOC Return to Section TOC Return to Master TOC Return to Master TOC Return to Master TOC Return to Master TOC NOTES F 28 F 28 SAE 400 SEVERE DUTY ...

Страница 69: ...cedures or are unable to perform the test repairs safely contact the Lincoln Electric Service Department for electrical trou bleshooting assistance before you proceed Call 1 888 935 3877 TEST DESCRIPTION This test will determine if the exciter rotor winding is operating at normal voltage MATERIALS NEEDED Miscellaneous hand tools Voltmeter Wiring diagram EXCITER ROTOR VOLTAGE TEST TROUBLESHOOTING A...

Страница 70: ...Open either or both of the doors on the control panel end of the SAE 400 machine WARNING Secure the doors in the open position using the door restraint system If the machine does not have a door restraint system remove the doors or securely restrain them to prevent them from falling closed 4 Remove the covers from the exciter auxiliary power alternator by removing the screws securing it See Figure...

Страница 71: ...oximately 2 to 4 VDC Check this voltage If this voltage reading is correct start the engine and continue the testing If this voltage is not within these limits perform the Flashing Voltage Tests NOTE If more than 30 seconds One minute for some models has passed the engine fault lamp will turn on and the fuel solenoid and flashing volt age will be turned off Before the engine can be started the eng...

Страница 72: ...ng tests 10 Check the D1 field bridge rectifier 11 Check the wiring and terminals connecting the D1 bridge rectifier to the Exciter stator winding See the wiring diagram 12 Perform the Exciter Stator Short Circuit and Ground Test When the Stator Short Circuit and Ground Tests have been completed reconnect the leads to the AC termi nals of the D1 field bridge rectifier Be sure that there are no loa...

Страница 73: ...t the Lincoln Electric Service Department for electrical trou bleshooting assistance before you proceed Call 1 888 935 3877 TEST DESCRIPTION This test will determine if the exciter auxiliary power alternator rotor winding is open shorted or grounded MATERIALS NEEDED Miscellaneous hand tools Ohmmeter Analog type meter required for dynamic resistance test Wiring diagram EXCITER ROTOR RESISTANCE AND ...

Страница 74: ...does not have a door restraint system remove the doors or securely restrain them to prevent them from falling closed 3 Remove the cover from the exciter auxiliary power alternator by removing the screws securing it See Figure F 8 4 Locate and label the leads connected to the rotor brush holder assembly Remove the leads to elec trically isolate the rotor windings TROUBLESHOOTING AND REPAIR F 34 F 3...

Страница 75: ...d Place one meter probe on either of the slip rings Place the other probe on any good unpainted chassis ground The resistance should be very high at least 500 000 500k ohms If the resistance measurements are not as specified the rotor may be faulty and should be replaced If these resistance values are normal continue testing using the dynamic rotor resistance and ground test TROUBLESHOOTING AND RE...

Страница 76: ...s be secure ly attached to the brush terminals using clips or termi nals BEFORE starting the engine See Figure F 10 2 Start the engine and run it at high idle speed 1800 RPM The resistance should read approximately 42 ohms at 77 deg F 25 deg C 3 Shut off engine and move one of the ohmmeter leads to a good clean chassis ground connection 4 Restart the engine and run it at high idle speed 1800 RPM T...

Страница 77: ...ures or are unable to perform the test repairs safely contact the Lincoln Electric Service Department for electrical trou bleshooting assistance before you proceed Call 1 888 935 3877 TEST DESCRIPTION This test checks the exciter rotor flashing voltage with the engine stopped MATERIALS NEEDED Miscellaneous hand tools Volt meter Wiring diagram FLASHING VOLTAGE TEST Engine not running TROUBLESHOOTIN...

Страница 78: ... the brush termi nals See the wiring diagram and Figure F 12 5 Set the RUN STOP switch to RUN Do not start the engine at this time 6 Within 30 seconds of switching the run stop switch to the run position read the flashing voltage across the brush connections The meter should read approximately 2 to 4 VDC NOTE If the flashing voltage reading is not taken with in 30 seconds 60 seconds with some mode...

