Page 2 - SAFETY; WARNING; CALIFORNIA PROPOSITION 65 WARNINGS; The Above For Diesel Engines
SAFETY i i Return to Master T OC Return to Master T OC Return to Master T OC Return to Master T OC SAE-400 SEVERE DUTY FOR ENGINEpowered equipment. 1.a. Turn the engine off before troubleshooting and maintenance work unless the maintenance work requires it to be running. ____________________________...
Page 3 - ii; ELECTRIC SHOCK can kill.
SAFETY ii ii Return to Master T OC Return to Master T OC Return to Master T OC Return to Master T OC SAE-400 SEVERE DUTY FUMES AND GASEScan be dangerous. 5.a. Welding may produce fumes and gases hazardous to health. Avoid breathing thesefumes and gases.When welding, keepyour head out of the fume. Us...
Page 4 - iii
SAFETY iii iii Return to Master T OC Return to Master T OC Return to Master T OC Return to Master T OC SAE-400 SEVERE DUTY Jan ‘07 FOR ELECTRICALLYpowered equipment. 8.a. Turn off input power using the disconnect switch at the fuse box before working onthe equipment. 8.b. Install equipment in accord...
Page 5 - iv; PRÉCAUTIONS DE SÛRETÉ
SAFETY iv iv Return to Master T OC Return to Master T OC Return to Master T OC Return to Master T OC SAE-400 SEVERE DUTY Mar ‘93 PRÉCAUTIONS DE SÛRETÉ Pour votre propre protection lire et observer toutes les instructions et les précautions de sûreté specifiques qui parraissent dans ce manuel aussi b...
Page 6 - b) radio and television transmitters and receivers
SAFETY v v Return to Master T OC Return to Master T OC Return to Master T OC Return to Master T OC SAE-400 SEVERE DUTY Electromagnetic Compatibility (EMC) ConformanceProducts displaying the CE mark are in conformity with European Community Council Directive of 3 May1989 on the approximation of the l...
Page 7 - Methods of Reducing Emissions
SAFETY vi vi Return to Master T OC Return to Master T OC Return to Master T OC Return to Master T OC SAE-400 SEVERE DUTY Electromagnetic Compatibility (EMC) The size of the surrounding area to be considered will depend on the structure of the building and otheractivities that are taking place. The s...
Page 8 - - MASTER TABLE OF CONTENTS FOR ALL SECTIONS -; RETURN TO MAIN INDEX; Page; vii; RETURN TO MAIN MENU
- MASTER TABLE OF CONTENTS FOR ALL SECTIONS - RETURN TO MAIN INDEX Page Safety . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .i-iv Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . ...
Page 9 - TABLE OF CONTENTS - INSTALLATION SECTION
A-1 A-1 SAE-400 SEVERE DUTY TABLE OF CONTENTS - INSTALLATION SECTION Return to Master T OC Return to Master T OC Return to Master T OC Return to Master T OC Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ...
Page 10 - INSTALLATION; TECHNICAL SPECIFICATIONS - SAE-400 SEVERE DUTY; OUTPUT - WELDER AND GENERATOR
INSTALLATION A-2 A-2 SAE-400 SEVERE DUTY Return to Section T OC Return to Section T OC Return to Section T OC Return to Section T OC Return to Master T OC Return to Master T OC Return to Master T OC Return to Master T OC TECHNICAL SPECIFICATIONS - SAE-400 SEVERE DUTY - Make/Model Description Speed (...
Page 11 - SAFETY PRECAUTIONS; STACKING; These machines cannot be stacked.; ANGLE OF OPERATION
INSTALLATION A-3 A-3 SAE-400 SEVERE DUTY Return to Section T OC Return to Section T OC Return to Section T OC Return to Section T OC Return to Master T OC Return to Master T OC Return to Master T OC Return to Master T OC Read this entire installation section before youstart installation. SAFETY PREC...
Page 12 - are Lincoln’s; PRE-OPERATION ENGINE SERVICE; Fill the fuel tank with clean, fresh diesel fuel.; • Do not leave unattended while; DIESEL FUEL ONLY
INSTALLATION A-4 A-4 SAE-400 SEVERE DUTY Return to Section T OC Return to Section T OC Return to Section T OC Return to Section T OC Return to Master T OC Return to Master T OC Return to Master T OC Return to Master T OC HIGH ALTITUDE OPERATION At higher altitudes, output derating may be necessary.A...
Page 13 - BATTERY CONNECTION; GASES FROM BATTERY can explode.; ENGINE COOLING SYSTEM
INSTALLATION A-5 A-5 SAE-400 SEVERE DUTY Return to Section T OC Return to Section T OC Return to Section T OC Return to Section T OC Return to Master T OC Return to Master T OC Return to Master T OC Return to Master T OC BATTERY CONNECTION WARNING: Use caution as the electrolyte is a strong acid tha...
Page 14 - WELDING OUTPUT CABLES; Table A.1 Combined Length of Electrode and; MACHINE GROUNDING; CAUTION
INSTALLATION A-6 A-6 SAE-400 SEVERE DUTY Return to Section T OC Return to Section T OC Return to Section T OC Return to Section T OC Return to Master T OC Return to Master T OC Return to Master T OC Return to Master T OC WELDING OUTPUT CABLES With the engine off, connect the electrode and workcables...
