Lincoln Electric SVM187-A - Manual

Lincoln Electric SVM187-A

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Table of Contents:

  • Page 2 – SAFETY; WARNING; CALIFORNIA PROPOSITION 65 WARNINGS; The Above For Diesel Engines
  • Page 3 – ii; ELECTRIC SHOCK can kill.
  • Page 4 – iii
  • Page 5 – iv; PRÉCAUTIONS DE SÛRETÉ
  • Page 6 – b) radio and television transmitters and receivers
  • Page 7 – Methods of Reducing Emissions
  • Page 8 – - MASTER TABLE OF CONTENTS FOR ALL SECTIONS -; RETURN TO MAIN INDEX; Page; vii; RETURN TO MAIN MENU
  • Page 9 – TABLE OF CONTENTS - INSTALLATION SECTION
  • Page 10 – INSTALLATION; TECHNICAL SPECIFICATIONS - SAE-400 SEVERE DUTY; OUTPUT - WELDER AND GENERATOR
  • Page 11 – SAFETY PRECAUTIONS; STACKING; These machines cannot be stacked.; ANGLE OF OPERATION
  • 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
  • Page 13 – BATTERY CONNECTION; GASES FROM BATTERY can explode.; ENGINE COOLING SYSTEM
  • Page 14 – WELDING OUTPUT CABLES; Table A.1 Combined Length of Electrode and; MACHINE GROUNDING; CAUTION
  • Page 15 – TABLE OF CONTENTS - OPERATION SECTION
  • Page 16 – OPERATION; ADDITIONAL SAFETY PRECAUTIONS; GENERAL DESCRIPTION; RECOMMENDED APPLICATIONS; OPERATING INSTRUCTIONS
  • Page 17 – DESIGN FEATURES AND ADVANTAGES; FOR STICK WELDING; DUTY CYCLE
  • Page 18 – ENGINE CONTROLS; continuously at high idle.; Muffler and Engine may be hot!
  • Page 19 – WELDER CONTROLS; LATION
  • 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”
  • Page 21 – TYPICAL FUEL CONSUMPTION; Welding Load
  • Page 22 – NOTES
  • Page 23 – TABLE OF CONTENTS - ACCESSORIES SECTION
  • Page 24 – ACCESSORIES; K704 Standard Accessory Kit -; MAINTENANCE
  • Page 25 – TABLE OF CONTENTS - MAINTENANCE SECTION
  • Page 26 – ROUTINE MAINTENANCE
  • 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
  • Page 28 – WATER SEPARATOR ELEMENT; Slide the new element onto the grommet post on the; SECONDARY FUEL FILTER; ENGINE MAINTENANCE COMPONENTS
  • Page 29 – SPARK ARRESTOR; For machines with separate spark arresting unit:
  • Page 31 – TABLE OF CONTENTS-THEORY OF OPERATION SECTION; FIGURE E.1 BLOCK LOGIC DIAGRAM
  • Page 32 – THEORY OF OPERATION; NOTE: Unshaded areas of Block Logic
  • Page 33 – AUTOMATIC ENGINE IDLE SYSTEM; FIGURE E.2 - ENGINE STARTING AND PROTECTION
  • Page 36 – Excitation and field control:
  • Page 37 – Producing weld current:
  • Page 38 – Series coils and reactor:
  • Page 41 – TABLE OF CONTENTS - TROUBLESHOOTING AND REPAIR; Test Procedures
  • Page 42 – TROUBLESHOOTING AND REPAIR; HOW TO USE TROUBLESHOOTING GUIDE
  • Page 43 – PC board can be damaged by static electricity.; PC BOARD TROUBLESHOOTING PROCEDURES
  • Page 45 – • If normal voltage is present,
  • Page 46 – Brush and Slip Ring
  • Page 47 – Perform the
  • Page 52 – • If voltage is present, check
  • Page 53 – Engine
  • Page 57 – Engine Idle
  • Page 61 – ENGINE RPM ADJUSTMENT TEST
  • Page 62 – TEST PROCEDURE; CAUTION: Do Not Short the Output Studs Together
  • Page 63 – Frequency counter method:; ENGINE RPM ADJUSTMENT PROCEDURE
  • Page 65 – BRUSH AND SLIP RING SERVICE PROCEDURE
  • Page 66 – FIGURE F.3 – EXCITER COVER SCREW LOCATIONS; PROCEDURE; Open either, or both of the doors on the control
  • Page 67 – BRUSHES; FIGURE F.4 – BRUSH LOCATIONS; Check for evidence of sticking brushes. Sticking
  • Page 69 – EXCITER ROTOR VOLTAGE TEST
  • Page 70 – FIGURE F.6 – EXCITER COVER SCREW LOCATIONS; Make sure that the battery is fully charged and in
  • Page 71 – FIGURE F.7 – EXCITER ROTOR VOLTAGE TEST; Connect the volt meter probes to the brush termi-
  • Page 73 – EXCITER ROTOR RESISTANCE AND GROUND TEST
  • Page 74 – FIGURE F.8 – EXCITER COVER SCREW LOCATIONS; Open either, or both of the doors on the control
  • Page 75 – FIGURE F.9 – SLIP RING LOCATIONS; Measure the resistance to ground. Place one meter
  • Page 76 – FIGURE F.10 – SLIP RING LOCATIONS; Brush and Slip Ring Service Procedure.
  • Page 77 – FLASHING VOLTAGE TEST
  • Page 78 – FIGURE F.11 – EXCITER COVER SCREW; FIGURE F.12 – FLASHING VOLTAGE TEST
  • Page 79 – FIGURE F.13 – IDLER/ENGINE PROTECTION PC BOARD CODES 10856; If the voltage is significantly higher than expected:
  • Page 80 – Connect positive voltmeter probe to the Idler /; If battery voltage is detected:; If the idler/engine protection PC board is getting