Страница 79: ...Be sure that the voltage reading was taken within 30 seconds after the run stop switch was moved to the run position Reset the switch and retest if nec essary This condition could be caused by a poor connection or a defective component in the flashing circuit Other possible causes include a shorted rotor winding a shorted field bridge rectifier or a failed Idler Engine protection PC board Continue...

Страница 80: ...for code 10856 J31 pin 1 for Codes 11199 and 11408 and check the voltage If no voltage is present check the run stop switch the circuit breaker and all connections between the bat tery engine starter solenoid ammeter run stop switch idler switch circuit breaker and the idler engine pro tection PC board See the wiring diagram If battery voltage is present at J1 pin 1for code 10856 J31 pin 1 for cod...

Страница 81: ...TION This test will determine if there are undesirable electrical connections between the exciter stator windings and chassis ground or between individual windings within the exciter sta tor This test should be performed if flashing voltage is present at the rotor slip rings rotor resistance the D1 field bridge rectifier and all associated wiring are proven to be good but the exciter stator output...

Страница 82: ...ohms minimum From chassis ground and one of the exciter wind ing leads From chassis ground and one of the neutral termi nals of the 115 VAC receptacle The neutral ter minal is the larger of the two slots From one of the neutral terminals of the 115 VAC receptacle to one of the exciter leads If any of these readings are less than 500 000 500k ohms be certain that the windings are completely dry and...

Страница 83: ... checking and servicing the welding generator com mutator and brushes MATERIALS NEEDED Miscellaneous hand tools 120 150 grit commutator stone 220 320 grit commutator stone IMPORTANT Do not use emery cloth or paper to clean the commutator Use only sand paper or a commutator stone CAUTION Stoning the commutator involves pressing an abrasive stone against a spin ning commutator This procedure can be ...

Страница 84: ...g the door restraint system If the machine does not have a door restraint system remove the doors or securely restrain them to prevent them from falling closed 3 Disconnect the negative battery cable 4 Remove the sheet metal covers protecting the welder generator brushes See Figure F 15 TROUBLESHOOTING AND REPAIR F 44 F 44 SAE 400 SEVERE DUTY Return to Section TOC Return to Section TOC Return to S...

Страница 85: ... the rocker position requires adjustment do not over tighten the rocker clamping screw This screw should be tightened to a torque of 70 to 75 Inch Lbs Over tightening can destroy the rocker Perform the Weld Circuit Ground and Short Circuit Test If the weld circuit is not grounded or shorted and poor brush quality or contamination is suspected replace the brushes and seat them with a commu tator st...

Страница 86: ...d output is abnormal the armature should be replaced If the commutator has uneven color but there is no sign of serious generator performance problems the commutator may only need to be cleaned by lightly stoning the surface See caution note on commutator stone usage Examine the brushes The brushes and springs should all be in place and not be excessively worn Brushes should be replaced if they ar...

Страница 87: ...roceed Call 1 888 935 3877 TEST DESCRIPTION This procedure checks for grounded components in the weld circuit It also checks for a short circuit condition between the positive and negative components of the weld circuit This test cannot detect a short circuit within the armature or a turn to turn short circuit with in a coil or coil set IMPORTANT The machine must be clean and completely dry before...

Страница 88: ... connected to the interpole coils Check for damaged dirty or missing brush holder insulators Check for a dam aged or dirty weld output WORK terminal 8 If the resistance measured at the ELECTRODE terminal is low examine the output control unit the series coils and the heavy leads and brush holders connected to them Check for damaged dirty or missing brush holder insulators Check for a dam aged or d...

Страница 89: ...oln Electric Service Department for electrical trou bleshooting assistance before you proceed Call 1 888 935 3877 TEST DESCRIPTION This procedure will determine if the welding generator shunt field coils are open shorted or grounded IMPORTANT The machine should be clean and windings must be completely dry before this test is done MATERIALS NEEDED Miscellaneous hand tools Ohm meter or Multimeter Wi...

Страница 90: ...ing diagram and internal generator diagram If the resistance is still significantly lower than 40 Ohms one of the coils is likely shorted Replace the shunt coil set Shunt Coil Ground Test 4 Place the polarity switch in the OFF position Locate the 500 Ohm resistor located on the back of the control panel just below the 115 VAC duplex receptacle Leave all of the leads connected to the resistor and m...