Page 15 - TABLE OF CONTENTS - OPERATION SECTION
TABLE OF CONTENTS - OPERATION SECTION B-1 B-1 Return to Master T OC Return to Master T OC Return to Master T OC Return to Master T OC SAE-400 SEVERE DUTY Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ...
Page 16 - OPERATION; ADDITIONAL SAFETY PRECAUTIONS; GENERAL DESCRIPTION; RECOMMENDED APPLICATIONS; OPERATING INSTRUCTIONS
OPERATION B-2 B-2 SAE-400 SEVERE DUTY Return to Section T OC Return to Section T OC Return to Section T OC Return to Section T OC Return to Master T OC Return to Master T OC Return to Master T OC Return to Master T OC WELDING SPARKS can causefire or explosion. • Do not weld near flammable material ....
Page 17 - DESIGN FEATURES AND ADVANTAGES; FOR STICK WELDING; DUTY CYCLE
OPERATION B-3 B-3 SAE-400 SEVERE DUTY Return to Section T OC Return to Section T OC Return to Section T OC Return to Section T OC Return to Master T OC Return to Master T OC Return to Master T OC Return to Master T OC DESIGN FEATURES AND ADVANTAGES FOR STICK WELDING • Excellent DC constant current o...
Page 18 - ENGINE CONTROLS; continuously at high idle.; Muffler and Engine may be hot!
OPERATION B-4 B-4 SAE-400 SEVERE DUTY Return to Section T OC Return to Section T OC Return to Section T OC Return to Section T OC Return to Master T OC Return to Master T OC Return to Master T OC Return to Master T OC ENGINE CONTROLS IGNITION SWITCH When placed in the “ON” position, this switch ener...
Page 19 - WELDER CONTROLS; LATION
OPERATION B-5 B-5 SAE-400 SEVERE DUTY Return to Section T OC Return to Section T OC Return to Section T OC Return to Section T OC Return to Master T OC Return to Master T OC Return to Master T OC Return to Master T OC WELDER CONTROLS POLARITY SWITCH Turn the Arc Polarity switch to electrode positive...
Page 20 - ENGINE OPERATION; STARTING INSTRUCTIONS; electrode with skin or wet clothing.; See additional warning information at the; COLD WEATHER STARTING; When overnight temperatures are between 10; STOPPING THE ENGINE; Turn the “IGNITION” switch to “OFF”
OPERATION B-6 B-6 SAE-400 SEVERE DUTY Return to Section T OC Return to Section T OC Return to Section T OC Return to Section T OC Return to Master T OC Return to Master T OC Return to Master T OC Return to Master T OC ENGINE OPERATION For added safety always operate the welder with thedoors closed. ...
Page 21 - TYPICAL FUEL CONSUMPTION; Welding Load
OPERATION B-7 B-7 SAE-400 SEVERE DUTY Return to Section T OC Return to Section T OC Return to Section T OC Return to Section T OC Return to Master T OC Return to Master T OC Return to Master T OC Return to Master T OC TYPICAL FUEL CONSUMPTION The typical fuel consumption of the SAE-400 for various o...
Page 22 - NOTES
Return to Section T OC Return to Section T OC Return to Section T OC Return to Section T OC Return to Master T OC Return to Master T OC Return to Master T OC Return to Master T OC NOTES B-8 B-8 SAE-400 SEVERE DUTY
Page 23 - TABLE OF CONTENTS - ACCESSORIES SECTION
TABLE OF CONTENTS - ACCESSORIES SECTION C-1 C-1 Return to Master T OC Return to Master T OC Return to Master T OC Return to Master T OC SAE-400 SEVERE DUTY Accessories . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ...
Page 24 - ACCESSORIES; K704 Standard Accessory Kit -; MAINTENANCE
ACCESSORIES C-2 C-2 SAE-400 SEVERE DUTY Return to Section T OC Return to Section T OC Return to Section T OC Return to Section T OC Return to Master T OC Return to Master T OC Return to Master T OC Return to Master T OC OPTIONAL FIELD INSTALLEDACCESSORIES K802-D Power Plug Kit - Kit includes male pl...
Page 25 - TABLE OF CONTENTS - MAINTENANCE SECTION
TABLE OF CONTENTS - MAINTENANCE SECTION D-1 D-1 Return to Master T OC Return to Master T OC Return to Master T OC Return to Master T OC SAE-400 SEVERE DUTY Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ...
Page 26 - ROUTINE MAINTENANCE
MAINTENANCE D-2 D-2 SAE-400 SEVERE DUTY Return to Section T OC Return to Section T OC Return to Section T OC Return to Section T OC Return to Master T OC Return to Master T OC Return to Master T OC Return to Master T OC ELECTRIC SHOCK can kill. ● Do not touch electrically live partssuch as output te...
Page 27 - BEARING MAINTENANCE; Shifting of the brushes may result in:; COOLING SYSTEM; When working on the fuel system; The SAE-400 SEVERE DUTY is equipped with a; Fuel; located before; Secondary Fuel Filter; located after
MAINTENANCE D-3 D-3 SAE-400 SEVERE DUTY Return to Section T OC Return to Section T OC Return to Section T OC Return to Section T OC Return to Master T OC Return to Master T OC Return to Master T OC Return to Master T OC BEARING MAINTENANCE This welder is equipped with a double-shielded ball bearingh...