  • Page 81 – EXCITER STATOR SHORT CIRCUIT & GROUND TEST
  • Page 83 – WELDING GENERATOR BRUSH AND COMMUTATOR INSPECTION AND
  • Page 84 – FIGURE F.15 – GENERATOR COVER SCREW LOCATIONS
  • Page 85 – FIGURE F.16 – GENERATOR COMPONENTS; Blackened Commutator:
  • Page 86 – Pitted and Arc Damaged Commutator:; Uneven Commutator appearance:; . Replace any insulators that are cracked
  • Page 87 – WELD CIRCUIT GROUND AND SHORT CIRCUIT TEST
  • Page 88 – WELD CIRCUIT GROUND AND SHORT CIRCUIT TEST (continued); Weld circuit ground test:; Output Control Unit
  • Page 89 – SHUNT FIELD COIL RESISTANCE AND GROUND TEST
  • Page 90 – SHUNT FIELD COIL RESISTANCE AND GROUND TEST (continued); Shunt Coil Resistance Test:
  • Page 91 – SHUNT FIELD CIRCUIT VOLTAGE TEST
  • Page 92 – SHUNT FIELD CIRCUIT VOLTAGE TEST (continued); Open both of the doors on the control panel end of
  • Page 93 – DEAD SHORT, 1ST STEP, AND OPEN REACTOR TESTS
  • Page 94 – FIGURE F.17 – OUTPUT CONTROL UNIT; Remove the load turn the Job Selector Rheostat to
  • Page 95 – ROCKER ADJUSTMENT PROCEDURE
  • 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-
  • Page 97 – |Measure the output voltage, it should read
  • Page 99 – INSPECTION AND SERVICE PROCEDURE
  • Page 100 – WINDING; INSPECTION AND SERVICE PROCEDURE (continued); Turn the engine off, open the doors on the control
  • Page 101 – Servicing the continuous control unit:
  • Page 102 – FIGURE F.21 – INSULATOR & SPRING LOCATIONS; INSPECTION AND SERVICE PROCEDURE (continued)
  • Page 103 – Connect any cables that had been removed.
  • Page 105 – ENGINE PROTECTION SYSTEM CIRCUIT TEST
  • Page 106 – ENGINE PROTECTION SYSTEM CIRCUIT TEST (continued); Open all of the doors on the SAE-400 machine.
  • Page 107 – Start the engine and allow it to run.
  • Page 109 – ENGINE ALTERNATOR TEST
  • Page 110 – Open the right side cover, on the radiator end of the
  • Page 113 – ENGINE FUEL SYSTEM VOLTAGE TESTS
  • Page 114 – FIGURE F.27 – PC BOARD; ENGINE FUEL SYSTEM VOLTAGE TESTS (continued); Make sure the batteries are in good condition, and
  • Page 115 – FIGURE F.28 – PC BOARD; Disconnect both solenoids and the engine tempera-
  • Page 117 – ALTERNATOR ROTOR REMOVAL AND REPLACEMENT
  • Page 118 – FIGURE F.29 – ROTOR REMOVAL; ALTERNATOR ROTOR REMOVAL AND REPLACEMENT (continued); Rotor Removal
  • Page 121 – ALTERNATOR STATOR REMOVAL AND REPLACEMENT
  • Page 122 – ALTERNATOR STATOR REMOVAL AND REPLACEMENT (continued); Alternator Rotor Removal
  • Page 124 – Replacing the Exciter Alternator Stator:
  • Page 125 – GENERATOR FRAME REMOVAL AND REPLACEMENT
  • Page 126 – GENERATOR FRAME REMOVAL AND REPLACEMENT (continued); Remove the generator frame
  • Page 127 – GENERATOR ARMATURE REMOVAL AND REPLACEMENT
  • Page 128 – FIGURE F.32 – SLING LIFT; GENERATOR ARMATURE REMOVAL AND REPLACEMENT (continued); Removing the Armature
  • Page 129 – RETEST AFTER REPAIR; Retest after repair; Perform the Engine RPM Adjustment Test; Field amps and volts:
  • Page 130 – TABLE OF CONTENTS - DIAGRAM SECTION
  • Page 131 – ELECTRICAL DIAGRAMS; ENGINE WELDERS; CONTROL W
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SVM187-A

October, 2008

Safety Depends on You

Lincoln arc welding and cutting
equipment is designed and built
with safety in mind.

However,

your

overall

safety

can

be

increased by proper installation
. . . and thoughtful operation on

your part.

DO NOT INSTALL,

OPERATE OR REPAIR THIS

EQUIPMENT WITHOUT READ-

ING THIS MANUAL AND THE

SAFETY PRECAUTIONS CON-

TAINED 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

T

OC

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to

Master

T

OC

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to

Master

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to

Master

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Safety

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• Sales and Service through Subsidiaries and Distributors Worldwide •

Cleveland, Ohio 44117-1199 U.S.A. TEL: 888-935-3877 FAX: 216.486.1751 WEB SITE: www.lincolnelectric.com

• World's Leader in Welding and Cutting Products •

Copyright © Lincoln Global Inc.

SAE-400 SEVERE DUTY

RETURN TO MAIN MENU

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Summary

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...

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