Страница 91: ...tric Service Department for electrical trou bleshooting assistance before you proceed Call 1 888 935 3877 TEST DESCRIPTION This procedure will determine if the shunt field coils are receiving the necessary power to operate correctly This test should be done if there is little or no output from the welding generator but aux iliary output is normal MATERIALS NEEDED Miscellaneous hand tools Volt mete...

Страница 92: ...ured voltage is normal but there is still no usable output from the welding generator perform the Shunt Field Coil Resistance and Ground Test If the correct voltage is not present at the 500 Ohm resistor check for voltage at the positive and negative terminals of the D2 bridge rectifier If about 140 VDC is present at the D2 bridge rectifier check the wiring between the rectifier the polarity switc...

Страница 93: ...tance before you proceed Call 1 888 935 3877 TEST DESCRIPTION This procedure tests the operation of the Output Control Unit Variable Reactor and the Series Field Coils in the welding generator This procedure should be done if the low end weld output too low too high or varies abnormally and the auxiliary output is normal MATERIALS NEEDED Miscellaneous Hand tools Ohm Meter Resistive load Bank A sho...

Страница 94: ...erator diagram 4 Begin rotating the output control until the output cur rent changes this is the first step or first turn of the reactor coil See Figure F 17 The output should measure 200 to 300 Amps at 0 2 to 4 Volts DC A slightly high reading in the Min position with no clear first step jump in output could indicate that the contacts are badly worn and the contact fingers rather than the contact...

Страница 95: ...ll performance and long generator and brush life Altering this adjustment is normally not recom mended unless one or more of the welding generator components affect ing this setting have been replaced In very unusual situations very small adjustments of the rocker may be beneficial if the machine is oper ating within the specified limits but the arc characteristics are unsatisfac tory for the desi...

Страница 96: ...actory position If it has been determined that a rocker adjustment is necessary on an unaltered machine the rocker should only be moved in very small increments and the total movement should be no more than the diameter of the drill mark Setting the Rocker if the factory drill mark is miss ing or invalid due to component replacement IMPORTANT The following procedures should only be attempted if al...

Страница 97: ... maximum re apply the load and adjust the load bank to apply a 500 Amp load to the machine WARNING Do not move the Current Control while the machine is under load 7 Measure the output voltage it should read between 45 and 51 Volts DC 8 Measure the engine RPM it should measure between 1680 and 1795 RPM If the engine RPM is not within specification Perform the Engine RPM Adjustment Test if the engin...

Страница 98: ...urn to Section TOC Return to Section TOC Return to Section TOC Return to Section TOC Return to Master TOC Return to Master TOC Return to Master TOC Return to Master TOC NOTES F 58 F 58 SAE 400 SEVERE DUTY ...

Страница 99: ...tat It works together with the series coils in the generator to regulate the weld output and the weld output volt amp curve See the theory of operation section of this manual for a more complete description This procedure should be performed if a visual inspection of the unit indicates excessive wear dirt or damage It should also be performed if the output control unit fails a ground test or if ca...

Страница 100: ...orn contacts Also look for missing or damaged insulators poor lead connections and damaged lead insulation If there is serious damage to the inside diameter of the winding the Output Control Unit should be replaced See Figures F19 and F 20 5 Disassemble the continuous control unit If service is necessary remove the fuel tank and dis connect the heavy cable attached to the output stud at the center...

Страница 101: ...e diameter Insulated steel wedge to the winding See Figure F 20 The resistance should be very high 500 000 500k Ohms min If the resistance is too low disconnect the remaining connection cable and look for any connection with chassis ground including any buildup of conductive dirt contacting the winding Repeat the above resistance tests If the low resistance is determined to be within the continuou...

Страница 102: ...lder assemblies by measuring the resistance as fol lows From the steel shaft to the rotating brush holder From the copper output stud to the output stud bracket The resistance should be very high 500 000 500k Ohms min If any of the contacts on the brush holder assembly are damaged install all new contacts and new springs 13 Assemble the flat washer spring clip and coil spring to the shaft See figu...

Страница 103: ...ng type pliers and a drift punch can be used to maneuver the bracket into position Tighten the screws 16 Connect any cables that had been removed Install fuel tank roof and doors Reconnect the battery cable TROUBLESHOOTING AND REPAIR F 63 F 63 SAE 400 SEVERE DUTY Return to Section TOC Return to Section TOC Return to Section TOC Return to Section TOC Return to Master TOC Return to Master TOC Return...