Page 28 - WATER SEPARATOR ELEMENT; Slide the new element onto the grommet post on the; SECONDARY FUEL FILTER; ENGINE MAINTENANCE COMPONENTS
MAINTENANCE D-4 D-4 SAE-400 SEVERE DUTY Return to Section T OC Return to Section T OC Return to Section T OC Return to Section T OC Return to Master T OC Return to Master T OC Return to Master T OC Return to Master T OC 1. Close the fuel shutoff valve located under the fuel tank. (on code 10856 valv...
Page 29 - SPARK ARRESTOR; For machines with separate spark arresting unit:
MAINTENANCE D-5 D-5 SAE-400 SEVERE DUTY Return to Section T OC Return to Section T OC Return to Section T OC Return to Section T OC Return to Master T OC Return to Master T OC Return to Master T OC Return to Master T OC GFCI RECEPTACLE TESTING AND RESET-TING PROCEDURE The GFCI receptacle should be p...
Page 31 - TABLE OF CONTENTS-THEORY OF OPERATION SECTION; FIGURE E.1 BLOCK LOGIC DIAGRAM
TABLE OF CONTENTS-THEORY OF OPERATION SECTION E-1 E-1 Return to Master T OC Return to Master T OC Return to Master T OC Return to Master T OC SAE-400 SEVERE DUTY Theory of Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ...
Page 32 - THEORY OF OPERATION; NOTE: Unshaded areas of Block Logic
THEORY OF OPERATION E-2 E-2 SAE-400 SEVERE DUTY Return to Section T OC Return to Section T OC Return to Section T OC Return to Section T OC Return to Master T OC Return to Master T OC Return to Master T OC Return to Master T OC ENGINE STARTING AND PROTEC-TION Turning on the run/stop switch supplies ...
Page 33 - AUTOMATIC ENGINE IDLE SYSTEM; FIGURE E.2 - ENGINE STARTING AND PROTECTION
THEORY OF OPERATION E-3 E-3 SAE-400 SEVERE DUTY Return to Section T OC Return to Section T OC Return to Section T OC Return to Section T OC Return to Master T OC Return to Master T OC Return to Master T OC Return to Master T OC AUTOMATIC ENGINE IDLE SYSTEM The automatic idle system reduces the engin...
Page 36 - Excitation and field control:
THEORY OF OPERATION E-6 E-6 SAE-400 SEVERE DUTY Return to Section T OC Return to Section T OC Return to Section T OC Return to Section T OC Return to Master T OC Return to Master T OC Return to Master T OC Return to Master T OC WELDING GENERATOR OPERA-TION Overview: The welding generator is coupled ...
Page 37 - Producing weld current:
THEORY OF OPERATION E-7 E-7 SAE-400 SEVERE DUTY Return to Section T OC Return to Section T OC Return to Section T OC Return to Section T OC Return to Master T OC Return to Master T OC Return to Master T OC Return to Master T OC WELDING GENERATOR OPERA-TION (Continued) Producing weld current: Weld cu...
Page 38 - Series coils and reactor:
THEORY OF OPERATION E-8 E-8 SAE-400 SEVERE DUTY Return to Section T OC Return to Section T OC Return to Section T OC Return to Section T OC Return to Master T OC Return to Master T OC Return to Master T OC Return to Master T OC WELDING GENERATOR OPERA-TION (Continued) Current Control: The Current Co...
Page 41 - TABLE OF CONTENTS - TROUBLESHOOTING AND REPAIR; Test Procedures
TABLE OF CONTENTS - TROUBLESHOOTING AND REPAIR F-1 F-1 Return to Master T OC Return to Master T OC Return to Master T OC Return to Master T OC SAE-400 SEVERE DUTY Troubleshooting and Repair . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ...
Page 42 - TROUBLESHOOTING AND REPAIR; HOW TO USE TROUBLESHOOTING GUIDE
TROUBLESHOOTING AND REPAIR F-2 F-2 SAE-400 SEVERE DUTY Return to Section T OC Return to Section T OC Return to Section T OC Return to Section T OC Return to Master T OC Return to Master T OC Return to Master T OC Return to Master T OC This Troubleshooting Guide is provided tohelp you locate and repa...
Page 43 - PC board can be damaged by static electricity.; PC BOARD TROUBLESHOOTING PROCEDURES
TROUBLESHOOTING AND REPAIR F-3 F-3 SAE-400 SEVERE DUTY Return to Section T OC Return to Section T OC Return to Section T OC Return to Section T OC Return to Master T OC Return to Master T OC Return to Master T OC Return to Master T OC Sometimes machine failures appear to be due to PCboard failures. ...
Page 45 - • If normal voltage is present,
OUTPUT PROBLEMS Observe Safety Guidelines detailed in the beginning of this manual. PROBLEMS (SYMPTOMS) POSSIBLE AREAS OF MISADJUSTMENT(S) RECOMMENDED COURSE OF ACTION If for any reason you do not understand the test procedures or are unable to perform the tests/repairs safely,contact the Lincoln El...
Page 46 - Brush and Slip Ring
OUTPUT PROBLEMS Observe Safety Guidelines detailed in the beginning of this manual. PROBLEMS (SYMPTOMS) POSSIBLE AREAS OF MISADJUSTMENT(S) RECOMMENDED COURSE OF ACTION If for any reason you do not understand the test procedures or are unable to perform the tests/repairs safely,contact the Lincoln El...
Page 47 - Perform the
OUTPUT PROBLEMS Observe Safety Guidelines detailed in the beginning of this manual. PROBLEMS (SYMPTOMS) POSSIBLE AREAS OF MISADJUSTMENT(S) RECOMMENDED COURSE OF ACTION If for any reason you do not understand the test procedures or are unable to perform the tests/repairs safely,contact the Lincoln El...
Page 52 - • If voltage is present, check
OUTPUT PROBLEMS Observe Safety Guidelines detailed in the beginning of this manual. PROBLEMS (SYMPTOMS) POSSIBLE AREAS OF MISADJUSTMENT(S) RECOMMENDED COURSE OF ACTION If for any reason you do not understand the test procedures or are unable to perform the tests/repairs safely,contact the Lincoln El...
Page 53 - Engine
OUTPUT PROBLEMS Observe Safety Guidelines detailed in the beginning of this manual. PROBLEMS (SYMPTOMS) POSSIBLE AREAS OF MISADJUSTMENT(S) RECOMMENDED COURSE OF ACTION If for any reason you do not understand the test procedures or are unable to perform the tests/repairs safely,contact the Lincoln El...
Page 57 - Engine Idle
OUTPUT PROBLEMS Observe Safety Guidelines detailed in the beginning of this manual. PROBLEMS (SYMPTOMS) POSSIBLE AREAS OF MISADJUSTMENT(S) RECOMMENDED COURSE OF ACTION If for any reason you do not understand the test procedures or are unable to perform the tests/repairs safely,contact the Lincoln El...
Page 61 - ENGINE RPM ADJUSTMENT TEST
Service and repair should be performed by only Lincoln Electric factory trained personnel.Unauthorized repairs performed on this equipment may result in danger to the technicianor machine operator and will invalidate your factory warranty. For your safety and to avoidelectrical shock, please observe...
Page 62 - TEST PROCEDURE; CAUTION: Do Not Short the Output Studs Together
IdlerSolenoid Spring Idler Rod SpeedControlLever BallJoint LockNut Pulley Fan Blades Possible Strobe-Tach Mark Points FIGURE F.1 – ENGINE COMPONENTS (CODE 10856) ENGINE RPM ADJUSTMENT TEST (continued) TEST PROCEDURE 1. Turn the engine off 2. Open the left side door, on the engine end of the machine....
Page 63 - Frequency counter method:; ENGINE RPM ADJUSTMENT PROCEDURE
SOLENOIDBRACKET BALLJOINT LOCK NUT IDLER ROD FIGURE F.2 – ENGINE COMPONENTS (CODE 11199 & 114080) ENGINE RPM ADJUSTMENT TEST (continued) Strobe-Tach Method (continued) 5. The tach should read between 1780 and 1810 RPM 6. Move the idle switch to the “AUTO IDLE” position and wait for the idle sole...
Page 65 - BRUSH AND SLIP RING SERVICE PROCEDURE
Service and repair should be performed by only Lincoln Electric factory trained personnel.Unauthorized repairs performed on this equipment may result in danger to the technicianor machine operator and will invalidate your factory warranty. For your safety and to avoidelectrical shock, please observe...
Page 66 - FIGURE F.3 – EXCITER COVER SCREW LOCATIONS; PROCEDURE; Open either, or both of the doors on the control
EXC I TER COVER F I VE SCREWS (TWO ON OTHER S I DE) FIGURE F.3 – EXCITER COVER SCREW LOCATIONS BRUSH AND SLIP RING SERVICE PROCEDURE (Exciter / Auxiliary Power Alternator) (continued) PROCEDURE 1. Open either, or both of the doors on the control panel end of the SAE-400 machine. WARNING: Secure the ...
Page 67 - BRUSHES; FIGURE F.4 – BRUSH LOCATIONS; Check for evidence of sticking brushes. Sticking
BRUSHES FIGURE F.4 – BRUSH LOCATIONS BRUSH AND SLIP RING SERVICE PROCEDURE (Exciter / Auxiliary Power Alternator) (continued) PROCEDURE (continued 5. Check for evidence of sticking brushes. Sticking brushes will normally result in the slip rings beingpitted and discolored from excessive arcing.Anoth...
Page 69 - EXCITER ROTOR VOLTAGE TEST
Service and repair should be performed by only Lincoln Electric factory trained personnel.Unauthorized repairs performed on this equipment may result in danger to the technicianor machine operator and will invalidate your factory warranty. For your safety and to avoidelectrical shock, please observe...
Page 70 - FIGURE F.6 – EXCITER COVER SCREW LOCATIONS; Make sure that the battery is fully charged and in
EXC I TER COVER F I VE SCREWS (TWO ON OTHER S I DE) FIGURE F.6 – EXCITER COVER SCREW LOCATIONS EXCITER ROTOR VOLTAGE TEST(continued) PROCEDURE 1. Turn engine off. 2. Make sure that the battery is fully charged and in good condition, and the battery connections areclean and tight. The Engine and gene...
Page 71 - FIGURE F.7 – EXCITER ROTOR VOLTAGE TEST; Connect the volt meter probes to the brush termi-
POSITIVE SLIP RING NEGATIVE SLIP RING BRUSH HOLDER ASSEMBLY BRUSHES VOLTMETER LEADS FIGURE F.7 – EXCITER ROTOR VOLTAGE TEST EXCITER ROTOR VOLTAGE TEST (continued) PROCEDURE (continued) 5. Connect the volt meter probes to the brush termi- nals. See the wiring diagram and Figure F.7 NOTE: On this mach...