Страница 104: ...urn to Section TOC Return to Section TOC Return to Section TOC Return to Section TOC Return to Master TOC Return to Master TOC Return to Master TOC Return to Master TOC NOTES F 64 F 64 SAE 400 SEVERE DUTY ...

Страница 105: ... Electric Service Department for electrical trou bleshooting assistance before you proceed Call 1 888 935 3877 TEST DESCRIPTION This test will help pinpoint a failure of the engine protection system and should be done if the engine fault light turns on and the engine shuts down shortly after startup and the engine is not actually in a fault condition MATERIALS NEEDED Miscellaneous hand tools Volt ...

Страница 106: ... and oil pressure are within the normal range If the engine is permitted to run while overheated or with low oil pressure severe engine damage will likely result and the engine warranty will not cover the damage Be absolutely certain that all wires are connected when the test is com pleted 1 Disconnect the lead from the engine coolant tem perature gage or switch Code 10856 temp gage Lead wire 221 ...

Страница 107: ...th these wires dis connected one of the engine protections switches is faulty or the engine alternator is faulty 9 Shut off the engine and reconnect any one of the three leads that had been disconnected in steps 1 through 3 then start the engine and allow it to run If the engine shuts down the component that had just been connected is faulty and should be repaired or replaced 10 If the engine cont...

Страница 108: ...urn to Section TOC Return to Section TOC Return to Section TOC Return to Section TOC Return to Master TOC Return to Master TOC Return to Master TOC Return to Master TOC NOTES F 68 F 68 SAE 400 SEVERE DUTY ...

Страница 109: ...ocedures or are unable to perform the test repairs safely contact the Lincoln Electric Service Department for electrical trou bleshooting assistance before you proceed Call 1 888 935 3877 TEST DESCRIPTION This test will determine if the engine alternator is operating normally MATERIALS NEEDED Voltmeter or multi meter Miscellaneous hand tools Wiring diagram ENGINE ALTERNATOR TEST TROUBLESHOOTING AN...

Страница 110: ...f the alterna tor Lead 237 for code 10856 Lead 51 for codes 11199 and 11408 the meter should read battery voltage Chassis ground to the alternator flash sense lead Lead 224 for cod 10856 Lead 59 for codes 11199 and 11408 the meter should read 0 volts Run stop switch on Chassis ground to the flash sense lead Lead 224 for cod 10856 Lead 59 for codes 11199 and 11408 the meter should read 11 5 to 12 9...

Страница 111: ...rature switch or oil pressure switch can also cause the flash sense voltage to measure low perform the Engine Protection System Test before replacing the alternator If the voltages are significantly different from those shown above check the wiring connected to the alter nator for faulty connections or bad insulation If the wiring is good the alternator is probably faulty and should be serviced or...

Страница 112: ...urn to Section TOC Return to Section TOC Return to Section TOC Return to Section TOC Return to Master TOC Return to Master TOC Return to Master TOC Return to Master TOC NOTES F 72 F 72 SAE 400 SEVERE DUTY ...

Страница 113: ... to perform the test repairs safely contact the Lincoln Electric Service Department for electrical trou bleshooting assistance before you proceed Call 1 888 935 3877 TEST DESCRIPTION This test will determine if the fuel system is getting the electrical power needed to function correctly MATERIALS NEEDED Miscellaneous hand tools Multimeter or a volt meter and ohm meter ENGINE FUEL SYSTEM VOLTAGE TE...

Страница 114: ...y charged then place the run stop switch in the run position Within 30 seconds check for bat tery voltage 11 to 13 VDC across the primary and secondary fuel solenoids and the fuel pump for Codes 11199 11408 See the wiring diagram NOTE The secondary solenoid will only have voltage if the fuel system temperature switch is closed Consult a Perkins engine service facility for precise information about...

Страница 115: ...l See wiring diagram If the correct voltage is present for test 2 but not for test 1 and the voltage reading was taken within 30 seconds of placing the run stop switch in the run posi tion The PC board is faulty and should be replaced IMPORTANT If the PC board is defective test the solenoids and engine temperature switch as follows before installing the new PC board 3 Disconnect both solenoids and...