Page 73 - EXCITER ROTOR RESISTANCE AND GROUND TEST
Service and repair should be performed by only Lincoln Electric factory trained personnel.Unauthorized repairs performed on this equipment may result in danger to the technicianor machine operator and will invalidate your factory warranty. For your safety and to avoidelectrical shock, please observe...
Page 74 - FIGURE F.8 – EXCITER COVER SCREW LOCATIONS; Open either, or both of the doors on the control
EXC I TER COVER F I VE SCREWS (TWO ON OTHER S I DE) FIGURE F.8 – EXCITER COVER SCREW LOCATIONS EXCITER ROTOR RESISTANCE AND GROUND TEST (Exciter / Auxiliary Power Alternator) (continued) PROCEDURE “Static” Tests: 1. Turn the engine off. 2. Open either, or both of the doors on the control panel end o...
Page 75 - FIGURE F.9 – SLIP RING LOCATIONS; Measure the resistance to ground. Place one meter
POSITIVESLIP RING NEGATIVESLIP RING BRUSH HOLDER ASSEMBLY OHMMETER LEADS BRUSHES FIGURE F.9 – SLIP RING LOCATIONS EXCITER ROTOR RESISTANCE AND GROUND TEST (Exciter / Auxiliary Power Alternator) (continued) PROCEDURE (continued) 5. Using the ohmmeter, check the rotor winding resis- tance across the s...
Page 76 - FIGURE F.10 – SLIP RING LOCATIONS; Brush and Slip Ring Service Procedure.
POSITIVE SLIP RING NEGATIVE SLIP RING BRUSH HOLDER ASSEMBLY BRUSHES VOLTMETER LEADS FIGURE F.10 – SLIP RING LOCATIONS EXCITER ROTOR RESISTANCE AND GROUND TEST (Exciter / Auxiliary Power Alternator) (continued) PROCEDURE (continued) “Dynamic” Tests: (Also referred to as flying resistance test) This t...
Page 77 - FLASHING VOLTAGE TEST
Service and repair should be performed by only Lincoln Electric factory trained personnel.Unauthorized repairs performed on this equipment may result in danger to the technicianor machine operator and will invalidate your factory warranty. For your safety and to avoidelectrical shock, please observe...
Page 78 - FIGURE F.11 – EXCITER COVER SCREW; FIGURE F.12 – FLASHING VOLTAGE TEST
EXC I TER COVER F I VE SCREWS (TWO ON OTHER S I DE) FIGURE F.11 – EXCITER COVER SCREW LOCATIONS FLASHING VOLTAGE TEST (Engine not running) (continued) PROCEDURE 1. Open either, or both of the doors on the control panel end of the SAE-400 machine. WARNING: Secure the doors in the open positionusing t...
Page 79 - FIGURE F.13 – IDLER/ENGINE PROTECTION PC BOARD CODES 10856; If the voltage is significantly higher than expected:
J1-1 (+) BATTERY VOLTAGE J1-10, FLASHING AND HOUR METER OUTPUT J1-5, CHASSIS GROUND FIGURE F.13 – IDLER/ENGINE PROTECTION PC BOARD CODES 10856 FLASHING VOLTAGE TEST (Engine not running) (continued) PROCEDURE (continued) 7. If this voltage reading is correct, the test is com- plete. If the voltage is...
Page 80 - Connect positive voltmeter probe to the Idler /; If battery voltage is detected:; If the idler/engine protection PC board is getting
J31-1, (+) BATTERY VOLTAGE I NPUT J31-10, FLASH I NG AND HOUR METER OUTPUT B-1 CHASS I S GROUND FIGURE F.14 – IDLER/ENGINE PROTECTION PC BOARD CODES 11199 AND 11408 FLASHING VOLTAGE TEST (Engine not running (continued) PROCEDURE (continued) 10. Connect positive voltmeter probe to the Idler / Engine ...
Page 81 - EXCITER STATOR SHORT CIRCUIT & GROUND TEST
Service and repair should be performed by only Lincoln Electric factory trained personnel.Unauthorized repairs performed on this equipment may result in danger to the technicianor machine operator and will invalidate your factory warranty. For your safety and to avoidelectrical shock, please observe...
Page 83 - WELDING GENERATOR BRUSH AND COMMUTATOR INSPECTION AND
Service and repair should be performed by only Lincoln Electric factory trained personnel.Unauthorized repairs performed on this equipment may result in danger to the technicianor machine operator and will invalidate your factory warranty. For your safety and to avoidelectrical shock, please observe...
Page 84 - FIGURE F.15 – GENERATOR COVER SCREW LOCATIONS
GENERATOR COVER FOUR SCREWS TOTAL FIGURE F.15 – GENERATOR COVER SCREW LOCATIONS WELDING GENERATOR BRUSH AND COMMUTATOR INSPECTION AND SERVICE (continued) PROCEDURE 1. Shut off the engine. 2. Open either, or both of the doors on the control panel end of the SAE-400 machine. WARNING: Secure the doors ...
Page 85 - FIGURE F.16 – GENERATOR COMPONENTS; Blackened Commutator:
ARMATURE COMMUTATOR SPRINGS BRUSH HOLDER PLATE BRUSHES BRUSH RETAINER BRUSH HOLDER INSULATORS MOUNTING SCREW DRILL MARK ROCKER FIGURE F.16 – GENERATOR COMPONENTS WELDING GENERATOR BRUSH AND COMMUTATOR INSPECTION AND SERVICE (continued) PROCEDURE 5. Examine the Commutator. Normal appearance: The comm...
Page 86 - Pitted and Arc Damaged Commutator:; Uneven Commutator appearance:; . Replace any insulators that are cracked
WELDING GENERATOR BRUSH AND COMMUTATOR INSPECTION AND SERVICE (continued) PROCEDURE (continued) Pitted and Arc Damaged Commutator: If pitting and arc damage to the commutator is evident,the machine may have been used with badly wornbrushes. The brush spring tension may have been toolow, or the brush...
Page 87 - WELD CIRCUIT GROUND AND SHORT CIRCUIT TEST
Service and repair should be performed by only Lincoln Electric factory trained personnel.Unauthorized repairs performed on this equipment may result in danger to the technicianor machine operator and will invalidate your factory warranty. For your safety and to avoidelectrical shock, please observe...
Page 88 - WELD CIRCUIT GROUND AND SHORT CIRCUIT TEST (continued); Weld circuit ground test:; Output Control Unit
WELD CIRCUIT GROUND AND SHORT CIRCUIT TEST (continued) PROCEDURE 1. Turn the engine off. Weld circuit ground test: 1. Rotate the output control to the minimum output position. 2. Measure the resistance between either of the two weld output terminals and a clean chassis groundconnection. 3. The resis...
Page 89 - SHUNT FIELD COIL RESISTANCE AND GROUND TEST
Service and repair should be performed by only Lincoln Electric factory trained personnel.Unauthorized repairs performed on this equipment may result in danger to the technicianor machine operator and will invalidate your factory warranty. For your safety and to avoidelectrical shock, please observe...
Page 90 - SHUNT FIELD COIL RESISTANCE AND GROUND TEST (continued); Shunt Coil Resistance Test:
SHUNT FIELD COIL RESISTANCE AND GROUND TEST (continued) PROCEDURE 1. Turn the engine off. 2. Open both of the doors on the control panel end of the SAE-400 machine. The roof may also need tobe removed on some models. WARNING: Secure the doors in the open positionusing the door restraint system. If t...
Page 91 - SHUNT FIELD CIRCUIT VOLTAGE TEST
Service and repair should be performed by only Lincoln Electric factory trained personnel.Unauthorized repairs performed on this equipment may result in danger to the technicianor machine operator and will invalidate your factory warranty. For your safety and to avoidelectrical shock, please observe...
Page 92 - SHUNT FIELD CIRCUIT VOLTAGE TEST (continued); Open both of the doors on the control panel end of
SHUNT FIELD CIRCUIT VOLTAGE TEST (continued) PROCEDURE 1. Turn the engine off. 2. Open both of the doors on the control panel end of the SAE-400 machine. The roof may need to beremoved on some models. WARNING: Secure the doors in the open positionusing the door restraint system. If themachine does n...
Page 93 - DEAD SHORT, 1ST STEP, AND OPEN REACTOR TESTS
Service and repair should be performed by only Lincoln Electric factory trained personnel.Unauthorized repairs performed on this equipment may result in danger to the technicianor machine operator and will invalidate your factory warranty. For your safety and to avoidelectrical shock, please observe...
Page 94 - FIGURE F.17 – OUTPUT CONTROL UNIT; Remove the load turn the Job Selector Rheostat to
WINDING CONTACT SPRINGS MOVABLE CONTACTSMin. (open) Position FIRST STEPCONTACTPOSITION ROTOR INSULATEDFILLER FIGURE F.17 – OUTPUT CONTROL UNIT DEAD SHORT, 1ST STEP, AND OPEN REACTOR TESTS (continued) PROCEDURE 1. If possible, bring the machine to normal tempera- ture by connecting a load bank and op...
Page 95 - ROCKER ADJUSTMENT PROCEDURE
Service and repair should be performed by only Lincoln Electric factory trained personnel.Unauthorized repairs performed on this equipment may result in danger to the technicianor machine operator and will invalidate your factory warranty. For your safety and to avoidelectrical shock, please observe...
Page 96 - The factory set point drill marks:; When the rocker is set for the first time at the facto-; Setting the Rocker -; if the factory drill mark is miss-
ARMATURE COMMUTATOR SPRINGS BRUSH HOLDER PLATE BRUSHES BRUSH RETAINER BRUSH HOLDER INSULATORS MOUNTING SCREW DRILL MARK ROCKER FIGURE F.18 – ROCKER W/MARKS ROCKER ADJUSTMENT PROCEDURE (continued) PROCEDURE The factory set point drill marks: 1. When the rocker is set for the first time at the facto- ...
Page 97 - |Measure the output voltage, it should read
ROCKER ADJUSTMENT PROCEDURE (continued) PROCEDURE (continued) Initial rocker placement: 1. The rocker should be initially positioned so thecenter of brushes visually lines up with thecenter of the main poles. Lining up the fourbrush holder studs with the four exciter brack-et mounting bolts is accep...