Страница 116: ...ns between Terminal B 1 and the negative battery terminal See wiring diagram If the correct voltage is not present for test 3 check the wiring between the engine temperature switch and run stop switch If the correct voltage is present for test 2 but not for test 1 and the voltage reading was taken within 30 seconds of placing the run stop switch in the run posi tion The PC board is faulty and shou...

Страница 117: ...m the test repairs safely contact the Lincoln Electric Service Department for electrical trou bleshooting assistance before you proceed Call 1 888 935 3877 TEST DESCRIPTION This procedure will aid the repair technician in the removal and replacement of the alter nator rotor MATERIALS NEEDED Miscellaneous hand tools Small gear puller 1 5 8 wrench 180 grit sandpaper strip ALTERNATOR ROTOR REMOVAL AN...

Страница 118: ...s 6 Disconnect and label the wires from the exciter brush holder Remove the screws and nuts holding the exciter brush holder and bracket assembly to the exciter frame then remove the brush holder and bracket assembly See Figure F 29 7 Bend the washer away from the rotor lock nut 8 Using the 1 5 8 wrench to remove the nut from the end of the armature shaft then remove the washer and sleeve collar N...

Страница 119: ... using the screws and nuts that had been removed earlier The brushes should ride as close as possible to the center of each slip ring If necessary gently bend the brush holder bracket to adjust the position 10 Use a long strip is 180 grit sandpaper to seat the exciter brushes Place the sandpaper strip between the slip rings and the brushes with the abrasive side against the brushes Pull the sand p...

Страница 120: ...urn to Section TOC Return to Section TOC Return to Section TOC Return to Section TOC Return to Master TOC Return to Master TOC Return to Master TOC Return to Master TOC NOTES F 80 F 80 SAE 400 SEVERE DUTY ...

Страница 121: ...able to perform the test repairs safely contact the Lincoln Electric Service Department for electrical trou bleshooting assistance before you proceed Call 1 888 935 3877 TEST DESCRIPTION This procedure will aid the repair technician in removal and replacement of the exciter alternator stator MATERIALS NEEDED Miscellaneous Hand Tools Pry Bar Wiring diagram ALTERNATOR STATOR REMOVAL AND REPLACEMENT ...

Страница 122: ...ction carefully mark the heavy leads connected to the brush holders and then disconnect them To aid in reassembly note the way these leads are connected routed and positioned 8 The front panel of the machine can be unbolted and moved to the side to provide the clearance neces sary to remove the exciter stator This can normally be done by disconnecting only the wires and cutting only the cable ties...

Страница 123: ...e Figure F 31 NOTE If these drill marks cannot be found the posi tions of the rocker and exciter bracket should be clearly marked so these parts can be pre cisely aligned when the machine is reassem bled 10 Loosen the rocker clamping screw but do not remove it 11 Use a hoist or other appropriate means to support the weight of the exciter frame assembly 12 Remove the four screws securing the excite...

Страница 124: ...nch Lbs DO NOT OVERTIGHTEN 7 Be certain that the brush holders are properly posi tioned and parallel with the commutator See the commutator and brush service procedure 8 Re attach the heavy generator leads to the brush holders Use the notes made during disassembly to assure that the leads are connected and routed cor rectly 9 If the original brushes are used install them in the same positions that...

Страница 125: ...re unable to perform the test repairs safely contact the Lincoln Electric Service Department for electrical trou bleshooting assistance before you proceed Call 1 888 935 3877 TEST DESCRIPTION This procedure will aid the technician in the removal and replacement of the case sheet metal covers MATERIALS NEEDED 3 8 wrench 7 16 wrench 1 2 wrench 3 4 wrench GENERATOR FRAME REMOVAL AND REPLACEMENT TROUB...

Страница 126: ...a tor frame off of the armature Adjust the height of the stator frame as needed to assure that it can slide off the armature without damage to any of the armature or stator windings Replacing the Generator Frame 1 During reassembly anti seize compound should be applied to the screw threads 2 Carefully inspect the mating surfaces of the engine adapter plate and the generator frame The mating surfac...