Page 99 - INSPECTION AND SERVICE PROCEDURE
Service and repair should be performed by only Lincoln Electric factory trained personnel.Unauthorized repairs performed on this equipment may result in danger to the technicianor machine operator and will invalidate your factory warranty. For your safety and to avoidelectrical shock, please observe...
Page 100 - WINDING; INSPECTION AND SERVICE PROCEDURE (continued); Turn the engine off, open the doors on the control
WINDING Contacts &Springs Output Stud Assembly BrushHolderAssembly FIGURE F.19 – BRUSH & SPRING OUTPUT CONTROL UNIT (VARIABLE REACTOR) INSPECTION AND SERVICE PROCEDURE (continued) PROCEDURE 1. Turn the engine off, open the doors on the control panel end of the machine and disconnect the nega...
Page 101 - Servicing the continuous control unit:
WINDING INSULATEDWEDGE FIGURE F.20 – BRUSH & SPRING OUTPUT CONTROL UNIT (VARIABLE REACTOR) INSPECTION AND SERVICE PROCEDURE (continued) PROCEDURE (continued) Servicing the continuous control unit: 8. Clean the continuous output control unit by using low pressure air to remove any excess dust and...
Page 102 - FIGURE F.21 – INSULATOR & SPRING LOCATIONS; INSPECTION AND SERVICE PROCEDURE (continued)
Steel Shaft Coil Spring SpringClip FlatWasher InsulatorTube Springs Contacts Insulator (Short Insulator Tube Not Shown) Output Stud Output StudBracket BrushHolder FIGURE F.21 – INSULATOR & SPRING LOCATIONS OUTPUT CONTROL UNIT (VARIABLE REACTOR) INSPECTION AND SERVICE PROCEDURE (continued) PROCED...
Page 103 - Connect any cables that had been removed.
FIGURE F.22 – SHAFT & TUBE OUTPUT CONTROL UNIT (VARIABLE REACTOR) INSPECTION AND SERVICE PROCEDURE (continued) PROCEDURE (continued) The shaft spring will need to be compressed and thebracket drawn close to the back of the output controlbefore the screws can be started and tightened.Locking type...
Page 105 - ENGINE PROTECTION SYSTEM CIRCUIT TEST
Service and repair should be performed by only Lincoln Electric factory trained personnel.Unauthorized repairs performed on this equipment may result in danger to the technicianor machine operator and will invalidate your factory warranty. For your safety and to avoidelectrical shock, please observe...
Page 106 - ENGINE PROTECTION SYSTEM CIRCUIT TEST (continued); Open all of the doors on the SAE-400 machine.
#237 #224 GROUND FIGURE F.23 – ENGINE ALTERNATOR CODE 10856 ENGINE PROTECTION SYSTEM CIRCUIT TEST (continued) PROCEDURE IMPORTANT: Before proceeding with this test, verifythat the engine has normal oil pressure,is not overheated, and the alternatordrive belt is in place and properly ten-sioned. Open...
Page 107 - Start the engine and allow it to run.
#59 #51 FIGURE F.24 – ENGINE ALTERNATOR CODE 11199 &11408 ENGINE PROTECTION SYSTEM CIRCUIT TEST (continued) PROCEDURE (continued) 4. Insulate and/or position these leads so they cannottouch chassis ground, any other electrical conduc-tor, or be damaged by any moving parts. 5. Start the engine an...
Page 109 - ENGINE ALTERNATOR TEST
Service and repair should be performed by only Lincoln Electric factory trained personnel.Unauthorized repairs performed on this equipment may result in danger to the technicianor machine operator and will invalidate your factory warranty. For your safety and to avoidelectrical shock, please observe...
Page 110 - Open the right side cover, on the radiator end of the
#237 #224 GROUND FIGURE F.25 – ALTERNATOR CODE 10856 ENGINE ALTERNATOR TEST (continued) PROCEDURE 1. Open the right side cover, on the radiator end of the SAE-400 machine. WARNING: Secure the door in the open position usingthe door restraint system. If the machinedoes not have a door restraint syste...
Page 113 - ENGINE FUEL SYSTEM VOLTAGE TESTS
Service and repair should be performed by only Lincoln Electric factory trained personnel.Unauthorized repairs performed on this equipment may result in danger to the technicianor machine operator and will invalidate your factory warranty. For your safety and to avoidelectrical shock, please observe...
Page 114 - FIGURE F.27 – PC BOARD; ENGINE FUEL SYSTEM VOLTAGE TESTS (continued); Make sure the batteries are in good condition, and
J1-5 (-), CHASSIS GROUND J1-9 (+), 11 TO 13 VOLTS TO FUEL SOLENOIDS J1-1 (+), BATTERY VOLTAGE INPUT TO PC BOARD FIGURE F.27 – PC BOARD ENGINE FUEL SYSTEM VOLTAGE TESTS (continued) PROCEDURE 1. Open the doors on the SAE-400 machine. WARNING: Secure the doors in the open positionusing the door restrai...
Page 115 - FIGURE F.28 – PC BOARD; Disconnect both solenoids and the engine tempera-
J31-1, (+) BATTERY VOLTAGE I NPUT J31-9 (+) OUTPUT TO FUEL SOLENO I DS AND PUMP B-1 (-) CHASS I S GROUND FIGURE F.28 – PC BOARD ENGINE FUEL SYSTEM VOLTAGE TESTS (continued) PROCEDURE For Code 10856: 1. Place the run/stop switch in the “RUN” position andwithin 30 seconds, check for battery voltagebet...