Страница 127: ... or are unable to perform the test repairs safely contact the Lincoln Electric Service Department for electrical trou bleshooting assistance before you proceed Call 1 888 935 3877 TEST DESCRIPTION This procedure will guide the technician in removing and replacing the welding generator armature MATERIALS NEEDED Rope sling Miscellaneous hand tools GENERATOR ARMATURE REMOVAL AND REPLACEMENT TROUBLESH...

Страница 128: ...Replacing the armature 1 Carefully inspect the mating surfaces of the fly wheel and armature coupling parts These surfaces must be clean and undamaged 2 Support the armature in a rope sling and carefully move it into position and align it to the flywheel 3 Rotate the armature 1 8 of a turn in either direction to engage the locking mechanism and line up the bolt holes Be certain that the coupling p...

Страница 129: ... terminals Damage to the output control unit may result Read the open circuit voltage OCV at the weld output terminals The voltage should mea sure 93 to 99 DC Volts Apply a 500 Amp load to the machine using the resistive load bank Check the engine RPM and weld terminal voltage The Engine RPM should be 1680 to 1795 The weld output volts should be 45 to 51 VDC AC Auxiliary Output Machine should be o...

Страница 130: ...am Generator Frame G 6 Schematic Complete Machine Code 10856 G5351 G 7 Schematic Complete Machine Code 11199 G4924 G 8 Schematic Complete Machine Code 11408 G5827 G 9 Idler Engine Shutdown PC Board Code 10856 L11007 2 G 10 Schematic Idler EngineShutdown PC Board Code 10856 L11006 2 G 11 Idler Engine Shutdown PC Board L12400 2 G 12 Schematic Idler EngineShutdown PC Board G4828 2 G 13 NOTE Many PC B...

Страница 131: ... R SEE BATTERY WIRING DIAGRAM TO LOWER PANEL GROUND SCREW 1 AC 203 AC D1 W SEE BATTERY WIRING DIAGRAM A 1 2 2CR E TO WORK TERMINAL R B WELD CURRENT SENSING SWITCH 602B RESISTORS NEG POS POLARITY SWITCH REMOTE CONTROL POTENTIOMETER BOX CONNECT TO BASE PLUG FOR REMOTE CONTROL POTENTIOMETER TOROID 201 B W 3 500 602A R 600A W U SWITCH FOR LOCAL OR REMOTE CONTROL SHOWN IN LOCAL POSITION Y 4 Y 3 X 1 X 4...

Страница 132: ...ANY PURPOSE WITHOUT THE EXPRESS WRITTEN PERMISSION OF LINCOLN GLOBAL INC PROPRIETARY CONFIDENTIAL A 1 6 2005 NEW CHANGE DETAIL SOLID EDGE STRP M20609 PARTS CAN INJURE MOVING maintenance work maintenance work unless the maintenance work Keep hands hair clothing and tools away requires it to be running Turn the engine or input power OFF before Have only qualified personnel perform WARNING from movin...

Страница 133: ...R REMOTE CONTROL POTENTIOMETER REMOTE CONTROL POTENTIOMETER BOX RESISTORS Y X U G W G 11B 820 810 REMOTE CONTROL GND C GND T GND S GND R 602C 203A CONNECT TOBASE GND F STARTING MOTOR B BLACK OR GREY R RED OR PINK G GREEN U BLUE N BROWN W WHITE LEAD COLOR CODE 238 TOWORK TERMINAL 5C GND B IDLER SWITCH 115V DUPLEX RECEPTACLE 230V DUPLEX RECEPTACLE 5B 41A 602A FUEL PUMP RHEOSTAT LEADS CONNECTEDTOENGI...

Страница 134: ...CH 115V DUPLEX RECEPTACLE 230V DUPLEX RECEPTACLE 5B 41A 602A FUEL PUMP RHEOSTAT LEADS CONNECTEDTOENGINE IDLER ENGINE P C BOARD SEE DETAIL 1 2 3 4 J33 6 5 1 2 3 4 1 2 3 4 5 6 7 8 9 10 J31 J32 B2 B3 B4 212D 212C 59 61 44 54 57 58 238A 55 TOCURRENT TRANSFORMER IDLER ENGINE PROTECTIONP C BOARD B1 GND A 844 844A CB3 20A CB2 20A 810 7A CB1 15A 11A GND N SAE 400 SAE 400SD WIRING DIAGRAM A M21283 R EN 166...

Страница 135: ...y not be accurate for all machines covered by this manual The wiring diagram specific to your code is pasted inside one of the enclosure panels of your machine Return to Section TOC Return to Section TOC Return to Section TOC Return to Section TOC Return to Master TOC Return to Master TOC Return to Master TOC Return to Master TOC ...

Страница 136: ...TER _ B 229 ALTERNATOR ROTOR R W 238 B 201 B UPPER PANEL GNDSCREW D1 35A 800V 120 OHMS 2 5W 1A 1000V 140vdc 41 5 oh ms 1 0 25C 11 13vdc located behind upper control panel on reactor box located behind upper control panel on reactor box diodeslocated behind upper control panel HOUR METER _ B 229 11 13vdc 30SEC TIMER Vbatt J1 1 0 J1 1 0 FUEL SOLENOID DRIVE CIRCUIT t reset reset hi P CHNL 30SEC TIMER...

Страница 137: ...2 bridge and CR1 contactor drive circuit on PC board at J1 pins 4 8 CR1 closes applying power to PC board at J2 pins 2 3 and disconnecting flashing circuit PC Board PWM circuit regulates output voltage by using voltage feedback from J1 pin 1 and control pot at J1 pin 6 to control current thru the shunt fields Note Rheostat Must be set to max for CV operation VV MODE POWER UP SEQUENCE Exciter rotor...

Страница 138: ...0A 35V 35 D C CC WELD OUTPUT MIN TO MAX OCV 57 97VDC 1800 RPM WELD RANGE 80 575 AMPS MAX LOAD 400A 40V 100 D C 1725 RPM CV MODE POWER UP SEQUENCE Exciter rotor is flashed from 12v battery supply at machine power up exciter winding builds up power Exciter winding powers D2 bridge and CR1 contactor drive circuit on PC board at J1 pins 4 8 CR1 closes applying power to PC board at J2 pins 2 3 and disc...

Страница 139: ... 14 PIN QUAD COMPARATOR X5 1 S15128 10 IC 431 VOLTAGE REF C8 1 S13490 39 C10 1 S13490 4 C13 1 S13490 15 D1 D3 D4 3 R34 1 S18380 1 THERMISTOR PTC 56 OHMS N B N B N C N B N C DESCRIPTION PC BOARD BLANK PART NO REQ D 1 ITEM 1 CAPACITORS MFD VOLTS CAUTION N A THIS DEVICE IS SUBJECT TO DAMAGE BY STATIC ELECTRICITY SEE E2454 BEFORE HANDLING N B DO NOT COAT WITH ENCAPSULATION MATERIAL 5 5 S14020 5 PLASTI...

Страница 140: ...0856 L11006 2 G 11 NOTE This diagram is for reference only It may not be accurate for all machines covered by this manual Return to Section TOC Return to Section TOC Return to Section TOC Return to Section TOC Return to Master TOC Return to Master TOC Return to Master TOC Return to Master TOC ...

Страница 141: ... 1 S9262 3 6 OR 8 PLAIN WASHER 9 1 M19436 2 POTTING TRAY 10 2 S8025 80 SELF TAPPING SCREW 11 1 E3768 4 LABEL 12 AS REQ E3539 ELECTRICAL INSULATING COMPOUND 13 200 g E2527 EPOXY ENCAPSULATING RESIN REFERENCES QTY PART NUMBER DESCRIPTION B1 B2 B3 B4 4 T13157 24 CONNECTOR TAB QC VERTICAL 1 4 EXTENDED C1 C2 C3 C4 C5 C6 C7 C8 C9 C10 C11 C12 C13 C19 C21 C24 16 S16668 11 CAPACITOR CEMO 0 1 50V 10 C14 C15...

Страница 142: ...C Return to Master TOC Return to Master TOC Return to Master TOC Return to Master TOC ELECTRICAL DIAGRAMS G 13 SAE 400 SEVERE DUTY SCHEMATIC IDLER ENGINE SHUTDOWN PC BOARD G4828 2 G 13 NOTE This diagram is for reference only It may not be accurate for all machines covered by this manual ...

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