Page 117 - ALTERNATOR ROTOR REMOVAL AND REPLACEMENT
Service and repair should be performed by only Lincoln Electric factory trained personnel.Unauthorized repairs performed on this equipment may result in danger to the technicianor machine operator and will invalidate your factory warranty. For your safety and to avoidelectrical shock, please observe...
Page 118 - FIGURE F.29 – ROTOR REMOVAL; ALTERNATOR ROTOR REMOVAL AND REPLACEMENT (continued); Rotor Removal
EXCITER ROTOR BRUSH HOLDER ASSEMBLY NUT WASHER SLEEVE COLLAR BRUSH HOLDER BRACKET FIGURE F.29 – ROTOR REMOVAL ALTERNATOR ROTOR REMOVAL AND REPLACEMENT (continued) PROCEDURE Rotor Removal 1. Turn off the engine. 2. Open either, or both of the doors on the control panel end of the SAE-400 machine. WAR...
Page 121 - ALTERNATOR STATOR REMOVAL AND REPLACEMENT
Service and repair should be performed by only Lincoln Electric factory trained personnel.Unauthorized repairs performed on this equipment may result in danger to the technicianor machine operator and will invalidate your factory warranty. For your safety and to avoidelectrical shock, please observe...
Page 122 - ALTERNATOR STATOR REMOVAL AND REPLACEMENT (continued); Alternator Rotor Removal
GENERATOR COVER FOUR SCREWS TOTAL FIGURE F.30 – GENERATOR COVER REMOVAL ALTERNATOR STATOR REMOVAL AND REPLACEMENT (continued) PROCEDURE 1. Turn off the engine. 2. Perform the Alternator Rotor Removal Procedure. 3. Remove the roof and doors. 4. Remove the four covers protecting the welding gen- erato...
Page 124 - Replacing the Exciter Alternator Stator:
ALTERNATOR STATOR REMOVAL AND REPLACEMENT (continued) Replacing the Exciter Alternator Stator: 1. During reassembly, anti-seize compound should be applied to the screw threads. 2. Inspect the mating surfaces of the generator frame and the exciter bracket assembly. These surfacesmust mate together co...
Page 125 - GENERATOR FRAME REMOVAL AND REPLACEMENT
Service and repair should be performed by only Lincoln Electric factory trained personnel.Unauthorized repairs performed on this equipment may result in danger to the technicianor machine operator and will invalidate your factory warranty. For your safety and to avoidelectrical shock, please observe...
Page 126 - GENERATOR FRAME REMOVAL AND REPLACEMENT (continued); Remove the generator frame
GENERATOR FRAME REMOVAL AND REPLACEMENT (continued) PROCEDURE Remove the generator frame 1. Turn off Engine. 2. Perform the Alternator Rotor Removal Procedure . 3. Perform the Alternator Stator Removal Procedure. 4. Disconnect all of the wires and cables that connect to the stator/frame assembly. Ca...
Page 127 - GENERATOR ARMATURE REMOVAL AND REPLACEMENT
Service and repair should be performed by only Lincoln Electric factory trained personnel.Unauthorized repairs performed on this equipment may result in danger to the technicianor machine operator and will invalidate your factory warranty. For your safety and to avoidelectrical shock, please observe...
Page 128 - FIGURE F.32 – SLING LIFT; GENERATOR ARMATURE REMOVAL AND REPLACEMENT (continued); Removing the Armature
BLOWER PADDLE/ARMATURE MOUNTING BOLTS (8) BLOWER PADDLE ROPE SLING FIGURE F.32 – SLING LIFT GENERATOR ARMATURE REMOVAL AND REPLACEMENT (continued) PROCEDURE Removing the Armature 1. Turn off the engine 2. Perform the Alternator Rotor Removal Procedure. 3. Perform the Alternator Stator Removal Proced...
Page 129 - RETEST AFTER REPAIR; Retest after repair; Perform the Engine RPM Adjustment Test; Field amps and volts:
RETEST AFTER REPAIR F-89 F-89 SAE-400 SEVERE DUTY Return to Section T OC Return to Section T OC Return to Section T OC Return to Section T OC Return to Master T OC Return to Master T OC Return to Master T OC Return to Master T OC Retest after repair The machine should be retested if any parts are re...
Page 130 - TABLE OF CONTENTS - DIAGRAM SECTION
TABLE OF CONTENTS - DIAGRAM SECTION G-1 G-1 Return to Master T OC Return to Master T OC Return to Master T OC Return to Master T OC SAE-400 SEVERE DUTY Electrical Diagrams . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ...
Page 131 - ELECTRICAL DIAGRAMS; ENGINE WELDERS; CONTROL W
ELECTRICAL DIAGRAMS G-2 SAE-400 SEVERE DUTY ® WIRING DIAGRAM - CONTROL - CODE 10856 (M19237) M19237 ENGINE WELDERS WIRING DIAGRAM NONE M18827 FEI - UNLESS OTHERW I SE SPEC I F I ED TOLERANCE MANUFACTUR I NG TOLERANCE PER E2056 ON 2 PLACE DEC I MALS I S ± .02 ON 3 PLACE DEC I MALS I S ± .002 ON ALL A...
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